RHD Frontera B Serise

WORKSHOP MANUAL
US VERSION
RIGHT HAND MODEL
EXP UBS
PubNo. RV99_02-01.E
TOP
WORKSHOP MANUAL
1999
Frontera (UE)
2000
Frontera (UE)
2001
Frontera (UE)
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TABLE OF CONTENTS
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WORKSHOP MANUAL
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FOREWORD
This manual includes special notes, important points, service data,
precautions, etc. That are needed for the maintenance, adjustments,
service, removal and installation of vehicle components.
All information, illustrations and specifications contained in this manual
are based on the latest product information available at the time of
publication.
All rights are reserved to make changes at any time without notice.
Arrangement of the material is shown in the table of contents on the
right-hand side of this page. A black spot on the first page of each
section can be seen on the edge of the book below each section title.
These point to a more detailed table of contents preceding each
section.
5A
5B
5C
5D
HEC
6A
6B
6C
6D1
6D2
6D3
6E1
6F
6G
6H
6J
7A
7A1
7B
7C
This manual applies to 1999 models.

8A
8B
8C
8D
8E
8F
8G
8H
8I
8J
9A
9J
9J1
10A
GENERAL INFORMATION
General Information
Maintenance and Lubrication
HEATING, VENTILATION AND AIR
CONDITIONING
HVAC System
STEERING
Power-Assisted System
SUSPENSION
Front Suspension
Rear Suspension
Wheel and Tire System
DRIVELINE/AXLE
Differential (Front)
Differential (Rear)
Driveline Control System
Drive Shaft System
Transfer Case
BRAKE
Brake Control System
Anti-Lock Brake System
Power-Assisted Brake System
Parking Brake System
6VD1
ENGINE
6A
Engine Mechanical
6B
Engine Cooling
6C
Engine Fuel
6D1
Engine Electrical
6D2
Ignition System
6D3
Starting and Charging System
6E2
Driveability and Emissions
6F
Engine Exhaust
6G
Engine Lubrication
6H
Engine Speed Control System
6J
Induction
TRANSMISSION
Automatic Transmission
Transmission Control System
Manual Transmission
Clutch
BODY AND ACCESSORIES
Lighting System
Wiper/Washer System
Entertainment
Wiring System
Meter and Gauge
Body Structure
Seats
Security and Locks
Sun Roof/Convertible Top
Exterior/Interior Trim
RESTRAINTS
Seat Belt System
Supplemental Restraint System (Air Bag System)
Restraint Control System
CONTROL SYSTEM
Cruise Control System
SECTION
GENERAL INFORMATION
0A1
GENERAL INFORMATION
CONTENTS
General Information ....................................... 0A - 1
Meintenance and Lubrication......................... 0B - 1
GENERAL INFORMATION
CONTENTS
General Repair Instruction.............................
Illustration Arrows ..........................................
Identification...................................................
Lifting Instructions..........................................
0A - 1
0A - 2
0A - 3
0A - 5
General Repair Instruction

1. If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, block" front or rear
wheels, set jack against the recommended lifting
points (see Lifting Instructions" in this section),
raise vehicle and support with chassis stands and
then perform the service operations.
2. Before performing service operations, disconnect
ground cable from the battery to reduce the chance
of cable damage and burning due to short circuiting.
3. Use a cover on body, seats and floor to protect them
against damage and contamination.
4. Brake fluid and antifreeze solution must be
handled with reasonable care, as they can cause
paint damage.
5. The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6. Use genuine Isuzu parts.
7. Used cotter pins, plastic clips, gaskets, Orings, oil
seals, lock washers and selflocking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in
groups. Keeping fixing bolts and nuts separate is
very important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly.
Also clean oil ports, etc. using compressed air, and
make certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
Standard Bolts Torque Specifications............ 0A - 8

Abbreviations Charts ..................................... 0A - 9
Service Parts Identification Plate ................... 0A - 11
oil or grease before installation.

11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.
13. When removing or replacing parts that require
refrigerant to be discharged from the air
conditioning system, be sure to use the Vehicle
Refrigerant Recovery and Recycling Equipment
(VRRRE) to recover and recycle Refrigerant134a.
14. When a service operation is completed, make a final
check to be sure the service has been done
properly and the problem has been corrected.
15. SUPPLEMENTAL RESTRAINT SYSTEM
The vehicle is equipped with a Supplemental
Restraint System (SRS) Air Bags. This system is
not to be serviced without consulting the
appropriate service information. Consult Section 9J
SRS System" if work is to be done on the front of
the vehicle such as bumper, sheet metal, seats,
wiring, steering wheel or column. Also review SRS
system information if any arc welding is to be done
on the vehicle. The SRS system equipped vehicle
can be identified by:
1. AIR BAG" warning light on the instrument
cluster.
2. A Code J" for fifth digit of Vehicle Identification
Number.
0A2
GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations.
Arrow Type
Arrow Type
Application
Application
Front of vehicle
Ambient/Clean air flow

Cool air flow
Up Side
Gas other than

ambient air
Hot air flow
Task Related
Ambient air mixed with

another gas
Can indicate
temperature change
Motion or direction
View Detail
View Angle
Lubrication point oil or

fluid
Lubrication point grease

Dimension (1:2)
Lubrication point jelly

Sectioning (1:3)
GENERAL INFORMATION
0A3
Identification
Vehicle Identification Number (VIN)
This is the legal identification of the vehicle. it is located
on the left bottom of the windshield. It can be easily
seen through the windshield from outside the vehicle.
F00RX018
F00RX017
0A4
GENERAL INFORMATION
Engine Serial Number
Transmission Serial Number
6VD1 Engine
The gasoline engine serial number is stamped on the
left rear lower area of the cylinder block above the
starter.
Manual : Stamped on the left side of the transmission

intermediate plate.
220RS025
F06RW001
X22SE Engine
rear end raised area of the cylinder block left side.
Automatic : Stamped on the identification plate, located

on the left side of the transmission above the mode
switch.
240RW019
035RW022
GENERAL INFORMATION
0A5
Lifting Instructions
Lifting Points and Supportable Point Locations
4 Door Model
C00RX002
0A6
GENERAL INFORMATION
2 Door Model
C00RX001
Lifting Point: Front

When using a floor jack, lift on the Convex portion of
the skid plate.
545RS001
Supportable Point: Front

Position the chassis stands at the bottom of the frame
sidemember, behind the front wheel.
501RS003
GENERAL INFORMATION
Lifting Point: Rear
Position the floor jack at the center of the rear axle
case when lifting the vehicle.
420RS002
Supportable Point: Rear

sidemember, just behind the trailing link bracket.
501RW002
Legend
(1) Trailing Link Bracket
EndOFCallout
0A7

Position the chassis stands at the bottom of the rear
axle case.
420RS001
0A8
GENERAL INFORMATION
Standard Bolts Torque Specifications

The torque values given in the following table should be
applied where a particular torque is not specified.
Strength Class
4.8
8.8
Refined
9.8
Non-Refined
Bolt
Identification
Bolt Diameter
Pitch (mm)
M 6X1.0
M 8X1.25
M 10X1.25
* M10X1.5
M12X1.25
* M12X1.75
M14X1.5
* M14X2.0
M16X1.5
* M16X2.0
M18X1.5
M20X1.5
M22X1.5
M24X2.0
4 8 Nm (3 6 lb ft)
8 18 Nm (6 13 lb ft)
21 34 Nm (15 25 lb ft)
20 33 Nm (14 25 lb ft)
49 74 Nm (36 54 lb ft)
45 69 Nm (33 51 lb ft)
77 115 Nm (56 85 lb ft)
72 107 Nm (53 79 lb ft)
104 157 Nm (77 116 lb ft)
100 149 Nm (74 110 lb ft)
151 226 Nm (111 166 lb ft)
206 310 Nm (152 229 lb ft)
251 414 Nm (185 305 lb ft)
359 539 Nm (265 398 lb ft)
The asterisk * indicates that the bolts are used for

femalethreaded parts that are made of soft materials
such as casting, etc.
5 10 Nm (4 7 lb ft)
12 23 Nm (9 17 lb ft)
28 46 Nm (20 34 lb ft)
28 45 Nm (20 33 lb ft)
61 91 Nm (45 67 lb ft)
57 84 Nm (42 62 lb ft)
93 139 Nm (69 103 lb ft)
88 131 Nm (65 97 lb ft)
135 204 Nm (100 150 lb ft)
130 194 Nm (95 143 lb ft)
195 293 Nm (144 216 lb ft)
270 405 Nm (199 299 lb ft)
363 544 Nm (268 401 lb ft)
431 711 Nm (318 524 lb ft)
17 30 Nm (12 22 lb ft)
37 63 Nm (27 46 lb ft)
36 60 Nm (27 44 lb ft)
76 114 Nm (56 84 lb ft)
72 107 Nm (53 79 lb ft)
114 171 Nm (84 126 lb ft)
107 160 Nm (79 118 lb ft)
160 240 Nm (118 177 lb ft)
153 230 Nm (113 169 lb ft)
230 345 Nm (169 255 lb ft)
317 476 Nm (234 351 lb ft)
425 637 Nm (313 469 lb ft)
554 831 Nm (409 613 lb ft)
GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A Ampere(s)
ABS Antilock Brake System
AC Alternating Current
A/C Air Conditioning
ACCEL Accelerator
ACC Accessory
ACL Air Cleaner
Adj Adjust
A/F Air Fuel Ratio
AIR Secondary Air Injection System
Alt Altitude
AMP Ampere(s)
ANT Antenna
ASM Assembly
A/T Automatic Transmission/Transaxle
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
Auth Authority
Auto Automatic
BARO Barometric Pressure
Bat Battery
B+ Battery Positive Voltage
Bbl Barrel
BHP Brake Horsepower
BPT Backpressure Transducer
BTDC Before Top Dead Center
C Degrees Celsius
CAC Charge Air Cooler
Calif California
cc Cubic Centimeter
CID Cubic Inch Displacement
CKP Crankshaft Position
CL Closed Loop
CLCC Closed Loop Carburetor Control
CMP Camshaft Position
CO Carbon Monoxide
Coax Coaxial
Conn Connector
Conv Converter
Crank Crankshaft
Cu. In. Cubic Inch
CV Constant Velocity
Cyl Cylinder(s)
DI Distributor Ignition
Diff Differential
Dist Distributor
DLC Data Link Connector
DOHC Double Overhead Camshaft
DTC Diagnostic Trouble Code
DTM Diagnostic Test Mode
DTT Diagnostic Test Terminal
DVM Digital Voltmeter (10 meg.)
DVOM Digital Volt Ohmmeter
EBCM Electronic Brake Control Module
ECM Engine Control Module
ECT Engine Coolant Temperature
0A9
EEPROM Electronically Erasable Programmable

Read Only Memory
EGR Exhaust Gas Recirculation
EI Electronic Ignition
ETR Electronically Tuned Receiver
EVAP Evaporation Emission
Exh Exhaust
F Degrees Fahrenheit
Fed Federal (All States Except Calif.)
FF Front Drive Front Engine
FL Fusible Link
FLW Fusible Link Wire
FP Fuel Pump
FRT Front
ft Foot
FWD Front Wheel Drive
4WD Four Wheel Drive
4 x 4 Four Wheel Drive
4 A/T Four Speed Automatic Transmission/Transaxle
Gal Gallon
GEN Generator
GND Ground
Gov Governor
g Gram
Harn Harness
HC Hydrocarbons
HD Heavy Duty
Hg Hydrargyrum (Mercury)
HiAlt High Altitude
HO2S Heated Oxygen Sensor
HVAC HeaterVentAirConditioning
IAC Idle Air Control
IAT Intake Air Temperature
IC Integrated Circuit / Ignition Control
ID Identification / Inside Diameter
IGN Ignition
INJ Injection
IP Instrument Panel
IPC Instrument Panel Cluster
Int Intake
ISC Idle Speed Control
J/B Junction Block
kg Kilograms
km Kilometers
km/h Kilometer per Hour
kpa Kilopascals
kV Kilovolts (thousands of volts)
kW Kilowatts
KS Knock Sensor
L Liter
lb ft Foot Pounds
lb in Inch Pounds
LF Left Front
LH Left Hand
LR Left Rear
LS Left Side
LWB Long Wheel Base
L4 InLine Four Cylinder Engine
MAF Mass Air Flow
MAN Manual
0A10
GENERAL INFORMATION
MAP Manifold Absolute Pressure

Max Maximum
MC Mixture Control
MFI Multiport Fuel Injection
MIL Malfunction Indicator Lamp
Min Minimum
mm Millimeter
MPG Miles Per Gallon
MPH Miles Per Hour
M/T Manual Transmission/Transaxle
MV Millivolt
N Newtons
NA Natural Aspirated
NC Normally Closed
NM Newton Meters
NO Normally Open
NOX Nitrogen, Oxides of
OBD On-Board Diagnostic
OD Outside Diameter
O/D Over Drive
OHC Overhead Camshaft
OL Open Loop
O2 Oxygen
O2S Oxygen Sensor
PAIR Pulsed Secondary Air Injection System
P/B Power Brakes
PCM Powertrain Control Module
PCV Positive Crankcase Ventilation
PRESS Pressure
PROM Programmable Read Only Memory
PNP Park/Neutral Position
P/S Power Steering
PSI Pounds per Square Inch
PSP Power Steering Pressure
Pt. Pint
Pri Primary
PWM Pulse Width Modulate
Qt. Quart
REF Reference
RF Right Front
RFI Radio Frequency Interference
RH Right Hand
RPM Revolutions Per Minute
RPM Sensor Engine Speed Sensor
RPO Regular Production Option
RR Right Rear
RS Right Side
RTV Room Temperature Vulcanizing
RWAL Rear Wheel Antilock Brake
RWD Rear Wheel Drive
SAE Society of Automotive Engineers
Sec Secondary
SFI Sequential Multiport Fuel Injection
SI System International
SIR Supplemental Inflatable Restraint System
SOHC Single Overhead Camshaft
Sol Solenoid
SPEC Specification
Speedo Speedometer
SRS Supplemental Restraint System
ST Start / Scan Tool

Sw Switch
SWB Short Wheel Base
SYN Synchronize
Tach Tachometer
TB Throttle Body
TBI Throttle Body Fuel Injection
TCC Torque Converter Clutch
TCM Transmission Control Module
TDC Top Dead Center
Term Terminal
TEMP Temperature
TOD Torque On Demand
TP Throttle Position
TRANS Transmission/Transaxle
TURBO Turbocharger
TVRS Television & Radio Suppression
TVV Thermal Vacuum Valve
TWC Three Way Catalytic Converter
3 A/T Three Speed Automatic Transmission/
Transaxle
2WD Two Wheel Drive
4 x 2 Two Wheel Drive
Ujoint Universal Joint
V Volt(s)
VAC Vacuum
VIN Vehicle Identification Number
VRRRE Vehicle Refrigerant Recovery and Recycling
Equipment
Vref ECM Reference Voltage
VSS Vehicle Speed Sensor
VSV Vacuum Switch Valve
V6 Six Cylinder V" Engine
V8 Eight Cylinder "V" Engine
W Watt(s)
w/ With
w/b Wheel Base
w/o Without
WOT Wide Open Throttle
GENERAL INFORMATION
Service Parts Identification Plate

The Vehicle Information Plate (Service Parts ID plate) is
provided on all vehicle models.
It is located on the center dash wall inside the engine
compartment. The plate lists the VIN (Vehicle
Identification Number), paint information and all
production options and special equipment on the
vehicle when it was shipped from the factory.
905RT013
0A11
SECTION
MAINTENANCE AND LUBRICATION
0B1
GENERAL INFORMATION
CONTENTS
Maintenance Schedule List............................
Service and Maintenance ..............................
Recommended Fluids and Lubricants ...........
Lubricant Viscosity Chart ...............................
0B - 1
0B - 2
0B - 9
0B - 10
Maintenance Schedule List

Normal Vehicle Use
The maintenance instructions in this Maintenance
Schedule are based on the assumption that the vehicle
will be used as designed:
to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of
the glove compartment door;
to be driven on reasonable road surfaces within legal
operating limits;
to be driven on a daily basis, as a general rule, for at
least several miles/kilometers;
to be driven on unleaded fuel
Unusual or severe operating conditions will require more
frequent vehicle maintenance, as specified in the
following sections.
Recommended Liquid Gasket .................... 0B - 12

Recommended Thread Locking Agents ..... 0B - 13
Maintenance Service Data............................. 0B - 14
0B2
Service and Maintenance
0B3
0B4
0B5
0B6
0B7
0B8
0B9
Recommended Fluids and Lubricants

USAGE
Engine
FLUID/LUBRICANT
API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil
chart on the following page for proper viscosity)
Engine coolant
Mixture of water and good quality ethylene glycol base

type antifreeze.
Brake system
DOT-3 hydraulic brake fluid.
Power steering system
DEXRON II-E Automatic transmission fluid.
Automatic transmission
DEXRON -III Automatic transmission fluid.
MUA Type Manual transmission & Transfer case
Engine oil
(See oil chart on following page for proper viscosity)
Rear axle and front axle
GL-5 gear lubricant (Standard differential)

GL-5 Limited slip differential gear lubricant together with
limited slip differential lubricant additive (Part No.
8-01052-358-0) or equivalent (If equipped with optional
limited slip differential) (See oil chart in this section for
proper viscosity)
Clutch system
a. Pivot points
Chassis grease
b. Clutch fork joint
Chassis grease
c. Master cylinder
DOT-3 hydraulic brake fluid
Hood latch assembly

a. Pivots and spring anchor
Engine oil
b. Release pawl
Chassis grease
Hood and door hinges
Engine oil
Chassis lubrication
Chassis grease
Parking brake cables
Chassis grease
Front wheel bearings
Multipurpose grease
Shift on the fly system
GL-5 gear lubricant (SAE 75W-90)
Body door hinge pins and linkage, fuel door hinge, rear
compartment lid hinges
Engine oil
Windshield washer solvent
Washer fluid
Key lock cylinder
Synthetic light weight engine oil (SAE 5W-30)
Accelerator linkage
Chassis grease
0B10
Lubricant Viscosity Chart

Lubricants should be carefully selected according to the
lubrication chart. It is also important to select viscosity

of lubricants according to the ambient temperature by
referring to the following table.
Oil Viscosity Chart for Gasoline Engine
905RT011
0B11
Oil Viscosity Chart for Manual Transmission and Transfer Case
B00RW002
Oil Viscosity Chart for Front Axle
B00RW003
0B12
Oil Viscosty Chart for Rear Axle
B00RW004
Recommended Liquid Gasket

Type
Brand Name
Manufacturer
Remarks
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
For Engine Repairs
RTV*
Silicon Base
Three Bond 1207B

Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281
Water Base
Three Bond 1141E
Three Bond
For Engine Repairs
Solvent
Three Bond 1104

Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 17430
Loctite
Loctite
Loctite
All
* RTV: Room Temperature Vulcanizer

NOTE:
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacturer's instructions at all times.
For Axle Case

Repairs T/M
Repairs T/M
3. Be absolutely sure to remove all lubricants and

moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 between two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
Recommended Thread Locking

Agents
LOCTITE Type
LOCTITE Color
LOCTITE 242
Blue
LOCTITE 262
Red
LOCTITE 271
Red
Application Steps
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
F00RW014
3. Tighten the bolts to the specified torque.

After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
NOTE: When the application procedures are specified
in this manual, follow them.
0B13
0B14
Maintenance Service Data

Service Data and Specifications
ENGINE
Valve clearance (cold): only V6-3.2L ENG
Intake 0.280.05 mm (0.0110.002 in)

Exhaust 0.30.05 mm (0.0120.002 in)
Spark plug type
K16PR-P11/PK16PR11/RC10PYP4
Spark plug gap
1.05 mm (0.04 in)
CLUTCH
Clutch pedal free play
5-15 mm (0.20-0.59 in)
BRAKE
Brake pedal free play
6-10 mm (0.24-0.39 in)
Parking brake travel
6-7 notches
Toe-in (Front)
02 mm (00.08 in)
Toe-in (Rear)
05 mm (00.2 in)
Camber (Front)
030'
Camber (Rear)
01
Caster (Front)
2 30'45'
ToeAxis (Rear)
PROPELLER SHAFT
Flange torque
63 Nm (46 lbft)
WHEEL AND TIRES
Size
WHEEL ALIGNMENT
235/75R15
Wheel nut torque
118 Nm (87 lbft)
Tire inflation pressure (Front)
200 kpa (29 psi)
180 kpa
* Tire inflation pressure (Rear)
200 kpa (29 psi)
180 kpa
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
Items
Metric Measure
U.S. Measure
80 L
21.1 Gal.
Oil Change with Filter
4.7 L
5.0 Qt
Oil Change without Filter
4.0 L
4.2 Qt
4.5 L
4.8 Qt
4.2 L
4.4 Qt
M/T (V63.2L ENG)
11.0 L
11.6 Qt
M/T (L42.2L ENG)
6.9 L
7.3 Qt
A/T
11.1 L
11.7 Qt
Manual (V63.2L ENG)
2.95 L
3.1 Qt
Manual (L42.2L ENG)
2.13 L
2.25 Qt
Automatic
8.6 L
9.1 Qt
1.45 L
1.5 Qt
Rear
1.77 L
1.87 Qt
Front
1.25 L
1.33 Qt
0.12 L
0.13 Qt
Power steering
1.0 L
1.1 Qt
Air conditioning (R-134a)
0.6 L
1.32 Qt
Fuel tank
* Crankcase (V63.2L ENGINE)
* Crankcase (L42.2L ENGINE)
Coolant
Transmission
Transfer
Axle
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
SECTION
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A1

CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution. . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation System. . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . .
Heater and Ventilation Associated Parts . .
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Inspection . . . . . . . . . . . . . . . . . .
Heater Unit. . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core and / or Mode Door . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Link Unit . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Control Link Unit. . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Link Unit and / or Mode door . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle
and Ventilation Duct. . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Control Lever Assembly and / or Control Cable
Control Lever Assembly, Control
Cable and Associated Parts . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A3
1A3
1A3
1A4
1A5
1A8
1A9
1A13
1A15
1A15
1A15
1A16
1A16
1A16
1A16
1A17
1A17
1A18
1A18
1A18
1A19
1A19
1A19
1A19
1A20
1A20
1A20
1A20
1A21
1A21
1A21
1A21
1A22
1A23
1A23
1A23
1A23
1A24
1A24
1A24
1A25
1A25
1A25
1A26
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Illumination Bulb . . . . . . . . . . .
Control Panel Illumination Bulb and
Associated Parts . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor and Associated Parts . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Procedure . . . . . . . . . . . . .
Leak Check. . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Assembly. . . . . . . . . . . . . . . . . .
Compressor Assembly and Associated
Parts (6VD1) . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts (X22SE) . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
New Compressor Installation . . . . . . . . . . .
Condenser Assembly. . . . . . . . . . . . . . . . . . .
Condenser Assembly and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor . . . . . . . . . . . . . . . . . .
Condenser Fan Motor and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch. . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch and Associated Parts. . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly. . . . . . . . . . . . . . . . . . .
Evaporator Assembly and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
1A27
1A28
1A28
1A28
1A28
1A28
1A28
1A28
1A28
1A29
1A29
1A36
1A38
1A46
1A47
1A48
1A54
1A54
1A54
1A55
1A56
1A56
1A57
1A57
1A58
1A58
1A58
1A58
1A59
1A59
1A59
1A59
1A60
1A60
1A60
1A60
1A61
1A61
1A61
1A61
1A62
1A62
1A62
1A63
1A2
Electronic Thermostat, Evaporator Core

and/or Expansion Valve . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications. . . . . . . . . . .
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Clutch Assembly (DKV-14D Type).
Parts Location View . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair. . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . .
Oil Specification . . . . . . . . . . . . . . . . . . . . .
Handling of Oil . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Check . . . . . . . . . . . . . . . .
Checking and Adjusting Oil Quantity for
Used Compressor . . . . . . . . . . . . . . . . . . .
Checking and Adjusting for Compressor
Replacement. . . . . . . . . . . . . . . . . . . . . . .
Contamination of Compressor Oil . . . . . . .
Oil Return Operation. . . . . . . . . . . . . . . . . .
Replacement of Component Parts . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System . . . . . . . .
Automatic Air Conditioner Parts
Configuration . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . .
Functions and Features . . . . . . . . . . . . . . .
Automatic Air Conditioner Block Diagram. .
Control Panel Layout . . . . . . . . . . . . . . . . .
Air Control Functions . . . . . . . . . . . . . . . . .
Operation and Functions of Control Panel
Switches . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of Construction, Movement and
Control of Major Parts of Automatic Air
Conditioner System . . . . . . . . . . . . . . . . .
1A64
1A64
1A64
1A65
1A66
1A66
1A66
1A67
1A68
1A71
1A71
1A71
1A72
1A73
1A73
1A73
1A75
1A75
1A77
1A77
1A77
1A77
1A77
1A78
1A78
1A78
1A78
1A79
1A81
1A82
1A82
1A82
1A83
1A84
1A90
1A91
1A92
1A93
1A94
1A97
Overview of Automatic Control of Automatic

Air Conditioner . . . . . . . . . . . . . . . . . . . . . 1A100
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 1A104
Troubleshooting, Its Overview and
Procedures . . . . . . . . . . . . . . . . . . . . . . . . 1A104
Auto Air Conditioner Control Unit Power
Supply Diagnosis . . . . . . . . . . . . . . . . . . . 1A105
Performance and Movement checklist for
Automatic Air Conditioner Related Parts . 1A107
Troubleshooting With Self-Diagnosis
Function . . . . . . . . . . . . . . . . . . . . . . . . . . 1A109
Inspection By Failed Location . . . . . . . . . . . . 1A113
Inspection of the Sensors . . . . . . . . . . . . . . 1A113
Inspection of the Intake Actuator System . 1A117
Inspection of the Mix Actuator System . . . . 1A120
Inspection of the Mode Actuator System . . 1A123
Inspection of the Fan Motor System . . . . . . 1A126
Inspection of the Magnetic Clutch System . 1A130
Condenser Fan Diagnosis . . . . . . . . . . . . . 1A133
Individual Inspection . . . . . . . . . . . . . . . . . . 1A136
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1A140
Power Transistor. . . . . . . . . . . . . . . . . . . . . 1A140
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A140
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A140
Automatic Heater/Air Conditioner Control Unit 1A140
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A140
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A140
Interior Temperature Sensor (Aspirator). . . 1A141
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A141
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A141
Outside Air Temperature Sensor . . . . . . . . 1A141
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A141
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A141
Solar Radiation Sensor. . . . . . . . . . . . . . . . 1A142
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A142
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A142
Electronic Thermostat. . . . . . . . . . . . . . . . . 1A142
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A142
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A142
Mode Actuator . . . . . . . . . . . . . . . . . . . . . . 1A143
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A143
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A143
Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . 1A143
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A143
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A143
Intake Actuator . . . . . . . . . . . . . . . . . . . . . . 1A144
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A144
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A144
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.
1A3
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.
Heating and Ventilation System

General Description
Heater
When the engine is warming up, the warmed engine
coolant is sent out into the heater core. The heater
system supplies warm air into the passenger
compartment to warm it up.
Outside air is circulated through the heater core of the
heater unit and then back into the passenger
compartment. By controlling the mixture of outside air
and heater core air, the most comfortable passenger
compartment temperature can be selected and
maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature control
knob. This knob acts to open and close the air mix door,
thus controlling the amount of air passed through the
heater core.
The air selector knob, with its different modes, also

allows you to select and maintain the most comfortable
temperature.
The air source select lever is used to select either
FRESH" for the introduction of the outside air, or
CIRC" for the circulation of the inside air. When the
lever is set to FRESH", the outside air is always taken
into the passenger compartment. When setting the
lever to CIRC" position, the circulation of air is
restricted only to the inside air with no introduction of
the outside air and the air in the passenger
compartment gets warm quickly. However, the lever is
normally set to FRESH" to prevent the windshield from
clouding.
1A4
Heater and Ventilation Associated Parts
840RX007
Legend
(1) Ventilation Duct
(2) Defroster Nozzle
(3) Lap Vent Duct
(4) Rear Heater Duct
EndOFCallout
(5)
(6)
(7)
(8)
(9)
Ventiration Lower Duct

Heater Unit
Duct (W/O A/C)
Evaporator Assembly (With A/C)
Blower Assembly
1A5
Ventilation
Setting the air source select lever to FRESH" position
allows the heating system to work with sending the
fresh air from outside.
The blower fan also serves to deliver fresh outside air to

the passenger compartment to assure adequate
ventilation.
810RW319
1A6
Control Lever Assembly

The control lever assembly has some cables to control
the mode and temperature of the heater unit and the
mode door for the air source of the blower assembly.
The fan control is used to control the amount of air sent

out by the resistor at four levels from LOW" to HIGH".
865RW006
Legend
(1) Air Source Select Lever
(2) Air Select Knob
(3) Fan Control Lever (Fan Switch)
(4) Air Conditioning (A/C) Switch (W/ A/C)

(5) Temperature Control Knob
(6) Middle Position
EndOFCallout
Air Source Select Lever
Temperature Control Knob
The intake of outside air and the circulation of inside air

are controlled by sliding this lever left or right.
When the temperature control knob is in the COLD"

position, the air mix door closes to block the flow air to
the heater core.
When the temperature control knob is in the HOT"
position, the air mix door opens to allow air to pass
through the heater core and heat the passenger
compartment.
Placing the knob in a intermediate position will cause a
lesser or greater amount air to reach the heater core. In
this mode the passenger compartment temperature can
be regulated.
Fan Control Lever

This lever controls the blower motor speed to regulate
the amount of air delivered to the defrost, foot, and
ventilation ducts:
1. Low
2. Medium Low
3. Medium High
4. High
1A7
Flow of Each Position of the All Select Dials
C01RX001
Air Select Knob

The air select knob allows you to direct heated air into
the passenger compartment through different outlets.
1. Vent In this position, air is discharged from the
upper air outlet. Air quantity is controlled by the fan
control lever.
2. Bi-Level In this position, air flow is divided
between the upper air outlets and the floor air
outlets, with warmer air delivered to the floor outlets
than the air delivered to the upper air outlets when
the temp lever is in middle position.
3. Foot In this position, air flow is delivered to the

foot, while sending a small amount of air to the
windshield.
4. Def/Foot In this position, air flow is delivered to
the foot, while sending approx. 40% of total amount
of air to the windshield.
5. Defrost In this position, most of the air is delivered
to the windshield and a small amount is delivered to
the side windows.
Moving the air source select lever to the CIRC" position
provides quickest heat delivery by closing the blower
assembly mode door. In this position, outside air is not
delivered to the passenger compartment.
1A8
Circuit Diagram
D08RX149
1A9
Diagnosis
Heating Cycle diagnosis
Condition
No heating or insufficient heating.
Possible cause
Correction
Blower motor does not run or runs

improperly.
Refer to FAN CONTROL LEVER

(FAN SWITCH) DIAGNOSIS".
Engine coolant temperature is low.
Check
the
engine
coolant
temperature after warming up the
engine and check the
thermostat.
Replace as necessary.
Insufficient engine coolant.
Add engine coolant as required.
Circulation volume of engine coolant

is insufficient.
Check if the water hose to the

heater core is clogged, collapsed or
twisted. Repair or replace as
necessary.
Heater core clogged or collapsed.
Clean or replace as necessary.
The heater cores is not provided

with air sent from the blower motor.
Repair the temperature control link

unit or mode doors.
Duct connections
unsealing.
Repair or replace as necessary.
defective
or
Control lever moves but mode door

does not operate.
Cable attaching clip is not correct.
Repair
Link unit of heater

assembly defective.
blower
Repair
The mode door cannot be set to the

mode selected.
Link unit of heater unit or blower

assembly defective.
Repair.
Control cable is not adjusted.
Adjust.
or
1A10
Fan Control Lever (Fan Switch) Diagnosis

Current flows to the blower motor through the heater
relay (X-6) to activate the rotation of the blower motor by
turning ON" the fan control knob (fan switch). Blower
motor speed is controlled in stages by the resistor, by
operating the switch from LOW" to HIGH".
For the inspection of the relays, switches and units in
each table, refer to INDIVIDUAL INSPECTION" in this
section.
D08RX250
Condition
Possible cause
Correction
Blower motor does not run.
Refer to Chart A
Blower motor does not run in certain

position (s).
Refer to Chart B, C, D and E
Blower motor does not stop at OFF"

position.
Refer to Chart F
1A11
Chart A" Blower Motor Does Not Run

Step
Action
Yes
No
Is relay (X-6) OK?
Go to Step 2
Replace
Is fuse F-4 (20A) OK?
Go to Step 3
Replace
Is resistor OK?
Go to Step 4
Replace
Is fan control lever OK?

Go to Step 5
Replace control
lever assembly.
Go to Step 6
Replace
Poor ground or
open circuit either
between chassis
side connector
terminal No. B5-1
and No. B3-2 or
No. I23-1 and body
ground (No. B-8).
Open circuit
between No. F-4
(20A) fuse and No.
B5-2.
Yes
No
Go to Step 2
Replace
Open circuit
between chassis
side connector
terminal No. B3-1
and No.I23-2.
Replace control
lever assembly.
Is blower motor OK?
1. Turn the ignition switch ON".

2. Turn fan control lever ON".
3. Check to see if battery voltage is present at chassis side
connector terminal No. B5-2
Is there a battery voltage?
Chart B" Blower Motor Does Not Run At Low Position

Step
Action
Is resistor OK?
Is fan control lever (Fan Switch) OK?
Chart C" Blower Motor Does Not Run At Medium Low Position
Step
Action
Is resistor OK?
Yes
No
Go to Step 2
Replace
Open circuit
between the
chassis side
connector terminal
No. B3-4 and No.
I23-3.
Replace control
lever assembly.
Chart D" Blower Motor Does Not Run At Medium High Position
Step
Action
Is resistor OK?
Yes
No
Go to Step 2
Replace
Open circuit
between chassis
side connector
terminal No. B3-6
and No. I23-4.
Replace control
lever assembly.
1A12
Chart E" Blower Motor Does Not Run At High Position

Step
Action
Is resistor OK?
Yes
No
Go to Step 2
Replace
Open circuit
between Chassis
side connector
terminal No. B3-3
and No. I23-5.
Replace control
lever assembly.
Chart F" Blower Motor Does Not Stop In The OFF" Position
Step
1
Action
Is the fan control lever (Fan Switch) OK?
Yes
No
Short circuit
between chassis
side connector
terminal No.B5-1
and
No.B3-2,No.B3-3
and No.I23-5,
No.B3-6 and
No.I23-4, No.B3-4
and No.I23-3 or
No.B3-1 and
No.I23-2
Replace control
lever assembly.
Individual Inspection
1A13
Resistor
Blower Motor
1. Disconnect the blower motor (B-5) connector from
the blower motor.
2. Connect the battery positive terminal to the No. 2
terminal of the blower motor and the negative to the
No. 1.
3. Be sure to check to see if the blower motor operates
correctly.
1. Disconnect the resistor (B-3) connector.

2. Check for continuity and resistance between the
terminals of the resistor.
873RW008
840RX013
Legend
(1) Resister Assembly
(2) Connector Terminal (Resister Side)
(3) Position Switch
EndOFCallout
1A14
Fan Control Lever (Fan Switch)
Heater Relay
1. Check for continuity between the terminals of the

fan switch.
1. Disconnect the heater relay (X-6).

When removing the connector for relay, unfasten
the tank lock of the connector by using a
screwdriver, then pull the relay (1) out.
825RX046
2. Check for continuity between the heater relay (X-6)

terminals.
D08RX157
Legend
(1) Control Lever Connector Terminal (Control
Lever Side)
(2) Position Switch
EndOFCallout
901RX071
1A15
Heater Unit
Heater Unit and Associated Parts
840RX006
Legend
(1) Instrument Panel Assembly
(2) Resistor Connector
(3) Heater Hose
(4) Heater Unit Assembly
(5) Duct (W/O A/C)
(6)
(7)
(8)
(9)
(10)
(11)
Evaporator Assembly (With A/C)

Lap Vent Duct
Rear Heater Duct
Ventilation Lower Duct
Instrument Panel Bracket
Cross Beam Assembly
EndOFCallout
Removal
1. Disconnect the battery ground cable.
2. Drain the engine coolant.
3. Discharge and recover refrigerant (with air
conditioning).
Refer to Refrigerant Recovery in this section.
4. Remove the Instrument panel assembly.
Refer to Instrument Panel Assembly in Body and
Accessories section.
5. Remove instrument panel bracket.
Refer to Cross Beam Assembly in Body and
6. Cross Beam Assembly.
Refer to Cross Beam Assembly in Body and
7. Disconnect resistor connector.
8. Remove duct.
9. Remove evaporator assembly (A/C only).
Refer to Evaporator Assembly in this section.
10. Remove driver lap vent duct.
11. Remove ventilation lower duct.
12. Remove rear heater duct.
Remove foot rest, carpet and 3 clips.
13. Remove heater unit assembly.
Disconnect heater hoses at heater unit.
1A16
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. When handling the PCM and the control unit, be
careful not to make any improper connection of the
connectors.
2. Adjust the control cables.

Refer to Control Lever Assembly in this section.
3. When installing the heater unit, defroster nozzle and
center vent duct, be sure that the proper seal is
made, without any gap between them.
4. After putting engine coolant in remove the air well
and confirm the quantity of coolant.
Heater Core and / or Mode Door

Disassembled View
860RX002
Legend
(1) Heater Unit
(2) Case (Temperature Control)
(3) Heater Core
(4) Case (Mode Control)

(5) Duct
(6) Mode Door
EndOFCallout
Removal

conditioning).
4. Remove heater unit.
Refer to Heater Unit in this section.
5. Remove duct.
6. Remove case (Mode control) and do not remove link
unit at this step.
7. Remove case (Temperature control) and separate
two halves of core case.
1A17
9. Pull out the mode door while raising up the catch of

the door lever.
860RX004
Legend
(1) Mode Door
(2) Door Lever
EndOFCallout
Inspection
860RW021
Legend
(1) Heater Core
(2) Core Case
Installation
EndOFCallout
8. Remove heater core.

noting the following point:
1. Check that each mode door operates properly.
860RW020-1
Legend
(1) Heater Core
EndOFCallout
Check for foreign matter in the heater core, stain or the

core fin defacement.
1A18
Heater Mode Control Link Unit

Disassembled View
860RW017
Legend
(1) Heater Unit
(3) Washer and Mode Main Lever
(4)
(5)
(6)
(7)
Rod
Mode Sub Lever
Door Lever
Clip
EndOFCallout
Removal
2. Drain engine coolant.
conditioning)
5. Remove the case (Mode control) from heater unit.
6. Remove washer and the mode main lever.
7. Remove rod.
8. Press the tab of the sub-lever inward, and take out
the sub-lever.
860RW018

9. Pull out the door lever while raising up the catch of
the door lever.
10. Remove clip.
1A19
Installation
To install, follow the remove steps in the reverse order,
1. Apply grease to the mode sub-lever and to the
abrasive surface of the heater unit.
2. After installing the link unit, check to see if the link
unit operates correctly.
Heater Temperature Control Link Unit

Disassembled View
860RX001
Legend
(1) Heater Unit
(2) Case (Temperature control)
(3) Door Lever
(4)
(5)
(6)
(7)
Sub Lever
Clip
Rod
Clip
EndOFCallout
Removal
conditioning).
5. Remove the case (Temperature control) from the

heater unit.
6. Remove rod.
7. Remove sub-lever.
the door lever.
9. Remove clip.
1A20
Installation
1. Apply grease to the sub-lever and to the abrasive

surface of the heater unit.
Blower Assembly
Blower Assembly and Associated Parts
840RX005
Legend
(2) Heater Unit
(3) Duct
(4) Evaporator Assembly (A/C only)
(5) Blower Assembly
EndOFCallout
Removal
2. Discharge and recover refrigerant
(with
air
conditioning).
3. Remove instrument panel assembly.
Refer to Instrument Panel Assembly in Body

structure section.
5. Remove duct.
6. Remove evaporator assembly (A/C only).
7. Disconnect blower motor connector.
8. Remove blower assembly.
1A21
Installation
Blower Link Unit and / or Mode door

Disassembled View
873RX002
Legend
(1) Blower Assembly
(2) Door Lever
(3) Sub Lever
EndOFCallout
Removal
conditioning).
Refer to Blower Assembly in this section.
4. Remove lower case.
(4) Lower Case

(5) Mode Door
(6) Upper Case
1A22
5. Separate the upper case and slit the lining parting

face with a knife.
873RW006

door lever.
8. Remove door lever.
Installation
1. Apply grease to the door lever and to the abrasive
surface of the upper case.
2. Apply an adhesive to the parting face of the lining
when assembling the upper case.
1A23
Blower Motor
Blower Motor and Associated Parts
873RX001
Legend
(1) Blower Motor Connector
(2) Attaching Screw
(3) Blower Motor Assembly
(4) Clip
(5) Fan
(6) Blower Motor
EndOFCallout
Removal
2. Remove blower motor connector.
3. Remove attaching screw.
4. Remove blower motor assembly.
5. Remove clip.
6. Remove fan.
7. Remove blower motor.
Installation
To install, follow the removal steps in the reverse order.
1A24
Rear Heater Duct, Defroster Nozzle and Ventilation Duct

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
840RX004
Legend
(1) Cross Beam Assembly
(3) Ventilation Lower Duct
(4) Lap Ventilation Duct
(5)
(6)
(7)
(8)
Rear Heater Duct

Instrument Panel Assembly
Instrument Panel Bracket
Center Ventilation Duct and Side Defroster
EndOFCallout
Removal
Structure section.
3. Remove center ventilation duct and side defroster
duct.
Remove 5 screws.
4. Remove lap ventilation duct.
5. Remove instrument panel brackets.
Refer to Cross Beam Assembly in Body Structure
section.
6. Remove cross beam assembly.

Refer to Cross Beam Assembly in Body Structure
section.
Remove foot rest carpet and 3 clips.
9. Remove defroster nozzle.
1A25
Installation
1. Connect each duct and nozzle securely leaving no
clearance between them and making no improper
matching.

Control Lever Assembly, Control Cable and Associated Parts
865RX009
Legend
(1) Control Cable
(2) Control Lever Assembly
EndOFCallout
(3) Meter Cluster Assembly

(4) Instrument Panel Driver Lower Cover Assembly
(5) Glove Box
1A26
Removal
2. Remove instrument panel driver lower cover
assembly.
3. Remove meter cluster assembly.
Structure section.
4. Remove glove box.
5. Remove the control lever attaching screws.
6. Pull the control lever assembly out and disconnect
the fan switch and air conditioning switch
connectors.
865RX012
7. Remove control level assembly.

8. Disconnect control cables at each unit side.
865RX010
1A27
Installation
1. Adjust the control cable.
865RX013
Air source control cable.

1 Slide the control lever to the left (CIRC"
position).
2 Connect the control cable at the CIRC"
position of the link unit of the blower assembly
and secure it with the clip.
Temperature control cable.
1 Turn the control knob to the left (MAX COLD"
position).
2 Connect the control cable at the COLD"
position of the temperature control link of the
heater unit and secure it with the clip.
Air select control cable
1 Turn the control knob to the right
(DEFROST" position).
2 Connect the control cable at the DEFROST"
position of the mode control link of the heater
unit and secure it with the clip.
2. Check the control cable operation.
1A28
Control Panel Illumination Bulb

Associated Parts
Removal
2. Remove control lever assembly.
3. Pull out the bulb socket from the panel by turning it
counterclockwise.
4. Pull the illumination bulb from the socket.
Installation
865RX011
Legend
(2) Bulb Socket
(3) Illumination Bulb
EndOFCallout
Resistor
Resistor and Associated Parts
Removal
3. Remove resistor connector.
4. Remove duct (heater only).
5. Remove resistor.
Installation
840RX016
Legend
(1) Duct (Heater only)
(2) Resistor
(4) Glove Box
EndOFCallout
1A29
Air Conditioning System

General Description
Air Conditioning Refrigerant Cycle Construction
C01RX004
Legend
(1) Electronic Thermostat
(2) Evaporator Core
(3) Evaporator Assembly
(4) Temperature Sensor
(5) Expansion Valve
(6) Blower Motor
(7) Pressure Switch or Pressure Sensor
(8) Receiver/Drier
EndOFCallout
The refrigeration cycle includes the following four
processes as the refrigerant changes repeatedly from
liquid to gas and back to liquid while circulating.
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Condenser
Compressor
Magnetic Clutch
Mode (HEAT) Control Door
Temp. Control Door (Air Mix Door)
Heater Core
Mode (VENT) Control Door
Heater Unit
Mode (DEF) Control Door
Evaporation
The refrigerant is changed from a liquid to a gas inside
1A30
the evaporator. The refrigerant mist that enters the

evaporator vaporizes readily. The liquid refrigerant
removes the required quantity of heat (latent heat of
vaporization) from the air around the evaporator core
cooling fins and rapidly vaporizes. Removing the heat
cools the air, which is then radiated from the fins and
lowers the temperature of the air inside the vehicle.
The refrigerant liquid sent from the expansion valve and
the vaporized refrigerant gas are both present inside the
evaporator as the liquid is converted to gas.
With this change from liquid to gas, the pressure inside
the evaporator must be kept low enough for vaporization
to occur at a lower temperature. Because of that, the
vaporized refrigerant is sucked into the compressor.
Compression
The refrigerant is compressed by the compressor until it
is easily liquefied at normal temperature.
The vaporized refrigerant in the evaporator is sucked
into the compressor.
This action maintains the
refrigerant inside the evaporator at a low pressure so
that it can easily vaporize, even at low temperatures
close to 0C (32).
Also, the refrigerant sucked into the compressor is
compressed inside the cylinder to increase the pressure
and temperature to values such that the refrigerant can
easily liquefy at normal ambient temperatures.
Condensation
The refrigerant inside the condenser is cooled by the
outside air and changes from gas to liquid.
The high temperature, high pressure gas coming from
the compressor is cooled and liquefied by the
condenser with outside air and accumulated in the
receiver/drier. The heat radiated to the outside air by the
high temperature, high pressure gas in the compressor
is called heat of condensation. This is the total quantity
of heat (heat of vaporization) the refrigerant removes
from the vehicle interior via the evaporator and the work
(calculated as the quantity of heat) performed for
compression.
Compressor
The compressor performs two main functions:
It compresses low-pressure and low-temperature
refrigerant vapor from the evaporator into high-pressure
and high-temperature refrigerant vapor to the
condenser.
It pumps refrigerant and refrigerant oil through the air
conditioning system.
This vehicle is equipped with a five-vane rotary
compressor.
The specified amount of the compressor oil is 150cc
(5.0fl.oz.).
The oil used in the HFC-134a system compressor
differs from that used in R-12 systems.
Also, compressor oil to be used varies according to the
compressor model. Be sure to avoid mixing two or more
different types of oil.
If the wrong oil is used, lubrication will be poor and the
compressor will seize or malfunction.
The magnetic clutch connector is a waterproof type.
Magnetic Clutch
The compressor is driven by the drive belt from the
crank pulley of the engine. If the compressor is activated
each time the engine is started, this causes too much
load to the engine. The magnetic clutch transmits the
power from the engine to the compressor and activates
it when the air conditioning is ON. Also, it cuts off the
power from the engine to the compressor when the air
conditioning is OFF. Refer to Compressor in this section
for magnetic clutch repair procedure.
Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize.
The process of lowering the pressure to encourage
vaporization before the liquefied refrigerant is sent to
the evaporator is called expansion. In addition, the
expansion valve controls the flow rate of the refrigerant
liquid while decreasing the pressure.
That is, the quantity of refrigerant liquid vaporized inside
the evaporator is determined by the quantity of heat
which must be removed at a prescribed vaporization
temperature. It is important that the quantity of
refrigerant be controlled to exactly the right value.
871RX009
Legend
(1) Magnetic Clutch
(2) Connector: Magnetic Clutch
(3) Compressor
EndOFCallout

Condenser
The condenser assembly is located in front of the
radiator. It provides rapid heat transfer from the
refrigerant to the cooling fins.
Also, it functions to cool and liquefy the high-pressure
and high-temperature vapor sent from the compressor
by the radiator fan or outside air.
A condenser may malfunction in two ways: it may leak,
or it may be restricted. A condenser restriction will
result in excessive compressor discharge pressure. If a
partial restriction is present, the refrigerant expands
after passing through the restriction.
Thus, ice or frost may form immediately after the
restriction. If air flow through the condenser or radiator
is blocked, high discharge pressures will result. During
normal condenser operation, the refrigerant outlet line
will be slightly cooler than the inlet line.
The vehicle is equipped with the parallel flow type
condenser. A larger thermal transmission area on the
inner surface of the tube allows the radiant heat to
increase and the ventilation resistance to decrease.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
1A31
The liquefied refrigerant from the condenser is mixed

with refrigerant gas containing air bubbles. If
refrigerant containing air bubbles. If refrigerant
containing air bubbles is sent to the expansion valve,
the cooling capacity will decrease considerably.
Therefore, the liquid and air bubbles are separated
and only the liquid is sent to the expansion valve.
The receiver/drier utilizes a filter and drier to remove
the dirt and water mixed in the cycling refrigerant.
The sight glass, installed atop the receiver/drier,
show the state of the refrigerant.
A receiver/drier may fail due to a restriction inside the
body of the unit. A restriction at the inlet to the receiver/
drier will cause high pressure.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
The receiver/drier of this vehicle is made of aluminum
with a smaller tank. It has a 300cc refrigerant capacity.
Dual Pressure Switch (V6,M/T)

The pressure switch (Dual pressure switch) is installed
on the upper part of the receiver/drier, to detect
excessively high pressure (high pressure switch) and
prevent compressor seizure due to the refrigerant
leaking (low pressure switch), so that the compressor is
able to be turned ON" or OFF".
Compressor
ON
(kPa/psi)
OFF
(kPa/psi)
Low-pressure
control
186.329.4
(27.04.3)
176.519.6
(25.62.8)
High-pressure
control
2350.4196.1
(340.728.4)
2942.0196.1
(426.628.4)
Triple Pressure Switch (V6, A/T)
875RX003
Legend
(1) Pressure Switch
(2) Receiver/Drier
(3) Condenser & Receiver Tank Assembly
(4) Condenser Fan (6VD1 A/T)
EndOFCallout
Triple pressure switch is installed on the upper part of

the receiver/drier. This switch is constructed with a
unitized type of two switches. One of them is a low and
high pressure switch (Dual pressure switch) to switch
ON" or OFF" the magnetic clutch as a result of
irregularly high-pressure or low pressure of the
refrigerant. The other one is a medium pressure switch
(Cycling switch) to switch ON" or OFF" the condenser
fan sensing the condenser high side pressure.
Receiver / Drier
Compressor
ON
(kPa/psi)
OFF
(kPa/psi)
The receiver/drier performs four functions:

As the quantity of refrigerant circulated varies
depending on the refrigeration cycle conditions,
sufficient refrigerant is stored for the refrigeration
cycle to operate smoothly in accordance with
fluctuations in the quantity circulated.
Low-pressure
control
186.329.4
(27.04.3)
176.524.5
(25.63.6)
High-pressure
control
2353.6196.1
(341.328.4)
2942.0196.1
(426.628.4)
1A32
Condenser fan
ON
(kPa/psi)
OFF
(kPa/psi)
Medium-pressure
control
1471.098.1
(213.314.2)
1078.7117.7
(156.417.1)
Pressure Sensor
The pressure sensor is installed on the upper part of the
receiver/drier. This sensor converts high pressure
detection of refrigerant to an electrical voltage signal
and supplies it to the PCM. The PCM controls switching
compressor idle speed and cooling fan operation by the
electrical voltage signal.
the force acting on the diaphragm and the spring

pressure.
The expansion valve regulates the flow rate of the
refrigerant. Accordingly, when a malfunction occurs to
this expansion valve, both discharge and suction
pressure get low, resulting in insufficient cooling
capacity of the evaporator.
The calibration has been changed to match the
characteristics of HFC-134a.
874RX009
Legend
(1) Expansion Valve
EndOFCallout
875RX002
Legend
(1) Pressure Switch
(2) Receiver Drier
EndOFCallout
Expansion Valve
This expansion valve is an external pressure type and it
is installed at the evaporator intake port.
The expansion valve converts the high pressure liquid
refrigerant sent from the receiver/drier to a low pressure
liquid refrigerant by forcing it through a tiny port before
sending it to the evaporator.
This type of expansion valve consists of a temperature
sensor, diaphragm, ball valve, ball seat, spring
adjustment screw, etc.
The temperature sensor contacts the evaporator outlet
pipe, and converts changes in temperature to pressure.
It then transmits these to the top chamber of the
diaphragm.
The refrigerant pressure is transmitted to the
diaphragm's bottom chamber through the external
equalizing pressure tube.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
Evaporator
The evaporator cools and dehumidifies the air before
the air enters the passenger compartment.
High-pressure liquid refrigerant flows through the
expansion valve into the low-pressure area of the
evaporator. The heat in the air passing through the
evaporator core is lost to the cooler surface of the core,
thereby cooling the air.
As heat is lost between the air and the evaporator core
surface, moisture in the vehicle condenses on the
outside surface of the evaporator core and is drained off
as water.
When the evaporator malfunctions, the trouble will show
up as an inadequate supply of cool air. The cause is
typically a partially plugged core due to dirt, or a
malfunctioning blower motor.
The evaporator core with a laminate louver fin is a
single-sided tank type where only one tank is provided
under the core.
1A33
874RX007
Legend
(1) Evaporator Core
(2) Expansion Valve
EndOFCallout
Electronic Thermostat (With Manual A/C)

The thermostat consists of the thermo sensor and
thermostat unit which functions electrically to reduce the
noises being generated while the system is in operation.
The electronic thermo sensor is mounted at the
evaporator core outlet and senses the surface
temperature of the evaporator core. Temperature
signals are input to the thermostat unit. This information
is compared by the thermo unit and results in the output
to operate the A/C thermostat relay and turn the
magnetic clutch ON or OFF to prevent evaporator
freeze-up.
A characteristic of the sensor is that the resistance
decreases as the temperature increases and the
resistance increases as the temperature decreases.
874RX008
Legend
(1) Thermo Sensor
(2) Evaporator Core
(3) Thermostat Unit
EndOFCallout
1A34
Refrigerant Line
Restriction in the refrigerant line will be indicated by:
1. Suction line A restricted suction line will cause
low suction pressure at the compressor, low
discharge pressure and little or no cooling.
2. Discharge line A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line A liquid line restriction will be
evidenced by low discharge and suction pressure
and insufficient cooling.
Refrigerant flexible hoses that have a low permeability
to refrigerant and moisture are used. These low
permeability hoses have a special nylon layer on the
inside.
852RS001
Legend
(1) Reinforcement Layer (Polyester)
(2) External Rubber Layer
(3) Internal Rubber Layer
(4) Resin Layer (Nylon)
EndOFCallout
1A35
Refrigerant Line Associated Parts
852RX008
Legend
(2) O-Ring
(3) Drain Hose
(4) Liquid Line (High Pressure Pipe)
(5) Suction Line (Low Pressure Hose)
EndOFCallout
(6)
(7)
(8)
(9)
(10)
(11)
Platform Seal
Condenser Assembly
Receiver Drier
Pressure Switch
Discharge Line (High Pressure Hose)
Compressor
1A36
Circuit Diagram
D08RX151
1A37
D08RX150
1A38
Diagnosis
Air Conditioning Cycle Diagnosis
Condition
No cooling or insufficient cooling.
Insufficient velocity of cooling air.
Possible cause
Correction
Magnetic clutch does not run.
Refer
to
Magnetic
Diagnosis" in this section.
Compressor is not rotating properly.

Drive belt is loosened or broken.
Adjust the drive belt to the specified

tension or replace the drive belt.

Magnetic clutch face is not clean
and slips.
Clean the magnetic clutch face or

replace.

Incorrect
clearance
between
magnetic drive plate and pulley.
Adjust the clearance. Refer

Compressor in this section.

Compressor oil leaks from the shaft
seal or shell.
Replace the compressor

Compressor is seized.
Insufficient or excessive charge of

refrigerant.
Discharge
and
recover
refrigerant.
Recharge to
specified amount.
Leaks in the refrigerant system.
Check the refrigerant system for

leaks and repair as necessary.
Discharge
and
recover
the
refrigerant.
Recharge to the
specified amount.
Condenser is clogged or insufficient

radiation.
Clean the condenser or replace as

necessary.
Temperature control link unit of the

heat unit is defective.
Repair the link unit.
Unsteady operation due to a foreign

substance in the expansion valve.
Replace the expansion valve.
Poor operation of the electronic

thermostat.
Check the electronic thermostat and

replace as necessary.
Evaporator clogged or frosted.
Check the evaporator core and

replace or clean the core.
Air leaking from the cooling unit or

air duct.
Check the evaporator and duct

connection,
then
repair
as
necessary.
Blower motor
properly.
Refer to Fan Control Lever (Fan

Switch) Diagnosis in this section.
*For the execution of the charging and discharging

operation in the table above, refer to Recovery,
Recycling, Evacuating and Charging in this section.
does
not
rotate
Clutch
to
the
the

Checking The Refrigerant System With Manifold Gauge
Since Refrigerant-134a (HFC-134a) is used in the air
conditioning
system in this vehicle, be sure to
use manifold gauges, charging hoses and other air
conditioning service tools
for HFC-134a when
checking the refrigerant system.
Conditions:
Run the engine at Idling
Air conditioning switch is ON"
Run the blower motor at HIGH" position
Temperature control lever set to MAX COLD"
Air source selector lever at CIRC"
Open the engine hood
Close all the doors
At ambient temperature: approx. 2530C (7786F).
Normal Pressure:
At low-pressure side: approx. 147.1294.2 kPa
(21.342.7 psi).
At high-pressure side: approx. 1372.91863.3 kPa
(199.1270.2 psi).
Refer
to
the
table
on
the
refrigerant
pressure-temperature relationship.
HFC-134a Pressure-Temperature Relationship
Pressure
Temperature
(kPa)
(psi)
(C)
(F)
36
5.3
20
4.4
67
9.7
15
104
15
10
14
147
21
23
196
28
32
255
37
41
314
45
10
50
392
57
15
59
471
68
20
68
569
82
25
77
677
98
30
86
785
114
35
95
912
132
40
104
1059
154
45
113
1216
176
50
122
1A39
1A40
Connect The Manifold Gauge

Low-pressure hose (LOW) Suction side
High pressure hose (HI) Discharge side
901RX060
Legend
(1) High Side
EndOFCallout
(2) Low Side

Condition
Possible cause
1A41
Correction
Discharge (High Gauge) Pressure

Abnormally High
Condenser clogged or dirty.

Abnormally High.
Insufficient cooling.
Excessive refrigerant in system.
Discharge and recover refrigerant.

Recharge to specified amount.

Abnormally High.
High pressure gauge drop.
(After
stopping A/C, the pressure drops
approx. 196kPa (28psi) quickly)
Air in system.
Evacuate and charge refrigerant

system.

Abnormally Low.
Insufficient cooling
Insufficient refrigerant in system.
Check for leaks. Discharge and

recover the refrigerant. Recharge to
the specified amount.

Abnormally Low.
Low pressure gauge indicates
vacuum.
Clogged
valve.

Abnormally Low.
Frost or dew on refrigerant line
before and after the receiver/drier or
expansion valve, and low pressure
gauge indicates vacuum.
Restriction caused by debris or

moisture in the receiver/drier.
Check system for restriction and

replace the receiver/drier.

Abnormally Low.
High and low pressure gauge
balanced quickly. (After turned off A/
C)
Compressor seal defective
Repair or replace the compressor.
Poor compression due to a defective

compressor gasket.
Suction (Low Gauge) Pressure

Abnormally High.
Low pressure gauge (Low pressure
gauge is lowered after condenser is
cooled by water.)
Discharge and recover refrigerant


Abnormally High.
Low pressure hose temperature.
(Low pressure hose temperature
around the compressor refrigerant
line connector is lower than around
evaporator.)
Unsatisfactory valve operation due

to defective temperature sensor of
expansion valve.
Expansion valve opens too long.

Abnormally High.
C)
Compressor gasket is defective.
Suction (Low Gauge)

Abnormally Low.

specified amount.
Expansion valve clogged.
Pressure

Abnormally Low.
Frost on the expansion valve inlet
line
Cooling fan
properly.
or
does
not
defective
Clean the condenser fins

operate
expansion
Check the cooling fan operation.
1A42

Condition
Possible cause
Correction

Abnormally Low
Receiver/drier inlet and outlet
refrigerant line temperature. (A
distinct difference in temperature
develops.)
Receiver/Drier clogged.
Replace the receiver/drier.

Abnormally Low.
Expansion valve outlet refrigerant
line. (Not cold and low pressure
gauge indicates vacuum.)
Expansion valve temperature sensor

is defective.

Abnormally Low.
When the refrigerant line is clogged
or blocked,
the low pressure
gauge reading will decrease, or a
vacuum reading may be shown.
Clogged or blocked refrigerant line.
Replace refrigerant line.

Abnormally Low.
Evaporator core is frozen.
Thermo switch defective.
Replace thermo switch.
Suction (Low Gauge) and Discharge

(High Gauge) Pressure Abnormally
High.
Discharge
and
recover
the
refrigerant, the Recharge to the
specified amount.
Clean the condenser fin.

High.
Suction (Low) pressure hose (Not
cold).
Air in system.
Evacuate and charge refrigerant.

Low.

recover refrigerant. Recharge to
specified amount.
1A43
Magnetic Clutch Diagnosis
D08RX249
When the air conditioning switch and the fan control

knob (fan switch) are turned on with the engine running,
current flows through the thermostat and

compressor relay to activate the magnetic clutch.
the
1A44
The air conditioning can be stopped by turning of the air

conditioning switch or the fan control knob (fan switch).
However, even when the air conditioning is in operation,
the electronic thermostat, the pressure switch or the
Powertrain Control Module (PCM;V6-3.2L)/ Engine
Control Module (ECM;L4-2.2L) is used to stop the air
conditioning temporarily
by turning off the magnetic
Magnetic Clutch Does Not Run
Step
clutch in the prearranged conditions to reduce the

engine load which is being
caused by the rise in the
engine coolant temperature, and the acceleration of the
vehicle, etc.
the table, refer to Individual Inspection" in this section.
Action
Value(s)
Yes
No
Is the fuse No. F-5 normal?
Go to Step 2
Replace the
fuse
Are the relay No.X-6 (heater relay). No.X-5

(Thermostat relay) and No.X-4 (compressor relay)
normal?
Go to Step 3
Replace the
relay
Is pressure switch normal?
Go to Step 4
Place the
pressure
switch.
Are the air conditioner switch and the fan control

switch normal?
Go to Step 5
Replace the A/
C switch and
fan control
switch
1. Turn the ignition switch ON" (the engine is run).

2. Turn the air conditioner switch and the fan control
switch on.
Is the battery voltage applied between harness side
connector terminal No.E3-1 and ground?
Approx.12V
Go to Step 6
Go to Step 7
Repair an open circuit between compressor side

terminal and ground or replace compressor.
Is the action complete?
Varify repair
Is there continuity between harness side connector

terminal No.X4-1 and No.E3-1?
Go to Step 9
Go to Step 8
Repair an open circuit between terminal No.X4-1 and

No.E3-1.
Go to Step 7

connector terminal No.X4-2 and ground, No.X4-5 and
ground?
Approx.12V
Go to Step 11
Go to Step 10
10
Repair and open circuit between terminal No.X4-2 and

No.F-5 fuse, No.X4-5 and No.F-5 fuse.
Go to Step 9
11

terminal No.X4-4 and No.C1-B14?
Go to Step 13
Go to Step 12
12

No.C1-B14.
Go to Step 11
13

connector terminal No.I24-2 and ground?
Approx.12V
Go to Step 15
Go to Step 14
14
Repair an open circuit between terminal No.I24-2 and

No.F-5 fuse.
Go to Step 13
15

connector terminal No.B4-3 and ground?
Approx.12V
Go to Step 17
Go to Step 16
1A45
Magnetic Clutch Does Not Run (Conts)

Step
Action
Value(s)
Yes
No
16
Repair an open circuit between terminal No.B4-3 and

No.I24-1.
Go to Step 15
17

terminal No.I23-6 and No.B-2?
Go to Step 19
Go to Step 18
18

No.B4-2.
Go to Step 17
19

terminal No.I23-1 and ground (No.B-8)?
Go to Step 21
Go to Step 20
20

No.B-8.
Go to Step 19
21

connector terminal No.C11-1 and ground?
Go to Step 23
Go to Step 22
22
Repair an open circuit between terminal No.C11-1

and No.F-5 fuse.
Go to Step 21
23

connector terminal No.X5-2 and ground?
Go to Step 25
Go to Step 24
24

No.C11-2.
Go to Step 23
25

Go to Step 27
Go to Step 26
26

No.X5-4.
Go to Step 25
27

terminal No.X5-1 and No.C3-E15?
Go to Step 29
Go to Step 28
28

No.C3-E15.
Verify repair
29
Replace the PCM.

Verify repair
CAUTION:
There are condition whitch air
conditioner system dose not operate except trouble
as follows.
1. The throttle is greater than 90%.
2. The ignition voltage is below 10.5 volts.
3. The engine speed is greater than 4500 RPM for 5
seconds or 5400 RPM.
4. The engine coolant temperature (ECT) is greater
than 125C (257F).
5. The intake air temperature (IAT) is less than 5C
(41F).
6. The power steering pressure switch signals a high
pressure condition.
1A46
Fan Control Knob (Fan Switch) And Air
Conditioning (A/C) Switch
1. Check for continuity between the fan switch and the
A/C switch side connector terminals.
Heater (X-6), Thermostat (X-5), Condenser

Fan (X-9) And Compressor (X-4) Relay
1. Disconnect relays and check for continuity and
resistance between relay terminals.
For handling of these relays, refer to Heater Relay
in this section.
901RX071
Pressure Switch
1. Disconnect pressure switch connector and check for
continuity between pressure switch side connector
terminals (1) and (2).
D08RX254
Legend
(1) A/C Switch Connector (switch side)
(2) Fan Switch Connector (switch side)
EndOFCallout
875RX010
1A47
General Repair Procedure
Repair Of Refrigerant Leaks
Precautions For Replacement or Repair of

Air Conditioning Parts
Refrigerant Line Connections

Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the
connecting portion from twisting or becoming damaged.
There are certain procedures, practices and

precautions that should be followed when servicing air
conditioning systems:
Keep your work area clean.
Always wear safety goggle and protective gloves
when working on refrigerant systems.
Beware of the danger of carbon monoxide fumes
caused by running the engine.
Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or
parts are reconnected or installed.
When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
Always install new O-rings whenever a connection is
disassembled.
Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
1 Use the J-39500 (ACR4: HFC-134a Refrigerant
Recovery / Recycling / Recharging / System) or
equivalent to thoroughly discharge and recover
the refrigerant.
2 Remove and replace the defective part.
3 After evacuation, charge the air conditioning
system and check for leaks.
852RS003
When connecting the refrigerant line at a block joint,

securely insert the projecting portion of the joint portion
into the connecting hole on the unit side and secure with
a bolt. Apply the specified
compressor oil to the
O-rings prior to connecting.
CAUTION: Compressor (PAG) oil to be used varies
according to the compressor model.
Be sure to
apply oil specified for the model of compressor.
850RW002
1A48
O-rings (2) must be fitted in the groove (1) of refrigerant

line.
Insert the nut into the union.

First, tighten the nut by hand as much as possible, then
tighten the nut to the specified torque.
850RW003
Leak Check
Inspection of refrigerant leak
Refrigerant leak may cause an adverse effect not only
on the performance and durability of each component of
the air-conditioner, but also on the global atmosphere.
Therefore, it is most important to repair refrigerant leak
when there is any leak found.
Inspection flow of refrigerant leak
Step
1
Action
Yes
No
1. Evacuate the refrigerant system.

2. Charge the refrigerant.
Is there any refrigerant leak?
Repair refrigerant
system.
Go to Step 2.
1. Operate the compressor for more than 5 minutes to raise the

pressure on the high pressure side.
Is there any refrigerant leak at high pressure components?
Repair refrigerant
system.
Compressor
operation to be
confirmed.
Inspection Steps
Check the components of air-conditioner to see if there
occurs any refrigerant leak along the flow of refrigerant.
To avoid an error in the detection of refrigerant leak,
make sure of there being no refrigerant vapor or
cigarette smoke around the vehicle before conducting
the inspection. Also, select a location where the
refrigerant vapor will not get blown off with wind.
Inspection should be conducted chiefly on the pipe
connections and sections where a marked oil
contamination is found. When refrigerant is leaking,
oil inside is also leaking at the same time.
It is possible to visually check the leak from inside the
cooling unit. Follow the method below when
checking. Remove the drain hose or resistor of the
cooling unit, and insert a leak detector to see if there

occurs any leak.
High Pressure Side
1. Discharger section of compressor.
2. Inlet/outlet section of condenser.
3. Inlet/outlet section of receiver driver.
4. Inlet section of cooling unit.
Low Pressure Side
1. Outlet section of cooling unit.
2. Intake section of compressor.

Major Checking Points of Refrigerant Leak
Compressor
Pipe connection
Sealing section of shaft
Mating section or cylinder
Condenser
Pipe connection
Welds of condenser body
Receiver driver
Pipe connection
Attaching section of pressure switch
Section around the sight glass
Evaporator unit (cooling unit)
Pipe connections
Connections of expansion valve
Brazed sections of evaporator
The evaporator and expansion valve are contained in
the case. Remove the drain hose or the resistor of the
cooling unit and insert a leak detector when checking
for any leak.
Flexible hose
Pipe connection
Caulking section of the hose
Hose (cracks, pinholes, flaws)
Pipe
Pipe connection
Pipe (cracks, flaws)
Charge valve
The charge valve, which is used to connect the gauge
manifold, is normally provided with a resin cap. When
the valve inside gets deteriorated, refrigerant will leak
out.
Leak at Refrigerant Line Connections

1. Check the torque on the refrigerant line fitting and, if
too loose, tighten to the specified torque.
Use two wrenches to prevent twisting and
damage to the line.
Do not over tighten.
2. Perform a leak test on the refrigerant line fitting.
3. If the leak is still present, discharge and recover the
refrigerant from the system.
4. Replace the O-rings.
O-rings cannot be reused. Always replace with
1A49
new ones.
Be sure to apply the specified compressor oil to
the new O-rings.
5. Retighten the refrigerant line fitting to the specified
torque.
damage to the line.
6. Evacuate, charge and retest the system.
Leaks In The Hose

If the compressor inlet or outlet hose is leaking, the
entire hose must be replaced. The refrigerant hose must
not be cut or spliced for repair.
1. Locate the leak.
2. Discharge and recover the refrigerant.
3. Remove the hose assembly.
Cap the open connections at once.
4. Connect the new hose assembly.
Use two wrenches to prevent twisting or damage
to the hose fitting.
Tighten the hose fitting to the specified torque.
5. Evacuate, charge and test the system.
Compressor Leaks
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
Recovery, Recycling,
Charging of HFC-134a
Evacuation
and
Air conditioning systems contain HFC-134a. This is a

chemical mixture which requires special handling
procedures to avoid personal injury.
Always wear safety goggles and protective gloves.
Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
If HFC-134a should come in contact with any part of
the body, flush the exposed area with cold water and
immediately seek medical help.
If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the
passenger compartment.
If it is necessary to fill a small HFC-134a container
from a large one, never fill the container completely.
Space should always be allowed above the liquid for
expansion.
HFC-134a and R-12 should never be mixed as their
compositions are not the same.
HFC-134a PAG oil tends to absorb moisture more
quickly than R-12 mineral oil and, therefore, should
be handled more carefully.
Keep HFC-134a containers stored below 40C
(100F).
1A50
WARNING:
SHOULD HFC-134A CONTACT YOUR EYE(S),
CONSULT A DOCTOR IMMEDIATELY.
DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER
OVER THE AFFECTED
AREA TO GRADUALLY
RAISE
THE
TEMPERATURE
OF
THE
REFRIGERANT ABOVE THE FREEZING POINT.
OBTAIN PROPER MEDICAL TREATMENT AS
SOON AS POSSIBLE. SHOULD THE HFC-134A
TOUCH THE SKIN, THE INJURY MUST BE
TREATED THE SAME AS SKIN WHICH HAS BEEN
FROSTBITTEN OR FROZEN.
3. When a part is removed, put a cap or a plug on the

connecting portion so that dust, dirt or moisture
cannot get into it.
Refrigerant Recycling
Recycle the refrigerant recovered by J-39500
(ACR4:HFC-134a Refrigerant Recovery / Recycling /
Recharging / System) or equivalent.
For the details of the actual operation, follow the steps in
the ACR4(or equivalent) Manufacturer's Instructions.
Evacuation of The Refrigerant System
Refrigerant Recovery
The refrigerant must be discharged and recovered by
using the J-39500 (ACR4:HFC-134a Refrigerant
Recovery/Recycling/Recharging/System) or equivalent
before removing or mounting air conditioning parts.
1. Connect the high and low charging hoses of the
ACR4(or equivalent) as shown below.
901RX058
Legend
(1) High Side
(2) Low Side
901RX057
Legend
(1) High Side
(2) Low Side
EndOFCallout
2. Recover the refrigerant
Manufacturer's Instructions.
by
following
the
EndOFCallout
Explained below is a method using a vacuum pump.
Refer to the ACR4(or equivalent) manufacturer's
instructions when evacuating the system with a ACR4(or
equivalent).
Air and moisture in the refrigerant will cause problems in
the air conditioning system. Therefore, before charging
the refrigerant, be sure to evacuate air and moisture
thoroughly from the system.
1. Connect the gauge manifold.
High-pressure valve (HI) Discharge-side.
Low-pressure valve (LOW) Suction-side.
3. Connect the center hose of the gauge manifold set
to the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
then open both hand valves.
5. When
the
low-pressure
gauge
indicates
approximately 750mmHg (30inHg), continue the
evacuation for 5 minutes or more.
6. Close both hand valves and stop the vacuum pump.

7. Check to ensure that the pressure does not change
after 10 minutes or more.
If the pressure changes, check the system for
leaks.
If leaks occur, retighten the refrigerant line
connections and repeat the evacuation steps.
8. If no leaks are found, again operate the vacuum
pump for 20 minutes or more. After confirming that
the gauge manifold pressure is at 750mmHg
(30inHg), close both hand valves.
9. Close positive shutoff valve. Stop the vacuum pump
and disconnect the center hose from the vacuum
pump.
1A51
Direct charging with a weight scale charging

station method
1. Make sure the evacuation process is correctly
completed.
2. Connect the center hose of the manifold gauge to
the weight scale.
3. Connect the low pressure charging hose of the
manifold gauge to the low pressure side service
valve of the vehicle.
4. Connect the high pressure charging hose of the
manifold gauge to the high pressure side service
Charging The Refrigerant System

There are various methods of charging refrigerant into
the air conditioning system.
These include using J-39500 (ACR4:HFC-134a
Refrigerant Recovery/Recycling/Recharging/System) or
equivalent and direct charging with a weight scale
charging station.
Charging Procedure
ACR4(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer's instruction.
901RX059
Legend
(1) Weight Scale
(2) Refrigerant Container
(3) High Side
(4) Low Side
901RX057
Legend
(1) High Side
(2) Low Side
EndOFCallout
EndOFCallout
5. Place the refrigerant container up right on a weight
scale.
Note the total weight before charging the refrigerant.
a Open the refrigerant container valve.
b Open the low side vale on the manifold gauge
set. Refer to the manufacturer's instructions for
a weight scale charging station.
1A52
6. Perform a system leak test:

Charge the system with approximately 200g
(0.44lbs) of HFC-134a.
Make sure the high pressure valve of the manifold
gauge is closed.
Check to ensure that the degree of pressure does
not change.
Check for refrigerant leaks by using a HFC-134a
leak detector.
If a leak occurs, recover the refrigerant. Repair
the leak and start all over again from the first step
of evacuation.
7. If no leaks are found, continue charging refrigerant
to the air conditioning system.
Charge the refrigerant until the scale reading
decreases by the amount of the charge specified.
Specified amount: 650g (1.43lbs)
If charging the system becomes difficult:
1 Run the engine at idle and close all the
vehicle doors.
2 Turn A/C switch ON".
3 Set the fan switch to its highest position.
4 Set the air source selector lever to CIRC".
5 Slowly open the low side valve on the
manifold gauge set.
WARNING: Be absolutely sure not to open the high
pressure valve of the manifold gauge. Should the
high pressure valve be opened, the high pressure
refrigerant would flow backward, and this may
cause the refrigerant container to burst.
8. When finished with the refrigerant charging, close
the low pressure valve of the manifold gauge and
container valve.
9. Check for refrigerant leaks.
Checking The A/C System

1. Run the engine and close all the vehicle doors.
2. Turn A/C switch ON", set the fan switch to its
highest position.
3. Set the air source lever to CIRC", set the
temperature lever to the full cool position.
4. Check the high and low pressure of the manifold
gauge.
Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:
The ambient temperature should be between 25
30C (7786F).
The pressure guideline for the high-pressure side
is approximately 1372.91863.3kPa (199.1
270.2 psi).
The pressure guideline for the low-pressure side
is approximately 147.1294.2kPa (21.342.7

psi).
If an abnormal pressure is found, refer to
Checking The Refrigerant System With Manifold
Gauge in this section.
5. Put your hand in front of the air outlet and move the
temperature control lever of the control panel to
different positions. Check if the outlet temperature
changes as selected by the control knob.
Reading Sight Glass
The sight glass provides accurate diagnosis only under
the following conditions.
If the vehicle can be tested under these conditions,
check the sight glass appearance and compare to the
chart below.
Engine speed idle
A/C switch ON"
Blower fan operating at highest speed
Air source selector lever at RECIRC"
Temperature control lever at coldest position
Ambient temperature below 30C (86F) and
humidity below 70% (See NOTE 1)
High side pressure less than 1667.1 kPa (241.7 psi)
(See NOTE 2)
NOTE: 1. If the vehicle cannot be moved to a testing
location that meets these specifications, then the sight
glass cannot be used for diagnosis. You must discharge
and recover the refrigerant, then recharge the system
with the specified amount of refrigerant.
Then continue checking the system performance.
NOTE: 2. If the high side pressure is greater than
stated, the sight glass cannot be used for diagnosis. You
must discharge and recover the refrigerant, then
recharge the system with the specified amount of
refrigerant.
Then
continue
checking
system
performance.
1A53
The high pressure

pipe is hot and the
low pressure pipe is
cold. There is a
distinct difference in
temperature between
them.
The high pressure

pipe is warm and the
cool. There is no
great difference in
temperature between
them.
There
is
litttle
difference
in
temperature between
the high pressure
pipe and the low
pressure pipe.
The high pressure

pipe is hot and the
slightly warm. There
is a defference in
temperature between
them.
Slight glass condition Almost transparent. A

flow of bubbles can
be seen, but they
disappear when the
throttle is opened.
A flow of bubbles
always can be seen.
It appears sometimes
transparent, and
sometimes frothy.
Something like fog

faintly can be seen.
Even at idle with the

fan at HI (with the
window fully open),
the bubbles cannnot
be seen.
NG
(Not enough
refrigerant)
NG
(Almost no
refrigerant)
NG
(Too much
refrigerant)
High and low

pressure pipe
temperature
Air conditioning cycle

condition
OK
1A54
Compressor Assembly
Compressor Assembly and Associated Parts (6VD1)
871RX021
Legend
(1) Magnetic Clutch Harness Connector
(2) Refrigerant Line Connector
EndOFCallout
Removal
3. Disconnect magnetic clutch harness connector.
4. Remove serpentine belt.
Move serpentine belt tensioner to loose side
using wrench then remove serpentine belt.
(3) Compressor
(4) Serpentine Belt
1A55
Installation
1. Install compressor.
Tighten the compressor fixing bolts to the
specified torque.
Torque: 19Nm (14lbft)
2. Connect refrigerant line connector.
Tighten the refrigerant line connector fixing bolts
to the specified torque.
850RX003
Legend
(1) Tensioner
(2) Idler Pulley
(3) Cooling Fan Pulley
(4) Serpentine Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator
EndOFCallout
5. Disconnect refrigerant line connector.
When removing the line connector, the
connecting part should immediately be plugged
or capped to prevent foreign matter from being
mixed into the line.
6. Remove compressor.

new ones.
Be sure to apply new compressor oil to the
O-rings when connecting refrigerant lines.
3. Install serpentine belt.
using wrench, then install serpentine belt to
normal position.
4. Connect magnetic clutch harness connector.
1A56
Compressor Assembly and Associated Parts (X22SE)
871RX022
Legend
(1) Magnetic Harness Connector
(2) Refrigerant Line Connector
EndOFCallout
Removal
(3) Compressor
(4) Serpentine Belt

1A57

normal position.
New Compressor Installation

The new compressor is filled with 150cc (5.0fl.oz.)of
compressor oil and nitrogen gas. When mounting the
compressor on the vehicle, perform the following steps;
1. Gently release nitrogen gas from the new
compressor.
Take care not to let the compressor oil flow out.
Inspect O-rings and replace if necessary.
850RX006
Legend
(3) Tensioner
(8) Generator
EndOFCallout
871RX008
2. Turn the compressor several times by hand and

release the compressor oil in the rotor.
3. When installing on a new system, the compressor
should installed as it is. When installing on a used
system, the compressor should be installed after
adjusting the amount of compressor oil. (Refer to
Compressor in this section)
Installation
specified torque.
new ones.
871RX013
1A58
Condenser Assembly
875RW008
Legend
(1) Engine Hood Lock
(2) Pressure Switch Connector
(3) Refrigerant Line
(4) Radiator Grille

(5) Engine Hood Front End Stay
(6) Condenser Assembly
EndOFCallout
Removal
2. Discharge and recover refrigerant.
3. Remove radiator grille.
4. Remove engine hood front end stay.
5. Remove engine hood lock.
Apply setting mark to the engine hood lock fixing
position before removing it.
6. Disconnect pressure switch connector.
7. Disconnect refrigerant line.
8. Remove condenser assembly.

Handle with care to prevent damaging the
condenser or radiator fin.
Installation
1. Install condenser assembly.
If installing a new condenser, be sure to add 30cc
(1.0fl.oz.) of new compressor oil to a new one.
Tighten the condenser fixing bolts to the specified
torque.
Torque: 6Nm (52lb in)
2. Connect refrigerant line.
Tighten the inlet line connector fixing bolt to the
specified torque.

Torque: 15 Nm (11 lb ft)
Tighten the outlet line connector fixing bolt to the
specified torque.
Torque: 6 Nm (52 lb in)
new ones.
1A59

O-rings when connecting the refrigerant line.
3. Connect pressure switch connector.
4. Install engine hood lock.
5. Install engine hood front end stay.
6. Install radiator grille.
Condenser Fan Motor

875RW009
Legend
(1) Condenser Fan Assembly
(2) Condenser Fan Motor
(3) Radiator Grille

(4) Shroud
(5) Fan
EndOFCallout
Removal
4. Remove condenser fan assembly.
Disconnect the fan motor connector and remove
the 4 fixing bolts.
5. Remove shroud.
Remove the 3 fixing nuts.
Loosen the condenser fixing nut and disconnect

the fan motor connector from bracket.
6. Remove fan.
Remove the fan fixing C-ring and plate.
7. Remove condenser fan motor.
Installation
noting the following point.
1. Route the fan motor harness in its previous position,
and fix it securely with clip and bracket.
1A60
Receiver / Drier
Receiver / Drier and Associated
Parts
Installation
1. If installing a new receiver/drier, be sure to add 30cc
2. Put the receiver/drier in the bracket and connect
with the refrigerant line. Check that no excessive
force is imposed on the line. Fasten the bracket bolt
to the receiver/drier.
3. Tighten the refrigerant line to the specified torque.
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
875RX001
Legend
(2) Pressure Switch
(4) Radiator Grille
(5) Receiver / Drier
(6) Bracket Bolt
EndOFCallout
Removal
When removing the line connected part, the
6. Remove bracket bolt.
7. Remove receiver/drier.
Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
1A61
Pressure Switch
Pressure
Parts
Switch
and
Associated
Installation
1. O-ring cannot be reused. Always replace with a new
one.
2. Be sure to apply new compressor oil to the O-ring
when connecting pressure switch.
3. Tighten the pressure switch to the specified torque.
875RX001
Legend
(2) Pressure Switch
(4) Radiator Grille
(6) Bracket Bolt
EndOFCallout
Removal
5. Disconnect pressure switch.
When removing the switch connected part, the
1A62
Evaporator Assembly
874RX010
Legend
(2) Drain Hose
(3) Resistor and Electronic Thermostat Connector
EndOFCallout
Removal
(5)
(6)
(7)
(8)
(9)
Bolt: Evaporator Fix

Glove Box
Sill Plate
Pad: Dash Side Trim
Reinforcement: Inst Panel Lower

4. Disconnect resistor (2) and electronic thermostat
connector (1).
1A63
Installation
1. To install a new evaporator assembly, add 50cc
(1.7fl.oz.) of new compressor oil to the new core.
2. Tighten the refrigerant outlet line to the specified
torque.
3. Tighten the refrigerant inlet line to the specified
torque.
ones.
when connecting lines.
840RW019
5. Disconnect drain hose.

Use a back-up wrench when disconnecting and
reconnecting the refrigerant lines.
When removing the refrigerant line connected
part, the connecting part should immediately be
plugged or capped to prevent foreign matter from
being mixed into the line.
7. Remove evaporator assembly.
1A64
Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View
874RX011
Legend
(1) Lining
(2) Upper Case
(4) Evaporator Core
(5) Lining: Case
(6)
(7)
(8)
(9)
(10)
(11)
Attaching Screw
Clip
Lower Case
Evaporator Assembly
O-ring
Expansion Valve
EndOFCallout
Removal
4. Remove the electronic thermostat sensor fixing clip.
Pull the sensor from the evaporator assembly.
5. Remove clip.
7. Remove upper case.
Slit the case parting face with a knife since the
lining is separated when removing the evaporator.
874RW034
1A65
Installation
Lift to remove the upper case.

1. The sensor is installed on the core with the clip.
2. The sensor must not interfere with the evaporator
core.
3. When installing the new evaporator core, install the
thermo sensor to the evaporator core specified
position with the clip in the illustration.
874RX013
9. Remove evaporator core.
874RX014
Legend
(1) Evaporator Core
(2) Thermo Sensor
(3) Lower Case
(4) Upper Case
874RX012
10. Remove expansion valve.

Tear off the insulator carefully.
Remove the sensor fixing clip.
Use a back-up wrench when disconnecting all
refrigerant pipes.
EndOFCallout
ones.
6. Be sure to install the sensor and the insulator on the
place where they were before.
7. To install a new evaporator core, add 50cc (1.7 fl.
oz.) of new compressor oil to the new core.
8. Tighten the refrigerant lines to the specified torque.
Refer to Main Data and Specifications for Torque
Specifications in this section.
when assembling the evaporator assembly.
1A66
Refrigerant Line
Refrigerant Line and Associated Parts
852RX009
Legend
(1) Clip and Clamp
(2) Liquid Line (High-Pressure Pipe)
(3) Discharge Line (High-Pressure Hose)

(4) Radiator Grille
(5) Suction Line (Low-Pressure Pipe)
EndOFCallout
Removal
4. Remove clip and clamp.
5. Disconnect liquid line (High-pressure pipe).
6. Disconnect suction line (Low-pressure pipe) using a
back-up wrench.
7. Disconnect suction line (Low-pressure hose) using
a back-up wrench.
8. Disconnect discharge line (High-pressure hose)
using a back-up wrench.
Use a backup wrench when disconnecting and
When removing the refrigerant line connecting

Installation
ones.
1A67
1A68
Main Data And Specifications

General Specifications
Heater Unit
Temperature control
Reheat air mix system
Capacity
3,700 Kcal./hr.
Air flow
280 m3/h
HEATER CORE
Type
Element dimension
Radiating area
AUTO A/C
Plate and corrugate-fin type
MANU A/C
Fin and tube type
MANU A/C
161 mm (6.3) 163 mm (6.4 in.) 45 mm (1.8 in.)
AUTO A/C
171 mm (6.7) 161 mm (6.3 in.) 25 mm (1 in.)
MANU A/C
Approx. 2.1 m2
AUTO A/C
Approx. 1.3 m2
AUTO A/C
4,100 Kcal./hr.
MANU A/C
4,200 Kcal./hr.
AUTO A/C
430 m3/hr
MANU A/C
470 m3/hr
EVAPORATOR ASSEMBLY
Capacity
Air flow
EVAPORATOR CORE
Type
Al-laminate louver fin type
Element dimension
235 mm (9.3 in.) 224 mm (8.8 in.) 60 mm (2.4 in.)
EXPANSION VALVE
Type
Internal pressure equalizer type
THERMOSTAT SWITCH
Type
Electronic thermostat
OFF: Below 0.5 0.5 C (32.9 0.9 F)
ON: Above 4.5 0.5 C (40.1 0.9 F)
CONDENSER
Type
Parallel flow type
Radiation performance
9,400 Kcal./hr
RECEIVER/DRIER
Type
Assembly includes sight glass with dual (triple) pressure

switch (V6) or pressure sensor (L14)
Internal volume
300 cc (10 fl.oz.)

PRESSURE SWITCH
Type
Dual pressure switch

Low pressure control
ON: 186.329.4 kPa (27.04.3 psi)
OFF: 176.524.5 kPa (25.63.6 psi)
High pressure control
ON: 2353.6196.1 kPa (341.328.4 psi)
OFF: 2942.0196.1 kPa (426.628.4 psi)
Triple pressure switch (V6, A/T)
ON: 196.329.4 kPa (27.04.3 psi)
OFF: 176.519.6 kPa (25.62.8 psi)
Medium pressure control
ON: 1471.098.1 kPa (213.314.2 psi)
OFF: 1078.7117.7 kPa (156.417.7 psi)
ON: 2353.6196.1 kPa (341.328.4 psi)
OFF: 2942.0196.1 kPa (426.628.4 psi)
REFRIGERANT
Type
HFC-134a
Specified amount
650 g (1.43 lbs.)
1A69
1A70
Torque Specifications
E06RX006
E06RX007
1A71
Compressor
Service Precaution
WARNING: This vehicle has a Supplemental
Restraint System (SRS). Refer to the SRS
Component 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 On-Vehicle
Service Information. Failure to follow CAUTIONS
could result in possible air bag deployment,
personal injury, or otherwise unneeded SRS system
repairs.
use supplemental coatings (paints, greases, or
and systems.
General Description
When servicing the compressor, keep dirt or foreign
material from getting on or into the compressor parts
and system. Clean tools and a clean work area are
important for proper service.
The compressor
connections and the outside of the compressor should
be cleaned before any "On-Vehicle" repair, or before
removal of the compressor. The parts must be kept
clean at all times and any parts to be reassembled
should be cleaned with Trichloroethane, naphtha,
kerosene, or equivalent solvent, and dried with dry air.
Use only lint free cloths to wipe parts.
The operations described below are based on bench
overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When the compressor
is removed from the vehicle for servicing, the oil
remaining in the compressor should be discarded and
new compressor oil added to the compressor.
Compressor malfunction will appear in one of four ways:
noise, seizure, leakage or low discharge pressure.
Resonant compressor noises are not cause for alarm;
however, irregular noise or rattles may indicate broken
parts or excessive clearances due to wear. To check
seizure, de-energize the magnetic clutch and check to
see if the drive plate can be rotated. If rotation is

impossible, the compressor is seized. Low discharge
pressure may be due to a faulty internal seal of the
compressor, or a restriction in the compressor. Low
discharge pressure may also be due to an insufficient
refrigerant charge or a restriction elsewhere in the
system. These possibilities should be checked prior to
servicing the compressor.
If the compressor is
inoperative, but is not seized, check to see if current is
being supplied to the magnetic clutch coil terminals.
The compressor oil used in the HFC-134a system
compressor differs from that used in R-12 systems.
DKV-14D Type Compressor

DKV-14D is equipped with five-vane rotary compressor.
These vanes are built into a rotor which is mounted on a
shaft.
When the shaft rotates, the vanes built into the cylinder
block assembly are operated by centrifugal force.
This changes the volume of the spare formed by the
rotor and cylinder, resulting in the intake and
compression of the refrigerant gas. The discharge valve
and the valve stopper, which protects the discharge
valve, are built into the cylinder block assembly. There
is no suction valve but a shaft seal is installed between
the shaft and head; a trigger valve, which applies back
pressure to the vanes, is installed in the cylinder block
and a refrigerant gas temperature sensor is installed in
the front head.
The specified quantity of compressor oil is contained in
the compressor to lubricate the various parts using the
refrigerant gas discharge pressure.
A01RS003
1A72
Diagnosis
Condition
Noise from compression
Noise from magnetic clutch
Not rotating
Possible cause
Defective rotor/piston
Replace compressor/cylinder and

shaft assembly
Defective shaft

shaft assembly
Defective bearing
Replace magnetic clutch
Defective clutch
Clearance between drive plate and

pulley not standard
Adjust the clearance or replace

magnetic clutch
Defective gasket
Replace compressor/gasket
Defective rotor/reed valve
Replace compressor/valve plate
Defective trigger valve/suction valve
Replace compressor/suction valve

shaft assembly
Defective shaft

shaft assembly
Rotating parts
insufficient oil
Oil and/or gas leakage
Correction
seized
due
to
Replace compressor
Defective seal
Replace compressor/shaft seal
Defective O-ring
Replace
1A73
Magnetic Clutch Assembly (DKV-14D Type)

Parts Location View
871RX012
Legend
(1) Drive Plate bolt
(2) Drive Plate
(3) Snap Ring
(4)
(5)
(6)
(7)
Pulley Assembly
Field Coil
Shim (s)
Lead Wire
EndOFCallout
Removal
2. Remove drive plate by using drive plate puller

J-33944-A (2) and forcing screw J-33944-4 (1).
1. Using drive plate holder J-33939 (1) to prevent the

drive plate from rotating, then remove the drive plate
bolt.
871RX016
901RX055
1A74
3. Remove shim (s).

4. Remove snap ring (1) by using snap ring pliers.
6. Loosen screw and disconnect the coil lead wire

connector.
871RS010
871RW016
5. Remove pulley assembly by using pulley puller pilot

J-38424, pulley puller J-8433 and pulley puller leg
J-24092-2.
7. Loosen three screws and remove the field coil.
871RS011
871RS009
1A75
Inspection and Repair

Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
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.
Coil
Check coil for loose connector or cracked insulation.
871RS013
Installation
1. Install field coil.
Align the located portion (1) of the field coil and
compressor.
4. Install snap ring.

5. Install shim (s).
6. Install the drive plate to the compressor drive shaft
together with the original shim(s)(1). Press the drive
plate by hand.
871RX010
871RX015
Tighten the mounting screw to the specified

torque.
Torque: 5Nm (44 lb in)
2. Connect the lead wire connector with the rubber
hold and tighten the screw.
3. Install pulley assembly by using pulley installer
J-33940-A and drive handle J-8092.
1A76
7. Install drive plate bolt by using drive plate holder

J-33939 (1) to prevent the drive plate from rotating.
Check to be sure that the clutch clearance is

between 0.3-0.6 mm (0.01-0.02 in.)
901RX055
871RX014
Tighten the drive plate bolt to the specified

torque.
If necessary, install adjusting shim(s).

Adjusting shims are available in the following
thickness.
Thickness
0.1 mm (0.0039 in.)
0.3 mm (0.0118 in.)
0.5 mm (0.0197 in.)

After tightening the drive plate bolt, check to be
sure the pulley rotates smoothly.
1A77
Compressor Oil
Oil Specification
The HFC-134a system requires a synthetic (PAG)
compressor oil whereas the R-12 system requires a
mineral compressor oil. The two oils must never be
mixed.
Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified for
the model of compressor.
Always use HFC-134a Vane Rotary Type
Compressor Oil (AIPDN Part No.2-90188-301-0)
Handling of Oil
The oil should be free from moisture, dust, metal
powder, etc.
Do not mix with other oil.
The water content in the oil increases when exposed
to the air. After use, seal oil from air immediately.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)
The compressor oil must be stored in steel
containers, not in plastic containers.
Compressor Oil Check

The oil used to lubricate the compressor is circulating
with the refrigerant.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
the original amount of oil.
871RX020
4. If the amount of oil drained is much less than 90 cc

(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure
below.
(Charging Amount)
(Collected Amount)
more than 90cc (3.0 fl.oz)
same as collected
amount
less than 90 cc (3.0 fl.oz)
90cc (3.0 fl.oz)
Oil Capacity
Capacity total in system: 150cc (5.0 fl.oz)
Compressor (Service parts) charging amount:
150 cc (5.0 fl.oz)
Checking and Adjusting Oil Quantity

for Used Compressor
1. Perform oil return operation. Refer to Oil Return
Operation in this section.
2. Discharge and recover refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
7. Install the compressor, then evacuate, charge and

perform the oil return operation.
8. Check system operation.
When it is impossible to preform oil return
operation, the compressor oil should be checked in
the following order:
compressor.
3. Check the oil for contamination.
4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to
the compressor to be installed.
5. If the amount of oil extracted is less than 90 cc (3.0
fl. oz.), recheck the compressor oil in the following
order.
6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor
and install it onto the vehicle.
1A78
7. Evacuate and recharge with the proper amount of

refrigerant.
8. Perform the oil return operation.
9. Remove the compressor and recheck the amount of
oil.
10. Adjust the compressor oil, if necessary.
(Collected Amount)
(Charging Amount)
more than 90 cc (3.0 fl.oz) same as collected

amount
90 cc (3.0 fl.oz)
Checking
and
Adjusting
Compressor Replacement
for
150 cc (5.0 fl.oz.) of oil is charged in compressor

(service parts). So it is necessary to drain the proper
amount of oil from the new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove
the compressor.
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
(Amount of oil drained
from used compressor)
(Draining amount of oil

from new compressor)
Same as drained amount
more than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

6. Evacuate, charge and perform the oil return
operation.
7. Check the system operation.
Contamination of Compressor Oil

Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a long
period of time (approximately one season), the oil never
becomes contaminated as long as there is nothing
wrong with the compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
The capacity of the oil has increased.
The oil has changed to red.
Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor oil
is
contaminated.
Whenever
contaminated
compressor oil is discovered, the receiver/drier
must be replaced.
Oil Return Operation

There is close affinity between the oil and the
refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system. When
checking the amount of oil in the system, or replacing
any component of the system, the compressor must be
run in advance for oil return operation. The procedure is
as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to ON"
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts

When replacing the system component parts, supply
the following amount of oil to the component parts to be
installed.
(Component parts to be
installed)
(Amount of Oil)
Evaporator
50 cc (1.7 fl. oz.)
Condenser
30 cc (1.0 fl. oz.)
Receiver/dryer
30 cc (1.0 fl. oz.)
Refrigerant line (one

piece)
10 cc (0.3 fl. oz.)
Main Data and Specifications

COMPRESSOR
Model
Type
Number of vanes
Rotor diameter
DKV-14D
Vane rotary type
5
64 mm (2.52 in.)
Stroke
8.75 mm (0.34 in.)
Displacement
140 cc (47.3 fl.oz.)
Maximum speed
7,000 rpm (up to 8,400 rpm)
Direction of rotation
Clockwise (Front-side view)
Lubrication system
Pressure differential type
Lubricant
R-134a Vane Rotary Type Compressor Oil

Be Equivalent to ZXL 200 PG
150 cc (5.0 fl.oz.)
Refrigerant
Refrigerant-134a (R-134a), 650 g (1.43 lbs.)
Shaft seal
Lip type
Weight
3.6 kg
MAGNETIC CLUTCH
Type
Rated voltage
Current consumption
Starting torque
Weight
Electromagnetic single-plate dry clutch

12 Volts D.C.
3.7 A
49 Nm (36 lbft)
2.4 kg (5.3 lbs.)
1A79
1A80
871RX011
1A81
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J-7624
Drive plate holder
J-24092-2
Pulley puller leg
J-33944-A
Drive plate puller
J-33940-A
Pulley installer
J-33944-4
Forcing screw
J-8092
Drive handle
J-38424
Pulley puller pilot
J-8433
Pulley puller
1A82
Automatic Air Conditioning System

General Description
Using a variety of sensors, this automatic heater and air
conditioner accurately senses outside air temperature,
solar
radiation
quantity,
evaporator's
blowing
temperature, and interior temperature, then enters
these data to the automatic heater/air conditioner
control unit (equipped with the built-in micro-computer).
The data provided to the control unit enables to
automatically control blow temperature and blow air
quantity, turn on or off the compressor and switch the

blow port as well as switching between the fresh air
intake and interior air circulation.
Resetting the automatic function allows you to switch to
the manual control mode.
The self-diagnoisis function of the automatic heater and
air conditioner control unit (with the built-in microcomputer) allows the unit to access and diagnose a
failed part easier and quicker.
Automatic Air Conditioner Parts Configuration
865RW010
Legend
(1) Intake Actuator
(3) Evapration Sensor
(4) Mix Actuator
(5) Mode Actuator
(6) Heater Unit
EndOFCallout
(7)
(8)
(9)
(10)
(11)
(12)
Interior Temperature Sensor

Automatic Air Conditioner Control Unit
Max High Relay
Blower Unit
Sollar Radiation Quantity Sensor
Outside Air Temperature Sensor
1A83
852RX005
Legend
(1) Evapolator Assembly
(2) O Ring
(3) Drain Hose
(5) Suction Line (Low Pressure Hose)
(6) Out Side Air Temperature Sensor
EndOFCallout
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Engine Hood Seal

Condenser Fan
Condenser Assembly
Receiver Dryer
Pressure Switch
High Pressure Hose
Compressor
1A84
Circuit Diagram
6VD1 Engine
D08RX145
1A85
D08RX146
1A86
D08RX147
1A87
D08RX148
1A88
D08RX144
1A89
D08RX143
1A90
Functions and Features

Automatic interior temperature control
This function enables to maintain the interior
temperature at the level specified from the
temperature control switch despite of changes in
factors such as vehicle speeds, outside air
temperature and number of passengers.
Maximum cooling and heating function
You can select FC (Full cool, namely maximum cooling
temperature) or FH (Full heat, maximum heating
temperature) from the temperature control lever.
Automatic air flow control
Air flow is automatically and consecutively fine tuned
according to the specified interior temperature and
changes in aperture of the heater unit mix door.
Mode (blow port) control
This function automatically selects either one of the
VENT, BI-LEVEL, FOOT or DEF mode for the blow
port according to changes of temperature on the
blow port. Using the mode switch allows you to
select a desired blow port manually.
Intake (switching between the fresh air intake and
circulation of interior air) control
The intake (switching between fresh air intake and
circulation of interior air) mode automatically selects
either FRESH (fresh air intake), MIX or RECIRC
(interior air circulation) according to changes of the
blow port temperature. Using the intake switch
allows you to select a desired intake port manually
(in the manual operation, FRESH and RECIRC
modes alone are available). Pressing the DEF
(defrost) mode switch selects the FRESH (fresh air
intake).
Cooler start-up timing control
This function is used for maintaining the air flow at
LOW" level until the evaporator is sufficiently cooled
down. It is intended to prevent a large volume of hot
air being blowing into inside of a vehicle when the
cooler is turned on in hot summer season.
Heater start-up timing control
This function is used for maintained the air flow at
LOW" level and also for maintaining the defrost
mode until temperature of coolant in the heater core
is sufficiently heated. It is intended to prevent a large
volume of cool air being blown into inside of a vehicle
when the heater is turned on in cold winter season.
Solar radiation quantity offset control
The photodiode on the solar radiation sensor
determines solar radiation quantity accurately to
offset interior temperature quickly.
Switch position storing function
This function is used for storing switch positions being
selected in the immediately preceding operation,
namely the last time the ignition has been turned off.
It simplifies the setup procedures when restarting the
system.
Self-diagnosis function
The self-diagnosis function turned on from the panel
switch makes your troubleshooting easier (for detail
of this function,
Self-Diagnosis").
refer
to
the
section
titled
1A91
Automatic Air Conditioner Block Diagram
F01RX001
1A92
Control Panel Layout
C01RW007
Legend
(1) Auto Switch
(2) Mode Switch
(3) DEF Switch
EndOFCallout
(4)
(5)
(6)
(7)
Intake Switch
Fan Switch
Air Conditioning Switch
1A93
Air Control Functions
C01RX002
Legend
(1) Interior Air Intake
(2) Fresh Air Intake
(3) Evaporator Core
(4) Air Mix Door
(5) DEF Door
(6) VENT Door
EndOFCallout
(7)
(8)
(9)
(10)
(11)
(12)
Foot Door
Sub Air Mix Door
Heater Unit
Heater Core
Evaporator Unit
Blower Unit
1A94
Operation and Functions of Control Panel Switches

Auto Switch
1. Pressing this switch turns on the automatic control
mode. It resets all manual switches except that for
the fan control. However, when the Manual REC is
selected for the intake or the Manual Open is
selected, the modes are maintained.
2. It causes the A/C (air conditioner) to the ON mode
(this function, however, available only when the fan
is turned on and also the compressor is turned on
because of the given outside air temperature level).
Indication
The AUTO LED comes on.
Currently selected mode for the Mode and Intake are
respectively indicated.
The A/C LED remains turned on even if the

compressor has been turned off because of the given
outside air temperature level. Pressing the air
conditioning switch in this state turns off the A/C LED.
Mode Switch
1. Pressing the VENT, B/L or FOOT switch selects the
corresponding mode.
2. When the Auto is selected for the Mode and Intake,
pressing the mode switch fixes the Intake to the
immediately preceding status.
Indication
Turns off the Auto LED.
Currently selected blow port is indicated.
DEF Switch
Press this switch to select the DEF mode.
Blow port
Intake port
A/C
MIX
DEF
Auto FRESH *1
ON mode *2
Auto
*1: When the manual REC is selected for the Intake, the
manual REC is maintained.
*2: The ON mode is enabled only when the fun is turned
on, and also the compressor is turned on because of
the given outside air temperature level.
Indication
The Auto LED is turned off.
DEF is indicated for the blow port, A/C LED comes on
(only when the fan is turned on), and status display is
provided for the Intake and Cold Air Bypass.
F01RX006
1A95
Intake Switch
Pressing this switch sequentially selects a different
intake port in the following order.
F01RX005
Fan Switch
Indication
The Auto LED maintains unaffected.
Currently selected intake port is indicated.
1. Sets the fan to the specified mode.

2. Even when the fan switch is turned off, status
display for the Mode, Intake and Cold Air Bypass is
maintained.

1. This knob is operable only when the fan is turned
on. It may be used for the MAX control of each
block except the fan.
2. When the manual mode is selected for the fan
control, this manual mode is maintained.
F01RX007
MAX Control
Mix
Fan
Mode
Intake
Cold air
bypass
A/C
MAX/COOL
Full cool
MAX/HI
VENT
REC*1
OPEN*2
ON mode*3
MAX/HEAT
Full hot
AUTO/HI
FOOT*4
FRESH
CLOSE
Current status
is maintained
1A96
*1: In the A/C: OFF mode, FRESH shall be selected.

*2: When the fan is turned ON, CLOSE shall be
selected.
*3: The ON mode is available only when ON is selected
for the fan as well as for the cold outside air ON/OFF
selection.
*4: When the MAX control is selected from the DEF
mode, this DEF mode shall be maintained.
F01RX008
Indication
As long as the MAX control is selected, the
immediately preceding indication shall be maintained
for the AUTO.
Status display is provided for others.

Pressing this switch turns on or off the A/C (air
conditioning) control. (The compressor remains turned
off if the fan is turned off and also the compressor has
been turned off because of the given outside air
temperature level.)
Indication
1. The A/C LED remains turned on even if the
compressor has been turned off because of the
given outside air temperature level. In this case,
however, the AUTO or DEF switch must be turned
on and the A/C ON mode must also be turned on
(by the MAX/C mode).
2. Pressing the A/C switch from the above state (1)
turns off the A/C LED.
1A97
Overview of Construction, Movement

and Control of Major Parts of
Automatic Air Conditioner System
Automatic Heater/Air Conditioner Control
Unit
Equipped with the built-in micro-computer, this control
unit operates on signals from sensors and input signals
from switches to offer total control of the blower fan, and
actuators used for the mode door, intake door and air
mix door.
Its self-diagnosis function enables quicker access to a
failed part and its more accurate troubleshooting.

It is a sensor used for detecting room temperature of a
vehicle. This sensor converts a given room temperature
into a resistance value before entering the data to the
automatic heater/air conditioner control unit.
This interior temperature sensor unites the power driven
aspirator and the motor fan so that a small amount of
room air may be constantly fed to the sensor.
This sensor is provided on the control panel.
845RX001
Legend
(1) Outside Air Temperature Sensor
EndOFCallout
Evapration Sensor
The evaporation sensor is the sensor to detect
temperature change of the side of evaporator blower
coming by fresh recirculation of intake door or on" off"
of compressor.
The temperature is converted to resistant rate.
And it works as thermostat to control to prevent freezing
of evaporator.
This sensor is installed in the upper case of evaporator.
865RW014
Legend
(1) Interior Temperature Sensor
(2) Automatic Air Conditioner Control Unit
EndOFCallout

This sensor is used for detecting temperature outside
the vehicle. It converts a given outside air temperature
Thermal effects from the condenser and radiator during
idling after a run can be measured and offset the
automatic amplifier.
This sensor is provided on the side plate situated at
upper right side of the condenser.
874RX014
Legend
(1) Evaporator Core
(2) Evapration Sensor
(3) Lower Case
(4) Upper Case
EndOFCallout
1A98
Solar Radiation Quantity Sensor
Max Hi Relay
It is a photodiode used for detecting quantity of solar

radiation.
This sensor converts the offset signal
generated by changes in the interior temperature (which
results from fluctuations in solar radiation) into
photoelectric current to enter into the automatic heater/
air conditioner control unit.
This sensor is provided at top of the defroster grill.
This relay turned on or off by the signal from the

automatic heater/air conditioner control unit. As the
Max Hi relay is turned on, supply voltage is directly fed
to the blower fan motor to select the Max Hi mode.
860RW028
865RW009
Legend
(1) Solar Radiation Sensor
Legend
(1) Blower Unit
(2) Max High Relay
EndOFCallout
Actuator
EndOFCallout
Power Transistor
Receiving base current from the automatic heater/air
conditioner control unit, the power transistor implements
stage-less speed change of the blower fan motor. This
transistor is provided on the evaporator.
The actuators are power driven type containing a small

motor. Receiving output current from the automatic
heater/air conditioner control unit, actuators drive the
heater and blower unit mode doors.
Actuators consist of the mode actuator used for
switching the mode (blow port selection), the mix
actuator used for changing aperture of the air mix door,
the intake actuator used for switching the intake
mode(fresh air/interior air) and the cold air bypassing
actuator.
874RX015
Legend
(2) Power Transistor
EndOFCallout
860RW029
1A99
Legend
(1) Mix Actuator
(2) Heater Unit
(3) Intake Actuator
(4) Mode Actuator
(5) Blower Unit
EndOFCallout
The actuator changes the motor speed using the gear
and drives each door rotating the output axis united with
the sliding contact.
C01RX016
Movement of Mix Actuator
860RW026
Legend
(1) Output Axis
(2) Motor
(3) Printed Circuit Board
(4) Sliding Contact
EndOFCallout
The mode and mix actuators are common actuators
with the built-in potentiometer. For the intake actuator,
the contact switch type is selected.
The potentiometer is a register assembled to the printed
circuit board of the mix and mode actuators. It detects
the air mix door position specified by rotation of the
output axis as a ratio of the variable terminal (VM)
voltage against the reference voltage (VDD: 5V), then
signals the value to the automatic heater/air conditioner
control unit.
Position of the air mix door is determined by the

controller on the automatic heater/air conditioner control
unit.
As the heat or cool side of the controller is grounded,
the transistor on the driver is activated and, thus, the
motor rotation is turned on.
The sliding contact
connected to the motor sends the position detection
signal from the potentiometer to the automatic heater/air
conditioner control unit. As the set temperature and
interior temperature are balanced, the controller returns
to the neutral and the motor rotation is stopped.
C-45
(+) side
(-) side
Rotation
direction
Remarks
Clockwise
Full heat side
Counter
clockwise
Full cool side
C01RX005
1A100
Movement of Mode Actuator
removed, thus stopping the motor.
As target position of the mode door is decided on the

controller of the control unit, the control unit reads the
position detection signal from the actuator to select the
clockwise or counter clockwise motor rotation direction.
Grounding the controller VENT or DEF side after the
direction selection activates the transistor on the driver,
thus turning on the motor rotation. Accompanying the
motor rotation, the sliding contact rotates, too. When
the target position is reached, the controller on the
control unit returns to the neutral and the motor stops.
Conduction pin
(+) side
(-) side
Rotation
direction
Remarks
Clockwise
VENT to DEF
direction
Counter
clockwise
DEF to VENT
direction
Grounding
terminal
Rotation
direction
Remarks
No.5 B-26
Clockwise
RE-CIRCULATI
ONMIXFRE
SH
C01RX006
Overview of Automatic Control of

Automatic Air Conditioner
The automatic heater and air conditioner on this vehicle
has the following features:
Interior temperature control.
Air flow control.
Mode (blow port) control.
Intake (switching between fresh air and interior air)
control.
Heater start timing control.
Cooler start timing control.
Compressor ON/OFF function according to outside
air temperature level.
Evaporator anti-freeze control.
Interior Temperature Control

C01RX017
Movement of Intake Actuator

The controller on the automatic heater/air conditioner
control unit selects an intake mode to be used.
As the Terminal No.5 B-26 is grounded via the sliding
contact on the terminal plate, the transistor on the driver
is activated, thus turning on the motor rotation. Then,
accompanying move of the motor, the sliding contact
rotates until grounding of the Terminal No.5 B-26 is
The automatic heater/air conditioner control unit

operates on the setup temperature signal from the
temperature control switch and other sensor signals to
derive the total signal. Then, the control unit compares
this signal against the signal from the potentiometer to
determine rotation direction of the mix actuator. The
mix actuator moves the air mix door to the aperture
specified by the total signal so that the specified interior
temperature is achieved.
If the compressor is turned off in the A/C (air
conditioning) mode, aperture of the air mix door is offset

according to the outside air temperature or the specified
interior temperature.
This function removes the
difference in the blowing temperature in this state and
that of when the compressor is turned on.
When FH or FC is selected for the setup temperature,
the air mix door is accordingly fixed to the Full Heat or
Full Cool mode.
When the VENT mode is selected, aperture of the air
mix door is controlled so that excessively heated air may
not be blown from the VENT blow port.
1A101
In the Manual Mode

Air flow specified from the fan switch is entered to the
automatic heater/air conditioner control unit as the
manual signal. The signal modifies the air flow to the
level specified from the fan switch so that the required
fan voltage is attained.
C01RX010
Mode (Blow Port) Control

C01RX011
Air Flow Control

In the Auto Mode
operates on the setup temperature signal and other
sensor signals to derive the total signal. Then, the
control unit adjusts base potential of the power
transistor to match it to the voltage pattern of the
target fan so that stage-less fan speed control can be
achieved.
When solar radiation quantity is detected in the VENT
or B/L mode, the control unit increases the minimum
fan voltage to offset.
When FH or FC is selected from the temperature
control switch, air flow is accordingly fixed to MAX HI
or AUTO HI.

operates on the setup temperature from the control
switch, and temperature and solar radiation quantify
from the sensors to determine the total mode control
signal. According to the pattern specified by this signal,
the control unit selects either one of the VENT,
BI-LEVEL, FOOT or DEF/FOOT mode.
The mode actuator determines the rotation direction
comparing the target position against the current
position being determined by the position detection
signal.
When FH or FC is selected for the temperature from the
temperature control switch, mode is accordingly fixed to
the VENT or FOOT.
In the manual operation of the mode switch, you can
select a desired blow port mode pressing the
corresponding mode switch.
1A102
Operating the DEF mode switch selects the DEF for

the blow port mode.
When the Mode Switch is depressed

If the automatic intake control is selected, the intake
is fixed to the currently selected mode.
C01RX009
Intake (Fresh air/interior air switching)

Control
In the Full Auto mode, the automatic heater/air
conditioner control unit operates on the setup
temperature signal and other sensor input signals to
derive the total signal.
According to the pattern
specified by this signal, the control unit provides the
intake control.
When the fan is turned off or the A/C (air conditioning) is
turned off, the intake is fixed to the FRESH mode.
When FC or FH is selected from the control switch, the
intake mode is accordingly fixed to the RECIRC or
FRESH.
In the Manual Operation
Pressing the FRESH (fresh air intake) or the RECIRC
(room air circulation) accordingly selects the FRESH
or RECIRC mode.
When the DEF Mode Switch is depressed
The intake mode is fixed to the FRESH. When the
MANU REC is selected, however, the mode is fixed
the RECIRC.
C01RX008
Compressor Control
In the automatic control mode, the automatic heater/air
conditioner control unit turns on or off the compressor
with the evaporator anti-freeze mechanism using the
evaporation sensor. And, when outside air is detected
to be low through the outside air temperature sensor
signal, the control unit turns off the compressor using
the compressor control function.
Manual Control
In the automatic control mode, pressing the A/C (air
conditioning) switch turns off the compressor.

Pressing the DEF mode switch automatically turns on
the compressor.
1A103
Cooling Start Timing Control

When the automatic heater/air conditioner is started,
cooling is turned on only when the temperature
detected by the interior temperature sensor is 30C or
above and the total signal derived from the sensor
signals has detected that the cooling condition is met.
When the cooling condition has been met, the fan
voltage across the blower fan motor terminal is set to
4.5V for 7 seconds maximum, then it is linearly
increased up to the auto airflow level at the rate of 0.6V/
sec.
C01RX007
Heating Start Timing Control

heating is turned on only when the coolant temperature
detected by the coolant temperature sensor is 18C or
less and total signal derived from the sensor signals has
detected that the heating condition is met.
If the coolant temperature detected by the sensor is
18C or less, 4.5V is set for the blower fan motor
terminal voltage and the DEF is selected for the blow
port mode.
When the temperature detected by the sensor is above
18C, the blow port mode is switched to the Auto
Control and the voltage across the blower fan motor
terminal is linearly increased from 4.5V to auto control
voltage (auto airflow).
840RX015
C06RX003
1A104
Troubleshooting
Troubleshooting, Its Overview and Procedures
The automatic heater and air conditioner equips with
the Self-Diagnosis Function" to check its major
components.
This function makes access to the sensors, actuators
and blower fan motor system easier when checking
them up and, when a failed part is located, this function
restores its original performance.
When
implementing
the
troubleshooting,
this
self-diagnosis function narrows the range to be
searched at the first step, then check relevant parts one

by one according to the Checking Procedures by Failed
Location".
As for a location this function is
unappreciable, the system accurately determines
characteristics of a given trouble and checks relevant
parts according to the Checking Procedures by Failed
Location".
The following illustrates basic troubleshooting flow.
Basic Troubleshooting Flow
F01RX009
1A105
Auto Air Conditioner Control Unit Power Supply Diagnosis

This check is required because a trouble on the auto
amplifier (control unit) power supply circuit or grounding
circuit prevents accurate troubleshooting.
D08RX284
Condition
Possible cause
Power source does not supply to auto

Correction
Refer to Chart A
1A106
Chart A": Check of Auto Amplifier Power Supply System

Step
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Disconnect the auto A/C control unit connector I20.

Is the battery voltage applied between the harness
side connector terminal No.I208 and the ground?
Approx. 12V
Go to Step 5
Go to Step 4
Repair an open circuit between the fuse C5 and

terminal No.I208.
Go to Step 4
Is there continuity between the harness

connector terminal No.I2016 and the ground?
Go to Step 7
Go to Step 6
Repair an open circuit between terminal No.I2016

and the ground No.B8.
Go to Step 5

Go to Step 9
Go to Step 8
Repair an open circuit between terminal No.I209 and

the ground No.B8.
Go to Step 7
Turn the lighting switch on.

Approx. 12V
Go to Step 11
Go to Step 10
10
Repair an open circuit between the lighting switch and

terminal No.I2010.
Go to Step 9
11
Turn the starter switch on.

Approx. 12V
Go to Step 12
Repair an open circuit between the fuse F5 and

terminal No.I207.
Verify repair
1
2
3
12
Is the fuse C5 normal?

Is the fuse F5 normal?
side
side
1A107
Performance and Movement checklist for Automatic Air Conditioner Related

Parts
Start the engine, and when the engine coolant reached
50C check performance and movement of the related
parts according the following checklist.
Performance Check Using the Manual Switch

No.
Item
Checking Approach
Condition
Operation
Auto switch must be

Blowing
temperature (check turned on (FAN-AUTO
movement of air MODE-AUTO)
mix door)
Airflow
volume Set temperature
(check movement 25.0C.
of the mode door)
1. Turn the fan knob

off.
from LOW to HI.
1. Cold air shall be blown out.

2. Hot air shall be blown out.
1. The fan shall be stopped, thus

stopping air blow, too.
2. Airflow volume shall change from
LOW to HI.
Set temperature to Press the mode switch LED corresponding to each mode
Blowing
25.0C.
Set the fan to change the blow port shall be turned on and the blow port
temperature
mode sequentially from mode shall be switched smoothly.
(check movement knob to HI.
the
VENT
through
of the mode door)
BI-LEVEL, FOOT up to
DEF.
The interior/outside Set temperature
air switching mode 25.0C.
(check movement
of intake door)
Compressor
5
to
1. Select FC for the

setup temperature.
2. Select FH for the
setup temperature.
Then, select the
MAX Control.
Acceptance criteria
to Turn the LED off using The LED indication shall be switched
the interior/outside air from OFF to ON accompanying a
switch (this introduces change in air blowing sound.
the outside air intake
mode). Then, the set
fan knob to HI and
press
the
interior/
outside switch to turn
on the LED.
Set the temperature to Press the OFF" switch.

18.0C (FC). (Outside 1. Press the Auto
air temperature is 0C
switch.
or above and interior
2. Press
the
Air
temperature at ordinary
Conditioner switch.
temperature.)
1. As the fan knob is set to the Auto

position, the A/C switch LED
shall come on and the
compressor shall be turned on.
2. As the A/C LED comes off, the
compressor shall be turned off.
1A108
Check of Auto Function

No.
Item
Checking Approach
Condition
Operation
Acceptance criteria
The LED shall come on.
Cold air shall be blown out.
The following LEDs shall come on:
Select FC for the

temperature.
Auto function
FAN KNOB AUTO"

MODE SW AUTO"
Change the
temperature
gradually starting
with 18C up to
32C.
Select FH for the

temperature.
Blow port mode:

Intake mode
Fan speed: MAX
Hi
A/C
The following phenomena shall be
recognized.
Temperature of blown air: Cold air is
changed to hot air.
Change in the air flow volume.
The blow port mode LED indication
changes in the following sequence:
Cold air shall be blown out. The

following LEDs shall come on.
Blow port mode:
Fan speed: Max.
1A109
Troubleshooting With Self-Diagnosis Function

Overview of Self-Diagnosis Function
The self-diagnosis is implemented in 3 steps for each
target. For detail of check procedure contained in each
step, refer to the relevant section of Check Procedure
by Failed Location" listed in the Self-Diagnosis
Operation Procedure.
For turning on the self-diagnosis function and switching

of the check step, refer to the flow chart given below.
You can reset the self-diagnosis function by turning the
ignition switch off or turning the DEF switch on for 5
seconds.
Self-Diagnosis Operation Procedure

Step
Action
Value(s)
Yes
No
1. Set the IG to the OFF position.

2. Apply 60W bulb light to the solar radiation sensor.
3. Set the temperature setting lever on the automatic
heater/air conditioner panel to the center position
(25C).
4. Set the fan switch on the same panel to the Auto
position.
Go to Step 2
While holding both the Auto switch and the DEF

switch on the automatic heater/air conditioner panel,
turn the IG off and then on.
Is the current trouble diagnosing function turned on
approximately in 10 seconds?
Go to Step 3
Does the A/C LED flash every 0.5 second interval?
Go to Step 4
Refer to *1.
Press the A/C switch once.

Go to Step 5
Refer to *2.
Go to Step 6
Repair or
replace the
output
equipment or
repair the
harness
Go to Step 1
Refer to *3 chart Check of Output Equipment".

Does each output equipment function normally
according to operation of the temperature setting
level?
Press the DEF switch for 5 seconds consecutively or

turn on and off the IG.
1A110
*1Displaying the Current Trouble Diagnosing Table

Start the engine while holding down both the Auto
switch and the DEF switch on the control panel, and the
table will appear in approximately 10 seconds to the
indicator lamp (LED) of the air conditioning switch.
Result of the diagnosis along the following 9 items will
be shown one by one in 0.5 second interval irrespective
of presence or absence of a trouble for a given item.
When the display 9 items is completed, it is repeated

with 3 seconds of interval in between. A failed item is
indicated by flashing of the LED that is repeated 3 times
within 0.5 seconds. If a trouble is indicated, you can
locate the failed section by knowing when in the total
sequence it has been displayed.
F01RX010
Item for Current Trouble Diagnosis
F01RX014

As shown above, display of result along nine items is
repeated with 3-second interval in between.
Note 1: When checking the solar radiation sensor, apply
sufficient light using a 60W bulb. Otherwise, it can be
diagnosed as failed.
Note 2: If the temperature setting lever is set on both
1A111
ends (one set to 18C, blue scale = Full cool and the
other to 31C, red scale = Full hot), they can be
Note 3: Likewise, the fan switch can be diagnosed as
failed if set on both ends.
*2Displaying the Past Trouble Diagnosing Table

The past trouble diagnosis displays only the items on
which trouble has recurred 16 times in the past.
If you press the air conditioning switch once while the
current trouble diagnosis is taking place, display of the
past trouble diagnosis will appear on the indicator lamp
(LED) of the air conditioning switch.
Results of the diagnosis along the following five items
are displayed one by one in 0.5 second interval

irrespective of presence or absence of a trouble. A failed
item is indicated by flashing of the LED that is repeated
3 times within 0.5 seconds. You can locate the failed
section by counting in what sequence it has been
displayed.
F01RX011
F01RX012
1A112
*3Check of Output Equipment
F01RX015
1A113
Inspection By Failed Location

Inspection of the Sensors
When the self-diagnosis function has determined that
trouble is present on the sensors, check them according
to the following flow chart.
F01RX013
1A114
Chart 1: Interior Temperature Sensor
D08RX233
Step
Action
Disconnect the interior temperature sensor connector.

(No.I-4)
Is performance of the sensor normal? (Refer to the
later section on Individual Inspection")
Is there continuity between the
connector No.I441 and No.I43?
2
3
4
5
Value(s)
Yes
No
Go to Step 2
Replace the
temperature
sensor
Go to Step 4
Go to Step 3
Repair an open circuit between terminal No.441 and

No.I43.
Go to Step 2

Go to Step 6
Go to Step 5

and No.I44.
Verify repair
Replace the auto air conditioner control unit.

Verify repair
harness
harness
side
side
1A115
Chart 2: Outside Air Temperature Sensor
D08RX232
Step
Action
Disconnect outside air temperature sensor connector.

(No.C8)
Is performance of the outside air temperature sensor
normal? (Refer to the later section on Individual
inspection")
Value(s)
Yes
No
Go to Step 2
Replace the
outside air
temperature
sensor
Connect the outside air temperature sensor Refer to the

later section
connector.
Is resistance between the harness side connector on Individual
inspection"
No.I442 and No.I4411 normal?
Go to Step 4
Go to Step 3

No.C81 or No.I4411 and No.C82.
Verify repair

Verify repair
1A116
Chart 3: Solar Radiation Sensor
D08RX231
Step
Action
Disconnect the solar radiation sensor connector.

(No.I50)
Is performance of the solar radiation sensor normal?
(Refer to the later section on individual inspection)
connector terminal No.I443 and No.I502?
2
3
4
5
Value(s)
Yes
No
Go to Step 2
Replace the
solar radiation
sensor.
Go to Step 4
Go to Step 4

No.502.
Go to Step 2

Go to Step 6
Go to Step 5

and I501.
Go to Step 4

Verify repair
side
side
1A117
Inspection of the Intake Actuator System
D08RX230
1A118

Condition
Possible cause
Correction
Does not work at all
Refer to Chart A
Control failure
Refer to Chart B
Chart A: Does Not Work At All

Step
1
2
3
4
6
7
8
9
10
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Go to Step 4
Replace the
relay
Turn on the ignition switch. (the engine is run.)

side connector terminal No.B263 and ground?
Approx 12V
Go to Step 6
Go to Step 5
Repair an open circuit between terminal No.B263

and No.X61.
Go to Step 4

Approx 12V
Go to Step 8
Go to Step 7
Go to Step 6
Go to Step 10
Go to Step 9
Repair an open circuit between No.I2011 and B264.

Verify repair

Verify repair

Is the relay X6 normal?
Replace the intake actuator motor.

connector terminal No.I2011 and No.B264?
side
1A119
Chart B: Failure on the Intake Control

Step
1
2
3
4
5
6
7
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Go to Step 4
Replace the
relay

Is the intake actuator stopped?
Go to Step 6
Go to Step 5
Replace or repair the auto air conditioner control unit.

Verify repair

connector terminal No.B265 and No.I4411?
Go to Step 8
Go to Step 7

and No.I4411.
Go to Step 6

Go to Step 10
Go to Step 9
Is the fuse No.C14 normal?

Is the fuse No.F5 normal?
Is the relay No.X6 normal?
side
side

and No.I4412.
Go to Step 8
10

Go to Step 12
Go to Step 11

and I44-13.
Go to Step 10
12

Go to Step 14
Go to Step 13
13
Repair an open circuit between harness No.B262

and No.I4414.
Go to Step 12
Go to Step 15
Go to Step 16
Replace or repair the intake actuator.

Verify repair
Replace or repair the air conditioner control unit.

Verify repair
11
14
15
16
side
side
1. Disconnect the intake actuator connector No.B

26.
2. Is the battery voltage applied between harness
side connector terminal
No.B266 and ground?
No.B262 and ground?
No.B261 and ground?
1A120
Inspection of the Mix Actuator System
D08RX229
Condition
Possible cause
Correction
Refer to Chart A
Control failure
Refer to Chart B
1A121
Chart A: Does Not work At All

Step
Action
Value(s)
Yes
No
1. Turn on the ignition switch (the engine is run).

2. Disconnect the mix actuator connector (C45).
3. Short-circuit the chassis harness side connector
terminal No.C452 and No.C457.
4. Using the temperature control lever, select FH for
the temperature.
Is the battery voltage applied on a regular interval
basis between the harness side connector terminal
No.C458 (-) and No.C456 (+)?
Go to Step 3
Go to Step 2
Varify repair
Go to Step 5
Go to Step 4
Verify repair
Go to Step 7
Go to Step 6

No.C458.
Go to Step 5

connector terminal No.I205 and No.C456?
Go to Step 9
Go to Step 8

No.C456.
Verify repair
Replace the mix actuator.

Verify repair
2
3
4
5
6
7
8

Using the temperature control lever, select FC for the
temperature.
No.C458 (+) and No.C456 (-)?
side
side
1A122
Chart B: Mix Actuator Control Failure

Step
Action
Value(s)
Yes
No
Turn the ignition switch (the engine is run).

Dose the mix actuator fully stroke when FH and FC of
the temperature control lever?
Go to Step 3
Go to Step 2
Repair or replace the air mix door or the link unit.

Varify repair
Go to Step 5
Go to Step 4
Repair an open circuit between terminal No.C452

and No.I4411.
Go to Step 3

terminal No.C457 and No.I445?
Go to Step 7
Go to Step 6

and No.I445.
Go to Step 5

connector terminal No.C453 and No.I4415?
Go to Step 9
Go to Step 8

and No.I4415.
Go to Step 7
Is sum of the voltage between the following chassis

harness side connector terminals approximately 5V?
No.I4415 and No.I525, No.I445 and No.I4411
Go to Step 11
Go to Step 10
10
Replace the actuator.

Verify repair

Verify repair
2
3
4
11

side
side
1A123
Inspection of the Mode Actuator System
D08RX228
Condition
Possible cause
Correction
Refer to Chart A
Control failure
Refer to Chart B
1A124

Step
Action
Value(s)
Yes
No

2. Disconnect the mode actuator connector (C48)
3. Select VENT pressing the mode actuator.
Is the battery voltage provided on a regular interval
between the harness side connector terminal
No.C481 (+) and No.C485 (-)?
Go to Step 3
Go to Step 2

Varify repair
Turn on the DEF mode switch.

between the chassis side connector terminal No.C48
5 (+) and No.C481 (-)?
Go to Step 5
Go to Step 4
Varify repair
Go to Step 7
Go to Step 6

and No.I204.
Go to Step 5

Go to Step 9
Go to Step 8
Verify repair
Verify repair
2
3
4
5
6
7
8

side
side

and No.I203.
Replace the mode actuator.
1A125
Chart B: Mode Actuator Control Failure

Step
Action
Value(s)
Yes
No
Turn on the ignition switch (the engine is run).

Dose the mode actuator fully stroke when the defrost
mode and the vent mode are selected?
Go to Step 3
Go to Step 2
Repair or replace the mode door or the link unit.

Go to Step 1
Go to Step 5
Go to Step 4

and No.I4411.
Go to Step 3

Go to Step 7
Go to Step 6
2
3
4

side
side

and No.I4410.
Go to Step 5

Go to Step 9
Go to Step 8

and No.I448.
Go to Step 7
Is sum of the voltage between the following harness

side connector terminal approximately 5V? Voltage
between No.I448 and No.I4410 plus voltage
between No.I448 and No.I4411
5V
Go to Step 11
Go to Step 10
10

Verify repair
Dose the mode actuator work normally through

manual operation?
Go to Step 13
Go to Step 12
12
Replace the sensor.

Verify repair
13

Verify repair
11
1A126
Inspection of the Fan Motor System
D08RX227

Condition
Possible cause
1A127
Correction
The fan dose not rotate at all
Refer to Chart A
The fan dose not rotate in the MAX

HI mode
Refer to Chart B
The fan dose not rotate in any mode

other than MAXHI
Refer to Chart C
The fan dose not stop
Refer to Chart D
Chart A: Fan Does Not Rotate At All

Step
1
2
3
5
6
7
8
9
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
relay

Go to Step 5
Go to Step 4
Repair an open circuit between terminal No.B52 and

No.F4 fuse.
Go to Step 3
Is there continuity between the harness side

connector terminal No.B51 and ground (No.B8)?
Go to Step 7
Go to Step 6

ground.

side connector terminal No.B51 and No.B52?
Go to Step 8
Go to Step 9
Replace the blower motor.

Verify repair
Refer to chart B and C.

Verify repair
Are the fuse No.F4 and No.F5 normal?

Are the relay No.X6 and No.B25 normal?
1A128
Chart B: Fan Does Not Rotate in MAX HI Mode

Step
1
2
4
5
6
7
8
9
10
Action
Value(s)
Yes
No
Go to Step 2
Replace the
relay

2. Set the fan switch to the MAX-HI.
connector terminal No.B51 and No.B252?
Go to Step 4
Go to Step 3

No.B252.
Go to Step 3

Go to Step 6
Go to Step 5

and ground (No.B8).
Go to Step 4

Go to Step 8
Go to Step 7

and No.F5 fuse.
Go to Step 6

side connector terminal No.I2012 and ground?
Go to Step 10
Go to Step 9

and No.I2012.
Verify repair

Verify repair
Is the MAX-HI relay (B25) normal?
1A129
Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI
Step
Action
Value(s)
Yes
No
Is the power transistor performance normal? (Refer to

the later section on individual inspection")
Go to Step 2
Replace the
power transistor

connector terminal No.B51 and No.B351, No.B51
and No.I4417?
Go to Step 4
Go to Step 3
Repair an open circuit between terminal.

No.B51 and B351
No.B51 and I4417
Go to Step 2

Go to Step 6
Go to Step 5

and ground.
Go to Step 4

Go to Step 8
Go to Step 7

and No.I4419.
Go to Step 6

Verify repair
side
Chart D: Fan Does Not Stop

Step
Action
Value(s)
Yes
No
1. Disconnect the max high relay, the power

transistor connector B35 and the auto A/C
control unit connector I44.
2. Turn on the ignition switch.
Does the blower motor stop?
Go to Step 3
Go to Step 2
Repair a short circuit between connector No.B51 and

No.B252, No.B51 and No.B351, or No.B51 and
I4417.
Verify repair
Is the max high relay normal? (Refer to the later

section on individual inspection".)
Go to Step 4
Replace the
relay
Reinstall the max high relay.

Does the blower motor start operating?
Go to Step 6
Go to Step 5
Repair a short circuit between connector No.B253

and No.I2012.
Go to Step 4
Is the power transistor normal? (Refer to the later

Go to Step 7
Replace the
power transistor
Replace the
auto A/C control
unit
3
4
5
6
7
Reinstall the power transistor.

1A130
Inspection of the Magnetic Clutch System

6VD1 Engine
D08RX226

Condition
Possible cause
Magnetic clutch does not work
1A131
Correction
Refer to Chart A
Chart A: Magnetic Clutch Does Not work

Step
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Go to Step 4
Replace the
thermo unit
Go to Step 5
Replace the
pressure switch
1. Turn the ignition switch on. (the engine is run.)

2. Push the air conditioner switch on.
side connector terminal No.E31 and the ground?
Go to Step 6
Go to Step 7
Repair or replace the magnetic clutch.

Verify repair
Go to Step 9
Go to Step 8
Repair an open circuit between terminal No.X41 and

No.E31.
Go to Step 7

side connector terminal No.X45 and ground, No.X4
2 and ground?
Go to Step 11
Go to Step 10

fuse No.F5, No.X42 and fuse No.F5.
Go to Step 9

Go to Step 13
Go to Step 12

and No.X44.
Go to Step 11

side connector terminal No.C112 and ground?
Go to Step 15
Go to Step 14

and fuse No.F5.
Go to Step 13

5 and ground?
Go to Step 17
Go to Step 16

No.C111, No.X55 and fuse No.F5.
Go to Step 15

Go to Step 19
Go to Step 18

I2014.
Go to Step 17

Is the relay No.X4 (compressor relay) No.X5 (A/C
thermo relay) and No.X6 (heater relay) normal?
Is the thermo unit normal?
Is the pressure switch normal?

connector terminal No.X41 and No.E31?
side
1A132
Chart A: Magnetic Clutch Does Not work (Contd)

Step
19
20
21
22
Action
Value(s)
Yes
No
Go to Step 21
Go to Step 20

No.E191.
Go to Step 20
Dose the thermo relay ON" when connecting ground

to the harness connector terminal No.H175?
Go to Step 23
Go to Step 22
Failure on the auto air conditioner control unit.

Verify repair

connector terminal No.I444 and ground?
CAUTION:
There are conditions which air
as follows.
1. The throttle is griater than 90%.
3. The engine speed greater than 4500 RPM for 5
than 125C (257F).
(41F).
pressure condition.
side
1A133
Condenser Fan Diagnosis

condenser fan stops when the air conditioning is turned
OFF" or when the pressure goes down below the set
pressure value.
While the air conditioning is ON, the cycling switch in

the triple pressure switch senses the refrigerant
pressure, and activates the condenser fan to improve
the cooling capacity of the condenser when the
refrigerant pressure exceeds a set pressure value. The
D08RX255
Condition
Possible cause
Correction
Condenser fan does not run.
Refer to Chart A
Condenser fan does not stop.
Refer to Chart B
1A134
Chart A" Condenser Fan Does Not Run

Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fusible link wire
Go to Step 3
Replace the
fuse
Is the heater relay (No.X6) and condenser fan relay

(No.X9) normal?
Go to Step 4
Replace the
relay
1. Disconnect the condenser fan motor connector

No.C24.
2. Connect the motor side connector terminal
No.C241 to the battery positive terminal and
No.C242 to the battery negative terminal.
Dose the fan operate?
Go to Step 6
Go to Step 5
Repair or replace the condenser fan motor.

Go to Step 4

connector terminal No.C242 and ground (C16)?
Go to Step 8
Go to Step 7

and No.C16.
Go to Step 6

connector terminal No.C241 and No.X91?
Go to Step 10
Go to Step 9

and No.X91.
Verify repair

side connector terminal No.X95 and ground?
Go to Step 12
Go to Step 11

No.FL2.
Go to Step 10

Go to Step 14
Go to Step 13

No.C113.
Go to Step 12

Go to Step 16
Go to Step 15

and No.I2014.
Verify repair
Connect the harness side connector terminal

No.C241 to the battery terminal and No.C242 to the
battery negative terminal.
Is the battery voltage between the pressure switch
Go to Step 18
Go to Step 17
Replace the triple pressure switch.

Verify repair

Verify repair
Is the fusible link No.FL2 normal?

side
side
1A135
Chart B" Condenser Fan Does Not Stop

Step
Action
Value(s)
Yes
No
1. Turn on the ignition switch ON" (the engine is

run).
2. Air conditioning switch OFF".
3. Disconnect the triple pressure switch.
Does the condenser fan stop?
Go to Step 2
Go to Step 3

Verify repair
Go to Step 4
Go to Step 5
Repair short circuit between terminal No.X94 and

No.C113.
Verify repair
Replace the relay condenser fan.

Verify repair
2
3
Disconnect the relay.

connector terminal No.X94 and ground?
side
1A136
Solar Radiation Sensor

1. Disconnect the interior temperature sensor
connector (I4).
2. Measure
resistance
between
the
interior
temperature sensor side terminal
No.I43 and
No.I44.
1. Disconnect the solar radiation sensor connector (I

50).
2. Measure the current value on the solar radiation
sensor when placed it approximately 15 cm away
from 60W incandescent lamp.
C01RX013
865RX007
1A137

1. Disconnect the connector (C8) on the outside air
temperature sensor.
2. Measure resistance between the outside air
temperature sensor side terminals.
C01RX015
MAX HI Relay
1. Remove the MAX HI relay connector (B25) from
the blower assembly.
2. Check the conduction between the MAX HI relay
side terminals.
C01RX012
Power Transistor
1. Remove the power transistor connector (B35) from
the evaporator assembly.
2. Check the conduction between the power transistor
side terminals.
C01RX014
Aspirator (Interior Temperature Sensor)

1. Turn on the ignition switch (the engine is started).
Start the air conditioner in Full Auto".
2. Make sure that the interior sensor suctions cigarette
smokes and such.
1A138

1. Dismount the interior temperature sensor from the
automatic heater/air
conditioner control unit.
Connect (+) end and (-) end of the battery to the
aspirator motor side terminals No.I41 and No.I4
2, respectively, then check if the motor
runs
normally.
Heater (X6), Thermostat (X5), Condenser

Fan (X9) And Compressor (X4) Relay
in this section.
901RX071
Condenser Fan
1. Disconnect the condenser fan connector.
2. Connect the battery positive terminal to the
condenser fan side connector
terminal No.C24-2
and negative to the No.C24-1.
3. Check that condenser fan is rotating correctly.
865RS017
875RW010

1. Disconnect the connector and check for continuity
between pressure switch side connector terminals
(1) and (2).
2. Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connector terminal (3) and (4) and the
fan operates.
875RX009
1A139
1A140
On-Vehicle Service
Power Transistor
Automatic Heater/Air
Control Unit
Conditioner
840RW028
Legend
(1) Power Transistor Connector
(3) Glove Box
(4) Reinforcement: Inst Panel Lower
EndOFCallout
Removal
865RW016

2. Disconnect the power transistor connector.
3. Remove power transistor.
Installation
To install, follow the removal step in the reverse order.
Legend
(1) Connector
(2) Automatic Air Control Unit
(4) Instrument Center Cluster
(5) Instrument Lower Cover
EndOFCallout
Removal
2. Remove instrument lower cover.
Structure section.
4. Remove the automatic heater/air conditioner control
unit attaching screws.
5. Pull the automatic heater/air conditioner unit out and
disconnect the connectors.
Installation
Interior
Temperature
(Aspirator)
Sensor
1A141
875RW017
865RW014
Legend
(1) Interior Temperature Sensor (Aspirator)
EndOFCallout
Removal
unit.
Refer to the automatic heater/air conditioner
control unit section.
3. Remove Interior temperature sensor (Aspirator).
Legend
(1) Out Side Air Temperature Sensor
(2) Radiator Grille
EndOFCallout
Removal
Refer to Radiator Grille in Body Structure section.
3. Disconnect the outside air temperature sensor
connector.
4. Remove the outside air temperature sensor.
Installation
Installation
1A142
Solar Radiation Sensor
Electronic Thermostat
865RW009
Legend
(1) Solar Radiation Sensor
EndOFCallout
Removal
2. Remove the solar radiation sensor.
3. Disconnect the solar radiation sensor connector.
Installation
874RW027
Legend
(1) Electronic Thermo Sensor
(3) Thermostat Assembly
EndOFCallout
Removal
Refer to Evaporator Assembly section.
3. Remove electronic thermostat.
Installation
Mode Actuator
1A143
Mix Actuator
860RW030
Legend
(1) A/T Control Unit
(2) Mode Actuator
(3) Actuator Rod
EndOFCallout
860RW033
Legend
(3) Actuator Rod
(4) Mix Actuator
EndOFCallout
Removal
2. Remove the PCM.
The connector shall remain connected.
3. Remove the actuator rod.
4. Remove the mode actuator.
Installation
To install, follow the remove step in the reverse order.
Removal
2. Remove the instrument panel assembly.
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the instrument panel center bracket.
5. Remove the mix actuator.
Installation
1A144
Intake Actuator
860RW034
Legend
(2) Intake Actuator
(3) Intake Actuator Connector
EndOFCallout
Removal
2. Remove the blower assembly.
Refer to Blower Assembly section.
3. Disconnect the intake actuator connector.
4. Remove the intake actuator.
Installation
SECTION
POWER-ASSISTED STEERING SYSTEM
2A1
STEERING
CONTENTS
Service Precaution.........................................
Diagnosis .......................................................
General Description .......................................
Power Steering System Test .........................
Maintenance ..................................................
Fluid Level .....................................................
Bleeding The Power Steering System ...........
Bleeding Procedure .......................................
Flushing The Power Steering System ...........
Steering Wheel Free Play Inspection ............
Front End Alignment Inspection
and Adjustment ..........................................
Main Data and Specifications ........................
Special Tools .................................................
Power Steering Unit ......................................
Power Steering Unit and Associated Parts.
Removal .....................................................
Installation ..................................................
Power Steering Unit Disassembled View ...
Disassembly ...............................................
Inspection and Repair.................................
Reassembly ................................................
Special Tools .................................................
Power Steering Pump ...................................
Power Steering Pump and
Associated Parts .....................................
Removal .....................................................
Installation ..................................................
Power Steering Pump Disassembled View
Disassembly ...............................................
Reassembly ................................................
Main Data and Specifications .....................
Transfer Gear Assembly ...............................
Transfer Gear Assembly
2A - 2
2A - 2
2A - 8
2A - 10
2A - 11
2A - 11
2A - 11
2A - 11
2A - 12
2A - 12
2A - 12
2A - 16
2A - 17
2A - 18
2A - 18
2A - 18
2A - 19
2A - 20
2A - 20
2A - 20
2A - 20
2A - 21
2A - 21
2A - 22
2A - 22
2A - 22
2A - 22
2A - 23
2A - 23
2A - 24
2A - 24
2A - 26
2A - 27
and Associated Parts ..............................

Removal......................................................
Installation...................................................
Supplemental Restraint System Steering
Wheel & Column........................................
Service Precaution......................................
SRS Connectors .........................................
Inflator Module ..............................................
Inflator Module and Associated Parts .........
Removal......................................................
Installation...................................................
Steering Wheel..............................................
Steering Wheel and Associated Parts ........
Removal......................................................
Installation...................................................
Combination Switch ......................................
Combination Switch and Associated Parts .
Removal......................................................
Installation...................................................
Lock Cylinder ................................................
Lock Cylinder and Associated Parts ...........
Removal......................................................
Installation...................................................
System Inspection ......................................
Steering Column ...........................................
Steering Column and Associated Parts ......
Removal......................................................
Insepction ...................................................
Installation...................................................
Wheel & Column and Associated Parts.....
Special Tools .................................................
2A - 27
2A - 27
2A - 27
2A - 27
2A - 28
2A - 28
2A - 28
2A - 30
2A - 30
2A - 30
2A - 31
2A - 31
2A - 32
2A - 32
2A - 32
2A - 34
2A - 35
2A - 35
2A - 35
2A - 37
2A - 39
2A - 39
2A - 39
2A - 41
2A - 42
2A - 43
2A - 43
2A - 43
2A - 46
2A - 47
2A - 48
2A - 49
2A - 49
2A - 49
2A2
Service Precaution
ORDER TO DETERMINE WHETHER YOU ARE
FOLLOW WARNINGS COULD RESULT IN
REPAIRS.

and systems.
Diagnosis
Since the problems in steering, suspension, wheels and
tires involve several systems, they must all be
considered when diagnosing a complaint. To identify
the symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and
correct any defects which are found.
1. Inspect tires for proper pressure and uneven wear.
2. Raise vehicle on a hoist, then inspect front and rear
suspension and steering linkage for loose or
damaged parts.
3. Spin the front wheels. Inspect for out-of-round tires,
out-of-balance tires, loose and/or rough wheel
bearings.
General Diagnosis
Condition
Vehicle Pulls
Abnormal or Excessive Tire Wear
Wheel Hop
Possible cause
Correction
Mismatched or uneven tires.
Replace tire.
Tires not adequately inflated.
Adjust tire pressure.
Broken or sagging springs.
Replace spring.
Radial tire lateral force.
Replace tire.
Improper wheel alignment.
Adjust wheel alignment.
Brake dragging in one wheel.
Repair brake.
Loose, bent or broken front or rear

suspension parts.
Tighten or replace the appropriate

suspension part(s).
Faulty shock absorbers.
Replace shock absorber.
Parts in power steering valve

defective.
Replace power steering unit.
Sagging or broken spring.
Replace spring.
Tire out of balance.
Balance or replace tire.
Check front end alignment.
Faulty shock absorber.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire and reduce load.
Tires not rotated periodically.
Replace or rotate tire.
Worn or loose road wheel bearings.
Replace wheel bearing.
Wobbly wheel or tires.
Replace wheel or tire.
Adjust the pressure.
Blister or bump on tire.
Replace tire.
Improper shock absorber operation.

Condition
Shimmy, Shake or Vibration
Hard Steering
Too Much Play In Steering
Poor Steering Wheel Returnability
Possible cause
2A3
Correction
Tire or wheel out of balance.
Balance wheels or replace tire/or

wheel.
Loose wheel bearings.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Excessive wheel runout.
Repair or replace wheel and/or tire.
Replace tire.
Excessive loaded radial runout of

tire/wheel assembly.
Replace tire or wheel.
Check wheel alignment.
Loose or worn steering linkage.
Tighten or replace steering linkage.
Loose steering unit.
Tighten steering unit.

suspension parts.

suspension parts.
Hub bearing preload misadjustment.
Adjust preload.

defective.
Bind in steering linkage ball studs,

upper or lower end ball joint.
Replace ball joint.
Tire not adequately inflated.
Inflate tires to proper pressure.
Bind in steering column or shaft.
Repair or replace.
Improper power steering system

operation.
Repair or replace.
Refer to Power steering system
diagnosis"
Wheel bearings worn.
Replace wheel bearings.
Loose steering unit or linkage.
Retighten or repair.
Worn or loose steering shaft

universal joint.
Retighten or replace steering shaft.
Bind in steering linkage ball joints.
Bind in upper or lower end ball

joints.
Bind in steering column and shaft.
Repair or replace.
Bind in steering gear.
Check and repair steering gear.
Loose steering wheel nut.
Retighten.
Worn wheel bearing.
Replace.
2A4

Condition
Abnormal Noise
Wandering or Poor Steering Stability
Erratic Steering When Braking
Possible cause
Correction
Worn, sticky or loose upper or lower

ball joint, steering linkage ball joints
or drive axle joints.
Replace.
Replace.
Worn upper or lower control arm

bushing.
Replace.
Loose stabilizer bar.
Retighten bolts or replace bushings.
Loose wheel nuts.
Tighten nuts. Check for elongated

wheel nut holes.
Replace wheel if required.
Loose suspension bolts or nuts.
Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel

bearings.
Broken suspension springs.
Replace spring.
Retighten mounting bolt.
Faulty steering unit.
Replace steering unit.
Mismatched or unevenly worn tires.
Replace tire or inflate tires to proper

pressure.
Loose steering linkage ball joints.
Tighten or replace stabilizer bar or

bushings.
Replace spring (pairs).
Worn wheel bearings.
Leaking caliper.
Repair or replace caliper.
Warped discs.
Replace brake disc.
Badly worn brake pads.
Replace brake pads.
Tires are inflated unequally.

Power Steering System
There is some noise in all power steering systems. One
of the most common is a hissing sound when the
steering wheel is fully turned and the car is not moving.
This noise will be most evident when the steering wheel
is operated while the brakes are applied. There is no
Condition
Rattle or Chucking Noise
2A5
relationship between this noise and steering

performance. Do not replace the valve unless the
hissing" noise is extremely objectionable. A
replacement valve will also have a slight noise, and is
not always a cure for the condition.
Possible cause
Correction
Pressure hose touching other parts

of vehicle.
Adjust hose position. Do not bend

tubing by hand.
Tie rod ends loose.
Tighten or replace tie rod end.
Loose steering unit mounting.
Tighten steering unit mounting.
Improper front wheel alignment.
Adjust front wheel alignment.
Wheel bearing worn.
Replace front wheel bearing.
Tie rod end binding.
Replace tie rod end.
Ball joint binding.
Replace ball joint.
Tight or frozen steering shaft

bearing.
Replace steering assembly.
Sticky or plugged steering unit valve.
Flush or replace steering unit.
Entry of air in the power steering

system.
Bleed the system.
Momentary Increase In Effort When

Turning Wheel Fast To Right or Left
High internal leakage.
Repair steering gear.
Power steering fluid level low.
Replenish fluid.
Steering Wheel Surges or Jerks

When Turning Especially During
Parking
Insufficient pump pressure.
Repair pump assembly.
Sticky steering unit valve.
Replenish fluid.
Excessive Wheel Kick Back or

Loose Steering
Air in system.
Bleed hydraulic system.
Tie rod end loose.
Tighten tie rod end.
Wheel bearing worn.
Excessive internal pump leakage.
Excessive internal steering gear

leakage.
Replenish fluid.
Pressure switch of the power

steering pump or its harness is
faulty.
Repair or replace.
Poor Return of Steering Wheel to

Center
Hard Steering or Lack or Power

Assist
Unstable Engine Idling or Stalling

When Turning
2A6
Power Steering Pump

Foaming milky power steering fluid, low fluid level, and
possible low pressure can be caused by air in the fluid,
or loss of fluid due to internal pump leakage. Check for
leak and correct. Bleed the system. Extremely cold
Condition
Low Pressure Due to Steering Pump
temperatures will cause air bubbles in the system if the

fluid level is low. If the fluid level is correct and the pump
still foams, remove the pump from the vehicle and
check housing for cracks. If the housing is cracked,
replace the pump housing.
Possible cause
Correction
Relief valve sticking or inoperative.
Replace relief valve.
Side plate not flat against cam ring.
Replace side plate.
Extreme wear of cam ring.
Replace cam ring.
Scored side plate or rotor.
Replace side plate or rotor.
Vanes sticking in rotor slots.
Repair or replace vanes and rotor.
Cracked or broken side plate.
Replace side plate.
Repair internal leakage.
Low Pressure Due to Steering Gear
Scored housing bore.
Replace housing.
Growling Noise In Steering Pump
Excessive back pressure in hoses or

steering unit caused by restriction.
Repair steering unit or pump.
Worn cam ring.
Replace cam ring.
Air in the fluid.
Low fluid level.
Replenish fluid.
Pump mounting loose.
Tighten mounting bolt.
Vane improperly installed.
Repair rotor and vane.
Swishing Noise In Steering Pump
Damaged relief valve.
Whining Noise In Steering Pump
Scored side plate and vanes.
Replace side plate and vanes.
Groaning Noise In Steering Pump
Rattling Noise In Steering Pump
Steering Column Lock System

Condition
Will Not Unlock
Will Not Lock
Key Cannot be Removed in

OFF-LOCK"
Possible cause
Correction
Damaged lock cylinder.
Replace lock cylinder.
Damaged park lock cable.
Replace park lock cable.
Lock spring broken or worn.
Ignition switch stuck.
Repair or replace ignition switch.
Park lock cable damaged.
Ignition switch is not set correctly.
Correct ignition switch.
Faulty shift lock mechanism.
Repair or replace the shift lock

mechanism.
Column
Condition
Noise in Column
Possible cause
Correction
Universal joint loose.
Tighten joint.
Shaft lock snap ring not seated.
Place snap ring in proper position.

Turn Signal Switch
This diagnosis covers mechanical problems only. Refer
Condition
Turn Signal Will Not Stay In Turn
Position
2A7
to Turn Signal Switch in Electrical section for electrical

diagnosis.
Possible cause
Correction
Foreign material or loose parts

preventing movement of yoke.
Repair or replace signal switch.
Broken or missing detent or

canceling spring.
Replace signal switch.
Loose switch mounting screws.
Tighten mounting screws.
Switch or anchor bosses broken.
Replace turn signal switch.
Broken, missing or out of position

detent, return or canceling spring.
Worn canceling cam.
Turn signal switch arm loose.
Tighten arm screw.
Broken or distorted yoke.
Loose or misplaced springs.
Foreign parts and/or material.
Repair turn signal switch.
Loose turn signal switch mounting

screws.
Broken lane change pressure pad or

spring hanger.
Broken, missing or misplaced lane

change spring.
Base of wire damaged.
Hazard Switch Cannot Be Turned

Off
Foreign material between hazard

switch to turn signal switch body.
Repair or replace hazard switch.
No Turn Signal Lights
Electrical failure in chassis harness.
Refer to Electrical section.
Inoperative turn signal flasher unit.
Replace flasher unit.
Loose chassis harness connector.
Repair loose connector.
Burned-out or damaged turn signal

bulb.
Replace bulb.
High resistance connection to

ground at bulb socket.
Repair bulb socket.
Turn Signal Will Not Cancel
Turn Signal Difficult To Operate
Turn Signal Will Not Indicate Lane

Change
Front or Rear Turn Signal Lights Not

Flashing
2A8
General Description
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering unit, a pressure hose
and a return hose.
Power Steering Unit
A02RW007
The power steering unit is rack and pinion type.

The toein angle can be adjusted by turning the rod on
each side.
The steering housing cannot be disassembled.
Hydraulic Pump
A02RX002

The hydraulic pump is vane-type design. The
submerged pump has housing and internal parts that
are inside the reservoir and operate submerged in oil.
There are two bore openings at the rear of the pump
housing. The larger opening contains the cam ring,
pressure plate, thrust plate, rotor and vane assembly,
and end plate. The smaller opening contains the
pressure line union, flow control valve and spring.
The flow control orifice is part of the pressure line union.
The pressure relief valve inside the flow control valve
limits the pump pressure.
2A9
Pressure Switch
When hydraulic pressure reaches 3430 kPa (35 kg/cm2/
500 psi), the pressure switch of the power steering
pump closes causing the Engine Control Module (ECM)
to actuate the idle air control valve, which increases the
engine rpm to prevent the overload-induced engine
speed slow down. The switch opens when hydraulic
pressure drops to 2940 kPa (30 kg/cm2/430 psi).
Steering Column
A02RW009
WARNING: TO AVOID DEPLOYMENT WHEN

TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED
VOLT-METER, OHMMETER, ETC., OR ANY TYPE
OF ELECTRICAL EQUIPMENT OTHER THAN
SPECIFIED IN THIS MANUAL. DO NOT USE A
NON-POWERED PROBE-TYPE TESTER.
INSTRUCTION IN THIS MANUAL MUST BE

FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
When servicing a vehicle equipped with Supplemental
Restraint System, pay close attention to all WARNINGS
and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
2A10
The steering column has three important features in

addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of

the vehicle.
The column can be disassembled and reassembled.
However, to insure the energy absorbing action, use
only the specified screws, bolts and nuts as designated,
and tighten them to the specified torque.
Handle the column with care when it is removed from
the vehicle. A sharp blow on the end of steering shaft or
Power Steering System Test

Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
EndOFCallout
Test of fluid pressure in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, if
necessary, must be made.
Inspect pump reservoir for proper fluid level.
Inspect pump belt for proper tension.
Inspect pump driver pulley condition.
(3) Power Steering Unit

(4) Power Steering Pump
1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5884001350 as
shown in the illustration. The gage must be
between the shutoff valve and pump. Open the
shutoff valve.
3. Check the fluid level. Fill the reservoir with power
steering fluid, to the Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.

4. Bleed the system. Refer to Bleeding the Power
Steering System in this section.
5. Start the engine and check the fluid level. Add
power steering fluid if required. When the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.
6. Fully close the shutoff valve. Record the highest
pressures.
If the pressure recorded is within 93009800 kPa
(95100 kg/cm2/13501420 psi), the pump is
functioning within its specifications.
If the pressure recorded is higher than 9800 kPa
(100 kg/cm2/1420 psi), the valve in the pump is
defective.
If the pressure recorded is lower than 9300 kPa
(95 kg/cm2/1350 psi), the valve or the rotating
group in the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the power
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regular
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must
be completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight.
Make sure the clips, clamps and supporting tubes and
hoses are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding
the Power Steering System in this section.
Inspect belt for tightness.
2A11
Inspect pulley for looseness or damage. The pulley

should not wobble with the engine running.
Inspect hoses so they are not touching any other
parts of the vehicle.
Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55C
(130F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to Bleeding the Power Steering
System in this section.
Bleeding The Power Steering System

When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the power
steering fluid system, noisy and unsatisfactory
operation of the system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only
power steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel
right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.
2A12
Flushing The Power Steering System

1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoir
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which may
cause a sudden fluid overflow at the reservoir.
4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the power
steering system components. Do not re-use any
drained power steering fluid.
Front End Alignment Inspection and

Adjustment
General Description
Front End Alignment" refers to the angular relationship
between the front wheels, the front suspension
attaching parts and the ground.
Proper front end alignment must be maintained in order
to insure efficient steering, good directional stability and
to prevent abnormal tire wear.
The most important factors of front end alignment are
wheel toe-in, wheel camber and axle caster.
Camber:
This illustration shows view from the front of the vehicle.
Steering Wheel Free Play Inspection
480RS004
Camber is the vertical tilting inward or outward of the

front wheels. When the wheels tilt outward at the top,
the camber is positive (+). When the wheels tilt inward
at the top, the camber is negative (-). The amount of tilt
measured in degrees from the vertical is called the
camber angle (1). If camber is extreme or unequal
between the wheels, improper steering and excessive
tire wear will result. Negative camber causes wear on
the inside of the tire, while positive camber causes wear
to the outside.
430RW020
1. With the tires in the straight-ahead position, check

the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running.
Free play: 0 30mm (0 1.18in)
2. Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. When test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.

Caster:
This illustration shows view from the side of the vehicle.
2A13
Toe-in is the measured amount the front wheels are turn

in. The actual amount of toe-in is normally a fraction of
a degree. Toe-in is measured from the center of the tire
treads or from the inside of the tires. The purpose of
toe-in is to insure parallel rolling of the front wheels and
to offset any small deflections of the wheel support
system which occurs when the vehicle is rolling forward.
Incorrect toe-in results in excessive toe-in and unstable
steering. Toe-in is the last alignment to be set in the
front end alignment procedure.
Inspection
480RS005
Caster (1) is the vertical tilting of the wheel axis either

forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt
is negative (-). On the short and long arm type
suspension you cannot see a caster angle without a
special instrument, but if you look straight down from the
top of the upper control arm to the ground, the ball
joints do not line up (fore and aft) when a caster angle
other than 0 degree is present. With a positive angle,
the lower ball joint would be slightly ahead (toward the
front of the vehicle) of the upper ball joint center line.
Toe-in:
This illustration shows view from the top of the vehicle.
480RS003
Before making any adjustments affecting caster, camber

or toe-in, the following front end inspection should be
made.
1. Inspect the tires for proper inflation pressure. Refer
to Main Data and Specifications in Wheel and Tire
System section.
2. Make sure that the vehicle is unladen condition
(With no passenger or loading).
3. Make sure that the spare tire is installed at the
normal position.
4. Inspect the front wheel bearings for proper
adjustment. Refer to Front Hub and Disc in
Driveline section.
5. Inspect the ball joints and tie rod ends. If excessive
looseness is noted, correct before adjusting. Refer
to Steering Linkage in this section.
6. Inspect the wheel and tires for run-out. Refer to
Wheel Replacement in Wheel and Tire System
section.
7. Inspect the trim height. If not within specifications,
the correction must be made before adjusting
caster.
8. Inspect the steering unit for looseness at the frame.
9. Inspect shock absorbers for leaks or any noticeable
noise. Refer to Shock Absorber in Suspension
section.
10. Inspect the control arms or stabilizer bar attachment
for looseness. Refer to Suspension section .
11. Inspect the front end alignment using alignment
equipment. Follow the manufacturer's instructions.
12. Park the vehicle must be on a level surface.
2A14
Trim Height Adjustment
Caster Adjustment
Adjust the trim height (1) by means of the adjusting bolt

on the height control arms.
The caster angle can be adjusted by means of the

caster shims (1) installed between the chassis frame
(2) and fulcrum pins.
CAUTION: When adjusting front end alignment, be

sure to begin with trim height first, as it may change
other adjusted alignments.
Caster angle: 230' 1

CAUTION: Left and right side must be equal within
30'.
450RS003
450RW006
410RS001
1. Check and adjust the tire inflation pressures.

2. Park the vehicle on a level ground and move the
front of the vehicle up and down several times to
settle the suspension.
3. Make necessary adjustment with the adjusting bolt
Trim height: 119 5mm (4.69 0.2in)
450RS002
NOTE: Difference of the caster shim front/rear

thickness should be 3.6mm (0.142in) or less. Overall
thickness of caster shim and camber shim should be
10.8mm (0.425in) or less.
Tighten the fulcrum pin bolt to the specified torque.
Torque: 152Nm (15.5kgm/112lbft)
2A15
Camber Adjustment
The camber angle can be adjusted by means of the
camber shims (2) installed in position between the
chassis frame (1) and fulcrum pins
Camber angle: 0 30'
King pin inclination: 1230' 30'
30'.
450RS005
NOTE: Overall thickness of caster shim and camber

shim should be 10.8mm (0.425in) or less.
450RW007
Position of shims
Caster shim
Camber shim
Camber angle
Caster angle
When removed
Decreases
Decreases
When removed
When added
Increases
Increases
When removed
Unchanged
Decreases
When added
Unchanged
Increases
When added
Decreases
Unchanged
When removed
Increases
Unchanged
Front side
Rear side
When added
2A16
Toe-in Adjustment
1. To adjust the toe-in angle, loosen the lock nuts (2)
on the tie rod (1) and turn the tie rod. Turn both rods
the same amount, to keep the steering wheel
centered .
Toe-in: 0 2mm (0 0.08in)
433RW006
2. Tighten the lock nut to the specified torque.


General Specification
230' 1
Caster
0 30'
Camber
1230' 30'
King pin inclination
0 2mm (0 0.08in)
Toe-in
Max. steering angle
inside
32.6 (+030' to 230' )
outside
31.8
2A17
Torque Specification
E02RX006
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884001350
(J29877A)
Tester;
Power steering
ILLUSTRATION
TOOL NO.
TOOL NAME
5884022970
(J39213)
Adapter;
Power steering tester
2A18
Power Steering Unit

Power Steering Unit and Associated Parts
431RW026
Legend
(1) Bracket
(2) Transfer Gear Assembly
(3) Power Steering Unit Assembly

(4) Crossmember
EndOFCallout
Removal
1. Remove the stone guard.
2. Remove the transfer gear assembly.
Make a setting mark across the coupling flange and
steering unit to ensure reassembly of the parts in
the original position.
3. Drain power steering fluid.
4. Remove the tie rod end assembly from knuckle.
Use tie rod end remover 5884020050.
901RW270

5. Disconnect the feed line and return line from
steering unit.
Remove the clips on the crossmember and frame.
Wire the power steering line to frame.
NOTE: Take care to prevent foreign matter from entry
when disconnect the power steering line.
6. Remove the torsion bar. Refer to Front Suspension
in Suspension section.
7. Remove the lower control arm bolt (Frame side).
Refer to Front Suspension in Suspension section.
8. Apply a setting mark across the crossmember and
frame so parts can be reassembled in their original
position.
431RX013
9. Remove the crossmember fixing bolt.

10. Remove the power steering unit with the
crossmember.
11. Remove the power steering unit.
Installation
1. Install power steering unit to crossmember.
Tighten fixing bolt to specified torque.
2. Install power steering unit with crossmember to
frame by aligning the setting marks made when
removing.
Tighten crossmember mounting bolt to specified
torque.
3. Install lower control arm bolt.
4. Install torsion bar.
5. Connect the feed line and return line.
2A19
6. Install tie-rod end assembly to knuckle.

7. Install transfer gear assembly.
Align the setting marks made at removal.
8. Install the stone guard.
9. Bleed the system.
Refer to Bleeding the Power Steering System in this
section.
2A20
Power Steering Unit Disassembled View
440RW005
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Tie-rod End
Lock Nut
Clip
Bellows
Band
Tie-rod Assembly
(7)
(8)
(9)
(10)
(11)
Tab Washer
Oil Line
Valve Housing Assembly
Mounting Rubber
Dust Cover
EndOFCallout
Disassembly
Tie-rod Assembly
NOTE: The valve housing is made of aluminum and

care should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
1. Loosen lock nut and remove tierod end.
2. Remove clip and band, then remove bellows.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.
If the resistance is insufficient or play is felt when

checked by moving the ball on the tie-rod, replace the
tie-rod assembly.

Inspect the following parts for wear, damage or any
abnormal conditions.
Tie-rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.
Rubber Parts
If wear or damage is found through inspection, replace
with new ones.
Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
Torque: 13Nm (1.3kgm/113lbin)
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
After tightening, bend tab washer against width
across flat of inner ball joint.
2A21
4. Apply a thin coat of grease to the shaft for smooth

installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.

Power Steering unit
Type
Rack and pinion
Rack stroke
152mm (5.98in)
Lock to lock
3.64
E02RX007
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884020050
(J29107)
Tie rod end remover
2A22
Power Steering Pump

Power Steering Pump and Associated Parts
436RX001
Legend
(1) Pump Assembly
(2) Hose, Suction
(3) Hose, Flexible

(4) Bolt
EndOFCallout
Removal
1. Remove the drive belt.
2. Place a drain pan below the pump.
3. Disconnect the suction hose.
4. Disconnect the flexible hose.
5. Remove the power steering fixing bolt and remove
the pump assembly.
Installation
1. Install the pump assembly to the pump braket,
tighten the fixing bolt to the specified torque.
2. Install the flexible hose.
Tighten the eye bolt to specified torque.
3. Install the drive belt.
4. Connect the suction hose, then fill and bleed
system.
section.
2A23
442RX001
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Bolt
Suction Pipe
O-ring
Shaft Assembly
Oil Seal
Front Housing
O-ring
O-ring
Side Plate
Rotor and Vane
Pin
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Cam
Pump Cartridge Assembly
O-ring
Snap Ring
Rear Housing
Bolt
Spring
Relief Valve
O-ring
Connector
Pressure Switch Assembly
EndOFCallout
Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent).
Be careful not to expose the oil seal of shaft
assembly to solvent.
2. Remove the bolt, suction pipe and O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the pressure switch assembly.
5. Remove the bolt, rear housing and O-ring.

6. Remove the snap ring.
7. Remove the shaft assembly.
8. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
9. Remove the pump cartridge assembly from the front
housing.
10. Remove two O-rings.
2A24
Cam
Make all necessary adjustments, repairs, and part

replacements if wear, damage, or other problems are
discovered during inspection.
The inner face of the arm should have a uniform contact

pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Rotor
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger
nail.
The parts with minor scores may be reused after
lapping the face.
Relief Valve
The sliding face of the valve must be free from burrs and
damage. The parts with minor scores may be reused
after smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.
442RS002
Check that the groove in the vane is free from excessive

wear and that the vane slides smoothly. When part
Vane
O-ring, Oil Seal, Snap Ring

Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts for
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
442RS003
Sliding faces of the vane should be free from wear.

(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install roter and vanes to cam.

5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
11. Install suction pipe with a new O-ring. Be sure to
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
14. Install pressure switch assembly and tighten it to
specified torque.
2A25
2A26

Oil pump
Type
Operating
fluid
Vane
ATF DEXRONIIE
E02RX008
2A27

Transfer Gear Assembly and Associated Parts
441RW002
Legend
(2) Bolt, Universal Joint (Steering Shaft Side)
(3) Fixing Bolt Nut
(4) Shim
(5) Bolt, Universal Joint (Steering Unit Side)
EndOFCallout
Removal
1. Apply a setting mark across the universal joint and
transfer gear so parts can be reassembled in their
original position.
2. Remove universal joint bolt (steering shaft side).
3. Remove universal joint bolt (steering unit side).
4. Loosen fixing bolt and nut and remove transfer gear
assembly with shim.
Installation
1. Install transfer gear assembly with shim by aligning
the setting marks made when removing.
2. Tighten bolt and nut to the specified torque.
3. Connect universal joint (both side) and tighten the
bolt to the specified torque.

The transfer gear assembly cannot be disassembled. If
damage or abnormal condition are found, replace to
new ones.
2A28
Supplemental Restraint System Steering Wheel & Column

Service Precaution
This steering wheel and column repair section covers
the Supplemental Restraint System (SRS) steering
column. The following repair procedures are specific to
SRS components. When servicing a vehicle equipped
with Supplemental Restraint System, pay close
attention to all WARNINGS and CAUTIONS.
section.
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
SAFE HANDLING OF INFLATOR MODULES
REQUIRES FOLLOWING THE PROCEDURES
DESCRIBED BELOW FOR BOTH LIVE AND
DEPLOYED MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWED
WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE
AIR BAG ASSEMBLY (AIR BAG) 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 POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) 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.
WHEN CARRYING A LIVE AIR BAG ASSEMBLY,

MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY AN
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 A LIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE THE 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.
TO
AVOID
DEPLOYMENT
WHEN
TROUBLESHOOTING THE SRS SYSTEM, DO NOT
BATTERY-POWERED
OR
A/C-POWERED
VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL
EQUIPMENT
OTHER
THAN
INSTRUCTIONS IN THIS MANUAL MUST BE
INJURY MAY RESULT.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit.
When removing the cable harness, do not pull the
cables. Otherwise, cable disconnection may occur.
When connect the SRS connector, insert the
connector completely. Imperfect locking may cause
malfunction of SRS circuit.
2A29
Removal
Installation
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).
To install the connector, hold the soket insulator(1) and

insert it. The cover insulator slides and connector will be
locked.
Do not hold the cover insulator(2).
827RW028
827RW027
2A30
Inflator Module
Inflator Module and Associated Parts
827RW071
Legend
(1) Horn Lead
(2) SRS Connector
(3) Fixing Bolt

(4) Inflator Module
EndOFCallout
Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to LOCK".
3. Disconnect the battery " terminal cable, and wait
at least 5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.
5. Loosen the inflator module fixing bolt from behind
the steering wheel assembly using a TORX driver
or equivalent until the inflator module can be
released from steering assembly .
827RW070

6. Disconnect the yellow 2-way SRS connector and
horn lead located behind the inflator module.
2A31
The inflator module consists of a cover, air bag, inflator,

and retainer. Inspect the inflator module mainly for the
following:
Check for holes, cracks, severe blemishes and
deformation on the cover.
Check that the retainer is not deformed.
Check for defects such as damage and breakage in
the lead wire for the igniter.
If an abnormality is found as the result of the inspection,
replace the inflator module with a new one.
Installation
1. Install inflator module.
2. Support the module and carefully connect the
module connector and horn lead.
827RW073
7. Remove inflator module.
NOTE: Pass the lead wire through the tabs on the

plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
3. Tighten bolts to specified torque.

WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE URETHANE
COVER AWAY FROM YOUR BODY AND SHOULD
ALWAYS BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT .
827RW072
4. Connect the yellow 2-way SRS connector located

5. Connect the battery " terminal cable.
6. Set ignition to ON" while watching warning light.
Light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints
section.
2A32
Steering Wheel
Steering Wheel and Associated Parts
827RW069
Legend
(1) Horn Lead
(2) SRS Connector
(3) Steering Wheel
(4) Steering Wheel Fixing Nut

(5) Inflator Module
EndOFCallout
CAUTION: Once the steering column is removed
from the vehicle, the column is extremely
susceptible to damage. Dropping the column
assembly on its end could collapse the steering
shaft or loosen the slide block which maintains
column rigidity. Leaning on the column assembly
could cause the jacket to bend or deform. Any of
the above damage could impair the column's
collapsible design. If it is necessary to remove the
steering wheel, use only the specified steering
wheel puller. Under no conditions should the end of
the shaft be hammered upon, as hammering could
loosen slide block which maintains column rigidity.
Removal
at least 5 minutes.

released from steering assembly.
2A33
9. Apply a setting mark (1) across the steering wheel

and shaft so parts can be reassembled in their
original position, then remove steering wheel.
430RW021
827RW070

behind the inflator module.
OTHERWISE, PERSONAL INJURY MAY RESULT.
10. Move the front wheels to the straight ahead position,

then use steering wheel remover 5852100160 to
remove the steering wheel.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
430RX005
827RW073
7. Disconnect horn lead.

8. Remove steering wheel fixing nut.
2A34
Installation
1. Install steering wheel by aligning the setting marks
made when removing.
absorbing unit.
2. Tighten the steering wheel fixing nut to the specified
torque.
3. Connect horn lead.
4. Support the module and carefully connect the SRS
connector.
wire from being pinches.
8. Turn the ignition switch to ON" while watching
warning light. Light should flash 7 times and then go
off. If lamp does not operate correctly, refer to
Restraints section.
2A35
Combination Switch
Combination Switch and Associated Parts
431RW028
Legend
(1) Steering Column Cover
(2) Steering Wheel
(3) Inflator Module
(4) Combination Switch and SRS Coil Assembly

(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)
EndOFCallout
Removal
at least 5 minutes.
CAUTION: The wheels of the vehicle must be

straight ahead and the steering column in the
LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly.
5. Remove the engine hood opening lever, then
remove instrument panel lower cover.
6. Remove the driver knee bolster (reinforcement).
2A36

released from steering assembly. Disconnect the
yellow 2-way SRS connector and horn lead located
behind the inflator module, then remove inflator
module.
WARNING: The INFLATOR MODULE SHOULD

827RW070
827RW072

original position. Move the front wheels to the
straight ahead position, then use steering wheel
remover 5852100160 to remove the steering
wheel.
827RW073
430RW021

absorbing unit.
2A37
Installation
1. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column. Then turn the SRS coil
counter clockwise to full, return about 3 turns and
align the neutral mark.
CAUTION: When turning the SRS coil counter
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
the SRS coil.
430RX005
9. Remove steering column cover.

10. Disconnect the wiring harness connectors located
under the steering column then remove combination
switch and SRS coil assembly.
NOTE: The SRS coil is a part of the combination switch
assembly, which can not be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly.
825RW288
825RW016
2A38
2. When installing the steering column cover, be sure

to route each wire harness as illustrated so that the
harnesses do not catch on any moving parts.
3. Align the setting marks made when removing then

install steering wheel.
absorbing unit.
torque.
5. Support the inflator module and carefully connect
the SRS connector and horn lead.
825RW017
Legend
(1)
(2)
(3)
(4)
Steering Column Cover

Starter Switch Harness
Combination Switch Harness
Inflator Module Harness
EndOFCallout
7. Install driver knee bolster (reinforcement).

8. Install instrument panel lower cover then Install the
engine hood opening lever.
9. Connect the SRS connector.
10. Connect the battery -" terminal cable.
warning light and check the light should flash 7
times and then go off. If lamp does not operate
correctly, refer to Restraints section.
2A39
Lock Cylinder
Lock Cylinder and Associated Parts
431RW027
Legend
(1)
(2)
(3)
(4)
(5)
Inflator Module
Steering Wheel
Combination Switch and SRS Coil Assembly
Snap Ring
(6)
(7)
(8)
(9)
(10)
Cushion Rubber
Lock Cylinder Assembly
Instrument Panel Lower Cover
Driver Knee Bolster (reinforcement)
Shift Lock Cable (for A/T)
EndOFCallout
Removal
at least 5 minutes.

"LOCK" position before disconnecting the steering
the coil assembly.
5. Remove the engine hood opening lever and steering
lower cover.
6. Remove driver knee bolster (reinforcement).
2A40


original position.
430RW021
827RW070


then use steering wheel remover 5852100160
to remove the steering wheel.
absorbing unit.
827RW073
430RX005

2A41
14. Remove snap ring.

15. Remove cushion rubber.
16. Remove shift lock cable (for A/T).
17. Disconnect the starter switch harness connector
located under the steering column then remove lock
cylinder assembly.
Installation
1. Install lock cylinder assembly.
2. Install shift lock cable (for A/T).
3. Install cushion rubber.
5. Install Combination switch and SRS coil assembly.
6. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark.
Forced further turning may damage the cable in the
SRS coil.
827RW072

13. Remove the combination switch assembly with SRS
coil.
825RW016
825RW288
2A42

to wire (through each harness) as illustrated so that
the harnesses starter switch, combination switch
and SRS coil may not catch wiring.

made during removal.
absorbing unit.
torque.
10. Support inflator module and carefully connect the
SRS connector and horn lead, then install inflator
module.
11. Tighten fixing bolts to specified torque.
825RW017
Legend
(1)
(2)
(3)
(4)

EndOFCallout

13. Install instrument panel lower cover, then install the
System Inspection
Turn the ignition switch to ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.
2A43
Steering Column
Steering Column and Associated Parts
431RW029
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Inflator Module
Steering Wheel
Snap Ring
Cushion Rubber
(7)
(8)
(9)
(10)
(11)
(12)

Shift Lock Cable (For A/T)
Steering Column Assembly
Second Steering Shaft
EndOFCallout
Removal
at least 5 minutes.

CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to become uncentered which
will cause damage to the SRS coil assembly.
2A44


wheel.
430RW021
827RW070

430RX005

827RW072

coil.
NOTE: SRS coil is a part of combination switch
assembly, which can not be replaced singly. Therefore,
be sure not to remove the SRS coil from the
2A45
18. Apply a setting mark (1) across the universal joint

and transfer gear to reassemble the parts in their
original position, then remove steering column
assembly and second shaft.
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft
universal joint.
825RW288

16. Remove shift lock cable (For A/T).
located under the steering column, then remove
lock cylinder assembly.
431RW009
2A46
Insepction
Column Tube
If the abnormal conditions are found through inspection,

replace the steering column assembly.
Check for collapes by measuring the distance as shown

in the figure.
Standard distance: 162.2-165.8 mm (6.386-6.528
in)
Column Capsule
Check capsules on steering column bracket assembly;
all must be securely seated in bracket slots and checked
for any loose conditions when pushed or pulled by hand.
431RW032
Column Universal Joint for Tilt Mechanism

431RW030
Check clearance between capsule and bracket. If must

be within 1mm (0.039 in).
If the resistance is felt when checked by rotate the joint,

Sheared Injected Plastic Pin

Check the sheared injected plastic pins for any loose
conditions or damage.
431RW031
431RW033
2A47
Shaft Length
Tilt Mechanism
Check the shaft length from the upper end of the slide
joint to the end of the shaft. If column length is not in
specifications, steering column should be replaced.
Tilt mechanism should moves smoothly.

While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.
Standard length: 291.7-295.7 mm (11.484-11.642

in)
Installation
1. Install steering column assembly and second
steering shaft.
2. Align the setting marks on the universal joint and
transfer gear made during removal.
3. Tighten the steering column fixing bolt (dash panel)
4. Tighten the steering column fixing nuts (cross
beam) to the specified torque.
5. Tighten the universal joint to the specified torque.
431RW034
Shaft Universal Joint (Lower End)

Shaft Bellows Pipe

Check the shaft bellows pipe for bend by using straight
edge. Measure the clearance between the bellows pipe
and the straight edge (at center of the bellows pipe).
Standard: Less than 1mm (0.039 in)
431RW035

7. Install shift lock cable (For A/T).
2A48

13. Install steering wheel and align the setting marks

made when removing.

the SRS coil.

absorbing unit.
torque.
module connector and horn lead, then install inflator
module.
825RW016

harnesses do not catch any moving parts.

18. Install instrument panel lower cover.
19. Install the engine hood opening lever.
20. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
System Inspection
light.
825RW017
Legend
(1)
(2)
(3)
(4)

EndOFCallout
2A49
Supplemental Restraint System Steering Wheel & Column and

Associated Parts
E02RX009
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5852100160
(J29752)
Steering wheel remover
SECTION
FRONT SUSPENSION
3C1
SUSPENSION
FRONT SUSPENSION
CONTENTS
Diagnosis ....................................................
Shock Absorber.............................................
Shock Absorber and Associated Parts .......
Removal .....................................................
Installation ..................................................
Stabilizer Bar.................................................
Stabilizer Bar and Associated Parts ...........
Removal .....................................................
Installation ..................................................
Torsion Bar....................................................
Torsion Bar and Associated Parts ..............
Removal .....................................................
Installation ..................................................
Knuckle .........................................................
Knuckle and Associated Parts ....................
Removal .....................................................
Installation ..................................................
Upper Control Arm ........................................
3C - 1
3C - 2
3C - 2
3C - 5
3C - 5
3C - 5
3C - 5
3C - 5
3C - 6
3C - 6
3C - 6
3C - 6
3C - 6
3C - 7
3C - 7
3C - 7
3C - 8
3C - 8
3C - 10
3C - 10
3C - 10
3C - 11
3C - 11
3C - 13
Service Precaution
REPAIRS.
Upper Control Arm and Associated

Parts........................................................
Removal......................................................
Installation...................................................
Lower Control Arm ........................................
Lower Control Arm and Associated
Parts........................................................
Removal......................................................
Installation...................................................
Upper Ball Joint .............................................
Upper Ball Joint and Associated Parts .......
Removal......................................................
Installation...................................................
Lower Ball Joint .............................................
Lower Ball Joint and Associated Parts .......
Removal......................................................
Installation...................................................
Special Tools .................................................
3C - 13
3C - 13
3C - 14
3C - 14
3C - 17
3C - 17
3C - 17
3C - 18
3C - 19
3C - 21
3C - 21
3C - 21
3C - 22
3C - 22
3C - 23
3C - 23
3C - 23
3C - 24
3C - 24
3C - 25
3C - 26

and systems.
3C2
FRONT SUSPENSION
General Description
The front suspension is designed to allow each wheel to
compensate for changes in the road surface level
without greatly affecting the opposite wheel. Each
wheel is independently connected to the frame by a
steering knuckle, ball joint assemblies, and upper and
lower control arms. The front wheels are held in proper
relationship to each other by two tie-rods which are
connected to steering arms on the knuckles, and to a
steering unit.
All models have a front suspension system consisting of
control arms, stabilizer bar, shock absorber and a
torsion bar. The front end of the torsion bar is attached
to the lower control arm. The rear of the torsion bar is
mounted into a height control arm at the crossmember.
Vehicle trim height is controlled by adjusting this arm.
Shock absorbers are mounted between the brackets on
the frame and the lower control arms. The lower portion
of each shock absorber is attached to the lower control
arm. The upper portion of each shock absorber extends
through a frame bracket and is secured with two rubber
bushings, two retainers and a nut.
Ball joint assemblies are bolted to the outer end of the
upper and lower control arm and are attached to the
steering knuckle.
The inner ends of the upper control arm have pressed in
bushings. Bolts, passing through the bushing, attach the
control arm to the frame. The inner ends of the lower
control arm are attached to the frame by bolts passing
through the bushings.
Side roll of the front suspension is controlled by a spring
steel stabilizer bar. It is mounted in rubber bushings,
which are held to the frame by brackets. The ends of
the stabilizer bar are connected to the lower control
arms by links.
Diagnosis
Condition
Vehicle Pulls
Wheel Hop
Possible cause
Correction
Replace tire.
Replace spring.
Replace tire.
Repair brake.

suspension parts.

suspension part(s).

defective.
Replace spring.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire.
FRONT SUSPENSION
Condition
Hard Steering
Possible cause
3C3
Correction

wheel.
Replace tire.


suspension parts.

suspension parts.
Adjust preload.

defective.

upper or lower ball joint.
Replace ball joint.
Repair or replace.

operation.
Repair or replace. Refer to Steering

section.

universal joint.
Bind in upper or lower ball joints.
Repair or replace.
Adjust pressure.
Retighten.
Worn wheel bearing.
Replace.
3C4
FRONT SUSPENSION
Condition
Abnormal Noise
Low or Uneven Trim Height
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction

ball joint, steering linkage ball joi nts
Replace.
Replace.

bushing.
Replace.
Loose wheel nuts.

wheel nut holes. Replace wheel if
required.

bearings.
Replace spring.

pressure.

bushings.
Leaking caliper.
Warped discs.
Replace brake disc.
Replace brake pads.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Incorrect springs.
Adjust or replace torsion bar.
Vehicle overloaded.
Reduce load.
Incorrect, broken or sagging springs.
Replace springs.
Tighten stabilizer bar bolts or

replace bushings.
Faulty shock absorber, struts or

mounting.
Vehicle overloaded.
Reduce load.
Excessive tire or wheel run out.
Worn ball joints.
Adjust tire balance.
FRONT SUSPENSION
3C5
Shock Absorber
Shock Absorber and Associated Parts
450RW009
Legend
(1) Nut
(2) Rubber Bushing and Washer
(3) Bolt and Nut
(4) Shock Absorber

EndOFCallout
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
3. Remove bolt and nut.
4. Remove nut.
5. Remove rubber bushing and washer.
6. Remove shock absorber.

Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts :
Shock absorber
Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
4. Install nut, then tighten it to the specified torque.
5. Install bolt and nut, then tighten to the specified
torque.
3C6
FRONT SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts
410RW007
Legend
(1) Rubber Bushing
(2) Bracket
(3) Link
(4) Nut
(5) Stabilizer Bar
EndOFCallout
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
4. Remove nut.
CAUTION: Be careful not to break the ball joint
boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.

Stabilizer bar
Rubber bushing
Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket, then tighten it to the specified torque.
4. Install link.
FRONT SUSPENSION
3C7
Torsion Bar
Torsion Bar and Associated Parts
410RS003
Legend
(1) Adjust Bolt, End Piece and Seat
(2) Height Control Arm
(3) Torsion Bar
EndOFCallout
Removal
2. Apply the setting marks(1) to the adjust bolt and end
piece, then remove adjust bolt, end piece and seat.
410RS004
3C8
FRONT SUSPENSION
3. Apply the setting marks(2) to the height control arm

and torsion bar, then remove height control arm.
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks(3).
410RS005
4. Apply the setting marks(3) to the torsion bar and

lower control arm, then remove torsion bar.
410RS007
410RS006
410RS006

Check the following parts:
Torsion bar
Height control arm
Adjust bolt
Rubber seat
FRONT SUSPENSION
2. Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks(2).
3C9
4. Apply grease to the serrated portions.

5. Install adjust bolt and seat, then turn the adjust bolt
to the setting mark(1) applied during disassembly.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering
section.
410RS005
3. Apply grease to the bolt portion of the end piece(4).

Apply grease to the portion of the seat(5) that fits
into the bracket.
410RS004
410RS008
3C10
FRONT SUSPENSION
Knuckle
Knuckle and Associated Parts
410RW006
Legend
(1)
(2)
(3)
(4)
(5)
Torsion Bar
Lower Ball Joint
Back Plate
Knuckle Assembly
Knuckle
(6)
(7)
(8)
(9)
(10)
Needle Bearing
Thrust Washer
Oil Seal
Upper Ball Joint
Wheel Speed Sensor
EndOFCallout
Removal
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.
4. Remove the hub assembly. Refer to Front Hub and

Disk in this section.
5. Remove tierod end from the knuckle. Refer to
Power Steering Unit in Steering section.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust bolt,
then remove torsion bar. Refer to Torsion Bar in this
section.
FRONT SUSPENSION
8. Remove wheel speed sensor.
9. Remove back plate.
10. Remove lower ball joint by using remover 58840
20050.
3C11
15. Remove needle bearing by using remover 58840

20000 and sliding hammer 5884000190.
CAUTION: Be careful not to damage the ball joint

boot.
901RW272
901RW271
11. Remove upper ball joint by using remover 58840

21210.
boot.

Knuckle
Knuckle arm
Needle bearing
Thrust washer
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and install
needle bearing by using installer 5884021280
and grip 5884000070.
901RW273
12. Remove knuckle assembly.

13. Remove oil seal.
14. Remove washer.
901RW275
3C12
FRONT SUSPENSION
2. Apply multipurpose type grease to the thrust

washer, and install washer with chamfered side
facing knuckle.
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g). Then use installer 5884021270 and grip 5
884000070 to install oil seal. After fitting the oil
seal to the installer, drive it to the knuckle using a
hammer or bench press until the tool front face
contacts with the thrust washer.
901RW274
4. Install knuckle assembly.

5. Install upper ball joint and tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
6. Install lower ball joint and tighten the nut to the
Torque: 147Nm (15.0kgm/lbft)
7. Install back plate.
8. Install wheel speed sensor.
9. Install torsion bar, refer to Torsion Bar in this section.
Alignment Inspection and Adjustment in Steering.
FRONT SUSPENSION
3C13
Upper Control Arm

Upper Control Arm and Associated Parts
450RW005
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Bolt and Plate

Camber Shims
Caster Shims
Nut Assembly
Upper Control Arm Assembly
Fulcrum Pin
(7)
(8)
(9)
(10)
(11)
(12)
Bushing
Plate
Nut
Speed Sensor Cable
Nut and Cotter Pin
Upper Ball Joint
EndOFCallout
Removal
this section.
3. Remove the brake caliper and disconnect brake

pipe. Refer to Disc Brakes in Brake section.
4. Support lower control arm with a jack.
5. Remove speed sensor cable.
6. Remove nut and cotter pin then remove knuckle
using remover 5884021210.
3C14
FRONT SUSPENSION

boot.
901RW276
16. Remove fulcrum pin.

901RW273
7. Remove upper ball joint.

8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut.
14. Remove plate.
15. Remove bushing by using remover 5884002560.

Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Upper control arm
Bushing
Fulcrum pin
Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5884002560
and 5884023070.
901RW277
901RW278
FRONT SUSPENSION
3C15
5. Install upper control arm assembly with the fulcrum

pin projections turned inward.
901RW279
3. Install plate.
4. Install nut and tighten fulcrum pin nut fingertight.
NOTE: Torque fulcrum pin nut after adjusting buffer
clearance.
450RS013
Legend
(1) Projection
(2) Outward
Buffer clearance: 22mm (0.87in)
EndOFCallout
6. Install the caster shims(2) between the chassis
frame and fulcrum pin.
7. Install the camber shims(1) between the chassis
450RS012
450RS014
3C16
FRONT SUSPENSION
8. Install nut assembly.

9. Install bolt and plate, then tighten the bolt to the
specified torque.
10. Install upper ball joint and tighten it to the specified
torque.
11. Install nut and cotter pin then tighten the nut to the
12. Install speed sensor cable.
FRONT SUSPENSION
3C17
Lower Control Arm

Lower Control Arm and Associated Parts
450RW010
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Nut, Front
Bush, Front
Bolt, Front
Nut, Rear
Bush, Rear
Bolt, Rear
Bolt, Lower Ball Joint
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Bolt, Torsion Bar Arm

Torsion Bar Arm Bracket
Torsion Bar
Lower Control Arm
Lower Ball Joint
Shock Absorber
Stabilizer Link
EndOFCallout
Removal
this section.
3. Remove the tie-rod end from the knuckle. Refer to

4. Remove the retaining ring from the front axle driving
shaft to release the shaft from hub. Refer to Front
Hub and Disc in Driveline/Axle section.
3C18
FRONT SUSPENSION
6. Remove front nut.

7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control
arm.
11. Remove the shock absorber lower end from the
lower control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove front bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 58840
21230.
19. Remove rear bushing by using remover 58840

21240.
901RW051
901RW154
901RW052

Lower control arm
Bushing
901RW155
FRONT SUSPENSION
Installation
1. Install rear bushing by using installer 588402124
0.
3C19
3. Install lower ball joint bolt.

4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install front bolt.
8. Install lower ball joint and tighten it to the specified
torque.
9. Install shock absorber and tighten it to the specified
torque.
10. Install stabilizer link and tighten it to the specified
torque.
11. Install torsion bar arm bracket and tighten it to the
specified torque.
901RW053
2. Install front bushing by using installer 58840

21230.
12. Install Torsion bar, refer to Torsion Bar in this

section.
13. Install rear nut and tighten lower link nut fingertight.
NOTE: Torque lower control arm nut after adjusting
buffer clearance.
901RW156
450RS012
3C20
FRONT SUSPENSION
14. Install front nut then tighten lower link nut

finger-tight.
buffer clearance .
section.
450RS012
FRONT SUSPENSION
3C21
Upper Ball Joint

Upper Ball Joint and Associated Parts
450RW004
Legend
(1) Bolt and Nut
(2) Upper Ball Joint
EndOFCallout
Removal
(3) Nut and Cotter Pin
3C22
FRONT SUSPENSION
3. Remove upper ball joint nut and cotter pin, then use
remover 5884021210 to remove the upper ball
joint from the knuckle.
boot.
After moving the ball joint 4 or 5 times, attach nut

then measure the preload.
Starting torque: 0.5 3.2Nm (0.050.33kgm/0.4
2.4lbft)
450RS024
901RW273

If the above limits specified are exceeded, replace the

ball joint assembly.
Installation

through inspection.
Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
Inspect screw/taper area of ball for damage.
If any defects are found by the above inspections,
replace the ball joint assembly with new one.
450RS023
1. Install upper ball joint.

2. Install bolt and nut, then tighten them to the
specified torque.
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque
FRONT SUSPENSION
3C23
Lower Ball Joint

Lower Ball Joint and Associated Parts
450RW011
Legend
(1) Bolt
(2) Lower Ball Joint
(3) Nut
EndOFCallout
Removal
this section.
6. Remove lower ball joint nut and cotter pin, then use
remover 5884020050 to remove the lower ball
boot.
901RW271
3C24
FRONT SUSPENSION
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.

Starting torque: 0.56.4Nm (0.050.65kgm/0.4
4.7lbft)

corrosion or any other abnormal condition are found
through inspection.
confirm its normal movement .
450RS024
If the above limits specified are exceeded, replace

the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut and tighten it to the specified torque.
450RS026
4. Install ball joint nut, then tighten it to the specified

torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
FRONT SUSPENSION
3C25

Front suspension
Type
Torsion bar spring
Length
Front shock absorber
Stabilizer bar
Independent wishbone arms, torsion bar spring

with stabilizer bar.
1142mm (45.0in)
Diameter
Short wheel base: 27.0 mm (1.06 in)

Long wheel base: 28.0 mm (1.10 in)
Type
Hydraulic, double acting, telescopic
Piston diameter
30.0mm (1.18in)
Stroke
125.0mm (4.92in)
Compressed length
255.0mm (10.04in)
Extended length
380.0mm (14.96in)
Diameter

E03RX006
3C26
FRONT SUSPENSION
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884020000
(J23907)
Remover;Needle bearing
5884000190
Sliding hammer
5884002560
(J29775)
Remover and Installer
Upper arm bushing
5884021280
(J36838)
Installer; Needle bearing
5884021230
(J36833)
Remover and Installer kit;
Lower arm front bushing
5884000070
(J8092)
Grip
5884021240
(J36834)
Lower arm rear bushing
5884021270
(J36837)
Installer; Oil seal
5884021210
(J36831)
Ball joint remover
5884023070
(J39376)
Installer; Upper arm
bushing
5884020050
(J29107)
Tie-rod end remover
SECTION
REAR SUSPENSION
3D1
SUSPENSION
REAR SUSPENSION
CONTENTS
Diagnosis ....................................................
Coil Spring.....................................................
Coil Spring and Associated Parts ...............
Removal .....................................................
Installation ..................................................
Shock Absorber.............................................
Removal .....................................................
Installation ..................................................
Trailing Link...................................................
Trailing Link and Associated Parts .............
Removal .....................................................
Installation ..................................................
3D- 1
3D- 1
3D- 2
3D - 5
3D- 5
3D- 5
3D- 6
3D- 6
3D - 7
3D- 7
3D- 7
3D- 7
3D- 7
3D - 8
3D- 8
3D- 8
3D- 8
3D- 9
Service Precaution
REPAIRS.
Upper Link .....................................................

Upper Link and Associated Parts ...............
Removal......................................................
Installation...................................................
Lateral Rod....................................................
Lateral Rod and Associated Parts ..............
Removal......................................................
Installation...................................................
Stabilizer Bar .................................................
Removal......................................................
Installation...................................................
Special Tools .................................................
3D - 10
3D- 10
3D- 10
3D- 10
3D- 11
3D - 12
3D- 12
3D- 12
3D- 12
3D- 13
3D - 14
3D- 14
3D- 14
3D- 14
3D- 15
3D- 16
3D- 18

and systems.
General Description
The rear suspension is a 5-link, coil spring type
suspension with a stabilizer bar, consisting of two
trailing links, two upper links, lateral rod, shock
absorber, and stabilizer. In this suspension, the links
are specially arranged to enable the rear axle to move
freely, thereby expanding suspension stroke, reducing
friction, and improving lateral rigidity and roll control.
All these result in improved stability, riding comfort, and
rough road maneuverability.
Each link connects the axle housing with the frame
through a runner bushing.
The axle housing is
supported by the trailing links and upper links
longitudinally and by the lateral rod latitudinally.
3D2
REAR SUSPENSION
Diagnosis
Condition
Vehicle Pulls
Wheel Hop
Possible cause
Correction
Replace tire.
Replace spring.
Replace tire.
Repair brake.

suspension parts.

suspension part(s).

defective.
Replace spring.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire.

wheel.
Replace tire.


suspension parts.

suspension parts.
Adjust preload.

defective.
REAR SUSPENSION
Condition
Hard Steering
Abnormal Noise
Possible cause
3D3
Correction

Replace ball joint.
Repair or replace.

operation.

section.

universal joint.
Repair or replace.
Adjust pressure.
Retighten.
Worn wheel bearing.
Replace.

Replace.
Replace.

bushing.
Replace.
Loose wheel nuts.

required.

bearings.
Replace spring.

pressure.

bushings.
3D4
REAR SUSPENSION
Condition
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction
Leaking caliper.
Warped discs.
Replace brake disc.
Replace brake pads.
Vehicle overloaded.
Reduce load.
Incorrect springs.
Vehicle overloaded.
Reduce load.
Replace springs.

replace bushings.

mounting.
Vehicle overloaded.
Reduce load.
Worn ball joints.
REAR SUSPENSION
3D5
Coil Spring
Coil Spring and Associated Parts
460RW034
Legend
(1)
(2)
(3)
(4)
Stabilizer Bar
Upper Link Fixing Bolt and Nut
Rubber Plate
Coil Spring
(5) Insulator
(6) Shock Absorbar
(7) Breather Hose
EndOFCallout
Removal
2. Support the rear axle case with a jack.
3. Disconnect brake hose at the crossmember.
4. Remove breather hose.
5. Remove upper link fixing bolt, nut and rubber plate
on the rear axle case (left-side only).
6. Disconnect the stabilizer bar at the stabilizer link.

7. Remove the shock absorber from the axle case.
8. Remove spring insulator.
9. Remove the insulator and coil spring while lowering
the rear axle case.
CAUTION: Be sure not to let the brake hose,
parking brake cable, and breather hose extend to
their full length.
3D6
REAR SUSPENSION
3. Install the insulator on the coil spring. Jack up the

axle case gently with the top of the coil spring set to
the spring seat on the frame side.

Coil spring
Insulator
Installation
1. Install coil spring and make sure that the coil spring
is installed in the proper position. Paint mark(1)
should be downward.
460RW013
4. Install shock absorber and tighten the nut lightly,

then retighten it to the specified torque after the
vehicle is at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
460RW001
2. Fit the end of the coil spring to the coil spring seat
and mount the coil spring on the rear axle case.
6. Install upper link with rubber plate and tighten fixing

bolt.
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to Bleeding the Brake Hydraulic System in
Brake section.
460RW004
REAR SUSPENSION
3D7
Shock Absorber
461RW001
Legend
(1) Nut, Bush and Washer
(2) Shock Absorber
(3) Nut and Washer
EndOFCallout
Removal
1. Remove shock absorber fixing nut, bush and washer
(upper side).
2. Remove shock absorber fixing nut and washer
(lower side).

Shock absorber
Rubber bushing
NOTE: When mounting rubber bushings, be sure not to
Installation
1. Install shock absorber. When mounting shock
absorber, be sure not to use grease on bushings or
any other nearby part.
2. Install nut and washer (lower side), then tighten the
nut lightly. Retighten to the bolt and nut specified
torque after the vehicle is at curb height.
3. Install nut, bush and washer (upper side), then
tighten the nut lightly. Retighten to the nut specified
3D8
REAR SUSPENSION
Trailing Link
Trailing Link and Associated Parts
460RW038
Legend
(1) Bolt and Nut (Axle side)
(2) Protector (Left side only)
(3) Bolt (Frame side)
EndOFCallout
Removal
1. Remove the parking brake cable from the trailing
link.
2. Remove the trailing link fixing bolt, nut and protector.
3. Remove trailing link.

1. Trailing link
2. Rubber bushing
Remove the rubber bushing by using remover 5
884022980.
901RW280
REAR SUSPENSION
Install the rubber bushing by using installer 5
884022980.
901RW281
Installation
1. Install trailing link. Make sure that the trailing link is
in its correct position.
NOTE: When mounting trailing link, be sure not to use
grease on bushings or any other nearby part.
460RW011
2. Install bolt, nut and protector. Tighten the bolts and

nuts lightly, then retighten them to the specified
3. Install parking brake cable.
CAUTION: The parking brake cable should not be
overstrained or slackened.
3D9
3D10
REAR SUSPENSION
Upper Link
Upper Link and Associated Parts
460RW037-1
Legend
(2) Rubber Plate
(3) Upper Link

EndOFCallout
Removal
1. Remove fuel tank. Refer to Engine Fuel in Engine
section.
2. Remove the speed sensor cable from the upper link.
3. Remove bolt, nut, rubber plate and protector.
4. Remove upper link.

1. Upper link
2. Rubber bushing
884025650.
901RW282
REAR SUSPENSION
Install the rubber bushing by using to installer 5
884025650.
901RW283
Installation
1. Install upper link. Make sure that the upper link is in
its correct position.
NOTE: When mounting upper link, be sure not to use
grease bushings or any other nearby part.
460RW012
2. Install bolt, nut, rubber plate and protector. Tighten

the bolts and nuts lightly, then retighten them to the
specified torque after the vehicle is at curb height.
4. Install fuel tank.
3D11
3D12
REAR SUSPENSION
Lateral Rod
Lateral Rod and Associated Parts
460RW036
Legend
(1) Bolt and Nut (Frame side)
(2) Lateral Rod
(3) Nut and Washer (Axle side)
EndOFCallout
Removal
1. Remove nut and washer.
3. Remove lateral rod.

1. Lateral rod
2. Rubber bushing (Frame side)
Remove the rubber bushing (Frame side) by
901RW284
REAR SUSPENSION
3D13
Install the rubber bushing (Frame side) by using

Installer 5884022990.
NOTE: When mounting rubber bushings, do not use
grease on bushings or any other nearby parts.
901RW286
Installation
1. Install lateral rod and make sure that the lateral rod
is in its correct position.
901RW285
3. Rubber bushing (Axle side)

Remove the rubber bushing (Axle side) by using
remover 5884023270.
NOTE: When mounting lateral rod, be sure not to use

460RW035
Legend
901RW287
Install the rubber bushing (Axle side) by using

installer 5884023270.
(1) Frame Side

(2) Axle Side
EndOFCallout
2. Install bolt and nut. Tighten the bolt and nut lightly,
then retighten them to the specified torque after the
3. Install nut and washer. Tighten the nut lightly, then
retighten the nut to the specified torque after the
3D14
REAR SUSPENSION
Stabilizer Bar
460RW009
Legend
(1) Bracket
(2) Link
(3) Bolt and Nut
(4) Stabilizer Bar

(5) Rubber Bushing
EndOFCallout
Removal
this section.
4. Remove link.
boot.
5. Remove bracket.

Stabilizer bar
Rubber bushing
Link
REAR SUSPENSION
Installation
2. Install bracket to axle housing and tighten to the
specified torque.
3. Install link.
4. Install bolt and nut, then tighten the nut to the
specified torque.
460RW010
3D15
3D16
REAR SUSPENSION

Rear suspension
Type
Coil spring
Long wheel base
Short wheel base
379.0mm (14.92in)
383.0mm (15.08in)
Spring diameter
12.4mm (0.49in)
12.5mm (0.49in)
Coil diameter (inner)
105mm (4.13in)
105mm (4.13in)
Effective No. of turns
5.62
6.59
Total No. of turns
7.12
8.09
Free length
Shock absorber
Stabilizer bar
5Link, coil spring type with stabilizer bar.
Type
Piston diameter
30mm (1.18in)
Stroke
175mm (6.89in)
Extended length
473.5mm (18.64in)
Compressed length
298.5mm (11.75in)
Diameter
19mm (0.75in)
REAR SUSPENSION
3D17
E03RX007
3D18
REAR SUSPENSION
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884022980
(J39214)
Remover and Installer;
Trailing link bushing
5884025650
(J43008)
Upper link bushing
5884023270
(J39792)
Lateral rod bushing (axle
side)
5884022990
(J3921)
Lateral rod bushing
SECTION
WHEEL AND TIRE SYSTEM
3E1
SUSPENSION
CONTENTS
Diagnosis ....................................................
Wheel ............................................................
Wheel and Associated Parts ......................
Removal .....................................................
3E - 1
3E - 2
3E - 3
3E - 11
3E - 11
3E - 11
Service Precaution
REPAIRS.
Installation...................................................
Tire ................................................................
Tire Replacement .......................................
General Balance Procedure .......................
Balancing Wheel and Tire...........................
3E - 11
3E - 12
3E - 12
3E - 12
3E - 13
3E - 14

and systems.
3E2
General Description
480RS008
Replacement wheels or tires must be equivalent to the

originals in load capacity, specified dimension and
mounting configuration. Improper size or type may
affect bearing life, brake performance, speedometer/
odometer calibration, vehicle ground clearance and tire
clearance to the body and chassis. All model are
equipped with metric sized tubeless steel belted radial
tires. Correct tire pressures and driving habits have an
important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp
braking increase premature and uneven wear.
3E3
Diagnosis
Condition
Vehicle Pulls
Wheel Hop
Possible cause
Correction
Replace tire.
Replace spring.
Replace tire.
Repair brake.

suspension parts.

suspension part(s).

defective.
Replace spring.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire.

wheel.
Replace tire.


suspension parts.

suspension parts.
Adjust preload.

defective.
3E4

Condition
Hard Steering
Abnormal Noise
Possible cause
Correction

Replace ball joint.
Repair or replace.

operation.

section.

universal joint.
Repair or replace.
Adjust pressure.
Retighten.
Worn wheel bearing.
Replace.

Replace.
Replace.

bushing.
Replace.
Loose wheel nuts.

required.

bearings.
Replace spring.

pressure.

bushings.

Condition
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction
Leaking caliper.
Warped discs.
Replace brake disc.
Replace brake pads.
Vehicle overloaded.
Reduce load.
Incorrect springs.
Vehicle overloaded.
Reduce load.
Replace springs.

replace bushings.

mounting.
Vehicle overloaded.
Reduce load.
Worn ball joints.
3E5
3E6
Irregular and Premature Wear
480RS001
Irregular and/or premature wear has many causes.

Some of them are incorrect inflation pressures, lack of
tire rotation, poor driving habits or improper wheel
alignment. Incorrect inflation is common cause of tire
premature wear.
NOTE: Due to their design, radial tires tend to wear
faster in the shoulder area, particularly on the front tires.
This makes regular rotation especially necessary. After
rotation, be sure to check wheel nut torque, and set tire
pressures.
Tire Rotation
Tire rotation is recommended to equalize wear for
longer tire life.
Tread Wear Indicators
480RS002
Legend
(1) Spare Tire
EndOFCallout
If the following conditions are noted, rotate the tires:

Front tire wear is different from rear.
Uneven wear exists across the tread of any tire.
Left and right front tire wear is unequal.
Left and right rear tire wear is unequal.
Check wheel alignment if the following conditions are
noted:
Wear is uneven across the tread of any front tire.
Front tire treads have a scuffed appearance with
feather" edges on one side of the tread ribs or
blocks.
480RS006
The original equipment tires have built-in tread wear

indicators(1) to show when tires need replacement.
These indicators may appear as wide bands. When the
indicators appear in two or more grooves at three
locations, tire replacement is recommended.

Inflation of Tires
3E7
4. Tire rim bruises and rupture.

5. Tire cord breakage.
6. High tire temperatures.
7. Reduced handling.
8. Reduced fuel economy.
Unequal pressure on same axle can cause:
1. Uneven braking.
2. Steering lead.
4. Swerve on acceleration.
Radial Tire Waddle
710RX004
Tire pressure, in cold condition (after vehicle has set for

three hours or more, and driven less than one mile),
should be checked monthly or before any extended trip.
Tire pressure increases approximately 15% when the
tires become hot during driving. Tire pressure
specification is shown on the label located on the left
door lock pillar.
NOTE: Check the tire pressure whenever irregular wear
is found. Tire inflation greatly affects tire wear. If the
alignment check does not reveal any alignment
problems, check the condition of the shock absorbers
and wheel/tire balance.
480RW011
Diagnosis List
If the following conditions are noted, rotation is required.
1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left and right front tire wear is unequal.
4. Left and right rear tire wear is unequal.
If the following conditions are noted, check the wheel
alignment.
3. Front tire treads have scuffed appearance with
feather" edges on one side of tread ribs or blocks.
4. There is cupping, flat spotting etc.
Higher than recommended pressure can cause:
1. Hard ride.
2. Poor steering stability.
3. Rapid and uneven wear at center of the tread.
Lower than recommended pressure can cause:
1. Tire squeal on turns.
2. Hard steering.
3. Rapid and uneven wear on the edges of the tread.
Waddle is side-to-side movement at the front and/or

rear of the car. It can be caused by the steel belt not
being straight within the tire, or by excessive lateral
runout of the tire or wheel. It is most noticeable at low
speed, about 8 to 48 km/h (5 to 30 mph). It may also
cause rough ride at 80 to 113 km/h (50 to 70 mph).
The car can be road tested to see which end of the car
has the faulty tire. If the tire causing the waddle is on
the rear, the rear end of the car will waddle". From the
driver's seat, it feels as if someone is pushing on the
side of the car.
If the faulty tire is on the front, the waddle is more easily
seen. The front sh eet metal appears to be moving back
and forth. It feels as if the driver's seat is the pivot point
in the car.
Another more time-consuming method of determining
the faulty tire is substituting tire and wheel assemblies
that are known to be good. Follow these steps:
1. Drive the car to determine if the waddle is coming
from the front or rear.
2. Install tire and wheel assemblies known to be good
(from a similar car) in place of those on the end of
the car which is waddling. If the waddle cannot be
isolated to front or rear, start with the rear tires.
3E8
3. Road test again. If improvement is noted, install the

original tire and wheel assemblies one at a time
until the faulty tire is found. If no improvement is
noted, install tires known to be good in place of all
four. Then, install the originals one at a time until the
faulty tire is found.
Radial Tire Lead/Pull

Lead/Pull" is vehicle deviation from a straight path, on a
level road with no pressure on the steering wheel.
Lead is usually caused by:
1. Poorly manufactured radial tires.
2. Uneven brake adjustment.

3. Wheel alignment.
The way in which a tire is built can produce lead in a car.
An example of this is placement of the belt. Off-center
belts on radial tires can cause the tire to develop a side
force while rolling straight down the road and the tire will
tend to roll like a cone.
The Radial Tire Lead/Pull Correction" chart should be
used to make sure that front wheel alignment is not
mistaken for tire lead.
Rear tires will not cause lead/pull.
Radial Tire Lead/Pull Correction Chart

Step
Action
1
1. Inflate tires to recommended pressure.

2. Road test vehicle on level uncrowned road.
Was a problem corrected?
Switch front tires side to side and road test again.
Did the vehicle lead in same direction?
Put tires back in original position and check alignment.

Yes
No
End.
Go to Step 2
If roughness
results,replace
tires.
Go to Step 3
Go to Step 4
Go to Step 5
End.
Go to Step 5
Install known good tire on one front side.

Replace tire.
Install a known
good tire in
place of other
front tire.
If lead
corrected,
replace tire.
Typical examples of abnormal tire ahead wear and

major causes:
CAUTION: Similar wear patterns can be caused by
worn suspension parts, misalignment of wheels and
tires, and other suspension related problems.
Spotty wear wear localized on shoulder sections, and
in an extreme cases, the tire becomes polygonal in
shape.
480RW002

1. Tire or wheel out of round or distorted.
2. Hub or knuckle out of round or distorted.
3. Play in hub bearings or ball joint.
4. Rotating parts out of balance.
Tread wear one-sided.
3E9
1. Once spotty wear develops in tread due to hard

braking or abrupt starting, localized wear tends to
be promoted.
Shoulder wear (generally wear develops in outer
shoulder):
480RW005
480RW003

2. Tire or wheel out of round.
Localized tread wear.
1. Camber or toe-in incorrect.

2. Shoulder wear caused by repeated hard-cornering.
Wear in shoulders at points opposed to each other.
480RW006
480RW004
3E10

2. Play in bearings or ball joint.
Premature wear in shoulders.
480RW007
1. Flexing of tire excessive due to under-inflation.

One sided feather edging.
480RW008
1. Wear caused by repeated hard cornering.

3E11
Wheel
Wheel and Associated Parts
480RX008
Legend
(1) Wheel Lug Nut
(2) Wheel and Tire
EndOFCallout
Removal
1. Loosen wheel lug nut by approximately 180 (half a
rotation), then raise the vehicle and remove the
nuts.
2. Remove wheel and tire.
NOTE: Never use heat to loosen a tight wheel lug nut.
The application of heat to the hub can shorten the life of
the wheel and may cause damage to wheel bearings.
Installation
1. Install wheel and tire.
2. Install wheel lug nut, and lower the vehicle. Tighten
the wheel lug nuts to the specified torque in
numerical order.
CAUTION: Before installing wheels, remove any
build-up of corrosion on the wheel mounting
surface and brake disc mounting surface by
scraping and wire brushing. Installing wheels
without good metal-to-metal contact at mounting
surfaces can cause wheel nuts to loosen, which
can later allow a wheel to come off while the vehicle
is moving.
NOTE: Valve caps should be on the valve stems to
keep dust and water out.
480RS020
3E12
Tire
Tire Replacement
When replacement is necessary, the original metric the
size should be used. Most metric tire sizes do not have
exact corresponding alphanumeric tire sizes. It is
recommended that new tires be installed in pairs on the
same axle. If necessary to replace only one tire, it
should be paired with tire having the most tread, to
equalize braking traction.
Steel
Aluminum
1 Vertical play:
Less than
1.5mm (0.059in)
1 Vertical play:
Less than
0.7mm (0.028in)
2 Horizontal play:
Less than
1.5mm (0.059in)
2 Horizontal play:
Less than
0.7mm (0.028in)
CAUTION: Do not mix different types of tires such

as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be
seriously affected and may result in loss of control.
Tire Dismounting
Remove valve cap on valve step and deflate the tire.
Then use a tire changing machine to mount or dismount
tires.
Follow the equipment manufacturer's instruction. Do
not use hand tools or tire lever alone to change tires as
they may damage the tire beads or wheel rim.
Tire Mounting
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, and light rust.
Before mounting a tire, the bead area should be well
lubricated with an approved tire lubricant.
After mounting, inflate the tire to 200kPa (2.0kg/cm2, 28
psi) so that beads are completely seated. Inflate the air
to specified pressure and install valve cap to the stem.
WARNING: NEVER STAND OVER TIRE WHEN
INFLATING. BEAD MAY BREAK WHEN BEAD
SNAPS OVER RIM'S SAFETY HUMP AND CAUSE
SERIOUS PERSONAL INJURY.
NEVER EXCEED 240 KPA (2.4kg/cm2, 35 PSI)
PRESSURE WHEN INFLATING. IF 240 KPA (2.4kg/
cm2, 35 PSI) PRESSURE WILL NOT SEAT BEADS,
DEFLATE, RE-LUBRICATE AND RE-INFLATE. OVER
INFLATION MAY CAUSE THE BEAD TO BREAK AND
CAUSE SERIOUS PErSONAL INJURY.
Tire Repair
There are many different materials on the market used
to repair tires.
Manufacturers have published detailed instructions on
how and when to repair tires. These instructions can
be obtained from the tire manufacturer if they are not
included with the repair kit.
Wheel Inspection
Damaged wheels and wheels with excessive run-out
must be replaced.
Wheel run out at rim (Base on hub Bore):
480RS012
General Balance Procedure

Deposits of mud, etc. must be cleaned from the inside of
the rim.
The tire should be inspected for the following: match
mount paint marks, bent rims, bulges, irregular tire
wear, proper wheel size and inflation pressure. Then
balance according to the equipment manufacturer's
recommendations.
There are two types of wheel and tire balance.
Static balance is the equal distribution of weight around
the wheel.
Assemblies that are statically unbalanced cause a
bouncing action called tramp. This condition will
eventually cause uneven tire wear.
3E13
Balancing Wheel and Tire

On-vehicle Balancing
On-Vehicle balancing methods vary with equipment and
tool manufacturers. Be sure to follow each
manufacturer's instructions during balancing operation.
Off-vehicle Balancing
Most electronic off-vehicle balancers are more accurate
than the on-vehicle spin balancers. They are easy to
use and give a dynamic balance. Although they do not
correct for drum or disc unbalance (as onvehicle spin
balancing does), they are very accurate.
480RS013
Legend
(1) Heavy Spot Wheel Shimmy
(2) Add Balance Weights Here
EndOFCallout
Dynamic balance is the equal distribution of weight on
each side of the wheel center-line so that when the tire
spins there is no tendency for the assembly to move
from side to side. Assemblies that are dynamically
unbalanced may cause shimmy.
480RS015
480RS014
Legend
(1) Heavy Spot Wheel Hop
EndOFCallout
WARNING: STONES SHOULD BE REMOVED FROM
THE TREAD TO AVOID OPERATOR INJURY DURING
SPIN BALANCING AND TO OBTAIN A GOOD
BALANCE.
3E14

Wheels
Standard tire
Size
15 x 6.5JJ
Offset
38.0mm (1.50in)
P.C.D., wheel studs
139.7mm (5.50in)
Size
P235/75R15
Pressure(Front)
200kPa (2.0kg/cm2,26psi)
Pressure(Rear)
E03RX008
SECTION
DIFFERENTIAL (FRONT)
4A11
DRIVELINE/AXLE
CONTENTS
Differential (Front) .........................................
Differential (Rear)..........................................
Driveline Control System...............................
Drive Shaft System .......................................
Transfer Case ...............................................
4A1 - 1
4A2 - 1
4B - 1
4C - 1
4D - 1
CONTENTS
Front Drive Axle ............................................
Diagnosis ....................................................
Pinion Shaft Oil Seal .....................................
Pinion Shaft Oil Seal and
Removal .....................................................
Installation ..................................................
Front Drive Axle Assembly............................
Front Drive Axle Assembly and
Removal .....................................................
4A1 - 1
4A1 - 2
4A1 - 2
4A1 - 3
4A1 - 3
4A1 - 3
4A1 - 4
4A1 - 4
4A1 - 5
4A1 - 5
4A1 - 6
Service Precaution
REPAIRS.
Installation...................................................
Differential Assembly ....................................
Disassembled View ....................................
Disassembly ...............................................
Reassembly ................................................
Differential Cage Assembly ...........................
Disassembly ...............................................
Reassembly ................................................
Special Tools .................................................
4A1 - 7
4A1 - 8
4A1 - 8
4A1 - 9
4A1 - 11
4A1 - 20
4A1 - 20
4A1 - 20
4A1 - 21
4A1 - 22
4A1 - 24
4A1 - 27

and systems.
4A12
Front Drive Axle

Diagnosis
Condition
Oil Leak At Front Axle
Possible cause
Correction
Worn or defective oil seal.
Replace the oil seal.
Front axle housing cracked.
Repair or replace.
Too much gear oil.
Correct the oil level.
Oil seal worn or defective.
Pinion flange loose or damaged.
Tighten or replace.
Noises In Front Axle Drive Shaft

Joint
Broken or worn drive shaft joints and

bellows (BJ and DOJ).
Replace the drive shaft joints and

bellows.
Clank" When Accelerating From

Coast"
Loose drive shaft joint to output

shaft bolts.
Tighten.
Damaged inner drive shaft joint.
Replace.
Excessive drive shaft joint angle.
Repair.
Worn or damaged drive shaft joints.
Replace.
Sticking spider assembly (inner

drive shaft joint).
Lubricate or replace.
Sticking joint assembly (outer drive

shaft joint).
Out of balance or out of round tires.
Balance or replace.
Front end out of alignment.
Align.
Insufficient gear oil.
Replenish the gear oil.
Wrong or poor grade gear oil.
Replace the gear oil.
Drive pinion to ring gear backlash

incorrect.
Adjust the backlash.
Worn or chipped ring gear, pinion

gear or side gear.
Replace the ring gear, pinion gear or

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.
Wheel bearing preload too tight.
Adjust the wheel bearing preload.
Incorrect front alignment.
Adjust the front alignment.
Steering unit loose or worn.
Tighten or replace.
Tire worn or improperly inflated.
Adjust the inflation or replace.
Front or rear suspension parts loose

or broken.
Tighten or replace.
Wheel bearing worn or improperly

adjusted.
Adjust or replace.
Worn ball joint or bush.
Replace the ball joint or bush.
Tighten or replace.
Replace or adjust the inflation.
Shock absorber worn.
Replace the shock absorber.
Oil Leak At Pinion Shaft
Shudder or Vibration During

Acceleration
Vibration At Highway Speeds

Noises in Front Axle
Wanders and Pulls
Front Wheel Shimmy
4A13
Pinion Shaft Oil Seal

Pinion Shaft Oil Seal and Associated Parts
415RX004
Legend
(1) Flange Nut
(2) Flange
(3) Oil Seal
(4) Outer Bearing

(5) Collapsible Spacer
EndOFCallout
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
4A14
3. Remove the front propeller shaft. Refer to Front

Propeller Shaft in this section.
4. Remove flange nut by using pinion flange holder 5
884021570.

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 9852212750
to install a new oil seal that has grease on seal lip.
415RW028
5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover 58840
23230.
415RW021
4. Install flange.
5. Install flange nut, refer to Differential Assembly
Overhaul for flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.
415RW048
8. Remove collapsible spacer.
4A15
Front Drive Axle Assembly

Front Drive Axle Assembly and Associated Parts
412RX010
Legend
(1) Propeller Shaft
(2) Mounting Nut
(3) Front Axle Case Assembly and Front Drive
Shaft Assembly
(4) Washer
EndOFCallout
(5)
(6)
(7)
(8)
(9)
Mounting Bolt
Tierod End; Power Steering Unit
Knuckle and Back Plate
Hub and Disc Assembly
Suspension Crossmember
4A16
Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
4. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake
section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller
Shaft in this section.
8. Loosen the height control arm of the torsion bar,
then remove the torsion bar from lower control arm.
refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock
absorber.
412RW058
15. Remove the bolts and nuts of the lower control arm
(Frame side), then disconnect the lower control arm
from frame.
16. Disconnect between the right side upper control arm
and the knuckle, then remove the knuckle with lower
control arm.
CAUTION: When removing the knuckle, be careful
not to damage the oil seal inside of the knuckle.
412RW057

Power Steering Unit in Steering Section.
13. Disconnect the hose of the shift on the fly, at the
hose clip portion (1).
14. Disconnect the shift switch connector (2).
410RW008
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts,
lower the jack slowly. Remove the left side drive
shaft end from the knuckle, then lower the axle
assembly from the vehicle.
CAUTION:
1. During the work, be sure that the axle assembly
is supported securly.
2. Be careful not to damage the bellows of the
power steering unit by interference.
3. Be careful not to damage the hose bracket of the
shift on the fly by interference.
4A17
5. Align the bolt hole of the lower control arm, install

the bolts and nuts.
NOTE: Adjust the buffer clearance before tighten the
bolts and nuts of the lower control arm.
6. Install the hose of the shift on the fly (1).
7. Install the shift switch connector (2) of the shift on
the fly.
Installation
2. Jack up the front drive axle assembly, install the left
side drive shaft to the knuckle, then install the mount
bolts and nuts.
CAUTION:
3. When installing the drive shaft to the knuckle,
be careful not to damage the oil seal inside of
the knuckle.
3. Tighten the mounting bolts and nuts to the specified
torque.
Torque:168Nm (17.2kgm/124 lbft)
412RW058
8. Install the tie-rod end of the power steering unit to

the knuckle, tighten the nut to the specified torque.
9. Install lower bolts and nuts of the shock absorber,
tighten it to the specified torque.
10. Install lower nuts of the stabilizer link, tighten it to
the specified torque.
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the
bearing preload.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the
caliper bracket to the specified torque.
412RX011
4. Install the right side knuckle with lower control arm

to the upper control arm.
Refer to Knuckle in Suspension section.
CAUTION: When insert the drive shaft to the
knuckle, be careful not to damage the oil seal inside
of the knuckle.

18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm
Refer to Lower Control Arm in Suspension section.
4A18
Differential Assembly
Disassembled View
415RX003
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Flange Nut
Flange
Dust Cover
Oil Seal
Outer Bearing
Outer Bearing Outer Race
Differential Carrier
Bearing Cap
Bolt
Inner Bearing Outer Race
EndOFCallout
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Collapsible Spacer
Pinion Gear
Inner Bearing
Adjust Shim
Diff Cage Assembly
Side Bearing Outer Race
Side Bearing
Adjust Shim
Bolt
Axle Case
Disassembly
1. Remove differential carrier fixing bolt.
2. Remove differential assembly.
3. Using holding fixture 5884002750 and holding
fixture base 5884000030, fix the differential
assembly to the bench.
4A19
6. Remove differential cage assembly.

7. Remove side bearing outer race, after removal,
keep the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
8. Remove side bearing, using remover 58840
00130, 5884000140 and adapter 98521
17430.
425RW046
4. Remove bearing cap bolt.

5. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
415RW023
9. Remove adjust shim, note the thickness and

position of the shims removed.
10. Remove the flange nut using holding wrench 5
884021570 after raising up its staked parts
completely.
425RS009
425RW057
4A110
11. Remove flange.

12. Remove dust cover.
13. Remove the drive pinion assembly using a soft
metal rod and a hammer.
16. Remove adjust shim.

18. Remove outer bearing.
19. Remove the inner bearing outer race (1) and the
outer bearing outer race (2) by using a brass bar
and a hammer.
425RS012

15. Remove the inner bearing using remover 58840
00150 and a press.
425RS014
425RS015
415RW033
4A111
Reassembly
1. Using installer 9852211410 and grip 58840
00070, install outer bearing outer race.
415RS009
Legend
415RW018

00070, install Inner bearing outer race.
(1) Pilot : 5884020850

(2) Nut and Bolt: 5884020890
(3) Gauge Plate : 5884020870
EndOFCallout
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Torque:98Nm (10kgm/72lbft)
415RW017
3. Install adjust shim and adjust drive pinion mounting

distance:
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the
inner and outer bearings.
2. Tighten the nut to the specified torque.
Torque:2.3Nm (0.2kgm/20lbin)
415RS010
Legend
(1)
(2)
(3)
(4)
Dial Indicator: 5884001260

Disc (2 pcs.): 5884020880
Arbor: 5884001280
Gauge Plate: 5884020870
EndOFCallout
4A112
4. Set the dial indicator to 0". Place it on the

mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the
dial indicator in this position.
6. After the ZERO setting is obtained, rotate the

gauging arbor until the dial indicator rod does
not touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
425RS020
Legend
(1)
(2)
(3)
(4)
Legend
(1) Example=Dial indicator reading of 0.085
Dial Indicator
Ganging Arbor
Plunger
Gauge Plate
EndOFCallout
5. Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicator
shows the greatest defection. At this point, once
again set the dial indicator to 0".
Repeat the procedure to verify the 0" setting.
EndOFCallout
7. Record the pinion depth code on the head of the
drive pinion.
The number indicates a necessary change in
the pinion mounting distance. A plus number
indicates the need for a greater mounting
distance (which can be achieved by decreasing
the shim thickness). A minus number indicates
the need for a smaller mounting distance (which
can be achieved by increasing the shim
thickness). If examination reveals pinion depth
code 0", the pinion is nominal".
425RS021
425RS023
4A113
8. Select the shim using chart;

Pinion
marking
Dial
indicator
reading
(Inches)
+10
+8
+6
+4
+2
10
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
2.18
(0.0858)
0.081
2.18
(0.0858)
2.20
(0.0866)
2.18
(0.0858)
2.20
(0.0866)
2.23
(0.0882)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
0.082
0.083
0.084
0.085
0.086
0.087
0.088
0.089
0.090
0.091
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
0.092
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
0.093
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
0.094
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
0.095
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
0.096
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.097
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.098
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.099
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.001
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.002
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.003
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.004
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.005
2.54
(0.1000)
2.56
(0.1008)
0.006
2.56
(0.1008)
NOTE: When ordering shims, find the part number in

the parts catalog by using the thickness of shims listed
in the ablve table.
4A114
4. Place the shim on the drive pinion. Install the inner

bearing onto the pinion using an installer 98522
11650 and a press.
NOTE: Do not apply pressure to the roller cage and
apply pressure only to the inner race.
9. Install duct cover.

10. Install flange.
11. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder 5884021570.
Torque:177-275 Nm(18-28kgm/130-203lbft)
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RW067
5. Discard the used collapsible spacer and install a

new one.
6. Install pinion gear.
8. Use oil seal installer 9852212750 to install a
new oil seal that has been soaked in front axle
lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RW024
425RW057
3. Adjust pinion bearing preload.

a Measure the bearing preload by using a
torque meter. Note the scale reading
required to rotate the flange.
b Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing:0.71.1Nm(6.511.5kgcm/5.6
10lbin)
Used bearing:0.40.5Nm(3.35.7kgcm/2.9
5.0lbin)
4A115
12. Install adjust shim.

1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
425RS027
4. Using punch 5884022930, stake the flange

nut at two points.
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3)
425RS029
Legend
(1) Drive handle:5884000070
(2) Installer:9852211640
(3) Pilot:9852117430
EndOFCallout
2. Insert the differential cage assembly with
bearing outer races into the side bearing bores
of the carrier.
415RW019
Legend
(1) 1.3mm or less
EndOFCallout
425RS030
3. Using two sets of feeler gauges, insert a feeler

stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator 5884001260 on the
carrier so that the indicator stem is at right
angles to a tooth on the ring gear.
4A116
5. Use bearing remover 5884000130, 58840
00140 and pilot 9852117430 to remove
side bearing.
425RS031
4. Adjust feeler gauge thickness from side to side

until ring gear backlash is in the specified range.
415RW020
Backlash:0.130.18mm(0.005 0.007in)
13. Install the side bearings together with the selected

shims.
425RS032
With zero end play and correct backlash

established, remove the feeler gauge packs,
determine the thickness of the shims required
and add 0.05 mm (0.002 in) to each shim pack
to provide side bearing preload. Always use new
shims.
425RS029
Legend
(1) Drive Handle:5884000070
(2) Installer: 9852211640
(3) Pilot: 9852117430
EndOFCallout
14. Install side bearing outer race.
15. Install differential cage assembly.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035
4A117
1. Measure the amount of run-out of the ring gear

at its rear face.
Standard: 0.02 mm (0.001 in)
Limit: 0.05 mm (0.002 in)
425RS037
Gear Tooth Contact Pattern Check and

Adjustment
1. Apply a thin coat of prussian blue or equivalent
to the faces of the 78 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.
17. Tighten the cap bolt to the specified torque.

425RS036
4A118
425RS038
Legend
(1)
(2)
(3)
(4)
Heel
Toe
Concave Side(Coast)
Convex Side(Drive)
EndOFCallout
425RS039
18. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
Torque:25Nm(2.5kgm/19lbft)
415RS014
3. Fill the axle case with hypoid gear lubricant, to

just below the filler hole.
Lubricant capacity:1.4liter(1.2 Imp qt/1.5 USqt)
4A119
4A120
Differential Cage Assembly

Disassembled View
415RS015
Legend
(1)
(2)
(3)
(4)
Pinion Gear
Thrust Washer
Side Gear
Cross Pin
(5)
(6)
(7)
(8)
Ring Gear
Bolt
Differential Cage
Lock Pin
EndOFCallout
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin,
using a 5mm (0.20 in) diameter drill.
425RS042
4A121
4. Remove the cross pin, using a soft metal rod and a

hammer.
415RS016
425RS043
5. Remove pinion gear.

6. Remove side gear.
7. Remove thrust washer.
Clearance between the differential pinion

and the cross pin measurement:
Standard: 0.06 - 0.12 mm (0.002 - 0.005 in)
Limit: 0.2 mm (0.008 in)

1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt.
4. Discard used bolts and install new ones..
Torque:108Nm(11.0Kgm/80lbft)
425RS045
4A122
Clearance between the side gear and the

differential box:
Standard: 0.03 - 0.10 mm (0.001 - 0.004 in)
Limit: 0.15 mm (0.006 in)
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by
engaging it with the side gears while turning both
pinion gears simultaneously in the same direction.
425RS046
Legend
(1) Side Gear
(2) Differential Box
EndOFCallout
425RS048
Play in splines between the side gear and

the axle shaft:
4. Install cross pin.

1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
Standard: 0.08 - 0.36 mm (0.003 - 0.014 in)

Limit: 0.5 mm (0.02 in)
425RS049
425RS047
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash: 0.03 - 0.08 mm (0.001 - 0.003 in)
Thickness of thrust washers available:
1.00mm, 1.05mm, 1.10mm(0.039in, 0.041in,
0.043in)
4A123
6. Clean the ring gear threaded holes to remove the

locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.
7. Tighten the bolts in diagonal sequence as
illustrated.
NOTE: Discard used bolts and install new ones.
425RS050
5. Install lock pin. After lock pin installation, stake the

cage to secure the lock pin.
415RS016
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
EndOFCallout
4A124

Axle tube Type
It consists of the duct, a cast iron housing and the axle

tube.
Gear type
Gear ratio
Hypoid
(to 1)
Differential type
Oil capacity
Type of lubricant
Axle shaft type
Hub locking Type
4.100 (6VD1 with A/T)

4.300 (6VD1 with M/T)
4.777 (X22SE with M/T)
Two pinion
liter (US qt)
1.4 (1.5) (Differential)

0.12 (0.13) (Actuator Housing: Shift on the fly)
GL5 (75W90)
Constant velocity joint (Birfield joint type and double offset
joint)
Rigid
4A125
E04RX008
4A126
E04RX014
4A127
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884021570
(J37221)
Holder; Pinion flange
9852117430
(J81072)
Adapter; Side bearing
plug
9852212750
(J24250)
Installer; Oil seal
5884000150
(J2291201)
Separator
5884002750
(J37264)
Differential holding fixture
(Use with 588400003
0 base)
9852211410
(J24256)
Installer; Outer bearing
outer race
5884000030
(J328920)
Holding fixture base
5884000070
(J8092)
Driver handle
5884000130
5884000140
(J22888)
Puller; Side bearing
9852212740
(J24252)
Installer; Inner bearing
outer race
4A128
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884020850
(J2177742)
Pilot
9852211650
(J613301)
Installer; Pinion bearing
5884020890
(J235979)
Nut and bolt
5884022930
(J39209)
Punch; End nut lock
5884020870
(J235977)
Gauge plate
9852211640
(J24244)
Installer; Side bearing
5884001260
(J8001)
Dial indicator
5884023230
(J39602)
Remover; Outer bearing
5884020880
(J235978)
Disc
5884001280
(J235971)
Arbor
SECTION
DIFFERENTIAL (REAR)
4A21
DRIVELINE/AXLE
DIFFERENTIAL (REAR)
CONTENTS
Diagnosis ....................................................
Axle Housing .................................................
Axle Housing and Associated Parts ...........
Removal .....................................................
Installation ..................................................
Axle Shaft, Oil Seal and Bearing...................
Axle Shaft and Associated Parts ................
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Pinion Oil Seal...............................................
Pinion Oil Seal and Associated Parts .........
Removal .....................................................
Installation ..................................................
Inspecting the Axle Before Disassembly ....
Disassembly ...............................................
4A2 - 1
4A2 - 2
4A2 - 3
4A2 - 5
4A2 - 5
4A2 - 5
4A2 - 7
4A2 - 7
4A2 - 7
4A2 - 7
4A2 - 8
4A2 - 8
4A2 - 10
4A2 - 10
4A2 - 10
4A2 - 11
4A2 - 11
4A2 - 13
4A2 - 13
4A2 - 14
4A2 - 14
Service Precaution
REPAIRS.

Reassembly ................................................
Side Bearing Preload Adjustment...............
Pinion Installation........................................
Determination of Backlash
& Preload Shims .....................................
Backlash Adjustment ..................................
Gear Tooth Pattern Check..........................
Adjustments Affecting Tooth Contact .........
Differential Case Assembly ...........................
Disassembly ...............................................
Reassembly ................................................
Limited Slip Differential Assembly .................
Disassembly ...............................................
Reassembly ................................................
Main Data And Specifications........................
Special Tools .................................................
4A2 - 16
4A2 - 17
4A2 - 21
4A2 - 22
4A2 - 23
4A2 - 24
4A2 - 25
4A2 - 26
4A2 - 27
4A2 - 27
4A2 - 28
4A2 - 28
4A2 - 28
4A2 - 29
4A2 - 29
4A2 - 29
4A2 - 31
4A2 - 31
4A2 - 33
4A2 - 35

and systems.
4A22
DIFFERENTIAL (REAR)
General Description
The rear axle assembly is of the semifloating type in
which the vehicle weight is carried on the axle housing .
The center line of the pinion gear is below the center
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the propeller
shaft to the rear wheels are enclosed in a salisbury type
axle housing (a carrier casting with tubes pressed and
welded into the carrier). A removable aluminum cover
at the rear of the axle housing permits rear axle service
without removal of the entire assembly from the vehicle.
The 8.9 inch ring gear rear axle uses a conventional ring
and pinion gear set to transmit the driving force of the
engine to the rear wheels. This gear set transfers this
driving force at a 90 degree angle from the propeller
shaft to the drive shafts.
The axle shafts are supported at the wheel end of the
shaft by a roller bearing.
The pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack located
between the gear end of the pinion and the roller
bearing that is pressed onto the pinion. The pinion
bearing preload is set by crushing a collapsible spacer
between the bearings in the axle housing.
The ring gear is bolted onto the differential case with 10
bolts.
The differential case is supported in the axle housing by
two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential case. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to preload
the bearings which are pressed onto the differential
case. Two bearing caps are used to hold the differential
into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues to
transmit the driving force. This prevents tire scuffing
when going around corners and prevents premature
wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at each
axle shaft end, and by a liquid gasket between the rear
cover and the axle housing.
Limited Slip Differential (LSD)

The axle assembly may be equipped with an limited slip
differential (LSD). It is similar to the standard differential
except that part of the torque from the ring gear is
transmitted through clutch packs between the side
gears and differential case.
The LSD construction permits differential action when
required for turning corners and transmits equal torque
to both wheels when driving straight ahead. However,
when one wheel tries to spin due to a patch of ice, etc.,
the clutch packs automatically provide more torque to
the wheel which is not trying to spin.
In diagnosing customer complaints, it is important to
recognize two things:

1. If, both wheels slip, with unequal traction, the LSD
has done all it can possibly do.
2. In extreame cases of differences in traction, the
wheel with the least traction may spin after the LSD
has transferred as much torque as possible to the
non-slipping wheel.
Limited Slip Differntials impose additional requirements
on lubricants, and require a special lubricant or lubricant
additive. Use 80W90 GL5 LSD lubricant.
Rear Axle Identification

The Bill of Material and build date information(1) is
stamped on the right axle tube on the rearward side.
The axle ratio is identified by a tag(3) which is secured
by a cover bolt. If the axle has limited-slip differntial, it
also will be identified with a tag(2) secured by a cover
bolt.
425RX001
DIFFERENTIAL (REAR)
Diagnosis
Many noises that seem to come from the rear axle
actually originate from other sources such as tires, road
surface, wheel bearings, engine, transmission, muffler,
or body drumming. Investigate to find the source of the
noise before disassembling the rear axle. Rear axles,
like any other mechanical device, are not absolutely
quiet but should be considered quiet unless some
abnormal noise is present.
To make a systematic check for axle noise, observe the
following:
1. Select a level asphalt road to reduce tire noise and
body drumming.
2. Check rear axle lubricant level to assure correct
level, and then drive the vehicle far enough to
thoroughly warm up the rear axle lubricant.
3. Note the speed at which noise occurs. Stop the
vehicle and put the transmission in neutral. Run the
engine speed slowly up and down to determine if
the noise is caused by exhaust, muffler noise, or
other engine conditions.
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa
(50 psi) (for test purposes only). This will change
noise caused by tires but will not affect noise caused
by the rear axle.
Rear axle nose usually stops when coasting at
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually
changes when comparing pull and coast, but tire
noise stays about the same.
Distinguish between tire noise and rear axle noise
by noting if the noise changes with various speeds
or sudden acceleration and deceleration. Exhaust
and axle noise vary under these conditions, while
tire noise remains constant and is more pronounced
at speeds of 32 to 48 km/h (20 to 30 mph). Further
check for tire noise by driving the vehicle over
smooth pavements or dirt roads (not gravel) with the
tires at normal pressure. If the noise is caused by
tires, it will change noticeably with changes in road
surface.
5. Loose or rough front wheel bearings will cause
noise which may be confused with rear axle noise;
however, front wheel bearing noise does not change
when comparing drive and coast. Light application
of the brake while holding vehicle speed steady will
often cause wheel bearing noise to diminish. Front
wheel bearings may be checked for noise by jacking
up the wheels and spinning them or by shaking the
wheels to determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when
correctly installed. Check to see that there is no link
or rod loosened or metaltometal contact.
7. Make sure that there is no metaltometal contact
between the floor and the frame.
4A23
After the noise has been determined to be in the axle,

the type of axle noise should be determined, in order to
make any necessary repairs.
Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to
55 mph) under four driving conditions.
1. In drive under acceleration or heavy pull.
2. Driving under load or under constant speed.
3. When using enough throttle to keep the vehicle from
driving the engine while the vehicle slows down
gradually (engine still pulls slightly).
4. When coasting with the vehicle in gear and the
throttle closed. The gear noise is usually more
noticeable between 48 and 64 km/h (30 and 40
mph) and 80 and 89 km/h (50 and 55 mph).
Bearing Noise
Bad bearings generally produce a rough growl or
grating sound, rather than the whine typical of gear
noise. Bearing noise frequently wowwows" at bearing
rpm, indicating a bad pinion or rear axle side bearing.
This noise can be confused with rear wheel bearing
noise.
Rear Wheel Bearing Noise

Rear wheel bearing noise continues to be heard while
coasting at low speed with transmission in the neutral.
Noise may diminish by gentle braking. Jack up the rear
wheels, spin them by hand and listen for noise at the
hubs. Replace any faulty wheel bearings.
Knock At Low Speeds

Low speed knock can be caused by worn universal
joints or a side gear hub counter bore in the cage that is
worn oversize. Inspect and replace universal joints or
cage and side gears as required.
Backlash Clunk
Excessive clunk on acceleration and deceleration can
be caused by a worn rear axle pinion shaft, a worn
cage, excessive clearance between the axle and the
side gear splines, excessive clearance between the side
gear hub and the counterbore in the cage, worn pinion
and side gear teeth, worn thrust washers, or excessive
drive pinion and ring gear backlash. Remove worn parts
and replace as required. Select closefitting parts when
possible. Adjust pinion and ring gear backlash.
4A24
DIFFERENTIAL (REAR)
Rear Axle Noise

Condition
Noise in Drive
Noisy when coasting
Intermittent noise
Constant noise
Noisy on turns
Possible cause
Correction
Excessive pinion to ring gear

backlash.
Adjust.
Worn pinion and ring gear.
Replace
Worn pinion .bearings.
Replace.
Loose pinion bearings.
Adjust.
Excessive pinion end play.
Adjust.
Worn side bearings.
Replace.
Loose side bearings.
Adjust.
Excessive ring gear run-out.
Replace.
Low oil level.
Replenish.
Wrong or poor grade oil.
Replace.
Bent axle housing.
Replace.
Axle noise heard when driving will

usually be heard also on coasting,
although not as loud.
Adjust or replace.
Pinion and ring gear too tight

(audible when slowing down and
disappears when driving).
Adjust.
Warped bevel ring.
Replace.
Loose differential case bolts.
Tighten.
Flat spot on pinion or ring gear

teeth.
Replace.
Flat spot on bearing.
Replace.
Worn pinion splines.
Replace.
Worn axle shaft dowel holes.
Replace.
Worn hub studs.
Replace.
Bent axle shaft.
Replace.
Worn differential side gears and

pinions.
Replace.
Worn differential shaft.
Replace.
Worn axle shaft splines.
Replace.
Limited Slip Differential

Condition
Possible cause
Correction
Does not lock
Broken clutch plates.
Replace the clutch plates.
Chatters in turns
Lubricant contaminated.
Drain lube when hot. Wipe carrier

clean. Refill with lube specified in
Main Data and Specifications at the
end of this section.
Clutch plates dateriorated.
Replace clutch plates.
Damaged case.
Replace unit.
Broken differential gears.
Replace gears.
Noise (in addition to normal clutch

engagement)
DIFFERENTIAL (REAR)
4A25
Axle Housing
Axle Housing and Associated Parts
420RW030
Legend
(1)
(2)
(3)
(4)
(5)
Lower Link
Stabilizer
Upper Link
Rear Propeller shaft
Shock Absorber
(6)
(7)
(8)
(9)
(10)
Lateral Rod
Brake Hose
Coil Spring
Parking Cable
Axle Assembly
EndOFCallout
Removal
stands.
The hoist must remain under the rear axle housing.
2. Take out brake fluid. Refer to Hydraulic Brakes in
Brake section.
3. Remove rear wheels and tires. Refer to Wheel
Replacement in Suspension section.
4. Remove propeller shaft. Refer to Rear Propeller
5. Drain the rear axle oil into a proper container.
6. Remove parking brake cable, release the
connection between the cable fixing clip equalizer.
Refer to Parking Brakes in Brake section.
7. Move the clip aside and pull out the breather hose.
8. Disconnect the ABS connectors (1) and remove the
brackets attached to the frame and center link.
350RW023
4A26
DIFFERENTIAL (REAR)
9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
12. Remove the lateral rod fixing bolt and nut from the
frame.
13. Remove the upper link mounting bolt and nut (3)
from the axle housing.
350RW020
10. Remove the shock absorber.

11. Remove the stabilizer linkage mounting bolts and
nuts (2) from the frame side.
460RW015
14. Remove the lower link fixing bolt and nut (4) from
the axle housing.
350RW024
460RW016
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the
vehicle on completion of steps 1 15.
17. Remove the brake caliper fixing bolt, loosen the
flare nut, release the clip and take out the brake
caliper together with the flexible hose.
18. Remove brake disc.
19. Remove antilock brake system speed sensor fixing
bolt and the clip and bracket on the axle housing.
20. Remove the brake pipe clip and fixing bolt on the
axle housing and take out the brake pipe.
DIFFERENTIAL (REAR)
Installation
1. Install brake pipe.
2. Connect Antilock brake system (ABS) speed sensor
and harness, refer to AntiLock Brake System in
Brake section.
3. Install brake disc.
4. Install brake caliper. Refer to Disk Brakes in Brake
section.
5. Install axle housing assembly.
6. Install coil spring and insulator.
7. Install the lower link fixing bolt and nut to the axle
housing. For the procedures in items 711, refer to
Suspension section.
8. Install the upper link bolt and nut to the axle
4A27
housing.
9. Install the lateral rod fixing nut and bolt to the frame
side.
10. Install the stabilizer linkage mounting nut and bolt to
the frame side.
11. Install the shock absorber.
12. Install brake tube flare nut, Refer to Disk Brakes in
Brake section.
13. Install ABS connector and bracket.
14. Connect breather hose.
15. Install parking brake cable, Refer to Parking Brakes
in Brake section.
16. Bleed brakes. Refer to Hydraulic Brakes in Brake
section.
Axle Shaft, Oil Seal and Bearing

Axle Shaft and Associated Parts
Removal
1. Raise the vehicle.
2. Remove rear wheels and brake calipers or drums.
Do not let calipers hang from the vehicle by the
brake line or hose. Wire them to frame of vehicle to
prevent damage.
3. Remove four nuts and lockwashers.
4. Remove shaft assembly from the axle housing.
5. Remove snap ring and bearing cup.
6. Break retainer ring with hammer and chisel.
420RW008
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Axle Shaft
Backing Plate
Oil Seal
Bearing
Axle Housing
Lock Washer
Nut
EndOFCallout
420RS026
4A28
DIFFERENTIAL (REAR)
Inspection
7. Break bearing cage with hammer and chisel.
Shaft for spalling or grooves from seal wear.

Retainer bent or damaged.
Replace items if required.
Installation
1. Emergency brake assembly.
2. Install retainer.
Note direction do not install backwards.
420RS027
8. Remove oil seal, retainer, and emergency brake

assembly.
9. Remove inner race from shaft with OTC1126
bearing splitter and press.
420RS029
3. Install oil seal. Note direction.
420RS028
DIFFERENTIAL (REAR)
4. Install bearing assembly, using installer and press.
5. Install retainer ring, using installer and press.
420RS030
NOTE: Install bearing with cup towards inboard side.
420RS033

7. Install axle shaft assembly into housing.
8. Install bolts, lockwashers, and nuts.
Tighten the retainer nuts to the specified torque.
Torque : 75Nm (7.6kgm/55lbft)
420RS031
4A29
4A210
DIFFERENTIAL (REAR)
Pinion Oil Seal

Pinion Oil Seal and Associated Parts
420RW013
Legend
(1) Flange Nut and Washer
(2) Flange
(3) Oil Seal
(4) Outer Oil Seal Slinger

(5) Outer Pinion Bearing (Cup and Cone)
EndOFCallout
Removal
1. Remove the rear propeller shaft. Refer to Rear
2. Drain the rear axle oil.
3. Check and record preload with an inch pound
torque wrench. This will give combined pinion
bearing, seal, carrier bearing, axle bearing and seal
preload.
425RW018
DIFFERENTIAL (REAR)
4. Remove flange nut and washer by using pinion
flange holder 5884001330 after raising up its
staked parts completely.
4A211
6. Remove oil seal.

7. Remove pinion oil seal slinger.
23230.
425RW070
5. Remove flange by using 5884001330.

Have a suitable container in place to catch
lubricant.
425RW072

1. Seal surface of the flange.
Installation
1. Install collapsible spacer, discard the used
425RW071
4A212
DIFFERENTIAL (REAR)

3. By using the seal installer 5884021650, install a
new oil seal (1) that has grease on seal lip.
4. Install flange.
5. The pinion washer and a new nut while holding the
pinion flange with 5884001330.
Tighten the nut until the pinion end play is just
taken up. Rotate the pinion while tightening the
nut to seat the bearings. Once there is not end
play in the pinion, the preload torque should be
checked.
Remove 5884001330. Using an inch-pound
torque wrench, check to make sure the pinion
preload is equal to or slightly over the reading
recorded during removal.
425RW050
425RW018
6. Install propeller shaft to the frange.

7. Install bolt and nut. Tighten the bolt and nut to the
specified torque.
DIFFERENTIAL (REAR)
4A213
Disassembled View
420RW018
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
ABS Speed Sensor

Housing
Outer Pinion Bearing (Cup and Cone)
Outer Oil Slinger
Oil Seal
Companion Flange Assembly
Pinion Nut Washer
Pinion Nut
Collapsible Spacer
Baffle Plate
Inner Pinion Bearing (Cup and Cone)
Inner Oil Slinger
Pinion gear adj. Shim-Selective (Position)
Ring gear and Pinion Gear Assembly
Exciter Ring
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Differential Case
Lock Pin
Axle Vent
Gasket
Cover and Clip Assembly
Fill Plug (with Magnet)
Mounting Bracket
Side Bearing Cap Bolt
Side Bearing Cap
Drive Gear Bolts
Differential Adjustment Shims (Side Bearing
Preload and Ring Gear/Pinion Backlash)
(27) Side Bearing (Cup and Cone)
(28) Differential Shaft
(29) Differential Side Gears
4A214
DIFFERENTIAL (REAR)
(30) Side Gear Thrust Washer

(31) Pinion Mate Gears
(32) Thrustwasher-Differential Pinion Mate Gear
EndOFCallout
Inspecting the Axle Before

Disassembly
4. Remove Differential case.

Pry the case from the axle housing at the
differential window".
1. Remove the axle cover from the rear axle and drain
the axle lubricant into a suitable container.
2. Check ring gear backlash. Refer to BACKLASH
ADJUSTMENT" in this section. This information can
be used to determine the cause of the axle problem.
It will also help when setting up the shim packs for
locating and preloading the differential cage.
3. Check case for metal chips and shavings.
Determine where these ships and shavings come
from, such as a broken gear or bearing cage.
If possible, determine the cause of the axle
problem before disassembly.
Disassembly
1. Remove axle shafts.
Refer to axle shaft replacement in this section.
2. Remove ABS sensor.
3. Remove bearing caps and bolts.
Mark the caps and the housing as left and right.
CAUTION: Bearing caps are machined with the
housing and must be assembled in the same
position as removed. Note the matched letter
stamped on the caps and carrier. When assembled,
the letters on the caps must agree in both the
hosizontal and vertical position with the letters on
the carrier.
420RW010
5. Remove side bearing outer races and shims.

Mark the races and shims as left and right, and
place them with the bearing cups.
6. Remove differential side bearings using remover 5
884025870 and plug 5884025850.
Select insert ; 303174 and collet halves ; 44801 in
remover kit 5884025870.
415RW041
420RW003
7. Remove ring gear bolts.

Ring gear bolts use right handed threads.
CAUTION: Do not pry the ring gear from the case.
This will damage the ring and the differential case.
DIFFERENTIAL (REAR)
8. Remove ring gear from the differential.
Drive the ring gear off with a brass drift if
necessary.
Check drive pinion bearing preload.
4A215
12. Remove collapsible spacer(1).
415RW011
425RW018
Check the pinion assembly for looseness by

moving it back and forth. (Looseness indicates
excessive bearing wear.)
9. Remove pinion flange nut and washer.
Use flange holder 5884001330 to hold the
pinion flange.
10. Remove pinion flange.
Use flange holder 5884001330 to remove the
pinion flange.
13. Remove outer seal, outer oil slinger and outer pinion
bearing.
14. Remove inner bearing, inner oil slinger and shim
from the pinion.
Press the bearing off the pinion using remover 5
884025870.
415RW042
415RW040
11. Remove pinion from the axle housing.

Thread the pinion nut halfway onto the pinion.
Drive the pinion out of the housing with a hammer
and a soft drift.
Remove the nut and then remove the pinion.

Remove the shim.
15. Remove bearing cups and baffle plate from the axle
housing using a hammer and a punch.
Work the cups out of the housing evenly, moving
the punch back and forth between one side of the
cup and the other.
The baffle plate will be destroyed and should be
replaced with a new one.
4A216
DIFFERENTIAL (REAR)
16. Remove exciter ring.

Remove the exciter ring from the differential using
a mallet or a brass hammer if it is required.
NOTE: Discard the exciter ring after removal.
Axle Housing
The carrier bore for nicks or burrs that would prevent
the outer diameter of the pinion seal from sealing,
Remove any burrs that are found.
The bearing cap bores for nicks or burrs.
The housing for cracks. Replace the housing if any
cracks are found.
The housing for foreign material such as metal chips,
dirt, or rust.
Pinion and Ring Gear
425RS097
Cleaning
Do not steam clean drive parts which have ground and
polished surfaces such as gears, bearings, and shafts.
These parts should be cleaned in a suitable solvent. All
parts should be disassembled before cleaning.
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may be
dried with cimpressed air. Do not allow the bearings to
spin while drying them with compressed air.

It is very important to carefully and thoroughly inspect
all drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or stress
and subsequent replacement of worn parts will
eliminate costly drive component repair after
reassembly.
Pinion and ring gear teeth for cracking, chipping,

scoring, or excessive wear.
Pinion splines for wear.
Pinion flange splines for wear.
The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause
damage to the seal's inside diameter and result in an
oil leak.
Replace all worn or broken parts.
Ring and pinion gears are matched sets and are both
replaced anytime a replacement of either is
necessary.
Bearings
Bearings visually and by feel.
The bearings should feel smooth when oiled and
rotated while applying as much hand pressure as
possible.
The large end of the bearing rollers for wear.
This is where tapered roller bearing wear is most
evident.
Bearing cups for wear, cracks, brinelling and scoring.
Bearing and cups are only replaced as sets.
If the rear axle was operated for an extended period
of time with very loose bearings, the ring gear and
drive pinion will also require replacement.
Low mileage bearings may have minute scratches
and pits on the rollers and the bearing cups from the
initial pre-load. Do not replace a bearing for this
reason.
Bearing cups for cracks or chips.
Shims
Shims for cracks and chips. Damaged shims should
be replaced with an equally sized service shim.
DIFFERENTIAL (REAR)
Reassembly
1. Install pinion bearing races and baffle plate using
outer bearing race installer 5884000080 / inner
bearing race installer 5884025690 and drive
handle 5884000070.
NOTE: Baffle plate must be installed, when install the
inner pinion bearing race.
4A217
2. Clean all the gauge parts.

3. Lubricate the outer and inner bearings with axle
lubricant.
4. Place the bearings into the pinion bearing races.
5. Place the inner oil slinger onto the inner pinion
bearing.
NOTE: The inner oil slinger must be placed between
gauge plate and inner pinion bearing when measuring
the pinion depth.
6. Install gauge plate 5884025780, inner pilot 5
884025730 stud and nut 5884001270 and
outer pilot 5884025750 to the pinion bore.
425RW073
420RW075
7. Hold the stud stationary at the flats of the stud

(and).
Tighten the stud nut
Torque: 2.2Nm (0.2kgm/1.6lbft)
8. Rotate the gauge plate and bearings several
complete revolutions to seat the bearings.
9. Tighten the stud nut until a torque of 1.6 to 2.2 Nm
(0.16 0.22kgm/1.2 to 1.6lbft.) is required to keep
the gauge plate in rotation.
425RW074
4A218
DIFFERENTIAL (REAR)
10. Assemble discs 5884025790, arbor 58840

01280 and dial indicator 5884001260 to the
side bearing bores.
NOTE: The bearing bores must be clean and burr-free.
14. Set the dial indicator to 0". Place it on the mounting

post of the gauging arbor with the contact button
touching the indicator pad.
Force the dial indicator downward until the needle
has made a half turn clockwise. Tighten down the
420RW076
11. Install the side bearing caps and tighten the bolts to
12. Rotate the gauge plate until the gauging area is
parallel with the discs.
13. Position the arbor assembly in the carrier so that the
plunger is centered on the gauge area of the gauge
plate.
425RS020
Legend
(1)
(2)
(3)
(4)
Dial Indicator
Ganging Arbor
Plunger
Gaug Plate
EndOFCallout
15. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate the
position at which the dial indicator shows the
greatest defection. At this point, once again set the
dial indicator to 0".
425RS021
DIFFERENTIAL (REAR)
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle points
to.
4A219

drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indicates
the need for a greater mounting distance (which can
be achieved by decreasing the shim thickness). A
minus number indicates the need for a smaller
mounting distance (which can be achieved by
increasing the shim thickness). If examination
reveals pinion depth code 0", the pinion is
nominal".
425RS022
Legend
EndOFCallout
425RS023
4A220
DIFFERENTIAL (REAR)
18. Select the shim using the chart;
Dial Indicator
Reading
(inches)
Marking (inches)
+3
+2
+1
-1
-2
0.027
-3
0.030
0.028
0.030
0.031
0.030
0.031
0.032
0.030
0.031
0.032
0.033
0.030
0.031
0.032
0.033
0.034
0.030
0.031
0.032
0.033
0.034
0.035
0.029
0.030
0.031
0.032
0.033
0.030
0.031
0.032
0.033
0.034
0.035
0.036
0.034
0.031
0.032
0.033
0.034
0.035
0.036
0.037
0.035
0.032
0.033
0.034
0.035
0.036
0.037
0.038
0.036
0.033
0.034
0.035
0.036
0.037
0.038
0.039
0.037
0.034
0.035
0.036
0.037
0.038
0.039
0.040
0.038
0.035
0.036
0.037
0.038
0.039
0.040
0.041
0.039
0.036
0.037
0.038
0.039
0.040
0.041
0.042
0.040
0.037
0.038
0.039
0.040
0.041
0.042
0.043
0.041
0.038
0.039
0.040
0.041
0.042
0.043
0.044
0.042
0.039
0.040
0.041
0.042
0.043
0.044
0.045
0.043
0.040
0.041
0.042
0.043
0.044
0.045
0.046
0.044
0.041
0.042
0.043
0.044
0.045
0.046
0.047
0.045
0.042
0.043
0.044
0.045
0.046
0.047
0.048
0.046
0.043
0.044
0.045
0.046
0.047
0.048
0.049
0.047
0.044
0.045
0.046
0.047
0.048
0.049
0.050
0.048
0.045
0.046
0.047
0.048
0.049
0.050
0.051
0.049
0.046
0.047
0.048
0.049
0.050
0.051
0.052
0.050
0.047
0.048
0.049
0.050
0.051
0.052
0.053
0.051
0.048
0.049
0.050
0.051
0.052
0.053
0.052
0.049
0.050
0.051
0.052
0.053
0.053
0.050
0.051
0.052
0.053
0.054
0.051
0.052
0.053
0.055
0.052
0.053
0.056
0.053
DIFFERENTIAL (REAR)
19. Remove bearing caps and depth gauging tools.
20. Install the correct pinion shim and inner oil slinger
onto pinion.
NOTE: Do not install pinion gear into housing at this
time.
21. If the exciter ring was removed, install the new
exciter ring onto the differential case by pressing
using the ring gear as a pilot.
425RS047
22. Install ring gear(1) to the differential case(2)
4A221
23. Install new ring gear bolts.

Tighten the ring gear bolts alternately in stages,
gradually pulling the ring gear onto the differential
case.
Tighten the ring gear bolts in sequence
415RS016
Side Bearing Preload Adjustment

1. The side bearing preload adjustment must be made
before installing the pinion.
2. The side bearing preload is adjusted by changing
the thickness of both hte left and right shims equally.
This maintain the original backlash.
3. Install master side bearings 5884025840 onto
the case.
Remove all nicks, burrs, dirt etc., from the hubs to
allow the master bearings to rotate freely.
425RW021
425RW077
4A222
DIFFERENTIAL (REAR)
4. Assemble the differential case into the housing (less

pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
NOTE: Dial indicator set should be capable of a
minimum travel of 5.08mm (0.2in).
425RW078
425RS107
5. Force the differetial assembly as far as it will go in

the opposite direction. Repeat these steps until the
same reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.
Pinion Installation
The bearing cups should have been installed in
Pinion Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the
pinion gear, then install the pinion inner bearing(3)
using installer 5884025740.
Drive the bearing until the bearing cone seats on

the pinion shims.
2. Install a new collpsible spacer.
Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.
Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
6. Install pinion oil seal using installer 5884021650.
7. Install the pinion flange to the pinion by tapping it
with a rawhide hammer until a few threads show
through the pinion flange.
8. Install pinion washer and a new nut while holding
the pinion flange with flange holder 588400133
0.
nut to seat the bearings.
Torque:217-678Nm (22.1-69.1kgm/160-500lbft)
Once there is no end play in the pinion, the
preload torque should be checked.
Remove flange holder 5884001330. Using a
torque wrench, check the pinion preload by
rotating the pinion with the wrench.
DIFFERENTIAL (REAR)
425RW018
Preload should be at 1.0 to 1.6Nm

(10.2-16.3kgcm/8 to 14inlbs.) on new bearings,
or 0.46 to 0.69Nm (4.7-7.0kgcm/4 to 6inlbs.) for
used bearings.
If the preload torque is below the preloads given
above, continue torquing the nut in small
increments. Check the preload after each
tightening. Each tightening increases the bearing
preload by several pounds. If the bearing preload
is exceeded, the pinion will have to be removed,
and a new collapsible spacer installed.
Once a preload of 1.0 to 1.4Nm
(10.2-14.3kgcm/8 to 12inlbs.) has been
obtained, rotate the pinion several times to
assure that the bearings have seated. Recheck
the preload, and adjust if necessary.
4A223
7. Force the ring gear to mesh with the pinion gear.

Rock the ring gear slightly to make sure the gear
teeth are meshed. Repeat this procedure several
times until the same reading is obtained each time.
Be sure the indicator reads zero(0) each time the
ring gear is forced back into contact with the cross
bore face. This reading will be the necessary
amount of thims to be placed between the
differential case and side bearing cone on the ring
gear side.
8. The remaining amount of shims, which is the
difference between the overall found in step 6 of
Side Bearing Pre-load Adjustment and step(7)
above, should be placed on the other side of the
differential case, plus additional 0.38mm (0.015in)
for obtaining preload and backlash.
9. Place the required amount of shims on each hub as
determined in the previous steps and assemble side
bearing cone by using installer 5884025800 and
handle 5884000070.
Determination of Backlash & Preload

Shims
1. Install master side bearings onto the case.
2. Install differential assembly into the carrier.
3. Install the bearing cap and finger tight bolts.
4. Set up the dial indicator.
5. Force the differential assembly away from the pinion
gear until it is completely seated against the cross
bore face of the carrier.
6. With force still applied to the differential case, place
the tip of dial indicator on a machined surface of the
differential case, if available, or on the head of a ring
gear screw, and set the indicator at zero(0).
425RW079
10. Total torque to rotate Increase of pinion torque to

rotate due to differential case assembly shall not
exceed 3.4Nm (34.7kgcm/30inlbs.) divided by the
gear ratio.
4A224
DIFFERENTIAL (REAR)
11. Assembly the spreader 5884025810 and

indicator to the carrier as shown in figure. Spread
the carrier 0.5mm (0.02in) for differential
installation.
6. Place the indicator stem at the heel end of a tooth.

Set the dial indicator so that the stem is in line
with the gear rotation and perpendicular to the
tooth angle.
420RW004
CAUTION: Do not spread the carrier over 0.5mm

(0.02in).
12. Remove the indicator.
Backlash Adjustment
1. Install the differential case assembly and bearing
caps.
2. Rotate the case several times to seat the bearings.
3. Remove the spreader.
4. Install the side bearing cap bolts.
Tighten side bearing cap bolts
5. Install a dial indicator to the case using a magnetic
base.
425RS087
7. Check and record the backlash at three points

around the ring gear.
The pinion must be held stationary when
checking backlash.
The backlash should be the same at each point
within 0.07mm (0.003in). If the backlash varies
more than 0.07mm (0.003in), check for burrs, a
distorted case flange, or uneven bolting
conditions.
8. Backlash at the minimum lash point measured
should be between 0.13 and 0.20mm (0.005 and
0.008in) for all new gear sets.
9. If the backlash is not within specifications, move the
ring gear in or out from the pinion by increasing the
thickness of one shims, and decreasing the
thickness of the other shim by the same amount.
This will maintain the correct rear axls side bearing
preload.
Moving 0.05mm (0.002in) worth of shim from one
side of the differential to the other will change the
backlash adjustment by 0.03mm (0.001in).
10. After obtaining correct tooth contact described in
later, install ABS speed sensor.
11. Install the cover with sealant.
12. Fill the axle lubricant.
DIFFERENTIAL (REAR)
Gear Tooth Pattern Check

Checking the ring gear to pinion tooth pattern is to be
done only after setting up the axle according to the
methods in this section. The pattern check is NEVER to
be used as an initial check, or instead of checking pinion
depth and backlash adjustments.
This check is only to be verify the correct adjustment of
the gear set after set up.
425RS038
Legend
(1)
(2)
(3)
(4)
Heel
Toe
Concave Side (Coast)
Convex Side (Drive)
EndOFCallout
4A225
1. Wipe all oil out of the carrier, and carefully clean

each tooth of the ring gear.
2. Use gear marking compound 1052351 or equivalent
and apply this mixture sparingly to all ring gear
teeth, using a medium-stiff brush. When properly
used, the area of pinion tooth contact will be visible
when hand load is applied.
3. Tighten the bearing cap bolts to the specified
torque.
4. Expand the brake shoes until a torque of 54 to
68Nm (5.5 to 6.9kgm/40 to 50 lbft.) is required to
turn the pinion. A test made without loading the
gears will not give a satisfactory pattern. Turn the
pinion flange with a wrench so that the ring gear
rotates one full revolution, then reverse the rotation
so that the ring gear rotates one revolution in the
opposite direction.
4A226
DIFFERENTIAL (REAR)
5. Observe the pattern on the ring gear teeth and

compare this with figure.
425RS039
Adjustments Affecting Tooth Contact

Two adjustments can be made which will affect tooth
contact pattern: backlash, and the position of the drive
pinion in the case. The effects of bearing preloads are
not readily apparent on head loaded tooth contact
pattern tests; however, these adjustments shuld be
within specifications before proceeding with backlash
and drive pinion adjustments.
The position of the drive pinion is adjusted by increasing
or decreasing the distance between the pinion head and
the centerline of the ring gear.
Decreasing the distance will move the pinion closer to
the centerline of the ring gear. Increasing the distance
will move the pinion farther away from the centerline of
the ring gear.
Backlash is adjusted by means of the side bearing
adjusting shims which move the entire case and ring
gear assembly closer to, or farther from, the drive
pinion. (The adjusting shims are also used to set side
bearing preload.)
If the thickness of the right shim is increased (along with
decreasing the left shim thickness), backlash will
increase.
The backlash will decrease if the left shim thickness is
increased (along with a decrease in right shim
thickness).
DIFFERENTIAL (REAR)
4A227
Differential Case Assembly

Disassembled View
425RW014
Legend
(1)
(2)
(3)
(4)
Thrust Washer (for Pinion Gear)

Pinion Mate Gear
Thrust Washer(for Side Gear)
Side Gear
EndOFCallout
(5)
(6)
(7)
(8)
Differential Shaft
Lock Pin
Bolt
Differential Case
4A228
DIFFERENTIAL (REAR)
Disassembly
Reassembly
1. Remove lock pin using a small drift.
1. Install side gear with thrust washer.

2. Install the pinion mate gear with thrust washer by
pinion mate gears simultaneously in the same
direction.
425RS098
2. Remove the differential shaft by using a soft metal

rod and a hammer.
425RS048
3. Install differential shaft.

1. Be sure to install the differential shaft so that it is
in alignment with the lock pin hole in the
differential case.
425RS043
3. Remove pinion mate gear and thrust washer.

4. Remove side gear and thrust washer.

Ring gear, pinion gear
Bearing
Side gear, pinion mate gear, differential shaft
Differential case, carrier
Thrust washer
Oil seal
425RS049
4. Install lock pin.

After lock pin installation, stake the case to secure
the lock pin.
DIFFERENTIAL (REAR)
4A229
Limited Slip Differential Assembly

Disassembled View
425RW004
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Thrust WasherDifferential Pinion Mate Gear

Pinion Mate Gear
Dished Spacer
Disc
Plate
Differential Plate Retainer
(7)
(8)
(9)
(10)
(11)
Lock Pin
Differential Case
Ring Gear Bolts
Differential Shaft
Differential Side Gear
EndOFCallout
Disassembly
1. Place the holder 5884025830 into a vise.
Position the differential on the holder with the ring
gear side down.
2. Remove Lock pin (1) from differential shaft using a
punch.
3. Remove Differential shaft (2) using hammer and
punch.
Place shop towel behind case to prevent differential
shaft from dropping out of case.
425RW005
4A230
DIFFERENTIAL (REAR)
4. Assemble clutch pack unloading tool 588402586

0.
a Install cap(3) to the bottom differential side gear.
b Install threaded screw cap(2) to top differential
side gear. Thread forcing screws(1) into
threaded screw cap until it becomes centered
into the bottom cap.
7. Assemble LSD service adapter 5884025820

onto long drive handle 5884000070. Insert it into
differential shaft hole of case. Pull on handle and
rotate case until pinion mate gears can be removed.
901RW289
901RW288
8. Remove pinion mate gears.

9. Hold side gear top clutch pack (1) with one hand
and remove positraction unloading tools.
Tighten forcing screw until tight enough to

collapse dished spacers and and allow
looseness between side and pinion mate gears.
5. Both pinion mate gear thrust washers using a shim
stock (1) of 0.51 mm (0.020 in.) or equivalent tool to
push out washers.
425RW008
10. Remove top side gear and clutch pack.
425RW007
6. Relieve tension of dished spacers by loosening

forcing screw.
NOTE:
You may have to adjust the forcing screw slightly to
allow the case to rotate.
NOTE:
Keep the stack of plates and discs intact and in
exactly the same position while they are being
removed.
11. Remove case from holder. Turn case with flange or
ring gear side up to allow side gear and clutch pack
to be removed from case.
DIFFERENTIAL (REAR)
12. Remove differential plate retainer from both clutch
packs to allow separation of the plates and discs.
NOTE:
Keep the discs and plates in the same order as they
were removed.
4A231
Reassembly
1. Lubricate thrust face of side gears, plates and discs
with the proper limited slip rear axle lubricant.
2. Assemble plates and discs in exactly in the same
position as they were removed, regardless of
whether they are new or original.
3. Install differential plate retainer to ears of plates.
NOTE:
Make sure both retainers are completely seated on
ears of plates.
4. Install clutch pack and side gear into bottom side
gear bore. Make sure clutch pack stays assembled
to side gear splines, and that retainers are
completely seated into pockets of case.
425RW009
Legend
(1)
(2)
(3)
(4)
Differential Plate
Differential Disc
Dished Spacer
Side Gear
EndOFCallout

Cleaning
NOTE:
To prevent clutch pack from falling out of case, hold
clutch pack in place by hand while repositioning case
on bench.
5. Install other side gear and clutch pack. Make sure
clutch pack stays assembled to side gear splines,
and retainers are completely seated into pockets of
case.
6. Hold clutch pack in position and assemble screw
cap(2), cap(3) and forcing screw(1). Tighten forcing
screw into bottom cap to hold both clutch packs in
position.
7. With tools assembled to case, position case on
holder 5884025830 by aligning splines of side
gear with those of shaft. Tighten forcing screw to
compress clutch packs in order to provide
clearance for pinion mate gears.
All parts with solvent.
Visual Inspection
Clean all parts with solvent.
Plates and Discs. If any one disc or plate in either
stack shows evidence of excessive wear or scoring,
the complete stack is to be replaced on both sides.
Side Gears and Pinion Mate Gears. The gear teeth of
these parts should be checked for extreme wear and
possible cracks. The external teeth of the side gear,
which retain the concentric groove discs, should also
be checked for wear or cracks.
If replacement of one gear is required due to wear,
etc., then both side gears, pinion mate gears, and
thrust washers are to be replaced.
Differential Shaft. If excessive wear is evident, the
differential shaft should be replaced.
Differential Plate Retainers. If wear is evident on any
one of the differential plate retainers, all four
retainers must be replaced.
Differential Case. If scoring, wear or metal pickup is
evident on the machined surfaces, replacement of the
case is necessary.
901RW288
8. Install pinion mate gears.

Place the pinion mate gears into the differential
180 degrees apart.
4A232
DIFFERENTIAL (REAR)
9. While holding gears in place, insert LSD service

adapter 5884025820 with long drive handle 5
884000070 in differential shaft hole of case. Pull
on long drive handle and rotate case, allowing
gears to turn. Make sure that holes in pinion mate
gears align with holes in case.
Stake metal of case over pin in two places, 180

degrees apart.
425RW013
901RW290
It may be necessary to adjust tension on forcing

screw to rotate case.
10. Tighten forcing screw to compress the clutch packs,
to allow installation of spherical thrust washers.
11. Lubricate spherical thrust washers (2), and
assemble into case (1). Use a small screw driver to
push washers into place. Remove tools.
425RW012
12. Position differential shaft in case and drive in with

hammer. Be sure lock pin hole of differential shaft
(5) is properly aligned to allow installation of lock
pin (3). Be sure that thrust washers and differential
pinion mate gears are aligned with the differential
case (4). Install new lock pin to proper depth using a
punch.
DIFFERENTIAL (REAR)
4A233

Rear axle
Type
Rear axle Size
Gear type
Salisbury, Semifloating
226mm (8.9in)
Hypoid
Gear ratio (to 1)
4.100 (6VD1 with A/T)

4.300 (6VD1 with M/T)
Differential type
Two pinion
Lubricant Grade
GL5: (Standard differential)

GL5, LSD: (Limited slip differential)
Locking Differential Lubricant
Capacity
80W90 GL5
(USE Limited Slip Differential Gear Lubricant or Friction
Modifier Organic Additive)
1.77 liter (1.87 US qt)
4A234
DIFFERENTIAL (REAR)
E04RX010
DIFFERENTIAL (REAR)
4A235
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884001330
(J861401)
Pinion flange holder
5884000070
(J8592)
Grip
5884021650
(J37263)
Installer; Pinion oil seal
5884025690
(J42836)
outer race
5884025870
(J42379)
Remover; Bearing
5884025750
(J42824)
Pilot;Outer
5884025850
(J39830)
plug
5884001270
(J2177743)
Nut & Stud
5884000080
(J861101)
outer race
5884025730
(J42827)
Pilot;Inner
4A236
DIFFERENTIAL (REAR)
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884025780
(J398372)
Gauge plate
5884023230
(J39602)
5884001260
(J8001)
Dial indicator
5884025810
(J24385B)
Spreader
5884025790
(J398371)
Disc (2 required)
5884025860
(J39858)
Clutch pack unloading
tool kit
5884001280
(J235971)
Arbor
5884025820
(J39834)
Limitedslip differential
(LSD) service adapter
5884025740
(J42828)
5884025830
(J39824)
Holder
5884025800
(J21784)
5884025840
(J39836)
Side bearing preload
master bearings
SECTION
DRIVELINE CONTROL SYSTEM
4B1
DRIVELINE/AXLE
CONTENTS
Shift On The Fly System ...............................
Outline of Shift on The Fly System .............
Functions of Indicator Lamp .......................
Diagnosis ....................................................
Shift On The Fly Vacuum Piping and
Electrical Equipment ................................
Vacuum Piping Diagram .............................
4B - 1
4B - 2
4B - 2
4B - 6
4B - 7
4B - 18
4B - 18
Service Precaution
REPAIRS.
Actuator Assembly......................................
Vacuum Tank..............................................
4WD Control Unit ..........................................
4WD Control Unit Associated Parts............
Removal......................................................
Installation...................................................
4B - 18
4B - 18
4B - 19
4B - 22
4B - 22
4B - 23
4B - 23

and systems.
4B2
Shift On The Fly System

Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electrically by
driver's pressing the 4WD switch (push button type) on
instrument panel.
This system controls below operations. (Shifting
between 4H" and 4L" must be performed by transfer
control lever on the floor.)
1. Shifting the transfer front output gear (Connecting

to, and disconnecting from, front propeller shaft by
motor actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
4. Indicator on instrument panel.
5. 4WD out signal to other Electronic Hydraulic Control
Unit.
System Diagrams
412RX009

Normal Operation
The motor actuator mounted on transfer rear case is
driven by signal from 4WD switch on instrument panel.
After complete the connecting transfer front output gear
to, or disconnecting it from, front propeller shaft,
4B3
condition of the transfer position switch changes. The

vacuum solenoid valve (VSV) is driven by the signal
from transfer position switch and the vacuum actuator
connects front wheels to, or disconnect them from, front
axles.
Time Chart of Shifting Under Normal Condition
F04RW002
4B4
Retrial
The motor actuator starts transfer gear shifting after
signal from 4WD switch on instrument panel has been
received. But the shifting may be impossible in cold
weather or under high speed condition. When 2
seconds have passed since transfer gear shifting
started and the transfer position switch dose not turn on
(the gear engagement is not completed), the motor
reverses its rotation for 1.2 seconds and tries again to
shift transfer gear. This procedure is repeated 3 times
in maximum. While this procedure, 4WD indicator lamp

blinks by 2 Hz.
If the transfer position switch does not turn on after
aforementioned procedure has been repeated 3 times,
the gear shifting is stopped and 4WD indicator lamp's
blinking changes from 2Hz to 4Hz to notify driver that
the gear shifting is stopped. This blinking of indicator
lamp continues until 4WD switch is returned from 4WD
to 2WD.
Time Chart of Shifting Under Severe Condition (retrial)
F04RX004

Warning at 4L" position :In view of the shifting
mechanism of transfer, the gear shifting from 4WD to
2WD at 4L" condition is impossible. Therefore, the
transfer position switch can not be turned off by 4WD
4B5
switch when vehicle is in 4L" condition. In the case this

condition continues for 2 seconds, the shifting to 2WD is
stopped and the indicator lamp's blinking changes from
2Hz to 4Hz to notify driver of wrong operation.
Time Chart of Shifting from 4WD to 2WD at 4L" Condition
F04RX005
4WD out signal to other Electronic Hydraulic

Control Unit : ECU of shift on the fly sends 4WD out
signal to other Electronic Hydraulic Control Unit as
below.
4WD out signal
(Period)
Vehicle Condition
Transfer position switch
Front axle switch
120 ms
2WD
2WD (Open)
2WD (Open)
240 ms
4WD
4WD (Close)
4WD (Close)
4B6
Functions of Indicator Lamp

Indication of vehicle condition : Indicator lamp is
controlled by ECU of shift on the fly and shows vehicle
conditions as below.
Indicator
Vehicle condition
4WD switch
Transfer position
switch
Front axle switch
Off
2WD
Off (Close)
2WD (Open)
2WD (Open)
On
4WD
On (Open)
4WD (Close)
4WD (Close)
Blink (2Hz)
Operating
On (Open)
4WD (Close)
2WD (Open)
Off (Close)
2WD (Open)
4WD (Close)
On (Open)
2WD (Open)
2WD (Open)
Off (Close)
4WD (Close)
4WD (Close)
Blink (4Hz)
Stop operating
Bulb check :The bulb of indicator lamp is checked for 2

seconds when ignition key is turned on.
Time Chart of Bulb Checking
F04RW004
Retrials from 2WD to 4WD :In cold weather or under

high speed condition, the gear shifting (engagement)
sometimes dose not complete by 3 trials. In such case,
the indicator lamp inform driver of this incident as
aforementioned chart (shown at Retrial in Outline of
shift on the fly system.)
Diagnosis
Before Judging That Troubles Occur
(Unfaulty mode)
When Switching from 2WD to 4WD
1. In case that blinking frequency of the 4WD
indicator changes from 2Hz to 4Hz.
When heavy synchronization load is needed, the
motor actuator tries the shifting transfer gear three
times including the activation shifting. While the
motor actuator tries shifting, the indicator blinks by
2Hz. If the third shifting fails, the indicator's blinking
changes from 2Hz to 4Hz at the same time that the
motor actuator shifted back to 2WD.
Heavy synchronization load occurs by
extremely lower temperature.
higher speed.rotation difference of wheels during
cornering.
Solution 1: Operate again after stop the vehicle
or slow down.
2. In case that the 4WD indicator continues
blinking by 2Hz for more than 11.5 seconds.
When there is rotation difference of wheels or there
is phase difference between front wheels and axles,
it is difficult to connect front wheels to front axles.
The 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.
4B7

blinking by 2Hz .
The 4WD indicator continues blinking by 2Hz until
both shifting the transfer gear and disconnecting the
front wheels are completed when switching 4WD to
2WD. When drive line is loaded with torsional
torque, the shifting transfer gear and disconnecting
front wheels are impossible. In this case, removal of
torsional torque on drive line make the shifting
transfer gear and disconnecting front wheels
possible.
meters.
2. In case that the 4WD indicator's blinking changes
from 2Hz to 4Hz.
Check the position of transfer lever. Is it at 4L"
position? In view of the shifting mechanism of
transfer, the gear shifting from 4WD to 2WD at 4L"
condition is impossible.
Solution 4: Push the 4WD switch to 4WD, shift
the transfer lever to High" position and reoperate the 4WD switch to 2WD.
4B8
Parts Location
D08RX290
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Battery
Relay & Fuse Box (Engine Room)
H32
Relay & Fuse Box (Instrument Panel)
I19
I1
I2
B8
B19
C32
EndOFCallout
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
H15
C16
C31
H18
H9 (X22SE)
C15
M21
H9 (6VD1), H10
M11, M12
4B9
Wiring Diagram 1
D08RX272
4B10
Wiring Diagram 2 (6VD1)
D08RX274
4B11
Wiring Diagram 2 (X22SE)
D08RX273
4B12
Connector List
No.
Connector face
No.
B-8
H-15
B-19
H-18
C-15
H-32
C-16
I-1
C-31
I-2
C-32
I-19
H-9
M-11
H-10
(6VD1
)
M-12
H-10
(X22S
E)
M-21
Connector face

Diagnosis of The Faults Based on the
Status of 4WD Indicator Lamp, 4WD Switch
and T/F Change Lever
Diagnosis charts are shown on below. If troubles can
not be solved after every chart was traced, troubles may
occur in the ECU. In this case, replace the ECU and
trace every chart again.
Step
Fault on Switching from 2WD to 4WD

1. In case that 4WD indicator's blinking changes
from 2Hz to 4Hz after Solution 1 is carried out.
Faults occur in the motor actuator or the transfer
case assembly. Remove the motor actuator and
check function. If problem was found and it was
repaired, try Solution 1 again. After that,
disassemble the transfer case assembly for check
and repair or replace. If incident is not improved
after above mentioned actions were taken, replace
the ECU.
2. In case that 4WD indicator does not blink nor
light, when switching from 2WD to 4WD.
Action
Yes
No
Go to Step 2
Turn on the ignition

and trace this chart
from start.
Go to Step 3
Burning out of
indicator lamp or
disconnection of
harness wire.
Trace this chart
from the start after
repair or replace.
1
Is ignition turned on?
2
Does the indicator light during two seconds initialization after
ignition is turned on?
3
Is the 4WD switch turned from 2WD to 4WD?
4B13
Short-circuit
(body short) on
harness of the
4WD switch.
Fault of the
4WD switch
(holding the
closed
condition).
Trace this chart
from the start
after repair or
replace.
Push the 4WD

switch to 4WD.
4B14
3. Case that the indicator keeps blinking by 2Hz

after aforementioned Solution 2 is carried out.
Step
1
Action
Check the air pressure and wear of all tires.
Were problems found?
Yes
No
Try Solution 2
after adjust the air
pressure and
replace worn tires.
Go to Step 2
Go to Step 3
Disconnection
of the motor
actuator
harness wiring.
Trace this chart
from the start
after repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults of
transfer case.
Disassemble
the transfer
case for check.
Trace this chart
from the start
after repair or
replace.
Go to Step 4
Faults on the
transfer position
switch or its
harness. Trace
this chart from
the start after
repair or
replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the diagnosis
chart in Front
Axle ASM
section. After
that, trace this
chart from the
start.
Can the transfer lever be operated from High to 4L or vice versa?
Pull out the hoses from vacuum actuator and operate 4WD
switch.
Is there negative pressure on either of hoses?

Step
4
Action
Yes
Check the axle switch.

Internal faults on
axle switch. Trace
this chart from the
start after replace.
4B15
No
Disconnection
on the axle
harness. Trace
this chart from
the start after
repair or
replace.
Faults on Front
Axle ASM.
Trace the
diagnosis chart
in Front Axle
ASM section.
After that, trace
this chart from
the start.

1. Case that indicator dose not blink nor turn out.
Step
Action
Yes
No
Go to Step 2
Short circuit of the

indicator harness.
Disconnection on
the 4WD switch
harness or
breakdown of the
4WD switch in
open state. Trace
this chart from the
start after repair or
replace.
Turn the 4WD

switch to 2WD
position. Trace this
chart from the
start.
1
Does the indicator turn out by ignition off?
2
Is the 4WD switch on 2WD position?
4B16
2. Case that indicator keeps 2Hz blinking after aforementioned Solution 3 is carried out.
Step
1
Action
2
Yes
No
Try Solution 3
pressure and
replace worn tires.
Go to Step 2
Faults on the
harness wiring
of motor
actuator. Trace
this chart from
the start after
repair or
replace.
Internal faults
on transfer
case.
Disassemble
the transfer
case for check.
Trace this chart
from the start
after repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after or replace.
Go to Step 3
Go to Step 4
Faults on the
transfer position
switch or its
harness. Trace
this chart from
the start after
repair or
replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the diagnosis
chart in Front
Axle ASM
section. After
that, trace this
chart from the
start.
switch.

Step
4
Action
Yes
Internal faults
on axle switch.
Trace this chart
from the start
after replace.
Faults on Front
Axle ASM.
Trace the
diagnosis chart
in Front Axle
ASM section.
After that, trace
this chart from
the start.
4B17
No
Short circuit (body

short) or
disconnection of
the axle harness.
Trace this chart
repair or replace.
3. Case that indicator's blinking changes to 4Hz

Step
Action
1
Yes
Faults on the
harness wiring
of motor
actuator. Trace
this chart from
the start after
repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults
on transfer
case.
Disassemble
the transfer
case for check.
Trace this chart
from the start
after repair or
replace.
No
Faults on the ECU.

Trace this chart
replace.
4B18
Shift On The Fly Vacuum Piping and Electrical Equipment

Vacuum Piping Diagram
C04RX001
Actuator Assembly
Vacuum Tank
412RW024
412RW025
4B19

Vacuum Piping
C04RW004
1. Pull out the Hose A in figure and install a vacuum

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.
10. If Check 8) or 9) has revealed stoppage, check and
see that there is no bend, foreign matter in the hose
or in the filter. If there is trouble, repair or replace.
Check Valve
C04RS004
1. Apply vacuum from the orange colored side(1).

Vacuum:400mmHg
2. Check leakage of vacuum.
3. Make sure that vacuum cannot be applied from the
black colored side(2).
4. If vacuum is not applicable as much as 400mmHg,
and if there is resistance on the intake side, replace
with a new check valve.
4B20
VSV Assembly
1. With battery not connected (Usual).

AC:There is continuity
Inspect the vehicle side harness as follows:
B:Closed
2. With battery connected
A B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.
Functional Detective Switch
412RX008
Legend
(1) Grey
(2) Blue
EndOFCallout
1. Remove connector.
2. Shift transfer lever to 2H and start the engine.
NOTE: The vehicle should not be started, with the
engine idling.
3. Make sure that there is continuity in the vehicle side
of harness. If there is no continuity, check transfer
shift switch and wiring.
Inspect the both VSVs as follows
412RW067
1. With ball (1) being free

AB:There is continuity
2. With ball forced into the switch
AB:No continuity
3. If 1) and 2) fail, replace with a new switch.
Motor Actuator Assembly

Inspect the function of the motor actuator assembly as
follows:
1. Disassemble the motor actuator from transfer rear
case.
F04RS004
412RW037
Legend
4B21
412RX002
Legend
(1)
(2)
(3)
(4)
(3) Shift Rod

(4) Connector
EndOFCallout
2. Connect the terminals as shown in figure.
Shift rod of the motor actuator moves and stops
at 4WD position.
2WD
4WD
Shift Rod
Connector
EndOFCallout
4. If 2) and 3) fail, replace with a new motor actuator.
Transfer Position Switch
412RX001
Legend
(1)
(2)
(3)
(4)
2WD
4WD
Shift Rod
Connector
EndOFCallout
at 2WD position.
412RW040
Legend
(1) Ball
EndOFCallout
1. With ball being free.
AB : There is continuity.
2. With ball forced into the switch.
AB : No continuity.
4B22
4WD Control Unit

4WD Control Unit Associated Parts
412RW042
Legend
(1) Center Console Assembly
EndOFCallout
(2) 4WD Control Unit
Removal
1. Remove center console assembly.
Refer to Interior Trim in Body and Accessories
section.
2. Remove two screws and harness connector (1) from
4WD control unit.
412RW041
Legend
(1) Harness Connector
EndOFCallout
Installation
1. Connect harness connector, then install 4WD
control unit.
2. Install center console assembly.
4B23
SECTION
DRIVE SHAFT SYSTEM
4C1
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Diagnosis ....................................................
Front Hub and Disc .......................................
Disassembly ...............................................
Reassembly ................................................
Front Drive Shaft Joint ..................................
Front Drive Shaft Joints Replacement ........
Front Axle Drive Shaft ...................................
Front Axle Drive Shaft and
Disassembly ...............................................
Inspection And Repair ................................
Bushing Replacement ................................
Reassembly ................................................
Shift On The Fly System and
Disassembly ...............................................
Reassembly ................................................
Special Tools ..............................................
Propeller Shaft ..............................................
General Description ....................................
Universal Joint ............................................
Diagnosis of Propeller Shaft and
4C - 1
4C - 2
4C - 2
4C - 3
4C - 3
4C - 3
4C - 4
4C - 5
4C - 8
4C - 8
4C - 9
4C - 9
4C - 10
4C - 11
4C - 11
4C - 11
4C - 14
4C - 14
4C - 14
4C - 16
4C - 19
4C - 22
4C - 24
4C - 25
4C - 25
4C - 26
Service Precaution
REPAIRS.
Universal Joint.........................................
Front Propeller Shaft .....................................
Front Propeller Shaft and
Removal......................................................
Installation...................................................
Slip Joint Disassembly................................
Universal Joint Disassembly
(Single Cardan Type) ..............................
(Double Cardan Type).............................
Universal Joint Reassembly
Slip Joint Reassembly ................................
Rear Propeller Shaft......................................
Rear Propeller Shaft and
Removal......................................................
Installation...................................................
Universal Joint Disassembly.......................
Inspection ...................................................
Universal Joint Reassembly .......................
4C - 27
4C - 28
4C - 28
4C - 28
4C - 29
4C - 29
4C - 30
4C - 32
4C - 33
4C - 35
4C - 36
4C - 38
4C - 39
4C - 40
4C - 40
4C - 40
4C - 40
4C - 41
4C - 42
4C - 44
4C - 45
4C - 46
4C - 47

and systems.
4C2
DRIVE SHAFT SYSTEM
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 front propeller shaft and universal
joint, refer to Front Propeller Shaft in this section.
Diagnosis
Condition
Possible cause
Correction
Repair or replace.
Too much gear oil.
Tighten or replace.

Joint


bellows.

Coast"

shaft bolts.
Tighten.
Replace.
Repair.
Replace.

drive shaft joint).

shaft joint).
Balance or replace.
Align.

incorrect.

gear or side gear.

side gear.
Wheel bearing worn.
Tighten or replace.
Tighten or replace.

or broken.
Tighten or replace.

adjusted.
Adjust or replace.
Tighten or replace.

Acceleration

Wanders and Pulls
Front Wheel Shimmy
DRIVE SHAFT SYSTEM
4C3
Front Hub and Disc

Disassembled View
411RW001
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Bolt
Cap
Snap Ring and Shim
Hub Flange
Lock Washer and Lock Screw
Hub Nut
Outer Bearing
(8)
(9)
(10)
(11)
(12)
(13)
Bolt
Wheel Pin
ABS Sensor Ring
Inner Bearing
Oil Seal
EndOFCallout
Disassembly
1. Before disassembly, select the 2WD position with
the 4WD switch.
2. Jack up the front of vehicle and support frame with
jack stands.
3. Remove the disc brake caliper assembly and hang it

on the frame with wires. Refer to Disk Brakes in
Brake section.
4. Remove Bolt.
5. Remove cap.
6. Remove snap ring and shim.
4C4
DRIVE SHAFT SYSTEM
7. Remove hub flange.

8. Remove lock washer and lock screw.
9. Use wrench 5884021170, remove hub nut.
Place hub on a suitable work surface and remove

the studs by using a hammer.
411RS004
411RW005
10. Remove hub and disc assembly.

11. Remove ABS sensor ring.
14. Remove inner bearing.
15. Remove bolt , if necessary, replace the wheel pin in
the following manner.
Apply a scribe mark(1) to disc to hub.
Clamp the hub and disc assembly in a vise, using
protective pads. Remove the 6 disctohub
retaining bolts.
411RS003

Hub
Hub bearing oil seal
Knuckle spindle
Disc
Caliper
Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)
ABS sensor ring
For inspection and servicing of disc caliper and related
parts, refer to Disc Brakes in Brake section.
DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.
Place the hub on a wood workbench or a block of
wood approx. 6" by 6 " to protect the wheel stud
ends and threads.
Insert a wheel stud using a hammer.
Be sure the wheel stud is started squarely and
seats completely.
4C5
3. Use installer 5884021190 and grip 58840

00070, then install the inner bearing by driving it
into the hub.
411RW006

00070 then install the outer bearing by driving it
into the hub.
411RS005
2. Align scribe marks(1) and attach the hub to the disc,

then tighten the bolts to the specified torque.
411RW007
411RS003
4C6
DRIVE SHAFT SYSTEM
5. Apply grease (NLGI No.2 or equivalent) to the lip

portion, then install oil seal by using installer 5
884021200 and grip 5884000070.
8. Install hub nut.

Turn to the place where there is a chamfer in the
tapped hole to the outer side, then attach the nut by
using front hub nut wrench 5884021170.
411RW008
6. Install ABS sensor ring, then tighten the bolts to the

specified torque.
7. Install hub and disc assembly.
Apply grease in the hub.
Apply wheel bearing type grease NLGI No. 2 or
equivalent to the outer and inner bearing.
Grease Amount
Hub: 35g (1.23oz)
Outer bearing: 10g (0.35oz)
Inner bearing: 15g (0.53oz)
411RW005
Preload Adjustment
1. Tighten the hub nut to 29 Nm (3.0kgm/22lbft),
then fully loosen the nut.
2. Tighten the hub nut to the value given below,
using a spring scale on the wheel pin.
New bearing and New oil seal
Bearing Preload: 20 25N (2.0 2.5kgm/4.4
5.5lb)
Used bearing and New oil seal
4.0lb)
If the measured bearing preload is outside the
specifications, adjust it by loosening or tightening
the bearing nut.
411RS009
Legend
(1) Inner Bearing
(2) Hub
(3) Outer Bearing
EndOFCallout
411RS011
DRIVE SHAFT SYSTEM

9. 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, then attach the
washer.
If the bolt holes in the lock plate are not aligned
with the corresponding holes in the nut, reverse
the lock plate.
If the bolt holes are still out of alignment, turn in
the nut just enough to obtain alignment.
Screw is to be fastened tightly so its head may
come lower than the surface of the washer.
4C7
10. Apply adhesive (LOCTITE 515 or equivalent) to

both joining flange faces then install hub flange.
11. Install snap ring and shim.
Adjust the clearance between the free wheeling
hub body and the snap ring.
Clearance: 0mm0.3mm (0in0.012in)
Shims Available: 0.2mm, 0.3mm, 0.5mm, 1.0mm
(0.008in, 0.012in, 0.020in, 0.039in)
411RW002
12. Install hub cap.

411RS012
4C8
DRIVE SHAFT SYSTEM
Front Drive Shaft Joint

Front Drive Shaft Joints
Replacement
Inspection Of Shift On The Fly System Gear

Oil
Refer to Front Drive Axle Assembly Replacement in

this section, and refer to Front Hub and Disc Overhaul
Front Hub Bearing Preload Check

Check the hub bearing preload at the wheel pin.
New bearing and New oil seal:
20 25N (2.0 2.5kgm/4.4 5.5lb)
Used bearing and New oil seal:
12 18N (1.2 1.8kgm/2.6 4.0lb)
412RW035
1. Open filler plug and make sure that the oil up to the
plug port.
If the oil is short, replenish with gear oil GL5 grade.
2. Tighten the filler plug to specified torque.
Torque:78Nm (8.0kgm/58lbft)
411RS011
DRIVE SHAFT SYSTEM
4C9
Front Axle Drive Shaft

Front Axle Drive Shaft and Associated Parts
412RX012
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Axle Case and Differential

Snap Ring
Bearing
Snap Ring
Oil Seal
Bracket
Bolt
Drive Shaft Joint Assembly
DOJ Case
Circlip
Ball
Snap Ring
EndOFCallout
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Ball Retainer
Ball Guide
Band
Bellows
Band
Band
Bellows
Band
BJ Shaft
Dust Seal
4C10
DRIVE SHAFT SYSTEM
Disassembly
NOTE: For the left side, follow the same steps as right
side.
1. Raise the hooked end of the band with a
screwdriver or equivalent.
4. Remove drive shaft joint assembly.

5. Remove the six balls (1) with a screwdriver or
equivalent.
412RS012
6. Using snap ring pliers, remove the snap ring (1)

fastening the ball retainer to the center shaft.
412RS009
2. Remove band(1).
3. Pry off circlip (1) with a screwdriver or equivalent.
412RS013
412RS010
DRIVE SHAFT SYSTEM
4C11
Bushing Replacement
7. Remove ball retainer, ball guide and bellows.

Remove the bushings using a remover 58840

23090 and hammer.
412RS014
9. Remove band(1).
10. Remove bellows.
11. Remove dust seal.
12. Remove BJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.
412RW051
By using installer and base 5884023090, press

fit the bushings into the bracket.
Inspection And Repair

1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
412RW052
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
5. Apply 150g of the specified grease in BJ.
6. Install dust seal.
installation then install bellows.
4C12
DRIVE SHAFT SYSTEM
8. Install band. Note the setting direction. After

installation, check that the bellows is free from
distortion.
13. Align the track on the ball (1) retainer with the
window in the cage, and install the six balls into
position.
412RS017
9. Install another bellows and fix band.

10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS018
14. Pack 150g of the specified grease in DOJ case, then

install drive shaft joint assembly. After reassembly,
move the DOJ longitudinally several times to get to
fit.
15. Install the circlip (1) so that open ends are
positioned away from the ball groove.
412RS019
412RS013
DRIVE SHAFT SYSTEM
412RS020
Legend
(1) Outer Case
(2) Circlip
(3) Open Ends
EndOFCallout
16. Install bellows. Adjust the air pressure within the
bellows by inserting a screwdriver or equivalent, so
that it equals atmospheric pressure.
412RS021
17. Install band. After installation, check that the bellows

is free from distortion.
4C13
4C14
DRIVE SHAFT SYSTEM

Shift On The Fly System and Associated Parts
412RW031
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Filler Plug
Bolt
Oil Seal
Snap Ring(External)
Inner Shaft Bearing
Snap Ring(Internal)
Inner Shaft
Needle Bearing
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Clutch Gear
Sleeve
Housing
Front Axle Drive Shaft(LH side) with Bracket
Bolt
Actuator Assembly
Bolt
EndOFCallout
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.
3. Remove actuator assembly and draw out actuator

ASM.
4. Remove housing.
5. Remove sleeve.
DRIVE SHAFT SYSTEM

6. Remove clutch gear.
7. Remove snap ring from front axle case by using
snap ring pliers.
4C15
10. Remove inner shaft bearing.

NOTE: Be careful not to damage the shaft.
412RW015
412RW017
8. Take out inner shaft from front axle case.

9. Remove snap ring from inner shaft by using snap
ring pliers.
11. Remove needle bearing from inner shaft by using a

remover 5884000270 and sliding hammer 5
884000840.
412RS045
412RW016
12. Remove oil seal from front axle case.

NOTE: Be careful not to damage the front axle case.
4C16
DRIVE SHAFT SYSTEM
Inner Shaft RunOut
Inspect the removed parts. If there are abnormalities

such as wear and damage, take corrective action or
replace.
With both end centers supported, rotate the shaft slowly

and measure deflection with a dial gauge.
Limit:0.5mm (0.02in)
NOTE: Do not heat the shaft to correct its bend.
Visual Check
1. Check and see if the inner shaft has such
abnormalities as wear and damage.
412RS026
Inner Shaft Bearing

412RW014
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
such an abnormality in its gear part (a slide with
sleeve), replace the shaft.
412RW006
Legend
(1) Inner Shaft Bearing
(2) Inner Shaft
(3) Clutch Gear
420RS008
EndOFCallout
1. Inspect the state of inner shaft bearing. If any
abnormality such as smoothlessness is found,
replace with a new inner shaft bearing.
2. Insert a clutch gear and check the state of needle
bearing.
3. If there is an abnormality such as smoothlessness,
replace the needle bearing.
DRIVE SHAFT SYSTEM
4C17
Sleeve Condition
Clutch Gear Condition
Check and see that there is not wear damage, or

cracking in the sleeve.
Check and see that there is not wear, damage, crack, or

any other abnormality in the clutch gear.
NOTE: Close inspection of the groove and inner gear

are required because those are important parts.
Clutch Gear Function
Sleeve Function
412RW066
412RW011
Operate the sleeve with the inner shaft combined with

the clutch gear and if smoothlessness is felt, replace the
sleeve.
If there is an abnormality such as roughness when

operated in combination with sleeve, replace the clutch
gear.
NOTE: When inspecting, gear oil should be applied to
the contact surface of gear.
Clutch Gear Journal Diameter
NOTE: Gear oil should be applied to the contact

surface of gear.
Check the width of sleeve center groove.
Make sure of the size illustrated.

Limit:36.98mm (1.456in)
412RW065
412RW022
4C18
DRIVE SHAFT SYSTEM
Actuator
Check and see that there is no damage, cracking, or
other abnormality.
Functional Check
412RW007
Disconnect the shift position switch and make sure of

function with a vacuum of 400 mmHg applied to Ports
A and B, in accordance with the table below.
412RW021
State
Port A
Port B
Function
400 mmHg
A/P
A/P
400 mmHg
If there is an abnormality, replace the actuator as an

assembly.
412RW013
NOTE:
1. If the actuator works under 400mmHg or less,
there is no functional problem.
2. Be careful not to permit the entry of water or dust
into the ports of the actuator.
Dimentional Check
Measure illustrated sizes 1, 2, and 3.
Limit
1=64.1mm (2.52in)
2=6.7mm (0.26in)
3=6.7mm (0.26in)
DRIVE SHAFT SYSTEM
4C19
2. Check the oil seal installation position (from shaft

end to oil seal).
Depth:24.225.2mm(0.950.99in)
412RS037
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer 5
884024070 and grip 5884000070.
412RS052
3. Force a new needle bearing into inner shaft by using

a Installer 5884024080 and grip 588400007
0.
412RW034
412RS051
4C20
DRIVE SHAFT SYSTEM
4. Place a new snap ring(internal) in inner shaft.

Force a new inner shaft bearing into the inner shaft.
8. Apply differential gear oil to clutch gear, then install

clutch gear.
9. Apply differential gear oil to sleeve, then install
sleeve.
10. Clean contact surface with the front axle and
actuator mounting surface. Apply liquid gasket to
the contact surface on the front axle case, then
install in the housing.
412RS044
5. Install snap ring(external).

NOTE: Be careful not to damage the inner shaft.
6. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.
412RW023
NOTE: Be careful not to damage seal.

7. Install snap ring internal in the groove of front axle
case.

12. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
NOTE: Be sure to install the snap ring properly.
13. Apply liquid gasket to the contact surface on the
actuator side.
412RW017
412RW012
DRIVE SHAFT SYSTEM

14. Align shift arm with the groove of sleeve and install
the actuator.
Torque:9Nm(0.9kgm/78lbin)
16. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
17. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity:1.4lit (1.48USqt)
Actuator Housing
Oil Capacity:0.12lit(0.13USqt)
18. Install filler plug through gasket and tighten to
specified torque.
4C21
4C22
DRIVE SHAFT SYSTEM

Front drive axle oil capacity
1.4 liter (1.48 US qt)(Differential)

0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricant
Axle shaft type
GL5 (75W90) Refer to chart in General Information

Constant velocity joint(Birfield joint type and double offset joint)
E04RX011
DRIVE SHAFT SYSTEM
4C23
E04RX012
4C24
DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884023090
(J39378)
Front Axle mount bushing
5884000070
(J8092)
Grip
5884000270
(J 26941)
Remover; Bearing needle
5884021170
(J36827)
Wrench; Hub nut
5884000840
(J261901)
Hammer; Sliding
5884021190
(J36829)
5884024070
(J41693)
Installer; Oil seal
5884021180
(J36828)
5884024080
(J41694)
Installer; Bearing needle
5884021200
(J36830)
Installer; Oil seal
DRIVE SHAFT SYSTEM
4C25
Propeller Shaft
General Description
401RX026
Legend
(1) Front Propeller Shaft (for 6VD1)
(2) Front Propeller Shaft (for X22SE)
(3) Rear Propeller Shaft;
Aluminum Tube Type
(for 6VD1, M/T model)
EndOFCallout

Steel Tube Type
(for X22SE, M/T model and 6VD1, A/T model)
4C26
DRIVE SHAFT SYSTEM
Torque is transmitted from the transmission to the axle

through propeller shaft and universal joint assembles.
All propeller shafts are the balanced tubular type. A
splined slip joint is provided in some drivelines.
Since the propeller shaft is total balanced carefully,
welding or any other modification are not permitted.
Alignment marks should be applied to each propeller
shaft before removal.
Be sure vehicle is stopped, engine is not running,
brake is secured and vehicle is secured to prevent
injury.
Be careful not to grip the propeller shaft tube too
tightly in the bise as this will be cause deformation.
Phasing
The propeller shaft is designed and built with the yoke
lugs (ears) in line with each other. This design produces
the smoothest running shaft possible, called phasing.
Vibration can be caused by an out-of-phase propeller
shaft. The propeller shaft will absorb vibrations from
speeding up and slowing down each time the universal
joint goes around. This vibration would be the same as
a person snapping rope and watching the "wave"
reaction flow to the end. A propeller shaft working in
phase would be similar to two persons snapping a rope
at the same time, and watching the "waves" meet and
cancel each other out. In comparison, this would be the
same as the universal joints on a propeller shaft. A total
cancellation of vibration produces a smooth flow of
power in the driveline. It is very important to apply a
reference mark to the propeller shaft before removal, to
assure installation alignment.
Universal Joint
401RW015
Legend
(1) Spider
(2) Yoke
EndOFCallout
A universal joint consists of two Y-shaped yokes
connected by a crossmember called a spider.
The spider is shaped like a cross. Universal joints are
designed to handle the effects of various loadings and
front or rear axle windup during acceleration. Within the
designed angle variations, the universal joint will
operate efficiently and safely. When the design angle is
changed or exceeded the operationallife of the joint may
decrease.
The bearings used in universal joints are of the needle
roller type. The needle rollers are held in place on the
trunnions by round bearing cups. The bearing cups are
held in the yokes by snap rings.
DRIVE SHAFT SYSTEM
4C27
Diagnosis of Propeller Shaft and Universal Joint

Condition
Universal Joint Noise.
Possible cause
Correction
Worn universal joint bearings.
Replace.
Improper lubrication.
Lubricate as directed.
Loose flange bolts.
Tighten to specifications.
Ping, Snap, or Click in Drive Line

(Usually Heard on Initial Load after
the Transmission is in Forward or
Reverse Gear)
Loose bushing bolts on the rear

springs or upper and lower control
arms.
Tighten the bolts to specified torque.
Loose or out-of-phase end yoke.
Remove end yoke, turn 180 degrees

from its original position, lubricate
the splines and reinstall. Tighten the
bolts and pinion nut to specified
torque.
Knocking or Clanking Noise in the

Driveline when in High or Neutral
Gear at 16km/h(10mph)
Worn or damaged universal joint
Replace the universal joint.
Squeak
Lack of lubricant.
Lubricate joints and splines. Also

check for worn or brinelled parts.
Shudder on Acceleration (Low

Speed)
Loose or missing bolts at the

flanges.
Replace or tighten bolts to specified

torque.
Incorrectly set front joint angle.
Install shim under the transmission

support mount to change the front
joint angle.
Worn universal joint.
Replace.
Incorrect shaft runout.
Replace.
Shaft out of balance.
Adjust.
Transmission rear housing bushing,

transfer case housing bushing worn.
Replace.
Yoke spline jammed.
Replace.
Rough surface on splined yoke;

burred nicked or worn.
Replace the seal. Minor burrs can

be Smoothed by careful use of
crocus cloth or fine stone honing.
Replace the yoke if badly burred.
Defective transmission rear oil seal.
Replace the transmission rear oil

seal and replenish the transmission
oil.
Vibration
Excessive Leak at the Front Spline

Yoke of Rear Propeller Shaft
4C28
DRIVE SHAFT SYSTEM
Front Propeller Shaft

Front Propeller Shaft and Associated Parts
401RW063
Legend
(1) Bolt, Nut and Washer (Front Axle Side)
(2) Front Propeller Shaft (Single Cardan Type)
(3) Bolt, Nut and Washer (Transfer Side)

(4) Front Propeller Shaft (Double Cardan Type)
EndOFCallout
Removal
1. Raise the vehicle on a hoist.
NOTE: Apply alignment marks on the flange at the front
propeller shaft both front and rear side.
401RS020
DRIVE SHAFT SYSTEM

2. Remove bolt, nut and washer (Front axle side).
3. Remove bolt, nut and washer (Transfer side).
4. Remove front propeller shaft.
Installation
NOTE: Never install the shaft assembly backwards.
Never insert bar between yoke lugs when tightening or
4C29
removing bolts. 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 is applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
Slip Joint Disassembly
401RW075
Legend
(1) Spline Yoke Assembly
(2) Clamp
(3) Boot
EndOFCallout
1. Lay the shaft horizontally on a bench and secure.
(4) Clamp
(5) Tube Assembly
2. Indicate the original assembled position (1) by

marking the phasing of the shaft prior to
disassembly.
4C30
DRIVE SHAFT SYSTEM

3. Using the flat blade of a screwdriver, pry the loose
end of the boot clamp upwards and away from the
propeller shaft boot. Be careful not to damage the
boot.
4. When boot clamps becomes loose, remove by
hand.
5. Repeat for the other boot clamp.
6. Remove the spline yoke assembly from the tube
assembly, by securing the boot with one hand and
pulling on the spline yoke.
7. Remove the boot from the tube assembly.
401RW037
Universal Joint Disassembly (Single Cardan Type)
401RW031
Legend
(1) Flange Yoke
(2) Snap Ring
EndOFCallout
(3) Spider
(4) Needle Roller Bearing
DRIVE SHAFT SYSTEM
4C31
1. Using a soft drift, tap the outside of the bearing cup

assembly to loosen snap ring. Tap bearing only
hard enough to break assembly away from snap
ring.
Remove snap ring from yoke. Turn joint over, tap
bearing away from snap ring, then remove opposite
snap ring.
Apply alignment marks (1) on the yokes of the
universal joint, then remove snap ring.
401RW020
401RW018
2. Set the yoke in the arbor press with a piece of tube

stock beneath it.
Place a solid plug on the upper bearing assembly
and press it through to release the lower bearing
assembly.
3. If the bearing assembly will not pull out by hand

after pressing, tap the base of the lug near the
bearing assembly to dislodge it.
4. To remove the opposite bearing, turn the yoke over
and straighten the spider in the open hole. Then
carefully press on the end of the spider so the
remaining bearing moves straight out of the bearing
spider hole. If the spider or bearing are cocked, the
bearing will score the walls of the spider hole and
ruin the yoke.
5. Repeat this procedure on the remaining bearing to
remove the spider from the yoke.
6. Make sure of proper position for reinstallation by
applying setting marks, then remove spider .
4C32
DRIVE SHAFT SYSTEM
Universal Joint Disassembly (Double Cardan Type)
401RW073
Legend
(1) Ball Stud Tube Yoke
(2) Cross and Bearing Kit
(3) Coupling Yoke
(4) Spring
(6) Flange Yoke
EndOFCallout
assembly to loosen snap ring. Tap bearing only hard
enough to break assembly away from snap ring.
2. Remove snap ring from yoke. Turn joint over, tap
snap ring.
401RW084
DRIVE SHAFT SYSTEM

3. Remove all snap rings from the yoke in similar
manner.
4. Set the outboard side of the center yoke in the arbor
press with a piece of tube stock beneath it. Place a
solid plug on the upper bearing cup assembly and
press it through to release the lower bearing cup
assembly.
Press the center bearing cup assembly partially
from the outboard side of the center yoke - enough
to grasp the bearing cup by vise jaws.
Do not press the bearing cup assembly completely
through.
4C33
6. Flip the assembly and repeat steps 4 and 5 for

removing the opposite side bearing cup assembly.
This will allow removal of the cross centering kit
assembly and spring.
Do not disassemble centering kit.
401RW068
7. Press the remaining bearing cup assemblies out on

the other cross as described above to complete
disassembly.
401RW083
5. Grasp the protruding bearing cup assembly by vise

jaws. Tap the tube yoke with a mallet and drift to
dislodge the bearing cup assembly from the yoke
hole.
NOTE: Tap in the center of the H" yoke. Never strike

the yokes at the bearing cup assembly holes because
the snap ring grooves may collapse and make
reassembly impossible.

condition is found through inspection.
NOTE: When any part of the journal assembly (spider,
needle roller bearing) requires replacement, be sure to
replace the entire assembly.
Check the following parts for wear, damage, noise or
any other abnormal conditions.
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Boot
401RW082
4C34
DRIVE SHAFT SYSTEM
Spider pin for wear

Spider pin should be smooth and free from fretting or
galling. Visible signs of needle presence is normal, but
wear should not be felt.
401RS027
Spline
401RW038
Propeller shaft runout

Support the propeller shaft on V-blocks (2) and check
for runout by holding the probe of a dial indicator (1) in
contact with the shaft.
Static runout limit:
0.13mm (0.005in)
TIR on the neck of the slip tube shaft (with a
boot).
0.25mm (0.010in)
The nylon-coated spline should be free from nicks and

dings and the underlying steel spline should not be
visible.
After cleaning the nylon coating spline, the coating
should exhibit only a slight indication of wear.
Grease volume is approximately 10 grams of grease in
total. Grease should be evenly applied to both the
female and the male slip splines using a small brush.
After assembly of the slip joint, the sliding joint should
be fully worked from the full collapsed to the full
extended position.
Play in the universal joint

Limit:Less than0.15mm (0.006in)
TIR on the ends of the tubing 3 inch from the

welds.
0.38mm (0.015in)
TIR at the linear center of the tube.
0.38mm (0.015in)
TIR for the full length of tube with 30" or less of
tubing.
(TIR : Total Indicator Reading)
401RW023
DRIVE SHAFT SYSTEM
4C35
Preload of the universal joint

Preload should be 0 to 24.9 kg(0 to11.3 lb). Joints
should rotate smoothly and freely and should exhibit no
rough or ratchety movement.
401RW020
401RW085
Boot
Check the boot for crack or damage. If necessary,
replace the boot.
If abnormal condition are found on the boot, inspect the
grease for mixing of foreign material.
If the grease is good condition, and slip joint works well,
replace the boot, replenish grease, and reassemble the
slip joint.
If the foreign material is found in the grease, check the
spline for wear and damage.
4. Install a snap ring.

Be sure the snap rings are properly seated in the
grooves.
5. Repeat steps 3 and 4 to install the opposite bearing.
If the joint is stiff, strike the yoke ears with a soft
hammer to seat needle bearings.
6. Align setting marks (1) and join the yokes.
Universal Joint Reassembly (Single

Cardan Type)
1. Install spider to flange yoke. Be sure to install the
spider by aligning the setting marks made during
disassembly.
2. Pack the four grease cavities of the spider with a
high quality, extreme pressure N.L.G.I. Grade 2
grease. Do not add additional grease to the bearing
cup assembly.
3. Move one end of the spider to cause a trunnion to
project through the spider hole beyond the outer
machined face of the yoke lug. Place a bearing over
the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment
with the spider hole and place a solid plug on the
upper bearing. Press the bearing into the spider
hole enough to install a snap ring.
401RW018
4C36
DRIVE SHAFT SYSTEM
Universal Joint Reassembly (Double

Cardan Type)
1. Pack the four grease cavities of the cross with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to bearing cup
assembly.
2. Fit a cross into the tube yoke.

5. Repeat steps 3 and 4 to install the opposite bearing
cup assembly. If the joint is stiff, strike the yoke ears
with a soft hammer to seat the needle bearing.
NOTE: Be sure the snap rings are properly seated in
the grooves.
401RW071
401RW069
3. Move an end of the cross to cause a trunnion to

project through the cross hole beyond the outer
machined face of the yoke lug. Place a bearing cup
assembly over the trunnion diameter and align it to
the cross hole. Using an arbor press, hold the
trunnion in alignment with the cross hole and place
a solid plug on the upper bearing cup assembly.
Press the bearing cup assembly into the cross hole
enough to install a snap ring.
6. Fit the center yoke (H Yoke) on the remaining two

trunnions and press bearing assemblies in place,
both sides as in steps 3 and 4 above. Install snap
rings.
401RW086
401RW070
DRIVE SHAFT SYSTEM

7. Install the journal onto the flange as per steps 3 and
4 above.
8. Install the centering kit assembly inside the center
yoke making sure the spring in the tube yoke is in
place.
401RW072
9. Fit the open trunnions of the flange assembly in to

the center yoke holes and the bearing assemblies
into the centering kit assembly.
10. Install bearings as per steps 3 and 4.
11. Check for proper assembly. Flex the double cardan
joint beyond center. The joint should snap over
cener in both directions when all needle rollers and
components are correctly assembled.
4C37
4C38
DRIVE SHAFT SYSTEM
Slip Joint Reassembly
401RW075
Legend
(1) Spline Yoke shaft
(2) Clamp
(3) Boot
EndOFCallout
1. Apply grease evenly to both the female and male
splines.
2. Apply a small amount of grease by finger to the
outer lips of the boot.
3. Slide the boot (smaller diameter side) onto the
spline yoke shaft being careful not to damage the
spline coating or boot.
4. Insert the spline yoke shaft into the tube assembly
being careful to maintain proper phasing. The
spider holes should be in line and as per originally
marked prior to disassembly.
5. Position boot onto tube and yoke shaft in final
position over boot grooves.
(4) Clamp
(5) Tube Assembly
6. Attach boot clamps and secure using pliers.

7. Be sure clamp is properly seated and secure.
CAUTION: Use new clamp which is the same parts
as original. Do not use other clamp to avoid bad
balancing of shaft or the grease leakage.
DRIVE SHAFT SYSTEM
4C39

Length (between two spiders
center)
M/T
A/T
6VD1
376 mm (14.80 in)
542 mm (21.34 in)
X22SE
294 mm (11.57 in)
401RX027
4C40
DRIVE SHAFT SYSTEM
Rear Propeller Shaft

Rear Propeller Shaft and Associated Parts
401RX028
Legend
(2) Rear Propeller Shaft
(3) Bolt, Nut and Washer (Rear Axle Side)
EndOFCallout
Removal
NOTE: Apply alignment marks on the flange at the rear
2. Remove transfer side bolt, nut and washer.
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.
Installation
removing bolts.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of
the propeller shaft.
1. Align the mark which is applied at removal.
2. Install rear propeller shaft and tighten the bolts to
DRIVE SHAFT SYSTEM
4C41
401RX004
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp
(3) Boot
EndOFCallout
2. Indicate the original assembled position by marking
the phasing of the shaft prior to disassembly.
boot.
(4) Clamp
(5) Tube and Universal Joint Assembly

hand.
6. Remove the slip yoke assembly from the driveshaft,
by securing the boot with one hand and pulling on
the slip yoke.
7. Remove the boot from the shaft assembly.
4C42
DRIVE SHAFT SYSTEM
401RX022
Legend
(1) Spider
(2) Flange Yoke
EndOFCallout
NOTE: Aluminum is softer than steel. Care must be
taken not to remove excessive material or damage
bearing holes.
If the vehicle has aluminum tube type propeller shaft,
flange yoke, boot kit, journal kit can be replaced. If other
parts are damaged, replace propeller shaft as assembly.
(3) Bearing
(4) Snap Ring
DRIVE SHAFT SYSTEM

1. Apply alignment marks on the yokes of the universal
joint, then remove the snap ring.
4C43

stock beneath it.
Place a solid plug on the upper bearing and press it
through to release the lower bearing.
401RW024
If the snap ring is stuck in position, remove paint

from the hole in the yoke or tap around the edge of
the bearing lightly with a soft drift.
401RW027
3. If the bearing will not pull out by hand after pressing,

tap the base of the lug near the bearing to dislodge
it.
and straighten the spider in the open spider hole.
Then carefully press on the end of the spider so the
ruin it.
401RW025
401RW026

4C44
DRIVE SHAFT SYSTEM
Inspection
Propeller shaft for run-out Aluminum tube type.
Static run-out limit :1.0mm(0.04in)
TIR full length of tubing maximum.
Propeller shaft for runout (Steel tube type).
Static runout limit :0.13mm(0.005in)
boot).
0.25mm(0.010in)
welds.
0.38mm(0.015in)
0.38mm(0.015in)
tubing.
(TIR: Total Indicator Reading)
401RW028
Preload of the universal joint.

Preload should be 0 to 49 N (0 to 5.0 kg/0 to 11.0 lb).
Joints should rotate smoothly and freely and should
exhibit no rough or ratchety movement.
401RW017
Play in universal joint.

Limit: Less than0.15mm(0.006in)
galling.
Visible signs of needle presence is normal, but wear
should not be felt.
401RW019
Inspect splines of slip joint for wear.

The nylon-coated spline should be free from nicks
and dings and the underlying steel spline should not
be visible.
should exhibit only slight indicator of wear.
Grease volume is approximately 10 grams of grease
in total. Grease should be evenly applied to both the
extended position.
DRIVE SHAFT SYSTEM

Aluminum tube type only: Inspect the aluminum
tubing for surface scratches and dents. These
scratches may not exceed 0.2 mm (0.008 in) in depth.
4C45

grease. Do not add additional grease to bearing
cup assembly.
hole enough to install snap ring.
401RW022
Aluminum tube type only: Visually inspect the circle

welds and fittings for any signs of cracks or signs of
deterioration. If there are any cracks that exceed 0.2
mm (0.008 in) in depth, the assembly must be
replaced.
Aluminum tube type only: Check to be sure there are
no missing balance weights. If balance weights are
missing and void has occurred in the aluminum
tubing greater than 0.2 mm (0.008 in), the assembly
must be replaced.
401RW026

the grooves.
hammer to seat the bearing.
5. Align the setting marks and join the yokes.
4C46
DRIVE SHAFT SYSTEM
401RX004
Legend
(2) Clamp
(3) Boot
EndOFCallout
splines.
4. Insert the spline yoke shaft spline into the tube
assembly being careful to maintain proper phasing.
The spider holes should be in line and as per
originally marked prior to disassembly.
position.
(4) Clamp

DRIVE SHAFT SYSTEM
4C47

4WD Model
Engine
Length (between two spiders center)
Universal joint type
X22SE
6VD1 (M/T)
6VD1 (A/T)
989.0mm (38.94in)
1212.5mm (47.73in)
1043.0mm (41.06in)
Cardan type
E04RX013
SECTION
TRANSFER CASE
4D1
FRONTERA
DRIVELINE/AXLE
TRANSFER CASE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly (A/T) . . . . . . . . . . . .
Transfer Case Assembly (A/T) and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Case Assembly (A/T) . . . . . . .
Transfer Rear Case Assembly (A/T) and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D1
4D2
4D4
4D4
4D4
4D4
4D6
4D6
4D7
4D8
4D11
4D11
4D11
4D13
Service Precaution
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
Transfer Rear Cover Assembly . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Detent, Shift Arm, and Interlock Pin
(Transfer Case Assembly) . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D16
4D16
4D17
4D17
4D19
4D19
4D20
4D21
4D21
4D23
4D23
4D24
4D27
4D30
4D37
4D40

use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
instructions can help you avoid damage to parts and
systems.
4D2
TRANSFER CASE
General Description
Transfer Case (for Manual Transmission)
A07RX005
TRANSFER CASE
4D3
Transfer Case (for Automatic Transmission)
A07RW0011
The transfer case is used to provide a means of providing

power flow to the front axle. The transfer case also
provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation when
the vehicle is driven on improved roads where four wheel
drive is not required. In addition, the transfer case
provides an additional gear reduction when placed in low
range, which is useful when difficult offroad conditions
are encountered.
A floor mounted shift lever is used to select the highlow
range. When four wheel drive switch has been turned on,
the four wheel drive indicator light is designed to come on
and the front axle has been engaged.
4D4
TRANSFER CASE
Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts
220RS015
Legend
(2) End Nut and Rear Companion Flange

(3) Oil Seal
Removal
Installation
1. Disconnect the rear propeller shaft (1) from the

transfer case side.
2. Remove end nut and rear companion flange (2),
using the companion flange holder 5884001330.
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 5884022920 to install the
rear seal (3) to the transfer rear case.
266RW026
3. Use the universal puller to remove the rear

companion flange and Oring.
4. Remove the oil seal from the transfer case.
220RW105
TRANSFER CASE
4. Install the rear companion flange (2) and Oring (2).
5. Use the companion flange holder 5884001330 to
install a new end nut (2) and tighten to the specified
torque.
Torque: 167 Nm (17.0 kgm/123 lb ft)
6. Use the punch 5884022930 to stake the end nut
at two spots.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the end nut (2) after staking.
266RW027
266RW002
4D5
7. Connect the rear propeller shaft to the transfer case

and tighten to the specified torque.
4D6
TRANSFER CASE
Transfer Case Assembly (A/T)

Transfer Case Assembly (A/T) and Associated Parts
260RX001
Legend
(1) Transfer Control Lever Knob
(2) Lower Cluster Assembly
(3) Rear Console
(4) Center Console
(5) Grommet Assembly and Transfer Control

Lever
(6) Transfer Protector
(8) Front Propeller Shaft
(9) Transfer Case Assembly
TRANSFER CASE
4D7
5. Remove center console (4).
Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to 2WD
using the 4WD push button switch on dash panel.
1. Disconnect battery ground cable.
2. Remove transfer control lever knob (1).
3. Remove lower cluster assembly (2).
256RW006
6. Remove grommet assembly and transfer control

lever (5).
740RW021
4. Remove rear console (3).
256RW007
256RW045
4D8
TRANSFER CASE
7. Raise and support vehicle with suitable stands. Drain

transfer case fluid.
8. Remove transfer protector (6).
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the input shaft spline as shown in the figure.
150RX010
9. Remove rear propeller shaft (7) and front propeller

shaft (8).
NOTE: Apply alignment marks on the flange at both front
and rear sides.
10. Disconnect harness connectors and clip.
Connector: transfer switch, 2WD4WD actuator,
speed sensor.
11. Support transmission case with a transmission jack.
12. Remove the top position bolt from transfer control
lever hole and others under the floor.
Remove transfer case (9) from the vehicle.
260RW001
TRANSFER CASE
4D9
2. Install transfer case (9) to the transmission. Tighten

transfer bolts as shown in the figure.
261RX001
3. Remove the transmission jack from transmission

side.
4. Connect harness connectors and clip.
speed sensor.
5. Install rear propeller shaft (7) and front propeller shaft
(8).
6. Install transfer protector (6).
150RX010
4D10
TRANSFER CASE
7. Fill transfer case fluid.

8. Lower the vehicle.
Install grommet assembly and transfer control lever
(5).
256RW007
9. Install center console (4), rear console (3) and lower

cluster assembly (2).
10. Install transfer control lever knob (1).
TRANSFER CASE
4D11
Transfer Rear Case Assembly (A/T)

Transfer Rear Case Assembly (A/T) and Associated Parts
220RW1331
Legend
(1) Speedometer Sensor, Speedometer Driven
Gear and Plate
(2) Front Companion Flange
(3) Rear Companion Flange
Removal
1. Remove the speedometer sensor (1).
2. Remove the plate (1).
(4)
(5)
(6)
(7)
(8)
Control Box Assembly

2WD4WD Actuator Heat Protector
2WD4WD Actuator Assembly
Transfer Rear Cover Assembly
Transfer Case Assembly
3. Remove the speedometer driven gear bushing and

driven gear (1).
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4D12
TRANSFER CASE
4. Remove front companion flange (2) and rear

companion flange (3), using the flange companion
holder 5884001330 to remove the end nut..
9. Remove the 2WD4WD actuator assembly bolts.

10. Pull the 2WD4WD actuator assembly (6) with
2WD4WD shift rod.
262RW067
5. Remove the front and rear companion flange.

NOTE: Use the universal puller to remove the rear
companion flange.
6. Disconnect the actuator breather hose and transfer
breather hose from control box (4).
7. Remove control box assembly (4).
8. Disconnect the actuator breather hose and
2WD4WD actuator heat protector (5) from the
2WD4WD actuator assembly (6).
220RW065
Legend
(6) 2WD4WD Actuator Assembly
(7) Rear Cover Assembly
(9) Shift Rod: 2WD4WD (Position: 2WD)
(10) Pull
(11) Position: 4WD
(12) Mode: 2WD
220RW0851
TRANSFER CASE
11. Off set the actuator assembly.
4D13
Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.
220RW028
12. Remove the actuator assembly (6).
220RS017
2. Install transfer rear cover assembly (7) to transfer

case assembly (8).
3. Perform the following steps before fitting the transfer
rear case.
1. Shift the highlow shift rod to the 4H side.
2. The cutaway portion of the select rod head (15)
should align with that of the rear case holes
stopper (16).
220RW066
Legend
(13) Position: 4WD
(14) Mode: 2WD
13. Remove transfer rear cover assembly (7) from
transfer case assembly.
230RW009
4D14
TRANSFER CASE
4. Tighten the transfer rear case bolts to the specified

torque.
8. Tighten the 2WD4WD actuator bolts to the specified

torque.
5. Shift the 2WD4WD shift rod (17) to the 4WD side.

6. Join the rod grooves of 2WD4WD actuator
assembly (6) and shift rod (17).
9. Connect the actuator breather hose to actuator.

10. Install actuator heat protector (5).
11. Install control box assembly (4).
12. Connect breather hoses to control box (4).
13. Install rear companion flange (3) and front companion
flange (2), using the companion flange holder
5884001330 to tighten the flange nuts to the
transfer case.
220RW067
Legend
(6) 2WD4WD Actuator Assembly (Mode: 2WD)
7. Push the 2WD4WD actuator assembly (6) with
2WD4WD shift rod (17) till the shift rod (17) reaches
the 2WD position.
262RW067
14. Tighten the new transfer flange nuts to the specified

torque.
Torque
Rear companion flange: 167 Nm (17.0 kgm/123
lb ft)
Front companion flange: 137 Nm (14.0 kgm/101
lb ft)
220RW068
Legend
(18) Position: 2WD
(19) Mode: 2WD
TRANSFER CASE
15. Use the punch 5884022930 to stake the rear
companion flange nut (3) at two spots.
4D15
16. Stake the front companion flange nut (2) at one spot.
staked portion of the flange nut after staking.
17. Install the Oring (23) to the speedometer driven gear
bushing (22).
18. Install the driven gear to the speedometer driven gear
bushing (22).
19. Install the speedometer driven gear assembly to the
transfer rear cover.
20. Install the plate (21) to the transfer rear case and
tighten to the specified torque.
21. Install the speedometer sensor and tighten to the
specified torque.
266RW027
225RW004
266RW002
Legend
(20) Bolt
(21) Plate
(22) Bushing
(23) Oring
4D16
TRANSFER CASE
226RW154
Legend
(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing
(5)
(6)
(7)
(8)
(9)
Bearing Snap Ring

Ball
Speedometer Drive Gear
Ball Bearing
Transfer Rear Cover (with oil seal)
Disassembly
1. Remove bearing snap ring, use a pair of snap ring
pliers to remove the snap ring (3).
226RS060
TRANSFER CASE
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal) (9).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5884000150.
4D17
Reassembly
Transfer rear cover (with oil seal) (9). Oil seal
replacement.
D Remove the oil seal from the transfer rear cover.
D Apply engine oil to the oil seal outer surfaces.
D Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
D Use the oil seal installer 5884022920 to install the
rear oil seal to the transfer rear cover.
226RW186
4. Remove speedometer drive gear (7).

5. Remove ball (6).
6. Remove bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove rear output shaft (2) from the ball bearing (4),
using a bench press and the bearing remover
5884000150.
220RW104
1. Install ball bearing (4) to the rear output shaft (2),

using the ball bearing installer 5884021590 and
the adapter 5884021921.
226RW187

Refer to TRANSFER CASE ASSEMBLY in this section
for inspection and repair.
262RW068
4D18
TRANSFER CASE
2. Install bearing snap ring (5), using a pair of snap ring

pliers.
3. Install ball (6).
4. Install speedometer drive gear (7).
226RS064
5. Use the ball bearing installer 5884021590 to

install the ball bearing (8).
226RW188
6. Install the rear output shaft assembly (1) to the

transfer rear cover (9).
7. Install bearing snap ring (3).
NOTE: The snap ring must be fully inserted into the
transfer rear cover snap ring groove.
TRANSFER CASE
4D19
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)

Disassembled View
262RW005
Legend
(1) Detent Ball, Spring and Plug
(2) Spring Pin and Bridge
(3) Spring Pin
(4) Spring
(5) 2WD4WD Shift Rod
(6) Shift Arm
(7) Shift Block
(8) 4WD Indicator Switch
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Interlock Pin
Spring
Select Rod Assembly
Spring Pin
HighLow Shift Rod
Shift Arm
Shift Block
Transfer Case
4D20
TRANSFER CASE
Disassembly
1. Remove detent ball, spring and plug (1).
2. Use a spring pin remover to remove the spring pin (2)
from the bridge (2).
5. Remove shift arm (6).

6. Remove shift block (7).
7. Remove 4WD indicator switch (8).
8. Use a magnetic tool to remove the interlock pin (9)
and spring (10) from the transfer case (16).
262RW011
3. Remove spring (4).

4. Engage the 2WD4WD sleeve with front output gear.
Remove the spring pin (3) from the block (7). Remove
the shift rod (5).
262RS005
9. Remove select rod assembly (11).

10. Use a spring pin remover to remove the shift arm
spring pin (12) from the shift arm (14) and shift block
(15). Remove the highlow shift rod (13) from transfer
case (16).
262RW022
262RS006

12. Remove shift block (15) from transfer case (16).
TRANSFER CASE
4D21

Reassembly
1. Place shift block (15) in transfer case (16).
2. Set shift arm (14) on the HighLow sleeve.
3. Push HighLow shift rod (13) through shift arm (14)
and block (15).
4. Engage the HighLow sleeve with the 4H (1) side.
5. Install the spring pin (12) to the shift block (15) and
shift arm (14).
262RW035
262RW034
6. Install select rod assembly (11), joining its lever to

shift block (15) groove.
7. Engage the HighLow sleeve with the 4H side and
install the interlock pin (9) and spring (10) in the
proper direction.
8. Place 2WD4WD shift block (7) in the transfer case
(16).
9. Set 2WD4WD shift arm (6) on the 2WD4WD
sleeve.
10. Puh 2WD4WD shift rod (5) through 2WD4WD shift
arm (6) and 2WD4WD shift block (7).
11. Install the 2WD4WD shift rod (5) with interlock pin
pushed in.
Legend
(18) 2WD4WD
(19) 4H Side
(20) Interlock pin
(21) 2WD
(22) 4WD
(23) Rod: 24
(24) Rod: HL
(25) 4H
(26) 4L
(27) 42
(28) 44
4D22
TRANSFER CASE
12. Install 4WD indicator switch and gasket (8).

Tighten to the specified torque.
13. Install spring (4).
14. Engage the 2WD4WD sleeve with the 4WD side and
install the spring pin (3).
262RW022
15. Install spring pin (2) and bridge (2).

16. Install detent ball, spring and plug and tighten the plug
TRANSFER CASE
4D23

Disassembled View
226RW209
Legend
(2) Ball Bearing
(3) Lock Nut
(4) Snap Ring (A/T)
(5) Input Shaft Assembly (A/T)
(6) HighLow Clutch Hub and Sleeve
(7) Transfer Input Gear
(8) Needle Bearing
(9) Bearing Collar
(10) Ball
(11) Plate
(12) Ball Bearing (A/T)
(13) Input Shaft (A/T)
(15) Front Output Gear Assembly
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
Bearing Snap Ring

Ball Bearing
Bearing Collar
SubGear Snap Ring (M/T)
Spacer (M/T)
Belleville Spring (M/T)
SubGear (antilash plate) (M/T)
Front Output Gear
Needle Bearing
Inside Ring
Outside Ring
Block Ring
2WD4WD Clutch Hub and Sleeve Assembly
Stopper Plate
Ball Bearing
Front Output Shaft
4D24
(32)
(33)
(34)
(35)
(36)
(37)
TRANSFER CASE
(38)
(39)
(40)
(41)
(42)
Bearing Snap Ring

Counter Gear Assembly
Snap Ring
Ball Bearing
Snap Ring
Ball Bearing
Disassembly
1. Use a pair of snap ring pliers to remove the snap ring
(1).
2. Use a bearing remover 5884021550 and puller
5884020270 to remove the ball bearing (2).
Spacer
Belleville Spring
SubGear (antilash plate)
Counter Gear
Transfer Case (with oil seal)
5. Remove the front companion flange.

6. Remove snap ring (4). (A/T)
7. Remove the input shaft assembly (5) from the
transfer case (42). (A/T)
265RW001
262RW069
3. Install the front companion flange temporarily.

4. Use the Companion flange holder 5884001330
and lock nut wrench 5884021560 to remove the
lock nut (3).
8. Use the universal puller to remove the highlow

clutch hub and sleeve (6), and transfer input gear (7).
226RS070
226RW190
TRANSFER CASE
9. Remove needle bearing (8).
10. Remove bearing collar (9).
4D25
14. Use a pair of snap ring pliers to remove the bearing

snap ring (14).
15. Use a plastic hammer to tap the front output gear
assembly (15) free.
226RS071
11. Remove ball (10).

12. Remove plate (11).
13. Use a bench press and the ball bearing remover
5884000150 to remove the ball bearing (12) from
the input shaft (13). (A/T)
262RS009
16. Remove bearing snap ring (16).

17. Use a bench press and the bearing remover
5884000150 to remove the following parts.
18. Remove ball bearing (17), and bearing collar (18).
Remove subgear snap ring (19), spacer (20),
belleville spring (21), and subgear (antilash plate)
(22). (M/T)
Remove front output gear (23) and needle bearing
(24).
265RW013
262RW070
19. Remove inside ring (25).

20. Remove outside ring (26).
21. Remove block ring (27).
22. Use a bench press and bearing remover
5884000150 to remove 2WD4WD clutch hub
and sleeve assembly (28) and stopper plate (29).
NOTE: Do not reuse the stopper plate.
4D26
TRANSFER CASE
23. Disassemble the 2WD4WD clutch hub and sleeve

assembly (28).
D Springs (1)

D Inserts (2)
D Clutch Hub (3)
D Sleeve (4)
226RW208
226RW133

front output shaft (31).
31. Remove spacer (38).

32. Remove belleville spring (39).
33. Remove subgear (antilash plate) (40).
34. Remove counter gear (41).
35. Remove transfer case (with oil seal) (42), performing
the following steps (M/T)
D Cover the shaft splines with adhesive tape (43).
A07RW022
262RW071

26. Remove the counter gear assembly (33) from the
transfer case (42).
(34).
(36).
Legend
(43) Adhesive Tape
(44) Oil Seal Lip
(45) Oil Seal Collar
(46) Bearing
D Remove the transfer case together with
intermediate plate with gear assembly from the
transmission case (M/T).
TRANSFER CASE
D Remove the transfer case from the intermediate
plat with gear assembly (M/T).

1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.
4D27
3. If the measured value exceeds the specified limit, the

clutch hub must be replaced.
Clutch hub spline play
Standard : 00.1 mm (00.004 in)
Limit : 0.2 mm (0.008 in)
Gears
1. Inspect all the gear teeth for signs of excessive wear
or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.
Front Output Gear Inside Diameter
1. Use an inside dial indicator to measure the gear inside
diameter.
gear must be replaced.
Gear inside diameter
Standard : 48.00048.013 mm (1.88981.8903 in)
Limit : 48.10 mm (1.894 in)
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS040
Clutch Hub Spline Play

1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
226RS043
4D28
TRANSFER CASE
Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
D Teeth for wear, scuffs, nicks, burrs or breaks.
D Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
D If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.
Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
block ring and the insert must be replaced.
226RW142
Clutch Hub and Insert Clearance
Block ring and insert clearance

Standard : 2.462.74 mm (0.0970.108 in)
Limit : 3.0 mm (0.118 in)
1. Use a thickness gauge to measure the clearance

between the clutch hub and the insert.
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.010.19 mm (0.00040.0075 in)
Limit : 0.3 mm (0.012 in)
226RS037
2WD4WD Synchronizer (3Cone)

between the block ring and the dog teeth.
2WD4WD synchronizer assembly must be
replaced.
Limit : 0.8 mm (0.031 in)
226RS038
TRANSFER CASE
4D29
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Limit : 22.8 mm (0.898 in)
Interlock pin
Limit : 15.3 mm (0.602 in)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
the shift arm must be replaced.
Shift arm thickness
Standard : 9.609.85 mm (0.3780.388 in)
Limit : 9.0 mm (0.354 in)
220RW035
Detent Spring Tension

1. Use a spring tester to measure the detent spring
tension.
Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.688.2 N (7.09.0 kg /15.419.8 lb)
Interlock pin
Standard : 9.8 N (1.0 kg/2.2 lb)
230RS006
4D30
TRANSFER CASE
Reassembly
M/T
Input Shaft Oil Seal Replacement

2. Apply the engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
4. Use the oil seal installer 5884022790 (A/T)
5884021930
(M/T)
and
driver
handle
5884000070 to install the oil seal to the transfer
case.
A/T
220RW132
Legend
(48) Transmission Side Oil Seal
(49) Transfer Side Oil Seal
220RW130
Legend
(47) Oil Seal
TRANSFER CASE
Front Output Shaft Oil Seal Replacement

2. Apply engine oil to the oil seal outer surfaces.
oil seal to the transfer case.
4D31
1. Install the transfer case (with oil seal) (42), performing

the following steps. (M/T)
This will prevent damage to the oil seal lip (44).
A07RW022
Legend
(43) Adhesive Tape
(44) Oil Seal Lip
(46) Bearing
D Apply recommended liquid gasket (LOCTITE
17430) or its equivalent to the transmission,
intermediate plate and transfer case fitting surfaces
(M/T).
220RW131
Legend
(50) Front Output Shaft Oil Seal
220RS026
4D32
TRANSFER CASE
Install the transfer case together with intermediate plate

with gear assembly to transmission case (M/T).
Tighten the transfer case bolts to the specified torque a
little at a time (M/T).
Torque : 37 Nm (3.8 kgm/27 lb ft)
2. Apply chassis grease (51) to the subgear (40) and
the counter gear (41) thrust surfaces.
226RS170
226RW155
3. Install subgear (40) to counter gear (41).

4. Install belleville spring (39).
5. Install spacer.
6. Install ball bearing, using a bench press.
7. Select a snap ring that will allow the minimum axial
play.
Clearance : 00.1 mm (00.004 in)
Snap ring availability:
Thickness
Colorcoding
1.50 mm (0.059 in)
White
1.55 mm (0.061 in)
Yellow
1.60 mm (0.063 in)
Blue
226RS021
8. Use a pair of snap ring pliers to install the snap ring

(36) to the counter gear (41).
SubGear (antilash plate) Preload
1. Hook a length of piano wire (52) over one of the
subgear (53) teeth.
2. Attach the other end of the piano wire (52) to a
spring balancer.
3. Measure the subgear preload.
Preload : 5998 N (6.010 kg/1322 lb)
TRANSFER CASE
4D33
14. Assemble the 2WD4WD clutch hub and sleeve

assembly (28).
226RW156
9. Install ball bearing (35), using a bench press.

10. Install snap ring (34).
11. Install the counter gear assembly (33) to the transfer
case (42).
(32) to the transfer case (42).
226RW140
15. Engage the springs in the same insert with the open
ends away from each other.

transfer case snap ring groove.
13. Use a bench press to install the ball bearing (30) to the
226RW141
262RS012
4D34
TRANSFER CASE
16. Install a new stopper plate (29) and the clutch hub and
sleeve assembly (28) to the front output shaft (31).
226RW157
Legend
(54) Front Output Gear
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 (28) together with the stopper plate
(29) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (27) to the clutch sleeve and hub
assembly (28).
20. Install the outside ring (26), inside ring (25) and
needle bearing (24) to the front output gear (23) and
bearing collar (18).
21. Apply engine oil to the thrust surfaces of the

subgear, the belleville spring, and the spacer (M/T).
262RW014
22. Install subgear (antilash plate) (22), belleville

spring (21) and spacer (20). (M/T)
23. Install subgear snap ring (19). (M/T)
24. Use a bench press to install the needle bearing collar
together with the front output gear assembly, aligning
inside ring claw with block ring groove.
NOTE: Coat all parts with transmission oil before

installing them.
262RS014
226RW139
TRANSFER CASE
26. Select a snap ring (16) that will allow the minimum
axial play.
4D35
(16) to the output shaft (31).
Sub-gear (anti-lash plate) preload (M/T)
subgear (53) teeth.

Snap ring thickness
Color coding
2. Attach the other end of the piano wire to (52) a

spring balancer.
1.55 mm (0.061 in)
White
1.60 mm (0.063 in)
Yellow
Preload: 5998 N (6.010 kg/1322 lb)
1.65 mm (0.065 in)
Blue
1.70 mm (0.067 in)
Pink
1.75 mm (0.069 in)
Green
1.80 mm (0.071 in)
Brown
1.85 mm (0.073 in)
Red
1.90 mm (0.075 in)
Orange
226RW156
28. Install front output gear assembly (15) to transfer

case (42).
input shaft (13). (A/T)
262RS015
265RS003
226RS021
4D36
TRANSFER CASE
31. Install plate (11), ball (10) and bearing collar (9).
NOTE: Put the snap ring (4) in the ball bearing side. (A/T)
32. Install needle bearing (8) and input gear (7).
facing the transfer input gear side (55).
38. Use the punch to stake the lock nut (3) at one spot.
39. Use a suitable drift and hammer to install the ball
bearing (2).
226RS079

226RW158
34. Install highlow clutch hub and sleeve (6), using a

bench press.
35. Install input shaft assembly (5) to transfer case (42).
(A/T)
36. Install the snap ring (4) to the transfer case (42). (A/T)
37. Install the front companion flange temporarily and use
the flange holder 5884001330 and lock nut
wrench 5884021560 to install the lock nut (3).
226RW190
TRANSFER CASE
4D37

Type
Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Constant mesh type gears shifting between low and high.
Control method
Remote (A/T) and direct (M/T) control with the gear shift lever on the floor
for gears shifting between low and high.
Electric control with the button switch on the instrument panel for gears
shifting between the 2 and 4 wheel driver mode.
Gear ratio
High; 1.000
Low; 2.050
Oil capacity
1.45 lit. (1.53 U.S. quart)
Type of lubricant
Engine oil
Refer to chart in Section 0
E07RX012
4D38
TRANSFER CASE
E07RX021
TRANSFER CASE
4D39
E07RX011
4D40
TRANSFER CASE
Special Tools
ILLUSTRATION
PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME
5884000150
Bearing
remover/installer
5884022920
Rear oil seal installer
5884022790
Transfer case oil seal
installer
5884021921
Bearing installer adapter
5884021560
Mainshaft nut wrench
5884001330
Flange holder
5884021590
Rear output shaft and
bearing installer
5884021550
Mainshaft end bearing
remover
5884022930
Punch; end nut
5884020270
Puller
5884022810
Front output shaft oil
seal installer
5884000070
Driver handle
TRANSFER CASE
ILLUSTRATION
PART NO.
PART NAME
5884021930
installer
4D41
SECTION
BRAKE CONTROL SYSTEM
5A1
BRAKES
CONTENTS
Brake Control System....................................
Anti-lock Brake System..................................
Power-assisted Brake System.......................
Parking Brake System ...................................
5A - 1
5B - 1
5C - 1
5D - 1

CONTENTS
Functional Description ...............................
System Components .................................
Electronic Hydraulic Control Unit (EHCU) .
ABS Warning Light ....................................
Wheel Speed Sensor .................................
G-Sensor ...................................................
Normal and Anti-lock Braking ....................
Brake Pedal Travel ....................................
Acronyms and Abbreviations .....................
General Diagnosis .........................................
General Information ...................................
ABS Service Precautions ..........................
Computer System Service Precautions .....
General Service Precautions .....................
Note on Intermittents .................................
Test Driving ABS Complaint Vehicles .......
ABS" Warning Light ..................................
Normal Operation ......................................
Tech 2 Scan Tool ......................................
DATA LIST ................................................
ACTUATOR TEST .....................................
Tech 2 Service Bleed ................................
Basic Diagnostic Flow Chart ......................
Basic Inspection Procedure .......................
EHCU Connector Pin-out Checks..................
Circuit Diagram ..........................................
Connector List ...........................................
Part Location .............................................
Symptom Diagnosis.......................................
Chart A-1 ABS Works Frequently But
Vehicle Does Not Decelerate ...................
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate
(Use TECH 2) ..........................................
Chart A-2 Uneven Braking Occurs
While ABS Works ....................................
Chart TA-2 Uneven Braking Occurs
While ABS Works (Use TECH 2) .............
Chart A-3, TA-3 The Wheels Are Locked .
5A - 2
5A - 3
5A - 4
5A - 10
5A - 10
5A - 10
5A - 10
5A - 10
5A - 10
5A - 10
5A - 11
5A - 11
5A - 11
5A - 11
5A - 11
5A - 11
5A - 12
5A - 12
5A - 12
5A - 12
5A - 13
5A - 16
5A - 17
5A - 21
5A - 23
5A - 23
5A - 24
5A - 25
5A - 27
5A - 29
5A - 30
5A - 30
5A - 31
5A - 31
5A - 31
5A - 32
Chart A-4 Brake Pedal Feed Is Abnormal . 5A - 32

Chart A-5, TA-5 Braking Sound
(From EHCU) Is Heard While Not Braking 5A - 33
Diagnosis By ABS" Warning Light
Illumination Pattern ...................................... 5A - 36
Diagnostic Trouble Codes (DTCs) ............. 5A - 37
Chart B-1 With the key in the ON position
(Before starting the engine). Warning
light (W/L) is not activated. ....................... 5A - 39
Chart B-2 CPU Error (DTC 14 (Flash out) /
C0271, C0272, C0273, C0284 (Serial
communications)) ..................................... 5A - 39
Chart B-3 Low or High Ignition Voltage
(DTC 15 (Flash out) / C0277, 0278 (Serial
Chart B-4 Excessive Dump Time
(DTC 17 (Flash out) / C0269 (Serial
Chart B-5 Excessive Isolation Time
Chart B-6 G-Sensor Output Failure
Chart B-7 Brake Switch Failure
Chart B-8 2WD Controller in 4WD Vehicle
Controller (DTC 13 (Flash out) / C0285
(Serial communications)), 4WD State
Input Signal Failure (DTC 24 (Flash out) /
C0282 (Serial communications)) .............. 5A - 42
Chart B-9 Pump Motor Failure (DTC 32
(Flash out) / C0267, C0268 (Serial
Chart B-10 EHCU Valve Relay Failure
(DTC 35 (Flash out) / C0265, C0266 (Serial
Chart B-11 FL Isolation Solenoid Coil
Failure (DTC 41 (Flash out) / C0245,
C0247 (Serial
5A2
communications)) .................................... 5A - 43
Chart B-12 FL Dump Solenoid Coil
C0248 (Serial communications)) ............. 5A - 43
Chart B-13 FR Isolation Solenoid Coil
Failure (DTC 43 (Flash out) /
C0241, C0243 (Serial communications)) . 5A - 44
Chart B-14 FR Dump Solenoid Coil
Failure (DTC 44(Flash out) /
Chart B-15 Rear Isolation Solenoid
Coil Failure (DTC 45 (Flash out) / C0251,
Chart B-16 Rear Dump Solenoid Coil
Chart B-17 FL Speed Sensor Open or
Shorted (DTC 51 (Flash out) / C0225 (Serial
Chart B-18 FR Speed Sensor Open or
Chart B-19 Rear Speed Sensor Open or
Service Precaution
REPAIRS.
Chart B-20 FL Speed Sensor Missing

Chart B-21 FR Speed Sensor Missing
Chart B-22 Rear Speed Sensor Missing
communications))...................................... 5A - 50
Chart B-23 Simultaneous Drop-out of
Front Speed Sensor Signal (DTC 64
(Flash out) / C0229 (Serial
Chart B-24 Wheel Speed Input
Abnormality (DTC 65 (Flash out) /
Chart C-1-1 FL Sensor Output Inspection
Procedure ................................................ 5A - 53
Chart C-1-2 FR Sensor Output Inspection
Procedure ................................................ 5A - 54
Chart C-1-3 Rear Sensor Output Inspection
Procedure ................................................ 5A - 55
Chart TC-1 Sensor Output Inspection
Procedure ................................................ 5A - 55

and systems.
General Description
The Anti-lock Brake System (ABS) works on all four
wheels. A combination of wheel speed sensor and
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking.
5A3
This system helps the driver maintain greater control of

the vehicle under heavy braking conditions.
NOTE: The Electronic Hydraulic Control Unit (EHCU)
comprises the Hydraulic Unit (H/U) and the coil
Integrated Module.
C05RW004
Legend
(1)
(2)
(3)
(4)
Electronic
Hydraulic
Hydraulic Unit (H/U)
Coil Integrated Module
EndOFCallout
(5) Front Wheel Speed Sensor

(6) Rear Wheel Speed Sensor
(7) Proportioning and Bypass (P&B) Valve
5A4
Functional Description
Solenoid Valve
C05RW012
Legend
(1) Isolation Valve
EndOFCallout
(2) Dump valve

Normal Braking
During normal (non anti-lock) braking, the solenoid
valves are without current and closed due to spring
force.
5A5
Brake fluid travels through the centre of the normally

open isolation valve around the normally closed dump
valve and on to the brake pistons.
C05RW010
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder
5A6
Pressure Isolation (Pressure Maintain)

The electro-hydraulic control unit is activated when the
brakes are applied which sends a signal to the coil
integrated module to prepare for a possible anti-lock
stop.
If the information from the wheel speed sensors
indicates excessive wheel deceleration (imminent
lockup), the first step in the anti-lock sequence is to
isolate the brake pressure being applied by the brake
pedal.
The microprocessor in the coil integrated module sends
a voltage to the coil to energize and close the isolation
valve. This prevents any additional fluid pressure
applied by the brake pedal from reaching the wheel.
With the isolation valves closed, further unnecessary
increase in the brake pressure is therefore prevented.
C05RW011
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder

Pressure Reduction
Once the brake pressure is isolated, it must be reduced
to allow the wheels to unlock. This is accomplished by
dumping a portion of the brake fluid pressure into a low
pressure accumulator.
The microprocessor activates the normally closed dump
valve to open, allowing fluid from the wheels to be
dumped into the accumulator. This is done with very
short activation pulses opening and closing the dump
valve passageway. Brake pressure is reduced at the
5A7
wheel and allows the wheel to begin rotating again. The

fluid from the brake piston is stored in the accumulator
against spring pressure and a portion of this fluid also
primes the pump.
The dump valves are operated independently to control
the deceleration of the wheel. At this point, the brake
pedal is isolated from the base brake system, the
hydraulic control unit pumps are primed and the
attenuators are ready to pump fluid.
C05RW009
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder
5A8
Pressure Increase (Re-apply)

The re-apply sequence is initiated to achieve optimum
braking. The isolation valve is momentarily opened to
allow master cylinder and pump pressure to reach the
brakes. This controlled pressure rise continues until the
wheel is at optimum brake output or until the brake
pressure is brought up to the master cylinder output
pressure.
If more pressure is required, more fluid is drawn from
the master cylinder and applied to the brakes. The
driver may feel slight pedal pulsations, or pedal drop,

this is normal and expected.
As fluid is re-applied to the brakes, the wheel speed will
reduce. If the wheels approach imminent lockup again,
the module will isolate, dump and re-apply again. This
cycle occurs in millisecond intervals, allowing several
cycles to occur each second. It is a much faster and
more controlled way of pumping the pedal".
C05RW014
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder

Brake Release
At the end of the anti-lock stop, when the brake pedal is
released, the pump will remain running for a short time
to help drain any fluid from the accumulators. As this
fluid returns into the system, the spring forces the piston
5A9
back to its original position.

The isolation valve opens and fluid may return to the
master cylinder. Conventional braking is then resumed.
C05RW013
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder
5A10
System Components
Electronic Hydraulic Control Unit (EHCU), three Wheel
Speed Sensors, Warning Light, and G-sensor.
Electronic Hydraulic Control Unit (EHCU)

The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the hydraulic unit
according to the signal from each sensor, cancelling
ABS to return to normal braking when a malfunction has
occurred in the ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
right side. It consists of a Motor, Plunger Pump,
Solenoid Valves.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front disc brake or both rear disc
brakes according to the signal sent from the EHCU.
Reservoir: Temporarily holds the brake fluid that returns
from the front and rear disc brake caliper so that
pressure of front disc brake caliper can be reduced
smoothly.
Plunger Pump: Feeds the brake fluid held in the
reservoir to the master cylinder.
Motor: Drives the pump according to the signal from
EHCU.
Check Valve: Controls the brake fluid flow.
ABS Warning Light
seconds after the ignition switch is to the ON" position.

