Opel Frontera 1998 2002 Workshop Manual Vol 2
Opel Frontera 1998 2002 Workshop Manual Vol 2
Opel Frontera 1998 2002 Workshop Manual Vol 2
F07RT034
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–9
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
* If equipped
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–11
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)
C07RW048
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
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
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)
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
standard.
7A1–22 TRANSMISSION CONTROL SYSTEM (4L30–E)
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)
D07RW029
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)
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 (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
D07RW031
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)
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) (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
D07RW006
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)
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
D07RT015
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)
D07RW009
D07RW009
D07RW033
D07RW009
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.
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
220RW108
401RS003
235RW014
150RW041
401RW060
MANUAL TRANSMISSION 7B–7
13. Disconnect the backup lamp switch, 4WD indicator
switch and 1–2 indicator switch harness connectors.
826RW023
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
220RW063
220RW109
220RW064
MANUAL TRANSMISSION 7B–11
220RW119 220RS005
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
220RS006
220RS007
141RW024
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
150RW041
220RW090
220RW115
7B–18 MANUAL TRANSMISSION
Transmission (AR-5)
Disassembled View
226RW182
226RW00001
220RW095
(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
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
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
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
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
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
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
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
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
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
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
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
226RW054
226RW056
MANUAL TRANSMISSION 7B–39
226RW085
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
226RW081
226RW083
MANUAL TRANSMISSION 7B–41
226RW062
226RW196
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
226RW105
226RW060
226RW095
226RW093
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
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
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
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
226RW109
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
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
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
226RW203
226RW118
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
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
220RW113
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
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.
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
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
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
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
226RW035
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
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
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
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
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
226RW004
220RW083
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
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
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
Torque Specifications
E07RW049
7B–70 MANUAL TRANSMISSION
Torque Specifications (Cont’d)
E07RW050
MANUAL TRANSMISSION 7B–71
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
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
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
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
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
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)
201RS004
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
201RW032 201RS010
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
220RW088
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
201RW020
201RS017
Clutch Control
Clutch Control Parts
(6VE1 LHD)
203RW017
203RW009
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
203RW011
Legend
(1) Push Rod
(2) Adjusting Bolt
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
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
203RS005
Master Cylinder
Disassembled View
208RW016
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.
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
206RS003
206RS004
206RS005
7C–26 CLUTCH
Damper Cylinder
Disassembled View
205RW005
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.
Torque Specifications
E07RW053
7C–28 CLUTCH
Torque Specifications (Cont’d)
(6VE1 LHD)
E07RW054
CLUTCH 7C–29
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
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
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
801RW004 801RW005
801RW017
801RW012
6. Connect the battery ground cable.
8A–6 LIGHTING SYSTEM
825RW104
801RW007
Installation
To install, follow the removal steps in the reverse order.
801RW015
Installation
To install, follow the removal steps in the reverse order.
LIGHTING SYSTEM 8A–7
803RS005
803RS005
Installation
To install, follow the removal steps in the reverse order.
8A–8 LIGHTING SYSTEM
803RW004
803RS006
LIGHTING SYSTEM 8A–9
803RW003
Stoplight Bulb
Removal and Installation
Refer to the Taillight Bulb in this section.
8A–10 LIGHTING SYSTEM
803RS004
803RS003
801RS002
Installation
To install, follow the removal steps in the reverse order.
LIGHTING SYSTEM 8A–11
801RW013
803RS002
Installation
To install, follow the removal steps in the reverse order.
8A–12 LIGHTING SYSTEM
803RS001
805RS005
LIGHTING SYSTEM 8A–13
803RS007
805RS006
8A–14 LIGHTING SYSTEM
805RS008
LIGHTING SYSTEM 8A–15
742RS001
805RS004
8A–16 LIGHTING SYSTEM
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
431RW005
8A–18 LIGHTING SYSTEM
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
821RW024
825RW027
8A–20 LIGHTING SYSTEM
310RS007
310RS006
LIGHTING SYSTEM 8A–21
310RW010
310RS003
821RW024
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
821RW024
825RW023
LIGHTING SYSTEM 8A–25
825RW025
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
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
D08RW539
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
Torque Specifications
Application Nꞏm kgꞏm Lb Ft Lb In
Steering Shaft Nut 34 3.5 25 —
WIPER/WASHER SYSTEM 8B–1
880RW007
WIPER/WASHER SYSTEM 8B–3
880RS006
8B–4 WIPER/WASHER SYSTEM
880RW008
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
880RS004
1. Wiper arm/blade
Before installing the wiper arm/blade to the shaft,
880RS005
885RS002
885RS001
880RS010
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
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
826RW020
885RS009
Installation
To install, follow the removal steps in the reverse order.
8B–10 WIPER/WASHER SYSTEM
885RS008
885RS005
885RS004
Installation
To install, follow the removal steps in the reverse order.
