Вы находитесь на странице: 1из 1335

Ranger

Repair Manual
(English, German, French, Spanish,
Italian, Portuguese)

Overhaul Manual
(English, German, French, Spanish,
Italian)

Wiring Diagrams

Right-Hand Drive ( - 07/2002)


(English)

Right-Hand Drive (08/2002 - )


(English)

Left-Hand Drive ( - 07/2002)


(English, German, French, Spanish,
Swedish, Greek, Italian, Portuguese)

Left-Hand Drive (08/2002 - )


(English, German, French, Spanish,
Swedish, Greek, Italian, Portuguese)

GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . .
RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . .
SERVICING PROCEDURE . . . . . . . . . . . . . . .
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADVISORY MESSAGES . . . . . . . . . . . . . . . . . .
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . .
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNDAMENTAL PROCEDURES . . . . . . . . . . . .
PREPARATION OF TOOLS AND
MEASURING EQUIPMENT . . . . . . . . . . . . . .
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION DURING REMOVAL,
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

GI11
GI11
GI11
GI13
GI13
GI13
GI14
GI15
GI15
GI15
GI15

ARRANGEMENT OF PARTS . . . . . . . . . . . . . .
CLEANING OF PARTS . . . . . . . . . . . . . . . . . . .
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
RUBBER PARTS AND TUBING . . . . . . . . . . .
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . .
VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . .
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . .
NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .

GI15
GI15
GI15
GI16
GI16
GI16
GI16
GI16
GI17
GI17
GI18
GI10

GI15

HOW TO USE THIS MANUAL


RANGE OF TOPICS
 This manual contains the procedures for
performing all of the required service operations.
The procedures are divided into the following five
basic operations.
(1) Removal/Installation
(2) Disassembly/Assembly
(3) Replacement
(4) Inspection
(5) Adjustment
 Simple operations which can be performed easily
just by looking at the vehicle, such as
removal/installation of parts, jacking, vehicle lift,
cleaning of parts, and visual inspection, have been
omitted.

SERVICING PROCEDURE
Inspection, Adjustment
 The procedures for inspections and adjustments
are divided into steps. Important points in regard to
the location and contents of the procedures are
explained in detail and are shown in the
illustrations.

SHOWS PROCEDURE ORDER


FOR SERVICE

SHOWS TIGHTENING
TORQUE
SPECIFICATIONS

GI1

HOW TO USE THIS MANUAL


SYMBOLS
 There are eight symbols indicating oil, grease,
sealant, and the use of SSTs. These symbols
show the points of applying or using such materials
during service.
Symbol

SST

Meaning

 The text sequence is as indicated by the arrows

shown below.
Example:

Kind

Apply oil

New appropriate
engine oil or
gear oil

Apply brake fluid

New appropriate
brake fluid

Apply automatic
transaxle/
transmission
fluid

New appropriate
automatic
transaxle/
transmission fluid

Apply grease

Appropriate
grease

Apply sealant

Appropriate
sealant

Apply petroleum
jelly

Appropriate
petroleum jelly

Replace part

O-ring, gasket,
etc.

Use SST

Appropriate SST

ADVISORY MESSAGES
Youll find several Warnings, Cautions, Notes,
Specifications and Upper and lower limits in this
manual.
Warning
 A Warning indicates a situation in which
serious injury or death could result if the
warning is ignored.
Caution
 A Caution indicates a situation in which
damage to the vehicle could result if the
caution is ignored.
Note
 A Note provides added information that will
help you to complete a particular procedure.
Specification
 The values indicate the allowable range when
performing inspections or adjustments.
Upper and lower limits
 The values indicate the upper and lower limits
that must not be exceeded when performing
inspections or adjustments.
TEXT SEQUENCE

GI3

UNITS
 The actual converted values for 2.7 kgf/cm2 are

UNITS
Electric current

A (ampere)

Electric power

W (watt)

Electric resistance

 (ohm)

Electric voltage

V (volt)

Length

264 kPa and 38.4 psi. In the top specification, 2.7


is used as an upper limit, so its converted values
are rounded down to 260 and 38. In the bottom
specification, 2.7 is used as a lower limit, so its
converted values are rounded up to 270 and 39.

mm (millimeter)
in (inch)
kPa (kilo pascal)

Negative pressure

mmHg (millimeters of mercury)


inHg (inches of mercury)
kPa (kilo pascal)

Positive pressure

kgf/cm2 (kilogram force per square


centimeter)
psi (pounds per square inch)

Number of
revolutions

rpm (revolutions per minute)


Nm (Newton meter)
kgfm (kilogram force meter)

Torque

kgfcm (kilogram force centimeter)


ftlbf (foot pound force)
inlbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)

Volume

ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)

Weight

g (gram)
oz (ounce)

Conversion to SI Units (Systme International


dUnits)
 All numerical values in this manual are based on SI
units. Numbers shown in conventional units are
converted from these values.
Rounding off
 Converted values are rounded off to the same
number of places as the SI unit value. For
example, if the SI unit value is 17.2 and the value
after conversion is 37.84, the converted value will
be rounded off to 37.8.
Upper and lower limits
 When the data indicates upper and lower limits, the
converted values are rounded down if the SI unit
value is an upper limit and rounded up if the SI unit
value is a lower limit. Therefore, converted values
for the same SI unit value may differ after
conversion. For example, consider 2.7 kgf/cm2 in
the following specifications:
210260 kPa {2.12.7 kgf/cm2, 3038 psi}
270310 kPa {2.73.2 kgf/cm2, 3945 psi}

GI4

FUNDAMENTAL PROCEDURES

FUNDAMENTAL PROCEDURES
PREPARATION OF TOOLS AND MESURING
EQUIPMENT
 Be sure that all necessary tools and measuring
equipment are available before starting any work.

SXU00008

ARRANGEMENT OF PARTS
 All disassembled parts should be carefully
arranged for reassembly.
 Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.

SXU00004

SPECIAL SERVICE TOOLS


 Use special tools when they are required.

49 SE01 310

SXU00009

CLEANING OF PARTS
 All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
DISASSEMBLY
 If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be
marked in a place that will not affect their
performance or external appearance and identified
so that reassembly can be performed easily and
efficiently.

Warning
 Using compressed air can cause dirt and
other particles to fly out, causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.

SXU00010
SXU00007

INSPECTION DURING REMOVAL, DISASSEMBLY


 When removed, each part should be carefully
inspected for malfunctioning, deformation,
damage, and other problems.

REASSEMBLY
 Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with new
ones:

GI5

Oil seals

Gaskets

O-rings

Lockwashers

Cotter pins

Nylon nuts

FUNDAMENTAL PROCEDURES

FUNDAMENTAL PROCEDURES
PREPARATION OF TOOLS AND MESURING
EQUIPMENT
 Be sure that all necessary tools and measuring
equipment are available before starting any work.

SXU00008

ARRANGEMENT OF PARTS
 All disassembled parts should be carefully
arranged for reassembly.
 Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.

SXU00004

SPECIAL SERVICE TOOLS


 Use special tools when they are required.

49 SE01 310

SXU00009

CLEANING OF PARTS
 All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
DISASSEMBLY
 If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be
marked in a place that will not affect their
performance or external appearance and identified
so that reassembly can be performed easily and
efficiently.

Warning
 Using compressed air can cause dirt and
other particles to fly out, causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.

SXU00010
SXU00007

INSPECTION DURING REMOVAL, DISASSEMBLY


 When removed, each part should be carefully
inspected for malfunctioning, deformation,
damage, and other problems.

REASSEMBLY
 Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with new
ones:

GI5

Oil seals

Gaskets

O-rings

Lockwashers

Cotter pins

Nylon nuts

FUNDAMENTAL PROCEDURES
 When reinstalling, position the hose clamp in the

original location on the hose, and squeeze the


clamp lightly with large pliers to ensure a good fit.

SXU00011

 Sealant, a gasket, or both should be applied to the

specified locations. When sealant is applied, parts


should be installed before sealant hardens.
Hardened sealant causes leakage.
 Oil should be applied to the moving components of
parts.
 Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before
reassembly.

SXU00015

TORQUE FORMULAS
 When using a torque wrenchSST combination,
the written torque must be recalculated due to the
extra length that the SST adds to the torque
wrench. Recalculate the torque using the following
formulas. Choose the formula that applies to you.
Torque Unit

Formula

Nm

Nm  [L/(L+A) ]

kgfm

kgfm  [L/(L+A) ]

kgfcm

kgfcm  [L/(L+A) ]

ftlbf

ftlbf  [L/(L+A) ]

inlbf

inlbf  [L/(L+A) ]

A: The length of the SST past the torque wrench


drive.
L: The length of the torque wrench.

SXU00012

ADJUSTMENT
 Use suitable gauges and/or testers when making
adjustments.

SST

SXU00016

VISE
 When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.

SXU00013

RUBBER PARTS AND TUBING


 Prevent gasoline or oil from getting on rubber parts
or tubing.

SXU00017

SXU00014

HOSE CLAMPS

GI6

FUNDAMENTAL PROCEDURES
 When reinstalling, position the hose clamp in the

original location on the hose, and squeeze the


clamp lightly with large pliers to ensure a good fit.

SXU00011

 Sealant, a gasket, or both should be applied to the

specified locations. When sealant is applied, parts


should be installed before sealant hardens.
Hardened sealant causes leakage.
 Oil should be applied to the moving components of
parts.
 Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before
reassembly.

SXU00015

TORQUE FORMULAS
 When using a torque wrenchSST combination,
the written torque must be recalculated due to the
extra length that the SST adds to the torque
wrench. Recalculate the torque using the following
formulas. Choose the formula that applies to you.
Torque Unit

Formula

Nm

Nm  [L/(L+A) ]

kgfm

kgfm  [L/(L+A) ]

kgfcm

kgfcm  [L/(L+A) ]

ftlbf

ftlbf  [L/(L+A) ]

inlbf

inlbf  [L/(L+A) ]

A: The length of the SST past the torque wrench


drive.
L: The length of the torque wrench.

SXU00012

ADJUSTMENT
 Use suitable gauges and/or testers when making
adjustments.

SST

SXU00016

VISE
 When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.

SXU00013

RUBBER PARTS AND TUBING


 Prevent gasoline or oil from getting on rubber parts
or tubing.

SXU00017

SXU00014

HOSE CLAMPS

GI6

ELECTRICAL SYSTEM
2. Inspect the terminals of waterproof connectors
from the connector side, as they cannot be
accessed from the wiring harness side.

ELECTRICAL SYSTEM
CONNECTORS
Disconnecting Connectors
 When disconnecting two connectors, grasp the
connectors, not the wires.

Caution
 To prevent damage to the terminal, wrap a
thin wire around the lead before inserting it
into the terminal.

SXU00020

 Connectors can be disconnected by pressing or

SXU00024

pulling the lock lever as shown.

SXU00021

Locking Connector
 When locking connectors, listen for a click that will
indicate they are securely locked.

SXU00022

Inspection
1. When a tester is used to inspect for continuity or to
measure voltage, insert the tester probe from the
wiring harness side.

SXU00023

GI7

NEW STANDARDS

NEW STANDARDS
 Following is a comparison of the previous standard and the new standard.
New Standard
Abbreviation
AP

Name

Previous Standard
Abbreviation

Accelerator Pedal

Accelerator Pedal

ACL

Air Cleaner

Air Cleaner

A/C

Air Conditioning

Air Conditioning

Barometric Pressure

Atmospheric Pressure

Battery Positive Voltage

VB

Battery Voltage

Brake Switch

Stoplight Switch

Calibration Resistor

Corrected Resistance

Camshaft Position Sensor

Crank Angle Sensor

CAC

Charge Air Cooler

Intercooler

CLS

Closed Loop System

Feedback System

CTP

Closed Throttle Position

Fully Closed

Closed Throttle Position Switch

Idle Switch

Clutch Position

BARO
B

CMP
sensor

CPP

Clutch Pedal Position

CIS

Continuous Fuel Injection System

CS sensor
CKP
sensor

Control Sleeve Sensor

EGI
CSP
sensor

Remark

Name

#6

Electronic Gasoline Injection System


Control Sleeve Position Sensor

Crankshaft Position Sensor

Crank Angle Sensor 2

DLC

Data Link Connector

Diagnosis Connector

DTM

Diagnostic Test Mode

Test Mode

DTC

#6

#1

Diagnostic Trouble Code(s)

Service Code(s)

DI

Distributor Ignition

Spark Ignition

DLI

Distributorless Ignition

Direct Ignition

Electronic Ignition

Electronic Spark Ignition

ECT

Engine Coolant Temperature

Water Thermo

EM

Engine Modification

Engine Modification

Engine Speed Input Signal

Engine RPM Signal

EVAP

Evaporative Emission

Evaporative Emission

EGR

Exhaust Gas Recirculation

Exhaust Gas Recirculation

FC

Fan Control

Fan Control

FF

Flexible Fuel

Flexible Fuel

4GR

Fourth Gear

Overdrive

Fuel Pump Relay

Circuit Opening Relay

#3

Fuel Cut Valve

#6

EI

FSO
solenoid

Fuel Shut Off Solenoid

FCV

GEN

Generator

Alternator

GND

Ground

Ground/Earth

HO2S

Heated Oxygen Sensor

Oxygen Sensor

Idle Air Control

Idle Speed Control

Incorrect Gear Ratio

IAC

#2

With heater

#1: Diagnostic trouble codes depend on the diagnostic test mode


#2: Controlled by the PCM
#3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#6: Part name of diesel engine

GI8

NEW STANDARDS

New Standard
Abbreviation

Name

Previous Standard
Abbreviation

Injection Pump

FIP

Fuel Injection Pump

Input/Turbine Speed Sensor

Pulse Generator

IAT

Intake Air Temperature

Intake Air Thermo

KS

Knock Sensor

Knock Sensor

MIL

Malfunction Indicator Lamp

Malfunction Indicator Light

MAP

Manifold Absolute Pressure

Intake Air Pressure

MAF
sensor

Mass Air Flow Sensor

Airflow Sensor

MFL

Multiport Fuel Injection

Multiport Fuel Injection

OBD

On-Board Diagnostic

Diagnosis/Self-Diagnosis

OL

Open Loop

Open Loop

Output Speed Sensor

Vehicle Speed Sensor 1

OC

Oxidation Catalytic Converter

Catalytic Converter

O2S

Oxygen Sensor

Oxygen Sensor

PNP

Park/Neutral Position

Park/Neutral Range

Remark

Name
#6

PCM Control Relay

Main Relay

PSP

Power Steering Pressure

Power Steering Pressure

PCM

Powertrain Control Module

ECU

Pressure Control Solenoid

Line Pressure Solenoid Valve

Pulsed Secondary Air Injection

Secondary Air Injection System

Pulsed
injection

Pump Speed Sensor

NE Sensor

#6

Secondary Air Injection

Secondary Air Injection System

Inject with
compressor

Secondary Air Pulse Valve

Reed Valve

Sequential Multipoint Fuel Injection

Sequential Fuel Injection

12 Shift Solenoid Valve

Shift A Solenoid Valve

23 Shift Solenoid Valve

Shift B Solenoid Valve

PAIR

AIR
SAPV
SFI

Shift Solenoid A

Shift Solenoid B

Engine Control Unit

Shift Solenoid C

34 Shift Solenoid Valve

3GR

Third Gear

3rd Gear

TWC

Three Way Catalytic Converter

Catalytic Converter

Throttle Body

Throttle Body

Throttle Position Sensor

Throttle Sensor

TB
TP sensor
TCV

Timer Control Valve

TCC

Torque Converter Clutch

Lock-up Position

TCM

Transmission (Transaxle) Control


Module

EC-AT Control Unit

Transmission (Transaxle) Fluid


Temperature Sensor

ATF Thermosensor

TR

Transmission (Transaxle) Range

Inhibitor Position

TC

Turbocharger

Turbocharger

Vehicle Speed Sensor

Vehicle Speed Sensor

Voltage Regulator

IC Regulator

VSS
VR

TCV

#4: Device that controls engine and powertrain


#6: Part name of diesel engine

GI9

Timing Control Valve

#6
#4

#6

NEW STANDARDS, ABBREVIATIONS

New Standard
Abbreviation
VAF
sensor
WU-TWC
WOT

Name

Previous Standard
Abbreviation

Volume Air Flow Sensor

Air flow Sensor

Warm Up Three Way Catalytic


Converter

Catalytic Converter

Wide Open Throttle

Fully Open

#5: Directly connected to exhaust manifold

ABBREVIATIONS
1ST . . . . . . . . . . . . . . . . .
2ND . . . . . . . . . . . . . . . . .
2W . . . . . . . . . . . . . . . . . .
3RD . . . . . . . . . . . . . . . . .
4TH . . . . . . . . . . . . . . . . .
4W . . . . . . . . . . . . . . . . . .
5TH . . . . . . . . . . . . . . . . .
BTDC . . . . . . . . . . . . . . . .
CARB . . . . . . . . . . . . . . .
CIS . . . . . . . . . . . . . . . . . .
EX . . . . . . . . . . . . . . . . . .
FIP . . . . . . . . . . . . . . . . . .
HLA . . . . . . . . . . . . . . . . .
H....................
IN . . . . . . . . . . . . . . . . . . .
L ....................
max. . . . . . . . . . . . . . . . . .
min. . . . . . . . . . . . . . . . . .
SST . . . . . . . . . . . . . . . . .
TDC . . . . . . . . . . . . . . . . .

First
Second
2-wheel
Third
Fourth
4-wheel
Fifth
Before top dead center
Carburetor
Continuous fuel injection
system
Exhaust
Fuel injection pump
Hydraulic lash adjuster
High
Intake
Low
Maximum
Minimum
Special service tool
Top dead center

GI10

Remark

Name

#5

NEW STANDARDS, ABBREVIATIONS

New Standard
Abbreviation
VAF
sensor
WU-TWC
WOT

Name

Previous Standard
Abbreviation

Volume Air Flow Sensor

Air flow Sensor

Warm Up Three Way Catalytic


Converter

Catalytic Converter

Wide Open Throttle

Fully Open

#5: Directly connected to exhaust manifold

ABBREVIATIONS
1ST . . . . . . . . . . . . . . . . .
2ND . . . . . . . . . . . . . . . . .
2W . . . . . . . . . . . . . . . . . .
3RD . . . . . . . . . . . . . . . . .
4TH . . . . . . . . . . . . . . . . .
4W . . . . . . . . . . . . . . . . . .
5TH . . . . . . . . . . . . . . . . .
BTDC . . . . . . . . . . . . . . . .
CARB . . . . . . . . . . . . . . .
CIS . . . . . . . . . . . . . . . . . .
EX . . . . . . . . . . . . . . . . . .
FIP . . . . . . . . . . . . . . . . . .
HLA . . . . . . . . . . . . . . . . .
H....................
IN . . . . . . . . . . . . . . . . . . .
L ....................
max. . . . . . . . . . . . . . . . . .
min. . . . . . . . . . . . . . . . . .
SST . . . . . . . . . . . . . . . . .
TDC . . . . . . . . . . . . . . . . .

First
Second
2-wheel
Third
Fourth
4-wheel
Fifth
Before top dead center
Carburetor
Continuous fuel injection
system
Exhaust
Fuel injection pump
Hydraulic lash adjuster
High
Intake
Low
Maximum
Minimum
Special service tool
Top dead center

GI10

Remark

Name

#5

ENGINE
(WL, WL Turbo, WL3, WLT3)
ENGINE OVERHAUL SERVICE
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . B2 1
ENGINE MOUNTING/DISMOUNTING . . . . B2 1
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 1
DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . B2 2
ENGINE DISASSEMBLY/ASSEMBLY . . . . B2 3
TIMING BELT DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . B2 3
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY (I) . . . . . . . . . . . . . . . . . . . . . . . B2 5
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY (II) . . . . . . . . . . . . . . . . . . . . . . B2 8
CYLINDER BLOCK DISASSEMBLY/
ASSEMBLY (I) . . . . . . . . . . . . . . . . . . . . . . . . B211
CYLINDER BLOCK DISASSEMBLY/
ASSEMBLY (II) . . . . . . . . . . . . . . . . . . . . . . B213
CYLINDER BLOCK DISASSEMBLY/
ASSEMBLY (III) . . . . . . . . . . . . . . . . . . . . . . B219
ENGINE INSPECTION/REPAIR . . . . . . . . . . B222
CYLINDER HEAD INSPECTION/
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B222
VALVE INSPECTION . . . . . . . . . . . . . . . . . . B222
VALVE GUIDE INSPECTION . . . . . . . . . . B223
VALVE GUIDE REPLACEMENT . . . . . . . B223
VALVE SEAT INSPECTION/REPAIR . . . B224
VALVE SPRING INSPECTION . . . . . . . . . B224
CAMSHAFT INSPECTION . . . . . . . . . . . . . B224
CAMSHAFT OIL CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B225
CAMSHAFT END PLAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B225

ENGINE OVERHAUL SERVICE


WARNING

CYLINDER BLOCK INSPECTION/


REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B226
OIL JET VALVE, NOZZLE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B226
PISTON INSPECTION . . . . . . . . . . . . . . . . B226
PISTON CLEARANCE INSPECTION/
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B226
PISTON RING CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B226
PISTON PIN CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B227
CRANKSHAFT INSPECTION . . . . . . . . . . B227
CRANKSHAFT OIL CLEARANCE
INSPECTION/REPAIR . . . . . . . . . . . . . . . B228
CRANKSHAFT END PLAY INSPECTION/
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B228
CONNECTING ROD INSPECTION . . . . B229
CONNECTING ROD OIL CLEARANCE
INSPECTION/REPAIR . . . . . . . . . . . . . . . B229
CONNECTING ROD SIDE CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B229
PISTON AND CONNECTING ROD
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B229
BALANCE SHAFT INSPECTION
(WL Turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . B230
BOLT INSPECTION . . . . . . . . . . . . . . . . . . . B230
TENSIONER SPRING INSPECTION . . . B230
VALVE CLEARANCE INSPECTION . . . . B231
GEAR CLEARANCE INSPECTION . . . . B231
PLUNGER SPRING INSPECTION . . . . . B231

ENGINE MOUNTING/DISMOUNTING

Warning
D Continuous exposure with USED engine oil
has caused skin cancer in laboratory mice.
Protect your skin by washing with soap and
water immediately after this work.

MOUNTING
1. Install the engine hanger (JE48 10 561C) to the
cylinder head by using bolt (99794 0820) or
(M8X1.25, 6T, Length 20mm {0.79 in}) as shown.

B21

Tightening torque
1925 Nm {1.92.6 kgfm,1418 ftlbf}

ENGINE MOUNTING/DISMOUNTING
2. Install the SSTs (arms and attachments) to the
holes as shown, and hand tighten the SST (bolts).

49 0107 680A

49 L010 102

49 L010 107

8. Remove the engine hanger (JE48 10 561C).


9. Drain the engine oil into a container.
10. Install the drain plug by using new washer.

49 L010 106

3. Assemble the SSTs (bolts, nuts and plate) to the


specified positions.

Tightening torque
3041 Nm {3.04.2 kgfm, 2230 ftlbf}

49 L010 101

DISMOUNTING
D Dismount in the reverse order of mounting.

49 L010 105

49 L010 104

4. Adjust the SST (bolts) so that less than 20 mm


{0.79 in} of thread is exposed.
5. Make the SSTs (plate and arms) parallel by
adjusting the SST (bolts and nuts).
6. Tighten the SST (bolts and nuts) to affix the SST
firmly.
PARALLEL
BOLT

PLATE

ARM
HOOK

ENGINE

NUT
WASHER

BOLT

NUT LESS THAN 20 mm


{0.79 in}

Warning
D Self-locking brake system of the engine
stand may not be effective when the engine
is held in an unbalanced position.
This could lead to sudden, rapid movement
of the engine and mounting stand handle
and cause serious injury.
Never keep the engine in an unbalanced
position, and always hold the rotating
handle firmly when turning the engine.
7. Mount the engine on the SST (engine stand).

B22

ENGINE DISASSEMBLY/ASSEMBLY

ENGINE DISASSEMBLY/ASSEMBLY
TIMING BELT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
5.08.8 Nm
{5090 kgfcm, 4478 inlbf}

R
R

1925 {1.92.6, 1418}

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

3851 {3.85.3, 2838}

1925 {1.92.6, 1418}

Water pump

Vacuum pump

Cylinder head cover


+ Assembly Note

Nm {kgfm, ftlbf}

Timing belt cover


+ Assembly Note

Tensioner, Tensioner spring


+ Disassembly Note

Pulley plate

Timing belt
+ Disassembly Note
+ Assembly Note

Tensioner, Tensioner Spring Disassembly Note


1. Turn the crankshaft clockwise and align the timing
marks as shown.

TIMING MARK
CAMSHAFT
PULLEY

TIMING MARK

TENSIONER
SPRING
TENSIONER
FIP PULLEY

B23

ENGINE DISASSEMBLY/ASSEMBLY
Timing belt deflection
9.010.0 mm {0.360.39 in} at
98 N {10 kgf, 22 lbf}

2. Remove the tensioner and tensioner spring.


Timing Belt Disassembly Note

Timing Belt Cover Assembly Note


D Tighten the timing belt cover bolts in the order
shown.

Caution
D The following will damage the belt and
shorten its life; Forcefully twisting it,
turning it inside out, or allowing oil or
grease on it.
D Mark the timing belt rotation on the belt for proper

reinstallation.

FAULTY

FAULTY

ROTATION
ARROW

FAULTY

Cylinder Head Cover Assembly Note


1. Before installing the cylinder head cover, inspect
the valve clearance. (Refer to ENGINE
INSPECTION/REPAIR, VALVE CLEARANCE
INSPECTION.)
2. Apply silicone sealant to the cylinder head as
shown.

FAULTY

25 mm {1.0 in} MIN.

Timing Belt Assembly Note


1. Turn the crankshaft clockwise and align the timing
marks as shown.
TENSIONER
LOCK BOLT

DEFLECTION
CHECKING
POINT
TIMING
MARK

TIMING MARK

Thickness
1.52.5 mm {0.0600.098 in}

CAMSHAFT
PULLEY

TENSIONER
SPRING
TENSIONER
FIP PULLEY

Caution
D Overtensioning of the timing belt can cause
breakage of the belt and the camshaft.
2. Verify that the FIP attaching bolts and nuts are
tightened to the specified torque.
This must be done to prevent overtensioning of the
timing belt after it has been installed.
3. Install the timing belt.
4. Install the tensioner, tensioner spring, and the lock
bolt.
5. Turn the crankshaft clockwise twice, and align the
timing marks. If they are not aligned, remove the
timing belt and repeat from Timing Belt Assembly
Note step 1.
6. Loosen the tensioner lock bolt to apply tension to
the belt. Do not apply tension other than that of the
tensioner spring.
7. Tighten the tensioner lock bolt. Be sure the
tensioner does not move together with the bolt
rotation.
8. Turn the crankshaft clockwise twice, and check the
timing belt deflection as shown. If it is incorrect,
repeat from Tensioner, Tensioner Spring
Disassembly Note.

B24

3. Tighten cylinder head cover bolts A and B.


Tightening torque
1.52.9 Nm {1530 kgfcm, 1426 inlbf}

A
ENGINE
FRONT
B

4. Tighten the cylinder head cover bolts in the order


shown.
Tightening torque
5.08.8 Nm {5090 kgfcm, 4478 inlbf}

ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER HEAD DISASSEMBLY/ASSEMBLY (I)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
29 {3.0, 22} + (90 105 ) + (90 105 )

6.49.3 Nm
{6595 kgfcm, 5782 inlbf}

1819 {1.82.0, 13.114.4}

R
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

123140 {12.514.3, 91103}


1925 {1.92.6, 1418}
Nm {kgfm, ftlbf}

Blind cover
+ Assembly Note

Seal plate
+ Assembly Note

Water temperature sender unit


+ Assembly Note

Water temperature sensor

Cylinder head
+ Disassembly Note
+ Assembly Note

Camshaft pully
+ Disassembly Note
+ Assembly Note

Cylinder head gasket


+ Assembly Note

B25

ENGINE DISASSEMBLY/ASSEMBLY
Camshaft Pulley Disassembly Note
D Hold the camshaft by using a wrench on the cast
hexagon.

3. Put a paint mark on each bolt head.


4. Using the marks as a reference, tighten the bolts
by turning each 90 105 in the sequence
shown.
5. Further tighten each bolt by turning another 90
105.

Cylinder Head Disassembly Note


1. Remove bolts A.
2. Loosen the cylinder head bolts in two or three
steps in the order shown.

PAINT MARK
A

90 105

90 105

PAINT MARK
A

6. Tighten bolts A.
Cylinder Head Gasket Assembly Note
D Apply silicone sealant to the cylinder head as
shown.

Tightening torque
1819 Nm {1.82.0 kgfm, 13.114.4 ftlbf}
Seal Plate Assembly Note
D Tighten the seal plate bolts in the order shown.

Thickness
2.03.0 mm {0.080.11 in}
16.0 mm
{0.63 in}
40.5 mm
{1.59 in}
48.5 mm
{1.91 in}

ENGINE
FRONT

9.0 mm
{0.35 in}

Cylinder Head Assembly Note


1. Apply clean engine oil to the threads and the seat
face of each bolt and install them.
2. Tighten the bolts in two or three steps in the order
shown in the figure.

Camshaft Pulley Assembly Note


D Hold the camshaft by using a wrench on the cast
hexagon and tighten the pulley lock bolt.

Tightening torque
29 Nm {3.0 kgfm, 22 ftlbf}

B26

ENGINE DISASSEMBLY/ASSEMBLY
Water Temperature Sender Unit Assembly Note
D Apply silicone sealant to the thread of the water
temperature sender unit as shown.

3 PITCHES

Blind Cover Assembly Note


D Apply silicone sealant to the blind cove as shown.
Thickness
1.52.5 mm {0.0600.098 in}

B27

ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER HEAD DISASSEMBLY/ASSEMBLY (II)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
11.314.2 Nm {115145 kgfcm, 100125 inlbf}

R
SST

1620 {1.62.1, 1215}

SST

SST
R
2030 {2.03.1, 1522}

R
3041 {3.04.2, 2230}

Nm {kgfm, ftlbf}

Camshaft cap
+ Disassembly Note
+ Assembly Note

Valve spring seat, upper

Valve spring
+ Assembly Note

Camshaft
+ Disassembly Note

Valve spring seat, lower

Rocker arm
+ Assembly Note

Valve

10

Pivot

Valve seal
+ Disassembly Note
+ Assembly Note

Valve keeper
+ Disassembly Note
+ Assembly Note

11

Water outlet pipe

Camshaft Cap Disassembly Note


1. Measure the camshaft end play.
(Refer to ENGINE INSPECTION/REPAIR,
CAMSHAFT END PLAY INSPECTION.)
2. Loosen the camshaft cap bolts in three or four
steps in the order shown.

ENGINE
FRONT

B28

ENGINE DISASSEMBLY/ASSEMBLY
Camshaft Disassembly Note
D Measure the camshaft oil clearance.
(Refer to ENGINE INSPECTION/REPAIR,
CAMSHAFT OIL CLEARANCE INSPECTION.)

49 L012 001

49 L012 002

Valve Keeper Disassembly Note


D Remove the valve keeper by using the SST.

VALVE SEAL

49 L012 005

49 0636 100B
49 B012 0A2
VALVE GUIDE

CYLINDER HEAD

Valve Spring Assembly Note


D Install the valve spring with the closer pitch toward
the cylinder head.

Valve Seal Disassembly Note


D Remove the valve seal by using the SST.

A GREATER
THAN B
B

49 S120 170
CYLINDER HEAD

Valve Keeper Assembly Note


D Install the valve keeper by using the SST.

VALVE SEAL

49 0636 100B

VALVE GUIDE

49 B012 0A2

Valve Seal Assembly Note


1. Assemble the SST so that depth L is as specified.
Depth L
15.6 mm {0.614 in}
49 L012 001

Rocker Arm Assembly Note


D If new locker arm is used, set dimension A as
follows.

Dimension A
04 mm {00.1 in}
49 L012 002
49 L012 005

11.5 mm {0.453 in}

2. Press the valve seal onto the valve guide by hand.


3. Tap the SST by using a plastic hammer until its
lower end touches the cylinder head.
A

B29

ENGINE DISASSEMBLY/ASSEMBLY
Camshaft Cap Assembly Note
1. Apply silicone sealant to the front camshaft cap
mounting surfaces as shown. Avoid sealant from
projected onto the camshaft journal, oil seal
surface, and camshaft thrust surface.

Caution
D Because there is little camshaft thrust
clearance, the camshaft must be held
horizontally while it is installed.
Otherwise, excessive force will be applied
to the thrust area, causing burr on the
thrust receiving area of the cylinder head
journal. To avoid this, the following
procedure must be observed.
2. Tighten the camshaft cap bolts gradually in three or
four steps in the order shown.

ENGINE
FRONT

3. Apply clean engine oil to the new oil seal.


4. Push the oil seal slightly in by hand.
5. Tap the oil seal into the cylinder head by using the
SST and a hammer.

49 S010 001

CYLIN
DER
HEAD

0.51.0 mm {0.020.03 in}

HAMMER
OIL SEAL

B210

ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (I)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.

R
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

1925 {1.92.6, 1418}

R
1925 {1.92.6, 1418}

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

3041 {3.04.2, 2230}

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

Nm {kgfm, ftlbf}

Oil pan
+ Disassembly Note
+ Assembly Note
Oil strainer

B211

Oil pipe

Oil drain plug

ENGINE DISASSEMBLY/ASSEMBLY
Oil Pan Disassembly Note
D Remove the oil pan by using a separator tool.
SEPARATOR TOOL

Oil Pan Assembly Note


D Apply silicone sealant to the oil pan as shown.
Thickness
2.03.0 mm {0.080.11 in}

OIL PAN

B212

ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (II)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}

1925 {1.92.6, 1418}

45.567.4 {4.636.88, 33.549.7}


(WL Turbo ONLY)

2533 {2.53.4,
1924}

5968
{6.07.0,
4450}

97102 {9.810.5, 7175}


1925 {1.92.6, 1418}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

1925 {1.92.6, 1418}

1925 {1.92.6, 1418}

344392 {3540, 260280}


7.911.7 Nm
{80120 kgfcm, 70104 inlbf}

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

Nm {kgfm, ftlbf}

Crankshaft pulley
+ Disassembly Note
+ Assembly Note

Flywheel
+ Disassembly Note
+ Assembly Note

FIP pulley
+ Disassembly Note
+ Assembly Note

10

End plate

11

Timing gear cover


+ Disassembly Note
+ Assembly Note

Rear cover
+ Disassembly Note
+ Assembly Note

12

Oil pump cover


+ Assembly Note

Oil pump

13

Driven gear

FIP gear
+ Disassembly Note

14

Plug

Timing gear
+ Assembly Note

15

Plunger spring

16

Control plunger

FIP

17

Oil pump body

Timing gear case


+ Disassembly Note
+ Assembly Note

B213

ENGINE DISASSEMBLY/ASSEMBLY
Crankshaft Pulley Disassembly Note
D Remove the crankshaft pulley by using the SST.

SEPARATOR TOOL

49 E011 1A0

2. Remove the oil seal by using a screwdriver


protected with a rag.

Caution
D The TDC sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the
operation control.
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with other
parts or improper handling.

RAG

FIP Gear Disassembly Note


1. Set the No.1 cylinder to compression TDC.
2. Rotate the flywheel ring gear from TDC to
approximately 30 BTDC (about 13 teeth on the
gear).
BTDC30
TDC

ABOUT
13 TEETH

FIP Pulley Disassembly Note


D Remove the FIP pulley by using the SST.

3. Verify that the end-gap (V groove) of the timing


gear case and the chip cut gear of the FIP gear are
aligned.
49 E011 1A0

Timing Gear Cover Disassembly Note


1. Remove the timing gear cover by using a separator
tool.

B214

Note
D If the chip cut gear is hard to find, move the
FIP gear on notch back and forth, then check
the chip cut gear.

ENGINE DISASSEMBLY/ASSEMBLY

GEAR CASE (V GROOVE)

5. Hold the crankshaft using the SST and loosen the


gear nut.

VIEW A

FIP GEAR

GEAR NUT

VIEW A

No.2 IDLER
FIP GEAR
(HELICAL GEAR)

CHIP CUT GEAR

49 E011 1A0

ABOUT 0.5 mm
{0.02 in}

6. Remove the FIP gear using the SST.

ABOUT 0.3 mm
{0.12 in}

Timing Gear Case Disassembly Note


D Remove the timing gear case by using the
separator tool.

SCISSORS GEAR

SEPARATOR TOOL

Warning
D When removing the imjection pump gear,
be sure to fix the scissors gear to the
injection pump gear using a lock bolt
(M8 1.25; length under the bolt head is
approximately 14 mm). Otherwise, the
scissors gear will rotate with the spring
force, causing personal injury.
Caution
D When removing the injection pump gear, be
sure to fix the scissors gear to the injection
pump gear using a lock bolt (M8 1.25;
length under the bolt head is approximately
14 mm) to prevent the scissors gear from
rotating with the spring force. Otherwise,
the scissors gear will not align with the
injection pump gear, and the injection pump
gear with the scissors gear will not engage
with the idler gear.
Note
D A injection pump gear with a scissors gear has
a lock bolt hole.

Flywheel Disassembly Note


D Remove the flywheel by using the SST.

49 E011 1A0

Rear Cover Disassembly Note


D Remove the oil seal by using a screwdriver
protected with a rag.

4. Fix the scissors gear to the injection pump gear


using a lock bolt (M8 1.25; lengh under the bolt
head is approximately 14 mm).
RAG
LOCK BOLT

Oil Pump Cover Assembly Note


D Tighten the bolts in two or three steps in the order
shown.

B215

ENGINE DISASSEMBLY/ASSEMBLY
Thickness
1.52.5 mm {0.0600.098 in}
R

Rear Cover Assembly Note


1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.
3. Press the oil seal in evenly by using the SST.

3. Tighten the bolts in two or three steps in the order


shown.

49 S011 103

00.5 mm {00.01 in}


REAR OIL SEAL

4. Apply silicone sealant to the rear cover as shown.


Thickness
2 mm {0.07 in}

Timing Gear Assembly Note


1. Make a paint mark on the chip cut gear of FIP
gear.
PAINT MARK

FIP GEAR
(HELICAL GEAR)

CHIP CUT
GEAR
SCISSORS GEAR

Flywheel Assembly Note


1. Hold the crankshaft by using the SST.
2. Tighten the bolts in the order shown.

2. Make a paint mark on the 11th and 12th teeth of


the helical gear counting clockwise from chip cut
gear.
CHIP CUT GEAR

KNOCK PIN

FIP GEAR

VIEW A

VIEW A
49 E011 1A0

Timing Gear Case Assembly Note


1. Install the new O-ring.
2. Apply silicone sealant to the timing gear case as
shown. Do not apply sealant to the O-ring.

PAINT MARK

3. Verify that the 11th and 12th teeth of the FIP gear
(helical gear) and the teeth of the scissors gear are
aligned, then mark a paint mark on the scissors
gear.

B216

ENGINE DISASSEMBLY/ASSEMBLY

SCISSORS GEAR

HELICAL GEAR

11 TEETH
12 TEETH

PAINT MARK

4. Set the No.1 cylinder to compression TDC.


5. Rotate the flywheel ring gear from TDC to
approximatey 30 BTDC (about 13 teeth on the
gear.)

FIP Gear Assembly Note


1. Install the FIP pulley using the SST.

BTDC30
TDC

ABOUT
13 TEETH

49 E011 1A0

2. Remove the lock bolt.


Timing Gear Cover Assembly Note
1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.
3. Press the oil seal in evenly by using the SST.