If the ABS" light stays ON" after the ignition switch is
the ON" position, or comes ON" and stays ON" while
driving, the Anti-lock Brake System should be inspected
for a malfunction according to the diagnosis procedure.
Wheel Speed Sensor

It consists of a sensor and a rotor. The sensor is
attached to the knuckle on the front wheels and to the
rear axle case on the rear differential.
The rotor is press-fit in the axle shaft.
The flux generated from electrodes magnetized by a
magnet in the sensor varies due to rotation of the rotor,
and the electromagnetic induction generates alternating
voltage in the coil. This voltage draws a sine curve"
with the frequency proportional to rotor speed and it
allows detection of wheel speed.
G-Sensor
The G-sensor installed inside the EHCU detects the
vehicle deceleration speed and sends a signal to the
EHCU. In 4WD operation, all four wheels may be
decelerated in almost the same phase, since all wheels
are connected mechanically.
This tendency is noticeable particularly on roads with
low friction coefficient, and the ABS control is adversely
affected.
The G-sensor judges whether the friction coefficient of
road surface is low or high, and changes the EHCU's
operating system to ensure ABS control.
Normal and Anti-lock Braking

Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power
assisted brake system. However, with the detection of
wheel lock-up, a slight bump or kick-back will be felt in
the brake pedal. This pedal bump" will be followed by a
series of short pedal pulsations which occurs in rapid
succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or popping
noise may be heard during brake applications when the
Anti-lock features is being used.
When the Anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on the
pedal will provide the shortest stopping distance.
825RX048
Vehicles equipped with the Anti-lock Brake System have

an amber ABS" warning light in the instrument panel.
The ABS" warning light will illuminate if a malfunction
in the Anti-lock Brake System is detected by the
Electronic Hydraulic Control Unit (EHCU). In case of
an electronic malfunction, the EHCU will turn ON" the
ABS" warning light and disable the Anti-lock braking
function.
The ABS" light will turn ON" for approximately three
Brake Pedal Travel

Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying
more force the pedal will continue to travel toward the
floor.
This extra brake pedal travel is normal.
5A11
Acronyms and Abbreviations
ABS Service Precautions
Several acronyms and abbreviations are commonly

used throughout this section:
Required Tools and Items:

Box Wrench
Brake Fluid
Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
ABS
Anti-lock Brake System
CIM
CKT
Circuit
DLC
Data Link Connector
EHCU
Electronic Hydraulic Control Unit
FL
Front Left
FR
Front Right
GEN
Generator
H/U
Hydraulic Unit
MV
Millivolts
RR
Rear
RPS
Revolution per Second
VDC
DC Volts
VAC
AC Volts
W/L
Warning Light
WSS
Wheel Speed Sensor
General Diagnosis
General Information
ABS troubles can be classified into two types, those
which can be detected by the ABS warning light and
those which can be detected as a vehicle abnormality
by the driver.
In either case, locate the fault in accordance with the
BASIC DIAGNOSTIC FLOWCHART" and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
5-8840-0366-0 High Impedance Multimeter

When circuit measurements are requested, use a circuit
tester with high impedance.
Computer System Service Precautions

The Anti-lock Brake System interfaces directly with the
Electronic Hydraulic Control Unit (EHCU) which is a
control computer that is similar in some regards to the
Powertrain Control Module. These modules are
designed to withstand normal current draws associated
with vehicle operation. However, care must be taken to
avoid overloading any of the EHCU circuits. In testing for
opens or shorts, do not ground or apply voltage to any
of the circuits unless instructed to do so by the
appropriate diagnostic procedure. These circuits should
only be tested with a high impedance multimeter
5-8840-0366-0 or special tools as described in this
section. Power should never be removed or applied to
any control module with the ignition in the ON" position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the OFF"
position.
General Service Precautions

The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock Brake
System damage.
If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU and valve
block connectors should be disconnected before the
welding operation begins.
The EHCU and valve block connectors should never
be connected or disconnected with the ignition ON" .
If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the ABS" warning light will
illuminate. But actually no trouble exists. After
inspection stop the engine once and re-start it, then
make sure that the ABS" warning light does not
illuminate.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS to a
5A12
non-operative state by removing the fuse for the ABS

(60A). After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning light does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case duplicating
the system malfunction during a test drive or a good
description of vehicle behavior from the customer may
be helpful in locating a most likely" failed component or
circuit. The symptom diagnosis chart may also be useful
in isolating the failure. Most intermittent problems are
caused by faulty electrical connections or wiring. When
an intermittent failure is encountered, check suspect
circuits for:
Suspected harness damage.
Poor mating of connector halves or terminals not fully
seated in the connector body (backed out).
Improperly formed or damaged terminals.
Test Driving ABS Complaint Vehicles

In case that there has been an abnormality in the
lighting pattern of ABS" warning light, the fault can be
located in accordance with the DIAGNOSIS BY ABS"
WARNING LIGHT ILLUMINATION PATTERN" . In case
of such trouble as can be detected by the driver as a
vehicle symptom, however, it is necessary to give a test
drive following the test procedure mentioned below,
thereby reproducing the symptom for trouble diagnosis
on a symptom basis:
1. Start the engine and make sure that the ABS" W/L
goes OFF. If the W/L remains ON, it means that the
Diagnostic Trouble Code (DTC) is stored.
Therefore, read the code and locate the fault.
NOTE: The DTC cannot be cleared if the vehicle speed
does not exceed 12 km/h (8 mph) at DTC, even though
the repair operation is completed.
2. Start the vehicle and accelerate to about 30 km/h
(19 mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop
the vehicle.
6. Be cautious of abnormality during the test. If the W/
L is actuated while driving, read the DTC and locate
the fault.
7. If the abnormality is not reproduced by the test,
make best efforts to reproduce the situation
reported by the customer.
8. If the abnormality has been detected, repair in
accordance with the SYMPTOM DIAGNOSIS" .
NOTE:
Be sure to give a test drive on a wide, even road with
a small traffic.
If an abnormality is detected, be sure to suspend the
test and start trouble diagnosis at once.
ABS" Warning Light

When ABS trouble occurs to actuate ABS" warning
light, the trouble code corresponding to the trouble is
stored in the EHCU. Only ordinary brake is available
with ABS being unactuated. Even when ABS" warning
light is actuated, if the starter switch is set ON after
setting it OFF once, the EHCU checks up on the entire
system and, if there is no abnormality, judges ABS to
work currently and the warning light is lit normally even
though the trouble code is stored.
NOTE: Illumination of the ABS" warning light indicates
that anti-lock braking is no longer available. Power
assisted braking without anti-lock control is still
available.
Normal Operation
ABS" Warning Light
When the ignition is first moved from OFF" to RUN" ,
the amber ABS" warning light will turn ON" . The
ABS" warning light will turn ON" during engine
starting and will usually stay ON" for approximately
three seconds after the ignition switch is returned to the
ON" position. The warning light should remain OFF" at
all other times.

Tech 2 Scan Tool
5A13
scan tool user guide.
From 98 MY, Isuzu dealer service departments are

recommended to use Tech 2. Please refer to Tech 2
901RW257
Legend
(1) PCMCIA Card
(2) SAE 16/19 Adaptor
(3) DLC Cable
EndOFCallout
(4) Tech2
5A14
Getting Started
Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The Isuzu 98 System PCMCIA card inserts into the
Tech 2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech 2.
4. Mark sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC (1).
Operating Procedure
The power up screen is displayed when you power up
the tester with the Isuzu systems PCMCIA card. Follow
the operating procedure below.
740RW165
6. The vehicle ignition turns on.

7. Power up the Tech 2.
8. Verify the Tech 2 power up display.
060RX065
060RW009
060RX063
5A15
5A16
DATA LIST
The data displayed by DATA LIST are as follows:
Display
Content
OK/NG Criteria for Data
Front Left Wheel Speed

Front Right Wheel Speed
Rear Wheel Speeds
km/h (MPH)
Start the vehicle and make sure of linear change in each

wheel speed.
Turn each wheel by hand and make sure that each
speed data change.
Warning Lamp
ON/OFF
To be OFF usually
ABS State
ON/OFF
To be OFF usually
ABS Relay
Active/Inactive
To be Active usually
4 Wheel Drive
Active/Inactive
2WD: Inactive
4WD: Active
Brake Switch
Active/Inactive
Inactive (Released)
Active (Pressed)
Brake Fluid Level
Normal or not
To be Normal usually
Return Pump
Active/Inactive
To be Inactive usually
DRP (Dynamic Rear

Proportioning)
Active/Inactive
Rear Dump Valve Commanded
Active/Inactive
Active/Inactive
Active/Inactive
GSensor
Voltage
0.00V when vehicle is stopped
Battery Voltage
Voltage
Between 1016.9V
Rear Dump Valve Feedback

Rear Isolation Valve
Commanded
Rear Isolation Valve Feedback
FL Dump Valve Commanded
FL Dump Valve Feedback
FL Isolation Valve Commanded
FL Isolation Valve Feedback
FR Dump Valve Commanded
FR Dump Valve Feedback
FR Isolation Valve Commanded
FR Isolation Valve Feedback

ACTUATOR TEST
This mode is used to exercise the ABS actuators and
make sure they operate normally. Prior to the test, pay
attention to the cautions below. (When checking the
solenoid valve system, be sure to jack up the vehicle.)
CAUTION:
Before testing, be sure that the brakes work
normally.
Make sure that the battery is fully charged.
5A17
Conduct the test by two persons (A TECH 2

operator and a vehicle checker).
Be sure to start ACTUATOR TEST with the engine
stopped.
Before testing, make sure that electrical trouble,
if any, has been completely repaired. Conducting
tests of ABS solenoid with electrical circuit
problem remaining uncorrected could damage
the control unit.
F05RX001
5A18
F05RX002
5A19
F05RX003
5A20
F05RX004
5A21
Tech 2 Service Bleed
F05RX005
5A22
F05RX006
5A23
Basic Diagnostic Flow Chart

Step
1
Action
1. Customer complaint.
2. Questioning to customer.
3. Basic inspection (Refer to Basic inspection procedure")
Using TECH 2?
Make sure of DTC by mode F0: Diagnostic Trouble Codes".
Is EHCU including DTC?
1. Repair of faulty part.

2. Elimination of DTC.
3. Inspection of ABS" W/L Illumination pattern with ignition SW
ON".
4. Test drive.
Does trouble repeat?
Yes
No
Go to Step 2
Go to Step 4
Clear code and

check for
repeatability.
Go to Step 3
Go to Step 5
Repeat the
diagnosis it the
symptom or
DTC appears
again
Go to Step 1
Go to Step 5
Clear code and

check for
repeatability
Go to Step 3
Trouble
diagnosis
based on
symptom (Refer
to SYMPTOM
DIAGNOSIS")
Go to Step 3
Check if the DTC is stored or not.

1. Reconnect all components. Ensure all component are

properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Finished
Go to Step 5
Yes
No
Basic Inspection Procedure

1. Basic Inspection of Service Brake
Step
Action
1
Is the fluid level normal?

Go to Step 2
2
3
4
5
Does fluid leak?
Repair
Go to Step 3
Is the booster function normal?
Go to Step 3
Go to Step 4
Repair
Go to Step 4
Go to Step 5
Repair
Go to Step 5
Is the pad and rotor normal?

Reconnect all components. Ensure all component are properly
mounted.
Replenish with
fluid
Go to Step 2
Finished
Go to Step 5
Yes
No
2. Ground Inspection
Step
1
Action
Does ABSrelated ground points normally?
Go to Step 2
2

mounted.
Finished
Repair
Go to Step 2
Go to Step 2
5A24
EHCU Connector Pin-out Checks
Perform checks with high impedance digital

multimeter 5-8840-0366-0 or equivalent.
Disconnect Electronic Hydraulic Control Module.

No.
Circuit to be Tested
Ignition
Switch
Position
Multimeter
Scale/Range
Measure
between Pin
Number
Nominal Value
Power supply
OFF
20DCV
1 (C5)
2 (C5)
Ignition enable
OFF
20DCV
1 (C4)
7 (C4)
0V to 0.1V
ON
20DCV
1 (C4)
7 (C4)
11.5V to 14.5V
Note
11.5V to 14.5V
Stoplight switch
OFF
20DCV
13 (C4)
7 (C4)
10.5V to 14.5V
Ground connection
OFF
200
7 (C4)
Ground
Less than 2
OFF
2 (C5)
Ground
Less than 0.2
OFF
2k
2 (C4)
10 (C4)
2.0k to 2.8k
OFF
200k
2 (C4)
7 (C4)
more than
100k
Insulation Resistance
OFF
200mACV
2 (C4)
10 (C4)
more than
200mV
Turn wheel at 1RPS
OFF
2k
3 (C4)
11 (C4)
2.0k to 2.8k
Internal Resistance
OFF
200k
3 (C4)
7 (C4)
more than
100k
OFF
200mACV
3 (C4)
11 (C4)
more than
200mV
Turn wheel at 1RPS
OFF
2k
4 (C4)
12 (C4)
1.2k to 2.0k
Internal Resistance
OFF
200k
4 (C4)
7 (C4)
more than
100k
OFF
200mACV
4 (C4)
12 (C4)
more than
200mV
Turn wheel at 1RPS
FL speed sensor
FR speed sensor
RR speed sensor
Press brake pedal
Internal Resistance
5A25
Circuit Diagram
D08RX216
5A26
D08RX215

Connector List
No.
Connector face
No.
B-19
F-4
B-23
H-5
C-4
H-15
H-25
C-5
H-14
C-6
H-19
C-13
C-33
H-26
C-16
C-36
E-28
E-30
I-1
C-34
I-2
Connector face
5A27
5A28
No.
I-18

Connector face
No.
Connector face
5A29
Part Location
D08RX217
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
C36
C5
C4
H14, H19
Relay & Fuse Box
I1
I2
B23
B19
F4
H26
H15
EndOFCallout
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
H25
C16
C13
H5
E30 (6VD1)
E28 (X22SE)
I18
C34
C6
C33
5A30
Symptom Diagnosis
The symptoms that cannot be indicated by warning light
can be divided in the following five categories:
1. ABS works frequently but vehicle does not
decelerate.
2. Uneven braking occurs while ABS works.
3. The wheels lock during braking.
No.
4. Brake pedal feel is abnormal.

5. Braking sound (from EHCU) is heard while not
braking.
These are all attributable to problems which cannot be
detected by EHCU self-diagnosis. Use the customer
complaint and a test to determine which symptom is
present. Then follow the appropriate flow chart listed
below.
Symptom
Diagnostic Flow Charts

Without TECH 2
With TECH 2
ABS works frequently but vehicle does not decelerate.
Chart A-1
Chart TA-1
Uneven braking occurs while ABS works.
Chart A-2
Chart TA-2
The wheels are locked.
Chart A-3
Chart TA-3
Brake pedal feel is abnormal.
Chart A-4
Braking sound (from EHCU) is heard while not braking.
Chart A-5
Chart TA-5
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate
Step
1
Action
Yes
Is braking force distribution normal between front and rear of

vehicle?
Go to Step 2
Repair brake
parts.
Go to Step 8
Go to Step 3
Repair axle
parts.
Go to Step 8
Are axle parts installed normally?
Is there play in each or any wheel speed sensor?
Is there damage, or powered iron sticking to each or any wheel

speed sensor/sensor ring?
Repair wheel
speed sensor.
Go to Step 8
Go to Step 4
Replace sensor
or sensor ring.
Go to Step 8
Go to Step 5
Go to Step 6
Replace wheel
speed sensor or
repair harness.
Go to Step 7
Go to Step 7
Replace
controller or
repair harness.
Go to Step 7
Is the output of each wheel speed sensor normal? (Refer to chart

C-1 or TC-1)
Is the input of 4WD controller normal?
Reconnect all components, ensure all components are properly

mounted.
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 7
5A31
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step
1
2
3
Action
Yes
No
1. Connect TECH 2.
2. Make sure of the output conditions of each sensor.
Is the output of each sensor normal?
Go to Step 2
Replace wheel
speed sensor.
Go to Step 3
Return to Chart A-1.

Was the Chart A-1 finished?
Go to Step 3
Go to Step 2
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Yes
No

mounted.
Chart A-2 Uneven Braking Occurs While ABS Works

Step
1
2
3
Action
Is there play in each or any sensor?
Damage or powdered iron sticking to each or any sensor/sensor
ring?
Repair.
Go to Step 5
Go to Step 2
Repair.
Go to Step 5
Go to Step 3
Is the output of each sensor normal? (Refer to chart C-1 or TC-1)
Go to Step 4
4
Is brake pipe connecting order correct?

Replace H/U.
Go to Step 5

mounted.
Repeat the Basic

diagnostic flow
chart"
Replace sensor
or repair
harness.
Go to Step 5
Reconnect
brake pipe
correctly.
Go to Step 5
Go to Step 5
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)
Step
Yes
No
1. Connect TECH 2.
Go to Step 2
Go to Step 3
Check piping by TECH 2 ACTUATOR TEST

Is the piping normal?
Replace EHCU.
Go to Step 4
Repair the pipe.

Go to Step 4
Repair and check the wheel speed sensor (Refer to chart B-20 to
B-23 , C-1 or TC-1).
Was the each chart finished?
Go to Step 4
Go to Step 3

mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 4
Action
5A32
Chart A-3, TA-3 The Wheels Are Locked

Step
Action
Is ABS working?
Is vehicle speed under 10 km/h (6mph)?
Is sensor output normal? (Chart C-1 or TC-1)
Yes
No
Go to Step 2
Go to Step 6
Normal.
Go to Step 3
Go to Step 4
Replace sensor
or repair
harness.
Go to Step 6
Go to Step 5
Replace 4WD
controller or
repair harness.
Go to Step 6
Is front 4WD controller normal?
Is hydraulic unit grounded properly?

mounted.
Replace EHCU.
Go to Step 6
Correct.
Go to Step 6
Repeat the Basic

diagnostic flow
chart"
Go to Step 6
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Harness NG
between brake
SW and EHCU.
Go to Step 6
Go to Step 5
Replace stop
light fuse.
Go to Step 6
Go to Step 6
Repair body
grounded
harness.
Go to Step 6
Chart A-4 Brake Pedal Feed Is Abnormal

Step
Action
Is the stop light actuated when the brake pedal is depressed?
1. Turn the ignition switch off.

2. Disconnected EHCU connector.
Is the check voltage EHCU connector terminals 13 to 7 when
brake pedal is depressed than battery voltage?
Is stop light fuse normal?
Is the check continuity between EHCU connector terminals, 7 to

body grounded?
Is brake SW normal?

mounted.
Repair stop
light harness.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Replace brake
SW.
Go to Step 6
Go to Step 6
5A33
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
Step
1
4
5
6
Action
Is this the first vehicle start after engine start?
Is vehicle speed under 10 km/h (6 mph)?
Check for the following condition:

At the time of shift down or clutch operation.
At the time of low road friction drive (ice or snow road) or rough
road drive.
At the time of high-speed turn.
At the time of passing curb.
At the time of operating electrical equipment switches.
At the time of racing the engine (over 5000 rpm).
Did it occur under any one condition above?
Is there play in each or any sensor/wheel speed sensor rings?
Damage or powdered iron sticking to each or any sensor/wheel
speed sensor ring?
Is each sensor output normal? (Refer to chart C-1 or TC-1).

mounted.
Yes
No
It is self
checking sound
Normal.
Go to Step 2
It is self
checking sound
Normal.
Go to Step 3
ABS may
sometime be
actuated even
when brake pedal
is not applied.
Go to Step 4
Repair.
Go to Step 7
Go to Step 5
Repair.
Go to Step 7
Go to Step 6
Check harness/
connector for
suspected
disconnection
If no
disconnection is
found, replace
Coil integrated
module.
Go to Step 7
Repeat the Basic
diagnostic flow
chart"
Repair.
Go to Step 7
Go to Step 7
5A34
Diagnostic Trouble Codes

Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
Flash out
Serial
Communications
Diagnosis
Item
Chart
No.
12
13
C0285
2 WD Controller in 4WD Vehicle Controller
Wiring
B-8
14
C0271
RAM read/write error
C0272
ROM checksum error
C0270
ALU function error
B-2
C0273
Inoperative isolation item
Coil
Integrated
Module
C0284
Loop time overrun
C0277
Low ignition voltage
C0278
High ignition voltage
Wiring
B-3
C0269
Excessive dump time
15
17
18
C0274
Excessive isolation time
21
C0276
G-Sensor Failure
22
C0281
Brake switch Failure
24
C0282
Open or shorted 44 input signal
32
C0267
Open motor circuit or shorted ECU output
C0268
Stalled motor or open ECU output
C0265
Open relay circuit
C0266
Shorted relay circuit
C0245
FL Open isolation solenoid or shorted ECU output
C0247
FL Shorted isolation solenoid or open ECU output
C0246
FL Open dump solenoid or shorted ECU output
C0248
FL Shorted dump solenoid or open ECU output
C0241
FR Open isolation solenoid or shorted ECU output
C0243
FR Shorted isolation solenoid or open ECU output
C0242
FR Open dump solenoid or shorted ECU output
C0244
FR Shorted dump solenoid or open ECU output
C0251
Rear Open isolation solenoid or shorted ECU output
C0253
Rear Shorted isolation solenoid or open ECU output
C0252
Rear Open dump solenoid or shorted ECU output
C0254
Rear Shorted dump solenoid or open ECU output
35
41
42
43
44
45
46
B-4
Coil
Integrated
Module
B-5
B-6
B-7
Wiring
B-8
Motor
B-9
Relay
B-10
B-11
B-12
B-13
Solenoid
B-14
B-15
B-16

Code
Diagnosis
Item
5A35
Chart
No.
Flash out
Serial
Communications
51
C0225
FL Open or shorted sensor
B-17
52
C0221
FR Open or shorted sensor
B-18
53
C0235
Rear Open or shorted sensor
B-19
61
C0226
FL Missing sensor signal
C0227
FL Sensor signal dropout
C0222
FR Missing sensor signal
C0223
FR Sensor signal dropout
C0236
Rear Missing sensor signal
C0237
Rear Sensor signal dropout
64
C0229
Simultaneous dropout of front sensor signal
65
C0238
Wheel speed error
C0286
Shorted indicator lamp
62
63
B-20
Sensor or
Wiring
B-21
B-22
B-23
Vehicle or
Sensor
B-24
Wiring
5A36

Illumination Pattern
In the event that there is abnormality in the ABS"
No.
Condition
warning light illumination pattern while the key is in the

ON position or if the warning light is actuated during
driving, trouble should be diagnosed on a illumination
pattern basis as follows:
ABS" Warning Light Illumination Pattern
Diagnostic
Warning light is
actuated normally
Normal
Warning light is not lit
Warning light lighting circuit

troubleGo to Chart B-1
Warning light remains

ON
Diagnostic trouble codes are

stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to
the flow charts.
Warning light is
actuated while driving

stored.
the flow charts.
Warning light goes at

12 km/h (8 mph) or
higher (After repairing
the faulty part)
Even after repairing the faulty

part the warning light (W/L)
dose not go out it vehicle is
at a stop.
Turn the ignition switch to the
ON position and drive the
vehicle at 12 km/h (8 mph)
or higher to make sure that
the warning light goes out.

Diagnostic Trouble Codes (DTCs)
When the warning light in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.
How to display and erase DTCs:
NOTE:
DTCs can be displayed also by TECH 2. Use
Diagnostic Trouble Codes" mode.
The DLC is located behind the driver side kick panel
5A37
1. How to start DTC display:

Confirm that the vehicle has come to a complete
stop (with the wheels standing still) and that the
brake pedal is not depressed. (Unless these two
condition are satisfied, DTC display cannot be
started.)
With IGN OFF, connect #12 terminal with #4
terminal or # 5 terminal (GND) . Then turn IGN
ON.
350RX008
Keep #12 terminal connected with #4 terminal or

# 5 terminal (GND) during DTC display. (If #12
terminal is separated from #4 terminal or # 5
terminal (GND) during display, display will stop.)
2. DTC display:
DTC is displayed by blinking warning light.
Double-digit display.
First, normal DTC 12 is displayed three times and
then any other DTCs are displayed three times.
(If no other DTCs have been stored, the display of
DTC 12 will be repeated.)

3. How to erase code:
Conduct brake switch ON/OFF operation 6 or
more times within 3 seconds of self-diagnosis
startup.
The code cannot be erased if more than 3
seconds have passed since self-diagnosis
startup, or if self-diagnosis has started with brake
switched on (brake pedaled).
B05RW005
5A38
4. Notes
If the following should occurs during Diagnostic
Trouble Code (DTC) display the display will be
discontinued. After initial check, the status that is
under the control of ABS will be returned :
The vehicle starts (The wheels turn) or the
brake pedal is depressed.
Up to 3 different codes can be stored.

If the ABS should turn OFF due to an intermittent
defect, the system will be restored at the next key
cycle, if the initial check finds no abnormality
(when IGN is switched from OFF to ON).
5. An example of DTC display
Display of DTC 23
B05RW006
After displaying DTC 12 three times, one DTC after

another is displayed, starting with the most recent
one. (However, display is discontinued after about 5
minutes.)
B05RS005
The DTC 12 is displayed repeatedly. (display is

discontinued after about 5 minutes after)
5A39
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L)
is not activated.
Step
1
2
Action
Is W/L fuse disconnected?
Is W/L burnt out?
1. Turn the key off.

2. Disconnect coil integrated module connector (C-4).
3. Turn the key ON.
Is the check voltage between coil integrated module connector
(C-4) terminals 6 and 7 than battery voltage?
Is the check continuity coil integrated module connector (C-4)
terminals, 1 and 7 and body ground.

mounted.
Yes
No
Replace fuse.
Go to Step 5
Go to Step 2
Replace W/L
bulb.
Go to Step 5
Go to Step 3
Go to Step 4
Repair harness
and connector.
Go to Step 5
Check harness
for suspected
disconnection
No fault found:
Replace EHCU.
Go to Step 5
Repair harness
and connector.
Go to Step 5
Repeat the Basic

diagnostic flow
chart"
Go to Step 5
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial
communications))
Step
1
Action
Yes
No

2. Disconnected coil integrated module connector.
3. Inspect coil integrated module ground.
Is the check resistance between the coil integrated module
connector terminals, 2 (C-5) and 7 (C-4) and body ground?
Go to Step 2
1. Turn the key off, connect the coil integrated module

connector.
2. Erase the trouble code.
3. Turn Ignition off, then on, to perform system self-check.
4. If warning light remains on, display trouble codes once again.
Is the check trouble code 14 (Flash out) / C0271, C0272, C0273,
C0284 (Serial communications)?
Inspect in
Replace EHCU.
accordance with
Go to Step 3
the DTC displayed.
1. Reconnect all components, ensure all components are

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Repair the body

ground
harness.
Go to Step 3
Go to Step 3
5A40
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial
communications))
Step
1
Action
Yes
Is the check battery voltage normal? (Battery capacity check)

2. Disconnect coil integrated module connector.
3. Turn the key on.
(C-4) terminals 1 and 7, higher than 10V?

properly mounted.
No
Go to Step 2
Charge or
replace battery.
Go to Step 2
Check harness
connector for
suspected
disconnection
Fault found:
Repair, and
perform system
self-check
No fault found:
replace EHCU.
Go to Step 3
Repair harness
or connector.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))
Step
1
Action
Yes
No
Check for anything causing extended ABS activation, such as

locked brakes or an erratic speed sensor signal.
Was a problem found?
Repair or Replace
Go to Step 2
1. The key turned off.

2. Replace EHCU.
properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 2
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))
Step
1
Action
Yes

Repair or Replace

2. Replace EHCU.
properly mounted.
Repeat the Basic

diagnostic flow
chart"
No
Go to Step 2
Go to Step 2
5A41
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))
Step
1
Action
2. Replace EHCU.
properly mounted.
Yes
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 1
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))
Step
Action

Is the check voltage coil integrated module connector (C-4)
terminals 13 to 7 when brake pedal is depressed than battery
voltage?
4
5
Is the check that pins C-5 connector 2, and C-4 connector 7 have
good ground?
Yes
No
Go to Step 2
Go to Step 4
Go to Step 3
Harness
between brake
SW and coil
integrated
module is faulty.
Go to Step 6
Check harness
/ connector for
disconnection
Fault found:
Repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repair.
Go to Step 6
Go to Step 5
Replace.
Go to Step 6
Abnormal
harness in stop
light circuit.
Repair the
harness.
Go to Step 6
Replace.
Go to Step 6

Is brake SW normal?

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 6
5A42
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial
communications)), 4WD State Input Signal Failure (DTC 24 (Flash out) / C0282 (Serial
communications))
Step
1
Action
Remove coil integrated module connector.
Is the coil integrated module connector (C-4) terminal 8 line
normally?
Yes
Go to Step 2
Repair.
Go to Step 3
Replace EHCU.
Go to Step 3
Replace 4WD
controller.
Go to Step 3
Is the 4WD controller normally?

properly mounted.
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))
Step
Action

3. Measure the voltage between terminal 1 of the coil integrated
module connector (C-5) and body ground.
Is the voltage equal to the battery voltage?
Yes
Go to Step 2
Repair fuse/
harness
between battery
and coil
integrated
module
connector (C-5)
terminal 1.
Go to Step 5
Go to Step 3
Connect to the
connector.
Go to Step 3
Go to Step 4
Replace EHCU.
Go to Step 5
Replace EHCU.
Go to Step 5
Replace EHCU.
Go to Step 5
Is the harness from the hydraulic unit connected to the coil

integrated module connector?
Is the harness from the hydraulic unit normally?
Is the check resistance of hydraulic unit connector terminals 1

and 2 between 0.2 and 1.0 ohms?

properly mounted.
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 5
5A43
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial
communications))
Step
Action

Yes
Replace EHCU.
Go to Step 2
2

properly mounted.
Repeat the Basic

diagnostic flow
chart"
No
Repair fuse and
harness coil
integrated
module
connector (C-5)
terminal 1 and
battery.
Go to Step 2
Go to Step 2
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."
1. Turn the key switch to off.

2. Disconnect the 2way EHCU connector (C5) from the
EHCU.
3. Inspect the connector for damage or corrosion.
Is the connector free from damage or corrosion?
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."
1. Replace the Coil Integrated Module.

2. Reconnect all component, ensure all components are
properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Was the EHCU Connector Pinout Checks" performed?
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A44
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A45
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial
communications))
Step
1
Action
3. Measure the resistance between coil integrated module
connector (C-4) terminals 2 and 10.
Is the resistance between 2.0k and 2.8k ohms?
Measure the FL speed sensor resistance at the sensor

connector.

properly mounted.
Yes
No
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace coil
integrated
module.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A46
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial
communications))
Step
1
Action
Measure the FR speed sensor resistance at the sensor

connector.

properly mounted.
Yes
No
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace coil
integrated
module.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A47
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial
communications))
Step
1
Action
Measure the Rear speed sensor resistance at the sensor

connector.

properly mounted.
Yes
No
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A48
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial
communications))
Step
1
2
3
4
5
Action
3. Measure the FL speed sensor resistance between coil
integrated module connector (C-4) terminals 2 and 10.
Is there play sensor/sensor rotor?
connector.
Damage and powered iron sticking to sensor/sensor ring?

Is sensor output normal? (Chart C-1-1 or TC-1)

properly mounted.
NOTE: Even after repairing the faulty part the warning

light (W/L) does not go out if the vehicle is at a stop.
Turn the ignition switch to the ON position and drive the
vehicle at 12 km/h (8 mph) or higher to make sure that
Yes
No
Go to Step 2
Go to Step 3
Repair.
Go to Step 6
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 6
Repair.
Go to Step 6
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Go to Step 4
Replace sensor.
Go to Step 6
Go to Step 5
Replace sensor.
Go to Step 6
Go to Step 6
5A49
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial
communications))
Step
1
2
3
4
5
Action
3. Measure the FR speed sensor resistance between coil
connector.


properly mounted.

Yes
No
Go to Step 2
Go to Step 3
Repair.
Go to Step 6
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 6
Repair.
Go to Step 6
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Go to Step 4
Replace sensor.
Go to Step 6
Go to Step 5
Replace sensor.
Go to Step 6
Go to Step 6
5A50
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial
communications))
Step
1
2
3
4
5
Action
3. Measure the Rear speed sensor resistance between coil
Measure the rear speed sensor resistance at the sensor
connector.


properly mounted.

Yes
No
Go to Step 2
Go to Step 3
Repair.
Go to Step 6
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 6
Repair.
Go to Step 6
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Go to Step 4
Replace sensor.
Go to Step 6
Go to Step 5
Replace sensor.
Go to Step 6
Go to Step 6
5A51
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) /
C0229 (Serial communications))
Step
1
5
6
7
Action
Yes
No

Go to Step 2
Go to Step 3
Measure the FR speed sensor resistance between coil integrated

module connector (C-4) terminals 3 and 11.
Is the resistance between 2.0k and 2.8 k ohms?
Go to Step 5
Go to Step 4
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 2
Replace sensor.
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 5
Replace sensor.
Go to Step 5

connector.

connector.

Is sensor output normal? (Chart C-1-1&C-1-2 or TC-1)

properly mounted.

Repair.
Go to Step 6
Go to Step 6
Repair.
Go to Step 7
Go to Step 7
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 8
Repeat Basic
diagnostic flow
chart"
Replace sensor.
Go to Step 8
Go to Step 8
5A52
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial
communications))
Step
Action
Using TECH 2?
1. Connect TECH 2.
2. Select Snap shot manual trigger.
3. With wheel speed data displayed, run the vehicle when
speed has arrived at 30 km/h (18 mph).
4. Check speed data on each wheel (refer to the criterion given
below). * 1
Is the abnormal sensor condition found?
3
4
5
6
7
Is there play in sensor/sensor ring?

Is there powdered iron sticking to sensor/sensor ring?
Is there a broken tooth or indentation in sensor ring?
Is there play in wheel bearing?
Yes
No
Go to Step 2
Go to Step 3
Replace.
Go to Step 8
Go to Step 3
All the sensors
should follow
the following
flowchart
(without using
TECH 2).
Repair.
Go to Step 8
Go to Step 4
Repair.
Go to Step 8
Go to Step 5
Replace sensor
ring.
Go to Step 8
Go to Step 6
Adjust or repair.
Go to Step 8
Go to Step 7
Replace EHCU.
Go to Step 8
Repair, and
perform system
self-check.
Go to Step 8
Is the check wiring between sensor and coil integrated module

normal?

properly mounted.
Sensor Signal Abnormality Criteria using TECH 2

1. While driving, the speed of one or two wheels is
25% or more higher or lower than that of the other
wheels.
2. The speed of one or two wheels is 10 km/h (6 mph)
or more higher or lower than that of the other
wheels.
3. During steady driving, wheel speed changes
abruptly.
*1 The vehicle must run on a level paved road.
It is important to verify that the correct tires are installed
on vehicle.
Repeat
<FmSdata>[rsquor
]Basic diagnostic
flow chart"
Go to Step 8
5A53
Unit Inspection Procedure

This section describes the following inspection
procedures referred to during SYMPTOM DIAGNOSIS"
and DIAGNOSIS BY ABS' WARNING LIGHT
ILLUMINATION PATTERN" :
Sensor Output Inspection
without TECH 2
with TECH 2
Chart C-1-1 to C-1-3
Chart TC-1
Chart C-1-1 FL Sensor Output Inspection Procedure

Step
1
Action
3. Jack up the vehicle with all four wheels off the ground.
Measure the AC voltage between coil integrated module
connector terminals while turning FL wheel at a speed of 1
RPS:
Is the check between coil integrated module connector (C-4)
terminals 2 and 10 than under 200 mV?
1. Disconnect the wheel speed sensor.
2. Measure resistance between the wheel speed sensor
connector terminals 1 and 2.
Is the check between connector (C-13) terminals 1 and 2 within
2.0k - 2.8k ohms?

mounted.
Yes
Go to Step 2
Connector is
faulty, or open
or short circuit
of harness
between wheel
speed sensor
connector and
coil integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
Repeat the Basic
diagnostic flow
chart"
No
OK.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Go to Step 3
5A54
Chart C-1-2 FR Sensor Output Inspection Procedure

Step
1
Action
connector terminals while turning FR wheel at a speed of 1
RPS:
2.0k - 2.8k ohms?

mounted.
Yes
Go to Step 2
Connector is
faulty, or open
or short circuit
of harness
between wheel
speed sensor
connector and
coil integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
Repeat the Basic
diagnostic flow
chart"
No
OK.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Go to Step 3
5A55
Chart C-1-3 Rear Sensor Output Inspection Procedure

Step
Action
Yes

3. Jack up the vehicle with all four wheels off the ground
measure the AC voltage between coil integrated module
connector terminals while turning Rear wheel at a speed of 1
RPS:
Go to Step 2

Is the check between connector (F-4) terminals 1 and 2 within
1.2k - 2.0k ohms?

mounted.
Connector is
faulty, or open
or short circuit
of harness
between wheel
speed sensor
connector and
coil integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
No
OK.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Yes
No
1. Connect TECH 2.
2. Check the wheel speed of each sensor by Data List.
Is the vehicle speed normal?
Go to Step 6
Go to Step 2
Check the sensor harness for suspected disconnection (check

while shaking harness/connector).
Is the sensor harness connection normal?
Replace speed
sensor.
Go to Step 4
Check the wheel speed of each sensor by Data List.

Go to Step 6
Go to Step 4
Replace speed
sensor.
Go to Step 5
Replace sensor
rotor.
Go to Step 5
Go to Step 6
Repair harness
or connector
between coil
integrated
module and
speed sensor.
Go to Step 6
Chart TC-1 Sensor Output Inspection Procedure

Step
1
Action
Check the sensor rotor.

Is the sensor rotor normal?
Check the harness between coil integrated module and speed

sensor.
Is the harness connection normal?

mounted.
Repeat the Basic

diagnostic flow
chart"
Repair.
Go to Step 3
Go to Step 6
5A56
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884003850
(J35616)
Connector test adapter kit
5884003660
(J39200)
High impedance
multimeter
7000086ISU
Tech 2 Set
(1) PCMCIA Card
(2) SAE 16/19 Adapter
(3) DLC Cable
(4) Tech 2
SECTION
ANTI-LOCK BRAKE SYSTEM
5B1
BRAKES
CONTENTS
Electronic Hydraulic Control Unit ..................
Electronic Hydraulic Control Unit and
Associated Parts .......................................
Removal .....................................................
Disassembly ...............................................
Reassembly ................................................
Installation ..................................................
Front Wheel Speed Sensor ...........................
5B - 1
5B - 2
5B - 2
5B - 2
5B - 3
5B - 3
5B - 3
5B - 3
5B - 4
Service Precaution
Front Wheel Speed Sensor and

Removal......................................................
Installation...................................................
Rear Wheel Speed Sensor ...........................
Removal......................................................
Installation...................................................
5B - 4
5B - 4
5B - 4
5B - 4
5B - 5
5B - 5
5B - 5
5B - 5

and systems.
5B2

Electronic Hydraulic Control Unit and Associated Parts
350RW017
Legend
(1) EHCU
(2) Bolt
(3) Bracket
(4) Bolt and Nut
EndOFCallout
Removal
1. Remove brake pipes.
After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry of
foreign matter.
2. Remove three bracke fixing bolts.
3. Disconnect red clip from harness connector.
350RW018
5B3
Disassembly
4. Remove harness connector.

5. Remove EHCU ASM.
6. Remove EHCU.
1. Remove fixing bolts from EHCU.

2. Remove coil integrated module from hydraulic unit.
Disassembled View
Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following points:
Torque:
Fixing bolts: 4.4 Nm (4.5 kgcm/39 lb in)
Installation
Torque:
Hydraulic unit fixing nuts : 22 Nm (2.2 kgm/16
lbft)
Ground cable : 14 Nm (1.4 kgm/10 lbft)
Brake pipe (joint bolts) : 16 Nm (1.6 kgm/12 lbft)
350RW025
Legend
(1) Fixing Bolts
(2) Coil Integrated Module
(3) Hydraulic Unit (H/U)
EndOFCallout
After installing the hydraulic unit, bleed brakes

completely. See Hydraulic Brakes in Powerassisted
brake system section.
5B4
Front Wheel Speed Sensor

Front Wheel Speed Sensor and Associated Parts
350RS033
Legend
(1) Speed Sensor Connector
(2) Sensor Cable Fixing Bolt (Upper side)
(3) Sensor Cable Fixing Bolt (Lower side)
(4) Speed Sensor Fixing Bolt

(5) Speed Sensor
EndOFCallout
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 bolt.
5. Remove speed sensor.

1. Check the speed sensor pole piece for presence of
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 removal of the sensor ring in

Section 4D Front hub and disc".
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
Torque: 7 Nm (0.7 kgm/61 lbin)
3. Install speed sensor cable fixing bolt (Lower side)
and tighten the fixing bolt to the specified torque.
Torque : 20 Nm (2.0 kgm/14 lbft)
4. Install speed sensor cable fixing bolt (Upper side)
NOTE: Confirm that a white line marked on the cable is
not twisted when connecting the speed sensor cable.
5. Install speed sensor connector.
5B5
Rear Wheel Speed Sensor

Removal
Installation
1. Disconnect harness connector (1).

2. Remove sensor fixing bolt (2) .
3. Remove speed sensor (3).
1. Install speed sensor (3).

2. Tighten the sensor fixing bolt (2) to the specified
torque.
3. Connect harness connector (1).
350RX003

350RX003
1. Check speed sensor pole piece for presence of

2. Check the pole piece for damage, and replace
speed sensor if necessary.
3. Check speed sensor cable for short or open, and
replace with a new one if necessary. To check for
cable short or open, bend or stretch the cable while
checking for continuity.
chipping, and if damaged, replace the axle shaft
Section 4A2 Differential (Rear)".
SECTION
POWER-ASSISTED BRAKE SYSTEM
5C1
BRAKES
CONTENTS
Diagnosis .......................................................
Hydraulic Brakes ...........................................
Filling Master Cylinder Reservoir................
Deterioration of Brake Fluid ........................
Leakage of Brake Fluid...............................
Bleeding Brake Hydraulic System ..............
Flushing Brake Hydraulic System...............
Brake Pipes and Hoses ..............................
Brake Hose Inspection ...............................
Front Caliper Brake Hose..............................
Front Caliper Brake Hose and
Removal .....................................................
Installation ..................................................
Rear Axle Brake Hose...................................
Rear Axle Brake Hose and
Removal .....................................................
Installation ..................................................
Brake Pipe.....................................................
Removal .....................................................
Installation ..................................................
P & B (Proportioning and Bypass) Valve ......
P & B (Proportioning and Bypass) Valve
Sectional View ..........................................
Removal .....................................................
Installation ..................................................
Brake Pedal...................................................
Checking Pedal Height ...............................
Checking Pedal Travel ...............................
Brake Pedal and Associated Parts .............
Removal .....................................................
Installation ..................................................
Stoplight Switch.............................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Fluid Reservoir Tank .....................................
Fluid Reservoir Tank and
Removal .....................................................
Installation ..................................................
Master Cylinder Assembly ............................
Master Cylinder Assembly and
5C - 2
5C - 2
5C - 5
5C - 6
5C - 9
5C - 9
5C - 9
5C - 9
5C - 9
5C - 10
5C - 10
5C - 10
5C - 11
5C - 11
5C - 11
5C - 11
5C - 12
5C - 12
5C - 12
5C - 12
5C - 13
5C - 13
5C - 13
5C - 14
5C - 14
5C - 14
5C - 14
5C - 15
5C - 16
5C - 16
5C - 16
5C - 17
5C - 17
5C - 17
5C - 18
5C - 18
5C - 18
5C - 18
5C - 19
5C - 20
5C - 20
5C - 20
5C - 20
5C - 21

Removal......................................................
Installation...................................................
Special Tools .................................................
Vacuum Booster Assembly ...........................
Vacuum Booster Assembly and
Removal......................................................
Installation...................................................
Exterior Components ....................................
Exterior Components and
Removal......................................................
Installation...................................................
Vacuum Booster Overhaul ............................
Vacuum Booster .........................................
Special Tools .................................................
Front Disc Brake Pads ..................................
Front Disc Brake Pads Inspection ..............
Front Disc Brake Pads and
Removal......................................................
Installation...................................................
Front Disc Brake Rotor..................................
Inspection ...................................................
Replacing Brake Rotors..............................
Refinishing Brake Rotors ............................
Front Disc Brake Caliper Assembly...............
Front Disc Brake Caliper Assembly and
Removal......................................................
Installation...................................................
Front Disc Brake Caliper ...............................
Front Disc Brake Caliper
Disassembled View...................................
Disassembly ...............................................
Reassembly ................................................
Rear Disc Brake Pads ...................................
Brake Pads Inspection................................
Brake Pads and Associated Parts ..............
Removal......................................................
Installation...................................................
5C - 21
5C - 21
5C - 21
5C - 23
5C - 23
5C - 23
5C - 24
5C - 24
5C - 24
5C - 24
5C - 25
5C - 27
5C - 27
5C - 27
5C - 28
5C - 28
5C - 28
5C - 28
5C - 29
5C - 30
5C - 31
5C - 31
5C - 31
5C - 32
5C - 32
5C - 34
5C - 34
5C - 34
5C - 34
5C - 36
5C - 36
5C - 36
5C - 37
5C - 39
5C - 39
5C - 39
5C - 40
5C - 40
5C - 42
5C - 43
5C - 43
5C - 43
5C - 44
5C - 44
5C2
Rear Disc Brake Rotor ..................................

Inspection ...................................................
Rear Drum (In Disc) Inside
Diameter Check ........................................
Rear Disc Brake Caliper Assembly ...............
Rear Disc Brake Caliper Assembly and
5C - 46
5C - 46
5C - 46
5C - 46
5C - 47
5C - 48
5C - 48
Removal......................................................
Installation...................................................
Rear Disc Brake Caliper................................
Rear Disc Brake Caliper
Disassembly ...............................................
Reassembly ................................................
Service Precaution
General Description

YOU ARE
IN
REPAIRS.
Master Cylinder Assembly
5C - 48
5C - 49
5C - 51
5C - 51
5C - 51
5C - 52
5C - 52
5C - 54

and systems.
330RS001

The master cylinder contains two pistons that supply the
hydraulic pressure for a dualcircuit braking system.
The primary piston provides the fluid pressure to the
front brakes, while the secondary piston provides the
fluid pressure to the rear brakes. If the pressure is lost
from either system, the remaining system will function to
stop the vehicle.
5C3
CAUTION:
1. The master cylinder is not repairable. If found
defective, it must be replaced as a complete
assembly.
2. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all
or part of the brake system. (Refer to Bleeding
Brake Hydraulic System" in this section.)
3. The torque values specified are for dry,
unlubricated fasteners.
4. Perform service operations on a clean bench
free from all mineral oil materials.
Brake Booster
331RS001
This booster is a tandem vacuum unit with a diaphragm

effective diameter 205mm + 230mm. In normal
operating mode, with the service brakes in the released
position, the tandem vacuum booster operates with
vacuum on both sides of its diaphragms. When the
brakes are applied, air at atmospheric pressure is
admitted to one side of each diaphragm to provide the
power assist. When the service brake is released, the
atmospheric air is shut off from the one side of each
diaphragm. The air is then drawn from the booster
through the vacuum check valve to the vacuum source.
CAUTION:
or part of the brake system.
3. The vacuum booster is not repairable and must
be replaced as complete assembly.
5C4
Disc Brake
Front Disc Brake
A05RW001
Rear Disc Brake
A05RW002
The disc brake assembly consists of a caliper, piston,

rotor, pad assembly and support bracket. The caliper
assembly has a single bore and is mounted to the
support bracket with two mounting bolts. The support
bracket allows the caliper to move laterally against the
rotor. The caliper is a onepiece casting with the
inboard side containing the piston bore. A square cut
rubber seal is located in a groove in the piston bore
which provides the hydraulic seal between the piston
and the cylinder wall.
NOTE:
1. Replace all components included in repair kits used
to service this caliper.
2. Lubricate rubber parts with clean brake fluid to ease
assembly.
disconnected, it may be necessary to bleed all or
part of the brake system.

4. Replace pads in axle sets only.
5. The torque values specified are for dry, unlubricated
fasteners.
6. Perform the service operation on a clean bench free
from all mineral oil materials.
Operation
Hydraulic pressure, created by applying the brake
pedal, is converted by the caliper to a stopping force.
This force acts equally against the piston and the
bottom of the caliper bore to move the piston outward
and to move (slide) the caliper inward resulting in a
clamping action on the rotor. This clamping action
forces the linings against the rotor, creating friction to
stop the vehicle.
Diagnosis
Road Testing The Brakes
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake
performance cannot be made if the roadway is wet,
greasy or covered with loose dirt so that all tires do not
grip the road equally. Testing will also be adversely
affected if the roadway is crowned so as to throw the
weight of the vehicle toward wheels on one side or if the
roadway is so rough that wheels tend to bounce. Test
the brakes at different vehicle speeds with both light and
heavy pedal pressure; however, avoid locking the
wheels and sliding the tires. Locked wheels and sliding
tires do not indicate brake efficiency, since heavily
braked but turning wheels will stop the vehicle in less
distance than locked wheels. More tiretoroad friction
is present with a heavily braked turning tire then with a
sliding tire.
The standard brake system is designed and balanced to
avoid locking the wheels except at very high
deceleration levels.
It is designed this way because the shortest stopping
distance and best control is achieved without brake
lockup.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake Performance
1. Tires: Tires having unequal contact and grip on the
road will cause unequal braking. Tires must be
equally inflated, identical in size, and the thread
pattern of right and left tires must be approximately
equal.
2. Vehicle Loading: A heavily loaded vehicle requires
more braking effort.
3. Wheel Alignment: Misalignment of the wheels,
particularly in regard to excessive camber and
caster, will cause the brakes to pull to one side.
Brake Fluid Leaks

With engine running at idle and the transmission in
Neutral", depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking.
Check the master cylinder fluid level. While a slight drop
in the reservoir level will result from normal lining wear,
an abnormally low level in reservoir indicates a leak in
the system. The hydraulic system may be leaking
internally as well as externally. Refer to Master Cylinder
Inspection". Also, the system may appear to pass this
test but still have slight leakage. If fluid level is normal,
check the vacuum booster push rod length. If an
incorrect length push rod is found, adjust or replace the
push rod. Check the brake pedal travel and the parking
brake adjustment.
5C5
When checking the fluid level, the master cylinder fluid

level may be low from the MAX" mark if the front and
rear linings are worn. This is not abnormal.
Warning Light Operation

When the ignition switch is in the START position, the
BRAKE" warning light should turn on and go off when
the ignition switch returns to the ON position.
The following conditions will activate the BRAKE" light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the
ignition switch is on.
2. Low fluid level. A low fluid level in the master
cylinder will turn the BRAKE" light on.
3. During engine cranking the BRAKE" light should
remain on. This notifies the driver that the warning
circuit is operating properly.
5C6
General Diagnosis
Condition
Brake Pull
Brake Roughness or Chatter

(Pulsates)
Excessive Pedal Effort
Possible cause
Correction
Tire inflation pressure is unequal.
Adjust
Front wheel alignment is incorrect.
Adjust
Unmatched tires on same axle.
Tires with approx. the same amount

of tread should be used on the same
axle.
Restricted brake pipes or hoses.
Check for soft hoses and damaged

lines. Replace with new hoses and
new doublewalled steel brake
piping.
Water or oil on the brake pads.
Clean or replace.
Brake pads hardened.
Replace
Brake pads worn excessively.
Replace
Brake rotor worn or scored.
Grind or replace.
Disc brake caliper malfunctioning.
Clean or replace.
Front hub bearing preload incorrect.
Adjust or replace.
Loose suspension parts.
Check all suspension mountings.
Loose calipers.
Check and tighten the bolts to

specifications.
Excessive lateral runout.
Check per instructions. If not within

specifications, replace or machine
the rotor.
Parallelism not within specifications.

the rotor.
Wheel bearings not adjusted.
Adjust wheel bearings to correct

specifications
Pad reversed (steel against iron).
Replace the brake pad and machine

rotor to within specifications.
Malfunctioning vacuum booster.
Check the vacuum booster

operation and repair, if necessary.
Partial system failure.
Check the front and rear brake

system for failure and repair. Also,
check the brake warning light. If a
failed system is found, the light
should indicate failure.
Excessively worn pad.
Check and replace pads in sets.
Piston in caliper stuck or sluggish.
Remove caliper and rebuild.
Fading brakes due to incorrect pad.
Remove and replace with original

equipment pad or equivalent.
Vacuum leak to vacuum booster.
Check for ruptured or loose hose.
Check the direction of check valve

within vacuum hose.
Correct vacuum hose direction.
Grease on the brake pads.
Replace or clean.

Condition
Excessive Brake Pedal Travel
Brake Drag
Grabbing or Uneven Braking Action

(All conditions listed under Pulls")
Possible cause
5C7
Correction
Air in hydraulic circuit.
Bleed the hydraulic circuit.
Level of brake fluid in the reservoir

too low.
Replenish brake fluid reservoir to

specified level and bleed hydraulic
circuit as necessary.
Master cylinder push rod clearance

excessive.
Adjust
Leakage in hydraulic system.
Correct or replace defective parts.
Master cylinder pistons not returning

correctly.
Adjust the stop light switch and

vacuum booster push rod. If
necessary, rebuild.
Check for soft hoses or damaged

pipes, and replace with new hoses
and new doublewalled steel brake
piping.
Parking brake maladjusted.
Adjust
Parking brake lining clearance

insufficient.
Adjust
Brake pedal free play insufficient.
Adjust the brake pedal height or

power cylinder operating rod.
Piston in the master cylinder

sticking.
Replace
Piston in the disc brake caliper

sticking.
Replace piston seals.
Brake pads sticking in caliper.
Clean
Return spring weakened.
Replace
Parking brake binding.
Overhaul the parking brakes and

correct.
Adjust or replace.
Parking brake shoes not returning.
Correct or replace the brake back

plate and brake shoe as necessary.
Obstructions in hydraulic circuit.
Clean
Rotor warped excessively.
Grind or replace.
Rear brake drum distorted.
Grind or replace.
Parking cable sticking.
Grind or replace.
Check operation and correct as

necessary.
Binding brake pedal mechanism.
Check and lubricate, if necessary.
Corroded caliper assembly.
Clean and lubricate.
5C8

Condition
Brake Noisy
Poor Brake Action
Possible cause
Correction
Brake pads are worn.
Replace
Brake pads are hardened.
Replace
Brake pads are in poor contact with

rotor.
Correct
Brake disc(s) warped, worn or

damaged.
Grind or replace.
Disc brake antisqueak shims

fatigued.
Replace
Front hub bearings are loose or

preload is incorrect.
Adjust or replace.
Brake disc is rusted.
Grind or replace.
Master cylinder faulty.
Correct or replace.
Vacuum booster faulty.
Correct or replace.
Level of brake fluid in reservoir too

low.
Replenish and bleed.
Bleed
Disc brake caliper faulty.
Clean or replace.
Water or oil on brake pads.
Clean or replace.
Brake pads in poor contact with the

rotor.
Correct
Brake pads worn.
Replace
Brake disc rusted.
Grind or replace.
Check valve in vacuum hose faulty.
Correct or replace.
5C9
Hydraulic Brakes
Filling Master Cylinder Reservoir
CAUTION: Use only specified brake fluid. Do not
use any fluid which contains a petroleum base. Do
not use a container which has been used for
petroleum based fluids or a container which is wet
with water. Petroleum based fluid will cause
swelling and distortion of rubber parts in the
hydraulic brake system. Water mixed with brake
fluid lowers the fluid boiling point. Keep all fluid
containers capped to prevent contamination.
Always fill the master cylinder reservoir when the
engine is cold.
Never allow the brake fluid to come in contact with
the painted surfaces.
The master cylinder reservoir must be kept properly
filled to ensure adequate reserve and to prevent air
and moisture from entering the hydraulic system.
However, because of expansion due to heat
absorbed from the brakes and the engine, the
reservoir must not be overfilled. The brake fluid
reservoir is on the master cylinder, which is located
under the hood on the left side of the cowl.
Thoroughly clean reservoir cap before removal to
avoid getting dirt into reservoir. Remove the
diaphragm. Add fluid as required to bring level to
the MAX" mark on the reservoir tank. Use DOT 3"
Hydraulic Brake Fluid. If the fluid cap diaphragm is
stretched, return it to the original position before
installing.
Deterioration of Brake Fluid

Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling
point of brake fluid. It may, in turn, result in vapor lock or
deteriorated rubber parts of the hydraulic system. Be
sure to change the brake fluid at specified intervals.
If the rubber parts are deteriorated, remove all the
system parts and clean them with alcohol. Prior to
reassembly, dry the cleaned parts with air to remove the
alcohol. Replace all the hoses and rubber parts of the
system.
Leakage of Brake Fluid

With engine idling, set shift lever in the neutral position
and continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually,
leakage from the hydraulic pressure system is possible.
Make sure by visual check that there is no leak.
Bleeding Brake Hydraulic System

A bleeding operation is necessary to remove air from
the hydraulic brake system whenever air is introduced
into the hydraulic system. It may be necessary to bleed
the hydraulic system at all four brakes if air has been
introduced through a low fluid level or by disconnecting

brake pipes at the master cylinder. If a brake pipe is
disconnected at one wheel, only that wheel cylinder/
caliper needs to be bled. If the pipes are disconnected
at any fitting located between the master cylinder and
brakes, then the brake system served by the
disconnected pipe must be bled.
1. For 4Wheel Antilock Brake System (ABS)
equipped vehicle, be sure to remove the ABS main
fuse 60A located at the relay and fuse box before
bleeding air. If you attempt to bleed air without
removing the main fuse, air cannot be let out
thoroughly, and this may cause damage to the
hydraulic unit. After bleeding air, be sure to replace
the ABS main fuse back to its original position.
2. Set the parking brake completely, then start the
engine.
NOTE: The vacuum booster will be damaged if the
bleeding operation is performed with the engine off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation
5. Always use new brake fluid for replenishment.
6. In replenishing brake fluid, take care that air bubbles
do not enter the brake fluid.
When the master cylinder is replaced or overhauled,
first bleed the air from the master cylinder, then from
each wheel cylinder and caliper following the
procedures described below.
Bleeding the Master Cylinder
7. Disconnect the rear wheel brake pipe (1) from the
master cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one
minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder with your finger, where the pipe was
disconnected then release the brake pedal slowly.
10. Release your finger from the delivery port when the
brake pedal returns completely.
11. Repeat steps 8 through 10 until the brake fluid
comes out of the delivery port during step 8.
NOTE: Do not allow the fluid level in the reservoir to go
below the halfway mark.
12. Reconnect the brake pipe (1) to the master cylinder
and tighten the pipe.
depressed.
14. Loosen the rear wheel brake pipe (1) at the master
cylinder.
5C10
15. Retighten the brake pipe, then release the brake

pedal slowly.
16. Repeat steps 13 through 15 until no air comes out of
the port when the brake pipe is loosened
NOTE: Be very careful not to allow the brake fluid to
come in contact with painted surfaces.
procedure 10 or more times for front wheels and 15

or more times for rear wheels.
26. Go to the next wheel in the sequence after each
wheel is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
sponginess" after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels spongy", the entire bleeding
procedure must be repeated.
28. After the bleeding operation is completed on the
each individual wheel, check the level of the brake
fluid in the reservoir and replenish up to the MAX"
level as necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
330RW012
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:
Right rear caliper or wheel cylinder
Left rear caliper or wheel cylinder
Right front caliper
Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed
air from the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube,
and submerge the free end of the transparent tube
in a transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times (once/
sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through
the tube.
23. Retighten the bleeder screw.
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is
completely removed.
It may be necessary to repeat the bleeding
It is recommended that the entire hydraulic system be

thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system.
Approximately one quart of fluid is required to flush the
hydraulic system.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contains the slightest trace of mineral oil. All
rubber parts that have been subjected to a
contaminated fluid must be replaced.
Brake Pipes and Hoses

The hydraulic brake system components are
interconnected by special steel piping and flexible
hoses. Flexible hoses are used between the frame and
the front calipers, the frame and rear axle case and the
rear axle and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to Bleeding the Brake
Hydraulic System" in this section.
Brake Hose Inspection

The brake hose should be inspected at least twice a
year. The brake hose assembly should be checked for
road hazard, cracks and chafing of the outer cover, and
for leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as
necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage
to the hoses may occur.
5C11
Front Caliper Brake Hose

Associated Parts
Removal
stands.
2. Remove the wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove bolt and gasket.
7. Remove hose.
Installation
noting the following points.
1. Tighten the brake pipes to the specified torque
Torque: 16 Nm (1.6 kgm/12 lbft)
2. Tighten the bolt to the specified torque.
352RW001
Legend
(1)
(2)
(3)
(4)
Bolt and Gasket

Clip
Hose
Brake Pipe
EndOFCallout

NOTE: Always use new gaskets and be sure to put the
hooked edge of the flexible hose end into the anti
rotation cavity.
After installing the brake hoses, bleed the brakes as
described in this section.
5C12
Rear Axle Brake Hose

Associated Parts
Removal
stands.
2. Remove wheel and tire assembly.
5. Remove clip.
6. Remove brake pipe.
7. Remove bolt.
8. Remove hose.
Installation
352RW002
Legend
(1)
(2)
(3)
(4)
(5)
Brake Pipe
Clip
Bolt
Brake Pipe
Hose
EndOFCallout

5C13
Brake Pipe
Removal
Installation

stands.
2. Remove wheel and tire assembly as necessary.
pipe fittings at both ends.
4. Remove brake pipe (1).

1. Tighten the brake pipes to the specified torque.
Master cylinder and P&B valve sides
Others
After installing the brake pipes, bleed the brakes as
330RW011
5. Remove plastic clip (2).
330RW002
5C14

P & B (Proportioning and Bypass)
Valve Sectional View
350RW014
Legend
(1)
(2)
(3)
(4)
Master Cylinder (Secondary)

Master Cylinder (Primary)
Rear Brake
Front Brake
EndOFCallout
The P&B valve contains two sections, each serving a
different function.
The proportioning section of the P&B valve proportions
outlet pressure to the rear brakes after a predetermined
rear input pressure has been reached. This is done to
prevent rear wheel lock up on the vehicles with light rear
wheel loads. The valve has a bypass feature which
assures full system pressure to the rear brakes in the
event of front brake system malfunction. Also full front
pressure is retained in the event of rear brake
malfunction.
The P&B valve is not repairable and must be replaced
as complete assembly.
Removal
1. The P&B valve is not repairable and must be
replaced as a complete assembly. Care must be
taken to prevent brake fluid from contacting any
painted surface.
2. Remove hydraulic pipes (1) and plug the pipes (1) to
prevent the loss of fluid or the entrance of dirt.
3. Remove bolt (3).
4. Remove P&B valve (2).
350RW026
Installation
1. Install P&B valve (2).
2. Install bolt (3) and tighten the bolt to the specified
torque.
3. Install hydraulic pipes (1) and tighten the bolt to the
specified torque.
4. After installing the brake pipes, bleed the brakes as
refer to Bleeding Brake Hydraulic System in this
section.
5C15

E05RX005
5C16
Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when
the pedal is fully released. Brake pedal height
adjustment should be performed as follows:
Adjust Brake Pedal
310RW022
NOTE: While adjusting the stoplight switch, make sure

that the threaded part of the stoplight switch does not
push the brake pedal.
h Tighten the stoplight switch lock nut.
i Connect the stoplight switch connector.
310RW021
1. Measure the brake pedal height after making sure

the pedal is fully returned by the pedal return spring.
Pedal height must be measured after starting the
engine and receiving it several times.
Checking Pedal Travel
Pedal Free Play: 8-11 mm (0.31-0.43 in)

Pedal Height: 193-203 mm (7.60-7.99 in)
NOTE: Pedal free play must be measured after turning
off the engine and stepping on the brake pedal firmly
five times or more.
2. If the measured value is not within the above range,
adjust the brake pedal as follows:
a Disconnect the stoplight switch connector.
b Loosen the stoplight switch lock nut.
c Rotate the stoplight switch so that it moves away
from the brake pedal.
d Loosen the lock nut (1) on the push rod.
e Adjust the brake pedal to the specified height by
rotating the push rod in the appropriate
direction.
f Tighten the lock nut to the specified torque.
Torque: 20 Nm(2.0 kgm/15 lbft)
g
Adjust the stoplight switch (2) to the specified

clearance (between the switch housing and the
brake pedal) by rotating the switch housing.
Clearance: 00.2 mm (00.008 in)
310RW021
1. Pedal height must be measured after starting the

engine and revving it several times to apply vacuum
to the vacuum booster fully.
NOTE: Pedal height must be 50 mm (1.97 in) or more
when about 490N (50kg/110Ib) of stepping force is
applied.
2. If the measured value is lower than the above range,
air existing in the hydraulic system is suspected.
Perform the bleeding procedure.
5C17
Brake Pedal and Associated Parts
310RW023
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Brake Pedal Bracket Assembly

Fulcrum Pin and Nut
Connector
Snap Pin
Return Spring
Pedal Assembly
(7)
(8)
(9)
(10)
Push Rod Pin

Lower Cover
Bolts and Nut
Driver Knee Bolster
EndOFCallout
Removal
at least 5 minutes.
2. Disconnect the yellow 3 way SRS connector located
3. Remove the engine hood opening lever.
4. Remove lower cover (8).
5. Remove driver knee bolster (10).
6. Disconnect the stop light switch connector (3).
Disconnect the anti-theft control module connector.
Refer to Body and Accessories section.
7. Remove snap pin (4) and push rod pin (7).
8. Remove the steering column shaft fixing bolt and
nut (9) on the steering wheel side, and lower the
steering column shaft.
9. Remove the brake pedal bracket assembly (1).
10. Remove return spring (5).

11. Remove fulcrum pin and nut (2).
12. Remove pedal assembly (6).
Installation
1. Apply grease to the entire circumference of the
fulcrum pin.
2. Install pedal assembly (6) and fulcrum pin and nut
(2).
Tighten the nut (2) to the specified torque.
3. Install the brake pedal bracket assembly (1).
Tighten the bolts and nuts soecified torque.
4. Install return spring (5).
5C18
5. Adjust pedal free travel.

Refer to Brake Pedal Adjustment in this section.
6. Tighten the steering column fixing bolt (9) (dash
panel) to the specified torque.
7. Tighten the steering column fixing nut (9) (Cross
Beam) to the specified torque.
Push rod pin (7).
9. Install push rod pin (7).

10. Install snap pin (4).
11. Connect the anti-theft control module connector.
12. Connect the stop light switch connector (3).
13. Install driver knee bolster (10) and lower cover (8).
15. Connect the yellow 3 way SRS connector located
Stoplight Switch
Parts Location
Installation
1. Adjust the stop light switch to the specified
clearance (between switch housing and brake
pedal) by rotating the switch housing.
Clearance : 0-0.2 mm (0-0.008 in)
NOTE: Do not attempt to force the push rod into
position during the stop light switch installation and
adjustment procedure.
310RW024
Legend
(1) Connector
(2) Switch
(3) Lock Nut
EndOFCallout
Removal
1. Disconnect connector (1)
2. Remove lock nut (3).
3. Remove switch (2).
310RW022
2. Connect connector (1).

3. Install lock nut (3).

Pedal free play
610 mm (0.23 0.39 in)
Pedal Height
173185 mm (6.817.28 in)
E05RX006
5C19
5C20
Fluid Reservoir Tank

Fluid Reservoir Tank and Associated Parts
330RW003
Legend
(1) Fluid Reservoir
(2) Electrical Connector
(3) Oring
(4) Retainer
EndOFCallout
Removal
4. Remove Oring.
NOTE: Before removing the fluid reservoir, remove the

brake fluid from the fluid reservoir.
1. Disconnect electrical connector.
2. Remove retainer (1).
Installation
1. Oring (1) must be set onto the fluid reservoir (2),
before installing fluid reservoir.
330RW004
3. Remove fluid reservoir and the fluid level sensor

built into the fluid reservoir. The fluid level sensor
cannot be removed for servicing.
330RW005
5C21

Master Cylinder Assembly and Associated Parts
330RW010
Legend
(2) Master Cylinder
(3) 2 attaching Nuts
(4) P&B Valve and Bracket

(5) Brake Pipes
(6) Spacer and 2 gaskets
EndOFCallout
Removal
CAUTION: When removing the master cylinder from
the vacuum booster, be sure to get rid of the
internal negative pressure of the vacuum booster
(by, for instance, disconnecting the vacuum hose) in
advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing the master cylinder, further, do not
hold the piston as it can be easily pulled out.
Outside surface of the piston is the surface on
which seals are to slide. Care should be taken to
keep the surface free of cuts and dents.
2. Remove brake pipes and after disconnecting the
brake pipe, cap or tape the openings of the brake

pipe to prevent the entry of foreign matter.
3. Remove 2 attaching nuts.
4. Remove P&B valve and bracket.
5. Remove master cylinder.
6. Remove spacer and the 2 gaskets.

Master Cylinder
The master cylinder is not repairable and must be
replaced as a complete assembly if found defective.
Inspection
Excessive brake pedal travel, malfunction or dragging
brake suggests that the master cylinder is defective. In
5C22
such cases perform the following visual check:

Visual Check
Make parts replacement as required if wear, distortion,
nicks, cuts, corrosion, or other abnormal conditions are
found through the following parts inspection:
Master cylinder body
Fluid reservoir
Oring
Functional Inspection of Master Cylinder

Piston
Push the primary piston (1) with your fingers to check
that it travels smoothly. If the motion is questionable,
replace the master cylinder as a complete assembly.
330RX001
Connect the master cylinder attachment (5) 58840

23060 with the end of the radiator cap tester (6) 5
884002770, and apply air pressure with the cap
tester. Make sure there is no rise in pressure and that
with the adjusting bolt further screwed in 5mm (align the
adjusting bolt to the 5" line). There should be a
pressure increase of 0.5 kg/cm2 or more.
330RW007

Inspect the master cylinder for function as follows. If any
abnormal function is found, replace with a new one.
Install the primary piston holder (3) 5884023060
(including the master cylinder attachment (5) and
master cylinder plug (7)) onto the master cylinder (4).
Make sure the spacer (2) (2 bolts) with its adjusting bolt
is screwed in up to the 0" line
330RX002
NOTE: When checking the front (or primary) side, be

sure to mount the master cylinder plug in the rear (or
secondary) port.
5C23

0" Line
5" Line
Apply air
pressure to the
front and rear
ports
No pressure
rise.
Pressure
increase of 0.5
kg/cm2 or more
Remarks
Checks port into

the atmospheric
pressure
chamber
Checks air
tightness of the
pressure
chamber
Type
Dualcircuit
Piston bore
diameter
25.4 mm (1.000 in)
NOTE:
1. Do not use an air compressor, as the air from the
compressor is mixed with compressor oil.
2. When installing the master cylinder onto the vacuum
booster, always adjust the vacuum booster push
rod. (Refer to Vacuum Booster" in this section).
3. After the master cylinder is installed onto the
vehicle, check for leakage, pedal travel and pedal
free play.
Installation
1. Install spacer and the 2 gaskets.
2. Install master cylinder.
When replacing the master cylinder or vacuum
booster or both, always measure the vacuum
booster push rod protrusion and adjust it as
necessary (Refer to Vacuum Booster" in section).
3. Install P&B valve and bracket.
4. Install 2 attaching nuts and tighten the attaching
nuts to the specified torque.
5. Install brake pipes and tighten the brake pipe to the
specified torque.
Others
E05RX007
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2306-0
(J-39242)
Primary Piston Holder
(including master cylinder
attachment and master
cylinder plug
6. Connect electrical connector.
5-8840-0277-0
(J-24460-01)
Radiator Cap Tester
5C24
Vacuum Booster Assembly

Vacuum Booster Assembly and Associated Parts
331RW005
Legend
(1)
(2)
(3)
(4)
Pin
Vacuum Booster Fixing Nut
Vacuum Hose
Master Cylinder
(5) Vacuum Booster

(6) Snap Pin
EndOFCallout
Removal
1. Before removing the vacuum booster assembly,
disconnect and remove the brake pipes.
2. Remove master cylinder, refer to Master Cylinder
Removal" in this section.
advance.
fluid run out.

3. Remove vacuum hose.
4. Disconnect the yoke clevis from the brake pedal.
5. Remove vacuum booster fixing nut.
6. Remove vacuum booster.

Vacuum Hose
1. Inspect the check valve (2), which is installed inside
the vacuum hose.
2. Air should pass freely from the vacuum booster (3)
to the engine (1).

3. Air should not pass from the engine (1) to the
vacuum booster (3). If it does, the check valve is
inoperative and must be replaced.
5C25
installing a push rod gauge on the vacuum booster.
331RW012
4. Measure dimension (4).

360RW001
Installation
Dimension (4) (Standard): 0.10.1 mm (0.0039

0.0039 in)
1. Perform vacuum booster and vacuum booster push

rod adjustment.
NOTE: When replacing either the master cylinder or
vacuum booster, be sure to measure push rod, and
adjust if required.
2. Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate
and seal assembly out of the shell inside.
331RW013
331RS003
3. Set push rod gauge 5884023000 on vacuum

booster, and apply negative pressure by means of
vacuum pump 5884002790 so that the pressure
in the vacuum booster becomes 500 mm Hg.
NOTE: Be sure to apply NEGATIVE pressure after
5C26
5. If dimension (4) is out of the standard range, adjust

push rod using the Push Rod Support 58840
23050.
331RW014
6. Mount plate and seal assembly in vacuum booster

front shell. Then install the retainer.
7. Install vacuum booster fixing nut and tighten the
specified torque.
8. Install yoke clevis.
9. Connect vacuum hose and make sure that the arrow
on the hose points in the direction of the engine.
10. Install master cylinder, refer to Master Cylinder
Installation" in this section.
5C27
Exterior Components
Exterior Components and Associated Parts
331RW006
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Yoke Clevis
Lock Nut
Retaining Clip
Valve Body Guard
Silencer
Filter
EndOFCallout
Removal
1. Remove master cylinder. Refer to Master Cylinder"
in this section.
2. Remove vacuum booster. Refer to Vacuum
Booster" in this section.
3. Remove yoke clevis.
4. Remove lock nut.
5. Remove retaining clip.
6. Remove valve body guard.
7. Remove silencer.
8. Remove filter.
9. Remove 2 gaskets and spacer.
(7)
(8)
(9)
(10)
(11)
2 Gaskets and Spacer

Vacuum Booster
Retainer
Plate and Seal Assembly
Master Cylinder
5C28
10. Remove retainer, using a small screwdriver to pry

out the retainer. Gently pull out the plate and seal
assembly from the shell.
through inspection. Check the following parts:

Yoke clevis
Valve body guard
Silencer
Filter plate and seal assembly
Installation
1. Install plate and seal assembly.
3. Install 2 gaskets and spacer.
4. Install filter.
5. Install silencer.
6. Install valve body guard.
8. Install lock nut and yoke clevis and tighten to the
specified torque.
331RS003

Visual Check
Make necessary parts replacement if cuts, nicks,
excessive wear, or other abnormal conditions are found
9. Install vacuum booster, refer to Vacuum Booster" in

this section.
10. Install master cylinder, refer to Master Cylinder" in
this section and after installation, perform brake
pedal check and adjustment. Refer to Brake Pedal"
in this section.
Vacuum Booster Overhaul

Vacuum Booster
The vacuum booster cannot be disassembled for repair.
Replace a defective vacuum booster with a new one.
5C29

Vacuum booster diaphragm diameter (Front)
205 mm (8.07 in)
Vacuum booster diaphragm diameter (Rear)
230 mm (9.06 in)
Push rod stroke
More than 32.0 mm (1.26 in)
Plunger diameter
10.25 mm (0.40 in)
Push rod diameter
27.4 mm (1.08 in)
E05RX008
5C30
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2300-0
(J-39216)
Push Rod Gauge
5-8840-0279-0
(J-23738-A)
Vacuum Pump
5-8840-2305-0
(J-39241)
Push Rod Support
5C31
Front Disc Brake Pads

Front Disc Brake Pads Inspection
Check the outer pad by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole in the top of the
caliper. Whenever the pad is worn to about the
thickness of the pad base, the pad should be removed
for further measurements. The pad should be replaced
anytime the pad thickness (1) is worn to within 1.00 mm
(0.039 in) of the pad itself.
The disc pads have a wear indicator that makes a noise
when the pad wears to where the replacement is
required.
Minimum limit (1): 1.0 mm (0.039 in)
302RS002
Front Disc Brake Pads and Associated Parts
302RW003
Legend
(1) Lock Bolt
(2) Caliper Assembly
(3) Pad Assembly
EndOFCallout
(4) Clip
(5) Outer Side
5C32
Removal
Installation
NOTE: If a squealing noise occurs from the front brake

while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.
Draw out twothirds of the brake fluid from the
reservoir.
Raise the vehicle and support it with suitable safety
stands.
1. Remove wheel and tire assembly, refer to Wheels
and Tires System" in Section 3E.
2. Remove lock bolt (1).
1. Install clip.
302RS005
2. Apply special grease (approximately 0.2g) to both

contacting surfaces of the inner shims (2). Wipe off
extruded grease after installing. Install pad
assembly with shim.
302RW004
3. Rotate caliper assembly and support the caliper

assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove Clip.
302RW005
Legend
(2) Inner Shim
(3) Wear Indicator
(4) Inner Side
EndOFCallout
302RW006
3. Use adjustable pliers to bottom the piston into the

caliper bore. Be careful do not damage the piston
boot and do not damage the flexible hose by twisting
or pulling it.
Install caliper assembly.
Set caliper assembly in place.
302RS008
4. Install lock bolt (5) and tighten the bolt to the

specified torque.
5C33
302RW018
5. Install wheel and tire assembly, refer to Wheels and

Tires System" in Section 3E.
6. Pump the brake pedal several times to make sure
that the pedal is firm. Check the brake fluid level in
the reservoir after pumping the brakes.
5C34
Front Disc Brake Rotor

Inspection
In the manufacturing of the brake rotor, all the
tolerances regarding surface finish, parallelism and
lateral runout are held very closely. Maintaining these
tolerances provides the surface necessary to assure
smooth brake operation.
Lateral Runout
Lateral runout is the movement of the rotor from side to
side as it rotates on the spindle. This could also be
referred to as rotor wobble".
This movement causes the piston to be knocked back
into its bore. This results in additional pedal travel and a
vibration during braking.
Checking Lateral Runout

1. Adjust the wheel bearing correctly, refer to
Differential" in Section 4A.
2. Attach a dial indicator to some portion of the
suspension so that the stem contacts the rotor face
about 29 mm (1.14 in) from the rotor edge.
3. Move the rotor one complete rotation and the lateral
runout should not exceed 0.13 mm (0.005 in).
411RS018
Replacing Brake Rotors

When installing new brake rotors, do not refinish the
surfaces. These parts are at the correct level of surface
finish.
Maximum runout: 0.13 mm (0.005 in)
Refinishing Brake Rotors

Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 24.60 mm (0.969 in). The minimum
refinish dimension is 24.97 mm (0.983 in).
When refinishing rotors, always use sharp cutting tools
or bits. Dull or worn tools leave a poor surface finish
which will affect initial braking performance. Vibration
dampening attachments should always be used when
refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
finish.
After refinishing, replace any rotor that does not meet
the minimum thickness of 24.97 mm (0.983 in). Do not
use a brake rotor that will not meet the specification.
411RS019
Minimum wear dimension: 24.60 mm (0.969 in)
Parallelism
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurement must be made at 29 mm (1.14
in) from the edge of the rotor.
The rotor thickness must not vary more than 0.010 mm
(0.0004 in) from point to point.
Refinish dimension: 24.97 mm (0.983 in)
411RW003
5C35
5C36
Front Disc Brake Caliper Assembly

Front Disc Brake Caliper Assembly and Associated Parts
302RW008
Legend
(1)
(2)
(3)
(4)
Guide Bolt
Brake Flexible Hose
Lock Bolt
Caliper Assembly
(5) Clip
(6) Support Bracket with Pad Assembly
(7) Pad Assembly
EndOFCallout
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Concernig wheel and tire assembly, refer to Wheels
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after
disconnecting the flexible hose (1), cap or tape the
openings to prevent entry of foreign material.
302RW009
5C37
4. Since the brake fluid flows out from the connecting

coupler, place a drain pan under the vehicle.
5. Remove guide bolt (2).
302RW011
Legend
302RW010
7. Remove caliper assembly.

8. Remove support bracket with pad assembly and
take care not to damage the flexible brake hose
when removing the support bracket.
9. Remove pad assembly with shim and mark the
lining locations if they are to be reinstalled.
10. Remove clip.
(4) Inner Shim

(5) Wear Indicator
(6) Inner Side
EndOFCallout
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Installation
1. Install clip.
302RW012
4. Install caliper assembly.

5. Install lock bolt (9) and guide bolt (8) and tighten the
302RS005
2. Apply special grease (approximately 0.2 g) to both

assembly with shim.
5C38
302RW013
6. Install brake flexible hose, always use new gaskets

and be sure to put the hooked edge of the flexible
hose end into the antirotation cavity then tighten
the Ibolt (10) to the specified torque.
302RW014
7. Install wheel and tire assembly, referring to Wheels

8. Bleed brakes. Refer to Hydraulic Brakes" in this
section.
5C39

Front Disc Brake Caliper Disassembled View
302RW015
Legend
(1)
(2)
(3)
(4)
(5)
Guide Bolt
Lock Bolt
Bleeder with Cap
Caliper Body
Dust Boot: Guide Bolt and Lock Bolt
EndOFCallout
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot: guide bolt and lock bolt.
(6)
(7)
(8)
(9)
Piston Seal
Piston
Dust Boot: Piston
Dust Boot Ring
5C40
4. Remove dust boot ring, using a small screwdriver.

Make necessary parts replacement, if wear, damage,
through inspection.
Rotor
Cylinder body
Cylinder bore
Piston
Guide bolt, lock bolt
Support bracket
NOTE: The piston seal, boot ring and dust boot are to
be replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new
ones.
Reassembly
302RS016
5. Insert a block of wood into the caliper and force out

the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: Do not place your fingers in front of the
piston in an attempt to catch or protect it when
applying compressed air. This could result in
personal injury.
1. Install caliper body.

2. Install bleeder with cap and tighten the cap to the
specified torque.
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in
the repair kit.
CAUTION: Use just enough air to ease the piston

out of the bore. If the piston is blown out, it may be
damaged.
302RS018
302RS017
6. Remove dust boot: piston.

7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
4. When inserting the piston into the cylinder, use

finger pressure only and do not use a mallet or other
impact tool, since damage to the cylinder wall or
piston seal can result.
Install piston.
302RS019
5. Apply special grease (approximately 1g) to the

piston and attach the dust boot to the piston and
caliper. Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.

7. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto
the lock bolt and guide bolt setting hole of the
support bracket.
5C41
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
5C42

Type
Floating, pin slide
Pad dimension
55 cm2 (8.52 in2)
Adjusting method
Piston diameter
Disc type
Selfadjusting
60.33 mm (2.38 in)
Ventilated
Disc thickness
26 mm (1.02 in)
Disc effective diameter
222 mm (8.74 in)
E05RX009
5C43
Rear Disc Brake Pads

Brake Pads Inspection
Check the outer pads by looking at each caliper from
when the pad wears to where replacement is required.
302RW016
Brake Pads and Associated Parts
306RW001
Legend
(2) Clip
EndOFCallout
(3) Lock Bolt

(4) Pad Assembly
5C44
Removal
Installation
NOTE: If a squealing noise occurs from the rear brake

should be replaced.
reservoir.
stands.
1. Remove wheel and tire assembly, referring to
Wheels and Tires System" in Section 3E.
2. Remove lock bolt (1)
1. Install clip (2).
306RW003

contacting surfaces of the inner shims. Wipe off
assembly with shim.
306RW002

damaged.
5. Remove clip.
306RW004
Legend
(3) Inner Shim
(4) Wear Indicator
EndOFCallout
306RW005

caliper bore. Be careful not to damage the piston
dust boot and do not damage the flexible hose by
twisting or pulling it. Install caliper assembly.
302RS008

specified torque.
5C45
306RW006
5C46
Rear Disc Brake Rotor

Inspection
Maximum parallelism: 0.010 mm (0.0004 in)

Lateral Runout

1. Adjust the wheel bearing correctly. Refer to Drive
Shaft System section.
3. Move the rotor one complete rotation.
The lateral runout should not exceed 0.13 mm
(0.005 in)
420RS013

finish.
411RS019
Parallelism

finish.
420RW002
Rear Drum (In Disc) Inside Diameter

Check
Check the rear drum inside diameter by measuring at
more than two portions as shown in the illustration.
If the inside diameter is greater than the limit, replace
the rear rotor.
Limit: 211.4 mm (8.32 in)
420RS035
5C47
5C48
Rear Disc Brake Caliper Assembly

Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
Legend
(1)
(2)
(3)
(4)
Brake Flexible Hose

Clip
Lock Bolt
Support Bracket
(5) Guide Bolt

(6) Pad Assembly with Shim
EndOFCallout
Removal
stands.
306RW008

5C49
306RW011
306RW009

10. Remove clip.
Legend
(5) Inner Shim
(6) Wear indicator
EndOFCallout
specified torque.
Installation
306RW012

5. Install lock bolt and guide bolt (8) and tighten the
306RW010

assembly with shim.
5C50
306RW013

the eyebolt (9) to the specified torque.
302RW017
7. Install the wheel and tire assembly, referring to

section.
5C51

Rear Disc Brake Caliper Disassembled View
306RW014
Legend
(1)
(2)
(3)
(4)
(5)
Guide Bolt
Lock Bolt
Bleeder with Cap
Caliper Body
Piston Seal
EndOFCallout
Disassembly
3. Remove dust boot; guide bolt and lock bolt.
(6)
(7)
(8)
(9)
Piston
Dust Boot: Piston
Dust Boot Ring
5C52

through inspection.
Rotor
Cylinder body
Cylinder bore
Piston
Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
302RS016

Remove piston.
personal injury.

specified torque.
3. Install piston seal and apply special rubber grease
to the piston seal and cylinder wall, then insert the
piston seal into the cylinder. The special rubber
grease is included in the repair kit.

damaged.
302RS018
302RS017


Install piston.
302RS019

302RS020

applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto
support bracket.
5C53
302RS021
5C54

Type
Floating, pin slide
Pad dimension
33 cm2 (5.11 in2)
Adjusting method
Piston diameter
Disc type
Disc thickness
Selfadjusting
41.3 mm (1.63 in)
Ventilated
18 mm (0.71 in)
269.2 mm (10.60 in)
E05RX010
SECTION
PARKING BRAKE SYSTEM
5D1
FRONTERA
BRAKES
CONTENTS
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever and Front Cable . . . . . .
Parking Brake Lever Assembly and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5D1
5D1
5D2
5D3
5D3
5D3
5D3
Service Precaution
fasteners joint interfaces. Generally, such coatings
clamping force, and may damage the fasteners.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
Parking Brake Rear Cable . . . . . . . . . . . . . . . .

Parking Brake Rear Cable and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment . . . . . . . . . . . . . . . .
5D4
5D4
5D5
5D5
5D6
5D6
5D7
General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the lever
can be held in that position until it is released. The position
of the lever is transmitted through cable/lever systems to
the rear wheels. These parts are designed to obtain
sufficient braking force even when parking on slopes.
When the parking brake is set, or when the ignition SW is
in theON position, the brake warning light illuminates.
The rear wheel parking brake is a duoservo brake
(mechanical inside expansion type) built in the rear disc
brake. Parking brake adjustment is made through the
adjusting hole (bored through back plate). Parking brake
lever stroke should be adjusted to 68 notches. Refer to
Parking Brake Adjustment in this section.
5D2
Operation
When pulled in the direction A, the parking lever presses
the secondary shoe against the brake drum using the
lever/shoe joint B as a fulcrum and pushes the strut in
the direction C. The strut ,in turn, presses the primary
shoe against the brake drum. Counter force D to the
primary shoe is transmitted again to the secondary shoe
through the fulcrum B. The secondary shoe contacts the

drum thereby producing braking effect. Clearance which
may result from worn parking brake shoe lining can be
adjusted by turning the adjusting screw. Refer to Parking
Brake Adjustment in this Section.
A05RS002
Legend
(1) Direction A
(2) Lever/Shoe Joint B as a fulcrum
(3) Direction C
(4) Counter Force D
(5) Parking Lever
(6) Secondary Shoe
(7) Adjusting Screw Notch
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Parking Cable Guide

Primary Shoe
Strut
Shoe Expanding Direction
Parking Brake Cable Guide
Adjusting Hole Plug
Adjusting Screw Notch
5D3
Parking Brake Lever and Front Cable

Parking Brake Lever Assembly and Associated Parts
311RW0131
Legend
(1) Rear Console
(2) Switch Connector
(3) Bolt
(4) Adjust Nut and Lock Nut
Removal
D Refer to Body and Accessories section.
2. Disconnect switch connector (2).
3. Remove bolt (3).
4. Remove adjust nut and lock nut (4).
5. Pull out equalizer (6) from trunnion pin (5).
6. Disconnect trunnion pin (5) from Parking brake lever
(8).
7. Disconnect parking brake rear cable (7).
(5)
(6)
(7)
(8)
Trunnion Pin
Equalizer
Parking Brake Rear Cable
Parking Brake Lever
Installation
1. Apply grease (BESCO L2 or equivalent) to the
connecting portion of the rear cable (7) and equalizer
(6).
2. Connect parking brake rear cable (7) to equalizer
3. Install trunnion pin (5) to parking brake lever (8).
4. Insert equalizer (6) into trunnion pin (5) and tighten
adjust nut and lock nut (4).
D To adjust the parking brake lever, see Parking
Brake Adjustment in this section.
Lock Nut Torque: 13 Nm (1.3 kgm/113 lb in)
5. Tighten the parking brake lever fixing bolt (3) to the
specified torque.
6. Connect switch connector (2).
7. Install rear console (1).
5D4

Parking Brake Rear Cable and Associated Parts
311RW014
Legend
(1) Rear Wheels
(3) Rotor (Drum)
(4) Holding Spring
(5) Upper Return Spring
(6) Lower Return Spring
(7) Shoe Assembly
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Cable Fixing Bolt

Bolt
Bolt
Bolt (Only Long Wheel Base Model)
Nut
Nut
Retainer
Rear Cable
Removal
1. Remove rear wheels (1).
2. Remove 2 bolts to remove the caliper assembly (2)
from the support bracket. Refer to Rear Disc Brakes
in Power Assisted Brake System section. Temporarily
hang the caliper with wire etc.
3. Remove rotor (drum) (3).
4. Remove holding spring (4), upper return spring (5)
and lower return spring (6).
5. Previously remove the rear cable from the parking
brake lever, then remove the brake shoe assembly
(7).
5D5
6. Install shoe assembly (7).

After installation of the shoe and cable assembly,
apply special grease (included in the repair kit) to the
following portions indicated in the figure.
308RS005
7. Install lower return spring (6) and upper return spring

(5).
The parking brake lever side (secondary side) return
spring must be installed on the outer side of the
primary side return spring.
308RW004
Legend
(1) Parking Brake Lever
6. Remove cable fixing bolt (8) and bolt (9) (10) (11).
7. Remove nut (12).
8. Remove nut (13) and retainer (14).
9. Remove rear cable (15).
Installation
connecting portion of the rear cable and equalizer.
Install rear cable (15).
2. Install retainer (14).
D Tighten nut (13) to the specified torque.
Torque: 41Nm (4.2 kgm/30lb ft)
3. Tighten nut (12) to the specified torque.
308RS003
Legend
(1) Outer Side
(2) Parking Lever

4. Tighten bolt (11) (10) (9) to the specified torque.
Torque: 6.5Nm (0.66 kgm/57lb in)
D To adjust the parking brake, refer to Parking Brake
Adjustment in this section.
5. Tighten the cable fixing bolt (8) to the specified
8. Install holding spring (4).

9. Install rotor (drum) (3).
10. Install caliper assembly (2).
11. Install rear wheels (1).
5D6

Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is less
than 1.0 mm (0.039 in).
Minimum limit: 1.0 m (0.039 in)
7. When poor braking effect possibly resulting from

insufficient breakin is felt, or just after replacement
of parking brake shoe, be sure to conduct breakin as
follows:
8. Forward 50 km/h (30 mph) 400 m (About 30
seconds) with a lever pull force of 15 kg (33 lb).
9. Backward 10 km/h (6 mph) 50 m (About 18
NOTE: Breakin procedures must be performed under
safe conditions and traffic rules.
D If braking effect still remains poor after the above
breakin, wait for some time until parking brake shoe
cools down and repeat the procedures 8. and 9. noted
above.
D On completion of breakin, inspect parking brake
lever stroke, and if the lever does not come within the
specified number of notches when pulled up,
readjust.
D Excessive breakin may cause premature wear of
the parking brake lining.
308RS004
Parking Brake Rotor (Drum) Inspection

Refer toRear Disc Brakes in Power-Assisted Brake
System section for inspection procedure of the rotor
(drum).
Parking Brake Adjustment

1. Prior to lever stroke adjustment, adjust rear brake
shoe/rotor (drum) gap. Perform this procedure with
loosening the adjust nut of the hand brake lever.
2. Remove the adjusting hole plug (rubber) and turn the
shoe adjusting screw downward with a small
screwdriver so that shoes will expand until they get
into close touch with the rotor. (Turn down the
adjusting screw notch by notch until the rotor does not
turn.)
3. Turn the adjusting screw in the opposite direction
(upward) until the rotor can be turned lightly. Standard
number of notches to turn upward: 7 or 8
Turn the rotor and make sure that there is no brake
dragging.
4. After the rear brake shoe/rotor (drum) gap has been
adjusted, perform parking brake cable adjustment.
5. Turn the adjusting nut so that the parking brake lever
travels 68 notches when pulled up with a force of 30
kg (66 lb).
6. Make sure there is no brake dragging. Then tighten
the cable lock nut
Torque : 13 Nm (113 lb in)
5D7

Model
Type
Drum inside diameter
Parking brake lever stroke
Duoservo
210 mm(8.27 in)
68 notches
When pulled with a force of 294 N (30 kgm/66 lb)
E05RX003
SECTION
ENGINE MECHANICAL (X22SE 2.2L)
6A1
ENGINE
CONTENTS
Engine Mechanical..........................................
Engine Cooling................................................
Engine Fuel .....................................................
Engine Electrical .............................................
Ignition System................................................
Starting and Charging System ........................
6A -1
6B -1
6C -1
6D1 -1
6D2 -1
6D3 -1
Driveability and Emissions ..............................

Engine Exhaust ...............................................
Engine Lubrication ..........................................
Engine Speed Control System ........................
Induction ..........................................................
6E1 -1
6F -1
6G -1
6H -1
6J -1

CONTENTS
Engine Diagnosis........................................
Cylinder Head Cover.....................................
Removal .....................................................
Installation ..................................................
Exhaust Manifold...........................................
Removal .....................................................
Installation ..................................................
Crankshaft Pulley ..........................................
Removal .....................................................
Installation ..................................................
Intake Manifold..............................................
Removal .....................................................
Installation ..................................................
Cylinder Head Assembly...............................
Removal .....................................................
Installation ..................................................
Timing Belt ....................................................
Removal .....................................................
Installation ..................................................
Camshaft.......................................................
Removal .....................................................
Installation ..................................................
Engine Assembly ..........................................
Engine and Associated Parts .....................
Removal .....................................................
Installation ..................................................
Cylinder Head ...............................................
Cylinder Head and Associated Parts ..........
Disassembly ...............................................
Reassembly ................................................
Valve Spring, Valve, Valve Guide .................
Valve Spring, Valve, Valve Guide and
Associated Parts ...................................
6A - 2
6A - 2
6A - 4
6A - 17
6A - 17
6A - 18
6A - 19
6A - 19
6A - 19
6A - 20
6A - 20
6A - 20
6A - 21
6A - 21
6A - 22
6A - 24
6A - 24
6A - 26
6A - 32
6A - 32
6A - 33
6A - 36
6A - 36
6A - 37
6A - 39
6A - 39
6A - 39
6A - 41
6A - 43
6A - 43
6A - 43
6A - 44
6A - 45
6A - 46
6A - 46
Disassembly ...............................................
Reassembly ................................................
Camshaft.......................................................
Camshaft and Associated Parts .................
Disassembly ...............................................
Reassembly ................................................
Crankshaft .....................................................
Crankshaft and Associated Parts ...............
Disassembly ...............................................
Reassembly ................................................
Piston and Connecting Rod ..........................
Piston, Connecting Rod and
Associate Parts .....................................
Disassembly ...............................................
Reassembly ................................................
Cylinder Block ...............................................
Cylinder Block and Associated Parts..........
Disassembly ...............................................
Reassembly ................................................
Cylinder Head Cover .....................................
Cylinder Head Cover and
Associated parts....................................
Removal......................................................
Installation...................................................
Balance Unit Assembly .................................
Balance Unit Assembly Associated Parts...
Disassembly ...............................................
Adjustment..................................................
Reassembly ................................................
Special Tools .................................................
6A - 47
6A - 47
6A - 48
6A - 49
6A - 49
6A - 49
6A - 50
6A - 51
6A - 51
6A - 51
6A - 52
6A - 53
6A - 54
6A - 57
6A - 57
6A - 57
6A - 58
6A - 60
6A - 61
6A - 61
6A - 62
6A - 62
6A - 63
6A - 64
6A - 64
6A - 65
6A - 65
6A - 67
6A - 67
6A - 68
6A - 68
6A - 70
6A - 72
6A - 77
6A2
Service Precaution
FOLLOW WARNINGS
COULD RESULT IN
REPAIRS.
and systems.
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and
protection of machined surfaces and friction areas is
part of the repair procedure. This is considered
standard shop practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and
lubricate the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

The four cylinders of this engine are identified by
numbers; cylinders 1, 2, 3 and 4, as counted from
crankshaft pulley.
General Information on Engine Service

The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due to
the small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may cause
damage to the oil pick up unit.
The 12volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause
extensive damage when the engine is started.
Cylinder Block
The cylinder block is made of cast iron. The crankshaft
is supported by five bearings. The bearing cap is made
of nodular cast iron.
Cylinder Head
The cylinder head is made of aluminum alloy casting
with a spark plug in the center.
Valve Train
Valve system is directacting invertered bucket tappet.
The valves clearance adjustment are hydraulic.
Hydraulic valve lash adjustment, no adjustment
necessary.
Intake Manifold
The intake manifold is made of aluminum alloy.
Exhaust Manifold
The exhaust manifold is made of high SiMo nodular
iron.
Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade
that meets the cylinder bore diameter. Each piston has
two compression rings and one oil ring. The piston pin is
made of caseharded steel. The connecting rods are
made of cast iron. The connecting rod bearings are
made of steel backed with babbitt metal.

Crankshaft and Bearings
The crankshaft is made of nodular cast iron. Pins and
journals are graded for correct size selection for their
bearing.
Balance Shaft
Type is lanchester (twin counterrotating shafts). The
balance shafts are made of cast iron and gears are hard
faced. The housing is made of cast iron. Backlash
adjustment method is shimbalancer housing to block
(selective fit).
6A3
6A4
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Trouble Shooting Procedure

Turn on headlights and starter switch.
Condition
Headlights go out or dim
considerably
Possible cause
Battery run down or under charged
Recharge or replace battery
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 a high tension cable from any spark plug.
Connect the spark plug tester J26792 (ST125), crank
Condition
Spark jumps across gap
No sparking takes place
Correction
the engine, and check if a spark is generated in the

spark plug tester. Before cranking the engine, make
sure that the spark plug tester is properly grounded. To
avoid electrical shock, do not touch the high tension
cable while the engine is running.
Possible cause
Correction
Spark plug defective
Clean, adjust spark gap or replace
Ignition timing incorrect
Refer to Ignition System
Fuel not reaching fuel injector(s) or

engine
Refer to item 3 (Trouble in fuel

system)
Valve timing incorrect
Adjust
Engine lacks compression
Refer to item 4 (Engine lacks

compression)
Ignition coil disconnected or broken
Connect properly or replace
Electronic Ignition System with

module
Replace
Poor connections in engine harness
Correct
Powertrain Control Module cable

disconnected or defective
Correct or replace
3. Trouble In Fuel System

Condition
Starting motor turns over and spark
occurs but engine does not start.
Possible cause
Correction
Fuel tank empty
Fill
Water in fuel system
Clean
Fuel filter clogged
Replace filter
Fuel pipe clogged
Clean or replace
Fuel pump defective
Replace
Fuel pump circuit open
Correct or replace
Evaporative Emission Control

System circuit clogged
Correct or replace
Multiport Fuel Injection System

faulty
Refer to Electronic Fuel Injection"

section

4. Engine Lacks Compression
Condition
Possible cause
Correction
Spark plug loosely fitted or spark

plug gasket defective
Tighten to specified torque or

replace gasket
Adjust
Cylinder head gasket defective
Replace gasket
Valve incorrectly seated
Lap valve
Valve stem seized
Replace valve and valve guide
Valve spring weakened
Replace
Cylinder or piston rings worn
Overhaul engine
Piston ring seized
Overhaul engine.
Engine Compression Test Procedure

1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking
speed is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle
reaches the maximum level. Note the reading.
9. Repeat the test with each cylinder.
The pressure difference between the individual
cylinders should not exceed 100kPa (14.5psi).
6A5
6A6
Rough Engine Idling or Engine Stalling

Condition
Trouble in fuel injection system
Trouble in emission control system
Others
Possible cause
Correction
Idle air control valve defective
Replace
Throttle shutting off incomplete
Correct or replace
Throttle position sensor circuit open

or shorted
Correct or replace
Fuel injector circuits open or shorted
Correct or replace
Fuel injectors damaged
Replace
Fuel pump relay defective
Replace
Manifold Absolute Pressure Sensor

cable disconnected or broken
Correct or replace

defective
Replace
Engine Coolant Temperature Sensor

Correct or replace

defective
Replace
Intake Air Temperature sensor cable

disconnected or broken
Correct or replace
Intake Air Temperature sensor

defective
Replace
Knock Sensor (KS) circuits open or

shorted
Correct or replace
KS defective
Replace
KS Module circuits open or ground
Correct or replace
KS Module defective
Replace
Vehicle Speed Sensor circuit open

or shorted
Correct or replace
Vehicle Speed Sensor defective
Replace
Powertrain Control Module defective
Replace
Exhaust Gas Recirculation Valve

faulty
Replace
Canister purge solenoid circuit open
Correct
Canister purge solenoid defective
Replace
Evaporative Emission Canister

Purge control valve defective
Replace
Trouble in ignition system
Refer to Hard Start Troubleshooting

Guide

Guide
Lap valve
Air Cleaner Filter clogged
Replace filter element
Readjust
Idle air control valve broken
Replace
6A7
Rough Engine Running

Condition
Engine misfires regularly
Engine knocks regularly

Engine lacks power
Possible cause
Correction
Ignition coil layer shorted
Replace
Spark plugs fouling
Clean or install hotter type plug
Spark plug(s) insulator nose leaking
Replace
Fuel injector(s) defective
Replace
Engine control module faulty
Replace
Spark plugs running too hot
Install colder type spark plugs
Powertrain control module faulty
Replace
Spark plugs fouled
Clean
Fuel injectors defective
Replace
Manifold Absolute Pressure (MAP)

Sensor or Manifold Absolute
Pressure Sensor circuit defective
Correct or replace

or Engine Coolant Temperature
Sensor circuit defective
Correct or replace
Engine Control Module faulty
Replace
Intake Air Temperature Sensor or

Intake Air Temperature Sensor
circuit defective
Correct or replace
Throttle Position Sensor or Throttle

Position Sensor circuit defective
Correct or replace
Knock Sensor or Knock Sensor

circuits defective
Correct or replace
Knock Sensor Module or Knock

Sensor Module circuits defective
Correct or replace
6A8
Hesitation
Condition
Hesitation on acceleration
Hesitation at high speeds

(Fuel pressure too low)

(Fuel injector not working normally)
Possible cause
Correction
Throttle Position Sensor adjustment

incorrect
Replace throttle valve assembly
Throttle Position Sensor circuit open

or shorted
Correct or replace
Excessive play in accelerator

linkage
Adjust or replace

Sensor circuit open or shorted
Correct or replace
MAP Sensor defective
Replace
Intake Air Temperature (IAT) Sensor

circuit open or shorted
Correct or replace
Knock Sensor (KS) Circuit open or

shorted
Correct or replace
KS defective
Replace
KS Module circuits open or shorted
Correct or replace
KS Module defective
Replace
IAT Sensor defective
Replace
Fuel tank strainer clogged
Clean or replace
Fuel pipe clogged
Clean or replace
Fuel filter clogged
Replace
Defective fuel pump system
Check and replace
Fuel Pressure Control Valve leaking
Replace
Power supply or ground circuit for

shorted or open
Check and correct or replace
Cable of Multiport Fuel Injection

System disconnected or defective
Correct or replace
Engine Control Module defective
Replace

or shorted
Correct or replace
Throttle Position Sensor defective
Replace

Correct or replace

defective
Replace
MAP Sensor cable open or shorted
Correct or replace
Replace
IAT Sensor circuit open or shorted
Correct or replace
Replace
KS Circuit open or shorted
Correct or replace
KS defective
Replace
KS Module circuit open or shorted
Correct or replace
KS Module defective
Replace
Throttle valve not wide opened
Power supply voltage too low
6A9
Engine Lacks Power

Condition
Trouble in fuel system
Trouble in intake or exhaust system

Ignition failure
Possible cause
Correction
Fuel Pressure Control Valve not

working normally
Replace
Fuel injector clogged
Clean or replace
Fuel pipe clogged
Clean
Fuel filter clogged or fouled
Replace
Fuel pump drive circuit not working

normally
Correct or replace
Fuel tank not sufficiently breathing

due to clogged Evaporative
Emission Control System circuit
Clean or replace
Clean
Inferior quality fuel in fuel system
Use fuel of specified octane rating
Engine Control Module supplied

poor voltage
Correct circuit
Throttle Position Sensor cable

Correct or replace
Replace

not working normally
Replace
Intake Air Temperature Sensor not

working normally
Replace

Correct or replace

defective
Replace
Replace
Air duct kinked or flattened
Correct or replace

Guide
Heat range of spark plug inadequate
Install spark plugs of adequate heat

range

module
Replace
6A10

Condition
Engine overheating
Possible cause
Correction
Level of Engine Coolant too low
Replenish
Thermo switch or fan motor

defective
Replace
Thermostat defective
Replace
Engine Coolant pump defective
Correct or replace
Radiator clogged
Clean or replace
Radiator filler cap defective
Replace
Level of oil in engine crankcase too

low or wrong oil in engine
Change or replenish
Resistance in exhaust system

increased
Clean exhaust system or replace

defective parts

incorrect
Adjust Wide Open Throttle switch

setting

or shorted
Correct or replace
Cylinder head gasket damaged
Replace
Engine overcooling
Replace (Use a thermostat set to

open at 92C (197.6F))
Refer to Hard Start
Others
Tire inflation pressure abnormal
Adjust to recommend pressures
Brake drag
Adjust
Clutch slipping
Adjust or replace

high
Correct level of engine oil

defective
Replace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and other
Condition
Noise from crank journals or from
crank bearings
(Faulty crank journals and crank
bearings usually make dull noise
that becomes more evident when
accelerating)
moving parts of the engine. It is, therefore, advisable to

locate the source of noise systematically.
Possible cause
Correction
Oil clearance increased due to worn

crank journals or crank bearings
Replace crank bearings and

crankshaft or regrind crankshaft and
install the over size bearing
Crankshaft out of round

Crank bearing seized
Crank bearing seized Replace crank

bearings and crankshaft or regrind
crankshaft and install the over size
bearing
6A11
Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defective
bearing by listening for abnormal noise that stops when
spark plug is shorted out.
Condition
Noise from connecting rods or from
connecting rod bearings
(Faulty connecting rods or
connecting rod bearings usually
make an abnormal noise slightly
higher than the crank bearing noise,
which becomes more evident when
engine is accelerated)
Possible cause
Correction
Bearing or crankshaft pin worn
Replace connecting rod bearings

and crankshaft or regrind crankshaft
and install the under size bearing
Crankpin out of round

Connecting rod bent
Correct or replace
Connecting rod bearing seized

Abnormal noise stops when the spark plug on the
cylinder with defective part is shorted out.
Condition
Piston and cylinder
(Faulty piston or cylinder usually
makes a combined mechanical
thumping noise which increases
when engine is suddenly
accelerated but diminishes gradually
as the engine warms up)
Possible cause
Correction
Piston clearance increased due to

cylinder wear
Replace piston and cylinder body
Piston seized
Piston ring broken
Piston defective
Replace pistons and others
Short out each spark plug and listen for change in
engine noise.
Condition
Piston pin noise
(Piston makes noise each time it
goes up and down)
Possible cause
Piston pin or piston pin hole worn
Correction
Replace piston, piston pin and
connecting rod assy
6A12
The slapping sound stops when spark plug on bad
cylinder is shorted out.
Condition
Timing belt noise
Possible cause
Correction
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 wheels defective
Replace
Timing belt comes in contact with

timing cover
Replace timing belt and timing cover
Valve and valve guide seized
Valve spring broken
Replace
Valve seat offpositioned
Correct
Crankshaft noise
Crankshaft end play excessive

(noise occurs when clutch is
engaged)
Replace thrust bearing
Engine knocking
Preignition due to use of spark plugs

of inadequate heat range
Install Spark Plugs of adequate heat

range
Fuel too low in octane rating
Replace fuel
Wide Open Throttle enrichment

system failure
Refer to Section 6E
Selection of transmission gear

incorrect
Caution operator of incorrect gear

selection
Engine overheating
Refer to Engine Lacks Power"
Water pump defective
Replace
Drive belt slipping
Adjust tension of drive belt or

replace drive belt
Valve noise
Others
6A13
Abnormal Combustion
Condition
Possible cause
Correction
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
Clean or replace
Replace
Power supply cable for fuel pump

loosely connected or defective
Reconnect, correct or replace

Correct or replace

defective
Replace
Engine Coolant Temperature (ECT)

Correct or replace
ECT Sensor defective
Replace

incorrect
Reconnect
Replace
Throttle Position Sensor connector

loosely connected
Reconnect
Vehicle Speed Sensor cable loosely

connected or defective
Correct or replace
Vehicle Speed Sensor loosely fixed
Fix tightly
Vehicle Speed Sensor in wrong

contact or defective
Replace
Engine Control Module cable loosely

Correct or replace
Heated Oxygen Sensor circuit open
Correct or replace
Heated Oxygen Sensor defective
Replace
Signal vacuum hose loosely fitted or

defective
Correct or replace

defective
Replace
ECT Sensor circuit open or shorted
Correct or replace
Replace
Evaporator system
Refer to Section 6E
Trouble in cylinder head parts
Carbon deposits in combustion

chamber
Remove carbon
Carbon deposit on valve, valve seat

and valve guide
Remove carbon
6A14
Engine Oil Consumption Excessive

Condition
Oil leaking
Possible cause
Correction
Oil pan drain plug loose
Retighten or replace gasket
Oil pan setting bolts loosened
Retighten
Oil pan gasket broken
Replace gasket
Front cover retaining bolts loose or

gasket broken
Head cover retaining bolts loose or

gasket broken
Oil filter adapter cracked
Replace
Oil filter attachings bolt loose or

rubber gasket broken
Retighten or replace oil filter
Crankshaft front or rear oil seal

defective
Replace oil seal
Oil pressure unit loose or broken
Retighten or replace
Blowby gas hose broken
Replace hose
Engine/Transmission coupling area
Replace oil seal
Oil leaking into combustion

chambers due to poor seal in valve
system
Valve stem oil seal defective
Replace
Valve stem or valve guide worn

chambers due to poor seal in
cylinder parts
Cylinders and pistons worn

excessively
Rebore cylinder and replace pistons

and others
Piston ring gaps incorrectly

positioned
Correct
Piston rings set with wrong side up
Correct
Piston ring sticking

and others
Piston ring and ring groove worn
Return ports in oil rings clogged
Clean piston and replace rings
Crank case ventilation, Positive

Crankcase Ventilation System
malfunctioning
Positive Crankcase Ventilation Hose

clogged
Clean
Others
Improper oil viscosity
Use oil of recommended S.A.E.

viscosity
Continuous high speed driving and/

or severe usage such as trailer
towing
Continuous high speed operation

and/or severe usage will normally
cause increased oil consumption
6A15
Fuel Consumption Excessive

Condition
Possible cause
Correction
Mixture too rich or too lean due to

trouble in fuel injection system
Refer to Abnormal Combustion"
Fuel cut function does not act
Misfiring or abnormal combustion

due to trouble in ignition system
Refer to Hard Start or Abnormal

Combustion Troubleshooting Guide
Others
Engine idle speed too high
Reset Idle Air Control Valve
Returning of accelerator control

sluggish
Correct
Fuel system leakage
Correct or replace
Clutch slipping
Correct
Brake drag
Correct

incorrect

selection
Excessive Exhaust Gas

Recirculation flow due to trouble in
Exhaust Gas Recirculation system
Refer to Abnormal Combustion
Oil Problems
Condition
Oil pressure too low
Oil contamination
Oil not reaching valve system
Possible cause
Correction
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

rod bearing worn
Replace
Wrong oil in use
Replace with new engine oil
Oil filter clogged
Replace oil filter
Cylinder head gasket damage
Replace gasket
Burned gases leaking
Replace piston and piston rings or

rebore cylinders
Oil passage in cylinder head or

cylinder body clogged
Clean or correct
Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil.
a Check the viscosity of the oil.
b Change the oil if the viscosity is outside the
specified standard.
c Refer to the Maintenance and Lubrication"
section of this manual.
2. Check the engine oil level.
The level should fall somewhere between the ADD"
and the FULL" marks on the oil level dipstick.
If the oil level does not reach the ADD" mark on the
oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.

4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach
normal operating temperature (About 80C).
6. Measure the oil pressure.
Oil pressure should be:
150 kPa (21.8 psi) at idle speed.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.
6A16
Malfunction Indicator Lamp

The instrument panel CHECK ENGINE" Malfunction
Indicator Lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of engine,
or senses malfunctions.
Condition
CHECK ENGINE" MIL does not
illuminate at the starting of engine
CHECK ENGINE" MIL illuminates,

and stays on
Possible cause
Correction
Bulb defective
Replace
MIL circuit open
Correct or replace
Command signal circuit to operate

self diagnostic system shorted
Correct or replace
Powertrain Control Module (PCM)

cable loosely connected,
Correct or replace
PCM defective
Replace
Deterioration heated oxygen sensor

of internal element
Replace
Heated oxygen sensor connector

terminal improper contact
Reconnect properly
Heated oxygen sensor lead wire

shorted
Correct
Heated oxygen sensor circuit open
Correct or replace
Deterioration engine coolant

temperature sensor of internal
element
Replace
Engine coolant temperature sensor

connector terminal improper contact
Reconnect properly

lead wire shorted
Correct

circuit open
Correct or replace
Throttle position sensor open or

shorted circuits
Correct or replace
Deterioration of crankshaft position

sensor
Replace
Crankshaft position sensor circuit

open or shorted
Correct or replace
Vehicle speed sensor circuit open
Correct or replace
Manifold absolute pressure sensor

Correct or replace
Intake air temperature sensor circuit

open or shorted
Correct or replace
Fuel injector circuit open or shorted
Correct or replace
PCM driver transistor defective
Replace PCM
Malfunctioning of PCM RAM

(Random Access Memory) or ROM
(Read Only Memory)
Replace PCM
6A17
Cylinder Head Cover

Removal
13. Remove four bolts and remove the crankshaft pulley

2. Disconnect PCV hose from cylinder head cover.
3. Remove intake duct.
4. Remove left side ground cable from cylinder head
cover and disconnect ground cable connector on the
left side wheel arch. Remove right side ground
cable from generator stay and disconnect ground
cable connector on the right side wheel arch.
5. Disconnect three(black, green and blue colors)
engine wire harness connectors from chassis
harness of left rear side of compartment.
6. Disconnect cooling fan wire harness connector from
cooling fan on left side top of fan shroud.
7. Move drive belt tensioner to loose side using wrench
then remove drive belt.
020RW014
14. Remove timing belt front cover.

15. Loose fixing bolt of timing belt rear cover then
remove the camshaft angle sensor.
033RW001
8. Remove PCV hose from cylinder block.

9. Remove intake duct stay from cylinder head.
10. Remove two bolts for remove ignition cable cover
from cylinder head cover.
11. Disconnect ignition cable from ignition plug.
12. Disconnect camshaft position sensor harness and
crankshaft angle sensor harness from behind
generator.
020RW012
16. Remove ten cylinder head cover fixing bolts and

remove the cylinder head cover.
6A18
Installation

then install the drive belt to normal position.
1. Install the camshaft position sensor and tighten

timing rear cover bolt.
Torque: 8 Nm (0.8Kgm/5.9 lbft)
033RW001
020RW012
2. Install the cylinder head cover and tighten bolts to

Torque: 8 Nm (0.8Kgm/5.9lbft)
3. Install the timing belt front cover then tighten fixing
bolts to the specified torque.
6. Connect ignition cable to ignition plug.

7. Install ignition cable cover to cylinder head cover
and tighten two bolt to the specified torque.
Torque: 3 Nm (0.3Kgm/2lbft)
8. Install intake duct bracket to cylinder block.
9. Install PCV hose flange to cylinder block to the
specified torque.
4. Install the crankshaft pulley, tighten fixing bolts to
020RW015
020RW014
10. Connect cooling fan wire harness connector to

11. Connect left side ground cable to cylinder head
cover and connect other side connector to left side
wheel arch terminal.
Connect right side ground cable to generator stay
and connect other side connector to right side wheel
arch terminal.

12. Connect three(black, green and blue colors) engine
wire harness connector to chassis harness of left
rear side of engine compartment.
6A19
13. Install intake duct.

14. Connect PCV hose to cylinder head cover.
15. Connect battery ground cable.
Exhaust Manifold
Removal
2. Disconnect PCV hose from air intake duct.
3. Remove a nut from air intake duct bracket and
loosen hose clamp on throttle body. Remove air
intake duct assembly with air cleaner cover.
4. Remove air intake duct bracket with ground cable.
5. Remove four fixing bolts on exhaust manifold heat
protector.
6. Remove fixing four nuts from flange of front exhaust
pipe and remove fixing bolts from silencer side.
011RW029
2. Install front exhaust pipe to exhaust manifold and

tighten fixing nut to the specified torque.
Torque: 25 Nm (2.6Kgm/18 lbft)
027RW005
7. Remove ten exhaust manifold fixing nuts then

remove exhaust manifold.
Installation
1. Install exhaust manifold and tighten fixing nuts to be
tightened in three steps.
Tightening sequence:
Step1: J G H B D C J G B D
027RW005
Step2: A B C D E F G H J K
Tightening torque:
Step1: 14 Nm (10 Ibft)
3. Tighten silencer side bolt to the specified torque.

4. Install exhaust manifold heat protector and tighten
bolt.
5. Install intake duct bracket with ground cable.
6. Install intake duct assembly to throttle body and air
6A20
cleaner then tighten nut to the intake duct bracket

and clamp on the throttle body side, also clamp air
cleaner cover.
7. Connect PCV hose to air intake duct.

Crankshaft Pulley
Removal
Installation

2. Move drive belt tensioner to loose side by using
wrench then remove drive belt.
1. Install the crankshaft pulley to crankshaft flange.

2. Tighten four bolt to the specified torque.
033RW001
3. Remove four crankshaft pulley fixing bolts, remove

crankshaft pulley.
020RW014

wrench, then install drive belt to normal position.
020RW014
033RW001
6A21
Intake Manifold
Removal
2. Remove PCV hose from air intake duct.
5. Remove water hoses from throttle body.
6. Disconnect the connector for throttle position
sensor, idle air control valve sensor from throttle
body.
7. Remove fuel pipe joint eye bolts from fuel rail and
disconnect wire harness from fuel injector.
065RW025
11. Remove water pipe fixing bolt then remove water

pipe.
12. Remove fixing bolt from bracket (Between cylinder
block and intake manifold) of intake manifold side.
042RW001
8. Disconnect hose from fuel pressure regulator then

remove fuel rail assembly.
9. Remove throttle valve control cable from throttle
body.
10. Remove fixing bolts for generator bracket.
025RW002
6A22
13. Remove ignition coil bracket fixing bolt.

14. Remove bolt and seven nuts, and remove intake
manifold.
025RW002
027RW002
4. Install water pipe to intake manifold.

5. Install generator bracket and tighten generator
bracket bolts.
Torque
Installation
1. Install intake manifold with gasket to cylinder head,
tighten bolt and nuts to the specified torque.
Long bolts: 35 Nm (3.6Kgm/25lbft)

Short bolts: 20 Nm (2.0Kgm/14lbft)
065RW025
027RW002
2. Install ignition coil bracket fixing bolt.

3. Install intake manifold bracket, tighten bolt.

6. Install fuel rail assembly to intake manifold and
connect hose between fuel pressure regulator and
throttle body.
7. Install fuel pipe and tighten joint eye bolt and
connect fuel injector harness.
042RW001
8. Connect the connector for throttle position sensor

and idle air control valve sensor to throttle body.
9. Install water hoses to throttle body.
and clamp on the throttle body side and air cleaner
side.
11. Install PCV hose to air intake duct.
12. Install throttle valve control cable to throttle body.
13. Confirm the free play of throttle valve control cable.
Free play: 5.7 to 6.3 mm
14. Fill engine coolant to full level from radiator filler
neck.
6A23
6A24
Cylinder Head Assembly

Removal
10. Remove three bolts from generator bracket then

remove the generator with brackets.

2. Disconnect connector of intake air temperature
sensor from intake air duct.
4. Remove nut from air intake duct bracket and loosen
hose clamp on throttle body. Remove air intake duct
assembly with air cleaner cover.
5. Remove intake air duct bracket from cylinder head.
065RW025
11. Disconnect crankshaft angle sensor connector.

12. Disconnect knock sensor connector.
13. Remove heater hose from adapter side.
14. Remove heater hose from water pipe side.
15. Remove water hose between water pipe and throttle
body.
16. Remove fuel pipe joint eye bolts from fuel rail
assembly and remove fuel pipe bracket with electric
ground cable.
033RW001
8. Remove radiator upper hose from engine side.

9. Remove four nuts of exhaust front pipe.
042RW001
6A25
27. Disconnect camshaft angle sensor connector.

28. Remove ten bolts and remove cylinder head cover.
29. Remove fixing bolt of timing belt tensioner then
remove timing belt tensioner.
17. Disconnect connector for evaporation valve.

18. Remove canister hose.
19. Remove fixing nut of intake manifold stay from
cylinder block side.
025RW002
20. Remove two bolts from intake manifold for water

pipe support and remove cylinder head assembly.
21. Remove engine harness cover and disconnect three
connectors from chassis harness on left rear side
engine compartment.
22. Disconnect connector for power steering pump
pressure switch.
23. Remove four bolts and remove crankshaft pulley.
020RW014
24. Remove two bolts and nut then remove timing belt
front cover.
25. Remove ventilation hose from cylinder block side
and from cylinder head side.
26. Remove two bolts, ignition cable cover and remove
ignition cables from spark plug.
020RW010
30. Remove timing belt.

CAUTION:
Do not bend or twist belt, otherwise its core could
be damaged. The belt should not be bent at a
radius less than 30 mm.
Timing belt drive gear counterhold with 58840
25980.
Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
Store timing belt in cool and dark place. Never
expose the belt direct sunlight or heat.
31. Remove two idle pulleys, the left side with idle pulley
bracket.
32. Remove two bolts and stud bolt and remove timing
belt rear cover.
33. Remove camshaft angle sensor
6A26
34. Disconnect engine oil pressure switch connector.
Installation
1. Put cylinder head gasket on the cylinder block.
050RW005
35. Remove camshaft assembly exhaust side.

36. Use 5884026000 to remove ten cylinder head
fixing bolts
012RW011
2. Install the cylinder head assembly, tighten cylinder

head bolts by four steps tightening method in the
following sequence to the specified torque.(use 5
884026000)
Torque: 25 Nm (2.5Kgm/18lbft) + 90 + 90 + 90
012RW007
012RW006

3. Install camshaft assembly exhaust side and tighten
camshaft bracket bolts in the sequence to the
specified torque.
6A27
7. Install left side idle pulley with idle pulley bracket,

tighten to the specified torque and install right side
idle pulley and tighten to the specified torque.
015RW014
4. Connect engine oil pressure switch connector.

5. Install camshaft angle sensor.
6. Install the timing belt rear cover and tighten three
Torque
M6 bolt: 6 Nm (0.6Kgm/4.4lbft)
020RW012
020RW016
8. Install timing belt tensioner then tighten it

temporarily until make alignment timing belt.
9. Install the cylinder head cover and tighten fixing bolt
temporally.
10. Install the timing belt and perform timing belt setting
procedure as follows.
1. Bring the engine top dead center No.1 cylinder
compression stroke by rotating the engine in the
direction of normal operation.
The engine is in this position when the notches
on the camshaft pulleys align with the marks on
the cylinder head cover(1), Check the
crankshaft pulley timing mark is aligned (2) also
check for water pump positioning ensure tabs
are aligned (3).
Rotate the engine two full turns in the
direction of normal operation until the engine
is again at top dead centre, No.1 cylinder
firing being careful that all movement is in a
clockwise direction.
6A28
If the engine is turned too far, do not turn

backwards, but continue to turn in the same
direction until the marks are again in line.
014RW063
014RW067
2. Place 5884026590 to between intake and

exhaust of camshaft drive gear to prevent
camshaft drive gear movement during timing
belt setting.
014RW066
014RW065

3. Set the timing belt shown in the illustration,
ensure that tension side of the timing belt is taut
and move the timing belt tension adjustment
lever clockwise, until the pointer of the tensioner
is flowing.
6A29
For new timing belt: The pointer must be at the

center of V" notch when viewed from the front
of the engine.
014RW062
4. Tighten fixing bolt of timing belt tensioner to the

specified torque.
014RX061
For used timing belt(over 60 minutes from new):

the pointer will be approx. 4 mm(0.16 in) to the
left of the center of the V" notch when viewed
from the front of the engine.
020RW010
014RW069
11. Tighten cylinder head cover to the specified torque.

12. Connect camshaft angle sensor connector.
13. Install the ignition cable to spark plug.
14. Install ignition cable cover and tighten two bolts.
15. Install ventilation hoses to cylinder block side and
cylinder head side.
16. Install timing belt front cover and tighten two bolts to
6A30

24. Install fuel pipe joint eye bolts to fuel rail assembly
and install fuel pipe bracket with electric ground
cable.
17. Install crankshaft pulley and tighten four bolts.

020RW014
18. Connect connector for power steering pump

pressure switch.
19. Connect engine harness connector to chassis
harness of the left rear of engine compartment and
install engine harness cover.
20. Install two bolts to intake manifold for water pipe
support.
21. Install fixing nut of intake manifold stay to cylinder
block.
042RW001
25. Install water hose between water pipe and throttle

body.
26. Install heater hose to water pipe side.
27. Install heater hose to adapter side.
28. Connect knock sensor connector.
29. Connect crankshaft angle sensor connector.
30. Install generator with bracket and tighten three bolts.
Torque
35 Nm (3.6Kgm/25lbft) for Long bolt
20 Nm (2.0Kgm/14lbft) for Short bolt
025RW002
22. Install canister hose.

23. Connect connector for evaporation valve.
065RW025

31. Install exhaust front pipe to exhaust manifold and
tighten four nuts to the specified torque.
6A31
34. Install intake air duct bracket to cylinder head.

35. Install air intake duct assembly with air cleaner
cover to throttle body and tighten nut to the air
intake duct bracket then tighten hose clamp.
Torque
7 Nm (0.7Kgm/5.1lbft) for nut
3 Nm (0.3Kgm/2.2lbft) for hose clamp bolt
37. Connect connector of intake air temperature sensor
on intake air duct.
39. Fill engine coolant to full level in the engine coolant
reservoir tank.
027RW005
32. Install radiator upper hose to engine.

033RW001
6A32
Timing Belt
Removal
5. Disconnect three connectors of engine harness

from chassis harness of left rear side of engine
compartment.
6. Remove nut and remove engine harness cover from
front of engine.
7. Remove two bolts then remove timing belt front
cover.
remove timing belt tensioner (1).
033RW001

connectors from left rear side of engine
compartment.
020RW010

CAUTION:
25980.
the life.
020RW014
6A33
Installation
014RW066
020RW010

procedure as follows:
are aligned (3).
014RW063
014RW067
6A34
2. Place 5884026590 between intake and

exhaust of camshaft drive gear for prevent to
belt setting.
014RW065

and move the timing belt t ension adjustment
is flowing.
014RX061

The pointer will be approx. 4 mm(0.16 in) to the
014RW069
014RW064

of the engine.
6A35

020RW014
014RW062
3. Tighten fixing bolt (1) of timing belt tensioner to the

specified torque.

then install drive belt to normal position.
033RW001
020RW010

5. Install engine harness cover to front top of engine
and tighten nut to the specified torque.
8. Connect engine harness three connector to chassis

harness of left rear side of engine compartment.
6A36
Camshaft
Removal
2. Remove cylinder head cover.
Refer to removal procedure for Cylinder Head Cover
in this manual.
3. Remove timing belt tensioner and remove timing
belt.
5. Remove camshaft drive gear from intake and

exhaust camshaft.
6. Remove twenty fixing bolts from intake and exhaust
camshaft bracket on the cylinder head, then remove
camshafts.
011RW015
020RW010
4. Use adjustable wrench to hexagonal portion of

camshaft, and remove fixing bolt from front end of
camshaft.
014RW074
CAUTION:
Do not damage camshaft lobe and journal.
Do not damage hydraulic lash adjuster(HLA) and
do not allow into foreign materials into cylinder
head.
7. Remove oil seal from camshaft.
Installation
1. Clean surface of camshaft bracket and HLA.
2. Apply engine oil to journal surface of camshaft
bracket and HLA.
3. Install camshaft to cylinder head.
4. Install camshaft bracket according to numerical as
shown in the illustration.
The bracket number is:
Exhaust: 1 to 5 from front
Intake: 6 to 10 from front.
6A37
Camshaft oil seal installation area on the cylinder

body of No.1, No.6 and camshaft bracket rear side
plug portion must be applied HN1023 or equivalent
as in the illustration.
014RW073
5. Tighten camshaft bracket bolts to the specified

torque by sequence in the illustration.
6. Use 5884026580 for installation camshaft oil
seal.
014RW052
014RW075
015RW014
6A38

Also align a guide hole on the camshaft drive gear
marked IN" for intake and EX" for exhaust to guide
pin on the camshaft when instaling the camshaft
drive gear.
014RW071
7. Install the camshaft drive gear. Align the timing mark

between notch on the camshaft drive gear(1) and
lug on the camshaft bracket(2).
014RW072
8. Tighten camshaft bracket fixing bolt to the specified

torque.
014RW076
015RW014
9. Install timing belt.

Refer to installation procedure for Timing Belt in this
manual.
10. Install cylinder head cover.
Refer to installation procedure for Cylinder Head
Cover in this manual.
6A39
Engine Assembly
Engine and Associated Parts
755RX032
Removal
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood to
original position exactly.
4. Remove engine hood.
5. Drain engine coolant from radiator.
6. Disconnect throttle valve control cable from throttle
valve on intake manifold.
7. Remove air duct with air cleaner cover.
8. Remove air cleaner assembly.
9. Disconnect three engine harness connectors from
chassis harness of left rear side engine
compartment.
10. Disconnect vacuum hose on the brake booster.
11. Disconnect cooling fan harness connector on the
left of fan shroud.
12. Disconnect ground cable connector from left and
right of front wheel arch upper side.
13. Remove clutch piping bracket from right side of
clutch housing.
14. Remove fuel piping bracket from transmission.

15. Remove four nuts from exhaust front pipe exhaust
manifold side and remove two bolts from rear side of
exhaust front pipe. Remove exhaust front pipe.
027RW005
6A40
16. Remove transmission mounting fixing bolts and nut

from cross member.
29. Remove engine mounting bolt from chassis frame

side.
022RW014
022RW005
17. Remove transmission front under cover from front

portion of clutch housing.
18. Disconnect two fuel pipes at right side of
transmission by quick type fuel hose connector.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
19. Disconnect canister hose next to fuel piping
connector.
20. Remove propeller shaft fixing bolt from rear side
transmission.
21. Remove fixing bolts between clutch housing and
transmission, then move transmission.
22. Remove power steering pump assembly then place
the power steering pump along with piping.
23. Disconnect two chassis harness connectors from
right rear side engine compartment (under fuse box)
and remove two harness clips.
24. Remove engine ground cable from chassis frame.
25. Remove radiator lower hose from engine side.
26. Remove two heater hoses from right side panel.
28. Remove harness clip from behind right horn.
022RW006
30. Lift up the engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. If assembled in the condition that dowels
have not been mounted in the specified position,
transmission damage can result.
1. position the engine assembly in the engine
compartment.
2. Tighten engine mounting bolt to frame side to the
specified torque.
6A41
3. Install harness clip behind right horn.

4. Install the radiator grille and install flasher lamp
assembly.
5. Install two heater hoses to right side panel.
6. Install radiator lower hose to engine.
7. Install engine ground cable to chassis frame.
8. Connect two chassis harness connectors to right
rear side engine room(under fuse box) and install
two harness clips.
9. Install power steering pump assembly and tighten
fixing bolts.
10. Install transmission assembly, refer to installation
procedure for Transmission section in this manual.
11. Install propeller shaft, refer to installation procedure
for Propeller section in this manual.
12. Connect canister hose next to fuel piping connector.
13. Connect two fuel pipes at right side transmission by
quick type connector.
14. Install transmission front under cover to front portion
of clutch housing.
15. Install transmission mounting fixing bolts and nuts to
cross member.
022RW005
022RW014
022RW006
6A42

silencer, then tighten fixing nuts and bolts to the
specified torque.
Torque
25 Nm (2.5Kgm/18lbft) for nut
68 Nm (6.9Kgm/50lbft) for bolt
17. Install fuel piping bracket to transmission.

18. Install clutch piping bracket to right side of clutch
housing.
19. Connect ground cable connector to left and right of
front wheel arch upper side.
20. Connect cooling fan harness connector on the left of
fan shroud.
21. Connect vacuum hose to the brake booster.
22. Connect three engine harness connectors to
chassis harness of left rear side of engine
compartment.
23. Install air cleaner assembly.
24. Install air duct with air cleaner cover to specified
torque.
Torque
7 Nm (0.7Kgm/5.1lbft) for air duct fixing
3 Nm (0.3Kgm/2.2lbft) for air duct clamp bolt
25. Connect throttle valve control cable to throttle valve
on the intake manifold.
Confirm the free play of throttle valve control cable.
027RW005
26. Install engine hood to original position.

Refer to installation procedure for Body section in
this manual.
27. Install battery, connect positive cable and ground
cable.
28. Fill engine coolant to full level in the coolant
reservoir tank.
6A43
Cylinder Head
Cylinder Head and Associated Parts
011RW010
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Cylinder Head Bolt

Camshaft Pulley Fixing Bolt
Camshaft Pulley
Camshaft Oil Seal
Camshaft Bracket Bolt
Camshaft Exhaust
(7)
(8)
(9)
(10)
(11)
Camshaft Intake
Tappet (HLA)
Split Collar
Valve Spring and Spring Upper Seat
Valve
EndOFCallout
Disassembly
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so that
they can be reinstalled in their original locations.
Before removing the cylinder head from the engine
and before disassembling the valve mechanism,

perform a compression test and note the results.
1. Remove camshaft pulley fixing bolt (2), then pulley
(3).
2. Remove camshaft bracket fixing bolt (5), camshaft
bracket, then camshaft exhaust (6), and intake side
(7).
6A44
3. Remove cylinder head.

Use 5884026000.
4. Valve spring, valve spring caps, compress valve
spring use 5884025460 (1) and Adapter 5
884026620 (2).
Valve keepers.

1. Check length and width of cylinder head sealing
surfaces for deformation and diagonals for warpage
use straight edge and feeler gauge.
011RW011
011RW014
5. Valves, valve stem seals use commercially

available remover pliers. Valve spring seats from
cylinder head.
2. Height of cylinder head (sealing surface to sealing

surface).
Dimension (I) 134 mm
011RW012
011RW013
Reassembly
1. Valves, valve stem seals. Refer to Valve Spring, Oil
Controller, Valve, Valve Guide in this section.
2. Valve spring, valve spring caps. Refer to Valve
Spring, Oil Controller, Valve, Valve Guide in this
section.
3. Install tappet (HLA).
4. Cylinder head with new cylinder head bolts to
cylinder block.
Tighten the bolts in 4 steps.
1st step: 25 Nm (2.5Kgm/18lbft)
2nd step: 90
3rd step: 90
4th step: 90
011RW014
5. Camshaft in cylinder head. Refer to Camshaft in this

section.
6. Camshaft pulley. Refer to Camshaft in this section.
6A45
6A46
Valve Spring, Valve, Valve Guide

Valve Spring, Valve, Valve Guide and Associated Parts
011RW024
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Camshaft Pulley Fixing Bolts

Camshaft Pulley
Camshaft Bracket Fixing Bolt
Camshaft Assembly Intake
Camshaft Assembly Exhaust
Cylinder Head Bolt
Cylinder Head
Tappet
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Split Collar
Spring Upper Seat
Valve Spring
Oil Seal
Spring Lower Seat
Valve Guide
Valve
Disassembly
6A47
1. Remove camshaft pulley (1), (2).

2. Remove camshaft assembly (Intake) (3), (4).
3. Remove camshaft assembly (Exhaust side) (5).
4. Remove cylinder head (6), (7).
5. Remove tappet (8).
6. Use 5884025460 valve spring compressor and
5884026620 adapter to remove split collar (9).
1. Use a internal micrometer to measure the diameter

valve guide.
Valve stem play
Intake : 0.03 to 0.057 mm (0.0012 to 0.0022in)
Exhaust : 0.04 to 0.067 mm (0.0016 to 0.0026in)
011RW020
Valve Guide
011RW014
7. Remove spring upper seat and valve spring (10),

(11).
8. Valve, valve guide use commercially available
remover pliers.
Valve spring lower seat from cylinder head.
CAUTION: Taking care not to damage the valve seat

contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratching or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.
Valve Seat
Valve seat width in cylinder head
Intake: 1.0 to 1.5 mm (0.039 to 0.0585 in)
Exhaust: 1.7 to 2.2 mm (0.0663 to 0.0858 in)
Valve Seat Insert Correction

Remove the carbon from the valve seat insert surface.
Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will
cause the valve seat to shrink.
011RW013
6A48
3. Strike the rod and pull it out.
2. Install valve to valve guide. Before install valve guide

apply engine oil to the outside of the valve stem.
3. Install valve spring to cylinder head. Attach the valve
spring to the lower spring seat.
4. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using 5884025460 valve
spring compressor for install the split collars.
014RS015
4. Carefully clean the valve seat pressfit section on

the cylinder head side.
5. Heat the pressfit section with steam or some other
means to cause expansion. Cool the valve seat with
dry ice or some other means.
6. Insert the pressfit section into the valve seat
horizontally.
7. Lap the valve and the seat.
Reassembly
1. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5884026630, drive
in a new oil controller.
014RS019
011RW014
5. Install tappet.
6. Install camshaft assembly.
Refer to installation procedure for Camshaft in
this manual.
6A49
Camshaft
Camshaft and Associated Parts
011RW023
Legend
(1)
(2)
(3)
(4)

Camshaft Pulley
Oil Seal
Camshaft Bracket
(5) Camshaft Bracket Fixing Bolt

(6) Camshaft Assembly Exhaust
(7) Camshaft Assembly Intake
EndOFCallout
Disassembly
1. Remove fixing bolt (1) for camshaft pulley (2).
2. Remove oil seal (3).
014RW035
6A50

4. Remove twenty fixing bolts (5) from inlet and
exhaust camshaft bracket, then camshaft brackets
(4).
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 50 Nm (5.1Kgm/37lbft) + 60 + 15
2. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the
specified torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
2. Align timing mark on intake camshaft and
exhaust camshaft to timing mark on camshaft
drive gear (one dot).
3. Tighten twenty bolts on numerical order one
side bank shown in the illustration.
4. If it required to replace oil seal of camshaft drive
gear, use 5884026580 for install the oil seal.
5. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.
011RW015
5. Remove camshaft assembly (6), (7).
014RW036
6A51
Crankshaft
Crankshaft and Associated Parts
015RW008
Legend
(1)
(2)
(3)
(4)
(5)

Oil Pump Assembly
Pan
Pan Support
Oil Strainer
(6)
(7)
(8)
(9)
(10)
Balance Unit Assembly

Piston and Connecting Rod Assembly
Main Bearing Cap
Crankshaft
Cylinder Block Assembly
EndOFCallout
Disassembly
1. Remove cylinder head assembly (1). Refer to
Cylinder head" in this manual.
2. Remove oil pan (3).
CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.
3. Remove oil pan support (4).

4. Remove oil strainer (5).
5. Remove oil pump assembly (5).
6. Balance unit assembly.
7. Remove piston and connecting rod assembly (7).
Refer to Piston, Piston Ring and Connecting Rod"
in this manual.
6A52
8. Remove flywheel.
9. Remove rear oil seal and oil baffle plate.
10. Remove main bearing cap (8).
11. Remove crankshaft (9).
12. Remove crankshaft pulse pickup sensor disc.

1. Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the
thrust clearance exceeds the specified limit, replace
the thrust bearings as a set.
4. Clean the upper and lower bearings as well as the

crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage
or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to
their original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
Thrust Clearance
Standard : 0.01 mm0.02 mm
(0.0004 in0.0008 in)
Limit : 0.21 mm (0.0118 in)
014RW055
9. Install main bearing caps, and tighten each bolt to

Main bearing caps bolts.
Torque:
014RW079
Main Bearing Clearance

1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
3. Remove the crankshaft.
2nd step: 45
3rd step: 15
Torque : 39 Nm (4.0Kgm/29lbft)

10. Measure the plastigage width and determine the oil
clearance. If the oil clearance exceeds the specified
limit, replace the main bearings as a set and/or
replace the crankshaft.
(0.0007 in0.0016 in)
6A53

1. Carefully set the crankshaft. Slowly rotate the
crankshaft and measure the runout. If the
crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Runout : 0.03 mm (0.0012 in)
Limit : 0.12 mm (0.0047 in)
014RW078
014RW077
11. Clean the plastigage from the bearings and the

crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection

Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil
seal fitting surfaces for excessive wear and damage.
Inspect the oil ports for obstructions.
2. Measure the diameter and the uneven wear of main

journal and crank pin. If the crankshaft wear
exceeds the specified limit, crankshaft must be
replaced.
Main journal diameter : 57.934 mm57.980 mm
(2.259 in2.261 in)
Crank pin diameter : 48.939 mm48.982 mm
(1.909 in.1.91 in.)
015RS009
6A54
Crankshaft Bearing Selection

When installing new crankshaft bearings or replacing
bearings, refer to the selection table below. Select and
install the new crankshaft bearings.
Crankshaft grinding dimensions
mm (in)
Production and Service

Crankshaft bearing journal dia.
Standard size
white
57.974 to 57.981 (2.2602.261)
green
57.981 to 57.988 (2.2612.2615)
brown
57.988 to 57.995 (2.26152.2618)
Undersize 0.25 (0.0097)

green/blue
57.732 to 57.738 (2.25152.2517)
brown/blue
57.738 to 57.745 (2.25172.252)
Undersize 0.5 (0.0195)

green/white
57.482 to 57.488 (2.24182.242)
brown/white
57.488 to 57.495 (2.2422.2423)
Guide bearing width

Standard size
25.950 to 26.002 (1.0121.014)
Undersize 0.25 (0.0097)
26.150 to 26.202 (1.0191.021)
26.350 to 26.402 (1.0271.029)
NOTE: Take care to ensure the bearings are positioned

correctly.
Crankshaft pulse pickup sensor disc inspection and
repair.
Inspect the crankshaft pulse pickup sensor disc for
excessive wear and damage.
Replace the crankshaft pulse pickup sensor disc if the
inspection exceeds wear and damage.
Reassembly
1. Crankshaft (12).
Install the crankshaft pulse pickup sensor disc.
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.
Carefully mount the crankshaft.
Apply engine oil to the thrust washer.
Assemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the crankshaft.
Tighten the crankshaft baring cap bolts in 3
steps:
2nd step: 45
3rd step: 15
015RW039

2. Rear oil seal (10).
Coat lip of seal rings thinly with protective grease.
Install seal ring into cylinder block, use 58840
26600 (1) and 5884025970 (2).
6A55
NOTE: Do not reuse the bolt.

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.
Piston rings position (A) every 180.
Oil scraper rings (B) offset 25 to 50 mm/1 to 2
in. to left and right from gap of intermediate ring.
015RW009
3. Flywheel (9).
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Use stopper (5884026610) to hold the
crankshaft.
015RW026
Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Match the numbered caps with the numbers on
the connecting rods. Align the punched marks on
the connecting rods and caps.
Arrow (1) on piston head points to engine timing
side, bead on connecting rod points to flywheel
side.
015RW010
5. Prevent from rotating.

Tighten the flywheel bolts in 3 steps:
2nd step: 30
3rd step: 15
015RW038
6A56
Tighten the bolts in 3 steps:

2nd step: 45
3rd step: 15
5. Install the balance unit assembly and tighten the
bolts in 2 steps:
2nd step: 45
Refer to the Balance Unit Assembly" section of this
manual.
6. Install oil pump assembly (5), refer to Oil Pump" in
this manual.
7. Install oil strainer.
8. Install oil pan support and tighten the bolts to the
specified torque.
9. Install oil pan.
1. Completely remove all residual sealant,
lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB
1207C or its equivalent) to the contact surfaces
of the oil pan. There must be no gaps in the
bead.
3. The oil pan support must be installed within 5
minutes after sealant application.
4. Tighten the bolts in to steps.
1st step: 8 Nm (0.8Kgm/5.8lbft)
2nd step: 30
10. Install cylinder head assembly, refer to Cylinder
Head" in this manual.
6A57
Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts
015RW037
Legend
(1)
(2)
(3)
(4)
(5)
(6)

Cylinder Head Gasket
Oil Pan Assembly
Pan Support
Oil Strainer
(7)
(8)
(9)
(10)
(11)
(12)

Piston Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Cap
EndOFCallout
Disassembly
1. Remove cylinder head assembly (1), refer to
Cylinder Head Removal" in this manual.
2. Remove cylinder head gasket (2).
3. Remove oil pan assembly and oil pan support (3)
refer toOil Pan and Oil Pan Support" in this manual.

4. Remove oil strainer.
5. Remove balance unit assembly.
6. Remove connecting rod cap with connecting rod
lower.
6A58

NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.
Remove any ridge or carbon build up from the top
end of the cylinder.
8. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
Piston Rings (8)

Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
Insert the piston ring into the bore.
Push the ring by the piston, at a right angle to the
wall, into the point at which the cylinder bore
diameter is the smallest.
Measure the ring end gap.
Compression Ring
1st ring
Standard:
0.30 mm0.50 mm
(0.0118 in0.0195 in)
2nd ring
Standard:
0.30 mm0.50 mm
(0.0118 in0.0195 in)
Oil ring
Standard:
0.40 mm1.40 mm
(0.0156 in0.0546 in)
015RW024
9. Remove the piston pin (9).

Heat the connecting rod and the piston pin with
oil heater, when it temperature is keep at 280
320C.
Push the piston pin with brass bar.
2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If the
piston ring groove / piston ring clearance exceeds
the specified limit, the piston must be replaced.
Compression Ring Clearance
(0.0008 in.0.0016 in)
NOTE: Keep the parts removed from each cylinder

separate. All parts must be reinstalled in their original
positions.
10. Piston (10).
11. Connecting rod (11).

Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
be replaced.
015RW025

Piston Pin (9)
6A59
Connecting Rods (11)
NOTE: Do not reuse the old piston pin.

1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three different
positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the
small end and pin does not conform to the specified
value, the connecting rod must be replaced.
(0.0008 in0.0016 in)
1. Measure the oil clearance between the connecting

rod and the crankshaft.
1. Remove the connecting rod cap nuts and the
rod caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn,
the entire bearing assembly must be replaced
as a set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.
4. Reinstall the rod caps (12) to their original
positions.
Tighten the rod cap nuts.
2nd step: 45
3rd step: 15
NOTE: Do not allow the crankshaft to rotate.
5. Remove the rod caps.
6. Measure the width of the plastigage and
determine the oil clearance. If the oil clearance
exceeds the limit, replace the rod bearing as a
set.
(0.0002 in0.0012 in)
014RW077
3. Insert the new pin into the piston and rotate it. If the
pin rotates smoothly with no backlash, the clearance
is normal. If there is backlash or roughness,
measure the clearance. If the clearance exceeds the
specified limit, the piston must be replaced.
Clearance
(0.0004 in.0.0005 in)
Limit : 0.12 mm (0.0047 in)

crankshaft pins.
6A60

mm (in)
(continued)
Conrod bearing journal dia.
Standard size
(no color code)
48.970 to 48.988 (1.90981.9105)
Undersize 0.25 (0.0097)

blue
48.720 to 48.738 (1.90011.9008)

white
48.470 to 48.488 (1.89031.891)
Conrod bearing journal width

Standard size
(no color code)
26.460 to 26.580 (1.03191.036)
Undersize 0.25 (0.0097)

blue
26.460 to 26.580 (1.03191.036)

white
26.460 to 26.580 (1.03191.036)
Conrod width
26.338 to 26.390 (1.02711.0292)
Reassembly
1. Install connecting rod
2. Install piston
3. Install piston pin
Apply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin hole
with normal finger pressure.
NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.
Attach the piston to the connecting rod with the
piston front mark and the connecting rod front
mark on the same side.
Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.
4. Install piston ring with the piston ring expander.
New piston rings with Top" uppermost use
commercially available pliers.
Position ring gaps:
1 Compression rings 180to each other as
illustrated.
2 Offset oil control rings 25 to 50 mm/1 to 2 in.
from gap of second compression ring.
015RW026
After installation, apply engine oil to the entire

circumference of the piston rings. Check to see
that all the rings rotate smoothly.
5. Install piston and connecting rod assembly.
Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces
and nuts.
Tighten the connecting rod cap nuts in 3 steps:
1st step : 35 Nm (3.6Kgm/26lbft)
2nd step: 45
3rd step: 15

NOTE: Do not apply engine oil to the bearing back
faces.
6. Oil gallery, refer to Crankshaft and Main Bearing" in
this manual.
7. Oil strainer and O-ring.
8. Install balance unit assembly, refer to Balance Unit
Assembly: in this manual.
6A61
9. Install oil pan support assembly, refer to Oil Pan

and Oil Pan Support" in this manual.
10. Install cylinder head gasket.
11. Install cylinder head assembly.
Refer to Cylinder Head" in this manual.
Cylinder Block
Cylinder Block and Associated Parts
015RW008
Legend
(1)
(2)
(3)
(4)
(5)

Oil Pump Assembly
Oil Pan
Oil Pan Support
Oil Strainer
EndOFCallout
(6)
(7)
(8)
(9)
(10)

Main Bearing Cap
Crankshaft
Cylinder Block
6A62
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove oil pan assembly.
4. Remove oil pan support.
6. Remove oil pump assembly.
8. Remove piston and connecting rod assembly.
9. Remove flywheel.
10. Remove rear oil seal retainer assembly.
11. Remove main bearing cap.
12. Remove crankshaft.
13. Remove cylinder block.

1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the
cylinder block. Be very careful not to allow any
material to accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal retainer,
and crankcase assembly installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary, use
a flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must either
be repaired or replaced.
Flatness
1. Using a straight edge and feeler gauge, check that
the upper surface of the cylinder block is not
warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if
the warpage exceeds the limit.
Warpage
Limit : 0.40 mm (0.0156 in)
Maximum repairable limit: 0.40 mm (0.0156 in)
012RW013
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.
If the measurement exceeds the specified limit, the
cylinder block must be replaced.
Diameter
Grade 1 : 85.975 mm85.985 mm
(3.3530 in3.3534 in)
Grade 2 : 85.985 mm86.025 mm
(3.3534 in3.3550 in)
Oversize : 0.5 mm (0.0195 in)
NOTE: For information on piston diameter, please refer
to the section Inspection of the Piston and Connecting
Rod Assembly" in this manual.
6A63
Reassembly
1. Install cylinder block.
2. Install crankshaft.
bearing faces.
faces.
3. Install rear oil seal.
26600 (1) and 5884025970 (2).
015RW010

faces.
Position ring gaps:
1 Compression rings 180 to each other as
illustrated (A).
from gap of second compression ring (B).
015RW009
4. Install flywheel
mounting faces.
install the washer.
crankshaft.
Prevent from rotating.
015RW026
6. Install balance unit assembly and tighten the bolts in

2 steps in the order shown:
2nd step: 30
3rd step: 15
2nd step : 45
7. Install oil pump assembly, refer to Oil Pump" in this

manual.
6A64
9. Install oil pan support.

10. Install oil pan assembly.
of the crankcase. There must be no gaps in the
bead.
3. The oil pan must be installed within 5 minutes
after sealant application.

4. Tighten the bolts and nuts to the specified
torque in 2 steps:
1st step : 8 Nm (0.8Kgm/5.8lbft)
2nd step : 30
Cylinder Head Cover

Cylinder Head Cover and Associated parts
010RW004
Legend
(1) Ignition Cable Cover
(2) Spark Plug
EndOFCallout
(3) Cylinder Head Cover
Removal
6A65
Installation
1. Remove two bolts and remove ignition cable cover

(1) from cylinder head cover (3).
2. Disconnect ignition cable and remove spark plag
(2).
4. Disconnect camshaft angle sensor harness and
generator.
5. Remove four bolts and remove the crankshaft pulley.
1. Install the camshaft angle sensor and tighten timing

rear cover bolt.
020RW012

020RW014

7. Loose fixing bolt of timing belt rear cover, then

020RW012

020RW014
6A66

033RW001

and tighten two bolts to the specified torque.
6A67

Balance Unit Assembly Associated Parts
051RW012
Legend
(1) Oil Pan
(2) Oil Pan Support
(3) Oil Strainer
EndOFCallout
(4) Balance Unit Assembly

(5) Shim
6A68
Disassembly
1. Remove the oil pan.
2. Remove the oil pan support.
3. Remove the oil strainer (1) from oil pump and the oil
baffle plate (2).
2. In this crankshaft position, the flattened side

(arrows) of both balancer shafts must face
downward and must be on a horizontal line.
051RW010
051RW009
Adjustment
3. Screw measuring device 5884026710 (3) with

long knurled bolt (1) into 1st balancer shaft (intake
side) and tighter hardtight measuring arm (5) must
point in 9 o'clock" direction shown in this illustration.
Install dial gauge holder with dial gauge (4) on
cylinder block.
1. Turn crankshaft in engine rotational direction to

alignment mark (2) 1st cylinder TDC".
051RW007
014RW066

4. Place pre tensioned probe (6) of gauge on
measuring arm of measuring device 588402671
0. The probe must be set precisely between the
notch marks, square to the plane surface (7).
6A69
6. The tooth backlash must be measured in 4 different

positions turn the crankshaft further at the
fastening bolt of the timing belt drive gear by 45 in
the engine rotational direction until the measuring
arm (2) is at 6 o'clock".
051RW006
5. Determine the left and right stops by turning the

knurled bolt (2).
Set the dial of the gauge to zero.
Use the knurled bolt (2) to move the 2nd balancer
shaft (exhaust side) back and forth. Again
simultaneously read off the tooth backlash from the
gauge.
The permissible tooth backlash is: 0.02 mm to
0.06mm (0.0008 to 0.0024in).
051RW008
7. Then loosen the knurled bolt (3) fix the measuring

arm at 9 o'clock" again and repeat the
measurement.
051RW007
8. If the value determined in one of the 4

measurements lies outside the tolerance 0.02mm to
0.06mm (0.0008 to 0.0024in), the tooth backlash
must be adjusted.
051RW007
6A70
9. Remove balance unit from cylinder block/crankshaft

bearing caps and remove with balancer piece. The
balancer piece has a number (code), for easy
assignment. The tooth backlash can be adjusted by
using a balancer piece with a different thickness.
Code
Thickness of balancer piece in mm
55
0.535 to 0.565
58
0.565 to 0.595
61
0.595 to 0.625
64
0.625 to 0.655
67
0.655 to 0.685
70
0.685 to 0.715
73
0.715 to 0.745
76
0.745 to 0.775
79
0.775 to 0.805
82
0.805 to 0.835
85
0.835 to 0.865
CAUTION: The next larger or smaller balancer

alters the tooth backlash by 0.02mm (0.0008in).
Example of selection of balancer piece: The
installed balancer piece with the code 70" gave a
tooth backlash of 0.08mm (0.0031in).
If a balancer piece with the code 67" is now
installed, the tooth backlash will be approx. 0.06mm
(0.0024in).
NOTE: Only one balancer piece may be installed.
Reassembly
2. Turn balancer shafts until the flattened sides

(arrows) of both balancer shafts face downward and
are on a horizontal line.
051RW010
3. Install selected balancer piece (2) with balancer

shaft unit to cylinder block/crankshaft bearing cap
tighten all fixing bolts to the specified torque.
4. After installing the balancer shaft unit, recheck the
tooth backlash and readjust if necessary.
CAUTION: If the balancer shaft unit has to be
replaced, use the thickest balancer piece with the
code 85" for the initial assembly this guarantees
tooth backlash in all conditions.
5. Install oil strainer to oil pump with new seal ring and
insert fixing bolts with locking agent to the specified
torque.
014RW066

Adjust surfaces of the cylinder block and the oil
pan support.
035RW026
7. Install oil pan.

2nd step: 30
6A71
6A72

Camshaft bracket, Timing gear camshaft side, Cylinder head
011RX001
6A73
Timing gear crankshaft (center bolt), Timing belt cover front, Timing belt cover rear, Timing belt tensioner,
Camshaft angle sensor
020RX001
6A74
Crankshaft main bearing, Oil pan support, Oil pan, Balance unit assembly, Connrod Cap, Oil pump, Oil
strainer
015RX004
6A75
Spark plug, Throttle body, EGR valve adaptor assembly, Bypass housing assembly, Thermostat assembly,
inlet manifold assembly, Exhaust manifold assembly, heat shield, Ignition cable cover
011RX002
6A76
Engine mount
022RX003
6A77
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884025970
Installer; Rear crankshaft
seal ring
5884026600
seal
5884026580
Remover/Installer;
Crankshaft carrier seal
5884026610
Locking device; Flywheel
5884025460
Compressor; Valve
spring (1)
(Use with
5884026620 (2) )
5884026630
Installer sleeve; Valve
stem seal
5884026620
Adapter; Compressor
Valve spring
5884026000
Socket wrench; Cylinder
head bolt
5884026590
Locking tool camshaft
gear
5884025980
Holding wrench; Driven
gear fix
6A78
ILLUSTRATION
TOOL NO.
TOOL NAME
5884026710
Screw measuring device
SECTION
ENGINE COOLING (X22SE 2.2L)
6B1

CONTENTS
Diagnosis ....................................................
Draining and Refilling Cooling System .......
Water Pump ..................................................
Water Pump and Associated Parts.............
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Thermostat ....................................................
6B - 1
6B - 2
6B - 4
6B - 4
6B - 5
6B - 5
6B - 5
6B - 5
6B - 5
6B - 6
Service Precaution
YOU ARE
IN
REPAIRS.
Removal......................................................
Inspection ...................................................
Installation...................................................
Radiator.........................................................
Radiator and Associated Parts ...................
Removal......................................................
Inspection ...................................................
Installation...................................................
Special Tool ...................................................
6B - 6
6B - 6
6B - 6
6B - 7
6B - 7
6B - 7
6B - 8
6B - 8
6B - 10
6B - 10

and systems.
6B2
General Description
111RW001
Legend
(1)
(2)
(3)
(4)
Water Pump
Thermostat
Radiator
Reserve Tank
(5)
(6)
(7)
(8)
Coolant Distributor
Cylinder Block and Head
Throttle Body
Heater
EndOFCallout
The Cooling System is a pressurized type, where the
water pump, which is cambelt driven, forces the
circulation of the coolant through the cylinder block and
head. The thermostat regulates the flow of coolant
between the radiator and the bypass circuit. The heater
is part of the bypass circuit. The throttle body preheat
is a separate circuit which is not regulated by the
thermostat. An oil cooler may be fitted as part of this
circuit.
Water Pump
The water pump is centrifugal type and is driven by
timing belt.
030RW003

Thermostat
6B3
Calculating mixing ratio
The thermostat is a bypass type and is a wax pellet type

with a air hole (1).
F06RW005
031RW003
Radiator
NOTE: Antifreeze solution + Water = Total cooling

system capacity.
Total Cooling System Capacity
7.2Lit (1.90US gal)
The radiator is a flow type with corrugated fins.
110RX005
Antifreeze Solution
Relation between Mixing ratio and Freezing
temperature of the engine coolant varies with the
ratio of antifreeze solution in water. Proper mixing
ratio can be determined by referring to the chart.
Supplemental inhibitors or additives claiming to
increase cooling capability that have not been
specifically approved by Isuzu are not recommended
for addition to the cooling system.
111RW002
Mixing ratio
Check the specific gravity of engine coolant in the
cooling system temperature ranges from 0 50
type hydrometer, then determine the
density of the engine coolant by referring to the table.
6B4
Diagnosis
Engine Cooling Trouble
Condition
Possible cause
Correction

Engine overheating
Low Engine Coolant level
Replenish
Thermo mater unit faulty
Replace
Faulty thermostat
Replace
Faulty Engine Coolant temperature

sensor
Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap
Replace
Low engine oil level or use of

improper engine oil
Replenish or change oil
Clogged exhaust system

faulty parts
Faulty Throttle Position sensor
Open or shorted Throttle Position

sensor circuit
Repair or replace
Damaged cylinder head gasket
Replace
Engine overcooling
Faulty thermostat
Replace
Engine slow to warmup
Faulty thermostat
Replace
Thermo unit faulty
Replace
Draining and Refilling Cooling System

Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
MIN" 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 at the bottom of the radiator.
2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do
not remove the cap while the engine and radiator
are still hot. Scalding fluid and steam can be blown
out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.4. Refill
the cooling system with the EC using a solution that
is at least 50 percent antifreeze but no more than 70
percent antifreeze.
4. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze but no
more than 70 percent antifreeze.

5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to MAX" line when the
engine is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to P" (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does
not go down. Then stop the engine and install the
radiator cap. Let the engine cool down.
9. After the engine has cooled, replenish with EC up to
the MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound
from the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8
to 10.
6B5
Water Pump
Water Pump and Associated Parts
030RW004
Legend
(1) Water Pump Assembly
(2) O Ring
(3) Bolt
EndOFCallout
Removal
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt, refer to Timing Belt" in this
manual.
5. Remove water pump assembly.
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
Engine Coolant (EC) leakage from the seal unit
Play or abnormal noise in the bearing
Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface
with silicon grease.
2. Install water pump assembly and tighten bolts to the
specified torque.
3. Timing belt
Install timing belt, refer to timing belt installation
step in Timing Belt" in this manual.
4. Connect radiator hose and replenish EC.
6B6
Thermostat
Removal
Inspection

2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
Suspend the thermostat in a waterfilled container

using thin wire. Place a thermometer next to the
thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
Confirm the temperature when the valve first begins to
open.
Valve opening temperature 92C (197.6F))
Confirm the temperature when the valve is fully opened.
Valve full open temperature 107C (224.6F))
Installation
1. Before installing thermostat, coat sealing surface
2. Install gasket.
3. Install thermostat housing and tighten bolts to the
specified torque.
031RW012

4. Installation rubber hose.
5. Replenish engine coolant (EC).
6. Start engine and check for EC leakage.
6B7
Radiator
Radiator and Associated Parts
110RX004
Legend
(1) Radiator
(2) Bracket
(3) Cooling Fan Assembly
(4) Radiator Cap

(5) Radiator Hose
(6) Lower Fan Guide
EndOFCallout
Removal
2. Disconnect cooling fan motor connector.
3. Loosen a drain plug to drain engine coolant.
4. Disconnect radiator inlet hose and outlet hose from
the engine.
5. Remove fan guide, clips on both sides and the
bottom lower with fan shroud.
6. Disconnect the reserve tank hose from radiator.
7. Remove bracket(2).
110RX003
6B8
8. Lift out the radiator assembly with hose, taking care

not to damage the radiator core with fan blade.
9. Remove rubber cushions on both sides at the
bottom.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Cooling System Leakage Check

Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196
kPa (28.5 psi) with a cap tester:
Leakage from the radiator
Leakage from the coolant pump
Leakage from the water hoses
Check the rubber hoses for swelling.
Cap tester: 5884002770
Adapter: 5884026030
Valve opening pressure kPa (psi) 93.3 122.7

(13.5 17.8)
Adapter: 5884026030
Check the condition of the vacuum valve in the center of
the valve seat side of the cap. If considerable rust or dirt
is found, or if the valve seat cannot be moved by hand,
clean or replace the cap.
Valve opening vacuum kPa (psi) 1.96 4.91 (0.28
0.71)
110RX002
Installation
1. Install rubber cushions on both sides of radiator
bottom.
2. Install radiator assembly with hose, taking care not
to damage the radiator core with a fan blade.
3. Install bracket and support the radiator upper tank
with the bracket and secure the radiator.
4. Connect reserve tank hose.
5. Install lower fan guide (6).
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the
fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator

Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all sign of scale and rust.

6. Connect radiator inlet hose and outlet hose to the
engine.
110RX003

8. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.
Important operation (in case of 100% engine
coolant change) procedure for filling with engine
coolant.
1. To change engine coolant, make sure that the
engine is cool.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
hot vapor or boiling water. To open the radiator cap,
put a piece of thick cloth on the cap and loosen the
cap slowly to reduce the pressure when the
coolant has become cooler.
2. Open radiator cap and drain the cooling system
by loosening the drain valve on the radiator and
on the cylinder body.
NOTE: For best result it is suggested that the engine
cooling system be flushed at least once a year. It is
advisable to flash the interior of the cooling system
including the radiator before using anti-freeze
(ethylene-glycol based).
Replace damaged rubber hoses as the engine
anti-freeze coolant is liable to leak out even minor
cracks.
Isuzu recommends to use Isuzu genuine anti-freeze
(ethylen-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
CAUTION: A failure to correctly fill the engine
cooling system in changing or topping up coolant
may sometimes cause the coolant to overflow from
the filler neck even before the engine and radiator
are completely full.
If the engine runs under this condition, shortage of
coolant may possibly result in engine overheating.
6B9
To avoid such trouble, the following precausions

should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler
neck using a filling hose which is smaller in
outside diameter of the filler neck. Otherwise air
between the filler neck and the filling hose will
block entry, preventing the system from
completely filling up.
4. Keep a filling rate of 9 liter/min or less. Filling
over this maximum rate may force air inside the
engine and radiator.
And also, the coolant overflow will increase,
making it difficult to determine whether or not
the system is completely full.
5. After filling the system to the full, pull out the
filling hose and check to see if air trapped in the
system is disclodged and the coolant level goes
down. Should the coolant level go down, repeat
topping-up until there is no more drop in the
coolant level.
6. After directly filling the radiator, fill the reservoir
to the maximum level.
7. Install and tighten radiator cap and start the
engine. After idling for 2 to 3 minutes, stop the
engine and reopen radiator cap. If the water
level is lower, replenish.
cap slowly to reduce the pressure when the coolant
has become cooler.
8. After tightening radiator cap, warm up the
engine at about 2,000 rpm.
Set heater adjustment to the highest
temperature position, and let the coolant
circulate also into heater water system.
9. Check to see the thermostat has opened
through the needle position of water
thermometer, conduct a 5-minute idling again
and stop the engine.
6B10

Cooling system
Engine Coolant forced circulation
Radiator
(1 tube in row) Tube type corrugated
Heat radiation capacity
54,000 kcal/h (62.8 kw)
Heat radiation area
7.677m2 (0.878ft2)
Radiator front area
0.264m2 (0.028ft2)
Radiator dry weight (with fan)
32N (7.2lb)
93.3 122.7kpa (13.5 17.8psi)
Radiator cap valve opening pressure

Engine coolant capacity
1.8lit (0.48 US gal)
Engine coolant pump
Centrifugal type
Thermostat
Bypass type
Engine coolant total capacity
7.2lit (1.9 US gal)
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884002770
Tester; radiator cap
5884026030
Adapter; radiator cap
SECTION
ENGINE FUEL (X22SE 2.2L)
6C1

CONTENTS
Fuel Metering..............................................
Fuel Filter ......................................................
Fuel Filter and Associated Parts.................
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Inspection ...................................................
InTank Fuel Filter......................................
Fuel Pump Flow Test..................................
Fuel Pump.....................................................
Fuel Pump and Associated Parts ...............
Removal .....................................................
Installation ..................................................
Fuel Tube / Quick Connector Fittings.........
Precautions.................................................
6C - 1
6C - 2
6C - 3
6C - 4
6C - 4
6C - 4
6C - 4
6C - 4
6C - 5
6C - 5
6C - 5
6C - 6
6C - 6
6C - 6
6C - 7
6C - 8
6C - 8
Service Precaution
REPAIRS.
Cautions During Work.................................

Removal......................................................
Reuse of QuickConnector.........................
Assembling Advice .....................................
Fuel Pump Relay...........................................
Fuel Tank ......................................................
Fuel Tank and Associated Parts.................
Removal......................................................
Installation...................................................
Fuel Gage Unit ..............................................
Removal and Installation ............................
Fuel Filler Cap ...............................................
Inspection ...................................................
Special Tool ...................................................
6C - 8
6C - 8
6C - 9
6C - 9
6C - 10
6C - 10
6C - 10
6C - 10
6C - 11
6C - 11
6C - 11
6C - 11
6C - 12
6C - 12
6C - 12
6C - 13
6C - 13

and systems.
6C2
General Description
140RX019
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Fuel Filter Cap

Fuel Tank
Rollover Valve
Fuel Pump and Sender Assembly
Fuel Filter
Fuel Rail
EndOFCallout
(7)
(8)
(9)
(10)
(11)
Intake Manifold
Fuel Pressure Control Valve
Throttle Valve
Canister
Evapo Pipe

When working on the fuel system, there are several
things to keep in mind:
Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
Replace all pipes with the same pipe and fittings that
were removed.
Clean and inspect O" rings. Replace if required.
Always relieve the line pressure before servicing any
fuel system components.
Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
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.
6C3
Fuel Metering
The Powertrain Control Module (PCM) 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 PCM.
With receipt of the signals sent from the MAP sensor,
Intake Air Temperature sensor and others, the PCM
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 PCM 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.
6C4
Fuel Filter
Fuel Filter and Associated Parts
140RX018
Legend
(1) Fuel Hose
(2) Fuel Filter
(3) Fuel Filter Holder

(4) Fuel Hose
EndOFCallout
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connections or leakage. For the fuel
system diagnosis, see Section Driveability and
Emission".
2. Remove fuel filler cap.
3. Disconnect fuel hoses(1) from fuel filter on both
engine side and fuel tank side.
4. Fuel filter fixing bolt.
Remove the fuel filter fixing bolt on fuel filter
holder(3).
5. Remove fuel filter(2).
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt or
sediment.
3. Check the drain and if it is clogged with dust, clean it
out with air.
Installation
1. Install the fuel filter in the proper direction.
2. Install fuel filter holder fixing bolt.
3. Connect fuel hoses on engine side and fuel tank
side.
4. Install fuel filler cap
5. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel leak
age.
6C5
3. Insert the hose from fuel feed pipe into a clean

container, and check for fuel pump flow rate.
4. Connect the pump relay terminals with a jumper
wire(1) as shown and start the fuel pump to
measure delivery.
InTank Fuel Filter

The filter is located on the lower end of the fuel pickup
tube in the fuel tank. It prevents dirt from entering the
fuel pipe and also stops water unless the filter is
completely submerged in the water. It is a self cleaning
type, not requiring scheduled maintenance. Excess
water and sediment in the tank restricts fuel supply to
the engine, resulting in engine stop. In such a case, the
tank must be cleaned throughly.
Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the
following checks.
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe
and hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing or
clogging.
140RW015
CAUTION: Never generate sparks when connecting

a jumper wire.
Delivery
Delivery
15 seconds
0.38 liters minimum
If the measure value is out of standard, conduct the

pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E
Fuel Control System".
6C6
Fuel Pump
Fuel Pump and Associated Parts
140RX016
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Fuel Feed Port

Fuel Tube/Quick Connector
Fuel Return Port
Connector; Fuel Feed Pump
Connector; Fuel Level Sensor
Fuel pump lock
(8)
(9)
(10)
(11)
(12)
(13)
Hose; Evaporative Fuel

Hose; Air Breather
Hose; Fuel Filler
Fuel Return Hose
Fuel Feed Hose
Fuel Tank Assembly
EndOFCallout
Removal
for loose connection or leakage. For the fuel system
diagnosis, see Section Driveability and Emission".
2. Loosen fuel filler cap.
3. Support underneath of the fuel tank assembly (13)
with a lifter.
4. Remove fuel tank assembly (13). Refer to Fuel

Tank Removal" in this section.
5. Remove Fuel Tube/Quick Connector (2).
NOTE: Handling of the fuel tube sure to refer Fuel
Tube/Quick Connector Fittings" in this section.

6. Remove fuel pump and sender (FPAS) assembly(4)
using 5884026020.
140RW068
NOTE:
After removing pump assembly (4), cover fuel tank to
prevent any dust entering.
Installation
1. Install FPAS assembly(4) using 5884026020.
2. Install Fuel Tube/Quick Connector (2).
3. Install fuel tank assembly(11). Refer to Fuel Tank
Installation".
4. Fill the tank with fuel and tighten fuel filler cap.
6C7
6C8
Fuel Tube / Quick Connector Fittings

Precautions
Lighting of Fires Prohibited.
Keep flames away from your work area to prevent the
inflammable from catching fire.
Disconnect the battery negative cable to prevent
shorting during work.
When welding or conducting other heat-generating
work on other parts, be sure to provide pretreatment
to protect the piping system from thermal damage or
spattering.
2. For removal of the delivery pipe (feeding fuel to the

engine), hold the connector in one hand, and hold
the retainer tab with the other hand and pull out the
connector, as illustrated. The pipe can be removed
with the retainer attached.
Cautions During Work

Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
The piping wet with battery electrolyte cannot be used.
Be careful not to give a bending or twisting force to the
piping during the work. If deformed, replace with a new
piping.
Removal
141RW019
1. Open the fuel cap to relieve the fuel pressure in the

tank.
If the fuel quick-connect fittings are dusty, clean with
an air blower, etc. and then remove it.
140RX015
As some pressure may remain in the piping, cover

the connector with a cloth, etc. to prevent the
splashing of fuel in the first disconnection of the
piping.
3. For removal of the return pipe (returnig fuel to the

tank), hold the pipe in one hand, and pull out the
connentor with the other hand while pressing the
square relieve button of the retainer, as illustrated.
141RW019

This work should be done by hands. Do not use any
tools. Should the pipe can hardly be removed from the
connector, use a lubricant (light oil) and/or push and pull
the connector longitudinally until the pipe is removed.
6C9
Reuse of QuickConnector
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.
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.
141RW021
When reusing the delivery pipe retainer, reuse

without removing the retainer from the pipe. If the
retainer is damaged or deformed, however, replace
with a new retainer.
Cover the connectors removed with a plastic bag,
etc. to prevent the entry of dust or rain water.
141RW018
Assembling Advice
141RX005
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.
6C10
Fuel Pump Relay

General Description
In order to control the FPAS operation, the FPAS relay is
provided. When the starter switch is turned to ON"
position, the FPAS relay operates the FPAS for 2
seconds.
When it is turned to START" position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPAS to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
140RX017
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Fuel Feed Port

Fuel Return Port
Connector; Fuel Level Sender
Fuel Pump Lock
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Hose; Air Breather

Hose; Fuel Filler
Fuel Return Hose
Fuel Feed Hose
Band; Fuel Tank Asm Fixing
Bolt; Fuel Tank Asm. Fixing
Protector; Fuel Tank
Fuel Tank Assembly
Removal
3. Support underneath of the fuel tank protector (15)
with a lifter.
4. Disconnect evaporative fuel hose (8) at the canister.
5. Disconnect fuel feed hose (12) and fuel return hose
(11) near the fuel filter.
NOTE: Plug both ends of the fuel hoses to prevent fuel
leakage.
6. Disconnect air breather hose (9) and fuel filler hose
(10) at the fuel filler neck.
NOTE: Cover fuel hose to prevent any dust entering.
7. Remove the four fuel tank assembly fixing bolts (14)
at four corners of the tank.
8. Let down the tank (16) and disconnect the wiring
connectors (5,6) and the emission hose at the
emission port on the fuel pump and sending
assembly (4).
9. Remove fuel tank assembly along with protectors
(15) .
NOTE: Handling of fuel tube sure to refer Fuel Tube/
Quick Connector Fittings" in this section.
11. Remove fuel pump and sender assembly (4) using

5884026020.
12. Remove protectors (15) by removing the band fixing
bolts (13).
Installation
1. Install protectors (15) and tighten the band fixing
2. Install fuel pump and sender (4) using 58840
26020.
4. Lift up fuel tank assembly (16) and connect the
emission hose to the emission port and the wiring
connectors (5,6) on the fuel pump and sending
assembly (4).
5. Install fuel tank assembly along with protectors and
tighten the four fixing bolts (14) to the specified
torque.
6. Connect fuel filler hose (10) and air breather hose
(9), and clip them firmly.
7. Connect fuel feed hose (12) and fuel return hose
8. Connect evaporative fuel hose (8).
9. Tighten fuel filler cap.
Fuel Gage Unit

Removal and Installation
As for removal and installation of the Fuel Gauge Unit,
refer to Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender
assembly.
6C11
6C12
Fuel Filler Cap

General Description
Fuel filler cap includes vacuum valve.
In case any high vacuum happen in tank, the valve
works to adjust the pressure to prevent the tank from
being damaged.
060RW098
Legend
(1) Vacuum Valve
(2) Fuel Filler Cap
EndOFCallout
Inspection
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
CAUTION:
The fuel filler cap valve has characteristics.
A defective valve, no valve at all or a valve with the
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.
6C13

140RX014
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884026020
Remover; fuel pump lock
(For S/W)
SECTION
ENGINE ELECTRICAL (X22SE 2.2L)
6D11
ENGINE
CONTENTS
Battery...........................................................
Diagnosis ....................................................
Battery Charging.........................................
6D1 - 1
6D1 - 2
6D1 - 2
6D1 - 2
6D1 - 3
Service Precaution
YOU ARE
IN
REPAIRS.
Jump Starting..............................................
Battery Removal .........................................
Battery Installation ......................................
6D1 - 3
6D1 - 4
6D1 - 4
6D1 - 5

and systems.
6D12
Battery
General Description
BLUE RING OR DOT NOT VISIBLE(4) Go to Step

3.
There are six battery fluid caps on top of the battery.

These are covered by a paper label.
The battery is completely sealed except for the six small
vent holes on the side. These vent holes permit the
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.
061RX001
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
Check for any other physical damage and correct it as
necessary.
3. Fluid Level Check

The fluid level should be between the upper level line(2)
and lower level line(3) on side of battery.
a CORRECT FLUID LEVEL Charge the battery.
b BELOW LOWER LEVEL Replace battery.
2. Hydrometer Check
There is a builtin hydrometer (Charge test indicator(1))
at the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a BLUE RING OR DOT VISIBLE(5) Go to Step 4.
061RX001
6D13
Battery Charging
4. Voltage Check
1. Put voltmeter test leads to battery terminals.
a VOLTAGE IS 12.4V OR ABOVE Go to Step 5.
b VOLTAGE IS UNDER 12.4V Go to procedure
(2) below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage rate
no higher than specified value.
Take voltage and amperage readings after charge.
a VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE Replace battery.
b VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE Drop charging voltage to
15V and charge for 10 15 hours. Then go to
Step 5.
c VOLTAGE IS BETWEEN 12V AND 16V
Continue charging at the same rate for an
additional 31/2 hours. Then go to Step 5.
d VOLTAGE BELOW 12V Replace Battery.
5. Load Test
1. Connect a voltmeter and a battery load tester
across the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
a VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE The battery
is good and should be returned to service.
b VOLTAGE IS LESS THAN MINIMUM LISTED
Replace battery.
ESTIMATED TEMPERATURE
MINIMUM
VOLTAGE
70
21
9.6
60
16
9.5
50
10
9.4
40
9.3
30
9.1
20
8.9
10
12
8.7
18
8.5
The battery temperature must be estimated by feel

and by the temperature the battery has been exposed
to for the preceding few hours.
Observe the following safety precautions when charging

the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick charged or slow charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
THE FOLLOWING:
1. Serous personal injury, particularly to your eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.
6D14
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.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.

5. Remove battery (5).
Jump Starting Procedure

1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the PARK"
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the NEUTRAL"
position.
Turn OFF" the ignition.
Turn OFF" all lights and any other accessory
requiring electrical power.
2. Look at the builtin hydrometer.
If the indication area of the builtin hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster 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 cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm (18
in.) from the battery of the vehicle whose battery is
being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.
Battery Removal
1. Remove negative cable (1).
2. Remove positive cable (2).
3. Remove retainer screw and rods (3).
061RX002
Battery Installation
1. Install battery (5).
3. Instal retainer screw and rods (3).
Make sure that the rod is hooked on the body side.
4. Install positive cable (2).
5. Install negative cable (1).

Model
24600
Voltage (V)
12
Cold Cranking Performance (Amp)
600
Reserve Capacity (Min)
118
Load Test (Amp)
300
BCI Group No.
24
6D15
SECTION
IGNITION SYSTEM (X22SE 2.2L)
6D21
ENGINE
CONTENTS
Diagnosis .......................................................
Ignition Module..............................................
Removal .....................................................
Installation ..................................................
Spark Plug.....................................................
6D2 - 1
6D2 - 1
6D2 - 1
6D2 - 2
6D2 - 2
6D2 - 2
6D2 - 2
Removal......................................................
Installation...................................................
Crankshaft Angle Sensor ..............................
Removal......................................................
Installation...................................................
6D2 - 2
6D2 - 2
6D2 - 3
6D2 - 4
6D2 - 4
6D2 - 4
6D2 - 5
Service Precaution
General Description

YOU ARE
IN
REPAIRS.
Ignition is done by the Ignition Module that fires.

Since the cylinder on exhaust stroke requires less
energy to fire its spark plug, energy from the ignition
coils can be utilized to fire the mating cylinder on
compression stroke.
A notch in the timing disc on the crankshaft activates the
crank angle sensor which then sends information such
as firing order and starting timing of ignition coil to the
PCM.
By receiving signals such as crank position,engine
speed,water temperature and Manifold Absolute
Pressure (MAP),the PCM controls the ignition timing.

and systems.
Diagnosis
Refer to Section Drivability and Emissions for the
diagnosis to electronic ignition system (El system).
6D22
Ignition Module
Removal
Installation

2. Remove ABS hydraulic unit assembly.
3. Remove master Vac and brake booster assembly.
4. Remove heater hoses from water rail.
5. Disconnect ignition coil cable from ignition module.
6. Remove connector from ignition module.
7. Remove ignition module assembly with bracket (1).
1. Install the ignition module assembly with bracket (1).

2. Connect ignition module connector and ignition
coil,then tighten bolt to the specified torque.
3. Connect ignition coil cable.
4. Install heater hoses.
5. Install master Vac and brake booster assembly.
6. Install ABS hydraulic unit assembly.
7. Bleed Air, brake system.
080RW001
080RW001
Spark Plug
Removal
1. Remove spark plugs.
Use spark plugs having low heat value (hot type plug)
if fuel and electrical systems are normal.
Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely burned.

The spark plug affects entire engine performance and
therefore its inspection is very important.
Check electrode and insulator for presence of
cracks,and replace if any.
Check electrode for wear,and replace if necessary.
Check gasket for damage,and replace if necessary.
Measure insulation resistance with an ohmmeter,and
replace if faulty.
Adjust spark plug gap to 0.7 mm (0.027 in) 0.8
(0.031 ).
Check fuel and electrical systems if spark plug is
extremely dirty.
Sooty Spark Plugs

Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance.
Possible causes:
Too rich mixture
Presence of oil in combustion chamber
Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily
oxidized electrode or blistered insulator nose.
6D23
Possible causes:
Too lean mixture
Improper heat value
Measuring Insulation Resistance

Measure insulation resistance using a 500 volt
megaohm meter.
Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 M
or more
011RS011
Installation
1. Spark plugs
Tighten spark plugs to the specified torque.
011RS010
Cleaning Spark Plugs

Clean spark plugs with a spark plug cleaner.
Raise the ground electrode to an angle of 45 to 60
degrees. if electrode is wet,dry it before cleaning.
After spark plug is thoroughly cleaned,check insulator
for presence of cracks.
Clean threads and metal body with a wire brush.
File the electrode tip if electrode is extremely worn.
Bend the ground electrode to adjust the spark plug
gap.
6D24
Crankshaft Angle Sensor

Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft angle sensor.
3. Remove crankshaft angle sensor from cylinder
block.
015RW021
Installation
1. Install crankshaft angle sensor into the cylinder
block.
Before installation,apply small amount of engine oil
to the Oring.
2. Reconnect wiring connector to crankshaft angle
sensor.

Ignition System
Ignition Form
Electronic Ignition System (El system) with Crankshaft angle Sensor
Spark Plug
Type
No. of Coils and Type
Coil Location
Torque
Electronic Spark Control

2 Solid State
Enginemounted
20 Nm (2.0 kgm/14 lb ft)
6D25
SECTION
STARTING AND CHARGING SYSTEM (X22SE 2.2L)
6D31
ENGINE
CONTENTS
Starting System.............................................
Diagnosis .......................................................
Starter ...........................................................
Removal .....................................................
Installation ..................................................
Characteristic Test......................................
Charging System...........................................
6D3 - 1
6D3 - 2
6D3 - 2
6D3 - 2
6D3 - 3
6D3 - 3
6D3 - 3
6D3 - 4
6D3 - 5
6D3 - 6
6D3 - 7
Service Precaution
YOU ARE
IN
REPAIRS.

General OnVehicle Inspection .....................
Generator ......................................................
Removal......................................................
Inspection ...................................................
Installation...................................................
Disassembly ...............................................
Reassembly ................................................
6D3 - 7
6D3 - 7
6D3 - 9
6D3 - 9
6D3 - 9
6D3 - 10
6D3 - 10
6D3 - 12
6D3 - 14
6D3 - 15

and systems.
6D32
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.
Diagnosis
Condition
Starter does not run
Possible cause
Correction
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
6D33
Starter
Removal
1. Battery ground cable.
2. Remove harness connectors (1) and (2).
065RW024
3. Connect harness.
4. Reconnect the battery ground cable.
065RW022
3. Remove bolts from starter (1), (2).
065RW024
Installation
1. Install starter assembly(6).
2. Install mounting bolts and tighten bolts to specified
torque (1), (2).
6D34
Disassembled View
065RW023
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Bolt
Magnetic Switch
Gear Case
Piston
Piston Shaft
Center Bracket
Armature
EndOFCallout
(8)
(9)
(10)
(11)
(12)
Yoke Assembly
Brush and Brush Holder
Washer
Rear Cover
Through Bolt
6D35
Brush Holder
Repair or replace necessary parts if extreme wear or

damage is found during inspection.
Check for continuity between brush holder (+) (4) and

base (). Replace, if there is continuity (i.e., insulation is
broken).
Armature
Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).
065RW015
Magnetic Switch
065RS015
Check for continuity between commutator and shaft.

Also, check for continuity between commutator and
armature core,armature core and shaft. Replace
commutator if there is continuity (i.e., internally
grounded).
Check for continuity of shunt coil between terminals S

and M.
Replace, if there is no continuity (i.e., coil is
disconnected).
065RW016
065RS016
Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
6D36
Continuity of Series Coil

Check for continuity between terminals S and M.
disconnected).
065RS025
Characteristic Test
065RW017
Continuity of Contacts
With the plunger faced downward, push down the
magnetic switch. In this state, check for continuity
between terminals B and M. Replace, if there is no
continuity (i.e., contacts are faulty).
065RW018
Pinion
Check if the pinion rotates smoothly in drive direction by
hand, or if it is locked when it is rotated in reverse. If not,
replace the pinion.
For easily confirming the characteristics, conduct the

noload 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)
(2)
(3)
(4)
(5)
Volt Meter
Revolution Indicator
Battery
Ammeter
Switch
EndOFCallout
6D37
Charging System
General Description
General OnVehicle Inspection
The charging system is an IC integral regulator charging

system and its main components are connected as
shown in illustration.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment. The rectifier connected to
the stator coil has eight diodes to transform AC voltage
into DC voltage.
This DC voltage is connected to the output terminal of
generator.
The operating condition of charging system is indicated

by the charge warning lamp. The warning lamp comes
on when the starter switch is turned to ON" position.
The charging system operates normally if the lamp goes
off when the engine starts.
If the warning lamp shows abnormality or if
undercharged or overcharged battery condition is
suspected, perform diagnosis by checking the charging
system as follows:
1. Check visually the belt and wiring connector.
6D38
2. With the engine stopped, turn the stator switch to

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.
066RW021
Legend
(1) Regulator
(2) Indicator Lamp
EndOFCallout
(3) Generator Assembly
6D39
Generator
Removal
Inspection

3. Disconnect terminal B" wiring connector and
connector.
4. Remove generator bracket (1), (2) and remove
generator assembly.
Generator Power and Circuit Diagram
066RW020
Legend
065RW025
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Load resistor, set parallel to battery

Battery
Voltmeter
Ammeter
Ignition Lock
Charge Telltale
Generator
EndOFCallout
1. Disconnect battery.
2. Close off connecting cable from alternator terminal
B+".
3. Set ammeter (measuring range 100A) in
disconnected line.
4. Connect controllable load resistor to battery
terminal.
5. Set resistor in front of connection to 0"; connect first
to battery, then to resistor.
6. Connect tachometer.
7. Connect oscilloscope according to manufacturer's
instructions.
8. Connect battery.
9. Start engine and read off resulting current at various
engine speeds.
6D310
Installation
Generator Power
1. Adjust load resistor, if the required load currents are
not attained.
2. The shape of the voltage curves on oscilloscope
curve should be regular.
3. Test value: 5 to 7A.
4. If the required minimum current intensity is not
attained, or if the oscilloscope picture shows
variations, the alternator should be overhauled.
1. Install generator assembly and bring generator

assembly to the position to be installed.
2. Install generator bracket (1), (2) and tighten to the
specified torque.
Torque:
Long bolt: 35 Nm (3.6 kgm/26 lb ft)
Short bolt: 20 Nm (2.0 kgm/15 lb ft)
066RW018
Regulated Voltage Circuit Diagram
065RW025
3. Connect wiring harness connector.

4. Move drive belt tensioner to loose side using
5. Reconnect battery ground cable.
Disassembly
1. Belt pulley nut.
066RW019
Legend
(1)
(2)
(3)
(4)
Battery
Ignition Lock
Charge Telltale
Resistor, for attainment of load current with the
battery set in series
(5) Voltmeter
(6) Ammeter
(7) Generator
EndOFCallout
066RW016

2. Spring ring, washer, belt pulley halves, spacing ring,
fan pinion, pulley spring.
3. Voltage regulator with brush holder.
6D311
7. Clawpole armature from drive bearing.

8. Lay suitable pipe piece (1) underneath.
066RW013
066RW014
4. Drive bearing with clawpole armature.

5. Mark housing halves.
6. 4 fastening bolts.
9. Bearing cover of drive bearing.

10. Ball bearing from drive bearing.
066RW017
066RW015
6D312
11. Ball bearing from armature shaft.
16. Spray sleeve (if present).

17. Carefully bend off diode plate.
18. Unsolder stator winding from diode plate.
066RW012
12. Nut from connecting pins B+" and D+".

13. Washers and insulating material.
14. Diode plate.
15. Remove together with stator winding from slip ring
bearing.
066RW010

Rotor Assembly
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500600
sandpaper.
066RW008
066RS014

2. Measure the slip ring diameter, and replace if it
exceeds the limit.
6D313
4. Check for continuity between slip ring and rotor

core.
In case of continuity, replace the rotor assembly.
066RS015
3. Check resistance between slip rings, and replace if

there is no continuity.
066RS017
Stator Coil
1. Measure resistance between respective phases.
2. Measure insulation resistance between stator coil
and core with a megaohmmeter.
If less than standard, replace the coil.
066RS016
066RS018
6D314
Brush
Clamp pulley to the vise, and tighten nut to the

specified torque.
Measure the brush length.

If more than limit, replace the brush.
Standard: 5 mm (0.20in)
066RS010
066RW009
Rectifier Assembly
Check for continuity across 1" and 2" in the 100W
range of multimeter.
066RW011
Change polarity, and make sure that there is continuity

in one direction, and not in the reverse direction. In
case of continuity in both directions, replace the rectifier
assembly.
Reassembly
To reassemble, follow the disassembly steps in the
1. Install pulley on the rotor.

Battery voltage
12
Rated output
100
(as viewed from pulley side)
Maximum speed
Clockwise
rpm
18000
6D315
SECTION
X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION
6E11
FRONTERA
ENGINE
ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .
TIGHTENING SPECIFICATIONS . . . . . . . .
DIAGRAMS AND SCHEMATICS . . . . . . . . . .
ECM WIRING DIAGRAM (1 of 10) . . . . . . .
ECM WIRING DIAGRAM (10 of 10) . . . . . .
ECM PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . .
ECM Pinout Table, 32Pin Red Connector
Row A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row B . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECM Pinout Table, 32Pin White Connector
Row C . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row D . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row E . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row F . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR . . . . . . . . . . . . . . . .
Undercarriage Component Locator Table .
Fuse And Relay Panel (Underhood
Electrical Center) . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS StrategyBased Diagnostics
StrategyBased Diagnostics . . . . . . . . . . . .
DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . .
No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Matching Symptom . . . . . . . . . . . . . . . . .
Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . .
No Trouble Found . . . . . . . . . . . . . . . . . . . . .
Verifying Vehicle Repair . . . . . . . . . . . . . . . .
GENERAL SERVICE INFORMATION . . . . . .
NonOEM Parts . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions Control Information Label . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . .
Visual/Physical Engine Compartment
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Knowledge Of Tools Required . . . . .
SERIAL DATA COMMUNICATIONS . . . . . . .
Class II Serial Data Communications . . . .
6E16
6E16
6E17
6E17
6E18
6E19
6E110
6E111
6E112
6E113
6E114
6E115
6E116
6E117
6E117
6E118
6E119
6E120
6E121
6E122
6E123
6E126
6E126
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E128
6E128
6E128
6E128
6E128
6E128
6E128
ONBOARD DIAGNOSTIC (OBD) . . . . . . . . .

OnBoard Diagnostic Tests . . . . . . . . . . . . .
Comprehensive Component Monitor
Diagnostic Operation . . . . . . . . . . . . . . . . . .
Common OBD Terms . . . . . . . . . . . . . . . . . .
The Diagnostic Executive . . . . . . . . . . . . . . .
DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Diagnostic Trouble Codes Using
A Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . .
Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . .
Getting Started . . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure (Example) . . . . . . . . .
DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC Information Mode . . . . . . . . . . . . . . . . .
Miscellaneous Test . . . . . . . . . . . . . . . . . . . .
Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control System Test . . . . . . . . . . . . .
Fuel System Test . . . . . . . . . . . . . . . . . . . . . .
EGR Control Test . . . . . . . . . . . . . . . . . . . . . .
Injector Balance Test . . . . . . . . . . . . . . . . . . .
Plotting Snapshot Graph . . . . . . . . . . . . . . .
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) . . . . . .
Flow Chart for Snapshot Replay (Plotting
Graph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY SYSTEMBASED DIAGNOSTICS
Primary SystemBased Diagnostics . . . . .
Fuel Control Heated Oxygen Sensors . . .
HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . .
ONBOARD DIAGNOSTIC (OBD) SYSTEM
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
Test Description . . . . . . . . . . . . . . . . . . . . . . .
A/C CLUTCH CONTROL CIRCUIT
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . .
ELECTRONIC IGNITION SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
VISUAL CHECK OF THE EVAPORATIVE
EMISSION CANISTER . . . . . . . . . . . . . . . . . .
6E128
6E128
6E129
6E129
6E130
6E131
6E132
6E132
6E134
6E134
6E135
6E136
6E136
6E137
6E137
6E138
6E140
6E140
6E142
6E143
6E143
6E144
6E145
6E146
6E147
6E147
6E147
6E147
6E148
6E148
6E148
6E148
6E150
6E150
6E150
6E151
6E153
6E153
6E12
IDLE AIR CONTROL (IAC) VALVE . . . . . . . .

ENGINE CONTROL MODULE (ECM)
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
MULTIPLE ECM INFORMATION SENSOR
DTCs SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST GAS RECIRCULATION (EGR)
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE Tech 2 DATA DEFINITIONS AND
RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPICAL SCAN DATA VALUES . . . . . . . . . . .
Test Conditions . . . . . . . . . . . . . . . . . . . . . . . .
2.2L L4 Engine . . . . . . . . . . . . . . . . . . . . . . .
NO MALFUNCTION INDICATOR LAMP
(MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION INDICATOR LAMP (MIL) ON
STEADY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE CRANKS BUT WILL NOT RUN . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM ELECTRICAL TEST . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Relief Procedure . . . . . . . . .
Fuel Gauge Installation . . . . . . . . . . . . . . . . .
FUEL SYSTEM DIAGNOSIS . . . . . . . . . . . . .
IDLE AIR CONTROL (IAC) SYSTEM CHECK
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD ABSOLUTE PRESSURE (MAP)
OUTPUT CHECK . . . . . . . . . . . . . . . . . . . . . . .
ECM DIAGNOSTIC TROUBLE CODES . . . .
ECM Diagnostic Trouble Codes . . . . . . . . .
6E153
6E153
6E154
6E154
6E154
6E157
6E157
6E159
6E159
6E159
6E162
6E162
6E162
6E162
6E165
6E165
6E165
6E165
6E167
6E169
6E169
6E173
6E173
6E173
6E173
6E174
6E174
6E176
6E176
6E176
6E177
6E177
6E181
6E181
6E181
6E183
6E183
6E183
6E185
6E185
6E185
6E187
6E187
DIAGNOSTIC TROUBLE CODE (DTC) P0106

CIRCUIT/RANGE PERFORMANCE
PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E189
SENSOR CIRCUIT LOW INPUT . . . . . . . . . . 6E192
CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . . . 6E195
INTAKE AIR TEMPERATURE (IAT) SENSOR
CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . . 6E198
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR CIRCUIT HIGH INPUT . . . . . . . . . 6E1106
THROTTLE POSITION (TP) SENSOR
CIRCUIT RANGE/PERFORMANCE
PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1109
CIRCUITLOW INPUT . . . . . . . . . . . . . . . . . . . 6E1112
O2 SENSOR CIRCUIT LOW VOLTAGE
(BANK 1 SENSOR 1) . . . . . . . . . . . . . . . . . . . 6E1118
O2 SENSOR CIRCUIT HIGH VOLTAGE
(BANK 1 SENSOR 1) . . . . . . . . . . . . . . . . . . . 6E1121
O2 SENSOR CIRCUIT NO ACTIVITY
DETECTED (BANK 1 SENSOR 1) . . . . . . . . 6E1124
O2 SENSOR HEATER CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1127
SYSTEM TOO LEAN (BANK 1) . . . . . . . . . . 6E1130
SYSTEM TOO RICH (BANK 1) . . . . . . . . . . 6E1134
INJECTOR CIRCUIT MALFUNCTION
CYLINDER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1138
CYLINDER 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1141
CYLINDER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1144

CYLINDER 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1147
KNOCK SENSOR (KS) CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1150
KNOCK SENSOR (KS) CIRCUIT LOW
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1153
CRANKSHAFT POSITION (CKP) SENSOR
CIRCUIT RANGE/PERFORMANCE . . . . . . . 6E1156
CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . . . 6E1158
CAMSHAFT POSITION (CMP) SENSOR
IGNITION COIL A PRIMARY/SECONDARY
CIRCUIT MALFUNCTION . . . . . . . . . . . . . . . 6E1166
IGNITION COIL B PRIMARY/SECONDARY
FLOW INSUFFICIENT DETECTED . . . . . . . 6E1170
EXCESSIVE FLOW DETECTED . . . . . . . . . 6E1173
SENSOR CIRCUIT LOW . . . . . . . . . . . . . . . . 6E1179
SENSOR CIRCUIT HIGH . . . . . . . . . . . . . . . . 6E1182
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM PURGE CONTROL
VALVE CIRCUIT MALFUNCTION . . . . . . . . . 6E1185
COOLING FAN 1 CONTROL CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1187
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1190
VEHICLE SPEED SENSOR (VSS) CIRCUIT
LOW INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1193
IDLE CONTROL SYSTEM RPM LOWER
THAN EXPECTED . . . . . . . . . . . . . . . . . . . . . . 6E1195
6E13

IDLE CONTROL SYSTEM RPM HIGHER
THAN EXPECTED . . . . . . . . . . . . . . . . . . . . . 6E1198
SYSTEM VOLTAGE HIGH . . . . . . . . . . . . . . . 6E1201
INTERNAL CONTROL MODULE MEMORY
CHECK SUM ERROR . . . . . . . . . . . . . . . . . . . 6E1203
SENSOR CIRCUIT INTERMITTENT HIGH
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1204
SENSOR CIRCUIT INTERMITTENT LOW
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1206
CIRCUIT INTERMITTENT HIGH VOLTAGE 6E1208
CIRCUIT INTERMITTENT LOW VOLTAGE 6E1211
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1213
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1215
CIRCUIT INTERMITTENT HIGH
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1218
CIRCUIT INTERMITTENT LOW
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1220
FUEL SYSTEM LEAN DURING
ACCELERATION . . . . . . . . . . . . . . . . . . . . . . . 6E1222
DIAGNOSTIC TROUBLE CODE (DTC) 1404
CLOSED VALVE . . . . . . . . . . . . . . . . . . . . . . . . 6E1225
ECM UNEXPECTED RESET . . . . . . . . . . . . . 6E1228
PCM A/D CONVERSION MALFUNCTION . 6E1230
5 VOLT REFERENCE VOLTAGE CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1232
ODM OUTPUT CIRCUIT FAULT . . . . . . . . . . 6E1234
SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . 6E1237
DEFAULT MATRIX TABLE . . . . . . . . . . . . . . . 6E1260
Camshaft Position (CMP) Sensor . . . . . . . . . . 6E1263
Crankshaft Position (CKP) Sensor . . . . . . . . . 6E1264
6E14
EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor .
Heated Oxygen Sensor (HO2S) . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor . . . . . . .
Manifold Absolute Pressure (MAP) Sensor .
Malfunction Indicator Lamp (MIL) . . . . . . . . . .
Engine Control Module (ECM) . . . . . . . . . . . .
Throttle Position (TP) Sensor . . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control (IAC) Valve . . . . . . . . . . . . . . .
Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . .
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . .
FUEL METERING SYSTEM Accelerator
Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal Replacement . . . . . . . . . . .
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator . . . . . . . . . . . . . . . . .
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle body (TB) . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC IGNITION SYSTEM Ignition
Control Module (ICM) . . . . . . . . . . . . . . . . . . .
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . .
EMISSIONS Catalytic Converter . . . . . . . . . .
Air Conditioning Relay . . . . . . . . . . . . . . . . . . .
Ignition Timing Adjustment . . . . . . . . . . . . . . .
EVAP Canister Hoses . . . . . . . . . . . . . . . . . . . .
EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . .
Linear Exhaust Gas
Recirculation (EGR) Valve . . . . . . . . . . . . . . . .
Wiring and Connectors . . . . . . . . . . . . . . . . . . .
ECM Connectors And Terminals . . . . . . . . . . .
Connectors And Terminals . . . . . . . . . . . . . . . .
Wire Harness Repair: Twisted Shielded
Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . .
WeatherPack Connector . . . . . . . . . . . . . . . .
ComPack III . . . . . . . . . . . . . . . . . . . . . . . . . . .
MetriPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION ECM AND
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58X Reference ECM Input . . . . . . . . . . . . . .
A/C Request Signal . . . . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor . . . . . . .
6E1266
6E1266
6E1267
6E1268
6E1269
6E1269
6E1270
6E1272
6E1273
6E1274
6E1275
6E1277
6E1278
6E1279
6E1280
6E1282
6E1282
6E1282
6E1282
6E1284
6E1285
6E1287
6E1289
6E1289
6E1291
6E1292
6E1294
6E1295
6E1295
6E1297
6E1297
6E1297
6E1297
6E1298
6E1298
6E1298
6E1298
6E1299
6E1299
6E1300
6E1300
6E1301
6E1302
6E1303
6E1303
6E1304
6E1304
6E1304
6E1304
Camshaft Position (CMP) Sensor And

Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor
Electrically Erasable Programmable Read
Only Memory (EEPROM) . . . . . . . . . . . . . .
Fuel Control Heated Oxygen Sensor
(Pre Catalyst) . . . . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor . . . . .
Linear Exhaust Gas Recirculation (EGR)
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor
Engine Control Module (ECM) . . . . . . . . . . .
ECM Function . . . . . . . . . . . . . . . . . . . . . . . . .
ECM Components . . . . . . . . . . . . . . . . . . . . .
ECM Voltage Description . . . . . . . . . . . . . . .
ECM Inputs/Outputs . . . . . . . . . . . . . . . . . . .
ECM Service Precautions . . . . . . . . . . . . . .
Throttle Position (TP) Sensor . . . . . . . . . . .
Transmission Range Switch . . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) . . . . . . . . . . . .
Use of Circuit Testing Tools . . . . . . . . . . . . .
Aftermarket Electrical And Vacuum
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Damage . . . . . . . . .
GENERAL DESCRIPTION AIR
INDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Induction System . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION FUEL
METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acceleration Mode . . . . . . . . . . . . . . . . . . . . .
Accelerator Controls . . . . . . . . . . . . . . . . . . .
Battery Voltage Correction Mode . . . . . . . .
CMP Signal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Flood Mode . . . . . . . . . . . . . . . . . . . . .
Deceleration Fuel Cutoff (DFCO) Mode . . .
Engine Speed/Vehicle Speed/ Fuel
Disable Mode . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Metering System Components . . . . . .
Fuel Metering System Purpose . . . . . . . . . .
Fuel Pressure Regulator . . . . . . . . . . . . . . . .
Fuel Pump Electrical Circuit . . . . . . . . . . . . .
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control (IAC) Valve . . . . . . . . . . . . .
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body Unit . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION ELECTRONIC
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . .
Camshaft Position (CMP) Sensor . . . . . . .
Crankshaft Position (CKP) Sensor . . . . . .
Electronic Ignition . . . . . . . . . . . . . . . . . . . . .
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . .
6E1304
6E1305
6E1305
6E1305
6E1306
6E1306
6E1306
6E1307
6E1307
6E1307
6E1307
6E1307
6E1308
6E1308
6E1308
6E1308
6E1308
6E1309
6E1309
6E1309
6E1309
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1311
6E1311
6E1311
6E1311
6E1312
6E1312
6E1312
6E1312
6E1313
6E1313
6E1313
6E1313
6E1313

Ignition Control . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control Module (ICM) . . . . . . . . . . .
Ignition Control ECM Output . . . . . . . . . . . .
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C CLUTCH DIAGNOSIS . . . . . . . . . . . . . . .
A/C Clutch Circuit Operation . . . . . . . . . . . .
A/C Clutch Circuit Purpose . . . . . . . . . . . . .
GENERAL DESCRIPTION EVAPORATIVE
EMISSION (EVAP) SYSTEM . . . . . . . . . . . . .
EVAP Emission Control System Purpose .
EVAP Emission Control System Operation
GENERAL DESCRIPTION EXHAUST
GAS RECIRCULATION (EGR) SYSTEM . .
EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . .
Linear EGR Valve . . . . . . . . . . . . . . . . . . . . .
Linear EGR Control . . . . . . . . . . . . . . . . . . . .
Linear EGR Valve Operation And Results
Of Incorrect Operation . . . . . . . . . . . . . . . . .
EGR Pintle Position Sensor . . . . . . . . . . . . .
GENERAL DESCRIPTION POSITIVE
CRANKCASE VENTILATION (PCV)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Ventilation System Purpose . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . .
6E1313
6E1314
6E1314
6E1314
6E1315
6E1316
6E1316
6E1316
6E1316
6E1316
6E1316
6E1317
6E1317
6E1317
6E1317
6E1317
6E1317
6E1317
6E1318
6E1318
6E1319
6E15
6E16
SPECIFICATIONS
TIGHTENING SPECIFICATIONS
Application
Nm
Lb Ft
kgm
Lb In
Crankshaft Position Sensor Mounting Bolt
0.9
78
EGR Nut
14
1.4
130
30
3.1
22
Fuel Drain Plug
20
2.0
14
Fuel Pressure Regulator Attaching Screw
6.5
0.6
60
Fuel Rail Bolts
0.7
75
Fuel Tank Undercover Retaining Bolts
36
3.7
27
Heated Oxygen Sensor
42
4.3
32
Spark Plugs
25
2.5
18
Throttle Body Mounting Bolts
13
1.3
120
VSS Retaining Bolt
13
1.3
120
6E17
DIAGRAMS AND SCHEMATICS

ECM WIRING DIAGRAM (1 of 10)
D06RX097
6E18
060RX091
6E19
D06RX099
6E110
060RX095
6E111
D06RX119
6E112
D06RX102
6E113
D06RX103
6E114
D06RX104
6E115
D06RX105
6E116
D06RX106
6E117
ECM PINOUTS
ECM Pinout Table, 32Pin Red Connector Row A
TS23344
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
A1
5 Volt Reference Signal
RED
5.0 V
5.0 V
Appropriate Sensor
A2
Knock Sensor Input
YEL
3.0 V (MAX)
A3
Not Used
A4
Battery Feed
RED/WHT
B+
B+
A5
Idle Air Control (IAC) A

High
BLU
B+/0.8 V
B+/0.8 V
General Description and

Operation, IAC
A6
IAC A Low
BLU/WHT
B+/0.8 V
B+/0.8 V

Operation, IAC
A7
IAC B Low
BLU/BLK
B+/0.8 V
B+/0.8 V

Operation, IAC
A8
IAC B High
BLU/RED
B+/0.8 V
B+/0.8 V

Operation, IAC
A9
Not Used
A10
Not Used
A11
Not Used
A12
Not Used
A13
Malfunction Indicator
Lamp (MIL) Control
WHT/GRN
0.40.9 V
B+
Chassis Electrical
A14
Rear Defogger Relay
RED/WHT
B+
B+
Classis Electrical
A15
EVAP Canister Vent

Solenoid Control
RED/BLU
B+
05 V
(varies)
A16
Not Used

Operation, Knock Sensor
Chassis Electrical

Operation, EVAP Emission
Control System
6E118
ECM Pinout Table, 32Pin Red Connector Row B
TS23344
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
BLU/ORG
5.0 V
5.0 V
Refer To
B1
Appropriate Sensor
B2
Not Used
B3
Not Used
B4
Not Used
B5
Not Used
B6
Not Used
B7
Exhaust Gas Recirculation

(EGR) Position Feedback
YEL/RED
0.6 V
0.6 V

Operation, Linear EGR
Control
B8
Intake Air Temperature

(IAT) Sensor
YEL/GRN
~3V
(0V = 151C)
~3 V
(5V = 40C)

Operation, IAT
B9
A/C Pressure Sensor

Signal
GRN
~1 V
~1 V
B10
Not Used
B11
Power Steering Pressure

(PSP) Switch Input
GRN/YEL
B+
B+

Operation, PSP
B12
Illumination Switch
GRN/YEL
B+
B+
Chassis Electrical
B13
Class 2 Data
ORN/BLK
0.0 V
0.0 V
B14
A/C Compressor Clutch

Relay Control Compressor
GRN/RED
0
(A/C OFF)
B+
(A/C ON)
B15
Not Used
B16
Not Used
A/C System
Diagnosis, Class 2 Serial

Data
Operation, A/C Clutch Circuit
Operation
6E119
ECM Pinout Table, 32Pin White Connector Row C
TS23345
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
C1
Injector Cylinder #2
GRN/RED
B+ Varies
B+ Varies
C2
Not Used
C3
Not Used
C4
Ignition Control Module

(ICM) Input
RED
0.0 V
0.1 V

Operation, Fuel Injector
C5
Crankshaft Position (CKP)

Sensor Low
BLUE
4.98 V
0.76 V
(at idle)

Operation, Crankshaft
Position Sensor
C6
Crankshaft Position
Sensor (CKP) High
GRN
5V
5V

Position Sensor
C7
ECM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C8
ECM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C9
ECM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C10
Tachometer Signal
BLK/RED

Operation
C11
Fuel Gauge PWM Output
YEL/RED
Varies with
Fuel Level
Varies with
Fuel Level

Operation
C12
High Fan Relay Control
RED/YEL
10.5 V
B+
Chassis Electrical
C13
Low Fan Relay Control
RED/BLU
Chassis Electrical
C14
Bank 1 HO2S 1 High
WHT
0.3 V
0.1 to 1.1 V

Operation, Fuel HO2S 1
C15
Bank 1 HO2S 1 Low
RED
0.0 V
0.1 V

C16
Not Used

6E120
ECM Pinout Table, 32Pin White Connector Row D
TS23345
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
D1
GRN/ORN
B+
B+

D2
Not Used
D3
GRN/WHT
B+
B+

D4
Not Used
D5

(ICM) Input
RED/BLK

Operation
D6
Not Used
D7
VSS Input
BLU/BLK
Chassis Electrical
D8
Sensor Ground 5 V
Reference A Return
GRN
0.0 V
0.0 V
Appropriate Sensor
D9
Sensor Ground 5 V
Reference B Return
BLU/YEL
0.0 V
0.0 V
Appropriate Sensor
D10
Not Used
D11
Camshaft Position Sensor

Input
BLU
5.0 V
4.6 V
D12
Not Used
D13
Not Used
D14
Not Used
D15
Not Used
D16
Not Used

Operation, Camshaft
Position Sensor
6E121
ECM Pinout Table, 32Pin White Connector Row E
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
RED/GRN
0.0V
B+
Chassis Electrical
E1
Not Used
E2
Fan Control
E3
Not Used
E4
Not Used
E5
Ignition Feed
BLK/YEL
B+
B+

Operation
E6

(EGR) Valve Low
YEL
B+ Varies
B+ Varies

Operation, EGR Control
E7
Not Used
E8
Throttle Position (TP)

Sensor Input
BLU
0.25 V
(0% = 0.25 V)
0.25 V
(at idle)
(100% =
4.75 V)

Operation, Throttle Position
Sensor
E9
Engine Coolant
Temperature (ECT)
Sensor Input
BLU/RED
2.3 V
(O V =
151C)
2.1 V
(5 V = 40C)

Operation, Engine Coolant
Temperature (ECT) Sensor
E10
Not Used
E11
Not Used
E12
Rear Defogger Switch
YEL/GRN
B+
B+
Chassis Electrical
E13
Fuel Pump (FP) Relay

Control
PNK/WHT
0.0 V
B+
OnVehicle Service, Fuel

Pump Relay
E14
Not Used
E15
A/C Request (Thermo

Relay)
GRN/BLK
0.0 V
0.0 V
E16
Ignition Feed
RED/BLU
B+
B+
Electric Cooling Fans

Operation
6E122
ECM Pinout Table, 32Pin White Connector Row F
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
F1
Not Used
F2
Not Used
F3
Not Used
F4
Not Used
F5
Not Used
F6
Not Used
F7
Not Used
F8
Manifold Absolute
Pressure (MAP) Sensor
Input
GRY
~4.7 V
(0 V = 10kPa)
~1.1 V
(5 V =
104kPa)
F9
Not Used
F10
Not Used
F11
Not Used
F12
DLC (Digital Input)
Class 2 Serial Data
F13
Injector C Cylinder #4
GRN
B+
B+

F14
Not Used
F15
Not Used
F16
Ignition Feed
RED/BLU
B+
B+

Operation

Operation, Manifold Absolute
Pressure
6E123
COMPONENT LOCATOR
755RX030
6E124
Engine Component Locator Table

Number
Name
Location
Rear of engine, near ignition coils
Linear Exhaust Gas Recirculation (EGR) Valve
On the left rear of the engine at the bulkhead
Heated Oxygen Sensor (HO2S), Bank 1,

Sensor 1
On the exhaust pipe, left side of engine,

immediately behind the exhaust manifold
Air Cleaner
Left front of the engine bay
On the intake air duct near the air cleaner
Camshaft Position (CMP) Sensor
Inside the front cover assembly
Positive Crankcase Ventilation (PCV) Port
On the right front corner of the valve cover
Fuel Pressure Regulator
On the forward end of the fuel rail, to the right of

the PVC port
Throttle Body
Between the intake air duct and the intake

manifold
10
Fuse/Relay Box
Along the inside of the right fender
11
Throttle Position (TP) Sensor
On the front of the throttle body
12
Idle Air Control (IAC) Valve
On the rear of the throttle body
13
Ignition Control Module (ICM)
Mounted on a heat sink on the lower right side of

the engine block, above the starter motor
14
Bolted to the front edge of the intake manifold,

under the fuel rail
15
High Fan Relay
In the relay box
16
Low Fan Relay
In the relay box
6E125
010RX001
028RX001
6E126
Undercarriage Component Locator Table

Name
Location
Fuel Pump Assembly
Installed in the top of the fuel tank
EVAP Canister
Behind rear axle, near fuel tank filler nozzle
EVAP Canister Purge Valve Solenoid
Vehicle Speed Sensor (VSS)
Protrudes from the right side of the transmission housing, near the
output shaft
Crankshaft Position (CKP) Sensor
Lower left hand front of engine, behind power steering pump bracket
Fuse And Relay Panel (Underhood Electrical Center)

Underhood (U/H) Fuse and Relay Panel
060RX096
DIAGNOSIS StrategyBased
Diagnostics
StrategyBased Diagnostics
The strategybased diagnostic is a uniform approach to
repair all Electrical/Electronic (E/E) systems. The
diagnostic flow can always be used to resolve an E/E
system problem and is a starting point when repairs are
necessary. The following steps will instruct the technician
how to proceed with a diagnosis:
1. Verify the customer complaint.
D To verify the customer complaint, the technician
should know the normal operation of the system.
2. Perform preliminary checks.
D Conduct a thorough visual inspection.
D Review the service history.
D Detect unusual sounds or odors.
D Gather diagnostic trouble code information to
achieve an effective repair.
3. Check bulletins and other service information.
D This includes videos, newsletters, etc.
4. Refer to service information (manual) system
check(s).
D System checks contain information on a system
that may not be supported by one or more DTCs.
System checks verify proper operation of the
system. This will lead the technician in an organized
approach to diagnostics.
5. Refer to service diagnostics.
DTC Stored
Follow the designated DTC chart exactly to make an
effective repair.
No DTC
Select the symptom from the symptom tables. Follow the
diagnostic paths or suggestions to complete the repair.
You may refer to the applicable component/system check
in the system checks.
No Matching Symptom
1. Analyze the complaint.
2. Develop a plan for diagnostics.
3. Utilize the wiring diagrams and the theory of
operation.
Combine technician knowledge with efficient use of the
available service information.
Intermittents
Conditions that are not always present are called
intermittents. To resolve intermittents, perform the
following steps:
1. Observe history DTCs, DTC modes, and
freezeframe data.
2. Evaluate the symptoms and the conditions described
by the customer.
6E127
3. Use a check sheet or other method to identify the

circuit or electrical system component.
4. Follow the suggestions for intermittent diagnosis
found in the service documentation.
Most Scan Tools, such as the Tech 2, have
datacapturing capabilities that can assist in detecting
intermittents.
No Trouble Found
This condition exists when the vehicle is found to operate
normally. The condition described by the customer may
be normal. Verify the customer complaint against another
vehicle that is operating normally. The condition may be
intermittent. Verify the complaint under the conditions
described by the customer before releasing the vehicle.
1. Reexamine the complaint.
When the complaint cannot be successfully found or
isolated, a reevaluation is necessary. The complaint
should be reverified and could be intermittent as
defined in Intermittents, or could be normal.
2. Repair and verify.
After isolating the cause, the repairs should be made.
Validate for proper operation and verify that the
symptom has been corrected. This may involve road
testing or other methods to verify that the complaint
has been resolved under the following conditions:
D Conditions noted by the customer.
D If a DTC was diagnosed, verify a repair by
duplicating conditions present when the DTC was
set as noted in the Failure Records or Freeze
Frame data.
Verifying Vehicle Repair

Verification of the vehicle repair will be more
comprehensive for vehicles with OBD II system
diagnostics. Following a repair, the technician should
perform the following steps:
IMPORTANT: Follow the steps below when you verify
repairs on OBD II systems. Failure to follow these steps
could result in unnecessary repairs.
1. Review and record the Failure Records and the
Freeze Frame data for the DTC which has been
diagnosed (Freeze Fame data will only be stored for
an A or B type diagnostic and only if the MIL (Check
Engine lamp) has been requested).
2. Clear the DTC(s).
3. Operate the vehicle within conditions noted in the
Failure Records and Freeze Frame data.
4. Monitor the DTC status information for the DTC which
has been diagnosed until the diagnostic test
associated with that DTC runs.
GENERAL SERVICE INFORMATION

NonOEM Parts
All of the OBD diagnostics have been calibrated to run
with OEM parts. Something as simple as a
highperformance exhaust system that affects exhaust
system back pressure could potentially interfere with the
6E128
operation of the EGR valve and thereby turn on the MIL

(Check Engine lamp). Small leaks in the exhaust
system near the post catalyst oxygen sensor can also
cause the MIL (Check Engine lamp) to turn on.
Aftermarket electronics, such as transceiver, stereos,
and antitheft devices, may radiate EMI into the control
system if they are improperly installed. This may cause a
false sensor reading and turn on the MIL (Check Engine
lamp).
Environment
Temporary environmental conditions, such as localized
flooding, will have an effect on the vehicle ignition system.
If the ignition system is rainsoaked, it can temporarily
cause engine misfire and turn on the MIL (Check Engine
lamp).
Emissions Control Information Label

The engine compartment Vehicle Emissions Control
Information Label contains important emission
specifications and setting procedures. In the upper left
corner is exhaust emission information. There is also an
illustrated emission components and vacuum hose
schematic.
This label is located in the engine compartment of every
vehicle. If the label has been removed it should be
replaced, it can be ordered from Isuzu Dealer ship.
Maintenance Schedule
Refer to the Maintenance Schedule.

Inspection
Perform a careful visual and physical engine
compartment inspection when performing any diagnostic
procedure or diagnosing the cause of an emission test
failure. This can often lead to repairing a problem without
further steps. Use the following guidelines when
performing a visual/physical inspection:
D Inspect all vacuum hoses for pinches, cuts,
disconnection, and Droper routing.
D Inspect hoses that are difficult to see behind other
components.
D Inspect all wires in the engine compartment for proper
connections, burned or chafed spots, pinched wires,
contact with sharp edges or contact with hot exhaust
manifolds or pipes.
Basic Knowledge Of Tools Required

NOTE: Lack of basic knowledge of this powertrain when
performing diagnostic procedures could result in an
incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to

effectively use this section of the Service Manual.
SERIAL DATA COMMUNICATIONS

Class II Serial Data Communications
Government regulations require that all vehicle
manufacturers establish a common communication
system. This vehicle utilizes the Class II communication
system. Each bit of information can have one of two
lengths: long or short. This allows vehicle wiring to be
reduced by transmitting and receiving multiple signals
over a single wire. The messages carried on Class II data
streams are also prioritized. If two messages attempt to
establish communications on the data line at the same
time, only the message with higher priority will continue.
The device with the lower priority message must wait. The
most significant result of this regulation is that it provides
Tech 2 manufacturers with the capability to access data
from any make or model vehicle that is sold.
The data displayed on the other Tech 2 will appear the
same, with some exceptions. Some Scan Tools will only
be able to display certain vehicle parameters as values
that are a coded representation of the true or actual value.
For more information on this system of coding, refer to
Decimal/Binary/Hexadecimal Conversions. On this
vehicle the Tech 2 displays the actual values for vehicle
parameters. It will not be necessary to perform any
conversions from coded values to actual values.
ONBOARD DIAGNOSTIC (OBD)

OnBoard Diagnostic Tests
A diagnostic test is a series of steps, the result of which is
a pass or fail reported to the diagnostic executive. When a
diagnostic test reports a pass result, the diagnostic
executive records the following data:
D The diagnostic test has been completed since the last
ignition cycle.
D The diagnostic test has passed during the current
ignition cycle.
D The fault identified by the diagnostic test is not
currently active.
When a diagnostic test reports a fail result, the diagnostic
ignition cycle.
D The fault identified by the diagnostic test is currently
active.
D The fault has been active during this ignition cycle.
D The operating conditions at the time of the failure.
Remember, a fuel trim DTC may be triggered by a list of
vehicle faults. Make use of all information available (other

DTCs stored, rich or lean condition, etc.) when
diagnosing a fuel trim fault.

Diagnostic Operation
Input Components:
Input components are monitored for circuit continuity and
outofrange values. This includes rationality checking.
Rationality checking refers to indicating a fault when the
signal from a sensor does not seem reasonable, i.e.
Throttle Position (TP) sensor that indicates high throttle
position at low engine loads or MAP voltage). Input
components may include, but are not limited to the
following sensors:
D Vehicle Speed Sensor (VSS)
D Crankshaft Position (CKP) sensor
D Throttle Position (TP) sensor
D Engine Coolant Temperature (ECT) sensor
D Camshaft Position (CMP) sensor
D Manifold Absolute Pressure (MAP) sensor
In addition to the circuit continuity and rationality check
the ECT sensor is monitored for its ability to achieve a
steady state temperature to enable Closed Loop fuel
control.
Output Components:
Output components are diagnosed for proper response to
control module commands. Components where
functional monitoring is not feasible will be monitored for
circuit continuity and outofrange values if applicable.
Output components to be monitored include, but are not
limited to the following circuit:
D Idle Air Control (IAC) Motor
D EVAP Canister Purge Valve Solenoid
D A/C relays
D Cooling fan relay(s)
D VSS output
D MIL control
Refer to ECM and Sensors in General Descriptions.
Passive and Active Diagnostic Tests
A passive test is a diagnostic test which simply monitors a
vehicle system or component. Conversely, an active test,
actually takes some sort of action when performing
diagnostic functions, often in response to a failed passive
test. For example, the EGR diagnostic active test will
force the EGR valve open during closed throttle decel
and/or force the EGR valve closed during a steady state.
Either action should result in a change in manifold
pressure.
Intrusive Diagnostic Tests
This is any onboard test run by the Diagnostic
Management System which may have an effect on
vehicle performance or emission levels.
WarmUp Cycle
A warmup cycle means that engine at temperature must
reach a minimum of 70C (160F) and rise at least 22C
(40F) over the course of a trip.
6E129
Freeze Frame
Freeze Frame is an element of the Diagnostic
Management System which stores various vehicle
information at the moment an emissionsrelated fault is
stored in memory and when the MIL is commanded on.
These data can help to identify the cause of a fault. Refer
to Storing And Erasing Freeze Fame Data for more
detailed information.
Failure Records
Failure Records data is an enhancement of the OBD
Freeze Frame feature. Failure Records store the same
vehicle information as does Freeze Frame, but it will store
that information for any fault which is stored in onboard
memory, while Freeze Frame stores information only for
emissionrelated faults that command the MIL ON.
Common OBD Terms

Diagnostic
When used as a noun, the word diagnostic refers to any
onboard test run by the vehicles Diagnostic
Management System. A diagnostic is simply a test run on
a system or component to determine if the system or
component is operating according to specification. There
are many diagnostics, shown in the following list:
D Oxygen sensors
D Oxygen sensor heaters
D EGR
Enable Criteria
The term enable criteria is engineering language for the
conditions necessary for a given diagnostic test to run.
Each diagnostic has a specific list of conditions which
must be met before the diagnostic will run. Enable
criteria is another way of saying conditions required.
The enable criteria for each diagnostic is listed on the first
page of the DTC description in Section 6E under the
heading Conditions for Setting the DTC. Enable criteria
varies with each diagnostic, and typically includes, but is
not limited to the following items:
D engine speed
D vehicle speed
D ECT
D MAP
D barometric pressure
D IAT
D TP
D A/C ON
6E130
Trip
Technically, a trip is a key onrunkey off cycle in which all
the enable criteria for a given diagnostic are met, allowing
the diagnostic to run. Unfortunately, this concept is not
quite that simple. A trip is official when all the enable
criteria for a given diagnostic are met. But because the
enable criteria vary from one diagnostic to another, the
definition of trip varies as well. Some diagnostics are run
when the vehicle is at operating temperature, some when
the vehicle first starts up; some require that the vehicle be
cruising at a steady highway speed, some run only when
the vehicle is at idle; some diagnostics function with the
TCC disabled. Some run only immediately following a
cold engine startup.
A trip then, is defined as a key onrunkey off cycle in
which the vehicle was operated in such a way as to satisfy
the enabling criteria for a given diagnostic, and this
diagnostic will consider this cycle to be one trip. However,
another diagnostic with a different set of enable criteria
(which were not met) during this driving event, would not
consider it a trip. No trip will occur for that particular
diagnostic until the vehicle is driven in such a way as to
meet all the enable criteria.
The Diagnostic Executive

The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:
D Commanding the MIL (Check Engine lamp) ON and
OFF
D DTC logging and clearing
D Freeze Frame data for the first emission related DTC
recorded
D Nonemission related Service Lamp (future)
D Operating conditions Failure Records buffer, (the
number of records will vary)
D Current status information on each diagnostic
D System Status (I/M ready)
The Diagnostic Executive records DTCs and turns ON
the MIL when emissionrelated faults occur. It can also
turn OFF the MIL if the conditions cease which caused the
DTC to set.
Diagnostic Information
The diagnostic charts and functional checks are designed
to locate a faulty circuit or component through a process
of logical decisions. The charts are prepared with the
requirement that the vehicle functioned correctly at the
time of assembly and that there are no multiple faults
present.
There is a continuous selfdiagnosis on certain control

functions. This diagnostic capability is complimented by
the diagnostic procedures contained in this manual. The
language of communicating the source of the malfunction
is a system of diagnostic trouble codes. When a
malfunction is detected by the control module, a
diagnostic trouble code is set and the Malfunction
Indicator Lamp (MIL) (Check Engine lamp) is
illuminated.
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) looks the same as
the MIL you are already familiar with (Check Engine
lamp). However, OBD requires that it illuminate under a
strict set of guide lines.
Basically, the MIL is turned ON when the ECM detects a
DTC that will impact the vehicle emissions.
The MIL is under the control of the Diagnostic Executive.
The MIL will be turned ON if an emissionsrelated
diagnostic test indicates a malfunction has occurred. It
will stay ON until the system or component passes the
same test, for three consecutive trips, with no
emissionsrelated faults.
Extinguishing the MIL
When the MIL is ON, the Diagnostic Executive will turn
OFF the MIL after three (3) consecutive trips that a test
passed has been reported for the diagnostic test that
originally caused the MIL to illuminate.
Although the MIL has been turned OFF, the DTC will
remain in the ECM memory (both Freeze Frame and
Failure Records) until forty(40) warmup cycles after no
faults have been completed.
If the MIL was set by either a fuel trim or misfirerelated
DTC, additional requirements must be met. In addition to
the requirements stated in the previous paragraph, these
requirements are as follows:
D The diagnostic tests that are passed must occur with
375 RPM of the RPM data stored at the time the last
test failed.
D Plus or minus ten (10) percent of the engine load that
was stored at the time the last test failed.
D Similar engine temperature conditions (warmed up or
warming up) as those stored at the time the last test
failed.
Meeting these requirements ensures that the fault which
turned on the MIL has been corrected.
The MIL (Check Engine lamp) is on the instrument panel
and has the following functions:
D It informs the driver that a fault that affects vehicle
emission levels has occurred and that the vehicle
should be taken for service as soon as possible.
D As a bulb and system check, the MIL will come ON
with the key ON and the engine not running. When the
engine is started, the MIL will turn OFF.
D When the MIL remains ON while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a Powertrain
OnBoard Diagnostic (OBD) System Check must be
performed. The procedures for these checks are
given in OnBoard Diagnostic (OBD) System Check.
These checks will expose faults which may not be
detected if other diagnostics are performed first.
DTC Types
Each DTC is directly related to a diagnostic test. The
Diagnostic Management System sets DTC based on the
failure of the tests during a trip or trips. Certain tests must
fail two (2) consecutive trips before the DTC is set. The
following are the four (4) types of DTCs and the
characteristics of those codes:
D Type A
D Emissions related
D Requests illumination of the MIL of the first trip with a
fail
D Stores a History DTC on the first trip with a fail
D Stores a Freeze Frame (if empty)
D Stores a Fail Record
D Updates the Fail Record each time the diagnostic
test fails
D Type B
D Emissions related
D Armed after one (1) trip with a fail
D Disarmed after one (1) trip with a pass
D Requests illumination of the MIL on the second
consecutive trip with a fail
D Stores a History DTC on the second consecutive trip
with a fail (The DTC will be armed after the first fail)
D Stores a Freeze Frame on the second consecutive
trip with a fail (if empty)
D Stores a Fail Record when the first test fails (not
dependent on consecutive trip fails)
test fails
(Some special conditions apply to misfire and fuel trim
DTCs)
D Type C (if the vehicle is so equipped)
D NonEmissions related
D Requests illumination of the Service Lamp or the
service message on the Drive Information Center
(DIC) on the first trip with a fail
D Does not store a Freeze Frame
D Stores Fail Record when test fails
test fails
D Type D. (Type D nonemissions related are not
utilized on certain vehicle applications).
D Does not request illumination of any lamp
test fails
6E131
IMPORTANT: Only four Fail Records can be stored.

Each Fail Record is for a different DTC. It is possible that
there will not be Fail Records for every DTC if multiple
DTCs are set.
Storing and Erasing Freeze Frame Data and Failure
Records
Government regulations require that engine operating
conditions be captured whenever the MIL is illuminated.
The data captured is called Freeze Frame data. The
Freeze Frame data is very similar to a single record of
operating conditions. Whenever the MIL is illuminated,
the corresponding record of operating conditions is
recorded to the Freeze Frame buffer.
Freeze Frame data can only be overwritten with data
associated with a misfire or fuel trim malfunction. Data
from these faults take precedence over data associated
with any other fault. The Freeze Frame data will not be
erased unless the associated history DTC is cleared.
Each time a diagnostic test reports a failure, the current
engine operating conditions are recorded in the Failure
Records buffer. A subsequent failure will update the
recorded operating conditions. The following operating
conditions for the diagnostic test which failed typically
include the following parameters:
D Engine Speed
D Engine Load
D Engine Coolant Temperature
D Vehicle Speed
D TP
D MAP/BARO
D Injector Base Pulse Width
D Loop Status
Intermittent Malfunction Indicator Lamp
In the case of an intermittent fault, the MIL (Check
Engine lamp) may illuminate and then (after three trips)
go OFF. However, the corresponding diagnostic trouble
code will be stored in the memory. When unexpected
diagnostic trouble codes appear, check for an intermittent
malfunction.
A diagnostic trouble code may reset. Consult the
Diagnostic Aids associated with the diagnostic trouble
code. A physical inspection of the applicable subsystem
most often will resolve the problem.
Data Link Connector (DLC)
The provision for communicating with the control module
is the Data Link Connector (DLC). It is located at the lower
left of the instrument panel. The DLC is used to connect to
the Tech 2 Scan tool. Some common uses of the Tech 2
are listed below:
D Identifying stored Diagnostic Trouble Codes (DTCs)
D Clearing DTCs
D Performing output control tests
D Reading serial data
6E132

When a Tech 2 is not available, DTCs can also be cleared
by disconnecting one of the following sources for at least
thirty (30) seconds.
NOTE: To prevent system damage, the ignition key must
be OFF when disconnecting or reconnecting battery
power.
D The power source to the control module. Examples:
fuse, pigtail at battery ECM connectors etc.
D The negative battery cable. (Disconnecting the
negative battery cable will result in the loss of other
onboard memory data, such as preset radio tuning).
TS24064

Verification of vehicle repair will be more comprehensive
for vehicles with OBD II system diagnostics. Following a
repair, the technician should perform the following steps:
1. Review and record the Fail Records and/or Freeze
Frame data for the DTC which has been diagnosed
(Freeze Frame data will only be stored for an A or B
type diagnostic and only if the MIL has been
requested).
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the Fail
Records and/or Freeze Frame data.
Following these steps are very important in verifying
repairs on OBD systems. Failure to follow these steps

A Tech 2 Scan Tool
The procedure for reading diagnostic trouble code(s) is to
use a diagnostic Scan tool. When reading DTC(s), follow
instructions supplied by tool manufacturer.
Clearing Diagnostic Trouble Codes
IMPORTANT: Do not clear DTCs unless directed to do
so by the service information provided for each diagnostic
procedure. When DTCs are cleared, the Freeze Frame
and Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
If the fault that caused the DTC to be stored into memory
has been corrected, the Diagnostic Executive will begin to
count the warmup cycles with no further faults
detected, the DTC will automatically be cleared from the
ECM memory.
To clear Diagnostic Trouble Codes (DTCs), use the
diagnostic Scan tool clear DTCs or clear information
function. When clearing DTCs follow instructions
supplied by the tool manufacturer.
6E133
Tech 2
recommended to use the Tech 2 scan tool. Please refer to
the Tech 2 user guide.
901RW180
Legend
(1) PCMCIA Card
(2) R232 Loop Back Connector

(4) DLC Cable
(5) Tech 2
6E134
Tech 2 Features
1. Tech 2 is a 12 volt system. Do not apply 24 volt.
2. After connecting and/or installing, the Vehicle
Communications Interface (VCI) module, PCMCIA
card and DLC connector to the Tech 2, connect the
tool to the vehicle DLC.
3. Make sure the Tech 2 is powered OFF when
removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the Tech
1 Mass Storage Cartridge.
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and
static electricity, so care should be taken in the
handling of the card.
7. The Tech 2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu by pressing the EXIT
key several times before shutting down.
9. To clear Diagnostic Trouble Codes (DTCs), open
Application Menu and press F1: Clear DTC Info.
6. Turn on the vehicle ignition.

7. Power the Tech 2 ON and Verify the Tech 2 power up
display.
060RW009
Getting Started
D Before operating the Isuzu PCMCIA card with the
1. The Isuzu 99 System PCMCIA card (1) inserts into
the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC cable
(4).
3. Connect the DLC cable to the Tech 2 (5)
4. Make sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
DLC.
810RW317
NOTE: The RS232 Loop back connector is only to use for

diagnosis of Tech 2 and refer to user guide of the Tech 2.
6E135
Operating Procedure (Example)

The power up screen is displayed when you power up the
tester with the Isuzu system PCMCIA card. Follow the
operating procedure below.
060RX058
060RX060
6E136
Menu
D The following table shows which functions are used
for the available equipment versions.
060RW223
060RW224
DTC Modes
The following is a brief description of each of the sub

menus in DTC Info and DTC. The order in which they
appear here is alphabetical and not necessarily the way
they will appear on the Tech 2.
DTC Information Mode

Use the DTC info mode to search for a specific type of
stored DTC information. There are six choices. The
service manual may instruct the technician to test for
DTCs in a certain manner. Always follow published
service procedures.
060RW229
On OBD II vehicles there are five options available in Tech

2 DTC mode to display the enhanced information
available. After selecting DTC, the following menu
appears:
D DTC Info
D Freeze Frame
D Fail Records (not all applications)
D Clear Info
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.
Fail This Ignition
This selection will display all DTCs that have failed during
the present ignition cycle.

History
This selection will display only DTCs that are stored in the
ECMs history memory. It will display all type A and B
DTCs that have requested the MIL and have failed within
the last 40 warm-up cycles. In addition, it will display all
type C and type D DTCs that have failed within the last 40
warm-up cycles.
Last Test Failed
This selection will display only DTCs that have failed the
last time the test run. The last test may have run during a
previous ignition cycle if a type A or type B DTC is
displayed. For type C and type D DTCs, the last failure
must have occurred during the current ignition cycle to
appear as Last Test Fail.
MILSVC or Message Request
This selection will display only DTCs that are requesting
the MIL. Type C and type D DTCs cannot be displayed
using this option. This selection will report type B DTCs
only after the MIL has been requested.
Not Run Since Code Cleared
This option will display up to 33 DTCs that have not run
since the DTCs were last cleared. Since any displayed
DTCs have not run, their condition (passing or failing) is
unknown.
Test Failed Since Code Cleared
This selection will display all active and history DTCs that
have reported a test failure since the last time DTCs were
cleared. DTCs that last failed more than 40 warm-up
cycles before this option is selected will not be displayed.
6E137
060RW228
4. Select F0:Lamps Test in the Miscellaneous Test.
Miscellaneous Test
This test consists of eight menus-Lights, Relays, EVAP,
IAC System, Fuel System, EGR Control, Variable Intake
Manifold Solenoid, and Injector Balance Tests.
In these tests, Tech 2 sends operating signals to the
systems to confirm their operations thereby to judge the
normality of electric circuits.
To judge intermittent trouble,
1. Confirm DTC freeze frame data, and match the
freeze frame data as test conditions with the data list
displayed by Miscellaneous Test.
2. Confirm DTC setting conditions, and match the
setting conditions as test conditions with the data list
060RX043
Lamps Test
This test is conducted check MIL and Low Fuel Lamp for
its working.
Tech2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
3. Select F3: Miscellaneous Test in the Application
Menu.
060RX044
6E138
5. Select F0:Malfunction Indicator Lamp.
4. Select F1:Relay Test in the Miscellaneous Test.
060RX019
6. Push On soft key.

7. Make sure Lamp illuminates.
8. If lamp illuminates, the Lamp is operating correctly.
D F1; Up Shift Lamp = Not Used
060RX046
5. Select F0:Fuel Pump Relay.
D F2; Low Fuel Lamp = Not Used
Relays Test
This test is conducted to check Fuel Pump Relay, A/C
Clutch Low Fan and High Fan for prepor operation.
Tech 2 must be used for this test.
Test Procedure:
2. Ignition SW is On.
Menu.
060RX047
060RW228

6E139
15. Select F2: Low Fan Relay.
060RX022
7. Control Fuel Pump Relay and check a data list.

8. If the data list chenges, the Fuel Pump Relay is
normal.
9. Select F1:A/C Clutch Relay.
10. *Run the Engine at idle.
11. Turn on Air Condtioning.
060RX048
16. Push On and Off of soft key.

17. Control Low Fan Relay and check a data list.
18. If the data list changes, the Low Fan Relay is normal.
19. Run the Fan Motor.
20. Select F3: High Fan Relay.
060RX049
060RX023

13. Control A/C Clutch Relay and check a data list.
14. If the data list changes, the A/C Clutch Relay is
normal.

22. Control High Fan Relay and check a data list.
If the data list changes, the High Fan Relay is normal.
6E140

5. Select F0: Purge Solenoid.
EVAP Test
This test is conducted check EVAP system for its working.
Test Procedure:
Menu.
060RX025
6. Push Decrease or Increase soft key.
060RW228
4. Select F2:EVAP Test in the Miscellaneous Test.
060RX026
7. Control EVAP Purge Solenoid and check a data list.

8. If the data list changes, the purge Solenoid is normal.
Ignition SW is On.
D F1; Vent Solenoid = Not Used
Idle Air Control System Test

060RX050
This test is conducted check to IAC system for proper

operation.
Test Procedure:

Menu.
6E141
5. Select F1: IAC Control Test.
060RX052
060RW228
4. Select F3: IAC System Test in the Miscellaneous

Test.
6. Push Increase or Decrease soft key.

7. Control IAC system and check a data list.
D F0: IAC Control
060RX051
060RX015
8. Select F1: IAC Reset.

9. Push Reset IAC soft key.
10. Control IAC Reset and check data list.
6E142
11. If data list changes, the IAC has been Reset.
4. Select F4: Fuel System in the Miscellaneous Menu.
060RW2311
060RX053
5. Select F0: Fuel Trim Reset.
Fuel System Test

This test is conducted check Fuel Level Gauge for proper
operation.
Test Procedure:
Menu.
060RX028
060RW228

6. Push Reset of soft key.
6E143
4. Select F5: EGR Control Test in the Miscellaneous

Test.
060RX029
D F1; Fuel Gauge Level = Not Used
060RX054
5. Control EGR Valve and check data list.
EGR Control Test

This test is conducted check EGR valve for proper
operation.
Test Procedure:
Menu.
060RX017
6. If the change, the EGR Control is normal.
Injector Balance Test
060RW228
This test is conducted to make sure the appropriate

electric signals are being sent to injectors Nos. 16.
Test Procedure:
6E144

Menu.
5. Select injector number and push injector off of soft

key.
060RW228
4. Select F6: Injector Balance Test in the Miscellaneous

Test.
060RW2301
6. Make sure of engine speed change.

7. If engine speed changes, the injector electric circuit is
normal.
If engine speed does not change, the injector electric
circuit or the injector itself is not normal.
Plotting Snapshot Graph

This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. It is an effective test particularly in emission
related evaluations.
060RX055
060RX037
For trouble diagnosis, you can collect graphic data (snap

shot) directly from the vehicle. You can replay the
snapshot data as needed. There fore, accurate diagnosis
is possible, even though the vehicle is not available.
6E145
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
060RX085
6E146
Flow Chart for Snapshot Replay (Plotting Graph)
060RX040
PRIMARY SYSTEMBASED
DIAGNOSTICS
Primary SystemBased Diagnostics
There are primary systembased diagnostics which
evaluate system operation and its effect on vehicle
emissions. The primary systembased diagnostics are
listed below with a brief description of the diagnostic
function:
Oxygen Sensor Diagnosis
The fuel control heated oxygen sensor (HO2S 1) is
diagnosed for the following conditions:
D Heater performance (time to activity on cold start)
D Slow response
D Response time (time to switch R/L or L/R)
D Inactive signal (output steady at bias voltage
approx. 450 mV)
D Signal fixed high
D Signal fixed low
The catalyst monitor heated oxygen sensor (HO2S 2) is
D Heater performance (time to activity on cold start).
D Signal fixed low during steady state conditions or
power enrichment (hard acceleration when a rich
mixture should be indicated).
D Signal fixed high during steady state conditions or
deceleration mode (deceleration when a lean mixture
should be indicated).
D Inactive sensor (output steady at approx. 438 mV).
If the oxygen sensor pigtail wiring, connector or terminal
are damaged, the entire oxygen sensor assembly must
be replaced. DO NOT attempt to repair the wiring,
connector or terminals. In order for the sensor to function
properly, it must have clean reference air provided to it.
This clean air reference is obtained by way of the oxygen
sensor wire(s). Any attempt to repair the wires, connector
or terminals could result in the obstruction of the
reference air and degrade oxygen sensor performance.
Refer to OnVehicle Service, Heated Oxygen Sensors.
6E147
Fuel Control Heated Oxygen Sensors

The main function of the fuel control heated oxygen
sensors is to provide the control module with exhaust
stream oxygen content information to allow proper fueling
and maintain emissions within mandated levels. After it
reaches operating temperature, the sensor will generate
a voltage, inversely proportional to the amount of oxygen
present in the exhaust gases. The control module uses
the signal voltage from the fuel control heated oxygen
sensors while in Closed Loop to adjust fuel injector
pulse width. While in Closed Loop, the ECM can adjust
fuel delivery to maintain an air/fuel ratio which allows the
best combination of emission control and driveability. The
fuel control heated oxygen sensors are also used to
determine catalyst efficiency.
HO2S Heater
Heated oxygen sensors are used to minimize the amount
of time required for Closed Loop fuel control to begin
operation and to allow accurate catalyst monitoring. The
oxygen sensor heater greatly decreases the amount of
time required for fuel control sensor (HO2S 1) to become
active. Oxygen sensor heaters are required by the
catalyst monitor sensor (HO2S 2) to maintain a
sufficiently high temperature which allows accurate
exhaust oxygen content readings further away from the
engine.
6E148
ONBOARD DIAGNOSTIC (OBD) SYSTEM CHECK
D06RX108
Circuit Description
Test Description
The onboard diagnostic system check is the starting

point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical
check of the ECM and engine grounds for cleanliness and
tightness.
The onboard diagnostic system check is an organized
approach to identifying a problem created by an
electronic engine control system malfunction.
Number(s) below refer to the step number(s) on the

Diagnostic Chart:
1. The MIL (Check Engine lamp) should be ON
steady with the ignition ON/engine OFF. If not,
isolate the malfunction in the MIL circuit.
2. Checks the Class 2 data circuit and ensures that the
ECM is able to transmit serial data.
3. This test ensures that the ECM is capable of
controlling the MIL and the MIL driver circuit is not
shorted to ground.
4. If the engine will not start, the Cranks But Will Not
Run chart should be used to diagnose the condition.
7. A Tech 2 parameter which is not within the typical
range may help to isolate the area which is causing
the problem.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminaltowire connection,
and damaged harness.
6E149
OnBoard Diagnostic (OBD) System Check

Step
Action
1.
2.
3.
4.
Go to Step 8
Go to Step 4
Go to MIL
(Check
Engine
Lamp) On
Steady
Go to Step 5
Go to Cranks
But Will Not
Run
Go to Step 6
Go to Step 7
Go to
Multiple
ECM
Information
Sensor DTCs
Set
Go to
applicable
DTC table
Go to Typial
Scan Data
Value
Go to
indicated
Component
System
Checks
Go to Step 2
Go to Step 9
Go to Step 2
Go to Step 10
Verify repair
1. Ignition OFF, disconnect the ECM.

2. Ignition ON, engine OFF.
3. Check the Class 2 data circuit for an open, short to
ground, or short to voltage. Also, check the DLC
ignition feed circuit for an open or short to ground
and the DLC ground circuits for an open.
4. If a problem found, repair as necessary.
1. Attempt to reprogram the ECM. Refer to Engine
Control Module (ECM) in OnVehicle Service.
2. Attempt to display ECM data with the Tech 2.
Does the Tech 2 display ECM engine data?
10
Go to Step 3
Compare ECM data values displayed on the Tech 2 to

the typical engine scan data values.

9
Are two or more of the following DTCs stored? P0107,

P0113, P0118, P0122, P0123.
Are the displayed values normal or close to the typical

values?
8
Go to No MIL
Select Display DTCs with the Tech 2.

Are any DTCs stored?
Go to Step 2
Attempt to start the engine.

Did the engine start and continue to run?
1. Using the Tech 2 output tests function, select MIL

dash lamp control and command the MIL OFF.
2. Observe the MIL.
Did the MIL turn OFF?
No
Ignition OFF.
Install a Tech 2.
Ignition ON.
Attempt to display ECM engine data with the Tech 2.
Does the Tech 2 display ECM data?

3
Yes

2. Observe the malfunction indicator lamp (MIL or
Check Engine lamp).
Is the MIL (Check Engine lamp) ON?
Value(s)
Replace the ECM.

6E150
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS
D06RX107
Circuit Description
When air conditioning and blower fan are selected, and if
the system has a sufficient refrigerent charge, a 12volt
signal is supplied to the A/C request input of the engine
control module (ECM). The A/C request signal may be
temporarily cancelled during system operation by the
electronic thermostat in the evaporator case. The
electronic thermostat may intermittently remove the
control circuit ground for the A/C thermostat relay to
prevent the evaporator from forming ice. When the A/C
request signal is received by the ECM, the ECM supplies
a ground from the compressor clutch relay if the engine
operating conditions are within acceptable ranges. With
the A/C compressor relay energized, battery voltage is
supplied to the compressor clutch coil.
The ECM will enable the compressor clutch to engage
whenever A/C has been selected with the engine running,
unless any of the following conditions are present:
D The throttle is greater than 90%.

D The ignition voltage is below 10.5 volts.
D The engine speed is greater than 4500 RPM for 5
D The engine coolant temperature (ECT) is greater
than 125C (257F)
D The intake air temperature (IAT) is less than 5C
(41F).
D The power steering pressure switch signals a high
pressure condition position.
Diagnostic Aids
To diagnose an intermittent fault, check for the following
conditions:
D Poor connection at the ECM Inspect harness
connections for backedout terminals, improper
mating, broken locks, improperly formed or damaged
terminals, and poor terminaltowire connection.

D Damaged harness Inspect the wiring harness for
damage; shorts to ground, shorts to battery voltage,
and open circuits. If the harness appears to be OK,
observe the A/C clutch while moving connnectors and
wiring harnesses related to the A/C. A sudden clutch
malfunction will indicate the source of the intermittent.
6E151
be used in diagnosing the system. The Tech 2 has the

ability to read the A/C request input to the ECM. The Tech
2 can display when the ECM has commended the A/C
clutch ON. The Tech 2 should have the ability to override
the A/C request signal and energize the A/C compressor
relay.
A/C Clutch Diagnosis

This chart should be used for diagnosing the electrical
portion of the A/C compressor clutch circuit. A Tech 2 will
A/C Clutch Control Circuit Diagnosis

Step
Action
Go to Step 2
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 5
Go to Step 4
Verify repair
Verify repair
Go to Step 6
1. Ignition OFF.
2. Remove the A/C Compressor Relay from the
Underhood Electrical Center.
4. Using a Digital Voltmeter (DVM), check for voltage
on the Fused pins of the A/C Compressor Clutch
Relat connector.
Check the suspect circuit(s) between the A/C
Compressor Clutch Relay connector and the Fuse for
the following conditions:
D A short to ground
D An open circuit
D A short to voltage
Was the problem found?
No
Go to OBD
System
Check

2. Review and record Tech 2 Failure Records data,
then clear the DTCs.
3. Operate the vehicle within the Failure Records
conditions as noted.
4. Using the Tech 2, monitor DTC info for DTC
P1546.
Does the DVM read the following value?

4
Yes
Was the OnBoard Diagnostic (OBD) System Check

performed?
Does the Tech 2 indicate DTC P1546 Ran and

Passed?
3
Value(s)
1. Ignition OFF.
2. Disconnect the Engine Controlm Module (ECM)
connectors from the ECM.
3. Check the A/C Compressor Clutch Relay control
circuit between the ECM and Underhood Electrical
Center for the following conditions:
D A short to ground
D An open circuit
6E152
A/C Clutch Control Circuit Diagnosis (Cont'd)

Step
Action
Go to Step 9
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Replace the A/C Compressor Clutch Relay.

No
1. Ignition OFF.
2. Check the A/C Compressor Clutch circuit between
the A/C Compressor Clutch Relay and A/C
Compressor Clutch for the following conditions:
D A short to ground
D An open circuit
Yes
1. Reinstall the A/C Compressor Clutch Relay.

2. Using a fused jumper, ground the A/C Compressor
Clutch Relay control circuit at the ECM connector.
Does the A/C Compressor turn ON?
Value(s)
Replace the ECM.

Verify repair.

DIAGNOSIS
If the engine cranks but will not run or immediately stalls,
the Engine Cranks But Will Not Start chart must be used
to determine if the failure is in the ignition system or the
fuel system.
VISUAL CHECK OF THE

EVAPORATIVE EMISSION CANISTER
6E153
The Tech 2 displays the IAC pintle position in counts. A

count of 0 indicates the ECM is commanding the IAC
pintle to be driven all the way into a fullyseated position.
This is usually caused by a vacuum leak.
The higher the number of counts, the more air is being
commanded to bypass the throttle blade. In order to
diagnose the IAC system, refer to IAC System Check.
For other possible causes of idle problems, refer to
Rough, Unstable, or Incorrect Idle, Stalling in Symptoms.

DIAGNOSIS
014RX001
D If the canister is cracked or damaged, replace the

canister.
D If fuel is leaking from the canister, replace the canister
and check hoses and hose routing.
014RX002
To read and clear diagnostic trouble codes, use a Tech 2.
IDLE AIR CONTROL (IAC) VALVE
901RX031
0006
6E154
IMPORTANT: Use of a Tech 2 is recommended to clear

diagnostic trouble codes from the ECM memory.
Diagnostic trouble codes can also be cleared by turning
the ignition OFF and disconnecting the battery power
from the ECM for 30 seconds. Turning off the ignition and
disconnecting the battery power from the ECM will cause
all diagnostic information in the ECM memory to be
cleared. Therefore, all the diagnostic tests will have to be
rerun.
Since the ECM can have a failure which may affect only
one circuit, following the diagnostic procedures in this
section will determine which circuit has a problem and
where it is.
If a diagnostic chart indicates that the ECM connections
or the ECM is the cause of a problem, and the ECM is
replaced, but this does not correct the problem, one of the
following may be the reason:
D There is a problem with the ECM terminal
connections. The terminals may have to be removed
from the connector in order to check them properly.
D The problem is intermittent. This means that the
problem is not present at the time the system is being
checked. In this case, make a careful physical
inspection of all components and wiring associated
with the affected system and refer to the Symptoms
portion of the manual.
D There is a shorted solenoid, relay coil, or harness.
Solenoids and relays are turned ON and OFF by the
ECM using internal electronic switches called drivers.
A shorted solenoid, relay coil, or harness will not
damage the ECM but will cause the solenoid or relay
to be inoperative.
MULTIPLE ECM INFORMATION

SENSOR DTCs SET
Circuit Description
The engine control module (ECM) monitors various
sensors to determine the engine operating conditions.
The ECM controls fuel delivery, spark advance, and
emission control device operation based on the sensor
inputs.
The ECM provides a sensor ground to all of the sensors.
The ECM applies 5 volts through a pullup resistor, and
determines the status of the following sensors by
monitoring the voltage present between the 5volt supply
and the resistor:
D The Fuel Tank Vapor Pressure Sensor
D The throttle position (TP) sensor
D The manifold absolute pressure (MAP) sensor
The ECM provides the following sensors with a 5volt
reference and a sensor ground signal:
D The Linear exhaust gas recirculation (EGR) valve
D The A/C Pressure Sensor
The ECM monitors the separate feedback signals from

these sensors in order to determine their operating
status.
Diagnostic Aids
Be sure to inspect ECM and engine grounds for being secure and clean.
A short to voltage in one of the sensor input circuits may
cause one or more of the following DTCs to be set:
D P0108
D P0113
D P0118
D P0123
If a sensor input circuit has been shorted to voltage, ensure that the sensor is not damaged. A damaged sensor
will continue to indicate a high or low voltage after the affected circuit has been repaired. If the sensor has been
damaged, replace it.
An open in the sensor ground circuit between the ECM
and the splice will cause one or more of the following
DTCs to be set:
D P0108
D P0113
D P0118
D P0123
A short to ground in the 5volt reference A circuit will
D P0107
D P0122
D P0112
D P0117
D P0454
D P0405
D P0532
Check for the following conditions:
D Poor connection at ECM. Inspect the harness
connectors for backedout terminals, improper
terminals, and a poor terminaltowire connection.
D Damaged harness. Inspect the wiring harness for
damage. If the harness is not damaged, observe an
affected sensors displayed value on the Tech 2 with
the ignition ON and the engine OFF while you move
the connectors and the wiring harnesses related to
the following sensors:
D IAT
D ECT
D TP
D MAP
D EGR
D A/C Pressure Sensor
6E155
Multiple ECM Information Sensor DTCs Set

Step
Action
Verify repair
Go to Step 5
Go to Step 6
Verify repair
0V
Go to Step 7
0V
Go to Step 8
0V
Go to Step 9
Go to Step 13
Go to Step 14
Go to Step 15
Measure the voltage between the IAT sensor signal

circuit at the ECM harness connector and ground.
Go to Step 16
Go to Step 20
Go to Step 17
Go to Step 13
Go to Step 19
0V
Measure the voltage between the A/C Pressure

Sensor circut at the ECM harness connector and
ground.
Does the voltage measure near the specified value?
Go to Step 10
0V
Measure the voltage between the ECT sensor signal

11
Measure the voltage between the TP sensor signal


10
Go to Step 4
Measure the voltage between the MAP sensor signal


9
Go to Step 3
Measure the voltage between the EGR pintle position

sensor signal circuit at the ECM harness connector and
ground.

8
Repair the open or the poor connection.

7
Go to Step 2
Check the sensor ground circuit for the following

conditions:
D A poor connection at the ECM or the affected
sensors.
D An open between the ECM connector and the
affected sensors.

6
Go to OBD
System
Check
Repair the open or short.
Is there an open or a poor connection?

5
No
1. Turn the ignition OFF, disconnect the ECM.

2. Turn the ignition ON, check the 5 volt reference
circuits for the following conditions:
D A poor connection at the ECM.
splice.
D A short to ground.
D A short to voltage.

4
Yes

performed?
Is there an open or short?

3
Value(s)
0V
6E156
Multiple ECM Information Sensor DTCs Set (Cont'd)

Step
Action
12
1. Disconnect the EGR valve.

2. Measure the voltage between the EGR pintle
position sensor signal circuit at the ECM harness
connector and ground.
13
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to OBD
System
Check
Locate and repair the short to voltage in the EGR pintle

position sensor signal circuit.
20
Verify repair
Locate and repair the short to voltage in the A/C

Pressure Sensor circuit.
19
Locate and repair the short to voltage in the ECT

sensor signal circuit.
18
Go to Step 17
Locate and repair the short to voltage in the IAT sensor

signal circuit.
17
Go to Step 12
0V
Locate and repair the short to voltage in the TP sensor

signal circuit.
16
No
Locate and repair the short to voltage in the MAP

15
Yes
Replace the EGR valve.

14
Value(s)
Replace the ECM.

EXHAUST GAS RECIRCULATION

(EGR) DIAGNOSIS
6E157
DECEL FUEL MODE Tech 2 Displays ACTIVE or

INACTIVE
ACTIVE displayed indicates that the ECM has detected
conditions appropriate to operate in deceleration fuel
mode. The ECM will command the deceleration fuel
mode when it detects a closed throttle position while the
vehicle is traveling over 20 mph. While in the deceleration
fuel mode, the ECM will decrease the amount of fuel
delivered by entering Open Loop and decreasing the
injector pulse width.
DESIRED EGR POS. Tech 2 Range 0%100%
Represents the EGR pintle position that the ECM is
commanding.
DESIRED IDLE Tech 2 Range 03187 RPM
The idle speed that the ECM is commanding. The ECM
will compensate for various engine loads based on engine
coolant temperature, to keep the engine at the desired
speed.
057RX001
An EGR flow check diagnosis of the linear EGR system is

covered by DTC P0401, P0404, and P0405. If EGR
diagnostic trouble code P0401 is encountered, refer to
the DTC charts.
ENGINE Tech 2 DATA DEFINITIONS

AND RANGES
A/C CLUTCH Tech 2 Displays ON or OFF
Indicates whether the ECM has commanded the A/C
clutch ON. Used in A/C system diagnostics.
A/C REQUEST Tech 2 Displays YES or NO
Indicates the state of the A/C request input circuit from the
HVAC controls. The ECM uses the A/C request signal to
determine whether A/C compressor operation is being
requested.
AIR/FUEL RATIO Tech 2 Range 0.025.5
Air/fuel ratio indicates the ECM commanded value. In
Closed Loop, the air/fuel ratio should normally be
displayed around 14.214.7. A lower air/fuel ratio
indicates a richer commanded mixture, which may be
seen during power enrichment or TWC protection modes.
A higher air/fuel ratio indicates a leaner commanded
mixture. This can be seen during deceleration fuel mode.
BARO kPa Tech 2 Range 10105 kPa/0.005.00
Volts
The barometric pressure reading is determined from the
MAP sensor signal monitored during key up and wide
open throttle (WOT) conditions. The barometric pressure
is used to compensate for altitude differences and is
normally displayed around 61104 depending on
altitude and barometric pressure.
CMP ACT. COUNTER Cam Position Activity
ECT (Engine Coolant Temperature) Tech 2 Range

40C to 151C (40F to 304F)
The engine coolant temperature (ECT) is mounted in the
coolant stream and sends engine temperature
information to the ECM. The ECM applies 5 volts to the
ECT sensor circuit. The sensor is a thermistor which
changes internal resistance as the temperature changes.
When the sensor is cold (high resistance), the ECM
monitors a high signal voltage and interprets that as a cold
engine. As the sensor warms (decreasing resistance),
the voltage signal will decrease and the ECM will interpret
the lower voltage as a warm engine.
EGR DUTY CYCLE Tech 2 Range 0%100%
Represents the EGR valve driver PWM signal from the
ECM. A duty cycle of 0% indicates that no EGR flow is
being commanded; a 100% duty cycle indicates
maximum EGR flow commanded.
EGR FEEDBACK Tech 2 Range 0.005.00 Volts
Indicates the EGR pintle position sensor signal voltage
being monitored by the ECM. A low voltage indicates a
fully extended pintle (closed valve); a voltage near 5 volts
indicates a retracted pintle (open valve).
EGR TEST COUNT Tech 2 Range 0255
Indicates the number of EGR flow test samples collected
during the current ignition cycle. Under normal operation,
only one sample is allowed during an ignition cycle. If the
ECM battery feed has been disconnected or a DTC
P0401 has been cleared, 10 EGR flow test samples will
be allowed during the ignition cycle. This is to allow repair
verification during a single ignition cycle.
ENGINE LOAD Tech 2 Range 0%100%
Engine load is calculated by the ECM from engine speed
and MAP sensor readings. Engine load should increase
with an increase in RPM or air flow.
ENGINE RUN TIME Tech 2 Range 00:00:00
99:99:99 Hrs:Min:Sec
Indicates the time elapsed since the engine was started.
If the engine is stopped, engine run time will be reset to
00:00:00.
ENGINE SPEED Range 09999 RPM
Engine speed is computed by the ECM from the 58X
reference input. It should remain close to desired idle
under various engine loads with engine idling.
6E158
FUEL PUMP Tech 2 Displays ON or OFF

Indicates the ECM commanded state of the fuel pump
relay driver circuit.
FUEL TRIM CELL Tech 2 Range 021
The fuel trim cell is dependent upon engine speed and
MAF sensor readings. A plot of RPM vs. MAF is divided
into 22 cells. Fuel trim cell indicates which cell is currently
active.
FUEL TRIM LEARN Tech 2 Displays NO or YES
When conditions are appropriate for enabling long term
fuel trim corrections, fuel trim learn will display YES. This
indicates that the long term fuel trim is responding to the
short term fuel trim. If the fuel trim learn displays NO, then
long term fuel trim will not respond to changes in short
term fuel trim.
HO2S BANK 1, SEN. 1 Tech 2 Range 01000 mV
Represents the fuel control exhaust oxygen sensor
output voltage. Should fluctuate constantly within a range
between 10 mV (lean exhaust) and 1000 mV (rich
exhaust) while operating in Closed Loop.
HO2S BANK 1, SEN. 1 Tech 2 Displays NOT
READY or READY
Indicates the status of the exhaust oxygen sensor. The
Tech 2 will indicate that the exhaust oxygen sensor is
ready when the ECM detects a fluctuating HO2S voltage
sufficient to allow Closed Loop operation. This will not
occur unless the exhaust sensor is warmed up.
HO2S WARM UP TIME BANK 1, SEN. 1 Tech 2
Range 00:00:0099:99:99 HRS:MIN:SEC
Indicates warmup time for each HO2S. The HO2S
warmup time is used for the HO2S heater test. The ECM
will run the heater test only after a cold start (determined
by engine coolant and intake air temperature at the time
of startup) and only once during an ignition cycle. When
the engine is started the ECM will monitor the HO2S
voltage. When the HO2S voltage indicates a sufficiently
active sensor, the ECM looks at how much time has
elapsed since startup. If the ECM determines that too
much time was required for the HO2S to become active,
a DTC will set. If the engine was warm when started,
HO2S warmup will display 00:00:00.
IAC POSITION Tech 2 Range 0255 Counts
Displays the commanded position of the idle air control
pintle in counts. A larger number of counts means that
more air is being commanded through the idle air
passage. Idle air control should respond fairly quickly to
changes in engine load to maintain desired idle RPM.
IAT (INTAKE AIR TEMPERATURE) Tech 2 Range
40C to 151C (40F to 304F)
The ECM converts the resistance of the intake air
temperature sensor to degrees. Intake air temperature
(IAT) is used by the ECM to adjust fuel delivery and spark
timing according to incoming air density.
IGNITION 1 Tech 2 Range 025.5 Volts
This represents the system voltage measured by the
ECM at its ignition feed.
INJ. PULSE BANK 1 Tech 2 Range 01000 msec.

Indicates the amount of time the ECM is commanding
each injector ON during each engine cycle. A longer
injector pulse width will cause more fuel to be delivered.
Injector pulse width should increase with increased
engine load.
MAP Tech 2 Range 10105 kPa (0.004.97 Volts)
The manifold absolute pressure (MAP) sensor measures
the change in the intake manifold pressure from engine
load, EGR flow, and speed changes. As intake manifold
pressure increases, intake vacuum decreases, resulting
in a higher MAP sensor voltage and kPa reading. The
MAP sensor signal is used to monitor intake manifold
pressure changes during the EGR flow test, to update the
BARO reading, and as an enabling factor for several of
the diagnostics.
MIL Tech 2 Displays ON or OFF
Indicates the ECM commanded state of the malfunction
indicator lamp (Check Engine Lamp).
POWER ENRICHMENT Tech 2 Displays ACTIVE
or INACTIVE
conditions appropriate to operate in power enrichment
mode. The ECM will command power enrichment mode
when a large increase in throttle position and load is
detected. While in the power enrichment mode, the ECM
will 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.
SPARK Tech 2 Range 64 to 64
Displays the amount of spark advance being commanded
by the ECM on the IC circuit.
STARTUP ECT Tech 2 Range 40C to 151C
(40F to 304F)
Indicates the engine coolant temperature at the time that
the vehicle was started. Used by the HO2S diagnostic to
determine if the last startup was a cold start.
(40F to 304F)
Indicates the intake air temperature at the time that the
vehicle was started. Used by the HO2S diagnostic to
TP ANGLE Tech 2 Range 0%100%
TP (throttle position) angle is computed by the ECM from
the TP sensor voltage. TP angle should display 0% at
idle and 100% at wide open throttle.
TP SENSOR Tech 2 Range 0.005.00 Volts
The voltage being monitored by the ECM on the TP
VEHICLE SPEED Tech 2 Range 0255 km/h
(0155 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 ECM has detected crankshaft
speed variations that indicate 2% or more cylinder firing
events are misfires.
TYPICAL SCAN DATA VALUES

Use the Typical Scan Data Values Table only after the
OnBoard Diagnostic System Check has been
completed, no DTC(s) were noted, and you have
determined that the onboard diagnostics are functioning
properly. Tech 2 values from a properlyrunning engine
may be used for comparison with the engine you are
diagnosing. The typical scan data values represent
values that would be seen on a normallyrunning engine.
NOTE: A Tech 2 that displays faulty data should not be
used, and the problem should be reported to the Tech 2
manufacturer. Use of a faulty Tech 2 can result in
misdiagnosis and unnecessary replacement of parts.
2.2L L4 Engine
Tech 2
Parameter
Data List
Units
Displayed
6E159
Only the parameters listed below are referred to in this

service manual for use in diagnosis. For further
information on using the Tech 2 to diagnose the ECM and
related sensors, refer to the applicable reference section
listed below. If all values are within the typical range
described below, for diagnosis, refer to the Symptoms
section.
Test Conditions
Engine running, lower radiator hose hot, transmission in
park or neutral, Closed Loop, accessories OFF, brake
not applied and air conditioning OFF.
Typical Data
Values (IDLE)
Typical Data
Values
(2500 RPM)
Refer To
Engine Speed
Engine
RPM
Within -50 to
+100 of
Desired Idle
Actul engine
speed
General Discription and

Operation
Desired Idle
Speed
Engine
RPM
750
800
General Discription and and

Operation, Idle Air Control
Engine Coolant
Tenpereture
Engine
80 100 (176
212 F)
80 100 (176
212 F)

Operation, Engin coolant
tempereture sensor
Start Up ECT
Engine

tempereture sensor
Intake Air
Tenpereture
Engine
0 100,
depends on
underhood
0 80, depends
on underhood

Operation, Intake Air
tempereture sensor
Start Up IAT
Engine

tempereture sensor
Manifold
Absolute
Pressure
Engine
kPa
23 40
19 32

Operation, Manifold
Absolute Pressure Sensor.
DTC P0106,P0107,P0108
Manifold
Absolute
Pressure
Engine
0.65 1.32
0.46 1.10

Operation, Manifold
DTC P0106,P0107,P0108
Barometric
Pressure
Engine
kPa
61 104
(depends pn
altitude and
barometric)
61 104
(depends pn
altitude and
barometric)

Opreration
Throttle Position
Engine
35

Opreration, Throttle Position
Sensor. DTC
P0121,P0122,P0123
Throttle Position
Sensor
Engine
0.35 0.39
0.55 0.59

Sensor. DTC
P0121,P0122,P0123
Air Fuel Ratio
Engine
Ratio:_to1
14.6:1
14.6:1

Operation, Fuel System
Metering Purpose, Fuel Trim
6E160
Tech 2
Parameter
Data List
Units
Displayed
Typical Data
Values (IDLE)
Typical Data
Values
(2500 RPM)
Refer To
Spark Advance
Engine
CA
10 12
27 29

Operation, Electronic
Ignition System
Engine Load
Engine
Fuel system
Status
Engine
Closed
Loop
EVAP System
EGR Duty Cycle
Engine

Operation, Liner EGR
Operation and Results of
Incorrect Operation
Desired EGR
Position
Engine

Operation, EGR Pintle
Position Sensor
EGR
Normalized
Engine
EGR Feed Back
Engine
0.6 0.8
0.6 0.8
EGR Closed
Pintle Position
Engine
Steps
20 40
20 40

Position Sensor
Knock Counter
Engine
Yes/No
Yes
Yes
DTC P0325,P0327
Knock Retard
Engine
CA
DTC P0325,P0327
A/C Pressure
Sensor
Engine
mV
DTC P0532,P0533
A/C Clutch
Relay
Engine
On/Off
Off

Operation, A/C Culutch
Circuit Operation
A/C Request
Engine
Yes/No
No

Operation, A/C Request
Signal
Low Fan
Comanded
Engine
Yes/No

Operation, Cooling Fan
Control. DTC P0480,P0481
High Fan
Comanded
Engine
Yes/No

Camshaft
Activity
Engine
Counts
0 255
0 255
DTC P0341,P0342
Fuel Pump
Engine
On/Off
On
On
Engine Fuel System
Deceleration
Fuel Cutoff
Engine
Inactive/Ac
tive
Inactive
Inactive

Operation
Idle Air Control
Engine
Steps

tempereture sensor
Vehicle Speed
Engine
MPH or
km/h
Manual Transmission
Ignition Voltage
Engine
12.8 14.1
12.8 14.1

Ignition System
Malfunction
Indicator Lamp
Engine
On/Off
Off
Off
OnBoard Diagnostic
System Check

Tech 2
Parameter
Data List
Units
Displayed
Typical Data
Values (IDLE)
Typical Data
Values
(2500 RPM)
6E161
Refer To
ABS Rough
Road
Engine
Misfire
Value
Okey
Okey
DTC P1380,P1381
B1S1 Status
(Bank1,Sensor1)
Engine
HO2S
Rich/Lean

Operation, Fuel Control
HO2S
B1S1 O2 Sensor
(Bank1,Sensor1)
Engine
HO2S
mV
50 950
changing quickly
50 950
changing quickly

HO2S
Fuel Trim
Learned
Engine
HO2S
Yes/No
Yes
Yes
Diagnosis, Fuel Trim Monitor
Fuel Trim Cell
Engine
HO2S
Cell No.
18
2 or 6
Diagnosis, Fuel Trim Cell

Diagnostic Weights
B1 Long Fuel
Trim
Engine
HO2S
DTC P0171,P0172
B2 Short Fuel
Trim
Engine
HO2S
DTC P0171,P0172
Power
Enrichment
Engine
HO2S
Yes/No
No
No

Operation, Acceleration
Mode
6E162
NO MALFUNCTION INDICATOR LAMP (MIL)
D06RX109
Circuit Description
The Check Engine lamp (MIL) should always be
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 engine control
module (ECM) turns the MIL ON by grounding the MIL
driver circuit.
Diagnostic Aids
An intermittent MIL may be caused by a poor connection,
rubbedthrough wire insulation, or a wire broken inside
the insulation. Check for the following items:
D Inspect the ECM harness and connections for
damaged
terminals,
poor
terminaltowire
connection, and damaged harness.
D If the engine runs OK, check for a faulty light bulb, an
open in the MIL driver circuit, or an open in the
instrument cluster ignition feed.
D If the engine cranks but will not run, check for an open
ECM ignition or battery feed, or a poor ECM to engine
ground.
Test Description
Diagnostic Chart:
2. A No MIL condition accompanied by a nostart
condition suggests a faulty ECM ignition feed or
battery feed circuit.
9. Using a test light connected to B+, probe each of
the ECM ground terminals to ensure that a good
ground is present. Refer to ECM Terminal End View
for terminal locations of the ECM ground circuits.
12. In this step, temporarily substitute a known good
relay for the ECM relay. The horn relay is nearby,
and it can be verified as good simply by honking
the horn. Replace the horn relay after completing
this step.
6E163
No Malfunction Indicator Lamp (MIL)

Step
Action
1.
2.
3.
4.
Go to Step 13
Go to Step 10
Go to Step 11
Go to Step 15
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 12
Go to Step 14
Go to Step 10
Go to Step 17
Go to Step 18
Substitute a known good relay for the ECM main

relay.
Go to Step 13
Repair the open in the ignition feed circuit.

14
Go to Step 5
Check for an open MIL driver circuit between the ECM

and the MIL.
Was the malfunction fixed?

13
Go to Step 16
Check for damaged terminals at the ECM.

12
Go to Step 4
Check for a faulty ECM ground connection.

11
Probe the battery feed circuit at the ECM harness

connector with a test light to ground.

10
Go to Step 6
Ignition OFF.
Disconnect the ECM.
Ignition ON.
Probe the ignition feed circuit at the ECM harness
Is the test light ON?

9
Go to Step 3
Check the ECM ignition feed and battery feed fuses

(15A Engine fuse and 15A ECM fuse).

8
1. Ignition OFF.
2. Disconnect the ECM.
3. Jumper the MIL driver circuit at the ECM connector
to ground.
4. Ignition ON.
Are both fuses OK?

7
Go to Step 2
1. Ignition ON.
2. Engine OFF.
3. Probe the ignition feed circuit at the cluster
Is the MIL ON?

6
Go to OBD
System
Check
Check the meter fuse for the instrument cluster ignition

feed circuit.

5
No
Is the fuse OK?

4
Yes

performed?
Does the engine start?

3
Value(s)
Locate and repair the open ECM battery feed circuit.

6E164
No Malfunction Indicator Lamp (MIL) (Cont'd)

Step
Action
15
Locate and repair the short to ground in the ECM

ignition feed circuit or ECM battery feed circuit.
16
No
Verify repair
Verify repair
Verify repair
Verify repair
Go to
Instrument
Panel in
Electrical
Diagnosis
Replace the ECM.

18
Yes
Locate and repair the short to ground in the ignition

feed circuit to the instrument cluster, and replace the
fuse.
17
Value(s)
Check the MIL driver circuit for a poor connection at the

instrument panel connector.
6E165
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY
D06RX110
Circuit Description
The malfunction indicator lamp (MIL) should always be
engine stopped. Ignition feed voltage is supplied directly
to the MIL indicator. The engine control module (ECM)
turns the MIL ON by grounding the MIL driver circuit.
The MIL should not remain ON with the engine running
and no DTC(s) set. A steady MIL with the engine running
and no DTC(s) suggests a short to ground in the MIL
driver circuit.
Diagnostic Aids
D Poor connection or damaged harness Inspect the

ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminaltowire connection, and
damaged harness.
Test Description
Diagnostic Chart:
2. If the MIL does not remain ON when the ECM is
disconnected, the MIL driver wiring is not faulty.
3. If the MIL driver circuit is OK, the instrument panel
cluster is faulty.
6E166
Malfunction Indicator Lamp (MIL) ON Steady

Step
Action
Go to Step 2
Go to Step 3
Go to Step 5
Go to OBD
System
Check
Go to Step 4
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step 6
Go to OBD
System
Check
Replace the instrument panel cluster.
1. Ignition OFF, reconnect the ECM.

2. Ignition ON, reprogram the ECM. Refer to
OnVehicle Service in Engine Control Module and
Sensors for procedures.
3. Using the Tech 2 output controls function, select
MIL dash lamp control and command the MIL OFF.
Go to OBD
System
Check
1. Ignition OFF, disconnect the instrument panel

cluster.
2. Check the MIL driver circuit between the ECM and
the instrument panel cluster for a short to ground.
3. If a problem is found, repair as necessary.

5
No

2. Ignition ON, observe the MIL (Service Engine Soon
lamp).
Was the MIL driver circuit shorted to ground?

4
Yes

performed?
Is the MIL ON?

3
Value(s)
Replace the ECM.

6E167
ENGINE CRANKS BUT WILL NOT RUN
D06RX099
6E168
D06RX091
Circuit Description
The electronic ignition system uses a dual coil method of
spark distribution. In this type of ignition system, the
engine control module (ECM) triggers the correct driver
inside the ignition control module (ICM), which then
triggers the correct ignition coil based on the 58X signal
received from the crankshaft position sensor (CKP). The
spark plug connected to the coil fires when the ICM opens
the ground circuit for the coils primary circuit.
During crank, the ECM monitors the CKP 58X signal. The
CKP signal is used to determine which cylinder will fire
first. After the CKP 58X signal has been processed by the
ECM, it will command all four injectors to allow a priming
shot of fuel for all the cylinders. After the priming, the
injectors are left OFF during the next four 58X reference
pulses from the CKP. This allows each cylinder a chance
to use the fuel from the priming shot. During this waiting
period, a camshaft position (CMP) signal pulse will have
been received by the ECM. The CMP signal allows the
ECM to operate the injectors sequentially based on
camshaft position. If the camshaft position signal is not
present at startup, the ECM will begin sequential fuel
delivery with a 1in4 chance that fuel delivery is correct.
The engine will run without a CMP signal, but will set a
DTC code.
Diagnostic Aids
An intermittent problem may be caused by a poor
connection, rubbedthrough wire insulation or a wire
broken inside the insulation. Check for the following
items:
damaged harness.
D Faulty engine coolant temperature sensor Using a
Tech 2, compare engine coolant temperature with
intake air temperature on a completely cool engine.
Engine coolant temperature should be within 10C of
intake air temperature. If not, replace the ECT sensor.
6E169
6E170
Engine Cranks But Will Not Run

Step
Action
Go to Step 2
Go to
Applicable
DTC Table
Go to Step 3
Go to Step 4
Go to Step 5
Verify repair
Go to Step 7
Go to Step 6
Check for a short to ground and replace the fuse.

1. Ignition ON.
2. Use a grounded test lamp to verify that B+ is
available at the ignition coil fuse, the engine device
fuse, and the ECM fuse.
Was B+ available at the fuses?
Check the 15A ignition coil fuse, the 15A engine device
fuse, and the 15A ECM fuse.

5
Repair the open ignition feed circuit.
Go to Fuel
System
Electrical Test
10
Go to Step 10
Go to Step 9
Verify repair
Go to Step 12
Go to Step 11
Verify repair
Go to Step 14
Go to Step 13
Verify repair
1. Ignition ON.
2. Using a Digital Voltmeter (DVM) check the ignition
wire coil at the ignition module harness connector?
B+
Repair the open circuit.
12
1. Ignition OFF.
2. With DVM, check for an open in the ground wire at
the ignition module harness connector.
Was the ground wire OK?
13
Go to Step 8
Repair the faulty circuit.
Was the voltage equal to the specified value?

11
Go to Step 16
1. Disconnect the ignition module harness connector.

2. Check for an open or short circuit between the
ignition control module and the ECM?
Go to Fuel
System
Diagnosis
1. Disconnect the ignition secondary wire at the No.1.

2. Install a spark tester 5884002790 at the end of
the disconnected ignition coil.
3. Clip the spark tester 5884002790 to a good
ground (not near the battery).
4. Observe the spark tester while the engine is
cranking.
Was a crisp blue spark observed? (Only one or two
sparks followed by no result is considered the same as
No Spark.)
No
Go to OBD
System
Check
Use the Tech 2 and check for any DTCs.
Was a fuse blown?

4
Yes

performed?

3
Value(s)
Repair the faulty wire.
6E171
Engine Cranks But Will Not Run (Cont'd)

Step
14
Action
Replace the ignition module, verify the repair.

Is there still a problem?
15
Go to Step 15
19
Go to Step 17
Go to Step 18
Go to Step 19
Go to Step 18
Verify repair
10,000 W per
foot
Go to Step 20
Go to Step 21
0.818 W
Use an ohmmeter to check the ignition coil secondary

winding resistance.
Replace the ignition coil.

Test the resistance of the coiltospark plug secondary
ignition wire.
Was the resistance greater than the specified value?
20
21
Replace the coiltospark plug secondary ignition wire

and any other secondary wires which exceed the
specified value.
10,000 W per
foot
1. Remove the spark plugs from all cylinders.
2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing
electrodes or cracked insulators.
Did your inspection reveal any spark plugs exhibiting
excessing fouling?
Verify repair
Go to Step 30
Go to Step 23
Go to Step 22
Is the fuel pressure within the specified values, and 285375 kPa
(4355 psi)
does it hold steady for 2 seconds?
Go to Step 25
Go to Step 24
Is any fuel pressure indicated?
Go to Fuel
System
Electrical Test
Verfiy repair.
23
Go to Step 21
Correct the
fouling
condition
22
Verify repair
Verify repair
Was the secondary winding resistance equal to the 9,00012,000

W
specified value?
18
No
Use an ohmmeter to check the ignition coil primary

winding resistance.
Was the primary winding resistance approximately
equal to the specified value?
17
Yes
Replace the ECM.

16
Value(s)
1. Ignition OFF, install a fuel pressure gauge at the test

fitting on the fuel supply line in the engine
compartment.
CAUTION: Use a shop cloth to absorb any fuel
leakage while making the connection.
2. Check the engine and observe the fuel pressure.
24
Go to Fuel
System
Diagnosis
6E172

Step
Action
25
1. Raise the vehicle and disconnect the CKP sensor

harness.
2. Ignition ON.
3. With a test light to ground, probe the CKP ignition
feed harness terminal.
Did the light illuminate?
26
31
Go to Step 28
Go to Step 29
Verify repair
Go to Step 31
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 30
Go to Step 30
Replace the ECM.

1. Test the fuel for contamination.
2. If a problem is found, clean the fuel system and
correct the contaminated fuel condition as
necessary. Replace the fuel filter and replace any
injectors that are not delivering fuel (see Injector
Balance Test).
32
Go to Step 27
Check the CKP Low circuit between the sensor and the
ECM for: an open circuit, a short to ground, or short to
voltage.
30
Go to Step 26
Replace the CKP position sensor.

29
No
Check the CKP High circuit between the sensor and the
ECM for a short to ground or open circuit.
28
Yes
1. Ignition ON.
2. At the CKP harness connector, connect a test lamp
between the ignition and ground terminals.
Did the lamp illuminate?
27
Value(s)
Go to Step 32
To diagnose the following conditions, refer to Engine

Mechanical:
D Slipped camshaft drive belt.
D Leaking or sticky valves or rings.
D Excessive valve deposits.
D Loose or worn rocker arms.
D Weak valve springs
D Leaking head gasket.
6E173
FUEL SYSTEM ELECTRICAL TEST
D06RX111
Circuit Description
Diagnostic Aids
When the ignition switch is first turned ON, the powertrain

control module (ECM) energizes the fuel pump relay
which applies power to the intank fuel pump. The fuel
pump relay will remain ON as long as the engine is
running or cranking and the ECM is receiving 58X
crankshaft position pulses. If no 58X crankshaft position
pulses are present, the ECM deenergizes the fuel pump
relay within 2 seconds after the ignition is turned ON or the
engine is stopped.
The fuel pump delivers fuel to the fuel rail and injectors,
then to the fuel pressure regulator. The fuel pressure
regulator controls fuel pressure by allowing excess fuel to
be returned to the fuel tank. With the engine stopped and
ignition ON, the fuel pump can be turned ON by using a
command by the Tech 2.

damaged harness.
Test Description
Diagnostic Chart:
2. If the fuel pump is operating but incorrect pressure
is noted, the fuel pump wiring is OK and the Fuel
System Pressure Test chart should be used for
diagnosis.
6E174
CAUTION: To reduce the risk of fire and personal

injury:
D It is necessary to relieve fuel system pressure
before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
D A small amount of fuel may be released when
disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before disconnecting, to
catch any fuel that may leak out. Place the towel in
an approved container when the procedure is
completed.
2. Remove the fuel pump relay from the underhood

relay center.
3. Start the engine and allow it to stall.
4. Crank the engine for an additional 3 seconds.
Fuel Gauge Installation

1. Remove the shoulder fitting cap.
2. Install fuel gauge 5884003780 to the fuel feed line
located in front of and above the right side valve
cover.
3. Reinstall the fuel pump relay.
Fuel Pressure Relief Procedure

1. Remove the fuel cap.
Fuel System Electrical Test

Step
Action
1.
2.
3.
4.
Go to Step 3
Go to Step 4
Test
completed
Go to Step 12
Go to Step 6
Go to Step 5
Verify repair
1. Connect a test light between the two wires that

connect to the fuel pump relay pullin coil.
2. Ignition ON.
Go to Step 12
Go to Step 7
1. With a test light connected to battery (), probe the

fuel pump relay connector at the wire which runs
from the relay pullin coil to the ECM.
2. Ignition ON.
Did the test light illuminate for 2 seconds and then turn
off?
Repair short or open battery feed to fuel pump relay.
off?
7
Go to Step 2
Ignition OFF.
Remove the fuel pump relay.
Ignition SW On, Engin Off.
Using a test light connected to ground, probe the
battery feed to the relay.

6
Go to OBD
System
Check
1. Verify that the pump is not running by removing the

fuel filler cap and listening.
2. Command the pump ON with the Tech 2.

5
No
1. Read the Caution above.

2. Relieve the fuel system pressure and install the fuel
pump pressure gauge to the test fitting.
3. Use a Tech 2 to command the fuel pump ON.
Did the pump turn OFF after 2 seconds?

4
Yes

performed?
Is there an immediate pressure buildup which

indicates the pump is running?
3
Value(s)
Go to Step 8
Go to Step 9
Verify repair
Locate and repair open in the fuel pump relay ground

circuit.
6E175
Fuel System Electrical Test (Cont'd)

Step
Action
Go to Step 15
Go to Step 13
Go to Step 17
Go to Step 14
Verify repair
Go to Step 18
Go to Step 16
Verify repair
Verify repair
Verify repair
1. Reconnect the horn relay in its proper location.

2. Replace the fuel pump relay.
18
Repair the open circuit in the fuel pump ground wire.

17
Verify repair
1. With the fuel pump electrical connector at the fuel

tank disconnected, connect a test light between the
feed wire and the ground wire (harness side).
2. Command the fuel pump ON with a Tech 2.
Did the test light illuminate for 2 seconds?
16
Go to Step 11

2. Check for a short circuit, blown fuse or open circuit
between the relay and the fuel tank.
15
Verify repair
1. Honk the horn to verify that the horn relay is

functioning.
2. Substitute the horn relay for the fuel pump relay.
3. Leave the test light connected as in step 12.
4. Command the fuel pump ON with the Tech 2.
Did the test light illuminate for 2 seconds when the fuel
pump was commanded ON?
14
1. Reconnect the fuel pump relay.

2. Disconnect the fuel pump electrical connector at the
fuel tank.
3. Using a test light connected to ground, probe the
fuel pump feed wire (harness side).
Did the light illuminate for 2 seconds?
13
Go to Step 10
Verify repair
Replace the ECM.

12
No
1. Check the fuel pump relay circuit for a poor terminal

connection at the ECM.
2. If a problem is found, replace terminal as necessary.
11
Yes
Check for short or open between the ECM and the fuel
pump relay.
10
Value(s)
Replace the fuel pump.

6E176
FUEL SYSTEM DIAGNOSIS
D06RX111
Circuit Description
Test Description
When the ignition switch is turned ON, the engine control

module (ECM) will turn ON the intank fuel pump. The
intank fuel pump will remain ON as long as the engine is
cranking or running and the ECM is receiving 58X
crankshaft position pulses. If there are no 58X crankshaft
position pulses, the ECM will turn the intank fuel pump
OFF 2 seconds after the ignition switch is turned ON or 2
seconds after the engine stops running.
The intank fuel pump is an electric pump within an
integral reservoir. The intank fuel pump supplies fuel
through an inline fuel filter to the fuel rail assembly. The
fuel pump is designed to provide fuel at a pressure above
the pressure needed by the fuel injectors. A fuel pressure
regulator, attached to the fuel rail, keeps the fuel available
to the fuel injectors at a regulated pressure. Unused fuel is
returned to the fuel tank by a separate fuel return line.

Diagnostic Chart:
2. Connect the fuel pressure gauge to the fuel feed
line as shown in the fuel system illustration. Wrap a
shop towel around the fuel pressure connection in
order to absorb any fuel leakage that may occur
when installing the fuel pressure gauge. With the
ignition switch ON and the fuel pump running, the
fuel pressure indicated by the fuel pressure gauge
should be 283376 kPa (4155 psi). This pressure
is controlled by the amount of pressure the spring
inside the fuel pressure regulator can provide.
3. A fuel system that cannot maintain a constant fuel
pressure has a leak in one or more of the following
areas:
D The fuel pump check valve.
D The fuel pump flex line.

D The valve or valve seat within the fuel pressure
regulator.
D The fuel injector(s)
4. Fuel pressure that drops off during acceleration,
cruise, or hard cornering may case a lean condition.
A lean condition can cause a loss of power, surging,
or misfire. A lean condition can be diagnosed using
a Tech 2. If an extremely lean condition occurs, the
oxygen sensor(s) will stop toggling. The oxygen
sensor output voltage(s) will drop below 500 mV.
Also, the fuel injector pulse width will increase.
IMPORTANT: Make sure the fuel system is not
operating in the Fuel CutOff Mode.
When the engine is at idle, the manifold pressure is
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
pressure being applied to the fuel pressure regulator
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel
pressure. The fuel pressure at idle will vary slightly as
the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel
pressure noted in step 2 with the engine OFF.
16. Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking. If
checking the spark plug associated with a particular
fuel injector for fouling or saturation does not
determine that a particular fuel injector is leaking,
use the following procedure:
D Remove the fuel rail, but leave the fuel lines and
injectors connected to the fuel rail. Refer to Fuel Rail
Assembly in OnVehicle Service.
D Lift the fuel rail just enough to leave the fuel injector
nozzles in the fuel injector ports.
CAUTION: In order to reduce the risk of fire and
personal injury that may result from fuel spraying on
the engine, verify that the fuel rail is positioned over
the fuel injector ports and verify that the fuel injector
retaining clips are intact.
D Pressurize the fuel system by connecting a 10 amp
fused jumper between B+ and the fuel pump relay
connector.
D Visually and physically inspect the fuel injector
nozzles for leaks.
17. A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition may
cause a DTC P0132 or a DTC P0172 to set.
Driveability conditions associated with rich
conditions can include hard starting (followed by
black smoke) and a strong sulfur smell in the
exhaust.
6E177
20. This test determines if the high fuel pressure is due

to a restricted fuel return line or if the high fuel
pressure is due to a faulty fuel pressure regulator.
21. A lean condition may result from fuel pressure
below 333 kPa (48 psi). A lean condition may cause
a DTC P0131 or a DTC P0171 to set. Driveability
conditions associated with lean conditions can
include hard starting (when the engine is cold),
hesitation, poor driveability, lack of power, surging,
and misfiring.
22. Restricting the fuel return line causes the fuel
pressure to rise above the regulated fuel pressure.
Command the fuel pump ON with the Tech 2. The
fuel pressure should rise above 376 kPa (55 psi) as
the fuel return line becomes partially closed.
NOTE: Do not allow the fuel pressure to exceed 414 kPa
(60 psi). Fuel pressure in excess of 414 kPa (60 psi) may
damage the fuel pressure regulator.
injury:
completed.

relay center.

located on the upper right side of the engine near the
EGR valve.
6E178
Fuel System Diagnosis

Step
Action
Value(s)

performed?
Yes
Go to Step 2
No
Go to OBD
System
Check
1. Turn the ignition OFF.

2. Turn the air conditioning system OFF.
3. Relieve fuel system pressure and install the fuel
pressure gauge.
4. Turn the ignition ON.
NOTE: The fuel pump will run for approximately 2
seconds. Use the Tech 2 to command the fuel pump
ON.
5. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
283376 kPa
(4155 psi)
Is the fuel pressure within the specified limits?
NOTE: The fuel pressure will drop when the fuel pump
stops running, then it should stabilize and remain
constant.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant?
5
6
Go to Step 4
Did the reading drop by the amount specified after the

engine was started?
21105 kPa
(315 psi)
Go to Step 5
Go to Step 9
Is fuel pressure dropping off during acceleration,

cruise, or hard cornering?
Go to Step 6
Check for
improper fuel
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
21105 kPa
(315 psi)
Go to Step 10
Go to Step 11
1. When the vehicle is at normal operating

temperature, turn the ignition ON to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure
gauge.
Visually and physically inspect the following items for a

restriction:
D The inpipe fuel filter.
D The fuel feed line.
Remove the fuel tank and visually and physically
inspect the following items:
D The fuel pump strainer for a restriction.
D The fuel line for a leak.
D Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas?

Go to Step 12
Was a restrication found?

7
Go to Step 17
Go to Step 3
1. Disconnect the vacuum hose from the fuel pressure

regulator.
2. With the engine idling, apply 1214 inches of
vacuum to the fuel pressure regulator.
gauge drop by the amount specified?
6E179
Fuel System Diagnosis (Cont'd)

Step
Action
10
Locate and repair the loss of vacuum to the fuel

pressure regulator.
11
Verify repair
Go to Step 13
Go to Step 15
Go to Step 14
Verify repair
Verify repair
Go to Step 8
Go to Step 11
Go to Step 16
Verify repair
376 kPa (55

psi)
Go to Step 18
Go to Step 21
Go to Step 19
Go to Step 20
Verify repair
Verify repair
1. If the pliers are still clamped to the fuel supply hose,

remove the locking pliers.
2. With suitable locking pliers which will not damage
the hose, clamp the fuel return line to prevent fuel
from returning to the fuel tank.
3. Run the fuel pump with the Tech 2.
4. After pressure has built up, remove power to the
pump.
16
Verify repair
Remove the fuel tank and inspect for leaky hose or

intank fuel line.
15
Visually inspect the fuel supply line and repair any

leaks.
14
Locate and replace any leaking fuel injector(s).

17
Is the fuel pressure indicated by the fuel pressure

gauge above the specified limit?
18
1. Relieve the fuel pressure. Refer to the Fuel

Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail return
outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
290376 kPa
(4255 psi)
19
Locate and correct the restriction in the fuel return line.

20
No

2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers which will not damage the hose.
13
Yes
Replace the fuel pressure regulator.

12
Value(s)
Visually and physically inspect the fuel rail outlet

passages for a restriction.
Was a restriction found?
Go to Step 11
6E180

Step
Action
Value(s)
21

gauge above the specified value?
0 kPa (0 psi)
22
Yes
Go to Step 22
No
Go to Step 23

2. Using suitable pliers which will not damage the fuel
hose, gradually apply pressure with the pliers to
pinch the flexible fuel return hose closed.
CAUTION: Do not let the fuel pressure exceed
the second specified value.
gauge rise above the first specified value?
23
414 kPa (60

psi)
Go to Step 11
Go to Step 7

2. Remove the fuel filler cap and listen for the sound of
the fuel pump running.
3. Turn the pump off.
Was the fuel pump running?
Go to Step 7
Go to Fuel
System
Electrical Test
Chart
6E181
D06RX112
Circuit Description
The engine control module (ECM) controls engine idle
speed with the idle air control (IAC) valve. To increase idle
speed, the ECM retracts the IAC valve pintle away from
its seat, allowing more air to bypass the throttle bore. To
decrease idle speed, it extends the IAC valve pintle
towards its seat, reducing bypass air flow. A Tech 2 will
read the ECM commands to the IAC valve in counts.
Higher counts indicate more air bypass (higher idle).
Lower counts indicate less air is allowed to bypass (lower
idle).
Diagnostic Aids
A slow, unstable, or fast idle may be caused by a non-IAC
system problem that cannot be overcome by the IAC
valve. Out of control range IAC Tech 2 counts will be
above 60 if idle is too low, and zero counts if idle is too

high. The following checks should be made to repair a
non-IAC system problem:
D Vacuum leak (high idle) If idle is too high, stop the
engine. Fully extend (low) IAC with the Tech 2. Start
the engine. If idle speed is above 800 RPM, locate
and correct the vacuum leak, including the PCV
system. Check for binding of the throttle blade or
linkage.
D Lean heated oxygen sensor signal (high air/fuel ratio)
The idle speed may be too high or too low. Engine
speed may vary up and down, and disconnecting the
IAC valve does not help. Diagnostic trouble codes
P0131, P0151, P0171, may be set. Tech 2 oxygen
(O2) voltage will be less than 100 mV (0.1 V). Check
for low regulated fuel pressure, water in fuel, or a
restricted injector.
6E182
D Rich heated oxygen sensor signal (low air/fuel ratio)

The idle speed will be too low. Tech 2 IAC counts will
usually be above 80. The system is obviously rich
and may exhibit black smoke in the exhaust.
Tech 2 O2 voltage will be fixed at about 750 mV (0.75
V). Check for high fuel pressure, or a leaking or
sticking injector. A silicon-contaminated heated
oxygen sensor will show an O2 voltage slow to
respond on Tech 2.
D Throttle body Remove the IAC valve and inspect the
bore for foreign material.
D IAC valve electrical connections IAC valve
connections should be carefully checked for proper
contact.
D PCV valve An incorrect or faulty PCV valve may
result in an incorrect idle speed. Refer to Diagnosis,
Rough Idle, Stalling. If intermittent poor driveability or
idle symptoms are resolved by disconnecting the
IAC, carefully recheck the connections and valve
terminal resistance, or replace the IAC.
Test Description
Diagnostic Chart.
1. The Tech 2 is used to extend and retract the IAC
valve. Valve movement is verified by an engine
speed change. If no change in engine speed
occurs, the valve can be resettled when removed
from the throttle body.
2. This step checks the quality of the IAC movement in
step 1. Between 700 revolutions per minute (RPM)
and about 1500 RPM, the engine speed should
change smoothly with each flash of the tester light
in both extend and retract. If the IAC valve is
retracted beyond the control range (about 1500
RPM), it may take many flashes to extend the IAC
valve before engine speed will begin to drop. This
is normal on certain engines. Fully extending the
IAC may cause engine stall. This may be normal.
Idle Air Control (IAC) System Check

Step
Action
1.
2.
3.
4.
5.
6.
7.
8.
RPM should change smoothly.

Does the RPM change within the range specified?
Go to Step 2
Go to Step 3
700-1500
RPM
Go to Step 3
Go to Step 4
Go to Step 5
Verify repair
Verify repair
Clear any obstruction from the IAC passages.

No
Check the IAC passages.

Are the IAC passages OK?
Yes
Ignition OFF.
Connect the Tech 2.
Set the parking brake.
Block the wheels.
Turn the air conditioning OFF.
Idle the engine in Park (A/T) or Neutral (M/T).
Operate the IAC test.
The engine speed should decrease and increase as
the IAC is cycled.
Does the RPM change?

2
Value(s)
Replace the IAC. Refer to On-Vehicle Service, Idle Air

Control Valve.
6E183
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK
D06RX113
Circuit Description
Diagnostic Aids
A properly operating exhaust gas recirculation (EGR)

system will directly affect the air/fuel requirements of the
engine. Since the exhaust gas introduced into the air/fuel
mixture is an inert gas (contains very little or no oxygen),
less fuel is required to maintain a correct air/fuel ratio.
Introducing exhaust gas into the combustion chamber
lowers combustion temperatures and reduces the
formation of oxides of nitrogen (NOx) in the exhaust gas.
Lower combustion temperatures also prevent detonation.
If the EGR pintle were to stay closed, the inert exhaust
gas would be replaced with air and the air/fuel mixture
would be leaner. The powertrain control module (ECM)
would compensate for the lean condition by adding fuel,
resulting in higher long term fuel trim values.
The EGR valve chart is a check of the EGR system. An

EGR pintle constantly in the closed position could cause
detonation and high emissions of NOx. It could also result
in high long term fuel trim values in the open throttle cell,
but not in the closed throttle cell. An EGR pintle constantly
in the open position would cause rough idle. Also, an EGR
valve mounted incorrectly (rotated 180) could cause a
rough idle without setting an EGR DTC. Check for the
following items:
D EGR passages Check for restricted or blocked EGR
passages.
D Manifold absolute pressure sensor A manifold
absolute pressure sensor may shift in calibration
enough to affect fuel delivery. Refer to Manifold
Absolute Pressure Output Check.
6E184
Exhaust Gas Recirculation (EGR) System Check

Step
Action
EGR system
working
properly. No
problem
found.
Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Go to Step 8
Go to Step 9
Go to DTC
P0404 chart
1. Ground the EGR valve metal case to battery ().

2. Using a Tech 2, command EGR ON and observe the
EGR valve pintle for movement.
1. Remove the EGR inlet and outlet pipes from the

intake and exhaust manifolds.
2. Visually and physically inspect manifold EGR ports
and EGR inlet and outlet pipes for blockage or
restriction caused by excessive deposits or other
damage.
Do the manifold EGR ports or inlet and outlet pipes
have excessive deposits, obstructions, or any
restrictions?
10
Verify repair
Clean or replace EGR system components as

necessary.
Does the EGR valve pintle move according to

command?
9
1. Remove the EGR valve.

2. Visually and physically inspect the EGR valve
pintle, valve passages and adapter for excessive
deposits, obstructions or any restrictions.
Does the EGR valve have excessive deposits,
obstructions or any restrictions?
Was the problem corrected?

8
Go to Step 3
Repair the EGR harness ignition feed.

Go to Step 2
1. Engine OFF.
2. Ignition ON.
3. Using a test light to ground, check the EGR harness
between the ignition feed and ground.
Does the test light illuminate?
1. Place the transmission selector in Park or Neutral.

2. Start the engine and idle until warm (Closed Loop).
3. Using a Tech 2, command EGR 50% ON.
Does the engine idle rough and lose RPMs?
No
Tighten the EGR valve.

Yes
Check the EGR valve for looseness.

Is the EGR valve loose?
Value(s)
Go to Step 10
EGR system
working
properly. No
problem
found.

necessary.
Verify repair
6E185
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK
D06RX114
Circuit Description
the changes in the intake MAP which result from engine
load (intake manifold vacuum) and engine speed
changes; and converts these into a voltage output. The
powertrain control module (ECM) sends a 5volt
reference voltage to the MAP sensor. As the MAP
changes, the output voltage of the sensor also changes.
By monitoring the sensor output voltage, the ECM knows
the MAP. A lower pressure (low voltage) output voltage
will be about 12 volts at idle. Higher pressure (high
voltage) output voltage will be about 44.8 volts at wide
open throttle. The MAP sensor is also used, under certain
conditions, to measure barometric pressure, allowing the
ECM to make adjustments for different altitudes. The
ECM uses the MAP sensor to diagnose proper operation
of the EGR system, in addition to other functions.
Test Description
IMPORTANT: Be sure to use the same diagnostic test
equipment for all measurements.
The number(s) below refer to the step number(s) on the
Diagnostic Chart:
1. When you compare the Tech 2 readings to a known

good vehicle, it is important to compare vehicles
that use MAP sensors that have the same part
number.
2. Applying 34 kPa (10 Hg) vacuum to the MAP sensor
should cause the voltage to be 1.52.1 volts less
than the voltage at step 1. Upon applying vacuum to
the sensor, the change in voltage should be
instantaneous. A slow voltage change indicates a
faulty sensor.
3. Check the vacuum hose to the sensor for leaking or
restriction. Be sure that no other vacuum devices
are connected to the MAP hose.
IMPORTANT: Make sure the electrical connector
remains securely fastened.
4. Disconnect the sensor from the bracket. Twist the
sensor with your hand to check for an intermittent
connection. Output changes greater than 0.10 volt
indicate a bad sensor.
6E186
Manifold Absolute Pressure (MAP) Output Check

Step
Action
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 4
Verify repair
Go to Step 6
Go to Step 7
Verify repair
Verify repair
Refer to OnVehicle Service, MAP Sensor.

Go to Step 5
Check the sensor connection.

Is the sensor connection good?
Go to Step 2
Repair the hose to ensure the hose supplies vacuum to

the MAP sensor only.
Check the sensor hose for leakage or restriction.

Does the hose supply vacuum to the MAP sensor only?
No
1. Disconnect the vacuum hose at the MAP sensor

and plug the hose.
2. Connect a hand vacuum pump to the MAP sensor.
3. Start the engine.
4. Apply 34 kPa (10 Hg) of vacuum and note the
voltage change.
Is the voltage change 1.52.1 volts less than step 1?
Yes
1. Turn the ignition OFF and leave it OFF for 15

seconds.
2. Ignition ON. Do not crank engine.
3. The Tech 2 should indicate a manifold absolute
pressure (MAP) sensor voltage.
4. Compare this scan reading to the scan reading of a
known good vehicle obtained using the exact same
procedure as in Steps 14.
Is the voltage reading the same +/ 0.40 volt?
Value(s)
Repair the poor connection.

6E187
ECM DIAGNOSTIC TROUBLE CODES

The following table lists the diagnostic trouble codes
supported by this vehicle application. If any DTCs not
listed here are displayed by a Scan Tool, the Tech 2 data
ECM Diagnostic Trouble Codes
DTC
may be faulty; notify the Tech 2 manufacturer of any

DTCs displayed that are not included in the following
table.
Description
Type
Illuminate MIL
P0106
MAP Circuit/Range Performance Problem
Yes
P0107
MAP Sensor Circuit Low Input
Yes
P0108
MAP Sensor Circuit High Input
Yes
P0112
IAT Sensor Circuit Low Input
Yes
P0113
IAT Sensor Circuit High Input
Yes
P0117
ECT Sensor Circuit Low Input
Yes
P0118
ECT Sensor Circuit High Input
Yes
P0121
TP Sensor Circuit Range/Performance Problem
No
P0122
TP Sensor Circuit Low Input
Yes
P0123
TP Sensor Circuit High Input
Yes
P0131
O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
Yes
P0132
O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
Yes
P0134
O2 Sensor Circuit No Activity Detected (Bank Sensor 1)
Yes
P0135
O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)
Yes
P0171
Fuel Trim System Too Lean (Bank 1)
Yes
P0172
Fuel Trim System Too Rich (Bank 1)
Yes
P0201
Injector Circuit Malfunction Cylinder 1
Yes
P0202
Yes
P0203
Yes
P0204
Yes
P0325
Knock Sensor Circuit Malfunction
Yes
P0327
Knock Sensor Circuit Low Input
Yes
P0336
CKP Sensor Circuit Range/Performance
Yes
P0337
CKP Sensor Circuit Low Input
Yes
P0341
CMP Sensor Circuit Range/Performance
Yes
P0342
CMP Sensor Circuit Low Input
Yes
P0351
Ignition Coil A Primary/Secondary
Yes
P0352
Ignition Coil B Primary/Secondary
Yes
P0401
EGR Flow Insufficient Detected
Yes
P0402
EGR Excessive Flow Detected
Yes
P0404
EGR Circuit Range/Performance
Yes
P0405
EGR Sensor Circuit Low
Yes
P0406
EGR Sensor Circuit High
Yes
P0443
EVAP Control System Purge Control Valve Circuit Malfunction
Yes
P0480
Cooling Fan 1 Control Circuit Malfunction
No
P0481
No
P0502
VSS Circuit Low Input
Yes
P0506
Idle Control System RPM Lower than expected
Yes
6E188
DTC
Description
Type
Illuminate MIL
P0507
Idle Control System RPM Higher than expected
Yes
P0563
System Voltage High
Yes
P0601
Internal Control Module Memory Check Sum Error
Yes
P1106
MAP Sensor Circuit Intermittent High Voltage
No
P1107
MAP Sensor Circuit Intermittent Low Voltage
No
P1111
IAT Sensor Circuit Intermittent High Voltage
No
P1112
IAT Sensor Circuit Intermittent Low Voltage
No
P1114
ECT Sensor Circuit Intermittent Low Voltage
No
P1115
ECT Sensor Circuit Intermittent High Voltage
No
P1121
TP Sensor Circuit Intermittent High Voltage
No
P1122
TP Sensor Circuit Intermittent Low Voltage
No
P1171
Fuel System Lean During Acceleration
Yes
P1404
EGR Closed Valve
Yes
P1625
PCM Unexpected Reset
Yes
P1627
PCM A/D Conversion Malfunction
Yes
P1635
5 Volt Reference Voltage Circuit Malfunction
Yes
P1640
ODM Output Circuit Fault
No
6E189
DIAGNOSTIC TROUBLE CODE (DTC) P0106 MANIFOLD ABSOLUTE

PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM
D06RX114
Circuit Description
The manifold absolute pressure (MAP) sensor responds
to changes in intake manifold pressure. The MAP sensor
signal voltage to the engine control module (ECM) varies
from below 2 volts at idle (low manifold pressure) to above
4 volts with the ignition ON engine not running or at
wideopen throttle (high manifold pressure).
A speed density method of determining engine load is
used on the 2.2L engine. This is calculated using inputs
from the MAP sensor, RPM, CKP Sensor, and the Intake
Air Temperature (IAT) sensor. The MAP sensor is the
main sensor used in this calculation, and measuring
engine load is its main function. The MAP sensor is also
used to determine manifold pressure changes while the
exhaust gas recirculation (EGR) flow test diagnostic is
being run, to determine engine vacuum level for some
other diagnostics and to determine barometric pressure
(BARO). Refer to DTC P0401.
The ECM monitors the MAP signals for voltages outside
the normal range (10104 kpa) of the MAP sensor. If the
ECM detects a MAP signal voltage that is excessively
low, Diagnostic Trouble Code P0106 will be set.
Diagnostic Trouble Code P0106 is a Type B Code.
Conditions for Setting the DTC

D No ECT, CKP, EGR, EVAP, MAP orTP sensor DTCs
present.
D Engine speed is steady, changing less than 20 RPM.
D Throttle position is steady, throttle angle changes less

than 5%.
D EGR flow rate is steady, changing less than 2%.
D IAC valve counts are steady, changing less than 3
counts.
D Engine speed is between 1000 RPM and 4000 RPM.
D ECT is above 10C (14F).
D No change in brake switch, A/C clutch, 3 or power
steering pressure switch status.
The above conditions are met for longer than 1.5 seconds
and the following condition is met in two consecutive trips:
D Actual MAP value varies more than 10 kPa.
D The MAP value must vary for a total of 10 seconds over
a 20second period of time that the samples were
monitored.
Action Taken When the DTC Sets

D The ECM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the
fault is detected.
D The ECM will default to a BARO value of 79.3 kPa.
D The ECM will store conditions which were present
when the Diagnostic Trouble Code was set as Freeze
Frame and in the Failure Records data.
6E190
Conditions for Clearing the MIL/DTC

D The ECM will turn the MIL OFF on the third consecutive
trip cycle during which the diagnostic has been run and
the fault condition is no longer present.
D A history Diagnostic Trouble Code P0106 will clear
after 40 consecutive warmup cycles have occurred
without a fault.
D Diagnostic Trouble Code P0106 can be cleared by
using the Scan Tools Clear Info function.
Diagnostic Aids
D Poor connection at ECM Inspect harness connectors
for backedout terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminaltowire connection.
D The MAP sensor shares a 5 Volt Reference with the TP
sensor and Fuel Pressure sensor.
If these codes are also set, it could indicate a

problem with the 5 Volt reference circuit.
D The MAP sensor shares a ground with the TP sensor
and Fuel Pressure sensor.
damage; an open circuit, a short to ground, or a short
to voltage. If the harness appears to be OK, observe
the MAP display on the Tech 2 while moving
connectors and wiring harnesses related to the sensor.
A change in the display will indicate the location of the
fault.
If Diagnostic Trouble Code P0106 cannot be duplicated,
the information included in the Failure Records data can
be useful in determining vehicle mileage since the
Diagnostic Trouble Code was last set. If it is determined
that the Diagnostic Trouble Code occurs intermittently,
performing the Diagnostic Trouble Code P1106 or P1107
Diagnostic Chart may isolate the cause of the fault.
DTC P0106 MAP Circuit/Range Performance Problem

Step
Action
Go to Step 2
Go to OBD
System
Check
Go to Step 3
Go to Step 4
Verify repair
Refer to
Diagnostic
Aids
0 V 10.3 kPa
Go to Step 6
Go to Step 5
Verify repair
Verify repair
1. Check for the following condition:

D Vacuum hoses disconnected, damaged, or
incorrectly routed?
D Intake manifold vacuum leaks;
D Vacuum leaks at throttle body;
D Vacuum leaks at EGR valve flange and pipes;
1. Disconnect the Manifold Absolute Pressure (MAP)
sensor electrical connector.
2. Observe the MAP value displayed on the Tech 2.
Is the MAP value near the specified value?
No
1. Ignition ON, engine OFF

3. Operate the vehicle within Failure Records
4. Using a Tech 2, monitor DTC info for Diagnostic
Trouble Code P0106.

4
Yes

performed?
Does the Tech 2 indicate that DTC P0106 ran and

passed?
3
Value(s)
Check the MAP sensor signal circuit; between the MAP

sensor and the Engine Control Module (ECM), for a
short to voltage?
Go to Step 12
Check the MAP sensor circuit, between the MAP

sensor and the ECM, the following conditions:
D A short to ground
D An open circuit
Go to Step 7
6E191
DTC P0106 MAP Circuit/Range Performance Problem (Cont'd)

Step
Action
12
Verify repair
5 volts 104
kPa
Go to Step 9
Verify repair
Go to Step 8
Go to Step 12
Go to Step 10
1. Ignition OFF.
2. Place a Digital Multimeter (DVM), set to measure
voltage, between the ground circuit and the 5 volt
signal circuit, both at the wiring harness MAP
sensor connector.
5 volts
11
Check the MAP sensor ground circuit, between the

MAP sensor and the ECM, for the following conditions:
D An open circuit
D A short to ground
10
No
1. Ignition OFF.
2. Place a fused jumper between the MAP sensor
circuit and the 5 volt signal circuit, both at the wiring
harness MAP sensor connector.
4. Observe the MAP value displayed on the Tech 2?
Does the Tech 2 read the following value? (if no, start
with the diagnosis chart for other sensors in the circuit
and see if 5V returns.)
Yes
Check the 5 volt signal circuit, between the MAP

sensor and the ECM, for the following conditions:
D An open circuit
D A short to ground
Value(s)
Go to Step 11
Go to Step 12
Replace the MAP sensor.

Verify repair.
Replace the ECM.
6E192

PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT
D06RX114
Circuit Description
signal voltage to the powertrain control module (ECM)
varies from below 2 volts at idle (low manifold pressure) to
above 4 volts with the ignition ON, engine not running or at
from the MAP sensor, the CKP Sensor, and the Intake Air
Temperature (IAT) sensor. The MAP sensor is the main
sensor used in this calculation, and measuring engine
load is its main function. The MAP sensor is also used to
determine manifold pressure changes while the exhaust
gas recirculation (EGR) flow test diagnostic is being run,
to determine engine vacuum level for some other
diagnostics and to determine barometric pressure
low, Diagnostic Trouble Code P0107 will be set. DTC
P0107 is a Type A Code.

D No TP sensor Diagnostic Trouble Codes present.
D Engine is running.
D System voltage greater than 11 volts.

D Throttle angle is above 0% if engine speed is less than
or equal to 1300 RPM.
D Throttle angle is above 5% if engine speed is above
1300 RPM.
D The MAP sensor indicates manifold absolute pressure
below 11 kPa for a total of approximately 10 seconds
over a 16second period.

(MIL) the first time the fault is detected.
D The ECM will use a MAP value based on speed density
calculation.

D A history DTC P0107 will clear after 40 consecutive
warmup cycles have occurred without a fault.
Diagnostic Aids
damage, shorts to ground, shorts to battery positive,
6E193
observe the MAP display on the Tech 2 while moving

fault.
D A faulty 5 volt reference circuit could also set a TP
Sensor Diagnostic Trouble Code because the two
sensors share the same 5 volt reference pin at the
ECM.
performing the Diagnostic Trouble Code P0107
DTC P0107 MAP Sensor Circuit Low Input

Step
Action

2. With the throttle closed, observe the MAP value
displayed on the Tech 2.
Go to Step 2
0V 10.3 kPa
at sea level
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
1. Ignition OFF.
2. Disconnect the MAP sensor electrical connector.
3. Jumper the 5 volt reference circuit and the MAP
signal together at the MAP sensor harness
connector.
4. Ignition ON.
Is the MAP value near the specified value? (if no, start
No
Go to OBD
System
Check

2. Review and record Tech 2 Failure Records data.
4. Using a Tech 2, monitor Diagnostic Trouble Code
info for Diagnostic Trouble Code P0107.
Does the Tech 2 indicate Diagnostic Trouble Code
P0107 failed?
Yes

performed?

3
Value(s)
Go to Step 10
5 V 104 kPa
Go to Step 5
1. Disconnect the jumper.

2. Connect a fused jumper between the 5 Volt signal
circuit and the MAP sensor signal circuit at the MAP
sensor harness connector.
5 V 104 kPa
Go to Step 6
Go to Step 8
6E194
DTC P0107 MAP Sensor Circuit Low Input (Cont'd)

Step
Action
Go to Step 7
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 11
Go to Step 9
Go to Step 11

11
Check the MAP sensor signal circuit for a poor

connection at the ECM and the MAP sensor; replace
the terminal if necessary.
Did the terminal require replacement?
10
Verify repair
1. Ignition OFF.
2. Disconnect the ECM, and check the MAP signal
circuit for an open, short to ground, or short to the
sensor ground circuit.
3. If the MAP sensor signal circuit is open or shorted to
ground, repair it as necessary.
Was the MAP signal circuit open or shorted to ground?
No
Check the 5 volt reference circuit for a poor connection

at the ECM and replace the terminal if necessary.
Yes
1. Ignition OFF.
2. Disconnect the ECM and check the 5 volt reference
circuit for an open or short to ground.
3. If the 5 volt reference circuit is open or shorted to
Was the 5 volt reference circuit open or shorted to
ground?
Value(s)
Replace the ECM.

6E195

PRESSURE (MAP) CIRCUIT HIGH INPUT
D06RX114
Circuit Description

D Throttle position is below 2.7% if engine speed is below

1000 RPM.
D Throttle position is below 10% if engine speed is above
1000 RPM.
above 90 kPa for a total of approximately 10 seconds

fault is detected.

without a fault.
Diagnostic Aids
6E196

D The MAP sensor share a ground with the TP sensor

fault.
Diagnostic Trouble Code was last set.
DTC P0108 MAP Sensor Circuit High Input

Step
Action
1. If the engine idle is rough, unstable or incorrect,

repair the idle problem before using this chart. Refer
to Symptoms section.
2. With the engine idling, note the MAP value on the
Tech 2.
1.
2.
3.
4.
About 4V 90
kPa
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
0 V 10.3 kPa
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 12

D A short to ground
D An open circuit
Go to Step 2

short to voltage.
Ignition OFF.
Disconnect the MAP sensor electrical connector.
Ignition ON.
Observe the MAP value displayed on the Tech 2.
5
No
Go to OBD
System
Check
1. Ignition ON engine OFF

4. Using the Tech 2, monitor DTC info for Diagnostic
Trouble Code P0108.
Does the Tech 2 indicate that DTC P0108 failed this
ignition?
Yes

performed?
Is the MAP reading above the specified value?

3
Value(s)

sensor and the ECM for the following conditions:
D An open circuit
D A short to ground
6E197
DTC P0108 MAP Sensor Circuit High Input (Cont'd)

Step
Action
1. Ignition OFF.
3. Ignition ON, Engine OFF.
Does the Tech 2 read the following value?
12
5 volts 104
kPa
Go to Step 9
Verify repair
No
Go to Step 12
Go to Step 10
1. Ignition OFF.
sensor connector.
11
Yes

D An open circuit
D A short to ground
10
Value(s)
Go to Step 11
Go to Step 12
5 Volts

Verify repair.
Replace the ECM.
Verify repair.
6E198
DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE (IAT)

SENSOR CIRCUIT LOW INPUT
D06RX116
Circuit Description
The intake air temperature (IAT) sensor is a thermistor
which measures the temperature of the air entering the
engine. The engine control module (ECM) applies 5 volts
through a pullup resistor to the IAT sensor. When the
intake air is cold, the sensor resistance is high and the
ECM will monitor a high signal voltage on the IAT signal
circuit. If the intake air is warm, the sensor resistance is
lower, causing the ECM to monitor a lower voltage.
Diagnostic Trouble Code P0112 will set when the ECM
detects an excessively low signal voltage (short to
ground) on the intake air temperature sensor signal
circuit. DTC P0112 is a Type A Code.

D The engine has been running for over 2 minutes.
D Vehicle speed is greater than 48 km/h (30 mph).
D IAT signal voltage less than 0.10 volts for a total of 12.5
seconds over a 25second period of time.
The above conditions are met for at least 2 seconds.

D The ECM will use a default IAT valve based on ECM
inputs and engine run time.

when the DTC was set as Freeze Frame and in the
Failure Records data.

D DTC P0112 can be cleared by using the Scan Tools
Clear Info function.
Diagnostic Aids
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
IAT display on the Tech 2 while moving connectors and
wiring harnesses related to the IAT sensor. A change
in the IAT display will indicate the location of the fault.
Test Description
Diagnostic Chart:
2. Verifies that the fault is present.
3. If Diagnostic Trouble Code P0112 can be repeated
only by duplicating the Failure Records condition,
refer to the Temperature vs. Resistance Value table.
The table may be used to test the IAT sensor at
various temperatures to evaluate the possibility of
a shifted sensor that may be stored above or
below a certain temperature. If this is the case,
replace the IAT sensor. If the IAT sensor appears
to be OK, the fault is intermittent; refer to
Diagnostic Aids.

C
OHMS
Temperature vs. Resistance Values (approximate)

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E199
6E1100
DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Input
Step
Action
1.
2.
3.
4.
Ignition OFF.
Disconnect the IAT sensor electrical connector.
Ignition ON.
Observe the intake air temperature on the Tech 2.
148C
(283F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
38C
(36F)
Go to Step 6
Go to Step 5
Verify Repair
Go to Step 7
Verify Repair
Verify Repair
Replace the IAT sensor.

Go to Step 2
1. Ignition OFF.
2. Disconnect the ECM electrical connectors.
3. Check the IAT sensor signal circuit for a short to
ground.
Is the IAT sensor signal circuit shorted to ground?
Go to OBD
System
Check
1. Ignition ON, engine OFF. Review and record Tech 2

3. Using a Tech 2, monitor the DTC info for
Diagnostic Trouble Code P0112.
Is the intake air temperature below the specified value?

5
No

2. Using a Tech 2, monitor the intake air temperature
(IAT).
Does the Tech 2 indicate DTC P0112 failed this

ignition?
4
Yes

performed?
Is the intake air temperature greater than the specified

value?
3
Value(s)
Replace the ECM.

6E1101

SENSOR CIRCUIT HIGH INPUT
D06RX118
Circuit Description
lower causing the ECM to monitor a lower voltage.
detects an excessively high signal voltage on the intake
air temperature sensor signal circuit. DTC P0113 is a
Type A Code.

D
D
D
D
D
The engine has been running for over 4 minutes.

Vehicle speed is less than 32 km/h (20 mph).
ECT signal temperature is above 60C (140F).
Mass air flow is less than 20g/second.
IAT signal voltage almost 5 volts which indicates an
intake air temperature less than 39C (38F) for a
total of 12.5 seconds over a 25second period.



without a fault.
Diagnostic Aids
observe the IAT display on the Tech 2 while moving
connectors and wiring harnesses related to the IAT
sensor. A change in the IAT display will indicate the
location of the fault.
6E1102


C
Test Description
Diagnostic Chart:
2.Verifies that the fault is present.
3.If Diagnostic Trouble Code P0113 can be repeated
only by duplicating the Failure Records conditions,
refer to the Temperature vs. Resistance Values
table.
a shifted sensor that may be open above or
Diagnostic Aids.
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Input
Step
Action
Ignition ON, engine OFF. Observe the Intake Air

Temp display on the Tech 2.
1. Ignition OFF.
2. Disconnect the IAT sensor electrical connector.
3. Jumper the IAT signal circuit and the sensor ground
circuit together at the IAT sensor harness
connector.
4. Ignition ON.
5. Observe the Intake Air Temp display on the Tech
2.
Is the Intake Air Temp at the specified value?
1. Jumper the IAT signal circuit at the IAT sensor

harness connector to chassis ground.
2.
No
Go to Step 2
Go to OBD
System
Check
5V 38C
(36F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
0V 140C
(284F)
Go to Step 6
Go to Step 5
0V 140C
(284F)
Go to Step 7
Go to Step 8

2. Review and record Tech 2 Failure Records data
parameters.
P0113 failed?
Yes

performed?
Is the Intake Air Temp below the specified value?

3
Value(s)
6E1103
DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Input (Cont'd)
Step
Action
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Verify repair
Verify repair
Go to Step 11
Replace the IAT sensor

11
Verify Repair
Check for a poor sensor ground or IAT signal circuit

terminal connection at the ECM and replace
terminal(s) if necessary.
Did any of the terminals need to be replaced?
10
Go to Step 10
1. Ignition OFF.
2. Disconnect the ECM, and check the IAT signal
circuit for an open.
3. If the IAT sensor signal circuit is open, repair it as
necessary.
Was the IAT signal circuit open?
No
1. Ignition OFF.
2. Disconnect the ECM, and check the IAT sensor
ground circuit for an open.
3. If the IAT sensor ground circuit is open, repair it as
necessary.
Was the IAT sensor ground circuit open?
Yes
Check for poor connections at the IAT sensor and

replace terminals if necessary.
Did any terminals require replacement?
Value(s)
Replace the ECM

6E1104
DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT

TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT
D06RX117
Circuit Description
The engine coolant temperature (ECT) sensor is a
thermistor mounted in the engine coolant stream. The
engine control module (ECM) applies a voltage (about 5
volts) through a pullup resistor to the ECT signal circuit.
When the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the ECM will measure a high
signal voltage. As the engine coolant warms, the sensor
resistance becomes lower, and the ECT signal voltage
measured at the ECM drops. With a fully warmedup
engine, the ECT signal voltage should measure about 1.5
to 2.0 volts. DTC P0117 is a Type A Code.


without a fault.
Diagnostic Aids
D Engine running time is longer than two minutes.

D The ECT sensor signal indicates an engine coolant
temperature greaterthan 150C (302F) (about 0.14
V) for a total of 12.5 seconds overa 25second period.

observe the ECT display on the Tech 2 while moving
connectors and wiring harnesses related to the ECT
sensor. A change in the ECT display will indicate the

D The ECM will substitute the ECT reading with a default
engine coolant temperature value. The default value is
based on startup intake air temperature and running
time.

6E1105

C
OHMS
Test Description
100
212
177

Diagnostic Chart:
table.
The table may be used to test the ECT sensor at
a shifted sensor that may be shorted above or
replace the ECT sensor. If the ECT sensor
appears to be OK, the fault is intermittent; refer to
Diagnostic Aids.
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Input
Step
Action
1. Ignition ON engine OFF.

2. Observe the Eng Cool Temp display on the Tech 2.
1. Disconnect the ECT sensor electrical connector.

Is the Eng Cool Temp at or below the specified value?
Go to Step 2
139C
(282F)
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
39C
(38F)
Go to Step 6
Go to Step 5
Verify repair
Go to Step 7
Verify repair
Verify repair
Replace the ECT sensor.

1. Ignition OFF.
2. Disconnect the ECM and check the ECT signal
circuit for a short to ground or a short to the sensor
ground circuit.
3. If the ECT signal circuit is shorted, repair it as
necessary.
Was the ECT signal circuit shorted to ground?
No
Go to OBD
System
Check

4. Using a Tech 2, monitor DTC info for DTC P0117.
ignition?
Yes

performed?
Is the Eng Cool Temp below the specified value?

3
Value(s)
Replace the ECM.

6E1106

TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT
D06RX117
Circuit Description
resistance becomes less, and the ECT signal voltage
measured at the ECM drops. With a fully warmed up
to 2.0 volts. If the ECM detect a continuous open in the
ECT sensor or circuit, then a code P0118 will set. DTC
P0118 is a type A code.

D Engine running time is longer than 2.5 minutes.
temperature of 39C (38F) or less (about 5 volts)
for a total of 12.5 seconds over a 25second period.

time.


without a fault.
Diagnostic Aids
and open circuit. If the harness appears to be OK,

performing the DTC P1115 Diagnostic Chart may isolate
the cause of the fault.
Test Description
Diagnostic Chart:
refer to the Temperature vs. Resistance Value
table.
Diagnostic Aids.

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E1107
6E1108
DTC P118 ECT Sensor Circuit High Input

Step
Action


2. Jumper the ECT signal circuit and the sensor
ground circuit together at the ECT sensor harness
connector.
Is the Eng Cool Temp at or above the specified value?
1. Jumper the ECT signal circuit at the ECT sensor

Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
140C
(284F)
Go to Step 6
Go to Step 5
140C
(284F)
Go to Step 7
Go to Step 8
Verify repair
Go to Step
10
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Go to Step
11
Verify repair
Verify repair

11
Go to Step 4
Check for a poor sensor ground or ECT signal circuit

10
39C
(38F)
1. Ignition OFF.
2. Disconnect the ECM, and check the ECT signal
3. If the ECT sensor signal circuit is open, repair it as
necessary.
Was the ECT signal circuit open?
Go to Step 2
1. Ignition OFF.
2. Disconnect the ECM, and check the ECT sensor
3. If the ECT sensor ground circuit is open, repair it as
necessary.
Was the ECT sensor ground circuit open?
Check for poor connections at the ECT sensor and

No
Go to OBD
System
Check

P0118 failed?
Yes

performed?

3
Value(s)
Replace the ECM.

6E1109
DIAGNOSTIC TROUBLE CODE (DTC) P0121 THROTTLE POSITION (TP)

SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
D06RX118
Circuit Description
The throttle position (Throttle Position) sensor circuit
provides a voltage signal that changes relative to throttle
blade angle. The signal voltage will vary from about 0.25
volts at closed throttle to about 4.75 volts at wide open
throttle (WOT).
The Throttle Position (TP) signal is used by the
powertrain control module (ECM) for fuel control and
most of the ECMcontrolled outputs. The ECM monitors
throttle position and compares actual throttle positions
from the TP sensor to a predicted TP value calculated
from engine speed. If the ECM detects an outofrange
condition, then a DTC code P0121 will set. DTC P0121 is
type A code.

D The Engine is running.
D No MAP, ECT, TP, CKP, EGR, EVAP or DTCs are set.
D IAC is between 10 and 160 counts.
D The MAP value changes by less than 2 kPa.
All the above mentioned conditions are met, and one of
the following conditions occurs for a total of 12.5 seconds
over a 25second period of time.
Stuck High
D MAP value is below 55 kPa.
D Actual TP value is greater than the ECMs estimated

TP value (Estimated TP value is based on MAP and
RPM).
Stuck Low
D Actual TP value is less than the ECMs estimated TP
value (Estimated TP value is based on MAP and
RPM).

fault is detected.
D The ECM will use a default throttle position based on
MAP and RPM.

without a fault.
6E1110
Diagnostic Aids
D Skewed MAP signal or faulty MAP sensor An
incorrect MAP signal may cause the ECM to incorrectly
calculate the predicted TP sensor value during high
engine load situations. Check for an unusually low
MAP reading. This condition can cause DTC P0121 to
be set.
D The TP sensor shares a 5 Volt reference with the MAP
D The TP sensor shares a ground with the MAP sensor
and the Fuel Pressure sensor.

fault.
If DTC P0121 cannot be duplicated, the information
included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set. If
it is determined that the DTC occurs intermittently,
performing the DTC P1122 or P1121 Diagnostic Chart
may isolate the cause of the fault.
DTC P0121 TP Sensor/Range Performance Problem

Step
Action
Go to Step 2
Refer to
Diagnostic
Aids
Go to Step 3
Go to Step 4
00.25 volts
0%
Go to Step 6
Verify repair
Verify repair
Go to Step 11
1. Ignition OFF.
2. Disconnect the Throttle Position (TP) Sensor
electrical connector, located on the RH side of the
Throttle body.
3. Start the vehicle, and monitor the TP value with the
Tech 2.
Check the TP sensor signal circuit; between the TP

short to voltage.

2. Monitor the TP value on the Tech 2 while moving the
throttle between 0% and 100%.
Does the TP value on the Tech 2 hold steadily within the

given range?
5
No
Go to OBD
System
Check

Does the TP value on the Tech 2 move smoothly from

0% (0.25 volts) to 100% (4.75 volts)? (if no, start with
the diagnosis chart for other sensors in the circuit and
see if 5V returns.)
4
Yes

performed?
Does the Tech 2 indicate that DTC P0121 Ran and

Passed?
3
Value(s)
Go to Step 5
Go to Step 12
Check the TP sensor circuit, between the TP sensor

and the ECM, the following conditions:
D A short to ground
D An open circuit
Go to Step 7
6E1111
DTC P0121 TP Sensor/Range Performance Problem (Cont'd)

Step
Action
1. Ignition OFF.
2. Place a fused jumper between the TP sensor circuit
and the 5 volt signal circuit both at the wiring
harness TP sensor connector.
4. Observe the TP value displayed on the Tech 2?
12
Verify repair
about 5 volts
100%
Go to Step 9
Verify repair
No
Go to Step 8
Go to Step 12
Go to Step 10
1. Ignition OFF.
signal circuit, both at the wiring harness TP sensor
connector.
11
Check the TP sensor ground circuit, between the TP

D An open circuit
D A short to ground
10
Yes
Check the 5 volt signal circuit, between the TP sensor

and the ECM, for the following conditions:
D An open circuit
D A short to ground
Value(s)
Go to Step 11
Go to Step 12
about 5 volts
Replace the TP sensor.

Verify repair.
Replace the ECM.
Verify repair.
6E1112

SENSOR CIRCUITLOW INPUT
D06RX118
Circuit Description
The throttle position (TP) sensor circuit provides a voltage
signal that changes relative to throttle blade angle. The
signal voltage will vary from below 1 volt at closed throttle
to about 4 volts at wide open throttle(WOT).
The TP signal is used by the engine control module
(ECM) for fuel control and most of the ECMcontrolled
outputs. If the ECM detect a continuous short to ground
in the TP sensor or circuit, then a code P0122 will set.
Diagnostic Trouble Code P0122 is type A code.

D The ignition is ON.
D Throttle Position sensor signal voltage is less than 0.22
volt for a total of 0.78 second over a 1.5second period.

MAP and RPM.


without a fault.
Diagnostic Aids
problem with the 5 Volt reference circuit or
components itself.
D The TP sensor share a ground with the MAP and the
Fuel Pressure sensor.
observe the throttle position display on the Tech 2 while
moving connectors and wiring harnesses related to the
TP sensor. A change in the display will indicate the
6E1113

DTC P0122 TP Sensor Circuit Low Input

Step
Action
0.22 V
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
5V
Go to Step
10
Go to Step 5
5V
Go to Step 6
Go to Step 8
Verify repair
Go to Step 7
Verify repair
Go to Step
12
1. Disconnect jumper.
2. Connect a test light between B+ and the Throttle
Position sensor signal circuit at the Throttle Position
Observe the Throttle Position Sensor display on the
Tech 2.
1. Ignition OFF.
ground?
Go to Step 2
1. Ignition OFF.
2. Disconnect the TP sensor electrical connector.
3. Jumper the 5 volt reference circuit and the Throttle
Position signal together at the Throttle Position
4. Ignition ON.
Observe the Throtle Position Sensor display on the
Tech 2.
Is the Throttle Position Sensor at the specified value?

(if no, start with the diagnosis chart for other sensors in
the circuit and see if 5V returns.)
6
Go to OBD
System
Check

4. Using a Tech 2, monitor the Diagnostic Trouble
Code info for Diagnostic Trouble Code P0122.

5
No

2. With the throttle closed, observe the Throttle
Position Sensor display on the Tech 2.
Does the Tech 2 indicate DTC P0122 failed?

4
Yes

performed?
Is the Throttle Position Sensor below the specified

value?
3
Value(s)

6E1114
DTC P0122 TP Sensor Circuit Low Input (Cont'd)

Step
Action
Go to Step 9
Verify repair
Go to Step
12
Verify repair
Go to Step
11
Verify repair
Verify repair

12
Verify repair
Check the TP sensor signal circuit for a poor

connection at the TP sensor and replace the terminal if
necessary.
11
No

connection at the ECM and replace the terminal if
necessary.
10
Yes
1. Ignition OFF.
2. Disconnect the ECM, and check the TP signal
3. If the TP sensor signal circuit is open or shorted to
Was the TP signal circuit open or shorted to ground?
Value(s)
Replace the ECM.

6E1115

D06RX118
Circuit Description

to about 4 volts at wide open throttle (WOT).
outputs. If the ECM detect a continuous open in the TP
sensor or circuit, then a code P0123 will set. DTC P0123
is a type A code.
without a fault.

components itself.
damage, shorts to ground, shorts to battery positive
observe the Throttle Position sensor display on the
Tech 2 while moving connectors and wiring harnesses
related to the TP sensor. A change in the display will
indicate the location of the fault.

D Throttle Position sensor signal voltage is greater than
4.78 volts for a total of 0.78 second over a 1.5second
period.

MAP and RPM.
Diagnostic Aids
6E1116
D Faulty Throttle Position sensor With the ignition key

ON engine OFF observe the TP sensor display on the
Tech 2 while slowly depressing the accelerator to wide
open throttle. If a voltage over 4.88 volts is seen at any
point in normal accelerator travel, replace the TP
sensor.
performing theDiagnostic Trouble Code P1121
Test Description
Diagnostic Chart:
7. Components that share the TP sensor 5 volt
reference circuit include the following devices:
D EGR valve
D MAP sensor
Disconnect the component while observing the
Throttle Position sensor display on the Tech 2. If
the reading changes drastically when this
component is disconnected, replace the
component that affected the reading.
DTC P0123 TP Sensor Circuit High Input

Step
Action
Go to Step 2
4.78 V
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
0V
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step
10
Verify repair
Go to Step
12
1. Disconnect the Throttle Position sensor electrical

connector.
2. Observe the Throttle Position Sensor display on
the Tech 2.
Probe the sensor ground circuit at the Throttle Position

sensor harness connector with a test light connected to
B+.
Go to OBD
System
Check

Is the Throttle Position Sensor near the specified

value? (if no, start with the diagnosis chart for other
sensors in the circuit and see if 5V returns.)
5
No


P0123 failed.
4
Yes

performed?
Is the Throttle Position Sensor above the specified

value?
3
Value(s)
1. Ignition OFF disconnect the ECM.

3. Check for a short to voltage on the TP sensor signal
circuit.
4. If the TP sensor signal circuit is shorted, repair it as
necessary.
Was the TP sensor signal circuit shorted?
6E1117
DTC P0123 TP Sensor Circuit High Input (Cont'd)

Step
Action
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step
11
Verify repair
Go to Step
12
Verify repair
Verify repair
Replace the Throttle Position sensor.

12
Verify repair
1. Ignition OFF.
2. Disconnect the ECM, and check for an open sensor
ground circuit to the Throttle Position sensor.
3. If a problem is found, repair it as necessary.
Was the sensor ground circuit to the Throttle Position
sensor open?
11
Check for poor electrical connections at the Throttle

Position sensor and replace terminals if necessary.
10
No

3. Check for a short to B+ on the 5 volt reference
circuit.
4. If the 5 volt reference circuit is shorted, repair it as
necessary.
Was the 5 volt reference circuit shorted?
Yes
1. Ignition ON.
2. Monitor the Throttle Position Sensor Tech 2
display while disconnecting each of the
components that share the 5 volt reference circuit
(one at a time).
3. If the Throttle Position Sensor Tech 2 display
changes, service the component(s) that caused the
display to change when disconnected.
Does disconnecting any of these components cause
the Throttle Position Sensor display to change?
Value(s)
Replace the ECM.

6E1118
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW

VOLTAGE (BANK 1 SENSOR 1)
D06RX119
Circuit Description
The engine control module (ECM) supplies a bias voltage

of about 450 mV between the heated oxygen sensor
(HO2S) signal and low circuits. When measured with a 10
megaW digital voltmeter, this may display as low as 350
mV. The oxygen sensor varies the voltage within a range
of about 1000 mV when the exhaust is rich, down through
about 10 mV when exhaust is lean. The ECM constantly
monitors the HO2S signal during Closed Loop operation
and compensates for a rich or lean condition by
decreasing or increasing injector pulse width as
necessary. If the Bank 1 HO2S 1 voltage remains
excessively low for an extended period of time,
Diagnostic Trouble Code P0131 will be set. DTC P0131 is
a type A code.

D Open Loop fuel control will be in effect.

D
D
D
D
No related Diagnostic Trouble Codes.

Vehicle is operating in Closed Loop.
Engine coolant temperature is above 60C (140F)
Closed Loop commanded air/fuel ratio is between
14.5 and 14.8.
D Throttle angle is between 3% and 19%.
All above conditions met for 0.3 seconds and the following
condition is met:
D Bank 1 HO2S 1 signal voltage remains below 22 mV
during normal Closed Loop operation for a total of
76.5 seconds over a 90second period of time.

without a fault.
Diagnostic Aids
D Heated oxygen sensor wiring The sensor pigtail may
be routed incorrectly and/or contacting the exhaust
system. Also, check for shorts to ground, shorts to
battery positive and open circuits.
D Poor ECM to engine block grounds.
D Fuel pressure The system will go lean if pressure is
too low. The ECM can compensate for some decrease.
However, if fuel pressure is too low, a Diagnostic

Trouble Code P0131 may be set. Refer to Fuel System
Diagnosis.
D Lean injector(s) Perform Injector Balance Test.
D Vacuum leaks Check for disconnected or damaged
vacuum hoses and for vacuum leaks at the intake
manifold, throttle body, EGR system, and PCV system.
D Exhaust leaks An exhaust leak may cause outside air
to be pulled into the exhaust gas stream past the
HO2S, causing the system to appear lean. Check for
exhaust leaks that may cause a false lean condition to
be indicated.
D Fuel contamination Water, even in small amounts,
can be delivered to the fuel injectors. The water can
cause a lean exhaust to be indicated. Excessive
alcohol in the fuel can also cause this condition. For the
procedure to check for fuel contamination, Refer to
Fuel System Diagnosis.
If none of the above conditions are present, replace the
affected HO2S.
Test Description
Diagnostic Chart:
3. Diagnostic Trouble Code P0131 failing during
operation may indicate a condition described in the
Diagnostic Aids above. If the Diagnostic Trouble
Code P0131 test passes while the Failure Records
conditions are being duplicated, an intermittent
condition is indicated.
Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
the condition that caused the Diagnostic Trouble Code to
be set occurs. This may assist in diagnosing the
condition.
6E1119
6E1120
DTC P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

Step
Action
Value(s)

performed?
1. Ignition OFF.
2. Reconnect the
disconnected.
3. Ignition ON.
ECM,
leave
the
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 5
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Verify repair
430450 mV
Refer to
Diagnostic
Aids
Go to Step 9
Verify repair
sensor
Does the Tech 2 indicate Bank 1 HO2S 1 voltage near

the specified value?
9
Go to Step 3
Repair the short between the high and low circuits.

Go to Step 4
1. Turn the ignition OFF HO2S 1 and ECM

disconnected.
2. Check for continuity between the high and low
signal circuits.
Was there continuity between the high and low circuits?
300 mV
Repair the Bank 1 HO2S 1 signal circuit.

Go to Step 2

3. Check the Bank 1 HO2S 1 high and low circuits for a
short to ground or a short to the heater ground
circuit.
Are the Bank 1 HO2S 1 signal circuits shorted to
ground?
Go to OBD
System
Check
1. Ignition ON engine OFF review and record Tech 2

Failure Records data and note parameters.
info for Diagnostic Trouble Code P0131 until the
Diagnostic Trouble Code P0131 test runs.
Note test result.
Does Tech 2 indicate DTC P0131 failed this ignition?
No
1. Install the Tech 2.

2. Run the engine at operating temperature.
3. Operate the vehicle within the parameters specified
under Conditions for Setting the Diagnostic
Trouble Code criteria included in Diagnostic
Support.
4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage.
Does the Bank 1 HO2S 1 voltage remain below the
specified value?
Yes
Replace the ECM.

6E1121
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH

D06RX119
Circuit Description
excessively high for an extended period of time,
a type A code.

D No related Diagnostic Trouble Codes.
D Engine coolant temperature is above 60C (140F).
D Closed Loop commanded air/fuel ratio is between
14.5 and 14.8.
All above conditions met for 0.3 seconds or vehicle in
Decelleration Fuel CutOff (DFCO) mode for 3 seconds,
and one of the following two conditions met:
D Bank 1 HO2S 1 signal voltage remains above 952 mV
76.5 seconds over a 90second period.
OR
during deceleration fuel cutoff mode (DFCO)
operation for 5 seconds.


without a fault.
using the Scan Tools Clear Info function or by
disconnecting the ECM battery feed.
Diagnostic Aids
Check the following items:
D Fuel pressure The system will go rich if pressure is
too high. The ECM can compensate for some
increase. However, if fuel pressure is too high, a
6E1122
D
D
D
D
D
Diagnostic Trouble Code P0132 may be set. Refer to

Perform Injector Balance Test Refer to Fuel System
Diagnosis.
Check the EVAP canister for fuel saturation If full of
fuel, check canister control and hoses. Refer to
Evaporative (EVAP) Emission Control System.
Check for a leak in the fuel pressure regulator
diaphragm by checking the vacuum line to the
regulator for the presence of fuel.
An intermittent TP sensor output will cause the system
to go rich due to a false indication of the engine
accelerating.
Silicon contamination of the HO2S can also cause a
high HO2S voltage to be indicated. This condition is
indicated by a powdery white deposit on the portion of
the HO2S exposed to the exhaust stream. If
contamination is noticed, replace the affected HO2S.
Operate the vehicle while monitoring the HO2S voltage
with a Tech 2. If the HO2S voltage is limited within a
range between 300 mV to 600 mV, check the HO2S
high and low circuit wiring and associated terminal
connections. If the wiring and connections are OK,
replace the HO2S.
Test Description
Diagnostic Chart:
deceleration fuel cutoff mode operation may
indicate a condition described in the Diagnostic
Aids above. If the Diagnostic Trouble Code P0132
test passes while the Failure Records conditions are
being duplicated, an intermittent condition is
indicated. Reviewing the Failure Records vehicle
mileage since the diagnostic test last failed may
help determine how often the condition that caused
the Diagnostic Trouble Code to be set occurs. This
may assist in diagnosing the condition.
6E1123
DTC P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

Step
Action

3. Operate the vehicle within parameters specified
under Conditions for Setting the DTC included in
Diagnostic Support.
1.
2.
3.
4.
Go to Step 4
Go to Step 3
Refer to
Diagnostic
Aids
Go to Step 4
514 V
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Go to Step 7
10 mV
Go to Step 8
Go to Step 9
Verify repair
Verify repair

2. Disconnect Bank 1 HO2S 1 and jumper the HO2S
high and low circuits (ECM side) to ground.
Replace Bank 1 HO2S 1.
952 mV (500
mV in
deceleration
fuel cutoff
mode)
1. Ignition OFF.
2. Disconnect the ECM connector.
3. Check for damage to the ECM pins and terminals.
Is Bank 1 HO2S 1 voltage below the specified value?

8
Go to Step 2
Repair short to voltage in signal circuit.

7
Ignition OFF.
Disconnect Bank 1 HO2S 1.
Ignition ON.
At HO2S 1 connector (ECM side) use a Digital
Voltmeter (DVM) to measure voltages at the high
and low signal terminals.
Are the voltages in the specified range?

5
No
Go to OBD
System
Check
1. Ignition ON review and record Tech 2 Failure

Records data.
4. Note the test result.
P0132 failed this ignition?
Yes

performed?
Does the Bank 1 HO2S 1 voltage remain above the

specified value?
3
Value(s)
Replace the ECM.

6E1124
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR CIRCUIT NO

ACTIVITY DETECTED (BANK 1 SENSOR 1)
D06RX119
Circuit Description

(HO2S) high and low circuits. When measured with a 10
MW digital voltmeter, this may display as low as 320 mV.
The oxygen sensor varies the voltage within a range of
about 1000 mV when the exhaust is rich, down through
necessary. If the Bank 1 HO2S 1 voltage remains at or
near the 450 mV bias for an extended period of time,
Diagnostic Trouble Code P0134 will be set, indicating an
open sensor signal or sensor low circuit. DTC P0134 is a
type B code.

(MIL) the second time the fault is detected.

D Engine run time is longer than 120 seconds.
D Oxygen sensor heater has been determined to be
functioning properly, and the oxygen sensor has
warmed to operating temperature.
All the above conditions are met and the following
condition is met:
D Bank 1 HO2S 1 signal voltage remains between 400
mV and 500 mV for a total of 76.5 seconds over a
90second period of time.

without a fault.
Diagnostic Aids
harness connectors for backedout terminals,
damaged
terminals,
poor
terminaltowire
D Faulty HO2S heater or heater circuit With the ignition
ON engine OFF after a cooldown period, the HO2S 1
voltage displayed on the Tech 2 is normally 455460
mV. A reading over 1000 mV indicates a signal line
shorted to voltage. A reading under 5 mV indicates a

signal line shorted to ground or signal lines shorted
together. Disconnect the HO2S and connect a test light
between the HO2S ignition feed and heater ground
circuits. If the test light does not light for 2 seconds
when the ignition is turned on, repair the open ignition
feed or sensor ground circuit as necessary. If the test
light lights and the HO2S signal and low circuits are
OK, replace the HO2S.
D Intermittent test With the ignition ON monitor the
HO2S signal voltage while moving the wiring harness
6E1125
and related connectors. If the fault is induced, the

HO2S signal voltage will change. This may help isolate
the location of the malfunction.
condition.
DTC P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

Step
Action
400500 mV
Go to Step 3
Go to Step 4
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Check for poor Bank 1 HO2S 1 high and low circuit

terminal connections at the Bank 1 HO2S 1 harness
connector and replace terminal(s) if necessary.
terminal connections at the ECM and replace terminals
if necessary.
Go to Step 2
Check for a damaged harness.

6
Go to OBD
System
Check
1. Ignition ON, engine OFF review and record Tech 2


5
No

3. Operate the engine above 1200 RPM for three
minutes.

4
Yes

performed?
Does the Tech 2 indicate Bank 1 HO2S 1 voltage

varying outside the specified values?
3
Value(s)
1. Ignition OFF.
2. With the ECM disconnected, check continuity of the
Bank 1 HO2S 1 high circuit.
3. If the Bank 1 HO2S 1 high circuit measures over 0.5
W, repair open or poor connection as necessary.
Was a Bank 1 HO2S 1 high circuit problem found and
corrected?
6E1126

(Cont'd)
Step
Action
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11
Verify repair
Verify repair
10 mV

11
No

Is Bank 1 HO2S 1 voltage approximately equal to the
specified value?
10
Yes
1. Ignition OFF.
Bank 1 HO2S 1 low circuit.
3. If the Bank 1 HO2S 1 low circuit measures over 5 W,
repair open or poor connection as necessary.
Was a Bank 1 HO2S 1 low circuit problem found and
corrected?
Value(s)
Replace the ECM.

6E1127
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT

MALFUNCTION
D06RX119
Circuit Description
of time required for Closed Loop fuel control operation
and to allow accurate catalyst monitoring. The oxygen
sensor heater greatly decreases the amount of time
required for fuel control sensors Bank 1 HO2S 1.
The engine control module (ECM) will run the heater test
only after a cold start (determined by engine coolant and
intake air temperature at the time of startup) and only
once during an ignition cycle. When the engine is started
the ECM will monitor the HO2S voltage. When the HO2S
voltage indicates a sufficiently active sensor, the ECM
looks at how much time has elapsed since startup. If the
ECM determines that too much time was required for the
Bank 1 HO2S 1 to become active, a Diagnostic Trouble
Code P0135 will set. DTC P0135 is a type B code.

D Intake air temperature (IAT) is less than 32C (90F)
at startup.
D Engine coolant temperature (ECT) is less than 32C
(90F) at startup.
D IAT and ECT are within 5C (9F) of each other at
startup.
D Ignition voltage is between 11 and 16.6 V.
D Average calculated air flow is less than 18 g/second
during sample period.
D Throttle angle is less than 40%.

D Bank 1 HO2S 1 voltage does not change more than
148 mV from the bias voltage (between 400 mV and
500 mV) for a longer amount of time than it should. The
maximum amount of time to come up to operating
range is 240 seconds. This warmup time depends on
the engine coolant temperature at startup and intake
air temperature at startup.

fault is detected.

without a fault.
6E1128
Diagnostic Aids
damage; shorts to ground, shorts to battery positive
fault.
condition.
2. The HO2S should be allowed to cool before

performing this test. If the HO2S heater is
functioning, the signal voltage will gradually increase
or decrease as the sensor element warms. If the
heater is not functioning, the HO2S signal will
remain near the 450 mV bias voltage.
4. Ensures that the ignition feed circuit to the HO2S is
not open or shorted. The test light should be
connected to a good chassis ground, in case the
HO2S low or HO2s heater ground circuit is faulty.
5. Checks the HO2S heater ground circuit.
6. Checks for an open or shorted HO2S heater
element.
10.An open HO2S signal or low circuit can cause the
HO2S heater to appear faulty. Check these circuits
before replacing the sensor.
Test Description
Diagnostic Chart:
DTC P0135 O2 Sensor Heater Circuit Malfunction

Step
Action
Go to Step 2
Go to OBD
System
Check
Above 650
mV or below
250 mV
Refer to
Diagnostic
Aids
Go to Step 3
Inspect the fuse for the Bank 1 HO2S 1 ignition feed.

Is the fuse open?
1.
2.
3.
4.
Go to Step 15
Go to Step 4
Ignition OFF.
Raise the vehicle.
Disconnect the Bank 1 HO2S 1 electrical connector.
Using a test light connected to a good ground (do
not use Bank 1 HO2S 1 heater ground or Bank 1
HO2S 1 low), probe the ignition feed circuit at the
Bank 1 HO2S 1 electrical connector (ECM harness
side).

5
No
NOTE: If the engine has just been operating, allow

engine to cool for about one half hour before
proceeding.
Does the HO2S voltage go from bias voltage to above

and below the specified values?
Yes

performed?
1. Ignition OFF, engine OFF.

2. Install a Tech 2.
3. Ignition ON engine OFF monitor the Bank 1 HO2S 1
voltage.
Value(s)
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Connect the test light between the Bank 1 HO2S 1

ignition feed and the Bank 1 HO2S 1 heater ground.
6E1129
DTC P0135 O2 Sensor Heater Circuit Malfunction (Cont'd)

Step
Action
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 13
Go to Step 14
Replace the Bank 1 HO2S 1.

15
Check for a poor Bank 1 HO2S 1 high circuit terminal

necessary.
14
Check for a poor Bank 1 HO2S 1 low circuit terminal

necessary.
13
Verify repair
1. Ignition OFF.
2. Disconnect the ECM and check the continuity of the
Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S
1 low circuit.
3. If the Bank 1 HO2S 1 high circuit or HO2S low circuit
measures over 5 W, repair open or poor connection
as necessary.
12
Check for a poor Bank 1 HO2S 1 high or low circuit

terminal connection at the Bank 1 HO2S 1 harness
11
Go to Step 9
1. Check for a poor connection at the Bank 1 HO2S 1

harness terminals.
2. If a poor connection is found, replace terminals.
Was a poor connection found?
10
Go to Step 10
36 ohms
Repair the open Bank 1 HO2S 1 heater ground circuit

to Bank 1 HO2S 1.
No
Repair the open Bank 1 HO2S 1 ignition feed circuit to

Bank 1 HO2S 1.
Yes
1. Allow the HO2S to cool for at least 10 minutes.

2. Using a Digital Voltmeter (DVM), measure the
resistance between the Bank 1 HO2S 1 ignition
feed and the Bank 1 HO2S 1 heater ground at the
Bank 1 HO2S 1 pigtail.
Is the HO2S heater resistance within the specified
values?
Value(s)
Locate and repair the short to ground in Bank 1 HO2S 1

ignition feed circuit and replace the fault fuse.
6E1130
DIAGNOSTIC TROUBLE CODE (DTC) P0171 SYSTEM TOO LEAN (BANK 1)
D06RX119
Circuit Description
To provide the best possible combination of driveability,
fuel economy, and emission control, a Closed Loop
air/fuel metering system is used. While in Closed Loop,
the engine control module (ECM) monitors the Bank 1
HO2S 1 signal and adjusts fuel delivery based upon the
HO2S signal voltage. A change made to fuel delivery will
be indicated by the long and short term fuel trim values
which can be monitored with a Tech 2. Ideal fuel trim
values are around 0%; if the HO2S signal indicates a lean
condition the ECM will add fuel, resulting in fuel trim
values above 0%. If a rich condition is detected, the fuel
trim values will be below 0%, indicating that the ECM is
reducing the amount of fuel delivered. If an excessively
lean condition is detected on Bank 1, the ECM will set
Diagnostic Trouble Code P0171. DTC P0171 is a type B
code.
The ECMs maximum authority to control long term fuel
trim allows a range between 14% and +20%. The ECM
monitors fuel trim under various engine speed/load fuel
trim cells before determining the status of the fuel trim
diagnostic.

D No Tech 2 test is being run.
D None of the following: EGR Diagnostic Trouble Codes,
HO2S Diagnostic Trouble Codes, (response,
transition, open, low volts, no activity), TP sensor
Diagnostic Trouble Codes, MAP Diagnostic Trouble
D
D
D
D
D
D
D
D
Codes, IAT Diagnostic Trouble Codes, canister purge

Diagnostic Trouble Codes, EVAP Diagnostic Trouble
Codes, injector circuit Diagnostic Trouble Codes, or
misfire Diagnostic Trouble Codes.
Engine coolant temperature is between 65C (149F)
and 104C (219F).
Intake air temperature is between 40C (40F) and
120C (248F).
Manifold absolute pressure is between 23.75 kPa and
99 kPa.
Engine speed is between 400 and 6000 RPM.
Barometric pressure is greater than 72.3 kPa.
System voltage is greater than 9.5v.
Engine is operating in Closed Loop.
The average of the short term fuel trim samples is
greater than 0.97 and the average of adaptive index
multiplier samples is greater than 1.21.

fault is detected.

after 40 consecutivewarmup cycles have occurred
without a fault.
Diagnostic Aids
observe the Bank 1 HO2S 1 display on the Tech 2 while
engine harness. A change in the display will indicate
the location of the fault.
condition.
Test Description
Diagnostic Chart:
2.Diagnostic Trouble Codes other than P0171 may
indicate a condition present which may cause a lean
condition. If this is the case, repairing the condition
which caused the other Diagnostic Trouble Code will
most likely correct the Diagnostic Trouble Code
P0171.
4.If the Diagnostic Trouble Code P0171 test passes
while the Failure Records conditions are being
duplicated, the lean condition is intermittent. Refer
to Diagnostic Aids or Symptoms for additional
information on diagnosing intermittent problems.
6E1131
6E1132
DTC P0171 System Too Lean (Bank 1)

Step
Action
Go to Step 3
L.T. Fuel
Trim: 20%
Go to Step 5
Go to Step 4
Go to Step 5
The lean
condition is
not present. If
a driveability
symptom still
exists, refer
to Symptoms
section.
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Go to Step
10
Above 5
counts
Go to Step
10
Go to Step 9
Verify repair
Go to Step
10
Visually and physically inspect the crankcase

ventilation valve for proper installation and repair any
problem found (refer to Crankcase Ventilation
System).
Start the engine and note the idle quality.
With the engine idling, observe the IDLE AIR
CONTROL display on the Tech 2.
Is the displayed value above the specified value?
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.
Visually and physically inspect the vacuum hoses for

disconnects, splits, kinks, improper routing and
improper connections and repair any problem found.
Is a high or unsteady idle being experienced?

8
Go to Step 2
1. Review and record the Tech 2 Failure Records data.

2. Clear the Diagnostic Trouble Code P0171 and
operate the vehicle to duplicate the Failure Records
conditions.
3. Monitor the Tech 2 Diagnostic Trouble Code info
for Diagnostic Trouble Code P0171 while operating
the vehicle to duplicate the Failure Records
conditions.
4. Continue operating the vehicle until the Diagnostic
Trouble Code P0171 test runs and note the test
result.
Did your inspection reveal a problem requiring repair?

7
1. Start the engine and operate the vehicle in Closed

Loop.
2. Observe the BANK 1 L.T. FUEL TRIM and display
on the Tech 2.

6
No
Go to OBD
System
Check
Are any DTCs set other than P0171?

5
Yes

performed?
Are the displayed values greater than the specified

values?
4
Value(s)
1. Visually and physically inspect the throttle body,

intake manifold, EGR valve and the EGR feed pipe
for vacuum leaks.
2. Repair any vacuum leaks as necessary.
Did your inspection reveal a vacuum leak?
6E1133
DTC P0171 System Too Lean (Bank 1) (Cont'd)

Step
Action
10
Perform the Idle Air Control (IAC) Valve Check and

correct any IAC problem as necessary.
Did this test isolate a problem requiring repair?
11
14
Go to Step
12
Verify repair
Go to Step
13
Verify repair
Go to Step
14
Verify repair
Go to Step
15
Verify repair
Go to Step
16
Verify repair
Go to Step
17
Verify repair
Go to Step
18
Verify repair
Refer to
Diagnostic
Aids
Perform the Injector Balance Test, and correct any

problem found (refer to Fuel Metering System).
Did the test isolate a problem?
18
Verify repair
Visually and physically inspect the Bank 1 exhaust

manifold for leaks and loose or missing hardware and
correct any problem found.
Did your inspection reveal a problem?
17
1. Visually and physically inspect the intake manifold,

injector Orings, EGR adapter, EGR valve and the
EGR feed pipes for vacuum leaks.
2. Repair any problem that is found.
16
Go to Step
11
Perform the Evaporative Emissions Control (EVAP)

Canister Purge Valve Check and repair EVAP system
problem if necessary.
15
Verify repair
Perform the procedure in Fuel System Pressure Test

and repair fuel system problem if necessary.
Did the test isolate a condition requiring repair?
1. Visually and physically inspect the Bank 1 HO2S 1

to ensure that it is installed securely and that the
Bank 1 HO2S 1 pigtail and wiring harness are not
contacting the exhaust or otherwise damaged.
2. If a problem is found, correct it as necessary.
No
1. Visually and physically inspect the ECM injector

grounds, power grounds and sensor grounds to
ensure that they are clean, tight, and in their proper
locations.
2. If a faulty ground condition is present, correct it as
necessary.
Did your inspection reveal a condition requiring repair?
13
Yes
Check the fuel for excessive water, alcohol, or other

contaminants (see Diagnosis in Engine Fuel for the
procedure) and correct the contaminated fuel condition
if present (see Engine Fuel).
Was the fuel contaminated?
12
Value(s)
6E1134
DIAGNOSTIC TROUBLE CODE (DTC) P0172 SYSTEM TOO RICH (BANK 1)
D06RX119
Circuit Description
heated oxygen sensor (HO2S) 1 and adjusts fuel delivery
based upon the HO2S signal voltages. A change made to
fuel delivery will be indicated by the long and short term
fuel trim values which can be monitored with a Tech 2.
Ideal fuel trim values are around 0%; if the HO2S signals
are indicating a lean condition the ECM will add fuel,
resulting in fuel trim values above 0%. If a rich condition is
detected, the fuel trim values will be below 0%, indicating
that the ECM is reducing the amount of fuel delivered. If
an excessively rich condition is detected on Bank 1, the
ECM will set Diagnostic Trouble Code P0172. DTC
P0172 is a type B code.
trim allows a range between 14% and +20%. The ECMs
maximum authority to control short term fuel trim allows a
range between 11% and +20%. The ECM monitors fuel
trim under various engine speed/load fuel trim cells
before determining the status of the fuel trim diagnostic.