WIPER/WASHER SYSTEM 8B–11
885RS003
Legend
(1) Washer Nozzle
(2) Spray Target
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
821RW024
825RW245
WIPER/WASHER SYSTEM 8B–13
808RW001
808RW002
8B–14 WIPER/WASHER SYSTEM
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
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
821RW034
8C–4 ENTERTAINMENT
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
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
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
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
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
B Black BR Brown
R Red GR Grey
G Green P Pink
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).)
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
6
1 2 3
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
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).
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
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
CONDENSER
FAN
D08RWC56
RELAY & FUSE BOX
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
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
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
D08RWB16
8.0
B/R
ECM ECM
(J3-1) (J3-2)
A B C D
D08RWB17
8.0
B/R
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
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
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
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
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
D08RWB21
STARTER SW STARTER SW
(ST) FL-1 (IG1) FL-1
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
D08RY00087
1
13 14
12
11
10
7
6
5 4
D08RW617
STARTER SW
BATT.(+) (ST)
8.0 3.0
B/R W/G
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
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
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
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
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
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
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
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
P C M
7
C-39
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
D08RY00101
PCM : POWERTRAIN CONTROL MODULE HO2S : HEATED OXYGEN SENSOR
P C M
D14 D15 C15 C14
C-2 C-2 C-2 C-2
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
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
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
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
1.0
B/R
E-29
VSV : VACUUM SWITCHING VALVE
PCM : POWERTRAIN CONTROL MODULE
COMMON CHAMBER
D08RY00186
0.85
B/Y
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
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
P C M
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
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)
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
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
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
1-2,3-4
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
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)
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
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
P C M
7
C-39
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
D08RY00095
PCM : POWERTRAIN CONTROL MODULE HO2S : HEATED OXYGEN SENSOR
P C M
D14 D15 C15 C14
C-2 C-2 C-2 C-2
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
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
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
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
1.0
B/R
E-29
VSV : VACUUM SWITCHING VALVE
PCM : POWERTRAIN CONTROL MODULE
COMMON CHAMBER
D08RY00098
0.85
B/Y
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
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
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
P C M
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
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)
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
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
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
1-2,3-4
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
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)
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
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
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
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
D08RW696
QOS/EGR CONTROL UNIT
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
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
D08RW985
QOS/EGR CONTROL UNIT
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
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
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
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
1 3 8
B-45 X-14 3 B-12
DIODE DIODE H-16
LIGHTING
SW
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
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
A B
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
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
R/G
D08RW655
C G
0.3
R/G
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
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
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
D08RW890-1
D F
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
R/G
D08RW891
C G
0.3
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
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
8 1 1 7
C-16 C-16 R-4 C-16 C-39
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
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
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
B
8 6 1 1 4 1
C-16 C-16 C-16 R-4 C-16 C-39 C-39
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
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
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
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
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
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
17 17
8
H-25 H-7
H-32
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
17 17
8
H-25 H-7
H-32
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
17 4
8
H-25 H-8
H-32
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
17 4
8
H-25 H-8
H-32
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
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
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
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
D08RW813
21 22
20 23 24
1
19
18
2
3
17
16
15 8
14
13
9
12
10
11
D08RY00425
BATT. (+)
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
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. (+)
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
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
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. (+)
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
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. (+)
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
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
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
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
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
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?
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
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
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
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
D08RW958
15
14
13
12 1
11
10
5
9
8
7 6
D08RW394
Diagnosis
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
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
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
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
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?
0.5
0.5 L/Y 0.85
3.0 6
L/W 0.85 G/W
W/G H-26 A
G/W
ABS
4WD
SW
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
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
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
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
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
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
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
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
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.(+)
0.5
0.5 L/Y 0.85
3.0 10
L/W 0.85 G/W
W/G H-25 A
G/W
ABS
4WD
SENSOR SWITCH
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
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
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
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
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
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
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
B-32
6
0.5
B
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
B-32
6
0.5
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
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
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
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
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
2 1 3 4
H-32 H-32 H-32 H-32
7 6 9 3
H-38 H-38 H-38 H-38
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
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
2 1 8 7
H-32 H-32 H-32 H-32
7 6 9 3
H-38 H-38 H-38 H-38
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
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
D08RY00228
A D C F
B E
TAIL RELAY 20 11 1 6
(4) H-9 H-24 H-9 H-9
0.5 0.5
B B
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