LOCK BOLT

49 0259 749
49 S010 301

Crankshaft Pulley Assembly Note


D Install the crankshaft pulley using the SST.

00.4 mm {00.01 in}


OIL SEAL

4. Apply silicone sealant to the timing gear cover as


shown.
Thickness
1.52.5 mm {0.0600.098 in}

49 E011 1A0

5. Tighten the bolts in two or three steps in the order


shown.

B217

ENGINE DISASSEMBLY/ASSEMBLY
Caution
D The TDC sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the
operation control.
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with other
parts or improper handling.

B218

ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (III)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.

27.031.8 {2.753.25, 19.923.5}


+ (82.5 97.5 )

1217 {1.21.8, 913}

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
42.6645.60 {4.354.65, 31.533.6} +
(90 105 )
Nm {kgfm, ftlbf}

Balance shaft (WL Turbo)


+ Disassembly Note

10

Connecting rod

11

Main bearing cap


+ Disassembly Note
+ Assembly Note

Connecting rod cap


+ Disassembly Note

Connecting rod bearing, lower

12

Main bearing, lower, Thrust bearing, lower

Piston, Connecting rod


+ Disassembly Note
+ Assembly Note

13

Crankshaft
+ Disassembly Note

14

Main bearing, upper, Thrust bearing, upper

Connecting rod bearing, upper

15

OIl jet valve, Nozzle

Piston ring

16

Cylinder block

Piston pin clip

Piston pin

Piston

B219

ENGINE DISASSEMBLY/ASSEMBLY
2. Tighten the bolts in two or three steps in the order
shown.

Balance shaft (WL Turbo) Disassembly Note


D Measure the balance shaft end play.
(Refer to ENGINE INSPECTION/REPAIR,
BALANCE SHAFT INSPECTION.)
(WL Turbo)

Tightening torque
7582 Nm {7.68.4 kgfm, 5560 ftlbf}

Connecting Rod Cap Disassembly Note


D Measure the connecting rod side clearance.
(Refer to ENGINE INSPECTION/REPAIR,
CONNECTING ROD SIDE CLEARANCE
INSPECTION.)
Piston, Connecting Rod Disassembly Note
1. Measure the connecting rod oil clearance.
(Refer to ENGINE INSPECTION/REPAIR,
CONNECTING ROD OIL CLEARANCE
INSPECTION/REPAIR.)
2. Check the oscillation torque.
(Refer to ENGINE INSPECTION/REPAIR, PISTON
AND CONNECTING ROD INSPECTION.)
3. Remove the piston pin by using the SST.

3. Loosen all bolts.


4. Tighten them in two or three steps as in step 2.
Tightening torque
42.6645.60 Nm
{4.354.65 kgfm, 31.533.6 ftlbf}
5. Put a paint mark on each bolt head.
6. Using the marks as a reference, tighten the bolts
by turning each 90 105 as in step 2.

49 G011 001

Main Bearing Cap Disassembly Note


1. Measure the crankshaft end play.
(Refer to ENGINE INSPECTION/REPAIR,
CRANKSHAFT END PLAY
INSPECTION/REPAIR.)
2. Loosen the main bearing cap bolts in two or three
steps in the order shown.

90 105
PAINT MARK

Piston, Connecting Rod Assembly Note


1. Assemble the piston and the connecting rod in the
direction from which they were disassembled.
2. Apply clean engine oil to the piston pin.
3. Install the piston pin until the pin contacts the clip
as shown. If the pin cannot be installed easily, heat
the piston.
F MARK

Crankshaft Disassembly Note


D Measure the main journal oil clearance.
(Refer to ENGINE INSPECTION/REPAIR,
CRANKSHAFT OIL CLEARANCE
INSPECTION/REPAIR.)

PROJECTION FOR
ALIGNING CONNECTING
ROD BEARING

Main Bearing Cap Assembly Note


1. Apply clean engine oil to the bolt threads and seat
faces of the lower cylinder block bolts.

4. Verify that the second ring is installed with tapered


face upward.
5. Verify that the top ring is installed with tapered face
side upward.

B220

ENGINE DISASSEMBLY/ASSEMBLY

SECTION OF
FIRST RING

SECTION OF
SECOND RING

6. Insert the piston and connecting rod assembly into


the cylinder with the F mark facing the front of the
engine.

F MARK

7. Align the matching marks on the connecting rod and


the connecting rod cap. Install the connecting rod
cap.
8. tighten the nuts in two or three steps.
Tightening torque
27.031.8 Nm
{2.753.25 kgfm, 19.923.5 ftlbf}
9. Put a paint mark on each nut.
10. Using the marks as a reference, tighten the nuts by
turning each 82.5 97.5.

82.5 97.5

PAINT MARK

B221

ENGINE INSPECTION/REPAIR
7. Inspect the combustion chamber insert crack.

ENGINE INSPECTION/REPAIR
CYLINDER HEAD INSPECTION/REPAIR
1. Carry out cooling flaw detection on the cylinder
head surface. Replace the cylinder head if
necessary.
2. Inspect for the following and repair or replace.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in the
seven directions as shown.

Crack
Limit: 10.0 mm {0.39 in}
8. If it exceeds the specification, replace the cylinder
head.

CRACK

Distortion
X direction: 0.020 mm {0.0008 in} max.
Y direction: 0.050 mm {0.0020 in} max.
Y

9. Measure the manifold contact surface distortion as


shown.
Distortion
0.05 mm {0.002 in} max.
10. If the distortion exceeds the maximum, grind the
surface or replace the cylinder head.

4. If the cylinder head distortion exceeds the


maximum, replace the cylinder head. Do not
attempt to repair a cylinder head by milling or
grinding.
5. Measure the receded or projected amount of
combustion chamber insert from cylinder head
surface.

Grinding
0.15 mm {0.006 in} max.

Recession: 0.020 mm {0.0008 in} max.


Projection: 0.005 mm {0.0002 in} max.
6. If it exceeds the maximum,replace the cylinder
head.

VALVE INSPECTION
1. Measure the valve head margin thickness of each
valve. Replace the valve if necessary.
Margin thickness
IN: 1.50 mm {0.059 in}
EX: 0.75 mm {0.030 in}

COMBUSTION CHAMBER
INSERT

THICKNESS

LENGTH

B222

ENGINE INSPECTION/REPAIR
2. Measure the length of each valve. Replace the
valve if necessary.
Standard length
IN: 111.60112.10 mm {4.3944.413 in}
EX: 111.50112.00 mm {4.3904.409 in}

Minimum length
IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
3. Measure the stem diameter of each valve in X and
Y directions at the three points (A, B, and C)
shown. Replace the valve if necessary.
Standard diameter
IN: 6.9706.985 mm {0.27450.2749 in}
EX: 6.9656.980 mm {0.27430.2748 in}

VALVE GUIDE REPLACEMENT


Valve Guide Removal
D Remove the valve guide from the combustion
chamber side by using the SST.
49 0249 010A

Minimum diameter
IN: 6.920 mm {0.2724 in}
EX: 6.915 mm {0.2722 in}
X
Y
VALVE GUIDE
A

Valve Guide Installation


1. Assemble the SSTs so that depth L is as specified.

Depth L
14.014.5 mm {0.560.57 in}

VALVE GUIDE INSPECTION


1. Measure the inner diameter of each valve guide in
X and Y directions at the three points (A, B, and
C)shown. Replace the valve guide if necessary.

49 L012 004

Standard inner diameter


7.0257.045 mm {0.27660.2773 in}
49 L012 003

Y
X
A

49 L012 002

2. Tap the valve guide in from the side opposite the


combustion chamber until the SST contacts the
cylinder head.
3. Verify that the valve guide projection height is
within the specification.
Standard height
14.014.5 mm {0.560.57 in}

49 L012 003

2. Measure the protrusion height (dimension A) of


each valve guide without lower valve spring seat.
Replace the valve guide if necessary.

49 L012 004

49 L012 002

Standard height
14.014.5 mm {0.560.57 in}

VALVE GUIDE

B223

ENGINE INSPECTION/REPAIR
VALVE SEAT INSPECTION/REPAIR
1. Measure the seat contact width. If necessary,
resurface the valve seat by using a 45 valve seat
cutter and/or resurface the valve face.

VALVE SPRING INSPECTION


1. Apply pressing force to the pressure spring and
check the spring height. Replace the valve spring if
necessary.

Standard width
IN: 1.62.2 mm {0.070.08 in}
EX: 1.72.3 mm {0.070.09 in}

Pressing force
239268 N {24.327.4 kgf, 53.560.2 lbf}
Standard height
35.5 mm {1.40 in}

SEAT CONTACT WIDTH

2. Verify that the valve seating position is at the


center of the valve face.
(1) If the seating position is too high, correct the
valve seat using a 60 cutter and a 45 cutter.
(2) If the seating position is too low, correct the
valve seat using a 37 (IN) or 30 (EX) cutter
and a 45 cutter.
IN

60
45
37

2. Measure the out-of-square of the valve spring.


Replace the valve spring if necessary.
Valve spring out-of-square
1.70 mm {0.0670} max.

EX

60
45
30

3. Measure the receded amount from the cylinder


head surface. If it exceeds the maximum, replace
the cylinder head.

CAMSHAFT INSPECTION
1. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout. Replace the
camshaft if necessary.

Recession
IN: 0.611.09 mm {0.0250.042 in}
EX: 0.711.19 mm {0.0280.046 in}

Runout
0.03 mm {0.001 in} max.

Maximum
IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}

B224

ENGINE INSPECTION/REPAIR
2. Measure the cam lobe height at the two points as
shown. Replace the camshaft if necessary.
Standard height
IN: 42.4042.50 mm {1.6701.673 in} (WL)
41.22141.321 mm {1.6231.626 in}
(WL Turbo)
EX: 42.39542.495 mm {1.6701.673 in}
Minimum height
IN: 42.050 mm {1.6555 in} (WL)
40.871 mm {1.6091 in} (WL Turbo)
EX:42.045 mm {1.6553 in}

CAMSHAFT OIL CLEARANCE INSPECTION


1. Position plastigage atop the journals in the axial
direction.
2. Install the camshaft cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER HEAD
DISASSEMBLY/ASSEMBLY (II), Camshaft Cap
Assembly Note.)
3. Remove the camshaft cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER HEAD
DISASSEMBLY/ASSEMBLY (II), Camshaft Cap
Disassembly Note.)
4. Measure the oil clearance. Replace the cylinder
head if necessary.
Standard clearance
No.1, 5: 0.0350.081 mm {0.00140.0031 in}
No.24: 0.0650.111 mm {0.00260.0043 in}
Maximum clearance
No.1, 5: 0.12 mm {0.0047 in}
No.24: 0.15 mm {0.0059 in}

3. Measure the journal diameters in X and Y


directions at the two points (A and B) as shown.
Replace the camshaft if necessary.
Standard diameter
No.1, No.5:
25.94025.965 mm {1.02131.0222 in}
No.2No.4:
25.91025.935 mm {1.02011.0210 in}
Minimum diameter
No.1, No.5: 25.890 mm {1.0193 in}
No.2No.4: 25.860 mm {1.0181 in}

CAMSHAFT END PLAY INSPECTION


1. Install the camshaft cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER HEAD
DISASSEMBLY/ASSEMBLY (II), Camshaft Cap
Assembly Note.)
2. Measure the camshaft end play. Replace the
cylinder head or camshaft if necessary.
Standard end play
0.0300.160 mm {0.00120.0062 in}

B
A

Maximum end play


0.200 mm {0.0078 in}

X
Y
Y
X

3. Remove the camshaft cap. (Refer to ENGINE


DISASSEMBLY/ASSEMBLY, CYLINDER HEAD
DISASSEMBLY/ASSEMBLY (II), Camshaft Cap
Disassembly Note.)

B225

ENGINE INSPECTION/REPAIR
CYLINDER BLOCK INSPECTION/REPAIR
1. Measure the distortion of the cylinder block top
surface in the seven directions as shown. Replace
if necessary.

Cylinder block distortion


X Direction: 0.020 mm {0.0008 in} max.
Y Direction: 0.050 mm {0.0020 in} max.

PISTON INSPECTION
D Measure the outer diameter of each piston at right
angle (90 ) to the piston pin, 19 mm {0.75 in}
above the buttom of piston.
Piston diameter
X

mm {in}

Size

2. Measure the cylinder bores in X and Y directions at


three leves A in each cylinder as shown.
X

Bore

Standard

92.95192.977 {3.65953.6605}

0.25 {0.01} oversize

93.18693.212 {3.66883.6697}

0.50 {0.02} oversize

93.43693.462 {3.67863.6795}

83.0 mm
{3.27 in}
A
MEASURING
POINT

3. If the cylinder bore exceeds the wear limit, replace


the cylinder block or rebore the cylinder and install
the oversize pistons so that the specified
piston-to-cylinder clearance is obtained.

PISTON CLEARANCE INSPECTION/REPAIR


1. Measure the piston-to-cylinder clearance.
Replace the piston or rebore the cylinders to fit
oversize piston if necessary.

Note
D Base the boring diameter on the diameter of an
oversize piston. All cylinder must be the same
diameter.
Cylinder bore

Standard clearance
0.0380.056 mm {0.00150.0022 in}
Maximum clearance
0.150 mm {0.0059 in}

mm {in}

Size

Bore

Standard

93.00093.022 {3.66153.6622}

0.25 {0.01} oversize

93.25093.272 {3.67133.6721}

0.50 {0.02} oversize

93.50093.522 {3.68113.6819}

Wear limit
0.150 mm {0.0059 in}

19.0 mm {0.75 in}

2. If the piston is replaced,the piston rings must also


be replaced.
PISTON RING CLEARANCE INSPECTION
1. Measure the piston ring-to-ring land clearance
around the entire circumference. Replace the
piston and piston ring if necessary.

OIL JET VALVE, NOZZLE INSPECTION


1. Apply compressed air to oil jet valve A and verify
that air passes through oil jet valve B If not, replace
the oil jet valve.
Air pressure
138196 kPa {1.42.0 kgf/cm2, 2028 psi}
2. Check the oil jet nozzle for clogs. Replace the
nozzle if necessary.

B226

Standard clearance
Top: 0.060.10 mm {0.00240.0039 in}
Second: 0.040.08 mm {0.00160.0031 in}
Oil: 0.030.07 mm {0.00120.0027 in}

ENGINE INSPECTION/REPAIR
Maximum clearance
0.150 mm {0.0059 in}

2. Insert the piston ring into the cylinder by hand and


use the piston to push it to the bottom of the ring
travel.
3. Measure each piston ring end gap with a feeler
gauge. Replace the piston ring if necessary.

3. Measure each piston pin diameter in X and Y


directions at the four points (A, B, C, and D) as
shown.
Standard diameter
31.99432.000 mm {1.25971.2598 in}
X

Standard end gap


Top: 0.220.32 mm {0.0090.012 in}
Second: 0.320.47 mm {0.0130.018 in}
Oil: 0.220.32 mm {0.0090.012 in}

A
B

Maximum end gap


1.00 mm {0.039 in}

C
D

4. Calculate the piston pin-to-piston pin bore


clearance. Replace the piston and/or piston pin if
necessary.
Standard clearance
0.0030.013 mm {0.00010.0005 in}

PISTON
RING

5. Calculate the connecting rod small end-to-piston


pin clearance. Replace the connecting rod or
piston pin.
PISTON PIN CLEARANCE INSPECTION
1. Measure each piston pin bore diameter in X and Y
directions at the four points (A, B, C, and D) as
shown.
Standard diameter
31.99732.007 mm {1.25981.2601 in}

Standard clearance
0.0120.039 mm {0.00050.0015 in}
CRANKSHAFT INSPECTION
1. Measure the crankshaft runout. Replace the
crankshaft if necessary.
Runout
0.05 mm {0.002 in} max.

A
B
C
D

2. Measure each connecting rod small end inner


diameter in X and Y directions as shown.
Standard diameter
32.01232.033 mm {1.26041.2611 in}

2. Measure the journal diameter in X and Y direction


at the two points (A and B) as shown. Replace the
crankshaft or grind the journal and install the
undersize bearing if necessary.

B227

ENGINE INSPECTION/REPAIR
Main journal

Standard clearance
No.1, 2, 4, 5:
0.0330.052 mm {0.00130.0020 in}
No.3:
0.050 mm 0.069 mm {0.00200.0026 in}

mm {in}

Bearing

Diameter

Journal No.

1, 2, 4, 5

Standard

66.93766.955
{2.63542.6360}

66.92066.938
{2.63472.6353}

0.25 {0.01}
undersize

66.68766.705
{2.62552.6261}

66.67066.688
{2.62482.6255}

0.50 {0.02}
undersize

66.43766.455
{2.61572.6163}

66.42066.438
{2.61502.6156}

0.75 {0.03}
undersize

66.18766.205
{2.60582.6064}

66.17066.188
{2.60522.6058}

Wear limit
0.05 mm {0.002 in}
Outofround
0.03 mm {0.001 in}
Crank pin

Maximum clearance
0.08 mm {0.003 in}
mm {in}
Bearing size
Standard

2.0032.018
{0.07890.0794}

0.25 {0.01} undersize

2.1212.131
{0.08360.0838}

0.50 {0.02} undersize

2.2462.256
{0.08850.0888}

0.75 {0.03} undersize

2.3712.381
{0.09340.0937}

mm {in}

Bearing size

Diameter

Standard

54.94054.955
{2.16302.1635}

0.25 {0.01} undersize

54.69054.705
{2.15322.1537}

0.50 {0.02} undersize

54.44054.455
{2.14342.1438}

0.75 {0.03} undersize

54.19054.205
{2.13352.1340}

CRANKSHAFT END PLAY INSPECTION/REPAIR


1. Install the main bearing cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK
DISASSEMBLY/ASSEMBLY (III), Main Bearing
Cap Assembly Note.)
2. Measure the crankshaft end play. If the end play
exceeds the maximum, replace the thrust bearing
or grind the crankshaft and install an undersize
bearing so that the specified end play is obtained.
Standard end play
0.0400.282 mm {0.00160.0111 in}

Wear limit
0.05 mm {0.002 in}

Maximum end play


0.300 mm {0.012 in}

Outofround
0.03 mm {0.001 in}
A

Diameter

mm {in}

Bearing size

CRANKSHAFT OIL CLEARANCE


INSPECTION/REPAIR
1. Position Plastigage atop the journals in the axial
direction.
2. Install the main bearig cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK
DISASSEMBLY/ASSEMBLY (III), Main Bearing
Cap Assembly Note.)
3. Remove the main bearing cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK
DISASSEMBLY/ASSEMBLY (III), Main Bearing
Cap Disassembly Note.)
4. Measure the main journal oil clearance. If the
clearance exceeds the maximum, replace the main
bearing or grind the main journal and install the
undersize bearings so that the specified oil
clearance is obtained.

Bearing thickness

Standard

2.4552.505
{0.09670.0986}

0.35 {0.014} undersize

2.6302.680
{0.10360.1055}

3. Remove the main bearing cap. (Refer to ENGINE


DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK
DISASSEMBLY/ASSEMBLY (III), Main Bearing
Cap Disassembly Note.)

B228

ENGINE INSPECTION/REPAIR
CONNECTING ROD INSPECTION
1. Measure each connecting rod for bending and
distortion. Replace the connecting rod if necessary.
Bending
0.075 mm {0.0030 in} max. /50 mm {2.0 in}
Center-to-center distance
151.95152.05 mm {5.9835.986 in}

mm {in}
Bearing size

Bearing thickness

Standard

1.5041.513
{0.05920.0595}

0.25 {0.01} undersize

1.6211.631
{0.06380.0642}

0.50 {0.02} undersize

1.7461.756
{0.06870.0691}

0.75 {0.03} undersize

1.8711.881
{0.07370.0740}

2. Measure the length of connecting rod bolt. Replace


the connecting rod and connecting rod cap if
necessary.
Standard length
67.568.5 mm {2.662.69 in}
Maximum length
69 mm {2.7 in}

CONNECTING ROD SIDE CLEARANCE


INSPECTION
1. Install the connecting rod cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK
DISASSEMBLY/ASSEMBLY (III), Piston and
Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance. Replace the connecting rod and cap if
necessary.
Standard clearance
0.1100.262 mm {0.00440.0103 in}
Maximum clearance
0.350 mm {0.037 in}

LENGTH

CONNECTING ROD OIL CLEARANCE


INSPECTION/REPAIR
1. Position Plastigage atop the journals in the axial
direction.
2. Install the connecting rod cap. (Refer to ENGINE
DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK
DISASSEMBLY/ASSEMBLY (III), Piston and
Connecting Rod Assembly Note.)
3. Remove the connecting rod cap.
4. Measure the crankpin oil clearance. If the
clearance exceeds the maximum, replace the
connecting rod bearing or grind the crankpin and
use undersize bearings so that the specified
clearance is obtained.
Standard clearance
0.0310.058 mm {0.00130.0022 in}

3. Remove the connecting rod cap


PISTON AND CONNECTING ROD INSPECTION
D Check the oscillation torque as shown. If the large
end does not drop by its own weight, replace the
piston or the piston pin.

Maximum clearance
0.080 mm {0.003 in}

B229

ENGINE INSPECTION/REPAIR
4. Measure the balance shaft bore in the cylinder
block. Calculate the clearance between the
balance shaft and balance shaft bore. Replace the
balance shaft and/or cylinder block if necessary.
Standard clearance
Front, rear:
0.0500.115 mm {0.00200.0045 in}
Center:
0.0800.145 mm {0.00320.0057 in}

BALANCE SHAFT INSPECTION (WL Turbo)


1. Install the balance shaft and tighten the thrust plate
fitting bolt.
Tightening torque
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
2. Measure the balance shaft end play. Replace the
balance shaft and/or cylinder block if necessary.
Standard end play
0.040.16 mm {0.0020.006 in}

BOLT INSPECTION
D Measure the length of each bolt. Replace the bolt if
necessary.
Cylinder head bolt
Bolt head mark

mm {in}
Standard
length

Maximum
length

101.2101.8
{3.9854.007}

102.5 {4.035}

113.2113.8
{4.4574.480}

114.5 {4.508}

Main bearing cap bolt


3. Measure the journal diameters in X and Y
directions at the two points (A and B) as shown.
Replace the balance shaft if necessary.

mm {in}

Standard length

84.785.3 {3.343.35}

Maximum length

86.0 {3.39}

Standard diameter
Front:
41.94541.960 mm {1.65141.6519 in}
Center:
39.94539.960 mm {1.57271.5732 in}
Rear;
37.97537.990 mm {1.49511.4956 in}

LENGTH

TENSIONER SPRING INSPECTION


D Measure the free length of the tensioner spring.
Replace the tensioner spring if necessary.
Free length
63.0 mm {2.48 in}

B230

ENGINE INSPECTION/REPAIR

FREE LENGTH

VALVE CLEARANCE INSPECTION


1. Turn the crankshaft and align the timing mark so
that the piston of the No.1 or No.4 cylinder is at
TDC of compression.
2. Measure the valve clearances A with the No.1
cylinder at TDC of compression, and those of B
with the No.4 cylinder at TDC of compression.

Standard side clearance


0.040.09 mm {0.0020.003 in}
Maximum side clearance
0.15 mm {0.006 in}

Valve clearance [engine cold]


IN: 0.050.15 mm {0.00200.0059 in}
EX: 0.150.25 mm {0.00600.0098 in}
A

ENGINE
FRONT

PLUNGER SPRING INSPECTION


D Measure the free length of the pressure spring.
Replace the plunger spring if necessary.
B

3. If it is not within the specification, adjust and


recheck the valve clearance.
4. Turn the crankshaft one full turn and measure the
remaining valve clearances. Adjust if necessary.
Tightening torque (locknut)
1620 Nm {1.62.1 kgfm, 1215 ftlbf}

FEELER GAUGE

ADJUST
SCREW
LOCKNUT

GEAR CLEARANCE INSPECTION


D Measure the following clearance. Replace the gear
and/or pump body if necessary.
Standard clearance
0.100.19 mm {0.0040.007 in}
Maximum clearance
0.20 mm {0.008 in}

B231

Free length
43.8 mm {1.72 in}

MANUAL TRANSMISSION
(R15MD, R15MXD)
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . .
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH HOUSING, EXTENSION
HOUSING, AND TRANSFER
CASE DISASSEMBLY/ASSEMBLY . . . . . . .
5TH/REVERSE GEAR AND
HOUSING PARTS DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J2 1
J2 1
J2 2

TRANSMISSION CASE
COMPONENTS DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . J210
MAINSHAFT AND COUNTER
SHAFT COMPONENTS
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . J213
MANUAL TRANSMISSION INSPECTION . . . J215

J2 5

MANUAL TRANSMISSION
PRECAUTION
1. Clean the transmission exterior thoroughly by using a steam cleaner or cleaning solvents before disassembly.
Warning
 Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear
protective eye wear whenever using compressed air.
Caution
 Cleaning sealed bearings by using cleaning fluids or a steam cleaner can wash the grease out of
the bearing.
2. Clean the removed parts by using cleaning solvent, and dry them by using compressed air.
Clean out all holes and passages by using compressed air, and check that there are no obstructions.
3. Use a plastic hammer when disassembling the transmission case and other light alloy metal parts.
4. Make sure each part is cleaned before assembling.
5. Coat all movable parts with the specified oil.
6. Replace parts whenever required.
7. Remove old sealant from contact surfaces before applying new sealant.
8. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transmission with transmission oil.

J21

MANUAL TRANSMISSION
CLUTCH HOUSING, EXTENSION HOUSING, AND TRANSFER CASE DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
42 (R15MD)

SELECTIVE USE
R

SST
R

R
R
4255
{4.25.6, 3040}

7.910.7 Nm
{80110 kgfcm,
69.495.4 inlbf}
4255
{4.25.6,
3040}
1925
{1.92.6,
1418}
1925
{1.92.6,
1418}

3146
{3.14.5,
2332}

2534
{2.53.5,
1825}

R
1925
{1.92.6,
1418}

R
R

2534
{2.53.5, 1825}

7.910.7 Nm
{80110 kgfcm,
69.495.4 inlbf}

7.910.7 Nm
{80110 kgfcm,
69.495.4 inlbf}

Nm {kgfm, ftlbf}

Clutch release collar

14

Snap ring

Clutch release fork

15

Clutch housing

Boot

16

Oil seal (except F2 engine)

Front cover (F2 engine)

17

Oil seal (F2 engine)


+ Assembly Note

Adjustment shim
+ Assembly Note

18

Under cover

Back-up light switch

19

Roll pin

Neutral switch (F2 CIS and G6 engine)

20

Control lever end

Vehicle speedometer sensor

21

Control rod

Control case

22

Stopper pin

10

Extension housing component

23

Oil pass

24

Oil seal (rear)


+ Assembly Note

25

Extension housing

11

Snap ring

12

Speedometer drive gear

13

Steel ball

J22

MANUAL TRANSMISSION
44 (R15MXD)

SELECTIVE
USE
R

1925
{1.92.6,
1418}

1925
{1.92.6,
1418}

4255
{4.25.6, 3040}

7.910.7 Nm
{80110 kgfcm,
7095 inlbf}

1925
{1.92.6, 1418}
3146
{3.14.5,
2332}

R
SST
R
R
2534
{2.53.5,
1825}

R
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}

3247
{3.24.8,
2734}
2534
{2.53.5, 1825}
4254
{4.25.6,
3140}

Nm {kgfm, ftlbf}

Clutch release collar

15

Extension housing
+ Disassembly Note

Clutch release fork

Boot

16

Control rod

Back-up light switch

17

Under cover

Neutral switch (G6 engine)

18

Vehicle speedometer sensor

Oil seal
+ Assembly Note

Control cover component

19

Oil pass

Roll pin

20

Plug

Transfer case

21

Spring

10

Control lever end

22

Steel ball

11

Input sleeve

23

Select lock spindle

12

Clutch housing

24

Washer

13

Oil seal (front)

25

Spring

14

Adjustment shim
+ Assembly Note

J23

MANUAL TRANSMISSION
Extension Housing Disassembly Note
 Turn the control rod in the direction of the arrow,
and remove the extension housing.

2. Measure the main drive gear bearing height.

3. The difference between the two measurements


indicates the required thickness of the adjustment
shim.

Oil Seal Assembly Note


 Apply oil to a new oil seal lip and install it in the
extension housing using the SST.

Standard thrust play


00.1 mm {00.004 in}
Adjustment shim thickness
0.3 mm {0.012 in}, 0.4 mm {0.016 in}
0.5 mm {0.020 in}, 0.6 mm {0.024 in}
0.7 mm {0.028 in}

49 U027 003

Oil Seal (F2 Engine) Assembly Note


 Apply the transmission oil to a new oil seal lip, and
install it to the clutch housing by using the SST.

Oil Seal (Rear) Assembly Note


1. Apply the transmission oil to a new oil seal.
2. Install the oil seal until it touches the case by using
a suitable piece of pipe.

PIPE

Adjustment Shim Assembly Note


1. Measure the depth of the main drive gear bearing
bore in the clutch housing with vernier calipers.

J24

MANUAL TRANSMISSION
5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

5TH/REVERSE
CLUTCH HUB
FRONT

FRONT
R
R
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}

SST

157235
{1624,
116173}

4058
{4.06.0,
2943}

SST

SST

R
R
1826
{1.82.7, 1419}

SELECTIVE
USE

SST

1925
{1.92.6,
1418}

SELECTIVE
USE
SST

FRONT

SST

RETAINING
RING

R
128196
{1320,
95144}

8.913.7 Nm
{90140 kgfcm,
79121 inlbf}

Nm {kgfm, ftlbf}

J25

MANUAL TRANSMISSION

5th/reverse shift rod end

3rd/4th shift rod end

38

Locknut (Mainshaft)
+ Disassembly Note
+ Assembly Note

1st/2nd shift rod end

Retaining ring

39

5th/reverse clutch hub component


+ Disassembly Note

Spring retainer

Spring

40

Reverse synchronizer ring


+ Disassembly Note

Pin and retaining ring

41

Reverse gear

Bearing housing

42

Bearing

Snap ring

43

Inner race

10

Thrust washer

44

Thrust washer

11

C-washer
+ Assembly Note

45

Thrust washer

46

Reverse idler gear shaft

12

Retaining ring

47

Reverse idler gear

13

Mainshaft rear bearing


+ Disassembly Note
+ Assembly Note

48

Thrust washer

49

Bearing cover

C-washer and retaining ring

50

Counter reverse gear

Locknut (counter shaft)


+ Disassembly Note
+ Assembly Note

51

Oil pass

14
15

16

Counter shaft rear bearing


+ Disassembly Note
+ Assembly Note

17

Counter 5th gear

18

Spacer

19

Set bolt and washer

20

Center housing

21

Oil pass

22

Blind cover

23

Thrust lock washer


+ Assembly Note

24

Steel ball

25

5th gear

26

Bearing

27

Retaining ring

28

5th synchronizer ring


+ Disassembly Note

29

Cap plug, spring, and detent ball

30

Retaining ring
+ Disassembly Note
+ Assembly Note

31

5th/reverse shift rod

32

Spring

33

5th/reverse shift fork

34

Interlock pin
+ Assembly Note

35

3rd/4th shift rod


+ Disassembly Note
+ Assembly Note

36

Interlock pin
+ Assembly Note

37

1st/2nd shift rod


+ Disassembly Note
+ Assembly Note

Mainshaft Rear Bearing Disassembly Note


Note
 The front and rear C-washers may have
different thicknesses.
1. Remove the snap ring, washer, retaining ring, and
C-washers.
2. For proper reassembly, identify the front and rear
C-washers.
3. Remove the mainshaft rear bearing by using the
SSTs.

49 H017 101
49 0839 425C

Locknut (Counter Shaft) Disassembly Note


1. Uncrimp the tab of the locknut.
2. Shift the clutch hub sleeves to 1st gear and
reverse gear to put the gears in a double-engaged
condition.
Note
 Use the protective plates to prevent damage to
the SST.
3. Hold the mainshaft by using the SST and a vise.
4. Remove the locknut.

J26

MANUAL TRANSMISSION

49 1243 465A

49 S120 440

Counter Shaft Rear Bearing Disassembly Note


 Remove the counter shaft rear bearing by using
the SST.

5th/reverse Clutch Hub Component Disassembly


Note
 Attach the SSTs to the bearing cover and remove
the component which consists of the following
parts:
(1) 5th/reverse clutch hub component
(2) Reverse synchronizer ring
(3) Reverse gear
49 H017 101
49 0839 425C

49 0839 425C

5th/reverse Synchronizer Ring Disassembly Note


 Tag and identify each synchronizer ring.
Retaining Ring Disassembly Note
1. Remove the roll pin from the 5th/reverse shift fork.
2. Remove the retaining ring by using the SST.
49 S017 401

Locknut (Mainshaft) Assembly Note


1. Shift into 1st gear and 4th gear to lock the rotation
of the mainshaft.
2. Install a new locknut and tighten it by using the
SST.

RETAINING
RING

Tightening torque
157235 Nm {1624 kgfm, 116173 ftlbf}

3rd/4th Shift Rod, 1st/2nd Shift Rod Disassembly


Note
1. Shift the transmission into 4th gear. This will
provide adequate space to drive out the spring pin.
Drive the spring pin from the 3rd/4th shift fork.
2. Slide the 3rd/4th shift rod out from the rear of the
transmission case.
3. Drive the spring pin from the 1st/2nd shift fork.
Slide the 1st/2nd shift rod out from the rear of the
transmission case.
4. Remove the interlock pins.
Locknut (Mainshaft) Disassembly Note
1. Uncrimp the tab of the locknut.
2. Shift into 1st gear and 4th gear to lock the rotation
of the mainshaft.
3. Remove the locknut by using the SST.

49 1243 465A

Note
 The total combined thickness of the front and
rear thrust washers must equal 6.0 mm {0.236
in}.
3. Inspect the clearance between the synchronizer
key and the exposed edge of the synchronizer ring.
If it is not as specified, adjust with the thrust
washers on the front and rear of the mainshaft
bearing.

J27

MANUAL TRANSMISSION
Clearance
2.0 mm {0.079 in} max.
Available thrust washer thickness
2.5 mm {0.098 in}, 3.0 mm {0.118 in}
3.5 mm {0.138 in}

5. Slide the two SSTs into the transmission case to


guide the interlock pins, and insert the first pin.
6. Remove the 3rd/4th shift fork guide from the case.
7. Slide the 3rd/4th shift rod containing the interlock
pin (small) into the case.
8. Secure the 3rd/4th shift rod onto the fork with the
new roll pin.
9. Insert the remaining interlock pin and remove the
SSTs.

4. Stake the locknut into the mainshaft groove.


1st/2nd Shift Rod, 3rd/4th Shift Rod, Interlock Pin
Assembly Note
1. Refer to the figure to identify each shift rod when
installing the shift rods in the following procedure.
Install them so that the detent grooves are facing
the detent balls.
DETENTS

1ST/2ND SHIFT ROD


3RD/4TH SHIFT ROD

49 0862 350
5TH/REVERSE SHIFT ROD

Retaining Ring Assembly Note


 Push back the spring, and install a new clip to the
5th/Reverse shift rod by using the SST.
2. Slide the 1st/2nd shift rod into the case.
3. Secure the 1st/2nd shift fork to the rod with a new
roll pin. The split in the roll pin must be facing in
the direction shown in the figure.

4. Install the interlock pins as shown in the figure


when doing steps 4 through 8.

49 S017 401

Thrust Lock Washer Assembly Note


1. Install the steel ball and thrust lock washer.
2. Install the 3.0 mm {0.118 in} C-washers and hold
them with a retaining ring.
3. Push the C-washers toward 5th gear and measure
the clearance between the C-washers and thrust
lock washer. If the clearance is not as specified,
select the proper thrust lock washer.
Standard
0.10.2 mm {0.0040.008 in}
Available thrust lock washer thickness
6.2 mm {0.244 in}, 6.3 mm {0.248in},
6.4 mm {0.252 in}, 6.5 mm {0.256in},
6.6 mm {0.260 in}, 6.7 mm {0.264in}

J28

MANUAL TRANSMISSION

PIPE

Counter Shaft Rear Bearing Assembly Note


 Drive on the counter shaft rear bearing by using
the SST.
49 F401 335A

C-washer Assembly Note


1. Install the C-washers and hold them in place with a
new retaining ring.
2. With points A and B pressed tightly together,
measure the clearance between the C-washers
and the groove. If the clearance is not as specified,
select the proper C-washers.
Standard
00.1 mm {00.004 in}
Available C-washer thickness
2.9 mm {0.114 in}, 3.0 mm {0.118 in},
3.1 mm {0.122 in}, 3.2 mm {0.126 in}

49 F401 331

Locknut (Counter Shaft) Assembly Note


1. Connect the SST to the mainshaft and mount it
securely in a vise.
2. Shift into 1st gear to lock the counter shaft.
Install the new counter shaft lock nut.
Tightening torque
128196 Nm {1320 kgfm, 95144 ftlbf}

49 S120 440

3. Stake the locknut into the counter shaft groove.


Main shaft Rear Bearing Assembly Note
 Drive on the mainshaft rear bearing by using a
suitable pipe.
Bearing inner diameter
22 mm {0.87 in}
Bearing outer diameter
56 mm {2.2 in}

J29

MANUAL TRANSMISSION
TRANSMISSION CASE COMPONENTS DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

SST
SELECTIVE
USE

SST
SST

SELECTIVE USE

SELECTIVE USE

SST

MOLYBDENUM
GREASE

Snap ring

Thrust washer
+ 5TH/REVERSE GEAR AND HOUSING PARTS
DISASSEMBLY/ASSEMBLY, Locknut (Mainshaft) Assembly Note

Main drive gear bearing


+ Disassembly Note
+ Assembly Note

Counter shaft front bearing


+ Disassembly Note
+ Assembly Note

Counter shaft center bearing


+ Disassembly Note
+ Assembly Note

Adjustment shim (counter shaft front bearing)


+ Assembly Note

Main drive gear

10

Counter shaft component

Mainshaft center bearing


+ Disassembly Note
+ Assembly Note

11

4th synchronizer ring

12

Bearing

Adjustment shim (mainshaft center bearing)


+ Assembly Note

13

3rd/4th shift fork

14

1st/2nd shift fork

15

Mainshaft gear component

16

Transmission case

Main Drive Gear Bearing Disassembly Note

J210

MANUAL TRANSMISSION
1. Install the SST between the 4th gear synchronizer
ring and main drive synchromesh gear.
49 F017 101

49 0839 425C

49 H017 101

2. Turn the bearing snap rings so that the ends are


90 to the transmission case grooves.
3. Install the SST making sure to hand-tighten the
side screws as tightly as possible, and remove the
main drive gear bearing.

Counter Shaft Center Bearing Disassembly Note


 Remove the counter shaft center bearing by using
the SST.

49 0839 425C

49 0839 425C

Counter Shaft Center Bearing Assembly Note


 Install the counter shaft center bearing onto the
rear of the counter shaft by using the SST.
49 F401 335A

Counter Shaft Front Bearing Disassembly Note


1. Turn the bearing snap rings so that the ends are
90 to the transmission case grooves.
2. Remove the counter shaft front bearing by using
the SST.

49 F401 331

49 0839 425C

Mainshaft Center Bearing Disassembly Note


 Remove the mainshaft center bearing by using the
SST.

Adjustment Shim (Mainshaft Center Bearing)


Assembly Note
 Measure the mainshaft center bearing thrust play
as follows.
(1) Measure the depth of the mainshaft center
bearing bore in the rear of the transmission
case.

J211

TRANSMISSION
CASE

MANUAL TRANSMISSION
(2) Measure the mainshaft center bearing height.
The difference between the two measurements
indicates the required thickness of the
adjustment shim.