D None of the following was set: EGR Diagnostic Trouble
Codes, HO2S Diagnostic Trouble Codes, (response,
transition, open, low volts, no activity), TPS Diagnostic
Trouble Codes, MAP Diagnostic Trouble Codes, IAT
D
D
D
D
D
D
D
D
Diagnostic Trouble Codes, canister purge Diagnostic

Trouble Codes, EVAP Diagnostic Trouble Codes,
injector circuit Diagnostic Trouble Codes, or misfire
Diagnostic Trouble Codes.
and 104C (219F).
120C(248F).
99 kPa.
System voltage is greater than 9.5 volts.
The average of the long term full trim samples is less
than 1.03 and the average of the adaptive index
multiplier samples is less than or equal to 0.82.

fault is detected.


without a fault.
Diagnostic Aids
the condition that caused the DTC to be set occurs. This
Test Description
Diagnostic Chart:
2. Diagnostic Trouble Codes other than P0172 may
which caused the other DTC will most likely correct
the DTC P0172.
4. If the Diagnostic Trouble Code P0172 test passes
duplicated, the rich condition is intermittent. Refer to
Diagnostic Aids or Symptoms for additional
6E1135
6E1136
DTC P0172 System Too Rich (Bank 1)

Step
Action
Go to Step 3
L.T. Fuel
Trim: 14%
Go to Step 5
Go to Step 4
The rich
condition is
not present. If
a driveability
symptom still
exists, refer
to Symptoms.
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Go to Step
10
Below 100
counts
Go to Step
10
Go to Step 9
Verify repair
Go to Step
10
Visually and physically inspect the air intake duct for

collapse or restriction and repair if necessary.
Is the IDLE AIR CONTROL value below the specified
value?
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.
Visually and physically inspect the air filter element and

replace it if necessary.
Is a low or unsteady idle being experienced?

8
Go to Step 2

conditions.
conditions.
Trouble Code P0172 test runs and note test result.

7

Loop.
2. Observe BANK 1 L.T. FUEL TRIM display on the
Tech 2.
Did the air filter require replacement?

6
No
Go to OBD
System
Check
Are any Diagnostic Trouble Codes set other than

P0172?

5
Yes

performed?
Are the displayed values more negative than the

specified values?
4
Value(s)
1. Ignition OFF.
2. Physically inspect the throttle body bore, throttle
plate, and IAC passages for coking and foreign
objects.
3. If a problem was found, repair as necessary.
6E1137
DTC P0172 System Too Rich (Bank 1) (Cont'd)

Step
Action
10
1. Perform the Idle Air Control (IAC) Valve Check.

Did the test isolate a problem requiring repair?
11
Verify repair
Go to Step
12
Minimum 0%
Maximum
100%
Go to Step
13
Go to Step
17
Verify repair
Go to Step
14
Verify repair
Go to Step
15
Verify repair
Go to Step
16
Verify repair
Refer to
Diagnostic
Aids
Verify repair
1. Remove and visually/physically inspect the Bank 1

HO2S 1 for silicon contamination. This will be
indicated by a powdery white deposit on the portion
of the HO2S that is exposed to the exhaust stream.
2. If contamination is evident on the Bank 1 HO2S 1,
replace the contaminated sensors.
Did the sensor require replacement?
17
Go to Step
11
1. Perform the Injector Balance Test.

2. If the test isolates a problem, repair as necessary
(refer to Fuel Metering System).
16
Verify repair
1. Perform the Evaporative Emissions Control

(EVAP) Canister Purge Valve Check.
2. If the test isolates a problem, repair as necessary.
15
1. Perform the Fuel System Pressure Test.

(refer to Engine Fuel or Fuel Metering System).
14
No
Ignition ON engine OFF monitor the TP Angle display

on the Tech 2 while slowly depressing the accelerator
pedal.
Does the TP Angle display increase steadily and
evenly from minimum value at closed throttle to
maximum value at wideopen throttle?
13
Yes

regulator and inspect the hose for the presence of
fuel.
2. If fuel is present in the vacuum hose, replace the
fuel pressure regulator (refer to Fuel Metering
System).
Did the fuel pressure regulator require replacement?
12
Value(s)
1. Check the TP sensor mounting screws and tighten

or replace them as necessary if they are loose or
missing.
2. If the screws are OK, replace the TP sensor.
6E1138
DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR CIRCUIT

MALFUNCTION CYLINDER 1
D06RX120
Circuit Description
The engine control module (ECM) has four individual
injector driver circuits. Each controls an injector. When a
driver circuit is grounded by the ECM, the injector is
activated. The ECM monitors the current in each driver
circuit. The ECM measures a voltage drop through a fixed
resistor and controls it. The voltage on each driver is
monitored to detect a fault. If the voltage is not what the
ECM expects to monitor on the circuit, a Diagnostic
Trouble Code is set. This Diagnostic Trouble Code is also
set if an injector driver is shorted to voltage. DTC P0201
is a type A code.


D The ECM will turn OFF the MIL on the third consecutive
trip cycle in which the diagnostic has been run and the
fault is no longer present.
after 40 consecutive warmup cycles occur without a
fault.
Diagnostic Aids
D
D
D
D
An injector driver circuit that is open or shorted to voltage

will cause a Diagnostic Trouble Code P0201 to set. It will
also cause a misfire due to an inoperative injector. A
misfire Diagnostic Trouble Code will also be set indicating
which cylinder is inoperative.
Long term and short term fuel trims that are excessively
high or low are a good indication that an injector is faulty.
Use Fuel Injector Coil Test Procedure to check for faulty
injectors.
The battery voltage is more than 9 volts.

Engine is running.
Fuel pump is ON.
The injector voltage does not equal the ignition voltage
when the injector is commanded OFF or the injector
voltage does not equal 0 volts when the injector is
commanded ON.
D The above conditions are met for 5 seconds.

6E1139
Test Description
Diagnostic Chart:
3.This step determines if Diagnostic Trouble Code
P0201 is the result of a hard failure or an
intermittent condition.
5. This step tests the harness wiring and ECM control
of the injectors using a test light.
The fuel injector test connector is a gray 5 pin
connector at the right rear of the valve cover. It
can be identified by a blue connector lock which is
tethered to the harness.
5884026060 is a test light with one light for
each cylinder. The test light fits on the injector test
connector.
If the test light is ON steady before cranking the
engine as well as while cranking the engine, then
the injector driver circuit is shorted to voltage.
If the test light blinks, the ECM and the wiring to
the injectors are OK. Fuel Injector Coil Test
Procedure will check if the injectors are faulty.
7. Because the test light was ON steady, voltage to the
injector is OK, but the driver circuit is grounded at all
times. This step determines if the circuit is shorted
to ground or the ECM is faulty.
901RX032
13. Normal injector resistance is slightly more than if

tested directly at the injector because it includes
resistance of the harness wires. The normal value is
about 13.5 W.
DTC P0201 Injector Circuit Malfunction Cylinder 1

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6
Will the engine start?
1. Install the Tech 2. Clear the Diagnostic Trouble

Code.
2. Idle the engine for one minute.
Does Diagnostic Trouble Code P0201 reset?
1. Review the Freeze Frame data with the ignition ON

and the engine OFF and note the parameters.
2. Operate the vehicle within the Freeze Frame
Does P0201 reset?
No
Go to OBD
System
Check
Yes
1. Ignition OFF.
2. Disconnect the injector test connector.
3. Install the injector test light 5884026060 on the
injector test connector.
4. Crank the engine while observing the light for
cylinder 1.
Does the injector test light blink?
6E1140
DTC P0201 Injector Circuit Malfunction Cylinder 1 (Cont'd)

Step
Action
12
15
Go to Step 9
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.
3. Clip one lead of an ohmmeter to the ignition pin on
the injector side of the test connector.
4. Touch the other lead to each of the other four pins in
the test connector, one pin at a time.
Repair the open circuit or open injector.

Check for an open circuit between the injector test
connector and the ECM connector for the Injector 1
control circuit.
Was there an open circuit?
16
Go to Step 8

2. Ignition ON.
3. Use a test light connected to ground to probe each
pin on the injector side of the connector.
Instead of normal injector resistance, did the ohmmeter

indicate an open in one of the injector circuits?
14
Repair the short to voltage in the injector driver circuit.
Did any terminal illuminate the test light?

13
Go to Step
10

2. Ignition ON.
terminal on the ECM side of the injector test
connector. Only the Ign+ terminal should illuminate
the test light.
Besides the Ign+, did any other terminal illuminate the
test light?
11
Go to Step 7
Replace the ECM.

10
Repair short to ground in the injector driver circuit.

No
1. Disconnect the ECM connector for the affected

injectors.
2. With a test light connected to B+, probe the affected
injector driver circuit.
Yes
Note whether the injector test light was OFF or ON

steady in step 5.
Was the test light ON steady while cranking the
engine?
Value(s)
6E1141

D06RX120
Circuit Description
is a type A code.


fault.
Diagnostic Aids
D
D
D
D

injectors.
The battery voltage is greater than 9 volts.

Engine is running.
Fuel pump is ON.
commanded ON.

6E1142
Test Description
Diagnostic Chart:
5.This step tests the harness wiring and ECM control
connector.
7.Because the test light was ON steady, voltage to the
901RX033

about 13.5 W.

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6

Code.

Does P0202 reset?
No
Go to OBD
System
Check
Yes
1. Ignition OFF.
injector connector.
cylinder 2.
6E1143

Step
Action
12
15
Go to Step 9
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.

control circuit.
16
Go to Step 8

2. Ignition ON.

14

13
Go to Step
10

2. Ignition ON.
the test light.
test light?
11
Go to Step 7
Replace the ECM.

10

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
6E1144

D06RX120
Circuit Description
injector driver circuits. Each controls an injector. When
the driver circuit is grounded by the ECM, the injector is
is a type A code.

when the DTC was setas Freeze Frame and in the

fault.
Diagnostic Aids
D
D
D
D

injectors.

Engine is running.
Fuel pump is ON.
commanded ON.

6E1145
Test Description
Diagnostic Chart:
3. This step determines if Diagnostic Trouble Code
connector.
901RX034

about 13.5 W.

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6

Code.

Does P0203 reset?
No
Go to OBD
System
Check
Yes
1. Ignition OFF.
injector connector.
cylinder 3.
6E1146

Step
Action
12
15
Go to Step 9
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.

control circuit.
16
Go to Step 8

2. Ignition ON.

14

13
Go to Step
10

2. Ignition ON.
the test light.
test light?
11
Go to Step 7
Replace the ECM.

10

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
6E1147

D06RX120
Circuit Description
set if an injector driver is shorted to voltage. DTC P0204 is
a type A code.


fault.
Diagnostic Aids
D
D
D
D

injectors.

Engine is running.
Fuel pump is ON.
commanded ON.

6E1148
Test Description
Diagnostic Chart:
connector.
901RX035

about 13.5 W.

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6
Go to Step 7
Go to Step
10
1. Install the Tech 2. Clear the DTC.

Does DTC P0204 reset?

Does P0204 reset?
1. Ignition OFF.
injector connector.
cylinder 4.
No
Go to OBD
System
Check
Yes

steady in step 5.
engine?
6E1149

Step
Action
12
15
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.

control circuit.
16

2. Ignition ON.

14
Go to OBD
System
Check

13
Go to Step 9

2. Ignition ON.
the test light.
test light?
11
Go to Step 8
Replace the ECM.

10
No

Yes

injectors.
Value(s)
6E1150
DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT

MALFUNCTION
D06RX121
Circuit Description
The knock sensor (KS) system is used to detect engine
detonation. The knock sensor produced an AC voltage
signal. The knock sensor sends this signal to the ECM.
The amplitude and the frequency of the AC voltage signal
depends upon the knock level being detected. The ECM
will then retard the spark timing based on the signals from
the Knock Sensor. DTC P0325 is a type B code.

D Engine run time is greater than 10 seconds.
D No P0327 Diagnostic Trouble Code set.
D Engine speed is above 2500 rpm.
All the above mentioned conditions are met, and the
following conditions are met for 8.75 seconds within a 10
second monitoring period:
D Any of the four A/D voltages exceeds 1.5625 Volts.
D Instantaneous A/D delta Voltage falls below 0.019531
Volts.

D The Malfunction Indicator Lamp (MIL) will illuminate
the second time the fault is detected.
D The ECM will record operating conditions at the time
the diagnostic fails.
D A history Diagnostic Trouble Code is stored.
D The ECM will use a calculated spark retard value in

order to minimize the knock during the conditions when
the knock is likely to occur. The calculated value will
vary based on the engine speed and load.

D The MIL will turn off after 3 consecutive ignition cycles
in which the diagnostic runs without a fault.
D A history Diagnostic Trouble Code will clear after 40
consecutive warm up cycles without a fault.
D A Tech 2 can clear the Diagnostic Trouble Codes.
Diagnostic Aids
Correct any abnormal engine noise before using the
diagnostic table.
Check for an open ignition feed circuit.
Test Description
Diagnostic Chart:
1. The Powertrain OBD System Check prompts the
technician to complete some basic checks and store
the freeze frame data and failure records data on
the Tech 2 if applicable. This creates an electronic
copy of the data taken when the malfunction
occurred. The information is then stored on the
Tech 2 for later reference.

2. If the conditions for the test as described above are
met, a Diagnostic Trouble Code P0325 will set and
MIL will illuminate.
4. If the engine has an internal knock or audible noise
that causes a knocking type noise on the engine
block, the knock sensor may be responding to the
noise.
6. The Tech 2 displays knock sensor activity in counts,
approximately 2050 at idle. The counts should
increase when engine speed is increased and the
counts should decrease when engine speed is
decreased.
6E1151
7. Any circuitry, that is suspected as causing the

complaint, should be thoroughly checked for backed
out terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage
to the wiring harness.
8. If the KS module was previously replaced and the
Diagnostic Trouble Code resets, a malfunctioning
ECM is indicated.
9. Checking the internal resistance of the knock sensor
verifies if the knock sensor or the wiring to the
knock sensor is OK.
DTC P0325 KS Circuit Malfunction

Step
Action
1.
2.
3.
4.
Go to Step 4
Go to Step
13
Go to Step 5
Go to Step 6
Go to Step
13
2500 RPM
Go to Step 7
Go to Step
11
Go to Step
13
Go to Step 8
Go to Step
13
90K 110K W
Go to Step 7
Go to Step
10
Replace the ECM.

Go to Step 3
Check for a poor connection at the ECM connector,

Knock sensor signal circuit and repair as necessary.
Was a repair necessary?
Go to Step 4
Slowly increase the engine speed to the specified

value.
Does the KS Activity increase with the engine speed?
Repair the mechanical engine problem or a loose

bracket or component.
Go to Step 2
Listen to the engine while raising and lowering the

engine speed.
Is a knock or audible noise present?
Go to
Powertrain
OBD System
Check
1. Turn the ignition switch ON, with engine OFF.

2. Review the Freeze Frame data and note the
parameters.
3. Operate the vehicle within the Conditions and
Conditions for Setting the DTC as noted.
Does the Malfunction Indicator Lamp (MIL) illuminate?
No
Start the engine.

Install a Tech 2.
Clear the Diagnostic Trouble Codes.
Run the engine at slightly more than 10% throttle
angle.

3
Yes
Was the Powertrain OnBoard Diagnostic (OBD)

System Check performed?
Value(s)
1. Turn the ignition switch OFF.

2. Disconnect the ECM connectors at the ECM.
3. With a Digital Voltmeter (DVM) connected to
ground, measure the resistance of the knock
sensor through the knock sensor signal circuit.
Is the measured value within the specified value?
6E1152
DTC P0325 KS Circuit Malfunction (Cont'd)

Step
Action
10
Check the knock sensor electrical connector for a poor

connection and repair as necessary.
11
13
Go to Step
11
Go to Step
13
Go to Step
12
Go to Step
13
Go to Step
14
Go to Step 2
Go to
applicable
DTC table
System OK
1. Using the Tech 2, clear the Diagnostic Trouble

Codes.
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for setting
this Diagnostic Trouble Code as specified in the
supporting text.
Does the Tech 2 indicate that this diagnostic has ran
and passed?
14
No
Go to Step
13
Replace the Knock Sensor (KS).

Yes
Check the knock sensor signal circuit for an open or a

short to ground or to voltage and repair as necessary.
12
Value(s)
Check is any additional Diagnostic Trouble Codes are

set.
Are any Diagnostic Trouble Codes displayed that have
not been diagnosed?
6E1153

LOW INPUT
D06RX121
Circuit Description
The ECM uses the Knock Sensor (KS) in order to detect
engine detonation. This allows the ECM to retard the
Ignition Control (IC) spark timing based on the KS signal
the ECM receives. The circuitry within the knock sensor
pulls down the ECMsupplied 5 volt signal, so that under
a no knock condition the signal on the KS circuit
measures about 1.3 volts. The knock sensors produce an
AC signal that rides on the 1.3 volts DC. The signals
amplitude and frequency are dependent upon the amount
of the knock being experienced.
The ECM determines whether the knock is occurring by
comparing the signal level on the KS circuit with a voltage
level on the noise channel. The noise channel allows the
CM to reject any false knock signal by indicating the
amount of normal engine mechanical noise present. The
normal engine noise varies depending on the engine
speed and load. Then the ECM determines that an
abnormally high noise channel voltage level is being
experienced, a Diagnostic Trouble Code P0327 sets.
This DTC is a type B DTC.

A/D Test
The following conditions are met for 7.5 seconds within a
10 second monitoring period:
D Engine speed is equal to or greater than 2000 RPM.
D A/D Voltage is less than or equal to 0.0977 Volts.
Gain Test
D Engine speed is greater than 2500 RPM.
D Gain is equal to or greater than 23.875 dB.

D The ECM will illuminate the MIL the second time the
fault is detected.
D The ECM will store the conditions which were present
then the Diagnostic Trouble Code set.

consecutive warmup cycles have occurred without a
fault.
D The Tech 2 Clear Info will clear the Diagnostic Trouble
Code.
Diagnostic Aids
A poor connection at the ECM. Inspect the knock sensor
and the ECM connectors for: , broken locks, improperly
formed or damaged terminals.
D Backed out terminals
6E1154
D Broken locks
D Improperly formed or damaged terminals
Also, check the wiring harness for: shorts to ground,
shorts to battery positive, and open circuits.
D A misrouted harness. Inspect the knock sensor
harness in order to ensure that it is not routed too close
to high voltage wires such as spark plug leads.
D Improper Knock Sensor torque specification. Torque
the Knock Sensor to 19Nm (1.9kgm/14 lbsft). Refer
to Fastener Notice.
Review the Fail Records vehicle mileage since the
diagnostic test last failed in order to help determine how
often the conditions that caused the DTC to set occur.

This may assist in diagnosing the condition.
Test Description
Diagnostic Chart:
2. Ensures that the fault is present.
6. Ensures that the knock sensor is capable of
detecting detonation.
DTC P0327 KS Circuit Low Input

Step
Action
Yes

No
Go to Step 2
Go to
Powertrain
OBD System
Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic
Aids
Approx. 5.0 V
Go to Step 5
Go to Step 8
100K W
Go to Step 6
Go to Step 9
1. Operate the engine within the conditions specified

in the diagnostic support Conditions for Setting the
DTC.
2. Using a Tech 2, monitor theDiagnostic Trouble
Code information for Diagnostic Trouble Code
P0327 until the Diagnostic Trouble Code P0327 test
runs.
3. Observe the test results.
Does the Tech 2 indicate the DTC P0327 failed this
ignition?
Value(s)
1. Turn ON the Ignition leaving the engine OFF.

2. Review the Tech 2 Fail Records data.
3.
IMPORTANT: Before clearing the DTCs, use the Tech
2 to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear Info
function is used.
4. Record the Tech 2 Fail Records data.
5. Operate the vehicle within the Fail Records
conditions.
6. Using a Tech 2, monitor the DTC info for the DTC
P0327 until the DTC P0327 test runs.
Does the Tech 2 indicate the DTC P0327 Failed This
Ignition?
1. Disconnect the KS Sensor electrical connector.

voltage between the KS signal circuit at the knock
sensor harness connectors and ground.
Is the voltage at the specified value?
Measure the resistance of the KS sensor by connecting

the between the KS sensor terminal and the engine
block.
Is the resistance of the KS sensor near the specified
value?
6E1155
DTC P0327 KS Circuit Low Input (Cont'd)

Step
Action
Go to Step
11
Go to Step 8
Go to Step
11
Go to Step
10
Go to Step
11
Go to Step
11
Go to Step
12
Go to Step 2
Go to
applicable
DTC table
System OK
Replace the ECM.

1.
2.
3.
4.
5.
6.
Using the Tech 2, select the DTC and the Clear Info.
Start the engine.
Idle at the normal operating temperature.
Select the DTC and the Specific.
Enter the DTC number which was set.
Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.
Does the Tech 2 indicate that this diagnostic ran and

passed?
12
Go to Step 9
Replace the KS Sensor. Refer to Knock Sensor.

11
Go to Step 7
Turn OFF the ignition.

Disconnect the ECM.
Turn ON the ignition.
Check the KS signal circuit between the ECM and
the KS sensor connector for an open, a short to
voltage, or a short to ground.
5. If a wiring problem is found, repair as necessary.

10
1.
2.
3.
4.

9
No
1. ReConnect the KS Sensor in order to monitor the

voltage between the KS sensor terminal and the
engine ground.
2. Tap on the engine lift bracket, near the KS Sensor,
while observing the signal indicated on the Tech 2.
Is any signal indicated on the while tapping on the
engine lift bracket?
Yes
1. Check the KS signal circuit for a poor terminal

connection at the knock sensor.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs in Engine Electrical.
Value(s)
Using the Tech 2, select the Capture Info and the

Review Info.
Are any DTCs displayed that have not been
diagnosed?
6E1156
DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP)

SENSOR CIRCUIT RANGE/PERFORMANCE
D06RX122
Circuit Description
The 58X reference signal is produced by the crankshaft

position (CKP) sensor. During one crankshaft revolution,
58 crankshaft pulses will be produced. The engine control
module (ECM) uses the 58X reference signal to calculate
engine RPM and crankshaft position. The ECM
constantly monitors the number of pulses on the 58X
reference circuit and compares them to the number of
camshaft position (CMP) signal pulses being received. If
the ECM receives an incorrect number of pulses on the
58X reference circuit, Diagnostic Trouble Code P0336 will
set. Diagnostic Trouble Code P0336 is a type B code.
without a fault.

D Extra or missing pulse is detected between
consecutive 58X reference pulses.
D Above condition is detected in 10 of 100 crankshaft
rotations.

fault is detected.
Diagnostic Aids
insulation. Check for:
D Poor connection Inspect the ECM harness and
connectors for improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminaltowire connection.
disconnect the ECM, turn the ignition on and observe
a voltmeter connected to the 58X reference circuit at
the ECM harness connector while moving connectors
and wiring harnesses related to the ECM. A change in
voltage will indicate the location of the fault.
6E1157

condition.
DTC P0336 CKP Sensor Circuit Range/Performance

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Refer to
Engine
Cranks But
Will Not Run
chart
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
2.5 V
Go to Step 8
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Verify repair
Go to Step 9
Verify repair

1.
2.
3.
4.
Review and record Failure Records information.

Clear Diagnostic Trouble Code P0336.
Start the engine and idle for 1 minute.
Observe Diagnostic Trouble Codes.
Is Diagnostic Trouble Code P0336 set?

4
1. Disconnect the ECM and CKP sensor.

2. Check for an open or a short to ground in the 58X
reference circuit between the CKP sensor
connector and the ECM harness connector.
1. Reconnect the ECM and CKP sensor.

2. Connect a Digital Voltmeter (DVM) to measure
voltage on the 58X reference circuit at the ECM
connector.
3. Observe the voltage while cranking the engine.
Is the voltage near the specified value?
Check the connections at the CKP sensor and replace

the terminals if necessary.
Replace the CKP sensor.

Check connections at the ECM and replace the

terminals if necessary.
No
Go to OBD
System
Check
Yes
Replace the ECM.

6E1158

D06RX122
Circuit Description

58 crankshaft reference pulses will be produced. The
engine control module (ECM) uses the 58X reference
signal to calculate engine RPM and crankshaft position.
The ECM constantly monitors the number of pulses on
the 58X reference circuit and compares them to the
number of camshaft position (CMP) signal pulses being
received. If the ECM does not receive pulses on the 58X
reference circuit, Diagnostic Trouble Code P0337 will set.
Diagnostic Trouble Code P0337 is a type B code.
without a fault.

D No camshaft position (CMP) sensor DTCs are set.
D Engine cranking.
D Crankshaft position (CKP) sensor signal is not present
between two cam pulses.
D CKP reference pulse is not detected within 24 CMP
pulses.

fault is detected.
Diagnostic Aids
6E1159

condition.
DTC P0337 CKP Sensor Circuit Low Input

Step
Action
Go to Step 4
Go to Step 9
Verify repair
Verify repair
Go to Step 6
2.5 V
Go to Step 9
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Verify repair
Go to Step
10
Verify repair

Check the connections at the ECM and replace the
10
Go to Step 3


9
Go to Step 5

2. Connect a DVM to measure voltage on the 58X
reference circuit at the ECM connector.

8
1. Ignition OFF.

7
Go to Step 2
Check 5 V reference or ground between the CKP

sensor and ECM and repair the open circuit, short to
ground or short to voltage.

6
Go to OBD
System
Check
1. Ignition ON.
2. With a DVM, backprobe the ECM connector 5 V
reference and ground connections.

5
No
1. Disconnect the CKP sensor.

2. Ignition ON.
3. Using a Digital Voltmeter (DVM), verify that 5 V
reference and ground are being supplied at the
sensor connector (ECM side).
Are 5 V reference and ground available at the ECM?

4
Yes

performed?
Are 5 V and ground being supplied to the sensor?

3
Value(s)
Replace the ECM.

6E1160
DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAMSHAFT POSITION (CMP)

D06RX123
Circuit Description
The camshaft position (CMP) sensor signal is produced
by the CMP sensor pulses when the engine is running and
crankshaft position (CKP) sync pulses are also being
received. The engine control module (ECM) uses the
CMP signal pulses to initiate sequential fuel injection. The
ECM constantly monitors the number of pulses on the
CMP signal circuit and compares the number of CMP
pulses to the number of 58X reference pulses received. If
CMP reference circuit, Diagnostic Trouble Code P0341
will set and the ECM will initiate injector sequence without
the CMP signal with a one in four chance that injector
sequence is correct. The engine will continue to start and
run normally, although the misfire diagnostic will be
affected if a misfiring condition occurs. DTC P0341 is a
type B code.

D The engine is running (CMP reference pulses are
being received).
D Above condition fails for 10 occurrences within 100 test
samples (15.6 m/s).

fault is detected.
D The ECM will initiate injector sequence without the

CMP signal with a one in four chance that injector
sequence is correct.
when the Diagnostic Trouble Code (DTC) was set as
Freeze Frame and in the Failure Records data.

D A history Diagnostic Trouble Code (DTC) P0341 will
clear after 40 consecutive warmup cycles have
occurred without a fault.
D Diagnostic Trouble Code (DTC) P0341 can be cleared
by using the Scan Tools Clear Info function.
Diagnostic Aids
D If a CKP Diagnostic Trouble Code (DTC) is also
indicated, there may be a problem with the ground
circuit because the CMP ground is spliced to the CKP
ground wire.
D If a fuel injector Diagnostic Trouble Code (DTC) is also
indicated, there may be a problem with the power
supply to the CMP. The wire supplying CMP power is
spliced to the wire supplying power to the fuel injectors.
insulation. Check for the following conditions:

disconnect the ECM, turn the ignition ON and observe
a voltmeter connected to the CMP signal circuit at the
6E1161
ECM harness connector while moving connectors and

wiring harnesses related to the CMP sensor. A change
in voltage will indicate the location of the fault.
the condition that caused the Diagnostic Trouble Code
(DTC) to be set occurs. This may assist in diagnosing the
condition.
DTC P0341 CMP Sensor Circuit Range/Performance

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
04 V
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 6
Verify repair
Verify repair
B+
Go to Step
12
Go to Step 8
B+
Go to Step
10
Go to Step 9
Verify repair
B+
Go to Step
12
Go to Step
11
Verify repair
1. Ignition ON.
4. Using a Tech 2, monitor DTC information for DTC
Does the Tech 2 indicate DTC P0341 failed this ignition
cycle?
1. Monitor voltage on the CMP signal circuit while

cranking the engine.
Does the voltage toggle between the specified values?
Check for a poor connection of the CMP signal wire at

the ECM terminal.
5
6
Repair the damaged pin or terminal at the ECM.

Replace the ECM
Is the repair complete?
1. Disconnect the CMP connector from the CMP

Sensor.
2. Ignition ON.
3. At the CMP connector, use a Digital Voltmeter
(DVM) to check the voltage between the voltage
signal wire and sensor ground.
Does the DVM indicate the specified value?
1. Ignition ON.
2. Use a DVM to measure between the ground and the
CMP positive connector.

10
1. Ignition ON.
2. Use a DVM to measure at the CMP connector
between the battery + and the CMP ground wire.
11
No
Go to OBD
System
Check
Yes
Repair the open ground wire.

6E1162
DTC P0341 CMP Sensor Circuit Range/Performance (Cont'd)

Step
Action
12
Use an ohmmeter to check continuity of the signal wire

between the CMP and the ECM.
13
Go to Step
13
Go to Step
14
Verify repair
Go to Step
15
Go to Step
16
Verify repair
Verify repair
Repair the signal circuit problem.

16
No
1. Ignition ON.
2. Check the signal wire for a short to ground or a short
to voltage.
15
Yes
Repair the open signal wire.

14
Value(s)
Replace the CMP Sensor.

6E1163

D06RX123
Circuit Description
received. The ECM uses the CMP signal pulses to initiate
sequential fuel injection. The ECM constantly monitors
the number of pulses on the CMP signal circuit and
compares the number of CMP pulses to the number of
58X reference pulses received. If the ECM does not
receive pulses on the CMP reference circuit, Diagnostic
Trouble Code (DTC) P0342 will set and the ECM will
initiate injector sequence without the CMP signal with a
one in four chance that injector sequence is correct. The
engine will continue to start and run normally, although
the misfire diagnostic will be affected if a misfiring
condition occurs. Diagnostic Trouble Code (DTC) P0342
is a type B code.

D The engine is running.
D The CMP sensor signal is not received by the ECM
once every 4 cylinders.
D The above condition occurs for 10 seconds.

fault is detected.


Diagnostic Aids
ground wire.
insulation. Check for the following:
6E1164


Test Description
Diagnostic Chart:
DTC P0342 Camshaft Position Sensor Circuit Low Input

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
04 V
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 6
Verify repair
Verify repair
B+
Go to Step
12
Go to Step 8
B+
Go to Step
10
Go to Step 9
Verify repair
B+
Go to Step
12
Go to Step
11
Verify repair
1. Ignition ON.
Did the Tech 2 indicate DTC P0342 failed this ignition
cycle?
1. Use a Digital Voltmeter (DVM) to monitor voltage on

the CMP signal circuit while cranking the engine.

the ECM terminal.
5
6

Replace the ECM.

Sensor.
2. Ignition ON.
3. At the CMP connector, check the voltage between
the voltage signal wire and sensor ground.
1. Ignition ON.

10
1. Ignition ON.
11
No
Go to OBD
System
Check
Yes

6E1165
DTC P0342 Camshaft Position Sensor Circuit Low Input (Cont'd)

Step
Action
12

13
Go to Step
13
Go to Step
14
Verify repair
Go to Step
15
Go to Step
16
Verify repair
Verify repair

16
No
1. Ignition ON.
to voltage.
15
Yes

14
Value(s)

6E1166
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION COIL A

PRIMARY/SECONDARY CIRCUIT MALFUNCTION
D06RX124
Circuit Description
The ignition control circuit provides a zero volt or a 5 volt

signal to the ignition control module. The normal circuit
voltage is zero volts. When the module receives the 5 volt
signal from the engine control module (ECM), it provides
a ground path for the B+ voltage supplied to the ignition
primary coil. When the ECM turns off the 5 volts to the
module, the module will remove the ground path of the
ignition primary coils; causing the magnetic field
produces a voltage in the secondary coils which fires the
spark plug.
The circuit between the ECM and the ignition control
module is monitored for an open circuit, short to voltage,
and short to ground. When the ECM detects a problem in
the ignition control circuit, it will set DTC P0351. DTC


D Poor connection at the ECM Inspect the harness
terminals, and poor terminaltowire connections.
damage; Open circuits, shorts to ground, or shorts to
Voltage. If the harness appears to be OK, observe the
Tech 2 display related to DTC P0351 while moving the
connector and wiring related to the ignition system. A
change in the display will indicate the location of the
fault.
D Ignition ON.
D Output voltage is not equal to 5 volts when output is
ON.
D Output voltage is not equal to 0 volt when output is
OFF.
D Twenty test failures within 40 samples of continuous
circuit monitoring.

Diagnostic Aids

6E1167

DTC P0351 Ignition Coil A Primary/Secondary Circuit Malfunction

Step
Action
Verify Repair
Go to Step 3
Verify Repair
Go to Step 4
Verify Repair
Go to Step 5
Verify Repair
Go to Step 6
Verify Repair
Go to Step 7
Go to Step 8
Verify Repair
Check for an open in the ignition control circuit.

Replace the ignition control module.
Verify repair.
Check the ignition control circuit for a short to voltage.

7
Go to Step 2
1. Ignition OFF.
2. Disconnect the ECM and the ignition control
module.
3. Check the ignition control circuit for a short to
voltage.

6
Go to OBD
System
Check
Check for a faulty connection or damaged terminals at

the ECM connector.

5
No

the ignition control module.

4
Yes

performed?

3
Value(s)
Replace the ECM.

6E1168
DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION COIL B

D06RX124
Circuit Description

spark plug.


fault.
D Ignition ON.
ON.
OFF.
circuit monitoring.

Diagnostic Aids

6E1169

DTC P0352 Ignition Coil B Primary/Secondary Circuit Malfunction

Step
Action
Verify Repair
Go to Step 3
Verify Repair
Go to Step 4
Verify Repair
Go to Step 5
Verify Repair
Go to Step 6
Verify Repair
Go to Step 7
Go to Step 8
Verify Repair

Verify repair.

7
Go to Step 2
1. Ignition OFF.
module.
voltage.

6
Go to OBD
System
Check

the ECM connector.

5
No


4
Yes

performed?

3
Value(s)
Replace the ECM.

6E1170
DIAGNOSTIC TROUBLE CODE (DTC) P0401 EXHAUST GAS RECIRCULATION

(EGR) FLOW INSUFFICIENT DETECTED
D06RX113
Circuit Description
The engine control module (ECM) tests the exhaust gas
recirculation (EGR) system during deceleration by
momentarily commanding the EGR valve to open while
monitoring the manifold absolute pressure (MAP) sensor
signal. When the EGR valve is opened, the ECM monitors
the change in MAP input signal. The ECM compares the
MAP change to a RPM vs. BARO table. When the ECM
interprets the change in MAP to be out of limits, the ECM
will set DTC P0401. The number of test samples required
to accomplish this may vary according to the severity of
the detected flow error.
Normally, the ECM will only allow one EGR flow test
sample to be taken during an ignition cycle. To aid in
verifying a repair, the ECM allows twelve test samples
during the first ignition cycle following a Tech 2 Clear Info
or a battery disconnect. Between nine and twelve
samples should be sufficient for the ECM to determine
adequate EGR flow and pass the EGR test. DTC P0401
is a type A code.

D No TP sensor, VSS, EVAP Purge, IAC, IAT sensor,
MAP sensor, EGR Pintle Position sensor, ECT sensor,
misfire DTCs set.
D Barometric pressure is above 72 kPa.
D Engine coolant temperature is greater than 60C

(140F).
D System voltage is between 11.5 and 16 volts.
D IAC position is steady, changing less than 5 counts.
D A/C clutch status is unchanged.
Start Test
D
D
D
D
D
TP angle is less than 0.8%.

EGR duty cycle is less than 1%.
MAP is steady, changing less than 1 kPa.
Engine speed is between 1200 RPM and 2000 RPM.
Compensated MAP between 10.3 kPa and 49.8 kPa.
Run Test
D Delta MAP is recorded during valve open conditions.
D EGR valve is ramped over a time interval.
Run Test will be aborted if any of the following are true:
D Vehicle speed changes by greater than 16 km/h
(10mph).
D Engine RPM changes by greater than 100 rpm.
D EGR is opened less than 95% of the commanded
amount.
During the Start Test and the Run Test, the EGR is closed
then opened. The associated change in MAP is
compared with the ECMs expected change value. If the

difference between the two values exceeds the ECMs
internal limit, a Diagnostic Trouble Code P0401 will set.
DTC P0401 is a type A code.
NOTE: Several deceleration cycles will be necessary to
run a sufficient number of EGR flow tests to determine a
pass or fail condition.

the first time the fault is detected.
D The MIL will turn OFF after three consecutive ignition
cycles in which the diagnostic runs without a fault.
Conditions for Clearing the DTC

D Diagnostic Trouble Codes can be cleared by using the
Tech 2.
Diagnostic Aids
wiring harness for damage. If the harness appears to
be OK, observe the Actual EGR Position display on the
related to the EGR valve. A change in the display will
D Ensure EGR valve is correctly mounted. See
OnVehicle Service.
condition.
NOTE: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possibly a
plugged catalytic converter) using the Restricted
Exhaust System Check.
6E1171
6E1172
DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected

Step
Action
Go to Step 2
Go to Step 4
Go to Step 3
Verify repair
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 7
Refer to
Diagnostic
Aids
Repair
complete
1. Inspect the exhaust system for modification of

original installed parts or leaks.
2. If a problem was found, repair exhaust system as
necessary.
2. Visually and physically inspect the pintle, valve
passages and the adapter for excessive deposits or
any kind of a restriction.
3. If a problem if found, clean or replace EGR system
components as necessary.
exhaust manifold and the intake manifold.
2. Inspect the manifold EGR ports and the EGR inlet
and outlet pipes for a blockage caused by excessive
deposits or other damage.
3. If a problem is found, correct the condition as
necessary.
Was a condition present that required repair?
Go to OBD
System
Check

6
No

2. Monitor the MAP signal with a Tech 2 while idling.
3. While idling, depress the accelerator pedal about
halfway down and immediately let the engine return
to idle.

5
Yes

performed?
Did the MAP value on the Tech 2 show an immediate

large change?
3
Value(s)

2. Clear Diagnostic Trouble Code and monitor the
Tech 2 System Info Screen while operating the
vehicle as specified in Diagnostic Aids.
6E1173

(EGR) EXCESSIVE FLOW DETECTED
D06RX113
Circuit Description
The Engine Control Module (ECM) closes the Exhaust
Gas Recirculation (EGR) system on engine startup to
test for excessive (any) flow. If the ECM determines that
EGR flow occurred on startup, in two consecutive trips,
then DTC P0402 will set. DTC P0402 is a type B code.

D Intake Air Temperature (IAT) is above 5C (41F).
D Engine RPM is less than 500 RPM.
D EGR Pintle Position if greater than 55 counts.
The above mentioned conditions must be met for 0.6
seconds during engine startup on two consecutive trips.
Diagnostic Aids

OnVehicle Service.
check the exhaust system for blockage (possible a
6E1174
DTC P0402 EGR Excessive Flow Detected

Step
Action
Go to Step 2
Go to
Diagnostic
Aids
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Refer to
Diagnostic
Aids

necessary.
No
Go to OBD
System
Check


4
Yes

performed?

3
Value(s)

necessary.
6E1175

(EGR) CIRCUIT RANGE/PERFORMANCE
D06RX113
Circuit Description
An Exhaust Gas Recirculation (EGR) system is used to
lower Oxides of Nitrogen (NOx) emission levels caused
by high combustion temperatures. It accomplishes this
by feeding small amounts of exhaust gases back into the
combustion chamber. When the air/fuel mixture is diluted
with the exhaust gases, combustion temperatures are
reduced.
A linear EGR valve is used on this system. The linear
EGR valve is designed to accurately supply exhaust
gases to the engine without the use of intake manifold
vacuum. The valve controls exhaust flow going into the
intake manifold from the exhaust manifold through an
orifice with a ECM controlled pintle. The ECM controls
the pintle position using inputs from the Throttle Position
(TP) and Manifold Absolute Pressure (MAP) sensors.
The ECM then commands the EGR valve to operate
when necessary by controlling an ignition signal through
the ECM. This can be monitored on a Tech 2 as the
Desired EGR Position.
The ECM monitors the results of its command through a
feedback signal. By sending a 5 volt reference and a
ground to the EGR valve, a voltage signal representing
the EGR valve pintle position is sent to the ECM. This
feedback signal can also be monitored on a Tech 2 and is
the actual position of the EGR pintle. The Actual EGR
position should always be near the commanded or
If the ECM detects a large difference between the

desired EGR position and actual EGR position, then
Diagnostic Trouble Code P0404 will set. DTC P0404 is a
type B code.

D IAT is greater than 5C (41F).
D EGR commanded ON (Desired EGR Position is
greater than 0%).
D Actual EGR Position differs from Desired EGR
Position by more than 15% for 5 seconds.

D Malfunction Indicator Lamp (MIL) will illuminate the
second time the fault is detected.
D The EGR Valve is disabled.

D Diagnostic Trouble Code(s) can be cleared by using a
Tech 2.
6E1176
Diagnostic Aids
Due to the moisture associated with exhaust systems, the
EGR valve may freeze and stick in colder weather at
times. After the vehicle is brought into a warm shop for
repairs, the valve warms and the problem disappears. By
watching the Actual EGR and Desired EGR Positions on
a cold vehicle with a Tech 2, the fault can be verified
easily. Check the freeze frame data to determine if the
Diagnostic Trouble Code was set when the vehicle was
cold by viewing the Engine Coolant Temperature (ECT).
Test Description
Diagnostic Chart:
the freeze frame and failure records data on the
Tech 2 if applicable. This created an electronic copy
of the data taken when the fault occurred. The
information is then stored on the Tech 2 for later
reference.
2. Commanding the EGR valve open determines
whether the EGR system can control the EGR valve
accurately and if the fault if present.
3. When the EGR valve electrical connector is
disconnected, the Tech 2 should display the Actual
EGR Position as 0%. If is does not, the fault lies
either in the EGR signal circuit or the ECM.
4. A test light, when connected to ground, will glow
dimly when the EGR valve is commanded to 25%,
and brighter as the EGR valve is commanded to
100%. If the test light flashes, check the sensor
ground for an open.
5. An open or poor connection condition may have
caused this Diagnostic Trouble Code to set. Be
sure to check the terminals for being backed out,
improperly formed or damaged, and for poor
tension.
7. The test light will have glowed brightly in the
previous step if the EGR control circuit was shorted
to B+ and the Actual EGR Position on the Tech 2
will display 100%. A test light that did not illuminate,
indicates that the circuit may be open or shorted to
ground.
9. If the EGR valve 5 volt reference is shorted to
voltage, the DVM will read battery voltage and
additional Diagnostic Trouble Codes may be set and
engine performance will be poor.
13. Although the circuitry acted correctly when
checked, a problem may still lie within the terminals
which would not show up in probe type testing. Be
tension.
17. All circuits to the EGR valve are OK at this point.

The fault lies internally in the EGR valve and
therefore must be replaced. Be sure all gasket
material is removed from the EGR mounting
surface. Even a small amount of material may
cause a Diagnostic Trouble Code P0401 to set. For
on vehicle service of the EGR Valve, refer to EGR
Valve.
18. Check the terminals for being backed out,
tension.
19. Clearing the Diagnostic Trouble Codes is a very
important step for this diagnostic. The clearing
function allows the EGR valve to relearn a new
pintle position as the old position was inaccurate
due to the malfunction that caused the Diagnostic
Trouble Code. The Diagnostic Trouble Code must
be cleared with the ignition switch ON, with the
engine OFF or when the engine is idling. If the
ECM sees a EGR command, the new pintle position
will not be learned.
6E1177
DTC P0404 EGR Circuit Range/Performance

Step
Action
Go to Step 5
25%, 50%,
75%, 100%
Go to Step 6
Go to Step 7
Go to Step
19
Go to Step 8
Go to Step 9
Go to Step
10
Go to Step
11
Go to Step
19
Go to Step
12
5V
Go to Step
13
Go to Step
14
Go to Step
19
Go to Step
12
Go to Step
15
Go to Step
16
Go to Step
19
Check the control circuit for a short to voltage and

repair as necessary.
Connect the test light to B+ and again probe the control
circuit.
Does the light illuminate?
12
Go to Step 4
With a Digital Voltmeter (DVM) connected to ground,

probe the 5 V reference circuit.

11
Check the signal circuit for a short to voltage and repair

as necessary.
Is the voltage measured near the specified value?

10
Go to Step 3
With the test light still connected to ground, again probe

the control circuit without commanding the EGR valve
with the Tech 2.

9
Go to Step
19
With the test light still connected to ground, probe the

signal circuit.

8
25%, 50%,
75%, 100%
Repair the open or poor connection in the EGR ground

circuit.

7
Go to Step 2
1. Connect the test light to ground.

2. Probe the EGR control circuit to the EGR valve.
3. Command the EGR valve to the specified values
using a Tech 2.

6
Go to
Powertrain
OBD System
Check
1. Turn the ignition switch ON, with the engine OFF.

2. Disconnect the EGR valve electrical connector.
3. With a test light connected to B+, probe the ground
circuit to the EGR valve.
As the command is raised, does the test light glow

brighter, flash or maintain a steady glow?
5
No

3. Command the EGR valve to the specified values.

4
Yes

performed?
Does the Actual EGR Position follow the Desired EGR

Position?
3
Value(s)
Replace the ECM.

6E1178
DTC P0404 EGR Circuit Range/Performance (Cont'd)

Step
Action
13
Check the EGR ground circuit for a poor connection or

proper terminal tension at the ECM and repair as
necessary.
14
16
17
Go to Step
19
Go to Step
12
Go to Step
19
Go to Step
12
Go to Step
19
Go to Step
18
Go to Step
19
Go to Step
19
Go to Step
12
Verify repair
Go to Step 2
Check the ECM electrical connector for a poor

19

18
Go to Step
17
Check the control circuit for an open or poor connection

at the EGR valve electrical connector and repair as
necessary.
No
Go to Step
19
Check the control circuit for a short to ground and repair

as necessary?
Yes
Check the 5 V reference circuit for a short to voltage

and repair as necessary.
15
Value(s)
1. Using the Tech 2, clear Diagnostic Trouble Codes.

2. Start engine and idle at normal operating
temperature.
3. Operate vehicle within the conditions for setting this
Diagnostic Trouble Code as specified in the
supporting text.
Does the Tech 2 indicate that this diagnostic Ran and
Passed?
6E1179

(EGR) SENSOR CIRCUIT LOW
D06RX113
Circuit Description
reduced.
intake manifold form the exhaust manifold through an
Position should always be near the commanded or
If the ECM detects a continuous short to ground in the

signal circuit or the sensor, then Diagnostic Trouble Code
P0405 will set. DTC P0405 is a type A code.

D The ECM sees less than 0.10 voltage from the EGR
valve sensor.
D A malfunction is present for 10 seconds.

the first time the malfunction is detected.

Tech 2.
6E1180
Diagnostic Aids
Diagnostic Trouble Code set when the vehicle was cold
by viewing the Engine Coolant Temperature (EGR).
Test Description
Diagnostic Chart:
Tech 2 if applicable. This creates an electronic copy
reference.
accurately and if the fault is present.

ground, the DVM will read no voltage and an
additional Diagnostic Trouble Code will be set and
engine performance will be poor. When this circuit
is open, only a Diagnostic Trouble Code P0405 will
be set.
4. Jumping the 5 volt reference circuit to the signal
circuit checks the signal circuit and ECM. The Tech
2 should display the Actual EGR Position as 100% if
the signal circuit and ECM are OK.
6. Although the ECM and circuitry acted correctly in the
previous step, a problem may still lie within the
terminals which would not show up in probe type
testing. Check the terminals for being backed out,
tension.
cause a Diagnostic Trouble Code P0405 to set.
Refer the EGR Valve for on vehicle service of the
EGR valve.
tension.
DTC P0405 EGR Sensor Circuit Low

Step
Action
Go to Step 2
Go to
Powertrain
OBD System
Check
25%, 50%,
75%, 100%
Go to Step
15
Go to Step 3
5V
Go to Step 4
Go to Step 5
100%
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9

ground, probe the 5 V reference circuit to the EGR
valve.
Jumper the EGR valve 5 volt reference circuit to the
signal circuit.
Does the Actual EGR Position display the specified
value?
No

Does the DVM read near the specified value?

4
Yes


Position?
3
Value(s)
1. Connect the test light to B+.

2. Probe the 5 V reference circuit to the EGR valve.
6E1181
DTC P0405 EGR Sensor Circuit Low (Cont'd)

Step
Action
Check the 5 V reference and signal circuits for a poor

connection or proper terminal tension and repair as
necessary.
10
Go to Step
15
Go to Step
13
Go to Step
15
Go to Step
14
Go to Step
15
Go to Step
15
Go to Step
13
Go to Step
15
Go to Step
14
Go to Step
15
Go to Step
15
Go to Step
13
Verify repair
Go to Step 2
Check the affected circuit for a poor connection or

proper terminal at the ECM and repair as necessary.
15
Replace the ECM.

14
Go to Step
12
Check for an open in the EGR valve signal circuit and

13
Go to Step
11
Check for a short to ground in the EGR valve signal

circuit and repair as necessary.
12

11
Go to Step
10
Check for an open in the EGR valve 5 V reference

No
Go to Step
15
Check for a short to ground in the EGR valve 5 V

reference circuit and repair as necessary.
Yes

2. Probe the signal circuit to the EGR valve.
Value(s)

Codes.
temperature.
supporting text.
passed?
6E1182

(EGR) SENSOR CIRCUIT HIGH
D06RX113
Circuit Description
by high combustion temperatures. It accomplishes this by
feeding small amounts of exhaust gases back into the
reduced.
orifice with a ECM controlled pintle. The ECM controls the
pintle position using inputs from the Throttle Position (TP)
and Manifold Absolute Pressure (MAP) sensors. The
ECM then commands the EGR valve to operate when
necessary by controlling an ignition signal through the
ECM. This can be monitored on a Tech 2 as the Desired
EGR Position.

signal circuit or the sensor, then DTC P0406 will set.
Diagnostic Trouble Code P0406 is a type A code.

valve sensor.

D The Malfunction Indicator Lamp (MIL) will illuminate.

consecutive warmup cycles without a fault.
D Diagnostic Trouble Code(s) can be cleared by using
the Tech 2.
Diagnostic Aids

6E1183

DTC P0406 EGR Sensor Circuit High

Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 6
Go to Step 4
Verify repair
less then 5 W
Go to Step 6
Verify repair
0 Volts 0%
Go to Step 9
Using a DVM, check the resistance of the EGR

solenoid.
Go to Step 14
Check the EGR solenoid valve Low circuit, between the

EGR sensor and the ECM, for the following conditions:
D An open circuit
D A short to ground
Go to Step 2
Check the ignition feed circuit, between the EGR

sensor and the Engine IG. fuse, for the following
conditions:
D An open circuit
D A short to ground

6
1. Ignition OFF.
2. Disconnect the Linear Exhaust Gas Recirculation
(EGR) Valve from the wiring harness.
on the ignition feed circuit at the Linear Exhaust Gas
Recirculation (EGR) Valve wiring harness
connector.

5
No
Go to
Powertrain
OBD System
Check

P0406.

4
Yes


Passed?
3
Value(s)
Go to Step 15
1. Ignition OFF.
2. Disconnect the Linear Gas Recirculation (EGR)
Valve from the wiring harness.
4. Observe the EGR value on the Tech 2.
Does the Tech 2 display the following value(s)?
Go to Step 8
6E1184
DTC P0406 EGR Sensor Circuit High (Cont'd)

Step
Action
11
14
15
Verify repair
Go to Step 13
Go to Step 12
about 5 volts
Go to Step 15
1. Ignition OFF.
2. Place a fused jumper wire between the 5 volt
Reference signal circuit and the EGR valve position
feedback circuit at the EGR wiring harness
connector.
Go to Step 10
Go to Step 11
Check the 5 volt signal return (ground) circuit, between

the EGR and the ECM, for the following conditions:
D An open circuit
D A short to ground
13
Go to Step 11
about 5 volts
1. Ignition OFF.
2. Place a DVM between the 5 volt Reference signal
circuit and the 5 volt signal return (ground) circuit at
the EGR wiring harness connector.
12
Verify repair
Check the 5 volt Reference signal circuit, between the

EGR and the ECM, for the following conditions:
D An open circuit
D A short to ground
No
Go to Step 15

on the 5 volt Reference signal circuit at the Linear
Exhaust Gas Recirculation (EGR) Valve wiring
harness connector.
10
Yes
Check the EGR position feedback circuit, between the

D An open circuit
D A short to ground
Value(s)
Verify repair
Go to Step 14
Go to Step 15
5 volts 100%
Replace the Linear Exhaust Gas Recirculation (EGR)

Valve.
Verify Repair.
Replace the ECM.
Verify repair.
6E1185
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP)

CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION
D06RX115
Circuit Description
The Engine Control Module (ECM) controls the

Evaporative Emission (EVAP) Canister Purge Solenoid
Valve through the use of a control (ground) circuit. If the
ECM commands the Purge solenoid to maximum duty
cycle (100%) but the voltage remains High (12 Volts); or, if
the ECM commands the Purge solenoid to minimum duty
cycle (0%) but the voltage remains Low (0 volts), then
DTC P0443 will set. DTC P0443 is a type A code.
D The ECM will illuminate the Malfunction Indicator Lamp

D The ECM will store the conditions that were present
when the DTC was set as Freeze Frame and in Failure
Records.

D Ignition voltage is greater than 10 volts
D Engine run time is greater than 32 seconds
The above mentioned conditions are met and one of the
following two conditions are met for 25 seconds within a
50 seconds test sample:
D ECM senses voltage is High with the EVAP Canister
Purge Solenoid commanded ON.
D ECM senses voltage is Low with the EVAP Canister
Purge Solenoid commanded OFF.

D The ECM will turn OFF the MIL after three consecutive
trips without a reported failure.
D A History DTC will clear after 40 consecutive trips
without a reported failure.
D The DTC can be cleared using the Scan Tools Clear
Info function.
Diagnostic Aids
D Poor connections , or a damaged harness Inspect the
harness connectors for: backedout terminals,
improper mating or damaged terminals. Also check for
open circuits, shorts to ground, and shorts to voltage.
6E1186
DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction
Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 5
Go to Step 4
Verify repair
less than 5 W
Go to Step 6
Go to Step 7
Verify repair
Go to Step 8
Using a DVM, check the resistance of the EVAP

Canister Purge Solenoid.
1. Ignition OFF.
2. Disconnect the Engine Control Module (ECM)
3. Check the EVAP Canister Purge Solenoid control
circuit between the ECM and EVAP Canister Purge
Solenoid for the following conditions:
D A short to ground
D An open circuit
Go to Step 2
Check the suspect circuit between the EVAP Canister

Purge Solenoid connector and the Engine IG. Fuse
for the following conditions:
D A short to ground
D An open circuit

6
1. Ignition OFF.
2. Disconnect the EVAP Canister Purge Solenoid from
the wiring harness connector from the EVAP
on the Engine IG. Fuse pin of the EVAP Canister
Purge Solenoid wiring harness connector.

5
No
Go to OBD
System
Check

P0443.

4
Yes

performed?

Passed?
3
Value(s)
Replace the EVAP Canister Purge Solenoid.

Verify Repair.
Replace the ECM.
6E1187
DIAGNOSTIC TROUBLE CODE (DTC) P0480 COOLING FAN 1 CONTROL

CIRCUIT MALFUNCTION
060RX090
Circuit Description

engagement of the cooling fan Low speed through the
use of a relay and a control circuit. If the ECM commands
the fan to Low speed and then senses that the fan did not
turn ON, or if the ECM commands the fan OFF from Low
speed and then senses that the fan did not turn OFF, the
ECM will set a DTC P0480. DTC P0480 is a type D code.
D The ECM will not turn on the Malfunction Indicator

Lamp.
Records.

D Ignition voltage is greater than 10 volts.
The above conditions are met and one of the following
conditions are met for 25 seconds within a 50 second test
sample:
D ECM sensed voltage is High with the Low Speed Fan
OFF.
OR
D ECM sensed voltage is Low with the Low Speed Fan
ON.

D A history DTC will clear after 40 consecutive trips
Info function.
Diagnostic Aids
D Poor connections or a damaged harness Inspect the
harness connectors for: backed out terminals,
6E1188
DTC P0480 Cooling Fan 1 Control Circuit Malfunction

Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 4
Go to Step 3
12 Volts
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 7
Go to Step 9
Go to Step 8
Check the suspect circuit between the Low Fan Relay

connector and Fuse for the following conditions:
D A short to ground
D An open circuit
1. Ignition OFF.
3. Check the Low Fan Relay control circuit between
the ECM and Underhood Electrical Center for the
following conditions:
D A short to ground
D An open circuit
Go to Step 2
1. Ignition ON.
2. Using a DVM, check for voltage on the ENGINE
FAN Fuse pin of the Low Fan Relay connector.

6
1. Ignition OFF.
2. Remove the Low Fan Relay from the Underhood
Electrical Center.
3. Ignition OFF.
on the ELEC. FAN Fuse pin of the Low fan Relay
connector.

5
No
Go to OBD
System
Check

P0480.

4
Yes

performed?

Passed?
3
Value(s)
1. Reinstall the Low Fan Relay.

2. Using a fused jumper, ground the Low Fan Relay
control circuit at the ECM connector.
Does the fan run at low speed?
6E1189
DTC P0480 Cooling Fan 1 Control Circuit Malfunction (Cont'd)

Step
Action
Yes
No
Replace the Low Fan Relay.

Value(s)
Verify repair
Replace the ECM.

Verify repair.
6E1190

CIRCUIT MALFUNCTION
060RX090
Circuit Description


Lamp.
Records.

sample:
D ECM sensed voltage is High with the High Speed Fan
OFF.
OR
ON.

Info function.
Diagnostic Aids
6E1191

Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 4
Go to Step 3
12 Volts
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 7
Go to Step 9
Go to Step 8

D A short to ground
D An open circuit
1. Ignition OFF.
D A short to ground
D An open circuit
Go to Step 2
1. Ignition ON.

6
1. Ignition OFF.
Electrical Center.
3. Ignition OFF.
connector.

5
No
Go to OBD
System
Check

P0480.

4
Yes

performed?

Passed?
3
Value(s)
1. Reinstall the High Fan Relay.

2. Using a fused jumper, ground the High Fan Relay
Does the fan run at High speed?
6E1192

Step
Action
Yes
No
Replace the High Fan Relay.

Value(s)
Verify repair
Replace the ECM.

Verify repair.
6E1193
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS)

CIRCUIT LOW INPUT
D06RX125
Circuit Description
The vehicle speed sensor has a magnet rotated by the
transmission output shaft. Attached to the sensor is a hall
effect circuit that interacts with the magnetic field created
by the rotating magnet. A 12volt operating supply for the
speed sensor hall circuit is supplied from the meter fuse.
The VSS pulses to ground the 5volt signal sent from the
engine control module (ECM) on the reference circuit.
The ECM interprets vehicle speed by the number of
pulses to ground per second on the reference circuit.
DTC P0502 is a type B code.

D System voltage is between 10 and 16 volts.
When the above conditions are met, one of the following
tests will run:
Decel Test
D MAP is less than 35 kPa.
D Throttle Position is less than 0.8%.
D Engine Speed is between 1500 RPM and 3500 RPM.
The Decel Test will fail if vehicle speed is less than 8 km/h
(5mph).
The Decel Test will pass if vehicle speed is greater than 24

km/h (15mph).
Power Test
D MAP is greater than 50 kPa.
D Throttle Position is between 25% and 70%.
The Power Test will fail if vehicle speed is less than 8 km/h
(5 mph).
The Power Test will pass if vehicle speed is greater than
8km/h (5mph) without any VSS DTCs present, or if
vehicle speed is greater than 49 km/h (30mph) with VSS
Diagnostic Trouble Codes present.

D Base shift logic on RPM only.

without a fault.
6E1194

Diagnostic Aids
D Poor connection at ECM: Inspect harness connectors
for backed out terminals, improper mating, broken

poor terminal to wire connection.
D Damaged harness: Inspect the wiring harness to the
EVAP vent solenoid, the EVAP purge solenoid, and the
fuel tank pressure sensor for an intermittent open or
intermittent short circuit.
DTC P0502 VSS Circuit Low Input

Step
Action
1. Ignition ON, sensor disconnected.

2. Using a Digital Voltmeter (DVM), measure at the
VSS connector between ground and voltage
supply.
10
Go to Step 4
Go to Step 3
Verify repair
Battery
voltage
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 9
10 K W
Verify repair
Go to Step 9
Verify repair
Verify repair
Verify repair
1. Ignition OFF.
2. Check the BLU/BLK wire between the VSS sensor
connector and the ECM for the following conditions:
D An open circuit
D A short to ground
Using a DVM, measure the resistance between the
VSS sensor body and transmission case (ground).
1. Remove the VSS from the transmission case.
2. Visually inspect the VSS for damage.
Does the VSS appear to be OK?
Go to Step 2
Repair the open or short to ground in the VSS sensor

circuit.
Is the resistance above the specified value?

8
Go to OBD
System
Check
Repair the open in the sensor ground circuit.
Was the faulty condition located?

7
No
1. Ignition OFF.
2. Disconnect the VSS connector.
3. Using a test light to battery +, probe the connector
ground wire.
Was the measurement near the specified value?

5
Yes

performed?

3
Value(s)
Replace the VSS.

Replace the ECM.
6E1195
DIAGNOSTIC TROUBLE CODE (DTC) P0506 IDLE CONTROL SYSTEM RPM

LOWER THAN EXPECTED
D06RX112
Circuit Description
speed by adjusting the position of the idle air control (IAC)
motor pintle. The IAC is a bidirectional stepper motor
driven by two coils. The ECM applies current to the IAC
coils in steps (counts) to extend the IAC pintle into a
passage in the throttle body to decrease air flow. The
ECM reverses the current to retract the pintle, increasing
air flow. This method allows highly accurate control of idle
speed and quick response to changes in engine load. If
the ECM detects a condition where too low of an idle
speed is present and the ECM is unable to adjust idle
speed by increasing the IAC counts, DTC P0506 will set,
indicating a problem with the idle control system. DTC

D No intrusive tests being run.
D Engine run time is more than 125 seconds.
D No TPS, VSS, ECT, EGR, MAP, IAT, low voltage, fuel
system or canister purge Diagnostic Trouble Codes
are set.
D Barometric pressure is greater than 72.7 kPa.
D Canister purge duty cycle is above 0%.
D Engine coolant temperature (ECT) is above 50C
(122F).
D Intake air temperature above 40C (40F).
D
D
D
D
D
MAP is less than 60 kPa.

Ignition voltage is between 9.5 volts and 16 volts.
The throttle is closed.
All conditions are met for 10 seconds.
Engine speed is at least 100 RPM lower than desired
idle, based upon ECM expectations.

fault is detected.

Diagnostic Aids
D Poor connection at ECM or IAC motor Inspect
damaged terminals, and poor terminaltowire
connection.
6E1196

damage; shorts to ground, shorts to battery positive,
and open circuits.
D Restricted air intake system Check for a possible
collapsed air intake duct, restricted air filter element, or
foreign objects blocking the air intake system.
D Throttle body Check for objects blocking the IAC
passage or throttle bore, excessive deposits in the IAC
passage and on the IAC pintle, and excessive deposits
in the throttle bore and on the throttle plate.
D Large vacuum leak Check for a condition that causes

a large vacuum leak, such as an incorrectly installed or
faulty PCV valve or brake booster hose disconnected.
condition.
DTC P0506 Idle Control System RPM Lower Than Expected

Step
Action
Go to Step 2
Go to other
Diagnostic
Trouble Code
first
Go to Step 3
+/50 RPM
No trouble
found. Go to
Diagnostic
Aids
Go to Step 4
Verify repair
Go to Step 5
Refer to
appropriate
section for
onvehicle
service
Go to Step 6
Verify repair
Go to Step 7

2. Turn all accessories OFF (A/C, rear defroster, etc.)
3. Using a Tech 2, command RPM up to 1500, down to
500, and then up to 1500 while monitoring Engine
Speed on the Tech 2.
1. Check the following circuits for an open, short to

voltage, short to ground, or poor connection at the
PCM:
D IAC A low
D IAC A high
D IAC B low
D IAC B high
Visually/physically inspect for the following conditions:
D Throttle body tampering (adjustment screw plug
removed).
D Restricted air intake system. Check for a possible
collapsed air intake duct, restricted air filter
element, or foreign objects blocking the air intake
system.
D Throttle body. Check for objects blocking the IAC
passage or throttle bore, excessive deposits in
the IAC passage and on the IAC pintle, and
excessive deposits in the throttle bore and on the
throttle plate.
Do any of the above require a repair?
No
Go to OBD
System
Check
Are any other Diagnostic Trouble Codes set?

5
Yes

performed?
Does the Engine Speed remain within the specified

value of Desired Idle for each RPM command?
4
Value(s)
1. Check for a poor connection at the IAC harness

connector.
2. If a problem is found, replace faulty terminals as
necessary.
6E1197
DTC P0506 Idle Control System RPM Lower Than Expected (Cont'd)
Step
Action
No
Go to Step 8
Go to Step 9
Verify repair
Verify repair
Replace the IAC valve.

Yes
Using a Digital Voltmeter (DVM), check the IAC valve

solenoids (A and B) for the following conditions:
D An open circuit
D A short to ground (the IAC body)
D A short together
Value(s)
Replace the ECM.

6E1198

HIGHER THAN EXPECTED
D06RX112
Circuit Description
the ECM detects a condition where too high of an idle
speed by increasing the IAC counts, Diagnostic Trouble
Code P0507 will set, indicating a problem with the idle
control system. DTC P0507 is a type B code.

system or canister purge DTCs are set.
(122F).
D Ignition voltage is between 9.5 volts and 16 volts.
D The throttle is closed.
D All conditions are met for 10 seconds.

D Engine speed is at least 200 RPM lower than desired
idle, based upon PCMs expectations.

D The PCM will illuminate the malfunction indicator lamp
fault is detected.
D The PCM will store conditions which were present

D The PCM will turn the MIL OFF on the third consecutive
without a fault.
Diagnostic Aids
D Poor connection at PCM or IAC motor Inspect
connection.

and open circuits.
D Vacuum leak Check for a condition that causes a
vacuum leak, such as disconnected or damaged
hoses, leaks at EGR valve and EGR pipe to intake
manifold, leak at the throttle body, a faulty or incorrectly
installed PCV valve, leaks at the intake manifold, etc.
D Throttle body Check for sticking throttle plate. Also
inspect the IAC passage for deposits or objects which
6E1199
will not allow the IAC pintle to fully extend or properly

seat.
reviewing the Failure Records vehicle mileage since the
condition.
DTC P0507 Idle Control System RPM Higher Than Expected

Step
Action
Go to Step 2
Go to other
Diagnostic
Trouble Code
first
Go to Step 3
+/50 RPM
No trouble
found. Go to
Diagnostic
Aids
Go to Step 4
Verify repair
Go to Step 5
Refer to
appropriate
section for
onvehicle
service
Go to Step 6
Verify repair
Go to Step 7


PCM:
D IAC A low
D IAC A high
D IAC B low
D IAC B high
D Vacuum leaks
removed).
D Throttle plate or throttle shaft for binding.
D Accelerator and cruise control cables for being
misadjusted or for binding.
D Faulty, missing, or incorrectly installed PCV
valve.
No
Go to OBD
System
Check

5
Yes

performed?

4
Value(s)

connector.
necessary.
6E1200
DTC P0507 Idle Control System RPM Higher Than Expected (Cont'd)
Step
Action
No
Go to Step 8
Go to Step 9
Verify repair
Verify repair

Yes

D An open circuit
D A short together
Value(s)
Replace the ECM.

6E1201
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
D06RX127
Circuit Description
The engine control module (ECM) monitors the system

voltage on the ignition feed terminals to the ECM. A
system voltage Diagnostic Trouble Code will set
whenever the voltage is above a calibrated value. DTC

without a fault.
Diagnostic Aids
D Ignition ON.
D System voltage is above 16.
Check for a faulty charging system components.

D The ECM will not illuminate the malfunction indicator
lamp (MIL) for the first time the malfunction is detected.
D The ECM will store as Failure Records conditions
which were present when the Diagnostic Trouble Code
was set. This information will not be stored as Freeze
Frame data.
6E1202
DTC P0563 System Voltage High

Step
Action
Go to Step 2
16 V
Go to Step 3
Go to Step 4
16 V
Replace
battery
Go to Step 4
16 V
Go to Step 5
Go to Step 6
Verify repair
Verify repair
1. Turn OFF all the accessories.

3. Select the ignition voltage parameter on the data
list.
4. Start the engine and raise the engine speed to 2000
RPM.
Replace or repair the generator (see Charging
System).
Is a malfunction present?
Go to OBD
System
Check
1. Charge the battery and clean the battery terminals.

2. Clean the battery ground cable connection if
corrosion is indicated.
Is the voltage above the specified value?

5
No

battery voltage at the battery.
Is the battery voltage greater than the specified value?

4
Yes

performed?

3
Value(s)
Replace the ECM.

6E1203
DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE

MEMORY CHECK SUM ERROR
014RX002
Circuit Description
The engine control module (ECM) used in this vehicle

utilizes an electrically erasable programmable readonly
memory (EEPROM). The EEPROM contains program
information and the calibrations required for engine,
transmission, and powertrain diagnostics operation.
Unlike the PROM used in past applications, the EEPROM
is not replaceable.
If the ECM detects a check sum error then DTC P0601 will
set. DTC P0601 is a type A code.

(MIL) the first time the malfunction is detected.
when the Diagnostic Trouble Code was set in the
Failure Records data only.

D The ECM detects an internal program fault (check sum
error).

without a fault.
DTC P0601 Internal Control Module Memory Check Sum Error

Step
Action
Value(s)
Yes

performed?
No
Go to Step 2
Go to OBD
System
Check
Verify repair
Replace the ECM.

6E1204

PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE
D06RX114
Circuit Description
signal voltage to the ECM varies from below 2 volts at idle
(low manifold pressure) to above 4 volts with the ignition
ON, engine not running or at wideopen throttle (high
manifold pressure).
from the MAP sensor, RPM, the CKP sensor, and the
Intake Air Temperature (IAT) sensor. The MAP sensor is
the main sensor used in this calculation, and measuring
engine load is its main function.
The MAP sensor is also used to determine manifold
pressure changes while the linear EGR flow test
diagnostic is being run, to determine engine vacuum level
for some other diagnostics and to determine barometric
pressure (BARO). Refer to Diagnostic Trouble Code 401.
The ECM compares the MAP sensor signal to a
calculated MAP based on throttle position and various
other engine load factors. If the ECM detects a MAP
signal that is intermittently above the calculated value,
type D code.

D No TP sensor Diagnostic Trouble Codes are present.
D Throttle angle is below 2.7% if engine speed is below

1000 RPM.
D Throttle angle is below 10% if engine speed is above
1000 RPM.
D The MAP sensor indicates an intermittent manifold
absolute pressure above 90 kPa for a total of
approximately 5 seconds over a 16second period of
time.

lamp (MIL).
when the Diagnostic Trouble Code was set as Failure
Records data only. This information will not be stored
as Freeze Frame data.

without a fault.
Diagnostic Aids
D Leaking or plugged vacuum supply line to the MAP
sensor.
D Inspect ECM harness connectors for backedout
terminals, improper mating, broken locks, improperly

formed or damaged terminals, and poor
D Inspect the wiring harness for damage; shorts to
ground, shorts to battery positive, and open circuits. If
6E1205
the harness appears to be OK, observe the MAP

display on the Tech 2 while moving connectors and
wiring harnesses related to the sensor. A change in the
display will indicate the location of the fault.
condition.
DTC P1106 MAP Sensor Circuit Intermittent High Voltage

Step
3
4
Action
Are Diagnostic Trouble Code P0463, and/or P1121

also set?
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step
10
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids
Verify repair
Verify repair
Check for a poor sensor ground circuit terminal

Check for an intermittent open or a faulty splice in the
Replace the faulty harness connector terminal for the

10
Go to DTC
P0108 chart
first
Check for an intermittent short to voltage on the 5 volt

reference circuit between the ECM and the following
components:
D Fuel Tank Vapor Pressure Sensor
D TP sensor
Was a problem found? (if no, start with the diagnosis

chart for other sensors in the circuit and see if 5V
returns.)
9
Go to Step 2
Check the MAP signal circuit between the MAP sensor

connector and the ECM for an intermittent short to
voltage.

8

connection at the MAP sensor.

7
No
Go to OBD
System
Check
Is DTC P0108 also set?

6
Yes

performed?

5
Value(s)
Locate and repair the intermittent open/short circuit in

the wiring harness as necessary.
6E1206

PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE
D06RX114
Circuit Description
4 volts with the ignition ON, engine not running or at
used on the 2.2l engine. This is calculated using inputs
from the MAP sensor, the CKP sensor, and the Intake Air
load is its main function.
pressure (BARO). Refer to DTC P0401.
signal that is intermittently below the calculated value,
DTC P1107 will set. DTC P1107 is a type D code.

D Throttle angle is below 0% if engine speed is less than

1300 RPM.
1300 RPM.
time.

lamp (MIL).

without a fault.
Diagnostic Aids

6E1207

fault.
condition.
DTC P1107 MAP Sensor Circuit Intermittent Low Voltage

Step
Action
Check for a poor 5 volt reference circuit terminal

Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step
10
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids
Verify repair
Verify repair
Replace the faulty harness connector terminal for the 5

volt reference circuit and/or the MAP signal circuit as
necessary.
10
Go to Step 3
Check for an intermittent open or a faulty splice in the 5

volt reference circuit.
returns.)
Go to DTC
P0107 chart
first
Check for a poor 5 volt reference terminal connection at

the ECM.
Go to Step 2
Check for an intermittent short to ground on the 5 volt

components:
D TP sensor

connector and the PCM for an intermittent open or
short to ground.
No
Go to OBD
System
Check
Is DTC P1122 and/or P0462 also set?
Yes

performed?
Value(s)
Repair the intermittent open/short circuit in the wiring

harness as necessary.
6E1208

SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE
D06RX117
Circuit Description
intermittently detects an excessively high signal voltage
on the intake air temperature sensor signal circuit. DTC
P1111 is a type D code.

D
D
D
D
D

Engine coolant temperature is above 60C (140F).
Calculated air flow is less than 20g/second.
IAT signal voltage indicates an intake air temperature
intermittently less than 39C (38F) (4.94 volts) for
approximately 2.5 seconds over a 25second period of
time.

D The ECM will substitute a default value for intake air
temperature.

when the Diagnostic Trouble Code set as Failure
D Diagnostic Trouble Code P1111 does not illuminate the
MIL.

Diagnostic Aids

condition.

C

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E1209
6E1210
DTC P1111 IAT Sensor Circuit Intermittent High Voltage

Step
Action
Go to DTC
P0113 chart
first
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Refer to
Diagnostic
Aids
1. Check the IAT signal circuit between the IAT sensor

connector and the ECM for an intermittent open.
voltage.
1. Check for a poor sensor ground circuit terminal
Go to Step 2
1. Check for a poor IAT signal circuit terminal

connection at the IAT sensor.

7


6
No
Go to OBD
System
Check

5
Yes

performed?

4
Value(s)
1. Check for an intermittent open or a faulty splice in

the sensor ground circuit.
6E1211

SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE
D06RX117
Circuit Description
circuit. If the intake air is warm, the sensor resistance
becomes lower, causing the ECM to monitor a lower
voltage. Diagnostic Trouble Code P1112 will set when the
ECM intermittently detects an excessively low signal
voltage on the intake air temperature sensor signal
circuit. DTC P1112 is a type D code.

D IAT signal voltage is greater than 148C (298F)
(about 0.10 volt) for a total of 2.5 seconds over a

lamp (MIL).

temperature.

without a fault.
Diagnostic Aids
6E1212

condition.

C
Test Description
Diagnostic Chart.
3. If DTC P1112 can be repeated only by duplicating
the Failure Records conditions, refer to the
Temperature vs. Resistance Value Chart.
The chart may be used to test the IAT sensor at
replace the IAT sensor.

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P1112 IAT Sensor Circuit Intermittent Low Voltage

Step
Action
Value(s)
Yes

performed?
Go to Step 2
Go to OBD
System
Check
Go to DTC
P0112 chart
first
Go to Step 3
Verify repair
Refer to
Diagnostic
Aids

connector and the PCM for an intermittent short to
ground.
No
6E1213

TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE
D06RX117
Circuit Description
engine control module (ECM) applies a voltage (about 5.0
to 2.0 volts. If the ECM detects an ECT signal that is
intermittently below the range of the ECT sensor,
type D code.

D Engine run time longer than 2 minutes.
D The ECT sensor signal is intermittently greater than
150C (302F) (about 0.10 volt) for a total of 10
seconds over a 100second period.

lamp (MIL).


without a fault.
Diagnostic Aids
condition.
6E1214

C

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P1114 ECT Sensor Circuit Intermittent Low Voltage

Step
2
3
Action
Value(s)
Yes

performed?
Go to Step 2
Go to OBD
System
Check
Go to DTC
P0117 first
Go to Step 3
Verify repair
Refer to
Diagnostic
Aids

1. Check the ECT signal circuit between the ECT
sensor connector and the ECM for an intermittent
short to ground.
No
6E1215

TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE
D06RX117
Circuit Description
to 2.0 volts. If the PCM detects an ECT signal that is
intermittently above the range of the ECT sensor,
Diagnostic Trouble Code P1115 will set. Diagnostic
Trouble Code P1115 is a type D code.

D Engine run time longer than 180 seconds.
39C (38F) (4.94 volts) for a total of 10 seconds

lamp (MIL).


without a fault.
Diagnostic Aids
condition.
6E1216

C

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E1217
DTC P1115 ECT Sensor Circuit Intermittent High Voltage

Step
2
3
Action
Go to DTC
P0118 first
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Refer to
Diagnostic
Aids

open.
short to voltage.
Go to Step 2
1. Check for a poor ECT signal circuit terminal

connection at the ECT sensor.

7


6
No
Go to OBD
System
Check

5
Yes

performed?

4
Value(s)

6E1218

D06RX118
Circuit Description

signal that changes relative to the throttle blade angle.
The signal voltage will vary from less than 1 volt at closed
throttle to more than 4 volts at wide open throttle (WOT).
(ECM) for fuel control and for most of the ECM controlled
outputs. If the ECM detects a TP signal that is
intermittently above the range of the TP sensor,
a type D code.

without a fault.

D TP sensor indicates a throttle position voltage
intermittently greater than 4.88 volts for a total of 0.15
seconds over a 1.5second period.

lamp (MIL).
Diagnostic Aids
D Poor connection at ECM Inspect the harness
components itself.

diagnostic test last failed may help to determine how often
6E1219

condition.
DTC P1121 TP Sensor Circuit Intermittent High Voltage

Step
Action

connection at the TP sensor.
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step
10
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids
Verify repair
Verify repair

10
Go to DTC
P0123 first

returns.)
Check for a poor sensor ground terminal connection at

the ECM.
Go to Step 2

components:
D MAP Sensor
Check the TP signal circuit between the TP sensor

voltage.
No
Go to OBD
System
Check
Is Diagnostic Trouble Code P0123 also set?

Yes

performed?
Value(s)
Repair intermittent open/short circuit in wiring harness

as necessary.
6E1220

D06RX118
Circuit Description

a type D code.

without a fault.

D TP sensor indicates a throttle position signal
intermittently less than 0.10 volt for a total of 0.15

lamp (MIL).
Diagnostic Aids
components itself.

6E1221

condition.
DTC P1122 TP Sensor Circuit Intermittent Low Voltage

Step
Action
Check for a poor 5 volt reference circuit or TP signal

circuit terminal connection at the TP sensor.
Go to DTC
P0122 first
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step 9
Go to Step 8
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids

returns.)

Go to Step 2

components:
D MAP Sensor

ground.
Replace the faulty harness connector terminal(s) for

the 5 volt reference circuit and/or the TP signal circuit
as necessary.
Repair
complete. If a
driveability
symptom still
exists, refer
to Symptoms.
10
No
Go to OBD
System
Check

Yes

performed?
Value(s)

as necessary.
Repair
complete. If a
driveability
symptom still
exists, refer
to Symptoms.
6E1222
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SYSTEM LEAN DURING

ACCELERATION
D06RX119
Circuit Description
The engine control module (ECM) internal circuitry can

identify if the vehicle fuel system is capable of supplying
adequate amounts of fuel during heavy acceleration
(power enrichment). The ECM monitors the voltage of the
oxygen sensor during power enrichment. When a power
enrichment mode of operation is requested during
Closed Loop operation (by heavy acceleration), the
ECM will provide more fuel to the engine. Under these
conditions the ECM should detect a rich condition (high
oxygen sensor voltage). If this rich exhaust is not
detected at this time, a Diagnostic Trouble Code P1171
will set. A plugged fuel filter or restricted fuel line can
prevent adequate amounts of fuel from being supplied
during power enrichment mode. DTC P1171 is a type A
code.

Diagnostic Aids
D
D
D
D

While in power enrichment mode the oxygen sensor
voltage remains below 400 mV for 3 seconds.

without a fault.
D A restricted fuel filter or fuel line can supply adequate

amounts of fuel at idle, but may not be able to supply
enough fuel during heavy acceleration.
D Water or alcohol in the fuel may cause low HO2S
voltage during acceleration.
D Check for faulty or plugged fuel injector(s).
D Check for low fuel.
Test Description
Diagnostic Chart:
4. When the engine is idling or at steady cruise, the
HO2S voltage should vary from between
approximately 100 mV to 900 mV. During power
enrichment mode, more fuel is needed and the
HO2S voltage should rise above 447 mV. This step
checks to see if the HO2S is operating properly.
5. Wrap a shop towel around the fuel pressure
connector to absorb any small amount of fuel
leakage that may occur when installing the gauge.
Ignition ON, pump pressure should be 235320
kPa.
7. Add Caution: Use correct pliers so damage to fuel
lines will not occur.
6E1223
6E1224
DTC P1171 Fuel System Lean During Acceleration

Step
Action
Go to Step 2
Go to
component
DTC charts
Go to Step 3
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Step 5
Go to OBD
System
Check
Go to Step 6
Verify repair
Go to Step 7
414 kPa 325

kPa
Go to
Diagnostic
Aids
Go to Step 8
Verify repair
Are any componentrelated Diagnostic Trouble Codes

set?
1. Check the vehicles fuel tank for an adequate
amount of fuel.
2. Add fuel to the vehicles fuel tank if the tank is almost
empty.
1. Using a Tech 2, observe HO2S 1 voltage while
running warm engine(75C95C [167F203F])
at 1200 RPM.
2. HO2S 1 voltage should vary within the specified
range.
1. Disconnect the fuel pump relay and crank the

engine to relieve the fuel pressure.
2. Install the fuel pressure gauge.
temperature.
4. Disconnect the vacuum line going to the fuel
pressure regulator.
With the engine running, is the fuel pressure within the
specified range?
284 325 kPa
Check for restricted fuel lines or restricted inline filter.

1.
2.
3.
4.
Ignition OFF.
Ignition ON, engine OFF.
Using a Tech 2, enable the fuel pump to operate.
Using pliers, slowly close the return line (do not
exceed the first specified value).
Using the pliers, can the fuel pressure be manipulated

to exceed the second specified value?
8
No
Go to OBD
System
Check
Does the voltage toggle back and forth within the

specified range?
100 900 mV
5
Yes

performed?
Was fuel added to the vehicles fuel tank?

4
Value(s)
Check for:
D Faulty fuel pump
D Restricted fuel pump strainer (sock)
D Incorrect fuel pump
D Incorrect fuel being used
D Hot fuel
6E1225
DIAGNOSTIC TROUBLE CODE (DTC) 1404 EXHAUST GAS RECIRCULATION

(EGR) CLOSED VALVE
D06RX113
Circuit Description
The engine control module (ECM) monitors the exhaust
gas recirculation(EGR) valve pintle position input to
ensure that the valve responds properly to commands
from the ECM to detect a fault if the pintle position sensor
and control circuits are open or shorted. If the ECM
detects a pintle position signal voltage below the normal
range of the pintle position sensor, or a signal voltage that
is not within a tolerance considered acceptable for proper
EGR control system operation, the ECM will set a DTC
P1404.

D IAT is above 5C (41)
D EGR actual position is 16 counts below the EGR low
threshold for at least 6.3 seconds.

fault is detected.


warm up cylcles without a fault.
Diagnostic Aids
D Excessive deposits on EGR valve pintle or seat
Check for deposits that may interfere with the EGR
valve pintle extending completely or cause the pintle to
stick.
be OK, observe the EGR actual position display on the
NOTE: If the EGR valve show signs of excessive heat,
6E1226
DTC P1404 EGR Closed Valve

Step
Action
Go to Step 3
12 volts
Go to Step 6
Go to Step 4
Verify repair
less than 5 W
Go to Step 6
Verify repair
0 volts 0%
Go to Step 9
Verify repair
Go to Step 14

D An Open circuit
D A short to ground
Go to Step 15
1. Ignition OFF.
Refer to
Diagnostic
Aids

solenoid.

7
Go to Step 2
Check the Ignition feed circuit, between the EGR

conditions:
D An Open circuit
D A short to ground

6
1. Ignition OFF.
on the Ignition feed circuit at the Linear Exhaust Gas
connector.

5
No
Go to OBD
System
Check

2. Review and record the Tech 2 Failure Records data,
the clear the DTCs.
conditions noted.
P1404.

4
Yes

performed?

Passed
3
Value(s)

D An Open circuit
D A short to ground
Go to Step 8
Go to Step 15
6E1227
DTC P1404 EGR Closed Valve (Cont'd)

Step
Action

harness connector.
10
14
15
Verify repair
Go to Step 13
Go to Step 12
about 5 volts
Go to Step 15
1. Ignition OFF.
reference signal circuit and the EGR valve position
connector.
Does the Tech 2 display the following value?
Go to Step 10
Go to Step 11

D An Open circuit
D A short to ground
13
Go to Step 11
No
about 5 volts
1. Ignition OFF.
2. Place a DVM between the 5 volt reference signal
12
Yes
Check the 5 volt reference signal circuit, between the

D An Open circuit
D A short to ground
11
Value(s)
Verify repair
Go to Step 14
Go to Step 15
5 volts 100%

Value.
Verify repair.
Replace the ECM.
Verify repair.
6E1228
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM UNEXPECTED RESET
014RX002
The engine control module (ECM) monitors unexpected

ECM reset. This will not turn on MIL light on, only records
code DTC P1625.

warm-up cycles have occurred without a fault.
D DTC P1625 can be cleared by using the Tech 2 Clear
Info function or by disconnecting the ECM battery
feed.
Diagnostic Aids
Circuit Description
D Clock or COP (Computer Operating Properly) reset.

lamp (MIL).
when the DTC was set as Failure Records only. This
information will not be stored as Freeze Frame data.

D The ECM will turn the MIL OFF on the third
consecutive trip cycle during which the diagnostic has
been run and the fault condition is no longer present.

D P1625 alone stored does not need diagnosis. Clear
DTC code.
NOTE: DTC P1625 is a DTC to record a ECM reset
history. If DTC P1625 is not reset and no engine
abnormality is found after clearance of DTC, it is not
necessary to do any farther processing.
6E1229
DTC P1625ECM Unexpected Reset

Step
Action
Value(s)
Was the On-Board Diagnostic (OBD) System Check

performed?
1.
2.
3.
4.
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Go to Step 4
Go to
Diagnostic
Aids
Verify repair
Ignition is On.
Install the Tech 2.
Start the engine at let it Idle.
On the Tech 2, select DTC info.

3
1.
2.
3.
4.
Ignition is On.
Clear DTC P1625 by using the Tech 2 Clear Info.
No
Go to OBD
System
Check
Yes
1. Check for aftermarket electronics, such as

transceiver stereos, and anti theft devices, they
may radiate EMI into the control system if they are
improperly installed. (This may cause a false
sensor reading and turn on the MIL.)
6E1230
DIAGNOSTIC TROUBLE CODE (DTC) P1627 PCM A/D CONVERSION

MALFUNCTION
014RX002
Circuit Description
The Engine Control Module (ECM) monitors the 5 volt

reference signal when the Ignition is ON. If the ECM
senses an Analog to Digital (A/D) conversion error within
the ECM, then DTC P1627 will set. DTC P1627 is a type A
code.
trip without a reported failure.
Info function.

D Any A/D DTCs set.

Records.
Diagnostic Aids
D Poor connections, or a damaged harness Inspect the
improper mating or damaged terminals. Also, check for
6E1231
DTC P1627 PCM A/D Conversion Malfunction

Step
Action
No
Go to Step 2
Go to OBD
System
Check
Refer to
Diagnostic
Aids
Go to Step 3
Verify repair
Go to Step 4

P1627.
Check the suspect 5 volt reference circuit(s) for the

D A short to ground
D An open circuit
Yes

performed?

Passed?
3
Value(s)
Replace the ECM.
6E1232
DIAGNOSTIC TROUBLE CODE (DTC) P1635 5 VOLT REFERENCE VOLTAGE

CIRCUIT MALFUNCTION
014RX002
Circuit Description

senses the 5 volt reference signal circuit is above 5.12
volts or below 4.88 volts, then DTC P1635 will set. DTC

Records.
D Ignition voltage is greater than 6.3 volts.

following two conditions are met for 5 seconds within a 10
second test sample:
D ECM senses the 5 volt reference signal circuit is above
5.12 volts.
OR
D ECM senses the 5 volt reference signal circuit is below
4.88 volts.
Info function.
Diagnostic Aids
Poor connections, or a damaged harness Inspect the
harness connectors for: backedout terminals, improper
mating or damaged terminals. Also, check for open
circuits, shorts to ground, and shorts to voltage.
6E1233
DTC P1635 5 Volt Reference Voltage Circuit Malfunction

Step
Action
No
Go to Step 2
Go to OBD
System
Check
Refer to
Diagnostic
Aids
Go to Step 3
Verify repair
Go to Step 4

P1635.

D A short to ground
D An open circuit
Yes

performed?

Passed?
3
Value(s)
Replace the ECM.
6E1234
DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM OUTPUT CIRCUIT FAULT
014RX002
Circuit Description
Output driver modules (ODMs) are used by the engine

control module(ECM) to turn ON many of the current
driven devices that are needed to control various engine
and transmission functions. Each ODM is capable of
controlling up to 11 separate outputs by applying ground
to the device which the ECM is commanding ON.
ODMs have the capability of diagnosing each output
circuit individually. DTC P1640 set indicates an improper
voltage level has been detected on an ODM output.
If the ECM detects an open circuit condition and a shorted
to voltage circuit condition on the same circuit at the same
time, then DTC P1640 will set. DTC P1640 is a type D
code.

warm up cycles occur without a fault.

D Ignition ON.
D Above conditions occur for at least 2.5 seconds.
D The ECM detects an open circuit condition and a
shorted to voltage circuit condition on the same circuit
at the same time.

lamp (MIL).
Diagnostic Aids
damage. If the harness appears to be OK, disconnect
the ECM, turn the ignition ON and observe a voltmeter
connected to the MIL driver circuit at the ECM harness
connector while moving connectors and wiring
harnesses relates to the MIL. A change in voltage will
D Reviewing the Failure Records vehicle mileage since
the diagnostic test last failed may help determine how
often the condition that caused the DTC to be set
occurs. This may assist in diagnosing the condition.
The following ECM pins are controlled by

output driver modules (ODMs):
D
D
D
D
A13
A14
B14
B16
MIL LAMP
Rear Defogger
A/C Clutch
EVAP Canister Parge Solenoid

D
D
D
D
D
A1 2 Low Fuel
C10 Tacho Meter
C11 Fuel Gauge
C13 Fan Low
C12 Fan High
Test Description
Diagnostic Chart.
6E1235
2. The Tech 2 Driver Module Status indicates the ECM

pin that is affected.
9. The Tech 2 may indicate short circuit even when
the problem is an open circuit. The cause of an
open circuit may be in the component itself.
11. A short to ground on the ignition side of the
component will blow the fuse. Since the fuse was
checked in Step 2, a short to ground would be
between the affected component and the ECM.
DTC P1640 Output Driver Module (ODM) A Fault

Step
Action
Value(s)
Yes
Go to Step 2
Go to OBD
System
Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
Was the Lamp of circuit for Check Engine?
Go to Step 7
Go to Step 13
1. Leave the ECM connector for the lamp driver circuit

disconnected.
2. Ignition ON.
3. Using a DVM, check the voltage at the ECM
connector for the affected lamp driver circuit.
B+
Go to Step 15
Go to Step 8
Go to Step 10
Go to Step 9
Verify repair
Go to Step 11
Go to Step 12
Verify repair

performed?
No
Check the fuse for the driver circuit that was shown as
faulty.
Was the fuse blown?
1. Check for a short to ground between the fuse and

the affected component.
2. Replace the fuse after making any necessary
repairs.

driver circuit.
Is there any damage to the ECM pin or connector?
Repair the damaged pin or terminal.

8
1. Ignition ON.
2. Check for battery voltage at the fuse for the affected
lamp circuit.
Was battery voltage available at the fuse?
Repair the open circuit between the ignition switch and

the fuse.
10
1. Ignition OFF.
driver terminal.
3. Connect an ohmmeter between a good ground and
the ECM connector for the affected driver.
Did the ohmmeter indicate continuity?
11
Repair the short to ground between the affected

component and its ECM driver terminal.
6E1236
DTC P1640 Output Driver Module (ODM) A Fault (Cont'd)

Step
Action
12
Repair the open circuit between the fuse and the ECM
driver terminal for the affected circuit.
13
No
Verify repair
B+
Go to Step 15
Go to Step 14
Go to Step 10
Go to Step 9
Verify repair
1. Run the engine at idle.

circuit.
15
Yes
1. Connect the ECM.

2. Start the engine and let it idle.
3. Backprobe the affected terminal at the ECM with a
DVM.
14
Value(s)
Replace the ECM.

SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the OnBoard
Diagnostic (OBD) System Check and verify all of the
following items:
D The engine control module (ECM) and malfunction
indicator lamp (MIL)(Check Engine lamp) are
operating correctly.
D There are no DTC(s) stored.
D Tech 2 data is within normal operating range. Refer to
Typical Scan Data Values.
D Verify the customer complaint and locate the correct
symptom in the table of contents. Perform the
procedure included in the symptom chart.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable
time. This check should include the following items:
D ECM grounds for cleanliness, tightness and proper
location.
D Vacuum hoses for splits, kinks, and proper
connections, as shown on the Vehicle Emission
Control Information label. Check thoroughly for any
type of leak or restriction.
D Air intake ducts for collapsed or damaged areas.
D Air leaks at throttle body mounting area, manifold
absolute pressure (MAP) sensor and intake manifold
sealing surfaces.
D Ignition component for cracking, hardness, and
carbon tracking.
D Wiring for proper connections, pinches and cuts.
INTERMITTENTS
An intermittent problem may or may not turn on the malfunction indicator lamp (MIL) or store a Diagnostic
Trouble Code. 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:
D Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
D Improperly formed or damaged terminal.
D All connector terminals in the problem circuit should
be carefully checked for proper contact tension.
D Poor terminaltowire 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 a Tech 2 to help detect intermittent conditions.
6E1237
The Scan Tools have several features that can be used to

locate an intermittent condition. Use the following feature
to find intermittent faults:
D Using a Scan Tools Freeze Frame buffer or Failure
Records buffer can aid in locating an intermittent
condition. Review and record the information in the
freeze frame or failure record associated with the
intermittent DTC being diagnosed. The vehicle can
be driven within the conditions that were present
when the DTC originally set.
To check for loss of diagnostic code memory, disconnect
the MAP sensor and idle the engine until the MIL (Check
Engine lamp) comes on. Diagnostic Trouble Code P0107
should be stored and kept in memory when the ignition is
turned OFF. If not, the ECM is faulty. When this test is
completed, make sure that you clear the Diagnostic
Trouble Code P0107 from memory.
An intermittent MIL (Check Engine lamp) with no stored
Diagnostic Trouble Code may be caused by the following:
D Ignition coil shorted to ground and arcing at ignition
wires or plugs.
D MIL (Check Engine lamp) wire to ECM shorted to
ground.
D Poor ECM grounds. Refer to the ECM wiring
diagrams.
Check for improper installation of electrical options such
as lights, cellular phones, etc. Check all wires from the
ECM to the ignition coils for poor connections.
Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
If problem has not been found, refer to ECM Connector
Symptom tables.
6E1238
HARD START SYMPTOM

DEFINITION:
Engine cranks, but does not start for a long time. Does
eventually run, or may start but immediately stalls.
Step
Action
No
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Go to Step 8
Go to Step 5
Go to Step 7
Go to Step 6
Verify repair
Verify repair
Verify repair
Go to Step 9
22.4 k W
Verify repair
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 visual/physical check performed?
Yes

performed?
Was a bulletin found that addresses the symptom?

3
Value(s)
Check engine coolant temperature (ECT) sensor for

shift in value.
1. After 8 hours with the hood up and the engine not
running, connect the Tech 2.
2. Ignition ON, engine not running.
3. Using the Tech 2, compare Engine Coolant
Temperature to Intake Air Temperature.
Are ECT and IAT within the specified value of each
5C ( 9F)
other?
1. Using a Tech 2, display the engine coolant

temperature and note the value.
2. Check the resistance of the engine coolant
temperature sensor.
3. For resistance specifications, refer to Temperature
vs. Resistance chart in DTC P0118.
Is the actual resistance near the resistance value in the
chart for the temperature that was noted?

Locate and repair high resistance or connection in the

ECT signal circuit or the ECT signal circuit or the ECM
sensor ground.
Check for a faulty, plugged, or incorrectly installed PCV
valve.
Visually/Physically inspect the secondary ignition

wires. Check for the following conditions:
D Verify that all ignition wire resistance are less than
the specified value.
D Verify that ignition wires are correctly routed to
eliminate crossfiring.
D Verify that ignition wires are not arcing to ground.
Spraying the secondary ignition wires with a light
mist of water may help locate an intermittent
problem.
Go to Step 10

Step
Action
10
Check for proper ignition voltage output with a spark

tester5-8840-0383-0.
11
14
15
Verify repair
9 kW12 kW
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 12
Go to Step 13
Go to Step 14
Go to Step 15
Go to Step 16
Perform the procedure in Fuel System Pressure Test to

determine if there is a problem with fuel delivery.
Go to Step 17
Check for the following engine mechanical problems

(refer to Engine Mechanical):
D Low compression
D Leaking cylinder head gaskets
D Worn camshaft
D Camshaft drive belt slipped or stripped
18
Verify repair
Check for water or alcohol contaminated fuel.

17
Check IAC operation. Perform the procedure in the

diagnostic chart DTC P0506, Step 6.

16
Verify repair
1. Check the ignition coil secondary resistance.

2. Replace the coil if it is not within the specified range
of resistance.
Did the coil require replacement?
Go to Step 18
1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
D Visual/physical inspection
D Tech 2 data
D Freeze Frame data/Failure Records buffer
D All electrical connections within a suspected
circuit and/or system
No
Go to Step 11
Check for a loose ignition control module ground.

13
Yes
1. Remove the spark plugs and check for gas or oil

fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
12
Value(s)
6E1239
Verify repair
Contact
Technical
Assistance
6E1240
SURGES AND/or CHUGGLES SYMPTOM

DEFINITION:
Engine power variation under steady throttle or cruise.
Feels like the vehicle speeds up and slows down with no
change in the accelerator pedal.
Step
Action
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
System OK
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair
Verify repair
Verify repair
Monitor Long Term Fuel Trim on the Tech 2.

Is Long Term Fuel Trim in the negative range (rich
condition)?
Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P0172.
Go to Step 10
Check items that can cause the engine to run lean.

Go to Step 10
Check for proper ignition voltage output with the spark

tester 5-8840-0383-0.
11
Verify repair
Check the fuel pressure. Refer to Fuel System

Pressure Test.

10
Check the fuel control Heated Oxygen Sensor

(HO2S1). When monitored on the Tech 2, the H02S1
should respond quickly to different throttle positions. If
it doesnt check for silicon or other contaminants from
fuel or use of improper RTV sealant. The sensors may
have a white powdery coating. Silicone contamination
sends a rich exhaust signal which causes the ECM to
command an excessively lean air/fuel mixture.

9
Go to Step 2
Be sure that the driver understands A/C compressor

operation as explained in the owners manual. Inform
the customer how the A/C clutch operate.

7
Go to OBD
System
Check

6
No

Is the customer experiencing a normal condition?

5
Yes

performed?

3
Value(s)
Go to Step 11

Go to Step 12

Step
Action
12

wires. Check for the following conditions.
eliminated crossfiring.
mist of water may help to locate an intermittent
problem.
13
16
19
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 14
Go to Step 15
Go to Step 16
Go to Step 17
Visually/physically check the vacuum hoses for splits,

kinks and proper connections and routing as shown on
the Vehicle Emission Control Information label.
18
9 kW 12 kW
Check the ECM grounds to verify that they are clean

and tight. Refer to the ECM wiring diagrams in
Electrical Diagnosis.
17
Verify repair
1. Check the injector connectors.

2. If any of the connectors are connected at an
improper cylinder, correct as necessary.
Go to Step 18
Check the exhaust system for a possible restriction:

D damaged or collapsed pipes
D internal muffler failure
D Refer to Restricted Exhaust System Check to
measure back pressure and determine if the
catalytic converter is plugged.
Go to Step 19
1. Review all the diagnostic procedures within this

table.
following:
D Visual/physical inspection.
D Tech 2 data.
D Freeze Frame data/Failure Records buffer.
circuit and/or system.
No
Go to Step 13
22.4 W

fouling, cracks, wear, improper gap, burned
electrodes, heavy deposits or improper heat range.
15
Yes
1. Check ignition coil secondary resistance.

of resistance.
14
Value(s)
6E1241
Verify repair
Contact
Technical
Assistance
6E1242
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM

DEFINITION:
Engine delivers less than expected power. Little or no
increase in speed when accelerator pedal is pushed down
partway.
Step
Action
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Check the fuel pressure. Refer to Fuel System Test.

10
Verify repair
1. Remove the spark plugs and check gas or oil


9

tester 5-8840-0385-0.

8
Go to Step 2
1. Remove and check the air filter element for dirt or

restrictions. Refer to Air Intake System in
OnVehicle Service.
2. Replace the air filter element if necessary.

7
Go to OBD
System
Check

6
No


5
Yes

performed?

3
Value(s)

D Damaged or collapsed pipes
D Internal muffler failure
measure backpressure and determine if the

Step
Action
11
Check for the following engine mechanical problems:

D Low compression
D Leaking cylinder head gasket
D Worn or incorrect camshaft
D Loose timing belt
12
Value(s)
Yes
No
Verify repair
Go to Step 12
Verify repair
Contact
Technical
Assistance

table.
following:
D Tech 2 data
D All electrical connections within suspected
6E1243
6E1244
DETONATION/SPARK KNOCK SYMPTOM

DEFINITION:
A mild to severe ping, usually worse under acceleration.
The engine makes sharp metallic knocks that change
with throttle opening.
Step
Action
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Go to Step 5
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Check fuel pressure. Refer to Fuel System Pressure

Test.
Check items that can cause an engine to run lean.
Check spark plugs for proper heat range. Refer to
General Information.
Were incorrect spark plugs installed?
1. Check for obvious overheating problems:

D Low engine coolant.
D Restricted air flow to radiator, or restricted
water flow through radiator.
D Incorrect coolant solution. It should be a 50/50
mix of approved antifreeze/water.
D Incorrect EGR operation. Refer to DTC
P0401.

8
Go to Step 2
1. If Tech 2 readings are normal and there are no

engine mechanical faults, fill the fuel tank with a
known quality gasoline that has a minimum octane
rating of 87. Refer to Typical Scan Values.
2. Reevaluate the vehicle performance.

7
Go to OBD
System
Check

6
No

Is detonation present?
5
Yes

performed?

3
Value(s)
1. Remove excessive carbon buildup with a top engine

cleaner. Refer to instructions on the top engine
cleaner can.
2. Reevaluate vehicle performance.
Is detonation still present?
Go to Step 10
Verify repair

Step
Action
10
Check for an engine mechanical problem. Perform a

cylinder compression check. Refer to Engine
Mechanical.
11
Value(s)
Yes
No
Go to Step 11
Verify repair

following:
D Tech 2 data
6E1245
Verify repair
Contact
Technical
Assistance
6E1246
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM

DEFINITION:
Engine runs unevenly at idle. If severe, the engine or
vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.
Step
Action
Go to Step 2
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Between 10
and 50
counts
Go to Step 8
Go to Step 7
Verify repair
Go to Step 7
0%
Go to Step 8
For further
diagnosis,
refer to DTC
P0123
Verify repair
Go to Step 9
Verify repair
Verify that the EGR valve is not mounted backwards.

1. Check for incorrect idle speed. Ensure that the
following conditions are present:
D Engine fully warm.
D Accessories are OFF.
2. Using a Tech 2, monitor IAC position.
1. Visually/physically inspect for the following
conditions:
D Restricted air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system.
D Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the IAC
passage and on the IAC pintle, and excessive
deposits in the throttle bore and on the throttle
plate.
D Check for a condition that causes a large
vacuum leak, such as an incorrectly installed
or faulty crankcase ventilation valve brake
booster hose.
Go to OBD
System
Check
Was a visual/physical check performed, including the

rotor, ignition coil and secondary ignition wires?
Is the IAC position within the specified values?

6
Using a Tech 2, monitor TP angle with the engine idling.

Is the TP angle at the specified value and steady?

tester 5-8840-0383-0.
No


5
Yes

performed?

3
Value(s)

2. If spark plugs are fouled, the cause of the fouling
must be determined before replacing the spark
plugs.
Go to Step 10

Step
Action
10
Check for a loose ignition control module ground. Refer

to Electrical Ignition System.
11
Value(s)
Yes
6E1247
No
Go to Step 11

condition)?
Verify repair
Go to Step 12
Go to Step 13
12
Check the items that can cause the engine to run rich.
13
Is Long Term Fuel Trim significantly in the positive

range (lean condition)?
14
18
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 16
Go to Step 17
Go to Step 18
1. Check for faulty motor mounts. Refer to Engine

Mechanical for inspection of mounts.
19
Verify repair
1. Check the following engine mechanical problems:

D Low compression
D Sticking or leaking valves
D Valve timing
D Broken valve springs
D Camshaft drive belt slipped or stripped.
Go to Step 19

following:
D Tech 2 data
Go to Step 15
Go to Step 14
Perform the Injector Coil/Balance Test.

17
Go to Step 14
Check the injector connections. If any of the injectors

are connected to an incorrect cylinder, correct as
necessary.
16
Verify repair
Check items that can cause the engine to run leading.

15
Go to Step 13
Verify repair
Contact
Technical
Assistance
6E1248
POOR FUEL ECONOMY SYMPTOM

DEFINITION:
Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time,
as previously shown by an actual road test.
Step
Action
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Go to Step 5
Go to Step 6
System OK
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Verify repair
Verify repair
Remove and check the air filter element for dirt or for
restrictions.
electrodes of heavy deposits.
2. Is spark plugs are fouled, the cause of fouling must
Check for low engine coolant level.
Go to Step 10
Check for an incorrect or faulty engine thermostat.

Refer to Engine Cooling.
11
Verify repair
1. Visually/physically check: Vacuum hoses for splits,

kinks, and improper connections and routing as
shown on the Vehicle Emission Control
Information label.

10
Review the items in Step 4 with the customer and

advise as necessary.

9
Go to Step 2
Check owners driving habits.

D Is the A/C ON full time (defroster mode ON)?
D Are tires at the correct pressure?
D Are excessively heavy loads being carried?
D Is acceleration too much, too often?

8
Go to OBD
System
Check

7
No


6
Yes

performed?

3
Value(s)
Go to Step 11
Check for low engine compression. Refer to Engine

Mechanical.
Go to Step 12

Step
Action
12
Check for excessive exhaust system backpressure.

Refer to Restricted Exhaust System Check. Possible
problems could be:
D Damaged or collapsed pipes.
D Internal muffler failure.
D Plugged catalytic converter.
13
15
Go to Step 13
Verify repair
Go to Step 15
Go to Step 14
Verify repair
Verify repair
Verify repair
Contact
Technical
Assistance
Check the air intake system and the crankcase for air
leaks.
Go to Step 16

table.
following:
D Tech 2 data
D All connections within a suspected circuit
and/or system
17
No
Diagnose and repair the inaccurate speedometer

condition as necessary. Refer to Vehicle Speed Sensor
in Electrical Diagnosis.

16
Yes
Check for proper calibration of the speedometer.

Does the speed indicated on the speedometer closely
match the vehicle speed displayed on the Tech 2?
14
Value(s)
6E1249
Go to Step 17
Perform the procedure in Fuel System Pressure Test.

Was the fuel pressure normal?
Verify repair
6E1250
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM

DEFINITION:
Vehicle fails an emission test. There is excessive rotten
egg smell. (Excessive odors do not necessarily indicate
excessive emissions.)
Step
Action
Value(s)

performed?

11
14
Go to Step 13
Go to Step 6
Go to Step 13
Go to Step 7
Go to Step 13
Go to Step 8
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 10
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12
Check the EVAP canister for fuel loading. Refer to

Evaporative Emission Control System.
1. Remove excessive carbon build-up with a top

engine cleaner. Refer to the instructions on the top
engine cleaner can.
2. Perform the exhaust emission test.
Go to Step 14
System OK
Does the vehicle pass the test?
System OK
Does the exhaust emission test indicate excessive HC

levels, or is Long Term Fuel Trim significantly in the
negative range (rich condition)?

13
Go to Step 5
Check for a problem with the engine cooling system.

12
Go to Step 13
Perform the Injector Balance Test by Tech 2.
Go to Step 4

necessary.

10
Go to Visual /
Physical
Check
1. Check for faulty, plugged or incorrectly installed

PCV valve.
2. Verify that the PCV system is not plugged.

9
Go to Step 3
1. Check the fuel pressure. Refer to Fuel System

Pressure Test.
Go to OBD
System
Check
Go to Step 13
1. Check fuel cap for proper installation.

2. Secure the fuel cap if necessary.
No
Check for vacuum leaks (vacuum lines, intake

manifold, throttle body, etc.)

6
Go to Step 2
Was visual/physical check performed?
Were any vacuum leaks found?

5
Yes
Perform the exhaust emission test.
Go to Step 14
Go to Step 15
Go to Step 16

Step
Action
15
1. Check items that can cause the engine to run rich.

Refer to Diagnostic Aids in DTC P0172 Diagnostic
Support.
Make any necessary repairs.
Value(s)
Yes

16
System OK
System OK
Verify repair
Verify repair
1. Check items that can cause the engine to run lean.

Go to Step 18
Check for the following engine mechanical problems.

D Low compression
D Valve timing
D Broken Valve springs
19
Go to Step 17
Check the EGR system (refer to DTC P0401).

18
No
Go to Step 17

17
6E1251
Go to Step 19

table.
following:
D Tech 2 data
Verify repair
Contact
Technical
Assistance
6E1252
DIESELING, RUNON SYMPTOM

DEFINITION:
Engine continues to run after key is turned OFF, but runs
very rough. If engine runs smoothly, check the ignition
switch and adjustment.
Step
Action
No
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Contact
Technical
Assistance

1. Check for a short between B+ and the ignition feed

circuit.
Yes

performed?

3
Value(s)

table.
following:
D Tech 2 data
and/or system
6E1253
BACKFIRE SYMPTOM
DEFINITION:
Fuel ignites in the intake manifold, or in the exhaust
system, making a loud popping noise.
Step
Action
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
1. Visually/physically inspect the secondary ignition

D Verify that all ignition wire resistances are less
than the specified value.
D Verify that ignition wires are not arcing to
ground. Spraying the secondary ignition wires
with a light mist of water may help locate an
intermittent problem.
Check for an intermittent ignition system malfunction:
D Intermittent CKP 58X signal.
D Intermittent ignition feed circuit or sensor ground
circuit to the crankshaft position sensor.
To determine if there is a problem with fuel delivery,
refer to Fuel System Diagnosis.


8
Go to Step 2
Check for proper ignition voltage output with spark

tester 5-8840-0383-0.

7
Go to OBD
System
Check

6
No


5
Yes

performed?

3
Value(s)
1. Check for the following engine mechanical

problems:
D Low compression
D Incorrect valve timing
Go to Step 10
6E1254
Step
Action
10
Check the intake and exhaust manifold(s) for casting

flash. Refer to Engine Mechanical.
11
Value(s)
Yes
Go to Step 11
Verify repair

table.
following:
D Tech 2 data
No
Verify repair
Contact
Technical
Assistance
6E1255
CUTS OUT, MISSES SYMPTOM

DEFINITION:
Steady pulsation or jerking that follows engine speed;
usually more pronounced as engine load increases.
Step
Action
Go to Step 2
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Go to Step 9
Is the long term fuel trim significantly in the positive

Go to Step 8
Go to Step 9
Verify repair
Go to Step 9
Between 5
and 50
counts
Go to Step 11
Go to Step 10
Verify repair


Is the Long Term Fuel Trim in the negative range (rich
condition)?
7
8



2. Using a Tech 2, monitor the IAC position.
10
No
Go to OBD
System
Check

5
Yes

performed?

3
Value(s)

conditions:
plate.
or faulty crankcase ventilation valve or brake
booster hose disconnected.
Go to Step 11
6E1256
Step
Action
11

necessary.
12
15
Verify repair
Verify repair
Verify repair
Go to Step 15
Go to Step 16
Go to Step 17
Go to Step 18
0%
Verify repair
Verify repair
Verify repair
Go to Step 20
Go to Step 21

table.
following:
D Tech 2 data
For further
diagnosis,
refer to DTC
P0123
Go to Step 19
Check for faulty motor mounts. Refer to Engine

Mechanical for inspection of the mounts.
21
Go to Step 14

D Low compression
20
Verify repair
Check the PCV valve for proper operation.

19
Go to Step 13
Using a Tech 2, monitor the TP angle with the engine

idling.
18
Verify repair

17
1. Remove spark plugs and check for gas or oil fouling,

cracks, wear, improper gap, burned electrodes of
heavy deposits.
16
Verify repair

tester J 26792.
No
Go to Step 12
1. Check for fuel in the pressure regulator vacuum

hose.
2. If fuel is present, replace the fuel pressure regulator
assembly.
14
Yes
1. Perform the Injector Coil/Balance Test.

13
Value(s)
Verify repair
Contact
Technical
Assistance
6E1257
HESITATION, SAG, STUMBLE SYMPTOM

DEFINITION:
Momentary lack of response as the accelerator is pushed
down. Can occur at any vehicle speed. Usually most
pronounced when first trying to make the vehicle move,
as from a stop sign. May cause the engine to stall if severe
enough.
Step
Action
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 13

Go to Step 10

tester 5-8840-0383-0. For the procedure, refer to
Electronic Ignition System.
Go to Step 11

Go to Step 9
Go to Step 10


11
Go to Step 3

10
Verify repair
Observe the TP angle display on the Tech 2 while

slowly increasing throttle pedal.

9

Pressure Test.

condition)?
8
Go to Step 2
1. Check the fuel control heated oxygen sensor

(HO2S1). The HO2S1 should respond quickly to
different to throttle positions. If it doesnt, check for
silicon or other contaminants from fuel or use of
improper RTV sealant. The sensors may have a
white powdery coating. Silicon contamination
sends a rich exhaust signal which causes the ECM
to command an excessively lean air/fuel mixture.
Does the TP angle display steadily increase from 0% at

closed throttle to 100% at WOT?
7
Go to OBD
System
Check

6
No


5
Yes

performed?

3
Value(s)
Go to Step 12
6E1258
Step
Action
12
Visually/physically inspect the secondary ignition

D Value that ignition wires are correctly routed to
problem.
13
14
Verify repair
9 kW 12kW
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 16
Go to Step 17
Visually/physically check vacuum hoses for splits,

kinks, and proper connections and routing as shown on
Go to Step 18

following:
D Tech 2 data
Go to Step 15


18
Verify repair


17
No
Go to Step 14
30,000 W

2. Replace the coil if it is not within the specified value.

16
Yes

15
Value(s)
Verify repair
Contact
Technical
Assistance
6E1259
RESTRICTED EXHAUST SYSTEM CHECK

Step
Action
Go to Step 2
Go to OBD
System
Check
8.62 kPa
(1.25 psi)
Go to Step 5
Go to Step 3
8.62 kPa
(1.25 psi)
Go to Step 5
Go to Step 4
8.62 kPa
(1.25 psi)
Go to Step 6
System OK
Verify repair
Verify repair
With the exhaust backpressure tester in place of

HO2S, and the engine at normal operating
temperature:
Increase the engine speed to 2000 RPM while
observing the gauge.
1. Reinstall the HO2S2. (Refer to Heated Oxygen

Sensors in OnVehicle Service for installation
procedure.)
2. Remove the HO2S1.
3. Install the Exhaust BackPressure Tester BT8515V
or equivalent in place of the HO2S1.
4. Bring the engine to normal operating temperature
while observing the gauge.
5. Increase the engine speed to 2000 RPM (allow 10
seconds for pressure build) and observe the gauge.
Did the reading exceed the specified value?
No

D For removal procedures, refer to Heated
Oxygen Sensors in OnVehicle Service.
2. Install the Exhaust Backpressure Tester in place of
the Bank 1 HO2S.
3. Idle the engine at normal operating temperature.
Does the reading exceed the amount of the value

column?
4
Yes

performed?
Does the reading on the gauge exceed the specified

value?
3
Value(s)
Repair a restiction in the exhaust system after the

catalytic converter.
Possible faults include:
D Collapsed pipe
Replace the restricted catalytic converter.
NOTE: Diagnostic Trouble Codes will be set by running

the vehicle to normal operating temperature after a cold
start with the O2 sensor disconnected. After performing
these tests, use the Tech 2 to erase the Diagnostic
Trouble Codes that were set by the lack of O2 sensor
activity.
6E1260
DEFAULT MATRIX TABLE

SERVICE PROCEDURE DEFAULT
STRATEGY
A referral strategy has been established to assist the
technician with additional information when the cause of
the failure cannot be determined. If no problem is found
after performing diagnostics, then for further diagnostic
information, refer to the default matrix table.

Strategy Based Diagnostic Charts
Initial Diagnosis
Default Section(s)
OnBoard Diagnostic (OBD) System

Check
Vehicle does not enter diagnostics.
Chassis Electrical

Check
Vehicle enters diagnostics and

communicates with the Tech 2. MIL is
ON in diagnostics. Engine does not
start and run.
Ignition System Check

Check
Engine starts and runs, no ECM codes

set. Customer complains of vibration.
ECM Power and Ground Check

Check.
Chassis Electrical

Check. ECM power and ground circuits
OK. Data link voltage incorrect.
Chassis Electrical
Symptoms
Initial Diagnosis
Default Section(s)
Intermittents
1. Onboard diagnostic (OBD)

system check.
2. Careful visual/physical inspections.
Chassis Electrical
Hard Starts
1. OBD system check.

2. Sensors (ECT, MAP, TP); MAP
output chart.
3. Fuel system electrical test, fuel
system diagnosis.
4. Ignition system.
5. IAC system check.
Engine Mechanical
Exhaust System Diagnosis
Surges and/or Chuggles
1.
2.
3.
4.
OBD system check.

Heated oxygen sensors.
Fuel system diagnosis.
Ignition system.
Calibration ID Broadcast
Code/Service Bulletins
Generator Output
Lack of Power, Sluggish or Spongy
1.
2.
3.
4.
5.
OBD system check.

Ignition system.
EGR operation.
EGR system check.
Refer to Exhaust System in

Engine Exhaust
TCC Operation
Calibration ID/Service Bulletins
Detonation / Spark Knock
1.
2.
3.
4.
5.
OBD system check.

EGR operation.
EGR system check.
Ignition system.
Cooling System

Symptoms
Initial Diagnosis
6E1261
Default Section(s)
Hesitation, Sag, Stumble
1.
2.
3.
4.
5.
OBD system check.

TP.
MAP output check.
Fuel injector and fuel injector
balance test.
6. EVAP emission canister purge
valve.
7. Ignition system.
EGR Operation
EGR System Check
Generator Output Voltage (refer
to Chassis Electrical)
Cuts Out, Misses

2. Cylinder balance test.
Rough, Unstable, or Incorrect Idle,

Stalling

2. Fuel injector and fuel injector
balance test.
valve check.
4. Ignition system.
5. IAC operation.
6. EGR operation.
MAP Output Check

Throttle Linkage
IAC System Check
EGR System Check
Exhaust Diagnosis
Poor Fuel Economy
1.
2.
3.
4.
TCC Operation
Exhaust System (refer to Engine
Exhaust)
Fuel System Electrical

Diagnosis
Fuel Injector
Fuel Injector Balance Test
Excessive Exhaust Emissions or

Odors
1.
2.
3.
4.
5.
EGR System Check

Exhaust Diagnosis
6.
7.
8.
9.
OBD system check.

Careful visual/physical inspection.
Ignition system.
Cooling system.
OBD system check.

Emission test.
Cooling system.
balance test.
EVAP emission canister purge
valve.
Crankcase ventilation system.
Ignition system.
MAP output check.
Dieseling, RunOn

2. Careful visual/physical inspection.
3. Fuel system diagnosis.
Backfire
1.
2.
3.
4.
Exhaust System Diagnosis,

Intake Casting Flash, Ignition
System Check
OBD system check.

Ignition system.
balance test.
5. EGR operation, EGR system
check.
6E1262

Symptoms
Initial Diagnosis
OBD system check.
Ignition system.
balance test.
Default Section(s)
Misfire
1.
2.
3.
4.
Catalyst Monitor

3. Heated oxygen sensors.
Exhaust System
Fuel Trim
1.
2.
3.
4.
Exhaust System Intake Air

System
Evaporative Emissions

Heated Oxygen Sensors

Exhaust System
OBD system check.

Vibrations, Transmission,
Driveshaft and Axle
6E1263
8. Remove the retaining bolt for the sensor and pull up

camshaft position sensor.
Camshaft Position (CMP)

Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove spark plug cover on top of valve cover by
removing four retaining bolts.
3. Disconnect electrical connector from the sensor.
014RX005
Installation Procedure
1. Insert camshaft position sensor in position.
2. Install retaining bolt.
014RX003
4. Remove drive belt. Refer to Engine Mechanical

Section.
5. Remove top harness cover installed on timing belt
cover by removing a retaining screw.
6. Remove the retaining bolts holding crankshaft pulley,
and pull crankshaft pulley while wiggling. Refer to
Engine Mechanical Section.
7. Remove the retaining screws for timing belt cover and
timing belt cover.
014RX007
3. Install the timing belt cover and the retaining screws.

4. Install the crank shaft pulley and the mounting bolts.
Holes for mounting bolts are off the pitch. The pulley
can be mounted only one way to install all mounting
bolts. Tighten the bolts. Refer to Engine Mechanical
section.
014RX004
6E1264
5. Install the drive belt. Refer to Engine Mechanical

Section.

Sensor
Removal Procedure
2. Remove the drive belt. Refer to Engine Mechanical
Section.
014RX005
6. Install the top harness cover onto timing belt cover.

7. Connect electrical connector to the sensor and
securely lock it.
8. Install the spark plug cover.
9. Connect the negative battery cable.
014RX003
3. Remove
the
pwer
steering
pump
and
mountingbracket from engine. Refer to Engine
Mechanical Section.
014RX004
014RX006

5. Remove the retaining bolt and sensor from the engine
block.
6E1265
3. Reinstall the power steering pump and bracket to the

engine.
NOTE: Use caution to avoid any hot oil that might drip
out.
014RX006
0013
4. Reinstall the accessory drive belt.

1. Install the crank shaft position sensor to its position.
2. Install and tighten the mounting bolt. Refer to Engine
Mechanical Section.
014RX003
0013
6E1266
EEPROM
Functional Check
EEPROM
The Electronically Erasable Programmable Read Only
Memory (EEPROM) is a permanent memory that is
physically soldered within the ECM. The EEPROM
contains program and calibration information that the
ECM needs to control Powertrain operation.
1. Perform the OnBoard Diagnostic System Check.

2. Start the engine and run for least one minute.
3. Check for DTCs using Tech 2.
4. If the ECM fails to program, proceed as follow:
D Ensure that all ECM connections are OK.
D Check the ITCS for latest version software.
D Attempt to program ECM again. If ECM still cannot
be programmed properly, replace ECM. The
replacement ECM must be programmed.
Engine Coolant Temperature

(ECT) Sensor
Removal Procedure
2. Drain enough engine coolant so that the coolant level
will be below the ECT sensor.
3. Remove electrical connector from the sensor located
on the intake manifold above the ignition coil.
4. Unscrew the sensor from the manifold.
014RX002
014RX008
901RX031
1. Install the sensor into the intake manifold. Do not over

tighten.

3. Add engine coolant to required level. Refer to Engine
Cooling System Section.
6E1267
4. Unscrew sensors form the exhaust pipe. 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 degree C.
Inspection Procedure
NOTE: Both sensors are identical. Inspect each inthe
same way.
1. Inspect the pigtail and the electrical connector for
grease, dirt, corrosion and bare wire or worn
insulation.
2. Inspect the louvered end of the sensor for grease,
dirt, excessive carbon build up or other contaminants.
0016
Heated Oxygen Sensor (HO2S)

Removal Procedure
2. Locate the two oxygen sensors.
D Bank 1 sensor 1 is mounted on the exhaust pipe
ahead of the catalytic converter.
behind the catalytic converter.
TS23739
3. Disconnect pig tail electrical connector.

IMPORTANT: The pigtail is permanently attached to
the sensor. Be careful not to pull the wires out.
014RX010
NOTE: If HO2S is reinstalled after removal, special

antiseize compound or the equivalent should be applied
to the threads. Special antiseize compound, (P/N
5613695), is used on the HO2S threads. This compound
consists of glass beads suspended in a liquid graphite
solution. The graphite burns away with exhaust heat, but
the glass beads will remain, making the sensor easier to
remove.
6E1268
1. Apply antiseize compound or the equivalent to the

thread.
(PostCatalytic Converter Heater Oxygen Sensor

Location)
014RX009
TS23739
2. Install HO2S on the exhaust pipe.

3. Tighten the sensor to 55 Nm (5.6 kgm/40 lb ft)
4. Connect the pig tail to the wiring harness.
Intake Air Temperature (IAT)

Sensor
(PreCatalytic Converter Heater Oxygen Sensor Location)
Removal Procedure
2. The IAT sensor is located in the intake air duct
between the air filter and the throttle body.
014RX010
014RX011

3. Disconnect the electrical connector from the sensor.
4. Remove the sensor from intake air duct by using a
rocking motion while pulling the sensor.
6E1269
3. Remove a mounting bolt securing the sensor to the

manifold.
4. Remove the sensor from the intake manifold using
0018
014RX012
1. Install the IAT sensor into intake air duct. Make sure
the sensoris pushed all the way into the intake air
duct.
1. Push MAP sensor into the manifold. Make sure the
sensor is pushed always into its position.
2. Install a mounting bolts and tighten.
014RX011
014RX013
Manifold Absolute Pressure

(MAP) Sensor

(MIL)
Removal Procedure
(The MAP sensoris located on the intake manifold
behind throttle body.)

Refer to Instrument Panel Removal Procedure.
6E1270
Engine Control Module (ECM)

Electrostatic Discharge (ESD)
Damage
Electronic components used in the control system are
often designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to same electronic
components. By comparison, it takes as much as 4000
volts for a person to even feel the zap of a static
discharge. There are several way for a person to become
statically charged. The most common methods of
charging are by friction and by induction. An example of
charging by friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charge of the same polarity
are drained off leaving the person highly charged with
opposite polarity. Static charge can cause damage,
therefore, it is important to use care when handling and
testing electronic components.
IMPORTANT: When replacing the production ECM

with a service ECM, it is important to transfer the
broadcast code and production ECM number to the
service ECM label. This will allow positive identification of
ECM parts throughout the service life of the vehicle. Do
not record this information on ECM metal cover.
Removal Procedure
2. Block the wheels.
3. Remove ashtray inner.
4. Remove a screw located behind ashtray.
NOTE: To prevent possible Electrostatic Discharge

damage, follow these guidelines:
D Do not touch the control module connector pins or
soldered components on the control module circuit
board.
D Do not open the replacement part package until the
part is ready to be installed.
D Before removing the parts from the package, ground
the package to a known good ground on the vehicle.
D If the parts been handled while sliding across the
seat, or while sitting from standing position, or walking
a distance, touch a known good ground before
installing the parts.
014RX002
NOTE: To prevent internal ECM damage, the ignition

must be OFF position in order to disconnect or reconnect
power to the ECM (for example: battery cable. pig tail,
ECM fuse, jumper cable, etc.).
014RX014
5. Pull out Face trim of console.

6. Remove two screws located inside of center console
storage box and pull up rear part of center console.
014RX015
7. Unscrew the shift knob.

8. Remove four screw holding front part of the console
and pull the console up.

9. Disconnect the red, white and blue electrical
connector at the ECM.
6E1271
1. Place ECM into its position and secure by four
mounting screws.
014RX016
10. Remove two nuts in the front of ECM.

11. Remove two nuts in the rear of ECM.
12. Pull the ECM out from dashboard.
014RX002
2. Connect all three connectors to ECM. All connectors

are color keyed. Same color male and female
connectors join together.
014RX002
014RX017
6E1272
3. Install the front center console and secure by four

retaining screws.
9. Remove wheel blocks.
014RX014
014RX016
4. Install the rear center console and secure it by two

retaining screw into storage box.

Removal Procedure
2. Disconnect the TPS electrical connector.
3. Remove the two screws and TP sensor from the
throttle body.
NOTE: Do not clean the TP sensor by soaking it in
solvent. The sensor will be damaged as a result.
014RX015
5. Snap face plate into its position and secure it by a

screw.
6. Insert ashtray inner.
7. Insert the shift knob.
101RX002
6E1273
Function Check
Use a Tech 2 to check the TP sensor output voltage at
closed throttle.
D The voltage should be under 0.25 volts.
D If the reading is greater than 0.25 volts, check the
throttle shaft to see if it is binding. Check that the
throttle cable is properly adjusted, also. Refer to
Throttle Cable Adjustment.
D If the throttle shaft is not binding and the throttle cable
is properly adjusted, install a new TP sensor.
101RX002

Removal Procedure
101RX003
1. Install the TP sensor on the throttle body with two
screws.

2. VSS is located on the right side of the transmission
case just ahead of the rear propeller shaft.
Disconnect the VSS electrical connector.
3. Remove the bolt and the VSS from the transmission
case by wiggling it slightly and pulling it straight out.
IMPORTANT: Have a container ready to catch any fluid
that leaks out when the VSS is removed from the transfer
case.
101RX003
2. Connect the electrical connector.
014RX020
6E1274
1. Inspect the electrical connector for signs of corrosion
or warping. Replace the VSS if the electrical
connector is corroded or warped.
2. Inspect the VSS driven gear for chips, breaks, or worn
condition. Replace the VSS if the driven gear is
chipped, broken or worn.
3. Inspect the Oring for wear, nicks, tears, or
looseness. Replace the Oring if necessary.
3. Connect electrical connector to the VSS.

4. Check the transmission oil level. Add oil if necessary.
014RX020
Air Filter
Removal Procedure
014RX021
1. Install the VSS in the transmission case with the
notch for the connector facing the rear.
2. Secure the VSS with mounting bolt. Tighten the bolt to
16 Nm (12 lb ft).
1. Disconnect electrical connector at the IAT sensor.

2. Release the four latches securing the lid to the air
cleaner housing.
3. Remove the air cleaner lid.
014RX019
014RX021

4. Remove the air filter element.
6E1275
4. Connect the electrical connector to the IAT sensor.
014RX023
014RX019
1. Install the air filter element in the air cleaner housing.
Removal Procedure
014RX023
2. Install the air cleaner lids.

3. Secure the three latches, holding the lid on the air
cleaner housing.
101RX002
2. Disconnect the IAC electrical connector.

3. Remove the two screws and IAC valve from the
throttle body.
6E1276
NOTE: Do not clean the IAC valve by soaking it in

solvent. The valve will be damaged as a result.
Measurement Procedure
D In order to install a new IAC valve, measure the
distance between the tip of the pintle and the
mounting flange. If that measurement is 28 mm or
less, the valve need no adjustment. If the
measurement is greater than 28 mm, apply finger
pressure and retract the valve. The force required to
retract the pintle on a new valve will not damage the
valve, shaft or pintle.
NOTE: Do not push or pull on the IAC valve pintle on IAC
valve that have been in service. The force required to
move the pintle may damage it.
IMPORTANT: Use an identical replacement part in
order to replace a valve. IAC valve pintle shape and
diameter are designed for the specific application.
014RX022
Cleaning and Inspection Procedure

D Clean the IAC valve Oring sealing surface, pintle
valve seat and air passage.
D Use carburetor cleaner and a parts cleaning brush to
remove carbon deposit. Do not use a cleaner that
contain methyl ethyl ketone. This is an extremely
strong solvent and not necessary for this type of
deposit.
D Shiny spots on the pintle are normal and do not
indicate misalignment or a bent pintle shaft.
D Inspect the IAC valve Oring for cuts, cracks or
distortion. Replace the Oring if damaged.
TS23746
1. Install IAC valve on the throttle valve body with the
two screws. Tighten the screw to 1 Nm ( 9 lb in).
0006
014RX022

2. Connect electrical connector to IAC valve.
6E1277
4. Loosen retaining clamps at the throttle body and at

the air filter box.
5. Disconnect brake booster vacuum hose at intake
manifold and at brake booster.
101RX002
Intake Air Duct
014RX025
Removal Procedure
2. Disconnect electrical connector at IAT sensor.
3. Remove the IAT sensor if necessary. Refer to Intake
Air Temperature Sensor Removal.
6. Remove retaining nut at the intake air duct bracket at

top of valve cover.
7. Disconnect the intake air duct from the throttle body
and at the air filter box.
014RX019
014RX011
6E1278
1. Connect the intake air duct at the throttle body and at
the air filter box. Make sure retaining hole is inserted
to the intake air duct bracket.
5. Install IAT sensor if necessary. Refer to Intake Air

Temperature Sensor Installation.
6. Connect electrical connector at IAT sensor.
014RX011
014RX019
2. Tighten retaining clamp at the throttle body and at the

air filter box.
3. Install a nut to the intake air duct bracket and tighten.
4. Connect brake booster vacuum hose to intake
manifold and to brake booster and secure them with
clamps.

Knock Sensor
Removal Procedure
1. Disconnect negative battery cable.
2. Disconnect pig tail electrical connector at near the top
of generator.
014RX026
014RX027

3. Unscrew retaining bolt from Knock Sensor located
passenger side of engine block just front of starter.
6E1279
Oil Pressure Switch

Removal Procedure
1. Disconnect battery negative cable.
2. Disconnect electrical connector at Oil Pressure
Switch.
014RX028
4. Remove Knock Sensor with retaining bolt.
1. Install Knock Sensor with retaining bolt.
2. Connect pig tail electrical connector.
3. Connect battery negative cable.
014RX030
3. Unscrew Oil Pressure Switch from Oil Filter Mounting

Housing.
014RX029
014RX031
6E1280

3. Remove accelerator control cable (on the throttle
valve end).
1. Install Oil Pressure Switch into Oil Filter Mounting
Housing and tighten.
101RW006
014RX028
FUEL METERING SYSTEM Accelerator Cable Assembly

Removal Procedure
1. Loosen the adjusting nut on the cable bracket
mounting on the throttle body.
2. Remove the cable clip from holding bracket.
4. Remove the accelerator control cable (on the

accelerator pedal end).
5. Remove the grommet.
6. Remove the accelerator control cable.
Check the following items, and replace the control cable if
any abnormality is found:
D The control cable should move smoothly.
D The control cable should not be bent or kinked.
D The control cable should be free of damage and
corrosion.
014RX032
014RX026
6E1281
6. Adjust the accelerator cable. Refer to Accelerator

Cable Adjustment Section.
1. Install the accelerator control cable.
2. Install the grommet.
3. Install the accelerator control cable on the accelerator
pedal.
014RX026
Accelerator Cable Adjustment

014RX032
4. Install the accelerator control cable on the throttle

valve.
Adjustment Procedure
1. Loosen the adjusting nut.
2. Loosen the jam nut.
3. Pull the outer cable while fully closing the throttle
valve.
4. Tighten the adjusting nut.
5. Tighten the jam nut.
6. Loosen the adjusting nut by three turns.
7. Tighten the jam nut again.
8. Manually operate valve.
IMPORTANT:
The valve lever must return up to the
stopper screw. If the valve lever does not reach the
stopper screw, repeat the procedure again from Step 1.
101RW006
5. Install the cable clip to the holding bracket.
014RX026
6E1282
Accelerator Pedal Replacement
Fuel Filler Cap

Fuel Filler Cap
Removal Procedure
1. Disconnect the accelerator pedal control cable from
the acceleratorpedal assembly.
2. Remove the two screws retaining the accelerator
pedal to the bulkhead.
3. Remove the accelerator pedal from the bulkhead.
The Fuel filter cap includes a vacuum valve and a

pressure valve. If high vacuum or pressure occurs in the
fuel tank, each valve works to adjust the pressure in order
to prevent damage to the tank at the EGR valve.
NOTE: Replace the fuel filler cap with the same typeof
filler cap that was originally installed on the vehicle.
D Check the seal ring in the filler cap for any abnormality
and for seal condition.
D Replace the filler cap if any abnormality is found.
014RX033
1. Install the accelerator pedal assembly to the
bulkhead with two screws.
2. Connect the accelerator control cable to the
accelerator pedal assembly.
3. Adjust accelerator cable if necessary. Refer to
Accelerator Cable Adjustment Section.
TS23767
Fuel Filter
Removal Procedure
014RX034
6E1283
6. Remove the fuel filter.
2. Remove the fuel filler cap.
041RW005
3. Disconnect the fuel lines from the fuel filter on the

engine side.
4. Disconnect the fuel line from the fuel filter on the fuel
tank side.
041RW007
1. Replace the fuel filter when the following occur:
D Fuel leaks from the fuel filter body
D The fuel filter body is damaged
D The fuel filter is clogged with dust or sediment
2. If the drain hole is clogged at filler neck is clogged with
dust, clean the drain hole with air.
041RW006
5. Remove the bolt on the fuel filter holder.
041RW008
6E1284

1. Install the fuel filter in the correct direction.
2. Install the bolt on the fuel filter holder.
3. Connect the fuel line on the engine side.
4. Connect the fuel line on the fuel tank side.
5. Install the fuel filler cap.
014RX035
2. Disconnect electrical connector from fuel injector.

3. Remove the fuel rail. Refer to Fuel Rail Removal
Procedure.
041RW006
Fuel Injectors
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil may
be contaminated with fuel. Check the oil for signs of
contamination and change the oil and filter if necessary.
NOTE: Use care in removing the fuel injector in order to
prevent damage to the fuel injector electrical connector
pins or fuel injector nozzles. The fuel injector is an
electrical component and should not be immersed in any
type of cleaner as this may damage the fuel injector.
IMPORTANT: Fuel injectors are serviced as complete
assembly only.
014RX036
4. Remove the fuel injector retainer clip.

5. Remove fuel injector assembly from fuel rail.
6. Remove Oring from the fuel injector.

7. Remove Oring backup from fuel injector.
6E1285
014RX037
014RX035
1. Inspect Oring for crack, damage or leaks.
2. Replace worn or damaged Oring.
3. Lubricate the new Orings with engine oil before
installation.
1. Lubricate the new Oring with engine oil.
2. Install the Oring backup on the fuel injector.
3. Install new Oring on the fuel injector.
4. Install all four injector on the fuel rail.
5. Use new injector retainer clip to retain the injector to
the fuel rail.
6. Coat the end of the fuel injector with engine oil.
Removal Procedure
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the fuel system pressure,
a small amount of fuel may be released when
servicing fuel lines or connections. Reduce the
chance of personal injury by covering the fuel line
fitting with a shop towel before disconnecting the
fittings. The towel will absorb any fuel that may leak
out. When the disconnect is completed, place the
towel in an approved container.
NOTE: Compressed air must never used to test or clean
a fuel pressure regulator, as damage to the fuel pressure
regulator may occur.
014RX037
7. Install fuel rail assembly. Refer to Fuel Rail

Installation Procedure.
014RX035
6E1286
NOTE: To prevent damage to the fuel pressure regulator,

do not immerse the pressure regulator in solvent.
1. Depressurize the fuel system. Referto Fuel Pressure
Relief Procedure.
3. Remove the fuel pump relay.
4. Disconnect the vacuum line form fuel pressure
regulator.
1. Insert the fuel pressure regulator into the fuel rail.
014RX039
2. Install the fuel pressure regulator retaining bracket

ant tighten with a screw.
3. Connect vacuum line onto the fuel pressure regulator.
014RX038
5. Remove the fuel pressure regulator retaining screw.

6. Remove the fuel pressure regulator retaining bracket.
7. Remove the fuel pressure regulator from fuel rail.
014RX038
4. Install the fuel pump relay.

014RX039

6. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel line.
6E1287
4. Crank the engine for about 30 seconds.

014RW089
014RX035
Fuel Pump Assembly

components.
Removal Procedure
2. Drain all fuel from fuel tank from filler neck.
3. Remove the fuel pump relay from the fuse and relay
box at right side of engine room.
014RW089
041RW005

relay box.
6E1288
4. Remove fuel tank. Refer to Fuel Tank Removal

Procedure.
5. Using J39763, twist the fuel pump counterclock
wise to release from fuel tank.
Inspect intank fuel filter for tears, damage or evidence of
dirt derbies or water in the fuel. If any of these condition
exist, replace the intank fuel filter.
041RX001
041RX003
6. Lift fuel pump to remove from fuel tank.
1. Insert the fuel pump assembly into fuel tank and place
them at its position.
041RX002
041RX002

2. Using J39763, twist fuel pump assembly clock wise
into the lock.
6E1289
1. Inserts the relay into the correct place in the fuse and
relay box with the catch slot aligned to retainer.
2. Press down until the catch of retainer engages.
3. Install fuse and relay box cover.
901RX036
3. Install the fuel tank. Refer to Fuel Tank Installation

Procedure.
014RW089
Fuel Rail Assembly

Removal Procedure
NOTE:
D Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminal and the injector spray tips.
D Fitting should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passage.
041RX004
Fuel Pump Relay

Removal Procedure
1. Remove the fuse and relay box cover located right
side of engine room.
2. Determine correct relay by consulting to the diagram
on the cover.
3. Insert a small screwdriver or use thumb pressure to
release the retainer of the relay.
4. Pull the relay straight up and out of the fuse and relay
box.
6E1290
IMPORTANT: An eightdigit identification number is

stamped on side of the fuel rail. Refer to this number when
you service the fuel rail or when a replacement part is
required.
7. If removal of fuel pressure regulator is necessary.

Refer to Fuel Pressure Regulator Removal
Procedure.
8. If removal of fuel injector is necessary. Refer to Fuel
Injectors Removal Procedure.
014RX035
1. Depressurize the fuel system. Refer to Fuel Pressure

Relief Procedure.
2. Disconnect the fuel inlet at the rear of the engine.
3. Disconnect the fuel return line at front of the engine.
4. Disconnect the injector electrical connectors.
5. Remove the nuts holding wiring harness onto fuel rail.
6. Remove the bolts retaining fuel rail to the intake
manifold.
Lift up the injectors carefully to separate them from intake
manifold.
014RX037
1. Install the fuel injectors if necessary. Refer to Fuel
Injector Installation Procedure.
2. Install the fuel pressure regulator if necessary. Refer
to Fuel Pressure Regulator Installation Procedure.
3. Place the fuel injector rail assembly on the manifold
and insert the injectors into each port by pushing fuel
rail.
Lift up the fuel rail with injectors as assembly. Do not separate the fuel injectors from fuel rail.
If an injector become separated from fuel rail, injector
backup Oring and injector retainer clip must be replaced.
Drain residual fuel from fuel rail into an approved container.
014RX037
4. Install two fuel rail retaining bolts. Tighten fuel rail

retaining bolts to 19 Nm (14 lb ft)
5. Place wiring harness in its place and secure it with two
nuts.
014RX036

6. Connect electrical connector to each fuel injector.
6E1291
3. Drain the fuel from fuel filler neck.

4. Disconnect the fuel filler hose at fuel tank.
5. Disconnect the air breather hose at the fuel tank.
6. Disconnect the evaporator hose at the fuel tank.
7. Hold entire fuel tank at the bottom with stands.
8. Disconnect fuel supply lines and fuel return line at
near the fuel filter inside of body frame.
014RX036
7. Connect the fuel supply line securely. Do not over

tighten.
8. Connect the fuel return line securely. Do not over
tighten.
10. Crank the engine until it start. Cranking the engine
fuel system. Check for leak. If fuel leak is observed,
stop engine immediately. Before correct fuel leak, be
sure to depressurize system again.
041RX005
9. Remove four bolts (two in front and two in rear)

holding fuel tank to the frame.
10. Lower tank assembly from the vehicle a little to make
access space on top.
11. Disconnect two electrical connectors at fuel pump.
014RX035
Fuel Tank
Removal Procedure
2. Remove fuel filer cap.
041RX006
12. Remove fuel tank assembly from the vehicle.

13. Remove four nuts retaining tank under guard to the
tank.
6E1292

7. Connect the fuel filler hose, the air breather hose and
EVAP hose onto fuel tank and secure them with
clamps.
14. Remove the tank from the guard.
041RX002
041RX006
1. Secure fuel tank into under guard with four retaining

bolts, if necessary.
2. Place the fuel tank assembly onto stands.
3. Lift the fuel tank assembly near the position.
4. Connect two electrical connectors at fuel pump.
5. Lift the fuel pump to its position and secure it with four
mounting bolts. Make sure that all hoses and fuel
lines are out of way between the fuel tank and the fuel
tank bracket. Tighten the fuel tank retaining bolts to
36 Nm (27 lb ft).
8. Pour fuel into fuel tank.

9. Install fuel filler cap securely.
10. Connect the battery negative cable.
041RX005
Throttle body (TB)

Removal Procedure
041RX007
6. Connect fuel supply and return lines.

2. Drain the cooling system. Refer to Cooling System.
3. Remove the air intake duct. Refer to Air Intake Duct
Removal Procedure.
4. Remove the accelerator cable from throttle. Refer to
Accelerator Cable Assembly Removal Procedure.

5. Disconnect the electrical connectors from the throttle
position sensor and the idle air control valve solenoid.
6. Disconnect all vacuum hoses below air horn.
7. Disconnect coolant lines.
1. If the throttle body gasket needs to be released,

remove any gasket material that may be stuck to the
mating surfaces of the manifold.
2. Do not leave any scratches in the aluminum casting.
014RX041
014RX025
8. Remove the mounting bolts retaining the throttle body

the intake manifold.
9. Lift up the throttle body from the intake manifolds.
6E1293
1. Install IAC valve onto the throttle body. Refer to Idle
Air Control Valve Solenoid Installation Procedure.
2. Install TPS onto the throttle body if necessary. Refer
to TPS Installation Procedure.
3. Place the gasket then the throttle body on the
manifold.
4. Install four mounting bolt. Tighten the throttle body
mounting bolt to 13.5 Nm (10 lb ft).
014RX040
10. Remove the gaskets from the intake manifolds.

11. Remove the IAC. Refer to Idle Air Control Valve
Solenoid Removal Procedure.
12. Remove TPS. Refer to Throttle Position Sensor
Removal Procedure.
NOTE: Do not use solvent of any type when you clean the
gasket surfaces on the intake manifold and the throttle
body assembly. The gasket surface and the throttle body
assembly may be damaged as results.
014RX041
5. Connect coolant line and secure them with clamps.

6. Connect all vacuum hoses and secure them with
clamps if necessary.
7. Install accelerator control cable bracket onto the
throttle body.
6E1294
8. Connect accelerator control cable to throttle plate.
ELECTRONIC IGNITION
SYSTEM Ignition Control
Module (ICM)
Removal Procedure
2. Disconnect the electrical connector from the ignition
control module.
3. Remove the two attaching screws.
4. Remove the ignition control module from the engine
block.
014RX025
9. Connect electrical connector at IAC valve and TPS.

10. Install the air intake duct. Refer to Air Intake Duct
11. Fill the cooling system with required coolant. Refer to
Engine Cooling System.
1. Fasten the module to the engine block with two

screws.
2. Reconnect the electrical connector.
3. Reconnect the negative battery terminal.
041RX042
101RX002
6E1295
Ignition Coil
Removal Procedure
2. Drain the cooling system. Refer to Engine Cooling
System.
3. Remove the heater supply and return hose.
4. Remove the coolant return hose.
5. Disconnect all four spark plug cables from the coil.
6. Disconnect electrical connector from the ignition coil.
7. Remove three mounting bolt from the ignition coil.
8. Remove the ignition coil from the bracket.
014RX044
Spark Plugs
Removal Procedure
Type: NGK BPR6ES11
Spark Gap : 1.05 MM (0.040)
Spark Plug Torque : 25 Nm (2.6 kgm/18 lb ft)
2. Remove four bolt holding spark plug cover plate to top
of valve cover, and remove the cover plate.
3. Pull ignition wire using hocks attached to end of spark
plug cable.
014RX043
1. Install the ignition coil onto the bracket with three
mounting bolts.
2. Connect electrical connector at the ignition coil.
3. Connect spark plug cable to the ignition coil.
4. Connect heater supply and return hose and secure
them with clamps.
5. Connect coolant return line and secure them with
clamps.
014RX043
6E1296

D Fuel mixture is too lean.
D Heat range is incorrect.
4. Remove the spark plug.
014RX045
014RX047
1. Check the insulator for cracks. Replace the spark
plug if crack are present.
2. Check the electrode condition and replace the spark
plug if necessary.
If vehicle usage does not conform to normal driving

conditions, a more suitable spark plug may be
substituted.
If fuel and electrical system are normal, in most cases of
this sort, the problem can be corrected by using a colder
type spark plug with the same physical dimensions as the
original equipment spark plug.
3. Check the gaskets for damage and replace if
necessary.
4. Measure the spark plug gap. The specification is 1.05
mm (0.040).
5. Adjust the spark gap by bending the grounded
electrode.
014RX046
If the spark plug electrodes and insulators are fouled with

carbon or oil, the engine will not operate efficiently.
There are number of possible causes:
D Fuel mixture is too rich.
D Oil in the combustion chamber.
D The spark plug gap is not set correctly.
If spark plug fouling is excessive, check the fuel and
electrical system for possible causes of trouble. If fuel and
electrical system are normal, install spark plug of a higher
heat range which have the same physical dimensions as
the original equipment spark plug.
The following symptoms are characteristics of spark
plugs that are running too hot:
014RX048
1. Tighten the spark plug to the 25 Nm (2.6 kgm/18 lb ft).
2. Push the spark plug cable in until it snaps in.

3. Install spark plug cover onto valve cover and secure it
with four retaining bolts.
6E1297
NOTE: Never puncture the spark plug cables insulation
with a needle or the pointed end of a probe into the cable.
An increase in resistance would be created which would
cause the cable to become defective.
1. If the cable has broken or cracked insulation, it must
be replaced.
2. If the terminals are corroded or loose, the cable must
be replaced.
3. Check that the cable resistance does not exceed 10 k
W per foot.
014RX049
Spark Plug Cables

Spark Plug Cables
The cable contains a synthetic conductor which is easily
damaged. Never stretch or kink the cable. Disconnect the
cable from spark plug and the ignition coil.
The original equipment cables and the ignition coil are
marked to show correct location of the cables. If spark
plug cables or the ignition coil are replaced previously,
before cables are removed from the ignition coil, mark the
cables and the coil so they can be reconnected in the
same position.
014RX051
EMISSIONS Catalytic Converter

Catalytic Converter
Refer to Engine Exhaust.
Air Conditioning Relay

Removal Procedure
1. Remove the fuse and relay box cover at right side of
engine room.
2. Refer to the diagram on the cover to determine which
is the correct relay.
3. Insert small screwdriver or use thumb pressure to
014RX050
6E1298
box.
2. Inspect the canister for damages.
014RX001
014RX052
1. Insert the relay into the correct place in the fuse and
1. Install EVAP canister onto crossmember with two
mounting bolts.
2. Connect all hoses and secure them with clamps.
Ignition Timing Adjustment

There is no timing adjustment. The timing signal is
furnished by the CKP and the CMP signal. ECM control
the ignition timing.
EVAP Canister Hoses

EVAP Canister Hoses
To see the routing of the EVAP canister hoses, refer to
Vehicle Emission Control Information in Diagnosis or
Emission Label located bottom side ofthe hood. Use
6148M or equivalent when you replace the EVAP canister
hoses.
EVAP Canister
Removal Procedure
1. Disconnect all hoses.
2. Remove two mounting bracket nuts.
1. Inspect the hoses for cracks, damage and leaks.
014RX054
Linear Exhaust Gas

Recirculation (EGR) Valve
Removal Procedure
2. Disconnect electrical connector at EGR valve.
3. Disconnect the electrical connector at Intake Air
Temperature Sensor.
4. Remove air intake duct. Refer to Air Intake Duct
Removal Procedure.
5. Remove crankshaft breather hose.

6. Remove two bolts holding EGR valve.
7. Remove EGR valve and gasket from the manifold.
6E1299

057RX001
014RX057
1. Inspect the air passage for a restrtiction. If there is
restriction, remove the object. Do not use any type of
solvent, it may damage electrical system of EGR
valve.
2. Inspect restriction for valve movement. If there is
restriction remove the object.
Wiring and Connectors

Wiring Harness Service
The control module harness electrically connects the
control module to the various solenoids, switches and
sensors in the vehicle engine compartment and
Replace wire harnesses with the proper part number
replacement.
Because of the low amperage and voltage levels utilized
in powertrain control systems, it is essential that all wiring
in environmentally exposed areas be repaired with crimp
and seal splice sleeves.
The following wire harness repair information is intended
as a general guideline only. Refer to Chassis Electrical for
all wire harness repair procedures.
ECM Connectors And Terminals

Removal Procedure
014RX056
1. Place the gasket and EGR valve on to the intake
manifold.
2. Install mounting bolts and tighten.
3. Connect electrical connector at EGR valve
4. Connect the crankshaft breather hose and secure it
with clamps.
1. Remove the connector terminal retainer.

2. Push the wire connected to the affected terminal
through the connector face so that the terminal is
exposed.
3. Service the terminal as necessary.
1. Bend the tab on the connector to allow the terminal to
be pulledinto position within the connector.
2. Pull carefully on the wire to install the connector
terminal retainer.
6E1300

3. Untwist the conductors.
4. Strip the insulation as necessary.
Connectors And Terminals

Use care when probing a connector and when replacing
terminals. It is possible to short between opposite
terminals. Damage to components could result. Always
use jumper wires between connectors for circuit
checking. NEVER probe through WeatherPack seals.
Use an appropriate connector test adapter kit which
contains an assortment of flexible connectors used to
probe terminals during diagnosis. Use an appropriate
fuse remover and test tool for removing a fuse and to
adapt the fuse holder to a meter for diagnosis.
Open circuits are often difficult to locate by sight because
oxidation or terminal misalignment are hidden by the
connectors. Merely wiggling a connector on a sensor, or
in the wiring harness, may temporarily correct the open
circuit. Intermittent problems may also be caused by
oxidized or loose connections.
Be certain of the type of connector/terminal before
making any connector or terminal repair. WeatherPack
and ComPack III terminals look similar, but are serviced
differently.
048
Wire Harness Repair: Twisted

Shielded Cable
1. Splice the wires using splice clips and rosin core

solder.
2. Wrap each splice to insulate.
3. Wrap the splice with mylar and with the drain
(uninsulated) wire.
Removal Procedure
1. Remove the outer jacket.
2. Unwrap the aluminum/mylar tape. Do not remove the
mylar.
049
047

4. Tape over the whole bundle to secure.
6E1301
1. Use splice clips and rosin core solder in order to splice
the two wires together.
050
Twisted Leads
052
2. Cover the splice with tape in order to insulate it from

the other wires.
Removal Procedure
1. Locate the damaged wire.
2. Remove the insulation as required.
053
051
6E1302
3. Twist the wires as they were before starting this

procedure.
1. Open the secondary lock hinge on the connector.
070
054
4. Tape the wires with electrical tape.
2. Use tool 5-8840-0388-0 or the equivalent to remove

the pin and the sleeve terminals. Push on
5-8840-0388-0 to release.
NOTE: Do not 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.
055
WeatherPack Connector
Tools Required
5-8840-0388-0 WeatherPack II Terminal Remover
Removal Procedure
A WeatherPack 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
form oxidation and deposits on the terminals. This
protection is important, because of the low voltage and
the low amperage found in the electronic systems.
071

3. Cut the wire immediately behind the cable seal.
6E1303
5. Push the terminal and the connector to engage the

locking tangs.
6. Close the secondary locking hinge.
ComPack III
ComPack III
The ComPack III terminal looks similar to some
WeatherPack terminals. This terminal is not sealed and
is used where resistance to the environment is not
required. Use the standard method when repairing a
terminal. Do not use the WeatherPack terminal tool
5-8840-0388-0 or equivalent. These will damage the
terminals.
072
Make certain the connectors are properly seated and all
of the sealing rings are in place when you reconnect the
leads. The secondary lock hinge provides a backup
locking feature for the connector. The secondary lock
hinge is used for added reliability. This flap should retain
the terminals even if the small terminal lock tangs are not
positioned properly.
Do not replace the WeatherPack connections with
standard connections. Read the instructions provided
with the WeatherPack connector and terminal
packages.
1. Replace the terminal.
2. Slip the new seal onto the wire.
3. Strip 5 mm (0.2) of insulation from the wire.
4. Crimp the terminal over the wire and the seal.
070
MetriPack
Tools Required
5-8840-0632-0 Terminal Remover
Removal Procedure
Some connectors use terminals called MetriPack Series
150. These may be used at the engine coolant
temperature (ECT) sensor.
1. Slide the seal (1) back on the wire.
2. Insert the 5-8840-0632-0 tool or equivalent (3) in
order to release the terminal locking tang (2).
3. Push the wire and the terminal out through the
connector. If you reuse the terminal, reshape the
locking tang.
073
6E1304

other than the expected amount, DTC P0336 will set. The
engine will not start and run without using the 58X
reference signal.
A/C Request Signal

This signal tells the ECM when the A/C mode is selected
at the A/C control switch. The ECM uses this signal to
adjust the idle speed before turning ON the A/C clutch.
The A/C compressor will be inoperative if this signal is not
available to the ECM.
For A/C wiring diagrams and diagnosis for the A/C
electrical system, refer to A/C Clutch Circuit Diagnosis.
060
The crankshaft position (CKP) sensor provides a signal

used by the powertrain control module (ECM) to calculate
the ignition sequence. The CKP sensor initiates the 58X
reference pulses which the ECM uses to calculate RPM
and crankshaft position. For additional information,
refer to Electronic Ignition System.
MetriPack terminals are also referred to as
pulltoseat terminals.
1. In order to install a terminal on a wire, the wire must be
inserted through the seal (2) and through the
connector (3).
2. The terminal (1) is then crimped onto the wire.
3. Then the terminal is pulled back into the connector to
seat it in place.
0013

Signal
061
GENERAL DESCRIPTION ECM

AND SENSORS
58X Reference ECM Input
The engine control module (ECM) uses this signal from
the crankshaft position (CKP) sensor to calculate engine
RPM and crankshaft position at all speeds. The ECM
also uses the pulses on this circuit to initiate injector
pulses. If the ECM receives no pulses on this circuit, DTC
P0337 will set. If the ECM receives a number of pulses
The camshaft position (CMP) sensor sends a signal to

the ECM. The ECM uses this signal as a sync pulse to
trigger the injectors in the proper sequence. The ECM
uses the CMP signal to indicate the position of the #1
piston during its power stroke. The CMP allows the ECM
to calculate true sequential fuel injection (SFI) mode of
operation. If the ECM detects an incorrect CMP signal
while the engine is running, DTC P0341 will set.
If the CMP signal is lost while the engine is running, the
fuel injection system will shift to a calculated sequential
fuel injection mode based on the last fuel injection pulse,
and the engine will continue to run. It will run in the
calculated sequential mode with a 1in4 chance of the
injector sequence being correct.
For further information, refer to
DTC P0341
DTC P0342.
6E1305
014RX007

thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream. Low
coolant temperature produces a high resistance of about
100,000 W at 40C (40F). High temperature causes a
low resistance of about 70 W at 130C (266F).
The ECM supplies a 5volt signal to the ECT sensor
through resistors internal to the ECM and then measures
the voltage after the internal resistor. This signal voltage
will be high when the engine is cold and low when the
engine is hot. By measuring the voltage, the ECM
calculates the engine coolant temperature. Engine
coolant temperature affects most of the systems that the
ECM controls.
The Tech 2 displays engine coolant temperature in
degrees. After engine startup, the temperature should
rise steadily to about 85C (185F). It then stabilizes
when the thermostat opens. If the engine has not been
run for several hours (overnight), the engine coolant
temperature and intake air temperature displays should
be close to each other. A hard fault in the engine coolant
sensor circuit will set DTC P0117 or DTC P0118. An
intermittent fault will set a DTC P1114 or P1115.
0016

Only Memory (EEPROM)
The electrically erasable programmable read only
memory (EEPROM) is a permanent memory chip that is
contains the program and the calibration information that
the ECM needs to control powertrain operation.
is not replaceable.
Fuel Control Heated Oxygen Sensor (Pre

Catalyst)
The fuel control heated oxygen sensor (Bank 1 HO2S 1)
is mounted in the exhaust stream where it can monitor the
oxygen content of the exhaust gas. The oxygen present in
the exhaust gas reacts with the sensor to produce a
voltage output. This voltage should constantly fluctuate
from approximately 100 mV to 900 mV. The heated
oxygen sensor voltage can be monitored with a Tech 2. By
monitoring the voltage output of the oxygen sensor, the
ECM calculates the pulse width command for the
injectors to produce the proper combustion chamber
mixture.
D Low HO2S voltage is a lean mixture which will result in
a rich command to compensate.
D High HO2S voltage is a rich mixture which will result in
a lean command to compensate.
An open Bank 1 HO2S 1 signal circuit will set a DTC
P0134 and the Tech 2 will display a constant voltage
between 400500 mV. A constant voltage below 300 mV
in the sensor circuit (circuit grounded) will set DTC
P0131. A constant voltage above 800 mV in the circuit will
set DTC P0132. The ECM can also detect HO2S
response problems. If the response time of an HO2S is
determined to be too slow, the ECM will store a DTC that
indicates degraded HO2S performance.
6E1306
0012
0017

which changes its resistance based on the temperature of
air entering the engine. Low temperature produces a high
resistance of about 100,000 W at 40C (104F). High
temperature causes low resistance of about 70 W at
130C (266F). The ECM supplies a 5volt signal to the
sensor through a resistor internal to the ECM, and then
monitors the signal voltage. The voltage will be high when
the incoming air is cold. The voltage will be low when the
incoming air is hot. By measuring the voltage, the ECM
calculates the incoming air temperature. The IAT sensor
signal is used to adjust spark timing according to the
incoming air density.
The Tech 2 displays the temperature of the air entering
the engine. The temperature should read close to the
ambient air temperature when the engine is cold and rise
as underhood temperature increases. If the engine has
not been run for several hours (overnight), the IAT sensor
temperature and engine coolant temperature should read
close to each other. A failure in the IAT sensor circuit will
set DTC P0112, or DTC P0113.

to changes in intake manifold pressure (vacuum). The
MAP sensor signal voltage to the ECM varies from below
2 volts at idle (high vacuum) to above 4 volts with the
ignition ON, engine not running or at wideopen throttle
(low vacuum).
The MAP sensor is used to determine the following:
D Manifold pressure changes while the linear EGR flow
test diagnostic is being run. Refer to DTC P0401.
D Engine vacuum level for other diagnostics.
D Barometric pressure (BARO).
If the ECM detects a voltage that is lower than the
possible range of the MAP sensor, DTC P0107 will be set.
A signal voltage higher than the possible range of the
sensor will set DTC P0108. The ECM can detect a shifted
MAP sensor. The ECM compares the MAP sensor signal
to a calculated MAP based on throttle position and
various engine load factors.

Control
The ECM monitors the exhaust gas recirculation (EGR)
actual position and adjusts the pintle position accordingly.
The ECM uses information from the following sensors to
control the pintle position:
D Engine coolant temperature (ECT) sensor.
D Throttle position (TP) sensor.
D Manifold Absolute Pressure (MAP) sensor.
014RX013

The engine control module (ECM) is located in the
passenger compartment below the center console. The
ECM controls the following:
D Fuel metering system.
D Ignition timing.
D Onboard diagnostics for powertrain functions.
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. The ECM performs the
diagnostic function of the system. It can recognize
operational problems, alert the driver through the Check
Engine lamp, and store diagnostic trouble codes (DTCs).
DTCs identify the problem areas to aid the technician in
making repairs.
6E1307
speed sensor (VSS). The ECM also controls certain

engine operations through the following:
D Fuel injector control
D Ignition control module
D Evaporative emission (EVAP) purge
D A/C clutch control
ECM Voltage Description

The ECM supplies a buffered voltage to various switches
and sensors. It can do this because resistors in the ECM
which are so high in value that a test light may not
illuminate when connected to the circuit. An ordinary shop
voltmeter may not give an accurate reading because the
voltmeter input impedance is too low. Use a 10megohm
input impedance digital voltmeter (such as J 39200) to
assure accurate voltage readings.
The input/output devices in the ECM include
analogtodigital converters, signal buffers, counters,
and special drivers. The ECM controls most components
with electronic switches which complete a ground circuit
when turned ON. These switches are arranged in groups
of 4 and 7, called either a quad driver module (QDM),
which can independently control up to 4 output terminals,
or Output Driver Module (ODM) which can independently
control up to 7 outputs. Not all outputs are always used.
ECM Inputs/Outputs
Inputs Operating Conditions Read
014RX002
ECM Function
The ECM supplies either 5 or 12 volts to power various
sensors or switches. The power is supplied through
resistors in the ECM which are so high in value that a test
light will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low.
Therefore, a digital voltmeter with at least 10 megW input
impedance is required to ensure accurate voltage
readings. Tool J 39200 meets this requirement.
The ECM controls output circuits such as the injectors,
IAC, cooling fan relays, etc., by controlling the ground or
the power feed circuit through transistors or through
either of the following two devices:
D Output Driver Module (ODM)
D Quad Driver Module (QDM)
ECM Components
The ECM is designed to maintain exhaust emission levels
to government mandated standards while providing
excellent driveability and fuel efficiency. The ECM
monitors numerous engine and vehicle functions via
electronic sensors such as the throttle position (TP)
sensor, heated oxygen sensor (HO2S), and vehicle
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Air Conditioning Compressor Clutch ON or OFF

Crankshaft Position
Exhaust Oxygen Content
Battery Voltage
Throttle Position
Fuel Tank Vapor Pressure
Fuel Tank Level
Exhaust Gas Recirculation (EGR) Feedback
Knock
Vehicle Speed
Fuel Pump Voltage
Camshaft Position
Outputs Systems Controlled

D
D
D
D
D
D
D
D
EVAP Canister Purge Solenoid

Exhaust Gas Recirculation (EGR)
Ignition Control
Fuel Injector Control
Idle Air Control
Coolant Fan Relays
Electric Fuel Pump Relay Compressor Clutch Relay
Air Conditioning
6E1308
D Diagnostics
OBD II Malfunction Indicator Lamp (Check Engine
lamp)
Data Output
D Tachometer Signal
ECM Service Precautions

The ECM is designed to withstand normal current draws
associated with vehicle operation. Avoid over loading any
circuit. When testing for opens and shorts, do not ground
or apply voltage to any of the ECMs circuits unless
instructed to do so. These circuits should only be tested
using digital voltmeter J 39200. The ECM should remain
connected to the ECM or to a recommended breakout
box.
101RX003
Transmission Range Switch

IMPORTANT: The vehicle should not be driven with the
transmission range switch disconnected; idle quality will
be affected.
The four inputs from the transmission range switch
indicate to the ECM which position is selected by the
transmission selector lever. This information is used for
ignition timing, EVAP canister purge, EGR and IAC valve
operation.
For more information on the transmission range switch,
refer to 4L30E Automatic Transmission.

014RX002

The throttle position (TP) sensor is a potentiometer
connected to the throttle shaft on the throttle body. The
ECM monitors the voltage on the signal line and
calculates throttle position. As the throttle valve angle is
changed (accelerator pedal moved), the TP sensor signal
also changes. At a closed throttle position, the output of
the TP sensor is about 0.25 volts. As the throttle valve
opens, the output increases so that at wide open throttle
(WOT), the output voltage should be about 4.75 volts.
The ECM calculates fuel delivery based on throttle valve
angle (driver demand). A broken or loose TP sensor may
cause intermittent bursts of fuel from an injector and
unstable idle because the ECM thinks the throttle is
moving. A hard failure in the TP sensor 5volt reference
or signal circuits will set either a DTC P0122 or DTC
P0123. A hard failure with the TP sensor ground circuit
may set DTC P0123 and DTC P0122. Once a DTC is set,
the ECM will use an artificial default value based on
engine RPM and mass air flow for the throttle position,
and some vehicle performance will return. A high idle may
result when either DTC P0122 or DTC P0123 is set. The
ECM can detect intermittent TP sensor faults.
The ECM determines the speed of the vehicle by

converting a pulsing voltage signal from the vehicle speed
sensor (VSS) into miles per hour. The ECM uses this
signal to operate the speedometer.
0008
Use of Circuit Testing Tools

Do not use a test light to diagnose the powertrain
electrical systems unless specifically instructed by the
6E1309
diagnostic procedures. Use Connector Test Adapter Kit J

35616 whenever diagnostic procedures call for probing
connectors.

Equipment
Aftermarket (addon) electrical and vacuum equipment is
defined as any equipment which connects to the vehicles
electrical or vacuum systems that is installed on a vehicle
after it leaves the factory. No allowances have been made
in the vehicle design for this type of equipment.
NOTE: No addon vacuum equipment should be added
to this vehicle.
NOTE: Addon electrical equipment must only be
connected to the vehicles electrical system at the battery
(power and ground).
Addon electrical equipment, even when installed to
these guidelines, may still cause the powertrain system to
malfunction. This may also include equipment not
connected to the vehicle electrical system such as
portable telephones and radios. Therefore, the first step
in diagnosing any powertrain problem is to eliminate all
aftermarket electrical equipment from the vehicle. After
this is done, if the problem still exists, it may be diagnosed
in the normal manner.
Electrostatic Discharge Damage

Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
electricity can cause damage to some electronic
volts for a person to feel even the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and induction.
D An example of charging by friction is a person sliding
across a vehicle seat.
D Charge by induction occurs when a person with
wellinsulated shoes stands near a highly charged
object and momentarily touches ground. Charges of
the same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
charges can cause damage, therefore it is important
to use care when handling and testing electronic
components.
TS23793
NOTE: To prevent possible electrostatic discharge

D Do not touch the ECM connector pins or soldered
components on the ECM circuit board.
D Do not touch any electronic sensor module
component leads.
D Before removing the part from the package, ground
D If the part has been handled while sliding across the
seat, while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.

INDUCTION
Air Induction System
The air induction system filters contaminants from the
outside air, and directs the progress of the air as it is
drawn into the engine. A remotemounted air cleaner
prevents dirt and debris in the air from entering the
engine. The air duct assembly routes filtered air to the
throttle body. Air enters the engine by the following steps:
1. Through the throttle body.
2. Into the intake manifold.
3. Through the cylinder head intake ports.
4. Into the cylinders.
6E1310
Deceleration Fuel Cutoff (DFCO) Mode

The ECM reduces the amount of fuel injected when it
detects a decrease in the throttle position and the air flow.
When deceleration is very fast, the ECM may cut off fuel
completely for short periods.
Engine Speed/Vehicle Speed/ Fuel Disable

Mode
The ECM monitors engine speed. It turns off the fuel
injectors when the engine speed increases above 6000
RPM. The fuel injectors are turned back on when engine
speed decreases below 5750 RPM.
Fuel Cutoff Mode

No fuel is delivered by the fuel injectors when the ignition
is OFF. This prevents engine runon. In addition, the
ECM suspends fuel delivery if no reference pulses are
detected (engine not running) to prevent engine flooding.
028RX002
Fuel Injector

METERING
Acceleration Mode
The ECM provides extra fuel when it detects a rapid
increase in the throttle position and the air flow.
Accelerator Controls
The accelerator control system is a cabletype system
with specific linkage adjustments.
Refer to Cable Adjustment.
The sequential multiport fuel injection (SFI) fuel injector is

a solenoidoperated device controlled by the ECM. The
ECM energizes the solenoid, which opens a valve to allow
fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Excess fuel not
used by the injectors passes through the fuel pressure
regulator before being returned to the fuel tank.
A fuel injector which is stuck partly open will cause a loss
of fuel pressure after engine shut down, causing long
crank times.
Battery Voltage Correction Mode

When battery voltage is low, the ECM will compensate for
the weak spark by increasing the following:
D The amount of fuel delivered.
D The idle RPM.
CMP Signal
The ECM uses the camshaft position (CMP) sensor
signal to determine the position of the number 1 piston
during its power stroke, allowing the ECM to calculate
true sequential multiport fuel injection (SFI). Loss of this
signal will set a DTC P0341 or DTC P0342. If the CMP
signal is lost while the engine is running, the fuel injection
system will shift to a calculated sequential fuel injection
based on the last fuel injection pulse, and the engine will
continue to run. The engine can be restarted and will run
in the calculated sequential mode with the fault is present,
with a 1in4 chance of being correct.
Clear Flood Mode

Clear a flooded engine by pushing the accelerator pedal
down all the way. The ECM then deenergizes the fuel
injectors. The ECM holds the fuel injectors deenergized
as long as the throttle remains above 80% and the engine
speed is below 800 RPM. If the throttle position becomes
less than 80%, the ECM again begins to pulse the
injectors ON and OFF, allowing fuel into the cylinders.
0003
Fuel Metering System Components

The fuel metering system is made up of the following
parts:
D The fuel injectors.
D The throttle body.
D The fuel rail.
D The fuel pressure regulator.
D The ECM.
D The crankshaft position (CKP) sensor.

D
D
D
D
6E1311
The camshaft position (CMP) sensor.

The idle air control (IAC) valve.
The fuel pump.
The fuel pump relay.
Basic System Operation

The fuel metering system starts with the fuel in the fuel
tank. An electric fuel pump, located in the fuel tank,
pumps fuel to the fuel rail through an inline fuel filter. The
pump is designed to provide fuel at a pressure above the
pressure needed by the injectors. A fuel pressure
regulator in the fuel rail keeps fuel available to the fuel
injectors at a constant pressure. A return line delivers
unused fuel back to the fuel tank. Refer to Section 6C for
further information on the fuel tank, line filter, and fuel
pipes.
Fuel Metering System Purpose

The basic function of the air/fuel metering system is to
control the air/fuel delivery to the engine. Fuel is delivered
to the engine by individual fuel injectors mounted in the
intake manifold near each intake valve.
The main control sensor is the heated oxygen sensor
(HO2S) located in the exhaust system. The HO2S tells
the ECM how much oxygen is in the exhaust gas. The
ECM changes the air/fuel ratio to the engine by controlling
the amount of time that the fuel injector is ON. The best
mixture to minimize exhaust emissions is 14.7 parts of air
to 1 part of gasoline by weight, which allows the catalytic
converter to operate most efficiently. Because of the
constant measuring and adjusting of the air/fuel ratio, the
fuel injection system is called a Closed Loop system.
The ECM monitors signals from several sensors in order
to determine the fuel needs of the engine. Fuel is
delivered under one of several conditions called modes.
All modes are controlled by the ECM.

The fuel pressure regulator is a diaphragmoperated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the other
side. The fuel pressure regulator maintains the fuel
pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separately.
If the pressure is too low, poor performance and a DTC
P0171, or DTC P1171 will be the result. If the pressure is
too high, a DTC P0172 will be the result. For information
on diagnosing fuel pressure conditions, refer to Fuel
System Diagnosis.
014RX038
Fuel Pump Electrical Circuit

When the key is first turned ON, the ECM energizes the
fuel pump relay for two seconds to build-up the fuel
pressure quickly. If the engine is not started within two
seconds, the ECM shuts the fuel pump off and waits until
the engine is cranked. When the engine is cranked and
the 58X crankshaft position signal has been detected by
the ECM, the ECM supplies 12 volts to the fuel pump relay
to energize the electric intank fuel pump.
An inoperative fuel pump will cause a nostart condition.
A fuel pump which does not provide enough pressure will
result in poor performance.
Fuel Rail
The fuel rail is mounted to the top of the engine and
distributes fuel to the individual injectors. Fuel is delivered
to the fuel inlet tube of the fuel rail by the fuel lines. The
fuel goes through the fuel rail to the fuel pressure
regulator. The fuel pressure regulator maintains a
constant fuel pressure at the injectors. Remaining fuel is
then returned to the fuel tank.
014RX036
6E1312

The purpose of the idle air control (IAC) valve is to control
engine idle speed, while preventing stalls due to changes
in engine load. The IAC valve, mounted in the throttle
body, controls bypass air around the throttle plate. By
moving the conical valve (pintle) in (to decrease air flow)
or out (to increase air flow), a controlled amount of air can
move around the throttle plate. If the RPM is too low, the
ECM will retract the IAC pintle, resulting in more air
moving past the throttle plate to increase the RPM. If the
RPM is too high, the ECM will extend the IAC pintle,
allowing less air to move past the throttle plate,
decreasing the RPM.
The IAC pintle valve moves in small steps called counts.
During idle, the proper position of the IAC pintle is
calculated by the ECM based on battery voltage, coolant
temperature, engine load, and engine RPM. If the RPM
drops below a specified value, and the throttle plate is
closed, the ECM senses a nearstall condition. The ECM
will then calculate a new IAC pintle valve position to
prevent stalls.
If the IAC valve is disconnected and reconnected with the
engine running, the idle RPM will be wrong. In this case,
the IAC must be reset. The IAC resets when the key is
cycled ON then OFF. When servicing the IAC, it should
only be disconnected or connected with the ignition OFF.
The position of the IAC pintle valve affects engine
startup and the idle characteristics of the vehicle. If the
IAC pintle is fully open, too much air will be allowed into
the manifold. This results in high idle speed, along with
possible hard starting and a lean air/fuel ratio. DTC
P0507 may set. If the IAC pintle is stuck closed, too little
air will be allowed in the manifold. This results in a low idle
speed, along with possible hard starting and a rich air/fuel
ratio. DTC P0506 may set. If the IAC pintle is stuck
partway open, the idle may be high or low and will not
respond to changes in the engine load.
When the engine is first started, the system is in Open

Loop operation. In Open Loop, the ECM ignores the
signal from the heated oxygen sensor (HO2S). It
calculates the air/fuel ratio based on inputs from the TP,
ECT, and MAP sensors.
The system remains in Open Loop until the following
conditions are met:
D The HO2S has a varying voltage output showing that
it is hot enough to operate properly (this depends on
temperature).
D The ECT has reached a specified temperature.
D A specific amount of time has elapsed since starting
the engine.
D Engine speed has been greater than a specified RPM
since startup.
The specific values for the above conditions vary with
different engines and are stored in the programmable
read only memory (PROM). When these conditions are
met, the system enters Closed Loop operation. In
Closed Loop, the ECM calculates the air/fuel ratio
(injector ontime) based on the signal from the HO2S.
This allows the air/fuel ratio to stay very close to 14.7:1.
Starting Mode
When the ignition is first turned ON, the ECM energizes
the fuel pump relay for two seconds to allow the fuel pump
to build up pressure. The ECM then checks the engine
coolant temperature (ECT) sensor and the throttle
position (TP) sensor to determine the proper air/fuel ratio
for starting.
The ECM 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.
Throttle Body Unit

The throttle body has a throttle plate to control the amount
of air delivered to the engine. The TP sensor and IAC
valve are also mounted on the throttle body.
Vacuum ports located behind the throttle plate provide the
vacuum signals needed by various components. Engine
coolant is directed through a coolant cavity in the throttle
body to warm the throttle valve and to prevent icing.
0006
Run Mode
The run mode has the following two conditions:
D Open Loop
D Closed Loop
014RX040
6E1313
D More coil cooldown time between firing events.

D Elimination of mechanical timing adjustments.
D Increased available ignition coil saturation time.
GENERAL DESCRIPTION
injector being correct.
For additional information, refer to DTC P0342.
0013
Ignition Coils
The 2.2L engine uses 2 ignition coils, 1 per 2 cylinders. A
twowire connector provides a 12volt primary supply
through the 15amp ignition coil fuse, and the ground wire
is connected to a groundswitching ignition module.
Radio frequency interference produced by the coil is
controlled by a condenser which is mounted near the
ignition coil.
014RX007

used by the engine control module (ECM) to calculate the
ignition sequence. The sensor initiates the 58X reference
pulses which the ECM uses to calculate RPM and
crankshaft position. For additional information, refer to
Electronic Ignition
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed air/fuel
mixture at the correct time. To provide optimum engine
performance, fuel economy, and control of exhaust
emissions, the ECM controls the spark advance of the
ignition system. Electronic ignition has the following
advantages over a mechanical distributor system:
D No moving parts.
D Less maintenance.
D Remote mounting capability.
D No mechanical load on the engine.
014RX044
Ignition Control
The ignition control (IC) spark timing is the ECMs method
of controlling the spark advance and the ignition dwell.
The IC spark advance and the ignition dwell are
calculated by the ECM using the following inputs:
D Engine speed.
D Crankshaft position (58X reference).
D Camshaft position (CMP) sensor.
6E1314
D
D
D
D
Engine coolant temperature (ECT) sensor.

Throttle position (TP) sensor.
Vehicle speed (vehicle speed sensor).
ECM and ignition system supply voltage.

The engine control module (ECM) controls engine ignition
through a solidstate switching unit called the ignition
control module (ICM). The software in the ECM uses
input from several sensors to determine the timing,
duration, and strength of the spark.
014RX007
014RX042
D The crankshaft position (CKP) sensor sends the ECM

a 58X signal related to the exact position of the
crankshaft.
Based on these sensor signals, as well as engine load

and engine coolant temperature information, the ECM
controls the switching function of the ICM by sending it a
5V signal. As long as the ICM receives the signal, it allows
battery voltage to the ignition coil. That voltage allows a
magnetic field to build in the coil.
When the ECM requires a spark plug to fire, it shuts off the
5V signal to the ICM grounding it internally. This triggers
the ICM to switch off the battery voltage to the ignition coil,
which causes the field to collapse. The lines of magnetic
force pass through the secondary portion of the coil as
they collapse. As they intersect the coil, they induce high
voltage in the secondary ignition circuit which travels
toward ground through the spark plug.
Ignition Control ECM Output

The ECM provides a zero volt (actually about 100 mV to
200 mV) or a 5volt output signal to the ignition control
(IC) module. When the ignition control (IC) module
receives the 5volt signal from the ECM, it provides a
ground path for the B+ supply to the primary side of the
coil and creates a magnetic field in the coil. When the
ECM shuts off the 5volt signal to the ignition control
module, the ground path for the primary coil is broken.
The magnetic field collapses and induces a high voltage
secondary impulse which fires the spark plug and ignites
the air/fuel mixture.
0013
D The camshaft position (CMP) sensor sends a signal

related to the position of the camshaft.
The ECM is responsible for maintaining proper spark and

fuel injection timing for all driving conditions. To provide
optimum driveability and emissions, the ECM monitors
the input signals from the following components in order
to calculate spark timing:
D Intake air temperature (IAT) sensor.
D Vehicle speed sensor (VSS).
D Crankshaft position (CKP) sensor.
Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequently 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.
Normal spark plug operation will result in brown to
grayishtan deposits appearing on the insulator portion of
the spark plug. A small amount of redbrown, yellow, and
white powdery material may also be present on the
insulator tip around the center electrode. These deposits
are normal combustion byproducts of fuels and
lubricating oils with additives. Some electrode wear will
also occur.
Carbon fouling of the spark plug is indicated by dry, black
carbon (soot) deposits on the portion of the spark plug in
the cylinder. Excessive idling and slow speeds under light
engine loads can keep the spark plug temperatures so
low that these deposits are not burned off. Very rich fuel
mixtures or poor ignition system output may also be the
cause.Refer to DTC P0172.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during breakin of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the normal
redbrown, yellow or white deposits of combustion
byproducts become sufficient to cause misfiring. In
some cases, these deposits may melt and form a shiny
glaze on the insulator around the center electrode. If the
fouling is found in only one or two cylinders, valve stem
clearances or intake valve seals may be allowing excess
lubricating oil to enter the cylinder, particularly if the
deposits are heavier on the side of the spark plug facing
the intake valve.
TS23995
6E1315
Excessive gap means that the air space between the

center and the side electrodes at the bottom of the spark
plug is too wide for consistent firing. This may be due to
improper gap adjustment or to excessive wear of the
electrode during use. A check of the gap size and
comparison to the gap specified for the vehicle in
Maintenance and Lubrication will tell if the gap is too wide.
A spark plug gap that is too small may cause an unstable
idle condition. Excessive gap wear can be an indication of
continuous operation at high speeds or with engine loads,
causing the spark to run too hot. Another possible cause
is an excessively lean fuel mixture.
TS23992
Low or high spark plug installation torque or improper

seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug and
the cylinder head seats must be in good contact for proper
heat transfer and spark plug cooling. Dirty or damaged
threads in the head or on the spark plug can keep it from
seating even though the proper torque is applied. Once
spark plugs are properly seated, tighten 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 blowby and damage
beyond simple gap wear may occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug
regapping, 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.
6E1316
A/C CLUTCH DIAGNOSIS

A/C Clutch Circuit Operation
TS23994
A broken or cracked lower insulator tip (around the center

electrode) may result from damage during regapping or
from heat shock (spark plug suddenly operating too
hot).
A 12volt signal is supplied to the A/C request input of the

ECM when the A/C is selected through the A/C control
switch.
The A/C compressor clutch relay is controlled through the
ECM. This allows the ECM to modify the idle air control
position prior to the A/C clutch engagement for better idle
quality. If the engine operating conditions are within their
specified calibrated acceptable ranges, the ECM will
enable the A/C compressor relay. This is done by
providing a ground path for the A/C relay coil within the
ECM. When the A/C compressor relay is enabled, battery
voltage is supplied to the compressor clutch coil. The
ECM will enable the A/C compressor clutch whenever the
engine is running and the A/C has been requested. The
ECM will not enable the A/C compressor clutch if any of
the following conditions are met:
D The engine speed is greater than 6315 RPM.
D The ECT is greater than 119C (246F).
D The throttle is more than 80% open.
A/C Clutch Circuit Purpose

The A/C compressor operation is controlled by the engine
control module (ECM) for the following reasons:
D It improves idle quality during compressor clutch
engagement.
D It improves wide open throttle (WOT) performance.
D It provides A/C compressor protection from operation
with incorrect refrigerant pressures.
The A/C electrical system consists of the following
components:
1. The A/C control switch.
2. The A/C refrigerant pressure switches.
3. The A/C compressor clutch.
4. The A/C compressor clutch relay.
5. The ECM.
A/C Request Signal

TS23993
D Damage during regapping can happen if the

gapping tool is pushed against the center electrode or
the insulator around it, causing the insulator to crack.
When regapping a spark plug, make the adjustment
by bending only the ground side terminal, keeping the
tool clear of other parts.
D Heat shock breakage in the lower insulator tip
generally occurs during several engine operating
conditions (high speeds or heavy loading) and may be
caused by overadvanced timing or low grade fuels.
Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack.
Spark plugs with less than the recommended amount of
service can sometimes be cleaned and regapped, then
returned to service. However, if there is any doubt about
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be
replaced.
at the A/C control switch. The ECM uses this input to
adjust the idle speed before turning on the A/C clutch. The
A/C compressor will be inoperative if this signal is not
GENERAL DESCRIPTION
SYSTEM
EVAP Emission Control System Purpose
The basic evaporative emission (EVAP) control system
used on all vehicles is the charcoal canister storage
method. Gasoline vapors from the fuel tank flow into the
canister through the inlet labeled TANK. These vapors
are absorbed into the activated carbon (charcoal) storage

device (canister) in order to hold the vapors when the
vehicle is not operating. The canister is purged by ECM
control when the engine coolant temperature is over 60C
(140F), the IAT reading is over 10C (50F), and the
engine has been running. Air is drawn canister through
the air inlet grid. The air mixes with the vapor and the
mixture is drawn into the intake manifold.

The EVAP canister purge is controlled by a solenoid valve
that allows the manifold vacuum to purge the canister.
The Engine Control Module (ECM) supplies a ground to
energize the solenoid valve (purge on). The EVAP purge
solenoid control is pulsewidth modulated (PWM) (turned
on and off several times a second). The duty cycle (pulse
width) is determined by engine operating conditions
including load, throttle position, coolant temperature and
ambient temperature. The duty cycle is calculated by the
ECM. The output is commanded when the appropriate
conditions have been met. These conditions are:
D The engine is fully warmed up.
D The engine has been running for a specified time.
D The IAT reading is above 10C (50F).
Poor idle, stalling and Poor driveability can be caused by:
D A malfunctioning purge solenoid.
D A damaged canister.
D Hoses that are split, cracked, or not connected
properly.
6E1317
vacuum. The valve controls EGR flow from the exhaust to

the intake manifold through an orifice with a
ECMcontrolled pintle. During operation, the ECM
controls pintle position by monitoring the pintle position
feedback signal. The feedback signal can be monitored
with a Tech 2 as Actual EGR Pos. Actual EGR Pos.
should always be near the commanded EGR position
(Desired EGR Pos.). The ECM also tests for EGR flow.
If incorrect flow is detected, DTC P0401 will set. If DTC
P0401 is set, refer to the DTC charts.
The linear EGR valve is usually activated under the
D Warm engine operation.
D Aboveidle speed.
Too much EGR flow at idle, cruise or cold operation may
cause any of the following conditions to occur:
D Engine stalls after a cold start.
D Engine stalls at idle after deceleration.
D Vehicle surges during cruise.
D Rough idle.
D DTC P0300 (misfire detected).
Too little or no EGR flow may allow combustion
temperatures to get too high. This could cause:
D Spark knock (detonation).
D Engine overheating.
D Emission test failure.
D DTC P0401 (EGR Flow Insufficient detected).
D Poor fuel economy.
GENERAL DESCRIPTION
(EGR) SYSTEM
EGR Purpose
The exhaust gas recirculation (EGR) system is used to
reduce emission levels of oxides of nitrogen (NOx). NOx
emission levels are caused by a high combustion
temperature. The EGR system lowers the NOx emission
levels by decreasing the combustion temperature.
Linear EGR Valve

The main element of the system is the linear EGR valve.
The EGR valve feeds small amounts of exhaust gas back
into the combustion chamber. The fuel/air mixture will be
diluted and combustion temperatures reduced.
Linear EGR Control

The ECM monitors the EGR actual position and adjusts
the pintle position accordingly. The ECM uses information
from the following sensors to control the pintle position:

Of Incorrect Operation
The linear EGR valve is designed to accurately supply
EGR to the engine independent of intake manifold
0017
EGR Pintle Position Sensor

The ECM monitors the EGR valve pintle position input to
from the ECM and to detect a fault if the pintle position
sensor and control circuits are open or shorted. If the
ECM detects a pintle position signal voltage outside the
normal range of the pintle position sensor, or a signal
voltage that is not within a tolerance considered
6E1318
acceptable for proper EGR system operation, the ECM

will set DTC P0404.
GENERAL DESCRIPTION
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM
Crankcase Ventilation System Purpose
The crankcase ventilation system is used to consume
crankcase vapors in the combustion process instead of
venting them to the atmosphere. Fresh air from the
throttle body is supplied to the crankcase and mixed with
blowby gases. This mixture is then passed through the
positive crankcase ventilation (PCV) port into the intake
manifold.
While the engine is running, exhaust gases and small
amounts of the fuel/air mixture escape past the piston
rings and enter the crankcase. These gases are mixed
with clean air entering through a tube from the air intake
duct.
028RX003
During normal, partthrottle operation, the system is

designed to allow crankcase gases to flow through the
PCV valve into the throttle body to be consumed by
normal combustion.
A plugged valve or PCV hose may cause the following
conditions:
D Rough idle.
D Stalling or slow idle speed.
D Oil leaks.
D Sludge in the engine.
A leaking PCV hose would cause:
D Rough idle.
D Stalling.
D High idle speed.
6E1319
SPECIAL TOOLS
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter (Digital
Voltmeter DVM)
5-8840-2640-0
(J 39194-B)
Wrench
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH2
5-8840-0632-0
(J 35689-A)
Terminal Remover
5-8840-0607-0
(J 34142-B)
Unpowered Test Light
5-8840-0388-0
(J 28742-A)
Weather Pack II
Terminal Remover
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter
Kit
5-8840-2606-0
(J 39021-45)
Injector Test Light
5-8840-0383-0
(J 26792/BT-7220-1)
Spark Tester
5-8840-0279-0
(J 23738-A)
Vacuum Pump with
Gauge
SECTION
ENGINE EXHAUST (X22SE 2.2L)
6F1
ENGINE
CONTENTS
Front Exhaust Pipe........................................
Front Exhaust Pipe and Associated Parts ..
Removal .....................................................
Installation ..................................................
Exhaust Silencer ...........................................
Exhaust Silencer and Associated Parts......
6F - 1
6F - 2
6F - 3
6F - 3
6F - 3
6F - 3
6F - 4
6F - 4
Service Precaution
YOU ARE
IN
REPAIRS.
Removal......................................................
Installation...................................................
Rear Exhaust pipe.........................................
Rear Exhaust pipe and Associated Parts ...
Removal......................................................
Installation...................................................
6F - 4
6F - 4
6F - 5
6F - 5
6F - 5
6F - 5
6F - 6

and systems.
6F2
General Description
150RX013
When inspecting or replacing exhaust system

components, make sure there is adequate clearance
from all points on the underbody to prevent overheating
the floor pan and possible damage to the passenger
compartment insulation and trim materials.
Check complete exhaust system and nearby body areas
and rear compartment lid for broken, damaged, missing
or mispositioned parts, open seams, holes, loose
connections or other deterioration which could permit
exhaust fumes to seep into the rear compartment or
passenger compartment. Dust or water in the rear
compartment may be an indication of a problem in one
of these areas. Any faulty areas should be corrected
immediately.
of unleaded fuel only.

Periodic maintenance of the exhaust system is not
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete
exhaust system.
A dual bed monolith catalytic converter is used in
combination with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction)
converter contains platinum and rhodium which lowers
the levels of nitrous oxide (NOx) as well as
hydrocarbons (HC) and carbon monoxide (Co).
Gasket
Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps,
rubber rings, and rubber blocks.
The installation of exhaust system supports is very
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.
Three Way Catalytic Converter

The three way catalytic converter is an emission control
device added to the exhaust system to reduce pollutants
from the exhaust gas stream.
CAUTION: The catalytic converter requires the use
The gasket must be replaced whenever a new exhaust

pipe, muffler or catalytic converter is installed.
6F3
Front Exhaust Pipe

Front Exhaust Pipe and Associated Parts
150RX012
Legend
(1) Front Exhaust Pipe Fixing Nuts
(2) O2 Sensor
(3) Front Exhaust Pipe with Three Way Catalytic
Converter
(4) Front Exhaust Pipe Mounting Rubber
(5) Front Exhaust Pipe Fixing Bolt

(6) Front Exhaust Pipe Fixing Bolt (Clamp)
(7) Front Exhaust Pipe Mounting Bracket
EndOFCallout
Removal
stands.
3. Disconnect O2 sensor harness connector and
remove front side O2 sensor (2).
4. Remove front exhaust pipe fixing bolts (6),(7).
5. Remove front exhaust pipe fixing four stud nuts from
exhaust manifold (1).
6. Remove front exhaust pipe (3).
Installation
1. Install front exhaust pipe (3) and tighten four stud
nuts (1) and two bolts (6) to the specified torque:

Torque:
Stud Nuts : 28 Nm (2.9 kgm/21 lbft)
Bolts (6) : 43 Nm (4.4 kgm/32 lbft)
2. Tighten front side O2 sensor and reconnect O2
6F4
Exhaust Silencer
Exhaust Silencer and Associated Parts
150RW032
Legend
(1)
(2)
(3)
(4)
(5)
Exhaust Silencer
Front Exhaust Pipe Fixing Bolt
Exhaust Silencer Fixing Nuts
Exhaust Rear Pipe
Mounting Rubber
(6) Mounting Rubber

(7) Mounting Rubber
(8) Exhaust Silencer Fixing Nuts
EndOFCallout
Removal
stands.
3. Remove exhaust silencer fixing nuts (3) then
disconnect rear exhaust pipe from exhaust silencer.
disconnect exhaust silencer from front exhaust pipe
(5).
5. Remove exhaust silencer mounting nuts (8) from
chassis side then remove exhaust silencer (1).
Installation
1. Install the exhaust silencer (1) chassis side and
tighten two nuts (8) to the specified torque.
Nuts: 15 Nm (1.5 kgm/11 lbft)
2. Install the exhaust silencer and tighten two Bolts (2)
on front exhaust pipe to specified torque.
Bolts: 43 Nm (4.4 kgm/32 lbft)
3. Install the rear exhaust pipe and tighten two nuts (3)
on exhaust silencer to specified torque.
6F5
Rear Exhaust pipe

Rear Exhaust pipe and Associated Parts
150RW032
Legend
(1)
(2)
(3)
(4)
(5)
Exhaust Silencer
Exhaust Rear Pipe
Mounting Rubber
(6) Mounting Rubber

(7) Mounting Rubber
EndOFCallout
Removal
stands.
3. Remove rear exhaust pipe fixing nuts (3), then
4. Remove mounting rubber (5), (6).
5. Remove rear exhaust pipe (4).
Installation
1. Install the mounting rubber (5), (6).
2. Install the exhaust pipe (4) and tighten two nuts (3)
6F6

150RX011
SECTION
ENGINE LUBRICATION (X22SE 2.2L)
6G1
ENGINE
CONTENTS
Oil Pump .......................................................
Oil Pump and Associated Parts ..................
6G - 1
6G - 2
6G - 3
6G - 3
Service Precaution
FOLLOW WARNINGS
COULD RESULT IN
REPAIRS.
Disassembly ............................................... 6G - 4
Inspection and Repair................................. 6G - 4
Reassembly ................................................ 6G - 4

and systems.
6G2
General Description
A gear-type oil pump is directly driven by the crankshaft
and draws oil from the oil pan, via the suction pipe. If
then passes the pressured oil through a full-flow
disposable oil filter, to the main oil gallery in the cylinder
Block. An oil pump pressure relief valve and oil filter
bypass valve are incorporated in the system.
From the main oil gallery in the cylinder block, the
cylinder head and crankshaft main bearings are
supplied with oil. The camshaft bearings and hydraulic

tappets are supplied through the main feed galleries in
the cylinder head. Vent valves allow air to be expelled
from the oil galleries in the cylinder head. The balance
shaft journals are directly fed from the crankshaft main
bearings. The connecting rod bearings are fed via
passages in the crankshaft. the oil returns to the oil pan
via passages in the cylinder block.
C06RW004
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Oil Strainer
Oil Pump
Relief Valve
Oil Filter
Safety Valve
Oil Gallery
Crankshaft Bearing
Crankshaft
Connecting Rod Bearing
EndOFCallout
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Connecting Rod
Piston
Oil Gallery; Cylinder Head
Camshaft
Camshaft Journal
HLV
Vent Valve
Oil Pan
6G3
Oil Pump
Oil Pump and Associated Parts
051RW004
Legend
(1) Oil Pump Assembly
(2) Oil Pressure Switch
(3) Gasket
EndOFCallout
(4) Sleeve
6G4
Disassembly
Oil Strainer
Check the oil strainer for cracking and scoring. If
cracking and scoring are found, the oil strainer must be
replaced.
1. Remove crankshaft timing pulley.

2. Remove oil pan.
6. Remove oil pressure switch.
7. Remove gasket.
8. Remove sleeve.

CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found through inspection.
Body and Gears

The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection:
Indentation of gear pair use feeler strip and straight
edge.
Dimension : 0.03 mm to 0.10 mm
051RW013
Reassembly
(0.0012 to 0.0039 in)
1. Install oil pressure switch to the oil pump.

2. Install the oil pump with the sleeve and the gasket.
Torque : 6 Nm (0.6 kgm/4.4 lbft)
4. Install Oil pan support.
5. Install the oil pan.
1st step: 8 Nm (0.8 kgm/5.8 lbft)
2nd step: 30
6. Install crankshaft timing pulley.
051RW014

1st step: 130 Nm (13.2 kgm/94 lbft)
2nd step: 45
SECTION
ENGINE SPEED CONTROL SYSTEM (X22SE 2.2L)
6H1
ENGINE
CONTENTS
Accelerator Pedal Control Cable...................
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Adjustment..................................................
6H - 1
6H - 2
6H - 2
6H - 2
6H - 2
6H - 2
Service Precaution
YOU ARE
IN
REPAIRS.
Accelerator Pedal ..........................................

Accelerator Pedal and Associated Parts ....
Removal......................................................
Installation...................................................
Adjustment..................................................
6H - 3
6H - 3
6H - 3
6H - 3
6H - 3

and systems.
6H2
Accelerator Pedal Control Cable
035RX004
Removal
1. Loosen the nut(5) on the cable bracket mounted.
2. Remove cable clip(3).
3. Disconnect accelerator pedal (AP) control cable(6).
(on throttle valve side)
4. Disconnect AP control cable(1). (on AP pedal(7)
side)
5. Remove grommet(2).
6. Remove AP control cable(4).
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.
Inspection
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 grommet(2).
3. Connect AP control cable(1). (on AP pedal(7) side)
4. Connect AP control cable(6). (on throttle valve side)
5. Install cable clip(3).
6. Install nut(5).
Adjustment
1. Loosen adjusting nut and lock nut.
035RX014
Legend
(1) Clearance (2 3.5 mm)
(2) Lock Nut
(3) Adjusting Nut
EndOFCallout
6H3
Accelerator Pedal
Accelerator Pedal and Associated
Parts
Adjustment
Manual Transmission:
Rotate counterclockwise to loosen the lock nut and
screw the stopper bolt in sufficiently.
Fully depress the pedal and hold it there by hand.
Next, rotate the stopper bolt until it hits the stopper of
pedal bracket. Then, lock the stopper bolt there.
035RX002
Legend
(1) Accelerator Pedal Control Cable
(2) Accelerator Pedal Assembly
EndOFCallout
Removal
1. Accelerator pedal control cable(1).
2. Accelerator pedal assembly(2).
Installation
1. Accelerator pedal assembly (2).
2. Accelerator pedal control cable (1).
SECTION
INDUCTION (X22SE 2.2L)
6J1
ENGINE
CONTENTS
Service Precaution......................................... 6J - 1
Air Cleaner Filter ........................................... 6J - 2
Removal ..................................................... 6J - 2
Service Precaution
YOU ARE
IN
REPAIRS.
Inspection ................................................... 6J - 2
Installation................................................... 6J - 2

and systems.
6J2
Air Cleaner Filter

Removal
1. Remove positive ventilation hose connector (1).
2. Remove intake air temperature sensor (2).
3. Remove air cleaner duct assembly (3).
4. Remove air cleaner element (4).
130RW002
Installation
130RX001
Inspection
Check the air cleaner filter for damage or dust clogging.
Replace if it is damaged, or clean if it is clogged.
Cleaning Method
Tap the air cleaner filter gently so as not to damage the
paper filter, or clean the element by blowing with
compressed air of about 490 kPa (71 psi) from the clean
side if it is extremely dirty.
1. Install air cleaner element.

2. Attach the air cleaner duct cover to the body
completely, then clamp it with the clip.
3. Install mass air temperature sensor.
4. Install positive crankcase ventilation hose
connector.
SECTION
ENGINE MECHANICAL (6VD1 3.2L)
6A1
FRONTERA
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System . . . . . . . . . . . .
6A
6B
6C
6D1
6D2
6D3
Driveability and Emissions . . . . . . . . . . . . . . . .

Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System . . . . . . . . . . . .
Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E
6F
6G
6H
6J
ENGINE MECHANICAL
CONTENTS
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring
and Valve Guide . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod . . .
6A2
6A3
6A4
6A19
6A19
6A20
6A22
6A22
6A23
6A25
6A25
6A25
6A27
6A27
6A27
6A28
6A28
6A28
6A29
6A29
6A29
6A30
6A30
6A31
6A34
6A34
6A34
6A37
6A37
6A37
6A38
6A38
6A38
6A39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve, Valve
Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide and Associated Parts . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustments . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
6A39
6A40
6A41
6A41
6A42
6A46
6A46
6A46
6A47
6A47
6A47
6A50
6A50
6A50
6A51
6A51
6A51
6A54
6A54
6A54
6A55
6A58
6A59
6A61
6A61
6A61
6A62
6A64
6A67
6A67
6A67
6A68
6A69
6A71
6A2
Piston and Connecting Rod . . . . . . . . . . . . . . .

Piston, Connecting Rod and Associate
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .
6A75
6A75
6A75
6A76
6A80
6A83
Service Precaution
RESTRAINT SYSTEM (SRS), REFER TO THE SRS
Cylinder Block and Associated Parts . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification . . . . . . . . . . . . . .
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A83
6A83
6A84
6A85
6A88
6A94

systems.
6A3
General Description
Cylinder Head
The cylinder head, made of aluminum alloy casting

employs a pentroof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in Vtype design. The ports are crossflow
type.

should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
D A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
D Whenever valve train components, pistons, piston
D At the time of installation, they should be installed in
D Battery cables should be disconnected before any
D The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.

D When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pickup unit.
D The 12volt electrical system is capable of damaging
battery.
D Any time the intake air duct or air cleaner is removed,
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum diecast casting
for 75Vtype 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.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.

Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.

The crankshaft is made of Ductile castiron. Pins and
bearing.
Engine Lubrication
The oil discharged by a trochoidtype oil pump driven by
the crankshaft is fed through fullflow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.
6A4
Engine Diagnosis
Hard Starting
Condition
Headlights
go
considerably
out
Possible cause
or
dim
Correction

Overhaul or replace
Overhaul or replace
2. Ignition Trouble Starting Motor Turns Over But Engine Does Not Start
Before starting the engine, make sure that the spark plug
Spark Test
tester is properly grounded. To avoid electrical shock, do
Disconnect an igniton coil from any spark plug. Connect
not touch the part where insulation of the igniton coil is
the spark plug tester J26792 (ST125), start the engine,
broken while the engine is running.
and check if a spark is generated in the spark plug tester.
Condition
Possible cause
Correction

engine

system)
Adjust

compression)
Electronic
module
Replace
Ignition
System
with
Correct

Correct or replace

Condition
occurs but engine does not start
start.
Possible cause
Correction
Fuel tank empty
Fill
Clean
Fuel filter clogged
Replace filter
Fuel pipe clogged
Clean or replace
Fuel pump defective
Replace
Correct or replace
Evaporative
Emission
Control
Multiport Fuel Injection System faulty
Correct or replace
Refer to Electronic Fuel Injection
section
6A5

Condition
Possible cause
Correction

Tighten to specified torque or replace

gasket
Adjust
Replace gasket
Lap valve
Valve stem seized
Valve spring weakened or broken
Replace
Overhaul engine
Piston ring seized
Overhaul engine.

ignition system.
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.

hole.
engaged until the compression gage needle reaches
the maximum level. Note the reading.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)
6A6

Condition
Possible cause
Correction
Replace
Correct or replace

or shorted
Correct or replace
Correct or replace
Replace
Replace
Mass Air flow (MAF) Sensor circuit

open or poor connections
Correct or replace
MAF Sensor defective
Replace

Sensor circuit open or poor
connections
Correct or replace
Replace

connections
Correct or replace
Replace
Intake Air Temperature (IAT) sensor

circuit open or poor connections
Correct or replace
IAT sensor defective
Replace
Knock Sensor (KS) cable broken or

poor connections
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Vehicle Speed Sensor (VSS) circuit

open or shorted
Correct or replace
VSS defective
Replace
Replace

Valve circuit open or poor
connections
Correct or replace
EGR Valve faulty
Replace
Canister purge valve circuit open or

poor connections
Correct or replace
Canister purge valve defective
Replace

Replace
Refer to Hard Start

Condition
Others
Possible cause
6A7
Correction
Refer to Hard Start
Lap valve
Readjust
Replace
Fast idle solenoid defective
Replace
Positive Crankcase Ventilation valve

defective or clogged
Replace

Condition
Engine misfires periodically
Engine knocks periodically

Engine lacks power
Possible cause
Correction
Replace
Spark plugs fouling
Replace
Replace
Replace
Replace
Spark plugs fouled
Clean
Replace
Mass Air flow Sensor or Intake

Airflow Sensor circuit defective
Correct or replace

Correct or replace

Sensor or ECT Sensor circuit
defective
Correct or replace
Powertrain Control Module faulty
Replace

or IAT Sensor circuit defective
Correct or replace
Throttle Position Sensor (TPS) or

TPS circuit defective
Correct or replace
Knock Sensor (KS) or KS circuits

defective
Correct or replace
KS Module or KS Module circuits

defective
Correct or replace
6A8
Hesitation
Condition


Possible cause
Throttle Position Sensor
adjustment incorrect
Correction
(TPS)
TPS circuit open or shorted
Correct or replace
Excessive play in accelerator linkage
Adjust or replace

Correct or replace
Replace

Correct or replace
Replace

Correct or replace

poor connections
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Replace
Clean or replace
Fuel pipe clogged
Clean or replace
Fuel filter clogged
Replace
Check and replace
Replace

shorted or open
Fuel Injector defective
Replace

System circuit open or poor
connections
Correct or replace

Condition
Possible cause
Correction
Replace
Throttle Position Sensor (TPS) cable

broken or poor connections
Correct or replace
TPS defective
Replace

Correct or replace
Replace

Correct or replace
Replace
MAP Sensor cable broken or poor

connections
Correct or replace
Replace
IAT Sensor circuit open or poor

connections
Correct or replace
Replace
KS circuit open or poor connections
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Throttle valve not fully opened
6A9
6A10
Engine Lacks Power

Condition

Ignition failure
Possible cause
Correction

working normally
Replace
Clean or replace
Fuel pipe clogged
Clean
Replace

normally
Correct or replace

due
to
clogged
Evaporative
Clean or replace
Clean
Powertrain Control Module supplied

poor voltage
Correct circuit

Correct or replace
cable
Replace
Mass Air flow Sensor not working

normally
Replace

Replace

working normally
Replace

Correct or replace
Replace
Replace
Correct or replace

Guide

range
Ignition coil defective
Replace

Condition
Engine overheating
Possible cause
6A11
Correction
Replenish
Fan clutch defective
Replace
Incorrect fan installed
Replace
Replace
Correct or replace
Radiator clogged
Clean or replace
Replace

low or wrong engine oil
Change or replenish
Resistance
increased

defective parts
in
exhaust

system
(TPS)
Replace with Throttle Valve ASM
Correct or replace
Replace
Engine overcooling

open at 82C (180F))
Refer to Hard Start
Others
Adjust to recommended pressures
Brake drag
Adjust
Clutch slipping
Adjust or replace

high

defective
Replace
6A12
Engine Noisy
originating in rotating parts, sliding parts and other mov-
ing parts of the engine. It is, therefore, advisable to locate

the source of noise systematically.
Condition
Possible cause
Correction

crank bearings
(Faulty
and crank
y crank journals
j
bearings usually make dull noise that
becomes more evident when
accelerating)


install the undersize bearing

Crank bearing seized. Replace crank

crankshaft and install the undersize
bearing
Condition
(Faulty
connecting
rods
or
y
g
engine
is accelerated))
g

Possible cause
Correction

pin and install the undersize bearing

Connecting rod bent
Correct or replace

Abnormal noise stops when the spark plug on the cylinder
with defective part is shorted out.
Condition
Possible cause
Correction
Piston and cylinder noise

makes
k
a combined
bi d mechanical
h i l
thumping
g noise which increases
when engine is suddenly accelerated
but diminishes gradually as the
engine warms up)

cylinder wear
Piston seized
Piston ring broken
Piston defective
Short out each spark plug and listen for change in engine
noise.
Condition
Piston pin noise
goes up and down)
Possible cause
Correction
connecting rod assy
6A13
The slapping sound stops when spark plug on bad cylinder is shorted out.
Condition
Timing belt noise
Possible cause
Correction
Replace pusher or adjust the tension

pulley or replace timing belt
Replace
Replace
Timing pulley defective
Replace

timing cover
Valve clearance incorrect
Replace adjusting shim
Valve spring broken or weakened
Replace
Correct
Camshaft worn out
Replace
Crankshaft noise

engaged)
Engine knocking


range
Carbon deposits
chambers
Clean
Valve noise
Others
in
combustion
Replace fuel

system failure
Refer to Section 6E
Selection
incorrect

selection
of
transmission
gear
Engine overheating
Refer to Engine Lacks Power
Replace
Drive belt slipping
Replace auto tentioner or drive belt
6A14
Abnormal Combustion
Condition
Possible cause
Replace
Fuel filter clogged
Replace
Fuel pump clogged
Clean or replace
Clean or replace
Clean or replace
Replace

Mass Air flow (MAF) sensor circuit

open or defective
Correct or replace
Replace

Correct or replace
Replace

Correct or replace
Replace

Correction
(TPS)
Readjust
TPS defective
Replace
TPS connector poor connections
Reconnect
Vehicle Speed Sensor (VSS) cable

poor connections or defective
Correct or replace
VSS loosely fixed
Fix tightly
VSS in wrong contact or defective
Replace

Correct or replace
Heated Oxygen (O2) Sensor circuit

open
Correct or replace
O2 Sensor defective
Replace

defective
Correct or replace

Valve circuit open or shorted
Correct or replace
EGR Valve defective
Replace

Correct or replace
Canister Purge Valve circuit open or

shorted
Correct or replace
Canister Purge Valve defective
Replace
Replace
Positive
Crankcase
Ventilation
(PCV) valve and hose clogged
Correct or replace
Evaporator system
Refer to Section 6E

Condition
Possible cause
Carbon deposits
chamber
in
6A15
Correction
combustion
Remove carbon

and valve guide
Remove carbon

Condition
Possible cause
Oil leaking
Correction
Crankcase fixing bolts loosened
Retighten
Retighten
Replace gasket

gasket broken
Head cover fixing

gasket broken
bolts loose or
Oil cooler adapter cracked
Replace
Oil cooler center bolt loose
Retighten
Oil cooler Oring broken
Replace
Oil cooler piping loose or broken
Replace
Oil filter attaching bolt loose or rubber

gasket broken
Oil cooler broken
Replace

defective
Replace oil seal
Replace hose
Positive Crankcase Ventilation Valve

clogged
Clean
Engine/Transmission coupling failed
Replace oil seal
Oil
leaking
into
combustion
chambers due to poor
oor seal in valve
system
Replace
Oil
leaking
into
combustion
chambers due to poor seal in cylinder
t
parts
Cylinders
and
excessively
Replace cylinder body assembly and

pistons
Positive
Crankcase
System malfunctioning
Ventilation
Piston
ring
positioned
pistons
gaps
worn
incorrectly
Correct
Correct

pistons

clogged
Clean
6A16

Condition
Others
Possible cause
Correction

viscosity
Continuous high speed driving

and/or severe usage such as trailer
towing

Possible cause
Correction

Condition

Fuel cut function does not work


Combustion
Others

sluggish
Correct
Fuel system leakage
Correct or replace
Clutch slipping
Correct
Brake drag
Correct
Selection
incorrect
of
transmission
gear
Excessive
Exhaust
Gas
Recirculation (EGR) flow due to
trouble in EGR system

selection
Lubrication Problems
Condition
Oil contamination
Possible cause
Correction
Wrong oil in use
Replace
Correct or replace
Oil pump worn
Replace
Correct or replace

rod bearing worn
Replace
Wrong oil in use
Oil filter clogged
Replace oil filter
Replace gasket

cylinder body assembly

Clean or correct

a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the Maintenance and Lubrication section
of this manual.
The level should fall somewhere between the ADD
and the FULL marks on the oil level dipstick.
If the oil level does not reach the ADD mark on the
6A17

5. Start the engine and allow the engine to reach normal
operating temperature (About 80C).
392550 kPa (56.980.4 psi) at 3000 rpm.
7. Stop the engine.

The instrument panel CHECK ENGINE Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system
Condition
CHECK ENGINE MIL does not
when the system checks the starting of engine, or senses

malfunctions.
Possible cause
Correction
Bulb defective
Replace
MIL circuit open
Correct or replace

Correct or replace

cable
loosely
connected,
Correct or replace
PCM defective
Replace
6A18

Condition
CHECK ENGINE MIL illuminates,

and stays on
Possible cause
Deterioration of heated
sensor internal element
Correction
oxygen
Replace
Heated
oxygen
(O2)
sensor
Reconnect properly
O2 sensor lead wire shorted
Correct
O2 sensor circuit open
Correct or replace
Deterioration of Engine Coolant

Temperature (ECT) sensor internal
element
Replace
ECT sensor connector

improper contact
Reconnect properly
terminal
ECT sensor lead wire shorted
Correct
ECT sensor circuit open
Correct or replace

shorted circuits
Correct or replace

sensor
Replace

open or shorted
Correct or replace
Correct or replace

Correct or replace

open or shorted
Correct or replace
Correct or replace
Replace PCM

(Read Only Memory)
Replace PCM
6A19
Cylinder Head Cover LH

Removal
2. Drain engine coolant from faucet bottom of radiator.
3. Remove engine cover from the dowels on the
common chamber.
5. Disconnect following wiring connectors and bonding

cable:
D Vacuum Switching Valve (VSV) for Induction Air
Control Valve (IACV) actuator
D Ignition coils for left bank
D Fuel injectors for left bank
D Idle air control (IAC) valve
D Throttle position sensor (TPS)
D Bonding cable
D Others as necessitated
6. Disconnect following vacuum hoses:
D Brake master VAC
D Canister
D VSV for IACV actuator
D Duty solenoid valve
D PCV
F06RW018
4. Remove air cleaner duct assembly (3) and air cleaner

element (4).
7. Disconnect radiator upper and lower hoses

8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
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
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
F06RW019
6A20

D The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
Legend
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(7) Drive Belt
12. Remove power steering oil pump pulley.
13. Remove fan pulley and bracket assembly.
14. Remove idle pulley assembly.
15. Remove auto tensioner assembly.
16. Remove crankshaft pulley using 5884001330
crankshaft holder.
17. Remove timing belt covers from the right bank side to
the left bank side in order.
18. Remove ignition coil assemblies for the left side bank.
014RW144
D Tighten bolts to the specified torque.

Torque : 9 Nm (0.9 Kgm/78 lb in)
060RW018
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
19. Remove cylinder head cover assembly.
010RW008
2. Install ignition coil assemblies and tighten the fixing

Installation
D Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
D 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.
3. Install timing belt covers from left bank side to right

bank side, and tighten the fixing bolts and nut to the
specified torque.
Torque : 19 Nm (1.9 Kgm/14 lb ft)
4. Install crankshaft pulley and tighten the fixing bolt
using 5884001330 crankshaft holder to the
specified torque.

5. Install auto tensioner assembly and tighten the fixing
Torque :
Shorter Bolt : 20 Nm (2.0 Kgm/14 lb ft)
Longer Bolt : 39 Nm (4.0 Kgm/29 lb ft)
6. Install idle pulley and bracket assembly and tighten
the fixing bolt to the specified torque.
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
8. Install power steering oil pump pulley and tighten the
fixing bolt to the specified torque.
9. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
10. Install cooling fan and clutch assembly and tighten
the fixing bolts to the specified torque.
11. Install upper fan guide and clip both side and tighten
12. Install engine harness and tighten the fixing bolts of
the retaining clip and bracket to the specified torque.
13. Connect radiator upper and lower hoses and clip
them securely.
14. Connect vacuum hoses of those which were
disconnected in the removal step.
15. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
16. Install air cleaner element and air cleaner duct
assembly, and clip the both end securely.
17. Connect Mass Air Flow (MAF) sensor connector,
Intake Air Temperature (IAT) sensor connector and
Positive Crankcase Ventilation (PCV) hose.
18. Install engine cover mating with the dowels.
6A21
6A22
Cylinder Head Cover RH

Removal
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.

and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
D Exhaust Gas Recirculation (EGR) valve
D Fuel injectors for right bank
D Ignition coils for right bank
D Bonding cable
D Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner

element (4).
F06RW019
130RW001
Legend
Legend
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(7) Drive Belt
12. Remove fan pulley and bracket assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5884001330
crankshaft holder.
6A23
16. Remove timing belt covers for right bank side.

17. Reomve timing belt covers for right bank side.
014RW143
D Tighten bolts in turn to the specified torque.

060RW001
Torque : 8.8 Nm (0.9 Kgm/78 lb in)
Legend
(2) Bolts
18. Remove ignition coil assemblies for the right side
bank.
19. Remove cylinder head cover assembly.
Installation
D Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
D 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.
minutes after sealant application before the sealant
hardens.
010RW007
2. Install ignition coil assemblies and tighten the fixing

3. Install timing belt cover and tighten the fixing bolts and
nut to the specified torque.
4. Install crankshaft pulley and tighten the fixing bolt
using 5884001330 crankshaft holder to the
specified torque.
Torque : 167 Nm (17 Kgm/123 lb ft)
5. Install auto tensioner assembly and tighten the fixing
Torque :
Shorter Bolt : 20 Nm (2.0 Kgm/14.8 lb ft)
Longer Bolt : 39 Nm (4.0 Kgm/28.8 lb ft)
6A24
6. Install idle pulley assembly and tighten the fixing bolt

Torque : 52 Nm (5.3 Kgm/38.4 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nm (2.2 Kgm/16.2 lb ft)
8. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
9. Install cooling fan clutch assembly and tighten the
fixing bolts to the specified torque.
Torque : 10 Nm (1.0 Kgm/88.5 lb in)
10. Install upper fan guide and clip both side and tighten
11. Install engine harness and tighten the fixing bolts of
the retaining clip and brackets to the specified torque.
12. Connect radiator upper and lower hoses and clip
them securely.
13. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
14. Install air cleaner element and air cleaner duct
assembly, and the clip both end securely.
15. Connect Mass Air Flow (MAF) sensor connector,
Intake Air Temperature (IAT) sensor connector and
Positive Crankcase Ventilation (PCV) hose.
16. Install engine cover mating with the dowels.
6A25
Common Chamber
Removal
2. Remove air cleaner duct assembly.
025RW001
130RW001
Legend
(5) Air Flow Sensor
3. Disconnect accelerator pedal cable from throttle body
and cable bracket.
4. Disconnect vacuum booster hose from common
chamber.
5. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.
6. Disconnect vacuum hose on canister Vacuum
Switching Value (VSV) and positive crankcase
ventilation hose, fuel rail assembly with pressure
control valve bracket.
7. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
8. Remove the four throttle body fixing bolts.
9. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber and remove
EGR valve assembly.
10. Remove two bolts from common chamber rear side
for remove fuel hose bracket.
11. Remove common chamber four bolts and four nuts
then remove the common chamber.
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt
Installation
1. Install common chamber and tighten bolts and nuts to
Torque :
Bolt : 25 Nm (2.5 Kgm/18 lb ft)
Nut : 25 Nm (2.5 Kgm/18 lb ft)
2. Install fuel hose bracket and tighten bolts to specified
torque.
3. Install exhaust gas recirculation valve assembly and
tighten bolt and nut to the specified torque.
4. Install throttle body and tighten bolts to the specified
torque.
5. Install ventilating hose to throttle valve and intake
duct.
6. Connect vacuum hoses on canister VSV and positive
crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.
7. Connect each connector without fail.
8. Connect vacuum booster hose.
9. Connect accelerator pedal cable.
6A26
10. Install air cleaner duct assembly.
130RW001
Legend
(4) Air Cleaner Element.
6A27
Exhaust Manifold LH
5. Remove heat protector two fixing bolts then the heat
protector.
6. Remove a bolt on engine LH side for air conditioner
(A/C) compressor bracket and loosen two bolts for
A/C compressor then move A/C compressor to front
side.
7. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Removal
2. Remove air cleaner duct assembly.
Installation
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
Torque: 57 Nm (5.8 Kgm/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 Nm (6.8 Kgm/49 lb ft)
Nuts: 43 Nm (4.4 Kgm/32 lb ft)
130RW001
Legend
3. Disconnect heated oxygen (O2) sensor connector.
4. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end of exhaust
front pipe.
150R014
Legend
(1) O2 Sensor
(2) Exhaust Front Pipe LH
4. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.
5. Reconnect O2 sensor connector.
6. Install air cleaner duct assembly.
150RX014
Legend
(1) O2 Sensor
6A28
Exhaust Manifold RH
Removal
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) EGR Valve
(2) EGR Pipe
6. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
150RX015
Legend
(1) Exhaust Front Pipe RH
(2) Heated Oxygen (O2) Sensor
4. Remove heat protector two fixing bolts then the heat
protector.
5. Remove exhaust gas recirculation (EGR) pipe fixing
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
2. Install the EGR pipe, tighten bolt and nut on exhaust
manifold to specified torque.
Tighten nut to EGR valve to the specified torque.
Tighten the bolt for EGR pipe bracket to specified
torque.
3. Install heat protector
4. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque:
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.
6A29
Crankshaft Pulley
Removal
850RW001
130RW001
Legend
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
Legend
(3) Tensioner
(4) Generator
(7) Serpentine Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5-8840-0133-0 crankshaft holder, hold crankshaft
pulley then remove center bolt and pulley.
Installation
1. Install crankshaft pulley using 5-8840-0133-0
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
2. Install cooling fan assembly and tighten bolts/nuts to
Torque : 22 Nm (2.2 Kgm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nm (1.0 Kgm/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.
6A30
Timing Belt
Removal
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
850RW001
014RW011
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
5884001330 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
the life.
3. Do not attempt to pry or stretch the belt with a
4. Store timing belt in a cool and dark place. Never
6A31
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley

1. Align the mark (notch) of crankshaft timing pulley
(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RY00043
Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing
Pulley.
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
6A32
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.
014RW00004
Legend
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
6. Install crankshaft pulley temporarily and tighten

center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
NOTE: It is recommended for easy installation that the

belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
014RW011

Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
6A33
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
3. Remove double clips or equivalent clips, from

timing belt pulleys.
Turn the crankshaft pulley clockwise by two turns.
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
4. Install crankshaft pulley using 5884001330, hold

the crankshaft pulley and tighten center bolt to the
specified torque.
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
6. Install power steering pump assembly and tighten to
Torque :
M8 bolt : 22 Nm (2.2 Kgm/16 lb ft)
M10 bolt : 46 Nm (4.7 Kgm/34 lb ft)
and fan bracket.
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
850RW001
Legend
(3) Auto Tensioner
(4) Generator
(7) Idle Pulley
(8) Drive Belt
020RW003

6A34
Camshaft
Removal
2. Remove crankshaft pulley.
D Refer to removal procedure for Crankshaft Pulley in
this manual.
D Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
D Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
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
three bolts to the specified torque.
2. Tighten bolt for camshaft drive gear assembly pulley
014RW027
7. Remove camshaft assembly.

8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
3. Tighten sub gear setting bolt.

1. Use the 5884024430 gear spring lever 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.
014RW023
014RW041

tighten twenty bolts on one side bank to the specified
torque.
2.
Align timing mark on intake camshaft (one dot for

right bank, two dot for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank
exhaust)
6A35
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
6A36
014RW024

(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
Legend
(1) Right Bank
(2) Left Bank
3. Tighten twenty bolts on numerical order an one

side bank as shown in the illustration.
014RW031
5. Install cylinder head cover RH.

D Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
HEAD COVER LH in this manual.
D Refer to installation procedure for TIMING BELT in
this manual.
8. Install crankshaft pulley.
D Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.
9. Install accelerator pedal cable.
6A37
Cylinder Head
Removal
3. Drain radiator coolant.
4. Drain engine oil.
this manual.
manual.
9. Remove common chamber.
D Refer to removal procedure for Common Chamber
in this manual.
1. Loosen eights bolts for tight cylinder head.
NOTE: There is discrimination mark R for right bank

and L for left bank on the cylinder head gasket as shown
in the illustration.
Do not reuse cylinder head gasket.
011RW005
2. Align dowel pin hole to dowel pin on the cylinder

block.
3. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
4. Using 9851142090 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 Nm (3.0 Kgm/21 lb ft)
Final : 64 Nm (6.5 Kgm/47 lb ft)
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
Installation
1. Install cylinder head assembly to cylinder block.
014RW029
6A38
2. Install common chamber.

D Refer to installation procedure for Common
Chamber in this manual.
D Refer to installation procedure for Cylinder Head

D Refer to installation procedure for Timing Belt in this
manual.
D Refer to installation procedure for Crankshaft
Pulley in this manual.
Valve Stem Oil Controller , Valve Spring and Valve Guide

Removal
Installation

D Drain engine coolant.
D Refer to removal procedure for Cylinder Head in
this manual.
4. Remove camshaft.
D Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5884024460 valve
spring compressor and 5884025470 valve spring
compressor adapter then remove upper valve spring
seat and lower seat.
014RW042
7. Remove oil controller using 5884006230 oil

controller remover, remove each valve stem oil
controller.
8. Remove valve guide using 5884025490 valve
guide replacer.
1. Install valve guide using 5884024420 valve guide

installer.
2. Install oil controller using 5884006240 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 5884024460 valve spring
compressor and 5884025470 valve spring
compressor adapter to install the split collars.
4. Install tappet with shim.
D Refer to installation procedure for Camshaft in this
manual.
D Refer to installation procedure for Cylinder Head in
this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.
6A39
Piston, Piston Ring and Connecting Rod

Removal
F06RW011
Legend
(1) Cylinder Head
(2) Crankcase with Oil Pan
(3) Oil Pipe

this manual.
(4) Oil Strainer

(5) Oil Gallery
(6) Piston with Connecting Rod Assembly
2. Remove crankcase with Oil Pan.

D Refer to removal procedure for Oil Pan and
Crankcase in this manual.
6A40
3. Remove oil strainer fixing bolts, remove oil strainer

assembly with O-ring.
015RW003
050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
4. Remove three fixing bolts, oil pipe with O-ring.
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.
Legend
(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark
2. Install oil gallery and tighten the bolts in two steps, in
the order shown in illustration.
Torque :
1st step : 29 Nm (3.0 Kgm/21 lb ft)
2nd step : 5565
Installation
1. Install piston with connecting rod assembly.
D 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.
D The bearing cap number must be the same as
connecting rod number.
D Apply engine oil to the thread and seating surface of
each nut.
D Tighten nuts to the specified torque.
D After tightening the nuts, make sure that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces
and connecting rod bearing fitting surfaces.
051RS009
3. Install oil pipe with O-ring.

4. Install oil strainer assembly with O-ring.
5. Install crankcase with Oil Pan.
D Refer to installation procedure for Oil Pan and
this manual.
6A41
Crankshaft and Main Bearings

Removal
F06RW010
Legend
(1) Engine Assembly
(4) Timing Belt
(6) Oil Pipe
(7) Oil Strainer
1. Remove engine assembly.

D Refer to removal procedure for Engine Assembly in
this manual.
manual.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Oil Pump Assembly

Cylinder Body Side Bolt
Oil Gallery
Flywheel
Rear Oil Seal Retainer
Connecting Rod Cap
Crankshaft Main Bearing Cap
Crankshaft and Main Bearing
3. Remove oil pan and crankcase.

4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
6A42

D Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
D Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.
D Install main bearing in the cylinder block and main
bearing cap respectively.
Apply new engine oil to upper and lower main
bearings.
NOTE:
D
D
D
D
D
D
Do not apply engine oil to the bearing back faces.

Make sure that main bearings are in correct position.
Install crankshaft with care.
Install thrust washer on No.3 journal.
Oil grooves in thrust washer must face the
crankshaft.
015RS013
2. Install crankshaft main bearing caps.

each bearing cap fixing bolt.
NOTE:
D Do not apply engine oil to the bearing back faces.
D Install bearing caps in the order of numbers, starting
with cylinder block front side.
D Tighten main bearing fixing bolts to the specified
torque.
D After tightening the bolts, make sure that the
3. Install connecting rod caps.
D The cap number must be same as connecting rod
number.
each nut.
4. Install rear oil seal retainer.
D Remove oil on cylinder block and retainer fitting
surface.
D Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
015RS012

D The oil seal retainer must be installed within 5
hardens.
6A43
D Tighten fixing bolts to the specified torque.

015RS018
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
D Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer.
D Tighten retainer fixing bolts to the specified torque.
6. Install oil gallery.

D Clean contact surface of oil gallery and main
bearing cap.
Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown in
illustration.
Torque :
2nd step : 5565
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
NOTE: Do not apply the oil to the bolts.
015RW001
5. Install flywheel.
D Clean tapped holes in the crankshaft.
D Remove oil on crankshaft and flywheel fitting
surface.
NOTE:
D Do not reuse the bolts.
D Do not apply oil or thread lock to the bolts.
012RS007
8. Install oil pump assembly.

D Remove oil on cylinder block and oil pump mounting
surface.
6A44
D Apply sealant (TB1207B or equivalent) to the oil

pump mounting surface.
D The oil pump assembly must be installed within 5
hardens.
D Apply engine oil to oil seal lip.
11. Install crankcase.

D Remove oil on crankcase mounting surface and dry
the surface.
D Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the crankcase
mounting surface. The bead must be continuous.
D Install oil pump in the cylinder block and tighten

D The crankcase must be installed within 5 minutes

after sealant application before the sealant
hardens.

051RW002
Legend
013RW010
013RW004
051RW001
9. Install oil strainer with O-ring, tighten to the specified

torque.
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
12. Install oil pan

D Remove oil on oil pan mounting surface and dry the
surface.
sealant (TB1207C or equivalent) to the oil pan
D The oil pan must be installed within 5 minutes after
sealant application to prevent premature hardening
of sealant.

013RW003
013RW002

manual.
14. Install engine assembly.
D Refer to installation procedure for Engine in this
manual.
6A45
6A46
Rear Oil Seal

Removal
1. Remove transmission assembly.
D Refer to removal procedure for Transmission
section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
5884022860.
015RS018
3. Install transmission.
D See Transmission section in this manual.
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
015RS017
D Remove oil on the crankshaft and flywheel
mounting surface.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
012RS009
6A47
Engine Assembly
Removal
515RX013

2. Remove battery.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original
position exactly.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Disconnect air duct with air cleaner cover.
9. Disconnect canister vacuum hose.
10. Disconnect vacuum booster hose.
11. Disconnect three engine harness connectors.
12. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front
axle and remove transmission harness bracket from
engine left side.
13. Disconnect ground cable between engine and frame.
14. Disconnect bonding cable connector on the back of
right dash panel.
15. Disconnect bonding cable terminal on the left bank.
16. Disconnect starter harness connector from starter.
17. Disconnect generator harness connector from
generator.
18. Disconnect coolant reserve tank hose from radiator.
19. Remove radiator upper and lower hoses.
20. Remove upper fan shroud.
23. Remove power steering pump fixing bolts, then

power steering pump. Place the power steering pump
along with piping on the body side.
24. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
on the body side.
25. Remove O2 sensor harness connectors from exhaust
front pipe.
26. Remove three exhaust pipe fixing nuts from each
bank.
27. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side of
vehicle.
28. Remove flywheel dust covers.
29. Disconnect two heater hoses from engine.
30. Disconnect fuel hoses from right side of transmission.
CAUTION: Plug fuel pipes on engine side and fuel
hoses from fuel tank.
31. Remove transmission assembly. Refer to
Transmission section in this manual.
32. Support the engine by engine hoist.
33. Remove two left side engine mount fixing bolts from
engine mount on chassis side.
34. Remove two right side engine mount fixing bolts from
Installation
transmission.
6A48
If the engine is assembled in the condition that the

dowels have not been mounted in the specified positions, the transmission may be damaged the transmission.
150RX015
Legend
(2) O2 Sensor
012RS009
1. Install engine assembly. Tighten engine mount fixing

bolts to frame to the specified torque.
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.
Torque:
150RX014
Legend
(1) O2 Sensor
and fan bracket.
clutch assembly.

9. Install air conditioner compressor to engine and
Torque :
M8 bolts : 22 Nm (2.2 Kgm/16 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22Nm (2.2 Kgm/16 lb ft)
6A49
17. Reconnect bonding cable terminal on left bank

18. Reconnect bonding cable terminal on the back of right
dash panel.
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
25. Reconnect air duct.
26. Reconnect accelerator cable and automatic cruise
control cable to throttle valve on common chamber.
850RW001
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
035RW007
Legend
(2) Throttle Lever
(3) Idle Air Control Valve
(4) Throttle Position Sensor
27. Install engine hood to the original position.
D Refer to installation procedure for Body section in
this manual.
6A50
Cylinder Head
011RW008
Legend
(1) Spark Plug
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(6) Camshaft Bracket
(7) Camshaft Exhaust
Disassembly
NOTE:
D During disassembly, be sure that the valve train
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Camshaft Intake
Retainer Fixing Bolt
Retainer Assembly
Tappet with Shim
Split Collar
Valve
D Before removing the cylinder head from the engine

1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).

bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5884024460 valve spring compressor
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
6A51
3. Cylinder head deck for corrosion, sand particles in

head and porosity.
CAUTION:
D Do not attempt to weld the cylinder head. Replace
it.
D Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are out of flat by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
014RW042
5. Remove spark plug (1).

CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.

1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blowby. If the gasket has failed,
determine the cause.
Insufficient torque on head bolts.
Improper installation
Loose or warped cylinder head
Missing dowel pins
Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
011RW019
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
1. Use 5884024430 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.
6A52
2. Tighten the M5 bolt to a suitable torque to prevent

the sub gear from moving .
Legend
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW025

Torque: 10 Nm (1.0 Kgm/89 lb in)
torque.
2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
dot).
014RW020
014RW023
Legend
(4) Dowel Pin
6A53
014RW024

Legend
(1) Right Bank
(2) Left Bank
3. Tighten twenty bolts in numerical order on one

014RW031
5. Tighten bolt for camshaft drive gear assembly pulley

6A54
Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend
(1) Camshaft Bracket Fixing Bolts
(2) Camshaft Assembly Inlet
(4) Shim
(5) Tappet
(6) Split Collar
Disassembly
1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).
(7)
(8)
(9)
(10)
(11)
(12)
Spring Upper Seat

Valve Spring
Oil Controller
Spring Lower Seat
Valve Guide
Valve
3. Remove camshaft assembly (Exhaust side).

4. Remove shim (4) and tappet (5).

5884025470 valve spring compressor adapter to
remove split collar.
6A55
2. Measure the valve spring squareness with a steel

square and replace the valve springs if the measured
value exceeds the specified limit.
Limit : 2 mm (0.0787 in)
014RW042
6. Remove valve spring.

7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5884024420
valve guide replacer.

Valve Spring
014RS005
3. Using a spring tester to compress the springs to the

installed height, measure the compressed spring
tension, and replace the springs if the measured
tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
CAUTION: Visually inspect the valve springs and

replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Limit : 43.6 mm (1.7165 in)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
scratchs or abnormal wear. If these conditions are
replaced as a set.
014RS004
6A56
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
(0.2353 in0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
(0.2343 in0.2350 in)
Limit : 5.90 mm (0.2323 in)
014RS008
2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5884024420, drive in
a new valve guide from the camshaft side, and check
the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RS007
2. Measure the inside diameter of the valve guide with a

micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
(0.0009 in0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
(0.0012 in0.0025 in)
Limit : 0.20 mm (0.00787 in)
Valve Guide Replacement

1. Using Valve guide replacer: 5884024420, drive
out the valve guide from the combustion chamber
side.
014RW046
3. Check the clearance. If the clearance is less than the

specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.
Valve Seat
1. Measure the protrusion of the valve stem when a new
valve is installed in the cylinder head. If the protrusion
of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.
Protrusion of valve stem
Intake

Limit: 39.47 mm (1.5539 in)
Exhaust
Limit: 39.45 mm (1.5531 in)
6A57
2. If the measured value exceeds the limit, replace

valve, valve guide and valve seat as a set.
Valve contact surface angle: 45
014RS012
014RW047
2. Measure the valve seat contact width. Make the

necessary corrections if the seat contact surface is
damaged or rough or if the contact width wear
exceeds the limit.
Valve seat contact width
Limit: 1.7 mm (0.0669 in)

1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and other
rough areas. This will bring the contact width back to
the standard value. Remove only the scratches and
rough areas. Do not cut away too much. Take care not
to cut away unblemished areas of the valve seat
surface.
Valve seat angle degree: 90
014RS011
Contact Surface Angle on Valve Seat on

Valve
1. Measure contact surface angle on valve seat.
014RW059
3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.
6A58
6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
7. After insertion, use a seat grinder to grind finish the

seating face. Carefully note the seating angle, the
contact width, and the depression.
Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer 5884024420, drive in a new valve guide
from the camshaft side.
Using oil controller replacer 5884006230, drive in
a new oil controller.
014RS014

2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
014RW058

spring to the lower spring seat. The painted area of
the valve spring should be facing downward.
014RS015
4. Carefully clean the valve seat pressfit section on the

cylinder head side.
horizontally.
Standard fitting interference: 0.14 mm0.09 mm
(0.0055 in0.0035 in)
014RS020

spring seat, using the 5884024460 valve spring
6A59
Valve Clearance Adjustments

NOTE: To adjust valve clearance, apply engine oil to the
cam as well as to the adjusting shim (2) with the cylinder
head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite to maximum cam lift (1) as shown in illistration
below.
014RW042

manual.
014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)

Intake: 0.23 mm0.33 mm
(0.0091 in0.0130 in)
Exhaust: 0.25 mm0.35 mm
(0.0098 in0.0138 in)
Selection of Adjusting Shim

Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement Standard valve)
Based on the above formula, the best suited shim should
be selected from 41 sorts of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.
6A60
Replacement of Shim
Let the cam push down the edge of tappet by using
5884024440 valve clearance adjusting tool and push
out the shim with a flat blade screw driver as shown in
illustrations below.
014RW084
014RW082
014RW083
6A61
Camshaft
014RW040
Legend
(5) Pulley Fixing Bolt
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley
using the 5884024470 universal holder.
(6)
(7)
(8)
(9)
(10)
Camshaft Drive Gear Pulley

Retainer
Camshaft Drive Gear
Oil Seal
6A62
014RW060

brackets (2).
014RW043
2. Use a micrometer to measure the diameter and the

uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
(1.0225 in1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)
014RW027

4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.

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)
014RS023
3. Place the camshaft on Vblocks.

Slowly rotate the camshaft and measure the runout
with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.

Runout
Limit : 0.1 mm (0.0039 in)
6A63
Oil Clearance
(0.0011 in0.0031 in)
Limit : 0.11 mm (0.0043 in)
014RW044
4. Measure the camshaft journal oil clearance.

1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
014RW037
5. Replace the cylinder head and/or camshaft if the

measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
014RW031
2. Subtract the camshaft outside diameter from the

camshaft bracket housing inside diameter.
014RW031
3. Measure the camshaft thrust clearance with a dial

indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
6A64

2. Align timing mark on intake camshaft (one dot for
dot).
Camshaft thrust Clearance

(0.0012 in.0.0031 in.)
Limit : 0.12 mm (0.0047 mm)
014RW035
014RW020
Reassembly
1. Use 5884024430 to turn sub gear to right
direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.
Legend
(4) Discerning Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
2. Tighten M5 bolt suitable torque for prevent

moving the sub gear.
014RW023
014RW041

torque.
Legend
(4) Dowel Pin
6A65
014RW024

Legend
(1) Right Bank
(2) Left Bank
3. Tighten twenty bolts in numerical order on one

4. If the oil seal requires replacement, use the

5884024450 to install the oil seal.
014RW034
014RW031
6A66
5. Tighten bolt for camshaft drive gear pulley to the

specified torque using the 5884024470 universal
holder.
014RW060
6A67
Crankshaft
013RW009
Legend
(1) Cylinder Head Assembly
(3) Oil Pipe and O-Ring
(4) Oil Strainer and O-Ring
(6) Cylinder Block Side Bolts
(7) Oil Gallery
Disassembly
Cylinder Head in this manual.
2. Remove crankcase with oil pan (2). Refer to Oil Pan
and Crankcase in this manual.
(8)
(9)
(10)
(11)
(12)
(13)
(14)

Flywheel
Rear Oil Seal Retainer and Oil Seal
Main Bearing Cap
Crankshaft
Main Bearing Cap Fixing Bolts
Oil Gallery Fixing Bolts

3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
6. Remove crankcase side bolts (6).
6A68
7. Remove oil gallery (7).

Refer to Piston, Piston Ring and Connecting Rod in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).

1. Crankshaft
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
(0.0024 in0.0094 in)
015RS004

Limit : 0.30 mm (0.0118 in)

The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
position.
NOTE: Do not set the plastigage on the oil hole.
015RS003

clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
015RS005
9. Install main bearing caps, oil gallery and crank case

bolts in the order shown, and tighten each bolt to the
specified torque.

NOTE: Do not apply engine oil to the crank case side
bolts.
6A69
Limit : 0.08 mm (0.0031 in)
Main bearing cap bolts.

Oil gallery fixing bolts.
Torque:
1st step: 29 Nm (3.0 Kgm/21 lb ft)
2nd step 55 65
Crank case side bolts
015RS008

crankshaft.
Crankshaft Inspection
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
the oil ports for obstructions.

015RS006
10. Remove the main bearing caps in the sequence

1. Carefully set the crankshaft on the Vblocks. Slowly

rotate the crankshaft and measure the runout. If the
Runout : 0.04 mm (0.0016 in)
015RS004

(0.0007 in0.0017 in)
015RS007
6A70

journal and crank pin. If the crankshaft wear exceeds
the specified limit, crankshaft must be replaced.
(2.5165 in2.5170 in)
2. Diameter size mark (1).

The diameter size marks are stamped on the No.1
crankshaft balancer as shown in the illustration.

(2.1229 in.2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015RS011

correctly.
015RS009

install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark (1) and the crankshaft journal.
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower
015RS010
1 Size
Mark
Main Bearing
Bore Diameter
68.994-69.000
(2.7163-2.7165)
68.987-68.993
(2.7160-2.7163)
68.980-68.986
(2.7157-2.7160)
6A71
Crank Shaft Main

Journal Diameter
2 Size
Mark
Crank
Shaft
Bearing
Size Mark
(Upper
Side)
63.918-63.925
(2.5165-2.5167)
Blue
63.926-63.933
(2.5168-2.5170)
63.918-63.925
(2.5165-2.5167)
0.029-0.048
(0.0011-0.0019)
63.926-63.933
(2.5168-2.5170)
0.027-0.046
(0.0011-0.0018)
63.918-63.925
(2.5165-2.5167)
63.926-63.933
(2.5168-2.5170)
Brown
Crank
Shaft
Bearing
Size Mark
(Lower
Side)
Oil Clearance
(Reference)
Blue
0.030-0.049
(0.0012-0.0019)
Brown
Green
Green
Yellow
Yellow
0.028-0.047
(0.0011-0.0019)
0.028-0.047
(0.0011-0.0019)
0.026-0.045
(0.0010-0.0018)
D Apply engine oil to the thrust washer.
Reassembly
1. Crankshaft
D Install the main bearings to the cylinder block and
D Assemble the thrust washer to the No.3 bearing

D Be sure that they are positioned correctly.

D Apply new engine oil to the upper and lower main
bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015RS013
2. Rear oil seal

D Remove the oil from the cylinder block and the
retainer mounting surface.
015RS012
D Carefully mount the crankshaft.
D Apply sealant (TB1207B or equivalent) to the

retainer mounting surface, following the pattern
The retainer must be installed within 5 minutes after
sealant application befor the sealant hardens.
6A72
015RW002
015RS017
3. Flywheel
Legend
D Apply engine oil to the oil seal lip.

mounting faces.
D Align the cylinder block dowel pin holes with the rear
retainer dowel pins.

install the washer.
D Tighten the rear retainer fixing bolts. New bolts

should be used when installing rear retainer.
4. Hold the crankshaft to prevent from rotating then

install the bolts in the order shown to the specified
torque.
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 5884022860 oil seal
installer.
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS018
015RW001
6A73

D Apply engine oil to the cylinder bores, the
015RS020
5. Install oil gallery (7) and tighten the bolts in 2 steps, in

the order shown.
1st step: 29 Nm (3.0 Kgm/22 lb ft)
2nd step: 55 65
015RX003
Legend
(1) No.1 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
D Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor. The
front marks must be facing the front of the engine.
D Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.
D Apply engine oil to the threads and seating faces of
the nuts.
D Tighten the nuts.
After tightening the cap nuts, check to see that the
NOTE: Do not apply engine oil to the bearing back faces.
051RS009
6. Cylinder block side bolts

D Tighten all the bolts to the specified torque in the
order shown.
bolts.
6A74

Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion
head in this manual.
012RS001
7. Install oil pump assembly (5), refer to Oil pump in

this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
10. Install crankcase with oil pan.
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
1207C or its equivalent) to the contact surfaces of
the oil pan. There must be no gaps in the bead.
3. The crankcase assembly must be installed within
5 minutes after sealant application to prevent
premature hardening of the sealant.
4. Tighten the bolts and nuts to the specified torque.
013RW010
6A75

015RW019
Legend
(2) Cylinder Head Gasket
(6) Oil Gallery
Disassembly
Cylinder Head Removal in this manual.
3. Remove crankcase with oil pan (3). Refer toOil Pan
(7)
(8)
(9)
(10)
(11)
(12)

Piston Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Cap

lower bearing (12).
6A76
015RS031
D Remove any ridge or carbon build up from the top

015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)

Pistons
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
any of the above conditions are found, the piston must be
replaced.
Piston Diameter
015RS022
10. Remove the piston pin (9) using 5884005510

piston pin service set and piston support with a press.
positions. Heating the connecting rod will permit easy
removal of the piston pin.
1. Measure the piston outside diameter with micrometer

at the piston grading position and a right angle to the
piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)
015RV014
6A77
012RS002
The size mark (1) for piston outside diameter is

represented as shown in illustration below.
Piston Rings
Outside Diameter
Size Mark A : 93.360 mm93.370 mm
(3.6756 in3.6760 in)

D Insert the piston ring into the bore.
Size Mark B : 93.371 mm93.380 mm

(3.6760 in3.6764 in)
D Push the ring by the piston, at a right angle to the

Size Mark C : 93.381 mm93.390 mm

(3.6764 in3.6768 in)
D Measure the ring end gap.

Compression Ring
1st ring
Standard:
0.300 mm0.400 mm
(0.0118 in0.0157 in)
Limit:
1.0 mm (0.0394 in)
2nd ring
Standard:
0.450 mm0.600 mm
(0.0177 in0.0236 in)
Limit:
1.2 mm (0.0472 in)
Oil ring
Standard:
0.150 mm0.450 mm
(0.0059 in0.0177 in)
Limit:
015RX002
Measure the cylinder bore inside diameter (refer to

Cylinder Block in this manual).
1.05 mm (0.0413 in)
6A78
015RS026
015RS028
D Positioning mark (1) is painted as shown in the

illustration.
Piston Pin
Marked T : No.1 Compression ring

positions.
small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.
Marked T2 : No.2 Compression ring
Standard : 0.023 mm0.038 mm (0.0009

in0.0015 in)
015RS027

piston ring groove / piston ring clearance exceeds the
(0.0006 in.0.0015 in)
Limit : 0.15mm (0.0059 in)
015RS029
is normal. If there is backlash or roughness, measure
the clearance. If the clearance exceeds the specified
limit, the piston must be replaced.
Clearance
(0.0004 in.0.0007 in)
Limit : 0.040 mm (0.0016 in)
6A79
Connecting Rods
1. Check the connecting rod alignment If either the bend
or the twist exceeds the specified limit, the connecting
rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)
015RS031

1. Remove the connecting rod cap nuts and the rod
caps (12).
number order.
015RS030
2. Measure the connecting rod thrust clearance. Use a

feeler gauge to measure the thrust clearance at the
large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod must
be replaced.
(0.0063 in.0.0138 in)

bearing is found to be damaged or badly worn, the
entire bearing assembly must be replaced as a
set. Reinstall the bearings in their original
Limit : 0.40 mm (0.0157 in)
015RS032
6A80

positions.

crankshaft pins.
Conrod Bearing Selection

Select and install the new connecting rod bearings,
paying close attention to the connecting rod big end
diameter size mark (1).

set.
NOTE: Take care not to confuse the alignment mark (2)

and the size mark (1) during the installation procedure.

(0.0007 in0.0017 in)
Limit : 0.08 mm (0.003 in)
015RS034
015RS008
1 Size Mark
Big end Bore

Diameter
56.994-57.000
(2.2439-2.2441)
56.988-56.994
(2.2436-2.2439)
56.982-56.988
(2.2434-2.2436)
Reassembly
2. Install piston
Crankshaft Pin
Diameter
53.922-53.937
(2.1229-2.1235)
Connecting Rod
Bearing Thickness
(Reference)
Color of
Size
Mark
Oil Clearance
(Reference)
1.512-1.516
(0.0595-0.0597)
Yellow
0.025-0.054
(0.0010-0.0021)
1.508-1.512
(0.0594-0.0595)
Green
0.027-0.056
(0.0011-0.0022)
1.504-1.508
(0.0592-0.0594)
Pink
0.029-0.058
(0.0011-0.0023)

D Apply a thin coat of engine oil to the piston pin. Try to
insert the piston pin into the piston pin hole with
normal finger pressure.
6A81
D Attach the piston to the connecting rod with the

piston front mark and the connecting rod front mark
on the same side.
015RS027
015RS036
D With 5884005510 Piston pin service set and a

press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
D Install piston rings in the following sequence.

1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
3. 1st compression ring
D The compression rings must be set with the T or T2
mark facing up.
D After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
The compression ring must be set with the T mark (1)
facing up.
015RS038
6A82

D Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.
D Tighten the connecting rod cap nuts
6. Oil gallery, refer to Crankshaft and main bearing in
this manual.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to Oil pan and
11. Install Cylinder head assembly.
D Refer to Cylinder head in this manual.
6A83
Cylinder Block
012RW010
Legend
Disassembly
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Oil Gallery
Flywheel
Rear Oil Seal Retainer Assembly
Main Bearing Cap
Crankshaft
Cylinder Block
5. Remove oil strainer and O-ring.

7. Remove crankcase side bolts.
10. Remove flywheel.
6A84

Cylinder Bore

material adhering to the upper surface of the cylinder
block. Be very careful not to allow any material to
accidentally drop into the cylinder block. Be very
careful not to scratch the cylinder block.
4. Visually inspect the cylinder block. If necessary, use a
flaw detector to perform a dye penetrate and
Flatness

Cylinder Bore Inside Diameter
Limit : 93.530 (3.6823)
If the measurement exceed the specified limit, the
Diameter
Grade A : 93.400 mm93.410 mm
(3.6772 in3.6776 in)
Grade B : 93.411 mm93.420 mm
(3.6776 in3.6779 in)
Grade C : 93.421 mm93.430 mm
(3.6780 in3.6783 in)
1. Using a straightedge and feeler gauge, check that

the upper surface of the cylinder block is not warped.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
012RS005

Rod Assembly in this manual.
D The Grade mark (1) is stamped at the position
illustrated.
012RS004
6A85
D Assemble the thrust washer to the No. 3 bearing

012RS006
Reassembly
015RS013

bearing faces.

surface.
hardens.
015RW002
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.
Legend
Torque: 25 Nm (2.5 Kgm/18.4 lb ft)
6A86

D Check to see that the piston ring end gaps are
015RW001
4. Install flywheel
mounting faces.
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
015RX003
Legend

D The front marks (1) must be facing the front of the

engine.
015RS018

015RS020
6. Install oil gallery and tighten the bolts in 2 steps in the

order shown.
2nd step : 55 65
012RS007
7. Install cylinder block side bolts (1) and tighten

crankcase bolts in sequence shown in the illustration.
6A87
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
13. Install cylinder head assembly. Refer to Cylinder
Head in this manual.
012RW005
8. Install oil pump assembly. Refer to Oil Pump in this

manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
2. Apply a correct width bead of sealant (TB 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
after sealant application to prevent premature
hardening of sealant.
6A88
Main Data and Specification

Item
Engine type, number of cylinders and arrangement
Form of combustion chamber
Specifications
6VD1
Water cooled, four cycle V6
Pent roof type
Valve mechanism
4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner type
Casted in cylinder drive
Total piston displacement

Cylinder bore x stroke
Compression ratio
Compression pressure at 300rpm
Engine idling speed rpm
Valve clearance
3165 cc
93.4mm x 77.0mm
(3.6772 in x 3.0315 in)
9.1 : 1
14.0 Kg/cm@
Non adjustable (750)
Intake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12in)
Oil capacity
Ignition timing
Spark plug
Plug gap
5.3 liters
Non adjustable
16 BTDC at idle rpm)
K16PRP11, PK16PR11, RC10PYP4
1.0 mm1.1 mm(0.0394 in 0.0433 in)
6A89
Ignition coil, Spark plug, Crankshaft position sensor and Under cover
Nm (Kgm/lb ft)
E06RX008
6A90
Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, EGR valve and EGR pipe
Nm (Kgm/lb ft)
E06RW043
6A91
Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt
cover, Oil pump, Oil gallery, Oil strainer and Water pump
Nm (Kgm/lb ft)
E06RW039
6A92
Connecting rod and Water pump
Nm (Kgm/lb ft)
E06RW042

Engine mount
6A93
Nm (Kgm/lb ft)
E06RW040
6A94
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884000110
(J2168702)
Remover; tie rod end
5884024410
Set Number of Valve
Compressor
5884024460
(J8062)
Compressor; Valve
Spring (1)
5884025470
(J42898)
Adapter; Compressor
Valve Spring (2)
5884006230
(J37281)
Remover; Oil controller
5884006240
(J38537)
Installer; Oil controller
5884024450
(J42985)
Installer; Camshaft oil
seal
5884025450
(J39206)
Installer; Pilot bearing
ILLUSTRATION
TOOL NO.
TOOL NAME
5884001330
(J861401)
Holder; Crankshaft
5884021530
(J37228)
Seal cutter
5884022860
(J39201)
Installer; Real oil seal
9851142090
(J242391)
Cylinder head bolt
wrench
5884024420
(J42899)
Replacer; Valve guide
(set) (1,2)
5884025480
(J42687)
Installer; Valve guide (1)
5884025490
(J379851)
Remover; Valve guide
(2)
5884024440
(J42689)
Adjusting Tool: Valve
clearance

ILLUSTRATION
TOOL NO.
TOOL NAME
5884024430
(J42686)
Lever; Gear spring
5884024470
(J43041)
Holder; Universal
6A95
SECTION
ENGINE COOLING
6B1
FRONTERA
ENGINE
ENGINE COOLING
CONTENTS
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling Cooling System . . . . .
Engine coolant change . . . . . . . . . . . . . . . . . . .
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6B1
6B2
6B5
6B6
6B6
6B7
6B7
6B7
6B7
6B7
6B8
6B8
6B8
Service Precaution
systems.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Associated Parts . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt and Cooling Fan . . . . . . . . . . . . . . .
Drive Belt and Associated Parts . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6B8
6B8
6B9
6B9
6B9
6B10
6B11
6B12
6B12
6B12
6B12
6B13
6B14
6B2
ENGINE COOLING
General Description
030RW001
Legend
(1) Water Pump
(2) Thermostat
(3) Radiator
(4) Reserve Tank
(5) Cooling Fan
(6) Cylinder Block
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Cylinder Head
Right Bank
Throttle Body
Cylinder Block
Cylinder Head
Left Bank
Heater
The cooling system is a pressurized Engine Coolant (EC)

forced circulation type which consists of a water pump,
thermostat cooling fan, radiator and other components.
The automatic transmission fluid is cooled by the EC in
radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
030RS001
ENGINE COOLING
Thermostat
6B3
Anti Freeze Solution
The thermostat is a wax pellet type with a air hole(1) and is

installed in the thermostat housing.
D Relation between the mixing ratio and freezing

temperature of the Engine Coolant varies with the
D Calculating mixing ratio
031RW002
Radiator
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted
with a cap in which the valve is operated at 88.2 117.6
kPa (12.8 17.0 psi) pressure. (No oil cooler provided for
M/T)
F06RW005

system capacity.
D Total Cooling System Capacity
D M/T 8.8Lit (2.32Us gal)
D A/T 8.4Lit (2.22Us gal)
110RW023
6B4
ENGINE COOLING
B06RW002
D Mixing ratio
cooling system temperature ranges from 0C to 50C
using a suction type hydrometer, then determine the
NOTE:
1. Even in the areas where the atmospheric
temperature is higher than 0C, 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%.
B06RW003
ENGINE COOLING
6B5
Diagnosis
Engine overheating
Replenish
Replace
Thermo meter unit faulty
Replace
Faulty thermostat
Replace

sensor
Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap
Replace

improper engine oil

faulty parts

sensor circuit
Repair or replace
Replace
Engine overcooling
Faulty thermostat
Replace
Faulty thermostat
Replace
Thermo unit faulty
Replace
6B6
ENGINE COOLING
Draining and Refilling Cooling

System
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the MIN
and MAX lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the MAX line.
Engine coolant change

1. To change engine coolant, make sure that the engine
is cool.
WARNING: WHEN THE COOLANT IS HEATED TO A
HIGH TEMPERATURE, BE SURE NOT TO LOOSEN
OR REMOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A
PIECE OF THICK CLOTH ON THE CAP AND LOOSEN
THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
Replace damaged rubber hoses as the engine anti-freeze
coolant is liable to leak out even minor cracks.
Isuzu recommends to use Isuzu genuine anti-freeze (ethylene-glycol based) or equivalent, for the cooling system
and not add any inhibitors or additives.
the filler neck even before the engine and radiator are
completely full.
To avoid such trouble, the following precautions
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between the
filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over this
maximum rate may force air inside the engine and
radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
5. After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
disclodged and the coolant level goes down. Should
the coolant level go down, repeat topping-up until
there is no more drop in the coolant level.
6. After directly filling the radiator, fill the reservoir to the
maximum level.
7. Install and tighten radiator cap and start the engine.
After idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
8. After tightening radiator cap, warm up the engine at
about 2,000 rpm.
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into heater
water system.
9. Check to see the thermostat has opened through the
needle position of water thermometer, conduct a
5-minute idling again and stop the engine.
10. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
11. Fill the coolant into the reservoir tank up to MAX line.
ENGINE COOLING
6B7
Water Pump
030RS002
Legend
(1) Timing Belt
(2) Idle Pulley
Removal
2. Drain coolant.
4. Remove timing belt. Refer to Timing Belt in this
manual.
5. Remove Idle pulley.
7. Remove gasket.

(4) Gasket

specified torque.
D Tightening order
The tightening order are in the illustrate.
NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bolt
thread.
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:
D Crack in the water pump body
D EC leakage from the seal unit
D Play or abnormal noise in the bearing
D Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket
before installation.
030RW008
6B8
ENGINE COOLING
3. Idle pulley
D Install idle pulley and tighten bolt to the specified
torque.
4. Timing belt
D Install timing belt. Refer to timing belt installation
step in Timing Belt in this manual.
5. Connect radiator inlet hose and replenish EC.
Thermostat
Thermostat and Associated Parts
031RS003
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a waterfilled container using
thin wire. Place a thermometer next to the thermostat.

open.
Valve opening temperature 74.5C 78.5C
(166.1F 173.3F)
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90C (194F)
wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
specified torque.
ENGINE COOLING
6B9
Radiator
110RW010
Legend
(1) Oil Cooler Hose For Automatic Transmission
(2) Radiator Hose
(3) Fan Guide, Lower
Removal
2. Loosen a drain plug (2) to drain Engine Coolant.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
the engine.
(4) Reserve Tank Hose

(5) Radiator Assembly
(6) Reserve Tank
5. Remove fan guide(1), clips (2) on both sides and the

bottom lock, then remove lower fan guide(3) with fan
shroud(4).
110RW001
110RW002
6B10
ENGINE COOLING
6. Disconnect the reserve tank hose(4) from radiator.

7. Remove bracket.
Valve opening vacuum kPa (psi) 1.96 4.91

(0.28 0.71)
110RS006
110RX001
8. Lift up and remove the radiator assembly with hose,

taking care not to damage the radiator core with a fan
blade.
9. Remove rubber cushions on both sides at the bottom.
Inspection
Radiator Cap
the standard range.
(12.8 17.1)
Adapter: 5884026030
the valve seat side of the cap. If considerable rust or dirt is
found, or if the valve seat cannot be moved by hand, clean
or replace the cap.
Radiator Core
straightened. Pay close attention to the base of the fin
when it is being straightened.

Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent.
Remove all signs of scale and rust.

through the filler neck at the specified pressure of 196 kPa
(28.5 psi) with a cap tester:
D Leakage from the radiator
D Leakage from the coolant pump
D Leakage from the water hoses
D Check the rubber hoses for swelling.
ENGINE COOLING 6B11

Adapter: 5884026030

110RS005
111RS001
Important operation (in case of 100% engine coolant

change) procedure for filling with engine coolant.
Installation
bottom.
2. Install radiator assembly with hose, taking care not to
damage the radiator core with a fan blade.
4. Connect reserve tank hose (4).
engine.
7. Connect oil cooler hose (1) to automatic
transmission.
1. Make sure that the engine is cool.

2. Open radiator cap pour coolant up to filler neck.
3. Pour coolant into reservoir tank up to MAX line.
4. Tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and
replenish.
5. After tightening radiator cap, warm up the engine
at about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
6. Check to see the thermostat has opened through
the needle position of water thermometer,
conduct a 5minute idling again and stop the
engine.
7. When the engine has been cooled, check filler
neck for water level and replenish if required.
Should extreme shortage of coolant is found,
check the cooling system and reservoir tank hose
for leakage.
8. Pour coolant into reservoir tank up tp MAX line.
110RX001
6B12
ENGINE COOLING
Drive Belt and Cooling Fan

Drive Belt and Associated Parts
015RW005
Legend
(2) Generator
The drive belt adjustment is not required as automatic

drive belt tensioner is equipped.
Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.
Installation
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
and fan bracket.
clutch assembly.
(4)
(5)
(6)
(7)
Water Pump and Cooling Fan Pulley

Idle Pulley
Tension Pulley
Drive Belt
ENGINE COOLING 6B13

M/T
Cooling system
Radiator
Heat radiation area
A/T
Engine coolant forced circulation

Tube type corrugated (2 tube in row)
70,000 kcal/h
77,800 kcal/h
9.74m@ (104.8ft@)
11.74m@ (126.4ft@)
Radiator front area

Radiator dry weight
Engine coolant pump
Delivery
0.263m@ (2.83ft@)
42N (9.4lb)
45N (10.1lb)
93.3 122.7kpa (13.5 17.8psi)

2.5lit (2.6U.S q.t.)
2.4lit (2.5U.S q.t.)
Centrifugal impeller type

300 (317) or more
Pump speed
5000 50 rpm
Thermostat
Wax pellet type with air hole
Valve opening temperature

74.5 78.5C (166.1 173.3F)

11.1lit (2.93U.S qt)
10.0lit (2.64U.S qt)
Nm (Kgm/lb ft)
E06RW041
6B14
ENGINE COOLING
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884002770
(J2446001)
5884026030
(J33984A)
SECTION
ENGINE FUEL (6VD1 3.2L)
6C1
FRONTERA
ENGINE
ENGINE FUEL
CONTENTS
Fuel Metering . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
InTank Fuel Filter . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tube / Quick Connector Fittings . . . . .
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .
6C1
6C2
6C3
6C4
6C4
6C4
6C4
6C4
6C4
6C5
6C6
6C6
6C6
6C6
6C7
6C7
Service Precaution
systems.
Cautions During Work . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of QuickConnector . . . . . . . . . . . . . . .
Assembling Advice . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank and Associated Parts . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . .
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6C7
6C7
6C8
6C9
6C9
6C9
6C10
6C10
6C10
6C11
6C11
6C11
6C11
6C11
6C11
6C12
6C2
General Description
140RW066
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump and Sender Assembly
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank

D Any time the fuel system is being worked on,
D Always keep a dry chemical (Class B) fire
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Fuel Rail Left

Left Bank
Common Chamber
Duty Solenoid Valve
Throttle Valve
Canister
Evapo Pipe
D Replace all pipes with the same pipe and fittings that
were removed.
D Clean and inspect O rings. Replace if required.
D Always relieve the line pressure before servicing any
D Do not attempt repairs on the fuel system until you

D Adhere to all Notices and Cautions.
Control System. The purpose of the system is to minimize
the escape of fuel vapors to the atmosphere.
Fuel Metering
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.
corresponding to the flow of the air drawn into the engine.
revolution. The PCM 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
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
6C3
6C4
Fuel Filter
Removal
diagnosis, see Section Driveability and Emission.

4. Fuel filter fixing bolt(2).
D Remove the fuel filter fixing bolt(2) on fuel filter
holder.
Inspection
2. Replace the filter if it is clogged with dirt or sediment.
3. Check the drain of receive rubber and if it is clogged
with dust, clean it up with air.
Installation
3. Connect fuel hoses on engine side(1) and fuel tank
side(2).
140RW010
Legend
(1) Fuel Filler Cap
2. Remove Fuel filler cap(1).
041RW001

Inspection
After installation, start engine and check for fuel leakage.
InTank Fuel Filter

041RW003
Legend
(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter
The filter is located on the lower end of fuel pickup tube in

the fuel tank. It prevents dirt from entering the fuel pipe
and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Fuel Pump Flow Test

following checks.
2. With the engine running, check the fuel feed pipe and
hose from fuel tank to injector for evidence of
clogging.
wire(1) as shown and start the fuel pump to measure
delivery.
140RX020

a jumper wire.
Delivery
Delivery
15 seconds
0.38 liters minimum

pressure test.
Pressure test
Fuel Control System.
6C5
6C6
Fuel Pump
140RX004
Legend
(1) Fuel Feed Port
(2) Fuel Tube/Quick Connector
(3) Fuel Return Port
(5) Connector; Fuel Feed Pump
Removal
with a lifter.
4. Remove fuel tank assembly(11). Refer to Fuel Tank
Removal in this section.
Tube/Quick Connector Fittings in this section.
(6)
(7)
(8)
(9)
(10)
(11)

Snap Ring
Hose; Air Breather
Hose; Fuel Filler
Fuel Tank Assembly
6. Remove fuel pump and sender (FPAS) assembly (4)

fixing snap ring and remove the FPAS assembly.
NOTE: After removing pump assembly (4), cover fuel
tank to prevent any dust entering.
Installation
1. Install FPAS assembly(4).
Installation.
6C7

Precautions
D Lighting of Fires Prohibited.
D Keep flames away from your work area to prevent the
D Disconnect the battery negative cable to prevent
D When welding or conducting other heat-generating
spattering.
As some pressure may remain in the piping, cover the

connector with a cloth, etc. to prevent the splashing
of fuel in the first disconnection of the piping.
engine), hold the connector in one hand, and hold the
retainer tab with the other hand and pull out the

piping.
Removal
tank.
141RW019

141RW036
141RW020
6C8
NOTE: This work should be done by hands. Do not use

any tools. Should the pipe can hardly be removed from
the connector, use a lubricant (light oil) and/or push and
pull the connector longitudinally until the pipe is removed.
(Delivery Pipe)
D Replace the pipe and connector if scratch, dent or
crack is found.
D Remove mud and dust from the pipe and make sure
D If the retainer removed according to the removal step
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
clicks.
141RW021

Cover the connectors removed with a plastic bag, etc.
to prevent the entry of dust or rain water.
141RW018
(Return Pipe)
crack is found.
D 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
141RW022

D 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.
6C9
Assembling Advice
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.
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.
141RW017
Fuel Pump Relay

General Description
provided. When the starter switch is turned to ON
seconds.
When it is turned to START position, the Engine Control
Module receives the reference pulse from the Ignition
Control Module and it operates the relay, again causing
the FPAS to feed fuel.
6C10
Fuel Tank
140RX005
Legend
(1) Roll Over&Float Valve
(2) Retaining Cover
(3) Hose; Evaporative Fuel
(4) Hose; Air Breather
(5) Hose; Fuel Filler
(6) Bolt; Fuel Tank Protector Fixing
(7) Snap Ring
(8) Connector; Fuel Level Sensor
Removal
with a lifter.
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)

Fuel Feed Port
Fuel Return Port
Fuel Tank Assembly
Hose; Fuel Feed
Hose; Fuel Return
Protector; Heat

leakage.
8. Let down the tank and disconnect the wiring
connectors (8,9).
(15,19) .
10. Remove retaining cover (2) and roll over & float valve
(1) along with the evaporative fuel hose and pipe (3).
ENGINE FUEL (6VD1 3.2L) 6C11

12. Remove fuel pump and sender assembly (10) by
removing the snap ring (7) along with the fuel hoses
(17,18).
13. Remove protectors (15,19) by removing the six fixing
bolts (6).

4. Install roll over & float valve (1) by fitting in of the
retaining cover (2).
5. Lift up fuel tank assembly and connect the wiring
connectors (8,9).
tighten the four fixing bolts to the specified torque.
Installation
1. Install protectors (15,19) and tighten the six fixing
2. Install fuel pump and sender assembly by fitting in of
the snap ring (7).
3. Install Fuel Tube/Quick connector (12).
7. Connect fuel filler hose (5) and air breather hose (4),
and clip them firmly.
8. Connect fuel feed hose (17) and fuel return hose (18),
Fuel Gauge Unit

refer to Fuel Tank of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender assembly.
Fuel Filler Cap

General Description
Inspection

In case any high vacuum happen in tank, the valve works
to adjust the pressure to prevent the tank from being
damaged.
140RW014
Legend
(1) Vacuum Valve
(2) Fuel Filler Cap
CAUTION:
6C12

Nm (kgm/lb ft)
140RX021
SECTION
ENGINE ELECTRICAL
6D11
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal . . . . . . . . . . . . . . . . . . . . . .
Battery Installation . . . . . . . . . . . . . . . . . . . . .
6D13
6D14
6D14
6D15
FRONTERA
ENGINE
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging . . . . . . . . . . . . . . . . . . . . . .
6D11
6D12
6D12
6D12
6D13
Service Precaution
systems.
6D12
ENGINE ELECTRICAL
Battery
General Description

escape of small amounts of gas generated by the battery.
The battery will refuse to accept an extensive charge.
charge, resulting in gassing and loss of battery fluid.)

a. CORRECT FLUID LEVEL Charge the battery.
b. BELOW LOWER LEVEL Replace battery.
3. The battery is much less vulnerable to self discharge

than a conventional type battery.
Diagnosis
Inspect the battery for obvious physical damage, such as
a cracked or broken case, which would permit electrolyte
loss.
necessary.
2. Hydrometer Check
a. BLUE RING OR DOT VISIBLE(5) Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE(4) Go to Step
3.
061RW001
4. Voltage Check
a. VOLTAGE IS 12.4V OR ABOVE Go to Step 5.
b. VOLTAGE IS UNDER 12.4V Go to procedure (2)
below.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
15V and charge for 10 15 hours. Then go to Step
5.
c. VOLTAGE IS BETWEEN 12V AND 16V
d. VOLTAGE BELOW 12V Replace Battery.
5. Load Test
1. Connect a voltmeter and a battery load tester across
the battery terminals.
061RW001
ENGINE ELECTRICAL
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE The battery is
good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED
Replace battery.
MINIMUM
VOLTAGE
70
21
9.6
60
16
9.5
50
10
9.4
40
9.3
30
9.1
20
8.9
10
12
8.7
18
8.5

and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
the battery:
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
or ring, it may be necessary to jiggle or tilt the battery.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
charge the battery.
Jump Starting
Battery
6D13

THE FOLLOWING:
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
explode.
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.
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.
short circuit.

transmission, place the selector level in the PARK
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the NEUTRAL position.
Turn OFF all lights and any other accessory
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
cause a ground connection, effectively neutralizing
the charging procedure.
6D14
ENGINE ELECTRICAL
4. Attach one end of the remaining cable to the negative

being charged.
Make sure that all unnecessary electrical accessories
have been turned OFF.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.
Battery Removal
061RX002

NOTE: Make sure that the rod is hooked on the body
side.
ENGINE ELECTRICAL

Model (JIS)
24R600
Voltage (V)
12
600
118
Load Test (Amp)
300
BCI Group No.
24
6D15
SECTION
IGNITION SYSTEM
6D21
FRONTERA
ENGINE
IGNITION SYSTEM
CONTENTS
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6D21
6D22
6D22
6D23
6D23
6D23
6D23
6D24
Service Precaution
systems.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Position Sensor . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6D24
6D24
6D24
6D25
6D25
6D25
6D26
6D22
IGNITION SYSTEM
General Description
Ignition is done by the electronic ignition (El) that directly
fires the spark plugs from ignition coils through spark plug
wires without using a distributor. A pair of ignition coils for
the cylinders having different phases by 360 (No.1 and
No.4,No.2 and No.5,No.3 and No.6) are fired
simultaneously.
Since the cylinder on exhaust stroke requires less energy
to fire its ignition plug, energy from the ignition coils can be
utilized to fire the mating cylinder on compression stroke.
After additional 360 rotation, respective cylinder strokes
are reversed.
The EI consists of six ignition coils,ignition control
module, crank angle sensor, powertrain control module
(PCM) and other components.
The ignition coils are connected with the PCM by means

of a 32 pin connector.
The ignition control module turns on/off the primary circuit
of ignition coils, and also it controls the ignition timing at
the engine speed below 538 rpm.
crank angle sensor which then sends information such as
firing order and starting timing of each ignition coil to the
PCM.
Further, the El employs ignition control (IC) to control
similar to a distributor system.
speed, water temperature and Manifold Absolute
Pressure (MAP), the PCM controls the ignition timing.
D06RX096
Diagnosis
IGNITION SYSTEM
6D23
Ignition Coil
Measure resistance of ignition coil assembly, and replace
the ignition coil assembly if its value exceeds the
standard.
Removal
2. Ignition coil connector and ignition coil.
D Disconnect three connector from ignition coil.
D Remove harness bracket bolt on cylinder head
cover.
D Remove fixing bolts on ignition coil.
060RW006
Installation
060RW121
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
1. Install the ignition coil assembly (3).

Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.

Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No.
Limit
1 to 2
Without 0 ohm or infinity

maximum ohm.
1 to 3
Same as above
2 to 3
Same as above
060RW121
6D24
IGNITION SYSTEM
Spark Plug
Removal

D Check electrode and insulator for presence of cracks,
and replace if any.
D Check electrode for wear, and replace if necessary.
D Check gasket for damage, and replace if necessary.
D Measure insulation resistance with an ohmmeter, and
replace if faulty.
D Adjust spark plug gap to 1.0 mm (0.04 in) 1.1 mm
(0.043 in).
D Check fuel and electrical systems if spark plug is
extremely dirty.
D Use spark plugs having low heat value (hot type plug)
D Use spark plugs having high heat value (cold type
Sooty Spark Plugs

Possible causes:
D Too rich mixture
D Presence of oil in combustion chamber
D Incorrectly adjusted spark plug gap
011RS010

D Clean spark plugs with a spark plug cleaner.
D Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.
D After spark plug is thoroughly cleaned, check
insulator for presence of cracks.
D Clean threads and metal body with a wire brush.
D File the electrode tip if electrode is extremely worn.
D Bend the ground electrode to adjust the spark plug
gap.
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:
D Too lean mixture
D Improper heat value

D Measure insulation resistance using a 500 volt
megaohm meter.
D Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 MW or more
011RS011
Installation
1. Spark plugs
D Tighten spark plugs to the specified torque.
IGNITION SYSTEM
Crankshaft Position Sensor

Removal
3. Remove crankshaft angle sensor from cylinder block.
012RS008
Installation
1. Install crankshaft angle sensor into the cylinder block.
Before installation,apply small amount of engine oil to
the Oring.
2. Reconnect wiring connector to crankshaft position
sensor.
6D25
6D26
IGNITION SYSTEM

Ignition System
Ignition Form
Spark Plug
Type
Plug gap
Torque
K16PRP11
RC10PYP4
PK16PR11
1.0 mm (0.04 in) 1.1 mm (0.043 in)
18 Nm (1.8 Kgm/13 lb ft)
Nm (Kgm/lb ft)
E06RX008
SECTION
STARTING AND CHARGING SYSTEM
6D31
FRONTERA
ENGINE
CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System . . . . . . . . . . . . . . . . . . . . . . . .
6D31
6D32
6D32
6D34
6D35
6D35
6D35
6D36
6D37
6D39
6D313
6D315
6D318
Service Precaution
systems.
General OnVehicle Inspection . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6D318
6D318
6D319
6D319
6D319
6D320
6D320
6D321
6D322
6D324
6D325
6D326
6D32
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.
6D33
C06RX004
6D34
Diagnosis
Charging failure
Battery Failure
Replace Battery

Starter failure
6D35
Starter
torque(5).
Removal
2. Disconnect heated oxygen (O2) sensor connector
(1).
3. Remove exhaust front left pipe(2).

3. Reconnect the connectors to terminals B and S
and tighten Terminals B to specified torque.
4. Install heat protector(3).
150RX015
4. Remove heat protector(3).

5. Disconnect starter wiring connector from terminals
B and S(4).
6. Remove starter assembly mounting bolts on inside
and outside(5).
7. Remove starter assembly toward the bottom of
engine(6).
065RW027
5. Install exhaust front left pipe and tighten bolts and

nuts to specified torque(2).
Stud Nuts
Nuts
6. Connect O2 sensor connector (2).
065RW027
Installation
150RX015
6D36
Disassembled View
065RW002
Legend
(1) Bolt (2 pcs)
(2) Ball Bearing
(3) Pinion
(4) Shift Lever
(5) Dust Cover
(6) Torsion Spring
(7) Dust Cover
(8) Magnetic Switch
(9) Nut
(10) Gear Case
(11) Bearing Cover
(12) ERing
(13) Thrust Washer (2)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Center Bracket
Pinion Shaft
Planet Gear (3)
Internal Gear
Center Bracket (A)
Yoke Assembly
Armature
Brush
Brush Holder
Thrust Washer
Rear Cover
Screw (2 pcs)
Through Bolt (2 pcs)
Disassembly
1. Loosen the nut(1) on terminal M of magnetic switch
and disconnect the connector cable.
2. Remove bolt (2 pcs) (2).
6D37
9. Remove screws and through bolts, then the rear

cover(9) then remove thrust washer(10).
10. Remove brush holder(6).
065RW005
065RW003
3. Remove magnetic switch(5).

4. Remove dust cover(4).
5. Remove torsion spring bolts, then the magnetic
switch assembly.
6. Remove torsion spring(3) from magnetic switch
assembly(5).
11. Raise a brush spring to detach brushes (4 pcs) from

the commutator face and pull off the brush holder(12)
and brush(11).
065RW006
12. Remove yoke assembly(14).

13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,
washer and center bracket.(A) (13).
065RW004
7. Remove screw (2 pcs) (8).

8. Remove through bolt (2 pcs) (7).
6D38
NOTE: In disassembling the yoke assembly, hold the

armature and pull off slowly the yoke assembly. Because
of strong magnetic force, avoid placing a metallic part
near armature.
17. Remove ball bearing(19).

18. Remove bearing cover(20).
19. Remove a ball bearing and bearing cover from the
gear case(18).
065RW007

16. Remove a dust cover and shift lever(16) from the gear
case.
065RW021
20. Internal gear(21).

21. Remove internal gear and planet gear(3) (22).
065RW009
065RW008

22. Remove an Ering(23) from the pinion shaft using a
flat blade screwdriver.
6D39

Armature
Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.
Limit: 32.0 mm (1.26 in)
065RW010
23. Holding the pinion shaft, push pinion toward the

center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.
24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft.
065RS014

disconnected).
065RW011
065RS015
6D310 STARTING AND CHARGING SYSTEM

grounded).
Polish the commutator surface with sandpaper #500 to

#600 if it is rough.
065RW012
065RS016
Measure runout of armature core and commutator with a

dial gauge. Repair or replace, if it exceeds the limit.
Armature
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
Commutator
Limit: 0.10 mm (0.004 in)
Measure the depth of insulator in commutator. Repair, if it

is below the limit.
Standard: 0.05 mm to 0.8 mm (0.02 in to 0.03 in)
Limit: 0.2 mm (0.008 in)
065RW013
Legend
(1) Steel Saw
(2) Insulator
(3) Commutator Segments
065RS017
6D311
Brush
Magnetic Switch

Standard: 16 mm (0.63 in)
Limit: 11 mm (0.43 in)
Check for continuity of shunt coil between terminals S and

M.
disconnected).
065RW016
065RW014
Brush Holder
broken).

disconnected).
065RW017
065RW015
Yoke Assembly

Check a magnet inside the yoke.

Replace the yoke assembly if it is broken.
065RS026
065RW018
Pinion
replace the pinion.
Ball Bearing
Clamp the inner race of the ball bearing with your finger,
and check for sticking or play when rotating the outer
race.
Replace, if abnormality is found.
065RS027
065RS025

Measure inner diameter of bushing in the rear cover, and
replace if it exceeds the limit.
Standard: 12.50 mm to 12.527 mm (0.492 in to
0.4932 in)
Limit: 12.60 mm (0.4961 in)
6D313
Reassembly
Grease application places
D
D
D
D
D
Bushing in rear cover and center bracket

Gears in reduction gear
Shift lever operating portion
Sliding portion of pinion
Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly

Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
Torque
Torque for each part (See Torque Specifications in
this section)
Pinion Jumpout Dimension
065RS028
Measure inner diameter of bushing in the center bracket

(P), and replace if it exceeds the limit.
0.7137 in)
Limit: 18.15 mm (0.7146 in)
065RS029
Connect the + cable of battery to terminal S and the

cable to terminal M. Turn the switch on, and measure
pinion travel dimension in thrust direction from the
jumpout position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
0.06 in)
065RS030

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:
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

Model
Specification
Rating
Voltage
12 V
Output
1.4 Kw
Time
30 sec
Number of teeth of pinion

Rotating direction(as viewed from pinion)
Weight(approx.)
9
Clockwise
37 N
No load characteristics
Voltage /Current
11.5V/90A or less
Speed
3000rpm or more
Load characteristics
Voltage/current
8.5V/350A or more
Torque
13.2Nm(117lbin.) or more
Speed
1000rpm or more
Locking characteristics
Voltage/current
Torque
2.4V/500A or less
11.8Nm(104lbin) or more
6D315
Nm (Kgm/lb ft)
E06RW044
6D317
Nm (Kgm/lb ft)
150RX016
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in illustration.
The regulator is a solid state type and it is mounted along
with the brush holder assembly inside the generator
installed on the rear end cover.
such as voltage adjustment.
The rectifier connected to the stator coil has diodes to

transform AC voltage into DC voltage.
generator.
F06RX002

A basic wiring diagram is shown in the illustration. When
operating normally, the indicator bulb will come on when
the switch is turned on, and will then go out when the
engine starts. If the indicator operates abnormally, or if an
undercharged or overcharged battery condition occurs,
the following procedure may be used to diagnose the
charging system. Remember that an undercharged
battery is often caused by accessories being left on
overnight, or by a defective switch which allows a bulb,
such as a trunk or glove box light, to stay on.
OBSERVE THE FOLLOWING PROCEDURE:

1. Visually check belt and wiring.
2. Go to step 5. for vehicles without charge indicator
light.
3. Switch on, engine stopped, light should be on. If not,
detach harness at generator, ground L terminal
lead.
a. Lamp lights, replace or repair generator.

b. Lamp dose not light, locate open circuit between
grounding lead and ignition switch. Bulb may be
open.
4. Switch on, engine running at moderate speed. Light
should be off. If not, detach wiring harness at
generator.
a. If light goes off, replace or repair generator.
b. If light stays on, check for grounded L terminal
wire in harness.
5. Battery undercharged or overcharged.
a. Detach wiring harness connector from generator.
b. With switch on, engine not running connect
voltmeter from ground to L terminal in wiring
harness, and to IG terminal. If used. Wiring
harness may connect to either L or IG or both.
c. Zero reading indicates open circuit between
terminal and battery. Connect as required.

d. Re-connect harness connector to generator, run
engine at moderate speed, with electrical
accessories turned off.
e. Measure voltage across battery. If above 16.0V,
replace or repair generator.
f. Connect ammeter at generator output terminal.
Turn on accessories, load battery with carbon pile
to obtain maximum amperes output.
Maintain voltage at 13.0V or above.
6D319
2. If not within 15 amperes of rated output, replace or

repair generator.
1. If within 15 amperes of rated output, generator is

OK.
Generator
Removal
Inspection

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).
1. Disconnect the wiring connector from generator.

2. With the engine stopped, turn starter switch to on
and connect a voltmeter between connector terminal
L (1) and ground or between terminal IG (2) and
ground.
066RX002
If voltage is not present, the line between battery and

connector is disconnected and so requires repair.
060RW002
3. Reconnect the wiring connector to the generator, run

the engine at middle speed, and turn off all electrical
devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., headlights). At this
time the amperes must not be less than 15A and the
voltage must not be less than 13V.
Installation
1. Install generator assembly to the position.
2. Install generator assembly and tighten the fixing bolts

Torque:
M10 bolt: 41 Nm (30 Ib ft)
M8 bolt: 21 Nm (15 Ib ft)
3. Connect wiring harness connector and direct terminal
B.
Disassembled View
066RW022
Legend
(1) Pulley Nut
(2) Pulley
(3) Front Cover Assembly
(4) Rotor Assembly
(5) Stator Assembly
(6) Through Bolt
(7)
(8)
(9)
(10)
(11)
(12)
Nut
Terminal Insulator
Rear Cover Assembly
Rectifier
Brush Holder Assembly
Regulator Assembly
6D321
4. Remove screws with bearing retainer from front cover

and remove bearing.
Disassembly
1. Remove the through bolt.
Insert the tip of a pry bar into the gaps between the
front cover and the stator core.
Pry apart and separate the front cover, rotor, the rear
cover and stator.
NOTE: Take care not to scratch or otherwise damage the
stator coil with pry bar.
F06RT023
5. Remove the mounting nuts holding the B terminal,

the diode, and the brush holder.
6. Separate the rear cover from the stator.
F06RT021
2. Clamp the rotor in a vise and then remove the nut and
pulley.
3. Remove the rotor assembly from front cover.
F06RT024
F06RT022

7. Remove bolts which secure stator terminal to rectifier
terminal, and remove stator.

Rotor Assembly
1. Check the face of the slip rings for contamination and
roughness. If found to be scored, dress with a fine
sandpaper (#500 600). If found to be contaminated,
clean with a cloth saturated with alcohol.
2. Measure the outside diameter of the slip rings.
Standard: 27mm (1.06in)
Limit: 26mm (1.02in)
066RS030
8. Remove Bolts which secure regulator, rectifier and

brush-holder, and separate these parts.
NOTE: Do not apply a shock or load to regulator, rectifier
and brush holder.
066RS032

Standard: 3.75W or less
066RW025
066RS033

4. Check for continuity between slip ring and rotor core.
6D323
2. Check for continuity across one of the stator coils and

stator core. If a continuity exists, replace the coil.
Standard: More than 1MW
066RS017
066RS035
Stator Coil
1. Check for continuity across the stator coils. If no
continuity exists, replace the coils.
Resistance value at 20C.
Standard: Approx. 0.07W
Brush
Standard: 18.0mm (0.709in)
Limit: 5.5mm (0.217in)
066RS034
066RW024
Rectifier Assembly
1. Measure the resistance between each diode terminal
and aluminum diode fin in forward and reverse
directions with the connection of the tester leads
switched. The diodes are normal if resistance is
nearly zero ohms in one direction and is infinitely high
in the other direction.
2. If a diode has no resistance or equal resistance in
both directions, it is defective and should be replaced
together with the holder.
066RS036
IC Regulator Assembly
Connect a variable resistor, two 12V batteries, a fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.
a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms /3W
2. Variable resistor (Rv) : 0-300 Ohms/12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0-50V/0.5 steps (4 Check points)
b. Measuring procedure
1. Measure the voltage V1 across the first battery
(BAT1). If the reading is between 10 and 13 volts,
the battery is normal.
2. Measure the voltage V3 across both the batteries
(BAT1, BAT2). If the reading is between 20 and 26
bolts, the batteries are normal.
3. Gradually increase the resistance of the variable
resistor from zero. Measure the voltage V2 (the
voltage across the F and E terminals).
Check to see that the voltage across V1 changes at
this time. If there is no change, the voltage regulator
is faulty and must be replaced.
4. Measure the voltage at V4 (the voltage across the
variable resistor center tap and terminal E with the
variable resistor resistance held constant). The
measure voltage should be within the specified
(14.40.3 volts) limits. If it is not, the regulator must
be replaced.
066RX003
Reassembly
NOTE:
D Never make battery connections with polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.
D Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.
D Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery .
Diodes may be damaged due to abnormal pulse
voltage generated bye the quick charger.
D When reassembling the front section to rear section,
insert a stiff wire into hole in the rear face of the rear
cover from the outboard side to support the brush in
raised position, then insert the front section to which
rotor is assembled.
D Reassemble parts carefully to be sure they fit into
their original position, paying attention to the
insulated portions.
D Wipe insulating tubes, washers and plates clean and
install them in position carefully to avoid getting oil or
grease on them.

1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in the
front cover.
6D325
Bench Test
Conduct a bench test of the generator.
066RS023
066RS022

Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified torque.
Preparation
Remove generator from the vehicle (see Generator
removal).
1. Secure generator to the bench test equipment and
connect wires.
Terminal IG for energization
Terminal L for neutral (warning lamp)
Terminal B for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.
066RS010
066RX001

Battery voltage
12
Rated output
90
Clockwise
Rated rotation speed
rpm
5000
Maximum speed
rpm
18000
SECTION
6VD1 3.2L ENGINE DRIVEABILITY AND EMISSIONS
6E21
FRONTERA
ENGINE
CONTENTS
Specification . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Specifications . . . . . . . . . . . . . . .
Diagrams and Schematics . . . . . . . . . . . . . . . .
PCM Wiring Diagram (1 of 8) . . . . . . . . . . . .
PCM Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 32-Way Red Connector
Row A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row B . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 32-Way White Connector
Row C . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row D . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 32-Way Blue Connector
Row E . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row F . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locators . . . . . . . . . . . . . . . . . . . .
Engine Component Locator Table . . . . . . . .
Undercarriage Component Locator . . . . . .
Sensors and Miscellaneous Component
Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse and Relay Panel (Underhood Electrical
Center) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strategy-Based Diagnostics . . . . . . . . . . . . .
DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . .
No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . .
No Trouble Found . . . . . . . . . . . . . . . . . . . . .
General Service Information . . . . . . . . . . . . . .
Non-OEM Parts . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . .
Maitenance Schedule . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E25
6E25
6E26
6E26
6E27
6E28
6E29
6E210
6E211
6E212
6E213
6E214
6E214
6E215
6E216
6E217
6E218
6E219
6E220
6E220
6E221
6E221
6E222
6E224
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E226
6E226
6E226
6E226
Basic Knowledge of Tools Required . . . . . .

Seral Data Communications . . . . . . . . . . . . . .
Class II Serial Data Communications . . . . .
On-Board Diagnostic (OBD) . . . . . . . . . . . . . .
On-Board Diagnostic Tests . . . . . . . . . . . . .
Common OBD Terms . . . . . . . . . . . . . . . . . .
DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . .
the TECH 2 Scan Tool . . . . . . . . . . . . . . . . .
Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . .
Getting Started . . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure (For Example) . . . . .
DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Test . . . . . . . . . . . . . . . . . . . . . .
EGR Control Test . . . . . . . . . . . . . . . . . . . . . .
Variable Intake Manifold Solenoid Test . . .
Plotting Snapshot Graph . . . . . . . . . . . . . . . . .
Flow Chart for Snapshot Replay
(Plotting Graph) . . . . . . . . . . . . . . . . . . . . . . .
Primary System-Based Diagnostics . . . . . . . .
Primary System-Based Diagnostics . . . . . .
Fuel Control Heated Oxygen Sensors . . . .
HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . .
On-Board Diagnostic (OBD) System Check
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
A/C Clutch Control Circuit Diagnosis . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition System Diagnosis . . . . . . .
6E226
6E226
6E226
6E226
6E226
6E227
6E227
6E228
6E229
6E230
6E230
6E231
6E231
6E232
6E232
6E233
6E234
6E234
6E235
6E235
6E237
6E237
6E239
6E240
6E241
6E241
6E242
6E243
6E244
6E245
6E245
6E245
6E245
6E246
6E246
6E246
6E248
6E249
6E249
6E249
6E254
6E22
Visual Check of The Evaporative Emission

Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E254
Fuel Metering System Check . . . . . . . . . . . . . 6E254
Idle Air Control (IAC) Valve . . . . . . . . . . . . . . . 6E254
Knock Sensor Diagnosis . . . . . . . . . . . . . . . . . 6E254
Powertrain Control Module (PCM) Diagnosis
6E254
Multiple PCM Information Sensor DTCS Set
6E254
Exhaust Gas Recirculation (EGR) Diagnosis
6E258
Engine Tech 2 Data Definitions and Ranges
6E258
Typical Scan Data Values . . . . . . . . . . . . . . . . 6E260
No Malfunction Indicator Lamp (MIL) . . . . . . .
6E265
Malfunction Indicator Lamp (MIL) ON
Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E268
Engine Cranks But Will Not Run . . . . . . . . . . . 6E271
Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . 6E279
Idle Air Control (IAC) System Check . . . . . . . 6E284
Knock Sensor (KS) System Check (Engine
Knock, Poor Performance, or Poor
Economy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E286
Exhaust Gas Recirculation (EGR) System
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E288
Manifold Absolute Pressure (MAP) Output
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E290
Evaporative (EVAP) Emissions Canister Purge
Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E292
PCM Diagnostic Trouble Codes . . . . . . . . . . .
6E295
Diagnostic Trouble Code (DTC) P0101 MAF
System Performance . . . . . . . . . . . . . . . . . . . . 6E298
Sensor Circuit Low Frequency . . . . . . . . . . . 6E2101
Sensor Circuit High Frequency . . . . . . . . . . . 6E2104
Diagnostic Trouble Code (DTC) P0107 MAP
Sensor Circuit Low Voltage . . . . . . . . . . . . . . 6E2106
Sensor Circuit Hight Voltage . . . . . . . . . . . . . 6E2109
Diagnostic Trouble Code (DTC) P0112 IAT
Sensor Circuit High Voltage . . . . . . . . . . . . . . 6E2115
Diagnostic Trouble Code (DTC) P0117 ECT
Diagnostic Trouble Code (DTC) P0121 TP
Sensor Circuit High Voltage . . . . . . . . . . . . . 6E2130
Diagnostic Trouble Code (DTC) P0131 HO2S
Circuit Low Voltage Bank 1 Sensor 1 . . . . . . 6E2133
Circuit High Voltage Bank 1 Sensor 1 . . . . . . 6E2136
Circuit Insufficient Activity Bank 1 Sensor 1 6E2139

Diagnostic Trouble Code (DTC) P0171 Fuel
Trim System Too Lean Bank 1 . . . . . . . . . . . . 6E2151
Trim System Rich Bank 1 . . . . . . . . . . . . . . . . 6E2155
Trim System Lean Bank 2 . . . . . . . . . . . . . . . 6E2159
Diagnostic Trouble Code (DTC) P0201 Injector
1 Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . 6E2167
Diagnostic Trouble Code (DTC) P0325 KS
Module Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2185
Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2187
Diagnostic Trouble Code (DTC) P0336 58X
Reference Signal Circuit . . . . . . . . . . . . . . . . . 6E2190
Diagnostic Trouble Code (DTC) P0337 CKP
Sensor Circuit Low Frequency . . . . . . . . . . . . 6E2192
Diagnostic Trouble Code (DTC) P0341 CMP
Sensor Circuit Performamce . . . . . . . . . . . . . 6E2195
Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . 6E2198
Diagnostic Trouble Code (DTC) P0351 Ignition
Diagnostic Trouble Code (DTC) P0404 EGR
Open Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2220
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2222
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2225

Diagnostic Trouble Code (DTC) P0502 VSS
Circuit Low Input . . . . . . . . . . . . . . . . . . . . . . . . 6E2228
Diagnositc Troule Code (DTC) P0562 System
Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2231
Diagnostic Trouble Code (DTC) P0563 System
Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2233
Diagnostic Trouble Code (DTC) P0601 PCM
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2234
System Lean Dueing Acceleration . . . . . . . . 6E2235
Diagnostic Trouble Code (DTC) P1380 ABS
Rough Road ABS System Fault . . . . . . . . . . 6E2238
Rough Road Class 2 Serial Link Error . . . . . 6E2239
Stuck Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2240
Diagnostic Trouble Code (DTC) P1508 IAC
System Low RPM . . . . . . . . . . . . . . . . . . . . . . . 6E2242
System High RPM . . . . . . . . . . . . . . . . . . . . . . 6E2245
Unexpected Reset . . . . . . . . . . . . . . . . . . . . . . 6E2248
Diagnostic Trouble Code (DTC) P1640 Output
Driver Module (ODM) A Fault . . . . . . . . . . . 6E2249
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 6E2251
Default Matrix Table . . . . . . . . . . . . . . . . . . . . . 6E2276
On-Vehicle Service Camshaft Position (CMP)
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2279
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2280
Engine Coolant Temperature (ECT) Sensor . 6E2280
Heated Oxygen Sensor (HO2S) . . . . . . . . . . . 6E2281
Intake Air Temperature (IAT) Sensor . . . . . . . 6E2283
Knock Sensor (KS) . . . . . . . . . . . . . . . . . . . . . . 6E2284
Mass Air Flow (MAF) Sensor . . . . . . . . . . . . . 6E2285
Manifold Absolute Pressure (MAP) Sensor . 6E2285
Malfunction Indicator Lamp (MIL) . . . . . . . . . . 6E2286
Powertrain Control Module (PCM) . . . . . . . . . 6E2286
EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2288
Throttle Position (TP) Sensor . . . . . . . . . . . . . 6E2288
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . 6E2288
Air Cleaner/Air Filter . . . . . . . . . . . . . . . . . . . . . 6E2290
Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6E2292
Accelerator Cable Assembly . . . . . . . . . . . . . . 6E2292
Accelerator Pedal Replacement . . . . . . . . . . . 6E2295
Fuel Fillter Cap . . . . . . . . . . . . . . . . . . . . . . . . . 6E2297
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2297
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . 6E2300
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2300
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . 6E2301
Fuel Metering System . . . . . . . . . . . . . . . . . . . . 6E2303
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . 6E2303
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . 6E2304
Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . 6E2304
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body (TB) . . . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition System . . . . . . . . . . . . . . . .
Catalytic Converter . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Purge Solenoid . . . . . . . . . . . .
Fuel Tank Vent Valve . . . . . . . . . . . . . . . . . . . .
Linear Exhaust Gas
Positive Crankcase Ventilation (PCV) Valve .
PCM Connectors and Terminals . . . . . . . . . . .
Wire Harness Repair: Twisted Shielded Cable
Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . .
Weather-Pack Connector . . . . . . . . . . . . . . . . .
Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (PCM and Sensors) . . .
58X Reference PCM Input . . . . . . . . . . . . . .
Camshaft Position (CMP) Sensor and
Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . .
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mass Air Flow (MAF) Sensor . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . .
PCM Function . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Components . . . . . . . . . . . . . . . . . . . . .
PCM Voltage Description . . . . . . . . . . . . . . .
PCM Input/Outputs . . . . . . . . . . . . . . . . . . . .
PCM Service Precautions . . . . . . . . . . . . . .
Transmission Fluid Temperature (TFT)
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aftermarket Electrical and Vacuum
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upshift Lamp . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (Air Induction) . . . . . . . .
Air Induction System . . . . . . . . . . . . . . . . . . .
General Description (Fuel Metering) . . . . . . .
6E23
6E2305
6E2305
6E2307
6E2308
6E2308
6E2308
6E2308
6E2310
6E2311
6E2311
6E2312
6E2313
6E2313
6E2313
6E2314
6E2315
6E2317
6E2317
6E2318
6E2318
6E2318
6E2318
6E2318
6E2318
6E2318
6E2318
6E2319
6E2319
6E2320
6E2320
6E2320
6E2321
6E2321
6E2321
6E2321
6E2321
6E2322
6E2322
6E2322
6E2322
6E2322
6E2323
6E2323
6E2323
6E2323
6E2323
6E2323
6E2324
6E24
CMP Signal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Flood Mode . . . . . . . . . . . . . . . . . . . . .
Deceleration Mode . . . . . . . . . . . . . . . . . . . .
Engine Speed/Vehicle Speed/Fuel
Disable Mode . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (Electronic Ignition
System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Position (CMP) Sensor . . . . . . . .
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control PCM Output . . . . . . . . . . . .
Knock Sensor (KS) PCM Input . . . . . . . . . .
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . . .
General Description (Evaporative (EVAP)
Emission System) . . . . . . . . . . . . . . . . . . . . . .
General Description (Exhaust Gas
Recirculation (EGR) System) . . . . . . . . . . . . .
EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . .
Linear EGR Valve . . . . . . . . . . . . . . . . . . . . .
Linear EGR Valve Operation and Results
of Incorrect Operation . . . . . . . . . . . . . . . . .
General Description (Positive Crankcase
Ventilation (PCV) System) . . . . . . . . . . . . . . .
Crankcase Ventilation System Operation .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2325
6E2325
6E2325
6E2325
6E2326
6E2326
6E2326
6E2326
6E2327
6E2327
6E2327
6E2327
6E2327
6E2327
6E2328
6E2329
6E2329
6E2329
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2332
6E2332
6E2332
6E2332
6E2332
6E2332
6E2333
6E2334
6E25
Specification
Tightening Specifications
Application
Nm
kgm
Lb Ft.
Lb In.
Camshaft Position Sensor Retaining Screw
0.9
78
0.9
78
EGR Bolt
14
1.4
122
EGR Nut
14
1.4
122
30
3.1
22
6.5
0.65
56
Fuel Rail Bolts
25
2.5
18
36
3.7
27
42
4.3
32
Lower Intake Manifold to Engine Block Bolts
25
2.5
18
Fuel Drain Plug
29
3.0
22
Lower Intake Manifold to Engine Block Nuts
25
2.5
18
Spark Plugs
18
1.8
13
13
1.3
113
Upper Intake Manifold to Lower Intake Manifold Bolts
25
2.5
18
VSS Retaining Bolt
13
1.3
113
6E26
Diagrams and Schematics

PCM Wiring Diagram (1 of 8)
D06RX128
6E27
D06RX003
6E28
D06RX146
6E29
D06RX129
6E210
D06RX130
6E211
D06RX131
6E212
D06RX132
6E213
D06RX133
6E214
PCM Pinouts
PCM Pinout Table, 32-Way Red Connector Row A
TS23344
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
A1
5 Volt Reference A
A2
Knock Sensor
A3
Not Used
A4
Battery Feed (ECM Fuse)
RED/WHT
A5

High
A6
Refer To
RED
5.0 V
5.0 V
Appropriate Sensor
YEL
0.0 V
0.0 V

B+
B+
BLU
B+/0.8 V
B+/0.8 V

Operation, IAC
IAC A Low
BLU/WHT
B+/0.8 V
B+/0.8 V

Operation, IAC
A7
IAC B Low
BLU/BLK
B+/0.8 V
B+/0.8 V

Operation, IAC
A8
IAC B High
BLU/RED
B+/0.8 V
B+/0.8 V

Operation, IAC
A9
Fluid (ATF) Lamp
ORN/BLK
B+
B+
(4L30E)
A10
Winter Lamp
PNK/GRN
B+
B+
(4L30E)
A11
Power Lamp
PNK/WHT
B+
B+
(4L30E)
A12
Not Used
A13
(Check Engine or MIL)
Lamp
WHT/GRN
0.0 V
B+
Chassis Electrical
A14
Check Transmission
Lamp Driver
VIO
B+
B+
Chassis Electrical
A15
EVAP Canister Purge

Signal
RED/BLU
B+
5.7 V
A16
Band Apply
YEL/BLK
B+
B+
Chassis Electrical

Control System
(4L30E)
6E215
PCM Pinout Table, 32-Way Red Connector Row B
TS23344
PIN
PIN Function
B1
5 Volt Reference B
B2
Wire Color
IGN ON
ENG RUN
Refer To
BLU/ORN
5.0 V
5.0 V
Appropriate Sensor
Ignition coil #4
RED/WHT
0.0 V
0.1 V

Operation, ICM
B3
Ignition coil #2
RED/BLK
0.0 V
0.1 V

Operation, ICM
B4
Ignition coil #6
RED/GRN
0.0 V
0.1 V

Operation, ICM
B5
Not Used
B6
Not Used
B7

(EGR)
YEL/RED
0.6 V
0.6 V

Control
B8

(IAT) Sensor
YEL/GRN
3 V
(depends on
temperature)
3 V
(depends on
temperature)

Operation, IAT
B9
Not Used
B10
Not Used
B11

(PSP) Switch
GRN/YEL
B+
B+

Operation, PSP
B12
Illuminated Switch
GRN/YEL
B+
B+
Chassis Electrical
B13
Class 2 Data
ORN/BLK
0.0 V
0.0 V
B14
A/C Clutch
GRY/RED
B+ (A/C
OFF)
B+ (A/C
OFF)

Operation
B15
Not Used
B16
Not Used

Data
6E216
PCM Pinout Table, 32-Way White Connector Row C
TS23345
PIN
PIN Function
C1
C2
IGN ON
ENG RUN
GRN/RED
B+
B+

Shift B Solenoid
BRN/BLK
0.0 V
0.0 V
(4L30E)
C3
GRN/YEL
B+
B+

C4
Ignition Control (IC)

Cylinder #1
RED
0.0 V
0.1 V

C5
Crankshaft Position
Sensor, A Circuit
YEL
0.3 V
2.2 V

Position Sensor
C6
Not Used
C7
PCM Ground
BLK/WHT
0.0 V
0.0 V
Chassis Electrical
C8
PCM Ground
BLK/RED
0.0 V
0.0 V
Chassis Electrical
C9
PCM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C10
Tachometer
BLK/RED
8.8 V
10.0 (at idle)
Chassis Electrical
C11
Variable Intake Manifold
WHT/BLU
0.0 V
0, B+ (More
than 3600
rpm)
Manual Transmission
C12
Rear Defogger Relay
RED/WHT
B+
B+
C13
Wire Color
Not Used
Refer To
Chassis Electrical
C14
Bank 2 HO2S 1 High
WHT
0.3 V
0.0-0.8 V

C15
Bank 2 HO2S 1 Low
RED
0.0 V
0.1 V

C16
Not Used
6E217
PCM Pinout Table, 32-Way White Connector Row D
TS23345
PIN
PIN Function
D1
D2
Wire Color
IGN ON
ENG RUN
GRN/ORN
B+
B+
Torque Converter Clutch

(TCC)
RED/YEL
0.0 V
0.0 V
D3
GRN/WHT
B+
B+
D4
Serial Data (8192)
RED
5.0 V
5.0 V
Chassis Electrical
D5
Ignition Control, Cylinder

#5
RED/YEL
0.0 V
0.1 V

Operation, Ignition Control
Module
D6

#3
RED/BLU
0.0 V
0.1 V

Operation
D7
Speedometer
BLU/BLK
0.0 V
0.1 V
(at rest)
D8
Sensor Ground 5V
Reference A Return
GRN
0.0 V
0.0 V
Appropriate Sensor
D9
Sensor Ground 5 V
Reference B Return
GRN
0.0 V
0.0 V
Appropriate Sensor
D10
Mass Air Flow (MAF)
YEL
4.9 V
4.2 V
General Description, Mass

Air Flow Sensor
D11
BLU
5.0 V
4.6 V

Operation, Camshaft
Position Sensor
D12
Not Used
D13
Not Used
D14
Bank 1 HO2S 1 Low
BLU
0.0 V
0.1 V

D15
Bank 1 HO2S 1 High
PNK
0.3 V
0.0-0.8 V

D16
Not Used
Refer To
On-Vehicle Service, Torque
Converter Clutch
Chassis Electrical
6E218
PCM Pinout Table, 32-Way Blue Connector Row E
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
E1
Vehicle Speed Sensor

Signal
YEL
0.0 V
0.1 V
(4L30E)
E2

Low
BRN
0.0 V
0.0 V
(4L30E)
E3
Pressure Control Solenoid

Low
RED/GRN
0.0 V
0.0 V
(4L30E)
E4

High
RED/BLK
0.0 V
0.0 V
(4L30E)
E5

(EGR) Ignition
BLK/YEL
B+
B+

E6

(EGR) Solenoid
YEL
B+
B+

E7
Transmission Range
Signal B
PNK
0.0 V
0.0 V
(4L30E)
E8

Sensor
BLU
0.6 V
0.6 V
(at idle)

Sensor
E9
Engine Coolant
Temperature (ECT)
Sensor
BLU/RED
2.3 V
2.1 V

E10
Not Used
E11

Sensor +5 Volt Reference
BRN
5.0 V
5.0 V

Position Sensor
E12
Transmission Range
Signal A
PNK/BLU
B+
B+
(4L30E)
E13
PNK/WHT
0.0 V
B+
On-Vehicle Service, Fuel

Pump Relay
E14
Shift High (BAND APPLY)
BRN/WHT
B+
B+
(4L30E)
E15
A/C Request
GRN/BLK
0.0 V
0.0 V
E16
Ignition Feed (1 of 2 F16)
RED/BLU
B+
B+
6E219
PCM Pinout Table, 32-Way Blue Connector Row F
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
F1
Not Used
F2
Transmission Range
Signal C
BLU/WHT
0.0 V
0.0 V
(4L30E)
F3
Transmission Range
Signal P
PNK/BLK
B+
B+
(4L30E)
F4
Brake Switch
RED
0.0 V
0.0 V
(4L30E)
F5
Power Switch
VIO
B+
B+
(4L30E)
F6
Winter Switch
VIO
B+
B+
(4L30E)
F7
Transmission Fluid
Temperature
GRN/RED
2.2 V
1.1 V
(4L30E)
F8
Manifold Absolute
Pressure (MAP)
GRY
4.7 V
1.1 V

Pressure
F9
YEL/GRN
B+
B+
Chassis Electrical
F10
Cruise Control
GRY/BLU
B+
B+
(4L30E)
F11
Kickdown Switch
LT BLU
B+
B+
(4L30E)
F12
Diag
B+
B+
F13
GRN
B+
B+

F14
Shift A Solenoid
YEL/GRN
B+
B+
(4L30E)
F15
GRN/BLK
B+
B+

F16
Ignition Feed (1 of 2 E16)
RED/BLU
B+
B+
ORN/BLU
6E220
Component Locators
Engine Component Locator
515RW017

Number
Name
Location
Crank Position (CKP) Sensor
Lower right side of the cylinder block
Rear right of the engine
Knock Sensor
Right hand side between right bank and left bank

of the cylinder block
Bolted to the top the upper intake manifold
Common Chamber
Top of the engine
EVAP Canister Purge Valve
Bolted to the front of the coolant pipe
Rear right side of the engine
Injection Coil
Top of the cylinder engine
Air Cleaner
10
Mass Air Flow (MAF) Sensor
Attached to the air filter box
11
On the rear side of the left cylinder head cover
12
On the intake air dukt near the throttle body
13
On the right of the throttle body
14
On the coolant crossover pipe at the front of the

engine,near the throttle body
15
On the left of the throttle body
16
Positive Crankcase Ventilator (PCV) Valve
On the left of the cylinder head
17
Fuse/Relay Box
6E221
Undercarriage Component Locator
014RW188

Number
Name
Location
Heated Oxygen Sensor (Bank 2)
Threated into the exhaust pipe ahead the

lefthand catalytic convertor
Fuel Filter
Located along the inside of the right frame

rail,ahead of the propeller shaft
Fuel Gauge Unit
Evaporative (EVAP) Canister
On the top of the bracket that is located behind

of the cross member
Protrudes from the transmission housing, just

ahead of the fuel tank
Threated into the exhaust pipe ahead

therighthand catalytic convertor
6E222
Sensors and Miscellaneous Component Locators
150RX023
T321070
014RW141
055RW003
T321067
041RW013
6E223
025RW008
060RW007
T321078
028RW001
6E224
Fuse and Relay Panel (Underhood Electrical Center)
755RX033
Diagnosis
Strategy-Based Diagnostics
The strategy-based diagnostic is a uniform approach to
check(s).
system. This will lead the technician in an
organized approach to diagnostics.
DTC Stored
effective repair.
No DTC
No Matching Symptom
operation.
Intermittents
following steps:
1. Observe history DTCs, DTC modes, and freezeframe
data.
by the customer.
6E225

Most scan tools, such as the Tech 2, have data-capturing
capabilities that can assist in detecting intermittents.
No Trouble Found
1. Re-examine the complaint.
isolated, a re-evaluation is necessary. The complaint
should be re-verified and could be intermittent as
Frame data.

diagnosed (Freeze Frame data will only be stored for
General Service Information

Non-OEM Parts
All of the OBD II diagnostics have been calibrated to run
with OEM parts.
Something as simple as a
high-performance exhaust system that affects exhaust
6E226

and anti-theft devices, may radiate EMI into the control
lamp).
Environment
If the ignition system is rain-soaked, it can temporarily
lamp).

schematic.
replaced. It can be ordered from Isuzu Dealer ship.
Maitenance Schedule

Inspection
Perform a careful
visual and physical engine
disconnections, and proper routing.
components.
manifolds or pipes.
Basic Knowledge of Tools Required

A basic understanding of hand tools is necessary to effectively use this section of the Service Manual.
Seral Data Communications

system.
This vehicle utilizes the Class II
communication system. Each bit of information can have
one of two lengths: long or short. This allows vehicle
wiring to be reduced by transmitting and receiving
multiple signals over a single wire. The messages carried
on Class II data streams are also prioritized. If two
messages attempt to establish communications on the
data line at the same time, only the message with higher
priority will continue. The device with the lower priority
message must wait. The most significant result of this
regulation is that it provides Tech 2 manufacturers with
the capability to access data from any make or model
vehicle that is sold.
same, with some exceptions. Some scan tools will only
On-Board Diagnostic (OBD)

On-Board Diagnostic Tests
a pass or fail reported to the diagnostic executive. When
a diagnostic test reports a pass result, the diagnostic
ignition cycle.
ignition cycle.
currently active.
ignition cycle.
active.

Input Components:
out-of-range values. This includes rationality checking.
signal from a sensor does not seem reasonable,
i.e.Throttle Position (TP) sensor that indicates high
throttle position at low engine loads or MAP voltage. Input
following sensors:
D Crankshaft Position (CKP) Sensor
D Knock Sensor (KS)
D Throttle Position (TP) Sensor
D Engine Coolant Temperature (ECT) Sensor
D Camshaft Position (CMP) Sensor
D Manifold Absolute Pressure (MAP) Sensor
D Mass Air Flow (MAF) Sensor
steady state temperature to enable closed loop fuel
control.
Output Components:
control module commands.
Components where
circuit continuity and out-of-range values if applicable.
limited to, the following circuit:
D Control module controlled EVAP Canister Purge
Valve
D Electronic Transmission controls
D A/C relays
D Cooling fan relay
D VSS output
D MIL control
Refer to PCM and Sensors in General Descriptions.
pressure.
6E227

This is any on-board test run by the Diagnostic
Warm-Up Cycle
A warm-up cycle means that engine at temperature must
Freeze Frame
information at the moment an emissions-related fault is
Failure Records
Failure Records data is an enhancement of the OBD II
Freeze Frame feature.Failure Records store the same
that information for any fault which is stored in on-board
emission-related faults that command the MIL on.
Common OBD Terms

Diagnostic
on-board test run by the vehicles Diagnostic
D Oxygen sensors
D EGR
Enable Criteria
D engine speed
D vehicle speed
D ECT
D MAF/MAP
D IAT
6E228
D TP
D TCC enabled
D A/C on
Trip
Technically, a trip is a key on-run-key off cycle in which all
definition of trip varies as well. Some diagnostic are run
the vehicle is idle; some diagnostics function with the
TCC disables. Some run only immediately following a
cold engine start-up.
A trip then, is defined as a key on-run-key off cycle in

follows:
D Commanding the MIL (Check Engine lamp) on and
off
recorded
D Non-emission related Service Lamp (future)
The Diagnostic Executive records DTCs and turns on the
MIL when emission-related faults occur. It can also turn
off the MIL if the conditions cease which caused the DTC
to set.
present.
There is a continuous self-diagnosis on certain control

functions. This diagnostic capability is complemented by
illuminated.
Basically, the MIL is turned on when the PCM detects a
The MIL will be turned on if an emissions-related
will stay on until the system or component passes the
same test, for three consecutive trips, with no emission
srelated faults.
When the MIL is on, the Diagnostic Executive will turn off
the MIL after three(3) consecutive trips that a test
Although the MIL has been turned off, the DTC will remain
in the PCM memory (both Freeze Frame and Failure
Records) until forty(40) warm-up cycles after no faults
have been completed.
If the MIL was set by either a fuel trim or misfire-related
test failed.
was stored at the time the last failed.
warming up ) as those stored at the time the last test
failed.
The MIL (Check Engine lamp) is on the instrument
panel and has the following functions:
with the key ON and the engine not running. When
the engine is started, the MIL will turn OFF.
On-Board Diagnostic (OBD) System Check must be
given in On-Board Diagnostic (OBD) System Check.
DTC Types
D Type A
D Emissions related
fail
test fails
D Type B
D Emissions related
test fails
DTCs)
D Non-Emissions related
D Stores a History DTC on thefirst trip with a fail
test fails
D Type D (Type D non-emissions related are not utilized
on certain vehicle applications).
D Dose not request illumination of any lamp
test fails
6E229
Only four Fail Records can be stored. Each Fail Record

is for a different DTC. It is possible that there will not be
Fail Records for every DTC if multiple DTCs are set.
Records
D Air Fuel Ratio
D Air Flow Rate
D Engine Speed
D Engine Load
D Vehicle Speed
D TP
D MAP/BARO
D Loop Status
malfunction.
The provision for communication with the contorl module
is the Data Link Connector (DLC). It is located at the
lower left of the instrument panel. The DLC is used to
connect to the Tech 2 Scan Tool. Some common uses of
the Tech 2 are listed below:
D Identifying stored Diagnostic Trouble Codes (DTCs).
D Clearing DTCs.
D Performing out put control tests.
6E230
D Reading serial data.

diagnostic Scan Tool clear DTCs or clear information
function.
When clearing DTCs follow instructions
power.
fuse, pigtail at battery PCM connectors etc.
on-board memory data, such as preset radio tuning).
TS24064

for vehicles with OBD II system diagnostic. Following a
requested).
2. Clear DTC(s).

the TECH 2 Scan Tool
use a diagnostic Scan Tool. When reading DTC(s), follow
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech 2.
count the warm-up cycles with no further faults
PCM memory.
6E231
Tech 2
recommended to use the Tech 2 Scan Tool. Please refer
to the Tech 2 user guide.
901RW180
Legend
(1) PCMCIA Card
(2) RS 232 Loop Back Connector
Tech 2 Features

(4) DLC Cable
(5) Tech2

snapshot.
6E232

Getting Started
Operating Procedure (For Example)

tester with the Isuzu systems PCMCIA card. Follow the

the Tech 2 (5).
(4).
DLC.
810RW317

display.
060RX060
060RW009

diagnosis of Tech 2. Refer to user guide of the Tech 2.
6E233
Menu
060RW224
DTC Modes
060RX086
060RW229
6E234

appears:
D DTC Info
D Freeze Frame
D Clear Info
060RW223


service procedures.
DTC Status
Fail This Ignition
History
PCMs history memory. It will display all type A and B
warm-up cycles.
Last Test Failed
last time the test ran. The last test may have run during a
unknown.
Miscellaneous Test
060RW221

normality of electric circuit.
3. Refer to the latest Service Bulletin.
Check to see if the Latest software is released or not.
And then Down Load the LATEST PROGRAMMED
SOFTWARE to the replacement PCM.
6E235
Lamps Test
its working.
Test Procedure:
Menu.
060RX019

F1: Low Fuel Lamp is not used.
Relays Test
060RW228
This test is conducted to check Fuel Pump Relay and A/C

Clutch for proper operation.
Test Procedure:
Menu.
060RX035
060RW228
6E236
060RX034
060RX022
7. Control Fuel Pump Relay and check data list.

8. If the data list changes, the Fuel Pump Relay is
normal.
060RX021
060RX023

12. Push On and Off soft keys.
13. Control A/C Clutch Relay and check data list.
normal.
6E237
EVAP Test
Test Procedure:
Menu.
060RX025
060RW228
060RX026
7. Control EVAP Purge Solenoid and check data list.

8. If the data list changes, the Purge Solenoid is normal.
F1: Vent Solenoid is not used.

This test is conducted to check IAC system for proper
operation.
Test Procedure:
060RX036
6E238

Menu.
060RW235
060RW228

Test.

7. Instruct IAC system and check data list.
060RX015
060RX007
8. If the data list changes, the IAC control is normal.

9. Select F0: RPM Control Test
6E239
Fuel System Test

operation.
Test Procedure:
Menu.
060RX016

11. Control RPM and check data list.
12. If the data list changes, the RPM control is normal.
060RW228
060RW2311
060RX032
6E240

Menu.
060RX028
F1: Fuel Gauge Level is not used.

6. Push Reset soft key.
060RW228

Test.
060RX029
060RX008
EGR Control Test

operation.
Test Procedure:

6E241
4. Select F6: Variable Intake Manifold Solenoid Test.
060RX017
6. If data list chouges, the EGR Control is normal.
060RX033
5. Push On or Off soft key.
Variable Intake Manifold Solenoid Test

This test is conducted check VIM Solenoid for proper
operation.
Test Procedure:
Menu.
060RX028
6. Control VIM Solenoid and check data list.

7. If data list changes, the VIM Solenoid is normal.
060RW228

Test Procedure:
6E242

Menu.

key.
060RW228

Test.
060RW2301

normal.
If engine speed does not changes, the injector electric

060RX006
060RX037

snapshot data as needed. Therefore, accurate diagnosis
6E243
060RX085
6E244
060RX040
Primary System-Based Diagnostics

There are primary system-based diagnostics which
emissions. The primary system-based diagnostics are
function:
The fuel control heated oxygen sensors (Bank 1 HO2S 1
and Bank 2 HO2S 1) are diagnosed for the following
conditions:
D Slow response
approx. 450 mV)
D Signal fixed high
D Signal fixed low
Refer to On-Vehicle Service Heated Oxygen Sensors.

sensors while in closed loop to adjust fuel injector pulse
width. While in closed loop, the PCM can adjust fuel
delivery to maintain an air/fuel ratio which allows the best
combination of emission control and driveability. The fuel
control heated oxygen sensors are also used to
HO2S Heater
of time required for closed loop fuel control to begin
time required for fuel control sensors (Bank 1 HO2S 1 and
Bank2 HO2S 1) to become active.
6E245
6E246
D06RX010
Circuit Description
Test Description
The on-board diagnostic system check is the starting

check of the PCM and engine grounds for cleanliness and
tightness.
The on-board diagnostic system check is an organized

Diagnostic Chart:
the No MIL chart should be used to isolate the
malfunction.
PCM is able to transmit serial data.
3. This test ensures that the PCM is capable of
controlling the MIL (Check Engine lamp) and the
MIL (Check Engine lamp) driver circuit is not
shorted to ground.
the problem.
Diagnostic Aids
rubbed-through wire insulation or a wire broken inside the
harness. Inspect the PCM harness and connector for
damaged terminals, poor terminal-to-wire connection,
6E247
On- Board Diagnostic (OBD) System Check

Step
Action
1.
2.
3.
4.
Go to Step 8
Go to Step 4
Go to MIL
(Check
Engine lamp)
On Steady
Go to Step 5
Go to Cranks
But Will Not
Run
Go to Step 6
Go to Step 7
Go to
Multiple
PCM
Information
Sensor DTCs
Set
Go to
applicable
DTC table
Go to
Symptom
Refer to
indicated
Component
System
Checks
Go to Step 2
Go to Step 9
Go to Step 2
Compare PCM data values displayed on the Tech 2 to

1. Ignition OFF, disconnect the PCM.

and the DLC ground circuit for an open.
Go to Step 3

P0108, P0113, P0118, P0122, P0123, P0712, P1404.

values?
8

Go to Step 2

Go to No MIL
(Check
Engine lamp)

(Check Engine lamp) dash lamp control and
command the MIL (Check Engine lamp) OFF.
(Refer to Miscellaneous Test)
2. Observe the MIL (Check Engine lamp).
Did the MIL (Check Engine lamp) turn OFF?
No
Ignition OFF.
Install Tech 2.
Ignition ON.
Attempt to display PCM engine data with the Tech 2.
Does the Tech 2 display PCM data?

3
Yes

Check Engine lamp).
Is the MIL (Check Engine lamp)ON?
Value(s)
Replace the PCM.

6E248
D06RX011
6E249
Circuit Description

the system has a sufficient refrigerant charge, a 12-volt
signal is supplied to the A/C request input of the
powertrain control module (PCM). The A/C request
signal may be temporarily canceled during system
operation by the electronic thermostat in the evaporator
case. The electronic thermostat may intermittently
remove the control circuit ground for the A/C thermostat
relay to prevent the evaporator from forming ice. When
the A/C request signal is received by the PCM, the PCM
supplies a ground from the compressor clutch relay if the
engine operating conditions are within acceptable
ranges. With the A/C compressor relay energized,
voltage is supplied to the compressor clutch coil.
The PCM will enable the compressor clutch to engage
than 125 C (257 F).
(41F).
pressure condition.

ability to read the A/C request input to the PCM. The Tech
2 can display when the PCM has commanded the A/C
clutch ON. The Tech 2 should have the ability to
override the A/C request signal and energize the A/C
compressor relay.
Diagnostic Aids
conditions:
D Poor connection at the PCMInspect connections for
backed-out terminals, improper mating, broken locks,
terminal-to-wire connection.
D Damaged harnessInspect the wiring harness for
damage. If the harness appears to OK, observe the
A/C clutch while moving connectors and wiring
harnesses related to the A/C. A sudden clutch
malfunction will indicate the source of the intermittent
fault.
Test Description
IMPORTANT: Do not engage the A/C compressor
clutch with the engine running if an A/C mode is not
selected at the A/C control switch.
The numbers below refer to the step numbers on the
Diagnostic Chart:
3. This a test determine is the problem is with the
refrigerant system. If the switch is open, A/C
pressure gauges will be used to determine if the
pressure switch is faulty or if the system is partially
discharged or empty.
4. Although the normal complaint will be the A/C clutch
failing to engage, it is possible for a short circuit to
cause the clutch to run when A/C has not been
selected. This step is a test for that condition.
7. There is an extremely low probability that both relays
will fail at the same time, so the substitution process
is one way to check the A/C Thermostat relay. Use
a known good relay to do a substitution check.
9. The blower system furnishes a ground for the A/C
control circuit, and it also shares a power source
through the Heater and A/C Relay. The blower
must be ON in order to test the A/C system.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to the
other DTC
chart(s) first
Go to Step 3
Go to Air
Conditioning
to diagnose
the cause of
the open
pressure
switch
Go to Step 4

performed?
Are any other DTCs stored?
1. Disconnect the electrical connector at the pressure

switch located on the receiver/drier.
2. Use an ohmmeter to check continuity across the
pressure switch (BRN to GRN/WHT).
Is the pressure switch open?
6E250

Step
Action
Value(s)
Yes
No
IMPORTANT: Before continuing with the diagnosis, the

following conditions must be met:
D The intake air temperature must be greater than
15C. (60F).
D The engine coolant temperature must be less
than 119C (246F).
1. A/C OFF.
2. Start the engine and idle for 1 minute.
3. Observe the A/C compressor.
Is the A/C compressor clutch engaged even though
A/C has not been requested?
Go to Step 45
Go to Step 5
Refer to
Diagnostic
Aids
Go to Step 6
Go to Step 34
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Dose the blower operate?
Go to Step 10
Go to Step 11
10
Repair the blower.
Verify repair
Go to Step 13
Go to Step 12
Verify repair
B+
Go to Step 15
Go to Step 14
Verify repair
1.
2.
3.
4.
Idle the engine.

A/C ON.
Blower ON.
Observe the A/C compressor.
Is the A/C compressor magnetic clutch engaged?

6
1.
2.
3.
4.
Engine idling.
A/C ON.
Blower ON.
Observe the A/C Request display on the Tech 2.
(Refer to the miscelluneous test)
Does the A/C Request display indicate Yes?

7
Temporarily substitute the A/C compressor relay in

place of the A/C thermostat relay, then repeat Step 5.
Did the A/C Request display indicate Yes?
Replace the original A/C thermostat relay.

11
Check for a faulty 10A A/C fuse in the passenger

compartment fuse panel.
Was the 10A fuse OK?
12
Check for short circuit and make repairs if necessary.

Replace the 10A A/C fuse.
13
1. Ignition ON.
2. Use a DVM to check voltage at the positive A/C
switch wire (BRN).
Was voltage equal to the specified value?
14
Repair the open wire (BRN) between the A/C switch

and the A/C fuse.
6E251

Step
Action
15
1. Remove the glove box to gain access to the A/C

thermostat.
2. Disconnect the thermostat connector.
3. Attach a fused jumper between ground and the
GRN/RED wire at the thermostat.
4. A/C ON.
5. Blower ON.
Dose A/C request indicate YES on the Tech 2?
16
Go to Step 19
Verify repair
Verify repair
Go to Step 21
Go to Step 22
Verify repair
Verify repair
Go to Step 24
Go to Step 25
Verify repair
Go to Step 26
Go to Step 27
Verify repair
B+
Go to Step 29
Go to Step 28
Repair the open circuit between the engine device fuse

and the A/C thermostat relay.
27
Go to Step 18
Check for an open circuit between the engine device

fuse and the A/C thermostat relay (WHT/GRN).
26
Repair the open circuit between the PCM and A/C

thermostat relay.
25
Go to Step 17
Check for an open circuit between A/C thermostat relay

and PCM A/C request terminal (E-15).
24
Go to Step 20
Replace the electronic A/C thermostat.

Is the an action complete?
23
B+
Repair the open wire (WHT) between the thermostat

and the blower switch.
22
Go to Step 23
Use an ohmmeter to check continuity between the

electronic A/C thermostat and the blower switch.
21
Go to Step 16
Replace the A/C switch.

20
Repair the open wire (LT GRN/BLK) between the

thermostat and the A/C switch.
19
No
Check for an open (LT GRN/BLK) wire between the

Was the wire open?
18
Yes
1. Ignition ON.
2. A/C switch ON.
3. Use a DVM to check voltage at the electronic A/C
thermostat.
17
Value(s)
1. Ignition ON.
2. Use a DVM to check voltage at the A/C pressure
switch (BRN).
6E252

Step
Action
28
Repair the open circuit between the 10A A/C fuse and
the pressure switch.
29
1.
2.
3.
4.
5.
Verify repair
Go to Step 32
Go to Step 33
Verify repair
Verify repair
B+
Go to Step 36
Go to Step 35
Verify repair
B+
Go to Step 40
Go to Step 37
Go to Step 38
Go to Step 39
Verify repair
Go to Step 32
Go to Step 33
Repair the open GRY/RED wire between the PCM and

the A/C compressor relay.
39
Check for an open GRY/RED wire between PCM

terminal B-14 and the A/C compressor relay.
Was the wire open?
38
Go to Step 31
A/C compressor relay removed.

Engine idling.
A/C ON.
Blower ON.
Use a DVM to measure voltage between the
GRY/RED wire at the A/C compressor relay socket
and battery+.
Did the DVM indicate the specified value?

37
Go to Step 30
Repair the faulty BRN wire between the A/C fuse and
the A/C compressor relay .
36
1. Remove the A/C compressor relay.

2. Ignition ON.
3. Use a DVM to check voltage at both of the BRN
wires at the A/C compressor relay socket.
Is the voltage equal to the specified value?
35
Replace the PCM.

34
Verify repair

33
Check for damaged pin or terminal at E-15 of the PCM.

Was a damaged pin or terminal found?
32
No
Repair the open circuit between the pressure switch

31
Yes

pressure switch (GRN/WHT) and the A/C thermostat
relay (GRN/WHT).
Was the circuit open?
30
Value(s)
Check for a damaged pin or terminal at B-14 of the

PCM.
Was a damaged pin or a terminal found?
6E253

Step
Action
40
1. A/C compressor relay removed.

2. Connect a fused jumper at the A/C compressor
relay socket between either BRN wire and the
BRN/YEL wire.
3. Engine idling.
4. A/C ON.
5. Blower ON.
Did the compressor magnetic clutch engage?
41
Go to Step 43
Go to Step 44
Verify repair
Verify repair
Go to Step 46
Go to Step 47
Verify repair
Go to Step 48
Go to Step 50
Go to Step 49
Go to Step 33
Verify repair
Verify repair
Repair the short to ground between the PCM and A/C

compressor relay.
50
Use a DVM to check for a short to ground between the

A/C compressor relay and B-14 of the PCM.
Was a short detected?
49
Verify repair
1. Reinstall the A/C compressor relay.

2. Remove the A/C thermostat relay.
3. Engine idling.
Is the compressor clutch still engaged when A/C is not
selected?
48
Repair the short to voltage between the A/C clutch and

A/C compressor relay.
47
Go to Step 42

2. Idle the engine.
selected?
46
Go to Step 41
Service the compressor clutch or replace the

compressor due to a faulty internal overheat switch.
45
Repair the open circuit between the compressor Clutch

and the A/C compressor relay.
44
No
Check for an open circuit between the A/C compressor

relay and the A/C clutch.
Was an open circuit found?
43
Yes
Repair the A/C compressor relay.

42
Value(s)
Repair the short to ground between the A/C thermostat

relay and the electronic thermostat.
6E254
Electronic Ignition System Diagnosis

to determine if the failure is the ignition system or the fuel
system.
Visual Check of The Evaporative

Emission Canister
canister.
Fuel Metering System Check

Some failures of the fuel metering system will result in an
Engine Cranks But Will Not Run symptom. If this
condition exists, refer to the Engine Cranks But Will Not
Run chart. This chart will determine if the problem is
caused by the ignition system, the PCM, or the fuel pump
electrical circuit.
Refer to Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to Fuel System
Diagnosis, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump. If a malfunction
occurs in the fuel metering system, it usually results in
either a rich HO2S signal or a lean HO2S signal. This
condition is indicated by the HO2S voltage, which causes
the PCM to change the fuel calculation (fuel injector pulse
width) based on the HO2S reading. Changes made to the
fuel calculation will be indicated by a change in the long
term fuel trim values which can be monitored with a Tech
2. Ideal long term fuel trim values are around 0%; for a
lean HO2S signal, the PCM will add fuel, resulting in a fuel
trim value above 0%. Some variations in fuel trim values
are normal because all engines are not exactly the same.
If the evaporative emission canister purge is ON, the
long term fuel trim may be as low as 38%. If the fuel trim
values are greater than +23%, refer to DTC P0131, DTC
P0151, DTC P0171, and DTC 1171 for items which can
cause a lean HO2S signal.

count of 0 indicates the PCM is commanding the IAC
pintle to be driven all the way into a fully-seated position.
This is usually caused by a large vacuum leak.
commanded to bypass the throttle blade. Refer to IAC
System Check in order to diagnose the IAC system.
Refer to Rough, Unstable, or Incorrect Idle, Stalling in
Symptoms for other possible causes of idle problems.
Knock Sensor Diagnosis

The Tech 2 has two data displays available for diagnosing
the knock sensor (KS) system. The two displays are
described as follows:
D Knock Retard indicates the number of degrees that

the spark timing is being retarded due to a knock
condition.
D KS Noise Channel indicates the current voltage
level being monitored on the noise channel.
DTCs P0325 and P0327 are designed to diagnose the KS
module, the knock sensor, and the related wiring. The
problems encountered with the KS system should set a
DTC. However, if no DTC was set but the KS system is
suspect because of a detonation complaint, refer to
Detonation/Spark Knock in Symptoms.

Diagnosis
diagnostic trouble codes from the PCM memory.
from the PCM for 30 seconds. Turning off the ignition and
disconnecting the battery power from the PCM will cause
all diagnostic information in the PCM memory to be
re-run.
Since the PCM can have a failure which may affect only
where it is.
If a diagnostic chart indicates that the PCM connections
or the PCM is the cause of a problem, and the PCM is
D There is a problem with the PCM terminal
checked. In this case, refer to the Symptoms portion
of the manual and make a careful physical inspection
of all components and wiring associated with the
affected system.
Solenoids and relays are turned ON and OFF by
the PCM using internal electronic switches called
drivers. A shorted solenoid, relay coil, or harness will
not damage the PCM but will cause the solenoid or
relay to be inoperative.
Multiple PCM Information Sensor

DTCS Set
Circuit Description
The powertrain control module (PCM) monitors various
The PCM controls fuel delivery, spark advance,
transmission operation, and emission control device
operation based on the sensor inputs.
The PCM provides a sensor ground to all of the sensors.
The PCM applies 5 volts through a pull-up resistor, and

monitoring the voltage present between the 5-volt supply
and the resistor:
D The engine coolant temperature (ETC) sensor
D The intake air temperature (IAT) sensor
D The transmission fluid temperature (TFT) sensor
The PCM provides the following sensors with a 5-volt
D The exhaust gas recirculating (EGR) pintle position
sensor
The PCM monitors the separate feedback signals from
status.
Diagnostic Aids
IMPORTANT: Be sure to inspect PCM and engine
grounds for being secure and clean.
D P0108
D P0113
D P0118
D P0123
D P0712
IMPORTANT: If a sensor input circuit has been shorted
to voltage, ensure that the sensor is not damaged. A
damaged sensor will continue to indicate a high or low
voltage after the affected circuit has been repaired. If the
sensor has been damaged, replace it.
An open in the sensor ground circuit between the PCM
DTCs to be set:
D P0108
D P0113
D P0118
D P0123
D P0712
A short to ground in the 5-volt reference A or B circuit will
D P0107
6E255
D P0122
An the in the 5-volt reference circuit A, between the PCM
DTCs to be set:
D P0122
An the in the 5-volt reference circuit B, between the PCM
DTCs to be set:
D P0107
D Poor connection at PCM. Inspect the harness
connectors for backed-out terminals, improper
mating, broken locks, improperly formed or damage
terminals, and a poor terminal-to-wire connection.
the ignition ON and the engine OFF while you
move the connectors and the wiring harnesses
related to the following sensors:
D IAT
D ECT
D TP
D MAP
D EGR
D TFT
Test Description
9. A faulty EGR valve can leak a small amount of
current from the ignition feed circuit to the 5-volt
reference A circuit. If the problem does not exist
with the EGR valve disconnected, replace the EGR
valve.
11-15. If a sensor input circuit has been shorted to
voltage, ensure that the sensor has not been
damaged. A damaged IAT or ECT sensor will
continue to indicate a high voltage or a low
temperature after the affected circuit has been
repaired. A dameged TP, MAP, fuel tank pressure,
or EGR pintle position sensor will indicate a high
voltage, a low voltage, or a fixed value after the
affected circuit has been repaired. If the sensor has
been damaged, replace it.
6E256
Multiple PCM Information Sensor DTCs Set

Step
Action
Go to Step 5
Go to Step 6
Verify repair
0V
Go to Step 7
Go to Step 11
0V
Go to Step 8
Go to Step 14
0V
Go to Step 9
Go to Step 15
0V
Go to Step 10
Go to Step 16
0V
Go to Step 11
Go to Step 17
0V
Go to Step 13
Go to Step 18
0V
Go to Step 20
Go to Step 19

circuit at the PCM harness connector and ground.
position sensor signal circuit at the PCM harness
12
Verify repair


11


10
Go to Step 4


9
Go to Step 3

sensor signal circuit at the PCM harness connector and
ground.

8

7
Go to Step 2

conditions:
D A poor connection at the PCM or the affected
sensors.
D An open between the PCM connector and the
affected sensors.

6
Go to OBD
System
Check

5
No
1. Turn the ignition OFF, disconnect the PCM.

2. Turn the ignition ON, check the 5 volt reference A
circuit for the following conditions:
D A poor connection at the PCM.
splice.

4
Yes

performed?

3
Value(s)
Measure the voltage between the TFT sensor signal

6E257
Multiple PCM Information Sensor DTCs Set (Cont'd)

Step
13
Action
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to OBD
System
Check
Locate and repair the short to voltage in the TFT sensor

signal circuit.
20

19

18
Verify repair

signal circuit.
17

signal circuit.
16
No

15
Yes

14
Value(s)
Replace the PCM.

6E258

Diagnosis
Pintle position error diagnosis is covered by DTC P0402,
P0404, P1404, P0405, P0406. If EGR diagnostic trouble
codes P0402, P0404, P1404, P0405, P0406 are
encountered, refer to the DTC charts.
Engine Tech 2 Data Definitions and

Ranges
A/C CLUTCHTech 2 Displays ON or OFF
Indicates whether the PCM has commanded the A/C
clutch ON. Used in A/C system diagnostic.
HVAC controls. The PCM uses the A/C request signal to
requested.
AIR/FUEL RATIO Tech 2 Range 0.0-25.5
Air/fuel ratio indicates the PCM commanded value. In
closed loop, the air/fuel ratio should normally be
BARO kPa Tech 2 Range 10-105 kPa/0.00-5.00
Volts
normally displayed around 61-104 depending on
ECT (Engine Coolant Temperature) Tech 2

Range 40C to 151C (40F to 304F)
information to the PCM. The PCM applies 5 volts to the
changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the PCM
the voltage signal will decrease and the PCM will interpret
EGR DUTY CYCLE Tech 2 Range 0%-100%
PCM. A duty cycle of 0% indicates that no EGR flow is
EGR FEEDBACK Tech 2 Range 0.00-5.00 Volts
being monitored by the PCM. A low voltage indicates a
ENGINE LOAD Tech 2 Range 0%-100%
Engine load is calculated by the PCM from engine speed
and MAF sensor readings. Engine load should increase
ENGINE RUN TIME Tech 2 Range
00:00:00-99:99:99 Hrs:Min:Sec
00:00:00.
ENGINE SPEED Range 0-9999 RPM
Engine speed is computed by the PCM from the 58X
CHECK TRANS LAMPAUTO TRANSMISSION

Indicates the need to check for a DTC with the Tech 2
when the lamp is flashing 0.2 seconds ON and 0.2
seconds OFF.
EVAP PURGE PWM Tech 2 Range 0%-100%

Represents the PCM commanded PWM duty cycle of the
EVAP purge solenoid valve. 0% displayed indicates no
purge; 100% displayed indicates full purge.
CMP ACT. COUNTER Cam Position

ActivityDECEL FUEL MODETech 2 Display
ACTIVE or INACTVE
ACTIVE displayed indicates that the PCM has detected
mode. The PCM will command the deceleration fuel
vehicle is traveling over 20 mph. While in the decreasing
fuel mode, the PCM will decrease the amount of fuel
delivered by entering open loop and decreasing the
EVAP VENT VALVE Tech 2 Displays PURGE or

NO PURGE
The EVAP purge vacuum valve is a normally closed valve
positioned in the purge line between the canister and the
EVAP purge solenoid. The EVAP purge vacuum valve
will open when vacuum increases to greater than 5 inches
of water in the purge line. The EVAP purge vacuum valve
is used by the PCM to monitor EVAP canister purge
solenoid opetation and purge system integrity. The EVAP
purge vacuum valve should be closed to ground with no
vacuum present (0% EVAP purge PWM). With EVAP
purge PWM at 25% or greater, the EVAP purge vacuum
valve should be open and PURGE should be indicated.
DESIRED EGR POS.Tech 2 Range 0%-100%

Represents the EGR pintle position that the PCM is
commanding.
DESIRED IDLE Tech 2 Range 0-3187 RPM
The idle speed that the PCM is commanding. The PCM
speed.
FUEL TRIM CELL Tech 2 Range 0-21

active.
6E259

fuel trim corrections, fuel trim learn will display YES.
This indicates that the long term fuel trim is responding to
the short term fuel trim. If the fuel trim learn displays
NO, then long term fuel trim will not respond to changes
in short term fuel trim.
KS NOISE CHANNEL (Knock Sensor)

Indicates the output from the KS noise channel. There is
always some electrical noise in an engine compartment
and to avoid mistaking this as engine knock, the output
from the knock sensor is compared to the output from the
noise channel. A knock condition is not set unless the
knock sensor output is greater than the noise channel
output.
HO2S BANK 1, SEN. 1Tech 2 Range 0-1132 mV

exhaust) while operating in closed loop.
LONG TERM FUEL TRIM BANK 1/BANK 2

The long term fuel trim is derived from the short term fuel
trim values and represents a long term correction of fuel
delivery for the bank in question. A value of 0% indicates
that fuel delivery requires no compensation to maintain
the PCM commanded air/fuel ratio. A negative value
significantly below 0% indicates that the fuel system is
rich and fuel delivery is being reduced (decreased injector
pulse width). A positive value significantly greater than
0% indicates that a lean condition exists and the PCM is
compensating by adding fuel (increased injector pulse
width). Because long term fuel trim tends to follow short
term fuel trim, a value in the negative range due to
canister purge at idle should not be considered unusual.
Fuel trim values at maximum authority may indicate an
excessively rich or lean system.
HO2S BANK2, SEN. 1Tech 2 Range 01132 mV

between 10mV (lean exhaust) and 1000 mV (rich
HO2S BANK 1, SEN. 1Tech 2 Displays READY
YES/NO
ready when the PCM detects a fluctuating HO2S voltage
sufficient to allow closed loop operation. This will not
occur unless the exhaust oxygen sensor is warmed up.
YES/NO
IAC POSITION Tech 2 Range 0-255 Counts
LOOP STATUS Tech 2 Displays OPEN or

CLOSED
CLOSED indicates that the PCM is controlling fuel
delivery according to oxygen sensor voltage. In OPEN
the PCM ignores the oxygen sensor voltage and bases
the amount of fuel to be delivered on TP sensor, engine
coolant, and MAF sensor inputs only.
MAF Tech 2 Range 0.0-512 gm/s
MAF (mass air flow) is the MAF input frequency
converted to grams of air per second. This indicates the
amount of air entering the engine.

40C to 151C (40F to 304F)
The PCM converts the resistance of the intake air
(IAT) is used by the PCM to adjust fuel delivery and spark
MAP Tech 2 Range 10-105 kPa (0.00-4.97 Volts)

the diagnostics.
IGNITION 1 Tech 2 Range 0-25.5 Volts

PCM at its ignition feed.

Indicates the PCM commanded state of the malfunction
indicator lamp.
INJ. PULSE BANK 1/INJ. PULSE BANK 2 Tech 2

Range 0-1000 msec.
Indicates the amount of time the PCM is commanding
engine load.

or INACTIVE
mode. The PCM will command power enrichment mode
detected. While in power enrichment mode, the PCM will
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.
6E260
RICH/LEAN BANK 1/ BANK 2 Tech 2 Displays

RICH or LEAN
Indicates whether oxygen sensor voltage is above a 600
mV threshold voltage (RICH) or below a 3000 mV
threshold voltage (LEAN). Should change constantly
while in closed loop, indicating that the PCM is controlling
the air/fuel mixture properly.
SHORT TERM FT BANK1/BANK2
Short term fuel trim to a bank represents a short term
correction to bank fuel delivery by the PCM in response
to the amount of time the bank fuel control oxygen sensor
voltage spends above or below the 450 mV threshold. If
the oxygen sensor voltage has mainly remained less than
450 mV, indicating a lean air/fuel mixture, short term fuel
trim will increase into the positive range above 0% and
the PCM will pass fuel. If the oxygen sensor voltage stays
mainly above the threshold, short term fuel trim will
decrease below 0% into the negative range while the
PCM reduces fuel delivery to compensate for the
indicated rich condition. Under certain conditions such as
extended idle and high ambient temperatures, canister
purge may cause short term fuel trim to read in the
negative range during normal operation. Fuel trim values
at maximum authority may indicate an excessively rich or
lean system.
by the PCM on the IC circuit.
START-UP ECT Tech 2 Range 40C to 151C
(40F to 304F)
determine if the last start-up was a cold start.
START-UP IAT Tech 2 Range 40C to 151C
(40F to 304F)
TP Tech 2 Range 0%-100%
TP (throttle position) angle is computed by the PCM from
TP SENSOR Tech 2 Range 0.00-5.00 Volts
The voltage being monitored by the PCM on the TP
Number
This indicates that the PCM has detected crankshaft
Typical Scan Data Values

On-Board Diagnostic System Check has been
determined that the on-board diagnostics are functioning
properly. Tech 2 values from a properly-running engine

values that would be seen on a normally-running engine.
information on using the Tech 2 to diagnose the PCM and
described below, refer to the Symptoms section for
diagnosis.
Test Conditions
park or neutral, closed loop, accessaries off, brake not
applied and air conditioning off.
6E261
3.5L V-6 Engine

Tech 2 Parameter
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
Engine Speed
Engine
RPM
Within 50 to +100 of
Desired Idle
Actul engine speed
Desired Idle Speed
Engine
RPM
750
800
Engine
C or F
80 100
(176 212 F)
80 100
(176 212 F)
Start Up ECT (Engine Coolant

Temperature)
Engine
C or F
Engine
C or F
0 100, depends on
underhood
0 80, depends on
underhood
Start Up IAT (Intake Air Temperature)
Engine
C or F
Engine
kPa
23 40
19 32
Engine
0.65 1.32
0.46 1.10
Barometric Pressure
Engine
kPa
61 104 (depends pn
altitude and
barometric)
61 104 (depends pn
altitude and
barometric)
Throttle Position
Engine
35
Engine
0.35 0.39
0.55 0.59
Mass Air Flow
Engine
g/s
2.85 6.65
9.5 16.5
Air Fuel Ratio
Engine
Ratio:_to1
14.7:1
14.7:1
Injection Pulse Bank 1
Engine
ms
2.0 4.0
2.5 4.0
Engine
ms
2.0 4.0
2.5 4.0
Spark Advance
Engine
CA
15 22
34 44
EGR Duty Cycle
Engine
Desired EGR Position
Engine
EGR Normalized
Engine
EGR Feedback
Engine
0.45 0.80
0.45 0.80
EGR Closed Pintle Position
Engine
Steps
20 40
20 40
Catalyst Protection Mode
Engine
Yes/No
No
No
Knock Sensor Noise Channel
Engine
0.10 0.40
0.50 1.75
A/C Clutch Relay
Engine
On/Off
Off
A/C Request
Engine
Yes/No
No
Camshaft Activity
Engine
Counts
0 255 always
increasing
0 255 always
increasing
EVAP Purge Solenoid (Evaporative

Emission)
Engine
On/Off
Off
Off
Fuel Pump
Engine
On/Off
On
On
Idle Air Control
Engine
Steps
Transmission Check Light
Engine
On/Off
Off
Off
Park/Neutral Position
Engine
P-N/R-D3-2-L
P-N
P-N
TCC Engaged
Engine
Yes/No
No
No
Vehicle Speed
Engine
MPH or
km/h
Ignition Voltage
Engine
12.8 14.1
12.8 14.1
6E262

Tech 2 Parameter
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
Fuel system Status
Engine
Closed
Loop
/Open
Loop
Closed Loop
Closed Loop
Power Enrichment
Engine
Yes/No
No
No
Engine Load
Engine
2.0 5.5
8.0 16.0
Time From Start
Engine
_:_:_
_:_:_
_:_:_
Deceleration Fuel Cutoff
Engine
Inactive/A
ctive
Inactive
Inactive
Engine
On/Off
Off
Off
VIM solenoid (Variable Intake

Manifold)
Engine
On/Off
On
On

Tech 2 Parameter
6E263
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
Engine Speed
O2
Sensor
RPM
Within -50 to +100 of

Desired Idle
Actul engine speed
Desired Idle Speed
O2
Sensor
RPM
750
800
O2
Sensor
C or F
80 100
(176 212 F)
80 100 (176 212

F)

Temperature)
O2
Sensor
C or F
O2
Sensor
C or F
0 100, depends on
underhood
0 80, depends on
underhood
O2
Sensor
C or F
O2
Sensor
kPa
23 40
19 32
Barometric Pressure
O2
Sensor
kPa
61 104 (depends pn
altitude and
barometric)
61 104 (depends pn
altitude and
barometric)
Throttle Position
O2
Sensor
35
O2
Sensor
0.35 0.39
0.55 0.59
Mass Air Flow
O2
Sensor
g/s
2.85 6.65
9.5 16.5
Air Fuel Ratio
O2
Sensor
g/s
2.85 6.65
9.5 16.5
B1 S1 O2 Sensor (Bank 1 Sensor 1)
O2
Sensor
mV
50 950 always
changing quickly
50 950 always
changing quickly
O2
Sensor
mV
50 950 always
changing quickly
50 950 always
changing quickly
B1 O2S Ready (Bank 1)
O2
Sensor
Yes/No
Yes
Yes
O2
Sensor
Yes/No
Yes
Yes
B1 S1 O2S Warm Up Time (Bank1

Sensor 1)
O2
Sensor
seconds
24 45
24 45

Sensor 1)
O2
Sensor
seconds
24 45
24 45
B1 Long Term Fuel Trim (Bank1)
O2
Sensor
O2
Sensor
B1 Short Term Fuel Trim (Bank1)
O2
Sensor
O2
Sensor
Fuel Trim Cell
O2
Sensor
Cell No.
20
2 or 6
Fuel Trim Learned
O2
Sensor
Yes/No
Yes
Yes
B1 S1 Status (Bank 1 Sensor 1)
O2
Sensor
Lich/Lean
6E264

Tech 2 Parameter
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
O2
Sensor
Lich/Lean
Engine Load
O2
Sensor
2.0 5.5
8.0 16.0
6E265
D06RX134
Circuit Description
MIL bulb through the meter fuse. The powertrain control
module (PCM) turns the MIL ON by grounding the MIL
driver circuit.
Diagnostic Aids
An intermittent MIL may be cased by a poor connection,
rubbed-through wire insulation, or a wire broken inside
D Inspect the PCM harness and connections for
damaged
terminals,
poor
terminal-to-wire
PCM ignition or battery feed, or a poor PCM to engine
ground.
Test Description
Diagnostic Chart.
2. A No MIL condition accompanied by a no-start
condition suggests a faulty PCM ignition feed or
9. Using a test light connected to B+, probe each of the
PCM ground terminals to ensure that a good ground
is present. Refer to PCM Terminal End View for
terminal locations of the PCM ground circuits.
12.In this step, temporarily substitute a known good
relay for the PCM relay. The horn relay is nearby,
this step.
6E266

Step
Action
1.
2.
3.
4.
Go to Step 5
Go to Step 13
Go to Step 10
Go to Step 11
Go to Step 7
Go to Step 15
Go to Step 8
Go to Step 12
Go to Step 9
Go to Step 14
Verify repair
Go to Step 10
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 13
Verify repair
Verify repair
Substitute a known good relay for the PCM main

relay.
14
Check for an open MIL driver circuit between the PCM

and the MIL.

13
Go to Step 16
Check for damaged terminals at the PCM.

12
Go to Step 4
Check for a faulty PCM ground connection.

11
Probe the battery feed circuit at the PCM harness


10
Go to Step 6
Ignition OFF.
Disconnect the PCM.
Ignition ON.
Probe the ignition feed circuit at the PCM harness

9
Go to Step 3
Check the PCM ignition feed and battery feed fuses (15
A engine fuse and 15 A PCM fuse).

8
1. Ignition OFF.
2. Disconnect the PCM.
3. Jumper the MIL driver circuit at the PCM connector
to ground.
4. Ignition ON.
Are both fuses OK?

7
Go to Step 2
Ignition ON, probe the ignition feed circuit at the

cluster connector with a test light to ground.
Is the MIL ON?

6
Go to OBD
System
Check

feed circuit.

5
No
Is the fuse OK?

4
Yes

performed?

3
Value(s)
Locate and repair the open PCM battery feed circuit.

6E267

Step
Action
15
Locate and repair the short to ground in the PCM

ignition feed circuit or PCM battery feed circuit.
16
No
Verify repair
Verify repair
Verify repair
Verify repair
Go to
Instrument
Panel in
Electrical
Diagnosis
Replace the PCM.

18
Yes

fuse.
17
Value(s)

6E268
D06RX012
Circuit description
illuminated and steady with ignition ON and the engine
stopped. Ignition feed voltage is supplied directly to the
MIL indicator. The powertrain control module (PCM)
turns the MIL ON by grounding the MIl driver circuit.
and no DTC(s) set. A steady MIl with the engine running
and no DTC(s) suggests a short to ground in the MIl driver
circuit.
Diagnostic Aids

PCM harness and connectors for improper mating,
terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
Diagnostic Chart.
2. If the MIL does not remain ON when the PCM is
cluster is faulty.
6E269

Step
Action
Go to Step 2
Go to Step 3
Go to Step 5
Go to OBD
System
Check
Go to Step 4
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step 6
Go to OBD
System
Check
1. Ignition OFF, reconnect the PCM.

MIL dash lamp control and command the MIL
OFF. (Refer to the miscellaneous test)
Go to OBD
System
Check

cluster.
2. Check the MIL driver circuit between the PCM and

5
No
1. Ignition OFF, disconnect PCM.

2. Ignition ON, observe the MIL (Service Engine
Soon lamp).

4
Yes
Was the On-Board diagnostic (OBD) System Check

performed?
Is the MIL ON?

3
Value(s)
Replace the PCM.

6E270
D06RX146

Circuit Description
The electronic Ignition system uses a coil-at-plug method
of spark distribution. In this type of ignition system, the
powertrain control module (PCM) triggers the correct
driver inside the ignition coil, which then triggers the
correct ignition coil based on the 58X signal received from
the crankshaft position sensor (CKP). The spark plug
connected to the coil fires when the ignition coil opens the
ground circuit for the coils primary circuit.
During crank, the PCM monitors the CKP 58X signal. The
PCM, it will command all six injectors to allow a priming
injectors are left OFF during the next six 58X reference
been received by the PCM. The CMP signal allows the
PCM to operate the injectors sequentially based on
present at start-up, the PCM will begin sequential fuel
delivery with a 1-in-6 chance that fuel delivery is correct.
DTC code.
Diagnostic Aids
connection, rubbed-through wire insulation or a wire
items:
terminals, poor terminal-to-wore connection, and
damaged harness.
intake air temperature. If not, replace the ECT
sensor.
Test Description
Diagnostic Chart.
5. An obvious cause of low fuel pressure would be an
empty fuel tank.
6. The engine will easily start and run if a few injectors
are disabled. It is not necessary to test all injectors
at this time since this step is only a test to verify that
all of the injectors have not been disabled by fuel
contamination.
7. A blinking test light verifies that the PCM is
monitoring the 58X crankshaft reference signal and
is capable of activating the injectors. If there is an
open or shorted driver circuit, DTCs 201206 should
be set.
6E271
19.By using a spark tester, each ignition coils ability to

produce 25,000 volts is verified.
25.If there is an open or shorted driver circuit, DTCs
201-206 should be set. All six injector driver circuits
can be checked at one time without removing the
intake manifold if a 5-8840-2636-0 test light is
available. This is the alternative procedure:
D With the ignition OFF, disconnect the gray
connector located at the rear of the air filter, attached
to a bracket on the purge canister.
D Connect test light 5-8840-2636-0 to the connector.
Do any of the light constantly illuminate or fail to blink
when the engine is cranked? If so, repair the short or
open circuit, or replace the PCM if indicated.
This procedure only tests the driver circuit as far as the
test connection, so step 31 is added to test the circuit all
the way to the injector.
6E272

Step
Action
Verify repair
285-375 kPa
(43-55 psi)
Go to Step 6
Go to Step 5
Go to Fuel
System
Electrical Test
Go to Fuel
System
Diagnosis
Go to Step 7
Go to Step 23
Go to Step 11
Go to Step 8
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 13
Go to Step 12
1. Remove the 5-pin connector at the ignition coil.

2. Ignition ON.
3. Use a test light at the harness connector to verify
that the module is being supplied with B+ and
ground.
Repair the open ignition feed circuit or ground circuit to
the ignition coil.
Repair the ignition module.
11
Go to Step 4
1. Ignition OFF.
2. Disconnect the 6-pin connector at the ignition coil.
3. With a test light to B+, probe each of the 6 exposed
ignition module pins, one at a time, while the engine
is cranked.

10
Go to Step 3
Install an injector test light at the #2 cylinder injector

harness connector (or install 5-8840-2636-0 test light
to the the injector test connector).

9
Does the light flash at each pin when the engine is

cranked?
8
Go to Step 2
1. Ignition OFF, install a fuel pressure gauge at the

test fitting on the fuel supply line in the engine
compartment. (Use a shop cloth to absorb any fuel
leakage while making the connection.)
2. Ignition ON, observe the fuel pressure.
Does the light blink when the engine is cranked?

7
Go to OBD
System
Check
Is the fuel pressure within the specified values, and

does it hold steady?
5
No
Check the 15 A ignition coil fuse, the 15 A engine

device fuse, and the 15A PCM fuse.

4
Yes

performed?
Was a fuse blown?