TAIL RELAY 10 9 6 5
(4) H-9 H-9 H-9 H-9
0.5 0.5
B B
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
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
D08RY00230
2
13 14 1
12
11 4
10
D08RW811
STARTER SW
BATT.(+) (IG1)
5.0 3.0
W B/Y
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
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
11 4 14
I-15 I-15 I-15
AUDIO
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
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
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
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
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
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.(+)
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
11 4 14
I-15 I-15 I-15
AUDIO
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
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
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)
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
D08RWA62
1
11
10
8
7
6
D08RWA52
STARTER SW STARTER SW
BATT(+) (IG2) BATT(+) (ACC)
0.3
B
1.25
B
2.0
B
15
H-48
2.0
2.0 2.0 2.0 B
B B B
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)
B C D E F G
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
CLOSE OPEN
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)
B C D E F G
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
CLOSE OPEN
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.(+)
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
D08RW704
STARTER SW
STARTER SW
(ST) BATT.(+)
BATT.(+) (ACC)
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
D08RW703
BATT.(+) BATT.(+)
5.0
W
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
D08RY00493
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT
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
DETECT
DETECT
DETECT
TAMPER
TAMPER
TAMPER
1.25
1.25 2.0 2.0 2.0
B
B B B B
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
BODY-RR
BODY-CTR BODY-RH BODY-LH BODY-LH BODY-RH
D08RW707
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT
14 15 14 15 7 2 7 2
H-22 H-22 H-18 H-18 H-23 H-23 H-19 H-19
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
H-23 H-19
1.25
B
1.25
B 2.0 2.0 2.0
B B B
D08RW708
STARTER SW
BATT.(+) BATT.(+) (ACC) BATT.(+) BATT.(+)
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
D08RY00494
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT
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
DETECT
DETECT
DETECT
TAMPER
TAMPER
TAMPER
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
D08RW687
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT
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
2.0 2.0 2.0
B
B B B
D08RW688
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT
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
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
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
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.(+)
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
D08RW920
STARTER SW
STARTER SW
(ST) BATT.(+)
BATT.(+) (ACC)
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
D08RW709
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT
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
DETECT
DETECT
DETECT
TAMPER
TAMPER
TAMPER
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
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
D08RW922
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT
14 15 14 15 7 2 7 2
H-22 H-22 H-18 H-18 H-23 H-23 H-19 H-19
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
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
Engine hood, doors and tailgate Check to see if doors are closed
are not fully closed and locked. and locked.
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 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
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.
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
3 Pull out starter key after turning it Check to see if indicator light K
back to “OFF” position. remains lit off.
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.
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
Lock left front door with locking Check to see if indicator light is All doors are
20 B
knob. steadily on. locked.
25 Close tailgate
ITEM OF
STEP OPERATION ITEM TO BE CHECKED MALFUNCTION REMARKS
ITEM OF
STEP OPERATION ITEM TO BE CHECKED MALFUNCTION REMARKS
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.
3
4
901RW180
060RW009
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
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
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
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
ODO/ REAR
TURN TURN FOG
CHARGE TRIP METER
-LH -RH LIGHT
METER
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
B-2 B-2
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
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
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
BRAKE PARKING
0.5 FLUID BRAKE
LB SW SW
1
C-15
E-1
1
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
F
HIGH
BEAM
ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER
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
B-2 B-2
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
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
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
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
ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER
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
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
B-2 B-2
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
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
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
D08RY00429
TAIL RELAY TURN SIGNAL/CORNERING
(4) LIGHT SW
13 20 19
H-16 H-25 H-25
ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER
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
B-1 B-1
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
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
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
D08RY00431
TAIL RELAY TURN SIGNAL/CORNERING
(4) LIGHT SW
6 20 19
H-16 H-25 H-25
ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER
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
1 2
C-9 C-9
B-1 B-1
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
D08RW639
A/T SHIFT INDICATOR CONTROL UNIT
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
D08RW949
A/T SHIFT INDICATOR CONTROL UNIT
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
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
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
0.5G/B
7 5
H - 41 H - 41
0.5BR/Y
0.5G/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
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
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
0.5BR
BODY ENG. FRAME I-23 H-24
LG
0.5
1
H-51
5W
BR
0.5
I-23 1
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
3 4 3
C-20 10A
3L/R
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
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
H-41
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
0.85 0.85
B B
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
A B C D 0.85 0.85
B B
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
2.0
B
4
H-57
2.0
B 2.0 2.0
B B
B-26 B-2 B-18
D08RW640
3.0
B/L
1
H-58
2.0
R
1
T-9
POWER SEAT SW-LH
FRT RR FRT RR
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
2.0
B
4
H-57
2.0
B B
D08RW951
A
3.0
B/L
1
H-58
2.0
R
1
T-9
POWER SEAT SW-RH
FRT RR FRT RR
M M
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
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
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
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
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
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
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
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
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)
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
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
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)
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
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
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)
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
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
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)
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
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
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.(+)
0.5 0.85
0.5 L/Y G/W
A
L/W
6
H-26
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
D08RW610
T.O.D. CONTROL UNIT
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
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-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
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-2 E-30
•Terminals marked with a star ( ) are gold plated.
BODY-FRT COMMON
CHAMBER
D08RWB41
S D M
1 2 1 2
H-66 H-66 H-64 H-64
1 2 1 2
B-34 B-34 B-23 B-23
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
〜
8D–562 WIRING SYSTEM
〜
WIRING SYSTEM 8D–563
〜
WIRING SYSTEM 8D–577
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.
821R200045
821R200046
821R200047
821R200048
821R200049
821R200050
825RW206
METER AND GAUGE 8E–9
825RW209
METER AND GAUGE 8E–11
821R200051
METER AND GAUGE 8E–13
821R200052
METER AND GAUGE 8E–15
825RW031
Installation
To install, follow the removal steps in the reverse order.