(2) Measure the counter shaft front bearing snap


ring height A.
(3) Choose an adjustment shim that will allow the
difference between the two measurements to
be equal to the standard bearing height.

Standard thrust play


R15MD: 00.1 mm {00.004 in}
R15MXD: 00.05 mm {00.002 in}
Adjustment shim thickness
0.1 mm {0.004 in}, 0.3 mm {0.012 in}

AB + Adjustment shim (s) =


0.91.0 mm {0.0360.039}
Standard bearing height on installing
0.91.0 mm {0.0350.039}
Adjustment shim thickness
0.1 mm {0.004 in}, 0.3 mm {0.012 in}

Mainshaft Center Bearing Assembly Note


1. Install the correct shim onto the mainshaft center
bearing. Refer to Adjustment Shim (Mainshaft
Center Bearing) Assembly Note.
2. Install the mainshaft center bearing by using a
suitable pipe.

0.91.0 mm
{0.035
0.039 in }

Counter Shaft Front Bearing Assembly Note


1. Install the correct shim onto the counter shaft front
bearing. Refer to Adjustment Shim (Counter Shaft
Front Bearing) Assembly Note.
2. Install the counter shaft front bearing by using the
SST. If the counter shaft front bearing or counter
shaft front bearing spacer is being replaced,
replace them as a component.

Bearing inner diameter


35 mm {1.4 in}
Bearing outer diameter
80 mm {3.1 in}

49 F401 335A

49 F401 331
PIPE

Adjustment Shim (Counter Shaft Front Bearing)


Assembly Note
 Measure the counter shaft front bearing thrust play
as follows.
(1) Measure depth B of the counter shaft front
bearing bore in the transmission case.

Main Drive Gear Bearing Assembly Note


1. Install the SST between the 4th synchronizer ring
and the main drive synchromesh gear.

J212

49 F017 101

MANUAL TRANSMISSION
2. Install the main drive gear bearing by using the
SSTs.
49 F017 101

49 0500 330

MAINSHAFT AND COUNTER SHAFT COMPONENTS DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

FRONT

3RD/4TH

1ST/2ND

1ST/2ND AND 3RD/4TH CLUTCH HUBS

FRONT

FRONT

J213

SST

MANUAL TRANSMISSION
2. Install the main drive gear bearing by using the
SSTs.
49 F017 101

49 0500 330

MAINSHAFT AND COUNTER SHAFT COMPONENTS DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

FRONT

3RD/4TH

1ST/2ND

1ST/2ND AND 3RD/4TH CLUTCH HUBS

FRONT

FRONT

J213

SST

MANUAL TRANSMISSION
1st/2nd Clutch Hub Component Disassembly Note
 Hold the mainshaft, and press the 1st/2nd clutch
hub component, 2nd synchronizer ring component,
and 2nd gear from the mainshaft.

1st gear

Bearing

Bearing race

1st synchronizer ring

3rd/4th clutch hub component


+ Disassembly Note
+ Assembly Note

3rd/4th clutch hub

Synchronizer key

Clutch hub sleeve

Synchronizer key spring

10

3rd synchronizer ring

11

Bearing

12

3rd gear

13

1st/2nd clutch hub component


+ Disassembly Note
+ Assembly Note

14

1st/2nd clutch hub

15

Synchronizer key

16

Clutch hub sleeve

17

Synchronizer key spring

18

2nd synchronizer component


+ Assembly Note

19

Inner cone

20

Double cone

21

Synchronizer ring

22

2nd gear

23

Bearing

24

Mainshaft

25

Counter shaft front bearing spacer


+ Assembly Note

26

Diaphragm spring

27

Friction gear

28

Counter shaft

Counter Shaft Front Bearing Spacer Assembly


Note
 Install the counter shaft front bearing spacer. If the
counter shaft front bearing or counter shaft front
bearing spacer is being replaced, replace them as
a component.
2nd Synchronizer Component Assembly Note
 Install the inner cone, double cone, and
synchronizer ring as shown in the figure.
SYNCHRONIZER
RING
DOUBLE CONE

INNER CONE

2ND GEAR

3rd/4th Clutch Hub Component Disassembly Note


1. Remove the snap ring from the front of the
mainshaft.
2. Position the SST between 2nd and 3rd gears, and
hold the mainshaft from underneath.
3. Press the mainshaft out from the 3rd gear, 3rd
synchronizer ring, and the 3rd/4th clutch hub
component.

1st/2nd Clutch Hub Component Assembly Note


 Set the needle bearing, 2nd gear, 2nd synchronizer
component, and the 1st/2nd clutch hub component
on the mainshaft. Press the parts onto the
mainshaft while keeping the parts from becoming
crooked or misaligned.

49 0636 145

J214

MANUAL TRANSMISSION
3rd/4th Clutch Hub Component Assembly Note
 Set the needle bearing, 3rd gear, 3rd synchronizer
ring, and the 3rd/4th clutch hub component on the
mainshaft. Press the parts onto the mainshaft by
using the SST, while keeping the parts from
becoming crooked or misaligned.

Control Rod Lever and Shift Rod Inspection


1. Measure the clearance between the control rod
lever and the shift rod gate.
Clearance
0.8 mm {0.031 in} max.

49 F401 331

MANUAL TRANSMISSION INSPECTION


Mainshaft Inspection
1. Measure the mainshaft runout.
Runout
0.03 mm {0.0012 in} max.

2. If not as specified, replace the control rod lever and


shift rod.
Shift Fork and Clutch Hub Sleeve Inspection
1. Measure the clearance between the hub sleeve
groove and shift fork.
Clearance
0.20.3 mm {0.0080.012 in}
Maximum
0.5 mm {0.020 in}

2. If not as specified, replace the mainshaft.


Gear (Bushing) Inspection
1. Measure the clearance between mainshaft and
gear (or bushing).
Clearance
0.15 mm {0.006 in} max.

2. If not as specified, replace the shift fork and clutch


hub sleeve.
Synchronizer Ring Inspection
1. Inspect the following, and replace the synchronizer
ring as necessary.
(1) Individual synchronizer ring teeth for wear and
cracks.
(2) The tapered surface for wear and cracks.
2. Set the synchronizer ring squarely in the gear.
3. Measure the clearance between the synchronizer
ring and flank surface of gear all around the
circumference.
Standard clearance
1.5 mm {0.059 in}
Minimum
0.8 mm {0.031 in}

2. If not as specified, replace the gear.

J215

MANUAL TRANSMISSION
3rd/4th Clutch Hub Component Assembly Note
 Set the needle bearing, 3rd gear, 3rd synchronizer
ring, and the 3rd/4th clutch hub component on the
mainshaft. Press the parts onto the mainshaft by
using the SST, while keeping the parts from
becoming crooked or misaligned.

Control Rod Lever and Shift Rod Inspection


1. Measure the clearance between the control rod
lever and the shift rod gate.
Clearance
0.8 mm {0.031 in} max.

49 F401 331

MANUAL TRANSMISSION INSPECTION


Mainshaft Inspection
1. Measure the mainshaft runout.
Runout
0.03 mm {0.0012 in} max.

2. If not as specified, replace the control rod lever and


shift rod.
Shift Fork and Clutch Hub Sleeve Inspection
1. Measure the clearance between the hub sleeve
groove and shift fork.
Clearance
0.20.3 mm {0.0080.012 in}
Maximum
0.5 mm {0.020 in}

2. If not as specified, replace the mainshaft.


Gear (Bushing) Inspection
1. Measure the clearance between mainshaft and
gear (or bushing).
Clearance
0.15 mm {0.006 in} max.

2. If not as specified, replace the shift fork and clutch


hub sleeve.
Synchronizer Ring Inspection
1. Inspect the following, and replace the synchronizer
ring as necessary.
(1) Individual synchronizer ring teeth for wear and
cracks.
(2) The tapered surface for wear and cracks.
2. Set the synchronizer ring squarely in the gear.
3. Measure the clearance between the synchronizer
ring and flank surface of gear all around the
circumference.
Standard clearance
1.5 mm {0.059 in}
Minimum
0.8 mm {0.031 in}

2. If not as specified, replace the gear.

J215

MANUAL TRANSMISSION

4. If not as specified, replace the synchronizer ring.

2. If not as specified, replace the reverse idler gear


and shaft.

2nd Synchronizer Component Inspection


1. Inspect individual synchronizer ring gear teeth for
damage, wear, and cracks. Replace the
synchronizer component if any such damage is
found.
2. Inspect for wear and damage to the tapered
surfaces of the inner cone, double cone and
synchronizer ring. Replace the synchronizer
component if any such damage is found.
3. Set the synchronizer component squarely in the
gear.
4. Measure the clearance between the synchronizer
ring and flank surface of the gear.
Clearance
1.5 mm {0.059 in}
Maximum
0.8 mm {0.013 in}

5. If not as specified, replace the 2nd synchronizer


component.
Reverse Idler Gear and Shaft Inspection
1. Measure the clearance between the reverse idler
gear bushing and shaft.
Clearance
0.020.05 mm {0.00080.0020 in}
Maximum
0.15 mm {0.006 in}

J216

TRANSFER
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER COMPONENT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SPROCKET COMPONENT
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . .

J3 1
J3 1
J3 2

OUTPUT SHAFT COMPONENT


DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . J3 5
TRANSFER COMPONENT ASSEMBLY . . . . J3 7
TRANSFER INSPECTION . . . . . . . . . . . . . . . . J310

J3 4

TRANSFER
PRECAUTION
1. Clean the transfer exterior thoroughly by using a steam cleaner or cleaning solvents before disassembly.
Warning
 Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear
protective eye wear whenever using compressed air.
Caution
 Cleaning sealed bearings by using cleaning fluids or a steam cleaner can wash the grease out of
the bearing.
2. Clean the removed parts by using cleaning solvent, and dry them by using compressed air.
Clean out all holes and passages by using compressed air, and check that there are no obstructions.
3. Use a plastic hammer when disassembling the transfer case and other light alloy metal parts.
4. Make sure each part is cleaned before assembling.
5. Coat all movable parts with the specified oil.
6. Replace parts whenever required.
7. Remove old sealant from contact surfaces before applying new sealant.
8. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transmission with transmission oil.

J31

TRANSFER
TRANSFER COMPONENT DISASSEMBLY
 Disassemble in the order indicated in the table.

SST

SST

SST

Stopper pin

14

Oil passage

Control lever end

15

Roll pin

Locknut
+ Disassembly Note

16

Spacer

17

HL shift fork

Companion flange

18

HL shift rod

44 indicator switch

19

Roll pin

Transfer neutral switch (RFW model)

20

Roll pin

Plug (except RFW model)

21

Retainer

Detent ball and spring

22

Spacer

Snap ring

23

2W4W shift end

10

Bearing (input shaft gear)


+ Disassembly Note

24

Roll pin

11

Adjustment shim

25

2W4W shift fork

12

Chain cover

26

Spring

13

Interlock pin

27

Spacer

28

2W4W shift rod

J32

TRANSFER

29

Retainer

30

Output shaft component, chain, and front drive


sprocket component
+ Disassembly Note

31

Input shaft gear

32

Bearing

33

Adjustment shim

34

Adjustment shim

35

Lock plate

36

Counter shaft gear support


+ Disassembly Note

37

O-ring

38

Thrust washer

39

Counter gear

40

Bearing

41

Spacer

42

Thrust washer

43

Oil seal

44

Snap ring

45

Bearing (front drive sprocket)


+ Disassembly Note

46

Oil seal

Bearing (Input Shaft Gear) Disassembly Note


 Remove the bearing by using the SST.

49 0839 425C

Output Shaft Component, Chain, and Front Drive


Sprocket Component Disassembly Note
 Remove the output shaft and the front drive
sprocket from the transfer case housing by lightly
tapping the input shaft gear and the front drive
sprocket by using a plastic hammer.

Locknut Disassembly Note


1. Hold the companion flange by using the SST and
remove the locknut.

49 S120 710

Counter Shaft Gear Support Disassembly Note


 Tap out the counter shaft gear support by using a
tape-wrapped screwdriver and a plastic hummer.

2. Remove the companion flange by lightly tapping


the back side by using a plastic hammer.

Bearing (Front Drive Sprocket) Disassembly Note


 Remove the bearing by using the SST.

49 F401 331

J33

TRANSFER
FRONT DRIVE SPROCKET COMPONENT
DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

SST

SST

Bearing
+ Disassembly Note
+ Assembly Note

Front drive sprocket

Bearing Disassembly Note


 Remove the bearings from both sides of the front
drive sprocket by using the SST.
49 0839 425C

Bearing Assembly Note


 Press the bearings on both sides of the front drive
sprocket by using the SST. Press the bearings on
until they stop.

49 0727 415

J34

TRANSFER
OUTPUT SHAFT COMPONENT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

SST

SST

Speedometer drive gear

Bearing (2W4W clutch hub side)


+ Disassembly Note
+ Assembly Note

Bearing (low gear side)


+ Disassembly Note
+ Assembly Note

10

Thrust lock washer

2W4W clutch hub

11

Steel ball

2W4W hub sleeve

12

Low gear

Drive sprocket

13

Needle bearing

Needle bearing

14

Roll pin

Spacer

15

HL hub sleeve

Thrust washer

16

Output shaft

J35

TRANSFER
Bearing (2W4W Clutch Hub Side) Disassembly
Note
 Remove the bearing from output shaft by using the
SST.
49 0839 425C

Bearing (Low Gear Side) Disassembly Note


 Remove the bearing, lock washer, steel ball and
low gear by using the press.

Bearing (Low Gear Side) Assembly Note


 Install the bearing by using the SST.

49 0727 415

Bearing (2W4W Clutch Hub Side) Assembly Note


 Install the bearing by using the SST.

49 F401 331

49 F401 336B

J36

TRANSFER
TRANSFER COMPONENT ASSEMBLY
 Assemble in the order indicated in the table.

R
R

2534 {2.53.5, 1825}

2534 {2.53.5, 1825}


1925
{1.92.6,
1418}

R
R
1925
{1.92.6,
1418}

SST
128177
{1318,
94130}

SELECTIVE USE
SST

SST

R
2534
{2.53.5,
1825}
1925
{1.92.6,
1418}

1925
{1.92.6,
1418}

R
SST

SST
SELECTIVE USE
SST

1925
{1.92.6,
1418}

3747
{3.74.8,
2734}

SST

R
R
SELECTIVE USE

APPLY SILICONE SEALANT

SST

APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

Nm {kgfm, ftlbf}

Bearing (front drive sprocket)


+ Assembly Note

13

Adjustment shim
+ Assembly Note

Snap ring

14

Oil seal
+ Assembly Note

Bearing (input shaft gear)


+ Assembly Note

15

Input shaft

Thrust washer

16

Snap ring

Spacer

17

Bearing

Bearing

18

Output shaft component

Counter gear

19

Front drive sprocket component

Thrust washer

20

Counter gear component

Chain
+ Assembly Note

10

O-ring

21

HL shift fork

11

Counter shaft gear support

22

Spacer

12

Lock plate

23

HL shift rod

24

Roll pin

J37

TRANSFER
Adjustment Shim Assembly Note
1. Measure the bearing bore depth (A) of the transfer
case by using vernier calipers.

25

2W4W shift end

26

Spacer

27

2W4W shift rod

28

Retainer

29

Spacer

30

Spring

31

2W4W shift fork

32

Retainer

33

Roll pin

34

Oil passage

35

Adjustment shim
+ Assembly Note

36

Adjustment shim
+ Assembly Note

37

Interlock pin

38

Chain cover

39

Detent ball and spring

40

Plug (except RFW model)

41

Transfer neutral switch (RFW model)

42

44 indicator switch

43

Oil seal
+ Assembly Note

44

Companion flange

45

Locknut
+ Assembly Note

46

Control lever end

47

Stopper pin

TRANSFER CASE

2. Measure height (B) of the bearing clip by using


vernier calipers and a surface plate.

BEARING

3. Calculate the difference between (A) and (B) to


determine the clearance.
Clearance=(A)(B)

Bearing (Front Drive Sprocket) Assembly Note


 Install the bearing to the transfer case by using the
SSTs.

CLEARANCE

49 G030 797

ADJUSTMENT SHIM
TRANSFER CASE
HOUSING

INPUT SHAFT

49 G026 102

4. Select and install the proper shim to obtain the


standard clearance.
Oil Seal Assembly Note
 Apply oil to the lip of a new oil seal and install the
oil seal in the transfer case by using the SST.

Standard clearance
00.1 mm {00.0039 in}
Adjustment shim thickness
0.6 mm {0.024 in}, 0.7 mm {0.028 in},
0.8 mm {0.032 in}, 0.9 mm {0.035 in},
1.0 mm {0.039 in}, 1.1 mm {0.043 in},
1.2 mm {0.047 in}, 1.3 mm {0.051 in},
1.4 mm {0.055 in}

49 0259 749

J38

TRANSFER
Bearing (Input Shaft Gear) Assembly Note
 Press the bearing on the input shaft gear by using
the SSTs.

Adjustment Shim Assembly Note


1. Measure the bearing height and the bearing bore
depth for the output shaft by using the SST.
2. Put the two pieces of the gauge set together and
measure the clearance.
49 U017 3A0A

49 0727 415

49 U027 003

Chain Assembly Note


Note
 Do not overtighten the chain expansion tool.
1. Install the chain on the drive sprocket component
and the front drive sprocket, and expand the chain
by using the SST to set the center to center
distance for easy installation into the transfer case.
49 S231 395A
49 U017 3A0A

3. Select the proper adjustment shim to adjust the


clearance.
Standard clearance
0.10.3 mm {0.0040.011 in}
Adjustment shim thickness
0.5 mm {0.020 in}, 0.6 mm {0.024 in},
0.7 mm {0.028 in}, 0.8 mm {0.031 in},
0.9 mm {0.035 in}, 1.0 mm {0.039 in},
1.1 mm {0.043 in}, 1.2 mm {0.047 in},
1.3 mm {0.051 in}, 1.4 mm {0.055 in},
1.5 mm {0.059 in}, 1.6 mm {0.063 in},
1.7 mm {0.067 in}

2. Install the front drive sprocket component into the


transfer case by lightly tapping it with a plastic
hammer, keeping the chain horizontal.

4. Select the proper adjustment shim for the front


drive sprocket bearing in same way as for the
output shaft side.
Standard clearance
00.1 mm {00.0039 in}
Adjustment shim thickness
0.5 mm {0.020 in}, 0.6 mm {0.024 in},
0.7 mm {0.028 in}, 0.8 mm {0.031 in},
0.9 mm {0.035 in}, 1.0 mm {0.039 in},
1.1 mm {0.043 in}, 1.2 mm {0.047 in},

3. After installing, check that the chain rotates


smoothly.

J39

TRANSFER

49 U017 3A0A

Oil Seal Assembly Note


 Apply oil to the lip of a new oil seal and install the
oil seal in the chain cover case by using the SST.

2. If not as specified, replace the shift fork and hub


sleeve.

49 0727 415

Locknut Assembly Note


1. Apply silicone sealant to the companion flange
spline.
2. Use a new locknut and tighten the flange. Hold the
companion flange by using the SST.
49 S120 710

TRANSFER INSPECTION
Hub Sleeve and Shift Fork Inspection
1. Measure the clearance between the hub sleeve
and shift fork.
Clearance
0.380.52 mm {0.0150.020 in}
Maximum
0.8 mm {0.031 in}

J310

TRANSFER

49 U017 3A0A

Oil Seal Assembly Note


 Apply oil to the lip of a new oil seal and install the
oil seal in the chain cover case by using the SST.

2. If not as specified, replace the shift fork and hub


sleeve.

49 0727 415

Locknut Assembly Note


1. Apply silicone sealant to the companion flange
spline.
2. Use a new locknut and tighten the flange. Hold the
companion flange by using the SST.
49 S120 710

TRANSFER INSPECTION
Hub Sleeve and Shift Fork Inspection
1. Measure the clearance between the hub sleeve
and shift fork.
Clearance
0.380.52 mm {0.0150.020 in}
Maximum
0.8 mm {0.031 in}

J310

TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . TD1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD1

MANUAL TRANSMISSION . . . . . . . . . . . . . . . TD11

TECHNICAL DATA
ENGINE
F2
Item

Specification

Cylinder head
Height

(mm {in})

Cylinder head gasket contact


surfaces distortion

(mm {in})

Manifold contact surface distortion

(mm {in})

Standard

91.9592.05 {3.6213.624}

Maximum
grinding

0.20 {0.008}

Maximum

0.15 {0.006}

Maximum

0.15 {0.006}

Maximum
grinding

0.20 {0.008}

Valve and valve guide

Margin thickness

IN

CARB: 1.802.20 {0.0710.086}


CIS: 0.81.2 {0.0320.047}

EX

CARB: 1.301.70 {0.0520.066}


CIS: 1.301.70 {0.0520.066}

(mm {in})

Standard

CARB: 115.61116.01 {4.5524.567}


CIS: 111.69112.09 {4.3984.412}

Minimum

CARB: 115.51 {4.548}


CIS: 111.39 {4.386}

Standard

CARB: 116.01116.41 {4.5684.583}


CIS: 111.49111.89 {4.3904.405}

Minimum

CARB: 115.71 {4.556}


CIS: 111.19 {4.378}

Standard

CARB: 6.9706.985 {0.27450.2749}


CIS: 8.0308.045 {0.31620.3167}

Maximum

CARB: 6.920 {0.2724}


CIS: 7.980 {0.3142}

Standard

CARB: 6.9656.980 {0.27430.2748}


CIS: 8.0258.040 {0.31600.3165}

Maximum

CARB: 6.915 {0.2722}


CIS: 7.975 {0.3140}

Standard

CARB: 7.0107.030 {0.27600.2767}


CIS: 8.0708.090 {0.31780.3185}

IN
Valve length

(mm {in})
EX

IN
Valve stem diameter

(mm {in})
EX

Valve guide inner diameter

(mm {in})

Valve guide protrusion height

(mm {in})

CARB: 19.820.3 {0.7800.799}


CIS: 19.119.6 {0.7520.771}

(mm {in})

1.21.6 {0.0480.062}

Valve seat
Valve seat contact width
Valve seat angle

Valve seat sinking


g
(valve protrusion height)

(mm {in})

IN

45

EX

45

Standard

CARB: 49.7 {1.957}


CIS: 46.5 {1.831}

Maximum

CARB: 51.2 {2.016}


CIS: 47.0 {1.850}

TD1

TECHNICAL DATA

Item

Specification

Valve spring
H: 41.0 mm
{1.614 in} (CARB)

203.10229.86 {20.7123.44, 45.5751.56}

H Inner: 36.5 mm
{1.437 in}
Outer: 41.0 mm
{1.614 in} (CIS)

Inner: 116.41131.80 {11.8713.44, 26.1230.51}


Outer: 243.70267.03 {24.8527.23, 54.6759.90}

H: 41.0 mm
{1.614 in} (CARB)

240.37272.03 {24.5127.74,53.9361.02}

EX

H Inner: 36.5 mm
{1.437 in}
Outer: 41.0 mm
{1.614 in} (CIS)

Inner: 116.41131.80 {11.8713.44, 26.1230.51}


Outer: 243.70267.03 {24.8527.23, 54.6759.90}

IN

Maximum

CARB: 1.73 {0.068}


CIS: Inner 1.6 {0.063}, Outer 1.8 {0.071}

EX

Maximum

CARB: 1.76 {0.069}


CIS: Inner 1.6 {0.063}, Outer 1.8 {0.071}

IN
Pressing
g force at valve spring
g
height H
(N {kgf, lbf})

Outofsquare

(mm {in})

Valve seal
Depth L

(mm {in})

CARB: 21.422.2 {0.8430.874}


CIS: 19.119.6 {0.7520.771}

Camshaft
Camshaft runout

Cam lobe height

(mm {in})

Maximum

0.03 {0.0012}

IN

Standard

CARB: 41.341 {1.6276}


CIS: 38.059 {1.4984}

EX

Standard

CARB: 41.851 {1.6477}


CIS: 38.059 {1.4984}

Standard

No.1, 5: 31.94031.965 {1.25751.2585}


No.2, 3, 4: 31.91031.935 {1.25631.2572}

Minimum

No.1, 5: 31.910 {1.2563}


No.2, 3, 4: 31.880 {1.2551}

(mm {in})

Journal diameter

(mm {in})

Standard

Journal oil clearance (mm {in})

No.1, 5

CARB: 0.0350.060 {0.001380.00236}


CIS: 0.0350.085 {0.001380.0033}

No.2, 3, 4

CARB: 0.0650.090 {0.002560.00354}


CIS: 0.0650.115 {0.002560.00453}

Maximum
End play
lay

(mm {in})

0.15 {0.006}
Standard

0.080.16 {0.003150.00629}

Maximum

0.20 {0.008}

Pushing distance of the camshaft oil seal


[from the edge of the cylinder head]

(mm {in})

0 {0}

Rocker arm and rocker arm shaft


(mm {in})

Standard

CARB: 19.00019.033 {0.74810.7493}


CIS: 16.00016.027 {0.63000.6309}

Rocker arm shaft outer diameter (mm {in})

Standard

CARB: 18.95918.980 {0.74650.7472}


CIS: 15.96615.984 {0.62860.6292}

Oil clearance between rocker


arm and shaft

Standard

CARB: 0.0200.074 {0.000790.00291}


CIS: 0.0160.061 {0.000630.00240}

Rocker arm inner diameter

(mm {in})

Cylinder block
Standard

301.43301.57 {11.86811.872}

Height

(mm {in})

Maximum
grinding

0.20 {0.008}

Distortion

(mm {in})

Maximum

0.15 {0.006}

TD2

TECHNICAL DATA

Item
Cylinder bore diameter
[M
[Measure
the
h cylinder
li d bore
b
at
70 mm {2.76 in} below the to
top
surface]
(mm {in})

Specification
Standard

86.00086.019 {3.38593.3865}

0.25 {0.01} oversize

86.25086.269 {3.39573.3964}

0.50 {0.02} oversize

86.50086.519 {3.40563.4062}

Wear limit

(mm {in})

0.15 {0.006}

Piston
Piston diameter
[M
[Measured
d at 90 to pin
i bore
b
axis and 18.0 mm {0.709 in}
below oil ring groove] (mm {in})
Clearance between piston and
cylinder oil

Standard

85.94385.965 {3.383583.38444}

0.25 {0.01} oversize

86.19386.215 {3.393423.39428}

0.50 {0.02} oversize

86.44386.465 {3.403273.40412}

Standard

0.0350.076 {0.00140.0029}

Maximum

0.15 {0.006}

Top

Standard

CARB: 0.0350.070 {0.00140.0027}


CIS: 0.0300.070 {0.0120.0027}

Second

Standard

0.0300.070 {0.00120.0027}

Oil

Standard

0.0700.160 {0.00280.0062}

Top,
Second

Maximum

0.15 {0.0059}

Oil

Maximum

(mm {in})

Piston ring

Clearance between piston


ring and ring groove (mm {in})

0.17 {0.0067}

Top
End g
gap
[Measured in cylinder]

(mm {in})

0.200.35 {0.0080.013}

Second

0.150.30 {0.0060.011}

Oil

0.200.70 {0.0080.027}

Maximum

1.0 {0.039}

Piston pin
Piston pin diameter

(mm {in})

Standard

21.97421.980 {0.86520.8653}

Piston pin bore diameter

(mm {in})

Standard

21.98821.998 {0.86570.8660}

Oil clearance between connecting


rod and piston pin
(mm {in})

Standard

0.0370.013 {0.00140.0006}

Oil clearance between piston pin


bore and piston pin
(mm {in})

Standard

0.0080.024 {0.000320.0094}

Connecting rod and connecting rod bearing


Length (center to center)

(mm {in})

Standard

158.45158.55 {6.2396.242}

Bending

(mm {in})

Maximum

0.075 {0.0029}/50 {1.97}

Distortion

(mm {in})

Maximum

0.180 {0.0070}/50 {1.97}

Connecting rod small end inner diameter


(mm {in})

Standard

21.94321.961 {0.86390.8646}

Standard

0.1100.262 {0.0050.010}

Maximum

0.30 {0.012}

Connecting rod side clearance

Connecting
g rod bearing
g size
(mm {in})

(mm {in})
Standard

1.5051.510 {0.05930.0594}

0.25 {0.01} undersize

1.6301.635 {0.06420.0643}

0.50 {0.02} undersize

1.7551.760 {0.06910.0692}

0.75 {0.03} undersize

1.8801.885 {0.07410.0742}

Connecting
g rod bearing
g oil clearance
(mm {in})

Standard

0.0270.067 {0.00110.0026}

Maximum

0.10 {0.004}

Maximum

0.03 {0.0012}

Crankshaft
Crankshaft runout

(mm {in})

TD3

TECHNICAL DATA

Item

Main journal diameter (mm {in})

Main jjournal oil clearance

Specification
Standard

59.93759.955 {2.35982.3604}

0.25 {0.01} undersize

59.68759.705 {2.34992.3505}

0.50 {0.02} undersize

59.43759.455 {2.34012.3407}

0.75 {0.03} undersize

59.18759.205 {2.33022.3309}

((mm {{in})
})

Standard

No.1, 2, 4, 5: 0.0250.043 {0.000990.00169}


No.3: 0.0310.049 {0.001230.00192}

Maximum

0.10 {0.004}
No.1, 2, 4, 5: 2.0042.022 {0.078900.07960}
No.3: 2.0042.019 {0.078900.07948}

Standard
Main bearing
g size

((mm {{in})
})

Crank pin jjournal diameter


(mm {in})

No.3 bearing
g width
(mm {in})

Crankshaft end play


lay

0.25 {0.01} undersize

2.1292.139 {0.083820.08421}

0.50 {0.02} undersize

2.2542.264 {0.088740.08913}

0.75 {0.03} undersize

2.3792.389 {0.093670.09405}

Standard

50.94050.955 {2.00562.0060}

0.25 {0.01} undersize

50.69050.705 {1.99571.9962}

0.50 {0.02} undersize

50.44050.455 {1.98591.9864}

0.75 {0.03} undersize

50.19050.205 {1.97601.9765}

Standard

27.9427.99 {1.10001.1019}

0.25 {0.01} undersize

28.0428.09 {1.10401.1060}

0.50 {0.02} undersize

28.1228.17 {1.10711.1090}

0.75 {0.03} undersize

28.2028.25 {1.11031.1122}

(mm {in})

Standard

0.080.18 {0.003150.00708}

Maximum

0.30 {0.012}

Timing belt
Timing belt deflection
[Applied pressure 98 N {10 kgf, 22 lbf}]

(mm {in})

New: 8.09.0 {0.320.35}


Used: 9.010.0 {0.360.39}

Tensioner spring free length

(mm {in})

63.0 {2.48}

Oil pump
Clearance between inner rotor
tooth tip and outer rotor

(mm {in})

Clearance between outer rotor


and body

(mm {in})

Side clearance

(mm {in})

Maximum

0.18 {0.007}

Standard

0.0900.176 {0.00360.0069}

Maximum

0.20 {0.008}

Standard

0.030.09 {0.00120.0035}

Maximum

0.10 {0.004}

Pressure spring free length

(mm {in})

Pushing distance of the front oil seal


[from the edge of the oil pump body]

(mm {in})

46.4 {1.827}
0 {0}

Rear oil seal


Pushing distance of the rear oil seal
[from the edge of the rear cover]

(mm {in})

TD4

00.5 {00.019}

TECHNICAL DATA
G6
Item

Specification

Cylinder head
Cylinder
y
head g
gasket contact surfaces
distortion
(mm {in})

Maximum

0.15 {0.006}

Maximum grinding

0.20 {0.008}

Manifold contact surfaces distortion

Maximum

0.15 {0.006}

Maximum grinding

0.20 {0.008}

(mm {in})
Valve and valve guide
Margin thickness

(mm {in})
IN

Valve length

(mm {in})
EX
IN

Valve stem diameter


(mm {in})

EX

IN

Maximum

1.0 {0.0394}

EX

Maximum

1.5 {0 .0591}

Standard
Maximum

112.215 {4.418}

Standard

113.42114.22 {4.4664.496}

Maximum

112.945 {4.447}

Standard

6.9706.985 {0.27440.2749}

Maximum

6.920 {0.2724}

Standard

6.9656.980 {0.27430.2748}

Maximum

6.915 {0.2722}

Valve guide inner diameter


Valve guide protrusion
rotrusion height

(mm {in})
(mm {in})

23.524.1 {0.9260.948}

EX

23.524.1 {0.9260.948}
(mm {in})

IN

Valve seat angle

(mm {in})
EX

1.21.6 {0.0480.062}
45

EX
IN

7.017.03 {0.27600.2767}

IN

Valve seat contact width

Valve dimension

112.29113.09 {4.4214.452}

45

Standard

49.0 {1.929}

Maximum

49.6 {1.953}

Standard

49.0 {1.929}

Maximum

49.6 {1.953}

Valve spring
Pressing
g force at valve spring
g height
g H
(N {kgf, lbf})
Out-of-square

(mm {in})

IN

H: 43.0 mm
{1.69 in}

195.2221.6 {19.922.6, 43.7849.72}

EX

H: 43.0 mm
{1.69 in}

195.2221.6 {19.922.6, 43.7849.72}

Maximum

TD5

1.73 {0.068}

TECHNICAL DATA

Item

Specification

Camshaft
Runout

(mm {in})
IN

Cam lobe height

(mm {in})
EX
Standard

Journal diameter

(mm {in})
Minimum

Journal oil clearance

(mm {in})

Standard

Maximum

0.03 {0.0012}

Standard

41.714 {1.6423}

Minimum

41.514 {1.6344}

Standard

41.988 {1.6531}

Minimum

41.788 {1.6452}

No.1, 5

29.94029.965 {1.17881.1797}

No.2, 3, 4

29.91029.935 {1.17761.1785}

No.1, 5
No.2, 3, 4
No.1, 5

(mm {in})

29.860 {1.1756}
0.0350.085 {0.00140.0033}

No.2, 3, 4

0.0650.115 {0.0260.0045}

Standard

0.020.15 {0.00080.0059}

Maximum

0.20 {0.0079}

Minimum
End play
lay

29.890 {1.1768}

0.15 {0.006}

Rocker arm and Rocker arm shaft


Rocker arm inner diameter

(mm {in})

21.00021.033 {0.82680.8280}

Rocker arm shaft diameter

(mm {in})

20.95920.980 {0.82520.8259}

Clearance between rocker arm and shaft

(mm {in})

0.0200.074 {0.00080.0029}

Cylinder block
Cylinder head gasket contact surfaces distortion
(mm {in})

Cylinder bore diameter

(mm {in})

Maximum

0.15 {0.006}

Maximum
grinding

0.20 {0.008}

Standard

92.00092.022 {3.62213.6229}

0.25 {0.01} oversize

92.25092.272 {3.63193.6327}

0.50 {0.02} oversize

92.50092.522 {3.64183.6425}

Wear limit

(mm {in})

0.15 {0.006}

Oil jet valve,nozzle


Nozzle opening pressure

(kPa {kgf/cm2, psi})

167225 {1.72.3, 2532}

Piston
Piston diameter
[M
[Measured
d at 90 to pin
i b
bore axis
i and
d
18 mm {0.71 in} above the bottom of
piston]
(mm {in})

Standard

91.93392.957 {3.61943.6203}

0.25 {0.01} oversize

92.18392.207 {3.62933.6301}

0.50 {0.02} oversize

92.43392.457 {3.63913.6400}

Clearance between piston


iston and cylinder

(mm {in})

Piston pin bore diameter

Standard

0.0580.074 {0.00230.0029}

Maximum

0.15 {0.006}

(mm {in})

22.98823.000 {0.90510.9055}

Piston ring
Clearance between piston ring and ring groove
(mm {in})

Top

0.030.07 {0.00120.0027}

Second

0.030.07 {0.00120.0027}

Maximum
End g
gap
[Measured in cylinder]

(mm {in})

0.15 {0.0059}

Top

0.200.35 {0.0080.013}

Second

0.200.40 {0.0080.015}

Oil (rail)

0.200.70 {0.0080.027}

Maximum

1.0 {0.039}

Piston pin
Diameter

(mm {in})

22.97422.980 {0.90450.9047}

Clearance between connecting rod and piston pin

(mm {in})

0.037 0.013 {0.0015 0.0005}

Clearance between piston and piston pin

(mm {in})

0.0080.026 {0.00040.0010}

TD6

TECHNICAL DATA

Item

Specification

Crankshaft
Runout

(mm {in})

Main jjournal diameter


(mm {in})

Standard

59.93759.955 {2.35982.3604}

0.25 {0.01} undersize

59.68759.705 {2.34992.3505}

0.50 {0.02} undersize

59.43759.455 {2.34012.3407}

0.75 {0.03} undersize

59.18759.205 {2.33022.3309}

Out-of-round

Crank pin
in diameter

(mm {in})

(mm {in})

50.94050.955 {2.00562.0060}

0.25 {0.01} undersize

50.69050.705 {1.99571.9962}

0.50 {0.02} undersize

50.44050.455 {1.98591.9864}

0.75 {0.03} undersize

50.19050.205 {1.97601.9765}

(mm {in})

Main journal oil clearance

(mm {in})

0.03 {0.001}

Standard

0.0250.044 {0.00100.0017}

Maximum

0.08 {0.003}

Standard

2.0072.022 {0.07900.0796}

0.25 {0.01} undersize

2.1322.137 {0.08400.0841}

0.50 {0.02} undersize

2.2572.262 {0.08890.0890}

0.75 {0.03} undersize

2.3822.387 {0.09380.0939}

Crankshaft end play


lay

No.4 main bearing


g width
(mm {in})

0.03 {0.001}

Standard

Out-of-round

Main jjournal bearing


g thickness
(mm {in})

0.03 {0.0012}

(mm {in})

Standard
Maximum

0.080.18 {0.003150.00708}
0.30 {0.012}

Standard

25.9425.99 {1.0221.023}

0.25 {0.01} undersize

26.0426.09 {1.0261.027}

0.50 {0.02} undersize

26.1226.17 {1.0291.030}

0.75 {0.03} undersize

26.2026.25 {1.0321.033}

Connecting rod
Small end inner diameter

(mm {in})

22.94322.961 {0.90330.9039}

Length [Center to center]

(mm {in})

166.45166.55 {6.5546.557}

Bending

(mm {in})

0.075 {0.0030} max./50 {2.0}

Distortion

(mm {in})

0.180 {0.0071} max./50 {2.0}

Connecting
g rod bearing
g oil clearance
(mm {in})

Connecting
g rod bearing
g
thickness
(mm {in})

Connecting rod side clearance

Standard

0.0270.067 {0.00110.0026}

Maximum

0.10 {0.0039}

Standard

1.5051.510 {0.05930.0594}

0.25 {0.01} undersize

1.6301.635 {0.06420.0643}

0.50 {0.02} undersize

1.7551.760 {0.06910.0692}

0.75 {0.03} undersize

1.8801.885 {0.07410.0742}

(mm {in})

Standard

0.1100.262 {0.00440.0103}

Maximum

0.30 {0.012}

Balance shaft
Clearance between balance shaft and
balance shaft bore
(mm {in})

Front

0.0500.115 {0.00200.0045}

Center

0.0800.145 {0.00320.0057}

Rear

0.0800.145 {0.00320.0057}

TD7

TECHNICAL DATA

Item

Specification

Oil pump
Relief spring free length

(mm {in})

46.4 {1.827}

Standard

0.020.18 {0.0080.0070}

(mm {in})

Maximum

0.22 {0.0087}

Clearance between outer rotor and bodyy


(mm {in})

Standard

0.1130.186 {0.00450.0073}

Maximum

0.20 {0.079}

Standard

0.0350.105 {0.00140.0041}

Maximum

0.14 {0.0055}

Clearance between inner rotor


tooth tip and outer rotor

Side clearance

(mm {in})

Oil seal
Rear oil seal tapping amount

(mm {in})

00.5 {00.019}

Front oil seal tapping amount

(mm {in})

00.7 {00.027}

WL, WL Turbo
Item
Cylinder head

Specification

Distortion

(mm {in})

Margin thickness

(mm {in})
IN

Valve length

(mm {in})
EX

Valve and
valve guide

IN
Valve stem diameter
(mm {in})

EX

IN

1.50 {0.059}

EX

0.75 {0.030}

Standard

111.60112.10 {4.3944.413}

Minimum

111.35 {4.384}

Standard

111.50112.00 {4.3904.409}

Minimum

111.25 {4.380}

Standard

6.9706.985 {0.27450.2749}

Minimum

6.920 {0.2724}

Standard

6.9656.980 {0.27430.2748}

Minimum

Guide inner diameter

(mm {in})

Valve guide protrusion


rotrusion height

(mm {in})

Seat contact width

(mm {in})

Seat angle
Valve seat
IN
Valve recession (mm {in})
EX

Valve spring

Pressing force at valve


spring height H
(N {kgf, lbf})
Out of square
Out-of-square

X: 0.020 {0.0008} max.