3
Value(s)
1. Reconnect the ignition coil connector.

2. Remove the electrical connector from each coil.
3. With a test light to B+, probe each of the coil
connectors at the wire which runs to the ignition
module. (Wire color will match the wire color at the
ignition module 6-pin connector green, or green
with a tracer.)
Does the light flash at each coil connector when the
engine is cranked?
6E273

Step
12
Action
Verify repair
Go to Step 17
Go to Step 16
Verify repair
Verify repair
Go to Step 18
Go to Step 20
Go to Step 19
Verify repair
Refasten all
coils with
their screws
Go to Step 21
Correct the
fouling
condition
Go to Step 22
Repeat Step 19 for each coil. Remove only one coil at a

time, and reinstall each coil on its spark plug after
testing, but do not refasten coils with screws at this
time.
After all coils have passed the spark test, does the
engine start?
21
Go to Step 14
Replace the ignition coil, and return to Step 19 to test

the remaining coils.
20
Go to Step 15
1. Remove any ignition coil and install a spark tester at

the spark plug end of the coil.
2. Observe the tester while the engine is cranking.
Was a crisp, blue spark observed? Only one or two
No Spark.
19

Balance Test).
18
Repair the open secondary ground circuit.

17
Verify repair
While the coil connectors are disconnected, touch

each connectors secondary ground terminal with a
test light to B+. (The ground wires are black.)
Did the test light illuminate at each coil connector?
16

15
No
1. Ignition ON.
2. While the coil connectors are disconnected, touch
each coil connectors ignition feed terminal with a
grounded test light (the ignition feed wire is black
with orange tracer).
Did the test light illuminate?
14
Yes
Check for an open circuit between the ignition coil.

13
Value(s)

excessive fouling?
6E274

Step
Action
22
Refer to Engine Mechanical Diagnosis to diagnose the

D Faulty or incorrect camshaft drive belts
D Leaking or sticky valves or rings
D Excessive valve deposits
D Loose or worn rocker arms
D Leaking head gasket
23
Go to Step 24
Go to Step 33
Go to Step 25
Go to Step 31
Go to Step 26
Go to Step 28
Go to Step 27
Go to Step 32
Verify repair
Go to Step 30
Go to Step 29
Verify repair
Go to Step 32
1. Using the same test location as in step 26, connect

a test light between the ignition terminal and one of
the driver circuits.
2. Crank the engine and observe the test light.
3. Repeat for each injector driver circuit.
Did the light blink during the test for each circuit?
29
Go to Step 24
Locate and repair the short to ground in the injector

driver circuit.
28
Verify repair

2. Ignition ON, observe the test light.
27
1. At the PCM (female) side of the connector

mentioned in step 25, connect a test light between
the ignition + terminal and one of the injector driver
circuits at the same connector.
2. Ignition ON.
3. Observe the test light, and repeat the test for each
Did the test light stay on when checking any of the 6
injector driver circuits?
26
No
1. Disconnect the 7-pin gray connector at the rear of

the air filter beneath the point where the air duct
attaches to the MAF sensor.
2. Ignition ON.
ignition terminal at the PCM (female) side of the
7-pin connector.
25
Yes
Observe the Engine Speed data display on the Tech 2

while cranking the engine.
Is the engine RPM indicated?
24
Value(s)
Check for an open injector driver circuit.

6E275

Step
Action
30
1. At the injector (male) side of the gray connector

mentioned in step 25, connect an ohmmeter
between the ignition pin and one of the driver circuit
pins.
2. Check for continuity in the circuit.
3. Repeat for each injector circuit. The readings
should be approximately equal to the specified
value for injector resistance.
31
Verify repair
Verify repair
Go to Step 35
Go to Step 34
Verify repair
Go to Step 37
Go to Step 36
Verify repair
Verify repair
Go to Step 38
Verify repair
Go to Step 32
Check the signal circuit between the sensor and the

PCM for a short to ground, short to voltage, or an open.
38
Check the sensor ground circuit for an open or short to

voltage.
37
Go to Step 7
1. Ignition ON.
2. At the CKP harness connector, connect a test light
36
Verify repair
Check the ignition feed wire between the sensor and

the PCM for a short to ground or open circuit.
35
12.5 ohms

harness.
2. Ignition ON.
3. With a test light to ground, probe the harness
ignition feed terminal.
34
No
Replace the PCM.

33
Yes
Repair the ignition feed circuit.

32
Value(s)

6E276
D06RX014
Circuit Description
Diagnostic Aids
When the ignition switch is first turned ON, the

powertrain control module (PCM) energizes the fuel
pump relay which applies power to the in-tank fuel pump.
The fuel pump relay will remain ON as long as the
engine is running or cranking and the PCM is receiving
58X crankshaft position pulses. If no 58X crankshaft
position pulses are present, the PCM de-energizes the
fuel pump relay within 2 seconds after the ignition is
turned ON or the engine is stopped.

damaged harness.
Test Description
Diagnostic Chart.
2. If the fuel pump is operating but incorrect pressure is
noted, the fuel pump wiring is OK and the Fuel
diagnosis.

injury:
completed.
6E277

relay center.

2. Install fuel gauge 5-8840-0378-0 to the fuel feed line
cover.


Step
Action
Go to Step 3
Go to Step 4
Test
completed
Go to Step 12
Go to Step 6
Go to Step 5
Verify repair
Go to Step 12
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair

connect to the fuel pump relay pull-in coil.
2. Ignition ON.

from the relay pullin coil to the PCM.
2. Ignition ON.
off?
off?
7
Go to Step 2
1. Ignition OFF.

6
Go to OBD
System
Check


5
No

3. Ignition SW is ON.

4
Yes

performed?
Is there an immediate pressure build-up which

3
Value(s)

circuit.
6E278

Step
Action
Verify repair
Go to Step 15
Go to Step 13
Go to Step 17
Go to Step 14
Verify repair
Go to Step 18
Go to Step 16
Verify repair
Verify repair
Verify repair
Replace the fuel pump relay.

18
Go to Step 11

17
Verify repair

16
Check for a short circuit, blown fuse or open circuit

between the relay and the fule tank.
15
Go to Step 10
1. Substitute a known good realy for the fuel pump

realy.
4. After this test, re-connect the known good relay in
its proper location.
14
Verify repair

fuel tank.
13
Replace the PCM.

12
No

connection at the PCM.
11
Yes
Check for short or open between the PCM and the fuel
pump relay.
10
Value(s)

6E279
140RW022
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Fuel Rail Left

Left Bank
Common Chamber
Duty Solenoid Valve
Throttle Valve
Canister
Evap Shut Off Valve
Circuit Description
Test Description
When the ignition switch is turned ON, the powertrain

control module (PCM) will turn ON the in-tank fuel
pump. The in-tank fuel pump will remain ON as long as
the engine is cranking or running and the PCM is receiving
58X crankshaft position pulses. If there are no 58X
crankshaft position pulses, the PCM will turn the in-tank
fuel pump OFF 2 seconds after the ignition switch is
turned ON or 2 seconds after the engine stops running.
The in-tank fuel pump is an electric pump within an
integral reservoir. The in-tank fuel pump supplies fuel
through an in-line fuel filter to the fuel rail assembly. The
to the fuel injectors at a regulated pressure. Unused fuel
is returned to the fuel tank by a separate fuel return line.

Diagnostic Chart.
2. Connect the fuel pressure gauge to the fuel feed line
as shown in the fuel system illustration. Wrap a
should be 333-376 kPa (48-55 psi). This pressure
areas:
6E280

regulator.
D The fuel injector(s).
operating in the Fuel Cut-Off Mode.
16.Check the spark plug associated with a particular
Assembly in On-Vehicle Service.
connector.
nozzles for leaks.
17.A rich condition may result from the fuel pressure
exhaust.
20.This test determines if the high fuel pressure is due

21.A lean condition may result from fuel pressure
below 333 kPa (48 psi). A lean condition may
Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold ), hesitation, poor driveability, lack of
power, surging , and misfiring.
22.Restricting the fuel return line causes the fuel
injury:
completed.

relay center.

2. Install fuel gauge 5-8840-0378-0 to the fuel supply
line located in front of and above the right side valve
cover.
6E281

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
290-376 kPa
(42-55 psi)
Go to Step 3
Go to Step 17
Go to Step 4
Go to Step 12

engine was started?
21-105 kPa
(3-15 psi)
Go to Step 5
Go to Step 9

Go to Step 6
Check for
improper fuel
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
21-105 kPa
(3-15 psi)
Go to Step 10
Go to Step 11

performed?
pressure gauge.
ON.
constant.
5
6
1. When the vehicle is at normal operation

gauge.
gauge.

restriction:
D The in-pipe fuel filter.



regulator.
2. With the engine idling, apply 12-14 inches of
6E282

Step
Action
10

pressure regulator.
11
18

Pressure Relief.
outlet passage.
19
Verify repair
Go to Step 13
Go to Step 15
Verify repair
Go to Step 14
Verify repair
Go to Step 8
Go to Step 11
Go to Step 16
Verify repair
376 kPa (55

psi)
Go to Step 18
Go to Step 21
290-376 kPa
(42-55 psi)
Go to Step 19
Go to Step 20
Verify repair
Verify repair
Go to Step 11

20

17

pump.
16
Verify repair

in-tank fuel line.
15

leaks.
14
No

13
Yes

12
Value(s)

6E283

Step
Action
Value(s)
21

0 kPa (0 psi)
Go to Step 22
Go to Step 23
376 kPa (55

Does the fuel pressure indicated by the fuel pressure psi). 414 kPa
(60 psi).
Go to Step 11
Go to Step 7
Go to Step 7
Go to Fuel
System
Electrical Test
Chart
22
Yes
No

23

6E284

Circuit Description
The powertrain control module (PCM) controls engine
idle speed with the idle air control (IAC) valve. To increase
idle speed, the PCM retracts the IAC valve pintle away
from its seat, allowing more air to bypass the throttle bore.
To decrease idle speed, it extends the IAC valve pintle
read the PCM commands to the IAC valve in counts.
idle).
Diagnostic Aids
engine. Fully extend (low) IAC with the Tech2. Start
linkage.
P0131, P0151, P0171, or P0174 may be set. Tech 2
oxygen (O2) voltage will be less than 100 mV (0.1 V).
Check for low regulated fuel pressure, water in fuel, or
a restricted injector.
respond on the Tech 2.

contact.
Test Description
Diagnostic Chart.
1. The Tech2 is used to extend and retract the IAC
6. Steps 1 and 2 verified the proper IAC valve
operation. This step checks the IAC circuits. Each
lamp on the noid light should flash red and green
while the IAC valve is cycled. While the sequence
of color is not important, if either light is OFF or
does not flash red and green, check the circuits for
faults, beginning with poor terminal contacts.
6E285

Step
Action
1.
2.
3.
4.
5.
6.
7.
8.

Go to Step 2
Go to Step 3
700-1500
RPM
Go to Step 3
Go to Step 4
Go to Step 5
Verify repair
Verify repair

No

Yes
Ignition OFF.
Connect the Tech2.
Block the wheels.
the IAC is cycled.

2
Value(s)

Control Valve.
6E286
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor
Economy)
D06RW0351
Circuit Description
Test Description
The knock sensor (KS) sends an AC voltage signal to the

powertrain control module (PCM). As the KS detects
engine knock, the signal to the PCM changes in amplitude
and frequency. The PCM retards timing if the engine
speed is over 900 RPM.

Diagnostic Chart.
9. The change in signal speed depends on how hard
the tapping is done. Normally there is about 1.5 to
10 mV at PCM pin A2 with the engine off. Loud
tapping should be able to make the reading jump to
20-25 mV AC.
Diagnostic Aids
If the KS system checks OK, but detonation is the
complaint, refer to Diagnosis, Detonation/Spark Knock.
Economy)
Step
Action
Go to Step 2
Go to Step 3
Go to Step 4
Verify repair
more than
0.1V
Go to Step 5
Go to Step 6
Verify repair
Repair the mechanical problem.

1.
2.
3.
4.
Install the Tech 2.

Turn the ignition ON.
On the Tech 2 select F0: Data List.
Cycle through the list until Knock Noise Channel is
displayed.
Is knock retard at the specified value?

5
No
Run the engine at 1500 RPM.

4
Yes
Go to DTC
P0325 or
DTC P0327
Is DTC P0325 or P0327 set?
Is there an internal engine knock?

3
Value(s)
Replace the PCM.

6E287
Economy) (Cont'd)
Step
Action
Yes
No

2. Monitor the knock retard display on the Tech 2 while
changing the throttle setting to place different loads
on the engine.
Is knock retard at the specified value? (Turn the ignition
OFF.)
Value(s)
Go to Step 9
Go to Step 7
B+
Go to Step 9
Go to Step 8
Verify repair
System OK
Go to Step 10
Verify repair
1. At the rear of the engine, behind the rear fuel

injector on the side, disconnect the 2-wire knock
NOTE: The connector for the knock sensor cannot
easily be removal unless common chamber is
removed. (Knock Sensor is on Right side of block).
Also, there are two (2) shield grounded wires.
The connector only has one wire (Yellow). Please
use another method.
2. Attach the positive lead of DVM to B+.
3. On the main harness side of the connector, use the
negative lead of the DVM to probe the connector pin
that is connected to black wire.
Dose the DVM indicate the specified value?
(Reconnect the knock sensor harness.)
Repair the open black wire ground for the shield which
prevents stray electromagnetic pulses from affecting
the knock signal.
1. Reconnect the wire harness if it was previously

disconnected in Step 7.
2. Set a DVM to AC voltage.
3. With the DVM, backprobe the PCM connector at
A2.
4. Tap the engine lift bracket with a socket extension.
Did the DVM show an increase in AC voltage while
tapping on the lift bracket?
10
Replace the knock sensor.

6E288
D06RW055
Circuit Description
Diagnostic Aids
A properly operation exhaust gas recirculation (EGR)

would be leaner. The powertrain control module (PCM)

but not in the closed throttle cell. An EGR pintle
constantly in the open position would cause a rough idle.
Also, an EGR mounted incorrectly (rotated 180) could
cause rough idle. Check for the following items:
passages.
6E289

Step
Action
EGR system
working
properly. No
problem
found.
Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Go to Step 8
Go to Step 9
Go to DTC
P1404 chart
Go to Step 10
EGR system
working
properly. No
problem
found.
Verify repair

damage.
restrictions?
10

2. Using a Tech 2, command EGR ON and observe
the EGR valve pintle for movement.
command?
Verify repair

necessary.

Go to Step 3

Go to Step 2
1. Engine OFF.
2. Ignition ON.
between the EGR valve and the ignition feed.

2. Start the engine and idle until warm.
3. Using a Tech 2, command EGR 50% ON. (Refer to
Miscellaneous Test)
No

Yes

Is the EGR valve Loose?
Value(s)

necessary.
6E290
D06RX135
Circuit Description
Test Description

powertrain control module (PCM) sends a 5-volt
By monitoring the the sensor output voltage, the PCM
knows the MAP. A lower pressure (low voltage) output
voltage will be about 1-2 volts at idle. Higher pressure
(high voltage) output voltage will be about 4-4.8 volts at
wide open throttle. The MAP sensor is also used, under
certain conditions, to measure barometric pressure,
allowing the PCM to make adjustments for different
altitudes. The PCM uses the MAP sensor to diagnose
proper operation of the EGR system, in addition to other
functions.
IMPORTANT: Be sure to used the same diagnostic test

Diagnostic Chart.
should cause the voltage to be 1.5-2.1 volts less
than the voltage at step 1. Upon applying vacuum
to the sensor, the change in voltage should be
faulty sensor.
6E291

Step
Action
1.
2.
3.
4.
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Refer to On-Vehicle Service, MAP Sensor.

Go to Step 5

Go to Step 2
Repair the material to block.

Check the sensor cover for leakage or restriction.

Does the cover supply vacuum to the MAP sensor
only?
No
Disconnect the MAP sensor and plug inletmanifold.

Connect a hand vacuum pump to the MAP sensor.
Start the engine.
Apply 34 kPa (10 Hg) of vacuum and note the
voltage change.
Is the voltage change 1.5-2.1 volts less than step 1?

3
Yes

seconds.
2. Ignition ON. Dont crank engine.
4. Compare this scan reading to scan reading of a
Is the voltage reading the same +/0.40 volt?
Value(s)

6E292
Evaporative (EVAP) Emissions Canister Purge Valve Check
D06RX016
Circuit Description
The evaporative emissions canister purge is controlled by
a solenoid that allows manifold and/or vacuum to purge
the canister when it is energized. The powertrain control
module (PCM) supplies a ground to energize the solenoid
valve (purge ON). The EVAP purge solenoid control is
turned ON and OFF several times a second. The duty
cycle (pulse width or ON time) is determined by engine
operating conditions including load, throttle position,
coolant temperature and ambient temperature. The duty
cycle is calculated by the PCM and the purge solenoid is
enabled when the appropriate conditions have been met:
D The engine run time after start is more than 60
seconds.
D The engine coolant temperature is above 30C
(86F).
D The fuel control system is operating in the closed-loop
mode.
Diagnostic Aids
D Make a visual check of vacuum hoses.
D Check the throttle body for possible cracked.
D Check the malfunction indicator lamp for a possible
mechanical problem.
Test Description
Diagnostic Chart.
1. Check to see if the solenoid is open or closed. The
solenoid is normally de-energized in this step, so it
should be closed.
2. This step checks to determine if the solenoid was
open due to an electrical circuit problem or a
defective solenoid.
3. This should normally energize the solenoid, opening
the valve and allowing the vacuum to drop (purge
ON).
6E293

Step
Action
Go to Step 4
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Verify repair
No problem
found in the
EVAP
emission
canister
purge valve
check
Refer to
Diagnostic
Aids
Replace the faulty purge solenoid. Refer to On-Vehicle

Service, EVAP Canister Purge Solenoid.
Replace the PCM.

Go to Step 2
Repair the short to ground.

Go to Step 3
Check for a short to ground in the RED/BLU wire.

Is there a short?
1. At the throttle body, put a cap over the vacuum port

where the hose was disconnected for testing. This
is to prevent a vacuum leak when the engine is
started.
2. Ignition OFF.
4. Apply vacuum to the purge solenoid with the hand
vacuum pump.
5. Start the engine, run at 2500 RPM.
6. Using the Tech 2, select F0: Engine, F3: Misc.
Tests, F0: EVAP Purge.
7. Turn the purge solenoid ON.
Did the vacuum drop when the purge was turned on?
No
1. Disconnect the solenoid electrical connector.

2. As in Step 1, apply vacuum (10 Hg or 34 kPa) to the
solenoid.
Does the solenoid hold the vacuum?
Yes
1. Ignition OFF.
3. At the throttle body, disconnect the hose that goes
to the pump solenoid.
4. Using a hand vacuum pump with an attached
vacuum gauge 5-8840-0279-0, apply vacuum (10
Hg or 34 kPa) to the solenoid.
Value(s)

2. At the throttle body, install a vacuum gauge where
the hose from the purge solenoid was disconnected
for testing.
4. Stabilize the engine speed at about 2500 RPM.
5. Momentarily snap the throttle open and let it return
to idle.
Is there approximately 10 Hg (34 kPa) of vacuum
available at the EVAP emission canister purge
solenoid?
6E294
Evaporative (EVAP) Emissions Canister Purge Valve Check (Cont'd)

Step
Action
Value(s)
Yes
No

2. Connect a test lamp between the harness
terminals.
Does the test lamp light?
Go to Step 7
Go to Step 10
Go to Step 11
Go to Step 12
Verify repair
12
Does on of the terminals light the test lamp?
Go to Step 13
Go to Step 14
13
Check for an open in the RED/BLU wire between the

purge solenoid and the PCM.
Go to Step 15
Go to Step 6
Verify repair
Verify repair
10
Probe terminal A and terminal B with a test lamp to

ground.
Does the test lamp light on both terminals?
11
Repair the short to voltage in the RED/BLUE wire.

14
Repair the open in the BLK/YEL wire.

15
Repair the open in the RED/BLU wire.

6E295
PCM Diagnostic Trouble Codes

supported by this vehicle application.If any DTCs not
listed here are displayed by a Tech 2, the Tech 2 data may
be faulty; notify the Tech 2 manufacturer of any DTCs

displayed that are not included in the following table.
Description
DTC
Type
Illuminate MIL
P0101
MAF System Performance
Yes
P0102
MAF Sensor Circuit Low Frequency
Yes
P0103
MAF Sensor Circuit High Frequency
Yes
P0107
MAP Sensor Circuit Low Voltage
Yes
P0108
MAP Sensor Circuit High Voltage
Yes
P0112
IAT Sensor Circuit Low Voltage
Yes
P0113
IAT Sensor Circuit High Voltage
Yes
P0117
ECT Sensor Circuit Low Voltage
Yes
P0118
ECT Sensor Circuit High Voltage
Yes
P0121
TP System Performance
Yes
P0122
TP Sensor Circuit Low Voltage
Yes
P0123
TP Sensor Circuit High Voltage
Yes
P0131
HO2S Circuit Low Voltage Bank 1 Sensor 1
Yes
P0132
HO2S Circuit High Voltage Bank 1 Sensor 1
Yes
P0134
HO2S Circuit Insufficient Activity Bank 1 Sensor 1
Yes
P0151
Yes
P0152
Yes
P0154
Yes
P0171
Fuel Trim System Lean Bank 1
Yes
P0172
Fuel Trim System Rich Bank 1
Yes
P0174
Yes
P0175
Yes
P0201
Injector 1 Control Circuit
Yes
P0202
Yes
P0203
Yes
P0204
Yes
P0205
Yes
P0206
Yes
P0325
KS Module Circuit
No
P0327
KS Sensor Circuit
No
P0336
58X Reference Signal Circuit
Yes
P0337
CKP Sensor Circuit Low Frequency
Yes
P0341
CMP Sensor Circuit Performance
Yes
P0342
CMP Sensor Circuit Low
Yes
P0351
Ignition 1 Control Circuit
Yes
P0352
Yes
P0353
Yes
P0354
Yes
6E296
DTC
Description
Type
Illuminate MIL
P0355
Yes
P0356
Yes
P0404
EGR Open Stuck
Yes
P0405
EGR Lo Volt
Yes
P0406
EGR Hi Voltage
Yes
P0502
Yes
P0562
System Voltage Low
No
P0563
System Voltage High
No
P0601
PCM Memory
Yes
P0705
Transmisson Rang Sensor Illegal Position (Refer to 4L30-E Automatic

Transmission)
No
P0706
Transmisson Range Sensor Performance (Refer to 4L30-E Automatic

Transmission)
No
P0712
Transmission Fluid Temperature (TFT) Low Voltage (Refer to 4L30-E

Automatic Transmission Diagnosis)
No
P0713
Transmission Fluid Temperature (TFT) High Voltage (Refer to 4L30-E

No
P0719
Brake Switch Circuit Low (Refer to 4L30-E Automatic Transmission

Diagnosis)
No
P0722
Output Speed Sensor Circuit No Signal (Refer to 4L30-E Automatic

Transmission)
Yes
P0723
Output Speed Sensor Circuit Intermittent Signal (Refer to 4L30-E

Automatic Transmission)
Yes
P0730
Incorrect Gear Ratio (Refer to 4L30-E Automatic Transmission)
No
P0748
Transmission Pressure Control Solenoid (PCS) Electrical Circuit Fault

(Refer to 4L30-E Automatic Transmission Diagnosis)
No
P0753
Transmission Shift Solenoid A Electrical Circuit Fault (Refer to 4L30-E

Yes
P0758
Transmission Shift Solenoid B Electrical Circuit Fault (Refer to 4L30-E

Yes
P1171
Yes
P1380
ABS Rough Road ABS System Fault
Yes
P1381
ABS Rough Class 2 Serial Link Error
Yes
P1404
EGR Closed Stuck
Yes
P1508
IAC System Low RPM
Yes
P1509
IAC System High RPM
Yes
P1618
Serial Peripheral Interface (SPI) PCM Interprocessor Communication

Error (Automatic Transmission Only)
Yes
P1625
Yes
P1640
Driver-1-Input High Voltage
No
P1790
TRANS ROM Checksum Error (Refer to 4L30-E Automatic Transmission

Diagnosis)
Yes
P1792
TRANS EEPROM Checksum Error (Refer to 4L30-E Automatic

Transmission Diagnosis)
Yes
P1835
TRANS Kick Down Switch Malfunction (Refer to 4L30-E Automatic

No

DTC
Description
6E297
Type
Illuminate MIL
P1850
Brake Band Apply Solenoid Manlfunction (Refer to 4L30-E Automatic

No
P1860
TCC PWM Solenoid Circuit Fault (Refer to 4L30-E Automatic

Yes
6E298
Diagnostic Trouble Code (DTC) P0101 MAF System Performance
D06RW057
Circuit Description
The mass air flow (MAF) sensor measures the amount of

air which passes through it into the engine during a given
time. The powertrain control module (PCM) uses the
mass air flow information to monitor engine operating
conditions for fuel delivery calculations. A large quantity
of air entering the engine indicates an acceleration or high
load situation, while a small quantity or air indicates
deceleration or idle.
The MAF sensor produces a frequency signal which can
be monitored using a Tech 2. The frequency will vary
within a range of around 4 to 7 g/s at idle to around 25 to 40
g/s at maximum engine load. DTC P0101 will be set if the
signal from the MAF sensor does not match a predicted
value based on throttle position and engine RPM.

fault is detected.
D The PCM calculates an airflow value based on idle air
control valve position, throttle position, RPM and
barometric pressure.

D No TP sensor or MAP sensor DTCs are set.
D The throttle is steady, TP angle doesnt change by
more than 1%.
D System voltage is between 11.5 volts and 16 volts.
D Calculated air flow is between 25 g/second and 40
g/second.
D Above conditions present for at least 1 second.
D MAF signal frequency indicates an airflow significantly
higher or lower than a predicted value based on throttle
position and engine RPM for a total of 12.5 seconds
over a 25-second period of time.

D The PCM will turn the MIL OFF on the third
Info function or by disconnecting the PCM battery
feed.
Diagnostic Aids
An intermittent may be caused by the following:
D Poor connections.
D Mis-routed harness.
D Rubbed through wire insulation.
D Broken wire inside the insulation.
Refer to Intermittents under service category Symptoms.
Any un-metered air may cause this DTC to set. Check for
the following:

D
D
D
D
D
D
The duct work at the MAF sensor for leaks.

An engine vacuum leak.
The PCV system for vacuum leaks.
An incorrect PCV valve.
The engine oil dip stick not fully seated.
The engine oil fill cap loose or missing.
Test Description
Diagnostic Chart.
6E299
2. The MAF system performance or rationality

diagnostic uses the MAP sensor signal along with
other input to calculate an expected airflow rate that
is then compared to the actual measured airflow
from the MAF sensor. The first few steps of this
table verify that the MAP sensor is working properly.
6. Verifies the signal circuit from the MAF sensor
electrical connector to the PCM.
Verifies whether a ground and B+ circuit is
available.
DTC P0101 MAF System Performance

Step
Action
Go to Step 2
Go to Step 6
Go toStep 3
11.5 to 12.5
Volt
Go to Step 5
Go to Step 4
Verify repair
Verify repair
Verify repair
Go to Step 7
1. Ignition OFF.
2. Check the 12 volt signal circuit for the following
conditions:
D An open circuit
D A short to ground
Check the MAF ground circuit for the following
conditions:
D An open circuit
Go to OBD
System
Check

2. Using a Digital Voltmeter (DVM), check the 12 volt
signal circuit for the correct voltage.

5
No
1. Ignition OFF.
2. Disconnect the Mass Air Flow (MAF) Sensor
harness connector from the MAF Sensor.
3. Place an unpowered test lamp between the 12 volt
signal circuit and the ground circuit, both at the MAF
Sensor connector.
4. Ignition ON, EngineOFF.
Did the DVM indicate a value within the following

range?
4
Yes

performed?
Did the test lamp illuminate?

3
Value(s)
1. Ignition OFF.
2. Check the MAF Sensor signal circuit between the
PCM and the MAF Sensor for the following
conditions:
D An open circuit
D A short to ground
D A short to battery voltage
6E2100
DTC P0101 MAF System Performance (Cont'd)

Step
Action
4 to 7 g/s
Go to Step 8
Go toStep 9
25 to 40 g/s
Go to Step 10
Go toStep 9
Verify repair
Verify repair
Replace the MAF Sensor.

10
No
Observe the Tech 2 value while increasing the engine

RPM to its upper limit.
Yes
1. Connect the MAF Sensor wiring harness connector

to the MAF Sensor.
2. Connect the Tech 2 to the vehicle.
3. Place the Transmission in Park/Neutral, and fully
apply the Parking Brake.
5. Select the Mass Air Flow (MAF) parameter on the
Tech 2.
With the engine idling, does the Tech 2 display the
following value(s)?
Value(s)
Replace the PCM.

6E2101
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency
D06RW057
Circuit Description
load situation, while a small quantity of air indicates
within a range of around 4 to 7 g/s at idle to around 1900
Hz at maximum engine load. DTC P0102 will be set if the
signal from the MAF sensor is below the possible range of
a normally operating MAF sensor.

D The engine is running above 500 RPM for greater than
10 seconds.
D System voltage is above 11.5 volts.
D MAF signal frequency is below 1.6 g/s for a total of
50-percent of the last 1000 samples monitored. A
sample is taken every cylinder event.

D The PCM calculates an air flow value based on idle air


feed.
Diagnostic Aids
D Poor connection at PCM Inspect harness connectors
for backed-out terminals, improper mating, broken
poor terminal-to-wire connection.
D Misrouted harness Inspect the MAF sensor harness
to ensure that it is not routed too close to high voltage
wires.
damage. If the harness appears to be OK, observe the
related to the MAF sensor. A change in the display will
D 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
6E2102
about 3-6 g/second at idle to 100 g/second or greater

at the time of the 1-2 shift. If not, check for a restriction.
determining vehicle mileage since the DTC was last set.
Test Description
2. This step verifies that the problem is present at idle.

4. A voltage reading of less than 4 or over 5 volts at the
MAF sensor signal circuit indicates a fault in the
wiring or a poor connection.
5. This verifies that ignition feed voltage and a good
ground are available at the MAF sensor.

Diagnostic Chart.
DTC P0102 MAF Sensor Circuit Low Frequency

Step
Action

2. With the engine idling, monitor MAF Frequency
display on the Tech 2.
1.
2.
3.
4.
Go to Step 4
Go to Step 5
Go to Step 4
Refer to
Diagnostic
Aids
5V
Go to Step 5
Go to Step 8
Go to Step 13
Go to Step 6
Go to Step 12
Go to Step 7
Verify repair
Go to Step 11
4V
Go to Step 9
Go to Step 10
1. Check for a poor connection at the MAF sensor.

2. If a poor connection is found, replace the faulty
terminal(s).
2.85 6.65
g/s
Connect a test light between the MAF sensor ignition

feed circuit and battery ground.
Go to Step 2

feed and ground circuits at the MAF sensor harness
connector.
Ignition OFF.
Disconnect the MAF sensor connector.
Using a DVM, measure voltage between the MAF
sensor signal circuit and battery ground.

5
No
Go to OBD
System
Check

ignition?
Yes

performed?
Is the MAF Frequency below the specified value?

3
Value(s)
1. Ignition OFF.
2. Disconnect the MAF sensor.
3. Disconnect the PCM connector for the MAF signal
circuit.
5. With the DVM, measure the voltage between the
MAF signal terminal at the PCM and battery ground.
Is the voltage under the specified value?
6E2103
DTC P0102 MAF Sensor Circuit Low Frequency (Cont'd)

Step
Action
1.
2.
3.
4.
1.
2.
3.
4.
Verify repair
Go to Step 13
Verify repair
Verify repair
Verify repair
Go to Step 14
Verify repair
Replace the MAF sensor.

14
Verify repair
Locate and repair the open in the ignition feed circuit to

the MAF sensor.
13
Locate and repair the open in the ground circuit to the

MAF sensor.
12
No
Ignition OFF.
Disconnect the PCM white connector.
Ignition ON.
Check the MAF sensor signal circuit between the
PCM and the MAF sensor for an open, short to
ground, or short to the MAF ground circuit.

11
Yes
Ignition OFF.
Ignition ON.
Check the MAF sensor signal circuit for a short to 5
volts.

10
Value(s)
Replace the PCM.

6E2104
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency
D06RW057
Circuit Description
signal from the MAF sensor is above the possible range of

D The engine is running above 500 RPM for more than
10 seconds.
D MAF signal frequency is above 40 g/s for a total of 50
percent of the last 200 samples monitored. A sample
is taken every cylinder event.


Conditions for clearing the MIL/DTC

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
4. A frequency reading with the MAF sensor connector
disconnected indicates an electromagnetic
interference (EMI) related fault.
6E2105
DTC P0103 MAF Sensor Circuit High Frequency

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
40 g/s
Go to Step 4
Go to Step 7
0 g/s
Go to Step 5
Go to Step 6
Verify repair
Go to Step 8
Verify repair
Go to Step 6
40 g/s
Go to Step 5
Go to Step 8
Verify repair

ignition?

Is MAF Frequency above the specified value?
1.
2.
3.
4.
Ignition OFF.
Ignition ON, engine idling.
Using a Tech 2, monitor MAF Frequency.
Does the Tech 2 indicate a MAF Frequency at the

specified value?
5

1. Check the MAF harness for incorrect routing near

high voltage components (solenoids, relays,
motors).
2. If incorrect routing is found, correct the harness
routing.

2. Quickly snap open throttle to wide open throttle
while under a road load and record value.
Does the Tech 2 indicate MAF Frequency above the
specified value?
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2106
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage
D06RX135
Circuit Description
MAP sensor signal voltage to the powertrain control
module (PCM) varies from below 2 volts at idle (high
vacuum) to above 4 volts with the ignition ON, engine
not running or at wide-open throttle (low vacuum).
The MAP sensor is used to determine manifold pressure.
The PCM monitors the MAP signals for voltages outside
the normal range of the MAP sensor. If the PCM detects a
MAP signal voltage that is excessively low, DTC P0107
will be set.


feed.
Diagnostic Aids
D No TP sensor DTCs present.

1000 RPM.
1000 RPM.
at or below 11 kPa for a total of approximately 10
seconds over a 16-second period.
D Ignition voltage more than 11 volts.

D Check for intermittent codes.
D The MAP sensor shares a ground with the Fuel Tank
Pressure Sensor, the ECT sensor, and the
Transmission Fluid Temperature sensor.
MAP display on the Tech 2 while moving connectors
and wiring harnesses related to the sensor. A change
in the display will indicate the location of the fault.

D The PCM will default to a BARO value of 79.3 kPa.

If it is determined that the DTC occurs intermittently,
D The MAP sensor shares a 5 Volt Reference with the
Fuel pressure sensor. If these codes are also set, it
6E2107
could indicate a problem with the 5 Volt reference

circuit.
D The MAP sensor shares a ground with the Fuel
pressure Sensor, the ECT sensor, and the
DTC P0107 MAP Sensor Circuit Low Voltage

Step
Action
Value(s)
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
5 V 104 kPa
Go to Step 10
Go to Step 5
5 V 104 kPa
Go to Step 6
Go to Step 8
Verify repair
Go to Step 7
Verify repair
Go to Step 11

11 kPa at sea
level
1. Ignition OFF.
3. Jumper the 5 volt reference A circuit and the MAP
connector.
4. Ignition ON.

2. Connect a test light between B+ and the MAP
sensor signal circuit at the MAP sensor harness
connector.
Is the MAP value near the specified value.
1. Ignition OFF.
2. Disconnect the PCM and check the 5 volt reference
A circuit for an open or short to ground.
3. If the 5 volt reference A circuit is open or shorted to
Was the 5 volt reference A circuit open or shorted to
ground?
No
Go to OBD
System
Check

performed?
Yes
Check the 5 volt reference A circuit for a poor

connection at the PCM and replace the terminal if
necessary.
6E2108
DTC P0107 MAP Sensor Circuit Low Voltage (Cont'd)

Step
Action
Verify repair
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Verify repair

11
No

connection at the PCM and the MAP sensor; replace
10
Yes
1. Ignition OFF.
2. Disconnect the PCM, and check the MAP signal
Value(s)
Replace the PCM.

6E2109
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit Hight Voltage
D06RX135
Circuit Description

vacuum) to above 4 volts with the key ON, engine not
running or at wide- open throttle (low vacuum).
MAP signal voltage that is excessively high, DTC P0108
will be set.

feed.

D Engine is running for more than 10 seconds.
D Throttle position is below 3% if engine speed is below
1000 RPM.
1000 RPM.
approximately 10 seconds over a 16-second period.

Diagnostic Aids
circuit.
6E2110

DTC P0108 MAP Sensor Circuit High Voltage

Step
Action
1.
2.
3.
4.
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
0.0 V 11 kPa
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Go to Step 8
Verify repair
Go to Step 12
Verify repair
Go to Step 10
1. Check for a poor sensor ground terminal connection

at the MAP sensor electrical connector.
2. If a problem if found, replace the faulty terminal.
Check for a plugged or leaking vacuum supply to the
MAP sensor.
Is the vacuum supply plugged or leaking?
Go to Step 4
1. Check the MAP signal circuit for a short to voltage or

a short to the 5 volt reference A circuit.
2. If the MAP sensor signal circuit is shorted, repair

8
90 kPa
Probe the sensor ground circuit with a test light to B+.
Was the MAP sensor signal circuit shorted?

7
Go to Step 2
Ignition OFF.
Ignition ON.
Note the MAP sensor voltage displayed on the Tech
2.

6
Go to OBD
System
Check

Is the MAP sensor voltage at the specified value? (If no,

start with diagnostic chart for other sensors in the
circuit and see if 5 V returns)
5
No

Tech 2.

ignition?
4
Yes

performed?

3
Value(s)

at the PCM.
2. If a problem is found, replace the faulty terminal.
6E2111
DTC P0108 MAP Sensor Circuit High Voltage (Cont'd)

Step
Action
10
1. Check the continuity of the MAP sensor ground

circuit.
2. If the MAP sensor ground circuit measures over 5
ohms, repair open or poor connection.
Was a condition found and corrected?
11
Yes
No
Verify repair
Go to Step 11
Verify Repair
Verify repair
Replace the PCM.

12
Value(s)

6E2112
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage
D06RW078
Circuit Description

engine. The powertrain control module (PCM) applies 5
volts through a pull-up resistor to the IAT sensor. When
the intake air is cold, the sensor resistance is high and the
PCM will monitor a high signal voltage on the IAT signal
lower, causing the PCM to monitor a lower voltage. DTC
P0112 will set when the PCM detects an excessively low
signal voltage on the intake air temperature sensor signal
circuit.

feed.

D Vehicle speed is greater than 30 mph (48 km/h) .
D IAT signal voltage indicates an intake air temperature
greater than 148C (298F) (about 5 volts) for a total
of 12.5 seconds over a 25-second period of time.

Diagnostic Aids
Test Description
Diagnostic Chart:

the Failure Records condition, refer to the
Temperature vs. Resistance Value table. The table
may be used to test the IAT sensor at various
temperatures to evaluate the possibility of a
shifted sensor that may be stored above or below
a certain temperature. If this is the case, replace
the IAT sensor. If the IAT sensor appears to be OK,
the fault is intermittent; refer to Diagnostic Aids.

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E2113
6E2114
DTC P0112 IAT Sensor Circuit Low Voltage

Step
Action
1.
2.
3.
4.
Ignition OFF.
Ignition ON.
148C
(283F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
38C
(36F)
Go to Step 6
Go to Step 5
Verify repair
Go to Step 7
Verify repair
Verify repair

Go to Step 2
1. Ignition OFF.
2. Disconnect the PCM electrical connectors.
ground.
Go to OBD
System
Check
1. Ignition ON, engine OFF. Review and record

Tech 2 Failure Records data.
3. Using a Tech 2, monitor the DTC info for DTC
P0112.

5
No

(IAT).

ignition?
4
Yes

performed?

value?
3
Value(s)
Replace the PCM.

6E2115
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage
D06RW078
Circuit Description

lower causing the PCM to monitor a lower voltage. DTC
P0113 will set when the PCM detects an excessively high
circuit.

feed.

D
D
D
D
D

Vehicle speed is less than 20 mph (32 km/h).
Mass air flow is less then 20 g/second.
less than 39C (38F) for total of 12.5 seconds over
a 25-second period.

Diagnostic Aids
Test Description
Diagnostic Chart:
6E2116

Temperature vs. Resistance Values table. The
table may be used to test the IAT sensor at various
shifted sensor that may be open above or below a
certain temperature. If this is the case, replace the
IAT sensor. If the IAT sensor appears to be OK, the
fault is intermittent; refer to Diagnostic Aids.

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E2117
DTC P0113 IAT Sensor Circuit High Voltage

Step
Action

1. Ignition OFF.
connector.
4. Ignition ON.
2.

2.
38C
(36F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
140C
(284F)
Go to Step 6
Go to Step 5
140C
(284F)
Go to Step 7
Go to Step 8
Verify repair
Go to Step 10
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Go to Step 11
1. Ignition OFF.
2. Disconnect the PCM, and check the IAT signal
necessary.
Go to Step 2
1. Ignition OFF.
2. Disconnect the PCM, and check the IAT sensor
necessary.

No
Go to OBD
System
Check

parameters.
Yes

performed?

3
Value(s)

terminal connection at the PCM and replace
6E2118
DTC P0113 IAT Sensor Circuit High Voltage (Cont'd)

Step
10
Action
Yes
No

11
Value(s)
Verify repair
Verify repair
Replace the PCM.

6E2119
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage
D06RX136
Circuit Description

thermistor mounted on a coolant crossover pipe at the
front of the engine. The powertrain control module (PCM)
applies a voltage (about 5 volts) through a pull-up resistor
to the ECT signal circuit. When the engine coolant is cold,
the sensor (thermistor) resistance is high, therefore the
PCM will measure a high signal voltage. As the engine
coolant warms, the sensor resistance becomes lower,
and the ECT signal voltage measured at the PCM drops.
With a fully warmed-up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts.

feed.

D Engine running time is longer than one minute.
temperature greater than 150C (302F) (about 0.10
V) for a total of 50 seconds over a 100-second period.

D The PCM will substitute the ECT reading with a default
engine coolant temperature value. The default value
is based on start-up intake air temperature and running
time.
Diagnostic Aids
ECT display on the Tech 2 while moving connectors
and wiring harnesses related to the ECT sensor. A
change in the ECT display will indicate the location of
the fault.
Test Description
Diagnostic Chart.
6E2120

table may be used to test the ECT sensor at various
shifted sensor that may be shorted above or below
the ECT sensor. If the ECT sensor appears to be
OK, the fault is intermittent; refer to Diagnostic Aids.

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P0117 ECT Sensor Low Voltage

Step
Action


Is the Eng Cool Temp at the specified value?
Go to Step 2
139C
(282F)
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
39C
(38F)
Go to Step 6
Go to Step 5
Verify repair
Go to Step 7
Verify repair
Verify repair

1. Ignition OFF.
2. Disconnect the PCM and check the ECT signal
ground circuit.
3. If the ECT signal circuit is shorted. repair it as
necessary.
No
Go to OBD
System
Check

ignition?
Yes

performed?

3
Value(s)
Replace the PCM.

6E2121
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage
D06RX136
Circuit Description

thermistor mounted in on a coolant crossover pipe at the
coolant warms, the sensor resistance becomes less, and
the ECT signal voltage measured at the PCM drops. With
a fully warmed-up engine, the ECT signal voltage should
measure about 1.5 to 2.0 volts.

feed.

for a total of 50 seconds over a 100-second period.

time.
Diagnostic Aids
the fault.
Test Description
Diagnostic Chart.
6E2122

Temperature vs. Resistance Value table. The

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E2123
DTC P0118 ECT Sensor Circuit High Voltage

Step
Action


connector.

Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
140C
(284F)
Go to Step 6
Go to Step 5
140C
(284F)
Go to Step 7
Go to Step 8
Verify repair
Go to Step 10
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Verify repair

11
Go to Step 4

10
39C
(38F)
1. Ignition OFF.
2. Disconnect the PCM, and check the ECT signal
necessary.
Go to Step 2
1. Ignition OFF.
2. Disconnect the PCM, and check the ECT sensor
necessary.

No
Go to OBD
System
Check

P0118.
Yes

performed?

3
Value(s)
Replace the PCM.

6E2124
Diagnostic Trouble Code (DTC) P0121 TP System Performance
D06RW059
Circuit Description
signal voltage will vary from about 0.6 volts at closed
throttle to about 4.5 volts at wide open throttle (WOT).
The TP signal is one of the most important inputs used by
the powertrain control module (PCM) for fuel control and
many of the PCM-controlled outputs. The PCM monitors
throttle position and compares actual throttle position
from engine speed. If the PCM detects an out-of-range
condition, DTC P0121 will set.

D
D
D
D
The engine is running.

No MAP DTCs, or P0121, P0123 DTCs are set.
MAP reading is below 55 kPa.
Throttle is steady, throttle angle is changing less than
1%.
D Predicted throttle angle is not close to actual throttle
angle.
D Above conditions are present for a total of 12.5
seconds over a 25-second period of time.

fault is detected.

D The PCM will use a default throttle position based on
mass air flow and RPM.

info function or by disconnecting the PCM battery
feed.
Diagnostic Aids
incorrect MAP signal may cause the PCM to incorrectly
be set.
D The TP Sensor shares a 5 Volt reference with the EGR
Valve.
components itself.
D The TP Sensor share a ground with the EGR Valve and
the IAT Sensor.

locks improperly formed or damaged terminals, and
6E2125

DTC P0121 TP System Performance

Step
Action
Observe the TP angle reading on the Tech 2 while

slowly opening the throttle.
Go to Step 6
65 kPa
Go to Step 5
Go to Step 4
Verify repair
Go to Step 12
Verify repair
Closed
throttle = 0%
Wide open
throttle =
100%
Refer to
Diagnostic
Aids
Go to Step 7
0V
Go to Step 8
Go to Step 9
5V
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
1. Connect a test light between the 5 volt reference A

circuit and the TP sensor signal circuit at the TP
2. Observe the TP sensor reading on the Tech 2.
Is the TP sensor reading at the specified value?
Go to Step 3
1. Disconnect the TP sensor.

Is the TP sensor reading near the specified value?
65 kPa
Does the TP angle increase steadily and evenly from

the closed throttle value to the wide open throttle
value?
7
Go to Step 2
1. Check the MAP signal circuit between the PCM and

the MAP sensor for an open, short to ground, or
short to the MAP ground circuit.
2. If the MAP signal circuit is open or shorted, repair it
as necessary.

6
Go to OBD
System
Check
1. Disconnected the MAP sensor.

circuit and the MAP signal circuit at the MAP sensor
harness connector.
3. Observe the MAP reading on the Tech 2.
Was the MAP signal circuit open or shorted?

5
No

Is the MAP reading less than the specified value? (If no,
start with diagnosis chart for other sensors in the circuit
4
Yes

performed?
Is the MAP reading less than the specified value?

3
Value(s)

1. TP signal circuit for a short to voltage.
2. TP sensor ground circuit for high resistance
between the PCM and the TP sensor.
3. TP sensor ground circuit for a poor connection.
4. If a problem is found, repair wiring harness as
necessary.
6E2126
DTC P0121 TP System Performance (Cont'd)

Step
10
Action
Value(s)
Yes
No

1. TP signal circuit or 5 volt reference A circuit for a
poor connection.
2. TP signal circuit or 5 volt reference A circuit for
high resistance between the PCM and the TP
sensor.
necessary.
11
Verify repair
Go to Step 12
Verify repair
Verify repair

12
Replace the PCM.

6E2127
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage
D06RW059
Circuit Description
signal voltage will vary from below 0.6 volts at closed
The TP signal is used by the powertrain control module
(PCM) for fuel control and many of the PCM-controlled
outputs.

D TP sensor signal voltage is less than 0.22 volt for a total
of 0.78 second over a 1.5-second period.



feed.
Diagnostic Aids
Valve.
components itself.
the IAT Sensor.
throttle position display on the Tech 2 while moving
connectors and wiring harnesses related to the TP
sensor. A change in the display will indicate the
6E2128
DTC P0122 TP Sensor Circuit Low Voltage

Step
Action
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
5V
Go to Step 10
Go to Step 5
5V
Go to Step 6
Go to Step 8
Verify repair
Go to Step 7
Verify repair
Go to Step 12
Verify repair
Go to Step 9
1. Ignition OFF.

necessary.
0.22 V
2. Connect a test light between B+ and the TP sensor
signal circuit at the TP sensor harness connector.
Observe the TP Sensor display on the Tech 2.

ground?
7
Go to Step 2
1. Ignition OFF.
3. Jumper the 5 volt reference A circuit and the TP
signal together at the TP sensor harness connector.
4. Ignition ON.
Is the TP Sensor at the specified value? (If no, start

with diagnosis chart for other sensors in the circuit and
see if 5V returns.)
6
Go to OBD
System
Check

P0122.
Is the TP Sensor at the specified value?

5
No

2. With the throttle closed, observe the TP Sensor

4
Yes

performed?
Is the TP Sensor below the specified value?

3
Value(s)
1. Ignition OFF.
2. Disconnect the PCM, and check the TP signal
6E2129
DTC P0122 TP Sensor Circuit Low Voltage (Cont'd)

Step
Action
Verify repair
Go to Step 12
Verify repair
Go to Step 11
Verify repair
Verify repair

12
No

necessary.
11
Yes

necessary.
10
Value(s)
Replace the PCM.

6E2130
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage
D06RW059
Circuit Description
many of the PCM-controlled outputs.

D TP sensor signal voltage is greater than 4.88 volts for
a total of 0.78 second over a 1.5-second period.



feed.
Diagnostic Aids
D The TP sensor shares a 5 Volt Reference with the EGR
Position sensor. Check the 5 Volt reference if these
DTCs are also set.
D The TP sensor shares a ground with the IAT sensor
and the EGR position Sensor. Check the ground if
these other DTCs are also set.
TP sensor display on the Tech 2 while moving
D Faulty TP sensor With the ignition key ON, engine
OFF, observe the TP sensor display on the Tech 2
while slowly depressing the accelerator to wide open
throttle. If a voltage over 4.88 volts is seen at any point
in normal accelerator travel, replace the TP sensor.
Test Description
Number (s) below refer to the step number(s) on the
Diagnostic Chart.
7. Components that share the TP sensor 5 volt reference
A circuit include the following device:
D EGR valve
6E2131
Disconnect the component while observing the TP

sensor display on the Tech 2. If the reading
changes drastically when this component is
disconnected, replace the component that
affected the reading.
DTC P0123 TP Sensor Circuit High Voltage

Step
Action
4.88 V
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
0V
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 10
Verify repair
Go to Step 12
Verify repair
Go to Step 8
Probe the sensor ground circuit at the TP sensor

harness connector with a test light connected to B+.
circuit.
necessary.
Go to Step 2

2. Observe the TP Sensor display on the Tech 2.(If
no, start with diagnostic chart other sensors in the

6
Go to OBD
System
Check

Is the TP Sensor near the specified value?

5
No

Does the Tech 2 indicate DTC P0123 failed.

4
Yes

performed?
Is the TP Sensor above the specified value?

3
Value(s)
1. Ignition ON.
2. Monitor the TP Sensor Tech 2 display while
disconnecting each of the components that share
the 5 volt reference A circuit (one at a time).
3. If the TP Sensor Tech 2 display changes, replace
the component that caused the display to change
when disconnected.
the TP Sensor display to change?
6E2132
DTC P0123 TP Sensor Circuit High Voltage (Cont'd)

Step
Action
Verify repair
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Verify repair

12
1. Ignition OFF.
2. Disconnect the PCM, and check for an open sensor
ground circuit to the TP sensor.
Was the sensor ground circuit to the TP sensor open?
11
No
Check for poor electrical connections at the TP sensor

and replace terminals if necessary.
10
Yes

3. Check for a short to B+ on the 5 volt reference A
circuit.
4. If the 5 volt reference A circuit is shorted, repair it
as necessary.
Was the 5 volt reference A circuit shorted?
Value(s)
Replace the PCM.

6E2133
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1
Sensor 1
D06RX137
Circuit Description
The powertrain control module (PCM) supplies a bias

voltage of about 450 mV between the heated oxygen
sensor (HO2S) signal high and signal low circuits. When
measured with a 10 megaohm digital voltmeter, this may
display as low as 350 mV. The oxygen sensor varies the
voltage within a range of about 1000 mV when the
exhaust is rich, down through about 10 mV when exhaust
is lean. The PCM constantly monitors the HO2S signal
during closed loop operation and compensates for a rich
or lean condition by decreasing or increasing injector
pulse width as necessary. If the Bank 1 HO2S 1 voltage
remains excessively low for an extended period of time,
DTC P0131 will be set.

D Open loop fuel control will be in effect.

D
D
D
D
No related DTCs.
Vehicle is operating in closed loop.
Closed loop commanded air/fuel ratio is between
14.5 and 14.8.
during normal closed loop operation for a total of 77

feed.
Diagnostic Aids
be routed incorrectly and contacting the exhaust
system.
D Poor PCM to engine block grounds.
too low. The PCM can compensate for some
6E2134
D
D
D
decrease. However, If fuel pressure is too low, a DTC

P0131 may be set. Refer to Fuel System Diagnosis.
Lean injector(s) Perform Injector Balance Test.
Vacuum leaks Check for disconnected or damaged
Exhaust leaks An exhaust leak may cause outside air
be indicated.
MAF sensor The system can go lean if the MAF
sensor signal indicates an engine airflow
measurement that is not correct. Disconnect the MAF
sensor to see if the lean condition is corrected. If so,
replace the MAF sensor.
Fuel contamination Water, even in small amounts,
alcohol in the fuel can also cause this condition. Refer
to Fuel System Diagnosis for the procedure to check
for fuel contamination.
affected HO2S.
Test Description
Number(s) below refer to step numbers on the diagnostic
chart.
3. DTC P0131 failing during operation may indicate a
condition described in the Diagnostic Aids above.
If the DTC P0131 test passes while the Failure
Records conditions are being duplicated, an
intermittent condition is indicated.
6E2135
DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1

Step
Action
Value(s)
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 5
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Verify repair
425475 mV
Refer to
Diagnostic
Aids
Go to Step 9
Verify repair

1. Ignition OFF.
2. Reconnect the
disconnected.
3. Ignition ON.
PCM,
leave
the
sensor

between the specified values?
9
Go to Step 3
1. Turn the ignition OFF, HO2S 1 and PCM

disconnected.
signal circuits.

8
Go to Step 4

7
22 mV

circuit.

6
Go to Step 2
1. Ignition ON, engine OFF, review and record Tech

2 Failure Records data and note parameters.
3. Using a Tech 2, monitor DTC info for DTC P0131
until the DTC P0131 test runs.
Note test result.

ground?
5

under Conditions for Setting the DTC criteria
included in Diagnostic Support.

4
No
Go to OBD
System
Check

performed?

specified value?
3
Yes
Replace the PCM.

6E2136
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1
Sensor 1
D06RX137
Circuit Description

remains excessively high for an extended period of time,


D No related DTCs.
D Engine coolant temperature is above 60C (140F)
D Closed loop commanded air/fuel ratio is between
14.5 and 14.8.
OR
during deceleration fuel cutoff mode operation for 3
seconds.

feed.
Diagnostic Aids
too high. The PCM can compensate for some
increase. However, if fuel pressure is too high, a DTC
D Perform Injector Balance Test Refer to Fuel System
Diagnosis.
D Check the EVAP canister for fuel saturation If full of

D MAF sensor The system can go rich if MAF sensor
signal indicates an engine airflow measurement that is
not correct. Disconnect the MAF sensor to see it the
rich condition is corrected. If so, replace the MAF
sensor.
D Check for a leak in the fuel pressure regulator
regulator for the presence of fuel. There should be no
fuel in the vacuum line.
D An intermittent TP sensor output will cause the system
accelerating.
D Shorted Heated Oxygen Sensor (HO2S) If the HO2S
is internally shorted, the HO2S voltage displayed on
the Tech 2 will be over 1 volt. Try disconnecting the
affected HO2S with the key ON, engine OFF. If the
displayed HO2S voltage changes from over 1000 mV
to around 450 mV, replace the HO2S. Silicon
contamination of the HO2S can also cause a high
HO2S voltage to be indicated. This condition is
the HO2S exposed to the exhaust stream.
If
D Open HO2S Signal Circuit or Faulty HO2SA poor
connection or open in the HO2S signal circuit can
cause the DTC to set during deceleration fuel mode.
An HO2S which is faulty and not allowing a full voltage
swing between the rich and lean thresholds can also
cause this condition.
Operate the vehicle by
monitoring the HO2S voltage with a Tech 2. If the
HO2S voltage is limited within a range between 300
mV to 600 mV, check the HO2S signal circuit wiring
and associated terminal conditions.
D If none of the above conditions are present, replace the
affected HO2S.
Test Description
Diagnostic Chart.
3. DTC P0132 failing during deceleration fuel cutoff
mode operation may indicate a condition described
in the Diagnostic Aids above. If the DTC P0132
indicated.
6E2137
6E2138
DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1

Step
Action

Diagnostic Support.
1.
2.
3.
4.
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
3-4 V
Go to Step 5
Go to Step 6
Verify repair
10 mV
Go to Step 7
Go to Step 8
425-475 mV
Refer to
Diagnostic
Aids
Go to Step 8
Verify repair
1. Disconnect the jumpers to ground from Bank 1

HO2S 1 PCM-side connector.
2. With the HO2S 1 connector disconnected, monitor
Bank 1 HO2S 1 voltage.
Is Bank 1 HO2S 1 voltage between the specified
values?
952 mV (500
mV in
deceleration
fuel cutoff
mode)
1. Ignition ON, engineOFF.

2. At Bank 1 HO2S 1 connector (PCM side) jumper
both the HO2S high and low signal circuits (PCM
side) to ground.
Go to Step 2

Ignition OFF.
Ignition ON.
At HO2S Bank 1 Sensor 1 connector (PCM side)
use a DVM to measure voltages at the high and low
signal terminals.

5
No
Go to OBD
System
Check
1. Ignition ON, review and record Tech 2 Failure

Records data.
ignition?
Yes

performed?

specified value?
3
Value(s)
Replace the PCM.

6E2139
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1
Sensor 1
D06RX138
Circuit Description
D The powertrain control module (PCM) supplies a bias
sensor (HO2S) high and low circuits. When measured
with a 10 megaohm digital voltmeter, this may display
as low as 320 mV. The oxygen sensor varies the
exhaust is rich, down through about 10 mV when
exhaust is lean. The PCM constantly monitors the
HO2S signal during closed loop operation and
compensates for a rich or lean condition by decreasing
or increasing injector pulse width as necessary. If the
Bank 1 HO2S 1 voltage remains at or near the 450 mV
bias for an extended period of time, DTC P0134 will be
set, indicating an open sensor signal or sensor low
circuit.
D Heated oxygen sensors are used to minimize the
amount of time required for closed loop fuel control
operation and to allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors Bank
1 HO2S 1 and Bank 2 HO2S 1 to become active.
Oxygen sensor heaters are required by post-catalyst
monitor sensors to maintain a sufficiently high
temperature for accurate exhaust oxygen content
readings further from the engine.

D No related DTCs.
D Battery voltage is above 10 volts.

functioning properly.
mV and 500 mV for a total of 77 seconds over a
90-second period of time.
Action Take When the DTC Sets


feed.
6E2140
Diagnostic Aids
harness connectors for backed-out terminals,
ON, engine OFF, after a cool down period, the
HO2S 1 voltage displayed on the Tech 2 is normally
455-460 mV. A reading over 1000 mV indicates a
signal line shorted to voltage. A reading under 5 mV
indicates a signal line shorted to ground or signal lines
shorted together. Disconnect the HO2S and connect
a test light between the HO2S ignition feed and heater
ground circuits. If the test light does not light for 2
seconds when the ignition is turned on, repair the open
ignition feed or sensor ground circuit as necessary. If
the test light lights and the HO2S signal and low circuits
are OK, replace the HO2S.
D Intermittent test With the Ignition ON, monitor the

Test Description
Diagnostic Chart.
3. If the DTC P0134 test passes while the Failure
DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1

Step
Action
Go to Step 2
400-500 mV
Go to Step 3
Go to Step 4
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7

Go to OBD
System
Check


5
No

3. Operate the engine above 1200 RPM for two
minutes.

ignition?
4
Yes

performed?

3
Value(s)

terminal connections at the PCM and replace terminals
if necessary.
6E2141
DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 (Cont'd)

Step
Action
Verify repair
Go to Step 8
Verify repair
Go to Step 9
0-10 mV
Go to Step 10
Go to Step 11
Verify repair
Verify repair

11

high and low circuits (PCM side) to ground.
Is Bank 1 HO2S 1 voltage in the specified range?
10
No
1. Ignition OFF.
2. With the PCM disconnected, check continuity of the
3. If the Bank 1 HO2S 1 low circuit measures over 5
ohms, repair open or poor connection as necessary.
corrected?
Yes
1. Ignition OFF.
corrected?
Value(s)
Replace the PCM.

6E2142
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2
Sensor 1
D06RX139
Circuit Description



D
D
D
D
No related DTCs.
The engine is operating in closed loop.
14.5 and 14.8.

feed.
Diagnostic Aids
be mispositioned and contacting the exhaust system.
decrease. However, if fuel pressure is too low, a DTC

be indicated.
D MAF sensor The system can go lean if the MAF
6E2143

affected HO2S.
Test Description
Diagnostic Chart.
intermittent condition is indicate.

Step
Action
Go to Step 2
22 mV
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 5
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
1. Turn ignition OFF.

3. Check the Bank 2 HO2S 1 high and low signal
circuits for a short to ground or a short to the heater
ground circuit.
Go to OBD
System
Check

4. Note test result.
Were Bank 2 HO2S 1 signal circuits shorted?

5
No


ignition?
4
Yes

performed?

specified value?
3
Value(s)
1. Ignition OFF.
2. Leave the PCM and HO2S 1 disconnected.
signal circuits.
6E2144
DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1 (Cont'd)

Step
Action
No
Verify repair
425-475 mV
Refer to
Diagnostic
Aids
Go to Step 9
Verify repair
1. Ignition OFF.
2. Reconnect the PCM, leave HO2S 1 disconnected.
3. Ignition ON.
Yes

Value(s)
Replace the PCM.

6E2145
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2
Sensor 1
D06RX139
Circuit Description
or lean condition by decreasing or increasing the injector

D No related DTCs.
D The engine is operating in closed loop.
(140F).
D Closed loop commanded air/fuel ratio between 14.5
and 14.8.
D Throttle angle between 3% and 19%.
OR

during deceleration fuel cutoff mode operation for up to
3 seconds.


feed.
Diagnostic Aids
D Rich injector(s) Perform Injector Balance Test.
6E2146
D Leaking injector Refer to Fuel System Diagnosis.

D Evaporative emissions (EVAP) system Check the
canister for fuel saturation. If the canister is full of fuel,
check EVAP control system components and hoses.
Refer to Evaporative Emission (EVAP) Control
System.
D MAF sensor The system can go rich if the MAF
measurement that is not correct Disconnect the MAF
sensor to see if rich condition is corrected. If so,
replace MAF sensor.
D Check for leaking fuel pressure regulator diaphragm by
checking vacuum line to regulator for the presence of
fuel. There should be no fuel in the vacuum line.
D TP sensor An intermittent TP sensor output will
cause the system to go rich, due to a false indication
of the engine accelerating.
contamination of the HO2S can cause a high HO2S
voltage to be indicated. This condition is indicated by
powdery white deposit on the portion of the HO2S
exposed to the exhaust stream. If contamination is
noticed, replace the affected HO2S.
D Open HO2S Signal Circuit of Faulty HO2S A poor
switch between the rich and lean thresholds can also
cause the condition. Operate the vehicle while
HO2S is voltage limited within a range between 300
and associated terminal connections.
affected HO2S.
Test Description
Diagnostic Chart.
indicated.
6E2147

Step
Action

2. Engine is at operating temperature.
1.
2.
3.
4.
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
3-4 V
Go to Step 5
Go to Step 6
Verify repair
10 mV
Go to Step 7
Go to Step 8
425-475 mV
Refer to
Diagnostic
Aids
Go to Step 8
Verify repair

Is the Bank 2 HO2S 1 voltage between the specified
values?
952 mV (500
mV in
deceleration
fuel cut-off
mode)

side) to ground.
Go to Step 2

Ignition OFF.
Ignition ON.
signal terminals.

5
No
Go to OBD
System
Check
1. Ignition ON.
ignition?
Yes

performed?

specified value?
3
Value(s)
Replace the PCM.

6E2148
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2
Sensor 1
D06RX140
Circuit Description
with a 10 megaohm digital voltmeter, this may display as
low as 320 mV. The oxygen sensor varies the voltage
within a range of about 1000 mV when the exhaust is rich,
down through about 10 mV when exhaust is lean. The
PCM constantly monitors the HO2S signal during closed
loop operation and compensates for a rich or lean
condition by decreasing or increasing injector pulse width
as necessary. If the Bank 2 HO2S 1 voltage remains at or
near the 450 mV bias for an extended period of time, DTC
P0154 will be set, indicating an open sensor signal or
sensor low circuit.
of time required for closed loop fuel control operation
required for fuel control sensors Bank 1 HO2S 1 and Bank
2 HO2S 1 to become active. Oxygen sensor heater are
required by post-catalyst monitor sensors to maintain a
sufficiently high temperature for accurate exhaust oxygen
content readings further from the engine.

D No related DTCs.
D Engine running time is longer than 40 seconds.

D Oxygen sensor heater is functioning properly.


feed.
Diagnostic Aids

damaged terminals, poor terminal-to-wire-connection,
ON, engine OFF, the HO2S 1 voltage displayed on
the Tech 2 is normally 455-460 mV. A reading over
1000 mV indicates a signal line shorted to voltage. A
reading under 5 mV indicates a signal line shorted to
ground or signal lines shorted together. If not,
disconnect the HO2S and connect a test light between
the HO2S ignition feed and heater ground circuits. If
the test light does not light for 2 seconds when the
ignition is turned on, repair the open ignition feed or
sensor ground circuit as necessary. If the test light
lights and the HO2S signal and low circuits are OK,
replace the HO2S.
D Intermittent test With the ignition ON, monitor the
6E2149

Test Description
Diagnostic Chart.

Step
Action
Go to Step 2
400-500 mV
Go to Step 3
Go to Step 4
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7

Check for a poor Bank 2 HO2S 1 high and low circuit
Go to OBD
System
Check

2. Review and record Tech 2 Failure Records data and
note parameters.

5
No

minutes.

ignition?
4
Yes

performed?

3
Value(s)

terminal connections at the PCM and replace
6E2150

Step
Action
Verify repair
Go to Step 8
Verify repair
Go to Step 9
0-10 mV
Go to Step 10
Go to Step 11
Verify repair
Verify repair

11

Is the Bank 2 HO2S 1 voltage in the specified range?
10
No
1. Ignition OFF.
2. With the PCM disconnected check continuity of the
corrected?
Yes
1. Ignition OFF.
corrected?
Value(s)
Replace the PCM.

6E2151
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Too Lean Bank 1
D06RW068
Circuit Description
fuel economy, and emission control, a closed loop
air/fuel metering system is used. While in closed loop,
the powertrain control module (PCM) monitors the Bank 1
HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel
delivery based upon the HO2S signal voltages. A change
made to fuel delivery will be indicated by the long and
short term fuel trim values which can be monitored with a
Tech 2. Ideal fuel trim values are around 0%; if the HO2S
signals are indicating a lean condition the PCM will add
fuel, resulting in fuel trim values above 0%. If a rich
condition is detected, the fuel trim values will be below
0%, indicating that the PCM is reducing the amount of fuel
delivered. If an excessively lean condition is detected on
Bank 1, the PCM will set DTC P0171.
The PCMs maximum authority to control long term fuel
trim allows a range between 15% (automatic
transmission) or 12% (manual transmission) and +20%.
The PCM monitors fuel trim under various engine
speed/load fuel trim cells before determining the status
the fuel trim diagnostic.

D None of the following: EGR DTCs, HO2S DTCs,
(response, transition, open, low volts, no activity), MAF
DTCs, TP sensor DTCs, MAP DTCs, IAT DTCs,
canister purge DTCs, EVAP DTCs, injector circuit
DTCs, or misfire DTCs.
D Engine coolant temperature is between 25C (77F)

and 100C (212F).
D Intake air temperature is between 40C (40F) and
120C (248F).
D Manifold absolute pressure is between 24 kPa and 99
kPa.
D Throttle angle is steady below 95%.
D Vehicle speed is below 136 km/h (85 mph).
D Engine speed is between 400 and 6000 RPM.
D Mass air flow (MAF) is between 2 g/second and 200
g/second.
D Ignition voltage is above 9.5 volts.
D Fuel system is in closed loop.
D Canister purge duty cycle is greater than 0% if on.

fault is detected.

6E2152

feed.
Diagnostic Aids
Bank 1 HO2S 1 display on the Tech 2 while moving
connectors and wiring harnesses related to the engine
harness. A change in the display will indicate the
Test Description
Diagnostic Chart.
2. DTCs other than P0171 and P0174 may indicate a
condition present which may cause a lean condition.
If this is the case, repairing the condition which
caused the other DTC will most likely correct the
DTC P0171/P0174.
Records conditions are being duplicated, the lean
condition is intermittent. Refer to Diagnostic Aids or
Symptoms for additional information on diagnosing
intermittent problems.
6E2153
DTC P0171 Fuel Trim System Lean Bank 1

Step
Action
Yes
Go to Step 2
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this chart
Go to Step 3
L.T. Fuel
Trim: +20%
Go to Step 5
Go to Step 4
Are any DTCs set other than P0171 and P0174?
1. Start the engine and operate the vehicle in closed

loop.
2. Observe the B1 Long Term Fuel Trim display on
the Tech 2.
No
Go to OBD
System
Check

performed?
Is the displayed value greater than the specified value?

4
Value(s)

2. Clear the DTC P0171/P0174 and operate the
vehicle to duplicate the Failure Records conditions.
3. Monitor the Tech 2 DTC info for DTC P0171 while
operating the vehicle to duplicate the Failure
Records conditions.
4. Continue operating the vehicle until the DTC P0171
test runs and note the test result.
ignition?
Go to Step 5
The lean
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms
section.
Was DTC P0174 also set?
Go to Step 6
Go to Step 15

disconnections, splits, kinks, improper routing and
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step11
Verify repair
Go to Step 11

7

System).
1. Inspect the MAF sensor inlet screen for damage or

for the presence of foreign objects which may
partially block the air flow sample through the MAF
sensor.
2. Correct any problem that is found as necessary.
Did your inspection of the MAF sensor reveal a
condition requiring repair?

10

for vacuum leaks.
6E2154
DTC P0171 Fuel Trim System Lean Bank 1 (Cont'd)

Step
Action
11

12
Verify repair
Go to Step 13
0%
Go to Step 19
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Refer to
Diagnostic
Aids
Verify repair

19

Did Injector Balance Test isolate a problem?
18
Go to Step 12

17
Verify repair

injector O-rings, EGR adapter, EGR valve and the
16
Perform the procedure in the Fuel System Pressure

Test and repair fuel system problem if necessary.
Did Fuel System Pressure Test isolate a condition
requiring repair?
15
No
1. Disconnect the MAF sensor electrical connector.

2. Operate the vehicle in closed loop while
monitoring the B1 Long Term Fuel Trim displayed
on the Tech 2.
Does BANK 1 S.T. FUEL TRIM value decrease to
near the specified value?
14
Yes
1. Visually and physically inspect the PCM injector

locations.
necessary.
13
Value(s)

6E2155
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1
D06RW068
Circuit Description
heated oxygen sensors (HO2S) 1 and Bank 2 HO2S 1
signals and adjusts fuel delivery based upon the HO2S
signal voltages. A change made to fuel delivery will be
indicated by the long and short term fuel trim values which
can be monitored with a Tech 2. Ideal fuel trim values are
around 0%; if the HO2S signals are indicating a lean
condition the PCM will add fuel, resulting in fuel trim
trim values will be below 0%, indicating that the PCM is
rich condition is detected on Bank 1, the PCM will set DTC
P0172.
transmission) or 12 (manual transmission) and +20%.
The PCMs maximum authority to control short term fuel
trim allows a range between 11% and +20%. The PCM
diagnostic.

D None of the following was set: EGR DTCs, HO2S

DTCs, (response, transition, open, low volts, no
activity), MAF DTCs, TPS DTCs, MAP DTCs, IAT
DTCs, canister purge DTCs, EVAP DTCs, injector
circuit DTCs, or misfire DTCs.
and 100C (212F).
120C (248F).
kPa.
g/second.
D Canister purge duty cycle is greater than 0%, if ON.

fault is detected.
6E2156

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
DTC P0172/P0175.
Records conditions are being duplicated, the rich
6E2157
DTC P0172 Fuel Trim System Rich Bank 1

Step
Action
Yes
Go to Step 2
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this chart
Go to Step 3
L.T. Fuel
Trim: 15%
(auto. trans.)
OR 12%
(man. trans.)
Go to Step 5
Go to Step 4

loop.
2. Observe B1 Long Term Fuel Trim display on the
Tech 2.
No
Go to OBD
System
Check

performed?
Is the displayed value more negative than the specified

value?
4
Value(s)

Records conditions.
test runs and note test result.
ignition?
Go to Step 5
The rich
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms.
Go to Step 6
Go to Step 15

Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11
Verify repair
Go to Step 11

7

Inspect the MAF sensor inlet screen for damage or for

the presence of foreign objects which may partially
block air flow through the screen and correct any
problem found.
condition requiring repair or replacement?

10
1. Ignition OFF.
objects.
6E2158
DTC P0172 Fuel Trim System Rich Bank 1 (Cont'd)

Step
Action
11

fuel.
System).
12
0%
Go to Step 21
Go to Step 14
Go to Step 15
Go to Step 18
Go to Step 16
Go to Step 17
Verify repair
Verify repair
Verify repair
Go to Step 19
Verify repair
Refer to
Diagnostic
Aids
Verify repair
Verify repair

missing.
21
Go to Step 20

20
Go to Step 13

2. If Injector Balance Test isolates a problem, repair as
necessary (refer to Fuel Metering System).
Did the Injector Balance Test isolate a problem
requiring repair?
19
Minimum 0%
Maximum
100%
Replace the PCM.

18
Go to Step 12

17
Verify repair
Check for short to ground in the wire (red/blue)

between the canister purge solenoid and PCM terminal
A-15.
Was there a short to ground?
16

2. Connect a test light between the harness connector
terminals of canister purge solenoid.
Is the test light on?
15
No

monitoring the B1 Long Term Fuel Trim and B1
Short Term Fuel Trim display on the Tech 2.
Did both values change to near the specified value?
14
Yes
Ignition ON, engine OFF, monitor the TP display on

the Tech 2 while slowly depressing the accelerator
pedal.
13
Value(s)

6E2159
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2
D06RW069
Circuit Description
trim allows a range between 15%(automatic
transmission) or 12%(manual transmission) and +20%.
speed/load fuel trim cells before determining the status of

and 100C (212F).
120C (248F).
kPa.
D Mass air flow is between 2 g/second and 200 g/second.

failure is detected.

D None of the following DTCs are set: idle system, EGR,
HO2S, (response, transition, open, low volts, no
activity), MAF, TP sensor, MAP, IAT, canister purge,
EVAP, injector circuit, or misfire.

6E2160

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
DTC P0171/P0174.
6E2161

Step
Action
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.
Go to Step 3
L.T. Fuel
Trim: +20%
Go to Step 5
Go to Step 4

performed?

loop.
the Tech 2.
Is the displayed values greater than the specified
values?
Value(s)

Records conditions.
test runs.
ignition?
Go to Step 5
The lean
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms
section.
Go to Step 6
Go to Step 15

improper disconnections and repair any problem
found.
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11

7

System).

sensor.

6E2162

Step
Action
10

for vacuum leaks.
11
Go to Step 12
Verify repair
Go to Step 13
0%
Go to Step 19
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Refer to
Diagnostic
Aids
Verify repair

19
Verify repair

Did the Injector Balance Test isolate a problem?
18

17
Go to Step 11

16
Verify repair

Did the Fuel System Pressure Test isolate a condition
requiring repair?
15

monitoring the B2 Short Term Fuel Trim displayed
on the Tech 2.
Does the B2 Short Term Fuel Trim value decrease to
14
No

locations.
necessary.
13
Yes

contaminants (see Diagnosis in Engine Fuel for
is present (see Engine Fuel).
12
Value(s)

6E2163
D06RW069
Circuit Description
delivered. If an excessively rich condition is detected on
diagnostic.

D
D
D
D
D
D
D
D
D
D
D
activity), MAF, TPS, MAP, IAT, canister purge, EVAP,

injector circuit, or misfire.
and 100C (212F).
120C (248F).
Manifold absolute pressure is between 24 kPa and 99
kPa.
Throttle angle is steady below 95%.
Vehicle speed is below 136 km/h (85 mph).
Mass air flow (MAF) is between 2 g/second and 200
g/second.
Ignition voltage is above 9.5 volts.
Fuel system is in closed loop.
Canister purge duty cycle is greater than 15%, if ON.


6E2164

feed.
Diagnostic Aids
Reviewing the Failure Records Vehicle mileage since the

Test Description
Diagnostic Chart.
DTC P0172/P0175.

Step
Action
Yes
Go to Step 2
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.
Go to Step 3
L.T. Fuel
Trim: 15%
(auto. trans.)
OR 12%
(man. trans.)
Go to Step 5
Go to Step 4

loop.
2. Observe the BANK 2 L.T. FUEL TRIM display on
the Tech 2.
No
Go to OBD
System
Check

performed?

value?
4
Value(s)

Records conditions.
test runs.
ignition?
Go to Step 5
The rich
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms
Go to Step 6
Go to Step 15

Verify repair
Go to Step 7
6E2165

Step
Action
Go to Step 10
Go to Step 11
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Minimum 0%
Maximum
100%
Go to Step 13
Go to Step 21
0%
Go to Step 22
Go to Step 14
Go to Step 15
Go to Step 18
Go to Step 16
Go to Step 17
Verify repair
Verify repair

17

A-15.
16
Go to Step 9

15
Verify repair

monitoring the B1 Lont Term Fuel Trim and BANK
2 S.T. FUEL TRIM display on the Tech 2.
14

2. Monitor the TP Angle display on the Tech 2 while
slowly depressing the accelerator pedal.
maximum value at wide-open throttle?
13
Go to Step 8

fuel.
System).
12
Verify repair
1. Turn the ignition off and physically inspect the

throttle body bore, throttle plate, and IAC passages
for coking and foreign objects.
11

10
No

problem found.
Yes

Value(s)
Replace the PCM.

6E2166

Step
Action
18

2. If the Injector Balance Test isolates a problem,
repair as necessary (refer to Fuel Metering
System).
requiring repair?
19
No
Verify repair
Go to Step 19
Verify repair
Refer to
Diagnostic
Aids
Verify repair
Verify repair

missing.
21
Yes

replace the contaminated sensor.
20
Value(s)

6E2167
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit
D06RW070
Circuit Description
The powertrain control module (PCM) has six individual

driver circuit is grounded by the PCM, the injector is
activated. The PCM monitors the current in each driver
circuit. The voltage on each driver is monitored to detect
a fault. If the voltage is not what the PCM expects to
monitor on the circuit, a DTC is set. This DTC is also set if
an injector driver is shorted to voltage or if there is an open
circuit.
D The PCM will turn OFF the MIL on the third

consecutive trip cycle in which the diagnostic has been
run and the fault is no longer present.
warm-up cycles occur without a fault.
feed.

will cause a DTC P0201 to set. It will also cause a misfire
due to an inoperative injector. A misfire DTC will also be
set indicating which cylinder is inoperative.
injectors.
D The battery voltage is more than 9 volts.

D The engine is turning, determined by 58X crankshaft
position input signal.
D The injector voltage does not equal the ignition voltage
commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.
3. This step determines if DTC P0201 is the result of a
hard failure or an intermittent condition.
6E2168
5. A special injector test connector is provided so that

the injectors can be electrically tested without
removal of the manifold. The test connector can be
identified by the blue connector lock which is
tethered to the wiring harness. If the light for
cylinder 1 is ON steady before cranking the engine
as well as while cranking the engine, then the
injector driver circuit is shorted to ground.
If the test light blinks while cranking, the PCM and
the wiring to the injectors are OK. The Fuel
Injector Coil Test Procedure will check if the
injectors are faulty.
7. Because the test light was ON steady, voltage to

the injector is OK, but the driver circuit is grounded
at all times. This step determines if the circuit is
shorted to ground or the PCM is faulty.
9.The reading should be about 12-14W.
10.Locating the open in the harness or in the injector
will require removal of the manifold to provide
access.
R321054
DTC P0201 Injector 1 Control Circuit

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes
1. Review the Freeze Frame data with the ignition

ON and the engine OFF and note the
parameters.
Does P0201 reset?
6E2169
DTC P0201 Injector 1 Control Circuit (Cont'd)

Step
Action
1. Engine OFF.
2. Disconnect the injector connector.
3. Install an injector test light 5-8840-2636-0 on the
4. Crank the engine and note the light.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

connector and the PCM.
14
Go to Step 9
Repair the short to voltage.

13
Go to Step 7
At the PCM side of the injector test connector, check

the green/white wire for a short to voltage.
Was there a short to voltage?
12
Repair the open injector harness wire or open injector.

11
Go to Step 6

2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 1 (green with white
tracer).
Does the ohmmeter indicate continuity?
10
Go to Fuel
Injector Coil
Test
Procedure

No
1. Disconnect the PCM connector for the affected

injectors.
Yes
Note whether the injector test light for cylinder 1 was

OFF or ON steady in step 5.
engine?
Value(s)
Replace the PCM.

6E2170
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.

the wiring to the injectors are OK. Fuel Injector
Coil Test Procedure will check if the injectors are
faulty.
6E2171

access.
R321055

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0202 reset?
6E2172

Step
Action
1. Engine OFF.
3. Install an injector test light 5-8840-2636-0 on
injector test connector
Does the cylinder 2 test light blink?
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/orange wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 2 (green with orange
tracer).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

engine?
Value(s)
Replace the PCM.

6E2173
D06RW070
Circuit Description

the driver circuit is grounded by the PCM, the injector is
circuit.

feed.

injectors.

D The engine is turning, determined by the 58X
crankshaft position input signal.
commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.
6E2174


access.
R321056

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0203 reset?
6E2175

Step
Action
1. Engine OFF.
2. Disconnect the injector test connector .
injector connector
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 3 (green).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

engine?
Value(s)
Replace the PCM.

6E2176
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.

6E2177

access.
R321057

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0204 reset?
6E2178

Step
Action
1. Engine OFF.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/red wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 4 (green/red).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
Replace the PCM.

6E2179
D06RW070
Circuit Description

circuit. The voltage on each driver is monitored to detect a
fault. If the voltage is not what the PCM expects to
circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.
6E2180

faulty.

access.
R321058

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0205 reset?
6E2181

Step
Action
1. Engine OFF.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/black wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 5 (green with black
tracer).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
Replace the PCM.

6E2182
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.

6E2183

access.
R321059

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0206 reset?
6E2184

Step
Action
1. Engine OFF.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/yellow wire for a short to voltage.
12
Repair the open injector harness wire or open injector

11
Go to Step 6

tracer) and the wire for cylinder 6 (green with yellow
tracer).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
Replace the PCM.

6E2185
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit
D06RW0351
Circuit Description
The knock sensor is used to detect engine detonation,
allowing the powertrain control module (PCM) to retard
ignition control (IC) spark timing based on the knock
sensor (KS) signal being received. The knock sensor
produces an AC signal so that under a no knock condition
the signal on the KS circuit measures about 0.007 V AC.
The KS signals amplitude and frequency depend upon
the amount of knock being experienced. The PCM
contains a non-replaceable knock filter module called a
signal-to-noise enhancement filter (SNEF) module. This
filter module in the PCM determines whether knock is
occurring by comparing the signal level on the KS circuit
with the voltage level on the noise channel. The noise
channel allows the PCM to reject any false knock signal
by knowing the amount of normal engine mechanical
noise present. Normal engine noise varies depending on
engine speed and load. When the PCM determines that
an abnormally low noise channel voltage level is being
experienced, a DTC P0325 will set.

D Engine has been running for at least 30 seconds.
D The PCM determines that its internal signal from its
knock filter module indicates a continuous knocking
condition for more than 10 seconds.

D The PCM will use a substitute default spark retard

value of 6 degrees to minimize knock during conditions
when knock is likely to occur.

feed.
Diagnostic Aids
D Poor connection at PCM Inspect the knock sensor
and PCM connectors for backed-out terminals, broken
locks, and improperly formed or damaged terminals.
D Misrouted harness Inspect the knock sensor harness
circuits such as spark plug coils.
Test Description
Diagnostic Chart.
6E2186
DTC P0325 KS Module Circuit

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair

performed?
IMPORTANT: If an engine knock can be heard, repair
the engine mechanical problem before proceeding with
this diagnostic.
under criteria included in Conditions for Setting the
DTC.
ignition?

2. Review and record Tech 2 Failure Records data for
DTC P0325.
conditions.
Does the Tech 2 indicate DTC P0325 test failed this
ignition?
Replace the PCM.

6E2187
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit
D06RW0351
Circuit Description
The powertrain control module (PCM) uses the knock
sensor to detect engine detonation, allowing the PCM to
retard ignition control (IC) spark timing based on the
knock sensor (KS) signal being received. The knock
sensor produces an AC signal so that under a no knock
condition the signal on the KS circuit measures about
0.007 V AC. The signal amplitude and frequency are
dependent upon the amount of knock being experienced.
The PCM monitors the KS signal and can diagnose the
KS sensor and circuitry.

D
D
D
D
D
Engine running time is at least 10 seconds.

The TP sensor is greater than 5%.
The ECT sensor is greater than 60C (140F).
The knock sensor signal voltage is less than 0.20 volts,
or greater than 4.8 volts.
D All conditions are present for more than 15 seconds.

fault is detected.
D The PCM will use a calculated spark retard value to

minimize knock during conditions when knock is likely
to occur. The calculated value will vary based on
engine speed and load.

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
6E2188
DTC P0327 KS Sensor Circuit

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 7
Verify repair
Go to Step 8
100K ohms
Go to Step 9
Go to Step 10

performed?
this diagnostic.
in diagnostic support Conditions for Setting the
DTC.
ignition?

conditions.
ignition?
Using a test light to battery +, check the black/blue wire

(PCM side) to verify that the shield connection is good.
Repair the open shield ground.


1. Ignition OFF, PCM disconnected.

2. Check the KS signal circuit between the PCM and
the knock sensor connector for an open, a short to

2. Knock sensor connected.
3. Measure the resistance of the knock sensor by
connecting the DVM between the PCM connector
and the engine block.
Is the resistance of the knock sensor near the specified
value?
6E2189
DTC P0327 KS Sensor Circuit (Cont'd)

Step
Action
No
Go to Step 11
Go to Step 10
Verify repair
Verify repair

11
Yes

2. Connect the DVM to monitor AC voltage between
the PCM connector and engine ground.
3. Tap on the engine lift bracket with a socket
extension while observing the signal indicated on
the DVM.
Is any signal indicated on the DVM while tapping on the
10
Value(s)
Replace the PCM.

6E2190
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit
D06RX145
Circuit Description

58 crankshaft pulses will be produced. The powertrain
control module (PCM) uses the 58X reference signal to
calculate engine RPM and crankshaft position. The PCM
the PCM receives an incorrect number of pulses on the
58X reference circuit, DTC P0336 will set.

fault is detected.

rotations.

feed.
Diagnostic Aids
D Poor connection Inspect the PCM harness and
6E2191
the PCM, turn the ignition on and observe a voltmeter

connected to the 58X reference circuit at the PCM
harness connector while moving connectors and
wiring harnesses related to the ICM. A change in
DTC P0336 58X Reference Signal Circuit

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
2.5 V
Go to Step 8
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Verify repair
Go to Step 10
Verify repair

1.
2.
3.
4.

Clear DTC P0336.
Observe DTCs.
Is DTC P0336 set?

4
1. Disconnect the PCM and CKP sensor.

connector and the PCM harness connector.
1. Reconnect the PCM and CKP sensor.

reference circuit at the PCM connector.

Replace the CKP sensor. Use caution to avoid any hot

oil that may drip out.
Check connections at the PCM and replace the

No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2192
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency
D06RX145
Circuit Description
powertrain control module (PCM) uses the 58X reference
The PCM constantly monitors the number of pulses on
received. If the PCM does not receive pulses on the 58X
reference circuit, DTC P0337 will set.

D Engine cranking.

pulses.

fault is detected.


feed.
Diagnostic Aids
6E2193

DTC P0337 CKP Sensor Circuit Low Frequency

Step
Action
1.
2.
3.
4.
Go to Step 3
Go to Chart 3
Go to Step 4
Refer to
Diagnostic
Aid
Go to Step 7
Go to Step 5
Go to Step 6
Go to Step 11
Verify repair
Verify repair
Go to Step 8
2.5 V
Go to Step 11
Go to Step 9

sensor and PCM and repair the open circuit, short to
1. Ignition OFF.
1. Ignition ON.
2. With a DVM, backprobe the PCM connector 5 V

7
Go to Step 2

2. Ignition ON.
3. Using a DVM, verify that 5 V reference and ground
are being supplied at the sensor connector (PCM
side).
Are 5 V reference and ground available at the PCM?

6
Go to OBD
System
Check

Clear DTC P0337.
Observe DTCs.
Are 4-6 volts and ground available at the sensor?

5
No
Is DTC P0337 set?

4
Yes

performed?

3
Value(s)

6E2194
DTC P0337 CKP Sensor Circuit Low Frequency (Cont'd)

Step
Action
Verify repair
Go to Step 10
Verify repair
Verify repair
Go to Step 12
Verify repair
Check the connections at the PCM and replace the

12
No
Replace the CKP sensor. Use caution and avoid hot oil
that may drip out.
11
Yes

10
Value(s)
Replace the PCM.

6E2195
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performamce
D06RX145
Circuit Description
The CMP signal is produced by the camshaft position

(CMP) sensor pulses when the engine is running and
received. The powertrain control module (PCM) uses the
CMP signal pulses to initiate sequential fuel injection.
the CMP signal circuit and compares the number of CMP
CMP reference circuit, DTC P0341 will set and the PCM
will initiate injector sequence without the CMP signal with
a one in six chance that injector sequence is correct. The
condition occurs.
D The engine is running (1X CMP reference pulses are

being received).
D The CMP sensor signal is not detected at the correct
interval every 6 cylinders.
D Above condition fails for 100 occurrences within 200
test samples.

fault is detected.
D The PCM will initiate the injector sequence without the
CMP signal with a one in six chance that the injector
6E2196

feed.
Diagnostic Aids
connected to the CMP signal circuit at the PCM
wiring harnesses related to the ICM and the CMP
sensor. A change in voltage will indicate the location

of the fault.
NOTE: On early-built Troopers, the Tech 2 indication for
CMP ACT. COUNTER (Cam Position Sensor activity)
will continue to count up, even if no cam position signal is
being received by the PCM. This problem can be
corrected by reprogramming the PCM with the latest
EEPROM program.
Test Description
Diagnostic Chart.
10.Determines whether the fault is being caused by a
missing camshaft magnet or a faulty sensor. The
voltage measured in this step should read around 4
volts, toggling to near 0 volts when the CMP sensor
interfaces with the camshaft magnet.
DTC P0341 CMP Sensor Circuit Performance

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
4-6 V
Go to Step 10
Go to Step 7
Verify repair
Verify repair
Go to Step 6
1. Ignition ON.
ignition?
Measure the voltage between the CMP sensor signal

circuit and the sensor ground circuit at the CMP sensor
harness connector.
If the voltage measured in step 3 was less than 4-6

volts, proceed directly to step 6 without completing this
step.
If the voltage in step 3 was greater than 4-6 V, repair the
short to voltage in the CMP feed circuit.
No
Go to OBD
System
Check

performed?
Yes
1. Check for poor connections at the camshaft

position sensor.
6E2197
DTC P0341 CMP Sensor Circuit Performance (Cont'd)

Step
Action
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
4-0 V
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Verify repair
Replace the camshaft position sensor.

14
Verify repair
Replace the faulty or missing camshaft position sensor.

13
1. Remove the CMP sensor.

Does the DVM display a voltage near the specified
value?
12
Go to Step 8
Backprobe the PCM connector with a DVM to monitor

voltage on the camshaft position input signal circuit
while cranking the engine with the sensor connected.
(Use rubber band, tape, or an assistant to keep the
DVM lead in contact with the sensor terminal during this
test.)
11
Verify repair
1. Check for poor connections at the PCM.

10
Check for a short or open in the sensor ground circuit.

No
1. Ignition OFF, disconnect the PCM (leave the CMP

sensor disconnected).
2. Ignition ON, check the following circuits:
D The CMP sensor signal circuit for an open or a
short to voltage.
D The CMP sensor input signal circuit for a short
to ground.
Yes
1. Ignition OFF, disconnect the PCM and the CMP

sensor.
2. Check the following circuits for an open between the
ignition control module and the CMP sensor:
D The sensor feed circuit.
Value(s)
Replace the PCM.

6E2198
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low
D06RX145
Circuit Description
The CMP signal produced by the camshaft position

received. The hall type CMP sensor and the CKP sensor
share 5 V and ground connections at the powertrain
control module (PCM). The third wire at the sensor is a
signal circuit to the PCM. The PCM uses the CMP signal
pulses to initiate sequential fuel injection. The PCM
constantly monitors the number of pulses on the CMP
signal circuit and compares the number of CMP pulses to
the number of 58X reference pulses received. If the PCM
does not receive pulses on the CMP reference circuit,
DTC P0342 will set and the PCM will initiate injector
sequence without the CMP signal with a one in six chance
that injector sequence is correct. The engine will continue
to start and run normally, although the misfire diagnostic
will be affected if a misfiring condition occurs.

D The CMP sensor signal is not received by the PCM

fault is detected.
D The PCM will initiate injector sequence without the

feed.
Diagnostic Aids
terminal to wire connection.
of the fault.
Test Description
Diagnostic Chart.
damaged camshaft or a faulty PCM. The voltage
measured in this step should read around 4 volts,
toggling to near 0 volts when the CMP sensor
6E2199
6E2200
DTC P0342 CMP Sensor Circuit Low

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
4-6 V
Go to Step 7
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
4-6 V
Go to Step 8
Go to Step 9
1. Ignition ON.
ignition?
1. Ignition ON.
2. Disconnect the CMP sensor.
3. Measure the voltage between the sensor feed
circuit and the sensor ground circuit at the CMP

sensor.
position sensor.

1. Check the following circuits between the PCM and

the CMP sensor:
D The sensor feed circuit. Open or short to
ground?
D The sensor ground circuit. Open or short to
voltage?
No
Go to OBD
System
Check

performed?
Yes

2. Measure the voltage between the CMP sensor
signal circuit and the sensor ground circuit at the
CMP sensor harness connector.
6E2201
DTC P0342 CMP Sensor Circuit Low (Cont'd)

Step
Action
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
0V
Go to Step 14
Go to Step 13
Verify repair
Verify repair

2. Ignition ON, check the following circuit:
D The CMP sensor signal circuit for an open.
1. Ignition ON.

14
Go to Step 9
Ignition OFF.
Leave the PCM disconnected.
Ignition ON.
Probe the camshaft position signal circuit with a test
light to ground.
5. If the test light is ON, locate and repair the short to
voltage in the camshaft position input signal circuit.

value?
13
Go to Step 12
1.
2.
3.
4.

12
Ignition OFF.
Ignition ON.
Probe the camshaft position signal circuit at the
PCM connector with a test light to B+.
ground in the camshaft position input signal circuit.
Was the test light ON?

11
No
1.
2.
3.
4.
Was either circuit shorted to ground?

10
Yes

2. Disconnect the PCM and connect a DVM to monitor
voltage on the camshaft position signal circuit at the
PCM connector.
3. Ignition ON.
4. Monitor the voltage display on the DVM while
repeatedly touching the CMP sensor signal circuit
at the CMP sensor connector with a test light to
ground.
Does the DVM voltage display switch between 0 and
approximately 5 volts when the test light is touched to
the CMP sensor signal circuit?
Value(s)
Replace the PCM.

6E2202
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit
D06RX018
Circuit Description
The powertrain control modules (PCM) control circuit 1
provides a zero-volt or a 5-volt output signal to the ignition
coil. The normal voltage on the circuit is zero volts. When
the ignition coil receives the 5-volt signal from the PCM, it
provides a ground path for the B+ supply to the primary
side of the number 1 ignition coil. When the PCM shuts off
the 5 volts to the ignition coil, the ignition coil turns OFF.
This causes the ignition coil primary magnetic field to
collapse, producing a voltage in the secondary coil which
fires the spark plug.
The circuit between the PCM and ignition coil is monitored
for an open circuit, short to voltage, and short to ground.
When the PCM detects a problem on ignition control
circuit 1, it will set a DTC P0351.

D The output voltage is not equal to 5 volts when output

is ON.
is OFF.
D Twenty test failures occur within 40 samples of
continuous spark events.


run and the fault condition is no longer present.

feed.
Diagnostic Aids
D Poor connection at PCM Inspect the harness
connectors for backed-out terminals, improper mating,
terminals, and poor terminal-to-wire connections.
fault.
6E2203
6E2204
DTC P0351 Ignition 1 Control Circuit

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13
Does the voltage measure between the specified

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

3. Operate the vehicle within Failure Record
4. Use a Tech 2 to monitor the DTC information for
DTC P0351 until the DTC P0351 test runs.
cycle?
Check for faulty connection at ignition coil.

Check for faulty connection at PCM connector.


2. Back probe the ignition control circuit 1 at the PCM
with a DVM.
1. Ignition ON, engine running.

2. Back probe the ignition control circuit at the PCM for
the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher?
1. Ignition OFF.
3. Check ignition control circuit 1 voltage at the ignition
coil connector while cranking the engine.

1. Ignition OFF.
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 1 for short to ground.
10
Check ignition control circuit 1 for short to voltage.

11
Check for an open ignition control circuit 1.

Was the ignition control circuit open?
12
Repair the open ignition control circuit.

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2205
D06RW072
Circuit Description

D The engine is turning, determined by the 58 X

is ON.
is OFF.


6E2206

feed.
Diagnostic Aids
fault.
6E2207

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

cycle?



with a DVM .

1. Ignition OFF.
coil connector while cranking the engine connector.

1. Ignition OFF.
10

11

12

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2208
D06RX018
Circuit Description


is ON.
is OFF.



feed.
Diagnostic Aids
fault.
6E2209
6E2210

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

cycle?



with a DVM.

1. Ignition OFF.

1. Ignition OFF.
10

11

12

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2211
D06RX018
Circuit Description


is ON.
is OFF.


6E2212

feed.
Diagnostic Aids
fault.
6E2213

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

cycle?



with a DVM.

1. Ignition OFF.

1. Ignition OFF.
10

11

12
Repair the open in ignition control circuit.

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2214
D06RX018
Circuit Description


is ON.
is OFF.



feed.
Diagnostic Aids
fault.
6E2215
6E2216

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

cycle?



with a DVM.

1. Ignition OFF.

1. Ignition OFF.
10

11

12

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2217
D06RX018
Circuit Description


is ON.
is OFF.


6E2218

feed.
Diagnostic Aids
fault.
6E2219

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

cycle?



with a DVM.

1. Ignition OFF.

1. Ignition OFF.
10

11

12

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2220
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck
D06RW055
Circuit Description
The powertrain control module (PCM) monitors the EGR
valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to
detect a fault if pintle position is different from
commanded position. If the PCM detects a pintle position
signal indicates more than 15 points different between
current and commanded and more than 15 seconds, the
PCM will set DTC P0404.

D
D
D
D
Ignition voltage is between 11 and 16 volts.

Intake Air temp is more than 3C.
Desire EGR position is more than 0.
The difference between desired EGR and current EGR
is less than 3%.
D Difference EGR pintle position between current and
commanded position becomes more than 15% and
last more than 15 seconds, and this condition meets
three times in a trip. Then it trigger, the PCM lights on.

(MIL) as soon as failure detected after consecutive 2nd
trip in which the fault is detected.

Records data.

feed.
Diagnostic Aids
D Excessive carbon deposit on EGR valve shaft may
cause EGR stuck open or unsmooth operation. Those
carbon deposit may occur by unusual port operation.
Clean up carbon may make smooth function of EGR
valve.
related to EGR valve. A change in the display will
6E2221
DTC P0404 EGR Open Stuck

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
Go to Step 4
Go to Step 5
Verify repair
Is the action
complete?
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 8
Go to Step 9
Verify repair
Verify repair
1. Ignition ON, engine OFF, review and record

Tech 2 Failure Records Data.
until the DTC P0404 test runs. Note the result.
Does the Tech 2 indicates DTC P0404 failed this
ignition?
1. Disconnect the EGR valve harness connector.

2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals?
4
5

1. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any excessive
carbon deposit on EGR shaft.
Was excessive carbon deposit on EGR valve shaft?
1. Clean up EGR valve shaft and inside of EGR valve.

2. Visually inspect damage of pintle and seat if is bent,
leakage may occur.
Was there any severe damage which affects function?
1.
2.
3.
4.
5.
6.

Does DTC P0404 still fail DTC test on the Tech 2?
Verify repair
Go to Step 7
Reconnect.
Ignition OFF.
Install the Tech 2.
Run the engine at idle.
On the Tech 2, select EGR control test.
Use the UP arrow to increase the EGR from 0% to
40%.
Did EGR work properly?

8
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2222
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage
D06RW055
Circuit Description

responds properly to command from the PCM. If current
pintle position voltage indicates less than 0.1 V and last
more than 10 seconds, then the PCM will set DTC P0405.

feed.

D Ignition voltage is between 11 and 16 volts.
D EGR pintle position output voltage is less than 0.1 volt
and last more than 10 sec. Action taken when the DTC
sets.

(MIL) as soon as failure detected.
Records data.
Diagnostic Aids
6E2223
DTC P0405 EGR Low Voltage

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
Go to Step 4
Go to Step 5
Verify repair
46 V
Go to Step 6
Go to Step 7
55.5 KW
Go to Step 10
Go to Step 17
46 V
Go to Step 8
Go to Step 18
Verify repair
Verify repair
1 to 1.25 KW
Go to Step 13
Go to Step 17
1. Ignition ON.
2. Backprobe with a DVM to measure voltage at EGR
valve pintle position pin and sensor ground pin.
Less than 0.1
Was voltage in range?
V
Go to Step 17
Go to Step 12

ignition?

pin or terminals.

1. Disconnect the EGR harness connector.

2. Ignition ON.
3. At the EGR valve, use a DVM to check the voltage
at the 5 volt reference wire (RED) and ground (B).

2. Measure resistance between terminal B and D.
Was resistance in range?
1. Ignition ON.
2. At the PCM connector, backprove with a DVM at the
5 volt reference for the EGR valve.
Repair the open 5 volt reference circuit.

Repair the damaged sensor ground wire.

10
No
Go to OBD
System
Check

performed?
Yes
1. Disconnect the EGR harness

2. Use an ohmmeter to measure between the pintle
position pin and the sensor ground pin on the EGR
valve.
NOTE: J-35616 Connector Test Adapter Kit may be
useful for gaining access to the recessed pins on the
valve.
Was the ohmmeter reading approximately equal to the
specified value?
11
6E2224
DTC P0405 EGR Low Voltage (Cont'd)

Step
12
13
Action
1. Ignition ON.
2. Backprobe with a DVM to measure voltage at PCM
sensor ground pin and pintle position pin.
Less than 0.1
Was voltage in range?
V
16
Go to Step 13
Go to Step 18
Go to Step 14
Go to Step 18
Verify repair
Go to Step 17
Go to Step 16
Repair short
circuit
Verify repair
Go to Step 17
Go to Step 18
Verify repair
Go to Step 4
Go to Step 19
Verify repair
1.
2.
3.
4.
Ignition OFF.
Disconnect the PCM.
Ignition ON.
Measure the voltage between the EGR pintle
position circuit and ground.
Less than 0.1
V
Is the measured voltage near the specified value?
Check for a short circuit between other wires and the
pintle position circuit
Is there any short circuit?
17

18
Examine the PCM pin and terminal connection.

Was there a damaged terminal?
19
No
Locate and repair the short to ground in the pintle

position circuit
15
Yes
1. Ignition OFF.
2. Disconnect the EGR harness.
3. Check short circuit between EGR pintle position
circuit and EGR ground circuit.
Was any short circuit?
14
Value(s)
Replace the PCM.

6E2225
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage
D06RW055
Circuit Description

responds properly to command from the PCM. If current
pintle position voltage indicates more than 4.8 V and last
more than 10 seconds, then the PCM will set DTC P0406.

feed.

D Ignition voltage is between 11 and 16 volts.
D EGR pintle position output voltage is more than 4.8 volt
and last more than 10 sec.

(MIL) as soon as failure detected.
Records data.
Diagnostic Aids
6E2226
DTC P0406 EGR High Voltage

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
Go to Step 4
Go to Step 5
Verify repair
Is the action
complete?
46 V
Go to Step 8
Go to Step 6
46 V
Go to Step 7
Go to Step 16
Verify repair
5 to 5 KW
Go to Step 9
Go to Step 15
Go to Step 15
Go to Step 10
Go to Step 14
Go to Step 11

ignition?

pin or terminals.


2. Ignition ON.
3. At the EGR valve, use a DVM to check the voltage
at the 5 volt reference wire (RED).
1. Ignition ON.
2. At the PCM connector, backprove with a DVM at the
5 volt reference for the EGR valve.
Did the DVM indicare the specified value?
Repair the open 5 volt reference circuit

No
Go to OBD
System
Check

performed?
Yes
1. Ignition OFF
3. Use a DVM to check for an resistance between D (5
V reference) and B (Sensor Ground) at EGR sensor
terminals.
NOTE: J-35616 Connector Test Adapter Kit may be
useful for gaining access to the recessed pins on the
valve.
Was the measured resistance in range?
1. Ignition OFF.
3. Use a DVM to check for an resistance between B
and C at EGR sensor terminal.
Is there an open circuit?
10
1. Ignition OFF.
2. Disconnect the EGR harness at PCM connector.
3. Use a DVM to check for shorted wire between A1
and B7.
Is there a shorted wire?
6E2227
DTC P0406 EGR High Voltage (Cont'd)

Step
11
12
Action
1. Ignition ON.
2. Use a DVM to backprove at terminal C of EGR
valve for voltage.
more than 4.8
Was measured voltage more than 4.8 V?
V
Go to Step 12
4.8 V
Go to Step 16
Go to Step 13
Verify repair
Verify repair
Go to Step 16
Verify repair
Verify repair

16
Go to Step 12
Replace EGR harness.

15
No
1. Locate short circuit at EGR harness between RED

to RED or GREEN, RED to YEL.
2. Replace EGR harness.
14
Yes
1. Ignition ON.
2. Stay the EGR harness connected.
3. Check voltage by backproving at PCM B7 terminal.
Was voltage more than 4.8 V?
13
Value(s)
Replace the PCM.

6E2228
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input
D06RX021
Circuit Description
effect circuit the interacts with the magnetic field treated
by the rotating magnet. A 12-volt operating supply for the
The VSS pulses to ground the 9-volt signal sent from the
powertrain control module (PCM) on the reference circuit.
The PCM interprets vehicle speed by the number of

D
D
D
D
D
D
Engine is running.
Throttle angle is between 10% and 40%.
Engine load is greater than 50 kPa.
MAP sensor indicates greater than 50 kPa manifold
pressure.
D PCM detects no VSS signal for 12.5 seconds over a

period of 25 seconds.


feed.
Test Description
Diagnostic Chart.
9. To avoid backprobing the VSS and possibly
damaging a seal or terminal, the VSS output can be
tested at the point where the transmission harness
connected to the engine harness. The green 16-way
connector is adjacent to a blue 16-way connector,
and it can be easily accessed by removing the air
cleaner assembly. The green 16-way connector is
separated, and battery voltage is applied to the VSS
through the yellow wire at one corner of the
connector. The VSS output can be monitored with a
DVM connected to the blue wire with a black tracer.
The two wires are next to each other in the 16-way
connector . The test connections are made on the
transmission side of the connector, the side that is
not clipped to the body sheetmetal.
6E2229
14. The speedometer-to-PCM VSS signal wire is

spliced to a wire leading to the cruise control
module. If a short to ground or voltage is found
between the PCM and speedometer, it could be
located between the splice and the cruise control
module.

Step
Action
Does the speedometer work?

2. Ignition ON.
ground wire.

2. Using a DVM, measure at the VSS connector
between ground and voltage supply.
Go to Step 10
Go to Step 3
Go to Step 5
Go to Step 4
Verify repair
Battery
voltage
Go to Step 7
Go to Step 6
Verify repair
7.5-8 V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Check for an open or short circuit between the

speedometer and the VSS.
Was an open or short circuit located?
Go to Step 2
1. Ignition ON, VSS disconnected.

2. Using a DVM, measure at the VSS connector
between ground and the blue/black wire from the
speedometer.
Go to OBD
System
Check
Repair the open or short to ground which may have

blown the meter fuse.
No
Repair the sensor ground.

Yes

performed?
Value(s)
Replace the speedometer.

6E2230
DTC P0502 VSS Circuit Low Input (Cont'd)

Step
Action
10
1. Ignition OFF.
2. Disconnect the MAF sensor. The connector
attaches the VSS wires from the transmission
harness to the left-side engine harness.
3. Disconnect the green 16-way connector.
4. Select a terminal adapter from kit 5-8840-0385-0
that can be used with a jumper to supply B+ to the
yellow (transmission side of the connector). There
are 2 yellow wires at that connector, but the correct
one is in the corner position.
5. Use another terminal adapter to attach a voltmeter
to the blue wire with a black tracer (next to the wire in
the previous step.)
6. At the transmission side of the green 16-way
connector, locate the black wire next to the VSS
yellow ign+ wire. The black wire is the VSS ground
wire. Use a terminal adapter to attach a jumper to
ground to the black VSS ground wire at the
transmission side of the connector.
7. Raise the rear wheels off the ground with
transmission in neutral.
Does the DVM toggle back and forth between 0.6 V and
10 V as the wheels (and driveshaft) are rotated?
11
No
Go to Step 12
Go to Step 11
Verify repair
Verify repair
Go to Step 13
Verify repair
Check for an open or short between the PCM and the

speedometer.
13
Yes
Replace the VSS.

12
Value(s)
Replace the PCM.

6E2231
Diagnositc Troule Code (DTC) P0562 System Voltage Low
D06RX022
Circuit Description
The powertrain control module (PCM) monitors the

system voltage on the ignition feed terminal to the PCM.
A system voltage DTC will set whenever the voltage is
below a calibrated value.

feed.

D Ignition ON.
D System voltage is below 11.5 volts for 15 minutes.

D The PCM will not illuminate the malfunction indicator
lamp (MIL).
D The PCM will store as Failure Records conditions
which were present when the DTC was set. This
Diagnostic Aids
If the DTC sets when an accessory is operated, check for
a poor connection or excessive current draw.
6E2232
DTC P0562 System Voltage Low

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Charge
battery, then
go to Step 3
2000 RPM
12.8-14.1 V
Go to Step 4
Go to
Starting/Char
ging
Check for
excessive
current draw
with ignition
OFF, engine
OFF.
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Using a DVM, measure the battery voltage at the

battery.
1. Ignition OFF.
2. Disconnect the PCM connector at the PCM.
3. Using a DVM, measure the battery voltage at the
PCM connector A-4.
Is it approximately equal to battery voltage?
1. Check for faulty connections at the PCM harness

terminals.
2. Repair as necessary.
Check for an open battery feed circuit to the PCM.

11.5 V
2. Select Ignition Volts on the Tech 2.
3. Start the engine and raise the engine speed to the
specified value.
4. Load the electrical system by turning on the
headlights, high blower, etc.
Is the ignition voltage approximately equal to the
specified value?
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2233
Diagnostic Trouble Code (DTC) P0563 System Voltage High

Circuit Description
The powertrain control module (PCM) monitors the
system voltage on the ignition feed terminals to the PCM.
A system voltage DTC will set whenever the voltage is
above a calibrated value.
D The PCM will store as Failure Records only conditions

which were present when the DTC was set. This
D Ignition ON.
D System voltage is above 16 volts for 15 minutes.

feed.
Diagnostic Aids

lamp (MIL).
If the DTC sets when an accessory is operated, check for

a poor connection or defective accessory.

Step
Action
Go to Step 2
Go to OBD
System
Check
11.5 V
Go to Step 3
Go to Step 4
11.5 V
Replace
battery
Go to Step 4
2000 RPM
Go to
Starting/Char
ging
Go to Step 5
Verify repair

1.
2.
3.
4.
Turn OFF all the accessories.

Install a Tech 2.
Select the ignition voltage parameter on the Tech 2.
Start the engine and raise the engine RPM to the
specified value.
Is the voltage more than 2.5 volts greater than the

measurement taken in step 2 or 3?
5
No
Using a DVM, measure the battery voltage at the

battery.
Is the battery voltage less than the specified value?

4
Yes

performed?
Is the battery voltage less than the specified value?

3
Value(s)
Replace the PCM.

6E2234
Diagnostic Trouble Code (DTC) P0601 PCM Memory

Circuit Description
The powertrain control module (PCM) used in this vehicle
utilizes an electrically erasable programmable read-only
is not replaceable.

D The PCM detects an internal program fault (check sum
error).

when the DTC was set in the Failure Records data only.

feed.

lamp (MIL).
DTC P0601 PCM Memory

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
Verify repair

performed?
Replace the PCM.
6E2235
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean Dueing Acceleration
D06RX141
Circuit Description
The powertrain control module (PCM) internal circuitry
can identify if the vehicle fuel system is capable of
supplying adequate amounts of fuel during heavy
acceleration (power enrichment). The PCM monitors the
voltage of the oxygen sensor during power enrichment.
When a power enrichment mode of operation is
requested during closed loop operation (by heavy
acceleration), the PCM will provide more fuel to the
engine. Under these conditions the PCM should detect a
rich condition (high oxygen sensor voltage). If this rich
exhaust is not detected at this time, a DTC P1171 will set.
A plugged fuel filter, restricted fuel line, restricted in-tank
filter or defective fuel pump can prevent adequate amouts
of fuel from being supplied during power enrichment
mode.

D No related DTCs.
D Engine is operating in closed loop power enrichment

mode for 3 seconds.
D While in power enrichment mode the oxygen sensor

(MIL) the first the fault is detected.

6E2236

feed.
Diagnostic Aids
D A restricted fuel filter or fuel line, restricted in-tank filter,
or a defective fuel pomp may supply adequate
Test Description
Diagnostic Chart.
approximately 100 mV to 900 mV. It is possible to
measure a satisfactory fuel pressure at idle even
though the pressure may drop at high flow
requirements. It may be necessary to watch fuel
pressure at high engine load.
leakage that may occur when installing gauge.
Ignition ON, pump pressure should be
280-320kPa.
6E2237

Step
Action
Go to Step 2
Go to
component
DTC charts
Go to Step 3
Go to Step 4
Go to Step 5
100-900 mV
Go to Fuel
System
Diagnosis
Go to Step 5
280-325 kPa
(41-46 psi)
Go to OBD
System
Check
Go to Step 6
Verify repair
Go to Step 7
Go to
Diagnostic
Aids
Go to Step 8
Verify repair
1. Place the transmission in park.

running warm engine 75C-95C (167F-203F) at
1200 RPM.
range.
4. Quickly open the throttle halfway for a few seconds.

temperature.
pressure regulator.
Check for restricted fuel lines or restricted in-line filter.


amount of fuel.
empty.

specified range?
6
1. Ignition OFF.
2. Remove the fuel pump relay and replace it with a
fused jumper which will connect the relays battery
terminal to the terminal leading to the fuel pump
fuse.
3. While the fuel pump is operating, use pliers to slowly
close the return line (do not exceed the first
specified value).
Using the pliers to restrict the return line, can the fuel 414 kPa (60
pressure be manipulated to exceed the second psi) 325 kPa
(46 psi)
specified value?
No
Go to OBD
System
Check
Are any component-related DTCs set?
Did the voltage suddenly rise toward the high end of the
specified range?
5
Yes

performed?

4
Value(s)
Check for:
D Faulty fuel pump
D Hot fuel
6E2238
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault
Circuit Description
The powertrain control module (PCM) monitors ABS fault

signal. When PCM receives fault signal, PCM will set
DTC P1380.

D DTC 1380 can be cleared by using Tech-II or
disconnecting the PCM battery feed.

D
D
D
D
D
D
D
Vehicle speed is more than 5 mph.

Load is less than 99%.
Engine revolution is less than 6250 rpm.
PCM receives ABS fault signals from ABS unit.
Ignition on.
Misfire DTCs exist.
100 test failures within 120 test samples.
Diagnostic Aids
D PCM and ABS communication line short circuit to other
line may cause faulty signal. Inspect communication
line.
D Follow ABS ECU diagnosis procedure, refer to ABS
procedure page.

D The PCM will store DTC 1380 only, no MIL turn on.
DTC P1380 ABS Rough Road ABS System Fault

Step
Action
No
Go to OBD
System
Check
Go to Step 2
Refer to ABS
diagnosis
After inspecting
ABS, repeat
Step 2
If problem still
exists, go to
Step 3
Clear DTC by
Tech 2
Repair wiring
Verify repair
Go to Step 4
Verify repair

Note the result.
Check short circuit among communication line of

PCM/ABS and others.
Does short circuit exist?
Yes

performed?
Does the Tech 2 indicates DTC P1380 DTCs failed this

ignition?
3
Value(s)
Replace the PCM.

6E2239
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link
Error
Circuit Description
The powertrain control module (PCM) monitors no ABS

signal. When PCM does not receive ABS signal, PCM will
set DTC P1381.
D A history code DTC P1381 will clear after 40

consecutive warm-up cycles have occurred without a
fault.
D DTC P1381 can be cleared by Tech-II or by
disconnecting the PCM battery feed.

D
D
D
D
D
D
D
PCM does not receive ABS signals from ABS ECU.

Vehicle speed is more than 0 mph.
Load is less than 99%.
Engine revolution is less than 6250rpm.
2.5 second after key on.
Misfire DTCs exist.
100 test failures within 120 test samples.
Diagnostic Aids
D Inspect open circuit of communication wire between
ABS ECU and PCM.
D Follow ABS ECU diagnosis procedure.
D The PCM will store DTC 1381 only, MIL on.
DTC P1381 ABS Rough Road Class 2 Serial Link Error

Step
Action
No
Go to OBD
System
Check
Go to Step 2
Refer to ABS
diagnosis
After inspecting
ABS, repeat
Step 2
If problem still
exists, go to
Step 3
Clear DTC by
Tech 2
Repair wiring
Verify repair
Go to Step 4
Verify repair

3. Using a Tech 2, monitor DTC inf. for DTC P1381.
Note the result.
Check open circuit among communication line of

PCM/ABS and others.
Does short circuit exist?
Yes

performed?
Does the Tech 2 indicates DTC P1381 DTCs failed this

ignition?
3
Value(s)
Replace the PCM.

6E2240
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed
D06RW055
Circuit Description

responds properly to commands from the PCM, and to
detect a fault if current pintle zero position is different from
the learned zero position. If the PCM detects a pintle
position signal indicates more than 30 % different
between current zero position and the learned zero
position for more than 5 seconds, and this condition exists
3 times during trip, then the PCM will set DTC P1404.

feed.

D Excessive carbon deposit on EGR valve shaft and/or
foreign material may cause the EGR valve not to fully
seated. The carbon deposit may occur by unusual port
operation. Remove foreign material and/or excessive
carbon deposit on EGR valve shaft may allow the EGR
valve to be fully seated.
wiring harness for damage.
D
D
D
D
Ignition voltage is between 11 and 16 volts.

Intake Air temp is more than 3C.
Desired EGR position is 0.
Difference of EGR pintle position between current and
the learned zero is more than 30 % for more than 5
seconds, and exists three time to the above condition
during a trip the PCM will set DTC 1404. Then it trigger
the PCM lights on.

(MIL) after consecutive 2nd trip in which the fault is
detected.
Records data.
Diagnostic Aids
6E2241
DTC P1404 EGR Stuck Closed

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
Go to Step 4
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Verify repair
Verify repair

3. Using a Tech 2, monitor DTC inf. for DTC P1404
ignition?

pin or terminals.

1. Remove EGR valve from Engine.

2. Inspect EGR valve for is any excessive carbon
deposit on EGR shaft.
3. Inspect for any foreign material inside of EGR valve.
Was excessive carbon deposit on EGR valve shaft
and/or foreign material in EGR valve ?
1. Clean up EGR valve shaft and inside of EGR valve.

2. Remove foreign material from EGR valve.
3. Visually inspect damage of pintle and seat to see if it
is bent If damaged leakage may occur.
Was there any severe damage which affects function?
1.
2.
3.
4.
5.
6.
1. Reset the learned zero EGR valve position.

2. Repeat step 7.

10
Verify repair
Go to Step 7
Install the EGR valve.

Ignition OFF.
Install the Tech 2.
Run the engine at idle.
On the Tech 2, select EGR control test.
Use the UP arrow to increase the EGR from 0% to
40%.

8
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2242
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM
T321115
Circuit Description
idle speed by adjusting the position of the idle air control
(IAC) motor pintle. The IAC is a bi-directional stepper
motor driven by two coils. The PCM applies current to the
IAC coils in steps (counts) to extend the IAC pintle into a
PCM reverses the current to retract the pintle, increasing
the PCM detects a condition where too low of an idle
speed is present and the PCM is unable to adjust idle
indicating a problem with the idle control system.

D None of these DTCs are set: TP sensor, VSS, ECT,
EGR, fuel system, MAF, MAP, IAT, canister purge,
injector control or ignition control.
(120F).
D Vehicle speed is less than 1 mph.
D The engine has been running for at least 125 seconds.
D Ignition voltage is between 9.5 volts and 16.7 volts.
D Engine speed is lower than desired idle.
D Engine speed is more than 100-200 RPM lower than

desired idle, based upon coolant temperature.
D All of the above conditions are met for 5 seconds.

fault is detected.

feed.
Diagnostic Aids
damaged terminals, and poor terminal-to-wire
connection.
D Damaged harness Inspect the wiring for damage.

collapsed air intake duct, restricted air filter element,
or foreign objects blocking the air intake system.
6E2243
faulty PCV valve or a disconnected brake booster

hose.
DTC P1508 IAC System Low RPM

Step
Action
Value(s)
No
Go to Step 2
Go to OBD
System
Check
50 RPM
No trouble
found. Go to
Diagnostic
Aids
Go to Step 3
Go to Step 5
Go to Step 4
Verify repair
Go to Step 8

performed?
2. Turn all accessories OFF(A/C, rear defroster,
etc).
500, and then up to 1500 while monitoring the
Engine Speed on the Tech 2.
NOTE: This Tech 2 command may cause the engine to
cut out when RPM goes above 1500. If this occurs,
the cutting out will stop when the Tech 2 command for
the test is discontinued, or if the Tech 2 command is
changed to less than 1500 RPM.
value of the Desired Idle for each RPM command?
Yes
1. Disconnect the IAC.

2. Install IAC Noid Light 5884023120 or
equivalent.
3. With the engine running, command RPM up to
1500, down to 500, and then up to 1500 while
observing the noid light.
Does each noid light cycle red and green (never
OFF)?

voltage, short ground, or poor connections at the
PCM:
D IAC A Low.
D IAC A High.
D IAC B Low.
D IAC B High.
2. If a problem is found, repair as necessary,
6E2244
DTC P1508 IAC System Low RPM (Cont'd)

Step
Action
Visually/physically inspect for following conditions:

system.
throttle plate.
No
Refer to
appropriate
section for
on-vehicle
service
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Verify repair

Yes

connector.
necessary.
Value(s)
Replace the PCM.

6E2245
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM
T321115
Circuit Description
D All of the above conditions are met for 5 seconds.

idle speed by adjusting the position of the idle air control
(IAC) motor pintle. The IAC is a bi-directional stepper
motor driven by two coils. The PCM applies current to the
IAC coils in steps (counts) to extend the IAC pintle into a
PCM reverses the current to retract the pintle, increasing
the PCM detect a condition where too high of an idle
speed is present and the PCM is unable to adjust idle
indicating a problem with the idle control system.

D None of these DTCs are set: TP sensor, VSS, ECT,
EGR, fuel system, MAF, MAP, IAT, canister purge,
injector control or ignition control.
D Engine speed is more than 100-200 RPM higher than
desired idle, based upon coolant temperature.
D The engine has been running for at least 125 seconds.
D Vehicle speed is less than 1 mph.
D Ignition voltage is between 9.5 volts and 16.7 volts.
D Engine speed is higher than desired idle.

fault is detected.

feed.
Diagnostic Aids
damaged terminals, and poor terminal-to-wire
connection.
D Damaged harness Inspect the wiring for damage.
hoses, leaks at the EGR valve and the EGR pipe to the
6E2246
intake manifold, leaks at the throttle body, faulty or

incorrectly installed PCV valve, leaks at the intake
manifold, etc.
keep the IAC pintle from fully extending.

DTC P1509 IAC System High RPM

Step
Action
Value(s)
No
Go to Step 2
Go to OBD
System
Check
50 RPM
No trouble
found. Go to
Diagnostic
Aids
Go to Step 3
Go to Step 5
Go to Step 4
Verify repair
Go to Step 8

performed?
2. Turn all accessories OFF (A/C, rear defroster,
etc.).
Yes
1. Disconnect the IAC.

2. Install IAC Noid Light 5884023120 or
equivalent.
3. With the engine running, command RPM up to
1500, down to 500, and then up to 1500 while
observing the noid light.
Does each noid light cycle red and green (never
OFF)?

voltage, short ground, or poor connections at the
PCM:
D IAC A Low.
D IAC A High.
D IAC B Low.
D IAC B High.
2. If a problem its found, repair as necessary.
6E2247
DTC P1509 IAC System High RPM (Cont'd)

Step
Action

D Vacuum leaks.
valve.
No
Refer to
appropriate
section for
on-vehicle
service
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Verify repair

Yes

connector.
necessary.
Value(s)
Replace the PCM.

6E2248
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset

Circuit Description
The powertrain control module (PCM) monitors

unexpected PCM reset. This will not turn on MIL light on,
only records code DTC P1625.

D DTC P1625 can be cleared by disconnecting the PCM
battery feed.


lamp (MIL).
Diagnostic Aids
DTC code.
DTC P1625 PCM Unexpected Reset

Step
Action
Value(s)
1.
2.
3.
4.
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Go to Step 4
Go to
Diagnostic
Aids
Verify repair
Ignition is ON.
Install the Tech 2.

3
1.
2.
3.
4.
Ignition is ON.
No
Go to OBD
System
Check

performed?
Yes

transceiver, stereos, and anti theft devices. May
radiate EMI into the control system if they are
improperly installed. (This may cause a false sensor
reading and turn on the MIL.)
6E2249
Diagnostic Trouble Code (DTC) P1640 Output Driver Module (ODM) A Fault
lamp (MIL).

feed.
Diagnostic Aids
damage, If the harness appears to be OK, disconnect
the PCM, turn the ignition ON and observe a
voltmeter connected to the suspect driver circuit at the
PCM harness connector while moving connectors and
wiring harnesses relates to the MIL. A change in
D Poor connection at component Examine for
damaged connectors, unplugged connector, or
damaged terminals at the following locations: canister

purge solenoid, Fuel level check.
The following PCM pins are controlled by

D
D
D
D
D
A13 MIL (Check Engine)

A14 Check T/M or Up-Shift
A15 EVAP Canister Purge
A16 Band Apply (4L30E)
B14 A/C Clutch
Test Description
Diagnostic Chart.
4. The Tech 2 Driver Module Status indicates the PCM
11.A short to ground on the ignition side of the
between the affected component and the PCM.

Step
Action
Go to Step 2
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
Were either of the lamp circuits for Check Engine or

Check Trans. indicated as faulty by the Tech 2?
Go to Step 7
Go to Step 13
faulty.
repairs.
driver circuit.
Is there any damage to the PCM pin or connector?
5
6
No
Go to OBD
System
Check

4
Yes

performed?
Was the fuse blown?

3
Value(s)
6E2250

Step
Action
Go to Step 9
Verify repair
Go to Step 11
Go to Step 12
Verify repair
Verify repair
B+
Go to Step 15
Go to Step 14
Go to Step 10
Go to Step 9
Verify repair

circuit.
15
Go to Step 10
1. Connect the PCM.

3. Backprobe the affected terminal at the PCM with a
DVM.
14
Repair the open circuit between the fuse and the PCM
13
Go to Step 8

component and its PCM driver terminal.
12
Go to Step 15
1. Ignition OFF.
driver terminal.
the PCM connector for the affected driver.
11
B+

the fuse.
10
No
1. Ignition ON.
lamp circuit.
Yes
1. Leave the PCM connector for the lamp driver circuit

disconnected.
2. Ignition ON.
3. Using a DVM, check the voltage at the PCM
Value(s)
Replace the PCM.

Symptom Diagnosis
Preliminary Checks
following items:
D The powertrain control module (PCM) and
malfunction indicator lamp (MIL) (Check Engine
lamp) are operating correctly.
Visual/Physical Check
time.
This check should include the following items:
D PCM grounds for cleanliness, tightness and proper
location.
D Air leaks at throttle body mounting area, mass air flow
(MAF) sensor and intake manifold sealing surfaces.
D Ignition components for cracking, hardness, and
carbon tracking.
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
check.
Road test the vehicle with a 5-8840-0285-0 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 a Tech 2 to help detect intermittent conditions. The
scan tool has several features that can be used to locate
6E2251
an intermittent condition. Use the following feature to find

intermittent faults:
D Using a Tech 2s Freeze Frame buffer or Failure
the MAP sensor and idle the engine until the MIL (Service
Engine Soon lamp) comes on. DTC P0107 should be
stored and kept in memory when the ignition is turned
OFF. If not, the PCM is faulty. When this test is
completed, make sure that you clear the DTC P0107 from
memory.
DTC may be caused by the following:
wires or plugs.
D MIL (Check Engine lamp) wire to PCM shorted to
ground.
D Poor PCM grounds. Refer to the PCM wiring
diagrams.
PCM to the ignition coils for poor connections.
If problem has not been found, refer to PCM Connector
Symptom tables.
6E2252
Hard Start Symptom

Step
Action
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Go to Step 9
Go to Step 5
Go to Step 7
Go to Step 6
Verify repair
Verify repair
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12

shift in value. After 8 hours with the hood up and the
engine not running, connect the Tech 2. With the
ignition ON and the engine not running, compare
engine coolant temperature to intake air temperature.
5C ( 9F)
other?

temperature sensor.
3. Refer to Engine Coolant Temperature Sensor
Temperature vs. Resistance chart on DTC P0118
Diagnostic Support for resistance specifications.
Is the resistance value near the resistance for the
temperature noted?

Locate and repair high resistance or poor connection in

the ECT signal circuit or the ECT sensor ground.
1. Check for a faulty, plugged, or incorrectly installed

PCV valve.
1. Check for water-or alchol-contaminated fuel.

10
1. Perform the procedure in Fuel System Pressure

Test.
11
No

Yes
DEFINITION:
performed?
Value(s)
1. Check for proper ignition voltage output with spark

tester 5-8840-0383-0. Refer to Electric Ignition
System for procedure.
6E2253
Hard Start Symptom (Cont'd)

Step
Action
12
1. Remove spark plugs. Check for wet plugs, cracks,

wear, improper gap, burned electrodes, or heavy
deposits. Refer to Electronic Ignition System.
Value(s)
Yes
No
NOTE: If spark plugs are gas or oil fouled, the cause of

the fouling must be determined before replacing the
spark plugs.
13
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Contact
Technical
Assistance
1. Check for a loose ignition coil ground.

Refer to Electronic Ignition System.
14
1. Remove the ignition coils and check the ignition

coils for cracks or carbon tracking.
2. If a problem is found, replace affected coil(s) as
necessary.
15
1. Check IAC operation. Perform the procedure in the

DTC P1508, 1509, Step 5 diagnostic table.
16

problems (refer to Engine Mechanical):
D Low compression
17

following:
D Tech 2 data
6E2254
Surges and/or Chuggles Symptom

Step
Action
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
System OK
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 10
Verify repair
Go to Step 10
Verify repair
Be sure that the driver understands transmission

torque converter clutch and A/C compressor operation
as explained in the owners manual.
Inform the customer how the TCC and the A/C clutch
operate.
No

Yes
DEFINITION:
Feels like the vehicle speeds up and slows down with
no change in the accelerator pedal.
performed?
Value(s)
1. Check the the fuel control heated oxygen sensors

(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they dont, check them
for silicone or other contaminants from fuel or use of
white powdery coating.
Silicone contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to Powertrain Control Module (PCM) and Sensors.

Pressure Test.
Monitor the long term fuel trim on the Tech 2.

Is the long term fuel trim significantly in the negative
range (rich condition)?

Support.

6E2255
Surges and/or Chuggles Symptom (Cont'd)

Step
Action
10

tester 5-8840-0383-0. Refer to Electric Ignition
11
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 14
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18

Refer to Electric Ignition System.
12
1. Check the ignition coils for cracks or carbon

tracking.
13
1. Remove the spark plugs and check for wet plugs,

cracks, wear, improper gap, burned electrodes, or
heavy deposits.
Refer to Electronic Ignition
System.
spark plugs.
14
1. Check the injector connections.

2. If any of the injector connectors are connected to an
incorrect cylinder, correct as necessary.
15
1. Check PCM grounds for the cleanliness, tightness

and proper locations. Refer to the PCM wiring
diagrams in Electrical Diagnosis.
16
1. Check MAF sensor connections.

2. If a problem is found, replace the faulty terminals as
necessary. Refer to Electrical Diagnosis for wiring
repair procedures.
17
1. Visually/physically check vacuum hoses for splits,

kinks, and proper connections and routing as
Information label.
6E2256
Surges and/or Chuggles Symptom (Cont'd)

Step
Action
18
1. Check the exhaust system for possible restriction:

D Inspect the exhaust system for damaged or
collapsed pipes.
D Inspect the muffler for heat distress or possible
internal failure.
D Check for a possible plugged three-way
catalytic converter by checking the exhaust
system back pressure. Refer to Restricted
19
Value(s)
Yes
Verify repair
Go to Step 19
Verify repair
Contact
Technical
Assistance

following:
D Tech 2 data
No
6E2257
Lack of Power, Sluggish or Spongy Symptom

Step
Action
Verify repair
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
1. Using a Tech 2, monitor the knock sensor (KS)

system for excessive spark retard activity. Refer to
Knock Sensor (KS) System.
3. On the Tech 2, select F3: Miscellaneous Test, F6:
Variable Intake Manifold.
4. Repeat Switch ON or OFF of VIM solenoid valve by
using the Tech 2.
5. Check the working solenoid sound if the actuator
works normally.
1. Check for water-or alcohol-contaminated fuel.


7
Go to Step 2

restrictions.
Refer to Air Intake System in
On-Vehicle Service.

6
Go to OBD
System
Check
Was a repair required?

5
No

Yes
DEFINITION:
increase in speed when accelerator pedal is pushed
down part-way.
performed?
Value(s)

tester 5-8840-0383-0. Refer to Electronic Ignition
6E2258
Lack of Power, Sluggish or Spongy Symptom (Cont'd)

Step
Action
Value(s)
Yes
No
1. Remove the spark plugs and check for wet plugs,

heavy deposits.
System.
spark plugs.
10
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Contact
Technical
Assistance
1. Check for an engine mechanical problem. Check

for low compression, incorrect or worn camshaft,
loose timing belt, etc. Refer to Engine Mechanical.
15
Verify repair
1. Check the torque converter clutch (TCC) for proper

operation.
Refer to 4L30E Transmission
Diagnosis.
14

collapsed pipes.
internal failure.
13
Go to Step 10
1. Check the PCM grounds for the cleanliness,

tightness and proper locations. Refer to the PCM
wiring diagrams in Electrical Diagnosis.
12
Verify repair

tracking.
11

following:
D Tech 2 data
6E2259
Detonation/Spark Knock Symptom

Step
Action
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Go to Step 5
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10

D Correct coolant solution should be a 50/50 mix
of approved antifreeze/coolant and water.
1. Check fuel a leak.
Verify repair
1. Check TCC operation.

Refer to 4L30-E
Transmission Diagnosis.

8
1. Check the transmission range switch circuit. Use a

Tech 2 and be sure the Tech 2 indicates that the
vehicle is in drive with the gear selector in drive or
overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).

7
Go to Step 2
If Tech 2 readings are normal (refer to Typical Scan

Values) and there are no engine mechanical faults, fill
the fuel tank with a known quality gasoline that has a
minimum octane rating of 87 and re-evaluate the
vehicle performance.

6
Go to OBD
System
Check
5
No

Yes
DEFINITION:
performed?
Value(s)
1. Check items that can cause an engine to run lean

(long term fuel trim significantly in the positive
range). For a lean condition, refer to Diagnostic
Aids in DTC P0171 Diagnostic Support.
6E2260
Detonation/Spark Knock Symptom (Cont'd)

Step
Action
10
1. Spark plugs for proper heat range. Refer to General

Information.
2. If incorrect spark plugs are installed, replace spark
plugs as necessary.
Did any spark plugs require replacement?
11
No
Verify repair
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Verify repair
Contact
Technical
Assistance
1. Check for an engine mechanical problem. Perform

a cylinder compression check. Refer to Engine
Mechanical.
13
Yes

cleaner can.
2. Re-evaluate vehicle performance.
12
Value(s)

following:
D Tech 2 data
6E2261
Rough, Unstable, or Incorrect Idle, Stalling Symptom

Step
Action
Go to Step 2
Go to Step 13
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Go to Step 9

Go to Step 8
Go to Step 9
Verify repair
Go to Step 9
Between 10
and 50
counts
Go to Step 11
Go to Step 10

1. Check the PCM grounds for cleanliness, tightness

and proper routing. Refer to the PCM wiring
Observe the long term fuel trim on the Tech 2.

7
8

Support.

Support.
No
Go to OBD
System
Check

3
Yes
DEFINITION:
vehicle may shake. Engine idle speed may vary in
RPM. Either condition may be severe enough to stall
the engine.
performed?
Value(s)

D The engine is fully warm.
D The accessories are OFF.
6E2262
Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont'd)

Step
Action
10

conditions:
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
D Throttle body. Check for objects blocking the
IAC passage or throttle bore, excessive
deposits in the IAC passage and on the IAC
pintle, and excessive deposits in the throttle
bore and on the throttle plate.
D Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty crankcase
ventilation valve or a disconnected brake
booster hose.
11
Verify repair
Go to Step 8
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17

System for the procedure.
15

hose.
assembly. Refer to Fuel Metering System.
14
No
1. Perform the Injector Coil/Balance Test in Fuel

Metering System.
13
Yes

necessary.
12
Value(s)

spark plugs.
16

Refer to Electrical Ignition System.
6E2263
Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont'd)

Step
Action
17
1. Check ignition coils for cracks or carbon tracking.

18
Verify repair
Go to Step 18
0%
Go to Step 19
Refer to DTC
P0123 for
further
diagnosis
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Verify repair
Contact
Technical
Assistance

overdrive.
21
No
1. Check the positive crankcase ventilation (PCV)

valve for proper operation. Refer to Crankcase
Ventilation System.
20
Yes
Using a Tech 2, monitor the throttle position (TP) angle

with the engine idling.
19
Value(s)
1. Check for the following engine mechanical items.

Refer to Engine Mechanical for diagnosis
procedures:
D Low compression
D Worn camshaft lobe(s)
D Worn rocker arms
22

23

following:
D Tech 2 data
6E2264
Poor Fuel Economy Symptom

Step
Action
Verify repair
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Go to Step 5
Go to Step 6
System OK
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10

Information label.
1. Remove and check the air filter element for dirt or for
restrictions. Refer to Air Intake System.


7
Go to Step 2


6
Go to OBD
System
Check

5
No

Yes
DEFINITION:
as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be
incorrect, and that may cause fuel economy to appear
poor when it is actually normal.)
performed?
Value(s)
1. Remove spark plugs and check for wet plugs,

heavy deposits. Refer to Spark Plug Replacement.
spark plugs.
1. Check for low engine coolant level. Refer to Engine

Cooling.
6E2265
Poor Fuel Economy Symptom (Cont'd)

Step
Action
10
1. Check for an incorrect or faulty engine thermostat.

11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Go to Step 16
Go to Step 15
Verify repair
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Contact
Technical
Assistance
Verify repair

2. When all procedures have been completed and no
following:
D Tech 2 data
and/or system.
18
1. Check the air intake system and the crankcase for

air leaks.
Refer to Air Intake System and
Crankcase Ventilation System.
17
Go to Step 11
Diagnose and repair an inaccurate speedometer

condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.
16
Verify repair

15

collapsed pipes.
internal failure.
14
No
1. Check the TCC operation. Refer to 4L30-E

Transmission Diagnosis.
13
Yes
1. Check for low engine compression. Refer to Engine

Mechanical.
12
Value(s)

6E2266
Excessive Exhaust Emissions or Odors Symptom

Step
Action
Go to Step 4
Go to Step 13
Go to Step 5
Go to Step 6
Go to Step 13
Go to Step 13
Go to Step 7
Go to Step 13
Go to Step 8
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 10
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12

Metering System.
1. Refer to Engine Cooling for cooling system
diagnosis.
11
Go to
Visual/Physic
al Check
1. Check the injector connections.

2. If any of the injectors are connected to an incorrect
cylinder, correct as necessary.

10
Go to Step 3
1. Check for a faulty, plugged, or incorrectly installed

crankcase ventilation valve; also check the
crankcase ventilation system for plugging.

9
Go to Step 13
1. Check the fuel pressure. Perform the procedure in

Fuel System Pressure Test.

8
1. Check the fuel cap for proper installation.


7
Go to Step 2
1. Check for vacuum leaks. Check vacuum lines,

intake manifold, throttle body, etc.
Was the fuel cap installed properly?

6
Go to OBD
System
Check
Was a thorough visual/physical check performed?
Were any vacuum leaks located?

5
No

Yes
DEFINITION:
Vehicle fails an emission test. Vehicle has excessive
rotten egg smell. (Excessive odors do not necessarily
indicate excessive emissions.)
performed?
Value(s)
1. Check EVAP canister for fuel loading. Refer to

6E2267
Excessive Exhaust Emissions or Odors Symptom (Cont'd)

Step
Action
12

cleaner. Refer to the instructions on the top engine
cleaner can.
14
15
Go to Step 14
System OK
Go to Step 14
Does the exhaust emission test indicate excessive CO

and HC levels or is long term fuel trim significantly in the
Go to Step 15
Go to Step 16
System OK
Go to Step 17
System OK
Go to Step 17
Go to Step 13
Go to Step 18
Go to Step 13
Go to Step 19
Verify repair
Contact
Technical
Assistance

Support. Make any necessary repairs.
Support. Make any necessary repairs.
17
1. Check the EGR system.

18
No
System OK

16
Yes

13
Value(s)
1. Check for an engine mechanical problem.

Perform a cylinder compression check (refer to
Engine Mechanical).
19

following:
D Tech 2 data
D Freeze Frame data/Failure Records butter
6E2268
Dieseling, Run-On Symptom

Step
Action
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Verify repair
Go to Step 5
Verify repair
Contact
Technical
Assistance
1. Check for a short between B+ and any of the ignition

feed circuits.
No

Yes
DEFINITION:
Engine continues to run after key is turned OFF, but
runs very rough. If engine runs smooth, check ignition
performed?
Value(s)

following:
D Tech 2 data
6E2269
Backfire Symptom
Step
Action
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
1. Check for proper ignition voltage coil output with

spark tester 5-8840-0383-0. Refer to Electronic
Ignition System for procedure.
No

Yes
DEFINITION:
performed?
Value(s)

heavy deposits.
System.
spark plugs. Refer to DTC P0172 to determine the
cause of a rich condition or Engine Mechanical for an oil
fouling condition.
1. Visually/physically inspect the ignition coils for

cracks.
1. Check for an intermittent ignition system

malfunction:
D Intermittent ignition feed circuit or sensor
ground circuit to the crankshaft position
sensor.

Pressure Test.
6E2270
Backfire Symptom (Cont'd)

Step
Action
Value(s)
Yes
No

conditions.
procedures:
D Low compression
10
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Contact
Technical
Assistance
1. Check the intake and exhaust manifold(s) for

casting flash. Refer to Engine Mechanical.
11

following:
D Tech 2 data
6E2271
Cuts Out, Misses Symptom

Step
Action
Go to Step 2
Go to Step 13
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Go to Step 9

Go to Step 8
Go to Step 9
Verify repair
Go to Step 9
Between 5
and 50
counts
Go to Step 11
Go to Step 10

1. Check the PCM grounds for clearness, tightness

Observe the long term fuel trim on the Tech 2.

7
8

Support.

Support.
No
Go to OBD
System
Check

3
Yes
DEFINITION:
performed?
Value(s)

D The engine is fully warm.
D The accessories are off.
6E2272
Cuts Out, Misses Symptom (Cont'd)

Step
Action
10

conditions:
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
D Throttle body. Check for objects blocking the
IAC passage or throttle bore, excessive
deposits in the IAC passage and on the IAC
pintle, and excessive deposits in the throttle
bore and on the throttle plate.
D Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty PCV valve or
brake booster hose disconnected .
11
Verify repair
Go to Step 8
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17

15

hose.
assembly. Refer to Fuel Metering System.
14
No

Metering System.
13
Yes

necessary.
12
Value(s)

spark plugs.
16

6E2273
Cuts Out, Misses Symptom (Cont'd)

Step
Action
17
1. Check ignition coils for cracks or carbon tracking.

18
Verify repair
Go to Step 18
0%
Go to Step 19
Refer to DTC
P0123 for
further
diagnosis
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Verify repair
Contact
Technical
Assistance

overdrive.
21
No
1. Check the PCV valve for proper operation. Refer to

Crankcase Ventilation System.
20
Yes

idling.
19
Value(s)
1. Check the following engine mechanical items.

procedures:
D Low compression
D Worn rocker arms
22

23

following:
D Tech 2 data
6E2274
Hesitation, Sag, Stumble Symptom

Step
Action
No
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to
Visual/Physic
al Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 18
Go to Step 8
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 10

Yes
DEFINITION:
Momentary lack of response as the accelerator is
pushed down. Can occur at any vehicle speed. Usually
most pronounced when first trying to make the vehicle
move, as from a stop sign. May cause the engine to stall
if severe enough.
performed?
Value(s)
1. Check the fuel control heated oxygen sensors

(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they dont, check them
for silicon or other contaminants from fuel or use of
white powdery coating.
Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to Powertrain Control Module (PCM) and Sensors.

Pressure Test.

Monitor the long term fuel trim on the Tech 2.


Support.

Support.
6E2275
Hesitation, Sag, Stumble Symptom (Cont'd)

Step
Action
10

11
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Contact
Technical
Assistance

12

tracking.
13

heavy deposits.
System.
spark plugs.
14
1. Check the PCM grounds for clearness, tightness

15
1. Check the MAF sensor connections.

2. If a problem is found, replace the faulty terminals as
necessary. Refer to Electrical Diagnosis for wiring
repair procedures.
16
1. Visually/physically check vacuum hoses for splits,

kinks, and proper connections and routing as
Information label.
17

following:
D Tech 2 data
6E2276
Default Matrix Table

Service Procedure Default Strategy
after performing diagnostics, then refer to the default
matrix table for further diagnostic information.
Default Matrix Table

Initial Diagnosis
Default Section(s)
On-Board Diagnostic (OBD) System

Check
Chassis Electrical

Check

start and run.

Check
Engine starts and runs, no PCM codes


Check

set. Customer complains of harsh or
soft shift, poor performance, delayed or
no engagement into drive or reverse,
transmission fluid leak, transmission
noise or vibration, or improper TCC
operation.
PCM Power and Ground Check

Check.
Chassis Electrical
PCM Power and Ground Check

Check. PCM power and ground circuits
Chassis Electrical

Check

set. Customer complains of harsh or
soft shift, poor performance, delayed or
no engagement into drive or reverse,
transmission fluid leak, transmission
noise or vibration, or improper TCC
operation.
Symptoms
Initial Diagnosis
Default Section(s)
Intermittents
1. On-board diagnostic (OBD)

system check.
Chassis Electrical
Hard Starts

2. Sensors (ECT, MAP, MAF, TP) ;
MAP output chart.
system diagnosis.
4. Ignition system.
Engine Mechanical, Ignition

System Check, Exhaust System
Diagnosis
1.
2.
3.
4.
/Service Bulletins, Ignition
System Check, Generator
Output, Exhaust System
Diagnosis, 4L30-E System Test
OBD system check.

Ignition system.
6E2277
Symptoms
Initial Diagnosis
Default Section(s)
1.
2.
3.
4.
5.
6.
OBD system check.

Ignition system.
Knock sensor.
EGR operation.
EGR system check.

Engine Exhaust, TCC
Operation, Calibration
ID/Service Bulletins
Detonation/Spark Knock
1.
2.
3.
4.
5.
6.
7.
8.
OBD system check.

Transmission range switch.
EGR operation.
EGR system check.
TCC operation.
Ignition system.
Knock sensor.
TCC operation, Cooling System,

Ignition System Check,
1.
2.
3.
4.
5.
OBD system check.

TP.
MAP output check.
balance test.
valve.
7. Ignition system.
EGR Operation, EGR System

Check, Generator Output
Voltage (refer to Chassis
Electrical), Calibration
ID/Service Bulletins, Ignition
System Check
Cuts Out, Misses


Stalling

balance test.
valve check.
4. Ignition system.
5. IAC operation.
6. EGR operation.
MAP Output Check, Throttle

Linkage, IAC System Check,
EGR System Check, A/C Clutch
Control Circuit Diagnosis,
Crankcase Ventilation System,
Calibration ID/Service Bulletins,
to Chassis Electrical), Exhaust
Diagnosis
Poor Fuel Economy
1.
2.
3.
4.
TCC Operation, Exhaust

System (refer to Engine
Exhaust)
OBD system check.

Ignition system.
Cooling system.

Diagnosis, Fuel System
Diagnosis, Fuel Injector and
Fuel Injector Balance Test.
6E2278
Symptoms
Initial Diagnosis
Default Section(s)

Odors
1.
2.
3.
4.
5.
EGR System Check, Exhaust

Diagnosis, Calibration
ID/Service Bulletins
6.
7.
8.
9.
OBD system check.

Emission test.
Cooling system.
balance test.
valve.
Ignition system.
MAP output check.
Dieseling, Run-On

Backfire
1.
2.
3.
4.


OBD system check.

Ignition system.
balance test.
check.

System Check
Exhaust System
On-Vehicle Service Camshaft

Position (CMP) Sensor
Removal Procedure
2. Remove the engine cover.
3. Remove the common chamber assembly.
Refer to Common Chamber in Engine Mechanical.
4. Install the lubricated O-ring.
1. Install the CMP sensor in the cylinder head.
2. Install the CMP sensor retaining bolt.
Tighten
D Tighten the retaining screw to 9 Nm
(0.9kgm/78 lb in.).
3. Connect the electrical connector to the CMP sensor.
014RW120
4. Disconnect the electrical connector to the CMP

sensor.
6E2279
014RV053
4. Install the common chamber assembly.

014RV053
5. Remove the CMP retaining bolt from the side of left

cylinder head.
6. Remove the CMP sensor from the cylinder head.
1. Inspect the sensor O-ring for cracks or leaks.
2. Replace the O-ring if it is worn or damaged.
3. Lubricate the new O-ring with engine oil.
014RW106
5. Install the engine cover.

6E2280

Sensor
Removal Procedure
2. Disconnect the electrical connector to the CKP
sensor.
3. Remove one bolt and the CKP sensor from the right
side of the engine block, just behind the mount.
out.
TS22909
3. Connect the electrical connector to the CKP sensor.


(ECT) Sensor
Removal Procedure
NOTE: Care must be taken when handling the engine
coolant temperature (ECT) sensor. Damage to the ECT
sensor will affect proper operation of the fuel injection
system.
TS22909
1. Inspect the sensor O-ring for cracks or leaks.
2. Replace the O-ring if it is worn or damaged.
3. Lubricate the new O-ring with engine oil.
4. Install the lubricated O-ring.

2. Drain the radiator coolant. Refer to Draining and
Refilling Cooling System in Engine Cooling.
3. Disconnect the electrical connector.
1. Install the CKP sensor in the engine block.
2. Install the CKP sensor mounting bolt.
Tighten
D Tighten the mounting bolt to 9 Nm (0.9kgm/78
lb in.).
014RW127

4. Remove the ECT sensor from the coolant crossover.
014RW086
1. Apply sealer or the equivalent to the threads of the
ECT sensor.
2. Install the ECT sensor in the coolant crossover.
Tighten
D Tighten the ECT sensor to 30 Nm (3.1kgm/22
lb ft.).
6E2281
014RW085
4. Fill the radiator with coolant. Refer to Draining and

Refilling Cooling System in Engine Cooling.

Removal Procedure
2. Locate the four oxygen sensors.
014RW086
060RX087
6E2282

ahead of the right-hand catalytic converter.
4. Remove the sensor from the exhaust pipe.

D 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 48C
(120F).
TS22912

ahead of the left-hand catalytic converter.
TS23739
All four sensors are identical. Inspect each in the same
way.
grease, dirt, corrosion, and bare wires or worn
insulation.
dirt, or other contaminations.
TS22914
3. Disconnect the pigtail from the wiring harness.

NOTE: Do not use a torch to remove an HO2S unless the
sensor is being replaced. Using a torch could damage the
sensor.
TS23739
6E2283
4. Disconnect the electrical connector from the IAT

sensor.
IMPORTANT:
D New or service sensors will already have the
compound applied to the threads. If a sensor is
removed and is to be reinstalled for any reason, the
threads must have anti-seize compound applied.
1. Apply anti-seize compound or the equivalent to the
threads of the oxygen sensor, if necessary.
2. Install the oxygen sensor on the exhaust pipe in its
original position.
Tighten
D Tighten the oxygen sensor to 55 Nm
(5.6kgm/40 lb in.).
TS23741
5. Remove the IAT sensor from the intake air duct by

using a rocking motion while pulling the sensor.
1. Install the IAT sensor into the grommet in the intake
air duct.
2. Correct the IAT electrical connector.
TS23739
3. Connect the pigtail to the wiring harness.


Sensor
Removal Procedure
2. Remove the engine cover
3. The IAT sensor is located in the intake air duct, behind
the throttle body.
TS23741
6E2284

NOTE: Do not apply thread sealant to the sensor threads.
The sensor is coated at the factory and applying
additional sealant will affect the sensors ability to detect
detonation.
Knock Sensor (KS)
1. Screw the knock sensor into the engine block.
Removal Procedure
2. Drain the cooling system. Refer to Draining and
Filling the Cooling System in Engine Cooling.
4. Remove the common chamber assembly.
Refer to Common Chamber in Engine Mechaical.
Tighten
D Tighten the knock sensor to 20 Nm
(2.0kgm/177 lb in.).
014RW103
2. Connect the electrical connector to the knock sensor.

3. Install the common chamber assembly.
014RW106
5. Disconnect the electrical connector from the knock

sensor.
014RW106
014RW103
6. Unscrew the knock sensor from the engine block.

5. Fill the cooling system.
Refer to Draining and Filling the Cooling System in
Engine Cooling.
6E2285
2. Install the intake air duct and the clamp on the MAF
sensor.
Removal Procedure
2. Disconnect the electrical connector from the MAF
sensor.
TS23781
3. Tighten the clamps to secure the MAF sensor to the

intake air duct and the air cleaner.
4. Connect the MAF electrical connector.
TS23740
3. Loosen the clamps which secure the intake air duct

and the air cleaner to the MAF sensor.
4. Remove the intake air duct from the MAF sensor.
5. Remove the MAF sensor from the air cleaner.

(MAP) Sensor
Removal Procedure
2. Disconnect the electrical connector from the MAP
sensor.
TS23781
1. Install the MAF sensor on the air cleaner with the
clamp.
055RW005
3. Remove the bolt securing the MAP sensor to the

mounting bracket on the common chamber.
6E2286
4. Remove the MAP sensor from the mounting bracket.
Powertrain Control Module

(PCM)
Service Precaution
damage to the PCM, do not touch the connector pins or
soldered components on the circuit board.

Damage
055RW002
1. Install the MAP sensor in the mounting bracket.
2. Install the mounting bracket retaining bolt on the
common chamber.
3. Connect the MAP electrical connector.
Electronic components used in the control systems are

components. By comparison, it takes as much as 4,000
discharge.
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause
damage, therefore, it is important to use care when
handling and testing electronic components.
board.
seat, or while sitting down from a standing position, or
055RW005

(MIL)
Removal and Installation Procedure
Refer to Warning light bulb, indicator light valve,
illumination light bulb, A/T indicator light bulb in Meter and
Gauge.
NOTE: To prevent internal PCM damage, the ignition

must be in the OFF position in order to disconnect or
reconnect power to the PCM (for example: battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.).
IMPORTANT: When replacing the production PCM
with a service PCM, it is important to transfer the
broadcast code and production PCM number to the
service PCM label. This will allow positive identification of
PCM parts throughout the service life of the vehicle. Do
not record this information on the metal PCM cover.
IMPORTANT: The ignition should always be in the
OFF position in order to install or remove the PCM
connectors.
Removal Procedure
6E2287

3. Remove the two screws attaching the rear console
and lift the upward rear console, then disconnect the
switch connector.
4. Remove the lower cluster assembly by pulling the
cover toward the rear.
5. Remove the transfer knob.
6. Remove the six screws attaching the upper console
and front console.
1. Insert the PCM into the dashboard.

D Line up the holes in front for the mounting screws.
2. Install the PCM with two screws in the front and one
screw at the left rear.
3. Plug the red, white, and blue connectors into the
appropriate sockets.
014RW111
745RX008
4. Install the front console and lower console.

5. Install the transfer knob.
6. Connect the switch connector and install the rear
console.
7. Disconnect the red, white, and blue electrical

connectors at the PCM.
8. Remove the two screws in the front of the PCM.
9. Remove the one screws at the left rear of the PCM.
10. Pull the PCM straight out from the dashboard.
745RX008
If the PCM is replaced, the new PCM will need to be

programmed.
014RW111
6E2288
EEPROM
1. Install the TP sensor on the throttle body with the
bolts.
General Description
physically soldered within the PCM. The EEPROM
PCM needs to control powertrain operation.
Functional Check
1. Perform the On-Board Diagnostic System Check.
2. Start the engine and run for one minute.
3. Scan for DTCs using the Tech 2.

Removal Procedure
3. Remove the bolts and the TP sensor from the throttle
body.
TS23747
2. Connect the TP electrical connector.

3. Install the negative battery cable.

Removal Procedure
CAUTION: The VSS is located on the right side of
the transfer case just ahead of the rear propeller
shaft and very close to the exhaust pipes. Be sure
that the exhaust pipes are cool enough to touch
before trying to remove the VSS. If the pipes are hot,
you could be burned.
2. Disconnect the VSS electrical connector.
TS23747

Function Check
closed throttle.
D The voltage should be under 0.85 volt.
D If the reading is greater than 0.85 volt, check the
TS23748

3. Remove the bolt and the clamp securing the VSS in
place.
case.
6E2289
2. Secure the VSS in place with the clamp and the bolt.
Tighten
D Tighten the bolt to 16 Nm (1.6 kgm/12 lb ft.).
TS23780
3. Connect the VSS electrical connector.

TS23780
4. Remove the VSS from the transfer case by wiggling it

slightly and pulling it straight out.
3. Inspect the O-ring for wear, nicks, tears, or
looseness. Replace the O-ring if necessary.
1. Install the VSS in the transfer case with the notch for
the connector facing the rear.
TS23748
4. Check the transfer case oil level.

necessary.
Add fluid if
6E2290

5. Remove the retaining bolts and the air cleaner
housing from the vehicle.
Air Cleaner/Air Filter

Removal Procedure
1. Loosen the clamp between the air cleaner lid and the
mass air flow sensor.
cleaner housing.
130RT002
1. Install the air cleaner housing in the vehicle with the
retaining bolts.
TS23973
130RT002
TS23794

6E2291

TS23794
3. Install the air cleaner lid on the MAF sensor and the air
cleaner housing.
TS23745
Cleaning, Inspection, and Measurement Procedure

D Clean the IAC valve O-ring sealing surface, pintle
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
If the air passage has heavy deposits, remove the
throttle body for complete cleaning.
TS23973
4. Tighten the clamp and secure the four latches

between the lid and the air cleaner housing.

Removal Procedure
3. Remove the bolts and the IAC valve from the throttle
body.
TS23746
6E2292
D Inspect the IAC valve O-ring for cuts, cracks, or

distortion. Replace the O-ring if damaged.
mounting flange. If that measurement is 28 mm (1.1
in.) or less, the valve needs no adjustment. If the
measurement is greater than 28 mm (1.1 in.), apply
finger pressure and retract the valve. The force
required to retract the pintle on a new valve will not
damage the valve, shaft, or pintle.
valves that have been in service. The force required to
2. Connect the IAC valve electrical connector.

Common Chamber
Removal and Installation Prodedure
Accelerator Cable Assembly

Removal Procedure
mounting on the common chamber.
TS23746
101RW005
3. Remove the accelerator control cable (on the throttle

valve end).
1. Install the IAC valve on the throttle body with the bolts.
101RW006
TS23745

6E2293
TS23982

TS23983

3. Install the accelerator control cable (on the
TS23983
corrosion.
TS23982
6E2294
4. Install the accelerator control cable (on the throttle

valve end).
035RW004
101RW006
5. Install the adjusting nut.

nut. Then, manually operating the throttle valve,
make sure that the valve lever returns up to the
stopper screw.
IMPORTANT: The valve lever must return up to the
stopper screw, repeat the procedure again from step 1.
5. It does not reach the stopper screw, repeat from step
1.
101RW007
6. Adjust the accelerator cable at the throttle body.

Refer to Accelerator Cable Adjustment.
1. Loosen the adjusting nut and lock nut.
2. Pull outer cable closing fully the throttle valve.
TS23782
6E2295
3. Disconnect the wiring harness from the kick-down

switch.
Removal Procedure
1. Disconnect the cruise control cable from the
TS24038
4. Remove the two screws from the accelerator pedal

assembly.
TS24053

the accelerator pedal assembly.
TS24055
5. Remove the accelerator pedal assembly from the

bulkhead.
TS24054
1. Install the accelerator pedal assembly on the
bulkhead.
6E2296
2. Install the two screws to the accelerator pedal

assembly.
TS24055
3. Connect the wiring harness to the kick-down switch.
4. Connect the accelerator pedal control cable to the

TS24054
5. Connect the cruise control cable to the accelerator

pedal assembly.
TS24038
TS24053
Pedal Stroke Adjustment Procedure

1. Loosen the jam nut and rotate the kick-down switch
counterclockwise.
6E2297
If high vacuum or high pressure occurs in the fuel tank,

each valve works to adjust the pressure in order to
prevent damage to the tank at the EGR valve.
TS23767
TS24039
2. Fully depress the pedal and hold it by hand. Rotate

the switch clockwise until the switch clicks.
3. Rotate the switch 1/2 turn further and lock it in this
position by tightening the jam nut.
NOTE: Replace the fuel filler cap with the same type of
Fuel Filter
Removal Procedure
TS24040
4. Step on the accelerator pedal and make sure there is

a clicking sound at the full-stroke position.
Fuel Fillter Cap

General Description
The fuel filler cap includes a vacuum valve and a pressure
valve.
041RW005
6E2298
3. Disconnect the fuel line from the fuel filter on the

engine side.
tank side.
041RW008
041RW006

D Fuel leaks from the fuel filter body.
D The fuel filter body is damaged.

D The fuel filter is clogged with dirt or sediment.
2. If the drain hole is clogged, clean the drain.
041RW007
041RW009
6E2299

041RW006
041RW008
041RW007
041RW005
6E2300
Fuel Gauge Unit

Removal Procedure
Refer to Fuel Gauge Unit In Engine Fuel.
014RW106
4. Remove the injector retainer clip.
014RW133
Fuel Injectors
Removal Procedure
contamination and change the oil and the filter if
necessary.
NOTE: Use care in removing the fuel injectors in order to
pins or the fuel injector nozzles. The fuel injector is an
F06RW017
IMPORTANT: Fuel injectors are serviced as a complete

assembly only.
2. Remove the upper intake manifold.
Refer to
Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to Fuel Rail.
5. Remove the fuel injector assembly.

6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.
6E2301
1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.
3. Install the fuel injector on the fuel rail.

Removal Procedure
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before disconnecting the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
NOTE: Compressed air must never be used to test or
clean a fuel pressure regulator, as damage to the fuel
pressure regulator may result.
F06RW017
4. Use new fuel injector retainer clips to retain the fuel

injector to the fuel rail.
6. Install the fuel rail. Refer to Fuel Rail.

Relief Procedure.
3. Remove the fuel pump relay. Refer to Fuel Pump
Relay.
4. Remove the pressure regulator hose from the fuel
pressure regulator.
014RW106
7. Install the upper intake manifold. Refer to Common

Chamber in Engine Mechanical.
014RW110
6E2302
5. Remove the two bolts from the protector that secures

the common chamber.
F06RW016
014RW109
6. Remove the fuel pressure regulator attaching screw.
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.
1. Install the fuel pressure regulator attaching screw.
Tighten
D Tighten the fuel pressure regulator attaching
screw to 3 Nm (0.3kgm/26 lb in.).
F06RW016
7. Remove the fuel pressure regulator from the fuel rail.
Disassembly Procedure
1. Remove the O-ring from the fuel pressure regulator.
2. Loosen the swivel nut.
3. Remove the fuel return line from the fuel pressure
regulator.
4. Remove the O-ring from the fuel return line.
D The O-ring may be left inside the fuel pressure
regulator instead of on the fuel return line.
F06RW016

2. Install the fuel pressure regulator on the fuel rail.
3. Install the two bolts to the protector that secures the
common chamber.
6E2303
CAUTION: After relieving the system pressure, a

small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before you disconnect the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
relay box. Refer to Fuel Pump Relay.
014RW109
4. Install the pressure regulator hose to the fuel

pressure regulator.
014RW089

4. Crank the engine for 30 seconds.
Fuel Pump Assembly

Removal Procedure
Refer toFuel Tank In Fuel Pump Relay.
014RW110
5. Install the fuel pump relay. Refer to Fuel Pump Relay.

fuel lines.
Fuel Metering System

components.
014RW133
6E2304
Fuel Pump Relay
Fuel Rail Assembly
Removal Procedure
Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
box.
NOTE:
D Do not attempt to remove the fuel inlet fitting on the
fuel rail. It is staked in place. Removing the fuel inlet
fitting will result in damage to the fuel rail or the
internal O-ring seal.
connector terminals and the injector spray tips.
D Fittings should be capped and holes plugged during
entering open lines and passages.
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.
014RW089
relay box with the catch slot facing forward.
TS24022
014RW089
2. Press down until the catch engages.

D An audible click will be heard.
3. Install the fuse and relay box cover.
Before removal, the fuel rail assembly may be cleaned

with a spray type engine cleaner. Follow the spray
package instructions. Do not immerse the fuel rails in
liquid cleaning solvent.
Relief Procedure in this Section.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.
5. Disconnect the connectors from manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Disconnect the vacuum hose on canister VSV and
positive crankcase ventilation hose.
7. Remove the common chamber Refer to the common
chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do not
separate the fuel injectors from the fuel rail.

2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retainer clip
must be replaced.
3. Drain residual fuel into an approved container.
6E2305
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.
fuel rail and in the injectors.
Fuel Tank
Removal Procedure
Refer toFuel Tank In Fuel Pump Relay.
014RW106
8. If removal of the fuel pressure regulator is necessary,

refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.
1. If the fuel injectors were removed, install them. Refer
to Fuel Injectors.
2. If the fuel pressure regulator was removed, install it.
Refer to Fuel Pressure Regulator.
3. Install the common chamber.Refer to common
chamber in engine Mechanical.
014RW134
Throttle Body (TB)

Removal Procedure
3. Remove the accelerator cable assembly. Refer to
Accelerator Cable in Engine Speed Control System..
4. Disconnect the electrical connectors:
D Idle air control (IAC) solenoid.
014RW106
6E2306
D Intake air temperature (IAT) sensor. Refer to Intake

Air Temperature Sensor.
body assembly. The gasket surfaces and the throttle
body assembly may be damaged as a result.
D If the throttle body gasket needs to be replaced,
D Do not leave any scratches in the aluminum casting.
035RW023
5. Disconnect the vacuum hose below the air horn.

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.
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.
5. Secure the gasket and the throttle body with the four
bolts.
D The vacuum lines must be properly routed under
the throttle body before tightening the mounting
bolts.
Tighten
D Tighten the throttle body mounting bolts to 24
Nm (2.4kgm/17 lb ft.).
035RW024
035RW024
12. Remove the IAC. Refer to Idle Air Control (IAC)

Solenoid.
13. Remove the TP sensor. Refer to Throttle Position
(TP) Sensor.
6. Install the coolant lines.

7. Connect all the vacuum lines.
8. Install the intake air duct.
9. Tighten the intake air duct clamp.
10. Connect all the electrical connectors:
D Idle air control (IAC) solenoid.

D Intake air temperature (IAT) sensor. Refer to Intake
Air Temperature Sensor.
6E2307
4. Remove the coil module and the spark plug boot from
the spark plug.
D Twist the coil module while pulling it straight up.
035RW023
11. Install the accelerator cable assembly. Refer to

Accelerator Cable in Engine Speed Control System..
12. Fill the cooling system. Refer to Cooling System.
014RW091
5. Use the spark plug socket in order to remove the

spark plug from the engine.
Spark Plug Gap Check
Electronic Ignition System

Removal Procedure
2. Disconnect the electrical connector at the coil
module.
3. Remove the two screws that secure the coil module to
the rocker cover.
D Check the gap of all spark plugs before installation.

D Use a round wire feeler gauge to ensure an accurate
check.
D Plugs installed with the wrong gap can cause poor
engine performance and excessive emissions.
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 gases, 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.
appropriate spark plug socket.
Use the
Tighten
D Tighten the spark plug to 18 Nm (1.8kgm/13 lb
ft.).
014RW108
6E2308
2. Install the coil module and spark plug boot over the
spark plug.

Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
box.
014RW108
3. Secure the coil module to the rocker cover with two

screws.
014RW090
relay box with the catch slot facing forward.
2. Press down until the catch engages.
D An audible click will be heard.
3. Install the fuse and relay box cover.
EVAP Canister Hoses

014RW091
4. Connect the electrical connector at the coil module.

Catalytic Converter
Service Information
To view the routing of the EVAP canister hoses, refer to
Vehicle Emission Control Information in Diagnosis. Use
hoses.
EVAP Canister
Refer to Engine Exhaust in Engine.
Removal Procedure
2. Disconnect the two hoses from the EVAP canister.

3. Disconnect the fuel vapor connector and the purge
hose from the EVAP canister vent solenoid.
5. Remove the retaining bolt on the mounting bracket

the slide the canister out of mounting bracket.
014RW130
4. Remove the two retaining bolts the EVAP canister to

the mounting bracket on the cross member.
6E2309
014RW129
1. Inspect the hoses for cracks and leaks.
2. Inspect the canister for a damaged case.
1. Slide the canister into mounting bracket the install the
mounting bracket bolt.
014RW131
014RW129
6E2310
2. Install the retaining bolts the EVAP canister to the

mounting bracket on the cross member.
2. Disconnect the vacuum hoses from the EVAP

canister purge solenoid.
014RW131
3. Connect the fuel vapor connector to the EVAP

canister vent solenoid.
4. Connect the two hoses to the EVAP canister.
014RW136
3. Remove the EVAP canister purge solenoid retaining

bolt from the upper intake manifold.
4. Remove the EVAP canister purge solenoid.
014RW130
014RW137

Removal Procedure
1. Disconnect the electrical connector from the EVAP
canister purge solenoid.
1. Install the EVAP canister purge solenoid on the upper

intake manifold.
2. Install the EVAP canister purge solenoid retaining
bolt.

3. Connect the vacuum hoses to the EVAP canister
purge solenoid.
6E2311
Linear Exhaust Gas

Removal Procedure
2. Disconnect the electrical connector at the EGR valve.
014RW137
4. Connect the electrical connector to the EVAP canister

purge solenoid.
014RW139
3. Remove the bolt and the nut from the upper intake
manifold.
014RW138
Fuel Tank Vent Valve

Refer to Fuel Pump
014RW098
4. Remove the EGR valve from the upper intake

manifold.
5. Remove the gasket from the upper intake manifold.
6E2312

2. Pull the PCV valve from the rubber grommet in the
right valve cover.
1. Install the gasket on the upper intake manifold.
2. Install the EGR valve on the upper intake manifold.
3. Secure the EGR valve and the gasket with the bolt
and the nut.
NOTE: It is possible to install the EGR valve rotated 180
from the correct position. Make sure that the base of the
valve is placed so that it aligns with the mounting flange.
014RW097
1. Shake the valve and listen for the rattle of the needle
inside the valve.
2. If the valve does not rattle, replace the valve.
014RW098
4. Connect the electrical connector at the EGR valve.
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
Positive Crankcase Ventilation

(PCV) Valve
Removal Procedure
1. Remove the vacuum hose at the PCV valve.
D Slide the clamp back to release the hose.
014RW097

replacement.
6E2313

Shielded Cable
Removal Procedure
mylar.
Connectors and Terminals

checking. NEVER probe through Weather-Pack seals.
making any connector or terminal repair. Weather-Pack
and Com-Pack III terminals look similar, but are serviced
differently.
047

PCM Connectors and Terminals

Removal Procedure
exposed.
048
be pulled into position within the connector.
terminal retainer.
solder.
6E2314

(uninsulated) wire.
051
049
050
Twisted Leads
Removal Procedure
052

the other wires.
6E2315
4. Tape the wires with electrical tape. Hold in place.
055
053

procedure.
Weather-Pack Connector
Tools Required
5884066320 Weather-Pack II Terminal Remover
Removal Procedure
A Weather-Pack connector can be identified by a rubber
from oxidation and deposits on the terminals. This
054
070
6E2316
2. Use tool 5884066320 or the equivalent to remove

the pin and the sleeve terminals.
Push on
5884066320 to release.
NOTE: Do the use an ordinary pick or the terminal may
Do not replace the Weather-Pack connections with

with the Weather-Pack connector and terminal packages.
071
073

locking tangs.
072
070
6E2317
Com-Pack III
General Information
The Com-Pack III terminal looks similar to some
Weather-Pack terminals. This terminal is not sealed and
terminal. Do not use the Weather-Pack terminal tool
5884066320 or equivalent. These will damage the
terminals.
Metri-Pack
Tools Required
5884006320 Terminal Remover
Removal Procedure
Some connectors use terminals called Metri-Pack Series
2. Insert the 5884006320 tool or equivalent (3) in
060

locking tang.
Metri-Pack terminals are also referred to as pull-to-seat
terminals.
connector (3).
061

seat it in place.
6E2318
General Description (PCM and

Sensors)
58X Reference PCM Input
The powertrain control module (PCM) uses this signal
from the crankshaft position (CKP) sensor to calculate
engine RPM and crankshaft position at all engine speeds.
The PCM also uses the pulses on this circuit to initiate
injector pulses. If the PCM receives no pulses on this
circuit, DTC P0337 will set. The engine will not start and
run without using the 58X reference signal.
A/C Request Signal

This signal tells the PCM when the A/C mode is selected
at the A/C control head. The PCM uses this to adjust the
idle speed before turning ON the A/C clutch. The A/C
compressor will be inoperative if this signal is not
available to the PCM.
Refer to A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for the A/C electrical system.

used by the powertrain control module (PCM) to calculate
reference pulses which the PCM uses to calculate RPM
and crankshaft position.
Refer to Electronic Ignition System for additional
information.
injection system will shift to a calculated sequential fuel

injection mode based on the last fuel injection pulse, and
the engine will continue to run. As long as the fault is
present, the engine can be restarted. It will run in the
calculated sequential mode with a 1-in-6 chance of the
Refer to DTC P0341 for further information.

coolant temperature produces a high resistance of
100,000 ohms at 40C (40F). High temperature
causes a low resistance of 70 ohms at 130C (266F).
The PCM supplies a 5-volt signal to the ECT sensor
through resistors in the PCM and measures the voltage.
The signal voltage will be high when the engine is cold and
low when the engine is hot. By measuring the voltage, the
PCM calculates the engine coolant temperature. Engine
PCM controls.
degrees. After engine start-up, the temperature should
sensor circuit will set DTC P0117 or DTC P0118.
0013
0016

Signal

The camshaft position (CMP) sensor sends a CMP signal

to the PCM. The PCM uses this signal as a syncpulse to
trigger the injectors in the proper sequence. The PCM
piston during its power stroke. This allows the PCM to
calculate true sequential fuel injection (SFI) mode of
operation. If the PCM detects an incorrect CMP signal
while the engine is running, DTC P0341 will set. If the
CMP signal is lost while the engine is running, the fuel

physically soldered within the PCM. The EEPROM
the PCM needs to control powertrain operation.

and Bank 2 HO2S 1) are mounted in the exhaust stream

where they can monitor the oxygen content of the exhaust
gas. The oxygen present in the exhaust gas reacts with
the sensor to produce a voltage output. This voltage
should constantly fluctuate from approximately 100 mV to
900 mV. The heated oxygen sensor voltage can be
monitored with a Tech 2. By monitoring the voltage output
of the oxygen sensor, the PCM calculates the pulse width
command for the injectors to produce the proper
combustion chamber mixture.
between 400-500 mV. A constant voltage below 300 mV
set DTC P0132. Faults in the Bank 2 HO2S 1 signal
circuit will cause DTC 0154 (open circuit), DTC P0151
(grounded circuit), or DTC P0152 (signal voltage high) to
set. The PCM can also detect HO2S response problems.
If the response time of an HO2S is determined to be too
slow, the PCM will store a DTC that indicates degraded
HO2S performance.
0012

resistance of 100,000 ohms at 40C (40F). High
temperature causes low resistance of 70 ohms at 130C
(266F) . The PCM supplies a 5-volt signal to the sensor
through a resistor in the PCM and monitors the signal
voltage. The voltage will be high when the incoming air is
cold. The voltage will be low when the incoming air is hot.
By measuring the voltage, the PCM calculates the
incoming air temperature. The IAT sensor signal is used
6E2319
to adjust spark timing according to the incoming air

density.
close to each other. A fault in the IAT sensor circuit will set
DTC P0112 or DTC P0113.
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.
A knock sensor system is used to control detonation. This
system is designed to retard spark timing up to 20
degrees to reduce detonation in the engine. This allows
the engine to use maximum spark advance to improve
driveability and fuel economy.
The knock sensor system has two major components:
D The knock sensor (KS) module.
D The knock sensor.
The knock sensor, mounted in the engine block near the
cylinders, detects abnormal vibration in the engine. The
sensor produces an AC output signal of about 10
millivolts. The signal amplitude and frequency are
dependent on the amount of knock being experienced.
The signal voltage increases with the severity of the
knock. This signal voltage is input to the PCM. The PCM
then retards the ignition control (IC) spark timing based
on the KS signal being received.
The PCM determines whether knock is occurring by
comparing the signal level on the KS circuit with the
voltage level on the noise channel. The noise channel
allows the PCM to reject any false knock signal by
indicating the amount of normal engine mechanical noise
present. Normal engine noise varies depending on the
engine speed and load. If the voltage level on the KS
noise channel circuit is below the range considered
normal, DTC P0327 will set, indicating a fault in the KS
circuit or the knock sensor. If the PCM determines that an
abnormal minimum or maximum noise level is being
experienced, DTC P0325 will set.
The PCM contains a knock sensor (KS) module. The KS
module contains the circuitry which allows the PCM to
utilize the KS signal and diagnose the KS sensor and the
KS circuitry. If the KS module is missing or faulty, a
continuous knock condition will be indicated, and the
PCM will set DTC P0325.
6E2320
Although it is a plug-in device, the KS module is not

replaceable. If the KS module is faulty, the entire PCM
must be replaced.
0007

0009

Control
The PCM monitors the exhaust gas recirculation (EGR)
The PCM uses information from the following sensors to
D Mass air flow (MAF) sensor.

The mass air flow (MAF) sensor measures the difference
between the volume and the quantity of air that enters the
engine. Volume means the size of the space to be filled.
Quantity means the number of air molecules that will fit
into the space. This information is important to the PCM
because heavier, denser air will hold more fuel than
lighter, thinner air. The PCM adjusts the air/fuel ratio as
needed depending on the MAF value. The Tech 2 reads
the MAF value and displays it in terms of grams per
second (gm/s). At idle, the Tech 2 should read between
4-7 gm/s on a fully warmed up engine. Values should
change quickly on acceleration. Values should remain
stable at any given RPM. A failure in the MAF sensor or
circuit will set DTC P0101, DTC P0102, or DTC P0103.

MAP sensor signal voltage to the PCM varies from below
ignition ON, engine not running or at wide-open throttle
(low vacuum).
If the PCM detects a voltage that is lower than the
sensor will set DTC P0108. The PCM can detect a shifted
MAP sensor. The PCM compares the MAP sensor signal
055RW004

The powertrain control module (PCM) is located in the
PCM controls the following:
D Transmission shifting (automatic transmission only).
D Ignition timing.
D On-board diagnostics for powertrain functions.
The PCM constantly observes the information from
various sensors. The PCM controls the systems that
affect vehicle performance. The PCM performs the
operational problems, alert the driver through the MIL
(Service Engine Soon lamp), and store diagnostic trouble
codes (DTCs). DTCs identify the problem areas to aid the
technician in making repairs.
D IPCM-6KT for automatic transmission-equipped
vehicles.
PCM Function
The PCM supplies either 5 or 12 volts to power various
resistances in the PCM which are so high in value that a
test light will not light when connected to the circuit. In
some cases, even an ordinary shop voltmeter will not give
an accurate reading because its resistance is too low.
Therefore, a digital voltmeter with at least 10 megohms
input impedance is required to ensure accurate voltage
readings. Tool 5884002850 meets this requirement.
The PCM controls output circuits such as the injectors,

speed sensor (VSS). The PCM also controls certain
D Knock sensor
D Automatic transmission shift functions
PCM Voltage Description

The PCM supplies a buffered voltage to various switches
and sensors. It can do this because resistance in the
PCM is so high in value that a test light may not illuminate
when connected to the circuit. An ordinary shop
voltmeter input impedance is too low. Use a 10-megohm
input impedance digital voltmeter (such as
5884002850) to assure accurate voltage readings.
The input/output devices in the PCM include
analog-to-digital converters, signal buffers, counters,
and special drivers. The PCM controls most components
when turned ON. These switches are arranged in
groups of 4 and 7, called either a surface-mounted quad
driver module (QDM), which can independently control up
to 4 output terminals, or QDMs which can independently
PCM Input/Outputs
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Air Conditioning ON or OFF

Crankshaft Position
Electronic Ignition
Battery Voltage
Throttle Position
Vehicle Speed
Fuel Pump Voltage
Mass Air Flow
Engine Knock
Camshaft Position
0005
PCM Components
The PCM is designed to maintain exhaust emission levels
excellent driveability and fuel efficiency. The PCM
6E2321
D
D
D
D
D
D
D
EVAP Canister Purge

Ignition Control
Fuel Control
Idle Air Control
Electric Fuel Pump
Air Conditioning
6E2322
D Diagnostics
Data Output
D Transmission Control Module
D Alternator Gain Control
PCM Service Precautions

The PCM is designed to withstand normal current draws
associated with vehicle operation. Avoid overloading any
or apply voltage to any of the PCMs circuits unless
using digital voltmeter (5884002850). The PCM
should remain connected to the PCM or to a
recommended breakout box.

PCM monitors the voltage on the signal line and
the TP sensor is low. As the throttle valve opens, the
output increases so that at wide open throttle (WOT), the
output voltage should be above 4 volts.
The PCM calculates fuel delivery based on throttle valve
unstable idle because the PCM thinks the throttle is
moving. A hard failure in the TP sensor 5-volt reference
the PCM will use an artificial default value based on
and some vehicle performance will return. A high idle
may result when either DTC P0122 or 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.
0021

Sensor
The transmission fluid temperature sensor is a thermistor
the transmission fluid. For a complete description of the
TFT sensor, refer to 4L30-E Automatic Transmission
Diagnosis
A failure in the TFT sensor or associated wiring will cause
DTC P0712 or DTC P0713 to set. In this case, engine
coolant temperature will be substituted for the TFT
sensor value and the transmission will operate normally.

be affected.
indicate to the PCM which position is selected by the
operation.
For more information on the transmission on the
transmission range switch, refer to 4L30-E Automatic
Transmission.

The PCM determines the speed of the vehicle by
converting a plusing voltage signal from the vehicle speed
sensor (VSS) into miles per hour. The PCM uses this
signal to operate the cruise control, speedometer, and the
TCC and shift solenoids in the transmission. For more
information on the TCC and shift solenoids, refer to
4L30-E Automatic Transmission.
0008

connectors.

Equipment
Aftermarket (add-on) electrical and vacuum equipment is
after it leaves the factory. No allowances have been
made in the vehicle design for this type of equipment.
NOTE: No add-on vacuum equipment should be added
to this vehicle.
NOTE: Add-on electrical equipment must only be
(power and ground).
Add-on electrical equipment, even when installed to

Electronic components used in the PCM are often
designed to carry very low voltage.
Electronic
discharge.
6E2323
TS23793

D Charge by induction occurs when a person with well
insulated shoes stands near a highly charged object
and momentary touches ground. Charges of the
same polarity are drained off leaving the person
components.
D Do not touch the PCM connector pins or soldered
components on the PCM circuit board.
D Do not touch the knock sensor module component
leads.
Upshift Lamp
Refer to Manual Transmission.
General Description (Air Induction)

drawn into the engine. A remote-mounted air cleaner
throttle body. Air enters the engine by to following steps:
6E2324
2. Into the common chamber.

less than 80%, the PCM again begins to pulse the

Deceleration Mode
The PCM reduces the amount of fuel injected when it
When deceleration is very fast, the PCM may cut off fuel
Engine Speed/Vehicle Speed/Fuel Disable

Mode
The PCM monitors engine speed. It turns off the fuel
injectors when the engine speed increase above 6400
Fuel Cutoff Mode

is OFF. This prevents engine run-on. In addition, the
PCM suspends fuel delivery if no reference pulses are
055RV010
General Description (Fuel Metering)

Acceleration Mode
The PCM provides extra fuel when it detects a rapid
The accelerator control system is a cable-type system
Fuel Injector
a solenoid-operated device controlled by the PCM. The
PCM energizes the solenoid, which opens a valve to allow
fuel delivery.
crank times.

When battery voltage is low, the PCM will compensate for
D The idle RPM.
D Ignition dwell time.
CMP Signal
The PCM uses this signal to determine the position of the
number 1 piston during its power stroke, allowing the
PCM to calculate true sequential multiport fuel injection
(SFI). Loss of this signal will set a DTC P0341. If the CMP
in the calculated sequential mode as long as the fault is
present, with a 1-in-6 chance of being correct.
Clear Flood Mode

down all the way. The PCM then de-energizes the fuel
injectors. The PCM holds the fuel injectors de-energized
0003

parts:
D The fuel rail.

D
D
D
D
D
D
D
6E2325
The fuel pressure regulator.

The PCM.
The crankshaft position (CKP) sensor.
The fuel pump.

pumps fuel to the fuel rail through an in-line fuel filter. The
pipes.
0011

the PCM how much oxygen is in the exhaust gas. The
PCM changes the air/fuel ratio to the engine by controlling
the amount of time that fuel injector is ON. The best
fuel injection system is called a closed loop system.
The PCM monitors signals from several sensors in order
All modes are controlled by the PCM.
When the key is first turned ON, the PCM energizes the
fuel pump relay for two seconds to build up the fuel
seconds, the PCM shuts the fuel pump off and waits until
the 58 X crankshaft position signal has been detected by
the PCM, the PCM supplies 12 volts to the fuel pump relay
to energize the electric in-tank fuel pump.
An inoperative fuel pump will cause a no-start condition.
Fuel Rail
distributes fuel to the individual injectors. Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines. The fuel goes through the fuel rail to the fuel
pressure regulator. The fuel pressure regulator maintains
a constant fuel pressure at the injectors. Remaining fuel
is then returned to the fuel tank.
The fuel pressure regulator is a diaphragm-operated

serviced separate.
P0131, DTC P0151,DTC P0171 will be the result. If the
pressure is too high, excessive odor and/or a DTC P0132,
DTC P0152,DTC P0172 or DTC P0175 will be the result.
Refer to Fuel System Diagnosis for information on
diagnosing fuel pressure conditions.
055RV009
6E2326

PCM will retract the IAC pintle, resulting in more air
RPM is too high, the PCM will extend the IAC pintle,
decreasing the RPM.
calculated by the PCM based on battery voltage, coolant
closed, the PCM senses a near-stall condition. The PCM
prevent stalls.
cycled ON then OFF. When servicing the IAC, it
should only be disconnected or connected with the
ignition OFF.
The position of the IAC pintle valve affects engine start-up
and the idle characteristics of the vehicle. If the IAC pintle
is fully open, too much air will be allowed into the manifold.
This results in high idle speed, along with possible hard
starting and a lean air/fuel ratio.

ECT, and MAF sensors.
The system remains in open loop until the following
conditions are met:
temperature).
the engine.
since start-up.
met, the system enters closed loop operation. In
closed loop, the PCM calculates the air/fuel ratio
(injector on-time) based on the signal from the HO2S.
Starting Mode
When the ignition is first turned ON, the PCM energizes
to build up pressure. The PCM then checks the engine
for starting.
The PCM controls the amount of fuel delivered in the
Throttle Body Unit

valve are also mounted on the throttle body. Vacuum
ports located behind the throttle plate provide the vacuum
signals needed by various components.
Engine coolant is directed through a coolant cavity in the
throttle body to warm the throttle valve and to prevent
icing.
0006
Run Mode
D Open loop
D Closed loop
When the engine is first started the system is in open
loop operation. In open loop, the PCM ignores the
0019
6E2327
General Description (Electronic

Ignition System)
The camshaft position (CMP) sensor is located on the
rear left side. As the camshaft sprocket turns, a magnet in
the sprocket activates the Hall-effect switch in the CMP
sensor. When the Hall-effect switch is activated, it
grounds the signal line to the PCM, pulling the camshaft
position sensor signal circuits applied voltage low. This is
a CMP signal. The CMP signals is created as piston #1 is
approximately 25 after top dead counter on the power
stroke. If the correct CMP signal is not received by the
PCM, DTC P0341 will be set.
0013
Ignition Coils
A separate coil-at-plug module is located at each spark
plug. The coil-at-plug module is attached to the engine
with two screws. It is installed directly to the spark plug by
an electrical contact inside a rubber boot. A three-way
connector provides 12-volt primary supply from the
15-amp ignition fuse, a ground-switching trigger line from
the PCM, and a ground.
0014

used by the powertrain control module (PCM) to calculate
the ignition sequence. The sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position. Refer to Electronic Ignition
System for additional information.
Electronic Ignition
emissions, the PCM controls the spark advance of the
D No moving parts.
D Less maintenance.
0001
Ignition Control
The ignition control (IC) spark timing is the PCMs method
calculated by the PCM using the following inputs:
D Engine speed.
D Knock signal (knock sensor).
6E2328
D
D
D
D
Park/Neutral position (PRNDL input).

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.
060RW015
TS22909

D The knock sensor tells the PCM if there is any
problem with pre-ignition or detonation.
This
information allows the PCM to retard timing, if
necessary.
The PCM applies 5V signal voltage to the ignition coil

requiring ignition. This signal sets on the power transistor
of the ignition coil to establish a grounding circuit for the
primary coil, applying battery voltage to the primary coil.
At the ignition timing, the PCM stops sending the 5V
signal voltage. Under this condition the power transistor
of the ignition coil is set off to cut the battery voltage to the
primary coil, thereby causing a magnetic field generated
in the primary coil to collapse. On this moment a line of
magnetic force flows to the secondary coil, and when this
magnetic line crosses the coil, high voltage induced by
the secondary ignition circuit to flow through the spark
plug to the ground.
TS24047
TS24037
Based on these sensor signals and engine load

information, the PCM sends 5V to each ignition coil.
Ignition Control PCM Output

The PCM provides a zero volt (actually about 100 mV to
200 mV) or a 5-volt output signal to the ignition control (IC)
module. Each spark plug has its own primary and
secondary coil module (coil-at-plug) located at the spark
plug itself. When the ignition coil receives the 5-volt signal
from the PCM, it provides a ground path for the B+ supply
to the primary side of the coil-at -plug module. This

energizes the primary coil and creates a magnetic field in
the coil-at-plug module. When the PCM shuts off the
5-volt signal to the ignition control module, the ground
path for the primary coil is broken. The magnetic field
collapses and induces a high voltage secondary impulse
which fires the spark plug and ignites the air/fuel mixture.
The circuit between the PCM and the ignition coil is
monitored for open circuits, shorts to voltage, and shorts
to ground. If the PCM detects one of these events, it will
set one of the following DTCs:
D P0351: Ignition coil Fault on Cylinder #1
Knock Sensor (KS) PCM Input

The knock sensor (KS) system is comprised of a knock
sensor and the PCM. The PCM monitors the KS signals
to determine when engine detonation occurs. When a
knock sensor detects detonation, the PCM retards the
spark timing to reduce detonation. Timing may also be
retarded because of excessive mechanical engine or
transmission noise.
6E2329

are normal combustion by-products of fuels and
also occur.
the cylinder. Excessive idling and slow speeds under
light engine loads can keep the spark plug temperatures
so low that these deposits are not burned off. Very rich
fuel mixtures or poor ignition system output may also be
the cause. Refer to DTC P0172.
oil during break-in of new or newly overhauled engines.
red-brown, yellow or white deposits of combustion by
products become sufficient to cause misfiring. In some
cases, these deposits may melt and form a shiny glaze on
the insulator around the center electrode. If the fouling is
found in only one or two cylinders, valve stem clearances
or intake valve seals may be allowing excess lubricating
oil to enter the cylinder, particularly if the deposits are
heavier on the side of the spark plug facing the intake
valve.

The PCM is responsible for maintaining proper spark and
optimum driveability and emissions, the PCM monitors
D PRNDL input from transmission range switch.
D Vehicle speed sensor (VSS) .
Spark Plug
operation at idling speed, they frequency fail at higher
generally poor engine performance.
Follow the
grayish-tan deposits appearing on the insulator portion of
the spark plug. A small amount of red-brown, yellow, and
TS23995

idle condition. Excessive gap wear can be an indication
of continuous operation at high speeds or with engine
6E2330
loads, causing the spark to run too hot. Another possible

cause is an excessively lean fuel mixture.
TS23994
TS23992

can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
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.
re-gapping, or heat shock to the insulator material. Upper

electrode) may result from damage during re-gapping or
hot).
TS23993
D Damage during re-gapping can happen if the gapping

tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack.
When re-gapping a spark plug, make the adjustment
caused by over-advanced timing or low grade fuels.
crack.
service can sometimes be cleaned and re-gapped , then
replaced.
6E2331
Refer to A/C Clutch Circuit Diagnosis for A/C wiring

diagrams and diagnosis for A/C electrical system.

A 12-volt signal is supplied to the A/C request input of the
PCM when the A/C is selected through the A/C control
switch.
PCM. This allows the PCM to modify the idle air control
specified calibrated acceptable ranges, the PCM will
PCM. When the A/C compressor relay is enabled,
battery voltage is supplied to the compressor clutch coil.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested. The PCM will not enable the A/C compressor
clutch if any of the following conditions are met:
D The IAT is less than 5C (41F).

The A/C compressor operation is controlled by the
powertrain control module (PCM) for the following
reasons:
D It improvises idle quality during compressor clutch
engagement.
D It improvises wide open throttle (WOT) performance.
components:
D The A/C control head.
D The A/C refrigerant pressure switches.
D The A/C compressor clutch.
D The A/C compressor clutch relay.
D The PCM.
A/C Request Signal

This signal tells the PCM when the A/C mode is selected
at the A/C control head. The PCM uses this to adjust the
idle speed before turning on the A/C clutch. The A/C
compressor will be inoperative if this signal is not
available to the PCM.
General Description (Evaporative

(EVAP) Emission System)
vehicle is not operating. The canister is purged by PCM
engine has been running. Air is drawn into the canister
through the air inlet grid. The air mixes with the vapor and
the mixture is drawn into the intake manifold.

The powertrain control module (PCM) supplies a ground
to energize the solenoid valve (purge on). The EVAP
purge solenoid control is pulse-width modulated (PWM)
(turned on and off several times a second). The duty
cycle (pulse width) is determined by engine operating
conditions including load, throttle positron, coolant
temperature and ambient temperature. The duty cycle is
calculated by the PCM. The output is commanded when
the appropriate conditions have been met. These
conditions are:
Poor idle, stalling and poor driveability can be caused by:
properly.

Recirculation (EGR) System)
EGR Purpose
The exhaust gas recirculation (EGR) system is use to
6E2332

PCM to control the pintle position properly, DTC P1404

will set. The PCM also tests for EGR flow.
D Above-idle speed.
D Rough idle.
057RW002
Linear EGR Valve

Linear EGR Control

The PCM monitors the EGR actual positron and adjusts
the pintle position accordingly. The uses information from
the following sensors to control the pintle position:

of Incorrect Operation
vacuum. The valve controls EGR flow from the exhaust
to the intake manifold through an orifice with a PCM
controlled pintle. During operation, the PCM controls
pintle position by monitoring the pintle position feedback
signal. The feedback signal can be monitored with a Tech
2 as Actual EGR Pos. Actual EGR Pos. should always
be near the commanded EGR position (Desired EGR
Pos.). If a problem with the EGR system will not allow the
0017

The PCM monitors the EGR valve pintle position input to
endure that the valve responds properly to commands
from the PCM and to detect a fault if the pintle position
PCM detects a pintle position signal voltage outside the
acceptable for proper EGR system operation, the PCM
will set DTC P1404.
General Description (Positive

Crankcase Ventilation (PCV) System)
The crankcase ventilation system is use to consume
blow-by gases. This mixture is then passed through the
6E2333
positive crankcase ventilation (PCV) valve into the

common chamber.
Crankcase Ventilation System Operation

The primary control is through the positive crankcase
ventilation (PCV) valve. The PCV valve meters the flow at
a rate that depends on the intake vacuum. The PCV valve
restricts the flow when the inlet vacuum is highest. In
addition, the PCV valve can seal the common chamber
off in case of sudden high pressure in the crankcase.
028RV002
While the engine is running, exhaust fuses and small

duct.
028RW002
During normal, part-throttle operation, the system is

normal combustion.
conditions:
D Rough idle.
D Stalling of slow idle speed.
D Oil leaks.
D Rough idle.
D Stalling.
D High idle speed.
6E2334
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-0285-0
High Impedance
Multimeter (Digital
Voltmeter DVM)
5-8840-2640-0
Wrench
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH2
5-8840-0632-0
Terminal Remover
5-8840-0607-0
5-8840-0388-0
Weather Pack II
Terminal Remover
5-8840-0385-0
5-8840-2636-0
Injector Test Light
5-8840-0383-0
Spark Tester
5-8840-2607-0
EVAP Pressure/Purge
Diagnostic Station
5-8840-0279-0
Vacuum Pump with
Gauge
SECTION
ENGINE EXHAUST
6F1
FRONTERA
ENGINE
ENGINE EXHAUST (6VD1 3.2L)
CONTENTS
Three Way Catalytic Converter RH and
Forked Exhaust Pipe . . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter RH and
Forked Exhaust Pipe and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter LH and
Three Way Catalytic Converter LH and
Forked Exhaust Pipe and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6F1
6F2
6F3
6F3
6F3
6F3
6F4
6F4
6F4
6F4
Service Precaution

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Silencer . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Silencer and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . .
Rear Exhaust pipe and Associated Parts .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6F5
6F5
6F5
6F5
6F6
6F6
6F6
6F6
6F7
6F7
6F7
6F7
6F8

systems.
6F2
ENGINE EXHAUST
General Description
150RX019

compartment may be an indication of a problem in one of
these areas. Any faulty areas should be corrected
immediately.
Hangers

advisable to check the condition of the complete exhaust
system.
Catalytic Converter Types:
the levels of nitrous oxide (NOx) as well as hydrocarbons
(HC) and carbon monoxide (Co).
Gasket
ENGINE EXHAUST
6F3
Three Way Catalytic Converter RH and Forked Exhaust Pipe

Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated
Parts
150RX017
Legend
(1) Three Way Catalytic Converter Fixing Nuts
(2) O2 Sensor Terminal Connector
(3) Three Way Catalytic Converter RH
(4) Mounting Rubber
(5) Forked Exhaust Pipe Fixing Bolts
Removal
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O2 sensor harness connectors (2).
4. Remove the forked exhaust pipe fixing bolts and nuts
(5) (8) (10) and the exhaust silencer fixing nuts (9),
then remove the forked exhaust pipe (7) and the
mass damper.
5. Remove the three way catalytic converter fixing nuts
(1) and the mounting rubber (4), then remove the
three way catalytic converter (3).
(6)
(7)
(8)
(9)
(10)
Mass Damper
Forked Exhaust Pipe
Forked Exhaust Pipe Fixing Nuts
Forked Exhaust Pipe Fixing Bolts
Installation
1. Install the three way catalytic converter (3) and the
mounting rubber (4), and tighten the fixing nuts (1) to
Torque
Nuts : 67 Nm (6.7kgm/49 lb ft)
2. Install the forked exhaust pipe (7) and the mass
damper (6), and tighten the fixing bolts (5) & nuts (8)
(9) to the specified torque.
Torque
Bolts&Nuts : 43 Nm (4.4kgm/32 lb ft)
3. Connect the O2 sensor connectors (2).
6F4
ENGINE EXHAUST
Three Way Catalytic Converter LH and Forked Exhaust Pipe

Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated
Parts
150RX018
Legend
(2) Mass Damper
(3) Forked Exhaust Pipe
(4) Forked Exhaust Pipe Fixing Nuts
Removal
stands.
3. Disconnect O2 sensor harness connectors (9).
4. Remove the forked exhaust pipe fixing bolts and nuts
(1) (4) (6) and the exhaust silencer fixing nuts (5), then
remove the forked exhaust pipe (3) and the mass
damper (2).
5. Remove the three way catalytic converter fixing nuts
(11) and the mounting rubber (7), then remove the
three way catalytic converter (8).
(6)
(7)
(8)
(9)
(10)
Forked Exhaust Pipe Fixing Bolts

Mounting Rubber
Three Way Catalytic Converter LH
O2 Sensor Terminal Connector
Three Way Catalytic Converter Fixing Nuts
Installation
1. Install the three way catalytic converter (8) and the
mounting rubber (7), and tighten the fixing nuts (11) to
the specific torque.
Torque
Nuts: 67 Nm (6.8kgm/49 lb ft)
damper (2), and tighten the fixing bolts (1) (6) and
nuts (4) (5) to the specified torque.
Torque
Bolts&Nuts: 43 Nm (4.4kgm/32 lb ft)
3. Connect the O2 sensor connectors (9).
ENGINE EXHAUST
6F5
Forked Exhaust Pipe

150RX022
Legend
(1) Mass Damper
Removal
stands.
3. Remove the forked exhaust pipe fixing bolts & nuts
(2) (4) (6) and the exhaust silencer fixing nuts (5), then
remove the forked exhaust pipe (3) and the mass
damper (1).
(4) Forked Exhaust Pipe Fixing Nuts

Installation
damper (1), and tighten the fixing bolts (2) (6) and the
Torque
Bolts&nuts : 43 Nm (4.4kgm/32 lb ft)
6F6
ENGINE EXHAUST
Exhaust Silencer
150RX021
Legend
(2) Support Rubber Fixing Nuts
Removal
stands.
3. Remove the support rubber fixing nuts (2), the
exhaust silencer fixing nuts (4) and rear exhaust pipe
fixing nuts (5), then remove the exhaust silencer (3).
(3) Exhaust Silencer

(5) Rear Exhaust Pipe Fixing Nuts
Installation
1. Install the exhaust silencer (3) and tighten the fixing
Torque
2. Tighten the support rubber fixing nuts (2) to the
specified torque.
Torque
Bolts: 15 Nm (1.5kgm/11 lb ft)
ENGINE EXHAUST
6F7
Rear Exhaust pipe

Rear Exhaust pipe and Associated
Parts
Removal
stands.
3. Remove the rear exhaust fixing nuts (2) and the
mounting rubbers (1) (3), then remove the rear
exhaust pipe (4).
Installation
1. Install the rear exhaust pipe (4) and the mounting
rubbers (1) (3), then tighten the fixing nuts (2) to the
specified torque.
Torque
150RW028
Legend
(1) Mounting Rubber
(2) Rear Exhaust Pipe Fixing Nuts
(3) Mounting Rubber
(4) Rear Exhaust Pipe
6F8
ENGINE EXHAUST

Nm (kgm/lb ft)
150RX020
SECTION
ENGINE LUBRICATION
6G1
FRONTERA
ENGINE
ENGINE LUBRICATION
CONTENTS
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump and Associated Parts . . . . . . . . . .
Oil Pump and Associated Parts . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Crankcase . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6G1
6G2
6G3
6G3
6G4
6G4
6G5
6G7
6G7
6G7
6G10
Service Precaution
systems.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Oil Seal . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6G10
6G10
6G12
6G12
6G12
6G13
6G13
6G13
6G14
6G15
6G2
ENGINE LUBRICATION
General Description
C06RW002
Legend
(1) Oil Strainer
(2) Oil Pump
(3) Relief Valve
(5) Oil Filter
(6) Safety Valve
(7) Oil Pressure Unit
(8) Oil Gallery
(9) Crankshaft Bearing
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Crankshaft
Connecting Rod
Piston
Camshaft
Camshaft Journal
Front Journal; Camshaft Drive Gear
Rear Journal; Camshaft Drive Gear
Oil Pan
ENGINE LUBRICATION
6G3
Oil Pump
051RW005
Legend
(1) Crankshaft Timing Pulley
(3) Oil Pipe
(4) Oil Strainer
(6) Plug
(7) Spring
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Relief Valve
Oil Pump Cover
Driven Gear
Drive Gear
Oil Seal
O-ring
Oil Pump Body
6G4
ENGINE LUBRICATION
D Badly worn or damaged gear teeth.
Measure the clearance between the body and the driven
gear with a feeler gauge.
(0.0039 in.0.0070 in)

3. Remove oil pipe.
6. Remove plug.
7. Remove spring.
8. Remove relief valve.
9. Remove oil pump cover.
10. Remove driven gear.
11. Remove drive gear.
13. Remove O-ring.
Limit : 0.20mm (0.0079 in)

conditions are found during inspection.
Relief Valve (8)

D Check to see that the relief valve slides freely.
D The oil pump must be replaced if the relief valve does
not slide freely.
D Replace the spring and/or the oil pump assembly (5) if
the spring is damaged or badly worn.
051RS004
D Measure the clearance between the drive gear and

driven gear with a feeler gauge.
(0.0043 in0.0094 in)
Limit : 0.35mm (0.0138 in)
051RS002
Body (14) and Gears (10, 11)

the conditions below is discovered during inspection.
D Badly worn or damaged driven gear (10).
D Badly worn drive gear (11) driving face.
D Badly scratched or scored body sliding face (14) or
driven gear (10).
051RS003
D Measure the side clearance with a precision straight

edge and a feeler gauge.
Clearance
(0.0011 in0.0035 in)
Limit : 0.15mm (0.0059 in)
ENGINE LUBRICATION
6G5
6. Install the plug (6).

051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking
and scoring are found, the oil strainer must be replaced.
051RS007
7. Install oil pump assembly (5).

D Carefully remove any oil from the cylinder body and
the pump. Apply sealant (TB1207B 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
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.
D Attach oil pump assembly to cylinder body.
D Tighten the oil pump fixing bolts.
Torque : 25 Nm (2.5 Kgm/18 lbft)
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.
After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the relief
valve and spring (7).
051RW002
6G6
ENGINE LUBRICATION
051RW001
Legend
013RW010
8. Install the new oil seal (12). Apply engine oil to the oil
seal lip before installation then use 5884022870
oil seal Installer, install oil seal.
015RS001
9. Install oil strainer (4) with O-ring (13).

10. Install oil pipe (3) with O-ring (13).
11. Install crankcase with oil pan (2).
the surface.
D Apply a proper 4.5 mm (0.7 in) wide bead of sealant
(TB1207C or equivalent) to the crankcase
hardens.
ENGINE LUBRICATION
6G7
Oil Pan and Crankcase

Removal
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
8. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
9. Remove pitman arm and relay lever assembly, using
the 5884020050 remover, remove pitman arm
from the steering unit and remove four fixing bolts for
relay lever assembly.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack
and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5884021530 sealer cutter,
remove oil pan.
013RS003
Installation
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
D The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.
013RS003
13. Remove crankcase fixing bolts.

14. Remove crankcase, using 5884021530 sealer
cutter, remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or damaged.
013RW010
6G8
ENGINE LUBRICATION
3. Install crankcase, tighten crankcase fixing bolts

3. Install axle housing assembly and tighten fixing bolts

Axle case bolts
Mounting bolts
013RW004
2. Install oil pan

1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (07 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of oil pan.
Sealant beat must be continuous.
D The crankcase must be installed within 5
minutes after sealant application befor the
sealant hardens.
013RW005
4. Install relay lever assembly and tighten fixing bolts.

5. Engage teeth of pitman arm and steering unit, and
tighten nut to the specified torque.
013RW006
013RW003
3. Install oil pan, tighten oil pan fixing bolts to the

specified torque.
Legend
(1) Pitman Arm
(2) Relay Lever
ENGINE LUBRICATION
6. Install suspension cross member and tighten fixing
013RW007
7. Install radiator under fan shroud.

8. Install stone guard.
9. Install engine oil level dipstick.
10. Fill engine oil until full level on engine oil gauge
dipstick.
6G9
6G10
ENGINE LUBRICATION
Oil Pump
Removal
D Use 5884022870 installer when installing new

oil seal.

3. Remove crankcase assembly.
this manual.
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
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
D Install oil pump assembly to the cylinder block.

NOTE: Do not damage oil seal during installation of oil
pump assembly.
015RS001
1. Install oil pump assembly

D Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.


hardens.
NOTE: Do not apply sealant to the oil ports.
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the

specified torque.
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
051RW002
ENGINE LUBRICATION
4. Install oil filter assembly and tighten bolts to the
specified torque.
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
5. Install timing pulley on crankshaft.
Install timing belt.
manual.
D Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.
8. Refill engine oil until full level on engine oil dipstick.
6G11
6G12
ENGINE LUBRICATION
Oil Pump Oil Seal

Removal
this manual.
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using 5884022870 installer.
015RS001
2. Install timing pulley to crankshaft.

manual.
5. Refill engine oil until full level.
ENGINE LUBRICATION
Oil Filter
Removal
3. Remove oil filter using 5884002030 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 5884002030 filter wrench.
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter
3. Fill engine oil until full level on dipstick.
6G13
6G14
ENGINE LUBRICATION

Item
Oil capacity
Specifications
6VD1
6VE1
5.3 liters
Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt cover, Oil pump, Oil gallery, Oil strainer
Nm (Kgm/lb ft)
E06RW045
ENGINE LUBRICATION
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884022870
(J39202)
Installer; Oil pump oil
seal
5884021530
(J37228)
Seal cutter
5884020050
(J29107)
Universal pitman arm
puller
5884002030
(J36390)
Wrench; Oil filter
6G15
SECTION
ENGINE SPEED CONTROL SYSTEM (6VD1 3.2L)
6H1
FRONTERA
ENGINE
CONTENTS
Accelerator Pedal Control Cable . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6H1
6H2
6H2
6H2
6H2
Service Precaution
systems.
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal and Associated Parts . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6H3
6H3
6H3
6H3
6H2
101RX001
Removal
1. Loosen the nut(5) on the cable bracket mounted on
the common chamber.
4. Disconnect AP control cable(1). (on AP pedal(7) side)
5. Remove molding cap(2).
Inspection
corrosion.
Installation
2. Install molding cap(2).
3. Connect AP control cable(1). (on AP side)
6. Install nut(5).
Accelerator Pedal
Parts
Removal
1. Accelerator Pedal control cable(1).
2. Wire Harness (A/T ONLY).
3. Accelerator Pedal assembly(2).
Installation
1. Accelerator Pedal assembly(2).
2. Wire Harness (A/T ONLY).
3. Accelerator Pedal control cable(1).
035RX002
Legend
6H3
SECTION
INDUCTION (6VD1 3.2L)
FRONTERA
ENGINE
CONTENTS
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6J1
6J2
6J2
6J2
6J2
Service Precaution
systems.
6J1
6J2
Air Cleaner Element

Removal
Installation
1. Remove positive ventilation hose connector(1).

2. Remove intake air temperature sensor(2).
3. Remove air flow sensor(3).
4. Remove air cleaner duct assembly(4).
5. Remove air cleaner element(5).
1. Install air cleaner element(5).

2. Attach the mass air cleaner duct cover to the body
completely, then clamp it with the clip(4).
3. Install air flow sensor(3).
4. Install air temprature sensor(2).
connector(1).
130RW003
Inspection
130RW003

Cleaning Method
130RW002
SECTION
AUTOMATIC TRANSMISSION (4L30E)
7A1
FRONTERA
TRANSMISSION
CONTENTS
Automatic Transmission (4L30E) . . . . . . . . .
Transmission Control System (4L30E) . . . .
Manual Transmission . . . . . . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7A
7A1
7B
7C

CONTENTS
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Reference Chart . . . . . . . . . . . . . . . . . .
Normal Operation of 1999 4L30E
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Information . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Procedure . . . . . . . . . . . . .
Preliminary Inspection Chart . . . . . . . . . . . . . .
Checking Transmission Fluid Level and
Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Check
Trans Indicator Chart . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Symptoms
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test . . . . . . . . . . . . . . . . . . . . . .
Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . .
Lockup Speed Chart . . . . . . . . . . . . . . . . . . . . .
Changing Transmission Fluid . . . . . . . . . . . . .
Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Lock Cable . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7A2
7A3
7A4
7A5
7A5
7A5
7A8
7A9
7A10
7A11
7A12
7A13
7A22
7A23
7A24
7A25
7A26
7A26
7A26
7A27
7A28
7A28
7A28
7A30
7A32
7A32
7A33
7A34
7A34
7A34
7A36
7A36
7A37
7A39
Solenoid (Main Case Valve Body) . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Adapter Case Valve Body) . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Main Case) . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Adapter Case) . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensor (Extension Housing) . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature Sensor
(Adapter Case) . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Oil Seal (Converter Housing) . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Extension Housing) . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (4L30E) . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Housing and Oil Pump Assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7A43
7A43
7A43
7A44
7A44
7A44
7A45
7A45
7A45
7A46
7A46
7A46
7A47
7A47
7A47
7A48
7A48
7A48
7A48
7A48
7A48
7A49
7A49
7A49
7A49
7A49
7A49
7A50
7A50
7A54
7A64
7A64
7A64
7A64
7A64
7A65
7A2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Case Valve Body . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter Case Valve Body . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch and Sprag Unit . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprag Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7A65
7A65
7A65
7A65
7A66
7A66
7A67
7A67
7A67
7A68
7A68
7A68
7A68
7A68
7A69
7A69
7A69
7A70
7A70
7A70
7A70
7A71
7A71
7A71
7A72
7A72
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
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
34 Accumulator Piston . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Clutch Piston and Center Support .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Overrun Clutch and Turbine Shaft . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
4L30E Parts List . . . . . . . . . . . . . . . . . . . . . . .
7A72
7A72
7A72
7A73
7A73
7A73
7A74
7A74
7A75
7A75
7A75
7A75
7A76
7A77
7A77
7A78
7A78
7A78
7A79
7A79
7A80
7A80
7A80
7A82
7A86
7A89

systems.
7A3
Construction
A07RS001
Legend
(1) Torque Converter Clutch (TCC)
(2) Fourth Clutch (C4)
(3) Overrun Clutch (OC)
(4) Overdrive Unit
(5) Reverse Clutch (RC)
(6) Second Clutch (C2)
(7)
(8)
(9)
(10)
Third Clutch (C3)

Ravigneaux Planetary Gear Set
Brake Band (B)
Overdrive Free Wheel (One Way Clutch)
(OFW)
(11) Sprag Free Wheel (One Way Clutch) (PFW)
7A4
Range Reference Chart
C07RT010
7A5
Normal Operation of 1999 4L30E

Transmission
Diagnosis
Torque Converter Clutch (TCC)

Application Conditions:
The systematic troubleshooting information covered by

this Section offers a practical and systematic approach to
diagnosing 4L30E transmission, using information that
can be obtained from road tests, electrical diagnosis, oil
pressure checks or noise evaluation.
The key to correcting a complaint is to make use of all of
the available symptoms and logically letting them direct
you to the cause.
When dealing with automatic transmission complaints, it
is best to gather as many symptoms as possible before
making the decision to remove the transmission from the
vehicle.
Frequently, the correction of the complaint does not
require removal of the transmission from the vehicle.
The TCC is normally applied in 2nd, 3rd and 4th gears

only when all of the following conditions exist:
The engine coolant temperature is above 70C
(158F).
The brake pedal is released.
The shift pattern requests TCC apply.
Moreover, TCC is always applied in 2nd, 3rd and 4th
gears when the transmission oil temperature is above
135C (275F).
This mode should be canceled at 125C (257F).
ATF Warning Lamp

The ATF warning lamp will be constantly on (not flashing)
if the transmission oil temperature is above 145C
(293F).
The ATF warning lamp goes off again when the
transmission oil temperature is below 125C (257F).
Special Shift Pattern When The Engine Is

Cold:
A special shift pattern is activated when the engine
coolant temperature is below 70C (158F). (34 shifts,
for example, are delayed for small throttle openings and
will occur a few MPH higher.)
Introduction
Driver Information
To analyze the problem fill out a complete description of
the owners complaint.
Please draw a circle around the right information and
complete the following form. (The next page is an
example of a completed form.)You can draw a circle
around many numbers if you are not sure.
7A6
F07RT036
Example of form completed.
7A7
F07RT037
7A8
General Diagnosis Procedure
F07RT038
7A9
Preliminary Inspection Chart
F07RX002
7A10 AUTOMATIC TRANSMISSION (4L30E)
Checking Transmission Fluid Level

and Condition
Checking fluid level and condition (color and odor) at
regular intervals will provide early diagnosis information
about the transmission. This information may be used to
correct a condition that, if not detected early, could result
in major transmission repairs.
IMPORTANT: When new, automatic transmission fluid
is red in color. As the vehicle is driven, the transmission
fluid will begin to look darker in color. The color may
eventually appear light brown.
A dark brown color with burnt odor may indicate
excessive fluid deterioration and signal a need for fluid
change.
Fluid Level
When adding or changing fluid, use only DEXRON III.
Refer to Maintenance and Lubrication in General
Information section for maintenance information and
servicing interval.
CAUTION: DO NOT OVERFILL.
Overfilling will cause foaming, loss of fluid, abnormal shifting and possible damage to the transmission.
1. Park the vehicle on level ground and apply the parking
brake firmly.
2. Check fluid level with engine running at idle.
NOTE: Be sure that transmission fluid temperature is
below 30C (86F).
3. Move the selector lever through all gear ranges.
4. Move the selector lever to Park.
5. Let engine idle for 3 minutes and open the overfill
screw (1).
6. Add released transmission fluid until it flows out over
the overfill screw opening.
7. Let engine idle until a fluid temperature between 32C
(90F) and 57C (135F) is reached, then close the
overfill screw (1).
NOTE: To prevent fluid leaks, the overfill screw and oil
drain screws gasket must be replaced each time these
screws are removed.
NOTE: Check transmission fluid temperature with scan
tool.
Minimum fluid level 57C (135F)
Maximum fluid level 32C (90F)
242RW003
CAUTION: Do not open overfill screw with engine

stopped.
CAUTION: DO NOT CHECK FLUID LEVEL UNDER
THESE CONDITIONS:
D Immediately after driving at sustained highway
speeds.
D In heavy city traffic during hot weather.
D If vehicle is towing a trailer.
If the vehicle has been operated under these conditions,
shut the engine off and allow the vehicle to cool for thirty
(30) minutes. After the cool down period, restart the
vehicle and continue from step 2 above.
7A11
Fluid Condition
FLUID CONDITION
NORMAL*
CONTAMINATED
COLOR
RED OR LIGHT
BROWN
BROWN
NONTRANSPAREN
T / PINK
BROWN
DRAIN
REQUIRED?
NO
YES
YES
YES
NONE
Very small amount of

foreign material in
bottom of pan
Contamination
by
coolant or other source
Large pieces of metal

or
other
foreign
material in bottom of
pan
Repair/replace
radiator cooler
Transmission
overhaul required
Check for:
D Damaged plates
and seals
D Contaminated
solenoids
Flush cooler
Add new fluid
Check level
Transmission
overhaul required
Flush cooler and
cooler lines
Add new fluid
Check level
CONTAMINATION
CORRECT
LEVEL AND
CONDITION
1. LOW LEVEL:
A. Add fluid to
obtain proper
level & check for
external leaks.
B. Correct cause of
leak.
2. HIGH LEVEL:
Remove excess
fluid
Remove both pans

Change filter
Flush cooler
Add new fluid
Check level
*Fluid should be changed according to maintenance

schedule.
Test Driving
Some 4L30E automatic transmission complaints will
require a test drive as a part of the diagnostic procedure.
Some codes will not set unless the vehicle is moving. The
purpose of the test drive is to duplicate the customers
complaint condition and set a current Powertrain Control
Module (PCM) trouble code. Perform this procedure
before each 4L30E automatic transmission repair, and
again after repairs are made.
IMPORTANT:
D Duplicate the condition under which the customers
complaint was observed.
D Depending on the complaint, the line pressure gauge
and the scan tool scan tool may be required during the
test drive.
D During the test drive, it is important to record all
necessary data from the areas being monitored, for
use in diagnosis. Also listen for and note any unusual
noises.
The following procedure should be used to test drive
4L30E automatic transmission complaint vehicles:
1. Turn the ignition ON without starting the engine.
Check that the CHECK TRANS lamp comes on for
approximately 2 to 3 seconds and then goes out and
remains out.
D If the lamp is flashing, GOTO Check Trans Indicator
in Transmission Control System (4L30E) section.
D If no serial data is present, GOTO OBD System
Check. Refer to Driveability and Emissions in
Engine section.
D If the lamp stays ON or stays OFF, GOTO Check

Trans Check in Transmission Control System
(4L30E) section.
2. Drive the vehicle. During the test drive, be sure that
the transmission achieves normal operating
temperature (approx. 20 minutes).
Allow the transmission to go through all of its gear
ranges, checking shift timing and firmness. Duplicate
the owner s complaint condition as closely as
possible during the test drive.
3. If, during the test drive, the CHECK TRANS lamp
comes on, use the scan tool to check for trouble
codes.
4. If, during the test drive, a problem is felt, but the
CHECK TRANS lamp does not come on and no
trouble codes are present, drive the vehicle with the
PCM disconnected (manually shifting the vehicle).
D In Manual L, the vehicle operates in first gear.
D In Manual 2, the vehicle operates in third gear.
D In Manual 3 or D, the vehicle operates in fourth
gear.
If the problem still exists with the PCM disconnected,
refer to Mechanical/Hydraulic Diagnosis in this
section.
5. If no problem has been found at this point, check all
underhood connections that supply power to the PCM
and ignition fuses. Physically and visually inspect all
the PCM harness connectors for loose or corroded
terminals. Inspect the PCM ground points.
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart

Perform Preliminary Inspection First!
When the CHECK TRANS indicator is flashing, it
indicates that a problem related to the transmission, the
Powertrain Control Module (PCM), or the vehicle harness
has occurred.
The system is now operating in a BACKUP MODE

where the risk of further damaging the transmission has
been reduced. The vehicle may be shifted manually.
If the initial problem is intermittent or seldom, switching
the engine OFF/ON might allow normal operation again
until the problem reoccurs.
F07RT013
7A13
Mechanical / Hydraulic Diagnosis Symptoms Index

Perform Preliminary Inspection First!
CHART
SYMPTOMS
NO ENGINE START IN NEUTRAL OR PARK
NO FORWARD GEARS IN ANY RANGE/NO REVERSE
NO ENGINE BRAKE IN ANY RANGE
POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT)
5a
DELAYS IN DRIVE AND REVERSE
5b
DELAYS IN REVERSE ONLY
HARSH 12 SHIFT
HARSH 34 SHIFT
9a
32 DOWNSHIFT COMPLAINT
9b
HARSH SHIFT WHEN SHIFTING INTO D OR ACCELERATING FROM STOP
9c
COASTDOWN HARSH SHIFT OR CLUNK AT 32 DOWNSHIFT
10
INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED
11
ENGINE FLARE AT SHIFTING DURING TURNING ONLY (USUALLY WITH WARM ENGINE)
12
ENGINE FLARE DURING 12 OR 23 SHIFT
13
SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING
14
POSSIBLE CAUSES OF TRANSMISSION NOISE
15a
POSSIBLE CAUSES OF LOW LINE PRESSURE
15b
POSSIBLE CAUSES OF HIGH LINE PRESSURE
16
POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS
NOTE: Numbers with parenthesis on the following charts

refer to Parts List at end of this section.
Chart 1: No Engine Start In Neutral Or Park

Step
Action
Yes
No
Does engine start when shift lever moved from drive to neutral
mostly in hot condition?
Go to Step 2
Go to Step 3
Retest vehicle
Go to Step 4
Go to Step 4
Go to Step 5
Retest vehicle
Go to Step 5
Locate and repair

open(s).
Replace mode
switch (63).
Does engine start in park at any condition?
Does engine also not start in neutral when shift lever moved from
park to neutral?
Check mode switch (63) setting. Readjust if necessary.

Problems fixed?
Check start circuit of mode switch (63) open in neutral.

Was open found?
Chart 2: No Forward Gears In Any Range/No Reverse

Step
Action
Check line pressure. Refer to Line Pressure Test in this section.
Yes
No
Go to Step 2
Use Chart 15a:

Possible Causes
of Low Line
Pressure in this
section.
Repair or replace
Yes
No
Go to Step 2
Use Chart 15a:

Possible Causes
of Low Line
Pressure in this
section.
Repair or replace
Was line pressure normal?
1. Check internal linkage:

Manual linkage (58) not moving manual valve (326).
2. Check for internal mechanical damage:
Turbine shaft (506) broken loose.
Overrun roller clutch (516) broken loose.
Chart 3: No Engine Brake In Any Range

Step
Action

1. Check for overrun clutch leaks caused by:

Damaged piston lip (513)
Check ball defective (504)
2. Check for overrun lockout valve (705) stuck by foreign
material.
3. Check for leaks at turbine shaft (506) caused by:
Teflon seal rings damaged (508)
Excessive wear of turbine shaft bearing surfaces.
7A15
Chart 4: Poor Shifting In All Gears (All Harsh Or All Soft)

Step
Action

No
Go to Step 2
Go to Step 3
Repair or replace
Go to Step 4
Use Chart 15a:

Possible Causes
of Low Line
Pressure in this
section.
Diagnose those
DTC(s) first.
Use Chart 15b:

Possible Causes
of High Line
Pressure in this
section.
1. Check for these conditions which could affect clutch apply

time:
Defective band apply solenoid (323).
Defective servo or/and accumulator piston.
Excessive clutch piston travel.
2. Check of possible causes of internal leaks:
Cut or damaged sealing ring(s)
Damaged sealing gasket(s)
Check ball missing or out of location in 2nd and 3rd clutch
pistons.
3. Check for causes of burned clutch plates or band.
Yes
Was the line pressure high?
Were DTCs P0560 and P0705 set?
Chart 5a: Delays In Drive and Reverse

NOTE: A short delay (less than 3 seconds) when first
engaging drive or reverse after allowing vehicle to sit
overnight is normal.
Step
Action
Yes
No
More than 3
second delay in
drive and reverse
with engine off 1
hour or less.
Teflon seals (508)
on turbine shaft
damaged. Repair
Use Chart 15a:

Possible Causes
of Low Line
Pressure in this
section.
Yes
No
Go to Step 2
Use Chart 15a:

Possible Causes
of Low Line
Pressure in this
section.
Repair
Chart 5b: Delays In Reverse Only

Step
Action

Main case valve body gasket (88) damaged.

Reverse check ball (85) in valve body (84) missing or out of
location.
Check for restrictions at valve body transfer plate orifice.
Chart 6: Diagnostic Trouble Code (DTC) P0730

Step
Action
Yes
No
Go to Step 2
Use Chart 15b:

Possible Causes
of High Line
Pressure in this
section.
Repair or replace
Shift solenoid A
stuck. Replace
shift solenoid A.
Goto Step 4
Repair or replace
1. 1st and 2nd gear missing or 3rd and 4th gear missing.
Check appropriate shift valve. If OK replace solenoid.
2. No engine brake in any range (All ranges in Drive and Reverse
are OK)
Check for suspected conditions modifying delays to clutch
apply:
Overrun clutch seal damaged.
Excessive overrun clutch piston travel.
Defective 34 accumulator piston.
Causes of internal leaks.
Causes of burned clutch plates.
3. 1st and 4th gear missing or 2nd and 3rd gear missing.
Shift solenoid A stuck. Replace shift solenoid A.
4. DTC P0730 is set in D range 1st gear above 3500 rpm.
Go to Step 3.
5. DTC P0730 is set in D range 3rd gear between 55-80 mph.
NOTE: Perform this test within safe and legal limits.
Check for suspected conditions modifying delays to clutch
apply:
4th clutch seal damaged.

Excessive 4th clutch piston travel.
Defective 34 accumulator piston.

3
Check 3rd gear in D in winter mode.

Does vehicle move?
Check for suspected conditions modifying delays to clutch apply:

2nd clutch seal damaged.
Excessive 2nd clutch piston travel.
Defective accumulator piston.
Check ball missing or out of location in 2nd clutch.
Seals cut, damaged or missing.
Gaskets defective.
7A17
Chart 7: Harsh 12 Shift

Step
Action
Yes
No
Check for 12
accumulator
valve (320) stuck
by foreign
material in main
case valve body.
Use Chart 15b:

Possible Causes
of High Line
Pressure in this
section.
Yes
No
Go to Step 2
Use Chart 15b:

Possible Causes
of High Line
Pressure in this
section.
Repair or replace
Yes
No
Go to Step 2
Use Chart 15a:

Possible Causes
of Low Line
Pressure in this
section.
Diagnose P1850
first.
Replace band
apply solenoid
(PWM) (323).
Chart 8: Harsh 34 Shift

Step
Action

1. Check for 34 accumulator valve (407) stuck in adapter case

valve body (401).
2. Check for 34 accumulator piston (18) stuck in adapter case
(20).
Chart 9a: 32 Downshift Complaint

Step
Action

Does DTC P1850 set?
Chart 9b: Harsh Shift When Shifting Into D Or Accelerating From Stop
Step
Action
Yes
No
Go to Step 2
Use Chart 15b:

Possible Causes
of High Line
Pressure in this
section.
Diagnose P1850
first.
Replace band
apply solenoid
(PWM) (323).
Does DTC P1850 set?
Chart 9c: Coastdown Harsh Shift Or Clunk At 32 Downshift

Step
Action
Yes
No
Go to Step 2
Use Chart 15b:

Possible Causes
of High Line
Pressure in this
section.
Diagnose P1850
first.
Replace band
apply solenoid
(PWM) (323).
Does DTC P1850 set?
Chart 10: Intermittent 4TH TO 2ND Gear Downshift At Steady Speed

Step
1
Action
Check for consistent speed sensor reading with scan tool.
Was the reading correct?
Yes
No
Replace mode
switch for
intermittent
contact.
Go to Step 2
Replace speed
sensor.
1. Check for wiring harness damage or short to ground. If OK, go

to (2).
2. Check transmission speed sensor connections. If OK, go to
(3).
3. Replace transmission speed sensor.
Was the replacement complete?
Chart 11: Engine Flare At Shifting During Turning Only (Usually With Warm Engine)
Step
1
Action
Check for oil leaks at transmission.
Yes
No
Replace
transmission oil
filter and gasket.
Yes
No
Go to Step 2
Use Chart 15a:

Possible Causes
of Low Line
Pressure in this
section.
Repair or replace
Chart 12: Engine Flare During 12 Or 23 Shift

Step
Action

1. Check for a stuck 12 accumulator valve (320).

2. Check for servo piston (106) leaks.
3. Check for a stuck band apply solenoid (323).
7A19
Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying
Step
Action
1. TCC shudder is one of the most commonly misdiagnosed

conditions in an automatic transmission.
The key to
diagnosing TCC shudder is to note when it happens and under
what conditions. Once the TCC has been fully applied, it is
nearly impossible to make it shudder. TCC shudder (short
burst of noise normally less than 1 second) will only occur
during clutch applying. It is not a steady state condition.
2. Drive until whole drivetrain is at normal operating temperature.
On 4WD vehicles, the test must be performed with transfer
case selector lever in 2H position.
Shudder is a short burst of noise normally less than 1 second
in duration, and can be induced by the following maneuver:
3. From coast condition at 50 mph in D range (Normal mode),
depress the throttle to 1/4-1/3 throttle. If present, shudder will
occur within 5 seconds together with TCC application.(The
scan tool may be used to determine the exact time of TCC).
Yes
No
Replace
transmission fluid
and filter (remove
both pans) and
flush cooler lines.
Replace
converter
assembly and
O-ring on turbine
shaft
Perform
mechanical
inspection of
other drivetrain
components.
Chart 14: Possible Causes of Transmission Noise

CAUTION: Before checking transmission for what
is believed to be transmission noise, ensure
presence and positioning of insulating plugs, pads
etc. Also make sure that noise does not come from
other drivetrain components.
Condition
Possible cause
Whine or Buzz
Knocking noise
transmission
transmission.
from
front
of
Knocking noise while driving, mostly

on acceleration.
Knocking noise when vehicle is

stationary
stationary.
Correction
Oil level low
Fill with ATF, check for external

leaks.
Plugged or restricted oil filter
Inspect oil filter.

Replace oil filter or ATF as necessary.
Damaged oil filter gasket
Replace oil filter gasket.
Loose bolts (Converter to flex plate)
Cracked or broken flex plate
Replace flex plate.
Converter damaged
Replace converter.
Transmission mount loose or broken
Tighten mount bolts or replace

transmission mount.
Cooler line mounts loose or broken
Tighten or replace cooler line

mounts.
Cooler lines touching body or frame
Loose flex plate mounting bolts
Cracked or broken flex plate
Replace flex plate.
Damaged converter
Replace converter.
Chart 15a: Possible Causes of Low Line Pressure

Step
1
Action
Check for defective throttle position sensor.

Check for plugged, loose, or damaged oil filter (79).

Check for a stuck force motor plunger (404). (Adapter case valve
body)
Check for a stuck feed limit valve (412). (Adapter case valve body)
Check for loose converter bolts (4 & 5).

Check for a stuck pressure regulator valve (208). (Oil pump)

Check for a stuck boost valve (205). (Oil pump)

Check for blocked intermediate oil passages to pressure

regulator valve. (Oil pump)
10
Check for defective oil pump (9, 201, 202 & 209).
11
No
Fill with ATF.
Go to Step 2
Replace throttle
position sensor.
Go to Step 3
Inspect oil filter,

tighten bolts or
replace oil filter
(79).
Go to Step 4
Replace force
motor plunger
(404).
Go to Step 5
Replace feed limit

valve (412).
Go to Step 6
Tighten converter
bolts (4 & 5).
Go to Step 7
Replace pressure
regulator valve
(208).
Go to Step 8
Replace boost
valve (205).
Go to Step 9
Replace oil
pump.
Go to Step 10
Replace oil
pump.
Go to Step 11
Install balls, or
correct ball
location.
Replace seals.
Replace gaskets.
Check oil level.

Yes
Check for internal leaks.

Check balls missing or out of location in valve bodies
Seals cut or damaged
Gaskets defective, etc.
7A21
Chart 15b: Possible Causes of High Line Pressure

NOTE: If transmission is operating in backup mode, high
line pressure will be present.
Action
Step
1
Check for defective throttle position sensor.

Check for a stuck force motor plunger (404). (Open

circuit/intermittent) (Adapter case valve body)
Check for a stuck feed limit valve (412). (Adapter case valve body)
Check converter bolts (4 & 5).

Check for a stuck pressure regulator valve (208). (Oil pump)

Check for a stuck boost valve (205). (Oil pump)

Check for internal leaks.

Check balls missing or out of location in valve bodies
Seals cut or missing
Gaskets defective, etc.
Chart 16: Possible Causes of

Transmission Fluid Leaks
Before attempting to correct an oil leak, the actual source
of the leak must be determined. In many cases, the
source of the leak may be difficult to determine due to
wind flow around the engine and transmission.
The suspected area should be wiped clean before inspecting for the source of the leak.
Yes
No
Replace throttle
position sensor.
Go to Step 2
Replace force
motor plunger
(404).
Go to Step 3
Replace feed limit

valve (412).
Go to Step 4
Tighten converter
bolts (4 & 5).
Go to Step 5
Replace pressure
regulator valve
(208).
Go to Step 6
Replace boost
valve (205).
Go to Step 7
Install balls, or
correct ball
location.
Replace seals.
Replace gaskets.
Oil leaks around the engine and transmission are generally carried toward the rear of the vehicle by the air
stream. In determining the source of an oil leak, the following two checks should be made:
1. With the engine running, check for external line
pressure leaks.
2. With the engine off, check for oil leaks due to the
raised oil level caused by drainback of converter oil
into the transmission.
Possible Causes of Fluid Leaks Due To Sealing Malfunction
240RX008
Legend
(1) Electrical Connector (Main Case) Seal
(2) Transmission Vent (Breather)
(3) Speed Sensor Oring
(4) Extension (Adapter) Lip Seal
(5) Extension (Adapter) to Main Case Gasket
(6) Overfill and Oil Drain Screws Gasket
(7) Oil Pan Gasket (Main Case)
(8) Selector Shaft Seal
Stall Test
The stall test allows you to check the transmission for
internal abrasion and the one way clutch for slippage.
Torque converter performance can also be evaluated.
The stall test results together with the road test results will
identify transmission components requiring servicing or
adjustment.
Stall Test Procedure:

1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid. Replenish if
necessary.
2. Block the wheels and set the parking brake.
3. Connect a tachometer to the engine.
4. Start the engine and allow it to idle until the engine
coolant temperature reaches 70 80C (158
176F).
(9) Oil Cooler Connectors (2)

(10) Oil Pan Gasket (Adapter Case)
(11) Converter housing attaching bolts not correctly
torqued
(12) Converter Housing Lip Seal
(13) Line Pressure Tap Plug
(14) Electrical Connector (Adapter Case) Seal
(15) Adapter Case Seal Rings (2)
5. Hold the brake pedal down as far as it will go.

6. Place the selector in the D range.
7. Gradually push the accelerator pedal to the floor.
The throttle valve will be fully open.
Note the engine speed at which the tachometer
needle stabilizes.
Stall Speed : 2,200 150 rpm
NOTE: Do not continuously run this test longer than 5
seconds.
8. Release the accelerator pedal.
9. Place the selector in the N range.
10. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
11. Repeat Steps 7 10 for the 3, 2, L and R
ranges.
Line Pressure Test

The line pressure test checks oil pump and control valve
pressure regulator valve function. It will also detect oil
leakage.
Line Pressure Test Procedure:

1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid.
Replenish if required.
2. Block the wheels and set the parking brake.
3. Remove the pressure detection plug at the left side of
the transmission case.
Set J29770A pressure gauge and adapter to the
pressure detection plug hole.
7A23
4. Start the engine and allow it to idle until the engine

coolant temperature reaches 70 80C (158
176F).
5. Hold the brake pedal down as far as it will go.
6. Place the selector in the D range.
7. Note the pressure gauge reading with the engine
idling.
8. Gradually push the accelerator pedal to the floor. The
throttle valve will be fully open.
Note the pressure gauge reading with the accelerator
pedal fully depressed.
NOTE: Do not continuously run this test longer than 5
seconds.
9. Release the accelerator pedal.
10. Place the selector in the N range.
11. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
12. Repeat Steps 7 11 for the 3, 2, L, and R
ranges.
13. Install a pressure detection plug to the transmission
case, applying recommended thread locking agent
(LOCTITE 242) or its equivalent to thread of plug.
Make sure that thread is cleaned before applying
locking agents.
14. Tighten the pressure detection plug to the specified
torque.
Torque: 9 14Nm (7 10lb ft)
241RS001
MODE
LEVER
POSITION
ENGINE SPEED
NORMAL/POWER
D,3,2,L
LINE PRESSURE
kPa
PSI
FORCE MOTOR
CURRENT
IDLE
312363
45.252.6
VARIABLE
IDLE
312 363
45.2 52.6
0.9 1.0A
NORMAL/POWER
WINTER
REVERSE
IDLE
419 486
60.7 70.5
0.9 1.0A
NORMAL/POWER
D, 3, 2, L
STALL SPEED
1,236 1320
179.3 191.4
0.1 0.2A
STALL SPEED
1,236 1320
179.3 191.4
0.1 0.2A
REVERSE
STALL SPEED
1,634 1743
236.9 252.8
0.1 0.2A
WINTER
WINTER
NORMAL/POWER
WINTER
Shift Speed Chart

Transfer gear ratio:
High: 1.000
Rear axle ratio:
4.100
Normal mode
Upshift
Range
Throttle
opening
12
23
(First Gear) (Second Gear) (Second Gear) (Third Gear)
km/h (mph)
km/h (mph)
34
(Third Gear) (Fourth Gear)
km/h (mph)
D
(Drive)
Fully opened
52 58 (33 36)
105 111 (66 69)
158 164 (99 102)
Half throttle
33 39 (21 24)
60 66 (37 41)
100 106 (62 66)
3
(Third)
Fully opened
52 58 (33 36)
105 111 (66 69)
Half throttle
33 39 (21 24)
60 66 (37 41)
2
(Second)
Fully opened
52 58 (33 36)
Half throttle
33 39 (21 24)
Downshift
Range
D
(Drive)
3
(Third)
2
(Second)
Throttle
opening
12
23
km/h (mph)
km/h (mph)
34
km/h (mph)
Fully opened
42 48 (26 30)
93 99 (58 62)
149 155 (93 97)
Half throttle
16 22 (10 14)
35 42 (22 26)
70 76 (43 47)
Fully closed
13 20 (8 12)
16 22 (10 14)
28 34 (17 21)
Fully opened
42 48 (26 30)
93 99 (58 62)
Half throttle
16 22 (10 14)
35 42 (22 26)
Fully closed
13 20 (8 12)
16 22 (10 14)
Fully opened
43 49 (27 31)
101 107 (63 67)
Half throttle
16 22 (9 13)
98 104 (61 65)
Fully closed
13 20 (8 12)
85 91 (53 57)
53 59 (33 37)
L
(First)
Power mode
Upshift
Range
Throttle
opening
12
23
km/h (mph)
km/h (mph)
34
km/h (mph)
D
(Drive)
Fully opened
52 58 (33 36)
105 111 (66 69)
180 186 (113 116)
Half throttle
38 45 (24 28)
77 83 (48 52)
129 133 (80 84)
3
(Third)
Fully opened
52 58 (33 36)
105 111 (66 69)
Half throttle
38 45 (24 28)
77 83 (48 52)
2
(Second)
Fully opened
52 58 (33 36)
Half throttle
38 45 (24 28)
7A25
Downshift
Range
D
(Drive)
3
(Third)
2
(Second)
12
23
km/h (mph)
km/h (mph)
Throttle
opening
34
km/h (mph)
Fully opened
43 49 (27 31)
96 102 (60 64)
170 176 (106 110)
Half throttle
22 28 (14 17)
55 61 (34 38)
102 108 (63 67)
Fully closed
13 20 (8 12)
25 31 (16 19)
48 54 (30 33)
Fully opened
43 49 (27 31)
96 102 (60 64)
Half throttle
22 28 (14 17)
55 61 (34 38)
Fully closed
13 20 (8 12)
25 31 (16 19)
Fully opened
43 49 (27 31)
101 107 (63 67)
Half throttle
22 28 (14 17)
98 104 (61 65)
Fully closed
13 20 (8 12)
85 91 (53 57)
53 59 (33 37)
L
(First)
Winter mode
D range, winter mode ON OFF
32 38 km/h (20 24 mph)
Lockup Speed Chart

Transfer gear ratio:
High: 1.000
Rear axle ratio:
4.100
Lockup ON
2nd
km/h
(mph)
3rd
km/h
(mph)
4th
km/h
(mph)
2nd
km/h
(mph)
3rd
km/h
(mph)
4th
km/h
(mph)
Normal
79 85
(49 53)
58 64
(36 40)
69 75
(43 47)
74 80
(46 50)
49 55
(30 34)
65 71
(40 44)
Power
79 85
(49 53)
84 90
(52 56)
84 90
(52 56)
74 80
(46 50)
76 82
(47 51)
81 87
(50 54)
Mode
D range Throttle
opening
i 9%
Lockup OFF
Changing Transmission Fluid

There is no need to change the transmission fluid unless
the transmission is used under one or more of the
following heavy duty conditions.
A. Repeated short trips
B. Driving on rough roads
C. Driving on dusty roads
D. Towing a trailer
If the vehicle is used under these conditions, change the
fluid every 20,000 miles (32,000 km.)
More over, the remaining life percentage of ATF can be
estimated by using Tech 2 as an auxiliary tool to judge the
right time for ATF replacement.
The remaining life percentage is calculated from ATFS
heat history. When it is close to 0%, ATF replacement is
recommended.
1. Place a large drain pan under the oil pan.
2. Remove the transmission oil drain screw (2) and drain
fluid.
3. Tighten drain screw (2).
NOTE: To prevent fluid leaks, the overfill screw and oil

drain screws gasket must be replaced each time these
screws are removed.
NOTE: Check transmission fluid temperature with scan
tool.
7. Reset Oil Life Monitor data by using Tech 2.
Refer to Tech 2 OBD II Connection in Transmission
Control System (4L30-E) section.

4. Remove the transmission overfill screw (1) and fill
transmission through overfill screw opening, using
DEXRONIII ATF.
NOTE: Add transmission fluid until it flows out over the
overfill screw opening.
242RW003
5. Let engine idle until a fluid temperature between 32C

(90F) and 57C (135F) is reached.
6. Add transmission fluid until it flows out over the overfill
screw opening, then close the overfill screw (1).
Selector Lever
Inspection
1. Make sure that when the selector lever is shifted from
P to L, a clicking can be felt at each shift position.
Make sure that the gear corresponds to that of the
position plate indicator.
2. Check to see if the selector lever can be shifted as
C07RW009
7A27
6. Remove center console.
Removal
2. Set ignition Key in LOCK position and selector lever
in P position.
3. Remove transfer control lever knob.
4. Remove lower cluster assembly.
256RW006
7. Remove selector lever knob and cover.
740RW021
5. Remove rear console.
256RW043
8. Disconnect select cable.

D Refer to Select Cable in this section.
9. Disconnect shift lock cable.
D Refer to Shift Lock Cable in this section.
10. Disconnect harness connector.
745RW011

5. Install selector lever knob and cover.
11. Remove selector lever subassembly.
256RW044
256RW043
6. Install center console.

7. Install rear console.
8. Install lower cluster assembly.
9. Install transfer control lever knob.
10. Connect negative () battery cable.
11. After installation, make sure that the selector lever
operates normally, and that each selector position is
properly indicated. (The red mark shows through the
window.)
Installation
1. Install selector lever subassembly.
2. Connect harness connector.
3. Connect shift lock cable.
D Refer to Shift Lock Cable in this section.
4. Connect select cable.
D Refer to Select Cable in this section.
Select Cable
Removal
1. Set selector lever in P position.
2. Remove transfer control lever knob, lower cluster
assembly, rear console, center console, selector
lever knob and cover.
D Refer to Selector Lever in this section.
3. Disconnect inner cable by pulling projection on pin.
256RW022
7A29
4. Press down claws and disconnect cable assembly.
A07RW017
5. Disconnect PCM harness connectors and remove

nuts that fasten grommet in select cable assembly.
6. Disconnect inner cable.
7. Pull lock.
A07RW015
210RW013

8. Slide sleeve and disconnect cable assembly.
A07RW082
9. Draw select cable assembly into the interior side.
Installation
1. Set selector lever in P position.
2. Let out select cable transmission side end from floor
hole.
3. Fit outer cable into bracket in selector lever assembly.
A07RW016
7A31
4. Set inner cable end in selector lever and push pin into
selector lever hole and inner cable end.
256RW023
7. Set select lever P position and connect inner cable

to select lever.
5. Check that lock projects.
A07RW015
6. Connect adjust end fitting attachment to the bracket

on transmission.
210RW013

8. Push lock into adjust end fitting attachment.
9. Install grommet.
10. About following installation steps, refer to Selector
Lever in this section.
A07RW014
Shift Lock Cable

4. Disconnect lock adjust.
Removal
1. Set ignition key in LOCK position and selector lever
in P position.
assembly, rear console, center console, selector
lever knob and cover.
D Refer to Selector Lever in this section.
3. Disconnect inner cable from selector lever assembly
then push claw and disconnect cable assembly.
256RW017
5. Remove instrument panel lower cover and steering

column cover.
256RW016

6. Remove spring pin and disconnect inner cable.
D Disconnect outer cable from bracket.
7A33
5. Check that cable moves smoothly, lightly pulling outer

cable rearward.
256RW008
256RW019
6. Connect lock adjust, aligning T mark in the Up

position.
Installation
1. Set ignition key in LOCK position and selector lever
in P position.
2. Connect outer cable to bracket near steering lock.
D Connect inner cable to steering lock and install
spring pin.
3. Install steering column cover and instrument lower
cover.
4. Install adjust body of cable assembly to bracket in
selector lever assembly.
D Install inner cable to lever, pulling inner cable with
outer cable.
256RW017
256RW018
7. About following installation steps, refer to Select

Lever in this section.
8. Check the shift lock operation:
a. Selector lever should not be moved out of P
position with ignition key in Lock position.
b. Selector lever can be moved out of P position with
ignition key in ONposition only when brake pedal
is depressed.
c. ignition key can be turned to LOCK position only
when selector lever is in P position (key can be
pulled out).
9. If a. and c. fail, readjust cable. If b. fails, readjust
connector wiring and brake pedal switch.
Mode Switch
Removal
1. Place selector lever in neutral.
3. Remove mode switch cover (1).
4. Disconnect selector lever (2) from the mode switch.
5. Remove bracket with cable (3).
6. Disconnect transmission harness from the mode
switch connector (4).
7. Remove bracket with mode switch connector from
8. Remove mode switch connector (4) from the bracket
(5).
9. Remove two mode switch bolts and nut then remove
mode switch (6).
c. Remove the mode switch cover.

d. Loosen the two 10 mm screws.
e. Rotate the mode switch until the slot in the mode
switch housing aligns with the selector shaft
bushing, and insert a 3/32 in. (2.4 mm) drill bit or
punch (1) into the slot.
f. Tighten the screws to 13 Nm (113 lb in).
g. After completing adjustment, snap the mode
switch cover into place.
h. Reinstall the selector lever.
249RW001
Procedure 2
210RW014
Installation
noting the following points;
1. Torque
Mode switch bolt: 13 Nm (113 lb in)
Selector lever nut: 23 Nm (17 lb ft)
2. Mode switch setting procedure
Perform either of the following adjustment
procedures:
Procedure 1
a. Place selector lever in neutral.
b. Remove selector lever from the mode switch.
a. Place selector lever in neutral.

b. Disconnect transmission harness connector from
mode switch connector.
c. Remove mode switch connector with bracket from
d. Connect multimeter (resistance mode) to
terminals 1(E) and 4(H) on mode switch connector.
e. Loosen two mounting screws.
f. Rotate mode switch slightly in both directions to
determine the range (approx. 5 degrees) of
electrical contact.
g. Position mode switch in middle of contact range.
h. Tighten two mounting screws.
i. Remove multimeter and install mode switch
harness connector with bracket to the
transmission case.
j. Connect transmission harness connector to mode
switch connector.
F07RW003
7A35
Transmission
Transmission and Associated Parts
240RX012
Legend
(1) Skid Plate
(5) Center Exhaust Pipe
(6) Harness Heat Protector
(7) Rear Mount Nut
(8) Third Crossmember
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Transmission Oil Cooler Pipe

Starter
Under Cover
Transfer Control Lever
Select Cable
Torque Converter Bolt (Non reusable part)
Engine-Transmission Bolt
Transmission Assembly
Removal
NOTE: Before remove transmission and transfer
using push button on dash panel.
7A37
3. Remove transfer protector.

4. Remove center exhaust pipe.

2. Remove rear propeller shaft and front propeller shaft.
and rear sides.
150RX008
5. Remove fuel
crossmember.
pipe
bracket
from
the
third
401RW008
141RX004
6. Disconnect transmission harness connector and clip.

Connector : Adapter case, mode switch, main case,
magnetic sensor, transfer switch, 24 actuator and
car speed sensor.
401RW007

7. Remove harness heat protector.
11. Remove oil pipe clamp and bracket from the

converter housing.
815RW002
8. Support transmission with a jack.

Remove rear mount nuts from the third
crossmember.
253RX002
12. Remove skid plate and loosen oil cooler pipe clamp
bolt at the engine mount side.
13. Remove select cable by disconnecting inner cable
from select lever and removing outer cable with
bracket.
F07RW008
9. Remove third crossmember.

10. Disconnect transmission oil cooler pipes from A/T
side.
256RW025
14. Remove starter.

15. Remove under covers from the transmission and
engine.

16. Remove transfer control lever fixing bolts and push up
transfer control lever.
7A39
Installation
1. Slowly raise transmission jack until front of the
transmission is aligned with rear of the engine. Join
the transmission to the engine.
2. Tighten engine-transmission bolts as shown in the
figure.
262RW015
17. Remove flex plate torque converter fixing bolts (6

pieces) by turning crankshaft.
240RX010
18. Remove engine-transmission fixing bolts.

19. Pull out transmission from the engine.
F07RW002
3. Align the flex plate torque converter bolt boss with flex
plate hole by turning the torque converter. Install flex
plate torque converter bolts (6 pieces) by turning the
crankshaft.
NOTE: Do not reuse the flex plate torque converter bolt.
262RW015
5. Install under covers to the transmission and engine.

6. Install starter.
240RX010
4. Install transfer control lever on the transfer case.

7. Install select cable by connecting inner cable to select
lever and installing outer cable with bracket.
7A41
12. Install rear mount nuts.

256RW025
F07RW008
8. Connect transmission oil cooler pipes to A/T.
13. Install harness heat protector.
9. Install oil cooler pipe clamp and bracket to the

converter housing.
815RW002
253RX002
10. Tighten oil cooler pipe clamp bolt at the engine mount
side and install skid plate.
11. Install third crossmember.
14. Connect transmission harness connector and clip.

Connector : Adapter case, mode switch, main case,
magnetic sensor, transfer switch, 24 actuator and
car speed sensor.
15. Connect fuel pipe to transmission side.
141RW035
16. Install fuel pipe bracket to the third crossmember.
18. Install transfer protector.
141RX004
17. Install center exhaust pipe.

150RX008
19. Install front propeller shaft and rear propeller shaft.

7A43
Solenoid (Main Case Valve Body)

Removal
Installation
1. Raise the vehicle and support it on jack stands.

3. Drain fluid.
4. Remove sixteen 10 mm screws, main case oil pan,
magnet, and gasket.
5. Remove three 13 mm screws, oil filter.
6. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
7. Remove spring pin for shift solenoid A, shift solenoid
B, and band control solenoid respectively, using
suitable pliers taking care not to damage solenoids.
1. Install shift solenoid A, shift solenoid B, band control

solenoid with new gaskets to main case valve body
respectively.
2. Carefully install spring pin with hammer to avoid
damage to valve body, etc.
243RW004
3. Connect wiring harness to solenoids.

4. Install oil filter with a new gasket and the three 13 mm
screws, tighten to the specified torque.
210RW010
5. Install magnet, main case oil pan with new gasket,

and sixteen 10 mm screws. Tighten the screws to the
specified torque.
6. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRONIII. Refer to Changing
Transmission Fluid in this section.
244RW003
8. Remove shift solenoid A, shift solenoid B, band

control solenoid, and gaskets from main case valve
body. Do not pull on wiring harness. Remove
solenoids by grasping the metal tip.
Solenoid (Adapter Case Valve Body)

Removal
Installation

3. Drain fluid.
4. Remove adapter case oil pan twelve fixing 10 mm
screws, adapter case oil pan, and gasket.
NOTE: Oil pan still contains transmission fluid. Place a
large drain container under the oil pan and drain the fluid
carefully.
5. Disconnect wiring harness from force motor solenoid
and converter clutch solenoid. Pull only on
connectors, not on wiring harness.
6. Remove 11 mm bolt and converter clutch solenoid
with two O-rings.
1. Install force motor solenoid, retainer, and 11 mm bolt

to adapter case valve body. Tighten the bolt to the
specified torque.
2. Install converter clutch solenoid with two O-rings, and
11 mm bolt to adapter case valve body. Tighten the
3. Connect wiring harness assembly to solenoids.
4. Install adapter case oil pan, new gasket, and twelve
10 mm screws. Tighten the screws to the specified
torque.
5. Fill transmission through overfill screw hole oil pan,
using ATF DEXRONIII. Refer to Changing
210RW011
7. Remove 11 mm bolt, retainer, and force motor

solenoid.
210RW009
7A45
Valve Body Assembly (Main Case)

4. Install seven 13 mm screws, and tighten them to the
specified torque.
Removal
3. Drain fluid.
4. Remove sixteen 10 mm screws, main case oil pan,
magnet and gasket.
5. Remove three 13 mm oil filter fixing screws, then
remove oil filter.
6. Remove two 13 mm manual detent fixing screws,
then remove roller and spring assembly.
7. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
8. Remove four 13 mm servo cover fixing screws, then
remove servo cover and gasket.
9. Remove seven 13 mm valve body fixing screws.
D Disconnect ground wire from the main case valve
body.
10. Remove main case valve body with manual valve link
and transfer plate. Note the position of the link (long
end into valve, short end into range selector lever).
11. Remove transfer plate gasket from main case.
12. Remove two check balls from main case.
243RS008
5. Install 8.5 mm connector of ground wire under the

head of this valve body bolt and reinstall it. Tighten the
Installation
1. Install two check balls to main case.
244RW001
244RW002
2. Inspect electrical 4 pin connector and seal of main

case. Replace if necessary.
3. Use two J25025B guide pin to install main case.
D Install valve body complete assembly and manual
valve link.
NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever.
Long end of link goes into valve.
6. Remove two guide pins from main case.

7. Install servo cover gasket, cover, and four 13 mm
screws. Tighten the screws to the specified torque.
8. Connect wiring harness to band control and shift
solenoids.
9. Install roller and spring assembly to manual detent.
D Install two 13 mm screws, and tighten them to the
specified torque.

10. Install oil filter and three 13 mm screws. Tighten to the
specified torque.
Torque : 20 Nm (15 lb ft)
11. Install oil pan gasket, magnet, oil pan and sixteen 10
mm screws. Tighten the screws to the specified
torque.
12. Fill transmission through overfill screw hole of oil pan,

using ATF DEXRONIII. Refer to Changing
Valve Body Assembly (Adapter Case)

Removal
3. Drain fluid.
4. Remove twelve 10 mm adapter case oil pan fixing
large drain container under the oil pan.
Drain the fluid carefully.
5. Disconnect wiring harness from force motor solenoid
and converter clutch solenoid. Pull only on
connectors, not on wiring harness.
6. Remove seven 13 mm screws from adapter case
valve body assembly, then remove transfer plate, two
gaskets, and adapter case valve body.
Installation
1. Inspect electrical 5 pin connector and seal of adapter
case. Replace if necessary.
2. Install gasket, transfer plate, and gasket.
3. Install adapter case valve body and seven 13 mm
4. Connect wiring harness assembly to converter clutch
solenoid and force motor.
5. Install oil pan gasket, oil pan, and twelve 10 mm
pan, using ATF DEXRONIII, refer to Changing
7A47

Removal
assembly, center console and rear console.
3. Disconnect PCM wiring harness connectors from

PCM.
4. Remove four PCM retaining screws.
5. Remove two brackets from PCM.
014RW221
Installation
1. Install two brackets to PCM.
2. Install four PCM retaining screws.
3. Connect PCM wiring harness connectors to PCM.
4. Install center console, rear console, lower cluster
assembly and transfer control lever knob.
Speed Sensor (Extension Housing)

Removal
Installation

3. Disconnect speed sensor harness connector from
speed sensor.
4. Remove one 10 mm screw and speed sensor with
O-ring.
1. Inspect the speed sensor O-ring, and replace it if

necessary.
2. Install speed sensor assembly and 10 mm screw.
3. Connect speed sensor harness connector to speed
sensor.
Transmission Oil Temperature Sensor (Adapter Case)

Removal
Installation

3. Drain fluid.
4. Remove twelve 10 mm adapter case oil pan fixing
large drain container under the oil pan and drain the fluid
carefully.
5. Disconnect wiring harness from force motor solenoid,
converter clutch solenoid, and 5 pin connector of
adapter case. Pull only on connectors, not on wiring
harness.
6. Disconnect ground wire from converter clutch
solenoid wiring harness connector.
7. Remove wiring harness assembly (transmission oil
temperature sensor).
243RW002
1. Connect ground wire to converter clutch solenoid

wiring harness connector of the wiring harness
assembly.
2. Install wiring harness assembly to converter clutch
solenoid, force motor, and 5 pin connector of adapter
case.
3. Install oil pan gasket, oil pan and twelve 10 mm fixing
pan, using ATF DEXRONIII.
Refer to Changing Transmission Fluid in this section.
7A49
Front Oil Seal (Converter Housing)

Removal
Installation
1. Remove transmission assembly from the vehicle

,refer to Transmission in this section.
2. Remove torque converter from converter housing.
3. Remove three screws and oil seal ring from converter
housing.
1. Apply clean ATF to the new oil seal ring lip.

D Install oil seal ring to converter housing, tighten to
2. Install torque converter to converter housing.
3. Install transmission assembly case to the vehicle,
refer to Transmission in this section.
241RW008
Rear Oil Seal (Extension Housing)

Removal
Installation
1. Remove transfer case assembly from the vehicle.

Refer to Transfer Case in Drive Line/Axle section.
2. Remove rear oil seal from transmission extension
housing.
241RW005
1. Use J36797 extension housing oil seal installer, and

install the rear oil seal to the transmission extension
housing.
2. Install the transfer case assembly to the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
Transmission (4L30E)
Disassembly
NOTE: During the disassembly and reassembly, perform
the following:
D Wash each part thoroughly, and blow air through each
oil passage and groove to eliminate blockage.
D Seal rings, roll pins, and gaskets should be replaced.
D When assembling the components, apply
DEXRONIII Automatic Transmission Fluid (ATF)
to each seal, rotating part, and sliding part.
D Do not dip part facings, such as clutch or brake drive
plates, in cleaner when washing it.
Also, always coat parts with new ATF two or three
times after cleaning with solvent.
1. Remove torque converter (1).
D Drain fluid from torque converter.
D Attach J876302 holding fixture to the
transmission and set it on J328920 holding
fixture base.
NOTE: Do not overtighten the tool, as case damage may
result.
2. Remove O-ring (2) from turbine shaft.

3. Remove two 10mm mode switch screws, selector
lever nut, cover, and mode switch (3).
4. Remove twelve 10mm adapter case oil pan (4) fixing
screws, adapter oil pan, and gasket.
5. Disconnect electrical wiring connections (5) from
solenoids and 5 pin connector of adapter case. Pull
on connectors only, not on wiring harness.
6. Remove seven 13mm adapter case valve body (6)
fixing screws, adapter case valve body assembly,
transfer plate, and two gaskets.
D Remove wiring harness and 5 pin connector.
7. Remove sixteen 10mm main case oil pan (7) fixing
screws, main oil pan, magnet, and gasket.
8. Remove three 13mm oil filter (8) fixing screws and oil
filter.
9. Remove two 13mm manual detent (9) fixing screws,
roller and spring, and manual detent.
10. Disconnect wiring harness assembly (10) from band
apply solenoid, shift solenoids, and main case 4 pin
connector.
Pull on connectors only, not on wiring harness.
11. Remove four 13mm servo cover (11) fixing screws,
servo cover, and gasket.
12. Remove seven 13mm valve body screws and ground
wire from main case.
D Remove wiring harness assembly (5) from the
adapter case side.
D Remove main valve body assembly (12) with
manual valve link and transfer plate. Note the
position of the link (long end into valve, short end
into range selector lever).
D Remove 4 pin connector.
D Remove gasket transfer plate from main case.
13. Remove two check balls (13) from main case.
420RW021
7A51
240RW022
14. Turn transmission to vertical position to drain fluid.

Return back to horizontal position when drained.
D Install J23075 servo piston spring compressor
with offset to the rear of case.
D Compress servo piston assembly.
D Remove servo piston retaining ring (14).
D Slowly release servo piston assembly (15).
D Remove tool.
15. Remove servo piston assembly (15), return spring
(16), and servo apply rod (17).
242RS002
16. Rotate transmission to horizontal position, pan side

down.
D Remove one 10mm screw, and speed sensor (18)
with O ring.
17. Remove seven 8mm extension housing hexagon
socket head screws, extension housing assembly
(19), and gasket.
18. Remove retaining ring (20).
NOTE: Use extra long, needle nose pliers.
19. Remove speed wheel (21).
20. Remove wheel parking lock (with seal ring) (22).
241RS002
21. Rotate transmission to vertical position, converter

housing up.
D Loosen the converter housing and oil pump
assembly fixing screws, but do not remove, the five
13 mm inner screws unless oil pump disassembly is
required.
D Remove seven outer screws.
D Remove converter housing and oil pump assembly
(23).
22. Remove gasket (24).
23. Remove selective thrust washer (25).
241RW004
24. Remove fourth clutch retainer (26).

25. Grasp turbine shaft and lift out the overrun clutch
housing assembly (27) and fourth clutch plates (28).
26. Remove thrust bearing assembly (29).
27. Remove overdrive internal gear (30).
28. Remove thrust washer (31).
7A53
252RS001
29. Remove adapter case and center support assembly

(with fourth clutch piston) (32).
30. Remove seal ring (33).
31. Remove selective thrust washer (34) and two O-ring
seals (35) from main case.
32. Use J23327 and J2332790 compressor to
compress the fourth clutch spring retainer and
springs (37).
D Release snap ring (36) from groove.
D Remove clutch compressor and snap ring (36).
33. Remove retainer and spring assembly (37).
34. Insert two converter housing/main case screws to
hold adapter case while pulling out fourth clutch
piston (38).
D Remove fourth clutch piston assembly (38) from the
adapter case.
D Remove converter housing/main case screws.
35. Grasp intermediate shaft, twist and pull out the
second and third clutch drum assemblies with reverse
clutch plates while holding onto output shaft (39).

36. Separate second (40) and third clutch (41)
assemblies.
37. Remove thrust washer (42).
38. Remove reverse clutch plates (43 and 44) and
reverse clutch pressure plate (45).
39. Remove bearing (46) and washer (47).
40. Remove planetary carrier assembly (48).
41. Remove thrust bearing (49).
42. Remove reaction sun gear (50)
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
NOTE: Insert wire in the center of the spring pin to

prevent it from collapsing during removal. Be aware of pin
height. Protect machined face of main case.
48. Remove parking lock and range selector lever 17 mm
nut (57).
49. Remove parking lock and range selector lever (56),
and actuator assembly.
50. Remove selector shaft (58).
NOTE: Inspect the shaft for burrs before removing to
prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
249RS004
Reassembly
1. Inspect selector shaft seal and replace it if necessary.
NOTE: Use a seal installer when replacing the seal.
D Install selector shaft.
NOTE: Spring pin groove must be positioned inside the
case.
242RW005
47. Rotate case to horizontal position, valve body side

facing up.
D Remove spring pin (55), using cutting pliers, then
remove parking lock and selector lever assembly
(56).
2. Install spring pin. Be sure the selector shaft can move

freely.Do not push the pin flush with the case surface.
Leave enough height for removal.
3. Install actuator assembly (1).
4. Install parking lock and range selector lever (2) and
new 17 mm nut. Tighten the nut to the specified
torque.
7A55
11. Install the thrust bearing (9) on the output shaft.

NOTE: Use petroleum jelly to hold the thrust bearing in
place.
249RS005
5. Rotate main case to vertical position, extension end

facing down.
D Install brake band assembly (3).
NOTE: Be sure to align servo pin area with the servo hole.
6. Install thrust bearing (4).
12. Align planetary pinions. Each pinion is marked with

double points to indicate the master tooth space and
exactly opposite with a single point to indicate the
master tooth. The markings on the planetary carrier
consist of double lines which are to be lined up with
the double points on two opposite pinions; the single
lines are to be lined up with the single points on the
other two pinions.
D After all four pinions are lined up, slide on the third
clutch assembly. Rotate third clutch and check
mark alignment. Considering that the ring gear
tooth between the double points of one planetary
pinion is tooth number 1, count the teeth to check
that the single points on the two adjacent pinions
are between teeth 23 and 24 of the ring gear, and
that the ring gear tooth between the double points of
the opposite pinion is tooth number 46. If the ring
gear and pinions are not lined up, remove and
realign them.
13. Install planetary carrier (8) with third clutch (12).
NOTE: Do not force. When properly aligned, the parts will
fit together easily.
NOTE: The case bushing acts as a guide for the thrust

bearing.
7. Install brake drum (5).
8. Install reaction sun gear (6).
9. Install needle bearing (7).
10. Inspect planetary carrier assembly (8) for wear and
damage. If necessary replace it.
D Measure pinion end play clearance with a feeler
gauge.
Clearance: 0.13mm0.89mm (0.005 in0.035 in)
If clearance is outside specified value, replace the
planetary carrier assembly.
248RS002
14. Remove the third clutch (12).

15. Install bearing (11) and washer (10).
248RS001

NOTE: Use petroleum jelly to hold the washer and
bearing in place.
247RS001
19. Install pressure plate (15) with lip side up, tang facing
valve body face.
20. Install reverse clutch plates. Start with a steel plate
(17) and alternate with a lined plate (16).
21. Install waved clutch plate (18) with center tang facing
valve body side.
242RW002
16. Carefully align the second clutch plate inner tangs.

D Install thrust washer, tangs pointing downward, and
locating tang positioned in slot on second clutch
hub.
NOTE: Use petroleum jelly to hold thrust washer in place.
17. Install third clutch and intermediate shaft assembly
(13) into the second clutch drum (14).
18. Install second and third clutch assemblies into the
main case. Twist output shaft and clutch assemblies
to ensure proper fit.
247RS002
22. Second clutch end play measurement

1. Install the J23085A Selective washer gauging
tool (with spacer ring) on the case flange and
against the intermediate shaft.
2. Position the inner shaft of the gauging tool against
the thrust surface of the second clutch hub.
3. Tighten thumb screw. Remove the tool.
4. Fit the spacer ring on the inner shaft of the tool.
5. Measure the gap and select appropriate washer
as shown in the chart.
7A57
Selective Thrust Washer

Gap: mm(in)
Color
1.53 1.63 (0.060 0.064)
Yellow
1.72 1.82 (0.068 0.072)
Red
1.91 2.01 (0.075 0.079)
Black
2.10 2.20 (0.083 0.087)
Natural
2.29 2.39 (0.090 0.094)
Green
2.48 2.58 (0.098 0.102)
Blue
FOLLOWING THE PROCEDURE SHOULD

RESULT IN FINAL ENDPLAY FROM 0.36 mm TO
0.79 mm (0.014 in TO 0.031 in)
247RS004
23. Inspect fourth clutch piston seals and replace if

necessary.
D Lubricate J38554 fourth clutch piston fitter and
install it on fourth clutch piston (19).
D Install fourth clutch piston (19) in adapter case (20).
D Remove fitter.
247RS003
252RS003
24. Install retainer and spring assembly (22) into fourth

clutch piston (21).
25. Install snap ring (23) in adapter case.
D Install J23327 and J2332790 fourth clutch
spring compressor.
D Seat snap ring in groove.
D Remove compressor.
252RW002
242RS004
29. Install thrust washer (26) into adapter case, with

tangs pointing downwards.
30. Preassemble overdrive internal gear (27) and thrust
bearing assembly (28) onto the turbine shaft and
overrun clutch assembly.
NOTE: Install bearing assembly, black side up. Use
petroleum jelly to keep assembly in place.
252RS004
26. Install selective washer using petroleum jelly.

27. Install two O-ring seals (24) in main case and adapter
case/main case seal ring (25).
28. Install J38588 guide pins.
D Install adapter case and center support assembly to
main case.
31. Install overdrive carrier (30) and internal gear

assembly into adapter case.
32. Install fourth clutch plates (29) in the following order:
Steel, Lined, Steel, Steel, Lined, Steel. Steel plates
go in with short tang facing towards valve body
surface.
33. Install fourth clutch retainer(31) with the notch facing
up and positioned towards valve body surface.
252RW004
7A59
252RS005
34. Overdrive clutch end play measurement

1. Install the J23085A selective washer gauging
tool on the adapter case flange and against the
input shaft.
2. Position the inner shaft of the tool against the
thrust surface of the overrun clutch housing.
3. Tighten thumb screw. Remove the tool.
4. Measure gap. Select appropriate size washer as
shown in the chart.
5. Set selective thrust washer aside.
Selective Thrust Washer
Gap: mm(in)
Color
1.53 1.63 (0.060 0.064)
Yellow
1.72 1.82 (0.068 0.072)
Red
1.91 2.01 (0.075 0.079)
Black
2.10 2.20 (0.083 0.087)
Natural
35. Install selective washer (32).
2.29 2.39 (0.090 0.094)
Green
2.48 2.58 (0.098 0.102)
Blue
NOTE: Use petroleum jelly to hold selective washer in

place.
252RS006
FOLLOWING THE PROCEDURE SHOULD RESULT IN FINAL ENDPLAY FROM 0.1 mm TO 0.8
mm (0.004 in TO 0.03 in)
36. Install gasket (33).

37. Install converter housing and oil pump assembly (34)
to adapter case.
D Fit and tighten seven outer 13 mm screws.

D Ensure free rotation of pump using J2308201
pump rotation tool.
6. Remove axial play checking tool and puller.

NOTE: If end play is not correct, repeat selective washer
selection.
252RW001
39. Inspect extension housing oil seal and replace if

necessary, using J36797 extension housing oil seal
installer.
D Rotate transmission to horizontal position, with
valve body side down.
D Inspect parking wheel seal ring.
necessary.
241RW010
38. Overdrive clutch end play measurement.

1. Fit J25022 and J247731 turbine shaft puller
on turbine shaft.
2. Position axial play checking tool on converter
housing mating face.
3. Pull turbine shaft upwards with puller until first
resistance is met. (due to weight of overdrive
assembly)
4. Maintain shaft in this position and set indicator to
zero.
5. Pull turbine shaft further upwards with puller.
Read end play shown on indicator.
End play: 0.1mm 0.8mm (0.004 in 0.031in)
Replace if
D Install wheel parking lock assembly (35).

40. Install speed wheel (36) and snap ring (37).
NOTE: Use extra long, needle nose pliers.
41. Install gasket onto extension assembly with a thin
coating of oil.
D Install extension housing assembly (38), and align
parking pawl shaft.
D Install actuator assembly into extension assembly.
D Install seven 8 mm hexagon socket head screws.
42. Inspect speed sensor O-ring. Replace if necessary.
D Install speed sensor assembly (39) and 10 mm
screw.
7A61
43. Main case end play measurement.

1. Attach axial play checking tool on the extension
housing and set indicator to zero on output shaft.
2. Manually push output shaft upwards.
End play: 0.36mm 0.80mm (0.014 in 0.031in)
3. Remove axial play checking tool.
4. If end play is not correct, repeat selective washer
selection.
241RS005
241RW009
44. Inspect servo piston seal ring. Replace if necessary.

D Ensure brake band is correctly positioned. Rotate
output shaft if necessary.
D Install J38428 servo piston fitter in servo bore.
D Install apply rod (40), round end toward band, return
spring (41) and piston assembly (42).
45. Install the J23075 servo spring compressor with
offset to rear of case.
D Compress servo piston seal ring, using fitter while
tightening the tool screw.
D Install servo piston retaining ring (43).
D Remove tool.
241RS004
D Adjust the brake band by tightening the servo

adjusting screw to 4.5 Nm torque. Be certain the
lock nut is loose, then back-off the screw five turns
exactly. Hold piston sleeve with wrench and tighten
lock nut to 18.5 Nm torque. Be certain the adjusting
screw does not turn.

NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever.
Long end of link goes into valve.
D Install seven 13 mm screws, tighten the specified
torque.
D Pass ground wire of adapter case wiring harness
assembly through the hole joining adapter fluid area
and main case fluid area.
D Assemble 8.5 mm connector of ground wire under
the head of this valve body bolt and reinstall it.
D Remove two guide pins.
242RW004
46. Install two check balls (44).

244RW001
49. Install servo cover gasket, cover (46) and four 13 mm

screws.
50. Connect wiring harness (47) to band control, shift
solenoids, and main case 4 pin connector.
51. Install manual detent roller and spring assembly (48)
with clip.
D Install two 13 mm screws.
52. Install oil filter (49) and three 13 mm screws.
53. Install oil pan gasket, magnet, main oil pan (50),
sixteen 10 mm screws.
244RW002
47. Inspect main case electrical connector and seal,

replace if necessary.
D Install electrical 4 pin connector/main case and
wiring harness.
48. Install two J25025B guide pins into main case.
D Install main case valve body complete assembly
(45) and manual valve link.
54. Inspect adapter case electrical connector and seal.

Replace if necessary.
D Install electrical five pin connector and harness
assembly (52) in bottom of adapter case.
55. Install gasket, transfer plate, and gasket.
D Install adapter case valve body (51) complete and
seven 13 mm screws.

56. Connect wiring harness harness assembly (52) to
converter clutch solenoid, force motor, and 5 pin
connector.
57. Install oil pan gasket, adapter case oil pan (53), and
twelve 10 mm screws.
D Rotate transmission, with bottom pan facing down.
58. Install mode switch (54), two 10 mm screws, selector
lever nut, and cover.
10 mm screw
Nut
D Adjust using setting tool, refer to Mode Switch in
this section.
59. Install O-ring (55) on turbine shaft.
7A63
60. Install torque converter (56)

The converter assembly must be replaced under any
of the following conditions:
a. Evidence of damage to the pump assembly.
b. Metal particles are found after flushing the cooler
lines.
c. External leaks in hub weld area.
d. Converter pilot broken, damaged, or poor fit into
crankshaft.
e. Converter hub scored or damaged.
f. Internal failure in stator.
g. Contamination from engine coolant.
h. Excess end play.
D Rotate transmission, bell housing up.
Spin
converter to insure proper fit.
pan, using ATF DEXRONIII. Refer to Changing
241RW016
Converter Housing and Oil Pump Assembly

Disassembled View
241RW003
Legend
(1) Converter Housing
(2) Outer Seal Ring
(3) Gasket
(4) Wear Plate

(6) Oil Seal Ring
Disassembly
1. Remove oil pump assembly from converter housing.
2. Remove outer seal ring.
3. Remove gasket.
4. Remove wear plate.
5. Remove oil seal ring.

Visual Check:
If any damage, deformation, or local wear is found in a
converter housing, outer seal ring, wear plate, or oil seal
ring, replace it.
Reassembly
1. Install wear plate onto oil pump assembly.
2. Install converter housing onto complete oil pump
assembly. Align with two short J38588 guide pins on
outer bolt holes.
D Loosely install five 13mm bolts.
D Center converter housing using J38557 centering
tool.
D Tighten five inner 13mm bolts in an alternating
pattern.
241RW002
3. Install oil seal ring (3 screws).

4. Install gasket.
5. Install outer seal ring.
7A65
Oil Pump
Disassembled View
241RS014
Legend
(1) Oil Pump Drive Gear
(2) Oil Pump Driven Gear
(3) Pin
(4) Plug
(5) Spring
(6) Converter Clutch Control Valve
(7) Snap Ring
(8) Spring Seat
(9) Spring
Disassembly
1. Remove oil pump drive gear (1) and driven gear (2).
2. Remove pin (3) from oil pump assembly (18).
3. Remove plug (4), spring (5), and converter clutch
control valve (6).
4. Remove snap ring (7) from oil pump assembly (18).
5. Remove spring seat (8), spring (9), and throttle signal
accumulator piston (10).
6. Remove sleeve pin (11) from oil pump assembly (18).
7. Remove sleeve (12), boost valve (13), spring seat
(14), valve spring (15), spring seat (16), and pressure
regulator valve (17).

Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Throttle Signal Accumulator Piston

Sleeve Pin
Sleeve
Boost Valve
Spring Seat
Valve Spring
Spring Seat
Pressure Regulator valve
Oil Pump Assembly
Reassembly
1. Lubricate and preinstall pressure regulator spring
seat (16) on valve (17), with the flat side against
shoulder.
2. Install pressure regulator valve (17) and spring seat
(16) assembly, valve spring (15), and spring seat (14)
with the flat side away from spring to oil pump
assembly (18).
3. Assemble boost valve (13) into sleeve (12).
4. Install boost valve and sleeve assembly, and sleeve
pin (11) to oil pump assembly (18).
5. Install throttle signal accumulator piston (10), spring
(9), and spring seat (8), with the flat side away from
the spring, and snap ring (7) to oil pump assembly
(18).
6. Install converter clutch control valve (6), spring (5),
plug (4), and pin (3) to oil pump assembly (18).
7. Install oil pump driven gear (2) and drive gear (1).
Main Case Valve Body

Disassembled View
244RS010
Legend
(1) Gaskets and Transfer Plate
(2) Manual Valve
(3) Band Control Solenoid
(4) Pin
(5) Waved Washer
(6) Spring Pin
(7) Solenoid A
(8) Retainer
(9) 12/34 Shift Valve
(10) Spring
(11) Spring Pin
(12) Solenoid B
(13) Retainer
(14) 23 Shift Valve
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Spring
Spring Pin
Plug
Spring
Low Pressure Control Valve
Spring Pin
Plug
Band Control Screen Assembly
Spring Pin
Plug
12 Accumulator Valve
12 Accumulator Control Valve
Check ball
Main Case Valve Body
Disassembly
1. Remove two 11mm bolts from valve body (28), then
remove gaskets and transfer plate (1).
2. Remove manual valve (2).
3. Push in band control solenoid (3) to compress waved
washer (5), and remove pin (4).
4. Remove band control solenoid (3) and waved washer
(5).
5. Remove spring pin (6) with a 3 mm dia. punch.
6. Remove solenoid A (7) by grasping the metal tip. Do
not grasp the connector housing.
7. Remove retainer (8), 12/34 shift valve (9) and
spring (10).
8. Remove spring pin (11) with a 3 mm dia. punch.
9. Remove solenoid B (12) by grasping the metal tip. Do
not grasp the connector housing.
10. Remove retainer (13), 23 shift valve (14), and spring
(15).
11. Remove spring pin (16), plug (17), spring (18) and low
pressure control valve (19).
12. Remove spring pin (20), plug (21), and band control
screen assembly (22).
13. Remove spring pin (23), plug (24), 12 accumulator
valve (25), and 12 accumulator control valve (26).
14. Remove 1 check ball (27) from valve body (28).
7A67
Reassembly
1. Install 12 accumulator control valve (26), 12
accumulator valve (25), plug (24), and spring pin (23).
2. Install band control screen assembly (22), plug (21),
and spring pin (20).
3. Install low pressure control valve (19), spring (18),
plug (17), and spring pin (16).
4. Install spring (15), 23 shift valve (14), retainer (13),
solenoid B (12), and spring pin (11).
5. Install spring (10), 12/34 shift valve (9), retainer (8),
solenoid A (7), and spring pin (6).
6. Install waved washer (5), band control solenoid (3),
and pin (4).
7. Install manual valve (2).
8. Install check ball (27) to valve body (28).
9. Install gasket (valve body/transfer plate) and transfer
plate using two J33872 guide pins.
D Install two 11mm bolts.

Inspect for the following, and replace any damaged or
worn parts:
1. Damage or wear to each valve.
2. Damage in oil passeges.
3. Cracks or damage to valve body.
4. Valve operations.
5. Spring fatigue.
244RS004
D Install gasket (transfer plate/main case).
Adapter Case Valve Body

Disassembled View
243RW001
Legend
(1) Converter Clutch Solenoid Assembly
(2) Retainer
(3) Force Motor Solenoid
(4) Retainer
(5) Plug
(6) 3/4 Accumulator Valve
(7) 3/4 Accumulator Control Valve
Disassembly
1. Remove 11mm bolt from valve body.
D Remove converter control solenoid assembly (1).
2. Remove 11mm bolt and retainer (2) from valve body.
D Remove force motor solenoid (3).
3. Remove retainer (4), plug (5), 3/4 accumulator valve
(6), and 3/4 accumulator control valve (7)
4. Remove spring (8), retaining ring (9), and feed limit
valve (10).
5. Remove plug retainer (11), O-ring (12), plug (13), and
force motor screen assembly (14).
D Use 5 mm bolt to pull plug.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Spring
Retaining Ring
Feed Iimit Valve
Plug Retainer
O-ring
Plug
Force Motor Screen Assembly
Adapter Case Valve Body

Inspect for the following, and replace any damaged or
worn parts:
1. Damage or wear to each valve.
2. Damage in oil passeges.
3. Cracks or damage to valve body.
4. Valve operations.
5. Spring fatigue.
Reassembly
1. Install force motor screen assembly (14), plug (13),
O-ring (12), and plug retainer (11).
2. Install feed limit valve (10), retaining ring (9), and
spring (8).

3. Install 3/4 accumulator control valve (7), 3/4
accumulator valve (6), plug (5), and retainer (4).
4. Install force motor solenoid (3).
D Place solenoid terminals pointing towards mating
face.
7A69
5. Install converter clutch solenoid assembly with two

O-rings (1) to valve body.
D Install bolt.
D Install retainer (2) and bolt.

Third Clutch and Sprag Unit

Disassembled View
248RW001
Legend
(1) Retaining Ring
(2) Input Sun Gear and Sprag Unit Assembly
(3) Retaining Washer
(4) Bearing
(5)
(6)
(7)
(8)
Thrust Washer
Clutch Plates
Third Clutch Spring Cushion Plate
Third Clutch Drum Assembly
Disassembly
1. Place the third clutch drum and intermediate shaft
assembly upright, using the overdrive internal gear as
a support.
2. Locate the ends of the retaining ring. Depress one
end of the ring using a small screwdriver instead of
the depressor handle provided with the tool
J-38450-A. Slide one blade down between the third
clutch drum and the retaining ring.
3. Remove a screwdriver and repeat this step for the
other end of retaining ring.
4. Install the remaining four blades approximately (five)
notches apart using a screwdriver to depress the
retaining ring.
5. Pull up on input sun gear and sprag unit assembly (1
and 2) to release the retaining ring from third clutch
drum assembly (8).
6. Remove the tool blades.
248RX001

7. Remove retaining washer (3), bearing (4), thrust
washer (5), and clutch plates (6 and 7) from the third
clutch drum assembly (8).

Visual Check:
damaged part.
6. Place J-38450-A blades between the retaining ring

and the third clutch drum apporximately (five)
notches apart, and one blade at each end of the
retaining ring (1). Push down on sprag assembly until
the assembly is seated into the third clutch drum
assembly (8).
7. Remove the tool blades and engage retaining ring
into groove of third clutch drum.
Reassembly
1. Place third clutch drum and intermediate shaft
assembly upright, using the overdrive internal gear as
a support.
2. Install third clutch spring cushion plate (7), bevel face
down.
3. Install third clutch plates (6) into third clutch drum
assembly (8). Start with the steel clutch plate and
alternate with lined plates.
4. Install thrust washer (5), bearing (4) and retaining
washer (3).
5. Fully engage the hub spline of the input sun gear and
sprag unit assembly (2) into the third clutch inner
tangs.
D Simultaneously rotate the outer sprag race to
engage into the third clutch drum assembly (8).
248RX002
Third Clutch
Disassembled View
248RS006
Legend
(1) Retaining Ring
(2) Spring Seat
(3) Springs
(4) Piston Assembly
(5) Third Clutch Drum
Disassemble
7A71
Reassembly
1. Compress spring seat using the J23075 spring

compressor and J2307512 adapter tool.
NOTE: Do not overstress the springs and seat. This will
cause damage to the spring seat.
D Remove the tool.
D Remove retaining ring (1).
1. The lip of the piston seal must point toward the front of
the transmission.
Lubricate the seal lip with
transmission fluid.
D Install piston assembly (4) into the third clutch drum
(5). Use the J23084 third clutch piston installer to
protect the outer seal during installation.
D Remove the seal installer.
248RS007
2. Release the spring seat (2).

NOTE: Do not let the spring seat catch in the ring groove.
D Remove spring seat (2) and springs (3).
3. Remove piston assembly (4) from third clutch drum
(5).

Visual check:
damaged part.
Operation check:
Shake the piston and listen for check ball movement.
Movement indicates proper check ball operation.
Replace the piston if the check ball is missing or falls out.
248RS008
2. Install twelve springs (3) and spring seat (2).

3. Place retaining ring (1) onto spring seat.
D Compress the piston springs, using the J23075
piston spring compressor and J2307512
adapter.
CAUTION: Do not overstress the springs and seat.
Do not let the spring seat catch in the ring groove.
This may cause damage to the spring seat.
D Install spring seat retaining ring (1).
D Remove the piston spring compressor and adapter.
Sprag Unit
Disassembled View
248RS009
Legend
(1) Retaining Ring
(2) Sprag Outer Race
(3) Ring
Disassembly
1. Remove the sprag outer race, retaining ring, and
sprag assembly from the third clutch hub and sun
gear assembly.
2. Remove the rings and sprag assembly from the sprag
outer race.
(4) Sprag Assembly

(5) Ring
(6) Third Clutch Hub and Sun Gear Assembly
NOTE: Check correct rotation by holding the sun gear in

your left hand and turning the outer race. The outer sprag
race should turn freely towards you and should lock
turning away from you.

Visual Check:
If any damage, deformation or local wear is found,
replace the damaged part.
Reassembly
NOTE: Flared shoulder of the sprag cage faces the sun
gear. This procedure must be followed exactly to be sure
that the sprag assembly is installed properly.
1. Install rings and sprag assembly onto the third clutch
hub and sun gear.
2. Install sprag outer race and retaining ring assembly
over the sprag cage assembly.
D Place third clutch hub and sun gear assembly on a
flat surface, sun gear facing up. Place sprag outer
race and sprag assembly over the sun gear
assembly, push down and turn the input sun
counterclockwise at the same time.
248RS010
7A73
Second Clutch
Disassembled View
247RW001
Legend
(1) Retaining Ring
(2) Ring Gear
(3) Retaining Ring
(4) Spacer
(5) Clutch Plates
(6)
(7)
(8)
(9)
(10)
(11)
Waved Washer
Retaining Ring
Spring Seat
Springs
Piston Assembly
Second Clutch Drum
Disassembly
1. Remove retaining ring (1) from second clutch drum
(11).
2. Remove ring gear (2), retaining ring (3), and spacer
(4).
3. Remove clutch plates (5) and waved washer (6).
4. Remove retaining ring (7) using J23327 compressor
to compress the spring seat (8).
5. Remove spring seat (8), springs (9) and piston
assembly (10) from second clutch drum (11).
247RS006

Visual Check:
damaged part.
Operation Check:
Shake the piston and listen for check ball movement.
Movement indicates proper check ball operation.
Replace the piston if the check ball is missing or falls out.
Reassembly
1. Install piston assembly (10) into the second clutch
drum (11).
D Lubricate the lip seal with transmission fluid. Use
the J23080A second clutch piston installer to
protect the outer piston lip seal.
NOTE: Lip of the seal should point toward front of
transmission.
D Remove the installer.
247RS007
2. Install twenty-two piston springs (9) and spring seat

(8) on the second clutch piston (10). Place retaining
ring (7) onto spring seat.
D Use the J23327 compressor to compress the
piston springs.
NOTE: Do not let spring seat catch in ring groove.
D Remove the compressor.
3. Install waved plate (6) and clutch plates (5). Start with
a steel plate and alternate with lined plates.
D Align second clutch inner tangs.
4. Install spacer (4), with the fluted end toward clutch
plates.
5. Install retaining ring (3), ring gear (2) and retaining
ring (1).
7A75
34 Accumulator Piston
Disassembled View
244RS005
(3) Spring
(4) Piston Assembly
Legend
(1) Snap Ring
(2) Cover
Disassembly
1. Install the J38559A cover compressor on adapter
case.
D Compress piston cover then remove snap ring.
242RW001

Visual Check:
242RS007
2. Install the J41096 cover remover and J38584

adapter to center hole of cover.
D Use the J23907 slide hammer to remove cover.
3. Remove spring and piston assembly.

damaged part.
Reassembly
1. Place the J38553 piston fitter into adaptor case and
push the piston into position, using suitable diameter
tube.
D Remove the piston fitter.
244RS006
2. Install spring and cover.

3. Install snap ring, using the J38559A compressor
tool.
D Install snap ring in groove.
D Remove the compressor tool.
242RS007
7A77
Reverse Clutch Piston and Center Support

Disassembled View
242RS006
Legend
(1) Retaining Ring
(2) Spring Seat
(3) Springs
(4) Piston Assembly
(5) Center Support
(6) Gasket
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Transfer Plate
Gasket
Restrictor
Retainer Plate
Plug
Spring
Overrun Lock Out Valve
Disassembly
Reassembly
1. Install the J23327 compressor tool on spring seat,

then compress the spring seat.
D Remove retaining ring (1).
NOTE: Do not over-stress the springs and seat, as this
will cause damage to the spring seat.
D Remove the compressor tool.
1. Install overrun lock out valve (13) and spring (12) to

center support.
NOTE: Ensure correct assembly of valve. The spring
should be located over the long small diameter end.
2. Install plug (11) and retainer plate (10).
3. Place restrictor (9) in the lube overdrive channel in the
adapter case housing.
247RS008
2. Remove spring seat (2) and springs (3).

3. Remove piston assembly (4).
4. Remove 8 bolts from center support (5), then remove
center support (5) from adapter case.
5. Remove gasket transfer plate/outer support (6),
center support transfer plate (7), and gasket transfer
plate/adapter case (8).
6. Remove restrictor (9) from adapter case housing.
7. Remove retainer plate (10), plug (11), spring (12), and
overrun lock out valve (13) from center support (5).

Visual Check:
damaged part.
242RS005
4. Install gasket transfer plate/adapter case (8), center

support transfer plate (7), and gasket transfer
plate/center support (6).
5. Install center support (5) with 8 bolts.
Torque : 25 Nm (18 lb ft)
6. Install piston assembly (4) into center support (5).
7. Install twenty four springs (3), spring seat (2), and
retaining ring (1).
D Install the J23327 compressor and compress
spring seat (2) and springs (3), then seat snap ring
(1) in groove.
D Remove the tool.
7A79
Overrun Clutch and Turbine Shaft

Disassembled View
252RW005
Legend
(1) Snap Ring
(2) Overdrive Carrier Assembly
(3) Sun Gear
(4) Turbine Shaft
(5) Snap Ring
(6) Backing Plate
(7) Clutch Plates
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Snap Ring
Overrun Roller Clutch Cam
Roller Clutch Assembly
Overrun Clutch Release Spring Retainer
Diaphragm Spring
Piston Assembly
Overrun Clutch Drum
Turbine Shaft Seal Rings
Disassembly
1. Position overrun clutch assembly upright, using the

overdrive internal gear as a support.
D Remove snap ring (1).
Overdrive Carrier Check

D Check pinion end play with a feeler gauge.
Clearance: 0.24mm0.64mm (0.0094in0.025in)
If clearance is outside specified value, replace overdrive
carrier assembly.
252RS009
2. Remove overdrive carrier assembly (2), sun gear (3)

and turbine shaft (4).
3. Remove snap ring (5), backing plate (6), and clutch
plates (7).
4. Compress diaphragm spring with the J2332791
compressor then remove snap ring (8).
252RS011
Visual Check:
damaged part.
Reassembly
1. Install turbine shaft seal rings (15) with grease
(petroleum jelly).
252RS010
5. Remove overrun roller clutch cam (9) and roller clutch

assembly (10).
6. Remove overrun clutch release spring retainer (11)
and diaphragm spring (12).
7. Remove piston assembly (13) from overrun clutch
drum (14).
8. Remove turbine shaft seal rings (15).
241RS008
2. Install the J38555 inner installer on the drum (14).

D Pre-install piston assembly into J38555 outer
installer.
D Install overrun clutch piston assembly (13). Use the
outer installer while pushing piston into drum (14).

D Remove the installer.
7A81
NOTE: Turn the assembly in a counter-clockwise

direction only until roller clutch enters the outer race.
After Installation, rotate the assembly and listen for loose
rollers.
11. Install turbine shaft (4) and snap ring (1).
252RS012
252RS013
3. Install diaphragm spring (12).

4. Install overrun clutch release spring retainer (11) (lip
faces upwards), overrun roller clutch assembly (10)
and cam (9).
5. Place snap ring loosely on spring retainer.
D Hold the J2332791 compressor in a vise and
compress piston return spring with compressor.
D Set snap ring (8) in ring groove.
D Remove the compressor.
6. Install clutch plates (7), start with steel plate and
alternate with lined plates.
7. Install backing plate (6).
9. Install overdrive sun gear with countersink pointing
downwards.
10. Install the overdrive carrier assembly (2).

Remarks
Model
THM 4L30E
Engine
V6 3.2L 6VD1
Type
Control systems
Gear ratio
Automatic four speed overdrive in

4th gear lockup clutch torque
converter
Shift control
Hydraulic
Shift pattern
Electronic
Shift quality
Electronic
Lockup clutch
Electronic
1st
2.856
2nd
1.618
3rd
1.000
4th (O/D)
0.723
Reverse
2.000
Gear set
Oil used
Noiseless, high torque capability

Name
ATF DEXRONIII
Qty liter (qt)
8.6 (9.1)
2,200 150
Torque converter
Reverse clutch
RC
Second clutch
C2
Third clutch
C3
Brake band
Stall speed (rpm)
Number of discs
Double wrap
Fourth clutch
C4
Overrun clutch
OC
Overdrive
OFW
10
Number of rollers
Principal
PFW
26
Number of sprags
Ravigneaux ty
type
e
gear train
g
(planetary gear
set)
Overdrive carrier
(planetary gear
set)
t)
Input sun gear
30
Pinion gear
19
Long pinion
23
Ring gear
90
Long pinion
19
Output sun gear
46
Sun gear
31
Pinion gear
24
Ring gear
81
Number of discs
Number of teeth
7A83
E07RX016
E07RX008
7A85
E07RW003
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J23075
Spring compressor (For
servo piston)
J23085A
Selective washer gaging
tool
J38450A
Third clutch snap ring
compressor
J2332790
Fourth clutch spring
compressor (Use with
J23327)
J2307512
Third clutch spring
compressor adapter
(Use with J23075)
J38553
3/4 Accumulator piston
fitter
J23084
Third clutch piston
installer
J41096
Cover remover (Use
with J38584)
J23327
Third clutch spring
compressor
J38584
Slide hammer adapter
(Use with J23907)
J23080A
Second clutch piston
installer
J38554
Fourth clutch piston fitter

ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
7A87
TOOL NO.
TOOL NAME
J38588
Guide pins; adapter
case to main case
J2308201
Oil pump rotation tool
J38555
Overrun clutch piston
seal installer set
J25025B
Guide pins; valve body
to main case
J33872
Guide pins; gasket and
transfer plate to valve
body
J38428
Servo piston fitter
J25022
Turbine shaft puller (Use
with J247731)
J2332791
Overrun clutch spring
compressor
J23129
Oil seal remover (Use
with J23907 and
J38584)
J38559A
3/4 Accumulator piston
cover compressor
J38557
Oil pump centering tool
J876302
Holding fixture

ILLUSTRATION
TOOL NO.
TOOL NAME
J36797
A/T extension housing
oil seal installer (Inside)
J328920
J29770A
Pressure gauge
J247731
End play fixture (Use
with J25022)
J23907
Slide hammer
7A89
4L30E Parts List

Case and Associated Parts
241RW014
Legend
(1) Torque Converter
(2) Screw, Seal Ring Assembly
(3) Seal Ring Assembly, Converter Housing
(4) Screw, Converter Housing/Main Case
(5) Screw, Converter Housing/Oil Pump
(6) Housing, Converter
(7) Plug, Converter Housing
(8) Seal, O-ring
(9) Wear Plate, Oil Pump Body
(10) Pump Assembly, Oil
(11) Gasket
(12) Washer, Thrust Selective
(13) Ring, Snap
(14) Cover, 34 Accumulator Piston
(15) Seal, O-ring, 34 Accumulator
(16) Spring, 34 Accumulator Piston
(17)
(18)
(19)
(20)
(22)
(23)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
Pin, 34 Accumulator Piston

Piston, 34 Accumulator
Ring, 34, Accumulator Piston
Case, Adapter
Connector, Electrical/Adapter Case
Screw, Pan
Restrictor, Oil
Gasket, Transfer Plate/Adapter
Plate, Transfer Adapter/Center Support
Support Assembly, Center
Screw, Center Support
Ring, Oil Seal
Seal, O-ring Main Case
Fitting, Cooler
Fitting Assembly, Cooler
Case, Main
Breather, Pipe

(38)
(39)
(42)
(43)
(44)
(45)
(46)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
Seal, O-ring
Reservoir
Gasket, Extension Case
Extension Assembly
Seal, O-ring/Speed Sensor
Sensor Assembly, Speed
Screw, Speed Sensor
Seal, Extension Assembly
Bearing, Needle/Extension
Screw, Extension/Main Case
Spring, Parking Pawl Lock
Pawl, Parking Lock
Connector, Electrical/Main Case
Actuator Assembly, Parking Lock
Nut, Parking Lock Lever
Link, Manual Valve
Pin, Spring
Lever, Parking Lock and Range Selector
Shaft, Selector
Seal, Selector Shaft
Mode Switch Assembly
Screw & Conical Washer Assembly
Shield, Mode Switch
Pan, Bottom/Adapter Case
Gasket, Bottom Pan/Adapter Case
Harness Assembly, Adapter Case
Screw, Valve Body
Valve Body Assembly, Adapter Case
Gasket, Adapter Valve Body
Plate, Adapter Valve Body/Transfer
Pan, Bottom/Main Case
(75)
(76)
(77)
(78)
(79)
(80)
(82)
(84)
(85)
(86)
(87)
(88)
(89)
(90)
(91)
(92)
(93)
(94)
(95)
(96)
(97)
(98)
(99)
(100)
(101)
(102)
(103)
(104)
(105)
(106)
Gasket, Bottom Pan/Main Case

Gasket, Oil Drain or Overfill Screw
Screw, Oil Drain or Overfill
Magnet, Chip Collector
Filter Oil
Harness Assembly, Main Case
Roller and Spring Assembly, Manual Detent
Valve Body Assembly, Main Case
Ball, Check
Gasket, Main V.B./Transfer Plate
Plate, Main V.B./Transfer
Gasket, Transfer/Main Case
Screw, Transfer Plate on V.B.
Screw, Servo Cover
Cover, Servo Piston
Gasket, Cover/Servo Piston
Ring, Retaining Servo Piston
Clip, Servo Piston
Nut, Servo Screw
Screw, Servo Piston
Piston, Servo
Seal, Ring/Servo Piston
Spring, Cushion/Servo Piston
Seat, Cushion Spring
Sleeve, Servo Piston Adjust
Rod, Apply/Servo Piston
Spring, Return/Servo Piston
Gasket, Adapter Case/Transfer Plate
Powertrain Control Module
Servo Piston Assembly
7A91
Pump Assembly
241RS019
Legend
(201) Gear, Oil Pump Drive
(202) Gear, Oil Pump Driven
(203) Pin, Boost Valve Sleeve
(204) Sleeve, Boost Valve
(205) Valve, Boost
(206) Seat, Spring/Pressure Regulator Valve
(207) Spring, Pressure Regulator Valve
(208) Valve, Pressure Regulator
(209)
(210)
(211)
(212)
(213)
(214)
(215)
(216)
(217)
Pump Assembly, Oil

Valve, Converter Clutch Control
Spring, Converter Clutch Control Valve
Plug, Converter Clutch Control Valve
Pin, Spring
Piston, Throttle Signal Accumulator
Spring, Throttle Signal Accumulator
Seat, Spring/Throttle Signal Accumulator
Ring, Snap/Throttle Signal Accumulator
Valve Body Assemblies
244RS009
Legend
(301) Body, Valve Main Case
(302) Pin, Spring
(303) Solenoid Assembly, ON/OFF N.C.
(304) Valve, 12 & 34 Shift
(305) Spring, 12 & 34 (23) Shift
(306) Retainer, Valve
(307) Solenoid Assembly, ON/OFF N.O.
(308) Valve, 23 Shift
(309) Pin, Spring
(310) Plug, Valve Bore
(311)
(312)
(317)
(318)
(320)
(321)
(322)
(323)
(324)
(325)
(326)
Spring, Valve Low Pressure Control

Valve, Low Pressure Control
Ball, Check
Valve, 12 Accumulator Control
Valve, 12 Accumulator
Washer, Waved PWM Solenoid
Pin, Solenoid PWM
Solenoid Assembly, Band Control PWM
Screen Assembly, PWM Solenoid
Plug, Screen
Valve, Manual
7A93
243RW003
Legend
(401) Body, Valve/Adapter Case
(402) Screw, Solenoid Force Motor
(403) Retainer, Force Motor
(404) Solenoid, Force Motor
(405) Plug, 34 Accumulator
(406) Plug and Spring Retainer
(407) Valve, 34 Accumulator
(409) Valve, 34 Accumulator Control
(410)
(411)
(412)
(413)
(414)
(415)
(416)
(417)
Spring, Feed Limit Valve

Ring, Retainer
Valve, Feed Limit
Seal, O-ring Plug Filter
Plug, Screen
Screen Assembly, Force Motor
Solenoid, Torque Conv. Clutch ON/OFF N.C.
Plug Retainer
Overdrive Internal Components
252RW003
Legend
(501) Retainer, 4th Clutch
(502) Plate, 4th Clutch (Steel)
(503) Plate Assembly, 4th Clutch (Lined)
(504) Retainer and Ball Assembly, Check Valve
(505) Seal, O-ring/Turbine Shaft
(506) Shaft, Turbine
(508) Ring, Oil Seal/Turbine Shaft
(510) Housing, Overrun Clutch
(513) Piston, Overrun Clutch
(514) Spring, Overrun Clutch Release
(515) Retainer, Release Spring/Overrun Clutch
(516) Roller Assembly, Overdrive Clutch
(517) Cam, Overdrive Roller Clutch
(518) Ring, Snap/Overrun Clutch Hub
(519) Gear, Overdrive Sun
(520)
(521)
(522)
(523)
(524)
(525)
(526)
(527)
(528)
(529)
(530)
(531)
(532)
(533)
(534)
Plate, Waved/Overrun Clutch

Plate, Overrun Clutch (Steel)
Plate Assembly, Overrun Clutch (Lined)
Plate, Backing/Overrun Clutch
Ring, Snap/Overrun Clutch Housing
Carrier Assembly, Overdrive Complete
Ring, Snap/Turbine Shaft/Carrier
Bearing Assembly, Thrust
Gear, Overdrive Internal
Washer, Thrust/Internal Gear/Support
Ring, Snap/Adapter/4th Clutch Spring
Retainer and spring assembly, 4th clutch
Piston, 4th Clutch
Seal, 4th Clutch Piston (Inner)
Seal, 4th Clutch Piston (outer)
7A95
Internal Components
247RW002
Legend
(608) Seal, Reverse Clutch Piston (Inner)
(609) Seal, Reverse Clutch Piston (Outer)
(610) Piston, Reverse Clutch
(611) Spring, Piston Clutch
(612) Seat, Spring/Reverse Clutch
(613) Ring, Retaining
(614) Plate, Waved/Reverse Clutch
(615) Plate, Reverse Clutch (Steel)
(616) Plate Assembly, Reverse Clutch (Lined)
(617) Plate, Reverse Clutch Pressure/Selective
(618) Drum Assembly, 2nd Clutch
(620) Seal, 2nd Clutch Piston (Inner)
(621) Seal, 2nd Clutch Piston (Outer)
(622) Piston, 2nd Clutch
(623) Seat, Spring/2nd Clutch
(625) Plate, Waved/2nd Clutch
(626) Plate, 2nd Clutch (Steel)
(627)
(628)
(629)
(630)
(631)
(632)
(634)
(635)
(636)
(637)
(638)
(639)
(640)
(641)
(642)
(643)
(644)
(645)
Plate Assembly, 2nd Clutch (Lined)

Spacer, 2nd Clutch
Ring, Retaining
Gear, Ring
Washer, Thrust/2nd Clutch/3rd Clutch
Thrust Washer, Clutch Hub
Drum Assembly, 3rd Clutch
Seal, 3rd clutch piston (Inner)
Washer, Retaining
Seal, 3rd Clutch Piston (Outer)
Piston 3rd Clutch
Seat, Spring/3rd Clutch
Ring, Retaining
Plate, Spring Cushion/3rd Clutch
Plate, 3rd Clutch (Steel)
Plate Assembly, 3rd Clutch (Lined)
Washer, Thrust/Input Sun
Bearing, Input Shaft/Gear Assembly

(646)
(647)
(648)
(649)
(650)
(651)
(652)
(653)
Gear Assembly, Input Sun

Race Assembly, Sprag
Ring, Retaining/Sprag
Ring, Retaining
Cage Assembly, Sprag
Bearing, Output Shaft/Input Sun
Washer, Output Shaft/Input Sun
Carrier Assembly, Planetary
(658)
(659)
(664)
(667)
(668)
(672)
(673)
(675)
Gear, Reaction Sun

Drum, Reaction Sun
Band Assembly, Brake
Seal, Ring/Wheel Parking Lock
Wheel, Parking Lock
Wheel, Speed
Ring, Retaining
Bearing, Thrust Assembly
Center Support Assembly
241RS010
Legend
(701) Center Support
(702) Retainer Plate
(703) Plug, Lockout

(704) Spring, Overrun Lockout
(705) Valve, Overrun Lockout
SECTION
TRANSMISSION CONTROL SYSTEM (4L30E)
7A11
FRONTERA
TRANSMISSION
CONTENTS
Electronic Control Diagram . . . . . . . . . . . . .
Control System Diagram . . . . . . . . . . . . . . .
Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . .
Band Apply Control . . . . . . . . . . . . . . . . . . . .
Torque Converter Clutch Control . . . . . . . . .
Line Pressure Control . . . . . . . . . . . . . . . . . .
OnBoard Diagnostic System . . . . . . . . . . .
Fail Safe Mechanism . . . . . . . . . . . . . . . . . . .
Torque Management Control . . . . . . . . . . . .
ATF Warning Control . . . . . . . . . . . . . . . . . . .
Shift Mode Control . . . . . . . . . . . . . . . . . . . . .
Gear Shift Control . . . . . . . . . . . . . . . . . . . . .
Winter Drive Mode . . . . . . . . . . . . . . . . . . . . .
Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . .
Functions of Input / Output Components . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Diagnosis . . . . . . . . . . . . . . . . . . .
Check Trans Indicator . . . . . . . . . . . . . . . . . .
Diagnostic Check . . . . . . . . . . . . . . . . . . . . . .
Check Trans Check . . . . . . . . . . . . . . . . . .
Tech 2 OBD II Connection . . . . . . . . . . . . . .
F0: Transmission Data . . . . . . . . . . . . . . . . .
F1: PC Solenoid Data . . . . . . . . . . . . . . . . . .
Flashing Code . . . . . . . . . . . . . . . . . . . . . . . .
OBD II Diagnostic Management System . .
16 Terminal Data Link Connector (DLC) .
Malfunction Indicator Lamp (MIL) . . . . . . . .
Types Of Diagnostic Trouble Codes (DTCs)
Clear DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC Check . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Precaution . . . . . . . . . . . . . . . . . . . . . . .
Information On PCM . . . . . . . . . . . . . . . . . . .
Intermittent Conditions . . . . . . . . . . . . . . . . .
Transmission and PCM Identification . . . . .
Isuzu Frontera . . . . . . . . . . . . . . . . . . . . . . . .
7A12
7A12
7A13
7A14
7A15
7A16
7A16
7A16
7A16
7A16
7A16
7A16
7A16
7A17
7A18
7A19
7A19
7A110
7A111
7A111
7A111
7A111
7A112
7A113
7A117
7A118
7A119
7A120
7A121
7A122
7A122
7A122
7A123
7A123
7A123
7A124
7A125
7A125
Diagnostic Trouble Code (DTC) Identification

DTC P0218/Flashing Code 71 Transmission
Fluid Over Temperature . . . . . . . . . . . . . . . . .
DTC P0560/Flashing Code 72 System Voltage
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Switch (Mode Switch) Illegal Position
Range Switch (Mode Switch) Performance .
Fluid Temperature (TFT) Sensor Circuit
Low Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Temperature (TFT) Sensor Circuit
High Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0719/Flashing Code 77 TCC Brake
Switch Circuit High (Stuck On) . . . . . . . . . . . .
Output Speed Sensor (OSS) Low Input . . . .
Output Speed Sensor (OSS) Intermittent . .
Incorrect Gear Ratio . . . . . . . . . . . . . . . . . . . .
DTC P0748/Flashing Code 82 Pressure
Control Solenoid (PCS) (Force Motor)
Circuit Electrical . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0753/Flashing Code 83 Shift Solenoid
A Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0758/Flashing Code 84 Shift Solenoid
B Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1790/Flashing Code 85 ROM
Transmission Side Bad Check Sum . . . . . . .
DTC P1792/Flashing Code 86 EEPROM
Transmission Side Bad Check Sum . . . . . . .
DTC P1835/Flashing Code 87 Kickdown
Switch Always On . . . . . . . . . . . . . . . . . . . . . .
DTC P1850/Flashing Code 88 Brake Band
Apply Solenoid Malfunction . . . . . . . . . . . . . .
DTC P1860/Flashing Code 89 TCC
Solenoid Electrical . . . . . . . . . . . . . . . . . . . . . .
7A126
7A127
7A129
7A132
7A135
7A138
7A141
7A144
7A147
7A150
7A153
7A156
7A158
7A161
7A165
7A166
7A167
7A169
7A173
7A12
Service Precaution
General Description
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
The 4L30E is a 4speed fully automatic transmission. It

uses a microcomputer as a control unit to judge running
conditions including throttle opening rate and vehicle
speed, then it sets the shifting point in the optimum timing
so that best driving performance can be achieved.
In addition, the builtin shift mode select function can
select three shift modes according to the drivers
preference:
D Normal mode Normal shift pattern.
D Winter mode Starts in 3rd gear to reduce slippage on
ice or snow.
D Power mode has a delayed upshift for when more
powerful acceleration is required.
Also, the builtin fail safe function (backup mode)
assures driving performance even if the vehicle speed
sensor, throttle signal or any solenoid fails.
Further, the selfdiagnostic function conducts diagnosis
in a short time when the control system fails, thus
improving serviceability.
The major features of 4L30E are as follows:
D A compact structure consisting of 2 sets of planetary
gears and flat torque converter.
D Electronic control selects the optimum shift mode
according to the driving conditions.
D Electronic control maintains the optimum hydraulic
pressure for clutch, band brake as well as
transmission so that shift feeling is improved.
D Two sets of planetary gears reduce friction of power
train.
Also, a lockup mechanism in the torque converter
reduces fuel consumption.

systems.
D Wide gear ratio and high torque rate of torque

converter provide excellent starting performance.
7A13
Electronic Control Diagram
C07RX008
7A14
C07RW026
7A15
Control System Diagram
C07RW0271
7A16
Shift Control
OnBoard Diagnostic System
The transmission gear is shifted according to the shift

pattern selected by the driver. In shifting gears, the gear
ratio is controlled by the ON/ OFF signal using the shift
solenoid A and the shift solenoid B.
Several malfunction displays can be stored in the

Powertrain Control Module (PCM) memory, and read out
of it afterward.
The serial data lines, which are required for the testing of
the final assembly and the coupling to other electronic
modules, can be regulated by this function.
Band Apply Control

The band apply is controlled when in the 32 downshift
(engine overrun prevention) and the garage shift (shock
control).
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow of
the oil.
Fail Safe Mechanism

If there is a problem in the transmission system, the PCM
will go into a backup mode.
The vehicle can still be driven, but the driver must use the
select lever to shift gears.
Torque Converter Clutch Control
Torque Management Control
The clutch ON/OFF is controlled by moving the converter

clutch valve through shifting Torque Converter Clutch
(TCC) solenoid using the ON/OFF signal.
The transmission control side sends the absolute spark

advance signal to the engine control side while the
transmission is being shifted. This controls the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the change of
speed.
Line Pressure Control

The throttle signal allows the current signal to be sent to
the force motor. After receiving the current signal, the
force motor activates the pressure regulator valve to
regulate the line pressure.
ATF Warning Control

The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning, TCC,
and the winter mode.
7A17
Shift Mode Control
F07RT035
7A18
Gear Shift Control
F07RT034
Winter Drive Mode

1. The winter switch will operate when switched on after
all of the following conditions are present:
a. The gear select position is D, N, R and P
range.
b. Vehicle speed is 7 mph (11 km/h) or less.
c. Transmission oil temperature is 120C (248F) or
less.
d. Kickdown switch is off.
e. Accelerator opening is at 8% or less.
2. Cancel Release
1. Cancellation by driver
a. Turning off the winter drive mode switch
b. Shifting select position to 3, 2, or L (Winter
drive mode is not canceled by selecting N, R,
or P from D)
c. Ignition key is turned off.
2. Automatic cancellation
a. When vehicle runs at 21mph (34 km/h) or more
for 1 second or more
b. When transmission oil temperature reaches
140C (284F) or above
NOTE: The mode returns to normal drive mode or power
drive mode after the winter drive mode is canceled.
Backup Mode
If a major system failure occurs which could affect safety
or damage the transmission under normal vehicle
operation, the diagnostic system detects the fault and
overrides the Powertrain Control Module (PCM).
The CHECK TRANS light flashes to alert the driver, and
the transmission must be manually shifted as follows:
Select lever position
Gear Ratio Selected
4 (Fourth)
Manual 3
4 (Fourth)
Manual 2
3 (Third)
Manual L
1 (First)
Reverse
Shifts are firmer to prevent clutch slip and consequent

wear. The fault should be corrected as soon as possible.
7A19
7A110 TRANSMISSION CONTROL SYSTEM (4L30E)
Functions of Input / Output Components

Components
I
N
P
U
T
S
I
G
N
A
L
O
U
T
P
U
T
S
I
G
N
A
L
Function
Speed sensor
(fixed to transmission
(T/M))
Senses rotation of output shaft and feeds the data to Powertrain Control Module
(PCM).
Throttle position sensor

(TPS)
(fixed to engine)
Senses the extent of throttle valve opening and the speed of the throttle valve
lever motion to open the valve. Feeds the data to PCM.
Brake Switch (SW)

(fixed to brake pedal)
Senses whether the driver has pressed the brake pedal or not and feeds the
information to PCM.
Kickdown SW
(fixed to accelerator pedal)
Senses whether the driver has pushed the accelerator pedal fully or not, and
feeds the information to PCM.
Mode SW (fixed to T/M)
Senses the select lever position, and feeds the information to PCM.
Power drive SW
(fixed to front console)
Senses whether the driver has selected the power mode, and feeds the
information to PCM.
T/M oil temp. sensor
Senses the T/M oil temperature and feeds the data to PCM
Senses the engine coolant temperature, and feeds the data to PCM.
Engine speed signal
Feeds the signals monitoring engine speed to PCM from crank angle sensor.
Air conditioning information
Senses whether the air conditioner has been switched on or not, and feeds the
information to PCM.
Winter switch (fixed to front

console)
Senses whether the driver has selected the winter mode, and feeds the
information to PCM.
Cruise controller (Overdrive OFF signal)
Downshift takes place when Overdrive OFF signal is received from auto cruise
control unit.
S
O
L
E
N
O
I
D
Shift solenoid A, B
Selects shift point and gear position suited to the vehicle running condition on
the basis of PCM output.
Band apply solenoid
Controls oil flow suited to the vehicle running condition on the basis of PCM
output.
Torque Converter
Clutch solenoid
Controls clutch engagement/disengagement suited to the vehicle running

condition on the basis of PCM output.
Force motor
(Pressure regulator
valve)
Adjusts the oil pump delivery pressure to line pressure suited to the vehicle
running condition on the basis of PCM output.
Power drive mode lamp
Informs the driver whether the vehicle is in power mode or not.
Winter drive mode lamp
Informs the driver whether the vehicle is in winter mode or not.
T/M monitor lamp

(CHECK TRANS)
Informs the driver of failure in the system.
ATF warning lamp
Lights when ATF oil temperature rises.
7A111
Diagnostic Check
Diagnosis
Electronic Diagnosis
How To Diagnose The Problem
1. To avoid incorrect diagnostics, this book needs to be
followed accurately. Unless stated, do not jump
directly to a section that could contain the
solution. Some important information may be
missed.
2. The sections in CAPITALS and bold are the main
sections that can be found in the contents.
3. The GOTO SECTION means to continue to check
going to the section.
4. The GOTHROUGH SECTION means to go
through the section and then to go back to the place
the GOTHROUGH was written.
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory of electricity.
This includes the meaning of voltage, amps, ohms,
and what happens in a circuit with an open or shorted
wire. You should also be able to read and understand
wiring diagrams.
This test determines if the transmission or its input, or

output, connections, or sensors are failing.
1. Connect the Tech 2: GOTHROUGH Tech 2 OBD II
CONNECTION.
2. Turn on the ignition but not the engine.
3. Push F0 on Tech 2 to see the Diagnostic Trouble
Code (DTC):
4. Do you have a DTC?
YES: write down all code numbers and do the DTC
CHECK
NO: the DTC can not help you find the problem.
1. GOTHROUGH CHECK TRANS CHECK
2. IF it is flashing and the flash is 0.8 seconds ON
and 0.8 seconds OFF, this means that you should
have a DTC stored. Please recheck GOTO
DIAGNOSTIC CHECK and if you find the same
problem, replace the Powertrain Control Module
(PCM).
Normal
Check Trans Indicator

Find CHECK TRANS indicator and verify if it is
A. Flashing: GOTO DIAGNOSTIC CHECK.
B. Staying on: GOTHROUGH CHECK TRANS
CHECK.
C. Is never ON when the ignition key is turned on:
GOTHROUGH CHECK TRANS CHECK
D. Is ON during 2 seconds at ignition but OFF after:
Normal operation. No DTC or malfunction.
C07RW047
Abnormal
821RW105
C07RX009
Check Trans Check
Abnormal
1. Indicator is ON during 2 seconds at ignition (or when

the engine is cranked) but it is OFF after the engine
starts. The indicator is working normally GOTO
DIAGNOSTIC CHECK.
C07RX009
3. Indicator is staying ON always when Ignition is ON.

1. This means that connection between the lamp
and the PCM is shorted to ground.
821RW105
Normal
2. Verify if instrument panel terminal 6 of connector

I1 is shorted to ground.
3. Verify if the PCM connector C1 (RED) terminal
A14 is shorted to ground.
4. Verify that the instrument panel terminal 12 of
connector I1 is connected to battery.
5. IF problem solved: GOTO CHECK TRANS
INDICATOR.
NO:Replace Powertrain Control Module (PCM).
4. Indicator is staying OFF with the ignition ON (engine
OFF).
1. This means that connection between the lamp
and the PCM is shorted to battery or opened.
2. Verify if instrument panel terminal 6 of connector
I1 is shorted to battery or open.
3. Verify if the PCM connector C1 (RED) terminal
A14 is shorted to battery or open.
C07RW047
2. Indicator is flashing and the flash is 0.8 seconds ON

and 0.8 seconds OFF always when ignition is on
(engine cranked or not). This means that there is a
malfunction. GOTO DIAGNOSTIC CHECK.
4. Verify that the instrument panel terminal 12 of

connector I1 is connected to battery. If not,
check the fuses and the connections voltage.
5. IF problem solved: GOTO CHECK TRANS
INDICATOR.
NO: Replace Powertrain Control Module (PCM).
7A113
D07RX015
Tech 2 OBD II Connection

In order to access OBD II Powertrain Control Module
(PCM) data, use of the Tech 2 scan tool kit (7000086) is
required.
1. The electronic diagnosis equipment is composed of:
1. Tech 2 handheld scan tool unit (7000057) and
DLC cable (3000095).
2. SAE 16/19 Pin Adapter (3000098)(1), RS232

Loop Back Connector (3000112)(2), and
PCMCIA Card (3000117)(3).
F07RW033
901RW176

2. Connecting the Tech 2
901RW180
Legend
(1) PCMCIA Card

(4) DLC Cable
(5) Tech 2

1. The Isuzu 99 System PCMCIA card (1) inserts
into the Tech 2 (5).
7A115
8. The power up screen is displayed when you

power up the tester with the Isuzu systems
PCMCIA card. Follow the operating procedure
below.
2. Connect the SAE 16/19 adapter (3) to the DLC

cable (4).
vehicle DLC.
810RW317

060RX004
060RW009

060RX009
Function Tests (Reset Oil Life Monitor)

When F4: Function Tests is selected from the Powertrain
Menu, a Reset Oil Life Monitor Menu screen appears.
When the ATF has been replaced, select F0 and reset
Oil Life Monitor data.
060RX094
Once the test vehicle has been identified an Application

(Powertrain) Menu screen appears. Please select the
appropriate application.
Data Display
When F1: Data Display is selected, a Data Display
Menu screen appears.
Please select either Transmission Data or PC Solenoid
Data.
060RX056
7A117
F0: Transmission Data

Item
Unit
Engine running at idle
Engine Speed
RPM
750 900 RPM
Vehicle Speed
km/h, MPH
0 MPH
Throttle Position
0%
0.5 1.0 V
kPa
approx. 40 kPa
Barometric Pressure
kPa
approx. 102 kPa
AT Output Speed (Automatic Transmission)
RPM
0 RPM
AT Input Speed Ratio (Automatic Transmission)

Ignition Voltage
0.0
V
AT Oil Temperature (Automatic Transmission)
C, F
AT Oil Life Monitor (Automatic Transmission)
12.8 14.1 V
70 80C (158 176F)
100 %
Commanded Gear
Current Gear
Mode Switch C
Inactive, Active
Inactive
Mode Switch B
Inactive, Active
Inactive
Mode Switch A
Inactive, Active
Active
Mode Switch G
Inactive, Active
Active
Actual Gear
Park
12 Shift Solenoid A
Off, On
Off
23 Shift Solenoid B
Off, On
On
Brake Switch
Off, On
Off
Solenoid Brake Band
Off, On
Off
TCC Slip Speed

TCC Status
TCC Solenoid
RPM
Disabled, Enabled
750 900 RPM

Enabled
Off, On
Off
TCC Duty Cycle
0%
TCC Apply Mode
No Apply, In Apply
No Apply
TCC Release Mode
No, Yes
No
TCC On Mode
No, Yes
No
TCC Off Mode
No, Yes
Yes
Default Gear
No, Yes
No
Engine Warm
No, Yes
Yes
A/C Request
Yes, No
Yes
A/C Clutch Relay
Off, On
On
Winter Switch
Off, On
Off
Winter Drive Lamp
Off, On
Off
Kickdown Switch
Off, On
Off
ATF Lamp (Automatic Transmission)
Off, On
Off
Power Switch
Normal, Power
Normal
Power Drive Lamp
Off, On
Off
ABS Status
On, Off
(Not used)
F1: PC Solenoid Data

Item
Unit
Engine running at idle
Engine Speed
RPM
750 900 RPM
Vehicle Speed
km/h, MPH
0 MPH
Throttle Position
0%
0.5 1.0 V
kPa
approx. 40 kPa
Barometric Pressure
kPa
approx. 102 kPa
PCS Current (Pressure Control Solenoid)
approx. 1.0 A
PCS Actual Current (Pressure Control Solenoid)
approx. 1.0 A
PCS Duty Cycle (Pressure Control Solenoid)
approx. 45 %
Desired PCS Pressure (Pressure Control Solenoid)
kPa
43 52 kPa
Shift Pressure (Line Pressure)
kPa
43 52 kPa
Transmission Temperature
C, F
75 110C (167 230F)
7A119
Flashing Code
1. A DTC (Flashing Code) can be displayed by the
Powertrain Control Module (PCM) by shorting
together terminals 6 and 4 or 5 (GND) of the Data Link
Connector (DLC) located right side of the drivers side
instrument panel.
821RW288
2.
1. In case there is no DTC stored in memory. The
CHECK ENGINE indicator flashes Normal Code
12 repeatedly.
810RW317
2. In case there is DTC stored in memory. First,

Normal Code 12 is displayed three times and
When all DTCs have been displayed they are
displayed again beginning from the first one.
3. Write down all codes numbers and GOTO DTC
CHECK.
C07RX006
OBD II Diagnostic Management System

Powertrain Control Module (PCM) Location
828RX004
Class 2 Serial Data Bus

OBD II technology requires a much more sophisticated
PCM than does OBD I technology. The OBD II PCM
diagnostic management system not only monitors
systems and components that can impact emissions, but
they also run active tests on these systems and
components. The decision making functions of OBD II
PCM have also greatly increased. To accommodate this
expansion in diagnostic complexity, Isuzu engineers have
designed the Class 2 serial data bus, which meets SAE
J1850 recommended practice for serial data.
Serial Data refers to information which is transferred in a
linear fashion over a single line, one bit at a time. A Data
Bus is an electronic pathway through which serial data
travels.
FRONTERA previously used a 5 volt data bus called

UART, which is an acronym for Universal Asynchronous
Receive and Transmit. When neither the vehicles
control module nor the diagnostic tool, such as a Tech 2,
are talking, the voltage level of the bus at rest is 5 volts.
The two computers talk to each other at a rate of 8,192
bits per second, by toggling or switching the voltage on
the data bus from 5 volts to ground.
Class 2 data, which is used on OBD II vehicles, is quite
different. Data is transferred at a rate of 10.4 kilobits per
second, and the voltage is toggled between zero and 7
volts.
7A121
C07RT006
Class 2 data is also pulse width modulated. Each bit of

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

OBD II standardizes Data Link Connector (DLC)
configurations. The DLC, formerly referred to as the
ALDL, will be a 16terminal connector found on the lower
right side of the drivers side instrument panel. All
manufacturers must conform to this 16terminal
standard.
810RW317

four categories: A, B, C, and D; only types A and B are
emission related The following descriptions define these
categories:
TYPE A
Will store the DTC and turn on the MIL (Check Engine
lamp) on the first trip in which an emissionrelated
diagnostic test has run and reported a test failed to the
Diagnostic Executive.
TYPE B
Will store the DTC and turn on the MIL on the second
consecutive trip in which an emissionrelated diagnostic
test has run and reported a test failed to the Diagnostic
Executive. After one failure, the type B DTC is armed,
or prepared to store a history code and turn on the MIL if
a second failure occurs. One passed test will disarm a
type B DTC. Some special conditions apply to misfire and
fuel trim DTCs. For a type B DTC to store and turn on the
MIL, two ignition cycles are required.
810RT022
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
PIN 10
PIN 11
PIN 12
PIN 13
PIN 14
PIN 15
PIN 16
(Not used)
J1850 Bus + L line on 2wire systems, or
single wire (Class 2)
(Not used)
Chassis ground pin
Signal ground pin
PCM diagnostic enable
(Not used)
(Not used)
Primary UART
(Not used)
(Not used)
ABS diagnostic or CCM diagnostic enable
SIR diagnostic enable
(Not used)
(Not used)
Battery power from vehicle unswitched
(4 AMP MAX.)

the MIL you are already familiar with (CHECK ENGINE
lamp). However, OBD II requires that it illuminate under a
strict set of guidelines. Basically, the MIL is turned on
when the PCM detects a DTC that will impact the vehicles
emissions.
The MIL will be turned on if a component or system which
has an impact on vehicle emissions indicates a
malfunction or fails to pass an emissionsrelated
diagnostic test. It will stay on until the system or
component passes the same test, for three consecutive
trips, with no emissionsrelated faults.
Types Of Diagnostic Trouble Codes (DTCs)

The Diagnostic Executive classifies Diagnostic Trouble
Codes (DTCs) into certain categories. Each type has
different requirements to set the code, and the Diagnostic
Executive will only illuminate the Malfunction Indicator
Lamp (MIL) for emissionsrelated DTCs. DTCs fall into
TYPE C
Will store the DTC and turn on a SERVICE lamp
(Check Trans lamp) on the first trip that a
nonemissionrelated diagnostic test has run and
reported a test failed to the Diagnostic Executive. This
type of DTC will be used in future applications.
TYPE D
Will store a DTC but will not turn on the MIL on the first
trip that a nonemissionrelated diagnostic test has run
and reported a test failed to the Diagnostic Executive.
These codes can be very helpful for vehicle service when
the driver may comment about a condition, but the MIL did
not turn on.
Clear DTC
NOTE: If you clear the DTC (Diagnostic Trouble Codes)
you will not be able to read any codes recorded during the
last occurrence.
NOTE: To use the DTC again to identify a problem, you
will need to reproduce the fault or the problem. This may
require a new test drive or just turning the ignition on (this
depends on the nature of the fault).
1. IF you have a Tech 2:
1. Connect the Tech 2 if it is still not connected
GOTHROUGH Tech 2 OBD II CONNECTION.
2. Push F1: Clear DTC Info in the Application
Menu and answer Yes to the question Do you
want to clear DTCs?
a. When a malfunction remains as it is the Tech 2
displays 4L30E CODES NOT CLEARED. This
means that the problem is still there or that the
recovery was not done. Please GOTO DTC
CHECK.
b. When a malfunction has been repaired and the
recovery is done the Tech 2 displays 4L30E
CODES CLEARED.

2. IF you have no Tech 2:
To clear the DTC, remove Fuse ECM (F13, 15A)
for at least 10 seconds.
2. There are several ways for a person to become

charging are by friction and induction. An example of
charging by friction is a person sliding across a car
seat, in which a charge of as much as 25,000 volts
can build up. Charging by induction occurs when a
person with well insulated shoes stands near a highly
charged object and momentarily touches ground.
Charges for the same polarity are drained off, leaving
the person highly charged with the opposite polarity.
Static charges of either type can cause damage,
therefore, it is important to use care when handling
and testing electronic components.
NOTICE:
To
discharge damage:
826RX017
DTC Check
1. Diagnostic Trouble Codes (DTC) have been identified
by Tech 2.
2. You have written the list of the DTCs. The order of the
malfunctions has no meanings for this PCM. Usually
only one or two malfunctions should be set for a given
problem.
3. Check directly the DTCs you identified. The DTCs are
sorted by number. Refer to Diagnostic Trouble Code
(DTC) Identification in this section.
PCM Precaution
The PCM can be damaged by:
1. The electrostatic discharge
2. The short circuit of some terminals to voltage or to
ground.
Electrostatic Discharge Damage Description:
1. Electronic components used to control systems are
often designed to carry very low voltage, and are very
susceptible to damage caused by electrostatic
discharge. It is possible for less than 100 volts of
static electricity to cause damage to some electronic
components. By comparison, it takes as much as
4,000 volts for a person to even feel the zap of a static
discharge.
7A123
prevent
possible
electrostatic
1. Do not touch the PCM connector pins or soldered

components on the PCM circuit board.
2. Be sure to follow the guidelines listed below if
servicing any of these electronic components:
3. Do not open the replacement part package until it is
time to install the part.
4. Avoid touching electrical terminals of the part.
5. Before removing the part from its package, ground
6. Always touch a known good ground before handling
the part. This step should be repeated before
installing the part if the part has been handled while
sliding across the seat, while sitting down from a
standing position or while walking some distance.
Information On PCM
1. The Powertrain Control Module (PCM) is located in
the center console and is the control center of the
electronic transmission control system.
2. The PCM must be maintained at a temperature below
85F (185C) at all times. This is most essential if the
vehicle is put through a paint baking process. The
PCM will become inoperative if its temperature
exceeds 85C (185F). Therefore, it is
recommended that the PCM be removed or that
temporary insulation be placed around the PCM
during the time the vehicle is in a paint oven or other
high temperature process.
3. The PCM is designed to process the various inputs
and then respond by sending the appropriate
electrical signals to control transmission upshift,
downshift, shift feel and torque converter clutch
engagement.
4. The PCM constantly interprets information from the
various sensors, and controls the systems that affect
transmission and vehicle performance. By analyzing
operational problems, the PCM is able to perform a
diagnostic function by displaying DTC(s) and aid the
technician in making repairs.
Intermittent Conditions
If the Tech 2 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
always be the prime suspect. Intermittents rarely occur
inside sophisticated electronic components such as the
PCM.
Use the DTC information to understand which wires and
sensors are involved.
When an intermittent problem is encountered, check
suspect circuits for:
1. Poor terminal to wire connection.
2. Terminals not fully seated in the connector body
(backed out).
3. Improperly formed or damaged terminals.
4. Loose, dirty, or corroded ground connections:
HINT: Any time you have an intermittent in more than
one circuit, check whether the circuits share a
common ground connection.
5. Pinched or damaged wires.
6. Electromagnetic 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, 2way radios, etc.
Use the F2: SNAPSHOT mode of the Tech 2 to help
isolate the cause of an intermittent fault. The snapshot
mode will record information before and after the problem
occurs. Set the snapshot to trigger on the suspect DTC
or, if you notice the reported symptom during the test
drive, trigger the snapshot manually.
After the snapshot has been triggered, command the
Tech 2 to play back the flow of data recorded from each of
the various sensors. Sign of an intermittent fault in a
sensor circuit is a sudden unexplainable jump in data
values out of the normal range.
7A125
Transmission and PCM Identification

The chart below contains a list of all important information
concerning rear axle ratio, Powertrain Control Module
(PCM), and transmission identification.
VEHICLE
Type
Engine
Isuzu/
Frontera
3.2L V6
Rr axle
Ratio
4.100
PCM
TRANSMISSION
ISUZU Parts No.
Calibration
Code
Isuzu Part No.
Model Code
8093561590
G20
8960180043
FL (44)
Isuzu Frontera
240RX011
Diagnostic Trouble Code (DTC)

Identification
DTC
NUMBER
FLASHING
CODE
P0218
71
Transmission Fluid Over Temperature
P0560
72
System Voltage Malfunction
P0705
73
Transmission Range Switch (Mode Switch) Illegal

Position
P0706
74
Transmission Range Switch (Mode Switch)

Performance
P0712
75
Transmission Fluid Temperature Sensor Circuit Low

Input (TFT)
P0713
76
Transmission Fluid Temperature (TFT) Sensor Circuit

High Input
P0719
77
TCC Brake Switch Circuit High (Stuck ON)
P0722
78
Transmission Output Speed Sensor (OSS) Low Input
Flash
P0723
79
Transmission Output Speed Sensor (OSS)

Intermittent
Flash
P0730
81
Transmission Incorrect Gear Ratio
Flash
P0748
82
Pressure Control Solenoid (PCS) (FORCE MOTOR)

Circuit Electrical
Flash
P0753
83
Shift Solenoid A Electrical
Flash
P0758
84
Shift Solenoid B Electrical
Flash
P1790
85
ROM Transmission Side Bad Check Sum
Flash
P1792
86
EEPROM Transmission Side Bad Check Sum
Flash
P1835
87
Kick Down Switch Always ON
P1850
88
Brake Band Apply Solenoid Malfunction
P1860
89
TCC Solenoid Electrical
DTC NAME
DTC TYPE
DEFINITION
Flashing Check Trans on 1st failure
No lamps
NOTE: On the following charts, refer to Powertrain

Control Module (PCM) section for Wiring System and the
Body and Accessories section for circuit diagram details,
parts location, and connector configuration.
DTC TYPE
CHECK
TRANS
Flash
7A127
DTC P0218/Flashing Code 71 Transmission Fluid Over Temperature
D07RX016
Circuit Description
The Transmission Fluid Temperature (TFT) sensor is a
thermister that controls the signal voltage to the PCM.
The PCM supplies a 5volt reference to the sensor on
circuit GRN/RED. When the transmission fluid is cold, the
sensor resistance is high and the PCM will sense high
signal voltage. As the fluid temperature warms to a
normal transmission operating temperature of 100C
(212F), the sensor resistance becomes less and the
voltage decreases to 1.5 to 2.0 volts.
This DTC detects a high transmission temperature for a
long period of time. This is a type D DTC.
Conditions For Setting The DTC

D No TFT DTCs P0712 or P0713.
D TFT is greater than 135C (275F).
D All conditions met for 21 seconds.
Action Taken When The DTC Sets

D Hot mode TCC Shift Pattern.
D The PCM will not illuminate the CHECK TRANS
Lamp.
D ATF Lamp ON. (greater than 145C (293F))
D Disable Eside TCC OFF request.
Conditions For Clearing The DTC

D The DTC can be cleared from the PCM history by
using a scan tool.
D The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
reported.
D The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled off
long enough to power down the PCM.
Diagnostic Aids
D Inspect the wiring for poor electrical connections at
the PCM and at the transmission 16way connector.
Look for possible bent, backed out, deformed or
damaged terminals. Check for weak terminal tension
as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.
D When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
D Check harness routing for a potential short to ground
in circuit GRN/RED.
D Scan tool TFT sensor temperature should rise
steadily to about 100C (212F), then stabilize.
D Check for a skewed (misscaled) sensor by
comparing the TFT sensor temperature to the
ambient temperature after a vehicle cold soak. A
skewed sensor can cause delayed garage shifts or
TCC complaints.
D Check for a possible torque converter stator problem.
D Verify customer driving habits, trailer towing, etc.
Test Description
diagnostic chart.
2. This test checks for a skewed sensor or shorted
circuit.
3. This test simulates a TFT DTC P0713.
DTC P0218/Flashing Code 71 Transmission Fluid Over Temperature

Step
Action
Perform the following checks:

D Check for possible engine system problems.
D Transmission fluid checking procedure. Refer to Checking
Transmission Fluid Level and Condition in Automatic
Transmission (4L30E) Section.
Were the checks performed?
Yes
No
Go to Step 2
Go to Step 3
Go to Diagnostic
Aids
Go to Internal
Wiring Harness
Check
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
1. Install the scan tool.

2. With the engine off, turn the ignition switch on.
NOTE: Before clearing DTC(s), use the scan tool to record Failure
Records for reference, as data will be lost when Clear Info
function is used.
3. Record the DTC Failure Records.
Is the TFT sensor signal voltage less than 0.33 volts?
1. Turn the ignition off.

2. Disconnect the transmission 16way connector H10
(additional DTCs may set).
Is the TFT sensor signal voltage greater than 4.92 volts?
Inspect/repair circuit GRN/RED for a short to ground.

1. Inspect the PCM for poor connections.

2. Replace the PCM if no poor connections were found.
Is the replacement complete?
1. After the repair is complete, use the scan tool to select DTC,
then Clear Info function and ensure the following conditions
are met:
TFT is less than 125C (257F) for at least 10 seconds.
2. Review the scan tool DTC Info.
Has the last test failed or is the current DTC displayed?
7A129
DTC P0560/Flashing Code 72 System Voltage Malfunction
D07RX017
Circuit Description
Circuit RED/WHT is the battery voltage feed for the PCM.
Circuit RED/BLU is the ignition voltage feed for the PCM.
This DTC detects a low voltage or a high voltage. This is a
type C DTC.

System Voltage Low:
D Engine speed is greater than 1,000 rpm.
D System voltage is less than 10 volts at a maximum
transmission temperature of 150C (302F).
D System voltage is less than 7.3 volts at a minimum
transmission temperature of 40C (40F).
System Voltage High:
D System voltage is greater than 16 volts for 2 seconds.

D
D
D
D
Fixed to 4th gear.

Maximum line pressure.
Inhibit TCC engagement.
The PCM will illuminate the CHECK TRANS Lamp.
Conditions For Clearing The DTC/CHECK

TRANS Lamp
D The PCM will turn off the CHECK TRANS lamp after
three consecutive ignition cycles without a failure
reported.
using a scan tool.
reported.
Diagnostic Aids
D Charging the battery with a battery charger and jump
starting an engine may set DTC(s). If DTC(s) set
when an accessory is operated, check for faulty
connections or excessive current draw.
D Check for faulty connections at the starter solenoid or
fusible link.
D Check for loose/damaged terminals at generator.
D Check belt wear/tension.
Test Description
diagnostic chart:
3. This test checks charging system voltage.
4. This test checks battery voltage input at the PCM.
6. This test checks ignition voltage input at the PCM.
DTC P0560/Flashing Code 72 System Voltage Malfunction

Step
1
Action
Yes
No
Go to Step 2
Go to Engine
Electrical in
Engine section
Go to Starting
and Charging
System in Engine
section
Go to Step 3
Go to Step 4
Go to Starting
and Charging
System in Engine
section
Go to Step 5
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 8
Go to Step 10
Go to Step 10
Go to Step 9

Records for reference, as data will be lost when the Clear Info
function is used.
3. Record the DTC Failure Records. Note: If any other DTCs
are present, refer to their applicable diagnostic charts before
continuing.
4. Using the J39200 DVOM, measure the battery voltage
across the battery terminals. Record the measurement for
future reference.
Is the voltage higher than 10.5 volts?
Start the engine and warm to normal operating temperature.

Is the generator/check engine light on?
1. Increase the engine speed to 1,0001,500 rpm.

2. Observe scan tool system voltage.
Is the system voltage within 1315 volts.

2. Disconnect the C1(RED) and C3 (BLUE) PCM connector
(additional DTCs will set).
4. Using the J39200 DVOM, measure the battery voltage input at
PCM connector terminals C1A4 and C3E16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals C1A4 and C3E16 that
is greater than 0.5 volts?
Repair the high resistance condition in circuit RED/WHT.

Was the circuit repaired?
1. Disconnect the C3 (BLUE) PCM connector.

2. Measure the ignition voltage input at PCM connector terminals
C3E16 and C3F16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals C3E16 and C3F16
that is greater than 0.5 volts?
Repair the high resistance condition is circuit RED/BLU.

Was the circuit repaired?
Check PCM connector terminals C1A4, C3E16 and C3F16 for

bent, damaged, or backed out connector pins. Also check for
weak terminal tension.
7A131
DTC P0560/Flashing Code 72 System Voltage Malfunction (Contd)

Step
9
Action
No
Go to Step 10
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Replace the PCM.

10
Yes
then Clear Info function and operate the vehicle under the
Start the vehicle and warm to normal operating temperature.
The PCM must see a system voltage between 10 and 16 volts.
DTC P0705/Flashing Code 73 Transmission Range Switch (Mode Switch) Illegal

Position
D07RX018
Circuit Description
D 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
position is indicated by the state of four ON/OFF
contracts. The range switch is located on one side of
the transmission. It is on the transmission manual
shaft and is fixed to the main case.
D The range switch is also used to provide the
information P or N to the engine crank wiring. The
engine can be cranked only if connector M16
terminal 4(H) is connected to terminal 1(E) which is
connected to ground.
D The range switch is also used to provide the backup
lamp power in reverse. This is the reason why the
range switch is supplied through a 15A fuse (C14).
This fuse can burn due to a short circuit in the back up
lamp.
This DTC detects when a fuse is open or the range switch
circuit does not work. This is a type D DTC.

D Range switch illegal positions met for 5 seconds.

D Default to D position.
D Inhibit torque management.
D Maximum line pressure.

Lamp.

using a scan tool.
reported.
Diagnostic Aids
D Refer to accompanying chart for the normal range
signals and the illegal combinations.
as well. Also check for a chafed wire that could short
to bare metal or other wiring. Inspect for a broken wire
inside the insulation.

D Refer to the Range Switch Logic Table or
Functional Test Procedure for further information.
Test Description
diagnostic chart:
2. This test checks the indicated range signal to the
manual valve actually selected.
5. This test checks for continuity between each
selected range switch connector terminals.
Range Switch Logic Table
Range Switch Pin
Range
g
Position
P(G)
Park
ON
OFF
OFF
ON
Reverse
ON
ON
OFF
OFF
Neutral
OFF
ON
OFF
ON
D4
OFF
ON
ON
OFF
D3
ON
ON
ON
ON
ON
OFF
ON
OFF
OFF
OFF
ON
ON
Illegal
OFF
OFF
OFF
OFF
Illegal
OFF
OFF
OFF
ON
7A133
DTC P0705/Flashing Code 73 Transmission Range Switch (Mode Switch) Illegal

Position
Step
Action

D The transmission linkage from the select lever to the manual
valve is adjusted properly.
D Diagnostic circuit check.
Yes
No
Go to Step 2
Go to Diagnostic
Aids
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 8
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

function is used.
4. Select each transmission range: D1, D2, D3, D4, N, R, and P.
Does each selected transmission range match the scan tool
Range Switch display?
Are all range switch pin displays incorrect?
Check fuse and wiring to the 8way connector terminal 5(D) for
opens.
Refer to Mode Switch in Automatic Transmission (4L30E)
section.
If no problem was found, replace the range switch.
1. Disconnect the 8way range switch connector.

2. Using ohmmeter, check continuity between terminal 5(D) and
respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8way
range switch connector.
3. Move shift selector lever through all positions and compare
results with Range Switch Logic Table.
Is one range switch pin display incorrect?
Check the affected wiring and connector, and repair.

Check the Powertrain Control Module (PCM) connectors for poor

connection.
If no problem was found, replace the PCM.
then Clear Info function and road test the vehicle.
7A135
DTC P0706/Flashing Code 74 Transmission Range Switch (Mode Switch)

Performance
D07RX018
Circuit Description
D 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
position is indicated by the state of four ON/OFF
contracts. The range switch is located on one side of
the transmission. It is on the transmission manual
shaft and is fixed to the main case.
D The range switch is also used to provide the
information P or N to the engine crank wiring. The
engine can be cranked only if connector M16
terminal 4(H) is connected to terminal 1(E) which is
connected to ground.
D The range switch is also used to provide the back up
lamp power in reverse. This is the reason why the
mode switch is supplied through a 15A fuse (C14).
This fuse can burn due to a short circuit in the back up
lamp.
D This DTC detects an invalid state of the range switch
or the range switch circuit by deciphering the range
switch inputs. This is a type D DTC.

This DTC will set if any of the following conditions occurs:
Condition 1 (R bad position):

D No output speed DTCP0722, P0723.
D Output speed greater then 3,200 RPM.

D Range switch indicates R.
Condition 2 (P or N bad position):

D
D
D
D
D
D
Engine is running.
No TPS codes.
Engine speed is less than 3,000 RPM.
TP angle is greater than 20%.
Range switch indicates P or N.
All conditions met for 4 seconds.

D Default to D position.
Lamp.

using a scan tool.
reported.
Diagnostic Aids
D Refer to the accompanying chart for the normal range
signals and the illegal combinations.
D Refer to the Range Switch Logic Table or
Functional Test Procedure for further information.
Test Description
diagnostic chart:
2. This test checks the indicated range signal to the
manual valve actually selected.
5. This test checks for continuity between each
selected range switch connector terminals.
Range Switch Logic Table
Range Switch Pin
Range
g
Position
P(G)
Park
ON
OFF
OFF
ON
Reverse
ON
ON
OFF
OFF
Neutral
OFF
ON
OFF
ON
D4
OFF
ON
ON
OFF
D3
ON
ON
ON
ON
ON
OFF
ON
OFF
OFF
OFF
ON
ON
Illegal
OFF
OFF
OFF
OFF
Illegal
OFF
OFF
OFF
ON
7A137
DTC P0706/Flashing Code 74 Transmission Range Switch (Mode Switch)

Performance
Step
Action

D The transmission linkage from the select lever to the manual
valve is adjusted properly.
D Diagnostic circuit check.
Yes
No
Go to Step 2
Go to Diagnostic
Aids
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 8
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

function is used.
4. Select each transmission range: D1, D2, D3, D4, N, R, and P.
Does each selected transmission range match the scan tool
Range Switch display?
Are all range switch pin displays incorrect?
Check fuse and wiring to the 8way connector terminal 5(D) for
opens.
Refer to Mode Switch in Automatic Transmission (4L30E)
section.
If no problem was found, replace the range switch.
1. Disconnect the 8way range switch connector.

2. Using ohmmeter, check continuity between terminal 5(D) and
respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8way
range switch connector.
3. Move shift selector lever through all positions and compare
results with Range Switch Logic Table.
Is one range switch pin display incorrect?
Check the affected wiring and connector, and repair.

Check the Powertrain Control Module (PCM) connectors for poor

connection.
If no problem was found, replace the PCM.
then Clear Info function and road test the vehicle.
DTC P0712/Flashing Code 75 Transmission Fluid Temperature (TFT) Sensor

Circuit Low Input
D07RX016
Circuit Description
The TFT sensor is a thermister that controls the signal
voltage to the PCM. The PCM supplies a 5volt reference
signal to the sensor on circuit GRN/RED. When the
transmission fluid is cold, the sensor resistance is high.
The PCM detects high signal voltage.
As the
transmission fluid temperature increases to the normal
operating temperature of 100C (212F), the sensor
resistance becomes less and the voltage decreases to
1.5 to 2 volts. With transmission fluid over temperature
and DTC P0218 also set, check the transmission cooling
system.
This DTC detects a continuous short to ground in the TFT
signal circuit or the TFT sensor. This is a type D DTC.

D
D
D
D
Battery voltage is between 10 and 16 volts.

Ignition is on.
TFT sensor indicating a voltage less than 0.4 volts.
All conditions met for 20 seconds.

D Transmission default temperature will be:
80C (176F) if engine temperature code is set.
100C (212F) if engine temperature is warm.
80C (176F) if engine run time is greater than 5
minutes.
21C (69.8F) if engine run time is less than 5
minutes.
Lamp.

using a scan tool.
reported.
Diagnostic Aids
D Check harness routing for a potential short to ground
in circuit GRN/RED. Scan tool TFT display should
rise steadily to about 100C (212F), then stabilize.
D Inspect the wiring for poor electrical connection at the
PCM and at the transmission 16way connector.
D The temperature to resistance value scale may be
used to test the TFT sensor at the various
temperature levels to evaluate the possibility of a
skewed (misscaled) sensor.
A skewed sensor could result in delayed garage
shifts or TCC complaints.
D Verify customer driving habits, trailer towing, etc.
7A139

Resistance Chart
Test Description
diagnostic chart:
2. This test checks for a short to ground or a skewed
sensor.
3. This test checks for an internal fault within the
transmission by creating an open.
Resistance (kW)
40
40
672
32
65
20
68
25
80
176
2.5
120
248
0.78
150
304
0.37
DTC P0712/Flashing Code 75 Transmission Fluid Temperature (TFT) Sensor Circuit Low
Input
Step
Action
Perform the transmission fluid checking procedure. Refer to

Checking Transmission Fluid Level and Condition in Automatic
Transmission (4L30E) section.
Yes
No
Go to Step 2
Refer to
Checking
Transmission
Fluid Level and
Condition in
Automatic
Transmission
(4L30E) section
Go to Step 3
Go to Diagnostic
Aids
Go to Step 4
Go to Step 9
Go to Diagnostic
Aids
Go to Step 5
Go to Diagnostic
Aids
Go to Step 6
Go to Step 8
Go to Step 7
Go to Diagnostic
Aids
Go to Step 8
Go to Step 12
Was the fluid checking procedure performed?

function is used.
Does the scan tool display a TFT sensor signal voltage less than
0.4 volts?

2. Disconnect the transmission 16way connector H10.
3. Turn the ignition on.
Does the TFT signal voltage change to match the voltage 4.92
volts?
Using the J39200 DVOM, measure the resistance between

terminals 3(C) and 5 (D).
Is the resistance within specifications? (See Resistance Chart.)
1. Disconnect the transmission 5way connector M6.

2. Using the J39200 DVOM, measure the resistance between
terminals 3(C) and 5(D).
1. Remove the transmission oil pan. Refer to Transmission Oil

Temperature Sensor (Adapter Case) in Automatic
Transmission (4L30E) section.
2. Check the internal wiring harness for a short to ground.
1. Disconnect the internal wiring harness at the TFT sensor.

2. Measure the resistance of the TFT sensor.
Replace the TFT Sensor.

DTC P0712/Flashing Code 75 Transmission Fluid Temperature (TFT) Sensor Circuit Low
Input (Contd)
Step
9
Action
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 12
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Replace the PCM. Refer to Powertrain Control Module (PCM) in

Automatic Transmission (4L30E) section.
12
Go to Step 12
Check the PCM for faulty connections.

11
No
Check circuit GRN/RED for a short to ground.

10
Yes
are met:
TFT sensor indicates a voltage greater than 0.33 volts for 2
seconds.
2. Review the scan tool DTC info.
7A141
DTC P0713/Flashing Code 76 Transmission Fluid Temperature (TFT) Sensor

Circuit High Input
D07RX016
Circuit Description
The TFT sensor is a thermistor that controls the signal
voltage to the PCM. The PCM supplies a 5volt reference
signal to the sensor on circuit GRN/RED. When the
transmission fluid is cold, the sensor resistance is high
and the PCM will sense high signal voltage. As the
transmission fluid temperature warms to the normal
operating temperature of 100C (212F), the sensor
resistance becomes less and the voltage decreases to
about 1.5 to 2 volts.
This DTC detects a continuous open or short to power in
the TFT signal circuit or the TFT sensor. This is a type D
DTC.

using a scan tool.
reported.
Diagnostic Aids
80C (176F) if engine run time is greater than 5

minutes.

D Scan tool displays transmission fluid temperature in
degrees. After transmission is operating, the
temperature should rise steadily to about 100C
(212F), then stabilize.
D The temperature to resistance value scale may be
used to check the TFT sensor at the various
temperature levels to evaluate the possibility of a
skewed (misscaled) sensor.
21C (69.8F) if engine run time is less than 5

minutes.
A skewed sensor could result in hard shifts or TCC

complaints.

D Battery voltage is between 10 and 16 volts.
D Ignition is on.
D TFT sensor indicating a voltage greater than 4.86
volts.

D Transmission default temperature will be:
80C (176F) if engine temperature code is set.
100C (212F) if engine temperature is warm.

Lamp.

Resistance Chart
Test Description
diagnostic chart:
2. This check verifies problem in the TFT sensor circuit.
3. This test simulates a TFT sensor DTC P0712. If the
PCM recognizes the low signal voltage (high
temperature), and the scan tool displays 146C
(295F) or greater, the PCM and wiring are OK.
4. This test checks the TFT sensor and internal wiring
harness.
Resistance (kW)
40
40
672
32
65
20
68
25
80
176
2.5
120
248
0.78
150
304
0.37
DTC P0713/Flashing Code 76 Transmission Fluid Temperature (TFT) Sensor Circuit High
Input
Step
Action
Perform the transmission fluid checking procedure.

Refer to Checking Transmission Fluid Level and Condition in
Yes
No
Go to Step 2
Refer to
Checking
Transmission
Fluid Level and
Condition in
Automatic
Transmission
(4L30E) section
Go to Step 3
Go to Diagnostic
Aids
Go to Step 4
Go to Step 9
Go to Diagnostic
Aids
Go to Step 5
Go to Diagnostic
Aids
Go to Step 6
Go to Step 13
Go to Step 7
Go to Diagnostic
Aids
Go to Step 8
Was the fluid checking procedure performed?

function is used.
Does the scan tool display a TFT sensor signal voltage greater
than 4.86 volts?

3. Install a fused jumper wire from terminal 3(C) to 5(D) on the
engine harness.
Does the TFT signal voltage drop to less than 0.4 volts?


1. Remove the transmission oil pan.

2. Check the internal wiring harness for an open. Refer to
Transmission Oil Temperature Sensor (Adapter Case) in
Was a problem found and corrected?
1. Disconnect the internal wiring harness at the TFT sensor.

2. Measure the resistance of the TFT sensor.
7A143
DTC P0713/Flashing Code 76 Transmission Fluid Temperature (TFT) Sensor Circuit High
Input (Contd)
Step
Action
Replace TFT sensor. Refer to Transmission Oil Temperature

Sensor (Adapter Case) in Automatic Transmission (4L30E)
section.
Go to Step 13
Go to Step 10
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12
Go to Step 13
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

13
Check the PCM for faulty or intermittent connections.

12
Go to Step 13
Check circuit GRN for an open.

11
No
Check circuit GRN/RED for an open or short to B+.

10
Yes
are met:
TFT sensor indicates a voltage less than 4.92 volts for 2
seconds.
DTC P0719/Flashing Code 77 TCC Brake Switch Circuit High (Stuck On)
D07RX019
Circuit Description
The brake switch is used to indicate brake pedal status.
The normally opened brake switch signal voltage circuit is
opened.
Brake switch supplies a B+ signal on circuit RED to the
PCM, when the brakes are applied. The PCM uses this
signal to deenergize the TCC solenoid when the brakes
are applied.
This DTC detects a closed brake switch during
accelerations. This is a type D DTC.

D No OSS DTCs P0722 or P0723.
D The PCM detects a closed brake switch/circuit (12
volts) for 2 seconds, and the following events occur
seven consecutive times: vehicle speed is less than 8
km/h (5 mph); then vehicle speed is between 8 and 32
km/h (5 and 20 mph) for 4 seconds; then vehicle
speed is greater than 32 km/h (20 mph) for 4 seconds.

D If throttle opening is greater than 10% and vehicle
speed is greater than 45 km/h (28 mph), then
disregard brake switch contingency for TCC off
mode.
D The PCM will not illuminate CHECK TRANS Lamp.

using a scan tool.

reported.
Diagnostic Aids
the PCM and brake switch. Look for possible bent,
backed out, deformed or damaged terminals. Check
for weak terminal tension as well. Also check for a
chafed wire that could short to bare metal or other
wiring. Inspect for a broken wire inside the insulation.
open condition, move or massage the wiring harness
while observing test equipment for a change.
D Check customer driving habits and/or unusual driving
conditions (i.e. stop and go, highway).
D Check brake switch for proper mounting and
adjustment.
Test Description
diagnostic chart:
2. This test checks for voltage at the brake switch.
5. This test checks the brake switch.
8. This test checks circuit RED at the PCM.
7A145
DTC P0719/Flashing Code 77 TCC Brake Switch Circuit High (Stuck On)
Step
Action

2. With the engine off, turn the ignition switch on. If ABS code
is set, check applicable fuse.
Yes
No
Go to Diagnostic
Aids
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 13
Go to Step 8
Go to Step 6
Go to Step 9
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 13
Go to Step 10
Go to Step 13
Go to Diagnostic
Aids
Go to Step 11
Go to Step 13
Go to Step 12
function is used.
4. Apply then release the brake pedal.
Does the scan tool display Brake Switch as closed with the
brake pedal applied, and then display open when the brake
pedal is released?
2

2. Back probe ignition feed circuit terminal I181 at the brake
switch.

2. Back probe circuit terminal I184 at the brake switch.
Is the test light off?
Repair the open in battery feed circuit terminal I181 to the brake
switch.
If fuse is open, check circuit terminal I184 for a short to ground.
Disconnect brake switch connector I18 and ignition switch on.

Check the brake switch short (I181 and I184).

Check circuit terminal I184 for a short to voltage.

Ignition switch on.

2. Check circuit terminal I184 for a short to voltage.
Replace the brake switch.

10

2. Reconnect the C3 (BLUE) PCM connector.
Does the scan tool display Brake Switch as open with the
brake applied, then display closed with the brake pedal
released?
11
Check the PCM for faulty or intermittent connections.

DTC P0719/Flashing Code 77 TCC Brake Switch Circuit High (Stuck On) (Contd)
Step
Action
12

13
are met:
The PCM brake switch signal must indicate 0 volts for 1
seconds with the brake pedal applied.
Yes
No
Go to Step 13
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
7A147
DTC P0722/Flashing Code 78 Transmission Output Speed Sensor (OSS) Low

Input
D07RW022
Circuit Description
Output speed information is provided to the PCM by the
OSS, which is a permanent magnet (PM) generator. The
PM generator produces a pulsing AC voltage. The AC
voltage level and number of pulses increases as the
speed of the vehicle increases. The PCM then converts
the pulsing voltage to output speed, which is used for
calculations. The vehicle speed can be displayed with a
scan tool.
This DTC detects a low output speed when there is a high
engine speed in a drive gear range. This is a type C
DTC.

D No MAP DTCs P0107 or P0108, P0106, P1106,
P1107.
D No TP DTCs P0122 or P0123.
D Not in Park or Neutral.
D TP angle is greater than 10%.
D Engine vacuum is between 0 and 70kPa.
D Engine speed is between 3000 and 7000 rpm.
D Transmission output speed is less than 0 rpm.

D
D
D
D
Fixed to 4th gear.


TRANS Lamp
D The PCM will turn off the CHECK TRANS Lamp after
reported.
using a scan tool. The DTC will be cleared from
history when the vehicle has achieved 40 warmup
cycles without a failure reported.
Diagnostic Aids
D An OSS DTC P0722 will set when no output speed is
at detected at start off.
PCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
open condition, move or massage the wiring harness
while observing test equipment for a change.
Test Description
diagnostic chart:
4. This test checks the OSS circuit.
5. This test checks the integrity of the OSS.
7. This test checks the 5volt and ground circuit of the
PCM.

Input
Step
Yes
No
Go to Diagnostic
Aids
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 16
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 17
Go to Step 8
Go to Step 16
Go to Step 10
Go to Step 17
Go to Step 9
Go to Step 17
10
Was the reading in step 8 less than 4.0 volts?
Go to Step 12
Go to Step 11
11
Was the reading in Step 8 greater than 5.1 volts?
Go to Step 15
12
Using the J 39200 DVOM to chassis ground, measure the voltage

on circuit RED.
Go to Step 13
Go to Step 14
Go to Step 17
Go to Step 17
Go to Step 16
Action
function is used.
4. Raise the drive wheels.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the Trans Output Speed
increase with the drive wheel speed?
Check for the most current and/or incorrect calibration.

Is the calibration current?

harness connector terminals C3E1 and C3E2.
Is the reading 3000 ohms?
1. Select AC volts.
2. Rotate the rear wheels, ensuring the driveshaft is turning.
Is the voltage greater than 0.5 volts?
Inspect circuits YEL and BRN for a poor connection or an open

circuit.
1.
2.
3.
4.
Reconnect the C3 (BLUE) PCM connector.

Disconnect the OSS harness from the OSS.
With the engine off, turn the ignition on.
Using the J 39200 DVOM, measure the voltage at the OSS
harness connector terminals M151 and M152.
Is the reading between 4.0 to 5.1 volts?

8
1. Remove the OSS.

2. Check the output shaft speed sensor rotor for damage or
misalignment. Refer to Speed Sensor (Extension Housing) in
Replace the OSS.