740RS004
825RW032
Installation
To install, follow the removal steps in the reverse order.
METER AND GAUGE 8E–17
826RS009
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
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
601RW009
601RW010
601RW003
Installation
To install, follow the removal steps in reverse order.
8F–8 BODY STRUCTURE
Rear Bumper
Parts Location
690RW001
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
690RS003
8F–10 BODY STRUCTURE
690RW010
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
690RS003
8F–12 BODY STRUCTURE
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
Cowl Cover
Parts Location
605RW009
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
610RS003
Air Bulge
Parts Location
610RW013
Installation
To install, follow the removal steps in the reverse order
noting the following points:
8F–16 BODY STRUCTURE
610RW012
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
610RW011
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
603RY00002
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
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
605RW008
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
420RS001
501RS001
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
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
740RY00028
740RW103
740RS014
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
827RW031
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
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
740RW100
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
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
630RS001
Removal
1. Disconnect the battery ground cable.
2. Remove door check arm pin (1).
810RS001
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
650RW007
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
Door Strikers
Adjustment
632RS001
630RS003
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.
631RS002
631RS005
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
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
651RW018
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
651RW019
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
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
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
645RS003
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
631RS009
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
651RW013
Legend
(1) Rear Door Waist Seal
631RS008
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
655RW010
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
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
681RW008
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
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
681RS004
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
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
683RS010
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
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
683RS012
683RS013
684RW001
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
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
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
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
682RS003
Legend
(1) Clip
(2) Tailgate Center Weatherstrip
682RS004
682RW006
8F–86 BODY STRUCTURE
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
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
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
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
667RW001
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
Installation
1. Install the moulding roof clips (1).
Install the clips on roof panel flange (2) to refer the
illustration.
645RW003
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
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
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
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
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
607RS007
607RS008
641RS005
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
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
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
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
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
750RX016
750RX017
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
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
750RX018
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
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
750RS011
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
750RS012
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
750RW008
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
Legend
(2) Heat Unit (Seat Cushion Side)
750RS018
Legend
(1) Heat Unit (Seat Back Side)
SEATS 8G–15
755RW031
755RS002
8G–16 SEATS
755RW056
755RS017
755RS005
SEATS 8G–19
755RW036
755RS017
755RW033
750RW011
755RS017
SEATS 8G–23
755RS005
755RW034
Disassembled View
755RW035
Reassembly
To reassemble, follow the disassembly steps in the
reverse order.
755RW032
676RY001
Removal Installation
1. Remove the foot rest pad. To install, follow the removal steps in the reverse order.
676RS002
E10RX006
SEATS 8G–27
E10RW031
SECURITY AND LOCKS 8H–1
632RS003
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
632RS006
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
652RW004
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
652RW003
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
655RW009
SECURITY AND LOCKS 8H–11
632RS011
635RS008
8H–12 SECURITY AND LOCKS
684RW008
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
684RW006
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
683RW014
8H–16 SECURITY AND LOCKS
683RW013
Legend
(1) Tailgate Inside Handle
684RW007
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
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”
632RS021
632RS019
SECURITY AND LOCKS 8H–21
632RY00002
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.
825RW029
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
828RS007
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.
901RW180
060RW009
665RS002
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
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
665RS009
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
Disassembled View
665RW035
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
665RW017
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
665RS015
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.
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
665RW034
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
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
635RW011
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
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
632RS015
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
632RS014
632RW007
8J–10 EXTERIOR/INTERIOR TRIM
655RW006
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
A10RS001
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
687RS003
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
760RW021
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
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
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
643RW007
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
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
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
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
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
686RW008
686RW007
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.
Installation
1. Install the fuel filler door.
686RS003
Legend
(1) Fuel Filler Door
EXTERIOR/INTERIOR TRIM 8J–27
603RW015
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
620RW005
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
620RW006
EXTERIOR/INTERIOR TRIM 8J–31
620RW003
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
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
683RW017
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
684RS001
8J–36 EXTERIOR/INTERIOR TRIM
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
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
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
720RS004
825RS052
Installation
To install, follow the removal steps in the reverse order.
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.
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
RESTRAINTS
CONTENTS
Seat Belt System . . . . . . . . . . . . . . . . . . . . . . 9A–1 Restraint Control System . . . . . . . . . . . . . . . . 9J1–1
Supplemental Restraint System (SRS) . . . . . 9J–1
Seat Belt
Front Seat Belt and Associated Parts (Long Wheel Base)
1
2
10
3
8
760RW022
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
1 3
4
5
6
9 8
760RW024
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
2
1
7
8
6
760RS006
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
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
1
2
760RW027
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
760RW023 760RS005
2
1
760RW030
760RW029
2
1 2 4
3
3
760RW026
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
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
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
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
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
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
D09RW014
9J–4 SUPPLEMENTAL RESTRAINT SYSTEM
810RW298
821RW037
825RS017
760RW033
827RS008
D09RW016
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.
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
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.
827RW056
901RX045
827RW054
827LW011
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.
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
Scan Tool
901RS146
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.