Y: 0.050 {0.0020} max.

6.915 {0.2722}
7.0257.045 {0.27660.2773}

IN

14.014.5 {0.560.57}

EX

14.014.5 {0.560.57}

IN

1.62.2 {0.070.08}

EX

1.72.3 {0.070.09}

IN

45

EX

45

Standard

0.611.09 {0.0250.042}

Maximum

1.50 {0.059}

Standard

0.711.19 {0.0280.046}

Maximum

1.60 {0.063}

IN

H: 35.5 mm
{1.40 in}

239268 {24.327.4, 53.560.2}

EX

H: 35.5 mm
{1.40 in}

239268 {24.327.4, 53.560.2}

(mm {in})

IN

1.70 {0.0670}

EX

1.70 {0.0670}

TD8

TECHNICAL DATA

Item

Specification

Camshaft runout

(mm {in})
Standard

IN
WL
EX
Lobe height

(mm {in})
WL
Tur
bo
-bo

Camshaft

IN
EX

No 1 5
No.1,
Journal diameter
(mm {in})

No 2 3,
3 4
No.2,

Camshaft end play


lay

(mm {in})

Distortion
Cylinder block

Cylinder bore diameter


(mm {in})

Piston

42.39542.495 {1.6701.673}

Minimum

42.045 {1.6553}

Standard

41.22141.321 {1.6231.626}

Minimum

40.871 {1.6091}

Standard

42.39542.495 {1.6701.673}

Minimum

42.045 {1.6553}

Standard

25.94025.965 {1.02131.0222}

Minimum

25.890 {1.0193}

Standard

25.91025.935 {1.02011.0210}

0.0650.111 {0.00260.0043}

Standard

0.0300.160 {0.00120.0062}

Maximum

0.200 {0.0078}
X: 0.020 {0.0008} max.
Y: 0.050 {0.0020} max.

Standard

93.00093.022 {3.66153.6622}

0.25 {0.01} oversize

93.25093.272 {3.67133.6721}

0.50 {0.02} oversize

93.50093.522 {3.68113.6819}

(mm {in})

0.150 {0.0059}

Standard

92.95192.977 {3.65953.6605}

0.25 {0.01} oversize

93.18693.212 {3.66883.6697}

0.50 {0.02} oversize

93.43693.462 {3.67863.6795}

Clearance between piston and


cylinder
(mm {in})

Clearance between piston ring


g
and ring groove
(mm {in})

Standard

0.0380.056 {0.00150.0022}

Maximum

0.150 {0.0059}

Top

0.060.10 {0.00240.0039}

Second

0.040.08 {0.00160.0031}

Oil

0.030.07 {0.00120.0027}

Maximum

Piston ring
End gap
g [Measured
[
in cylinder]
y
]
(mm {in})

0.150 {0.0059}

Top

0.220.32 {0.0090.012}

Second

0.320.47 {0.0130.018}

Oil (rail)

0.220.32 {0.0090.012}

Maximum

Piston pin

25.860 {1.0181}
0.0350.081 {0.00140.0031}

No.2, 3, 4

(mm {in})

Wear limit
Piston diameter measured
at 90
90 to pin
in bore axis and
19.0 mm {0.75} above the
bottom of piston
(mm {in})

42.050 {1.6555}

Standard

No.1, 5
(mm {in})

42.4042.50 {1.6701.673}

Minimum

Minimum

Camshaft jjournal oil clearance

0.03 {0.001} max.

Diameter

(mm {in})

Clearance between connecting rod and


piston pin

(mm {in})

Clearance between piston and piston pin

(mm {in})

TD9

1.00 {0.039}
31.99432.007 {1.25981.2601}
0.0030.013 {0.00010.0005}
0.0120.039 {0.00050.0015}

TECHNICAL DATA

Item

Specification

Crankshaft runout

Main jjournal diameter


(mm {in})

(mm {in})
Standard

66.93766.955 {2.63542.6360},
66.92066.938 {2.63472.6353} (No.3)

0.25 {0.01} undersize

66.68766.705 {2.62552.6261},
66.67066.688 {2.62482.6255} (No.3)

0.50 {0.02} undersize

66.43766.455 {2.61572.6163},
66.42066.438 {2.61502.6156} (No.3)

0.75 {0.03} undersize

66.18766.205 {2.60582.6040},
66.17066.188 {2.60522.6058} (No.3)

Out-of-round

(mm {in})

Crankshaft
Crankpin diameter

(mm {in})

Out-of-round
Main jjournal oil clearance

Crankshaft end play


lay

Connecting
rod and
connecting
d bearing
b i
rod

Tensioner
spring

((mm {{in})
})

(mm {in})

0.03 {0.001} max.

Standard

54.94054.955 {2.16302.1635}

0.25 {0.01}
undersize

54.69054.705 {2.15322.1537}

0.50 {0.02}
undersize

54.44054.455 {2.14342.1438}

0.75 {0.03}
undersize

54.19054.205 {2.13352.1340}

(mm {in})
Standard

0.03 {0.001} max.


0.0330.052 {0.00130.0020}
0.0500.069 {0.00200.0026} (No.3)

Maximum

0.080 {0.003}

Standard

0.0400.282 {0.00160.0111}

Maximum

0.300 {0.012}

Length [Center to center]

(mm {in})

151.95152.05 {5.9835.986}

Bending

(mm {in})

0.075 {0.0030} max. /50 {2.0}

Standard

0.1100.262 {0.00440.0103}

(mm {in})

Maximum

0.350 {0.037}

Connecting
g rod bearing
g oil clearance
(mm {in})

Standard

0.0310.058 {0.00130.0022}

Maximum

0.080 {0.003}

Connecting
g rod side clearance

Free length

63.0 {2.48}

Gear clearance

(mm {in})

Side clearance

(mm {in})

Oil pump
um

Plunger
spring

0.05 {0.002} max.

Free length

Standard

0.100.19 {0.0040.007}

Maximum

0.20 {0.008}

Standard

0.040.09 {0.0020.003}

Maximum

0.15 {0.006}

(mm {in})

TD10

43.8 {1.72}

TECHNICAL DATA
MANUAL TRANSMISSION
M15MD, M15MXD
Manual transmission

Item

M15MD

M15MXD

Manual transmission
Type
Transmission oil

Viscosity

A.P.I. Service GL4 or GL5


All-season

SAE 75W90

Above 10 C {50 F}

SAE 80W90

Capacity

Mainshaft

(L {US qt, lmp qt})

Runout

(mm {in})

Clearance between
mainshaft and gear
(or bush)

(mm {in})

2.0 {2.1, 1.8}

2.5 {2.6, 2.2}

Maximum

0.03 {0.0012}

Wear limit

0.15 {0.006}

Reverse
idler gear and
shaft

Clearance between
reverse idler gear bush and
shaft
(mm {in})

Standard

0.020.05 {0.00080.0019}

Wear limit

0.15 {0.006}

Shift fork
and clutch hub
sleeve

Clearance between shift fork


and clutch hub sleeve (mm {in})

Standard

0.20.3 {0.0080.011}

Wear limit

0.5 {0.020}

Synchronizer
y
ring

Clearance between
synchronizer ring and side of
gear when fitted
(mm {in})

Standard

1.5 {0.059}

Wear limit

0.8 {0.031}

Spring

Free length
(mm {in})

Shift rod (5th/reverse)

66.5 {2.62}

Detent ball (1st/2nd)

22 5 {0
22.5
{0.89}
89}

Detent ball (3rd/4th)


Transfer

A.P.I. Service GL4 or


GL5

Type
Transfer oil

Viscosity
Capacity

Hub sleeve and


shift fork

All-season

SAE 75W90

Above 10 C {50 F}
(L {US qt, lmp qt})

Clearance between hub sleeve


and shift fork
(mm {in})

SAE 80W90
2.0 {2.1, 1.8}

Standard

0.380.52
{0.0150.020}

Wear limit

0.8 {0.031}

TD11

TECHNICAL DATA
R15MD, R15MXD
Manual transmission

Item

R15MD

R15MXD

Manual transmission
Type
Transmission oil

Viscosity

A.P.I. Service GL4 or GL5


All-season
Above 10 C {50 F}

Capacity

Mainshaft

SAE 75W90
(L {US qt, lmp qt})

Runout

(mm {in})

Clearance between
mainshaft and gear
(or bush)

(mm {in})

SAE 80W90
2.8 {3.0, 2.5}

3.2 {3.4, 2.8}

Maximum

0.03 {0.0012}

Wear limit

0.15 {0.006}

Reverse
idler gear and
shaft

Clearance between
reverse idler gear bush and
shaft
(mm {in})

Standard

0.020.05 {0.00080.0019}

Wear limit

0.15 {0.006}

Shift fork
and clutch hub
sleeve

Clearance between shift fork


and clutch hub sleeve (mm {in})

Standard

0.20.3 {0.0080.011}

Wear limit

0.5 {0.020}

Synchronizer
y
ring

Clearance between
synchronizer ring and side of
gear when fitted
(mm {in})

Standard

1.5 {0.059}

Wear limit

0.8 {0.031}

Control rod lever


and shift rod

Clearance between control rod


lever and shift rod gate
(mm {in})

Clearance

0.8 {0.031}

Transfer
A.P.I. Service GL4 or
GL5

Type
Transfer oil

Viscosity
Capacity

Hub sleeve and


shift fork

All-season

SAE 75W90

Above 10 C {50 F}
(L {US qt, lmp qt})

Clearance between hub sleeve


and shift fork
(mm {in})

SAE 80W90
2.0 {2.1, 1.8}

Standard

0.380.52
{0.0150.020}

Wear limit

0.8 {0.031}

TD12

SPECIAL TOOLS
SPECIAL TOOLS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST2
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . ST6
TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . ST10
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . ST15
REMOTE FREE WHEEL (4x4) . . . . . . . . . . . ST18
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . ST20

ST1

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST21
ST30
ST32
ST33
ST34
ST35

SPECIAL TOOLS

Engine
Mazda Tool Number
49 L010 1A0

Ford Tool Number


Mounting Stand
303-435 (21-187)

Mounting Plate for 303-435-06


303-435-11 (21-146C)

49 S013 102
Commercially available
Not
applicable

49 S010 1A0
Commercially available
Not
applicable

49 9014 001
Commercially available
Not
applicable

49 0636 100B

Compressor, Valve Spring


303-060 (21-024)

49 B012 0A2

Adapter for 303-060


303-060-02 (21-024-02)

ST2

SPECIAL TOOLS

49 S120 170

Pliers, Valve Stem Oil Seal


303-508 (21-211)

49 L012 0A0A

Installer, Intake Valve Stem Oil Seal


303-247 (21-130A)

49 0249 010A
Commercially available
Not
applicable

49 G011 001
Commercially available
Not
applicable

49 S015 1A1
Commercially available
Not
applicable

49 S120 215A

Remover, Crankshaft Timing Pulley


303-249 (21-132)

49 S010 301

Installer, Driver Pinion Oil Seal


204-088 (14-030)

ST3

SPECIAL TOOLS

49 0259 749
Commercially available
Not
applicable

49 S010 001

Installer, Timing Cover Oil Seal


303-427 (21-178)

49 S011 103

Installer, Wheel Speed Sensor Ring


205-307 (15-089)

49 S011 102A

Locking Tool, Flywheel


303-254 (21-135)

Socket, Cylinder Head Bolt


303-393 (21-168)

49 E011 1A0

Universal Flange Holding Wrench


205-072 (15-030A)_

49 0187 280
Commercially available
Not
applicable

ST4

SPECIAL TOOLS

49 G014 001

Wrench, Oil Filter


Use OTC tool GV 6883
Not
applicable

49 L011 2A0

Adapter for 205-047-07


205-047-05 (15-011-06)
Graphic
not
available

Adapter for 205-047-07


205-047-06 (15-011-07)

Adapter for 205-047-07


205-047-07 (15-011-08)

49 S120 710

Universal Flange Holding Wrench


205-072 (15-030A)

49 S011 103

Installer, Wheel Speed Sensor Ring


205-307 (15-089)

ST5

Graphic
not
available

Graphic
not
available

SPECIAL TOOLS

Transmission
Mazda Tool Number

Ford Tool Number

49 SE01 310A

Aligner, Clutch Plate


308-204 (16-067)

49 0839 425C

Remover, Mainshaft Needle Bearing


Sleeve
308-191 (16-056)

Remover, Bearing/Gear
205-310 (15-091)

Thrust Pad for 205-071


307-115 (17-019)

Remover, Drop Arm


204-015 (14-008)

Remover, Bearing/Gear
205-311 (15-092)

Center Screw
205-034 (15-002)

ST6

Graphic
not
available

SPECIAL TOOLS

49 H017 101

Adapter for 307-272


307-272-01 (17-061-01)

49 1243 465A

Socket, Output Shaft Nut


308-108 (16-039)

49 0710 520

Remover, Bearing/Gear
205-310 (15-091)

49 F027 005

Adapter for 205-066


205-066-03 (15-033-03)

49 F027 007

Installer, Drive Pinion Oil Seal


204-088 (14-030)

ST7

Graphic
not
available

SPECIAL TOOLS

49 F401 331

Installer, Extension Housing Oil Seal


307-028 (17-002)

Installer, Drive Pinion Bearing


205-068 (15-042)

Remover/Installer, Lower Arm Bushing


204-058 (14-027)

Installer, Drive Pinion Oil Seal


204-088 (14-030)

49 0862 350
Commercially available
Not
applicable

49 F017 101

49 G030 795

Holding Tool, Synchronizer Ring


308-422 (16-093)

Installer, Oil Pump Oil Seal


307-032 (17-010A)

ST8

Graphic
not
available

SPECIAL TOOLS

49 F401 335A

Installer, Input Shaft Oil Seal


307-210 (17-041)

49 U027 003

Installer, Oil Pump Oil Seal


307-032 (17-010A)

49 S120 440

Screwdriver
Not
applicable

49 S017 401

Gears
Not
applicable

ST9

SPECIAL TOOLS

Transfer Box
Mazda Tool Number

Ford Tool Number

49 S120 710

Universal Flange Holding Wrench


205-072 (15-030A)

49 0839 425C

Remover, Bearing/Gear
205-310 (15-091)

Remover, Bearing/Gear
205-311 (15-092)

ST10

SPECIAL TOOLS

49 F401 331

Installer, Extension Housing Oil Seal


307-028 (17-002)

Remover/Installer, Lower Arm Bushing


204-058 (14-027)

Remover, Bearing/Gear
205-310 (15-091)

Installer, Driver Pinion Bearing


205-068 (15-042)

Installer, Differential Double Lip Oil Seal


308-203 (16-066)

49 0727 415

Installer, Differential Bearing


205-082 (15-037)

Installer, Torque Converter Oil Seal


307-273 (17-052)

ST11

SPECIAL TOOLS

49 0727 415

Installer, Halfshaft Oil Seal


308-119 (16-071)

Socket, Output Shaft Nut


308-108 (16-039)

49 0727 415

Installer, Drive Pinion Bearing


205-068 (15-042)

Installer, Extension Housing Oil Seal


307-028 (17-002)

49 G030 370

Support Plate, Gear Removal


308-198 (16-063)

49 G030 797

Socket, Guide Sleeve


308-109 (16-040A)

49 G026 102

Socket, Guide Sleeve


308-109 (16-040A)

ST12

SPECIAL TOOLS

49 0258 749

Installer, Torque Converter Oil Seal


307-273 (17-052)

49 S231 395A

Spreader, Transfer Chain


308-423 (16-094)

49 0500 330

Graphic
not
available

Remover, Bearing/Gear
205-310 (15-091)

Depth Gauge
Commercially available
Not
applicable

49 U017 3A0A

Adjustment Tool, Transfer Case


308-424 (16-095)

Graphic
not
available

Commercially available
Not
applicable

49 F401 336B

Installer, Differential Double Lip Oil Seal


308-203 (16-066)

ST13

SPECIAL TOOLS

49 0636 145

Remover, Bearing/Gear
205-310 (15-091)

ST14

SPECIAL TOOLS

Front Differential
Mazda Tool Number

Ford Tool Number

49 M005 581

Mounting Bracket, Engine/Differential


205-329 (15-105A)

49 S120 710

Universal Flange Holding Wrench


205-072 (15-030A)

49 H027 002

Remover, Bearing/Gear
205-310 (15-091)

49 0727 570

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

49 8531 565

Gauge, Master Pinion


205-059 (15-020)

49 0305 555

Preload Sleeve
205-060 (15-023)

49 0259 720

Universal Flange Holding Wrench


205-072 (15-030A)

ST15

SPECIAL TOOLS

49 0839 425C

Remover, Bearing/Gear
205-310 (15-091)

Thurst Pad for 205-071


307-115 (17-019)

Remover, Mainshaft Needle Bearing


Sleeve
308-191 (16-056)

49 G030 338

Installer, Front Differential Bearing Cup


204-281 (14-056)

Graphic
not
available

49 F027 004
Commercially available
Not
applicable

49 F027 005

Installer, Front Differential Oil Seal


204-282 (14-057)

ST16

Graphic
not
available

SPECIAL TOOLS

49 U027 003

Installer, Drive Pinion Bearing


205-082 (15-037)

Installer, Drive Pinion Bearing


205-068 (15-042)

49 G030 795

Installer, Front Differential Oil Seal


204-283 (14-058)

49 0350 555

Gauge, Master Pinion


205-059 (15-020)

49 0350 565

Gauge, Master Pinion


205-059 (15-020)

49 0350 567

Gauge, Master Pinion


205-059 (15-020)

49 0350 568

Gauge, Master Pinion


205-059 (15-020)

ST17

Graphic
not
available

SPECIAL TOOLS

Remote Free Wheel (4x4)


Mazda Tool Number
49 U027 005

49 U027 006

Ford Tool Number


Installer, Remote Freewheel Bearing
204-284 (14-059)

Installer, Remote Freewheel Bearing


204-285 (14-060)

49 U027 004

Remover, Rear Wheel Hub Oil Seal


205-174 (15-072)

49 U027 004

Remover, Oil Seal


303-112 (21-051)

49 M005 796

Installer, Remote Freewheel Dust Seal


204-286 (14-061)

Graphic
not
available

Graphic
not
available

Graphic
not
available

49 0813 215 A
Commercially available
Not
applicable

49 W027 001

Remover/Installer, Pivot Bushing


205-342 (15-110)

ST18

SPECIAL TOOLS

49 U027 007

Installer, Remote Freewheel Oil Seal


204-287 (14-062)

ST19

Graphic
not
available

SPECIAL TOOLS

Front Axle
Mazda Tool Number
49 T028 3A0

Ford Tool Number


Separator, Ball Joint
211-020 (13-006)

Remover, Mainshaft Needle Bearing


Sleeve
308-191 (16-056)

49 H033 101

Installer, Rear Wheel Hub Bearing


Cone/Oil Seal
205-101 (15-051)

49 B025 001

Installer, Input Shaft Bearing Cone


308-041 (16-020)

49 F019 001

Installer, Timing Cover Oil Seal


303-427 (21-178)

ST20

SPECIAL TOOLS

Rear Axle
Mazda Tool Number
49 S120 645A

49 0603 635A

Ford Tool Number


Holding Tool, Rear Axle Shaft
205-496 (15-112)

Wrench, Rear Axle Shaft Bearing


205-497 (15-113)

49 S126 204

Remover, Bearing/Gear
205-311 (15-092)

T57L-500-B

Mounting Bracket, Engine/Differential


205-329 (15-105-A)

308-047 (T77F-1102-A)

Remover, Rear Wheel Hub Oil Seal


205-174 (15-072)

Remover, Oil Seal


303-112 (21-051)

ST21

Graphic
not
available

Graphic
not
available

SPECIAL TOOLS

205-D064 (D84L-1123-A)

Remover, Bearing/Gear
205-310 (15-091)

Remover, Bearing/Gear
205-311 (15-092)

205-456

Adjustment Gauge, Drive Pinion


205-058 (15-019)

205-110 (T76P-4020-A10)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


205-044-02 (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST22

SPECIAL TOOLS

205-457

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST23

SPECIAL TOOLS

205-105 (T76P-4020-A3)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST24

SPECIAL TOOLS

205-109 (T76P-4020-A9)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST25

SPECIAL TOOLS

205-111 (T76P-4020-A11)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

205-090 (T75L-1165-B)

Installer, Drive Pinion Bearing


205-068 (15-042)

ST26

SPECIAL TOOLS

205-024 (T76P-4616-A)

Installer, Differential Bearing Cone


205-066 (15-033)

Adapter for 205-066


205-066-02 (15-033-02A)

Adapter for 205-066


205-066-03 (15-033-03)

205-092 (T57L-1165-DA)

Installer, Differential Bearing


205-081 (15-032)

205-007 (T56T-4676-B)

Installer, Drive Pinion Oil Seal


205-077 (15-047A)

Installer, Drive Pinion Oil Seal


205-115 (15-058)

ST27

SPECIAL TOOLS

49 S126 205

Adapter for 205-311 (Extension)


205-311-02 (15-092-02)

Adapter for 205-311 (Extension)


205-311-03 (15-092-03)

49 S126 208

Remover, Bearing/Gear
205-310 (15-091)

Adapter for 205-311 (Extension)


205-311-04 (15-092-04)

49 S120 748
Commercially available
Not
applicable

49 F027 004
Commercially available
Not
applicable

49 U027 003

Installer, Differential Bearing


205-082 (15-037)

ST28

SPECIAL TOOLS

49 H025 001
Commercially available
Not
applicable

T83T-4205-A1
Not essential
Not
applicable

T83T-4205-A2
Not essential
Not
applicable

T83T-4205-A3
Not essential
Not
applicable

T83T-4205-A4
Not essential
Not
applicable

ST29

SPECIAL TOOLS

Steering
Mazda Tool Number

Ford Tool Number

49 T028 3A0

Separator, Ball Joint


211-020 (13-006)

49 1232 670 A

Pressure Gauge, Power Steering


211-190 (13-018)

49 H002 671

Pressure Gauge, Power Steering


211-190 (13-018)

Adapter for 211-190 (Connector)


211-190-01 (13-018-01)

49 G032 3A4

Adapter for 211-190 (Connector)


211-190-01 (13-018-01)

49 T028 3A0

Remover, Mainshaft Bearing


308-200 (16-056)

49 B032 304

Pressure Gauge, Power Steering


211-190 (13-018)

ST30

SPECIAL TOOLS

49 0180 510B

Clamp Connector, Preload Gauge


211-021 (13-004A)

Clamp Connector, Preload Gauge


211-041 (13-008A)

49 0223 695E

Remover, Mainshaft Bearing


308-200 (16-056)

ST31

Graphic
not
available

SPECIAL TOOLS

Brakes
Mazda Tool Number

Ford Tool Number

49 0259 770B
Commercially available
Not
applicable

49 U043 0A0
Commercially available
Not
applicable

49 0221 600C

Retractor, Brake Caliper Piston


206-005 (12-014)

49 0208 701A

Remover, O-Ring Seal


100-010 (17-063)

49 B043 001

Setter, Brake Servo Push Rod


206-016 (12-010)

49 EC43 003A
Commercially available
Not
applicable

49 B043 004
Commercially available
Not
applicable

ST32

SPECIAL TOOLS

Suspension
Mazda Tool Number
49 U034 2AO

Ford Tool Number


Remover/Installer, Pivot Bushing
205-342 (15-110)

Installer, Crankshaft Rear Oil Seal


303-395 (21-171)

49 U039 615

Remover/Installer, Pivot Bushing


205-342 (15-110)

Remover/Installer, Rear Axle Bush


205-035 (15-003)

ST33

Graphic
not
available

SPECIAL TOOLS

Air Conditioning
Mazda Tool Number

Ford Tool Number

49 C081 0A0A
Commercially available
Not
applicable

49 C061 012
Commercially available
Not
applicable

49 C061 013
Commercially available
Not
applicable

49 H061 005

Installer, Drive Pinion Oil Seal


205-046 (15-010A)

ST34

SPECIAL TOOLS

General
Mazda Tool Number

Ford Tool Number

49 0305 870A
Commercially available
Not
applicable

49 9140 074

Holding Fixture, Dial Indicator Gauge


310-017 (23-018)

49 9200 146

Adapter for 303-396


303-396-02 (24-001-02)

49 9200 147

Pressure Tester, Cooling System


303-396 (24-001A)

49 0259 888A
Commercially available
Not
applicable

49 01670280
Commercially available
Not
applicable

49 N088 0A0
Commercially available
Not
applicable

ST35

SPECIAL TOOLS

49 L018 901
Commercially available
Not
applicable

ST36

CONTENTS
Title

Section

General Information

RANGER
Repair
Manual

Engine

FOREWORD
This Manual has been prepared to
provide information covering normal
service repairs and maintenance for the
RANGER SERIES.

B1

WL, WL Turbo

B2

F2

B3
D

Cooling System

E
G6

F1

WL, WL Turbo

F2

F2 CIS

F3

F2 CARB

F4

Engine Electrical System

Clutch

Ford Motor Company


APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown on the following page.

G6

Lubrication System

Fuel and Emission


Control Systems

As all information in this manual was the


best available at the time of printing,
vehicle specification and other information
will be updated in Service Information.

GI

Manual Transmission

M15MD
M15MXD
R15MD
R15MXD
Transfer

ST

J1
J2
J3

Propeller Shaft

Front and Rear Axles

Steering System

Braking System

Suspension

Body

Body Electrical System

Heater and Air Conditioner Systems

Technical Data

TD

Special Tools

ST

2001 Ford Motor Company


All rights reserved. Reproduction by any means,
electronic or mechanical including photocopying,
recording or by any information storage and retrieval
system or translation in whole or part is not permitted
without written authorization from Ford Motor Company.
PRINTED NOVEMBER 2001
F1611099A, F1751001I

VEHICLE IDENTIFICATION NUMBERS (VIN)


WF0 DMB]30WW
WF0 LMB]30WW
WF0 DMDD30WW

100001
100001
100001

WF0 LMDD30WW
WF0 DMFE40WW
WF0 LMFE40WW

100001
100001
100001

WF0 BMF]30WW
WF0 BME]30WW
WF0 DMF]30WW
WF0 DME]30WW
WF0 LMF]30WW
WF0 LME]30WW
WF0 BMD]30WW
WF0 BMC]30WW
WF0 DMD]30WW
WF0 DMC]30WW
WF0 LMD]30WW
WF0 LMC]30WW
WF0 BMB]30WW
WF0 BMA]30WW
WF0 DMB]30WW
WF0 DMA]30WW
WF0 LMB]30WW
WF0 LMA]30WW
WF0 LMBE40:W
WF0 LMBD20:W
WF0 LMDD20:W
WF0 LMDE40:W
WF0 LMFE40:W

100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001

WF0 BMFE40WW
WF0 BMEE40WW
WF0 DMFE40WW
WF0 DMEE40WW
WF0 LMFE40WW
WF0 LMEE40WW
WF0 BMD]40WW
WF0 BMC]40WW
WF0 DMD]40WW
WF0 DMC]40WW
WF0 LMD]40WW
WF0 LMC]40WW
WF0 BMB]40WW
WF0 BMA]40WW
WF0 DMB]40WW
WF0 DMA]40WW
WF0 LMB]40WW
WF0 LMA]40WW
WF0 BMBD20:W
WF0 LMAD20:W
WF0 BMDE40:W
WF0 BMDD20:W

100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001

MNC BSB]30WW
MNC BSA]30WW
MNC BSB]3WWW
MNC BSA]3WWW

100001
100001
100001
100001

MNC BSB]30WW
MNC BSA]30WW

100001
100001

General specs. (L.H.D.)


MNC BSF]30WW
100001
MNC BSE]30WW
100001
MNC BSF]3WWW
100001
MNC BSE]3WWW 100001
General specs. (R.H.D.)
MNB BSF]30WW
100001
MNB BSE]30WW
100001
MNB BSBD50WW 100001
MNB BSAD50WW 100001

RELATED MATERIALS
RANGER Training Manual . . . . . . . . . . . . . . . . . . . . . . . .
RANGER Overhaul Manual . . . . . . . . . . . . . . . . . . . . . . .
RANGER Wiring Diagrams
(European, General specs. (L.H.D.)) . . . . . . . . . . . . . .
RANGER Wiring Diagrams
(European, General specs. (R.H.D.)) . . . . . . . . . . . . . .
RANGER Standard Repair Times
(Australian, European, General specs.) . . . . . . . . . . .
RANGER Body Measurement Manual
(Australian, European, General specs.) . . . . . . . . . . .

F3261099A
F1612099A
F1613099A
F1614099A
F2181098K
F3271098K

GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . .
RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . .
SERVICING PROCEDURE . . . . . . . . . . . . . . .
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADVISORY MESSAGES . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PROCEDURE . . . . . .
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . .
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNDAMENTAL PROCEDURES . . . . . . . . . . . .
PROTECTION OF THE VEHICLE . . . . . . . . . .
PREPARATION OF TOOLS AND
MEASURING EQUIPMENT . . . . . . . . . . . . . .
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . .
DISCONNECTION OF THE NEGATIVE
BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . .
REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION DURING REMOVAL,
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
ARRANGEMENT OF PARTS . . . . . . . . . . . . . .
CLEANING OF PARTS . . . . . . . . . . . . . . . . . . .
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .

GI11
GI11
GI11
GI13
GI13
GI13
GI16
GI17
GI18
GI18
GI18
GI18
GI18
GI18
GI18
GI18
GI18
GI19
GI19
GI19

HOW TO USE THIS MANUAL


RANGE OF TOPICS
D This manual contains the procedures for performing
all of the required service operations. The
procedures are divided into the following five basic
operations.
(1) Removal/Installation
(2) Disassembly/Assembly
(3) Replacement
(4) Inspection
(5) Adjustment
D Simple operations which can be performed easily
just by looking at the vehicle, such as
removal/installation of parts, jacking, vehicle lift,
cleaning of parts, and visual inspection, have been
omitted.

RUBBER PARTS AND TUBING . . . . . . . . . . .


HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . .
VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION OF RADIO SYSTEM . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . .
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL TROUBLESHOOTING
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JACKING POSITIONS . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFT (2 SUPPORTS) POSITIONS . . .
SAFETY STAND POSITIONS . . . . . . . . . . . . . . .
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOWING HOOKS . . . . . . . . . . . . . . . . . . . . . . . .
TIEDOWN HOOKS . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION NUMBER LOCATIONS . . . . .
VEHICLE IDENTIFICATION NUMBER . . . . . .
ENGINE IDENTIFICATION NUMBER . . . . . . .
VIN CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .

GI19
GI19
GI10
GI10
GI10
GI10
GI11
GI11
GI11
GI13
GI15
GI15
GI15
GI16
GI17
GI17
GI18
GI18
GI18
GI20
GI21
GI23

SERVICING PROCEDURE
Inspection, Adjustment
D The procedures for inspections and adjustments
are divided into steps. Important points in regard
to the location and contents of the procedures are
explained in detail and are shown in the
illustrations.

SHOWS PROCEDURE ORDER


FOR SERVICE

SHOWS TIGHTENING
TORQUE
SPECIFICATIONS

GI1

HOW TO USE THIS MANUAL


Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only the removal/installation procedures which need to
be performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts which require the use of special service tools for
removal/installation are also shown.
3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or information concerning a procedure.
Refer to this information when servicing the related part.
SHOWS SERVICE
ITEM (S)

Procedure

Indicates any relevant


references which need to be
followed during installation.

Removal/Installation
Portion
Inspection After
Installation Portion

SHOWS SPECIAL
SERVICE TOOL (SST)
FOR SERVICE OPERATION

SHOWS PROCEDURE ORDER


FOR SERVICE
Install the parts
by performing
Steps 13 in
reverse order

SHOWS APPLICATION
POINTS OF GREASE, ETC.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS

SHOWS EXPENDABLE PARTS

SHOWS DETAILS
SHOWS TIGHTENING
TORQUE UNITS

SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE

SHOWS SPECIAL
SERVICE TOOL (SST)
NO.

SHOWS REFERRAL
NOTES FOR
SERVICE

GI2

HOW TO USE THIS MANUAL


SYMBOLS
D There are eight symbols indicating oil, grease,
sealant, and the use of SSTs. These symbols
show the points of applying or using such materials
during service.
Apply oil

SST

TROUBLESHOOTING PROCEDURE
Basic Flow of Troubleshooting

Appropriate new
engine oil or
gear oil

Apply brake fluid

Appropriate new
brake fluid

Apply automatic
transaxle/
transmission
fluid

Appropriate new
automatic
transaxle/
transmission fluid

Apply grease

Appropriate
grease

Apply sealant

Appropriate
sealant

Apply petroleum
jelly

Appropriate
petroleum jelly

Replace part

O-ring, gasket,
etc.

Use SST

Appropriate SST

ADVISORY MESSAGES
Youll find several Warnings, Cautions, Notes,
Specifications and Upper and lower limits in this
manual.
Warning
D A Warning indicates a situation in which
serious injury or death could result if the
warning is ignored.
Caution
D A Caution indicates a situation in which
damage to the vehicle could result if the
caution is ignored.
Note
D A Note provides added information that will
help you to complete a particular procedure.
Specification
D The values indicate the allowable range when
performing inspections or adjustments.
Upper and lower limits
D The values indicate the upper and lower limits
that must not be exceeded when performing
inspections or adjustments.

SECTION F ONLY
ACTUAL TROUBLESHOOTING PROCEDURES
SECTION K
ONLY

IF
MENTIONED

SECTION F
ONLY

On-board diagnosis
D The service codes are important hints for repairing
malfunctions that are difficult to simulate. By
following the service code, perform the inspection
to quickly and accurately diagnose the malfunction.
D The self-diagnostic function is used during
inspection. When a service code is shown,
specifying the cause of a malfunction, continue the
inspection according to the items indicated by the
self-diagnostic function.
Engine tune-up (Section F)
D Any necessary adjustments are made after starting
the engine.
Basic inspection (Section K)
D The basic inspection is performed to quickly
narrow down the possible causes after a
malfunction occurs regardless of the symptoms.
ST The basic inspection is performed to also locate
the region of many malfunction symptoms.
Diagnostic index
D The diagnostic index lists the symptoms of the
malfunctions. Select the symptoms pertaining or
most closely pertaining to the actual malfunction.
Quick diagnosis chart (If mentioned)
D The quick diagnosis chart lists the diagnosis and
inspection procedures to be performed specifically
relating to the cause of the malfunction.
Symptom troubleshooting
D Symptom troubleshooting quickly determines the
location of the malfunction according to the type of
symptoms.

GI3

HOW TO USE THIS MANUAL


Procedures For Use
Using the basic inspection
D Perform the basic inspection before the symptom troubleshooting.
D Perform each step in the order shown.
D The reference column lists the location of the detailed procedure for each basic inspection.
D Although inspection and adjustment are performed as according to the procedures referred to in the reference
column, if the cause of the malfunction is discovered during the basic inspection, continue the procedures as
indicated in the remarks column.
SHOWS INSPECTION
ORDER

SHOWS ITEM NAMES FOR


THE DETAILED PROCEDURES

SHOW POINTS REQUIRING


ATTENTION IN REGARD TO
INSPECTION RESULTS

Perform malfunction diagnosis according to No. 26


HOLD INDICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON or
No. 27 HOLD INDICATOR LIGHT ILLUMINATES
WHEN HOLD SWITCH IS NOT TURNED ON

Using the diagnostic index


D The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting.
D The exact malfunction symptoms can be selected using the details.

GI4

HOW TO USE THIS MANUAL


Using the quick diagnosis chart
D The chart lists the relation between the symptoms and cause of the malfunction.
D The chart is effective in quickly narrowing down the relation between the symptoms and cause of the
malfunction and specifying the region of the common cause when multiple malfunction symptoms occur.
D The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can
be selected by looking down the diagnostic inspection column of the chart.

PARTS WHICH MAY BE THE CAUSE OF


PROBLEMS
ENGINE QUICK DIAGNOSTIC CHART

PART WHICH MAY BE


THE SYMPTOM

CHOOSE THE ACTUAL


SYMPTOM

ST

GI5

HOW TO USE THIS MANUAL


Using the symptom troubleshooting
D Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for each
trouble symptom.

TROUBLESHOOTING
HINTS describes
possible point of
malfunction.

TROUBLE SYMPTOM

STEP shows the


order of
troubleshooting.

ACTION describes the


appropriate action to
take as a result
(Yes/No) of
INSPECTION.

INSPECTION
describes an
inspection (method) to
quickly determine the
failed part.

Reference page(s) for


the detailed procedure
to perform
INSPECTION is shown.
How to perform ACTION
is described in the relative
material shown.

TEXT SEQUENCE
D The text sequence is as indicated by the arrows shown below.
Example:

GI6

UNITS
D The actual converted values for 2.7 kgf/cm2 are

UNITS
Electric current

A (ampere)

Electric power

W (watt)

Electric resistance

W (ohm)

Electric voltage

V (volt)

Length

264 kPa and 38.4 psi. In the top specification, 2.7


is used as an upper limit, so its converted values
are rounded down to 260 and 38. In the bottom
specification, 2.7 is used as a lower limit, so its
converted values are rounded up to 270 and 39.

mm (millimeter)
in (inch)
kPa (kilo pascal)

Negative pressure

mmHg (millimeters of mercury)


inHg (inches of mercury)
kPa (kilo pascal)

Positive pressure

kgf/cm2 (kilogram force per square


centimeter)
psi (pounds per square inch)

Number of
revolutions

rpm (revolutions per minute)


Nm (Newton meter)
kgfm (kilogram force per meter)

Torque

kgfcm (kilogram force per centimeter)


ftlbf (foot pound) force
inlbf (inch pound) force
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)

Volume

ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)

Weight

g (gram)
oz (ounce)

Conversion to SI Units (Systme International


dUnits)
D All numerical values in this manual are based on SI
units. Numbers shown in conventional units are
converted from these values.

ST

Rounding off
D Converted values are rounded off to the same
number of places as the SI unit value. For
example, if the SI unit value is 17.2 and the value
after conversion is 37.84, the converted value will
be rounded off to 37.8.
Upper and lower limits
D When the data indicates upper and lower limits, the
converted values are rounded down if the SI unit
value is an upper limit and rounded up if the SI unit
value is a lower limit. Therefore, converted values
for the same SI unit value may differ after
conversion. For example, consider 2.7 kgf/cm2 in
the following specifications:
210260 kPa {2.12.7 kgf/cm2, 3038 psi}
270310 kPa {2.73.2 kgf/cm2, 3945 psi}

GI7

FUNDAMENTAL PROCEDURES
REMOVAL OF PARTS
D While correcting a problem, try also to determine
its cause. Begin work only after first learning which
parts and subassemblies must be removed and
disassembled for replacement or repair. After
removing the part, plug all holes and ports to
prevent foreign material from entering.

FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE
D Always be sure to cover fenders, seats, and floor
areas before starting work.

PREPARATION OF TOOLS AND MEASURING


EQUIPMENT
D Be sure that all necessary tools and measuring
equipment are available before starting any work.

DISASSEMBLY
D If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be
marked in a place that will not affect their
performance or external appearance and identified
so that reassembly can be performed easily and
efficiently.

SPECIAL SERVICE TOOLS


D Use special tools when they are required.

INSPECTION DURING REMOVAL, DISASSEMBLY


D When removed, each part should be carefully
inspected for malfunctioning, deformation,
damage, and other problems.

DISCONNECTION OF THE NEGATIVE BATTERY


CABLE
D Before beginning any work, turn the ignition switch
to LOCK, then disconnect the negative battery
cable and wait for more than 1 minute to allow the
backup power supply of the SAS unit to deplete its
stored power.
Disconnecting the battery cable will delete the
memories of the clock, audio, and DTCs, etc.
Therefore, it is neccessary to verify those
memories before disconnecting the cable.

ARRANGEMENT OF PARTS
D All disassembled parts should be carefully
arranged for reassembly.
D Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.

GI8

FUNDAMENTAL PROCEDURES
D Oil should be applied to the moving components of

parts.
D Specified oil or grease should be applied at the

prescribed locations (such as oil seals) before


reassembly.

CLEANING OF PARTS
D All parts to be reused should be carefully and
thoroughly cleaned using the appropriate method.
SXU00012

Warning
D Using compressed air can cause dirt and
other particles to fly out, causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.

ADJUSTMENT
D Use suitable gauges and/or testers when making
adjustments.

SXU00013

RUBBER PARTS AND TUBING


D Prevent gasoline or oil from spilling on rubber parts
or tubing.

REASSEMBLY
D Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with new
ones:
1

Oil seals

Gaskets

O-rings

Lockwashers

Cotter pins

Nylon nuts

ST
SXU00014

HOSE CLAMPS
D When reinstalling, position the hose clamp in the
original location on the hose, and squeeze the
clamp lightly with large pliers to ensure a good fit.

SXU00011

D Sealant, a gasket, or both should be applied to the

specified locations. When sealant is applied, parts


should be installed before sealant hardens.
Hardened sealant causes leaks.

SXU00015

GI9

FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM


TORQUE FORMULAS
D When using a torque wrench-SST combination, the
written torque must be recalculated due to the
extra length that the SST adds to the torque
wrench. Recalculate the torque using the following
formulas. Choose the formula that applies to you.
Torque Unit

Formula

kgfm

kgfm

[L/(L+A) ]

kgfcm

kgfcm

ftlbf

ftlbf

[L/(L+A) ]

inlbf

inlbf

[L/(L+A) ]

[L/(L+A) ]

A: The length of the SST past the torque wrench drive.


L: The length of the torque wrench.

INSTALLATION OF RADIO SYSTEM


If a radio system is installed improprerly or if a highpowered type is used, the CIS and other systems may
be affected.
When the vehicle is to be equipped with a radio,
observe the following precautions.
1. Install the antenna at the farthest point from control
modules.
2. Install the antenna feeder as far as possible from
the control modules harness, and perpendicular to
wiring harnesses.
3. Do not install a high-powered radio system.
4. After installing the radio system, start and idle the
engine, then confirm that the engine is not
influenced by output waves from the system.

SXU00016

VISE
D When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.

SXU00017

DYNAMOMETER
When test-running a vehicle on dynamometer :
D Place a fan, preferably a vehicle-speed
proportional type, in front of the vehicle.
D Connect an exhaust gas ventilation unit.
D Cool the exhaust pipes with a fan.
D Keep the area around the vehicle uncluttered.
D Watch the water temperature gauge.

GI10

ELECTRICAL SYSTEM
Disconnecting Connectors
D When disconnecting two connectors, grasp the
connectors, not the wires.

ELECTRICAL SYSTEM
ELECTRICAL PARTS
Battery Cable
D Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
cable.

SXU00020

D Connectors can be disconnected by pressing or

pulling the lock lever as shown.


SXU00018

Wiring Harness
D To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.

SXU00021

Locking Connector
D When locking connectors, listen for a click that will
indicate they are securely locked.

CONNECTORS
Data Link Connector
D Insert the probe into the service hole when
connecting a jumper wire to the data link
connector.
Caution
D Inserting a jumper wire probe into the data
link connector terminal may damage the
terminal.

SXU00022

Inspection
1. When a tester is used to check for continuity or to
measure voltage, insert the tester probe from the
wiring harness side.

SXU00019

SXU00023

2. Check the terminals of waterproof connectors from


the connector side, as they cannot be accessed
from the wiring harness side.

GI11

ELECTRICAL SYSTEM
Caution
D To prevent damage to the terminal, wrap a
thin wire around the lead before inserting it
into the terminal.

SXU00027

SXU00024

Terminals
Inspection
D Pull lightly on individual wires to check that they
are secured in the terminal.

Wiring Harness
Wiring color codes
D Two-color wires are indicated by a two-color code
symbol.
D The first letter indicates the base color of the wire
and the second the color of the stripe.
CODE

COLOR

CODE

COLOR

Black

Orange

BR

Brown

Pink

Green

Red

GY

Gray

Violet

Blue

White

LB

Light Blue

Yellow

LG

Light Green

B/R

BR/Y
BLACK

SXU00025

Replacement
D Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to insert
it until it locks securely.
D Insert a thin piece of metal from the terminal side
of the connector, and then, with the terminal
locking tab pressed down, pull the terminal out
from the connector.

RED

BROWN

YELLOW

SXU00028

Fuse
Replacement
D When replacing a fuse, be sure to replace it with
one of the same capacity. If a fuse fails again, the
circuit probably has a short and the wiring should
be inspected.
D Be sure that the negative battery cable is
disconnected before replacing a main fuse.

TYPE A
TYPE B

SXU00026

Sensors, Switches, and Relays


D Handle sensors, switches, and relays carefully. Do
not drop them or strike them against other objects.

WGIWXX0049E

GI12

ELECTRICAL SYSTEM
D When replacing a pullout fuse, use the fuse puller.

Other
Vehicle harnessside connectors, such as the DLC2,
have to be viewed from the terminal side.

WGIWXX0050E

Direction of View for Connector


Partside connector
Direction of view is from the terminal side.

WGIWXX0102E

ELECTRICAL TROUBLESHOOTING TOOLS


Jumper Wire
D A jumper wire is used to create a temporary circuit.
Connect the jumper wire between the terminals of
a circuit to bypass a switch.
Caution
D Do not connect a jumper wire from the
power source line to a body ground; this
may cause burning or other damage to
wiring harnesses or electronic components.

WGIWXX0100E

* : Part names are shown only when there are multiple


connector drawings.

Vehicle harness side connector


Direction of view is from the harness side.

SXU00032

Voltmeter
D The DC voltmeter is used to measure circuit
voltage. A voltmeter with a range of 15 V or more
is used by connecting the positive (+) probe (red
lead wire) to the point where voltage is to be
measured and the negative () probe (black lead
wire) to a body ground.
WGIWXX0101E

* : Part names are shown only when there are multiple


connector drawings.

GI13

ELECTRICAL SYSTEM

VOLTMETER

BLACK LEAD

POWER SOURCE LINE

Ohmmeter
D The ohmmeter is used to measure the resistance
between two points in a circuit, and to check for
continuity and short circuits.
Caution
D Do not connect the ohmmeter to any circuit
to which voltage is applied. This will
damage the ohmmeter.

RED LEAD
GROUND

POWER SOURCE LINE

GROUND LINE

OHMMETER

GI14

SXU00034

JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS, SAFETY


STAND POSITIONS

JACKING POSITIONS

REAR

Warning
D Improperly jacking a vehicle is dangerous.
The vehicle can slip off the jack and cause
serious injury. Use only the correct front
and rear jacking positions and block the
wheels.
Use safety stands to support the vehicle after it has
been lifted.
FRONT

SAFETY STAND POSITIONS


FRONT

REAR

REAR

VEHICLE LIFT (2 SUPPORTS)


POSITIONS
FRONT

GI15

TOWING
(With Manual Transmission)
If the transmission, rear axle, and steering system are
not damaged, the vehicle may be towed on all four
wheels. If any of these components are damaged, use
wheel dollies.

TOWING
Proper lifting and towing are necessary to prevent
damage to the vehicle.
Government and local laws must be followed.

If all four wheels are on the ground, the vehicle may be


towed only forward. Do not exceed 45 km/h (28 mph)
and a distance of 15 km (9.3 miles); you could damage
the transmission.
If speed must exceed 45 km/h (28 mph) or a towing
distance of 15 km (9.3 miles), use one of these
methods:

Wheel dollies

D Place the rear wheels on dollies.


D Tow with the rear wheels off the ground.
D Disconnect the propeller shaft.

If the transmission or rear axle is inoperative, tow with


the rear wheels off the ground.
Caution
D Follow these instructions when towing the
vehicle with all wheels on the ground or
with the front wheels on the ground and the
rear wheels raised.

Wheel dollies

(4 4 Model)
1. Put the transfer case in 2H.
2. Set the transfer case at 2H and the hubs
at FREE.

Caution
D Do not tow with sling-type equipment. This
could damage your vehicle. Use wheel-lift
or flatbed equipment.

(All Models)
1. Set the transmission in neutral.
2. Turn the engine switch to ACC position.
3. Release the parking brake.
D Remember that power assist for the brakes

and steering will not be available when the


engine is not running.
If your Ford has 4 4, change to 2-wheel drive before
having the vehicle towed. If this is not possible, tow
with all four wheels raised.

GI16

TOWING
TOWING HOOKS
Caution
D The towing hooks should be used only in
an emergency (e.g. to get the vehicle out of
a ditch or a snow bank).
D When using the towing hooks, always pull
the cable or chain in a straight direction
with respect to the hook. Apply no
sideways force.
FRONT
4 4

TIEDOWN HOOKS
Caution
D Do not use the hook loops under the front
for towing. They are designed ONLY for
tying down the vehicle when it is being
transported. Using them for towing will
damage the bumper.
FRONT
4 2

4 4

GI17

IDENTIFICATION NUMBER LOCATIONS

IDENTIFICATION NUMBER
LOCATIONS
VEHICLE IDENTIFICATION NUMBER

ENGINE IDENTIFICATION NUMBER


G6

F2 CIS
F2 CARB

WL, WL Turbo

GI18

IDENTIFICATION NUMBER LOCATIONS

ZCF4016W200

D Euro 3 and non Euro 3 regulation models are distinguished as follows:


Euro 3 Regulation models (WL3, WLT3) are equipped with an EGR water cooler in the engine room.
Non-Euro 3 Regulation models are not equipped with an EGR water cooler in the engine room.

GI19

VIN CODE

VIN CODE
VIN CODE

VUE0035456

GI20

NEW STANDARDS

NEW STANDARDS
D Following is a comparison of the previous standard and the new standard.
New Standard
Abbreviation
AP

Name

Previous Standard
Abbreviation

Accelerator Pedal

Accelerator Pedal

ACL

Air Cleaner

Air Cleaner

A/C

Air Conditioning

Air Conditioning

Barometric Pressure

Atmospheric Pressure

BARO
B)

Battery Positive Voltage

VB

Battery Voltage

Brake Switch

Stoplight Switch

Calibration Resistor

Corrected Resistance

Camshaft Position Sensor

Crank Angle Sensor

CAC

Charge Air Cooler

Intercooler

CLS

Closed Loop System

Feedback System

CTP

Closed Throttle Position

Fully Closed

Closed Throttle Position Switch

Idle Switch

CPP

Clutch Pedal Position

Clutch Position

CIS

Continuous Fuel Injection System

CMP
sensor

CS sensor
CKP
sensor

Control Sleeve Sensor

EGI
CSP
sensor

#6

Electronic Gasoline Injection System


Control Sleeve Position Sensor

Crankshaft Position Sensor

Crank Angle Sensor 2

DLC

Data Link Connector

Diagnosis Connector

DTM

Diagnostic Test Mode

Test Mode

DTC

Diagnostic Trouble Code(s)

Service Code(s)

DI

Distributor Ignition

Spark Ignition

DLI

Distributorless Ignition

Direct Ignition

EI

Remark

Name

#6

#1

Electronic Ignition

Electronic Spark Ignition

ECT

Engine Coolant Temperature

Water Thermo

EM

Engine Modification

Engine Modification

Engine Speed Input Signal

Engine RPM Signal

EVAP

Evaporative Emission

Evaporative Emission

EGR

Exhaust Gas Recirculation

Exhaust Gas Recirculation

FC

Fan Control

Fan Control

FF

Flexible Fuel

Flexible Fuel

4GR

Fourth Gear

Overdrive

Fuel Pump Relay

Circuit Opening Relay

#3

Fuel Cut Valve

#6

FSO
solenoid

Fuel Shut Off Solenoid

FCV

GEN

Generator

Alternator

GND

Ground

Ground/Earth

HO2S

Heated Oxygen Sensor

Oxygen Sensor

Idle Air Control

Idle Speed Control

IAC

IDM Relay

Spill Valve Relay

Incorrect Gear Ratio

Injection Pump

FIP

Fuel Injection Pump

Input/Turbine Speed Sensor

Pulse Generator

IAT

Intake Air Temperature

Intake Air Thermo

KS

Knock Sensor

Knock Sensor

MIL

Malfunction Indicator Lamp

Malfunction Indicator Light

GI21

#2

With heater
#6
#6

NEW STANDARDS

New Standard
Abbreviation
MAP

Name

Previous Standard
Abbreviation

Manifold Absolute Pressure

Intake Air Pressure

MAF
sensor

Mass Air Flow Sensor

Airflow Sensor

MFL

Multiport Fuel Injection

Multiport Fuel Injection

OBD

On-Board Diagnostic

Diagnosis/Self-Diagnosis

OL

Open Loop

Open Loop

Output Speed Sensor

Vehicle Speed Sensor 1

OC

Oxidation Catalytic Converter

Catalytic Converter

O2S

Oxygen Sensor

Oxygen Sensor

PNP

Park/Neutral Position

Park/Neutral Range

Remark

Name

PCM Control Relay

Main Relay

PSP

Power Steering Pressure

Power Steering Pressure

PCM

Powertrain Control Module

ECU

Pressure Control Solenoid

Line Pressure Solenoid Valve

Pulsed Secondary Air Injection

Secondary Air Injection System

Pulsed
injection

Pump Speed Sensor

NE Sensor

#6

Secondary Air Injection

Secondary Air Injection System

Injection with
air pump

Secondary Air Pulse Valve

Reed Valve

Sequential Multipoint Fuel Injection

Sequential Fuel Injection

12 Shift Solenoid Valve

Shift A Solenoid Valve

23 Shift Solenoid Valve

Shift B Solenoid Valve

PAIR

AIR
SAPV
SFI

Shift Solenoid A

Shift Solenoid B

Engine Control Unit

Shift Solenoid C

34 Shift Solenoid Valve

3GR

Third Gear

3rd Gear

TWC

Three Way Catalytic Converter

Catalytic Converter

Throttle Body

Throttle Body

Throttle Position Sensor

Throttle Sensor

TB
TP sensor
TCV

Timer Control Valve

TCC

Torque Converter Clutch

Lock-up Position

TCM

Transmission (Transaxle) Control


Module

EC-AT Control Unit

Transmission (Transaxle) Fluid


Temperature Sensor

ATF Thermosensor

TR

Transmission (Transaxle) Range

Inhibitor Position

TC

Turbocharger

Turbocharger

Vehicle Speed Sensor

Vehicle Speed Sensor

Voltage Regulator

VSS
VR
VAF sensor
WUTWC
WOT

TCV

Timing Control Valve

IC Regulator

Volume Air Flow Sensor

Airflow Meter

Warm Up Three Way Catalytic


Converter

Catalytic Converter

Wide Open Throttle

Fully Open

#6
#4

#6

#5

#1: Diagnostic trouble codes depend on the diagnostic test mode


#2: Controlled by the PCM
#3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4: Device that controls engine and powertrain
#5: Directly connected to exhaust manifold
#6: Part name of diesel engine

GI22

CONVENTIONAL BRAKE SYSTEM

ABBREVIATIONS
ABBREVIATIONS TABLE
A/C

Air conditioner

LSPV

Load sensing proportioning valve

ABDC

After bottom dead center

Motor

ABS

Antilock brake system

MAX

Maximum

ACC

Accessories

MFW

Manual freewheel

ATDC

After top dead center

MIN

Minimum

ATF

Automatic transmission fluid

OFF

Switch off

BBDC

Before bottom dead center

ON

Switch on

BTDC

Before top dead center

PCV

Positive crankcase ventilation

CARB

Carburetor

P/S

Power steering

CM

Control Module

PID

Parameter identification

ELR

Emergency locking retractor

RF

Right front

EX

Exhaust

RFW

Remote freewheel

FIP

Fuel injection pump

RH

Right hand

HI

High

R.H.D.

Right hand drive

HLA

Hydraulic lash adjuster

RR

Right rear

HU

Hydraulic unit

SAS

Sophisticated air bag sensor

IG

Ignition

SST

Special service tool

IN

Intake

SW

Switch

INT

Intermittent

TDC

Top dead center

LF

Left front

TNS

Tail number side lights

LH

Left hand

2WD

2 wheel drive

L.H.D.

Left hand drive

WDS

Worldwide diagnostic system

LO

Low

4WD

4 wheel drive

LR

Left rear

4 2

4 wheel 2 drive

LSD

Limited slip differential

4 4

4 wheel 4 drive

P23

ENGINE
(WL, WL Turbo, WL3, WLT3)
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B21
DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . B21
DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . B22
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . B22
VALVE CLEARANCE
INSPECTION/ADJUSTMENT . . . . . . . . . . . . . B22
COMPRESSION INSPECTION . . . . . . . . . . . . . . . B24
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B25
TIMING BELT REMOVAL/INSTALLATION . . . . B25
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . B27
CYLINDER HEAD GASKET
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . B27

ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . B2 10
ROCKER ARM REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . B2 10
FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . B212
FRONT OIL SEAL REPLACEMENT . . . . . . . B212
REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . B214
REAR OIL SEAL REPLACEMENT . . . . . . . . B214
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B215
ENGINE REMOVAL/INSTALLATION . . . . . . B215
ENGINE DISASSEMBLY/ASSEMBLY . . . . . B216

DRIVE BELT

Deflection
(mm {in})

DRIVE BELT INSPECTION


Drive Belt Deflection Check
1. Check the drive belt deflection when the engine is
cold, or at least 30 minutes after the engine has
stopped. Apply pressure 98 N {10 kgf, 22 lbf}
midway between the specified pulleys.
GENERATOR

Drive belt

*New

Used

Limit

Generator

7.09.0
{0.280.35}

8.010.0
{0.320.39}

16.0
{0.63}

5.06.2
{0.200.24}

6.06.5
{0.240.25}

11.3
{0.44}

9.511.8
{0.380.46}

11.012.5
{0.440.49}

18.0
{0.71}

A/C

MEASURING
POINT

* A belt that has been on a running engine for less than


five minutes.
WATER
PUMP

2. If the deflection is not within the specification,


adjust it. (Refer to DRIVE BELT, DRIVE BELT
ADJUSTMENT.)

GENERATOR
CRANKSHAFT
PULLEY
MEASURING
POINT a

A/C

CRANKSHAFT
PULLEY

Drive Belt Tension Check


1. Belt tension can be checked in place of belt
deflection. Check the drive belt tension when the
engine is cold, or at least 30 minutes after the
engine has stopped. Using the SST, check the belt
tension between any two pulleys.

A/C
COMPRESSOR

49 9200 020A
MEASURING
POINT b
WHEN MEASURED

WHEN SET

B21

DRIVE BELT, VALVE CLEARANCE


Tension

VALVE CLEARANCE
(N {kgf, lbf})

Drive belt

*New

Used

Limit

Generator

442637
{4565,
99143}

383539
{3955,
86121}

177
{18, 40}

A/C

403519
{4153,
91116}

354431
{3644,
8096}

181
{18.5, 41}

* A belt that has been on a running engine for less than


five minutes.

VALVE CLEARANCE INSPECTION/ADJUSTMENT


1. Remove the EGR pipe (WL3,WLT3). (See EGR
SYSTEM REMOVAL/INSTALLATION.)
2. Remove the cylinder head cover.
3. Turn the crankshaft and align the timing mark with
the indicator pin so that the piston of the No. 1 or
No. 4 cylinders is at TDC of the compression.
4. Measure the valve clearances A with the No.1
cylinder at TDC of compression, and those of B
with the No.4 cylinder at TDC of compression.
Valve clearance
IN: 0.050.15 mm {0.00200.0059 in}
[Engine cold]
0.15 mm {0.0059 in}
[Engine hot (Reference)]
EX:0.150.25 mm {0.00600.0098 in}
[Engine cold]
0.25 mm {0.0098 in}
[Engine hot (Reference)]

1. If the tension is not within the specification, adjust


it. (Refer to DRIVE BELT, DRIVE BELT
ADJUSTMENT.)
DRIVE BELT ADJUSTMENT
1. Loosen the mounting bolt and locknut A.
2. Adjust the belt deflection or tension by turning
adjusting bolt B. (Refer to DRIVE BELT, DRIVE
BELT INSPECTION.)
3. Tighten the mounting bolt and locknut A.

GENERATOR
B
ENGINE
FRONT

A 1925
{1.92.6,
1418}

WATER
PUMP

GENERATOR

3246

A {3.24.7,

CRANKSHAFT
PULLEY

2433}

Caution
D Loosening the locknut and the adjust screw
while the cam lobe is not pressing down the
rocker arm will damage the claw of the
rocker arm. When loosening the locknut
and the adjust screw, rotate the crankshaft
clockwise and be sure that the cam lobe
presses down the rocker arm firmly as
shown in the figure.

A/C

3851
{3.85.3, A
2838}

A/C
COMPRESSOR

CRANKSHAFT
PULLEY

Nm {kgfm, ftlbf}

4. Inspect the belt deflection or tension. (Refer to


DRIVE BELT, DRIVE BELT INSPECTION.)

ZCF2212W002

5. If not within the specification, adjust and recheck


the valve clearance.
6. Turn the crankshaft one full turn and measure the
remaining valve clearances. Adjust if necessary.
Tightening torque (locknut)
1620 Nm {1.62.1 kgfm, 1215 ftlbf}

B22

VALVE CLEARANCE

FEELER
GAUGE

ADJUST
SCREW

LOCKNUT

7. Install the cylinder head cover. (Refer to


CYLINDER HEAD GASKET, CYLINDER HEAD
GASKET REPLACEMENT, Cylinder Head Cover
Installation Note.)
8. Install the EGR pipe (WL3,WLT3). (See EGR
SYSTEM REMOVAL/INSTALLATION.)

B23

COMPRESSION INSPECTION

COMPRESSION INSPECTION
Warning
D When the engine and the oil are hot, they
can badly burn. Turn off the engine and wait
until they are cool.
1. Verify that the battery is fully charged. Recharge it
if necessary. (Refer to Section G, CHARGING
SYSTEM, BATTERY INSPECTION, Battery.)
2. Warm up the engine to the normal operating
temperature.
3. Stop the engine and allow it to cool off for about 10
minutes.

(3) If the compression in adjacent cylinders stays


low, the cylinder head gasket may be damaged
or the cylinder head distorted and overhaul is
required.
10. Remove the SST.
11. Install the glow plug. (Refer to Section F2, INTAKE
AIR SYSTEM, GLOW PLUG
REMOVAL/INSTALLATION.)
12. Connect the FCV (fuel cut valve) connector.

Warning
D Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate
skin and eyes. To prevent fuel from
spurting out of the injection nozzle hole, do
not ground the FCV (fuel cut valve) terminal.
4. Disconnect the FCV (fuel cut valve) connector.
5. Remove all the glow plugs. (Refer to Section F2,
INTAKE AIR SYSTEM, GLOW PLUG
REMOVAL/INSTALLATION.)
6. Install the SSTs into the glow plug hole.
49 S010 1A0
49 S013 102

7. Crank the engine and note the maximum gauge


reading.
8. Check each cylinder as above.
Compression
(kPa {kgf/cm2, psi} [rpm])
Item

Engine
WL, WL Turbo

Standard

2942 {30, 427} [200]

Minimum

2648 {27, 384} [200]

9. If the compression in one or more cylinders is low,


pour a small amount of clean engine oil into the
cylinder and recheck the compression.
(1) If the compression increases, the piston, the
piston rings, or cylinder wall may be worn and
overhaul is required.
(2) If the compression stays low, a valve may be
stuck or improperly seated and overhaul is
required.

B24

TIMING BELT
3. Remove the tensioner and tensioner spring.

TIMING BELT

Timing Belt Installation Note


1. Measure the tensioner spring free length. Replace
the tensioner spring if necessary.

TIMING BELT REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Free length
63.0 mm {2.48 in}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

3851 {3.85.3, 2838}


Nm {kgfm, ftlbf}

FREE LENGTH

Timing belt cover


+ Installation Note

Tensioner, tensioner spring

Timing belt
+ Removal Note
+ Installation Note

2. Turn the crankshaft clockwise and align the timing


marks as shown.
TIMING MARK
TENSIONER
LOCK BOLT

Timing Belt Removal Note

CAMSHAFT
PULLEY

Caution
D Forcefully twisting the belt, turning it inside
out, or allowing oil or grease on it will
damage the belt and shorten its life.

TENSIONER
SPRING
TENSIONER
TIMING MARK

FAULTY

FAULTY

Caution
D Overtensioning of the timing belt can cause
breakage of the belt and the camshaft.

FAULTY

ROTATION
ARROW

25 mm {1.0 in} MIN.

3. Verify that the FIP attaching bolts and nuts are


tightened to the specified torque. This must be
done to prevent overtensioning of the timing belt
after it has been installed.
4. Install the timing belt.
5. Install the tensioner, tensioner spring, and
hand-tighten the lock bolt.
6. Turn the crankshaft clockwise twice, and align the
timing marks. If they are not aligned, remove the
timing belt and repeat from Timing Belt
Installation Note Step 2.
7. Loosen the tensioner lock bolt to apply tension to
the belt. Do not apply tension other than that of the
tensioner spring.
8. Tighten the tensioner lock bolt. Be sure the
tensioner does not move together with the bolt
rotation.
9. Turn the crankshaft clockwise twice, and check the
timing belt deflection as shown. If it is incorrect,
repeat from Timing Belt Removal Note.

FAULTY

1. Mark the timing belt rotation on the belt for proper


reinstallation.
2. Turn the crankshaft clockwise and align the timing
marks as shown.
TIMING MARK

CAMSHAFT
PULLEY
TENSIONER
SPRING
TENSIONER
TIMING MARK

FIP PULLEY

FIP PULLEY

B25

TIMING BELT
Timing belt deflection
9.010.0 mm {0.360.39 in} at
98 N {10 kgf, 22 lbf}
TENSIONER
LOCK BOLT

DEFLECTION
CHECKING
POINT

CAMSHAFT
PULLEY
TENSIONER
SPRING
TENSIONER
FIP PULLEY

Timing Belt Cover Installation Note


D Tighten the timing belt cover bolts in the order
shown.

ST

B26

CYLINDER HEAD GASKET

CYLINDER HEAD GASKET


CYLINDER HEAD GASKET REPLACEMENT
Warning
D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety
Procedures. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL
SYSTEM.)
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E,
ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the intake manifold, air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR
SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
4. Remove the injection nozzle. (Refer to Section F2, FUEL SYSTEM, INJECTION NOZZLE
REMOVAL/INSTALLATION.)
5. Remove the turbocharger. (WL Turbo) (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
6. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
10. Check the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
11. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
12. Start the engine and
(1) Inspect for engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, PREPARATION, Idle Speed Adjustment.)
13. Inspect the compression. (Refer to COMPRESSION INSPECTION.)

5.08.8 Nm
{5090 kgfcm,
4478 inlbf}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

1819 {1.82.0, 13.114.4}


29 {3.0, 22} + (90105) + (90105)

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

3851 {3.85.3, 2838}

Nm {kgfm, ftlbf}

B27

CYLINDER HEAD GASKET

Drive belt

Cylinder head cover


+ Installation Note

Cylinder head bolt


+ Removal Note
+ Installation Note

Cylinder head

Cylinder head gasket


+ Installation Note

LENGTH

Cylinder Head Bolt Removal Note


1. Remove bolts A.
2. Loosen the cylinder head bolts in two or three
steps in the order shown.

2. Apply clean engine oil to the threads and the seat


face of each bolt and install them.
3. Tighten the bolts in two or three steps in the order
shown in the figure.

Tightening torque
29 Nm {3.0 kgfm, 22 ftlbf}
A

Cylinder Head Gasket Installation Note


D Apply silicone sealant to the cylinder head as
shown.

Thickness
2.03.0 mm {0.080.11 in}

4. Put a paint mark on each bolt head.


5. Using the marks as a reference, tighten the bolts
by turning each 90105 in the sequence shown.
6. Further tighten each bolt by turning another
90105.

16.0 mm
{0.63 in}
40.5 mm
{1.59 in}

ENGINE
FRONT

PAINT MARK
90105

48.5 mm
{1.91 in}

90105

9.0 mm
{0.35 in}

ST
Cylinder Head Bolt Installation Note
1. Measure the length of each bolt. Replace the bolt if
necessary.

PAINT MARK

7. Tighten bolts A.

Cylinder head bolt


(mm {in})
Bolt head mark

Standard
length

Maximum
length

101.2101.8
{3.9854.007}

102.5 {4.035}

113.2113.8
{4.4574.480}

114.5 {4.508}

B28

Tightening torque
1819 Nm {1.82.0 kgfm, 13.114.4 ftlbf}

CYLINDER HEAD GASKET


Cylinder Head Cover Installation Note
1. Apply silicone sealant to the cylinder head as
shown.
Thickness
1.52.5 mm {0.0600.098 in}

2. Tighten cylinder head cover bolts A and B.


Tightening torque
1.52.9 Nm {1530 kgfcm, 1426 inlbf}

A
ENGINE
FRONT
B

3. Tighten the cylinder head cover bolts in the order


shown.
Tightening torque
5.08.8 Nm {5090 kgfcm, 4478 inlbf}

B29

ROCKER ARM

ROCKER ARM
ROCKER ARM REMOVAL/INSTALLATION
Caution
D Removing the camshaft under load can break the camshaft. When removing the camshaft, be sure
to prevent the camshaft from pressing down the rocker arm. (SeeVALVE CLEARANCE
INSPECTION/ADJUSTMENT.)
1. Disconnect the negative battery cable.
2. Remove the EGR pipe (WL3,WLT3). (See EGR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION.)
4. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.

5.08.8 Nm
{5090 kgfcm,
4478 inlbf}

11.314.2 Nm
{115145 kgfcm, 100125 inlbf}
1620 {1.62.1, 1215}

R
SST

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
3041 {3.04.2, 2230}

123140 {12.514.3, 91103}

ST
Nm {kgfm, ftlbf}

Cylinder head cover


+ VALVE CLEARANCE, VALVE CLEARANCE
INSPECTION/ADJUSTMENT
+ CYLINDER HEAD GASKET, CYLINDER HEAD
GASKET REPLACEMENT, Cylinder Head Cover
Installation Note
Camshaft pulley
+ Removal Note
+ Installation Note

Seal plate
+ Installation Note

Camshaft
+ Removal Note
+ Installation Note

Rocker arm
+ Installation Note

Pivot

B210

ROCKER ARM
Camshaft Pulley Removal Note
D Hold the camshaft by using a wrench on the cast
hexagon.

2. Tighten the camshaft cap bolts gradually in three or


four steps in the order shown.
Camshaft Removal Note
Note
D Mark the camshaft caps so that they can be
reinstalled in the position from which they were
removed.

ENGINE
FRONT

D Loosen the camshaft cap bolts in three or four

steps in the order shown.

ENGINE
FRONT

3. Apply clean engine oil to the new oil seal.


4. Push the oil seal slightly in by hand.
5. Tap the oil seal into the cylinder head by using the
SST and a hammer.
6. To ensure that the oil seal is installed accurately,
measure distance between the end of the cylinder
head and the face of the oil seal.
49 S010 001

Rocker Arm Installation Note


D If a new rocker arm is used, set dimension
follows.

as
0.51.0 mm
{0.020.03 in}

Dimension A
04 mm {00.1 in}
HAMMER

CYLINDER
HEAD

OIL SEAL

Seal Plate Installation Note


D Tighten the seal plate bolts in the order shown.
A

Camshaft Installation Note


1. Apply silicone sealant to the front camshaft cap
mounting surfaces as shown. Prevent sealant from
getting onto the camshaft journal, oil seal surface,
and camshaft thrust surface.

B211

ROCKER ARM, FRONT OIL SEAL


Camshaft Pulley Installation Note
D Hold the camshaft by using a wrench on the cast
hexagon and tighten the pulley lock bolt.

FRONT OIL SEAL


FRONT OIL SEAL REPLACEMENT
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (Refer to Section E,
COOLING SYSTEM SERVICE WARNINGS.)
(Refer to Section E, ENGINE COOLANT, ENGINE
COOLANT REPLACEMENT.)
3. Remove the upper radiator hose.
4. Remove the radiator cowling and cooling fan.
(Refer to Section E, WATER PUMP, WATER
PUMP REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect the engine oil level.
8. Adjust the drive belt deflection. (Refer to DRIVE
BELT, DRIVE BELT ADJUSTMENT.)
SST
R
SST
350390
{3540,
260280}

Nm {kgfm, ftlbf}

Drive belt

Crankshaft pulley
+ Removal Note
+ Installation Note

Front oil seal


+ Removal Note
+ Installation Note

Crankshaft Pulley Removal Note


D Hold the crankshaft by using the SST.
Caution
D Turning the crankshaft after the crankshaft
pulley is removed can cause the timing
gear to become dislocated.
D Removing the key can cause the key
groove to become misaligned.

49 S011 102A

B212

REAR OIL SEAL


Caution
(WL3, WLT3)
D The TDC sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the
operation control.
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with other
parts or improper handling.

D The TDC sensor plate is a very important


part for engine operation control; any
deformation of the plate may disable the
operation control.
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with other
parts or improper handling.

Front Oil Seal Removal Note


1. Cut the oil seal lip by using a razor knife.
2. Remove the oil seal by using a screwdriver
protected with a rag.

RAG
CE2220W003

Front Oil Seal Installation Note


1. Apply clean engine oil to the new oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly by using the SST and a
hammer.
4. To ensure that the oil seal is installed accurately,
measure the distance between the end of the gear
case cover and the face of the front oil seal.
GEAR CASE COVER

49 S010 301

00.4 mm
{00.01 in}

HAMMER

FRONT OIL SEAL

Crankshaft Pulley Installation Note


D Hold the crankshaft by using the SST.

49 S011 102A

Caution
(WL3, WLT3)

B213

FRONT OIL SEAL

REAR OIL SEAL


REAR OIL SEAL REPLACEMENT
1. Disconnect the negative battery cable.
2. Remove the flywheel. (Refer to Section H,
CLUTCH UNIT, CLUTCH UNIT
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the engine oil level. (Refer to Section D,
ENGINE OIL, ENGINE OIL INSPECTION.)

SST

Rear oil seal


+ Removal Note
+ Installation Note

Rear Oil Seal Removal Note


1. Cut the oil seal lip by using a razor knife.
2. Remove the oil seal by using a screwdriver
protected with a rag.

RAG

Rear Oil Seal Installation Note


1. Apply clean engine oil to the new oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly by using the SST and a
hammer.
4. To ensure that the oil seal is installed accurately,
measure the distance between the end of the rear
cover and the face of the rear oil seal.
49 S011 103

REAR COVER

00.5 mm {00.01 in}

HAMMER

REAR OIL SEAL

B214

ENGINE

ENGINE
ENGINE REMOVAL/INSTALLATION
Warning
D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety
Procedures. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL
SYSTEM.)
1. Remove the air intake pipe. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.)
3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)
4. Remove the front pipe. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
5. Remove the transmission. (Refer to section J1J2, TRANSMISSION, TRANSMISSION
REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
10. Start the engine and
(1) Inspect the engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed
Adjustment.)
11. Perform a road test.

1925
{1.92.6,
1418}

9.914.7 Nm
{100150 kgfcm,
86.8130 inlbf}

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

3246 {3.24.7, 2433}

2030
{2.03.1, 1522}
Nm {kgfm, ftlbf}

Cooling fan

Drive belt

3
4

P/S oil pump


+ Removal Note

Accelerator cable

Engine mount nut

A/C compressor
+ Removal Note

Engine
+ Removal/Installation Note

B215

ENGINE
A/C Compressor Removal Note
D Remove the A/C compressor with the pipe still
connected. Position the A/C compressor so that it
is out of the way.
P/S Oil Pump Removal Note
D Remove the P/S oil pump with the oil hose still
connected. Position the P/S oil pump so that it is
out of the way.
Engine Removal/Installation Note
D Install the engine hanger (JE48 10 561C) to the
cylinder head by using bolt (99794 0820) or (M8
1.25, 6T, length 20 mm {0.79 in}) as shown.

ENGINE DISASSEMBLY/ASSEMBLY
1. Remove the intake-air system. (Refer to Section
F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Remove the exhaust system. (Refer to Section F2,
EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
3. Remove the oil cooler. (Refer to Section D, OIL
COOLER, OIL COOLER
REMOVAL/INSTALLATION.)
4. Disassemble in the ordre indicated in the table.
5. Assemble in the reverse order of disassembly.

1217 {1.21.8, 913}

Tightening torque
1925 Nm {1.92.6 kgfm, 1418 ftlbf}
3851
{3.85.3,
2838}

ENGINE
FRONT

3246
{3.24.7,
2433}

1925 {1.92.6, 1418}

3851
{3.85.3,
2838}

Nm {kgfm, ftlbf}

Drive belt

Generator

Idler

A/C compressor bracket

Engine mount bracket

Oil pressure switch


+ Section D, OIL PRESSURE INSPECTION

Water pump pulley

B216

LUBRICATION SYSTEM
OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . .
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL INSPECTION . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . .
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . .

D1
D2
D2
D2
D2
D2

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER REMOVAL/INSTALLATION . . . . .
OIL COOLER BODY INSPECTION . . . . . . . . . .
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN REMOVAL/INSTALLATION . . . . . . . . .

D3
D3
D4
D4
D4

G6

: 305402 kPa
{3.14.1 kgf/cm2, 4558 psi}
[3,000 rpm]
WL
: 452529 kPa
{4.65.4 kgf/cm2, 6676 psi}
[3,000 rpm]
WL Turbo : 402480 kPa
{4.14.9 kgf/cm2, 5969 psi}
[3,000 rpm]

OIL PRESSURE INSPECTION


Warning
 Continuous exposure with USED engine oil
has caused skin cancer in laboratory mice.
Protect your skin by washing with soap and
water immediately after this work.
 When the engine and the oil are hot, they
can badly burn. Turn off the engine and wait
until they are cool.

5. If the pressure is not as specified, inspect for the


cause and repair or replace as necessary.
6. Stop the engine and wait until it becomes cool.
7. Remove the SST.
8. Apply silicone sealant to the oil pressure switch
threads as shown.