13
Repair the open in circuit BRN.

14
Check circuit YEL for a short to ground or open.

7A149

Input (Contd)
Step
15
Action
Go to Step 17
Go to Step 17
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

automatic Transmission (4L30E) section.
17
No
Repair the short to B+ in circuit YEL.

16
Yes
Transmission output speed is greater than 101 rpm for 3
seconds.
DTC P0723/Flashing Code 79 Transmission Output Speed Sensor (OSS)

Intermittent
D07RW022
Circuit Description
Output speed information is provided to the PCM by the
OSS, which is a permanent magnet (PM) generator. The
PM generator produces a pulsing AC voltage. The AC
voltage level and number of pulses increases as the
speed of the vehicle increases. The PCM then converts
the pulsing voltage to output speed, which is used for
calculations. The vehicle speed can be displayed with a
scan tool.
This DTC detects a low output speed when there is a high
engine speed in a drive gear range. This is a type C
DTC.

In Park or Neutral:
D Transmission output speed change is greater than
10000 rpm.
D Conditions met for 6 seconds.
D Engine running time is greater than 2 seconds.
Not in Park or Neutral:
D Transmission output speed change is greater than
512 rpm.
D Conditions met for 0.075 seconds
D Engine running time is greater than 2 seconds.
D Engine vacuum is less than 70 kPa.
D Output speed is greater than 1380 rpm for 1 second.
D NORAWNOLAST < 60 rpm for 6 seconds.
D NORAW: Latest raw data of output shaft speed.
D NOLAST: Fitered previous data of output speed.

D Fixed to 4th gear.
D Inhibit TCC engagement.
D The PCM will illuminate the CHECK TRANS Lamp.

TRANS Lamp
reported.
using a scan tool.
reported.
Diagnostic Aids
D A OSS DTC P0723 will set when output speed has
been detected and is lost.
PCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
Test Description
diagnostic chart:
4. This test checks the OSS circuit.
5. This test checks the integrity of the OSS.
7. This test checks the 5volt and ground circuit of the
PCM.
7A151

Intermittent
Step
Yes
No
Go to Diagnostic
Aids
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 16
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 17
Go to Step 8
Go to Step 16
Go to Step 10
Go to Step 17
Go to Step 9
Go to Step 17
10
Was the reading in step 8 less than 4.0 volts?
Go to Step 12
Go to Step 11
11
Was the reading in Step 8 greater than 5.1 volts?
Go to Step 15
12
Using the J 39200 DVOM to chassis ground, measure the voltage

on circuit YEL.
Go to Step 13
Go to Step 14
Go to Step 17
Go to Step 17
Go to Step 16
Action
function is used.
4. Raise the drive wheels.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the Trans Output Speed
increase with the drive wheel speed?
Check for the most current and/or incorrect calibration.

Is the calibration current?

harness connector terminals C3E1 and C3E2.
Is the reading 3,000 ohms?
1. Select AC volts.
2. Rotate the rear wheels, ensuring the driveshaft is turning.
Is the voltage greater than 0.5 volts?
Inspect circuits YEL and BRN for a poor connection or an open

circuit.
1.
2.
3.
4.
Reconnect the C3 (BLUE) PCM connector.

Disconnect the OSS harness from the OSS.
With the engine off, turn the ignition on.
Using the J 39200 DVOM, measure the voltage at the OSS
harness connector terminals M151 and M152.

8
1. Remove the OSS.

2. Check the output shaft speed sensor rotor for damage or
misalignment. Refer to Speed Sensor (Extension Housing) in
Replace the OSS.

13
Repair the open in circuit BRN.

14
Check circuit YEL for a short to ground or open.


Intermittent (Contd)
Step
15
Action
Go to Step 17
Go to Step 17
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

17
No
Repair the short to B+ in circuit YEL.

16
Yes
Transmission output speed is greater than 101 rpm for 3
seconds.
7A153
DTC P0730/Flashing Code 81 Transmission Incorrect Gear Ratio
D07RT015
Circuit Description
D The Powertrain Control Module (PCM) calculates the
slippage of the converter and transmission based
upon the engine speed, the output speed, and the
current gear ratio.
D The slippage of the converter at a high enough engine
speed is low. The transmission should not slip more
than a given value when there is no shift.
D This DTC detects a slip at each gear. This is a type
C DTC.

D No Output Speed Sensor DTC(s) P0722, P0723.
D Not in Park, Neutral or Reverse.
D Engine speed is greater than 3500 rpm.
D
D
D
D
3 seconds since upshift.

3 seconds since downshift.
3 seconds since garage shift (ND).
And one of the following conditions occur:
Slip is greater than 753 rpm in 1st gear.
Slip is greater than 713 rpm in 2nd gear.
Slip is greater than 694 rpm on 3rd gear.
Slip is greater than 685 rpm on 4th gear.
D All conditions met for 5.5 seconds.


TRANS Lamp
D The PCM will turn off the CHECK TRANS Lamp
after three consecutive ignition cycles without a
failure reported.
D The DTC can be cleared from PCM memory by using
a scan tool. The DTC can also be cleared from
memory when the vehicle has made 40 warmup
cycles without a failure reported.
D The PCM will cancel the DTC Actions Taken items
when the fault conditions no longer exist and the
ignition is cycles off long enough to power down the
PCM.
Diagnostic Aids
D Check for intermittent output speed sensor circuit
problems.
D Check for possible incorrect calibration. (PCM part
No., tire specifications, and rear axle ratio)
Test Description
diagnostic chart:
2. This step checks for possible low fluid level causing
slipping resulting in an undefined gear ratio.
3. This step checks for correct gear ratios for
commanded gears.
4. This step checks for low line pressure.
7A155
DTC P0730/Flashing Code 81 Transmission Incorrect Gear Ratio

Step
Action
Visually inspect the transmission cooling system for fluid leaks.

D Refer to Chart 16: Possible Causes of Transmission Fluid
Leaks of Mechanical/Hydraulic Diagnosis Symptoms Index in
Was condition found and corrected?
Yes
No
Go to Step 6
Go to Step 2
Go to Step 3
Go to Checking
Transmission
Fluid Level and
Condition in
Automatic
Transmission
(4L30E) section
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Refer to Checking Transmission Fluid Level and Condition in

Has transmission fluid checking procedure been performed?

2. Turn the ignition switch to the on position.
3. Engine not running.
NOTE: Before clearing DTC(s) use the scan tool to record the
Failure Records for reference, as data will be lost when the Clear
Info function is used.
4. Record the Failure Record data.
5. Use the scan tool snapshot mode to record transmission gear
ratios.
6. Drive vehicle in transmission gear ranges 1, 2, 3, and D with
the engine speed is greater than 3,500 rpm for 5.5 seconds.
7. Record each transmission gear.
1st:2.73 2.99
2nd:1.54 1.71
3rd:0.93 1.05
4th:0.66 0.78
Does commanded gear ratio match ranges as shown?
Perform line pressure check.

D Refer to Line Pressure Test in Automatic Transmission
(4L30E) section.
Check for possible clutch slippage.

D Refer to Chart 6: Diagnostic Trouble Code (DTC) P0730 of
Mechanical/Hydraulic Diagnosis Symptoms Index in
then Clear info function.
2. Operate the vehicle under the following conditions:
D Drive the vehicle in D4 with the engine speed greater than
3,500 rpm to obtain any one of the following gear ratios for
seven seconds.
1st 1:2.73 1:2.99
2nd 1:1.54 1:1.71
3rd 1:0.93 1:1.05
4th 1:0.66 1:0.78
Has the last test failed?
DTC P0748/Flashing Code 82 Pressure Control Solenoid (PCS) (Force Motor)

Circuit Electrical
D07RX020
Circuit Description
The PCS is a PCMcontrolled device used to regulate
transmission line pressure. The PCM compares TPS
voltage, engine rpm, and other inputs to determine the
line pressure appropriate for a given load. The PCM will
regulate the pressure by applying a varying amperage to
the PCS. The applied amperage can vary from 0.1 to 1
amp, and is monitored by the PCM.
This DTC detects a continuous open or short to ground in
the PCS circuit or the PCS. This is a type C DTC.

D The PCM detects that the different between
commanded and actual current is 200 milliampere
(mA) for over 1 second.


TRANS Lamp
D The PCM will turn off the CHECK TRANS Lamp
after three consecutive ignition cycles without a
failure reported.
D The DTC can be cleared from PCM history by using a
scan tool.
D The DTC will be cleared from memory when the

vehicle has achieved 40 warmup cycles without a
failure reported.
Diagnostic Aids
PCM and at the transmission 5way connector. Look
for possible bent, backed out, deformed or damaged
terminals. Check for weak terminal tension as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.
Test Description
diagnostic chart:
1. This test checks the ability of the PCM to command
the PCS.
2. This test checks the PCS and internal wiring harness
for incorrect resistance.
7A157
DTC P0748/Flashing Code 82 Pressure Control Solenoid (PCS) (Force Motor) Circuit
Electrical
Step
1
Action
Is the PC Act. Current reading always within 0.16 amp?
Go to Step 9
Go to Step 9
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step 9
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

Go to Step 4
Inspect/repair circuits C3E4, M62(B), C3E3, M61(E) for a

short to ground or poor connections.
Go to Step 5
Inspect/repair circuits C3E4, M62(B), C3E3, M61(E).

Go to Step 3
Repair the internal wiring harness for an open.

Go to Step 6
Replace the PCS.

Go to Step 2
1. Remove the transmission oil pan. Refer to Solenoid (Adapter

Case Valve Body) in Automatic Transmission (4L30E)
section.
2. Disconnect the internal wiring harness at the PCS.
3. Measure the resistance of the PCS.
Is the resistance within 37 ohms?
Go to Diagnostic
Aids

terminals M62(B) and M61(E).
No

function is used.
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.
Yes
are met:
The PCS duty cycle is not at its electrical high or low limit.
DTC P0753/Flashing Code 83 Shift Solenoid A Electrical
D07RW014
Circuit Description
D The shift solenoid A is a simple on/off solenoid
located in the main case valve body. The solenoid is
the normally closed type. In second or third gear the
Powertrain Control Module (PCM) energizes the
solenoid to open a fluid inlet port. When the port is
open, fluid pressure actuates the shift valve.
D The solenoid is activated by a current. This current is
produced by applying a voltage to one side (the High
side) and a ground to the other side (Low side).
D The High Side Driver (HSD) is a circuit of the PCM
that acts as a switch between the solenoids and the
supply voltage. The High side of the solenoid is
permanently supplied with voltage, except in
BACKUP MODE or when ignition is off the HSD is
turned off.
the shift solenoid A circuit or the shift solenoid A. This is a
type C DTC.

D Ignition is on, Engine run.
D The PCM commands the solenoid on and the
voltage remains high (B+), or the PCM commands
the solenoid off and the voltage remains low (zero
volts).

D
D
D
D

Immediate landing to 4th gear.

TRANS Lamp
reported.
using a scan tool.
reported.
Diagnostic Aids

D An open ignition feed circuit can cause multiple DTCs
to set.
D A shift solenoid B DTC P0756 could also set with a
shift solenoid A electrical failure.
7A159
4. This test measures the resistance of the component.

8. This test checks the function of the shift solenoid A
and the transmission internal wiring harness.
Shift Solenoid Status Chart
Gear
Shift solenoid A
Shift solenoid B
1st
OFF
ON
Test Description
2nd
ON
ON

diagnostic chart:
2. This test checks for power to the shift solenoid A
from the ignition through the PCM.
3rd
ON
OFF
4th
OFF
OFF
DTC P0753/Flashing Code 83 Shift Solenoid A Electrical

Step
1
Action
Yes
No
Go to Step 2
Go to Diagnostic
Aids
Go to Step 3
Go to Step 4
Go to Step 10
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 7
Go to Step 13
Go to Step 8
Go to Step 12
Go to Step 9
Go to Step 14
Go to Step 15

2. With the engine on, turn the ignition switch on.
function is used.
Were DTCs P0753, P0758, P1860 set?

2. Using the J39200 DVOM, measure the voltage between PCM
connector terminals C3E14 and C2C8 (GND).
Is the voltage within 1012 volts?
1.
2.
3.
4.
Turn the ignition off.

Disconnect the C3 (BLUE) PCM connector.
Turn the ignition on.
Using the J39200 DVOM, measure the voltage between PCM
connector terminals C3F14 and ground.
Is the voltage within 10 12 volts?

4

PCM connector terminals C3E14 and C3F14.
Is the resistance within 18 20 ohms?
1. Disconnect the C1 (RED) and C2 (WHITE) PCM connectors.

2. Using the J39200 DVOM, check a continuity between PCM
terminals C3F14 and ground.
Is there a continuity?
1. Disconnect the 16way harness connector H10.

terminals H106 and H105.
Using the J39200 DVOM, check a continuity between C3 (BLUE)

PCM terminal E14 and ground.
1. Disconnect the transmission main case 4 pin connector M7.

terminals M73(D) and M74(C).
DTC P0753/Flashing Code 83 Shift Solenoid A Electrical (Contd)

Step
9
Action
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 18
Go to Step 18
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Repair the PCM connector connection.

18
Go to Step 18
The PCM may be faulty.

17
The shift solenoid A is faulty.

Replace the shift solenoid A. Refer to Solenoid (Main Case Valve
Body) in Automatic Transmission (4L30E) section.
16
Go to Step 18
The wiring harness between transmission 16way connector

H10 and transmission main case connector M7 is open or has a
poor connection.
15
The wiring harness between PCM connector C3 and transmission

16way connector H10 is open or poor connection.
14
Go to Step 18
The wiring harness between PCM connector terminals C3E14

and transmission harness terminal M74(C) is shorted to ground.
13
Go to Step 16
The wiring harness between PCM connector terminal

J3F14 and transmission harness terminal M73(D) is shorted to
ground.
12
Go to Step 17
The wiring harness between PCM connector terminals C3F14

and transmission harness terminal M73(D) is shorted to voltage.
11
No
Check every connection at the PCM connector.

10
Yes
D The shift solenoid A is commanded on and the voltage
drops to zero.
D The shift solenoid A is commanded off and the voltage
increases to B+.
7A161
DTC P0758/Flashing Code 84 Shift Solenoid B Electrical
D07RW014
Circuit Description
D The shift solenoid B is a simple on/off solenoid
located in the main case valve body. It is normally
open. When the port is open, fluid pressure actuates
the shift valve. In first or second gear, the Powertrain
Control Module (PCM) energizes the solenoid to
close a fluid inlet port.
D The solenoid is activated by current. This current is
permanently supplied with voltage. In BACKUP
MODE or when the ignition is off, the HSD is turned
off.
the shift solenoid B circuit or shift solenoid B. This is a
type C DTC.

volts).

D
D
D
D
Fixed to 4th gear.


TRANS Lamp
reported.
using a scan tool.
reported.
Diagnostic Aids

Shift Solenoid Status Chart
Test Description
diagnostic chart:
4. This test measures the resistance of the component.
6. This test checks the function of the shift solenoid B
and the transmission internal wiring harness.
10.This test checks for power to the shift solenoid B
from the ignition through the PCM.
Gear
Shift solenoid A
Shift solenoid B
1st
OFF
ON
2nd
ON
ON
3rd
ON
OFF
4th
OFF
OFF
DTC P0758/Flashing Code 84 Shift Solenoid B Electrical

Step
1
Action
Yes
No
Go to Step 3
Go to Step 2
Go to Step 7
Go to Diagnostic
Aids
Go to Step 14
Go to Step 4
Go to Step 15
Go to Step 5
Go to Step 16
Go to Step 6
Go to Step 17
Go to Step 18
Go to Step 8
Go to Step 9
Go to Step 19
Go to Step 10

function is used.
Were DTCs P0753, P0758, P1860 set?
1. The engine on.

2. Apply brake pedal and select transmission range D.
3. Press and hold down the winter switch and select transmission
mode winter.
Does the scan tool display DTC P0758 at 3rd gear?
1.
2.
3.
4.
Turn the ignition off.

Disconnect the C2 (WHITE) and C3 (BLUE) PCM connectors.
Turn the ignition on.
Using the J39200 DVOM, measure the voltage between PCM
connector terminals C2C2 and C2C8.
Is the voltage within 10 12 volts?

4

PCM connector terminals C2C2 and C3E14.

1. Disconnect the transmission main case connector M7.

terminals M71(A) and M74(C).

2. Disconnect the C2 (WHITE) and C3 (BLUE) PCM connectors.
PCM connector terminals C2C2 and C3E14.
Using the J39200 DVOM, check a continuity between PCM

connector terminal C2C2 and ground.
7A163
DTC P0758/Flashing Code 84 Shift Solenoid B Electrical (Contd)

Step
Action

10
Go to Step 24
Go to Diagnostic
Aids
Go to Step 25
Go to Step 25
Go to Step 25
Go to Step 25
Go to Step 25
Go to Step 25
Go to Step 25

C2C2 and transmission main case connector terminal M71(A)
is shorted to ground.
20
Go to Step 13
The shift solenoid B is faulty, or the internal wiring harness from

the shift solenoid B is shorted.
19
Go to Step 25
The wiring harness between transmission 16way connector and

transmission main case connector is shorted.
18
Go to Step 23
The wiring harness between PCM connector and transmission

16way connector is shorted.
17
Go to Step 22
The PCM internal terminal C2C2 is shorted to voltage.

16
Go to Step 12

C2C2 and transmission main case terminal M71(A) is shorted
to voltage.
15
Go to Step 21
1. Connect the C2 (WHITE) and C3 (BLUE) PCM connectors to

the PCM.
2. Turn the ignition on, the engine on.
3. Repeat Step 2.
Does the scan tool display DTC P0758 at 3rd gear?
14
Go to Step 11
Check every connection of the PCM and transmission 16way

connector H10.
13
Go to Step 20

terminals M71(A) and M74(C).
12
No
Using the J39200 DVOM, check a continuity between PCM

connector terminal C3E14 and ground.
11
Yes
The wiring harness between PCM connector terminal C2C2 and

transmission 16way connector terminal H1012, or between
PCM connector terminal C3E14 and 16way connector terminal
H105 is open.
DTC P0758/Flashing Code 84 Shift Solenoid B Electrical (Contd)

Step
Action
21
The wiring harness between PCM connector terminal C3E14

and transmission main case connector terminal M74(C) is
shorted to ground.
22
Go to Step 25
Go to Step 25
Go to Step 25
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Replace the PCM.

25
Go to Step 25
The internal wiring harness from the shift solenoid B is open, or

the shift solenoid B is faulty.
24
No

terminal H1012 and transmission main case connector terminal
M71(A), or between H105 and M74(C) is open.
23
Yes
D The shift solenoid B is commanded on and voltage drops to
zero.
D The shift solenoid B is commanded off and voltage
increases to B+.
7A165
DTC P1790/Flashing Code 85 ROM Transmission Side Bad Check Sum

Circuit Description
Transmission Side Read Only Memory (ROM) and
Electronically Erasable Programmable Read Only
Memory (EEPROM) is an electronic circuit that controls
the transmission controls in the Powertrain Control
Module (PCM).
This DTC detects a check sum error. This is a type C
DTC.

TRANS Lamp

D Detects check sum error for 1 second.

D Immediate landing to 4th gear.
reported.
using a scan tool.
reported.
DTC P1790/Flashing Code 85 ROM Transmission Side Bad Check Sum

Step
Yes
No
Was DTC P1790 set?
Go to Step 4
Go to Step 2
Was DTC P1792 set?
Go to Step 3
1. Remove the PCM. Refer to Powertrain Control Module (PCM)

in Automatic Transmission (4L30E) section.
2. Using the ITCS reprogram the transmission EEPROM.
Go to Step 5
Go to Step 5
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Action
function is used.
Was the reprogramming complete?

4
Replace the PCM.

then Clear Info function and operate the vehicle.
DTC P1792/Flashing Code 86 EEPROM Transmission Side Bad Check Sum

Circuit Description
Transmission Side Read Only Memory (ROM) and
Memory (EEPROM) is an electronic circuit that controls
the transmission controls in the Powertrain Control
Module (PCM).
This DTC detects a check sum error. This is a type C
DTC.

TRANS Lamp

D Detects check sum error for 1 second.

D Immediate landing to 4th gear.
reported.
using a scan tool.
reported.
DTC P1792/Flashing Code 86 EEPROM Transmission Side Bad Sum

Step
Yes
No
Was DTC P1790 set?
Go to Step 4
Go to Step 2
Was DTC P1792 set?
Go to Step 3
1. Remove the PCM. Refer to Powertrain Control Module (PCM)

in Automatic Transmission (4L30E) section.
2. Using the ITCS reprogram the transmission EEPROM.
Go to Step 5
Go to Step 5
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Action
function is used.
Was the reprogramming complete?

4
Replace the PCM.

then Clear Info function and operate the vehicle.
7A167
DTC P1835/Flashing Code 87 Kickdown Switch Always On
D07RW015
Circuit Description
D When the driver presses the accelerator pedal down
fully, the kickdown switch closes, sending a ground
signal to the Powertrain Control Module (PCM).
D This information is used to perform shifts at high
engine speed.
D When the kickdown switch is closed, the Throttle
Position Sensor (TPS) is already at 100%.
D This DTC detects a closed kickdown switch when TP
angle is less than 70%.
D This is a type D DTC.

D
D
D
D
No TP DTCs P0122 or P0123.

TP angle is less than 70%.
Kickdown switch is on.
All conditions met for 1 second.
Action Taken When The DTC Sets.

D Kickdown mode control is off.
Lamp.

using a scan tool.
reported.
Diagnostic Aids
D Check the wiring harness for a short to ground
between the PCM and kickdown switch.
D Check the kickdown switch for failure.
D Check kickdown adjustment.
Test Description
diagnostic chart:
1. This test checks for short to ground or kickdown
switch failure.
3. This test checks for regulation kickdown switch.
DTC P1835/Flashing Code 87 Kickdown Switch Always On

Step
1
Action
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 7
Go to Step 5
Go to Diagnostic
Aids
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 9
Go to Step 9
Go to Step 9
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table

function is used.
Does the scan tool display Kickdown switch low (closed
switch)?

3. Using the J39200 DVOM, check a continuity between PCM
connector terminal C3F11 and ground.
The TP angle goes from 0% to 100% with the accelerator pedal

depressed.
Does the kickdown switch on when TP angle is below 70%?
1. Disconnect the kickdown switch connector C29.

2. Using the J39200 DVOM, check a continuity between
terminals C291 and C292.
Adjust the kickdown switch.

Does the kickdown switch on when TP angle is above 95%?
Replace the kickdown switch.


Repair the short to ground in circuit LT BLUE.

then Clear Info function and ensure the following condition is
met:
The torque converter stator temperature switch circuit does not
indicate a hot mode when the transmission fluid temperature is
less than 60C (140F) for at least 5 seconds.
7A169
DTC P1850/Flashing Code 88 Brake Band Apply Solenoid Malfunction
D07RW014
Circuit Description
D The brake band apply solenoid is a normally open
solenoid which controls the flow of fluid for brake band
application. The Powertrain Control Module (PCM)
uses Pulse Width Modulation (PWM) and changes
the duty cycle to control the solenoid. The PCM turns
the solenoid on (energized) and off (deenergized) at a
constant frequency. The length of time the solenoid is
energized during each on/off cycle is called the pulse
width. By varying or modulating the pulse width, the
solenoid output pressure is changed. Since the
solenoid is normally open, increasing the pulse width
increases the duty cycle and decreases the output
pressure. PWM control provides smooth band
application without an accumulator. The band is only
applied in first and second gears.
D In the event of an electrical failure (open), the
solenoid regulates at the maximum oil flow (0% duty
cycle).
D The solenoid is activated by a current. This current is
permanently supplied with voltage. When the ignition
is off, the HSD is turned off.

the brake band apply solenoid circuit or the brake band
apply solenoid. This is a type D DTC.

volts).
D All conditions met in 1.3 seconds.

D Inhibit brake band apply solenoid.
Lamp.

using a scan tool.
reported.
Diagnostic Aids
Test Description


diagnostic chart:
2. This test checks for power to the brake band apply
solenoid from the ignition through the PCM.
3. This test checks the resistance of the transmission
internal wiring harness and brake band apply
solenoid.
4. This test checks the ability of the PCM and wiring to
control the ground circuit.
DTC P1850/Flashing Code 88 Brake Band Apply Solenoid Malfunction

Step
1
Action
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 11
Go to Step 12
Go to Step 25
Go to Step 3
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 16
Go to Step 17
Go to Step 18
Go to Step 25
Go to Step 9
Go to Step 16
Go to Step 10

function is used.
Were DTCs P0753, P0758 set?
Using the J39200 DVOM, back probe between PCM connector

terminals C3E14 and C2C8.
Is the voltage between 10 to 12 volts?

2. Disconnect the C1 (RED) and C3 (BLUE) PCM connectors.
PCM connector terminals C1A16 and C3E14.

terminals C1A16 and C2C8.
Is the voltage between 10 to 12 volts?

2. Disconnect the C1 (RED) and C3 (BLUE) PCM connectors.
3. Using the J39200 DVOM, check continuity between PCM
terminal C3E14 and ground.

2. Using the J39200 DVOM, check continuity between connector
H107 and ground.

2. Using the J39200 DVOM, check continuity between the
terminal M72(B) and ground.
1. Disconnect the J1 (RED) PCM Connector.

the PCM connector terminals C1A16 and C3E14.

the terminal H107 and H105.
7A171
DTC P1850/Flashing Code 88 Brake Band Apply Solenoid Malfunction (Contd)

Step
Action
10

the terminals M72(B) and M74(C).
11
Go to Step 20
Go to Step 17
Go to Step 22
Go to Step 26
Go to Step 26
Go to Step 26
Go to Step 26
Go to Step 26
Go to Step 26
Go to Step 26
The wiring harness between the PCM connector terminal C1A16

and transmission 16way connector terminal H107 is shorted to
ground.
22
Go to Step 24
The brake band apply solenoid is faulty, or the internal wiring

harness from the brake band apply solenoid is open.
21
Go to Step 21
The wiring harness between the transmission 16way connector

terminal H105 and the transmission main case connector
terminal M74(C) is open.
20
Go to Step 15

terminal M74(C) is shorted to ground.
19
Go to Step 14
The brake band apply solenoid is faulty, or the internal wiring

harness from the brake band apply solenoid is shorted to ground.
18
Go to Step 23
The wiring harness between PCM terminal C3E14 and

transmission 16way connector terminal H105 is open.
17
Go to Step 25

2. Using the J39200 DVOM, check continuity between terminal
M72(B) and ground.
16
Go to Step 13

the terminals M72(B) and M74(C).
15
Go to Step 20

2. Using the J39200 DVOM, check continuity between terminal
H107 and ground.
14
Go to Step 19

the terminal H107 and H105.
13
No
Using the J39200 DVOM, check continuity between PCM

terminal C1A16 and ground.
12
Yes

terminal M72(B) is shorted to ground.
DTC P1850/Flashing Code 88 Brake Band Apply Solenoid Malfunction (Contd)

Step
Action
23
The wiring harness between the PCM connector terminal C1A16

and the 16way connector terminal H107 is open.
24
Go to Step 26
Go to Step 26
Go to Step 26
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Check every connection at the PCM.

If OK, replace the PCM. Refer to Powertrain Control Module
(PCM) in Automatic Transmission (4L30E) section.
26
No

terminal M72(B) is open.
25
Yes
are met:
D The brake band apply solenoid is commanded on and the
volts drop to zero.
D The brake band apply solenoid is commanded off and the
volts increase to B+.
7A173
DTC P1860/Flashing Code 89 TCC Solenoid Electrical
D07RW016
Circuit Description
The PCM allows current to flow through the solenoid coil.
This current flow through the solenoid coil creates a
magnetic field that magnetizes the solid core. The
magnetized core attracts the check ball to seat against
spring pressure. This blocks the exhaust for the TCC
signal fluid and allows 23 drive fluid to feed to TCC signal
circuit. The TCC signal fluid pressure acts on the TCC
regulator valve to regulate line pressure and to apply fluid
pressure to the torque converter clutch shift valve. When
the TCC shift valve is in the apply position, regulated
apply fluid pressure is directed through the TCC valve to
apply the torque converter clutch. The TCC solenoid is
used in conjunction with the TCC solenoid to regulate fluid
to the torque converter. The TCC solenoid is attached to
the valve body within the transmission.
This DTC detects a continuous open or short to ground or
ignition in the TCC circuit or the TCC solenoid. This is a
type D DTC.

D
D
D
D
D
Battery voltage is between 10 and 16 volts.

No shift solenoid A DTCs P0753.
No shift solenoid B DTCs P0758.
Ignition on. Engine run.
The PCM commands the solenoid on and the
voltage remains low (zero volts).
D The PCM commands the solenoid off and the
voltage remains high (B+).


Lamp.

using a scan tool.
reported.
Diagnostic Aids
Test Description
diagnostic chart:
2. This test checks for voltage to the solenoid.
3. This test checks the ability of the PCM and wiring to
control the ignition circuit.
8. This test checks the resistance of the TCC solenoid
and the internal wiring harness.
DTC P1860/Flashing Code 89 TCC Solenoid Electrical

Step
1
Action
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 9
Go to Diagnostic
Aids
Go to Step 6
Go to Step 7
Go to Step 18
Go to Step 19
Go to Step 18
Go to Step 19
Go to Step 15
Go to Step 8
Go to Step 16
Go to Step 17
Go to Step 18
Go to Step 10
Go to Step 12
Go to Step 11
Go to Step 13
Go to Step 14

Records for reference, as data will be lost when theClear Info
function is used.

terminals C2D2 and C2C8.
Is the voltage 0?
1. Apply brake pedal and select transmission range D.

2. Do a test drive, and increase the vehicle speed to TCC on at
4th.
Does the scan tool display DTC P1860 at TCC ON?

2. Disconnect the C2 (WHITE) PCM connector.
PCM connector terminals C2D2 and C2C8.
The wiring harness between PCM connector terminal C2D2 and

transmission adapter case connector terminal M64(A) is shorted
to voltage.
Intermittent condition.
Check the wiring harness and terminals between PCM connector
J2 and transmission adapter case connector M6.

terminal H104 and ground.
1. Disconnect the transmission adapter case connector M6.

terminal M64(A) and ground.

2. Disconnect the C2 (WHITE) PCM connector.
terminals C2D2 and C2C8.
10

terminal H104 and ground.
11
1. Disconnect the transmission adapter case connector M6.

terminal M64(A) and ground.
7A175
DTC P1860/Flashing Code 89 TCC Solenoid Electrical (Contd)

Step
Action
12

transmission 16way connector terminal H104 is shorted to
ground.
13
Go to Step 20
Go to Step 20
Go to Step 20
Go to Step 20
Go to Step 20
Begin diagnosis
again
Go to Step 1
Repair verified
Exit DTC table
Check the PCM connector terminal C2D2, transmission 16way

connector terminal H104 and transmission adapter case
connector terminal M64(A).
20
Go to Step 20
Check every connection at the PCM.

If OK, replace the PCM. Refer to Powertrain Control Module
(PCM) in Automatic Transmission (4L30E) section.
19
The TCC solenoid is faulty, or the internal wiring harness from the
TCC solenoid is open.
18
Go to Step 20

terminal H104 and adapter case terminal M64(A) is open.
17

transmission 16way connector terminal H104 is open.
16
Go to Step 20
The TCC solenoid is faulty, or the internal wiring harness from the
TCC solenoid is shorted to ground.
15
No

H10 and adapter case connector M6 is shorted to ground.
14
Yes
are met:
D The TCC solenoid is commanded on and the volts increase
to B+.
D The TCC solenoid is commanded off and the volts drop to
zero.
SECTION
MANUAL TRANSMISSION
7B1
FRONTERA
TRANSMISSION
MANUAL TRANSMISSION MUA 5C (4X4)
CONTENTS
Diagnosis (MUA) . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (MUA) . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Case and Transfer Case . . . . .
Major Component (MUA) . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Plate with Gear Assembly,
Detent, Shift Arm, and Interlock Pin (MUA) .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
7B1
7B2
7B4
7B5
7B5
7B5
7B10
7B15
7B15
7B16
7B19
7B25
7B25
7B26
Service Precaution
systems.

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear and 5th Gear (MUA) . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Gear Shaft, Main Gear Shaft, and
Counter Gear Shaft (MUA) . . . . . . . . . . . . . . .
Disassmebled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools (MUA) . . . . . . . . . . . . . . . . . . .
7B27
7B28
7B29
7B29
7B30
7B32
7B32
7B38
7B38
7B39
7B40
7B43
7B49
7B53
7B2
MANUAL TRANSMISSION
General Description
MUA5C Transmission
For 6VD1
A07RX005
MANUAL TRANSMISSION
7B3
For X22SE
A07RX008
The MUA5C is a constant mesh transmission,

synchronized in all speeds. The transmission is designed
for a great reduction of the shift effort and the quietest
possible operation.
Principle parts of the transmission are the integral clutch
housing, intermediate plate, the transfer case, the rear
cover, and the gears.
The transmission control box and transfer control box are
built into the transmission and transfer case.
7B4
MANUAL TRANSMISSION
Diagnosis (MUA)
Condition
Abnormal noise
Hard Shifting
Walking or Jumping out of gear
Possible cause
Flywheel pilot bearing worn
Replace
Bearings worn or broken (Mainshaft,

counter shaft, and transfer shaft)
Replace
Gear tooth contact surfaces worn or

scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)
Replace
Splines
worn
(Mainshaft,
synchronizer clutch hub)
Replace
Gear or bearing thrust face seized
Replace
Lack of backlash between meshing

gears
Replace
Improper clutch pedal free play
Readjust
Change lever sliding portions worn
Repair or replace Regrease
Shift block, shift rod and/or control

box sliding faces worn
Replace
Shift arm and synchronizer sleeve

groove worn
Replace worn parts
Thrust washer, collar, and/or gear

thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Synchronizer parts worn
Replace
Detent ball worn
Replace
Detent spring weakened or broken
Replace
Shift rod and/or control box sliding

faces worn
Replace
Shift arm and synchronizer sleeve

groove worn
Replace worn parts
Thrust washer, collar, and/or gear

thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Bearings worn or broken
Replace
Splines
worn
synchronizer hub)
Oil leakage
Correction
(Mainshaft,
Replace
Synchronizer spring weakened or

broken
Replace
Loose drain plug(s) and/or filler

plug(s)
Tighten Replenish oil
Defective or improperly installed

gasket(s)
Replace
Oil seal worn or scratched
Replace
MANUAL TRANSMISSION
7B5
Transmission (MUA)
Disassembled View
220RX006
Legend
(1) Gear Control Lever Knob
(3) Center Console
(4) Grommet Assembly
(5) Gear Control Lever and Transfer Control Lever
(9) Center Exhaust Pipe
Removal
NOTE: Befor removing transmission assembly from
vehicle, change the transfar mode to 2WD using the 4WD
push button on dash panel.
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Harness Clamp
Harness Heat Protector
Slave Cylinder
Dust Cover
Rear Mount Nut
Third Crossmember
Starter
Flywheel Undercover
Transmission Retaining Nut and Bolt
Transmission

2. Remove gear control lever knob(1).
3. Remove transfer control lever knob(2).
7B6
MANUAL TRANSMISSION
4. Remove lower cluster assembly.
6. Remove center console(3).
740RW021
5. Remove rear console.
F07RW018
7. Remove grommet assembly(4).
256RW045
F07RW016
MANUAL TRANSMISSION
8. Remove gear control lever(5) and transfer control
lever(5).
9. Raise and support vehicle with suitable stands.
Remove transfer protector(6).
7B7
11. Remove front propeller shaft(8).

and rear sides.
401RW007
150RX010
12. Remove center exhaust pipe(9) (6VD1).
10. Remove rear propeller shaft(7).

and rear sides.
150RX009
401RW008
7B8
MANUAL TRANSMISSION
13. Loosen the exhaust pipe nuts at the exhaust manifold

side (X22SE).
14. Disconnect transmission harness connectors and
clip.
Connector: Transfer switch, 24 actuator, speed
sensor, back up switch 12 indicator switch (6VD1)
and 34 indicator switch (6VD1).
18. Remove dust covers(13) (6VD1).

19. Support transmission with a transmission jack.
15. Remove transmission harness clamps(10) from the

transmission case and bracket.
220RS001
20. Remove engine rear mount nuts(14) from third

crossmember.
220RS028
16. Remove harness heat protector(11) (6VD1).

17. Remove slave cylinder(12) and flexible hose fixing
bracket (X22SE).
F07RW008
21. Remove third crossmember(15) by removing six

fixing bolts.
22. Remove starter(16) (6VD1).
23. Remove flywheel under cover(17). 6VD1:3 pieces,
X22SE:1 piece.
205RW001
MANUAL TRANSMISSION
7B9
24. Use clutch release bearing remover 5884022910

to disconnect the clutch release bearing from the
clutch pressure plate (6VD1).
220RW109
25. Pull the shift fork toward the transmission to press the
clutch release bearing against the clutch pressure
plate (6VD1).
26. Insert the clutch release bearing remover
5884022910 between the wedge collar and the
release bearing (6VD1).
NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RS003
7B10
MANUAL TRANSMISSION
27. Turn the remover to separate the release bearing

(6VD1).
220RX007
28. Remove the front skid plate and then remove one
right side bolt from the front (X22SE).
29. Remove transmission retaining nut and bolts(18).
Remove transmission(19) from the vehicle.
Installation
the top gear shaft spline.
2. Drain coolant and disconnect the lower heater pipe
from the hose on the back of the engine at right side
(X22SE).
3. Turn the heater pipe assembly backward not to
interfere with the transmission (X22SE).
4. Disconnect fuel pipes from hoses at the front side of
the transmission (X22SE).
5. 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.
6. Align the top gear shaft spline with the clutch driven
plate spline.
220RS007
7. Install the transmission to the engine.

8. Connect the heater pipe with the hose (X22SE).
MANUAL TRANSMISSION
7B11
9. Tighten the transmission nut and bolts as shown in

the figure.
225RX004
7B12
MANUAL TRANSMISSION
225RX005
10. Connect the fuel pipes with the hoses (X22SE).

11. Apply a force of 59 78 N (6.0 8.0 kg/
13.2 17.6 lb) to the tip of the shift fork in the
direction of the transmission to engage the clutch
pressure plate and release bearing (6VD1).
NOTE: A click sound is heard when the release bearing
and the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine side while applying
a force of about 25 N (2.5 kg/5.5 lb). If the shift fork will
not move, then they are securely engaged (6VD1).
220RS006
MANUAL TRANSMISSION
12. Install flywheel under cover(17). 6VD1: 3 pieces,
X22SE: 1 piece.
Torque: 8 Nm (0.8 kgm/69 lb in)
13. Install starter(16) (6VD1).
7B13
18. Connect transmission harness connectors and clip.

Connector: transfer switch, 24 actuator, car speed
sensor, 12 indicator switch (6VD1) and 34 indicator
switch (6VD1).
19. Install bracket and transmission harness clamps(10)
to the transmission case.
20. Install harness heat protector(11) (6VD1).
21. Connect fuel pipe to transmission side.

14. Install third crossmember(15).
15. Install engine rear mount nuts(14).
Remove the transmission jack from transmission
side.
16. Apply grease to top hole portion of the shift fork.
Install slave cylinder(12) and flexible hose fixing
bracket (X22SE).
220RW046
220RS007
Legend
(1) Apply Grease
17. Install clutch dust covers(13) to clutch housing
(6VD1).
220RW047
7B14
MANUAL TRANSMISSION
22. Install center exhaust pipe(9) (6VD1).

150RX010
150RX009
23. Tighten the exhaust pipe nuts at the manifold

(X22SE).
24. Install front(8) and rear propeller shaft(7).
25. Install transfer protector(6).
Lower the vehicle.
26. Install gear control lever(5) and transfer control

lever(5).
27. Install grommet assembly(4).
28. Install center console(3), rear console and lower
cluster assembly.
29. Install transfer control lever knob(2) and gear control
lever knob(1).
31. Replenish engine coolant (X22SE).
MANUAL TRANSMISSION
7B15
Transmission Case and Transfer Case

Major Component (MUA)
220RX005
Legend
(1) Clutch Release Bearing
(2) Shift Fork
(3) Fulcrum Bridge
(4) Front Cover (with Oil Seal)
(5) Counter Front Bearing Snap Ring
(6) Top Gear Bearing Snap Ring
(7) Speedometer Sensor and Speedometer Driven
Gear
(10) Gear Control Box Assembly
(12) Transfer Rear Case Assembly
(13) Detent, Shift Arm, and Interlock Pin
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
Ball Bearing
Lock Nut
High-Low Clutch Hub and Sleeve
Transfer Input Gear
Needle Bearing
Bearing Collar
Ball
Plate
Bearing Snap Ring
Front Output Gear Assembly
Bearing Snap Ring
12 and 34 Indicator Switch, Pin, and Ball
Intermediate Plate with Gear Assembly
Transmission Case
7B16
MANUAL TRANSMISSION
Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case
and transfer case and drain the lubricant.
3. Remove the clutch release bearing(1) from the
transmission case.
5. Remove the fulcrum bridge bolts (6VD1).

D Remove the fulcrum bridge(3) (6VD1) from the
transmission case.
Remove the front cover(4) and gasket from the
transmission case.
201RS022
201RS020
4. Remove the snap pin (6VD1).

Remove the shift fork pin (6VD1) and shift fork(2)
from the fulcrum bridge(3) (6VD1).
6. Remove counter front bearing snap ring(5) and top

gear bearing snap ring(6).
Use a pair of snap ring pliers to remove the snap ring.
226RS001
201RS021
MANUAL TRANSMISSION
7. Remove the speedometer sensor(7).
Remove the plate(7).
Remove the driven gear bushing and driven gear(7).
7B17

3. Pull the 2WD4WD actuator assembly with
2WD4WD shift rod.

before removal.
8. Remove front companion flange(8) and rear
companion flange(9) using the flange holder
5884001330 to remove the end nut.
220RW027
266RW026
9. Disconnect breather hose from transmission and

remove gear control box assembly(10).
10. Remove 2WD4WD actuator assembly(11) by
performing the following steps:
1. Disconnect the actuator breather hose from
2WD4WD actuator assembly(11).
Legend
(3) Pull
(4) Rear Case Assembly
(5) Position: 4WD
(6) Position: 2WD
4. Offset the actuator assembly.
220RW028
220RW0851
7B18
MANUAL TRANSMISSION
5884020270 to remove the ball bearing(15).
5. Remove the actuator assembly.
220RW029
Legend
(7) Position: 4WD
(8) Mode: 2WD
NOTE: Before removing the transmission and transfer
262RW069

Use the flange holder 5884001330 and lock nut
wrench 5884021560 to remove the lock nut(16).
Remove the front companion flange.
11. Remove the transfer rear cover assembly(12) from

the transfer case(28).
12. Regarding detent, shift arm, and interlock pin(13)
disassembly, refer to Detent, Shift Arm, and Interlock
Pin in Drive Line/Axle section.
snap ring(14).
226RW190
MANUAL TRANSMISSION
7B19
16. Remove high-low clutch sleeve(17).

Use the universal puller to remove the high-low clutch
hub(17) and transfer input gear(18).
262RS009
226RS070
17. Remove needle bearing(19), bearing collar(20),

ball(21), and plate(22).
20. Remove bearing snap ring(25) by using a pair of snap

ring pliers.
21. Remove the counter gear assembly(26) from the
transfer case(28).
22. Remove 12 and 34 indicator switch, pin and
ball(27).
23. Remove the transfer case assembly(28) from the
transmission case.
D Refer to Transfer Case Assembly in Drive Line/Axle
section for repair of transfer case assembly.
24. Pull out intermediate plate with gear assembly(29)
from transmission case.
Reassembly
226RS071

snap ring(23).
assembly(24) free.
1. Apply recommended liquid gasket (LOCTITE 17430)

or its equivalent to the transmission case(30),
intermediate plate(29) and transfer case(28) fitting
surfaces.
2. Install the intermediate plate with gear assembly(29)
to the transmission case(30).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.
3. Install the transfer case assembly(28) to the
intermediate plate with gear assembly.
Tighten the eight transmission-transfer case bolts to
Refer to Transfer Rear Case Assembly in Drive
Line/Axle section for oil seal replacement.
4. Install 12 and 34 indicator switch, pin and ball(27)
(6VD1).
5. Install the counter gear assembly(26) to the transfer
case(28).
6. Use a pair of snap ring pliers to install the snap
ring(25) to the transfer case(28).
7B20
MANUAL TRANSMISSION

7. Install front output gear assembly(24).
(23) to the transfer case(28).
9. Install plate(22), ball(21), bearing collar(20), needle
bearing(19), and transfer input gear(18).
10. Install High-low clutch hub and sleeve(17).
The clutch hub face (with the heavy boss) must be
facing the transfer input gear side.
226RW190
12. Use the punch to stake the lock nut at one spot.
bearing(15).
226RW152

D Use the flange holder 5884001330 and lock nut
wrench 5884021560 to install the lock nut(16).
226RS079
14. Use a pair of snap ring pliers to install the bearing

snap ring(14).
15. Regarding detent, shift arm, and interlock pin(13)
assembly, refer to Detent, Shift Arm, and Interlock Pin
in Drive Line/Axle section.
16. Apply recommended liquid gasket (LOCTITE 17430)
or its equivalent to the transfer rear case fitting faces.
MANUAL TRANSMISSION
220RS017

rear cover(11):
1. Shift the High-Low shift rod to the 4H side.
2. The cut-away portion of select rod head should
align with the rear case holes stopper.
7B21
220RW030
Legend
(13) Rear Case Assembly
3. Push the 2WD4WD actuator assembly with
2WD4WD shift rod till the shift rod reaches the
2WD position.
230RS002
18. Tighten the eleven transfer rear case bolts to the

specified torque.
19. Install 2WD4WD actuator assembly(11) by
performing the following steps.
1. Shift the 2WD4WD shift rod to the 4WD side.
assembly and shift rod.
220RW031
Legend
(14) Position: 2WD
(15) Mode: 2WD
4. Tighten the 2WD4WD actuator bolts to the
specified torque.
7B22
MANUAL TRANSMISSION
20. Install a new packing and gear control box

assembly(10).
Install the harness clips and brackets and then tighten
four new gear control box bolts to the specified
torque.
266RW026

companion flange nut at two spots.
D Stake the front companion flange nut at one spot.
261RW043
21. Install the rear and front companion flange(9) (8).

Install the O-ring(9).
Use the flange holder J861411 to tighten the flange
nuts(9) (8) to the transfer case.
Tighten new transfer flange nuts(9) (8) to the
specified torque.
Rear Companion Flange
Front Companion Flange
266RW027
MANUAL TRANSMISSION
7B23
24. Install the plate to the transfer rear cover.

25. Install the speedometer sensor.
26. Install top gear bearing snap ring(6) and counter front
bearing snap ring(5).
Use a pair of snap ring pliers to install the snap rings
to the mainshaft and countershaft.
The snap rings must be fully inserted into the bearing
snap ring groove.
27. Install a new packing and front cover (with oil seal) (4)
to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
266RS003
23. Install the O-ring (4) to the speedometer driven gear

bushing(3).
Install the driven gear to the speedometer driven gear
bushing(3).
Install the speedometer driven gear assembly(7) to
the transfer rear cover.
D After cleaning the bolt hole, dry it thoroughly with air.

D After cleaning the screw face of a removed bolt or new
one, dry it thoroughly. Apply recommended liquid
gasket (LOCTITE 242) or its equivalent before
tightening it.
Tighten six new front cover bolts to the specified
torque.
28. Install the fulcrum bridge(3) to the transmission case.
Tighten three fulcrum bridge bolts to the specified
torque (6VD1).
220RS009
225RW008
7B24
MANUAL TRANSMISSION
29. Apply grease to the pin hole inner circumferences and

thrust surfaces (6VD1).
Attach the shift fork(2) to the fulcrum bridge(3) by
inserting the shift fork pin from the bottom side of the
fulcrum bridge (6VD1).
Install the washer and snap pin (6VD1).
NOTE: Ensure release bearing is properly positioned

during installation, as shown in the figure (6VD1).
201RS019
201RS018
30. Apply grease to the areas shown in the figure (6VD1).
201RW017
Install the release bearing(1) to the shift fork(2) in the

proper direction.
MANUAL TRANSMISSION
7B25
Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin (MUA)
Disassembled View
220RS010
Legend
(1) Detent Spring Plate and Gasket
(2) Detent Spring
(3) Detent Ball
(4) Spring
(5) Rev5th Shift Rod
(6) Rev5th Shift Arm and Reverse Inhibitor
(7)
(8)
(9)
(10)
(11)
(12)
1st2nd Shift Rod

3rd4th Shift Rod
3rd4th Shift Arm
1st2nd Shift Arm
Interlock Pin
Intermediate Plate and Gear Assembly
7B26
MANUAL TRANSMISSION
D Use a spring pin remover to remove the shift arm
spring pins from the shift arms and the shift rods.
Disassembly
1. Remove detent spring plate and gasket(1), detent
spring(2) and detent ball(3).
Use a magnetic hand to remove the detent balls from
the intermediate plate.
230RS004
D Move the 3rd4th shift rod forward.
220RS011
2. Remove spring(4).
3. Remove rev5th shift rod(5), and rev5th shift arm
and reverse inhibitor(6).
Remove 1st2nd shift rod(7), 3rd4th shift rod(8),
3rd4th shift arm(9), and 1st2nd shift arm (10).
D Hold a round bar against the shift rod end.
230RS005
D Remove the rev5th, 1st2nd and 3rd4th shifter

rods carefully. Interlock pins are located between
the shifter rods in the intermediate plate.
4. Remove interlock pin(11) from intermediate plate and
gear assembly(12).
230RS003
MANUAL TRANSMISSION
7B27

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

D Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit,
Shift Arm Thickness
Standard
1st2nd
3rd4th
Rev.5th
Limit
9.609.85 mm
(0.3780.388 in)
9.0 mm
(0.354 in)
9.609.80 mm
(0.3780.386 in)
220RS012

D Use a spring tester to measure the valve spring
tension.
Compressed height
Standard
20 mm (0.787 in)
87.2 97.1 N
(8.9 9.9 kg/
19.6 21.8 lb)
230RS006

D Use a vernier caliper to measure the detent spring
free length.
Standard
Limit
26.8 mm (1.06 in)
26.2 mm (1.03 in)
220RS013
7B28
MANUAL TRANSMISSION
Reassembly
1. Install 1st2nd shift arm(10) and 3rd4th shift arm(9)
to intermediate plate and gear assembly(12).
2. Install 3rd4th shift rod(8) and 1st2nd shift rod(7).
D Install the interlock pin(11) to the shift rod.
D Install the shift rod together with the interlock pin to
Do not allow the interlock pin to fall from the shift
rod.
D Hold a round bar against the shift rod end lower face
to protect it against damage.
D Install a new spring pin.
Never reinstall the used spring pin.
3. Install rev5th shift arm and reverse inhibitor(6) and

rev5th shift rod(5).
D Apply oil to the reverse inhibitor inner surface.
D Install the interlock pin(11) to the shift rod.
D Install the shift rod together with the interlock pin to
Do not allow the interlock pin to fall from the shift
rod.
D Hold a round bar against the shift rod end lower face
to protect it against damage.
D Install a new spring pin.
Never reinstall the used spring pin.
4. Install spring(4).
5. Put detent balls(3) in the intermediate plate holes.
D Apply oil to the detent balls.
6. Install detent springs(2) and detent spring plate and
gasket(1).
D Install a new gasket and the detent spring plate.
D Tighten the detent spring plate bolts to the specified
torque.
Torque: 20 Nm (2.0 kgm/ 14 lb ft)
230RS007
220RS030
Legend
(1) Warped
MANUAL TRANSMISSION
7B29
Reverse Gear and 5th Gear (MUA)

Disassembled View
226RW213
Legend
(1) Oil Seal Collar
(2) Ball Bearing
(3) Retainer
(4) Thrust Plate
(5) Thrust Washer and Lock Ball
(6) Reverse Idler Gear Snap Ring
(7) Reverse Idler Gear Assembly
(8) Idle Shaft Pin
(9) Thrust Washer
(10) Reverse Idler Gear
(11) Reverse Idler Shaft
(13) Ball Bearing
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Counter 5th Gear

Counter Reverse Gear
5th Gear
5th Block Ring
Needle Bearing
Mainshaft Nut
Rev5th Synchronizer Assembly
Reverse Block Ring
Reverse Gear
Needle Baring
Bearing Plate and Screw
Bearing Snap Ring
Intermediate Plate
7B30
MANUAL TRANSMISSION
5. Remove the reverse idler gear assembly(7) from the
intermediate plate(26).
Disassembly
1. Set the retaining ring remover 5884021580 and
puller 5884020270 to the retainer(3) and the
mainshaft end.
226RS005
262RW079
2. Remove the retainer(3) together with the bearing(2)

and the oil seal collar(1).
The universal puller may be used in place of the
retaining ring remover.
3. Remove thrust plate(4) and thrust washer and lock
ball(5).
4. Use a pair of snap ring pliers to remove reverse idler
gear snap ring(6).
6. Remove idle shaft pin(8), thrust washer(9), reverse

idler gear(10), and reverse idler shaft(11).
7. Use a pair of snap ring pliers to remove the snap
ring(12).
8. Attach the bearing remover to the counter gear shaft.
Use the bearing remover to remove the ball
bearing(13) and the counter 5th gear(14).
226RS006
9. Remove counter reverse gear(15).
226RS004
MANUAL TRANSMISSION
10. Remove 5th gear(16), 5th block ring(17), and needle
bearing (2 piece type) (18).
226RS007
11. Attach the holding fixture 5884021600 and base

5884000030 to the mainshaft and the counter
gear.
7B31
12. Engage the 3rd4th synchronizer with the 3rd gear.

Engage the 1st2nd synchronizer with the 1st gear.
226RW210
Use the mainshaft nut wrench 5884021560 to

remove the mainshaft nut(19).
226RW211
226RW212
7B32
MANUAL TRANSMISSION
13. Use pry bars between the reverse gear(22) and

bearing plate(24) to remove the Rev5th
synchronizer assembly(20) together with reverse
block ring(21) and reverse gear(22).
16. Use the snap ring pliers(1) to remove the mainshaft

bearing snap ring(29).
226RS011
226RS010
14. Remove needle bearing(23).

15. Use the torx bit wrench 5884000470(T45) to
remove the bearing plate and screw(24) from the
intermediate plate.
17. Hold the snap ring open with the pliers.

Push the intermediate plate(26) toward the rear of the
transmission to remove it.
The bearing snap ring(25) will come free.

Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.
Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Install the holding fixture 5884021600 and base
5884000030 to the mainshaft and the counter
gear.
220RW137
226RW212
MANUAL TRANSMISSION
7B33
2. Place the holding fixture (with the mainshaft and the

counter shaft) in a vise.
Install the intermediate plate(26).
3. Install bearing snap ring(25).
4. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw(24).
Tighten the screws to the specified torque by using
torx bit wrench 5884000470.
226RS013
220RW137
5. Install needle bearing(23), reverse gear(22), and

reverse block ring(21).
6. Assemble rev5th synchronizer assembly(20) by
performing the following steps.
1. Turn the clutch hub face(1) toward the sleeve
groove(2) (rear side) on the outer circumference.
2. Check that the inserts(3) fit snugly into the block
ring insert grooves.
3. Check that the inserts springs(4) are fitted to the
inserts as shown in the illustration.
4. Check that the clutch hub(5) and the sleeve(6)
slide smoothly.
5. Install the synchronizer assembly(20) to the
mainshaft.
facing the reverse gear(22) side.
226RS049
7B34
MANUAL TRANSMISSION
7. Mesh the 1st2nd and 3rd4th synchronizers with

both the 1st and 3rd gears (double engagement).
9. Use a punch to stake the mainshaft nut at one spot.
226RW153
226RS015
This will prevent the mainshaft from turning.

8. Install the new mainshaft hub nut(19).
Use the mainshaft nut wrench 5884021560 to
tighten the mainshaft nut(19) to the specified torque.
10. Install needle bearing(18), 5th block ring(17), and 5th

gear(16).
11. Apply engine oil to the counter reverse gear(15) and
the reverse gear(22).
Install the counter reverse gear(15) to the counter
shaft.
The reverse gear projection must be facing the
intermediate plate.
226RW214
226RW151
MANUAL TRANSMISSION
12. Install the counter 5th gear(14) to the transmission.
7B35
D There are six snap ring sizes available.

The snap rings are color-coded to indicate their
thickness.
226RS019
13. Install ball bearing(13) and bearing snap ring by

D Select the snap ring(12) which will provide the
minimum clearance between the ball bearing and
the snap ring.
226RS021
Ball Bearing and Snap Ring Clearance

Standard: 00.15 mm (00.0059 in)
Snap Ring Availability
Thickness
Color Coding
1.1 mm (0.043 in)
White
1.2 mm (0.047 in)
Yellow
1.3 mm (0.051 in)
Blue
1.4 mm (0.055 in)
Pink
1.5 mm (0.059 in)
Green
1.6 mm (0.063 in)
Brown
D Use a pair of snap ring pliers to install the snap

ring(12) to the counter gear shaft.
The snap ring must be fully inserted into the counter
gear shaft snap ring groove.
226RS020
14. Assemble reverse idler shaft(11), reverse idler

gear(10), thrust washer(9), and idle shaft pin(8) into
reverse idler gear assembly(7).
15. Select reverse idler gear snap ring(6) which will
provide the minimum clearance between the
intermediate plate(26) and the snap ring(6).
7B36
MANUAL TRANSMISSION
D Use a pair of snap ring pliers to install the snap ring
to the reverse idler shaft.
The snap ring must be fully inserted into the reverse
idler shaft snap ring groove.
16. Install thrust washer and lock ball(5) by performing
the following steps:
D Use a thickness gauge to measure the clearance
between the 5th gear and the thrust washer.
5th Gear and Thrust Washer Clearance
Standard: 0.10 0.25 mm (0.004 0.010 in)
D Measure clearance A as shown in the figure.
226RS022
D There are three snap ring sizes available.

The snap rings are color-coded to indicate their
thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 0.15 mm (0 0.0059 in)
Thickness
Color Coding
1.2 mm (0.047 in)
White
1.3 mm (0.051 in)
Yellow
1.4 mm (0.055 in)
Blue
226RS023
D Select appropriate thrust washer from chart.

D There are four thrust washer sizes available.
D The thrust washers are color coded to indicate their
thickness.
226RS021
MANUAL TRANSMISSION
Thrust Washer Availability
Thickness
mm (in)
Color
Coding
7.9 (0.311)
White
8.058.1
0.150.25
(0.3170.319) (0.0060.010)
8.0 (0.315)
Yellow
8.18.2
0.10.25
(0.3190.323) (0.0040.010)
8.1 (0.319)
Green
8.28.3
0.10.25
(0.3230.327) (0.0040.010)
8.2 (0.323)
Bluen
8.38.36
0.10.21
(0.3270.329) (0.0040.008)
A mm (in)
Clearance
mm (in)
7B37
18. Apply engine oil to the bearing inner and outer

circumference.
Use the installer 5884021590 to install the ball
bearing(2) to the mainshaft in proper direction.
226RW215
19. Install oil seal collar(1).
226RS024
D Apply grease to the thrust washer and the lock ball.

D Install the thrust washer and the lock ball.
17. Install thrust plate(4) and retainer(3).
7B38
MANUAL TRANSMISSION
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)
Disassmebled View
226RS026
Legend
(1) Top Gear Shaft Snap Ring
(2) Top Gear Shaft
(3) Ball Bearing
(4) Needle Bearing
(5) Top Block Ring
(6) Mainshaft Snap Ring
(7) 3rd4th Synchronizer Assembly
(8) 3rd Block Ring
(9) 3rd Gear
(10) Needle Bearing
(11) Needle Bearing Collar
(12) Mainshaft Ball Bearing
(13) 1st Gear Thrust Bearing
(14) 1st Gear
(15) 1st Inside Ring
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
1st Outside Ring

1st Block Ring
Needle Bearing
Clutch Hub Snap Ring
1st2nd Synchronizer Assembly
2nd Block Ring
2nd Outside Ring
2nd Inside Ring
2nd Gear
Needle Bearing
Mainshaft
Bearing Snap Ring
Front Rollar Bearing
Center Roller Bearing
Counter Gear Shaft
MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring(1).
2. Remove top gear shaft(2) with ball bearing(3).
5884000150 to remove the ball bearing(3).
7B39

5884000150 to remove the 3rd4th synchronizer
assembly(7) as a set.
Disassemble the synchronizer assembly.
226RW217
226RW216
4. Remove needle bearing(4) and top block ring(5),

mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the mainshaft
snap ring(6).
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove 3rd block ring(8), 3rd gear(9), and needle
bearing(10).
8. Remove needle bearing collar(11).
5884000150 to remove the 1st gear(14) together
with the mainshaft ball bearing(12) and 1st gear thrust
bearing(13).
226RS028
226RW218
7B40
MANUAL TRANSMISSION
10. Disassemble 1st inside ring(15), 1st outside ring(16),

and 1st block ring(17).
11. Remove needle bearing(18).
12. Use a pair of snap ring pliers to remove the clutch hub
snap ring(19).

5884000150 to remove the front roller
bearing(28).
226RW219
17. Remove center roller bearing(29) from counter gear

shaft(30).
226RS031

5884000150 to remove the 2nd gear(24) together
with 1st2nd synchronizer assembly(20), 2nd block
ring(21), 2nd outside ring(22), and 2nd inside
ring(23).
Disassemble the synchronizer assembly.

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Block Ring and Dog Teeth Clearance

226RW220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
14. Remove needle bearing(25) from mainshaft(26).
15. Remove bearing snap ring(27)
226RS035
If the measured value exceeds the specified limit, the

block ring must be replaced.
MANUAL TRANSMISSION
Standard
Limit
1.5 mm (0.059 in)
0.8 mm (0.032 in)
7B41

Block and Insert Clearance
1st2nd Synchronizer (3CONE)

Standard
Limit
3rd4th
3.46 3.74 mm
(0.136 0.147 in)
4.0 mm
(0.158 in)
1st2nd
4.34 4.66 mm
(0.171 0.183 in)
4.9 mm
(0.193 in)
Rev5th
3.59 3.91 mm
(0.141 0.154 in)
4.1 mm
(0.161 in)

226RS036
If the measured value exceeds the specified limit,the

1st2nd synchronizer assembly must be replaced.
Standard
Limit
1.5 mm (0.059 in)
0.8 mm (0.032 in)

226RS038

D Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.

3rd4th
1st2nd
Rev5th
226RS037
Standard
Limit
0.01 0.19 mm
(0.0004 0.0075 in)
0.3 mm
(0.012 in)
0.09 0.31 mm
(0.0035 0.0122 in)
0.4 mm
(0.016 in)
7B42
MANUAL TRANSMISSION
Gear Inside Diameter
Mainshaft Run-out
D Install the mainshaft to V-blocks.
D Use a dial indicator to measure the mainshaft central
portion run-out.
Standard
Limit
45.000 45.013 mm
(1.771 1.772 in)
45.100 mm
(1.776 in)
2nd
52.000 52.013 mm
(2.047 2.048 in)
52.100 mm
(2.051 in)
Rev.
48.000 48.013 mm
(1.889 1.890 in)
48.100 mm
(1.894 in)
5th
32.000 32.013 mm
(1.259 1.260 in)
32.100 mm
(1.246 in)
1st
3rd
Reverse Idler Gear and Idler Gear Shaft

Clearance
D Use a micrometer to measure the idler gear shaft
diameter.
D Use an inside dial indicator to measure the idler gear
inside diameter.
226RS039
If the measured mainshaft run-out exceeds the

specified limit, the mainshaft must be replaced.
Mainshaft Runout
Limit: 0.05 mm (0.0020 in)
Gear Inside Diameter

D Use an inside dial indicator to measure the gear inside
diameter.
226RS041
D Calculate the idler gear and idler gear shaft

clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
idle gear and/or the idler gear shaft must be replaced.
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.0410.074 mm (0.0160.0029 in)
Limit: 0.150 mm (0.0059 in)
226RS040

the gear must be replace.
MANUAL TRANSMISSION
7B43

D Set a dial indicator to the clutch hub to be measured.
226RS043
226RS042
D Move the clutch hub as far as possible to both the right

and the left.
1st2nd
3rd4th
Rev. 5th
Standard
Limit
0 0.1 mm
(0 0.004 in)
0.2 mm
(0.008 in)
0 0.2 mm
(0 0.008 in)
0.3 mm
(0.012 in)
Reassembly
1. Install center roller bearing(29) to counter gear
shaft(30).
D Apply engine oil to the bearing inner and outer
circumferences.
D Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the direction
of arrow.
Ball Bearing Play

D Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS044
2. Install front roller bearing(28) by performing the

following steps.
D Use bearing installer to install the front roller
bearing inner race to the counter gear shaft.
D Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.
D Use bearing installer J35283 to install the ring.
7B44
MANUAL TRANSMISSION
5. Assemble 2nd inside ring(23), 2nd outside ring(22),
and 2nd block ring(21).
D Apply engine oil to the synchronizer ring friction
surfaces.
226RS045
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
226RS047
3. Install bearing snap ring(27) to mainshaft(26).

4. Apply engine oil to the needle bearing(25) and the 2nd
gear thrust surfaces.
Install the needle bearing(25) and the 2nd gear(24) to
the mainshaft.
The 2nd gear dog teeth must be facing the
transmission rear side.
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing
6. Assemble 1st2nd synchronizer assembly by
2. Check that the inserts springs(4) are fitted to the
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
facing the 2nd gear side.
226RS046
MANUAL TRANSMISSION
7B45
226RS048
226RS050
There are three snap ring sizes available.

The snap rings are color coded to indicate their
thickness.
226RS049
7. Install clutch hub snap ring(19) by performing the

following steps:
D Select the snap ring which will provide the minimum
clearance between the 1st2nd clutch hub and the
snap ring.
226RS021
Clutch Hub and Snap Ring Clearance

Standard: 0 0.1 mm (0 0.004 in)
Thickness
Color Coding
1.80 mm (0.071 in)
White
1.85 mm (0.073 in)
Yellow
1.90 mm (0.075 in)
Blue

to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
7B46
MANUAL TRANSMISSION
9. Install the 1st gear thrust bearing and the race(13) to
the main shaft.
The thrust bearing side must be facing the
226RS031
8. Install needle bearing(18), 1st block ring(17), 1st

outside ring(16), 1st inside ring(15), and 1st gear(14).
D Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
D Install the needle bearing and the 1st gear to the
mainshaft.
The 1st gear dog teeth must be facing the
226RS054
10. Apply engine oil to the mainshaft ball bearing(12) and

the mainshaft(26).
Install the ball bearing(12) and needle bearing
collar(11) to the mainshaft(26).
The ball bearing snap ring groove must be facing the
transmission rear side.
Use a bench press and installer J613301 to slowly
force the collar into place.
226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
226RS055
MANUAL TRANSMISSION
7B47
11. Apply engine oil to the needle bearing and the 3rd
gear thrust surfaces.
Install the needle bearing(10) and the 3rd gear(9) to
the mainshaft.
The 3rd gear dog teeth must be facing the
226RS049
14. Select and install mainshaft snap ring(6) in the

following way:
D Select the snap ring which will provide the minimum
clearance between the 3rd4th clutch hub and the
snap ring.
226RS056
12. Install 3rd block ring(8).

13. Check and install 3rd4th synchronizer assembly(7)
by the following steps:
2. Check that the insert springs(4) are fitted to the
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
facing the 3rd gear side.
226RS058
There are three snap ring sizes available.

The snap rings are color coded to indicate their
thickness.
226RW2211
7B48
MANUAL TRANSMISSION
15. Install top block ring(5).
16. Apply grease to the bearing inner and outer
circumferences and install needle bearing(4).
17. Use a bench press to install the top gear shaft ball
bearing(3) to the top gear shaft(2).
226RS021
Clutch Hub and Snap Ring Clearance

Standard: 0 0.1 mm (0 0.004 in)
Thickness
Color Coding
1.80 mm (0.071 in)
White
1.85 mm (0.073 in)
Yellow
1.90 mm (0.075 in)
Blue

to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
226RS059
The snap ring groove must be facing the transmission

front side.
18. Use a pair of snap ring pliers to install the top gear
shaft snap ring(1) to the bearing.
MANUAL TRANSMISSION
7B49

MUA 5C Manual Transmission 5 Speed
4X4
Transmission type
Fully synchronized forward and reverse gears
Transfer case
Synchronized type gears shifting between the 2 and

4wheel drive mode.
Constant mesh type gears between low and high
Control method
Gear ratio: Transmission
Gear ratio: Transfer
Remote control with the gear shift lever on the floor.

1st
3.767
2nd
2.248
3rd
1.404
4th
1.000
5th
0.809
Rev.
3.873
High
1.000
Low
2.050
Transmission oil capacity
2.95 lit. (3.12 US qt)
Transfer oil capacity
1.45 lit. (1.53 US qt)
Type of lubricant
Engine oil: Refer to the chart in SECTION 0
7B50
MANUAL TRANSMISSION
E07RX015
About arrow mark, refer to Transmission(MUA) Installation in this section.
MANUAL TRANSMISSION
7B51
Torque Specifications (Contd)
E07RX014
7B52
MANUAL TRANSMISSION
Torque Specifications (Contd)
E07RX013
MANUAL TRANSMISSION
7B53
Special Tools (MUA)

ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884021580
Mainshaft collar remover
5884021590
installer
5884020270
Puller
5884000150
Bearing
remover/installer
5884021600
Holding fixture
5884000260
Front cover oil seal
installer
5884000030
9852211650
Mainshaft collar installer
5884021560
Wrench
5884022910
Remover; Clutch release
bearing
5884000470
Tork bit wrench
(T45)
5884001330
Flange holder
7B54
MANUAL TRANSMISSION
ILLUSTRATION
TOOL NO.
TOOL NAME
5884022930
Punch; end nut
5884021940
Counter shaft bearing
installer
5884021550
Bearing remover
SECTION
CLUTCH
7C1
FRONTERA
TRANSMISSION
CLUTCH
CONTENTS
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly (X22SE, MUA) . . . . . . . . . .
Clutch Assembly (X22SE, MUA) and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly (6VD1, MUA) . . . . . . . . . . . .
Clutch Assembly (6VD1, MUA) and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location View . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7C1
7C2
7C8
7C9
7C9
7C9
7C10
7C13
7C15
7C15
7C15
7C17
7C21
7C23
7C23
7C24
Service Precaution
systems.

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Damper Cylinder . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
7C24
7C25
7C27
7C27
7C27
7C27
7C28
7C28
7C28
7C28
7C29
7C30
7C30
7C30
7C30
7C30
7C31
7C33
7C2
CLUTCH
The clutch assembly consists of the pressure plate
assembly and the driven plate assembly.
The clutch pedal is connected to the release bearing
through the shift fork.
The driven plate assembly is installed between the
flywheel and the pressure plate. Diaphragm spring
pressure holds the driven plate against the flywheel and
the pressure plate to provide the friction necessary to
engage the clutch.
Depressing the clutch pedal moves the shift fork against
the release bearing.
The release bearing force
overcomes the force of the diaphragm spring and
separates the driven plate from the flywheel and pressure
plate to disengage the clutch.
For 6VD1 (3.2L) engine model, the pulltype clutch is
employed.
General Description
Clutch
X22SE, MUA
A07RW035
6VD1, MUA
A07RW031
CLUTCH
7C3
Master Cylinder
A07RW071
The master cylinder converts mechanical energy into

hydraulic energy.
Depressing the clutch pedal causes the push rod to move
against the piston to close the return port.
Clutch fluid is forced out of the master cylinder.

Releasing the clutch pedal causes the return spring to
force the piston back to its original position.
7C4
CLUTCH
Damper Cylinder
A07RS004
In order to reduce the occurrence of noises at the clutch

hydraulic system, the damper cylinder is used in the
clutch hydraulic line between the master cylinder and

slave cylinder.
CLUTCH
7C5
Slave Cylinder
X22SE, MUA
A07RW028
6VD1, MUA
A07RW037
The slave cylinder converts hydraulic energy into

mechanical energy. Hydraulic fluid supplied by the
master cylinder moves the slave cylinder piston to
actuate the shift fork. The mechanical energy produced

by the slave cylinder is directly proportional to the
diameters of the master cylinder and the slave cylinder.
7C6
CLUTCH
Pressure Plate Assembly

X22SE, MUA
A07RW024
6VD1, MUA
A07RW025
The pressure plate assembly consists of the clutch cover,

the pressure plate with diaphragm spring.
Operating the clutch pedal causes the pressure plate to

move in an axial direction to engage and disengage the
clutch.
CLUTCH
7C7
Driven Plate Assembly

X22SE, MUA
A07RW026
6VD1, MUA
A07RW027
The driven plate assembly consists of the plate and the

facing.
The plate consists of the clutch center, the cushioning
plate, and the torsion springs.
The facing is riveted to both sides of the cushioning plate.

The cushioning plate provides a longer service life by
minimizing wear and vibration at the clutch contact
surfaces.
7C8
CLUTCH
Diagnosis
Condition
Dragging
Slipping
Chattering
Possible cause
Correction
Air in circuit.
Bleed and check for damage.
Driven plate worn or warped.
Replace.
Clutch fork off the ball stud.
Install correctly and lubricate.
Diaphragm spring weak or tip of

fingers worn.
Replace.
Driven plate sticking on splines.
Clean and free splines and lubricate

with grease.
Pilot bearing worn or damaged.
Replace.
Master cylinder and slave cylinder

seals worn.
Replace.
Clutch facing worn.
Replace.
Driven plate friction pads worn or

oilsoaked.
Replace and check for leaks as

needed.
Diaphragm spring weak.
Replace pressure plate.
Pressure plate or flywheel warped.
Replace.
Master cylinder and slave cylinder

seals worn.
Replace as needed.
Clutch facing in poor contact or

facing warped.
Replace.
Surface of facing hardened.
Replace.
Driven plate friction pads oil soaked.
Replace and check for leaks.
Damper
broken.
Replace.
springs
weakened
or
Rivets on clutch plate loosened.
Replace.
Pressure plate or flywheel warped.
Replace as needed.
Replace the pressure plate.
Clutch fork loose or off the ball stud.
Replace the retaining spring or install

the fork correctly.
Driven plate springs weak or oil in the

damper.
Replace and check for leaks as

needed.
Release bearing binding.
Clean, or replace if damaged, and

lubricate.
Clutch fork off the ball stud or loose

spring tension.
Install correctly, and lubricate.
Linkage return springs weak.
Replace.
Release bearing worn or damaged.
Replace.
Clutch fork off the ball stud.
Install correctly and lubricate.
Pilot bearing loose.
Replace.
Pedal stays on the floor when

disengaged
Replace bearing binding.
Free up, or replace, and lubricate.
Replace the pressure plate.
Pedal is hard to push
Hydraulic line blocked or crimped.
Clean out or replace.
Master or slave cylinders bindinig.
Repair or replace as needed.
Driven plate worn.
Replace.
Ball stud not lubricated or incorrectly

lubricated.
Lubricate with high temperature

grease.
Rattling
Release bearing noisy with the clutch

engaged
Noisy
Squeaking
CLUTCH
7C9
Clutch Assembly (X22SE, MUA)

Clutch Assembly (X22SE, MUA) and Associated Parts
201RX003
Legend
(1) Transmission Assembly
(2) Pressure Plate Assembly
(3) Driven Plate Assembly
Removal
1. Remove transmission assembly, refer to MANUAL
TRANSMISSION of Section 7B for REMOVAL AND
INSTALLATION procedure.
(4) Release Bearing

(5) Shift Fork
(6) Crank Shaft Bearing
7C10
CLUTCH
2. Use the clutch pilot aligner (7) J42877 (MUA) to

prevent the driven plate assembly from falling free.
5. Remove pressure plate assembly (2) and driven plate

assembly (3).
6. Remove release bearing (4).
NOTE: The release bearing is permanently packed with
lubricant and should not be soaked in cleaning solvent, as
this will dissolve the lubricant.
7. Remove shift fork.
D Do not remove crank shaft bearing (6) except for
replacement.
Remove the crank shaft bearing (6) using remover
5884020000
and
sliding
hammer
5884000190.
201RX002
Legend
(7) Pilot Aligner
3. Mark the flywheel, clutch cover and pressure plate (2)
lug for alignment when installing.
4. Loosen the clutch cover bolts in the numerical order
015RW107

Make necessary adjustments, repairs, and part

Visually inspect the pressure plate friction surface for
excessive wear and heat cracks. If excessive wear or
deep heat cracks are present, the pressure plate must be
replaced.
201RS036
CLUTCH
7C11
4. Note the pressure gauge reading.
Pressure Plate Warpage

Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
Clutch Set Force

Standard: 5488N (559 kg/1235lb)
201RS038
If any of the measured values exceed the specified limit,

the pressure plate must be replaced.
Clutch Cover
Visually inspect the entire clutch cover for excessive
wear, cracking, and other damage. The clutch cover must
be replaced if any of these conditions are present.
201RW015
Diaphragm Spring Finger Height

1. Place a 8.0mm (0.315in) spacer beneath the
pressure plate.
2. Fully compress the pressure plate and diaphragm
spring.
There are two ways to do this:
a. Use a bench press to press down on the assembly
from the top.
b. Tighten the fixing bolts.
3. Measure the spring finger height from base to spring
tip.
pressure plate assembly must be replaced.
Spring Finger Height
Standard: 37.5 mm 39.5 mm (1.48 in 1.56 in)
201RS039
Clutch Set Force

1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate. A
metal sheet with thickness of 8.0mm (0.315in) may
be used in place of the driven plate.
3. Compress the pressure plate assembly until the
distance becomes 4mm (0.157in).
A07RX002
7C12
CLUTCH
Shift Fork
1. Visually inspect the surfaces of the shift fork making
contact with the shift block.
2. Remove any minor stepping or abrasion from the shift
block with an oil stone.
3. Apply molybdenum disulfide type grease to the areas
as shown in the figure.
MUA
3. Check that the driven plate moves smoothly on the

transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be
removed with an oil stone.
Driven Plate Warpage

1. Insert the clutch pilot aligner J42877 (MUA) into the
driven plate splined hub.
The clutch pilot aligner must be held perfectly
horizontal.
2. Set a dial indicator to the driven plate outside
circumference.
F07RW030

1. Visually inspect the torsion spring for looseness,
breakage, and weakening. If any of these conditions
are discovered, the driven plate assembly must be
replaced.
2. Visually inspect the facing surfaces for cracking and
excessive scorching. Visually inspect the facing
surfaces for the presence of oil or grease. If any of
these conditions are discovered, the facing must be
cleaned or replaced.
201RS008
3. Slowly turn the driven plate. Read the dial indicator as

you turn the driven plate.
driven plate assembly must be replaced.
Limit: 1.0 mm (0.039 in)
Driven Plate Splined Hub Spline Wear

1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear
shaft spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the
driven plate.
Limit: 1.0 mm (0.039 in)
201RS007
CLUTCH
7C13

Check the cover for cracks and distortion, and the
diaphragm spring for heat distortion, loosened rivets.
Check the diaphragm spring for wear.
201RS009
Rivet Head Depression

Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression (1) from the facing
surface (2).
Be sure to measure the rivet head depression on both
sides of the driven plate. If the measured value is less
than the specified limit, the facing must be replaced.
Standard: MIN 1.3 mm (0.051 in)
Limit: 0.2 mm (0.008 in)
201RS047
Installation
1. Clean and lubricate with grease.
2. Use installer J1522 to install crankshaft bearing (6).
X22SE
015RS078
201RS010
7C14
CLUTCH

as shown in the figure and install shift fork (5).
5. Install driven plate assembly by using aligner

J42877 (MUA).
MUA
201RS049
F07RW030
4. Pack the inside recess (A) and coat the rubbing

surface (B) of the release bearing with grease as
shown in the figure.
6. Tighten the bolts holding the pressure plate assembly

(2) in the order shown in the figure.
Torque: 18Nm (1.8 kgm/13 lb ft)
201RS050
7. Remove the aligner.

NOTE: Do not strike the aligner with a hammer to remove
it.
8. Install transmission assembly (1) to the engine. Refer
to Transmission Installation in Manual Transmission
section.
A07RW075
CLUTCH
7C15
Clutch Assembly (6VD1, MUA)

Clutch Assembly (6VD1, MUA) and Associated Parts
201RS023
Legend
(1) Transmission Assembly
Removal
1. Refer to MANUAL TRANSMISSION of Section 7B
for REMOVAL AND INSTALLATION procedure of
transmission assembly (1).
(4)
(5)
(6)
(7)
Release Bearing
Shift Fork
Fulcrum Bridge
Flywheel Assembly and Crankshaft Bearing
7C16
CLUTCH
2. Use the pilot aligner J24547 to prevent the driven

plate assembly (3) from falling free.
201RS001
5. Remove the snap pin. Remove the shift fork pin and
shift fork from the fulcrum bridge.
201RS025
6. Remove the fulcrum bridge bolts. Remove the

fulcrum bridge (6) from the transmission case.
Legend
(8) Pilot Aligner
3. Mark the flywheel, clutch cover and pressure plate lug
for alignment when installing.
4. Remove the release bearing (4) from the
transmission case.
201RS026
201RS024
CLUTCH
D Do not remove crankshaft bearing (7) except for
replacement.
D Use the remover 5884020000 and sliding
hammer 5884000190 to remove the crankshaft
bearing.
7C17

D Use a straight edge and a feeler gauge to measure
the pressure plate friction surface flatness in four
directions. If any of the measured values exceed the
specified limit, the pressure plate must be replaced.
Limit: 0.3 mm (0.012 in)
015RW053
201RS003
Make necessary correction or parts replacement if wear,

damage, or any other abnormal condition are found
through inspection.

D Visually check the pressure plate friction surface for
excessive wear and heat cracks. If excessive wear or
deep heat cracks are present, the pressure plate
must be replaced.
Clutch Cover
D Visually check the entire clutch cover for excessive
wear, cracking, and other damage. The clutch cover
must be replaced if any of these conditions are
present.
201RS004
201RS002
7C18
CLUTCH
Clutch Set Force

1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate. A
metal sheet with thickness of 8.0mm (0.315in) may
be used in place of the driven plate.
3. Compress the pressure plate assembly until the
distance becomes 12mm (0.472in).
4. Note the pressure gauge reading. If the measured
value is less than the specified limit, the pressure
plate assembly must be replaced.
Clutch Set Force
Standard: 7208N (735 kg/1621lb)
Limit: 6669N (980 kg/1499lb)
201RW016
201RW014
D Visually check the torsion spring for looseness,

breakage, and weakening. If any of these conditions
are discovered, the driven plate assembly must be
replaced.
D Visually check the facing surfaces for cracking and
excessive scorching. Visually inspect the facing
surfaces for the presence of oil or grease. If any of
these conditions are discovered, the facing must be
cleaned or replaced.
D Check that the driven plate moves smoothly on the
transmission top gear shaft spline. Minor ridges on
the top gear shaft spline may be removed with an oil
stone.
Diaphragm Spring Finger Height

1. Place a new driven plate or a 8.0mm (0.315in) spacer
beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm
spring.
There are two ways to do this:
a. Use a bench press to press down on the assembly
from the top.
b. Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be
4998N (510 kg/1122lb) in direction of release, when
clutch cover assembly is bolted to the flywheel.
3. Measure the spring height from base to spring tip. If
the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Spring Finger Height
Standard: 49.9 51.9 mm (1.965 2.043 in)
201RS007
CLUTCH
7C19

1. Insert the clutch pilot aligner J24547 into the driven
plate splined hub. The clutch pilot aligner must be
held perfectly horizontal.
2. Set a dial indicator to the driven plate outside
circumference.
3. Slowly turn the driven plate. Read the dial indicator as
you turn the driven plate. If the measured value
exceeds the specified limit, the driven plate assembly
must be replaced.
201RS009

D Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression (1) from the facing
surface (2).
D Be sure to measure the rivet head depression on both
sides of the driven plate. If the measured value is less
than the specified limit, the driven plate assembly
must be replaced.
Standard
Fly wheel side
1.21.8mm
(0.0470.071in)
Pressure plate
side
1.62.2mm
(0.0620.087in)
201RS008
Limit
0.2mm
(0.008in)
1. Clean the driven plate splined hub.

2. Install the driven plate to the transmission top gear
shaft spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the
driven plate. If the measured value exceeds the
specified limit, the driven plate assembly must be
replaced.
201RS010
7C20
CLUTCH
Release Bearing
Wedge Collar (10)
D Visually check the release bearing for excessive play,

noise and breakage. If any of these conditions are
discovered, the release bearing must be replaced.
D Visually check the surfaces of the wedge collar

making contact with the release bearing for excessive
wear and damage.
D Replace exhibiting excessive wear or damage.
201RS011
D When replacing the release bearing (4), replace both

the wedge collar (10) and wire ring (11) at the same
time.
201RS013
Shift Fork
D Visually check the surfaces of the shift fork making
contact with the release bearing for excessive wear
and damage.
D Remove any minor stepping or abrasion from shift
fork with an oil stone. Replace exhibiting excessive
wear or damage.
201RS012
Legend
(4) Release Bearing
(10) Wedge collar
(11) Wire Ring
201RS014
CLUTCH
Installation
1. Clean and lubricate with grease.
2. Use the installer 5884001250 and driver handle
5884000070 to install the crankshaft bearing (7).
015RW054
3. Install the fulcrum bridge (6) to the transmission case.

Tighten three fulcrum bridge bolts to the specified
torque.
7C21
4. Apply molybdenum disulfide type grease to the pin

hole inner circumferences and thrust surfaces.
Attach the shift fork (5) to the fulcrum bridge (6) and
insert the pin from below of the fulcrum bridge. Install
the washer and snap pin.
201RS018

201RW012
201RS026
7C22
CLUTCH
Install the release bearing (4) in the proper direction.

NOTE: Ensure release bearing is properly positioned
during installation, as shown in the figure.
7. Tighten the bolts holding the pressure plate assembly

(2) in the order shown in the figure.
201RS017

201RS019
6. Use the pilot aligner 5852530010 to install the

driven plate assembly (3).
8. Remove the aligner.

NOTE: Do not strike the aligner with a hammer to remove
it.
9. Install transmission assembly to the engine.
201RX004
CLUTCH
7C23
Clutch Control
Parts Location View
203RX001
Legend
(1) Master Cylinder Assembly
(2) Pedal Assembly
(3) Pin and Jaw Joint Pin
(4) Oil Line Pipe and Hose

(5) Slave Cylinder Assembly
(6) Damper Cylinder Assembly
7C24
CLUTCH
Removal
1. Disconnect the ground battery cable.
2. Remove the instrument panel lower cover (7) and
driver knee bolster panel assembly (8).
7. Remove master cylinder assembly (1).

8. Remove damper cylinder assembly (6).
9. Remove oil line hose (5).

Make necessary adjustments, repairs, and part
replacements if wear, damage or other problems are
740RW162
Legend
(7) Driver Lower Cover
(8) Driver Knee Bolster Panel
3. Remove pin and jaw joint pin (3).
5. Remove oil line pipe (4).
6. Remove slave cylinder assembly (5).
X22SE MUA
205RW001
CLUTCH
7C25
3. With clutch switch.

1. Turn the clutch switch until the switch bolt just
touches the clutch pedal arm.
Installation
Clutch Pedal Adjustment
1. With clutch switch.
1. Disconnect clutch switch connector.
2. Loosen lock nut, then turn switch out until there is
a gap between the switch plunger and clutch
pedal.
2. Adjust clutch switch by backing it out half a turn,

and measure the clearance between the clutch
pedal arm and the clutch switch bolt end.
F07RW027
208RX004
Legend
(7) Push Rod
(8) Clutch Switch
2. Loosen clutch master cylinder push rod lock nut. Turn
push rod by hand to set clutch pedal height to within
specification. Tighten push rod lock nut.
Clutch Pedal Height
Legend
(8) Clutch Switch
(10) Clutch Pedal Arm
(11) Lock Nut
(12) Bracket
(13) Back Out Switch 1/2 Turn
3. Lock the lock nut.
4. Connect clutch switch connector.
Clutch Switch and Clutch Pedal Clearance
178 188 mm (7.01 7.40 in)
0.5 1.5 mm (0.020 0.059 in)

4. After adjusting the clutch pedal height, push the
clutch pedal by hand to ensure the clutch pedal free
play is within specification.
Pedal Free Play
5 15 mm (0.20 0.59 in)
5. Perform clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the
wheels.
2. Start the engine, fully step on the clutch pedal
slowly and move the shift lever 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 (H3)
MIN. 30 mm (1.18 in)
F07RW026
7C26
CLUTCH
vinyl tube to the bleeder screw and insert the
other end of the vinyl tube into a transparent
container.
2. Pump the clutch pedal repeatedly and hold it
depressed.
F07RW028
6. If the measured value exceeds the specified limit,

check the following points and repair if necessary:
D Hydraulic circuit for fluid leakage or air in circuit.
D Clutch disc warped.
D Diaphragm spring weakened or tip of fingers worn.
D Driven plate sticking on sprines.
D Release bearing worn or damaged.
D Master cylinder and slave cylinder worn.
Torque
D Master cylinder to dash panel
16 Nm (1.6 kgm/12 lb ft)
D Clutch pedal to dash panel
15 Nm (1.5 kgm/11 lb ft)
D Master cylinder push rod to yoke
17 Nm (1.7 kgm/12 lb ft)
D Clutch pipe to master cylinder
20 Nm (2.0 kgm/14 lb ft)
D Clutch pipe to damper cylinder
12 Nm (1.2 kgm/104 lb in)
D Clutch pipe to flex, hose
20 Nm (2.0 kgm/14 lb ft)
D Flexible hose to slave cylinder (6VD1)
20 Nm (2.0 kgm/14 lb ft)
D Slave cylinder to case
40 Nm (4.1 kgm/30 lb ft)
D Slave cylinder bleeder screw
8 Nm (0.8 kgm/69 lb in)
D Clutch pipe to slave cylinder (X22SE)
20 Nm (2.0 kgm/14 lb ft)
Bleeding
1. Check the level of clutch fluid in the reservoir and
replenish if necessary.
2. Bleeding the slave cylinder.
1. Remove the rubber cap from the bleeder screw
and wipe clean the bleeder screw. Connect a
203RS005
3. Loosen the bleeder screw to release clutch fluid

with air bubbles into the container, then tighten
the bleeder screw immediately.
4. Release the clutch pedal carefully. Repeat the
above operation until air bubbles disappear from
the clutch fluid being pumped out into the
container. During the bleeding operation, keep
the clutch fluid reservoir filled to the specified
level. Reinstall the rubber cap.
CLUTCH
7C27
Master Cylinder
208RX003
Legend
(1) Reservoir Cap
(2) Inner Cap
(3) Seal
(4) Reservoir
Disassembly
1. Disassemble reservoir cap (1), inner cap (2), seal (3),
clip (5), and reservoir (4).
2. Disassembly gasket (7), yoke (9), nut (8) and body
sub assembly.
(5)
(6)
(7)
(8)
(9)
Clip
Body Sub Assembly
Gasket
Nut
Yoke

Make the necessary adjustments, repair, and part
during inspection.
Reassembly
reverse order.
7C28
CLUTCH
Slave Cylinder
Disassembled View
206RS002
Legend
(1) Push Rod
(2) Boot
(3) Piston and Piston Cup

(4) Spring
(5) Cylinder Body
Disassembly
1. Disassemble boot (1), push rod (2), piston and piston
cup (3), and spring (4) from cylinder body (5).

Make the necessary adjustments, repairs, and part
during inspection.
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it
if necessary.
206RS003
CLUTCH
Piston and Piston Cup
7C29
Reassembly
1. Visually inspect the disassembled piston and piston

cup for excessive wear and damage.

Piston Assembly
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the
front of cylinder. Use care so as not to scratch the
cylinder.
206RS004
Replace the inner parts with new parts if necessary.

2. Measure the clearance between slave cylinder wall
and piston.
206RS006
206RS005

slave cylinder assembly must be replaced.
Limit: 0.15 mm (0.0059 in)
7C30
CLUTCH
Damper Cylinder
Disassembled View
205RW005
Legend
(1) Cylinder Body
(2) Spring
(3) Piston Assembly
Disassembly
1. Disassembly cover and gasket (6).
2. Disassembly damper rubber (5).
3. Disassembly spacer (4).
4. Disassembly piston assembly (3).
5. Disassembly spring (2).
6. Disassembly cylinder body (1).
(4) Spacer
(5) Damper Rubber
(6) Cover and Gasket

Check damper rubber and piston cup for cracks,
deformation or damage.
Replace the damper cylinder assembly if necessary.
Reassembly
To assemble, follow the disassembly steps in the reverse
order.
CLUTCH
7C31

Engine
Type
Size
X22SE
6VD1
Dry single plate type with diaphragm spring

240 mm (9.45 in)
260 mm (10.24 in)
Outside diameter
299 mm (11.77 in)
332 mm (13.07 in)
Clamping force
5488 N (1235 lb)
7208 N (1621 lb)
37.5 39.5 mm (1.476 1.555 in)
49.9 51.9 mm (1.965 2.043 in)
240 160 mm (9.45 6.30 in)
260 170 mm (10.24 6.70 in)
Clutch disengaged
8.3 mm (0.327 in)
8.6 mm (0.339 in)
Clutch engaged
8.0 mm (0.315 in)
8.0 mm (0.315 in)
251 2 cm@ (39 2 in@)
304 2 cm@ (47 2 in@)
Pressure plate
Spring finger height

Driven plate
Outside diameter inside diameter
Thickness
Total friction area

Clutch control type
Hydraulic
5 15 mm (0.20 0.59 in)
Clutch pedal stroke
165.5 175.5 mm (6.52 6.91 in)
Clutch pedal height
178 188 mm (7.01 7.40 in)
X22SE, MUA
E07RX019
7C32
CLUTCH
6VD1, MUA
E07RX020
E07RX018
CLUTCH
7C33
Special Tools
ILLUSTRATION
PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME
5852530010
Driven plate aligner
(6VD1)
J1522
Crankshaft pilot bearing
installer (X22SE)
J42877
Driven plate aligner
(X22SE MUA)
5884000070
Driver handle
5884020000
5884000190
Pilot bearing remover
and Sliding hammer
5884000130
Bearing puller
5884001240
Adapter
5884000070
Crankshaft pilot bearing
installer (6VD1)
SECTION
LIGHTING SYSTEM
8A1

LIGHTING SYSTEM
CONTENTS
Headlight Bulb...............................................
Removal .....................................................
Installation ..................................................
Headlight Assembly ......................................
Removal .....................................................
Installation ..................................................
Headlight Adjustment .................................
Fog Light Bulb ...............................................
Removal .....................................................
Installation ..................................................
Fog Light Assembly.......................................
Removal .....................................................
Installation ..................................................
Fog Light Adjustment..................................
Clearance Light Bulb.....................................
Removal .....................................................
Installation ..................................................
Front Combination Light Assembly ...............
Removal .....................................................
Installation ..................................................
Taillight Bulb..................................................
Removal .....................................................
Installation ..................................................
License Plate Light Bulb (Bumper Type).......
Removal .....................................................
Installation ..................................................
License Plate Light Bulb (Tailgate Type) ......
Removal .....................................................
Installation ..................................................
Stoplight Bulb ................................................
Removal .....................................................
Installtion ....................................................
High Mounted Stoplight Assembly
(4Door Model)............................................
Removal .....................................................
Installation ..................................................
High Mounted Stoplight Bulb
(4Door Model)............................................
Removal .....................................................
Installation ..................................................
High Mounted Stoplight Assembly
(2Door Model)............................................
Removal .....................................................
Installation ..................................................
High Mounted Stoplight Bulb
(2Door Model)............................................
Removal .....................................................
Installation ..................................................
8A - 2
8A - 3
8A - 3
8A - 3
8A - 3
8A - 3
8A - 3
8A - 4
8A - 4
8A - 4
8A - 4
8A - 5
8A - 5
8A - 5
8A - 5
8A - 5
8A - 5
8A - 5
8A - 6
8A - 6
8A - 6
8A - 6
8A - 6
8A - 6
8A - 7
8A - 7
8A - 7
8A - 7
8A - 7
8A - 7
8A - 8
8A - 8
8A - 8
8A - 8
8A - 8
8A - 8
8A - 9
8A - 9
8A - 9
8A - 9
8A - 9
8A - 9
8A - 10
8A - 10
8A - 10
Backup Light Bulb .........................................

Removal......................................................
Installation...................................................
Front Turn Signal Light Bulb .........................
Removal......................................................
Installation...................................................
Side Turn Signal Light Bulb...........................
Removal......................................................
Installation...................................................
Rear Turn Signal Light Bulb ..........................
Removal......................................................
Installation...................................................
Dome Light Bulb............................................
Removal......................................................
Installation...................................................
Courtesy Light Bulb .......................................
Removal......................................................
Installation...................................................
Map Light Bulb ..............................................
Removal......................................................
Installation...................................................
Luggage Room Light Bulb (4Door Model).....
Removal......................................................
Installation...................................................
Luggage Room Light Bulb (2Door Model).....
Removal......................................................
Installation...................................................
HVAC Bezel Illumination Light Bulb ..............
Shift Lever Illumination Light Bulb (A/T) ........
Removal......................................................
Installation...................................................
Ashtray Illumination Bulb...............................
Removal......................................................
Installation...................................................
Starter Switch ................................................
Lighting Switch (Combination Switch) ...........
DimmerPassing Switch
(Combination Switch) ................................
Door Switch ...................................................
Removal......................................................
Installation...................................................
Rear Defogger Switch ...................................
Removal......................................................
Installation...................................................
Key Remind Switch (Starter Switch) .............
8A - 10
8A - 10
8A - 10
8A - 11
8A - 11
8A - 11
8A - 11
8A - 11
8A - 11
8A - 12
8A - 12
8A - 12
8A - 12
8A - 12
8A - 12
8A - 13
8A - 13
8A - 13
8A - 13
8A - 13
8A - 13
8A - 14
8A - 14
8A - 14
8A - 14
8A - 14
8A - 14
8A - 15
8A - 15
8A - 15
8A - 15
8A - 15
8A - 16
8A - 16
8A - 16
8A - 16
8A - 16
8A - 16
8A - 16
8A - 16
8A - 16
8A - 17
8A - 17
8A - 17
8A - 17
8A - 17
8A - 17
8A - 18
8A2
LIGHTING SYSTEM

Hazard Warning Light Switch........................
Removal .....................................................
Installation ..................................................
4WD Switch...................................................
Removal .....................................................
Installation ..................................................
Backup Light Switch (M/T) ............................
Removal .....................................................
8A - 18
8A - 18
8A - 18
8A - 18
8A - 18
8A - 18
8A - 19
8A - 19
8A - 19
8A - 19
8A - 19
Service Precaution
REPAIRS.
Installation................................................... 8A - 19
Turn Signal Light Switch
(Combination Switch) ................................ 8A - 19
Removal and Installation ............................ 8A - 19
Light and Bulb Specifications (4Door Model
Spear Tire Under Mount Type)............ 8A - 20
Light and Bulb Specifications (4Door Model
Spear Tire Tail Gate Type) .................. 8A - 21
Light and Bulb Specifications
(2Door Model) ......................................... 8A - 22

and systems.
LIGHTING SYSTEM
8A3
Headlight Bulb
Removal
2. Remove the headlight bulb.
Disconnect the connector (3).
Remove the socket retaining ring (1) by turning it
counterclockwise.
Remove the cup (2).
Remove the spring.
CAUTION: The halogen light bulb produces heat
and temperature rises high, therefore, if the glass
surface is contaminated it will be burnt by heat
leaving stains which will not come out. This may
reduce the illuminating power or damage the bulb
due to thermal deformation during evaporation. In
order to prevent this problem, do not touch the
glass surface with your fingers.
801RW026
Installation
Headlight Assembly
Removal
2. Remove the radiator grille (1).
Remove eight clips and a screw.
3. Remove the side marker light (3).
Remove three screws.
Disconnect the connector.
4. Remove the headlight assembly (2).
Remove four screws.
825RW283
Installation
CAUTION: After installing the headlight, be sure to
adjust the headlight aim.
8A4
LIGHTING SYSTEM
Headlight Adjustment
Horizontal Adjustment
Preparation
Use a screwdriver for horizontal adjustment.
Place the unloaded vehicle on a level surface and check

to see if the inflation pressure of the tires is correct, the
lenses are clean, and the battery is sufficiently charged.
Adjust the aim with the headlight tester, if necessary.
When adjusting, follow the procedure of the tester
manufacture's.
Vertical Adjustment
Use a screwdriver for vertical adjustment.
825RW277
825RW278
Fog Light Bulb

Removal
2. Remove the fog light bulb (2).
Open the rear cover (1).
Remove the dust cover.
Disconnect the bulb connector.
Remove the clip (3).
801RW002
Installation
LIGHTING SYSTEM
8A5
Fog Light Assembly

Removal
CAUTION: After installing the fog light, be sure to

adjust the fog light aim.

2. Remove the fog light assembly (1).
Remove two nuts from the bracket.
Fog Light Adjustment

Vertical Adjustment
Turn the adjusting screw with a screwdriver to adjust the
aim of the fog light vertically.
801RW021
Installation
801RW022
Clearance Light Bulb

Removal
2. Disconnect the connector.
3. Remove the socket retaining ring by turning it
counterclockwise.
4. Remove the clearance light bulb (2).
Remove the rubber cap.
Pull out the bulb socket (1).
801RW025
Installation
8A6
LIGHTING SYSTEM
Front Combination Light Assembly

Removal
Installation

2. Remove the side combination light.
Refer to Side Marker Light Bulb in this section.
3. Disconnect the connector.
Taillight Bulb
Removal
2. Remove the rear combination light assembly (1).
3. Pull out the rear combination light assembly to ward
you.
4. Remove the bulb holder (2).

Remove the two wing nuts (1).
825RX054
Remove the bulb (3) by turning it

counterclockwise while pushing it at the same
time.
825RX053
825RX055
Installation
LIGHTING SYSTEM
8A7
License Plate Light Bulb (Bumper Type)

Removal
2. Remove the lens cover (3).
Remove two screws.
3. Remove the lens (2).
4. Remove the bulb (1).
Pull out the bulb from the socket.
825RW070
Installation
License Plate Light Bulb (Tailgate Type)

Removal
Installation

2. Remove the lens cover (3).
Remove two screws.
Pull out the bulb from the socket (1).
803RW014
8A8
LIGHTING SYSTEM
Stoplight Bulb
Removal

time.

825RX058
825RX054
Installtion
High Mounted Stoplight Assembly (4Door Model)

Removal
2. Remove the high mount stoplight assembly (2).
Remove the cover (3).
Disconnect the connectors (1).
Remove two screws.
803RX001
Installation
LIGHTING SYSTEM
8A9
High Mounted Stoplight Bulb (4Door Model)

Removal
2. Remove the cover.
Remove the socket by turning it
counterclockwise.
825RW071-1
Installation
High Mounted Stoplight Assembly (2Door Model)

Removal
2. Remove the high mounted stoplight assembly (1).
Remove the two screws.
Pull out the high mounted stoplight assembly (1).
Disconnect the connectorb (2) .
803RX009
Installation
8A10
LIGHTING SYSTEM
High Mounted Stoplight Bulb (2Door Model)

Removal
2. Remove the cover (2).
803RX002-1
Installation
Backup Light Bulb

Removal
2. Remove the rear combination light assembly.
Refer to the Taillight Bulb removal step 2 in this
section.

time.
825RX056
Installation
825RX054
LIGHTING SYSTEM
8A11
Front Turn Signal Light Bulb

Removal
2. Remove the radiator grille.
Refer to Engine Hood and Fender in section.
3. Remove the front turn signal light (2).
Remove the front turn signal light socket by
turning it counterclockwise.
Remove the bulb by turning it counterclockwise
while pushing it at the same time.
825RW067
Installation
Side Turn Signal Light Bulb

Removal
2. Remove the side turnsignal light assembly.
Pushing in the rear direction of vehicle, pull out it
toward you.
3. Remove the bulb (1) by turning it counterclockwise.
801RW024
Installation
8A12
LIGHTING SYSTEM
Rear Turn Signal Light Bulb

Removal

time.

2. Remove the rear combination light assembly.
Refer to the Taillight Bulb in this section.
825RX057
Installation
825RX054
Dome Light Bulb

Removal
Pull out the bulb.
825RW075
Installation
LIGHTING SYSTEM
8A13
Courtesy Light Bulb

Removal
Pull out the bulb.
825RW076
Installation
Map Light Bulb

Removal
Installation

Pull out the bulb.
825RW105
8A14
LIGHTING SYSTEM
Luggage Room Light Bulb (4Door Model)

Removal
Pull out the bulb.
825RW077
Installation
Luggage Room Light Bulb (2Door Model)

Removal
Installation

Pull out the bulb.
805RX002
LIGHTING SYSTEM
8A15
HVAC Bezel Illumination Light Bulb

Refer to Control Panel Illumination bulb in Heating,
Ventilation and Air Conditioning (HVAC) section.
Shift Lever Illumination Light Bulb (A/T)

Removal
Installation

2. Remove the console assembly.
Remove four screws.
Turn the bulb socket counterclockwise.
Pull out the bulb from the socket.
825RW287
8A16
LIGHTING SYSTEM
Ashtray Illumination Bulb

Removal
2. Remove the lower cluster panel(1).
Structure section.
3. Disconnector the connector (2).
4. Turn the socket counterclockwise to remove it then
pull out the bulb(3).
45RW013
Installation
Starter Switch
Refer to Lock cylinder in steering section.
Lighting Switch (Combination Switch)

Refer to Combination Switch in Steering section.
DimmerPassing Switch (Combination Switch)

LIGHTING SYSTEM
8A17
Door Switch
Removal
2. Remove the door switch (2).
Remove the screw (1).
825RW289
Installation

Removal
2. Remove the meter cluster assembly (1).
Structure section.
3. Remove the rear defogger switch (2).
Disconnect the switch connector.
Push the lock from the back side of the meter
cluster assembly.
825RW280
Installation
8A18
LIGHTING SYSTEM
Key Remind Switch (Starter Switch)

Refer to Lock Cylinder in Steering section.
Hazard Warning Light Switch

Removal
Structure section.
3. Remove the hazard warning switch (2).
cluster assembly.
825RW279
Installation
Stoplight Switch
Refer to Stoplight Switch in Brake section.
LIGHTING SYSTEM
8A19
4WD Switch
Removal
Structure section.
3. Remove the 4WD switch (2).
cluster assembly.
825RW275-1
Installation
Backup Light Switch (M/T)

Removal
Installation

2. Remove the backup light switch (1).

1. Apply liquid gasket to the screw portion of the switch
to prevent oil leak.
230RW010
Turn Signal Light Switch (Combination Switch)

8A20
LIGHTING SYSTEM
Light and Bulb Specifications (4Door Model Spear Tire Under Mount Type)
810RX016
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Map Light
Meter
Fog Light
Headlight/Clearance Light
Front Turn Signal Light
Side Turn Signal Light
High Mounted Stoplight
EndOFCallout
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Luggage Room Light

Dome Light
Courtesy Light
Stoplight
Backup Light
Taillight
Rear Turn Signal Light
License Plate Light
LIGHTING SYSTEM
8A21
Light and Bulb Specifications (4Door Model Spear Tire Tail Gate Type)
810RX022
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Map Light
Meter
Fog Light
EndOFCallout
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Luggage Room Light

Dome Light
Courtesy Light
Stoplight
Backup Light
Taillight
License Plate Light
8A22
LIGHTING SYSTEM
Light and Bulb Specifications (2Door Model)
801RX023
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Map Light
Meter
Fog Light
Dome Light
Courtesy Light
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Stoplight
Taillight
Backup Light
License Plate Light
Luggage Room Light
LIGHTING SYSTEM
Light and Bulb Specifications
Light Name
8A23
Bulb No.
Rated
Power
Number of
Bulbs
Lens Color
Remarks
60w/55w,
5w
White
Halogen
Front Turn signal Light
21w
Amber
Fog Light
55w
White
21w
Amber
Backup Light
21w
White
Taillight
5w
Red
Stoplight
21w
Red
5w
Red
License Plate Light (Tailgate type)
5w (5W)
1 (2)
White
Map Light
5w
White
Dome Light
7w
White
Luggage Room Light (2Door Model)
5w(3.4w)
1(1)
White
Courtesy Light
3.4w
White
Check Trans
1.4w
Red
Meter
A/T Oil Temp
3w
Red
Meter
Cruise Set
1.4w
Green
Meter
Power Drive
1.4w
Amber
Meter
Winter Drive
1.4w
Green
Meter
Turn Signal
1.4w
Green
Meter
High Beam
1.4w
Blue
Meter
ABS
1.4w
Amber
Meter
Seat Belt
2w
Red
Meter
(Check Engine)
1.4w
Amber
Meter
Low Fuel
1.4w
Amber
Meter
4WD
1.4w
Green
Meter
Oil Pressure
1.4w
Red
Meter
Brake System
1.4w
Red
Meter
Charge
1.4w
Red
Meter
A/T Shift Position
1.4w
P,N,D,3,2,L
:Green
R: Amber
Meter
Air Bag
2w
Red
Meter
Meter
3.4w
Shift lever
1.4w
Indicator/Warning
Light
Illumination Light
Halogen
Meter
White
Shift lever
SECTION
WIPER/WASHER SYSTEM
8B1

WIPER / WASHER SYSTEM
CONTENTS
Windshield Wiper/Washer System................
Windshield Wiper And Washer Switch..........
Windshield Wiper Motor ................................
Removal .....................................................
Installation ..................................................
Windshield Washer Motor .............................
Removal .....................................................
Installation ..................................................
Windshield Washer Spray Pattern ................
Windshield Wiper Linkage.............................
Windshield Wiper Linkage and
Removal .....................................................
Installation ..................................................
Windshield Wiper Arm/Blade ........................
Removal .....................................................
Installation ..................................................
Windshield Wiper Blade Rubber ...................
Removal .....................................................
Installation ..................................................
Rear Wiper/Washer System..........................
Rear Wiper and Washer Switch ....................
Removal .....................................................
Installation ..................................................
Rear Wiper Motor (4Door Model) ..................
8B - 1
8B - 2
8B - 2
8B - 2
8B - 2
8B - 2
8B - 2
8B - 2
8B - 3
8B - 3
8B - 3
8B - 4
8B - 5
8B - 5
8B - 5
8B - 5
8B - 6
8B - 6
8B - 6
8B - 7
8B - 7
8B - 7
8B - 8
8B - 8
8B - 8
8B - 8
8B - 8
8B - 9
Service Precaution
REPAIRS.
Removal......................................................
Installation...................................................
Rear Wiper Motor (2Door Model) ..................
Removal......................................................
Installation...................................................
Rear Washer Motor .......................................
Removal......................................................
Installation...................................................
Alarm and Relay Control Unit........................
Removal......................................................
Installation...................................................
Rear Wiper Arm/Blade (4Door Model) ..........
Removal......................................................
Installation...................................................
Rear Wiper Arm/Blade (2Door Model) ..........
Removal......................................................
Installation...................................................
Rear Washer Nozzle (4Door Model) .............
Removal......................................................
Installation...................................................
Rear Washer Spray Pattern........................
Rear Washer Nozzle (2Door Model) .............
Removal......................................................
Installation...................................................
Rear Washer Spray Pattern........................
Rear Wiper Blade Rubber .............................
Removal......................................................
Installation...................................................
8B - 9
8B - 9
8B - 10
8B - 10
8B - 10
8B - 11
8B - 11
8B - 11
8B - 11
8B - 11
8B - 11
8B - 12
8B - 12
8B - 12
8B - 12
8B - 12
8B - 12
8B - 13
8B - 13
8B - 13
8B - 13
8B - 14
8B - 14
8B - 14
8B - 14
8B - 15
8B - 15
8B - 15
8B - 16

and systems.
8B2
WIPER/WASHER SYSTEM
Windshield Wiper/Washer System

General Description
The circuit consists of the starter switch, windshield
wiper & washer switch, windshield wiper motor,
windshield washer motor and alarm & relay control unit.
When the windshield wiper & washer switch is turned on
with the starter switch on, the battery voltage is applied

to the wiper motor to activate the wiper.
The washer motor squirts glass cleaning fluid while the
washer switch is being pushed. The alarm & relay
control unit relay is used to control motion of the wiper.
Windshield Wiper And Washer Switch

Windshield Wiper Motor

Removal
2. Disconnect the connector (2).
3. Remove 4 mounting bolts (3).
4. Remove the windshield wiper motor(1).
880RX011
Installation
880RW002
5. Remove the crank arm fixing ball (4).
WIPER/WASHER SYSTEM
8B3
Windshield Washer Motor

Removal
Installation

2. Remove the fender inner liner (right side).
3. Disconnect the windshield washer motor connector
and the rear washer motor connector.
4. Disconnect the windshield washer hose connector
and the rear washer hose connector.
5. Remove the filler neck (2).
Remove the bolt.
6. Remove the washer tank (1).
Remove the three nuts.
7. Pull out the windshield washer motor (4) from the
washer tank.
880RW028
8B4
WIPER/WASHER SYSTEM
Windshield Washer Spray Pattern
880RW024
Legend
(1) Spray Target
(2) Washer Nozzle
EndOFCallout
WIPER/WASHER SYSTEM
8B5
Windshield Wiper Linkage

Windshield Wiper Linkage and Associated Parts
880RW026-1
Legend
(1) Windshield Wiper Arm/Blade
(2) Vent Cowl Cover
(3) Windshield Wiper Linkage Assembly
(4) Windshield Wiper Motor

(5) Windshield Wiper Arm Nut
EndOFCallout
Removal
2. Remove the windshield wiper arm/blade.
3. Remove the vent cowl cover.
4. Remove the windshield wiper motor.
5. Remove the pivot assembly mounting nuts, fixing
screws.
6. Take out the windshield wiper linkage assembly
from the opening of the cowl.
Installation
8B6
WIPER/WASHER SYSTEM
Windshield Wiper Arm/Blade

Removal
Installation
1. Dry the cap(2) off with the tip of a screwdriver.

2. Remove the nut.
3. Remove the wiper arm/blade(1).

880RW027
880RW023
1. Before installing the wiper arm/blade to the shaft,

confirm that the motor stops at the autostop
position.
2. Set the wiper arm/blade so that the tips of both
blades are positioned about 40mm (1.57in) from
the upper edge of the cowl cover as shown in the
figure.
3. Tighten the nuts to the specified torque.
WIPER/WASHER SYSTEM
8B7
Windshield Wiper Blade Rubber

Removal
Installation
1. Push the wiper blade lock(1) while pulling the wiper

blade in the arrow direction as shown in the figure.
CAUTION: When the wiper blade has been
removed, wrap the tip of the wiper arm with cloth, to
avoid damaging the glass.
880RS011
2. Pull the end of rubber and remove the projection(3)

from the click of the blade stay (2).
880RS010
3. Pull the rubber out in the same direction.

1. Install the click of the blade stay in the groove of the
new rubber and slide it in. Complete wiper blade
installation by pushing the click.
885RS002
2. Finally, check that the click of the stay has caught in

the hole of the rubber.
885RS001
8B8
WIPER/WASHER SYSTEM
Rear Wiper/Washer System

General Description
The circuit consists of the starter switch, rear wiper &
washer switch, rear wiper motor, rear washer motor and
Alarm & relay control unit.
When the rear wiper & washer switch is turned on with
the starter switch on, the battery voltage is applied to

the wiper motor to activate the wiper.
The washer motor squirts glass cleaning fluid while the
washer switch is being pushed. The alarm & relay
control unit is used to control motion of the wiper.
Rear Wiper and Washer Switch

Removal
2. Remove the dash side trim panel(1).
3. Remove the lower cover assembly(2).
Refer to Instrument panel Assembly in Body
Structure section.
825RW285
Installation
1. Push the switch with your fingers until it locks
securely.
821RW293-1
4. Remove the meter cluster assembly(3).

5. Remove the rear wiper & washer switch (4).
cluster assembly.
WIPER/WASHER SYSTEM
8B9
Rear Wiper Motor (4Door Model)

Removal
Installation

2. Remove the tailgate trim pad.
3. Remove the wiper arm/blade.
Refer to Rear Wiper Arm/Blade in section.
4. Remove the rear wiper motor (1).
Remove the motor shaft nut (2).
Remove the rear wiper motor fixing screws.

1. Before installing the wiper arm/blade to the motor
shaft, confirm that the motor stops at the autostop
position.
2. Install the wiper arm/blade so that the wiper arm (5)
contact with the stopper portion (6) on the hatch
gate cover (3) as shown in the figure.
885RW001-1
885RW005-1
3. Tighten the motor shaft nut (2) to the specified

torque.
4. Tighten the wiper arm nut (4) to the specified
torque.
8B10
WIPER/WASHER SYSTEM
Rear Wiper Motor (2Door Model)

Removal
Installation

2. Remove the tailgate trim pad.
3. Remove the wiper arm/blade.
Refer to Rear Wiper Arm/Blade in section.
4. Remove the rear wiper motor (1).
Remove the rear wiper shaft nut and the rear
wiper motor fixing screws.

1. Before installing the wiper arm/blade to the motor
shaft, confirm that the motor stops at the autostop
position.
2. Install the wiper arm/blade (4) on the hatch gate as
Wiper blade is set on defogger line (5).
885RX004-1
885RW001-1
3. Tighten the motor shaft nut (2) to the specified

torque.
Torque: 6Nm (0.6kgm/52 lbin)
4. Tighten the wiper arm nut (3) to the specified
torque.
Torque: 9Nm (0.9kgm/78 lbin)
WIPER/WASHER SYSTEM
8B11
Rear Washer Motor

Removal
2. Remove the fender inner liner (right side).
and the rear washer motor connector.
4. Disconnect the windshield washer hose connector
and the rear washer hose connector.
5. Remove the filler neck (2).
Remove the bolt.
6. Remove the washer tank (1).
Remove the three nuts.
7. Pull out the rear washer motor (3) from the washer
tank.
880RW028
Installation
Alarm and Relay Control Unit

Removal
Installation

2. Remove the instrument panel (1).
3. Remove the alarm and relay control unit (2).
Remove the fixing screw and disconnect the
connector.
826RW039
8B12
WIPER/WASHER SYSTEM
Rear Wiper Arm/Blade (4Door Model)

Removal
Installation
1. Remove the arm nut(2).

Refer to Rear Wiper Motor (4door Model) in this section.
885RW007
Rear Wiper Arm/Blade (2Door Model)

Removal
Installation
1. Remove the arm nut(2).

Refer to Rear Wiper Motor (2door Model) in this section.
885RX003
WIPER/WASHER SYSTEM
8B13
Rear Washer Nozzle (4Door Model)

Removal
Rear Washer Spray Pattern
1. Remove the washer nozzle(1).

Pull out the washer nozzle from the washer hose
(2).
885RW013
Legend
885RW003
Installation
(1) Washer Nozzle

(2) Spray Target
EndOFCallout
8B14
WIPER/WASHER SYSTEM
Rear Washer Nozzle (2Door Model)

Removal
Rear Washer Spray Pattern
1. Remove the washer nozzle(1).

Pull out the washer nozzle and disconnect the
washer hose.
885RX005
Legend
885RX001
Installation
(1) Washer Nozzle

(2) Spray Target
EndOFCallout
WIPER/WASHER SYSTEM
8B15
Rear Wiper Blade Rubber

Removal
Installation
1. Remove the wiper blade from the wiper arm.

2. Push out the wiper rubber from the wiper blade by
sliding it horizontally while holding down the rubber
on the wiper blade convex (1) side.
1. Install the wiper blade rubber.

Insert the tip of wiper rubber (2) from the opposite
side of removal in the arrow direction.
CAUTION: When the wiper blade has been

removed, wrap the tip of the wiper arm with cloth, to
avoid damaging the glass.
880RX001
Check if the convex part (3) of wiper blade is

installed in the groove of the wiper rubber.
880RW022
880RX002
8B16
WIPER/WASHER SYSTEM

Application
Nm
kgm
LbFt
LbIn
Windshield Wiper Arm Nuts
23
2.3
17
Rear Wiper Motor Shaft Nut (4Door model)
10
1.0
87
Rear Wiper Motor Shaft Nut (2Door model)
0.6
52
Rear Wiper Arm Nut (4Door model)
14
1.4
122
Rear Wiper Arm Nut (2Door model)
0.9
78
SECTION
ENTERTAINMENT
8C1

ENTERTAINMENT
CONTENTS
Cigarette Lighter............................................
Removal .....................................................
Installation ..................................................
Digital Clock ..................................................
Removal .....................................................
Installation ..................................................
Rod Type Antenna ........................................
Removal .....................................................
Installation ..................................................
Radio.............................................................
Removal .....................................................
8C - 1
8C - 2
8C - 2
8C - 2
8C - 2
8C - 2
8C - 2
8C - 3
8C - 3
8C - 3
8C - 3
8C - 4
8C - 4
Service Precaution
REPAIRS.
Installation...................................................
Speaker .........................................................
Front Speaker .............................................
Tweeter Assembly ......................................
Rear Speaker (4Door Model)......................
Rear Speaker (2Door Model)......................
Accessory Socket..........................................
Front Accessory Socket..............................
Rear Accessory Socket ..............................
Horn ..............................................................
Removal......................................................
Installation...................................................
8C - 4
8C - 5
8C - 5
8C - 5
8C - 5
8C - 6
8C - 6
8C - 6
8C - 6
8C - 7
8C - 7
8C - 7

and systems.
8C2
ENTERTAINMENT
Cigarette Lighter
General Description
When the cigarette lighter is pushed in with the starter
switch at either ACC" or ON" position, a circuit is
formed in the cigarette lighter case to heat the lighter
coil.
The cigarette lighter springs back to its original position
after the lighter coil is heated.
Removal
2. Remove the lower cluster assembly (1).
Structure section.
3. Remove the cigarette lighter assembly (2).
Disconnect the connectors.
Remove the socket (3).
826RW004-1
Installation
1. When installing the bezel, align the projected
portion of the socket with the notch of the bezel.
Digital Clock
Removal
2. Remove the dash side trim panel-LH (1).
Structure section.
3. Remove the lower cover assembly (2).
Refer to instrument Panel Assembly in Body
Structure section.
821RW293-1

Refer to instrument Panel Assembly in Body
Structure section.
5. Remove the digital clock (4).
Remove the fixing screw.
ENTERTAINMENT
8C3
Installation
821RW291
Rod Type Antenna

Removal
2. Turn the antenna rod (2) counterclockwise to
remove it.
3. Remove three screws and nine clips to remove the
fender inner liner (4).
4. Disconnect the feeder cable connector at the inside
of the vehicle, remove the housing bracket screw
(1), turn the lock nut counterclockwise to remove it
together with the base mold and then remove the
housing (3).
890RX021
Installation
8C4
ENTERTAINMENT
Radio
Removal
3. Remove the radio (2).

Remove the two fixing screws.
Disconnect the connector (4) and the antenna
cable (3).

Structure section.
890RW085
890RW086
Installation
ENTERTAINMENT
8C5
Speaker
Front Speaker
Removal
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).
635RW009
Installation
Rear Speaker (4Door Model)

Removal
890RX012
Installation
Tweeter Assembly

2. Remove the roof rear lining (1).
Release the locks and clips.
3. Remove the speaker (2).
Remove the four screws.
Removal
2. Remove the front door trim pad (2).
Refer to Front Window Regulator, Glass And
Glass Run in Body Structure section:
3. Remove the tweeter (1).
890RX028
8C6
ENTERTAINMENT
Installation
Rear Speaker (2Door Model)

Removal
2. Pull the grille (1) to release the locks clips and then
remove it.
3. Remove four screws and disconnect the connector
(3) to remove the speaker (2).
890RW048-1
Installation
Accessory Socket
Front Accessory Socket
Rear Accessory Socket
Removal
Removal

3. Remove the front accessory socket (4).
Pull out the front accessory socket from the
socket cover (3).

2. Remove the rear accessory socket (2).
Pull out the front accessory socket from the
socket cover (3).
810RW004
810RW326
Installation
Installation

ENTERTAINMENT
8C7
Horn
Removal
Installation

Refer to Engine Hood and Fender in Body
Structure section.
3. Remove the horn (1).
Remove the horn mounting bolt.
828RX001
SECTION
WIRING SYSTEM
8D1
FRONTERA

WIRING SYSTEM
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . .
Fuse, Fusible Link and Circuit Breaker
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay & Fuse Box (Engine Room) . . . . . . .
Relay & Fuse Box (Instrument panel) . . . .
Fuse Block Circuit . . . . . . . . . . . . . . . . . . . . .
Reference Table of Fuse, Fusible Link and
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . .
Relay Location . . . . . . . . . . . . . . . . . . . . . . . .
Diode Location . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Point . . . . . . . . . . . . . . . . . . . . . . .
Cable Harness Routing . . . . . . . . . . . . . . . . .
Start and Charging . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Headlight and Fog Light . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Light, Tail Light and License
Plate Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Illumination Light . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Light, Hazard Warning Light . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8D2
8D3
8D25
8D25
8D26
8D26
8D27
8D33
8D35
8D37
8D39
8D43
8D46
8D46
8D47
8D49
8D50
8D50
8D51
8D64
8D67
8D77
8D79
8D79
8D80
8D82
8D83
8D87
8D87
8D88
8D90
8D91
8D93
8D93
8D94
8D97
8D98
8D99
8D99
8D100
8D102
8D103
8D105
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Light . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dome Light, Luggage Room Light, Courtesy
Light, Map Light, Seat Belt Switch and
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Door Lock . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Window . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AntiLock Brake System (ABS) . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
A/T Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Windshield Wiper and Washer . . . . . . . . . . . .
8D105
8D106
8D107
8D109
8D111
8D111
8D112
8D113
8D114
8D116
8D116
8D117
8D118
8D119
8D120
8D120
8D121
8D127
8D128
8D129
8D129
8D130
8D133
8D134
8D136
8D136
8D137
8D138
8D139
8D144
8D144
8D145
8D147
8D148
8D152
8D152
8D153
8D155
8D156
8D156
8D157
8D158
8D159
8D2
WIRING SYSTEM
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wiper/Washer . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Defogger/Mirror Defogger . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Cigarette Lighter, Digital Clock and
Accessory Socket . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Door Mirror . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Keyless Entry System . . . . . . . . . . . . . . . . . .
8D159
8D160
8D163
8D164
8D170
8D170
8D171
8D176
8D177
8D181
8D181
8D182
8D187
8D190
8D190
8D191
8D192
8D193
8D193
8D194
8D195
8D196
8D197
8D197
8D198
8D200
8D201
8D203
8D203
8D204
8D208
8D209
Service Precaution
Meter and Warning/Indicator Light . . . . . . . . .

Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/T Shift Indicator . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Heater and Air Conditioning . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Heater and Air Conditioning . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplemental Restraint System (SRS)
Air Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Shift on the Fly System . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Harness Connector Faces . . . . . . . . . . . . . .
8D210
8D210
8D211
8D218
8D219
8D224
8D224
8D225
8D227
8D228
8D228
8D229
8D231
8D232
8D232
8D233
8D239
8D240
8D240
8D241
8D242
8D243
8D244
8D244
8D245
8D246
8D247
8D247
8D249
8D251
8D252

parts and systems.
WIRING SYSTEM
General Description
The chassis electrical system is a 12volt system with a
negative ground polarity.
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
identification.)
The wire size is determined by load capacity and the
length of wire required.
The vehicle harness are: body harness, chassis harness,
engine room harness, instrument harness, transmission
harness, engine ECGI harness, dome light harness, door
harness, rear body harness, tailgate harness, SRS
harness and battery cables.
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.
8D3
Connecting the Battery Cable

Follow the disconnecting procedure in the reverse order.
CAUTION: Clean the battery terminal and apply a
light coat of grease to prevent terminal corrosion.
Disconnecting the Connector
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards
you (1).
Other tang locks are released by pressing them forward
(2).
Determine which type of tang lock is on the connector
being handled.
Firmly grasp both sides (male and female) of the
connector.
Release the tang lock and carefully pull the two halves of
the connector apart.
Notes for Working on Electrical Items

Disconnecting the Battery Cable
1. All switches should be in the OFF position.
2. Disconnect the battery ground cable (2).
3. Disconnect the battery positive cable (1).
CAUTION: It is important that the battery ground
cable be disconnected first. Disconnecting the
battery positive cable first can result in a short
circuit.
D08RW128
Never pull on the wires to separate the connectors. This

will result in wire breakage as shown in the figure.
061RW002
D08RW129
8D4
WIRING SYSTEM
When removing the connector for relay (MR5B type) (3),

unfasten the tang lock of the connector by using a
screwdriver, then pull the relay out as shown in the figure.
D08RW131
Connecting the Connector

Firmly grasp both sides (male and female) of the
connector. Be sure that the connector pins and pin holes
match, Be sure that both sides of the connector are
aligned with each other.
Firmly but carefully push the two sides of the connector
together until a distinct click is heard.
Connector Inspection
Use a circuit tester to check the connector for continuity.
Insert the test probes (1) from the connector wire side.
D08RW132
Never insert the circuit tester test probes (2) into the
connector open end to test the continuity.
Broken or open connector terminals will result.
D08RW133
D08RW130
WIRING SYSTEM
Waterproof Connector Inspection
It is not possible to insert the test probes (2) into the
connector wire side of a waterproof connector.
Use one side of a connector (1) with its wires cut to make
the test. Connect the test connector (3) to the connector
to be tested. Connect the test probes to the cut wires to
check the connector continuity.
8D5
Connector Pin Removal Pin Tang Lock Type

1. Insert a slender shaft (1) into the connector housing
open end (5).
2. Push the tang lock (2) flat (toward the wire (3) side of
the connector.
Pull the wire with pin (4) free from the wire side of the
connector.
D08RW134
D08RW136
Connector Pin Removal Connector Housing Tang

Lock Type
1. Insert a slender shaft (1) into the connector housing
open end (5).
2. Push the tang lock (2) up (in the direction of the arrow
in the illustration).
Pull the wire (3) with pin (4) free from the wire side of
the connector.
Connector Pin Insertion

1. Check that the tang lock (1) is fully up.
2. Insert the pin (3) from the connector wire (2) side.
Push the pin in until the tang lock closes firmly.
3. Gently pull on the wires to make sure that the
connector pin is firmly set in place.
D08RW137
D08RW135
8D6
WIRING SYSTEM
Parts Handling
Be careful when handling electrical parts. They should not
be dropped or thrown, because short circuiting or other
damage may result.
3. Use a grommet or guard tube to protect the wiring

harness from contacting a sharp edge or surface.
D08RW139
D08RW138
4. Position the wiring harness with enough clearance

from the other parts and guard the wiring harness with
a vinyl tube (2) and clips (1) to avoid direct contact.
Cable Harness
1. When installing the parts, be careful not to pinch or
wedge the wiring harness.
2. All electrical connections must be kept clean and
tight.
D08RW141
D08RW139
WIRING SYSTEM
5. The wiring harness between engine and chassis
should be long enough to prevent chafing or damage
due to various vibrations.
8D7
The center the spline clip (1) under the stripped wires
and hold it in place.
D08RW143
D08RW142
Splicing Wire
1. If the harness is taped, remove the tape. To avoid wire
insulation damage, use a sewing seam ripper
(available from sewing supply stores) to cut open the
harness.
If the harness has a black plastic conduit, simply pull
out the desired wire.
D Open the crimping tool to its full width and rest one
handle on a firm flat surface.
D Center the back of the splice clip on the proper anvil
and close the crimping tool to the point where the
back of the splice clip touches the wings of the clip.
D Make sure that the clip and wires are still in the correct
position. Then, apply steady pressure until the
crimping tool closes as shown in the figure.
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 11/2 (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.
D08RW144
8D8
WIRING SYSTEM
Before crimping the ends of the clip (1), be sure that:

D The wires extend beyond the clip in each direction.
D No strands of wire are cut loose, and
D No insulation is caught under the clip.
Crimp the splice again, once on each end.
Does not let the crimping tool (2) extend beyond the edge
of the clip or you may damage or nick the wires as shown
in the figure.
D08RW145
5. Apply 60/40 resin core solder to the opening in the

back of the clip as shown in the figure.
Follow the manufacturers instructions for the solder
equipment you are using.
6. Center and roll the splicing tape.

The tape should cover the entire splice.
Roll on enough tape to duplicate the thickness of the
insulation on the existing wires.
Does not flag the tape. Flagged tape may not provide
enough insulation, and the flagged ends will tangle
with the other wires in the harness as shown in the
figure.
D08RW147
If the wire does not belong in a conduit or other

harness covering, tape the wire again. use a winding
motion to cover the first piece of tape as shown in the
figure.
D08RW148
D08RW146
WIRING SYSTEM
8D9
Symbols and Abbreviations

Symbols
Symbol
Meaning of Symbol
Symbol
Meaning of Symbol
Fuse
Contact wiring
Fusible link
Battery
Fusible link wire
Diode
Switch
Electronic parts
Switch
Resistor
Switch
(Normal close type)
Speaker
8D10
WIRING SYSTEM
Symbol
Meaning of Symbol
Symbol
Meaning of Symbol
Buzzer
Coil (inductor), solenoid,

magnetic valve
Circuit breaker
Relay
Bulb
Connector
Double filament bulb
Light emitting diode
Motor
Reed switch
Variable register Rheostat
Condenser
WIRING SYSTEM
Symbol
Meaning of Symbol
Horn
Vacuum switching valve
8D11
8D12
WIRING SYSTEM
Abbreviations
Abbreviation
A
Meaning of Abbreviation
Abbreviation
Meaning of Abbreviation
Ampere (S)
kW
Kilowatt
ABS
Anti-lock brake system
LH
Left hand
ASM
Assembly
LWB
Long wheel base
AC
Alternating current
M/T
Manual transmission
A/C
Air conditioner
OD
Over drive
ACC
Accessories
OPT
Option
A/T
PCM
Powertrain control module
C/B
Circuit breaker
QOS
Quick on start
CSD
Cold start device
RH
Right hand
DIS
Direct ignition system
RR
Rear
EBCM
Electronic brake control module
SDM
Sensing and diagnostic module
ECGI
Electronic control gasoline injection
SRS
Supplemental restraint system
ECM
Engine control module
ST
ECU
Electronic control unit
STD
Standard
EFE
Early fuel evaporation
SW
Switch
EGR
Exhaust gas recirculation
SWB
Short wheel base
4A/T
4-speed automatic transmission
3A/T
3-speed automatic transmission
4WD
Four-wheel drive
FL
Fusible link
FRT
Front
H/L
Headlight
IC
Integrated circuit
IG
Ignition
V
VSV
W
WOT
W/
W/O
Start
Volt
Vacuum switching valve
Watt (S)
Wide open throttle
With
Without
WIRING SYSTEM
Parts for Electrical Circuit

Wiring Wire color
All wires have colorcoded insulation.
Wires belonging to a systems main harness will have a
single color (1). Wires belonging to a systems subcircuits
will have a colored stripe (2). Striped wires use the
following code to show wire size and colors.
F08RW001
D08RW150
8D13
Wiring Wire Color Coding

Abbreviations are used to indicate wire color within a
circuit diagram.
Refer to the following table.
Colorcoding
Meaning
Black
White
Red
Green
Yellow
Blue
Orange
BR
Brown
LG
Light green
GR
Grey
Pink
LB
Light blue
Violet
8D14
WIRING SYSTEM
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, shown below, are specified by AWG
(American Wire Gauge) (Nominal size means
approximate cross sectional area (1).)
D08RW151
Wiring Wire Size Table

Nominal size
Cross sectional area

(mm@)
Outside diameter
(mm)
Allowable current (A)
AWG size
(cross reference)
0.3
0.372
1.5
22
0.5
0.563
1.7
12
20
0.85
0.885
1.9
16
18
1.25
1.287
2.2
21
16
2.091
2.7
28
14
3.296
3.6
37.5
12
5.227
4.4
53
10
7.952
5.5
67
15
13.36
7.0
75
20
20.61
8.2
97
WIRING SYSTEM
Fuse
Fuses are the most common form of circuit protection
used in vehicle wiring. A fuse is a thin piece of wire or strip
of metal encased in a glass it or plastic housing. It is wired
in series with the circuit in protects. When there is an
overload of current in a circuit, such as a short of a
ground, the metal strip is designed to burn out and
interrupt the flow of current. This prevents a surge of high
current from reaching and damaging other components in
the circuit.
Determine the cause of the overloaded before replacing
the fuse.
The replacement fuse must have the same amperage
specification as the original fuse.
Never replace a blown fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other serious
circuit damage. A blown fuse is easily identified as shown
in the figure.
810RX001
8D15
8D16
WIRING SYSTEM
Fusible Link
The fusible link is primarily used to protect circuits where
high amounts of current flow and where it would not be
practical to use a fuse. For example, the starter circuit.
When a current overload occurs, the fusible link melts
open and interrupts the flow of current so as to prevent the
rest of the wiring harness from burning.
Determine the cause of the overload before replacing the
fusible link. the replacement fusible link must have the
same amperage specification as the original fusible link.
Never replace a blown fusible link with fusible link of a
different amperage specification. Doing so can result in
an electrical fire or other serious circuit damage.
A blown fusible link is easily identified as shown in the
figure.
D08RW154
Fusible Link Specifications

Type
Rating
Case Color
Maximum Circuit Current (A)
Connector
30A
Pink
15
Connector
40A
Green
20
Bolted
50A
Red
25
Bolted/Connector
60A
Yellow
30
Bolted
80A
Black
40
Bolted
100A
Blue
50
WIRING SYSTEM
Circuit Breaker
The circuit breaker is a protective device designed to
open the circuit when a current load is in excess of rated
breaker capacity. If there is a short or other type of
overload condition in the circuit, the excessive current will
open the circuit between the circuit breaker terminals.
The reset knob (1) pops out when the circuit is open. Push
the reset knob in place to restore the circuit after repairing
it.
D08RW155
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.
D08RW156
8D17
8D18
WIRING SYSTEM
Relay Specifications and Configurations
F00RX012
*Relay
contact shown in the wiring diagram indicates

condition before actuation.
WIRING SYSTEM
8D19
Diode Diode Specifications and Configurations

MARK /
COLOR
SHAPE
CONSTRUCTION
CHECKING: THERE SHOULD BE CONTINUITY

IN EITHER A OR B WHEN A CIRCUIT TESTER
IS CONNECTED WITH DIODE TERMINAL
Diode Maximum Rating (Temp. = 77F (25C)

Items
Rating
Peak reverse voltage
400V
Transient peak reverse voltage
500V
Average output current
1.5A
Working ambient temperature
22F176F (30C80C)
Storage temperature
40F212F (40C100C)
Remarks
Temp. = 104F (40C)
8D20
WIRING SYSTEM
D Connector is identified with a connector number (6)
Connector
D The connector pin shape (2) determines whether the
connector is male (3) or female (1).
D08RW161
D08RW159
D The applicable terminal number (7) is shown for each

connector.
D The symbol illustrated in the figure is used as

connector, in the circuit of this section.
D08RW162
D08RW160
Legend
(4) Female Side Connector
(5) Male Side Connector
WIRING SYSTEM
D Connector terminal numbers (10) are clearly shown.
Make side connector (9) terminal numbers are in
sequence from upper right to lower left.
Female side connector (8) terminal numbers are in
sequence from upper left to lower right.
D08RW163
NOTE:
1. For those connectors on which specific terminal
numbers or symbols are shown (such as PCM), the
terminal numbers or symbols are used in the circuit
diagram, irrespective of the above rule.
Refer to the following figure.
8D21
2. The connectors used for relays have their own

terminal number assignment, irrespective of the
above rule.
Refer to the following figure.
Double Lock Type Connector

Doublelock type yellow color connectors are used for
supplemental restraint systemair bag circuit. When
removing the cable harness, disconnect the connector by
unlocking at two places, outside (1) and inside (2). In such
a case, do not pull the cables. Otherwise, cable
disconnection may occur.
When connecting the connector, insert the connector
completely and lock at outside. Imperfect locking may
cause malfunction of SRS system circuit.
D08RW164
F00RX010
8D22
WIRING SYSTEM
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.
D08RWD38
WIRING SYSTEM
8D23
Circuit Diagram
The circuit diagram shows the power supply (1) the load
or loads (2) and the grounding point(s) (3).
D08RX124
8D24
WIRING SYSTEM
Harness Connector Faces

The harness connector faces show each connectors
number (1), configuration (2) and the pin number (3).
F00RX011
WIRING SYSTEM
8D25

Fuse, Fusible Link and Circuit Breaker Location
810RX013
Legend
(1) Relay & Fuse Box (Engine Room)
(2) Relay & Fuse Box (Instrument panel)
8D26
WIRING SYSTEM
Relay & Fuse Box (Instrument panel)
Fuse
No.
Capacity
F-1
15A
F-2
10A
F-3
F-4
20A
F-5
10A
F-6
F-7
F-8
10A
F-9
Fuse
Indication on label
No.
Capacity
HAZARD
C-1
20A
ACC. SOCKET
HORN
C-2
10A
(AUDIO)
C-3
15A
CIGAR LIGHTER
BLOWER
C-4
15A
TAIL/ILLUMI. LIGHT
A/C
C-5
10A
DOME LIGHT
C-6
15A
STOP LIGHT
C-7
20A
(POWER DOOR LOCK)
H/L LIGHT-LH
C-8
10A
(MIRROR DEFOG)
10A
H/L LIGHT-RH
C-9
15A
(REAR DEFOG)
F-10
15A
FOG LIGHT
C-10
15A
(REAR DEFOG)
F-11
20A
O2 SENSOR
C-11
15A
METER
F-12
20A
FUEL PUMP
C-12
15A
ENGINE IG.
F-13
15A
ECM
C-13
15A
IG. COIL
F-14
C-14
15A
BACK UP/TURN LIGHT
FL-1
60A
ABS
C-15
15A
ELEC. IG.
FL-2
30A
(COND.FAN)
C-16
20A
FRONT WIPER & WASHER
FL-3
C-17
10A
(REAR WIPER & WASHER)
FL-4
100A
MAIN
C-18
FL-5
60A
IGN.
C-19
15A
(AUDIO)
FL-6
30A
ELEC. FAN
C-20
10A
STARTER
C-21
30A
(POWER WINDOW)
C-22
10A
SRS
C-23
Indication on label
WIRING SYSTEM
8D27
Fuse Block Circuit1 (6VD1)
D08RX278
8D28
WIRING SYSTEM
Fuse Block Circuit1 (X22SE)
D08RX279
WIRING SYSTEM
8D29
Fuse Block Circuit2 (6VD1)
D08RX280
8D30
WIRING SYSTEM
Fuse Block Circuit2 (X22SE)
D08RX281
WIRING SYSTEM
8D31
Fuse Block Circuit3
D08RX282
8D32
WIRING SYSTEM
Fuse Block Circuit4
D08RX283
WIRING SYSTEM
8D33
Reference Table of Fuse, Fusible Link and Circuit Breaker

Fuse (Relay and Fuse Box Engine Room)
Fuse No.
Capacity
Indication on label
Parts (Load)
F-1
15A
HAZARD
F-2
10A
HORN
F-4
20A
BLOWER
F-5
10A
A/C
F-8
10A
H/L LIGHT - LH
Headlight - LH, High beam indicator light, Fog light relay
F-9
10A
H/L LIGHT - RH
Headlight - RH
F-10
15A
FOG LIGHT
Fog light
F-11
20A
O2SENSOR
Oxygen sensor
F-12
20A
FUEL PUMP
Fuel pump
F-13
15A
ECM
F-14
FL-1
60A
ABS
FL-2
30A
COND.FAN
FL-4
100A
MAIN
FL-5
60A
IGN.
FL-6
30A
ELEC. FAN
Hazard warning light

Alarm & relay control unit, Horn, Anti - theft horn
Blower motor, Blower resistor
A/C thermostat relay, Electronic thermostat,
A/C compressor relay, Magnetic clutch
Engine control module
EHCU
(6VD1) Condenser fan unit
(X22SE) Electric fan relay, Electric fan
Fuse (Relay & Fuse Box Instrument Panel)

Fuse No.
Capacity
Indication on label
C-1
20A
ACC. SOCKET
C-2
10A
(AUDIO)
C-3
15A
CIGAR LIGHTER
C-4
15A
TAIL/ILLUMI. LIGHT
C-5
10A
DOME LIGHT
Stop light, Dome light, Courtesy light - LH, Courtesy light

- RH, Courtesy light RR - LH, Courtesy light RR - RH,
Luggage room light, Alarm & relay control unit, Digital
clock, Audio
C-6
15A
STOP LIGHT
Stop light switch, Rear combination light - LH, Rear

combination light - RH, High mounted stop light
C-7
20A
(POWER DOOR
LOCK)
C-8
10A
(MIRROR DEFOG)
Mirror defogger
C-9
15A
(REAR DEFOG)
Rear defogger
C-10
15A
(REAR DEFOG)
Rear defogger
C-11
15A
METER
C-12
15A
ENGINE IG.
Parts (Load)
Acc socket relay, Acc socket
Audio
Cigarette Lighter
Tail relay, Parking light & Side marker light, Tail light
License plate light, Illumination controller, Illumination
light, A/T shift indicator control unit
FRT door lock & Power window SW, Door lock actuator,
Anti- theft indicator light
Indicator and warning lights (meter), Meter gauge,

Vehicle speed sensor
Generator, ECM main relay, VSV; purge solenoid, Coil
drive, PCM, EGR valve
8D34
WIRING SYSTEM
Fuse (Relay & Fuse Box Instrument Panel)

Fuse No.
Capacity
Indication on label
C-13
15A
IG. COIL
C-14
15A
BACKUP/TURN
LIGHT
C-15
15A
ELEC. IG.
C-16
20A
FRONT WIPER &

WASHER
Windshield wiper motor, Windshield washer motor,

Alarm & relay control unit
C-17
10A
(REAR WIPER &

WASHER
Rear wiper motor, Rear washer motor, Alarm & relay &
control unit
C-19
15A
(AUDIO)
C-20
10A
STARTER
C-22
10A
SRS
Parts (Load)
Ignition coil
Mode SW, PCM, Turn signal light, Backup light, Cruise
control unit, A/T shift indicator control unit
Alarm & relay control unit, Rear defogger relay, Mirror
defogger - LH, Mirror defogger - RH, Rear defogger SW,
Power window relay, Cruise control unit, Shift lock relay,
4WD control unit, VSV; FRT axle (c), VSV; FRT axle (d)
Audio
Starter, Starter relay, Anti - theft cotroller
SRS warning light, SDM
PCM: Power train module, VSV: Vacuum switching valve

Fusible Link (Relay and Fuse Box Engine Room)
Fuse Link No.
Capacity
Indication on label
FL-1
60A
ABS
FL-2
30A
COND. FAN
FL-4
100A
MAIN
FL-5
60A
IGN.
FL-6
30A
ELEC. FAN
ABS: Anti - lock Brake System

Circuit Breaker (Relay & Fuse Box Instrument Panel)
Fuse No.
Capacity
Indication on label
Parts (Load)
C-21
30A
(POWER WINDOW)
Power window relay, Power window SW, Power window

motor, Sun roof motor, Sun roof control unit, Sun roof
SW, Safety stop SW, Limit SW, Power seat switch, Front
tilt motor & SW, Rear tilt motor & SW, Slide motor, Recliner moror & SW
WIRING SYSTEM
8D35
Relay Location
810RX014
Legend
(2) Relay & Fuse Box (Instrument panel)

(3) Relay Box (Engine Room)
8D36
WIRING SYSTEM
Relay List
Connector No.
X1
X2
X3
X4
X5
X6
X7
X8
X9
Head
light
Fog
light
Starter
A/C
comp.
Thermo
Heater
Fuel
pump
ECM
COND
FAN
6VD1
X22SE
X10
X15
X16
I34
I35
I36
I37
I38
I39
Elecfan-hi
Elecfanlo
Taillight
Power
window
ACC
socket
Rear defogger
6VD1
X22SE
Usage
Engine
Connector No.
Usage
Engine
WIRING SYSTEM
8D37
Diode Location
810RW3201
Legend
(1) X11
(2) X12
(3) X13
(4) X14
(5)
(6)
(7)
(8)
I51
I45
Relay & Fuse Box (Instrument panel)
8D38
WIRING SYSTEM
Diode List
Connector No.
X11
X12
X13
X14
I51
I45
Brake
Tailgate SW,
Door SW.
Doom light
Alarm &
relay control
unit
6VD1
X22SE
Usage
Engine
WIRING SYSTEM
8D39
Grounding Point
Reference Table
Connector No.
Cable harness
Location
Parts (Load)
B6
Vanity mirror illumination, RR turn signal light - RH, Sun

roof control unit, Sun roof motor, Spot light, Taillight - RH,
Stoplight - RH
B8
Vanity mirror illumination, Rear defogger relay, Rear

defogger SW, FRT door lock & power window SW RH,
Cruise control unit, Digital clock, Cigarette lighter, Mirror
defogger RH, Blower motor, Blower resistor, Electronic
thermostat, A/T shift lock, Flasher unit, Audio
Door lock actuator, FRT power window & door lock SW
LH, RR wiper intermittent relay, Mirror defogger LH,
Seat belt SW, Stoplight LH
Anti theft controller, Heater & A/C relay, Tail relay,
PCM, Headlight, High beam indicator light, Lighting relay,
Fog light relay, Illumination controller, Flasher unit,
Cornering relay, Power window relay, Headlight wiper
motor, Turn signal indicator light, Luggage room light,
Map light, Alarm & relay control unit
Fuel pump, RR door lock & power window SW, Shift lock
controller, Power door mirror motor, Mirror defogger SW,
Seat belt warning light
Fuel tank unit, Fuel warning light.
C16
Engine room
harness
FenderLH
FRT combination light LH, FRT turn signal light LH,

Cornering light LH, Vehicle speed snsor
Windshield washer motor (FRT)
Brake warning light, PCM
Data link connector
FRT combination light RH, Cornering light RH, FRT
turn signal light RH
Fog light, EHCU
Kick down SW
Oxygen sensor, FRT-LH, FRT-RH, RR-LH, RR-RH, 4WD
indicator light, VSV; FRT axle
C36
Engine room
harness
FenderRH
Windshield wiper motor

Engine hood SW
Windshield washer motor, Windshield washer motor
Body harness
E28
BodyCenter
Engine ECGI
harness
Common
chamber
Instrument
harness
Body-FRT
E30
I43
Ignition coil, Coil driver, EGR valve, I.A.T.S., T.P.S.

PCM, ECM main relay, Fuel pump relay, Cam position
sensor
Crank position sensor, Knock sensor, PCM, Mass air flow
sensor, Data link connector
SDM
8D40
WIRING SYSTEM
Location 1
D08RW054
D08RW050
Legend
(1) B6, B7, B8
(3) C36
(4) EHCU
WIRING SYSTEM
8D41
Location 2
Legend
(1) E28
(2) I43
(3) H15
D08RW048
D08RWD07
D08RW052
D08RW053
(4)
(5)
(6)
(7)
P6
Cruise Control Actuator
P7
Frame
8D42
WIRING SYSTEM
Location 3
D08RW051
Legend
(1) P10
(2) Battery
WIRING SYSTEM
8D43
Cable Harness Routing
D08RX275
Legend
(1) Battery () Cable
(2) Battery (+) Cable
(3) H2, H3
(4) Battery Cable Harness
(5) C36
(6) H13, H14, H19, H32
(7) Instrument Harness
(8) H24
(9) RR Door Harness RH
(10) Transmission Harness (X22SE)
(11) L2 (Map Light)
(12) H21
(13) Hatch Galss Harness
(14) Roof Harness
(15) Tair Gate Harness
(16) RR Door Harness LH
(17) Chassis Harness
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
FRT Door Harness LH

H33
H15, H16, H17, H31
C16
B8
Body Harness
Engine Harness
H4, H5, H6
H9, H10, H11 (6VD1)
Transmission Harness (6VD1)
Engine Room Harness
P7
P9
P1
H1
Battery
P5
8D44
WIRING SYSTEM
(2Door Model)
D08RX277
Legend
(1) Engine Room Harness
(2) C36
(4) Body Harness
(5) B11
(6) Hight Mounted Stoplight (G4)
(7) Tailer Connector
(8) H34 (Tail Gate Harness Connector)
(9)
(10)
(11)
(12)
(13)
(14)
B20
H37
Resin Harness
B8
Instrument Harness
Body Harness & Engine Room Harness
Connector
(15) I43
(16) C16
WIRING SYSTEM
8D45
(4Door Model)
D08RX276
Legend
(2) Engine Room Harness & Body Harness
Connector
(3) Relay & Fuse Box (Instrument Panel)
(4) FRT Door Harness RH
(5) H28
(6) Body Harness
(7) H20
(8)
(9)
(10)
(11)
(12)
(13)
(14)
H21
Hatch Glass Harness
Tail Gate Harness
G11
TRAILER Connector
B8
Body Harness & Engine Room Harness
Connector
(15) H33
8D46
WIRING SYSTEM
Start and Charging

General Description
This system consists of starter, AC generator, starter
relay, clutch start SW (M/T), mode SW (A/T) and heater &
A/C relay.
When starter SW is set to ST position with A/T select
lever at P (Parking) or N (Neutral) position (Mode SW
ON), or clutch pedal depressed (Clutch start SW ON),
battery positive voltage is applied to starter solenoid coil
through starter relay to start starter. At the some time,
starter relay cuts off blower motor and A/C circuit.
WIRING SYSTEM
8D47
Circuit Diagram1 (6VD1)
D08RX189
8D48
WIRING SYSTEM
Circuit Diagram1 (X22SE)
D08RX188
WIRING SYSTEM
8D49
Parts Location
D08RX190
Legend
(1) X3
(2) H2, H3
(3) C36
(4) H13
(5) Relay & Fuse Box (C11, C20)
(6) I1
(7) Starter Switch
(8) H16
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
B8
Mode Switch (M16)
H10
P4
P3
P8
P9
H1
Battery
8D50
WIRING SYSTEM

General Description
The Powertrain Control Module (PCM) is located in the
The PCM constantly monitors the information from
various sensors, and controls the systems that affect
vehicle performance.
The PCM performs the diagnostic function of the system.
It can recognize operational problems, alert the driver
through the Malfunction Indicator Light (MIL) and store a
Diagnostic Trouble Code (DTC) or DTC(s) which identify
the problem areas to aid the technician in making repairs.
The PCM is designed to process the various input
informations and then send the necessary electrical
responses to control fuel delivery, spark timing and other
emission control systems. The input information has an
interrelation to more than one output therefore, if the one
input failed, it could affect more than one system
operation.
Refer to Driveability and Emission in Engine Section and
Automatic Transmission in Transmission section.
WIRING SYSTEM
8D51
D08RX158
8D52
WIRING SYSTEM
D08RX159
WIRING SYSTEM
8D53
Circuit Diagram3 (6VD1 M/T)
D08RX176
8D54
WIRING SYSTEM
Circuit Diagram3 (6VD1 A/T)
D08RX160
WIRING SYSTEM
8D55
D08RX161
8D56
WIRING SYSTEM
D08RX162
WIRING SYSTEM
8D57
D08RX163
8D58
WIRING SYSTEM
D08RX164
WIRING SYSTEM
8D59
D08RX165
8D60
WIRING SYSTEM
D08RX166
WIRING SYSTEM
8D61
D08RX167
8D62
WIRING SYSTEM
D08RX168
WIRING SYSTEM
8D63
D08RX169
8D64
WIRING SYSTEM
Parts Location 1 (6VD1)
D08RX170
Legend
(1) Battery
(2) X7, X8
(3) H12, H13, H14, H19, H32
(4) Relay & Fuse Box (I34, I39)
(5) I1
(6) I9
(7) PCM (C1, C2, C3)
(8) F1
(9) H15, H16, H17
(10) C16
(11) H9, H10, H11
(12) B8
(13) C37
(14) E27
(15) E26
(16) E37
(17) E38
(18) E7
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
E39
E25
E24
E20
E34
E35
E30
E8
E14
E13
E33
E5
E43
E42
E41
E40
H4, H5, H6
E6
E12
WIRING SYSTEM
(38) E4
(39) E32
(40) E11
(41) E36
(42) E28
(43) C34
8D65
8D66
WIRING SYSTEM
Parts Location 2 (Transmission control)
D08RX171
Legend
(1) M10
(2) H12, H13, H14, H19, H32
(3) C34
(4) I17
(5) I1
(6) I9
(7) I18
(8) B19
(9) B8
(10) H15, H16, H17
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
M10
M15
M7
M16
M6
M17
M18
H9, H10, H11
E5
C29
B24
WIRING SYSTEM
8D67
D08RX177
8D68
WIRING SYSTEM
D08RX178
WIRING SYSTEM
8D69
D08RX179
8D70
WIRING SYSTEM
D08RX180
WIRING SYSTEM
8D71
D08RX181
8D72
WIRING SYSTEM
D08RX182
WIRING SYSTEM
8D73
D08RX183
8D74
WIRING SYSTEM
D08RX184
WIRING SYSTEM
8D75
D08RX185
8D76
WIRING SYSTEM
D08RX186
WIRING SYSTEM
8D77
Parts Location
D08RX187
Legend
(1) X7, X8
(2) X15, X16
(3) C36
(4) H32
(5) I41, I42
(6) Relay & Fuse Box
(7) C1, C2, C3 (PCM)
(8) C37
(9) H16
(10) F3
(11) F1
(12) E1
(13) E14
(14) E27
(15) E7
(16) E28, E30
(17) E37
(18) E8
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
E5
E6
E12
E33
E25
E11
E26
E32
E43
E9
E4
E3
H6
H5
H4
H25
C16
B8
H9
8D78
WIRING SYSTEM
(38) M13
(39) C11
(40) M10
(41) C35
WIRING SYSTEM
Headlight and Fog Light

General Description
The circuit consists of headlight, fog light, lighting switch,
dimmerpassing switch, fog light switch, high beam
indicator, lighting relay and fog light relay. When starter
switch is turned on by setting it at headlight position,
lighting relay is activated to turn on headlight. Optical axis
of headlight can be turned up or down by operating
dimmer switch while headlight is on. Passing switch is
independent of lighting switch, and optical axis of passing
light can be turned up only while switch lever is pulled up
and held in this state.
When fog light switch is turned on while headlight on at
lowbeam, fog light relay is activated to turn on fog light.
8D79
8D80
WIRING SYSTEM
Circuit Diagram1
D08RX192
WIRING SYSTEM
8D81
Circuit Diagram2
D08RX191
8D82
WIRING SYSTEM
Parts Location
D08RWD001
Legend
(1) X1, X2
(2) C36
(3) H13, H14, H32
(5) I5
(6) I10
(7) Lighting Switch
(8) I32 (Combination Switch)
(9) B8
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
C16
C22
Fog Light LH
C21
Head Light LH
C10
C17
Fog Light RH
Head Light RH
WIRING SYSTEM
8D83
Diagnosis
Both Headlights Inoperative
Step
Action
Go to Step 2
Ground it
securely
Go to Step 2
Replace the
switch
Go to Step 3
Replace the
switch
Go to Step 5
Repair an
open circuit
Approx. 12V
Go to Step 6
Repair an
open circuit
between
battery and
the lighting
relay
Go to Step 7
Go to Step 6
Go to Step 8
Repair an
open circuit
Repair an
open circuit
Check continuity between the lighting switch and the

ground B8.
I32 terminal 2 and the ground?
Check continuity of dimmer-passing switch.

Is there continuity between switch side connector I32
terminal 5 and 4 with the switch turned to low position,
and terminal 1 and 4 with the switch turned to high
position?
Remove the lighting relay from the relay and fuse box.
connector X1 terminal 5 and the ground, X1 terminal
2 and the ground?
Check continuity between the lighting relay and the

lighting switch.
X1 terminal 4 and I32 terminal 9?
Check continuity between the lighting relay and fuse

F8 or F9.
X1 terminal 3 and fuse F8 or F9?
No
Disconnect the combination switch connector I32.

terminals 9 and 2 with the switch turned to headlight
position?
Yes
Check the ground terminal B8.

Is B8 grounded securely?
Value(s)
Check continuity between the dimmer-passing switch

and the ground.
terminal 4 and the ground B8?
Headlight On The Left (or Right) Side Inoperative

Step
1
2
Action
Yes
Is the fuse F8 or F9 normal?

Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
bulb
Approx. 12V
Reconnect
the headlight
connector
securely
Repair an
open circuit
between the
fuse and
headlight
1. Reinstall the bulb.

2. Turn the lighting switch to headlight position.
connector C21 terminal 3 and the ground or C10
terminal 3 and the ground?
No
Remove the headlight bulb on the left or right side.

Is the bulb normal?
3
Value(s)
8D84
WIRING SYSTEM
Headlights In LowBeam Inoperative

Step
Action
Yes

terminal 5 and 4 with the switch at low-beam position?
Value(s)
No
Go to Step 2
Repair or
replace the
switch
Verify repair
Repair an open circuit between connector H-13

terminal 15 and connector I-32 terminal 5.
Headlight In HighBeam Inoperative

Step
Action
Yes

terminal 1 and 4 with the switch at high-beam position?
Value(s)
No
Go to Step 2
Repair or
replace the
switch
Verify repair
Repair an open circuit between connector H13

terminal 14 and connector I32 terminal 1.
Headlights Remain On When Lighting Switch Turned Off

Step
Action
Yes
No
1. Turn the lighting switch to off position.

2. Disconnect the combination switch connector I32.
Do the headlights still remain on?
Value(s)
Go to Step 3
Go to Step 2
Go to Step 1
Replace the
relay
Go to Step 4
Verity repair
Repair or replace the lighting switch.

NOTE: There should be no continuity between switch
side connector I32 terminal 9 and 2.
Remove the lighting relay.

Is there continuity between the relay side connector
X1 terminal 1 and 5?
Repair short circuit between the lighting relay and the

lighting switch.
Headlight Comes On With Lighting Switch At Parking Light Position

Step
Action
Value(s)
Yes
No
Repair or replace the lighting switch.

NOTE: There should be no continuity between switch
side connector I32 terminal 9 and 2 when the switch is
turned to parking light position.
Verify repair
WIRING SYSTEM
8D85
(While Headlight Is On In LowBeam) Both Fog Lights Inoperative

Step
1
2
3
Action
5
6
Go to Step 2
Replace the
fuse(s)
Go to Step 3
Ground it
securely
Approx. 12V
Go to Step 5
Go to Step 4
Is there action complete?
Go to Step 3

X2 terminal 4 and the ground?
Go to Step 7
Go to Step 6
Go to Step 5
Approx. 12V
Replace the
fog light relay
Go to Step 8
Go to Step 9
Repair or
replace the
switch.

I32 terminal 3 and I32 terminal 3?
Go to Step 10
Repair an
open circuit

connector I34 terminal 2, 4 and the ground?
Approx. 12V
Go to Step 12
Go to Step 11
Go to Step 10
Is C36 grounded securely?

Remove the foglight relay.
Repair an open circuit between Fuse F10 connector

X2 terminal 5.
Repair an open circuit between connector X2 terminal

4 and the ground C36.
1. Turn the lighting switch to clearance light position.
2. Turn the fog light switch on.
connector X2 terminal 2 and the ground?
Disconnect the lighting switch connector I32.

Is there continuity between the switch side connector
terminal 2 and 3?
10
11
Disconnect the tail relay.

connector I34 terminal 2 or 4.
12
13
14
No

7
Yes
Are the fuse F10 and C4 normal?

connector X2 terminal 5 and the ground?
4
Value(s)
1. Disconnect the fog light switch.

2. Turn the switch on.
Is there continuity between the switch terminal 3 and 4?
Go to Step 13
Repair or
replace the
switch
Is there continuity between harness side connector I5

terminal 4 and connector I34 terminal 1?
Go to Step 14
Repair an
open circuit

terminal 3 and connector X2 terminal 2?
Replace the
tail relay
Repair an
open circuit
8D86
WIRING SYSTEM
(While Headlight Is On In LowBeam) Fog Light On the Left (or Right) Side Inoperative
Step
1
2
3
Action
Yes
Is the fog light bulb on the left or right side normal?
No
Go to Step 2
Replace the
bulb
Go to Step 3
Ground it
Securely
Go to Step 4
Repair an
open circuit
Verify repair
Is C16 or C36 grounder securely?

Disconnect the fog light connector C22 or C17.
Is there continuity between the fog light harness side
connector terminal 2 and the ground?
Value(s)
Repair an open circuit between fog light relay

connector X2 terminal 1 and fog light connector
terminal 1.
WIRING SYSTEM
Clearance Light, Tail Light and License Plate Light

General Description
The circuit consists of lighting switch, clearance light, tail
light and license plate light.
All these lights come on when lighting switch is turned on
with the switch to either parking or headlight position.
8D87
8D88
WIRING SYSTEM
Circuit Diagram1
D08RX193
WIRING SYSTEM
8D89
Circuit Diagram2
D08RX194
8D90
WIRING SYSTEM
Parts Location
D08RWD04
Legend
(1) C36
(2) H19, H32
(3) Lighting Switch
(4) I32
(5) B9
(6) Tail Light RH
(7) G8
(8) License Plate Light (Bumper Type)
(9) G3 (Tailgate Type)
(10) G2 (Tailgate Type)
(11) H22
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Tail Light LH
B13
H27
H25
H16
C16
C 49
Clearance Light LH
C20
Clearance Light RH
B6, B8
WIRING SYSTEM
8D91
Diagnosis
Both Tail Lights Inoperative
Step
Action
Value(s)
Yes
No
Repair an open circuit between the tail relay and the

taillights.
Verify repair
Tail Light On The Left (or Right) Side Inoperative

Step
Action
Value(s)
Remove the taillight bulb on the left or right side.

Go to Step 2
Replace the
bulb
Approx. 12V
Go to Step 4
Go to Step 3
Verify repair
Verify repair
Disconnect the taillight connector B9 or B13.

connector B9 or B13 terminal 4 or 3 and the ground?

taillight on the left or right side.
No
Is the bulb normal?

2
Yes
Repair an open circuit between the taillight on the left or

right side and the ground.
Clearance Light Inoperative

Step
Action
Value(s)
Yes
No

taillights.
Verify repair
Clearance Light On The Left (or Right) Side Inoperative

Step
Action
Go to Step 2
Replace the
bulb
Approx. 12V
Go to Step 4
Go to Step 3
Verify repair
Verify repair

clearance light on the left or right side.
No
Disconnect the clearance light connector C49 or

C50.
connector C49, or C50 terminal 4 and the ground?
Yes
Remove the clearance light bulb on the left or right side.

Is the bulb normal?
Value(s)
Repair an open circuit between the clearance light and

the ground?
8D92
WIRING SYSTEM
License Plate Light Inoperative

Step
Action
Do the taillights come on?
Remove the license plate light bulb.

Is the bulb normal?
Go to Step 2
Go to Step 6
Go to Step 3
Replace bulb
Approx. 12V
Go to Step 5
Go to Step 4
Verify repair
Verify repair
Verify repair
Repair an open circuit between the license plate light

and the ground B8.
No

terminal 6 and the license plate light.
Yes
1. Disconnect the license plate light connector G8.

2. Turn the lighting switch on.
connector G8 terminal 1 and the ground?
Value(s)
Refer to the diagnosis procedure for Both Taillight

Inoperative in this section.
WIRING SYSTEM
Interior Illumination Light

General Description
The circuit consists of lighting switch, tail relay, and
illumination lights.
All these lights come on when lighting switch is turned on
with the switch to either parking or headlight position.
8D93
8D94
WIRING SYSTEM
Circuit Diagram1
D08RX195
WIRING SYSTEM
8D95
Circuit Diagram2
D08RX196
8D96
WIRING SYSTEM
Circuit Diagram3
D08RX197
WIRING SYSTEM
8D97
Parts Location
D08RX198
Legend
(1) H19, H32
(2) I19
(3) I6
(4) I5
(5) Lighting Switch
(6) I2
(7) I9
(8) I27
(9) I16
(10) I17
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
I11
I33
B24
H25
B8
I15
I40
I3
I32
I1
Relay & Fuse Box (I34)
8D98
WIRING SYSTEM
Diagnosis
Interior Illumination Lights Inoperative
Step
Action
No
Go to Step 3
Go to Step 2
Verify repair
Verify repair
Refer to the diagnosis procedure in Clearance Light,

Taillight and License Plate Light section.
Yes
Turn the light switch to clearance light position.

Do the exterior light come on?
Value(s)
Repair an open circuit between tail relay harness side

connector I34 terminal 1 and interior lights.
WIRING SYSTEM
Turn Signal Light, Hazard Warning Light

General Description
The circuit consists of turn signal/light switch
(combination switch) turn signal light, hazard warning
switch and flasher unit. When turn signal light switch is
turned on with starter switch on, turn signal light will
operate. When turn signal light is flashing, indicator light
in meter also starts flashing. When hazard warning switch
is turned on, current flows to flasher unit through hazard
warning switch to cause hazard warning light to flash
independent of position of starter switch. At the same
time, indicator lights in meter also start flashing.
8D99
8D100
WIRING SYSTEM
Circuit Diagram1
D08RX199
WIRING SYSTEM
8D101
Circuit Diagram2
D08RX200
8D102
WIRING SYSTEM
Parts Location
D08RX201
Legend
(1) C40
(2) C36
(3) H14, H19, H32
(5) Turn Signal light Switch
(6) I32, I47
(7) H 23 (2Door Model)
(8) B9
(9) Rear Turn Signallight RH
(10) I11
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
C16
Rear Turn Signallight LH
B13
H23 (4Door Model)
C 43
C23
Front Turn Signallight LH
B 8
C18
Front Turn Signallight RH
WIRING SYSTEM
8D103
Diagnosis
Turn Signal Light Does Not Flash
Step
Action
Value(s)
Is fuse C14 normal?
Replace the
fuse
Go to Step 3
Replace or
replace the
switch
Approx. 12V
Go to Step 5
Go to Step 4
Go to Step 3
Approx. 12V
Go to Step 7
Go to Step 6
Go to Step 5

I-47 terminal 2 and the ground B8?
Go to Step 9
Go to Step 8
Go to Step 7
1. Turn the hazard warning switch off.

2. Disconnect the switch connector I11.
terminal 5 and 10?

connector I11 terminal 5 and the ground?
Repair an open circuit between the fuse C14 and the

hazard warning switch.
1. Reconnect the connector I11 with the hazard

warning switch.
2. Disconnect the flasher unit connector I47.
connector I-47 terminal 3 and the ground?
7
8
Repair an open circuit between connector I11 terminal

10 and connector I47 terminal 3.
Repair an open circuit between connector I47

terminal 2 and the ground B8.
10
11
1. Reconnect the flasher unit connector I47.

2. Disconnect the turn signal light switch connector
I32.
Is there continuity between switch side connector
terminal 6 and 7 with the switch turned to the left
position, and terminal 6 and 8 with the switch turned to
the right position?
Go to Step 10
Repair or
replace the
switch

I47 terminal 1 and harness side connector I32
terminal 6?
Go to Step 12
Go to Step 11
Verify repair
Verify repair

terminal 1 and connector I32 terminal 6.
12
No
Go to Step 2
Yes
Replace the flasher unit.

8D104
WIRING SYSTEM
Turn Signal Light Flashes Too Quickly

Step
Action
Do all of turn signal lights flash?
Replace the flasher unit.
3
4
Value(s)
Yes
No
Go to Step 2
Go to Step 3
Verify repair
Is the bulb of turn signal light that does not work

normal?
Go to Step 4
Replace the
bulb
Verify repair
Repair an open circuit between the turn signal light

switch and the turn signal light.
WIRING SYSTEM
Stoplight
General Description
The circuit consists of stoplight, high mounted stoplight
and stoplight switch.
With brake pedal depressed, stoplight switch is turned to
on to illuminate stoplight.
Stoplight switch controls not only the operation of
stoplight but also the input of cruise cancel signals to
cruise control unit.
8D105
8D106
WIRING SYSTEM
Circuit Diagram
D08RX202
WIRING SYSTEM
8D107
Parts Location (2Door Model)
D08RX203
Legend
(1) H19
(3) I18
(4) B9
(5) Stoplight RH
(6) G4
(7)
(8)
(9)
(10)
(11)
(12)

H37
Stoplight LH
B13
B8
B6
8D108
WIRING SYSTEM
D08RX203
Legend
(1) H19
(3) I18
(4) B9
(5) Stoplight RH
(6) H21
(7)
(8)
(9)
(10)
(11)
(12)
G10, G11
Stoplight LH
B13
B8
B6
WIRING SYSTEM
8D109
Diagnosis
Both Stoplights Inoperative
Step
Action
Value(s)
3
4
No
Go to Step 2
Replace the
fuse
Dieconnect the stoplight switch connector I18.

Is there continuity between connector I18 terminal 1
and 4 with the brake pedal depressed?
Go to Step 3
Replace or
replace the
switch

Approx. 12V
Go to Step 5
Go to Step 4
Verify repair
Verify repair

connector I18 terminal 1.
Yes
Repair an open circuit between stoplight switch and the

stoplight.
Stoplight On The Left (or Right) Side Inoperative

Step
Action
No
Approc. 12V
Go to Step 2
Go to Step 3
Verify repair
Verify repair
Repair an open circuit between the stoplight and the

ground.
Yes
1. Disconnect the stoplight connector B9 or B13.

2. Depress the brake pedal.
Is the battery voltage applied between stoplight
harness side connector terminal 2 and the ground?
Value(s)
Repair an open circuit between the stoplight switch and

the stoplight.
8D110
WIRING SYSTEM
High Mounted Stoplight Inoperative

Step
Action
Go to Step 3
Go to Step 2
Verify repair
Go to Step 4
Ground it
securely
Go to Step 6
Go to Step 5
Go to Step 4
Go to Step 7
Repair or
replace the
light
Verify repair
1. Disconnect the high mounted stoplight connector.
2. Depress the brake pedal.
connector G11 terminal 1 or connector G4 terminal 2
Appprox. 12V
and the ground?

terminal 10 and the high mounted stoplight.
No
Refer to the diagnosis procedure for Both Stoplights

inoperative in this section.
Yes
Depress the brake pedal.

Do the stoplight come on?
Value(s)
Is there continuity between high mounted stoplight side

connector terminals?
Repair an open circuit between the high mounted
stoplight and the ground B6.
WIRING SYSTEM
Backup Light
General Description
The circuit consists of backup light switch (M/T), mode
switch (A/T) and backup light.
When shift lever is set to R position, backup light switch
(M/T) or mode switch (A/T) is activated to illuminate
backup light.
8D111
8D112
WIRING SYSTEM
Circuit Diagram
D08RX204
WIRING SYSTEM
8D113
Parts Location
D08RWD19
Legend
(1) B9
(2) Backup Light RH
(3) Backup Light LH
(4) B13
(5) H15, H16
(6) B8
(7)
(8)
(9)
(10)
(11)
(12)
B6
H9, H10, (6VD1 M/T)
M8, M9 (X22SE)
H10, (6VD1 A/T)
M16
Relay & Fuse Box
8D114
WIRING SYSTEM
Diagnosis
Both Backup Lights Inoperative
Step
1
2
3
Action
Go to Step 2
Replace the
fuse
Go to Step 3
Ground then
securely
Approx. 12V
Go to Step 5
Go to Step 4
Go to Step 3
Go to Step 6
Repair or
replace the
switch
Approx. 12V
Go to Step 8
Go to Step 7
Verify repair
Verify repair
Are B6 and B8 ground securely?

1. Disconnect the mode switch connector M16 or
backup light switch connector M8 and M9.
2. Turn the starter switch on.

connector M16 terminal 5 or connector M8 terminal
1.
Set the transmission gear to the reverse position.
Is there continuity between mode switch side
connector terminal 2 and 5, or backup light switch side
connector terminals?
1. Reconnect the mode switch connector M16 or

backup light switch connector M8 and M9.
2. Disconnect the backup light connector B9 or B13.
Is the battery voltage applied between the backup light
harness side connector terminal 5 and the ground?
Repair an open circuit between the mode switch or

backup light switch and the backup lights.
No

5
Yes

connector M-16 terminal 5 and the ground, or harness
side connector M8 terminal 1 and the ground?
4
Value(s)
Repair an open circuit between backup lights and the

ground.
Backup Light On The Left (or Right) Side Inoperative

Step
Action
Go to Step 2
Replace the
bulb
Approx. 12V
Go to Step 4
Go to Step 3
Verify repair
Verify repair

terminal 12 and the backup light on the left or right side.
No
1. Set the transmission gear to the reverse position.

Is the battery voltage applied between backup light
harness side connector B9 or B13 terminal 5 and the
ground?
Yes
Remove the backup light bulb on the left or right side.

Is the bulb normal?
Value(s)
Repair an open circuit between the backup light on the

left or right side and the ground.
WIRING SYSTEM
8D115
Backup Lights Remain On

Step
Action
Value(s)
Yes
No
Repair or replace the mode switch or the backup light

switch.
Verify repair
8D116
WIRING SYSTEM
Horn
General Description
The circuit consists of horn (high note), horn (low note),
horn relay (alarm & relay control unit) and horn switch.
When horn switch is pushed, (independent of position of
starter switch) horn relay is activated to sound horns.
WIRING SYSTEM
8D117
Circuit Diagram
D08RX205
8D118
WIRING SYSTEM
Parts Location
D08RWD18
Legend
(1) H14
(2) SRS Coil ASM
(3) Horn Switch
(4) I41, I42
(5)
(6)
(7)
(8)
(9)
I32
Horn (Low note)
C14
C12
Horn (High note)
WIRING SYSTEM
8D119
Diagnosis
Horn Do Not Sound
Step
1
2
Action
Go to Step 2
Replace the
fuse
Approx. 12V
Go to Step 4
Go to Step 3
Verify repair
Go to Step 6
Go to Step 5
Verify repair
Go to Step 7
Repair or
replace the
switch
Does the horn work?
Go to Step 8
Replace the
horn

terminal between the horn and the alarm & relay control
unit?
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Disconnect the alarm & relay control unit connector

I41 and I42.
Repair an open circuit between the fuse F2 and the

alarm & relay control unit.
Disconnect the horn switch connector.
I32 terminal 12 and connector I42 terminal 20, 23 or
14?
Repair an open circuit between the alarm & relay

control unit and the horn switch.
Press the horn switch.

terminal 12 and the ground?
1. Disconnect the horn connector.

2. Connect the battery positive terminal to the horn
side connector terminal 1.
Replace the alarm & relay control unit.

10
No

4
Yes

connector I41 terminal 2 or 3 (6VD1), connector I42
terminal 12 (X22SE) and the ground?
3
Value(s)
Repair an open circuit between the horn and the alarm

& relay control unit.
Horn Do Not Stop Sounding

Step
Action
Disconnect the horn switch connector I32.

Do the horn stop sounding?
Value(s)
Yes
Repair or
replace the
horn switch
Go to Step 2
Repair short
circuit
Replace the
alarm & relay
control unit

I42.
terminal 20 (23 or 14) and the ground?
No
8D120
WIRING SYSTEM
Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat
Belt Switch and Warning Buzzer
General Description
The circuit consists of door switch, dome light, luggage
room light, courtesy light, map light tail relay, key cylinder
switch and alarm & relay control unit.
Dome light comes on with dome light switch turned to
door position and any door open.
The buzzer sounds when starter switch is turned to either
ACC or OFF position and FRT doorRH, is opened
with lighting switch on.
The buzzer also sounds when FRT doorRH is opened
with starter key left in starter switch key cylinder.
These functions are controlled by alarm & relay control
unit.
WIRING SYSTEM
8D121
D08RX208
8D122
WIRING SYSTEM
D08RX210
WIRING SYSTEM
8D123
D08RX206
8D124
WIRING SYSTEM
D08RX209
WIRING SYSTEM
8D125
D08RX211
8D126
WIRING SYSTEM
D08RX207
WIRING SYSTEM
8D127
Parts Location
D08RWD17
Legend
(2) FRT Door SWRH
(3) B1
(4) D24
(5) RR CourtesyLightRH
(6) B21
(7) RR Door SWRH
(8) Map Light
(9) L2
(10) Dome Light
(11) L3
(12) B11 (4Door Model)
(13) Luggage Room Light
(14) G13 (2Door Model)
(15) G1
(16) H37
(17) Tailgate Switch
(18) B20
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
H22
RR Door SWLH
B16
RR CourtesyLightLH
H29
FRT Door SWLH
H30
FRT CourtesyLightLH
D18
H33
I26
I41, I42
B8
H24
FRT CourtesyLightRH
D7
H28
I46
H19, H32
8D128
WIRING SYSTEM
Diagnosis
Dome Light Inoperative
Step
Action
3
4
No
Go to Step 2
Replace the
bulb
1. Reinstall the bulb.

2. Disconnect the dome light connector L3.
3. Set the dome light switch to door position.
Is there continuity between the dome light side
connector terminal 1 and 3?
Go to Step 3
Repair or
replace the
dome light

connector L3 terminal 3 and the ground?
Approx. 12V
Go to Step 4
Go to Step 5
Verify repair
Verify repair

dome light.
Yes
Remove the dome light bulb.

Is the bulb normal?
Value(s)
Repair an open circuit between the dome light and the

door switch or the tail gate switch.
WIRING SYSTEM
Power Door Lock

General Description
The door lock system consists of door lock switch keyless
entry control unit and door lock actuator. Door lock switch
on drivers side can actuate the door lock mechanism.
Locking or unlocking the lock switch on the driver side
causes the door lock mechanism to be locked or
unlocked.
At this time, the current flows for approx. 1 second from
door lock switch on drivers side to door lock actuator to
run the motor.
When the key is in the key cylinder, Door Lock can not be
done.
8D129
8D130
WIRING SYSTEM
Circuit Diagram1 (4Door Model)
D08RX243
WIRING SYSTEM
8D131
D08RX295
8D132
WIRING SYSTEM
Circuit Diagram2
D08RX242
WIRING SYSTEM
8D133
Parts Location
D08RWD15
Legend
(1) H28
(2) H19, H32
(3) D8
(4) FRT Door Lock ActuatorRH
(5) H24
(6) FRT Door Lock SwitchRH
(7) D6, D5
(8) D23
(9) RR Door Lock ActuatorRH
(10) I26
(11) FRT Door Lock ActuatorLH
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
D14
RR Door Lock ActuatorLH
B 30
D28
H29
D17
FRT Door Lock SwitchLH
H33
B8
H34, H22 (2Door Model)
G7
8D134
WIRING SYSTEM
Diagnosis
All The Doors Do Not Lock And Unlock By Door Lock SWRH
Step
1
2
Action
Go to Step 2
Replace the
fuse
Approx. 12V
Go to Step 4
Go to Step 3
Verify repair
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Disconnect the FRT door lock actuatorRH connector

D8.
Replace the FRT power window & door lock SWRH.


switch.

D5 terminal 10 and connector D8 terminal 1 (or
connector D5 terminal 12 and connector D8 terminal
2)?
5
No
Disconnect the front power window & door lock

SWRH connector D5.

4
Yes

connector D5 terminal 11 and the ground?
3
Value(s)
Repair an open circuit between the FRT power window

& door lock SWRH and door lock actuator.
All The Doors Do Not Lock and Unlock by FRT Door Lock SWLH
Step
Action
No
Go to Step 2
Go to Step 3
Verify repair
Verify repair
Replace the FRT power window & door lock SWLH.

Yes
Disconnect the FRT power window & door lock

SWRH and LH connector D5 and D17.
D5 terminal 13 and connector D17 terminal 6 (or
connector D5 terminal 14 and connector D17
terminal 7)?
Value(s)
Repair an open circuit between the FRT power window

& door lock SWRH and LH.
WIRING SYSTEM
8D135
All the Doors Do Not Not Lock and Unlock by Door Lock Key SW
Step
1
2
Action
No
Go to Step 2
Ground it
securely
Go to Step 4
Go to Step 3
Verify repair
Go to Step 5
Repair or
replace the
switch
Verify repair
Disconnect the door lock key SW connector D6.
Repair an open circuit between connector D6 terminal

2 and the ground B8.
Yes

D6 terminal 2 and the ground?
3
Value(s)

terminal 1 and 2 when the switch is turned to lock
position, and terminal 2 and 3 when the switch is turned
to unlock position?
Repair an open circuit between the door lock key SW
and FRT power window & door lock SWRH.
8D136
WIRING SYSTEM
Power Window
General Description
The power window system consists of power window
switches, power window motors and power window relay.
With the starter switch in ON position, the battery
voltage is supplied through power window relay to the
power window switches Selection of up or down switch
changes over the motor rotating direction to open or close
the window.
When the lock switch on the switch panel on the driver
side is pressed, the power window switch is in open state.
As a result, the power source to the other switches are cut
off, and the power window motors do not run.
WIRING SYSTEM
8D137
Circuit Diagram1
D08RX213
8D138
WIRING SYSTEM
Parts Location
D08RWD14
Legend
(1) H28
(2) D2
(3) H32
(5) Power Window Motor (FRT RH)
(6) Power Window SW (FRT RH)
(7) D5
(8) Power Window Motor (RR RH)
(9) D20
(10) D22
(11) Power Window SW (RR RH)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Power Window SW (FRT LH)

Power Window SW (RR LH)
D27
D25
Power Window Motor (RR LH)
H29
D17
D11
Power Window Motor (FRT LH)
H33
B8
H24
WIRING SYSTEM
8D139
Diagnosis
All Window Do Not Operate
Step
Action
Value(s)
3
4
Replace the
fuse
Go to Step 3
Replace the
circuit
breaker
Go to Step 4
Ground it
securely
Approx. 12V
Go to Step 6
Go to Step 5
Go to Step 4
Approx. 12V
Go to Step 8
Go to Step 7
Go to Step 6

I35 terminal 3 and the ground B8?
Replace the
relay
Go to Step 9
Verify repair
Is the circuit breaker C21 normal?
Disconnect the power window relay connector I35.
Repair an open circuit between the circuit breaker

C21 and connector I35 terminal 2.

connector I-35 terminal 4 and the ground?
8
9
No
Go to Step 2
Yes


8D140
WIRING SYSTEM
Window On The Drivers Side Does Not Operate

Step
Action
Go to Step 3
Go to Step 2
Go to Step 1
Replace the
front power
window &
door lock
switchRH
Go to Step 4
Go to Step 5
Replace the
motor
Verify repair
1. Disconnect the front power window motorRH

connector D2.
2. Connect the battery position terminal with the motor
side connector D2 terminal 1 or 2, and connect the
battery negative terminal with the motor side
connector D2 terminal 2 or 1.
Does the motor operate?
Approx. 12V
Connect the battery position terminal with harness side

connector D5 terminal 3 or 5, and the negative
terminal with harness side connector D5 terminal 5 or
3.
No

terminal 1 and connector D5 terminal 4.
Yes

Value(s)
Repair an open circuit between the front power window

and door lock switchRh and the front power window
motorRH.
WIRING SYSTEM
8D141
Window On The Front Passengers Side Does Not Operate

Step
1
2
Action
Go to Step 4
Go to Step 3
Go to Step 2
Approx. 12V
Go to Step 6
Go to Step 5
Go to Step 4
Replace the
front power
window and
door lock
switchLH
Go to Step 7
Go to Step 8
Replace the
motor
Verify repair
Connector the battery positive terminal with harness

side connector D17 terminal 1 or 4, and connect the
battery negative terminal with harness side connector
D17 terminal 4 or 1.
1. Disconnect the front power window motorRH
connector D11.
2. Connector the battery positive terminal with the
motor side connector D11 terminal 1 or 2, and
connect the battery negative terminal with the motor
side connector D11 terminal 2 or 1.
Ground it
securely

terminal 1 and connector D17 terminal 2.

7
Go to Step 2

6
Repair an open circuit between connector D17


5
No
Disconnect the front power window and door lock

switchLH connector D17.

4
Yes

D17 terminal 3 and the ground B8?
3
Value(s)
Repair an open circuit between the front power window

and door lock switchLH and the front power window
motorLH.
8D142
WIRING SYSTEM
Rear Window On The Left (or Right) Side Does Not Operate
Step
Action
Go to Step 3
Go to Step 2
Go to Step 1

D22 terminal 3 and the ground B6, or harness side
connector D27 terminal 3 and the ground B6 or 8?
Go to Step 5
Go to Step 4
Go to Step 3
Replace the
rear power
window
switchLH or
RH
Go to Step 6
Go to Step 7
Replace the
motor
Verify repair

terminal 1 and connector D22 terminal 4 or connector
D27 terminal 4.
Repair an open circuit between connector D22

terminal 3 or connector D27 terminal 3 and the ground
B6 or 8.
Connect the battery positive terminal with harness side
connector D22 terminals 5 or harness side connector
D27 terminal 5, and connect the battery negative
terminal with harness side connector D22 terminal 6
or harness side connector D27 terminal 6.
1. Disconnect the rear power window motor connector

D20 or D25.
2. Connect the battery positive terminal with motor
side connector D20 or D25 terminal 1 or 2, and
connect the battery negative terminal with the motor
side connector D20 or D25 terminal 2 or 1.
No
Approx. 12V

5
Yes
1. Disconnect the rear power window switchRH

connector D22 or the rear power window and door
lock switchLH connector D27.
connector D22 terminal 4 and the ground, or harness
side connector D27 terminal 4 and the ground?
Value(s)
Repair an open circuit between the rear power window

switch and the rear power window motor.
Window On The Front Passengers Side Does Not Operate by the Front Power Window
and Door Lock SwitchRH
Step
Action
Disconnect the front power window and door lock

switchRH connector D5 and the front power window
and door lock switchLH connector D17.
D5 terminal 8 and harness side connector D17
terminal 5?
Value(s)
Yes
No
Replace the
front power
window and
door lock
switchLH
Go to Step 2
Verify repair
Repair an open circuit between connector D5 terminal

8 and connector D17 terminal 5.
WIRING SYSTEM
8D143
Lock SW Does Not Function

Step
Action
Value(s)
Yes
No
Repair or replace the front power window and door lock

switchRH.
Verify repair
8D144
WIRING SYSTEM
Cruise Control
General Description
Top Up Function
The circuit consists of cruise control unit, cruise main

switch, combination switch clutch switch (M/T), mode
switch (A/T), stoplight switch, actuator and indicator
lights. Cruise control system keeps the vehicle running at
a fix speed until a signal canceling this fixed speed is
received.When the cruise main switch is turned on with
the vehicle in the running mode, the battery voltage is
applied to the control unit.
When a signal from the combination switch is input to the
control unit while vehicle is in this state, the actuator is
activated to operate the system. Also, while the system is
operating, the cruise indicator light in the meter panel
lights up.
During cruise control driving, the set speed can be

increased 1.6 km/h each time by operating the
accelerator switch quickly within 0.6 sec.
Set Function
During cruise control driving, the set speed can be

lowered 1.6 km/h each time by operating the coast switch
quickly within 0.6 sec.
When the cruise main switch turned on and the set switch
is depressed with the vehicle speed within the set limit
and cancel operation is refused the vehicle speed when
the set switch is released is stored in the control unit as
the set speed. But in case of the vehicle speed is over
maximum limit speed of cruise control, maximum limit
speed in the control unit is stored as the set speed.
Resume Function
Unless the vehicle speed falls below the minimum speed
limit after canceling the set speed by the cancel switch,
pushing the resume switch causes the vehicle to resume
the speed before cancellation.
Acceleration Function
During cruise control driving, pushing the acceleration
switch (on time is more than 0.6 sec.) causes an increase
in cruise speed and vehicle accelerates at a controlled
rate until acceleration switch released. Vehicle speed at
the acceleration switch released plus 1.0 km/h is stored in
the control unit as the set speed.
Coast Function
During cruise control driving, pushing the coast switch (on
time is more than 0.6 sec.) causes a decrease in cruise
speed and the vehicle decelerate at a controlled rate until
coast switch released. Vehicle speed at the coast switch
released ,minus 1.0 km/h is stored in the control unit as
the set speed.
Top down Function
Cancel Function
During cruise control driving, the cruise control is
released if the control unit receives a signal from the
cancel switch, mode switch, clutch switch or brake
switch. But the set speed is not erased.
Down Cancel Function

The cruise control is canceled when the vehicle speed
becomes the set speed minus 20 km/h during the cruise
control working and the set speed is erased.
Over Drive (OD) Cancel Function

OD cancel function is required when the vehicle speed
becomes the set speed minus 3 km/h during the cruise
control working. OD cancel function is enabled when the
acceleration function and/or resume function are working
except the vehicle speed is in more than 120 km/h.
WIRING SYSTEM
8D145
Circuit Diagram1
D08RX154
8D146
WIRING SYSTEM
Circuit Diagram2
D08RX155
WIRING SYSTEM
8D147
Parts Location
D08RX156
Legend
(1) C26
(2) H12, H13, H19, H32
(3) Stoplight Switch (I18)
(5) I6
(6) I9
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Clutch Switch (I14)

PCM
Cruise Control Unit (B18)
B8
H15
Mode Switch (M16)
H10, H11
8D148
WIRING SYSTEM
Diagnosis
The cruise control unit uses the cruise main indicator light
and diagnosis the failure, when the control unit detects
abnormality on the table below.
POSSIBLE CAUSE
PART
Actuator
Cruise control unit
Vehicle sspeed
eed sensor
Switch
DETECTION PERIOD
DTC
Motor system short circuit
Energizing motor
1-1
Clutch system open circuit
Energizing clutch
1-2
Clutch system open circuit
Energizing clutch
1-2
Mechanical defect
Cruise controlling
1-3
Close side of motor system open circuit
Cruise controlling
1-1
Open side of motor system continuously

energizing
While starter SW on
1-4
Clutch output abnormality
While starter SW on
1-4
Signal of vehicle speed disconnection
Cruise controlling
2-1
Signal of vehicle speed abnormality
Cruise controlling
2-1
Turning on switch at all times
While starter SW on
3-1
Turning on switch at the same time
While starter SW on
3-1
DTC : Diagnostic Trouble Code
DTC Display Condition

1. While starter switch on and vehicle speed is 0 km/h,
the DTC output begins in top priority by cancel switch
turn on and off being repeated three times for 2 sec.
while cruise main switch pushing on, and stops the
DTC output whether vehicle speed is more than 10
km/h or the resume switch is turned on.
2. The cruise control unit outputs the DTC(s) in order
from small figure of the code.
3. The header of display of DTC(s) is assumed 4 sec.,
and it is 2 sec. between different king of codes.
4. The DTC(s) are erased with the starter switch turned
off.
WIRING SYSTEM
8D149
DTC Display Format

1. When no DTCs are detected. (The unit : sec.)
F08RW003
2. When two or more DTCs are detected. (The unit : sec.)
F08RW004
8D150
WIRING SYSTEM
Diagnosis
DTC 11 Motor System Short Circuit
Step
Action
1. Turn the starter switch off.

2. Disconnect the actuator connector C-26.
3. Measure resistance between actuator
connector terminal 1 and 2.
Value(s)
Yes
No
side
NOTE: If the control plate position is fully opened or

fully closed, resistance can not be measured.
Is the resistance within range specified in the value(s)
column?
2
More than
4.2W
Go to Step 2
Replace the
actuator
No continuity
Replace the
control unit
Repair or
replace the
harness
Measure continuity between harness side connector

C-26 terminal 1 and the ground, terminal 2 and the
ground, and terminals 1 and 2.
Are the result same as specified in the value(s)
column?
DTC 12 Clutch System Open or Short Circuit

Step
Action

Value(s)
Replace the
actuator
Go to Step 3
Adjust or
replace the
switch
Go to Step 4
Repair open
circuit
No continuity
Replace the
control unit
Repair short
circuit
1. Reconnect the stoplight switch connector I-18

2. Check continuity between harness side connector
B-18 terminal 6 and I-18 terminal 3, C-26 terminal 4
and B-18 terminal 8.
Is there continuity between terminals?
Go to Step 2
34.7 42.4W
1. Disconnect the stoplight switch connector I-18.

2. Check continuity between switch side connector
terminal 2 and 3.
No
side

column?
2
Yes
Check continuity between harness side connector

C-26 terminal 3 and ground, C-26 terminal 4 and
ground, B-18 terminals 6 and the ground.
Are the results same as specified in the value(s)
column?
WIRING SYSTEM
8D151
DTC 13 Mechanical Defect

Step
Action
Value(s)

3. Connect the battery positive terminal to the actuator
side connector terminal 3 and the battery negative
terminal to terminal 4.
Does the control plate move by hand?
Replace the
actuator
Go to Step 2
Go to Step 3
Replace the
actuator
Go to Step 4
Replace the
actuator
Replace the
control unit
Repair or
replace
harness
Connect the battery positive terminal to the actuator

side connector terminal 2 and 3, and the battery
negative terminal to terminal 1 and 4.
Does the control plate move to full close side?
Check continuity between harness side connector
C-26 terminal 1 and B-18 terminal 7, C-26 terminal 2
No
Connect the battery positive terminal to the actuator

side connector terminal 1 and 3, and the battery
negative terminal to terminal 2 and 4.
Do the control plate move to full open side?
Yes
DTC 14 Close Side of Motor System Continuously Energizing

Step
Action

Value(s)
Yes
No
side
NOTE: If the control plate position is fully opened or

fully closed, resistance can not be measured.
column?
2
More than
4.2W
Go to Step 2
Replace the
actuator
Replace the
control unit
Repair or
replace the
harness
Measure continuity between harness side connector

C-26 terminal 2 and B-18 terminal 15, C-26 terminal 1
8D152
WIRING SYSTEM
AntiLock Brake System (ABS)

General Description
The circuit consists of the starter switch, stoplight switch
EHCU wheel speed sensor, ABS warning light, BRAKE
warning light, and data link connector.
When the service brake is applied while in the running
mode, the EHCU (Electronic Hydraulic Control Unit)
judges which wheel is about to lock by using the wheel
rotation speed signals sent from the three wheel speed
sensors at the front wheels and rear differential. And the
brake fluid pressure applied to the four wheels is
controlled by the EHCU to prevent the wheels from
locking.
Refer to Brake Control System in Brakes section in detail.
WIRING SYSTEM
8D153
Circuit Diagram1
D08RX216
8D154
WIRING SYSTEM
Circuit Diagram2
D08RX215
WIRING SYSTEM
8D155
Parts Location
D08RX217
Legend
(1) C36
(2) C5
(3) C4
(4) H14, H19
(6) I1
(7) I2
(8) B23
(9) B19
(10) F4
(11) H26
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
H15
H25
C16
C13
H5
E30 (6VD1)
E28 (X22SE)
I18
C34
C6
C33
8D156
WIRING SYSTEM
A/T Shift Lock

General Description
With the starter switch in the ON position and the shift
lever in P position, the shift lever cannot be shifted from
P to another position unless the brake pedal is
depressed. This is because, unless the brake pedal is
depressed, the solenoid pin underneath the shift lever
retracts and the link lever then locks the shift lever cam.
WIRING SYSTEM
8D157
Circuit Diagram1
D08RY00882
8D158
WIRING SYSTEM
Parts Location
D08RWD16
Legend
(2) H19, H32, H12
(4) I18
(5)
(6)
(7)
(8)
B8
A/T Shift Lever
B2
I40
WIRING SYSTEM
Windshield Wiper and Washer

General Description
The system consists of a windshield wiper and washer
switch, alarm & relay control unit, windshield wiper motor
and windshield washer motor. With the starter switch in
the ON position, when the windshield wiper switch is
turned on (ON or HI) the battery voltage is applied to
the windshield wiper motor to operate the wipers.
When the INT switch is turned on, the operation of the
wipers is controlled by the alarm & relay control unit.
When the WASHER switch is turned on, the operation of
the wipers is also controlled by the alarm & relay control
unit and the windshield washer motor operates to squirt
the washing solution when the washer switch is pressed.
8D159
8D160
WIRING SYSTEM
Circuit Diagram (6VD1 M/T)
D08RX220
WIRING SYSTEM
8D161
Circuit Diagram (6VD1 A/T)
D08RX218
8D162
WIRING SYSTEM
Circuit Diagram (X22SE)
D08RX219
WIRING SYSTEM
8D163
Parts Location
D08RWD12
Legend
(1) C28
(2) H13, H32
(3) C27
(4) C36
(6) Combination Switch Box
(7)
(8)
(9)
(10)
(11)
(12)
(13)
FRT Windshield Wiper, Washer Switch

I41, I42
C16
B8
FRT Windshield Wiper Motor
Windshield Washer Tank
Windshield Washer Motor
8D164
WIRING SYSTEM
Diagnosis
Windshield Wiper Does Not Operate At Any Switch Position
Step
1
2
3
Action
Replace the
fuse
Go to Step 3
Ground it
securely
Go to Step 5
Go to Step 4
Go to Step 3
Approx. 12V
Go to Step 7
Go to Step 6
Go to Step 5
Repair or
replace the
windshield
wiper motor
Repair or
replace the
switch
Repair an open circuit between connector C27

terminal 3 and the ground C36.
1. Disconnect the windshield wiper & washer switch
connector I31.

Go to Step 2
Disconnect the windshield wiper motor connector

C27.

6
No

5
Yes

C27 terminal 3 and the ground?
4
Value(s)
Is the continuity between the windshield wiper and

washer switch terminal normal?
WIRING SYSTEM
8D165
Windshield Wiper Does Not Operate At INT Position

Step
Action
Value(s)
1. Disconnect the windshield wiper and washer switch

connector I31.
2. Turn the windshield wiper and washer switch to INT
position.
Go to Step 2
Go to Step 3
Ground it
securely
Approx. 12V
Go to Step 5
Go to Step 4
Verify repair
Approx. 12V
Replace the
alarm and
relay control
unit
Go to Step 6
Verify repair
1. Reconnect the windshield wiper and washer switch
connector I31.
2. Disconnect the alarm and relay control unit
connector I41 and I42.
connector I42 terminal 12 (connector I41 terminal 7
or 9) and the ground?

terminal 2 and the alarm & relay control unit.
No
Repair or
replace the
switch

terminal 2 and 3, 5 and 6?
2
Yes

connector I41 terminal 3 or connector I42 terminal 13
and the ground?
alarm & relay control unit.
Windshield Wiper Does Not Operate At LO Position

Step
Action
Value(s)
Yes
No
Repair or replace the windshield wiper and washer

switch.
NOTE: There should be continuity between switch
side connector I31 terminal 3 and 5 with the switch
turned to the LOW position.
Verify repair
8D166
WIRING SYSTEM
Windshield Wiper Does Not Operate At HI Position

Step
Action
No
Go to Step 2
Repair or
replace the
switch
Approx. 12V
Repair or
replace the
windshield
wiper motor
Go to Step 3
Verify repair

connector I31.
2. Disconnect the windshield wiper motor connector
C27.
connector C27 terminal 1 and the ground?
Yes

connector I31.
2. Turn the windshield wiper and washer switch to the
HIGH position.
terminal 3 and 4?
Value(s)

terminal 4 and connector C27 terminal 1.
WIRING SYSTEM
8D167
AutoStop Function Of The Windshield Wiper Motor Does Not Operate

Step
Action
Value(s)
Yes
Disconnect the windshield wiper and washer switch

connector I31.
Turn the windshield wiper and washer switch off.
terminal 5 and 6?
No
Go to Step 2
Repair or
replace the
switch
Approx. 12V
Go to Step 4
Go to Step 3
Go to Step 2
Go to Step 5
Repair or
replace the
motor
Approx. 12V
Go to Step 7
Go to Step 6
Go to Step 5
intermittently
Go to Step 9
Go to Step 8
Go to Step 7
Disconnect the windshield wiper motor connector

C27.

connector C27 terminal 6.
1. Connect the battery positive terminal with motor

side connector C27 terminal 2 and the battery
negative terminal with terminal 3.
2. While the motor is operating at low speed,
disconnect the battery positive terminal from
terminal 2 and then connect it with terminal 6 again.
3. Under this condition, connect motor side connector
terminal 5 with terminal 2.
Does the motor stop at the correct position?
Disconnect the alarm and relay control unit connector

I41 and I42.
and the ground?

connector I41 terminal 3 or connector I42 terminal
13.

connector I31 and windshield wiper motor
connector C27.
low position.
connector I41 terminal 4 (1 or 2) and the ground?
Approx. 12V

terminal 5 and connector I41 terminal 4 (1 or 2).
8D168
WIRING SYSTEM
Step
Action
1. Connect the alarm and relay control unit harness

side connector I41 terminal 4 and connector I42
terminal 11 (connector I41 terminal 1 and
connector I42 terminal 12/connector I41 terminal
1 and 2).
off position.
10
Value(s)
Yes
No
Replace the
alarm and
relay control
unit
Go to Step 10
Verify repair

terminal 6 and the alarm & relay control unit.
WIRING SYSTEM
8D169
Windshield Wiper Motor Does Not Stop

Step
Action
Value(s)
Yes

connector I31.
2. Turn the switch off.
NOTE: When the switch is turned of OFF position,
there is no continuity between the switch terminals
except terminal 5 and 6.
Is the continuity between the switch terminal normal?
No
Go to Step 2
Repair or
replace the
switch
Verify repair
Repair or replace the windshield motor.

Windshield Washer Motor Does Not Operate

Step
Action
Does the windshield wiper motor operate?
Go to Step 3
Replace the
fuse
Approx. 12V
Go to Step 5
Go to Step 4
Go to Step 3
Go to Step 6
Ground it
securely
Go to Step 7
Repair or
replace the
switch
Go to Step 8
Repair or
replace the
motor
Approx. 12V
Go to Step 10
Go to Step 9
Verify repair
Verify repair

connector I31.

terminal 7 and connector C28 terminal 1.
10
Go to Step 2

C28.
2. Connect the battery positive terminal with the motor
side connector C28 terminal 1 and connect the
battery negative terminal with terminal 2.

9
Go to Step 6
Turn the windshield wiper and washer switch to the

washer position.

8

terminal 1 and 7?
7
No

Yes

connector I31.
Value(s)

8D170
WIRING SYSTEM
Rear Wiper/Washer
General Description
The system consists of the rear wiper and washer switch,
the rear wiper motor, the rear washer motor and the alarm
& relay control unit. The rear wiper provides intermittent
and riseup functions and is controlled by the alarm & relay
control unit. When the hatch gate is open, the rear wiper
does not operate. The hatch gate actuator does not
operate while the rear wiper is operating.
WIRING SYSTEM
8D171
D08RX221
8D172
WIRING SYSTEM
D08RX222
WIRING SYSTEM
8D173
D08RX223
8D174
WIRING SYSTEM
D08RX224
WIRING SYSTEM
8D175
D08RX225
8D176
WIRING SYSTEM
Parts Location
D08RWD111
Legend
(1) C30
(2) FRT & Rear Washer Tank
(3) C36
(4) H13
(6) G1
(7) G6
(8) Rear Wiper Motor
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
B20 (2Door Model)

H22
H21 (2Door Model)
B6 (2Door Model)
B8
I16
I41, I42
H31
C16
WIRING SYSTEM
8D177
Diagnosis
Rear Wiper Motor Does Not Operate
Step
Action
Value(s)
Replace the
fuse
Go to Step 3
Repair or
replace the
switch
Approx. 12V
Go to Step 5
Go to Step 4
Go to Step 3
Approx. 12V
Go to Step 7
Go to Step 6
Go to Step 5

I16 terminal 7 and harness side connector I42
terminal 5 or connector I42 terminal 20?
Go to Step 9
Go to Step 8
Go to Step 7
1. Disconnect the rear wiper/washer switch connector

I16.
2. Turn the rear wiper switch on.
terminal 5 and 7?
Turn the starter switch on



I41 and I42.
and the ground?

connector I41 terminal 12 or connector I42 terminal
6.

terminal 7 and connector I42 terminal 5 or connector
I42 terminal 20.
10
11
1. Disconnect the rear wiper motor connector G6.

side connector G6 terminal 4 and the battery
negative terminal with the motor side connector
G6 terminal 6.
Go to Step 10
Repair or
replace the
motor

I41 terminal 6 or terminal 5 and harness side
connector G6 terminal 4?
Go to Step 12
Go to Step 11
Go to Step 10
Replace the
alarm & relay
control unit
Go to Step 13
Verify repair

terminal 6 or terminal 5 and connector G6 terminal 4.
12
13
No
Go to Step 2
Yes

I41 terminal 5 (or terminal 4) or the ground and
harness side connector G6 terminal 6?
Repair an open circuit between connector G6 terminal
6 and connector I41 terminal 5 (or terminal 4) or the
ground B6.
8D178
WIRING SYSTEM
Auto-Stop Function Of The Rear Wiper Motor Does Not Operate (X22SE Model)
Step
Action
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 2
Replace the
alarm & relay
control unit
Go to Step 5
Verify repair
Turn the start switch on

connector G6 terminal 5.

I41 and I42.
G6 terminal 3 and harness side connector I41
terminal 12?
No
Repair or
replace the
motor

connector G6 terminal 5 and the ground?
Adpprox. 12V
3
Yes
1. Disconnect the rear wiper motor connector G6

side connector G6 terminal 4 and the battery
3. While the motor is operating, disconnect the battery
positive terminal from terminal 4 and then connect it
with terminal 5 again.
4. Under this condition, connect the motor side
connector terminal 3 with terminal 4.
Value(s)
Repair an open circuit between connector G6 terminal

3 and connector I41 terminal 12.
Rear Wiper Motor Does Not Operate With Rear Wiper/Washer Switch At Wiper Position
Step
Action
No
Go to Step 2
Repair or
replace the
switch
Approx. 12V
Replace the
alarm & relay
control unit
Go to Step 3
Verify repair
1. Reconnect the rear wiper/washer switch connector

I16.
2. Disconnect the alarm & relay control unit connector
I41 and I42.
connector I42 terminal 5 or terminal 20 and the
ground?
Yes

I16.
2. Turn the switch to rear wiper position.
I16 terminal 5 and 7?
Value(s)

terminal 7 and connector I42 terminal 5 or terminal 20.
WIRING SYSTEM
8D179
Rear Wiper Motor Does Not Operate With Rear Wiper/Washer Switch At Washer Position
Step
Action
No
Go to Step 2
Repair or
replace the
switch
Approx. 12V
Replace the
alarm & relay
control unit
Go to Step 3
Verify repair
1. Reconnect the rear wiper/washer switch connector

I16.
2. Disconnect the alarm & relay control unit connector
I41 and I42.
connector I42 terminal 6 (21 or 19) and the ground?
Yes

I16.
2. Turn the switch to the washer position.
Value(s)

terminal 4 and connector I42 terminal 6 (21 or 19).
Rear Wiper Motor Does Not Stop Operating

Step
Action
Value(s)
Yes
No

I16.
2. Turn the switch to the off position.
NOTE: There should be no continuity.
Repair or
replace the
switch
Replace the
alarm& relay
control unit
8D180
WIRING SYSTEM
Rear Washer Motor Does Not Operate

Step
Action
Does the rear wiper motor operate?
Go to Step 3
Replace the
fuse
Go to Step 4
Replace the
switch
Approx. 12V
Go to Step 6
Go to Step 5
Go to Step 4
Go to Step 7
Repair or
replace the
motor
Approx. 12V
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Repair an open circuit between the rear wiper/washer

motor and the alarm & relay control unit.
Go to Step 2
Reconnect the rear wiper/washer switch connector

I16.
Go to Step 6
1. Disconnect the rear wiper motor connector C30.

side connector C30 terminal 1 and the battery

No

Yes

I16.
2. Turn the switch to the rear washer position.
Value(s)

WIRING SYSTEM
Rear Defogger/Mirror Defogger

General Description
The system consists of the rear defogger and mirror
defogger switch, the rear defogger & mirror defogger
relay, the rear defogger & mirror defogger and the
Powertrain Control Module (PCM).
When the rear defogger and mirror defogger switch is
turned on with the starter switch on, the rear defogger and
mirror defogger relay is activated and the battery voltage
is applied to the rear defogger and mirror defogger.
The PCM is provided with the timer. When the operation
time of the timer elapses which has been set in advance,
the rear defogger and mirror defogger relay is
automatically deactivated and the rear defogger and
mirror defogger is turned off.
8D181
8D182
WIRING SYSTEM
Circuit Diagram1
D08RX240
WIRING SYSTEM
8D183
D08RX238
8D184
WIRING SYSTEM
D08RX241
WIRING SYSTEM
8D185
D08RX239
Legend
(1) Rear Defogger & Mirror Defogger Switch
(2) H19, H32
(4) D3
(5) Door Mirror RH
(6) H28
(7) G12
(8) G9
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
H21
B8
B6
PCM
I17
H33
D12
Door Mirror LH
8D186
WIRING SYSTEM
D08RWD10
Legend
(1) RR Defogger & Mirror Defogger Switch
(2) H19, H32
(4) D3
(5) H28
(7) H10
(8) H21
(9) G9
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
G10
G11
G12
B8
B6
PCM
H31
H33
D12
WIRING SYSTEM
8D187
Diagnosis
Rear Defogger Does Not Operate
Step
Action
Value(s)
Are the fuse C9, C10 and C17 normal?
Replace the
fuse(s)
Go to Step 3
Ground it
(them)
securely
Approx. 12V
Go to Step 5
Go to Step 4
Go to Step 3
Approx. 12V
Go to Step 7
Go to Step 6
Go to Step 5
Go to Step 9
Go to Step 8
Go to Step 7

I17 terminal 4 and connector C3 terminal F9 or
connector C3 terminal E12?
Go to Step 11
Go to Step 10
Go to Step 9

Go to Step 13
Go to Step 12
Go to Step 11
Are B6 and/or B8 grounded securely?
Remove the rear defogger relay.

Is the battery voltage applied between the rear
defogger relay harness side connector I39 terminal 2
and the ground?
Repair an open circuit between the battery and



Disconnect the PCM connector C1, C2 and C3.

I39 terminal 3 and harness side connector C2
terminal C12 or connector C1 terminal A14?
10
11
12

terminal 3 and connector C2 terminal C12 or
connector C1 terminal A14.

terminal 4 and connector C3 terminal F9 or connector
C3 terminal E12.

13
14
No
Go to Step 2
Yes
1. Reconnect the rear defogger relay.

2. Ground the PCM harness side connector C2
terminal C12 or connector C1 terminal A14.
defogger harness side connector G9 terminal 1 and
the ground?
Approx. 12V
Go to Step 14
Repair an
open circuit
between the
fuse C9 or
C10 and the
rear defogger
Is there continuity between the rear defogger harness

side connector G12 terminal 1 and the ground?
Go to Step 16
Go to Step 15
8D188
WIRING SYSTEM
Step
Action
15
Repair an open circuit between connector G12

16
No
Go to Step 14
Approx. 12V
Go to Step 18
Go to Step 17
Verify repair
Verify repair
Replace the PCM.

18
Yes
1. Reconnect the PCM connector C2 and C3 or

C1.
2. Turn the rear defogger switch on.
defogger harness side connector G9 terminal 1 and
the ground?
17
Value(s)
Repair broken heat wire or connector poor contact of

the rear defogger.
WIRING SYSTEM
8D189
Rear Defogger Timer Does Not Function

Step
Action
Value(s)
Yes
No
Replace the PCM.

Verify repair
8D190
WIRING SYSTEM
Audio
General Description
The audio circuit is designed for the current to flow
through the receiver circuit when the radio switch is
turned on with the starter switch in ACC or ON.
Current runs through the memory circuit of the audio
regardless of the position of the starter switch.
WIRING SYSTEM
8D191
Circuit Diagram1
D08RX244
8D192
WIRING SYSTEM
Parts Location
D08RWD13
Legend
(1) H28
(2) H19, H32
(3) FRT Speaker RH
(4) D10
(5) D13
(6) Tweeter RH
(8) RR Speaker RH (2Door model)
(9) RR Speaker RH (4Door model)
(10) B10
(11) B12
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
RR Speaker LH (4Door model)

Tweeter LH
RR Speaker LH (2Door model)
D4
D1
FRT Speaker LH
H33
H31
B8
Audio
I15
WIRING SYSTEM
Cigarette Lighter, Digital Clock and Accessory Socket

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.
8D193
8D194
WIRING SYSTEM
Circuit Diagram
D08RX245
WIRING SYSTEM
8D195
Parts Location
D08RWD081
Legend
(1) H32
(3) I27
(4) Digital Clock
(5) Rear Accessory Socket
(6)
(7)
(8)
(9)
(10)
(11)
B14, B15
B8
Cigarette Lighter
Front Accessory Socket
I28, I29
I21, I22
8D196
WIRING SYSTEM
Diagnosis
Cigarette Lighter Does Not Work
Step
1
2
3
Action
Go to Step 2
Replace the
fuse
Go to Step 3
Ground it
securely
Approx. 12V
Go to Step 5
Go to Step 4
Go to Step 3
Repair or
replace the
cigarette
lighter
assembly
Go to Step 6
Verify repair
1. Disconnect the cigarette lighter connector I22.

2. Turn the starter switch to the ACC or ON position.

Disconnect the cigarette lighter connector I21.
I21 terminal 1 and the ground B8?
No

5
Yes

4
Value(s)

Cigarette Lighter Does Not Spring Out After Being Heated

Step
Action
Value(s)
Yes
No
Repair or replace the cigarette lighter.

Verify repair
WIRING SYSTEM
Power Door Mirror

General Description
The system consists of the starter switch, the mirror
control switch, and door mirrors on both sides.
When the mirror control switch is operated with the starter
switch at either ACC or ON position, the motor in the
door mirror (on either side) rotates to allow the horizontal
and vertical adjustment of mirror angles.
8D197
8D198
WIRING SYSTEM
Circuit Diagram1
D08RW246
WIRING SYSTEM
8D199
Circuit Diagram2
D08RX247
8D200
WIRING SYSTEM
Parts Location
D08RX248
Legend
(1) H19
(2) I12
(3) Door Mirror RH
(4) Door Mirror LH
(5) D12
(6)
(7)
(8)
(9)
(10)
(11)
H33
H31
B8
D3
H28
WIRING SYSTEM
8D201
Diagnosis
Mirrors On Both Sides Do Not Operate
Step
1
2
3
Action
5
6
No
Go to Step 2
Replace the
fuse
Go to Step 3
Ground it
securely
Approx. 12V
Go to Step 5
Go to Step 4
Go to Step 3
Is there continuity between the harness side connector

Go to Step 7
Go to Step 6
Verify repair
Verify repair
Is the B8 ground securely?

Disconnect the mirror control switch connector I12.


terminal 6 and mirror.
Yes
Is the battery voltage applied between the harness side

4
Value(s)
Repair or replace the mirror control switch.

Mirrors On the Left (or Right) Side Does Not Operate

Step
Action
No
Go to Step 3
Go to Step 2
Go to Step 1
Repair or
replace the
mirror control
switch
Replace the
mirror

terminal 6 and connector D12 or D3 terminal 4?
Yes
Disconnect the mirror control switch connector I12

and mirror connector D12 or D3.
I12 terminal 6 and connector D12 or D3 terminal 4?
Value(s)
Connect the battery positive terminal to the mirror side

connector terminal 4, and the battery negative terminal
to the mirror side connector terminal 7 or 8.
Dose the mirror operate?
Mirrors On Both Sides Operate Only In The Vertical (Or Horizontal) Direction
Step
Action
Value(s)
Yes
No
Repair or replace the door mirror control switch.

Verify repair
8D202
WIRING SYSTEM
Mirror On Left (or Right) Sides Operate Only In The Vertical (Or Horizontal) Direction
Step
Action
Yes
1. Disconnect the mirror connector D12 or D3.

2. Connector the battery positive terminal to the mirror
connector terminal 4, and the battery negative
terminal to the mirror connector terminal 7 or 8.
No
Does the mirror operate?
Go to Step 2
Replace the
mirror

I12 terminal 7 and connector D12 terminal 7
(connector I12 terminal 4 and connector D12
terminal 8, connector I12 terminal 8 and connector
D3 terminal 7, connector I12 terminal 5 and
connector D3 terminal 8)?
Go to Step 4
Go to Step 3
Verify repair
Verify repair
Repair an open circuit between the mirror control

switch and the mirror LH or RH
Value(s)
Repair or replace the mirror control switch.

WIRING SYSTEM
8D203
Keyless Entry
General Description
This circuit consists of the keyless entry control unit, the
front door lock, & power window switch (RH), the starter
switch, the dome light, the door switch and the tail gate
switch and possible to lock/unlock each door by operation
of transmitter. Basic function of system is as follows.
1. Lock/unlock function
When the Keyless entry control unit receives the
signal from the transmitter, the control unit sends the
locker unlock signal to the front door lock and power
window switch (RH).
Function code (lock or unlock) and proper ID code for
each vehicle are added to the signal. But, when
starter switch is on or any of the doors opens,
lock/unlock function is not unable to work.
2. Answer back function
When receiving the signal from the transmitter, the
keyless entry control unit responds by using the dome
light. In case of being locked, the keyless entry control
unit turns on the dome light at two times (about 0.5
second at each time). In case of being unlocked, it
turns on the dome light at one time (about 3 seconds).
3. Autolock function
After unlock function is done, in case of effecting one
of following conditions within about 30 seconds, the
keyless entry control unit automatically sends the
lock signal to lock each door.
1. The doors are closed.
2. Starter key is not inserted
3. The lock operation is not done by transmitter.
8D204
WIRING SYSTEM
D08RX251
WIRING SYSTEM
8D205
D08RX252
8D206
WIRING SYSTEM
D08RX361
WIRING SYSTEM
8D207
D08RX252
8D208
WIRING SYSTEM
Parts Location
D08RWD27
Legend
(1) H28
(2) H14, H19, H32
(5) Courtesy Light RH
(6) D7
(7) FRT Door Lock Switch RH
(8) Starter Switch
(9) B27
(10) RR Door Switch RH
(11) I26
(12) Dome Light
(13) L3
(14) B11 (4Door Model)
(16) G13 (2Door Model)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
G1
B20
H37
H22
H30
B16
B17 (FRT Door Switch LH)
Courtesy Light LH
D18
H33
H31
B8
I46
B1
FRT Door Switch RH
D5
WIRING SYSTEM
8D209
Keyless Entry System

ID Code Registration
This procedure registers a new ID code. When total
number of registered ID codes and newly registered ID
code exceed four, they are erased in order of older one.
Step
Action
Yes
No
1. Confirm that all the doors are closed and unlocked.

2. Open the drivers side door.
3. Insert the key into the starter switch.
Value(s)
Go to Step 2
Go to Step 1
Go to Step 3
Go to Step 1
Go to Step 4
Go to Step 1
Go to Step 5
Go to Step 1
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 1
Go to Step 8
Go to Step 1
Go to Step 9
Go to Step 1
Go to Step 1
Go to Step 1
Turn the starter switch to ACC position and then to OFF

position three times.
NOTE: This step must be carried out within five
seconds after step 1.
Close the drivers side door and then open it two times.
NOTE: This step must be carried out within ten
1. Turn the starter switch to ACC position and then to

OFF position three times.
2. Close the drivers side door and then open it.
NOTE: This step must be carried out within ten
The control unit lock and unlocks the doors one times.
Does the control unit work normally?
Operate the lock or unlock button of the transmitter.

NOTE: This step must be carried out within twenty
The control unit locks and unlock the doors one times.
Does the control unit work normally?
Operate the lock or unlock button of the transmitter.

NOTE: This step must be carried out within twenty
The control unit compares the two codes sent from the
transmitter.
If the code succeeds in registration, the control unit
locks and unlocks the doors one time.
If the two codes are different from each other or fails in
registration, the control unit locks and unlocks the
doors three times.
NOTE: In any case, this procedure is finished.
8D210
WIRING SYSTEM
Meter and Warning/Indicator Light

General Description
The circuit consists of the starter switch, meter assembly,
vehicle speed sensor, alarm & relay control unit, lighting
switch, turn signal switch, engine coolant temperature
unit, oil pressure unit, Powertrain Control Module, fuel
tank unit, 4WD control unit, oil pressure switch, parking
brake switch, brake fluid switch, seat belt switch,
illumination controller.
The meter ASM contains the speedometer, tachometer,
voltmeter, engine coolant temperature gauge, oil
pressure gauge, fuel gauge and warning/indicator lights.
The meter warning/indicator lights and their bulb sockets
are a unit, they are installed from the back of the
speedometer assembly.
WIRING SYSTEM
8D211
Circuit Diagram 1 (6VD1 M/T)
D08RX257
8D212
WIRING SYSTEM
Circuit Diagram 1 (6VD1 A/T)
D08RX256
WIRING SYSTEM
8D213
Circuit Diagram 1 (X22SE)
D08RX258
8D214
WIRING SYSTEM
Circuit Diagram 2
D08RX259
WIRING SYSTEM
8D215
Circuit Diagram 3
D08RX260
8D216
WIRING SYSTEM
Circuit Diagram 4
D08RX261
WIRING SYSTEM
8D217
Circuit Diagram 5
D08RX262
8D218
WIRING SYSTEM
Parts Location
D08RX265
Legend
(1) H2
(2) H13, H14, H19, H32
(4) C6
(5) E19
(6) I9
(7) I2
(8) I10
(9) I1
(10) B22
(11) B23
(12) B8
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
C16
Alarm & Relay Control Unit
Fuel Tank Unit
Fuel Tank
F1
H25
H15, H16, H17, H31
H9 (X22SE)
H5, H6
M10
H9 (6VD1)
E1 (6VD1)
E1 (X22SE)
WIRING SYSTEM
8D219
Diagnosis
Speedometer and Odometer Do Not Function
Step
1
2
Action
Value(s)

Go to Step 2
Ground it
securely
Go to Step 4
Go to Step 3
Go to Step 2
Approx. 12V
Go to Step 6
Go to Step 5
Go to Step 4
Go to Step 8
Go to Step 7
Verify repair
Replace the
meter
assembly
Replace the
vehicle speed
sensor
Disconnect the vehicle speed sensor connector M10.
Repair an open circuit between connector M10


connector M10 terminal 1 and the ground?

connector M10 terminal 1.
Disconnect the meter connector I2.

terminal 12 and harness side connector M10 terminal
3?

12 and connector M10 terminal 3.
No

M10 terminal 2 and the ground?
3
Yes
1. Disconnect the meter connector I1.

2. Connector a resistance of 1.3 to 5K ohm (1.4W or
more) between harness side connector I1 terminal
12 and harness side connector I2 terminal 12.
3. Install a speedometer tester.
4. Check the waveform at the time when the vehicle
speed is 60 Km/h with a oscilloscope.
NOTE: Normal waveform shows between approx. 12V
and 2V and its cycle is 23.6msec
Is the waveform normal?
Speedometer Does Not Function (Odometer is Normal)

Step
Action
Value(s)
Yes
No
Replace the meter assembly.
Verify repair
Odometer Does Not Function (Speedometer is Normal)

Step
Action
Value(s)
Yes
No
Replace the meter assembly.

Verify repair
8D220
WIRING SYSTEM
Speedometer Pointer Fluctuates (May be Wide Fluctuation)

Step
Action
NOTE: Refer to the step 8 of diagnosis procedure for

Speedometer and Odometer Does Not Function is this
section.
Is the vehicle speed sensor signal normal?
Value(s)
Yes
No
Replace the
meter
assembly
Go to step 2
Verify repair
Repair a poor connections of the connectors or a failure

in the circuit between connector 12 terminal 12 and
Speedometer Pointer Jumps Erratically

Step
Action

Speedometer and Odometer Does Not Function is this
section.
Is the vehicle speed sensor signal normal?
Value(s)
Yes
No
Replace the
meter
assembly
Go to step 2
Verify repair
Repair a poor connections of the connectors or a failure

in the circuit between connector 12 terminal 12 and
Tachometer Does Not Function

Step
Action
Value(s)
No

2. Check the waveform of terminal 6 when the engine
revolution is 3000 rpm with a oscilloscope.
NOTE: Normal waveform shows between 4.3V and
0.4V and its cycle is 6.7m sec.
Yes
Replace the
meter
assembly
Is the circuit between connector I2 terminal 6 and the

PCM connector C2 terminal C10 normal?
Replace the
PCM
Go to step 2
Repair the
circuit
Tachometer Pointer Fluctuates (May Be Wide Fluctuation)

Step
Action
Value(s)

Tachometer Does Not Function in this section.
Yes
Replace the
meter
assembly

Replace the
PCM
No
Go to step 2
Repair the
circuit
WIRING SYSTEM
8D221
Tachometer Pointer Jumps Erratically

Step
Action
Value(s)

Tachometer Does Not Function in this section.
Yes
Replace the
meter
assembly

Replace the
PCM
No
Go to step 2
Repair the
circuit
Engine Coolant Temperature (ECT) Gauge Pointer Does Not Move

Step
1
2
Action
Value(s)
Is the engine coolant temperature (ECT) unit connector

E19 connected securely?
Go to step 2
Connect it
securely
No
Replace the
ECT unit
Go to step 3
Replace the
meter
assembly
Repair the
circuit
1. Disconnect the ECT unit connector E19.

2. Connect a 3.4W bulb between harness side
connector E19 terminal 1 and the ECT unit ground.
Does the ECT gauge pointer move about 10 seconds
after that?
Yes

terminal 7 and connector E19 terminal 1?
Engine Coolant Temperature (ECT) Gauge Reading is Too Low

Step
Action

3. Connect harness side connector E19 terminal 1
with the ground.
Does the indication of the ECT gauge vary?
Yes
No
Replace the
ECT unit
Go to step 2
Go to step 3
Replace the
meter
assembly
Verify repair

2. Connect meter side connector I1 terminal 7 with
the ground.
Value(s)

7 and connector E19 terminal 1.
8D222
WIRING SYSTEM
Engine Coolant Temperature (ECT) Gauge Pointer Overshoots (or Goes Up To the H
Range)
Step
Action

3. Connect harness side connector E19 terminal 1
with the ground.
Yes
No
Replace the
ECT unit
Go to step 2
Go to step 3
Replace the
meter
assembly
Verify repair

Value(s)

7 and connector E19 terminal 1.
Fuel Gauge Needle Does Not Move

Step
1
2
Action
Go to step 2
Ground it
securely
Go to step 4
Go to step 3
Verify repair
Replace the
fuel tank unit
Go to step 5
Replace the
meter
assembly
Go to step 6
Verify repair
1. Connect a 3.4W bulb between the harness side

connector F1 terminal 3 and the ground.

I2 terminal 14 and connector F1 terminal 3?
Repair an open circuit between connector F1 terminal

2 and the ground B8.
Does the fuel gauge needle fluctuate after about 90

seconds?
5
No
Disconnect the fuel tank unit connector F1.

4
Yes

F1 terminal 2 and the ground?
3
Value(s)
Repair an open circuit between the meter assembly

and the fuel tank unit.
WIRING SYSTEM
8D223
Even the Tank is Filled Up With Fuel, The Needle Does Not Reach F
Step
Action
No
Go to step 2
Go to step 3
Verify repair
Repair or
replace the
fuel tank unit
Replace the
meter
assembly
Repair a poor connection of the fuel tank unit connector

F1.
Yes
Disconnect and connect the fuel tank unit connector

F1 several times.
Does the indication of the fuel gauge vary?
Value(s)
1. Disconnect the fuel tank unit connector F1.

2. Connect the harness side connector F1 terminal 2
and 3 with a lead wire.
Does the fuel gauge needle overshoot to F after about
5 minutes?
Even When The Tank Is Not Filled With Fuel, The Needle Overshoots To F
Step
Action
1. Disconnect the fuel tank unit connector F1.

Does the needle point to E?
Value(s)
Is there a short circuit between the meter connector I2

terminal 14 and the fuel tank unit connector F1
terminal 3?
Yes
No
Replace the
fuel tank unit
Go to step 2
Repair a
short circuit
Replace the
meter
assembly
8D224
WIRING SYSTEM
A/T Shift Indicator

General Description
The circuit consists of the starter switch, mode switch,
alarm & relay control unit and A/T shift indicator (meter).
WIRING SYSTEM
8D225
Circuit Diagram1
D08RX263
8D226
WIRING SYSTEM
Circuit Diagram2
D08RX264
WIRING SYSTEM
8D227
Parts Location
D08RX266
Legend
(1) Battery
(3) H32
(4) C36
(5) I10
(6) Starter Switch
(7)
(8)
(9)
(10)
(11)
(12)
B8
Alarm & Relay Control Unit
H16, H17
M16
H10
H11
8D228
WIRING SYSTEM
Heater and Air Conditioning

General Description
The heater and air conditioning system consists of
pressure switch, A/C switch, electronic thermostat,
blower motor, fan switch, magnetic clutch for A/C
compressor, blower resistor, relays and PCM (or ECM).
Basically the air conditioning system works while the A/C
switch and the fan switch are turned on, and stops
working when the pressure switch turns off or the
electronic thermostat cuts off the circuit.
The PCM (or the ECM) also stops working of the air
conditioning system to reduce the engine load.
Refer to Heating and Ventilation System, and Air
Conditioning System in HVAC System.
WIRING SYSTEM
8D229
Circuit Diagram1
D08RX151
8D230
WIRING SYSTEM
Circuit Diagram2
D08RX150
WIRING SYSTEM
8D231
Parts Location
D08RX271
Legend
(2) C36
(4) E3
(5) I23
(6) I24
(7) B4
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
B3
B5
H15, H16, H31
B8
H6
C11
Condenser
H13, H32
8D232
WIRING SYSTEM
Heater and Air Conditioning

General Description
Using the signals from a variety of sensors, the full
automatic heater and air conditioning system accurately
senses outside air temperature, solar radiation quantity,
evaporators blowing temperature, heater core water
temperature and interior temperature. These signals
enable the control unit to automatically control blow
temperature and air blow quantity, turn on or off the
compressor and switch the blow port as well as switching
between the fresh air intake and interior air circulation.
Resetting the automatic function allows the system to
switch to the manual control mode.
The self-diagnosis function of the control unit allows the
unit to access and diagnose failed parts easier and
quicker.
Refer to Air Conditioning System in HVAC System.
WIRING SYSTEM
8D233
Circuit Diagram1
D08RX145
8D234
WIRING SYSTEM
Circuit Diagram2
D08RX146
WIRING SYSTEM
8D235
Circuit Diagram3
D08RX147
8D236
WIRING SYSTEM
Circuit Diagram4
D08RX148
WIRING SYSTEM
8D237
Circuit Diagram5
D08RX144
8D238
WIRING SYSTEM
Circuit Diagram6
D08RX143
WIRING SYSTEM
8D239
Parts Location
D08RX270
Legend
(2) C36
(4) I6
(5) E19
(6) I40
(7) I20
(8) I4
(9) C45
(10) B26
(11) B25
(12) B5
(13) H15, H16, H17, H31
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
B27
B18
C45
C48
B8
H6
E3
C11
C8
Condenser Fan
C24
C7
H14, H32
8D240
WIRING SYSTEM
Sunroof
General Description
The circuit consists of the starter switch, sunroof switch,
sunroof control unit, limit switch, and sunroof motor.
When the sunroof switch is turned on, the battery voltage
is applied to the sunroof control unit through the circuit
breaker and the power window relay on the circuit.
Accordingly, when the sunroof switch is set to Open or
Close position, the open or close relay incorporated into
the control unit is activated to change the rotational
direction of the sunroof motor to open or close the
sunroof.
Also, the operational process (full close limit stop full
open safety stop full close) of the sunroof is
controlled by the control unit in accordance with signals
received from the sunroof switch and limit switch.
WIRING SYSTEM
8D241
Circuit Diagram1
D08RX269
8D242
WIRING SYSTEM
Parts Location
D08RWD231
Legend
(1) H32
(2) C36
(4) Sunroof Switch
(5)
(6)
(7)
(8)
(9)
Sunroof Motor
L1
Sunroof Control Unit
H30
B8
WIRING SYSTEM
8D243
Diagnosis
Sunroof Inoperative
Step
Action
No
Approx. 12V
Go to Step 3
Go to Step 2
Verify reapir
Verify repair
Repair an open circuit between the power widow relay

and the sunroof control unit.
Yes
1. Disconnect the sunroof connector L1.

Is the battery voltage applied between the harness side
connector L1 terminal 1 and the ground?
Value(s)
Replace the sunroof control unit.

Safety Stop Mechanism Inoperative

Step
Action
Value(s)
Yes
No
Replace the sunroof control unit.

Verify repair
8D244
WIRING SYSTEM
Supplemental Restraint System (SRS) Air Bag

General Description
The circuit consists of Sensing and Diagnostic Module
(SDM), drivers air bag assembly, SRS coil assembly,
passengers air bag assembly, and AIR BAG warning
light. SDM, SRS coil assembly (driver side only), driver air
bag assembly, passenger air bag assembly and
connector wire make up the deployment loops. The
function of the deployment loops is to supply current
through air bag assembly, which will cause deployment of
the air bags in the event of a frontal crash of sufficient
force, up to 30 degrees off the center line of the vehicle.
The air bag assemblies are only supplied enough current
to deploy when the SDM detects vehicle velocity changes
severe enough to warrant deployment.
The SDM contains a sensing device which converts
vehicle velocity changes to an electrical signal.
The electrical signal generated is processed by the SDM
and then compared to a value stored in memory. When
the generated signal exceeds the stored value, the SDM
will cause current to flow through the air bag assembly
deploying the air bags.
Refer to Supplemental Restraint System (SRS) and
Restraint Control System in Restraints.
WIRING SYSTEM
8D245
Circuit Diagram
D08RX268
8D246
WIRING SYSTEM
Parts Location
D08RX267
Legend
(1) H32
(2) I43
(3) C34
(4) I1
(5) SRS Coil Assembly
(6) I30
(7) Passenger Air Bag Assembly
(8) H16
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
C16
I25
H5
SDM
E28 (X22SE)
E30 (6VD1)
I32
I49
WIRING SYSTEM
Shift on the Fly System

General Description
The circuit consists of the starter switch, 4WD control
unit, actuator (transfer), 4WD switch, front axle vacuum
switching valve, front axle switch and 4WD indicator
(meter).
Refer to Driveline Control System (Shift on the Fly) in
Driveline/Axle.
8D247
8D248
WIRING SYSTEM
Circuit Diagram1
D08RX272
WIRING SYSTEM
8D249
D08RX274
8D250
WIRING SYSTEM
D08RX273
WIRING SYSTEM
8D251
Parts Location
D08RX290
Legend
(1) Battery
(3) H32
(5) I19
(6) I1
(7) I2
(8) B8
(9) B19
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
C32
H15
C16
C31
H18
H9 (X22SE)
C15
M21
H9 (6VD1), H10
M11, M12
8D252
WIRING SYSTEM
Harness Connector Faces

No.
Connector face
No.
B-1
B-10
B-2
B-11
B-3
B-12
B-4
B-13
B-5
B-14
B-6
B-15
B-7
B-16
B-8
B-17
B-9
B-18
Connector face
WIRING SYSTEM
No.
Connector face
No.
B-19
B-28
B-29
B-20
B-30
B-21
B-31
B-34
B-22
B-35
B-23
C-1
B-24
C-2
B-25
C-3
B-26
C-4
B-27
C-5
Connector face
8D253
8D254
No.
WIRING SYSTEM
Connector face
No.
C-6
C-14
C-7
C-15
C-8
C-16
C-9
C-17
C-10
C-18
C-11
C-19
C-11
C-20
C-12
C-21
C-13
C-22
Connector face
WIRING SYSTEM
No.
Connector face
No.
C-23
C-32
C-24
C-33
C-25
C-34
C-26
C-35
C-27
C-36
C-28
C-37
C-29
C-40
C-30
C-43
C-31
C-45
Connector face
8D255
8D256
No.
WIRING SYSTEM
Connector face
No.
C-48
D-7
C-49
D-8
C-50
D-9
D-1
D-10
D-2
D-11
D-3
D-12
D-4
D-13
D-5
D-14
D-6
D-15
Connector face
WIRING SYSTEM
No.
Connector face
No.
D-16
D-25
D-17
D-26
D-18
D-27
D-19
D-28
D-20
D-29
D-21
E-1
D-22
E-2
D-23
E-3
D-24
E-4
Connector face
8D257
8D258
No.
WIRING SYSTEM
Connector face
No.
E-5
E-14
E-6
E-15
E-18
E-7
E-19
E-8
E-20
E-9
E-10
E-21
E-23
E-11
E-24
E-12
E-25
E-13
E-26
E-14
E-27
Connector face
WIRING SYSTEM
No.
Connector face
No.
E-28
E-39
E-29
E-40
E-30
E-41
E-31
E-42
E-32
E-43
E-33
E-44
E-34
E-36
E-45
E-37
F-1
E-38
F-2
Connector face
8D259
8D260
No.
WIRING SYSTEM
Connector face
No.
F-3
G-8
F-4
G-9
G-1
G-10
G-2
G-11
G-3
G-12
G-4
G-13
G-5
H-1
G-6
H-2
(X22
SE)
G-7
H-2
(6VD
1)
Connector face
WIRING SYSTEM
No.
Connector face
No.
H-3
H-11
H-4
H-12
H-5
H-13
H-6
H-14
H-7
H-15
H-8
H-16
H-9
H-17
H-10
(A/T)
H-18
H-10
(M/T)
H-19
Connector face
8D261
8D262
No.
WIRING SYSTEM
Connector face
No.
H-20
H-29
H-21
H-30
(4Do
or)
H-22
H-30
(2Do
or)
H-23
H-31
H-24
H-32
H-25
H-33
H-26
H-34
H-27
H-35
H-36
H-28
H-37
Connector face
WIRING SYSTEM
No.
Connector face
No.
I-1
I-10
I-2
I-11
I-3
I-12
I-4
I-13
I-5
I-14
I-6
I-15
I-7
I-16
I-8
I-17
I-9
I-18
Connector face
8D263
8D264
No.
WIRING SYSTEM
Connector face
No.
I-19
I-28
I-20
I-29
I-21
I-30
I-22
I-31
I-23
I-32
I-24
I-33
I-25
I-34
I-26
I-35
I-27
I-36
Connector face
WIRING SYSTEM
No.
Connector face
No.
I-37
I-46
I-38
I-47
I-39
I-48
I-40
I-49
I-41
I-50
I-42
I-51
I-43
L-1
I-44
L-2
I-45
L-3
Connector face
8D265
8D266
No.
WIRING SYSTEM
Connector face
No.
L-4
M-12
L-5
M-13
M-1
M-5
M-14
M-6
M-15
M-7
M-16
M-8
M-17
M-9
M-18
M-10
M-19
M-11
M-20
Connector face
WIRING SYSTEM
No.
Connector face
No.
M-21
P-9
P-1
P-10
P-2
X-1
P-3
X-2
P-4
X-3
P-5
X-4
P-6
X-5
P-7
X-6
P-8
X-7
Connector face
8D267
8D268
No.
X-8
X-9
X-10
X-11
X-12
X-13
X-14
X-15
X-16
WIRING SYSTEM
Connector face
SECTION
METER AND GAUGE
8E1

METER AND GAUGE
CONTENTS
Meter Assembly ............................................
Layout for Meters/Gauges, Warning Lights,
Indicator Lights and Illumination
Lights ......................................................
Table for Meter/Gauge Connector
Terminal Connections .............................
Removal .....................................................
Installation ..................................................
Warning Light Bulb, Indicator Light Bulb,
8E - 1
8E - 2
8E - 2
8E - 2
8E - 6
8E - 10
8E - 10
Service Precaution
REPAIRS.
Illumination Light Bulb, A/T Shift Indicator

Light Bulb...................................................
Removal......................................................
Installation...................................................
Vehicle Speed Sensor...................................
Removal......................................................
Installation...................................................
Fuel Tank Unit ...............................................
Removal......................................................
Installation...................................................
8E - 10
8E - 10
8E - 10
8E - 11
8E - 11
8E - 11
8E - 11
8E - 11
8E - 11
8E - 12

and systems.
8E2
METER AND GAUGE
Meter Assembly
General Description
The meter assembly has the speedometer, tachometer,
engine coolant temperature gauge, fuel gauge and
warning/indicator lights. These gauges and warning/
indicator lights can be removed and installed from the
back side of meter assembly.
Layout for Meters/Gauges, Warning

Lights, Indicator Lights and
Illumination Lights
Meter Assembly W/A/T (Front View)
825RX038
Legend
(1)
(2)
(3)
(4)
Engine Coolant Temperature Gauge

Tachometer
Warning Light Lens
Speedometer
EndOFCallout
(5)
(6)
(7)
(8)
Fuel Gauge
Reset Knob
Warning Light Lens
A/T Shift Indicator
METER AND GAUGE
8E3
Meter Assembly W/A/T (Rear View)
825RX039
Legend
(9) Illumination Light
(10) LCD Light
EndOFCallout

8E4
METER AND GAUGE
Meter Assembly W/M/T (Front View)
825RX036
Legend
(1)
(2)
(3)
(4)
Engine Coolant Temperature Gauge

Tachometer
Warning Light Lens
Speedometer
EndOFCallout
(5) Fuel Gauge

(6) Reset Knob
(7) Warning Light Lens
METER AND GAUGE
8E5
Meter Assembly W/M/T (Rear View)
825RX037
Legend
(10) LCD Light
EndOFCallout

8E6
METER AND GAUGE
Table for Meter/Gauge Connector Terminal Connections

Meter Assembly W/M/T
825RX014
METER AND GAUGE

Connector No. I1
Terminal
Function
Connector No. I9
Terminal
Function
1 Illumination ()
2 Illumination (+)
4 Oil pressure warning light
5 Check engine warning light
7 Engine coolant temperature gauge
8 Brake warning light
9 Ground (Gauge)
10 Charge warning light
10
11
11 Battery (+)
12 Starter switch
12
13 Air bag warning light

14
15 Seat belt warning light

16 Illumination (+)
Connector No. I10

Terminal
Function
1 Turn signal indicator light (Left)
2 Turn signal indicator light (Right)
3 Ground
Connector No. I2
Terminal
Function
5 Illumination ()
9 Highbeam indicator light ()
6 Tachometer
10 Highbeam indicator light (+)
9 ABS indicator light

10 4WD indicator light
11
12 Speedometer
13 Ground
14 Fuel gauge
8E7
8E8
METER AND GAUGE
Meter Assembly W/A/T
825RX013
METER AND GAUGE

Connector No. I1
Terminal
Function
Connector No. I9
Terminal
Function
1 Illumination ()
2 Illumination (+)
4 Oil pressure warning light
5 Check engine warning light
6 Check trans warning light
7 Engine coolant temperature gauge
7 Power drive indicator light
8 Brake warning light
8 Winter drive indicator light
9 Ground (Gauge)
10 Charge warning light
10
11
11 Battery (+)
12 Starter switch
12
13 Air bag warning light

14 A/T oil temp warning light
15 Seat belt warning light
16 Illumination (+)
Connector No. I10

Terminal
Function
1 L position (A/T)
2 2 position (A/T)
Connector No. I2
Terminal
Function
3 3 position (A/T)
4 D position (A/T)
1 Turn signal indicator light (Left)
5 N position (A/T)
2 Turn signal indicator light (Right)
6 R position (A/T)
3 Ground
7 P position (A/T)
5 Illumination ()
9 Highbeam indicator light ()
6 Tachometer
7
10 Highbeam indicator light (+)
8 Cruise set
9 ABS indicator light
10 4WD indicator light
11
12 Speedometer
13 Gnd
14 Fuel gauge
8 A/T shift indicator light
8E9
8E10
METER AND GAUGE
Removal
5. Remove four fixing screws and disconnect the meter

connectors to remove the meter assembly(4).

2. Remove the Dash Side Trim Panel RH (3).
3. Remove the lower cover Assembly(2).
Structure section.
4. Remove the meter cluster Assembly(1).
Structure section.
825RW284
CAUTION: The removed meter assembly should be

placed upright or with its face side up.
Installation
821RW292-1
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb,

A/T Shift Indicator Light Bulb
Removal
2. Remove the meter assembly(1).
Refer to the Meter Assembly removal steps in
Meter and Gauge section.
3. Hold the bulb socket by hand and rotate it
counterclockwise to remove the socket & bulb(2)
from the meter body.
825RW059
Installation
METER AND GAUGE
8E11

Removal
Installation

2. Disconnect the connector, remove the vehicle speed
sensor (1) by rotating it.

1. Tighten the vehicle speed sensor to the specified
torque.
220RX003
Fuel Tank Unit

Removal
Installation

2. Remove the fuel tank(1).
Refer to the Fuel Tank in Engine Fuel section
3. Disconnect the connectors, remove five screws and
then remove the fuel tank unit(2).
825RW060
8E12
METER AND GAUGE

Application
Vehicle Speed Sensor Fixing
Nm
kgm
LbFt
LbIn
27
2.8
20
SECTION
BODY STRUCTURE
8F1

BODY STRUCTURE
CONTENTS
Frame............................................................
Frame Dimensions (LWB) ..........................
Frame Dimensions (SWB) ..........................
General Description (Bumper) .......................
Front Bumper ................................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Front Bumper Slider Bracket.........................
Removal .....................................................
Installation ..................................................
Rear Bumper.................................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Rear Bumper Slider.......................................
Removal .....................................................
Installation ..................................................
General Description (Sheet Metal) ................
Engine Hood .................................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Engine Hood Lock.........................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Radiator Grille ...............................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Front Fender Panel .......................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Body Mounting ..............................................
Parts Location.............................................
Tightening Torque ......................................
Body Dimension ............................................
Front Section ..............................................
Room Section (SWB) .................................
Room Section (LWB) ..................................
Rear Section (SWB) ...................................
Rear Section (LWB)....................................
Side Body Section (Front side) ...................
Side Body Section (Rear side) ...................
General Description (Body) ...........................
8F - 2
8F - 3
8F - 3
8F - 3
8F - 4
8F - 5
8F - 5
8F - 5
8F - 6
8F - 6
8F - 7
8F - 7
8F - 7
8F - 8
8F - 8
8F - 9
8F - 9
8F - 10
8F - 10
8F - 10
8F - 11
8F - 11
8F - 11
8F - 12
8F - 12
8F - 14
8F - 14
8F - 14
8F - 15
8F - 16
8F - 16
8F - 16
8F - 17
8F - 18
8F - 18
8F - 18
8F - 19
8F - 21
8F - 21
8F - 21
8F - 22
8F - 22
8F - 25
8F - 27
8F - 29
8F - 31
8F - 33
8F - 35
8F - 37
Instrument Panel Assembly ..........................

Parts Location.............................................
Removal......................................................
Installation...................................................
Front Door Assembly ....................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Rear Door Assembly .....................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Front Window Regulator, Glass and
Glass Run....................................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Rear Window Regulator, Glass and
Glass Run....................................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Rear Tailgate (LWB) .....................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Rear Tailgate (SWB) .....................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Rear Hatchgate (LWB) ..................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Adjustment..................................................
Tailgate Glass (SWB)....................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Spare Tire Carrier .........................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Windshield.....................................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Rear Quarter Glass (LWB) ............................
Parts Location.............................................
8F - 37
8F - 37
8F - 38
8F - 40
8F - 41
8F - 41
8F - 41
8F - 42
8F - 43
8F - 43
8F - 43
8F - 44
8F - 45
8F - 45
8F - 46
8F - 47
8F - 48
8F - 48
8F - 49
8F - 50
8F - 51
8F - 51
8F - 52
8F - 53
8F - 54
8F - 54
8F - 54
8F - 55
8F - 56
8F - 56
8F - 57
8F - 57
8F - 59
8F - 60
8F - 60
8F - 60
8F - 61
8F - 62
8F - 62
8F - 62
8F - 62
8F - 63
8F - 63
8F - 63
8F - 64
8F - 67
8F - 67
8F2
BODY STRUCTURE
Removal .....................................................
Installation ..................................................
Rear Quarter Glass (SWB) ...........................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
8F - 67
8F - 68
8F - 69
8F - 69
8F - 69
8F - 69
Side Window Glass (SWB)............................

Parts Location.............................................
Removal......................................................
Installation...................................................
Special Tools .................................................
8F - 71
8F - 71
8F - 71
8F - 71
8F - 73
8F - 76
Service Precaution

parts and systems.
BODY STRUCTURE
8F3
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.
Frame Dimensions (LWB)
501RX015
8F4
BODY STRUCTURE
Frame Dimensions (SWB)
501RX016
BODY STRUCTURE
8F5
General Description (Bumper)

Front and rear bumpers consist of bumper fascia,
support, and reinforcement.
The absorbing capability for both front and rear bumper

systems are achieved through reinforcements in each
bumper.
Front Bumper
Parts Location
601RW019
Legend
(1)
(2)
(3)
(4)
Backbar
Front Bumper Reinforcement Assembly
Support Assembly
Front Bumper Slider
EndOFCallout
(5) Bumper Fascia

(6) Front Bumper Assembly
8F6
BODY STRUCTURE
Removal
Installation

2. Disconnect front fog light connector (With fog light).
3. Remove the front bumper fixing bolts.
Remove the two bolts from both sides of the front
bumper.
To install, follow the removal steps in reverse order

1. Tighten the front bumper assembly fixing bolts to the
specified torque.
Torque : 147 Nm (15 kgm/108 lb ft)
2. Front bumper adjustment
When the bolts fixing front bumper assembly are
tightened, adjustment should be made between
the back bar and front side bumper so that a
clearance of 14.5 mm (0.57 in) is provided
between the lower side of the fender and the
upper side of the front bumper.
601RW004
4. Remove the front bumper assembly.

5. Remove the support assembly.
Remove the three fixing bolts.
6. Remove the front bumper reinforcement assembly.
Remove the eleven fixing bolts.
7. Remove the three bolts at each backbar and remove
backbars.
8. Remove the front fog light assembly (With fog light).
9. Remove the front bumper slider(1).
Remove the two screws(4) and the two nuts(3),
and release the claw from the washer(2).
601RW018
614RX002
BODY STRUCTURE
8F7
Front Bumper Slider Bracket

Removal
Installation

2. Remove the front bumper.
Refer to Front Bumper in this section.
3. Remove the three nuts(1) and draw out the slider
bracket(2).
601RW017
To install, follow the removal steps in reverse order.
8F8
BODY STRUCTURE
Rear Bumper
Parts Location
690RX002
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Protector
Rear Mud Flap
Bumper Bracket
Rear Bumper Support
Rear Bumper Slider Bracket
Rear Corner Bumper
Backber
Rear Bumper Reinforcement Assembly
Rear License Plate Bracket
EndOFCallout
(10)
(11)
(12)
(13)
(14)
(15)
(16)
License Plate Light Assembly

Rear License Plate Extension
Reflector Assembly
Rear Bumper Assembly
Rear Center Bumper
Rear Bumper Fixing Bolt
License Plate Light Harness
BODY STRUCTURE
8F9
Removal
2. Remove the rear mud flaps.
Remove the four bolts.
3. Remove the protectors.
Remove the three clips.
4. Remove the spare tire.
5. Remove the bumper brackets.
Remove the two nuts.
6. Remove the rear bumper supports.
Remove the nut and bolt.
7. Remove the rear bumper assembly(1).
Remove the two bolts(2) from each side.
Disconnect the license plate light harness
connector.
690RW017
14. Remove the backbers from the rear bumper

reinforcement assembly.
Remove the three bolts at each backber.
Installation
To install, follow the removal steps in reverse order,
1. Partially tighten the rear bumper bolts(2) (3) and
adjust the clearance between the body (tailgate)
and the rear bumper(1).
Then fully tighten the rear bumper bolts(2) (3).
690RW015
8. Remove the license plate light assembly and license

plate harness.
9. Remove the rear license plate extension and
bracket.
10. Remove the rear center bumper.
Remove the ten clips from the step part and three
bolts from each upper and lower sides.
11. Remove the reflector assemblies.
12. Remove the rear corner bumpers.
Remove the three bolts from each rear corner
bumper.
13. Remove the rear bumper slider brackets(1).
Remove the two screws(4) and two nuts(3), and
then remove claw caught in the washer(2).
690RW008
8F10
BODY STRUCTURE
2. Rear bumper adjustment.

When the bolts fixing rear bumper assembly are
tightened, adjustment should be made with shims
so that clearances shown in the figure below are
provided between the body (tailgate) (4) and the
rear bumper(5).
690RW009
3. Tighten the spare tire fixing bolts to the specified

torque.
Rear Bumper Slider

Removal
Installation
1. Remove the Rear bumper.

Refer to Rear bumper removal (in this section).
2. Remove the rear bumper slider(1).
Remove the three bolts(2).
690RW016
To install, follow the removal steps in reverse order,

1. Apply chassis grease to the slider and the slider
bracket moving surface.
BODY STRUCTURE
8F11
General Description (Sheet Metal)

This section includes items of front end sheet metal that
are attached by bolts, screws or clips and related
accessory components.
Anticorrosion materials have been applied to the interior
surfaces of some metal panels to provide rust
resistance.
When servicing these panels, areas on which this
material has been disturbed, should be properly
recoated with servicetype anticorrosion material.
Engine Hood
Parts Location
610RW015
Legend
(1) Engine Hood Assembly
(2) Windowshield Washer Nozzle Tube
EndOFCallout
(3) Hood Hinge Bolt
8F12
BODY STRUCTURE
Removal
Installation
1. Open the hood.

2. Support the hood.
3. Remove the windshield washer nozzle tube.

1. Tighten the engine hood hinge fixing bolts to the
specified torque.
Torque : 10 Nm (1.0 kgm/87 lb in)
2. Check the engine hood and fender(1).
Height (step): 0.5 mm (0.02 in)
Adjust clearance with the hinges on the engine
hood.
Adjust height (step) with the hood rests(2).
880RS001
4. Remove the hood hinge bolts.

Before removing the hinges from the engine
hood, scribe a mark showing location of the
hinges to facilitate installation in the original
position.
610RW016
610RS006
5. Remove the engine hood.
610RX001
BODY STRUCTURE
610RX008
8F13
8F14
BODY STRUCTURE
Engine Hood Lock

Parts Location
610RX010
Legend
(1) Hood Lock Control Lever
(2) Control Cable
(3) Engine Hood Lock Assembly
(4) Radiator Grille

(5) Inner Liner
EndOFCallout
Removal
1. Remove the hood lock control lever.
2. Remove the inner liner.
3. Remove the control cable.
Remove the cable fixing clips from the body
panel.
Refer to Radiator Grille in this section.
5. Remove the engine hood lock assembly.
Apply setting marks(1) to the hood lock assembly
and the body prior to removal.
610RX009
BODY STRUCTURE
Installation
To install, follow the removal steps in the reverse order
1. Reroute the control cable to its original position, and
check and see if the lock assembly and control lever
work normally.
2. Tighten the hood lock assembly fixing bolts to the
specified torque.
8F15
8F16
BODY STRUCTURE
Radiator Grille
Parts Location
603RX003
Legend
(1) Radiator Grille Rubber
(2) Screw
(3) Radiator Grille Assembly

(4) Clip
EndOFCallout
Removal
1. Open the hood.
2. Support the hood.
Raise the clips on the radiator grille and remove
screw.
603RS006
BODY STRUCTURE
4. Pull out the radiator grille rubber from fender panel
front lower side.
Installation
1. Install the radiator grille clips remaining on the body
side in the radiator grille, and then install the radiator
grille on the body.
8F17
8F18
BODY STRUCTURE
Front Fender Panel

Parts Location
605RX001
Legend
(1)
(2)
(3)
(4)
(5)
Antenna Assembly
Front Fender Panel
Front Wheel Arch Moulding (If so equipped)
Front Mud Flap
EndOFCallout
Removal
2. Remove the radiator grille assembly.
Refer to Radiator Grille in this section.
(6) Inner Liner

(7) Front Combination Light Assembly
(8) Radiator Grille
BODY STRUCTURE
8F19
8. Remove the front fender panel.

Remove the eight fixing bolts.
3. Remove the front combination light assembly.

Remove the fixing screw and disconnect the
connector.
614RX006
801RW027
4. Remove the front mud flap.

5. Remove the inner liner.
9. Remove the front wheel arch moulding (If so

equipped).
Refer to Wheel Arch Moulding in Exterior/Interior
Trim section.
Installation
1. Tighten the front fender panel fixing bolts to the
specified torque.
2. Check the fender and front door(1).
Height (step): Flush
647RS001
6. Remove the antenna assembly.

Refer to Rod Type Antenna in Entertainment
section.
7. Remove the side turn signal light.
Refer to Side Turn Signal Light Bulb in Lighting
System section.
610RW020
8F20
BODY STRUCTURE
610RW001
BODY STRUCTURE
8F21
Body Mounting
Parts Location
501RX017
Legend
(1)
(2)
(3)
(4)
No.1 Body Mounting

No.2 Body Mounting
No.3 Body Mounting
No.4 Body Mounting (LWB only)
(5) No.5 Body Mounting

(6) Body Side Mounting Bracket
(7) Frame Side Mounting Bracket
EndOFCallout
Tightening Torque
1. Tighten the body mounting bolts to specified torque.
* mark position
(LWB) Torque : 50 Nm (5.1 kgm/41 lb ft)
(SWB) Torque : 103 Nm (10.5 kgm/76 lb ft)
8F22
BODY STRUCTURE
Body Dimension
Front Section
A10RW034
BODY STRUCTURE
8F23
A10RW035
8F24
BODY STRUCTURE
A10RW036
BODY STRUCTURE
8F25
Room Section (SWB)
A10RW037
8F26
BODY STRUCTURE
A10RW038
BODY STRUCTURE
8F27
Room Section (LWB)

Refer to SWB for front side of room section.
A10RW039
8F28
BODY STRUCTURE
A10RW040
BODY STRUCTURE
8F29
Rear Section (SWB)
A10RW041
8F30
BODY STRUCTURE
A10RW042
BODY STRUCTURE
8F31
Rear Section (LWB)
A10RW043
8F32
BODY STRUCTURE
A10RW044
BODY STRUCTURE
8F33
Side Body Section (Front side)
A10RW045
8F34
BODY STRUCTURE
A10RW046
BODY STRUCTURE
8F35
Side Body Section (Rear side)
A10RW047
8F36
BODY STRUCTURE
A10RW048
BODY STRUCTURE
8F37
General Description (Body)


Parts Location
740RX067
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Cross Beam
Instrument Harness Assembly
Meter Assembly
Instrument Panel Center Reinforcement
Meter Cluster Assembly
Driver knee Bolster Assembly
Instrument Panel Driver Lower Cover Assembly
Lower Cluster Assembly
Front Console Assembly
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)

Audio Sub Box
Radio Assembly
Glove Box
Passenger Lower Bracket
Glove Box Side Reinforcement
Instrument Upper Reinforcement
Dash Side Trim Panel
Passenger Air Bag Cover
Passenger Air Bag
Passenger Air Bag Reinforcement
8F38
BODY STRUCTURE
(22) Instrument Panel Stay

(23) Vent Duct Assembly
EndOFCallout
Removal
CAUTION: For precautions on installation or
removal of SRS air bag system, refer to
Supplemental Restraint System (SRS) AIR BAG in
Restraint section.
2. Remove the lower cluster assembly.
Remove screw (3) and pull out the cluster at the
clip positions (1).
Disconnect the cigarette lighter connectors (2).
470RW007
7. Remove the instrument panel driver lower cover

assembly.
Remove the engine hood opener two fixing
screws and another one fixing screw.
After four clips are pried, disconnect switch
connector and duct.
470RW006
3. Remove the radio assembly and audio sub box.

Refer to Radio in Entertainment section.
4. Remove the front and rear consoles.
Refer to Consoles in Exterior/Interior Trim
section.
5. Remove the dash side trim panels.
Remove the sill plates, then remove the trim
panels.
6. Remove the glove box.
610RW023
8. Remove the meter cluster assembly.

Remove the five fixing screws, two clips and
switch connectors.
9. Remove the meter assembly.
Remove the four fixing screws and disconnect the
connectors.
10. Remove the driver knee bolster assembly.
Remove the six fixing bolts and screw.
BODY STRUCTURE
8F39
11. Remove the control lever assembly.

Refer to Control Lever Assembly and/or Control
Cable in Heating, Ventilation and Air Conditioning
(HVAC) section.
Supplemental Restraint System (SRS) AIR BAG in
Restraint section.
Disconnect the instrument harness connectors
(six connectors on the driver's side, three
connectors on the passenger side and two
connectors on the center side).
Disconnect radio antenna cable plug and the
ground cable fixing bolts from dash side panel.
Remove the two fixing bolts of passenger air bag
assembly and disconnect the connector.
Remove the two fixing screws from fuse box.
After pry the three hole cover from the surface of
instrument panel, remove the three nuts.
Remove the six bolts and one screw.
827RW024
14. Remove the vent duct assembly.

Remove the five fixing screws.
15. Remove the passenger lower bracket.
Remove the three screws.
16. Remove the glove box side reinforcement.
17. Remove the instrument upper reinforcement.
Remove the nine screws.
18. Remove the instrument panel center reinforcement.
Remove the six screws.
19. Remove the instrument panel harness assembly
(1).
Remove the clips.
740RX070
13. Remove the passenger air bag.

Remove the four fixing nuts.
Supplemental Restraint System in Restraint
section.
740RX069
20. Remove the instrument panel stays.

Remove the two fixing nuts and two fixing bolts
for each bracket.
8F40
BODY STRUCTURE
21. Remove the cross beam.

Remove the five fixing nuts, two fixing bolts
(upper) and six fixing bolts (lower).
840RW025
Installation
Refer to Control Lever Assembly in Heating,
Ventilation and Air Conditioning (HVAC) section.
BODY STRUCTURE
8F41
Front Door Assembly

Parts Location
630RW002
Legend
(1) Front Door Assembly
(2) Lower Hinge Bolt
(3) Door Harness Connection
(4) Door Check Arm Pin

(5) Upper Hinge Bolt
EndOFCallout
Removal
2. Apply a setting mark on the body side hinge.
3. Remove the door check arm pin.
630RW001
8F42
BODY STRUCTURE
4. Remove the upper and lower hinge bolts.

Position a wood block under the door for
protection and support the door assembly with
hands during removal or installation.
Installation
1. Align the door fitting to the body.
Check the fender and front door (1).
Check the front door and rear door (2).
Check the rear door and body (3) (4).
Adjust clearance with door hinges.
Adjust height (step) by tapping on the fender
lightly with a rubber hammer.
635RW003
5. Remove the door harness connection.

Pull the door harness grommet out in order to
disconnect the harness connection.
610RW024
2. Tighten the door hinge bolts to the specified torque.

3. Apply chassis grease to the door check arm pin and
the door hinge moving surface.
630RW004
6. Remove the front door assembly.
BODY STRUCTURE
8F43
Rear Door Assembly

Parts Location
650RW003
Legend
(1) Rear Door Assembly
(2) Lower Hinge Bolt
(3) Door Harness Connection
(4) Door Check Arm Pin

(5) Upper Hinge Bolt
EndOFCallout
Removal
4. Remove the upper and lower hinge bolts.

Position a wood block under the door for
protection and support the door assembly with
hands during removal or installation.

2. Apply a setting mark on the body side hinge.
3. Remove the door check arm pin.
650RW001
630RW003
8F44
BODY STRUCTURE
5. Remove the door harness connection.

Pull the door harness grommet out in order to
disconnect the door harness connection.
630RW004
6. Remove the rear door assembly.
Installation
1. Align the door fitting to the body by referring to Front
Door Assembly in this section.
2. Tighten the door hinge bolts to the specified torque.
3. Apply chassis grease to the check arm pin and the
door hinge moving surface.
BODY STRUCTURE
8F45
Front Window Regulator, Glass and Glass Run

Parts Location
635RW015
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Glass Run
Glass
Window Regulator
Waist Seal
Outside Handle
Locking Link
Door Lock Assembly
Waterproof Sheet
Door Trim Panel
Courtesy Light Lens
EndOFCallout
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Speaker Grille
Grip Cover
Inside Handle
Power Window Switch
Speaker Assembly
Tweeter
Door Mirror Cover
Door Mirror Assembly
8F46
BODY STRUCTURE
Removal
2. Remove the power window switch.
Pry out the power window switch and remove the
connectors.
4. Remove the speaker grille (1).

Pull out the front side of the grille.
5. Remove the speaker assembly (2).
Remove the four screws and disconnect the
speaker harness connector (3).
890RX012
635RW016
3. Remove the screw while pulling the inside lever

toward you and then remove the inside handle.
6. Remove the door mirror cover.

7. Remove the grip cover.
8. Remove the five screws (1), (3) and pull out the trim
panel at the six clip positions (2).
632RW003
635RW007
BODY STRUCTURE
9. Remove the waterproof sheet.
10. Remove the two screws through the access hole
and pull out the glass upward.
8F47
12. Remove the window regulator.

Remove the seven fixing bolts.
Disconnect the window regulator motor harness
connector.
13. Remove the glass run.
Pull the glass run (6) out from the door frame
groove.
631RW006
11. Turn the glass inside out and pull it up from its rear
side.
631RS007
Installation
1. Check to see that the window regulator operates
smoothly and the glass opens and closes properly.
2. Install the waterproof sheet with no clearance
between the door panel and the waterproof sheet.
631RW007
8F48
BODY STRUCTURE
Rear Window Regulator, Glass and Glass Run

Parts Location
655RW011
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Glass Run
Glass
Fixed Glass
Window Regulator
Outside Handle
Door Lock Assembly
Bracket
Rear Corner Garnish
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
Door Trim Panel

Courtesy Light Lens
Power Window Switch
Inside Handle
Waterproof Sheet
Waist Seal
BODY STRUCTURE
Removal
8F49

7. Remove the bracket.
8. Remove the waterproof sheet (1).
Taking notice of the door harness, peel the
waterproof sheet off the door panel carefully.

3. Remove the one screw at the pull case.
651RS002
655RW003
4. Remove the rear corner garnish.

5. Pull out the trim panel at the eight clip positions.
Disconnect the power window switch connector
and courtesy light connector.
9. Remove the fixed glass.

Remove one bolt and screw as shown in the
figure, then pull it upward.
651RW002
655RW002
8F50
BODY STRUCTURE
10. Remove the glass.

First, align the height of regulator to the access
hole. Remove two screws attaching bottom
channel and regulator, then remove the glass.
11. Remove the window regulator.

Remove the six fixing bolts and pull the regulator
out from the lower hole of the door panel.
651RW006
Remove the window glass by tilting it as

necessary.
651RW005
12. Remove the glass run.

Pull the glass run out from the door frame.
Installation
1. Check to see that the window regulator operates
smoothly and the glass opens and closes properly.
2. Install the waterproof sheet with no clearance
between the door panel and the waterproof sheet.
651RW007
BODY STRUCTURE
8F51
Rear Tailgate (LWB)

Parts Location
681RW010
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Hatchgate Lock Assembly

Tailgate Assembly
Tailgate Bell Crank
Hinges
Plug
Tailgate Stopper Link
Waterproof Sheet
Trim Cover Assembly
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Rear Wiper Motor

Dove Tail
Key Cylinder
Tailgate Lock Assembly
Hatchgate Lock Actuator Assembly
Outside Handle
Tailgate Waist Seal
8F52
BODY STRUCTURE
Removal
2. Remove the tailgate trim cover assembly (3).
Remove the two screws (2) holding the hatchgate
lock assembly (1) first and the two screws fixing
the trim cover assembly. Pull up the trim cover
while detaching the clips from tailgate panel.
6. Remove the key cylinder.

Disconnect the locking links.
Remove the key cylinder retaining clip with
screwdriver to remove the key cylinder.
683RW025
683RW001
3. Remove the tailgate trim brackets (2).

Remove the three fixing screws (3) and screw
grommets (1).
Remove the waterproof sheet, taking special care
so as not to break it.
681RW014
5. Remove the hatchgate lock.

Disconnect the lock link and connector and
remove the three fixing bolts.
7. Remove the hatchgate lock actuator assembly.

Disconnect the actuator harness connector.
Remove the two nuts holding hatchgate lock
actuator assembly from inside.
8. Remove the outside handle.
Remove the two bolts holding the outside handle
from inside.
9. Remove the tailgate lock assembly.
Remove the three screws holding the lock
assembly.
10. Remove the dove tail.
11. Remove the tailgate locking links.
12. Remove the rear wiper arm.
Refer to Rear Wiper Arm/Blade in Wiper/Washer
System section.
13. Remove the rear wiper motor.
14. Remove the tailgate harness cable.
15. Remove the spare tire carrier.
Refer to Spare Tire Carrier in this section.
16. Remove the tailgate stopper link.
17. Remove the tailgate assembly.
Remove the tailgate assembly, taking care so as
not to damage the hinge. Tailgate assembly is
heavy and removal operation require two people.
18. Remove the tailgate waist seal.
BODY STRUCTURE
Installation
1. When setting up links, pay attention to the position
and direction of the links.
683RW003
Legend
(1)
(2)
(3)
(4)
Tailgate Lock Link

Outside Handle
Key Cylinder Lock Link
Cancel Mechanism
EndOFCallout
2. Tighten the tailgate hinge fixing bolts to the
specified torque.
Torque: 34 Nm (3.5 kgm/25 Ib ft)
3. Tighten the tailgate stopper link fixing bolts to the
specified torque.
4. Tighten the dove tail fixing bolts to the specified
torque.
8F53
8F54
BODY STRUCTURE
Rear Tailgate (SWB)

Parts Location
681RX002
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Tailgate Assembly
Hinges
Tailgate Stopper Link
Waterproof Sheet
Tailgate Trim Cover Assembly
Rear Wiper Motor
(7)
(8)
(9)
(10)
(11)
Dove Tail
Key Cylinder
Outside Handle
EndOFCallout
Removal
2. Remove the spare tire carrier.
Refer to Spare Tire Carrier in this section.
3. Remove the rear wiper arm.

System section.
BODY STRUCTURE
4. Remove the tailgate glass stay and tailgate glass.
Refer to Tailgate Glass (SWB) in this section.
5. Remove the tailgate trim cover assembly.
Remove the two screws fixing the trim cover
assembly and pull up the trim cover after
detaching the clips from tailgate panel.
grommets (1).
8F55
Remove the tailgate assembly, taking care so as

not to damage the hinge. Tailgate assembly is
heavy and removal operation requires two
people.
Installation
1. Tighten the tailgate hinge fixing bolts to the
specified torque.
2. Tighten the tailgate stopper link fixing bolts to the
specified torque.
3. Tighten the dove tail fixing bolts to the specified
torque.
681RW014
8. Remove the rear wiper motor.

Disconnect the motor connector and remove the
two fixing bolts.
Disconnect the locking links.
Remove the key cylinder retaining clip with
screwdriver to remove the key cylinder.
from inside.
Disconnect the locking link.
12. Remove the tailgate lock assembly.
assembly.
13. Remove the dove tail.
14. Remove the tailgate harness cable.
15. Remove the tailgate stopper link.
16. Remove the tailgate assembly.
8F56
BODY STRUCTURE
Rear Hatchgate (LWB)

Parts Location
682RW002
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
High Mount Stoplight

Hatchgate Hinge
Hinge Collar
Hatchgate Glass Seal
Hatchgate Gas Stay
Hatchgate Ball Stud
Ball Stud Spacer
Ball Stud Fastener
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Hatchgate Glass
Hatchgate Striker
Striker Fastener
High Mount Stoplight Fastener
Outside Handle Collar
Outside Handle
High Mount Stoplight Spacer
BODY STRUCTURE
Removal
8F57
Installation

2. Disconnect the high mount stoplight and rear
defogger harness connectors.
3. Remove the hatchgate ball stud (LH and RH).
Remove gas stay fixing screw and pull up the gas
stay assembly (3) from the ball stud by spreading
the retainer (2) holding the ball stud at the end of
the gas stay with screwdriver (1), etc.

1. Attach the upper seal (1) to the hatchgate glass (2)
indicated portion (3) so that the end of the glass
contacts the bottom of the upper seal.
682RW003
683RW004
4. Remove the hatchgate hinge nuts from body side.

5. Remove the hatchgate glass.
When pulling down the hatchgate glass, exercise
special care so as not to damage it.
Hatchgate glass assembly is heavy and removal
operation requires the two people.
6. Remove the two screws to remove hatchgate striker
and fastener.
8. Remove the hinges.
9. Remove the high mount stoplight.
10. Remove the hatchgate finisher.
2. When installing the hatchgate glass, first attach the

hinge to the hatchgate glass. Align the stud of the
hinge to the hole at body while supporting the
hatchgate glass with two people at indicated
positions (1), and then partially tighten the hinge to
body nut (2).
After adjustment (refer to Adjustment in this section)
is completed, fully tighten the nut, hinge to body nut.
Hatchgate hinge assembly for left and right sides
from each other.
682RW005
8F58
BODY STRUCTURE
3. When installing gas stay assembly (1), first install

the gas stay onto the rear quarter panel with fixing
screw (2) and fastener (3) and then attach the gas
stay upper end to the ball stud by spreading the
retainer with screwdriver, etc. Gas stay assemblies
for left and right sides differ from each other (The
letter (4) L(LH) or R(RH) is embossed on the gas
stay assembly.)
683RW005
4. When installing hatchgate striker assembly, first

partially tighten the fixing screw and close the
hatchgate and tailgate. Then fully tighten the fixing
screw with the condition that the striker fits the
hatchgate lock assembly at the tailgate.
Make sure that clearance exists between hatchgate
striker and lock assembly.
After installation, again make sure that the striker
fits the lock assembly properly.
5. Tighten the nuts; hinge to body (LH and RH)
6. Tighten the screws; glass and hinge fix (LH and RH)
NOTE: When installing the hinge to the body, exercise
special care not to damage the body paint surface.
7. Tighten the hatchgate striker fixing screws.
BODY STRUCTURE
8F59
Adjustment
Hatchgate alignment is obtained by moving
hatchgate hinges.
682RW004
Legend
(1)
(2)
(3)
(4)
(5)
Hatchgate Striker
Hatchgate Glass
Tailgate Outer Panel
Tailgate Inner Panel
Trim Cover
EndOFCallout
(6)
(7)
(8)
(9)

Quarter Trim
Hatchgate Glass Seal
Quarter Outer Panel
8F60
BODY STRUCTURE
Tailgate Glass (SWB)

Parts Location
682RW011
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Tailgate Trim Cover

Tailgate Seal
Tailgate Glass Assembly
Tailgate Moulding
Tailgate Glass Stay
Bolt
Cap
(8)
(9)
(10)
(11)
(12)
(13)
Screw
Collar
Gasket
Clip
Grommet
Nut
EndOFCallout
Removal
2. Remove the spare tire.
3. Remove the rear wiper.

System section.
4. Disconnect the rear defogger connectors (LH &
RH).
BODY STRUCTURE
5. Remove the tailgate glass stays.
Remove the two seats of two tailgate trim cover
fixing bolts.
6. Remove the tailgate glass assembly.
Remove the two caps each on the left and right
sides, then remove the screws.
Remove the two clips from the two ends of the
tailgate moulding, then lift the glass assembly up
and out.
Removing and installing the glass assembly
require two persons.
7. Remove the tailgate seal.
Installation
1. Tighten the tailgate glass stay fixing bolts to the
specified torque.
2. Make sure the lip is properly oriented when
installing the tailgate seal.
8F61
8F62
BODY STRUCTURE
Spare Tire Carrier

Parts Location
530RX005
Legend
(1) Spare Tire
(2) Spare Tire Carrier
EndOFCallout
Removal
1. Remove the spare tire (1).
2. Remove the spare tire carrier (2) by using spare tire
carrier nut wrench 5884020950 (J34355).
Installation
1. Spare tire carrier.
Tighten the carrier fixing bolts to the specified
torque.
2. Spare tire
Tighten the spare tire fixing bolts to the specified
torque.
BODY STRUCTURE
8F63
Windshield
Parts Location
607RW002
Legend
(1) Windshield Wiper Arm
(2) Windshield Upper Moulding
(3) Windshield
(4) Windshield Side Moulding

(5) Windshield Support
(6) Front Cowl Cover
EndOFCallout
Removal
2. Remove the front pillar trim cover.
Turn up the finisher and pry the trim cover clips
free from the body panel.
3. Remove the sunvisors and sunvisor holders.
Refer to Headlining in Exterior/Interior Trim
section.
4. Remove the rear view mirror.
8F64
BODY STRUCTURE
Turn the channel mount (2) 90 degrees clockwise

and pull down.
Attach some cloth tape (1) on the body for

protecting the painting surface.
825RX045
5. Remove the windshield wiper arm.

Refer to Windshield Wiper Arm/Blade in Wiper/
Washer System section.
6. Remove the windshield side moulding.
Pull the moulding out from drip rail.
7. Remove the front cowl cover.
8. Remove the windshield support.
9. Remove the upper moulding.
10. Remove the windshield.
Use a knife to cut through part of the adhesive
caulking material.
Secure one end of a piece of steel piano wire
(0.02 inches in diameter) to a piece of wood that
can serve as a handle.
Use a pair of needle nose pliers to insert the
other end of the piano wire through the adhesive
caulking material at the edge of the windshield
glass.
Secure the other end of the piano wire to another
piece of wood.
With the aid of an assistant, carefully move the
piano wire with a sawing motion to cut through
the adhesive caulking material around the entire
circumference of the windshield glass.
607RS014
Clean the remaining adhesive caulking material

from the area of the body which holds the
windshield.
Installation
1. Clean the bonding surfaces of both the windshield
and body panel with a soft rag and white gasoline.
2. Install the spacer.
Attach spacers in ten locations as shown in the
figure.
Always use new spacer.
607RW004
BODY STRUCTURE
3. Install the windshield upper moulding.
Peel off the tear-away paper from the windshield
upper moulding, and start applying it with one
end of the glass and cut away the surplus at the
other end of the glass for length adjustment.
Always use new upper moulding.
4. Temporary install the windshield support.
5. Apply the primer to the windshield and body panel.
Apply the primer (3) (Sun star # 435-40 or
equivalent) to the windshield side bonding
surface as shown in the figure.
8F65
Apply the primer (Sun star # 435-95 or

equivalent) to the body side bonding surface.
NOTE: Apply an adhesive 3 minutes or more but within
24 hours after the application of primer. If more than 24
hours have passed, reapply primer.
Primer should be handled as following:
1. Use the primer manufactured 3 months or less
ago and having been kept in an refrigerator.
2. Wipe off primer-stains on positions other than
requires application.
3. Stir the primer for a minute or more before use.
607RW003
Legend
(1) Adhesive
(2) Sealing Dam
(3) Primer Coating Area
EndOFCallout
(4) Windshield
(5) Upper Moulding
8F66
BODY STRUCTURE
6. Apply the adhesive (1) to the windshield.

After drying primer completely, apply a sealing
adhesive (Sun star # 555 or equivalent) along the
edge of the glass so that the sealing adhesive
has a 20 mm (0.79 in) junction at middle of the
base of the glass.
NOTE: Affix the glass within 5 minutes of application.
607RS017
607RW015
NOTE: Apply an adhesive 3 minutes or more but within

24 hours after the application of primer. If more than 24
hours have passed, reapply primer.
Adhesive should be handled as follows:
1. Use the adhesive manufactured 3 months or
less ago.
2. Wipe off adhesive-stains on positions other than
requires application.
7. Install the windshield.
Set the windshield with sealing adhesive applied
to entire circumference in the body panel.
Specifically, adjust windshield support with the
upper moulding making contact with the body
panel, press the glass, and tighten the windshield
support.
8. Install the front cowl cover.

9. Install side moulding.
Use white gasoline and a soft cloth to wipe away
any excess adhesive.
Cure the bonding at a temperature of 20
30C (68F 86F) for 24 hours.
Check that the windshield does not leak water.
607RX010
10. Install windshield wiper arm.
BODY STRUCTURE
8F67
Rear Quarter Glass (LWB)

Parts Location
641RX004
Legend
(1)
(2)
(3)
(4)
(5)
Quarter Trim Panel

Rear Quarter Glass Moulding
Rear Quarter Glass
Clip
Body Panel
(6)
(7)
(8)
(9)
Clip
Velcro Fastener
Primer Coating Area (Glass side & Body side)
Sealant
EndOFCallout
Removal
2. Remove the rear quarter trim panel.
Refer to Interior Trim Panels in Exterior/Interior
Trim section.
3. Remove the rear quarter glass.

Refer to Windshield in this section.
8F68
BODY STRUCTURE
Installation
1. Rear quarter glass.
Clean the bonding surfaces of both the glass and
the body panel.
Be absolutely sure to apply glass primer to the
side glass.
Be absolutely sure to apply body primer fully to
the body.
NOTE: Immediately wipe off the primer left on the body
or extruded sealant.
Attach the fastener to the indicated position of
body with sealant as shown in the figure.
Apply the sealant to the circumference of glass as
Insert the location pins on glass into the panel,
push the glass against the panel, and bond them.
Attach the moulding to the body with sealant.
Cure the bonding at a temperature of 20
30C (68F 86F) for 24 hours.
Check that the rear quarter glass does not leak
water.
2. Install the rear quarter trim panel.
BODY STRUCTURE
8F69
Rear Quarter Glass (SWB)

Parts Location
641RW011
Legend
(1)
(2)
(3)
(4)
Resin Top
Velcro Fastener
Rear Quarter Glass Assembly
Dam Seal
(5)
(6)
(7)
(8)
Adhesive
Body Panel
Weather Strip
Clip
EndOFCallout
Removal
2. Remove the rear quarter glass assembly.
Installation
1. Use alcohol or the like to wipe clean the areas of the
resin top and glass assembly that are to be affixed
to each other.
2. Apply the primer (2) to the area of the resin top to
which the glass is to be affixed.
Top edge (1) and bottom edge (3) primer coat
areas.
641RX002
8F70
BODY STRUCTURE
3. Stick the velcro fasteners to the body in the

specified locations.
4. Install the rear quarter glass assembly (1).
Apply the primer (4) to the rear quarter glass as
Stick the dam seal (2) in place and then apply
adhesive (3), as shown in the figure.
Allow a 20mm (0.79 in) overlap at the ends of the
adhesive.
Insert the glass clips into the hole in the panel
and then push the glass against the panel to affix
it in place.
641RX001
BODY STRUCTURE
8F71
Side Window Glass (SWB)

Parts Location
641RX003
Legend
(1)
(2)
(3)
(4)
(5)
Spacer
Primer Coating Area on Glass Side
Side Window Moulding
Adhesive
Clip
(6)
(7)
(8)
(9)
(10)
Side Window Glass

Velcro Fastener
Side Window Garnish Assembly
Body Panel
Primer Coating Area on Body Side
EndOFCallout
Removal
1. Remove the quarter trim cover.
Refer to Interior Trim Panels (SWB) in Exterior/
Interior Trim section.
2. Remove the side window garnish assembly.
Pull out the three clips to disengage them.
3. Remove the side window moulding.
4. Remove the side window glass.
Installation
1. Install the side window glass.
Clean the areas of the glass and body panel that
are to be affixed to each other.

Apply the primer to the specified areas of the
glass and body panel.
Stick the spacer and velcro fastener in place in
the specified locations.
Apply the adhesive to the entire circumference of
the glass, as shown in the figure.
Insert the glass clips into the panel and then push
the glass against the panel to affix it in place.
Wipe away any adhesive that oozes out around
the edges.
2. Install the side window garnish assembly.
Install it securely so that it does not come loose in
places.
8F72
BODY STRUCTURE
3. Install the side window moulding.

Insert it securely so that it does not come loose in
places.
Make sure that there is no water leakage from the
side window glass.
4. Install the quarter trim cover.
BODY STRUCTURE
8F73

501RX018
8F74
BODY STRUCTURE
630RX021
681RX003
601RX004
BODY STRUCTURE
8F75
650RX001
682RX002
8F76
BODY STRUCTURE
530RX006
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884020950
(J34355)
Spare Tire Carrier Nut
Wrench
SECTION
SEATS
8G1

SEATS
CONTENTS
Front Seat Assembly.....................................
Front Seat Assembly and Associated
Parts .........................................................
Removal .....................................................
Installation ..................................................
Rear Seat Assembly (LWB) ..........................
Rear Seat Cushion Assembly and
Removal .....................................................
Installation ..................................................
8G - 1
8G - 2
8G - 2
8G - 2
8G - 4
8G - 5
8G - 5
8G - 5
8G - 6
Service Precaution
Rear Seat Back Assembly and

Removal......................................................
Installation...................................................
Rear Seat Assembly (SWB) ..........................
Rear Seat Assembly and Associated
Parts..........................................................
Removal......................................................
Installation...................................................
Main Data and Specifications........................
Torque Specifications .................................
8G - 7
8G - 7
8G - 8
8G - 9
8G - 9
8G - 10
8G - 10
8G - 11
8G - 11

clamping force, and may damage the fastener.
parts and systems.
8G2
SEATS
Front Seat Assembly

Front Seat Assembly and Associated Parts
750RX011
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Headrest
Guide Holder
Seat Back Assembly
Reclining Device
Side Cover
Reclining Knob
(7)
(8)
(9)
(10)
(11)
Rear Cover
Seat Adjuster
Front Seat Belt Buckle Assembly
Hinge Cover
Front Seat Assembly
EndOFCallout
Removal
2. Remove the rear covers.
3. Remove the front seat assembly.

Remove the four fixing bolts.
Disconnect the seat belt warning connector
(Drivers side only).
SEATS
4. Pull out the reclining knob.
5. Remove the side cover.
Remove the two screws.
6. Remove the headrest.
7. Remove the reclining device.
Turn up the seat back trim cover in order to
remove the reclining device fixing bolts (LWB).
8G3
8. Remove the seat back assembly.

Remove the seat back assembly fixing nut on the
opposite side of the reclining device.
750RS007
750RS006
Remove the push nut (2) of device (1) and

disconnect the walk-in cable (3) (SWB).
9. Remove the trim cover (Seat back side).

10. Remove the guide holder.
Pull the guide holder out by holding the bottom
end of it from the seat back assembly.
11. Remove the seat adjuster.
Disconnect the release wire (4) and remove the
fixing bolts.
750RW034
750RW006
12. Remove the seat belt buckle assembly.

13. Remove the trim cover (Seat cushion side).
8G4
SEATS
Installation
1. Tighten the reclining device fixing bolts to the
specified torque.
2. Tighten the front seat assembly fixing bolts to the
specified torque.
SEATS
8G5
Rear Seat Assembly (LWB)

Rear Seat Cushion Assembly and Associated Parts
755RW066
Legend
(1)
(2)
(3)
(4)
Rear Seat Lock Striker

Rear Seat Lock Assembly
Rear Seat Belt Buckle Assembly
Seat Cushion Hinge
(5) Hinge Cover

(6) Seat Cushion Fixing Bolt
(7) Rear Seat Cushion Assembly
EndOFCallout
Removal
1. Remove the hinge covers.
2. Remove the seat cushion fixing bolts.
3. Remove the seat cushion assembly.
Pull on the strap of the rear seat lock assembly to
release the seat lock.
4. Remove the seat cushion hinges.
8G6
SEATS
5. Remove the rear cushion trim cover (1) and rear

seat cushion pad (2).
Remove cushion trim cover from rear cushion
frame (3) with prying the plastic retainers (4).
Installation
1. Tighten the rear seat lock assembly and rear seat
belt buckle assembly fixing bolts to the specified
torque.
2. Tighten the rear seat lock striker fixing bolts to the
specified torque.
3. Tighten the seat cushion hinge fixing bolts to the
specified torque.
755RX028
6. Remove the rear seat lock assembly and rear seat

belt buckle assembly.
7. Remove the rear seat lock strikers.
Remove the four bolts at each striker.
SEATS
8G7
Rear Seat Back Assembly and Associated Parts
755RW065
Legend
(1)
(2)
(3)
(4)
Headrest
Seat Back Assembly
Guide Holder
Release Knob
(5)
(6)
(7)
(8)
Seat Lock Cover

Side Hinge
Body Floor Panel
Center Hinge
EndOFCallout
Removal
1. Pull on the release knob and fold the seat back
assembly forward.
2. Remove the luggage floor carpets.
Remove the carpet fixing nine clips at each from
the backside of the seat back assembly.
3. Remove the seat back assembly.
Remove the four fixing bolts at each seat back.
4. Remove the seat lock covers.

5. Remove the headrests.
6. Remove the release knobs.
Turn the knob counterclockwise to remove it.
7. Remove the trim covers.
8. Remove the guide holders.
9. Remove the side hinges.
Remove the one fixing nut at each side hinge.
8G8
SEATS
10. Remove the center hinge.

Remove the two fixing bolts.
Installation
1. Tighten the center hinge fiixng bolts to the specified
torque.
2. Tighten the side hinge fixing nuts to the specified
torque.
Torque: 29 Nm (3.0 kgm/22lbft)
SEATS
8G9
Rear Seat Assembly (SWB)

Rear Seat Assembly and Associated Parts
755RW067-1
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Headrest
Guide Holder
Rear Seat Back Assembly
Release Knob
Seat Lock Cover
Seat Lock Assembly
Rear Seat Belt Buckle Assembly
Reclining Device
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Device Cover
Rear Seat Cushion Assembly
Support Cover
Rear Seat Leg
Rear Seat Leg Cover
Rear Floor Lock Striker
Free Hinge Cover
8G10
SEATS
Removal
1. Fold the rear seat backs forward.
Pull up on the left and right release knobs.
2. Remove the rear seat leg covers.
Remove the one screw and clip from each.
3. Remove the rear seat assembly.
Remove the two sets of two fixing bolts from left
and right sides, then pull on the seat lock strap to
release the seat lock.
4. Remove the device covers (left and right).
Remove the three screws from each.
5. Remove the release knobs (left and right).
6. Remove the rear seat back assemblies (left and
right).
Remove the two sets of two reclining device fixing
bolts from the sides of the seat backs.
7. Remove the headrests.
8. Remove the trim covers.
9. Remove the guide holders.
10. Remove the reclining devices.
Remove the two sets of two fixing bolts from the
sides of the seat cushions.
11. Remove the rear seat legs (left and right).
12. Remove the support covers (left and right).
Remove the three screws from each.
13. Remove the seat lock covers (left and right).
14. Remove the seat lock assemblies and the rear seat
belt buckle assemblies (left and right).
Remove the two sets of two fixing bolts.
15. Remove the free hinge cover.
Installation
1. Tighten the seat lock assemblies and the rear
seatbelt buckle assemblies to the specified torque.
2. Tighten the reclining devices to the specified torque.
3. Tighten the rear seat assembly fixing bolts to the
specified torque.
SEATS
8G11

760RX015
8G12
SEATS
755RX022
SECTION
SECURITY AND LOCKS
8H1

SECURITY AND LOCKS
CONTENTS
Front Door Lock Assembly............................
Front Door Lock Assembly and
Removal .....................................................
Installation ..................................................
Front Outside Handle ....................................
Front Outside Handle and
Removal .....................................................
Installation ..................................................
Rear Door Lock Assembly ............................
Rear Door Lock Assembly and
Removal .....................................................
Installation ..................................................
Rear Outside Handle.....................................
Rear Outside Handle and
Removal .....................................................
Installation ..................................................
Tailgate Lock and Hatchgate Lock (LWB).....
Tailgate Lock, Hatchgate Lock and
Removal .....................................................
Installation ..................................................
8H - 1
8H - 2
8H - 2
8H - 3
8H - 4
8H - 5
8H - 5
8H - 5
8H - 5
8H - 6
8H - 6
8H - 7
8H - 7
8H - 8
8H - 8
8H - 8
8H - 8
8H - 9
8H - 9
8H - 10
8H - 11
Service Precaution
REPAIRS.
Tailgate Lock (SWB) .....................................

Tailgate Lock and Associated Parts ...........
Removal......................................................
Installation...................................................
Fuel Filler Door Lock .....................................
Fuel Filler Door Lock and
Removal......................................................
Installation...................................................
Key ................................................................
Key Coding .................................................
Key Styles...................................................
Power Door Lock System..............................
Door Lock Key Switch.................................
Front Door Lock Actuator............................
Rear Door Lock Actuator ............................
Tailgate Lock Actuator ................................
Fuel Filler Door Lock Actuator ....................
Keyless Entry System ...................................
Keyless Entry Control Unit..........................
Keyless Entry Control Unit/Transmitter
Replacement ...........................................
8H - 12
8H - 12
8H - 12
8H - 13
8H - 14
8H - 14
8H - 14
8H - 15
8H - 16
8H - 16
8H - 16
8H - 17
8H - 17
8H - 17
8H - 17
8H - 17
8H - 17
8H - 17
8H - 18
8H - 18
8H - 18
8H - 18
8H - 19

and systems.
8H2
SECURITY AND LOCKS
Front Door Lock Assembly

Front Door Lock Assembly and Associated Parts
635RW018
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Outside Handle
Door Locking Link
Door Lock Assembly
Waterproof Sheet
Door Trim Panel
Courtesy Light Lens
EndOFCallout
(7)
(8)
(9)
(10)
(11)
Speaker Grille
Grip Cover
Inside Handle
Power Window Switch
Speaker Assembly
SECURITY AND LOCKS
Removal
2. Remove the power window switch (1).
Pry out the power window switch and remove the
connectors.
8H3
5. Remove the speaker assembly (2).

Remove four screws and disconnect the speaker
harness connector (3).
890RX012
635RW016

6. Remove the courtesy light lens.

7. Remove the five screws (1), (3) and pull out the door
trim panel at the six clip positions (2).
Disconnect the tweeter connector and courtesy
light connector.
632RW003
4. Remove the speaker grille (1).

Pull out the front side of the grille.
635RW007

9. Raise the glass up to the uppermost position, and
then remove the rear guide rail.
8H4
SECURITY AND LOCKS
10. Disconnect the locking links then remove the door

lock assembly fixing screws and door lock assembly.
Installation
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 Nm (0.7kgm/61lbin)
3. Check that the door lock operates smoothly.
652RW002
SECURITY AND LOCKS
8H5
Front Outside Handle

Front Outside Handle and Associated Parts
635RW018
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Outside Handle
Door Locking Link
Door Lock Assembly
Waterproof Sheet
Door Trim Panel
Courtesy Light Lens
(7)
(8)
(9)
(10)
(11)
Speaker Grille
Grip Cover
Inside Handle
Power Window Switch
Speaker Assembly
EndOFCallout
Removal
2. Remove the door trim panel.
Refer to Front Door Lock Assembly in this
section.
4. Disconnect the locking links and remove the outside
handle.
5. Remove the fixing clip to remove the door lock
cylinder.
Installation
1. Be sure to install the door lock cylinder at a right
angle to the outside handle.
2. Check for smooth outside handle and lock cylinder
operation.
3. Tighten the outside handle fixing bolts to the
specified torque.
Torque 9Nm (0.9kgm/78lbin)
8H6
SECURITY AND LOCKS
Rear Door Lock Assembly

Rear Door Lock Assembly and Associated Parts
655RW012
Legend
(1)
(2)
(3)
(4)
(5)
Outside Handle
Door Lock Assembly
Bracket
Rear Corner Garnish
Door Trim Panel
EndOFCallout
(6)
(7)
(8)
(9)
Courtesy Light Lens

Power Window Switch
Inside Handle
Waterproof Sheet
SECURITY AND LOCKS
Removal
8H7
7. Remove the bracket.

9. Disconnect the locking links and remove the door
lock assembly fixing screws to remove the door lock
assembly.

2. Remove rear corner garnish.
3. Remove courtesy light lens.
5. Remove the two screws at the pull case and
courtesy light.
Installation
2. Tighten the door lock assembly fixing screws to the
specified torque.
3. Check that the door lock operates smoothly.
655RW003
6. Pull out the trim panel at the eight clip positions.

Disconnect the power window switch connector
and courtesy light connector.
655RW002
8H8
SECURITY AND LOCKS
Rear Outside Handle

Rear Outside Handle and Associated Parts
655RW012
Legend
(1)
(2)
(3)
(4)
(5)
Outside Handle
Door Lock Assembly
Bracket
Rear Corner Garnish
Door Trim Panel
(6)
(7)
(8)
(9)
Courtesy Light Lens

Power Window Switch
Inside Handle
Waterproof Sheet
EndOFCallout
Removal
Refer to Rear Door Lock Assembly in this section.
4. Disconnect the locking link and remove fixing bolts
to remove the outside handle.
Installation
1. Check that the outside handle operates smoothly.
2. Tighten the outside handle fixing bolts to the
specified torque.
SECURITY AND LOCKS
8H9
Tailgate Lock and Hatchgate Lock (LWB)

Tailgate Lock, Hatchgate Lock and Associated Parts
681RW015
Legend
(1)
(2)
(3)
(4)
(5)

Tailgate Assembly
Tailgate Lock Relay Lever
Waterproof Sheet
Trim Cover Assembly
EndOFCallout
(6)
(7)
(8)
(9)
Key Cylinder
Outside Handle
8H10
SECURITY AND LOCKS
Removal
2. Remove the tailgate trim cover assembly (3).
Remove the two screws (2) holding the hatchgate
lock assembly (1) first and the two screws fixing
the trim cover assembly. Pull up the trim cover
while detaching the clips from tailgate panel.
5. Remove the hatchgate lock.

Disconnect the lock link and connector and
remove the three fixing bolts.
Disconnect the lock links.
Remove the key cylinder retaining clip with screw
driver to remove the key cylinder.
683RW025
683RW001

Remove the three screws (3) and screw
grommets (1).
681RW014

from inside.
9. Remove tailgate lock assembly.
assembly.
SECURITY AND LOCKS
Installation
1. When setting up links, pay attention to the position
and direction of the links.
683RW003
Legend
(1)
(2)
(3)
(4)
Tailgate Lock Link

Outside Handle
Key Cylinder Link
Cancel Mechanism
EndOFCallout
3. Check that the tailgate lock operates correctly after
installing it.
4. Tighten the hatchhgate lock assembly fixing bolts to
8H11
8H12
SECURITY AND LOCKS
Tailgate Lock (SWB)

Tailgate Lock and Associated Parts
681RW013
Legend
(1)
(2)
(3)
(4)
Tailgate Assembly
Waterproof sheet
Trim Cover Assembly
Key Cylinder
EndOFCallout
Removal
2. Remove the tailgate glass assembly and tailgate
glass stay.
Refer to Tailgate Glass (SWB) in Body Structure
section.
3. Remove the tailgate trim cover assembly.
Remove the two screws fixing the trim cover
assembly and pull up the trim cover after
detaching the clips from tailgate panel.
grommets (1).
(5) Tailgate Lock Assembly

(6) Outside Handle
(7) Hatchgate Lock Actuator Assembly
SECURITY AND LOCKS

8H13
Installation
2. Tighten the hatchhgate lock assembly fixing screws
3. Check that the tailgate lock operates correctly after
installing it.
681RW014

Remove the key cylinder retaining clip with screw
driver to remove the key cylinder.
Disconnect the lock link.
from inside.
9. Remove tailgate lock assembly.
assembly.
8H14
SECURITY AND LOCKS
Fuel Filler Door Lock

Fuel Filler Door Lock and Associated Parts
This illustration is based on the SWB model.
686RW014
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Link (SWB only)

Clip (SWB only)
Fuel Filler Door Lock Actuator Assembly
Rod
Accessory Socket
Luggage Trim Cover
(7)
(8)
(9)
(10)
(11)
Rear End Floor Trim Cover

Canopy Cover
Luggage Side Lid Assembly
Luggage Side Upper Cover
Luggage Side Front Cover
EndOFCallout
Removal
2. Unlock the fuel filler door.
3. Remove the luggage trim cover on the left side.
Remove the two clips, then canopy cover.
Remove the luggage side lid assembly.
Remove the luggage side upper cover.
Remove the luggage side front cover.
Remove the one fixing screw on the front upper
side of the luggage trim cover.
Remove the rear and floor trim cover.
Disconnect the accessory socket connector.
4. Remove the quarter trim cover (LWB).

Refer to Interior Trim Panel in Exterior/Interior
section.
5. Remove the fuel filler door lock actuator assembly.
Remove the two fixing bolts and one fixing screw.
(For LWB, one bolt and two screws.)
6. Remove the fixing clip of the link.
SECURITY AND LOCKS

7. Remove the fuel filler door lock cap (2).
While pressing the two lock portions of the cap
from inside of the vehicle, push the cap into the
hole. Open the fuel filler door (3) and remove the
cap out of the installation hole (1).
686RW013
8. Remove the fuel filler door lock actuator assembly.

Disconnect the body harness connector.
8H15
Installation
1. Install the cap by using the actuator assembly rod
as a guide.
2. Take care not to pinch the drain hose and the
harness while tightening the actuator fixing bolts
and nut.
8H16
SECURITY AND LOCKS
Key
Key Coding
730RX001
Legend
(1) Key (Actual size)
(2) Key Code Tag
EndOFCallout
One key is used for the ignition, door, and tailgate lock
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.
(3) Position
(4) Level
Key Styles
730RX002
Legend
(1) Blank Key Style A"
(2) Blank Key Style B"
EndOFCallout
The keys come in styles A or B depending on the key
code cutting combination. When the first position in the
combination is a 1, 2 or 3, Style A is used. When the
first position is a 4, Style B (factory pre-cut key) is used.
SECURITY AND LOCKS
8H17
Power Door Lock System

General Description
Front Door Lock Actuator
The circuit consists of the door lock (& power window)

switch, door lock actuator for the front and rear door,
tailgate lock actuator, fuel filler door lock actuator and
the door lock key switch.
The front door lock switchLH is always provided with
the battery voltage.
The key or the inside lock button on the both driver's
and the front passenger's door can activate the lock
mechanism of all the doors (including the tailgate).
When the driver's door lock switch or the front
passenger's door lock switch is turned on, current flows
for about one second to the door lock actuator of each
door connected in parallel with the front door lock (&
power window) switchLH to activate the actuator to
lock and unlock the doors.
Door Lock Key Switch
Refer to Fuel Filler Door Lock in this section.

Refer to Front Door Lock Assembly in this section.
Refer to Front Door Lock Assembly in this section.
Rear Door Lock Actuator

Refer to Rear Door Lock Assembly in this section.
Tailgate Lock Actuator

Refer to Tailgate Lock Assembly in this section.
Fuel Filler Door Lock Actuator

8H18
SECURITY AND LOCKS
Keyless Entry System

General Description
This circuit consists of the keyless entry control unit, the
front door lock & power window switch (RH), the starter
switch, the dome light, the door switch and the tail gate
switch and possible to be locked/unlocked each door by
operation of transmitter. Basic function of system is as
follows.
Keyless Entry Control Unit

Removal
2. Remove the instrument panel assembly (1).
Structure section.
3. Remove the keyless entry control unit (2).
Remove two fixing screws.
Keyless Entry Control Unit/

Transmitter Replacement
Keyless Entry Control Unit Replacement
1. Remove and install the control unit.
Refer to Keyless Entry Control Unit in this section.
2. Register ID code.
Refer to ID Code Registration in Wiring System
section.
3. Check that the keyless entry system works normally.
Transmitter Replacement
1. Prepare a new transmitter.
2. Regiter ID code.
Refer to ID Code Registration in Wiring System
section.
Transmitter Battery Replacement

1. Remove a screw to remove the cover.
2. Remove the batteries.
3. Set the new batteries into the transmitter.
4. Install the cover to the transmitter.
826RW007
Installation
SECURITY AND LOCKS
8H19

635RX008
SECTION
SUNROOF/CONVERTIBLE TOP
8I1

CONTENTS
Sunroof Glass (LWB) ....................................
Sunroof Glass and Associated Parts ..........
Removal .....................................................
Installation ..................................................
Sunroof Glass (SWB)....................................
Sunroof Glass and Associated Parts ..........
Removal .....................................................
Installation ..................................................
Sunroof Deflector (LWB) ...............................
Removal .....................................................
Installation ..................................................
Sunroof Deflector (SWB)...............................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Sunshade (LWB)...........................................
Removal .....................................................
Installation ..................................................
Sunroof Frame Complete Assembly (LWB) ..
Sunroof Frame Complete Assembly
and Associated Parts ................................
Removal .....................................................
Installation ..................................................
8I - 1
8I - 2
8I - 2
8I - 2
8I - 3
8I - 3
8I - 3
8I - 4
8I - 4
8I - 5
8I - 5
8I - 5
8I - 6
8I - 6
8I - 6
8I - 6
8I - 7
8I - 7
8I - 7
8I - 8
8I - 9
8I - 9
8I - 9
8I - 10
Service Precaution
Sunroof Switch ..............................................

Removal......................................................
Installation...................................................
Sunroof Control Unit......................................
Removal......................................................
Installation...................................................
Safety Stop Switch ........................................
Removal......................................................
Installation...................................................
Limit Switch ...................................................
Removal......................................................
Installation...................................................
Sunroof Motor ...............................................
Removal......................................................
Installation...................................................
Resin Top Assembly .....................................
Resin Top Assembly and Associated Parts
Removal......................................................
Installation...................................................
Seat Belt Cross Bar Assembly ......................
Seat Belt Cross Bar Assembly
and Associated Parts ................................
Removal......................................................
Installation...................................................
8I - 10
8I - 10
8I - 10
8I - 11
8I - 11
8I - 11
8I - 11
8I - 11
8I - 11
8I - 12
8I - 12
8I - 12
8I - 12
8I - 12
8I - 12
8I - 13
8I - 13
8I - 13
8I - 14
8I - 15
8I - 15
8I - 15
8I - 16
8I - 17

parts and systems.
8I2
Sunroof Glass (LWB)

Sunroof Glass and Associated Parts
665RW004
Legend
(1) Sunroof Weatherstrip
(2) Sunroof Glass
EndOFCallout
Removal
1. Tilt the sunroof and open the sunshade.
3. Pull out the front of sight shield (2).
4. Remove four sunroof glass fixing Torx screws (3) to
remove the sunroof glass (1).
665RW011
Installation
1. Be sure to install the sunroof weatherstrip so that
the joint of the weatherstrip is on the rear side of the
vehicle.
2. Temporary install the glass to the sunroof frame.
3. Open and shut the sunroof four to five times to
position correctly the sunroof weatherstrip and the
glass in the longitudinal and latitudinal setting
positions.
8I3
4. Adjust the setting position to flush the surface

between the roof panel and weatherstrip of sunroof
glass.
5. Tighten the sunroof glass fixing screws to the
specified torque.
Torque: 4Nm (0.4 kgm/35lbin)
6. After the sunroof glass is installed, recheck the roof
panel and sunroof glass for vertical install position.
If out of standard, adjust with fixing screws.
Sunroof Glass (SWB)

Sunroof Glass and Associated Parts
665RW028
Legend
(1) Sunroof Weather Strip
(2) Sunroof Glass Assembly
EndOFCallout
(3) Sunshade Assembly
8I4
Removal

section.

2. Remove the sunshade assembly.
Turn the knobs (1) 90 degrees and pull it out at
angle. Then pull the sunroof handle (2) to
disengage the lock.
Installation
nothing the following points.
1. When attaching the sunroof weather strip (1), make
sure that the lip (2) securely overlaps the headlining
(3).
Assemble with the positioning marks centered
toward the rear of the vehicle.
665RW025
3. Remove the sunroof glass assembly.

Push the safety lever (2) behind the handle and
push in on the hinge pins (1) from the left and
right to disengage them. Raise the rear end of the
sunroof glass assembly at an angle pull it free.
666RW007
2. Tighten the sunroof handle plate fixing nuts to the

specified torque.
Torque: 8 Nm (0.8 kgm/69 Ib in)
665RW026
4. Remove the sunroof handle cover and sunroof

handle plate.
Remove the screw form the cover and the three
fixing nuts form the plate.
5. Remove the weather strip.
6. Remove the headlining.
8I5
Sunroof Deflector (LWB)

Removal
Installation
1. Open the sunroof.

Let a 5 mm drill go through two blind rivets (2) to
disengage riveted portions.
2. Remove the sunroof deflector (1).
665RW008
8I6
Sunroof Deflector (SWB)

Parts Location
665RX001
Legend
(1) Side Deflector Assembly (RH)
(2) Center Deflector Assembly
(3) Side Deflector Assembly (LH)
(4) Roof Panel (Front side)

(5) Rear Sunroof Deflector Assembly
(6) Roof Panel (Resin Top side)
EndOFCallout
Removal
2. Remove the sunroof glass.
Refer to Sunroof Glass in this section.
3. Remove the headlining (Front roof side).
section.
4. Remove the sunroof deflector.
Remove the fixing screws.
Installation
8I7
Sunshade (LWB)
Disassembled View
665RW012
Legend
(1) Sunroof Glass
(2) Sight Shield
(3) Sunshade Stopper

(4) Sunshade
EndOFCallout
Removal
1. Tilt the sunroof.
3. Remove the sunroof glass.
4. Pull the sight shield upward using screwdriver.
665RW006
8I8
5. Remove 2 sunshade stopper fixing screws and

remove sunshade stopper (1).
665RW007
6. Pull out the sunshade (4) up to the guide rail edge.

Lift the front of sunshade and clear the projection (3)
of sunshade through the notch (2) of guide rail edge,
then draw the sunshade out of the roof.
665RW009
Installation
8I9
Sunroof Frame Complete Assembly (LWB)

Sunroof Frame Complete Assembly and Associated Parts
665RW005
Legend
(1) Sunroof Drain Hose
(2) Sunroof Frame Complete Assembly
(3) Headlining
EndOFCallout
Removal

section.
8I10
3. Disconnect the sunroof drain hose at the sunroof

frame side as shown in the figure.
4. Disconnect the sunroof harness connection.

5. Remove two sunroof frame complete assembly
fixing nuts (front side) and six fixing bolts from the
frame complete assembly, and then remove the
sunroof frame complete assembly.
NOTE: Be sure to remove the frame complete
assembly while supporting it.
Installation
1. Install the sunroof frame complete assembly.
2. After installing the frame complete assembly, loosen
the sunroof glass fixing nuts and adjust the sunroof
glass setting position.
3. Install the sunroof drain hose.
4. Install the headlining.
section.
665RW010
Sunroof Switch
Removal
Installation

2. Remove the sunroof switch (1).
Remove the switch by pushing the spring with the
tip of a screwdriver.
825RW091
8I11
Sunroof Control Unit

Removal
2. Remove the headlining (2).
section.
3. Remove the sunroof control unit (1).
Disconnect two connectors.
Remove two screws.
665RW013
Installation
Safety Stop Switch

Removal
Installation

2. Remove the sunroof drive unit assembly (1) to
remove the safety stop switch (2).
Refer to Sunroof Frame Complete Assembly in
this section.
665RS022
8I12
Limit Switch
Removal
2. Remove the sunroof drive unit assembly (1) to
remove the limit switch (2).
Refer to Sunroof Frame Complete Assembly in
this section.
665RS025
Installation
Sunroof Motor
Removal
2. Remove the headlining (2).
section.
3. Remove the sunroof motor (1).
Remove three nuts and two screws.
665RW014
Installation
8I13
Resin Top Assembly

Resin Top Assembly and Associated Parts
688RW006
Legend
(1) Rear Sunroof Assembly
(2) Resin Top Assembly
(3) High Mount Stoplight
(4) Air Outlet Grille Assembly

(5) Rear Quarter Glass
EndOFCallout
Removal
2. Remove the rear sunroof glass.
3. Remove the sunroof deflector.
Remove the four fixing screws.
4. Remove the rear roof bracket covers (4) and remove
the both sets of two bolts (3) on the resin top sides
of the rear roof brackets (2).
666RW010
8I14
5. Remove the air outlet grille assembly (LH & RH).

Remove the two screws and pull the grille
assemblies off toward the rear.
6. Remove the luggage light assembly and disconnect
the connector.
7. Remove the high mount stoplight assembly and
disconnect the connector.
8. Disconnect the rear washer hose (Right side, inside
air outlet grille assembly).
688RW007
9. Disconnect the harness connector for the resin top

(Left side, behind the luggage side trim).
Remove the canopy cover (1), the luggage side
lid (2) and luggage side upper cover (3). Then pull
out the harness and disconnect the connector.
686RX001
10. Remove the resin top assembly.

Remove the two fixing bolts each and nut each
from the left and right sides, then lift the resin top
up and off.
Installation
1. Removing and mounting the resin top should always
be performed by two persons.
2. Tighten the resin top fixing bolts and nuts to the
specified torque.
8I15

Seat Belt Cross Bar Assembly and Associated Parts
688RW008
Legend
(1) Seat Belt Cross Bar Assembly
(2) Rear Seat Belt Assembly
EndOFCallout
Removal
2. Remove the resin top Assembly.
Refer to Resin Top Assembly in this section.
3. Remove the canopy cover (1).
Remove the two fixing clips.
4. Remove the luggage side lid (2).
5. Remove the luggage side upper cover (3).
6. Remove the luggage side front cover (4).
686RX001
8I16

8. Remove the rear end floor trim cover.
9. Remove the right luggage side trim cover.
Remove the jack & tool lid and take out the tools.
Then remove the fixing screw and pull the clips
out from the body panel.
Installation
1. Tighten the rear seat belt anchor bolts to the
specified torque.
2. Tighten the seat belt cross bar assembly fixing bolts
687RW005
To remove the left luggage side trim cover,

disconnect the accessory socket connector.
10. Remove the rear seat belt assembly.
Refer to Rear Seat Belt in Restraints section.
11. Remove the seat belt cross bar assembly.
Remove the two sets of seven fixing bolts on the
left and right sides. One set of the fixing bolts are
also used to secure the resin top in place.
688RW009
8I17

Application
Nm
kgm
lb ft
lb in
Sunroof Glass Fixing Screws (LWB)
0.4
35
Sunroof Handle Plate Fixing Nuts (SWB)
0.8
69
Resin Top Assembly Fixing Bolts and Nuts
15
1.5
11
Rear Seat Belt Anchor Bolts
39
4.0
29
Seat Belt Cross Bar Assembly Fixing Bolts
19
1.9
14
SECTION
EXTERIOR/INTERIOR TRIM
8J1

EXTERIOR / INTERIOR TRIM
CONTENTS
Consoles .......................................................
Consoles and Associated Parts..................
Removal .....................................................
Installation ..................................................
Front Door Trim Panel...................................
Front Door Trim Panel and
Removal .....................................................
Installation ..................................................
Rear Door Trim Panel ...................................
Rear Door Trim Panel and
Removal .....................................................
Installation ..................................................
Interior Trim Panels (LWB)............................
Interior Trim Panels and
Removal .....................................................
Installation ..................................................
Interior Trim Panels (SWB) ...........................
Interior Trim Panels and
Removal .....................................................
Installation ..................................................
Headlining (LWB) ..........................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Headlining (SWB)..........................................
Parts Location.............................................
Removal .....................................................
8J - 1
8J - 2
8J - 2
8J - 2
8J - 2
8J - 3
8J - 3
8J - 4
8J - 4
8J - 5
8J - 5
8J - 6
8J - 6
8J - 7
8J - 7
8J - 7
8J - 8
8J - 9
8J - 9
8J - 9
8J - 10
8J - 11
8J - 11
8J - 11
8J - 12
8J - 13
8J - 13
8J - 14
Service Precaution
REPAIRS.
Installation...................................................
Wheel Arch Protector (LWB) .........................
Wheel Arch Protector and
Removal......................................................
Installation...................................................
Wheel Arch Protector (SWB).........................
Wheel Arch Protector and
Removal......................................................
Installation...................................................
Wheel Arch Moulding (SWB).........................
Wheel Arch Moulding and
Removal......................................................
Installation...................................................
Fuel Filler Door..............................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Roof Rail .......................................................
Parts Location.............................................
Removal......................................................
Installation...................................................
Power Door Mirror System ............................
Door Mirror Switch ......................................
Power Window System .................................
Power Window Switch Driver Seat Side .....
Power Window Motor..................................
8J - 14
8J - 15
8J - 15
8J - 15
8J - 15
8J - 16
8J - 16
8J - 16
8J - 16
8J - 17
8J - 17
8J - 17
8J - 18
8J - 19
8J - 19
8J - 19
8J - 19
8J - 20
8J - 20
8J - 20
8J - 20
8J - 21
8J - 21
8J - 21
8J - 22
8J - 22
8J - 22
8J - 23
8J - 25

and systems.
8J2
Consoles
Consoles and Associated Parts
745RX004
Legend
(1) Front Console
(2) Console Brackets
(3) Rear Console Assembly
EndOFCallout
Removal
2. Remove the shift knob (M/T) / transfer knob (A/T).
3. Remove the rear console assembly.
Open the rear console lid and remove two
screws.
4. Remove the front console assembly.
Remove six fixing screws and disconnect the

accessory socket connector.
Installation
8J3
Front Door Trim Panel

Front Door Trim Panel and Associated Parts
635RW015
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Glass Run
Glass
Power Window Regulator
Outer Waste Seal
Outside Handle
Locking Link
Door Lock Assembly/Door Lock Actuator
Waterproof Sheet
Door Trim Panel
EndOFCallout
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Courtesy Light Lens

Speaker Grill
Grip Cover
Inside Handle
Power Window Switch
Speaker Assembly
Tweeter
Door Mirror Cover
Door Mirror Assembly
8J4
Removal
7. Remove the inside handle fixing screw.

2. Remove the door mirror cover (2).
3. Remove the door mirror assembly (1).
Remove the three fixing bolts and disconnect the
connectors.
CAUTION: Take care not to apply excessive force

on the inside handle link, lest this link is elongated,
which could make it impossible to operate the door
with the inside handle.
632RW003
635RW006
4. Remove the power window switch (1).

Pry the power window switch out and disconnect
the switch connector.

Remove the five fixing screws (1), (3) in order to
pull out the six clip positions (2) from the door
panel.
635RW007
635RW016
5. Remove the speaker cover.

6. Remove the front speaker.
Remove the front speaker fixing screws in order
to disconnect the speaker connector.
Disconnect the tweeter and courtesy light

connectors to lift the door trim panel and unlock
the engagement of the waist seal section. Then,
pass the inside handle through the mounting hole
of the trim panel, and detach the trim panel.
9. Remove the inside handle.
10. Remove the tweeter.
Installation
8J5
Rear Door Trim Panel

Rear Door Trim Panel and Associated Parts
655RW011
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Glass Run
Glass
Fix Window Glass
Power Window Regulator
Outside Handle
Door Lock Assembly
Bracket
EndOFCallout
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Rear Door Corner Garnish

Door Trim Panel
Courtesy Light Lens
Power Window Switch
Inside Handle
Waterproof Sheet
Outer Waste Seal
8J6
Removal

Pull out the eight clip positions from the door
panel.

2. Remove the one screw from the pullcase.
655RW002
655RW003
3. Remove the inside handle fixing screw.

CAUTION: Take care not to apply excessive force
on the inside handle link, lest this link be elongated,
which could make it impossible to operate the door
with the inside handle.
4. Remove the rear door corner garnish.
Disconnect the power window switch and

courtesy light connectors to lift the trim panel and
unlock the engagement of the waist seal section,
then pass the inside lever through the mounting
hole of the trim panel, and detach the trim panel.
6. Remove the inside handle.
Remove the fixing screws of switch from backside
of rear door trim.
Installation
8J7
Interior Trim Panels (LWB)

Interior Trim Panels and Associated Parts
643RW012
Legend
(1)
(2)
(3)
(4)
(5)
Assist Grip (Front & Rear)

Door Finisher (Front & Rear)
Quarter Trim Cover
Rear Roof Trim Cover
Tailgate Weather Strip
(6)
(7)
(8)
(9)
(10)

Sill Plate (Front & Rear)
Center Pillar Lower Trim Cover
Center Pillar Upper Trim Cover
Front Pillar Trim Cover
EndOFCallout
Removal
2. Remove the sill plates (Front & Rear).
3. Remove the dash side trim cover.
4. Remove the center pillar lower trim cover.
Remove the lower anchor bolt cover and lower
anchor bolt from the front seat belt.
Pry the trim cover clips free from the body panel.
5. Remove the door finishers (Front & Rear).

6. Remove the center pillar upper trim cover.
Ply the trim cover clips free from the body panel.
8. Remove the tailgate weather strip.
8J8
10. Remove the luggage room light.

Remove the luggage room light lens (1) and the
fixing screw.
Disconnect the luggage room light connector.
14. Remove the front pillar assist grip (1) (Front & Rear).
Open the both sides of the assist grip cover (2)
and remove the fixing screws and the front pillar
assist grip.
743RW003
825RW100
11. Remove the rear roof trim cover.

12. Remove the lower anchor bolt cover and the lower
anchor bolt (5) from the rear seat belt.
13. Remove the quarter trim cover (1).
Remove the tool box lid (3) and three fixing
screws (4).
Pry the quarter trim cover retainers (2) free from
the body panel.
Disconnect the accessory socket connector (LH
side).
643RW001
Installation
1. Tighten the seat belt anchor bolt to the specified
torque.
8J9
Interior Trim Panels (SWB)

Interior Trim Panels and Associated Parts
643RW010
Legend
(1)
(2)
(3)
(4)
(5)
Assist Grip (Front & Rear)

Quarter Upper Trim Cover
Weather Strip
(6)
(7)
(8)
(9)
(10)
Luggage Side Trim Cover

Quarter Lower Trim Cover
Sill Plate
Door Seal Finisher
Front Pillar Trim Cover
EndOFCallout
Removal
Refer to Resin Top Assembly in Sunroof/
Convertible Top section.
Refer to Rear Seat Assembly in Seats section.

5. Remove the luggage sid trim cover.
Refer to Seat Belt Cross Bar Assembly in
Sunroof/Convertible Top section.
6. Remove the sill plate.
7. Remove the dash side trim cover.
8J10
8. Remove the rear speaker assembly.

Disengage the front portion of the speaker grille
(1) and pull it forward and off.
Remove the three fixing screws securing the
speaker (2) in place and disconnect the
connector (3).
12. Remove the door seal finisher.

13. Remove the dome light.
Remove the dome light lens (2) and the fixing
screws.
Disconnect the dome light connector.
805RX001
890RW048-1
9. Remove the front and rear seat belt lower anchor

bolts.
10. Remove the quarter lower trim cover.
Disengage the clips from the body panel by
twisting them free.
11. Remove the assist grips (1) (Front & Rear).
Open the both sides of the assist grip cover (2)
and remove the fixing screws.
14. Remove the rear roof bracket.

16. Remove the quarter upper trim cover.
Installation
1. Tighten the front and rear seat belt anchor bolts to
743RW003
8J11
Headlining (LWB)
Parts Location
666RX003
Legend
(1)
(2)
(3)
(4)
(5)
Interior Trim Panels

Clip
Headlining (Without Sunroof)
Assist Grip
Dome Light
(6)
(7)
(8)
(9)
(10)
Headlinng (With Sun Roof)

Sunroof Finisher (With Sunroof)
Sunroof Switch (With Sunroof)
Sunvisors
Sunvisor Holder
EndOFCallout
Removal
2. Remove the interior trim panels.
Refer to Interior Trim Panels (LWB) in this section.

Remove the dome light lens and the fixing
screws.
Disconnect the dome light connectors.
8J12
4. Remove the sunroof switch (With sunroof).

Pry the clip positions free from the sunroof switch
bracket and disconnect the connector.
Installation
1. Install the headlining so that the fixing clips will not
come off.
2. To install the sunroof finisher (1), first fit it in at one
place with the headlining (3) close to the sunroof
frame complete (2), then install the entire finisher
tightly by hitting it with a plastic hammer, not
allowing it to move up.
665RW002
5. Remove the sunvisors.

Remove the fixing screws and pull out the
sunvisor holder (1) to remove it.
665RW003
743RS006
6. Remove the sunroof finisher (With sunroof).

Remove the headlining fixing clips.
8J13
Headlining (SWB)
Parts Location
666RX002
Legend
(1)
(2)
(3)
(4)
Interior Trim Panels

Rear Roof Cover & Roof Bracket
Assist Grip
EndOFCallout
(5)
(6)
(7)
(8)
Dome Light
Sunroof Finisher
Sunvisors
Headlining
8J14
Removal
2. Remove the rear roof bracket cover (4), rear roof
bracket (2) connecting with resin top (1) and rear
roof trim cover (3) by removing four fixing bolts.
6. Remove the interior trim panels.

Refer to Interior Trim Panels (SWB) in this
section.
7. Remove the sunroof glass assembly.
Refer to Sunroof Glass (SWB) in Sunroof/
8. Remove the sunroof handle cover and sunroof
handle plate.
Remove the screw from the cover and the three
fixing nuts from the plate.
9. Remove the sunvisor.
Remove the sunvisor fixing screws and the
sunvisor holder.
10. Remove the sunroof finisher.
Installation
1. In case of installing sunroof finisher (1), fit the lip (2)
to the headlining surely.
666RW006
3. Remove the dome light lens.

Remove the fixing screws.
666RW007
666RW004
8J15
Wheel Arch Protector (LWB)

Wheel Arch Protector and Associated Parts
620RW019
Legend
(1)
(2)
(3)
(4)
(5)
Wheel Arch Protector

Rear Door Panel
Rear Door Wheel Arch Seal
Wheel Arch Cover
Body Panel
(6)
(7)
(8)
(9)
Double Sided Adhesive Tape

Clip
Screw Grommet
Clip
EndOFCallout
Removal
1. Remove the wheel arch cover.
Remove the four fixing screws.
2. Remove the wheel arch protector.
Remove the two fixing screws from the back side
of the rear door panel and pull out the clips at
three positions.
3. Remove the rear door wheel arch seal.
After disengaging five clips, peel off the double
sided adhesive tape.
Installation
1. Use a new double sided adhesive tape whenever
installing the rear door wheel arch seal.
Using a white gasoline, clean the places in advance
where a double sided adhesive tape is affixed.
8J16
Wheel Arch Protector (SWB)

Wheel Arch Protector and Associated Parts
620RW018
Legend
(1) Wheel Arch Protector
(2) Spire Nut
(3) Quarter Outer Panel
EndOFCallout
Removal
1. Remove the wheel arch protecter.
Remove the four fixing screws and pull out the
clips at two positions.
Installation
(4) Screw Grommet

(5) Screw
(6) Clip
8J17
Wheel Arch Moulding (SWB)

Wheel Arch Moulding and Associated Parts
620RW017
Legend
(1) Front Wheel Arch Moulding
(2) Front Mud Flap
(3) Rear Wheel Arch Moulding
EndOFCallout
Removal
1. Remove the front mud flap (2).
Remove the four fixing screws (1).
(Three of four screws are fixed together with
moulding.)
647RW002
8J18
2. Remove the front wheel arch moulding.

Remove the three fixing screws and pull out the
clips at three positions from the fender panel.
3. Remove the rear wheel arch moulding.
Remove the seven fixing screws and pull out the
clips at three positions from the quarter outer
panel.
2. Install the front wheel arch moulding (2).

Install the six spire nuts (1) to the body panel (4).
Put the four clips (3) of the front wheel arch
moulding into the body in order of A, B, C and D.
3. Install the six fixing screws (6).
(Three of six screws are fixed together with the front
mud flap.)
Installation
1. Install the rear wheel arch moulding (2).
Install the six spire nuts (1) and one screw
grommet (4) to the body panel (5).
Put the three clips of the rear wheel arch
moulding into the body panel in order of A, B and
C.
Install the seven fixing screws (3).
620RW015
4. Install the front mud flap.
620RW016
8J19
Fuel Filler Door

Parts Location
Removal
1. Open the fuel filler door.
2. Remove the fuel filler door.
3. Pull out the fuel filler door buffer.
4. Pull out the fuel filler hinge buffer.
Installation
1. Install the fuel filler door to match the basic hole.
2. Adjust the clearance between quarter outer panel
(1) and fuel filler door (2).
686RW010
Legend
(1)
(2)
(3)
(4)
(5)
Fuel Filler Door Fixing Screw

Basic Hole
Fuel Filler Door Buffer
Fuel Filler Door
Fuel Filler Door Hinge Buffer
EndOFCallout
686RX003
8J20
Roof Rail
Parts Location
660RW022
Legend
(1)
(2)
(3)
(4)
SWB
Roof Rail Assembly
Roof Rail Fixing Bolt
Rear Roof Rail Cover
EndOFCallout
Removal
1. Remove the front and rear of roof rail cover.
Pry the roof rail covers.
2. Remove the roof rail sub assembly.
Remove the four fixing bolts at each roof rail.
Installation
1. Tighten the roof rail sub assembly fixing bolts to the
specified torque.
(5) Roof Rail Sub Assembly

(6) LWB
(7) Front Roof Rail Cover
8J21
Power Door Mirror System

General Description
Door Mirror Switch
The system consists of the starter switch, door mirror

switch, rear defogger/mirror defogger switch and door
mirrors on both sides.
When the door mirror switch is operated with the starter
switch at either ACC" or ON" position, the motor in the
door mirror (on either side) rotates to allow the
horizontal and vertical adjustment of mirror angles.
When the rear defogger/mirror defogger switch is turned
ON" (with the starter switch at ON" position), the
heaters in both left and right mirrors and the rear
hatchgate glass are activated to defog both mirrors and
rear hatchgate glass at the same time.
Removal
2. Remove the instrument panel lower cover (1).
Refer to the instrument panel assembly in Body
Structure section.
3. Remove the door mirror switch (2).
825RW266
Installation
Rear Defogger/Mirror Defogger Switch

Refer to Rear Defogger/Mirror Switch in Lighting
System section.
Door Mirrors
Refer to Front Door Trim Panel in this section.
8J22
Power Window System

General Description
Front Passenger Seat Side
The power window system consists of power window

switches and power window motors on driver and
passenger sides and power window relay. With the
starter switch in ON" position, the battery voltage is
supplied through power window relay to the power
window switches on driver and passenger sides.
Selection of up or down switch changes the motor
rotating direction to open or close the window.
When the lock switch on the switch panel on the driver
side is pressed, the power window switch is in open
state. As a result, the power source to the other
switches are cut off, and the power window motors do
not run.
Removal
2. Remove the switch (1).
Pull out the switch by pushing the spring with the
Power Window Switch Driver Seat

Side
Removal
2. Remove the switch (1).
Pull out the switch by pushing the spring with the
825RW264
Installation
Rear-Left and Right Sides

Removal
2. Remove the rear door trim panel (2).
Refer to Rear Door Trim Panel in this section.
Disconnect the rear power window switch (1)
connector.
825RW265
Installation
3. Remove the rear power window switch (1).
Remove the switch fixing screw from the back
side of the rear door trim (2).
8J23
Power Window Motor

Driver Seat Side
Removal
2. Remove the window regulator assembly (2).
Refer to Window Regulator and Glass in Body
Structure section.
3. Remove the power window motor (1).
825RW081
825RW096
Installation
Front Passenger Seat Side

Refer to Front Window Motor Driver Seat Side in this
section.
825RW079
Installation
8J24
Rear-Left Side
Removal
2. Remove the rear window regulator assembly (2).
Refer to Rear Window Regulator and Glass in
Body Structure section.
3. Remove the power window motor (1).
825RW095
Installation
Rear-Right Side
Refer to Rear Power Window Motor Left Side in this
section.
8J25

Application
Nm
kgm
lb ft
lb in
Front & Rear Seat Belt Anchor Bolts
39
4.0
29
Roof Rail Fixing Bolts
0.8
69
SECTION
SEAT BELT SYSTEM
9A1
RESTRAINTS
SEAT BELT SYSTEM
CONTENTS
Front Seat Belt (LWB) ...................................
Front Seat Belt and Associated Parts.........
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Front Seat Belt (SWB)...................................
Front Seat Belt and Associated Parts.........
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Rear Seat Belt (LWB)....................................
Rear Seat Belt and Associated Parts .........
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Rear Seat Belt (SWB) ...................................
Rear Seat Belt and Associated Parts .........
9A - 1
9A - 2
9A - 2
9A - 2
9A - 2
9A - 3
9A - 4
9A - 4
9A - 4
9A - 5
9A - 5
9A - 6
9A - 6
9A - 6
9A - 7
9A - 8
9A - 9
9A - 9
Service Precaution
REPAIRS.
Removal......................................................
Inspection ...................................................
Installation...................................................
Front Seat Buckle Assembly .........................
Removal......................................................
Installation...................................................
Rear Center Seat Belt / Buckle Assembly.....
Rear Center Seat Belt / Buckle Assembly
and Associated Parts ............................
Removal......................................................
Installation...................................................
Child Seat Tether Anchor
Bracket (Child Restraint)..........................
Child Seat Tether Anchor Bracket
and Associated Parts ............................
Installation...................................................
9A - 9
9A - 10
9A - 10
9A - 11
9A - 11
9A - 11
9A - 12
9A - 12
9A - 12
9A - 12
9A - 13
9A - 13
9A - 13
9A - 13
9A - 14

and systems.
9A2
SEAT BELT SYSTEM
Front Seat Belt (LWB)

Front Seat Belt and Associated Parts
760RW040
Legend
(1)
(2)
(3)
(4)
(5)
Door Seal Finisher (Front & Rear)

Adjustable Shoulder Anchor Assembly
Seat Belt Upper Anchor Bolt
Center Pillar Upper Trim Cover
Front Seat Belt Assembly
(6)
(7)
(8)
(9)
(10)
Seat Belt Lower Anchor Bolt

Center Pillar Lower Trim Cover
Retractor
Rear Sill Plate
Front Sill Plate
EndOFCallout
Removal
Inspection

2. Remove the sill plate (Front & Rear).
3. Remove the seat belt lower anchor bolt.
4. Remove the center pillar lower trim cover.
5. Remove the door seal finisher (Front & Rear).
6. Remove the center pillar upper trim cover.
7. Remove the seat belt upper anchor bolt.
8. Remove the retractor fixing bolt.
9. Remove the seat belt assembly.
10. Remove the adjustable shoulder anchor assembly.
If any of the following abnormalities is found, replace on

an assembly basis.
Deform and malfunction of adjustable shoulder
anchor.
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.
SEAT BELT SYSTEM

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.
9A3
Installation
1. Tighten the adjustable shoulder anchor assembly
2. Tighten the seat belt anchor bolts (Upper & Lower)
and the retractor fixing bolts to the specified torque.
9A4
SEAT BELT SYSTEM
Front Seat Belt (SWB)

Front Seat Belt and Associated Parts
760RW041
Legend
(1)
(2)
(3)
(4)
(5)
(6)

Quarter Upper Trim Cover
Assist Grip
Quarter Lower Trim Cover
EndOFCallout
Removal
Refer to Resin Top Assembly in Sunroof/
4. Remove the luggage side trim cover.
Refer to Rear Seat Belt (SWB) in this section.
5. Remove the sill plate.
6. Remove the seat belt lower anchor bolt (Front &
Rear).
(7)
(8)
(9)
(10)
(11)
Front Seat Belt Assembly

Seat Belt Lower Anchor Belt
Retractor
Sill Plate
Door Seal Finisher
SEAT BELT SYSTEM

7. Remove the rear speaker (2).
Remove the speaker grille (1) and remove the
speaker fixing screws.
9A5

12. Remove the assist grip.
13. Remove the door seal finisher.
14. Remove the quarter upper trim cover.
16. Remove the retractor fixing bolt.
17. Remove the seat belt assembly.
Remove two bolts.
Inspection
890RW048-1
8. Remove the quarter lower trim cover.

Pry the trim cover retainers free from the body
panel.
Remove the dome light lens and the fixing
screws.
10. Remove the rear roof bracket (2).
Remove the rear roof bracket cover (4) and
remove rear roof bracket connecting with resin
top (1) and rear roof trim cover (3) by removing
four fixing bolts.

an assembly basis.
anchor.
angle check.
at 45 or larger.
2. ELR lock check.
Installation
and retractor fixing bolts to the specified torque.
2. Tighten the seat belt anchor bolts to the specified
torque.
666RW006
9A6
SEAT BELT SYSTEM
Rear Seat Belt (LWB)

Rear Seat Belt and Associated Parts
755RW068
Legend
(1)
(2)
(3)
(4)
(5)
(6)

Slider Plate Trim Assembly
Quarter Trim Cover
Tailgate Weather Strip
EndOFCallout
Removal
4. Remove the luggage room light.
Remove the luggage room light lens (1) and the
fixing screw.
(7)
(8)
(9)
(10)
(11)
(12)

Seat Belt Lower Anchor Bolt
Rear Seat Belt Assembly
Retractor
Rear Sill Plate
Rear Door Seal Finisher
SEAT BELT SYSTEM

Disconnect the luggage room light connector.
9A7
Pull out the seat belt through the hole (3) on the
slider plate trim.
825RW100

6. Remove the rear sill plate.
7. Remove the rear seat belt lower anchor bolt cover
and the lower anchor bolt (5).
8. Remove the quarter trim cover (1).
Remove the tool box lid (3) and 3 fixing screws
(4).
Pry the quarter trim cover retainers (2) free from
the body panel.
643RW011
9. Remove the slider plate trim assembly (2).

Remove the two fixing screws from the adjustable
shoulder anchor (1).
755RW069

11. Remove the retractor.
Inspection
an assembly basis.
anchor.
9A8
SEAT BELT SYSTEM
angle check.
at 45 or larger.
2. ELR lock check.
Installation
2. Tighten the seat belt anchor bolts (Upper & Lower)
and the retractor fixing bolts to the specified torque.
SEAT BELT SYSTEM
9A9
Rear Seat Belt (SWB)

Rear Seat Belt and Associated Parts
755RW071
Legend
(1)
(2)
(3)
(4)

Shoulder Anchor Cover
Rear Seat Belt Assembly
(5) Retractor
(6) Seat Belt Lower Anchor Bolt
(7) Quarter Lower Trim Cover
EndOFCallout
Removal
2. Remove the canopy cover (1).
Remove two fixing clips.
3. Remove the luggage side lid (2).
4. Remove the luggage side front cover (4).
5. Remove the luggage side upper cover (3).
686RX001
9A10
SEAT BELT SYSTEM

8. Remove the luggage side trim cover (RH).
Remove the jack & tool lid and remove the tool.
Remove fixing screw and pry the trim cover
retainers free from the body panel.
Inspection
an assembly basis.
687RW005
9. Remove the luggage side trim cover (LH).

Remove fixing screw and pry the trim cover
retainers free from the body panel.
Disconnect the accessory socket connectors.
10. Remove the seat belt lower anchor bolt.
11. Remove the shoulder anchor cover (2).
Release the hooked portion of cover from the
shoulder anchor (1).

angle check.
at 45 or larger.
2. ELR lock check.
Installation
1. Align the projection of the retractor to the square
hole of the seat belt cross bar assembly bracket.
2. Tighten the retractor fixing bolts to the specified
torque.
3. Tighten the seat belt anchor bolt to the specified
torque.
755RW070

13. Remove the retractor.
SEAT BELT SYSTEM
9A11
Front Seat Buckle Assembly

Removal
Installation

2. Disconnect the seat belt warning connector (driver's
side) and remove a clip.
3. Remove the front seat buckle assembly (1).

1. Tighten the buckle anchor bolt to the specified
torque.
760RW043
9A12
SEAT BELT SYSTEM
Rear Center Seat Belt / Buckle Assembly

Rear Center Seat Belt / Buckle Assembly and Associated Parts
755RX029
Legend
(1) SWB
(2) Rear Seat Lock Assembly
(3) Rear Seat Belt Buckle Assembly
(4) Seat Lock Cover

(5) LWB
(6) Rear Cushion Frame Assembly
EndOFCallout
Removal
1. Remove the seat lock cover (SWB).
2. Remove the rear cushion frame assembly (LWB).
3. Remove the rear seat lock assembly and rear seat
belt buckle assembly.
Installation
1. Tighten the rear seat lock assembly and rear seat
belt buckle assembly fixing bolts to the specified
torque.
NOTE: Removal and installation procedure of rear
center seat belt assembly same as rear seat belt buckle
assembly procedures.
SEAT BELT SYSTEM
9A13
Child Seat Tether Anchor Bracket (Child Restraint)

General Description
Plastic plug is provided at two or three places on the
luggage floor panel.
LWB
Remove the center plug fom the floor panel.
SWB
Remove the right plug from the floor panel.
Install the bracket to the hole where the plug is

removed.
Alternatively, the bracket may be installed in the
right-hand or left-hand plug hole.
Child Seat Tether Anchor Bracket and Associated Parts
760RX019
Legend
(1) Rear Seat (LWB)
(2) Rear seat (SWB)
(3) Luggage Floor carpet
EndOFCallout
Installation
1. Turn the plug counterclockwise to remove it.
2. Install the bracket such that its tether belt hook hole
is facing toward the front of the vehicle.
3. Tighten the fixing bolt to the specified torque.
(4) Child Seat Tether Anchor Bracket

(5) Tether Anchor Plug
9A14
SEAT BELT SYSTEM

760RX018
SEAT BELT SYSTEM
9A15
755RX026
SECTION
SUPPLEMENTAL RESTRAINT SYSTEM
9J1
RESTRAINTS
CONTENTS
SRS Component and Wiring Location View ..
Component Description .................................
Definition........................................................
Diagnosis .......................................................
SRS Connector Body Face Views .................
Repairs and Inspections Required After
an Accident ..................................................
OnVehicle Service .......................................
Air Bag Assembly Handling / Shipping /
Scrapping.....................................................
Special Tools .................................................
Sensing and Diagnostic Module (SDM) ........
Service Precautions....................................
Removal .....................................................
Installation ..................................................
Driver Air Bag Assembly ...............................
Removal .....................................................
Installation ..................................................
9J - 1
9J - 2
9J - 4
9J - 4
9J - 7
9J - 8
9J - 9
9J - 9
9J - 10
9J - 11
9J - 27
9J - 33
9J - 35
9J - 35
9J - 35
9J - 35
9J - 37
9J - 37
9J - 37
9J - 37
Service Precaution
Steering Wheel..............................................
Removal......................................................
Installation...................................................
SRS Coil Assembly .......................................
Removal......................................................
How to Disconnect the horn terminal..........
How to Connect Horn Terminal .................
Installation...................................................
Steering Column ...........................................
Removal......................................................
Installation...................................................
Passenger Air Bag Assembly........................
Removal......................................................
Installation...................................................
SRS Air Bag System Inspection Standards
For Repair ....................................................
9J - 38
9J - 38
9J - 38
9J - 39
9J - 40
9J - 40
9J - 40
9J - 42
9J - 42
9J - 43
9J - 45
9J - 45
9J - 45
9J - 47
9J - 49
9J - 49
9J - 49
9J - 49
9J - 50
9J - 51

parts and systems.
9J2
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
827RX050
System Description
827RX044
Legend
(1) Deployed Air Bag
(2) Knee Bolster
(3) Seat Belt
EndOFCallout
The Supplemental Restraint System (SRS) helps
supplement the protection offered by the driver and front
passenger seat belts by deploying an air bag from the
center of the steering wheel and from the top of the right
side of the instrument panel.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. To further absorb the crash
energy there is a knee bolster located beneath the
instrument panel for both the driver and passenger, and
the steering column is collapsible.
The SRS consists of the Sensing and Diagnostic

Module (SDM), the driver air bag assembly, the SRS coil
assembly, the passenger air bag assembly, and the AIR
BAG warning lamp in the instrument cluster. The
SDM, SRS coil assembly (driver side only), driver air
bag assembly, passenger air bag assembly and
connector wire make up the deployment loops. The
function of the deployment loops is to supply current
through air bag assembly, which will cause deployment
of the air bags in the event of a frontal crash of sufficient
force, up to 30 degrees off the centerline of the vehicle.
The air bag assemblies are only supplied enough
current to deploy when the SDM detects vehicle velocity
changes severe enough to warrant deployment.
The SDM contains a sensing device which converts
vehicle velocity change to an electrical signal. The
electrical signal generated is processed by the SDM
and then compared to a value stored in memory. When
the generated signal exceeds the stored value, the SDM
will cause current to flow through the air bag assembly
deploying the air bags.
9J3
D09RX002
9J4
SRS Component and Wiring

Location View
810RX015
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Battery
Relay & Fuse Box
SRS Coil Assembly
Driver Air Bag Assembly
Meter Assembly
Passenger Air Bag Assembly
SDM
Starter Switch
Fuse Box, SRS, METER
EndOFCallout
Component Description
SDM (Sensing and Diagnostic Module)
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING A 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 POINTED
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.
The SDM is designed to perform the following functions
in the Supplemental Restraint System (SRS):
1. Energy Reserve The SDM maintains 24Volt
Loop Reserve (24VLR) energy supply to provide
deployment energy when ignition voltage is lost in a
frontal crash.
2. Frontal Crash Detection The SDM monitors
vehicle velocity changes to detect frontal crashes
which are severe enough to warrant deployment.
3. Air Bag Deployment When a frontal crash of
sufficient force is detected, the SDM will cause
enough current to flow through the air bag assembly
to deploy the air bag.
4. Malfunction Detection The SDM performs
diagnostic monitoring of SRS electrical components
and sets a diagnostic trouble code when a
malfunction is detected.
5. Frontal Crash Recording The SDM records
information regarding SRS status during frontal
crash.
6. Malfunction Diagnosis The SDM displays SRS
diagnostic trouble codes and system status
information through the use of a scan tool.
7. Driver Notification The SDM warns the vehicle
driver of SRS malfunctions by controlling the Air
Bag" warning lamp.
The SDM is connected to the SRS wiring harness by a
24pin connector. This harness connector uses a
shorting clip across certain terminals in the contact
area. This shorting clip connects the AIR BAG"
warning lamp to ground when the SDM harness
connector is disconnected or Connector Position
Assurance (CPA) is not inserted even if completely
connected. This will cause the AIR BAG" warning
lamp to come ON" steady whenever the ignition switch
is at the ON or START positions with the SDM
disconnected.
827RW067
9J5
821RW116
Legend
(1) Connector Position Assurance (CPA)
(2) Supplemental Restraint System (SRS) Harness
(3) Sensing and Diagnostic Module (SDM)
EndOFCallout
Air Bag" Warning Lamp

Ignition voltage is applied to the AIR BAG" warning
lamp when the ignition switch is at the ON or START
positions. The SDM controls the lamp by providing
ground with a lamp driver. The AIR BAG" warning lamp
is used in the SRS to do the following:
1. Verify lamp and SDM operation by flashing SEVEN
(7) times when the ignition switch is first turned
ON".
2. Warn the vehicle driver of SRS electrical system
malfunctions which could potentially affect the
operation of the SRS. These malfunctions could
result in nondeployment in case of a frontal crash or
deployment for conditions less severe than
intended.
The AIR BAG" warning lamp is the key to driver
notification of SRS malfunctions. For proper lamp
operation, refer to the SRS Diagnostic System Check"
in this section.
SRS Coil Assembly

The SRS coil assembly consists of two current carrying
coils. This is attached to the steering column and allow
rotation of the steering wheel while maintaining
continuous contact of the driver deployment loop to the
driver air bag assembly.
There is a shorting clip on the yellow 2pin connector
near the base of steering column which connects the
SRS coil to the SRS wiring harness.
The shorting clip shorts to the SRS coil and driver air
bag assembly when the yellow 2pin connector is
disconnected. The circuit to the driver air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing the
steering column or other SRS components.
825RS071
Air Bag Assemblies

The air bag assembly consist of an inflatable air bag
9J6
assembly and an inflator (a canister of gasgenerating

material and an initiating device). When the vehicle is
in a frontal crash of sufficient force.
The SDM causes current flow through the deployment
loops. Current passing through the inflator ignites the
material in the air bag assembly. The gas produced
from this reaction rapidly inflates the air bag assembly.
There is a shorting clip on the driver air bag assembly
connector which connects the SRS coil assembly. The
shorting clip shorts across the driver air bag assembly
circuits when driver air bag assembly connector is
disconnected.
The circuit to the driver air bag assembly is shorted in
this way to help prevent unwanted deployment of the air
bag when servicing the driver air bag assembly, the
steering column or other Supplemental Restraint
System (SRS) components.
827RX051
Steering Column
The steering column absorbs energy and is designed to
compress in a frontal crash to decrease the chance of
injury to the driver.
827RX038
There is a shorting clip on the passenger air bag

assembly connector which connects to the SRS
harness. The shorting clip shorts across the
passenger air bag assembly circuit when the passenger
air bag assembly connector is disconnected. The
circuit to the passenger air bag assembly is shorted in
this way to help prevent unwanted deployment of the air
bag when servicing the passenger air bag assembly, the
instrument panel or other SRS components.
431RX014

Knee Bolster
The knee bolsters are used to absorb energy to protec
knees and control the forward movement of the vehicle's
front seat occupants during a frontal crash, by limiting
leg movement.
9J7
Deployment Loops
The circuits which supply current to the air bag
assemblies to deploy the air bag.
Formerly Code", a numerical designator used by the
SDM to indicate specific SRS malfunctions.
Driver Current Source
An output of the SDM which applies current into the
driver air bag assembly circuit during the Initiator
Assembly Resistance Test".
An assembly located in the steering wheel hub
consisting of an inflatable bag, an inflator and an
initiator.
EEPROM
Memory. Memory which retains its contents when
power is removed from the SDM.
740RS021
Definition
Air Bag
An inflatable cloth cushion designed to deploy in certain
frontal crashes. It supplements the protection offered by
the seat belts by distributing the impact load more
evenly over the vehicle occupant's head and torso.
(B+)
Battery voltage, (B+) The voltage available at the
battery at the time of the indicated measurement. With
the key ON" and the engine not running, the system
voltage will likely be between 12 and 12.5 volts. At idle
the voltage may be 14 to 16 volts. The voltage could be
as low as 10 volts during engine cranking.
Bulb Check
The Sensing and Diagnostic Module (SDM) will cause
the AIR BAG" warning lamp to flash seven times and
then go OFF" whenever the ignition switch transitions
to the ON position from any other ignition switch position
and no malfunctions are detected.
CONTINUOUS MONITORING"
Tests performed by the SDM on the SRS every 100
milliseconds while Ignition 1" voltage is in the normal
operating voltage range at the SDM.
Formerly DLC" a connector which allows
communication with an external computer, such as a
scan tool.
Deploy
To inflate the air bag.
Ignition Cycle
The voltage at the SDM Ignition 1" inputs, with ignition
switch ON", is within the normal operating voltage
range for at least ten seconds before turning ignition
switch OFF".
Ignition 1
A battery voltage (B+) circuit which is only powered with
the ignition switch in the ON, or START positions.
Initiator
The electrical component inside the air bag assembly
which, when sufficient current flows, sets off the
chemical reaction that inflates the air bag.
Initiator Assembly Resistance Test"
Tests performed once each ignition cycle when no
malfunctions are detected during TurnON" or
Continuous Monitoring." This test checks for the
correct SDM configuration for the vehicle, shorts to
Ignition 1" in the deployment loops, high resistance or
opens in the Driver Side High", Driver Side Low",
Passenger Side High" and Passenger Side Low"
circuits and measures the resistance of the inflator
assembly consisting of: 1) Initiators, 2) SRS coil
assembly (driver side only), 3) Connectors and
associated wiring.
Normal Operating Voltage Range
The voltage measured between the SDM Ignition 1"
terminals and Ground" terminals is between 9 and 16
volts.
Passenger Current Source
An output of the SDM which applies current into the
passenger air bag assembly circuit during the Initiator
Assembly Resistance Test".
An assembly located in the left side of the instrument
panel consisting of an inflatable bag, an inflator and an
initiator.
9J8
Scan Tool
An external computer used to read diagnostic
information from onboard computers via the data link
connector.
SDM
Sensing and Diagnostic Module which provides reserve
energy to the deployment loops, deploys the air bags
when required and performs diagnostic monitoring of all
SRS components.
Serial Data
Information representing the status of the SRS.
SRS
Supplemental Restraint System.
SRS Coil Assembly
An assembly of two currentcarrying coils in the driver
deployment loop that allows the rotation of the steering
wheel while maintaining the continuous contact of the
driver deployment loop to the driver air bag assembly.
SRS Wiring Harness
The wires and connectors that electrically connect the
components in the Supplemental Restraint System
(SRS).
TurnON"
Test which the Sensing and Diagnostic Module (SDM)
performs on the SRS once during each ignition cycle
immediately after Ignition 1" voltage is applied to the
SDM and before Continuous Monitoring".
Diagnosis
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERYPOWERED OR ACPOWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED PROVETYPE TESTER. INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED
CAREFULLY, OTHERWISE PERSONAL INJURY MAY
RESULT.

The SRS Diagnostic System Check" must always be
the starting point of any SRS diagnosis. The SRS
Diagnostic System Check" checks for proper AIR BAG"
warning lamp operation and checks for SRS diagnostic
trouble codes using the scan tool.
1. Current diagnostic trouble codes Malfunctions that
are presently being detected. Current diagnostic
trouble codes are stored in Random Access
Memory (RAM).
2. History diagnostic trouble codes All malfunctions
detected since the last time the history memory was
cleared. History diagnostic trouble codes are
stored in Electronically Erasable Programmable
Read Only Memory (EEPROM).
Scan Tool Diagnostics

A scan tool is used to read current and history
diagnostic trouble codes and to clear all diagnostic
trouble codes after a repair is completed. The scan tool
must be updated to communicate with the SRS through
a replaceable cartridge before it can be used for SRS
diagnostics. To use the scan tool, connect it to the data
link connector and turn the ignition switch ON". The
scan tool reads serial data from the SDM Serial Data"
line terminal 24" to the data link connector terminal 9".
Use of Special Tools

VOLTMETER, OHMMETER, ETC, OR ANY TYPE OF
POWERED PROVETYPE TESTER. INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED
CAREFULLY, OTHERWISE PERSONAL INJURY MAY
RESULT. YOU SHOULD BE FAMILIAR WITH THE
TOOLS LISTED IN THIS SECTION UNDER THE
HANDLING SRS SPECIAL TOOLS.
You should be able to measure voltage and resistance.
You should be familiar with proper use of a scan tool
such as the Tech 2 Diagnostic Computer, SRS Driver/
Passenger Load Tool 5884024210, Connector Test
Adapter Kit 5884003850, and the DVM (Digital
Multimeter) 5884002850.
9J9
SRS Connector Body Face Views
D09RW003
Legend
(1)
(2)
(3)
(4)
Sensing and Diagnostic Module (SDM)

Air Bag" Warning Lamp
(5) Supplemental Restraint System (SRS) Coil

Assembly
(6) Data Link Connector (DLC)
EndOFCallout
Repairs and Inspections Required

After an Accident
NOTE: If any SRS components are damaged, they
must be replaced. If SRS component mounting points
are damaged, they must be replaced.
Never use SRS parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized dealer; they may be used for SRS
repairs.
Do not attempt to service the SDM, the SRS coil
assembly, or the air bag assembly. Service of these
items is by replacement only.
Verify the part number of replacement air bag
assembly.
CAUTION: Never use the air bag assembly from
another vehicle.
Use only the air bag assembly for UE models.
CAUTION: Proper operation of the sensors and
Supplemental Restraint System (SRS) requires that

any repairs to the vehicle structure return it to the
original production configuration. Deployment
requires, at a minimum, replacement of the SDM, air
bag assembly and dimensional inspection of the
steering column. Any visible damage to the SDM
mounting bracket (s) requires replacement, and the
steering column must be dimensionally inspected,
whether deployment occurred or not.
Accident With Deployment Component

Replacement and Inspections
Certain SRS components must be replaced or
inspected for damage after a frontal crash involving air
bag deployment. Those components are:
Air bag assembly
SDM
CAUTION: Refer to SDM Replacement Guidelines"
below for important information on Sensing and
9J10
Diagnostic Module (SDM) replacement in both

deployment and non deployment crashes.
Supplemental Restraint System (SRS) coil
assemblyInspect wiring and connector for any
signs of scorching, melting, or damage due to
excessive heat. Replace if damaged. Refer to SRS
coil assembly in this section.
Accident With or Without Deployment

Component Inspection
Certain SRS and restraint system components must be
inspected after any crash, whether the air bag deployed
or not. Those components are:
Steering columnDimensionally inspect per
Checking Steering Column for Accident Damage" in
3 of this workshop manual.
Knee bolsters and mounting points Inspect for any
distortion, bending, cracking, or other damage.
Instrument panel steering column reinforcement
plate Inspect for any distortion, bending, cracking,
or other damage.
Instrument panel bracesInspect for any distortion,
bending, cracking, or other damage.
Seat belts and mounting pointsRefer to Seat
Belts" in 10 of this workshop manual.
SDM Replacement Guidelines

SDM replacement policy requires replacement of SDM,
after crash involving air bag deployment when SRS
Warning Lamp" turn ON", SRS Diagnosis" should be
done according to Section".
Wiring Damage
If any SRS wire harness is damaged, it should be
replaced. Don't repair SRS. It is replace only.
OnVehicle Service
Service Precautions
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
The SDM in DriverPassenger SRS can maintain
sufficient voltage to cause a deployment for up to 15
seconds after the ignition switch is turned OFF", the
battery is disconnected, or the fuse powering the SDM
is removed.
Many of the service procedures require removal of the
SRS" fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected
from the deployment loop as noted in the Disabling the
SRS" procedure that follows, service can begin
immediately without waiting for the 15 second time
period to expire.
Disabling The SRS

Removal
Turn the ignition switch to lock" and remove key.
1. Remove SRS fuse METER and SRS, from left
dash side lower fuse block or disconnect battery.
2. Disconnect yellow 2pin connector at the base of
steering column.
3. Remove glove box assembly, Refer to Passenger
Air Bag Assembly Replacement" in section.
4. Disconnect yellow 2pin connector behind the glove
box assembly.
SRS Connector (Plastic Body And Terminal

Metal Pin) Damage
CAUTION: With the SRS" fuse removed and

ignition switch ON", AIR BAG" warning lamp will
be ON". This is normal operation and does not
indicate an SRS malfunction.
If any connector or terminal in the SRS wire harness

(except pigtails) is damaged, it should be replaced.
Enabling The SRS
SRS Wire Pigtail Damage

If the wiring pigtail (a wire or wires attached directly to
the device, not by a connector) is damaged, the entire
component (with pigtail) must be replaced. Examples of
pigtail" components are the driver air bag assembly, the
passenger air bag assembly, and the SRS coil
assembly.
Installation
another vehicle. Use only the air bag assembly for
UE models.
Turn ignition switch to LOCK" and remove key.
1. Connect yellow 2pin connector passenger air bag
assembly.
2. Install glove box assembly, refer to Passenger Air
Bag Assembly Replacement" in section.
3. Connect yellow 2pin connector at the base of
steering column.
4. Install AIR BAG" fuse METER and SRS to left
dash side lower fuse block or connect battery.
Turn ignition switch to ON" and verify that the AIR
9J11
BAG" warning lamp flashes seven times and then turns

OFF" If it does not operate as described, perform the
Supplemental Restraint System (SRS) Diagnostic
System Check" in section.
Handling / Installation / Diagnosis

1. Air bag assembly should not be subjected to
temperatures above 93C (200F).
2. Air bag assembly, and Sensing and Diagnostic
Module (SDM) should not be used if they have been
dropped from a height of 100 centimeters (3.28
feet).
3. When a SDM is replaced, it must be oriented with
the arrow on the sensor pointing toward the front of
the vehicle. It is very important for the SDM to be
located flat on the mounting surface, parallel to the
vehicle datum line. It is important that the SDM
mounting surface is free of any dirt or other foreign
material.
4. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code.
5. The SRS Diagnostic System Check" must be the
starting point of any SRS diagnostics. The SRS
Diagnostic System Check" will verify proper AIR
BAG" warning lamp operation and will lead you to
the correct chart to diagnose any SRS malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
827RX037
WARNING: WHEN CARRYING A LIVE AIR BAG

ASSEMBLY, MAKE SURE THE BAG OPENING IS
POINTED AWAY FROM YOU. IN CASE OF AN
ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN
DEPLOY WITH MINIMAL CHANCE OF INJURY.
NEVER CARRY THE AIR BAG ASSEMBLY BY THE
WIRES OR CONNECTOR ON THE UNDERSIDE OF
THE MODULE.
Air Bag Assembly Handling /

Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) air bag assembly. The rapid gas
generation produced during deployment of the air bag
could cause the air bag assembly, or an object in front of
the air bag assembly, to be thrown through the air in the
unlikely event of an accidental deployment.
827RS044
9J12
Air Bag Assembly Shipping Procedure For

Live (Undeployed) Air Bag Assemblies
Service personnel should refer to the latest Service
Bulletins for proper Supplemental Restraint System
(SRS) air bag assembly shipping procedures.
Deployed Air Bag Assembly

You should wear gloves and glasses. 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 Ammounium Chloride may be
found in amounts of about 1% (each) of the total
particulate.
Air Bag Assembly Scrapping Procedure

During the course of a vehicle's useful life, certain
situations may arise which will necessitate the disposal
of a live (undeployed) air bag assembly. This
information covers proper procedures for disposing of a
live air bag assembly.
Before a live air bag assembly can be disposed of, it
must be deployed. Alive air bag assembly must not be
disposed of through normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER SRS
AIR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. AN UNDPLOYED
AIR BAG ASSEMBLY 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 LAW.
In situations which require deployment of a live air bag
assembly module, deployment may be accomplished
inside or outside the vehicle. The method employed
depends upon the final disposition of the particular
vehicle, as noted in Deployment Outside Vehicle" and
Deployment Inside Vehicle" in this section.
Cautions About Air Bag Deployment And

Disposal
Failure to follow proper procedures could result in
erroneous air bag deployment which may cause
personal injury be sure to follow proper procedures.
1. Turn off (Lock) the ignition switch and disconnect the
minus terminal of the battery, then start the work 15
or more sec later. (Air bag is designed to work by
the back-up power source even if the battery power
source is cut off at vehicle collision).
2. Be sure not to disassemble the air bag.
3. Do not give an impact to the air bag and bring the air
bag close to magnet. (The air bag could deploy
unexpectedly).
4. Place the air bag with its trim cover up.
5. Do not let the air bag deploy directly on the floor.
(The air bag may be blown off 20 30 cm (6.5 or 10
feet)).
6. Be sure to install the air bag firmly to a deployment
tool (fixing tool).
7. Set a battery 10 m (33 feet) or more away from the
air bag.
8. Before disconnecting air bag harness, ground the
worker by touching the vehicle outer panel with bare
hand.
9. When connecting or disconnecting the harness, do
not work just in front of the air bag.
10. As deployment gives rise to big sound, warn the
people around against it. Further, try to reduce the
sound by covering the steering wheel or tires, and
shut the vehicle windows in case of deployment
inside the vehicle.
11. As deployment generates smoke, select a well
ventilated place. (In case of deployment indoors,
avoid deployment just under a fire alarm, smoke
sensor, and fluorescent lamps).
12. Be careful not to inhale the smoke after deployment.
13. If part of the vehicle glass is damaged, cover the
vehicle with a car cover to prevent the glass from
braking at the time of deployment.
14. Do not touch the air bag immediately after
deployment, since it remains hot for 30 minutes.
15. Do not water the air bag immediately after
deployment.
16. Wear safety glasses and gloves throughout the work
and wash the glasses and gloves after the work.
17. Do not reuse the removed air bag for another
vehicle. (Deployment characteristic is different with
vehicle types).
Deployment Outside Vehicle (Driver Air

Bag Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be returned
to useful service after a functionally or cosmetically
deficient air bag assembly is replaced. Deployment and
disposal of a malfunctioning air bag assembly is, of
course, subject to any required retention period.
For deployment of a live (undeployed) air bag assembly
outside the vehicle, the deployment procedure must be
followed exactly. Always wear safety glasses during this
deployment procedure until a deployed air bag
assembly is scrapped or until an undeployed air bag
assembly is shipped. Before performing the procedures
you should be familiar with servicing the SRS and with
proper handling of the air bag assembly. Procedures

should be read fully before they are performed.
The following procedure requires use of 588402468
0 Supplemental Restraint System (SRS) Deployment
Harness with the appropriate pigtail adapter. The
procedure also requires the use of 5884024200
Driver Side SRS Deployment Fixture. Do not attempt
this procedure without 5884024680 and fixture 5
884024200.
9J13
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.
18. Turn ignition switch to LOCK", remove key and put
on safety glasses.
19. Inspect 5884024190 SRS Deployment Harness
and appropriate pigtail adapter for damage. If
harness or pigtail adapter is damaged, discard and
obtain a replacement.
20. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other. SRS deployment harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed.
901RX046
827RS003
21. Connect the appropriate pigtail adapter to the SRS

deployment harness.
901RX062
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
DRIVER 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 SAFETY GLASSES THROUGHOUT THIS
827RS004
9J14
1. Remove the driver air bag assembly from vehicle.