901RW107
901RW106
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
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
827RW044
Legend
(1) SDM
(2) SRS Harness
(3) Connector Position Assurance
SUPPLEMENTAL RESTRAINT SYSTEM 9J–35
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
827RT008
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
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
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
430RT009
430RS004
SUPPLEMENTAL RESTRAINT SYSTEM 9J–41
430RS004
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
825RX033
827RX029
SUPPLEMENTAL RESTRAINT SYSTEM 9J–43
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
740RT015
431RS013
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
827RT008
Removal
827RS001
760RW028
9J–50 SUPPLEMENTAL RESTRAINT 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
D09RW014
D09RW014
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady
D09RW014
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
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
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.
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.”
D09RW014
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.
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
D09RW014
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
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
825RW058
431RW005
CRUISE CONTROL SYSTEM 10A–5
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.
825RW050
CRUISE CONTROL SYSTEM 10A–7
Cruise Actuator
Actuator Cable Diagram (LHD)
825RW051
825RW221
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
PAGE NEXT
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
HOME
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
HOME
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
HOME
PAGE BACK
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
+
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
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)
1 2 1
0.5Y/B
4 6 1 2
0.5L/B
3 TRANSISTOR
2
H-4
I-50
0.5Y/B
0.5G/R
0.3GR/W
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
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)
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
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
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
11
2 H-48
0.5BR
0.3B
2L/B
3 5
0.3BR
4
THERMO UNIT
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
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
D08RY00117
FULL AUTO display MIX ACTUATOR
AIR MIX DOOR
POTENTIOMETER
MODE indication
(LED) (Blow port)
AC display (LED)
INTAKE ACTUATOR
INTAKE DOOR
REC MIX FRESH
FAN indication (LED)
FAN KNOB
AUTO SET
POWER
TRANSISTOR FAN MOTOR
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
(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
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
Heat Side
Cool Side
N
Connection
M
8
Driver
1.0
Voltage ratio VM/VDD
Full heat
VDD
+
VM 0.5
–
Full cool 0
0 50 100%
Full cool Full heat
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
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
Control unit
Ambient sensor
Full heat
Air conditioning
ON mode
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
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
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
C01RY00012
100%
(MAX HI)
3 SEC
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
840RY00009
Occurrence of a trouble
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
D08RY00175
F01RX002
F01RX004
Indication for presence
of a trouble Indication for normal state
LED on
LED off
In car sensor
Ambient sensor
Duct sensor
Mix actuator
F01RY00008
Indication for presence of a trouble Indication for normal state
LED on
LED off
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.
YES
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
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
H-26 H-13
D08RY00178
Auto A/C Control Unit Mix Actuator
I-32
(Potentio Meter)
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
H-25 H-26
D08RY00180
B-36
C-19 25A
FUSE
C-20 10A
FUSE 10
2
H-26
B-5
0.3 BR
Blower Motor M
B-5
1
2 L/B
H-20
2.0L/B
17
14
I-33 1 2 1
I-50 I-51 I-51
2B
2B
0.3 GR/L
1
2.0 B
B-1 H-20
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
BODY-LH
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
D08RY00183
A
4 3 2 1
1 2
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
C01RY00002
AUTO 30
25
20
C01RW020
2 1 2 1
4 3
4 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
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
871RX010
901RX055
871RX014
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
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
871RY00017
10. Remove front cylinder head. 15. Remove rear cylinder head.
871RY00019 871RY00020
1
2
3
4
5
871RY00022
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
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
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
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
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
1 1
3
901RW007
871RW005
Legend
(1) Stake Front Head 0.28–0.35 mm Deep
(0.10–015 in)
(2) Clutch Coil Housing
(3) Front Head Surface
3
4
871RW006
Legend
(1) Suction Port J-23128-A
(2) Discharge Port
(3) Mounting Boss
(4) Mounting Boss
(5) Pressure Relief Valve 901RW008
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.
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
415RW015
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
412RY00001
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
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
412RS004
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
Differential Assembly
Disassembled View
415RW001
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
425RS014
425RW041
425RS015
415RW033
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
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
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
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)
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 2.24 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)
2.54 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
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
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
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
415RS015
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
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
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
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
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
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
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
Axle Housing
Axle Housing and Associated Parts
420RW022
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
Axle Shaft
Axle Shaft and Associated Parts
420RY00005
311RS001 420RY00011
420RY00012
420RS008
4A2A–8 DIFFERENTIAL (REAR 220mm)
420RS009
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).
425RW054
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
Differential Assembly
Differential Assembly and Associated Parts
425RW055
425RS006
DIFFERENTIAL (REAR 220mm) 4A2A–13
Disassembled View
415RW035
415RW031
425RW057
425RW056
425RS015
415RW039
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
415RW026
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)
425RW048
415RW029
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
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
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)
415RW034
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
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
415RW036
425RS050
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
425RY001
425RS055
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
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
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
425RW065
Legend
(1) Side Gear Holder : 5–8840–2381–0
DIFFERENTIAL (REAR 220mm) 4A2A–35
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)
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
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)
Axle Housing
Axle Housing and Associated Parts
420RY00007
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
Axle Shaft
Axle Shaft and Associated Parts
420RY00005
311RS001 420RY00011
420RY00012
420RS008
DIFFERENTIAL (REAR 244mm) 4A2B–9
420RS009
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).