1. Remove the oil pressure switch.


2. Screw the SST into the oil pressure switch
installation hole.
F2, G6

1.02.0 mm
{0.0400.078 in}

49 0187 280

4.06.0 mm
{0.160.23 in}
WL,
WL TURBO

9. Install the oil pressure switch before the sealant


hardens.
Tightening torque
1217 Nm {1.21.8 kgfm, 913 ftlbf}
10. Start the engine and inspect for oil leakage.
49 0187 280

3. Warm up the engine to normal operating


temperature.
4. Run the engine at the specified speed, and note
the gauge readings.
Note
 The oil pressure can vary with viscosity and
temperature.
Oil pressure
F2
: 295392 kPa
{3.04.0 kgf/cm2, 4356 psi}
[3,000 rpm]

D1

ENGINE OIL, OIL FILTER

ENGINE OIL

OIL FILTER

ENGINE OIL INSPECTION


1. Position the vehicle on level ground.
2. Warm up the engine to normal operating
temperature and stop it.
3. Wait for five minutes.
4. Remove the dipstick and inspect for oil level and
condition. Verify that the oil level is within the F and
L marks on the dipstick.
5. Add or replace oil if necessary.

OIL FILTER REPLACEMENT


1. Remove the oil filter by using the SST or the filter
wrench.

49 9014 001

ENGINE OIL REPLACEMENT


Warning
 When the engine and the engine oil are hot,
they can badly burn. Dont burn yourself
with either.
 A vehicle that is lifted but not securely
supported on safety stands is dangerous. It
can slip or fall, causing death or serious
injury. Never work around or under a lifted
vehicle if it is not securely supported on
safety stands.
 Continuous exposure with USED engine oil
has caused skin cancer in laboratory mice.
Protect your skin by washing with soap and
water immediately after this work.
1. Position the vehicle on level ground.
2. Remove the oil filler cap and the oil pan drain plug.
3. Drain the oil into a container.
4. Install the drain plug by using a new washer.
Tightening torque
3041 Nm {3.04.2 kgfm, 2230 ftlbf}
5. Refill the engine oil with the specified type and
amount of engine oil.
6. Refit the oil filler cap.
7. Run the engine and inspect for oil leakage.
8. Inspect the oil level and add oil if necessary. (Refer
to ENGINE OIL, ENGINE OIL INSPECTION.)
Note
 The actual oil level may vary from the specified
capacity in some cases.
Oil capacity
(L {US qt, Imp qt})
Engine
Item

F2

G6

WL, WL
Turbo

Oil replacement

3.9
{4.1, 3.4}

4.5
{4.8, 4.0}

5.6
{5.9, 4.9}

Oil and oil filter


replacement

4.2
{4.4, 3.7}

4.7
{5.0, 4.4}

6.3
{6.7, 5.5}

Total
(dry engine)

4.6
{4.9, 4.0}

5.5
{5.8, 4.8}

6.7
{7.1, 5.9}

D2

2. Use a clean rag to wipe off the mounting surface


on the oil filter body.
3. Apply engine oil to the O-ring and tighten the filter
according to the installation directions on the side
of the oil filter using the SST or the filter wrench.
4. Start the engine and inspect for oil leakage.
5. Inspect for the oil level and add oil if necessary.
(Refer to ENGINE OIL, ENGINE OIL
INSPECTION.)

OIL COOLER

OIL COOLER
OIL COOLER REMOVAL/INSTALLATION
G6, WL, WL Turbo
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the turbocharger. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.) (WL Turbo model.)
4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.)
5. Remove in the order shown in the figure.
6. Install in the reverse order of removal.
7. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E, ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)
8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
9. Start the engine and inspect for engine coolant leakage.
G6

3039 {3.04.0, 2228}


Nm {kgfm, ftlbf}

Water hose

Nut

Oil cooler

WL, WL TURBO
R
3049 {3.05.0, 2236}

7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
1925 {1.92.6, 1418}

R
1925 {1.92.6, 1418}

R
Nm {kgfm, ftlbf}

Dipstick pipe

Radiator hose

Thermostat case

Insulator

D3

Oil cooler body


+ Installation Note

Oil cooler

OIL COOLER, OIL PAN


Oil Cooler Body Installation Note
WL, WL Turbo
 Tighten the mounting bolts and nuts in the order
shown.

OIL PAN
OIL PAN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine oil. (Refer to ENGINE OIL,
ENGINE OIL REPLACEMENT.)
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
5. Fill with the specified amount and type of engine
oil. (Refer to ENGINE OIL, ENGINE OIL
REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
F2, G6

OIL COOLER BODY INSPECTION


WL, WL Turbo
 Measure the spring free length. Replace the spring
if necessary.
Standard free length
Bypass valve spring: 36.7 mm {1.44 in}
Pressure control valve spring: 54.7 mm {2.15 in}
BYPASS VALVE SPRING

7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
3041
{3.04.2, 2230}

3851
{3.85.3,
2838}

3851
{3.85.3,
2838}

PRESSURE CONTROL VALVE SPRING

Nm {kgfm, ftlbf}

D4

Gusset plate

Oil pan
+ Removal Note
+ Installation Note

OIL COOLER, OIL PAN


Oil Cooler Body Installation Note
WL, WL Turbo
 Tighten the mounting bolts and nuts in the order
shown.

OIL PAN
OIL PAN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine oil. (Refer to ENGINE OIL,
ENGINE OIL REPLACEMENT.)
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
5. Fill with the specified amount and type of engine
oil. (Refer to ENGINE OIL, ENGINE OIL
REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
F2, G6

OIL COOLER BODY INSPECTION


WL, WL Turbo
 Measure the spring free length. Replace the spring
if necessary.
Standard free length
Bypass valve spring: 36.7 mm {1.44 in}
Pressure control valve spring: 54.7 mm {2.15 in}
BYPASS VALVE SPRING

7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
3041
{3.04.2, 2230}

3851
{3.85.3,
2838}

3851
{3.85.3,
2838}

PRESSURE CONTROL VALVE SPRING

Nm {kgfm, ftlbf}

D4

Gusset plate

Oil pan
+ Removal Note
+ Installation Note

OIL COOLER, OIL PAN


Oil Cooler Body Installation Note
WL, WL Turbo
 Tighten the mounting bolts and nuts in the order
shown.

OIL PAN
OIL PAN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine oil. (Refer to ENGINE OIL,
ENGINE OIL REPLACEMENT.)
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
5. Fill with the specified amount and type of engine
oil. (Refer to ENGINE OIL, ENGINE OIL
REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
F2, G6

OIL COOLER BODY INSPECTION


WL, WL Turbo
 Measure the spring free length. Replace the spring
if necessary.
Standard free length
Bypass valve spring: 36.7 mm {1.44 in}
Pressure control valve spring: 54.7 mm {2.15 in}
BYPASS VALVE SPRING

7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
3041
{3.04.2, 2230}

3851
{3.85.3,
2838}

3851
{3.85.3,
2838}

PRESSURE CONTROL VALVE SPRING

Nm {kgfm, ftlbf}

D4

Gusset plate

Oil pan
+ Removal Note
+ Installation Note

OIL PAN
Oil Pan Installation Note

WL, WL TURBO

Caution
 If the bolts are reused, remove the old
sealant from the bolt threads. Tightening a
bolt that has old sealant on it can cause
bolt hole damage.

94115
{9.511.8, 6985}

CRACKS

OLD SEALANT

5580
{5.68.2,
4159}

7.910.7 Nm
{80110 kgfcm,
7095 inlbf}

Crossmember (4WD)

Oil pan
+ Removal Note
+ Installation Note

1. Apply silicone sealant to the oil pan along the


inside of the bolt holes and overlap the ends.
Nm {kgfm, ftlbf}

Thickness
2.03.0 mm {0.080.11 in}

OIL PAN

Oil Pan Removal Note


1. Remove the oil pan mounting bolts.
Caution
 Pry tools can easily scratch the cylinder
block or oil baffle and oil pan contact
surfaces. Prying off the oil pan can also
easily bend the oil pan flange.

2. Install the oil pan before the sealant hardens.

2. Use a separator tool to separate the oil pan.


SEPARATOR TOOL

D5

COOLING SYSTEM
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT LEVEL INSPECTION . . . .
ENGINE COOLANT REPLACEMENT . . . . . . . .
ENGINE COOLANT LEAKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR CAP INSPECTION . . . . . . . . . . . . . .
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR REMOVAL/INSTALLATION . . . . . . .

E1
E1
E1
E2
E3
E3
E3
E3

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT REMOVAL/INSTALLATION . . . .
THERMOSTAT INSPECTION . . . . . . . . . . . . . . .
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP REMOVAL/INSTALLATION . . . .
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING FAN REMOVAL/INSTALLATION . . .
COOLING FAN INSPECTION . . . . . . . . . . . . . . .

E4
E4
E5
E6
E6
E7
E7
E7

ENGINE COOLANT
Warning
 Removing the radiator cap or loosening the
radiator drain plug while the engine is
running, or when the engine and radiator
are hot is dangerous. Scalding coolant and
steam may shoot out and cause serious
injury. It may also damage the engine and
cooling system.
 Turn off the engine and wait until it is cool.
Even then, be very careful when removing
the cap. Wrap a thick cloth around it and
slowly turn it counterclockwise to the first
stop. Step back while the pressure escapes.
 When youre sure all the pressure is gone,
press down on the cap still using a cloth
turn it, and remove it.
 When the engine and the engine coolant are
hot, they can badly burn. Turn off the
engine and wait until they are cool before
draining the engine coolant.
ENGINE COOLANT LEVEL INSPECTION
1. Remove the radiator cap.
2. Verify that the coolant level is near the radiator filler
neck.
3. Verify that the coolant level in the radiator reservoir
is between the FULL and LOW marks.
4. Add coolant if necessary.
ENGINE COOLANT REPLACEMENT
1. Drain the coolant in the radiator reservoir.
2. Remove the radiator cap and loosen the radiator
drain plug.

TYPE A

DRAIN
PLUG
TYPE B

3. Drain the coolant into a container.


4. Flush the cooling system with water until all traces
of color are gone.
5. Let the system drain completely.
6. Tighten the radiator drain plug.
Tightening torque
Type A: 1.52.9 Nm
{1530 kgfcm, 1426 inlbf}
Type B: 0.91.1 Nm
{9.012 kgfcm, 7.910 inlbf}
Caution
 The engine has aluminum parts that can be
damaged by alcohol or methanol antifreeze.
Do not use alcohol or methanol in the
cooling system. Use only
ethylene-glycol-based coolant.
 Use only soft (demineralized) water in the
coolant mixture. Water that contains
minerals will cut down on the coolants
effectiveness.
7. Referring to the following graph and chart, select
proper gravity of the coolant. Slowly pour the
coolant into the radiator up to the coolant filler port.
Filling pace
1.0 L {1.1 US qt, 0.88 Imp qt}/min. [max]

E1

ENGINE COOLANT

SPECIFIC
GRAVITY

Caution
 Applying more than 103 kPa {1.05 kgf/cm2,
14.9 psi} (F2) or 122 kPa {1.25 kgf/cm2, 17.7
psi} (G6, WL, WL Turbo) can damage the
hoses, fittings, and other components, and
cause leakage.

COOLANT PROTECTION

1,100
1,090
1,080

49 9200 147

1,070
1,060

50%
40%

1,050
30%
1,040
1,030

49 9200 146

1,020
1,010
1,000
0

5. Verify that the pressure is held. If not, inspect the


system for coolant leakage.

10
0
10
20
30
40
50
60
70
80
90
{ 14 } { 32 } { 50 } { 68 } { 86 } { 104 }{ 122 } { 140 } { 158 } { 176 } { 194 }
COOLANT TEMPERATURE C { F }

Antifreeze solution mixture percentage

Water

Coolant

Gravity
at 20C
{68F}

Above 16C {3F}

65

35

1,054

Above 26C {15F}

55

45

1,066

Above 40C {40F}

45

55

1,078

Volume percentage
Coolant protection

1. Fill the coolant into the reservoir up to the FULL


mark.
2. Fully install the radiator cap.
3. Start the engine and let it idle for approx. 10
minutes. If the coolant temperature becomes too
high, stop the engine to prevent it from
overheating.
4. After the engine warms up, run it at approx. 2,500
rpm for five minutes.
5. Increase the engine speed to approx. 3,000 rpm
for five seconds, then return to idle. Repeat several
times.
6. Stop the engine and wait until it is cool.
7. Inspect the coolant level. If it is low, repeat Steps
712.
8. Inspect for coolant leakage.
ENGINE COOLANT LEAKAGE INSPECTION
1. Inspect the coolant level. (Refer to ENGINE
COOLANT, ENGINE COOLANT LEVEL
INSPECTION.)
2. Remove the radiator cap.
3. Connect a radiator cap tester and the SST to the
radiator filler neck.
4. Apply pressure to the radiator.
Pressure
F2: 103 kPa {1.05 kgf/cm2, 14.9 psi}
G6, WL, WL Turbo:
122 kPa {1.25 kgf/cm2, 17.7 psi}

E2

RADIATOR CAP, RADIATOR

RADIATOR CAP

RADIATOR

RADIATOR CAP INSPECTION

RADIATOR REMOVAL/INSTALLATION
1. Drain the engine coolant. (Refer to ENGINE
COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove in the order indiacted in the table.
3. Install in the reverse order of removal.
4. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)

Warning
 Removing the radiator cap while the engine
is running, or when the engine and radiator
are hot is dangerous. Scalding coolant and
steam may shoot out and cause serious
injury. It may also damage the engine and
cooling system.
 Turn off the engine and wait until it is cool.
Even then, be very careful when removing
the cap. Wrap a thick cloth around it and
slowly turn it counterclockwise to the first
stop. Step back while the pressure escapes.
 When youre sure all the pressure is gone,
press down on the cap still using a cloth
turn it, and remove it.

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
1826
{1.82.7, 1419}
1826
{1.82.7,
1419}

1. Attach the radiator cap to a radiator cap tester with


the SST. Apply pressure gradually.
2. Verify that the pressure becomes stable within the
specification.
Pressure
F2: 74102 kPa
{0.751.05 kgf/cm2, 10.714.9 psi}
G6, WL, WL Turbo: 94122 kPa
{0.951.25 kgf/cm2, 13.517.7 psi}
3. If the pressure is held for 10 seconds, the radiator
cap is normal.

Nm {kgfm, ftlbf}

49 9200 147

Radiator hose

Lower radiator cowling

Radiator cowling

Radiator

ST

E3

THERMOSTAT

THERMOSTAT

Upper radiator hose

THERMOSTAT REMOVAL/INSTALLATION
1. Drain the engine coolant. (Refer to ENGINE
COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)

Thermostat cover

Thermostat
+ Installation Note

WL, WL TURBO

F2

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

1925
{1.92.6, 1418}

R
1925
{1.92.6, 1418}

Nm {kgfm, ftlbf}

Nm {kgfm, ftlbf}

Upper radiator hose

Thermostat cover

Thermostat
+ Installation Note

Dipstick pipe

Lower radiator hose

Thermostat cover

Thermostat
+ Installation Note

Thermostat Installation Note


F2, G6
1. Install the thermostat into the cylinder head with
the jiggle pin at the top.
2. Install a new gasket with the seal print side facing
the cylinder head.

G6

JIGGLE PIN
1925
{1.92.6, 1418}

AA

PRINT

1925
{1.92.6, 1418}

WL, WL Turbo
 Install the thermostat into the thermostat cover,
aligning the projection on the gasket to the
thermostat cover as shown.

Nm {kgfm, ftlbf}

E4

THERMOSTAT

GASKET
PROJECTION

THERMOSTAT COVER

THERMOSTAT INSPECTION
Warning
 During inspection, the thermostat and water
are extremely hot and they can badly burn.
Do not touch the thermostat and water
directly.
Inspect the thermostat for the following and replace as
necessary.
 Open valve in room temperature
 Opening temperature and lift of the valve
Initial-opening temperature
F2: 83.589.5 C {183193 F}
G6: 86.589.5 C {188193 F} (Main valve)
83.586.5 C {183187 F} (Sub valve)
WL, WL Turbo: 8084 C {176183 F}
Full open temperature
F2, G6
: 100 C {212 F}
WL, WL Turbo : 95 C {203 F}
Full open lift
G6
: 8.0 mm {0.31 in} min. (Main valve)
1.5 mm {0.06 in} min. (Sub valve)
F2, WL, WL Turbo: 8.5 mm {0.33 in} min.

ST

E5

THERMOSTAT

GASKET
PROJECTION

THERMOSTAT COVER

THERMOSTAT INSPECTION
Warning
 During inspection, the thermostat and water
are extremely hot and they can badly burn.
Do not touch the thermostat and water
directly.
Inspect the thermostat for the following and replace as
necessary.
 Open valve in room temperature
 Opening temperature and lift of the valve
Initial-opening temperature
F2: 83.589.5 C {183193 F}
G6: 86.589.5 C {188193 F} (Main valve)
83.586.5 C {183187 F} (Sub valve)
WL, WL Turbo: 8084 C {176183 F}
Full open temperature
F2, G6
: 100 C {212 F}
WL, WL Turbo : 95 C {203 F}
Full open lift
G6
: 8.0 mm {0.31 in} min. (Main valve)
1.5 mm {0.06 in} min. (Sub valve)
F2, WL, WL Turbo: 8.5 mm {0.33 in} min.

E5

WATER PUMP

WATER PUMP

WL, WL TURBO

WATER PUMP REMOVAL/INSTALLATION


1. Remove the cooling fan. (Refer to COOLING FAN,
COOLING FAN REMOVAL/INSTALLATION.)
2. Remove the timing belt (F2). (Refer to Section B3,
TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION.)
3. Drain the engine coolant. (Refer to ENGINE
COOLANT, ENGINE COOLANT REPLACEMENT.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)

1925
{1.92.6, 1418}

F2
1922
{1.92.3, 1416}

Nm {kgfm, ftlbf}
1925
{1.92.6, 1418}

3851
{3.85.3, 2838}
Nm {kgfm, ftlbf}

G6

1922
{1.92.2, 1416}
Nm {kgfm, ftlbf}

E6

Water pump

Idler

COOLING FAN

COOLING FAN
COOLING FAN REMOVAL/INSTALLATION
1. Remove the drive belt.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Adjust the drive belt (generator) deflection. (Refer
to Section B1, B2, B3, DRIVE BELT, DRIVE BELT
ADJUSTMENT.)

F2, G6: 7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}


WL, WL TURBO: 1925 {1.92.6, 1418}

Nm {kgfm, ftlbf}

Cooling fan

Water pump pulley

COOLING FAN INSPECTION


1. Rotate the cooling fan by hand and inspect for
abnormal noise and looseness. Replace the
cooling fan if necessary. (Refer to COOLING FAN,
COOLING FAN REMOVAL/INSTALLATION.)

E7

FUEL AND EMISSION CONTROL SYSTEMS


(WL, WL Turbo, WL3, WLT3)
ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . F2 2
ENGINE TUNE-UP PREPARATION . . . . . . . . F2 2
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . F2 2
IDLE-UP SPEED ADJUSTMENT . . . . . . . . . . . F2 2
INJECTION TIMING ADJUSTMENT . . . . . . . . F2 4
INTAKE-AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . F2 5
VACUUM HOSE ROUTING DIAGRAM . . . . . F2 5
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2 7
TURBOCHARGER INSPECTION . . . . . . . . . F2 10
GLOW PLUG REMOVAL/INSTALLATION . . F2 11
GLOW PLUG INSPECTION . . . . . . . . . . . . . . F2 11
GLOW PLUG RELAY
REMOVAL/INSTALLATION . . . . . . . . . . . . . F2 12
GLOW PLUG RELAY INSPECTION . . . . . . . . F212
GLOW PLUG CORD INSPECTION . . . . . . . . F213
ACCELERATOR PEDAL
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F213
ACCELERATOR PEDAL COMPONENT
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . F214
ACCELERATOR CABLE
INSPECTION/ADJUSTMENT . . . . . . . . . . . . F215
IDLING KNOB, IDLING CABLE INSPECTION F215
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . F216
BEFORE REPAIR PROCEDURE . . . . . . . . . . F216
AFTER REPAIR PROCEDURE . . . . . . . . . . . . F216
FUEL TANK REMOVAL/INSTALLATION . . . . F217
FUEL FILTER DISASSEMBLY/ASSEMBLY . . F219
FUEL FILTER AIR BLEEDING . . . . . . . . . . . . . F220
SEDIMENTOR WATER DRAINING . . . . . . . . . F220
SEDIMENTOR SWITCH INSPECTION . . . . . F220
FUEL WARMER INSPECTION . . . . . . . . . . . . F221
FUEL INJECTION PUMP (FIP) INSPECTION F221
FUEL INJECTION PUMP (FIP)
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F222
INJECTION NOZZLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F223
INJECTION NOZZLE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . F224
INJECTION NOZZLE INSPECTION . . . . . . . . F224
FUEL SHUT OFF (FSO) SOLENOID
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . F225
ELECTRONIC GOVERNOR INSPECTION . . F226
FUEL CUT VALVE (FCV)
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F226
FUEL CUT VALVE (FCV) INSPECTION . . . . . F226
FICD SOLENOID VALVE NO.1, NO.2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F227
TIMER CONTROL VALVE (TCV)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F228
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . F229
EXHAUST SYSTEM INSPECTION . . . . . . . . . F229
EXHAUST SYSTEM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F229
EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F231
ROLLOVER VALVE INSPECTION . . . . . . . . . F231
EVAPORATIVE CHAMBER INSPECTION . . . F231
EGR VALVE INSPECTION . . . . . . . . . . . . . . . . F232
EGR SOLENOID VALVE INSPECTION . . . . . F232
EGR SOLENOID VALVE (VENT) INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F233

EGR CONTROL SOLENOID VALVE


INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F233
INTAKE SHUTTER VALVE ACTUATOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F234
EGR PIPE, EGR VALVE REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . F234
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F237
COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . F237
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F239
POWERTRAIN CONTROL MODULE (PCM)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F241
MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F249
INTAKE AIR TEMPERATURE (IAT) SENSOR
NO.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . F250
NE SENSOR INSPECTION . . . . . . . . . . . . . . . F250
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION . . . . . . . . . . . . . . . . . F251
FUEL TEMPERATURE SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F251
PUMP SPEED SENSOR INSPECTION . . . . F252
CONTROL SLEEVE (CS) SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . F252
TIMER POSITION SENSOR INSPECTION . F253
INJECTION PUMP EPROM INSPECTION . F253
TDC SENSOR REMOVAL/INSTALLATION . F254
TDC SENSOR INSPECTION . . . . . . . . . . . . . F254
EGR VALVE POSITION SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . F255
BOOST SENSOR INSPECTION . . . . . . . . . . F255
PCM CONTROL RELAY INSPECTION . . . . F256
ACCELERATOR POSITION SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . F256
ACCELERATOR POSITION SENSOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . F256
IDLE SWITCH INSPECTION . . . . . . . . . . . . . F257
IDLE SWITCH ADJUSTMENT . . . . . . . . . . . . F258
CONTROL LEVER POSITION SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . F259
CLUTCH SWITCH INSPECTION . . . . . . . . . F260
NEUTRAL SWITCH INSPECTION . . . . . . . . F261
ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . F262
DTC READING PROCEDURE . . . . . . . . . . . . . F262
AFTER REPAIR PROCEDURE . . . . . . . . . . . . F262
OBD READ/CLEAR DIAGNOSTIC TEST
RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F266
OBD PARAMETER IDENTIFICATION (PID)
ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F266
ONBOARD DIAGNOSTIC TEST . . . . . . . . . . F267
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . F2118
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . F2118
INTERMITTENT CONCERN
TROUBLESHOOTING . . . . . . . . . . . . . . . . . F2118
TROUBLESHOOTING ITEM TABLE . . . . . . . F2120
QUICK DIAGNOSIS CHART . . . . . . . . . . . . . F2121
SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . F2151

F21

ENGINE TUNE-UP
2. Verify that the idle speed is within the specification.

ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATION
WL/WLTURBO
1. Warm up the engine to normal operating
temperature.
2. Turn the all electrical loads off.
3. Connect a tachometer.

Specification
General (L.H.D.) : 760800 (780$20) rpm
Europe and UK : 700740 (720$20) rpm
Caution
D Turning the idle switch (Europe and UK
only) with its connector connected can
break the harness. Be sure to disconnect
the connector when turning the idle switch
more than one rotation.

ENGINE TUNE-UP PREPARATION WL3/WLT3


(EURO 3 REGULATION MODELS)
1. Warm up the engine to normal operating
temperature.
2. Shift the transmission into neutral (MT) or P range
(AT).
3. Turn off all electrical loads.
4. Turn on the test mode.

3. If not as specified, loosen the idle switch locknut


and adjust the idle speed by turning the idle switch.
LOCKNUT
11.814.7 Nm
{120150 kgfcm,
104130 inlbf}

Caution
D Connecting to the wrong DLC terminal may
cause a malfunction. Carefully connect only
to the specified terminal.

IDLE SWITCH

Connect DLC terminal TEN to the body ground


using a jumper wire.

4. After adjusting the idle speed, tighten the locknut


securely.
WL3/WLT3 (EURO 3 REGULATION MODELS)
1. Perform Engine tune-up preparation.
2. Verify that the idle speed is within the specification.
Specification
695745 (720 25) rpm

XME3908W005

D If not as specified, inspect the following parts.


Accelerator position sensor
ECT sensor
TDC sensor
Pump speed sensor
D If the parts are normal, replace the PCM.
3. Turn off the test mode.
Disconnect the jumper wire.

IDLE SPEED ADJUSTMENT


WL
1. Perform Engine tune-up preparation.
2. Verify that the idle speed is within the specification.
Specification
700740 (720$20) rpm
3. If not within the specification, adjust the idle speed
by turning the IAS (idle adjustment screw).
LOCKNUT
5.98.8 Nm
{6090 kgfcm,
5378 inlbf}

IAS

IDLE-UP SPEED ADJUSTMENT


WL / WL Turbo
1. Perform Engine tune-up preparation.
2. Turn all electrical loads off in neutral shift position.
3. Apply vacuum of 53.3 kPa {400 mmHg, 15.8
inHg} or over to actuator B, and measure the
idle-up speed.
WL

ADJUSTING
SCREW B
ADJUSTING
SCREW C

LOCKNUT B

4. After adjusting the idle speed, tighten the locknut


securely.
ACTUATOR A

WL Turbo
1. Perform Engine tune-up preparation.

ACTUATOR B

F22

ENGINE TUNE-UP
WL, WL Turbo
ADJUSTING
SCREW B

ADJUSTING
SCREW C

LOCKNUT B

ACTUATOR A
ACTUATOR B

Specification
12001500 (1,350$150) rpm
4. If not within the specification, do as follows;
Loosen the locknut B.
Adjust the idle-up speed by turning the
adjusting screw B.
Tighten the locknut B.
Tightening torque
5.98.8 Nm {6090 kgfcm, 5378 inlbf}
5. Release actuator B to atmosphere and apply
vacuum of 53.3 kPa {400 mmHg, 15.8 inHg} or
over to actuator A, and measure the idle-up speed.
Specification
WL vehicle: 805855 (830$25) rpm
WL Turbo, WL (Europe only):
825875 (850$25) rpm
6. If not as specified, adjust the idle-up speed by
turning adjusting screw C.
WL3/WLT3 (EURO 3 REGULATION MODELS)
1. Perform Engine tune-up preparation.
2. Inspect the idle-up speed.
Verify that the idle-up speed is within the
specification under the following load condition.
(Excludes temporary idle speed drop just after
the electrical loads turn on.)
D If not as specified, replace the PCM.
Specification
Idle-up speed (rpm)
Load condition
A/C ON

Neutral (MT)
P range (AT)
725775 (750 25)

F23

ENGINE TUNE-UP
INJECTION TIMING ADJUSTMENT

6. Turn the crankshaft counterclockwise to approx.


30 BTDC. (Align the SST installation hole on the
crankshaft pulley.)
7. Turn the crankshaft lightly right and left, and verify
that the dial gauge indicator does not move. Then
set the indicator to 0 mm {0 in}.
8. Turn the crankshaft clockwise to position the
indicator pin to 10 ATDC (white mark) and read
the dial indicator.

Warning
D Fuel vapor is hazardous. It can very easily
ignite, causing serious injury and damage.
Always keep sparks and flames away from
fuel.
D Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate
skin and eyes. To prevent this, always
observe the Fuel Line Safety Procedures,
Fuel Hose Installation.

INDICATOR PIN
BTDC 0
(YELLOW MARK)

Caution
D After tightening the FIP mounting nuts and
bolt after loosening them, be sure to
inspect the timing belt tension. If the belt
tension is not inspected, the timing belt and
the camshaft may become damaged. (Refer
to Section B2, TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt
Installation Note.)
1. Remove the injection pipes (Refer to FUEL
SYSTEM, FUEL INJECTION PUMP (FIP)
REMOVAL/INSTALLATION.)
2. Remove the cooling fan (Refer to Section E,
COOLING FAN, COOLING FAN
REMOVAL/INSTALLATION.)
3. Turn the crankshaft pulley at slow rotation to align
the timing mark (BTDC 0 : yellow mark) with
indicator pin.

ATDC 10 (WHITE MARK)

Specification
0.951.05 mm {0.0380.041 in}
(1.0$0.05 mm {0.039$0.019 in})
9. If not as specified, adjust by loosening the FIP
mounting nut and bolt and turn the FIP.
10. Tighten the FIP mounting nuts and then the bolt.
Tightening torque
1925 Nm {1.92.6 kgfm, 1418 ftlbf}
MOUNTING NUT

INDICATOR PIN
BTDC 0
(YELLOW MARK)

MOUNTING BOLT
ATDC 10 (WHITE MARK)

4. Remove the hydraulic head plug from the injection


pump.
5. Mount the SST into the plug hole on the hydraulic
head so that the dial indicator probe touches the
plunger end of the pump and the dial indicator
indicates approx. 2.0 mm {0.079 in}.
49 9140 074

11. Remove the SST.


12. Install the hydraulic head plug and a new gasket.
Tightening torque
1419 Nm {1.42.0 kgfm, 1114 ftlbf}
13. Connect the injection pipes. (Refer to FUEL
SYSTEM, INJECTION NOZZLE
REMOVAL/INSTALLATION.)
14. Bleed the air from the fuel filter. (Refer to FUEL
SYSTEM, FUEL FILTER AIR BLEEDING.)
15. Inspect for fuel leakage.
16. Check the timing belt tension. (Refer to Section B2,
TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt Installation
Note.)

F24

INTAKE-AIR SYSTEM

INTAKE-AIR SYSTEM
VACUUM HOSE ROUTING DIAGRAM
TO POWER
BRAKE UNIT

WL

FICD SOLENOID
VALVE No.1
FICD SOLENOID
VALVE No.2

FICD ACTUATOR

VACUUM PUMP

WL TURBO

TO POWER
BRAKE UNIT
FICD SOLENOID
VALVE No.2

TO RFW
ACTUATOR

4WD ONLY
FICD SOLENOID
VALVE No.1

EGR VALVE

EGR SOLENOID
VALVE

FICD ACTUATOR

VACUUM PUMP

F25

INTAKE-AIR SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)

ZCF4010W004

F26

INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
Warning
D When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the intake-air system.
WL
1. Disconnect the negative battery cable.
2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

7.910.7 Nm
{80110 kgfcm,
7095 inlbf}

18.725.4
{1.92.6,
13.818.8}
2.02.9 Nm
{2030 kgfcm, 1826 inlbf}

2.02.9 Nm
{2030 kgfcm,
1826 inlbf}
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}

18.725.4
{1.92.6,
13.818.8}

8.912.7 Nm
{90130 kgfcm,
79112 inlbf}

7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
Nm {kgfm, ftlbf}

Fresh-air duct

FICD solenoid valve No.1

Air cleaner

FICD solenoid valve No.2

Air hose

FICD solenoid valve bracket

Resonance chamber

Intake manifold

Air intake pipe

F27

INTAKE-AIR SYSTEM
WL Turbo
1. Disconnect the negative battery cable.
2. Drain the engine coolant from radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT
REPLACEMENT.)
3. Remove the front mud guard. (Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL
REMOVAL/INSTALLATION.)
4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Refill the engine coolant to radiator.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
STEP 1

4.9 Nm {50 kgfcm, 43 inlbf}

4.9 Nm {50 kgfcm, 43 inlbf}

8.912.7 Nm
{90130 kgfcm,
79112 inlbf}

2.02.9 Nm
{2030 kgfcm, 1826 inlbf}

7.911.7 Nm
{80120 kgfcm,
70104 inlbf}

7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
4.9 Nm
{50 kgfcm, 43 inlbf}

7.911.7 Nm
{80120 kgfcm,
70104 inlbf}

8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}

Fresh-air duct

Air intake pipe

Air cleaner

Air hose

Air intake hose

Charge air cooler

Air hose

Air hose

F28

INTAKE-AIR SYSTEM

STEP 2

1925
{1.92.6, 1418}

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

1925
{1.92.6, 1418}

1925 {1.92.6, 1418}


1925 {1.92.6, 1418}

Nm {kgfm, ftlbf}

FICD solenoid valve No.1

FICD solenoid valve bracket

FICD solenoid valve No.2

Air intake pipe

EGR solenoid valve

Intake manifold

F29

INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTION
Wastegate Actuator Inspection
Caution
D Compressed air used in the workshop is
highly pressurized and can damage the
actuator. Adjust the air pressure with a
transformer, and inspect the actual
pressure by using an air blower before
actual use. Stop blowing air if the rod
moved.

MIRROR
TURBOCHARGER

4. Inspect all fins of compressor wheel while rotating


the compressor wheel by hand.
5. If the compressor wheel is interfering with the
housing, it is likely that more than two fins are
damaged, cracked or bent. Replace the
turbocharger.
Note
D If scratches are found inside the housing but
the fins are okay, the turbocharger is okay.
Scratches are made in the turbocharger made
by factory.

1. Disconnect the air hose of the wastegate actuator


on the compressor housing side.
2. Apply the compressed air using the air gun.
3. Note the air pressure when the wastegate actuator
is moved.
Specification
107115 kPa
{1.091.18 kgf/cm2, 15.516.8 psi}
WASTEGATE
ACTUATOR

ROD

4. If not within the specification, replace the


turbocharger. (Refer to EXHAUST SYSTEM,
EXHAUST SYSTEM REMOVAL/INSTALLATION.)

Turbine Wheels Inspection


1. Remove the air hose. (Refer to INTAKE-AIR
SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Remove the joint pipe. (Refer to EXHAUST
SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
3. Set the small mirror as shown and inspect the
turbine wheel from view B.
Note
D To make work accurate, use a penlight to
inspect.

Compressor Wheels Inspection


1. Remove the air hose. (Refer to INTAKE-AIR
SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Remove the joint pipe. (Refer to EXHAUST
SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
3. Set the small mirror as shown and inspect the
compressor wheel from view A.

MIRROR

Note
D To make work accurate, use a penlight to
inspect.

TURBOCHARGER

4. Inspect all fins of turbine wheel while rotating the


turbine wheel by hand.

F210

INTAKE-AIR SYSTEM
5. If the turbine wheel is interfering with the housing,
it is likely that one or more fins are damaged,
cracked or bent. Replace the turbocharger.

Glow plug installation note


1. Tighten the glow plug it at least one pitch by hand,
and continue tightening with a tool.
Glow plug cleaning before installation note
WL3 / WLT3 (Euro 3 Regulation Models)

Note
D Grinding marks on the shaft are normal. This
mark is for adjusting the shaft balance at the
factory.

Caution
D Carbon on the glow plug can damage the
glow plug and engine. Remove carbon on
the glow plug and fitting holes before
installing the glow plug.
1. Wrap tape on both a 5.5 mm and a 5.7 mm drills,
starting from the tip to a point 50 mm from the tip.

GRINDING MARK

GLOW PLUG REMOVAL/INSTALLATION


Caution
D Do not damage the heated section of the
glow plug.
D Do not reuse a glow plug that has been
dropped over a height of 10 cm, even when
there are no scratches and resistance is
normal (0.5 ohms at normal temperature).
D Do not remove the glow plug unless you
are replacing it.
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

ZCF4010W002

2. Push in the 5.5 mm drill until the section covered


with tape is fully inserted.
3. Turn the drill by hand to remove the carbon on the
fitting holes.
4. Repeat steps 2. and 3. for the 5.7 mm drill.
GLOW PLUG INSPECTION
WL/ WLT models
1. Remove the glow plug cord.
2. Inspect the resistance between the glow plug
terminal and the cylinder head.
Specification
Glow plug resistance
Approx. 0.75 [20 C {68 F}]
GLOW PLUG

ZCF4010W001

Glow plug cord

Glow plug
(SeeGlow plug removal note)
(SeeGlow plug installation note)
(SeeGlow plug cleaning before installation note)

Glow plug removal note


1. When removing the glow plug, first loosen it at
least one pitch using a tool, then loosen by hand.

3. If not as specified, replace the glow plug.

F211

INTAKE-AIR SYSTEM
GLOW PLUG INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
1. Remove the glow plug cord. (SeeGLOW PLUG
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the glow plug
terminal and the cylinder head using an ohmmeter.

GLOW PLUG RELAY INSPECTION


System Inspection
1. Carry out the Glow system inspection. (Refer to
TROUBLESHOOTING, SYSTEM INSPECTION,
Glow System Inspection.)
2. If not as specified, perform the further inspection
for the glow plug relay.
Continuity Inspection
Note
D Perform the following test only when directed.
1. Remove the glow plug relay.
2. Inspect for continuity between terminals C and D of
the glow plug relay under the following conditions.

YYJ4010W105

D If there is no continuity, replace the glow plug.

Glow plug resistance


Approx. 0.5 ohm [20C {68F}]
3. Install the glow plug cord.
GLOW PLUG RELAY REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove glow plug relay.
3. Install the glow plug relay.

: Continuity

8.912.7 Nm
{90130 kgfcm,
79112 inlbf}

GLOW PLUG
RELAY

Step

B+

GND

3. If there is no continuity, replace the glow plug relay.


(Refer to GLOW PLUG RELAY
REMOVAL/INSTALLATION.) If as specified but the
System Inspection is failed, inspect following:
Open circuit
D Power circuit (Glow plug relay connector terminal A
(1-pin: R/B) and battery)
D Power circuit (Glow plug relay connector terminal
A
123456567
(2-pin) and PCM connector terminal O)
D GND circuit (Glow plug relay connector terminal A
(1-pin: R) and glow plug cord)
D GND circuit (Glow plug relay connector terminal B
(2-pin) and engine GND)
D Signal circuit (Glow plug relay connector terminal A
(1-pin: R) and PCM connector terminal I)

4. Connect the negative battery cable.

Short circuit
D Glow plug relay connector terminal A (1-pin: R/B)
and battery to GND.
D Glow plug relay connector terminal A (2-pin) and
PCM connector terminal O to GND.
D Glow plug relay connector terminal A (1-pin: R)
and PCM connector terminal I to GND.
4. Repair or replace faulty areas.
5. Install the glow plug relay.

F212

INTAKE-AIR SYSTEM
GLOW PLUG CORD INSPECTION
1. Remove the glow plug cord. (Refer to GLOW
PLUG REMOVAL/INSTALLATION.)
2. Verify that the glow plug cord is not broken or bent.
3. Verify there is continuity at both ends of the glow
plug cord.
4. If there is no continuity, replace the glow plug cord.

Except General (R.H.D.)