Refer to driver air bag assembly Removal in this
Section.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR OTHER
SURFACE, ALWAYS FACE THE AIR BAG AND TRIM
COVER 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.
22. Clear a space on the ground about 183 cm (6 feet)
in 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.
827RX042
27. Connect the driver air bag assembly to the pigtail

adapter on the Supplemental Restraint System
(SRS) deployment harness. Deployment harness
shall remain shorted and not be connected to a
power source until the air bag is to be deployed.
The driver air bag assembly will immediately deploy
the air bag when a power source is connected to it.
827RX039
23. Place the J41497 on the bench vice. This is

necessary to provide sufficient stabilization of the
fixture during deployment.
24. Attach the Driver air bag assembly in the J41497.
Air bag assembly must be mounted such that the
bag will deploy upward. SECURELY HAND
TIGHTEN ALL FASTENERS PRIOR TO
DEPLOYMENT.
25. Extent double pole extension cord to a position for
away 10 m (33 feet) from the air bag assembly.
26. Place a power source near the shorted end of the
SRS deployment harness. Recommended
application: 12 volts minimum, 2 amps minimum. A
vehicle battery is suggested.
NOTE: Ensure that the pigtail adapter is firmly seated

into the driver air bag assembly connector. Failure to
fully seat the connectors may leave the shorting bar
located in the driver air bag assembly connector
functioning (shorted) and may result in non deployment
of the driver air bag assembly.
28. Verify that the area around the driver air bag
assembly is clear of all people and loose or
flammable objects.
29. Verify that the driver air bag assembly is firmly and
properly in 5884024200.
30. Notify all people in the immediate area that you
intend to deploy the driver air bag. The deployment
will be accompanied by a substantial noise which
may startle the uninformed.
31. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deploy
the driver air bag.

WARNING: 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.
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.
32. Connect the Supplemental Restraint System (SRS)
deployment harness wires to the power source to
immediately deploy the driver air bag.
Recommended application: 12 volts minimum, 2
amps minimum. A vehicle battery is suggested.
33. Disconnect the SRS deployment harness from the
power source.
other.
35. In the unlikely event that the driver air bag assembly
did not deploy after following these procedures,
proceed immediately with Steps 24 through 26. If
the driver air bag assembly did deploy, proceed with
Steps 20 through 23.
36. Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible irritation
and heat when handling the deployed 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.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE VERY HOT. ALLOW THE INFLATOR
MODULE TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE
DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN FIRE OR
PERSONAL INJURY.
AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE DRIVER AIR BAG
ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH
THE METAL AREAS OF THE DRIVER AIR BAG
ASSEMBLY FOR ABOUT TEN MINUTES AFTER
DEPLOYMENT. IF THE DEPLOYED DRIVER AIR BAG
ASSEMBLY MUST BE MOVED BEFORE IT IS COOL,
9J15
WEAR GLOVES AND HANDLE BY THE AIR BAG OR

TRIM COVER.
37. Disconnect the pigtail adapter from the driver air
bag assembly as soon after deployment as possible.
This will prevent damage to the pigtail adapter or
SRS deployment harness due to possible contact
with the hot driver air bag assembly canister. The
pigtail adapter can be reused. They should,
however, be inspected for damage after each
deployment and replaced if necessary.
38. Dispose of the deployed driver air bag assembly
through normal refuse channels after it has cooled
for at least 30 minutes.
39. Wash your hands with mild soap and water
afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the driver air bag assembly did not
deploy after following these procedures.
40. Ensure that the SRS deployment harness has been
disconnected from the power source and that its two
banana plugs have been shorted together by fully
seating one banana plug into the other.
827RW055
41. Disconnect the pigtail adapter from the driver air

bag assembly.
ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR
MODULE UNATTENDED ON A BENCH OR OTHER
COVER 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
42. Temporarily store the driver air bag assembly with
its trim cover facing up, away from the surface upon
which it rests.
9J16
Deployment Outside Vehicle (Passenger

Air Bag Assembly)
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR BAG ASSEMBLIES MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS. THE
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
procedures, you should be familiar with servicing the
SRS system and with proper handling of the air bag
assembly. Procedures should be read fully before they
are performed.
The following procedure requires use of 588402468
0 SRS Deployment Harness with the appropriate pigtail
adapter. The procedure also requires the use of 5
884024200 Passenger Side Supplemental Restraint
System (SRS) Deployment Fixture. Do not attempt this
procedure without 5884024680 and fixture 58840
24200.
901RX046
901RW088

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 SAFETY GLASSES THROUGHOUT THIS
ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
NOTE: This information applies only to passenger air
bag assembly. Information for disposing of a live driver
air bag assembly can be found in Deployment Outside
Vehicle" (Driver Air Bag Assembly) in this section.
43. Turn ignition switch to LOCK" remove key, and put
on safety glasses.
44. Inspect 5884024190 SRS Deployment Harness
and appropriate pigtail adapter for damage. If
harness or pigtail is damaged, discard and obtain a
replacement.
45. Short the two SRS Deployment Harness leads
other. The SRS Deployment Harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed.
9J17
884024200. Air bag assembly must be mounted

such that the bag will deploy upward. SECURELY
HANDTIGHTEN ALL FASTENERS PRIOR TO
DEPLOYMENT.
51. Extend double pole extension cord to a position for
52. Place a power source near the shorted end of the
SRS deployment harness. (Recommended
vehicle battery is suggested.)
827RS003
46. Connect the appropriate pigtail adapter to the

Supplemental Restraint System (SRS) Deployment
Harness
827RX043
827RS004
47. Remove passenger air bag assembly from vehicle.

Refer to Passenger Air Bag Assembly Removal " in
this Section.
48. Clear a space on the ground approximately 183 cm
(6 feet) in clearance where the fixture with attached
air bag assembly is to be placed for deployment. 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 is no activity and
sufficient ventilation is recommended. Ensure that
no loose or flammable objects are within the
deployment area.
49. Place the 5884024200 on the bench vice. This
is necessary to provide sufficient stabilization of the
fixture during deployment.
50. Attach the passenger air bag assembly in the 5
53. Connect the air bag assembly to the pigtail adapter

on the SRS deployment harness. The SRS
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.
into the air bag assembly connector. Failure to fully seat
the connectors may leave the shorting bar located in the
air bag assembly connector functioning (shorting the
deployment circuit) and may result in non deployment of
the air bag assembly.
54. Verify that the area around the passenger air bag
assembly is clear of all people and loose or
flammable objects.
55. Verify that the passenger air bag assembly is firmly
and properly in 5884024200.
9J18
56. Notify all people in the immediate area of your

intention to deploy the passenger air bag assembly.
The deployment will be accompanied by a
substantial noise which may startle the uninformed.
57. Separate the two banana plugs on the
Supplemental Restraint System (SRS) deployment
harness.
NOTE: When air bag deploys, the rapid gas expansion
will create a substantial noise. Notify all people in the
immediate area that you intend to deploy the air bag
assembly.
WARNING: 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.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
PROCEDURES IN THE ORDER LISTED MAY
58. 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.
59. Disconnect the SRS deployment harness from the
power source.
other.
61. 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
deployed as intended, proceed with Steps 20
through 23.
62. Put on a pair of shop gloves and safety glasses to
and heat when handling the deployed air bag
assembly. After the air bag assembly has been
deployed, the surface of the air bag may contain a
powdery residue. This powder consists primarily of
cornstarch (used to lubricate the bag as it inflates)
and by products of the chemical reaction. Sodium
hydroxide dust (similar to lye soap) is produced as a
by product of the deployment reaction. The sodium
hydroxide quickly reacts with the atmospheric
moisture and is converted to sodium carbonate and
sodium bicarbonate (baking soda). Therefore, it is
unlikely that sodium hydroxide will be present for
very long after deployment.
OBSERVED WHEN HANDLING A DEPLOYED AIR

WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY TO
COOL BEFORE HANDLING ANY METAL PORTION
OF IT. DO NOT PLACE THE DEPLOYED INFLATOR
MODULE NEAR ANY FLAMMABLE OBJECTS.
FAILURE TO FOLLOW PROCEDURES MAY RESULT
IN FIRE OR PERSONAL INJURY. AFTER AN AIR
BAG ASSEMBLY HAS BEEN DEPLOYED, THE
METAL CANISTER AND SURROUNDING AREAS OF
THE AIR BAG ASSEMBLY WILL BE HOT. DO NOT
TOUCH THE METAL AREAS OF THE AIR BAG
ASSEMBLY FOR ABOUT THIRTY MINUTES AFTER
DEPLOYMENT. IF THE DEPLOYED AIR BAG
WEAR GLOVES AND HANDLE BY THE AIR BAG
ITSELF.
63. 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.
64. Dispose of the deployed air bag assembly through
normal refuse channels after it has cooled for at
least 30 minutes.
afterward.
unlikely event that the air bag assembly did not deploy
after following the above procedures.
disconnected from the the power source and that its
two banana plugs have been shorted together by
fully seating one banana plug into the other.
827RW055

assembly.
9J19

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
68. Temporarily store the air bag assembly with the bag
facing up, away from the surface upon which it rests.
Deployment Outside Vehicle (Fixing Air

Bag on Tire)
Read and understand the items of CAUTIONS ABOUT
AIR BAG DEPLOYMENT AND DISPOSAL
PROCEDURES and Usage of Deployment Tool for
safe deployment of air bag.
1. Remove air bag assembly from vehicle. Refer to air
bag assembly Removal in this section.
2. Inspect 5884024190 Supplemental Restraint
System (SRS) Deployment Harness and
appropriate pigtail adapter for damage. If harness or
pigtail is damaged, discard and obtain a
replacement.
3. Extend double pole extension cord to a position far
4. Place a power source near the extended end of
SRS air bag deployment harness. (Use of 12V
battery is recommended).
827RW055
6. Prepare four 15 inch or larger tires without wheel

and two same size tires with wheels.
827RX041
827RX040
Legend
(A) 10 m (33 feet) or more
EndOFCallout
5. Insert one of the banana plugs into the other
banana plug to short the two SRS air bag
deployment harness. Do not the harness to a power
source until deployment.
7. How to fix Driver air bag.

1. Fix the air bag with its trim cover up on a tire
with a wheel using an automobile use wire
harness, (core size: 1.3 mm2 (0.05 inch)) or a
wire trebly at two or more points.
2. Connect SRS air bag assembly to the double
pole extension cord of the air bag deployment
harness.
Do not connect the deployment harness to a
power source until air bag deployment.
(If connected the SRS air bag assembly deploys
immediately)
9J20
827RW058
827RW054
3. Place three tires without wheel on the tire on

which air bag is fixed and a tire with a wheel on
top.
Bind the five tires with a rope so that the tires
may not collapse.
2. Connect Supplemental Restraint System (SRS)

air bag assembly to the deployment harness
double pole extension cord end. Be sure not to
connect the deployment harness to a power
source. (If connected the SRS air bag assembly
deploys immediately).
827RW053
Legend
EndOFCallout
8. How to fix Passenger air bag.
1. Fix the air bag with its trim cover side fixing the
center of a tire without a wheel using an
automobile use wire harness, (core size: 1.3
mm (0.05 inch)) or a wire trebly at two or more
points.
827RW054
3. Put a tire without wheel on another, put the tire

on which the air bag is fixing, put a tire without a
wheel, and finally put a tire with a wheel on top.
Bind the tires with a rope so that the tires pile
may not collapse.
827RW050
Legend
EndOFCallout
9. Notify all people in the immediate area of your
intention to deploy the passenger air bag assembly.
The deployment will be accompanied by a
substantial noise which may startle the uninformed.
WARNING: DEPLOYED 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 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.
10. Connect the Supplemental Restraint System (SRS)
deployment harness wires to the power source to
immediately deploy the air bag assembly.
Recommended application : 12 volts minimum, 2
amps minimum. A vehicle battery is suggested.
9J21
827LW011

OBSERVED WHEN HANDING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL
SURFACES OF THE AIR BAG ASSEMBLY WILL BE
VERY HOT. ALLOW THE AIR BAG ASSEMBLY TO
COOL BEFORE HANDLING ANY METAL PORTION
OF IT. DO NOT PLACE THE DEPLOYED INFLATOR
MODULE NEAR ANY FLAMMABLE OBJECTS.
FAILURE TO FOLLOW PROCEDURES MAY RESULT
IN FIRE OR PERSONAL INJURY. AFTER AN AIR
BAG ASSEMBLY HAS BEEN DEPLOYED, THE
METAL CANISTER AND SURROUNDING AREAS OF
THE AIR BAG ASSEMBLY WILL BE HOT. DO NOT
TOUCH THE METAL AREAS OF THE AIR BAG
ASSEMBLY FOR ABOUT THIRTY MINUTES AFTER
DEPLOYMENT. IF THE DEPLOYED AIR BAG
WEAR GLOVES AND HANDLE BY THE AIR BAG IT
SELF.
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.
12. Dispose of the deployed air bag assembly through
normal refuse channels after it has cooled for at
least 30 minutes.
afterward.
after following the above procedures.
disconnected from the power source and that its two
banana plugs have been shorted together by fully
9J22

Deployment Inside Vehicle (Vehicle
Scrapping Procedure)
seating one banana plug into the other.
Deployment inside vehicle is proper when the vehicle is

to be destroyed or salvaged for component parts. This
includes, but is not limited to, the following situations:
1. The vehicle has completed its useful life.
2. The vehicle has been damaged beyond repair in a
non deployment 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.
827RW055

assembly.
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
3. Temporarily store the air bag assembly with the bag
facing up, away from the surface upon which it rests.
066RW030

MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR BAG ASSEMBLIES MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS. THE
FEDERAL, STATE AND/OR LOCAL LAWS.
15. Turn ignition switch to LOCK", remove key and put
on safety glasses.
16. Remove all loose objects from front seats.
17. Disconnect Supplemental Restraint System (SRS)
coil assembly, yellow 2pin connector located at the
base of the steering column.
18. Cut the SRS coil assembly yellow 2pin harness
connector from the vehicle leaving at least 16 cm
(six inches) of wire at the connector.
19. Strip 13 mm (1/2 inch) of insulation from yellow
green and yellowblack wire lead of the connector.
20. Cut two 900 cm (30 feet) deployment wires from 0.8
mm2 (18 gauge) or thicker multistrand wire. These
wires will be used to fabricate the driver deployment
harness.
21. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.

4. 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.
9J23
5. Bend twisted connection made in the previous step

flat and wrap tightly with electrical tape to insulate
and secure.
F09HV009
F09RX001

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
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
CONNECTED TO IT. WEAR SAFETY GLASSES
THROUGHOUT THIS ENTIRE DEPLOYMENT AND
DISPOSAL PROCEDURE.
22. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
23. Twist together, bend and tape the remaining

connector wire lead to the remaining deployment
wire.
24. Connect the deployment harness to the driver air
bag assembly, yellow 2pin connector at the base of
the steering column. Route deployment harness
out the driver side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
CONNECTED TO IT.
Connecting the deployment wires to the power
source should always be the final step in the air bag
assembly deployment procedure.
Failure to follow procedures in the order listed could
result in personal injury.
25. Disconnect passenger air bag assembly, yellow 2
pin connector located behind glove box assembly.
26. Cut the passenger air bag assembly harness
connector from the vehicle leaving at least 16 cm
(six inches) of wire at the connector.
27. Strip 13 mm (1/2 inch) of insulation from yellow
green and yellowred wire lead of the connector.
28. Cut two 900 cm (30 feet) deployment wires from 0.8
mm2 (18 gauge) or thicker multistrand wire. These
wires will be used to fabricate the passenger
deployment harness.
29. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
9J24
6. 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.
7. Bend twisted connection made in the previous step

flat and wrap tightly with electrical tape to insulate
and secure.
F09HV009
F09RX001

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
DEPLOY THE AIR BAG WHEN SAFETY GLASSES
THROUGHOUT THIS ENTIRE DEPLOYMENT AND
DISPOSAL PROCEDURE.
30. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
31. Twist together, bend and tape the remaining

connector wire lead to the remaining deployment
wire.
32. Connect the deployment harness to the passenger
air bag assembly, yellow 2pin connector located
behind the glove box assembly. Route deployment
harness out the passenger side of the vehicle.
CONNECTED TO IT. CONNECTING THE
DEPLOYMENT WIRES SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
PROCEDURES IN THE ORDER LISTED COULD
33. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
34. Stretch the driver and passenger deployment
harness to their full length.
35. Completely cover windshield area and front door
window openings with a drop cloth, blanket or
similar item. This reduces the possibility of injury
due to possible fragmentation of the vehicle's glass
or interior.
36. Notify all people in the immediate area that you
intend to deploy the air bags. The deployment will
be accompanied by a substantial noise which may
startle the uninformed.
37. Separate the two ends of the driver deployment
harness wires.
9J25

SOURCE UNTIL THE AIR BAG IS TO A POWER
DEPLOYMENT WIRES TO THE POWER SOURCE
SHOULD ALWAYS BE THE FINAL STEP IN THE AIR
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.
assembly.
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery
residue. This powder consists primarily of
cornstarch (used to lubricate the bag as it inflates)
and by products of the chemical reaction. Sodium
hydroxide dust (similar to lye soap) is produced as a
by product of the deployment reaction. The sodium
hydroxide then quickly reacts with atmospheric
moisture and is converted to sodium carbonate and
sodium bicarbonate (baking soda). Therefore, it is
unlikely that sodium hydroxide will be present after
deployment.
NOTE: When the air bag deploys, the rapid gas

expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deploy
the air bags.
38. Connect the driver deployment harness wires to a
power source to immediately deploy the driver air
bag assembly. Recommended application: 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
39. Separate the two ends of the passenger deployment
harness wires.

OBSERVED WHEN HANDLING A DEPLOYED AIR
WILL BE VERY HOT. ALLOW THE AIR BAG
ASSEMBLY TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE HOT
DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES COULD RESULT IN FIRE OR
PERSONAL INJURY.
After an air bag assembly has been deployed, the
metal canister and surrounding areas of the air bag
assembly will be very hot. Do not touch the metal
areas of the air bag assembly for about 30 minutes
after deployment. If the deployed air bag assembly
must be moved before it is cool, wear gloves and
handle by the air bag or trim cover.
41. Short the driver deployment harness wires by
twisting together one end from each. Repeat this
procedure for the passenger deployment harness.
42. Carefully remove drop cloth from vehicle and clean
off any fragments or discard drop cloth entirely.
43. Disconnect driver deployment harness and
passenger deployment harness from vehicle and
discard.
44. In the unlikely event that either or both of the air bag
assemblies did not deploy after following these
procedures, proceed immediately with Steps 36
through 37. If the air bag assembly deployed,
proceed to step 35.
45. With both air bags deployed, the vehicle may be
scrapped in the same manner as a nonSRS
equipped vehicle.

SOURCE UNTIL THE AIR BAG IS TO A POWER
DEPLOYMENT WIRES TO THE POWER SOURCE
SHOULD ALWAYS BE THE FINAL STEP IN THE AIR
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.
40. Connect the passenger deployment harness wires
to a power source to immediately deploy the
passenger air bag assembly. Recommended
vehicle battery is suggested. (Driver air bag
assembly) Put on a pair of shop gloves and safety
gasses to protect your hands and eyes from
possible irritation and heat when handling the
deployed 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.
(Passenger air bag assembly)
Put on a pair of shop gloves and safety glasses to
and heat when handling the deployed air bag

after following these procedures.
46. Remove the undeployed air bag assembly (s) from
the vehicle. For driver air bag assembly refer to in
the Passenger Air Bag Assembly Removal" in this
section.
9J26

COVER UP, AWAY FROM THE SURFACE. THIS IS
NECESSARY SO THAT A FREE SPACE IS PROVIDED
TO ALLOW THE AIR BAG TO EXPAND IN THE
UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT.
FAILURE TO FOLLOW PROCEDURES COULD
47. Temporarily store the air bag assembly with the air
bag opening facing up, away from the surface upon
which it rests.
Deployed Air Bag Assembly Handling

protect your hands and eyes from possible irritation and
heat when handling the deployed air bag assembly.
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.
(Passenger air bag assembly)
protect your hands and eyes from possible irritation and
heat when handling the deployed air bag assembly.
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to lye
soap) is produced as a by product of the deployment
reaction. The sodium hydroxide then quickly reacts with
atmospheric moisture and is converted to sodium
carbonate and sodium bicarbonate (baking soda).
Therefore, it is unlikely that sodium hydroxide will be
present after deployment.
9J27
Special Tools
POWERED PROBETYPE TESTER.
INJURY MAY RESULT.
5884024210 (J41433) SRS Driver/

Passenger Load Tool
The Supplemental Restraint System (SRS) Driver/
Passenger Load Tool 5884024210 is used only
when called for in this section. It is used as a
diagnostic aid and safety device to prevent inadvertent
air bag assembly deployment.
The load tool has four yellow connectors attached to its
case.
The three small connectors are electrically functional
and serve as resistive load substitutions.
No more than two connectors are used at any time.
One of the small connectors is used to substitute for the
load of the driver air bag assembly when it is connected
at the top of the column to the SRS coil assembly.
Another small connector is used to substitute for the
load of the driver air bag assembly and the SRS coil
assembly when it is connected at the base of the
column to the SRS wiring harness. The third small
connector is used to substitute for the load of the
passenger air bag assembly when connected to the
passenger air bag assembly harness connector.
By substituting the resistance of the load tool when
called for, a determination can be made as to whether
an inflator circuit component is causing system
malfunction and which component is causing the
malfunction. The load tool should be used only when
specifically called for in the diagnostic procedures.
901RS146
5884002850 (J39200) DVM

The 5884002850 Digital Multimeter (DVM) is the
preferred DVM for use in SRS diagnosis and repair.
However, 5884003660 may be used if 58840
02850 is not available. No other DVMs are approved
for SRS diagnosis and repair.
901RS153
9J28
Scan Tool
The Tech 2 is used to read and clear SRS Diagnostic
Trouble Codes (DTCs). Refer to the Tech 2 Operator's
Manual for specific information on how to use the Tech
2.
901RW176
5884024680 (J42986) SRS Deployment

Tool
The 5884024680 Supplemental Restraint System
(SRS) Deployment Tool must be used for deployment of
the undeployed air bag.
901RX046
5884003850 (J35616A) Connector

Test Adapter Kit
5884024290 (J42987) SRS Adapter For

Load Tool
The 5884003850 Connector Test Adapter Kit must

be used whenever a diagnostic procedure requests
checking or probing a terminal. Using the appropriate
adapter will ensure that no damage to the terminal will
occur from the Digital Multimeter (DVM) prove, such as
spreading or bending. 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.
The J42987 SRS Adapter be used for connect

previous load tool to new SRS system when inspect
SRS system harness.
901RW107
901RS151

5884024200 (J41497) SRS Deployment
Fixture
The 5884024200 SRS Deployment Fixture must be
used for deployment of the undeployed passenger side
air bag.
901RW088
9J29
9J30
Tech 2 Scan Tool

From 1999 Vehi CROSS (VX), dealer service
departments are recommended to use Tech 2. Please
refer to Tech 2 scan tool user guide.
901RW180
Legend
(1) PCMCIA Card
(4) Data Link Connector (DLC) Cable

(5) Tech2
EndOFCallout
Getting Started
the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).

9J31
Operating Procedure

vehicle Data Link Connector (DLC).
740RX068

060RW009
NOTE: The RS232 loop back connector is only to use

for diagnosis of Tech 2 and refer to user guide of the
Tech 2.
060RX001
9J32
060RW013
Service Precaution
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.
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) COMPONENTS OR SRS WIRING, FOLLOW
THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
The Sensing and Diagnostic Module (SDM) in Driver
Passenger SRS can maintain sufficient voltage to cause
a deployment for up to 15 seconds after the ignition
switch is turned OFF," the battery is disconnected, or
the fuse powering the SDM is removed.
Many of the service procedures require removal of the
SRS1" fuse, and disconnection of the air bag
assembly from the deployment loop to avoid an
accidental deployment. If the air bag assembly is
disconnected from the deployment loop as noted in the
Disabling the SRS" procedure that follows, service can
begin immediately without waiting for the 15 second
time period to expire.
Disabling The SRS

Removal
Turn the ignition switch to OFF" and turn the steering
wheel so that the vehicle's wheels are pointing straight
ahead.
6. Remove SRS fuse METER and SRS, from left dash
side lower fuse block or disconnect battery.
7. Disconnect yellow 2pin connector at the base of
steering column.
8. Remove glove box assembly; Refer to Passenger
Air Bag Assembly Replacement" in this section.
9. Disconnect passenger air bag assembly yellow 2
pin connector behind the glove box assembly.
CAUTION: With the SRS" fuse removed and
ignition switch ON," the AIR BAG" warning lamp
will be ON." This is normal operation and does not
indicate an SRS malfunction.
Enabling The SRS

Installation
Turn ignition switch to LOCK" and remove key.
9J33
1. Connect yellow 2pin connector passenger air bag

assembly.
2. Install glove box assembly, Refer to Passenger Air
Bag Assembly Replacement" in this section.
3. Connect yellow 2pin connector at the base of the
steering column.
4. Install AIR BAG" fuse METER and SRS to left dash
side lower fuse block or connect battery.
Turn ignition switch to ON" and verify that the AIR
BAG" warning lamp flashes seven times and then turns
OFF" If it does not operate as described, perform the
SRS Diagnostic System Check" in section.
Handling / Installation / Diagnosis

5. Air bag assembly should not be subjected to
temperatures above 93C (200F).
6. Air bag assembly, and SDM should not be used if
they have been dropped from a height of 100 cm
(3.3 feet) or more.
7. When a SDM is replaced, it must be oriented with
the arrow on the SDM pointing toward the front of
the vehicle. It is very important for the SDM to be
located flat on the mounting surface, parallel to the
vehicle datum line. It is important that the SDM
mounting surface is free of any dirt or other foreign
material.
8. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code.
9. The SRS Diagnostic System Check" must be the
Diagnostic System Check" will verify proper AIR
BAG" warning lamp operation and will lead you to
the correct chart to diagnose any SRS malfunctions.
diagnostic time, incorrect diagnosis, and incorrect
parts replacements.
Inspections Required After An Accident

CAUTION: Certain SRS components must be
replaced after a frontal crash involving air bag
deployment.
In all types of accidents regardless of Air Bag"
deployment, visually inspect all of the following
components and replace as required:
Driver air bag assembly
Passenger air bag assembly
Steering wheel
SRS coil assembly
Steering column
Knee bolster and instrument panel mounting
attachments
Driver seat and belt
Passenger seat and belt
SDM
9J34
Be sure to replace Sensing and Diagnostic Module

(SDM) in accordance with SDM Replacement
Guidelines. In cases of collision without causing air bag
deployment, SDM could be used unless this manual
instructs to replace.
CAUTION: Refer to SDM replacement Guidelines
below for important information on SDM
replacement in both deployment and non
deployment crashes.
SDM Replacement Guidelines
1. In case that the air bag has been deployed, replace
the SDM.
2. When DTC 51, 53 and 71 are set.
3. When SDM fell down from a 100 cm (3.3 feet)
height.
All above is SDM replacement Guideline.
Inspection is needed also on the following.
Inspect Supplemental Restraint System (SRS) coil
assembly wiring and steering wheel for any signs of
scorching meting 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 in this Section of this manual.
Never use SRS parts from another vehicle. This does
not include remanufactured parts purchased from an
authorized 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.
9J35
Sensing and Diagnostic Module (SDM)

Service Precautions
1. Remove air conditioning duct for rear seat.

(Transform the duct during removing it)
WARNING: DURING SERVICE PROCEDURES, BE

VERY CAREFUL WHEN HANDLING SDM. NEVER
STRIKE OR JAR SDM. UNDER SOME
CIRCUMSTANCES, IT COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY
OR IMPROPER OPERATION OF THE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM
MOUNTING BRACKET BOLTS MUST BE
CAREFULLY TORQUED TO ASSURE PROPER
OPERATION. NEVER POWER UP THE SRS WHEN
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE.
THE SDM COULD BE ACTIVATED WHEN POWERED
WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE
WHICH COULD CAUSE DEPLOYMENT AND RESULT
IN PERSONAL INJURY.
WARNING: PROPER OPERATION OF THE SENSING
AND DIAGNOSTIC MODULE (SDM) REQUIRES THE
SDM TO BE RIGIDLY ATTACHED TO THE VEHICLE
STRUCTURE AND THAT THE ARROW ON THE
SENSOR BE POINTING TOWARD THE FRONT OF
THE VEHICLE.
SDM is specifically calibrated and is keyed to the SDM
location SRS wiring harness. Caution should be used to
ensure proper location of the SDM. The keying of the
SDM to its location and wiring harness connectors
should never be modified in the field.
827RW023
10. Pull CPA (3) (Connector Position Assurancered

color) out and push connector lock down to
disconnect the SDM harness connector (2).
11. Remove the three SDM fixing bolts and remove
SDM (1).
Removal
1. Disable the SRS. (Refer to Disable the SRS" in this
manual)
2. Remove dressing panel around the radio and
disconnect cigar lighter harness.
3. Remove the transfer sift lever knob.
4. Remove the center console.
5. Remove three connector from Powertrain Control
Module (PCM).
6. Remove PCM with bracket.(Fixed four bolts)
7. Remove right side stay between instrument panel
and floor.
8. Remove driver and passenger seat.
9. Turn over carpet to rear side.
827RW044
Installation
1. Install the SDM (1) on bracket and fixing bolts and
tighten the fixing bolts to the specified torque.
Torque: 10 3 Nm (1.0 0.3 kgm//87 26 lbin)
1. Connect the SDM harness connector (2) and after
that, put CPA into connector (3).
9J36
2. Install air conditioning duct for rear seat to normal

position.
2. Return carpet normal position.
3. Install right side stay between instrument panel and
floor, tighten to the specified torque.
Torque: 10 3 Nm (1.0 0.3 kgm/87 26 lbin)
4. Install PCM with bracket and tighten to the specified
torque.
Torque: 10 3 Nm (1.0 0.3 kgm/87 26 lbin)
5. Reconnect three connector to Powertrain Control
Module (PCM).
6. Install the center console.
7. Install the transfer shift lever knob.
8. Install the dressing panel around the radio and
reconnect cigar lighter harness.
9. Enable the SRS. (Refer to Enabling the SRS" in this
manual)
9J37

Service Precautions
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
POWDER 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.
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 A LIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
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
OTHERWISE, PERSONAL INJURY COULD RESULT.
827RX036
3. Disconnect connector and remove air bag assembly.

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
Removal
1. Disable the Supplemental Restraint System (SRS).
(Refer to Disabling the SRS" in this section.)
2. Remove air bag assembly from steering wheel by
removing two bolts. Lift air bag assembly out of
steering wheel.
827RX035
Installation
1. Connect air bag to wiring harness connector.
plastic cover (wire protector) of air bag to prevent lead
3. Install air bag into steering wheel and tighten bolts
to specified sequence as shown in figure.
Torque: 8.8 Nm (0.9 kgm/78 lbin)
another vehicle.
9J38
Use only the air bag assembly for UE.
4. Enable the Supplemental Restraint System (SRS).

(Refer to Enabling the SRS" in this section.)
Steering Wheel
Service Precautions
AFTERWARDS.
Removal
1. Disable the SRS. (Refer to Disabling the SRS" in
this section.)
827RX034
2. Remove the air bag assembly (5) from steering

wheel (6) by removing two bolts (7). Lift air bag
assembly out of steering wheel.

827RX036
9J39
Installation
3. Disconnect connector (2) and remove air bag

assembly.
1. Install the steering wheel and align the setting

marks (3).
2. Tighten the steering wheel fixing nut (4) to the
specified torque.
3. Connect horn lead (1).
4. Connect air bag to wiring harness connector (2).
(7) to specified sequence as show in figure.
UE.
827RX035
3. Disconnect horn lead (1)

4. Remove steering wheel attachment nut (4).
5. Move the tires to the straight ahead position before
removing the steering wheel. Install steering wheel
puller onto steering wheel and remove steering
wheel with 5852100160.
original position.
827RX034
6. Enable the Supplemental Restraint System (SRS).

(Refer to Enabling The SRS" in this section.)
827RW063
7. Feed wiring through the wheel and remove wheel.

absorbing unit.
9J40
SRS Coil Assembly

Service Precaution
AFTERWARDS.
Removal
1. Disable the SRS. (Refer to "Disabling the SRS" in
this section.)
825RX047


827RX036
9J41
10. Remove the steering column cover (3).

11. Disconnect the wiring harness connectors (10)
located at the base of steering column.
12. Disconnect the horn terminal NO.2 from connector
and remove the tape binding harness. (Refer to How
to Disconnect the horn terminal in this section.)
4. Disconnect the 2pin yellow connector (2) and

remove air bag assembly.
827RX035
3. Disconnect horn lead connector (1).

4. Remove the steering wheel attachment nut (5).
removing the steering wheel and remove wheel with
5852100160.
original position.
827RW063
7. Feed wiring though the wheel and remove wheel.

in the direction of the shaft by using a hammer or
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
8. Remove the steering lower cover.
827RX029
13. Remove four bolts of combination switch assembly

(9) attached to steering lock and remove the
combination switch assembly (with SRS coil) from
steering shaft.
825RX047
9J42
5. Remove four bolts of SRS coil assembly and

remove the SRS coil assembly from the combination
switch.
6. Pull out the terminal of lead wire coming to black

connector NO.12 while lifting the lock part with a
minitenes screw driver (-).
825RX033
827RX046
Legend
How to Disconnect the horn terminal

1. Lift the white part of black connector with a
minitenes screw driver (-) and release connector
terminal lock.
(1) Lock
(2) Minitenes screw driver (-)
(3) Terminal
EndOFCallout
How to Connect Horn Terminal

1. Insert horn terminal from behind black connector
NO.12 until connector lock works.
827RX045
Legend
(1) Minitenes screw driver (-)
(2) Connector lock knob
EndOFCallout
827RX047
Legend
(1) Terminal
(2) Connector lock knob
EndOFCallout

7. Push white connector into the black connector for a
double lock.
9J43
8. Install the combination switch assembly (with SRS

coil) to steering lock of steering shaft and tighten the
four bolts to a specified tightening torque.
827RX048
825RX047
Installation
1. Set cancel cam and SRS coil in position and install
the SRS coil to combination switch by tightening the
four bolts to a specified tightening torque with four
bolts.
Torque: 0.5 Nm (0.05 kgm/0.4 lb ft)
3. Connect the wiring harness connectors (10) located

at the base of steering column.
4. Turn the SRS coil clockwise to full, return about 3
turns and align the neutral mark.
NOTE: Whenever installing the new combination switch
with SRS coil, be sure to tear off the lock pin for aligning
the neutral position before it is installed to the base of
steering column.
825RX033
2. Insert the horn terminal into the connector NO.12

and bind the combination switch harness and SRS
coil harness with a tape.(Refer to How to Connect
the horn terminal in this section.)
825RX032
CAUTION: When turning the SRS coil clockwise to

full, stop turning if resistance is felt. Forced further
turning may damage the cable in the SRS coil.
9J44

10. Install Air Bag (6) into steering wheel and tighten
bolts (8) to specified sequence as figure.
9. Install the steering column cover (3).

CAUTION: When installing the steering column
cover, be sure to through each harness as
illustrated so that the harnesses starter switch,
combination switch and SRS coil may not catch
wiring.
Torque: 8.8 Nm (0.9 kgm/78 lb in)

UE.
825RS048
5. Install the driver knee bloster assembly.

6. Install the steering lower cover.
7. Install the steering wheel and align the setting
marks (4).
specified torque.
10. Connect air bag to wiring harness connector (2).
825RX047
11. Enable the SRS. (Refer to Enabling The SRS in

this section.)
9J45
Steering Column
Service Precaution
AFTERWARDS.
Removal
1. Disable the Supplemental Restraint System (SRS).
(Refer to Disabling The SRS" in this section.)

431RX012


827RX036
9J46

absorbing unit.
13. Remove the combination switch assembly with
Supplemental Restraint System (SRS) coil (9).
3. Disconnect the 2pin yellow connector (7) and

remove air bag assembly.

assembly, which cannot be replaced separately.
15. Remove the cushion rubber.
16. Disconnect shift lock cable.
(12) located base of steering column.
18. Remove steering lock cylinder assembly (11).
19. Remove the 2nd shaft (14) from the column shaft
assembly (13) by removing bolt (15).
20. Remove steering column assembly (13).
827RX035
4. Disconnect horn lead connector (8).

5. Remove the steering wheel attachment nut (3).
removing the steering wheel and removing wheel
with 5852100160.
original position.
827RW063
8. Feed wiring though the wheel and remove wheel.

9. Remove the steering lower cover.
11. Remove the steering column cover (1).
12. Disconnect the wiring harness connectors (10)
located at the base of steering column.
431RX012
9J47
Installation
1. Install the 2nd shaft (14) to the column shaft
assembly (13).
2. Install the steering column assembly (13).
3. Tighten the steering column fixing bolts (dash panel
side) to the specified torque.
4. Tighten the steering column fixing nuts (Cross
6. Install steering lock cylinder assembly (11).
7. Connect shift lock cable.
10. Install the combination switch assembly with
Supplemental Restraint System (SRS) coil (9).
11. Connect the wiring harness connector (10) located
on the base of steering column.
12. Turn the SRS coil clockwise to full, return about 3
turns and align the neutral mark.
825RS048
CAUTION: When installing the steering column

cover, be sure to wire (through each harness) as
illustrated so that the harnesses starter switch,
combination switch and SRS coil may not catch
wiring.
14. Install the steering wheel (2) and align the setting
marks (6).
specified torque.
17. Connect air Bag wiring harness connector (7).
825RX032
CAUTION: When turning the SRS coil clockwise to

full, stop turning if resistance is felt. Further forced
turning may damage the cable in the SRS coil.
13. Install steering column cover (1).
9J48
(5) to specified sequence as shown in figure.
another vehicle.
Use only the air bag assembly for UE.
431RX012
19. Enable the Supplemental Restraint System (SRS)

(Refer to Enabling The SRS" in this section.)
9J49

Service Precaution
AFTERWARDS.
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
827RX051
Installation
1. Install passenger air bag assembly from glove box
opening of instrument panel.
2. Install reinforcement from glove box opening of
instrument panel.
3. Install air bag assembly fixing nuts and bolts, and
tighten to specified torque.
Torque: 7.8 Nm (69 lbin)
4. Connect air bag assembly harness connector.
5. Install glove box assembly.
6. Enable the SRS (Refer to Enabling the SRS" in this
section.)
Removal
1. Disable the SRS. (Refer to Disabling the SRS" in
this section.)
2. Remove glove box assembly.
3. Disconnect passenger air bag assembly harness
connector.
4. Remove air bag assembly fixing bolts and nuts.
5. Remove reinforcement.
6. Remove passenger air bag assembly from glove
box opening of instrument panel.
827RW062
9J50

Fastener Tightening Specification
Application
Nm
kgm
Ib Ft
Ib In
SDM
10
1.0
87
Driver air bag fixing bolt
8.8
0.9
78
Steering wheel fixing bolt
34
3.5
25
Steering column (dash panel side fixing bolts)
20
2.0
15
Steering column (Cross beam side fixing nuts)
17
1.7
13
Steering column (Universal joint fixing bolt)
31
3.2
23
Passenger Air Bag fixing bolts and nuts
0.6
52
9J51
SRS Air Bag System Inspection Standards For Repair

Parts Name
Inspection Standard
Collision
Trouble
Driver Air bag

Assembly
Passenger Air bag

Assembly
Sensing and
Diagnostic Module
(SDM)
SRS Coil Assembly
SRS Harness
Steering Wheel
Steering Column
Part Replacement Standard

1. Air bag has deployed due to collision.
2. Pad surface has crack or scratch.
3. Connector has cracks.
4. Harness is disconnected or scratched.
5. Air bag is soaked in water, oil etc.
6. Air bag has fallen from a height of about 10 cm (3.3) feet.
7. Trouble diagnosis in Workshop Manual resulted in part
replacement.
1. Air bag has deployed due to collision.

2. SDM is crack or deformed.
4. SDM has fallen from a height of about 100 cm (3.3 feet).
replacement.
1. Burn or melt due to overheat.

2. Case is cracked or deformed.
replacement.
1. Air bag circuit wire harness is disconnected or damaged.

replacement.
1. Bracket is deformed.
2. A new air bag cannot be installed with ease.
3. When a new air bag is installed, pad interferes with the steering
wheel, and clearance is uneven.
1. Capsule is broken.
2. The fitting of column collapses.
3. Bellows pipe is deformed.
Instrument Panel &

Knee bolster &
Cover Glove box.
Seat Seat Belt
Wood shield Glass
1. Dent, bend, cracks, and deform.
Mounts
1. Repair or replace if dent, bend, cracks, and deform are found.

2. Retighten to specified torque if loose.
Inspection Standards
In cases of collision: When any type of collision has occurred regardless of air bag deployment.
In cases of trouble code: When trouble code has been detected by TECH 2 in case of the AIR BAG WARNING LIGHT
failing to work or remaining lighted.
SECTION
RESTRAINT CONTROL SYSTEM
9J11
RESTRAINTS
SRS CONTROL SYSTEM
CONTENTS
Diagnostic Information ...................................
Parts For Electrical Circuit .............................
System Schematic .........................................
SRS Diagnostic System Check .....................
Chart A SDM Integrity Check........................
Chart B AIR BAG" Warning Lamp Comes
ON" Steady .................................................
Chart C AIR BAG" Warning Lamp Does
Not Comes ON" Steady ..............................
DTC 15 Passenger Deployment Loop
Resistance High...........................................
Resistance Low............................................
Open ............................................................
Short To Ground ..........................................
9J1 - 1
9J1 - 2
9J1 - 4
9J1 - 5
9J1 - 5
9J1 - 9
9J1 - 11
9J1 - 13
9J1 - 16
9J1 - 19
9J1 - 22

Short To Voltage .......................................... 9J1 - 28
DTC 21 Driver Deployment Loop
Resistance High........................................... 9J1 - 31
Resistance Low............................................ 9J1 - 34
Short To Ground .......................................... 9J1 - 37
Short To Voltage .......................................... 9J1 - 40
DTC 26 Driver Deployment Loop Open........ 9J1 - 44
DTC 51 Deployment Event Commanded ..... 9J1 - 47
DTC 53 Deployment Commanded With
Deployment Loop Fault Or Energy Reserves
Out Of Range............................................... 9J1 - 49
DTC 61 Warning Lamp Circuit Failure.......... 9J1 - 52
DTC 71 Internal SDM Fault .......................... 9J1 - 54
9J1 - 25
Service Precaution

parts and systems.
9J12
other conditions exist.
Diagnostic Procedures
Diagnostic Codes
WARNING: WHEN FASTENERS ARE REMOVED,

ALWAYS REINSTALL THEN 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.
The Sensing and Diagnostic Module (SDM) maintains a

history record of all diagnostic codes that have been
detected since the SRS codes were last cleared during
service.
1. Active CodesFaults that are presently detected
this ignition cycle. Active codes are stored in
Random Access Memory (RAM).
2. History CodesAll faults detected since the last
time the history fault memory was cleared. History
codes are stored in Electronically Erasable
Programmable Read only Memory (EEPROM).

NONPOWERED, PROBETYPE TESTER.
INJURY MAY RESULT.
The diagnostic procedures used in this section are
designed to aid in finding and repairing SRS problems.
Outlined below are the steps to find and repair SRS
problems quickly and effectively. Failure to carefully
follow these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect parts
Replacement.
1. Perform The SRS Diagnostic System Check."
The Supplemental Restraint System (SRS)
Diagnostic System Check" should always be the
Diagnostic System Check" checks for proper AIR
BAG" warning lamp operation and checks for SRS
trouble codes using both Flash Code" and Scan
Tool" Methods.
2. Refer To The Proper Diagnostic Chart As
Directed By The SRS Diagnostic System
Check."
The SRS Diagnostic System Check" will lead you
to the correct chart to diagnose any SRS problems.
diagnostic time, incorrect diagnosis and incorrect
parts Replacement.
3. Repeat the SRS Diagnostic System Check"
After Any Repair Or Diagnostic Procedures Have
Been Performed.
Performing the SRS Diagnostic System Check"
after all repair or diagnostic procedures will assure
that the repair has been made correctly and that no
How To Read Trouble Codes

All codes (Active and history) can be read (or cleared)
by using a scan tool or equivalent.
If a Diagnostic Trouble Code (DTC) is not available,
have the vehicle serviced by dealer.
How To Clear Trouble Codes

Trouble codes can only be cleared by using a scan tool.
If a scan tool is not available then inform the owner of
the stored codes and suggest that the codes are
cleared upon the next visit to a dealership.
Scan Tool Diagnostics

A scan tool can be used to read current and history
codes and to clear all history codes after a repair is
complete. The scan tool must be updated to
communicate with the SRS through a replaceable
cartridge for SRS diagnostics. To use the scan tool,
connect it to the Data Link Connector (DLC) and turn
the ignition switch ON". Then follow the manufacturer's
directions for communication with the SRS. The scan
tool reads serial data from the Sensing and Diagnostic
Module (SDM) Serial Data" output (terminal 24) to the
DLC.
Basic Knowledge Required

Before using this section of the Service Manual, there is
some basic knowledge which will be required. Without
this knowledge, you will have trouble using the
diagnostic procedures in this section. Use care to
prevent harm or unwanted deployment. Read all
cautions in the service manual and on warning labels
attached to SRS components.
Basic Electrical Circuits

You should understand the basic theory of electricity
including series and parallel circuits, and understand
the voltage drops across series resistors. You should
know the meaning of voltage (volts), current (amps),
and resistance (ohms). You should understand what
happens in a circuit with an open or a shorted wire. You

should be able to read and understand a wiring
diagram.
Flash Code" Diagnostics

Flash code diagnostics can be used to read current
codes and to determine if history codes are present but
cannot be used to clear codes or read history codes.
Flash code diagnostics is enabled by grounding by
terminal 13 shorting to terminal 4 of the DLC with the
ignition switch ON". Grounding terminal 13 of the DLC
pulls the Diagnostics Request" input (Terminal 1) of the
SDM low and signals the SDM to enter the flash code
diagnostic display mode.
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 13 of the DLC.
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 enabled 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
current or history codes present, the SDM will display
code 12 until ground is removed from the DLC at
terminal 13. Flash Code 13" will be displayed if there
are history codes. To read the history codes, a scan
tool must be used.
9J13
9J14
Parts For Electrical Circuit
All wires have color-coded insulation.

Wires belonging to a systems main harness wil have a
single color. Wires belonging to a systems sub-circuits
will have a colored stripe. Striped wires use the following
code to show wire size and colors.
Wiring
Wire Color
D08RX174
Legend
D08RX175
Abbreviations are used to indicate wire color within a

circuit diagram.
Refer to the following table.
(1) Colored Stripe

(2) Single Color
EndOFCallout
Wire Color Coding
Color-coding
Meaning
Color-coding
Meaning
Black
BR
Brown
White
LG
Light green
Red
GR
Grey
Green
Pink
Yellow
LB
Light blue
Blue
Violet
Orange
Distinction of Circuit by Wire Base Color

Base
color
Circuits
Starter circuit and grounding circuit
Charging circuit
Lighting circuit
Signal circuits
Base
color
Y
L, O, BR,
LG, GR, P,
SB, V
Circuits
Instrument circuit
Other circuit
9J15
System Schematic
D09RX002
SRS Diagnostic System Check

The diagnostic procedures used in this section are
designed to find and repair Supplemental Restraint
System (SRS) malfunctions. To get the best results, it
is important to use the diagnostic charts and follow the
sequence listed below:
A Perform the SRS Diagnostic System Check."
The SRS Diagnostic System Check" must be the
Diagnostic System Check" checks for proper AIR
BAG" warning lamp operation, the ability of the
Sensing and Diagnostic Module (SDM) to
communicate through the Serial Data" line and
whether SRS diagnostic trouble codes exist.
B Refer to the proper diagnostic chart as directed by
the SRS Diagnostic System Check."
The SRS Diagnostic System Check" will lead you
to the correct chart to diagnose any SRS

malfunctions. Bypassing these procedures may
result in extended diagnostic time, incorrect
diagnosis and incorrect parts replacement.
C Repeat the SRS Diagnostic System Check" after
any repair or diagnostic procedures have been
performed.
Performing the SRS Diagnostic System Check"
after all repair or diagnostic procedures will ensure
that the repair has been made correctly and that no
other malfunctions exist
Circuit Description
When the ignition switch is first turned ON", ignition 1"
voltage is applied from the SRS" fuse to the SDM at the
ignition 1" input terminals 12". The SDM responds by
flashing the AIR BAG" warning lamp seven times while
performing tests on the SRS.
9J16
Notes On System Check Chart:

Number(s) below refer to step number(s) on the
Supplemental Restraint System Diagnostic System
Check" chart.
1. The AIR BAG" warning lamp should flash seven
times after ignition is first turned ON."
2. After the AIR BAG" warning lamp flashes seven
times, it should turn OFF."
3. Improper operation of the AIR BAG" warning lamp is
indicated. This test differentiates a warning lamp
stays ON" condition from a warning lamp does not
come ON" condition.
4. This test checks for the proper operation of the Serial
Data" line. This test will also determine whether
history diagnostic trouble codes are stored and, if so,
identify them.
5. This test checks for proper operation of the Serial
Data" line. This test will also identify the stored
diagnostic trouble codes and whether they are
current or history.
Diagnostic Aids:
The order in which diagnostic trouble codes are
diagnosed is very important. Failure to diagnose the
diagnostic trouble codes in the order specified may
result in extended diagnostic time, incorrect diagnosis
and incorrect parts Replacement.
9J17
SRS Diagnostic System Check

Step
Action
Yes
No
Note the AIR BAG" warning lamp when ignition switch is turned
ON."
Does the AIR BAG" warning lamp flash seven (7) times?
Go to Step 2
Go to Step 3
Note the AIR BAG" warning lamp after it flashed 7 times.

Does the AIR BAG" warning lamp go OFF"?
Go to Step 4
Go to Step 5
Go to Chart B.
Go to Chart C.
2
3
Note the AIR BAG" warning lamp when ignition switch is turned
ON."
Does the AIR BAG" warning lamp come ON" steady?
1. Ignition switch OFF."
2. Connect a scan tool to data link connector.
3. Follow direction given in the scan tool instruction manual.
4. Ignition switch ON."
5. Request the SRS diagnostic trouble code display recode all
history diagnostic trouble code(s) specify as such, on repair
order.
Is diagnostic trouble code(s) displayed?
Ignition switch
OFF."
When DTC 71
is set, go to
DTC 71 chart.
For all other
history codes
refer to
Diagnostics
Aids" for that
specific DTC.
A history DTC
indicates the
malfunction has
been repaired
or is
intermittent.
SRS is
functional and
free of
malfunctions,
no further
diagnosis is
required.
If scan tool
indicates No
Data Received,"
refer to chassis
electrical
section.
9J18
Step
Action

2. Connect a scan tool to data link connector.
3. Follow directions as given in the scan tool instruction manual.
5. Request the SRS diagnostic trouble code display, recode all
diagnostic trouble code(s), specifying as current or history on
repair order.
Is diagnostic trouble code(s) displayed?
Yes
Ignition switch
OFF."
When DTC 53
is set, go to
DTC 53 chart.
When DTC 51
is set, go to
DTC 51 chart.
When DTC 19
is set, go to
DTC 19 chart.
When DTC 25
is set, go to
DTC 25 chart.
Diagnose
remaining
current DTCs
from lowest to
highest.
When only
history DTCs
exist, Refer to
Diagnostics
Aids" for that
specific DTC.
A history DTC
indicates the
malfunction has
been repaired
or is
intermittent.
No
If scan tool
indicates No Data
Received," refer to
chassis electrical
section.
9J19
Chart A SDM Integrity Check
D09RX002
Circuit Description:
Chart Test Description:
When the Sensing and Diagnostic Module (SDM)

recognizes ignition 1" voltage, applied to terminals 12",
is greater than 9 volts, the AIR BAG" warning lamp is
flashed 7 times to verify operation. At this time the
SDM performs TurnON" tests followed by Continuous
Monitoring" tests. When a malfunction is detected, the
SDM sets a current diagnostic trouble code and
illuminates the AIR BAG" warning lamp. The SDM will
clear current diagnostic trouble codes and move them to
a history file when the malfunction is no longer detected
and/or the ignition switch is cycled, except for
Diagnostic Trouble Codes (DTCs) 51, 53 and 71. DTC
71 can only be cleared using a scan tool Clear Codes"
command in case that the malfunction on DTC 71 has
been solved and no DTCs 51 and 53 were remained.
DTCs 51, 53 and 71 can not be cleared after a Clear
Codes" command is issued.

diagnostic chart:
1. This test confirms a current malfunction. If no current
malfunction is occurring (history DTC set) the
Diagnostic Aids" for the appropriate diagnostic
trouble code should be referenced. The SDM should
not be replaced for a history diagnostic trouble code.
2. This test checks for a malfunction introduced into the
SRS during the diagnostic process. It is extremely
unlikely that a malfunctioning SDM would cause a
new malfunction to occur during the diagnostic
process.
3. When all circuitry outside the SDM has been found to
operate properly, as indicated by the appropriate
diagnostic chart, then and only then should the SDM
be replaced.
9J110
Chart A SDM Integrity Check

WARNING: DURING SERVICE PROCEDURES. BE
VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR
JAR THE SDM. NEVER POWER UP THE SRS WHEN
THE SDM IS NOT RIGIDLY ATTACHED TO THE
VEHICLE. ALL SDM AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED AND
THE ARROW MUST BE POINTING TOWARD THE

FRONT OF THE VEHICLE TO ENSURE PROPER
OPERATION OF THE SRS. THE SDM COULD BE
ACTIVATED WHEN POWERED WHILE NOT RIGIDLY
ATTACHED TO THE VEHICLE WHICH COULD
CAUSE DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
Step
Action
1. This chart assumes that the SRS Diagnostic System Check"

and either a symptom chart or a diagnostic trouble code chart
diagnosis have been performed When all circuitry outside the
SDM has been found to operate properly, as indicated by the
appropriate diagnostic chart, and the symptom or DTC
remains current, the following diagnostic procedures must be
performed to verify the need for SDM Replacement.
3. Reconnect all SRS components, ensure all components are
properly mounted.
4. Ensure the ignition switch has been OFF" for at least 15
seconds.
5. Note AIR BAG" warning lamp as ignition switch is turned
ON."
Does warning lamp flash 7 times then go OFF"?
Using a scan tool, request diagnostic trouble code display.

Is the same symptom or DTC occurring as was when the SRS
Diagnostic System Check " was first performed?
1. Clear SRS Diagnostic Trouble Codes."

2. Ignition switch OFF" for at least two minutes.
3. Note AIR BAG" warning lamp as ignition switch is turned
ON."
Does warning lamp flash 7 times then go OFF"?
Reconnect all SRS components, ensure all components are

properly mounted.
Yes
No
The symptom
or DTC is no
longer
occurring.
Clear SRS
diagnostic
trouble codes.
Repeat the
SRS
Diagnostic
System Check."
Go to Step 2
Ignition switch
OFF."
Go to the
appropriate
chart for the
indicated
malfunction.
Go to Step 3
SRS is
functional and
free of
malfunctions.
No further
diagnosis is
required.
Go to Step 4
Ignition switch
OFF."
Replace SDM.
Go to Step 4
Repeat the SRS

Diagnostic System
Check."
Go to Step 4
9J111
Chart B AIR BAG" Warning Lamp Comes ON" Steady
D09RX002
voltage is applied from the METER fuse to AIR BAG",
warning lamp which is connected to Supplemental
Restraint System (SRS) warning lamp", terminal 7".
The SRS" fuses apply system voltage to the ignition
1" inputs, terminals 12". The Sensing and Diagnostic
Module (SDM) responds by flashing the AIR BAG"
warning lamp 7 times. If ignition 1" voltage is less than
9 volts, the AIR BAG" warning lamp will come ON"
solid with no DTCs set.

Number (s) below refer to step number (s) on the
diagnostic chart.
2. This test checks for an open in the ignition 1" circuit
to the SDM.
3. This test checks for the voltage of ignition 1."
4. This test determines whether the malfunction is a

short to ground in Circuit IB04 GREEN.
9J112
Chart B AIR BAG" Warning Lamp Comes ON" Steady

Step
Action
Yes
No
1. When measurements are requested in this chart use 5

884002850 DVM with correct terminal adapter from 5
884003850.
3. Connect scan tool to data link connector, Follow directions as
given in the scan tool instruction manual.
5. Request SRS diagnostic trouble code display.
Does scan tool indicate No Data Received"?
Go to Step 2
Go to Step 3

2. Inspect SDM harness connector connection to SDM.
Is it securely connected to the SDM?
Ignition switch
OFF."
Replace SDM.
Go to Step 5
Go to Step 4
Ignition switch
OFF."
Replace SDM.
Go to Step 5
Go to Chart A.
Replace SRS
harness.
Go to Step 5
Using scan tool, request SRS data list.

Is ignition" more than 9 volts?

2. Disconnect SRS coil and passenger air bag assemblies.
Yellow 2pin connectors located at base of steering column
and behind the glove box assembly.
3. Disconnect SDM.
4. Measure resistance from SDM harness connector terminal
6" to ground.
Does DVM display 0L" (infinite)?
properly mounted.
Connect SDM
securely to de
activate
shorting clip in
SDM harness
connector.
Go to Step 5
Repeat the
SRS
Diagnostic
System Check."
Go to Step 5
9J113
Chart C AIR BAG" Warning Lamp Does Not Comes ON" Steady
D09RX002
voltage is applied from the METER" fuse to the AIR
BAG" warning lamp which is connected to
Supplemental Restraint System (SRS) warning lamp",
terminal 7". The SRS" fuse apply system voltage to
the ignition 1" inputs, terminals 12". The Sensing and
Diagnostic Module (SDM) responds by flashing the AIR
BAG" warning lamp seven times. If ignition 1" voltage
is more than 16 volts, the AIR BAG" warning lamp will
be still OFF" solid with no DTCs set.

diagnostic chart:
1. This test decides whether power is available to SDM
warning lamp power feed circuit.
2. This test determines whether the voltage is present in
the warning lamp circuit.

3. This test determines if the malfunction is in the
instrument cluster.
4. This test checks for open in the warning lamp
circuitry.
5. This test isolates the IB04GREEN circuit and checks
for a short in the IB04GREEN circuit to B+.
8. This test checks for a short from the SDM warning
lamp power feed circuit to ground.
9. This test determines whether the short to ground is
due to a short in the wiring.
9J114
Chart C AIR BAG" Warning Lamp Does Not Comes ON" Steady
Step
1
Action
Yes
No

884003850.
3. Remove and inspect METER" fuse to the AIR BAG"
warning lamp.
Is fuse good?
Go to Step 2
Go to Step 7

3. Disconnect SDM.
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

2. Remove instrument meter cluster.
3. Check for proper connection to instrument cluster at IB04
GRN terminal.
4. If OK, then remove and inspect AIR BAG" bulb.
Is bulb good?
Go to Step 5
Replace bulb.
Go to Step 6
Go to Chart A.
Replace SRS
harness.
Go to Step 6

2. Disconnect instrument meter cluster harness connector.
4. Measure voltage on SDM harness connector from terminal
7" to terminal 6" (ground).
Is voltage 1 volt or less?
1. Install bulb.
2. Measure resistance from instrument meter cluster harness
connector IB04GRN terminal to SDM harness connector
terminal 7".
Is resistance 5.0 ohms or less?
properly mounted.
Service
instrument
meter cluster.
Go to Step 6
Replace SRS
harness.
Go to Step 6
Repeat the SRS

Diagnostic System
Check."
Go to Step 6
Were you sent here from chart C?
Go to Step 8
Go to Step 1
1. Replace METER" fuse.

2. Ignition switch ON" wait 10 seconds then ignition switch
OFF."
3. Remove and inspect METER" fuse.
Is fuse good?
Install METER"
fuse.
Go to Step 10
Go to Step 9

Step
9
10
Action
2. Disconnect SDM.
3. Replace METER" fuse.
4. Ignition switch ON" wait to 10 seconds.
5. Ignition switch OFF".
6. Remove and inspection METER" fuse.
Is fuse good?
properly mounted.
Yes
9J115
No
Install METER"
fuse.
Go to Chart A.
Replace SRS
harness.
Replace
METER" fuse.
Go to Step 10
Repeat the
SRS
Diagnostic
System Check."
Go to Step 10
9J116
DTC 15 Passenger Deployment Loop Resistance High
D09RX002
DTC Will Set When:
When the ignition switch is turned ON", the Sensing

and Diagnostic Module (SDM) will perform tests to
diagnose critical malfunctions within itself. Upon
passing these tests ignition 1", and deployment loop
voltages are measured to ensure they are within their
respective normal voltage ranges. The SDM then
proceeds with the Resistance Measurement Test".
Passenger Bag Low" terminal 16" is grounded
through a resister and the passenger current source
connected to Passenger Bag High" terminal 15" allows
a known amount of current to flow. By monitoring the
voltage difference between Passenger Bag High" and
Passenger Bag Low" the SDM calculates the
combined resistance of the passenger air bag
assembly, harness wiring Circuits(CKTs) IB07
YELLOW/GREEN and IB08YELLOW/RED connector
terminal contact.
The combined resistance of the passenger air bag

assembly, harness wiring CKTs IB07YELLOW/GREEN
and IB08YELLOW/RED, and connector terminal
contact is above a specified value. This test is run once
each ignition cycle during the Resistance
Measurement Test" when:
1. No higher priority faults" are detected during Turn
ON."
2. Ignition 1" voltage is in the specified value.
Action Taken:
SDM turns ON" the AIR BAG" warning lamp and sets
a diagnostic trouble code.

DTC Will Clear When:
The ignition switch is turned OFF."
DTC Chart Test Description:

diagnostic chart:
2. This test determines whether the malfunction is in the
Sensing and Diagnostic Module (SDM).
3. This test verifies proper connection of the yellow 2
pin connector.
4. This test checks for proper contact and/or corrosion
of the yellow 2pin connector terminals.
5. The test checks for a malfunctioning passenger air
bag assembly.
6. This test determines whether the malfunction is due
to high resistance in the wiring.
Diagnostic Aids:
An intermittent condition is likely to be caused by a poor
connection at the passenger air bag assembly harness
connector terminals 1" and 2", SDM terminal 15" and
16", or a poor wire to terminal connection in
Circuits(CKTs) IB07YELLOW/GREEN and IB08
YELLOW/RED. This test for this diagnostic trouble
code is only run while the AIR BAG" warning lamp is
performing the bulb check, unless Diagnostic Trouble
Code (DTC) 17 or DTC 26 is detected. When a scan
tool Clear Codes" command is issued and the
malfunction is still present, the DTC will not reappear
until the next ignition cycle.
9J117
9J118
DTC 15 Passenger Deployment Loop Resistance High

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.
Was the SRS Diagnostic System Check" performed?

884003850.
2. Use scan tool data list function, read and record the
passenger deployment loop resistance.
Is passenger resist more than 2.9 ohms?
2. Make sure the passenger air bag assembly yellow 2pin
connector located behind the glove box assembly is seated
properly.
Is the yellow 2pin connector connected properly?
1. Disconnect and inspect the passenger air bag assembly

yellow 2pin connector located behind the glove box
assembly.
2. If OK, reconnect the passenger air bag assembly 2pin
connector.
Is DTC 15 current?
2. Disconnect SRS coil and passenger air bag 2pin connectors
located at the base of the steering column and behind the
glove box assembly.
3. Connect 5884024210 SRS driver / passenger load tool
and appropriate adapters to SRS coil and passenger air bag
assembly harness connectors.
Is DTC 15 current?
2. There has been an increase in the total circuit resistance of
the passenger inflator deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking CKTs IB07YEL/GRN and IB08YEL/RED, and
SDM connector terminal 15" and 16" to locate the root
cause.
Was a fault found?
1. Reconnect all components ensure all component are
properly mounted.
2. Clear diagnostic trouble codes.
Go to Step 4
Seat passenger
air bag
assembly
yellow 2pin
connector
properly.
Go to Step 7
Go to Step 5
Ignition switch
OFF."
Go to Step 7
Go to Step 6
Ignition switch
OFF."
Replace the
passenger air
bag assembly.
Go to Step 7
Replace SRS
harness.
Go to Step 7
Repeat the SRS
Diagnostic System
Check."
Go to Chart A.
Go to Step 7
9J119
DTC 16 Passenger Deployment Loop Resistance Low
D09RX002
DTC Will Set When:

proceeds with the Resistance Measurement Test".
Passenger Bag Low" terminal 16" is grounded through
a resistor and the passenger current source connected
to Passenger Bag High" terminal 15" allows a known
amount of current to flow. By monitoring the voltage
difference between Passenger Bag High" and
Passenger Bag Low", the SDM calculates the
YELLOW/GREEN and IB08YELLOW/RED connector
terminal contact.
The combined resistance of the passenger air bag

assembly, harness wiring CKTs IB07YELLOW/
GREEN and IB08YELLOW/RED, and connector
terminal contact is above a specified value. This test is
run once each ignition cycle during the Resistance
ON",
Action Taken:
9J120


diagnostic chart:
3. This test verifies connection of the yellow 2pin
connector.
4. This test cheeks for proper operation of the shorting
clip in the yellow 2pin connector.
5. The test checks for a malfunction passenger air bag
assembly.
6. This test determines whether the malfunctioning is
due to shorting in the wiring.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short
between Circuits(CKTs) IB07YELLOW/GREEN and
IB08YELLOW/RED, or a malfunctioning shorting clip
on the passenger air bag assembly which would require
replacement of the air bag assembly. The test for this
diagnostic trouble code is only run while AIR BAG"
warning lamp is performing the bulb check, unless
Diagnostic Trouble Code (DTC) 17 or DTC 26 is
detected. When a scan tool Clear Codes" command is
issued and the malfunction is still present, the DTC will
not reappear until the next ignition cycle.
9J121
DTC 16 Passenger Deployment Loop Resistance Low

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.

884003850.
2. Using scan tool data list function, read and record the
passenger deployment loop resistance.
Is passenger resist. less than 1.4 ohms?
properly.

assembly.
2. If OK, reconnect the passenger air bag assembly 2pin
connector.
Is DTC 16 current?
located at the base of the steering column and behind the
glove box assembly.
Is DTC 16 current?
2. There has been a decrease in the total circuit resistance of
the passenger inflator deployment loop.
cause.
Was a fault found?
1. Reconnect all components, ensure all component are
properly mounted.
Go to Step 4
Seat passenger
air bag
assembly
yellow 2pin
connector
properly.
Go to Step 7
Go to Step 5
Ignition switch
OFF."
Go to Step 7
Go to Step 6.
Ignition switch
OFF."
Replace the
passenger air
bag assembly.
Go to Step 7
Replace SRS
harness.
Go to Step 7
Repeat the SRS
Diagnostic System
Check."
Go to Chart A.
Go to Step 7
9J122
DTC 17 Passenger Deployment Loop Open
D09RX002
DTC Will Set When:

passing these tests, ignition 1", and deployment loop
respective normal voltage ranges. During Continuous
Monitoring" diagnostics, a fixed amount of current is
flowing in the deployment loop. This produces
proportional voltage drops in the loop. By monitoring
the voltage difference between Passenger Bag High"
and Passenger Bag Low", the SDM calculates the
YELLOW/GREEN and IB08 YELLOW/RED, and
connector terminal contact.
The voltage difference between Passenger Bag High"

terminal 15" and Passenger Bag Low" terminal 16" is
above or equal to a specified value for 500 milliseconds
during Continuous Monitoring".
Action Taken:

The voltage difference between Passenger Bag High"
terminal 15" and Passenger Bag Low" terminal 16" is
below a specified value for 500 milliseconds during
Continuous Monitoring".

diagnostic chart:
pin connector.
4. This test cheeks for proper contact and/or corrosion
of the shorting clip in the yellow 2pin connector
terminals.
5. The test checks for a malfunctioning passenger air
bag assembly.
6. This test determines whether there is an open in the
wiring.
Diagnostic Aids:
connection at the passenger air bag assembly harness
connector terminals 1" and 2," SDM terminals 15"
and 16," or an open in Circuits IB07YELLOW/GREEN
and IB08YELLOW/RED.
9J123
9J124
DTC 17 Passenger Deployment Loop Open

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.

884003850.
2. Using scan tool data list function, read and record the
passenger differential voltage.
Is passenger differential voltage. more than 4.25 volts?
Go to Step 4
Seat passenger
air bag
assembly
yellow 2pin
connector
properly.
Go to Step 7
Go to Step 5
Ignition switch
OFF."
Go to Step 7
Go to Step 6
Ignition switch
OFF."
Replace the
passenger air
bag assembly.
Go to Step 7

properly.

assembly.
2. If OK, reconnected the passenger air bag assembly yellow 2
pin connector.
Is DTC 17 current?
2. Disconnect SRS coil and passenger air bag assembly yellow
2pin connectors located at the base of the steering column
Is DTC 17 current?
2. There has been an open circuit in the passenger inflator
deployment loop.
cause.
Was a fault found?
1. Reconnect all components ensure all component are
properly mounted.
Replace SRS
harness.
Go to Step 7
Repeat the SRS
Diagnostic System
Check."
Go to Chart A.
Go to Step 7
9J125
DTC 18 Passenger Deployment Loop Short To Ground
D09RX002
Monitoring".

respective normal voltage ranges.
The SDM monitors the voltages at Driver Bag Low"
terminal 4" and Passenger Bag Low" terminal 16" to
detect short to ground in the air bag assembly circuits.
Action Taken:
DTC Will Set When:

Neither of the two air bag assemblies is open.
Ignition 1" is within the normal operating voltage range.
Once these conditions are met and the voltage at
Passenger Bag Low" is below a specified value,
Diagnostic Trouble Code (DTC) 18 will set. This test is
run once each ignition cycle and Continuous

This malfunction is no longer occurring and the ignition
switch is turned OFF".

Number(s) below refer to circled number(s) on the
diagnostic chart:
2. This test determines whether the SDM is
malfunctioning.
3. This test isolates the malfunction to one side of the
passenger air bag assembly yellow 2pin connector
9J126
behind glove box compartment.

4. This test determines whether the malfunction is in
Circuit(CKT) IB07YELLOW/GREEN.
CKT IB08YELLOW/RED.
Diagnostic Aids:
to ground in the passenger air bag assembly circuit.
Inspect CKTs IB07YELLOW/GREEN and IB08
YELLOW/RED carefully for cutting or chafing. If the
wiring pigtail of the passenger air bag assembly is
damaged, the component must be replaced.
9J127
DTC 18 Passenger Deployment Loop Short To Ground

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.

884003850.
3. Connect scan tool data link connector. Follow directions as
given in the scan tool operator's manual.
5. Read passenger sense LO.
Is passenger sense LO less than 1.5 volts?
2. Disconnect passenger air bag assembly yellow 2pin
connector behind the glove box assembly..
3. Leave driver air bag assembly connected.
Connect SRS driver / passenger load tool 5884024210
and appropriate adapter to passenger air bag assembly
harness connector.
Is DTC 18 current?
2. Disconnect SRS driver / passenger load tool.
3. Measure resistance on SDM harness connector from
terminal 15" to terminal 6" (ground).
Measure resistance on SDM harness connector from terminal 6"
16" to terminal (ground).
properly mounted.
Go to Step 4
Ignition switch
OFF."
Replace
passenger air
bag assembly.
Go to Step 6
Go to Step 5
Replace SRS
harness.
Go to Step 6
Go to Chart A.
Replace SRS
harness.
Go to Step 6
Repeat the SRS

Diagnostic System
Check."
Go to Step 6
9J128
DTC 19 Passenger Deployment Loop Short To Voltage
D09RX002
Action Taken:

The SDM monitors the voltages at Driver Bag Low"
detect short to B+ in the air bag assembly circuits.
DTC 19 and also DTC 71.
DTC Will Set When:

Once these conditions are met and the voltage at
Passenger Bag Low" is above a specified value,
Diagnostic Trouble Code (DTC) 19 will set. This test is
run once each ignition cycle and Continuous
Monitoring".

The SDM is replaced.

diagnostic chart:
SDM.
passenger air bag assembly yellow 2pin connector
behind glove box compartment.
Circuit(CKT) IB07YELLOW/GREEN.

CKT IB08YELLOW/RED.
Diagnostic Aids:
to B+ in the passenger air bag assembly circuit.
Inspect CKTs IB07YELLOW/GREEN and IB08
YELLOW/RED carefully for cutting or chafing. If the
wiring pigtail of the passenger air bag assembly is
damaged, the component must be replaced. A careful
inspection of CKT IB07YELLOW/GREEN and IB08
YELLOW/RED, including the passenger air bag
assembly pigtail is essential to ensure that the
replacement Sensing and Diagnostic Module (SDM) will
not be damaged.
9J129
9J130
DTC 19 Passenger Deployment Loop Short To Voltage

CAUTION: When DTC 19 has been set, it is
necessary to replace the Sensing and Diagnostic
Module (SDM). Setting Diagnostic Trouble Code
(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
Step
1
longer present, DTC 71 will remain current. Ensure

that the short to voltage condition is repaired prior
to installing a replacement SDM to avoid damaging
the SDM.
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.

884003850.
5. Read passenger sense LO.
Is passenger sense LO more than 3.5 volts?
2. Disconnect passenger air bag assembly yellow 2pin
connector behind the glove box assembly.
3. Leave driver air bag assembly connected.
4. Connect SRS driver / passenger load tool 5884024210
and appropriate adapter to passenger air bag assembly
harness connector.
Is passenger sense LO more than 3.5 volts?
2. Disconnect SDM.
terminal 15" to terminal 12" (IGNITION 1).
Measure resistance on SDM harness connector from terminal
16" to terminal 12" (IGNITION 1).
Go to Step 4
Ignition switch
OFF."
Replace
passenger air
bag assembly.
Go to Step 6
Go to Step 5
Replace SRS
harness.
Go to Step 6
Go to Chart A.
Replace SRS
harness.
Go to Step 6

properly mounted.
Ignition switch
OFF."
Replace SDM.
Go to Step 7

properly mounted.
Repeat the SRS

Diagnostic System
Check."
Go to Chart A.
Go to Step 7
9J131
DTC 21 Driver Deployment Loop Resistance High
D09RX002
DTC Will Set When:

The SDM then proceeds with the Resistance
Measurement Test" Driver Bag Low" terminal 4" is
grounded through a current sink and the driver current
source connected to Driver Bag High" terminal 3"
allows a known amount of current to flow. By monitoring
the voltage difference between Driver Bag High" and
Driver Bag Low", the SDM calculates the combined
resistance of the driver air bag assembly, SRS coil
YELLOW and IB06YELLOW/BLACK, and connector
terminal contact.
The combined resistance of the driver air bag assembly,

SRS Coil assembly, harness wiring CKTs IB05
YELLOW and IB06YELLOW/BLACK, and connector
terminal contact is above a specified value. This test
No higher priority faults" are detected during TurnON"
Ignition 1" voltage is in the specified value.
Action Taken:
DTC 21.

The ignition switch is turned OFF".
9J132

diagnostic chart:
pin connector at the base of the steering column.
of the 2pin connector terminals at the base of
steering column.
5. This test isolate the malfunction to one side of the
Supplemental Restraint System (SRS) coil assembly
yellow 2 pin connector located at the base of the
steering column.
to high resistance in the wiring.
SRS coil assembly or the driver air bag assembly.
Diagnostic Aids:
connection at terminals 1" and 2" of the SRS coil 2
pin connector at the base of the steering column,
terminal 1" and 2" of the driver air bag assembly 2pin
connector at the top of the steering column, SDM
terminals 3" and 4" or a poor wire to terminal
connection in Circuit IB05YELLOW or IB06YELLOW/
BLACK. The test for this diagnostic trouble code is only
run while the AIR BAG" warning lamp is performing the
bulb check, unless Diagnostic Trouble Code (DTC) 17 or
DTC 26 is detected. When a scan tool Clear Codes"
command is issued and the malfunction is still present,
the DTC will not reappear until the next ignition cycle.
9J133
DTC 21 Driver Deployment Loop Resistance High

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.

884003850.
2. Use scan tool data list function, read and record the driver
deployment loop resistance.
Is driver deployment loop resistance more than 4.4 ohms?
2. Disconnect driver air bag assembly yellow 2pin connector
located at base of steering column is seated properly.
Is the 2pin connector connected properly?
Go to Step 4
Seat SRS coil

assembly 2pin
connector
properly.
Go to Step 8
1. Disconnect and inspect the SRS coil assembly yellow 2pin

connector located base of steering column.
2. If OK, reconnect the SRS coil assembly yellow 2pin
connector.
Is DTC 21 current?
Go to Step 5
Ignition switch
OFF."
Go to Step 8

2. Disconnect SRS coil and passenger air bag assembly yellow
2pin connectors located at the base of steering column and
behind the glove box assembly.
and appropriate adapter to SRS coil and passenger air bag
Is DTC 21 current?
Go to Step 6

2. There has been a increase in the total circuit resistance of the
driver deployment loop.
checking CKTs IB05YEL/IB06YEL/BLK, and SDM
connector terminal 3" and 4" to locate the root cause.
Was a fault found?
Replace SRS
harness.
Go to Step 8

Disconnect SRS driver / passenger load tool from SRS coil
assembly harness connector.
on the top of steering column.
Reconnect SRS coil assembly harness connector as the
base of steering column.
Ignition switch ON."
Is DTC 21 current?
Ignition switch
OFF."
Replace SRS
COIL
ASSEMBLY.
Refer to in this
section.
Go to Step 8
Reconnect all components, ensure all component are properly

mounted.
Clear diagnostic trouble codes.
Repeat the SRS

Diagnostic System
Check."
Go to Step 7
Go to Chart A.
Ignition switch
OFF."
Replace driver
air bag
assembly.
Go to Step 8
Go to Step 8.
9J134
DTC 22 Driver Deployment Loop Resistance Low
D09RX002
DTC Will Set When:

proceeds with the Resistance Measurement Test"
Driver Bag Low" terminal 4" is grounded through a
current sink and the driver current source connected to
Driver Bag High" terminal 3" allows a known amount
of current to flow. By monitoring the voltage difference
between Driver Bag High" and Driver Bag Low" the
SDM calculates the combined resistance of the driver
air bag assembly, Supplemental Restraint System
(SRS) coil assembly, harness wiring Circuits(CKTs)
IB05YELLOW and IB06YELLOW/BLACK and
The combined resistance of the driver air bag assembly,

SRS coil assembly, harness wiring CKTs IB05
YELLOW and IB06YELLOW/BLACK and connector
terminal contact is above a specified value. This test is
ON"
Action Taken:
DTC 22.


diagnostic chart:
4. This test checks for proper operation of the shorting
clip in the yellow 2pin connector.
5. This test isolate the malfunction to one side of the
yellow 2pin connector located at the base of
steering column.
to shorting in the wiring.
Diagnostic Aids:
between Circuits IB05YELLOW or IB06YELLOW/
BLACK or a malfunctioning shorting clip on the driver air
bag assembly or SRS coil assembly which would
require replacement of the component. The test for this
diagnostic trouble code is only run while the AIR BAG"
warning lamp is performing the bulb check, unless
Diagnostic Trouble Code (DTC) 17 or DTC 26 is
detected. When a scan tool Clear Codes" command is
issued and the malfunction is still present, the DTC will
not reappear until the next ignition cycle.
9J135
9J136
DTC 22 Driver Deployment Loop Resistance Low

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.

884003850.
deployment loop resistance.
Is driver resist. less than 1.9 ohms?
2. Make sure the SRS coil assembly yellow 2pin connector
located at the base of steering column is seated properly.
Is the 2pin connector connected properly?
Go to Step 4
Seat driver air

bag assembly
2pin connector
properly.
Go to Step 8

2. If OK, reconnect the driver air bag assembly yellow 2pin
connector.
Is DTC 22 current?
Go to Step 5
Ignition switch
OFF."
Go to Step 8

located at the base of steering column and behind the glove
box assembly.
Is DTC 22 current?
Go to Step 6

2. There has been a decrease in the total circuit resistance of
the driver deployment loop.
checking CKTs IB05YEL and IB06YEL/BLK, and SDM
connector terminal 3" and 4" to locate the root cause.
Was a fault found?
Replace SRS
harness.
Go to Step 8

2. Disconnect SRS driver / passenger load tool from SRS coil
3. Connect SRS driver / passenger load tool 5884024210 to
the top of steering column.
4. Reconnect SRS coil assembly harness connector as the
Is DTC 22 current?
Ignition switch
OFF."
Replace SRS
coil assembly.
Refer to in this
section.
Go to Step 8

properly mounted.
Repeat the SRS

Diagnostic System
Check."
Go to Step 7
Go to Chart A.
Ignition switch
OFF."
Replace driver
air bag
assembly.
Go to Step 8
Go to Step 8
9J137
DTC 24 Driver Deployment Loop Short To Ground
D09RX002
Action Taken:

The SDM monitors the voltage at Driver Bag Low"
detect shorts to ground in the air bag assembly circuits.
DTC Will Set When:

Neither of the two air bag assemblies is open.
This test is run once each ignition cycle and
Continuous Monitoring". Once these conditions are
met and the voltage at Driver Bag Low" is below a
specified value, DTC 24 will set.

The malfunction is no longer occurring and the ignition
is turned OFF."

diagnostic chart:
malfunctioning
yellow 2pin connector at the base of the steering
column.
9J138

Circuit(CKT) IB05YELLOW.
CKT IB06YELLOW/BLACK.
Diagnostic Aids:
to ground in the driver air bag assembly circuit. Inspect
CKTs IB05YELLOW and IB06YELLOW/BLACK
carefully for cutting or chafing.
9J139
DTC 24 Driver Deployment Loop Short To Ground

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."

884003850.
Ignition switch ON."
4. Read driver sense LO.
Is driver sense LO less than 1.5 volts?
Go to Step 3
Go to Chart A.

2. Disconnect SRS coil assembly yellow 2pin connector
located at base of the steering column. Leave passenger air
bag assembly connected.
and appropriate adapter to SRS coil assembly harness
connector.
Is DTC 24 current?
Go to Step 4
Go to Step 6

2. Disconnect SDM.
4. Measure resistance on SDM harness connector 3" to
terminal 6" (ground).
to terminal 6" (ground).
2. Disconnect SRS driver / passenger load tool 5884024210
from SRS coil assembly harness connector.
and appropriate adapter 5884003850 to driver air bag
assembly harness connector. Located top of the steering
column.
Is DTC 24 current?
properly mounted.
Go to Step 5
Replace SRS
harness.
Go to Step 7
Go to Chart A.
Replace SRS
harness.
Go to Step 7
Ignition switch
OFF."
Replace SRS
coil assembly.
Refer to in this
section.
Go to Step 7
Repeat the SRS
Diagnostic System
Check."
Ignition switch
OFF."
Replace driver
air bag
assembly.
Go to Step 7
Go to Step 7
9J140
DTC 25 Driver Deployment Loop Short To Voltage
D09RX002
Action Taken:

The SDM monitors the voltage at Driver Bag Low"
detect shorts to B+ in the air bag assembly circuits.
DTC 25 and also DTC 71
DTC Will Set When:

Ignition 1" is in the normal operating voltage range.
This test is run once each ignition cycle and
Continuous Monitoring". Once these conditions are
met and the voltage at Driver Bag Low" is above a
specified value, Diagnostic Trouble Code (DTC) 25 will
set.


diagnostic chart:
malfunctioning.
Supplemental Restraint System coil assembly yellow
2pin connector at the base of steering column.
Circuit(CKT) IB05YELLOW.

CKT IB06YELLOW/BLACK.
or the driver air bag assembly.
Diagnostic Aids:
to B+ in the driver air bag assembly circuit. Inspect
CKTs IB05YELLOW and IB06YELLOW/BLACK
carefully for cutting or chafing. If the wiring pigtail of the
driver air bag assembly and SRS coil assembly is
damaged, the components must be replaced. A
careful inspection of CKT IB05YELLOW and IB06
YELLOW/BLACK, including the SRS coil assembly and
driver air bag assembly is essential to ensure that the
replacement Sensing and Diagnostic Module (SDM) will
not be damaged.
9J141
9J142
DTC 25 Driver Deployment Loop Short To Ignition

CAUTION: When Diagnostic Trouble Code (DTC) 25
has been set, it is necessary to replace the Sensing
and Diagnostic Module (SDM). Setting DTC 25 will
also cause DTC 71 to set. When a scan tool CLEAR
CODES" command is issued and the malfunction is
Step
1
no longer present, DTC 71 will remain current.

Ensure that the short to voltage condition is
repaired prior to installing a replacement SDM to
avoid damaging the SDM.
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."

884003850.
5. Read driver sense LO.
Is driver sense LO more than 3.5 volts?
Go to Step 3
Go to Chart A.

2. Disconnect SRS coil assembly yellow 2pin connector at the
base of the steering column. Leave passenger air bag
assembly connected.
and appropriate adapter to SRS coil assembly harness
connector.
Go to Step 4
Go to Step 6

2. Disconnect SDM.
3. Disconnect SRS drive / passenger load tool.
terminal 3" to terminal 12" (Ignition 1).
to terminal 12" (Ignition 1).
Go to Step 5
Replace SRS
harness.
Go to Step 7
Go to Chart A.
Replace SRS
harness.
Go to Step 7

and appropriate adapter 5884003850 to driver air bag
assembly harness connector located of top of the steering
column.
Ignition switch
OFF."
Replace SRS
coil assembly.
Go to Step 7

properly mounted.
Replace SDM.
Go to Step 8
Ignition switch
OFF."
Replace driver
air bag
assembly.
Go to Step 7
Go to Chart A.

Step
8
Action
properly mounted.
9J143
Yes
No
Repeat the SRS

Diagnostic System
Check."
Go to Step 8
9J144
DTC 26 Driver Deployment Loop Open
D09RX002
DTC Will Set When:

During Continuous Monitoring" diagnostics, a fixed
amount of current is following in the deployment loop.
This produces proportional voltage drops in the loop.
By monitoring the voltage difference between Driver
Bag High" and Driver Bag Low", the SDM calculates
the combined resistance of the driver air bag assembly,
SRS coil assembly, harness wiring Circuits(CKTs)
IB05YELLOW and IB06YELLOW/BLACK, and
The voltage difference between Driver Bag High"

terminal 3" and Driver Bag Low" terminal 4" is above
or equal to a specified value for 500 milliseconds during
Continuous Monitoring."
Action Taken:

The voltage difference between Driver Bag High"
terminal 3" and Driver Bag Low" terminal 4" is below
a specified value for 500 milliseconds during
Continuous Monitoring."

Number(s) below refer to circled number(s) on the
diagnostic chart:
of the yellow 2pin connector at the base of the
steering column.
yellow 2pin connector located at the base of
steering column.
5. This test determines whether the open is in the
wiring.
Diagnostic Aids:
connection at the driver air bag assembly harness 2
pin connector terminals 1" and 2" at the top of the
steering column, SRS coil assembly harness 2pin
connection terminals 1" and 2", SDM terminals 3"
and 4", or an open in Circuits(CKTs) IB05YELLOW
and IB06YELLOW/BLACK.
9J145
9J146
DTC 26 Driver Deployment Loop Open

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Go to Step 3
Go to Chart A.

884003850.
differential voltage.
Is driver differential voltage more than 4.25 volts?
Go to Step 4
Seat driver air

bag assembly
2pin
connector.
Go to Step 8

2. If OK, reconnect the SRS coil assembly yellow 2pin
connector.
3. Ignition switch ON".
Is DTC 26 current?
Go to Step 5
Ignition switch
OFF."
Go to Step 8

2. Disconnect SRS coil and passenger air bag assembly, yellow
2pin connectors located at the base of steering column and
behind the glove box assembly.
Is DTC 26 current?
Go to Step 6

2. Make sure the SRS coil assembly yellow 2pin connector
located at the base of steering column is seated properly.

2. There has been an open circuit in the driver deployment loop.
Use the high resolution ohmmeter mode of the DVM while
checking CKTs IB05 YEL and IB06 YEL/BLK, and SDM
connector terminal 3" AND 4" to locate the root cause.
Was a fault found?
Replace SRS
harness.
Go to Step 8

2. Disconnect SRS driver / passenger load tool from SRS coil
on steering column.
Is DTC 26 current?
Ignition switch
OFF."
Replace SRS
coil assembly,
refer to in this
section.
Go to Step 8

properly mounted.
Repeat the SRS

Diagnostic System
Check."
Go to Step 7
Go to Chart A.
Ignition switch
OFF."
Replace driver
air bag
assembly.
Go to Step 8
Go to Step 8
9J147
DTC 51 Deployment Event Commanded
D09RX002
Crash Data", and sets a diagnostic trouble code.
The Sensing and Diagnostic Module (SDM) contains a

sensing device which converts vehicle velocity changes
to an electrical signal. The electrical signal generated
is processed by the SDM and then compared to a value
stored in memory. When the generated signal exceeds
the stored value, the SDM will cause current to flow
through the air bag assembly deploying the air bags and
causing Diagnostic Trouble Code (DTC) 51 to set.
DTC Will Set When:

The SDM detects a frontal crash, up to 30 degrees off
the centerline of the vehicle, of sufficient force to
warrant deployment of the air bags.
Action Taken:
SDM turns ON" the AIR BAG" warning lamp records

diagnostic chart:
2. If air bag assembly (s) has not deployed, DTC 51 may
have falsely set.
3. If DTC 51 has set with no signs of frontal impact, the
diagnostic trouble code has falsely set.
9J148
DTC 51 Deployment Event Commanded

FASTENERS MUST BE CAREFULLY TORQUED
AND THE ARROW MUST BE POINTING TOWARD
Step
1
THE FRONT OF THE VEHICLE TO ENSURE PROPER

OPERATION OF THE SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). THE SDM COULD BE ACTIVATED
WHEN POWERED WHILE NOT RIGIDLY ATTACHED
TO THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY.
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Ignition switch OFF."

Have air bag assemblies deployed?
Inspect front of vehicle and undercarriage for signs of impact.

Were signs of impact found?
Replace
components
and perform
inspections as
directed in
repairs and
inspections
required after
an accident" in
this section.
Clear
diagnostic
trouble codes.
Repeat the
SRS
Diagnostic
System Check."
Go to Step 3
Replace
components
and perform
inspections as
directed in
repairs and
inspections
required after
an accident" in
this section.
Clear
diagnostic
trouble codes.
Repeat the
SRS
Diagnostic
System Check."
Ignition switch
OFF."
Replace SDM.
Reconnect all
SRS system
components,
ensure all
components
are properly
mounted.
Repeat the
SRS
Diagnostic
System Check."
9J149
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy

Reserves Out Of Range
D09RX002
The Sensing and Diagnostic Module (SDM) contains a
sensing drive which converts vehicle velocity changes
to an electrical signal. The electrical signal generated
is processed by the SDM and then compared to a value
stored in memory. When the generated signal exceeds
the stored value, the SDM will cause current to flow
through the air bag assembly deploying the air bags.
Diagnostic Trouble Code (DTC) 53 is set accompanying
with DTC 51 when a deployment occurs while an air bag
assembly circuit fault is present that could possible
result in a no deployment situation in one or both air bag
assemblies.
DTC Will Set When:

The SDM detects a frontal crash, up to 30 degrees off
the centerline of the vehicle, of sufficient force to

warrant deployment of the air bags and an inflator circuit
fault is present.
Action Taken:
SDM turns ON" the AIR BAG" warning lamp records
Crash Data", and sets a diagnostic trouble code.

The SDM is replaced. If DTC 53 is set, one or more
DTCs will be set in addition to DTC 53. Malfunction(s)
setting DTC(s) (other than DTC 71) must be repaired so
that DTC(s) will not be set when a new SDM is
installed.
9J150

diagnostic chart:
2. If air bag assembly has not deployed, Diagnostic
Trouble Code (DTC) 53 may have falsely set.
3. If DTC 53 has set with no signs of frontal impact, the
diagnostic trouble code has falsely set.
9J151
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of
Range
FASTENERS MUST BE CAREFULLY TORQUED AND
THE ARROW MUST BE POINTING TOWARD THE
Step
1
FRONT OF THE VEHICLE TO ENSURE PROPER

INJURY.
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Ignition switch OFF."

Have air bag assemblies deployed?
Inspect front of vehicle and undercarriage for signs of impact.

Were signs of impact found?
Replace
components
and perform
inspections as
directed in
repairs and
inspections
required after
an accident" in
this section.
Clear
diagnostic
trouble codes.
Repeat the
SRS
Diagnostic
System Check."
Go to Step 3
Replace
components
and perform
inspections as
directed in
repairs and
inspections
required after
an accident" in
this section.
Clear
diagnostic
trouble codes.
Repeat the
SRS
Diagnostic
System Check."
Ignition switch
OFF."
Replace SDM.
Reconnect all
SRS system
components,
ensure all
components
are properly
mounted.
Repeat the
SRS
Diagnostic
System Check."
9J152
DTC 61 Warning Lamp Circuit Failure
D09RX002
When the ignition switch is turned ON", battery voltage
is applied to the AIR BAG" warning lamp and to the
ignition 1" input terminal 12". The Sensing and
Diagnostic Module (SDM) responds by flashing the AIR
BAG" warning lamp seven times. The SDM monitors
the lamp driver output by comparing the output state at
Supplemental Restraint System (SRS) warning lamp"
terminal 7" to the microprocessor commanded state.
When ignition 1" is in the specified value, and the
output state Does not match the commanded state of
the lamp driver for 500 milliseconds, DTC 61 is set.
DTC Will Set When:

Ignition 1" voltage is in the specified value and the
output state at the SRS warning lamp" terminal does
not match the commanded state of the lamp driver for
500 milliseconds. This test is run every 100
milliseconds during Continuous Monitoring" tests and

once per each ignition cycle at the beginning.
Action Taken:
SDM attempts to turn ON" the AIR BAG" warning lamp
and sets a diagnostic trouble code.

Diagnostic Aids:
Refer to Charts B and C to diagnose warning lamp
circuit malfunctions.
9J153
DTC 61 Warning Lamp Circuit Failure

Step
1
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
1. Malfunctions within the AIR BAG" warning lamp circuitry will

set this diagnostic trouble code.
2. These malfunctions are addressed in the SRS Diagnostic
System Check" via Chart B and Chart C.
3. Failure to properly perform the SRS Diagnostic System
Check" may result in misdiagnosis.
5. Clear SRS diagnostic trouble codes.
Is DTC 61 SET?
Ignition switch
OFF."
Go to Chart A.
Repeat the SRS

Diagnostic System
Check."
9J154
DTC 71 Internal SDM Fault
D09RX002
13) DTC 53
Diagnostic Trouble Code (DTC) 71 is an indication of a

potential internal Sensing and Diagnostic Module
(SDM) malfunction and will set if any of the following
conditions are detected:
1) Deployment or microprocessor energy reserve
failure.
2) Electronically Erasable Programmable Read Only
Memory failure. (EEPROM).
3) Random Only Memory failure. (ROM).
4) Random Access Memory failure. (RAM).
5) Calibration check sum failure.
6) Deployment switch faults.
7) Accelerometer fault.
8) Arming sensor fault.
9) Diagnostic current faults.
10) DTC 19
11) DTC 25
12) DTC 51
DTC Will Set When:

Any of the above indicated malfunctions are detected by
the SDM. The malfunctions described above are
tested mainly during Continuous Monitoring" and some
ones run each ignition cycle.
Action Taken:

A scan tool Clear Codes" commanded is received by
the SDM. Some of the indicated malfunctions will only
allow the AIR BAG" warning lamp to go out.
But when DTC 19, 25, 51, 53 are also set, SDM is
Replaced.
9J155
DTC 71 Internal SDM Fault

FASTENERS MUST BE CAREFULLY TORQUED
AND THE ARROW MUST BE POINTING TOWARD
THE FRONT OF THE VEHICLE TO ENSURE PROPER
Step
1
INJURY.
CAUTION: When Diagnostic Trouble Code (DTC) 19
or 25 or 51 or 53 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.
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check."
Note SRS Diagnostic System Check."

Is DTC 19 or 25 or 51 or 53 also set (current or history)? (Refer to
notice above).
Go to DTC 19 if
DTC 19 is set.
Go to DTC 25 if
DTC 25 is set.
Go to DTC 51 if
DTC 51 is set.
Go to DTC 53 if
DTC 53 is set.
Ignition switch
OFF."
Replace SDM.
Repeat the
SRS
Diagnostic
System Check."
SECTION
CRUISE CONTROL SYSTEM
10A1
CONTROL SYSTEMS
CONTENTS
Diagnosis .......................................................
Brake Switch .................................................
Adjustment..................................................
Clutch Switch ................................................
Adjustment..................................................
Cruise Control Unit........................................
Removal .....................................................
Installation ..................................................
10A - 1
10A - 2
10A - 2
10A - 3
10A - 3
10A - 3
10A - 3
10A - 3
10A - 3
10A - 4
10A - 4
10A - 4
Service Precaution
Cruise Actuator .............................................

Actuator Cable Diagram .............................
Removal......................................................
Installation...................................................
Adjustment..................................................
Mode Switch..................................................
Cruise Control Main Switch ...........................
Removal......................................................
Installation...................................................
Cruise Control Switch (Combination Switch).
10A - 5
10A - 5
10A - 5
10A - 5
10A - 6
10A - 6
10A - 6
10A - 6
10A - 6
10A - 6
10A - 7
10A - 7

parts and systems.
10A2
General Description
The cruise control keeps the vehicle running at a fixed
speed until a signal canceling this fixed speed is
received.
When the main switch AUTO CRUISE" is turned on
with the vehicle in the running mode, the battery voltage
is applied to the control unit. When a signal from the
control switch is input to the control unit while the
vehicle is in this state, the cruise control actuator is
activated to operate the system. Also, while the system
is operating, the AUTO CRUISE" indicator light in the
meter assembly lights up.
1 . SET/COAST Switch Function

1. Set Function: When the SET/COAST switch is
pressed and released with the main switch on, the
speed at which the vehicle is running at that
moment is stored in the memory, and the vehicle
automatically runs at the speed stored.
2. Coast-Down Function: When the SET/COAST
switch is kept on while the vehicle is running, the
vehicle decelerates during that time. The speed at
which vehicle is running when the control switch is
turned off is stored in the memory, and the vehicle
automatically returns to the stored speed.
3. Tap-Down Function: When the SET/COAST switch
is turned on and off instantaneously while the
vehicle is running, the vehicle decelerates a mile for
each on/off operation. The vehicle speed at which
the vehicle was running when the SET/COAST was
turned off last is stored in the memory, and the
vehicle automatically returns to this stored speed.
2 . RESUME/ACCEL Switch Function

1. Resume Function: When the RESUME, ACCEL
switch is turned on/off after the system is
temporarily deactivated by pressing the brake or
clutch pedal while the vehicle is running, the vehicle
resumes, the speed stored before the system was
released.
2. Accelerate Function: When the RESUME/ACCEL
switch is kept on after the system is released
completely, the vehicle accelerates its speed during
that time. The vehicle speed at which the vehicle
was running when the switch was turned off is
stored in the memory, and the vehicle automatically
returns to this speed.
3. Tap-Up Function: When the RESUME/ACCEL
switch is turned on and off instantaneously while the
vehicle is running, the vehicle accelerates a mile for
each on/off operation. The vehicle speed at which
the vehicle was running when the switch was turned
off last is stored in the memory, and the vehicle
automatically returns to this stored speed.
3 . CANCEL Function
1. Temporary Cancellation:
When the brake pedal is pressed.
When the clutch pedal is pressed. (M/T)
When the select lever is shifted to any position
other than D", 3", 2" or L". (A/T)
When the vehicle speed has decreased about 20
km/h or more than the stored speed.
2. Complete Cancellation:
When the starter switch or the main switch is
turned off.
When the failsafe function is activated.
Diagnosis
Refer to the Cruise Control System Diagnosis in Wiring
System section.
10A3
Brake Switch
Refer to the Stoplight Switch Replacement in Brake
section.
Adjustment
1. Check that the brake pedal (3) is fully returned by
pedal return spring.
2. Disconnect the switch connector.
3. Loosen the lock nut (2).
4. Rotate the brake switch (1) by hand until push rod
disappears from brake switch tip (4).
5. Return the brake switch by a half turn.
6. Tighten the lock nut.
7. Connect the switch connector.
310RS028
Clutch Switch
Refer to the Clutch Control in Clutch section.
Adjustment
1. Turn the clutch switch (1) until the switch plunger is
fully retracted against the clutch pedal arm.
2. Adjust clutch switch by backing it out half a turn and
measure the clearance (4) between the clutch pedal
arm (3) and the clutch switch.
3. Lock the lock nut(2).
4. Connect clutch switch connector.
Clutch Switch (bolt) and Clutch Pedal Clearance
0.5 1.5 mm (0.020 0.059 in)
203RS016-1
10A4
Cruise Control Unit

Removal
2. Remove the rear console box assembly.
Remove four screws.
3. Remove the cover (3).
Remove four nuts.
4. Remove the cruise control unit (1).
825RX017
Installation
10A5
Cruise Actuator
Actuator Cable Diagram
825RW093
Legend
(1) Cruise Actuator Assembly
(2) Cruise Control Cable
(3) Accelerator Cable
(4) Throttle Link (Cruise Control Side)
EndOFCallout
Removal
2. Remove the cruise actuator assembly (4).
Remove the cable end (1) from the throttle link
(cruise control side).
Loosen two fixing nuts (2).
Remove three actuator assembly fixing screws.
825RW049
Installation
1. Take care not to bend the cable excessively.
10A6
Adjustment
After installing the cruise actuator, the following steps
must be carried out for cruise control cable adjustment.
1. Install the cruise control cable end (3) to the throttle
link (4).
2. Put the screw portion of the cable in the bracket (5).
3. Put the nut (1) to the bracket and then tighten the
nut (2).
If the distance between the throttle link (4) and
the throttle link lever (6) is out of the specified
range, loosen the nut (2) to adjust it.
035RW140
Mode Switch
Refer to Mode Switch in Automatic Transmission
section.
Cruise Control Main Switch

Removal
Structure section.
3. Remove the cruise control main switch (2).
To remove the switch, push the lock from the back
side of the instrument panel cluster assembly.
825RX035
Installation
Cruise Control Switch (Combination Switch)

Refer to Lighting Switch (Combination Switch) in
Lighting System section.
10A7
HOME
SECTION
TABLE OF CONTENTS
Click
0A
0B
WORKSHOP MANUAL
1A
2A
FRONTERA
(UE)
3C
3D
3E
4A1
4A2
4B
4C
4D
FOREWORD
This manual includes special notes, important points, service data,
precautions, etc. That are needed for the maintenance, adjustments,
service, removal and installation of vehicle components.
All information, illustrations and specifications contained in this manual
are based on the latest product information available at the time of
publication.
All rights are reserved to make changes at any time without notice.
Arrangement of the material is shown in the table of contents on the
right-hand side of this page. A black spot on the first page of each
section can be seen on the edge of the book below each section title.
These point to a more detailed table of contents preceding each
section.
5A
5B
5C
5D
HEC
6A
6B
6C
6D1
6D2
6D3
6E1
6F
6G
6H
6J
7A
7A1
7B
7C
This manual applies to 2000 models.

8A
8B
8C
8D
8E
8F
8G
8H
8I
8J
9A
9J
9J1
10A
GENERAL INFORMATION
General Information
Maintenance and Lubrication
CONDITIONING
HVAC System
STEERING
Power-Assisted System
SUSPENSION
Front Suspension
Rear Suspension
Wheel and Tire System
DRIVELINE/AXLE
Differential (Front)
Differential (Rear)
Driveline Control System
Drive Shaft System
Transfer Case
BRAKE
Brake Control System
Anti-Lock Brake System
Power-Assisted Brake System
Parking Brake System
6VD1
ENGINE
6A
Engine Mechanical
6B
Engine Cooling
6C
Engine Fuel
6D1
Engine Electrical
6D2
Ignition System
6D3
Starting and Charging System
6E2
Driveability and Emissions
6F
Engine Exhaust
6G
Engine Lubrication
6H
Engine Speed Control System
6J
Induction
TRANSMISSION
Transmission Control System
Manual Transmission
Clutch
Lighting System
Wiper/Washer System
Entertainment
Wiring System
Meter and Gauge
Body Structure
Seats
Security and Locks
Sun Roof/Convertible Top
Exterior/Interior Trim
RESTRAINTS
Seat Belt System
Supplemental Restraint System (Air Bag System)
Restraint Control System
CONTROL SYSTEM
Cruise Control System
SECTION
GENERAL INFORMATION
0A1
GENERAL INFORMATION
CONTENTS
General Information ....................................... 0A - 1
Meintenance and Lubrication......................... 0B - 1
GENERAL INFORMATION
CONTENTS
General Repair Instruction.............................
Illustration Arrows ..........................................
Identification...................................................
Lifting Instructions..........................................
0A - 1
0A - 2
0A - 3
0A - 5
General Repair Instruction

1. If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, block" front or rear
wheels, set jack against the recommended lifting
points (see Lifting Instructions" in this section),
raise vehicle and support with chassis stands and
then perform the service operations.
2. Before performing service operations, disconnect
ground cable from the battery to reduce the chance
of cable damage and burning due to short circuiting.
3. Use a cover on body, seats and floor to protect them
against damage and contamination.
4. Brake fluid and antifreeze solution must be
handled with reasonable care, as they can cause
paint damage.
5. The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6. Use genuine Isuzu parts.
7. Used cotter pins, plastic clips, gaskets, Orings, oil
seals, lock washers and selflocking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in
groups. Keeping fixing bolts and nuts separate is
very important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly.
Also clean oil ports, etc. using compressed air, and
make certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
Standard Bolts Torque Specifications............ 0A - 8

Abbreviations Charts ..................................... 0A - 9
Service Parts Identification Plate ................... 0A - 11
oil or grease before installation.

11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.
13. When removing or replacing parts that require
refrigerant to be discharged from the air
conditioning system, be sure to use the Vehicle
Refrigerant Recovery and Recycling Equipment
(VRRRE) to recover and recycle Refrigerant134a.
14. When a service operation is completed, make a final
check to be sure the service has been done
properly and the problem has been corrected.
15. SUPPLEMENTAL RESTRAINT SYSTEM
The vehicle is equipped with a Supplemental
Restraint System (SRS) Air Bags. This system is
not to be serviced without consulting the
appropriate service information. Consult Section 9J
SRS System" if work is to be done on the front of
the vehicle such as bumper, sheet metal, seats,
wiring, steering wheel or column. Also review SRS
system information if any arc welding is to be done
on the vehicle. The SRS system equipped vehicle
can be identified by:
1. AIR BAG" warning light on the instrument
cluster.
2. A Code J" for fifth digit of Vehicle Identification
Number.
0A2
GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations.
Arrow Type
Arrow Type
Application
Application
Front of vehicle
Ambient/Clean air flow

Cool air flow
Up Side
Gas other than

ambient air
Hot air flow
Task Related
Ambient air mixed with

another gas
Can indicate
temperature change
Motion or direction
View Detail
View Angle
Lubrication point oil or

fluid
Lubrication point grease

Dimension (1:2)
Lubrication point jelly

Sectioning (1:3)
GENERAL INFORMATION
0A3
Identification
Vehicle Identification Number (VIN)
This is the legal identification of the vehicle. it is located
on the left bottom of the windshield. It can be easily
seen through the windshield from outside the vehicle.
F00RX018
905RY00022
0A4
GENERAL INFORMATION
Engine Serial Number
Transmission Serial Number
6VD1 Engine
left rear lower area of the cylinder block above the
starter.
Manual : Stamped on the left side of the transmission

intermediate plate.
220RS025
F06RW001
X22SE Engine
rear end raised area of the cylinder block left side.
Automatic : Stamped on the identification plate, located

on the left side of the transmission above the mode
switch.
240RW019
035RW022
GENERAL INFORMATION
0A5
Lifting Instructions
Lifting Points and Supportable Point Locations
4 Door Model
C00RX002
0A6
GENERAL INFORMATION
2 Door Model
C00RX001
Lifting Point: Front

When using a floor jack, lift on the Convex portion of
the skid plate.
545RS001
Supportable Point: Front

sidemember, behind the front wheel.
501RS003
GENERAL INFORMATION
Lifting Point: Rear
Position the floor jack at the center of the rear axle
case when lifting the vehicle.
420RS002

sidemember, just behind the trailing link bracket.
501RW002
Legend
(1) Trailing Link Bracket
EndOFCallout
0A7

Position the chassis stands at the bottom of the rear
axle case.
420RS001
0A8
GENERAL INFORMATION
Standard Bolts Torque Specifications

The torque values given in the following table should be
applied where a particular torque is not specified.
Strength Class
4.8
8.8
Refined
9.8
Non-Refined
Bolt
Identification
Bolt Diameter
Pitch (mm)
M 6X1.0
M 8X1.25
M 10X1.25
* M10X1.5
M12X1.25
* M12X1.75
M14X1.5
* M14X2.0
M16X1.5
* M16X2.0
M18X1.5
M20X1.5
M22X1.5
M24X2.0
4 8 Nm (3 6 lb ft)
8 18 Nm (6 13 lb ft)
21 34 Nm (15 25 lb ft)
20 33 Nm (14 25 lb ft)
49 74 Nm (36 54 lb ft)
45 69 Nm (33 51 lb ft)
77 115 Nm (56 85 lb ft)
72 107 Nm (53 79 lb ft)
104 157 Nm (77 116 lb ft)
100 149 Nm (74 110 lb ft)
151 226 Nm (111 166 lb ft)
206 310 Nm (152 229 lb ft)
251 414 Nm (185 305 lb ft)
359 539 Nm (265 398 lb ft)
The asterisk * indicates that the bolts are used for

femalethreaded parts that are made of soft materials
such as casting, etc.
5 10 Nm (4 7 lb ft)
12 23 Nm (9 17 lb ft)
28 46 Nm (20 34 lb ft)
28 45 Nm (20 33 lb ft)
61 91 Nm (45 67 lb ft)
57 84 Nm (42 62 lb ft)
93 139 Nm (69 103 lb ft)
88 131 Nm (65 97 lb ft)
135 204 Nm (100 150 lb ft)
130 194 Nm (95 143 lb ft)
195 293 Nm (144 216 lb ft)
270 405 Nm (199 299 lb ft)
363 544 Nm (268 401 lb ft)
431 711 Nm (318 524 lb ft)
17 30 Nm (12 22 lb ft)
37 63 Nm (27 46 lb ft)
36 60 Nm (27 44 lb ft)
76 114 Nm (56 84 lb ft)
72 107 Nm (53 79 lb ft)
114 171 Nm (84 126 lb ft)
107 160 Nm (79 118 lb ft)
160 240 Nm (118 177 lb ft)
153 230 Nm (113 169 lb ft)
230 345 Nm (169 255 lb ft)
317 476 Nm (234 351 lb ft)
425 637 Nm (313 469 lb ft)
554 831 Nm (409 613 lb ft)
GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A Ampere(s)
ABS Antilock Brake System
AC Alternating Current
ACCEL Accelerator
ACC Accessory
ACL Air Cleaner
Adj Adjust
A/F Air Fuel Ratio
AIR Secondary Air Injection System
Alt Altitude
AMP Ampere(s)
ANT Antenna
ASM Assembly
A/T Automatic Transmission/Transaxle
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
Auth Authority
Auto Automatic
BARO Barometric Pressure
Bat Battery
B+ Battery Positive Voltage
Bbl Barrel
BHP Brake Horsepower
BPT Backpressure Transducer
BTDC Before Top Dead Center
C Degrees Celsius
CAC Charge Air Cooler
Calif California
cc Cubic Centimeter
CID Cubic Inch Displacement
CKP Crankshaft Position
CL Closed Loop
CLCC Closed Loop Carburetor Control
CMP Camshaft Position
CO Carbon Monoxide
Coax Coaxial
Conn Connector
Conv Converter
Crank Crankshaft
Cu. In. Cubic Inch
CV Constant Velocity
Cyl Cylinder(s)
DI Distributor Ignition
Diff Differential
Dist Distributor
DLC Data Link Connector
DOHC Double Overhead Camshaft
DTC Diagnostic Trouble Code
DTM Diagnostic Test Mode
DTT Diagnostic Test Terminal
DVM Digital Voltmeter (10 meg.)
DVOM Digital Volt Ohmmeter
EBCM Electronic Brake Control Module
ECM Engine Control Module
ECT Engine Coolant Temperature
0A9
EEPROM Electronically Erasable Programmable

Read Only Memory
EGR Exhaust Gas Recirculation
EI Electronic Ignition
ETR Electronically Tuned Receiver
EVAP Evaporation Emission
Exh Exhaust
F Degrees Fahrenheit
Fed Federal (All States Except Calif.)
FF Front Drive Front Engine
FL Fusible Link
FLW Fusible Link Wire
FP Fuel Pump
FRT Front
ft Foot
FWD Front Wheel Drive
4WD Four Wheel Drive
4 x 4 Four Wheel Drive
4 A/T Four Speed Automatic Transmission/Transaxle
Gal Gallon
GEN Generator
GND Ground
Gov Governor
g Gram
Harn Harness
HC Hydrocarbons
HD Heavy Duty
Hg Hydrargyrum (Mercury)
HiAlt High Altitude
HO2S Heated Oxygen Sensor
HVAC HeaterVentAirConditioning
IAC Idle Air Control
IAT Intake Air Temperature
IC Integrated Circuit / Ignition Control
ID Identification / Inside Diameter
IGN Ignition
INJ Injection
IP Instrument Panel
IPC Instrument Panel Cluster
Int Intake
ISC Idle Speed Control
J/B Junction Block
kg Kilograms
km Kilometers
km/h Kilometer per Hour
kpa Kilopascals
kV Kilovolts (thousands of volts)
kW Kilowatts
KS Knock Sensor
L Liter
lb ft Foot Pounds
lb in Inch Pounds
LF Left Front
LH Left Hand
LR Left Rear
LS Left Side
LWB Long Wheel Base
L4 InLine Four Cylinder Engine
MAF Mass Air Flow
MAN Manual
0A10
GENERAL INFORMATION
MAP Manifold Absolute Pressure

Max Maximum
MC Mixture Control
MFI Multiport Fuel Injection
MIL Malfunction Indicator Lamp
Min Minimum
mm Millimeter
MPG Miles Per Gallon
MPH Miles Per Hour
M/T Manual Transmission/Transaxle
MV Millivolt
N Newtons
NA Natural Aspirated
NC Normally Closed
NM Newton Meters
NO Normally Open
NOX Nitrogen, Oxides of
OBD On-Board Diagnostic
OD Outside Diameter
O/D Over Drive
OHC Overhead Camshaft
OL Open Loop
O2 Oxygen
O2S Oxygen Sensor
PAIR Pulsed Secondary Air Injection System
P/B Power Brakes
PCM Powertrain Control Module
PCV Positive Crankcase Ventilation
PRESS Pressure
PROM Programmable Read Only Memory
PNP Park/Neutral Position
P/S Power Steering
PSI Pounds per Square Inch
PSP Power Steering Pressure
Pt. Pint
Pri Primary
PWM Pulse Width Modulate
Qt. Quart
REF Reference
RF Right Front
RFI Radio Frequency Interference
RH Right Hand
RPM Revolutions Per Minute
RPM Sensor Engine Speed Sensor
RPO Regular Production Option
RR Right Rear
RS Right Side
RTV Room Temperature Vulcanizing
RWAL Rear Wheel Antilock Brake
RWD Rear Wheel Drive
SAE Society of Automotive Engineers
Sec Secondary
SFI Sequential Multiport Fuel Injection
SI System International
SIR Supplemental Inflatable Restraint System
SOHC Single Overhead Camshaft
Sol Solenoid
SPEC Specification
Speedo Speedometer
SRS Supplemental Restraint System
ST Start / Scan Tool

Sw Switch
SWB Short Wheel Base
SYN Synchronize
Tach Tachometer
TB Throttle Body
TBI Throttle Body Fuel Injection
TCC Torque Converter Clutch
TCM Transmission Control Module
TDC Top Dead Center
Term Terminal
TEMP Temperature
TOD Torque On Demand
TP Throttle Position
TRANS Transmission/Transaxle
TURBO Turbocharger
TVRS Television & Radio Suppression
TVV Thermal Vacuum Valve
TWC Three Way Catalytic Converter
3 A/T Three Speed Automatic Transmission/
Transaxle
2WD Two Wheel Drive
4 x 2 Two Wheel Drive
Ujoint Universal Joint
V Volt(s)
VAC Vacuum
VIN Vehicle Identification Number
VRRRE Vehicle Refrigerant Recovery and Recycling
Equipment
Vref ECM Reference Voltage
VSS Vehicle Speed Sensor
VSV Vacuum Switch Valve
V6 Six Cylinder V" Engine
V8 Eight Cylinder "V" Engine
W Watt(s)
w/ With
w/b Wheel Base
w/o Without
WOT Wide Open Throttle
GENERAL INFORMATION
Service Parts Identification Plate

The Vehicle Information Plate (Service Parts ID plate) is
provided on all vehicle models.
It is located on the center dash wall inside the engine
compartment. The plate lists the VIN (Vehicle
Identification Number), paint information and all
production options and special equipment on the
vehicle when it was shipped from the factory.
905RY00010
0A11
SECTION
0B1
GENERAL INFORMATION
CONTENTS
Maintenance Schedule List............................
Service and Maintenance ..............................
Recommended Fluids and Lubricants ...........
Lubricant Viscosity Chart ...............................
0B - 1
0B - 2
0B - 9
0B - 10
Maintenance Schedule List

Normal Vehicle Use
The maintenance instructions in this Maintenance
Schedule are based on the assumption that the vehicle
will be used as designed:
to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of
the glove compartment door;
to be driven on reasonable road surfaces within legal
operating limits;
to be driven on a daily basis, as a general rule, for at
least several miles/kilometers;
to be driven on unleaded fuel
Unusual or severe operating conditions will require more
frequent vehicle maintenance, as specified in the
following sections.
Recommended Liquid Gasket .................... 0B - 12

Recommended Thread Locking Agents ..... 0B - 13
Maintenance Service Data............................. 0B - 14
0B2
Service and Maintenance
0B3
0B4
0B5
0B6
0B7
0B8
0B9
Recommended Fluids and Lubricants

USAGE
Engine
FLUID/LUBRICANT
API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil
chart on the following page for proper viscosity)
Engine coolant
Mixture of water and good quality ethylene glycol base

type antifreeze.
Brake system
DOT-3 hydraulic brake fluid.
Power steering system
MUA Type Manual transmission & Transfer case
Engine oil
(See oil chart on following page for proper viscosity)
Rear axle and front axle
GL-5 gear lubricant (Standard differential)

GL-5 Limited slip differential gear lubricant together with
limited slip differential lubricant additive (Part No.
8-01052-358-0) or equivalent (If equipped with optional
limited slip differential) (See oil chart in this section for
proper viscosity)
Clutch system
a. Pivot points
Chassis grease
b. Clutch fork joint
Chassis grease
c. Master cylinder
DOT-3 hydraulic brake fluid
Hood latch assembly

a. Pivots and spring anchor
Engine oil
b. Release pawl
Chassis grease
Hood and door hinges
Engine oil
Chassis lubrication
Chassis grease
Parking brake cables
Chassis grease
Front wheel bearings
Multipurpose grease
GL-5 gear lubricant (SAE 75W-90)
Body door hinge pins and linkage, fuel door hinge, rear
compartment lid hinges
Engine oil
Windshield washer solvent
Washer fluid
Key lock cylinder
Synthetic light weight engine oil (SAE 5W-30)
Accelerator linkage
Chassis grease
0B10
Lubricant Viscosity Chart

Lubricants should be carefully selected according to the
lubrication chart. It is also important to select viscosity

of lubricants according to the ambient temperature by
referring to the following table.
Oil Viscosity Chart for Gasoline Engine
905RT011
0B11
Oil Viscosity Chart for Manual Transmission and Transfer Case
B00RW002
Oil Viscosity Chart for Front Axle
B00RW003
0B12
Oil Viscosty Chart for Rear Axle
B00RW004
Recommended Liquid Gasket

Type
Brand Name
Manufacturer
Remarks
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
For Engine Repairs
RTV*
Silicon Base
Three Bond 1207B

Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281
Water Base
Three Bond 1141E
Three Bond
For Engine Repairs
Solvent
Three Bond 1104

Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 17430
Loctite
Loctite
Loctite
All
* RTV: Room Temperature Vulcanizer

NOTE:
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacturer's instructions at all times.
For Axle Case

Repairs T/M
Repairs T/M
3. Be absolutely sure to remove all lubricants and

moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 between two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
Recommended Thread Locking

Agents
LOCTITE Type
LOCTITE Color
LOCTITE 242
Blue
LOCTITE 262
Red
LOCTITE 271
Red
Application Steps
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
F00RW014

After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
NOTE: When the application procedures are specified
in this manual, follow them.
0B13
0B14
Maintenance Service Data

Service Data and Specifications
ENGINE
Valve clearance (cold): only V6-3.2L ENG
Intake 0.280.05 mm (0.0110.002 in)

Exhaust 0.30.05 mm (0.0120.002 in)
Spark plug type
K16PR-P11/PK16PR11/RC10PYP4
Spark plug gap
1.05 mm (0.04 in)
CLUTCH
5-15 mm (0.20-0.59 in)
BRAKE
Brake pedal free play
6-10 mm (0.24-0.39 in)
Parking brake travel
6-7 notches
Toe-in (Front)
02 mm (00.08 in)
Toe-in (Rear)
05 mm (00.2 in)
Camber (Front)
030'
Camber (Rear)
01
Caster (Front)
2 30'45'
ToeAxis (Rear)
PROPELLER SHAFT
Flange torque
63 Nm (46 lbft)
WHEEL AND TIRES
Size
WHEEL ALIGNMENT
235/75R15
Wheel nut torque
118 Nm (87 lbft)
Tire inflation pressure (Front)
200 kpa (29 psi)
180 kpa
* Tire inflation pressure (Rear)
200 kpa (29 psi)
180 kpa
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
Items
Metric Measure
U.S. Measure
80 L
21.1 Gal.
4.7 L
5.0 Qt
4.0 L
4.2 Qt
4.5 L
4.8 Qt
4.2 L
4.4 Qt
M/T (V63.2L ENG)
11.0 L
11.6 Qt
M/T (L42.2L ENG)
6.9 L
7.3 Qt
A/T
11.1 L
11.7 Qt
Manual (V63.2L ENG)
2.95 L
3.1 Qt
Manual (L42.2L ENG)
2.13 L
2.25 Qt
Automatic
8.6 L
9.1 Qt
1.45 L
1.5 Qt
Rear
1.77 L
1.87 Qt
Front
1.25 L
1.33 Qt
0.12 L
0.13 Qt
Power steering
1.0 L
1.1 Qt
Air conditioning (R-134a)
0.6 L
1.32 Qt
Fuel tank
* Crankcase (V63.2L ENGINE)
* Crankcase (L42.2L ENGINE)
Coolant
Transmission
Transfer
Axle
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
SECTION
1A1

CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution. . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation System. . . . . . . . . . .
Heater and Ventilation Associated Parts . .
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit. . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core and / or Mode Door . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Link Unit . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Control Link Unit. . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Link Unit and / or Mode door . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle and
Ventilation Duct . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Control Lever Assembly, Control Cable
and Associated Parts . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A3
1A3
1A3
1A4
1A5
1A8
1A9
1A13
1A15
1A15
1A15
1A16
1A16
1A16
1A16
1A17
1A17
1A18
1A18
1A18
1A19
1A19
1A19
1A19
1A20
1A20
1A20
1A21
1A21
1A21
1A21
1A21
1A22
1A23
1A23
1A23
1A23
1A24
1A24
1A24
1A25
1A25
1A25
1A26
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Illumination Bulb . . . . . . . . . . .
Associated Parts . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor and Associated Parts . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Procedure . . . . . . . . . . . . .
Leak Check. . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Assembly. . . . . . . . . . . . . . . . . .
Parts (6VD1) . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts (X22SE) . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
New Compressor Installation . . . . . . . . . . .
Condenser Assembly. . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch. . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch and Associated Parts. . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly. . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
1A27
1A28
1A28
1A28
1A28
1A28
1A28
1A28
1A28
1A29
1A29
1A36
1A38
1A46
1A47
1A48
1A54
1A54
1A54
1A55
1A56
1A56
1A57
1A57
1A58
1A58
1A58
1A58
1A59
1A59
1A59
1A59
1A60
1A60
1A60
1A60
1A61
1A61
1A61
1A61
1A62
1A62
1A62
1A63
1A2
Electronic Thermostat, Evaporator Core

and/or Expansion Valve . . . . . . . . . . . . . . . .
1A64
1A64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A64
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
1A65
Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . .
1A66
1A66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A66
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
1A67
Main Data And Specifications. . . . . . . . . . .
1A68
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . .
1A71
Service Precaution . . . . . . . . . . . . . . . . . . .
1A71
1A71
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
1A72
Magnetic Clutch Assembly (DKV-14G Type).
1A73
Parts Location View . . . . . . . . . . . . . . . . . .
1A73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A73
Inspection and Repair. . . . . . . . . . . . . . . . .
1A75
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
1A75
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . .
1A77
Oil Specification . . . . . . . . . . . . . . . . . . . . .
1A77
Handling of Oil . . . . . . . . . . . . . . . . . . . . . .
1A77
Compressor Oil Check . . . . . . . . . . . . . . . .
1A77
Checking and Adjusting Oil Quantity for
Used Compressor . . . . . . . . . . . . . . . . . . .
1A77
Checking and Adjusting for Compressor
Replacement. . . . . . . . . . . . . . . . . . . . . . .
1A78
Contamination of Compressor Oil . . . . . . .
1A78
Oil Return Operation. . . . . . . . . . . . . . . . . .
1A78
Replacement of Component Parts . . . . . . .
1A78
1A79
Special Tools . . . . . . . . . . . . . . . . . . . . . . .
1A81
Automatic Air Conditioning System . . . . . . . .
1A82
1A82
Automatic Air Conditioner Parts Configuration 1A82
1A83
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . .
1A84
Functions and Features . . . . . . . . . . . . . . .
1A90
Automatic Air Conditioner Block Diagram. .
1A91
Control Panel Layout . . . . . . . . . . . . . . . . .
1A92
Air Control Functions . . . . . . . . . . . . . . . . .
1A93
Operation and Functions of Control Panel
Switches . . . . . . . . . . . . . . . . . . . . . . . . . .
1A94
Overview of Construction, Movement and
Control of Major Parts of Automatic Air
Conditioner System . . . . . . . . . . . . . . . . .
1A97
Automatic Air Conditioner . . . . . . . . . . . . . 1A100
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 1A104
Troubleshooting, Its Overview and

Procedures . . . . . . . . . . . . . . . . . . . . . . . .
Auto Air Conditioner Control Unit Power
Supply Diagnosis . . . . . . . . . . . . . . . . . . .
Performance and Movement checklist
for Automatic Air Conditioner Related
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting With Self-Diagnosis
Function . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection By Failed Location . . . . . . . . . . . .
Inspection of the Sensors . . . . . . . . . . . . . .
Inspection of the Intake Actuator System .
Inspection of the Mix Actuator System . . . .
Inspection of the Mode Actuator System . .
....................................
Inspection of the Fan Motor System . . . . . .
Inspection of the Magnetic Clutch System .
Condenser Fan Diagnosis . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . .
Power Transistor. . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Heater/Air Conditioner
Control Unit . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
In Car Sensor . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Sensor . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Thermostat. . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Actuator . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Actuator . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
1A104
1A105
1A107
1A109
1A113
1A113
1A117
1A120
1A123
1A125
1A126
1A130
1A133
1A136
1A140
1A140
1A140
1A140
1A140
1A140
1A140
1A141
1A141
1A141
1A141
1A141
1A141
1A142
1A142
1A142
1A142
1A142
1A142
1A143
1A143
1A143
1A143
1A143
1A143
1A144
1A144
1A144
Service Precaution
YOU ARE
IN
REPAIRS.
1A3

and systems.
Heating and Ventilation System

General Description
Heater
When the engine is warming up, the warmed engine
coolant is sent out into the heater core. The heater
system supplies warm air into the passenger
compartment to warm it up.
Outside air is circulated through the heater core of the
heater unit and then back into the passenger
compartment. By controlling the mixture of outside air
and heater core air, the most comfortable passenger
compartment temperature can be selected and
maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature control
knob. This knob acts to open and close the air mix door,
thus controlling the amount of air passed through the
heater core.
The air selector knob, with its different modes, also

allows you to select and maintain the most comfortable
temperature.
The air source select lever is used to select either
FRESH" for the introduction of the outside air, or
CIRC" for the circulation of the inside air. When the
lever is set to FRESH", the outside air is always taken
into the passenger compartment. When setting the
lever to CIRC" position, the circulation of air is
restricted only to the inside air with no introduction of
the outside air and the air in the passenger
compartment gets warm quickly. However, the lever is
normally set to FRESH" to prevent the windshield from
clouding.
1A4
Heater and Ventilation Associated Parts
840RY00049
Legend
(2) Heater Hose
(4) Ventiration Lower Duct
EndOFCallout
(5)
(6)
(7)
(8)
Heater Unit
Evaporator Assembly
Blower Assembly
Ventilation Duct
1A5
Ventilation
Setting the air source select lever to FRESH" position
allows the heating system to work with sending the
fresh air from outside.
The blower fan also serves to deliver fresh outside air to

the passenger compartment to assure adequate
ventilation.
810RW319
1A6

The control lever assembly has some cables to control
the mode and temperature of the heater unit and the
mode door for the air source of the blower assembly.
The fan control is used to control the amount of air sent

out by the resistor at four levels from LOW" to HIGH".
865RW006
Legend
(1) Air Source Select Lever
(2) Air Select Knob
(3) Fan Control Lever (Fan Switch)
(4) Air Conditioning (A/C) Switch (W/ A/C)

(5) Temperature Control Knob
(6) Middle Position
EndOFCallout
Air Source Select Lever
The intake of outside air and the circulation of inside air

are controlled by sliding this lever left or right.
When the temperature control knob is in the COLD"

position, the air mix door closes to block the flow air to
the heater core.
When the temperature control knob is in the HOT"
position, the air mix door opens to allow air to pass
through the heater core and heat the passenger
compartment.
Placing the knob in a intermediate position will cause a
lesser or greater amount air to reach the heater core. In
this mode the passenger compartment temperature can
be regulated.
Fan Control Lever

This lever controls the blower motor speed to regulate
the amount of air delivered to the defrost, foot, and
ventilation ducts:
1. Low
2. Medium Low
3. Medium High
4. High
1A7
Flow of Each Position of the All Select Dials
C01RX001
Air Select Knob

The air select knob allows you to direct heated air into
the passenger compartment through different outlets.
1. Vent In this position, air is discharged from the
upper air outlet. Air quantity is controlled by the fan
control lever.
2. Bi-Level In this position, air flow is divided
between the upper air outlets and the floor air
outlets, with warmer air delivered to the floor outlets
than the air delivered to the upper air outlets when
the temp lever is in middle position.
3. Foot In this position, air flow is delivered to the

foot, while sending a small amount of air to the
windshield.
4. Def/Foot In this position, air flow is delivered to
the foot, while sending approx. 40% of total amount
of air to the windshield.
5. Defrost In this position, most of the air is delivered
to the windshield and a small amount is delivered to
the side windows.
Moving the air source select lever to the CIRC" position
provides quickest heat delivery by closing the blower
assembly mode door. In this position, outside air is not
delivered to the passenger compartment.
1A8
Circuit Diagram
D08RX149
1A9
Diagnosis
Heating Cycle diagnosis
Condition
No heating or insufficient heating.
Possible cause
Correction
Blower motor does not run or runs

improperly.
Refer to FAN CONTROL LEVER

(FAN SWITCH) DIAGNOSIS".
Engine coolant temperature is low.
Check
the
engine
coolant
temperature after warming up the
engine and check the
thermostat.
Replace as necessary.
Insufficient engine coolant.
Add engine coolant as required.
Circulation volume of engine coolant

is insufficient.
Check if the water hose to the

heater core is clogged, collapsed or
twisted. Repair or replace as
necessary.
Heater core clogged or collapsed.
Clean or replace as necessary.
The heater cores is not provided

with air sent from the blower motor.
Repair the temperature control link

unit or mode doors.
Duct connections
unsealing.
defective
or
Control lever moves but mode door

does not operate.
Cable attaching clip is not correct.
Repair
Link unit of heater

assembly defective.
blower
Repair
The mode door cannot be set to the

mode selected.
Link unit of heater unit or blower

assembly defective.
Repair.
Control cable is not adjusted.
Adjust.
or
1A10
Fan Control Lever (Fan Switch) Diagnosis

Current flows to the blower motor through the heater
relay (X-6) to activate the rotation of the blower motor by
turning ON" the fan control knob (fan switch). Blower
motor speed is controlled in stages by the resistor, by
operating the switch from LOW" to HIGH".
each table, refer to INDIVIDUAL INSPECTION" in this
section.
D08RX250
Condition
Possible cause
Correction
Blower motor does not run.
Refer to Chart A
Blower motor does not run in certain

position (s).
Refer to Chart B, C, D and E
Blower motor does not stop at OFF"

position.
Refer to Chart F
1A11
Chart A" Blower Motor Does Not Run

Step
Action
Yes
No
Is relay (X-6) OK?
Go to Step 2
Replace
Is fuse F-4 (20A) OK?
Go to Step 3
Replace
Is resistor OK?
Go to Step 4
Replace
Is fan control lever OK?

Go to Step 5
Replace control
lever assembly.
Go to Step 6
Replace
Poor ground or
open circuit either
between chassis
side connector
terminal No. B5-1
and No. B3-2 or
No. I23-1 and body
ground (No. B-8).
Open circuit
between No. F-4
(20A) fuse and No.
B5-2.
Yes
No
Go to Step 2
Replace
Open circuit
between chassis
side connector
terminal No. B3-1
and No.I23-2.
Replace control
lever assembly.
Is blower motor OK?
1. Turn the ignition switch ON".

2. Turn fan control lever ON".
3. Check to see if battery voltage is present at chassis side
connector terminal No. B5-2
Is there a battery voltage?
Chart B" Blower Motor Does Not Run At Low Position

Step
Action
Is resistor OK?
Chart C" Blower Motor Does Not Run At Medium Low Position
Step
Action
Is resistor OK?
Yes
No
Go to Step 2
Replace
Open circuit
between the
chassis side
connector terminal
No. B3-4 and No.
I23-3.
Replace control
lever assembly.
Chart D" Blower Motor Does Not Run At Medium High Position
Step
Action
Is resistor OK?
Yes
No
Go to Step 2
Replace
Open circuit
between chassis
side connector
terminal No. B3-6
and No. I23-4.
Replace control
lever assembly.
1A12
Chart E" Blower Motor Does Not Run At High Position

Step
Action
Is resistor OK?
Yes
No
Go to Step 2
Replace
Open circuit
between Chassis
side connector
terminal No. B3-3
and No. I23-5.
Replace control
lever assembly.
Chart F" Blower Motor Does Not Stop In The OFF" Position
Step
1
Action
Is the fan control lever (Fan Switch) OK?
Yes
No
Short circuit
between chassis
side connector
terminal No.B5-1
and
No.B3-2,No.B3-3
and No.I23-5,
No.B3-6 and
No.I23-4, No.B3-4
and No.I23-3 or
No.B3-1 and
No.I23-2
Replace control
lever assembly.
1A13
Resistor
Blower Motor
1. Disconnect the blower motor (B-5) connector from
the blower motor.
2. Connect the battery positive terminal to the No. 2
terminal of the blower motor and the negative to the
No. 1.
3. Be sure to check to see if the blower motor operates
correctly.
1. Disconnect the resistor (B-3) connector.

2. Check for continuity and resistance between the
terminals of the resistor.
873RW008
840RX013
Legend
(1) Resister Assembly
(2) Connector Terminal (Resister Side)
(3) Position Switch
EndOFCallout
1A14
Fan Control Lever (Fan Switch)
Heater Relay
1. Check for continuity between the terminals of the

fan switch.
1. Disconnect the heater relay (X-6).

When removing the connector for relay, unfasten
the tank lock of the connector by using a
screwdriver, then pull the relay (1) out.
825RX046
2. Check for continuity between the heater relay (X-6)

terminals.
D08RX157
Legend
(1) Control Lever Connector Terminal (Control
Lever Side)
(2) Position Switch
EndOFCallout
901RX071
1A15
Heater Unit
Heater Unit and Associated Parts
840RY00046
Legend
(3) Heater Hose
(4) Heater Unit Assembly
(5)
(6)
(7)
(8)
(9)
Evaporator Assembly
Rear Heater Duct
Instrument Panel Stay
Center Ventilation Duct and Side Defroster
EndOFCallout
Removal
conditioning).
Refer to Instrument Panel Assembly in Body and
5. Remove instrument panel stay.
6. Remove center ventilation duct and side defroster.

Remove foot rest, carpet and 3 clips.
11. Remove heater unit assembly.
Disconnect heater hoses at heater unit.
1A16
Installation
1. When handling the PCM and the control unit, be
careful not to make any improper connection of the
connectors.

3. When installing the heater unit, defroster nozzle and
center vent duct, be sure that the proper seal is
made, without any gap between them.
4. After putting engine coolant in remove the air well
and confirm the quantity of coolant.
Heater Core and / or Mode Door

Disassembled View
860RX002
Legend
(1) Heater Unit
(2) Case (Temperature Control)
(3) Heater Core

(5) Duct
(6) Mode Door
EndOFCallout
Removal

conditioning).
5. Remove duct.
6. Remove case (Mode control) and do not remove link
unit at this step.
7. Remove case (Temperature control) and separate
two halves of core case.
1A17

the door lever.
860RX004
Legend
(1) Mode Door
(2) Door Lever
EndOFCallout
Inspection
860RW021
Legend
(1) Heater Core
(2) Core Case
Installation
EndOFCallout
8. Remove heater core.

1. Check that each mode door operates properly.
860RW020-1
Legend
(1) Heater Core
EndOFCallout
Check for foreign matter in the heater core, stain or the

core fin defacement.
1A18
Heater Mode Control Link Unit

Disassembled View
860RY00012
Legend
(1) Heater Unit
(3) Mode Sub Lever
(4)
(5)
(6)
(7)
Door Lever
Clip
Washer and Mode Main Lever
Rod
EndOFCallout
Removal
conditioning)
5. Remove the case (Mode control) from heater unit.
6. Remove washer and the mode main lever.
7. Remove rod.
8. Press the tab of the sub-lever inward, and take out
the sub-lever.
860RW018

the door lever.
10. Remove clip.
1A19
Installation
To install, follow the remove steps in the reverse order,
1. Apply grease to the mode sub-lever and to the
abrasive surface of the heater unit.
Heater Temperature Control Link Unit

Disassembled View
860RX001
Legend
(1) Heater Unit
(2) Case (Temperature control)
(3) Door Lever
(4)
(5)
(6)
(7)
Sub Lever
Clip
Rod
Clip
EndOFCallout
Removal
conditioning).
5. Remove the case (Temperature control) from the

heater unit.
6. Remove rod.
the door lever.
9. Remove clip.
1A20
Installation
1. Apply grease to the sub-lever and to the abrasive

surface of the heater unit.
Blower Assembly
Blower Assembly and Associated Parts
840RY00045
Legend
(2) Blower Assembly
(3) Blower Motor Harness Connector
(4) Resistor Harness Connector
(5) Heater Hose
EndOFCallout
(6)
(7)
(8)
(9)
(10)
(11)
Heater Unit Assembly

Evaporator Assembly
Rear Heater Duct
Instrument Panel Stay
Cross Beam Assembly
Removal
conditioning).
structure section.
4. Disconnect resistor harness connector.
1A21

6. Disconnect blower motor harness connector.
Installation
Blower Link Unit and / or Mode door

Disassembled View
873RX002
Legend
(1) Blower Assembly
(2) Door Lever
(3) Sub Lever
(4) Lower Case

(5) Mode Door
(6) Upper Case
EndOFCallout
Removal
conditioning).
(with
air

Refer to Blower Assembly in this section.
1A22
5. Separate the upper case and slit the lining parting

face with a knife.
873RW006

door lever.
8. Remove door lever.
Installation
1. Apply grease to the door lever and to the abrasive
surface of the upper case.
when assembling the upper case.
1A23
Blower Motor
Blower Motor and Associated Parts
873RX001
Legend
(1) Blower Motor Connector
(2) Attaching Screw
(3) Blower Motor Assembly
(4) Clip
(5) Fan
(6) Blower Motor
EndOFCallout
Removal
2. Remove blower motor connector.
4. Remove blower motor assembly.
5. Remove clip.
6. Remove fan.
7. Remove blower motor.
Installation
1A24
Rear Heater Duct, Defroster Nozzle and Ventilation Duct

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
840RY00047
Legend
(1) Cross Beam Assembly
(3) Ventilation Lower Duct

(6) Instrument Panel Stay
(7) Center Ventilation Duct and Side Defroster
EndOFCallout
Removal
Structure section.
3. Remove center ventilation duct and side defroster
duct.
Remove 5 screws.
4. Remove instrument panel Stay.
5. Remove cross beam assembly.

Remove foot rest carpet and 3 clips.
8. Remove defroster nozzle.
Installation
1A25

1. Connect each duct and nozzle securely leaving no
clearance between them and making no improper
matching.

Control Lever Assembly, Control Cable and Associated Parts
865RX009
Legend
(1) Control Cable
EndOFCallout

(4) Instrument Panel Driver Lower Cover Assembly
(5) Glove Box
1A26
Removal
2. Remove instrument panel driver lower cover
assembly.
Structure section.
5. Remove the control lever attaching screws.
6. Pull the control lever assembly out and disconnect
the fan switch and air conditioning switch
connectors.
865RX012
7. Remove control level assembly.

8. Disconnect control cables at each unit side.
865RX010
1A27
Installation
865RX013
Air source control cable.

1 Slide the control lever to the left (CIRC"
position).
2 Connect the control cable at the CIRC"
position of the link unit of the blower assembly
and secure it with the clip.
Temperature control cable.
1 Turn the control knob to the left (MAX COLD"
position).
2 Connect the control cable at the COLD"
position of the temperature control link of the
heater unit and secure it with the clip.
Air select control cable
1 Turn the control knob to the right
(DEFROST" position).
2 Connect the control cable at the DEFROST"
position of the mode control link of the heater
unit and secure it with the clip.
2. Check the control cable operation.
1A28
Control Panel Illumination Bulb

Associated Parts
Removal
2. Remove control lever assembly.
3. Pull out the bulb socket from the panel by turning it
counterclockwise.
4. Pull the illumination bulb from the socket.
Installation
865RX011
Legend
(2) Bulb Socket
(3) Illumination Bulb
EndOFCallout
Resistor
Resistor and Associated Parts
Removal
Remove the 2 inside clips.
3. Remove passenger knee bolster reinforcement.
4. Remove resistor harness connector.
5. Remove resistor.
Installation
840RX021
Legend
(1) Resistor
(2) Passenger Knee Bolster Reinforcement
(3) Resistor Harness Connector
(4) Glove Box
EndOFCallout
1A29
Air Conditioning System

General Description
Air Conditioning Refrigerant Cycle Construction
C01RX004
Legend
(2) Evaporator Core
(4) Temperature Sensor
(5) Expansion Valve
(6) Blower Motor
(7) Pressure Switch or Pressure Sensor
(8) Receiver/Drier
EndOFCallout
The refrigeration cycle includes the following four
processes as the refrigerant changes repeatedly from
liquid to gas and back to liquid while circulating.
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Condenser
Compressor
Magnetic Clutch
Mode (HEAT) Control Door
Temp. Control Door (Air Mix Door)
Heater Core
Mode (VENT) Control Door
Heater Unit
Mode (DEF) Control Door
Evaporation
The refrigerant is changed from a liquid to a gas inside
1A30
the evaporator. The refrigerant mist that enters the

evaporator vaporizes readily. The liquid refrigerant
removes the required quantity of heat (latent heat of
vaporization) from the air around the evaporator core
cooling fins and rapidly vaporizes. Removing the heat
cools the air, which is then radiated from the fins and
lowers the temperature of the air inside the vehicle.
The refrigerant liquid sent from the expansion valve and
the vaporized refrigerant gas are both present inside the
evaporator as the liquid is converted to gas.
With this change from liquid to gas, the pressure inside
the evaporator must be kept low enough for vaporization
to occur at a lower temperature. Because of that, the
vaporized refrigerant is sucked into the compressor.
Compression
The refrigerant is compressed by the compressor until it
is easily liquefied at normal temperature.
The vaporized refrigerant in the evaporator is sucked
into the compressor.
This action maintains the
refrigerant inside the evaporator at a low pressure so
that it can easily vaporize, even at low temperatures
close to 0C (32).
Also, the refrigerant sucked into the compressor is
compressed inside the cylinder to increase the pressure
and temperature to values such that the refrigerant can
easily liquefy at normal ambient temperatures.
Condensation
The refrigerant inside the condenser is cooled by the
outside air and changes from gas to liquid.
The high temperature, high pressure gas coming from
the compressor is cooled and liquefied by the
condenser with outside air and accumulated in the
receiver/drier. The heat radiated to the outside air by the
high temperature, high pressure gas in the compressor
is called heat of condensation. This is the total quantity
of heat (heat of vaporization) the refrigerant removes
from the vehicle interior via the evaporator and the work
(calculated as the quantity of heat) performed for
compression.
Compressor
The compressor performs two main functions:
It compresses low-pressure and low-temperature
refrigerant vapor from the evaporator into high-pressure
and high-temperature refrigerant vapor to the
condenser.
It pumps refrigerant and refrigerant oil through the air
conditioning system.
This vehicle is equipped with a five-vane rotary
compressor.
The specified amount of the compressor oil is 150cc
(5.0fl.oz.).
The oil used in the HFC-134a system compressor
differs from that used in R-12 systems.
The magnetic clutch connector is a waterproof type.
Magnetic Clutch
The compressor is driven by the drive belt from the
crank pulley of the engine. If the compressor is activated
each time the engine is started, this causes too much
load to the engine. The magnetic clutch transmits the
power from the engine to the compressor and activates
it when the air conditioning is ON. Also, it cuts off the
power from the engine to the compressor when the air
conditioning is OFF. Refer to Compressor in this section
for magnetic clutch repair procedure.
Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize.
The process of lowering the pressure to encourage
vaporization before the liquefied refrigerant is sent to
the evaporator is called expansion. In addition, the
expansion valve controls the flow rate of the refrigerant
liquid while decreasing the pressure.
That is, the quantity of refrigerant liquid vaporized inside
the evaporator is determined by the quantity of heat
which must be removed at a prescribed vaporization
temperature. It is important that the quantity of
refrigerant be controlled to exactly the right value.
871RX026
Legend
(1) Magnetic Clutch
(3) Compressor
EndOFCallout

Condenser
The condenser assembly is located in front of the
radiator. It provides rapid heat transfer from the
refrigerant to the cooling fins.
Also, it functions to cool and liquefy the high-pressure
and high-temperature vapor sent from the compressor
by the radiator fan or outside air.
A condenser may malfunction in two ways: it may leak,
or it may be restricted. A condenser restriction will
result in excessive compressor discharge pressure. If a
partial restriction is present, the refrigerant expands
after passing through the restriction.
Thus, ice or frost may form immediately after the
restriction. If air flow through the condenser or radiator
is blocked, high discharge pressures will result. During
normal condenser operation, the refrigerant outlet line
will be slightly cooler than the inlet line.
The vehicle is equipped with the parallel flow type
condenser. A larger thermal transmission area on the
inner surface of the tube allows the radiant heat to
increase and the ventilation resistance to decrease.
1A31
The liquefied refrigerant from the condenser is mixed

with refrigerant gas containing air bubbles. If
refrigerant containing air bubbles. If refrigerant
containing air bubbles is sent to the expansion valve,
the cooling capacity will decrease considerably.
Therefore, the liquid and air bubbles are separated
and only the liquid is sent to the expansion valve.
The receiver/drier utilizes a filter and drier to remove
the dirt and water mixed in the cycling refrigerant.
The sight glass, installed atop the receiver/drier,
show the state of the refrigerant.
A receiver/drier may fail due to a restriction inside the
body of the unit. A restriction at the inlet to the receiver/
drier will cause high pressure.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
The receiver/drier of this vehicle is made of aluminum
with a smaller tank. It has a 300cc refrigerant capacity.
Dual Pressure Switch (V6,M/T)

The pressure switch (Dual pressure switch) is installed
on the upper part of the receiver/drier, to detect
excessively high pressure (high pressure switch) and
prevent compressor seizure due to the refrigerant
leaking (low pressure switch), so that the compressor is
able to be turned ON" or OFF".
Compressor
ON
(kPa/psi)
OFF
(kPa/psi)
Low-pressure
control
186.329.4
(27.04.3)
176.519.6
(25.62.8)
High-pressure
control
2350.4196.1
(340.728.4)
2942.0196.1
(426.628.4)
875RX003
Legend
(1) Pressure Switch
(2) Receiver/Drier
(3) Condenser & Receiver Tank Assembly
(4) Condenser Fan (6VD1 A/T)
EndOFCallout
Triple pressure switch is installed on the upper part of

the receiver/drier. This switch is constructed with a
unitized type of two switches. One of them is a low and
high pressure switch (Dual pressure switch) to switch
ON" or OFF" the magnetic clutch as a result of
irregularly high-pressure or low pressure of the
refrigerant. The other one is a medium pressure switch
(Cycling switch) to switch ON" or OFF" the condenser
fan sensing the condenser high side pressure.
Receiver / Drier
Compressor
ON
(kPa/psi)
OFF
(kPa/psi)
The receiver/drier performs four functions:

As the quantity of refrigerant circulated varies
depending on the refrigeration cycle conditions,
sufficient refrigerant is stored for the refrigeration
cycle to operate smoothly in accordance with
fluctuations in the quantity circulated.
Low-pressure
control
186.329.4
(27.04.3)
176.524.5
(25.63.6)
High-pressure
control
2353.6196.1
(341.328.4)
2942.0196.1
(426.628.4)
1A32
Condenser fan
ON
(kPa/psi)
OFF
(kPa/psi)
Medium-pressure
control
1471.098.1
(213.314.2)
1078.7117.7
(156.417.1)
Pressure Sensor
The pressure sensor is installed on the upper part of the
receiver/drier. This sensor converts high pressure
detection of refrigerant to an electrical voltage signal
and supplies it to the PCM. The PCM controls switching
compressor idle speed and cooling fan operation by the
electrical voltage signal.
the force acting on the diaphragm and the spring

pressure.
The expansion valve regulates the flow rate of the
refrigerant. Accordingly, when a malfunction occurs to
this expansion valve, both discharge and suction
pressure get low, resulting in insufficient cooling
capacity of the evaporator.
The calibration has been changed to match the
characteristics of HFC-134a.
874RY00023
Legend
(1) Expansion Valve
(2) Insulator
875RY00015
Legend
(1) Pressure Switch
(2) Receiver Drier
EndOFCallout
Expansion Valve
This expansion valve is an external pressure type and it
is installed at the evaporator intake port.
The expansion valve converts the high pressure liquid
refrigerant sent from the receiver/drier to a low pressure
liquid refrigerant by forcing it through a tiny port before
sending it to the evaporator.
This type of expansion valve consists of a temperature
sensor, diaphragm, ball valve, ball seat, spring
adjustment screw, etc.
The temperature sensor contacts the evaporator outlet
pipe, and converts changes in temperature to pressure.
It then transmits these to the top chamber of the
diaphragm.
The refrigerant pressure is transmitted to the
diaphragm's bottom chamber through the external
equalizing pressure tube.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
EndOFCallout
Evaporator
The evaporator cools and dehumidifies the air before
the air enters the passenger compartment.
High-pressure liquid refrigerant flows through the
expansion valve into the low-pressure area of the
evaporator. The heat in the air passing through the
evaporator core is lost to the cooler surface of the core,
thereby cooling the air.
As heat is lost between the air and the evaporator core
surface, moisture in the vehicle condenses on the
outside surface of the evaporator core and is drained off
as water.
When the evaporator malfunctions, the trouble will show
up as an inadequate supply of cool air. The cause is
typically a partially plugged core due to dirt, or a
malfunctioning blower motor.
The evaporator core with a laminate louver fin is a
single-sided tank type where only one tank is provided
under the core.
1A33
874RY00022
Legend
(1) Evaporator Core
(2) Insulator
(3) Expansion Valve
EndOFCallout
Electronic Thermostat (With Manual A/C)

The thermostat consists of the thermo sensor and
thermostat unit which functions electrically to reduce the
noises being generated while the system is in operation.
The electronic thermo sensor is mounted at the
evaporator core outlet and senses the surface
temperature of the evaporator core. Temperature
signals are input to the thermostat unit. This information
is compared by the thermo unit and results in the output
to operate the A/C thermostat relay and turn the
magnetic clutch ON or OFF to prevent evaporator
freeze-up.
A characteristic of the sensor is that the resistance
decreases as the temperature increases and the
resistance increases as the temperature decreases.
874RX008
Legend
(1) Duct Sensor
(2) Evaporator Core
(3) Thermostat Unit
EndOFCallout
1A34
Refrigerant Line
Restriction in the refrigerant line will be indicated by:
1. Suction line A restricted suction line will cause
low suction pressure at the compressor, low
discharge pressure and little or no cooling.
2. Discharge line A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line A liquid line restriction will be
evidenced by low discharge and suction pressure
and insufficient cooling.
Refrigerant flexible hoses that have a low permeability
to refrigerant and moisture are used. These low
permeability hoses have a special nylon layer on the
inside.
852RS001
Legend
(1) Reinforcement Layer (Polyester)
(2) External Rubber Layer
(3) Internal Rubber Layer
(4) Resin Layer (Nylon)
EndOFCallout
1A35
Refrigerant Line Associated Parts
852RY00036
Legend
(2) O-Ring
(4) Pressure Switch
(5) Receiver Drier
EndOFCallout
(6)
(7)
(8)
(9)
(10)
(11)
Platform Seal
Condenser Assembly
Discharge Line (High Pressure Hose)
Compressor
Suction Line (Low Pressure Hose)
Drain Hose
1A36
Circuit Diagram
D08RX151
1A37
D08RX150
1A38
Diagnosis
Air Conditioning Cycle Diagnosis
Condition
No cooling or insufficient cooling.
Insufficient velocity of cooling air.
Possible cause
Correction
Magnetic clutch does not run.
Refer
to
Magnetic
Diagnosis" in this section.

Drive belt is loosened or broken.
Adjust the drive belt to the specified

tension or replace the drive belt.

Magnetic clutch face is not clean
and slips.
Clean the magnetic clutch face or

replace.

Incorrect
clearance
between
magnetic drive plate and pulley.
Adjust the clearance. Refer

Compressor in this section.

Compressor oil leaks from the shaft
seal or shell.

Compressor is seized.
Insufficient or excessive charge of

refrigerant.
Discharge
and
recover
refrigerant.
Recharge to
specified amount.
Leaks in the refrigerant system.
Check the refrigerant system for

leaks and repair as necessary.
Discharge
and
recover
the
refrigerant.
Recharge to the
specified amount.
Condenser is clogged or insufficient

radiation.
Clean the condenser or replace as

necessary.
Temperature control link unit of the

heat unit is defective.
Repair the link unit.
Unsteady operation due to a foreign

substance in the expansion valve.
Poor operation of the electronic

thermostat.
Check the electronic thermostat and

replace as necessary.
Evaporator clogged or frosted.
Check the evaporator core and

replace or clean the core.
Air leaking from the cooling unit or

air duct.
Check the evaporator and duct

connection,
then
repair
as
necessary.
Blower motor
properly.
Refer to Fan Control Lever (Fan

Switch) Diagnosis in this section.
*For the execution of the charging and discharging

operation in the table above, refer to Recovery,
Recycling, Evacuating and Charging in this section.
does
not
rotate
Clutch
to
the
the

Checking The Refrigerant System With Manifold Gauge
Since Refrigerant-134a (HFC-134a) is used in the air
conditioning
system in this vehicle, be sure to
use manifold gauges, charging hoses and other air
conditioning service tools
for HFC-134a when
checking the refrigerant system.
Conditions:
Run the engine at Idling
Air conditioning switch is ON"
Run the blower motor at HIGH" position
Temperature control lever set to MAX COLD"
Air source selector lever at CIRC"
Open the engine hood
Close all the doors
At ambient temperature: approx. 2530C (7786F).
Normal Pressure:
At low-pressure side: approx. 147.1294.2 kPa
(21.342.7 psi).
At high-pressure side: approx. 1372.91863.3 kPa
(199.1270.2 psi).
Refer
to
the
table
on
the
refrigerant
pressure-temperature relationship.
HFC-134a Pressure-Temperature Relationship
Pressure
Temperature
(kPa)
(psi)
(C)
(F)
36
5.3
20
4.4
67
9.7
15
104
15
10
14
147
21
23
196
28
32
255
37
41
314
45
10
50
392
57
15
59
471
68
20
68
569
82
25
77
677
98
30
86
785
114
35
95
912
132
40
104
1059
154
45
113
1216
176
50
122
1A39
1A40
Connect The Manifold Gauge

Low-pressure hose (LOW) Suction side
High pressure hose (HI) Discharge side
901RX060
Legend
(1) High Side
(2) Low Side
EndOFCallout

Condition
Possible cause
1A41
Correction

Abnormally High

Abnormally High.
Discharge and recover refrigerant.


Abnormally High.
High pressure gauge drop.
(After
stopping A/C, the pressure drops
approx. 196kPa (28psi) quickly)
Air in system.
Evacuate and charge refrigerant

system.

Abnormally Low.

the specified amount.

Abnormally Low.
Low pressure gauge indicates
vacuum.
Clogged
valve.

Abnormally Low.
Frost or dew on refrigerant line
before and after the receiver/drier or
expansion valve, and low pressure
gauge indicates vacuum.
Restriction caused by debris or

moisture in the receiver/drier.
Check system for restriction and

replace the receiver/drier.

Abnormally Low.
C)
Compressor seal defective
Poor compression due to a defective

compressor gasket.

Abnormally High.
Low pressure gauge (Low pressure
gauge is lowered after condenser is
cooled by water.)
Discharge and recover refrigerant


Abnormally High.
Low pressure hose temperature.
(Low pressure hose temperature
around the compressor refrigerant
line connector is lower than around
evaporator.)
Unsatisfactory valve operation due

to defective temperature sensor of
expansion valve.
Expansion valve opens too long.

Abnormally High.
C)
Compressor gasket is defective.
Suction (Low Gauge)

Abnormally Low.

specified amount.
Expansion valve clogged.
Pressure

Abnormally Low.
Frost on the expansion valve inlet
line
Cooling fan
properly.
or
does
not
defective
Clean the condenser fins

operate
expansion
Check the cooling fan operation.
1A42

Condition
Possible cause
Correction

Abnormally Low
Receiver/drier inlet and outlet
refrigerant line temperature. (A
distinct difference in temperature
develops.)
Receiver/Drier clogged.
Replace the receiver/drier.

Abnormally Low.
Expansion valve outlet refrigerant
line. (Not cold and low pressure
gauge indicates vacuum.)
Expansion valve temperature sensor

is defective.

Abnormally Low.
When the refrigerant line is clogged
or blocked,
the low pressure
gauge reading will decrease, or a
vacuum reading may be shown.
Clogged or blocked refrigerant line.
Replace refrigerant line.

Abnormally Low.
Evaporator core is frozen.
Thermo switch defective.
Replace thermo switch.

High.
Discharge
and
recover
the
refrigerant, the Recharge to the
specified amount.
Clean the condenser fin.

High.
Suction (Low) pressure hose (Not
cold).
Air in system.
Evacuate and charge refrigerant.

Low.

recover refrigerant. Recharge to
specified amount.
1A43
Magnetic Clutch Diagnosis
D08RX249
When the air conditioning switch and the fan control

knob (fan switch) are turned on with the engine running,
current flows through the thermostat and

compressor relay to activate the magnetic clutch.
the
1A44
The air conditioning can be stopped by turning of the air

conditioning switch or the fan control knob (fan switch).
However, even when the air conditioning is in operation,
the electronic thermostat, the pressure switch or the
Powertrain Control Module (PCM;V6-3.2L)/ Engine
Control Module (ECM;L4-2.2L) is used to stop the air
conditioning temporarily
by turning off the magnetic
Magnetic Clutch Does Not Run
Step
clutch in the prearranged conditions to reduce the

engine load which is being
caused by the rise in the
engine coolant temperature, and the acceleration of the
vehicle, etc.
the table, refer to Individual Inspection" in this section.
Action
Value(s)
Yes
No
Is the fuse No. F-5 normal?
Go to Step 2
Replace the
fuse
Are the relay No.X-6 (heater relay). No.X-5

(Thermostat relay) and No.X-4 (compressor relay)
normal?
Go to Step 3
Replace the
relay
Is pressure switch normal?
Go to Step 4
Place the
pressure
switch.
Are the air conditioner switch and the fan control

switch normal?
Go to Step 5
Replace the A/
C switch and
fan control
switch
1. Turn the ignition switch ON" (the engine is run).

2. Turn the air conditioner switch and the fan control
switch on.
connector terminal No.E3-1 and ground?
Approx.12V
Go to Step 6
Go to Step 7
Repair an open circuit between compressor side

terminal and ground or replace compressor.
Varify repair

terminal No.X4-1 and No.E3-1?
Go to Step 9
Go to Step 8

No.E3-1.
Go to Step 7

connector terminal No.X4-2 and ground, No.X4-5 and
ground?
Approx.12V
Go to Step 11
Go to Step 10
10
Repair and open circuit between terminal No.X4-2 and

No.F-5 fuse, No.X4-5 and No.F-5 fuse.
Go to Step 9
11

terminal No.X4-4 and No.C1-B14?
Go to Step 13
Go to Step 12
12

No.C1-B14.
Go to Step 11
13

connector terminal No.I24-2 and ground?
Approx.12V
Go to Step 15
Go to Step 14
14

No.F-5 fuse.
Go to Step 13
15

Approx.12V
Go to Step 17
Go to Step 16
1A45
Magnetic Clutch Does Not Run (Conts)

Step
Action
Value(s)
Yes
No
16

No.I24-1.
Go to Step 15
17

terminal No.I23-6 and No.B-2?
Go to Step 19
Go to Step 18
18

No.B4-2.
Go to Step 17
19

terminal No.I23-1 and ground (No.B-8)?
Go to Step 21
Go to Step 20
20

No.B-8.
Go to Step 19
21

connector terminal No.C11-1 and ground?
Go to Step 23
Go to Step 22
22
Repair an open circuit between terminal No.C11-1

and No.F-5 fuse.
Go to Step 21
23

connector terminal No.X5-2 and ground?
Go to Step 25
Go to Step 24
24

No.C11-2.
Go to Step 23
25

Go to Step 27
Go to Step 26
26

No.X5-4.
Go to Step 25
27

terminal No.X5-1 and No.C3-E15?
Go to Step 29
Go to Step 28
28

No.C3-E15.
Verify repair
29
Replace the PCM.

Verify repair
CAUTION:
There are condition whitch air
as follows.
1. The throttle is greater than 90%.
3. The engine speed is greater than 4500 RPM for 5
than 125C (257F).
(41F).
pressure condition.
1A46
Fan Control Knob (Fan Switch) And Air
Conditioning (A/C) Switch
1. Check for continuity between the fan switch and the
A/C switch side connector terminals.
Heater (X-6), Thermostat (X-5), Condenser

Fan (X-9) And Compressor (X-4) Relay
in this section.
901RX071
Pressure Switch
1. Disconnect pressure switch connector and check for
continuity between pressure switch side connector
terminals (1) and (2).
D08RX254
Legend
(1) A/C Switch Connector (switch side)
(2) Fan Switch Connector (switch side)
EndOFCallout
875RY00024
1A47
General Repair Procedure
Repair Of Refrigerant Leaks
Precautions For Replacement or Repair of

Air Conditioning Parts
Refrigerant Line Connections

Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the
connecting portion from twisting or becoming damaged.
There are certain procedures, practices and

precautions that should be followed when servicing air
conditioning systems:
Keep your work area clean.
Always wear safety goggle and protective gloves
when working on refrigerant systems.
Beware of the danger of carbon monoxide fumes
caused by running the engine.
Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or
parts are reconnected or installed.
When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
Always install new O-rings whenever a connection is
disassembled.
Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
1 Use the J-39500 (ACR4: HFC-134a Refrigerant
Recovery / Recycling / Recharging / System) or
equivalent to thoroughly discharge and recover
the refrigerant.
2 Remove and replace the defective part.
3 After evacuation, charge the air conditioning
system and check for leaks.
852RS003
When connecting the refrigerant line at a block joint,

securely insert the projecting portion of the joint portion
into the connecting hole on the unit side and secure with
a bolt. Apply the specified
compressor oil to the
O-rings prior to connecting.
CAUTION: Compressor (PAG) oil to be used varies
according to the compressor model.
Be sure to
apply oil specified for the model of compressor.
850RW002
1A48
O-rings (2) must be fitted in the groove (1) of refrigerant

line.
Insert the nut into the union.

First, tighten the nut by hand as much as possible, then
tighten the nut to the specified torque.
850RW003
Leak Check
Inspection of refrigerant leak
Refrigerant leak may cause an adverse effect not only
on the performance and durability of each component of
the air-conditioner, but also on the global atmosphere.
Therefore, it is most important to repair refrigerant leak
when there is any leak found.
Inspection flow of refrigerant leak
Step
1
Action
Yes
No
1. Evacuate the refrigerant system.

2. Charge the refrigerant.
Is there any refrigerant leak?
Repair refrigerant
system.
Go to Step 2.
1. Operate the compressor for more than 5 minutes to raise the

pressure on the high pressure side.
Is there any refrigerant leak at high pressure components?
Repair refrigerant
system.
Compressor
operation to be
confirmed.
Inspection Steps
Check the components of air-conditioner to see if there
occurs any refrigerant leak along the flow of refrigerant.
To avoid an error in the detection of refrigerant leak,
make sure of there being no refrigerant vapor or
cigarette smoke around the vehicle before conducting
the inspection. Also, select a location where the
refrigerant vapor will not get blown off with wind.
Inspection should be conducted chiefly on the pipe
connections and sections where a marked oil
contamination is found. When refrigerant is leaking,
oil inside is also leaking at the same time.
It is possible to visually check the leak from inside the
cooling unit. Follow the method below when
checking. Remove the drain hose or resistor of the
cooling unit, and insert a leak detector to see if there

occurs any leak.
High Pressure Side
1. Discharger section of compressor.
2. Inlet/outlet section of condenser.
3. Inlet/outlet section of receiver driver.
4. Inlet section of cooling unit.
Low Pressure Side
1. Outlet section of cooling unit.
2. Intake section of compressor.

Major Checking Points of Refrigerant Leak
Compressor
Pipe connection
Sealing section of shaft
Mating section or cylinder
Condenser
Pipe connection
Welds of condenser body
Receiver driver
Pipe connection
Attaching section of pressure switch
Section around the sight glass
Evaporator unit (cooling unit)
Pipe connections
Connections of expansion valve
Brazed sections of evaporator
The evaporator and expansion valve are contained in
the case. Remove the drain hose or the resistor of the
cooling unit and insert a leak detector when checking
for any leak.
Flexible hose
Pipe connection
Caulking section of the hose
Hose (cracks, pinholes, flaws)
Pipe
Pipe connection
Pipe (cracks, flaws)
Charge valve
The charge valve, which is used to connect the gauge
manifold, is normally provided with a resin cap. When
the valve inside gets deteriorated, refrigerant will leak
out.
Leak at Refrigerant Line Connections

1. Check the torque on the refrigerant line fitting and, if
too loose, tighten to the specified torque.
damage to the line.
Do not over tighten.
2. Perform a leak test on the refrigerant line fitting.
3. If the leak is still present, discharge and recover the
refrigerant from the system.
4. Replace the O-rings.
1A49
new ones.
Be sure to apply the specified compressor oil to
the new O-rings.
5. Retighten the refrigerant line fitting to the specified
torque.
damage to the line.
6. Evacuate, charge and retest the system.
Leaks In The Hose

If the compressor inlet or outlet hose is leaking, the
entire hose must be replaced. The refrigerant hose must
not be cut or spliced for repair.
1. Locate the leak.
3. Remove the hose assembly.
Cap the open connections at once.
4. Connect the new hose assembly.
Use two wrenches to prevent twisting or damage
to the hose fitting.
Tighten the hose fitting to the specified torque.
5. Evacuate, charge and test the system.
Compressor Leaks
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
Recovery, Recycling,
Charging of HFC-134a
Evacuation
and
Air conditioning systems contain HFC-134a. This is a

chemical mixture which requires special handling
procedures to avoid personal injury.
Always wear safety goggles and protective gloves.
Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
If HFC-134a should come in contact with any part of
the body, flush the exposed area with cold water and
immediately seek medical help.
If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the
If it is necessary to fill a small HFC-134a container
from a large one, never fill the container completely.
Space should always be allowed above the liquid for
expansion.
HFC-134a and R-12 should never be mixed as their
compositions are not the same.
HFC-134a PAG oil tends to absorb moisture more
quickly than R-12 mineral oil and, therefore, should
be handled more carefully.
Keep HFC-134a containers stored below 40C
(100F).
1A50
WARNING:
SHOULD HFC-134A CONTACT YOUR EYE(S),
CONSULT A DOCTOR IMMEDIATELY.
DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER
OVER THE AFFECTED
AREA TO GRADUALLY
RAISE
THE
TEMPERATURE
OF
THE
REFRIGERANT ABOVE THE FREEZING POINT.
OBTAIN PROPER MEDICAL TREATMENT AS
SOON AS POSSIBLE. SHOULD THE HFC-134A
TOUCH THE SKIN, THE INJURY MUST BE
TREATED THE SAME AS SKIN WHICH HAS BEEN
FROSTBITTEN OR FROZEN.
3. When a part is removed, put a cap or a plug on the

connecting portion so that dust, dirt or moisture
cannot get into it.
Refrigerant Recycling
Recycle the refrigerant recovered by J-39500
(ACR4:HFC-134a Refrigerant Recovery / Recycling /
Recharging / System) or equivalent.
For the details of the actual operation, follow the steps in
the ACR4(or equivalent) Manufacturer's Instructions.
Evacuation of The Refrigerant System
Refrigerant Recovery
The refrigerant must be discharged and recovered by
using the J-39500 (ACR4:HFC-134a Refrigerant
Recovery/Recycling/Recharging/System) or equivalent
before removing or mounting air conditioning parts.
1. Connect the high and low charging hoses of the
ACR4(or equivalent) as shown below.
901RX058
Legend
(1) High Side
(2) Low Side
901RX057
Legend
(1) High Side
(2) Low Side
EndOFCallout
2. Recover the refrigerant
Manufacturer's Instructions.
by
following
the
EndOFCallout
Explained below is a method using a vacuum pump.
Refer to the ACR4(or equivalent) manufacturer's
instructions when evacuating the system with a ACR4(or
equivalent).
Air and moisture in the refrigerant will cause problems in
the air conditioning system. Therefore, before charging
the refrigerant, be sure to evacuate air and moisture
thoroughly from the system.
1. Connect the gauge manifold.
High-pressure valve (HI) Discharge-side.
Low-pressure valve (LOW) Suction-side.
3. Connect the center hose of the gauge manifold set
to the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
then open both hand valves.
5. When
the
low-pressure
gauge
indicates
approximately 750mmHg (30inHg), continue the
evacuation for 5 minutes or more.
6. Close both hand valves and stop the vacuum pump.

7. Check to ensure that the pressure does not change
after 10 minutes or more.
If the pressure changes, check the system for
leaks.
If leaks occur, retighten the refrigerant line
connections and repeat the evacuation steps.
8. If no leaks are found, again operate the vacuum
pump for 20 minutes or more. After confirming that
the gauge manifold pressure is at 750mmHg
(30inHg), close both hand valves.
9. Close positive shutoff valve. Stop the vacuum pump
and disconnect the center hose from the vacuum
pump.
1A51
Direct charging with a weight scale charging

station method
1. Make sure the evacuation process is correctly
completed.
2. Connect the center hose of the manifold gauge to
the weight scale.
3. Connect the low pressure charging hose of the
manifold gauge to the low pressure side service
4. Connect the high pressure charging hose of the
manifold gauge to the high pressure side service
Charging The Refrigerant System

There are various methods of charging refrigerant into
the air conditioning system.
These include using J-39500 (ACR4:HFC-134a
Refrigerant Recovery/Recycling/Recharging/System) or
equivalent and direct charging with a weight scale
charging station.
Charging Procedure
ACR4(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer's instruction.
901RX059
Legend
(1) Weight Scale
(2) Refrigerant Container
(3) High Side
(4) Low Side
901RX057
Legend
(1) High Side
(2) Low Side
EndOFCallout
EndOFCallout
5. Place the refrigerant container up right on a weight
scale.
Note the total weight before charging the refrigerant.
a Open the refrigerant container valve.
b Open the low side vale on the manifold gauge
set. Refer to the manufacturer's instructions for
a weight scale charging station.
1A52
6. Perform a system leak test:

Charge the system with approximately 200g
(0.44lbs) of HFC-134a.
Make sure the high pressure valve of the manifold
gauge is closed.
Check to ensure that the degree of pressure does
not change.
Check for refrigerant leaks by using a HFC-134a
leak detector.
If a leak occurs, recover the refrigerant. Repair
the leak and start all over again from the first step
of evacuation.
7. If no leaks are found, continue charging refrigerant
to the air conditioning system.
Charge the refrigerant until the scale reading
decreases by the amount of the charge specified.
Specified amount: 650g (1.43lbs)
If charging the system becomes difficult:
1 Run the engine at idle and close all the
vehicle doors.
2 Turn A/C switch ON".
3 Set the fan switch to its highest position.
4 Set the air source selector lever to CIRC".
5 Slowly open the low side valve on the
manifold gauge set.
WARNING: Be absolutely sure not to open the high
pressure valve of the manifold gauge. Should the
high pressure valve be opened, the high pressure
refrigerant would flow backward, and this may
cause the refrigerant container to burst.
8. When finished with the refrigerant charging, close
the low pressure valve of the manifold gauge and
container valve.
9. Check for refrigerant leaks.
Checking The A/C System

1. Run the engine and close all the vehicle doors.
2. Turn A/C switch ON", set the fan switch to its
highest position.
3. Set the air source lever to CIRC", set the
temperature lever to the full cool position.
4. Check the high and low pressure of the manifold
gauge.
Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:
The ambient temperature should be between 25
30C (7786F).
The pressure guideline for the high-pressure side
is approximately 1372.91863.3kPa (199.1
270.2 psi).
The pressure guideline for the low-pressure side
is approximately 147.1294.2kPa (21.342.7

psi).
If an abnormal pressure is found, refer to
Checking The Refrigerant System With Manifold
Gauge in this section.
5. Put your hand in front of the air outlet and move the
temperature control lever of the control panel to
different positions. Check if the outlet temperature
changes as selected by the control knob.
Reading Sight Glass
The sight glass provides accurate diagnosis only under
the following conditions.
If the vehicle can be tested under these conditions,
check the sight glass appearance and compare to the
chart below.
Engine speed idle
A/C switch ON"
Blower fan operating at highest speed
Air source selector lever at RECIRC"
Temperature control lever at coldest position
Ambient temperature below 30C (86F) and
humidity below 70% (See NOTE 1)
High side pressure less than 1667.1 kPa (241.7 psi)
(See NOTE 2)
NOTE: 1. If the vehicle cannot be moved to a testing
location that meets these specifications, then the sight
glass cannot be used for diagnosis. You must discharge
and recover the refrigerant, then recharge the system
with the specified amount of refrigerant.
Then continue checking the system performance.
NOTE: 2. If the high side pressure is greater than
stated, the sight glass cannot be used for diagnosis. You
must discharge and recover the refrigerant, then
recharge the system with the specified amount of
refrigerant.
Then
continue
checking
system
performance.
1A53
The high pressure

pipe is hot and the
cold. There is a
distinct difference in
temperature between
them.
The high pressure

pipe is warm and the
cool. There is no
great difference in
temperature between
them.
There
is
litttle
difference
in
temperature between
the high pressure
pipe and the low
pressure pipe.
The high pressure

pipe is hot and the
slightly warm. There
is a defference in
temperature between
them.
Slight glass condition Almost transparent. A

flow of bubbles can
be seen, but they
disappear when the
throttle is opened.
A flow of bubbles
always can be seen.
It appears sometimes
transparent, and
sometimes frothy.
Something like fog

faintly can be seen.
Even at idle with the

fan at HI (with the
window fully open),
the bubbles cannnot
be seen.
NG
(Not enough
refrigerant)
NG
(Almost no
refrigerant)
NG
(Too much
refrigerant)
High and low

pressure pipe
temperature
Air conditioning cycle

condition
OK
1A54
Compressor Assembly
Compressor Assembly and Associated Parts (6VD1)
852RY00018
Legend
(1) Compressor Bracket
(3) Compressor
(4) O-ring
(5) To Evaporator
EndOFCallout
Removal
(6)
(7)
(8)
(9)
Suction Line (Low-Pressure Hose)

Discharge Line (Hight-Pressure Hose)
To Condenser
Serpentine Belt
1A55
Installation
specified torque.
Torque: 19Nm (1.9kgm/14lb ft)
850RW009
Legend
(5) Generator
(6) Tensioner
(7) Idler Pulley
EndOFCallout

new ones.
normal position.
1A56
Compressor Assembly and Associated Parts (X22SE)
852RY00031
Legend
(1) Compressor Bracket
(2) Magnetic Harness Connector
(3) Compressor
(4) O-ring
EndOFCallout
Removal
(5)
(6)
(7)
Suction Line (Low-Pressure Hose)

Discharge Line (High-Pressure Hose)
Serpentine Belt

1A57
New Compressor Installation

The new compressor is filled with 150cc (5.0fl.oz.)of
compressor oil and nitrogen gas. When mounting the
compressor on the vehicle, perform the following steps;
1. Gently release nitrogen gas from the new
compressor.
Take care not to let the compressor oil flow out.
Inspect O-rings and replace if necessary.
850RX006
Legend
(3) Tensioner
EndOFCallout
871RX033
2. Turn the compressor several times by hand and

release the compressor oil in the rotor.
3. When installing on a new system, the compressor
should installed as it is. When installing on a used
system, the compressor should be installed after
adjusting the amount of compressor oil. (Refer to
Compressor in this section)
Installation
specified torque.
new ones.
normal position.
871RX035
1A58
Condenser Assembly
875RY00008
Legend
(1) Engine Hood Lock
(4) Radiator Grille

(5) Engine Hood Front End Stay
(6) Condenser Assembly
EndOFCallout
Removal
4. Remove engine hood front end stay.
5. Remove engine hood lock.
Apply setting mark to the engine hood lock fixing
position before removing it.
8. Remove condenser assembly.

Handle with care to prevent damaging the
condenser or radiator fin.
Installation
1. Install condenser assembly.
If installing a new condenser, be sure to add 30cc
Tighten the condenser fixing bolts to the specified
torque.
Torque: 6Nm (0.6kgm/52lb in)
2. Connect refrigerant line.
Tighten the inlet line connector fixing bolt to the
specified torque.
Torque: 15 Nm (1.5kgm/11 lb ft)

Tighten the outlet line connector fixing bolt to the
specified torque.
Torque: 6 Nm (0.6kgm/52 lb in)
new ones.
1A59
O-rings when connecting the refrigerant line.

3. Connect pressure switch connector.
4. Install engine hood lock.
5. Install engine hood front end stay.
6. Install radiator grille.
Condenser Fan Motor

875RY00007
Legend
(1) Condenser Fan Assembly
(2) Condenser Fan Motor
(3) Radiator Grille

(4) Shroud
(5) Fan
EndOFCallout
Removal
4. Remove condenser fan assembly.
Disconnect the fan motor connector and remove
the 4 fixing bolts.
5. Remove shroud.
Remove the 3 fixing nuts.
Loosen the condenser fixing nut and disconnect
the fan motor connector from bracket.

6. Remove fan.
Remove the fan fixing C-ring and plate.
7. Remove condenser fan motor.
Installation
1. Route the fan motor harness in its previous position,
and fix it securely with clip and bracket.
1A60
Receiver / Drier
Receiver / Drier and Associated
Parts
Installation
1. If installing a new receiver/drier, be sure to add 30cc
2. Put the receiver/drier in the bracket and connect
with the refrigerant line. Check that no excessive
force is imposed on the line. Fasten the bracket bolt
to the receiver/drier.
ones.
when connecting the refrigerant line.
875RY00012
Legend
(3) Radiator Grille
(5) Bracket Bolt
EndOFCallout
Removal
When removing the line connected part, the
6. Remove bracket bolt.
7. Remove receiver/drier.
Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
1A61
Pressure Switch
Pressure
Parts
Switch
and
Associated
Installation
1. O-ring cannot be reused. Always replace with a new
one.
2. Be sure to apply new compressor oil to the O-ring
when connecting pressure switch.
3. Tighten the pressure switch to the specified torque.
875RY00012
Legend
(3) Radiator Grille
(5) Bracket Bolt
EndOFCallout
Removal
5. Disconnect pressure switch.
When removing the switch connected part, the
1A62
Evaporator Assembly
874RY00024
Legend
(2) Drain Hose
(3) Resistor and Electronic Thermostat Connector
EndOFCallout
Removal
(5)
(6)
(7)
(8)
(9)
Evaporator Assembly
Glove Box
Sill Plate
Dash Side Trim Pad
Inst Panel Lower Reinforcement

4. Disconnect resistor (2) and electronic thermostat
connector (1).
1A63
Installation
1. To install a new evaporator assembly, add 50cc
(1.7fl.oz.) of new compressor oil to the new core.
2. Tighten the refrigerant outlet line to the specified
torque.
3. Tighten the refrigerant inlet line to the specified
torque.
ones.
874RY00025
5. Disconnect drain hose.

Use a back-up wrench when disconnecting and
When removing the refrigerant line connected
1A64
Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View
874RY00026
Legend
(1) Lining
(2) Upper Case
(4) Evaporator Core
(5) Lining: Case
(6)
(7)
(8)
(9)
(10)
Attaching Screw
Lower Case
Evaporator Assembly
O-ring
Expansion Valve
EndOFCallout
Removal
4. Remove the electronic thermostat sensor fixing clip.
Pull the sensor from the evaporator assembly.
6. Remove upper case.
Slit the case parting face with a knife since the
lining is separated when removing the evaporator.
874RW034
1A65
Installation
Lift to remove the upper case.

1. The sensor is installed on the core with the clip.
2. The sensor must not interfere with the evaporator
core.
3. When installing the new evaporator core, install the
thermo sensor to the evaporator core specified
position with the clip in the illustration.
874RY00027
8. Remove evaporator core.
874RX014
Legend
(1) Evaporator Core
(2) Thermo Sensor
(3) Lower Case
(4) Upper Case
874RY00028
9. Remove expansion valve.

Tear off the insulator carefully.
Remove the sensor fixing clip.
Use a back-up wrench when disconnecting all
refrigerant pipes.
EndOFCallout
ones.
6. Be sure to install the sensor and the insulator on the
place where they were before.
7. To install a new evaporator core, add 50cc (1.7 fl.
oz.) of new compressor oil to the new core.
8. Tighten the refrigerant lines to the specified torque.
when assembling the evaporator assembly.
1A66
Refrigerant Line
852RY00032
Legend
(1) Clip and Clamp
(2) Liquid Line (High-Pressure Pipe)
(3) Radiator Grille

(4) Discharge Line (High-Pressure Hose)
(5) Suction Line (Low-Pressure Pipe)
EndOFCallout
Removal
4. Remove clip and clamp.
5. Disconnect liquid line (High-pressure pipe).
6. Disconnect suction line (Low-pressure pipe) using a
back-up wrench.
7. Disconnect suction line (Low-pressure hose) using
a back-up wrench.
8. Disconnect discharge line (High-pressure hose)
using a back-up wrench.
Use a backup wrench when disconnecting and
When removing the refrigerant line connecting

Installation
ones.
1A67
1A68

Heater Unit
Temperature control
Reheat air mix system
Capacity
3,700 Kcal./hr.
Air flow
280 m3/h
HEATER CORE
Type
Element dimension
Radiating area
AUTO A/C
Plate and corrugate-fin type
MANU A/C
Fin and tube type
MANU A/C
161 mm (6.3) 163 mm (6.4 in.) 45 mm (1.8 in.)
AUTO A/C
171 mm (6.7) 161 mm (6.3 in.) 25 mm (1 in.)
MANU A/C
Approx. 2.1 m2
AUTO A/C
Approx. 1.3 m2
AUTO A/C
4,100 Kcal./hr.
MANU A/C
4,200 Kcal./hr.
AUTO A/C
430 m3/hr
MANU A/C
470 m3/hr
EVAPORATOR ASSEMBLY
Capacity
Air flow
EVAPORATOR CORE
Type
Al-laminate louver fin type
Element dimension
235 mm (9.3 in.) 224 mm (8.8 in.) 60 mm (2.4 in.)
EXPANSION VALVE
Type
Internal pressure equalizer type
THERMOSTAT SWITCH
Type
Electronic thermostat
OFF: Below 0.5 0.5 C (32.9 0.9 F)
ON: Above 4.5 0.5 C (40.1 0.9 F)
CONDENSER
Type
Parallel flow type
Radiation performance
9,400 Kcal./hr
RECEIVER/DRIER
Type
Assembly includes sight glass with dual (triple) pressure

switch (V6) or pressure sensor (L4)
Internal volume
300 cc (10 fl.oz.)

PRESSURE SWITCH
Type
Dual pressure switch

ON: 186.329.4 kPa (27.04.3 psi)
OFF: 176.524.5 kPa (25.63.6 psi)
ON: 2353.6196.1 kPa (341.328.4 psi)
OFF: 2942.0196.1 kPa (426.628.4 psi)
Triple pressure switch (V6, A/T)
ON: 196.329.4 kPa (27.04.3 psi)
OFF: 176.519.6 kPa (25.62.8 psi)
Medium pressure control
ON: 1471.098.1 kPa (213.314.2 psi)
OFF: 1078.7117.7 kPa (156.417.7 psi)
ON: 2353.6196.1 kPa (341.328.4 psi)
OFF: 2942.0196.1 kPa (426.628.4 psi)
REFRIGERANT
Type
HFC-134a
Specified amount
650 g (1.43 lbs.)
1A69
1A70
Nm (kgm/lb ft)
E06RY00007
E06RY00008
1A71
Compressor
Service Precaution
WARNING: This vehicle has a Supplemental
Restraint System (SRS). Refer to the SRS
Component 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 On-Vehicle
Service Information. Failure to follow CAUTIONS
could result in possible air bag deployment,
personal injury, or otherwise unneeded SRS system
repairs.
use supplemental coatings (paints, greases, or
and systems.
General Description
When servicing the compressor, keep dirt or foreign
material from getting on or into the compressor parts
and system. Clean tools and a clean work area are
important for proper service.
The compressor
connections and the outside of the compressor should
be cleaned before any "On-Vehicle" repair, or before
removal of the compressor. The parts must be kept
clean at all times and any parts to be reassembled
should be cleaned with Trichloroethane, naphtha,
kerosene, or equivalent solvent, and dried with dry air.
Use only lint free cloths to wipe parts.
The operations described below are based on bench
overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When the compressor
is removed from the vehicle for servicing, the oil
remaining in the compressor should be discarded and
new compressor oil added to the compressor.
Compressor malfunction will appear in one of four ways:
noise, seizure, leakage or low discharge pressure.
Resonant compressor noises are not cause for alarm;
however, irregular noise or rattles may indicate broken
parts or excessive clearances due to wear. To check
seizure, de-energize the magnetic clutch and check to
see if the drive plate can be rotated. If rotation is

impossible, the compressor is seized. Low discharge
pressure may be due to a faulty internal seal of the
compressor, or a restriction in the compressor. Low
discharge pressure may also be due to an insufficient
refrigerant charge or a restriction elsewhere in the
system. These possibilities should be checked prior to
servicing the compressor.
If the compressor is
inoperative, but is not seized, check to see if current is
being supplied to the magnetic clutch coil terminals.
The compressor oil used in the HFC-134a system
compressor differs from that used in R-12 systems.
DKV-14G Type Compressor

DKV-14G is equipped with five-vane rotary compressor.
These vanes are built into a rotor which is mounted on a
shaft.
When the shaft rotates, the vanes built into the cylinder
block assembly are operated by centrifugal force.
This changes the volume of the spare formed by the
rotor and cylinder, resulting in the intake and
compression of the refrigerant gas. The discharge valve
and the valve stopper, which protects the discharge
valve, are built into the cylinder block assembly. There
is no suction valve but a shaft seal is installed between
the shaft and head; a trigger valve, which applies back
pressure to the vanes, is installed in the cylinder block
and a refrigerant gas temperature sensor is installed in
the front head.
The specified quantity of compressor oil is contained in
the compressor to lubricate the various parts using the
refrigerant gas discharge pressure.
A01RS003
1A72
Diagnosis
Condition
Noise from compression
Noise from magnetic clutch
Not rotating
Possible cause

shaft assembly
Defective shaft

shaft assembly
Defective bearing
Defective clutch
Clearance between drive plate and

pulley not standard
Adjust the clearance or replace

magnetic clutch
Defective gasket
Replace compressor/gasket
Defective rotor/reed valve
Replace compressor/valve plate
Defective trigger valve/suction valve
Replace compressor/suction valve

shaft assembly
Defective shaft

shaft assembly
Rotating parts
insufficient oil
Oil and/or gas leakage
Correction
seized
due
to
Replace compressor
Defective seal
Replace compressor/shaft seal
Defective O-ring
Replace
1A73
Magnetic Clutch Assembly (DKV-14G Type)

Parts Location View
871RX025
Legend
(1) Drive Plate bolt
(2) Drive Plate
(3) Snap Ring
(4)
(5)
(6)
(7)
Pulley Assembly
Field Coil
Shim (s)
Lead Wire
EndOFCallout
Removal
2. Remove drive plate by using drive plate puller

J-33944-A (2) and forcing screw J-33944-4 (1).
1. Using drive plate holder J-33939 (1) to prevent the

drive plate from rotating, then remove the drive plate
bolt.
871RX023
871RX029
1A74
3. Remove shim (s).

4. Remove snap ring (1) by using snap ring pliers.
6. Loosen screw and disconnect the field coil wire

connector.
871RY00030
871RY00029
5. Remove pulley assembly by using pulley puller pilot

J-38424(2), pulley puller J-8433(1) and pulley puller
leg J-24092-2(3).
7. Loosen three screws and remove the field coil.
871RY00034
871RY00033
1A75

Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
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.
Coil
Check coil for loose connector or cracked insulation.
871RY00032
Installation
1. Install field coil.
Align the located portion (1) of the field coil and
compressor.

5. Install shim (s).
6. Install the drive plate to the compressor drive shaft
together with the original shim(s)(1). Press the drive
plate by hand.
871RY00035
871RY00031
Tighten the mounting screw to the specified

torque.
Torque: 5Nm (0.5kgm/44 lb in)
2. Connect the lead wire connector with the rubber
hold and tighten the screw.
3. Install pulley assembly by using pulley installer
J-33940-A(2) and drive handle J-8092(1).
1A76
7. Install drive plate bolt by using drive plate holder

J-33939 (1) to prevent the drive plate from rotating.
Check to be sure that the clutch clearance is

between 0.3-0.6 mm (0.01-0.02 in.)
871RX029
Tighten the drive plate bolt to the specified

torque.
After tightening the drive plate bolt, check to be
sure the pulley rotates smoothly.
871RY00028
Legend
(1) Dial Gauge
(2) Pulley Assembly
(3) Field Coil Wire Connector
EndOFCallout
If necessary, install adjusting shim(s).
Adjusting shims are available in the following
thickness.
Thickness
0.1 mm (0.0039 in.)
0.3 mm (0.0118 in.)
0.5 mm (0.0197 in.)
1A77
Compressor Oil
Oil Specification
The HFC-134a system requires a synthetic (PAG)
compressor oil whereas the R-12 system requires a
mineral compressor oil. The two oils must never be
mixed.
Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified for
the model of compressor.
Always use HFC-134a Vane Rotary Type
Compressor Oil (AIPDN Part No.2-90188-301-0)
Handling of Oil
The oil should be free from moisture, dust, metal
powder, etc.
Do not mix with other oil.
The water content in the oil increases when exposed
to the air. After use, seal oil from air immediately.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)
The compressor oil must be stored in steel
containers, not in plastic containers.
Compressor Oil Check

The oil used to lubricate the compressor is circulating
with the refrigerant.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
the original amount of oil.
871RX020
4. If the amount of oil drained is much less than 90 cc

(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure
below.
(Charging Amount)
(Collected Amount)
more than 90cc (3.0 fl.oz)
same as collected
amount
90cc (3.0 fl.oz)
Oil Capacity
Capacity total in system: 150cc (5.0 fl.oz)
Compressor (Service parts) charging amount:
150 cc (5.0 fl.oz)
Checking and Adjusting Oil Quantity

for Used Compressor
1. Perform oil return operation. Refer to Oil Return
Operation in this section.
compressor.
7. Install the compressor, then evacuate, charge and

perform the oil return operation.
8. Check system operation.
When it is impossible to preform oil return
operation, the compressor oil should be checked in
the following order:
compressor.
3. Check the oil for contamination.
4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to
the compressor to be installed.
5. If the amount of oil extracted is less than 90 cc (3.0
fl. oz.), recheck the compressor oil in the following
order.
6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor
and install it onto the vehicle.
1A78
7. Evacuate and recharge with the proper amount of

refrigerant.
8. Perform the oil return operation.
9. Remove the compressor and recheck the amount of
oil.
10. Adjust the compressor oil, if necessary.
(Collected Amount)
(Charging Amount)
more than 90 cc (3.0 fl.oz) same as collected

amount
90 cc (3.0 fl.oz)
Checking
and
Adjusting
Compressor Replacement
for
150 cc (5.0 fl.oz.) of oil is charged in compressor

(service parts). So it is necessary to drain the proper
amount of oil from the new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove
the compressor.
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
(Amount of oil drained
from used compressor)
(Draining amount of oil

from new compressor)
Same as drained amount
more than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

6. Evacuate, charge and perform the oil return
operation.
7. Check the system operation.
Contamination of Compressor Oil

Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a long
period of time (approximately one season), the oil never
becomes contaminated as long as there is nothing
wrong with the compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
The capacity of the oil has increased.
The oil has changed to red.
Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor oil
is
contaminated.
Whenever
contaminated
compressor oil is discovered, the receiver/drier
must be replaced.
Oil Return Operation

There is close affinity between the oil and the
refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system. When
checking the amount of oil in the system, or replacing
any component of the system, the compressor must be
run in advance for oil return operation. The procedure is
as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to ON"
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts

When replacing the system component parts, supply
the following amount of oil to the component parts to be
installed.
(Component parts to be
installed)
(Amount of Oil)
Evaporator
50 cc (1.7 fl. oz.)
Condenser
30 cc (1.0 fl. oz.)
Receiver/dryer
30 cc (1.0 fl. oz.)
Refrigerant line (one

piece)
10 cc (0.3 fl. oz.)

COMPRESSOR
Model
Type
Number of vanes
Rotor diameter
DKV-14G
Vane rotary type
5
64 mm (2.52 in.)
Stroke
8.75 mm (0.34 in.)
Displacement
140 cc (47.3 fl.oz.)
Maximum speed
7,000 rpm (up to 8,400 rpm)
Lubrication system
Pressure differential type
Lubricant
HFC-134a Vane Rotary Type Compressor Oil

Be Equivalent to ZXL 200 PG
150 cc (5.0 fl.oz.)
Refrigerant
HFC-134a, 650 g (1.43 lbs.)
Shaft seal
Lip type
Weight
3.6 kg
MAGNETIC CLUTCH
Type
Rated voltage
Current consumption
Starting torque
Weight
Electromagnetic single-plate dry clutch

12 Volts D.C.
3.7 A
49 Nm (36 lbft)
2.4 kg (5.3 lbs.)
1A79
1A80
Nm (kgm/lb in)
871RY00038
1A81
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J-33939
Drive plate holder
J-24092-2
Pulley puller leg
J-33944-A
Drive plate puller
J-33940-A
Pulley installer
J-33944-4
Forcing screw
J-8092
Drive handle
J-38424
Pulley puller pilot
J-8433
Pulley puller
1A82
Automatic Air Conditioning System

General Description
Using a variety of sensors, this automatic heater and air
conditioner accurately senses outside air temperature,
solar
radiation
quantity,
evaporator's
blowing
temperature, and interior temperature, then enters
these data to the automatic heater/air conditioner
control unit (equipped with the built-in micro-computer).
The data provided to the control unit enables to
automatically control blow temperature and blow air
quantity, turn on or off the compressor and switch the

blow port as well as switching between the fresh air
intake and interior air circulation.
Resetting the automatic function allows you to switch to
the manual control mode.
The self-diagnoisis function of the automatic heater and
air conditioner control unit (with the built-in microcomputer) allows the unit to access and diagnose a
failed part easier and quicker.
Automatic Air Conditioner Parts Configuration
865RY00025
Legend
(1) Ambient Sensor
(2) Intake Actuator
(4) Duct Sensor
(5) Sun Sensor
(6) Mix Actuator
EndOFCallout
(7)
(8)
(9)
(10)
(11)
(12)
Mode Actuator
Heater Unit
In Car Sensor
Automatic Air Conditioner Control Unit
Max High Relay
Blower Unit
1A83
852RY00035
Legend
(2) O Ring
(4) Ambient Sensor
(5) Engine Hood Seal
(6) Receiver Dryer
EndOFCallout
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Pressure Switch
High Pressure Hose
Condenser Assembly
Condenser Fan
Compressor
Suction Line (Low Pressure Hose)
Drain Hose
1A84
Circuit Diagram
6VD1 Engine
D08RX145
1A85
D08RX146
1A86
D08RY00885
1A87
D08RX148
1A88
D08RX144
1A89
D08RX143
1A90
Functions and Features

Automatic interior temperature control
This function enables to maintain the interior
temperature at the level specified from the
temperature control switch despite of changes in
factors such as vehicle speeds, outside air
temperature and number of passengers.
Maximum cooling and heating function
You can select FC (Full cool, namely maximum cooling
temperature) or FH (Full heat, maximum heating
temperature) from the temperature control lever.
Automatic air flow control
Air flow is automatically and consecutively fine tuned
according to the specified interior temperature and
changes in aperture of the heater unit mix door.
Mode (blow port) control
This function automatically selects either one of the
VENT, BI-LEVEL, FOOT or DEF mode for the blow
port according to changes of temperature on the
blow port. Using the mode switch allows you to
select a desired blow port manually.
Intake (switching between the fresh air intake and
circulation of interior air) control
The intake (switching between fresh air intake and
circulation of interior air) mode automatically selects
either FRESH (fresh air intake), MIX or RECIRC
(interior air circulation) according to changes of the
blow port temperature. Using the intake switch
allows you to select a desired intake port manually
(in the manual operation, FRESH and RECIRC
modes alone are available). Pressing the DEF
(defrost) mode switch selects the FRESH (fresh air
intake).
Cooler start-up timing control
This function is used for maintaining the air flow at
LOW" level until the evaporator is sufficiently cooled
down. It is intended to prevent a large volume of hot
air being blowing into inside of a vehicle when the
cooler is turned on in hot summer season.
Heater start-up timing control
This function is used for maintained the air flow at
LOW" level and also for maintaining the defrost
mode until temperature of coolant in the heater core
is sufficiently heated. It is intended to prevent a large
volume of cool air being blown into inside of a vehicle
when the heater is turned on in cold winter season.
Solar radiation quantity offset control
The photodiode on the solar radiation sensor
determines solar radiation quantity accurately to
offset interior temperature quickly.
Switch position storing function
This function is used for storing switch positions being
selected in the immediately preceding operation,
namely the last time the ignition has been turned off.
It simplifies the setup procedures when restarting the
system.
Self-diagnosis function
The self-diagnosis function turned on from the panel
switch makes your troubleshooting easier (for detail
of this function,
Self-Diagnosis").
refer
to
the
section
titled
1A91
Automatic Air Conditioner Block Diagram
F01RY00006
1A92
Control Panel Layout
C01RW007
Legend
(1) Auto Switch
(2) Mode Switch
(3) DEF Switch
EndOFCallout
(4)
(5)
(6)
(7)
Intake Switch
Fan Switch
1A93
Air Control Functions
C01RX002
Legend
(1) Interior Air Intake
(2) Fresh Air Intake
(3) Evaporator Core
(4) Air Mix Door
(5) DEF Door
(6) VENT Door
EndOFCallout
(7)
(8)
(9)
(10)
(11)
(12)
Foot Door
Sub Air Mix Door
Heater Unit
Heater Core
Evaporator Unit
Blower Unit
1A94
Operation and Functions of Control Panel Switches

Auto Switch
1. Pressing this switch turns on the automatic control
mode. It resets all manual switches except that for
the fan control. However, when the Manual REC is
selected for the intake or the Manual Open is
selected, the modes are maintained.
2. It causes the A/C (air conditioner) to the ON mode
(this function, however, available only when the fan
is turned on and also the compressor is turned on
because of the given outside air temperature level).
Indication
The AUTO LED comes on.
Currently selected mode for the Mode and Intake are
respectively indicated.
The A/C LED remains turned on even if the

compressor has been turned off because of the given
outside air temperature level. Pressing the air
conditioning switch in this state turns off the A/C LED.
Mode Switch
1. Pressing the VENT, B/L or FOOT switch selects the
corresponding mode.
2. When the Auto is selected for the Mode and Intake,
pressing the mode switch fixes the Intake to the
immediately preceding status.
Indication
Turns off the Auto LED.
Currently selected blow port is indicated.
DEF Switch
Press this switch to select the DEF mode.
Blow port
Intake port
A/C
MIX
DEF
Auto FRESH *1
ON mode *2
Auto
*1: When the manual REC is selected for the Intake, the
manual REC is maintained.
*2: The ON mode is enabled only when the fun is turned
on, and also the compressor is turned on because of
the given outside air temperature level.
Indication
The Auto LED is turned off.
DEF is indicated for the blow port, A/C LED comes on
(only when the fan is turned on), and status display is
provided for the Intake and Cold Air Bypass.
F01RX006
1A95
Intake Switch
Pressing this switch sequentially selects a different
intake port in the following order.
F01RX005
Fan Switch
Indication
The Auto LED maintains unaffected.
Currently selected intake port is indicated.
1. Sets the fan to the specified mode.

2. Even when the fan switch is turned off, status
display for the Mode, Intake and Cold Air Bypass is
maintained.

1. This knob is operable only when the fan is turned
on. It may be used for the MAX control of each
block except the fan.
2. When the manual mode is selected for the fan
control, this manual mode is maintained.
F01RX007
MAX Control
Mix
Fan
Mode
Intake
Cold air
bypass
A/C
MAX/COOL
Full cool
MAX/HI
VENT
REC*1
OPEN*2
ON mode*3
MAX/HEAT
Full hot
AUTO/HI
FOOT*4
FRESH
CLOSE
Current status
is maintained
1A96
*1: In the A/C: OFF mode, FRESH shall be selected.

*2: When the fan is turned ON, CLOSE shall be
selected.
*3: The ON mode is available only when ON is selected
for the fan as well as for the cold outside air ON/OFF
selection.
*4: When the MAX control is selected from the DEF
mode, this DEF mode shall be maintained.
F01RX008
Indication
As long as the MAX control is selected, the
immediately preceding indication shall be maintained
for the AUTO.
Status display is provided for others.

Pressing this switch turns on or off the A/C (air
conditioning) control. (The compressor remains turned
off if the fan is turned off and also the compressor has
been turned off because of the given outside air
temperature level.)
Indication
1. The A/C LED remains turned on even if the
compressor has been turned off because of the
given outside air temperature level. In this case,
however, the AUTO or DEF switch must be turned
on and the A/C ON mode must also be turned on
(by the MAX/C mode).
2. Pressing the A/C switch from the above state (1)
turns off the A/C LED.
1A97
Overview of Construction, Movement

and Control of Major Parts of
Automatic Air Conditioner System
Automatic Heater/Air Conditioner Control
Unit
Equipped with the built-in micro-computer, this control
unit operates on signals from sensors and input signals
from switches to offer total control of the blower fan, and
actuators used for the mode door, intake door and air
mix door.
Its self-diagnosis function enables quicker access to a
failed part and its more accurate troubleshooting.
In Car Sensor
It is a sensor used for detecting room temperature of a
vehicle. This sensor converts a given room temperature
This in car sensor unites the power driven aspirator and
the motor fan so that a small amount of room air may be
constantly fed to the sensor.
This sensor is provided on the control panel.
875RY00021
Legend
(1) Ambient Sensor
EndOFCallout
Duct Sensor
The duct sensor is the sensor to detect temperature
change of the side of evaporator blower coming by fresh
recirculation of intake door or on" off" of compressor.
The temperature is converted to resistant rate.
And it works as thermostat to control to prevent freezing
of evaporator.
This sensor is installed in the upper case of evaporator.
865RX015
Legend
(1) In Car Sensor
(2) Automatic Air Conditioner Control Unit
EndOFCallout
Ambient Sensor
This sensor is used for detecting temperature outside
the vehicle. It converts a given outside air temperature
Thermal effects from the condenser and radiator during
idling after a run can be measured and offset the
automatic amplifier.
This sensor is provided on the side plate situated at
upper right side of the condenser.
874RX014
Legend
(1) Evaporator Core
(2) Duct Sensor
(3) Lower Case
(4) Upper Case
EndOFCallout
1A98
Sun Sensor
Max Hi Relay
It is a photodiode used for detecting quantity of solar

radiation.
This sensor converts the offset signal
generated by changes in the interior temperature (which
results from fluctuations in solar radiation) into
photoelectric current to enter into the automatic heater/
This sensor is provided at top of the defroster grill.
This relay turned on or off by the signal from the

automatic heater/air conditioner control unit. As the
Max Hi relay is turned on, supply voltage is directly fed
to the blower fan motor to select the Max Hi mode.
860RW028
865RW009
Legend
(1) Sun Sensor
Legend
(1) Blower Unit
(2) Max High Relay
EndOFCallout
Actuator
EndOFCallout
Power Transistor
Receiving base current from the automatic heater/air
conditioner control unit, the power transistor implements
stage-less speed change of the blower fan motor. This
transistor is provided on the evaporator.
The actuators are power driven type containing a small

motor. Receiving output current from the automatic
heater/air conditioner control unit, actuators drive the
heater and blower unit mode doors.
Actuators consist of the mode actuator used for
switching the mode (blow port selection), the mix
actuator used for changing aperture of the air mix door,
the intake actuator used for switching the intake
mode(fresh air/interior air) and the cold air bypassing
actuator.
874RX015
Legend
EndOFCallout
860RW029
1A99
Legend
(1) Mix Actuator
(2) Heater Unit
(3) Intake Actuator
(4) Mode Actuator
(5) Blower Unit
EndOFCallout
The actuator changes the motor speed using the gear
and drives each door rotating the output axis united with
the sliding contact.
C01RX016
Movement of Mix Actuator
860RW026
Legend
(1) Output Axis
(2) Motor
(3) Printed Circuit Board
(4) Sliding Contact
EndOFCallout
The mode and mix actuators are common actuators
with the built-in potentiometer. For the intake actuator,
the contact switch type is selected.
The potentiometer is a register assembled to the printed
circuit board of the mix and mode actuators. It detects
the air mix door position specified by rotation of the
output axis as a ratio of the variable terminal (VM)
voltage against the reference voltage (VDD: 5V), then
signals the value to the automatic heater/air conditioner
control unit.
Position of the air mix door is determined by the

controller on the automatic heater/air conditioner control
unit.
As the heat or cool side of the controller is grounded,
the transistor on the driver is activated and, thus, the
motor rotation is turned on.
The sliding contact
connected to the motor sends the position detection
signal from the potentiometer to the automatic heater/air
conditioner control unit. As the set temperature and
interior temperature are balanced, the controller returns
to the neutral and the motor rotation is stopped.
C-45
(+) side
(-) side
Rotation
direction
Remarks
Clockwise
Full heat side
Counter
clockwise
Full cool side
C01RX005
1A100
Movement of Mode Actuator
removed, thus stopping the motor.
As target position of the mode door is decided on the

controller of the control unit, the control unit reads the
position detection signal from the actuator to select the
clockwise or counter clockwise motor rotation direction.
Grounding the controller VENT or DEF side after the
direction selection activates the transistor on the driver,
thus turning on the motor rotation. Accompanying the
motor rotation, the sliding contact rotates, too. When
the target position is reached, the controller on the
control unit returns to the neutral and the motor stops.
Conduction pin
(+) side
(-) side
Rotation
direction
Remarks
Clockwise
VENT to DEF
direction
Counter
clockwise
DEF to VENT
direction
Grounding
terminal
Rotation
direction
Remarks
No.5 B-26
Clockwise
RE-CIRCULATI
ONMIXFRE
SH
C01RX006

Automatic Air Conditioner
The automatic heater and air conditioner on this vehicle
has the following features:
Interior temperature control.
Air flow control.
Mode (blow port) control.
Intake (switching between fresh air and interior air)
control.
Heater start timing control.
Cooler start timing control.
Compressor ON/OFF function according to outside
air temperature level.
Evaporator anti-freeze control.
Interior Temperature Control

C01RX017
Movement of Intake Actuator

The controller on the automatic heater/air conditioner
control unit selects an intake mode to be used.
As the Terminal No.5 B-26 is grounded via the sliding
contact on the terminal plate, the transistor on the driver
is activated, thus turning on the motor rotation. Then,
accompanying move of the motor, the sliding contact
rotates until grounding of the Terminal No.5 B-26 is

operates on the setup temperature signal from the
temperature control switch and other sensor signals to
derive the total signal. Then, the control unit compares
this signal against the signal from the potentiometer to
determine rotation direction of the mix actuator. The
mix actuator moves the air mix door to the aperture
specified by the total signal so that the specified interior
temperature is achieved.
If the compressor is turned off in the A/C (air
conditioning) mode, aperture of the air mix door is offset

according to the outside air temperature or the specified
interior temperature.
This function removes the
difference in the blowing temperature in this state and
that of when the compressor is turned on.
When FH or FC is selected for the setup temperature,
the air mix door is accordingly fixed to the Full Heat or
Full Cool mode.
When the VENT mode is selected, aperture of the air
mix door is controlled so that excessively heated air may
not be blown from the VENT blow port.
1A101
In the Manual Mode

Air flow specified from the fan switch is entered to the
automatic heater/air conditioner control unit as the
manual signal. The signal modifies the air flow to the
level specified from the fan switch so that the required
fan voltage is attained.
C01RY00008
Mode (Blow Port) Control

C01RY00015
Air Flow Control

In the Auto Mode
operates on the setup temperature signal and other
sensor signals to derive the total signal. Then, the
control unit adjusts base potential of the power
transistor to match it to the voltage pattern of the
target fan so that stage-less fan speed control can be
achieved.
When solar radiation quantity is detected in the VENT
or B/L mode, the control unit increases the minimum
fan voltage to offset.
When FH or FC is selected from the temperature
control switch, air flow is accordingly fixed to MAX HI
or AUTO HI.

operates on the setup temperature from the control
switch, and temperature and solar radiation quantify
from the sensors to determine the total mode control
signal. According to the pattern specified by this signal,
the control unit selects either one of the VENT,
BI-LEVEL, FOOT or DEF/FOOT mode.
The mode actuator determines the rotation direction
comparing the target position against the current
position being determined by the position detection
signal.
When FH or FC is selected for the temperature from the
temperature control switch, mode is accordingly fixed to
the VENT or FOOT.
In the manual operation of the mode switch, you can
select a desired blow port mode pressing the
corresponding mode switch.
1A102
Operating the DEF mode switch selects the DEF for

the blow port mode.
When the Mode Switch is depressed

If the automatic intake control is selected, the intake
is fixed to the currently selected mode.
C01RY00009
Intake (Fresh air/interior air switching)

Control
In the Full Auto mode, the automatic heater/air
conditioner control unit operates on the setup
temperature signal and other sensor input signals to
derive the total signal.
According to the pattern
specified by this signal, the control unit provides the
intake control.
When the fan is turned off or the A/C (air conditioning) is
turned off, the intake is fixed to the FRESH mode.
When FC or FH is selected from the control switch, the
intake mode is accordingly fixed to the RECIRC or
FRESH.
In the Manual Operation
Pressing the FRESH (fresh air intake) or the RECIRC
(room air circulation) accordingly selects the FRESH
or RECIRC mode.
When the DEF Mode Switch is depressed
The intake mode is fixed to the FRESH. When the
MANU REC is selected, however, the mode is fixed
the RECIRC.
C01RY00012
Compressor Control
In the automatic control mode, the automatic heater/air
conditioner control unit turns on or off the compressor
with the evaporator anti-freeze mechanism using the
evaporation sensor. And, when outside air is detected
to be low through the outside air temperature sensor
signal, the control unit turns off the compressor using
the compressor control function.
Manual Control
In the automatic control mode, pressing the A/C (air
conditioning) switch turns off the compressor.

Pressing the DEF mode switch automatically turns on
the compressor.
1A103
Cooling Start Timing Control

cooling is turned on only when the temperature
detected by the interior temperature sensor is 30C or
above and the total signal derived from the sensor
signals has detected that the cooling condition is met.
When the cooling condition has been met, the fan
voltage across the blower fan motor terminal is set to
4.5V for 7 seconds maximum, then it is linearly
increased up to the auto airflow level at the rate of 0.6V/
sec.
C01RY00010
Heating Start Timing Control

heating is turned on only when the coolant temperature
detected by the coolant temperature sensor is 18C or
less and total signal derived from the sensor signals has
detected that the heating condition is met.
If the coolant temperature detected by the sensor is
18C or less, 4.5V is set for the blower fan motor
terminal voltage and the DEF is selected for the blow
port mode.
When the temperature detected by the sensor is above
18C, the blow port mode is switched to the Auto
Control and the voltage across the blower fan motor
terminal is linearly increased from 4.5V to auto control
voltage (auto airflow).
840RX015
C06RX003
1A104
Troubleshooting
Troubleshooting, Its Overview and Procedures
The automatic heater and air conditioner equips with
the Self-Diagnosis Function" to check its major
components.
This function makes access to the sensors, actuators
and blower fan motor system easier when checking
them up and, when a failed part is located, this function
restores its original performance.
When
implementing
the
troubleshooting,
this
self-diagnosis function narrows the range to be
searched at the first step, then check relevant parts one

by one according to the Checking Procedures by Failed
Location".
As for a location this function is
unappreciable, the system accurately determines
characteristics of a given trouble and checks relevant
parts according to the Checking Procedures by Failed
Location".
The following illustrates basic troubleshooting flow.
Basic Troubleshooting Flow
F01RX009
1A105
Auto Air Conditioner Control Unit Power Supply Diagnosis

This check is required because a trouble on the auto
amplifier (control unit) power supply circuit or grounding
circuit prevents accurate troubleshooting.
D08RX284
Condition
Possible cause
Power source does not supply to auto

Correction
Refer to Chart A
1A106
Chart A": Check of Auto Amplifier Power Supply System

Step
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Disconnect the auto A/C control unit connector I20.

Approx. 12V
Go to Step 5
Go to Step 4

terminal No.I208.
Go to Step 4

Go to Step 7
Go to Step 6

and the ground No.B8.
Go to Step 5

Go to Step 9
Go to Step 8

the ground No.B8.
Go to Step 7
Turn the lighting switch on.

Approx. 12V
Go to Step 11
Go to Step 10
10
Repair an open circuit between the lighting switch and

terminal No.I2010.
Go to Step 9
11

Approx. 12V
Go to Step 12
Repair an open circuit between the fuse F5 and

terminal No.I207.
Verify repair
1
2
3
12

side
side
1A107
Performance and Movement checklist for Automatic Air Conditioner Related

Parts
Start the engine, and when the engine coolant reached
50C check performance and movement of the related
parts according the following checklist.
Performance Check Using the Manual Switch

No.
Item
Checking Approach
Condition
Operation
Auto switch must be

Blowing
temperature (check turned on (FAN-AUTO
movement of air MODE-AUTO)
mix door)
Airflow
volume Set temperature
(check movement 25.0C.
of the mode door)

off.
from LOW to HI.
1. Cold air shall be blown out.

2. Hot air shall be blown out.
1. The fan shall be stopped, thus

stopping air blow, too.
2. Airflow volume shall change from
LOW to HI.
Set temperature to Press the mode switch LED corresponding to each mode
Blowing
25.0C.
Set the fan to change the blow port shall be turned on and the blow port
temperature
mode sequentially from mode shall be switched smoothly.
(check movement knob to HI.
the
VENT
through
of the mode door)
BI-LEVEL, FOOT up to
DEF.
The interior/outside Set temperature
air switching mode 25.0C.
(check movement
of intake door)
Compressor
5
to
1. Select FC for the

setup temperature.
2. Select FH for the
setup temperature.
Then, select the
MAX Control.
Acceptance criteria
to Turn the LED off using The LED indication shall be switched
the interior/outside air from OFF to ON accompanying a
switch (this introduces change in air blowing sound.
the outside air intake
mode). Then, the set
fan knob to HI and
press
the
interior/
outside switch to turn
on the LED.
Set the temperature to Press the OFF" switch.

18.0C (FC). (Outside 1. Press the Auto
air temperature is 0C
switch.
or above and interior
2. Press
the
Air
temperature at ordinary
Conditioner switch.
temperature.)
1. As the fan knob is set to the Auto

position, the A/C switch LED
shall come on and the
compressor shall be turned on.
2. As the A/C LED comes off, the
compressor shall be turned off.
1A108
Check of Auto Function

No.
Item
Checking Approach
Condition
Operation
Acceptance criteria
The LED shall come on.
Cold air shall be blown out.
The following LEDs shall come on:
Select FC for the

temperature.
Auto function
FAN KNOB AUTO"

MODE SW AUTO"
Change the
temperature
gradually starting
with 18C up to
32C.
Select FH for the

temperature.
Blow port mode:

Intake mode
Fan speed: MAX
Hi
A/C
The following phenomena shall be
recognized.
Temperature of blown air: Cold air is
changed to hot air.
Change in the air flow volume.
The blow port mode LED indication
changes in the following sequence:
Cold air shall be blown out. The

following LEDs shall come on.
Blow port mode:
Fan speed: Max.
1A109
Troubleshooting With Self-Diagnosis Function

Overview of Self-Diagnosis Function
The self-diagnosis is implemented in 3 steps for each
target. For detail of check procedure contained in each
step, refer to the relevant section of Check Procedure
by Failed Location" listed in the Self-Diagnosis
Operation Procedure.
For turning on the self-diagnosis function and switching

of the check step, refer to the flow chart given below.
You can reset the self-diagnosis function by turning the
ignition switch off or turning the DEF switch on for 5
seconds.
Self-Diagnosis Operation Procedure

Step
Action
Value(s)
Yes
No
1. Set the IG to the OFF position.

2. Apply 60W bulb light to the solar radiation sensor.
3. Set the temperature setting lever on the automatic
heater/air conditioner panel to the center position
(25C).
4. Set the fan switch on the same panel to the Auto
position.
Go to Step 2
While holding both the Auto switch and the DEF

switch on the automatic heater/air conditioner panel,
turn the IG off and then on.
Is the current trouble diagnosing function turned on
approximately in 10 seconds?
Go to Step 3
Go to Step 4
Refer to *1.
Press the A/C switch once.

Go to Step 5
Refer to *2.
Go to Step 6
Repair or
replace the
output
equipment or
repair the
harness
Go to Step 1
Refer to *3 chart Check of Output Equipment".

Does each output equipment function normally
according to operation of the temperature setting
level?
Press the DEF switch for 5 seconds consecutively or

turn on and off the IG.
1A110
*1Displaying the Current Trouble Diagnosing Table

Start the engine while holding down both the Auto
switch and the DEF switch on the control panel, and the
table will appear in approximately 10 seconds to the
indicator lamp (LED) of the air conditioning switch.
Result of the diagnosis along the following 9 items will
be shown one by one in 0.5 second interval irrespective
of presence or absence of a trouble for a given item.
When the display 9 items is completed, it is repeated

with 3 seconds of interval in between. A failed item is
indicated by flashing of the LED that is repeated 3 times
within 0.5 seconds. If a trouble is indicated, you can
locate the failed section by knowing when in the total
sequence it has been displayed.
F01RX010
Item for Current Trouble Diagnosis
F01RY00008

As shown above, display of result along nine items is
repeated with 3-second interval in between.
Note 1: When checking the solar radiation sensor, apply
sufficient light using a 60W bulb. Otherwise, it can be
Note 2: If the temperature setting lever is set on both
1A111
ends (one set to 18C, blue scale = Full cool and the
other to 31C, red scale = Full hot), they can be
Note 3: Likewise, the fan switch can be diagnosed as
failed if set on both ends.
*2Displaying the Past Trouble Diagnosing Table

The past trouble diagnosis displays only the items on
which trouble has recurred 16 times in the past.
If you press the air conditioning switch once while the
current trouble diagnosis is taking place, display of the
past trouble diagnosis will appear on the indicator lamp
(LED) of the air conditioning switch.
Results of the diagnosis along the following five items
are displayed one by one in 0.5 second interval

irrespective of presence or absence of a trouble. A failed
item is indicated by flashing of the LED that is repeated
3 times within 0.5 seconds. You can locate the failed
section by counting in what sequence it has been
displayed.
F01RX011
F01RY00007
1A112
*3Check of Output Equipment
F01RX015
1A113
Inspection By Failed Location

Inspection of the Sensors
When the self-diagnosis function has determined that
trouble is present on the sensors, check them according
to the following flow chart.
F01RY00005
1A114
Chart 1: In Car Sensor
D08RY00888
Step
Action
Value(s)
Yes
No
Disconnect the in car sensor connector. (No.I-4)

Is performance of the sensor normal? (Refer to the
later section on Individual Inspection")
Go to Step 2
Replace the in
car sensor

Go to Step 4
Go to Step 3
Repair an open circuit between terminal No.441 and

No.I43.
Go to Step 2

Go to Step 6
Go to Step 5

and No.I44.
Verify repair

Verify repair
2
3
4
5
harness
harness
side
side
1A115
Chart 2: Ambient Sensor
D08RY00886
Step
Action
Value(s)
Yes
No
Disconnect ambient sensor connector. (No.C8)

Is performance of the ambient sensor normal? (Refer
to the later section on Individual inspection")
Go to Step 2
Replace the
ambient sensor
Connect the ambient sensor connector.

Refer to the
Is resistance between the harness side connector later section
No.I442 and No.I4411 normal?
on Individual
inspection"
Go to Step 4
Go to Step 3

No.C81 or No.I4411 and No.C82.
Verify repair

Verify repair
1A116
Chart 3: Sun Sensor
D08RY00887
Step
Action
Value(s)
Yes
No
Disconnect the sun sensor connector. (No.I50)

Is performance of the sun sensor normal? (Refer to
the later section on individual inspection)
Go to Step 2
Replace the
sun sensor.

Go to Step 4
Go to Step 4

No.502.
Go to Step 2

Go to Step 6
Go to Step 5

and I501.
Go to Step 4

Verify repair
2
3
4
5
side
side
1A117
Inspection of the Intake Actuator System
D08RX230
1A118

Condition
Possible cause
Correction
Refer to Chart A
Control failure
Refer to Chart B

Step
1
2
3
4
6
7
8
9
10
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Go to Step 4
Replace the
relay

Approx 12V
Go to Step 6
Go to Step 5

and No.X61.
Go to Step 4

Approx 12V
Go to Step 8
Go to Step 7
Go to Step 6
Go to Step 10
Go to Step 9
Repair an open circuit between No.I2011 and B264.

Verify repair

Verify repair

Is the relay X6 normal?
Replace the intake actuator motor.

connector terminal No.I2011 and No.B264?
side
1A119
Chart B: Failure on the Intake Control

Step
1
2
3
4
5
6
7
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Go to Step 4
Replace the
relay

Is the intake actuator stopped?
Go to Step 6
Go to Step 5
Replace or repair the auto air conditioner control unit.

Verify repair

Go to Step 8
Go to Step 7

and No.I4411.
Go to Step 6

Go to Step 10
Go to Step 9
Is the fuse No.C14 normal?

Is the relay No.X6 normal?
side
side

and No.I4412.
Go to Step 8
10

Go to Step 12
Go to Step 11

and I44-13.
Go to Step 10
12

Go to Step 14
Go to Step 13
13
Repair an open circuit between harness No.B262

and No.I4414.
Go to Step 12
Go to Step 15
Go to Step 16
Replace or repair the intake actuator.

Verify repair
Replace or repair the air conditioner control unit.

Verify repair
11
14
15
16
side
side
1. Disconnect the intake actuator connector No.B

26.
2. Is the battery voltage applied between harness
side connector terminal
No.B266 and ground?
No.B262 and ground?
No.B261 and ground?
1A120
Inspection of the Mix Actuator System
D08RX229
Condition
Possible cause
Correction
Refer to Chart A
Control failure
Refer to Chart B
1A121
Chart A: Does Not work At All

Step
Action
Value(s)
Yes
No

2. Disconnect the mix actuator connector (C45).
3. Short-circuit the chassis harness side connector
terminal No.C452 and No.C457.
4. Using the temperature control lever, select FH for
the temperature.
No.C458 (-) and No.C456 (+)?
Go to Step 3
Go to Step 2
Varify repair
Go to Step 5
Go to Step 4
Verify repair
Go to Step 7
Go to Step 6

No.C458.
Go to Step 5

Go to Step 9
Go to Step 8

No.C456.
Verify repair
Replace the mix actuator.

Verify repair
2
3
4
5
6
7
8

Using the temperature control lever, select FC for the
temperature.
No.C458 (+) and No.C456 (-)?
side
side
1A122
Chart B: Mix Actuator Control Failure

Step
Action
Value(s)
Yes
No
Turn the ignition switch (the engine is run).

Dose the mix actuator fully stroke when FH and FC of
the temperature control lever?
Go to Step 3
Go to Step 2
Repair or replace the air mix door or the link unit.

Varify repair
Go to Step 5
Go to Step 4

and No.I4411.
Go to Step 3

Go to Step 7
Go to Step 6

and No.I445.
Go to Step 5

Go to Step 9
Go to Step 8

and No.I4415.
Go to Step 7
Is sum of the voltage between the following chassis

harness side connector terminals approximately 5V?
No.I4415 and No.I525, No.I445 and No.I4411
Go to Step 11
Go to Step 10
10

Verify repair

Verify repair
2
3
4
11

side
side
1A123
Inspection of the Mode Actuator System
D08RX228
Condition
Possible cause
Correction
Refer to Chart A
Control failure
Refer to Chart B
1A124

Step
Action
Value(s)
Yes
No

2. Disconnect the mode actuator connector (C48)
3. Select VENT pressing the mode actuator.
between the harness side connector terminal
No.C481 (+) and No.C485 (-)?
Go to Step 3
Go to Step 2

Varify repair
Turn on the DEF mode switch.

between the chassis side connector terminal No.C48
5 (+) and No.C481 (-)?
Go to Step 5
Go to Step 4
Varify repair
Go to Step 7
Go to Step 6

and No.I204.
Go to Step 5

Go to Step 9
Go to Step 8
Verify repair
Verify repair
2
3
4
5
6
7
8

side
side

and No.I203.
Replace the mode actuator.
1A125
Chart B: Mode Actuator Control Failure

Step
Action
Value(s)
Yes
No

Dose the mode actuator fully stroke when the defrost
mode and the vent mode are selected?
Go to Step 3
Go to Step 2
Repair or replace the mode door or the link unit.

Go to Step 1
Go to Step 5
Go to Step 4

and No.I4411.
Go to Step 3

Go to Step 7
Go to Step 6
2
3
4

side
side

and No.I4410.
Go to Step 5

Go to Step 9
Go to Step 8

and No.I448.
Go to Step 7
Is sum of the voltage between the following harness

side connector terminal approximately 5V? Voltage
between No.I448 and No.I4410 plus voltage
between No.I448 and No.I4411
5V
Go to Step 11
Go to Step 10
10

Verify repair
Dose the mode actuator work normally through

manual operation?
Go to Step 13
Go to Step 12
12
Replace the sensor.

Verify repair
13

Verify repair
11
1A126
Inspection of the Fan Motor System
D08RX227

Condition
Possible cause
1A127
Correction
The fan dose not rotate at all
Refer to Chart A
The fan dose not rotate in the MAX

HI mode
Refer to Chart B
The fan dose not rotate in any mode

other than MAXHI
Refer to Chart C
The fan dose not stop
Refer to Chart D
Chart A: Fan Does Not Rotate At All

Step
1
2
3
5
6
7
8
9
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
relay

Go to Step 5
Go to Step 4

No.F4 fuse.
Go to Step 3

Go to Step 7
Go to Step 6

ground.

side connector terminal No.B51 and No.B52?
Go to Step 8
Go to Step 9
Replace the blower motor.

Verify repair
Refer to chart B and C.

Verify repair
Are the fuse No.F4 and No.F5 normal?

Are the relay No.X6 and No.B25 normal?
1A128
Chart B: Fan Does Not Rotate in MAX HI Mode

Step
1
2
4
5
6
7
8
9
10
Action
Value(s)
Yes
No
Go to Step 2
Replace the
relay

2. Set the fan switch to the MAX-HI.
connector terminal No.B51 and No.B252?
Go to Step 4
Go to Step 3

No.B252.
Go to Step 3

Go to Step 6
Go to Step 5

and ground (No.B8).
Go to Step 4

Go to Step 8
Go to Step 7

and No.F5 fuse.
Go to Step 6

Go to Step 10
Go to Step 9

and No.I2012.
Verify repair

Verify repair
Is the MAX-HI relay (B25) normal?
1A129
Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI
Step
Action
Value(s)
Yes
No
Is the power transistor performance normal? (Refer to

the later section on individual inspection")
Go to Step 2
Replace the
power transistor

connector terminal No.B51 and No.B351, No.B51
and No.I4417?
Go to Step 4
Go to Step 3
Repair an open circuit between terminal.

No.B51 and B351
No.B51 and I4417
Go to Step 2

Go to Step 6
Go to Step 5

and ground.
Go to Step 4

Go to Step 8
Go to Step 7

and No.I4419.
Go to Step 6

Verify repair
side
Chart D: Fan Does Not Stop

Step
Action
Value(s)
Yes
No
1. Disconnect the max high relay, the power

transistor connector B35 and the auto A/C
control unit connector I44.
2. Turn on the ignition switch.
Does the blower motor stop?
Go to Step 3
Go to Step 2
Repair a short circuit between connector No.B51 and

No.B252, No.B51 and No.B351, or No.B51 and
I4417.
Verify repair
Is the max high relay normal? (Refer to the later

Go to Step 4
Replace the
relay
Reinstall the max high relay.

Go to Step 6
Go to Step 5
Repair a short circuit between connector No.B253

and No.I2012.
Go to Step 4
Is the power transistor normal? (Refer to the later

Go to Step 7
Replace the
power transistor
Replace the
auto A/C control
unit
3
4
5
6
7
Reinstall the power transistor.

1A130
Inspection of the Magnetic Clutch System

6VD1 Engine
D08RX226

Condition
Possible cause
Magnetic clutch does not work
1A131
Correction
Refer to Chart A
Chart A: Magnetic Clutch Does Not work

Step
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fuse
Go to Step 3
Replace the
fuse
Go to Step 4
Replace the
thermo unit
Go to Step 5
Replace the
pressure switch
1. Turn the ignition switch on. (the engine is run.)

2. Push the air conditioner switch on.
side connector terminal No.E31 and the ground?
Go to Step 6
Go to Step 7
Repair or replace the magnetic clutch.

Verify repair
Go to Step 9
Go to Step 8

No.E31.
Go to Step 7

2 and ground?
Go to Step 11
Go to Step 10

fuse No.F5, No.X42 and fuse No.F5.
Go to Step 9

Go to Step 13
Go to Step 12

and No.X44.
Go to Step 11

Go to Step 15
Go to Step 14

and fuse No.F5.
Go to Step 13

5 and ground?
Go to Step 17
Go to Step 16

No.C111, No.X55 and fuse No.F5.
Go to Step 15

Go to Step 19
Go to Step 18

I2014.
Go to Step 17

Is the relay No.X4 (compressor relay) No.X5 (A/C
thermo relay) and No.X6 (heater relay) normal?
Is the thermo unit normal?
Is the pressure switch normal?

connector terminal No.X41 and No.E31?
side
1A132
Chart A: Magnetic Clutch Does Not work (Contd)

Step
19
20
21
22
Action
Value(s)
Yes
No
Go to Step 21
Go to Step 20

No.E191.
Go to Step 20
Dose the thermo relay ON" when connecting ground

to the harness connector terminal No.H175?
Go to Step 23
Go to Step 22
Failure on the auto air conditioner control unit.

Verify repair

connector terminal No.I444 and ground?
CAUTION:
There are conditions which air
as follows.
1. The throttle is griater than 90%.
3. The engine speed greater than 4500 RPM for 5
than 125C (257F).
(41F).
pressure condition.
side
1A133
Condenser Fan Diagnosis

condenser fan stops when the air conditioning is turned
OFF" or when the pressure goes down below the set
pressure value.
While the air conditioning is ON, the cycling switch in

the triple pressure switch senses the refrigerant
pressure, and activates the condenser fan to improve
the cooling capacity of the condenser when the
refrigerant pressure exceeds a set pressure value. The
D08RX255
Condition
Possible cause
Correction
Condenser fan does not run.
Refer to Chart A
Condenser fan does not stop.
Refer to Chart B
1A134
Chart A" Condenser Fan Does Not Run

Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Action
Value(s)
Yes
No
Go to Step 2
Replace the
fusible link wire
Go to Step 3
Replace the
fuse
Is the heater relay (No.X6) and condenser fan relay

(No.X9) normal?
Go to Step 4
Replace the
relay
1. Disconnect the condenser fan motor connector

No.C24.
2. Connect the motor side connector terminal
No.C241 to the battery positive terminal and
No.C242 to the battery negative terminal.
Dose the fan operate?
Go to Step 6
Go to Step 5
Repair or replace the condenser fan motor.

Go to Step 4

connector terminal No.C242 and ground (C16)?
Go to Step 8
Go to Step 7

and No.C16.
Go to Step 6

connector terminal No.C241 and No.X91?
Go to Step 10
Go to Step 9

and No.X91.
Verify repair

side connector terminal No.X95 and ground?
Go to Step 12
Go to Step 11

No.FL2.
Go to Step 10

Go to Step 14
Go to Step 13

No.C113.
Go to Step 12

Go to Step 16
Go to Step 15

and No.I2014.
Verify repair
Connect the harness side connector terminal

No.C241 to the battery terminal and No.C242 to the
battery negative terminal.
Is the battery voltage between the pressure switch
Go to Step 18
Go to Step 17

Verify repair

Verify repair
Is the fusible link No.FL2 normal?

side
side
1A135
Chart B" Condenser Fan Does Not Stop

Step
Action
Value(s)
Yes
No
1. Turn on the ignition switch ON" (the engine is

run).
2. Air conditioning switch OFF".
3. Disconnect the triple pressure switch.
Does the condenser fan stop?
Go to Step 2
Go to Step 3

Verify repair
Go to Step 4
Go to Step 5
Repair short circuit between terminal No.X94 and

No.C113.
Verify repair
Replace the relay condenser fan.

Verify repair
2
3
Disconnect the relay.

connector terminal No.X94 and ground?
side
1A136
Sun Sensor
In Car Sensor
1. Disconnect the in car sensor connector (I4).
2. Measure resistance between the in car sensor side
terminal No.I43 and No.I44.
1. Disconnect the sun sensor connector (I50).

2. Measure the current value on the sun sensor when
placed it
approximately 15 cm away from 60W
incandescent lamp.
C01RX013
865RX007
1A137
Ambient Sensor
1. Disconnect the connector (C8) on the ambient
sensor.
2. Measure resistance between the ambient sensor
side terminals.
C01RX015
MAX HI Relay
1. Remove the MAX HI relay connector (B25) from
the blower assembly.
2. Check the conduction between the MAX HI relay
side terminals.
C01RX012
Power Transistor
1. Remove the power transistor connector (B35) from
the evaporator assembly.
2. Check the conduction between the power transistor
side terminals.
C01RX014
In Car Sensor
1. Turn on the ignition switch (the engine is started).
Start the air conditioner in Full Auto".
2. Make sure that the interior sensor suctions cigarette
smokes and such.
1A138
In Car Sensor
1. Dismount the in car sensor from the automatic
heater/air
conditioner control unit. Connect (+)
end and (-) end of the battery to the aspirator motor
side terminals No.I41 and No.I42, respectively,
then check if the motor runs normally.
Heater (X6), Thermostat (X5), Condenser

Fan (X9) And Compressor (X4) Relay
in this section.
901RX071
Condenser Fan
1. Disconnect the condenser fan connector.
2. Connect the battery positive terminal to the
condenser fan side connector
terminal No.C24-2
and negative to the No.C24-1.
3. Check that condenser fan is rotating correctly.
C01RW020
875RW010

1. Disconnect the connector and check for continuity
between pressure switch side connector terminals
(1) and (2).
2. Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connector terminal (3) and (4) and the
fan operates.
875RX009
1A139
1A140
On-Vehicle Service
Power Transistor
Automatic Heater/Air
Control Unit
Conditioner
874RY00029
Legend
(2) Passenger knee bolster Reinforcement
(3) Power Transistor Connector
(4) Glove Box
EndOFCallout
Removal
2. Remove passenger knee bolster reinforcement.
3. Disconnect the power transistor connector.
4. Remove power transistor.
Installation
865RW016
Legend
(1) Connector
(5) Instrument Lower Cover
EndOFCallout
Removal
2. Remove instrument lower cover.
Structure section.
unit attaching screws.
5. Pull the automatic heater/air conditioner unit out and
disconnect the connectors.
Installation
In Car Sensor
1A141
Ambient Sensor
865RW014
Legend
(1) In Car Sensor
875RY00022
Legend
(1) Ambient Sensor
(2) Radiator Grille
EndOFCallout
EndOFCallout
Removal
Removal

unit.
Refer to the automatic heater/air conditioner
control unit section.
3. Remove in car sensor.
Installation

Refer to Radiator Grille in Body Structure section.
3. Disconnect the ambient sensor connector.
4. Remove the ambient sensor.
Installation
1A142
Sun Sensor
Electronic Thermostat
865RW009
Legend
(1) Sun Sensor
EndOFCallout
Removal
2. Remove the sun sensor.
3. Disconnect the sun sensor connector.
Installation
874RW027
Legend
(1) Duct Sensor
(3) Thermostat Assembly
EndOFCallout
Removal
Refer to Evaporator Assembly section.
3. Remove electronic thermostat.
Installation
Mode Actuator
1A143
Mix Actuator
860RW030
Legend
(1) A/T Control Unit
(2) Mode Actuator
(3) Actuator Rod
EndOFCallout
860RW033
Legend
(2) Instrument Panel Center Cluster
(3) Actuator Rod
(4) Mix Actuator
EndOFCallout
Removal
2. Remove the A/T control unit.
The connector shall remain connected.
4. Remove the mode actuator.
Installation
Removal
2. Remove the instrument panel assembly.
Structure section.
3. Remove the instrument panel center cluster.
5. Remove the mix actuator.
Installation
1A144
Intake Actuator
860RX018
Legend
(2) Intake Actuator
(3) Intake Actuator Connector
EndOFCallout
Removal
2. Remove the blower assembly.
Refer to Blower Assembly section.
3. Disconnect the intake actuator connector.
4. Remove the intake actuator.
Installation
SECTION
2A1
STEERING
CONTENTS
Diagnosis .......................................................
Power Steering System Test .........................
Maintenance ..................................................
Fluid Level .....................................................
Bleeding The Power Steering System ...........
Bleeding Procedure .......................................
Flushing The Power Steering System ...........
Steering Wheel Free Play Inspection ............
Front End Alignment Inspection
and Adjustment ..........................................
Special Tools .................................................
Power Steering Unit ......................................
Power Steering Unit and Associated Parts.
Removal .....................................................
Installation ..................................................
Power Steering Unit Disassembled View ...
Disassembly ...............................................
Reassembly ................................................
Special Tools .................................................
Power Steering Pump ...................................
Power Steering Pump and
Removal .....................................................
Installation ..................................................
Disassembly ...............................................
Reassembly ................................................
Transfer Gear Assembly ...............................
2A - 2
2A - 2
2A - 8
2A - 10
2A - 11
2A - 11
2A - 11
2A - 11
2A - 12
2A - 12
2A - 12
2A - 16
2A - 17
2A - 18
2A - 18
2A - 18
2A - 19
2A - 20
2A - 20
2A - 20
2A - 20
2A - 21
2A - 21
2A - 22
2A - 22
2A - 22
2A - 22
2A - 23
2A - 23
2A - 24
2A - 24
2A - 26
2A - 27
and Associated Parts ..............................

Removal......................................................
Installation...................................................
Wheel & Column........................................
SRS Connectors .........................................
Inflator Module ..............................................
Inflator Module and Associated Parts .........
Removal......................................................
Installation...................................................
Steering Wheel..............................................
Steering Wheel and Associated Parts ........
Removal......................................................
Installation...................................................
Combination Switch ......................................
Combination Switch and Associated Parts .
Removal......................................................
Installation...................................................
Lock Cylinder ................................................
Lock Cylinder and Associated Parts ...........
Removal......................................................
Installation...................................................
Steering Column ...........................................
Steering Column and Associated Parts ......
Removal......................................................
Insepction ...................................................
Installation...................................................
Wheel & Column and Associated Parts.....
Special Tools .................................................
2A - 27
2A - 27
2A - 27
2A - 27
2A - 28
2A - 28
2A - 28
2A - 30
2A - 30
2A - 30
2A - 31
2A - 31
2A - 32
2A - 32
2A - 32
2A - 34
2A - 35
2A - 35
2A - 35
2A - 37
2A - 39
2A - 39
2A - 39
2A - 41
2A - 42
2A - 43
2A - 43
2A - 43
2A - 46
2A - 47
2A - 48
2A - 49
2A - 49
2A - 49
2A2
Service Precaution
YOU ARE
IN
REPAIRS.

and systems.
Diagnosis
Since the problems in steering, suspension, wheels and
tires involve several systems, they must all be
considered when diagnosing a complaint. To identify
the symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and
correct any defects which are found.
1. Inspect tires for proper pressure and uneven wear.
2. Raise vehicle on a hoist, then inspect front and rear
suspension and steering linkage for loose or
damaged parts.
3. Spin the front wheels. Inspect for out-of-round tires,
out-of-balance tires, loose and/or rough wheel
bearings.
General Diagnosis
Condition
Vehicle Pulls
Wheel Hop
Possible cause
Correction
Replace tire.
Replace spring.
Replace tire.
Repair brake.

suspension parts.

suspension part(s).

defective.
Replace spring.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire.

Condition
Hard Steering
Possible cause
2A3
Correction

wheel.
Replace tire.


suspension parts.

suspension parts.
Adjust preload.

defective.

upper or lower end ball joint.
Replace ball joint.
Repair or replace.

operation.
Repair or replace.
Refer to Power steering system
diagnosis"

universal joint.
Bind in upper or lower end ball

joints.
Repair or replace.
Retighten.
Worn wheel bearing.
Replace.
2A4

Condition
Abnormal Noise
Possible cause
Correction

ball joint, steering linkage ball joints
Replace.
Replace.

bushing.
Replace.
Loose wheel nuts.

wheel nut holes.
Replace wheel if required.

bearings.
Replace spring.

pressure.

bushings.
Leaking caliper.
Warped discs.
Replace brake disc.
Replace brake pads.

Power Steering System
There is some noise in all power steering systems. One
of the most common is a hissing sound when the
steering wheel is fully turned and the car is not moving.
This noise will be most evident when the steering wheel
is operated while the brakes are applied. There is no
Condition
Rattle or Chucking Noise
2A5
relationship between this noise and steering

performance. Do not replace the valve unless the
hissing" noise is extremely objectionable. A
replacement valve will also have a slight noise, and is
not always a cure for the condition.
Possible cause
Correction
Pressure hose touching other parts

of vehicle.
Adjust hose position. Do not bend

tubing by hand.
Tie rod ends loose.
Tighten or replace tie rod end.
Loose steering unit mounting.
Tighten steering unit mounting.
Improper front wheel alignment.
Adjust front wheel alignment.
Wheel bearing worn.
Replace front wheel bearing.
Tie rod end binding.
Replace tie rod end.
Ball joint binding.
Replace ball joint.
Tight or frozen steering shaft

bearing.
Replace steering assembly.
Sticky or plugged steering unit valve.
Entry of air in the power steering

system.
Bleed the system.
Momentary Increase In Effort When

Turning Wheel Fast To Right or Left
Replenish fluid.
Steering Wheel Surges or Jerks

When Turning Especially During
Parking
Replenish fluid.
Excessive Wheel Kick Back or

Loose Steering
Air in system.
Tie rod end loose.
Tighten tie rod end.
Wheel bearing worn.
Excessive internal pump leakage.
Excessive internal steering gear

leakage.
Replenish fluid.
Pressure switch of the power

steering pump or its harness is
faulty.
Repair or replace.
Poor Return of Steering Wheel to

Center
Hard Steering or Lack or Power

Assist
Unstable Engine Idling or Stalling

When Turning
2A6
Power Steering Pump

Foaming milky power steering fluid, low fluid level, and
possible low pressure can be caused by air in the fluid,
or loss of fluid due to internal pump leakage. Check for
leak and correct. Bleed the system. Extremely cold
Condition
Low Pressure Due to Steering Pump
temperatures will cause air bubbles in the system if the

fluid level is low. If the fluid level is correct and the pump
still foams, remove the pump from the vehicle and
check housing for cracks. If the housing is cracked,
replace the pump housing.
Possible cause
Correction
Relief valve sticking or inoperative.
Side plate not flat against cam ring.
Replace side plate.
Extreme wear of cam ring.
Replace cam ring.
Cracked or broken side plate.
Replace side plate.
Repair internal leakage.
Low Pressure Due to Steering Gear
Scored housing bore.
Replace housing.
Growling Noise In Steering Pump
Excessive back pressure in hoses or

steering unit caused by restriction.
Repair steering unit or pump.
Worn cam ring.
Replace cam ring.
Air in the fluid.
Low fluid level.
Replenish fluid.
Pump mounting loose.
Tighten mounting bolt.
Vane improperly installed.
Repair rotor and vane.
Swishing Noise In Steering Pump
Damaged relief valve.
Whining Noise In Steering Pump
Scored side plate and vanes.
Replace side plate and vanes.
Groaning Noise In Steering Pump
Rattling Noise In Steering Pump
Steering Column Lock System

Condition
Will Not Unlock
Will Not Lock
Key Cannot be Removed in

OFF-LOCK"
Possible cause
Correction
Damaged park lock cable.
Lock spring broken or worn.
Ignition switch stuck.
Repair or replace ignition switch.
Park lock cable damaged.
Ignition switch is not set correctly.
Correct ignition switch.
Faulty shift lock mechanism.
Repair or replace the shift lock

mechanism.
Column
Condition
Noise in Column
Possible cause
Correction
Universal joint loose.
Tighten joint.
Shaft lock snap ring not seated.
Place snap ring in proper position.

Turn Signal Switch
This diagnosis covers mechanical problems only. Refer
Condition
Turn Signal Will Not Stay In Turn
Position
2A7
to Turn Signal Switch in Electrical section for electrical

diagnosis.
Possible cause
Correction
Foreign material or loose parts

preventing movement of yoke.
Repair or replace signal switch.
Broken or missing detent or

canceling spring.
Replace signal switch.
Loose switch mounting screws.
Switch or anchor bosses broken.
Broken, missing or out of position

detent, return or canceling spring.
Worn canceling cam.
Turn signal switch arm loose.
Tighten arm screw.
Broken or distorted yoke.
Loose or misplaced springs.
Foreign parts and/or material.
Repair turn signal switch.
Loose turn signal switch mounting

screws.
Broken lane change pressure pad or

spring hanger.
Broken, missing or misplaced lane

change spring.
Base of wire damaged.
Hazard Switch Cannot Be Turned

Off
Foreign material between hazard

switch to turn signal switch body.
Repair or replace hazard switch.
No Turn Signal Lights
Electrical failure in chassis harness.
Refer to Electrical section.
Inoperative turn signal flasher unit.
Replace flasher unit.
Burned-out or damaged turn signal

bulb.
Replace bulb.
High resistance connection to

ground at bulb socket.
Repair bulb socket.
Turn Signal Will Not Cancel
Turn Signal Difficult To Operate
Turn Signal Will Not Indicate Lane

Change
Front or Rear Turn Signal Lights Not

Flashing
2A8
General Description
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering unit, a pressure hose
and a return hose.
Power Steering Unit
A02RW007
The power steering unit is rack and pinion type.

The toein angle can be adjusted by turning the rod on
each side.
The steering housing cannot be disassembled.
Hydraulic Pump
A02RX002

The hydraulic pump is vane-type design. The
submerged pump has housing and internal parts that
are inside the reservoir and operate submerged in oil.
There are two bore openings at the rear of the pump
housing. The larger opening contains the cam ring,
pressure plate, thrust plate, rotor and vane assembly,
and end plate. The smaller opening contains the
pressure line union, flow control valve and spring.
The flow control orifice is part of the pressure line union.
The pressure relief valve inside the flow control valve
limits the pump pressure.
2A9
Pressure Switch
When hydraulic pressure reaches 3430 kPa (35 kg/cm2/
500 psi), the pressure switch of the power steering
pump closes causing the Engine Control Module (ECM)
to actuate the idle air control valve, which increases the
engine rpm to prevent the overload-induced engine
speed slow down. The switch opens when hydraulic
pressure drops to 2940 kPa (30 kg/cm2/430 psi).
Steering Column
431RY00009

TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT
BATTERY-POWERED OR A/C-POWERED
VOLT-METER, OHMMETER, ETC., OR ANY TYPE
OF ELECTRICAL EQUIPMENT OTHER THAN
INSTRUCTION IN THIS MANUAL MUST BE

INJURY MAY RESULT.
When servicing a vehicle equipped with Supplemental
Restraint System, pay close attention to all WARNINGS
and CAUTIONS.
section.
2A10
The steering column has three important features in

addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of

the vehicle.
The column can be disassembled and reassembled.
However, to insure the energy absorbing action, use
only the specified screws, bolts and nuts as designated,
and tighten them to the specified torque.
Handle the column with care when it is removed from
the vehicle. A sharp blow on the end of steering shaft or
Power Steering System Test

Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
EndOFCallout
Test of fluid pressure in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, if
necessary, must be made.
Inspect pump reservoir for proper fluid level.
Inspect pump belt for proper tension.
Inspect pump driver pulley condition.
(3) Power Steering Unit

1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5884001350 as
shown in the illustration. The gage must be
between the shutoff valve and pump. Open the
shutoff valve.
3. Check the fluid level. Fill the reservoir with power
steering fluid, to the Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.

4. Bleed the system. Refer to Bleeding the Power
Steering System in this section.
5. Start the engine and check the fluid level. Add
power steering fluid if required. When the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.
6. Fully close the shutoff valve. Record the highest
pressures.
If the pressure recorded is within 93009800 kPa
(95100 kg/cm2/13501420 psi), the pump is
functioning within its specifications.
If the pressure recorded is higher than 9800 kPa
(100 kg/cm2/1420 psi), the valve in the pump is
defective.
If the pressure recorded is lower than 9300 kPa
(95 kg/cm2/1350 psi), the valve or the rotating
group in the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the power
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regular
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must
be completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight.
Make sure the clips, clamps and supporting tubes and
hoses are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding
the Power Steering System in this section.
Inspect belt for tightness.
2A11
Inspect pulley for looseness or damage. The pulley

should not wobble with the engine running.
Inspect hoses so they are not touching any other
parts of the vehicle.
Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55C
(130F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to Bleeding the Power Steering
System in this section.
Bleeding The Power Steering System

When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the power
steering fluid system, noisy and unsatisfactory
operation of the system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only
power steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel
right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.
2A12
Flushing The Power Steering System

1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoir
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which may
cause a sudden fluid overflow at the reservoir.
4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the power
steering system components. Do not re-use any
drained power steering fluid.
Front End Alignment Inspection and

Adjustment
General Description
Front End Alignment" refers to the angular relationship
between the front wheels, the front suspension
attaching parts and the ground.
Proper front end alignment must be maintained in order
to insure efficient steering, good directional stability and
to prevent abnormal tire wear.
The most important factors of front end alignment are
wheel toe-in, wheel camber and axle caster.
Camber:
This illustration shows view from the front of the vehicle.
Steering Wheel Free Play Inspection
480RS004
Camber is the vertical tilting inward or outward of the

front wheels. When the wheels tilt outward at the top,
the camber is positive (+). When the wheels tilt inward
at the top, the camber is negative (-). The amount of tilt
measured in degrees from the vertical is called the
camber angle (1). If camber is extreme or unequal
between the wheels, improper steering and excessive
tire wear will result. Negative camber causes wear on
the inside of the tire, while positive camber causes wear
to the outside.
430RW020
1. With the tires in the straight-ahead position, check

the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running.
Free play: 0 30mm (0 1.18in)
2. Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. When test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.

Caster:
This illustration shows view from the side of the vehicle.
2A13
Toe-in is the measured amount the front wheels are turn

in. The actual amount of toe-in is normally a fraction of
a degree. Toe-in is measured from the center of the tire
treads or from the inside of the tires. The purpose of
toe-in is to insure parallel rolling of the front wheels and
to offset any small deflections of the wheel support
system which occurs when the vehicle is rolling forward.
Incorrect toe-in results in excessive toe-in and unstable
steering. Toe-in is the last alignment to be set in the
front end alignment procedure.
Inspection
480RS005
Caster (1) is the vertical tilting of the wheel axis either

forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt
is negative (-). On the short and long arm type
suspension you cannot see a caster angle without a
special instrument, but if you look straight down from the
top of the upper control arm to the ground, the ball
joints do not line up (fore and aft) when a caster angle
other than 0 degree is present. With a positive angle,
the lower ball joint would be slightly ahead (toward the
front of the vehicle) of the upper ball joint center line.
Toe-in:
This illustration shows view from the top of the vehicle.
480RS003
Before making any adjustments affecting caster, camber

or toe-in, the following front end inspection should be
made.
1. Inspect the tires for proper inflation pressure. Refer
to Main Data and Specifications in Wheel and Tire
System section.
2. Make sure that the vehicle is unladen condition
(With no passenger or loading).
3. Make sure that the spare tire is installed at the
normal position.
4. Inspect the front wheel bearings for proper
adjustment. Refer to Front Hub and Disc in
Driveline section.
5. Inspect the ball joints and tie rod ends. If excessive
looseness is noted, correct before adjusting. Refer
to Steering Linkage in this section.
6. Inspect the wheel and tires for run-out. Refer to
Wheel Replacement in Wheel and Tire System
section.
7. Inspect the trim height. If not within specifications,
the correction must be made before adjusting
caster.
8. Inspect the steering unit for looseness at the frame.
9. Inspect shock absorbers for leaks or any noticeable
noise. Refer to Shock Absorber in Suspension
section.
10. Inspect the control arms or stabilizer bar attachment
for looseness. Refer to Suspension section .
11. Inspect the front end alignment using alignment
equipment. Follow the manufacturer's instructions.
12. Park the vehicle must be on a level surface.
2A14
Trim Height Adjustment
Caster Adjustment
Adjust the trim height (1) by means of the adjusting bolt

The caster angle can be adjusted by means of the

caster shims (1) installed between the chassis frame
(2) and fulcrum pins.
CAUTION: When adjusting front end alignment, be

sure to begin with trim height first, as it may change
other adjusted alignments.
Caster angle: 230' 1

30'.
450RS003
450RW006
410RS001
1. Check and adjust the tire inflation pressures.

2. Park the vehicle on a level ground and move the
front of the vehicle up and down several times to
settle the suspension.
3. Make necessary adjustment with the adjusting bolt
Trim height: 119 5mm (4.69 0.2in)
450RS002
NOTE: Difference of the caster shim front/rear

thickness should be 3.6mm (0.142in) or less. Overall
thickness of caster shim and camber shim should be
10.8mm (0.425in) or less.
2A15
Camber Adjustment
The camber angle can be adjusted by means of the
camber shims (2) installed in position between the
chassis frame (1) and fulcrum pins
Camber angle: 0 30'
King pin inclination: 1230' 30'
30'.
450RS005
NOTE: Overall thickness of caster shim and camber

shim should be 10.8mm (0.425in) or less.
450RW007
Position of shims
Caster shim
Camber shim
Camber angle
Caster angle
When removed
Decreases
Decreases
When removed
When added
Increases
Increases
When removed
Unchanged
Decreases
When added
Unchanged
Increases
When added
Decreases
Unchanged
When removed
Increases
Unchanged
Front side
Rear side
When added
2A16
Toe-in Adjustment
1. To adjust the toe-in angle, loosen the lock nuts (2)
on the tie rod (1) and turn the tie rod. Turn both rods
the same amount, to keep the steering wheel
centered .
Toe-in: 0 to +2mm (0 to +0.08in)
433RW006
2. Tighten the lock nut to the specified torque.


230' 1
Caster
0 30'
Camber
1230' 30'
King pin inclination

Toe-in
Max. steering angle
0 to +2mm (0 to +0.08in)
inside
32.6 (+030' to 230' )
outside
31.8
2A17
E02RX006
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884001350
(J29877A)
Tester;
Power steering
ILLUSTRATION
TOOL NO.
TOOL NAME
5884022970
(J39213)
Adapter;
Power steering tester
2A18
Power Steering Unit

Power Steering Unit and Associated Parts
431RW026
Legend
(1) Bracket
(3) Power Steering Unit Assembly

(4) Crossmember
EndOFCallout
Removal
2. Remove the transfer gear assembly.
Make a setting mark across the coupling flange and
steering unit to ensure reassembly of the parts in
the original position.
3. Drain power steering fluid.
4. Remove the tie rod end assembly from knuckle.
Use tie rod end remover 5884020050.
901RW270

5. Disconnect the feed line and return line from
steering unit.
Remove the clips on the crossmember and frame.
Wire the power steering line to frame.
NOTE: Take care to prevent foreign matter from entry
when disconnect the power steering line.
6. Remove the torsion bar. Refer to Front Suspension
7. Remove the lower control arm bolt (Frame side).
8. Apply a setting mark across the crossmember and
frame so parts can be reassembled in their original
position.
431RX013
9. Remove the crossmember fixing bolt.

10. Remove the power steering unit with the
crossmember.
11. Remove the power steering unit.
Installation
1. Install power steering unit to crossmember.
Tighten fixing bolt to specified torque.
2. Install power steering unit with crossmember to
frame by aligning the setting marks made when
removing.
Tighten crossmember mounting bolt to specified
torque.
3. Install lower control arm bolt.
4. Install torsion bar.
5. Connect the feed line and return line.
2A19
6. Install tie-rod end assembly to knuckle.

7. Install transfer gear assembly.
Align the setting marks made at removal.
9. Bleed the system.
section.
2A20
Power Steering Unit Disassembled View
440RW005
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Tie-rod End
Lock Nut
Clip
Bellows
Band
Tie-rod Assembly
(7)
(8)
(9)
(10)
(11)
Tab Washer
Oil Line
Valve Housing Assembly
Mounting Rubber
Dust Cover
EndOFCallout
Disassembly
Tie-rod Assembly
NOTE: The valve housing is made of aluminum and

care should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
1. Loosen lock nut and remove tierod end.
2. Remove clip and band, then remove bellows.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.
If the resistance is insufficient or play is felt when

checked by moving the ball on the tie-rod, replace the
tie-rod assembly.

Inspect the following parts for wear, damage or any
abnormal conditions.
Tie-rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.
Rubber Parts
If wear or damage is found through inspection, replace
with new ones.
Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
After tightening, bend tab washer against width
across flat of inner ball joint.
2A21

installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.

Power Steering unit
Type
Rack and pinion
Rack stroke
152mm (5.98in)
Lock to lock
3.64
E02RX007
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884020050
(J29107)
Tie rod end remover
2A22
Power Steering Pump

Power Steering Pump and Associated Parts
436RX001
Legend
(1) Pump Assembly
(2) Hose, Suction
(3) Hose, Flexible

(4) Bolt
EndOFCallout
Removal
1. Remove the drive belt.
2. Place a drain pan below the pump.
3. Disconnect the suction hose.
4. Disconnect the flexible hose.
5. Remove the power steering fixing bolt and remove
the pump assembly.
Installation
1. Install the pump assembly to the pump braket,
tighten the fixing bolt to the specified torque.
2. Install the flexible hose.
Tighten the eye bolt to specified torque.
3. Install the drive belt.
4. Connect the suction hose, then fill and bleed
system.
section.
2A23
442RX001
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Bolt
Suction Pipe
O-ring
Shaft Assembly
Oil Seal
Front Housing
O-ring
O-ring
Side Plate
Rotor and Vane
Pin
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Cam
Pump Cartridge Assembly
O-ring
Snap Ring
Rear Housing
Bolt
Spring
Relief Valve
O-ring
Connector
Pressure Switch Assembly
EndOFCallout
Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent).
Be careful not to expose the oil seal of shaft
assembly to solvent.
2. Remove the bolt, suction pipe and O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the pressure switch assembly.
5. Remove the bolt, rear housing and O-ring.

7. Remove the shaft assembly.
8. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
9. Remove the pump cartridge assembly from the front
housing.
10. Remove two O-rings.
2A24
Cam
Make all necessary adjustments, repairs, and part

The inner face of the arm should have a uniform contact

pattern without a sign of step wear. When part
Rotor
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger
nail.
The parts with minor scores may be reused after
lapping the face.
Relief Valve
The sliding face of the valve must be free from burrs and
damage. The parts with minor scores may be reused
after smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.
442RS002
Check that the groove in the vane is free from excessive

wear and that the vane slides smoothly. When part
Vane
O-ring, Oil Seal, Snap Ring

Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts for
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
442RS003
Sliding faces of the vane should be free from wear.

(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install roter and vanes to cam.

5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
11. Install suction pipe with a new O-ring. Be sure to
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
14. Install pressure switch assembly and tighten it to
specified torque.
2A25
2A26

Oil pump
Type
Operating
fluid
Vane
ATF DEXRONIII
E02RX008
2A27

Transfer Gear Assembly and Associated Parts
441RW002
Legend
(2) Bolt, Universal Joint (Steering Shaft Side)
(3) Fixing Bolt Nut
(4) Shim
(5) Bolt, Universal Joint (Steering Unit Side)
EndOFCallout
Removal
1. Apply a setting mark across the universal joint and
transfer gear so parts can be reassembled in their
original position.
2. Remove universal joint bolt (steering shaft side).
3. Remove universal joint bolt (steering unit side).
4. Loosen fixing bolt and nut and remove transfer gear
assembly with shim.
Installation
1. Install transfer gear assembly with shim by aligning
the setting marks made when removing.
2. Tighten bolt and nut to the specified torque.
3. Connect universal joint (both side) and tighten the

The transfer gear assembly cannot be disassembled. If
damage or abnormal condition are found, replace to
new ones.
2A28
Supplemental Restraint System Steering Wheel & Column

Service Precaution
This steering wheel and column repair section covers
the Supplemental Restraint System (SRS) steering
column. The following repair procedures are specific to
SRS components. When servicing a vehicle equipped
with Supplemental Restraint System, pay close
attention to all WARNINGS and CAUTIONS.
section.
SAFE HANDLING OF INFLATOR MODULES
REQUIRES FOLLOWING THE PROCEDURES
DESCRIBED BELOW FOR BOTH LIVE AND
DEPLOYED MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWED
WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE
AIR BAG ASSEMBLY (AIR BAG) 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 POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) 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.
WHEN CARRYING A LIVE AIR BAG ASSEMBLY,

MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY AN
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 A LIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
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.
TO
AVOID
DEPLOYMENT
WHEN
TROUBLESHOOTING THE SRS SYSTEM, DO NOT
BATTERY-POWERED
OR
A/C-POWERED
VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL
EQUIPMENT
OTHER
THAN
INJURY MAY RESULT.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit.
When removing the cable harness, do not pull the
cables. Otherwise, cable disconnection may occur.
When connect the SRS connector, insert the
connector completely. Imperfect locking may cause
malfunction of SRS circuit.
2A29
Removal
Installation
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).
To install the connector, hold the soket insulator(1) and

insert it. The cover insulator slides and connector will be
locked.
Do not hold the cover insulator(2).
827RW028
827RW027
2A30
Inflator Module
Inflator Module and Associated Parts
827RW071
Legend
(1) Horn Lead
(2) SRS Connector
(3) Fixing Bolt

(4) Inflator Module
EndOFCallout
Removal
at least 5 minutes.
released from steering assembly .
827RW070

2A31
The inflator module consists of a cover, air bag, inflator,

and retainer. Inspect the inflator module mainly for the
following:
Check for holes, cracks, severe blemishes and
deformation on the cover.
Check that the retainer is not deformed.
Check for defects such as damage and breakage in
the lead wire for the igniter.
If an abnormality is found as the result of the inspection,
replace the inflator module with a new one.
Installation
1. Install inflator module.
module connector and horn lead.
827RW073


OTHERWISE, PERSONAL INJURY MAY RESULT .
827RW072

6. Set ignition to ON" while watching warning light.
Light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints
section.
2A32
Steering Wheel
Steering Wheel and Associated Parts
827RW069
Legend
(1) Horn Lead
(2) SRS Connector
(3) Steering Wheel
(4) Steering Wheel Fixing Nut

(5) Inflator Module
EndOFCallout
CAUTION: Once the steering column is removed
from the vehicle, the column is extremely
susceptible to damage. Dropping the column
assembly on its end could collapse the steering
shaft or loosen the slide block which maintains
column rigidity. Leaning on the column assembly
could cause the jacket to bend or deform. Any of
the above damage could impair the column's
collapsible design. If it is necessary to remove the
steering wheel, use only the specified steering
wheel puller. Under no conditions should the end of
the shaft be hammered upon, as hammering could
loosen slide block which maintains column rigidity.
Removal
at least 5 minutes.

2A33

original position, then remove steering wheel.
430RW021
827RW070

behind the inflator module.

then use steering wheel remover 5852100160 to
remove the steering wheel.
absorbing unit.
430RX005
827RW073

8. Remove steering wheel fixing nut.
2A34
Installation
made when removing.
absorbing unit.
torque.
4. Support the module and carefully connect the SRS
connector.
wire from being pinches.
warning light. Light should flash 7 times and then go
off. If lamp does not operate correctly, refer to
Restraints section.
2A35
Combination Switch
Combination Switch and Associated Parts
431RW028
Legend
(1) Steering Column Cover
(2) Steering Wheel
(3) Inflator Module
(4) Combination Switch and SRS Coil Assembly

(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)
EndOFCallout
Removal
at least 5 minutes.

LOCK" position before disconnecting the steering
the coil assembly.
6. Remove the driver knee bolster (reinforcement).
2A36

released from steering assembly. Disconnect the
yellow 2-way SRS connector and horn lead located
behind the inflator module, then remove inflator
module.
WARNING: The INFLATOR MODULE SHOULD

827RW070
827RW072

wheel.
827RW073
430RW021

absorbing unit.
2A37
Installation
under the steering column. Then turn the SRS coil
counter clockwise to full, return about 3 turns and
align the neutral mark.
the SRS coil.
430RX005

under the steering column then remove combination
switch and SRS coil assembly.
825RW288
825RW016
2A38

harnesses do not catch on any moving parts.
3. Align the setting marks made when removing then

install steering wheel.
absorbing unit.
torque.
5. Support the inflator module and carefully connect
the SRS connector and horn lead.
825RW017
Legend
(1)
(2)
(3)
(4)

EndOFCallout

8. Install instrument panel lower cover then Install the
9. Connect the SRS connector.
10. Connect the battery -" terminal cable.
warning light and check the light should flash 7
times and then go off. If lamp does not operate
correctly, refer to Restraints section.
2A39
Lock Cylinder
Lock Cylinder and Associated Parts
431RW027
Legend
(1)
(2)
(3)
(4)
(5)
Inflator Module
Steering Wheel
Snap Ring
(6)
(7)
(8)
(9)
(10)
Cushion Rubber
Shift Lock Cable (for A/T)
EndOFCallout
Removal
at least 5 minutes.

"LOCK" position before disconnecting the steering
the coil assembly.
5. Remove the engine hood opening lever and steering
lower cover.
2A40


original position.
430RW021
827RW070


then use steering wheel remover 5852100160
to remove the steering wheel.
absorbing unit.
827RW073
430RX005

2A41

16. Remove shift lock cable (for A/T).
located under the steering column then remove lock
cylinder assembly.
Installation
2. Install shift lock cable (for A/T).
5. Install Combination switch and SRS coil assembly.
Forced further turning may damage the cable in the
SRS coil.
827RW072

coil.
825RW016
825RW288
2A42

to wire (through each harness) as illustrated so that
the harnesses starter switch, combination switch
and SRS coil may not catch wiring.

made during removal.
absorbing unit.
torque.
10. Support inflator module and carefully connect the
SRS connector and horn lead, then install inflator
module.
11. Tighten fixing bolts to specified torque.
825RW017
Legend
(1)
(2)
(3)
(4)

EndOFCallout

13. Install instrument panel lower cover, then install the
System Inspection
light.
2A43
Steering Column
Steering Column and Associated Parts
431RW029
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Inflator Module
Steering Wheel
Snap Ring
Cushion Rubber
(7)
(8)
(9)
(10)
(11)
(12)

Shift Lock Cable (For A/T)
Steering Column Assembly
Second Steering Shaft
EndOFCallout
Removal
at least 5 minutes.

CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to become uncentered which
will cause damage to the SRS coil assembly.
2A44


wheel.
430RW021
827RW070

430RX005

827RW072

coil.
assembly, which can not be replaced singly. Therefore,
be sure not to remove the SRS coil from the
2A45
18. Apply a setting mark (1) across the universal joint

and transfer gear to reassemble the parts in their
original position, then remove steering column
assembly and second shaft.
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft
universal joint.
825RW288

16. Remove shift lock cable (For A/T).
located under the steering column, then remove
lock cylinder assembly.
431RW009
2A46
Insepction
Column Tube
If the abnormal conditions are found through inspection,

Check for collapes by measuring the distance as shown

in the figure.
Standard distance: 162.2-165.8 mm (6.386-6.528
in)
Column Capsule
Check capsules on steering column bracket assembly;
all must be securely seated in bracket slots and checked
for any loose conditions when pushed or pulled by hand.
431RY00010
Column Universal Joint for Tilt Mechanism

431RW030
Check clearance between capsule and bracket. If must

be within 1mm (0.039 in).

Sheared Injected Plastic Pin

Check the sheared injected plastic pins for any loose
conditions or damage.
431RW031
431RY00011
2A47
Shaft Length
Tilt Mechanism
Check the shaft length from the center of the universal

joint to the end of the shaft. If column length is not in
specifications, steering column should be replaced.
Tilt mechanism should moves smoothly.

While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.
Standard length: 662.2-664.2 mm (26.149-26.228

in)
Installation
1. Install steering column assembly and second
steering shaft.
2. Align the setting marks on the universal joint and
transfer gear made during removal.
3. Tighten the steering column fixing bolt (dash panel)
4. Tighten the steering column fixing nuts (cross
431RY00012
Shaft Universal Joint (Lower End)

Shaft Bellows Pipe

Check the shaft bellows pipe for bend by using straight
edge. Measure the clearance between the bellows pipe
and the straight edge (at center of the bellows pipe).
Standard: Less than 1mm (0.039 in)
431RW035

7. Install shift lock cable (For A/T).
2A48

13. Install steering wheel and align the setting marks

made when removing.

the SRS coil.

absorbing unit.
torque.
module connector and horn lead, then install inflator
module.
825RW016

harnesses do not catch any moving parts.

18. Install instrument panel lower cover.
20. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
System Inspection
light.
825RW017
Legend
(1)
(2)
(3)
(4)

EndOFCallout
2A49
Supplemental Restraint System Steering Wheel & Column and

Associated Parts
430RY00006
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5852100160
(J29752)
Steering wheel remover
SECTION
FRONT SUSPENSION
3C1
SUSPENSION
FRONT SUSPENSION
CONTENTS
Diagnosis ....................................................
Shock Absorber.............................................
Removal .....................................................
Installation ..................................................
Stabilizer Bar.................................................
Removal .....................................................
Installation ..................................................
Torsion Bar....................................................
Torsion Bar and Associated Parts ..............
Removal .....................................................
Installation ..................................................
Knuckle .........................................................
Knuckle and Associated Parts ....................
Removal .....................................................
Installation ..................................................
Upper Control Arm ........................................
3C - 1
3C - 2
3C - 2
3C - 5
3C - 5
3C - 5
3C - 5
3C - 5
3C - 6
3C - 6
3C - 6
3C - 6
3C - 6
3C - 7
3C - 7
3C - 7
3C - 8
3C - 8
3C - 10
3C - 10
3C - 10
3C - 11
3C - 11
3C - 13
Service Precaution
REPAIRS.
Upper Control Arm and Associated

Parts........................................................
Removal......................................................
Installation...................................................
Lower Control Arm ........................................
Lower Control Arm and Associated
Parts........................................................
Removal......................................................
Installation...................................................
Upper Ball Joint .............................................
Upper Ball Joint and Associated Parts .......
Removal......................................................
Installation...................................................
Lower Ball Joint .............................................
Lower Ball Joint and Associated Parts .......
Removal......................................................
Installation...................................................
Special Tools .................................................
3C - 13
3C - 13
3C - 14
3C - 14
3C - 17
3C - 17
3C - 17
3C - 18
3C - 19
3C - 21
3C - 21
3C - 21
3C - 22
3C - 22
3C - 23
3C - 23
3C - 23
3C - 24
3C - 24
3C - 25
3C - 26

and systems.
3C2
FRONT SUSPENSION
General Description
The front suspension is designed to allow each wheel to
compensate for changes in the road surface level
without greatly affecting the opposite wheel. Each
wheel is independently connected to the frame by a
steering knuckle, ball joint assemblies, and upper and
lower control arms. The front wheels are held in proper
relationship to each other by two tie-rods which are
connected to steering arms on the knuckles, and to a
steering unit.
All models have a front suspension system consisting of
control arms, stabilizer bar, shock absorber and a
torsion bar. The front end of the torsion bar is attached
to the lower control arm. The rear of the torsion bar is
mounted into a height control arm at the crossmember.
Vehicle trim height is controlled by adjusting this arm.
Shock absorbers are mounted between the brackets on
the frame and the lower control arms. The lower portion
of each shock absorber is attached to the lower control
arm. The upper portion of each shock absorber extends
through a frame bracket and is secured with two rubber
bushings, two retainers and a nut.
Ball joint assemblies are bolted to the outer end of the
upper and lower control arm and are attached to the
steering knuckle.
The inner ends of the upper control arm have pressed in
bushings. Bolts, passing through the bushing, attach the
control arm to the frame. The inner ends of the lower
control arm are attached to the frame by bolts passing
through the bushings.
Side roll of the front suspension is controlled by a spring
steel stabilizer bar. It is mounted in rubber bushings,
which are held to the frame by brackets. The ends of
the stabilizer bar are connected to the lower control
arms by links.
Diagnosis
Condition
Vehicle Pulls
Wheel Hop
Possible cause
Correction
Replace tire.
Replace spring.
Replace tire.
Repair brake.

suspension parts.

suspension part(s).

defective.
Replace spring.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire.
FRONT SUSPENSION
Condition
Hard Steering
Possible cause
3C3
Correction

wheel.
Replace tire.


suspension parts.

suspension parts.
Adjust preload.

defective.

Replace ball joint.
Repair or replace.

operation.

section.

universal joint.
Repair or replace.
Adjust pressure.
Retighten.
Worn wheel bearing.
Replace.
3C4
FRONT SUSPENSION
Condition
Abnormal Noise
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction

Replace.
Replace.

bushing.
Replace.
Loose wheel nuts.

required.

bearings.
Replace spring.

pressure.

bushings.
Leaking caliper.
Warped discs.
Replace brake disc.
Replace brake pads.
Vehicle overloaded.
Reduce load.
Incorrect springs.
Vehicle overloaded.
Reduce load.
Replace springs.

replace bushings.

mounting.
Vehicle overloaded.
Reduce load.
Worn ball joints.
FRONT SUSPENSION
3C5
Shock Absorber
450RW009
Legend
(1) Nut
(3) Bolt and Nut
(4) Shock Absorber

EndOFCallout
Removal
stands.
4. Remove nut.

Shock absorber
Rubber bushing
Installation
2. Install shock absorber.
5. Install bolt and nut, then tighten to the specified
torque.
3C6
FRONT SUSPENSION
Stabilizer Bar
410RW007
Legend
(1) Rubber Bushing
(2) Bracket
(3) Link
(4) Nut
(5) Stabilizer Bar
EndOFCallout
Removal
4. Remove nut.
CAUTION: Be careful not to break the ball joint
boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.

Stabilizer bar
Rubber bushing
Link ball joint
Installation
3. Install bracket, then tighten it to the specified torque.
4. Install link.
FRONT SUSPENSION
3C7
Torsion Bar
Torsion Bar and Associated Parts
410RS003
Legend
(1) Adjust Bolt, End Piece and Seat
(2) Height Control Arm
(3) Torsion Bar
EndOFCallout
Removal
2. Apply the setting marks(1) to the adjust bolt and end
piece, then remove adjust bolt, end piece and seat.
410RS004
3C8
FRONT SUSPENSION
3. Apply the setting marks(2) to the height control arm

and torsion bar, then remove height control arm.
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks(3).
410RS005
4. Apply the setting marks(3) to the torsion bar and

lower control arm, then remove torsion bar.
410RS007
410RS006
410RS006

Torsion bar
Height control arm
Adjust bolt
Rubber seat
FRONT SUSPENSION
2. Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks(2).
3C9
4. Apply grease to the serrated portions.

5. Install adjust bolt and seat, then turn the adjust bolt
to the setting mark(1) applied during disassembly.
section.
410RS005
3. Apply grease to the bolt portion of the end piece(4).

Apply grease to the portion of the seat(5) that fits
into the bracket.
410RS004
410RS008
3C10
FRONT SUSPENSION
Knuckle
Knuckle and Associated Parts
410RW006
Legend
(1)
(2)
(3)
(4)
(5)
Torsion Bar
Lower Ball Joint
Back Plate
Knuckle Assembly
Knuckle
(6)
(7)
(8)
(9)
(10)
Needle Bearing
Thrust Washer
Oil Seal
Upper Ball Joint
Wheel Speed Sensor
EndOFCallout
Removal
this section.
3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.
4. Remove the hub assembly. Refer to Front Hub and

Disk in this section.
5. Remove tierod end from the knuckle. Refer to
7. Loosen torsion bar by height control arm adjust bolt,
then remove torsion bar. Refer to Torsion Bar in this
section.
FRONT SUSPENSION
8. Remove wheel speed sensor.
9. Remove back plate.
10. Remove lower ball joint by using remover 58840
20050.
3C11
15. Remove needle bearing by using remover 58840

20000 and sliding hammer 5884000190.

boot.
901RW272
901RW271
11. Remove upper ball joint by using remover 58840

21210.
boot.

Knuckle
Knuckle arm
Needle bearing
Thrust washer
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and install
needle bearing by using installer 5884021280
and grip 5884000070.
901RW273
12. Remove knuckle assembly.

14. Remove washer.
901RW275
3C12
FRONT SUSPENSION
2. Apply multipurpose type grease to the thrust

washer, and install washer with chamfered side
facing knuckle.
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g). Then use installer 5884021270 and grip 5
884000070 to install oil seal. After fitting the oil
seal to the installer, drive it to the knuckle using a
hammer or bench press until the tool front face
contacts with the thrust washer.
901RW274
4. Install knuckle assembly.

5. Install upper ball joint and tighten the nut to the
6. Install lower ball joint and tighten the nut to the
Torque: 147Nm (15.0kgm/lbft)
7. Install back plate.
8. Install wheel speed sensor.
9. Install torsion bar, refer to Torsion Bar in this section.
Alignment Inspection and Adjustment in Steering.
FRONT SUSPENSION
3C13
Upper Control Arm

Upper Control Arm and Associated Parts
450RW005
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Bolt and Plate

Camber Shims
Caster Shims
Nut Assembly
Upper Control Arm Assembly
Fulcrum Pin
(7)
(8)
(9)
(10)
(11)
(12)
Bushing
Plate
Nut
Speed Sensor Cable
Nut and Cotter Pin
Upper Ball Joint
EndOFCallout
Removal
this section.
3. Remove the brake caliper and disconnect brake

pipe. Refer to Disc Brakes in Brake section.
5. Remove speed sensor cable.
6. Remove nut and cotter pin then remove knuckle
3C14
FRONT SUSPENSION

boot.
901RW276
16. Remove fulcrum pin.

901RW273

8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut.
14. Remove plate.
15. Remove bushing by using remover 5884002560.

through inspection.
Upper control arm
Bushing
Fulcrum pin
Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5884002560
and 5884023070.
901RW277
901RW278
FRONT SUSPENSION
3C15
5. Install upper control arm assembly with the fulcrum

pin projections turned inward.
901RW279
3. Install plate.
4. Install nut and tighten fulcrum pin nut fingertight.
NOTE: Torque fulcrum pin nut after adjusting buffer
clearance.
450RS013
Legend
(1) Projection
(2) Outward
EndOFCallout
6. Install the caster shims(2) between the chassis
7. Install the camber shims(1) between the chassis
450RS012
450RS014
3C16
FRONT SUSPENSION
8. Install nut assembly.

9. Install bolt and plate, then tighten the bolt to the
specified torque.
10. Install upper ball joint and tighten it to the specified
torque.
11. Install nut and cotter pin then tighten the nut to the
FRONT SUSPENSION
3C17
Lower Control Arm

Lower Control Arm and Associated Parts
450RW010
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Nut, Front
Bush, Front
Bolt, Front
Nut, Rear
Bush, Rear
Bolt, Rear
Bolt, Lower Ball Joint
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Bolt, Torsion Bar Arm

Torsion Bar Arm Bracket
Torsion Bar
Lower Control Arm
Lower Ball Joint
Shock Absorber
Stabilizer Link
EndOFCallout
Removal
this section.

3C18
FRONT SUSPENSION
6. Remove front nut.

7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control
arm.
11. Remove the shock absorber lower end from the
lower control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove front bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 58840
21230.
19. Remove rear bushing by using remover 58840

21240.
901RW051
901RW154
901RW052

Lower control arm
Bushing
901RW155
FRONT SUSPENSION
Installation
1. Install rear bushing by using installer 588402124
0.
3C19
3. Install lower ball joint bolt.

4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install front bolt.
8. Install lower ball joint and tighten it to the specified
torque.
9. Install shock absorber and tighten it to the specified
torque.
10. Install stabilizer link and tighten it to the specified
torque.
11. Install torsion bar arm bracket and tighten it to the
specified torque.
901RW053
2. Install front bushing by using installer 58840

21230.
12. Install Torsion bar, refer to Torsion Bar in this

section.
13. Install rear nut and tighten lower link nut fingertight.
buffer clearance.
901RW156
450RS012
3C20
FRONT SUSPENSION
14. Install front nut then tighten lower link nut

finger-tight.
buffer clearance .
section.
450RS012
FRONT SUSPENSION
3C21
Upper Ball Joint

Upper Ball Joint and Associated Parts
450RW004
Legend
(1) Bolt and Nut
(2) Upper Ball Joint
EndOFCallout
Removal
3C22
FRONT SUSPENSION
3. Remove upper ball joint nut and cotter pin, then use
remover 5884021210 to remove the upper ball
boot.

Starting torque: 0.5 3.2Nm (0.050.33kgm/0.4
2.4lbft)
450RS024
901RW273

If the above limits specified are exceeded, replace the

ball joint assembly.
Installation

through inspection.
confirm its normal movement.
450RS023
1. Install upper ball joint.

2. Install bolt and nut, then tighten them to the
specified torque.
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque
FRONT SUSPENSION
3C23
Lower Ball Joint

Lower Ball Joint and Associated Parts
450RW011
Legend
(1) Bolt
(2) Lower Ball Joint
(3) Nut
EndOFCallout
Removal
this section.
6. Remove lower ball joint nut and cotter pin, then use
remover 5884020050 to remove the lower ball
boot.
901RW271
3C24
FRONT SUSPENSION
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.

Starting torque: 0.56.4Nm (0.050.65kgm/0.4
4.7lbft)

corrosion or any other abnormal condition are found
through inspection.
confirm its normal movement .
450RS024
If the above limits specified are exceeded, replace

the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut and tighten it to the specified torque.
450RS026
4. Install ball joint nut, then tighten it to the specified

torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
FRONT SUSPENSION
3C25

Front suspension
Type
Torsion bar spring
Length
Front shock absorber
Stabilizer bar
Independent wishbone arms, torsion bar spring

with stabilizer bar.
1142mm (45.0in)
Diameter

Type
Piston diameter
30.0mm (1.18in)
Stroke
125.0mm (4.92in)
Compressed length
255.0mm (10.04in)
Extended length
380.0mm (14.96in)
Diameter

E03RX006
3C26
FRONT SUSPENSION
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884020000
(J23907)
Remover;Needle bearing
5884000190
Sliding hammer
5884002560
(J29775)
Remover and Installer
Upper arm bushing
5884021280
(J36838)
Installer; Needle bearing
5884021230
(J36833)
Lower arm front bushing
5884000070
(J8092)
Grip
5884021240
(J36834)
Lower arm rear bushing
5884021270
(J36837)
Installer; Oil seal
5884021210
(J36831)
Ball joint remover
5884023070
(J39376)
Installer; Upper arm
bushing
5884020050
(J29107)
Tie-rod end remover
SECTION
REAR SUSPENSION
3D1
SUSPENSION
REAR SUSPENSION
CONTENTS
Diagnosis ....................................................
Coil Spring.....................................................
Coil Spring and Associated Parts ...............
Removal .....................................................
Installation ..................................................
Shock Absorber.............................................
Removal .....................................................
Installation ..................................................
Trailing Link...................................................
Trailing Link and Associated Parts .............
Removal .....................................................
Installation ..................................................
3D- 1
3D- 1
3D- 2
3D - 5
3D- 5
3D- 5
3D- 6
3D- 6
3D - 7
3D- 7
3D- 7
3D- 7
3D- 7
3D - 8
3D- 8
3D- 8
3D- 8
3D- 9
Service Precaution
REPAIRS.
Upper Link .....................................................

Upper Link and Associated Parts ...............
Removal......................................................
Installation...................................................
Lateral Rod....................................................
Lateral Rod and Associated Parts ..............
Removal......................................................
Installation...................................................
Stabilizer Bar .................................................
Removal......................................................
Installation...................................................
Special Tools .................................................
3D - 10
3D- 10
3D- 10
3D- 10
3D- 11
3D - 12
3D- 12
3D- 12
3D- 12
3D- 13
3D - 14
3D- 14
3D- 14
3D- 14
3D- 15
3D- 16
3D- 18

and systems.
General Description
The rear suspension is a 5-link, coil spring type
suspension with a stabilizer bar, consisting of two
trailing links, two upper links, lateral rod, shock
absorber, and stabilizer. In this suspension, the links
are specially arranged to enable the rear axle to move
freely, thereby expanding suspension stroke, reducing
friction, and improving lateral rigidity and roll control.
All these result in improved stability, riding comfort, and
rough road maneuverability.
Each link connects the axle housing with the frame
through a runner bushing.
The axle housing is
supported by the trailing links and upper links
longitudinally and by the lateral rod latitudinally.
3D2
REAR SUSPENSION
Diagnosis
Condition
Vehicle Pulls
Wheel Hop
Possible cause
Correction
Replace tire.
Replace spring.
Replace tire.
Repair brake.

suspension parts.

suspension part(s).

defective.
Replace spring.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire.

wheel.
Replace tire.


suspension parts.

suspension parts.
Adjust preload.

defective.
REAR SUSPENSION
Condition
Hard Steering
Abnormal Noise
Possible cause
3D3
Correction

Replace ball joint.
Repair or replace.

operation.

section.

universal joint.
Repair or replace.
Adjust pressure.
Retighten.
Worn wheel bearing.
Replace.

Replace.
Replace.

bushing.
Replace.
Loose wheel nuts.

required.

bearings.
Replace spring.

pressure.

bushings.
3D4
REAR SUSPENSION
Condition
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction
Leaking caliper.
Warped discs.
Replace brake disc.
Replace brake pads.
Vehicle overloaded.
Reduce load.
Incorrect springs.
Vehicle overloaded.
Reduce load.
Replace springs.

replace bushings.

mounting.
Vehicle overloaded.
Reduce load.
Worn ball joints.
REAR SUSPENSION
3D5
Coil Spring
Coil Spring and Associated Parts
460RW034
Legend
(1)
(2)
(3)
(4)
Stabilizer Bar
Upper Link Fixing Bolt and Nut
Rubber Plate
Coil Spring
(5) Insulator
(6) Shock Absorbar
(7) Breather Hose
EndOFCallout
Removal
2. Support the rear axle case with a jack.
3. Disconnect brake hose at the crossmember.
4. Remove breather hose.
5. Remove upper link fixing bolt, nut and rubber plate
on the rear axle case (left-side only).
6. Disconnect the stabilizer bar at the stabilizer link.

7. Remove the shock absorber from the axle case.
8. Remove spring insulator.
9. Remove the insulator and coil spring while lowering
the rear axle case.
CAUTION: Be sure not to let the brake hose,
parking brake cable, and breather hose extend to
their full length.
3D6
REAR SUSPENSION
3. Install the insulator on the coil spring. Jack up the

axle case gently with the top of the coil spring set to
the spring seat on the frame side.

Coil spring
Insulator
Installation
1. Install coil spring and make sure that the coil spring
is installed in the proper position. Paint mark(1)
should be downward.
460RW013
4. Install shock absorber and tighten the nut lightly,

then retighten it to the specified torque after the
NOTE: When mounting shock absorber, be sure not to
460RW001
2. Fit the end of the coil spring to the coil spring seat
and mount the coil spring on the rear axle case.
6. Install upper link with rubber plate and tighten fixing

bolt.
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to Bleeding the Brake Hydraulic System in
Brake section.
460RW004
REAR SUSPENSION
3D7
Shock Absorber
461RW001
Legend
(1) Nut, Bush and Washer
(2) Shock Absorber
(3) Nut and Washer
EndOFCallout
Removal
1. Remove shock absorber fixing nut, bush and washer
(upper side).
2. Remove shock absorber fixing nut and washer
(lower side).

Shock absorber
Rubber bushing
Installation
1. Install shock absorber. When mounting shock
absorber, be sure not to use grease on bushings or
any other nearby part.
2. Install nut and washer (lower side), then tighten the
nut lightly. Retighten to the bolt and nut specified
3. Install nut, bush and washer (upper side), then
tighten the nut lightly. Retighten to the nut specified
3D8
REAR SUSPENSION
Trailing Link
Trailing Link and Associated Parts
460RW038
Legend
EndOFCallout
Removal
1. Remove the parking brake cable from the trailing
link.
2. Remove the trailing link fixing bolt, nut and protector.
3. Remove trailing link.

1. Trailing link
2. Rubber bushing
884022980.
901RW280
REAR SUSPENSION
Install the rubber bushing by using installer 5
884022980.
901RW281
Installation
1. Install trailing link. Make sure that the trailing link is
in its correct position.
NOTE: When mounting trailing link, be sure not to use
460RW011
2. Install bolt, nut and protector. Tighten the bolts and

nuts lightly, then retighten them to the specified
3. Install parking brake cable.
CAUTION: The parking brake cable should not be
overstrained or slackened.
3D9
3D10
REAR SUSPENSION
Upper Link
Upper Link and Associated Parts
460RW037-1
Legend
(2) Rubber Plate
(3) Upper Link

EndOFCallout
Removal
1. Remove fuel tank. Refer to Engine Fuel in Engine
section.
2. Remove the speed sensor cable from the upper link.
3. Remove bolt, nut, rubber plate and protector.
4. Remove upper link.

1. Upper link
2. Rubber bushing
884025650.
901RW282
REAR SUSPENSION
Install the rubber bushing by using to installer 5
884025650.
901RW283
Installation
1. Install upper link. Make sure that the upper link is in
its correct position.
NOTE: When mounting upper link, be sure not to use
grease bushings or any other nearby part.
460RW012
2. Install bolt, nut, rubber plate and protector. Tighten

the bolts and nuts lightly, then retighten them to the
specified torque after the vehicle is at curb height.
4. Install fuel tank.
3D11
3D12
REAR SUSPENSION
Lateral Rod
Lateral Rod and Associated Parts
460RW036
Legend
(1) Bolt and Nut (Frame side)
(2) Lateral Rod
(3) Nut and Washer (Axle side)
EndOFCallout
Removal
1. Remove nut and washer.
3. Remove lateral rod.

1. Lateral rod
2. Rubber bushing (Frame side)
Remove the rubber bushing (Frame side) by
901RW284
REAR SUSPENSION
3D13
Install the rubber bushing (Frame side) by using

Installer 5884022990.
NOTE: When mounting rubber bushings, do not use
grease on bushings or any other nearby parts.
901RW286
Installation
1. Install lateral rod and make sure that the lateral rod
is in its correct position.
901RW285
3. Rubber bushing (Axle side)

Remove the rubber bushing (Axle side) by using
remover 5884023270.
NOTE: When mounting lateral rod, be sure not to use

460RW035
Legend
901RW287
Install the rubber bushing (Axle side) by using

installer 5884023270.
(1) Frame Side

(2) Axle Side
EndOFCallout
2. Install bolt and nut. Tighten the bolt and nut lightly,
then retighten them to the specified torque after the
3. Install nut and washer. Tighten the nut lightly, then
retighten the nut to the specified torque after the
3D14
REAR SUSPENSION
Stabilizer Bar
460RW009
Legend
(1) Bracket
(2) Link
(3) Bolt and Nut
(4) Stabilizer Bar

(5) Rubber Bushing
EndOFCallout
Removal
this section.
4. Remove link.
boot.
5. Remove bracket.

Stabilizer bar
Rubber bushing
Link
REAR SUSPENSION
Installation
2. Install bracket to axle housing and tighten to the
specified torque.
3. Install link.
4. Install bolt and nut, then tighten the nut to the
specified torque.
460RW010
3D15
3D16
REAR SUSPENSION

Rear suspension
Type
Coil spring
Long wheel base
Short wheel base
379.0mm (14.92in)
383.0mm (15.08in)
Spring diameter
12.4mm (0.49in)
12.5mm (0.49in)
Coil diameter (inner)
105mm (4.13in)
105mm (4.13in)
Effective No. of turns
5.62
6.59
Total No. of turns
7.12
8.09
Free length
Shock absorber
Stabilizer bar
5Link, coil spring type with stabilizer bar.
Type
Piston diameter
30mm (1.18in)
Stroke
175mm (6.89in)
Extended length
473.5mm (18.64in)
Compressed length
298.5mm (11.75in)
Diameter
19mm (0.75in)
REAR SUSPENSION
3D17
E03RX007
3D18
REAR SUSPENSION
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884022980
(J39214)
Trailing link bushing
5884025650
(J43008)
Upper link bushing
5884023270
(J39792)
Lateral rod bushing (axle
side)
5884022990
(J3921)
Lateral rod bushing
SECTION
3E1
SUSPENSION
CONTENTS
Diagnosis ....................................................
Wheel ............................................................
Wheel and Associated Parts ......................
Removal .....................................................
3E - 1
3E - 2
3E - 3
3E - 11
3E - 11
3E - 11
Service Precaution
REPAIRS.
Installation...................................................
Tire ................................................................
Tire Replacement .......................................
General Balance Procedure .......................
Balancing Wheel and Tire...........................
3E - 11
3E - 12
3E - 12
3E - 12
3E - 13
3E - 14

and systems.
3E2
General Description
480RS008
Replacement wheels or tires must be equivalent to the

originals in load capacity, specified dimension and
mounting configuration. Improper size or type may
affect bearing life, brake performance, speedometer/
odometer calibration, vehicle ground clearance and tire
clearance to the body and chassis. All model are
equipped with metric sized tubeless steel belted radial
tires. Correct tire pressures and driving habits have an
important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp
braking increase premature and uneven wear.
3E3
Diagnosis
Condition
Vehicle Pulls
Wheel Hop
Possible cause
Correction
Replace tire.
Replace spring.
Replace tire.
Repair brake.

suspension parts.

suspension part(s).

defective.
Replace spring.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire.

wheel.
Replace tire.


suspension parts.

suspension parts.
Adjust preload.

defective.
3E4

Condition
Hard Steering
Abnormal Noise
Possible cause
Correction

Replace ball joint.
Repair or replace.

operation.

section.

universal joint.
Repair or replace.
Adjust pressure.
Retighten.
Worn wheel bearing.
Replace.

Replace.
Replace.

bushing.
Replace.
Loose wheel nuts.

required.

bearings.
Replace spring.

pressure.

bushings.

Condition
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction
Leaking caliper.
Warped discs.
Replace brake disc.
Replace brake pads.
Vehicle overloaded.
Reduce load.
Incorrect springs.
Vehicle overloaded.
Reduce load.
Replace springs.

replace bushings.

mounting.
Vehicle overloaded.
Reduce load.
Worn ball joints.
3E5
3E6
Irregular and Premature Wear
480RS001
Irregular and/or premature wear has many causes.

Some of them are incorrect inflation pressures, lack of
tire rotation, poor driving habits or improper wheel
alignment. Incorrect inflation is common cause of tire
premature wear.
NOTE: Due to their design, radial tires tend to wear
faster in the shoulder area, particularly on the front tires.
This makes regular rotation especially necessary. After
rotation, be sure to check wheel nut torque, and set tire
pressures.
Tire Rotation
Tire rotation is recommended to equalize wear for
longer tire life.
Tread Wear Indicators
480RS002
Legend
(1) Spare Tire
EndOFCallout
If the following conditions are noted, rotate the tires:

Front tire wear is different from rear.
Uneven wear exists across the tread of any tire.
Left and right rear tire wear is unequal.
Check wheel alignment if the following conditions are
noted:
Wear is uneven across the tread of any front tire.
Front tire treads have a scuffed appearance with
feather" edges on one side of the tread ribs or
blocks.
480RS006
The original equipment tires have built-in tread wear

indicators(1) to show when tires need replacement.
These indicators may appear as wide bands. When the
indicators appear in two or more grooves at three
locations, tire replacement is recommended.

Inflation of Tires
3E7
4. Tire rim bruises and rupture.

5. Tire cord breakage.
6. High tire temperatures.
8. Reduced fuel economy.
Unequal pressure on same axle can cause:
1. Uneven braking.
2. Steering lead.
4. Swerve on acceleration.
Radial Tire Waddle
710RX004
Tire pressure, in cold condition (after vehicle has set for

three hours or more, and driven less than one mile),
should be checked monthly or before any extended trip.
Tire pressure increases approximately 15% when the
tires become hot during driving. Tire pressure
specification is shown on the label located on the left
door lock pillar.
NOTE: Check the tire pressure whenever irregular wear
is found. Tire inflation greatly affects tire wear. If the
alignment check does not reveal any alignment
problems, check the condition of the shock absorbers
and wheel/tire balance.
480RW011
Diagnosis List
If the following conditions are noted, rotation is required.
1. Front tire wear is different from rear.
4. Left and right rear tire wear is unequal.
If the following conditions are noted, check the wheel
alignment.
3. Front tire treads have scuffed appearance with
feather" edges on one side of tread ribs or blocks.
4. There is cupping, flat spotting etc.
Higher than recommended pressure can cause:
1. Hard ride.
2. Poor steering stability.
3. Rapid and uneven wear at center of the tread.
Lower than recommended pressure can cause:
1. Tire squeal on turns.
2. Hard steering.
3. Rapid and uneven wear on the edges of the tread.
Waddle is side-to-side movement at the front and/or

rear of the car. It can be caused by the steel belt not
being straight within the tire, or by excessive lateral
runout of the tire or wheel. It is most noticeable at low
speed, about 8 to 48 km/h (5 to 30 mph). It may also
cause rough ride at 80 to 113 km/h (50 to 70 mph).
The car can be road tested to see which end of the car
has the faulty tire. If the tire causing the waddle is on
the rear, the rear end of the car will waddle". From the
driver's seat, it feels as if someone is pushing on the
side of the car.
If the faulty tire is on the front, the waddle is more easily
seen. The front sh eet metal appears to be moving back
and forth. It feels as if the driver's seat is the pivot point
in the car.
Another more time-consuming method of determining
the faulty tire is substituting tire and wheel assemblies
that are known to be good. Follow these steps:
1. Drive the car to determine if the waddle is coming
from the front or rear.
2. Install tire and wheel assemblies known to be good
(from a similar car) in place of those on the end of
the car which is waddling. If the waddle cannot be
isolated to front or rear, start with the rear tires.
3E8
3. Road test again. If improvement is noted, install the

original tire and wheel assemblies one at a time
until the faulty tire is found. If no improvement is
noted, install tires known to be good in place of all
four. Then, install the originals one at a time until the
faulty tire is found.
Radial Tire Lead/Pull

Lead/Pull" is vehicle deviation from a straight path, on a
level road with no pressure on the steering wheel.
Lead is usually caused by:
1. Poorly manufactured radial tires.
2. Uneven brake adjustment.

3. Wheel alignment.
The way in which a tire is built can produce lead in a car.
An example of this is placement of the belt. Off-center
belts on radial tires can cause the tire to develop a side
force while rolling straight down the road and the tire will
tend to roll like a cone.
The Radial Tire Lead/Pull Correction" chart should be
used to make sure that front wheel alignment is not
mistaken for tire lead.
Rear tires will not cause lead/pull.
Radial Tire Lead/Pull Correction Chart

Step
Action
1
1. Inflate tires to recommended pressure.

2. Road test vehicle on level uncrowned road.
Switch front tires side to side and road test again.
Did the vehicle lead in same direction?
Put tires back in original position and check alignment.

Yes
No
End.
Go to Step 2
If roughness
results,replace
tires.
Go to Step 3
Go to Step 4
Go to Step 5
End.
Go to Step 5
Install known good tire on one front side.

Replace tire.
Install a known
good tire in
place of other
front tire.
If lead
corrected,
replace tire.
Typical examples of abnormal tire ahead wear and

major causes:
CAUTION: Similar wear patterns can be caused by
worn suspension parts, misalignment of wheels and
tires, and other suspension related problems.
Spotty wear wear localized on shoulder sections, and
in an extreme cases, the tire becomes polygonal in
shape.
480RW002

3. Play in hub bearings or ball joint.
Tread wear one-sided.
3E9
1. Once spotty wear develops in tread due to hard

braking or abrupt starting, localized wear tends to
be promoted.
Shoulder wear (generally wear develops in outer
shoulder):
480RW005
480RW003

2. Tire or wheel out of round.
Localized tread wear.

2. Shoulder wear caused by repeated hard-cornering.
Wear in shoulders at points opposed to each other.
480RW006
480RW004
3E10

2. Play in bearings or ball joint.
Premature wear in shoulders.
480RW007
1. Flexing of tire excessive due to under-inflation.

One sided feather edging.
480RW008
1. Wear caused by repeated hard cornering.

3E11
Wheel
Wheel and Associated Parts
480RX008
Legend
(1) Wheel Lug Nut
(2) Wheel and Tire
EndOFCallout
Removal
1. Loosen wheel lug nut by approximately 180 (half a
rotation), then raise the vehicle and remove the
nuts.
2. Remove wheel and tire.
NOTE: Never use heat to loosen a tight wheel lug nut.
The application of heat to the hub can shorten the life of
the wheel and may cause damage to wheel bearings.
Installation
1. Install wheel and tire.
2. Install wheel lug nut, and lower the vehicle. Tighten
the wheel lug nuts to the specified torque in
numerical order.
CAUTION: Before installing wheels, remove any
build-up of corrosion on the wheel mounting
surface and brake disc mounting surface by
scraping and wire brushing. Installing wheels
without good metal-to-metal contact at mounting
surfaces can cause wheel nuts to loosen, which
can later allow a wheel to come off while the vehicle
is moving.
NOTE: Valve caps should be on the valve stems to
keep dust and water out.
480RS020
3E12
Tire
Tire Replacement
When replacement is necessary, the original metric the
size should be used. Most metric tire sizes do not have
exact corresponding alphanumeric tire sizes. It is
recommended that new tires be installed in pairs on the
same axle. If necessary to replace only one tire, it
should be paired with tire having the most tread, to
equalize braking traction.
Steel
Aluminum
1 Vertical play:
Less than
1.5mm (0.059in)
1 Vertical play:
Less than
0.7mm (0.028in)
2 Horizontal play:
Less than
1.5mm (0.059in)
2 Horizontal play:
Less than
0.7mm (0.028in)
CAUTION: Do not mix different types of tires such

as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be
seriously affected and may result in loss of control.
Tire Dismounting
Remove valve cap on valve step and deflate the tire.
Then use a tire changing machine to mount or dismount
tires.
Follow the equipment manufacturer's instruction. Do
not use hand tools or tire lever alone to change tires as
they may damage the tire beads or wheel rim.
Tire Mounting
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, and light rust.
Before mounting a tire, the bead area should be well
lubricated with an approved tire lubricant.
After mounting, inflate the tire to 200kPa (2.0kg/cm2, 28
psi) so that beads are completely seated. Inflate the air
to specified pressure and install valve cap to the stem.
WARNING: NEVER STAND OVER TIRE WHEN
INFLATING. BEAD MAY BREAK WHEN BEAD
SNAPS OVER RIM'S SAFETY HUMP AND CAUSE
SERIOUS PERSONAL INJURY.
NEVER EXCEED 240 KPA (2.4kg/cm2, 35 PSI)
PRESSURE WHEN INFLATING. IF 240 KPA (2.4kg/
cm2, 35 PSI) PRESSURE WILL NOT SEAT BEADS,
DEFLATE, RE-LUBRICATE AND RE-INFLATE. OVER
INFLATION MAY CAUSE THE BEAD TO BREAK AND
CAUSE SERIOUS PErSONAL INJURY.
Tire Repair
There are many different materials on the market used
to repair tires.
Manufacturers have published detailed instructions on
how and when to repair tires. These instructions can
be obtained from the tire manufacturer if they are not
included with the repair kit.
Wheel Inspection
Damaged wheels and wheels with excessive run-out
must be replaced.
Wheel run out at rim (Base on hub Bore):
480RS012
General Balance Procedure

Deposits of mud, etc. must be cleaned from the inside of
the rim.
The tire should be inspected for the following: match
mount paint marks, bent rims, bulges, irregular tire
wear, proper wheel size and inflation pressure. Then
balance according to the equipment manufacturer's
recommendations.
There are two types of wheel and tire balance.
Static balance is the equal distribution of weight around
the wheel.
Assemblies that are statically unbalanced cause a
bouncing action called tramp. This condition will
eventually cause uneven tire wear.
3E13
Balancing Wheel and Tire

On-vehicle Balancing
On-Vehicle balancing methods vary with equipment and
tool manufacturers. Be sure to follow each
manufacturer's instructions during balancing operation.
Off-vehicle Balancing
Most electronic off-vehicle balancers are more accurate
than the on-vehicle spin balancers. They are easy to
use and give a dynamic balance. Although they do not
correct for drum or disc unbalance (as onvehicle spin
balancing does), they are very accurate.
480RS013
Legend
(1) Heavy Spot Wheel Shimmy
EndOFCallout
Dynamic balance is the equal distribution of weight on
each side of the wheel center-line so that when the tire
spins there is no tendency for the assembly to move
from side to side. Assemblies that are dynamically
unbalanced may cause shimmy.
480RS015
480RS014
Legend
(1) Heavy Spot Wheel Hop
EndOFCallout
WARNING: STONES SHOULD BE REMOVED FROM
THE TREAD TO AVOID OPERATOR INJURY DURING
SPIN BALANCING AND TO OBTAIN A GOOD
BALANCE.
3E14

Wheels
Standard tire
Size
15 x 6.5JJ
Offset
38.0mm (1.50in)
P.C.D., wheel studs
139.7mm (5.50in)
Size
P235/75R15
Pressure(Front)
Pressure(Rear)
E03RX008
SECTION
4A11
DRIVELINE/AXLE
CONTENTS
Differential (Front) .........................................
Differential (Rear)..........................................
Driveline Control System...............................
Drive Shaft System .......................................
Transfer Case ...............................................
4A1 - 1
4A2 - 1
4B - 1
4C - 1
4D - 1
CONTENTS
Front Drive Axle ............................................
Diagnosis ....................................................
Pinion Shaft Oil Seal .....................................
Pinion Shaft Oil Seal and
Removal .....................................................
Installation ..................................................
Front Drive Axle Assembly............................
Front Drive Axle Assembly and
Removal .....................................................
4A1 - 1
4A1 - 2
4A1 - 2
4A1 - 3
4A1 - 3
4A1 - 3
4A1 - 4
4A1 - 4
4A1 - 5
4A1 - 5
4A1 - 6
Service Precaution
REPAIRS.
Installation...................................................
Disassembly ...............................................
Reassembly ................................................
Differential Cage Assembly ...........................
Disassembly ...............................................
Reassembly ................................................
Special Tools .................................................
4A1 - 7
4A1 - 8
4A1 - 8
4A1 - 9
4A1 - 11
4A1 - 20
4A1 - 20
4A1 - 20
4A1 - 21
4A1 - 22
4A1 - 24
4A1 - 27

and systems.
4A12
Front Drive Axle

Diagnosis
Condition
Possible cause
Correction
Repair or replace.
Too much gear oil.
Tighten or replace.

Joint


bellows.

Coast"

shaft bolts.
Tighten.
Replace.
Repair.
Replace.

drive shaft joint).

shaft joint).
Balance or replace.
Align.

incorrect.

gear or side gear.

side gear.
Wheel bearing worn.
Tighten or replace.
Tighten or replace.

or broken.
Tighten or replace.

adjusted.
Adjust or replace.
Tighten or replace.

Acceleration

Wanders and Pulls
Front Wheel Shimmy
4A13
Pinion Shaft Oil Seal

Pinion Shaft Oil Seal and Associated Parts
415RX004
Legend
(1) Flange Nut
(2) Flange
(3) Oil Seal
(4) Outer Bearing

(5) Collapsible Spacer
EndOFCallout
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
4A14
3. Remove the front propeller shaft. Refer to Front

4. Remove flange nut by using pinion flange holder 5
884021570.

1. Seal surface of the pinion.
Installation
1. Install collapsible spacer. Discard the used
3. Install oil seal, use oil seal installer 9852212750
to install a new oil seal that has grease on seal lip.
415RW028
5. Remove flange.
6. Remove oil seal.
23230.
415RW021
4. Install flange.
5. Install flange nut, refer to Differential Assembly
Overhaul for flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.
415RW048
4A15
Front Drive Axle Assembly

Front Drive Axle Assembly and Associated Parts
412RX010
Legend
(1) Propeller Shaft
(2) Mounting Nut
(3) Front Axle Case Assembly and Front Drive
Shaft Assembly
(4) Washer
EndOFCallout
(5)
(6)
(7)
(8)
(9)
Mounting Bolt
Tierod End; Power Steering Unit
Knuckle and Back Plate
Suspension Crossmember
4A16
Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
4. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake
section.
6. Remove the hub and disc assembly.
7. Remove the propeller shaft, refer to Front Propeller
8. Loosen the height control arm of the torsion bar,
then remove the torsion bar from lower control arm.
refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock
absorber.
412RW058
15. Remove the bolts and nuts of the lower control arm
(Frame side), then disconnect the lower control arm
from frame.
16. Disconnect between the right side upper control arm
and the knuckle, then remove the knuckle with lower
control arm.
CAUTION: When removing the knuckle, be careful
not to damage the oil seal inside of the knuckle.
412RW057

Power Steering Unit in Steering Section.
13. Disconnect the hose of the shift on the fly, at the
hose clip portion (1).
14. Disconnect the shift switch connector (2).
410RW008
18. Remove the front axle mounting bolts and nuts,
lower the jack slowly. Remove the left side drive
shaft end from the knuckle, then lower the axle
assembly from the vehicle.
CAUTION:
1. During the work, be sure that the axle assembly
is supported securly.
4A17
5. Align the bolt hole of the lower control arm, install

the bolts and nuts.
NOTE: Adjust the buffer clearance before tighten the
bolts and nuts of the lower control arm.
6. Install the hose of the shift on the fly (1).
7. Install the shift switch connector (2) of the shift on
the fly.
Installation
2. Jack up the front drive axle assembly, install the left
side drive shaft to the knuckle, then install the mount
bolts and nuts.
CAUTION:
3. When installing the drive shaft to the knuckle,
be careful not to damage the oil seal inside of
the knuckle.
3. Tighten the mounting bolts and nuts to the specified
torque.
412RW058
8. Install the tie-rod end of the power steering unit to

the knuckle, tighten the nut to the specified torque.
9. Install lower bolts and nuts of the shock absorber,
tighten it to the specified torque.
10. Install lower nuts of the stabilizer link, tighten it to
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the
bearing preload.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the
caliper bracket to the specified torque.
412RX011
4. Install the right side knuckle with lower control arm

to the upper control arm.
Refer to Knuckle in Suspension section.
CAUTION: When insert the drive shaft to the
knuckle, be careful not to damage the oil seal inside
of the knuckle.

18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm
Refer to Lower Control Arm in Suspension section.
4A18
Disassembled View
415RX003
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Flange Nut
Flange
Dust Cover
Oil Seal
Outer Bearing
Outer Bearing Outer Race
Differential Carrier
Bearing Cap
Bolt
Inner Bearing Outer Race
EndOFCallout
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Collapsible Spacer
Pinion Gear
Inner Bearing
Adjust Shim
Diff Cage Assembly
Side Bearing Outer Race
Side Bearing
Adjust Shim
Bolt
Axle Case
Disassembly
1. Remove differential carrier fixing bolt.
2. Remove differential assembly.
3. Using holding fixture 5884002750 and holding
fixture base 5884000030, fix the differential
assembly to the bench.
4A19
6. Remove differential cage assembly.

7. Remove side bearing outer race, after removal,
keep the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
8. Remove side bearing, using remover 58840
00130, 5884000140 and adapter 98521
17430.
425RW046
4. Remove bearing cap bolt.

5. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
415RW023
9. Remove adjust shim, note the thickness and

position of the shims removed.
10. Remove the flange nut using holding wrench 5
884021570 after raising up its staked parts
completely.
425RS009
425RW057
4A110
11. Remove flange.

12. Remove dust cover.
13. Remove the drive pinion assembly using a soft
metal rod and a hammer.
16. Remove adjust shim.

19. Remove the inner bearing outer race (1) and the
outer bearing outer race (2) by using a brass bar
and a hammer.
425RS012

15. Remove the inner bearing using remover 58840
00150 and a press.
425RS014
425RS015
415RW033
4A111
Reassembly
00070, install outer bearing outer race.
415RS009
Legend
415RW018

00070, install Inner bearing outer race.
(1) Pilot : 5884020850

(2) Nut and Bolt: 5884020890
(3) Gauge Plate : 5884020870
EndOFCallout
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
415RW017
3. Install adjust shim and adjust drive pinion mounting

distance:
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the
inner and outer bearings.
2. Tighten the nut to the specified torque.
Torque:2.3Nm (0.2kgm/20lbin)
415RS010
Legend
(1)
(2)
(3)
(4)
Dial Indicator: 5884001260

Disc (2 pcs.): 5884020880
Arbor: 5884001280
Gauge Plate: 5884020870
EndOFCallout
4A112
4. Set the dial indicator to 0". Place it on the

mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the

gauging arbor until the dial indicator rod does
not touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
425RS020
Legend
(1)
(2)
(3)
(4)
Legend
Dial Indicator
Ganging Arbor
Plunger
Gauge Plate
EndOFCallout
5. Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicator
shows the greatest defection. At this point, once
again set the dial indicator to 0".
EndOFCallout
drive pinion.
The number indicates a necessary change in
the pinion mounting distance. A plus number
indicates the need for a greater mounting
distance (which can be achieved by decreasing
the shim thickness). A minus number indicates
the need for a smaller mounting distance (which
can be achieved by increasing the shim
thickness). If examination reveals pinion depth
code 0", the pinion is nominal".
425RS021
425RS023
4A113
8. Select the shim using chart;

Pinion
marking
Dial
indicator
reading
(Inches)
+10
+8
+6
+4
+2
10
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
2.18
(0.0858)
0.081
2.18
(0.0858)
2.20
(0.0866)
2.18
(0.0858)
2.20
(0.0866)
2.23
(0.0882)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
0.082
0.083
0.084
0.085
0.086
0.087
0.088
0.089
0.090
0.091
2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
0.092
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
0.093
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
0.094
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
0.095
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
0.096
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.097
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.098
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.099
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.001
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.002
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.003
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.004
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.005
2.54
(0.1000)
2.56
(0.1008)
0.006
2.56
(0.1008)
NOTE: When ordering shims, find the part number in

the parts catalog by using the thickness of shims listed
in the ablve table.
4A114
4. Place the shim on the drive pinion. Install the inner

bearing onto the pinion using an installer 98522
11650 and a press.
NOTE: Do not apply pressure to the roller cage and
apply pressure only to the inner race.
9. Install duct cover.

10. Install flange.
11. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder 5884021570.
Torque:177-275 Nm(18-28kgm/130-203lbft)
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RW067
5. Discard the used collapsible spacer and install a

new one.
6. Install pinion gear.
8. Use oil seal installer 9852212750 to install a
new oil seal that has been soaked in front axle
lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RW024
425RW057
3. Adjust pinion bearing preload.

a Measure the bearing preload by using a
torque meter. Note the scale reading
required to rotate the flange.
b Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing:0.71.1Nm(6.511.5kgcm/5.6
10lbin)
Used bearing:0.40.5Nm(3.35.7kgcm/2.9
5.0lbin)
4A115
12. Install adjust shim.

1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
425RS027
4. Using punch 5884022930, stake the flange

nut at two points.
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3)
425RS029
Legend
(1) Drive handle:5884000070
(2) Installer:9852211640
(3) Pilot:9852117430
EndOFCallout
2. Insert the differential cage assembly with
bearing outer races into the side bearing bores
of the carrier.
415RW019
Legend
(1) 1.3mm or less
EndOFCallout
425RS030
3. Using two sets of feeler gauges, insert a feeler

stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator 5884001260 on the
carrier so that the indicator stem is at right
angles to a tooth on the ring gear.
4A116
5. Use bearing remover 5884000130, 58840
00140 and pilot 9852117430 to remove
side bearing.
425RS031
4. Adjust feeler gauge thickness from side to side

until ring gear backlash is in the specified range.
415RW020
Backlash:0.130.18mm(0.005 0.007in)
13. Install the side bearings together with the selected

shims.
425RS032
With zero end play and correct backlash

established, remove the feeler gauge packs,
determine the thickness of the shims required
and add 0.05 mm (0.002 in) to each shim pack
to provide side bearing preload. Always use new
shims.
425RS029
Legend
(1) Drive Handle:5884000070
(2) Installer: 9852211640
(3) Pilot: 9852117430
EndOFCallout
14. Install side bearing outer race.
15. Install differential cage assembly.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035
4A117
1. Measure the amount of run-out of the ring gear

at its rear face.
Limit: 0.05 mm (0.002 in)
425RS037
Gear Tooth Contact Pattern Check and

Adjustment
1. Apply a thin coat of prussian blue or equivalent
to the faces of the 78 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.
17. Tighten the cap bolt to the specified torque.

425RS036
4A118
425RS038
Legend
(1)
(2)
(3)
(4)
Heel
Toe
Concave Side(Coast)
Convex Side(Drive)
EndOFCallout
425RS039
18. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
415RS014
3. Fill the axle case with hypoid gear lubricant, to

just below the filler hole.
Lubricant capacity:1.4liter(1.2 Imp qt/1.5 USqt)
4A119
4A120
Differential Cage Assembly

Disassembled View
415RS015
Legend
(1)
(2)
(3)
(4)
Pinion Gear
Thrust Washer
Side Gear
Cross Pin
(5)
(6)
(7)
(8)
Ring Gear
Bolt
Differential Cage
Lock Pin
EndOFCallout
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin,
using a 5mm (0.20 in) diameter drill.
425RS042
4A121
4. Remove the cross pin, using a soft metal rod and a

hammer.
415RS016
425RS043
5. Remove pinion gear.

6. Remove side gear.
7. Remove thrust washer.
Clearance between the differential pinion

and the cross pin measurement:
Standard: 0.06 - 0.12 mm (0.002 - 0.005 in)
Limit: 0.2 mm (0.008 in)

1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt.
4. Discard used bolts and install new ones..
Torque:108Nm(11.0Kgm/80lbft)
425RS045
4A122
Clearance between the side gear and the

differential box:
Standard: 0.03 - 0.10 mm (0.001 - 0.004 in)
Limit: 0.15 mm (0.006 in)
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by
pinion gears simultaneously in the same direction.
425RS046
Legend
(1) Side Gear
(2) Differential Box
EndOFCallout
425RS048
Play in splines between the side gear and

the axle shaft:
4. Install cross pin.

1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
Standard: 0.08 - 0.36 mm (0.003 - 0.014 in)

Limit: 0.5 mm (0.02 in)
425RS049
425RS047
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash: 0.03 - 0.08 mm (0.001 - 0.003 in)
Thickness of thrust washers available:
1.00mm, 1.05mm, 1.10mm(0.039in, 0.041in,
0.043in)
4A123
6. Clean the ring gear threaded holes to remove the

locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.
7. Tighten the bolts in diagonal sequence as
illustrated.
425RS050
5. Install lock pin. After lock pin installation, stake the

cage to secure the lock pin.
415RS016
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
EndOFCallout
4A124

Axle tube Type
It consists of the duct, a cast iron housing and the axle

tube.
Gear type
Gear ratio
Hypoid
(to 1)
Differential type
Oil capacity
Type of lubricant
Axle shaft type
Hub locking Type
4.100 (6VD1 with A/T)

4.300 (6VD1 with M/T)
Two pinion
liter (US qt)
1.4 (1.5) (Differential)

0.12 (0.13) (Actuator Housing: Shift on the fly)
GL5 (75W90)
Constant velocity joint (Birfield joint type and double offset
joint)
Rigid
4A125
E04RX008
4A126
E04RX014
4A127
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884021570
(J37221)
Holder; Pinion flange
9852117430
(J81072)
plug
9852212750
(J24250)
Installer; Oil seal
5884000150
(J2291201)
Separator
5884002750
(J37264)
Differential holding fixture
(Use with 588400003
0 base)
9852211410
(J24256)
outer race
5884000030
(J328920)
5884000070
(J8092)
Driver handle
5884000130
5884000140
(J22888)
Puller; Side bearing
9852212740
(J24252)
outer race
4A128
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884020850
(J2177742)
Pilot
9852211650
(J613301)
5884020890
(J235979)
Nut and bolt
5884022930
(J39209)
Punch; End nut lock
5884020870
(J235977)
Gauge plate
9852211640
(J24244)
5884001260
(J8001)
Dial indicator
5884023230
(J39602)
5884020880
(J235978)
Disc
5884001280
(J235971)
Arbor
SECTION
DIFFERENTIAL (REAR)
4A21
DRIVELINE/AXLE
DIFFERENTIAL (REAR)
CONTENTS
Diagnosis ....................................................
Axle Housing .................................................
Axle Housing and Associated Parts ...........
Removal .....................................................
Installation ..................................................
Axle Shaft, Oil Seal and Bearing...................
Axle Shaft and Associated Parts ................
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Pinion Oil Seal...............................................
Pinion Oil Seal and Associated Parts .........
Removal .....................................................
Installation ..................................................
Inspecting the Axle Before Disassembly ....
Disassembly ...............................................
4A2 - 1
4A2 - 2
4A2 - 3
4A2 - 5
4A2 - 5
4A2 - 5
4A2 - 7
4A2 - 7
4A2 - 7
4A2 - 7
4A2 - 8
4A2 - 8
4A2 - 10
4A2 - 10
4A2 - 10
4A2 - 11
4A2 - 11
4A2 - 13
4A2 - 13
4A2 - 14
4A2 - 14
Service Precaution
REPAIRS.

Reassembly ................................................
Side Bearing Preload Adjustment...............
Pinion Installation........................................
Determination of Backlash
& Preload Shims .....................................
Backlash Adjustment ..................................
Gear Tooth Pattern Check..........................
Adjustments Affecting Tooth Contact .........
Differential Case Assembly ...........................
Disassembly ...............................................
Reassembly ................................................
Limited Slip Differential Assembly .................
Disassembly ...............................................
Reassembly ................................................
Main Data And Specifications........................
Special Tools .................................................
4A2 - 16
4A2 - 17
4A2 - 21
4A2 - 22
4A2 - 23
4A2 - 24
4A2 - 25
4A2 - 26
4A2 - 27
4A2 - 27
4A2 - 28
4A2 - 28
4A2 - 28
4A2 - 29
4A2 - 29
4A2 - 29
4A2 - 31
4A2 - 31
4A2 - 33
4A2 - 35

and systems.
4A22
DIFFERENTIAL (REAR)
General Description
The rear axle assembly is of the semifloating type in
which the vehicle weight is carried on the axle housing .
The center line of the pinion gear is below the center
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the propeller
shaft to the rear wheels are enclosed in a salisbury type
axle housing (a carrier casting with tubes pressed and
welded into the carrier). A removable aluminum cover
at the rear of the axle housing permits rear axle service
without removal of the entire assembly from the vehicle.
The 8.9 inch ring gear rear axle uses a conventional ring
and pinion gear set to transmit the driving force of the
engine to the rear wheels. This gear set transfers this
driving force at a 90 degree angle from the propeller
shaft to the drive shafts.
The axle shafts are supported at the wheel end of the
shaft by a roller bearing.
The pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack located
between the gear end of the pinion and the roller
bearing that is pressed onto the pinion. The pinion
bearing preload is set by crushing a collapsible spacer
between the bearings in the axle housing.
The ring gear is bolted onto the differential case with 10
bolts.
The differential case is supported in the axle housing by
two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential case. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to preload
the bearings which are pressed onto the differential
case. Two bearing caps are used to hold the differential
into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues to
transmit the driving force. This prevents tire scuffing
when going around corners and prevents premature
wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at each
axle shaft end, and by a liquid gasket between the rear
cover and the axle housing.
Limited Slip Differential (LSD)

The axle assembly may be equipped with an limited slip
differential (LSD). It is similar to the standard differential
except that part of the torque from the ring gear is
transmitted through clutch packs between the side
gears and differential case.
The LSD construction permits differential action when
required for turning corners and transmits equal torque
to both wheels when driving straight ahead. However,
when one wheel tries to spin due to a patch of ice, etc.,
the clutch packs automatically provide more torque to
the wheel which is not trying to spin.
In diagnosing customer complaints, it is important to
recognize two things:

1. If, both wheels slip, with unequal traction, the LSD
has done all it can possibly do.
2. In extreame cases of differences in traction, the
wheel with the least traction may spin after the LSD
has transferred as much torque as possible to the
non-slipping wheel.
Limited Slip Differntials impose additional requirements
on lubricants, and require a special lubricant or lubricant
additive. Use 80W90 GL5 LSD lubricant.
Rear Axle Identification

The Bill of Material and build date information(1) is
stamped on the right axle tube on the rearward side.
The axle ratio is identified by a tag(3) which is secured
by a cover bolt. If the axle has limited-slip differntial, it
also will be identified with a tag(2) secured by a cover
bolt.
425RX001
DIFFERENTIAL (REAR)
Diagnosis
Many noises that seem to come from the rear axle
actually originate from other sources such as tires, road
surface, wheel bearings, engine, transmission, muffler,
or body drumming. Investigate to find the source of the
noise before disassembling the rear axle. Rear axles,
like any other mechanical device, are not absolutely
quiet but should be considered quiet unless some
abnormal noise is present.
To make a systematic check for axle noise, observe the
following:
1. Select a level asphalt road to reduce tire noise and
body drumming.
2. Check rear axle lubricant level to assure correct
level, and then drive the vehicle far enough to
thoroughly warm up the rear axle lubricant.
3. Note the speed at which noise occurs. Stop the
vehicle and put the transmission in neutral. Run the
engine speed slowly up and down to determine if
the noise is caused by exhaust, muffler noise, or
other engine conditions.
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa
(50 psi) (for test purposes only). This will change
noise caused by tires but will not affect noise caused
by the rear axle.
Rear axle nose usually stops when coasting at
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually
changes when comparing pull and coast, but tire
noise stays about the same.
Distinguish between tire noise and rear axle noise
by noting if the noise changes with various speeds
or sudden acceleration and deceleration. Exhaust
and axle noise vary under these conditions, while
tire noise remains constant and is more pronounced
at speeds of 32 to 48 km/h (20 to 30 mph). Further
check for tire noise by driving the vehicle over
smooth pavements or dirt roads (not gravel) with the
tires at normal pressure. If the noise is caused by
tires, it will change noticeably with changes in road
surface.
5. Loose or rough front wheel bearings will cause
noise which may be confused with rear axle noise;
however, front wheel bearing noise does not change
when comparing drive and coast. Light application
of the brake while holding vehicle speed steady will
often cause wheel bearing noise to diminish. Front
wheel bearings may be checked for noise by jacking
up the wheels and spinning them or by shaking the
wheels to determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when
correctly installed. Check to see that there is no link
or rod loosened or metaltometal contact.
7. Make sure that there is no metaltometal contact
between the floor and the frame.
4A23
After the noise has been determined to be in the axle,

the type of axle noise should be determined, in order to
make any necessary repairs.
Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to
55 mph) under four driving conditions.
1. In drive under acceleration or heavy pull.
2. Driving under load or under constant speed.
3. When using enough throttle to keep the vehicle from
driving the engine while the vehicle slows down
gradually (engine still pulls slightly).
4. When coasting with the vehicle in gear and the
throttle closed. The gear noise is usually more
noticeable between 48 and 64 km/h (30 and 40
mph) and 80 and 89 km/h (50 and 55 mph).
Bearing Noise
Bad bearings generally produce a rough growl or
grating sound, rather than the whine typical of gear
noise. Bearing noise frequently wowwows" at bearing
rpm, indicating a bad pinion or rear axle side bearing.
This noise can be confused with rear wheel bearing
noise.
Rear Wheel Bearing Noise

Rear wheel bearing noise continues to be heard while
coasting at low speed with transmission in the neutral.
Noise may diminish by gentle braking. Jack up the rear
wheels, spin them by hand and listen for noise at the
hubs. Replace any faulty wheel bearings.
Knock At Low Speeds

Low speed knock can be caused by worn universal
joints or a side gear hub counter bore in the cage that is
worn oversize. Inspect and replace universal joints or
cage and side gears as required.
Backlash Clunk
Excessive clunk on acceleration and deceleration can
be caused by a worn rear axle pinion shaft, a worn
cage, excessive clearance between the axle and the
side gear splines, excessive clearance between the side
gear hub and the counterbore in the cage, worn pinion
and side gear teeth, worn thrust washers, or excessive
drive pinion and ring gear backlash. Remove worn parts
and replace as required. Select closefitting parts when
possible. Adjust pinion and ring gear backlash.
4A24
DIFFERENTIAL (REAR)
Rear Axle Noise

Condition
Noise in Drive
Noisy when coasting
Intermittent noise
Constant noise
Noisy on turns
Possible cause
Correction
Excessive pinion to ring gear

backlash.
Adjust.
Worn pinion and ring gear.
Replace
Worn pinion .bearings.
Replace.
Loose pinion bearings.
Adjust.
Excessive pinion end play.
Adjust.
Worn side bearings.
Replace.
Loose side bearings.
Adjust.
Excessive ring gear run-out.
Replace.
Low oil level.
Replenish.
Wrong or poor grade oil.
Replace.
Bent axle housing.
Replace.
Axle noise heard when driving will

usually be heard also on coasting,
although not as loud.
Adjust or replace.
Pinion and ring gear too tight

(audible when slowing down and
disappears when driving).
Adjust.
Warped bevel ring.
Replace.
Loose differential case bolts.
Tighten.
Flat spot on pinion or ring gear

teeth.
Replace.
Flat spot on bearing.
Replace.
Worn pinion splines.
Replace.
Worn axle shaft dowel holes.
Replace.
Worn hub studs.
Replace.
Bent axle shaft.
Replace.
Worn differential side gears and

pinions.
Replace.
Worn differential shaft.
Replace.
Worn axle shaft splines.
Replace.
Limited Slip Differential

Condition
Possible cause
Correction
Does not lock
Replace the clutch plates.
Chatters in turns
Lubricant contaminated.
Drain lube when hot. Wipe carrier

clean. Refill with lube specified in
Main Data and Specifications at the
end of this section.
Clutch plates dateriorated.
Damaged case.
Replace unit.
Broken differential gears.
Replace gears.
Noise (in addition to normal clutch

engagement)
DIFFERENTIAL (REAR)
4A25
Axle Housing
Axle Housing and Associated Parts
420RW030
Legend
(1)
(2)
(3)
(4)
(5)
Lower Link
Stabilizer
Upper Link
Rear Propeller shaft
Shock Absorber
(6)
(7)
(8)
(9)
(10)
Lateral Rod
Brake Hose
Coil Spring
Parking Cable
Axle Assembly
EndOFCallout
Removal
stands.
The hoist must remain under the rear axle housing.
2. Take out brake fluid. Refer to Hydraulic Brakes in
Brake section.
3. Remove rear wheels and tires. Refer to Wheel
Replacement in Suspension section.
4. Remove propeller shaft. Refer to Rear Propeller
5. Drain the rear axle oil into a proper container.
6. Remove parking brake cable, release the
connection between the cable fixing clip equalizer.
Refer to Parking Brakes in Brake section.
7. Move the clip aside and pull out the breather hose.
8. Disconnect the ABS connectors (1) and remove the
brackets attached to the frame and center link.
350RW023
4A26
DIFFERENTIAL (REAR)
9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
12. Remove the lateral rod fixing bolt and nut from the
frame.
13. Remove the upper link mounting bolt and nut (3)
from the axle housing.
350RW020
10. Remove the shock absorber.

11. Remove the stabilizer linkage mounting bolts and
nuts (2) from the frame side.
460RW015
14. Remove the lower link fixing bolt and nut (4) from
the axle housing.
350RW024
460RW016
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the
vehicle on completion of steps 1 15.
17. Remove the brake caliper fixing bolt, loosen the
flare nut, release the clip and take out the brake
caliper together with the flexible hose.
18. Remove brake disc.
19. Remove antilock brake system speed sensor fixing
bolt and the clip and bracket on the axle housing.
20. Remove the brake pipe clip and fixing bolt on the
axle housing and take out the brake pipe.
DIFFERENTIAL (REAR)
Installation
1. Install brake pipe.
2. Connect Antilock brake system (ABS) speed sensor
and harness, refer to AntiLock Brake System in
Brake section.
3. Install brake disc.
4. Install brake caliper. Refer to Disk Brakes in Brake
section.
5. Install axle housing assembly.
6. Install coil spring and insulator.
7. Install the lower link fixing bolt and nut to the axle
housing. For the procedures in items 711, refer to
Suspension section.
8. Install the upper link bolt and nut to the axle
4A27
housing.
9. Install the lateral rod fixing nut and bolt to the frame
side.
10. Install the stabilizer linkage mounting nut and bolt to
the frame side.
11. Install the shock absorber.
12. Install brake tube flare nut, Refer to Disk Brakes in
Brake section.
13. Install ABS connector and bracket.
14. Connect breather hose.
15. Install parking brake cable, Refer to Parking Brakes
in Brake section.
16. Bleed brakes. Refer to Hydraulic Brakes in Brake
section.
Axle Shaft, Oil Seal and Bearing

Axle Shaft and Associated Parts
Removal
1. Raise the vehicle.
2. Remove rear wheels and brake calipers or drums.
Do not let calipers hang from the vehicle by the
brake line or hose. Wire them to frame of vehicle to
prevent damage.
3. Remove four nuts and lockwashers.
4. Remove shaft assembly from the axle housing.
5. Remove snap ring and bearing cup.
6. Break retainer ring with hammer and chisel.
420RW008
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Axle Shaft
Backing Plate
Oil Seal
Bearing
Axle Housing
Lock Washer
Nut
EndOFCallout
420RS026
4A28
DIFFERENTIAL (REAR)
Inspection
7. Break bearing cage with hammer and chisel.
Shaft for spalling or grooves from seal wear.

Retainer bent or damaged.
Replace items if required.
Installation
1. Emergency brake assembly.
Note direction do not install backwards.
420RS027
8. Remove oil seal, retainer, and emergency brake

assembly.
9. Remove inner race from shaft with OTC1126
bearing splitter and press.
420RS029
3. Install oil seal. Note direction.
420RS028
DIFFERENTIAL (REAR)
4. Install bearing assembly, using installer and press.
5. Install retainer ring, using installer and press.
420RS030
NOTE: Install bearing with cup towards inboard side.
420RS033

7. Install axle shaft assembly into housing.
8. Install bolts, lockwashers, and nuts.
Tighten the retainer nuts to the specified torque.
Torque : 75Nm (7.6kgm/55lbft)
420RS031
4A29
4A210
DIFFERENTIAL (REAR)
Pinion Oil Seal

Pinion Oil Seal and Associated Parts
420RW013
Legend
(1) Flange Nut and Washer
(2) Flange
(3) Oil Seal
(4) Outer Oil Seal Slinger

(5) Outer Pinion Bearing (Cup and Cone)
EndOFCallout
Removal
1. Remove the rear propeller shaft. Refer to Rear
2. Drain the rear axle oil.
3. Check and record preload with an inch pound
torque wrench. This will give combined pinion
bearing, seal, carrier bearing, axle bearing and seal
preload.
425RW018
DIFFERENTIAL (REAR)
4. Remove flange nut and washer by using pinion
flange holder 5884001330 after raising up its
staked parts completely.
4A211
6. Remove oil seal.

7. Remove pinion oil seal slinger.
23230.
425RW070
5. Remove flange by using 5884001330.

Have a suitable container in place to catch
lubricant.
425RW072

1. Seal surface of the flange.
Installation
1. Install collapsible spacer, discard the used
425RW071
4A212
DIFFERENTIAL (REAR)

3. By using the seal installer 5884021650, install a
new oil seal (1) that has grease on seal lip.
4. Install flange.
5. The pinion washer and a new nut while holding the
pinion flange with 5884001330.
nut to seat the bearings. Once there is not end
play in the pinion, the preload torque should be
checked.
Remove 5884001330. Using an inch-pound
torque wrench, check to make sure the pinion
preload is equal to or slightly over the reading
recorded during removal.
425RW050
425RW018
6. Install propeller shaft to the frange.

7. Install bolt and nut. Tighten the bolt and nut to the
specified torque.
DIFFERENTIAL (REAR)
4A213
Disassembled View
420RW018
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
ABS Speed Sensor

Housing
Outer Pinion Bearing (Cup and Cone)
Outer Oil Slinger
Oil Seal
Companion Flange Assembly
Pinion Nut Washer
Pinion Nut
Collapsible Spacer
Baffle Plate
Inner Pinion Bearing (Cup and Cone)
Inner Oil Slinger
Pinion gear adj. Shim-Selective (Position)
Ring gear and Pinion Gear Assembly
Exciter Ring
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Differential Case
Lock Pin
Axle Vent
Gasket
Cover and Clip Assembly
Fill Plug (with Magnet)
Mounting Bracket
Side Bearing Cap Bolt
Side Bearing Cap
Drive Gear Bolts
Differential Adjustment Shims (Side Bearing
Preload and Ring Gear/Pinion Backlash)
(27) Side Bearing (Cup and Cone)
(28) Differential Shaft
(29) Differential Side Gears
4A214
DIFFERENTIAL (REAR)
(30) Side Gear Thrust Washer

(31) Pinion Mate Gears
(32) Thrustwasher-Differential Pinion Mate Gear
EndOFCallout
Inspecting the Axle Before

Disassembly
4. Remove Differential case.

Pry the case from the axle housing at the
differential window".
1. Remove the axle cover from the rear axle and drain
the axle lubricant into a suitable container.
2. Check ring gear backlash. Refer to BACKLASH
ADJUSTMENT" in this section. This information can
be used to determine the cause of the axle problem.
It will also help when setting up the shim packs for
locating and preloading the differential cage.
3. Check case for metal chips and shavings.
Determine where these ships and shavings come
from, such as a broken gear or bearing cage.
If possible, determine the cause of the axle
problem before disassembly.
Disassembly
1. Remove axle shafts.
Refer to axle shaft replacement in this section.
2. Remove ABS sensor.
3. Remove bearing caps and bolts.
Mark the caps and the housing as left and right.
CAUTION: Bearing caps are machined with the
housing and must be assembled in the same
position as removed. Note the matched letter
stamped on the caps and carrier. When assembled,
the letters on the caps must agree in both the
hosizontal and vertical position with the letters on
the carrier.
420RW010
5. Remove side bearing outer races and shims.

Mark the races and shims as left and right, and
place them with the bearing cups.
6. Remove differential side bearings using remover 5
884025870 and plug 5884025850.
415RW041
420RW003
7. Remove ring gear bolts.

Ring gear bolts use right handed threads.
CAUTION: Do not pry the ring gear from the case.
This will damage the ring and the differential case.
DIFFERENTIAL (REAR)
8. Remove ring gear from the differential.
Drive the ring gear off with a brass drift if
necessary.
Check drive pinion bearing preload.
4A215
12. Remove collapsible spacer(1).
415RW011
425RW018
Check the pinion assembly for looseness by

moving it back and forth. (Looseness indicates
excessive bearing wear.)
9. Remove pinion flange nut and washer.
Use flange holder 5884001330 to hold the
pinion flange.
10. Remove pinion flange.
Use flange holder 5884001330 to remove the
pinion flange.
13. Remove outer seal, outer oil slinger and outer pinion
bearing.
14. Remove inner bearing, inner oil slinger and shim
from the pinion.
Press the bearing off the pinion using remover 5
884025870.
415RW042
415RW040
11. Remove pinion from the axle housing.

Thread the pinion nut halfway onto the pinion.
Drive the pinion out of the housing with a hammer
and a soft drift.
Remove the nut and then remove the pinion.

Remove the shim.
15. Remove bearing cups and baffle plate from the axle
housing using a hammer and a punch.
Work the cups out of the housing evenly, moving
the punch back and forth between one side of the
cup and the other.
The baffle plate will be destroyed and should be
replaced with a new one.
4A216
DIFFERENTIAL (REAR)
16. Remove exciter ring.

Remove the exciter ring from the differential using
a mallet or a brass hammer if it is required.
NOTE: Discard the exciter ring after removal.
Axle Housing
The carrier bore for nicks or burrs that would prevent
the outer diameter of the pinion seal from sealing,
The bearing cap bores for nicks or burrs.
The housing for cracks. Replace the housing if any
cracks are found.
The housing for foreign material such as metal chips,
dirt, or rust.
Pinion and Ring Gear
425RS097
Cleaning
Do not steam clean drive parts which have ground and
polished surfaces such as gears, bearings, and shafts.
These parts should be cleaned in a suitable solvent. All
parts should be disassembled before cleaning.
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may be
dried with cimpressed air. Do not allow the bearings to
spin while drying them with compressed air.

It is very important to carefully and thoroughly inspect
all drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or stress
and subsequent replacement of worn parts will
eliminate costly drive component repair after
reassembly.
Pinion and ring gear teeth for cracking, chipping,

scoring, or excessive wear.
Pinion splines for wear.
Pinion flange splines for wear.
The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause
damage to the seal's inside diameter and result in an
oil leak.
Replace all worn or broken parts.
Ring and pinion gears are matched sets and are both
replaced anytime a replacement of either is
necessary.
Bearings
Bearings visually and by feel.
The bearings should feel smooth when oiled and
rotated while applying as much hand pressure as
possible.
The large end of the bearing rollers for wear.
This is where tapered roller bearing wear is most
evident.
Bearing cups for wear, cracks, brinelling and scoring.
Bearing and cups are only replaced as sets.
If the rear axle was operated for an extended period
of time with very loose bearings, the ring gear and
drive pinion will also require replacement.
Low mileage bearings may have minute scratches
and pits on the rollers and the bearing cups from the
initial pre-load. Do not replace a bearing for this
reason.
Bearing cups for cracks or chips.
Shims
Shims for cracks and chips. Damaged shims should
be replaced with an equally sized service shim.
DIFFERENTIAL (REAR)
Reassembly
1. Install pinion bearing races and baffle plate using
outer bearing race installer 5884000080 / inner
bearing race installer 5884025690 and drive
handle 5884000070.
NOTE: Baffle plate must be installed, when install the
inner pinion bearing race.
4A217
2. Clean all the gauge parts.

3. Lubricate the outer and inner bearings with axle
lubricant.
4. Place the bearings into the pinion bearing races.
5. Place the inner oil slinger onto the inner pinion
bearing.
NOTE: The inner oil slinger must be placed between
gauge plate and inner pinion bearing when measuring
the pinion depth.
6. Install gauge plate 5884025780, inner pilot 5
884025730 stud and nut 5884001270 and
outer pilot 5884025750 to the pinion bore.
425RW073
420RW075
7. Hold the stud stationary at the flats of the stud

(and).
Tighten the stud nut
Torque: 2.2Nm (0.2kgm/1.6lbft)
8. Rotate the gauge plate and bearings several
complete revolutions to seat the bearings.
9. Tighten the stud nut until a torque of 1.6 to 2.2 Nm
(0.16 0.22kgm/1.2 to 1.6lbft.) is required to keep
the gauge plate in rotation.
425RW074
4A218
DIFFERENTIAL (REAR)
10. Assemble discs 5884025790, arbor 58840

01280 and dial indicator 5884001260 to the
side bearing bores.
NOTE: The bearing bores must be clean and burr-free.
14. Set the dial indicator to 0". Place it on the mounting

post of the gauging arbor with the contact button
touching the indicator pad.
Force the dial indicator downward until the needle
has made a half turn clockwise. Tighten down the
420RW076
11. Install the side bearing caps and tighten the bolts to
12. Rotate the gauge plate until the gauging area is
parallel with the discs.
13. Position the arbor assembly in the carrier so that the
plunger is centered on the gauge area of the gauge
plate.
425RS020
Legend
(1)
(2)
(3)
(4)
Dial Indicator
Ganging Arbor
Plunger
Gaug Plate
EndOFCallout
15. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate the
position at which the dial indicator shows the
greatest defection. At this point, once again set the
dial indicator to 0".
425RS021
DIFFERENTIAL (REAR)
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle points
to.
4A219

drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indicates
the need for a greater mounting distance (which can
be achieved by decreasing the shim thickness). A
minus number indicates the need for a smaller
mounting distance (which can be achieved by
increasing the shim thickness). If examination
reveals pinion depth code 0", the pinion is
nominal".
425RS022
Legend
EndOFCallout
425RS023
4A220
DIFFERENTIAL (REAR)
18. Select the shim using the chart;
Dial Indicator
Reading
(inches)
Marking (inches)
+3
+2
+1
-1
-2
0.027
-3
0.030
0.028
0.030
0.031
0.030
0.031
0.032
0.030
0.031
0.032
0.033
0.030
0.031
0.032
0.033
0.034
0.030
0.031
0.032
0.033
0.034
0.035
0.029
0.030
0.031
0.032
0.033
0.030
0.031
0.032
0.033
0.034
0.035
0.036
0.034
0.031
0.032
0.033
0.034
0.035
0.036
0.037
0.035
0.032
0.033
0.034
0.035
0.036
0.037
0.038
0.036
0.033
0.034
0.035
0.036
0.037
0.038
0.039
0.037
0.034
0.035
0.036
0.037
0.038
0.039
0.040
0.038
0.035
0.036
0.037
0.038
0.039
0.040
0.041
0.039
0.036
0.037
0.038
0.039
0.040
0.041
0.042
0.040
0.037
0.038
0.039
0.040
0.041
0.042
0.043
0.041
0.038
0.039
0.040
0.041
0.042
0.043
0.044
0.042
0.039
0.040
0.041
0.042
0.043
0.044
0.045
0.043
0.040
0.041
0.042
0.043
0.044
0.045
0.046
0.044
0.041
0.042
0.043
0.044
0.045
0.046
0.047
0.045
0.042
0.043
0.044
0.045
0.046
0.047
0.048
0.046
0.043
0.044
0.045
0.046
0.047
0.048
0.049
0.047
0.044
0.045
0.046
0.047
0.048
0.049
0.050
0.048
0.045
0.046
0.047
0.048
0.049
0.050
0.051
0.049
0.046
0.047
0.048
0.049
0.050
0.051
0.052
0.050
0.047
0.048
0.049
0.050
0.051
0.052
0.053
0.051
0.048
0.049
0.050
0.051
0.052
0.053
0.052
0.049
0.050
0.051
0.052
0.053
0.053
0.050
0.051
0.052
0.053
0.054
0.051
0.052
0.053
0.055
0.052
0.053
0.056
0.053
DIFFERENTIAL (REAR)
19. Remove bearing caps and depth gauging tools.
20. Install the correct pinion shim and inner oil slinger
onto pinion.
NOTE: Do not install pinion gear into housing at this
time.
21. If the exciter ring was removed, install the new
exciter ring onto the differential case by pressing
using the ring gear as a pilot.
425RS047
22. Install ring gear(1) to the differential case(2)
4A221
23. Install new ring gear bolts.

Tighten the ring gear bolts alternately in stages,
gradually pulling the ring gear onto the differential
case.
Tighten the ring gear bolts in sequence
415RS016
Side Bearing Preload Adjustment

1. The side bearing preload adjustment must be made
before installing the pinion.
2. The side bearing preload is adjusted by changing
the thickness of both hte left and right shims equally.
This maintain the original backlash.
3. Install master side bearings 5884025840 onto
the case.
Remove all nicks, burrs, dirt etc., from the hubs to
allow the master bearings to rotate freely.
425RW021
425RW077
4A222
DIFFERENTIAL (REAR)
4. Assemble the differential case into the housing (less

pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
NOTE: Dial indicator set should be capable of a
minimum travel of 5.08mm (0.2in).
425RW078
425RS107
5. Force the differetial assembly as far as it will go in

the opposite direction. Repeat these steps until the
same reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.
Pinion Installation
The bearing cups should have been installed in
Pinion Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the
pinion gear, then install the pinion inner bearing(3)
using installer 5884025740.
Drive the bearing until the bearing cone seats on

the pinion shims.
2. Install a new collpsible spacer.
Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.
Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
6. Install pinion oil seal using installer 5884021650.
7. Install the pinion flange to the pinion by tapping it
with a rawhide hammer until a few threads show
through the pinion flange.
8. Install pinion washer and a new nut while holding
the pinion flange with flange holder 588400133
0.
nut to seat the bearings.
Torque:217-678Nm (22.1-69.1kgm/160-500lbft)
Once there is no end play in the pinion, the
preload torque should be checked.
Remove flange holder 5884001330. Using a
torque wrench, check the pinion preload by
rotating the pinion with the wrench.
DIFFERENTIAL (REAR)
425RW018
Preload should be at 1.0 to 1.6Nm

(10.2-16.3kgcm/8 to 14inlbs.) on new bearings,
or 0.46 to 0.69Nm (4.7-7.0kgcm/4 to 6inlbs.) for
used bearings.
If the preload torque is below the preloads given
above, continue torquing the nut in small
increments. Check the preload after each
tightening. Each tightening increases the bearing
preload by several pounds. If the bearing preload
is exceeded, the pinion will have to be removed,
and a new collapsible spacer installed.
Once a preload of 1.0 to 1.4Nm
(10.2-14.3kgcm/8 to 12inlbs.) has been
obtained, rotate the pinion several times to
assure that the bearings have seated. Recheck
the preload, and adjust if necessary.
4A223
7. Force the ring gear to mesh with the pinion gear.

Rock the ring gear slightly to make sure the gear
teeth are meshed. Repeat this procedure several
times until the same reading is obtained each time.
Be sure the indicator reads zero(0) each time the
ring gear is forced back into contact with the cross
bore face. This reading will be the necessary
amount of thims to be placed between the
differential case and side bearing cone on the ring
gear side.
8. The remaining amount of shims, which is the
difference between the overall found in step 6 of
Side Bearing Pre-load Adjustment and step(7)
above, should be placed on the other side of the
differential case, plus additional 0.38mm (0.015in)
for obtaining preload and backlash.
9. Place the required amount of shims on each hub as
determined in the previous steps and assemble side
bearing cone by using installer 5884025800 and
handle 5884000070.
Determination of Backlash & Preload

Shims
1. Install master side bearings onto the case.
2. Install differential assembly into the carrier.
3. Install the bearing cap and finger tight bolts.
4. Set up the dial indicator.
5. Force the differential assembly away from the pinion
gear until it is completely seated against the cross
bore face of the carrier.
6. With force still applied to the differential case, place
the tip of dial indicator on a machined surface of the
differential case, if available, or on the head of a ring
gear screw, and set the indicator at zero(0).
425RW079
10. Total torque to rotate Increase of pinion torque to

rotate due to differential case assembly shall not
exceed 3.4Nm (34.7kgcm/30inlbs.) divided by the
gear ratio.
4A224
DIFFERENTIAL (REAR)
11. Assembly the spreader 5884025810 and

indicator to the carrier as shown in figure. Spread
the carrier 0.5mm (0.02in) for differential
installation.
6. Place the indicator stem at the heel end of a tooth.

Set the dial indicator so that the stem is in line
with the gear rotation and perpendicular to the
tooth angle.
420RW004
CAUTION: Do not spread the carrier over 0.5mm

(0.02in).
12. Remove the indicator.
Backlash Adjustment
1. Install the differential case assembly and bearing
caps.
2. Rotate the case several times to seat the bearings.
3. Remove the spreader.
4. Install the side bearing cap bolts.
Tighten side bearing cap bolts
5. Install a dial indicator to the case using a magnetic
base.
425RS087
7. Check and record the backlash at three points

around the ring gear.
The pinion must be held stationary when
checking backlash.
The backlash should be the same at each point
within 0.07mm (0.003in). If the backlash varies
more than 0.07mm (0.003in), check for burrs, a
distorted case flange, or uneven bolting
conditions.
8. Backlash at the minimum lash point measured
should be between 0.13 and 0.20mm (0.005 and
0.008in) for all new gear sets.
9. If the backlash is not within specifications, move the
ring gear in or out from the pinion by increasing the
thickness of one shims, and decreasing the
thickness of the other shim by the same amount.
This will maintain the correct rear axls side bearing
preload.
Moving 0.05mm (0.002in) worth of shim from one
side of the differential to the other will change the
backlash adjustment by 0.03mm (0.001in).
10. After obtaining correct tooth contact described in
later, install ABS speed sensor.
11. Install the cover with sealant.
12. Fill the axle lubricant.
DIFFERENTIAL (REAR)
Gear Tooth Pattern Check

Checking the ring gear to pinion tooth pattern is to be
done only after setting up the axle according to the
methods in this section. The pattern check is NEVER to
be used as an initial check, or instead of checking pinion
depth and backlash adjustments.
This check is only to be verify the correct adjustment of
the gear set after set up.
425RS038
Legend
(1)
(2)
(3)
(4)
Heel
Toe
Concave Side (Coast)
Convex Side (Drive)
EndOFCallout
4A225
1. Wipe all oil out of the carrier, and carefully clean

each tooth of the ring gear.
2. Use gear marking compound 1052351 or equivalent
and apply this mixture sparingly to all ring gear
teeth, using a medium-stiff brush. When properly
used, the area of pinion tooth contact will be visible
when hand load is applied.
3. Tighten the bearing cap bolts to the specified
torque.
4. Expand the brake shoes until a torque of 54 to
68Nm (5.5 to 6.9kgm/40 to 50 lbft.) is required to
turn the pinion. A test made without loading the
gears will not give a satisfactory pattern. Turn the
pinion flange with a wrench so that the ring gear
rotates one full revolution, then reverse the rotation
so that the ring gear rotates one revolution in the
opposite direction.
4A226
DIFFERENTIAL (REAR)
5. Observe the pattern on the ring gear teeth and

compare this with figure.
425RS039
Adjustments Affecting Tooth Contact

Two adjustments can be made which will affect tooth
contact pattern: backlash, and the position of the drive
pinion in the case. The effects of bearing preloads are
not readily apparent on head loaded tooth contact
pattern tests; however, these adjustments shuld be
within specifications before proceeding with backlash
and drive pinion adjustments.
The position of the drive pinion is adjusted by increasing
or decreasing the distance between the pinion head and
the centerline of the ring gear.
Decreasing the distance will move the pinion closer to
the centerline of the ring gear. Increasing the distance
will move the pinion farther away from the centerline of
the ring gear.
Backlash is adjusted by means of the side bearing
adjusting shims which move the entire case and ring
gear assembly closer to, or farther from, the drive
pinion. (The adjusting shims are also used to set side
bearing preload.)
If the thickness of the right shim is increased (along with
decreasing the left shim thickness), backlash will
increase.
The backlash will decrease if the left shim thickness is
increased (along with a decrease in right shim
thickness).
DIFFERENTIAL (REAR)
4A227
Differential Case Assembly

Disassembled View
425RW014
Legend
(1)
(2)
(3)
(4)
Thrust Washer (for Pinion Gear)

Pinion Mate Gear
Thrust Washer(for Side Gear)
Side Gear
EndOFCallout
(5)
(6)
(7)
(8)
Differential Shaft
Lock Pin
Bolt
Differential Case
4A228
DIFFERENTIAL (REAR)
Disassembly
Reassembly
1. Remove lock pin using a small drift.
1. Install side gear with thrust washer.

2. Install the pinion mate gear with thrust washer by
pinion mate gears simultaneously in the same
direction.
425RS098
2. Remove the differential shaft by using a soft metal

rod and a hammer.
425RS048
3. Install differential shaft.

1. Be sure to install the differential shaft so that it is
in alignment with the lock pin hole in the
differential case.
425RS043
3. Remove pinion mate gear and thrust washer.

4. Remove side gear and thrust washer.

Ring gear, pinion gear
Bearing
Side gear, pinion mate gear, differential shaft
Differential case, carrier
Thrust washer
Oil seal
425RS049
4. Install lock pin.

After lock pin installation, stake the case to secure
the lock pin.
DIFFERENTIAL (REAR)
4A229
Limited Slip Differential Assembly

Disassembled View
425RW004
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Thrust WasherDifferential Pinion Mate Gear

Pinion Mate Gear
Dished Spacer
Disc
Plate
Differential Plate Retainer
(7)
(8)
(9)
(10)
(11)
Lock Pin
Differential Case
Ring Gear Bolts
Differential Shaft
Differential Side Gear
EndOFCallout
Disassembly
1. Place the holder 5884025830 into a vise.
Position the differential on the holder with the ring
gear side down.
2. Remove Lock pin (1) from differential shaft using a
punch.
3. Remove Differential shaft (2) using hammer and
punch.
Place shop towel behind case to prevent differential
shaft from dropping out of case.
425RW005
4A230
DIFFERENTIAL (REAR)
4. Assemble clutch pack unloading tool 588402586

0.
a Install cap(3) to the bottom differential side gear.
b Install threaded screw cap(2) to top differential
side gear. Thread forcing screws(1) into
threaded screw cap until it becomes centered
into the bottom cap.
7. Assemble LSD service adapter 5884025820

onto long drive handle 5884000070. Insert it into
differential shaft hole of case. Pull on handle and
rotate case until pinion mate gears can be removed.
901RW289
901RW288
8. Remove pinion mate gears.

9. Hold side gear top clutch pack (1) with one hand
and remove positraction unloading tools.
Tighten forcing screw until tight enough to

collapse dished spacers and and allow
looseness between side and pinion mate gears.
5. Both pinion mate gear thrust washers using a shim
stock (1) of 0.51 mm (0.020 in.) or equivalent tool to
push out washers.
425RW008
10. Remove top side gear and clutch pack.
425RW007
6. Relieve tension of dished spacers by loosening

forcing screw.
NOTE:
You may have to adjust the forcing screw slightly to
allow the case to rotate.
NOTE:
Keep the stack of plates and discs intact and in
exactly the same position while they are being
removed.
11. Remove case from holder. Turn case with flange or
ring gear side up to allow side gear and clutch pack
to be removed from case.
DIFFERENTIAL (REAR)
12. Remove differential plate retainer from both clutch
packs to allow separation of the plates and discs.
NOTE:
Keep the discs and plates in the same order as they
were removed.
4A231
Reassembly
1. Lubricate thrust face of side gears, plates and discs
with the proper limited slip rear axle lubricant.
2. Assemble plates and discs in exactly in the same
position as they were removed, regardless of
whether they are new or original.
3. Install differential plate retainer to ears of plates.
NOTE:
Make sure both retainers are completely seated on
ears of plates.
4. Install clutch pack and side gear into bottom side
gear bore. Make sure clutch pack stays assembled
to side gear splines, and that retainers are
completely seated into pockets of case.
425RW009
Legend
(1)
(2)
(3)
(4)
Differential Plate
Differential Disc
Dished Spacer
Side Gear
EndOFCallout

Cleaning
NOTE:
To prevent clutch pack from falling out of case, hold
clutch pack in place by hand while repositioning case
on bench.
5. Install other side gear and clutch pack. Make sure
clutch pack stays assembled to side gear splines,
and retainers are completely seated into pockets of
case.
6. Hold clutch pack in position and assemble screw
cap(2), cap(3) and forcing screw(1). Tighten forcing
screw into bottom cap to hold both clutch packs in
position.
7. With tools assembled to case, position case on
holder 5884025830 by aligning splines of side
gear with those of shaft. Tighten forcing screw to
compress clutch packs in order to provide
clearance for pinion mate gears.
All parts with solvent.
Visual Inspection
Clean all parts with solvent.
Plates and Discs. If any one disc or plate in either
stack shows evidence of excessive wear or scoring,
the complete stack is to be replaced on both sides.
Side Gears and Pinion Mate Gears. The gear teeth of
these parts should be checked for extreme wear and
possible cracks. The external teeth of the side gear,
which retain the concentric groove discs, should also
be checked for wear or cracks.
If replacement of one gear is required due to wear,
etc., then both side gears, pinion mate gears, and
thrust washers are to be replaced.
Differential Shaft. If excessive wear is evident, the
differential shaft should be replaced.
Differential Plate Retainers. If wear is evident on any
one of the differential plate retainers, all four
retainers must be replaced.
Differential Case. If scoring, wear or metal pickup is
evident on the machined surfaces, replacement of the
case is necessary.
901RW288
8. Install pinion mate gears.