425RY00010
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
Differential Assembly
Differential Assembly and Associated Parts
425RY00016
425RS006
4A2B–14 DIFFERENTIAL (REAR 244mm)
Disassembled View
415RY00002
425RW058
415RW041
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
425RS015
415RW042
DIFFERENTIAL (REAR 244mm) 4A2B–17
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
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)
0.083 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)
0.006 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
415RW029
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
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)
415RY00001
425RY00002
425RW033
425RS043
425RY00005
Legend
(1) Side gear
(2) Differential box
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
425RW033
425RY00009
4A2B–28 DIFFERENTIAL (REAR 244mm)
425RY001
425RS055
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
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
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
425RW065
Legend
(1) Side Gear Holder : 5–8840–2381–0
DIFFERENTIAL (REAR 244mm) 4A2B–35
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)
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)
C04RW015
412RS032 412RS033
4B1–4 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
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.
412RS071
Legend
(1) Grey
(2) Blue
412RS048
F04RS004
4B1–6 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
412RW040
Legend
(1) Ball
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
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)
D08RW852
D08RW854
D08RW831
D08RW853
D08RW845
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–17
D08RW841
4B1–18 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
D08RW843
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–19
D08RW844
4B1–20 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
D08RW842
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–21
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
C04RW013
412RS032 412RS033
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–33
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.
412RS071
Legend
(1) Grey
(2) Blue
412RS048
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.
412RW038
Legend
(1) 2WD 412RW040
412RW044
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
General Description
C07RW014–1
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.
System Components
Parts Location
A07RY00002
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
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)
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
C04RY00011
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
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
C04RY00015
4B2–18 DRIVE LINE CONTROL SYSTEM (TOD)
D08RW621
D08RW753
D08RW367
D08RY00610
D04RY00041
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–23
D04RY00042
4B2–24 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00043
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–25
D04RY00044
4B2–26 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00045
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–27
D04RY00046
4B2–28 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00047
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–29
D04RY00048
4B2–30 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00049
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–31
D04RY00050
4B2–32 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00074
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–33
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
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)
D04RW032
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–37
810RW310
901RW180
810RW308
060RY027
060RW009
060RY00269
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–43
D04RY00059
4B2–46 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00059
4B2–48 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00059
4B2–50 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00059
4B2–52 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00059
4B2–54 DRIVE LINE CONTROL SYSTEM (TOD)
The signal voltage from the TPS deviates from the stan-
dard range.
D04RY00053
4B2–56 DRIVE LINE CONTROL SYSTEM (TOD)
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
D04RY00060
4B2–60 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00060
4B2–62 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00061
4B2–64 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00062
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–65
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)
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
D04RY00063
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–73
C07RW012–1
D04RY00114
4B2–76 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00115
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
D04RY00114
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–81
D04RY00115
4B2–82 DRIVE LINE CONTROL SYSTEM (TOD)
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
D04RY00114
4B2–84 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00115
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–85
Transfer position 4L
D04RY00114
4B2–88 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00115
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–89
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
D04RY00054
4B2–92 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00064
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–95
D04RY00065
4B2–96 DRIVE LINE CONTROL SYSTEM (TOD)
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)
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)
Transfer position —
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–111
D04RY00072
D04RY00073
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–113
D04RY00073
4B2–116 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00073
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–119
D04RY00073
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–121
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
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
420RW014
311RS001 420RW023
420RW024
420RS008
4C–6 DRIVE SHAFT SYSTEM
420RW025
420RS010
420RW027
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
411RW001
411RS004
411RW005
411RS003
DRIVE SHAFT SYSTEM 4C–11
411RW006
411RS005
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
411RS009
Legend
(1) Inner Bearing
(2) Hub 411RS011
411RS012
411RW002
4C–14 DRIVE SHAFT SYSTEM
411RW009
411RW010 411RW011
411RW005
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
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
411RW013
Legend
(1) Inner Assembly
(2) Apply Grease
(3) Body
411RW016
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
411RS012
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
411RS001
412RT002
DRIVE SHAFT SYSTEM 4C–23
412RW003
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
412RW051
412RS014
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
412RS019 412RW053
412RS020
Legend
(1) Outer Case
(2) Circlip
(3) Open Ends
412RW004
412RW017
412RW016
412RS045
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
Sleeve Function
412RW010
412RW022
412RW009
4C–32 DRIVE SHAFT SYSTEM
Actuator
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
412RW007
412RW021
State Port A Port B Function
C –400 mmHg A/P E
D A/P –400 mmHg F
412RS037 412RS051
412RS044
412RW017
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
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
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
401RW058
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
401RS019
4C–40 DRIVE SHAFT SYSTEM
401RW057
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
401RW055
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 .