ACCELERATOR PEDAL REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the column cover. (Refer to Section N,
MANUAL STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
WL/ WLT models
General (R.H.D.)
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

R
1925
{1.92.6,
1418}

1925
{1.92.6, 1418}

R
5.0 Nm {50 kgfcm, 44
inlbf}

Idling knob

Idling cable

Brake switch connector

Accelerator cable
+ Installation Note

Spring pin

Clevis pin

E clip

Pin

Bushing

10

Push rod

11

Clevis

12

Nut

13

Nut

14

Pedal component
+ Installation Note

Nm {kgfm, ftlbf}

F213

Accelerator cable
+ Installation Note

Accelerator pedal

INTAKE-AIR SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
R.H.D.

Pedal Component Installation Note


D Carry out the BRAKE PEDAL HEIGHT
INSPECTION procedure after installing the pedal
component. (Refer to Section P, BRAKE PEDAL
HEIGHT INSPECTION.)
D Carry out the CLUTCH PEDAL INSPECTION
procedure after installing the pedal component.
(Refer to Section H, CLUTH PEDAL
INSPECTION/ADJUSTMENT.)
Accelerator Cable Installation Note
D Carry out the ACCELERATOR CABLE
INSPECTION/ADJUSTMENT procedure after
installing the accelerator cable. (Refer to
ACCELERATOR CABLE
INSPECTION/ADJUSTMENT.)
ACCELERATOR PEDAL COMPONENT
DISASSEMBLY/ASSEMBLY
WL3 / WLT3 (Euro 3 Regulation Models)
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

ZCF4010W013

L.H.D.

ZCF4010W005

Brake switch connector

Idle switch connector

Accelerator position sensor connector

Spring pin

Clevis pin

E clip

Pin

Bushing

Push rod

10

Clevis

11

Nut

12

Nut

13

Pedal component (See NO TAG Pedal component


installation note)

14

Accelerator pedal component

ZCF4010W006

F214

Accelerator pedal

Idle switch
(SeeNO TAG IDLE SWITCH ADJUSTMENT)

Accelerator position sensor


(See NO TAG ACCELERATOR POSITION
SENSOR ADJUSTMENT)

INTAKE-AIR SYSTEM
ACCELERATOR CABLE
INSPECTION/ADJUSTMENT
1. Warm up the engine, then turn the engine switch
off.
2. Measure the free play of the accelerator cable.

LOCKNUT

Free play
13 mm {0.040.11 in}
3. If not as specified, adjust by turning locknut.
IDLING KNOB, IDLING CABLE INSPECTION
General (R.H.D.)
1. Verify that the accelerator pedal is in the idling
position, when the idling knob is not turned.
2. Verify that the accelerator pedal moves in the
direction that engine speed increases, when the
idling knob is turned to the right.
3. Verify that the accelerator pedal returns to the
idling position when the idling knob is turned to the
left.

IDLING KNOB

F215

FUEL SYSTEM

FUEL SYSTEM
BEFORE REPAIR PROCEDURE
Warning
D Fuel vapor is hazardous. It can very easily
ignite, causing serious injury and damage.
Always keep sparks and flames away from
fuel.
D Fuel in the fuel system is under high pressure

when the engine is not running.


Warning
D Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate
skin and eyes. To prevent this, always
complete the following Fuel Line Safety
Procedures.
Fuel Line Safety Procedures
D Avoid fuel line spills and leaks by completing the
following procedures.
(1) Remove the fuel-filler cap and release the
pressure in the fuel tank.
(2) When disconnecting a fuel hose, wrap a rag
around it to protect against fuel leakage.
(3) Plug the fuel hose after removal.
AFTER REPAIR PROCEDURE
Warning
D Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. When installing the
fuel hose, observe Fuel Hose Installation
described below.
Fuel Hose Installation
D Verify that there is no damage or deformation on
the fuel hose and fuel pipe when installing.

F216

FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
Warning
D Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire
may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
1. Disconnect the negative battery cable.
2. Complete the BEFORE REPAIR PROCEDURE. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
3. Remove the drain plug and drain the fuel from the fuel tank.
4. Remove the rear flap.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Complete the AFTER REPAIR PROCEDURE. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
STRETCH CAB 2WD, DOUBLE CAB 2WD
1.12.1 Nm {1122 kgfcm, 1019 inlbf}

1.12.1 Nm {1122 kgfcm, 1019 inlbf}

7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}

WITH BOX

1.12.1 Nm
{1122 kgfcm,
1019 inlbf}

SEAL
RUBBER
R

2.54.6 Nm
{2547 kgfcm,
2240 inlbf}
2.53.5 Nm
{2536 kgfcm,
2226 inlbf}

11.816.6 Nm
{120170 kgfcm,
105147 inlbf}
11.816.6 Nm
{120170 kgfcm,
105147 inlbf}

1622
{1.62.3, 1216}

1622
{1.62.3, 1216}

1.12.1 Nm
{1122 kgfcm,
1019 inlbf}

WITHOUT BOX

3246
{3.24.7, 2433}

EUROPE

DRAIN PLUG
2632 {2.63.3, 1923}
3246 {3.24.7, 2433}

EXCEPT EUROPE
Nm {kgfm, ftlbf}

F217

FUEL SYSTEM

STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB

1.12.1 Nm {1122 kgfcm, 1019 inlbf}


1.12.1 Nm {1122 kgfcm, 1019 inlbf}

SEAL
R
RUBBER
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

R
WITH BOX

1.12.1 Nm
{1122 kgfcm,
1019 inlbf}

R
2.54.6 Nm
{2547 kgfcm,
2240 inlbf}
2.53.5 Nm
{2536 kgfcm,
2226 inlbf}

11.816.6 Nm
{120170 kgfcm,
105147 inlbf}
11.816.6 Nm
{120170 kgfcm,
105147 inlbf}

1622
{1.62.3, 1216}
1.12.1 Nm
{1122 kgfcm,
1019 inlbf}

WITHOUT BOX

1622
{1.62.3, 1216}

3246
{3.24.7, 2433}

EUROPE
DRAIN HOSE
2632 {2.63.3, 1923}

3246 {3.24.7, 2433}

EXCEPT EUROPE
Nm {kgfm, ftlbf}

Evaporative chamber (If equipped)

Joint hose
+ Installation Note

Evaporative hose
+ Installation Note

Fuel gauge sender unit

Breather hose
+ Installation Note

Rollover valve

10

Fuel-filler pipe

3
4

Under guard

11

Dust cover

Fuel hose
+ Installation Note

12

Fuel inlet pipe

Fuel tank

13

Check valve (twoway)

14

Evaporative chamber

F218

FUEL SYSTEM
Evaporative Hose Installation Note
D Fit each hose onto the respective fittings within the
specification, and install clamps as shown.
Length
Evaporative hose: 25 mm {0.98 in}

912 mm
{0.360.47 in}

10 mm {0.39 in}

912 mm
{0.360.47 in}

VIEW A

EVAPORATIVE HOSE

Fuel Hose Installation Note


D Fit each hose onto the respective fittings within the
specification, and install clamp as shown.
Length
Fuel hose: 25 mm {0.98 in}

VIEW B

FUEL FILTER DISASSEMBLY/ASSEMBLY


1. Disconnect the negative battery cable.
2. Complete the BEFORE REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Disassemble in the order indicated in the table.
4. Assemble in the reverse order of removal.
5. Complete the AFTER REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, AFTER REPAIR
PROCEDURE.)
6. Bleed air from the fuel filter. (Refer to FUEL
SYSTEM, FUEL FILTER AIR BLEEDING.)
7. Start the engine and verify that fuel does not leak
from the fuel system.
8. If fuel leaks, reassemble the fuel filter.
WITH FUEL
WARMER

10 mm {0.39 in}

1925 {1.92.6, 1418}

WITHOUT FUEL WARMER

FUEL HOSE

Breather Hose Installation Note


D Fit each hose onto the respective fittings within the
specification, and install clamp as shown.

Nm {kgfm, ftlbf}

Length
Breather hose: 25 mm {0.98 in}

10 mm {0.39 in}

BREATHER HOSE

Joint Hose Installation Note


D Fit the joint hose onto the respective fittings within
the specification, and install clamps as shown.
Length
Joint hose: 35 {1.4 in}

F219

FUEL SYSTEM

Connector

Fuel hose

Priming pump

Fuel filter
+ Assembly Note

Sedimentor switch
+ Assembly Note

Drain plug

Fuel warmer

SEDIMENTOR SWITCH INSPECTION


Continuity Inspection
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Drain fuel from the fuel filter.
(Refer to FUEL SYSTEM, SEDIMENTOR WATER
DRAINING.)
3. Remove the sedimentor switch.
4. Inspect continuity of the sedimentor switch by
using an ohmmeter.

Sedimentor Switch Assembly Note


D Apply a small amount of fuel to a new O-ring.
Tighten the sedimentor switch enough to the fuel
filter by hand.
Fuel Filter Assembly Note
D Apply a small amount of fuel to the fuel filter
O-ring. Tighten the fuel filter approx. 3/4 by hand
after the O-ring contacts the priming pump.

Float

Continuity

Up

Yes

Down

No
UP
DOWN

FUEL GAUGE SENDER UNIT


REMOVAL/INSTALLATION
(Refer to FUEL SYSTEM, FUEL TANK
REMOVAL/INSTALLATION)

FLOAT

FUEL GAUGE SENDER UNIT INSPECTION


(Refer to Section T, WARNING AND INDICATOR
SYSTEM, FUEL GAUGE SENDER UNIT
INSPECTION.)
FUEL FILTER AIR BLEEDING
Caution
D Continuously cranking the engine for over
30 seconds can damage the battery and the
starter.

5. If not as specified, replace the sedimentor switch.


If as specified, inspect following:
Open circuit
D GND circuit (Sedimentor switch connector
terminal B and body GND)
D Power circuit (Sedimentor switch connector
terminal A and engine switch connector
terminal C)

D Repeat cranking the engine for 30 seconds and

stop for 510 seconds until the engine starts.

SEDIMENTOR SWITCH

SEDIMENTOR WATER DRAINING


1. Disconnect the negative battery cable.
2. Complete the BEFORE REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Loosen the drain plug located at the bottom of the
fuel filter.
4. Pump the priming pump and drain the water.
5. After all the water has been drained, tighten the
drain plug.
6. Complete the AFTER REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, AFTER REPAIR
PROCEDURE.)
7. Reconnect the negative battery cable.

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

ENGINE SWITCH
A

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

F220

FUEL SYSTEM
pump auxiliary parts are possibly
malfunctioning:

Short circuit
D GND circuit (Sedimentor switch connector
terminal B and body GND to power circuit)
D Power circuit (Sedimentor switch connector
terminal A and engine switch connector
terminal C to GND)

1. Electronic governor
2. Timer position sensor
3. Control sleeve (CS) sensor
4. Fuel temperature sensor
5. Timer control valve (TCV)

6. Repair or replace faulty areas.


7. Install the sedimentor switch.
8. Reconnect the negative battery cable.
9. Bleed air from the fuel filter.(Refer to FUEL
SYSTEM, FUEL FILTER AIR BLEEDING.)

Location of the connectors on the injection pump

FUEL WARMER INSPECTION


With fuel warmer
1. Disconnect the negative battery cable.
2. Complete the BEFORE REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Remove the fuel warmer. (Refer to FUEL
SYSTEM, FUEL FILTER
DISASSEMBLY/ASSEMBLY.)
4. Verify that the resistance between terminal A and
the fuel warmer body is within the specification
when vacuum of 26.640.0 kPa
{200300mmHg, 7.911.8 inHg} is applied
to port A of the fuel warmer.

ZCF4012W003

Specification
Water temperature C {F}

Resistance ()

20 {68}

0.51.5

5. If not as specified, replace the fuel warmer.


FUEL INJECTION PUMP (FIP) INSPECTION
Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.
D Consult your distributor for disassembly if any FIP

internal parts are possibly malfunctioning.


WL3 / WLT3 (Euro 3 Regulation Models)
Injection pump auxiliary parts inspection
Caution
D Consult authorized BOSCH parts distributor
for repair if any of the following injection

F221

FUEL SYSTEM

ZCF4012W007

ZCF4012W005

Terminal

Part name

Terminal

Pump speed sensor (+)

Pump speed sensor ()

TCV ()

TCV (+)

Part name

Fuel temperature sensor ()

CS sensor

CS sensor (+)

CS sensor ()

Electronic governor (+)

FSO solenoid

Fuel temperature sensor (+)

Electronic governor ()

ZCF4012W010

Terminal

Part name

TCV body (+)

TCV body ()

FUEL INJECTION PUMP (FIP)


REMOVAL/INSTALLATION
Caution
D After removing/installing the FIP, be sure to
inspect the timing belt tension. If the belt
tension is not inspected, the timing belt and
the camshaft may become damaged. (Refer
to section B2, TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt
Installation Note.)

ZCF4012W006

Terminal

Part name

Timer position sensor

Timer position sensor ()

Timer position sensor (+)

Injection pump EPROM (VCC)

Injection pump EPROM (DI/DO)

Injection pump EPROM (CLK)

Injection pump EPROM (CS)

Injection pump EPROM (GND)

1. Disconnect the negative battery cable.


2. Complete the BEFORE REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Remove the FICD solenoid valve bracket. (Refer to
INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
4. Remove the air intake pipe. (Refer to INTAKE-AIR
SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
5. Set the No.1 cylinder to TDC.
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.

F222

FUEL SYSTEM
8. Complete the AFTER REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, AFTER REPAIR
PROCEDURE.)
9. Inspect injection timing. (Refer to ENGINE
TUNE-UP, INJECTION TIMING ADJUSTMENT.)
10. Check the timing belt tension. (Refer to Section B2,
TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt Installation
Note.)

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

2.43.4 Nm
{2535 kgfcm,
2230 inlbf}

FIP PULLY
LOCKNUT

INJECTION NOZZLE REMOVAL/INSTALLATION


Caution
D Cover the outlet of the injection pipe and
fuel hose with a rag.
D Catch the fuel with a rag.

5968
{6.07.0,
4450}

A
1925
{1.92.6,
1418}

1. Disconnect the negative battery cable.


2. Complete the BEFORE REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Remove the FICD solenoid valve bracket. (Refer to
INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Complete the AFTER REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, AFTER REPAIR
PROCEDURE.)

A
R

2529
{2.53.0, 1921}

49 S120 215A

1925
{1.92.6, 1418}

Nm {kgfm, ftlbf}

Injection pipe

Accelerator cable

Fuel hose

Connector

Vacuum hose

Timing belt cover


+ Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Cover
Installation Note.

FIP mounting bolt

FIP mounting nut

FIP
+ Removal Note

10

Key

5968 {6.07.0, 4450}


2732
{2.73.3,
2023}

R
R

2.43.4 Nm
{2535 kgfcm,
2230 inlbf}

2529
{2.53.0, 1921}

FIP Removal Note


1. Remove the two FIP pulley mounting bolts.
2. Loosen the FIP pulley locknut.
3. Remove the pulley with the SST.

Nm {kgfm, ftlbf}

F223

Injection pipe

Fuel leak pipe

Fuel leak washer

Injection nozzle
+ Installation Note

FUEL SYSTEM

Nozzle washer

Corrugated gasket
+ Installation Note

D When the nozzle body or the needle valve is

damaged, replace them as a set.


INJECTION NOZZLE INSPECTION

Corrugated Gasket Installation Note


D Install the bead side facing combustion chamber.

Caution
D Fuel and fuel tank used for the nozzle tester
must be kept clean. Otherwise, foreign
material may get stuck between the nozzle
and the nozzle tester, causing damage.

Injection Nozzle Installation Note


D Install each injection nozzle onto the FIP, matching
their identification color rings as shown.

Injection Starting Pressure


1. Connect the injection nozzle to a nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Slowly lower the nozzle tester handle and note the
pressure when injection starts.

INJECTION NOZZLE
FIP

Injection starting pressure


11.412.1 MPa
{116124 kgf/cm2, 16501760 psi} (New)
More than 10.0 MPa
{102 kgf/cm2, 1450 psi} (Inspection)

COLOR RING

INJECTION NOZZLE DISASSEMBLY/ASSEMBLY


4. If the injection starting pressure is not within the
specification, adjust it by installing the correct shim.

Caution
D The injection port is very small so it must
be kept clean. Otherwise, foreign material
may get stuck in the injection nozzle,
causing damage.

Note
D Adding/subtracting 0.02 mm {0.0008 in}
thickness shim increases/decreases the
starting pressure approx. 470 kPa {4.8
kgf/cm2, 68 psi}.

1. Disassemble in the order indicated in the table.


2. Assemble in the reverse order of disassembly.

ADJUSTING SHIM

2949
{3.05.0,
2236}
Nm {kgfm, ftlbf}

Nozzle holder body


+ Disassembly Note

Ring

Shim

Nozzle spring

Spring seat

Spacer

Needle valve
+ Assembly Note

Nozzle body

Retaining nut

Atomization
1. Connect the injection nozzle to the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Lower the handle several times as quickly as
possible so that a pulsating whistling sound is
heard, and note the atomization pattern.
(1) Uniform, proper atomization
(2) Incorrect injection angle and direction
(1)

(2)

Nozzle Holder Body Disassembly Note


D Secure the retaining nut in a vise and remove the
nozzle holder body.
NORMAL

Needle Valve Assembly Note

F224

FAULTY
ANGLE

FAULTY
DIRECTION

FUEL SYSTEM
4. If necessary, disassemble and clean or replace the
injection nozzle.
Nozzle Leakage
1. Connect the injection nozzle to the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Apply 8.8 MPa {90 kgf/cm2, 1,280 psi} pressure to
the injection nozzle, and inspect for fuel leakage
from the nozzle spray port.

CORRECT

4. Remove the needle valve from the nozzle body.


5. Clean the needle valve and the nozzle body with
clean light oil.
6. Verify that the needle valve moves smoothly in the
nozzle body.
7. If not, replace the nozzle assembly.

FUEL SHUT OFF (FSO) SOLENOID INSPECTION


WL3 / WLT3 (Euro 3 Regulation models)
Onvehicle inspection
Continuity inspection

WRONG

4. If fuel leaks, disassemble and clean or replace the


injection nozzle.
Operating Inspection
1. Verify that the needle valve and nozzle body are
not damaged.
2. Verify that the nozzle body is not damaged. Hold
the nozzle body upright and insert approximately
two thirds of the needle valve; then see if the
needle valve drops to the valve seat by its own
weight when released.

Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect for continuity between the terminals under
the following conditions.

NEEDLE VALVE

ZCF4012W008

NOZZLE
BODY

Injection Nozzle Cleaning


1. Inspect the outer and inner surfaces of the injection
nozzle for carbon accumulation.
2. If carbon is observed on the outer surface, remove
it by using a hard wood chip.
3. If carbon is observed inside of the nozzle, remove
it by using a toothpick.

4. Remove the terminal cover of the FSO solenoid.


5. Verify that the resistance between the FSO
solenoid terminal and the FSOsolenoid body is
within the specification.
D If not as specified, replace the FSO solenoid.
D If as specified, but the engine does not start,
perform the following offvehicle inspection.

ZCF4012W009

F225

FUEL SYSTEM
D If as specified, carry out the Circuit
Open/Short Inspection.

Specification
FSO temperature (C {F})

Resistance (ohm)

1333 {55.491.4}

7.59.7

Offvehicle inspection
Operation inspection
1. Remove the FSO solenoid.
2. Connect the battery positive voltage to the FSO
solenoid terminal and ground the FSO solenoid
body.
3. Verify that the valve stem is drawn into the valve.
D If not as specified, replace the FSO solenoid.
D If as specified, carry out the Circuit
Open/Short Inspection.

ZCF4012W004

Specification

ZCF4012W002

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (injection pump connector A terminal
J and PCM connector terminal 4W)

Terminal

Atmospheric
temperature (C {F})

Resistance (ohm)

IL

1828 {64.482.4}

0.580.84

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (Injection pump connector A terminal
I and PCM connector terminal 4x)
D Signal circuit (Injection pump connector A terminal
L and PCM connector terminal 4Y)
Short circuit
D Electronic governor connector terminal L and PCM
connector terminal 4Y to GND.
FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION
Without immobilizer system
1. Disconnect the negative battery cable.
2. Complete the BEFORE REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Remove the FCV.
4. Install in the reverse order of removal.
NUT
2.02.4 Nm
{2025 kgfcm,
1821 inlbf}

ZCF4012W001

Short circuit
D Injection pump connector A terminal J and PCM
connector terminal 4W to GND.

FCV
1525
{1.52.6, 1118}

ELECTRONIC GOVERNOR INSPECTION


WL3 / WLT3 (Euro 3 Regulation models)
Resistance inspection

Nm {kgfm, ftlbf}

Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect for resistance between the terminals under
the following conditions.
D Consult authorized BOSCH parts distributor for
repair if the electronic governor is possibly
malfunctioning.

FUEL CUT VALVE (FCV) INSPECTION


Without immobilizer system
On-vehicle Inspection
Note
D Perform the following test only when directed.
1. With the engine idling, disconnect the FCV
connector and verify that the engine stops.

F226

FUEL SYSTEM
2. If the engine does not stop, carry out the following
inspection.
Off-vehicle Inspection
1. Disconnect the negative battery cable.
2. Remove the FCV.
3. Connect the battery positive voltage to the FCV
terminal and GND the FCV body,
4. Verify that the FCV stem is drawn into the FCV.

2. Remove the FICD solenoid valve No.1, No.2.


(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION.)
3. Inspect for airflow between ports of the solenoid
valve.
: Continuity
: Airflow
Terminal

Step

Port

B+

GND

1
2

B
GND

A
B

B+

C
123456567

5. Replace the FCV if not as specified.


If as specified, inspect following:
Open circuit
D GND circuit (FCV body and engine switch
connector terminal IG1)
D Power circuit (FCV connector terminal and
engine switch connector terminal IG1)

AIR FILTER

4. If not as specified, replace the faulty FICD solenoid


valve.
If as specified but the System Inspection is failed,
inspect following:
Vacuum hose improper routing, kinks or leakage.
Open circuit
D GND circuit (FICD solenoid valve No.1 connector
terminal B and PCM connector terminal C)
D GND circuit (FICD solenoid valve No.2 connector
terminal B and PCM connector terminal P)
D Power circuit (FICD solenoid valve No.1 connector
terminal A and engine switch connector terminal
IG1)
D Power circuit (FICD solenoid valve No.2 connector
terminal A and engine switch connector terminal
IG1)

ENGINE SWITCH
A

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

ENGINE SWITCH

Short circuit
D GND circuit (FCV body and engine switch
connector terminal IG1 to GND)
D Power circuit (FCV connector terminal and
engine switch connector terminal IG1 to GND)
6. Repair or replace faulty areas.
7. Install the FCV.
8. Reconnect the negative battery cable.

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

FICD SOLENOID VALVE NO.1, NO.2 INSPECTION


System Inspection
1. Carry out the FICD System Inspection. (Refer to
TROUBLESHOOTING, SYSTEM INSPECTION,
FICD System Inspection.)
2. If not as specified, perform the further inspection
for the FICD solenoid valve No.1, No.2.
Airflow Inspection
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.

Short circuit
D GND circuit (FICD solenoid valve No.1 connector
terminal B and PCM connector terminal IG1)
D GND circuit (FICD solenoid valve No.2 connector
terminal B and PCM connector terminal P)
D Power circuit (FICD solenoid valve No.1 connector
terminal A and engine switch connector terminal
IG1 to GND)
D Power circuit (FICD solenoid valve No.2 connector
terminal A and engine switch connector terminal
IG1 to GND)
5. Repair or replace faulty areas.

F227

FUEL SYSTEM
D If no continuity is detected, perform resistance
inspection.

6. Install the FICD solenoid valve No.1, No.2.


7. Reconnect the negative battery cable.
TIMER CONTROL VALVE (TCV) INSPECTION
Europe and UK
1. Carry out the Timer Control Valve (TCV) Control
Inspection. (Refer to TROUBLESHOOTING,
SYSTEM INSPECTION, Timer Control Valve
(TCV) Control Inspection.)
2. If not as specified, perform the further inspection
for the TCV.
Continuity Inspection
WL / WLT Models

ZCF4012W004

Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the FIP connector (8pin terminal).
3. Verify that there is continuity between the FIP
connector terminal D and TCV body.
FIP

Resistance inspection
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector D.
D Consult authorized BOSCH parts distributor for
repair if the timer control valve (TCV) is
possibly malfunctioning.
D If as specified, carry out the Circuit
Open/Short Inspection.
Specification

Terminal

Atmospheric
temperature (C {F})

Resistance (ohm)

AB

1030 {5086}

10.311.7

COMPONENT SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

4. If not as specified, send TCV to a distributor for


replacement. If the TCV is okay, but PCM terminal
voltage is out of specification, inspect as follows
and repair or replace as necessary.
Open circuit
D Power circuit (FIP connector terminal D and
PCM connector terminal H)
Short circuit
D FIP connector terminal D and PCM connector
terminal H to GND
5. Repair or replace faulty areas.
6. Reconnect the FIP connector.
Euro3 Regulation models
Note
D Perform the following test only when directed.

ZCF4012W010

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (Injection pump connector D terminal
A and PCM control relay connector terminal D)
D Signal circuit (Injection pump connector D terminal
B and PCM connector terminal 4U)
Short circuit
D Injection pump connector D terminal B and PCM
connector terminal 4U to GND.

1. Disconnect the negative battery cable.


2. Disconnect the injection pump connector A.
3. Inspect for continuity between the terminals B and
C using an ohmmeter.

F228

EXHAUST SYSTEM

EXHAUST SYSTEM
EXHAUST SYSTEM INSPECTION
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
2. If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION
Warning
D When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
WL

TURKEY and GENERAL


(R.H.D., L.H.D.)

EUROPE and UK

Nm {kgfm, ftlbf}

Tail pipe

Front pipe

Main silencer

Exhaust manifold insulator

Exhaust manifold

D Middle pipe (Turkey and General (R.H.D.,

L.H.D.)
D OC (Europe and UK)

F229

EXHAUST SYSTEM

WL TURBO

EUROPE and UK

TURKEY and GENERAL


(R.H.D., L.H.D.)

Nm {kgfm, ftlbf}

Tail pipe

Joint pipe

Main silencer

Turbocharger
+ Removal Note

Oil pipe
+ Installation Note

Exhaust manifold

D Middle pipe (General (L.H.D.))


D OC (Europe and UK)

Front pipe

Exhaust manifold insulator

F230

EXHAUST SYSTEM, EMISSION SYSTEM


Oil Pipe Installation Note
D Be sure to confirm that the turbocharger is installed
correctly, then install the oil pipe.
Water pipe
D Install the water pipe and tighten to the specified
torque.

EMISSION SYSTEM
ROLLOVER VALVE INSPECTION
1. Remove the rollover valve. (Refer to FUEL
SYSTEM, FUEL TANK
REMOVAL/INSTALLATION.)
2. Blow from port A and verify that there is airflow.

Tightening torque
2435 Nm {2.43.6 kgfm, 1826 ftlbf}
OIL PIPE

WATER PIPE

3. Turn the valve over and blow from port A. Verify


that there is no airflow.

Turbocharger Removal Note


D Do not drop the turbocharger.
D Do not bend the wastegate actuator mounting or
rod.
D Cover the intake, exhaust and oil passages to
prevent dirt or other objects from entering.
A

4. If not as specified, replace the rollover valve.


EVAPORATIVE CHAMBER INSPECTION
If equipped
1. Remove the evaporative chamber. (Refer to FUEL
SYSTEM, FUEL TANK
REMOVAL/INSTALLATION.)
2. Blow from port A and verify that there is airflow
from port B.

3. If not as specified, replace the evaporative


chamber.

F231

EMISSION SYSTEM
EGR VALVE INSPECTION
WL Turbo for Europe and UK
Airflow Inspection

B
GND

Note
D Perform the following test only when directed.
1. Remove the EGR valve.
2. Inspect for airflow between 1 and 2 when vacuum
is applied using a vacuum pump as shown in the
figure.

A
B

B+

AIR FILTER

4. If not as specified, replace the EGR solenoid valve.


If the EGR solenoid valve is okay, but PCM
terminal voltage is out of specification, inspect as
follows and repair or replace as necessary.
D Vacuum hose improper routing, kinks or leakage.
Open circuit
D Power circuit (EGR solenoid valve connector
terminal A and PCM connector terminal 1R)
D GND circuit (EGR solenoid valve connector
terminal B and body GND through common
connector)

Specification WL Turbo for Europe and UK


Vacuum (kPa {mmHg, inHg})

Airflow

Below 21.325.3
{160 190, 6.3 7.4}

Yes

Except above

No

EGR SOLENOID VALVE

Specification WLT3 (Euro 3 Regulation Models)


Vacuum
kPa {mmHg, inHg}

Airflow

Below 30.0 36.6


{225 275,8.9 10.8}

Yes

Except above

No

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

Short circuit
D EGR solenoid valve connector terminal A and PCM
connector terminal 1R.
5. Repair or replace faulty areas.
6. Install the EGR solenoid valve connector.

3. If not as specified, replace the EGR valve.


EGR SOLENOID VALVE INSPECTION
WL Turbo for Europe and UK
Airflow Inspection
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Remove the EGR solenoid valve (Refer to
INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION, WL Turbo.)
3. Inspect for airflow between ports of the solenoid
valve.
: Continuity
Step

Terminal
A

B+

GND

WLT3 (Euro 3 Regulation Models)


1. Inspect airflow between the ports under the
following conditions.
D If not as specified, replace the EGR solenoid
valve (vacuum).
D If as specified, carry out the Circuit
Open/Short Inspection.

: Airflow
Port

ZCF4016W004

1
2

F232

EMISSION SYSTEM

ZCF4016W003

ZCF4016W005

D If as specified, carry out the Circuit


Open/Short Inspection.

ZCF4016W006
ZCF4016W004

ZCF4016W005

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (EGR solenoid valve (vacuum)
connector terminal A and PCM control relay
connector terminal D)
D GND circuit (EGR solenoid valve (vacuum)
connector terminal B and PCM connector terminal
4T)
Short circuit
D EGR solenoid valve (vacuum) connector terminal A
and PCM control relay connector terminal D to
GND

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (EGR solenoid valve (vent) connector
terminal A and PCM control relay connector
terminal D)
D GND circuit (EGR solenoid valve (vent) connector
terminal B and PCM connector terminal 4Q)
Short circuit
D EGR solenoid valve (vent) connector terminal A
and PCM control relay connector terminal D to
GND
EGR CONTROL SOLENOID VALVE INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
1. Inspect airflow between the ports under the
following conditions.
D If not as specified, replace the EGR control
solenoid valve.
D If as specified, carry out the Circuit
Open/Short Inspection.

EGR SOLENOID VALVE (VENT) INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)
1. Inspect airflow between the ports under the
following conditions.
D If not as specified, replace the EGR solenoid
valve (vent).
D If as specified, carry out the Circuit
Open/Short Inspection.

YTA4114W105

ZCF4016W001

F233

EMISSION SYSTEM
D If as specified, carry out the Circuit
Open/Short Inspection.

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (EGR control solenoid valve
connector terminal A and PCM control relay
connector terminal D)
D GND circuit (EGR control solenoid valve connector
terminal B and PCM connector terminal 4I)
Short circuit
D EGR control solenoid valve connector terminal A
and PCM control relay connector terminal D to
GND
INTAKE SHUTTER VALVE ACTUATOR INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
1. Disconnect the vacuum hose from the intake
shutter valve actuator.
2. Connect a vacuum pump to the intake shutter
valve actuator.
3. Apply vacuum and verify that the rod moves.
D If the rod does not move, replace the intake
shutter valve.
Specification
Vacuum
kPa {mmHg, inHg}

Rod movement

Below 5.3 {40, 1.57}

Starts to move

Above 26.6 {200, 7.9}

Fully pulled

YTA4114W105

ZCF4016W002

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (intake shutter solenoid valve
connector terminal A and PCM control relay
connector terminal D)
D GND circuit (intake shutter solenoid valve
connector terminal B and PCM connector terminal
4Z)
Short circuit
D Intake shutter solenoid valve connector terminal A
and PCM control relay connector terminal D to
GND
EGR PIPE, EGR VALVE REMOVAL/INSTALLATION
WL Turbo for Europe and UK
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

ZCF4016W007

INTAKE SHUTTER SOLENOID VALVE INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)
1. Inspect airflow between the ports under the
following conditions.
D If not as specified, replace the intake shutter
solenoid valve.

F234

EMISSION SYSTEM
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

1925
{1.92.6, 1418}

1925
{1.92.6, 1418}
3540
{3.54.0,
2529}
Nm {kgfm, ftlbf}

EGR pipe

EGR valve

WL3 / WLT3 (Euro 3 Regulation Models)


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

ZCF4016W009

EGR pipe

EGR water cooler

EGR valve

Intake shutter valve (WLT-3)

F235

EMISSION SYSTEM
EGR system installation note
1. Temporarily tighten bolts and nuts in order of A to
E.
2. Tighten the bolts and nuts in order of A to E.

ZCF4016W010

F236

CONTROL SYSTEM

CONTROL SYSTEM
COMPONENT PARTS

WL TURBO

WL TURBO

*1:
*2:

Glow indicator light

10

A/C relay

Temperature control dial

11

TCV*2

Engine switch

12

Control lever position sensor*2

PCM

13

Glow plug

FICD solenoid valve No.2

14

NE sensor

FICD solenoid valve No.1

15

Idle switch*2

EGR solenoid valve*1

16

Starter

ECT sensor

17

Glow plug relay

DLC

WL Turbo for Europe and UK


Europe and UK

F237

CONTROL SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)

ZCF4040W045

PCM

14

Timer position sensor

MAF/IAT sensor

15

Control sleeve (CS) sensor

IAT sensor No.2

16

EGR valve position sensor

Boost sensor

17

Glow plug relay

ECT sensor

18

PCM control relay

TDC sensor

19

A/C relay

Accelerator position sensor

20

DLC

Idle switch

21

Battery

Clutch switch

22

A/C switch

10

Fuel temperature sensor

23

Engine switch

11

Pump speed sensor

24

Starter

12

Injection pump EPROM

25

Glow indicator light

13

TCV

26

Neutral switch

F238

CONTROL SYSTEM
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL/INSTALLATION
WL / WLT Models
1. Disconnect the battery negative cable.
2. Remove the drivers side front side trim. (Refer to
Section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

8.912.7 Nm
{90130 kgfcm, 78112 inlbf}

PCM connector

PCM installation nut

PCM

F239

CONTROL SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
1. Disconnect the battery negative cable.
2. Remove the passengers side front side trim.
3. Remove in the order indicated in the table.

ZCF4040W050

Set bolt (with immobilizer)


(SeeSet bolt removal note)
(SeeSet bolt installation note)

PCM cover

PCM connector

PCM

Bracket

F240

CONTROL SYSTEM
Set bolt removal note
1. Using a chisel and a hammer, cut a groove on the
head of the set bolt so that a screwdriver can be
inserted.
2. Loose the set bolt by using an impact screwdriver
or pliers.

5. Install the PCM. (Refer to POWERTRAIN


CONTROL MODULE (PCM)
REMOVAL/INSTALLATION.)
6. Install the drivers side front side trim. (Refer to
Section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)

ZCF4040W051

Set bolt installation note


1. Install new set bolt and tighten it until the neck of
the bolt is cut.

ZCF4040W052

POWERTRAIN CONTROL MODULE (PCM)


INSPECTION
Caution
D The PCM terminal voltages vary with
change in measuring conditions and
vehicle conditions. Always carry out a total
inspection of the input systems, output
systems, and PCM to determine the cause
of trouble. Otherwise, a wrong diagnosis
will be made.
WL / WLT Models
1. Remove the drivers side front side trim. (Refer to
Section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
2. Remove the PCM with the connector connected.
(Refer to POWERTRAIN CONTROL MODULE
(PCM) REMOVAL/INSTALLATION.)
Note
D With the PCM connector connected, body
ground the voltmeter negative () lead and
measure the voltage at each PCM terminal by
inserting the voltmeter positive (+) lead.
3. Measure the voltage of each PCM terminals by
using a voltmeter.
4. If the output voltage is not normal while each input
voltage is normal, inspect the related device
systems. When they are normal, replace the PCM.

F241

CONTROL SYSTEM
Terminal Voltage (Reference)
Europe and UK
S
T
Terminal

A
A*1

B
C

Q
R

Signal

Constant
voltage

System
ground
FICD
control

O
P

Turkey and General (R.H.D. ,L.H.D.)

E C

Connected
to

D Control
lever
position
sensor
D EGR
valve
position
sensor

O M K I G E C A
P N L J H F D B

Test condition

Engine
switch

ON
OFF

Idle

Ground

Constant

FICD solenoid valve


No.1

Idle

Start

ECT

ECT is below 20C {68F}.

Engine
switch
(Starter)

Engine switch is on.

ECT sensor

Engine
switch is on.

While cranking
ECT is 20C {68F}.
After warm-up

Engine
speed
(Input)

NE sensor

A/C
(With A/C)

Temperature
control dial

Engine switch is on.


Idle
Engine
switch is on.

Temperature control dial is


off and fan switch is off.

Temperature control dial is


at position other than off
and fan switch is on.

H
H*1

*1:

Idle (Control
lever open
or close)

Idle switch

Engine
switch is on.

Below
1.0

Action

D Inspect related harness.

D Inspect PCM.
D Inspect related harness.

Approx.
5.0

ECT is above 20C {68F}.


D

Voltage
(V)

Approx.
5.0

Accelerator pedal is depressed.


Accelerator pedal is released.

Europe and UK

F242

Below
1.0
Below
1.0
B+
Below
1.0
Approx.
10
Approx.
3.1
Approx.
0.8
Approx.
0
Approx.
0.05
B+

Below
1.0

B+
Below
1.0

D Inspect related harness.


D Inspect FICD solenoid

valve No.1.
+ FUEL SYSTEM, FICD
SOLENOID VALVE No.1,
No.2 INSPECTION
D Inspect related harness
D Inspect related harness

D Inspect engine coolant

temperature sensor.
+ ECT SENSOR
INSPECTION
D Inspect related harness
D Inspect NE sensor.
+ NE SENSOR
INSPECTION
D Inspect related harness
D Inspect microswitch.
+ Section U, CONTROL
SYSTEM, HEATER
CONTROL UNIT
INSPECTION
D Inspect fan switch.
+ Section U, CONTROL
SYSTEM, HEATER
CONTROL UNIT
INSPECTION
D Inspect related harness

D Inspect idle switch.


+ IDLE SWITCH
INSPECTION
D Inspect related harness.

CONTROL SYSTEM

Terminal

Signal
Glow plug
voltage

Connected
to
Glow plug

Test condition
ECT is below 60C
{140F}.

For less than approx. 15


seconds after turning
engine switch on.
Over approx. 15 seconds
after turning engine switch
on.

ECT is
above 60C
{140F}.

For less than 10 minutes


after starting engine.
Over 10 minutes after
starting engine.
While cranking
For less than approx. 2
seconds after turning engine switch on.
Over approx. 2 seconds
after turning engine switch
on.
While cranking

J*1

L*1

L*2

Power
supply

Control lever position


(Detection)

Engine
switch

Control lever position


sensor

Engine
switch

Engine
switch is on.

Approx.
4.2

Accelerator pedal is fully


closed.

Approx.
0.81.5

Engine
switch

Engine
switch

N*1

Glow indicator light control

A/C control
(With A/C)

Glow indicator light

B+

Idle
OFF

Below
1.0

ON

B+

Engine switch is on.

B+

Idle

B+

A/C is not operating

Engine switch is off.

Below
1.0
Below
1.0

Engine switch is on and within approx. 4.5


sec. (25 C {77 F}).

A/C relay

Over 4.5 seconds (25 C {77 F}) after


turning engine switch on.

B+

Engine switch is on.