Place the pinion mate gears into the differential
180 degrees apart.
4A232
DIFFERENTIAL (REAR)
9. While holding gears in place, insert LSD service

adapter 5884025820 with long drive handle 5
884000070 in differential shaft hole of case. Pull
on long drive handle and rotate case, allowing
gears to turn. Make sure that holes in pinion mate
gears align with holes in case.
Stake metal of case over pin in two places, 180

degrees apart.
425RW013
901RW290
It may be necessary to adjust tension on forcing

screw to rotate case.
10. Tighten forcing screw to compress the clutch packs,
to allow installation of spherical thrust washers.
11. Lubricate spherical thrust washers (2), and
assemble into case (1). Use a small screw driver to
push washers into place. Remove tools.
425RW012
12. Position differential shaft in case and drive in with

hammer. Be sure lock pin hole of differential shaft
(5) is properly aligned to allow installation of lock
pin (3). Be sure that thrust washers and differential
pinion mate gears are aligned with the differential
case (4). Install new lock pin to proper depth using a
punch.
DIFFERENTIAL (REAR)
4A233

Rear axle
Type
Rear axle Size
Gear type
Salisbury, Semifloating
226mm (8.9in)
Hypoid
Gear ratio (to 1)
4.100 (6VD1 with A/T)

4.300 (6VD1 with M/T)
Differential type
Two pinion
Lubricant Grade
GL5: (Standard differential)

GL5, LSD: (Limited slip differential)
Locking Differential Lubricant
Capacity
80W90 GL5
(USE Limited Slip Differential Gear Lubricant or Friction
Modifier Organic Additive)
1.77 liter (1.87 US qt)
4A234
DIFFERENTIAL (REAR)
E04RX010
DIFFERENTIAL (REAR)
4A235
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884001330
(J861401)
Pinion flange holder
5884000070
(J8592)
Grip
5884021650
(J37263)
Installer; Pinion oil seal
5884025690
(J42836)
outer race
5884025870
(J42379)
Remover; Bearing
5884025750
(J42824)
Pilot;Outer
5884025850
(J39830)
plug
5884001270
(J2177743)
Nut & Stud
5884000080
(J861101)
outer race
5884025730
(J42827)
Pilot;Inner
4A236
DIFFERENTIAL (REAR)
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884025780
(J398372)
Gauge plate
5884023230
(J39602)
5884001260
(J8001)
Dial indicator
5884025810
(J24385B)
Spreader
5884025790
(J398371)
Disc (2 required)
5884025860
(J39858)
Clutch pack unloading
tool kit
5884001280
(J235971)
Arbor
5884025820
(J39834)
Limitedslip differential
(LSD) service adapter
5884025740
(J42828)
5884025830
(J39824)
Holder
5884025800
(J21784)
5884025840
(J39836)
Side bearing preload
master bearings
SECTION
4B1
DRIVELINE/AXLE
CONTENTS
Outline of Shift on The Fly System .............
Functions of Indicator Lamp .......................
Diagnosis ....................................................
Shift On The Fly Vacuum Piping and
Electrical Equipment ................................
Vacuum Piping Diagram .............................
4B - 1
4B - 2
4B - 2
4B - 6
4B - 7
4B - 18
4B - 18
Service Precaution
REPAIRS.
Actuator Assembly......................................
Vacuum Tank..............................................
4WD Control Unit ..........................................
4WD Control Unit Associated Parts............
Removal......................................................
Installation...................................................
4B - 18
4B - 18
4B - 19
4B - 22
4B - 22
4B - 23
4B - 23

and systems.
4B2

Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electrically by
driver's pressing the 4WD switch (push button type) on
instrument panel.
This system controls below operations. (Shifting
between 4H" and 4L" must be performed by transfer
control lever on the floor.)
1. Shifting the transfer front output gear (Connecting

to, and disconnecting from, front propeller shaft by
motor actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
4. Indicator on instrument panel.
5. 4WD out signal to other Electronic Hydraulic Control
Unit.
System Diagrams
412RX009

Normal Operation
The motor actuator mounted on transfer rear case is
driven by signal from 4WD switch on instrument panel.
After complete the connecting transfer front output gear
to, or disconnecting it from, front propeller shaft,
4B3
condition of the transfer position switch changes. The

vacuum solenoid valve (VSV) is driven by the signal
from transfer position switch and the vacuum actuator
connects front wheels to, or disconnect them from, front
axles.
Time Chart of Shifting Under Normal Condition
F04RW002
4B4
Retrial
The motor actuator starts transfer gear shifting after
signal from 4WD switch on instrument panel has been
received. But the shifting may be impossible in cold
weather or under high speed condition. When 2
seconds have passed since transfer gear shifting
started and the transfer position switch dose not turn on
(the gear engagement is not completed), the motor
reverses its rotation for 1.2 seconds and tries again to
shift transfer gear. This procedure is repeated 3 times
in maximum. While this procedure, 4WD indicator lamp

blinks by 2 Hz.
If the transfer position switch does not turn on after
aforementioned procedure has been repeated 3 times,
the gear shifting is stopped and 4WD indicator lamp's
blinking changes from 2Hz to 4Hz to notify driver that
the gear shifting is stopped. This blinking of indicator
lamp continues until 4WD switch is returned from 4WD
to 2WD.
Time Chart of Shifting Under Severe Condition (retrial)
F04RX004

Warning at 4L" position :In view of the shifting
mechanism of transfer, the gear shifting from 4WD to
2WD at 4L" condition is impossible. Therefore, the
transfer position switch can not be turned off by 4WD
4B5
switch when vehicle is in 4L" condition. In the case this

condition continues for 2 seconds, the shifting to 2WD is
stopped and the indicator lamp's blinking changes from
2Hz to 4Hz to notify driver of wrong operation.
Time Chart of Shifting from 4WD to 2WD at 4L" Condition
F04RX005
4WD out signal to other Electronic Hydraulic

Control Unit : ECU of shift on the fly sends 4WD out
signal to other Electronic Hydraulic Control Unit as
below.
4WD out signal
(Period)
Vehicle Condition
Transfer position switch
Front axle switch
120 ms
2WD
2WD (Open)
2WD (Open)
240 ms
4WD
4WD (Close)
4WD (Close)
4B6
Functions of Indicator Lamp

Indication of vehicle condition : Indicator lamp is
controlled by ECU of shift on the fly and shows vehicle
conditions as below.
Indicator
Vehicle condition
4WD switch
Transfer position
switch
Front axle switch
Off
2WD
Off (Close)
2WD (Open)
2WD (Open)
On
4WD
On (Open)
4WD (Close)
4WD (Close)
Blink (2Hz)
Operating
On (Open)
4WD (Close)
2WD (Open)
Off (Close)
2WD (Open)
4WD (Close)
On (Open)
2WD (Open)
2WD (Open)
Off (Close)
4WD (Close)
4WD (Close)
Blink (4Hz)
Stop operating
Bulb check :The bulb of indicator lamp is checked for 2

seconds when ignition key is turned on.
Time Chart of Bulb Checking
F04RW004
Retrials from 2WD to 4WD :In cold weather or under

high speed condition, the gear shifting (engagement)
sometimes dose not complete by 3 trials. In such case,
the indicator lamp inform driver of this incident as
aforementioned chart (shown at Retrial in Outline of
shift on the fly system.)
Diagnosis
Before Judging That Troubles Occur
(Unfaulty mode)
1. In case that blinking frequency of the 4WD
indicator changes from 2Hz to 4Hz.
When heavy synchronization load is needed, the
motor actuator tries the shifting transfer gear three
times including the activation shifting. While the
motor actuator tries shifting, the indicator blinks by
2Hz. If the third shifting fails, the indicator's blinking
changes from 2Hz to 4Hz at the same time that the
motor actuator shifted back to 2WD.
Heavy synchronization load occurs by
extremely lower temperature.
higher speed.rotation difference of wheels during
cornering.
Solution 1: Operate again after stop the vehicle
or slow down.
blinking by 2Hz for more than 11.5 seconds.
When there is rotation difference of wheels or there
is phase difference between front wheels and axles,
it is difficult to connect front wheels to front axles.
The 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.
meters.
4B7

blinking by 2Hz .
The 4WD indicator continues blinking by 2Hz until
both shifting the transfer gear and disconnecting the
front wheels are completed when switching 4WD to
2WD. When drive line is loaded with torsional
torque, the shifting transfer gear and disconnecting
front wheels are impossible. In this case, removal of
torsional torque on drive line make the shifting
transfer gear and disconnecting front wheels
possible.
meters.
2. In case that the 4WD indicator's blinking changes
from 2Hz to 4Hz.
Check the position of transfer lever. Is it at 4L"
position? In view of the shifting mechanism of
transfer, the gear shifting from 4WD to 2WD at 4L"
condition is impossible.
Solution 4: Push the 4WD switch to 4WD, shift
the transfer lever to High" position and reoperate the 4WD switch to 2WD.
4B8
Parts Location
D08RX290
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Battery
H32
I19
I1
I2
B8
B19
C32
EndOFCallout
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
H15
C16
C31
H18
H9 (X22SE)
C15
M21
H9 (6VD1), H10
M11, M12
4B9
Wiring Diagram 1
D08RX272
4B10
Wiring Diagram 2 (6VD1)
D08RX274
4B11
Wiring Diagram 2 (X22SE)
D08RX273
4B12
Connector List
No.
Connector face
No.
B-8
H-15
B-19
H-18
C-15
H-32
C-16
I-1
C-31
I-2
C-32
I-19
H-9
M-11
H-10
(6VD1
)
M-12
H-10
(X22S
E)
M-21
Connector face

Diagnosis of The Faults Based on the
Status of 4WD Indicator Lamp, 4WD Switch
and T/F Change Lever
Diagnosis charts are shown on below. If troubles can
not be solved after every chart was traced, troubles may
occur in the ECU. In this case, replace the ECU and
trace every chart again.
Step

1. In case that 4WD indicator's blinking changes
from 2Hz to 4Hz after Solution 1 is carried out.
Faults occur in the motor actuator or the transfer
case assembly. Remove the motor actuator and
check function. If problem was found and it was
repaired, try Solution 1 again. After that,
disassemble the transfer case assembly for check
and repair or replace. If incident is not improved
after above mentioned actions were taken, replace
the ECU.
2. In case that 4WD indicator does not blink nor
light, when switching from 2WD to 4WD.
Action
Yes
No
Go to Step 2
Turn on the ignition

and trace this chart
from start.
Go to Step 3
Burning out of
indicator lamp or
disconnection of
harness wire.
Trace this chart
repair or replace.
1
Is ignition turned on?
2
Does the indicator light during two seconds initialization after
ignition is turned on?
3
Is the 4WD switch turned from 2WD to 4WD?
4B13
Short-circuit
(body short) on
harness of the
4WD switch.
Fault of the
4WD switch
(holding the
closed
condition).
Trace this chart
from the start
after repair or
replace.
Push the 4WD

switch to 4WD.
4B14
3. Case that the indicator keeps blinking by 2Hz

Step
1
Action
Yes
No
Try Solution 2
pressure and
replace worn tires.
Go to Step 2
Go to Step 3
Disconnection
of the motor
actuator
harness wiring.
Trace this chart
from the start
after repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults of
transfer case.
Disassemble
the transfer
case for check.
Trace this chart
from the start
after repair or
replace.
Go to Step 4
Faults on the
transfer position
switch or its
harness. Trace
this chart from
the start after
repair or
replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the diagnosis
chart in Front
Axle ASM
section. After
that, trace this
chart from the
start.
switch.

Step
4
Action
Yes

Internal faults on
axle switch. Trace
this chart from the
start after replace.
4B15
No
Disconnection
on the axle
harness. Trace
this chart from
the start after
repair or
replace.
Faults on Front
Axle ASM.
Trace the
diagnosis chart
in Front Axle
ASM section.
After that, trace
this chart from
the start.

1. Case that indicator dose not blink nor turn out.
Step
Action
Yes
No
Go to Step 2
Short circuit of the

indicator harness.
Disconnection on
the 4WD switch
harness or
breakdown of the
4WD switch in
open state. Trace
this chart from the
start after repair or
replace.
Turn the 4WD

switch to 2WD
position. Trace this
chart from the
start.
1
Does the indicator turn out by ignition off?
2
Is the 4WD switch on 2WD position?
4B16
2. Case that indicator keeps 2Hz blinking after aforementioned Solution 3 is carried out.
Step
1
Action
2
Yes
No
Try Solution 3
pressure and
replace worn tires.
Go to Step 2
Faults on the
harness wiring
of motor
actuator. Trace
this chart from
the start after
repair or
replace.
Internal faults
on transfer
case.
Disassemble
the transfer
case for check.
Trace this chart
from the start
after repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after or replace.
Go to Step 3
Go to Step 4
Faults on the
transfer position
switch or its
harness. Trace
this chart from
the start after
repair or
replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the diagnosis
chart in Front
Axle ASM
section. After
that, trace this
chart from the
start.
switch.

Step
4
Action
Yes
Internal faults
on axle switch.
Trace this chart
from the start
after replace.
Faults on Front
Axle ASM.
Trace the
diagnosis chart
in Front Axle
ASM section.
After that, trace
this chart from
the start.
4B17
No
Short circuit (body

short) or
disconnection of
the axle harness.
Trace this chart
repair or replace.
3. Case that indicator's blinking changes to 4Hz

Step
Action
1
Yes
Faults on the
harness wiring
of motor
actuator. Trace
this chart from
the start after
repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults
on transfer
case.
Disassemble
the transfer
case for check.
Trace this chart
from the start
after repair or
replace.
No
Faults on the ECU.

Trace this chart
replace.
4B18
Shift On The Fly Vacuum Piping and Electrical Equipment

Vacuum Piping Diagram
C04RX001
Actuator Assembly
Vacuum Tank
412RW024
412RW025
4B19

Vacuum Piping
C04RW004
1. Pull out the Hose A in figure and install a vacuum

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.
10. If Check 8) or 9) has revealed stoppage, check and
see that there is no bend, foreign matter in the hose
or in the filter. If there is trouble, repair or replace.
Check Valve
C04RS004
1. Apply vacuum from the orange colored side(1).

Vacuum:400mmHg
2. Check leakage of vacuum.
3. Make sure that vacuum cannot be applied from the
black colored side(2).
4. If vacuum is not applicable as much as 400mmHg,
and if there is resistance on the intake side, replace
with a new check valve.
4B20
VSV Assembly
1. With battery not connected (Usual).

AC:There is continuity
Inspect the vehicle side harness as follows:
B:Closed
2. With battery connected
A B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.
Functional Detective Switch
412RX008
Legend
(1) Grey
(2) Blue
EndOFCallout
1. Remove connector.
2. Shift transfer lever to 2H and start the engine.
NOTE: The vehicle should not be started, with the
engine idling.
3. Make sure that there is continuity in the vehicle side
of harness. If there is no continuity, check transfer
shift switch and wiring.
Inspect the both VSVs as follows
412RW067
1. With ball (1) being free

AB:There is continuity
2. With ball forced into the switch
AB:No continuity
Motor Actuator Assembly

Inspect the function of the motor actuator assembly as
follows:
1. Disassemble the motor actuator from transfer rear
case.
F04RS004
412RW037
Legend
4B21
412RX002
Legend
(1)
(2)
(3)
(4)
(3) Shift Rod

(4) Connector
EndOFCallout
at 4WD position.
2WD
4WD
Shift Rod
Connector
EndOFCallout
4. If 2) and 3) fail, replace with a new motor actuator.
Transfer Position Switch
412RX001
Legend
(1)
(2)
(3)
(4)
2WD
4WD
Shift Rod
Connector
EndOFCallout
at 2WD position.
412RW040
Legend
(1) Ball
EndOFCallout
1. With ball being free.
AB : There is continuity.
2. With ball forced into the switch.
AB : No continuity.
4B22
4WD Control Unit

4WD Control Unit Associated Parts
412RW042
Legend
(1) Center Console Assembly
EndOFCallout
Removal
1. Remove center console assembly.
Refer to Interior Trim in Body and Accessories
section.
2. Remove two screws and harness connector (1) from
4WD control unit.
412RW041
Legend
(1) Harness Connector
EndOFCallout
Installation
1. Connect harness connector, then install 4WD
control unit.
2. Install center console assembly.
4B23
SECTION
DRIVE SHAFT SYSTEM
4C1
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Diagnosis ....................................................
Front Hub and Disc .......................................
Disassembly ...............................................
Reassembly ................................................
Front Drive Shaft Joint ..................................
Front Drive Shaft Joints Replacement ........
Front Axle Drive Shaft ...................................
Front Axle Drive Shaft and
Disassembly ...............................................
Bushing Replacement ................................
Reassembly ................................................
Shift On The Fly System and
Disassembly ...............................................
Reassembly ................................................
Special Tools ..............................................
Propeller Shaft ..............................................
Universal Joint ............................................
Diagnosis of Propeller Shaft and
4C - 1
4C - 2
4C - 2
4C - 3
4C - 3
4C - 3
4C - 4
4C - 5
4C - 8
4C - 8
4C - 9
4C - 9
4C - 10
4C - 11
4C - 11
4C - 11
4C - 14
4C - 14
4C - 14
4C - 16
4C - 19
4C - 22
4C - 24
4C - 25
4C - 25
4C - 26
Service Precaution
REPAIRS.
Universal Joint.........................................
Front Propeller Shaft .....................................
Front Propeller Shaft and
Removal......................................................
Installation...................................................
Rear Propeller Shaft......................................
Rear Propeller Shaft and
Removal......................................................
Installation...................................................
Universal Joint Disassembly.......................
Inspection ...................................................
Universal Joint Reassembly .......................
4C - 27
4C - 28
4C - 28
4C - 28
4C - 29
4C - 29
4C - 30
4C - 32
4C - 33
4C - 35
4C - 36
4C - 38
4C - 39
4C - 40
4C - 40
4C - 40
4C - 40
4C - 41
4C - 42
4C - 44
4C - 45
4C - 46
4C - 47

and systems.
4C2
DRIVE SHAFT SYSTEM
General Description
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 front propeller shaft and universal
joint, refer to Front Propeller Shaft in this section.
Diagnosis
Condition
Possible cause
Correction
Repair or replace.
Too much gear oil.
Tighten or replace.

Joint


bellows.

Coast"

shaft bolts.
Tighten.
Replace.
Repair.
Replace.

drive shaft joint).

shaft joint).
Balance or replace.
Align.

incorrect.

gear or side gear.

side gear.
Wheel bearing worn.
Tighten or replace.
Tighten or replace.

or broken.
Tighten or replace.

adjusted.
Adjust or replace.
Tighten or replace.

Acceleration

Wanders and Pulls
Front Wheel Shimmy
DRIVE SHAFT SYSTEM
4C3
Front Hub and Disc

Disassembled View
411RW001
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Bolt
Cap
Snap Ring and Shim
Hub Flange
Lock Washer and Lock Screw
Hub Nut
Outer Bearing
(8)
(9)
(10)
(11)
(12)
(13)
Bolt
Wheel Pin
ABS Sensor Ring
Inner Bearing
Oil Seal
EndOFCallout
Disassembly
1. Before disassembly, select the 2WD position with
the 4WD switch.
2. Jack up the front of vehicle and support frame with
jack stands.
3. Remove the disc brake caliper assembly and hang it

on the frame with wires. Refer to Disk Brakes in
Brake section.
4. Remove Bolt.
5. Remove cap.
6. Remove snap ring and shim.
4C4
DRIVE SHAFT SYSTEM
7. Remove hub flange.

8. Remove lock washer and lock screw.
9. Use wrench 5884021170, remove hub nut.
Place hub on a suitable work surface and remove

the studs by using a hammer.
411RS004
411RW005
10. Remove hub and disc assembly.

11. Remove ABS sensor ring.
14. Remove inner bearing.
15. Remove bolt , if necessary, replace the wheel pin in
the following manner.
Apply a scribe mark(1) to disc to hub.
Clamp the hub and disc assembly in a vise, using
protective pads. Remove the 6 disctohub
retaining bolts.
411RS003

Hub
Hub bearing oil seal
Knuckle spindle
Disc
Caliper
Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)
ABS sensor ring
For inspection and servicing of disc caliper and related
parts, refer to Disc Brakes in Brake section.
DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.
Place the hub on a wood workbench or a block of
wood approx. 6" by 6 " to protect the wheel stud
ends and threads.
Insert a wheel stud using a hammer.
Be sure the wheel stud is started squarely and
seats completely.
4C5

00070, then install the inner bearing by driving it
into the hub.
411RW006

00070 then install the outer bearing by driving it
into the hub.
411RS005
2. Align scribe marks(1) and attach the hub to the disc,

then tighten the bolts to the specified torque.
411RW007
411RS003
4C6
DRIVE SHAFT SYSTEM
5. Apply grease (NLGI No.2 or equivalent) to the lip

portion, then install oil seal by using installer 5
884021200 and grip 5884000070.
8. Install hub nut.

Turn to the place where there is a chamfer in the
tapped hole to the outer side, then attach the nut by
using front hub nut wrench 5884021170.
411RW008
6. Install ABS sensor ring, then tighten the bolts to the

specified torque.
7. Install hub and disc assembly.
Apply grease in the hub.
Apply wheel bearing type grease NLGI No. 2 or
equivalent to the outer and inner bearing.
Grease Amount
Hub: 35g (1.23oz)
Outer bearing: 10g (0.35oz)
Inner bearing: 15g (0.53oz)
411RW005
Preload Adjustment
1. Tighten the hub nut to 29 Nm (3.0kgm/22lbft),
then fully loosen the nut.
2. Tighten the hub nut to the value given below,
using a spring scale on the wheel pin.
New bearing and New oil seal
5.5lb)
Used bearing and New oil seal
4.0lb)
If the measured bearing preload is outside the
specifications, adjust it by loosening or tightening
the bearing nut.
411RS009
Legend
(1) Inner Bearing
(2) Hub
(3) Outer Bearing
EndOFCallout
411RS011
DRIVE SHAFT SYSTEM

9. 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, then attach the
washer.
If the bolt holes in the lock plate are not aligned
with the corresponding holes in the nut, reverse
the lock plate.
If the bolt holes are still out of alignment, turn in
the nut just enough to obtain alignment.
Screw is to be fastened tightly so its head may
come lower than the surface of the washer.
4C7
10. Apply adhesive (LOCTITE 515 or equivalent) to

both joining flange faces then install hub flange.
11. Install snap ring and shim.
Adjust the clearance between the free wheeling
hub body and the snap ring.
Clearance: 0mm0.3mm (0in0.012in)
Shims Available: 0.2mm, 0.3mm, 0.5mm, 1.0mm
(0.008in, 0.012in, 0.020in, 0.039in)
411RW002
12. Install hub cap.

411RS012
4C8
DRIVE SHAFT SYSTEM
Front Drive Shaft Joint

Front Drive Shaft Joints
Replacement
Inspection Of Shift On The Fly System Gear

Oil
Refer to Front Drive Axle Assembly Replacement in

this section, and refer to Front Hub and Disc Overhaul
Front Hub Bearing Preload Check

Check the hub bearing preload at the wheel pin.
New bearing and New oil seal:
20 25N (2.0 2.5kgm/4.4 5.5lb)
Used bearing and New oil seal:
12 18N (1.2 1.8kgm/2.6 4.0lb)
412RW035
1. Open filler plug and make sure that the oil up to the
plug port.
If the oil is short, replenish with gear oil GL5 grade.
2. Tighten the filler plug to specified torque.
411RS011
DRIVE SHAFT SYSTEM
4C9
Front Axle Drive Shaft

Front Axle Drive Shaft and Associated Parts
412RX012
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Axle Case and Differential

Snap Ring
Bearing
Snap Ring
Oil Seal
Bracket
Bolt
Drive Shaft Joint Assembly
DOJ Case
Circlip
Ball
Snap Ring
EndOFCallout
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Ball Retainer
Ball Guide
Band
Bellows
Band
Band
Bellows
Band
BJ Shaft
Dust Seal
4C10
DRIVE SHAFT SYSTEM
Disassembly
NOTE: For the left side, follow the same steps as right
side.
4. Remove drive shaft joint assembly.

5. Remove the six balls (1) with a screwdriver or
equivalent.
412RS012
6. Using snap ring pliers, remove the snap ring (1)

fastening the ball retainer to the center shaft.
412RS009
2. Remove band(1).
3. Pry off circlip (1) with a screwdriver or equivalent.
412RS013
412RS010
DRIVE SHAFT SYSTEM
4C11
Bushing Replacement
7. Remove ball retainer, ball guide and bellows.

Remove the bushings using a remover 58840

23090 and hammer.
412RS014
9. Remove band(1).
10. Remove bellows.
11. Remove dust seal.
12. Remove BJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.
412RW051
By using installer and base 5884023090, press

fit the bushings into the bracket.

1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
412RW052
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
5. Apply 150g of the specified grease in BJ.
6. Install dust seal.
installation then install bellows.
4C12
DRIVE SHAFT SYSTEM
8. Install band. Note the setting direction. After

installation, check that the bellows is free from
distortion.
13. Align the track on the ball (1) retainer with the
window in the cage, and install the six balls into
position.
412RS017
9. Install another bellows and fix band.

10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS018
14. Pack 150g of the specified grease in DOJ case, then

install drive shaft joint assembly. After reassembly,
move the DOJ longitudinally several times to get to
fit.
15. Install the circlip (1) so that open ends are
positioned away from the ball groove.
412RS019
412RS013
DRIVE SHAFT SYSTEM
412RS020
Legend
(1) Outer Case
(2) Circlip
(3) Open Ends
EndOFCallout
16. Install bellows. Adjust the air pressure within the
bellows by inserting a screwdriver or equivalent, so
that it equals atmospheric pressure.
412RS021
17. Install band. After installation, check that the bellows

is free from distortion.
4C13
4C14
DRIVE SHAFT SYSTEM

Shift On The Fly System and Associated Parts
412RW031
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Filler Plug
Bolt
Oil Seal
Snap Ring(External)
Inner Shaft Bearing
Snap Ring(Internal)
Inner Shaft
Needle Bearing
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Clutch Gear
Sleeve
Housing
Front Axle Drive Shaft(LH side) with Bracket
Bolt
Actuator Assembly
Bolt
EndOFCallout
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.
3. Remove actuator assembly and draw out actuator

ASM.
4. Remove housing.
5. Remove sleeve.
DRIVE SHAFT SYSTEM

6. Remove clutch gear.
7. Remove snap ring from front axle case by using
snap ring pliers.
4C15
10. Remove inner shaft bearing.

NOTE: Be careful not to damage the shaft.
412RW015
412RW017
8. Take out inner shaft from front axle case.

9. Remove snap ring from inner shaft by using snap
ring pliers.
11. Remove needle bearing from inner shaft by using a

remover 5884000270 and sliding hammer 5
884000840.
412RS045
412RW016
12. Remove oil seal from front axle case.

NOTE: Be careful not to damage the front axle case.
4C16
DRIVE SHAFT SYSTEM
Inner Shaft RunOut
Inspect the removed parts. If there are abnormalities

such as wear and damage, take corrective action or
replace.
With both end centers supported, rotate the shaft slowly

and measure deflection with a dial gauge.
NOTE: Do not heat the shaft to correct its bend.
Visual Check
1. Check and see if the inner shaft has such
abnormalities as wear and damage.
412RS026
Inner Shaft Bearing

412RW014
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
such an abnormality in its gear part (a slide with
sleeve), replace the shaft.
412RW006
Legend
(1) Inner Shaft Bearing
(2) Inner Shaft
(3) Clutch Gear
420RS008
EndOFCallout
1. Inspect the state of inner shaft bearing. If any
abnormality such as smoothlessness is found,
replace with a new inner shaft bearing.
2. Insert a clutch gear and check the state of needle
bearing.
3. If there is an abnormality such as smoothlessness,
replace the needle bearing.
DRIVE SHAFT SYSTEM
4C17
Sleeve Condition
Clutch Gear Condition
Check and see that there is not wear damage, or

cracking in the sleeve.
Check and see that there is not wear, damage, crack, or

any other abnormality in the clutch gear.
NOTE: Close inspection of the groove and inner gear

are required because those are important parts.
Clutch Gear Function
Sleeve Function
412RW066
412RW011
Operate the sleeve with the inner shaft combined with

the clutch gear and if smoothlessness is felt, replace the
sleeve.
If there is an abnormality such as roughness when

operated in combination with sleeve, replace the clutch
gear.
NOTE: When inspecting, gear oil should be applied to
the contact surface of gear.
Clutch Gear Journal Diameter
NOTE: Gear oil should be applied to the contact

surface of gear.
Check the width of sleeve center groove.
Make sure of the size illustrated.

Limit:36.98mm (1.456in)
412RW065
412RW022
4C18
DRIVE SHAFT SYSTEM
Actuator
Check and see that there is no damage, cracking, or
other abnormality.
Functional Check
412RW007
Disconnect the shift position switch and make sure of

function with a vacuum of 400 mmHg applied to Ports
A and B, in accordance with the table below.
412RW021
State
Port A
Port B
Function
400 mmHg
A/P
A/P
400 mmHg
If there is an abnormality, replace the actuator as an

assembly.
412RW013
NOTE:
1. If the actuator works under 400mmHg or less,
there is no functional problem.
2. Be careful not to permit the entry of water or dust
into the ports of the actuator.
Dimentional Check
Measure illustrated sizes 1, 2, and 3.
Limit
1=64.1mm (2.52in)
2=6.7mm (0.26in)
3=6.7mm (0.26in)
DRIVE SHAFT SYSTEM
4C19
2. Check the oil seal installation position (from shaft

end to oil seal).
Depth:24.225.2mm(0.950.99in)
412RS037
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer 5
884024070 and grip 5884000070.
412RS052
3. Force a new needle bearing into inner shaft by using

a Installer 5884024080 and grip 588400007
0.
412RW034
412RS051
4C20
DRIVE SHAFT SYSTEM
4. Place a new snap ring(internal) in inner shaft.

Force a new inner shaft bearing into the inner shaft.
8. Apply differential gear oil to clutch gear, then install

clutch gear.
9. Apply differential gear oil to sleeve, then install
sleeve.
10. Clean contact surface with the front axle and
actuator mounting surface. Apply liquid gasket to
the contact surface on the front axle case, then
install in the housing.
412RS044
5. Install snap ring(external).

NOTE: Be careful not to damage the inner shaft.
6. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.
412RW023
NOTE: Be careful not to damage seal.

7. Install snap ring internal in the groove of front axle
case.

12. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
NOTE: Be sure to install the snap ring properly.
13. Apply liquid gasket to the contact surface on the
actuator side.
412RW017
412RW012
DRIVE SHAFT SYSTEM

14. Align shift arm with the groove of sleeve and install
the actuator.
Torque:9Nm(0.9kgm/78lbin)
16. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
17. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity:1.4lit (1.48USqt)
Actuator Housing
Oil Capacity:0.12lit(0.13USqt)
18. Install filler plug through gasket and tighten to
specified torque.
4C21
4C22
DRIVE SHAFT SYSTEM

Front drive axle oil capacity
1.4 liter (1.48 US qt)(Differential)

0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricant
Axle shaft type
GL5 (75W90) Refer to chart in General Information

Constant velocity joint(Birfield joint type and double offset joint)
E04RX011
DRIVE SHAFT SYSTEM
4C23
E04RX012
4C24
DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884023090
(J39378)
Front Axle mount bushing
5884000070
(J8092)
Grip
5884000270
(J 26941)
Remover; Bearing needle
5884021170
(J36827)
Wrench; Hub nut
5884000840
(J261901)
Hammer; Sliding
5884021190
(J36829)
5884024070
(J41693)
Installer; Oil seal
5884021180
(J36828)
5884024080
(J41694)
Installer; Bearing needle
5884021200
(J36830)
Installer; Oil seal
DRIVE SHAFT SYSTEM
4C25
Propeller Shaft
General Description
401RX026
Legend
(1) Front Propeller Shaft (for 6VD1)
(2) Front Propeller Shaft (for X22SE)
Aluminum Tube Type
(for 6VD1, M/T model)
EndOFCallout

Steel Tube Type
(for X22SE, M/T model and 6VD1, A/T model)
4C26
DRIVE SHAFT SYSTEM
Torque is transmitted from the transmission to the axle

through propeller shaft and universal joint assembles.
All propeller shafts are the balanced tubular type. A
splined slip joint is provided in some drivelines.
Since the propeller shaft is total balanced carefully,
welding or any other modification are not permitted.
Alignment marks should be applied to each propeller
shaft before removal.
Be sure vehicle is stopped, engine is not running,
brake is secured and vehicle is secured to prevent
injury.
Be careful not to grip the propeller shaft tube too
tightly in the bise as this will be cause deformation.
Phasing
The propeller shaft is designed and built with the yoke
lugs (ears) in line with each other. This design produces
the smoothest running shaft possible, called phasing.
Vibration can be caused by an out-of-phase propeller
shaft. The propeller shaft will absorb vibrations from
speeding up and slowing down each time the universal
joint goes around. This vibration would be the same as
a person snapping rope and watching the "wave"
reaction flow to the end. A propeller shaft working in
phase would be similar to two persons snapping a rope
at the same time, and watching the "waves" meet and
cancel each other out. In comparison, this would be the
same as the universal joints on a propeller shaft. A total
cancellation of vibration produces a smooth flow of
power in the driveline. It is very important to apply a
reference mark to the propeller shaft before removal, to
assure installation alignment.
Universal Joint
401RW015
Legend
(1) Spider
(2) Yoke
EndOFCallout
A universal joint consists of two Y-shaped yokes
connected by a crossmember called a spider.
The spider is shaped like a cross. Universal joints are
designed to handle the effects of various loadings and
front or rear axle windup during acceleration. Within the
designed angle variations, the universal joint will
operate efficiently and safely. When the design angle is
changed or exceeded the operationallife of the joint may
decrease.
The bearings used in universal joints are of the needle
roller type. The needle rollers are held in place on the
trunnions by round bearing cups. The bearing cups are
held in the yokes by snap rings.
DRIVE SHAFT SYSTEM
4C27
Diagnosis of Propeller Shaft and Universal Joint

Condition
Universal Joint Noise.
Possible cause
Correction
Worn universal joint bearings.
Replace.
Improper lubrication.
Lubricate as directed.
Loose flange bolts.
Ping, Snap, or Click in Drive Line

(Usually Heard on Initial Load after
the Transmission is in Forward or
Reverse Gear)
Loose bushing bolts on the rear

springs or upper and lower control
arms.
Tighten the bolts to specified torque.
Loose or out-of-phase end yoke.
Remove end yoke, turn 180 degrees

from its original position, lubricate
the splines and reinstall. Tighten the
bolts and pinion nut to specified
torque.
Knocking or Clanking Noise in the

Driveline when in High or Neutral
Gear at 16km/h(10mph)
Worn or damaged universal joint
Replace the universal joint.
Squeak
Lack of lubricant.
Lubricate joints and splines. Also

check for worn or brinelled parts.
Shudder on Acceleration (Low

Speed)
Loose or missing bolts at the

flanges.
Replace or tighten bolts to specified

torque.
Incorrectly set front joint angle.
Install shim under the transmission

support mount to change the front
joint angle.
Worn universal joint.
Replace.
Incorrect shaft runout.
Replace.
Shaft out of balance.
Adjust.
Transmission rear housing bushing,

transfer case housing bushing worn.
Replace.
Yoke spline jammed.
Replace.
Rough surface on splined yoke;

burred nicked or worn.
Replace the seal. Minor burrs can

be Smoothed by careful use of
crocus cloth or fine stone honing.
Replace the yoke if badly burred.
Defective transmission rear oil seal.
Replace the transmission rear oil

seal and replenish the transmission
oil.
Vibration
Excessive Leak at the Front Spline

Yoke of Rear Propeller Shaft
4C28
DRIVE SHAFT SYSTEM
Front Propeller Shaft

Front Propeller Shaft and Associated Parts
401RW063
Legend
(1) Bolt, Nut and Washer (Front Axle Side)
(2) Front Propeller Shaft (Single Cardan Type)

(4) Front Propeller Shaft (Double Cardan Type)
EndOFCallout
Removal
NOTE: Apply alignment marks on the flange at the front
401RS020
DRIVE SHAFT SYSTEM

2. Remove bolt, nut and washer (Front axle side).
3. Remove bolt, nut and washer (Transfer side).
4. Remove front propeller shaft.
Installation
4C29
removing bolts. 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 is applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
401RW075
Legend
(1) Spline Yoke Assembly
(2) Clamp
(3) Boot
EndOFCallout
(4) Clamp
(5) Tube Assembly
2. Indicate the original assembled position (1) by

marking the phasing of the shaft prior to
disassembly.
4C30
DRIVE SHAFT SYSTEM

boot.
hand.
6. Remove the spline yoke assembly from the tube
assembly, by securing the boot with one hand and
pulling on the spline yoke.
7. Remove the boot from the tube assembly.
401RW037
Universal Joint Disassembly (Single Cardan Type)
401RW031
Legend
(1) Flange Yoke
(2) Snap Ring
EndOFCallout
(3) Spider
(4) Needle Roller Bearing
DRIVE SHAFT SYSTEM
4C31

assembly to loosen snap ring. Tap bearing only
hard enough to break assembly away from snap
ring.
Remove snap ring from yoke. Turn joint over, tap
snap ring.
Apply alignment marks (1) on the yokes of the
universal joint, then remove snap ring.
401RW020
401RW018

stock beneath it.
Place a solid plug on the upper bearing assembly
and press it through to release the lower bearing
assembly.
3. If the bearing assembly will not pull out by hand

after pressing, tap the base of the lug near the
bearing assembly to dislodge it.
and straighten the spider in the open hole. Then
carefully press on the end of the spider so the
ruin the yoke.
6. Make sure of proper position for reinstallation by
applying setting marks, then remove spider .
4C32
DRIVE SHAFT SYSTEM
Universal Joint Disassembly (Double Cardan Type)
401RW073
Legend
(1) Ball Stud Tube Yoke
(3) Coupling Yoke
(4) Spring
(6) Flange Yoke
EndOFCallout
assembly to loosen snap ring. Tap bearing only hard
enough to break assembly away from snap ring.
2. Remove snap ring from yoke. Turn joint over, tap
snap ring.
401RW084
DRIVE SHAFT SYSTEM

3. Remove all snap rings from the yoke in similar
manner.
4. Set the outboard side of the center yoke in the arbor
press with a piece of tube stock beneath it. Place a
solid plug on the upper bearing cup assembly and
press it through to release the lower bearing cup
assembly.
Press the center bearing cup assembly partially
from the outboard side of the center yoke - enough
to grasp the bearing cup by vise jaws.
Do not press the bearing cup assembly completely
through.
4C33
6. Flip the assembly and repeat steps 4 and 5 for

removing the opposite side bearing cup assembly.
This will allow removal of the cross centering kit
assembly and spring.
Do not disassemble centering kit.
401RW068
7. Press the remaining bearing cup assemblies out on

the other cross as described above to complete
disassembly.
401RW083
5. Grasp the protruding bearing cup assembly by vise

jaws. Tap the tube yoke with a mallet and drift to
dislodge the bearing cup assembly from the yoke
hole.
NOTE: Tap in the center of the H" yoke. Never strike

the yokes at the bearing cup assembly holes because
the snap ring grooves may collapse and make
reassembly impossible.

condition is found through inspection.
NOTE: When any part of the journal assembly (spider,
needle roller bearing) requires replacement, be sure to
replace the entire assembly.
Check the following parts for wear, damage, noise or
any other abnormal conditions.
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Boot
401RW082
4C34
DRIVE SHAFT SYSTEM
Spider pin for wear

galling. Visible signs of needle presence is normal, but
wear should not be felt.
401RS027
Spline
401RW038
Propeller shaft runout

Support the propeller shaft on V-blocks (2) and check
for runout by holding the probe of a dial indicator (1) in
contact with the shaft.
Static runout limit:
0.13mm (0.005in)
boot).
0.25mm (0.010in)
The nylon-coated spline should be free from nicks and

dings and the underlying steel spline should not be
visible.
should exhibit only a slight indication of wear.
Grease volume is approximately 10 grams of grease in
total. Grease should be evenly applied to both the
extended position.
Play in the universal joint

Limit:Less than0.15mm (0.006in)

welds.
0.38mm (0.015in)
0.38mm (0.015in)
tubing.
401RW023
DRIVE SHAFT SYSTEM
4C35
Preload of the universal joint

Preload should be 0 to 24.9 kg(0 to11.3 lb). Joints
should rotate smoothly and freely and should exhibit no
rough or ratchety movement.
401RW020
401RW085
Boot
Check the boot for crack or damage. If necessary,
replace the boot.
If abnormal condition are found on the boot, inspect the
grease for mixing of foreign material.
If the grease is good condition, and slip joint works well,
replace the boot, replenish grease, and reassemble the
slip joint.
If the foreign material is found in the grease, check the
spline for wear and damage.

Be sure the snap rings are properly seated in the
grooves.
hammer to seat needle bearings.
6. Align setting marks (1) and join the yokes.
Universal Joint Reassembly (Single

Cardan Type)
1. Install spider to flange yoke. Be sure to install the
spider by aligning the setting marks made during
disassembly.
grease. Do not add additional grease to the bearing
cup assembly.
hole enough to install a snap ring.
401RW018
4C36
DRIVE SHAFT SYSTEM
Universal Joint Reassembly (Double

Cardan Type)
1. Pack the four grease cavities of the cross with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to bearing cup
assembly.
2. Fit a cross into the tube yoke.

5. Repeat steps 3 and 4 to install the opposite bearing
cup assembly. If the joint is stiff, strike the yoke ears
with a soft hammer to seat the needle bearing.
the grooves.
401RW071
401RW069
3. Move an end of the cross to cause a trunnion to

project through the cross hole beyond the outer
machined face of the yoke lug. Place a bearing cup
assembly over the trunnion diameter and align it to
the cross hole. Using an arbor press, hold the
trunnion in alignment with the cross hole and place
a solid plug on the upper bearing cup assembly.
Press the bearing cup assembly into the cross hole
enough to install a snap ring.
6. Fit the center yoke (H Yoke) on the remaining two

trunnions and press bearing assemblies in place,
both sides as in steps 3 and 4 above. Install snap
rings.
401RW086
401RW070
DRIVE SHAFT SYSTEM

7. Install the journal onto the flange as per steps 3 and
4 above.
8. Install the centering kit assembly inside the center
yoke making sure the spring in the tube yoke is in
place.
401RW072
9. Fit the open trunnions of the flange assembly in to

the center yoke holes and the bearing assemblies
into the centering kit assembly.
10. Install bearings as per steps 3 and 4.
11. Check for proper assembly. Flex the double cardan
joint beyond center. The joint should snap over
cener in both directions when all needle rollers and
components are correctly assembled.
4C37
4C38
DRIVE SHAFT SYSTEM
401RW075
Legend
(1) Spline Yoke shaft
(2) Clamp
(3) Boot
EndOFCallout
splines.
4. Insert the spline yoke shaft into the tube assembly
being careful to maintain proper phasing. The
spider holes should be in line and as per originally
marked prior to disassembly.
position over boot grooves.
(4) Clamp
(5) Tube Assembly

DRIVE SHAFT SYSTEM
4C39

Length (between two spiders
center)
M/T
A/T
6VD1
376 mm (14.80 in)
542 mm (21.34 in)
X22SE
294 mm (11.57 in)
401RX027
4C40
DRIVE SHAFT SYSTEM
Rear Propeller Shaft

Rear Propeller Shaft and Associated Parts
401RX028
Legend
(3) Bolt, Nut and Washer (Rear Axle Side)
EndOFCallout
Removal
NOTE: Apply alignment marks on the flange at the rear
2. Remove transfer side bolt, nut and washer.
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.
Installation
removing bolts.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of
the propeller shaft.
1. Align the mark which is applied at removal.
2. Install rear propeller shaft and tighten the bolts to
DRIVE SHAFT SYSTEM
4C41
401RX004
Legend
(2) Clamp
(3) Boot
EndOFCallout
2. Indicate the original assembled position by marking
the phasing of the shaft prior to disassembly.
boot.
(4) Clamp

hand.
6. Remove the slip yoke assembly from the driveshaft,
by securing the boot with one hand and pulling on
the slip yoke.
7. Remove the boot from the shaft assembly.
4C42
DRIVE SHAFT SYSTEM
401RX022
Legend
(1) Spider
(2) Flange Yoke
EndOFCallout
NOTE: Aluminum is softer than steel. Care must be
taken not to remove excessive material or damage
bearing holes.
If the vehicle has aluminum tube type propeller shaft,
flange yoke, boot kit, journal kit can be replaced. If other
parts are damaged, replace propeller shaft as assembly.
(3) Bearing
(4) Snap Ring
DRIVE SHAFT SYSTEM

1. Apply alignment marks on the yokes of the universal
joint, then remove the snap ring.
4C43

stock beneath it.
Place a solid plug on the upper bearing and press it
through to release the lower bearing.
401RW024
If the snap ring is stuck in position, remove paint

from the hole in the yoke or tap around the edge of
the bearing lightly with a soft drift.
401RW027
3. If the bearing will not pull out by hand after pressing,

tap the base of the lug near the bearing to dislodge
it.
and straighten the spider in the open spider hole.
Then carefully press on the end of the spider so the
ruin it.
401RW025
401RW026

4C44
DRIVE SHAFT SYSTEM
Inspection
Propeller shaft for run-out Aluminum tube type.
Static run-out limit :1.0mm(0.04in)
TIR full length of tubing maximum.
Propeller shaft for runout (Steel tube type).
Static runout limit :0.13mm(0.005in)
boot).
0.25mm(0.010in)
welds.
0.38mm(0.015in)
0.38mm(0.015in)
tubing.
(TIR: Total Indicator Reading)
401RW028
Preload of the universal joint.

Preload should be 0 to 49 N (0 to 5.0 kg/0 to 11.0 lb).
Joints should rotate smoothly and freely and should
exhibit no rough or ratchety movement.
401RW017
Play in universal joint.

Limit: Less than0.15mm(0.006in)
galling.
Visible signs of needle presence is normal, but wear
should not be felt.
401RW019
Inspect splines of slip joint for wear.

The nylon-coated spline should be free from nicks
and dings and the underlying steel spline should not
be visible.
should exhibit only slight indicator of wear.
Grease volume is approximately 10 grams of grease
in total. Grease should be evenly applied to both the
extended position.
DRIVE SHAFT SYSTEM

Aluminum tube type only: Inspect the aluminum
tubing for surface scratches and dents. These
scratches may not exceed 0.2 mm (0.008 in) in depth.
4C45

grease. Do not add additional grease to bearing
cup assembly.
hole enough to install snap ring.
401RW022
Aluminum tube type only: Visually inspect the circle

welds and fittings for any signs of cracks or signs of
deterioration. If there are any cracks that exceed 0.2
mm (0.008 in) in depth, the assembly must be
replaced.
Aluminum tube type only: Check to be sure there are
no missing balance weights. If balance weights are
missing and void has occurred in the aluminum
tubing greater than 0.2 mm (0.008 in), the assembly
must be replaced.
401RW026

the grooves.
hammer to seat the bearing.
5. Align the setting marks and join the yokes.
4C46
DRIVE SHAFT SYSTEM
401RX004
Legend
(2) Clamp
(3) Boot
EndOFCallout
splines.
4. Insert the spline yoke shaft spline into the tube
assembly being careful to maintain proper phasing.
The spider holes should be in line and as per
originally marked prior to disassembly.
position.
(4) Clamp

DRIVE SHAFT SYSTEM
4C47

4WD Model
Engine
Length (between two spiders center)
Universal joint type
X22SE
6VD1 (M/T)
6VD1 (A/T)
989.0mm (38.94in)
1212.5mm (47.73in)
1043.0mm (41.06in)
Cardan type
E04RX013
SECTION
TRANSFER CASE
4D1
DRIVELINE/AXLE
TRANSFER CASE
CONTENTS
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly (A/T) . . . . . . . . . . . .
Transfer Case Assembly (A/T) and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Case Assembly (A/T) . . . . . . .
Transfer Rear Case Assembly (A/T) and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D1
4D2
4D4
4D4
4D4
4D4
4D6
4D6
4D7
4D8
4D11
4D11
4D11
4D13
Service Precaution
Transfer Rear Cover Assembly . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Detent, Shift Arm, and Interlock Pin
(Transfer Case Assembly) . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D16
4D16
4D17
4D17
4D19
4D19
4D20
4D21
4D21
4D23
4D23
4D24
4D27
4D30
4D37
4D40

systems.
4D2
TRANSFER CASE
General Description
Transfer Case (for Manual Transmission)
A07RX005
TRANSFER CASE
4D3
Transfer Case (for Automatic Transmission)
A07RW0011
The transfer case is used to provide a means of providing

power flow to the front axle. The transfer case also
provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation when
the vehicle is driven on improved roads where four wheel
drive is not required. In addition, the transfer case
provides an additional gear reduction when placed in low
range, which is useful when difficult offroad conditions
are encountered.
A floor mounted shift lever is used to select the highlow
range. When four wheel drive switch has been turned on,
the four wheel drive indicator light is designed to come on
and the front axle has been engaged.
4D4
TRANSFER CASE
Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts
220RS015
Legend
(2) End Nut and Rear Companion Flange

(3) Oil Seal
Removal
Installation
1. Disconnect the rear propeller shaft (1) from the

transfer case side.
2. Remove end nut and rear companion flange (2),
using the companion flange holder 5884001330.
1. Install oil seal and apply engine oil to the oil seal outer
surfaces.
2. Apply the recommended grease (BESCO L2) or
rear seal (3) to the transfer rear case.
266RW026
3. Use the universal puller to remove the rear

companion flange and Oring.
220RW105
TRANSFER CASE
4. Install the rear companion flange (2) and Oring (2).
5. Use the companion flange holder 5884001330 to
install a new end nut (2) and tighten to the specified
torque.
6. Use the punch 5884022930 to stake the end nut
at two spots.
staked portion of the end nut (2) after staking.
266RW027
266RW002
4D5
7. Connect the rear propeller shaft to the transfer case

and tighten to the specified torque.
4D6
TRANSFER CASE
Transfer Case Assembly (A/T)

Transfer Case Assembly (A/T) and Associated Parts
260RX001
Legend
(2) Lower Cluster Assembly
(3) Rear Console
(4) Center Console
(5) Grommet Assembly and Transfer Control

Lever
(9) Transfer Case Assembly
TRANSFER CASE
4D7
5. Remove center console (4).
Removal
NOTE: Before removing transmission and transfer
2. Remove transfer control lever knob (1).
3. Remove lower cluster assembly (2).
256RW006
6. Remove grommet assembly and transfer control

lever (5).
740RW021
256RW007
256RW045
4D8
TRANSFER CASE
7. Raise and support vehicle with suitable stands. Drain

transfer case fluid.
8. Remove transfer protector (6).
Installation
the input shaft spline as shown in the figure.
150RX010
9. Remove rear propeller shaft (7) and front propeller

shaft (8).
and rear sides.
10. Disconnect harness connectors and clip.
speed sensor.
11. Support transmission case with a transmission jack.
12. Remove the top position bolt from transfer control
lever hole and others under the floor.
Remove transfer case (9) from the vehicle.
260RW001
TRANSFER CASE
4D9
2. Install transfer case (9) to the transmission. Tighten

transfer bolts as shown in the figure.
261RX001
3. Remove the transmission jack from transmission

side.
4. Connect harness connectors and clip.
speed sensor.
5. Install rear propeller shaft (7) and front propeller shaft
(8).
6. Install transfer protector (6).
150RX010
4D10
TRANSFER CASE
7. Fill transfer case fluid.

8. Lower the vehicle.
Install grommet assembly and transfer control lever
(5).
256RW007
9. Install center console (4), rear console (3) and lower

cluster assembly (2).
10. Install transfer control lever knob (1).
TRANSFER CASE
4D11
Transfer Rear Case Assembly (A/T)

Transfer Rear Case Assembly (A/T) and Associated Parts
220RW1331
Legend
(1) Speedometer Sensor, Speedometer Driven
Gear and Plate
Removal
1. Remove the speedometer sensor (1).
2. Remove the plate (1).
(4)
(5)
(6)
(7)
(8)
Control Box Assembly

2WD4WD Actuator Heat Protector
2WD4WD Actuator Assembly
3. Remove the speedometer driven gear bushing and

driven gear (1).
before removal.
4D12
TRANSFER CASE
4. Remove front companion flange (2) and rear

companion flange (3), using the flange companion
holder 5884001330 to remove the end nut.

10. Pull the 2WD4WD actuator assembly (6) with
2WD4WD shift rod.
262RW067
5. Remove the front and rear companion flange.

NOTE: Use the universal puller to remove the rear
companion flange.
6. Disconnect the actuator breather hose and transfer
breather hose from control box (4).
7. Remove control box assembly (4).
8. Disconnect the actuator breather hose and
2WD4WD actuator heat protector (5) from the
2WD4WD actuator assembly (6).
220RW065
Legend
(10) Pull
(11) Position: 4WD
(12) Mode: 2WD
220RW0851
TRANSFER CASE
11. Off set the actuator assembly.
4D13
Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.
220RW028
12. Remove the actuator assembly (6).
220RS017
2. Install transfer rear cover assembly (7) to transfer

case assembly (8).
rear case.
1. Shift the highlow shift rod to the 4H side.
2. The cutaway portion of the select rod head (15)
should align with that of the rear case holes
stopper (16).
220RW066
Legend
(13) Position: 4WD
(14) Mode: 2WD
13. Remove transfer rear cover assembly (7) from
transfer case assembly.
230RW009
4D14
TRANSFER CASE
4. Tighten the transfer rear case bolts to the specified

torque.
8. Tighten the 2WD4WD actuator bolts to the specified

torque.
5. Shift the 2WD4WD shift rod (17) to the 4WD side.

assembly (6) and shift rod (17).

10. Install actuator heat protector (5).
11. Install control box assembly (4).
12. Connect breather hoses to control box (4).
13. Install rear companion flange (3) and front companion
flange (2), using the companion flange holder
5884001330 to tighten the flange nuts to the
transfer case.
220RW067
Legend
7. Push the 2WD4WD actuator assembly (6) with
2WD4WD shift rod (17) till the shift rod (17) reaches
the 2WD position.
262RW067
14. Tighten the new transfer flange nuts to the specified

torque.
Torque
Rear companion flange: 167 Nm (17.0 kgm/123
lb ft)
Front companion flange: 137 Nm (14.0 kgm/101
lb ft)
220RW068
Legend
(18) Position: 2WD
(19) Mode: 2WD
TRANSFER CASE
companion flange nut (3) at two spots.
4D15
16. Stake the front companion flange nut (2) at one spot.
17. Install the Oring (23) to the speedometer driven gear
bushing (22).
18. Install the driven gear to the speedometer driven gear
bushing (22).
19. Install the speedometer driven gear assembly to the
transfer rear cover.
20. Install the plate (21) to the transfer rear case and
21. Install the speedometer sensor and tighten to the
specified torque.
266RW027
225RW004
266RW002
Legend
(20) Bolt
(21) Plate
(22) Bushing
(23) Oring
4D16
TRANSFER CASE
226RW154
Legend
(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(4) Ball Bearing
(5)
(6)
(7)
(8)
(9)
Bearing Snap Ring

Ball
Speedometer Drive Gear
Ball Bearing
Transfer Rear Cover (with oil seal)
Disassembly
1. Remove bearing snap ring, use a pair of snap ring
pliers to remove the snap ring (3).
226RS060
TRANSFER CASE
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal) (9).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5884000150.
4D17
Reassembly
Transfer rear cover (with oil seal) (9). Oil seal
replacement.
D Remove the oil seal from the transfer rear cover.
D Apply engine oil to the oil seal outer surfaces.
D Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
D Use the oil seal installer 5884022920 to install the
rear oil seal to the transfer rear cover.
226RW186
4. Remove speedometer drive gear (7).

5. Remove ball (6).
6. Remove bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove rear output shaft (2) from the ball bearing (4),
using a bench press and the bearing remover
5884000150.
220RW104
1. Install ball bearing (4) to the rear output shaft (2),

using the ball bearing installer 5884021590 and
the adapter 5884021921.
226RW187

262RW068
4D18
TRANSFER CASE
2. Install bearing snap ring (5), using a pair of snap ring

pliers.
3. Install ball (6).
4. Install speedometer drive gear (7).
226RS064
5. Use the ball bearing installer 5884021590 to

install the ball bearing (8).
226RW188
6. Install the rear output shaft assembly (1) to the

transfer rear cover (9).
transfer rear cover snap ring groove.
TRANSFER CASE
4D19
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)

Disassembled View
262RW005
Legend
(1) Detent Ball, Spring and Plug
(2) Spring Pin and Bridge
(3) Spring Pin
(4) Spring
(5) 2WD4WD Shift Rod
(6) Shift Arm
(7) Shift Block
(8) 4WD Indicator Switch
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Interlock Pin
Spring
Select Rod Assembly
Spring Pin
HighLow Shift Rod
Shift Arm
Shift Block
Transfer Case
4D20
TRANSFER CASE
Disassembly
1. Remove detent ball, spring and plug (1).
2. Use a spring pin remover to remove the spring pin (2)
from the bridge (2).

6. Remove shift block (7).
7. Remove 4WD indicator switch (8).
8. Use a magnetic tool to remove the interlock pin (9)
and spring (10) from the transfer case (16).
262RW011
3. Remove spring (4).

4. Engage the 2WD4WD sleeve with front output gear.
Remove the spring pin (3) from the block (7). Remove
the shift rod (5).
262RS005
9. Remove select rod assembly (11).

10. Use a spring pin remover to remove the shift arm
spring pin (12) from the shift arm (14) and shift block
(15). Remove the highlow shift rod (13) from transfer
case (16).
262RW022
262RS006

12. Remove shift block (15) from transfer case (16).
TRANSFER CASE
4D21

Reassembly
1. Place shift block (15) in transfer case (16).
2. Set shift arm (14) on the HighLow sleeve.
3. Push HighLow shift rod (13) through shift arm (14)
and block (15).
4. Engage the HighLow sleeve with the 4H (1) side.
5. Install the spring pin (12) to the shift block (15) and
shift arm (14).
262RW035
262RW034
6. Install select rod assembly (11), joining its lever to

shift block (15) groove.
7. Engage the HighLow sleeve with the 4H side and
install the interlock pin (9) and spring (10) in the
proper direction.
8. Place 2WD4WD shift block (7) in the transfer case
(16).
9. Set 2WD4WD shift arm (6) on the 2WD4WD
sleeve.
10. Puh 2WD4WD shift rod (5) through 2WD4WD shift
arm (6) and 2WD4WD shift block (7).
11. Install the 2WD4WD shift rod (5) with interlock pin
pushed in.
Legend
(18) 2WD4WD
(19) 4H Side
(20) Interlock pin
(21) 2WD
(22) 4WD
(23) Rod: 24
(24) Rod: HL
(25) 4H
(26) 4L
(27) 42
(28) 44
4D22
TRANSFER CASE
12. Install 4WD indicator switch and gasket (8).

Tighten to the specified torque.
14. Engage the 2WD4WD sleeve with the 4WD side and
install the spring pin (3).
262RW022
15. Install spring pin (2) and bridge (2).

16. Install detent ball, spring and plug and tighten the plug
TRANSFER CASE
4D23

Disassembled View
226RW209
Legend
(2) Ball Bearing
(3) Lock Nut
(4) Snap Ring (A/T)
(5) Input Shaft Assembly (A/T)
(6) HighLow Clutch Hub and Sleeve
(7) Transfer Input Gear
(8) Needle Bearing
(9) Bearing Collar
(10) Ball
(11) Plate
(12) Ball Bearing (A/T)
(13) Input Shaft (A/T)
(15) Front Output Gear Assembly
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
Bearing Snap Ring

Ball Bearing
Bearing Collar
SubGear Snap Ring (M/T)
Spacer (M/T)
Belleville Spring (M/T)
SubGear (antilash plate) (M/T)
Front Output Gear
Needle Bearing
Inside Ring
Outside Ring
Block Ring
2WD4WD Clutch Hub and Sleeve Assembly
Stopper Plate
Ball Bearing
Front Output Shaft
4D24
(32)
(33)
(34)
(35)
(36)
(37)
TRANSFER CASE
(38)
(39)
(40)
(41)
(42)
Bearing Snap Ring

Snap Ring
Ball Bearing
Snap Ring
Ball Bearing
Disassembly
(1).
Spacer
Belleville Spring
SubGear (antilash plate)
Counter Gear
Transfer Case (with oil seal)
5. Remove the front companion flange.

6. Remove snap ring (4). (A/T)
7. Remove the input shaft assembly (5) from the
transfer case (42). (A/T)
265RW001
262RW069

4. Use the Companion flange holder 5884001330
and lock nut wrench 5884021560 to remove the
lock nut (3).
8. Use the universal puller to remove the highlow

clutch hub and sleeve (6), and transfer input gear (7).
226RS070
226RW190
TRANSFER CASE
10. Remove bearing collar (9).
4D25

snap ring (14).
assembly (15) free.
226RS071
11. Remove ball (10).

12. Remove plate (11).
the input shaft (13). (A/T)
262RS009

5884000150 to remove the following parts.
18. Remove ball bearing (17), and bearing collar (18).
Remove subgear snap ring (19), spacer (20),
belleville spring (21), and subgear (antilash plate)
(22). (M/T)
Remove front output gear (23) and needle bearing
(24).
265RW013
262RW070
19. Remove inside ring (25).

20. Remove outside ring (26).
21. Remove block ring (27).
22. Use a bench press and bearing remover
5884000150 to remove 2WD4WD clutch hub
and sleeve assembly (28) and stopper plate (29).
NOTE: Do not reuse the stopper plate.
4D26
TRANSFER CASE
23. Disassemble the 2WD4WD clutch hub and sleeve

assembly (28).
D Springs (1)

D Inserts (2)
D Clutch Hub (3)
D Sleeve (4)
226RW208
226RW133

31. Remove spacer (38).

32. Remove belleville spring (39).
33. Remove subgear (antilash plate) (40).
34. Remove counter gear (41).
35. Remove transfer case (with oil seal) (42), performing
the following steps (M/T)
A07RW022
262RW071

26. Remove the counter gear assembly (33) from the
transfer case (42).
(34).
(36).
Legend
(43) Adhesive Tape
(44) Oil Seal Lip
(46) Bearing
D Remove the transfer case together with
intermediate plate with gear assembly from the
transmission case (M/T).
TRANSFER CASE
D Remove the transfer case from the intermediate
plat with gear assembly (M/T).

1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.
4D27

Clutch hub spline play
Limit : 0.2 mm (0.008 in)
Gears
1. Inspect all the gear teeth for signs of excessive wear
or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.
Front Output Gear Inside Diameter
1. Use an inside dial indicator to measure the gear inside
diameter.
gear must be replaced.
Gear inside diameter
Standard : 48.00048.013 mm (1.88981.8903 in)
Limit : 48.10 mm (1.894 in)
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS040

1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as possible to both the right
and the left.
226RS043
4D28
TRANSFER CASE
Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
D Teeth for wear, scuffs, nicks, burrs or breaks.
D Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
D If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.

1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
226RW142

Standard : 2.462.74 mm (0.0970.108 in)
Limit : 3.0 mm (0.118 in)

Clutch hub and insert clearance
Standard : 0.010.19 mm (0.00040.0075 in)
Limit : 0.3 mm (0.012 in)
226RS037
2WD4WD Synchronizer (3Cone)

2WD4WD synchronizer assembly must be
replaced.
Limit : 0.8 mm (0.031 in)
226RS038
TRANSFER CASE
4D29
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
1. Use a vernier caliper to measure the detent spring
free length.
Detent spring free length
Detent ball
Limit : 22.8 mm (0.898 in)
Interlock pin
Limit : 15.3 mm (0.602 in)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
Shift arm thickness
Standard : 9.609.85 mm (0.3780.388 in)
Limit : 9.0 mm (0.354 in)
220RW035

1. Use a spring tester to measure the detent spring
tension.
Detent ball
Standard : 68.688.2 N (7.09.0 kg /15.419.8 lb)
Interlock pin
Standard : 9.8 N (1.0 kg/2.2 lb)
230RS006
4D30
TRANSFER CASE
Reassembly
M/T
Input Shaft Oil Seal Replacement

2. Apply the engine oil to the oil seal outer surfaces.
4. Use the oil seal installer 5884022790 (A/T)
5884021930
(M/T)
and
driver
handle
5884000070 to install the oil seal to the transfer
case.
A/T
220RW132
Legend
(48) Transmission Side Oil Seal
(49) Transfer Side Oil Seal
220RW130
Legend
(47) Oil Seal
TRANSFER CASE
Front Output Shaft Oil Seal Replacement

2. Apply engine oil to the oil seal outer surfaces.
oil seal to the transfer case.
4D31
1. Install the transfer case (with oil seal) (42), performing

the following steps. (M/T)
This will prevent damage to the oil seal lip (44).
A07RW022
Legend
(43) Adhesive Tape
(44) Oil Seal Lip
(46) Bearing
D Apply recommended liquid gasket (LOCTITE
17430) or its equivalent to the transmission,
intermediate plate and transfer case fitting surfaces
(M/T).
220RW131
Legend
(50) Front Output Shaft Oil Seal
220RS026
4D32
TRANSFER CASE
Install the transfer case together with intermediate plate

with gear assembly to transmission case (M/T).
Tighten the transfer case bolts to the specified torque a
little at a time (M/T).
2. Apply chassis grease (51) to the subgear (40) and
the counter gear (41) thrust surfaces.
226RS170
226RW155
3. Install subgear (40) to counter gear (41).

4. Install belleville spring (39).
5. Install spacer.
6. Install ball bearing, using a bench press.
7. Select a snap ring that will allow the minimum axial
play.
Thickness
Colorcoding
1.50 mm (0.059 in)
White
1.55 mm (0.061 in)
Yellow
1.60 mm (0.063 in)
Blue
226RS021

(36) to the counter gear (41).
SubGear (antilash plate) Preload
subgear (53) teeth.
2. Attach the other end of the piano wire (52) to a
spring balancer.
Preload : 5998 N (6.010 kg/1322 lb)
TRANSFER CASE
4D33
14. Assemble the 2WD4WD clutch hub and sleeve

assembly (28).
226RW156

11. Install the counter gear assembly (33) to the transfer
case (42).
226RW140
15. Engage the springs in the same insert with the open
ends away from each other.

226RW141
262RS012
4D34
TRANSFER CASE
16. Install a new stopper plate (29) and the clutch hub and
sleeve assembly (28) to the front output shaft (31).
226RW157
Legend
(54) Front Output Gear
facing the front output gear side.
18. Use a bench press to slowly force the clutch hub and
sleeve assembly (28) together with the stopper plate
(29) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (27) to the clutch sleeve and hub
assembly (28).
20. Install the outside ring (26), inside ring (25) and
needle bearing (24) to the front output gear (23) and
bearing collar (18).
21. Apply engine oil to the thrust surfaces of the

subgear, the belleville spring, and the spacer (M/T).
262RW014
22. Install subgear (antilash plate) (22), belleville

spring (21) and spacer (20). (M/T)
23. Install subgear snap ring (19). (M/T)
24. Use a bench press to install the needle bearing collar
together with the front output gear assembly, aligning
inside ring claw with block ring groove.
NOTE: Coat all parts with transmission oil before

installing them.
262RS014
226RW139
TRANSFER CASE
26. Select a snap ring (16) that will allow the minimum
axial play.
4D35
(16) to the output shaft (31).
Sub-gear (anti-lash plate) preload (M/T)
subgear (53) teeth.

Snap ring thickness
Color coding
2. Attach the other end of the piano wire to (52) a

spring balancer.
1.55 mm (0.061 in)
White
1.60 mm (0.063 in)
Yellow
Preload: 5998 N (6.010 kg/1322 lb)
1.65 mm (0.065 in)
Blue
1.70 mm (0.067 in)
Pink
1.75 mm (0.069 in)
Green
1.80 mm (0.071 in)
Brown
1.85 mm (0.073 in)
Red
1.90 mm (0.075 in)
Orange
226RW156
28. Install front output gear assembly (15) to transfer

case (42).
input shaft (13). (A/T)
262RS015
265RS003
226RS021
4D36
TRANSFER CASE
31. Install plate (11), ball (10) and bearing collar (9).
NOTE: Put the snap ring (4) in the ball bearing side. (A/T)
32. Install needle bearing (8) and input gear (7).
facing the transfer input gear side (55).
38. Use the punch to stake the lock nut (3) at one spot.
bearing (2).
226RS079

226RW158
34. Install highlow clutch hub and sleeve (6), using a

bench press.
35. Install input shaft assembly (5) to transfer case (42).
(A/T)
36. Install the snap ring (4) to the transfer case (42). (A/T)
37. Install the front companion flange temporarily and use
the flange holder 5884001330 and lock nut
wrench 5884021560 to install the lock nut (3).
226RW190
TRANSFER CASE
4D37

Type
Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Constant mesh type gears shifting between low and high.
Control method
Remote (A/T) and direct (M/T) control with the gear shift lever on the floor
for gears shifting between low and high.
Electric control with the button switch on the instrument panel for gears
shifting between the 2 and 4 wheel driver mode.
Gear ratio
High; 1.000
Low; 2.050
Oil capacity
1.45 lit. (1.53 U.S. quart)
Type of lubricant
Engine oil
Refer to chart in Section 0
E07RX012
4D38
TRANSFER CASE
E07RX021
TRANSFER CASE
4D39
E07RX011
4D40
TRANSFER CASE
Special Tools
ILLUSTRATION
PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME
5884000150
Bearing
remover/installer
5884022920
Rear oil seal installer
5884022790
installer
5884021921
Bearing installer adapter
5884021560
Mainshaft nut wrench
5884001330
Flange holder
5884021590
Rear output shaft and
bearing installer
5884021550
remover
5884022930
Punch; end nut
5884020270
Puller
5884022810
Front output shaft oil
seal installer
5884000070
Driver handle
TRANSFER CASE
ILLUSTRATION
PART NO.
PART NAME
5884021930
installer
4D41
SECTION
5A1
BRAKES
CONTENTS
Brake Control System....................................
Anti-lock Brake System..................................
Power-assisted Brake System.......................
Parking Brake System ...................................
5A - 1
5B - 1
5C - 1
5D - 1

CONTENTS
Functional Description ...............................
System Components .................................
Electronic Hydraulic Control Unit (EHCU) .
ABS Warning Light ....................................
Wheel Speed Sensor .................................
G-Sensor ...................................................
Normal and Anti-lock Braking ....................
Brake Pedal Travel ....................................
Acronyms and Abbreviations .....................
General Information ...................................
ABS Service Precautions ..........................
Computer System Service Precautions .....
General Service Precautions .....................
Note on Intermittents .................................
Test Driving ABS Complaint Vehicles .......
ABS" Warning Light ..................................
Normal Operation ......................................
Tech 2 Scan Tool ......................................
DATA LIST ................................................
ACTUATOR TEST .....................................
Tech 2 Service Bleed ................................
Basic Diagnostic Flow Chart ......................
Basic Inspection Procedure .......................
EHCU Connector Pin-out Checks..................
Circuit Diagram ..........................................
Connector List ...........................................
Part Location .............................................
Symptom Diagnosis.......................................
Chart A-1 ABS Works Frequently But
Vehicle Does Not Decelerate ...................
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate
(Use TECH 2) ..........................................
Chart A-2 Uneven Braking Occurs
While ABS Works ....................................
Chart TA-2 Uneven Braking Occurs
While ABS Works (Use TECH 2) .............
Chart A-3, TA-3 The Wheels Are Locked .
5A - 2
5A - 3
5A - 4
5A - 10
5A - 10
5A - 10
5A - 10
5A - 10
5A - 10
5A - 10
5A - 11
5A - 11
5A - 11
5A - 11
5A - 11
5A - 11
5A - 12
5A - 12
5A - 12
5A - 12
5A - 13
5A - 16
5A - 17
5A - 21
5A - 23
5A - 23
5A - 24
5A - 25
5A - 27
5A - 29
5A - 30
5A - 30
5A - 31
5A - 31
5A - 31
5A - 32
Chart A-4 Brake Pedal Feed Is Abnormal . 5A - 32

Chart A-5, TA-5 Braking Sound
(From EHCU) Is Heard While Not Braking 5A - 33
Illumination Pattern ...................................... 5A - 36
Diagnostic Trouble Codes (DTCs) ............. 5A - 37
Chart B-1 With the key in the ON position
(Before starting the engine). Warning
light (W/L) is not activated. ....................... 5A - 39
Chart B-2 CPU Error (DTC 14 (Flash out) /
C0271, C0272, C0273, C0284 (Serial
Chart B-3 Low or High Ignition Voltage
(DTC 15 (Flash out) / C0277, 0278 (Serial
Chart B-4 Excessive Dump Time
Chart B-5 Excessive Isolation Time
Chart B-6 G-Sensor Output Failure
Chart B-7 Brake Switch Failure
Chart B-8 2WD Controller in 4WD Vehicle
Controller (DTC 13 (Flash out) / C0285
(Serial communications)), 4WD State
Input Signal Failure (DTC 24 (Flash out) /
Chart B-9 Pump Motor Failure (DTC 32
(Flash out) / C0267, C0268 (Serial
Chart B-10 EHCU Valve Relay Failure
Chart B-11 FL Isolation Solenoid Coil
C0247 (Serial
5A2
Chart B-12 FL Dump Solenoid Coil
Chart B-13 FR Isolation Solenoid Coil
Chart B-14 FR Dump Solenoid Coil
Failure (DTC 44(Flash out) /
Chart B-15 Rear Isolation Solenoid
Coil Failure (DTC 45 (Flash out) / C0251,
Chart B-16 Rear Dump Solenoid Coil
Chart B-17 FL Speed Sensor Open or
Chart B-18 FR Speed Sensor Open or
Chart B-19 Rear Speed Sensor Open or
Service Precaution
REPAIRS.
Chart B-20 FL Speed Sensor Missing

Chart B-21 FR Speed Sensor Missing
Chart B-22 Rear Speed Sensor Missing
communications))...................................... 5A - 50
Chart B-23 Simultaneous Drop-out of
Front Speed Sensor Signal (DTC 64
(Flash out) / C0229 (Serial
Chart B-24 Wheel Speed Input
Abnormality (DTC 65 (Flash out) /
Chart C-1-1 FL Sensor Output Inspection
Procedure ................................................ 5A - 53
Chart C-1-2 FR Sensor Output Inspection
Procedure ................................................ 5A - 54
Chart C-1-3 Rear Sensor Output Inspection
Procedure ................................................ 5A - 55
Chart TC-1 Sensor Output Inspection
Procedure ................................................ 5A - 55

and systems.
General Description
The Anti-lock Brake System (ABS) works on all four
wheels. A combination of wheel speed sensor and
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking.
5A3
This system helps the driver maintain greater control of

the vehicle under heavy braking conditions.
NOTE: The Electronic Hydraulic Control Unit (EHCU)
comprises the Hydraulic Unit (H/U) and the coil
Integrated Module.
C05RW004
Legend
(1)
(2)
(3)
(4)
Electronic
Hydraulic
EndOFCallout
(5) Front Wheel Speed Sensor

(6) Rear Wheel Speed Sensor
(7) Proportioning and Bypass (P&B) Valve
5A4
Functional Description
Solenoid Valve
C05RW012
Legend
(1) Isolation Valve
EndOFCallout
(2) Dump valve

Normal Braking
During normal (non anti-lock) braking, the solenoid
valves are without current and closed due to spring
force.
5A5
Brake fluid travels through the centre of the normally

open isolation valve around the normally closed dump
valve and on to the brake pistons.
C05RW010
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder
5A6
Pressure Isolation (Pressure Maintain)

The electro-hydraulic control unit is activated when the
brakes are applied which sends a signal to the coil
integrated module to prepare for a possible anti-lock
stop.
If the information from the wheel speed sensors
indicates excessive wheel deceleration (imminent
lockup), the first step in the anti-lock sequence is to
isolate the brake pressure being applied by the brake
pedal.
The microprocessor in the coil integrated module sends
a voltage to the coil to energize and close the isolation
valve. This prevents any additional fluid pressure
applied by the brake pedal from reaching the wheel.
With the isolation valves closed, further unnecessary
increase in the brake pressure is therefore prevented.
C05RW011
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder

Pressure Reduction
Once the brake pressure is isolated, it must be reduced
to allow the wheels to unlock. This is accomplished by
dumping a portion of the brake fluid pressure into a low
pressure accumulator.
The microprocessor activates the normally closed dump
valve to open, allowing fluid from the wheels to be
dumped into the accumulator. This is done with very
short activation pulses opening and closing the dump
valve passageway. Brake pressure is reduced at the
5A7
wheel and allows the wheel to begin rotating again. The

fluid from the brake piston is stored in the accumulator
against spring pressure and a portion of this fluid also
primes the pump.
The dump valves are operated independently to control
the deceleration of the wheel. At this point, the brake
pedal is isolated from the base brake system, the
hydraulic control unit pumps are primed and the
attenuators are ready to pump fluid.
C05RW009
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder
5A8
Pressure Increase (Re-apply)

The re-apply sequence is initiated to achieve optimum
braking. The isolation valve is momentarily opened to
allow master cylinder and pump pressure to reach the
brakes. This controlled pressure rise continues until the
wheel is at optimum brake output or until the brake
pressure is brought up to the master cylinder output
pressure.
If more pressure is required, more fluid is drawn from
the master cylinder and applied to the brakes. The
driver may feel slight pedal pulsations, or pedal drop,

this is normal and expected.
As fluid is re-applied to the brakes, the wheel speed will
reduce. If the wheels approach imminent lockup again,
the module will isolate, dump and re-apply again. This
cycle occurs in millisecond intervals, allowing several
cycles to occur each second. It is a much faster and
more controlled way of pumping the pedal".
C05RW014
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder

Brake Release
At the end of the anti-lock stop, when the brake pedal is
released, the pump will remain running for a short time
to help drain any fluid from the accumulators. As this
fluid returns into the system, the spring forces the piston
5A9
back to its original position.

The isolation valve opens and fluid may return to the
master cylinder. Conventional braking is then resumed.
C05RW013
Legend
(1) Brake
EndOFCallout
(2) Master Cylinder
5A10
System Components
Electronic Hydraulic Control Unit (EHCU), three Wheel
Speed Sensors, Warning Light, and G-sensor.
Electronic Hydraulic Control Unit (EHCU)

The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the hydraulic unit
according to the signal from each sensor, cancelling
ABS to return to normal braking when a malfunction has
occurred in the ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
right side. It consists of a Motor, Plunger Pump,
Solenoid Valves.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front disc brake or both rear disc
brakes according to the signal sent from the EHCU.
Reservoir: Temporarily holds the brake fluid that returns
from the front and rear disc brake caliper so that
pressure of front disc brake caliper can be reduced
smoothly.
Plunger Pump: Feeds the brake fluid held in the
reservoir to the master cylinder.
Motor: Drives the pump according to the signal from
EHCU.
Check Valve: Controls the brake fluid flow.
ABS Warning Light
seconds after the ignition switch is to the ON" position.

If the ABS" light stays ON" after the ignition switch is
the ON" position, or comes ON" and stays ON" while
driving, the Anti-lock Brake System should be inspected
for a malfunction according to the diagnosis procedure.
Wheel Speed Sensor

It consists of a sensor and a rotor. The sensor is
attached to the knuckle on the front wheels and to the
rear axle case on the rear differential.
The rotor is press-fit in the axle shaft.
The flux generated from electrodes magnetized by a
magnet in the sensor varies due to rotation of the rotor,
and the electromagnetic induction generates alternating
voltage in the coil. This voltage draws a sine curve"
with the frequency proportional to rotor speed and it
allows detection of wheel speed.
G-Sensor
The G-sensor installed inside the EHCU detects the
vehicle deceleration speed and sends a signal to the
EHCU. In 4WD operation, all four wheels may be
decelerated in almost the same phase, since all wheels
are connected mechanically.
This tendency is noticeable particularly on roads with
low friction coefficient, and the ABS control is adversely
affected.
The G-sensor judges whether the friction coefficient of
road surface is low or high, and changes the EHCU's
operating system to ensure ABS control.
Normal and Anti-lock Braking

Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power
assisted brake system. However, with the detection of
wheel lock-up, a slight bump or kick-back will be felt in
the brake pedal. This pedal bump" will be followed by a
series of short pedal pulsations which occurs in rapid
succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or popping
noise may be heard during brake applications when the
Anti-lock features is being used.
When the Anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on the
pedal will provide the shortest stopping distance.
825RX048
Vehicles equipped with the Anti-lock Brake System have

an amber ABS" warning light in the instrument panel.
The ABS" warning light will illuminate if a malfunction
in the Anti-lock Brake System is detected by the
Electronic Hydraulic Control Unit (EHCU). In case of
an electronic malfunction, the EHCU will turn ON" the
ABS" warning light and disable the Anti-lock braking
function.
The ABS" light will turn ON" for approximately three
Brake Pedal Travel

Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying
more force the pedal will continue to travel toward the
floor.
This extra brake pedal travel is normal.
5A11
Acronyms and Abbreviations
ABS Service Precautions
Several acronyms and abbreviations are commonly

used throughout this section:
Required Tools and Items:

Box Wrench
Brake Fluid
Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
ABS
Anti-lock Brake System
CIM
CKT
Circuit
DLC
Data Link Connector
EHCU
FL
Front Left
FR
Front Right
GEN
Generator
H/U
Hydraulic Unit
MV
Millivolts
RR
Rear
RPS
Revolution per Second
VDC
DC Volts
VAC
AC Volts
W/L
Warning Light
WSS
Wheel Speed Sensor
General Diagnosis
General Information
ABS troubles can be classified into two types, those
which can be detected by the ABS warning light and
those which can be detected as a vehicle abnormality
by the driver.
In either case, locate the fault in accordance with the
BASIC DIAGNOSTIC FLOWCHART" and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
5-8840-0366-0 High Impedance Multimeter

When circuit measurements are requested, use a circuit
tester with high impedance.
Computer System Service Precautions

The Anti-lock Brake System interfaces directly with the
Electronic Hydraulic Control Unit (EHCU) which is a
control computer that is similar in some regards to the
Powertrain Control Module. These modules are
designed to withstand normal current draws associated
with vehicle operation. However, care must be taken to
avoid overloading any of the EHCU circuits. In testing for
opens or shorts, do not ground or apply voltage to any
of the circuits unless instructed to do so by the
appropriate diagnostic procedure. These circuits should
only be tested with a high impedance multimeter
5-8840-0366-0 or special tools as described in this
section. Power should never be removed or applied to
any control module with the ignition in the ON" position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the OFF"
position.
General Service Precautions

The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock Brake
System damage.
If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU and valve
block connectors should be disconnected before the
welding operation begins.
The EHCU and valve block connectors should never
be connected or disconnected with the ignition ON" .
If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the ABS" warning light will
illuminate. But actually no trouble exists. After
inspection stop the engine once and re-start it, then
make sure that the ABS" warning light does not
illuminate.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS to a
5A12
non-operative state by removing the fuse for the ABS

(60A). After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning light does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case duplicating
the system malfunction during a test drive or a good
description of vehicle behavior from the customer may
be helpful in locating a most likely" failed component or
circuit. The symptom diagnosis chart may also be useful
in isolating the failure. Most intermittent problems are
caused by faulty electrical connections or wiring. When
an intermittent failure is encountered, check suspect
circuits for:
Suspected harness damage.
Poor mating of connector halves or terminals not fully
seated in the connector body (backed out).
Improperly formed or damaged terminals.
Test Driving ABS Complaint Vehicles

In case that there has been an abnormality in the
lighting pattern of ABS" warning light, the fault can be
located in accordance with the DIAGNOSIS BY ABS"
WARNING LIGHT ILLUMINATION PATTERN" . In case
of such trouble as can be detected by the driver as a
vehicle symptom, however, it is necessary to give a test
drive following the test procedure mentioned below,
thereby reproducing the symptom for trouble diagnosis
on a symptom basis:
1. Start the engine and make sure that the ABS" W/L
goes OFF. If the W/L remains ON, it means that the
Diagnostic Trouble Code (DTC) is stored.
Therefore, read the code and locate the fault.
NOTE: The DTC cannot be cleared if the vehicle speed
does not exceed 12 km/h (8 mph) at DTC, even though
the repair operation is completed.
2. Start the vehicle and accelerate to about 30 km/h
(19 mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop
the vehicle.
6. Be cautious of abnormality during the test. If the W/
L is actuated while driving, read the DTC and locate
the fault.
7. If the abnormality is not reproduced by the test,
make best efforts to reproduce the situation
reported by the customer.
8. If the abnormality has been detected, repair in
accordance with the SYMPTOM DIAGNOSIS" .
NOTE:
Be sure to give a test drive on a wide, even road with
a small traffic.
If an abnormality is detected, be sure to suspend the
test and start trouble diagnosis at once.
ABS" Warning Light

When ABS trouble occurs to actuate ABS" warning
light, the trouble code corresponding to the trouble is
stored in the EHCU. Only ordinary brake is available
with ABS being unactuated. Even when ABS" warning
light is actuated, if the starter switch is set ON after
setting it OFF once, the EHCU checks up on the entire
system and, if there is no abnormality, judges ABS to
work currently and the warning light is lit normally even
though the trouble code is stored.
NOTE: Illumination of the ABS" warning light indicates
that anti-lock braking is no longer available. Power
assisted braking without anti-lock control is still
available.
Normal Operation
ABS" Warning Light
When the ignition is first moved from OFF" to RUN" ,
the amber ABS" warning light will turn ON" . The
ABS" warning light will turn ON" during engine
starting and will usually stay ON" for approximately
three seconds after the ignition switch is returned to the
ON" position. The warning light should remain OFF" at
all other times.

Tech 2 Scan Tool
5A13
scan tool user guide.

recommended to use Tech 2. Please refer to Tech 2
901RW257
Legend
(1) PCMCIA Card
(3) DLC Cable
EndOFCallout
(4) Tech2
5A14
Getting Started
1. The Isuzu 98 System PCMCIA card inserts into the
Tech 2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech 2.
vehicle DLC (1).
Operating Procedure
740RW165

7. Power up the Tech 2.
060RX065
060RW009
060RX063
5A15
5A16
DATA LIST
The data displayed by DATA LIST are as follows:
Display
Content
OK/NG Criteria for Data
Front Left Wheel Speed

Front Right Wheel Speed
Rear Wheel Speeds
km/h (MPH)
Start the vehicle and make sure of linear change in each

wheel speed.
Turn each wheel by hand and make sure that each
speed data change.
Warning Lamp
ON/OFF
To be OFF usually
ABS State
ON/OFF
To be OFF usually
ABS Relay
Active/Inactive
To be Active usually
4 Wheel Drive
Active/Inactive
2WD: Inactive
4WD: Active
Brake Switch
Active/Inactive
Inactive (Released)
Active (Pressed)
Brake Fluid Level
Normal or not
To be Normal usually
Return Pump
Active/Inactive
DRP (Dynamic Rear

Proportioning)
Active/Inactive
Rear Dump Valve Commanded
Active/Inactive
Active/Inactive
Active/Inactive
GSensor
Voltage
0.00V when vehicle is stopped
Battery Voltage
Voltage
Between 1016.9V
Rear Dump Valve Feedback

Rear Isolation Valve
Commanded
Rear Isolation Valve Feedback
FL Dump Valve Commanded
FL Dump Valve Feedback
FL Isolation Valve Commanded
FL Isolation Valve Feedback
FR Dump Valve Commanded
FR Dump Valve Feedback
FR Isolation Valve Commanded
FR Isolation Valve Feedback

ACTUATOR TEST
This mode is used to exercise the ABS actuators and
make sure they operate normally. Prior to the test, pay
attention to the cautions below. (When checking the
solenoid valve system, be sure to jack up the vehicle.)
CAUTION:
Before testing, be sure that the brakes work
normally.
Make sure that the battery is fully charged.
5A17
Conduct the test by two persons (A TECH 2

operator and a vehicle checker).
Be sure to start ACTUATOR TEST with the engine
stopped.
Before testing, make sure that electrical trouble,
if any, has been completely repaired. Conducting
tests of ABS solenoid with electrical circuit
problem remaining uncorrected could damage
the control unit.
F05RX001
5A18
F05RX002
5A19
F05RX003
5A20
F05RX004
5A21
Tech 2 Service Bleed
F05RX005
5A22
F05RX006
5A23
Basic Diagnostic Flow Chart

Step
1
Action
1. Customer complaint.
2. Questioning to customer.
3. Basic inspection (Refer to Basic inspection procedure")
Using TECH 2?
Make sure of DTC by mode F0: Diagnostic Trouble Codes".
1. Repair of faulty part.

2. Elimination of DTC.
3. Inspection of ABS" W/L Illumination pattern with ignition SW
ON".
4. Test drive.
Does trouble repeat?
Yes
No
Go to Step 2
Go to Step 4
Clear code and

check for
repeatability.
Go to Step 3
Go to Step 5
Repeat the
diagnosis it the
symptom or
DTC appears
again
Go to Step 1
Go to Step 5
Clear code and

check for
repeatability
Go to Step 3
Trouble
diagnosis
based on
symptom (Refer
to SYMPTOM
DIAGNOSIS")
Go to Step 3
Check if the DTC is stored or not.

1. Reconnect all components. Ensure all component are

properly mounted.
Finished
Go to Step 5
Yes
No
Basic Inspection Procedure

1. Basic Inspection of Service Brake
Step
Action
1
Is the fluid level normal?

Go to Step 2
2
3
4
5
Does fluid leak?
Repair
Go to Step 3
Is the booster function normal?
Go to Step 3
Go to Step 4
Repair
Go to Step 4
Go to Step 5
Repair
Go to Step 5
Is the pad and rotor normal?

mounted.
Replenish with
fluid
Go to Step 2
Finished
Go to Step 5
Yes
No
2. Ground Inspection
Step
1
Action
Does ABSrelated ground points normally?
Go to Step 2
2

mounted.
Finished
Repair
Go to Step 2
Go to Step 2
5A24
EHCU Connector Pin-out Checks
Perform checks with high impedance digital

multimeter 5-8840-0366-0 or equivalent.
Disconnect Electronic Hydraulic Control Module.

No.
Circuit to be Tested
Ignition
Switch
Position
Multimeter
Scale/Range
Measure
between Pin
Number
Nominal Value
Power supply
OFF
20DCV
1 (C5)
2 (C5)
Ignition enable
OFF
20DCV
1 (C4)
7 (C4)
0V to 0.1V
ON
20DCV
1 (C4)
7 (C4)
11.5V to 14.5V
Note
11.5V to 14.5V
Stoplight switch
OFF
20DCV
13 (C4)
7 (C4)
10.5V to 14.5V
Ground connection
OFF
200
7 (C4)
Ground
Less than 2
OFF
2 (C5)
Ground
Less than 0.2
OFF
2k
2 (C4)
10 (C4)
2.0k to 2.8k
OFF
200k
2 (C4)
7 (C4)
more than
100k
OFF
200mACV
2 (C4)
10 (C4)
more than
200mV
Turn wheel at 1RPS
OFF
2k
3 (C4)
11 (C4)
2.0k to 2.8k
Internal Resistance
OFF
200k
3 (C4)
7 (C4)
more than
100k
OFF
200mACV
3 (C4)
11 (C4)
more than
200mV
Turn wheel at 1RPS
OFF
2k
4 (C4)
12 (C4)
1.2k to 2.0k
Internal Resistance
OFF
200k
4 (C4)
7 (C4)
more than
100k
OFF
200mACV
4 (C4)
12 (C4)
more than
200mV
Turn wheel at 1RPS
FL speed sensor
FR speed sensor
RR speed sensor
Press brake pedal
Internal Resistance
5A25
Circuit Diagram
D08RX216
5A26
D08RX215

Connector List
No.
Connector face
No.
B-19
F-4
B-23
H-5
C-4
H-15
H-25
C-5
H-14
C-6
H-19
C-13
C-33
H-26
C-16
C-36
E-28
E-30
I-1
C-34
I-2
Connector face
5A27
5A28
No.
I-18

Connector face
No.
Connector face
5A29
Part Location
D08RX217
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
C36
C5
C4
H14, H19
Relay & Fuse Box
I1
I2
B23
B19
F4
H26
H15
EndOFCallout
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
H25
C16
C13
H5
E30 (6VD1)
E28 (X22SE)
I18
C34
C6
C33
5A30
Symptom Diagnosis
The symptoms that cannot be indicated by warning light
can be divided in the following five categories:
1. ABS works frequently but vehicle does not
decelerate.
2. Uneven braking occurs while ABS works.
3. The wheels lock during braking.
No.
4. Brake pedal feel is abnormal.

5. Braking sound (from EHCU) is heard while not
braking.
These are all attributable to problems which cannot be
detected by EHCU self-diagnosis. Use the customer
complaint and a test to determine which symptom is
present. Then follow the appropriate flow chart listed
below.
Symptom
Diagnostic Flow Charts

Without TECH 2
With TECH 2
ABS works frequently but vehicle does not decelerate.
Chart A-1
Chart TA-1
Uneven braking occurs while ABS works.
Chart A-2
Chart TA-2
The wheels are locked.
Chart A-3
Chart TA-3
Brake pedal feel is abnormal.
Chart A-4
Braking sound (from EHCU) is heard while not braking.
Chart A-5
Chart TA-5
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate
Step
1
Action
Yes
Is braking force distribution normal between front and rear of

vehicle?
Go to Step 2
Repair brake
parts.
Go to Step 8
Go to Step 3
Repair axle
parts.
Go to Step 8
Are axle parts installed normally?
Is there play in each or any wheel speed sensor?
Is there damage, or powered iron sticking to each or any wheel

speed sensor/sensor ring?
Repair wheel
speed sensor.
Go to Step 8
Go to Step 4
Replace sensor
or sensor ring.
Go to Step 8
Go to Step 5
Go to Step 6
Replace wheel
speed sensor or
repair harness.
Go to Step 7
Go to Step 7
Replace
controller or
repair harness.
Go to Step 7
Is the output of each wheel speed sensor normal? (Refer to chart

C-1 or TC-1)
Is the input of 4WD controller normal?

mounted.
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 7
5A31
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step
1
2
3
Action
Yes
No
1. Connect TECH 2.
Go to Step 2
Replace wheel
speed sensor.
Go to Step 3
Return to Chart A-1.

Was the Chart A-1 finished?
Go to Step 3
Go to Step 2
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Yes
No

mounted.
Chart A-2 Uneven Braking Occurs While ABS Works

Step
1
2
3
Action
Is there play in each or any sensor?
Damage or powdered iron sticking to each or any sensor/sensor
ring?
Repair.
Go to Step 5
Go to Step 2
Repair.
Go to Step 5
Go to Step 3
Is the output of each sensor normal? (Refer to chart C-1 or TC-1)
Go to Step 4
4
Is brake pipe connecting order correct?

Replace H/U.
Go to Step 5

mounted.
Repeat the Basic

diagnostic flow
chart"
Replace sensor
or repair
harness.
Go to Step 5
Reconnect
brake pipe
correctly.
Go to Step 5
Go to Step 5
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)
Step
Yes
No
1. Connect TECH 2.
Go to Step 2
Go to Step 3
Check piping by TECH 2 ACTUATOR TEST

Is the piping normal?
Replace EHCU.
Go to Step 4
Repair the pipe.

Go to Step 4
Repair and check the wheel speed sensor (Refer to chart B-20 to
B-23 , C-1 or TC-1).
Was the each chart finished?
Go to Step 4
Go to Step 3

mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 4
Action
5A32
Chart A-3, TA-3 The Wheels Are Locked

Step
Action
Is ABS working?
Is vehicle speed under 10 km/h (6mph)?
Is sensor output normal? (Chart C-1 or TC-1)
Yes
No
Go to Step 2
Go to Step 6
Normal.
Go to Step 3
Go to Step 4
Replace sensor
or repair
harness.
Go to Step 6
Go to Step 5
Replace 4WD
controller or
repair harness.
Go to Step 6
Is front 4WD controller normal?
Is hydraulic unit grounded properly?

mounted.
Replace EHCU.
Go to Step 6
Correct.
Go to Step 6
Repeat the Basic

diagnostic flow
chart"
Go to Step 6
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Harness NG
between brake
SW and EHCU.
Go to Step 6
Go to Step 5
Replace stop
light fuse.
Go to Step 6
Go to Step 6
Repair body
grounded
harness.
Go to Step 6
Chart A-4 Brake Pedal Feed Is Abnormal

Step
Action

2. Disconnected EHCU connector.
Is the check voltage EHCU connector terminals 13 to 7 when
brake pedal is depressed than battery voltage?
Is the check continuity between EHCU connector terminals, 7 to

body grounded?
Is brake SW normal?

mounted.
Repair stop
light harness.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Replace brake
SW.
Go to Step 6
Go to Step 6
5A33
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
Step
1
4
5
6
Action
Is this the first vehicle start after engine start?
Is vehicle speed under 10 km/h (6 mph)?
Check for the following condition:

At the time of shift down or clutch operation.
At the time of low road friction drive (ice or snow road) or rough
road drive.
At the time of high-speed turn.
At the time of passing curb.
At the time of operating electrical equipment switches.
At the time of racing the engine (over 5000 rpm).
Did it occur under any one condition above?
Is there play in each or any sensor/wheel speed sensor rings?
Damage or powdered iron sticking to each or any sensor/wheel
speed sensor ring?
Is each sensor output normal? (Refer to chart C-1 or TC-1).

mounted.
Yes
No
It is self
checking sound
Normal.
Go to Step 2
It is self
checking sound
Normal.
Go to Step 3
ABS may
sometime be
actuated even
when brake pedal
is not applied.
Go to Step 4
Repair.
Go to Step 7
Go to Step 5
Repair.
Go to Step 7
Go to Step 6
Check harness/
connector for
suspected
disconnection
If no
disconnection is
found, replace
Coil integrated
module.
Go to Step 7
Repeat the Basic
diagnostic flow
chart"
Repair.
Go to Step 7
Go to Step 7
5A34

Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
Flash out
Serial
Communications
Diagnosis
Item
Chart
No.
12
13
C0285
2 WD Controller in 4WD Vehicle Controller
Wiring
B-8
14
C0271
RAM read/write error
C0272
ROM checksum error
C0270
ALU function error
B-2
C0273
Inoperative isolation item
Coil
Integrated
Module
C0284
Loop time overrun
C0277
Low ignition voltage
C0278
High ignition voltage
Wiring
B-3
C0269
Excessive dump time
15
17
18
C0274
Excessive isolation time
21
C0276
G-Sensor Failure
22
C0281
Brake switch Failure
24
C0282
Open or shorted 44 input signal
32
C0267
Open motor circuit or shorted ECU output
C0268
Stalled motor or open ECU output
C0265
Open relay circuit
C0266
Shorted relay circuit
C0245
FL Open isolation solenoid or shorted ECU output
C0247
FL Shorted isolation solenoid or open ECU output
C0246
FL Open dump solenoid or shorted ECU output
C0248
FL Shorted dump solenoid or open ECU output
C0241
FR Open isolation solenoid or shorted ECU output
C0243
FR Shorted isolation solenoid or open ECU output
C0242
FR Open dump solenoid or shorted ECU output
C0244
FR Shorted dump solenoid or open ECU output
C0251
Rear Open isolation solenoid or shorted ECU output
C0253
Rear Shorted isolation solenoid or open ECU output
C0252
Rear Open dump solenoid or shorted ECU output
C0254
Rear Shorted dump solenoid or open ECU output
35
41
42
43
44
45
46
B-4
Coil
Integrated
Module
B-5
B-6
B-7
Wiring
B-8
Motor
B-9
Relay
B-10
B-11
B-12
B-13
Solenoid
B-14
B-15
B-16

Code
Diagnosis
Item
5A35
Chart
No.
Flash out
Serial
Communications
51
C0225
FL Open or shorted sensor
B-17
52
C0221
FR Open or shorted sensor
B-18
53
C0235
Rear Open or shorted sensor
B-19
61
C0226
FL Missing sensor signal
C0227
FL Sensor signal dropout
C0222
FR Missing sensor signal
C0223
FR Sensor signal dropout
C0236
Rear Missing sensor signal
C0237
Rear Sensor signal dropout
64
C0229
Simultaneous dropout of front sensor signal
65
C0238
Wheel speed error
C0286
Shorted indicator lamp
62
63
B-20
Sensor or
Wiring
B-21
B-22
B-23
Vehicle or
Sensor
B-24
Wiring
5A36

Illumination Pattern
In the event that there is abnormality in the ABS"
No.
Condition
warning light illumination pattern while the key is in the

ON position or if the warning light is actuated during
driving, trouble should be diagnosed on a illumination
pattern basis as follows:
ABS" Warning Light Illumination Pattern
Diagnostic
Warning light is
actuated normally
Normal
Warning light is not lit
Warning light lighting circuit

troubleGo to Chart B-1
Warning light remains

ON

stored.
the flow charts.
Warning light is
actuated while driving

stored.
the flow charts.
Warning light goes at

12 km/h (8 mph) or
higher (After repairing
the faulty part)
Even after repairing the faulty

part the warning light (W/L)
dose not go out it vehicle is
at a stop.
Turn the ignition switch to the
ON position and drive the
vehicle at 12 km/h (8 mph)
or higher to make sure that

Diagnostic Trouble Codes (DTCs)
When the warning light in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.
How to display and erase DTCs:
NOTE:
DTCs can be displayed also by TECH 2. Use
Diagnostic Trouble Codes" mode.
The DLC is located behind the driver side kick panel
5A37
1. How to start DTC display:

Confirm that the vehicle has come to a complete
stop (with the wheels standing still) and that the
brake pedal is not depressed. (Unless these two
condition are satisfied, DTC display cannot be
started.)
With IGN OFF, connect #12 terminal with #4
terminal or # 5 terminal (GND) . Then turn IGN
ON.
350RX008
Keep #12 terminal connected with #4 terminal or

# 5 terminal (GND) during DTC display. (If #12
terminal is separated from #4 terminal or # 5
terminal (GND) during display, display will stop.)
2. DTC display:
DTC is displayed by blinking warning light.
Double-digit display.
First, normal DTC 12 is displayed three times and
(If no other DTCs have been stored, the display of
DTC 12 will be repeated.)

3. How to erase code:
Conduct brake switch ON/OFF operation 6 or
more times within 3 seconds of self-diagnosis
startup.
The code cannot be erased if more than 3
seconds have passed since self-diagnosis
startup, or if self-diagnosis has started with brake
switched on (brake pedaled).
B05RW005
5A38
4. Notes
If the following should occurs during Diagnostic
Trouble Code (DTC) display the display will be
discontinued. After initial check, the status that is
under the control of ABS will be returned :
The vehicle starts (The wheels turn) or the
brake pedal is depressed.
Up to 3 different codes can be stored.

If the ABS should turn OFF due to an intermittent
defect, the system will be restored at the next key
cycle, if the initial check finds no abnormality
(when IGN is switched from OFF to ON).
5. An example of DTC display
Display of DTC 23
B05RW006
After displaying DTC 12 three times, one DTC after

another is displayed, starting with the most recent
one. (However, display is discontinued after about 5
minutes.)
B05RS005
The DTC 12 is displayed repeatedly. (display is

discontinued after about 5 minutes after)
5A39
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L)
is not activated.
Step
1
2
Action
Is W/L fuse disconnected?
Is W/L burnt out?

2. Disconnect coil integrated module connector (C-4).
3. Turn the key ON.
(C-4) terminals 6 and 7 than battery voltage?
Is the check continuity coil integrated module connector (C-4)
terminals, 1 and 7 and body ground.

mounted.
Yes
No
Replace fuse.
Go to Step 5
Go to Step 2
Replace W/L
bulb.
Go to Step 5
Go to Step 3
Go to Step 4
Repair harness
and connector.
Go to Step 5
Check harness
for suspected
disconnection
No fault found:
Replace EHCU.
Go to Step 5
Repair harness
and connector.
Go to Step 5
Repeat the Basic

diagnostic flow
chart"
Go to Step 5
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial
communications))
Step
1
Action
Yes
No

3. Inspect coil integrated module ground.
Is the check resistance between the coil integrated module
connector terminals, 2 (C-5) and 7 (C-4) and body ground?
Go to Step 2
1. Turn the key off, connect the coil integrated module

connector.
2. Erase the trouble code.
3. Turn Ignition off, then on, to perform system self-check.
4. If warning light remains on, display trouble codes once again.
Is the check trouble code 14 (Flash out) / C0271, C0272, C0273,
C0284 (Serial communications)?
Inspect in
Replace EHCU.
accordance with
Go to Step 3
the DTC displayed.

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Repair the body

ground
harness.
Go to Step 3
Go to Step 3
5A40
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial
communications))
Step
1
Action
Yes
Is the check battery voltage normal? (Battery capacity check)

3. Turn the key on.
(C-4) terminals 1 and 7, higher than 10V?

properly mounted.
No
Go to Step 2
Charge or
replace battery.
Go to Step 2
Check harness
connector for
suspected
disconnection
Fault found:
Repair, and
perform system
self-check
No fault found:
replace EHCU.
Go to Step 3
Repair harness
or connector.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))
Step
1
Action
Yes
No

Repair or Replace
Go to Step 2

2. Replace EHCU.
properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 2
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))
Step
1
Action
Yes

Repair or Replace

2. Replace EHCU.
properly mounted.
Repeat the Basic

diagnostic flow
chart"
No
Go to Step 2
Go to Step 2
5A41
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))
Step
1
Action
2. Replace EHCU.
properly mounted.
Yes
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 1
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))
Step
Action

Is the check voltage coil integrated module connector (C-4)
terminals 13 to 7 when brake pedal is depressed than battery
voltage?
4
5
Is the check that pins C-5 connector 2, and C-4 connector 7 have
good ground?
Yes
No
Go to Step 2
Go to Step 4
Go to Step 3
Harness
between brake
SW and coil
integrated
module is faulty.
Go to Step 6
Check harness
/ connector for
disconnection
Fault found:
Repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repair.
Go to Step 6
Go to Step 5
Replace.
Go to Step 6
Abnormal
harness in stop
light circuit.
Repair the
harness.
Go to Step 6
Replace.
Go to Step 6

Is brake SW normal?

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 6
5A42
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial
communications)), 4WD State Input Signal Failure (DTC 24 (Flash out) / C0282 (Serial
communications))
Step
1
Action
Remove coil integrated module connector.
Is the coil integrated module connector (C-4) terminal 8 line
normally?
Yes
Go to Step 2
Repair.
Go to Step 3
Replace EHCU.
Go to Step 3
Replace 4WD
controller.
Go to Step 3
Is the 4WD controller normally?

properly mounted.
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))
Step
Action

Yes
Go to Step 2
Repair fuse/
harness
between battery
and coil
integrated
module
connector (C-5)
terminal 1.
Go to Step 5
Go to Step 3
Connect to the
connector.
Go to Step 3
Go to Step 4
Replace EHCU.
Go to Step 5
Replace EHCU.
Go to Step 5
Replace EHCU.
Go to Step 5
Is the harness from the hydraulic unit connected to the coil

integrated module connector?
Is the harness from the hydraulic unit normally?
Is the check resistance of hydraulic unit connector terminals 1

and 2 between 0.2 and 1.0 ohms?

properly mounted.
No
Repeat the Basic

diagnostic flow
chart"
Go to Step 5
5A43
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial
communications))
Step
Action

Yes
Replace EHCU.
Go to Step 2
2

properly mounted.
Repeat the Basic

diagnostic flow
chart"
No
Repair fuse and
harness coil
integrated
module
connector (C-5)
terminal 1 and
battery.
Go to Step 2
Go to Step 2
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A44
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A45
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial
communications))
Step
1
Action
Yes
No
Go to Step 2
Go to EHCU
Connector Pinout
Checks."

EHCU.
Go to Step 3
Repair the
connector. Repeat
the Basic
Diagnostic Flow
Chart."

properly mounted.
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial
communications))
Step
1
Action

connector.

properly mounted.
Yes
No
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace coil
integrated
module.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A46
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial
communications))
Step
1
Action

connector.

properly mounted.
Yes
No
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace coil
integrated
module.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A47
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial
communications))
Step
1
Action
Measure the Rear speed sensor resistance at the sensor

connector.

properly mounted.
Yes
No
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
5A48
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial
communications))
Step
1
2
3
4
5
Action
connector.


properly mounted.

Yes
No
Go to Step 2
Go to Step 3
Repair.
Go to Step 6
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 6
Repair.
Go to Step 6
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Go to Step 4
Replace sensor.
Go to Step 6
Go to Step 5
Replace sensor.
Go to Step 6
Go to Step 6
5A49
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial
communications))
Step
1
2
3
4
5
Action
3. Measure the FR speed sensor resistance between coil
connector.


properly mounted.

Yes
No
Go to Step 2
Go to Step 3
Repair.
Go to Step 6
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 6
Repair.
Go to Step 6
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Go to Step 4
Replace sensor.
Go to Step 6
Go to Step 5
Replace sensor.
Go to Step 6
Go to Step 6
5A50
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial
communications))
Step
1
2
3
4
5
Action
3. Measure the Rear speed sensor resistance between coil
Measure the rear speed sensor resistance at the sensor
connector.


properly mounted.

Yes
No
Go to Step 2
Go to Step 3
Repair.
Go to Step 6
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 6
Repair.
Go to Step 6
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repeat the Basic
diagnostic flow
chart"
Go to Step 4
Replace sensor.
Go to Step 6
Go to Step 5
Replace sensor.
Go to Step 6
Go to Step 6
5A51
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) /
C0229 (Serial communications))
Step
1
5
6
7
Action
Yes
No

Go to Step 2
Go to Step 3
Measure the FR speed sensor resistance between coil integrated

module connector (C-4) terminals 3 and 11.
Is the resistance between 2.0k and 2.8 k ohms?
Go to Step 5
Go to Step 4
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 2
Replace sensor.
Go to Step 2
Repair harness
abnormality
between
sensors and
coil integrated
module.
Go to Step 5
Replace sensor.
Go to Step 5

connector.

connector.

Is sensor output normal? (Chart C-1-1&C-1-2 or TC-1)

properly mounted.

Repair.
Go to Step 6
Go to Step 6
Repair.
Go to Step 7
Go to Step 7
Check for faults

in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 8
Repeat Basic
diagnostic flow
chart"
Replace sensor.
Go to Step 8
Go to Step 8
5A52
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial
communications))
Step
Action
Using TECH 2?
1. Connect TECH 2.
2. Select Snap shot manual trigger.
3. With wheel speed data displayed, run the vehicle when
speed has arrived at 30 km/h (18 mph).
4. Check speed data on each wheel (refer to the criterion given
below). * 1
Is the abnormal sensor condition found?
3
4
5
6
7
Is there play in sensor/sensor ring?

Is there powdered iron sticking to sensor/sensor ring?
Is there a broken tooth or indentation in sensor ring?
Is there play in wheel bearing?
Yes
No
Go to Step 2
Go to Step 3
Replace.
Go to Step 8
Go to Step 3
All the sensors
should follow
the following
flowchart
(without using
TECH 2).
Repair.
Go to Step 8
Go to Step 4
Repair.
Go to Step 8
Go to Step 5
Replace sensor
ring.
Go to Step 8
Go to Step 6
Adjust or repair.
Go to Step 8
Go to Step 7
Replace EHCU.
Go to Step 8
Repair, and
perform system
self-check.
Go to Step 8
Is the check wiring between sensor and coil integrated module

normal?

properly mounted.
Sensor Signal Abnormality Criteria using TECH 2

1. While driving, the speed of one or two wheels is
25% or more higher or lower than that of the other
wheels.
2. The speed of one or two wheels is 10 km/h (6 mph)
or more higher or lower than that of the other
wheels.
3. During steady driving, wheel speed changes
abruptly.
*1 The vehicle must run on a level paved road.
It is important to verify that the correct tires are installed
on vehicle.
Repeat
<FmSdata>[rsquor
]Basic diagnostic
flow chart"
Go to Step 8
5A53
Unit Inspection Procedure

This section describes the following inspection
procedures referred to during SYMPTOM DIAGNOSIS"
and DIAGNOSIS BY ABS' WARNING LIGHT
ILLUMINATION PATTERN" :
Sensor Output Inspection
without TECH 2
with TECH 2
Chart C-1-1 to C-1-3
Chart TC-1
Chart C-1-1 FL Sensor Output Inspection Procedure

Step
1
Action
connector terminals while turning FL wheel at a speed of 1
RPS:
2.0k - 2.8k ohms?

mounted.
Yes
Go to Step 2
Connector is
faulty, or open
or short circuit
of harness
between wheel
speed sensor
connector and
coil integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
Repeat the Basic
diagnostic flow
chart"
No
OK.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Go to Step 3
5A54
Chart C-1-2 FR Sensor Output Inspection Procedure

Step
1
Action
connector terminals while turning FR wheel at a speed of 1
RPS:
2.0k - 2.8k ohms?

mounted.
Yes
Go to Step 2
Connector is
faulty, or open
or short circuit
of harness
between wheel
speed sensor
connector and
coil integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
Repeat the Basic
diagnostic flow
chart"
No
OK.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Go to Step 3
5A55
Chart C-1-3 Rear Sensor Output Inspection Procedure

Step
Action
Yes

3. Jack up the vehicle with all four wheels off the ground
measure the AC voltage between coil integrated module
connector terminals while turning Rear wheel at a speed of 1
RPS:
Go to Step 2

Is the check between connector (F-4) terminals 1 and 2 within
1.2k - 2.0k ohms?

mounted.
Connector is
faulty, or open
or short circuit
of harness
between wheel
speed sensor
connector and
coil integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
No
OK.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Repeat the Basic

diagnostic flow
chart"
Go to Step 3
Yes
No
1. Connect TECH 2.
2. Check the wheel speed of each sensor by Data List.
Go to Step 6
Go to Step 2
Check the sensor harness for suspected disconnection (check

while shaking harness/connector).
Is the sensor harness connection normal?
Replace speed
sensor.
Go to Step 4
Check the wheel speed of each sensor by Data List.

Go to Step 6
Go to Step 4
Replace speed
sensor.
Go to Step 5
Replace sensor
rotor.
Go to Step 5
Go to Step 6
Repair harness
or connector
between coil
integrated
module and
speed sensor.
Go to Step 6
Chart TC-1 Sensor Output Inspection Procedure

Step
1
Action
Check the sensor rotor.

Is the sensor rotor normal?
Check the harness between coil integrated module and speed

sensor.
Is the harness connection normal?

mounted.
Repeat the Basic

diagnostic flow
chart"
Repair.
Go to Step 3
Go to Step 6
5A56
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884003850
(J35616)
Connector test adapter kit
5884003660
(J39200)
High impedance
multimeter
7000086ISU
Tech 2 Set
(1) PCMCIA Card
(3) DLC Cable
(4) Tech 2
SECTION
5B1
BRAKES
CONTENTS
Electronic Hydraulic Control Unit ..................
Electronic Hydraulic Control Unit and
Removal .....................................................
Disassembly ...............................................
Reassembly ................................................
Installation ..................................................
Front Wheel Speed Sensor ...........................
5B - 1
5B - 2
5B - 2
5B - 2
5B - 3
5B - 3
5B - 3
5B - 3
5B - 4
Service Precaution
Front Wheel Speed Sensor and

Removal......................................................
Installation...................................................
Rear Wheel Speed Sensor ...........................
Removal......................................................
Installation...................................................
5B - 4
5B - 4
5B - 4
5B - 4
5B - 5
5B - 5
5B - 5
5B - 5

and systems.
5B2

Electronic Hydraulic Control Unit and Associated Parts
350RW017
Legend
(1) EHCU
(2) Bolt
(3) Bracket
(4) Bolt and Nut
EndOFCallout
Removal
1. Remove brake pipes.
After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry of
foreign matter.
2. Remove three bracke fixing bolts.
3. Disconnect red clip from harness connector.
350RW018
5B3
Disassembly
4. Remove harness connector.

5. Remove EHCU ASM.
6. Remove EHCU.
1. Remove fixing bolts from EHCU.

2. Remove coil integrated module from hydraulic unit.
Disassembled View
Reassembly
To reassembly, follow the disassembly steps in the
Torque:
Fixing bolts: 4.4 Nm (4.5 kgcm/39 lb in)
Installation
Torque:
Hydraulic unit fixing nuts : 22 Nm (2.2 kgm/16
lbft)
Ground cable : 14 Nm (1.4 kgm/10 lbft)
Brake pipe (joint bolts) : 16 Nm (1.6 kgm/12 lbft)
350RW025
Legend
(1) Fixing Bolts
(2) Coil Integrated Module
(3) Hydraulic Unit (H/U)
EndOFCallout
After installing the hydraulic unit, bleed brakes

completely. See Hydraulic Brakes in Powerassisted
brake system section.
5B4
Front Wheel Speed Sensor

Front Wheel Speed Sensor and Associated Parts
350RS033
Legend
(1) Speed Sensor Connector
(2) Sensor Cable Fixing Bolt (Upper side)
(3) Sensor Cable Fixing Bolt (Lower side)
(4) Speed Sensor Fixing Bolt

(5) Speed Sensor
EndOFCallout
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 bolt.
5. Remove speed sensor.

1. Check the speed sensor pole piece for presence of
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.
chipping, and if damaged, replace the sensor ring

Section 4D Front hub and disc".
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
3. Install speed sensor cable fixing bolt (Lower side)
4. Install speed sensor cable fixing bolt (Upper side)
NOTE: Confirm that a white line marked on the cable is
not twisted when connecting the speed sensor cable.
5. Install speed sensor connector.
5B5
Rear Wheel Speed Sensor

Removal
Installation
1. Disconnect harness connector (1).

2. Remove sensor fixing bolt (2) .
3. Remove speed sensor (3).
1. Install speed sensor (3).

2. Tighten the sensor fixing bolt (2) to the specified
torque.
3. Connect harness connector (1).
350RX003

350RX003
1. Check speed sensor pole piece for presence of

2. Check the pole piece for damage, and replace
speed sensor if necessary.
3. Check speed sensor cable for short or open, and
replace with a new one if necessary. To check for
cable short or open, bend or stretch the cable while
checking for continuity.
chipping, and if damaged, replace the axle shaft
Section 4A2 Differential (Rear)".
SECTION
5C1
BRAKES
CONTENTS
Diagnosis .......................................................
Hydraulic Brakes ...........................................
Filling Master Cylinder Reservoir................
Deterioration of Brake Fluid ........................
Leakage of Brake Fluid...............................
Bleeding Brake Hydraulic System ..............
Flushing Brake Hydraulic System...............
Brake Pipes and Hoses ..............................
Brake Hose Inspection ...............................
Front Caliper Brake Hose..............................
Removal .....................................................
Installation ..................................................
Rear Axle Brake Hose...................................
Removal .....................................................
Installation ..................................................
Brake Pipe.....................................................
Removal .....................................................
Installation ..................................................
P & B (Proportioning and Bypass) Valve ......
Sectional View ..........................................
Removal .....................................................
Installation ..................................................
Brake Pedal...................................................
Checking Pedal Height ...............................
Checking Pedal Travel ...............................
Brake Pedal and Associated Parts .............
Removal .....................................................
Installation ..................................................
Parts Location.............................................
Removal .....................................................
Installation ..................................................
Fluid Reservoir Tank .....................................
Fluid Reservoir Tank and
Removal .....................................................
Installation ..................................................
Master Cylinder Assembly ............................
Master Cylinder Assembly and
5C - 2
5C - 2
5C - 5
5C - 6
5C - 9
5C - 9
5C - 9
5C - 9
5C - 9
5C - 10
5C - 10
5C - 10
5C - 11
5C - 11
5C - 11
5C - 11
5C - 12
5C - 12
5C - 12
5C - 12
5C - 13
5C - 13
5C - 13
5C - 14
5C - 14
5C - 14
5C - 14
5C - 15
5C - 16
5C - 16
5C - 16
5C - 17
5C - 17
5C - 17
5C - 18
5C - 18
5C - 18
5C - 18
5C - 19
5C - 20
5C - 20
5C - 20
5C - 20
5C - 21

Removal......................................................
Installation...................................................
Special Tools .................................................
Vacuum Booster Assembly ...........................
Vacuum Booster Assembly and
Removal......................................................
Installation...................................................
Exterior Components ....................................
Exterior Components and
Removal......................................................
Installation...................................................
Vacuum Booster Overhaul ............................
Vacuum Booster .........................................
Special Tools .................................................
Front Disc Brake Pads ..................................
Front Disc Brake Pads Inspection ..............
Front Disc Brake Pads and
Removal......................................................
Installation...................................................
Front Disc Brake Rotor..................................
Inspection ...................................................
Front Disc Brake Caliper Assembly...............
Front Disc Brake Caliper Assembly and
Removal......................................................
Installation...................................................
Front Disc Brake Caliper ...............................
Disassembly ...............................................
Reassembly ................................................
Rear Disc Brake Pads ...................................
Brake Pads Inspection................................
Brake Pads and Associated Parts ..............
Removal......................................................
Installation...................................................
5C - 21
5C - 21
5C - 21
5C - 23
5C - 23
5C - 23
5C - 24
5C - 24
5C - 24
5C - 24
5C - 25
5C - 27
5C - 27
5C - 27
5C - 28
5C - 28
5C - 28
5C - 28
5C - 29
5C - 30
5C - 31
5C - 31
5C - 31
5C - 32
5C - 32
5C - 34
5C - 34
5C - 34
5C - 34
5C - 36
5C - 36
5C - 36
5C - 37
5C - 39
5C - 39
5C - 39
5C - 40
5C - 40
5C - 42
5C - 43
5C - 43
5C - 43
5C - 44
5C - 44
5C2
Rear Disc Brake Rotor ..................................

Inspection ...................................................
Rear Drum (In Disc) Inside
Diameter Check ........................................
Rear Disc Brake Caliper Assembly ...............
Rear Disc Brake Caliper Assembly and
5C - 46
5C - 46
5C - 46
5C - 46
5C - 47
5C - 48
5C - 48
Removal......................................................
Installation...................................................
Rear Disc Brake Caliper................................
Disassembly ...............................................
Reassembly ................................................
Service Precaution
General Description

YOU ARE
IN
REPAIRS.
5C - 48
5C - 49
5C - 51
5C - 51
5C - 51
5C - 52
5C - 52
5C - 54

and systems.
330RS001

The master cylinder contains two pistons that supply the
hydraulic pressure for a dualcircuit braking system.
The primary piston provides the fluid pressure to the
front brakes, while the secondary piston provides the
fluid pressure to the rear brakes. If the pressure is lost
from either system, the remaining system will function to
stop the vehicle.
5C3
CAUTION:
1. The master cylinder is not repairable. If found
defective, it must be replaced as a complete
assembly.
or part of the brake system. (Refer to Bleeding
Brake Hydraulic System" in this section.)
4. Perform service operations on a clean bench
free from all mineral oil materials.
Brake Booster
331RS001
This booster is a tandem vacuum unit with a diaphragm

effective diameter 205mm + 230mm. In normal
operating mode, with the service brakes in the released
position, the tandem vacuum booster operates with
vacuum on both sides of its diaphragms. When the
brakes are applied, air at atmospheric pressure is
admitted to one side of each diaphragm to provide the
power assist. When the service brake is released, the
atmospheric air is shut off from the one side of each
diaphragm. The air is then drawn from the booster
through the vacuum check valve to the vacuum source.
CAUTION:
or part of the brake system.
3. The vacuum booster is not repairable and must
be replaced as complete assembly.
5C4
Disc Brake
Front Disc Brake
A05RW001
Rear Disc Brake
A05RW002
The disc brake assembly consists of a caliper, piston,

rotor, pad assembly and support bracket. The caliper
assembly has a single bore and is mounted to the
support bracket with two mounting bolts. The support
bracket allows the caliper to move laterally against the
rotor. The caliper is a onepiece casting with the
inboard side containing the piston bore. A square cut
rubber seal is located in a groove in the piston bore
which provides the hydraulic seal between the piston
and the cylinder wall.
NOTE:
1. Replace all components included in repair kits used
to service this caliper.
2. Lubricate rubber parts with clean brake fluid to ease
assembly.
disconnected, it may be necessary to bleed all or
part of the brake system.

4. Replace pads in axle sets only.
5. The torque values specified are for dry, unlubricated
fasteners.
6. Perform the service operation on a clean bench free
from all mineral oil materials.
Operation
Hydraulic pressure, created by applying the brake
pedal, is converted by the caliper to a stopping force.
This force acts equally against the piston and the
bottom of the caliper bore to move the piston outward
and to move (slide) the caliper inward resulting in a
clamping action on the rotor. This clamping action
forces the linings against the rotor, creating friction to
stop the vehicle.
Diagnosis
Road Testing The Brakes
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake
performance cannot be made if the roadway is wet,
greasy or covered with loose dirt so that all tires do not
grip the road equally. Testing will also be adversely
affected if the roadway is crowned so as to throw the
weight of the vehicle toward wheels on one side or if the
roadway is so rough that wheels tend to bounce. Test
the brakes at different vehicle speeds with both light and
heavy pedal pressure; however, avoid locking the
wheels and sliding the tires. Locked wheels and sliding
tires do not indicate brake efficiency, since heavily
braked but turning wheels will stop the vehicle in less
distance than locked wheels. More tiretoroad friction
is present with a heavily braked turning tire then with a
sliding tire.
The standard brake system is designed and balanced to
avoid locking the wheels except at very high
deceleration levels.
It is designed this way because the shortest stopping
distance and best control is achieved without brake
lockup.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake Performance
1. Tires: Tires having unequal contact and grip on the
road will cause unequal braking. Tires must be
equally inflated, identical in size, and the thread
pattern of right and left tires must be approximately
equal.
2. Vehicle Loading: A heavily loaded vehicle requires
more braking effort.
3. Wheel Alignment: Misalignment of the wheels,
particularly in regard to excessive camber and
caster, will cause the brakes to pull to one side.
Brake Fluid Leaks

With engine running at idle and the transmission in
Neutral", depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking.
Check the master cylinder fluid level. While a slight drop
in the reservoir level will result from normal lining wear,
an abnormally low level in reservoir indicates a leak in
the system. The hydraulic system may be leaking
internally as well as externally. Refer to Master Cylinder
Inspection". Also, the system may appear to pass this
test but still have slight leakage. If fluid level is normal,
check the vacuum booster push rod length. If an
incorrect length push rod is found, adjust or replace the
push rod. Check the brake pedal travel and the parking
brake adjustment.
5C5
When checking the fluid level, the master cylinder fluid

level may be low from the MAX" mark if the front and
rear linings are worn. This is not abnormal.
Warning Light Operation

When the ignition switch is in the START position, the
BRAKE" warning light should turn on and go off when
the ignition switch returns to the ON position.
The following conditions will activate the BRAKE" light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the
ignition switch is on.
2. Low fluid level. A low fluid level in the master
cylinder will turn the BRAKE" light on.
3. During engine cranking the BRAKE" light should
remain on. This notifies the driver that the warning
circuit is operating properly.
5C6
General Diagnosis
Condition
Brake Pull
Brake Roughness or Chatter

(Pulsates)
Excessive Pedal Effort
Possible cause
Correction
Tire inflation pressure is unequal.
Adjust
Front wheel alignment is incorrect.
Adjust
Unmatched tires on same axle.
Tires with approx. the same amount

of tread should be used on the same
axle.
Check for soft hoses and damaged

lines. Replace with new hoses and
new doublewalled steel brake
piping.
Water or oil on the brake pads.
Clean or replace.
Brake pads hardened.
Replace
Brake pads worn excessively.
Replace
Brake rotor worn or scored.
Grind or replace.
Disc brake caliper malfunctioning.
Clean or replace.
Adjust or replace.
Loose suspension parts.
Check all suspension mountings.
Loose calipers.
Check and tighten the bolts to

specifications.
Excessive lateral runout.

the rotor.
Parallelism not within specifications.

the rotor.
Wheel bearings not adjusted.
Adjust wheel bearings to correct

specifications
Pad reversed (steel against iron).
Replace the brake pad and machine

rotor to within specifications.
Check the vacuum booster

operation and repair, if necessary.
Partial system failure.
Check the front and rear brake

system for failure and repair. Also,
check the brake warning light. If a
failed system is found, the light
should indicate failure.
Excessively worn pad.
Check and replace pads in sets.
Piston in caliper stuck or sluggish.
Remove caliper and rebuild.
Fading brakes due to incorrect pad.
Remove and replace with original

equipment pad or equivalent.
Vacuum leak to vacuum booster.
Check for ruptured or loose hose.
Check the direction of check valve

within vacuum hose.
Correct vacuum hose direction.
Grease on the brake pads.
Replace or clean.

Condition
Excessive Brake Pedal Travel
Brake Drag
Grabbing or Uneven Braking Action

(All conditions listed under Pulls")
Possible cause
5C7
Correction
Bleed the hydraulic circuit.
Level of brake fluid in the reservoir

too low.
Replenish brake fluid reservoir to

specified level and bleed hydraulic
Master cylinder push rod clearance

excessive.
Adjust
Leakage in hydraulic system.
Correct or replace defective parts.
Master cylinder pistons not returning

correctly.
Adjust the stop light switch and

vacuum booster push rod. If
necessary, rebuild.
Check for soft hoses or damaged

pipes, and replace with new hoses
and new doublewalled steel brake
piping.
Parking brake maladjusted.
Adjust
Parking brake lining clearance

insufficient.
Adjust
Brake pedal free play insufficient.
Adjust the brake pedal height or

power cylinder operating rod.
Piston in the master cylinder

sticking.
Replace
Piston in the disc brake caliper

sticking.
Replace piston seals.
Brake pads sticking in caliper.
Clean
Return spring weakened.
Replace
Parking brake binding.
Overhaul the parking brakes and

correct.
Adjust or replace.
Parking brake shoes not returning.
Correct or replace the brake back

plate and brake shoe as necessary.
Obstructions in hydraulic circuit.
Clean
Rotor warped excessively.
Grind or replace.
Rear brake drum distorted.
Grind or replace.
Parking cable sticking.
Grind or replace.
Check operation and correct as

necessary.
Binding brake pedal mechanism.
Check and lubricate, if necessary.
Corroded caliper assembly.
Clean and lubricate.
5C8

Condition
Brake Noisy
Poor Brake Action
Possible cause
Correction
Brake pads are worn.
Replace
Brake pads are hardened.
Replace
Brake pads are in poor contact with

rotor.
Correct
Brake disc(s) warped, worn or

damaged.
Grind or replace.
Disc brake antisqueak shims

fatigued.
Replace
Front hub bearings are loose or

preload is incorrect.
Adjust or replace.
Brake disc is rusted.
Grind or replace.
Master cylinder faulty.
Correct or replace.
Vacuum booster faulty.
Correct or replace.
Level of brake fluid in reservoir too

low.
Replenish and bleed.
Bleed
Disc brake caliper faulty.
Clean or replace.
Water or oil on brake pads.
Clean or replace.
Brake pads in poor contact with the

rotor.
Correct
Brake pads worn.
Replace
Brake disc rusted.
Grind or replace.
Check valve in vacuum hose faulty.
Correct or replace.
5C9
Hydraulic Brakes
Filling Master Cylinder Reservoir
CAUTION: Use only specified brake fluid. Do not
use any fluid which contains a petroleum base. Do
not use a container which has been used for
petroleum based fluids or a container which is wet
with water. Petroleum based fluid will cause
swelling and distortion of rubber parts in the
hydraulic brake system. Water mixed with brake
fluid lowers the fluid boiling point. Keep all fluid
containers capped to prevent contamination.
Always fill the master cylinder reservoir when the
engine is cold.
Never allow the brake fluid to come in contact with
the painted surfaces.
The master cylinder reservoir must be kept properly
filled to ensure adequate reserve and to prevent air
and moisture from entering the hydraulic system.
However, because of expansion due to heat
absorbed from the brakes and the engine, the
reservoir must not be overfilled. The brake fluid
reservoir is on the master cylinder, which is located
under the hood on the left side of the cowl.
Thoroughly clean reservoir cap before removal to
avoid getting dirt into reservoir. Remove the
diaphragm. Add fluid as required to bring level to
the MAX" mark on the reservoir tank. Use DOT 3"
Hydraulic Brake Fluid. If the fluid cap diaphragm is
stretched, return it to the original position before
installing.
Deterioration of Brake Fluid

Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling
point of brake fluid. It may, in turn, result in vapor lock or
deteriorated rubber parts of the hydraulic system. Be
sure to change the brake fluid at specified intervals.
If the rubber parts are deteriorated, remove all the
system parts and clean them with alcohol. Prior to
reassembly, dry the cleaned parts with air to remove the
alcohol. Replace all the hoses and rubber parts of the
system.
Leakage of Brake Fluid

With engine idling, set shift lever in the neutral position
and continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually,
leakage from the hydraulic pressure system is possible.
Make sure by visual check that there is no leak.
Bleeding Brake Hydraulic System

A bleeding operation is necessary to remove air from
the hydraulic brake system whenever air is introduced
into the hydraulic system. It may be necessary to bleed
the hydraulic system at all four brakes if air has been
introduced through a low fluid level or by disconnecting

brake pipes at the master cylinder. If a brake pipe is
disconnected at one wheel, only that wheel cylinder/
caliper needs to be bled. If the pipes are disconnected
at any fitting located between the master cylinder and
brakes, then the brake system served by the
disconnected pipe must be bled.
1. For 4Wheel Antilock Brake System (ABS)
equipped vehicle, be sure to remove the ABS main
fuse 60A located at the relay and fuse box before
bleeding air. If you attempt to bleed air without
removing the main fuse, air cannot be let out
thoroughly, and this may cause damage to the
hydraulic unit. After bleeding air, be sure to replace
the ABS main fuse back to its original position.
2. Set the parking brake completely, then start the
engine.
NOTE: The vacuum booster will be damaged if the
bleeding operation is performed with the engine off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation
5. Always use new brake fluid for replenishment.
6. In replenishing brake fluid, take care that air bubbles
do not enter the brake fluid.
When the master cylinder is replaced or overhauled,
first bleed the air from the master cylinder, then from
each wheel cylinder and caliper following the
procedures described below.
Bleeding the Master Cylinder
7. Disconnect the rear wheel brake pipe (1) from the
master cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one
minute.
depressed.
9. Completely seal the delivery port of the master
cylinder with your finger, where the pipe was
disconnected then release the brake pedal slowly.
10. Release your finger from the delivery port when the
brake pedal returns completely.
11. Repeat steps 8 through 10 until the brake fluid
comes out of the delivery port during step 8.
NOTE: Do not allow the fluid level in the reservoir to go
below the halfway mark.
12. Reconnect the brake pipe (1) to the master cylinder
and tighten the pipe.
depressed.
14. Loosen the rear wheel brake pipe (1) at the master
cylinder.
5C10
15. Retighten the brake pipe, then release the brake

pedal slowly.
16. Repeat steps 13 through 15 until no air comes out of
the port when the brake pipe is loosened
NOTE: Be very careful not to allow the brake fluid to
come in contact with painted surfaces.
procedure 10 or more times for front wheels and 15

or more times for rear wheels.
26. Go to the next wheel in the sequence after each
wheel is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
sponginess" after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels spongy", the entire bleeding
procedure must be repeated.
28. After the bleeding operation is completed on the
each individual wheel, check the level of the brake
fluid in the reservoir and replenish up to the MAX"
level as necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
330RW012
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:
Right rear caliper or wheel cylinder
Left rear caliper or wheel cylinder
Right front caliper
Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed
air from the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube,
and submerge the free end of the transparent tube
in a transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times (once/
sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through
the tube.
23. Retighten the bleeder screw.
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is
completely removed.
It may be necessary to repeat the bleeding
It is recommended that the entire hydraulic system be

thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system.
Approximately one quart of fluid is required to flush the
hydraulic system.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contains the slightest trace of mineral oil. All
rubber parts that have been subjected to a
contaminated fluid must be replaced.
Brake Pipes and Hoses

The hydraulic brake system components are
interconnected by special steel piping and flexible
hoses. Flexible hoses are used between the frame and
the front calipers, the frame and rear axle case and the
rear axle and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to Bleeding the Brake
Hydraulic System" in this section.
Brake Hose Inspection

The brake hose should be inspected at least twice a
year. The brake hose assembly should be checked for
road hazard, cracks and chafing of the outer cover, and
for leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as
necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage
to the hoses may occur.
5C11
Front Caliper Brake Hose

Associated Parts
Removal
stands.
2. Remove the wheel and tire assembly.
5. Remove clip.
6. Remove bolt and gasket.
7. Remove hose.
Installation
352RW001
Legend
(1)
(2)
(3)
(4)
Bolt and Gasket

Clip
Hose
Brake Pipe
EndOFCallout

NOTE: Always use new gaskets and be sure to put the
hooked edge of the flexible hose end into the anti
rotation cavity.
5C12
Rear Axle Brake Hose

Associated Parts
Removal
stands.
2. Remove wheel and tire assembly.
5. Remove clip.
6. Remove brake pipe.
7. Remove bolt.
8. Remove hose.
Installation
352RW002
Legend
(1)
(2)
(3)
(4)
(5)
Brake Pipe
Clip
Bolt
Brake Pipe
Hose
EndOFCallout

5C13
Brake Pipe
Removal
Installation

stands.
2. Remove wheel and tire assembly as necessary.
pipe fittings at both ends.
4. Remove brake pipe (1).

1. Tighten the brake pipes to the specified torque.
Others
After installing the brake pipes, bleed the brakes as
330RW011
5. Remove plastic clip (2).
330RW002
5C14

P & B (Proportioning and Bypass)
Valve Sectional View
350RW014
Legend
(1)
(2)
(3)
(4)
Master Cylinder (Secondary)

Master Cylinder (Primary)
Rear Brake
Front Brake
EndOFCallout
The P&B valve contains two sections, each serving a
different function.
The proportioning section of the P&B valve proportions
outlet pressure to the rear brakes after a predetermined
rear input pressure has been reached. This is done to
prevent rear wheel lock up on the vehicles with light rear
wheel loads. The valve has a bypass feature which
assures full system pressure to the rear brakes in the
event of front brake system malfunction. Also full front
pressure is retained in the event of rear brake
malfunction.
The P&B valve is not repairable and must be replaced
as complete assembly.
Removal
1. The P&B valve is not repairable and must be
replaced as a complete assembly. Care must be
taken to prevent brake fluid from contacting any
painted surface.
2. Remove hydraulic pipes (1) and plug the pipes (1) to
prevent the loss of fluid or the entrance of dirt.
3. Remove bolt (3).
4. Remove P&B valve (2).
350RW026
Installation
1. Install P&B valve (2).
2. Install bolt (3) and tighten the bolt to the specified
torque.
3. Install hydraulic pipes (1) and tighten the bolt to the
specified torque.
4. After installing the brake pipes, bleed the brakes as
refer to Bleeding Brake Hydraulic System in this
section.
5C15

330RY00012
5C16
Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when
the pedal is fully released. Brake pedal height
adjustment should be performed as follows:
Adjust Brake Pedal
310RW022
NOTE: While adjusting the stoplight switch, make sure

that the threaded part of the stoplight switch does not
push the brake pedal.
h Tighten the stoplight switch lock nut.
i Connect the stoplight switch connector.
310RW021
1. Measure the brake pedal height after making sure

the pedal is fully returned by the pedal return spring.
Pedal height must be measured after starting the
engine and receiving it several times.
Checking Pedal Travel
Pedal Free Play: 8-11 mm (0.31-0.43 in)

Pedal Height: 193-203 mm (7.60-7.99 in)
NOTE: Pedal free play must be measured after turning
off the engine and stepping on the brake pedal firmly
five times or more.
2. If the measured value is not within the above range,
adjust the brake pedal as follows:
a Disconnect the stoplight switch connector.
b Loosen the stoplight switch lock nut.
c Rotate the stoplight switch so that it moves away
from the brake pedal.
d Loosen the lock nut (1) on the push rod.
e Adjust the brake pedal to the specified height by
rotating the push rod in the appropriate
direction.
f Tighten the lock nut to the specified torque.
Torque: 20 Nm(2.0 kgm/15 lbft)
g
Adjust the stoplight switch (2) to the specified

clearance (between the switch housing and the
brake pedal) by rotating the switch housing.
310RW021
1. Pedal height must be measured after starting the

engine and revving it several times to apply vacuum
to the vacuum booster fully.
NOTE: Pedal height must be 50 mm (1.97 in) or more
when about 490N (50kg/110Ib) of stepping force is
applied.
2. If the measured value is lower than the above range,
air existing in the hydraulic system is suspected.
Perform the bleeding procedure.
5C17
Brake Pedal and Associated Parts
310RY00008
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Brake Pedal Bracket Assembly

Fulcrum Pin and Nut
Connector
Snap Pin
Return Spring
Pedal Assembly
(7)
(8)
(9)
(10)
Push Rod Pin

Lower Cover
Bolts and Nut
Driver Knee Bolster
EndOFCallout
Removal
at least 5 minutes.
2. Disconnect the yellow 3 way SRS connector located
3. Remove the engine hood opening lever.
4. Remove lower cover (8).
5. Remove driver knee bolster (10).
6. Disconnect the stop light switch connector (3).
Disconnect the anti-theft control module connector.
7. Remove snap pin (4) and push rod pin (7).
8. Remove the steering column shaft fixing bolt and
nut (9) on the steering wheel side, and lower the
steering column shaft.
9. Remove the brake pedal bracket assembly (1).
10. Remove return spring (5).

11. Remove fulcrum pin and nut (2).
Installation
fulcrum pin.
2. Install pedal assembly (6) and fulcrum pin and nut
(2).
Tighten the nut (2) to the specified torque.
3. Install the brake pedal bracket assembly (1).
Tighten the bolts and nuts soecified torque.
4. Install return spring (5).
5C18
5. Adjust pedal free travel.

Refer to Brake Pedal Adjustment in this section.
6. Tighten the steering column fixing bolt (9) (dash
panel) to the specified torque.
7. Tighten the steering column fixing nut (9) (Cross
Beam) to the specified torque.
Push rod pin (7).
9. Install push rod pin (7).

10. Install snap pin (4).
11. Connect the anti-theft control module connector.
12. Connect the stop light switch connector (3).
13. Install driver knee bolster (10) and lower cover (8).
15. Connect the yellow 3 way SRS connector located
Stoplight Switch
Parts Location
Installation
1. Adjust the stop light switch to the specified
clearance (between switch housing and brake
pedal) by rotating the switch housing.
Clearance : 0-0.2 mm (0-0.008 in)
NOTE: Do not attempt to force the push rod into
position during the stop light switch installation and
adjustment procedure.
310RW024
Legend
(1) Connector
(2) Switch
(3) Lock Nut
EndOFCallout
Removal
1. Disconnect connector (1)
2. Remove lock nut (3).
3. Remove switch (2).
310RW022
2. Connect connector (1).

3. Install lock nut (3).

Pedal free play
610 mm (0.23 0.39 in)
Pedal Height
173185 mm (6.817.28 in)
E05RX006
5C19
5C20
Fluid Reservoir Tank

Fluid Reservoir Tank and Associated Parts
330RW003
Legend
(1) Fluid Reservoir
(3) Oring
(4) Retainer
EndOFCallout
Removal
4. Remove Oring.
NOTE: Before removing the fluid reservoir, remove the

brake fluid from the fluid reservoir.
Installation
1. Oring (1) must be set onto the fluid reservoir (2),
before installing fluid reservoir.
330RW004
3. Remove fluid reservoir and the fluid level sensor

built into the fluid reservoir. The fluid level sensor
cannot be removed for servicing.
330RW005
5C21

Master Cylinder Assembly and Associated Parts
330RW010
Legend
(2) Master Cylinder
(3) 2 attaching Nuts
(4) P&B Valve and Bracket

(5) Brake Pipes
(6) Spacer and 2 gaskets
EndOFCallout
Removal
advance.
fluid run out.
2. Remove brake pipes and after disconnecting the
brake pipe, cap or tape the openings of the brake

pipe to prevent the entry of foreign matter.
3. Remove 2 attaching nuts.
4. Remove P&B valve and bracket.
5. Remove master cylinder.
6. Remove spacer and the 2 gaskets.

Master Cylinder
The master cylinder is not repairable and must be
replaced as a complete assembly if found defective.
Inspection
Excessive brake pedal travel, malfunction or dragging
brake suggests that the master cylinder is defective. In
5C22
such cases perform the following visual check:

Visual Check
Make parts replacement as required if wear, distortion,
nicks, cuts, corrosion, or other abnormal conditions are
found through the following parts inspection:
Master cylinder body
Fluid reservoir
Oring

Piston
Push the primary piston (1) with your fingers to check
that it travels smoothly. If the motion is questionable,
replace the master cylinder as a complete assembly.
330RX001
Connect the master cylinder attachment (5) 58840

23060 with the end of the radiator cap tester (6) 5
884002770, and apply air pressure with the cap
tester. Make sure there is no rise in pressure and that
with the adjusting bolt further screwed in 5mm (align the
adjusting bolt to the 5" line). There should be a
pressure increase of 0.5 kg/cm2 or more.
330RW007

Inspect the master cylinder for function as follows. If any
abnormal function is found, replace with a new one.
Install the primary piston holder (3) 5884023060
(including the master cylinder attachment (5) and
master cylinder plug (7)) onto the master cylinder (4).
Make sure the spacer (2) (2 bolts) with its adjusting bolt
is screwed in up to the 0" line
330RX002
NOTE: When checking the front (or primary) side, be

sure to mount the master cylinder plug in the rear (or
secondary) port.
5C23

0" Line
5" Line
Apply air
pressure to the
front and rear
ports
No pressure
rise.
Pressure
increase of 0.5
kg/cm2 or more
Remarks
Checks port into

the atmospheric
pressure
chamber
Checks air
tightness of the
pressure
chamber
Type
Dualcircuit
Piston bore
diameter
25.4 mm (1.000 in)
NOTE:
1. Do not use an air compressor, as the air from the
compressor is mixed with compressor oil.
2. When installing the master cylinder onto the vacuum
booster, always adjust the vacuum booster push
rod. (Refer to Vacuum Booster" in this section).
3. After the master cylinder is installed onto the
vehicle, check for leakage, pedal travel and pedal
free play.
Installation
1. Install spacer and the 2 gaskets.
2. Install master cylinder.
When replacing the master cylinder or vacuum
booster or both, always measure the vacuum
booster push rod protrusion and adjust it as
necessary (Refer to Vacuum Booster" in section).
3. Install P&B valve and bracket.
4. Install 2 attaching nuts and tighten the attaching
nuts to the specified torque.
5. Install brake pipes and tighten the brake pipe to the
specified torque.
Others
330RY00010
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2306-0
(J-39242)
Primary Piston Holder
(including master cylinder
attachment and master
cylinder plug
5-8840-0277-0
(J-24460-01)
Radiator Cap Tester
5C24
Vacuum Booster Assembly

Vacuum Booster Assembly and Associated Parts
331RW005
Legend
(1)
(2)
(3)
(4)
Pin
Vacuum Booster Fixing Nut
Vacuum Hose
Master Cylinder
(5) Vacuum Booster

(6) Snap Pin
EndOFCallout
Removal
1. Before removing the vacuum booster assembly,
disconnect and remove the brake pipes.
2. Remove master cylinder, refer to Master Cylinder
Removal" in this section.
advance.
fluid run out.

3. Remove vacuum hose.
4. Disconnect the yoke clevis from the brake pedal.
5. Remove vacuum booster fixing nut.
6. Remove vacuum booster.

Vacuum Hose
1. Inspect the check valve (2), which is installed inside
the vacuum hose.
2. Air should pass freely from the vacuum booster (3)
to the engine (1).

3. Air should not pass from the engine (1) to the
vacuum booster (3). If it does, the check valve is
inoperative and must be replaced.
5C25
installing a push rod gauge on the vacuum booster.
331RW012
4. Measure dimension (4).

360RW001
Installation
Dimension (4) (Standard): 0.10.1 mm (0.0039

0.0039 in)
1. Perform vacuum booster and vacuum booster push

rod adjustment.
NOTE: When replacing either the master cylinder or
vacuum booster, be sure to measure push rod, and
adjust if required.
2. Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate
and seal assembly out of the shell inside.
331RW013
331RS003
3. Set push rod gauge 5884023000 on vacuum

booster, and apply negative pressure by means of
vacuum pump 5884002790 so that the pressure
in the vacuum booster becomes 500 mm Hg.
NOTE: Be sure to apply NEGATIVE pressure after
5C26
5. If dimension (4) is out of the standard range, adjust

push rod using the Push Rod Support 58840
23050.
331RW014
6. Mount plate and seal assembly in vacuum booster

front shell. Then install the retainer.
7. Install vacuum booster fixing nut and tighten the
specified torque.
8. Install yoke clevis.
9. Connect vacuum hose and make sure that the arrow
on the hose points in the direction of the engine.
10. Install master cylinder, refer to Master Cylinder
Installation" in this section.
5C27
Exterior Components
Exterior Components and Associated Parts
331RW006
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Yoke Clevis
Lock Nut
Retaining Clip
Valve Body Guard
Silencer
Filter
EndOFCallout
Removal
1. Remove master cylinder. Refer to Master Cylinder"
in this section.
2. Remove vacuum booster. Refer to Vacuum
Booster" in this section.
3. Remove yoke clevis.
4. Remove lock nut.
5. Remove retaining clip.
6. Remove valve body guard.
7. Remove silencer.
8. Remove filter.
9. Remove 2 gaskets and spacer.
(7)
(8)
(9)
(10)
(11)
2 Gaskets and Spacer

Vacuum Booster
Retainer
Plate and Seal Assembly
Master Cylinder
5C28
10. Remove retainer, using a small screwdriver to pry

out the retainer. Gently pull out the plate and seal
assembly from the shell.
through inspection. Check the following parts:

Yoke clevis
Valve body guard
Silencer
Filter plate and seal assembly
Installation
1. Install plate and seal assembly.
3. Install 2 gaskets and spacer.
4. Install filter.
5. Install silencer.
6. Install valve body guard.
8. Install lock nut and yoke clevis and tighten to the
specified torque.
331RS003

Visual Check
Make necessary parts replacement if cuts, nicks,
excessive wear, or other abnormal conditions are found
9. Install vacuum booster, refer to Vacuum Booster" in

this section.
10. Install master cylinder, refer to Master Cylinder" in
this section and after installation, perform brake
pedal check and adjustment. Refer to Brake Pedal"
in this section.
Vacuum Booster Overhaul

Vacuum Booster
The vacuum booster cannot be disassembled for repair.
Replace a defective vacuum booster with a new one.
5C29

Vacuum booster diaphragm diameter (Front)
205 mm (8.07 in)
Vacuum booster diaphragm diameter (Rear)
230 mm (9.06 in)
Push rod stroke
More than 32.0 mm (1.26 in)
Plunger diameter
10.25 mm (0.40 in)
Push rod diameter
27.4 mm (1.08 in)
330RY00011
5C30
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2300-0
(J-39216)
Push Rod Gauge
5-8840-0279-0
(J-23738-A)
Vacuum Pump
5-8840-2305-0
(J-39241)
Push Rod Support
5C31
Front Disc Brake Pads

Front Disc Brake Pads Inspection
Check the outer pad by looking at each caliper from
when the pad wears to where the replacement is
required.
302RS002
Front Disc Brake Pads and Associated Parts
302RW003
Legend
(1) Lock Bolt
(3) Pad Assembly
EndOFCallout
(4) Clip
(5) Outer Side
5C32
Removal
Installation
NOTE: If a squealing noise occurs from the front brake

should be replaced.
reservoir.
stands.
1. Remove wheel and tire assembly, refer to Wheels
1. Install clip.
302RS005

assembly with shim.
302RW004

damaged.
5. Remove Clip.
302RW005
Legend
(2) Inner Shim
(3) Wear Indicator
(4) Inner Side
EndOFCallout
302RW006

caliper bore. Be careful do not damage the piston
boot and do not damage the flexible hose by twisting
or pulling it.
Install caliper assembly.
302RS008

specified torque.
5C33
302RW018
5. Install wheel and tire assembly, refer to Wheels and

Tires System" in Section 3E.
5C34
Front Disc Brake Rotor

Inspection
Lateral Runout

1. Adjust the wheel bearing correctly, refer to
Differential" in Section 4A.
3. Move the rotor one complete rotation and the lateral
runout should not exceed 0.13 mm (0.005 in).
411RS018

finish.

finish.
411RS019
Parallelism
411RW003
5C35
5C36
Front Disc Brake Caliper Assembly

Front Disc Brake Caliper Assembly and Associated Parts
302RW008
Legend
(1)
(2)
(3)
(4)
Guide Bolt
Brake Flexible Hose
Lock Bolt
Caliper Assembly
(5) Clip
(6) Support Bracket with Pad Assembly
(7) Pad Assembly
EndOFCallout
Removal
stands.
2. Concernig wheel and tire assembly, refer to Wheels
302RW009
5C37

302RW011
Legend
302RW010

10. Remove clip.
(4) Inner Shim

(5) Wear Indicator
(6) Inner Side
EndOFCallout
specified torque.
Installation
1. Install clip.
302RW012

5. Install lock bolt (9) and guide bolt (8) and tighten the
302RS005
2. Apply special grease (approximately 0.2 g) to both

assembly with shim.
5C38
302RW013

the Ibolt (10) to the specified torque.
302RW014

section.
5C39

Front Disc Brake Caliper Disassembled View
302RW015
Legend
(1)
(2)
(3)
(4)
(5)
Guide Bolt
Lock Bolt
Bleeder with Cap
Caliper Body
EndOFCallout
Disassembly
3. Remove dust boot: guide bolt and lock bolt.
(6)
(7)
(8)
(9)
Piston Seal
Piston
Dust Boot: Piston
Dust Boot Ring
5C40

through inspection.
Rotor
Cylinder body
Cylinder bore
Piston
Support bracket
NOTE: The piston seal, boot ring and dust boot are to
be replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new
ones.
Reassembly
302RS016

Remove piston.
personal injury.

specified torque.
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in
the repair kit.

damaged.
302RS018
302RS017


Install piston.
302RS019

302RS020

applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto
support bracket.
5C41
302RS021
5C42

Type
Floating, pin slide
Pad dimension
55 cm2 (8.52 in2)
Adjusting method
Piston diameter
Disc type
Selfadjusting
60.33 mm (2.38 in)
Ventilated
Disc thickness
26 mm (1.02 in)
222 mm (8.74 in)
E05RX009
5C43
Rear Disc Brake Pads

Brake Pads Inspection
Check the outer pads by looking at each caliper from
when the pad wears to where replacement is required.
302RW016
Brake Pads and Associated Parts
306RW001
Legend
(2) Clip
EndOFCallout
(3) Lock Bolt

(4) Pad Assembly
5C44
Removal
Installation
NOTE: If a squealing noise occurs from the rear brake

should be replaced.
reservoir.
stands.
2. Remove lock bolt (1)
306RW003

contacting surfaces of the inner shims. Wipe off
assembly with shim.
306RW002

damaged.
5. Remove clip.
306RW004
Legend
(3) Inner Shim
(4) Wear Indicator
EndOFCallout
306RW005

caliper bore. Be careful not to damage the piston
dust boot and do not damage the flexible hose by
twisting or pulling it. Install caliper assembly.
302RS008

specified torque.
5C45
306RW006
5C46
Rear Disc Brake Rotor

Inspection
Maximum parallelism: 0.010 mm (0.0004 in)

Lateral Runout

1. Adjust the wheel bearing correctly. Refer to Drive
Shaft System section.
3. Move the rotor one complete rotation.
The lateral runout should not exceed 0.13 mm
(0.005 in)
420RS013

finish.
306RY00013
Parallelism

finish.
420RW002
Rear Drum (In Disc) Inside Diameter

Check
Check the rear drum inside diameter by measuring at
more than two portions as shown in the illustration.
If the inside diameter is greater than the limit, replace
the rear rotor.
Limit: 211.4 mm (8.32 in)
420RS035
5C47
5C48
Rear Disc Brake Caliper Assembly

Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
Legend
(1)
(2)
(3)
(4)
Brake Flexible Hose

Clip
Lock Bolt
Support Bracket
(5) Guide Bolt

(6) Pad Assembly with Shim
EndOFCallout
Removal
stands.
306RW008

5C49
306RW011
306RW009

10. Remove clip.
Legend
(5) Inner Shim
(6) Wear indicator
EndOFCallout
specified torque.
Installation
306RW012

5. Install lock bolt and guide bolt (8) and tighten the
306RW010

assembly with shim.
5C50
306RW013

the eyebolt (9) to the specified torque.
302RW017
7. Install the wheel and tire assembly, referring to

section.
5C51

Rear Disc Brake Caliper Disassembled View
306RW014
Legend
(1)
(2)
(3)
(4)
(5)
Guide Bolt
Lock Bolt
Bleeder with Cap
Caliper Body
Piston Seal
EndOFCallout
Disassembly
3. Remove dust boot; guide bolt and lock bolt.
(6)
(7)
(8)
(9)
Piston
Dust Boot: Piston
Dust Boot Ring
5C52

through inspection.
Rotor
Cylinder body
Cylinder bore
Piston
Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
302RS016

Remove piston.
personal injury.

specified torque.
3. Install piston seal and apply special rubber grease
to the piston seal and cylinder wall, then insert the
piston seal into the cylinder. The special rubber
grease is included in the repair kit.

damaged.
302RS018
302RS017


Install piston.
302RS019

302RS020

applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto
support bracket.
5C53
302RS021
5C54

Type
Floating, pin slide
Pad dimension
33 cm2 (5.11 in2)
Adjusting method
Piston diameter
Disc type
Disc thickness
Selfadjusting
41.3 mm (1.63 in)
Ventilated
18 mm (0.71 in)
269.2 mm (10.60 in)
E05RX010
SECTION
5D1
BRAKES
CONTENTS
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever and Front Cable . . . . . .
Parking Brake Lever Assembly and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5D1
5D1
5D2
5D3
5D3
5D3
5D3
Service Precaution
parts and systems.
Parking Brake Rear Cable . . . . . . . . . . . . . . . .

Parking Brake Rear Cable and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment . . . . . . . . . . . . . . . .
5D4
5D4
5D5
5D5
5D6
5D6
5D7
General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the lever
can be held in that position until it is released. The position
of the lever is transmitted through cable/lever systems to
the rear wheels. These parts are designed to obtain
sufficient braking force even when parking on slopes.
When the parking brake is set, or when the ignition SW is
in theON position, the brake warning light illuminates.
The rear wheel parking brake is a duoservo brake
(mechanical inside expansion type) built in the rear disc
brake. Parking brake adjustment is made through the
adjusting hole (bored through back plate). Parking brake
lever stroke should be adjusted to 68 notches. Refer to
Parking Brake Adjustment in this section.
5D2
Operation
When pulled in the direction A, the parking lever presses
the secondary shoe against the brake drum using the
lever/shoe joint B as a fulcrum and pushes the strut in
the direction C. The strut ,in turn, presses the primary
shoe against the brake drum. Counter force D to the
primary shoe is transmitted again to the secondary shoe
through the fulcrum B. The secondary shoe contacts the

drum thereby producing braking effect. Clearance which
may result from worn parking brake shoe lining can be
adjusted by turning the adjusting screw. Refer to Parking
Brake Adjustment in this Section.
A05RS002
Legend
(1) Direction A
(2) Lever/Shoe Joint B as a fulcrum
(3) Direction C
(4) Counter Force D
(5) Parking Lever
(6) Secondary Shoe
(7) Adjusting Screw Notch
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Parking Cable Guide

Primary Shoe
Strut
Shoe Expanding Direction
Parking Brake Cable Guide
Adjusting Hole Plug
Adjusting Screw Notch
5D3
Parking Brake Lever and Front Cable

Parking Brake Lever Assembly and Associated Parts
311RW0131
Legend
(1) Rear Console
(2) Switch Connector
(3) Bolt
(4) Adjust Nut and Lock Nut
Removal
2. Disconnect switch connector (2).
3. Remove bolt (3).
4. Remove adjust nut and lock nut (4).
5. Pull out equalizer (6) from trunnion pin (5).
6. Disconnect trunnion pin (5) from Parking brake lever
(8).
7. Disconnect parking brake rear cable (7).
(5)
(6)
(7)
(8)
Trunnion Pin
Equalizer
Parking Brake Lever
Installation
connecting portion of the rear cable (7) and equalizer
(6).
2. Connect parking brake rear cable (7) to equalizer
3. Install trunnion pin (5) to parking brake lever (8).
4. Insert equalizer (6) into trunnion pin (5) and tighten
adjust nut and lock nut (4).
D To adjust the parking brake lever, see Parking
Brake Adjustment in this section.
Lock Nut Torque: 13 Nm (1.3 kgm/113 lb in)
5. Tighten the parking brake lever fixing bolt (3) to the
specified torque.
6. Connect switch connector (2).
7. Install rear console (1).
5D4

Parking Brake Rear Cable and Associated Parts
311RY00004
Legend
(1) Rear Wheels
(3) Rotor (Drum)
(4) Holding Spring
(5) Upper Return Spring
(6) Lower Return Spring
(7) Shoe Assembly
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Cable Fixing Bolt

Bolt
Bolt
Bolt (Only Long Wheel Base Model)
Nut
Nut
Retainer
Rear Cable
Removal
1. Remove rear wheels (1).
2. Remove 2 bolts to remove the caliper assembly (2)
from the support bracket. Refer to Rear Disc Brakes
in Power Assisted Brake System section. Temporarily
hang the caliper with wire etc.
3. Remove rotor (drum) (3).
4. Remove holding spring (4), upper return spring (5)
and lower return spring (6).
5. Previously remove the rear cable from the parking
brake lever, then remove the brake shoe assembly
(7).
5D5
6. Install shoe assembly (7).

After installation of the shoe and cable assembly,
apply special grease (included in the repair kit) to the
following portions indicated in the figure.
308RS005
7. Install lower return spring (6) and upper return spring

(5).
The parking brake lever side (secondary side) return
spring must be installed on the outer side of the
primary side return spring.
308RW004
Legend
(1) Parking Brake Lever
6. Remove cable fixing bolt (8) and bolt (9) (10) (11).
7. Remove nut (12).
8. Remove nut (13) and retainer (14).
9. Remove rear cable (15).
Installation
connecting portion of the rear cable and equalizer.
Install rear cable (15).
D Tighten nut (13) to the specified torque.
3. Tighten nut (12) to the specified torque.
308RS003
Legend
(1) Outer Side
(2) Parking Lever

4. Tighten bolt (11) (10) (9) to the specified torque.
D To adjust the parking brake, refer to Parking Brake
Adjustment in this section.
5. Tighten the cable fixing bolt (8) to the specified
8. Install holding spring (4).

9. Install rotor (drum) (3).
10. Install caliper assembly (2).
11. Install rear wheels (1).
5D6

Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is less
than 1.0 mm (0.039 in).
Minimum limit: 1.0 m (0.039 in)
7. When poor braking effect possibly resulting from

insufficient breakin is felt, or just after replacement
of parking brake shoe, be sure to conduct breakin as
follows:
8. Forward 50 km/h (30 mph) 400 m (About 30
9. Backward 10 km/h (6 mph) 50 m (About 18
NOTE: Breakin procedures must be performed under
safe conditions and traffic rules.
D If braking effect still remains poor after the above
breakin, wait for some time until parking brake shoe
cools down and repeat the procedures 8. and 9. noted
above.
D On completion of breakin, inspect parking brake
lever stroke, and if the lever does not come within the
specified number of notches when pulled up,
readjust.
D Excessive breakin may cause premature wear of
the parking brake lining.
308RS004
Parking Brake Rotor (Drum) Inspection

Refer toRear Disc Brakes in Power-Assisted Brake
System section for inspection procedure of the rotor
(drum).
Parking Brake Adjustment

1. Prior to lever stroke adjustment, adjust rear brake
shoe/rotor (drum) gap. Perform this procedure with
loosening the adjust nut of the hand brake lever.
2. Remove the adjusting hole plug (rubber) and turn the
shoe adjusting screw downward with a small
screwdriver so that shoes will expand until they get
into close touch with the rotor. (Turn down the
adjusting screw notch by notch until the rotor does not
turn.)
3. Turn the adjusting screw in the opposite direction
(upward) until the rotor can be turned lightly. Standard
number of notches to turn upward: 7 or 8
Turn the rotor and make sure that there is no brake
dragging.
4. After the rear brake shoe/rotor (drum) gap has been
adjusted, perform parking brake cable adjustment.
5. Turn the adjusting nut so that the parking brake lever
travels 68 notches when pulled up with a force of 30
kg (66 lb).
6. Make sure there is no brake dragging. Then tighten
the cable lock nut
5D7

Model
Type
Drum inside diameter
Parking brake lever stroke
Duoservo
210 mm(8.27 in)
68 notches
When pulled with a force of 294 N (30 kgm/66 lb)
311RY00010
SECTION
6A1
ENGINE
CONTENTS
Engine Mechanical..........................................
Engine Cooling................................................
Engine Fuel .....................................................
Engine Electrical .............................................
Ignition System................................................
Starting and Charging System ........................
6A -1
6B -1
6C -1
6D1 -1
6D2 -1
6D3 -1
Driveability and Emissions ..............................

Engine Exhaust ...............................................
Engine Lubrication ..........................................
Engine Speed Control System ........................
Induction ..........................................................
6E1 -1
6F -1
6G -1
6H -1
6J -1

CONTENTS
Engine Diagnosis........................................
Cylinder Head Cover.....................................
Removal .....................................................
Installation ..................................................
Exhaust Manifold...........................................
Removal .....................................................
Installation ..................................................
Crankshaft Pulley ..........................................
Removal .....................................................
Installation ..................................................
Intake Manifold..............................................
Removal .....................................................
Installation ..................................................
Cylinder Head Assembly...............................
Removal .....................................................
Installation ..................................................
Timing Belt ....................................................
Removal .....................................................
Installation ..................................................
Camshaft.......................................................
Removal .....................................................
Installation ..................................................
Engine Assembly ..........................................
Engine and Associated Parts .....................
Removal .....................................................
Installation ..................................................
Cylinder Head ...............................................
Cylinder Head and Associated Parts ..........
Disassembly ...............................................
Reassembly ................................................
Valve Spring, Valve, Valve Guide .................
Valve Spring, Valve, Valve Guide and
Associated Parts ...................................
6A - 2
6A - 2
6A - 4
6A - 17
6A - 17
6A - 18
6A - 19
6A - 19
6A - 19
6A - 20
6A - 20
6A - 20
6A - 21
6A - 21
6A - 22
6A - 24
6A - 24
6A - 26
6A - 32
6A - 32
6A - 33
6A - 36
6A - 36
6A - 37
6A - 39
6A - 39
6A - 39
6A - 41
6A - 43
6A - 43
6A - 43
6A - 44
6A - 45
6A - 46
6A - 46
Disassembly ...............................................
Reassembly ................................................
Camshaft.......................................................
Camshaft and Associated Parts .................
Disassembly ...............................................
Reassembly ................................................
Crankshaft .....................................................
Crankshaft and Associated Parts ...............
Disassembly ...............................................
Reassembly ................................................
Piston and Connecting Rod ..........................
Piston, Connecting Rod and
Associate Parts .....................................
Disassembly ...............................................
Reassembly ................................................
Cylinder Block ...............................................
Cylinder Block and Associated Parts..........
Disassembly ...............................................
Reassembly ................................................
Cylinder Head Cover .....................................
Cylinder Head Cover and
Associated parts....................................
Removal......................................................
Installation...................................................
Balance Unit Assembly .................................
Balance Unit Assembly Associated Parts...
Disassembly ...............................................
Adjustment..................................................
Reassembly ................................................
Special Tools .................................................
6A - 47
6A - 47
6A - 48
6A - 49
6A - 49
6A - 49
6A - 50
6A - 51
6A - 51
6A - 51
6A - 52
6A - 53
6A - 54
6A - 57
6A - 57
6A - 57
6A - 58
6A - 60
6A - 61
6A - 61
6A - 62
6A - 62
6A - 63
6A - 64
6A - 64
6A - 65
6A - 65
6A - 67
6A - 67
6A - 68
6A - 68
6A - 70
6A - 72
6A - 77
6A2
Service Precaution
FOLLOW WARNINGS
COULD RESULT IN
REPAIRS.
and systems.
General Description
should be understood that proper cleaning and
protection of machined surfaces and friction areas is
part of the repair procedure. This is considered
standard shop practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and
lubricate the surfaces on initial operation.
Whenever valve train components, pistons, piston
At the time of installation, they should be installed in
Battery cables should be disconnected before any

The four cylinders of this engine are identified by
numbers; cylinders 1, 2, 3 and 4, as counted from
crankshaft pulley.

When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due to
the small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may cause
damage to the oil pick up unit.
The 12volt electrical system is capable of damaging
battery.
Any time the intake air duct or air cleaner is removed,
material into the cylinder which could cause
extensive damage when the engine is started.
Cylinder Block
The cylinder block is made of cast iron. The crankshaft
is supported by five bearings. The bearing cap is made
of nodular cast iron.
Cylinder Head
The cylinder head is made of aluminum alloy casting
with a spark plug in the center.
Valve Train
Valve system is directacting invertered bucket tappet.
The valves clearance adjustment are hydraulic.
Hydraulic valve lash adjustment, no adjustment
necessary.
Intake Manifold
The intake manifold is made of aluminum alloy.
Exhaust Manifold
The exhaust manifold is made of high SiMo nodular
iron.

Aluminum pistons are used after selecting the grade
that meets the cylinder bore diameter. Each piston has
two compression rings and one oil ring. The piston pin is
made of caseharded steel. The connecting rods are
made of cast iron. The connecting rod bearings are
made of steel backed with babbitt metal.

The crankshaft is made of nodular cast iron. Pins and
bearing.
Balance Shaft
Type is lanchester (twin counterrotating shafts). The
balance shafts are made of cast iron and gears are hard
faced. The housing is made of cast iron. Backlash
adjustment method is shimbalancer housing to block
(selective fit).
6A3
6A4
Engine Diagnosis
Hard Starting
Trouble Shooting Procedure

Condition
Headlights go out or dim
considerably
Possible cause

Overhaul or replace
Overhaul or replace
2. Ignition Trouble Starting Motor Turns Over But

Engine Does Not Start
Spark Test
Disconnect a high tension cable from any spark plug.
Connect the spark plug tester J26792 (ST125), crank
Condition
Correction
the engine, and check if a spark is generated in the

spark plug tester. Before cranking the engine, make
sure that the spark plug tester is properly grounded. To
avoid electrical shock, do not touch the high tension
cable while the engine is running.
Possible cause
Correction

engine

system)
Adjust

compression)

module
Replace
Correct

Correct or replace

Condition
occurs but engine does not start.
Possible cause
Correction
Fuel tank empty
Fill
Clean
Fuel filter clogged
Replace filter
Fuel pipe clogged
Clean or replace
Fuel pump defective
Replace
Correct or replace
Evaporative Emission Control

Correct or replace

faulty
Refer to Electronic Fuel Injection"

section

Condition
Possible cause
Correction

Tighten to specified torque or

replace gasket
Adjust
Replace gasket
Lap valve
Valve stem seized
Valve spring weakened
Replace
Overhaul engine
Piston ring seized
Overhaul engine.

ignition system.
box.
6. Engage the starter and check that the cranking
speed is approximately 300 rpm.
hole.
engaged until the compression gage needle
reaches the maximum level. Note the reading.
The pressure difference between the individual
cylinders should not exceed 100kPa (14.5psi).
6A5
6A6

Condition
Others
Possible cause
Correction
Replace
Correct or replace

or shorted
Correct or replace
Correct or replace
Replace
Replace

Correct or replace

defective
Replace

Correct or replace

defective
Replace
Intake Air Temperature sensor cable

Correct or replace
Intake Air Temperature sensor

defective
Replace
Knock Sensor (KS) circuits open or

shorted
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Vehicle Speed Sensor circuit open

or shorted
Correct or replace
Vehicle Speed Sensor defective
Replace
Replace

faulty
Replace
Canister purge solenoid circuit open
Correct
Canister purge solenoid defective
Replace

Replace

Guide

Guide
Lap valve
Readjust
Replace
6A7

Condition
Engine misfires regularly
Engine knocks regularly

Engine lacks power
Possible cause
Correction
Replace
Spark plugs fouling
Replace
Replace
Engine control module faulty
Replace
Replace
Spark plugs fouled
Clean
Replace

Correct or replace

or Engine Coolant Temperature
Sensor circuit defective
Correct or replace
Engine Control Module faulty
Replace
Intake Air Temperature Sensor or

circuit defective
Correct or replace
Throttle Position Sensor or Throttle

Position Sensor circuit defective
Correct or replace
Knock Sensor or Knock Sensor

circuits defective
Correct or replace
Knock Sensor Module or Knock

Sensor Module circuits defective
Correct or replace
6A8
Hesitation
Condition


Possible cause
Correction

incorrect

or shorted
Correct or replace
Excessive play in accelerator

linkage
Adjust or replace

Correct or replace
Replace

Correct or replace

shorted
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Replace
Clean or replace
Fuel pipe clogged
Clean or replace
Fuel filter clogged
Replace
Check and replace
Replace

shorted or open

System disconnected or defective
Correct or replace
Replace

or shorted
Correct or replace
Replace

Correct or replace

defective
Replace
MAP Sensor cable open or shorted
Correct or replace
Replace
IAT Sensor circuit open or shorted
Correct or replace
Replace
KS Circuit open or shorted
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Throttle valve not wide opened
6A9
Engine Lacks Power

Condition

Ignition failure
Possible cause
Correction

working normally
Replace
Clean or replace
Fuel pipe clogged
Clean
Replace

normally
Correct or replace

due to clogged Evaporative
Clean or replace
Clean
Engine Control Module supplied

poor voltage
Correct circuit
Throttle Position Sensor cable

Correct or replace
Replace

Replace

working normally
Replace

Correct or replace

defective
Replace
Replace
Correct or replace

Guide

range

module
Replace
6A10

Condition
Engine overheating
Possible cause
Correction
Replenish
Thermo switch or fan motor

defective
Replace
Replace
Correct or replace
Radiator clogged
Clean or replace
Replace

low or wrong oil in engine
Change or replenish
Resistance in exhaust system

increased

defective parts

incorrect
Adjust Wide Open Throttle switch

setting

or shorted
Correct or replace
Replace
Engine overcooling

open at 92C (197.6F))
Refer to Hard Start
Others
Adjust to recommend pressures
Brake drag
Adjust
Clutch slipping
Adjust or replace

high

defective
Replace
Engine Noisy
Condition
crank bearings
(Faulty crank journals and crank
bearings usually make dull noise
that becomes more evident when
accelerating)

Possible cause
Correction



Crank bearing seized Replace crank

crankshaft and install the over size
bearing
6A11
Condition
(Faulty connecting rods or
engine is accelerated)
Possible cause
Correction


Connecting rod bent
Correct or replace

Abnormal noise stops when the spark plug on the
cylinder with defective part is shorted out.
Condition
Piston and cylinder
makes a combined mechanical
thumping noise which increases
when engine is suddenly
accelerated but diminishes gradually
as the engine warms up)
Possible cause
Correction

cylinder wear
Piston seized
Piston ring broken
Piston defective
Short out each spark plug and listen for change in
engine noise.
Condition
Piston pin noise
goes up and down)
Possible cause
Correction
connecting rod assy
6A12
Condition
Timing belt noise
Possible cause
Correction
Replace pusher or adjust the

tension pulley or replace timing belt
Replace
Replace
Timing wheels defective
Replace

timing cover
Valve spring broken
Replace
Correct
Crankshaft noise

engaged)
Engine knocking


range
Replace fuel

system failure
Refer to Section 6E

incorrect

selection
Engine overheating
Replace
Drive belt slipping
Adjust tension of drive belt or

replace drive belt
Valve noise
Others
6A13
Abnormal Combustion
Condition
Possible cause
Correction
Replace
Fuel filter clogged
Replace
Fuel pump clogged
Clean or replace
Clean or replace
Clean or replace
Replace

loosely connected or defective

Correct or replace

defective
Replace

Correct or replace
Replace

incorrect
Reconnect
Replace
Throttle Position Sensor connector

loosely connected
Reconnect
Vehicle Speed Sensor cable loosely

Correct or replace
Vehicle Speed Sensor loosely fixed
Fix tightly
Vehicle Speed Sensor in wrong

contact or defective
Replace
Engine Control Module cable loosely

Correct or replace
Heated Oxygen Sensor circuit open
Correct or replace
Heated Oxygen Sensor defective
Replace

defective
Correct or replace

defective
Replace
ECT Sensor circuit open or shorted
Correct or replace
Replace
Evaporator system
Refer to Section 6E
Carbon deposits in combustion

chamber
Remove carbon

and valve guide
Remove carbon
6A14

Condition
Oil leaking
Possible cause
Correction
Retighten
Replace gasket

gasket broken
Head cover retaining bolts loose or

gasket broken
Replace
Oil filter attachings bolt loose or

rubber gasket broken

defective
Replace oil seal
Replace hose
Engine/Transmission coupling area
Replace oil seal

chambers due to poor seal in valve
system
Replace

chambers due to poor seal in
cylinder parts
Cylinders and pistons worn

excessively

and others
Piston ring gaps incorrectly

positioned
Correct
Correct

and others
Crank case ventilation, Positive

malfunctioning
Positive Crankcase Ventilation Hose

clogged
Clean
Others

viscosity
Continuous high speed driving and/

or severe usage such as trailer
towing

6A15

Condition
Possible cause
Correction

Fuel cut function does not act


Combustion Troubleshooting Guide
Others

sluggish
Correct
Fuel system leakage
Correct or replace
Clutch slipping
Correct
Brake drag
Correct

incorrect

selection
Excessive Exhaust Gas

Recirculation flow due to trouble in
Exhaust Gas Recirculation system
Oil Problems
Condition
Oil contamination
Possible cause
Correction
Wrong oil in use
Replace
Correct or replace
Oil pump worn
Replace
Correct or replace

rod bearing worn
Replace
Wrong oil in use
Replace with new engine oil
Oil filter clogged
Replace oil filter
Replace gasket

rebore cylinders

Clean or correct

a Check the viscosity of the oil.
b Change the oil if the viscosity is outside the
specified standard.
c Refer to the Maintenance and Lubrication"
section of this manual.
The level should fall somewhere between the ADD"
and the FULL" marks on the oil level dipstick.
If the oil level does not reach the ADD" mark on the

5. Start the engine and allow the engine to reach
normal operating temperature (About 80C).
150 kPa (21.8 psi) at idle speed.
7. Stop the engine.
6A16

The instrument panel CHECK ENGINE" Malfunction
system when the system checks the starting of engine,
or senses malfunctions.
Condition
CHECK ENGINE" MIL does not
CHECK ENGINE" MIL illuminates,

and stays on
Possible cause
Correction
Bulb defective
Replace
MIL circuit open
Correct or replace

Correct or replace

cable loosely connected,
Correct or replace
PCM defective
Replace
Deterioration heated oxygen sensor

of internal element
Replace
Heated oxygen sensor connector

terminal improper contact
Reconnect properly
Heated oxygen sensor lead wire

shorted
Correct
Heated oxygen sensor circuit open
Correct or replace
Deterioration engine coolant

temperature sensor of internal
element
Replace

Reconnect properly

lead wire shorted
Correct

circuit open
Correct or replace

shorted circuits
Correct or replace

sensor
Replace

open or shorted
Correct or replace
Correct or replace

Correct or replace

open or shorted
Correct or replace
Correct or replace
Replace PCM

(Read Only Memory)
Replace PCM
6A17
Cylinder Head Cover

Removal
13. Remove four bolts and remove the crankshaft pulley

2. Disconnect PCV hose from cylinder head cover.
3. Remove intake duct.
4. Remove left side ground cable from cylinder head
cover and disconnect ground cable connector on the
left side wheel arch. Remove right side ground
cable from generator stay and disconnect ground
cable connector on the right side wheel arch.
5. Disconnect three(black, green and blue colors)
engine wire harness connectors from chassis
harness of left rear side of compartment.
6. Disconnect cooling fan wire harness connector from
020RW014

15. Loose fixing bolt of timing belt rear cover then
033RW001
8. Remove PCV hose from cylinder block.

9. Remove intake duct stay from cylinder head.
10. Remove two bolts for remove ignition cable cover
from cylinder head cover.
12. Disconnect camshaft position sensor harness and
generator.
020RW012

6A18
Installation

1. Install the camshaft position sensor and tighten

timing rear cover bolt.
Torque: 8 Nm (0.8Kgm/5.9 lbft)
033RW001
020RW012


and tighten two bolt to the specified torque.
8. Install intake duct bracket to cylinder block.
9. Install PCV hose flange to cylinder block to the
specified torque.
020RW015
020RW014
10. Connect cooling fan wire harness connector to

11. Connect left side ground cable to cylinder head
cover and connect other side connector to left side
wheel arch terminal.
Connect right side ground cable to generator stay
and connect other side connector to right side wheel
arch terminal.

12. Connect three(black, green and blue colors) engine
wire harness connector to chassis harness of left
rear side of engine compartment.
6A19
13. Install intake duct.

14. Connect PCV hose to cylinder head cover.
Exhaust Manifold
Removal
2. Disconnect PCV hose from air intake duct.
4. Remove air intake duct bracket with ground cable.
5. Remove four fixing bolts on exhaust manifold heat
protector.
6. Remove fixing four nuts from flange of front exhaust
pipe and remove fixing bolts from silencer side.
011RW029
2. Install front exhaust pipe to exhaust manifold and

tighten fixing nut to the specified torque.
Torque: 25 Nm (2.6Kgm/18 lbft)
027RW005
7. Remove ten exhaust manifold fixing nuts then

remove exhaust manifold.
Installation
1. Install exhaust manifold and tighten fixing nuts to be
tightened in three steps.
Tightening sequence:
Step1: J G H B D C J G B D
027RW005
Tightening torque:
3. Tighten silencer side bolt to the specified torque.

4. Install exhaust manifold heat protector and tighten
bolt.
5. Install intake duct bracket with ground cable.
6A20

and clamp on the throttle body side, also clamp air
cleaner cover.
7. Connect PCV hose to air intake duct.

Crankshaft Pulley
Removal
Installation

wrench then remove drive belt.
1. Install the crankshaft pulley to crankshaft flange.

2. Tighten four bolt to the specified torque.
033RW001
3. Remove four crankshaft pulley fixing bolts, remove

crankshaft pulley.
020RW014

020RW014
033RW001
6A21
Intake Manifold
Removal
5. Remove water hoses from throttle body.
6. Disconnect the connector for throttle position
sensor, idle air control valve sensor from throttle
body.
7. Remove fuel pipe joint eye bolts from fuel rail and
disconnect wire harness from fuel injector.
065RW025
11. Remove water pipe fixing bolt then remove water

pipe.
12. Remove fixing bolt from bracket (Between cylinder
block and intake manifold) of intake manifold side.
042RW001
8. Disconnect hose from fuel pressure regulator then

remove fuel rail assembly.
9. Remove throttle valve control cable from throttle
body.
10. Remove fixing bolts for generator bracket.
025RW002
6A22
13. Remove ignition coil bracket fixing bolt.

14. Remove bolt and seven nuts, and remove intake
manifold.
025RW002
027RW002
4. Install water pipe to intake manifold.

5. Install generator bracket and tighten generator
bracket bolts.
Torque
Installation
1. Install intake manifold with gasket to cylinder head,
tighten bolt and nuts to the specified torque.
Long bolts: 35 Nm (3.6Kgm/25lbft)

Short bolts: 20 Nm (2.0Kgm/14lbft)
065RW025
027RW002
2. Install ignition coil bracket fixing bolt.

3. Install intake manifold bracket, tighten bolt.

6. Install fuel rail assembly to intake manifold and
connect hose between fuel pressure regulator and
throttle body.
7. Install fuel pipe and tighten joint eye bolt and
connect fuel injector harness.
042RW001
8. Connect the connector for throttle position sensor

and idle air control valve sensor to throttle body.
9. Install water hoses to throttle body.
and clamp on the throttle body side and air cleaner
side.
12. Install throttle valve control cable to throttle body.
13. Confirm the free play of throttle valve control cable.
14. Fill engine coolant to full level from radiator filler
neck.
6A23
6A24

Removal
10. Remove three bolts from generator bracket then

remove the generator with brackets.

2. Disconnect connector of intake air temperature
sensor from intake air duct.
4. Remove nut from air intake duct bracket and loosen
hose clamp on throttle body. Remove air intake duct
assembly with air cleaner cover.
5. Remove intake air duct bracket from cylinder head.
065RW025
11. Disconnect crankshaft angle sensor connector.

12. Disconnect knock sensor connector.
13. Remove heater hose from adapter side.
14. Remove heater hose from water pipe side.
15. Remove water hose between water pipe and throttle
body.
16. Remove fuel pipe joint eye bolts from fuel rail
assembly and remove fuel pipe bracket with electric
ground cable.
033RW001
8. Remove radiator upper hose from engine side.

9. Remove four nuts of exhaust front pipe.
042RW001
6A25
27. Disconnect camshaft angle sensor connector.

28. Remove ten bolts and remove cylinder head cover.
remove timing belt tensioner.
17. Disconnect connector for evaporation valve.

18. Remove canister hose.
19. Remove fixing nut of intake manifold stay from
cylinder block side.
025RW002
20. Remove two bolts from intake manifold for water

pipe support and remove cylinder head assembly.
connectors from chassis harness on left rear side
engine compartment.
22. Disconnect connector for power steering pump
pressure switch.
020RW014
24. Remove two bolts and nut then remove timing belt
front cover.
25. Remove ventilation hose from cylinder block side
and from cylinder head side.
26. Remove two bolts, ignition cable cover and remove
ignition cables from spark plug.
020RW010

CAUTION:
25980.
the life.
31. Remove two idle pulleys, the left side with idle pulley
bracket.
32. Remove two bolts and stud bolt and remove timing
belt rear cover.
33. Remove camshaft angle sensor
6A26
34. Disconnect engine oil pressure switch connector.
Installation
050RW005
35. Remove camshaft assembly exhaust side.

36. Use 5884026000 to remove ten cylinder head
fixing bolts
012RW011
2. Install the cylinder head assembly, tighten cylinder

head bolts by four steps tightening method in the
following sequence to the specified torque.(use 5
884026000)
Torque: 25 Nm (2.5Kgm/18lbft) + 90 + 90 + 90
012RW007
012RW006

3. Install camshaft assembly exhaust side and tighten
camshaft bracket bolts in the sequence to the
specified torque.
6A27
7. Install left side idle pulley with idle pulley bracket,

tighten to the specified torque and install right side
idle pulley and tighten to the specified torque.
015RW014
4. Connect engine oil pressure switch connector.

5. Install camshaft angle sensor.
6. Install the timing belt rear cover and tighten three
Torque
020RW012
020RW016

9. Install the cylinder head cover and tighten fixing bolt
temporally.
procedure as follows.
are aligned (3).
Rotate the engine two full turns in the
direction of normal operation until the engine
is again at top dead centre, No.1 cylinder
firing being careful that all movement is in a
clockwise direction.
6A28
If the engine is turned too far, do not turn

backwards, but continue to turn in the same
direction until the marks are again in line.
014RW063
014RW067
2. Place 5884026590 to between intake and

exhaust of camshaft drive gear to prevent
belt setting.
014RW066
014RW065

and move the timing belt tension adjustment
is flowing.
6A29

of the engine.
014RW062
4. Tighten fixing bolt of timing belt tensioner to the

specified torque.
014RX061

the pointer will be approx. 4 mm(0.16 in) to the
020RW010
014RW069
11. Tighten cylinder head cover to the specified torque.

12. Connect camshaft angle sensor connector.
13. Install the ignition cable to spark plug.
14. Install ignition cable cover and tighten two bolts.
15. Install ventilation hoses to cylinder block side and
cylinder head side.
6A30

24. Install fuel pipe joint eye bolts to fuel rail assembly
and install fuel pipe bracket with electric ground
cable.

020RW014
18. Connect connector for power steering pump

pressure switch.
19. Connect engine harness connector to chassis
harness of the left rear of engine compartment and
install engine harness cover.
20. Install two bolts to intake manifold for water pipe
support.
21. Install fixing nut of intake manifold stay to cylinder
block.
042RW001
25. Install water hose between water pipe and throttle

body.
26. Install heater hose to water pipe side.
27. Install heater hose to adapter side.
28. Connect knock sensor connector.
29. Connect crankshaft angle sensor connector.
30. Install generator with bracket and tighten three bolts.
Torque
35 Nm (3.6Kgm/25lbft) for Long bolt
20 Nm (2.0Kgm/14lbft) for Short bolt
025RW002
22. Install canister hose.

23. Connect connector for evaporation valve.
065RW025

tighten four nuts to the specified torque.
6A31
34. Install intake air duct bracket to cylinder head.

35. Install air intake duct assembly with air cleaner
cover to throttle body and tighten nut to the air
intake duct bracket then tighten hose clamp.
Torque
7 Nm (0.7Kgm/5.1lbft) for nut
3 Nm (0.3Kgm/2.2lbft) for hose clamp bolt
37. Connect connector of intake air temperature sensor
on intake air duct.
39. Fill engine coolant to full level in the engine coolant
reservoir tank.
027RW005
32. Install radiator upper hose to engine.

033RW001
6A32
Timing Belt
Removal
5. Disconnect three connectors of engine harness

from chassis harness of left rear side of engine
compartment.
6. Remove nut and remove engine harness cover from
front of engine.
7. Remove two bolts then remove timing belt front
cover.
remove timing belt tensioner (1).
033RW001

connectors from left rear side of engine
compartment.
020RW010

CAUTION:
25980.
the life.
020RW014
6A33
Installation
014RW066
020RW010

procedure as follows:
are aligned (3).
014RW063
014RW067
6A34
2. Place 5884026590 between intake and

exhaust of camshaft drive gear for prevent to
belt setting.
014RW065

and move the timing belt t ension adjustment
is flowing.
014RX061

The pointer will be approx. 4 mm(0.16 in) to the
014RW069
014RW064

of the engine.
6A35

020RW014
014RW062
3. Tighten fixing bolt (1) of timing belt tensioner to the

specified torque.

033RW001
020RW010

5. Install engine harness cover to front top of engine
and tighten nut to the specified torque.
8. Connect engine harness three connector to chassis

harness of left rear side of engine compartment.
6A36
Camshaft
Removal
2. Remove cylinder head cover.
Refer to removal procedure for Cylinder Head Cover
in this manual.
3. Remove timing belt tensioner and remove timing
belt.
5. Remove camshaft drive gear from intake and

exhaust camshaft.
6. Remove twenty fixing bolts from intake and exhaust
camshaft bracket on the cylinder head, then remove
camshafts.
011RW015
020RW010
4. Use adjustable wrench to hexagonal portion of

camshaft, and remove fixing bolt from front end of
camshaft.
014RW074
CAUTION:
Do not damage camshaft lobe and journal.
Do not damage hydraulic lash adjuster(HLA) and
do not allow into foreign materials into cylinder
head.
7. Remove oil seal from camshaft.
Installation
1. Clean surface of camshaft bracket and HLA.
2. Apply engine oil to journal surface of camshaft
bracket and HLA.
3. Install camshaft to cylinder head.
4. Install camshaft bracket according to numerical as
The bracket number is:
Exhaust: 1 to 5 from front
Intake: 6 to 10 from front.
6A37
Camshaft oil seal installation area on the cylinder

body of No.1, No.6 and camshaft bracket rear side
plug portion must be applied HN1023 or equivalent
as in the illustration.
014RW073
5. Tighten camshaft bracket bolts to the specified

torque by sequence in the illustration.
6. Use 5884026580 for installation camshaft oil
seal.
014RW052
014RW075
015RW014
6A38

Also align a guide hole on the camshaft drive gear
marked IN" for intake and EX" for exhaust to guide
pin on the camshaft when instaling the camshaft
drive gear.
014RW071
7. Install the camshaft drive gear. Align the timing mark

between notch on the camshaft drive gear(1) and
lug on the camshaft bracket(2).
014RW072
8. Tighten camshaft bracket fixing bolt to the specified

torque.
014RW076
015RW014

Refer to installation procedure for Timing Belt in this
manual.
Refer to installation procedure for Cylinder Head
Cover in this manual.
6A39
Engine Assembly
Engine and Associated Parts
755RX032
Removal
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood to
original position exactly.
5. Drain engine coolant from radiator.
6. Disconnect throttle valve control cable from throttle
valve on intake manifold.
7. Remove air duct with air cleaner cover.
9. Disconnect three engine harness connectors from
chassis harness of left rear side engine
compartment.
10. Disconnect vacuum hose on the brake booster.
11. Disconnect cooling fan harness connector on the
left of fan shroud.
12. Disconnect ground cable connector from left and
right of front wheel arch upper side.
13. Remove clutch piping bracket from right side of
clutch housing.
14. Remove fuel piping bracket from transmission.

15. Remove four nuts from exhaust front pipe exhaust
manifold side and remove two bolts from rear side of
exhaust front pipe. Remove exhaust front pipe.
027RW005
6A40
16. Remove transmission mounting fixing bolts and nut

from cross member.
29. Remove engine mounting bolt from chassis frame

side.
022RW014
022RW005
17. Remove transmission front under cover from front

portion of clutch housing.
18. Disconnect two fuel pipes at right side of
transmission by quick type fuel hose connector.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
19. Disconnect canister hose next to fuel piping
connector.
20. Remove propeller shaft fixing bolt from rear side
transmission.
21. Remove fixing bolts between clutch housing and
transmission, then move transmission.
22. Remove power steering pump assembly then place
the power steering pump along with piping.
23. Disconnect two chassis harness connectors from
right rear side engine compartment (under fuse box)
and remove two harness clips.
24. Remove engine ground cable from chassis frame.
25. Remove radiator lower hose from engine side.
26. Remove two heater hoses from right side panel.
28. Remove harness clip from behind right horn.
022RW006
30. Lift up the engine assembly.
Installation
side. If assembled in the condition that dowels
have not been mounted in the specified position,
transmission damage can result.
1. position the engine assembly in the engine
compartment.
2. Tighten engine mounting bolt to frame side to the
specified torque.
6A41
3. Install harness clip behind right horn.

4. Install the radiator grille and install flasher lamp
assembly.
5. Install two heater hoses to right side panel.
6. Install radiator lower hose to engine.
7. Install engine ground cable to chassis frame.
8. Connect two chassis harness connectors to right
rear side engine room(under fuse box) and install
two harness clips.
9. Install power steering pump assembly and tighten
fixing bolts.
10. Install transmission assembly, refer to installation
procedure for Transmission section in this manual.
11. Install propeller shaft, refer to installation procedure
for Propeller section in this manual.
12. Connect canister hose next to fuel piping connector.
13. Connect two fuel pipes at right side transmission by
quick type connector.
14. Install transmission front under cover to front portion
of clutch housing.
15. Install transmission mounting fixing bolts and nuts to
cross member.
022RW005
022RW014
022RW006
6A42

silencer, then tighten fixing nuts and bolts to the
specified torque.
Torque
25 Nm (2.5Kgm/18lbft) for nut
68 Nm (6.9Kgm/50lbft) for bolt
17. Install fuel piping bracket to transmission.

18. Install clutch piping bracket to right side of clutch
housing.
19. Connect ground cable connector to left and right of
front wheel arch upper side.
20. Connect cooling fan harness connector on the left of
fan shroud.
21. Connect vacuum hose to the brake booster.
22. Connect three engine harness connectors to
chassis harness of left rear side of engine
compartment.
24. Install air duct with air cleaner cover to specified
torque.
Torque
7 Nm (0.7Kgm/5.1lbft) for air duct fixing
3 Nm (0.3Kgm/2.2lbft) for air duct clamp bolt
25. Connect throttle valve control cable to throttle valve
on the intake manifold.
Confirm the free play of throttle valve control cable.
027RW005
26. Install engine hood to original position.

Refer to installation procedure for Body section in
this manual.
27. Install battery, connect positive cable and ground
cable.
28. Fill engine coolant to full level in the coolant
reservoir tank.
6A43
Cylinder Head
011RW010
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Cylinder Head Bolt

Camshaft Pulley
Camshaft Oil Seal
Camshaft Bracket Bolt
Camshaft Exhaust
(7)
(8)
(9)
(10)
(11)
Camshaft Intake
Tappet (HLA)
Split Collar
Valve
EndOFCallout
Disassembly
NOTE:
During disassembly, be sure that the valve train
Before removing the cylinder head from the engine

1. Remove camshaft pulley fixing bolt (2), then pulley
(3).
bracket, then camshaft exhaust (6), and intake side
(7).
6A44
3. Remove cylinder head.

Use 5884026000.
4. Valve spring, valve spring caps, compress valve
spring use 5884025460 (1) and Adapter 5
884026620 (2).
Valve keepers.

1. Check length and width of cylinder head sealing
surfaces for deformation and diagonals for warpage
use straight edge and feeler gauge.
011RW011
011RW014
5. Valves, valve stem seals use commercially

available remover pliers. Valve spring seats from
cylinder head.
2. Height of cylinder head (sealing surface to sealing

surface).
Dimension (I) 134 mm
011RW012
011RW013
Reassembly
1. Valves, valve stem seals. Refer to Valve Spring, Oil
Controller, Valve, Valve Guide in this section.
2. Valve spring, valve spring caps. Refer to Valve
Spring, Oil Controller, Valve, Valve Guide in this
section.
3. Install tappet (HLA).
4. Cylinder head with new cylinder head bolts to
cylinder block.
Tighten the bolts in 4 steps.
2nd step: 90
3rd step: 90
4th step: 90
011RW014
5. Camshaft in cylinder head. Refer to Camshaft in this

section.
6. Camshaft pulley. Refer to Camshaft in this section.
6A45
6A46
Valve Spring, Valve, Valve Guide

Valve Spring, Valve, Valve Guide and Associated Parts
011RW024
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Camshaft Pulley Fixing Bolts

Camshaft Pulley
Camshaft Bracket Fixing Bolt
Camshaft Assembly Intake
Camshaft Assembly Exhaust
Cylinder Head Bolt
Cylinder Head
Tappet
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Split Collar
Spring Upper Seat
Valve Spring
Oil Seal
Spring Lower Seat
Valve Guide
Valve
Disassembly
6A47
1. Remove camshaft pulley (1), (2).

2. Remove camshaft assembly (Intake) (3), (4).
3. Remove camshaft assembly (Exhaust side) (5).
4. Remove cylinder head (6), (7).
5. Remove tappet (8).
5884026620 adapter to remove split collar (9).
1. Use a internal micrometer to measure the diameter

valve guide.
Valve stem play
Intake : 0.03 to 0.057 mm (0.0012 to 0.0022in)
Exhaust : 0.04 to 0.067 mm (0.0016 to 0.0026in)
011RW020
Valve Guide
011RW014
7. Remove spring upper seat and valve spring (10),

(11).
8. Valve, valve guide use commercially available
remover pliers.
Valve spring lower seat from cylinder head.
CAUTION: Taking care not to damage the valve seat

scratching or abnormal wear. If these conditions are
replaced as a set.
Valve Seat
Valve seat width in cylinder head
Intake: 1.0 to 1.5 mm (0.039 to 0.0585 in)
Exhaust: 1.7 to 2.2 mm (0.0663 to 0.0858 in)

Remove the carbon from the valve seat insert surface.

2. Allow the rod to cool for a few minutes. This will
cause the valve seat to shrink.
011RW013
6A48

spring to the lower spring seat.
4. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using 5884025460 valve
spring compressor for install the split collars.
014RS015
4. Carefully clean the valve seat pressfit section on

the cylinder head side.
horizontally.
Reassembly
Using oil controller replacer 5884026630, drive
in a new oil controller.
014RS019
011RW014
5. Install tappet.
Refer to installation procedure for Camshaft in
this manual.
6A49
Camshaft
011RW023
Legend
(1)
(2)
(3)
(4)

Camshaft Pulley
Oil Seal
Camshaft Bracket

EndOFCallout
Disassembly
1. Remove fixing bolt (1) for camshaft pulley (2).
014RW035
6A50

4. Remove twenty fixing bolts (5) from inlet and
exhaust camshaft bracket, then camshaft brackets
(4).
Reassembly
tighten twenty bolts on one side bank to the
specified torque.
2. Align timing mark on intake camshaft and
exhaust camshaft to timing mark on camshaft
drive gear (one dot).
3. Tighten twenty bolts on numerical order one
side bank shown in the illustration.
4. If it required to replace oil seal of camshaft drive
gear, use 5884026580 for install the oil seal.
5. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.
011RW015
014RW036
6A51
Crankshaft
015RW008
Legend
(1)
(2)
(3)
(4)
(5)

Oil Pump Assembly
Pan
Pan Support
Oil Strainer
(6)
(7)
(8)
(9)
(10)

Main Bearing Cap
Crankshaft
Cylinder Block Assembly
EndOFCallout
Disassembly
Cylinder head" in this manual.
2. Remove oil pan (3).
3. Remove oil pan support (4).

4. Remove oil strainer (5).
6. Balance unit assembly.
Refer to Piston, Piston Ring and Connecting Rod"
in this manual.
6A52
8. Remove flywheel.
9. Remove rear oil seal and oil baffle plate.
12. Remove crankshaft pulse pickup sensor disc.

1. Crankshaft
measure the crankshaft thrust clearance. If the
thrust clearance exceeds the specified limit, replace
the thrust bearings as a set.

The bearings must be replaced as a set if damage
or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to
their original positions.
position.
Thrust Clearance
(0.0004 in0.0008 in)
Limit : 0.21 mm (0.0118 in)
014RW055
9. Install main bearing caps, and tighten each bolt to

Main bearing caps bolts.
Torque:
014RW079

clearance.
2. Remove the main bearing cap fixing bolts.
2nd step: 45
3rd step: 15
Torque : 39 Nm (4.0Kgm/29lbft)

(0.0007 in0.0016 in)
6A53

1. Carefully set the crankshaft. Slowly rotate the
crankshaft and measure the runout. If the
Runout : 0.03 mm (0.0012 in)
Limit : 0.12 mm (0.0047 in)
014RW078
014RW077

crankshaft.
Crankshaft (12) Inspection

pins for excessive wear and damage. Inspect the oil
seal fitting surfaces for excessive wear and damage.
Inspect the oil ports for obstructions.

journal and crank pin. If the crankshaft wear
exceeds the specified limit, crankshaft must be
replaced.
(2.259 in2.261 in)
(1.909 in.1.91 in.)
015RS009
6A54

install the new crankshaft bearings.
mm (in)

Crankshaft bearing journal dia.
Standard size
white
57.974 to 57.981 (2.2602.261)
green
57.981 to 57.988 (2.2612.2615)
brown
57.988 to 57.995 (2.26152.2618)
Undersize 0.25 (0.0097)

green/blue
57.732 to 57.738 (2.25152.2517)
brown/blue
57.738 to 57.745 (2.25172.252)

green/white
57.482 to 57.488 (2.24182.242)
brown/white
57.488 to 57.495 (2.2422.2423)
Guide bearing width

Standard size
25.950 to 26.002 (1.0121.014)
Undersize 0.25 (0.0097)
26.150 to 26.202 (1.0191.021)
26.350 to 26.402 (1.0271.029)

correctly.
Crankshaft pulse pickup sensor disc inspection and
repair.
Inspect the crankshaft pulse pickup sensor disc for
excessive wear and damage.
Replace the crankshaft pulse pickup sensor disc if the
inspection exceeds wear and damage.
Reassembly
1. Crankshaft (12).
Install the crankshaft pulse pickup sensor disc.
bearing faces.
NOTE: Do not apply engine oil to the main bearing
back faces.
Assemble the thrust washer to the No.3 bearing
Tighten the crankshaft baring cap bolts in 3
steps:
2nd step: 45
3rd step: 15
015RW039

2. Rear oil seal (10).
26600 (1) and 5884025970 (2).
6A55

Piston rings position (A) every 180.
Oil scraper rings (B) offset 25 to 50 mm/1 to 2
in. to left and right from gap of intermediate ring.
015RW009
3. Flywheel (9).
mounting faces.
install the washer.
crankshaft.
015RW026
Insert the piston/connecting rod assemblies into

The front marks must be facing the front of the
engine.
Match the numbered caps with the numbers on
the connecting rods. Align the punched marks on
the connecting rods and caps.
Arrow (1) on piston head points to engine timing
side, bead on connecting rod points to flywheel
side.
015RW010
5. Prevent from rotating.

2nd step: 30
3rd step: 15
015RW038
6A56

2nd step: 45
3rd step: 15
5. Install the balance unit assembly and tighten the
bolts in 2 steps:
2nd step: 45
Refer to the Balance Unit Assembly" section of this
manual.
6. Install oil pump assembly (5), refer to Oil Pump" in
this manual.
8. Install oil pan support and tighten the bolts to the
specified torque.
9. Install oil pan.
of the oil pan. There must be no gaps in the
bead.
3. The oil pan support must be installed within 5
minutes after sealant application.
4. Tighten the bolts in to steps.
2nd step: 30
6A57

015RW037
Legend
(1)
(2)
(3)
(4)
(5)
(6)

Cylinder Head Gasket
Oil Pan Assembly
Pan Support
Oil Strainer
(7)
(8)
(9)
(10)
(11)
(12)

Piston Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Cap
EndOFCallout
Disassembly
1. Remove cylinder head assembly (1), refer to
Cylinder Head Removal" in this manual.
3. Remove oil pan assembly and oil pan support (3)
refer toOil Pan and Oil Pan Support" in this manual.

lower.
6A58

Remove any ridge or carbon build up from the top
Piston Rings (8)

Insert the piston ring into the bore.
Push the ring by the piston, at a right angle to the
Measure the ring end gap.
Compression Ring
1st ring
Standard:
0.30 mm0.50 mm
(0.0118 in0.0195 in)
2nd ring
Standard:
0.30 mm0.50 mm
(0.0118 in0.0195 in)
Oil ring
Standard:
0.40 mm1.40 mm
(0.0156 in0.0546 in)
015RW024
9. Remove the piston pin (9).

Heat the connecting rod and the piston pin with
oil heater, when it temperature is keep at 280
320C.
Push the piston pin with brass bar.

piston ring groove / piston ring clearance exceeds
the specified limit, the piston must be replaced.
(0.0008 in.0.0016 in)

positions.
10. Piston (10).
11. Connecting rod (11).

Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
any of the above conditions are found, the piston must
be replaced.
015RW025

Piston Pin (9)
6A59
Connecting Rods (11)

positions.
small end. If the fitting interference between the
small end and pin does not conform to the specified
value, the connecting rod must be replaced.
(0.0008 in0.0016 in)

1. Remove the connecting rod cap nuts and the
rod caps (12).
number order.
bearing is found to be damaged or badly worn,
the entire bearing assembly must be replaced
as a set. Reinstall the bearings in their original
positions.
2nd step: 45
3rd step: 15
set.
(0.0002 in0.0012 in)
014RW077
is normal. If there is backlash or roughness,
measure the clearance. If the clearance exceeds the
Clearance
(0.0004 in.0.0005 in)
Limit : 0.12 mm (0.0047 in)

crankshaft pins.
6A60

mm (in)
(continued)
Conrod bearing journal dia.
Standard size
(no color code)
48.970 to 48.988 (1.90981.9105)
Undersize 0.25 (0.0097)

blue
48.720 to 48.738 (1.90011.9008)

white
48.470 to 48.488 (1.89031.891)
Conrod bearing journal width

Standard size
(no color code)
26.460 to 26.580 (1.03191.036)
Undersize 0.25 (0.0097)

blue
26.460 to 26.580 (1.03191.036)

white
26.460 to 26.580 (1.03191.036)
Conrod width
26.338 to 26.390 (1.02711.0292)
Reassembly
2. Install piston
Apply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin hole
with normal finger pressure.
Attach the piston to the connecting rod with the
piston front mark and the connecting rod front
mark on the same side.
Heat the connecting rod small end to a suitable
New piston rings with Top" uppermost use
commercially available pliers.
Position ring gaps:
1 Compression rings 180to each other as
illustrated.
from gap of second compression ring.
015RW026
After installation, apply engine oil to the entire

circumference of the piston rings. Check to see
that all the rings rotate smoothly.
Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces
and nuts.
Tighten the connecting rod cap nuts in 3 steps:
2nd step: 45
3rd step: 15

faces.
6. Oil gallery, refer to Crankshaft and Main Bearing" in
this manual.
8. Install balance unit assembly, refer to Balance Unit
Assembly: in this manual.
6A61
9. Install oil pan support assembly, refer to Oil Pan

and Oil Pan Support" in this manual.
Refer to Cylinder Head" in this manual.
Cylinder Block
015RW008
Legend
(1)
(2)
(3)
(4)
(5)

Oil Pump Assembly
Oil Pan
Oil Pan Support
Oil Strainer
EndOFCallout
(6)
(7)
(8)
(9)
(10)

Main Bearing Cap
Crankshaft
Cylinder Block
6A62
Disassembly
3. Remove oil pan assembly.
9. Remove flywheel.

material adhering to the upper surface of the
cylinder block. Be very careful not to allow any
material to accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
4. Visually inspect the cylinder block. If necessary, use
a flaw detector to perform a dye penetrate and
Flatness
1. Using a straight edge and feeler gauge, check that
the upper surface of the cylinder block is not
warped.
2. The cylinder block must be reground or replaced if
the warpage exceeds the limit.
Warpage
Limit : 0.40 mm (0.0156 in)
012RW013
Cylinder Bore
If the measurement exceeds the specified limit, the
Diameter
Grade 1 : 85.975 mm85.985 mm
(3.3530 in3.3534 in)
Grade 2 : 85.985 mm86.025 mm
(3.3534 in3.3550 in)
Oversize : 0.5 mm (0.0195 in)
Rod Assembly" in this manual.
6A63
Reassembly
bearing faces.
faces.
3. Install rear oil seal.
26600 (1) and 5884025970 (2).
015RW010

faces.
Position ring gaps:
1 Compression rings 180 to each other as
illustrated (A).
from gap of second compression ring (B).
015RW009
4. Install flywheel
mounting faces.
install the washer.
crankshaft.
Prevent from rotating.
015RW026
6. Install balance unit assembly and tighten the bolts in

2 steps in the order shown:
2nd step: 30
3rd step: 15
2nd step : 45
7. Install oil pump assembly, refer to Oil Pump" in this

manual.
6A64

10. Install oil pan assembly.
of the crankcase. There must be no gaps in the
bead.
after sealant application.

4. Tighten the bolts and nuts to the specified
torque in 2 steps:
1st step : 8 Nm (0.8Kgm/5.8lbft)
2nd step : 30
Cylinder Head Cover

Cylinder Head Cover and Associated parts
010RW004
Legend
(1) Ignition Cable Cover
(2) Spark Plug
EndOFCallout
(3) Cylinder Head Cover
Removal
6A65
Installation
1. Remove two bolts and remove ignition cable cover

(1) from cylinder head cover (3).
2. Disconnect ignition cable and remove spark plag
(2).
4. Disconnect camshaft angle sensor harness and
generator.
5. Remove four bolts and remove the crankshaft pulley.
1. Install the camshaft angle sensor and tighten timing

rear cover bolt.
020RW012

020RW014

7. Loose fixing bolt of timing belt rear cover, then

020RW012

020RW014
6A66

033RW001

and tighten two bolts to the specified torque.
6A67

Balance Unit Assembly Associated Parts
051RW012
Legend
(1) Oil Pan
(2) Oil Pan Support
(3) Oil Strainer
EndOFCallout
(4) Balance Unit Assembly

(5) Shim
6A68
Disassembly
1. Remove the oil pan.
2. Remove the oil pan support.
3. Remove the oil strainer (1) from oil pump and the oil
baffle plate (2).
2. In this crankshaft position, the flattened side

(arrows) of both balancer shafts must face
downward and must be on a horizontal line.
051RW010
051RW009
Adjustment
3. Screw measuring device 5884026710 (3) with

long knurled bolt (1) into 1st balancer shaft (intake
side) and tighter hardtight measuring arm (5) must
point in 9 o'clock" direction shown in this illustration.
Install dial gauge holder with dial gauge (4) on
cylinder block.

051RW007
014RW066

4. Place pre tensioned probe (6) of gauge on
measuring arm of measuring device 588402671
0. The probe must be set precisely between the
notch marks, square to the plane surface (7).
6A69
6. The tooth backlash must be measured in 4 different

positions turn the crankshaft further at the
fastening bolt of the timing belt drive gear by 45 in
the engine rotational direction until the measuring
arm (2) is at 6 o'clock".
051RW006
5. Determine the left and right stops by turning the

knurled bolt (2).
Set the dial of the gauge to zero.
Use the knurled bolt (2) to move the 2nd balancer
shaft (exhaust side) back and forth. Again
simultaneously read off the tooth backlash from the
gauge.
The permissible tooth backlash is: 0.02 mm to
0.06mm (0.0008 to 0.0024in).
051RW008
7. Then loosen the knurled bolt (3) fix the measuring

arm at 9 o'clock" again and repeat the
measurement.
051RW007
8. If the value determined in one of the 4

measurements lies outside the tolerance 0.02mm to
0.06mm (0.0008 to 0.0024in), the tooth backlash
must be adjusted.
051RW007
6A70
9. Remove balance unit from cylinder block/crankshaft

bearing caps and remove with balancer piece. The
balancer piece has a number (code), for easy
assignment. The tooth backlash can be adjusted by
using a balancer piece with a different thickness.
Code
Thickness of balancer piece in mm
55
0.535 to 0.565
58
0.565 to 0.595
61
0.595 to 0.625
64
0.625 to 0.655
67
0.655 to 0.685
70
0.685 to 0.715
73
0.715 to 0.745
76
0.745 to 0.775
79
0.775 to 0.805
82
0.805 to 0.835
85
0.835 to 0.865
CAUTION: The next larger or smaller balancer

alters the tooth backlash by 0.02mm (0.0008in).
Example of selection of balancer piece: The
installed balancer piece with the code 70" gave a
tooth backlash of 0.08mm (0.0031in).
If a balancer piece with the code 67" is now
installed, the tooth backlash will be approx. 0.06mm
(0.0024in).
NOTE: Only one balancer piece may be installed.
Reassembly
2. Turn balancer shafts until the flattened sides

(arrows) of both balancer shafts face downward and
are on a horizontal line.
051RW010
3. Install selected balancer piece (2) with balancer

shaft unit to cylinder block/crankshaft bearing cap
tighten all fixing bolts to the specified torque.
4. After installing the balancer shaft unit, recheck the
tooth backlash and readjust if necessary.
CAUTION: If the balancer shaft unit has to be
replaced, use the thickest balancer piece with the
code 85" for the initial assembly this guarantees
tooth backlash in all conditions.
5. Install oil strainer to oil pump with new seal ring and
insert fixing bolts with locking agent to the specified
torque.
014RW066

Adjust surfaces of the cylinder block and the oil
pan support.
035RW026
7. Install oil pan.

2nd step: 30
6A71
6A72

Camshaft bracket, Timing gear camshaft side, Cylinder head
011RX001
6A73
Timing gear crankshaft (center bolt), Timing belt cover front, Timing belt cover rear, Timing belt tensioner,
Camshaft angle sensor
020RX001
6A74
Crankshaft main bearing, Oil pan support, Oil pan, Balance unit assembly, Connrod Cap, Oil pump, Oil
strainer
015RX004
6A75
Spark plug, Throttle body, EGR valve adaptor assembly, Bypass housing assembly, Thermostat assembly,
inlet manifold assembly, Exhaust manifold assembly, heat shield, Ignition cable cover
011RX002
6A76
Engine mount
022RX003
6A77
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5884025970
seal ring
5884026600
seal
5884026580
Remover/Installer;
Crankshaft carrier seal
5884026610
Locking device; Flywheel
5884025460
Compressor; Valve
spring (1)
(Use with
5884026620 (2) )
5884026630
Installer sleeve; Valve
stem seal
5884026620
Adapter; Compressor
Valve spring
5884026000
Socket wrench; Cylinder
head bolt
5884026590
Locking tool camshaft
gear
5884025980
Holding wrench; Driven
gear fix
6A78
ILLUSTRATION
TOOL NO.
TOOL NAME
5884026710
Screw measuring device
SECTION
6B1

CONTENTS
Diagnosis ....................................................
Draining and Refilling Cooling System .......
Water Pump ..................................................
Water Pump and Associated Parts.............
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Thermostat ....................................................
6B - 1
6B - 2
6B - 4
6B - 4
6B - 5
6B - 5
6B - 5
6B - 5
6B - 5
6B - 6
Service Precaution
YOU ARE
IN
REPAIRS.
Removal......................................................
Inspection ...................................................
Installation...................................................
Radiator.........................................................
Radiator and Associated Parts ...................
Removal......................................................
Inspection ...................................................
Installation...................................................
Special Tool ...................................................
6B - 6
6B - 6
6B - 6
6B - 7
6B - 7
6B - 7
6B - 8
6B - 8
6B - 10
6B - 10

and systems.
6B2
General Description
111RW001
Legend
(1)
(2)
(3)
(4)
Water Pump
Thermostat
Radiator
Reserve Tank
(5)
(6)
(7)
(8)
Coolant Distributor
Cylinder Block and Head
Throttle Body
Heater
EndOFCallout
The Cooling System is a pressurized type, where the
water pump, which is cambelt driven, forces the
circulation of the coolant through the cylinder block and
head. The thermostat regulates the flow of coolant
between the radiator and the bypass circuit. The heater
is part of the bypass circuit. The throttle body preheat
is a separate circuit which is not regulated by the
thermostat. An oil cooler may be fitted as part of this
circuit.
Water Pump
The water pump is centrifugal type and is driven by
timing belt.
030RW003

Thermostat
6B3
Calculating mixing ratio
The thermostat is a bypass type and is a wax pellet type

with a air hole (1).
F06RW005
031RW003
Radiator

system capacity.
Total Cooling System Capacity
7.2Lit (1.90US gal)
The radiator is a flow type with corrugated fins.
110RX005
Antifreeze Solution
Relation between Mixing ratio and Freezing
temperature of the engine coolant varies with the
111RW002
Mixing ratio
cooling system temperature ranges from 0 50
type hydrometer, then determine the
6B4
Diagnosis
Condition
Possible cause
Correction

Engine overheating
Replenish
Thermo mater unit faulty
Replace
Faulty thermostat
Replace

sensor
Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap
Replace

improper engine oil

faulty parts

sensor circuit
Repair or replace
Replace
Engine overcooling
Faulty thermostat
Replace
Faulty thermostat
Replace
Thermo unit faulty
Replace
Draining and Refilling Cooling System

clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
MIN" and MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the
MAX" line.
1. Completely drain the cooling system by opening the
drain plug at the bottom of the radiator.
2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do
not remove the cap while the engine and radiator
are still hot. Scalding fluid and steam can be blown
out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.4. Refill
the cooling system with the EC using a solution that
is at least 50 percent antifreeze but no more than 70
percent antifreeze.
4. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze but no
more than 70 percent antifreeze.

5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to MAX" line when the
engine is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to P" (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does
not go down. Then stop the engine and install the
radiator cap. Let the engine cool down.
9. After the engine has cooled, replenish with EC up to
the MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound
from the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8
to 10.
6B5
Water Pump
030RW004
Legend
(2) O Ring
(3) Bolt
EndOFCallout
Removal
2. Drain coolant.
4. Remove timing belt, refer to Timing Belt" in this
manual.
Inspection
Should any of the following problems occur, the entire
water pump assembly must be replaced:
Crack in the water pump body
Engine Coolant (EC) leakage from the seal unit
Play or abnormal noise in the bearing
Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface
specified torque.
3. Timing belt
Install timing belt, refer to timing belt installation
step in Timing Belt" in this manual.
4. Connect radiator hose and replenish EC.
6B6
Thermostat
Removal
Inspection

Suspend the thermostat in a waterfilled container

using thin wire. Place a thermometer next to the
thermostat.
open.
Valve opening temperature 92C (197.6F))
Valve full open temperature 107C (224.6F))
Installation
1. Before installing thermostat, coat sealing surface
2. Install gasket.
specified torque.
031RW012

6B7
Radiator
110RX004
Legend
(1) Radiator
(2) Bracket
(3) Cooling Fan Assembly
(4) Radiator Cap

(5) Radiator Hose
(6) Lower Fan Guide
EndOFCallout
Removal
2. Disconnect cooling fan motor connector.
3. Loosen a drain plug to drain engine coolant.
the engine.
5. Remove fan guide, clips on both sides and the
bottom lower with fan shroud.
6. Disconnect the reserve tank hose from radiator.
7. Remove bracket(2).
110RX003
6B8
8. Lift out the radiator assembly with hose, taking care

not to damage the radiator core with fan blade.
9. Remove rubber cushions on both sides at the
bottom.
Inspection
Radiator Cap
the standard range.

through the filler neck at the specified pressure of 196
kPa (28.5 psi) with a cap tester:
Leakage from the radiator
Leakage from the coolant pump
Leakage from the water hoses
Check the rubber hoses for swelling.
Adapter: 5884026030

(13.5 17.8)
Adapter: 5884026030
the valve seat side of the cap. If considerable rust or dirt
is found, or if the valve seat cannot be moved by hand,
clean or replace the cap.
Valve opening vacuum kPa (psi) 1.96 4.91 (0.28
0.71)
110RX002
Installation
bottom.
2. Install radiator assembly with hose, taking care not
to damage the radiator core with a fan blade.
4. Connect reserve tank hose.
110RS006
Radiator Core
straightened. Pay close attention to the base of the
fin when it is being straightened.

Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all sign of scale and rust.

engine.
110RX003

Important operation (in case of 100% engine
coolant change) procedure for filling with engine
coolant.
1. To change engine coolant, make sure that the
engine is cool.
cap slowly to reduce the pressure when the
coolant has become cooler.
2. Open radiator cap and drain the cooling system
by loosening the drain valve on the radiator and
on the cylinder body.
Replace damaged rubber hoses as the engine
anti-freeze coolant is liable to leak out even minor
cracks.
Isuzu recommends to use Isuzu genuine anti-freeze
(ethylen-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
the filler neck even before the engine and radiator
are completely full.
6B9
To avoid such trouble, the following precausions

3. To refill engine coolant, pour coolant up to filler
neck using a filling hose which is smaller in
outside diameter of the filler neck. Otherwise air
between the filler neck and the filling hose will
block entry, preventing the system from
completely filling up.
4. Keep a filling rate of 9 liter/min or less. Filling
over this maximum rate may force air inside the
engine and radiator.
And also, the coolant overflow will increase,
making it difficult to determine whether or not
the system is completely full.
5. After filling the system to the full, pull out the
filling hose and check to see if air trapped in the
system is disclodged and the coolant level goes
down. Should the coolant level go down, repeat
topping-up until there is no more drop in the
coolant level.
6. After directly filling the radiator, fill the reservoir
to the maximum level.
7. Install and tighten radiator cap and start the
engine. After idling for 2 to 3 minutes, stop the
engine and reopen radiator cap. If the water
level is lower, replenish.
cap slowly to reduce the pressure when the coolant
has become cooler.
8. After tightening radiator cap, warm up the
engine at about 2,000 rpm.
Set heater adjustment to the highest
temperature position, and let the coolant
9. Check to see the thermostat has opened
through the needle position of water
thermometer, conduct a 5-minute idling again
and stop the engine.
6B10

Cooling system
Engine Coolant forced circulation
Radiator
(1 tube in row) Tube type corrugated
54,000 kcal/h (62.8 kw)
Heat radiation area
7.677m2 (0.878ft2)
Radiator front area
0.264m2 (0.028ft2)
Radiator dry weight (with fan)
32N (7.2lb)
93.3 122.7kpa (13.5 17.8psi)

1.8lit (0.48 US gal)
Engine coolant pump
Centrifugal type
Thermostat
Bypass type
7.2lit (1.9 US gal)
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884002770
5884026030
SECTION
6C1

CONTENTS
Fuel Metering..............................................
Fuel Filter ......................................................
Fuel Filter and Associated Parts.................
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Inspection ...................................................
InTank Fuel Filter......................................
Fuel Pump Flow Test..................................
Fuel Pump.....................................................
Fuel Pump and Associated Parts ...............
Removal .....................................................
Installation ..................................................
Fuel Tube / Quick Connector Fittings.........
Precautions.................................................
6C - 1
6C - 2
6C - 3
6C - 4
6C - 4
6C - 4
6C - 4
6C - 4
6C - 5
6C - 5
6C - 5
6C - 6
6C - 6
6C - 6
6C - 7
6C - 8
6C - 8
Service Precaution
REPAIRS.
Cautions During Work.................................

Removal......................................................
Reuse of QuickConnector.........................
Assembling Advice .....................................
Fuel Pump Relay...........................................
Fuel Tank ......................................................
Fuel Tank and Associated Parts.................
Removal......................................................
Installation...................................................
Fuel Gage Unit ..............................................
Fuel Filler Cap ...............................................
Inspection ...................................................
Special Tool ...................................................
6C - 8
6C - 8
6C - 9
6C - 9
6C - 10
6C - 10
6C - 10
6C - 10
6C - 11
6C - 11
6C - 11
6C - 11
6C - 12
6C - 12
6C - 12
6C - 13
6C - 13

and systems.
6C2
General Description
140RX019
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Fuel Filter Cap

Fuel Tank
Rollover Valve
Fuel Filter
Fuel Rail
EndOFCallout
(7)
(8)
(9)
(10)
(11)
Intake Manifold
Throttle Valve
Canister
Evapo Pipe

Any time the fuel system is being worked on,
Always keep a dry chemical (Class B) fire
Replace all pipes with the same pipe and fittings that
were removed.
Clean and inspect O" rings. Replace if required.
Always relieve the line pressure before servicing any
Do not attempt repairs on the fuel system until you
Adhere to all Notices and Cautions.
Control System. The purpose of the system is to
minimize the escape of fuel vapors to the atmosphere.
6C3
Fuel Metering
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.
corresponding to the flow of the air drawn into the
engine.
revolution. The PCM 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
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
6C4
Fuel Filter
Fuel Filter and Associated Parts
140RX018
Legend
(1) Fuel Hose
(2) Fuel Filter
(3) Fuel Filter Holder

(4) Fuel Hose
EndOFCallout
Removal
for loose connections or leakage. For the fuel
system diagnosis, see Section Driveability and
Emission".
2. Remove fuel filler cap.
4. Fuel filter fixing bolt.
Remove the fuel filter fixing bolt on fuel filter
holder(3).
Inspection
2. Replace the filter if it is clogged with dirt or
sediment.
3. Check the drain and if it is clogged with dust, clean it
out with air.
Installation
3. Connect fuel hoses on engine side and fuel tank
side.
Inspection
After installation, start engine and check for fuel leak
age.
6C5

wire(1) as shown and start the fuel pump to
measure delivery.
InTank Fuel Filter

The filter is located on the lower end of the fuel pickup
tube in the fuel tank. It prevents dirt from entering the
fuel pipe and also stops water unless the filter is
completely submerged in the water. It is a self cleaning
type, not requiring scheduled maintenance. Excess
water and sediment in the tank restricts fuel supply to
the engine, resulting in engine stop. In such a case, the
tank must be cleaned throughly.
Fuel Pump Flow Test

following checks.
2. With the engine running, check the fuel feed pipe
and hose from fuel tank to injector for evidence of
clogging.
140RW015

a jumper wire.
Delivery
Delivery
15 seconds
0.38 liters minimum

pressure test.
Pressure test
Fuel Control System".
6C6
Fuel Pump
140RX016
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Fuel Feed Port

Fuel Return Port
Fuel pump lock
(8)
(9)
(10)
(11)
(12)
(13)

Hose; Air Breather
Hose; Fuel Filler
Fuel Return Hose
Fuel Feed Hose
Fuel Tank Assembly
EndOFCallout
Removal
with a lifter.
4. Remove fuel tank assembly (13). Refer to Fuel

Tank Removal" in this section.

6. Remove fuel pump and sender (FPAS) assembly(4)
using 5884026020.
140RW068
NOTE:
After removing pump assembly (4), cover fuel tank to
prevent any dust entering.
Installation
1. Install FPAS assembly(4) using 5884026020.
Installation".
6C7
6C8

Precautions
Lighting of Fires Prohibited.
Keep flames away from your work area to prevent the
Disconnect the battery negative cable to prevent
When welding or conducting other heat-generating
spattering.

engine), hold the connector in one hand, and hold
the retainer tab with the other hand and pull out the

piping.
Removal
141RW019

tank.
140RX015
As some pressure may remain in the piping, cover

the connector with a cloth, etc. to prevent the
splashing of fuel in the first disconnection of the
piping.

141RW019

This work should be done by hands. Do not use any
tools. Should the pipe can hardly be removed from the
connector, use a lubricant (light oil) and/or push and pull
the connector longitudinally until the pipe is removed.
6C9
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud and dust from the pipe and make sure
If the retainer removed according to the removal step
clicks, try pulling it out to make sure that it is not
drawn and is securely locked.
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
clicks.
141RW021

Cover the connectors removed with a plastic bag,
etc. to prevent the entry of dust or rain water.
141RW018
Assembling Advice
141RX005

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.
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.
6C10
Fuel Pump Relay

General Description
provided. When the starter switch is turned to ON"
seconds.
When it is turned to START" position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPAS to feed fuel.
Fuel Tank
140RX017
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Fuel Feed Port

Fuel Return Port
Connector; Fuel Level Sender
Fuel Pump Lock
EndOFCallout
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Hose; Air Breather

Hose; Fuel Filler
Fuel Return Hose
Fuel Feed Hose
Band; Fuel Tank Asm Fixing
Fuel Tank Assembly
Removal
with a lifter.
leakage.
8. Let down the tank (16) and disconnect the wiring
connectors (5,6) and the emission hose at the
emission port on the fuel pump and sending
assembly (4).
(15) .
11. Remove fuel pump and sender assembly (4) using

5884026020.
12. Remove protectors (15) by removing the band fixing
bolts (13).
Installation
1. Install protectors (15) and tighten the band fixing
2. Install fuel pump and sender (4) using 58840
26020.
4. Lift up fuel tank assembly (16) and connect the
emission hose to the emission port and the wiring
connectors (5,6) on the fuel pump and sending
assembly (4).
tighten the four fixing bolts (14) to the specified
torque.
6. Connect fuel filler hose (10) and air breather hose
7. Connect fuel feed hose (12) and fuel return hose
Fuel Gage Unit

refer to Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender
assembly.
6C11
6C12
Fuel Filler Cap

General Description
In case any high vacuum happen in tank, the valve
works to adjust the pressure to prevent the tank from
being damaged.
060RW098
Legend
(1) Vacuum Valve
(2) Fuel Filler Cap
EndOFCallout
Inspection
CAUTION:
6C13

140RX014
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884026020
Remover; fuel pump lock
(For S/W)
SECTION
6D11
ENGINE
CONTENTS
Battery...........................................................
Diagnosis ....................................................
Battery Charging.........................................
6D1 - 1
6D1 - 2
6D1 - 2
6D1 - 2
6D1 - 3
Service Precaution
YOU ARE
IN
REPAIRS.
Jump Starting..............................................
Battery Removal .........................................
Battery Installation ......................................
6D1 - 3
6D1 - 4
6D1 - 4
6D1 - 5

and systems.
6D12
Battery
General Description
BLUE RING OR DOT NOT VISIBLE(4) Go to Step

3.

escape of small amounts of gas generated by the
battery.
The battery will refuse to accept an extensive
charge.
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self
discharge than a conventional type battery.
061RX001
Diagnosis
Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permit
electrolyte loss.
necessary.

a CORRECT FLUID LEVEL Charge the battery.
b BELOW LOWER LEVEL Replace battery.
2. Hydrometer Check
a BLUE RING OR DOT VISIBLE(5) Go to Step 4.
061RX001
6D13
Battery Charging
4. Voltage Check
a VOLTAGE IS 12.4V OR ABOVE Go to Step 5.
b VOLTAGE IS UNDER 12.4V Go to procedure
(2) below.
a VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
b VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
15V and charge for 10 15 hours. Then go to
Step 5.
c VOLTAGE IS BETWEEN 12V AND 16V
d VOLTAGE BELOW 12V Replace Battery.
5. Load Test
1. Connect a voltmeter and a battery load tester
across the battery terminals.
a VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE The battery
is good and should be returned to service.
b VOLTAGE IS LESS THAN MINIMUM LISTED
Replace battery.
MINIMUM
VOLTAGE
70
21
9.6
60
16
9.5
50
10
9.4
40
9.3
30
9.1
20
8.9
10
12
8.7
18
8.5

and by the temperature the battery has been exposed
to for the preceding few hours.

the battery:
procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
or ring, it may be necessary to jiggle or tilt the
battery.
5. The sealed battery used on this vehicle may be
either quick charged or slow charged in the same
manner as other batteries.
charge the battery.
Jump Starting
Battery
THE FOLLOWING:
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles particularly.
explode.
working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
6D14
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.
short circuit.


transmission, place the selector level in the PARK"
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the NEUTRAL"
position.
Turn OFF" the ignition.
Turn OFF" all lights and any other accessory
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 cause a ground connection, effectively
neutralizing the charging procedure.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
being charged.
Make sure that all unnecessary electrical
accessories have been turned OFF".
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.
Battery Removal
061RX002
Make sure that the rod is hooked on the body side.

Model
24600
Voltage (V)
12
600
118
Load Test (Amp)
300
BCI Group No.
24
6D15
SECTION
6D21
ENGINE
CONTENTS
Diagnosis .......................................................
Ignition Module..............................................
Removal .....................................................
Installation ..................................................
Spark Plug.....................................................
6D2 - 1
6D2 - 1
6D2 - 1
6D2 - 2
6D2 - 2
6D2 - 2
6D2 - 2
Removal......................................................
Installation...................................................
Crankshaft Angle Sensor ..............................
Removal......................................................
Installation...................................................
6D2 - 2
6D2 - 2
6D2 - 3
6D2 - 4
6D2 - 4
6D2 - 4
6D2 - 5
Service Precaution
General Description

YOU ARE
IN
REPAIRS.
Ignition is done by the Ignition Module that fires.

Since the cylinder on exhaust stroke requires less
energy to fire its spark plug, energy from the ignition
coils can be utilized to fire the mating cylinder on
compression stroke.
crank angle sensor which then sends information such
as firing order and starting timing of ignition coil to the
PCM.
speed,water temperature and Manifold Absolute
Pressure (MAP),the PCM controls the ignition timing.

and systems.
Diagnosis
6D22
Ignition Module
Removal
Installation

2. Remove ABS hydraulic unit assembly.
3. Remove master Vac and brake booster assembly.
4. Remove heater hoses from water rail.
5. Disconnect ignition coil cable from ignition module.
6. Remove connector from ignition module.
7. Remove ignition module assembly with bracket (1).
1. Install the ignition module assembly with bracket (1).

2. Connect ignition module connector and ignition
coil,then tighten bolt to the specified torque.
3. Connect ignition coil cable.
4. Install heater hoses.
5. Install master Vac and brake booster assembly.
6. Install ABS hydraulic unit assembly.
7. Bleed Air, brake system.
080RW001
080RW001
Spark Plug
Removal
Use spark plugs having low heat value (hot type plug)
Use spark plugs having high heat value (cold type

Check electrode and insulator for presence of
cracks,and replace if any.
Check electrode for wear,and replace if necessary.
Check gasket for damage,and replace if necessary.
Measure insulation resistance with an ohmmeter,and
replace if faulty.
Adjust spark plug gap to 0.7 mm (0.027 in) 0.8
(0.031 ).
Check fuel and electrical systems if spark plug is
extremely dirty.
Sooty Spark Plugs

Possible causes:
Too rich mixture
Presence of oil in combustion chamber
Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily
oxidized electrode or blistered insulator nose.
6D23
Possible causes:
Too lean mixture
Improper heat value

Measure insulation resistance using a 500 volt
megaohm meter.
Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 M
or more
011RS011
Installation
1. Spark plugs
Tighten spark plugs to the specified torque.
011RS010

Clean spark plugs with a spark plug cleaner.
Raise the ground electrode to an angle of 45 to 60
degrees. if electrode is wet,dry it before cleaning.
After spark plug is thoroughly cleaned,check insulator
for presence of cracks.
Clean threads and metal body with a wire brush.
File the electrode tip if electrode is extremely worn.
Bend the ground electrode to adjust the spark plug
gap.
6D24
Crankshaft Angle Sensor

Removal
3. Remove crankshaft angle sensor from cylinder
block.
015RW021
Installation
1. Install crankshaft angle sensor into the cylinder
block.
Before installation,apply small amount of engine oil
to the Oring.
2. Reconnect wiring connector to crankshaft angle
sensor.

Ignition System
Ignition Form
Spark Plug
Type
No. of Coils and Type
Coil Location
Torque
Electronic Spark Control

2 Solid State
Enginemounted
20 Nm (2.0 kgm/14 lb ft)
6D25
SECTION
6D31
ENGINE
CONTENTS
Starting System.............................................
Diagnosis .......................................................
Starter ...........................................................
Removal .....................................................
Installation ..................................................
Characteristic Test......................................
Charging System...........................................
6D3 - 1
6D3 - 2
6D3 - 2
6D3 - 2
6D3 - 3
6D3 - 3
6D3 - 3
6D3 - 4
6D3 - 5
6D3 - 6
6D3 - 7
Service Precaution
YOU ARE
IN
REPAIRS.

General OnVehicle Inspection .....................
Generator ......................................................
Removal......................................................
Inspection ...................................................
Installation...................................................
Disassembly ...............................................
Reassembly ................................................
6D3 - 7
6D3 - 7
6D3 - 9
6D3 - 9
6D3 - 9
6D3 - 10
6D3 - 10
6D3 - 12
6D3 - 14
6D3 - 15

and systems.
6D32
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.
Diagnosis
Condition
Possible cause
Correction
Charging failure
Battery Failure
Replace Battery

Starter failure
6D33
Starter
Removal
2. Remove harness connectors (1) and (2).
065RW024
3. Connect harness.
065RW022
3. Remove bolts from starter (1), (2).
065RW024
Installation
torque (1), (2).
6D34
Disassembled View
065RW023
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Bolt
Magnetic Switch
Gear Case
Piston
Piston Shaft
Center Bracket
Armature
EndOFCallout
(8)
(9)
(10)
(11)
(12)
Yoke Assembly
Brush and Brush Holder
Washer
Rear Cover
Through Bolt
6D35
Brush Holder


broken).
Armature
disconnected).
065RW015
Magnetic Switch
065RS015

grounded).
Check for continuity of shunt coil between terminals S

and M.
disconnected).
065RW016
065RS016
Brush
6D36

disconnected).
065RS025
Characteristic Test
065RW017
065RW018
Pinion
replace the pinion.
For easily confirming the characteristics, conduct the

noload test as follows:
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)
(2)
(3)
(4)
(5)
Volt Meter
Revolution Indicator
Battery
Ammeter
Switch
EndOFCallout
6D37
Charging System
General Description
The charging system is an IC integral regulator charging

system and its main components are connected as
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.
such as voltage adjustment. The rectifier connected to
the stator coil has eight diodes to transform AC voltage
into DC voltage.
generator.
The operating condition of charging system is indicated

by the charge warning lamp. The warning lamp comes
on when the starter switch is turned to ON" position.
The charging system operates normally if the lamp goes
off when the engine starts.
If the warning lamp shows abnormality or if
undercharged or overcharged battery condition is
suspected, perform diagnosis by checking the charging
system as follows:
1. Check visually the belt and wiring connector.
6D38
2. With the engine stopped, turn the stator switch to

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.
066RW021
Legend
(1) Regulator
(2) Indicator Lamp
EndOFCallout
(3) Generator Assembly
6D39
Generator
Removal
Inspection

3. Disconnect terminal B" wiring connector and
connector.
4. Remove generator bracket (1), (2) and remove
generator assembly.
Generator Power and Circuit Diagram
066RW020
Legend
065RW025
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Load resistor, set parallel to battery

Battery
Voltmeter
Ammeter
Ignition Lock
Charge Telltale
Generator
EndOFCallout
1. Disconnect battery.
2. Close off connecting cable from alternator terminal
B+".
3. Set ammeter (measuring range 100A) in
disconnected line.
4. Connect controllable load resistor to battery
terminal.
5. Set resistor in front of connection to 0"; connect first
to battery, then to resistor.
6. Connect tachometer.
7. Connect oscilloscope according to manufacturer's
instructions.
8. Connect battery.
9. Start engine and read off resulting current at various
engine speeds.
6D310
Installation
Generator Power
1. Adjust load resistor, if the required load currents are
not attained.
2. The shape of the voltage curves on oscilloscope
curve should be regular.
3. Test value: 5 to 7A.
4. If the required minimum current intensity is not
attained, or if the oscilloscope picture shows
variations, the alternator should be overhauled.
1. Install generator assembly and bring generator

assembly to the position to be installed.
2. Install generator bracket (1), (2) and tighten to the
specified torque.
Torque:
Long bolt: 35 Nm (3.6 kgm/26 lb ft)
Short bolt: 20 Nm (2.0 kgm/15 lb ft)
066RW018
Regulated Voltage Circuit Diagram
065RW025
3. Connect wiring harness connector.

4. Move drive belt tensioner to loose side using
Disassembly
1. Belt pulley nut.
066RW019
Legend
(1)
(2)
(3)
(4)
Battery
Ignition Lock
Charge Telltale
Resistor, for attainment of load current with the
battery set in series
(5) Voltmeter
(6) Ammeter
(7) Generator
EndOFCallout
066RW016

2. Spring ring, washer, belt pulley halves, spacing ring,
fan pinion, pulley spring.
3. Voltage regulator with brush holder.
6D311
7. Clawpole armature from drive bearing.

8. Lay suitable pipe piece (1) underneath.
066RW013
066RW014
4. Drive bearing with clawpole armature.

5. Mark housing halves.
6. 4 fastening bolts.
9. Bearing cover of drive bearing.

10. Ball bearing from drive bearing.
066RW017
066RW015
6D312
11. Ball bearing from armature shaft.
16. Spray sleeve (if present).

17. Carefully bend off diode plate.
18. Unsolder stator winding from diode plate.
066RW012
12. Nut from connecting pins B+" and D+".

13. Washers and insulating material.
14. Diode plate.
15. Remove together with stator winding from slip ring
bearing.
066RW010

Rotor Assembly
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500600
sandpaper.
066RW008
066RS014

2. Measure the slip ring diameter, and replace if it
exceeds the limit.
6D313
4. Check for continuity between slip ring and rotor

core.
066RS015

066RS017
Stator Coil
1. Measure resistance between respective phases.
2. Measure insulation resistance between stator coil
and core with a megaohmmeter.
If less than standard, replace the coil.
066RS016
066RS018
6D314
Brush
Clamp pulley to the vise, and tighten nut to the

specified torque.

Standard: 5 mm (0.20in)
066RS010
066RW009
Rectifier Assembly
Check for continuity across 1" and 2" in the 100W
range of multimeter.
066RW011
Change polarity, and make sure that there is continuity

in one direction, and not in the reverse direction. In
case of continuity in both directions, replace the rectifier
assembly.
Reassembly

Battery voltage
12
Rated output
100
Maximum speed
Clockwise
rpm
18000
6D315
SECTION
6E11
FRONTERA
ENGINE
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .
TIGHTENING SPECIFICATIONS . . . . . . . .
DIAGRAMS AND SCHEMATICS . . . . . . . . . .
ECM WIRING DIAGRAM (10 of 10) . . . . . .
ECM PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . .
Row A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row B . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row C . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row D . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row E . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row F . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR . . . . . . . . . . . . . . . .
Fuse And Relay Panel (Underhood
Electrical Center) . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS StrategyBased Diagnostics
StrategyBased Diagnostics . . . . . . . . . . . .
DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . .
No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . .
No Trouble Found . . . . . . . . . . . . . . . . . . . . .
GENERAL SERVICE INFORMATION . . . . . .
NonOEM Parts . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Knowledge Of Tools Required . . . . .
SERIAL DATA COMMUNICATIONS . . . . . . .
Class II Serial Data Communications . . . .
6E16
6E16
6E17
6E17
6E18
6E19
6E110
6E111
6E112
6E113
6E114
6E115
6E116
6E117
6E117
6E118
6E119
6E120
6E121
6E122
6E123
6E126
6E126
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E127
6E128
6E128
6E128
6E128
6E128
6E128
6E128
ONBOARD DIAGNOSTIC (OBD) . . . . . . . . .

OnBoard Diagnostic Tests . . . . . . . . . . . . .
Common OBD Terms . . . . . . . . . . . . . . . . . .
DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . .
Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . .
Getting Started . . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure (Example) . . . . . . . . .
DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Test . . . . . . . . . . . . . . . . . . . . . .
EGR Control Test . . . . . . . . . . . . . . . . . . . . . .
Plotting Snapshot Graph . . . . . . . . . . . . . . .
Flow Chart for Snapshot Replay (Plotting
Graph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY SYSTEMBASED DIAGNOSTICS
Primary SystemBased Diagnostics . . . . .
Fuel Control Heated Oxygen Sensors . . .
HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . .
ONBOARD DIAGNOSTIC (OBD) SYSTEM
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
A/C CLUTCH CONTROL CIRCUIT
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
VISUAL CHECK OF THE EVAPORATIVE
EMISSION CANISTER . . . . . . . . . . . . . . . . . .
6E128
6E128
6E129
6E129
6E130
6E131
6E132
6E132
6E134
6E134
6E135
6E136
6E136
6E137
6E137
6E138
6E140
6E140
6E142
6E143
6E143
6E144
6E145
6E146
6E147
6E147
6E147
6E147
6E148
6E148
6E148
6E148
6E150
6E150
6E150
6E151
6E153
6E153
6E12
IDLE AIR CONTROL (IAC) VALVE . . . . . . . .

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
MULTIPLE ECM INFORMATION SENSOR
DTCs SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE Tech 2 DATA DEFINITIONS AND
RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPICAL SCAN DATA VALUES . . . . . . . . . . .
Test Conditions . . . . . . . . . . . . . . . . . . . . . . . .
2.2L L4 Engine . . . . . . . . . . . . . . . . . . . . . . .
NO MALFUNCTION INDICATOR LAMP
(MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION INDICATOR LAMP (MIL) ON
STEADY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE CRANKS BUT WILL NOT RUN . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM ELECTRICAL TEST . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM DIAGNOSIS . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT CHECK . . . . . . . . . . . . . . . . . . . . . . .
ECM DIAGNOSTIC TROUBLE CODES . . . .
ECM Diagnostic Trouble Codes . . . . . . . . .
6E153
6E153
6E154
6E154
6E154
6E157
6E157
6E159
6E159
6E159
6E162
6E162
6E162
6E162
6E165
6E165
6E165
6E165
6E167
6E169
6E169
6E173
6E173
6E173
6E173
6E174
6E174
6E176
6E176
6E176
6E177
6E177
6E181
6E181
6E181
6E183
6E183
6E183
6E185
6E185
6E185
6E187
6E187

CIRCUIT/RANGE PERFORMANCE
PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E189
CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . . 6E198
SENSOR CIRCUIT HIGH INPUT . . . . . . . . . 6E1106
CIRCUIT RANGE/PERFORMANCE
PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1109
CIRCUITLOW INPUT . . . . . . . . . . . . . . . . . . . 6E1112
O2 SENSOR CIRCUIT LOW VOLTAGE
(BANK 1 SENSOR 1) . . . . . . . . . . . . . . . . . . . 6E1118
O2 SENSOR CIRCUIT HIGH VOLTAGE
(BANK 1 SENSOR 1) . . . . . . . . . . . . . . . . . . . 6E1121
O2 SENSOR CIRCUIT NO ACTIVITY
DETECTED (BANK 1 SENSOR 1) . . . . . . . . 6E1124
O2 SENSOR HEATER CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1127
SYSTEM TOO LEAN (BANK 1) . . . . . . . . . . 6E1130
SYSTEM TOO RICH (BANK 1) . . . . . . . . . . 6E1134
CYLINDER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1138
CYLINDER 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1141
CYLINDER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1144

CYLINDER 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1147
KNOCK SENSOR (KS) CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1150
KNOCK SENSOR (KS) CIRCUIT LOW
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1153
IGNITION COIL A PRIMARY/SECONDARY
IGNITION COIL B PRIMARY/SECONDARY
FLOW INSUFFICIENT DETECTED . . . . . . . 6E1170
EXCESSIVE FLOW DETECTED . . . . . . . . . 6E1173
SENSOR CIRCUIT LOW . . . . . . . . . . . . . . . . 6E1179
SENSOR CIRCUIT HIGH . . . . . . . . . . . . . . . . 6E1182
CONTROL SYSTEM PURGE CONTROL
VALVE CIRCUIT MALFUNCTION . . . . . . . . . 6E1185
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1187
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1190
VEHICLE SPEED SENSOR (VSS) CIRCUIT
LOW INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1193
IDLE CONTROL SYSTEM RPM LOWER
THAN EXPECTED . . . . . . . . . . . . . . . . . . . . . . 6E1195
6E13

IDLE CONTROL SYSTEM RPM HIGHER
THAN EXPECTED . . . . . . . . . . . . . . . . . . . . . 6E1198
SYSTEM VOLTAGE HIGH . . . . . . . . . . . . . . . 6E1201
INTERNAL CONTROL MODULE MEMORY
CHECK SUM ERROR . . . . . . . . . . . . . . . . . . . 6E1203
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1204
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1206
CIRCUIT INTERMITTENT HIGH VOLTAGE 6E1208
CIRCUIT INTERMITTENT LOW VOLTAGE 6E1211
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1213
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1215
CIRCUIT INTERMITTENT HIGH
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1218
CIRCUIT INTERMITTENT LOW
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1220
FUEL SYSTEM LEAN DURING
ACCELERATION . . . . . . . . . . . . . . . . . . . . . . . 6E1222
DIAGNOSTIC TROUBLE CODE (DTC) 1404
CLOSED VALVE . . . . . . . . . . . . . . . . . . . . . . . . 6E1225
ECM UNEXPECTED RESET . . . . . . . . . . . . . 6E1228
PCM A/D CONVERSION MALFUNCTION . 6E1230
5 VOLT REFERENCE VOLTAGE CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 6E1232
ODM OUTPUT CIRCUIT FAULT . . . . . . . . . . 6E1234
SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . 6E1237
DEFAULT MATRIX TABLE . . . . . . . . . . . . . . . 6E1260
Camshaft Position (CMP) Sensor . . . . . . . . . . 6E1263
Crankshaft Position (CKP) Sensor . . . . . . . . . 6E1264
6E14
EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor .
Heated Oxygen Sensor (HO2S) . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor . . . . . . .
Manifold Absolute Pressure (MAP) Sensor .
Malfunction Indicator Lamp (MIL) . . . . . . . . . .
Engine Control Module (ECM) . . . . . . . . . . . .
Throttle Position (TP) Sensor . . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control (IAC) Valve . . . . . . . . . . . . . . .
Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . .
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . .
FUEL METERING SYSTEM Accelerator
Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal Replacement . . . . . . . . . . .
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator . . . . . . . . . . . . . . . . .
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle body (TB) . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC IGNITION SYSTEM Ignition
Control Module (ICM) . . . . . . . . . . . . . . . . . . .
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMISSIONS Catalytic Converter . . . . . . . . . .
Ignition Timing Adjustment . . . . . . . . . . . . . . .
EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . .
Linear Exhaust Gas
ECM Connectors And Terminals . . . . . . . . . . .
Connectors And Terminals . . . . . . . . . . . . . . . .
Wire Harness Repair: Twisted Shielded
Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . .
WeatherPack Connector . . . . . . . . . . . . . . . .
ComPack III . . . . . . . . . . . . . . . . . . . . . . . . . . .
MetriPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION ECM AND
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58X Reference ECM Input . . . . . . . . . . . . . .
6E1266
6E1266
6E1267
6E1268
6E1269
6E1269
6E1270
6E1272
6E1273
6E1274
6E1275
6E1277
6E1278
6E1279
6E1280
6E1282
6E1282
6E1282
6E1282
6E1284
6E1285
6E1287
6E1289
6E1289
6E1291
6E1292
6E1294
6E1295
6E1295
6E1297
6E1297
6E1297
6E1297
6E1298
6E1298
6E1298
6E1298
6E1299
6E1299
6E1300
6E1300
6E1301
6E1302
6E1303
6E1303
6E1304
6E1304
6E1304
6E1304

Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Control Heated Oxygen Sensor
(Pre Catalyst) . . . . . . . . . . . . . . . . . . . . . . . .
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECM Function . . . . . . . . . . . . . . . . . . . . . . . . .
ECM Components . . . . . . . . . . . . . . . . . . . . .
ECM Voltage Description . . . . . . . . . . . . . . .
ECM Inputs/Outputs . . . . . . . . . . . . . . . . . . .
ECM Service Precautions . . . . . . . . . . . . . .
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Induction System . . . . . . . . . . . . . . . . . .
METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CMP Signal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Flood Mode . . . . . . . . . . . . . . . . . . . . .
Deceleration Fuel Cutoff (DFCO) Mode . . .
Engine Speed/Vehicle Speed/ Fuel
Disable Mode . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION ELECTRONIC
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . .
Camshaft Position (CMP) Sensor . . . . . . .
Crankshaft Position (CKP) Sensor . . . . . .
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . .
6E1304
6E1305
6E1305
6E1305
6E1306
6E1306
6E1306
6E1307
6E1307
6E1307
6E1307
6E1307
6E1308
6E1308
6E1308
6E1308
6E1308
6E1309
6E1309
6E1309
6E1309
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1310
6E1311
6E1311
6E1311
6E1311
6E1312
6E1312
6E1312
6E1312
6E1313
6E1313
6E1313
6E1313
6E1313

Ignition Control Module (ICM) . . . . . . . . . . .
Ignition Control ECM Output . . . . . . . . . . . .
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C CLUTCH DIAGNOSIS . . . . . . . . . . . . . . .
GENERAL DESCRIPTION EVAPORATIVE
EMISSION (EVAP) SYSTEM . . . . . . . . . . . . .
GENERAL DESCRIPTION EXHAUST
GAS RECIRCULATION (EGR) SYSTEM . .
EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . .
Linear EGR Valve . . . . . . . . . . . . . . . . . . . . .
Of Incorrect Operation . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION POSITIVE
CRANKCASE VENTILATION (PCV)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . .
6E1313
6E1314
6E1314
6E1314
6E1315
6E1316
6E1316
6E1316
6E1316
6E1316
6E1316
6E1317
6E1317
6E1317
6E1317
6E1317
6E1317
6E1317
6E1318
6E1318
6E1319
6E15
6E16
SPECIFICATIONS
TIGHTENING SPECIFICATIONS
Application
Nm
Lb Ft
kgm
Lb In
0.9
78
EGR Nut
14
1.4
130
30
3.1
22
Fuel Drain Plug
20
2.0
14
6.5
0.6
60
Fuel Rail Bolts
0.7
75
36
3.7
27
42
4.3
32
Spark Plugs
25
2.5
18
13
1.3
120
VSS Retaining Bolt
13
1.3
120
6E17
DIAGRAMS AND SCHEMATICS

D06RX097
6E18
060RX091
6E19
D06RX099
6E110
060RX095
6E111
D06RX119
6E112
D06RX102
6E113
D06RX103
6E114
D06RX104
6E115
D06RX105
6E116
D06RX106
6E117
ECM PINOUTS
ECM Pinout Table, 32Pin Red Connector Row A
TS23344
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
A1
RED
5.0 V
5.0 V
Appropriate Sensor
A2
Knock Sensor Input
YEL
3.0 V (MAX)
A3
Not Used
A4
Battery Feed
RED/WHT
B+
B+
A5

High
BLU
B+/0.8 V
B+/0.8 V

Operation, IAC
A6
IAC A Low
BLU/WHT
B+/0.8 V
B+/0.8 V

Operation, IAC
A7
IAC B Low
BLU/BLK
B+/0.8 V
B+/0.8 V

Operation, IAC
A8
IAC B High
BLU/RED
B+/0.8 V
B+/0.8 V

Operation, IAC
A9
Not Used
A10
Not Used
A11
Not Used
A12
Not Used
A13
Lamp (MIL) Control
WHT/GRN
0.40.9 V
B+
Chassis Electrical
A14
Rear Defogger Relay
RED/WHT
B+
B+
Classis Electrical
A15
EVAP Canister Vent

Solenoid Control
RED/BLU
B+
05 V
(varies)
A16
Not Used

Chassis Electrical

Control System
6E118
ECM Pinout Table, 32Pin Red Connector Row B
TS23344
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
BLU/ORG
5.0 V
5.0 V
Refer To
B1
Appropriate Sensor
B2
Not Used
B3
Not Used
B4
Not Used
B5
Not Used
B6
Not Used
B7

(EGR) Position Feedback
YEL/RED
0.6 V
0.6 V

Control
B8

(IAT) Sensor
YEL/GRN
~3V
(0V = 151C)
~3 V
(5V = 40C)

Operation, IAT
B9
A/C Pressure Sensor

Signal
GRN
~1 V
~1 V
B10
Not Used
B11

(PSP) Switch Input
GRN/YEL
B+
B+

Operation, PSP
B12
Illumination Switch
GRN/YEL
B+
B+
Chassis Electrical
B13
Class 2 Data
ORN/BLK
0.0 V
0.0 V
B14
A/C Compressor Clutch

Relay Control Compressor
GRN/RED
0
(A/C OFF)
B+
(A/C ON)
B15
Not Used
B16
Not Used
A/C System

Data
Operation
6E119
ECM Pinout Table, 32Pin White Connector Row C
TS23345
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
C1
GRN/RED
B+ Varies
B+ Varies
C2
Not Used
C3
Not Used
C4

(ICM) Input
RED
0.0 V
0.1 V

C5

Sensor Low
BLUE
4.98 V
0.76 V
(at idle)

Position Sensor
C6
Crankshaft Position
Sensor (CKP) High
GRN
5V
5V

Position Sensor
C7
ECM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C8
ECM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C9
ECM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C10
Tachometer Signal
BLK/RED

Operation
C11
Fuel Gauge PWM Output
YEL/RED
Varies with
Fuel Level
Varies with
Fuel Level

Operation
C12
High Fan Relay Control
RED/YEL
10.5 V
B+
Chassis Electrical
C13
Low Fan Relay Control
RED/BLU
Chassis Electrical
C14
Bank 1 HO2S 1 High
WHT
0.3 V
0.1 to 1.1 V

C15
Bank 1 HO2S 1 Low
RED
0.0 V
0.1 V

C16
Not Used

6E120
ECM Pinout Table, 32Pin White Connector Row D
TS23345
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
D1
GRN/ORN
B+
B+

D2
Not Used
D3
GRN/WHT
B+
B+

D4
Not Used
D5

(ICM) Input
RED/BLK

Operation
D6
Not Used
D7
VSS Input
BLU/BLK
Chassis Electrical
D8
Sensor Ground 5 V
Reference A Return
GRN
0.0 V
0.0 V
Appropriate Sensor
D9
Sensor Ground 5 V
Reference B Return
BLU/YEL
0.0 V
0.0 V
Appropriate Sensor
D10
Not Used
D11

Input
BLU
5.0 V
4.6 V
D12
Not Used
D13
Not Used
D14
Not Used
D15
Not Used
D16
Not Used

Operation, Camshaft
Position Sensor
6E121
ECM Pinout Table, 32Pin White Connector Row E
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
RED/GRN
0.0V
B+
Chassis Electrical
E1
Not Used
E2
Fan Control
E3
Not Used
E4
Not Used
E5
Ignition Feed
BLK/YEL
B+
B+

Operation
E6

(EGR) Valve Low
YEL
B+ Varies
B+ Varies

E7
Not Used
E8

Sensor Input
BLU
0.25 V
(0% = 0.25 V)
0.25 V
(at idle)
(100% =
4.75 V)

Sensor
E9
Engine Coolant
Temperature (ECT)
Sensor Input
BLU/RED
2.3 V
(O V =
151C)
2.1 V
(5 V = 40C)

E10
Not Used
E11
Not Used
E12
YEL/GRN
B+
B+
Chassis Electrical
E13

Control
PNK/WHT
0.0 V
B+
OnVehicle Service, Fuel

Pump Relay
E14
Not Used
E15
A/C Request (Thermo

Relay)
GRN/BLK
0.0 V
0.0 V
E16
Ignition Feed
RED/BLU
B+
B+

Operation
6E122
ECM Pinout Table, 32Pin White Connector Row F
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
F1
Not Used
F2
Not Used
F3
Not Used
F4
Not Used
F5
Not Used
F6
Not Used
F7
Not Used
F8
Manifold Absolute
Pressure (MAP) Sensor
Input
GRY
~4.7 V
(0 V = 10kPa)
~1.1 V
(5 V =
104kPa)
F9
Not Used
F10
Not Used
F11
Not Used
F12
DLC (Digital Input)
Class 2 Serial Data
F13
Injector C Cylinder #4
GRN
B+
B+

F14
Not Used
F15
Not Used
F16
Ignition Feed
RED/BLU
B+
B+

Operation

Pressure
6E123
COMPONENT LOCATOR
755RX030
6E124

Number
Name
Location
Rear of engine, near ignition coils
On the left rear of the engine at the bulkhead
Heated Oxygen Sensor (HO2S), Bank 1,

Sensor 1
On the exhaust pipe, left side of engine,

immediately behind the exhaust manifold
Air Cleaner
On the intake air duct near the air cleaner
Inside the front cover assembly
Positive Crankcase Ventilation (PCV) Port
On the right front corner of the valve cover
On the forward end of the fuel rail, to the right of

the PVC port
Throttle Body
Between the intake air duct and the intake

manifold
10
Fuse/Relay Box
11
On the front of the throttle body
12
On the rear of the throttle body
13
Mounted on a heat sink on the lower right side of

the engine block, above the starter motor
14
Bolted to the front edge of the intake manifold,

under the fuel rail
15
High Fan Relay
In the relay box
16
Low Fan Relay
In the relay box
6E125
010RX001
028RX001
6E126

Name
Location
Fuel Pump Assembly
EVAP Canister
EVAP Canister Purge Valve Solenoid
Protrudes from the right side of the transmission housing, near the
output shaft
Lower left hand front of engine, behind power steering pump bracket
Fuse And Relay Panel (Underhood Electrical Center)

Underhood (U/H) Fuse and Relay Panel
060RX096
DIAGNOSIS StrategyBased
Diagnostics
StrategyBased Diagnostics
The strategybased diagnostic is a uniform approach to
check(s).
system. This will lead the technician in an organized
approach to diagnostics.
DTC Stored
effective repair.
No DTC
No Matching Symptom
operation.
Intermittents
following steps:
1. Observe history DTCs, DTC modes, and
freezeframe data.
by the customer.
6E127

Most Scan Tools, such as the Tech 2, have
datacapturing capabilities that can assist in detecting
intermittents.
No Trouble Found
1. Reexamine the complaint.
isolated, a reevaluation is necessary. The complaint
should be reverified and could be intermittent as
Frame data.

diagnosed (Freeze Fame data will only be stored for
GENERAL SERVICE INFORMATION

NonOEM Parts
All of the OBD diagnostics have been calibrated to run
with OEM parts. Something as simple as a
highperformance exhaust system that affects exhaust
6E128

and antitheft devices, may radiate EMI into the control
lamp).
Environment
If the ignition system is rainsoaked, it can temporarily
lamp).

schematic.
replaced, it can be ordered from Isuzu Dealer ship.
Maintenance Schedule

Inspection
Perform a careful visual and physical engine
disconnection, and Droper routing.
components.
manifolds or pipes.
Basic Knowledge Of Tools Required

A basic understanding of hand tools is necessary to

effectively use this section of the Service Manual.
SERIAL DATA COMMUNICATIONS

system. This vehicle utilizes the Class II communication
system. Each bit of information can have one of two
lengths: long or short. This allows vehicle wiring to be
reduced by transmitting and receiving multiple signals
over a single wire. The messages carried on Class II data
streams are also prioritized. If two messages attempt to
establish communications on the data line at the same
time, only the message with higher priority will continue.
The device with the lower priority message must wait. The
most significant result of this regulation is that it provides
Tech 2 manufacturers with the capability to access data
from any make or model vehicle that is sold.
same, with some exceptions. Some Scan Tools will only
ONBOARD DIAGNOSTIC (OBD)

OnBoard Diagnostic Tests
a pass or fail reported to the diagnostic executive. When a
diagnostic test reports a pass result, the diagnostic
ignition cycle.
ignition cycle.
currently active.
ignition cycle.
active.


Input Components:
outofrange values. This includes rationality checking.
signal from a sensor does not seem reasonable, i.e.
Throttle Position (TP) sensor that indicates high throttle
position at low engine loads or MAP voltage). Input
following sensors:
D Crankshaft Position (CKP) sensor
D Throttle Position (TP) sensor
D Engine Coolant Temperature (ECT) sensor
D Camshaft Position (CMP) sensor
steady state temperature to enable Closed Loop fuel
control.
Output Components:
control module commands. Components where
circuit continuity and outofrange values if applicable.
limited to the following circuit:
D EVAP Canister Purge Valve Solenoid
D A/C relays
D Cooling fan relay(s)
D VSS output
D MIL control
Refer to ECM and Sensors in General Descriptions.
pressure.
This is any onboard test run by the Diagnostic
WarmUp Cycle
A warmup cycle means that engine at temperature must
6E129
Freeze Frame
information at the moment an emissionsrelated fault is
Failure Records
Failure Records data is an enhancement of the OBD
Freeze Frame feature. Failure Records store the same
that information for any fault which is stored in onboard
emissionrelated faults that command the MIL ON.
Common OBD Terms

Diagnostic
onboard test run by the vehicles Diagnostic
D Oxygen sensors
D EGR
Enable Criteria
D engine speed
D vehicle speed
D ECT
D MAP
D IAT
D TP
D A/C ON
6E130
Trip
Technically, a trip is a key onrunkey off cycle in which all
definition of trip varies as well. Some diagnostics are run
the vehicle is at idle; some diagnostics function with the
TCC disabled. Some run only immediately following a
cold engine startup.
A trip then, is defined as a key onrunkey off cycle in

follows:
D Commanding the MIL (Check Engine lamp) ON and
OFF
recorded
D Nonemission related Service Lamp (future)
The Diagnostic Executive records DTCs and turns ON
the MIL when emissionrelated faults occur. It can also
turn OFF the MIL if the conditions cease which caused the
DTC to set.
present.
There is a continuous selfdiagnosis on certain control

functions. This diagnostic capability is complimented by
illuminated.
Basically, the MIL is turned ON when the ECM detects a
The MIL will be turned ON if an emissionsrelated
will stay ON until the system or component passes the
same test, for three consecutive trips, with no
emissionsrelated faults.
When the MIL is ON, the Diagnostic Executive will turn
OFF the MIL after three (3) consecutive trips that a test
Although the MIL has been turned OFF, the DTC will
remain in the ECM memory (both Freeze Frame and
Failure Records) until forty(40) warmup cycles after no
faults have been completed.
If the MIL was set by either a fuel trim or misfirerelated
test failed.
was stored at the time the last test failed.
warming up) as those stored at the time the last test
failed.
The MIL (Check Engine lamp) is on the instrument panel
and has the following functions:
with the key ON and the engine not running. When the
engine is started, the MIL will turn OFF.
OnBoard Diagnostic (OBD) System Check must be
given in OnBoard Diagnostic (OBD) System Check.
DTC Types
D Type A
D Emissions related
fail
test fails
D Type B
D Emissions related
test fails
DTCs)
test fails
D Type D. (Type D nonemissions related are not
utilized on certain vehicle applications).
D Does not request illumination of any lamp
test fails
6E131
IMPORTANT: Only four Fail Records can be stored.

Each Fail Record is for a different DTC. It is possible that
there will not be Fail Records for every DTC if multiple
DTCs are set.
Records
D Engine Speed
D Engine Load
D Vehicle Speed
D TP
D MAP/BARO
D Loop Status
malfunction.
The provision for communicating with the control module
is the Data Link Connector (DLC). It is located at the lower
left of the instrument panel. The DLC is used to connect to
the Tech 2 Scan tool. Some common uses of the Tech 2
are listed below:
D Identifying stored Diagnostic Trouble Codes (DTCs)
D Clearing DTCs
D Performing output control tests
D Reading serial data
6E132

power.
fuse, pigtail at battery ECM connectors etc.
onboard memory data, such as preset radio tuning).
TS24064

for vehicles with OBD II system diagnostics. Following a
requested).
2. Clear DTC(s).

A Tech 2 Scan Tool
use a diagnostic Scan tool. When reading DTC(s), follow
count the warmup cycles with no further faults
ECM memory.
diagnostic Scan tool clear DTCs or clear information
function. When clearing DTCs follow instructions
6E133
Tech 2
recommended to use the Tech 2 scan tool. Please refer to
the Tech 2 user guide.
901RW180
Legend
(1) PCMCIA Card
(2) R232 Loop Back Connector

(4) DLC Cable
(5) Tech 2
6E134
Tech 2 Features
snapshot.

display.
060RW009
Getting Started
the Tech 2 (5).
(4).
DLC.
810RW317

6E135
Operating Procedure (Example)

tester with the Isuzu system PCMCIA card. Follow the
060RX058
060RX060
6E136
Menu
060RW223
060RW224
DTC Modes


service procedures.
060RW229

appears:
D DTC Info
D Freeze Frame
D Clear Info
060RW221
DTC Status
Fail This Ignition

History
ECMs history memory. It will display all type A and B
warm-up cycles.
Last Test Failed
last time the test run. The last test may have run during a
unknown.
6E137
060RW228
Miscellaneous Test
normality of electric circuits.
060RX043
Lamps Test
its working.
Test Procedure:
Menu.
060RX044
6E138
060RX019

D F1; Up Shift Lamp = Not Used
060RX046
D F2; Low Fuel Lamp = Not Used
Relays Test
This test is conducted to check Fuel Pump Relay, A/C
Clutch Low Fan and High Fan for prepor operation.
Test Procedure:
Menu.
060RX047
060RW228

6E139
15. Select F2: Low Fan Relay.
060RX022
7. Control Fuel Pump Relay and check a data list.

8. If the data list chenges, the Fuel Pump Relay is
normal.
060RX048

17. Control Low Fan Relay and check a data list.
18. If the data list changes, the Low Fan Relay is normal.
20. Select F3: High Fan Relay.
060RX049
060RX023

13. Control A/C Clutch Relay and check a data list.
normal.

22. Control High Fan Relay and check a data list.
If the data list changes, the High Fan Relay is normal.
6E140

EVAP Test
Test Procedure:
Menu.
060RX025
060RW228
060RX026
7. Control EVAP Purge Solenoid and check a data list.

8. If the data list changes, the purge Solenoid is normal.
Ignition SW is On.
D F1; Vent Solenoid = Not Used

060RX050
This test is conducted check to IAC system for proper

operation.
Test Procedure:

Menu.
6E141
060RX052
060RW228

Test.

7. Control IAC system and check a data list.
D F0: IAC Control
060RX051
060RX015

6E142
060RW2311
060RX053
Fuel System Test

operation.
Test Procedure:
Menu.
060RX028
060RW228

6. Push Reset of soft key.
6E143

Test.
060RX029
D F1; Fuel Gauge Level = Not Used
060RX054
EGR Control Test

operation.
Test Procedure:
Menu.
060RX017
6. If the change, the EGR Control is normal.
060RW228

Test Procedure:
6E144

Menu.

key.
060RW228

Test.
060RW2301

normal.
If engine speed does not change, the injector electric

060RX055
060RX037

snapshot data as needed. There fore, accurate diagnosis
6E145
060RX085
6E146
060RX040
PRIMARY SYSTEMBASED
DIAGNOSTICS
Primary SystemBased Diagnostics
There are primary systembased diagnostics which
emissions. The primary systembased diagnostics are
function:
The fuel control heated oxygen sensor (HO2S 1) is
D Slow response
approx. 450 mV)
D Signal fixed high
D Signal fixed low
The catalyst monitor heated oxygen sensor (HO2S 2) is
D Heater performance (time to activity on cold start).
D Signal fixed low during steady state conditions or
power enrichment (hard acceleration when a rich
mixture should be indicated).
D Signal fixed high during steady state conditions or
deceleration mode (deceleration when a lean mixture
should be indicated).
D Inactive sensor (output steady at approx. 438 mV).
Refer to OnVehicle Service, Heated Oxygen Sensors.
6E147

sensors while in Closed Loop to adjust fuel injector
pulse width. While in Closed Loop, the ECM can adjust
fuel delivery to maintain an air/fuel ratio which allows the
best combination of emission control and driveability. The
fuel control heated oxygen sensors are also used to
HO2S Heater
of time required for Closed Loop fuel control to begin
time required for fuel control sensor (HO2S 1) to become
active. Oxygen sensor heaters are required by the
catalyst monitor sensor (HO2S 2) to maintain a
sufficiently high temperature which allows accurate
exhaust oxygen content readings further away from the
engine.
6E148
ONBOARD DIAGNOSTIC (OBD) SYSTEM CHECK
D06RX108
Circuit Description
Test Description
The onboard diagnostic system check is the starting

check of the ECM and engine grounds for cleanliness and
tightness.
The onboard diagnostic system check is an organized

Diagnostic Chart:
isolate the malfunction in the MIL circuit.
ECM is able to transmit serial data.
3. This test ensures that the ECM is capable of
controlling the MIL and the MIL driver circuit is not
shorted to ground.
the problem.
Diagnostic Aids
harness. Inspect the ECM harness and connectors for
damaged terminals, poor terminaltowire connection,
6E149
OnBoard Diagnostic (OBD) System Check

Step
Action
1.
2.
3.
4.
Go to Step 8
Go to Step 4
Go to MIL
(Check
Engine
Lamp) On
Steady
Go to Step 5
Go to Cranks
But Will Not
Run
Go to Step 6
Go to Step 7
Go to
Multiple
ECM
Information
Sensor DTCs
Set
Go to
applicable
DTC table
Go to Typial
Scan Data
Value
Go to
indicated
Component
System
Checks
Go to Step 2
Go to Step 9
Go to Step 2
Go to Step 10
Verify repair

and the DLC ground circuits for an open.
4. If a problem found, repair as necessary.
1. Attempt to reprogram the ECM. Refer to Engine
Control Module (ECM) in OnVehicle Service.
2. Attempt to display ECM data with the Tech 2.
Does the Tech 2 display ECM engine data?
10
Go to Step 3
Compare ECM data values displayed on the Tech 2 to


9

P0113, P0118, P0122, P0123.

values?
8
Go to No MIL

Go to Step 2


dash lamp control and command the MIL OFF.
2. Observe the MIL.
No
Ignition OFF.
Install a Tech 2.
Ignition ON.
Attempt to display ECM engine data with the Tech 2.
Does the Tech 2 display ECM data?

3
Yes

Check Engine lamp).
Is the MIL (Check Engine lamp) ON?
Value(s)
Replace the ECM.

6E150
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS
D06RX107
Circuit Description
the system has a sufficient refrigerent charge, a 12volt
signal is supplied to the A/C request input of the engine
control module (ECM). The A/C request signal may be
temporarily cancelled during system operation by the
electronic thermostat in the evaporator case. The
electronic thermostat may intermittently remove the
control circuit ground for the A/C thermostat relay to
prevent the evaporator from forming ice. When the A/C
request signal is received by the ECM, the ECM supplies
a ground from the compressor clutch relay if the engine
operating conditions are within acceptable ranges. With
the A/C compressor relay energized, battery voltage is
supplied to the compressor clutch coil.
The ECM will enable the compressor clutch to engage

than 125C (257F)
(41F).
pressure condition position.
Diagnostic Aids
conditions:
D Poor connection at the ECM Inspect harness
connections for backedout terminals, improper

damage; shorts to ground, shorts to battery voltage,
observe the A/C clutch while moving connnectors and
wiring harnesses related to the A/C. A sudden clutch
malfunction will indicate the source of the intermittent.
6E151

ability to read the A/C request input to the ECM. The Tech
2 can display when the ECM has commended the A/C
clutch ON. The Tech 2 should have the ability to override
the A/C request signal and energize the A/C compressor
relay.


Step
Action
Go to Step 2
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 5
Go to Step 4
Verify repair
Verify repair
Go to Step 6
1. Ignition OFF.
2. Remove the A/C Compressor Relay from the
Underhood Electrical Center.
on the Fused pins of the A/C Compressor Clutch
Relat connector.
Check the suspect circuit(s) between the A/C
Compressor Clutch Relay connector and the Fuse for
the following conditions:
D A short to ground
D An open circuit
No
Go to OBD
System
Check

P1546.

4
Yes

performed?

Passed?
3
Value(s)
1. Ignition OFF.
2. Disconnect the Engine Controlm Module (ECM)
3. Check the A/C Compressor Clutch Relay control
circuit between the ECM and Underhood Electrical
Center for the following conditions:
D A short to ground
D An open circuit
6E152

Step
Action
Go to Step 9
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Replace the A/C Compressor Clutch Relay.

No
1. Ignition OFF.
2. Check the A/C Compressor Clutch circuit between
the A/C Compressor Clutch Relay and A/C
Compressor Clutch for the following conditions:
D A short to ground
D An open circuit
Yes
1. Reinstall the A/C Compressor Clutch Relay.

2. Using a fused jumper, ground the A/C Compressor
Clutch Relay control circuit at the ECM connector.
Does the A/C Compressor turn ON?
Value(s)
Replace the ECM.

Verify repair.

DIAGNOSIS
to determine if the failure is in the ignition system or the
fuel system.
VISUAL CHECK OF THE

EVAPORATIVE EMISSION CANISTER
6E153

count of 0 indicates the ECM is commanding the IAC
pintle to be driven all the way into a fullyseated position.
This is usually caused by a vacuum leak.
commanded to bypass the throttle blade. In order to
diagnose the IAC system, refer to IAC System Check.
For other possible causes of idle problems, refer to
Rough, Unstable, or Incorrect Idle, Stalling in Symptoms.

DIAGNOSIS
014RX001

canister.
014RX002
IDLE AIR CONTROL (IAC) VALVE
901RX031
0006
6E154

diagnostic trouble codes from the ECM memory.
from the ECM for 30 seconds. Turning off the ignition and
disconnecting the battery power from the ECM will cause
all diagnostic information in the ECM memory to be
rerun.
Since the ECM can have a failure which may affect only
where it is.
If a diagnostic chart indicates that the ECM connections
or the ECM is the cause of a problem, and the ECM is
D There is a problem with the ECM terminal
checked. In this case, make a careful physical
inspection of all components and wiring associated
with the affected system and refer to the Symptoms
portion of the manual.
Solenoids and relays are turned ON and OFF by the
ECM using internal electronic switches called drivers.
A shorted solenoid, relay coil, or harness will not
damage the ECM but will cause the solenoid or relay
to be inoperative.
MULTIPLE ECM INFORMATION

SENSOR DTCs SET
Circuit Description
The engine control module (ECM) monitors various
The ECM controls fuel delivery, spark advance, and
emission control device operation based on the sensor
inputs.
The ECM provides a sensor ground to all of the sensors.
The ECM applies 5 volts through a pullup resistor, and
monitoring the voltage present between the 5volt supply
and the resistor:
D The Fuel Tank Vapor Pressure Sensor
The ECM provides the following sensors with a 5volt
D The Linear exhaust gas recirculation (EGR) valve
D The A/C Pressure Sensor
The ECM monitors the separate feedback signals from

status.
Diagnostic Aids
Be sure to inspect ECM and engine grounds for being secure and clean.
D P0108
D P0113
D P0118
D P0123
If a sensor input circuit has been shorted to voltage, ensure that the sensor is not damaged. A damaged sensor
will continue to indicate a high or low voltage after the affected circuit has been repaired. If the sensor has been
damaged, replace it.
An open in the sensor ground circuit between the ECM
DTCs to be set:
D P0108
D P0113
D P0118
D P0123
A short to ground in the 5volt reference A circuit will
D P0107
D P0122
D P0112
D P0117
D P0454
D P0405
D P0532
D Poor connection at ECM. Inspect the harness
terminals, and a poor terminaltowire connection.
the ignition ON and the engine OFF while you move
the connectors and the wiring harnesses related to
the following sensors:
D IAT
D ECT
D TP
D MAP
D EGR
D A/C Pressure Sensor
6E155
Multiple ECM Information Sensor DTCs Set

Step
Action
Verify repair
Go to Step 5
Go to Step 6
Verify repair
0V
Go to Step 7
0V
Go to Step 8
0V
Go to Step 9
Go to Step 13
Go to Step 14
Go to Step 15

Go to Step 16
Go to Step 20
Go to Step 17
Go to Step 13
Go to Step 19
0V
Measure the voltage between the A/C Pressure

Sensor circut at the ECM harness connector and
ground.
Go to Step 10
0V

11


10
Go to Step 4


9
Go to Step 3

sensor signal circuit at the ECM harness connector and
ground.

8

7
Go to Step 2

conditions:
D A poor connection at the ECM or the affected
sensors.
affected sensors.

6
Go to OBD
System
Check

5
No
1. Turn the ignition OFF, disconnect the ECM.

2. Turn the ignition ON, check the 5 volt reference
circuits for the following conditions:
D A poor connection at the ECM.
splice.

4
Yes

performed?

3
Value(s)
0V
6E156
Multiple ECM Information Sensor DTCs Set (Cont'd)

Step
Action
12

position sensor signal circuit at the ECM harness
13
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to OBD
System
Check

20
Verify repair
Locate and repair the short to voltage in the A/C

Pressure Sensor circuit.
19

18
Go to Step 17

signal circuit.
17
Go to Step 12
0V

signal circuit.
16
No

15
Yes

14
Value(s)
Replace the ECM.


(EGR) DIAGNOSIS
6E157
DECEL FUEL MODE Tech 2 Displays ACTIVE or

INACTIVE
mode. The ECM will command the deceleration fuel
vehicle is traveling over 20 mph. While in the deceleration
fuel mode, the ECM will decrease the amount of fuel
delivered by entering Open Loop and decreasing the
DESIRED EGR POS. Tech 2 Range 0%100%
Represents the EGR pintle position that the ECM is
commanding.
DESIRED IDLE Tech 2 Range 03187 RPM
The idle speed that the ECM is commanding. The ECM
speed.
057RX001
An EGR flow check diagnosis of the linear EGR system is

covered by DTC P0401, P0404, and P0405. If EGR
diagnostic trouble code P0401 is encountered, refer to
the DTC charts.
ENGINE Tech 2 DATA DEFINITIONS

AND RANGES
A/C CLUTCH Tech 2 Displays ON or OFF
Indicates whether the ECM has commanded the A/C
clutch ON. Used in A/C system diagnostics.
HVAC controls. The ECM uses the A/C request signal to
requested.
AIR/FUEL RATIO Tech 2 Range 0.025.5
Air/fuel ratio indicates the ECM commanded value. In
Closed Loop, the air/fuel ratio should normally be
BARO kPa Tech 2 Range 10105 kPa/0.005.00
Volts
normally displayed around 61104 depending on
CMP ACT. COUNTER Cam Position Activity
ECT (Engine Coolant Temperature) Tech 2 Range

40C to 151C (40F to 304F)
information to the ECM. The ECM applies 5 volts to the
changes internal resistance as the temperature changes.
When the sensor is cold (high resistance), the ECM
the voltage signal will decrease and the ECM will interpret
EGR DUTY CYCLE Tech 2 Range 0%100%
ECM. A duty cycle of 0% indicates that no EGR flow is
EGR FEEDBACK Tech 2 Range 0.005.00 Volts
being monitored by the ECM. A low voltage indicates a
EGR TEST COUNT Tech 2 Range 0255
Indicates the number of EGR flow test samples collected
during the current ignition cycle. Under normal operation,
only one sample is allowed during an ignition cycle. If the
ECM battery feed has been disconnected or a DTC
P0401 has been cleared, 10 EGR flow test samples will
be allowed during the ignition cycle. This is to allow repair
verification during a single ignition cycle.
ENGINE LOAD Tech 2 Range 0%100%
Engine load is calculated by the ECM from engine speed
and MAP sensor readings. Engine load should increase
ENGINE RUN TIME Tech 2 Range 00:00:00
99:99:99 Hrs:Min:Sec
00:00:00.
ENGINE SPEED Range 09999 RPM
Engine speed is computed by the ECM from the 58X
6E158
FUEL PUMP Tech 2 Displays ON or OFF

Indicates the ECM commanded state of the fuel pump
relay driver circuit.
FUEL TRIM CELL Tech 2 Range 021
active.
fuel trim corrections, fuel trim learn will display YES. This
indicates that the long term fuel trim is responding to the
short term fuel trim. If the fuel trim learn displays NO, then
long term fuel trim will not respond to changes in short
term fuel trim.
HO2S BANK 1, SEN. 1 Tech 2 Range 01000 mV
exhaust) while operating in Closed Loop.
HO2S BANK 1, SEN. 1 Tech 2 Displays NOT
READY or READY
ready when the ECM detects a fluctuating HO2S voltage
sufficient to allow Closed Loop operation. This will not
occur unless the exhaust sensor is warmed up.
HO2S WARM UP TIME BANK 1, SEN. 1 Tech 2
Range 00:00:0099:99:99 HRS:MIN:SEC
Indicates warmup time for each HO2S. The HO2S
warmup time is used for the HO2S heater test. The ECM
will run the heater test only after a cold start (determined
by engine coolant and intake air temperature at the time
of startup) and only once during an ignition cycle. When
the engine is started the ECM will monitor the HO2S
voltage. When the HO2S voltage indicates a sufficiently
active sensor, the ECM looks at how much time has
elapsed since startup. If the ECM determines that too
much time was required for the HO2S to become active,
a DTC will set. If the engine was warm when started,
HO2S warmup will display 00:00:00.
IAC POSITION Tech 2 Range 0255 Counts
40C to 151C (40F to 304F)
The ECM converts the resistance of the intake air
(IAT) is used by the ECM to adjust fuel delivery and spark
IGNITION 1 Tech 2 Range 025.5 Volts
ECM at its ignition feed.
INJ. PULSE BANK 1 Tech 2 Range 01000 msec.

Indicates the amount of time the ECM is commanding
engine load.
MAP Tech 2 Range 10105 kPa (0.004.97 Volts)
the diagnostics.
Indicates the ECM commanded state of the malfunction
indicator lamp (Check Engine Lamp).
or INACTIVE
mode. The ECM will command power enrichment mode
detected. While in the power enrichment mode, the ECM
will 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.
by the ECM on the IC circuit.
(40F to 304F)
(40F to 304F)
TP ANGLE Tech 2 Range 0%100%
TP (throttle position) angle is computed by the ECM from
TP SENSOR Tech 2 Range 0.005.00 Volts
The voltage being monitored by the ECM on the TP
VEHICLE SPEED Tech 2 Range 0255 km/h
(0155 mph)
The vehicle speed sensor signal is converted into km/h
and mph for display.
Number
This indicates that the ECM has detected crankshaft
TYPICAL SCAN DATA VALUES

OnBoard Diagnostic System Check has been
determined that the onboard diagnostics are functioning
properly. Tech 2 values from a properlyrunning engine
values that would be seen on a normallyrunning engine.
2.2L L4 Engine
Tech 2
Parameter
Data List
Units
Displayed
6E159

information on using the Tech 2 to diagnose the ECM and
described below, for diagnosis, refer to the Symptoms
section.
Test Conditions
park or neutral, Closed Loop, accessories OFF, brake
not applied and air conditioning OFF.
Typical Data
Values (IDLE)
Typical Data
Values
(2500 RPM)
Refer To
Engine Speed
Engine
RPM
Within -50 to
+100 of
Desired Idle
Actul engine
speed

Operation
Desired Idle
Speed
Engine
RPM
750
800

Operation, Idle Air Control
Engine Coolant
Tenpereture
Engine
80 100 (176
212 F)
80 100 (176
212 F)

tempereture sensor
Start Up ECT
Engine

tempereture sensor
Intake Air
Tenpereture
Engine
0 100,
depends on
underhood
0 80, depends
on underhood

tempereture sensor
Start Up IAT
Engine

tempereture sensor
Manifold
Absolute
Pressure
Engine
kPa
23 40
19 32

Operation, Manifold
DTC P0106,P0107,P0108
Manifold
Absolute
Pressure
Engine
0.65 1.32
0.46 1.10

Operation, Manifold
DTC P0106,P0107,P0108
Barometric
Pressure
Engine
kPa
61 104
(depends pn
altitude and
barometric)
61 104
(depends pn
altitude and
barometric)

Opreration
Throttle Position
Engine
35

Sensor. DTC
P0121,P0122,P0123
Throttle Position
Sensor
Engine
0.35 0.39
0.55 0.59

Sensor. DTC
P0121,P0122,P0123
Air Fuel Ratio
Engine
Ratio:_to1
14.6:1
14.6:1

Operation, Fuel System
Metering Purpose, Fuel Trim
6E160
Tech 2
Parameter
Data List
Units
Displayed
Typical Data
Values (IDLE)
Typical Data
Values
(2500 RPM)
Refer To
Spark Advance
Engine
CA
10 12
27 29

Ignition System
Engine Load
Engine
Fuel system
Status
Engine
Closed
Loop
EVAP System
EGR Duty Cycle
Engine

Operation, Liner EGR
Operation and Results of
Incorrect Operation
Desired EGR
Position
Engine

Position Sensor
EGR
Normalized
Engine
EGR Feed Back
Engine
0.6 0.8
0.6 0.8
EGR Closed
Pintle Position
Engine
Steps
20 40
20 40

Position Sensor
Knock Counter
Engine
Yes/No
Yes
Yes
DTC P0325,P0327
Knock Retard
Engine
CA
DTC P0325,P0327
A/C Pressure
Sensor
Engine
mV
DTC P0532,P0533
A/C Clutch
Relay
Engine
On/Off
Off

Operation, A/C Culutch
Circuit Operation
A/C Request
Engine
Yes/No
No

Operation, A/C Request
Signal
Low Fan
Comanded
Engine
Yes/No

High Fan
Comanded
Engine
Yes/No

Camshaft
Activity
Engine
Counts
0 255
0 255
DTC P0341,P0342
Fuel Pump
Engine
On/Off
On
On
Engine Fuel System
Deceleration
Fuel Cutoff
Engine
Inactive/Ac
tive
Inactive
Inactive

Operation
Idle Air Control
Engine
Steps

tempereture sensor
Vehicle Speed
Engine
MPH or
km/h
Manual Transmission
Ignition Voltage
Engine
12.8 14.1
12.8 14.1

Ignition System
Malfunction
Indicator Lamp
Engine
On/Off
Off
Off
OnBoard Diagnostic
System Check

Tech 2
Parameter
Data List
Units
Displayed
Typical Data
Values (IDLE)
Typical Data
Values
(2500 RPM)
6E161
Refer To
ABS Rough
Road
Engine
Misfire
Value
Okey
Okey
DTC P1380,P1381
B1S1 Status
(Bank1,Sensor1)
Engine
HO2S
Rich/Lean

HO2S
B1S1 O2 Sensor
(Bank1,Sensor1)
Engine
HO2S
mV
50 950
changing quickly
50 950
changing quickly

HO2S
Fuel Trim
Learned
Engine
HO2S
Yes/No
Yes
Yes
Diagnosis, Fuel Trim Monitor
Fuel Trim Cell
Engine
HO2S
Cell No.
18
2 or 6
Diagnosis, Fuel Trim Cell

Diagnostic Weights
B1 Long Fuel
Trim
Engine
HO2S
DTC P0171,P0172
B2 Short Fuel
Trim
Engine
HO2S
DTC P0171,P0172
Power
Enrichment
Engine
HO2S
Yes/No
No
No

Operation, Acceleration
Mode
6E162
NO MALFUNCTION INDICATOR LAMP (MIL)
D06RX109
Circuit Description
MIL bulb through the meter fuse. The engine control
module (ECM) turns the MIL ON by grounding the MIL
driver circuit.
Diagnostic Aids
An intermittent MIL may be caused by a poor connection,
D Inspect the ECM harness and connections for
damaged
terminals,
poor
terminaltowire
ECM ignition or battery feed, or a poor ECM to engine
ground.
Test Description
Diagnostic Chart:
2. A No MIL condition accompanied by a nostart
condition suggests a faulty ECM ignition feed or
9. Using a test light connected to B+, probe each of
the ECM ground terminals to ensure that a good
ground is present. Refer to ECM Terminal End View
for terminal locations of the ECM ground circuits.
12. In this step, temporarily substitute a known good
relay for the ECM relay. The horn relay is nearby,
this step.
6E163

Step
Action
1.
2.
3.
4.
Go to Step 13
Go to Step 10
Go to Step 11
Go to Step 15
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 12
Go to Step 14
Go to Step 10
Go to Step 17
Go to Step 18
Substitute a known good relay for the ECM main

relay.
Go to Step 13

14
Go to Step 5
Check for an open MIL driver circuit between the ECM

and the MIL.

13
Go to Step 16
Check for damaged terminals at the ECM.

12
Go to Step 4
Check for a faulty ECM ground connection.

11
Probe the battery feed circuit at the ECM harness


10
Go to Step 6
Ignition OFF.
Disconnect the ECM.
Ignition ON.
Probe the ignition feed circuit at the ECM harness

9
Go to Step 3
Check the ECM ignition feed and battery feed fuses

(15A Engine fuse and 15A ECM fuse).

8
1. Ignition OFF.
3. Jumper the MIL driver circuit at the ECM connector
to ground.
4. Ignition ON.
Are both fuses OK?

7
Go to Step 2
1. Ignition ON.
2. Engine OFF.
3. Probe the ignition feed circuit at the cluster
Is the MIL ON?

6
Go to OBD
System
Check

feed circuit.

5
No
Is the fuse OK?

4
Yes

performed?

3
Value(s)
Locate and repair the open ECM battery feed circuit.

6E164

Step
Action
15
Locate and repair the short to ground in the ECM

ignition feed circuit or ECM battery feed circuit.
16
No
Verify repair
Verify repair
Verify repair
Verify repair
Go to
Instrument
Panel in
Electrical
Diagnosis
Replace the ECM.

18
Yes

fuse.
17
Value(s)

6E165
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY
D06RX110
Circuit Description
The malfunction indicator lamp (MIL) should always be
engine stopped. Ignition feed voltage is supplied directly
to the MIL indicator. The engine control module (ECM)
turns the MIL ON by grounding the MIL driver circuit.
and no DTC(s) set. A steady MIL with the engine running
and no DTC(s) suggests a short to ground in the MIL
driver circuit.
Diagnostic Aids

damaged harness.
Test Description
Diagnostic Chart:
2. If the MIL does not remain ON when the ECM is
cluster is faulty.
6E166

Step
Action
Go to Step 2
Go to Step 3
Go to Step 5
Go to OBD
System
Check
Go to Step 4
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step 6
Go to OBD
System
Check
1. Ignition OFF, reconnect the ECM.

2. Ignition ON, reprogram the ECM. Refer to
OnVehicle Service in Engine Control Module and
Sensors for procedures.
MIL dash lamp control and command the MIL OFF.
Go to OBD
System
Check

cluster.
2. Check the MIL driver circuit between the ECM and

5
No

2. Ignition ON, observe the MIL (Service Engine Soon
lamp).

4
Yes

performed?
Is the MIL ON?

3
Value(s)
Replace the ECM.

6E167
ENGINE CRANKS BUT WILL NOT RUN
D06RX099
6E168
D06RX091
Circuit Description
The electronic ignition system uses a dual coil method of
spark distribution. In this type of ignition system, the
engine control module (ECM) triggers the correct driver
inside the ignition control module (ICM), which then
triggers the correct ignition coil based on the 58X signal
received from the crankshaft position sensor (CKP). The
spark plug connected to the coil fires when the ICM opens
the ground circuit for the coils primary circuit.
During crank, the ECM monitors the CKP 58X signal. The
ECM, it will command all four injectors to allow a priming
injectors are left OFF during the next four 58X reference
been received by the ECM. The CMP signal allows the
ECM to operate the injectors sequentially based on
present at startup, the ECM will begin sequential fuel
delivery with a 1in4 chance that fuel delivery is correct.
DTC code.
Diagnostic Aids
connection, rubbedthrough wire insulation or a wire
items:
damaged harness.
intake air temperature. If not, replace the ECT sensor.
6E169
6E170

Step
Action
Go to Step 2
Go to
Applicable
DTC Table
Go to Step 3
Go to Step 4
Go to Step 5
Verify repair
Go to Step 7
Go to Step 6

1. Ignition ON.
2. Use a grounded test lamp to verify that B+ is
available at the ignition coil fuse, the engine device
fuse, and the ECM fuse.
Was B+ available at the fuses?
Check the 15A ignition coil fuse, the 15A engine device
fuse, and the 15A ECM fuse.

5
Go to Fuel
System
Electrical Test
10
Go to Step 10
Go to Step 9
Verify repair
Go to Step 12
Go to Step 11
Verify repair
Go to Step 14
Go to Step 13
Verify repair
1. Ignition ON.
2. Using a Digital Voltmeter (DVM) check the ignition
wire coil at the ignition module harness connector?
B+
12
1. Ignition OFF.
2. With DVM, check for an open in the ground wire at
the ignition module harness connector.
Was the ground wire OK?
13
Go to Step 8
Repair the faulty circuit.

11
Go to Step 16
1. Disconnect the ignition module harness connector.

2. Check for an open or short circuit between the
ignition control module and the ECM?
Go to Fuel
System
Diagnosis
1. Disconnect the ignition secondary wire at the No.1.

2. Install a spark tester 5884002790 at the end of
the disconnected ignition coil.
3. Clip the spark tester 5884002790 to a good
ground (not near the battery).
4. Observe the spark tester while the engine is
cranking.
Was a crisp blue spark observed? (Only one or two
No Spark.)
No
Go to OBD
System
Check
Use the Tech 2 and check for any DTCs.
Was a fuse blown?

4
Yes

performed?

3
Value(s)
Repair the faulty wire.
6E171

Step
14
Action
Replace the ignition module, verify the repair.

15
Go to Step 15
19
Go to Step 17
Go to Step 18
Go to Step 19
Go to Step 18
Verify repair
10,000 W per
foot
Go to Step 20
Go to Step 21
0.818 W
Use an ohmmeter to check the ignition coil secondary

winding resistance.

Test the resistance of the coiltospark plug secondary
ignition wire.
Was the resistance greater than the specified value?
20
21
Replace the coiltospark plug secondary ignition wire

and any other secondary wires which exceed the
specified value.
10,000 W per
foot
excessing fouling?
Verify repair
Go to Step 30
Go to Step 23
Go to Step 22
Is the fuel pressure within the specified values, and 285375 kPa
(4355 psi)
does it hold steady for 2 seconds?
Go to Step 25
Go to Step 24
Go to Fuel
System
Electrical Test
Verfiy repair.
23
Go to Step 21
Correct the
fouling
condition
22
Verify repair
Verify repair
Was the secondary winding resistance equal to the 9,00012,000

W
specified value?
18
No
Use an ohmmeter to check the ignition coil primary

winding resistance.
Was the primary winding resistance approximately
equal to the specified value?
17
Yes
Replace the ECM.

16
Value(s)
1. Ignition OFF, install a fuel pressure gauge at the test

fitting on the fuel supply line in the engine
compartment.
CAUTION: Use a shop cloth to absorb any fuel
leakage while making the connection.
2. Check the engine and observe the fuel pressure.
24
Go to Fuel
System
Diagnosis
6E172

Step
Action
25

harness.
2. Ignition ON.
3. With a test light to ground, probe the CKP ignition
feed harness terminal.
26
31
Go to Step 28
Go to Step 29
Verify repair
Go to Step 31
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 30
Go to Step 30
Replace the ECM.

Balance Test).
32
Go to Step 27
Check the CKP Low circuit between the sensor and the
ECM for: an open circuit, a short to ground, or short to
voltage.
30
Go to Step 26

29
No
Check the CKP High circuit between the sensor and the
ECM for a short to ground or open circuit.
28
Yes
1. Ignition ON.
2. At the CKP harness connector, connect a test lamp
Did the lamp illuminate?
27
Value(s)
Go to Step 32
To diagnose the following conditions, refer to Engine

Mechanical:
D Slipped camshaft drive belt.
D Leaking or sticky valves or rings.
D Excessive valve deposits.
D Loose or worn rocker arms.
D Leaking head gasket.
6E173
FUEL SYSTEM ELECTRICAL TEST
D06RX111
Circuit Description
Diagnostic Aids
When the ignition switch is first turned ON, the powertrain

control module (ECM) energizes the fuel pump relay
which applies power to the intank fuel pump. The fuel
pump relay will remain ON as long as the engine is
running or cranking and the ECM is receiving 58X
crankshaft position pulses. If no 58X crankshaft position
pulses are present, the ECM deenergizes the fuel pump
relay within 2 seconds after the ignition is turned ON or the
engine is stopped.

damaged harness.
Test Description
Diagnostic Chart:
2. If the fuel pump is operating but incorrect pressure
is noted, the fuel pump wiring is OK and the Fuel
diagnosis.
6E174

injury:
completed.

relay center.

cover.


Step
Action
1.
2.
3.
4.
Go to Step 3
Go to Step 4
Test
completed
Go to Step 12
Go to Step 6
Go to Step 5
Verify repair

connect to the fuel pump relay pullin coil.
2. Ignition ON.
Go to Step 12
Go to Step 7

from the relay pullin coil to the ECM.
2. Ignition ON.
off?
off?
7
Go to Step 2
Ignition OFF.
Remove the fuel pump relay.
Ignition SW On, Engin Off.
Using a test light connected to ground, probe the

6
Go to OBD
System
Check


5
No


4
Yes

performed?
Is there an immediate pressure buildup which

3
Value(s)
Go to Step 8
Go to Step 9
Verify repair

circuit.
6E175

Step
Action
Go to Step 15
Go to Step 13
Go to Step 17
Go to Step 14
Verify repair
Go to Step 18
Go to Step 16
Verify repair
Verify repair
Verify repair

2. Replace the fuel pump relay.
18

17
Verify repair

16
Go to Step 11

2. Check for a short circuit, blown fuse or open circuit
between the relay and the fuel tank.
15
Verify repair
1. Honk the horn to verify that the horn relay is

functioning.
2. Substitute the horn relay for the fuel pump relay.
14

fuel tank.
13
Go to Step 10
Verify repair
Replace the ECM.

12
No

11
Yes
Check for short or open between the ECM and the fuel
pump relay.
10
Value(s)

6E176
FUEL SYSTEM DIAGNOSIS
D06RX111
Circuit Description
Test Description
When the ignition switch is turned ON, the engine control

module (ECM) will turn ON the intank fuel pump. The
intank fuel pump will remain ON as long as the engine is
cranking or running and the ECM is receiving 58X
crankshaft position pulses. If there are no 58X crankshaft
position pulses, the ECM will turn the intank fuel pump
OFF 2 seconds after the ignition switch is turned ON or 2
seconds after the engine stops running.
The intank fuel pump is an electric pump within an
integral reservoir. The intank fuel pump supplies fuel
through an inline fuel filter to the fuel rail assembly. The
to the fuel injectors at a regulated pressure. Unused fuel is
returned to the fuel tank by a separate fuel return line.

Diagnostic Chart:
2. Connect the fuel pressure gauge to the fuel feed
line as shown in the fuel system illustration. Wrap a
should be 283376 kPa (4155 psi). This pressure
areas:

regulator.
D The fuel injector(s)
operating in the Fuel CutOff Mode.
16. Check the spark plug associated with a particular
Assembly in OnVehicle Service.
connector.
nozzles for leaks.
17. A rich condition may result from the fuel pressure
exhaust.
6E177
20. This test determines if the high fuel pressure is due

21. A lean condition may result from fuel pressure
below 333 kPa (48 psi). A lean condition may cause
a DTC P0131 or a DTC P0171 to set. Driveability
conditions associated with lean conditions can
include hard starting (when the engine is cold),
hesitation, poor driveability, lack of power, surging,
and misfiring.
22. Restricting the fuel return line causes the fuel
injury:
completed.

relay center.

located on the upper right side of the engine near the
EGR valve.
6E178

Step
Action
Value(s)

performed?
Yes
Go to Step 2
No
Go to OBD
System
Check

pressure gauge.
ON.
283376 kPa
(4155 psi)
constant.
5
6
Go to Step 4

engine was started?
21105 kPa
(315 psi)
Go to Step 5
Go to Step 9

Go to Step 6
Check for
improper fuel
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
21105 kPa
(315 psi)
Go to Step 10
Go to Step 11
1. When the vehicle is at normal operating

gauge.
gauge.

restriction:
D The inpipe fuel filter.

Go to Step 12
Was a restrication found?

7
Go to Step 17
Go to Step 3

regulator.
2. With the engine idling, apply 1214 inches of
6E179

Step
Action
10

pressure regulator.
11
Verify repair
Go to Step 13
Go to Step 15
Go to Step 14
Verify repair
Verify repair
Go to Step 8
Go to Step 11
Go to Step 16
Verify repair
376 kPa (55

psi)
Go to Step 18
Go to Step 21
Go to Step 19
Go to Step 20
Verify repair
Verify repair

pump.
16
Verify repair

intank fuel line.
15

leaks.
14

17

18

Pressure Relief.
outlet passage.
290376 kPa
(4255 psi)
19

20
No

13
Yes

12
Value(s)

Go to Step 11
6E180

Step
Action
Value(s)
21

0 kPa (0 psi)
22
Yes
Go to Step 22
No
Go to Step 23

23
414 kPa (60

psi)
Go to Step 11
Go to Step 7

Go to Step 7
Go to Fuel
System
Electrical Test
Chart
6E181
D06RX112
Circuit Description
speed with the idle air control (IAC) valve. To increase idle
speed, the ECM retracts the IAC valve pintle away from
its seat, allowing more air to bypass the throttle bore. To
decrease idle speed, it extends the IAC valve pintle
read the ECM commands to the IAC valve in counts.
idle).
Diagnostic Aids

engine. Fully extend (low) IAC with the Tech 2. Start
linkage.
P0131, P0151, P0171, may be set. Tech 2 oxygen
(O2) voltage will be less than 100 mV (0.1 V). Check
for low regulated fuel pressure, water in fuel, or a
restricted injector.
6E182

respond on Tech 2.
contact.
Test Description
Diagnostic Chart.
1. The Tech 2 is used to extend and retract the IAC

Step
Action
1.
2.
3.
4.
5.
6.
7.
8.

Go to Step 2
Go to Step 3
700-1500
RPM
Go to Step 3
Go to Step 4
Go to Step 5
Verify repair
Verify repair

No

Yes
Ignition OFF.
Connect the Tech 2.
Block the wheels.
the IAC is cycled.

2
Value(s)

Control Valve.
6E183
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK
D06RX113
Circuit Description
Diagnostic Aids
A properly operating exhaust gas recirculation (EGR)

would be leaner. The powertrain control module (ECM)

but not in the closed throttle cell. An EGR pintle constantly
in the open position would cause rough idle. Also, an EGR
valve mounted incorrectly (rotated 180) could cause a
rough idle without setting an EGR DTC. Check for the
following items:
passages.
6E184

Step
Action
EGR system
working
properly. No
problem
found.
Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Go to Step 8
Go to Step 9
Go to DTC
P0404 chart

2. Using a Tech 2, command EGR ON and observe the
EGR valve pintle for movement.

damage.
restrictions?
10
Verify repair

necessary.

command?
9


8
Go to Step 3

Go to Step 2
1. Engine OFF.
2. Ignition ON.
between the ignition feed and ground.

2. Start the engine and idle until warm (Closed Loop).
3. Using a Tech 2, command EGR 50% ON.
No

Yes

Is the EGR valve loose?
Value(s)
Go to Step 10
EGR system
working
properly. No
problem
found.

necessary.
Verify repair
6E185
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK
D06RX114
Circuit Description
powertrain control module (ECM) sends a 5volt
By monitoring the sensor output voltage, the ECM knows
the MAP. A lower pressure (low voltage) output voltage
will be about 12 volts at idle. Higher pressure (high
voltage) output voltage will be about 44.8 volts at wide
open throttle. The MAP sensor is also used, under certain
conditions, to measure barometric pressure, allowing the
ECM to make adjustments for different altitudes. The
ECM uses the MAP sensor to diagnose proper operation
of the EGR system, in addition to other functions.
Test Description
IMPORTANT: Be sure to use the same diagnostic test
Diagnostic Chart:
1. When you compare the Tech 2 readings to a known

good vehicle, it is important to compare vehicles
that use MAP sensors that have the same part
number.
should cause the voltage to be 1.52.1 volts less
than the voltage at step 1. Upon applying vacuum to
the sensor, the change in voltage should be
faulty sensor.
3. Check the vacuum hose to the sensor for leaking or
restriction. Be sure that no other vacuum devices
are connected to the MAP hose.
6E186

Step
Action
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 4
Verify repair
Go to Step 6
Go to Step 7
Verify repair
Verify repair
Refer to OnVehicle Service, MAP Sensor.

Go to Step 5

Go to Step 2
Repair the hose to ensure the hose supplies vacuum to

the MAP sensor only.
Check the sensor hose for leakage or restriction.

Does the hose supply vacuum to the MAP sensor only?
No
1. Disconnect the vacuum hose at the MAP sensor

and plug the hose.
2. Connect a hand vacuum pump to the MAP sensor.
4. Apply 34 kPa (10 Hg) of vacuum and note the
voltage change.
Is the voltage change 1.52.1 volts less than step 1?
Yes

seconds.
2. Ignition ON. Do not crank engine.
4. Compare this scan reading to the scan reading of a
Is the voltage reading the same +/ 0.40 volt?
Value(s)

6E187
ECM DIAGNOSTIC TROUBLE CODES

supported by this vehicle application. If any DTCs not
listed here are displayed by a Scan Tool, the Tech 2 data
ECM Diagnostic Trouble Codes
DTC
may be faulty; notify the Tech 2 manufacturer of any

DTCs displayed that are not included in the following
table.
Description
Type
Illuminate MIL
P0106
MAP Circuit/Range Performance Problem
Yes
P0107
MAP Sensor Circuit Low Input
Yes
P0108
MAP Sensor Circuit High Input
Yes
P0112
IAT Sensor Circuit Low Input
Yes
P0113
IAT Sensor Circuit High Input
Yes
P0117
ECT Sensor Circuit Low Input
Yes
P0118
ECT Sensor Circuit High Input
Yes
P0121
TP Sensor Circuit Range/Performance Problem
No
P0122
TP Sensor Circuit Low Input
Yes
P0123
TP Sensor Circuit High Input
Yes
P0131
O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
Yes
P0132
O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
Yes
P0134
O2 Sensor Circuit No Activity Detected (Bank Sensor 1)
Yes
P0135
O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)
Yes
P0171
Fuel Trim System Too Lean (Bank 1)
Yes
P0172
Fuel Trim System Too Rich (Bank 1)
Yes
P0201
Yes
P0202
Yes
P0203
Yes
P0204
Yes
P0325
Knock Sensor Circuit Malfunction
Yes
P0327
Knock Sensor Circuit Low Input
Yes
P0336
CKP Sensor Circuit Range/Performance
Yes
P0337
CKP Sensor Circuit Low Input
Yes
P0341
CMP Sensor Circuit Range/Performance
Yes
P0342
CMP Sensor Circuit Low Input
Yes
P0351
Ignition Coil A Primary/Secondary
Yes
P0352
Ignition Coil B Primary/Secondary
Yes
P0401
EGR Flow Insufficient Detected
Yes
P0402
EGR Excessive Flow Detected
Yes
P0404
EGR Circuit Range/Performance
Yes
P0405
EGR Sensor Circuit Low
Yes
P0406
EGR Sensor Circuit High
Yes
P0443
EVAP Control System Purge Control Valve Circuit Malfunction
Yes
P0480
No
P0481
No
P0502
Yes
P0506
Idle Control System RPM Lower than expected
Yes
6E188
DTC
Description
Type
Illuminate MIL
P0507
Idle Control System RPM Higher than expected
Yes
P0563
System Voltage High
Yes
P0601
Internal Control Module Memory Check Sum Error
Yes
P1106
MAP Sensor Circuit Intermittent High Voltage
No
P1107
MAP Sensor Circuit Intermittent Low Voltage
No
P1111
IAT Sensor Circuit Intermittent High Voltage
No
P1112
IAT Sensor Circuit Intermittent Low Voltage
No
P1114
ECT Sensor Circuit Intermittent Low Voltage
No
P1115
ECT Sensor Circuit Intermittent High Voltage
No
P1121
TP Sensor Circuit Intermittent High Voltage
No
P1122
TP Sensor Circuit Intermittent Low Voltage
No
P1171
Yes
P1404
EGR Closed Valve
Yes
P1625
Yes
P1627
PCM A/D Conversion Malfunction
Yes
P1635
5 Volt Reference Voltage Circuit Malfunction
Yes
P1640
ODM Output Circuit Fault
No
6E189

PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM
D06RX114
Circuit Description
4 volts with the ignition ON engine not running or at
low, Diagnostic Trouble Code P0106 will be set.
Diagnostic Trouble Code P0106 is a Type B Code.

D No ECT, CKP, EGR, EVAP, MAP orTP sensor DTCs
present.
D Engine speed is steady, changing less than 20 RPM.
D Throttle position is steady, throttle angle changes less

than 5%.
D EGR flow rate is steady, changing less than 2%.
D IAC valve counts are steady, changing less than 3
counts.
D Engine speed is between 1000 RPM and 4000 RPM.
D No change in brake switch, A/C clutch, 3 or power
steering pressure switch status.
The above conditions are met for longer than 1.5 seconds
and the following condition is met in two consecutive trips:
D Actual MAP value varies more than 10 kPa.
D The MAP value must vary for a total of 10 seconds over
a 20second period of time that the samples were
monitored.

fault is detected.
6E190

without a fault.
Diagnostic Aids

fault.
performing the Diagnostic Trouble Code P1106 or P1107
DTC P0106 MAP Circuit/Range Performance Problem

Step
Action
Go to Step 2
Go to OBD
System
Check
Go to Step 3
Go to Step 4
Verify repair
Refer to
Diagnostic
Aids
0 V 10.3 kPa
Go to Step 6
Go to Step 5
Verify repair
Verify repair
1. Check for the following condition:

D Vacuum hoses disconnected, damaged, or
incorrectly routed?
D Intake manifold vacuum leaks;
D Vacuum leaks at throttle body;
D Vacuum leaks at EGR valve flange and pipes;
1. Disconnect the Manifold Absolute Pressure (MAP)
sensor electrical connector.
No
1. Ignition ON, engine OFF

4. Using a Tech 2, monitor DTC info for Diagnostic
Trouble Code P0106.

4
Yes

performed?
Does the Tech 2 indicate that DTC P0106 ran and

passed?
3
Value(s)

short to voltage?
Go to Step 12

D A short to ground
D An open circuit
Go to Step 7
6E191
DTC P0106 MAP Circuit/Range Performance Problem (Cont'd)

Step
Action
12
Verify repair
5 volts 104
kPa
Go to Step 9
Verify repair
Go to Step 8
Go to Step 12
Go to Step 10
1. Ignition OFF.
sensor connector.
5 volts
11

D An open circuit
D A short to ground
10
No
1. Ignition OFF.
Does the Tech 2 read the following value? (if no, start
Yes

D An open circuit
D A short to ground
Value(s)
Go to Step 11
Go to Step 12

Verify repair.
Replace the ECM.
6E192

PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT
D06RX114
Circuit Description
from the MAP sensor, the CKP Sensor, and the Intake Air
load is its main function. The MAP sensor is also used to
determine manifold pressure changes while the exhaust
gas recirculation (EGR) flow test diagnostic is being run,
to determine engine vacuum level for some other
diagnostics and to determine barometric pressure

D System voltage greater than 11 volts.

or equal to 1300 RPM.
1300 RPM.
below 11 kPa for a total of approximately 10 seconds

D The ECM will use a MAP value based on speed density
calculation.

Diagnostic Aids
6E193

fault.
D A faulty 5 volt reference circuit could also set a TP
Sensor Diagnostic Trouble Code because the two
sensors share the same 5 volt reference pin at the
ECM.
DTC P0107 MAP Sensor Circuit Low Input

Step
Action

Go to Step 2
0V 10.3 kPa
at sea level
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
1. Ignition OFF.
3. Jumper the 5 volt reference circuit and the MAP
connector.
4. Ignition ON.
No
Go to OBD
System
Check

P0107 failed?
Yes

performed?

3
Value(s)
Go to Step 10
5 V 104 kPa
Go to Step 5

2. Connect a fused jumper between the 5 Volt signal
circuit and the MAP sensor signal circuit at the MAP
5 V 104 kPa
Go to Step 6
Go to Step 8
6E194
DTC P0107 MAP Sensor Circuit Low Input (Cont'd)

Step
Action
Go to Step 7
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 11
Go to Step 9
Go to Step 11

11

connection at the ECM and the MAP sensor; replace
10
Verify repair
1. Ignition OFF.
2. Disconnect the ECM, and check the MAP signal
No

Yes
1. Ignition OFF.
ground?
Value(s)
Replace the ECM.

6E195

PRESSURE (MAP) CIRCUIT HIGH INPUT
D06RX114
Circuit Description

D Throttle position is below 2.7% if engine speed is below

1000 RPM.
1000 RPM.
above 90 kPa for a total of approximately 10 seconds

fault is detected.

without a fault.
Diagnostic Aids
6E196

D The MAP sensor share a ground with the TP sensor

fault.
DTC P0108 MAP Sensor Circuit High Input

Step
Action

Tech 2.
1.
2.
3.
4.
About 4V 90
kPa
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
0 V 10.3 kPa
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 12

D A short to ground
D An open circuit
Go to Step 2

short to voltage.
Ignition OFF.
Ignition ON.
Observe the MAP value displayed on the Tech 2.
5
No
Go to OBD
System
Check

4. Using the Tech 2, monitor DTC info for Diagnostic
Trouble Code P0108.
Does the Tech 2 indicate that DTC P0108 failed this
ignition?
Yes

performed?

3
Value(s)

sensor and the ECM for the following conditions:
D An open circuit
D A short to ground
6E197
DTC P0108 MAP Sensor Circuit High Input (Cont'd)

Step
Action
1. Ignition OFF.
12
5 volts 104
kPa
Go to Step 9
Verify repair
No
Go to Step 12
Go to Step 10
1. Ignition OFF.
sensor connector.
11
Yes

D An open circuit
D A short to ground
10
Value(s)
Go to Step 11
Go to Step 12
5 Volts

Verify repair.
Replace the ECM.
Verify repair.
6E198

D06RX116
Circuit Description
lower, causing the ECM to monitor a lower voltage.
detects an excessively low signal voltage (short to
ground) on the intake air temperature sensor signal
circuit. DTC P0112 is a Type A Code.

D IAT signal voltage less than 0.10 volts for a total of 12.5
seconds over a 25second period of time.
The above conditions are met for at least 2 seconds.



Diagnostic Aids
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
Test Description
Diagnostic Chart:
3. If Diagnostic Trouble Code P0112 can be repeated
refer to the Temperature vs. Resistance Value table.
a shifted sensor that may be stored above or
Diagnostic Aids.

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E199
6E1100
DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Input
Step
Action
1.
2.
3.
4.
Ignition OFF.
Ignition ON.
148C
(283F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
38C
(36F)
Go to Step 6
Go to Step 5
Verify Repair
Go to Step 7
Verify Repair
Verify Repair

Go to Step 2
1. Ignition OFF.
2. Disconnect the ECM electrical connectors.
ground.
Go to OBD
System
Check
1. Ignition ON, engine OFF. Review and record Tech 2


5
No

(IAT).

ignition?
4
Yes

performed?

value?
3
Value(s)
Replace the ECM.

6E1101

D06RX118
Circuit Description
detects an excessively high signal voltage on the intake
air temperature sensor signal circuit. DTC P0113 is a
Type A Code.

D
D
D
D
D

Mass air flow is less than 20g/second.
IAT signal voltage almost 5 volts which indicates an
intake air temperature less than 39C (38F) for a
total of 12.5 seconds over a 25second period.



without a fault.
Diagnostic Aids
6E1102


C
Test Description
Diagnostic Chart:
table.
a shifted sensor that may be open above or
Diagnostic Aids.
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Input
Step
Action

1. Ignition OFF.
connector.
4. Ignition ON.
2.

2.
No
Go to Step 2
Go to OBD
System
Check
5V 38C
(36F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
0V 140C
(284F)
Go to Step 6
Go to Step 5
0V 140C
(284F)
Go to Step 7
Go to Step 8

parameters.
P0113 failed?
Yes

performed?

3
Value(s)
6E1103
DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Input (Cont'd)
Step
Action
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Verify repair
Verify repair
Go to Step 11
Replace the IAT sensor

11
Verify Repair

10
Go to Step 10
1. Ignition OFF.
2. Disconnect the ECM, and check the IAT signal
necessary.
No
1. Ignition OFF.
2. Disconnect the ECM, and check the IAT sensor
necessary.
Yes

Value(s)
Replace the ECM

6E1104

TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT
D06RX117
Circuit Description
resistance becomes lower, and the ECT signal voltage
measured at the ECM drops. With a fully warmedup
to 2.0 volts. DTC P0117 is a Type A Code.


without a fault.
Diagnostic Aids
D Engine running time is longer than two minutes.

temperature greaterthan 150C (302F) (about 0.14
V) for a total of 12.5 seconds overa 25second period.


time.

6E1105

C
OHMS
Test Description
100
212
177

Diagnostic Chart:
table.
Diagnostic Aids.
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Input
Step
Action


Is the Eng Cool Temp at or below the specified value?
Go to Step 2
139C
(282F)
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
39C
(38F)
Go to Step 6
Go to Step 5
Verify repair
Go to Step 7
Verify repair
Verify repair

1. Ignition OFF.
2. Disconnect the ECM and check the ECT signal
ground circuit.
3. If the ECT signal circuit is shorted, repair it as
necessary.
No
Go to OBD
System
Check

ignition?
Yes

performed?

3
Value(s)
Replace the ECM.

6E1106

TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT
D06RX117
Circuit Description
to 2.0 volts. If the ECM detect a continuous open in the
ECT sensor or circuit, then a code P0118 will set. DTC

for a total of 12.5 seconds over a 25second period.

time.


without a fault.
Diagnostic Aids
and open circuit. If the harness appears to be OK,

Test Description
Diagnostic Chart:
refer to the Temperature vs. Resistance Value
table.
Diagnostic Aids.

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E1107
6E1108
DTC P118 ECT Sensor Circuit High Input

Step
Action


connector.

Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
140C
(284F)
Go to Step 6
Go to Step 5
140C
(284F)
Go to Step 7
Go to Step 8
Verify repair
Go to Step
10
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Go to Step
11
Verify repair
Verify repair

11
Go to Step 4

10
39C
(38F)
1. Ignition OFF.
2. Disconnect the ECM, and check the ECT signal
necessary.
Go to Step 2
1. Ignition OFF.
2. Disconnect the ECM, and check the ECT sensor
necessary.

No
Go to OBD
System
Check

P0118 failed?
Yes

performed?

3
Value(s)
Replace the ECM.

6E1109

SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
D06RX118
Circuit Description
The throttle position (Throttle Position) sensor circuit
provides a voltage signal that changes relative to throttle
blade angle. The signal voltage will vary from about 0.25
volts at closed throttle to about 4.75 volts at wide open
throttle (WOT).
The Throttle Position (TP) signal is used by the
powertrain control module (ECM) for fuel control and
most of the ECMcontrolled outputs. The ECM monitors
throttle position and compares actual throttle positions
from engine speed. If the ECM detects an outofrange
condition, then a DTC code P0121 will set. DTC P0121 is
type A code.

D The Engine is running.
D No MAP, ECT, TP, CKP, EGR, EVAP or DTCs are set.
D IAC is between 10 and 160 counts.
D The MAP value changes by less than 2 kPa.
All the above mentioned conditions are met, and one of
the following conditions occurs for a total of 12.5 seconds
over a 25second period of time.
Stuck High
D Actual TP value is greater than the ECMs estimated

TP value (Estimated TP value is based on MAP and
RPM).
Stuck Low
D Actual TP value is less than the ECMs estimated TP
value (Estimated TP value is based on MAP and
RPM).

fault is detected.
MAP and RPM.

without a fault.
6E1110
Diagnostic Aids
incorrect MAP signal may cause the ECM to incorrectly
be set.
D The TP sensor shares a ground with the MAP sensor
and the Fuel Pressure sensor.

fault.
performing the DTC P1122 or P1121 Diagnostic Chart
may isolate the cause of the fault.
DTC P0121 TP Sensor/Range Performance Problem

Step
Action
Go to Step 2
Refer to
Diagnostic
Aids
Go to Step 3
Go to Step 4
00.25 volts
0%
Go to Step 6
Verify repair
Verify repair
Go to Step 11
1. Ignition OFF.
2. Disconnect the Throttle Position (TP) Sensor
electrical connector, located on the RH side of the
Throttle body.
3. Start the vehicle, and monitor the TP value with the
Tech 2.
Check the TP sensor signal circuit; between the TP

short to voltage.

2. Monitor the TP value on the Tech 2 while moving the
throttle between 0% and 100%.
Does the TP value on the Tech 2 hold steadily within the

given range?
5
No
Go to OBD
System
Check

Does the TP value on the Tech 2 move smoothly from

0% (0.25 volts) to 100% (4.75 volts)? (if no, start with
the diagnosis chart for other sensors in the circuit and
see if 5V returns.)
4
Yes

performed?

Passed?
3
Value(s)
Go to Step 5
Go to Step 12
Check the TP sensor circuit, between the TP sensor

and the ECM, the following conditions:
D A short to ground
D An open circuit
Go to Step 7
6E1111
DTC P0121 TP Sensor/Range Performance Problem (Cont'd)

Step
Action
1. Ignition OFF.
2. Place a fused jumper between the TP sensor circuit
and the 5 volt signal circuit both at the wiring
harness TP sensor connector.
4. Observe the TP value displayed on the Tech 2?
12
Verify repair
about 5 volts
100%
Go to Step 9
Verify repair
No
Go to Step 8
Go to Step 12
Go to Step 10
1. Ignition OFF.
signal circuit, both at the wiring harness TP sensor
connector.
11
Check the TP sensor ground circuit, between the TP

D An open circuit
D A short to ground
10
Yes
Check the 5 volt signal circuit, between the TP sensor

and the ECM, for the following conditions:
D An open circuit
D A short to ground
Value(s)
Go to Step 11
Go to Step 12
about 5 volts

Verify repair.
Replace the ECM.
Verify repair.
6E1112

SENSOR CIRCUITLOW INPUT
D06RX118
Circuit Description
to about 4 volts at wide open throttle(WOT).
outputs. If the ECM detect a continuous short to ground
in the TP sensor or circuit, then a code P0122 will set.
Diagnostic Trouble Code P0122 is type A code.

D Throttle Position sensor signal voltage is less than 0.22
volt for a total of 0.78 second over a 1.5second period.

MAP and RPM.


without a fault.
Diagnostic Aids
components itself.
6E1113

DTC P0122 TP Sensor Circuit Low Input

Step
Action
0.22 V
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
5V
Go to Step
10
Go to Step 5
5V
Go to Step 6
Go to Step 8
Verify repair
Go to Step 7
Verify repair
Go to Step
12
2. Connect a test light between B+ and the Throttle
Position sensor signal circuit at the Throttle Position
Observe the Throttle Position Sensor display on the
Tech 2.
1. Ignition OFF.
ground?
Go to Step 2
1. Ignition OFF.
3. Jumper the 5 volt reference circuit and the Throttle
Position signal together at the Throttle Position
4. Ignition ON.
Observe the Throtle Position Sensor display on the
Tech 2.

(if no, start with the diagnosis chart for other sensors in
the circuit and see if 5V returns.)
6
Go to OBD
System
Check

4. Using a Tech 2, monitor the Diagnostic Trouble
Code info for Diagnostic Trouble Code P0122.

5
No


4
Yes

performed?
Is the Throttle Position Sensor below the specified

value?
3
Value(s)

6E1114
DTC P0122 TP Sensor Circuit Low Input (Cont'd)

Step
Action
Go to Step 9
Verify repair
Go to Step
12
Verify repair
Go to Step
11
Verify repair
Verify repair

12
Verify repair

necessary.
11
No

necessary.
10
Yes
1. Ignition OFF.
2. Disconnect the ECM, and check the TP signal
Value(s)
Replace the ECM.

6E1115

D06RX118
Circuit Description

to about 4 volts at wide open throttle (WOT).
outputs. If the ECM detect a continuous open in the TP
sensor or circuit, then a code P0123 will set. DTC P0123
is a type A code.
without a fault.

components itself.
damage, shorts to ground, shorts to battery positive
observe the Throttle Position sensor display on the
related to the TP sensor. A change in the display will

D Throttle Position sensor signal voltage is greater than
4.78 volts for a total of 0.78 second over a 1.5second
period.

MAP and RPM.
Diagnostic Aids
6E1116
D Faulty Throttle Position sensor With the ignition key

ON engine OFF observe the TP sensor display on the
Tech 2 while slowly depressing the accelerator to wide
open throttle. If a voltage over 4.88 volts is seen at any
point in normal accelerator travel, replace the TP
sensor.
performing theDiagnostic Trouble Code P1121
Test Description
Diagnostic Chart:
7. Components that share the TP sensor 5 volt
reference circuit include the following devices:
D EGR valve
D MAP sensor
Disconnect the component while observing the
Throttle Position sensor display on the Tech 2. If
the reading changes drastically when this
component is disconnected, replace the
component that affected the reading.
DTC P0123 TP Sensor Circuit High Input

Step
Action
Go to Step 2
4.78 V
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
0V
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step
10
Verify repair
Go to Step
12
1. Disconnect the Throttle Position sensor electrical

connector.
2. Observe the Throttle Position Sensor display on
the Tech 2.
Probe the sensor ground circuit at the Throttle Position

sensor harness connector with a test light connected to
B+.
Go to OBD
System
Check

Is the Throttle Position Sensor near the specified

value? (if no, start with the diagnosis chart for other
sensors in the circuit and see if 5V returns.)
5
No


P0123 failed.
4
Yes

performed?
Is the Throttle Position Sensor above the specified

value?
3
Value(s)

circuit.
necessary.
6E1117
DTC P0123 TP Sensor Circuit High Input (Cont'd)

Step
Action
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step
11
Verify repair
Go to Step
12
Verify repair
Verify repair
Replace the Throttle Position sensor.

12
Verify repair
1. Ignition OFF.
2. Disconnect the ECM, and check for an open sensor
ground circuit to the Throttle Position sensor.
Was the sensor ground circuit to the Throttle Position
sensor open?
11
Check for poor electrical connections at the Throttle

Position sensor and replace terminals if necessary.
10
No

3. Check for a short to B+ on the 5 volt reference
circuit.
4. If the 5 volt reference circuit is shorted, repair it as
necessary.
Was the 5 volt reference circuit shorted?
Yes
1. Ignition ON.
2. Monitor the Throttle Position Sensor Tech 2
display while disconnecting each of the
components that share the 5 volt reference circuit
(one at a time).
3. If the Throttle Position Sensor Tech 2 display
changes, service the component(s) that caused the
display to change when disconnected.
the Throttle Position Sensor display to change?
Value(s)
Replace the ECM.

6E1118
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW

D06RX119
Circuit Description

excessively low for an extended period of time,
a type A code.


D
D
D
D

Vehicle is operating in Closed Loop.
Closed Loop commanded air/fuel ratio is between
14.5 and 14.8.
All above conditions met for 0.3 seconds and the following
condition is met:
76.5 seconds over a 90second period of time.

without a fault.
Diagnostic Aids
be routed incorrectly and/or contacting the exhaust
system. Also, check for shorts to ground, shorts to
battery positive and open circuits.
D Poor ECM to engine block grounds.
too low. The ECM can compensate for some decrease.
However, if fuel pressure is too low, a Diagnostic

Trouble Code P0131 may be set. Refer to Fuel System
Diagnosis.
be indicated.
alcohol in the fuel can also cause this condition. For the
procedure to check for fuel contamination, Refer to
affected HO2S.
Test Description
Diagnostic Chart:
operation may indicate a condition described in the
Diagnostic Aids above. If the Diagnostic Trouble
Code P0131 test passes while the Failure Records
conditions are being duplicated, an intermittent
condition is indicated.
condition.
6E1119
6E1120
DTC P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

Step
Action
Value(s)

performed?
1. Ignition OFF.
2. Reconnect the
disconnected.
3. Ignition ON.
ECM,
leave
the
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 5
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Verify repair
430450 mV
Refer to
Diagnostic
Aids
Go to Step 9
Verify repair
sensor

9
Go to Step 3

Go to Step 4
1. Turn the ignition OFF HO2S 1 and ECM

disconnected.
signal circuits.
300 mV

Go to Step 2

circuit.
ground?
Go to OBD
System
Check
1. Ignition ON engine OFF review and record Tech 2

Note test result.
No

under Conditions for Setting the Diagnostic
Trouble Code criteria included in Diagnostic
Support.
specified value?
Yes
Replace the ECM.

6E1121
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH

D06RX119
Circuit Description
excessively high for an extended period of time,
a type A code.

D Closed Loop commanded air/fuel ratio is between
14.5 and 14.8.
All above conditions met for 0.3 seconds or vehicle in
Decelleration Fuel CutOff (DFCO) mode for 3 seconds,
and one of the following two conditions met:
76.5 seconds over a 90second period.
OR
during deceleration fuel cutoff mode (DFCO)
operation for 5 seconds.


without a fault.
Diagnostic Aids
too high. The ECM can compensate for some
increase. However, if fuel pressure is too high, a
6E1122
D
D
D
D
D
Diagnostic Trouble Code P0132 may be set. Refer to

Perform Injector Balance Test Refer to Fuel System
Diagnosis.
Check the EVAP canister for fuel saturation If full of
Check for a leak in the fuel pressure regulator
regulator for the presence of fuel.
An intermittent TP sensor output will cause the system
accelerating.
Silicon contamination of the HO2S can also cause a
high HO2S voltage to be indicated. This condition is
the HO2S exposed to the exhaust stream. If
Operate the vehicle while monitoring the HO2S voltage
with a Tech 2. If the HO2S voltage is limited within a
range between 300 mV to 600 mV, check the HO2S
high and low circuit wiring and associated terminal
connections. If the wiring and connections are OK,
replace the HO2S.
Test Description
Diagnostic Chart:
deceleration fuel cutoff mode operation may
indicate a condition described in the Diagnostic
Aids above. If the Diagnostic Trouble Code P0132
indicated. Reviewing the Failure Records vehicle
mileage since the diagnostic test last failed may
help determine how often the condition that caused
the Diagnostic Trouble Code to be set occurs. This
6E1123
DTC P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

Step
Action

Diagnostic Support.
1.
2.
3.
4.
Go to Step 4
Go to Step 3
Refer to
Diagnostic
Aids
Go to Step 4
514 V
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Go to Step 7
10 mV
Go to Step 8
Go to Step 9
Verify repair
Verify repair

952 mV (500
mV in
deceleration
fuel cutoff
mode)
1. Ignition OFF.
2. Disconnect the ECM connector.
3. Check for damage to the ECM pins and terminals.

8
Go to Step 2

7
Ignition OFF.
Ignition ON.
At HO2S 1 connector (ECM side) use a Digital
Voltmeter (DVM) to measure voltages at the high
and low signal terminals.

5
No
Go to OBD
System
Check
1. Ignition ON review and record Tech 2 Failure

Records data.
Yes

performed?

specified value?
3
Value(s)
Replace the ECM.

6E1124
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR CIRCUIT NO

ACTIVITY DETECTED (BANK 1 SENSOR 1)
D06RX119
Circuit Description

(HO2S) high and low circuits. When measured with a 10
MW digital voltmeter, this may display as low as 320 mV.
The oxygen sensor varies the voltage within a range of
about 1000 mV when the exhaust is rich, down through
necessary. If the Bank 1 HO2S 1 voltage remains at or
near the 450 mV bias for an extended period of time,
Diagnostic Trouble Code P0134 will be set, indicating an
open sensor signal or sensor low circuit. DTC P0134 is a
type B code.


functioning properly, and the oxygen sensor has
warmed to operating temperature.
All the above conditions are met and the following
condition is met:
mV and 500 mV for a total of 76.5 seconds over a

without a fault.
Diagnostic Aids
damaged
terminals,
poor
terminaltowire
ON engine OFF after a cooldown period, the HO2S 1
voltage displayed on the Tech 2 is normally 455460
mV. A reading over 1000 mV indicates a signal line
shorted to voltage. A reading under 5 mV indicates a

signal line shorted to ground or signal lines shorted
together. Disconnect the HO2S and connect a test light
between the HO2S ignition feed and heater ground
circuits. If the test light does not light for 2 seconds
when the ignition is turned on, repair the open ignition
feed or sensor ground circuit as necessary. If the test
light lights and the HO2S signal and low circuits are
OK, replace the HO2S.
D Intermittent test With the ignition ON monitor the
6E1125

condition.

Step
Action
400500 mV
Go to Step 3
Go to Step 4
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8

terminal connections at the ECM and replace terminals
if necessary.
Go to Step 2

6
Go to OBD
System
Check
1. Ignition ON, engine OFF review and record Tech 2


5
No

3. Operate the engine above 1200 RPM for three
minutes.

4
Yes

performed?

3
Value(s)
1. Ignition OFF.
W, repair open or poor connection as necessary.
corrected?
6E1126

(Cont'd)
Step
Action
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11
Verify repair
Verify repair
10 mV

11
No

Is Bank 1 HO2S 1 voltage approximately equal to the
specified value?
10
Yes
1. Ignition OFF.
3. If the Bank 1 HO2S 1 low circuit measures over 5 W,
repair open or poor connection as necessary.
corrected?
Value(s)
Replace the ECM.

6E1127
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT

MALFUNCTION
D06RX119
Circuit Description
of time required for Closed Loop fuel control operation
required for fuel control sensors Bank 1 HO2S 1.
The engine control module (ECM) will run the heater test
only after a cold start (determined by engine coolant and
intake air temperature at the time of startup) and only
once during an ignition cycle. When the engine is started
the ECM will monitor the HO2S voltage. When the HO2S
voltage indicates a sufficiently active sensor, the ECM
looks at how much time has elapsed since startup. If the
ECM determines that too much time was required for the
Bank 1 HO2S 1 to become active, a Diagnostic Trouble
Code P0135 will set. DTC P0135 is a type B code.

D Intake air temperature (IAT) is less than 32C (90F)
at startup.
D Engine coolant temperature (ECT) is less than 32C
(90F) at startup.
D IAT and ECT are within 5C (9F) of each other at
startup.
D Ignition voltage is between 11 and 16.6 V.
D Average calculated air flow is less than 18 g/second
during sample period.
D Throttle angle is less than 40%.

D Bank 1 HO2S 1 voltage does not change more than
148 mV from the bias voltage (between 400 mV and
500 mV) for a longer amount of time than it should. The
maximum amount of time to come up to operating
range is 240 seconds. This warmup time depends on
the engine coolant temperature at startup and intake
air temperature at startup.

fault is detected.

without a fault.
6E1128
Diagnostic Aids
fault.
condition.
2. The HO2S should be allowed to cool before

performing this test. If the HO2S heater is
functioning, the signal voltage will gradually increase
or decrease as the sensor element warms. If the
heater is not functioning, the HO2S signal will
remain near the 450 mV bias voltage.
4. Ensures that the ignition feed circuit to the HO2S is
not open or shorted. The test light should be
connected to a good chassis ground, in case the
HO2S low or HO2s heater ground circuit is faulty.
5. Checks the HO2S heater ground circuit.
6. Checks for an open or shorted HO2S heater
element.
10.An open HO2S signal or low circuit can cause the
HO2S heater to appear faulty. Check these circuits
before replacing the sensor.
Test Description
Diagnostic Chart:
DTC P0135 O2 Sensor Heater Circuit Malfunction

Step
Action
Go to Step 2
Go to OBD
System
Check
Above 650
mV or below
250 mV
Refer to
Diagnostic
Aids
Go to Step 3
Inspect the fuse for the Bank 1 HO2S 1 ignition feed.

Is the fuse open?
1.
2.
3.
4.
Go to Step 15
Go to Step 4
Ignition OFF.
Raise the vehicle.
Disconnect the Bank 1 HO2S 1 electrical connector.
Using a test light connected to a good ground (do
not use Bank 1 HO2S 1 heater ground or Bank 1
HO2S 1 low), probe the ignition feed circuit at the
Bank 1 HO2S 1 electrical connector (ECM harness
side).

5
No
NOTE: If the engine has just been operating, allow

engine to cool for about one half hour before
proceeding.
Does the HO2S voltage go from bias voltage to above

and below the specified values?
Yes

performed?

3. Ignition ON engine OFF monitor the Bank 1 HO2S 1
voltage.
Value(s)
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 8
Connect the test light between the Bank 1 HO2S 1

ignition feed and the Bank 1 HO2S 1 heater ground.
6E1129
DTC P0135 O2 Sensor Heater Circuit Malfunction (Cont'd)

Step
Action
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 13
Go to Step 14
Replace the Bank 1 HO2S 1.

15
Check for a poor Bank 1 HO2S 1 high circuit terminal

necessary.
14
Check for a poor Bank 1 HO2S 1 low circuit terminal

necessary.
13
Verify repair
1. Ignition OFF.
2. Disconnect the ECM and check the continuity of the
Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S
1 low circuit.
3. If the Bank 1 HO2S 1 high circuit or HO2S low circuit
measures over 5 W, repair open or poor connection
as necessary.
12
Check for a poor Bank 1 HO2S 1 high or low circuit

terminal connection at the Bank 1 HO2S 1 harness
11
Go to Step 9
1. Check for a poor connection at the Bank 1 HO2S 1

harness terminals.
2. If a poor connection is found, replace terminals.
10
Go to Step 10
36 ohms
Repair the open Bank 1 HO2S 1 heater ground circuit

to Bank 1 HO2S 1.
No
Repair the open Bank 1 HO2S 1 ignition feed circuit to

Bank 1 HO2S 1.
Yes
1. Allow the HO2S to cool for at least 10 minutes.

resistance between the Bank 1 HO2S 1 ignition
feed and the Bank 1 HO2S 1 heater ground at the
Bank 1 HO2S 1 pigtail.
Is the HO2S heater resistance within the specified
values?
Value(s)
Locate and repair the short to ground in Bank 1 HO2S 1

ignition feed circuit and replace the fault fuse.
6E1130
DIAGNOSTIC TROUBLE CODE (DTC) P0171 SYSTEM TOO LEAN (BANK 1)
D06RX119
Circuit Description
HO2S 1 signal and adjusts fuel delivery based upon the
HO2S signal voltage. A change made to fuel delivery will
be indicated by the long and short term fuel trim values
which can be monitored with a Tech 2. Ideal fuel trim
values are around 0%; if the HO2S signal indicates a lean
condition the ECM will add fuel, resulting in fuel trim
trim values will be below 0%, indicating that the ECM is
lean condition is detected on Bank 1, the ECM will set
Diagnostic Trouble Code P0171. DTC P0171 is a type B
code.
trim allows a range between 14% and +20%. The ECM
diagnostic.

D None of the following: EGR Diagnostic Trouble Codes,
HO2S Diagnostic Trouble Codes, (response,
transition, open, low volts, no activity), TP sensor
Diagnostic Trouble Codes, MAP Diagnostic Trouble
D
D
D
D
D
D
D
D
Codes, IAT Diagnostic Trouble Codes, canister purge

Diagnostic Trouble Codes, EVAP Diagnostic Trouble
Codes, injector circuit Diagnostic Trouble Codes, or
misfire Diagnostic Trouble Codes.
and 104C (219F).
120C (248F).
99 kPa.
System voltage is greater than 9.5v.
The average of the short term fuel trim samples is
greater than 0.97 and the average of adaptive index
multiplier samples is greater than 1.21.

fault is detected.

after 40 consecutivewarmup cycles have occurred
without a fault.
Diagnostic Aids
condition.
Test Description
Diagnostic Chart:
2.Diagnostic Trouble Codes other than P0171 may
which caused the other Diagnostic Trouble Code will
most likely correct the Diagnostic Trouble Code
P0171.
4.If the Diagnostic Trouble Code P0171 test passes
duplicated, the lean condition is intermittent. Refer
to Diagnostic Aids or Symptoms for additional
6E1131
6E1132
DTC P0171 System Too Lean (Bank 1)

Step
Action
Go to Step 3
L.T. Fuel
Trim: 20%
Go to Step 5
Go to Step 4
Go to Step 5
The lean
condition is
not present. If
a driveability
symptom still
exists, refer
to Symptoms
section.
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Go to Step
10
Above 5
counts
Go to Step
10
Go to Step 9
Verify repair
Go to Step
10

System).
Is the displayed value above the specified value?
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.


8
Go to Step 2

conditions.
conditions.
Trouble Code P0171 test runs and note the test
result.

7

Loop.
2. Observe the BANK 1 L.T. FUEL TRIM and display
on the Tech 2.

6
No
Go to OBD
System
Check
Are any DTCs set other than P0171?

5
Yes

performed?
Are the displayed values greater than the specified

values?
4
Value(s)

for vacuum leaks.
6E1133
DTC P0171 System Too Lean (Bank 1) (Cont'd)

Step
Action
10
Perform the Idle Air Control (IAC) Valve Check and

correct any IAC problem as necessary.
Did this test isolate a problem requiring repair?
11
14
Go to Step
12
Verify repair
Go to Step
13
Verify repair
Go to Step
14
Verify repair
Go to Step
15
Verify repair
Go to Step
16
Verify repair
Go to Step
17
Verify repair
Go to Step
18
Verify repair
Refer to
Diagnostic
Aids

18
Verify repair

17

injector Orings, EGR adapter, EGR valve and the
16
Go to Step
11
Perform the Evaporative Emissions Control (EVAP)

Canister Purge Valve Check and repair EVAP system
problem if necessary.
15
Verify repair
Perform the procedure in Fuel System Pressure Test

and repair fuel system problem if necessary.
Did the test isolate a condition requiring repair?

No
1. Visually and physically inspect the ECM injector

locations.
necessary.
13
Yes

12
Value(s)
6E1134
DIAGNOSTIC TROUBLE CODE (DTC) P0172 SYSTEM TOO RICH (BANK 1)
D06RX119
Circuit Description
heated oxygen sensor (HO2S) 1 and adjusts fuel delivery
based upon the HO2S signal voltages. A change made to
fuel delivery will be indicated by the long and short term
fuel trim values which can be monitored with a Tech 2.
Ideal fuel trim values are around 0%; if the HO2S signals
are indicating a lean condition the ECM will add fuel,
resulting in fuel trim values above 0%. If a rich condition is
detected, the fuel trim values will be below 0%, indicating
that the ECM is reducing the amount of fuel delivered. If
an excessively rich condition is detected on Bank 1, the
ECM will set Diagnostic Trouble Code P0172. DTC
trim allows a range between 14% and +20%. The ECMs
maximum authority to control short term fuel trim allows a
range between 11% and +20%. The ECM monitors fuel
trim under various engine speed/load fuel trim cells
before determining the status of the fuel trim diagnostic.

D None of the following was set: EGR Diagnostic Trouble
Codes, HO2S Diagnostic Trouble Codes, (response,
transition, open, low volts, no activity), TPS Diagnostic
Trouble Codes, MAP Diagnostic Trouble Codes, IAT
D
D
D
D
D
D
D
D
Diagnostic Trouble Codes, canister purge Diagnostic

Trouble Codes, EVAP Diagnostic Trouble Codes,
injector circuit Diagnostic Trouble Codes, or misfire
Diagnostic Trouble Codes.
and 104C (219F).
120C(248F).
99 kPa.
System voltage is greater than 9.5 volts.
The average of the long term full trim samples is less
than 1.03 and the average of the adaptive index
multiplier samples is less than or equal to 0.82.

fault is detected.


without a fault.
Diagnostic Aids
Test Description
Diagnostic Chart:
2. Diagnostic Trouble Codes other than P0172 may
which caused the other DTC will most likely correct
the DTC P0172.
4. If the Diagnostic Trouble Code P0172 test passes
duplicated, the rich condition is intermittent. Refer to
Diagnostic Aids or Symptoms for additional
6E1135
6E1136
DTC P0172 System Too Rich (Bank 1)

Step
Action
Go to Step 3
L.T. Fuel
Trim: 14%
Go to Step 5
Go to Step 4
The rich
condition is
not present. If
a driveability
symptom still
exists, refer
to Symptoms.
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Go to Step
10
Below 100
counts
Go to Step
10
Go to Step 9
Verify repair
Go to Step
10

Is the IDLE AIR CONTROL value below the specified
value?
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.


8
Go to Step 2

conditions.
conditions.
Trouble Code P0172 test runs and note test result.

7

Loop.
2. Observe BANK 1 L.T. FUEL TRIM display on the
Tech 2.

6
No
Go to OBD
System
Check
Are any Diagnostic Trouble Codes set other than

P0172?

5
Yes

performed?
Are the displayed values more negative than the

specified values?
4
Value(s)
1. Ignition OFF.
objects.
6E1137
DTC P0172 System Too Rich (Bank 1) (Cont'd)

Step
Action
10
1. Perform the Idle Air Control (IAC) Valve Check.

11
Verify repair
Go to Step
12
Minimum 0%
Maximum
100%
Go to Step
13
Go to Step
17
Verify repair
Go to Step
14
Verify repair
Go to Step
15
Verify repair
Go to Step
16
Verify repair
Refer to
Diagnostic
Aids
Verify repair

17
Go to Step
11

(refer to Fuel Metering System).
16
Verify repair
1. Perform the Evaporative Emissions Control

(EVAP) Canister Purge Valve Check.
2. If the test isolates a problem, repair as necessary.
15
1. Perform the Fuel System Pressure Test.

(refer to Engine Fuel or Fuel Metering System).
14
No
Ignition ON engine OFF monitor the TP Angle display

on the Tech 2 while slowly depressing the accelerator
pedal.
13
Yes

fuel.
System).
12
Value(s)

missing.
6E1138

D06RX120
Circuit Description
is a type A code.


fault.
Diagnostic Aids
D
D
D
D

injectors.
The battery voltage is more than 9 volts.

Engine is running.
Fuel pump is ON.
commanded ON.

6E1139
Test Description
Diagnostic Chart:
connector.
901RX032

about 13.5 W.

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6

Code.

Does P0201 reset?
No
Go to OBD
System
Check
Yes
1. Ignition OFF.
cylinder 1.
6E1140

Step
Action
12
15
Go to Step 9
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.

control circuit.
16
Go to Step 8

2. Ignition ON.

14

13
Go to Step
10

2. Ignition ON.
the test light.
test light?
11
Go to Step 7
Replace the ECM.

10

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
6E1141

D06RX120
Circuit Description
is a type A code.


fault.
Diagnostic Aids
D
D
D
D

injectors.

Engine is running.
Fuel pump is ON.
commanded ON.

6E1142
Test Description
Diagnostic Chart:
5.This step tests the harness wiring and ECM control
connector.
7.Because the test light was ON steady, voltage to the
901RX033

about 13.5 W.

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6

Code.

Does P0202 reset?
No
Go to OBD
System
Check
Yes
1. Ignition OFF.
injector connector.
cylinder 2.
6E1143

Step
Action
12
15
Go to Step 9
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.

control circuit.
16
Go to Step 8

2. Ignition ON.

14

13
Go to Step
10

2. Ignition ON.
the test light.
test light?
11
Go to Step 7
Replace the ECM.

10

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
6E1144

D06RX120
Circuit Description
is a type A code.

when the DTC was setas Freeze Frame and in the

fault.
Diagnostic Aids
D
D
D
D

injectors.

Engine is running.
Fuel pump is ON.
commanded ON.

6E1145
Test Description
Diagnostic Chart:
connector.
901RX034

about 13.5 W.

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6

Code.

Does P0203 reset?
No
Go to OBD
System
Check
Yes
1. Ignition OFF.
injector connector.
cylinder 3.
6E1146

Step
Action
12
15
Go to Step 9
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.

control circuit.
16
Go to Step 8

2. Ignition ON.

14

13
Go to Step
10

2. Ignition ON.
the test light.
test light?
11
Go to Step 7
Replace the ECM.

10

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
6E1147

D06RX120
Circuit Description
set if an injector driver is shorted to voltage. DTC P0204 is
a type A code.


fault.
Diagnostic Aids
D
D
D
D

injectors.

Engine is running.
Fuel pump is ON.
commanded ON.

6E1148
Test Description
Diagnostic Chart:
connector.
901RX035

about 13.5 W.

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
Chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Fuel
Injector Coil
Test
Procedure
Go to Step 6
Go to Step 7
Go to Step
10


Does P0204 reset?
1. Ignition OFF.
injector connector.
cylinder 4.
No
Go to OBD
System
Check
Yes

steady in step 5.
engine?
6E1149

Step
Action
12
15
Go to OBD
System
Check
Go to Step
11
Go to Step
12
Verify repair
Go to Step
11
Go to Step
13
Go to Step
14
Go to Step
15
Verify repair
Go to Step
16
Go to Step 9
Verify repair

2. Ignition OFF.

control circuit.
16

2. Ignition ON.

14
Go to OBD
System
Check

13
Go to Step 9

2. Ignition ON.
the test light.
test light?
11
Go to Step 8
Replace the ECM.

10
No

Yes

injectors.
Value(s)
6E1150

MALFUNCTION
D06RX121
Circuit Description
The knock sensor (KS) system is used to detect engine
detonation. The knock sensor produced an AC voltage
signal. The knock sensor sends this signal to the ECM.
The amplitude and the frequency of the AC voltage signal
depends upon the knock level being detected. The ECM
will then retard the spark timing based on the signals from
the Knock Sensor. DTC P0325 is a type B code.

D No P0327 Diagnostic Trouble Code set.
D Engine speed is above 2500 rpm.
All the above mentioned conditions are met, and the
following conditions are met for 8.75 seconds within a 10
second monitoring period:
D Any of the four A/D voltages exceeds 1.5625 Volts.
D Instantaneous A/D delta Voltage falls below 0.019531
Volts.

the second time the fault is detected.


D The MIL will turn off after 3 consecutive ignition cycles
in which the diagnostic runs without a fault.
D A Tech 2 can clear the Diagnostic Trouble Codes.
Diagnostic Aids
Correct any abnormal engine noise before using the
diagnostic table.
Check for an open ignition feed circuit.
Test Description
Diagnostic Chart:
the freeze frame data and failure records data on
the Tech 2 if applicable. This creates an electronic
copy of the data taken when the malfunction
occurred. The information is then stored on the
Tech 2 for later reference.

2. If the conditions for the test as described above are
met, a Diagnostic Trouble Code P0325 will set and
MIL will illuminate.
4. If the engine has an internal knock or audible noise
that causes a knocking type noise on the engine
block, the knock sensor may be responding to the
noise.
6. The Tech 2 displays knock sensor activity in counts,
approximately 2050 at idle. The counts should
increase when engine speed is increased and the
counts should decrease when engine speed is
decreased.
6E1151
7. Any circuitry, that is suspected as causing the

complaint, should be thoroughly checked for backed
out terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage
to the wiring harness.
8. If the KS module was previously replaced and the
Diagnostic Trouble Code resets, a malfunctioning
ECM is indicated.
9. Checking the internal resistance of the knock sensor
verifies if the knock sensor or the wiring to the
knock sensor is OK.
DTC P0325 KS Circuit Malfunction

Step
Action
1.
2.
3.
4.
Go to Step 4
Go to Step
13
Go to Step 5
Go to Step 6
Go to Step
13
2500 RPM
Go to Step 7
Go to Step
11
Go to Step
13
Go to Step 8
Go to Step
13
90K 110K W
Go to Step 7
Go to Step
10
Replace the ECM.

Go to Step 3
Check for a poor connection at the ECM connector,

Knock sensor signal circuit and repair as necessary.
Go to Step 4
Slowly increase the engine speed to the specified

value.
Does the KS Activity increase with the engine speed?
Repair the mechanical engine problem or a loose

bracket or component.
Go to Step 2
Listen to the engine while raising and lowering the

engine speed.
Is a knock or audible noise present?
Go to
Powertrain
OBD System
Check
1. Turn the ignition switch ON, with engine OFF.

2. Review the Freeze Frame data and note the
parameters.
3. Operate the vehicle within the Conditions and
Conditions for Setting the DTC as noted.
No
Start the engine.

Install a Tech 2.
Clear the Diagnostic Trouble Codes.
Run the engine at slightly more than 10% throttle
angle.

3
Yes

Value(s)
1. Turn the ignition switch OFF.

2. Disconnect the ECM connectors at the ECM.
ground, measure the resistance of the knock
sensor through the knock sensor signal circuit.
Is the measured value within the specified value?
6E1152
DTC P0325 KS Circuit Malfunction (Cont'd)

Step
Action
10
Check the knock sensor electrical connector for a poor

11
13
Go to Step
11
Go to Step
13
Go to Step
12
Go to Step
13
Go to Step
14
Go to Step 2
Go to
applicable
DTC table
System OK

Codes.
temperature.
3. Operate the vehicle within the conditions for setting
this Diagnostic Trouble Code as specified in the
supporting text.
Does the Tech 2 indicate that this diagnostic has ran
and passed?
14
No
Go to Step
13
Replace the Knock Sensor (KS).

Yes
Check the knock sensor signal circuit for an open or a

short to ground or to voltage and repair as necessary.
12
Value(s)
Check is any additional Diagnostic Trouble Codes are

set.
Are any Diagnostic Trouble Codes displayed that have
not been diagnosed?
6E1153

LOW INPUT
D06RX121
Circuit Description
The ECM uses the Knock Sensor (KS) in order to detect
engine detonation. This allows the ECM to retard the
Ignition Control (IC) spark timing based on the KS signal
the ECM receives. The circuitry within the knock sensor
pulls down the ECMsupplied 5 volt signal, so that under
a no knock condition the signal on the KS circuit
measures about 1.3 volts. The knock sensors produce an
AC signal that rides on the 1.3 volts DC. The signals
amplitude and frequency are dependent upon the amount
of the knock being experienced.
The ECM determines whether the knock is occurring by
comparing the signal level on the KS circuit with a voltage
level on the noise channel. The noise channel allows the
CM to reject any false knock signal by indicating the
amount of normal engine mechanical noise present. The
normal engine noise varies depending on the engine
speed and load. Then the ECM determines that an
abnormally high noise channel voltage level is being
experienced, a Diagnostic Trouble Code P0327 sets.
This DTC is a type B DTC.

A/D Test
D Engine speed is equal to or greater than 2000 RPM.
D A/D Voltage is less than or equal to 0.0977 Volts.
Gain Test
D Engine speed is greater than 2500 RPM.
D Gain is equal to or greater than 23.875 dB.

D The ECM will illuminate the MIL the second time the
fault is detected.
D The ECM will store the conditions which were present
then the Diagnostic Trouble Code set.

consecutive warmup cycles have occurred without a
fault.
D The Tech 2 Clear Info will clear the Diagnostic Trouble
Code.
Diagnostic Aids
A poor connection at the ECM. Inspect the knock sensor
and the ECM connectors for: , broken locks, improperly
formed or damaged terminals.
D Backed out terminals
6E1154
D Broken locks
D Improperly formed or damaged terminals
Also, check the wiring harness for: shorts to ground,
shorts to battery positive, and open circuits.
D A misrouted harness. Inspect the knock sensor
harness in order to ensure that it is not routed too close
to high voltage wires such as spark plug leads.
D Improper Knock Sensor torque specification. Torque
the Knock Sensor to 19Nm (1.9kgm/14 lbsft). Refer
to Fastener Notice.
Review the Fail Records vehicle mileage since the
diagnostic test last failed in order to help determine how
often the conditions that caused the DTC to set occur.

This may assist in diagnosing the condition.
Test Description
Diagnostic Chart:
6. Ensures that the knock sensor is capable of
detecting detonation.
DTC P0327 KS Circuit Low Input

Step
Action
Yes

No
Go to Step 2
Go to
Powertrain
OBD System
Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic
Aids
Approx. 5.0 V
Go to Step 5
Go to Step 8
100K W
Go to Step 6
Go to Step 9

in the diagnostic support Conditions for Setting the
DTC.
2. Using a Tech 2, monitor theDiagnostic Trouble
Code information for Diagnostic Trouble Code
P0327 until the Diagnostic Trouble Code P0327 test
runs.
Does the Tech 2 indicate the DTC P0327 failed this
ignition?
Value(s)
1. Turn ON the Ignition leaving the engine OFF.

2. Review the Tech 2 Fail Records data.
3.
IMPORTANT: Before clearing the DTCs, use the Tech
2 to record the Freeze Frame and the Failure Records
for reference. This data will be lost when the Clear Info
function is used.
4. Record the Tech 2 Fail Records data.
5. Operate the vehicle within the Fail Records
conditions.
6. Using a Tech 2, monitor the DTC info for the DTC
Does the Tech 2 indicate the DTC P0327 Failed This
Ignition?
1. Disconnect the KS Sensor electrical connector.

voltage between the KS signal circuit at the knock
sensor harness connectors and ground.
Is the voltage at the specified value?
Measure the resistance of the KS sensor by connecting

the between the KS sensor terminal and the engine
block.
Is the resistance of the KS sensor near the specified
value?
6E1155
DTC P0327 KS Circuit Low Input (Cont'd)

Step
Action
Go to Step
11
Go to Step 8
Go to Step
11
Go to Step
10
Go to Step
11
Go to Step
11
Go to Step
12
Go to Step 2
Go to
applicable
DTC table
System OK
Replace the ECM.

1.
2.
3.
4.
5.
6.
Using the Tech 2, select the DTC and the Clear Info.
Start the engine.
Idle at the normal operating temperature.
Select the DTC and the Specific.
Enter the DTC number which was set.
Operate the vehicle within the conditions for setting
this DTC as specified in the supporting text.

passed?
12
Go to Step 9
Replace the KS Sensor. Refer to Knock Sensor.

11
Go to Step 7

Disconnect the ECM.
Turn ON the ignition.
Check the KS signal circuit between the ECM and
the KS sensor connector for an open, a short to
5. If a wiring problem is found, repair as necessary.

10
1.
2.
3.
4.

9
No
1. ReConnect the KS Sensor in order to monitor the

voltage between the KS sensor terminal and the
engine ground.
2. Tap on the engine lift bracket, near the KS Sensor,
while observing the signal indicated on the Tech 2.
Is any signal indicated on the while tapping on the
Yes

connection at the knock sensor.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs in Engine Electrical.
Value(s)
Using the Tech 2, select the Capture Info and the

Review Info.
Are any DTCs displayed that have not been
diagnosed?
6E1156

D06RX122
Circuit Description

58 crankshaft pulses will be produced. The engine control
module (ECM) uses the 58X reference signal to calculate
engine RPM and crankshaft position. The ECM
58X reference circuit, Diagnostic Trouble Code P0336 will
set. Diagnostic Trouble Code P0336 is a type B code.
without a fault.

rotations.

fault is detected.
Diagnostic Aids
6E1157

condition.
DTC P0336 CKP Sensor Circuit Range/Performance

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Refer to
Engine
Cranks But
Will Not Run
chart
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
2.5 V
Go to Step 8
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Verify repair
Go to Step 9
Verify repair

1.
2.
3.
4.

Clear Diagnostic Trouble Code P0336.
Observe Diagnostic Trouble Codes.
Is Diagnostic Trouble Code P0336 set?

4


2. Connect a Digital Voltmeter (DVM) to measure
voltage on the 58X reference circuit at the ECM
connector.


Check connections at the ECM and replace the

No
Go to OBD
System
Check
Yes
Replace the ECM.

6E1158

D06RX122
Circuit Description

engine control module (ECM) uses the 58X reference
The ECM constantly monitors the number of pulses on
received. If the ECM does not receive pulses on the 58X
reference circuit, Diagnostic Trouble Code P0337 will set.
Diagnostic Trouble Code P0337 is a type B code.
without a fault.

D Engine cranking.
pulses.

fault is detected.
Diagnostic Aids
6E1159

condition.
DTC P0337 CKP Sensor Circuit Low Input

Step
Action
Go to Step 4
Go to Step 9
Verify repair
Verify repair
Go to Step 6
2.5 V
Go to Step 9
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Verify repair
Go to Step
10
Verify repair

Check the connections at the ECM and replace the
10
Go to Step 3


9
Go to Step 5

reference circuit at the ECM connector.

8
1. Ignition OFF.

7
Go to Step 2

sensor and ECM and repair the open circuit, short to

6
Go to OBD
System
Check
1. Ignition ON.
2. With a DVM, backprobe the ECM connector 5 V

5
No

2. Ignition ON.
3. Using a Digital Voltmeter (DVM), verify that 5 V
reference and ground are being supplied at the
sensor connector (ECM side).
Are 5 V reference and ground available at the ECM?

4
Yes

performed?
Are 5 V and ground being supplied to the sensor?

3
Value(s)
Replace the ECM.

6E1160

D06RX123
Circuit Description
received. The engine control module (ECM) uses the
CMP signal pulses to initiate sequential fuel injection. The
ECM constantly monitors the number of pulses on the
CMP signal circuit and compares the number of CMP
CMP reference circuit, Diagnostic Trouble Code P0341
will set and the ECM will initiate injector sequence without
the CMP signal with a one in four chance that injector
sequence is correct. The engine will continue to start and
run normally, although the misfire diagnostic will be
affected if a misfiring condition occurs. DTC P0341 is a
type B code.

D The engine is running (CMP reference pulses are
being received).
D Above condition fails for 10 occurrences within 100 test
samples (15.6 m/s).

fault is detected.


Diagnostic Aids
ground wire.
insulation. Check for the following conditions:

6E1161

the condition that caused the Diagnostic Trouble Code
(DTC) to be set occurs. This may assist in diagnosing the
condition.
DTC P0341 CMP Sensor Circuit Range/Performance

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
04 V
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 6
Verify repair
Verify repair
B+
Go to Step
12
Go to Step 8
B+
Go to Step
10
Go to Step 9
Verify repair
B+
Go to Step
12
Go to Step
11
Verify repair
1. Ignition ON.
cycle?
1. Monitor voltage on the CMP signal circuit while

cranking the engine.

the ECM terminal.
5
6

Replace the ECM

Sensor.
2. Ignition ON.
3. At the CMP connector, use a Digital Voltmeter
(DVM) to check the voltage between the voltage
signal wire and sensor ground.
1. Ignition ON.

10
1. Ignition ON.
11
No
Go to OBD
System
Check
Yes

6E1162
DTC P0341 CMP Sensor Circuit Range/Performance (Cont'd)

Step
Action
12

13
Go to Step
13
Go to Step
14
Verify repair
Go to Step
15
Go to Step
16
Verify repair
Verify repair

16
No
1. Ignition ON.
to voltage.
15
Yes

14
Value(s)

6E1163

D06RX123
Circuit Description
received. The ECM uses the CMP signal pulses to initiate
sequential fuel injection. The ECM constantly monitors
the number of pulses on the CMP signal circuit and
compares the number of CMP pulses to the number of
58X reference pulses received. If the ECM does not
receive pulses on the CMP reference circuit, Diagnostic
Trouble Code (DTC) P0342 will set and the ECM will
initiate injector sequence without the CMP signal with a
one in four chance that injector sequence is correct. The
condition occurs. Diagnostic Trouble Code (DTC) P0342
is a type B code.

D The CMP sensor signal is not received by the ECM

fault is detected.


Diagnostic Aids
ground wire.
insulation. Check for the following:
6E1164


Test Description
Diagnostic Chart:
DTC P0342 Camshaft Position Sensor Circuit Low Input

Step
Action
Value(s)

performed?
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
04 V
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 6
Verify repair
Verify repair
B+
Go to Step
12
Go to Step 8
B+
Go to Step
10
Go to Step 9
Verify repair
B+
Go to Step
12
Go to Step
11
Verify repair
1. Ignition ON.
Did the Tech 2 indicate DTC P0342 failed this ignition
cycle?
1. Use a Digital Voltmeter (DVM) to monitor voltage on

the CMP signal circuit while cranking the engine.

the ECM terminal.
5
6

Replace the ECM.

Sensor.
2. Ignition ON.
3. At the CMP connector, check the voltage between
the voltage signal wire and sensor ground.
1. Ignition ON.

10
1. Ignition ON.
11
No
Go to OBD
System
Check
Yes

6E1165
DTC P0342 Camshaft Position Sensor Circuit Low Input (Cont'd)

Step
Action
12

13
Go to Step
13
Go to Step
14
Verify repair
Go to Step
15
Go to Step
16
Verify repair
Verify repair

16
No
1. Ignition ON.
to voltage.
15
Yes

14
Value(s)

6E1166
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION COIL A

D06RX124
Circuit Description

spark plug.


fault.
D Ignition ON.
ON.
OFF.
circuit monitoring.

Diagnostic Aids

6E1167

DTC P0351 Ignition Coil A Primary/Secondary Circuit Malfunction

Step
Action
Verify Repair
Go to Step 3
Verify Repair
Go to Step 4
Verify Repair
Go to Step 5
Verify Repair
Go to Step 6
Verify Repair
Go to Step 7
Go to Step 8
Verify Repair

Verify repair.

7
Go to Step 2
1. Ignition OFF.
module.
voltage.

6
Go to OBD
System
Check

the ECM connector.

5
No


4
Yes

performed?

3
Value(s)
Replace the ECM.

6E1168
DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION COIL B

D06RX124
Circuit Description

spark plug.


fault.
D Ignition ON.
ON.
OFF.
circuit monitoring.

Diagnostic Aids

6E1169

DTC P0352 Ignition Coil B Primary/Secondary Circuit Malfunction

Step
Action
Verify Repair
Go to Step 3
Verify Repair
Go to Step 4
Verify Repair
Go to Step 5
Verify Repair
Go to Step 6
Verify Repair
Go to Step 7
Go to Step 8
Verify Repair

Verify repair.