401RS007
401RW049
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
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.
401RS028
401RS012
4C–46 DRIVE SHAFT SYSTEM
401RW057
Torque Specifications
E04RW021
4C–48 DRIVE SHAFT SYSTEM
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
401RW059
401RS022
401RS023
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
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
401RW054
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.
401RS007
401RS012
401RS028
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
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
A07RW054
4D1–4 TRANSFER CASE (STANDARD TYPE)
A07RW053
TRANSFER CASE (STANDARD TYPE) 4D1–5
A07RW001
4D1–6 TRANSFER CASE (STANDARD TYPE)
A07RW056
TRANSFER CASE (STANDARD TYPE) 4D1–7
A07RW055
220RW105
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
260RW001
256RW030
TRANSFER CASE (STANDARD TYPE) 4D1–11
220RW102
262RW067
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
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
266RW002
Disassembly
226RW154
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
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
226RS064
226RW188
220RW116
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
Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.
230RW004
262RW067
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
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
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
226RS064
226RW188
262RW074
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
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)
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
226RW132
265RW001
226RS070
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
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
226RS040
226RS037
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
220RW106
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)
226RS075
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)
262RW060
262RS015
262RS014
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
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
F07RW083
261RW024
260RW006
261RW004–1
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
260RW007
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
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
266RW028
4D2–12 TRANSFER CASE (TOD)
261RW007
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
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
261RW009–1
11. Using snap ring pliers, install the snap ring to the
transfer cover assembly.
4D2–16 TRANSFER CASE (TOD)
266RW006
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
266RW017
4D2–18 TRANSFER CASE (TOD)
266RW008
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
261RW018
261RW010–1
Disassembly 6. Remove the spring pin that fixes the reduction fork to
the lock-up shaft.
1. Remove the output shaft.
261RW020
261RW029
261RW021
266RW012
Transfer Case
Disassembled View
265RW015
261RW036
261RW040
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
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
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
261RW049
261RW003
4D2–30 TRANSFER CASE (TOD)
Transfer Case
Disassembled View
265RW015
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
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
261RW038
261RW010–1
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
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
266RW008
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
266RW010
266RW006
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
266RW013
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
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
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.
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
901RW257
060RW009
350RV014
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
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
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
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
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
350RV010
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
B05RS005
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
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
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
350RW013
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
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
350RW012
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
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
350RW008
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.
・
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
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
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
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
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
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
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector F06RW019
014RW144
060RW018
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies 010RW008
F06RW018
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
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
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
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
150RW062
Legend
(1) Exhaust Front Pipe LH
150RW062
Legend
(1) Exhaust Front Pipe LH
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
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
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.
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
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
014RW031
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
014RW042
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
F06RW011
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
F06RW010
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
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
013RW004
013RW003
013RW002
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
150RW062
Legend
(1) Exhaust Front Pipe LH
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
014RW042
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.
014RW025
014RW020
ENGINE MECHANICAL 6A–55
014RW024
014RW031
014RW039
014RW042
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
014RS007
014RS012
014RS011
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
014RW058
014RS015
014RW042
Legend
(1) Cam
(2) Shim
(3) Tappet
014RW084
014RW082
014RW083
ENGINE MECHANICAL 6A–63
Camshaft
Camshaft and Associated Parts
014RW040
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
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
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
014RW041
014RW023
014RW024
014RW031 014RW060
014RW034
Crankshaft
Crankshaft and Associated Parts
013RW009
015RS003
015RS005
015RS008
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
015RS011
015RS009
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
015RS013
015RW002 015RS017
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
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
012RS001
013RW010
ENGINE MECHANICAL 6A–77
015RW019
015RS031 015RX001
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
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
015RS026 015RS028
015RS027
015RS031
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
015RS027
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
Cylinder Block
Cylinder Block and Associated Parts
012RW010
012RS005
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
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
012RW005
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
030RS001
ENGINE COOLING 6B–3
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
Water Pump
Water Pump and Associated Parts
030RS002
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
Radiator
Radiator and Associated Parts
110RW003
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
110RS005
111RS001
015RW005
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
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
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
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
140RW002
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 Tank
Fuel Tank and Associated Parts
035RW048
141RW021
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
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
140RW021
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
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.
Battery Removal
061RS002
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
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.
060RW006
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
Spark Plug
Removal
1. Remove spark plugs.
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:
Too lean mixture
Improper heat value
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
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
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
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
Disassembled View
065RW002
065RW005
065RW006
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
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
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
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)
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
E06RW044
STARTING AND CHARGING SYSTEM 6D3–17
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
Disassembled View
066RW007
060RW003
060RW005
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
066RS014
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
066RS021
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
066RS010
B06RW001
6D3–26 STARTING AND CHARGING SYSTEM
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
I
6E–6 ENGINE DRIVEABILITY AND EMISSIONS
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
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
TS23344
TS23345
TS23345
TS23345
TS23345
TS23346
TS23346
TS23346
Component Locators
Engine Component Locator (This illustration is based on RHD model.)
060RW210
ENGINE DRIVEABILITY AND EMISSIONS 6E–29
Engine Component Locator Table
755RW062
ENGINE DRIVEABILITY AND EMISSIONS 6E–31
Engine Component Locator Table
F00RW040
TS23336
6E–34 ENGINE DRIVEABILITY AND EMISSIONS
Sensors and Miscellaneous Component
Locators
For EC.
060RW194 T321066
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
TS24064
901RW180
060RW220
060RW014
060RW009
060RW228
DTC Modes
060RW218
060RW229
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.
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
060RW235 060RW232
060RW233
060RW231
TS321119
D06RW085
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.
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
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:
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.
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.
D06RW00007
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
D06RW101
140RW020
D06RW035
D06RW106
D06RW102
D06RW103
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.
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
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage
D06RW102
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.
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage
D06RW026
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage
D06RW026
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.
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage
060RY00304
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
D06RW028
D06RW028
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1
Sensor 1
060RW236
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1
Sensor 1
060RW236
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1
Sensor 1
060RW237
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2
Sensor 1
060RW190
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2
Sensor 1
060RW190
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
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
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
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
D06RW034
R321054
D06RW034
R321055
D06RW034
R321056
D06RW034
R321057
D06RW034
R321058
D06RW034
R321059
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.
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
D06RW032
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency
D06RW032
D06RW032
D06RW032
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.
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.
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.
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.
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.
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.
D06RW106
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.
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
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
D06RW019
D06RW020
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio
Bank 2 Sensor 1
060RW190
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration
060RW193–1
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.
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
T321115
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
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).
Diagnostic Aids
Check for the following conditions:
P1625 alone stored does not need diagnosis. Clear
DTC code.
ENGINE DRIVEABILITY AND EMISSIONS 6E–259
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
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
014RW120
014RV053
014RV053
014RW106
TS22909
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
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
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
TS23739
ENGINE DRIVEABILITY AND EMISSIONS 6E–295
TS23741
Installation Procedure
1. Install the IAT sensor into the grommet in the intake
air duct.
2. Correct the IAT electrical connector.
TS23739
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
014RW103
014RW103
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. 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
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
Installation Procedure
1. Install the TP sensor on the throttle body with the
bolts.
TS23760
TS23748
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
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
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
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
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
035RW004
101RW007
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
TS24053
TS24055
TS24054
ENGINE DRIVEABILITY AND EMISSIONS 6E–309
TS24054
TS24055
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
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
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
TS22911
TS23771
6E–314 ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the wiring connector to the fuel gauge unit.
014RW164
014RW164
014RW109
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
014RW110
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
TS23795
ENGINE DRIVEABILITY AND EMISSIONS 6E–319
T321092
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
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
TS23796
TS23770
Installation Procedure
1. Install the fuel tank.
Place the flanges on the left and right side of the
tank on the bracket. TS23769
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
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
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
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
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
014RW136
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
014RW097
Inspection Procedure
014RW098
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
Installation Procedure
1. Bend the tab on the connector to allow the terminal to
be pulled into position within the connector. 048
051
049
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
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
071
070
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
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.
0016 0012
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
055RW004
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
TS23793
Deceleration Mode
The PCM reduces the amount of fuel injected when it 0003
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
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
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
TS22909
060RW015
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
TS23994
TS23992
0017
028RV002
028RW002
Special Tools
901RW180
5-8840-0285-0
(J 39200) BT-8515
High Impedance Exhaust Back Pressure
Multimeter (Digital Tester or common tool
Voltmeter – DVM)
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
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
150RW059
ENGINE EXHAUST 6F–3
150RW058
150RW063
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
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
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
E06RW033
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
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
Oil Pump
Oil Pump and Associated Parts
051RW005
051RS004
051RS002
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
013RS003
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. 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
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
051RW001
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
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
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
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
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
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 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
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
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
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
010R200002
060RY00002
Legend
(1) Long Type Ignition Coil Assemblies (# 1 # 5)
(2) Short Type Ignition Coil Assembly (# 6)
F06RY001
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
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
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
Exhaust Manifold RH
Removal
035RX016
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
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)
014RW005
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley 014RW003
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
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
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
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
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
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
014RW042
F06RW011
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)
F06RY002
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
015RW001
5. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on crankshaft and flywheel fitting
surface. 012RS007
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
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
035R200004
Legend
(1) Throttle Position Sensor Connector
(2) Throttle Valve Assembly
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
Cylinder Head
Cylinder Head and Associated Parts
011RW008
014RW042
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
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
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
014RW031
014RW039
014RW042
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
014RS007
014RS012
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
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
014RW084
014RW082
014RW083
6A–60 ENGINE MECHANICAL (6VE1 3.5L)
Camshaft
Camshaft and Associated Parts
014R100028
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
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
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
014RW041
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
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
014R100031
014RW060
ENGINE MECHANICAL (6VE1 3.5L) 6A–67
Crankshaft
Crankshaft and Associated Parts
013RW009
015RS003
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
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)
015RS010
015R200005
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
015RS017
015RS018
015RS020