7
Go to Step 2
1. Ignition OFF.
module.
voltage.

6
Go to OBD
System
Check

the ECM connector.

5
No


4
Yes

performed?

3
Value(s)
Replace the ECM.

6E1170

(EGR) FLOW INSUFFICIENT DETECTED
D06RX113
Circuit Description
The engine control module (ECM) tests the exhaust gas
recirculation (EGR) system during deceleration by
momentarily commanding the EGR valve to open while
monitoring the manifold absolute pressure (MAP) sensor
signal. When the EGR valve is opened, the ECM monitors
the change in MAP input signal. The ECM compares the
MAP change to a RPM vs. BARO table. When the ECM
interprets the change in MAP to be out of limits, the ECM
will set DTC P0401. The number of test samples required
to accomplish this may vary according to the severity of
the detected flow error.
Normally, the ECM will only allow one EGR flow test
sample to be taken during an ignition cycle. To aid in
verifying a repair, the ECM allows twelve test samples
during the first ignition cycle following a Tech 2 Clear Info
or a battery disconnect. Between nine and twelve
samples should be sufficient for the ECM to determine
adequate EGR flow and pass the EGR test. DTC P0401
is a type A code.

D No TP sensor, VSS, EVAP Purge, IAC, IAT sensor,
MAP sensor, EGR Pintle Position sensor, ECT sensor,
misfire DTCs set.
D Engine coolant temperature is greater than 60C

(140F).
D System voltage is between 11.5 and 16 volts.
D IAC position is steady, changing less than 5 counts.
D A/C clutch status is unchanged.
Start Test
D
D
D
D
D
TP angle is less than 0.8%.

EGR duty cycle is less than 1%.
MAP is steady, changing less than 1 kPa.
Compensated MAP between 10.3 kPa and 49.8 kPa.
Run Test
D Delta MAP is recorded during valve open conditions.
D EGR valve is ramped over a time interval.
Run Test will be aborted if any of the following are true:
D Vehicle speed changes by greater than 16 km/h
(10mph).
D Engine RPM changes by greater than 100 rpm.
D EGR is opened less than 95% of the commanded
amount.
During the Start Test and the Run Test, the EGR is closed
then opened. The associated change in MAP is
compared with the ECMs expected change value. If the

difference between the two values exceeds the ECMs
internal limit, a Diagnostic Trouble Code P0401 will set.
DTC P0401 is a type A code.
NOTE: Several deceleration cycles will be necessary to
run a sufficient number of EGR flow tests to determine a
pass or fail condition.

the first time the fault is detected.

Tech 2.
Diagnostic Aids
OnVehicle Service.
condition.
check the exhaust system for blockage (possibly a
6E1171
6E1172
DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected

Step
Action
Go to Step 2
Go to Step 4
Go to Step 3
Verify repair
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 7
Refer to
Diagnostic
Aids
Repair
complete

necessary.
necessary.
Go to OBD
System
Check

6
No

2. Monitor the MAP signal with a Tech 2 while idling.
3. While idling, depress the accelerator pedal about
halfway down and immediately let the engine return
to idle.

5
Yes

performed?
Did the MAP value on the Tech 2 show an immediate

large change?
3
Value(s)

6E1173

(EGR) EXCESSIVE FLOW DETECTED
D06RX113
Circuit Description
The Engine Control Module (ECM) closes the Exhaust
Gas Recirculation (EGR) system on engine startup to
test for excessive (any) flow. If the ECM determines that
EGR flow occurred on startup, in two consecutive trips,
then DTC P0402 will set. DTC P0402 is a type B code.

D Intake Air Temperature (IAT) is above 5C (41F).
D Engine RPM is less than 500 RPM.
D EGR Pintle Position if greater than 55 counts.
The above mentioned conditions must be met for 0.6
seconds during engine startup on two consecutive trips.
Diagnostic Aids

OnVehicle Service.
6E1174
DTC P0402 EGR Excessive Flow Detected

Step
Action
Go to Step 2
Go to
Diagnostic
Aids
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Refer to
Diagnostic
Aids

necessary.
No
Go to OBD
System
Check


4
Yes

performed?

3
Value(s)

necessary.
6E1175

(EGR) CIRCUIT RANGE/PERFORMANCE
D06RX113
Circuit Description
reduced.
intake manifold from the exhaust manifold through an
position should always be near the commanded or
If the ECM detects a large difference between the

desired EGR position and actual EGR position, then
type B code.

D EGR commanded ON (Desired EGR Position is
greater than 0%).
D Actual EGR Position differs from Desired EGR
Position by more than 15% for 5 seconds.

D Malfunction Indicator Lamp (MIL) will illuminate the
second time the fault is detected.

D Diagnostic Trouble Code(s) can be cleared by using a
Tech 2.
6E1176
Diagnostic Aids
Diagnostic Trouble Code was set when the vehicle was
cold by viewing the Engine Coolant Temperature (ECT).
Test Description
Diagnostic Chart:
Tech 2 if applicable. This created an electronic copy
reference.
accurately and if the fault if present.
3. When the EGR valve electrical connector is
disconnected, the Tech 2 should display the Actual
EGR Position as 0%. If is does not, the fault lies
either in the EGR signal circuit or the ECM.
4. A test light, when connected to ground, will glow
dimly when the EGR valve is commanded to 25%,
and brighter as the EGR valve is commanded to
100%. If the test light flashes, check the sensor
ground for an open.
5. An open or poor connection condition may have
caused this Diagnostic Trouble Code to set. Be
tension.
7. The test light will have glowed brightly in the
previous step if the EGR control circuit was shorted
to B+ and the Actual EGR Position on the Tech 2
will display 100%. A test light that did not illuminate,
indicates that the circuit may be open or shorted to
ground.
voltage, the DVM will read battery voltage and
additional Diagnostic Trouble Codes may be set and
engine performance will be poor.
13. Although the circuitry acted correctly when
checked, a problem may still lie within the terminals
which would not show up in probe type testing. Be
tension.

cause a Diagnostic Trouble Code P0401 to set. For
on vehicle service of the EGR Valve, refer to EGR
Valve.
tension.
19. Clearing the Diagnostic Trouble Codes is a very
important step for this diagnostic. The clearing
function allows the EGR valve to relearn a new
pintle position as the old position was inaccurate
due to the malfunction that caused the Diagnostic
Trouble Code. The Diagnostic Trouble Code must
be cleared with the ignition switch ON, with the
engine OFF or when the engine is idling. If the
ECM sees a EGR command, the new pintle position
will not be learned.
6E1177
DTC P0404 EGR Circuit Range/Performance

Step
Action
Go to Step 5
25%, 50%,
75%, 100%
Go to Step 6
Go to Step 7
Go to Step
19
Go to Step 8
Go to Step 9
Go to Step
10
Go to Step
11
Go to Step
19
Go to Step
12
5V
Go to Step
13
Go to Step
14
Go to Step
19
Go to Step
12
Go to Step
15
Go to Step
16
Go to Step
19
Check the control circuit for a short to voltage and

Connect the test light to B+ and again probe the control
circuit.
12
Go to Step 4
With a Digital Voltmeter (DVM) connected to ground,

probe the 5 V reference circuit.

11
Check the signal circuit for a short to voltage and repair

as necessary.
Is the voltage measured near the specified value?

10
Go to Step 3
With the test light still connected to ground, again probe

the control circuit without commanding the EGR valve
with the Tech 2.

9
Go to Step
19
With the test light still connected to ground, probe the

signal circuit.

8
25%, 50%,
75%, 100%
Repair the open or poor connection in the EGR ground

circuit.

7
Go to Step 2

2. Probe the EGR control circuit to the EGR valve.
3. Command the EGR valve to the specified values
using a Tech 2.

6
Go to
Powertrain
OBD System
Check

3. With a test light connected to B+, probe the ground
circuit to the EGR valve.
As the command is raised, does the test light glow

brighter, flash or maintain a steady glow?
5
No


4
Yes

performed?

Position?
3
Value(s)
Replace the ECM.

6E1178
DTC P0404 EGR Circuit Range/Performance (Cont'd)

Step
Action
13
Check the EGR ground circuit for a poor connection or

proper terminal tension at the ECM and repair as
necessary.
14
16
17
Go to Step
19
Go to Step
12
Go to Step
19
Go to Step
12
Go to Step
19
Go to Step
18
Go to Step
19
Go to Step
19
Go to Step
12
Verify repair
Go to Step 2
Check the ECM electrical connector for a poor

19

18
Go to Step
17
Check the control circuit for an open or poor connection

at the EGR valve electrical connector and repair as
necessary.
No
Go to Step
19
Check the control circuit for a short to ground and repair

as necessary?
Yes
Check the 5 V reference circuit for a short to voltage

and repair as necessary.
15
Value(s)
1. Using the Tech 2, clear Diagnostic Trouble Codes.

temperature.
supporting text.
Does the Tech 2 indicate that this diagnostic Ran and
Passed?
6E1179

(EGR) SENSOR CIRCUIT LOW
D06RX113
Circuit Description
reduced.

signal circuit or the sensor, then Diagnostic Trouble Code
P0405 will set. DTC P0405 is a type A code.

valve sensor.

the first time the malfunction is detected.

Tech 2.
6E1180
Diagnostic Aids
Test Description
Diagnostic Chart:
Tech 2 if applicable. This creates an electronic copy
reference.
accurately and if the fault is present.

ground, the DVM will read no voltage and an
additional Diagnostic Trouble Code will be set and
engine performance will be poor. When this circuit
is open, only a Diagnostic Trouble Code P0405 will
be set.
4. Jumping the 5 volt reference circuit to the signal
circuit checks the signal circuit and ECM. The Tech
2 should display the Actual EGR Position as 100% if
the signal circuit and ECM are OK.
6. Although the ECM and circuitry acted correctly in the
previous step, a problem may still lie within the
terminals which would not show up in probe type
testing. Check the terminals for being backed out,
tension.
cause a Diagnostic Trouble Code P0405 to set.
Refer the EGR Valve for on vehicle service of the
EGR valve.
tension.
DTC P0405 EGR Sensor Circuit Low

Step
Action
Go to Step 2
Go to
Powertrain
OBD System
Check
25%, 50%,
75%, 100%
Go to Step
15
Go to Step 3
5V
Go to Step 4
Go to Step 5
100%
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9

ground, probe the 5 V reference circuit to the EGR
valve.
Jumper the EGR valve 5 volt reference circuit to the
signal circuit.
Does the Actual EGR Position display the specified
value?
No

Does the DVM read near the specified value?

4
Yes


Position?
3
Value(s)

2. Probe the 5 V reference circuit to the EGR valve.
6E1181
DTC P0405 EGR Sensor Circuit Low (Cont'd)

Step
Action
Check the 5 V reference and signal circuits for a poor

connection or proper terminal tension and repair as
necessary.
10
Go to Step
15
Go to Step
13
Go to Step
15
Go to Step
14
Go to Step
15
Go to Step
15
Go to Step
13
Go to Step
15
Go to Step
14
Go to Step
15
Go to Step
15
Go to Step
13
Verify repair
Go to Step 2
Check the affected circuit for a poor connection or

proper terminal at the ECM and repair as necessary.
15
Replace the ECM.

14
Go to Step
12
Check for an open in the EGR valve signal circuit and

13
Go to Step
11
Check for a short to ground in the EGR valve signal

12

11
Go to Step
10
Check for an open in the EGR valve 5 V reference

No
Go to Step
15
Check for a short to ground in the EGR valve 5 V

reference circuit and repair as necessary.
Yes

2. Probe the signal circuit to the EGR valve.
Value(s)

Codes.
temperature.
supporting text.
passed?
6E1182

(EGR) SENSOR CIRCUIT HIGH
D06RX113
Circuit Description
by high combustion temperatures. It accomplishes this by
feeding small amounts of exhaust gases back into the
reduced.
orifice with a ECM controlled pintle. The ECM controls the
pintle position using inputs from the Throttle Position (TP)
and Manifold Absolute Pressure (MAP) sensors. The
ECM then commands the EGR valve to operate when
necessary by controlling an ignition signal through the
ECM. This can be monitored on a Tech 2 as the Desired
EGR Position.

signal circuit or the sensor, then DTC P0406 will set.
Diagnostic Trouble Code P0406 is a type A code.

valve sensor.

D The Malfunction Indicator Lamp (MIL) will illuminate.

consecutive warmup cycles without a fault.
D Diagnostic Trouble Code(s) can be cleared by using
the Tech 2.
Diagnostic Aids

6E1183

DTC P0406 EGR Sensor Circuit High

Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 6
Go to Step 4
Verify repair
less then 5 W
Go to Step 6
Verify repair
0 Volts 0%
Go to Step 9

solenoid.
Go to Step 14

D An open circuit
D A short to ground
Go to Step 2
Check the ignition feed circuit, between the EGR

conditions:
D An open circuit
D A short to ground

6
1. Ignition OFF.
on the ignition feed circuit at the Linear Exhaust Gas
connector.

5
No
Go to
Powertrain
OBD System
Check

P0406.

4
Yes


Passed?
3
Value(s)
Go to Step 15
1. Ignition OFF.
2. Disconnect the Linear Gas Recirculation (EGR)
Valve from the wiring harness.
Go to Step 8
6E1184
DTC P0406 EGR Sensor Circuit High (Cont'd)

Step
Action
11
14
15
Verify repair
Go to Step 13
Go to Step 12
about 5 volts
Go to Step 15
1. Ignition OFF.
Reference signal circuit and the EGR valve position
connector.
Go to Step 10
Go to Step 11

D An open circuit
D A short to ground
13
Go to Step 11
about 5 volts
1. Ignition OFF.
2. Place a DVM between the 5 volt Reference signal
12
Verify repair
Check the 5 volt Reference signal circuit, between the

D An open circuit
D A short to ground
No
Go to Step 15

harness connector.
10
Yes

D An open circuit
D A short to ground
Value(s)
Verify repair
Go to Step 14
Go to Step 15
5 volts 100%

Valve.
Verify Repair.
Replace the ECM.
Verify repair.
6E1185
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP)

CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION
D06RX115
Circuit Description

Evaporative Emission (EVAP) Canister Purge Solenoid
Valve through the use of a control (ground) circuit. If the
ECM commands the Purge solenoid to maximum duty
cycle (100%) but the voltage remains High (12 Volts); or, if
the ECM commands the Purge solenoid to minimum duty
cycle (0%) but the voltage remains Low (0 volts), then
DTC P0443 will set. DTC P0443 is a type A code.

Records.

D Ignition voltage is greater than 10 volts
D Engine run time is greater than 32 seconds
following two conditions are met for 25 seconds within a
50 seconds test sample:
D ECM senses voltage is High with the EVAP Canister
Purge Solenoid commanded ON.
D ECM senses voltage is Low with the EVAP Canister
Purge Solenoid commanded OFF.

D The ECM will turn OFF the MIL after three consecutive
trips without a reported failure.
Info function.
Diagnostic Aids
D Poor connections , or a damaged harness Inspect the
6E1186
DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction
Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 5
Go to Step 4
Verify repair
less than 5 W
Go to Step 6
Go to Step 7
Verify repair
Go to Step 8
Using a DVM, check the resistance of the EVAP

1. Ignition OFF.
3. Check the EVAP Canister Purge Solenoid control
circuit between the ECM and EVAP Canister Purge
Solenoid for the following conditions:
D A short to ground
D An open circuit
Go to Step 2
Check the suspect circuit between the EVAP Canister

Purge Solenoid connector and the Engine IG. Fuse
for the following conditions:
D A short to ground
D An open circuit

6
1. Ignition OFF.
2. Disconnect the EVAP Canister Purge Solenoid from
the wiring harness connector from the EVAP
on the Engine IG. Fuse pin of the EVAP Canister
Purge Solenoid wiring harness connector.

5
No
Go to OBD
System
Check

P0443.

4
Yes

performed?

Passed?
3
Value(s)
Replace the EVAP Canister Purge Solenoid.

Verify Repair.
Replace the ECM.
6E1187

CIRCUIT MALFUNCTION
060RX090
Circuit Description


Lamp.
Records.

sample:
D ECM sensed voltage is High with the Low Speed Fan
OFF.
OR
D ECM sensed voltage is Low with the Low Speed Fan
ON.

Info function.
Diagnostic Aids
6E1188

Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 4
Go to Step 3
12 Volts
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 7
Go to Step 9
Go to Step 8

D A short to ground
D An open circuit
1. Ignition OFF.
D A short to ground
D An open circuit
Go to Step 2
1. Ignition ON.

6
1. Ignition OFF.
Electrical Center.
3. Ignition OFF.
connector.

5
No
Go to OBD
System
Check

P0480.

4
Yes

performed?

Passed?
3
Value(s)
1. Reinstall the Low Fan Relay.

2. Using a fused jumper, ground the Low Fan Relay
Does the fan run at low speed?
6E1189

Step
Action
Yes
No
Replace the Low Fan Relay.

Value(s)
Verify repair
Replace the ECM.

Verify repair.
6E1190

CIRCUIT MALFUNCTION
060RX090
Circuit Description


Lamp.
Records.

sample:
OFF.
OR
ON.

Info function.
Diagnostic Aids
6E1191

Step
Action
Refer to
Diagnostic
Aids
Go to Step 3
12 Volts
Go to Step 4
Go to Step 3
12 Volts
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 7
Go to Step 9
Go to Step 8

D A short to ground
D An open circuit
1. Ignition OFF.
D A short to ground
D An open circuit
Go to Step 2
1. Ignition ON.

6
1. Ignition OFF.
Electrical Center.
3. Ignition OFF.
connector.

5
No
Go to OBD
System
Check

P0480.

4
Yes

performed?

Passed?
3
Value(s)
1. Reinstall the High Fan Relay.

2. Using a fused jumper, ground the High Fan Relay
Does the fan run at High speed?
6E1192

Step
Action
Yes
No
Replace the High Fan Relay.

Value(s)
Verify repair
Replace the ECM.

Verify repair.
6E1193
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS)

CIRCUIT LOW INPUT
D06RX125
Circuit Description
effect circuit that interacts with the magnetic field created
by the rotating magnet. A 12volt operating supply for the
The VSS pulses to ground the 5volt signal sent from the
engine control module (ECM) on the reference circuit.
The ECM interprets vehicle speed by the number of
DTC P0502 is a type B code.

D System voltage is between 10 and 16 volts.
When the above conditions are met, one of the following
tests will run:
Decel Test
D Throttle Position is less than 0.8%.
The Decel Test will fail if vehicle speed is less than 8 km/h
(5mph).
The Decel Test will pass if vehicle speed is greater than 24

km/h (15mph).
Power Test
D MAP is greater than 50 kPa.
D Throttle Position is between 25% and 70%.
The Power Test will fail if vehicle speed is less than 8 km/h
(5 mph).
The Power Test will pass if vehicle speed is greater than
8km/h (5mph) without any VSS DTCs present, or if
vehicle speed is greater than 49 km/h (30mph) with VSS
Diagnostic Trouble Codes present.

D Base shift logic on RPM only.

without a fault.
6E1194

Diagnostic Aids
D Poor connection at ECM: Inspect harness connectors
for backed out terminals, improper mating, broken

D Damaged harness: Inspect the wiring harness to the
EVAP vent solenoid, the EVAP purge solenoid, and the
fuel tank pressure sensor for an intermittent open or
intermittent short circuit.

Step
Action

2. Using a Digital Voltmeter (DVM), measure at the
VSS connector between ground and voltage
supply.
10
Go to Step 4
Go to Step 3
Verify repair
Battery
voltage
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 9
10 K W
Verify repair
Go to Step 9
Verify repair
Verify repair
Verify repair
1. Ignition OFF.
2. Check the BLU/BLK wire between the VSS sensor
connector and the ECM for the following conditions:
D An open circuit
D A short to ground
Using a DVM, measure the resistance between the
VSS sensor body and transmission case (ground).
1. Remove the VSS from the transmission case.
2. Visually inspect the VSS for damage.
Does the VSS appear to be OK?
Go to Step 2
Repair the open or short to ground in the VSS sensor

circuit.
Is the resistance above the specified value?

8
Go to OBD
System
Check
Repair the open in the sensor ground circuit.
Was the faulty condition located?

7
No
1. Ignition OFF.
ground wire.

5
Yes

performed?

3
Value(s)
Replace the VSS.

Replace the ECM.
6E1195

LOWER THAN EXPECTED
D06RX112
Circuit Description
the ECM detects a condition where too low of an idle
indicating a problem with the idle control system. DTC

system or canister purge Diagnostic Trouble Codes
are set.
(122F).
D
D
D
D
D
MAP is less than 60 kPa.

Ignition voltage is between 9.5 volts and 16 volts.
The throttle is closed.
All conditions are met for 10 seconds.
Engine speed is at least 100 RPM lower than desired
idle, based upon ECM expectations.

fault is detected.

Diagnostic Aids
D Poor connection at ECM or IAC motor Inspect
connection.
6E1196

and open circuits.
collapsed air intake duct, restricted air filter element, or
foreign objects blocking the air intake system.

faulty PCV valve or brake booster hose disconnected.
condition.
DTC P0506 Idle Control System RPM Lower Than Expected

Step
Action
Go to Step 2
Go to other
Diagnostic
Trouble Code
first
Go to Step 3
+/50 RPM
No trouble
found. Go to
Diagnostic
Aids
Go to Step 4
Verify repair
Go to Step 5
Refer to
appropriate
section for
onvehicle
service
Go to Step 6
Verify repair
Go to Step 7


PCM:
D IAC A low
D IAC A high
D IAC B low
D IAC B high
removed).
system.
throttle plate.
No
Go to OBD
System
Check

5
Yes

performed?

4
Value(s)

connector.
necessary.
6E1197
DTC P0506 Idle Control System RPM Lower Than Expected (Cont'd)
Step
Action
No
Go to Step 8
Go to Step 9
Verify repair
Verify repair

Yes

D An open circuit
D A short together
Value(s)
Replace the ECM.

6E1198

HIGHER THAN EXPECTED
D06RX112
Circuit Description
the ECM detects a condition where too high of an idle
speed by increasing the IAC counts, Diagnostic Trouble
Code P0507 will set, indicating a problem with the idle
control system. DTC P0507 is a type B code.

system or canister purge DTCs are set.
(122F).
D Ignition voltage is between 9.5 volts and 16 volts.
D All conditions are met for 10 seconds.

D Engine speed is at least 200 RPM lower than desired
idle, based upon PCMs expectations.

fault is detected.

D The PCM will turn the MIL OFF on the third consecutive
without a fault.
Diagnostic Aids
connection.

and open circuits.
hoses, leaks at EGR valve and EGR pipe to intake
manifold, leak at the throttle body, a faulty or incorrectly
installed PCV valve, leaks at the intake manifold, etc.
6E1199
will not allow the IAC pintle to fully extend or properly

seat.
condition.
DTC P0507 Idle Control System RPM Higher Than Expected

Step
Action
Go to Step 2
Go to other
Diagnostic
Trouble Code
first
Go to Step 3
+/50 RPM
No trouble
found. Go to
Diagnostic
Aids
Go to Step 4
Verify repair
Go to Step 5
Refer to
appropriate
section for
onvehicle
service
Go to Step 6
Verify repair
Go to Step 7


PCM:
D IAC A low
D IAC A high
D IAC B low
D IAC B high
D Vacuum leaks
removed).
valve.
No
Go to OBD
System
Check

5
Yes

performed?

4
Value(s)

connector.
necessary.
6E1200
DTC P0507 Idle Control System RPM Higher Than Expected (Cont'd)
Step
Action
No
Go to Step 8
Go to Step 9
Verify repair
Verify repair

Yes

D An open circuit
D A short together
Value(s)
Replace the ECM.

6E1201
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
D06RX127
Circuit Description
The engine control module (ECM) monitors the system

voltage on the ignition feed terminals to the ECM. A
system voltage Diagnostic Trouble Code will set
whenever the voltage is above a calibrated value. DTC

without a fault.
Diagnostic Aids
D Ignition ON.
D System voltage is above 16.
Check for a faulty charging system components.

lamp (MIL) for the first time the malfunction is detected.
D The ECM will store as Failure Records conditions
which were present when the Diagnostic Trouble Code
was set. This information will not be stored as Freeze
Frame data.
6E1202

Step
Action
Go to Step 2
16 V
Go to Step 3
Go to Step 4
16 V
Replace
battery
Go to Step 4
16 V
Go to Step 5
Go to Step 6
Verify repair
Verify repair
1. Turn OFF all the accessories.

3. Select the ignition voltage parameter on the data
list.
4. Start the engine and raise the engine speed to 2000
RPM.
Replace or repair the generator (see Charging
System).
Is a malfunction present?
Go to OBD
System
Check

Is the voltage above the specified value?

5
No

battery voltage at the battery.

4
Yes

performed?

3
Value(s)
Replace the ECM.

6E1203
DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE

MEMORY CHECK SUM ERROR
014RX002
Circuit Description
The engine control module (ECM) used in this vehicle

utilizes an electrically erasable programmable readonly
is not replaceable.
If the ECM detects a check sum error then DTC P0601 will
set. DTC P0601 is a type A code.

(MIL) the first time the malfunction is detected.
when the Diagnostic Trouble Code was set in the
Failure Records data only.

D The ECM detects an internal program fault (check sum
error).

without a fault.
DTC P0601 Internal Control Module Memory Check Sum Error

Step
Action
Value(s)
Yes

performed?
No
Go to Step 2
Go to OBD
System
Check
Verify repair
Replace the ECM.

6E1204

PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE
D06RX114
Circuit Description
signal voltage to the ECM varies from below 2 volts at idle
(low manifold pressure) to above 4 volts with the ignition
ON, engine not running or at wideopen throttle (high
manifold pressure).
from the MAP sensor, RPM, the CKP sensor, and the
Intake Air Temperature (IAT) sensor. The MAP sensor is
the main sensor used in this calculation, and measuring
engine load is its main function.
pressure (BARO). Refer to Diagnostic Trouble Code 401.
signal that is intermittently above the calculated value,
type D code.

D Throttle angle is below 2.7% if engine speed is below

1000 RPM.
1000 RPM.
time.

lamp (MIL).

without a fault.
Diagnostic Aids
D Leaking or plugged vacuum supply line to the MAP
sensor.
D Inspect ECM harness connectors for backedout
terminals, improper mating, broken locks, improperly

formed or damaged terminals, and poor
D Inspect the wiring harness for damage; shorts to
ground, shorts to battery positive, and open circuits. If
6E1205
the harness appears to be OK, observe the MAP

display on the Tech 2 while moving connectors and
wiring harnesses related to the sensor. A change in the
display will indicate the location of the fault.
condition.
DTC P1106 MAP Sensor Circuit Intermittent High Voltage

Step
3
4
Action
Are Diagnostic Trouble Code P0463, and/or P1121

also set?
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step
10
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids
Verify repair
Verify repair


10
Go to DTC
P0108 chart
first

components:
D TP sensor

returns.)
9
Go to Step 2

voltage.

8


7
No
Go to OBD
System
Check

6
Yes

performed?

5
Value(s)
Locate and repair the intermittent open/short circuit in

the wiring harness as necessary.
6E1206

PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE
D06RX114
Circuit Description
4 volts with the ignition ON, engine not running or at
used on the 2.2l engine. This is calculated using inputs
from the MAP sensor, the CKP sensor, and the Intake Air
load is its main function.
pressure (BARO). Refer to DTC P0401.
signal that is intermittently below the calculated value,
DTC P1107 will set. DTC P1107 is a type D code.

D Throttle angle is below 0% if engine speed is less than

1300 RPM.
1300 RPM.
time.

lamp (MIL).

without a fault.
Diagnostic Aids

6E1207

fault.
condition.
DTC P1107 MAP Sensor Circuit Intermittent Low Voltage

Step
Action

Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step
10
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids
Verify repair
Verify repair
Replace the faulty harness connector terminal for the 5

volt reference circuit and/or the MAP signal circuit as
necessary.
10
Go to Step 3

returns.)
Go to DTC
P0107 chart
first
Check for a poor 5 volt reference terminal connection at

the ECM.
Go to Step 2

components:
D TP sensor

connector and the PCM for an intermittent open or
short to ground.
No
Go to OBD
System
Check
Is DTC P1122 and/or P0462 also set?
Yes

performed?
Value(s)
Repair the intermittent open/short circuit in the wiring

harness as necessary.
6E1208

D06RX117
Circuit Description
intermittently detects an excessively high signal voltage
on the intake air temperature sensor signal circuit. DTC
P1111 is a type D code.

D
D
D
D
D

Calculated air flow is less than 20g/second.
intermittently less than 39C (38F) (4.94 volts) for
approximately 2.5 seconds over a 25second period of
time.

temperature.

D Diagnostic Trouble Code P1111 does not illuminate the
MIL.

Diagnostic Aids

condition.

C

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E1209
6E1210
DTC P1111 IAT Sensor Circuit Intermittent High Voltage

Step
Action
Go to DTC
P0113 chart
first
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Refer to
Diagnostic
Aids

connector and the ECM for an intermittent open.
voltage.
Go to Step 2
1. Check for a poor IAT signal circuit terminal


7


6
No
Go to OBD
System
Check

5
Yes

performed?

4
Value(s)

6E1211

D06RX117
Circuit Description
circuit. If the intake air is warm, the sensor resistance
becomes lower, causing the ECM to monitor a lower
voltage. Diagnostic Trouble Code P1112 will set when the
ECM intermittently detects an excessively low signal
voltage on the intake air temperature sensor signal
circuit. DTC P1112 is a type D code.

D IAT signal voltage is greater than 148C (298F)
(about 0.10 volt) for a total of 2.5 seconds over a

lamp (MIL).

temperature.

without a fault.
Diagnostic Aids
6E1212

condition.

C
Test Description
Diagnostic Chart.
Temperature vs. Resistance Value Chart.
The chart may be used to test the IAT sensor at
replace the IAT sensor.

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P1112 IAT Sensor Circuit Intermittent Low Voltage

Step
Action
Value(s)
Yes

performed?
Go to Step 2
Go to OBD
System
Check
Go to DTC
P0112 chart
first
Go to Step 3
Verify repair
Refer to
Diagnostic
Aids

connector and the PCM for an intermittent short to
ground.
No
6E1213

TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE
D06RX117
Circuit Description
to 2.0 volts. If the ECM detects an ECT signal that is
intermittently below the range of the ECT sensor,
type D code.

D Engine run time longer than 2 minutes.
150C (302F) (about 0.10 volt) for a total of 10
seconds over a 100second period.

lamp (MIL).


without a fault.
Diagnostic Aids
condition.
6E1214

C

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P1114 ECT Sensor Circuit Intermittent Low Voltage

Step
2
3
Action
Value(s)
Yes

performed?
Go to Step 2
Go to OBD
System
Check
Go to DTC
P0117 first
Go to Step 3
Verify repair
Refer to
Diagnostic
Aids

short to ground.
No
6E1215

TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE
D06RX117
Circuit Description
to 2.0 volts. If the PCM detects an ECT signal that is
intermittently above the range of the ECT sensor,
Diagnostic Trouble Code P1115 will set. Diagnostic
Trouble Code P1115 is a type D code.

D Engine run time longer than 180 seconds.
39C (38F) (4.94 volts) for a total of 10 seconds

lamp (MIL).


without a fault.
Diagnostic Aids
condition.
6E1216

C

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E1217
DTC P1115 ECT Sensor Circuit Intermittent High Voltage

Step
2
3
Action
Go to DTC
P0118 first
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Refer to
Diagnostic
Aids

open.
short to voltage.
Go to Step 2
1. Check for a poor ECT signal circuit terminal


7


6
No
Go to OBD
System
Check

5
Yes

performed?

4
Value(s)

6E1218

D06RX118
Circuit Description

a type D code.

without a fault.

D TP sensor indicates a throttle position voltage
intermittently greater than 4.88 volts for a total of 0.15

lamp (MIL).
Diagnostic Aids
components itself.

6E1219

condition.
DTC P1121 TP Sensor Circuit Intermittent High Voltage

Step
Action

connection at the TP sensor.
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step
10
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids
Verify repair
Verify repair

10
Go to DTC
P0123 first

returns.)
Check for a poor sensor ground terminal connection at

the ECM.
Go to Step 2

components:
D MAP Sensor

voltage.
No
Go to OBD
System
Check

Yes

performed?
Value(s)

as necessary.
6E1220

D06RX118
Circuit Description

a type D code.

without a fault.

D TP sensor indicates a throttle position signal
intermittently less than 0.10 volt for a total of 0.15

lamp (MIL).
Diagnostic Aids
components itself.

6E1221

condition.
DTC P1122 TP Sensor Circuit Intermittent Low Voltage

Step
Action
Check for a poor 5 volt reference circuit or TP signal

circuit terminal connection at the TP sensor.
Go to DTC
P0122 first
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step
10
Go to Step 8
Go to Step 9
Go to Step 8
Go to Step 9
Go to Step 8
Go to Step
10
Refer to
Diagnostic
Aids

returns.)

Go to Step 2

components:
D MAP Sensor

ground.
Replace the faulty harness connector terminal(s) for

the 5 volt reference circuit and/or the TP signal circuit
as necessary.
Repair
complete. If a
driveability
symptom still
exists, refer
to Symptoms.
10
No
Go to OBD
System
Check

Yes

performed?
Value(s)

as necessary.
Repair
complete. If a
driveability
symptom still
exists, refer
to Symptoms.
6E1222
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SYSTEM LEAN DURING

ACCELERATION
D06RX119
Circuit Description
The engine control module (ECM) internal circuitry can

identify if the vehicle fuel system is capable of supplying
adequate amounts of fuel during heavy acceleration
(power enrichment). The ECM monitors the voltage of the
oxygen sensor during power enrichment. When a power
enrichment mode of operation is requested during
Closed Loop operation (by heavy acceleration), the
ECM will provide more fuel to the engine. Under these
conditions the ECM should detect a rich condition (high
oxygen sensor voltage). If this rich exhaust is not
detected at this time, a Diagnostic Trouble Code P1171
will set. A plugged fuel filter or restricted fuel line can
prevent adequate amounts of fuel from being supplied
during power enrichment mode. DTC P1171 is a type A
code.

Diagnostic Aids
D
D
D
D

While in power enrichment mode the oxygen sensor

without a fault.
D A restricted fuel filter or fuel line can supply adequate

Test Description
Diagnostic Chart:
approximately 100 mV to 900 mV. During power
enrichment mode, more fuel is needed and the
HO2S voltage should rise above 447 mV. This step
checks to see if the HO2S is operating properly.
leakage that may occur when installing the gauge.
Ignition ON, pump pressure should be 235320
kPa.
6E1223
6E1224

Step
Action
Go to Step 2
Go to
component
DTC charts
Go to Step 3
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids
Go to Step 5
Go to OBD
System
Check
Go to Step 6
Verify repair
Go to Step 7
414 kPa 325

kPa
Go to
Diagnostic
Aids
Go to Step 8
Verify repair
Are any componentrelated Diagnostic Trouble Codes

set?
amount of fuel.
empty.
running warm engine(75C95C [167F203F])
at 1200 RPM.
range.

temperature.
pressure regulator.
specified range?
284 325 kPa
Check for restricted fuel lines or restricted inline filter.

1.
2.
3.
4.
Ignition OFF.
Using a Tech 2, enable the fuel pump to operate.
Using pliers, slowly close the return line (do not
exceed the first specified value).
Using the pliers, can the fuel pressure be manipulated

to exceed the second specified value?
8
No
Go to OBD
System
Check
Does the voltage toggle back and forth within the

specified range?
100 900 mV
5
Yes

performed?

4
Value(s)
Check for:
D Faulty fuel pump
D Hot fuel
6E1225
DIAGNOSTIC TROUBLE CODE (DTC) 1404 EXHAUST GAS RECIRCULATION

(EGR) CLOSED VALVE
D06RX113
Circuit Description
The engine control module (ECM) monitors the exhaust
gas recirculation(EGR) valve pintle position input to
from the ECM to detect a fault if the pintle position sensor
and control circuits are open or shorted. If the ECM
detects a pintle position signal voltage below the normal
range of the pintle position sensor, or a signal voltage that
is not within a tolerance considered acceptable for proper
EGR control system operation, the ECM will set a DTC
P1404.

D IAT is above 5C (41)
D EGR actual position is 16 counts below the EGR low
threshold for at least 6.3 seconds.

fault is detected.


warm up cylcles without a fault.
Diagnostic Aids
D Excessive deposits on EGR valve pintle or seat
Check for deposits that may interfere with the EGR
valve pintle extending completely or cause the pintle to
stick.
NOTE: If the EGR valve show signs of excessive heat,
6E1226
DTC P1404 EGR Closed Valve

Step
Action
Go to Step 3
12 volts
Go to Step 6
Go to Step 4
Verify repair
less than 5 W
Go to Step 6
Verify repair
0 volts 0%
Go to Step 9
Verify repair
Go to Step 14

D An Open circuit
D A short to ground
Go to Step 15
1. Ignition OFF.
Refer to
Diagnostic
Aids

solenoid.

7
Go to Step 2
Check the Ignition feed circuit, between the EGR

conditions:
D An Open circuit
D A short to ground

6
1. Ignition OFF.
on the Ignition feed circuit at the Linear Exhaust Gas
connector.

5
No
Go to OBD
System
Check

2. Review and record the Tech 2 Failure Records data,
the clear the DTCs.
conditions noted.
P1404.

4
Yes

performed?

Passed
3
Value(s)

D An Open circuit
D A short to ground
Go to Step 8
Go to Step 15
6E1227
DTC P1404 EGR Closed Valve (Cont'd)

Step
Action

harness connector.
10
14
15
Verify repair
Go to Step 13
Go to Step 12
about 5 volts
Go to Step 15
1. Ignition OFF.
reference signal circuit and the EGR valve position
connector.
Does the Tech 2 display the following value?
Go to Step 10
Go to Step 11

D An Open circuit
D A short to ground
13
Go to Step 11
No
about 5 volts
1. Ignition OFF.
2. Place a DVM between the 5 volt reference signal
12
Yes
Check the 5 volt reference signal circuit, between the

D An Open circuit
D A short to ground
11
Value(s)
Verify repair
Go to Step 14
Go to Step 15
5 volts 100%

Value.
Verify repair.
Replace the ECM.
Verify repair.
6E1228
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM UNEXPECTED RESET
014RX002
The engine control module (ECM) monitors unexpected

ECM reset. This will not turn on MIL light on, only records
code DTC P1625.

Info function or by disconnecting the ECM battery
feed.
Diagnostic Aids
Circuit Description

lamp (MIL).

D The ECM will turn the MIL OFF on the third

DTC code.
NOTE: DTC P1625 is a DTC to record a ECM reset
history. If DTC P1625 is not reset and no engine
abnormality is found after clearance of DTC, it is not
necessary to do any farther processing.
6E1229
DTC P1625ECM Unexpected Reset

Step
Action
Value(s)

performed?
1.
2.
3.
4.
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Go to Step 4
Go to
Diagnostic
Aids
Verify repair
Ignition is On.
Install the Tech 2.

3
1.
2.
3.
4.
Ignition is On.
No
Go to OBD
System
Check
Yes

transceiver stereos, and anti theft devices, they
may radiate EMI into the control system if they are
improperly installed. (This may cause a false
sensor reading and turn on the MIL.)
6E1230
DIAGNOSTIC TROUBLE CODE (DTC) P1627 PCM A/D CONVERSION

MALFUNCTION
014RX002
Circuit Description

senses an Analog to Digital (A/D) conversion error within
the ECM, then DTC P1627 will set. DTC P1627 is a type A
code.
Info function.

D Any A/D DTCs set.

Records.
Diagnostic Aids
D Poor connections, or a damaged harness Inspect the
improper mating or damaged terminals. Also, check for
6E1231
DTC P1627 PCM A/D Conversion Malfunction

Step
Action
No
Go to Step 2
Go to OBD
System
Check
Refer to
Diagnostic
Aids
Go to Step 3
Verify repair
Go to Step 4

P1627.

D A short to ground
D An open circuit
Yes

performed?

Passed?
3
Value(s)
Replace the ECM.
6E1232
DIAGNOSTIC TROUBLE CODE (DTC) P1635 5 VOLT REFERENCE VOLTAGE

CIRCUIT MALFUNCTION
014RX002
Circuit Description

senses the 5 volt reference signal circuit is above 5.12
volts or below 4.88 volts, then DTC P1635 will set. DTC

Records.
D Ignition voltage is greater than 6.3 volts.

following two conditions are met for 5 seconds within a 10
second test sample:
D ECM senses the 5 volt reference signal circuit is above
5.12 volts.
OR
D ECM senses the 5 volt reference signal circuit is below
4.88 volts.
Info function.
Diagnostic Aids
Poor connections, or a damaged harness Inspect the
harness connectors for: backedout terminals, improper
mating or damaged terminals. Also, check for open
circuits, shorts to ground, and shorts to voltage.
6E1233
DTC P1635 5 Volt Reference Voltage Circuit Malfunction

Step
Action
No
Go to Step 2
Go to OBD
System
Check
Refer to
Diagnostic
Aids
Go to Step 3
Verify repair
Go to Step 4

P1635.

D A short to ground
D An open circuit
Yes

performed?

Passed?
3
Value(s)
Replace the ECM.
6E1234
DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM OUTPUT CIRCUIT FAULT
014RX002
Circuit Description
Output driver modules (ODMs) are used by the engine

control module(ECM) to turn ON many of the current
driven devices that are needed to control various engine
and transmission functions. Each ODM is capable of
controlling up to 11 separate outputs by applying ground
to the device which the ECM is commanding ON.
ODMs have the capability of diagnosing each output
circuit individually. DTC P1640 set indicates an improper
voltage level has been detected on an ODM output.
If the ECM detects an open circuit condition and a shorted
to voltage circuit condition on the same circuit at the same
time, then DTC P1640 will set. DTC P1640 is a type D
code.

warm up cycles occur without a fault.

D Ignition ON.
D Above conditions occur for at least 2.5 seconds.
D The ECM detects an open circuit condition and a
shorted to voltage circuit condition on the same circuit
at the same time.

lamp (MIL).
Diagnostic Aids
the ECM, turn the ignition ON and observe a voltmeter
connected to the MIL driver circuit at the ECM harness
connector while moving connectors and wiring
harnesses relates to the MIL. A change in voltage will
D Reviewing the Failure Records vehicle mileage since
the diagnostic test last failed may help determine how
often the condition that caused the DTC to be set
occurs. This may assist in diagnosing the condition.
The following ECM pins are controlled by

D
D
D
D
A13
A14
B14
B16
MIL LAMP
Rear Defogger
A/C Clutch
EVAP Canister Parge Solenoid

D
D
D
D
D
A1 2 Low Fuel
C10 Tacho Meter
C11 Fuel Gauge
C13 Fan Low
C12 Fan High
Test Description
Diagnostic Chart.
6E1235
2. The Tech 2 Driver Module Status indicates the ECM

11. A short to ground on the ignition side of the
between the affected component and the ECM.

Step
Action
Value(s)
Yes
Go to Step 2
Go to OBD
System
Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
Was the Lamp of circuit for Check Engine?
Go to Step 7
Go to Step 13
1. Leave the ECM connector for the lamp driver circuit

disconnected.
2. Ignition ON.
3. Using a DVM, check the voltage at the ECM
B+
Go to Step 15
Go to Step 8
Go to Step 10
Go to Step 9
Verify repair
Go to Step 11
Go to Step 12
Verify repair

performed?
No
faulty.
Was the fuse blown?

repairs.

driver circuit.
Is there any damage to the ECM pin or connector?

8
1. Ignition ON.
lamp circuit.

the fuse.
10
1. Ignition OFF.
driver terminal.
the ECM connector for the affected driver.
11

component and its ECM driver terminal.
6E1236

Step
Action
12
Repair the open circuit between the fuse and the ECM
13
No
Verify repair
B+
Go to Step 15
Go to Step 14
Go to Step 10
Go to Step 9
Verify repair

circuit.
15
Yes
1. Connect the ECM.

3. Backprobe the affected terminal at the ECM with a
DVM.
14
Value(s)
Replace the ECM.

SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
following items:
D The engine control module (ECM) and malfunction
indicator lamp (MIL)(Check Engine lamp) are
operating correctly.
VISUAL/PHYSICAL CHECK
time. This check should include the following items:
D ECM grounds for cleanliness, tightness and proper
location.
D Air leaks at throttle body mounting area, manifold
absolute pressure (MAP) sensor and intake manifold
sealing surfaces.
D Ignition component for cracking, hardness, and
carbon tracking.
INTERMITTENTS
An intermittent problem may or may not turn on the malfunction indicator lamp (MIL) or store a Diagnostic
Trouble Code. DO NOT use the Diagnostic Trouble Code
(DTC) charts for intermittent problems. The fault must be
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 a Tech 2 to help detect intermittent conditions.
6E1237
The Scan Tools have several features that can be used to

locate an intermittent condition. Use the following feature
to find intermittent faults:
D Using a Scan Tools Freeze Frame buffer or Failure
the MAP sensor and idle the engine until the MIL (Check
Engine lamp) comes on. Diagnostic Trouble Code P0107
should be stored and kept in memory when the ignition is
turned OFF. If not, the ECM is faulty. When this test is
completed, make sure that you clear the Diagnostic
Trouble Code P0107 from memory.
Diagnostic Trouble Code may be caused by the following:
wires or plugs.
D MIL (Check Engine lamp) wire to ECM shorted to
ground.
D Poor ECM grounds. Refer to the ECM wiring
diagrams.
ECM to the ignition coils for poor connections.
If problem has not been found, refer to ECM Connector
Symptom tables.
6E1238
HARD START SYMPTOM

DEFINITION:
Step
Action
No
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Go to Step 8
Go to Step 5
Go to Step 7
Go to Step 6
Verify repair
Verify repair
Verify repair
Go to Step 9
22.4 k W
Verify repair

Yes

performed?

3
Value(s)

shift in value.
1. After 8 hours with the hood up and the engine not
running, connect the Tech 2.
3. Using the Tech 2, compare Engine Coolant
Temperature to Intake Air Temperature.
5C ( 9F)
other?

temperature sensor.
3. For resistance specifications, refer to Temperature
vs. Resistance chart in DTC P0118.
Is the actual resistance near the resistance value in the
chart for the temperature that was noted?

Locate and repair high resistance or connection in the

ECT signal circuit or the ECT signal circuit or the ECM
sensor ground.
Check for a faulty, plugged, or incorrectly installed PCV
valve.

problem.
Go to Step 10

Step
Action
10
Check for proper ignition voltage output with a spark

tester5-8840-0383-0.
11
14
15
Verify repair
9 kW12 kW
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 12
Go to Step 13
Go to Step 14
Go to Step 15
Go to Step 16
Perform the procedure in Fuel System Pressure Test to

determine if there is a problem with fuel delivery.
Go to Step 17
Check for the following engine mechanical problems

(refer to Engine Mechanical):
D Low compression
D Worn camshaft
18
Verify repair

17
Check IAC operation. Perform the procedure in the

diagnostic chart DTC P0506, Step 6.

16
Verify repair

of resistance.
Go to Step 18

following:
D Tech 2 data
No
Go to Step 11

13
Yes

fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat range.
12
Value(s)
6E1239
Verify repair
Contact
Technical
Assistance
6E1240
SURGES AND/or CHUGGLES SYMPTOM

DEFINITION:
Feels like the vehicle speeds up and slows down with no
change in the accelerator pedal.
Step
Action
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
System OK
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair
Verify repair
Verify repair

condition)?
Go to Step 10

Go to Step 10

tester 5-8840-0383-0.
11
Verify repair

Pressure Test.

10
Check the fuel control Heated Oxygen Sensor

(HO2S1). When monitored on the Tech 2, the H02S1
should respond quickly to different throttle positions. If
it doesnt check for silicon or other contaminants from
fuel or use of improper RTV sealant. The sensors may
have a white powdery coating. Silicone contamination
sends a rich exhaust signal which causes the ECM to
command an excessively lean air/fuel mixture.

9
Go to Step 2
Be sure that the driver understands A/C compressor

operation as explained in the owners manual. Inform
the customer how the A/C clutch operate.

7
Go to OBD
System
Check

6
No


5
Yes

performed?

3
Value(s)
Go to Step 11

Go to Step 12

Step
Action
12

wires. Check for the following conditions.
eliminated crossfiring.
mist of water may help to locate an intermittent
problem.
13
16
19
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 14
Go to Step 15
Go to Step 16
Go to Step 17
Visually/physically check the vacuum hoses for splits,

kinks and proper connections and routing as shown on
18
9 kW 12 kW

17
Verify repair
1. Check the injector connectors.

2. If any of the connectors are connected at an
improper cylinder, correct as necessary.
Go to Step 18

D damaged or collapsed pipes
D internal muffler failure
measure back pressure and determine if the
Go to Step 19

table.
following:
D Tech 2 data.
No
Go to Step 13
22.4 W

15
Yes
1. Check ignition coil secondary resistance.

of resistance.
14
Value(s)
6E1241
Verify repair
Contact
Technical
Assistance
6E1242
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM

DEFINITION:
increase in speed when accelerator pedal is pushed down
partway.
Step
Action
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Check the fuel pressure. Refer to Fuel System Test.

10
Verify repair
1. Remove the spark plugs and check gas or oil


9

tester 5-8840-0385-0.

8
Go to Step 2

restrictions. Refer to Air Intake System in
OnVehicle Service.

7
Go to OBD
System
Check

6
No


5
Yes

performed?

3
Value(s)

D Damaged or collapsed pipes
measure backpressure and determine if the

Step
Action
11

D Low compression
D Loose timing belt
12
Value(s)
Yes
No
Verify repair
Go to Step 12
Verify repair
Contact
Technical
Assistance

table.
following:
D Tech 2 data
D All electrical connections within suspected
6E1243
6E1244
DETONATION/SPARK KNOCK SYMPTOM

DEFINITION:
Step
Action
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Go to Step 5
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Check fuel pressure. Refer to Fuel System Pressure

Test.
Check items that can cause an engine to run lean.
Check spark plugs for proper heat range. Refer to
General Information.
Were incorrect spark plugs installed?

D Incorrect coolant solution. It should be a 50/50
mix of approved antifreeze/water.
D Incorrect EGR operation. Refer to DTC
P0401.

8
Go to Step 2
1. If Tech 2 readings are normal and there are no

engine mechanical faults, fill the fuel tank with a
known quality gasoline that has a minimum octane
rating of 87. Refer to Typical Scan Values.
2. Reevaluate the vehicle performance.

7
Go to OBD
System
Check

6
No

5
Yes

performed?

3
Value(s)

cleaner can.
2. Reevaluate vehicle performance.
Go to Step 10
Verify repair

Step
Action
10
Check for an engine mechanical problem. Perform a

cylinder compression check. Refer to Engine
Mechanical.
11
Value(s)
Yes
No
Go to Step 11
Verify repair

following:
D Tech 2 data
6E1245
Verify repair
Contact
Technical
Assistance
6E1246
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM

DEFINITION:
vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.
Step
Action
Go to Step 2
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Between 10
and 50
counts
Go to Step 8
Go to Step 7
Verify repair
Go to Step 7
0%
Go to Step 8
For further
diagnosis,
refer to DTC
P0123
Verify repair
Go to Step 9
Verify repair
Verify that the EGR valve is not mounted backwards.

2. Using a Tech 2, monitor IAC position.
conditions:
plate.
or faulty crankcase ventilation valve brake
booster hose.
Go to OBD
System
Check
Was a visual/physical check performed, including the

rotor, ignition coil and secondary ignition wires?

6
Using a Tech 2, monitor TP angle with the engine idling.


tester 5-8840-0383-0.
No


5
Yes

performed?

3
Value(s)

2. If spark plugs are fouled, the cause of the fouling
must be determined before replacing the spark
plugs.
Go to Step 10

Step
Action
10
Check for a loose ignition control module ground. Refer

to Electrical Ignition System.
11
Value(s)
Yes
6E1247
No
Go to Step 11

condition)?
Verify repair
Go to Step 12
Go to Step 13
12
Check the items that can cause the engine to run rich.
13
Is Long Term Fuel Trim significantly in the positive

14
18
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 16
Go to Step 17
Go to Step 18

19
Verify repair
1. Check the following engine mechanical problems:

D Low compression
D Valve timing
Go to Step 19

following:
D Tech 2 data
Go to Step 15
Go to Step 14
Perform the Injector Coil/Balance Test.

17
Go to Step 14

necessary.
16
Verify repair
Check items that can cause the engine to run leading.

15
Go to Step 13
Verify repair
Contact
Technical
Assistance
6E1248
POOR FUEL ECONOMY SYMPTOM

DEFINITION:
as previously shown by an actual road test.
Step
Action
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Go to Step 5
Go to Step 6
System OK
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Verify repair
Verify repair
Remove and check the air filter element for dirt or for
restrictions.
2. Is spark plugs are fouled, the cause of fouling must
Check for low engine coolant level.
Go to Step 10
Check for an incorrect or faulty engine thermostat.

11
Verify repair

Information label.

10


9
Go to Step 2


8
Go to OBD
System
Check

7
No


6
Yes

performed?

3
Value(s)
Go to Step 11
Check for low engine compression. Refer to Engine

Mechanical.
Go to Step 12

Step
Action
12
Check for excessive exhaust system backpressure.

Refer to Restricted Exhaust System Check. Possible
problems could be:
D Damaged or collapsed pipes.
D Internal muffler failure.
D Plugged catalytic converter.
13
15
Go to Step 13
Verify repair
Go to Step 15
Go to Step 14
Verify repair
Verify repair
Verify repair
Contact
Technical
Assistance
Check the air intake system and the crankcase for air
leaks.
Go to Step 16

table.
following:
D Tech 2 data
and/or system
17
No
Diagnose and repair the inaccurate speedometer

condition as necessary. Refer to Vehicle Speed Sensor
in Electrical Diagnosis.

16
Yes

14
Value(s)
6E1249
Go to Step 17

Verify repair
6E1250
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM

DEFINITION:
Vehicle fails an emission test. There is excessive rotten
egg smell. (Excessive odors do not necessarily indicate
excessive emissions.)
Step
Action
Value(s)

performed?

11
14
Go to Step 13
Go to Step 6
Go to Step 13
Go to Step 7
Go to Step 13
Go to Step 8
Go to Step 13
Go to Step 9
Go to Step 13
Go to Step 10
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12
Check the EVAP canister for fuel loading. Refer to

1. Remove excessive carbon build-up with a top

engine cleaner. Refer to the instructions on the top
engine cleaner can.
Go to Step 14
System OK
System OK
Does the exhaust emission test indicate excessive HC

levels, or is Long Term Fuel Trim significantly in the

13
Go to Step 5
Check for a problem with the engine cooling system.

12
Go to Step 13
Perform the Injector Balance Test by Tech 2.
Go to Step 4

necessary.

10
Go to Visual /
Physical
Check
1. Check for faulty, plugged or incorrectly installed

PCV valve.
2. Verify that the PCV system is not plugged.

9
Go to Step 3

Pressure Test.
Go to OBD
System
Check
Go to Step 13
1. Check fuel cap for proper installation.

No
Check for vacuum leaks (vacuum lines, intake

manifold, throttle body, etc.)

6
Go to Step 2
Was visual/physical check performed?
Were any vacuum leaks found?

5
Yes
Go to Step 14
Go to Step 15
Go to Step 16

Step
Action
15

Support.
Value(s)
Yes

16
System OK
System OK
Verify repair
Verify repair

Go to Step 18
Check for the following engine mechanical problems.

D Low compression
D Valve timing
D Broken Valve springs
19
Go to Step 17
Check the EGR system (refer to DTC P0401).

18
No
Go to Step 17

17
6E1251
Go to Step 19

table.
following:
D Tech 2 data
Verify repair
Contact
Technical
Assistance
6E1252
DIESELING, RUNON SYMPTOM

DEFINITION:
Engine continues to run after key is turned OFF, but runs
very rough. If engine runs smoothly, check the ignition
Step
Action
No
Go to Step 2
Go to OBD
System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Contact
Technical
Assistance

1. Check for a short between B+ and the ignition feed

circuit.
Yes

performed?

3
Value(s)

table.
following:
D Tech 2 data
and/or system
6E1253
BACKFIRE SYMPTOM
DEFINITION:
Step
Action
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
1. Visually/physically inspect the secondary ignition

D Verify that ignition wires are not arcing to
ground. Spraying the secondary ignition wires
with a light mist of water may help locate an
intermittent problem.
Check for an intermittent ignition system malfunction:
D Intermittent ignition feed circuit or sensor ground
circuit to the crankshaft position sensor.
To determine if there is a problem with fuel delivery,
refer to Fuel System Diagnosis.


8
Go to Step 2

tester 5-8840-0383-0.

7
Go to OBD
System
Check

6
No


5
Yes

performed?

3
Value(s)

problems:
D Low compression
Go to Step 10
6E1254
Step
Action
10
Check the intake and exhaust manifold(s) for casting

flash. Refer to Engine Mechanical.
11
Value(s)
Yes
Go to Step 11
Verify repair

table.
following:
D Tech 2 data
No
Verify repair
Contact
Technical
Assistance
6E1255
CUTS OUT, MISSES SYMPTOM

DEFINITION:
Step
Action
Go to Step 2
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Go to Step 9

Go to Step 8
Go to Step 9
Verify repair
Go to Step 9
Between 5
and 50
counts
Go to Step 11
Go to Step 10
Verify repair


condition)?
7
8



10
No
Go to OBD
System
Check

5
Yes

performed?

3
Value(s)

conditions:
plate.
or faulty crankcase ventilation valve or brake
booster hose disconnected.
Go to Step 11
6E1256
Step
Action
11

necessary.
12
15
Verify repair
Verify repair
Verify repair
Go to Step 15
Go to Step 16
Go to Step 17
Go to Step 18
0%
Verify repair
Verify repair
Verify repair
Go to Step 20
Go to Step 21

table.
following:
D Tech 2 data
For further
diagnosis,
refer to DTC
P0123
Go to Step 19
Check for faulty motor mounts. Refer to Engine

Mechanical for inspection of the mounts.
21
Go to Step 14

D Low compression
20
Verify repair
Check the PCV valve for proper operation.

19
Go to Step 13

idling.
18
Verify repair

17
1. Remove spark plugs and check for gas or oil fouling,

cracks, wear, improper gap, burned electrodes of
heavy deposits.
16
Verify repair

tester J 26792.
No
Go to Step 12

hose.
assembly.
14
Yes
1. Perform the Injector Coil/Balance Test.

13
Value(s)
Verify repair
Contact
Technical
Assistance
6E1257
HESITATION, SAG, STUMBLE SYMPTOM

DEFINITION:
Momentary lack of response as the accelerator is pushed
down. Can occur at any vehicle speed. Usually most
pronounced when first trying to make the vehicle move,
as from a stop sign. May cause the engine to stall if severe
enough.
Step
Action
Go to Step 4
Go to Visual /
Physical
Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 13

Go to Step 10

tester 5-8840-0383-0. For the procedure, refer to
Go to Step 11

Go to Step 9
Go to Step 10


11
Go to Step 3

10
Verify repair


9

Pressure Test.

condition)?
8
Go to Step 2
1. Check the fuel control heated oxygen sensor

(HO2S1). The HO2S1 should respond quickly to
different to throttle positions. If it doesnt, check for
silicon or other contaminants from fuel or use of
white powdery coating. Silicon contamination
sends a rich exhaust signal which causes the ECM
to command an excessively lean air/fuel mixture.

7
Go to OBD
System
Check

6
No


5
Yes

performed?

3
Value(s)
Go to Step 12
6E1258
Step
Action
12
Visually/physically inspect the secondary ignition

D Value that ignition wires are correctly routed to
problem.
13
14
Verify repair
9 kW 12kW
Verify repair
Verify repair
Verify repair
Verify repair
Go to Step 16
Go to Step 17
Visually/physically check vacuum hoses for splits,

kinks, and proper connections and routing as shown on
Go to Step 18

following:
D Tech 2 data
Go to Step 15


18
Verify repair


17
No
Go to Step 14
30,000 W

2. Replace the coil if it is not within the specified value.

16
Yes

15
Value(s)
Verify repair
Contact
Technical
Assistance
6E1259
RESTRICTED EXHAUST SYSTEM CHECK

Step
Action
Go to Step 2
Go to OBD
System
Check
8.62 kPa
(1.25 psi)
Go to Step 5
Go to Step 3
8.62 kPa
(1.25 psi)
Go to Step 5
Go to Step 4
8.62 kPa
(1.25 psi)
Go to Step 6
System OK
Verify repair
Verify repair
With the exhaust backpressure tester in place of

HO2S, and the engine at normal operating
temperature:
Increase the engine speed to 2000 RPM while
observing the gauge.
1. Reinstall the HO2S2. (Refer to Heated Oxygen

Sensors in OnVehicle Service for installation
procedure.)
3. Install the Exhaust BackPressure Tester BT8515V
or equivalent in place of the HO2S1.
4. Bring the engine to normal operating temperature
while observing the gauge.
5. Increase the engine speed to 2000 RPM (allow 10
seconds for pressure build) and observe the gauge.
Did the reading exceed the specified value?
No

D For removal procedures, refer to Heated
Oxygen Sensors in OnVehicle Service.
2. Install the Exhaust Backpressure Tester in place of
the Bank 1 HO2S.
3. Idle the engine at normal operating temperature.
Does the reading exceed the amount of the value

column?
4
Yes

performed?
Does the reading on the gauge exceed the specified

value?
3
Value(s)
Repair a restiction in the exhaust system after the

catalytic converter.
Possible faults include:
D Collapsed pipe
Replace the restricted catalytic converter.
NOTE: Diagnostic Trouble Codes will be set by running

the vehicle to normal operating temperature after a cold
start with the O2 sensor disconnected. After performing
these tests, use the Tech 2 to erase the Diagnostic
Trouble Codes that were set by the lack of O2 sensor
activity.
6E1260

SERVICE PROCEDURE DEFAULT
STRATEGY
after performing diagnostics, then for further diagnostic
information, refer to the default matrix table.

Initial Diagnosis
Default Section(s)

Check
Chassis Electrical

Check

start and run.

Check
Engine starts and runs, no ECM codes


Check.
Chassis Electrical

Check. ECM power and ground circuits
Chassis Electrical
Symptoms
Initial Diagnosis
Default Section(s)
Intermittents
1. Onboard diagnostic (OBD)

system check.
Chassis Electrical
Hard Starts

2. Sensors (ECT, MAP, TP); MAP
output chart.
system diagnosis.
4. Ignition system.
Engine Mechanical
1.
2.
3.
4.
OBD system check.

Ignition system.
Code/Service Bulletins
Generator Output
1.
2.
3.
4.
5.
OBD system check.

Ignition system.
EGR operation.
EGR system check.

Engine Exhaust
TCC Operation
Detonation / Spark Knock
1.
2.
3.
4.
5.
OBD system check.

EGR operation.
EGR system check.
Ignition system.
Cooling System

Symptoms
Initial Diagnosis
6E1261
Default Section(s)
1.
2.
3.
4.
5.
OBD system check.

TP.
MAP output check.
balance test.
valve.
7. Ignition system.
EGR Operation
EGR System Check
Cuts Out, Misses


Stalling

balance test.
valve check.
4. Ignition system.
5. IAC operation.
6. EGR operation.
MAP Output Check

Throttle Linkage
IAC System Check
EGR System Check
Exhaust Diagnosis
Poor Fuel Economy
1.
2.
3.
4.
TCC Operation
Exhaust System (refer to Engine
Exhaust)

Diagnosis
Fuel Injector
Fuel Injector Balance Test

Odors
1.
2.
3.
4.
5.
EGR System Check

Exhaust Diagnosis
6.
7.
8.
9.
OBD system check.

Ignition system.
Cooling system.
OBD system check.

Emission test.
Cooling system.
balance test.
valve.
Ignition system.
MAP output check.
Dieseling, RunOn

Backfire
1.
2.
3.
4.

System Check
OBD system check.

Ignition system.
balance test.
check.
6E1262

Symptoms
Initial Diagnosis
OBD system check.
Ignition system.
balance test.
Default Section(s)
Misfire
1.
2.
3.
4.
Catalyst Monitor

3. Heated oxygen sensors.
Exhaust System
Fuel Trim
1.
2.
3.
4.
Exhaust System Intake Air

System


Exhaust System
OBD system check.

Vibrations, Transmission,
Driveshaft and Axle
6E1263
8. Remove the retaining bolt for the sensor and pull up

camshaft position sensor.
Camshaft Position (CMP)

Sensor
Removal Procedure
2. Remove spark plug cover on top of valve cover by
removing four retaining bolts.
014RX005
1. Insert camshaft position sensor in position.
2. Install retaining bolt.
014RX003
4. Remove drive belt. Refer to Engine Mechanical

Section.
5. Remove top harness cover installed on timing belt
cover by removing a retaining screw.
6. Remove the retaining bolts holding crankshaft pulley,
and pull crankshaft pulley while wiggling. Refer to
Engine Mechanical Section.
7. Remove the retaining screws for timing belt cover and
timing belt cover.
014RX007
3. Install the timing belt cover and the retaining screws.

4. Install the crank shaft pulley and the mounting bolts.
Holes for mounting bolts are off the pitch. The pulley
can be mounted only one way to install all mounting
bolts. Tighten the bolts. Refer to Engine Mechanical
section.
014RX004
6E1264
5. Install the drive belt. Refer to Engine Mechanical

Section.

Sensor
Removal Procedure
2. Remove the drive belt. Refer to Engine Mechanical
Section.
014RX005
6. Install the top harness cover onto timing belt cover.

7. Connect electrical connector to the sensor and
securely lock it.
8. Install the spark plug cover.
014RX003
3. Remove
the
pwer
steering
pump
and
mountingbracket from engine. Refer to Engine
Mechanical Section.
014RX004
014RX006

5. Remove the retaining bolt and sensor from the engine
block.
6E1265
3. Reinstall the power steering pump and bracket to the

engine.
out.
014RX006
0013
4. Reinstall the accessory drive belt.

1. Install the crank shaft position sensor to its position.
2. Install and tighten the mounting bolt. Refer to Engine
Mechanical Section.
014RX003
0013
6E1266
EEPROM
Functional Check
EEPROM
ECM needs to control Powertrain operation.
1. Perform the OnBoard Diagnostic System Check.

2. Start the engine and run for least one minute.
3. Check for DTCs using Tech 2.
4. If the ECM fails to program, proceed as follow:
D Ensure that all ECM connections are OK.
D Check the ITCS for latest version software.
D Attempt to program ECM again. If ECM still cannot
be programmed properly, replace ECM. The
replacement ECM must be programmed.

(ECT) Sensor
Removal Procedure
2. Drain enough engine coolant so that the coolant level
will be below the ECT sensor.
3. Remove electrical connector from the sensor located
on the intake manifold above the ignition coil.
4. Unscrew the sensor from the manifold.
014RX002
014RX008
901RX031
1. Install the sensor into the intake manifold. Do not over

tighten.

3. Add engine coolant to required level. Refer to Engine
Cooling System Section.
6E1267
4. Unscrew sensors form the exhaust pipe. 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 degree C.
NOTE: Both sensors are identical. Inspect each inthe
same way.
grease, dirt, corrosion and bare wire or worn
insulation.
dirt, excessive carbon build up or other contaminants.
0016

Removal Procedure
2. Locate the two oxygen sensors.
ahead of the catalytic converter.
behind the catalytic converter.
TS23739
3. Disconnect pig tail electrical connector.

014RX010
NOTE: If HO2S is reinstalled after removal, special

antiseize compound or the equivalent should be applied
to the threads. Special antiseize compound, (P/N
5613695), is used on the HO2S threads. This compound
consists of glass beads suspended in a liquid graphite
solution. The graphite burns away with exhaust heat, but
the glass beads will remain, making the sensor easier to
remove.
6E1268
1. Apply antiseize compound or the equivalent to the

thread.
(PostCatalytic Converter Heater Oxygen Sensor

Location)
014RX009
TS23739
2. Install HO2S on the exhaust pipe.

3. Tighten the sensor to 55 Nm (5.6 kgm/40 lb ft)
4. Connect the pig tail to the wiring harness.

Sensor
(PreCatalytic Converter Heater Oxygen Sensor Location)
Removal Procedure
2. The IAT sensor is located in the intake air duct
between the air filter and the throttle body.
014RX010
014RX011

4. Remove the sensor from intake air duct by using a
6E1269
3. Remove a mounting bolt securing the sensor to the

manifold.
4. Remove the sensor from the intake manifold using
0018
014RX012
1. Install the IAT sensor into intake air duct. Make sure
the sensoris pushed all the way into the intake air
duct.
1. Push MAP sensor into the manifold. Make sure the
sensor is pushed always into its position.
2. Install a mounting bolts and tighten.
014RX011
014RX013

(MAP) Sensor

(MIL)
Removal Procedure
(The MAP sensoris located on the intake manifold
behind throttle body.)

Refer to Instrument Panel Removal Procedure.
6E1270

Damage
Electronic components used in the control system are
electricity can cause damage to same electronic
discharge. There are several way for a person to become
charging are by friction and by induction. An example of
charging by friction is a person sliding across a car seat.
momentarily touches ground. Charge of the same polarity
are drained off leaving the person highly charged with
opposite polarity. Static charge can cause damage,
therefore, it is important to use care when handling and
testing electronic components.
IMPORTANT: When replacing the production ECM

with a service ECM, it is important to transfer the
broadcast code and production ECM number to the
service ECM label. This will allow positive identification of
ECM parts throughout the service life of the vehicle. Do
not record this information on ECM metal cover.
Removal Procedure
3. Remove ashtray inner.
4. Remove a screw located behind ashtray.

board.
D Before removing the parts from the package, ground
D If the parts been handled while sliding across the
seat, or while sitting from standing position, or walking
a distance, touch a known good ground before
installing the parts.
014RX002
NOTE: To prevent internal ECM damage, the ignition

must be OFF position in order to disconnect or reconnect
power to the ECM (for example: battery cable. pig tail,
ECM fuse, jumper cable, etc.).
014RX014
5. Pull out Face trim of console.

6. Remove two screws located inside of center console
storage box and pull up rear part of center console.
014RX015
7. Unscrew the shift knob.

8. Remove four screw holding front part of the console
and pull the console up.

9. Disconnect the red, white and blue electrical
connector at the ECM.
6E1271
1. Place ECM into its position and secure by four
mounting screws.
014RX016
10. Remove two nuts in the front of ECM.

11. Remove two nuts in the rear of ECM.
12. Pull the ECM out from dashboard.
014RX002
2. Connect all three connectors to ECM. All connectors

are color keyed. Same color male and female
connectors join together.
014RX002
014RX017
6E1272
3. Install the front center console and secure by four

retaining screws.
9. Remove wheel blocks.
014RX014
014RX016
4. Install the rear center console and secure it by two

retaining screw into storage box.

Removal Procedure
3. Remove the two screws and TP sensor from the
throttle body.
014RX015
5. Snap face plate into its position and secure it by a

screw.
6. Insert ashtray inner.
7. Insert the shift knob.
101RX002
6E1273
Function Check
closed throttle.
D The voltage should be under 0.25 volts.
D If the reading is greater than 0.25 volts, check the
101RX002

Removal Procedure
101RX003
1. Install the TP sensor on the throttle body with two
screws.

2. VSS is located on the right side of the transmission
case just ahead of the rear propeller shaft.
Disconnect the VSS electrical connector.
3. Remove the bolt and the VSS from the transmission
case by wiggling it slightly and pulling it straight out.
case.
101RX003
014RX020
6E1274
3. Inspect the Oring for wear, nicks, tears, or
looseness. Replace the Oring if necessary.
3. Connect electrical connector to the VSS.

4. Check the transmission oil level. Add oil if necessary.
014RX020
Air Filter
Removal Procedure
014RX021
1. Install the VSS in the transmission case with the
notch for the connector facing the rear.
2. Secure the VSS with mounting bolt. Tighten the bolt to
16 Nm (12 lb ft).
1. Disconnect electrical connector at the IAT sensor.

cleaner housing.
014RX019
014RX021

6E1275
4. Connect the electrical connector to the IAT sensor.
014RX023
014RX019
Removal Procedure
014RX023
2. Install the air cleaner lids.

3. Secure the three latches, holding the lid on the air
cleaner housing.
101RX002

3. Remove the two screws and IAC valve from the
throttle body.
6E1276

Measurement Procedure
mounting flange. If that measurement is 28 mm or
less, the valve need no adjustment. If the
measurement is greater than 28 mm, apply finger
pressure and retract the valve. The force required to
retract the pintle on a new valve will not damage the
valve, shaft or pintle.
valve that have been in service. The force required to
014RX022
Cleaning and Inspection Procedure

D Clean the IAC valve Oring sealing surface, pintle
D Use carburetor cleaner and a parts cleaning brush to
remove carbon deposit. Do not use a cleaner that
contain methyl ethyl ketone. This is an extremely
strong solvent and not necessary for this type of
deposit.
D Shiny spots on the pintle are normal and do not
D Inspect the IAC valve Oring for cuts, cracks or
distortion. Replace the Oring if damaged.
TS23746
1. Install IAC valve on the throttle valve body with the
two screws. Tighten the screw to 1 Nm ( 9 lb in).
0006
014RX022

2. Connect electrical connector to IAC valve.
6E1277
4. Loosen retaining clamps at the throttle body and at

the air filter box.
5. Disconnect brake booster vacuum hose at intake
manifold and at brake booster.
101RX002
Intake Air Duct
014RX025
Removal Procedure
2. Disconnect electrical connector at IAT sensor.
3. Remove the IAT sensor if necessary. Refer to Intake
Air Temperature Sensor Removal.
6. Remove retaining nut at the intake air duct bracket at

top of valve cover.
7. Disconnect the intake air duct from the throttle body
and at the air filter box.
014RX019
014RX011
6E1278
1. Connect the intake air duct at the throttle body and at
the air filter box. Make sure retaining hole is inserted
to the intake air duct bracket.
5. Install IAT sensor if necessary. Refer to Intake Air

Temperature Sensor Installation.
6. Connect electrical connector at IAT sensor.
014RX011
014RX019
2. Tighten retaining clamp at the throttle body and at the

air filter box.
3. Install a nut to the intake air duct bracket and tighten.
4. Connect brake booster vacuum hose to intake
manifold and to brake booster and secure them with
clamps.

Knock Sensor
Removal Procedure
1. Disconnect negative battery cable.
2. Disconnect pig tail electrical connector at near the top
of generator.
014RX026
014RX027

3. Unscrew retaining bolt from Knock Sensor located
passenger side of engine block just front of starter.
6E1279
Oil Pressure Switch

Removal Procedure
1. Disconnect battery negative cable.
2. Disconnect electrical connector at Oil Pressure
Switch.
014RX028
4. Remove Knock Sensor with retaining bolt.
1. Install Knock Sensor with retaining bolt.
2. Connect pig tail electrical connector.
014RX030
3. Unscrew Oil Pressure Switch from Oil Filter Mounting

Housing.
014RX029
014RX031
6E1280

3. Remove accelerator control cable (on the throttle
valve end).
1. Install Oil Pressure Switch into Oil Filter Mounting
Housing and tighten.
101RW006
014RX028
FUEL METERING SYSTEM Accelerator Cable Assembly

Removal Procedure
mounting on the throttle body.
2. Remove the cable clip from holding bracket.

corrosion.
014RX032
014RX026
6E1281
6. Adjust the accelerator cable. Refer to Accelerator

Cable Adjustment Section.
3. Install the accelerator control cable on the accelerator
pedal.
014RX026
Accelerator Cable Adjustment

014RX032
4. Install the accelerator control cable on the throttle

valve.
1. Loosen the adjusting nut.
2. Loosen the jam nut.
3. Pull the outer cable while fully closing the throttle
valve.
4. Tighten the adjusting nut.
5. Tighten the jam nut.
6. Loosen the adjusting nut by three turns.
7. Tighten the jam nut again.
8. Manually operate valve.
IMPORTANT:
The valve lever must return up to the
stopper screw, repeat the procedure again from Step 1.
101RW006
5. Install the cable clip to the holding bracket.
014RX026
6E1282
Fuel Filler Cap

Fuel Filler Cap
Removal Procedure
the acceleratorpedal assembly.
2. Remove the two screws retaining the accelerator
pedal to the bulkhead.
3. Remove the accelerator pedal from the bulkhead.
The Fuel filter cap includes a vacuum valve and a

pressure valve. If high vacuum or pressure occurs in the
fuel tank, each valve works to adjust the pressure in order
to prevent damage to the tank at the EGR valve.
NOTE: Replace the fuel filler cap with the same typeof
014RX033
1. Install the accelerator pedal assembly to the
bulkhead with two screws.
2. Connect the accelerator control cable to the
3. Adjust accelerator cable if necessary. Refer to
Accelerator Cable Adjustment Section.
TS23767
Fuel Filter
Removal Procedure
014RX034
6E1283
041RW005
3. Disconnect the fuel lines from the fuel filter on the

engine side.
tank side.
041RW007
D Fuel leaks from the fuel filter body
D The fuel filter body is damaged
D The fuel filter is clogged with dust or sediment
2. If the drain hole is clogged at filler neck is clogged with
dust, clean the drain hole with air.
041RW006
041RW008
6E1284

014RX035
2. Disconnect electrical connector from fuel injector.

3. Remove the fuel rail. Refer to Fuel Rail Removal
Procedure.
041RW006
Fuel Injectors
Removal Procedure
contamination and change the oil and filter if necessary.
NOTE: Use care in removing the fuel injector in order to
pins or fuel injector nozzles. The fuel injector is an
IMPORTANT: Fuel injectors are serviced as complete
assembly only.
014RX036
4. Remove the fuel injector retainer clip.

5. Remove fuel injector assembly from fuel rail.
6. Remove Oring from the fuel injector.

7. Remove Oring backup from fuel injector.
6E1285
014RX037
014RX035
1. Inspect Oring for crack, damage or leaks.
2. Replace worn or damaged Oring.
3. Lubricate the new Orings with engine oil before
installation.
1. Lubricate the new Oring with engine oil.
2. Install the Oring backup on the fuel injector.
3. Install new Oring on the fuel injector.
4. Install all four injector on the fuel rail.
5. Use new injector retainer clip to retain the injector to
the fuel rail.
Removal Procedure
components.
NOTE: Compressed air must never used to test or clean
a fuel pressure regulator, as damage to the fuel pressure
regulator may occur.
014RX037
7. Install fuel rail assembly. Refer to Fuel Rail

014RX035
6E1286

1. Depressurize the fuel system. Referto Fuel Pressure
Relief Procedure.
4. Disconnect the vacuum line form fuel pressure
regulator.
1. Insert the fuel pressure regulator into the fuel rail.
014RX039
2. Install the fuel pressure regulator retaining bracket

ant tighten with a screw.
3. Connect vacuum line onto the fuel pressure regulator.
014RX038
5. Remove the fuel pressure regulator retaining screw.

6. Remove the fuel pressure regulator retaining bracket.
7. Remove the fuel pressure regulator from fuel rail.
014RX038

014RX039

fuel line.
6E1287
4. Crank the engine for about 30 seconds.

014RW089
014RX035
Fuel Pump Assembly

components.
Removal Procedure
2. Drain all fuel from fuel tank from filler neck.
3. Remove the fuel pump relay from the fuse and relay
box at right side of engine room.
014RW089
041RW005

relay box.
6E1288
4. Remove fuel tank. Refer to Fuel Tank Removal

Procedure.
5. Using J39763, twist the fuel pump counterclock
wise to release from fuel tank.
Inspect intank fuel filter for tears, damage or evidence of
dirt derbies or water in the fuel. If any of these condition
exist, replace the intank fuel filter.
041RX001
041RX003
6. Lift fuel pump to remove from fuel tank.
1. Insert the fuel pump assembly into fuel tank and place
them at its position.
041RX002
041RX002

2. Using J39763, twist fuel pump assembly clock wise
into the lock.
6E1289
1. Inserts the relay into the correct place in the fuse and
901RX036
3. Install the fuel tank. Refer to Fuel Tank Installation

Procedure.
014RW089
Fuel Rail Assembly

Removal Procedure
NOTE:
connector terminal and the injector spray tips.
D Fitting should be capped and holes plugged during
entering open lines and passage.
041RX004
Fuel Pump Relay

Removal Procedure
1. Remove the fuse and relay box cover located right
side of engine room.
2. Determine correct relay by consulting to the diagram
on the cover.
3. Insert a small screwdriver or use thumb pressure to
box.
6E1290
IMPORTANT: An eightdigit identification number is

stamped on side of the fuel rail. Refer to this number when
you service the fuel rail or when a replacement part is
required.
7. If removal of fuel pressure regulator is necessary.

Refer to Fuel Pressure Regulator Removal
Procedure.
8. If removal of fuel injector is necessary. Refer to Fuel
Injectors Removal Procedure.
014RX035

Relief Procedure.
2. Disconnect the fuel inlet at the rear of the engine.
3. Disconnect the fuel return line at front of the engine.
4. Disconnect the injector electrical connectors.
5. Remove the nuts holding wiring harness onto fuel rail.
6. Remove the bolts retaining fuel rail to the intake
manifold.
Lift up the injectors carefully to separate them from intake
manifold.
014RX037
1. Install the fuel injectors if necessary. Refer to Fuel
Injector Installation Procedure.
2. Install the fuel pressure regulator if necessary. Refer
to Fuel Pressure Regulator Installation Procedure.
3. Place the fuel injector rail assembly on the manifold
and insert the injectors into each port by pushing fuel
rail.
Lift up the fuel rail with injectors as assembly. Do not separate the fuel injectors from fuel rail.
If an injector become separated from fuel rail, injector
backup Oring and injector retainer clip must be replaced.
Drain residual fuel from fuel rail into an approved container.
014RX037
4. Install two fuel rail retaining bolts. Tighten fuel rail

retaining bolts to 19 Nm (14 lb ft)
5. Place wiring harness in its place and secure it with two
nuts.
014RX036

6. Connect electrical connector to each fuel injector.
6E1291
3. Drain the fuel from fuel filler neck.

4. Disconnect the fuel filler hose at fuel tank.
5. Disconnect the air breather hose at the fuel tank.
6. Disconnect the evaporator hose at the fuel tank.
7. Hold entire fuel tank at the bottom with stands.
8. Disconnect fuel supply lines and fuel return line at
near the fuel filter inside of body frame.
014RX036
7. Connect the fuel supply line securely. Do not over

tighten.
8. Connect the fuel return line securely. Do not over
tighten.
10. Crank the engine until it start. Cranking the engine
fuel system. Check for leak. If fuel leak is observed,
stop engine immediately. Before correct fuel leak, be
sure to depressurize system again.
041RX005
9. Remove four bolts (two in front and two in rear)

holding fuel tank to the frame.
10. Lower tank assembly from the vehicle a little to make
access space on top.
11. Disconnect two electrical connectors at fuel pump.
014RX035
Fuel Tank
Removal Procedure
2. Remove fuel filer cap.
041RX006
12. Remove fuel tank assembly from the vehicle.

13. Remove four nuts retaining tank under guard to the
tank.
6E1292

7. Connect the fuel filler hose, the air breather hose and
EVAP hose onto fuel tank and secure them with
clamps.
14. Remove the tank from the guard.
041RX002
041RX006
1. Secure fuel tank into under guard with four retaining

bolts, if necessary.
2. Place the fuel tank assembly onto stands.
3. Lift the fuel tank assembly near the position.
4. Connect two electrical connectors at fuel pump.
5. Lift the fuel pump to its position and secure it with four
mounting bolts. Make sure that all hoses and fuel
lines are out of way between the fuel tank and the fuel
tank bracket. Tighten the fuel tank retaining bolts to
36 Nm (27 lb ft).
8. Pour fuel into fuel tank.

9. Install fuel filler cap securely.
041RX005
Throttle body (TB)

Removal Procedure
041RX007
6. Connect fuel supply and return lines.

3. Remove the air intake duct. Refer to Air Intake Duct
Removal Procedure.
4. Remove the accelerator cable from throttle. Refer to
Accelerator Cable Assembly Removal Procedure.

5. Disconnect the electrical connectors from the throttle
position sensor and the idle air control valve solenoid.
6. Disconnect all vacuum hoses below air horn.
7. Disconnect coolant lines.
1. If the throttle body gasket needs to be released,

2. Do not leave any scratches in the aluminum casting.
014RX041
014RX025
8. Remove the mounting bolts retaining the throttle body

the intake manifold.
9. Lift up the throttle body from the intake manifolds.
6E1293
1. Install IAC valve onto the throttle body. Refer to Idle
Air Control Valve Solenoid Installation Procedure.
2. Install TPS onto the throttle body if necessary. Refer
to TPS Installation Procedure.
3. Place the gasket then the throttle body on the
manifold.
4. Install four mounting bolt. Tighten the throttle body
mounting bolt to 13.5 Nm (10 lb ft).
014RX040
10. Remove the gaskets from the intake manifolds.

11. Remove the IAC. Refer to Idle Air Control Valve
Solenoid Removal Procedure.
12. Remove TPS. Refer to Throttle Position Sensor
Removal Procedure.
body assembly. The gasket surface and the throttle body
assembly may be damaged as results.
014RX041
5. Connect coolant line and secure them with clamps.

6. Connect all vacuum hoses and secure them with
clamps if necessary.
7. Install accelerator control cable bracket onto the
throttle body.
6E1294
8. Connect accelerator control cable to throttle plate.
ELECTRONIC IGNITION
SYSTEM Ignition Control
Module (ICM)
Removal Procedure
2. Disconnect the electrical connector from the ignition
control module.
3. Remove the two attaching screws.
4. Remove the ignition control module from the engine
block.
014RX025
9. Connect electrical connector at IAC valve and TPS.

1. Fasten the module to the engine block with two

screws.
2. Reconnect the electrical connector.
3. Reconnect the negative battery terminal.
041RX042
101RX002
6E1295
Ignition Coil
Removal Procedure
2. Drain the cooling system. Refer to Engine Cooling
System.
3. Remove the heater supply and return hose.
4. Remove the coolant return hose.
5. Disconnect all four spark plug cables from the coil.
6. Disconnect electrical connector from the ignition coil.
7. Remove three mounting bolt from the ignition coil.
8. Remove the ignition coil from the bracket.
014RX044
Spark Plugs
Removal Procedure
Type: NGK BPR6ES11
Spark Gap : 1.05 MM (0.040)
Spark Plug Torque : 25 Nm (2.6 kgm/18 lb ft)
2. Remove four bolt holding spark plug cover plate to top
of valve cover, and remove the cover plate.
3. Pull ignition wire using hocks attached to end of spark
plug cable.
014RX043
1. Install the ignition coil onto the bracket with three
mounting bolts.
2. Connect electrical connector at the ignition coil.
3. Connect spark plug cable to the ignition coil.
4. Connect heater supply and return hose and secure
them with clamps.
5. Connect coolant return line and secure them with
clamps.
014RX043
6E1296

D Fuel mixture is too lean.
D Heat range is incorrect.
014RX045
014RX047
1. Check the insulator for cracks. Replace the spark
plug if crack are present.
2. Check the electrode condition and replace the spark
plug if necessary.
If vehicle usage does not conform to normal driving

conditions, a more suitable spark plug may be
substituted.
If fuel and electrical system are normal, in most cases of
this sort, the problem can be corrected by using a colder
type spark plug with the same physical dimensions as the
original equipment spark plug.
3. Check the gaskets for damage and replace if
necessary.
4. Measure the spark plug gap. The specification is 1.05
mm (0.040).
5. Adjust the spark gap by bending the grounded
electrode.
014RX046
If the spark plug electrodes and insulators are fouled with

carbon or oil, the engine will not operate efficiently.
There are number of possible causes:
D Fuel mixture is too rich.
D Oil in the combustion chamber.
D The spark plug gap is not set correctly.
If spark plug fouling is excessive, check the fuel and
electrical system for possible causes of trouble. If fuel and
electrical system are normal, install spark plug of a higher
heat range which have the same physical dimensions as
the original equipment spark plug.
The following symptoms are characteristics of spark
plugs that are running too hot:
014RX048
1. Tighten the spark plug to the 25 Nm (2.6 kgm/18 lb ft).
2. Push the spark plug cable in until it snaps in.

3. Install spark plug cover onto valve cover and secure it
with four retaining bolts.
6E1297
NOTE: Never puncture the spark plug cables insulation
with a needle or the pointed end of a probe into the cable.
An increase in resistance would be created which would
cause the cable to become defective.
1. If the cable has broken or cracked insulation, it must
be replaced.
2. If the terminals are corroded or loose, the cable must
be replaced.
3. Check that the cable resistance does not exceed 10 k
W per foot.
014RX049
Spark Plug Cables

Spark Plug Cables
The cable contains a synthetic conductor which is easily
damaged. Never stretch or kink the cable. Disconnect the
cable from spark plug and the ignition coil.
The original equipment cables and the ignition coil are
marked to show correct location of the cables. If spark
plug cables or the ignition coil are replaced previously,
before cables are removed from the ignition coil, mark the
cables and the coil so they can be reconnected in the
same position.
014RX051
EMISSIONS Catalytic Converter

Catalytic Converter
Refer to Engine Exhaust.

Removal Procedure
1. Remove the fuse and relay box cover at right side of
engine room.
2. Refer to the diagram on the cover to determine which
3. Insert small screwdriver or use thumb pressure to
014RX050
6E1298
box.
2. Inspect the canister for damages.
014RX001
014RX052
1. Install EVAP canister onto crossmember with two
mounting bolts.
2. Connect all hoses and secure them with clamps.

There is no timing adjustment. The timing signal is
furnished by the CKP and the CMP signal. ECM control
the ignition timing.
EVAP Canister Hoses

EVAP Canister Hoses
To see the routing of the EVAP canister hoses, refer to
Vehicle Emission Control Information in Diagnosis or
Emission Label located bottom side ofthe hood. Use
hoses.
EVAP Canister
Removal Procedure
1. Disconnect all hoses.
2. Remove two mounting bracket nuts.
1. Inspect the hoses for cracks, damage and leaks.
014RX054
Linear Exhaust Gas

Removal Procedure
2. Disconnect electrical connector at EGR valve.
3. Disconnect the electrical connector at Intake Air
Temperature Sensor.
4. Remove air intake duct. Refer to Air Intake Duct
Removal Procedure.
5. Remove crankshaft breather hose.

6. Remove two bolts holding EGR valve.
7. Remove EGR valve and gasket from the manifold.
6E1299

057RX001
014RX057
1. Inspect the air passage for a restrtiction. If there is
restriction, remove the object. Do not use any type of
solvent, it may damage electrical system of EGR
valve.
2. Inspect restriction for valve movement. If there is
restriction remove the object.

replacement.
ECM Connectors And Terminals

Removal Procedure
014RX056
1. Place the gasket and EGR valve on to the intake
manifold.
2. Install mounting bolts and tighten.
3. Connect electrical connector at EGR valve
4. Connect the crankshaft breather hose and secure it
with clamps.

exposed.
be pulledinto position within the connector.
terminal retainer.
6E1300


checking. NEVER probe through WeatherPack seals.
making any connector or terminal repair. WeatherPack
and ComPack III terminals look similar, but are serviced
differently.
048

Shielded Cable

solder.
(uninsulated) wire.
Removal Procedure
mylar.
049
047

6E1301
050
Twisted Leads
052

the other wires.
Removal Procedure
053
051
6E1302

procedure.
070
054
4. Tape the wires with electrical tape.
2. Use tool 5-8840-0388-0 or the equivalent to remove

the pin and the sleeve terminals. Push on
5-8840-0388-0 to release.
NOTE: Do not use an ordinary pick or the terminal may
055
WeatherPack Connector
Tools Required
5-8840-0388-0 WeatherPack II Terminal Remover
Removal Procedure
A WeatherPack connector can be identified by a rubber
form oxidation and deposits on the terminals. This
071

6E1303

locking tangs.
ComPack III
ComPack III
The ComPack III terminal looks similar to some
WeatherPack terminals. This terminal is not sealed and
terminal. Do not use the WeatherPack terminal tool
5-8840-0388-0 or equivalent. These will damage the
terminals.
072
Do not replace the WeatherPack connections with
with the WeatherPack connector and terminal
packages.
070
MetriPack
Tools Required
5-8840-0632-0 Terminal Remover
Removal Procedure
Some connectors use terminals called MetriPack Series
2. Insert the 5-8840-0632-0 tool or equivalent (3) in
locking tang.
073
6E1304

other than the expected amount, DTC P0336 will set. The
engine will not start and run without using the 58X
reference signal.
A/C Request Signal

at the A/C control switch. The ECM uses this signal to
adjust the idle speed before turning ON the A/C clutch.
The A/C compressor will be inoperative if this signal is not
060

used by the powertrain control module (ECM) to calculate
reference pulses which the ECM uses to calculate RPM
and crankshaft position. For additional information,
refer to Electronic Ignition System.
MetriPack terminals are also referred to as
pulltoseat terminals.
connector (3).
seat it in place.
0013

Signal
061
GENERAL DESCRIPTION ECM

AND SENSORS
58X Reference ECM Input
The engine control module (ECM) uses this signal from
the crankshaft position (CKP) sensor to calculate engine
RPM and crankshaft position at all speeds. The ECM
also uses the pulses on this circuit to initiate injector
pulses. If the ECM receives no pulses on this circuit, DTC
P0337 will set. If the ECM receives a number of pulses

For further information, refer to
DTC P0341
DTC P0342.
6E1305
014RX007

coolant temperature produces a high resistance of about
100,000 W at 40C (40F). High temperature causes a
low resistance of about 70 W at 130C (266F).
The ECM supplies a 5volt signal to the ECT sensor
through resistors internal to the ECM and then measures
the voltage after the internal resistor. This signal voltage
will be high when the engine is cold and low when the
engine is hot. By measuring the voltage, the ECM
calculates the engine coolant temperature. Engine
ECM controls.
degrees. After engine startup, the temperature should
sensor circuit will set DTC P0117 or DTC P0118. An
intermittent fault will set a DTC P1114 or P1115.
0016

the ECM needs to control powertrain operation.
is not replaceable.
Fuel Control Heated Oxygen Sensor (Pre

Catalyst)
The fuel control heated oxygen sensor (Bank 1 HO2S 1)
is mounted in the exhaust stream where it can monitor the
oxygen content of the exhaust gas. The oxygen present in
the exhaust gas reacts with the sensor to produce a
voltage output. This voltage should constantly fluctuate
from approximately 100 mV to 900 mV. The heated
oxygen sensor voltage can be monitored with a Tech 2. By
monitoring the voltage output of the oxygen sensor, the
ECM calculates the pulse width command for the
injectors to produce the proper combustion chamber
mixture.
between 400500 mV. A constant voltage below 300 mV
set DTC P0132. The ECM can also detect HO2S
response problems. If the response time of an HO2S is
determined to be too slow, the ECM will store a DTC that
indicates degraded HO2S performance.
6E1306
0012
0017

resistance of about 100,000 W at 40C (104F). High
temperature causes low resistance of about 70 W at
130C (266F). The ECM supplies a 5volt signal to the
sensor through a resistor internal to the ECM, and then
monitors the signal voltage. The voltage will be high when
the incoming air is cold. The voltage will be low when the
incoming air is hot. By measuring the voltage, the ECM
calculates the incoming air temperature. The IAT sensor
signal is used to adjust spark timing according to the
incoming air density.
close to each other. A failure in the IAT sensor circuit will
set DTC P0112, or DTC P0113.

MAP sensor signal voltage to the ECM varies from below
ignition ON, engine not running or at wideopen throttle
(low vacuum).
D Manifold pressure changes while the linear EGR flow
test diagnostic is being run. Refer to DTC P0401.
If the ECM detects a voltage that is lower than the
sensor will set DTC P0108. The ECM can detect a shifted
MAP sensor. The ECM compares the MAP sensor signal

Control
The ECM monitors the exhaust gas recirculation (EGR)
The ECM uses information from the following sensors to
D Manifold Absolute Pressure (MAP) sensor.
014RX013

The engine control module (ECM) is located in the
ECM controls the following:
D Ignition timing.
D Onboard diagnostics for powertrain functions.
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. The ECM performs the
operational problems, alert the driver through the Check
Engine lamp, and store diagnostic trouble codes (DTCs).
DTCs identify the problem areas to aid the technician in
making repairs.
6E1307
speed sensor (VSS). The ECM also controls certain

D A/C clutch control
ECM Voltage Description

The ECM supplies a buffered voltage to various switches
and sensors. It can do this because resistors in the ECM
which are so high in value that a test light may not
illuminate when connected to the circuit. An ordinary shop
voltmeter input impedance is too low. Use a 10megohm
input impedance digital voltmeter (such as J 39200) to
assure accurate voltage readings.
The input/output devices in the ECM include
analogtodigital converters, signal buffers, counters,
and special drivers. The ECM controls most components
when turned ON. These switches are arranged in groups
of 4 and 7, called either a quad driver module (QDM),
which can independently control up to 4 output terminals,
or Output Driver Module (ODM) which can independently
ECM Inputs/Outputs
014RX002
ECM Function
The ECM supplies either 5 or 12 volts to power various
resistors in the ECM which are so high in value that a test
light will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low.
Therefore, a digital voltmeter with at least 10 megW input
impedance is required to ensure accurate voltage
readings. Tool J 39200 meets this requirement.
The ECM controls output circuits such as the injectors,
ECM Components
The ECM is designed to maintain exhaust emission levels
excellent driveability and fuel efficiency. The ECM
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Air Conditioning Compressor Clutch ON or OFF

Crankshaft Position
Battery Voltage
Throttle Position
Fuel Tank Vapor Pressure
Fuel Tank Level
Exhaust Gas Recirculation (EGR) Feedback
Knock
Vehicle Speed
Fuel Pump Voltage
Camshaft Position

D
D
D
D
D
D
D
D

Ignition Control
Fuel Injector Control
Idle Air Control
Coolant Fan Relays
Electric Fuel Pump Relay Compressor Clutch Relay
Air Conditioning
6E1308
D Diagnostics
OBD II Malfunction Indicator Lamp (Check Engine
lamp)
Data Output
D Tachometer Signal
ECM Service Precautions

The ECM is designed to withstand normal current draws
associated with vehicle operation. Avoid over loading any
or apply voltage to any of the ECMs circuits unless
using digital voltmeter J 39200. The ECM should remain
connected to the ECM or to a recommended breakout
box.
101RX003

be affected.
indicate to the ECM which position is selected by the
operation.
For more information on the transmission range switch,
refer to 4L30E Automatic Transmission.

014RX002

ECM monitors the voltage on the signal line and
the TP sensor is about 0.25 volts. As the throttle valve
opens, the output increases so that at wide open throttle
(WOT), the output voltage should be about 4.75 volts.
The ECM calculates fuel delivery based on throttle valve
unstable idle because the ECM thinks the throttle is
moving. A hard failure in the TP sensor 5volt reference
the ECM will use an artificial default value based on
and some vehicle performance will return. A high idle may
result when either DTC P0122 or DTC P0123 is set. The
ECM can detect intermittent TP sensor faults.
The ECM determines the speed of the vehicle by

converting a pulsing voltage signal from the vehicle speed
sensor (VSS) into miles per hour. The ECM uses this
signal to operate the speedometer.
0008

6E1309

connectors.

Equipment
Aftermarket (addon) electrical and vacuum equipment is
after it leaves the factory. No allowances have been made
in the vehicle design for this type of equipment.
NOTE: No addon vacuum equipment should be added
to this vehicle.
NOTE: Addon electrical equipment must only be
(power and ground).
Addon electrical equipment, even when installed to

Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
discharge.
D Charge by induction occurs when a person with
wellinsulated shoes stands near a highly charged
object and momentarily touches ground. Charges of
the same polarity are drained off leaving the person
components.
TS23793

D Do not touch the ECM connector pins or soldered
components on the ECM circuit board.
D Do not touch any electronic sensor module
component leads.

INDUCTION
drawn into the engine. A remotemounted air cleaner
throttle body. Air enters the engine by the following steps:
2. Into the intake manifold.
6E1310
Deceleration Fuel Cutoff (DFCO) Mode

The ECM reduces the amount of fuel injected when it
When deceleration is very fast, the ECM may cut off fuel
Engine Speed/Vehicle Speed/ Fuel Disable

Mode
The ECM monitors engine speed. It turns off the fuel
injectors when the engine speed increases above 6000
Fuel Cutoff Mode

is OFF. This prevents engine runon. In addition, the
ECM suspends fuel delivery if no reference pulses are
028RX002
Fuel Injector

METERING
Acceleration Mode
The ECM provides extra fuel when it detects a rapid
The accelerator control system is a cabletype system

a solenoidoperated device controlled by the ECM. The
ECM energizes the solenoid, which opens a valve to allow
fuel delivery.
crank times.

When battery voltage is low, the ECM will compensate for
D The idle RPM.
CMP Signal
The ECM uses the camshaft position (CMP) sensor
signal to determine the position of the number 1 piston
during its power stroke, allowing the ECM to calculate
true sequential multiport fuel injection (SFI). Loss of this
signal will set a DTC P0341 or DTC P0342. If the CMP
in the calculated sequential mode with the fault is present,
with a 1in4 chance of being correct.
Clear Flood Mode

down all the way. The ECM then deenergizes the fuel
injectors. The ECM holds the fuel injectors deenergized
less than 80%, the ECM again begins to pulse the
0003

parts:
D The fuel rail.
D The fuel pressure regulator.
D The ECM.
D The crankshaft position (CKP) sensor.

D
D
D
D
6E1311

The fuel pump.

pumps fuel to the fuel rail through an inline fuel filter. The
pipes.

the ECM how much oxygen is in the exhaust gas. The
ECM changes the air/fuel ratio to the engine by controlling
the amount of time that the fuel injector is ON. The best
fuel injection system is called a Closed Loop system.
The ECM monitors signals from several sensors in order
All modes are controlled by the ECM.

The fuel pressure regulator is a diaphragmoperated
serviced separately.
P0171, or DTC P1171 will be the result. If the pressure is
too high, a DTC P0172 will be the result. For information
on diagnosing fuel pressure conditions, refer to Fuel
System Diagnosis.
014RX038

When the key is first turned ON, the ECM energizes the
fuel pump relay for two seconds to build-up the fuel
seconds, the ECM shuts the fuel pump off and waits until
the 58X crankshaft position signal has been detected by
the ECM, the ECM supplies 12 volts to the fuel pump relay
to energize the electric intank fuel pump.
An inoperative fuel pump will cause a nostart condition.
Fuel Rail
distributes fuel to the individual injectors. Fuel is delivered
to the fuel inlet tube of the fuel rail by the fuel lines. The
fuel goes through the fuel rail to the fuel pressure
regulator. The fuel pressure regulator maintains a
constant fuel pressure at the injectors. Remaining fuel is
then returned to the fuel tank.
014RX036
6E1312

ECM will retract the IAC pintle, resulting in more air
RPM is too high, the ECM will extend the IAC pintle,
decreasing the RPM.
calculated by the ECM based on battery voltage, coolant
closed, the ECM senses a nearstall condition. The ECM
prevent stalls.
cycled ON then OFF. When servicing the IAC, it should
only be disconnected or connected with the ignition OFF.
The position of the IAC pintle valve affects engine
startup and the idle characteristics of the vehicle. If the
IAC pintle is fully open, too much air will be allowed into
the manifold. This results in high idle speed, along with
possible hard starting and a lean air/fuel ratio. DTC
P0507 may set. If the IAC pintle is stuck closed, too little
air will be allowed in the manifold. This results in a low idle
speed, along with possible hard starting and a rich air/fuel
ratio. DTC P0506 may set. If the IAC pintle is stuck
partway open, the idle may be high or low and will not
respond to changes in the engine load.
When the engine is first started, the system is in Open

Loop operation. In Open Loop, the ECM ignores the
ECT, and MAP sensors.
The system remains in Open Loop until the following
conditions are met:
temperature).
the engine.
since startup.
met, the system enters Closed Loop operation. In
Closed Loop, the ECM calculates the air/fuel ratio
(injector ontime) based on the signal from the HO2S.
Starting Mode
When the ignition is first turned ON, the ECM energizes
to build up pressure. The ECM then checks the engine
for starting.
The ECM controls the amount of fuel delivered in the
Throttle Body Unit

valve are also mounted on the throttle body.
Vacuum ports located behind the throttle plate provide the
vacuum signals needed by various components. Engine
coolant is directed through a coolant cavity in the throttle
body to warm the throttle valve and to prevent icing.
0006
Run Mode
D Open Loop
D Closed Loop
014RX040
6E1313

GENERAL DESCRIPTION
injector being correct.
For additional information, refer to DTC P0342.
0013
Ignition Coils
The 2.2L engine uses 2 ignition coils, 1 per 2 cylinders. A
twowire connector provides a 12volt primary supply
through the 15amp ignition coil fuse, and the ground wire
is connected to a groundswitching ignition module.
Radio frequency interference produced by the coil is
controlled by a condenser which is mounted near the
ignition coil.
014RX007

used by the engine control module (ECM) to calculate the
ignition sequence. The sensor initiates the 58X reference
pulses which the ECM uses to calculate RPM and
crankshaft position. For additional information, refer to
Electronic Ignition
emissions, the ECM controls the spark advance of the
D No moving parts.
D Less maintenance.
014RX044
Ignition Control
The ignition control (IC) spark timing is the ECMs method
calculated by the ECM using the following inputs:
D Engine speed.
6E1314
D
D
D
D
Engine coolant temperature (ECT) sensor.

Throttle position (TP) sensor.
ECM and ignition system supply voltage.

The engine control module (ECM) controls engine ignition
through a solidstate switching unit called the ignition
control module (ICM). The software in the ECM uses
input from several sensors to determine the timing,
duration, and strength of the spark.
014RX007
014RX042
D The crankshaft position (CKP) sensor sends the ECM

a 58X signal related to the exact position of the
crankshaft.
Based on these sensor signals, as well as engine load

and engine coolant temperature information, the ECM
controls the switching function of the ICM by sending it a
5V signal. As long as the ICM receives the signal, it allows
battery voltage to the ignition coil. That voltage allows a
magnetic field to build in the coil.
When the ECM requires a spark plug to fire, it shuts off the
5V signal to the ICM grounding it internally. This triggers
the ICM to switch off the battery voltage to the ignition coil,
which causes the field to collapse. The lines of magnetic
force pass through the secondary portion of the coil as
they collapse. As they intersect the coil, they induce high
voltage in the secondary ignition circuit which travels
toward ground through the spark plug.
Ignition Control ECM Output

The ECM provides a zero volt (actually about 100 mV to
200 mV) or a 5volt output signal to the ignition control
(IC) module. When the ignition control (IC) module
receives the 5volt signal from the ECM, it provides a
ground path for the B+ supply to the primary side of the
coil and creates a magnetic field in the coil. When the
ECM shuts off the 5volt signal to the ignition control
module, the ground path for the primary coil is broken.
The magnetic field collapses and induces a high voltage
secondary impulse which fires the spark plug and ignites
the air/fuel mixture.
0013

The ECM is responsible for maintaining proper spark and

optimum driveability and emissions, the ECM monitors
D Vehicle speed sensor (VSS).
Spark Plug
operation at idling speed, they frequently fail at higher
generally poor engine performance. Follow the
grayishtan deposits appearing on the insulator portion of
the spark plug. A small amount of redbrown, yellow, and
are normal combustion byproducts of fuels and
also occur.
the cylinder. Excessive idling and slow speeds under light
engine loads can keep the spark plug temperatures so
low that these deposits are not burned off. Very rich fuel
mixtures or poor ignition system output may also be the
cause.Refer to DTC P0172.
oil during breakin of new or newly overhauled engines.
redbrown, yellow or white deposits of combustion
byproducts become sufficient to cause misfiring. In
some cases, these deposits may melt and form a shiny
glaze on the insulator around the center electrode. If the
fouling is found in only one or two cylinders, valve stem
clearances or intake valve seals may be allowing excess
lubricating oil to enter the cylinder, particularly if the
deposits are heavier on the side of the spark plug facing
the intake valve.
TS23995
6E1315

idle condition. Excessive gap wear can be an indication of
continuous operation at high speeds or with engine loads,
causing the spark to run too hot. Another possible cause
is an excessively lean fuel mixture.
TS23992

can cause excessive center electrode wear. The plug and
the cylinder head seats must be in good contact for proper
heat transfer and spark plug cooling. Dirty or damaged
threads in the head or on the spark plug can keep it from
seating even though the proper torque is applied. Once
spark plugs are properly seated, tighten 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 blowby and damage
beyond simple gap wear may occur.
regapping, or heat shock to the insulator material. Upper
6E1316
A/C CLUTCH DIAGNOSIS

TS23994

electrode) may result from damage during regapping or
hot).
A 12volt signal is supplied to the A/C request input of the

ECM when the A/C is selected through the A/C control
switch.
ECM. This allows the ECM to modify the idle air control
specified calibrated acceptable ranges, the ECM will
ECM. When the A/C compressor relay is enabled, battery
voltage is supplied to the compressor clutch coil. The
ECM will enable the A/C compressor clutch whenever the
engine is running and the A/C has been requested. The
ECM will not enable the A/C compressor clutch if any of
the following conditions are met:

The A/C compressor operation is controlled by the engine
control module (ECM) for the following reasons:
D It improves idle quality during compressor clutch
engagement.
D It improves wide open throttle (WOT) performance.
components:
1. The A/C control switch.
2. The A/C refrigerant pressure switches.
3. The A/C compressor clutch.
4. The A/C compressor clutch relay.
5. The ECM.
A/C Request Signal

TS23993
D Damage during regapping can happen if the

gapping tool is pushed against the center electrode or
the insulator around it, causing the insulator to crack.
When regapping a spark plug, make the adjustment
caused by overadvanced timing or low grade fuels.
crack.
service can sometimes be cleaned and regapped, then
replaced.
at the A/C control switch. The ECM uses this input to
adjust the idle speed before turning on the A/C clutch. The
A/C compressor will be inoperative if this signal is not
GENERAL DESCRIPTION
SYSTEM

vehicle is not operating. The canister is purged by ECM
engine has been running. Air is drawn canister through
the air inlet grid. The air mixes with the vapor and the
mixture is drawn into the intake manifold.

The Engine Control Module (ECM) supplies a ground to
energize the solenoid valve (purge on). The EVAP purge
solenoid control is pulsewidth modulated (PWM) (turned
on and off several times a second). The duty cycle (pulse
width) is determined by engine operating conditions
including load, throttle position, coolant temperature and
ambient temperature. The duty cycle is calculated by the
ECM. The output is commanded when the appropriate
conditions have been met. These conditions are:
Poor idle, stalling and Poor driveability can be caused by:
properly.
6E1317
vacuum. The valve controls EGR flow from the exhaust to

the intake manifold through an orifice with a
ECMcontrolled pintle. During operation, the ECM
controls pintle position by monitoring the pintle position
feedback signal. The feedback signal can be monitored
with a Tech 2 as Actual EGR Pos. Actual EGR Pos.
should always be near the commanded EGR position
(Desired EGR Pos.). The ECM also tests for EGR flow.
If incorrect flow is detected, DTC P0401 will set. If DTC
P0401 is set, refer to the DTC charts.
D Aboveidle speed.
D Rough idle.
D DTC P0300 (misfire detected).
D DTC P0401 (EGR Flow Insufficient detected).
GENERAL DESCRIPTION
(EGR) SYSTEM
EGR Purpose
The exhaust gas recirculation (EGR) system is used to
Linear EGR Valve

Linear EGR Control

The ECM monitors the EGR actual position and adjusts
the pintle position accordingly. The ECM uses information
from the following sensors to control the pintle position:

Of Incorrect Operation
0017

The ECM monitors the EGR valve pintle position input to
from the ECM and to detect a fault if the pintle position
ECM detects a pintle position signal voltage outside the
6E1318
acceptable for proper EGR system operation, the ECM

will set DTC P0404.
GENERAL DESCRIPTION
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM
The crankcase ventilation system is used to consume
blowby gases. This mixture is then passed through the
positive crankcase ventilation (PCV) port into the intake
manifold.
While the engine is running, exhaust gases and small
duct.
028RX003
During normal, partthrottle operation, the system is

normal combustion.
conditions:
D Rough idle.
D Stalling or slow idle speed.
D Oil leaks.
D Rough idle.
D Stalling.
D High idle speed.
6E1319
SPECIAL TOOLS
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter (Digital
Voltmeter DVM)
5-8840-2640-0
(J 39194-B)
Wrench
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH2
5-8840-0632-0
(J 35689-A)
Terminal Remover
5-8840-0607-0
(J 34142-B)
5-8840-0388-0
(J 28742-A)
Weather Pack II
Terminal Remover
5-8840-0385-0
(J 35616-A/BT-8637)
Kit
5-8840-2606-0
(J 39021-45)
Injector Test Light
5-8840-0383-0
(J 26792/BT-7220-1)
Spark Tester
5-8840-0279-0
(J 23738-A)
Vacuum Pump with
Gauge
SECTION
6F1
ENGINE
CONTENTS
Front Exhaust Pipe........................................
Front Exhaust Pipe and Associated Parts ..
Removal .....................................................
Installation ..................................................
Exhaust Silencer ...........................................
Exhaust Silencer and Associated Parts......
6F - 1
6F - 2
6F - 3
6F - 3
6F - 3
6F - 3
6F - 4
6F - 4
Service Precaution
YOU ARE
IN
REPAIRS.
Removal......................................................
Installation...................................................
Rear Exhaust pipe.........................................
Rear Exhaust pipe and Associated Parts ...
Removal......................................................
Installation...................................................
6F - 4
6F - 4
6F - 5
6F - 5
6F - 5
6F - 5
6F - 6

and systems.
6F2
General Description
150RX013

compartment may be an indication of a problem in one
of these areas. Any faulty areas should be corrected
immediately.

advisable to check the condition of the complete
exhaust system.
Catalytic Types:
the levels of nitrous oxide (NOx) as well as
hydrocarbons (HC) and carbon monoxide (Co).
Gasket
Hangers


6F3
Front Exhaust Pipe

Front Exhaust Pipe and Associated Parts
150RX012
Legend
(1) Front Exhaust Pipe Fixing Nuts
(2) O2 Sensor
(3) Front Exhaust Pipe with Three Way Catalytic
Converter
(4) Front Exhaust Pipe Mounting Rubber
(5) Front Exhaust Pipe Fixing Bolt

(6) Front Exhaust Pipe Fixing Bolt (Clamp)
(7) Front Exhaust Pipe Mounting Bracket
EndOFCallout
Removal
stands.
3. Disconnect O2 sensor harness connector and
remove front side O2 sensor (2).
4. Remove front exhaust pipe fixing bolts (6),(7).
5. Remove front exhaust pipe fixing four stud nuts from
exhaust manifold (1).
6. Remove front exhaust pipe (3).
Installation
1. Install front exhaust pipe (3) and tighten four stud
nuts (1) and two bolts (6) to the specified torque:

Torque:
Stud Nuts : 28 Nm (2.9 kgm/21 lbft)
2. Tighten front side O2 sensor and reconnect O2
6F4
Exhaust Silencer
150RW032
Legend
(1)
(2)
(3)
(4)
(5)
Exhaust Silencer
Exhaust Rear Pipe
Mounting Rubber
(6) Mounting Rubber

(7) Mounting Rubber
EndOFCallout
Removal
stands.
disconnect exhaust silencer from front exhaust pipe
(5).
5. Remove exhaust silencer mounting nuts (8) from
chassis side then remove exhaust silencer (1).
Installation
1. Install the exhaust silencer (1) chassis side and
tighten two nuts (8) to the specified torque.
2. Install the exhaust silencer and tighten two Bolts (2)
on front exhaust pipe to specified torque.
Bolts: 43 Nm (4.4 kgm/32 lbft)
3. Install the rear exhaust pipe and tighten two nuts (3)
6F5
Rear Exhaust pipe

Rear Exhaust pipe and Associated Parts
150RW032
Legend
(1)
(2)
(3)
(4)
(5)
Exhaust Silencer
Exhaust Rear Pipe
Mounting Rubber
(6) Mounting Rubber

(7) Mounting Rubber
EndOFCallout
Removal
stands.
3. Remove rear exhaust pipe fixing nuts (3), then
4. Remove mounting rubber (5), (6).
5. Remove rear exhaust pipe (4).
Installation
1. Install the mounting rubber (5), (6).
2. Install the exhaust pipe (4) and tighten two nuts (3)
6F6

150RX011
SECTION
6G1
ENGINE
CONTENTS
Oil Pump .......................................................
Oil Pump and Associated Parts ..................
6G - 1
6G - 2
6G - 3
6G - 3
Service Precaution
FOLLOW WARNINGS
COULD RESULT IN
REPAIRS.
Disassembly ............................................... 6G - 4
Inspection and Repair................................. 6G - 4
Reassembly ................................................ 6G - 4

and systems.
6G2
General Description
A gear-type oil pump is directly driven by the crankshaft
and draws oil from the oil pan, via the suction pipe. If
then passes the pressured oil through a full-flow
disposable oil filter, to the main oil gallery in the cylinder
Block. An oil pump pressure relief valve and oil filter
bypass valve are incorporated in the system.
From the main oil gallery in the cylinder block, the
cylinder head and crankshaft main bearings are
supplied with oil. The camshaft bearings and hydraulic

tappets are supplied through the main feed galleries in
the cylinder head. Vent valves allow air to be expelled
from the oil galleries in the cylinder head. The balance
shaft journals are directly fed from the crankshaft main
bearings. The connecting rod bearings are fed via
passages in the crankshaft. the oil returns to the oil pan
via passages in the cylinder block.
C06RW004
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Oil Strainer
Oil Pump
Relief Valve
Oil Filter
Safety Valve
Oil Gallery
Crankshaft Bearing
Crankshaft
EndOFCallout
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Connecting Rod
Piston
Camshaft
Camshaft Journal
HLV
Vent Valve
Oil Pan
6G3
Oil Pump
051RW004
Legend
(3) Gasket
EndOFCallout
(4) Sleeve
6G4
Disassembly
Oil Strainer
Check the oil strainer for cracking and scoring. If
cracking and scoring are found, the oil strainer must be
replaced.

2. Remove oil pan.
6. Remove oil pressure switch.
7. Remove gasket.
8. Remove sleeve.

conditions are found through inspection.
Body and Gears

the conditions below is discovered during inspection:
Indentation of gear pair use feeler strip and straight
edge.
Dimension : 0.03 mm to 0.10 mm
051RW013
Reassembly
(0.0012 to 0.0039 in)
1. Install oil pressure switch to the oil pump.

2. Install the oil pump with the sleeve and the gasket.
4. Install Oil pan support.
5. Install the oil pan.
1st step: 8 Nm (0.8 kgm/5.8 lbft)
2nd step: 30
051RW014

1st step: 130 Nm (13.2 kgm/94 lbft)
2nd step: 45
SECTION
6H1
ENGINE
CONTENTS
Accelerator Pedal Control Cable...................
Removal .....................................................
Inspection ...................................................
Installation ..................................................
Adjustment..................................................
6H - 1
6H - 2
6H - 2
6H - 2
6H - 2
6H - 2
Service Precaution
YOU ARE
IN
REPAIRS.
Accelerator Pedal ..........................................

Accelerator Pedal and Associated Parts ....
Removal......................................................
Installation...................................................
Adjustment..................................................
6H - 3
6H - 3
6H - 3
6H - 3
6H - 3

and systems.
6H2
035RX004
Removal
1. Loosen the nut(5) on the cable bracket mounted.
4. Disconnect AP control cable(1). (on AP pedal(7)
side)
5. Remove grommet(2).
2. Pull outer cable while closing fully the throttle valve.

nut.
Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
step 1.
Inspection
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
2. Install grommet(2).
3. Connect AP control cable(1). (on AP pedal(7) side)
6. Install nut(5).
Adjustment
1. Loosen adjusting nut and lock nut.
035RX014
Legend
(1) Clearance (2 3.5 mm)
(2) Lock Nut
(3) Adjusting Nut
EndOFCallout
6H3
Accelerator Pedal
Parts
Adjustment
Manual Transmission:
Rotate counterclockwise to loosen the lock nut and
screw the stopper bolt in sufficiently.
Fully depress the pedal and hold it there by hand.
Next, rotate the stopper bolt until it hits the stopper of
pedal bracket. Then, lock the stopper bolt there.
035RX002
Legend
EndOFCallout
Removal
1. Accelerator pedal control cable(1).
2. Accelerator pedal assembly(2).
Installation
1. Accelerator pedal assembly (2).
2. Accelerator pedal control cable (1).
SECTION
6J1
ENGINE
CONTENTS
Service Precaution......................................... 6J - 1
Air Cleaner Filter ........................................... 6J - 2
Removal ..................................................... 6J - 2
Service Precaution
YOU ARE
IN
REPAIRS.
Inspection ................................................... 6J - 2
Installation................................................... 6J - 2

and systems.
6J2
Air Cleaner Filter

Removal
1. Remove positive ventilation hose connector (1).
2. Remove intake air temperature sensor (2).
3. Remove air cleaner duct assembly (3).
4. Remove air cleaner element (4).
130RW002
Installation
130RX001
Inspection
Cleaning Method
1. Install air cleaner element.

2. Attach the air cleaner duct cover to the body
completely, then clamp it with the clip.
3. Install mass air temperature sensor.
connector.
SECTION
6A1
FRONTERA
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System . . . . . . . . . . . .
6A
6B
6C
6D1
6D2
6D3
Driveability and Emissions . . . . . . . . . . . . . . . .

Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System . . . . . . . . . . . .
Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E
6F
6G
6H
6J
ENGINE MECHANICAL
CONTENTS
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt (Serpentine Belt) . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring and
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A2
6A3
6A4
6A19
6A19
6A21
6A22
6A23
6A23
6A24
6A25
6A25
6A26
6A27
6A27
6A28
6A29
6A29
6A29
6A30
6A30
6A31
6A32
6A32
6A32
6A33
6A33
6A34
6A38
6A38
6A38
6A42
6A42
6A42
6A44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide and Associated Parts . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustments . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
6A44
6A44
6A45
6A45
6A46
6A47
6A47
6A48
6A52
6A52
6A52
6A54
6A54
6A54
6A57
6A57
6A57
6A58
6A58
6A58
6A59
6A59
6A59
6A60
6A63
6A64
6A66
6A66
6A66
6A67
6A69
6A73
6A73
6A73
6A74
6A2

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and Connecting Rod . . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
6A75
6A77
6A81
6A81
6A81
6A82
6A86
Service Precaution
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block and Associated Parts . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A89
6A89
6A89
6A90
6A91
6A94
6A100

systems.
6A3
General Description
Cylinder Head
The cylinder head, made of aluminum alloy casting

employs a pentroof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in Vtype design. The ports are crossflow
type.

should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
D A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
D Whenever valve train components, pistons, piston
D At the time of installation, they should be installed in
D Battery cables should be disconnected before any
D The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.

D When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pickup unit.
D The 12volt electrical system is capable of damaging
battery.
D Any time the intake air duct or air cleaner is removed,
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum diecast casting
for 75Vtype 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.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.

Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.

The crankshaft is made of Ductile castiron. Pins and
bearing.
Engine Lubrication
The oil discharged by a trochoidtype oil pump driven by
the crankshaft is fed through fullflow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.
6A4
Engine Diagnosis
Hard Starting
Condition
Headlights
go
considerably
out
Possible cause
or
dim
Correction

Overhaul or replace
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
the spark plug tester J26792 (ST125), 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
Condition
tester is properly grounded. To avoid electrical shock, do

not touch the part where insulation of the igniton coil is
broken while the engine is running.
Possible cause
Correction

engine

system)
Adjust

compression)
Electronic
module
Replace
Ignition
System
with
Correct

Correct or replace

Condition
occurs but engine does not start
start.
Possible cause
Correction
Fuel tank empty
Fill
Clean
Fuel filter clogged
Replace filter
Fuel pipe clogged
Clean or replace
Fuel pump defective
Replace
Correct or replace
Evaporative
Emission
Control
Multiport Fuel Injection System faulty
Correct or replace
Refer to Electronic Fuel Injection
section
6A5

Condition
Possible cause
Correction

Tighten to specified torque or replace

gasket
Adjust
Replace gasket
Lap valve
Valve stem seized
Valve spring weakened or broken
Replace
Overhaul engine
Piston ring seized
Overhaul engine.

ignition system.
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.

hole.
engaged until the compression gage needle reaches
the maximum level. Note the reading.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)
6A6

Condition
Possible cause
Correction
Replace
Correct or replace

or shorted
Correct or replace
Correct or replace
Replace
Replace

Correct or replace
Replace

connections
Correct or replace
Replace

connections
Correct or replace
Replace
Intake Air Temperature (IAT) sensor

circuit open or poor connections
Correct or replace
IAT sensor defective
Replace
Knock Sensor (KS) cable broken or

poor connections
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Vehicle Speed Sensor (VSS) circuit

open or shorted
Correct or replace
VSS defective
Replace
Replace

Valve circuit open or poor
connections
Correct or replace
EGR Valve faulty
Replace
Canister purge valve circuit open or

poor connections
Correct or replace
Canister purge valve defective
Replace

Replace
Refer to Hard Start

Condition
Others
Possible cause
6A7
Correction
Refer to Hard Start
Lap valve
Readjust
Replace
Fast idle solenoid defective
Replace
Positive Crankcase Ventilation valve

defective or clogged
Replace

Condition
Engine misfires periodically
Engine knocks periodically

Engine lacks power
Possible cause
Correction
Replace
Spark plugs fouling
Replace
Replace
Replace
Replace
Spark plugs fouled
Clean
Replace
Mass Air flow Sensor or Intake

Airflow Sensor circuit defective
Correct or replace

Correct or replace

Sensor or ECT Sensor circuit
defective
Correct or replace
Powertrain Control Module faulty
Replace

or IAT Sensor circuit defective
Correct or replace
Throttle Position Sensor (TPS) or

TPS circuit defective
Correct or replace
Knock Sensor (KS) or KS circuits

defective
Correct or replace
KS Module or KS Module circuits

defective
Correct or replace
6A8
Hesitation
Condition


Possible cause
Correction
(TPS)
Correct or replace
Excessive play in accelerator linkage
Adjust or replace

Correct or replace
Replace

Correct or replace
Replace

Correct or replace

poor connections
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Replace
Clean or replace
Fuel pipe clogged
Clean or replace
Fuel filter clogged
Replace
Check and replace
Replace

shorted or open
Fuel Injector defective
Replace

System circuit open or poor
connections
Correct or replace

Condition
Possible cause
Correction
Replace
Throttle Position Sensor (TPS) cable

Correct or replace
TPS defective
Replace

Correct or replace
Replace

Correct or replace
Replace
MAP Sensor cable broken or poor

connections
Correct or replace
Replace
IAT Sensor circuit open or poor

connections
Correct or replace
Replace
KS circuit open or poor connections
Correct or replace
KS defective
Replace
Correct or replace
KS Module defective
Replace
Throttle valve not fully opened
6A9
6A10
Engine Lacks Power

Condition

Ignition failure
Possible cause
Correction

working normally
Replace
Clean or replace
Fuel pipe clogged
Clean
Replace

normally
Correct or replace

due
to
clogged
Evaporative
Clean or replace
Clean
Powertrain Control Module supplied

poor voltage
Correct circuit

Correct or replace
cable
Replace
Mass Air flow Sensor not working

normally
Replace

Replace

working normally
Replace

Correct or replace
Replace
Replace
Correct or replace

Guide

range
Ignition coil defective
Replace

Condition
Engine overheating
Possible cause
6A11
Correction
Replenish
Fan clutch defective
Replace
Replace
Replace
Correct or replace
Radiator clogged
Clean or replace
Replace

low or wrong engine oil
Change or replenish
Resistance
increased

defective parts
in
exhaust

system
(TPS)
Replace with Throttle Valve ASM
Correct or replace
Replace
Engine overcooling

open at 82C (180F))
Refer to Hard Start
Others
Adjust to recommended pressures
Brake drag
Adjust
Clutch slipping
Adjust or replace

high

defective
Replace
6A12
Engine Noisy
Condition
Possible cause
Correction

crank bearings
(Faulty
and crank
y crank journals
j
bearings usually make dull noise that
becomes more evident when
accelerating)



Crank bearing seized. Replace crank

crankshaft and install the undersize
bearing
Condition
(Faulty
connecting
rods
or
y
g
engine
is accelerated))
g
Possible cause
Correction


Connecting rod bent
Correct or replace

Abnormal noise stops when the spark plug on the cylinder
with defective part is shorted out.
Condition
Possible cause
Piston and cylinder noise

makes
k
a combined
bi d mechanical
h i l
thumping
g noise which increases
when engine is suddenly accelerated
but diminishes gradually as the
engine warms up)

cylinder wear
Piston seized
Piston ring broken
Piston defective
Correction
Short out each spark plug and listen for change in engine
noise.
Condition
Piston pin noise
goes up and down)
Possible cause
Correction
connecting rod assy
6A13
Condition
Timing belt noise
Possible cause
Correction
Replace pusher or adjust the tension

pulley or replace timing belt
Replace
Replace
Timing pulley defective
Replace

timing cover
Valve clearance incorrect
Replace adjusting shim
Valve spring broken or weakened
Replace
Correct
Camshaft worn out
Replace
Crankshaft noise

engaged)
Engine knocking


range
Carbon deposits
chambers
Clean
Valve noise
Others
in
combustion
Replace fuel

system failure
Refer to Section 6E
Selection
incorrect

selection
of
transmission
gear
Engine overheating
Replace
Drive belt slipping
Replace auto tentioner or drive belt
6A14
Abnormal Combustion
Condition
Possible cause
Replace
Fuel filter clogged
Replace
Fuel pump clogged
Clean or replace
Clean or replace
Clean or replace
Replace

Mass Air flow (MAF) sensor circuit

open or defective
Correct or replace
Replace

Correct or replace
Replace

Correct or replace
Replace

Correction
(TPS)
Readjust
TPS defective
Replace
TPS connector poor connections
Reconnect
Vehicle Speed Sensor (VSS) cable

Correct or replace
VSS loosely fixed
Fix tightly
VSS in wrong contact or defective
Replace

Correct or replace
Heated Oxygen (O2) Sensor circuit

open
Correct or replace
O2 Sensor defective
Replace

defective
Correct or replace

Valve circuit open or shorted
Correct or replace
EGR Valve defective
Replace

Correct or replace
Canister Purge Valve circuit open or

shorted
Correct or replace
Canister Purge Valve defective
Replace
Replace
Positive
Crankcase
Ventilation
(PCV) valve and hose clogged
Correct or replace
Evaporator system
Refer to Section 6E

Condition
Possible cause
Carbon deposits
chamber
in
6A15
Correction
combustion
Remove carbon

and valve guide
Remove carbon

Condition
Possible cause
Oil leaking
Correction
Crankcase fixing bolts loosened
Retighten
Retighten
Replace gasket

gasket broken
Head cover fixing

gasket broken
bolts loose or
Oil cooler adapter cracked
Replace
Oil cooler center bolt loose
Retighten
Oil cooler Oring broken
Replace
Oil cooler piping loose or broken
Replace
Oil filter attaching bolt loose or rubber

gasket broken
Oil cooler broken
Replace

defective
Replace oil seal
Replace hose

clogged
Clean
Engine/Transmission coupling failed
Replace oil seal
Oil
leaking
into
combustion
chambers due to poor
oor seal in valve
system
Replace
Oil
leaking
into
combustion
chambers due to poor seal in cylinder
t
parts
Cylinders
and
excessively

pistons
Positive
Crankcase
System malfunctioning
Ventilation
Piston
ring
positioned
pistons
gaps
worn
incorrectly
Correct
Correct

pistons

clogged
Clean
6A16

Condition
Others
Possible cause
Correction

viscosity
Continuous high speed driving

and/or severe usage such as trailer
towing

Possible cause
Correction

Condition

Fuel cut function does not work


Combustion
Others

sluggish
Correct
Fuel system leakage
Correct or replace
Clutch slipping
Correct
Brake drag
Correct
Selection
incorrect
of
transmission
gear
Excessive
Exhaust
Gas
Recirculation (EGR) flow due to
trouble in EGR system

selection
Lubrication Problems
Condition
Oil contamination
Possible cause
Correction
Wrong oil in use
Replace
Correct or replace
Oil pump worn
Replace
Correct or replace

rod bearing worn
Replace
Wrong oil in use
Oil filter clogged
Replace oil filter
Replace gasket

cylinder body assembly

Clean or correct

a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the Maintenance and Lubrication section
of this manual.
The level should fall somewhere between the ADD
and the FULL marks on the oil level dipstick.
If the oil level does not reach the ADD mark on the
5. Start the engine and allow the engine to reach normal
operating temperature (About 80C).
392550 kPa (56.980.4 psi) at 3000 rpm.
7. Stop the engine.
6A17
6A18

The instrument panel CHECK ENGINE Malfunction
system when the system checks the starting of engine, or
senses malfunctions.
Condition
CHECK ENGINE MIL does not
CHECK ENGINE MIL illuminates,

and stays on
Possible cause
Correction
Bulb defective
Replace
MIL circuit open
Correct or replace

Correct or replace

cable
loosely
connected,
Correct or replace
PCM defective
Replace
Deterioration of heated
sensor internal element
oxygen
Replace
Heated
oxygen
(O2)
sensor
Reconnect properly
O2 sensor lead wire shorted
Correct
O2 sensor circuit open
Correct or replace
Deterioration of Engine Coolant

Temperature (ECT) sensor internal
element
Replace
ECT sensor connector

improper contact
Reconnect properly
terminal
ECT sensor lead wire shorted
Correct
ECT sensor circuit open
Correct or replace

shorted circuits
Correct or replace

sensor
Replace

open or shorted
Correct or replace
Correct or replace

Correct or replace

open or shorted
Correct or replace
Correct or replace
Replace PCM

(Read Only Memory)
Replace PCM
6A19
Drive Belt (Serpentine Belt)
033R100002
Legend
(1) Upper Fan Guide
(2) Cooling Fan and Fan Clutch
Removal
1. Disconnect the battery negative cable.
2. Remove the two bolts form upper side fan guide and
four clamps (4) from side of the fan guide for remove
the upper fan guide (1).
3. Remove the four nuts (3) from the fan pulley and
remove the cooling fan with the fan clutch (2).
4. Move the drive belt tensioner to loose side using
wrench then remove drive belt (5).
(3) Nut
(4) Clamp
(5) Drive Belt (Serpentine belt)
6A20
850RW001
Legend
(3) Tensioner
CAUTION:
a radius less then 30 mm.
the life.
4. Store the belt in a cool and dark place. Never
(4)
(5)
(6)
(7)
Generator
Air Conditioner Compressor
Power Steering Oil Pump
Drive (serpentine) Belt
6A21

1. Replace the drive belt, if found the worn or damaged
on the belt during inspection.
2. Inspect the belt life indicator, replace the drive belt if
the belt life indicator indicate with out limited.
F06R100010
Legend
(1) Automatic Drive Belt Tensioner
(2) Drive Belt Tension Lower Limit
(3) Tension Pulley; Drive Belt Tensioner

(4) Drive Belt Life Indicator
(5) Drive Belt Tensioner Higher Limit
6A22
Installation
1. Move the drive belt tensioner to loose side using
wrench, then install the drive belt to normal position.
850RW001
Legend
(3) Tensioner
2. Install the cooling fan with the fan clutch and tighten
the four nuts.
Torque : 10 Nm (1.0 kgm/87 lb in) for fan and
fan clutch.
Torque : 22 Nm (2.2 kgm/16 lb ft) for fan pulley
and fan bracket.
3. Install the upper fan guide.
Tighten the two bolts to specified torque.
(4)
(5)
(6)
(7)
Generator
Air Conditioner Compressor
Power Steering Oil Pump
Drive (serpentine) Belt
6A23
Cylinder Head Cover LH

Removal
2. Remove the engine cover from the dowels on the
common chamber.
5. Disconnect the heater hose bracket.

6. Remove the engine harness from the cylinder head
cover.
7. Remove the ignition coil assemblies from the left
cylinder bank.
F06RW018
3. Disconnect the wires and the bonding cables.

D Vacuum Switching Valve (VSV) for Induction Air
Control Valve (IACV) actuator
D Ignition coils for left cylinder bank
D Fuel injectors for left cylinder bank
D Bonding cable
D Other parts as required
4. Disconnect the following vacuum hoses.
D PCV
060RW018
Legend
(2) Bolts
8. Remove the cylinder head cover assembly.
6A24

2. Install the ignition coil assemblies and tighten the
Installation
1. Install the cylinder head cover.
D Clean the sealing surface of the cylinder head and
the cylinder head cover to remove oil and sealing
3. Install the heater hose bracket and tighten the bolts.
D Apply a 2-3 mm bead of sealant (TB-1207B or

equivalent) to the 8 arched areas of the camshaft
bracket (front and rear).
4. Install the engine harness and tighten the fixing bolts

of the retaining clip and bracket to the specified
torque.

014RW144
D Tighten the bolts to the specified torque, using the

tightening sequence shown in the illustration.
010RW008


5. Connect the vacuum hoses.
6. Connect the wires and bonding cables.
7. Connect the MAF sensor connector, the IAT sensor
connector and the PCV hose.
8. Install the engine cover by aligning the dowels.
6A25
Cylinder Head Cover RH

4. Remove the engine harness from the cylinder head
cover.
Removal
2. Remove the engine cover from the dowels on the
common chamber.
060RW001
F06RW018
3. Disconnect the wires and bonding cables.

D Exhaust Gas Recirculation (EGR) valve
D Fuel injectors for right cylinder bank
D Ignition coils for right cylinder bank
D Bonding cable
Legend
(2) Bolts
5. Remove the ignition coil assemblies from the right
cylinder bank.
6. Remove the cylinder head cover assembly.
6A26

2. Install the ignition coil assemblies and tighten the
Installation
1. Install the cylinder head cover.
D Clean the sealing surface of the cylinder head and
the cylinder head cover to remove the oil and
sealing materials completely.
D Apply a 2-3 mm bead of sealant (TB-1207B or
equivalent) to the 8 arched areas of the camshaft
bracket.
014RW143
D Tighten the bolts to the specified torque, using the

tightening sequence shown in the illustration.
010RW007

3. Install the engine harness and tighten the fixing bolts
of the retaining clip and the brackets to the specified
torque.
4. Connect the wires and the bonding cables.
5. Install the engine cover by alining the dowels.
6A27
Common Chamber
Removal
2. Drain the engine coolant from the tap at the bottom of
radiator (Approximately 2 liters).
4. Remove the air cleaner duct assembly (3) and the air
cleaner element (4).
8. Disconnect the following vacuum hoses.

D Brake booster
D Left cylinder bank PCV
D Fuel pressure regulator
9. Remove the ventilation hose from the throttle valve
and the intake duct and then remove the water hose.
10. Loosen the clamps securing the 2 rubber hoses to the
fuel pipes (rear side of the transmission).
WARNING: SPILLED GASOLINE IS AN EXTREMELY
DANGEROUS FIRE HAZARD.
D Plug the rubber hoses leading from the fuel
tank to prevent fuel leakage.
D Drain residual from the fuel pipes into a
suitable container.
130RW001
Legend
11. Remove the 4 throttle body fixing bolts.

12. Remove the EGR valve assembly fixing nut and bolt
on common chamber together with the pipe fixing nut.
13. Remove the fuel rail with fuel injectors.
14. Loosen the installation bolt to remove the fuel hose
bracket from the lower rear of the left cylinder head.
15. Remove the 2 bolts from common chamber rear side
to remove the fuel hose bracket.
16. Remove the common chamber 4 nuts and 4 bolts
then remove the common chamber.

and positive crankcase ventilation (PCV) hose before the
air cleaner duct assembly is removed.
5. Disconnect the accelerator pedal cable and the auto
cruise cable from the throttle body and cable bracket.
6. Disconnect the vacuum booster hose from the
common chamber.
7. Disconnect the wires and bonding cables.
D Manifold absolute pressure (MAP) sensor
D Vacuum switching valve (VSV) for induction air
control valve (IACV) actuator
D Fuel injectors
D Exhaust gas recirculation (EGR) valve
025RW001
Legend
(1) Common Chamber
(3) Bolt
6A28
Installation
1. Install the common chamber and tighten the nuts and
Torque :
Bolt : 25 Nm (2.5 kgm/18 lb ft)
Nut : 25 Nm (2.5 kgm/18 lb ft)
2. Install the fuel hose bracket and tighten the bolts to
3. Install the fuel rail with fuel injectors.
4. Install the EGR valve assembly and tighten the nuts
and bolts to the specified torque.
5. Tighten the EGR valve pipe nut.
6. Install the throttle body and tighten the bolts to the
specified torque.
7. Install the ventilating hose to the throttle valve and
intake duct.
8. Connect the vacuum hoses.
(disconnected during the removal procedure).
9. Connect the each connector without fail.
10. Connect the vacuum booster hose.
11. Connect the wires and bonding cables.
(disconnected during the removal procedure).
12. Connect the accelerator pedal cable.
Accelerator pedal cable adjustment
1. Loosen the adjusting nut and screw cap.
2. Pull out the outer cable while fully closing the
throttle valve.
3. Tighten the adjusting nut and lock nut temporarily.
4. Loosen the adjusting nut by 3 turns and tighten
the lock nut.
Then manually operating the throttle valve.
Make sure that the valve lever returns up to the
stopper screw.
step 1.
035RW004
Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut
13. Install the air cleaner element and air cleaner duct
assembly.
Clip the hose at both ends.
6A29
Exhaust Manifold LH
11. Remove the 8 exhaust manifold fixing nuts and the
exhaust manifold from the engine.
Removal
2. Raise the vehicle and support it with chassis stands.
3. Remove the left side wheel and tire assembly.
4. Remove the mud fender skirt.
5. Disconnect the O2 sensor connector.
6. Remove the 3 stud nuts from the exhaust pipe flange.
7. Remove the 2 bolts from the rear end of the front
exhaust pipe with catalytic converter.
8. Remove the front exhaust pipe with catalytic
converter rubber support.
9. Move the front exhaust pipe with catalytic converter to
the rear.
027RY00006
Legend
(1) Exhaust Manifold Heat Protector
(2) Exhaust Manifold
Installation
1. Install the exhaust manifold and exhaust manifold
gasket.
D Do not reuse the old exhaust manifold nuts.
Use new nuts and tighten to the specified torque.
150RY00039
Legend
(2) Bolt
(3) Rubber Support
(4) Stud Nut
(5) O2 Sensor
10. Remove the exhaust manifold heat protector.
2. Install the exhaust manifold heat protector.

3. Fix the front exhaust pipe with catalytic converter to
the exhaust manifold flange stud bolts and
hand-tighten the nuts.
4. Hang the front exhaust pipe with catalytic converter
on the chassis (pipe to rubber support/rubber support
to chassis).
5. Hand-tighten the 2 bolts at the rear end of the front
exhaust pipe.
6. Tighten the exhaust pipe flange stud nuts.
7. Tighten the 2 bolts at the rear end of the front exhaust
pipe.
8. Connect the O2 sensor connector.
9. Install the mud fender skirt.
10. Install the left side wheel and tire assembly.
6A30
Exhaust Manifold RH
Removal
2. Raise the vehicle and support it with chassis stands.
3. Remove the right side wheel and tire assembly.
4. Remove the mud fender skirt.
5. Disconnect the O2 sensor connector (5).
6. Remove the 3 stud nuts (6) from the exhaust pipe
flange.
7. Remove the 2 bolts (4) from the rear end of the left
side front exhaust pipe with catalytic converter.
8. Remove the 4 nuts (1) from the front end of the
silencer.
9. Remove the 2 nuts (3) from the rear end of the
silencer.
10. Remove the rubber support (8) from the right-front
exhaust pipe.
11. Move the front exhaust pipe (7), the center exhaust
pipe (9) and the silencer assembly (2) to the rear.
150RY00040

12. Remove the exhaust gas recirculation (EGR) pipe
fixing bolts from the exhaust manifold.
13. Remove the EGR pipe bracket and bolt from the rear
side of the cylinder head.
14. Loosen the nut between the EGR pipe and the EGR
valve.
6A31
Installation
1. Install the exhaust manifold and exhaust manifold
gasket.
D Do not reuse the old exhaust manifold nuts.
Use new nuts and tighten to the specified torque.
2. Install the exhaust manifold heat protector.
3. Install the EGR pipe between the exhaust manifold
and the EGR valve.
Tighten the fixing nuts and bolts to the specified
torque.
D Exhaust manifold (2)
D Rear cylinder head (1)
D EGR pipe and EGR valve.
4. Fix the front exhaust pipe with catalytic converter to
the exhaust manifold flange stud bolts and
hand-tighten the nuts.
5. Hang the front exhaust pipe with catalytic converter
from the chassis (pipe to rubber support/rubber
support to chassis).
6. Fix the front end of silencer and hand-tighten the 4
nuts.
7. Fix the end of the left side front exhaust pipe and
hand-tighten the bolts.
8. Fix the rear end of the silencer to the rear exhaust
pipe bolts and hand tighten the nuts.
9. Tighten the exhaust pipe flange stud nuts.
F06RY00036
Legend
(1) Pipe Fixing Nut
(2) Bracket and Bolt
(3) Pipe Fixing Bolt
15. Remove the exhaust manifold heat protector.
16. Remove the 8 exhaust manifold fixing nuts and the
exhaust manifold from the engine.

10. Tighten the front end silencer nuts.
11. Tighten the fixing bolts at the end of the left-side front
exhaust pipe.
12. Tighten the nuts at the rear of the silencer.
6A32
Crankshaft Pulley
Removal
3. Remove the serpentine belt.
D Refer to the removal procedure for Drive Belt
(Serpentine Belt) in this manual.
4. Remove the 4 cooling fan fixing nuts and the cooling
fan with clutch assembly.
5. Remove the fan pulley bracket (2 nuts and 1 bolt) and
the fan pulley bracket.
6. Use the crankshaft holder (J-8614-01), to hold the
crankshaft pulley.
7. Remove the crankshaft center bolt and the pulley.
Installation
1. Use the crankshaft holder (J-8614-01), to hold the
crankshaft pulley.
2. Tighten center bolt to the specified torque.
3. Install the fan pulley bracket and tighten the nuts and
4. Install the fan with clutch assembly to the fan pulley
bracket.
5. Use a wrench to force the auto-tensioner pulley
toward the bottom of the engine.
Place the serpentine belt over the pulley.
6. Install the upper fan guide.
6A33
Timing Belt
Removal
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. The rod must always be facing
upward.
850RW001
014R100020
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when
compressing the pusher rod.
5. Remove cooling fan assembly four nuts, then the

cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
5884001330 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
CAUTION:
a radius less than 30 mm.
the life.
4. Store timing belt in a cool and dark place. Never
expose the belt to direct sunlight or heat.
6A34
Installation
014R100015
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
6A35

a. Align the mark (notch) of crankshaft timing pulley
(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW00004
Legend
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
b. Align the alignment mark on the RH bank camshaft
drive gear pulley (2) to the alignment mark of the
cylinder head cover RH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary the rotate the camshaft pulley until
the camshaft lobes are in the position as shown in
the diagram on page 6A34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the
camshaft pulley to achieve alignment of all marks.
c. 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.
d. Align the alignment mark on the LH bank camshaft

drive gear pulley (2) to the alignment mark of the
cylinder head cover LH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary the rotate the camshaft pulley until
the camshaft lobes are in the position as shown in
the diagram on page 6A34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the
camshaft pulley to achieve alignment of all marks.
e. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent clip.
6A36
NOTE: It is recommended for easy installation that the

belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
014R100020
014RW00005
Legend
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
f. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley and
the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when
compressing the pusher rod.
After release the push rod from the locking pin, the
rod projection is approximate 5 mm.

a. Install the pusher while pushing the tension pulley
to the belt.
b. Pull out pin from the pusher.
NOTE: When reusing the pusher, compress the pusher
rod with approximately 980 N (220 lb/100 kg) and insert
a pin (1.4 mm piano wire).
014R100032
Legend
(1) Tensioner Pulley
(2) Crankshaft Pulley Rotation Direction
(4) Pusher Assembly
c. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley by six turns and check
for timing mark alignment.

3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
6A37
4. Install crankshaft pulley using 5884001330, hold

the crankshaft pulley and tighten center bolt to the
specified torque.
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.

6. Install power steering pump assembly and tighten to
Torque :
M8 bolt : 22 Nm (2.2 kgm/16 lb ft)
M10 bolt : 46 Nm (4.7 kgm/34 lb ft)
and fan bracket.
clutch assembly.
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
850RW001
020RW003
Legend
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
Legend
(3) Auto Tensioner
(4) Generator
(7) Idle Pulley
(8) Drive Belt
6A38
Camshaft
Removal
this manual.
manual.
brackets.
014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
Installation
014RW027

a. Use the 5884024430 gear spring lever to turn
sub gear to right direction until it aligns with the M5
bolt hole between camshaft driven gear and sub
gear.
b. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.
7. Remove camshaft assembly.

8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
014RW041

3. Align the timing mark on the retainer and dowel pin of
the camshaft drive gear.
torque.
a. Apply engine oil to camshaft journal and bearing
b. Align timing mark on intake camshaft (one dot for
right bank, two dot for left bank) and exhaust
dot).
6A39
Legend
(1) Discrimination Mark for Right Bank Intake
Camshaft Gear
(2) Alignment Mark for Right Bank (One Dot)
(3) Camshaft Timing Gear for Right Bank Intake
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
014R100025
6A40
014R100027
Legend
LE : Left Bank Exhaust
RE : Right Bank Exhaust
(2) Alignment Mark
One Dot for Right Bank
Two Dots for Left Bank
(3) Camshaft Timing Gear for Exhaust
014R100024
Legend
(1) Timing Mark on the Camshaft Drive Gear for
Left Bank Intake Camshaft
Left Bank Exhaust Camshaft
(3) Dowel Pin
c. Tighten the twenty bolts in numerical order on one
bank as shown in the illustration.
014R100023
Legend
Right Bank Exhaust Camshaft
Right Bank Intake Camshaft
(3) Dowel Pin
014RW031

5. Tighten the bolt for camshaft drive gear assembly
pulley fixing to the specified torque.
HEAD COVER RH in this manual.
HEAD COVER LH in this manual.
D Refer to installation procedure for TIMING BELT in
this manual.
D Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.
6A41
6A42
Cylinder Head
Removal
this manual.
manual.
9. Remove common chamber.
D Refer to removal procedure for Common Chamber
in this manual.
1. Loosen eights bolts for tight cylinder head.
NOTE: There is discrimination mark R for right bank

and L for left bank on the cylinder head gasket as shown
in the illustration.
Do not reuse cylinder head gasket.
011RW005
b. Align dowel pin hole to dowel pin on the cylinder

block.
c. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
d. Using 9851142090 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 Nm (3.0 kgm/22 lb ft)
Final : 64 Nm (6.5 kgm/47 lb ft)
014RW028
Legend
(1) Cylinder Head
(3) Camshaft
Installation
1. Install cylinder head assembly to cylinder block.
a. Put cylinder head gasket on the cylinder block.
014RW029

2. Install common chamber.
D Refer to installation procedure for Common
Chamber in this manual.
manual.
6A43
6A44
Valve Stem Oil Controller , Valve Spring and Valve Guide

Removal
Installation

D Drain engine coolant.
this manual.
4. Remove camshaft.
D Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5884024460 valve
spring compressor and 5884025470 valve spring
compressor adapter then remove upper valve spring
seat and lower seat.
014RW042
7. Remove oil controller using 5884006230 oil

controller remover, remove each valve stem oil
controller.
8. Remove valve guide using 5884025490 valve
guide replacer.
1. Install valve guide using 5884024420 valve guide

installer.
2. Install oil controller using 5884006240 oil
controller installer.
spring seat, using 5884024460 valve spring
manual.
this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.
6A45
Piston, Piston Ring and Connecting Rod

Removal
F06RW011
Legend
(1) Cylinder Head
(3) Oil Pipe

this manual.
(4) Oil Strainer

(5) Oil Gallery
(6) Piston with Connecting Rod Assembly
2. Remove crankcase with Oil Pan.

6A46

015RW003
050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
4. Remove three fixing bolts, oil pipe with O-ring.
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.
Legend
(2) Piston Grade
(3) Connecting Rod Front Mark
2. Install oil gallery and tighten the bolts in two steps, in
the order shown in illustration.
Torque :
1st step : 29 Nm (3.0 kgm/22 lb ft)
2nd step : 5565
Installation
1. Install piston with connecting rod assembly.
D 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.
D The bearing cap number must be the same as
connecting rod number.
each nut.
051RS009

NOTE: Do not apply engine oil to the bearing back faces
and connecting rod bearing fitting surfaces.
3. Install oil pipe with O-ring.

4. Install oil strainer assembly with O-ring.
5. Install crankcase with Oil Pan.
this manual.
6A47
Crankshaft and Main Bearings

Removal
F06RW010
Legend
(1) Engine Assembly
(4) Timing Belt
(6) Oil Pipe
(7) Oil Strainer

D Refer to removal procedure for Engine Assembly in
this manual.
manual.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Oil Pump Assembly

Cylinder Body Side Bolt
Oil Gallery
Flywheel
Rear Oil Seal Retainer
Connecting Rod Cap
Crankshaft Main Bearing Cap
Crankshaft and Main Bearing
3. Remove oil pan and crankcase.

4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
6A48

D Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
9. Remove flywheel.
10. Remove rear oil seal retainer.
D Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.
D Install main bearing in the cylinder block and main
bearing cap respectively.
Apply new engine oil to upper and lower main
bearings.
NOTE:
D
D
D
D
D
D
Do not apply engine oil to the bearing back faces.

Make sure that main bearings are in correct position.
Install crankshaft with care.
Install thrust washer on No.3 journal.
Oil grooves in thrust washer must face the
crankshaft.
015R100033
2. Install crankshaft main bearing caps.

each bearing cap fixing bolt.
NOTE:
D Do not apply engine oil to the bearing back faces.
D Install bearing caps in the order of numbers, starting
with cylinder block front side.
D Tighten main bearing fixing bolts to the specified
torque.
D After tightening the bolts, make sure that the
3. Install connecting rod caps.
D The cap number must be same as connecting rod
number.
each nut.
surface.
015RS012

hardens.
6A49

015RS018
015RW002
For manual transmission.
Legend
015RV015
For automatic transmission.
015RW001
D Remove oil on crankshaft and flywheel fitting
surface.
NOTE:
D Do not reuse the bolts.
D Do not apply oil or thread lock to the bolts.
6. Install oil gallery.

D Clean contact surface of oil gallery and main
bearing cap.
Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown in
illustration.
Torque :
2nd step : 5565
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
6A50
NOTE: Do not apply the oil to the bolts.
051RW001
012RS007
8. Install oil pump assembly.

D Remove oil on cylinder block and oil pump mounting
surface.
D Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.
hardens.
D Install oil pump in the cylinder block and tighten
9. Install oil strainer with O-ring, tighten to the specified

torque.
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
the surface.
sealant (TB1207C or equivalent) to the crankcase
hardens.
051RW002
Legend
013RW010
013RW004
12. Install oil pan

D Remove oil on oil pan mounting surface and dry the
surface.
sealant (TB1207C or equivalent) to the oil pan
D The oil pan must be installed within 5 minutes after
sealant application to prevent premature hardening
of sealant.
013RW003
6A51
013RW002

manual.
14. Install engine assembly.
D Refer to installation procedure for Engine in this
manual.
6A52
Rear Oil Seal

Removal
1. Remove transmission assembly.
D Refer to removal procedure for Transmission
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
5884022860.
015RS018
For manual transmission.
015RS017
D Remove oil on the crankshaft and flywheel
mounting surface.
015RV015
For automatic transmission.

3. Install transmission.
D See Transmission section in this manual.
transmission.
Otherwise, the transmission may be damaged.
012RS009
6A53
6A54
Engine Assembly
Removal
F06RY00016

2. Remove battery.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original
position exactly.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Disconnect air duct with air cleaner cover.
9. Disconnect canister vacuum hose.
10. Disconnect vacuum booster hose.
11. Disconnect three engine harness connectors.
12. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front
axle and remove transmission harness bracket from
engine left side.
13. Disconnect ground cable between engine and frame.
14. Disconnect bonding cable connector on the back of
right dash panel.
15. Disconnect bonding cable terminal on the left bank.
16. Disconnect starter harness connector from starter.
17. Disconnect generator harness connector from
generator.
18. Disconnect coolant reserve tank hose from radiator.
19. Remove radiator upper and lower hoses.
20. Remove upper fan shroud.
23. Remove power steering pump fixing bolts, then

power steering pump. Place the power steering pump
along with piping on the body side.
24. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
on the body side.
25. Remove O2 sensor harness connectors from exhaust
front pipe.
26. Remove three exhaust pipe fixing nuts from each
bank.
27. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side of
vehicle.
28. Remove flywheel dust covers.
29. Disconnect two heater hoses from engine.
30. Disconnect fuel hoses from right side of transmission.
CAUTION: Plug fuel pipes on engine side and fuel
hoses from fuel tank.
31. Remove transmission assembly. Refer to
Transmission section in this manual.
32. Support the engine by engine hoist.
33. Remove two left side engine mount fixing bolts from
34. Remove two right side engine mount fixing bolts from
Installation
transmission.
6A55
If the engine is assembled in the condition that the

dowels have not been mounted in the specified
positions, the transmission may be damaged the
transmission.
150RX015
Legend
(2) O2 Sensor
012RS009
1. Install engine assembly. Tighten engine mount fixing

bolts to frame to the specified torque.
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.
Torque:
Nuts: 43 Nm (4.4 kgm/32 lb ft)
Stud nuts: 67 Nm (6.8 kgm/49 lb ft)
150RX014
Legend
(1) O2 Sensor
and fan bracket.
clutch assembly.
6A56
9. Install air conditioner compressor to engine and

Torque :
M8 bolts : 22 Nm (2.2 kgm/16 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22Nm (2.2 kgm/16 lb ft)
17. Reconnect bonding cable terminal on left bank

18. Reconnect bonding cable terminal on the back of right
dash panel.
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
25. Reconnect air duct.
26. Reconnect accelerator cable and automatic cruise
control cable to throttle valve on common chamber.
850RW001
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
035RW007
Legend
(2) Throttle Lever
(3) Idle Air Control Valve
(4) Throttle Position Sensor
27. Install engine hood to the original position.
D Refer to installation procedure for Body section in
this manual.
6A57
Cylinder Head
011RW008
Legend
(1) Spark Plug
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(7) Camshaft Exhaust
Disassembly
NOTE:
D During disassembly, be sure that the valve train
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Camshaft Intake
Retainer Assembly
Tappet with Shim
Split Collar
Valve
D Before removing the cylinder head from the engine

1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
6A58

bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove the cylinder head assembly.
4. Remove tappet with shim (11).
5. Use the 5884024460 valve spring compressor
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
CAUTION:
D Do not attempt to weld the cylinder head. Replace
it.
D Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are out of flat by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
014RW042
6. Remove spark plug (1).

CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
011RW019
5. Water jacket sealing plugs seating surfaces.

1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blowby. If the gasket has failed,
determine the cause.
Insufficient torque on head bolts.
Improper installation
Loose or warped cylinder head
Missing dowel pins
Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
Reassembly
1. Reassemble the valve, valve seat, valve spring and
split collars.
Refer to the reassembly procedure for valve spring,
oil controller, valve, valve guide in this manual.
2. Install the cylinder head assembly to cylinder block.
Refer to the installation procedure for cylinder head
in this manual.
3. Install the camshaft assembly.
Refer to the installation procedure for camshaft in this
manual.
4. Install the spark plug and tighten all the spark plugs to
specified torque.
6A59
Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend
(1) Camshaft Bracket Fixing Bolts
(2) Camshaft Assembly Inlet
(4) Shim
(5) Tappet
(6) Split Collar
Disassembly
1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).
(7)
(8)
(9)
(10)
(11)
(12)
Spring Upper Seat

Valve Spring
Oil Controller
Spring Lower Seat
Valve Guide
Valve
3. Remove camshaft assembly (Exhaust side).

4. Remove shim (4) and tappet (5).
6A60

5884025470 valve spring compressor adapter to
remove split collar.
2. Measure the valve spring squareness with a steel

square and replace the valve springs if the measured
value exceeds the specified limit.
Limit : 2 mm (0.0787 in)
014RW042
6. Remove valve spring.

7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5884024420
valve guide replacer.

Valve Spring
014RS005
3. Using a spring tester to compress the springs to the

installed height, measure the compressed spring
tension, and replace the springs if the measured
tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
CAUTION: Visually inspect the valve springs and

replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Limit : 43.6 mm (1.7165 in)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
scratchs or abnormal wear. If these conditions are
replaced as a set.
014RS004
6A61
1. Measure the valve stem diameter with a micrometer.

If the valve stem diameter is less than the specified
as a set.
Diameter of Valve Stem
Intake
(0.2353 in0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
(0.2343 in0.2350 in)
Limit : 5.90 mm (0.2323 in)
014RS008
2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5884024420, drive in
a new valve guide from the camshaft side, and check
the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RS007
2. Measure the inside diameter of the valve guide with a

micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
(0.0009 in0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
(0.0012 in0.0025 in)
Limit : 0.20 mm (0.00787 in)
Valve Guide Replacement

1. Using Valve guide replacer: 5884024420, drive
out the valve guide from the combustion chamber
side.
014RW046
3. Check the clearance. If the clearance is less than the

specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.
Valve Seat
1. Measure the protrusion of the valve stem when a new
valve is installed in the cylinder head. If the protrusion
of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.
Protrusion of valve stem
Intake
6A62
Limit: 39.47 mm (1.5539 in)

Exhaust
Limit: 39.45 mm (1.5531 in)
2. If the measured value exceeds the limit, replace

valve, valve guide and valve seat as a set.
Valve contact surface angle: 45
014RS012
014RW047
2. Measure the valve seat contact width. Make the

necessary corrections if the seat contact surface is
damaged or rough or if the contact width wear
exceeds the limit.
Valve seat contact width
Limit: 1.7 mm (0.0669 in)

1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and other
rough areas. This will bring the contact width back to
the standard value. Remove only the scratches and
rough areas. Do not cut away too much. Take care not
to cut away unblemished areas of the valve seat
surface.
Valve seat angle degree: 90
014RS011
Contact Surface Angle on Valve Seat on

Valve
1. Measure contact surface angle on valve seat.
014RW059
3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.

6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
6A63
7. After insertion, use a seat grinder to grind finish the

seating face. Carefully note the seating angle, the
contact width, and the depression.
Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer 5884024420, drive in a new valve guide
from the camshaft side.
Using oil controller replacer 5884006230, drive in
a new oil controller.
014RS014

2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
014RW058

spring to the lower spring seat. The painted area of
the valve spring should be facing downward.
014RS015
4. Carefully clean the valve seat pressfit section on the

cylinder head side.
horizontally.
Standard fitting interference: 0.14 mm0.09 mm
(0.0055 in0.0035 in)
014RS020
6A64

spring seat, using the 5884024460 valve spring
014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
014RW042

manual.
Valve Clearance Adjustments

NOTE: To adjust valve clearance, apply engine oil to the
cam as well as to the adjusting shim (2) with the cylinder
head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite to maximum cam lift (1) as shown in illistration
below.
Valve Clearance Standard Value (cold)

Intake: 0.28 mm (0.0110 in)
Exhaust: 0.3 mm (0.0118 in)
Selection of Adjusting Shim

Thickness of removed shim.
+
Valve clearance measurement.
Standard valve clearance.

Thickness of shim to be selected.
Based on the above formula, the best suited shim should

be selected from 41 sorts of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.
6A65
Replacement of Shim
Let the cam push down the edge of tappet by using
5884024440 valve clearance adjusting tool and push
out the shim with a flat blade screw driver as shown in
illustrations below.
014RW084
014RW082
014RW083
6A66
Camshaft
014R100028
Legend
(5) Pulley Fixing Bolt
(6)
(7)
(8)
(9)
(10)
(11)
Camshaft Drive Gear Pulley

Retainer
Camshaft Drive Gear
Oil Seal
Oring
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley
using the 5884024470 universal holder.
014RW060

brackets (2).
6A67

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)
014RW027

4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.
5. Use the snap ring pliers to remove the snap ring(1).
6. Remove the wave washer(2), sub gear(3) and spring
camshaft gear(4) from the camshaft assembly(5).
014RW043
2. Use a micrometer to measure the diameter and the

uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
(1.0225 in1.0233 in)
Limit : 25.8 mm (1.0157 in)
014R100018
Legend
(1) Snap Ring
(2) Wave Washer
(3) Sub Gear
(4) Spring; Camshaft Gear
(5) Camshaft Assembly
014RS023
6A68
3. Place the camshaft on Vblocks.

Slowly rotate the camshaft and measure the runout
with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Runout
Limit : 0.1 mm (0.0039 in)
2. Subtract the camshaft outside diameter from the

camshaft bracket housing inside diameter.
Oil Clearance
(0.0011 in0.0031 in)
Limit : 0.11 mm (0.0043 in)
014RW037
014RW044
4. Measure the camshaft journal oil clearance.

1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
5. Replace the cylinder head and/or camshaft if the

measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
014RW031
014RW031

3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
Camshaft thrust Clearance
(0.0012 in.0.0031 in.)
6A69
3. Align the dowel pin on the sub gear to the clearance of

the spring ; camshaft gear made in step 2 and install
the sub gear (3).
4. Install the wave washer (2). Use snap ring pliers to
install the snap ring (1).
Limit : 0.12 mm (0.0047 mm)
014R100018
014RW035
Reassembly

a. Use 5884024430 gear spring lever to pre-load
the sub gear. Turn the sub gear in a clockwise
direction until the M5 bolt hole aligns with the hole
in the camshaft driven gear.
b. Install the M5 bolt and tighten to a suitable torque to
prevent the sub gear from moving.

2. Install the spring ; camshaft gear(1) into the camshaft
assembly.
Ensure the clearance is between the right side of the
spring; camshaft gear (1) and the dowel pin (2).
014RW041
014R100017
6. Align the timing mark on the retainer and dowel pin of

the camshaft drive gear.
torque.
a. Apply engine oil to camshaft journal and bearing
6A70
b. Align timing mark on intake camshaft (one dot for

dot).
014R100026
014R100016
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
Legend
(1) Alignment Mark on the Camshaft Gear
(2) Alignment Mark on the Camshaft Drive Gear
014R100027
014R100025
Legend
(1) Discrimination Mark for Right Bank Intake
Camshaft Gear
(2) Alignment Mark for Right Bank (One Dot)
(3) Camshaft Timing Gear for Right Bank Intake
Legend
LE : Left Bank Exhaust
RE : Right Bank Exhaust
(2) Alignment Mark
One Dot for Right Bank
Two Dots for Left Bank
(3) Camshaft Timing Gear for Exhaust
6A71
c. Tighten twenty bolts in numerical order on one side

bank as shown in the illustration.
014R100023
Legend
Right Bank Exhaust Camshaft
Right Bank Intake Camshaft
(3) Dowel Pin
014RW031
8. If the oil seal requires replacement, use the

5884024450 to install the oil seal.
014RW034
014R100024
Legend
Left Bank Intake Camshaft
Left Bank Exhaust Camshaft
(3) Dowel Pin
6A72
9. If the camshaft end plug requires replacement, use

the 5884024450 to install the camshaft end plug.
014R100031
10. Tighten bolt for camshaft drive gear pulley to the

specified torque using the 5884024470 universal
holder.
014RW060
6A73
Crankshaft
013RW009
Legend
(7) Oil Gallery
Disassembly
Cylinder Head in this manual.
2. Remove crankcase with oil pan (2). Refer to Oil Pan
(8)
(9)
(10)
(11)
(12)
(13)
(14)

Flywheel
Rear Oil Seal Retainer and Oil Seal
Main Bearing Cap
Crankshaft
Main Bearing Cap Fixing Bolts
Oil Gallery Fixing Bolts

6. Remove crankcase side bolts (6).
6A74

Refer to Piston, Piston Ring and Connecting Rod in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).

1. Crankshaft
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
(0.0024 in0.0094 in)
015RS004

Limit : 0.30 mm (0.0118 in)

The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
position.
NOTE: Do not set the plastigage on the oil hole.
015RS003

clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
015RS005
9. Install main bearing caps, oil gallery and crank case

bolts in the order shown, and tighten each bolt to the
specified torque.

bolts.
Main bearing cap bolts.
6A75

(0.0007 in0.0017 in)
Limit : 0.08 mm (0.0031 in)
Oil gallery fixing bolts.

Torque:
1st step: 29 Nm (3.0 kgm/22 lb ft)
2nd step 55 65
Crank case side bolts
015RS008

crankshaft.
Crankshaft Inspection
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
the oil ports for obstructions.
015RS006
10. Remove the main bearing caps in the sequence


1. Carefully set the crankshaft on the Vblocks. Slowly
rotate the crankshaft and measure the runout. If the
Runout : 0.04 mm (0.0016 in)
015RS004

015RS007
6A76

journal and crank pin. If the crankshaft wear exceeds
the specified limit, crankshaft must be replaced.
(2.5165 in2.5170 in)
2. Diameter size mark for the crankshaft.

The diameter size marks are stamped on the No.1
crankshaft balancer as shown in the illustration.

(2.1229 in.2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015R100034
015RS009

install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark for the cylinder block.
Legend
(1) Crankshaft No.1 Balancer
(2) Crankshaft Journal Grade
The grade number stamped 1,2,3,4 journal
from left to right
correctly.
015RS012
001R100001
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

Main
Bearing
Grade Mark
On Cylinder
Block
Main Bearing Bore

Diameter
mm (in)
68.994-69.000
(2.7163-2.7165)
68.987-68.993
(2.7160-2.7163)
68.980-68.986
(2.7157-2.7160)
Crank Shaft Main

Journal Diameter
mm (in)
Crankshaft
Bearing
Grade Mark
On
Crankshaft
Crankshaft
Bearing Size
Mark (collor
indicator)
63.918-63.925
(2.5165-2.5167)
Blue
63.926-63.933
(2.5168-2.5170)
63.918-63.925
(2.5165-2.5167)
63.926-63.933
(2.5168-2.5170)
63.918-63.925
(2.5165-2.5167)
63.926-63.933
(2.5168-2.5170)
6A77
Oil Clearance
(Reference)
mm (in)
Brown
0.0190.043
(0.00070.0017)
Green
Yellow
Reassembly
1. Crankshaft

D Assemble the thrust washer to the No.3 bearing

bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015R100033
2. Rear oil seal

D Remove the oil from the cylinder block and the
retainer mounting surface.
015RS012
D Apply sealant (TB1207B or equivalent) to the

retainer mounting surface, following the pattern
The retainer must be installed within 5 minutes
after sealant application befor the sealant hardens.
6A78
015RS017
015RW002
3. Flywheel
Legend
D Apply engine oil to the oil seal lip.

mounting faces.
D Align the cylinder block dowel pin holes with the rear
retainer dowel pins.

install the washer.
D Tighten the rear retainer fixing bolts. New bolts

should be used when installing rear retainer.
4. Hold the crankshaft to prevent from rotating then

install the bolts in the order shown to the specified
torque.
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 5884022860 oil seal
installer.
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS018
For manual transmission

015RW001
6A79
D Apply engine oil to the threads and seating faces of

the nuts.
D Tighten the nuts.
After tightening the cap nuts, check to see that the
015RV015
For automatic transmission

015RS020
5. Install oil gallery (7) and tighten the bolts in 2 steps, in

the order shown.
1st step: 29 Nm (3.0 kgm/22 lb ft)
2nd step: 55 65
015RX003
Legend
each cylinder with the piston ring compressor. The
front marks must be facing the front of the engine.
D Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.
051RS009
6. Cylinder block side bolts

D Tighten all the bolts to the specified torque in the
order shown.
6A80

bolts.

013RW010
012RS001
7. Install oil pump assembly (5), refer to Oil pump in

this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
1207C or its equivalent) to the contact surfaces of
the oil pan. There must be no gaps in the bead.
3. The crankcase assembly must be installed within
5 minutes after sealant application to prevent
premature hardening of the sealant.
Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion
head in this manual.
6A81

015RW019
Legend
(6) Oil Gallery
Disassembly
Cylinder Head Removal in this manual.
3. Remove crankcase with oil pan (3). Refer toOil Pan
(7)
(8)
(9)
(10)
(11)
(12)

Piston Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Cap

lower bearing (12).
6A82
015RS031
D Remove any ridge or carbon build up from the top

015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)

Pistons
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
any of the above conditions are found, the piston must be
replaced.
Piston Diameter
015RS022
10. Remove the piston pin (9) using 5884005510

piston pin service set and piston support with a press.
positions. Heating the connecting rod will permit easy
removal of the piston pin.
1. Measure the piston outside diameter with micrometer

at the piston grading position and a right angle to the
piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)
015RV014
6A83
012RS002
The size mark (1) for piston outside diameter is

represented as shown in illustration below.
Piston Rings
Outside Diameter
Size Mark A : 93.360 mm93.370 mm
(3.6756 in3.6760 in)

D Insert the piston ring into the bore.
Size Mark B : 93.371 mm93.380 mm

(3.6760 in3.6764 in)
D Push the ring by the piston, at a right angle to the

Size Mark C : 93.381 mm93.390 mm

(3.6764 in3.6768 in)
D Measure the ring end gap.

Compression Ring
1st ring
Standard:
0.300 mm0.400 mm
(0.0118 in0.0157 in)
Limit:
1.0 mm (0.0394 in)
2nd ring
Standard:
0.450 mm0.600 mm
(0.0177 in0.0236 in)
Limit:
1.2 mm (0.0472 in)
Oil ring
Standard:
0.150 mm0.450 mm
(0.0059 in0.0177 in)
Limit:
015RX002
Measure the cylinder bore inside diameter (refer to

Cylinder Block in this manual).
1.05 mm (0.0413 in)
6A84
015RS026
015RS028
D Positioning mark (1) is painted as shown in the

illustration.
Piston Pin

positions.
small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.
Standard : 0.023 mm0.038 mm (0.0009

in0.0015 in)
015RS027

piston ring groove / piston ring clearance exceeds the
(0.0006 in.0.0015 in)
Limit : 0.15mm (0.0059 in)
015RS029
is normal. If there is backlash or roughness, measure
the clearance. If the clearance exceeds the specified
limit, the piston must be replaced.
Clearance
(0.0004 in.0.0007 in)
Limit : 0.040 mm (0.0016 in)
6A85
Connecting Rods
1. Check the connecting rod alignment If either the bend
or the twist exceeds the specified limit, the connecting
rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)
015RS031

1. Remove the connecting rod cap nuts and the rod
caps (12).
number order.
015RS030
2. Measure the connecting rod thrust clearance. Use a

feeler gauge to measure the thrust clearance at the
large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod must
be replaced.
(0.0063 in.0.0138 in)

bearing is found to be damaged or badly worn, the
entire bearing assembly must be replaced as a
set. Reinstall the bearings in their original
Limit : 0.40 mm (0.0157 in)
015RS032
6A86

positions.

crankshaft pins.
Conrod Bearing Selection

Select and install the new connecting rod bearings,
paying close attention to the connecting rod big end
diameter size mark (1).

set.
NOTE: Take care not to confuse the alignment mark (2)

and the size mark (1) during the installation procedure.

(0.0007 in0.0017 in)
Limit : 0.08 mm (0.003 in)
015RS034
015RS008
Connecting
Rod Bearing
Grade Mark
On
Connecting
Rod
Big end Bore

Diameter
56.994-57.000
(2.2439-2.2441)
56.988-56.994
(2.2436-2.2439)
56.982-56.988
(2.2434-2.2436)
Reassembly
2. Install piston
Crankshaft Pin
Diameter
53.922-53.937
(2.1229-2.1235)
Connecting Rod
Bearing Thickness
(Reference)
Color of
Size
Mark
Oil Clearance
(Reference)
1.512-1.516
(0.0595-0.0597)
Yellow
0.025-0.054
(0.0010-0.0021)
1.508-1.512
(0.0594-0.0595)
Green
0.027-0.056
(0.0011-0.0022)
1.504-1.508
(0.0592-0.0594)
Pink
0.029-0.058
(0.0011-0.0023)

D Apply a thin coat of engine oil to the piston pin. Try to
insert the piston pin into the piston pin hole with
normal finger pressure.
6A87
D Attach the piston to the connecting rod with the

piston front mark and the connecting rod front mark
on the same side.
015RS027
015RS036
D With 5884005510 Piston pin service set and a

press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
D Install piston rings in the following sequence.

1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
3. 1st compression ring
D The compression rings must be set with the T or T2
mark facing up.
D After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
The compression ring must be set with the T mark (1)
facing up.
015RS038
6A88

D Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.
D Tighten the connecting rod cap nuts
6. Oil gallery, refer to Crankshaft and main bearing in
this manual.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to Oil pan and
11. Install Cylinder head assembly.
D Refer to Cylinder head in this manual.
6A89
Cylinder Block
012RW010
Legend
Disassembly
4. Remove oil pipe and O-ring.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Oil Gallery
Flywheel
Rear Oil Seal Retainer Assembly
Main Bearing Cap
Crankshaft
Cylinder Block
5. Remove oil strainer and O-ring.

7. Remove crankcase side bolts.
10. Remove flywheel.
6A90

Cylinder Bore

material adhering to the upper surface of the cylinder
block. Be very careful not to allow any material to
accidentally drop into the cylinder block. Be very
careful not to scratch the cylinder block.
4. Visually inspect the cylinder block. If necessary, use a
flaw detector to perform a dye penetrate and
Flatness

Cylinder Bore Inside Diameter
Limit : 93.530 (3.6823)
If the measurement exceed the specified limit, the
Diameter
Grade A : 93.400 mm93.410 mm
(3.6772 in3.6776 in)
Grade B : 93.411 mm93.420 mm
(3.6776 in3.6779 in)
Grade C : 93.421 mm93.430 mm
(3.6780 in3.6783 in)
1. Using a straightedge and feeler gauge, check that

the upper surface of the cylinder block is not warped.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
012RS005

Rod Assembly in this manual.
D The cylinder bore Grade mark (1) is stamped at the
position illustrated.
012RS004
6A91
D Assemble the thrust washer to the No. 3 bearing

012RS006
Reassembly
015R100033

bearing faces.

surface.
hardens.
015RW002
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.
Legend
6A92

D Check to see that the piston ring end gaps are
015RW001
4. Install flywheel
mounting faces.
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
015RX003
Legend

D The front marks (1) must be facing the front of the

engine.
015RS018

015RS020
6. Install oil gallery and tighten the bolts in 2 steps in the

order shown.
2nd step : 55 65
012RS007
7. Install cylinder block side bolts (1) and tighten

crankcase bolts in sequence shown in the illustration.
6A93
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
13. Install cylinder head assembly. Refer to Cylinder
Head in this manual.
012RW005
8. Install oil pump assembly. Refer to Oil Pump in this

manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
2. Apply a correct width bead of sealant (TB 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
after sealant application to prevent premature
hardening of sealant.
6A94

Item
Engine type, number of cylinders and arrangement
Form of combustion chamber
Specifications
6VD1
Water cooled, four cycle V6
Pent roof type
Valve mechanism
4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner type
Casted in cylinder drive
Total piston displacement

Cylinder bore x stroke
Compression ratio
Compression pressure at 300rpm
Engine idling speed rpm
Valve clearance
3165 cc
93.4mm x 77.0mm
(3.6772 in x 3.0315 in)
9.1 : 1
14.0 kg/cm@
Non adjustable (750)
Intake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12in)
Oil capacity
Ignition timing
Spark plug
Plug gap
5.3 liters
Non adjustable
16 BTDC at idle rpm)
K16PRP11, PK16PR11, RC10PYP4
1.0 mm1.1 mm(0.0394 in 0.0433 in)
6A95
Ignition coil, Spark plug, Crankshaft position sensor and Under cover
Nm (kgm/lb ft)
E06RX008
6A96
Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, EGR valve and EGR pipe
Nm (kgm/lb ft)
E06RW043
6A97
Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt
cover, Oil pump, Oil gallery, Oil strainer and Water pump
Nm (kgm/lb ft)
E06RW039
6A98
Connecting rod and Water pump

Nm (kgm/lb ft)
E06RW042
6A99
Engine mount
Nm (kgm/lb ft)
E06RW040
6A100 ENGINE MECHANICAL (6VD1 3.2L)
Special Tool
ILLUSTRATION
TOOL NO.
TOOL NAME
5884000110
(J2168702)
Remover; tie rod end
5884024410
Set Number of Valve
Compressor
5884024460
(J8062)
Compressor; Valve
Spring (1)
5884025470
(J42898)
Adapter; Compressor
Valve Spring (2)
5884006230
(J37281)
Remover; Oil controller
5884006240
(J38537)
Installer; Oil controller
5884024450
(J42985)
Installer; Camshaft oil
seal
5884025450
(J39206)
Installer; Pilot bearing
ILLUSTRATION
TOOL NO.
TOOL NAME
5884001330
(J861401)
Holder; Crankshaft
5884021530
(J37228)
Seal cutter
5884022860
(J39201)
Installer; Real oil seal
9851142090
(J242391)
Cylinder head bolt
wrench
5884024420
(J42899)
Replacer; Valve guide
(set) (1,2)
5884025480
(J42687)
Installer; Valve guide (1)
5884025490
(J379851)
Remover; Valve guide
(2)
5884024440
(J42689)
Adjusting Tool: Valve
clearance

ILLUSTRATION
TOOL NO.
TOOL NAME
5884024430
(J42686)
Lever; Gear spring
5884024470
(J43041)
Holder; Universal
6A101
SECTION
ENGINE COOLING (6VD1 3.2L)
6B1
FRONTERA
ENGINE
ENGINE COOLING
CONTENTS
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling Cooling System . . . . .
Engine coolant change . . . . . . . . . . . . . . . . . . .
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6B1
6B2
6B5
6B6
6B6
6B7
6B7
6B7
6B7
6B7
6B8
6B8
6B8
Service Precaution
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Associated Parts . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt and Cooling Fan . . . . . . . . . . . . . . .
Drive Belt and Associated Parts . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6B8
6B8
6B9
6B9
6B9
6B10
6B11
6B12
6B12
6B12
6B12
6B13

systems.
6B2
General Description
030RW001
Legend
(1) Water Pump
(2) Thermostat
(3) Radiator
(4) Reserve Tank
(5) Cooling Fan
(6) Cylinder Block
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Cylinder Head
Right Bank
Throttle Body
Cylinder Block
Cylinder Head
Left Bank
Heater
The cooling system is a pressurized Engine Coolant (EC)

forced circulation type which consists of a water pump,
thermostat cooling fan, radiator and other components.
The automatic transmission fluid is cooled by the EC in
radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
030RS001
Thermostat
6B3
Anti Freeze Solution
The thermostat is a wax pellet type with a air hole(1) and is

installed in the thermostat housing.
D Relation between the mixing ratio and freezing

temperature of the Engine Coolant varies with the
D Calculating mixing ratio
031RW002
Radiator
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted
with a cap in which the valve is operated at 88.2 117.6
kPa (12.8 17.0 psi) pressure. (No oil cooler provided for
M/T)
F06RW005

system capacity.
D Total Cooling System Capacity
D M/T 8.8Lit (2.32Us gal)
D A/T 8.4Lit (2.22Us gal)
110RW023
6B4
B06RW002
D Mixing ratio
cooling system temperature ranges from 0C to 50C
using a suction type hydrometer, then determine the
NOTE:
1. Even in the areas where the atmospheric
temperature is higher than 0C, 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%.
B06RW003
6B5
Diagnosis
Condition
Engine overheating
Possible cause
Correction
Replenish
Replace
Thermo meter unit faulty
Replace
Faulty thermostat
Replace

sensor
Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap
Replace

improper engine oil

faulty parts

sensor circuit
Repair or replace
Replace
Engine overcooling
Faulty thermostat
Replace
Faulty thermostat
Replace
Thermo unit faulty
Replace
6B6
Draining and Refilling Cooling

System
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the MIN
and MAX lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the MAX line.
Engine coolant change

1. To change engine coolant, make sure that the engine
is cool.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
Replace damaged rubber hoses as the engine anti-freeze
coolant is liable to leak out even minor cracks.
Isuzu recommends to use Isuzu genuine anti-freeze (ethylene-glycol based) or equivalent, for the cooling system
and not add any inhibitors or additives.
the filler neck even before the engine and radiator are
completely full.
To avoid such trouble, the following precautions
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between the
filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over this
maximum rate may force air inside the engine and
radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
5. After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
disclodged and the coolant level goes down. Should
the coolant level go down, repeat topping-up until
there is no more drop in the coolant level.
6. After directly filling the radiator, fill the reservoir to the
maximum level.
7. Install and tighten radiator cap and start the engine.
After idling for 2 to 3 minutes, stop the engine and
replenish.
8. After tightening radiator cap, warm up the engine at
about 2,000 rpm.
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into heater
water system.
9. Check to see the thermostat has opened through the
needle position of water thermometer, conduct a
5-minute idling again and stop the engine.
10. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
11. Fill the coolant into the reservoir tank up to MAX line.
6B7
Water Pump
030RS002
Legend
(1) Timing Belt
(2) Idle Pulley
Removal
2. Drain coolant.
4. Remove timing belt. Refer to Timing Belt in this
manual.
5. Remove Idle pulley.
7. Remove gasket.

(4) Gasket

specified torque.
D Tightening order
The tightening order are in the illustrate.
NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bolt
thread.
Inspection
wear or damage is found during inspection. Should any of
the following problems occur, the entire water pump
assembly must be replaced:
D Crack in the water pump body
D EC leakage from the seal unit
D Play or abnormal noise in the bearing
D Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket
before installation.
030RW008
6B8
3. Idle pulley
D Install idle pulley and tighten bolt to the specified
torque.
4. Timing belt
D Install timing belt. Refer to timing belt installation
step in Timing Belt in this manual.
5. Connect radiator inlet hose and replenish EC.
Thermostat
Thermostat and Associated Parts
031RS003
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a waterfilled container using
thin wire. Place a thermometer next to the thermostat.

open.
Valve opening temperature 74.5C 78.5C
(166.1F 173.3F)
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90C (194F)
wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
specified torque.
6B9
Radiator
110RW010
Legend
(1) Oil Cooler Hose For Automatic Transmission
(2) Radiator Hose
(3) Fan Guide, Lower
Removal
2. Loosen a drain plug (2) to drain Engine Coolant.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
the engine.
(4) Reserve Tank Hose

(5) Radiator Assembly
(6) Reserve Tank
5. Remove fan guide(1), clips (2) on both sides and the

bottom lock, then remove lower fan guide(3) with fan
shroud(4).
110RW001
110RW002
6B10
6. Disconnect the reserve tank hose(4) from radiator.

7. Remove bracket.
Valve opening vacuum kPa (psi) 1.96 4.91

(0.28 0.71)
110RS006
110RX001
8. Lift up and remove the radiator assembly with hose,

taking care not to damage the radiator core with a fan
blade.
9. Remove rubber cushions on both sides at the bottom.
Inspection
Radiator Cap
the standard range.
(12.8 17.1)
the valve seat side of the cap. If considerable rust or dirt is
found, or if the valve seat cannot be moved by hand, clean
or replace the cap.
Radiator Core
straightened. Pay close attention to the base of the fin
when it is being straightened.

Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent.
Remove all signs of scale and rust.

through the filler neck at the specified pressure of 150 kPa
(22 psi) with a cap tester:
D Leakage from the radiator
D Leakage from the coolant pump
D Leakage from the water hoses
D Check the rubber hoses for swelling.
110RS005
6B11
111RS001
Important operation (in case of 100% engine coolant

change) procedure for filling with engine coolant.
Installation
bottom.
2. Install radiator assembly with hose, taking care not to
damage the radiator core with a fan blade.
4. Connect reserve tank hose (4).
engine.
7. Connect oil cooler hose (1) to automatic
transmission.
1. Make sure that the engine is cool.

2. Open radiator cap pour coolant up to filler neck.
3. Pour coolant into reservoir tank up to MAX line.
4. Tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and
replenish.
5. After tightening radiator cap, warm up the engine
at about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
6. Check to see the thermostat has opened through
the needle position of water thermometer,
conduct a 5minute idling again and stop the
engine.
7. When the engine has been cooled, check filler
neck for water level and replenish if required.
Should extreme shortage of coolant is found,
check the cooling system and reservoir tank hose
for leakage.
8. Pour coolant into reservoir tank up tp MAX line.
110RX001

6B12
Drive Belt and Cooling Fan

Drive Belt and Associated Parts
015RW005
Legend
(2) Generator
The drive belt adjustment is not required as automatic

drive belt tensioner is equipped.
Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.
Installation
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
and fan bracket.
clutch assembly.
(4)
(5)
(6)
(7)
Water Pump and Cooling Fan Pulley

Idle Pulley
Tension Pulley
Drive Belt
6B13

M/T
Cooling system
Radiator
Heat radiation area
A/T
Engine coolant forced circulation

Tube type corrugated (2 tube in row)
70,000 kcal/h
77,800 kcal/h
9.74m@ (104.8ft@)
11.74m@ (126.4ft@)
Radiator front area

Radiator dry weight
Engine coolant pump
Delivery
0.263m@ (2.83ft@)
42N (9.4lb)
45N (10.1lb)
93.3 122.7kpa (13.5 17.8psi)

2.5lit (2.6U.S q.t.)
2.4lit (2.5U.S q.t.)
Centrifugal impeller type

300 (317) or more
Pump speed
5000 50 rpm
Thermostat
Wax pellet type with air hole
Valve opening temperature

74.5 78.5C (166.1 173.3F)

11.1lit (2.93U.S qt)
10.0lit (2.64U.S qt)
Nm (kgm/lb ft)
E06RW041
SECTION
6C1
FRONTERA
ENGINE
ENGINE FUEL
CONTENTS
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
InTank Fuel Filter . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6C1
6C2
6C4
6C4
6C4
6C4
6C4
6C4
6C5
6C6
6C6
6C6
6C6
Service Precaution
Fuel Tube / Quick Connector Fittings . . . . .

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions During Work . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank and Associated Parts . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6C7
6C7
6C7
6C7
6C9
6C10
6C10
6C10
6C11
6C11
6C11
6C11
6C12

systems.
6C2
General Description
140RW066
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank

D Any time the fuel system is being worked on,
D Always keep a dry chemical (Class B) fire
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Fuel Rail Left

Left Bank
Common Chamber
Duty Solenoid Valve
Throttle Valve
Canister
Evapo Pipe
D Replace all pipes with the same pipe and fittings that
were removed.
D Clean and inspect O rings. Replace if required.
D Always relieve the line pressure before servicing any
D Do not attempt repairs on the fuel system until you

D Adhere to all Notices and Cautions.
Control System. The purpose of the system is to minimize
the escape of fuel vapors to the atmosphere.
Fuel Metering
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.
corresponding to the flow of the air drawn into the engine.
revolution. The PCM 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
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
6C3
6C4
Fuel Filter
Removal

4. Fuel filter fixing bolt(2).
D Remove the fuel filter fixing bolt(2) on fuel filter
holder.
Inspection
2. Replace the filter if it is clogged with dirt or sediment.
3. Check the drain of receive rubber and if it is clogged
with dust, clean it up with air.
Installation
3. Connect fuel hoses on engine side(1) and fuel tank
side(2).
140RW010
Legend
(1) Fuel Filler Cap
2. Remove Fuel filler cap(1).
041RW001

Inspection
After installation, start engine and check for fuel leakage.
InTank Fuel Filter

041RW003
Legend
(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter
The filter is located on the lower end of fuel pickup tube in

the fuel tank. It prevents dirt from entering the fuel pipe
and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Fuel Pump Flow Test

following checks.
2. With the engine running, check the fuel feed pipe and
hose from fuel tank to injector for evidence of
clogging.
wire(1) as shown and start the fuel pump to measure
delivery.
140RX020

a jumper wire.
Delivery
Delivery
15 seconds
0.38 liters minimum

pressure test.
Pressure test
Fuel Control System.
6C5
6C6
Fuel Pump
140RX004
Legend
(1) Fuel Feed Port
(2) Fuel Tube/Quick Connector
(3) Fuel Return Port
Removal
with a lifter.
4. Remove fuel tank assembly(11). Refer to Fuel Tank
Removal in this section.
(6)
(7)
(8)
(9)
(10)
(11)

Snap Ring
Hose; Air Breather
Hose; Fuel Filler
Fuel Tank Assembly
6. Remove fuel pump and sender (FPAS) assembly (4)

fixing snap ring and remove the FPAS assembly.
NOTE: After removing pump assembly (4), cover fuel
tank to prevent any dust entering.
Installation
1. Install FPAS assembly(4).
Installation.
6C7

Precautions
D Lighting of Fires Prohibited.
D Keep flames away from your work area to prevent the
D Disconnect the battery negative cable to prevent
D When welding or conducting other heat-generating
spattering.
As some pressure may remain in the piping, cover the

connector with a cloth, etc. to prevent the splashing
of fuel in the first disconnection of the piping.
engine), hold the connector in one hand, and hold the
retainer tab with the other hand and pull out the

piping.
Removal
tank.
141RW019

141RW036
141RW020
6C8
NOTE: This work should be done by hands. Do not use

any tools. Should the pipe can hardly be removed from
the connector, use a lubricant (light oil) and/or push and
pull the connector longitudinally until the pipe is removed.
(Delivery Pipe)
crack is found.
D Remove mud and dust from the pipe and make sure
D If the retainer removed according to the removal step
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
clicks.
141RW021

Cover the connectors removed with a plastic bag, etc.
to prevent the entry of dust or rain water.
141RW018
(Return Pipe)
crack is found.
D 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
141RW022

D 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.
6C9
Assembling Advice
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.
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.
141RW017
Fuel Pump Relay

General Description
provided. When the starter switch is turned to ON
seconds.
When it is turned to START position, the Engine Control
Module receives the reference pulse from the Ignition
Control Module and it operates the relay, again causing
the FPAS to feed fuel.
6C10
Fuel Tank
140RX005
Legend
(1) Roll Over&Float Valve
(2) Retaining Cover
(3) Hose; Evaporative Fuel
(4) Hose; Air Breather
(5) Hose; Fuel Filler
(6) Bolt; Fuel Tank Protector Fixing
(7) Snap Ring
(8) Connector; Fuel Level Sensor
Removal
with a lifter.
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)

Fuel Feed Port
Fuel Return Port
Fuel Tank Assembly
Hose; Fuel Feed
Hose; Fuel Return
Protector; Heat

leakage.
8. Let down the tank and disconnect the wiring
connectors (8,9).
(15,19) .
10. Remove retaining cover (2) and roll over & float valve
(1) along with the evaporative fuel hose and pipe (3).
ENGINE FUEL (6VD1 3.2L) 6C11

12. Remove fuel pump and sender assembly (10) by
removing the snap ring (7) along with the fuel hoses
(17,18).
13. Remove protectors (15,19) by removing the six fixing
bolts (6).

4. Install roll over & float valve (1) by fitting in of the
retaining cover (2).
5. Lift up fuel tank assembly and connect the wiring
connectors (8,9).
tighten the four fixing bolts to the specified torque.
Installation
1. Install protectors (15,19) and tighten the six fixing
2. Install fuel pump and sender assembly by fitting in of
the snap ring (7).
3. Install Fuel Tube/Quick connector (12).
7. Connect fuel filler hose (5) and air breather hose (4),
8. Connect fuel feed hose (17) and fuel return hose (18),
Fuel Gauge Unit

refer to Fuel Tank of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender assembly.
Fuel Filler Cap

General Description
Inspection

In case any high vacuum happen in tank, the valve works
to adjust the pressure to prevent the tank from being
damaged.
140RW014
Legend
(1) Vacuum Valve
(2) Fuel Filler Cap
CAUTION:
6C12

Nm (kgm/lb ft)
140RY00018
SECTION
ENGINE ELECTRICAL (6VD1 3.2L)
6D11
FRONTERA
ENGINE
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging . . . . . . . . . . . . . . . . . . . . . .
6D11
6D12
6D12
6D12
6D13
Service Precaution
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal . . . . . . . . . . . . . . . . . . . . . .
Battery Installation . . . . . . . . . . . . . . . . . . . . .
6D13
6D14
6D14
6D15

systems.
6D12
Battery
General Description

escape of small amounts of gas generated by the battery.
The battery will refuse to accept an extensive charge.
charge, resulting in gassing and loss of battery fluid.)

a. CORRECT FLUID LEVEL Charge the battery.
b. BELOW LOWER LEVEL Replace battery.
3. The battery is much less vulnerable to self discharge

than a conventional type battery.
Diagnosis
Inspect the battery for obvious physical damage, such as
a cracked or broken case, which would permit electrolyte
loss.
necessary.
2. Hydrometer Check
a. BLUE RING OR DOT VISIBLE(5) Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE(4) Go to Step
3.
061RW001
4. Voltage Check
a. VOLTAGE IS 12.4V OR ABOVE Go to Step 5.
b. VOLTAGE IS UNDER 12.4V Go to procedure (2)
below.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
15V and charge for 10 15 hours. Then go to Step
5.
c. VOLTAGE IS BETWEEN 12V AND 16V
d. VOLTAGE BELOW 12V Replace Battery.
5. Load Test
1. Connect a voltmeter and a battery load tester across
the battery terminals.
061RW001

a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE The battery is
good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED
Replace battery.
MINIMUM
VOLTAGE
70
21
9.6
60
16
9.5
50
10
9.4
40
9.3
30
9.1
20
8.9
10
12
8.7
18
8.5

and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
the battery:
procedure.
charge reduced if the battery feels hot to the touch.
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
or ring, it may be necessary to jiggle or tilt the battery.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
charge the battery.
Jump Starting
Battery
6D13

THE FOLLOWING:
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
explode.
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.
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.
short circuit.

transmission, place the selector level in the PARK
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the NEUTRAL position.
Turn OFF all lights and any other accessory
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
cause a ground connection, effectively neutralizing
the charging procedure.
6D14
4. Attach one end of the remaining cable to the negative

being charged.
Make sure that all unnecessary electrical accessories
have been turned OFF.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.
Battery Removal
061RX002

NOTE: Make sure that the rod is hooked on the body
side.

Model (JIS)
24R600
Voltage (V)
12
600
118
Load Test (Amp)
300
BCI Group No.
24
6D15
SECTION
IGNITION SYSTEM (6VD1 3.2L)
6D21
FRONTERA
ENGINE
IGNITION SYSTEM
CONTENTS
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6D21
6D22
6D22
6D23
6D23
6D23
6D23
Service Precaution
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement spark plugs . . . . . . . . . . . . . . .
Crankshaft Position Sensor . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6D24
6D24
6D24
6D25
6D25
6D25
6D26

systems.
6D22
General Description
Ignition is done by the electronic ignition (El) that directly
fires the spark plugs from ignition coils through spark plug
wires without using a distributor. A pair of ignition coils for
the cylinders having different phases by 360 (No.1 and
No.4,No.2 and No.5,No.3 and No.6) are fired
simultaneously.
Since the cylinder on exhaust stroke requires less energy
to fire its ignition plug, energy from the ignition coils can be
utilized to fire the mating cylinder on compression stroke.
After additional 360 rotation, respective cylinder strokes
are reversed.
The EI consists of six ignition coils,ignition control
module, crank angle sensor, powertrain control module
(PCM) and other components.
The ignition coils are connected with the PCM by means

of a 32 pin connector.
The ignition control module turns on/off the primary circuit
of ignition coils, and also it controls the ignition timing at
the engine speed below 538 rpm.
crank angle sensor which then sends information such as
firing order and starting timing of each ignition coil to the
PCM.
Further, the El employs ignition control (IC) to control
similar to a distributor system.
speed, water temperature and Manifold Absolute
Pressure (MAP), the PCM controls the ignition timing.
D06RX096
Diagnosis
6D23
Ignition Coil
Measure resistance of ignition coil assembly, and replace
the ignition coil assembly if its value exceeds the
standard.
Removal
2. Ignition coil connector and ignition coil.
D Disconnect three connector from ignition coil.
D Remove harness bracket bolt on cylinder head
cover.
D Remove fixing bolts on ignition coil.
060RW006
Installation
060RW121
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
1. Install the ignition coil assembly (3).

Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.

Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No.
Limit
1 to 2
Without 0 ohm or infinity

maximum ohm.
1 to 3
Same as above
2 to 3
Same as above
060RW121
6D24
Spark Plug
Inspection
Poor spark plug condition adversely affects engine
performance. Carefully inspect each spark plug following
the procedure outlined below.
2. Check the plug for dirt and other foreign material.
If the plug is extremely dirty, the fuel and electrical
systems must be checked.
7. Check the spark plug gap. Replace the spark plug if

the gap is not as specified.
Standard: 1.011 mm (0.040.043 in)
Limit: 1.3 mm (0.05 in)
3. If necessary, clean the spark plugs by placing them in

a spark plug cleaning machine for no more than 20
seconds.
4. Check the electrode and insulator for wear and/or
cracking. If there is significant wear or cracking, the
plug must be replaced.
5. Check the gasket for damage. Replace the gasket if
necessary.
6. Measure the insulation resistance with a 500-volt
megaohm meter. Replace the plug if the resistance is
less than the specified value.
Insulation resistance: 50 MW or more
011RS011
D Do not attempt to adjust the gap of an old spark

plug. Replace the plug and adjust the gap of the
new plug if required.
D Take care not to damage the spark plug tip during
handling.
8. Tighten the spark plugs to the specified torque.
Replacement spark plugs

D Under normal conditions (no problem with the fuel
and/or electrical systems), use replacement spark
plugs with a low heat value (hot-type plug).
D If insulator and electrode scorching is significant, use
replacement spark plugs plugs with a high heat value
(cold-type plug).
011RS010
Crankshaft Position Sensor

Removal
3. Remove crankshaft angle sensor from cylinder block.
012RS008
Installation
1. Install crankshaft angle sensor into the cylinder block.
Before installation,apply small amount of engine oil to
the Oring.
2. Reconnect wiring connector to crankshaft position
sensor.
6D25
6D26

Ignition System
Ignition Form
Spark Plug
Type
Plug gap
Torque
K16PRP11
RC10PYP4
PK16PR11
1.0 mm (0.04 in) 1.1 mm (0.043 in)
18 Nm (1.8 kgm/13 lb ft)
Nm (kgm/lb ft)
E06RX008
SECTION
STARTING AND CHARGING SYSTEM (6VD1 3.2L)
6D31
FRONTERA
ENGINE
CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System . . . . . . . . . . . . . . . . . . . . . . . .
6D31
6D32
6D32
6D34
6D35
6D35
6D35
6D36
6D37
6D39
6D313
6D315
6D318
Service Precaution
General Description . . . . . . . . . . . . . . . . . . . .
General OnVehicle Inspection . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
6D318
6D318
6D319
6D319
6D319
6D320
6D320
6D321
6D322
6D324
6D325
6D326

systems.
6D32
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.
6D33
C06RX004
6D34
Diagnosis
Condition
Possible cause
Correction
Charging failure
Battery Failure
Replace Battery

Starter failure
6D35
Starter
torque(5).
Removal
2. Disconnect heated oxygen (O2) sensor connector
(1).
3. Remove exhaust front left pipe(2).

3. Reconnect the connectors to terminals B and S
and tighten Terminals B to specified torque.
4. Install heat protector(3).
150RX015
4. Remove heat protector(3).

5. Disconnect starter wiring connector from terminals
B and S(4).
6. Remove starter assembly mounting bolts on inside
and outside(5).
7. Remove starter assembly toward the bottom of
engine(6).
065RW027
5. Install exhaust front left pipe and tighten bolts and

nuts to specified torque(2).
Stud Nuts
Nuts
6. Connect O2 sensor connector (2).
065RW027
Installation
150RX015
6D36
Disassembled View
065RW002
Legend
(1) Bolt (2 pcs)
(2) Ball Bearing
(3) Pinion
(4) Shift Lever
(5) Dust Cover
(6) Torsion Spring
(7) Dust Cover
(8) Magnetic Switch
(9) Nut
(10) Gear Case
(11) Bearing Cover
(12) ERing
(13) Thrust Washer (2)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Center Bracket
Pinion Shaft
Planet Gear (3)
Internal Gear
Center Bracket (A)
Yoke Assembly
Armature
Brush
Brush Holder
Thrust Washer
Rear Cover
Screw (2 pcs)
Through Bolt (2 pcs)
Disassembly
1. Loosen the nut(1) on terminal M of magnetic switch
and disconnect the connector cable.
2. Remove bolt (2 pcs) (2).
6D37
9. Remove screws and through bolts, then the rear

cover(9) then remove thrust washer(10).
10. Remove brush holder(6).
065RW005
065RW003
3. Remove magnetic switch(5).

5. Remove torsion spring bolts, then the magnetic
switch assembly.
6. Remove torsion spring(3) from magnetic switch
assembly(5).
11. Raise a brush spring to detach brushes (4 pcs) from

the commutator face and pull off the brush holder(12)
and brush(11).
065RW006
12. Remove yoke assembly(14).

13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,
washer and center bracket.(A) (13).
065RW004
7. Remove screw (2 pcs) (8).

8. Remove through bolt (2 pcs) (7).
6D38
NOTE: In disassembling the yoke assembly, hold the

armature and pull off slowly the yoke assembly. Because
of strong magnetic force, avoid placing a metallic part
near armature.
17. Remove ball bearing(19).

18. Remove bearing cover(20).
19. Remove a ball bearing and bearing cover from the
gear case(18).
065RW007

16. Remove a dust cover and shift lever(16) from the gear
case.
065RW021
20. Internal gear(21).

21. Remove internal gear and planet gear(3) (22).
065RW009
065RW008

22. Remove an Ering(23) from the pinion shaft using a
flat blade screwdriver.
6D39

Armature
Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.
Limit: 32.0 mm (1.26 in)
065RW010
23. Holding the pinion shaft, push pinion toward the

center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.
24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft.
065RS014

disconnected).
065RW011
065RS015
6D310 STARTING AND CHARGING SYSTEM (6VD1 3.2L)

grounded).
Polish the commutator surface with sandpaper #500 to

#600 if it is rough.
065RW012
065RS016
Measure runout of armature core and commutator with a

dial gauge. Repair or replace, if it exceeds the limit.
Armature
Limit: 0.10 mm (0.004 in)
Commutator
Limit: 0.10 mm (0.004 in)
Measure the depth of insulator in commutator. Repair, if it

is below the limit.
Standard: 0.05 mm to 0.8 mm (0.02 in to 0.03 in)
Limit: 0.2 mm (0.008 in)
065RW013
Legend
(1) Steel Saw
(2) Insulator
(3) Commutator Segments
065RS017
6D311
Brush
Magnetic Switch

Standard: 16 mm (0.63 in)
Limit: 11 mm (0.43 in)
Check for continuity of shunt coil between terminals S and

M.
disconnected).
065RW016
065RW014
Brush Holder
broken).

disconnected).
065RW017
065RW015
Yoke Assembly

Check a magnet inside the yoke.

Replace the yoke assembly if it is broken.
065RS026
065RW018
Pinion
replace the pinion.
Ball Bearing
Clamp the inner race of the ball bearing with your finger,
and check for sticking or play when rotating the outer
race.
Replace, if abnormality is found.
065RS027
065RS025

Measure inner diameter of bushing in the rear cover, and
replace if it exceeds the limit.
0.4932 in)
Limit: 12.60 mm (0.4961 in)
6D313
Reassembly
Grease application places
D
D
D
D
D
Bushing in rear cover and center bracket

Gears in reduction gear
Shift lever operating portion
Sliding portion of pinion
Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly

Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
Torque
Torque for each part (See Torque Specifications in
this section)
Pinion Jumpout Dimension
065RS028
Measure inner diameter of bushing in the center bracket

(P), and replace if it exceeds the limit.
0.7137 in)
Limit: 18.15 mm (0.7146 in)
065RS029
Connect the + cable of battery to terminal S and the

cable to terminal M. Turn the switch on, and measure
pinion travel dimension in thrust direction from the
jumpout position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
0.06 in)
065RS030

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:
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

Model
Specification
Rating
Voltage
12 V
Output
1.4 Kw
Time
30 sec
Number of teeth of pinion

Rotating direction(as viewed from pinion)
Weight(approx.)
9
Clockwise
37 N
No load characteristics
Voltage /Current
11.5V/90A or less
Speed
3000rpm or more
Load characteristics
Voltage/current
8.5V/350A or more
Torque
13.2Nm(117lbin.) or more
Speed
1000rpm or more
Locking characteristics
Voltage/current
Torque
2.4V/500A or less
11.8Nm(104lbin) or more
6D315
Nm (kgm/lb in)
E06RY00009
6D317
Nm (kgm/lb ft)
150RY00044
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in illustration.
The regulator is a solid state type and it is mounted along
with the brush holder assembly inside the generator
installed on the rear end cover.
such as voltage adjustment.
The rectifier connected to the stator coil has diodes to

transform AC voltage into DC voltage.
generator.
F06RX002

A basic wiring diagram is shown in the illustration. When
operating normally, the indicator bulb will come on when
the switch is turned on, and will then go out when the
engine starts. If the indicator operates abnormally, or if an
undercharged or overcharged battery condition occurs,
the following procedure may be used to diagnose the
charging system. Remember that an undercharged
battery is often caused by accessories being left on
overnight, or by a defective switch which allows a bulb,
such as a trunk or glove box light, to stay on.
OBSERVE THE FOLLOWING PROCEDURE:

1. Visually check belt and wiring.
2. Go to step 5. for vehicles without charge indicator
light.
3. Switch on, engine stopped, light should be on. If not,
detach harness at generator, ground L terminal
lead.
a. Lamp lights, replace or repair generator.

b. Lamp dose not light, locate open circuit between
grounding lead and ignition switch. Bulb may be
open.
4. Switch on, engine running at moderate speed. Light
should be off. If not, detach wiring harness at
generator.
a. If light goes off, replace or repair generator.
b. If light stays on, check for grounded L terminal
wire in harness.
5. Battery undercharged or overcharged.
a. Detach wiring harness connector from generator.
b. With switch on, engine not running connect
voltmeter from ground to L terminal in wiring
harness, and to IG terminal. If used. Wiring
harness may connect to either L or IG or both.
c. Zero reading indicates open circuit between
terminal and battery. Connect as required.

d. Re-connect harness connector to generator, run
engine at moderate speed, with electrical
accessories turned off.
e. Measure voltage across battery. If above 16.0V,
replace or repair generator.
f. Connect ammeter at generator output terminal.
Turn on accessories, load battery with carbon pile
to obtain maximum amperes output.
Maintain voltage at 13.0V or above.
6D319
2. If not within 15 amperes of rated output, replace or

repair generator.
1. If within 15 amperes of rated output, generator is

OK.
Generator
Removal
Inspection

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).
1. Disconnect the wiring connector from generator.

2. With the engine stopped, turn starter switch to on
and connect a voltmeter between connector terminal
L (1) and ground or between terminal IG (2) and
ground.
066RX002
If voltage is not present, the line between battery and

connector is disconnected and so requires repair.
060RW002
3. Reconnect the wiring connector to the generator, run

the engine at middle speed, and turn off all electrical
devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., headlights). At this
time the amperes must not be less than 15A and the
voltage must not be less than 13V.
Installation
1. Install generator assembly to the position.
2. Install generator assembly and tighten the fixing bolts
3. Connect wiring harness connector and direct terminal

B.
Torque:
M10 bolt: 41 Nm (4.2 kgm/30 Ib ft)
M8 bolt: 21 Nm (2.1 kgm/15 Ib ft)
Disassembled View
066RW022
Legend
(1) Pulley Nut
(2) Pulley
(3) Front Cover Assembly
(4) Rotor Assembly
(5) Stator Assembly
(6) Through Bolt
(7)
(8)
(9)
(10)
(11)
(12)
Nut
Terminal Insulator
Rear Cover Assembly
Rectifier
Brush Holder Assembly
Regulator Assembly
6D321
4. Remove screws with bearing retainer from front cover

and remove bearing.
Disassembly
1. Remove the through bolt.
Insert the tip of a pry bar into the gaps between the
front cover and the stator core.
Pry apart and separate the front cover, rotor, the rear
cover and stator.
NOTE: Take care not to scratch or otherwise damage the
stator coil with pry bar.
F06RT023
5. Remove the mounting nuts holding the B terminal,

the diode, and the brush holder.
6. Separate the rear cover from the stator.
F06RT021
2. Clamp the rotor in a vise and then remove the nut and
pulley.
3. Remove the rotor assembly from front cover.
F06RT024
F06RT022

7. Remove bolts which secure stator terminal to rectifier
terminal, and remove stator.

Rotor Assembly
1. Check the face of the slip rings for contamination and
roughness. If found to be scored, dress with a fine
sandpaper (#500 600). If found to be contaminated,
clean with a cloth saturated with alcohol.
2. Measure the outside diameter of the slip rings.
Standard: 27mm (1.06in)
Limit: 26mm (1.02in)
066RS030
8. Remove Bolts which secure regulator, rectifier and

brush-holder, and separate these parts.
NOTE: Do not apply a shock or load to regulator, rectifier
and brush holder.
066RS032

Standard: 3.75W or less
066RW025
066RS033

4. Check for continuity between slip ring and rotor core.
6D323
2. Check for continuity across one of the stator coils and

stator core. If a continuity exists, replace the coil.
Standard: More than 1MW
066RS017
066RS035
Stator Coil
1. Check for continuity across the stator coils. If no
continuity exists, replace the coils.
Resistance value at 20C.
Standard: Approx. 0.07W
Brush
066RS034
066RW024
Rectifier Assembly
1. Measure the resistance between each diode terminal
and aluminum diode fin in forward and reverse
directions with the connection of the tester leads
switched. The diodes are normal if resistance is
nearly zero ohms in one direction and is infinitely high
in the other direction.
2. If a diode has no resistance or equal resistance in
both directions, it is defective and should be replaced
together with the holder.
066RS036
IC Regulator Assembly
Connect a variable resistor, two 12V batteries, a fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.
a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms /3W
2. Variable resistor (Rv) : 0-300 Ohms/12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0-50V/0.5 steps (4 Check points)
b. Measuring procedure
1. Measure the voltage V1 across the first battery
(BAT1). If the reading is between 10 and 13 volts,
the battery is normal.
2. Measure the voltage V3 across both the batteries
(BAT1, BAT2). If the reading is between 20 and 26
bolts, the batteries are normal.
3. Gradually increase the resistance of the variable
resistor from zero. Measure the voltage V2 (the
voltage across the F and E terminals).
Check to see that the voltage across V1 changes at
this time. If there is no change, the voltage regulator
is faulty and must be replaced.
4. Measure the voltage at V4 (the voltage across the
variable resistor center tap and terminal E with the
variable resistor resistance held constant). The
measure voltage should be within the specified
(14.40.3 volts) limits. If it is not, the regulator must
be replaced.
066RX003
Reassembly
NOTE:
D Never make battery connections with polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.
D Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.
D Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery .
Diodes may be damaged due to abnormal pulse
voltage generated bye the quick charger.
D When reassembling the front section to rear section,
insert a stiff wire into hole in the rear face of the rear
cover from the outboard side to support the brush in
raised position, then insert the front section to which
rotor is assembled.
D Reassemble parts carefully to be sure they fit into
their original position, paying attention to the
insulated portions.
D Wipe insulating tubes, washers and plates clean and
install them in position carefully to avoid getting oil or
grease on them.

1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in the
front cover.
6D325
Bench Test
Conduct a bench test of the generator.
066RS023
066RS022

Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified torque.
Preparation
Remove generator from the vehicle (see Generator
removal).
1. Secure generator to the bench test equipment and
connect wires.
Terminal IG for energization
Terminal L for neutral (warning lamp)
Terminal B for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.
066RS010
066RX001

Battery voltage
12
Rated output
90
Clockwise
Rated rotation speed
rpm
5000
Maximum speed
rpm
18000
SECTION
6E21
FRONTERA
ENGINE
CONTENTS
Specification . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Specifications . . . . . . . . . . . . . . .
Diagrams and Schematics . . . . . . . . . . . . . . . .
PCM Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row B . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row C . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row D . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row E . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Row F . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locators . . . . . . . . . . . . . . . . . . . .
Engine Component Locator Table . . . . . . . .
Undercarriage Component Locator . . . . . .
Sensors and Miscellaneous Component
Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse and Relay Panel (Underhood Electrical
Center) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . .
No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . .
No Trouble Found . . . . . . . . . . . . . . . . . . . . .
General Service Information . . . . . . . . . . . . . .
Non-OEM Parts . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . .
Maitenance Schedule . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E25
6E25
6E26
6E26
6E27
6E28
6E29
6E210
6E211
6E212
6E213
6E214
6E214
6E215
6E216
6E217
6E218
6E219
6E220
6E220
6E221
6E221
6E222
6E224
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E225
6E226
6E226
6E226
6E226
Basic Knowledge of Tools Required . . . . . .

Seral Data Communications . . . . . . . . . . . . . .
Class II Serial Data Communications . . . . .
On-Board Diagnostic (OBD) . . . . . . . . . . . . . .
On-Board Diagnostic Tests . . . . . . . . . . . . .
Common OBD Terms . . . . . . . . . . . . . . . . . .
DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . .
the TECH 2 Scan Tool . . . . . . . . . . . . . . . . .
Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . .
Getting Started . . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure (For Example) . . . . .
DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Test . . . . . . . . . . . . . . . . . . . . . .
EGR Control Test . . . . . . . . . . . . . . . . . . . . . .
Variable Intake Manifold Solenoid Test . . .
Plotting Snapshot Graph . . . . . . . . . . . . . . . . .
Flow Chart for Snapshot Replay
(Plotting Graph) . . . . . . . . . . . . . . . . . . . . . . .
Primary System-Based Diagnostics . . . . . . . .
Primary System-Based Diagnostics . . . . . .
HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
A/C Clutch Control Circuit Diagnosis . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition System Diagnosis . . . . . . .
6E226
6E226
6E226
6E226
6E226
6E227
6E227
6E228
6E229
6E230
6E230
6E231
6E231
6E232
6E232
6E233
6E234
6E234
6E235
6E235
6E237
6E237
6E239
6E240
6E241
6E241
6E242
6E243
6E244
6E245
6E245
6E245
6E245
6E246
6E246
6E246
6E248
6E249
6E249
6E249
6E254
6E22
Visual Check of The Evaporative Emission

Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E254
Fuel Metering System Check . . . . . . . . . . . . . 6E254
Knock Sensor Diagnosis . . . . . . . . . . . . . . . . . 6E254
Powertrain Control Module (PCM) Diagnosis
6E254
Multiple PCM Information Sensor DTCS Set
6E254
Exhaust Gas Recirculation (EGR) Diagnosis
6E258
Engine Tech 2 Data Definitions and Ranges
6E258
Typical Scan Data Values . . . . . . . . . . . . . . . . 6E260
No Malfunction Indicator Lamp (MIL) . . . . . . .
6E265
Malfunction Indicator Lamp (MIL) ON
Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E268
Engine Cranks But Will Not Run . . . . . . . . . . . 6E271
Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . 6E279
Idle Air Control (IAC) System Check . . . . . . . 6E284
Knock Sensor (KS) System Check (Engine
Knock, Poor Performance, or Poor
Economy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E286
Exhaust Gas Recirculation (EGR) System
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E288
Manifold Absolute Pressure (MAP) Output
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E290
Evaporative (EVAP) Emissions Canister Purge
Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E292
PCM Diagnostic Trouble Codes . . . . . . . . . . .
6E295
Sensor Circuit Low Frequency . . . . . . . . . . . 6E2101
Sensor Circuit High Frequency . . . . . . . . . . . 6E2104
Sensor Circuit Hight Voltage . . . . . . . . . . . . . 6E2109
Sensor Circuit High Voltage . . . . . . . . . . . . . 6E2130

Trim System Too Lean Bank 1 . . . . . . . . . . . . 6E2151
Trim System Lean Bank 2 . . . . . . . . . . . . . . . 6E2159
Module Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2185
Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2187
Diagnostic Trouble Code (DTC) P0336 58X
Reference Signal Circuit . . . . . . . . . . . . . . . . . 6E2190
Diagnostic Trouble Code (DTC) P0337 CKP
Sensor Circuit Low Frequency . . . . . . . . . . . . 6E2192
Sensor Circuit Performamce . . . . . . . . . . . . . 6E2195
Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . 6E2198
Open Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2220
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2222
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2225

Diagnostic Trouble Code (DTC) P0502 VSS
Circuit Low Input . . . . . . . . . . . . . . . . . . . . . . . . 6E2228
Diagnositc Troule Code (DTC) P0562 System
Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2231
Diagnostic Trouble Code (DTC) P0563 System
Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2233
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2234
System Lean Dueing Acceleration . . . . . . . . 6E2235
Rough Road ABS System Fault . . . . . . . . . . 6E2238
Rough Road Class 2 Serial Link Error . . . . . 6E2239
Stuck Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2240
System Low RPM . . . . . . . . . . . . . . . . . . . . . . . 6E2242
System High RPM . . . . . . . . . . . . . . . . . . . . . . 6E2245
Unexpected Reset . . . . . . . . . . . . . . . . . . . . . . 6E2248
Diagnostic Trouble Code (DTC) P1640 Output
Driver Module (ODM) A Fault . . . . . . . . . . . 6E2249
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 6E2251
Default Matrix Table . . . . . . . . . . . . . . . . . . . . . 6E2276
On-Vehicle Service Camshaft Position (CMP)
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2279
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2280
Engine Coolant Temperature (ECT) Sensor . 6E2280
Heated Oxygen Sensor (HO2S) . . . . . . . . . . . 6E2281
Intake Air Temperature (IAT) Sensor . . . . . . . 6E2283
Knock Sensor (KS) . . . . . . . . . . . . . . . . . . . . . . 6E2284
Mass Air Flow (MAF) Sensor . . . . . . . . . . . . . 6E2285
Manifold Absolute Pressure (MAP) Sensor . 6E2285
Malfunction Indicator Lamp (MIL) . . . . . . . . . . 6E2286
Powertrain Control Module (PCM) . . . . . . . . . 6E2286
EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2288
Throttle Position (TP) Sensor . . . . . . . . . . . . . 6E2288
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . 6E2288
Air Cleaner/Air Filter . . . . . . . . . . . . . . . . . . . . . 6E2290
Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6E2292
Accelerator Cable Assembly . . . . . . . . . . . . . . 6E2292
Accelerator Pedal Replacement . . . . . . . . . . . 6E2295
Fuel Fillter Cap . . . . . . . . . . . . . . . . . . . . . . . . . 6E2297
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2297
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . 6E2300
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2300
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . 6E2301
Fuel Metering System . . . . . . . . . . . . . . . . . . . . 6E2303
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . 6E2303
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . 6E2304
Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . 6E2304
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body (TB) . . . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition System . . . . . . . . . . . . . . . .
Catalytic Converter . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Purge Solenoid . . . . . . . . . . . .
Fuel Tank Vent Valve . . . . . . . . . . . . . . . . . . . .
Linear Exhaust Gas
Positive Crankcase Ventilation (PCV) Valve .
PCM Connectors and Terminals . . . . . . . . . . .
Wire Harness Repair: Twisted Shielded Cable
Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . .
Weather-Pack Connector . . . . . . . . . . . . . . . . .
Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (PCM and Sensors) . . .
58X Reference PCM Input . . . . . . . . . . . . . .
Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . .
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mass Air Flow (MAF) Sensor . . . . . . . . . . . .
PCM Function . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Components . . . . . . . . . . . . . . . . . . . . .
PCM Voltage Description . . . . . . . . . . . . . . .
PCM Input/Outputs . . . . . . . . . . . . . . . . . . . .
PCM Service Precautions . . . . . . . . . . . . . .
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upshift Lamp . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (Air Induction) . . . . . . . .
Air Induction System . . . . . . . . . . . . . . . . . . .
General Description (Fuel Metering) . . . . . . .
6E23
6E2305
6E2305
6E2307
6E2308
6E2308
6E2308
6E2308
6E2310
6E2311
6E2311
6E2312
6E2313
6E2313
6E2313
6E2314
6E2315
6E2317
6E2317
6E2318
6E2318
6E2318
6E2318
6E2318
6E2318
6E2318
6E2318
6E2319
6E2319
6E2320
6E2320
6E2320
6E2321
6E2321
6E2321
6E2321
6E2321
6E2322
6E2322
6E2322
6E2322
6E2322
6E2323
6E2323
6E2323
6E2323
6E2323
6E2323
6E2324
6E24
CMP Signal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Flood Mode . . . . . . . . . . . . . . . . . . . . .
Deceleration Mode . . . . . . . . . . . . . . . . . . . .
Engine Speed/Vehicle Speed/Fuel
Disable Mode . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (Electronic Ignition
System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Position (CMP) Sensor . . . . . . . .
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . .
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2324
6E2325
6E2325
6E2325
6E2325
6E2326
6E2326
6E2326
6E2326
6E2327
6E2327
6E2327
6E2327
6E2327
6E2327
Ignition Control PCM Output . . . . . . . . . . . .

Knock Sensor (KS) PCM Input . . . . . . . . . .
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . . .
General Description (Evaporative (EVAP)
Emission System) . . . . . . . . . . . . . . . . . . . . . .
Recirculation (EGR) System) . . . . . . . . . . . . .
EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . .
Linear EGR Valve . . . . . . . . . . . . . . . . . . . . .
of Incorrect Operation . . . . . . . . . . . . . . . . .
General Description (Positive Crankcase
Ventilation (PCV) System) . . . . . . . . . . . . . . .
Crankcase Ventilation System Operation .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E2328
6E2329
6E2329
6E2329
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2331
6E2332
6E2332
6E2332
6E2332
6E2332
6E2332
6E2333
6E2334
6E25
Specification
Tightening Specifications
Application
Nm
kgm
Lb Ft.
Lb In.
Camshaft Position Sensor Retaining Screw
0.9
78
0.9
78
EGR Bolt
14
1.4
122
EGR Nut
14
1.4
122
30
3.1
22
6.5
0.65
56
Fuel Rail Bolts
25
2.5
18
36
3.7
27
42
4.3
32
Lower Intake Manifold to Engine Block Bolts
25
2.5
18
Fuel Drain Plug
29
3.0
22
Lower Intake Manifold to Engine Block Nuts
25
2.5
18
Spark Plugs
18
1.8
13
13
1.3
113
Upper Intake Manifold to Lower Intake Manifold Bolts
25
2.5
18
VSS Retaining Bolt
13
1.3
113
6E26
Diagrams and Schematics

D06RX128
6E27
D06RX003
6E28
D06RX146
6E29
D06RX129
6E210
D06RX130
6E211
D06RX131
6E212
D06RX132
6E213
D06RX133
6E214
.PCM Pinouts
PCM Pinout Table, 32-Way Red Connector Row A
TS23344
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
A1
5 Volt Reference A
A2
Knock Sensor
A3
Not Used
A4
Battery Feed (ECM Fuse)
RED/WHT
A5

High
A6
Refer To
RED
5.0 V
5.0 V
Appropriate Sensor
YEL
0.0 V
0.0 V

B+
B+
BLU
B+/0.8 V
B+/0.8 V

Operation, IAC
IAC A Low
BLU/WHT
B+/0.8 V
B+/0.8 V

Operation, IAC
A7
IAC B Low
BLU/BLK
B+/0.8 V
B+/0.8 V

Operation, IAC
A8
IAC B High
BLU/RED
B+/0.8 V
B+/0.8 V

Operation, IAC
A9
Fluid (ATF) Lamp
ORN/BLK
B+
B+
(4L30E)
A10
Winter Lamp
PNK/GRN
B+
B+
(4L30E)
A11
Power Lamp
PNK/WHT
B+
B+
(4L30E)
A12
Not Used
A13
(Check Engine or MIL)
Lamp
WHT/GRN
0.0 V
B+
Chassis Electrical
A14
Check Transmission
Lamp Driver
VIO
B+
B+
Chassis Electrical
A15
EVAP Canister Purge

Signal
RED/BLU
B+
5.7 V
A16
Band Apply
YEL/BLK
B+
B+
Chassis Electrical

Control System
(4L30E)
6E215
PCM Pinout Table, 32-Way Red Connector Row B
TS23344
PIN
PIN Function
B1
5 Volt Reference B
B2
Wire Color
IGN ON
ENG RUN
Refer To
BLU/ORN
5.0 V
5.0 V
Appropriate Sensor
Ignition coil #4
RED/WHT
0.0 V
0.1 V

Operation, ICM
B3
Ignition coil #2
RED/BLK
0.0 V
0.1 V

Operation, ICM
B4
Ignition coil #6
RED/GRN
0.0 V
0.1 V

Operation, ICM
B5
Not Used
B6
Not Used
B7

(EGR)
YEL/RED
0.6 V
0.6 V

Control
B8

(IAT) Sensor
YEL/GRN
3 V
(depends on
temperature)
3 V
(depends on
temperature)

Operation, IAT
B9
Not Used
B10
Not Used
B11

(PSP) Switch
GRN/YEL
B+
B+

Operation, PSP
B12
Illuminated Switch
GRN/YEL
B+
B+
Chassis Electrical
B13
Class 2 Data
ORN/BLK
0.0 V
0.0 V
B14
A/C Clutch
GRY/RED
B+ (A/C
OFF)
B+ (A/C
OFF)

Operation
B15
Not Used
B16
Not Used

Data
6E216
PCM Pinout Table, 32-Way White Connector Row C
TS23345
PIN
PIN Function
C1
C2
IGN ON
ENG RUN
GRN/RED
B+
B+

Shift B Solenoid
BRN/BLK
0.0 V
0.0 V
(4L30E)
C3
GRN/YEL
B+
B+

C4
Ignition Control (IC)

Cylinder #1
RED
0.0 V
0.1 V

C5
Crankshaft Position
Sensor, A Circuit
YEL
0.3 V
2.2 V

Position Sensor
C6
Not Used
C7
PCM Ground
BLK/WHT
0.0 V
0.0 V
Chassis Electrical
C8
PCM Ground
BLK/RED
0.0 V
0.0 V
Chassis Electrical
C9
PCM Ground
BLK/BLU
0.0 V
0.0 V
Chassis Electrical
C10
Tachometer
BLK/RED
8.8 V
10.0 (at idle)
Chassis Electrical
C11
Variable Intake Manifold
WHT/BLU
0.0 V
0, B+ (More
than 3600
rpm)
Manual Transmission
C12
Rear Defogger Relay
RED/WHT
B+
B+
C13
Wire Color
Not Used
Refer To
Chassis Electrical
C14
Bank 2 HO2S 1 High
WHT
0.3 V
0.0-0.8 V

C15
Bank 2 HO2S 1 Low
RED
0.0 V
0.1 V

C16
Not Used
6E217
PCM Pinout Table, 32-Way White Connector Row D
TS23345
PIN
PIN Function
D1
D2
Wire Color
IGN ON
ENG RUN
GRN/ORN
B+
B+
Torque Converter Clutch

(TCC)
RED/YEL
0.0 V
0.0 V
D3
GRN/WHT
B+
B+
D4
Serial Data (8192)
RED
5.0 V
5.0 V
Chassis Electrical
D5

#5
RED/YEL
0.0 V
0.1 V

Operation, Ignition Control
Module
D6

#3
RED/BLU
0.0 V
0.1 V

Operation
D7
Speedometer
BLU/BLK
0.0 V
0.1 V (at
rest)
D8
Sensor Ground 5V
Reference A Return
GRN
0.0 V
0.0 V
Appropriate Sensor
D9
Sensor Ground 5 V
Reference B Return
GRN
0.0 V
0.0 V
Appropriate Sensor
D10
Mass Air Flow (MAF)
YEL
4.9 V
4.2 V
General Description, Mass

Air Flow Sensor
D11
BLU
5.0 V
4.6 V

Operation, Camshaft
Position Sensor
D12
Not Used
D13
Not Used
D14
Bank 1 HO2S 1 Low
BLU
0.0 V
0.1 V

D15
Bank 1 HO2S 1 High
PNK
0.3 V
0.0-0.8 V

D16
Not Used
Refer To
On-Vehicle Service, Torque
Converter Clutch
Chassis Electrical
6E218
PCM Pinout Table, 32-Way Blue Connector Row E
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
E1

Signal
YEL
0.0 V
0.1 V
(4L30E)
E2

Low
BRN
0.0 V
0.0 V
(4L30E)
E3

Low
RED/GRN
0.0 V
0.0 V
(4L30E)
E4

High
RED/BLK
0.0 V
0.0 V
(4L30E)
E5

(EGR) Ignition
BLK/YEL
B+
B+

E6

(EGR) Solenoid
YEL
B+
B+

E7
Transmission Range
Signal B
PNK
0.0 V
0.0 V
(4L30E)
E8

Sensor
BLU
0.6 V
0.6 V (at
idle)

Sensor
E9
Engine Coolant
Temperature (ECT)
Sensor
BLU/RED
2.3 V
2.1 V

E10
Not Used
E11

Sensor +5 Volt Reference
BRN
5.0 V
5.0 V

Position Sensor
E12
Transmission Range
Signal A
PNK/BLU
B+
B+
(4L30E)
E13
PNK/WHT
0.0 V
B+
On-Vehicle Service, Fuel

Pump Relay
E14
Shift High (BAND APPLY)
BRN/WHT
B+
B+
(4L30E)
E15
A/C Request
GRN/BLK
0.0 V
0.0 V
E16
Ignition Feed (1 of 2 F16)
RED/BLU
B+
B+
6E219
PCM Pinout Table, 32-Way Blue Connector Row F
TS23346
PIN
PIN Function
Wire Color
IGN ON
ENG RUN
Refer To
F1
Not Used
F2
Transmission Range
Signal C
BLU/WHT
0.0 V
0.0 V
(4L30E)
F3
Transmission Range
Signal P
PNK/BLK
B+
B+
(4L30E)
F4
Brake Switch
RED
0.0 V
0.0 V
(4L30E)
F5
Power Switch
VIO
B+
B+
(4L30E)
F6
Winter Switch
VIO
B+
B+
(4L30E)
F7
Transmission Fluid
Temperature
GRN/RED
2.2 V
1.1 V
(4L30E)
F8
Manifold Absolute
Pressure (MAP)
GRY
4.7 V
1.1 V

Pressure
F9
YEL/GRN
B+
B+
Chassis Electrical
F10
Cruise Control
GRY/BLU
B+
B+
(4L30E)
F11
Kickdown Switch
LT BLU
B+
B+
(4L30E)
F12
Diag
B+
B+
F13
GRN
B+
B+

F14
Shift A Solenoid
YEL/GRN
B+
B+
(4L30E)
F15
GRN/BLK
B+
B+

F16
Ignition Feed (1 of 2 E16)
RED/BLU
B+
B+
ORN/BLU
6E220
Component Locators
Engine Component Locator
515RW017

Number
Name
Location
Crank Position (CKP) Sensor
Lower right side of the cylinder block
Rear right of the engine
Knock Sensor
Right hand side between right bank and left bank

of the cylinder block
Bolted to the top the upper intake manifold
Common Chamber
Top of the engine
EVAP Canister Purge Valve
Bolted to the front of the coolant pipe
Rear right side of the engine
Injection Coil
Top of the cylinder engine
Air Cleaner
10
Attached to the air filter box
11
On the rear side of the left cylinder head cover
12
On the intake air dukt near the throttle body
13
On the right of the throttle body
14
On the coolant crossover pipe at the front of the

engine,near the throttle body
15
On the left of the throttle body
16
Positive Crankcase Ventilator (PCV) Valve
On the left of the cylinder head
17
Fuse/Relay Box
6E221
Undercarriage Component Locator
014RW188

Number
Name
Location
Threated into the exhaust pipe ahead the

lefthand catalytic convertor
Fuel Filter
Located along the inside of the right frame

rail,ahead of the propeller shaft
Fuel Gauge Unit
Evaporative (EVAP) Canister
On the top of the bracket that is located behind

of the cross member
Protrudes from the transmission housing, just

ahead of the fuel tank
Threated into the exhaust pipe ahead

therighthand catalytic convertor
6E222
Sensors and Miscellaneous Component Locators
150RX023
060RW111
014RW141
055RW003
T321067
041RW013
6E223
025RW008
060RW007
T321078
028RW001
6E224
Fuse and Relay Panel (Underhood Electrical Center)
755RX033
Diagnosis
The strategy-based diagnostic is a uniform approach to
check(s).
system. This will lead the technician in an
organized approach to diagnostics.
DTC Stored
effective repair.
No DTC
No Matching Symptom
operation.
Intermittents
following steps:
1. Observe history DTCs, DTC modes, and freezeframe
data.
by the customer.
6E225

Most scan tools, such as the Tech 2, have data-capturing
capabilities that can assist in detecting intermittents.
No Trouble Found
1. Re-examine the complaint.
isolated, a re-evaluation is necessary. The complaint
should be re-verified and could be intermittent as
Frame data.

diagnosed (Freeze Frame data will only be stored for
General Service Information

Non-OEM Parts
All of the OBD II diagnostics have been calibrated to run
with OEM parts.
Something as simple as a
high-performance exhaust system that affects exhaust
6E226

and anti-theft devices, may radiate EMI into the control
lamp).
Environment
If the ignition system is rain-soaked, it can temporarily
lamp).

schematic.
replaced. It can be ordered from Isuzu Dealer ship.
Maitenance Schedule

Inspection
Perform a careful
visual and physical engine
disconnections, and proper routing.
components.
manifolds or pipes.
Basic Knowledge of Tools Required

A basic understanding of hand tools is necessary to effectively use this section of the Service Manual.
Seral Data Communications

system.
This vehicle utilizes the Class II
communication system. Each bit of information can have
one of two lengths: long or short. This allows vehicle
wiring to be reduced by transmitting and receiving
multiple signals over a single wire. The messages carried
on Class II data streams are also prioritized. If two
messages attempt to establish communications on the
data line at the same time, only the message with higher
priority will continue. The device with the lower priority
message must wait. The most significant result of this
regulation is that it provides Tech 2 manufacturers with
the capability to access data from any make or model
vehicle that is sold.
same, with some exceptions. Some scan tools will only
On-Board Diagnostic (OBD)

On-Board Diagnostic Tests
a pass or fail reported to the diagnostic executive. When
a diagnostic test reports a pass result, the diagnostic
ignition cycle.
ignition cycle.
currently active.
ignition cycle.
active.

Input Components:
out-of-range values. This includes rationality checking.
signal from a sensor does not seem reasonable,
i.e.Throttle Position (TP) sensor that indicates high
throttle position at low engine loads or MAP voltage. Input
following sensors:
D Crankshaft Position (CKP) Sensor
D Knock Sensor (KS)
D Throttle Position (TP) Sensor
D Engine Coolant Temperature (ECT) Sensor
D Camshaft Position (CMP) Sensor
D Manifold Absolute Pressure (MAP) Sensor
D Mass Air Flow (MAF) Sensor
steady state temperature to enable closed loop fuel
control.
Output Components:
control module commands.
Components where
circuit continuity and out-of-range values if applicable.
limited to, the following circuit:
D Control module controlled EVAP Canister Purge
Valve
D Electronic Transmission controls
D A/C relays
D VSS output
D MIL control
Refer to PCM and Sensors in General Descriptions.
pressure.
This is any on-board test run by the Diagnostic
6E227
Warm-Up Cycle
A warm-up cycle means that engine at temperature must
Freeze Frame
information at the moment an emissions-related fault is
Failure Records
Failure Records data is an enhancement of the OBD II
Freeze Frame feature.Failure Records store the same
that information for any fault which is stored in on-board
emission-related faults that command the MIL on.
Common OBD Terms

Diagnostic
on-board test run by the vehicles Diagnostic
D Oxygen sensors
D EGR
Enable Criteria
D engine speed
D vehicle speed
D ECT
D MAF/MAP
D IAT
D TP
D TCC enabled
D A/C on
6E228
Trip
Technically, a trip is a key on-run-key off cycle in which all
definition of trip varies as well. Some diagnostic are run
the vehicle is idle; some diagnostics function with the
TCC disables. Some run only immediately following a
cold engine start-up.
A trip then, is defined as a key on-run-key off cycle in

follows:
D Commanding the MIL (Check Engine lamp) on and
off
recorded
D Non-emission related Service Lamp (future)
The Diagnostic Executive records DTCs and turns on the
MIL when emission-related faults occur. It can also turn
off the MIL if the conditions cease which caused the DTC
to set.
present.
There is a continuous self-diagnosis on certain control

functions. This diagnostic capability is complemented by
illuminated.
Basically, the MIL is turned on when the PCM detects a
The MIL will be turned on if an emissions-related
will stay on until the system or component passes the
same test, for three consecutive trips, with no emission
srelated faults.
When the MIL is on, the Diagnostic Executive will turn off
the MIL after three(3) consecutive trips that a test
Although the MIL has been turned off, the DTC will remain
in the PCM memory (both Freeze Frame and Failure
Records) until forty(40) warm-up cycles after no faults
have been completed.
If the MIL was set by either a fuel trim or misfire-related
test failed.
was stored at the time the last failed.
warming up ) as those stored at the time the last test
failed.
The MIL (Check Engine lamp) is on the instrument
panel and has the following functions:
with the key ON and the engine not running. When
the engine is started, the MIL will turn OFF.
On-Board Diagnostic (OBD) System Check must be
given in On-Board Diagnostic (OBD) System Check.
DTC Types
D Type A
D Emissions related
fail
test fails
D Type B
D Emissions related
test fails
DTCs)
D Stores a History DTC on thefirst trip with a fail
test fails
D Type D (Type D non-emissions related are not utilized
on certain vehicle applications).
D Dose not request illumination of any lamp
test fails
6E229
Only four Fail Records can be stored. Each Fail Record

is for a different DTC. It is possible that there will not be
Fail Records for every DTC if multiple DTCs are set.
Records
D Air Fuel Ratio
D Air Flow Rate
D Engine Speed
D Engine Load
D Vehicle Speed
D TP
D MAP/BARO
D Loop Status
malfunction.
The provision for communication with the contorl module
is the Data Link Connector (DLC). It is located at the
lower left of the instrument panel. The DLC is used to
connect to the Tech 2 Scan Tool. Some common uses of
the Tech 2 are listed below:
D Identifying stored Diagnostic Trouble Codes (DTCs).
D Clearing DTCs.
D Performing out put control tests.
6E230
D Reading serial data.

diagnostic Scan Tool clear DTCs or clear information
function.
When clearing DTCs follow instructions
power.
fuse, pigtail at battery PCM connectors etc.
on-board memory data, such as preset radio tuning).
TS24064

for vehicles with OBD II system diagnostic. Following a
requested).
2. Clear DTC(s).

the TECH 2 Scan Tool
use a diagnostic Scan Tool. When reading DTC(s), follow
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech 2.
count the warm-up cycles with no further faults
PCM memory.
6E231
Tech 2
recommended to use the Tech 2 Scan Tool. Please refer
to the Tech 2 user guide.
901RW180
Legend
(1) PCMCIA Card
Tech 2 Features

(4) DLC Cable
(5) Tech2

snapshot.
6E232

Getting Started
Operating Procedure (For Example)

tester with the Isuzu systems PCMCIA card. Follow the

the Tech 2 (5).
(4).
DLC.
810RW317

display.
060RY027
060RW009

diagnosis of Tech 2. Refer to user guide of the Tech 2.
6E233
Menu
060RW224
DTC Modes
060RX086
060RW229
6E234

appears:
D DTC Info
D Freeze Frame
D Clear Info
060RW223


service procedures.
DTC Status
Fail This Ignition
History
PCMs history memory. It will display all type A and B
warm-up cycles.
Last Test Failed
last time the test ran. The last test may have run during a
unknown.
Miscellaneous Test
060RW221

normality of electric circuit.
3. Refer to the latest Service Bulletin.
Check to see if the Latest software is released or not.
And then Down Load the LATEST PROGRAMMED
SOFTWARE to the replacement PCM.
6E235
Lamps Test
its working.
Test Procedure:
Menu.
060RX019

F1: Low Fuel Lamp is not used.
Relays Test
060RW228
This test is conducted to check Fuel Pump Relay and A/C

Clutch for proper operation.
Test Procedure:
Menu.
060RX035
060RW228
6E236
060RX034
060RX022
7. Control Fuel Pump Relay and check data list.

8. If the data list changes, the Fuel Pump Relay is
normal.
060RX021
060RX023
12. Push On and Off soft keys.

13. Control A/C Clutch Relay and check data list.
normal.
6E237
EVAP Test
Test Procedure:
Menu.
060RX025
060RW228
060RX026
7. Control EVAP Purge Solenoid and check data list.

8. If the data list changes, the Purge Solenoid is normal.
F1: Vent Solenoid is not used.

060RX036
This test is conducted to check IAC system for proper

operation.
Test Procedure:
6E238

Menu.
060RW235
060RW228

Test.

7. Instruct IAC system and check data list.
060RX015
060RX007
8. If the data list changes, the IAC control is normal.

9. Select F0: RPM Control Test
6E239
Fuel System Test

operation.
Test Procedure:
Menu.
060RX016

11. Control RPM and check data list.
12. If the data list changes, the RPM control is normal.
060RW228
060RW2311
060RX032
6E240

Menu.
060RX028
F1: Fuel Gauge Level is not used.

6. Push Reset soft key.
060RW228

Test.
060RX029
060RX008
EGR Control Test

operation.
Test Procedure:

6E241
4. Select F6: Variable Intake Manifold Solenoid Test.
060RX017
6. If data list chouges, the EGR Control is normal.
060RX033
5. Push On or Off soft key.
Variable Intake Manifold Solenoid Test

This test is conducted check VIM Solenoid for proper
operation.
Test Procedure:
Menu.
060RX028
6. Control VIM Solenoid and check data list.

7. If data list changes, the VIM Solenoid is normal.
060RW228

Test Procedure:
6E242

Menu.

key.
060RW228

Test.
060RW2301

normal.
If engine speed does not changes, the injector electric

060RX006
060RX037

snapshot data as needed. Therefore, accurate diagnosis
6E243
060RX085
6E244
060RX040

There are primary system-based diagnostics which
emissions. The primary system-based diagnostics are
function:
and Bank 2 HO2S 1) are diagnosed for the following
conditions:
D Slow response
approx. 450 mV)
D Signal fixed high
D Signal fixed low
Refer to On-Vehicle Service Heated Oxygen Sensors.

sensors while in closed loop to adjust fuel injector pulse
width. While in closed loop, the PCM can adjust fuel
delivery to maintain an air/fuel ratio which allows the best
combination of emission control and driveability. The fuel
control heated oxygen sensors are also used to
HO2S Heater
of time required for closed loop fuel control to begin
time required for fuel control sensors (Bank 1 HO2S 1 and
Bank2 HO2S 1) to become active.
6E245
6E246
D06RX010
Circuit Description
Test Description
The on-board diagnostic system check is the starting

check of the PCM and engine grounds for cleanliness and
tightness.
The on-board diagnostic system check is an organized

Diagnostic Chart:
the No MIL chart should be used to isolate the
malfunction.
PCM is able to transmit serial data.
3. This test ensures that the PCM is capable of
controlling the MIL (Check Engine lamp) and the
MIL (Check Engine lamp) driver circuit is not
shorted to ground.
the problem.
Diagnostic Aids
harness. Inspect the PCM harness and connector for
6E247
On- Board Diagnostic (OBD) System Check

Step
Action
1.
2.
3.
4.
Go to Step 8
Go to Step 4
Go to MIL
(Check
Engine lamp)
On Steady
Go to Step 5
Go to Cranks
But Will Not
Run
Go to Step 6
Go to Step 7
Go to
Multiple
PCM
Information
Sensor DTCs
Set
Go to
applicable
DTC table
Go to
Symptom
Refer to
indicated
Component
System
Checks
Go to Step 2
Go to Step 9
Go to Step 2
Compare PCM data values displayed on the Tech 2 to


and the DLC ground circuit for an open.
Go to Step 3

P0108, P0113, P0118, P0122, P0123, P0712, P1404.

values?
8

Go to Step 2

Go to No MIL
(Check
Engine lamp)

(Check Engine lamp) dash lamp control and
command the MIL (Check Engine lamp) OFF.
2. Observe the MIL (Check Engine lamp).
Did the MIL (Check Engine lamp) turn OFF?
No
Ignition OFF.
Install Tech 2.
Ignition ON.
Attempt to display PCM engine data with the Tech 2.
Does the Tech 2 display PCM data?

3
Yes

Check Engine lamp).
Is the MIL (Check Engine lamp)ON?
Value(s)
Replace the PCM.

6E248
D06RX011
6E249
Circuit Description

the system has a sufficient refrigerant charge, a 12-volt
signal is supplied to the A/C request input of the
powertrain control module (PCM). The A/C request
signal may be temporarily canceled during system
operation by the electronic thermostat in the evaporator
case. The electronic thermostat may intermittently
remove the control circuit ground for the A/C thermostat
relay to prevent the evaporator from forming ice. When
the A/C request signal is received by the PCM, the PCM
supplies a ground from the compressor clutch relay if the
engine operating conditions are within acceptable
ranges. With the A/C compressor relay energized,
voltage is supplied to the compressor clutch coil.
The PCM will enable the compressor clutch to engage
than 125 C (257 F).
(41F).
pressure condition.

ability to read the A/C request input to the PCM. The Tech
2 can display when the PCM has commanded the A/C
clutch ON. The Tech 2 should have the ability to
override the A/C request signal and energize the A/C
compressor relay.
Diagnostic Aids
conditions:
D Poor connection at the PCMInspect connections for
backed-out terminals, improper mating, broken locks,
D Damaged harnessInspect the wiring harness for
damage. If the harness appears to OK, observe the
A/C clutch while moving connectors and wiring
harnesses related to the A/C. A sudden clutch
malfunction will indicate the source of the intermittent
fault.
Test Description
IMPORTANT: Do not engage the A/C compressor
clutch with the engine running if an A/C mode is not
selected at the A/C control switch.
Diagnostic Chart:
3. This a test determine is the problem is with the
refrigerant system. If the switch is open, A/C
pressure gauges will be used to determine if the
pressure switch is faulty or if the system is partially
discharged or empty.
4. Although the normal complaint will be the A/C clutch
failing to engage, it is possible for a short circuit to
cause the clutch to run when A/C has not been
selected. This step is a test for that condition.
7. There is an extremely low probability that both relays
will fail at the same time, so the substitution process
is one way to check the A/C Thermostat relay. Use
a known good relay to do a substitution check.
9. The blower system furnishes a ground for the A/C
control circuit, and it also shares a power source
through the Heater and A/C Relay. The blower
must be ON in order to test the A/C system.

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to the
other DTC
chart(s) first
Go to Step 3
Go to Air
Conditioning
to diagnose
the cause of
the open
pressure
switch
Go to Step 4

performed?
Are any other DTCs stored?
1. Disconnect the electrical connector at the pressure

switch located on the receiver/drier.
2. Use an ohmmeter to check continuity across the
pressure switch (BRN to GRN/WHT).
Is the pressure switch open?
6E250

Step
Action
Value(s)
Yes
No
IMPORTANT: Before continuing with the diagnosis, the

following conditions must be met:
D The intake air temperature must be greater than
15C. (60F).
D The engine coolant temperature must be less
than 119C (246F).
1. A/C OFF.
2. Start the engine and idle for 1 minute.
3. Observe the A/C compressor.
Is the A/C compressor clutch engaged even though
A/C has not been requested?
Go to Step 45
Go to Step 5
Refer to
Diagnostic
Aids
Go to Step 6
Go to Step 34
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Dose the blower operate?
Go to Step 10
Go to Step 11
10
Repair the blower.
Verify repair
Go to Step 13
Go to Step 12
Verify repair
B+
Go to Step 15
Go to Step 14
Verify repair
1.
2.
3.
4.
Idle the engine.

A/C ON.
Blower ON.
Observe the A/C compressor.
Is the A/C compressor magnetic clutch engaged?

6
1.
2.
3.
4.
Engine idling.
A/C ON.
Blower ON.
Observe the A/C Request display on the Tech 2.
(Refer to the miscelluneous test)
Does the A/C Request display indicate Yes?

7
Temporarily substitute the A/C compressor relay in

place of the A/C thermostat relay, then repeat Step 5.
Did the A/C Request display indicate Yes?
Replace the original A/C thermostat relay.

11
Check for a faulty 10A A/C fuse in the passenger

compartment fuse panel.
Was the 10A fuse OK?
12
Check for short circuit and make repairs if necessary.

Replace the 10A A/C fuse.
13
1. Ignition ON.
2. Use a DVM to check voltage at the positive A/C
switch wire (BRN).
14
Repair the open wire (BRN) between the A/C switch

and the A/C fuse.
6E251

Step
Action
15
1. Remove the glove box to gain access to the A/C

thermostat.
2. Disconnect the thermostat connector.
3. Attach a fused jumper between ground and the
GRN/RED wire at the thermostat.
4. A/C ON.
5. Blower ON.
Dose A/C request indicate YES on the Tech 2?
16
Go to Step 19
Verify repair
Verify repair
Go to Step 21
Go to Step 22
Verify repair
Verify repair
Go to Step 24
Go to Step 25
Verify repair
Go to Step 26
Go to Step 27
Verify repair
B+
Go to Step 29
Go to Step 28
Repair the open circuit between the engine device fuse

27
Go to Step 18
Check for an open circuit between the engine device

fuse and the A/C thermostat relay (WHT/GRN).
26
Repair the open circuit between the PCM and A/C

thermostat relay.
25
Go to Step 17
Check for an open circuit between A/C thermostat relay

and PCM A/C request terminal (E-15).
24
Go to Step 20
Replace the electronic A/C thermostat.

Is the an action complete?
23
B+
Repair the open wire (WHT) between the thermostat

and the blower switch.
22
Go to Step 23

electronic A/C thermostat and the blower switch.
21
Go to Step 16
Replace the A/C switch.

20
Repair the open wire (LT GRN/BLK) between the

19
No
Check for an open (LT GRN/BLK) wire between the

Was the wire open?
18
Yes
1. Ignition ON.
2. A/C switch ON.
3. Use a DVM to check voltage at the electronic A/C
thermostat.
17
Value(s)
1. Ignition ON.
2. Use a DVM to check voltage at the A/C pressure
switch (BRN).
6E252

Step
Action
28
Repair the open circuit between the 10A A/C fuse and
the pressure switch.
29
1.
2.
3.
4.
5.
Verify repair
Go to Step 32
Go to Step 33
Verify repair
Verify repair
B+
Go to Step 36
Go to Step 35
Verify repair
B+
Go to Step 40
Go to Step 37
Go to Step 38
Go to Step 39
Verify repair
Go to Step 32
Go to Step 33
Repair the open GRY/RED wire between the PCM and

the A/C compressor relay.
39
Check for an open GRY/RED wire between PCM

terminal B-14 and the A/C compressor relay.
Was the wire open?
38
Go to Step 31
A/C compressor relay removed.

Engine idling.
A/C ON.
Blower ON.
Use a DVM to measure voltage between the
GRY/RED wire at the A/C compressor relay socket
and battery+.

37
Go to Step 30
Repair the faulty BRN wire between the A/C fuse and
the A/C compressor relay .
36

2. Ignition ON.
3. Use a DVM to check voltage at both of the BRN
wires at the A/C compressor relay socket.
Is the voltage equal to the specified value?
35
Replace the PCM.

34
Verify repair

33
Check for damaged pin or terminal at E-15 of the PCM.

Was a damaged pin or terminal found?
32
No
Repair the open circuit between the pressure switch

31
Yes

pressure switch (GRN/WHT) and the A/C thermostat
relay (GRN/WHT).
Was the circuit open?
30
Value(s)
Check for a damaged pin or terminal at B-14 of the

PCM.
Was a damaged pin or a terminal found?
6E253

Step
Action
40
1. A/C compressor relay removed.

2. Connect a fused jumper at the A/C compressor
relay socket between either BRN wire and the
BRN/YEL wire.
3. Engine idling.
4. A/C ON.
5. Blower ON.
Did the compressor magnetic clutch engage?
41
Go to Step 43
Go to Step 44
Verify repair
Verify repair
Go to Step 46
Go to Step 47
Verify repair
Go to Step 48
Go to Step 50
Go to Step 49
Go to Step 33
Verify repair
Verify repair
Repair the short to ground between the PCM and A/C

compressor relay.
50
Use a DVM to check for a short to ground between the

A/C compressor relay and B-14 of the PCM.
Was a short detected?
49
Verify repair
1. Reinstall the A/C compressor relay.

2. Remove the A/C thermostat relay.
3. Engine idling.
selected?
48
Repair the short to voltage between the A/C clutch and

A/C compressor relay.
47
Go to Step 42

2. Idle the engine.
selected?
46
Go to Step 41
Service the compressor clutch or replace the

compressor due to a faulty internal overheat switch.
45
Repair the open circuit between the compressor Clutch

and the A/C compressor relay.
44
No
Check for an open circuit between the A/C compressor

relay and the A/C clutch.
Was an open circuit found?
43
Yes
Repair the A/C compressor relay.

42
Value(s)
Repair the short to ground between the A/C thermostat

relay and the electronic thermostat.
6E254
Electronic Ignition System Diagnosis

to determine if the failure is the ignition system or the fuel
system.
Visual Check of The Evaporative

Emission Canister
canister.
Fuel Metering System Check

Some failures of the fuel metering system will result in an
Engine Cranks But Will Not Run symptom. If this
condition exists, refer to the Engine Cranks But Will Not
Run chart. This chart will determine if the problem is
caused by the ignition system, the PCM, or the fuel pump
electrical circuit.
Refer to Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to Fuel System
Diagnosis, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump. If a malfunction
occurs in the fuel metering system, it usually results in
either a rich HO2S signal or a lean HO2S signal. This
condition is indicated by the HO2S voltage, which causes
the PCM to change the fuel calculation (fuel injector pulse
width) based on the HO2S reading. Changes made to the
fuel calculation will be indicated by a change in the long
term fuel trim values which can be monitored with a Tech
2. Ideal long term fuel trim values are around 0%; for a
lean HO2S signal, the PCM will add fuel, resulting in a fuel
trim value above 0%. Some variations in fuel trim values
are normal because all engines are not exactly the same.
If the evaporative emission canister purge is ON, the
long term fuel trim may be as low as 38%. If the fuel trim
values are greater than +23%, refer to DTC P0131, DTC
P0151, DTC P0171, and DTC 1171 for items which can
cause a lean HO2S signal.

count of 0 indicates the PCM is commanding the IAC
pintle to be driven all the way into a fully-seated position.
This is usually caused by a large vacuum leak.
commanded to bypass the throttle blade. Refer to IAC
System Check in order to diagnose the IAC system.
Refer to Rough, Unstable, or Incorrect Idle, Stalling in
Symptoms for other possible causes of idle problems.
Knock Sensor Diagnosis

The Tech 2 has two data displays available for diagnosing
the knock sensor (KS) system. The two displays are
described as follows:
D Knock Retard indicates the number of degrees that
the spark timing is being retarded due to a knock
condition.
D KS Noise Channel indicates the current voltage

level being monitored on the noise channel.
DTCs P0325 and P0327 are designed to diagnose the KS
module, the knock sensor, and the related wiring. The
problems encountered with the KS system should set a
DTC. However, if no DTC was set but the KS system is
suspect because of a detonation complaint, refer to
Detonation/Spark Knock in Symptoms.

Diagnosis
diagnostic trouble codes from the PCM memory.
from the PCM for 30 seconds. Turning off the ignition and
disconnecting the battery power from the PCM will cause
all diagnostic information in the PCM memory to be
re-run.
Since the PCM can have a failure which may affect only
where it is.
If a diagnostic chart indicates that the PCM connections
or the PCM is the cause of a problem, and the PCM is
D There is a problem with the PCM terminal
checked. In this case, refer to the Symptoms portion
of the manual and make a careful physical inspection
of all components and wiring associated with the
affected system.
Solenoids and relays are turned ON and OFF by
the PCM using internal electronic switches called
drivers. A shorted solenoid, relay coil, or harness will
not damage the PCM but will cause the solenoid or
relay to be inoperative.
Multiple PCM Information Sensor

DTCS Set
Circuit Description
The powertrain control module (PCM) monitors various
The PCM controls fuel delivery, spark advance,
transmission operation, and emission control device
operation based on the sensor inputs.
The PCM provides a sensor ground to all of the sensors.
The PCM applies 5 volts through a pull-up resistor, and
monitoring the voltage present between the 5-volt supply
and the resistor:
D The engine coolant temperature (ETC) sensor
D The intake air temperature (IAT) sensor

D The transmission fluid temperature (TFT) sensor
The PCM provides the following sensors with a 5-volt
D The exhaust gas recirculating (EGR) pintle position
sensor
The PCM monitors the separate feedback signals from
status.
Diagnostic Aids
IMPORTANT: Be sure to inspect PCM and engine
grounds for being secure and clean.
D P0108
D P0113
D P0118
D P0123
D P0712
IMPORTANT: If a sensor input circuit has been shorted
to voltage, ensure that the sensor is not damaged. A
damaged sensor will continue to indicate a high or low
voltage after the affected circuit has been repaired. If the
sensor has been damaged, replace it.
An open in the sensor ground circuit between the PCM
DTCs to be set:
D P0108
D P0113
D P0118
D P0123
D P0712
A short to ground in the 5-volt reference A or B circuit will
D P0107
D P0122
An the in the 5-volt reference circuit A, between the PCM
DTCs to be set:
6E255
D P0122
An the in the 5-volt reference circuit B, between the PCM
DTCs to be set:
D P0107
D Poor connection at PCM. Inspect the harness
connectors for backed-out terminals, improper
mating, broken locks, improperly formed or damage
terminals, and a poor terminal-to-wire connection.
the ignition ON and the engine OFF while you
move the connectors and the wiring harnesses
related to the following sensors:
D IAT
D ECT
D TP
D MAP
D EGR
D TFT
Test Description
9. A faulty EGR valve can leak a small amount of
current from the ignition feed circuit to the 5-volt
reference A circuit. If the problem does not exist
with the EGR valve disconnected, replace the EGR
valve.
11-15. If a sensor input circuit has been shorted to
voltage, ensure that the sensor has not been
damaged. A damaged IAT or ECT sensor will
continue to indicate a high voltage or a low
temperature after the affected circuit has been
repaired. A dameged TP, MAP, fuel tank pressure,
or EGR pintle position sensor will indicate a high
voltage, a low voltage, or a fixed value after the
affected circuit has been repaired. If the sensor has
6E256
Multiple PCM Information Sensor DTCs Set

Step
Action
Verify repair
Go to Step 5
Go to Step 6
Verify repair
0V
Go to Step 7
Go to Step 11
0V
Go to Step 8
Go to Step 14
0V
Go to Step 9
Go to Step 15
0V
Go to Step 10
Go to Step 16
0V
Go to Step 11
Go to Step 17
0V
Go to Step 13
Go to Step 18

11


10
Go to Step 4


9
Go to Step 3

sensor signal circuit at the PCM harness connector and
ground.

8

7
Go to Step 2

conditions:
D A poor connection at the PCM or the affected
sensors.
affected sensors.

6
Go to OBD
System
Check

5
No
1. Turn the ignition OFF, disconnect the PCM.

2. Turn the ignition ON, check the 5 volt reference A
circuit for the following conditions:
D A poor connection at the PCM.
splice.

4
Yes

performed?

3
Value(s)

position sensor signal circuit at the PCM harness
6E257
Multiple PCM Information Sensor DTCs Set (Cont'd)

Step
Action
12
Measure the voltage between the TFT sensor signal

13
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Verify repair
Go to OBD
System
Check
Locate and repair the short to voltage in the TFT sensor

signal circuit.
20

19
Go to Step 19

18
Go to Step 20

signal circuit.
17
0V

signal circuit.
16
No

15
Yes

14
Value(s)
Replace the PCM.

6E258

Diagnosis
Pintle position error diagnosis is covered by DTC P0402,
P0404, P1404, P0405, P0406. If EGR diagnostic trouble
codes P0402, P0404, P1404, P0405, P0406 are
encountered, refer to the DTC charts.
Engine Tech 2 Data Definitions and

Ranges
A/C CLUTCHTech 2 Displays ON or OFF
Indicates whether the PCM has commanded the A/C
clutch ON. Used in A/C system diagnostic.
HVAC controls. The PCM uses the A/C request signal to
requested.
AIR/FUEL RATIO Tech 2 Range 0.0-25.5
Air/fuel ratio indicates the PCM commanded value. In
closed loop, the air/fuel ratio should normally be
BARO kPa Tech 2 Range 10-105 kPa/0.00-5.00
Volts
normally displayed around 61-104 depending on
CHECK TRANS LAMPAUTO TRANSMISSION
Indicates the need to check for a DTC with the Tech 2
when the lamp is flashing 0.2 seconds ON and 0.2
seconds OFF.
CMP ACT. COUNTER Cam Position
ActivityDECEL FUEL MODETech 2 Display
ACTIVE or INACTVE
mode. The PCM will command the deceleration fuel
vehicle is traveling over 20 mph. While in the decreasing
fuel mode, the PCM will decrease the amount of fuel
delivered by entering open loop and decreasing the
DESIRED EGR POS.Tech 2 Range 0%-100%
Represents the EGR pintle position that the PCM is
commanding.
DESIRED IDLE Tech 2 Range 0-3187 RPM
The idle speed that the PCM is commanding. The PCM
speed.
ECT (Engine Coolant Temperature) Tech 2

Range 40C to 151C (40F to 304F)
information to the PCM. The PCM applies 5 volts to the
changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the PCM
the voltage signal will decrease and the PCM will interpret
EGR DUTY CYCLE Tech 2 Range 0%-100%
PCM. A duty cycle of 0% indicates that no EGR flow is
EGR FEEDBACK Tech 2 Range 0.00-5.00 Volts
being monitored by the PCM. A low voltage indicates a
ENGINE LOAD Tech 2 Range 0%-100%
Engine load is calculated by the PCM from engine speed
and MAF sensor readings. Engine load should increase
ENGINE RUN TIME Tech 2 Range
00:00:00-99:99:99 Hrs:Min:Sec
00:00:00.
ENGINE SPEED Range 0-9999 RPM
Engine speed is computed by the PCM from the 58X
EVAP PURGE PWM Tech 2 Range 0%-100%
Represents the PCM commanded PWM duty cycle of the
EVAP purge solenoid valve. 0% displayed indicates no
purge; 100% displayed indicates full purge.
EVAP VENT VALVE Tech 2 Displays PURGE or
NO PURGE
The EVAP purge vacuum valve is a normally closed valve
positioned in the purge line between the canister and the
EVAP purge solenoid. The EVAP purge vacuum valve
will open when vacuum increases to greater than 5 inches
of water in the purge line. The EVAP purge vacuum valve
is used by the PCM to monitor EVAP canister purge
solenoid opetation and purge system integrity. The EVAP
purge vacuum valve should be closed to ground with no
vacuum present (0% EVAP purge PWM). With EVAP
purge PWM at 25% or greater, the EVAP purge vacuum
valve should be open and PURGE should be indicated.
FUEL TRIM CELL Tech 2 Range 0-21
active.
6E259

fuel trim corrections, fuel trim learn will display YES.
This indicates that the long term fuel trim is responding to
the short term fuel trim. If the fuel trim learn displays
NO, then long term fuel trim will not respond to changes
in short term fuel trim.
KS NOISE CHANNEL (Knock Sensor)

Indicates the output from the KS noise channel. There is
always some electrical noise in an engine compartment
and to avoid mistaking this as engine knock, the output
from the knock sensor is compared to the output from the
noise channel. A knock condition is not set unless the
knock sensor output is greater than the noise channel
output.
HO2S BANK 1, SEN. 1Tech 2 Range 0-1132 mV

LONG TERM FUEL TRIM BANK 1/BANK 2

The long term fuel trim is derived from the short term fuel
trim values and represents a long term correction of fuel
delivery for the bank in question. A value of 0% indicates
that fuel delivery requires no compensation to maintain
the PCM commanded air/fuel ratio. A negative value
significantly below 0% indicates that the fuel system is
rich and fuel delivery is being reduced (decreased injector
pulse width). A positive value significantly greater than
0% indicates that a lean condition exists and the PCM is
compensating by adding fuel (increased injector pulse
width). Because long term fuel trim tends to follow short
term fuel trim, a value in the negative range due to
canister purge at idle should not be considered unusual.
Fuel trim values at maximum authority may indicate an
excessively rich or lean system.
HO2S BANK2, SEN. 1Tech 2 Range 01132 mV

between 10mV (lean exhaust) and 1000 mV (rich
YES/NO
YES/NO
IAC POSITION Tech 2 Range 0-255 Counts
LOOP STATUS Tech 2 Displays OPEN or

CLOSED
CLOSED indicates that the PCM is controlling fuel
delivery according to oxygen sensor voltage. In OPEN
the PCM ignores the oxygen sensor voltage and bases
the amount of fuel to be delivered on TP sensor, engine
coolant, and MAF sensor inputs only.
MAF Tech 2 Range 0.0-512 gm/s
MAF (mass air flow) is the MAF input frequency
converted to grams of air per second. This indicates the
amount of air entering the engine.

40C to 151C (40F to 304F)
The PCM converts the resistance of the intake air
(IAT) is used by the PCM to adjust fuel delivery and spark
MAP Tech 2 Range 10-105 kPa (0.00-4.97 Volts)

the diagnostics.
IGNITION 1 Tech 2 Range 0-25.5 Volts

PCM at its ignition feed.

Indicates the PCM commanded state of the malfunction
indicator lamp.
INJ. PULSE BANK 1/INJ. PULSE BANK 2 Tech 2

Range 0-1000 msec.
Indicates the amount of time the PCM is commanding
engine load.

or INACTIVE
mode. The PCM will command power enrichment mode
detected. While in power enrichment mode, the PCM will
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.
6E260
RICH/LEAN BANK 1/ BANK 2 Tech 2 Displays

RICH or LEAN
Indicates whether oxygen sensor voltage is above a 600
mV threshold voltage (RICH) or below a 3000 mV
threshold voltage (LEAN). Should change constantly
while in closed loop, indicating that the PCM is controlling
the air/fuel mixture properly.
SHORT TERM FT BANK1/BANK2
Short term fuel trim to a bank represents a short term
correction to bank fuel delivery by the PCM in response
to the amount of time the bank fuel control oxygen sensor
voltage spends above or below the 450 mV threshold. If
the oxygen sensor voltage has mainly remained less than
450 mV, indicating a lean air/fuel mixture, short term fuel
trim will increase into the positive range above 0% and
the PCM will pass fuel. If the oxygen sensor voltage stays
mainly above the threshold, short term fuel trim will
decrease below 0% into the negative range while the
PCM reduces fuel delivery to compensate for the
indicated rich condition. Under certain conditions such as
extended idle and high ambient temperatures, canister
purge may cause short term fuel trim to read in the
negative range during normal operation. Fuel trim values
at maximum authority may indicate an excessively rich or
lean system.
by the PCM on the IC circuit.
START-UP ECT Tech 2 Range 40C to 151C
(40F to 304F)
START-UP IAT Tech 2 Range 40C to 151C
(40F to 304F)
TP Tech 2 Range 0%-100%
TP (throttle position) angle is computed by the PCM from
TP SENSOR Tech 2 Range 0.00-5.00 Volts
The voltage being monitored by the PCM on the TP
Number
This indicates that the PCM has detected crankshaft
Typical Scan Data Values

On-Board Diagnostic System Check has been
determined that the on-board diagnostics are functioning
properly. Tech 2 values from a properly-running engine

values that would be seen on a normally-running engine.
information on using the Tech 2 to diagnose the PCM and
described below, refer to the Symptoms section for
diagnosis.
Test Conditions
park or neutral, closed loop, accessaries off, brake not
applied and air conditioning off.
6E261
3.2L V-6 Engine

Tech 2 Parameter
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
Engine Speed
Engine
RPM
Within 50 to +100 of
Desired Idle
Actul engine speed
Desired Idle Speed
Engine
RPM
750
800
Engine
C or F
80 100 (176 212

F)
80 100 (176 212

F)

Temperature)
Engine
C or F
Engine
C or F
0 100, depends on
underhood
0 80, depends on
underhood
Engine
C or F
Engine
kPa
23 40
19 32
Engine
0.65 1.32
0.46 1.10
Barometric Pressure
Engine
kPa
61 104 (depends pn
altitude and
barometric)
61 104 (depends pn
altitude and
barometric)
Throttle Position
Engine
35
Engine
0.35 0.39
0.55 0.59
Mass Air Flow
Engine
g/s
2.85 6.65
9.5 16.5
Air Fuel Ratio
Engine
Ratio:_to1
14.7:1
14.7:1
Engine
ms
2.0 4.0
2.5 4.0
Engine
ms
2.0 4.0
2.5 4.0
Spark Advance
Engine
CA
15 22
34 44
EGR Duty Cycle
Engine
Desired EGR Position
Engine
EGR Normalized
Engine
EGR Feedback
Engine
0.45 0.80
0.45 0.80
EGR Closed Pintle Position
Engine
Steps
20 40
20 40
Catalyst Protection Mode
Engine
Yes/No
No
No
Knock Sensor Noise Channel
Engine
0.10 0.40
0.50 1.75
A/C Clutch Relay
Engine
On/Off
Off
A/C Request
Engine
Yes/No
No
Camshaft Activity
Engine
Counts
0 255 always
increasing
0 255 always
increasing
EVAP Purge Solenoid (Evaporative

Emission)
Engine
On/Off
Off
Off
Fuel Pump
Engine
On/Off
On
On
Idle Air Control
Engine
Steps
Transmission Check Light
Engine
On/Off
Off
Off
Park/Neutral Position
Engine
P-N/R-D3-2-L
P-N
P-N
TCC Engaged
Engine
Yes/No
No
No
Vehicle Speed
Engine
MPH or
km/h
Ignition Voltage
Engine
12.8 14.1
12.8 14.1
6E262

Tech 2 Parameter
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
Fuel system Status
Engine
Closed
Loop
/Open
Loop
Closed Loop
Closed Loop
Power Enrichment
Engine
Yes/No
No
No
Engine Load
Engine
2.0 5.5
8.0 16.0
Time From Start
Engine
_:_:_
_:_:_
_:_:_
Deceleration Fuel Cutoff
Engine
Inactive/A
ctive
Inactive
Inactive
Engine
On/Off
Off
Off
VIM solenoid (Variable Intake

Manifold)
Engine
On/Off
On
On

Tech 2 Parameter
6E263
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
Engine Speed
O2
Sensor
RPM
Within -50 to +100 of

Desired Idle
Actul engine speed
Desired Idle Speed
O2
Sensor
RPM
750
800
O2
Sensor
C or F
80 100 (176 212

F)
80 100 (176 212

F)

Temperature)
O2
Sensor
C or F
O2
Sensor
C or F
0 100, depends on
underhood
0 80, depends on
underhood
O2
Sensor
C or F
O2
Sensor
kPa
23 40
19 32
Barometric Pressure
O2
Sensor
kPa
61 104 (depends pn
altitude and
barometric)
61 104 (depends pn
altitude and
barometric)
Throttle Position
O2
Sensor
35
O2
Sensor
0.35 0.39
0.55 0.59
Mass Air Flow
O2
Sensor
g/s
2.85 6.65
9.5 16.5
Air Fuel Ratio
O2
Sensor
g/s
2.85 6.65
9.5 16.5
O2
Sensor
mV
50 950 always
changing quickly
50 950 always
changing quickly
O2
Sensor
mV
50 950 always
changing quickly
50 950 always
changing quickly
O2
Sensor
Yes/No
Yes
Yes
O2
Sensor
Yes/No
Yes
Yes

Sensor 1)
O2
Sensor
seconds
24 45
24 45

Sensor 1)
O2
Sensor
seconds
24 45
24 45
O2
Sensor
O2
Sensor
O2
Sensor
O2
Sensor
Fuel Trim Cell
O2
Sensor
Cell No.
20
2 or 6
Fuel Trim Learned
O2
Sensor
Yes/No
Yes
Yes
O2
Sensor
Lich/Lean
6E264

Tech 2 Parameter
Data List
Units
Displayed
Typical Data Values

(IDLE)
Typical Data Values

(2500 RPM)
O2
Sensor
Lich/Lean
Engine Load
O2
Sensor
2.0 5.5
8.0 16.0
6E265
D06RX012
Circuit Description
MIL bulb through the meter fuse. The powertrain control
module (PCM) turns the MIL ON by grounding the MIL
driver circuit.
Diagnostic Aids
An intermittent MIL may be cased by a poor connection,
D Inspect the PCM harness and connections for
damaged
terminals,
poor
terminal-to-wire
PCM ignition or battery feed, or a poor PCM to engine
ground.
Test Description
Diagnostic Chart.
2. A No MIL condition accompanied by a no-start
condition suggests a faulty PCM ignition feed or
9. Using a test light connected to B+, probe each of the
PCM ground terminals to ensure that a good ground
is present. Refer to PCM Terminal End View for
terminal locations of the PCM ground circuits.
12.In this step, temporarily substitute a known good
relay for the PCM relay. The horn relay is nearby,
this step.
6E266

Step
Action
1.
2.
3.
4.
Go to Step 5
Go to Step 13
Go to Step 10
Go to Step 11
Go to Step 7
Go to Step 15
Go to Step 8
Go to Step 12
Go to Step 9
Go to Step 14
Verify repair
Go to Step 10
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 13
Verify repair
Verify repair
Substitute a known good relay for the PCM main

relay.
14
Check for an open MIL driver circuit between the PCM

and the MIL.

13
Go to Step 16
Check for damaged terminals at the PCM.

12
Go to Step 4
Check for a faulty PCM ground connection.

11
Probe the battery feed circuit at the PCM harness


10
Go to Step 6
Ignition OFF.
Disconnect the PCM.
Ignition ON.
Probe the ignition feed circuit at the PCM harness

9
Go to Step 3
Check the PCM ignition feed and battery feed fuses (15
A engine fuse and 15 A PCM fuse).

8
1. Ignition OFF.
3. Jumper the MIL driver circuit at the PCM connector
to ground.
4. Ignition ON.
Are both fuses OK?

7
Go to Step 2
Ignition ON, probe the ignition feed circuit at the

cluster connector with a test light to ground.
Is the MIL ON?

6
Go to OBD
System
Check

feed circuit.

5
No
Is the fuse OK?

4
Yes

performed?

3
Value(s)
Locate and repair the open PCM battery feed circuit.

6E267

Step
Action
15
Locate and repair the short to ground in the PCM

ignition feed circuit or PCM battery feed circuit.
16
No
Verify repair
Verify repair
Verify repair
Verify repair
Go to
Instrument
Panel in
Electrical
Diagnosis
Replace the PCM.

18
Yes

fuse.
17
Value(s)

6E268
D06RX012
Circuit description
illuminated and steady with ignition ON and the engine
stopped. Ignition feed voltage is supplied directly to the
MIL indicator. The powertrain control module (PCM)
turns the MIL ON by grounding the MIl driver circuit.
and no DTC(s) set. A steady MIl with the engine running
and no DTC(s) suggests a short to ground in the MIl driver
circuit.
Diagnostic Aids

damaged harness.
Test Description
Diagnostic Chart.
2. If the MIL does not remain ON when the PCM is
cluster is faulty.
6E269

Step
Action
Go to Step 2
Go to Step 3
Go to Step 5
Go to OBD
System
Check
Go to Step 4
Go to OBD
System
Check
Go to OBD
System
Check
Go to Step 6
Go to OBD
System
Check
1. Ignition OFF, reconnect the PCM.

MIL dash lamp control and command the MIL
OFF. (Refer to the miscellaneous test)
Go to OBD
System
Check

cluster.
2. Check the MIL driver circuit between the PCM and

5
No
1. Ignition OFF, disconnect PCM.

2. Ignition ON, observe the MIL (Service Engine
Soon lamp).

4
Yes
Was the On-Board diagnostic (OBD) System Check

performed?
Is the MIL ON?

3
Value(s)
Replace the PCM.

6E270
D06RX145
060RY00303
Circuit Description
The electronic Ignition system uses a coil-at-plug method
of spark distribution. In this type of ignition system, the
powertrain control module (PCM) triggers the correct
driver inside the ignition coil, which then triggers the
correct ignition coil based on the 58X signal received from
the crankshaft position sensor (CKP). The spark plug
connected to the coil fires when the ignition coil opens the
ground circuit for the coils primary circuit.
During crank, the PCM monitors the CKP 58X signal. The
PCM, it will command all six injectors to allow a priming
injectors are left OFF during the next six 58X reference
been received by the PCM. The CMP signal allows the
PCM to operate the injectors sequentially based on
present at start-up, the PCM will begin sequential fuel
delivery with a 1-in-6 chance that fuel delivery is correct.
DTC code.
Diagnostic Aids
connection, rubbed-through wire insulation or a wire
items:
terminals, poor terminal-to-wore connection, and
damaged harness.
intake air temperature. If not, replace the ECT
sensor.
Test Description
Diagnostic Chart.
5. An obvious cause of low fuel pressure would be an
empty fuel tank.
6. The engine will easily start and run if a few injectors
are disabled. It is not necessary to test all injectors
at this time since this step is only a test to verify that
all of the injectors have not been disabled by fuel
contamination.
6E271
7. A blinking test light verifies that the PCM is

monitoring the 58X crankshaft reference signal and
is capable of activating the injectors. If there is an
open or shorted driver circuit, DTCs 201-206 and a
misfire DTC 301-306 should be set.
By using a spark tester, each ignition coils ability to
produce 25,000 volts is verified.
If there is an open or shorted driver circuit, DTCs
201-206 should be set. All six injector driver circuits
can be checked at one time without removing the
intake manifold if a 5884026190 test light is
available. This is the alternative procedure:
D With the ignition OFF, disconnect the gray
connector located at the rear of the air filter, attached
to a bracket on the purge canister.
D Connect test light 5-8840-2636-0 to the connector.
Do any of the light constantly illuminate or fail to blink
when the engine is cranked? If so, repair the short or
open circuit, or replace the PCM if indicated.
This procedure only tests the driver circuit as far as the
test connection, so step 25 is added to test the circuit all
the way to the injector.
6E272

Step
Action
Verify repair
285-375 kPa
(43-55 psi)
Go to Step 6
Go to Step 5
Go to Fuel
System
Electrical Test
Go to Fuel
System
Diagnosis
Go to Step 7
Go to Step 23
Go to Step 14
Go to Step 18
Go to Step 10
Go to Step 9
Verify repair
Go to Step 12
Go to Step 11
Verify repair
Verify repair
Go to Step 13

While the coil connectors are disconnected, touch
each connectors secondary ground terminal with a
test light to B+. (The ground wires are black.)
Repair the open secondary ground circuit.
12
1. Ignition ON.
2. While the coil connectors are disconnected, touch
each coil connectors ignition feed terminal with a
grounded test light (the ignition feed wire is black
with orange tracer).
Did the test light illuminate at each coil connector?

11
Go to Step 4

harness connector.

10
Go to Step 3

harness connector (or install 5-8840-2636-0 test light
to the the injector test connector).

9

8
Go to Step 2
1. Ignition OFF, install a fuel pressure gauge at the

test fitting on the fuel supply line in the engine
compartment. (Use a shop cloth to absorb any fuel
leakage while making the connection.)
2. Ignition ON, observe the fuel pressure.

7
Go to OBD
System
Check
Is the fuel pressure within the specified values, and

does it hold steady?
5
No
Check the 15 A ignition coil fuse, the 15 A engine

device fuse, and the 15A PCM fuse.

4
Yes

performed?
Was a fuse blown?

3
Value(s)

Balance Test).
6E273

Step
Action
13
1. Remove any ignition coil and install a spark tester at

the spark plug end of the coil.
2. Observe the tester while the engine is cranking.
Was a crisp, blue spark observed? Only one or two
No Spark.
14
Verify repair
Refasten all
coils with
their screws
Go to Step 16
Correct the
fouling
condition
Go to Step 17
Verify repair
Go to Step 19
Go to Step 19
Go to Step 28
Go to Step 20
Go to Step 26
Observe the Engine Speed data display on the scan

tool while cranking the engine.
Is the engine RPM indicated? (If the scan tool is
normally powered from the cigarette lighter socket, and
if the scan tool display goes blank while cranking the
engine, it will be necessary to power the scan tool
directly from the vehicle battery.)
19
Go to Step 14
Refer to Engine Mechanical Diagnosis to diagnose the

D Faulty or incorrect camshaft drive belts
D Leaking or sticky valves or rings
D Excessive valve deposits
D Leaking head gasket
18
Go to Step 15

excessive fouling?
17
No
Repeat Step 13 for each coil. Remove only one coil at a

time, and reinstall each coil on its spark plug after
testing, but do not refasten coils with screws at this
time.
After all coils have passed the spark test, does the
engine start?
16
Yes
Replace the ignition coil, and return to Step 13 to test

the remaining coils.
15
Value(s)
1. Disconnect the 7-pin gray connector at the rear of

the air filter beneath the point where the air duct
attaches to the MAF sensor.
2. Ignition ON.
ignition terminal at the PCM (female) side of the
7-pin connector.
6E274

Step
Action
20
1. At the PCM (female) side of the connector

mentioned in step 19, connect a test light between
the ignition + terminal and one of the injector driver
circuits at the same connector.
2. Ignition ON.
3. Observe the test light, and repeat the test for each
Did the test light stay on when checking any of the 6
injector driver circuits?
21
Go to Step 22
Go to Step 27
Verify repair
Go to Step 25
Go to Step 24
Verify repair
Go to Step 27
12.5 ohms
Verify repair
Go to Step 8
Verify repair
Verify repair
Go to Step 30
Go to Step 29
Verify repair
Repair the ignition feed circuit.

27
Go to Step 23
1. At the injector (male) side of the gray connector

mentioned in step 19, connect an ohmmeter
between the ignition pin and one of the driver circuit
pins.
2. Check for continuity in the circuit.
3. Repeat for each injector circuit. The readings
should be approximately equal to the specified
value for injector resistance.
26
Go to Step 21
Check for an open injector driver circuit.

25
1. Using the same test location as in step 20, connect

a test light between the ignition terminal and one of
the driver circuits.
2. Crank the engine and observe the test light.
3. Repeat for each injector driver circuit.
Did the light blink during the test for each circuit?
24
No
Locate and repair the short to ground in the injector

driver circuit.
23
Yes

2. Ignition ON, observe the test light.
22
Value(s)
Replace the PCM.

IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
28

harness.
2. Ignition ON.
3. With a test light to ground, probe the harness
ignition feed terminal.
29
Check the ignition feed wire between the sensor and

the PCM for a short to ground or open circuit.
6E275

Step
Action
30
1. Ignition ON.
2. At the CKP harness connector, connect a test light
31
No
Go to Step 32
Go to Step 31
Verify repair
Verify repair
Go to Step 33
Verify repair
Go to Step 27
Check the signal circuit between the sensor and the

PCM for a short to ground, short to voltage, or an open.
33
Yes
Check the sensor ground circuit for an open or short to

voltage.
32
Value(s)

6E276
D06RX014
Circuit Description
Diagnostic Aids
When the ignition switch is first turned ON, the

powertrain control module (PCM) energizes the fuel
pump relay which applies power to the in-tank fuel pump.
The fuel pump relay will remain ON as long as the
engine is running or cranking and the PCM is receiving
58X crankshaft position pulses. If no 58X crankshaft
position pulses are present, the PCM de-energizes the
fuel pump relay within 2 seconds after the ignition is
turned ON or the engine is stopped.

damaged harness.
Test Description
Diagnostic Chart.
2. If the fuel pump is operating but incorrect pressure is
noted, the fuel pump wiring is OK and the Fuel
diagnosis.

injury:
completed.
6E277

relay center.

2. Install fuel gauge 5-8840-0378-0 to the fuel feed line
cover.


Step
Action
Go to Step 3
Go to Step 4
Test
completed
Go to Step 12
Go to Step 6
Go to Step 5
Verify repair
Go to Step 12
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair

connect to the fuel pump relay pull-in coil.
2. Ignition ON.

from the relay pullin coil to the PCM.
2. Ignition ON.
off?
off?
7
Go to Step 2
1. Ignition OFF.

6
Go to OBD
System
Check


5
No

3. Ignition SW is ON.

4
Yes

performed?
Is there an immediate pressure build-up which

3
Value(s)

circuit.
6E278

Step
Action
Verify repair
Go to Step 15
Go to Step 13
Go to Step 17
Go to Step 14
Verify repair
Go to Step 18
Go to Step 16
Verify repair
Verify repair
Verify repair
Replace the fuel pump relay.

18
Go to Step 11

17
Verify repair

16
Check for a short circuit, blown fuse or open circuit

between the relay and the fule tank.
15
Go to Step 10
1. Substitute a known good realy for the fuel pump

realy.
4. After this test, re-connect the known good relay in
its proper location.
14
Verify repair

fuel tank.
13
Replace the PCM.

12
No

11
Yes
Check for short or open between the PCM and the fuel
pump relay.
10
Value(s)

6E279
140RW022
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Fuel Rail Left

Left Bank
Common Chamber
Duty Solenoid Valve
Throttle Valve
Canister
Evap Shut Off Valve
Circuit Description
Test Description
When the ignition switch is turned ON, the powertrain

control module (PCM) will turn ON the in-tank fuel
pump. The in-tank fuel pump will remain ON as long as
the engine is cranking or running and the PCM is receiving
58X crankshaft position pulses. If there are no 58X
crankshaft position pulses, the PCM will turn the in-tank
fuel pump OFF 2 seconds after the ignition switch is
turned ON or 2 seconds after the engine stops running.
The in-tank fuel pump is an electric pump within an
integral reservoir. The in-tank fuel pump supplies fuel
through an in-line fuel filter to the fuel rail assembly. The
to the fuel injectors at a regulated pressure. Unused fuel
is returned to the fuel tank by a separate fuel return line.

Diagnostic Chart.
2. Connect the fuel pressure gauge to the fuel feed line
as shown in the fuel system illustration. Wrap a
should be 333-376 kPa (48-55 psi). This pressure
areas:
6E280

regulator.
D The fuel injector(s).
operating in the Fuel Cut-Off Mode.
16.Check the spark plug associated with a particular
Assembly in On-Vehicle Service.
connector.
nozzles for leaks.
17.A rich condition may result from the fuel pressure
exhaust.
20.This test determines if the high fuel pressure is due

21.A lean condition may result from fuel pressure
below 333 kPa (48 psi). A lean condition may
Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold ), hesitation, poor driveability, lack of
power, surging , and misfiring.
22.Restricting the fuel return line causes the fuel
injury:
completed.

relay center.

2. Install fuel gauge 5-8840-0378-0 to the fuel supply
line located in front of and above the right side valve
cover.
6E281

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
290-376 kPa
(42-55 psi)
Go to Step 3
Go to Step 17
Go to Step 4
Go to Step 12

engine was started?
21-105 kPa
(3-15 psi)
Go to Step 5
Go to Step 9

Go to Step 6
Check for
improper fuel
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
21-105 kPa
(3-15 psi)
Go to Step 10
Go to Step 11

performed?
pressure gauge.
ON.
constant.
5
6
1. When the vehicle is at normal operation

gauge.
gauge.

restriction:
D The in-pipe fuel filter.



regulator.
2. With the engine idling, apply 12-14 inches of
6E282

Step
Action
10

pressure regulator.
11
18

Pressure Relief.
outlet passage.
19
Verify repair
Go to Step 13
Go to Step 15
Verify repair
Go to Step 14
Verify repair
Go to Step 8
Go to Step 11
Go to Step 16
Verify repair
376 kPa (55

psi)
Go to Step 18
Go to Step 21
290-376 kPa
(42-55 psi)
Go to Step 19
Go to Step 20
Verify repair
Verify repair
Go to Step 11

20

17

pump.
16
Verify repair

in-tank fuel line.
15

leaks.
14
No

13
Yes

12
Value(s)

6E283

Step
Action
Value(s)
21

0 kPa (0 psi)
Go to Step 22
Go to Step 23
376 kPa (55

Does the fuel pressure indicated by the fuel pressure psi). 414 kPa
(60 psi).
Go to Step 11
Go to Step 7
Go to Step 7
Go to Fuel
System
Electrical Test
Chart
22
Yes
No

23

6E284

Circuit Description
idle speed with the idle air control (IAC) valve. To increase
idle speed, the PCM retracts the IAC valve pintle away
from its seat, allowing more air to bypass the throttle bore.
To decrease idle speed, it extends the IAC valve pintle
read the PCM commands to the IAC valve in counts.
idle).
Diagnostic Aids
engine. Fully extend (low) IAC with the Tech2. Start
linkage.
P0131, P0151, P0171, or P0174 may be set. Tech 2
oxygen (O2) voltage will be less than 100 mV (0.1 V).
Check for low regulated fuel pressure, water in fuel, or
a restricted injector.
respond on the Tech 2.

contact.
Test Description
Diagnostic Chart.
1. The Tech2 is used to extend and retract the IAC
6. Steps 1 and 2 verified the proper IAC valve
operation. This step checks the IAC circuits. Each
lamp on the noid light should flash red and green
while the IAC valve is cycled. While the sequence
of color is not important, if either light is OFF or
does not flash red and green, check the circuits for
faults, beginning with poor terminal contacts.
6E285

Step
Action
1.
2.
3.
4.
5.
6.
7.
8.

Go to Step 2
Go to Step 3
700-1500
RPM
Go to Step 3
Go to Step 4
Go to Step 5
Verify repair
Verify repair

No

Yes
Ignition OFF.
Connect the Tech2.
Block the wheels.
the IAC is cycled.

2
Value(s)

Control Valve.
6E286
Knock Sensor (KS) System Check

(Engine Knock, Poor Performance, or Poor Economy)
D06RW035
Circuit Description
Test Description
The knock sensor (KS) sends an AC voltage signal to the

powertrain control module (PCM). As the KS detects
engine knock, the signal to the PCM changes in amplitude
and frequency. The PCM retards timing if the engine
speed is over 900 RPM.

Diagnostic Chart.
9. The change in signal speed depends on how hard
the tapping is done. Normally there is about 1.5 to
10 mV at PCM pin A2 with the engine off. Loud
tapping should be able to make the reading jump to
20-25 mV AC.
Diagnostic Aids
If the KS system checks OK, but detonation is the
complaint, refer to Diagnosis, Detonation/Spark Knock.

(Engine Knock, Poor Performance, or Poor Economy)
Step
Action
Go to Step 2
Go to Step 3
Go to Step 4
Verify repair
more than
0.1V
Go to Step 5
Go to Step 6
Verify repair
Repair the mechanical problem.

1.
2.
3.
4.
Install the Tech 2.

Turn the ignition ON.
On the Tech 2 select F0: Data List.
Cycle through the list until Knock Noise Channel is
displayed.
Is knock retard at the specified value?

5
No
Run the engine at 1500 RPM.

4
Yes
Go to DTC
P0325 or
DTC P0327
Is DTC P0325 or P0327 set?
Is there an internal engine knock?

3
Value(s)
Replace the PCM.

6E287

(Engine Knock, Poor Performance, or Poor Economy) (Cont'd)
Step
Action
Yes
No

2. Monitor the knock retard display on the Tech 2 while
changing the throttle setting to place different loads
on the engine.
Is knock retard at the specified value? (Turn the ignition
OFF.)
Value(s)
Go to Step 9
Go to Step 7
B+
Go to Step 9
Go to Step 8
Verify repair
System OK
Go to Step 10
Verify repair
1. At the rear of the engine, behind the rear fuel

injector on the side, disconnect the 2-wire knock
NOTE: The connector for the knock sensor cannot
easily be removal unless common chamber is
removed. (Knock Sensor is on Right side of block).
Also, there are two (2) shield grounded wires.
The connector only has one wire (Yellow). Please
use another method.
2. Attach the positive lead of DVM to B+.
3. On the main harness side of the connector, use the
negative lead of the DVM to probe the connector pin
that is connected to black wire.
Dose the DVM indicate the specified value?
(Reconnect the knock sensor harness.)
Repair the open black wire ground for the shield which
prevents stray electromagnetic pulses from affecting
the knock signal.
1. Reconnect the wire harness if it was previously

disconnected in Step 7.
2. Set a DVM to AC voltage.
3. With the DVM, backprobe the PCM connector at
A2.
4. Tap the engine lift bracket with a socket extension.
Did the DVM show an increase in AC voltage while
tapping on the lift bracket?
10

6E288
D06RW055
Circuit Description
Diagnostic Aids
A properly operation exhaust gas recirculation (EGR)

would be leaner. The powertrain control module (PCM)

but not in the closed throttle cell. An EGR pintle
constantly in the open position would cause a rough idle.
Also, an EGR mounted incorrectly (rotated 180) could
cause rough idle. Check for the following items:
passages.
6E289

Step
Action
EGR system
working
properly. No
problem
found.
Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Go to Step 8
Go to Step 9
Go to DTC
P1404 chart
Go to Step 10
EGR system
working
properly. No
problem
found.
Verify repair

damage.
restrictions?
10

2. Using a Tech 2, command EGR ON and observe
the EGR valve pintle for movement.
command?
Verify repair

necessary.

Go to Step 3

Go to Step 2
1. Engine OFF.
2. Ignition ON.
between the EGR valve and the ignition feed.

2. Start the engine and idle until warm.
3. Using a Tech 2, command EGR 50% ON. (Refer to
Miscellaneous Test)
No

Yes

Is the EGR valve Loose?
Value(s)

necessary.
6E290
D06RX135
Circuit Description
Test Description

powertrain control module (PCM) sends a 5-volt
By monitoring the the sensor output voltage, the PCM
knows the MAP. A lower pressure (low voltage) output
voltage will be about 1-2 volts at idle. Higher pressure
(high voltage) output voltage will be about 4-4.8 volts at
wide open throttle. The MAP sensor is also used, under
certain conditions, to measure barometric pressure,
allowing the PCM to make adjustments for different
altitudes. The PCM uses the MAP sensor to diagnose
proper operation of the EGR system, in addition to other
functions.
IMPORTANT: Be sure to used the same diagnostic test

Diagnostic Chart.
should cause the voltage to be 1.5-2.1 volts less
than the voltage at step 1. Upon applying vacuum
to the sensor, the change in voltage should be
faulty sensor.
6E291

Step
Action
1.
2.
3.
4.
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Refer to On-Vehicle Service, MAP Sensor.

Go to Step 5

Go to Step 2
Repair the material to block.

Check the sensor cover for leakage or restriction.

Does the cover supply vacuum to the MAP sensor
only?
No
Disconnect the MAP sensor and plug inletmanifold.

Connect a hand vacuum pump to the MAP sensor.
Start the engine.
Apply 34 kPa (10 Hg) of vacuum and note the
voltage change.
Is the voltage change 1.5-2.1 volts less than step 1?

3
Yes

seconds.
2. Ignition ON. Dont crank engine.
4. Compare this scan reading to scan reading of a
Is the voltage reading the same +/0.40 volt?
Value(s)

6E292
D06RX016
Circuit Description
The evaporative emissions canister purge is controlled by
a solenoid that allows manifold and/or vacuum to purge
the canister when it is energized. The powertrain control
module (PCM) supplies a ground to energize the solenoid
valve (purge ON). The EVAP purge solenoid control is
turned ON and OFF several times a second. The duty
cycle (pulse width or ON time) is determined by engine
operating conditions including load, throttle position,
coolant temperature and ambient temperature. The duty
cycle is calculated by the PCM and the purge solenoid is
enabled when the appropriate conditions have been met:
D The engine run time after start is more than 60
seconds.
(86F).
D The fuel control system is operating in the closed-loop
mode.
Diagnostic Aids
D Make a visual check of vacuum hoses.
D Check the throttle body for possible cracked.
D Check the malfunction indicator lamp for a possible
mechanical problem.
Test Description
Diagnostic Chart.
1. Check to see if the solenoid is open or closed. The
solenoid is normally de-energized in this step, so it
should be closed.
2. This step checks to determine if the solenoid was
open due to an electrical circuit problem or a
defective solenoid.
3. This should normally energize the solenoid, opening
the valve and allowing the vacuum to drop (purge
ON).
6E293

Step
Action
Go to Step 4
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Verify repair
No problem
found in the
EVAP
emission
canister
purge valve
check
Refer to
Diagnostic
Aids
Replace the faulty purge solenoid. Refer to On-Vehicle

Service, EVAP Canister Purge Solenoid.
Replace the PCM.

Go to Step 2

Go to Step 3
Check for a short to ground in the RED/BLU wire.

Is there a short?
1. At the throttle body, put a cap over the vacuum port

where the hose was disconnected for testing. This
is to prevent a vacuum leak when the engine is
started.
2. Ignition OFF.
4. Apply vacuum to the purge solenoid with the hand
vacuum pump.
5. Start the engine, run at 2500 RPM.
6. Using the Tech 2, select F0: Engine, F3: Misc.
Tests, F0: EVAP Purge.
7. Turn the purge solenoid ON.
Did the vacuum drop when the purge was turned on?
No

2. As in Step 1, apply vacuum (10 Hg or 34 kPa) to the
solenoid.
Yes
1. Ignition OFF.
3. At the throttle body, disconnect the hose that goes
to the pump solenoid.
4. Using a hand vacuum pump with an attached
vacuum gauge 5-8840-0279-0, apply vacuum (10
Hg or 34 kPa) to the solenoid.
Value(s)

2. At the throttle body, install a vacuum gauge where
the hose from the purge solenoid was disconnected
for testing.
4. Stabilize the engine speed at about 2500 RPM.
5. Momentarily snap the throttle open and let it return
to idle.
Is there approximately 10 Hg (34 kPa) of vacuum
available at the EVAP emission canister purge
solenoid?
6E294
Evaporative (EVAP) Emissions Canister Purge Valve Check (Cont'd)

Step
Action
Value(s)
Yes
No

2. Connect a test lamp between the harness
terminals.
Does the test lamp light?
Go to Step 7
Go to Step 10
Go to Step 11
Go to Step 12
Verify repair
12
Does on of the terminals light the test lamp?
Go to Step 13
Go to Step 14
13
Check for an open in the RED/BLU wire between the

purge solenoid and the PCM.
Go to Step 15
Go to Step 6
Verify repair
Verify repair
10
Probe terminal A and terminal B with a test lamp to

ground.
Does the test lamp light on both terminals?
11
Repair the short to voltage in the RED/BLUE wire.

14
Repair the open in the BLK/YEL wire.

15
Repair the open in the RED/BLU wire.

6E295

supported by this vehicle application.If any DTCs not
listed here are displayed by a Tech 2, the Tech 2 data may
be faulty; notify the Tech 2 manufacturer of any DTCs
displayed that are not included in the following table.
DTC
Description
Type
Illuminate MIL
P0101
MAF System Performance
Yes
P0102
MAF Sensor Circuit Low Frequency
Yes
P0103
MAF Sensor Circuit High Frequency
Yes
P0107
MAP Sensor Circuit Low Voltage
Yes
P0108
MAP Sensor Circuit High Voltage
Yes
P0112
IAT Sensor Circuit Low Voltage
Yes
P0113
IAT Sensor Circuit High Voltage
Yes
P0117
ECT Sensor Circuit Low Voltage
Yes
P0118
ECT Sensor Circuit High Voltage
Yes
P0121
TP System Performance
Yes
P0122
TP Sensor Circuit Low Voltage
Yes
P0123
TP Sensor Circuit High Voltage
Yes
P0131
Yes
P0132
Yes
P0134
Yes
P0151
Yes
P0152
Yes
P0154
Yes
P0171
Yes
P0172
Yes
P0174
Yes
P0175
Yes
P0201
Yes
P0202
Yes
P0203
Yes
P0204
Yes
P0205
Yes
P0206
Yes
P0325
KS Module Circuit
No
P0327
KS Sensor Circuit
No
P0336
58X Reference Signal Circuit
Yes
P0337
CKP Sensor Circuit Low Frequency
Yes
P0341
CMP Sensor Circuit Performance
Yes
P0342
CMP Sensor Circuit Low
Yes
P0351
Yes
P0352
Yes
P0353
Yes
6E296
P0354
Yes
P0355
Yes
P0356
Yes
P0404
EGR Open Stuck
Yes
P0405
EGR Lo Volt
Yes
P0406
EGR Hi Voltage
Yes
P0502
Yes
P0562
System Voltage Low
No
P0563
System Voltage High
No
P0601
PCM Memory
Yes
P0705
Transmisson Rang Sensor Illegal Position (Refer to 4L30-E Automatic

Transmission)
No
P0706
Transmisson Range Sensor Performance (Refer to 4L30-E Automatic

Transmission)
No
P0712
Transmission Fluid Temperature (TFT) Low Voltage (Refer to 4L30-E

No
P0713
Transmission Fluid Temperature (TFT) High Voltage (Refer to 4L30-E

No
P0719
Brake Switch Circuit Low (Refer to 4L30-E Automatic Transmission

Diagnosis)
No
P0722
Output Speed Sensor Circuit No Signal (Refer to 4L30-E Automatic

Transmission)
Yes
P0723
Output Speed Sensor Circuit Intermittent Signal (Refer to 4L30-E

Automatic Transmission)
Yes
P0730
Incorrect Gear Ratio (Refer to 4L30-E Automatic Transmission)
No
P0748
Transmission Pressure Control Solenoid (PCS) Electrical Circuit Fault

(Refer to 4L30-E Automatic Transmission Diagnosis)
No
P0753
Transmission Shift Solenoid A Electrical Circuit Fault (Refer to 4L30-E

Yes
P0758
Transmission Shift Solenoid B Electrical Circuit Fault (Refer to 4L30-E

Yes
P1171
Yes
P1380
ABS Rough Road ABS System Fault
Yes
P1381
ABS Rough Class 2 Serial Link Error
Yes
P1404
EGR Closed Stuck
Yes
P1508
IAC System Low RPM
Yes
P1509
IAC System High RPM
Yes
P1618
Serial Peripheral Interface (SPI) PCM Interprocessor Communication

Error (Automatic Transmission Only)
Yes
P1625
Yes
P1640
Driver-1-Input High Voltage
No
P1790
TRANS ROM Checksum Error (Refer to 4L30-E Automatic Transmission

Diagnosis)
Yes
P1792
TRANS EEPROM Checksum Error (Refer to 4L30-E Automatic

Yes
P1835
TRANS Kick Down Switch Malfunction (Refer to 4L30-E Automatic

No

P1850
Brake Band Apply Solenoid Manlfunction (Refer to 4L30-E Automatic

No
P1860
TCC PWM Solenoid Circuit Fault (Refer to 4L30-E Automatic

Yes
6E297
6E298
Diagnostic Trouble Code (DTC) P0101 MAF System Performance
D06RW057
Circuit Description

load situation, while a small quantity or air indicates
within a range of around 4 to 7 g/s at idle to around 25 to 40
g/s at maximum engine load. DTC P0101 will be set if the
signal from the MAF sensor does not match a predicted
value based on throttle position and engine RPM.

fault is detected.

D No TP sensor or MAP sensor DTCs are set.
D The throttle is steady, TP angle doesnt change by
more than 1%.
D System voltage is between 11.5 volts and 16 volts.
D Calculated air flow is between 25 g/second and 40
g/second.
D Above conditions present for at least 1 second.
D MAF signal frequency indicates an airflow significantly
higher or lower than a predicted value based on throttle
position and engine RPM for a total of 12.5 seconds
over a 25-second period of time.

feed.
Diagnostic Aids
An intermittent may be caused by the following:
D Poor connections.
D Mis-routed harness.
D Rubbed through wire insulation.
D Broken wire inside the insulation.
Refer to Intermittents under service category Symptoms.
Any un-metered air may cause this DTC to set. Check for
the following:

D
D
D
D
D
D
The duct work at the MAF sensor for leaks.

An engine vacuum leak.
The PCV system for vacuum leaks.
An incorrect PCV valve.
The engine oil dip stick not fully seated.
The engine oil fill cap loose or missing.
Test Description
Diagnostic Chart.
6E299
2. The MAF system performance or rationality

diagnostic uses the MAP sensor signal along with
other input to calculate an expected airflow rate that
is then compared to the actual measured airflow
from the MAF sensor. The first few steps of this
table verify that the MAP sensor is working properly.
6. Verifies the signal circuit from the MAF sensor
electrical connector to the PCM.
Verifies whether a ground and B+ circuit is
available.
DTC P0101 MAF System Performance

Step
Action
Go to Step 2
Go to Step 6
Go toStep 3
11.5 to 12.5
Volt
Go to Step 5
Go to Step 4
Verify repair
Verify repair
Verify repair
Go to Step 7
1. Ignition OFF.
2. Check the 12 volt signal circuit for the following
conditions:
D An open circuit
D A short to ground
Check the MAF ground circuit for the following
conditions:
D An open circuit
Go to OBD
System
Check

2. Using a Digital Voltmeter (DVM), check the 12 volt
signal circuit for the correct voltage.

5
No
1. Ignition OFF.
2. Disconnect the Mass Air Flow (MAF) Sensor
harness connector from the MAF Sensor.
3. Place an unpowered test lamp between the 12 volt
signal circuit and the ground circuit, both at the MAF
Sensor connector.
4. Ignition ON, EngineOFF.
Did the DVM indicate a value within the following

range?
4
Yes

performed?
Did the test lamp illuminate?

3
Value(s)
1. Ignition OFF.
2. Check the MAF Sensor signal circuit between the
PCM and the MAF Sensor for the following
conditions:
D An open circuit
D A short to ground
D A short to battery voltage
6E2100
DTC P0101 MAF System Performance (Cont'd)

Step
Action
4 to 7 g/s
Go to Step 8
Go toStep 9
25 to 40 g/s
Go to Step 10
Go toStep 9
Verify repair
Verify repair
Replace the MAF Sensor.

10
No
Observe the Tech 2 value while increasing the engine

RPM to its upper limit.
Yes
1. Connect the MAF Sensor wiring harness connector

to the MAF Sensor.
2. Connect the Tech 2 to the vehicle.
3. Place the Transmission in Park/Neutral, and fully
apply the Parking Brake.
5. Select the Mass Air Flow (MAF) parameter on the
Tech 2.
With the engine idling, does the Tech 2 display the
following value(s)?
Value(s)
Replace the PCM.

6E2101
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency
D06RW057
Circuit Description
signal from the MAF sensor is below the possible range of

D The engine is running above 500 RPM for greater than
10 seconds.
D MAF signal frequency is below 1.6 g/s for a total of
50-percent of the last 1000 samples monitored. A
sample is taken every cylinder event.

D The PCM calculates an air flow value based on idle air


feed.
Diagnostic Aids
D Misrouted harness Inspect the MAF sensor harness
wires.
related to the MAF sensor. A change in the display will
D 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
6E2102
about 3-6 g/second at idle to 100 g/second or greater

at the time of the 1-2 shift. If not, check for a restriction.
Test Description

4. A voltage reading of less than 4 or over 5 volts at the
MAF sensor signal circuit indicates a fault in the
wiring or a poor connection.
5. This verifies that ignition feed voltage and a good
ground are available at the MAF sensor.

Diagnostic Chart.
DTC P0102 MAF Sensor Circuit Low Frequency

Step
Action

1.
2.
3.
4.
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
5V
Go to Step 5
Go to Step 8
Go to Step 13
Go to Step 6
Go to Step 12
Go to Step 7
Verify repair
Go to Step 11
4V
Go to Step 9
Go to Step 10
1. Check for a poor connection at the MAF sensor.

2. If a poor connection is found, replace the faulty
terminal(s).
2.85 6.65
g/s

feed circuit and battery ground.
Go to Step 2

feed and ground circuits at the MAF sensor harness
connector.
Ignition OFF.
Using a DVM, measure voltage between the MAF
sensor signal circuit and battery ground.

5
No
Go to OBD
System
Check

ignition?
Yes

performed?
Is the MAF Frequency below the specified value?

3
Value(s)
1. Ignition OFF.
2. Disconnect the MAF sensor.
3. Disconnect the PCM connector for the MAF signal
circuit.
5. With the DVM, measure the voltage between the
MAF signal terminal at the PCM and battery ground.
Is the voltage under the specified value?
6E2103
DTC P0102 MAF Sensor Circuit Low Frequency (Cont'd)

Step
Action
1.
2.
3.
4.
1.
2.
3.
4.
Verify repair
Go to Step 13
Verify repair
Verify repair
Verify repair
Go to Step 14
Verify repair

14
Verify repair
Locate and repair the open in the ignition feed circuit to

the MAF sensor.
13
Locate and repair the open in the ground circuit to the

MAF sensor.
12
No
Ignition OFF.
Ignition ON.
Check the MAF sensor signal circuit between the
PCM and the MAF sensor for an open, short to
ground, or short to the MAF ground circuit.

11
Yes
Ignition OFF.
Ignition ON.
Check the MAF sensor signal circuit for a short to 5
volts.

10
Value(s)
Replace the PCM.

6E2104
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency
D06RW057
Circuit Description
signal from the MAF sensor is above the possible range of

D The engine is running above 500 RPM for more than
10 seconds.
D MAF signal frequency is above 40 g/s for a total of 50
percent of the last 200 samples monitored. A sample
is taken every cylinder event.


Conditions for clearing the MIL/DTC

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
4. A frequency reading with the MAF sensor connector
disconnected indicates an electromagnetic
interference (EMI) related fault.
6E2105
DTC P0103 MAF Sensor Circuit High Frequency

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
40 g/s
Go to Step 4
Go to Step 7
0 g/s
Go to Step 5
Go to Step 6
Verify repair
Go to Step 8
Verify repair
Go to Step 6
40 g/s
Go to Step 5
Go to Step 8
Verify repair

ignition?

Is MAF Frequency above the specified value?
1.
2.
3.
4.
Ignition OFF.
Ignition ON, engine idling.
Using a Tech 2, monitor MAF Frequency.
Does the Tech 2 indicate a MAF Frequency at the

specified value?
5

1. Check the MAF harness for incorrect routing near

high voltage components (solenoids, relays,
motors).
2. If incorrect routing is found, correct the harness
routing.

2. Quickly snap open throttle to wide open throttle
while under a road load and record value.
Does the Tech 2 indicate MAF Frequency above the
specified value?
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2106
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage
D06RX135
Circuit Description
vacuum) to above 4 volts with the ignition ON, engine
not running or at wide-open throttle (low vacuum).
The MAP sensor is used to determine manifold pressure.
MAP signal voltage that is excessively low, DTC P0107
will be set.


feed.
Diagnostic Aids

1000 RPM.
1000 RPM.
at or below 11 kPa for a total of approximately 10
D Ignition voltage more than 11 volts.

D Check for intermittent codes.
D The MAP sensor shares a ground with the Fuel Tank
Pressure Sensor, the ECT sensor, and the


If it is determined that the DTC occurs intermittently,
6E2107

circuit.
DTC P0107 MAP Sensor Circuit Low Voltage

Step
Action
Value(s)
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
5 V 104 kPa
Go to Step 10
Go to Step 5
5 V 104 kPa
Go to Step 6
Go to Step 8
Verify repair
Go to Step 7
Verify repair
Go to Step 11

11 kPa at sea
level
1. Ignition OFF.
3. Jumper the 5 volt reference A circuit and the MAP
connector.
4. Ignition ON.

2. Connect a test light between B+ and the MAP
sensor signal circuit at the MAP sensor harness
connector.
Is the MAP value near the specified value.
1. Ignition OFF.
ground?
No
Go to OBD
System
Check

performed?
Yes

necessary.
6E2108
DTC P0107 MAP Sensor Circuit Low Voltage (Cont'd)

Step
Action
Verify repair
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Verify repair

11
No

connection at the PCM and the MAP sensor; replace
10
Yes
1. Ignition OFF.
2. Disconnect the PCM, and check the MAP signal
Value(s)
Replace the PCM.

6E2109
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit Hight Voltage
D06RX135
Circuit Description

vacuum) to above 4 volts with the key ON, engine not
running or at wide- open throttle (low vacuum).
MAP signal voltage that is excessively high, DTC P0108
will be set.

feed.

D Engine is running for more than 10 seconds.
D Throttle position is below 3% if engine speed is below
1000 RPM.
1000 RPM.
approximately 10 seconds over a 16-second period.

Diagnostic Aids
circuit.
6E2110
DTC P0108 MAP Sensor Circuit High Voltage

Step
Action
1.
2.
3.
4.
Go to Step 4
Refer to
Diagnostic
Aids
0.0 V 11 kPa
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Go to Step 8
Verify repair
Go to Step 12
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Check for a plugged or leaking vacuum supply to the

MAP sensor.
at the PCM.
10
Go to Step 3

at the MAP sensor electrical connector.
2. If a problem if found, replace the faulty terminal.
Is the vacuum supply plugged or leaking?

9
Go to Step 4
1. Check the MAP signal circuit for a short to voltage or

a short to the 5 volt reference A circuit.
2. If the MAP sensor signal circuit is shorted, repair

8
90 kPa
Probe the sensor ground circuit with a test light to B+.
Was the MAP sensor signal circuit shorted?

7
Go to Step 2
Ignition OFF.
Ignition ON.
Note the MAP sensor voltage displayed on the Tech
2.

6
Go to OBD
System
Check

Is the MAP sensor voltage at the specified value? (If no,

start with diagnostic chart for other sensors in the
5
No

Tech 2.

ignition?
4
Yes

performed?

3
Value(s)
1. Check the continuity of the MAP sensor ground

circuit.
2. If the MAP sensor ground circuit measures over 5
ohms, repair open or poor connection.
Was a condition found and corrected?
6E2111
DTC P0108 MAP Sensor Circuit High Voltage (Cont'd)

Step
11
Action
Yes
No
Replace the PCM.

12
Value(s)
Verify Repair
Verify repair

6E2112
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage
D06RW078
Circuit Description

lower, causing the PCM to monitor a lower voltage. DTC
P0112 will set when the PCM detects an excessively low
circuit.

feed.

D Vehicle speed is greater than 30 mph (48 km/h) .
D IAT signal voltage indicates an intake air temperature
greater than 148C (298F) (about 5 volts) for a total
of 12.5 seconds over a 25-second period of time.

Diagnostic Aids
Test Description
Diagnostic Chart:

the Failure Records condition, refer to the
Temperature vs. Resistance Value table. The table
may be used to test the IAT sensor at various
shifted sensor that may be stored above or below
the IAT sensor. If the IAT sensor appears to be OK,
the fault is intermittent; refer to Diagnostic Aids.

C
OHMS
100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
Temperature
vs. Resistance
Values
(approximate)
6E2113
6E2114
DTC P0112 IAT Sensor Circuit Low Voltage

Step
Action
1.
2.
3.
4.
Ignition OFF.
Ignition ON.
148C
(283F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
38C
(36F)
Go to Step 6
Go to Step 5
Verify repair
Go to Step 7
Verify repair
Verify repair

Go to Step 2
1. Ignition OFF.
2. Disconnect the PCM electrical connectors.
ground.
Go to OBD
System
Check
1. Ignition ON, engine OFF. Review and record

Tech 2 Failure Records data.
P0112.

5
No

(IAT).

ignition?
4
Yes

performed?

value?
3
Value(s)
Replace the PCM.

6E2115
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage
D06RW078
Circuit Description

lower causing the PCM to monitor a lower voltage. DTC
P0113 will set when the PCM detects an excessively high
circuit.

feed.

D
D
D
D
D

Vehicle speed is less than 20 mph (32 km/h).
Mass air flow is less then 20 g/second.
less than 39C (38F) for total of 12.5 seconds over
a 25-second period.

Diagnostic Aids
Test Description
Diagnostic Chart:
6E2116

table may be used to test the IAT sensor at various
shifted sensor that may be open above or below a
certain temperature. If this is the case, replace the
IAT sensor. If the IAT sensor appears to be OK, the
fault is intermittent; refer to Diagnostic Aids.

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E2117
DTC P0113 IAT Sensor Circuit High Voltage

Step
Action

1. Ignition OFF.
connector.
4. Ignition ON.
2.

2.
38C
(36F)
Go to Step 4
Go to Step 3
Refer to Test
Description
Refer to
Diagnostic
Aids
more than
140C
(284F)
Go to Step 6
Go to Step 5
more than
140C
(284F)
Go to Step 7
Go to Step 8
Verify repair
Go to Step 10
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Go to Step 11
1. Ignition OFF.
2. Disconnect the PCM, and check the IAT signal
necessary.
Go to Step 2
1. Ignition OFF.
2. Disconnect the PCM, and check the IAT sensor
necessary.

No
Go to OBD
System
Check

parameters.
Yes

performed?

3
Value(s)

6E2118
DTC P0113 IAT Sensor Circuit High Voltage (Cont'd)

Step
10
Action
Yes
No

11
Value(s)
Verify repair
Verify repair
Replace the PCM.

6E2119
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage
060RY00304
Circuit Description

thermistor mounted on a coolant crossover pipe at the
coolant warms, the sensor resistance becomes lower,
and the ECT signal voltage measured at the PCM drops.
With a fully warmed-up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts.

feed.

D Engine running time is longer than one minute.
temperature greater than 150C (302F) (about 0.10
V) for a total of 50 seconds over a 100-second period.

time.
Diagnostic Aids
the fault.
Test Description
Diagnostic Chart.
6E2120


C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
DTC P0117 ECT Sensor Low Voltage

Step
Action


Go to Step 2
139C
(282F)
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
39C
(38F)
Go to Step 6
Go to Step 5
Verify repair
Go to Step 7
Verify repair
Verify repair

1. Ignition OFF.
2. Disconnect the PCM and check the ECT signal
ground circuit.
3. If the ECT signal circuit is shorted. repair it as
necessary.
No
Go to OBD
System
Check

ignition?
Yes

performed?

3
Value(s)
Replace the PCM.

6E2121
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage
060RY00304
Circuit Description

thermistor mounted in on a coolant crossover pipe at the
coolant warms, the sensor resistance becomes less, and
the ECT signal voltage measured at the PCM drops. With
a fully warmed-up engine, the ECT signal voltage should
measure about 1.5 to 2.0 volts.

feed.

for a total of 50 seconds over a 100-second period.

time.
Diagnostic Aids
the fault.
Test Description
Diagnostic Chart.
6E2122

Temperature vs. Resistance Value table. The

C
OHMS

100
212
177
80
176
332
60
140
667
45
113
1188
35
95
1802
25
77
2796
15
59
4450
41
7280
23
12300
15
21450
30
22
52700
40
40
100700
6E2123
DTC P0118 ECT Sensor Circuit High Voltage

Step
Action
Refer to
Diagnostic
Aids
151C
Go to Step 6
Go to Step 5
151C
Go to Step 7
Go to Step 8
Verify repair
Go to Step 10
Verify repair
Go to Step 9
Verify repair
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Verify repair

11
Refer to Test
Description
1. Ignition OFF.
2. Disconnect the PCM, and check the ECT signal
necessary.

10
Go to Step 3
1. Ignition OFF.
2. Disconnect the PCM, and check the ECT sensor
necessary.

9
Go to Step 4


8
39C


7
Go to Step 2

connector.

6
Go to OBD
System
Check

P0118.

5
No


4
Yes

performed?

3
Value(s)
Replace the PCM.

6E2124
Diagnostic Trouble Code (DTC) P0121 TP System Performance
D06RW059
Circuit Description
many of the PCM-controlled outputs. The PCM monitors
throttle position and compares actual throttle position
from engine speed. If the PCM detects an out-of-range
condition, DTC P0121 will set.

D
D
D
D
The engine is running.

No MAP DTCs, or P0121, P0123 DTCs are set.
MAP reading is below 55 kPa.
Throttle is steady, throttle angle is changing less than
1%.
D Predicted throttle angle is not close to actual throttle
angle.
D Above conditions are present for a total of 12.5

fault is detected.


info function or by disconnecting the PCM battery
feed.
Diagnostic Aids
incorrect MAP signal may cause the PCM to incorrectly
be set.
Valve.
components itself.
the IAT Sensor.

locks improperly formed or damaged terminals, and
6E2125

DTC P0121 TP System Performance

Step
Action
Observe the TP angle reading on the Tech 2 while

slowly opening the throttle.
Go to Step 6
65 kPa
Go to Step 5
Go to Step 4
Verify repair
Go to Step 12
Verify repair
Closed
throttle = 0%
Wide open
throttle =
100%
Refer to
Diagnostic
Aids
Go to Step 7
0V
Go to Step 8
Go to Step 9
5V
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12

circuit and the TP sensor signal circuit at the TP
Is the TP sensor reading at the specified value?
Go to Step 3
1. Disconnect the TP sensor.

Is the TP sensor reading near the specified value?
65 kPa
Does the TP angle increase steadily and evenly from

the closed throttle value to the wide open throttle
value?
7
Go to Step 2
1. Check the MAP signal circuit between the PCM and

the MAP sensor for an open, short to ground, or
short to the MAP ground circuit.
2. If the MAP signal circuit is open or shorted, repair it
as necessary.

6
Go to OBD
System
Check
1. Disconnected the MAP sensor.

circuit and the MAP signal circuit at the MAP sensor
harness connector.
Was the MAP signal circuit open or shorted?

5
No

Is the MAP reading less than the specified value? (If no,
start with diagnosis chart for other sensors in the circuit
4
Yes

performed?
Is the MAP reading less than the specified value?

3
Value(s)

1. TP signal circuit for a short to voltage.
2. TP sensor ground circuit for high resistance
between the PCM and the TP sensor.
3. TP sensor ground circuit for a poor connection.
necessary.
6E2126
DTC P0121 TP System Performance (Cont'd)

Step
10
Action
Value(s)
Yes
No

1. TP signal circuit or 5 volt reference A circuit for a
poor connection.
2. TP signal circuit or 5 volt reference A circuit for
high resistance between the PCM and the TP
sensor.
necessary.
11
Verify repair
Go to Step 12
Verify repair
Verify repair

12
Replace the PCM.

6E2127
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage
D06RW059
Circuit Description
signal voltage will vary from below 0.6 volts at closed
The TP signal is used by the powertrain control module
(PCM) for fuel control and many of the PCM-controlled
outputs.

D TP sensor signal voltage is less than 0.22 volt for a total
of 0.78 second over a 1.5-second period.



feed.
Diagnostic Aids
Valve.
components itself.
the IAT Sensor.
throttle position display on the Tech 2 while moving
6E2128
DTC P0122 TP Sensor Circuit Low Voltage

Step
Action
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
5V
Go to Step 10
Go to Step 5
5V
Go to Step 6
Go to Step 8
Verify repair
Go to Step 7
Verify repair
Go to Step 12
Verify repair
Go to Step 9
1. Ignition OFF.

necessary.
0.22 V
2. Connect a test light between B+ and the TP sensor
signal circuit at the TP sensor harness connector.

ground?
7
Go to Step 2
1. Ignition OFF.
3. Jumper the 5 volt reference A circuit and the TP
signal together at the TP sensor harness connector.
4. Ignition ON.
Is the TP Sensor at the specified value? (If no, start

with diagnosis chart for other sensors in the circuit and
see if 5V returns.)
6
Go to OBD
System
Check

P0122.
Is the TP Sensor at the specified value?

5
No


4
Yes

performed?
Is the TP Sensor below the specified value?

3
Value(s)
1. Ignition OFF.
2. Disconnect the PCM, and check the TP signal
6E2129
DTC P0122 TP Sensor Circuit Low Voltage (Cont'd)

Step
Action
Verify repair
Go to Step 12
Verify repair
Go to Step 11
Verify repair
Verify repair

12
No

necessary.
11
Yes

necessary.
10
Value(s)
Replace the PCM.

6E2130
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage
D06RW059
Circuit Description
many of the PCM-controlled outputs.

D TP sensor signal voltage is greater than 4.88 volts for
a total of 0.78 second over a 1.5-second period.



feed.
Diagnostic Aids
D The TP sensor shares a 5 Volt Reference with the EGR
Position sensor. Check the 5 Volt reference if these
DTCs are also set.
D The TP sensor shares a ground with the IAT sensor
and the EGR position Sensor. Check the ground if
these other DTCs are also set.
TP sensor display on the Tech 2 while moving
D Faulty TP sensor With the ignition key ON, engine
OFF, observe the TP sensor display on the Tech 2
while slowly depressing the accelerator to wide open
throttle. If a voltage over 4.88 volts is seen at any point
in normal accelerator travel, replace the TP sensor.
Test Description
Number (s) below refer to the step number(s) on the
Diagnostic Chart.
7. Components that share the TP sensor 5 volt reference
A circuit include the following device:
D EGR valve
6E2131
Disconnect the component while observing the TP

sensor display on the Tech 2. If the reading
changes drastically when this component is
disconnected, replace the component that
affected the reading.
DTC P0123 TP Sensor Circuit High Voltage

Step
Action
4.88 V
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
0V
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 10
Verify repair
Go to Step 12
Verify repair
Go to Step 8
Probe the sensor ground circuit at the TP sensor

harness connector with a test light connected to B+.
circuit.
necessary.
Go to Step 2

2. Observe the TP Sensor display on the Tech 2.(If
no, start with diagnostic chart other sensors in the

6
Go to OBD
System
Check

Is the TP Sensor near the specified value?

5
No

Does the Tech 2 indicate DTC P0123 failed.

4
Yes

performed?
Is the TP Sensor above the specified value?

3
Value(s)
1. Ignition ON.
2. Monitor the TP Sensor Tech 2 display while
disconnecting each of the components that share
the 5 volt reference A circuit (one at a time).
3. If the TP Sensor Tech 2 display changes, replace
the component that caused the display to change
when disconnected.
the TP Sensor display to change?
6E2132
DTC P0123 TP Sensor Circuit High Voltage (Cont'd)

Step
Action
Verify repair
Go to Step 9
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Verify repair

12
1. Ignition OFF.
2. Disconnect the PCM, and check for an open sensor
ground circuit to the TP sensor.
Was the sensor ground circuit to the TP sensor open?
11
No
Check for poor electrical connections at the TP sensor

and replace terminals if necessary.
10
Yes

3. Check for a short to B+ on the 5 volt reference A
circuit.
4. If the 5 volt reference A circuit is shorted, repair it
as necessary.
Was the 5 volt reference A circuit shorted?
Value(s)
Replace the PCM.

6E2133

P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1
D06RX137
Circuit Description



D
D
D
D
No related DTCs.
Vehicle is operating in closed loop.
14.5 and 14.8.

feed.
Diagnostic Aids
be routed incorrectly and contacting the exhaust
system.
6E2134
D
D
D
decrease. However, If fuel pressure is too low, a DTC

Lean injector(s) Perform Injector Balance Test.
Vacuum leaks Check for disconnected or damaged
Exhaust leaks An exhaust leak may cause outside air
be indicated.
MAF sensor The system can go lean if the MAF
Fuel contamination Water, even in small amounts,
affected HO2S.
Test Description
Number(s) below refer to step numbers on the diagnostic
chart.
6E2135

Step
Action
Value(s)
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 5
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
Verify repair
425475 mV
Refer to
Diagnostic
Aids
Go to Step 9
Verify repair

1. Ignition OFF.
2. Reconnect the
disconnected.
3. Ignition ON.
PCM,
leave
the
sensor

between the specified values?
9
Go to Step 3
1. Turn the ignition OFF, HO2S 1 and PCM

disconnected.
signal circuits.

8
Go to Step 4

7
22 mV

circuit.

6
Go to Step 2

Note test result.

ground?
5


4
No
Go to OBD
System
Check

performed?

specified value?
3
Yes
Replace the PCM.

6E2136

P0132 HO2S Circuit High Voltage Bank 1 Sensor 1
D06RX137
Circuit Description



D No related DTCs.
D Engine coolant temperature is above 60C (140F)
D Closed loop commanded air/fuel ratio is between
14.5 and 14.8.
OR
during deceleration fuel cutoff mode operation for 3
seconds.

feed.
Diagnostic Aids
D Perform Injector Balance Test Refer to Fuel System
Diagnosis.
D Check the EVAP canister for fuel saturation If full of

D MAF sensor The system can go rich if MAF sensor
signal indicates an engine airflow measurement that is
not correct. Disconnect the MAF sensor to see it the
rich condition is corrected. If so, replace the MAF
sensor.
D Check for a leak in the fuel pressure regulator
regulator for the presence of fuel. There should be no
fuel in the vacuum line.
D An intermittent TP sensor output will cause the system
accelerating.
contamination of the HO2S can also cause a high
HO2S voltage to be indicated. This condition is
the HO2S exposed to the exhaust stream.
If
D Open HO2S Signal Circuit or Faulty HO2SA poor
swing between the rich and lean thresholds can also
cause this condition.
Operate the vehicle by
HO2S voltage is limited within a range between 300
and associated terminal conditions.
affected HO2S.
Test Description
Diagnostic Chart.
indicated.
6E2137
6E2138

Step
Action

Diagnostic Support.
1.
2.
3.
4.
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
3-4 V
Go to Step 5
Go to Step 6
Verify repair
10 mV
Go to Step 7
Go to Step 8
425-475 mV
Refer to
Diagnostic
Aids
Go to Step 8
Verify repair

Is Bank 1 HO2S 1 voltage between the specified
values?
952 mV (500
mV in
deceleration
fuel cutoff
mode)

side) to ground.
Go to Step 2

Ignition OFF.
Ignition ON.
signal terminals.

5
No
Go to OBD
System
Check
1. Ignition ON, review and record Tech 2 Failure

Records data.
ignition?
Yes

performed?

specified value?
3
Value(s)
Replace the PCM.

6E2139

P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1
D06RX138
Circuit Description
D The powertrain control module (PCM) supplies a bias
with a 10 megaohm digital voltmeter, this may display
as low as 320 mV. The oxygen sensor varies the
exhaust is rich, down through about 10 mV when
exhaust is lean. The PCM constantly monitors the
HO2S signal during closed loop operation and
compensates for a rich or lean condition by decreasing
or increasing injector pulse width as necessary. If the
Bank 1 HO2S 1 voltage remains at or near the 450 mV
bias for an extended period of time, DTC P0134 will be
set, indicating an open sensor signal or sensor low
circuit.
D Heated oxygen sensors are used to minimize the
amount of time required for closed loop fuel control
operation and to allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors Bank
1 HO2S 1 and Bank 2 HO2S 1 to become active.
Oxygen sensor heaters are required by post-catalyst
monitor sensors to maintain a sufficiently high
temperature for accurate exhaust oxygen content
readings further from the engine.

D No related DTCs.

functioning properly.
Action Take When the DTC Sets


feed.
6E2140
Diagnostic Aids
ON, engine OFF, after a cool down period, the
HO2S 1 voltage displayed on the Tech 2 is normally
455-460 mV. A reading over 1000 mV indicates a
signal line shorted to voltage. A reading under 5 mV
indicates a signal line shorted to ground or signal lines
shorted together. Disconnect the HO2S and connect
a test light between the HO2S ignition feed and heater
ground circuits. If the test light does not light for 2
seconds when the ignition is turned on, repair the open
ignition feed or sensor ground circuit as necessary. If
the test light lights and the HO2S signal and low circuits
are OK, replace the HO2S.
D Intermittent test With the Ignition ON, monitor the

Test Description
Diagnostic Chart.

Step
Action
Go to Step 2
400-500 mV
Go to Step 3
Go to Step 4
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7

Go to OBD
System
Check


5
No

minutes.

ignition?
4
Yes

performed?

3
Value(s)

terminal connections at the PCM and replace terminals
if necessary.
6E2141

Step
Action
Verify repair
Go to Step 8
Verify repair
Go to Step 9
0-10 mV
Go to Step 10
Go to Step 11
Verify repair
Verify repair

11

Is Bank 1 HO2S 1 voltage in the specified range?
10
No
1. Ignition OFF.
corrected?
Yes
1. Ignition OFF.
corrected?
Value(s)
Replace the PCM.

6E2142

P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1
D06RX139
Circuit Description



D
D
D
D
No related DTCs.
The engine is operating in closed loop.
14.5 and 14.8.

feed.
Diagnostic Aids
be mispositioned and contacting the exhaust system.
decrease. However, if fuel pressure is too low, a DTC

be indicated.
D MAF sensor The system can go lean if the MAF
6E2143

affected HO2S.
Test Description
Diagnostic Chart.
intermittent condition is indicate.

Step
Action
Go to Step 2
22 mV
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 5
Go to Step 6
Verify repair
Go to Step 7
Go to Step 8
1. Turn ignition OFF.

3. Check the Bank 2 HO2S 1 high and low signal
circuits for a short to ground or a short to the heater
ground circuit.
Go to OBD
System
Check

Were Bank 2 HO2S 1 signal circuits shorted?

5
No


ignition?
4
Yes

performed?

specified value?
3
Value(s)
1. Ignition OFF.
2. Leave the PCM and HO2S 1 disconnected.
signal circuits.
6E2144
DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1 (Cont'd)

Step
Action
No
Verify repair
425-475 mV
Refer to
Diagnostic
Aids
Go to Step 9
Verify repair
1. Ignition OFF.
2. Reconnect the PCM, leave HO2S 1 disconnected.
3. Ignition ON.
Yes

Value(s)
Replace the PCM.

6E2145

P0152 HO2S Circuit High Voltage Bank 2 Sensor 1
D06RX139
Circuit Description
or lean condition by decreasing or increasing the injector

D No related DTCs.
D The engine is operating in closed loop.
(140F).
D Closed loop commanded air/fuel ratio between 14.5
and 14.8.
D Throttle angle between 3% and 19%.
OR

during deceleration fuel cutoff mode operation for up to
3 seconds.


feed.
Diagnostic Aids
D Rich injector(s) Perform Injector Balance Test.
6E2146
D Leaking injector Refer to Fuel System Diagnosis.

D Evaporative emissions (EVAP) system Check the
canister for fuel saturation. If the canister is full of fuel,
check EVAP control system components and hoses.
Refer to Evaporative Emission (EVAP) Control
System.
D MAF sensor The system can go rich if the MAF
measurement that is not correct Disconnect the MAF
sensor to see if rich condition is corrected. If so,
replace MAF sensor.
D Check for leaking fuel pressure regulator diaphragm by
checking vacuum line to regulator for the presence of
fuel. There should be no fuel in the vacuum line.
D TP sensor An intermittent TP sensor output will
cause the system to go rich, due to a false indication
of the engine accelerating.
contamination of the HO2S can cause a high HO2S
voltage to be indicated. This condition is indicated by
powdery white deposit on the portion of the HO2S
exposed to the exhaust stream. If contamination is
noticed, replace the affected HO2S.
D Open HO2S Signal Circuit of Faulty HO2S A poor
switch between the rich and lean thresholds can also
cause the condition. Operate the vehicle while
HO2S is voltage limited within a range between 300
and associated terminal connections.
affected HO2S.
Test Description
Diagnostic Chart.
indicated.
6E2147

Step
Action

2. Engine is at operating temperature.
1.
2.
3.
4.
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
3-4 V
Go to Step 5
Go to Step 6
Verify repair
10 mV
Go to Step 7
Go to Step 8
425-475 mV
Refer to
Diagnostic
Aids
Go to Step 8
Verify repair

Is the Bank 2 HO2S 1 voltage between the specified
values?
952 mV (500
mV in
deceleration
fuel cut-off
mode)

side) to ground.
Go to Step 2

Ignition OFF.
Ignition ON.
signal terminals.

5
No
Go to OBD
System
Check
1. Ignition ON.
ignition?
Yes

performed?

specified value?
3
Value(s)
Replace the PCM.

6E2148

P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1
D06RX140
Circuit Description
with a 10 megaohm digital voltmeter, this may display as
low as 320 mV. The oxygen sensor varies the voltage
within a range of about 1000 mV when the exhaust is rich,
down through about 10 mV when exhaust is lean. The
PCM constantly monitors the HO2S signal during closed
loop operation and compensates for a rich or lean
condition by decreasing or increasing injector pulse width
as necessary. If the Bank 2 HO2S 1 voltage remains at or
near the 450 mV bias for an extended period of time, DTC
P0154 will be set, indicating an open sensor signal or
sensor low circuit.
of time required for closed loop fuel control operation
required for fuel control sensors Bank 1 HO2S 1 and Bank
2 HO2S 1 to become active. Oxygen sensor heater are
required by post-catalyst monitor sensors to maintain a
sufficiently high temperature for accurate exhaust oxygen
content readings further from the engine.

D No related DTCs.
D Engine running time is longer than 40 seconds.

D Oxygen sensor heater is functioning properly.


feed.
Diagnostic Aids

damaged terminals, poor terminal-to-wire-connection,
ON, engine OFF, the HO2S 1 voltage displayed on
the Tech 2 is normally 455-460 mV. A reading over
1000 mV indicates a signal line shorted to voltage. A
reading under 5 mV indicates a signal line shorted to
ground or signal lines shorted together. If not,
disconnect the HO2S and connect a test light between
the HO2S ignition feed and heater ground circuits. If
the test light does not light for 2 seconds when the
ignition is turned on, repair the open ignition feed or
sensor ground circuit as necessary. If the test light
lights and the HO2S signal and low circuits are OK,
replace the HO2S.
D Intermittent test With the ignition ON, monitor the
6E2149

Test Description
Diagnostic Chart.

Step
Action
Go to Step 2
400-500 mV
Go to Step 3
Go to Step 4
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7

Go to OBD
System
Check

2. Review and record Tech 2 Failure Records data and
note parameters.

5
No

minutes.

ignition?
4
Yes

performed?

3
Value(s)

terminal connections at the PCM and replace
6E2150

Step
Action
Verify repair
Go to Step 8
Verify repair
Go to Step 9
0-10 mV
Go to Step 10
Go to Step 11
Verify repair
Verify repair

11

Is the Bank 2 HO2S 1 voltage in the specified range?
10
No
1. Ignition OFF.
corrected?
Yes
1. Ignition OFF.
corrected?
Value(s)
Replace the PCM.

6E2151
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Too Lean Bank 1
D06RW068
Circuit Description
transmission) or 12% (manual transmission) and +20%.
speed/load fuel trim cells before determining the status

D None of the following: EGR DTCs, HO2S DTCs,
(response, transition, open, low volts, no activity), MAF
DTCs, TP sensor DTCs, MAP DTCs, IAT DTCs,
canister purge DTCs, EVAP DTCs, injector circuit
DTCs, or misfire DTCs.

and 100C (212F).
120C (248F).
kPa.
g/second.
D Canister purge duty cycle is greater than 0% if on.

fault is detected.

6E2152

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
DTC P0171/P0174.
6E2153

Step
Action
Yes
Go to Step 2
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this chart
Go to Step 3
L.T. Fuel
Trim: +20%
Go to Step 5
Go to Step 4

loop.
the Tech 2.
No
Go to OBD
System
Check

performed?
Is the displayed value greater than the specified value?

4
Value(s)

Records conditions.
test runs and note the test result.
ignition?
Go to Step 5
The lean
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms
section.
Go to Step 6
Go to Step 15

disconnections, splits, kinks, improper routing and
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step11
Verify repair
Go to Step 11

7

System).

sensor.

10

for vacuum leaks.
6E2154

Step
Action
11

12
Verify repair
Go to Step 13
0%
Go to Step 19
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Refer to
Diagnostic
Aids
Verify repair

19

Did Injector Balance Test isolate a problem?
18
Go to Step 12

17
Verify repair

16

Did Fuel System Pressure Test isolate a condition
requiring repair?
15
No

monitoring the B1 Long Term Fuel Trim displayed
on the Tech 2.
Does BANK 1 S.T. FUEL TRIM value decrease to
14
Yes

locations.
necessary.
13
Value(s)

6E2155
D06RW068
Circuit Description
heated oxygen sensors (HO2S) 1 and Bank 2 HO2S 1
signals and adjusts fuel delivery based upon the HO2S
signal voltages. A change made to fuel delivery will be
indicated by the long and short term fuel trim values which
can be monitored with a Tech 2. Ideal fuel trim values are
around 0%; if the HO2S signals are indicating a lean
condition the PCM will add fuel, resulting in fuel trim
trim values will be below 0%, indicating that the PCM is
rich condition is detected on Bank 1, the PCM will set DTC
P0172.
transmission) or 12 (manual transmission) and +20%.
diagnostic.

D None of the following was set: EGR DTCs, HO2S

DTCs, (response, transition, open, low volts, no
activity), MAF DTCs, TPS DTCs, MAP DTCs, IAT
DTCs, canister purge DTCs, EVAP DTCs, injector
circuit DTCs, or misfire DTCs.
and 100C (212F).
120C (248F).
kPa.
g/second.

fault is detected.
6E2156

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
DTC P0172/P0175.
6E2157

Step
Action
Yes
Go to Step 2
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this chart
Go to Step 3
L.T. Fuel
Trim: 15%
(auto. trans.)
OR 12%
(man. trans.)
Go to Step 5
Go to Step 4

loop.
2. Observe B1 Long Term Fuel Trim display on the
Tech 2.
No
Go to OBD
System
Check

performed?

value?
4
Value(s)

Records conditions.
test runs and note test result.
ignition?
Go to Step 5
The rich
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms.
Go to Step 6
Go to Step 15

Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11
Verify repair
Go to Step 11

7


problem found.

10
1. Ignition OFF.
objects.
6E2158

Step
Action
11

fuel.
System).
12
0%
Go to Step 21
Go to Step 14
Go to Step 15
Go to Step 18
Go to Step 16
Go to Step 17
Verify repair
Verify repair
Verify repair
Go to Step 19
Verify repair
Refer to
Diagnostic
Aids
Verify repair
Verify repair

missing.
21
Go to Step 20

20
Go to Step 13

2. If Injector Balance Test isolates a problem, repair as
necessary (refer to Fuel Metering System).
requiring repair?
19
Minimum 0%
Maximum
100%
Replace the PCM.

18
Go to Step 12

17
Verify repair

A-15.
16

15
No

monitoring the B1 Long Term Fuel Trim and B1
Short Term Fuel Trim display on the Tech 2.
14
Yes
Ignition ON, engine OFF, monitor the TP display on

the Tech 2 while slowly depressing the accelerator
pedal.
13
Value(s)

6E2159
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2
D06RW069
Circuit Description
speed/load fuel trim cells before determining the status of

and 100C (212F).
120C (248F).
kPa.
D Mass air flow is between 2 g/second and 200 g/second.


activity), MAF, TP sensor, MAP, IAT, canister purge,
EVAP, injector circuit, or misfire.

6E2160

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
DTC P0171/P0174.
6E2161

Step
Action
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.
Go to Step 3
L.T. Fuel
Trim: +20%
Go to Step 5
Go to Step 4

performed?

loop.
the Tech 2.
Is the displayed values greater than the specified
values?
Value(s)

Records conditions.
test runs.
ignition?
Go to Step 5
The lean
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms
section.
Go to Step 6
Go to Step 15

improper disconnections and repair any problem
found.
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11

7

System).

sensor.

6E2162

Step
Action
10

for vacuum leaks.
11
Go to Step 12
Verify repair
Go to Step 13
0%
Go to Step 19
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Refer to
Diagnostic
Aids
Verify repair

19
Verify repair

Did the Injector Balance Test isolate a problem?
18

17
Go to Step 11

16
Verify repair

Did the Fuel System Pressure Test isolate a condition
requiring repair?
15

monitoring the B2 Short Term Fuel Trim displayed
on the Tech 2.
Does the B2 Short Term Fuel Trim value decrease to
14
No

locations.
necessary.
13
Yes

contaminants (see Diagnosis in Engine Fuel for
is present (see Engine Fuel).
12
Value(s)

6E2163
D06RW069
Circuit Description
delivered. If an excessively rich condition is detected on
diagnostic.

D
D
D
D
D
D
D
D
D
D
D
activity), MAF, TPS, MAP, IAT, canister purge, EVAP,

injector circuit, or misfire.
and 100C (212F).
120C (248F).
Manifold absolute pressure is between 24 kPa and 99
kPa.
Throttle angle is steady below 95%.
Vehicle speed is below 136 km/h (85 mph).
Mass air flow (MAF) is between 2 g/second and 200
g/second.
Ignition voltage is above 9.5 volts.
Fuel system is in closed loop.
Canister purge duty cycle is greater than 15%, if ON.


6E2164

feed.
Diagnostic Aids
Reviewing the Failure Records Vehicle mileage since the

Test Description
Diagnostic Chart.
DTC P0172/P0175.

Step
Action
Yes
Go to Step 2
Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
chart.
Go to Step 3
L.T. Fuel
Trim: 15%
(auto. trans.)
OR 12%
(man. trans.)
Go to Step 5
Go to Step 4

loop.
2. Observe the BANK 2 L.T. FUEL TRIM display on
the Tech 2.
No
Go to OBD
System
Check

performed?

value?
4
Value(s)

Records conditions.
test runs.
ignition?
Go to Step 5
The rich
condition is
not present.
If a
driveability
symptom still
exists, refer
to Symptoms
Go to Step 6
Go to Step 15

Verify repair
Go to Step 7
6E2165

Step
Action
Go to Step 10
Go to Step 11
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Minimum 0%
Maximum
100%
Go to Step 13
Go to Step 21
0%
Go to Step 22
Go to Step 14
Go to Step 15
Go to Step 18
Go to Step 16
Go to Step 17
Verify repair
Verify repair

17

A-15.
16
Go to Step 9

15
Verify repair

monitoring the B1 Lont Term Fuel Trim and BANK
2 S.T. FUEL TRIM display on the Tech 2.
14

2. Monitor the TP Angle display on the Tech 2 while
slowly depressing the accelerator pedal.
maximum value at wide-open throttle?
13
Go to Step 8

fuel.
System).
12
Verify repair
1. Turn the ignition off and physically inspect the

throttle body bore, throttle plate, and IAC passages
for coking and foreign objects.
11

10
No

problem found.
Yes

Value(s)
Replace the PCM.

6E2166

Step
Action
18

2. If the Injector Balance Test isolates a problem,
repair as necessary (refer to Fuel Metering
System).
requiring repair?
19
No
Verify repair
Go to Step 19
Verify repair
Refer to
Diagnostic
Aids
Verify repair
Verify repair

missing.
21
Yes

replace the contaminated sensor.
20
Value(s)

6E2167
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.
6E2168


access.
R321054

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0201 reset?
6E2169

Step
Action
1. Engine OFF.
2. Disconnect the injector connector.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/white wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 1 (green with white
tracer).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

engine?
Value(s)
Replace the PCM.

6E2170
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.

faulty.
6E2171

access.
R321055

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0202 reset?
6E2172

Step
Action
1. Engine OFF.
injector test connector
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/orange wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 2 (green with orange
tracer).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

engine?
Value(s)
Replace the PCM.

6E2173
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.
6E2174


access.
R321056

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0203 reset?
6E2175

Step
Action
1. Engine OFF.
2. Disconnect the injector test connector .
injector connector
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 3 (green).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

engine?
Value(s)
Replace the PCM.

6E2176
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.

6E2177

access.
R321057

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0204 reset?
6E2178

Step
Action
1. Engine OFF.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/red wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 4 (green/red).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
Replace the PCM.

6E2179
D06RW070
Circuit Description

circuit. The voltage on each driver is monitored to detect a
fault. If the voltage is not what the PCM expects to
circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.
6E2180

faulty.

access.
R321058

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0205 reset?
6E2181

Step
Action
1. Engine OFF.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/black wire for a short to voltage.
12

11
Go to Step 6

tracer) and the wire for cylinder 5 (green with black
tracer).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
Replace the PCM.

6E2182
D06RW070
Circuit Description

circuit.

feed.

injectors.

commanded ON.

Diagnostic Aids
Test Description
Diagnostic Chart.

6E2183

access.
R321059

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 5
Go to Step 4
Go to Step 5
Go to
Diagnostic
Aids

No
Go to OBD
System
Check

performed?
Yes

parameters.
Does P0206 reset?
6E2184

Step
Action
1. Engine OFF.
Go to Step 8
Go to Step 15
Go to OBD
System
Check
Go to Step 11
Go to Step 10
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair

15

14
Go to Step 9

13
Go to Step 7

the green/yellow wire for a short to voltage.
12
Repair the open injector harness wire or open injector

11
Go to Step 6

tracer) and the wire for cylinder 6 (green with yellow
tracer).
10
Go to Fuel
Injector Coil
Test
Procedure

No

injectors.
Yes

steady in step 5.
engine?
Value(s)
Replace the PCM.

6E2185
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit
D06RW0351
Circuit Description
The knock sensor is used to detect engine detonation,
allowing the powertrain control module (PCM) to retard
ignition control (IC) spark timing based on the knock
sensor (KS) signal being received. The knock sensor
produces an AC signal so that under a no knock condition
the signal on the KS circuit measures about 0.007 V AC.
The KS signals amplitude and frequency depend upon
the amount of knock being experienced. The PCM
contains a non-replaceable knock filter module called a
signal-to-noise enhancement filter (SNEF) module. This
filter module in the PCM determines whether knock is
occurring by comparing the signal level on the KS circuit
with the voltage level on the noise channel. The noise
channel allows the PCM to reject any false knock signal
by knowing the amount of normal engine mechanical
noise present. Normal engine noise varies depending on
engine speed and load. When the PCM determines that
an abnormally low noise channel voltage level is being
experienced, a DTC P0325 will set.

D Engine has been running for at least 30 seconds.
D The PCM determines that its internal signal from its
knock filter module indicates a continuous knocking
condition for more than 10 seconds.

D The PCM will use a substitute default spark retard

value of 6 degrees to minimize knock during conditions
when knock is likely to occur.

feed.
Diagnostic Aids
D Poor connection at PCM Inspect the knock sensor
and PCM connectors for backed-out terminals, broken
locks, and improperly formed or damaged terminals.
D Misrouted harness Inspect the knock sensor harness
circuits such as spark plug coils.
Test Description
Diagnostic Chart.
6E2186
DTC P0325 KS Module Circuit

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair

performed?
this diagnostic.
under criteria included in Conditions for Setting the
DTC.
ignition?

2. Review and record Tech 2 Failure Records data for
DTC P0325.
conditions.
Does the Tech 2 indicate DTC P0325 test failed this
ignition?
Replace the PCM.

6E2187
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit
D06RW0351
Circuit Description
The powertrain control module (PCM) uses the knock
sensor to detect engine detonation, allowing the PCM to
retard ignition control (IC) spark timing based on the
knock sensor (KS) signal being received. The knock
sensor produces an AC signal so that under a no knock
condition the signal on the KS circuit measures about
0.007 V AC. The signal amplitude and frequency are
dependent upon the amount of knock being experienced.
The PCM monitors the KS signal and can diagnose the
KS sensor and circuitry.

D
D
D
D
D
Engine running time is at least 10 seconds.

The TP sensor is greater than 5%.
The ECT sensor is greater than 60C (140F).
The knock sensor signal voltage is less than 0.20 volts,
or greater than 4.8 volts.
D All conditions are present for more than 15 seconds.

fault is detected.
D The PCM will use a calculated spark retard value to

minimize knock during conditions when knock is likely
to occur. The calculated value will vary based on
engine speed and load.

feed.
Diagnostic Aids
Test Description
Diagnostic Chart.
6E2188
DTC P0327 KS Sensor Circuit

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to OBD
System
Check
Go to Step 4
Go to Step 3
Go to Step 4
Refer to
Diagnostic
Aids
Go to Step 6
Go to Step 5
Verify repair
Verify repair
Go to Step 7
Verify repair
Go to Step 8
100K ohms
Go to Step 9
Go to Step 10

performed?
this diagnostic.
in diagnostic support Conditions for Setting the
DTC.
ignition?

conditions.
ignition?
Using a test light to battery +, check the black/blue wire

(PCM side) to verify that the shield connection is good.
Repair the open shield ground.



2. Check the KS signal circuit between the PCM and
the knock sensor connector for an open, a short to

2. Knock sensor connected.
3. Measure the resistance of the knock sensor by
connecting the DVM between the PCM connector
and the engine block.
Is the resistance of the knock sensor near the specified
value?
6E2189
DTC P0327 KS Sensor Circuit (Cont'd)

Step
Action
No
Go to Step 11
Go to Step 10
Verify repair
Verify repair

11
Yes

2. Connect the DVM to monitor AC voltage between
the PCM connector and engine ground.
3. Tap on the engine lift bracket with a socket
extension while observing the signal indicated on
the DVM.
Is any signal indicated on the DVM while tapping on the
10
Value(s)
Replace the PCM.

6E2190
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit
D06RX145
Circuit Description

58 crankshaft pulses will be produced. The powertrain
control module (PCM) uses the 58X reference signal to
calculate engine RPM and crankshaft position. The PCM
58X reference circuit, DTC P0336 will set.

fault is detected.

rotations.

feed.
Diagnostic Aids
6E2191

DTC P0336 58X Reference Signal Circuit

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to Engine
Cranks But
Will Not Run
chart
Go to Step 4
Refer to
Diagnostic
Aids
Verify repair
Go to Step 5
2.5 V
Go to Step 8
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Verify repair
Go to Step 10
Verify repair

1.
2.
3.
4.

Clear DTC P0336.
Observe DTCs.
Is DTC P0336 set?

4



Replace the CKP sensor. Use caution to avoid any hot

oil that may drip out.
Check connections at the PCM and replace the

No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2192
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency
D06RX145
Circuit Description
powertrain control module (PCM) uses the 58X reference
received. If the PCM does not receive pulses on the 58X
reference circuit, DTC P0337 will set.

D Engine cranking.

pulses.

fault is detected.


feed.
Diagnostic Aids
6E2193

DTC P0337 CKP Sensor Circuit Low Frequency

Step
Action
1.
2.
3.
4.
Go to Step 3
Go to Chart 3
Go to Step 4
Refer to
Diagnostic
Aid
Go to Step 7
Go to Step 5
Go to Step 6
Go to Step 11
Verify repair
Verify repair
Go to Step 8
2.5 V
Go to Step 11
Go to Step 9

sensor and PCM and repair the open circuit, short to
1. Ignition OFF.
1. Ignition ON.
2. With a DVM, backprobe the PCM connector 5 V

7
Go to Step 2

2. Ignition ON.
3. Using a DVM, verify that 5 V reference and ground
are being supplied at the sensor connector (PCM
side).
Are 5 V reference and ground available at the PCM?

6
Go to OBD
System
Check

Clear DTC P0337.
Observe DTCs.
Are 4-6 volts and ground available at the sensor?

5
No
Is DTC P0337 set?

4
Yes

performed?

3
Value(s)

6E2194
DTC P0337 CKP Sensor Circuit Low Frequency (Cont'd)

Step
Action
Verify repair
Go to Step 10
Verify repair
Verify repair
Go to Step 12
Verify repair
Check the connections at the PCM and replace the

12
No
Replace the CKP sensor. Use caution and avoid hot oil
that may drip out.
11
Yes

10
Value(s)
Replace the PCM.

6E2195
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performamce
D06RX145
Circuit Description
The CMP signal is produced by the camshaft position

received. The powertrain control module (PCM) uses the
CMP signal pulses to initiate sequential fuel injection.
the CMP signal circuit and compares the number of CMP
CMP reference circuit, DTC P0341 will set and the PCM
will initiate injector sequence without the CMP signal with
a one in six chance that injector sequence is correct. The
condition occurs.
D The engine is running (1X CMP reference pulses are

being received).
D The CMP sensor signal is not detected at the correct
interval every 6 cylinders.
D Above condition fails for 100 occurrences within 200
test samples.

fault is detected.
D The PCM will initiate the injector sequence without the
6E2196

feed.
Diagnostic Aids

of the fault.
NOTE: On early-built Troopers, the Tech 2 indication for
CMP ACT. COUNTER (Cam Position Sensor activity)
will continue to count up, even if no cam position signal is
being received by the PCM. This problem can be
corrected by reprogramming the PCM with the latest
EEPROM program.
Test Description
Diagnostic Chart.
missing camshaft magnet or a faulty sensor. The
voltage measured in this step should read around 4
volts, toggling to near 0 volts when the CMP sensor
DTC P0341 CMP Sensor Circuit Performance

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
4-6 V
Go to Step 10
Go to Step 7
Verify repair
Verify repair
Go to Step 6
1. Ignition ON.
ignition?
Measure the voltage between the CMP sensor signal

circuit and the sensor ground circuit at the CMP sensor
harness connector.
If the voltage measured in step 3 was less than 4-6

volts, proceed directly to step 6 without completing this
step.
If the voltage in step 3 was greater than 4-6 V, repair the
short to voltage in the CMP feed circuit.
No
Go to OBD
System
Check

performed?
Yes

position sensor.
6E2197
DTC P0341 CMP Sensor Circuit Performance (Cont'd)

Step
Action
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
4-0 V
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Verify repair

14
Verify repair
Replace the faulty or missing camshaft position sensor.

13

value?
12
Go to Step 8
Backprobe the PCM connector with a DVM to monitor

voltage on the camshaft position input signal circuit
while cranking the engine with the sensor connected.
(Use rubber band, tape, or an assistant to keep the
DVM lead in contact with the sensor terminal during this
test.)
11
Verify repair

10
Check for a short or open in the sensor ground circuit.

No

2. Ignition ON, check the following circuits:
D The CMP sensor signal circuit for an open or a
short to voltage.
D The CMP sensor input signal circuit for a short
to ground.
Yes

sensor.
2. Check the following circuits for an open between the
ignition control module and the CMP sensor:
D The sensor feed circuit.
Value(s)
Replace the PCM.

6E2198
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low
D06RX145
Circuit Description
The CMP signal produced by the camshaft position

received. The hall type CMP sensor and the CKP sensor
share 5 V and ground connections at the powertrain
control module (PCM). The third wire at the sensor is a
signal circuit to the PCM. The PCM uses the CMP signal
pulses to initiate sequential fuel injection. The PCM
constantly monitors the number of pulses on the CMP
signal circuit and compares the number of CMP pulses to
the number of 58X reference pulses received. If the PCM
does not receive pulses on the CMP reference circuit,
DTC P0342 will set and the PCM will initiate injector
sequence without the CMP signal with a one in six chance
that injector sequence is correct. The engine will continue
to start and run normally, although the misfire diagnostic
will be affected if a misfiring condition occurs.

D The CMP sensor signal is not received by the PCM

fault is detected.
D The PCM will initiate injector sequence without the

feed.
Diagnostic Aids
terminal to wire connection.
of the fault.
Test Description
Diagnostic Chart.
damaged camshaft or a faulty PCM. The voltage
measured in this step should read around 4 volts,
toggling to near 0 volts when the CMP sensor
6E2199
6E2200
DTC P0342 CMP Sensor Circuit Low

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Refer to
Diagnostic
Aids
4-6 V
Go to Step 7
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
4-6 V
Go to Step 8
Go to Step 9
1. Ignition ON.
ignition?
1. Ignition ON.
2. Disconnect the CMP sensor.
3. Measure the voltage between the sensor feed
circuit and the sensor ground circuit at the CMP

sensor.
position sensor.

1. Check the following circuits between the PCM and

the CMP sensor:
D The sensor feed circuit. Open or short to
ground?
D The sensor ground circuit. Open or short to
voltage?
No
Go to OBD
System
Check

performed?
Yes

2. Measure the voltage between the CMP sensor
signal circuit and the sensor ground circuit at the
CMP sensor harness connector.
6E2201
DTC P0342 CMP Sensor Circuit Low (Cont'd)

Step
Action
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
0V
Go to Step 14
Go to Step 13
Verify repair
Verify repair

2. Ignition ON, check the following circuit:
D The CMP sensor signal circuit for an open.
1. Ignition ON.

14
Go to Step 9
Ignition OFF.
Ignition ON.
Probe the camshaft position signal circuit with a test
light to ground.
voltage in the camshaft position input signal circuit.

value?
13
Go to Step 12
1.
2.
3.
4.

12
Ignition OFF.
Ignition ON.
Probe the camshaft position signal circuit at the
PCM connector with a test light to B+.
ground in the camshaft position input signal circuit.
Was the test light ON?

11
No
1.
2.
3.
4.
Was either circuit shorted to ground?

10
Yes

2. Disconnect the PCM and connect a DVM to monitor
voltage on the camshaft position signal circuit at the
PCM connector.
3. Ignition ON.
4. Monitor the voltage display on the DVM while
repeatedly touching the CMP sensor signal circuit
at the CMP sensor connector with a test light to
ground.
Does the DVM voltage display switch between 0 and
approximately 5 volts when the test light is touched to
the CMP sensor signal circuit?
Value(s)
Replace the PCM.

6E2202
060RY00303
Circuit Description


is ON.
is OFF.



feed.
Diagnostic Aids
fault.
6E2203
6E2204

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

cycle?



with a DVM.

1. Ignition OFF.

1. Ignition OFF.
10

11

12

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2205
060RY00303
Circuit Description

D The engine is turning, determined by the 58 X

is ON.
is OFF.


6E2206

feed.
Diagnostic Aids
fault.
6E2207

Step
Action
Value(s)
Go to Step 2
Go to Step 3
Go to
Diagnostic
Aids
Verify repair
Go to Step 4
Verify repair
Go to Step 5
25-55 mV
Go to Step 6
Go to Step 9
100-180 mV
Go to Step 7
Go to Step 13

200-1200 mV
values?
Go to Step 8
Go to Step 11
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair

cycle?



with a DVM .

1. Ignition OFF.
coil connector while cranking the engine connector.

1. Ignition OFF.
10

11

12

13
No
Go to OBD
System
Check

performed?
Yes
Replace the PCM.

6E2208
060RY00303
Circuit Description


is ON.
is OFF.



feed.
Diagnostic Aids
fault.
the condition tha

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WORKSHOP MANUAL

This manual applies to 1999 models.

General Repair Instruction

Standard Bolts Torque Specifications............ 0A - 8

oil or grease before installation.

Ambient/Clean air flow

Gas other than

Ambient air mixed with

Lubrication point oil or

Lubrication point grease

Lubrication point jelly

Engine Serial Number

Transmission Serial Number

Manual : Stamped on the left side of the transmission

Automatic : Stamped on the identification plate, located

Lifting Point: Front

Supportable Point: Front

Supportable Point: Rear

Supportable Point: Rear

Standard Bolts Torque Specifications

The asterisk * indicates that the bolts are used for

EEPROM Electronically Erasable Programmable

MAP Manifold Absolute Pressure

ST Start / Scan Tool

Service Parts Identification Plate

Maintenance Schedule List

Recommended Liquid Gasket .................... 0B - 12

MAINTENANCE AND LUBRICATION

Service and Maintenance

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

Recommended Fluids and Lubricants

Mixture of water and good quality ethylene glycol base

DOT-3 hydraulic brake fluid.

Power steering system

DEXRON II-E Automatic transmission fluid.

DEXRON -III Automatic transmission fluid.

MUA Type Manual transmission & Transfer case

Rear axle and front axle

GL-5 gear lubricant (Standard differential)

b. Clutch fork joint

DOT-3 hydraulic brake fluid

Hood latch assembly

Hood and door hinges

Parking brake cables

Front wheel bearings

Shift on the fly system

GL-5 gear lubricant (SAE 75W-90)

Windshield washer solvent

Key lock cylinder

Synthetic light weight engine oil (SAE 5W-30)

MAINTENANCE AND LUBRICATION

Lubricant Viscosity Chart

lubrication chart. It is also important to select viscosity

Oil Viscosity Chart for Gasoline Engine

MAINTENANCE AND LUBRICATION

Oil Viscosity Chart for Manual Transmission and Transfer Case

Oil Viscosity Chart for Front Axle

MAINTENANCE AND LUBRICATION