B+

Idle

B+

D Inspect engine switch.


+ Section T, POWER
SYSTEM, IGNITION
SWITCH INSPECTION
D Inspect related harness.
D Inspect control lever posi-

tion sensor.
+ CONTROL LEVER
POSITION SENSOR
INSPECTION
D Inspect related harness.
D Inspect related harness.

6.97.1

A/C is not operating


A/C is operating

N*2

B+

Accelerator pedal is fully


open.

A/C is operating
M

Below
1.0

B+

Power
supply

A/C relay

Below
1.0
B+
B+

ON

Engine switch is on.

D Inspect related harness

B+

Below
1.0

Instrument
cluster

Action

Below
1.0

OFF

Engine
speed (Output)

A/C control
(With A/C)

Voltage
(V)
B+

*1:

Europe and UK
*2: Turkey and General (R.H.D., L.H.D.)

F243

Below
1.0

D Inspect engine switch.


+ Section T, POWER
SYSTEM, IGNITION
SWITCH INSPECTION
D Inspect related harness.
D Inspect A/C relay.
+ Section U, CONTROL
SYSTEM, A/C RELAY
INSPECTION
D Inspect related harness.
D Inspect glow indicator

light
+ Section T, WARNING
AND INDICATOR
SYSTEM, WARNING
AND INDICATOR LIGHT
BULB REPLACEMENT
D Inspect related harness.
D Inspect A/C relay.
+ Section U, CONTROL
SYSTEM, A/C RELAY
INSPECTION
D Inspect related harness.

CONTROL SYSTEM

Terminal

Signal
Glow system

Connected
to
Glow plug
relay

Test condition
Engine coolant temperature is below
60C
{140F}.

For less than approx. 15


seconds after turning engine switch on.
Over approx. 15 seconds
after turning engine switch
on.
For less than 10 minutes
after starting engine.
Over 10 minutes after
starting engine.

Engine coolant temperature is


above 60C
{140F}.

FICD
control

FICD solenoid valve


No.2

Idle

B+

Below
1.0

B+
B+

Over approx. 2 seconds


after turning engine switch
on.

Below
1.0

is not at OFF
D Engine coolant temperature is below 60C
{140F}.
D Temperature control dial

D Inspect glow plug relay.


+ INTAKE-AIR SYSTEM,
GLOW PLUG RELAY
INSPECTION
D Inspect related harness.

Below
1.0

For less than approx. 2 seconds after turning engine


switch on.

D Temperature control dial

Action

B+

While cranking

While cranking
P

Voltage
(V)

B+
Below
1.0

D Inspect FICD solenoid

B+

valve No.2.
+ FUEL SYSTEM, FICD
SOLENOID VALVE No.1,
No.2 INSPECTION
D Inspect related harness.

B+

D Inspect TCV.
+ CONTROL SYSTEM,
TIMER CONTROL VALVE
(TCV) INSPECTION
D Inspect related harness.

is not at OFF
D Engine coolant temperature is above 60C
{140F}.
Q
Q*1

Timer
control

TCV

Engine switch is on.


Idle

R*3

EGR valve
control

S
S*1

Diagnostic
test mode

Below
1.0

EGR
solenoid
valve

Engine switch is on.


Idle

Data link
connector
(DLC) (Terminal TEN)

T*1

DTC output

Data link
connector
(DLC) (Terminal FEN)

Below
1.0

Engine
switch is on.

B+

Open terminal TEN

B+

Short terminal TEN

Below
1.0

No DTC output

Below
1.0

DTC output

0B+

*1:

Europe and UK
Turkey and General (R.H.D., L.H.D.)
*3: WL Turbo for Europe and UK
*2:

F244

D Inspect EGR solenoid

valve.
+ EMISSION SYSTEM,
EGR SOLENOID VALVE
INSPECTION
D Inspect related harness.

D Inspect related harness.

D Inspect related harness.

CONTROL SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
Caution
D The PCM terminal voltages vary with change in measuring conditions and vehicle conditions.
Always carry out a total inspection of the input systems, output systems, and PCM to determine the
cause of trouble. Otherwise, diagnosis will be incorrect.
Note
D PIDs for the following parts are not available on
1. Connect the WDS or equivalent to the DLC. (See
this model. Go to the appropriate part
ONBOARD DIAGNOSTIC TEST)
inspection page.
2. Turn the engine switch on.
Electronic governor
3. Measure the value.
Pump speed sensor
D If value is not within the specification, follow the
Injection pump EPROM
instructions in Action column.
EGR control solenoid valve
PID Monitor Table
Monitor item
(Definition)
ACCS (A/C relay)

Unit/
Condition
ON/OFF

ACSW (A/C switch)

ON/OFF

ARPMDES (Target
engine speed)

rpm

BARO (Barometric
pressure in PCM)

kPa Bar psi

ECT (Engine
coolant
temperature)

Inspect following PIDs: TP, ECT,


ACSW, PNP, VS, STARTER.
Inspect A/C relay.
(See Section U)

A/C switch and fan switch is on with


engine switch on: ON
A/C switch is off with engine switch
on: OFF

Inspect refrigerant pressure


switch.
(See Section U)

A/C ON: 750 rpm


Other: 720 rpm

Inspect A/C switch.


(See Section U)

Elevation 0400 m {01310 ft}:


100103 kPa {1.001.03 Bar,
14.514.9 psi}

Replace PCM.

3C

1Q

ECT is 20C {68F}: 20C {68F}


ECT is 85C {185F}: 85C {185F}

Inspect ECT sensor.


(See NO TAG ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
INSPECTION)

1T

Inspect following PIDs: ECT, TP,


IDLE SW, MAF, IAT, RPM,
EGRVP.
Inspect EGR solenoid valve (vent).
(See NO TAG EGR SOLENOID
VALVE (VENT) INSPECTION)

4Q

Inspect following PIDs: ECT, TP,


IDLE SW, MAF, IAT, RPM,
EGRVP.
Inspect EGR solenoid valve (vent).
(See NO TAG EGR SOLENOID
VALVE (VACUUM) INSPECTION)

4T

Engine switch is on: approx. 0.6 V


Idle: above 3.0 V

Inspect EGR valve position


sensor.
(See 55 EGR VALVE POSITION
SENSOR INSPECTION)

1F

Fuel temperature is 20C {68F}:


20C {68F}:

Inspect fuel temperature sensor.


(See 51 FUEL TEMPERATURE
SENSOR INSPECTION)

1L

Fuel temperature is 20C {68F}:


2.42.6 V
Fuel temperature is 70C {158F}:
0.70.9 V

Inspect fuel temperature sensor.


(See 51 FUEL TEMPERATURE
SENSOR INSPECTION)

ECT is 20C {68F}: 3.03.2 V


ECT is 85C {185F}: 0.70.9 V

4L

Inspect control sleeve (CS)


sensor.
(See 52 CONTROL SLEEVE (CS)
SENSOR INSPECTION)

Engine switch is on: 0100%


Idle: 0100%

PCM
terminal

Engine switch is off: below 1.0 V


Engine switch is on or idle: approx.
2.5 V

EGRVP (EGR
valve position)

FLT V (Fuel
temperature signal
voltage)

Engine switch is on: OFF


A/C switch is on and fan switch is on
at idle: ON

Engine switch is on: 0100%


Idle: 0100%

EGRV (EGR
solenoid valve
(vacuum))

FLT (Fuel
temperature
sensor)

F
V

EGRA (EGR
solenoid valve
(vent))

Action

Elevation 0400 m {01310 ft}:


approx. 4.0 V

V
CS P (Control
sleeve signal
voltage)

Condition/Specification

F245

1L

CONTROL SYSTEM

Monitor item
(Definition)

Unit/
Condition

Condition/Specification

ON/OFF

Idle: ON
Engine switch is on: ON
Engine speed is above 5,100 rpm:
OFF
DTC P1182, P0251, P0606, P1226 is
detected: OFF

Follow appropriate DTC


troubleshooting
(See NO TAG DTC TABLE)

Inspect following PIDs: ECT, VSS,


VPWR.
Inspect glow plug relay.
(See NO TAG RELAY
INSPECTION)

GPC (Glow plug


control)

ON/OFF

ECT below 60C {140F}


D For 15 s after engine switch on:
ON
D After 6.5 s10 min elapse from
engine switch on: OFF
D For 6.5 s10 min after engine
started: ON
D After 15 s elapse from engine
started: OFF
ECT above 60C {140F}
D For 6.5 s after engine switch on:
ON
D After 6.5 s elapse from engine
switch on: OFF

GPL (Glow
indicator light)

ON/OFF

For 4 s after engine switch on (ECT is Inspect instrument cluster.


20 C {68 F}): ON
(See Section T)

FSOV (FSO
solenoid control)

IASV (Intake
shutter valve)

IAT
(IAT sensor No.2)

IATDC
(IAT sensor No.1)

ON/OFF

F
V

IDLE SW
(Idle switch)

ON/OFF

MAF (MAF sensor


input voltage)

MAINRLY (PCM
control relay)

ON/OFF

MAP
(Boost sensor)

kPa Bar psi


V

PNP
(Neutral/clutch
switch)

ON/OFF

RPM (Engine
speed)

rpm

STARTER (Engine
switch)

ON/OFF

TPS (Timer
position sensor
signal)

PCM
terminal

4W

4V

4S

Inspect following PIDs: RPM,


BARO, ECT, IAT, VS
Inspect intake shutter solenoid
valve.
(See NO TAG INTAKE SHUTTER
SOLENOID VALVE INSPECTION

4Z*

Inspect IAT sensor No.2.


(See 50 INTAKE AIR
TEMPERATURE (IAT) SENSOR
NO.2 INSPECTION)

1J

Inspect MAF/IAT sensor.


(See 49 MASS AIR FLOW
(MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
INSPECTION)

3D

Accelerator pedal is released: ON


Other: OFF

Inspect idle switch.


(See NO TAG IDLE SWITCH
INSPECTION)

3O

Engine switch is on: below 1.0 V


Idle: 1.62.0 V

Inspect MAF/IAT sensor.


(See 49 MASS AIR FLOW
(MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
INSPECTION)

4E

Engine switch is on: ON


Other: OFF

Inspect engine switch.


(See Section T)

3B

Idle: 101kPa {1.01 Bar, 14.7psi}

Inspect boost sensor.


(See 55 BOOST SENSOR
INSPECTION)

1P

Neutral position or clutch pedal is


depressed: ON
Others: OFF

Inspect neutral and clutch switch.


(See 61 NEUTRAL SWITCH
INSPECTION)
(See 60 CLUTCH SWITCH
INSPECTION)

1D

A/C ON: 725775rpm


Other: 695745rpm

Inspect following PIDs: TP V, MAP


V, RPM

1H

Engine switch at START: ON


Other: OFF

Inspect engine switch.


(See Section T)

1U

Engine switch is ON: 0%


Idle: 100%

Inspect timer position sensor.


(See 53 TIMER POSITION
SENSOR INSPECTION)

1K

Engine switch is on: OFF


Idle: ON

IAT is 20C {68F}: 20C {68F}


IAT is 30C {86F}: 30C {86F}
IAT is 20C {68F}: 2.32.5 V
IAT is 30C {86F}: 1.82.0 V

Action

IAT is 20C {68F}: 20C {68F}


IAT is 30C {86F}: 30C {86F}
IAT is 20C {68F}: 2.32.5 V
IAT is 30C {86F}: 1.82.0 V

Idle: approx. 2.6V

F246

CONTROL SYSTEM

TEST (TEN
terminal (in DLC))

ON/OFF

TP V (Accelerator
position signal
voltage)

TP2 V (Accelerator
position signal
voltage)

VPWR (Battery
positive voltage)

VSS (Vehicle
speed)

km/h

mph

Terminal TEN (DLC) is shorted to


GND: ON
Terminal TEN (DLC) is open: OFF

Inspect wiring from DLC terminal


TEN to PCM terminal 2A.

Accelerator pedal is depressed:


3.43.8 V
Accelerator pedal is
released:0.50.7 V

Inspect accelerator position


sensor.
(See 56 ACCELERATOR
POSITION SENSOR
INSPECTION)

1R

Accelerator pedal is depressed:


3.43.8 V
Accelerator pedal is released:
0.50.7 V

Inspect accelerator position


sensor.
(See 56 ACCELERATOR
POSITION SENSOR
INSPECTION)

2C

Engine switch is ON: B+


Other: below 1.0 V

Inspect PCM control relay.


(See NO TAG RELAY
INSPECTION)

4C

Vehicle speed is 20 km/h {12.5 mph}:


20 km/h {12.5 mph}
Vehicle speed is 40 km/h {25 mph}:
40 km/h {25 mph}

Inspect Instrument cluster.


(See Section T)

F247

2A

1N

CONTROL SYSTEM
Not using SSTs (WDS or equivalent) at constant
voltage terminal inspection
1. Turn the engine switch to ON.
2. Measure the voltage between the accelerator
position sensor connector (vehicle side) terminal A
and body GND using a voltmeter.

3 Verify there is no continuity between the


accelerator position sensor connector
(vehicle side) terminal A and battery
positive harness using an ohmmeter.
D If there is continuity, repair the related
harnesses.

ZCF4040W017

(1) Measurement voltage is 0 V.


1 Turn the engine switch to OFF.
2 Disconnect the accelerator position sensor
connector (applied constant voltage).
3 Verify there is no continuity between the
accelerator position sensor connector
(vehicle side) terminal A and body GND
using an ohmmeter.
D If there is continuity, repair the related
harnesses.

ZCF4040W017

(3) Measurement voltage is approx. 5 V.


D Constant voltage terminal of PCM is okay.
Not using SSTs (WDS or equivalent) at GND
terminal inspection
1. Turn the engine switch to OFF.
2. Disconnect the PCM connectors.
3. Inspect for continuity between the PCM GND
terminals and body GND using an ohmmeter.
D If there is no continuity, repair the related
harnesses.
PCM GND terminal
1B
4A
4B

ZCF4040W017

4 Inspect for continuity between the PCM


connector (vehicle side) terminal 1A and
accelerator position sensor connector
(vehicle side) terminal A (applied constant
voltage) using an ohmmeter.
D If there is no continuity, repair the
related harnesses.

Not using SSTs (WDS or equivalent) at power


supply terminal inspection
1. Turn the engine switch to ON.
2. Disconnect the PCM connectors.
3. Measure the voltage between the PCM battery
power terminal connectors and body GND using an
ohmmeter.
D If not as specified, repair the related
harnesses.
Power supply terminal voltage: B+
PCM power supply terminal
1C

ZCF4040W017

(2) Measurement voltage is B+.


1 Turn the engine switch to OFF.
2 Disconnect the battery positive harness
and battery negative harness.

F248

CONTROL SYSTEM
D Signal circuit (MAF/IAT sensor connector terminal
C and PCM connector terminal 4E)
D GND circuit (MAF/IAT sensor connector terminal B
and PCM connector terminal 4A)

Not using SSTs (WDS or equivalent) at serial


communication terminal inspection
1. Turn the engine switch to OFF.
2. Disconnect the PCM connectors.
3. Verify there is continuity between the PCM
connector terminal 2B and DLC KLN terminal.
D If not as specified, repair the related
harnesses.

ZCF4040W009

Short circuit
D MAF/IAT sensor connector terminal A and PCM
control relay connector terminal D to GND
D MAF/IAT sensor connector terminal C and PCM
connector terminal 4E to GND

ZCF4040W057

MASS AIR FLOW (MAF)/INTAKE AIR


TEMPERATURE (IAT) SENSOR INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)

IAT sensor No.1 resistance inspection


1. Disconnect the MAF/IAT sensor connector.
2. Measure the resistance between MAF/IAT sensor
terminals D and E using an ohmmeter.
D If not as specified, replace the MAF/IAT sensor.
D If as specified, carry out the Circuit open/short
inspection.
Specification

Note
D Perform the following inspection only when
directed.

Ambient temperature (C {F})

Resistance (kilo
ohm)

20 {68}

2.22.7

30 {86}

1.41.9

MAF sensor voltage inspection


1. Turn the engine switch to ON.
2. Set the WDS or equivalent and monitor the MAF
PID.
D If not as specified, perform the Circuit
open/short inspection.
MAF PID
below 1.0 V
3. Start the engine and warm up the engine
completely.
4. Monitor the MAF PID at idle.
D If not as specified, perform the Circuit
open/short inspection.

ZCF4040W010

MAF PID
1.62.0 V
CIrcuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (MAF/IAT sensor connector terminal
A and PCM control relay connector terminal D)

CIrcuit open/short inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Signal circuit (MAF/IAT sensor connector terminal
D and PCM connector terminal 3D)
D GND circuit (MAF/IAT sensor connector terminal E
and PCM connector terminal 1B)

F249

CONTROL SYSTEM
NE SENSOR INSPECTION

Short circuit
D MAF/IAT sensor connector terminal D and PCM
connector terminal 3D

Note
D Perform the following test only when directed.

INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2


INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
Inspection of resistance

1. Disconnect the NE sensor connector.


2. Measure the resistance between the NE sensor
connector terminals A and B by using an
ohmmeter.

Note
D Perform the following test only when directed.
A

1. Place the IAT sensor No.2 in water with a


thermometer, and heat the water gradually.

Specification
800920
3. If not as specified, replace the NE sensor.

W5U140WZC

2. Measure the resistance of the IAT sensor No.2


using an ohmmeter.
D If not as specified, replace the IAT sensor No.2.
D If IAT sensor No.2 is okay, but PID value is out
of specification, perform the Circuit open/short
inspection.
Specification
Water temperature (C {F})

Resistance (kilohm)

20 {68}

2.212.69

80 {176}

0.290.354

Circuit open/short inspection


1. Inspect for an open or short circuit in the following
siring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Signal circuit (IAT sensor No.2 connector terminal
A and PCM connector terminal J)
D GND circuit (IAT sensor No.2 connector terminal B
and PCM connector terminal B)

Tightening torque
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
4. If NE sensor is okay, but PCM terminal F voltage is
out of specification, inspect the following:
Open circuit
D Engine speed (input) circuit (NE sensor
connector terminal A and PCM connector
terminal F)
D GND circuit (NE sensor connector terminal B
and PCM connector terminal B)
Short circuit
D NE sensor connector terminal A and PCM
connector terminal F to GND
5. Repair or replace faulty areas.
6. Reconnect the NE sensor connector.

ZCF4040W015

Short circuit
D IAT sensor No.2 connector terminal A and PCM
connector terminal J to GND.

F250

CONTROL SYSTEM
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
Note
D Perform the following test only when directed.
1. Drain the engine coolant from the radiator. (Refer
to Section E, ENGINE COOLANT, ENGINE
COOLANT REPLACEMENT.)
2. Disconnect the ECT sensor connector.
3. Remove the ECT sensor.
4. Place the sensor in water with a thermometer, and
heat the water gradually.

Open circuit
D Reference voltage circuit (ECT sensor
connector terminal A and PCM connector
terminal E through common connector)
D GND circuit (ECT sensor connector terminal B
and PCM connector terminal B through
common connector)
Short circuit
D ECT sensor connector terminal A and PCM
connector terminal E through common
connector to GND
10. Repair or replace faulty areas.
11. Reconnect the ECT sensor connector.
WL3 / WLT3 (Euro 3 Regulation Models)
D If ECT sensor is okay, but PID value is out of
specification, perform the Circuit open/short
inspection.
Circuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harness.
Open circuit
D Reference voltage circuit (ECT sensor connector
terminal A and PCM connector terminal 1T)
D GND circuit (ECT sensor connector terminal B and
PCM connector terminal 1B)

5. Measure the resistance between engine coolant


temperature sensor terminals A and B by using an
ohmmeter.
Specification
Water temperature (C {F})

Resistance (k)

20 {68}

2.272.73

80 {176}

0.290.34

ZCF4040W016

Short circuit
D ECT sensor connector terminal A and PCM
connector terminal 1T to GND.
FUEL TEMPERATURE SENSOR INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
Resistance Inspection

6. If not as specified, replace the ECT sensor.


7. Refill the radiator with the specified engine coolant.
(Refer to Section E, ENGINE COOLANT, ENGINE
COOLANT REPLACEMENT.)
8. Install the ECT sensor.
Tightening torque
1623 Nm {1.62.4 kgfm, 1217 inlbf}
WL / WLT Models
9. If ECT sensor is okay, but PCM terminal E voltage
is out of specification, inspect as follows:

Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect the resistance between the terminals under
the following condition.
D Consult authorized BOSCH parts distributor for
repair if the fuel temperature sensor is possibly
malfunctioning.

F251

CONTROL SYSTEM
D Consult authorized BOSCH parts distributor for
repair if the pump speed sensor is possibly
malfunctioning:
D If pump speed sensor is okay, but PID value is
out of specification, perform the Circuit
open/short inspection.

D If fuel temperature sensor is okay, but PID


value is out of specification, perform the
Circuit open/short inspection.

ZCF4040W001

Specification
Terminal

Atmospheric
temperature C {F}

Resistance (ohm)

EK

2030 {6886}

1.42.6

ZCF4040W002

Specification

Circuit open/short inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power supply circuit (Injection pump connector A
terminal K and PCM connector terminal 1L)
D Ground circuit (Injection pump connector A
terminal E and PCM connector terminal 1B)

Terminal

Atmospheric
temperature C {F}

Resistance (ohm)

AB

2030 {6886}

1.461.78

Circuit open/short inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
Open circuit
D Power circuit (Pump speed sensor connector
terminal A and PCM connector terminal 2K)
D GND circuit (Pump speed sensor connector
terminal B and PCM connector terminal 2D)

ZCF4012W001
ZCF4040W003

Short circuit
D Injection pump connector A terminal K and PCM
connector terminal 1L to GND

Short circuit
D Pump speed sensor connector terminal A and
PCM connector terminal 2K to GND

PUMP SPEED SENSOR INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)
Resistance Inspection

CONTROL SLEEVE (CS) SENSOR INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)
Resistance inspection

Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the connector C of the injection pump
auxiliary part. (See NO TAG Injection pump
auxiliary parts inspection)
3. Inspect the resistance between the terminals A and
B under the following condition.

Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect the resistance between the terminals under
the following condition.

F252

CONTROL SYSTEM
D Consult authorized BOSCH parts distributor for
repair if the CS sensor is possibly
malfunctioning:
D If the CS sensor is okay, but PID value is out of
specified, perform the CS sensor circuit
open/short inspection.

3. Inspect the resistance between the terminals under


the following condition.
D Consult authorized BOSCH parts distributor for
repair if the timer position sensor is possibly
malfunctioning:
D If timer position sensor is okay, but PID value is
out of specification, perform the Circuit
open/short inspection.

ZCF4040W001

Specification

ZCF4040W004

Terminal

Atmospheric
temperature C {F}

Resistance (ohm)

GH

1828 {66.482.4}

11.212.4

GF

1828 {66.482.4}

FH

1828 {66.482.4}

Specification
Terminal

Resistance (ohm)

Atmospheric
temperature C {F}

5.66.2

AB

76.387.7

1535 {5995}

5.66.2

AC

76.387.7

1535 {5995}

CS sensor circuit open/short inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D if there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (Injection pump connector A terminal
G and PCM connector terminal 1O)
D CS sensor signal circuit (CS sensor connector
terminal F and PCM connector terminal 1Q)
D Ground circuit (Injection pump connector A
terminal H and PCM connector terminal 1M)

Circuit open/short inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (Injection pump connector B terminal
C and PCM connector terminal 1I)
D Timer position signal circuit (Injection pump
connector B terminal A and PCM connector
terminal 1K)
D Ground circuit (Injection pump connector B and
PCM connector terminal 1G)

ZCF4012W001

Short circuit
D Injection pump connector A terminal G and PCM
connector terminal 1O to GND
D Injection pump connector A terminal F and PCM
connector terminal 1Q to GND

ZCF4040W005

Short circuit
D Injection pump connector B terminal C and PCM
connector terminal 1I to GND
D Injection pump connector B terminal A and PCM
connector terminal 1K to GND

TIMER POSITION SENSOR INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)
Resistance inspection

INJECTION PUMP EPROM INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)

Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector B.

F253

Caution
D Do not input voltage to B terminal in the
injection pump EPROM.Doing so will cause
a malfunction of the injection pump
EPROM.

CONTROL SYSTEM
Note
D Perform the following test only when directed.

5. Verify that there is no interference between the


TDC sensor and the plate.

1. Disconnect the negative battery cable.


2. Disconnect the injection pump connector B.
3. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
D If the wiring harnesses are okay, but the
injection pump EPROM is possibly
malfunctioning, consult authorized BOSCH
parts distributor for repair.
ZCF4040W024

ZCF4040W005

Circuit open/short inspection


Open circuit
D Power Circuit (Injection pump connector B terminal
D and PCM connector terminal 1A)
D Injection pump EPROM signal Circuit (Injection
pump connector B terminal E and PCM connector
terminal 1S)
D Injection pump EPROM signal Circuit (Injection
pump connector B terminal F and PCM connector
terminal 2E)
D Injection pump EPROM signal Circuit (Injection
pump connector B terminal G and PCM connector
terminal 2L)
D GND circuit (Injection pump connector B H and
PCM connector terminal 1B)
Short circuit
D Power Circuit (Injection pump connector B terminal
D and PCM connector terminal 1A to GND)
D Injection pump EPROM signal Circuit (Injection
pump connector B terminal E and PCM connector
terminal 1S to GND)
D Injection pump EPROM signal Circuit (Injection
pump connector B terminal F and PCM connector
terminal 2E to GND)
D Injection pump EPROM signal Circuit (Injection
pump connector B terminal G and PCM connector
terminal 2L to GND)

TDC sensor installation bolt

TDC sensor

TDC SENSOR INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)
Wave profile Inspection
1. Set oscilloscope.
Measuring terminals
PCM terminal: 1H(+)1B(-)
2. Verify that output voltage when ON and OF and
output pattern are within the specification.

ZCF4040W043

3. If not as specified, perform the following


inspections and repair or replace the
malfunctioning part.
D When output voltage is approc.5.0V constant
Open circuit between PCM terminal 1H and
TDC sensor terminal B
D When output voltage is approx. 0V constant
Short circuit between PCM terminal 1H and
TDC sensor terminal B
Open/Short circuit between power TDC
sensor terminal A and PCM control relay
terminal D
D When NE signal is ON and OFF with low
output voltage or no oscillation

TDC SENSOR REMOVAL/INSTALLATION


WL3 / WLT3 (Euro 3 Regulation Models)
1. Disconnect the negative battery cable.
2. Remove the crankshaft pulley.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

F254

CONTROL SYSTEM
D GND circuit (EGR valve position sensor connector
terminal A and PCM connector terminal 1B)

TDC sensor plate read station has


malfunction

ZCF4040W042

EGR VALVE POSITION SENSOR INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)

ZCF4040W009

Short circuit
D EGR valve position sensor connector terminal B
and PCM connector terminal 1A to GND
D EGR valve position sensor connector terminal C
and PCM connector terminal 1F to GND

Note
D Perform the following inspection only when
directed.

BOOST SENSOR INSPECTION


WL3 / WLT3 (Euro 3 Regulation Models)

EGR valve position sensor voltage inspection


1. Turn the engine switch to ON.
2. Set the WDS or equivalent and monitor the
EGRVP PID.
D If not as specified, perform the Circuit
open/short inspection.

Note
D Perform the following test only when detected.

EGRVP PID
approx. 0.6 V
3. Start the engine and warm up the engine
completely.
4. Monitor the EGRVP PID.
D If not as specified, perform the Circuit
open/short inspection.
EGRVP PID
above 3.0V
CIrcuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (EGR valve position sensor
connector terminal B and PCM connector terminal
1A)
D Signal circuit (EGR valve position sensor
connector terminal C and PCM connector terminal
1F)

1. Inspect the boost sensor for damage and cracks.


2. Inspect vacuum hose for improper routing, kinks or
leakage.
D If the above are okay, perform the Circuit
open/short inspection.
D If the above open or short circuit are correct,
replace the boost sensor.
Circuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Boost circuit (Boost sensor connector terminal B
and PCM connector terminal 1P)
D Constant voltage circuit (Boost sensor connector
terminal A and PCM connector terminal 1A)
D Ground circuit (Boost sensor connector terminal C
and PCM connector terminal 1B)

ZCF4040W011

Short circuit
D Boost circuit (Boost sensor connector terminal B
and PCM connector terminal 1P to GND)
D Constant voltage circuit (Boost sensor connector
terminal A and PCM connector terminal 1A to
GND)

F255

CONTROL SYSTEM
PCM CONTROL RELAY INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
1. Inspect the PCM control relay. (SeeRELAY
INSPECTION.)
ACCELERATOR POSITION SENSOR INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
Note
D Perform the following test only when directed.
1. Visually inspect all accelerator pedal components
for looseness.
2. Verify that the accelerator position sensor is
installed to the accelerator pedal properly.
3. Check the power circuit voltage.
(1) Verify that the voltage between the PCM
terminals 1A (power circuit) and 1B (ground
circuit) is 4.755.25 V.

D Signal circuit (Accelerator position sensor


connector terminal B and PCM connector terminal
1R)
D Signal circuit (Accelerator position sensor
connector terminal C and PCM connector terminal
2C)
D GND circuit (Accelerator position sensor connector
terminal D and PCM connector terminal 1B)
Short circuit
D Accelerator position sensor connector terminal B
and PCM connector terminal 1R to GND.
D Accelerator position sensor connector terminal C
and PCM connector terminal 2C to GND.
ACCELERATOR POSITION SENSOR ADJUSTMENT
WL3 / WLT3 (Euro 3 Regulation Models)
Caution
D Adjusting the accelerator position sensor
unnecessarily may adversely affect engine
control. Therefore, adjust accelerator
position sensor only when it is replaced.

Note
D Voltage at the PCM terminal 1R may deviate
when the power circuit voltage is abnormal.

Note
D Perform the following test only when directed.
D Accelerator position sensor adjustment is
based on the output voltage with the
accelerator pedal fully released. Therefore, be
sure to adjust according to the following
procedure. (Begin adjustment with the
accelerator pedal fully released.)

ZCF4040W019

4. Verify that the voltage between the PCM terminals


1R (accelerator position detection signal) and 1B is
as shown below according to the accelerator pedal
conditions.
D If not as specified, carry out the Circuit
Open/Short Inspection.
D If the circuit is OK, replace the accelerator
position sensor.

1. Visually inspect all accelerator pedal components


for looseness.
2. Install the accelerator position sensor.
3. Check the power circuit voltage.
(1) Verify that the voltage between the PCM
terminals 1A (power circuit) and 1B (ground
circuit) is 4.755.25 V.
Note
D Voltage at the PCM terminal 1R may deviate
when the power circuit voltage is abnormal.

Specification
Accelerator pedal
condition

Output voltage (V)

Fully released

0.50.7(Target value: 0.6)

Gradually depressed

Increases linearly

Fully depressed

3.43.8(Target value: 3.6)

Circuit Open/Short Inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (Accelerator position sensor
connector terminal A and PCM connector terminal
1A)

ZCF4040W019

4. Adjust the output voltage when the accelerator


pedal is fully released.
(1) Verify that the voltage between the PCM
terminals 1R (accelerator position detection
signal) and 1B is as shown below according to
the accelerator pedal conditions.
D If not as specified, move the accelerator
position sensor to adjust the installation

F256

CONTROL SYSTEM
position of the accelerator position sensor
so that the PCM terminal 1R voltage is
within the specification.

Specification
: Continuity
Measuring
condition

Specification
Accelerator pedal
condition

Output voltage (V)

Fully released

0.50.7(Target value: 0.6)

Gradually depressed

Increases linearly

Terminal
E

GND

Not accelerated
Other

Caution
D Turning the idle switch with its connector
connected can break the harness. Be sure
to disconnect the connector when turning
the idle switch more than one rotation.
4. If not as specified, loosen the idle switch locknut
and adjust the continuity by turning the idle switch.
5. If not as specified, replace the idle switch. If the
idle switch is okay, but PCM terminal voltage is out
of specification, inspect as follows and repair or
replace as necessary.

ZCF4040W020

5. Verify that the output voltage when the accelerator


pedal is fully depressed.
(1) Depress the accelerator pedal fully and verify
that the voltage at the PCM terminal 1R is
within the specification.

Open circuit
D Power supply circuit (Idle switch connector terminal
E and PCM connector terminal 2H through
common connector)
D GND circuit (Idle switch connector terminal and
body GND)

Specification
3.43.8V (Target value: 3.6 V)
6. After completion of Steps 1. through 5, inspect the
idle switch.
IDLE SWITCH INSPECTION
Europe and UK
Continuity Inspection
WL / WLT Models
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the 8-pin connector of FIP.
3. Inspect for continuity between the idle switch
terminal E and ground using an ohmmeter.

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

Short circuit
D Power supply circuit (Idle switch connector terminal
E and PCM connector terminal H through common
connector to GND)
6. Repair or replace faulty areas.
7. Reconnect the 8-pin connector of FIP.
WL3 / WLT3 (Euro3 Regulation models)
Note
D Perform the following test only when directed.

COMPONENT SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

1. Verify that the accelerator position sensor is


normal.
2. Visually inspect all accelerator pedal components
for looseness.
3. Verify that the idle switch is installed to the
accelerator pedal properly.
4. Verify that the power circuit voltage.

F257

CONTROL SYSTEM
Open circuit
D Signal circuit (Idle switch connector terminal A and
PCM connector terminal 3O)
D GND circuit (Idle switch connector terminal B and
body GND)
D Power circuit (Accelerator position sensor
connector terminal A and PCM connector terminal
1A)
D Signal circuit (Accelerator position sensor
connector terminal B and PCM connector terminal
1R)
D Signal circuit (Accelerator position sensor
connector terminal C and PCM connector terminal
2C)
D GND circuit (Accelerator position sensor connector
terminal D and PCM connector terminal 1B)
Short circuit
D Idle switch connector terminal A and PCM
connector terminal 3C to GND.
D Accelerator position sensor connector terminal B
and PCM connector terminal 1R to GND.
D Accelerator position sensor connector terminal C
and PCM connector terminal 2C to GND.

(1) Verify that the voltage between the PCM


terminals 1A (power circuit) and 1B (ground
circuit) is 4.755.25 V.
Note
D Voltage at the PCM terminal 1R may deviate
when the power circuit voltage is abnormal.

ZCF4040W025

5. Verify that the voltage at the PCM terminal 3O (idle


signal) is 1 V or less with the accelerator pedal fully
released.
6. Depress the accelerator pedal gradually and hold
the pedal when the PCM terminal 3O voltage
changes to approximately 10 V.
7. Verify that the voltage between the PCM terminals
1R (accelerator position detection signal) and 1B is
within the specification.
D If not as specified, carry out the Circuit
Open/Short Inspection.
D If the circuit is OK, replace the idle switch.
Specification
1.01.2 V (Target value: 1.1 V)
Circuit Open/Short Inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.

IDLE SWITCH ADJUSTMENT


WL3 / WLT3 (Euro3 Regulation models)
Caution
D Adjusting the idle switch unnecessarily
may adversely affect engine control.
Therefore, adjust the idle switch only when
it is replaced.
Note
D Perform the following test only when directed.
1. Verify that the accelerator position sensor is
normal.
2. Visually inspect all accelerator pedal components
for looseness.
3. Loosen the locknut that secures the idle switch.
4. Verify that the power circuit voltage.
(1) Verify that the voltage between the PCM
terminals 1A (power circuit) and 1B (ground
circuit) is 4.755.25 V.
Note
D Voltage at the PCM terminal 1R may deviate
when the power circuit voltage is abnormal.

F258

CONTROL SYSTEM
D Perform the following test only when directed.

1. Verify that the FIP control lever is fully closed.


2. Turn the engine switch on and measure the PCM
terminal J voltage.
Specification

ZCF4040W025

5. Depress the accelerator pedal by hand and secure


it when the voltage between the PCM terminals 1R
(accelerator position detection signal) and 1B is
within the range specified below.
Voltage range
1.01.2V (Target value: 1.1 V)

Measuring condition

Voltage (V)

Accelerator pedal is fully


open.

Approx. 4.2

Accelerator pedal is fully


closed.

Approx. 0.81.5

3. If not as specified, replace the control lever


position sensor. When the reading is out of
specification, send the FIP with the control lever
position sensor to a distributor to repair. If the PCM
terminal voltage is out of specification, inspect as
follows and repair or replace as necessary.
Open circuit
D Constant voltage circuit (Control lever position
sensor connector terminal B and PCM connector
terminal A through common connector)
D Control lever position signal circuit (Control lever
position sensor connector terminal A and PCM
connector terminal J through common connector)
D GND circuit (Control lever position sensor
connector terminal C and PCM connector terminal
B through common connector)

ZCF4040W026

6. Turn the idle switch under the condition in Step 5.


Secure the idle switch when the continuity turns
from OFF to ON, and tighten the locknut.

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

Short circuit
D Control lever position sensor connector terminal B
and PCM connector terminal A through common
connector to GND
D Control lever position sensor connector terminal A
and PCM connector terminal J through common
connector to GND
ZCF4040W028

7. Release the accelerator pedal. Depress the


accelerator pedal again and verify that the idle
switch continuity changes from OFF to ON when
the PCM terminal 1R voltage is within 1.01.2 V.
D If the continuity does not change, repeat
Step 6.

4. Repair or replace faulty areas.


5. Reconnect the 8-pin connector of FIP.

CONTROL LEVER POSITION SENSOR


INSPECTION
Europe and UK
Output Voltage Inspection
Note

F259

CONTROL SYSTEM
CLUTCH SWITCH INSPECTION
WL3 / WLT3 (Euro3 Regulation models)
Inspection of Continuity
Note
D Perform the following test only when directed.
1. Inspect continuity between the clutch switch
terminals using an ohmmeter.
D If not as specified, replace the clutch switch.
D If clutch switch is okay, but PID value is out of
specification, perform the Circuit open/short
inspection.
Specification
ZCF4040W025

6. Depress the accelerator pedal by hand and secure


it when the voltage between the PCM terminals 1R
(accelerator position detection signal) and 1B is
within the range specified below.
ZCF4040W054

Voltage range
1.01.2V (Target value: 1.1 V)

ZCF4040W007
ZCF4040W026

7. Turn the idle switch under the condition in Step 5.


Secure the idle switch when the continuity turns
from OFF to ON, and tighten the locknut.

2. Reconnect the clutch switch connector.


Circuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (Clutch switch connector terminal A
and PCM connector terminal 1D)
D GND circuit (Clutch switch connector terminal B
and GND.)
Short circuit
D Clutch switch connector terminal A and PCM
connector terminal 1D to GND.

ZCF4040W028

8. Release the accelerator pedal. Depress the


accelerator pedal again and verify that the idle
switch continuity changes from OFF to ON when
the PCM terminal 1R voltage is within 1.01.2 V.
D If the continuity does not change, repeat
Step 6.

F260

CONTROL SYSTEM
NEUTRAL SWITCH INSPECTION
WL3 / WLT3 (Euro3 Regulation models)
Note
D Perform the following inspection only when
directed.
Continuity inspection
1. Inspect for continuity between the neutral switch
terminals using an ohmmeter.

ZCF4040W018

D If the neutral switch is okay, but the PNP PID is


out of specification, carry out of the Circuit
open/short inspection.
D If not as specified, replace the neutral switch.
Specification

ZCF4040W047

Circuit open/short inspection


1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (neutral switch terminal A and PCM
terminal 1D)
D GND circuit (neutral switch terminal B and GND)
Short circuit
D Neutral switch terminal A and PCM connector
terminal 1D to GND

F261

ON-BOARD DIAGNOSTIC SYSTEM

ON-BOARD DIAGNOSTIC SYSTEM


Europe and UK only
WL / WLT Models
DTC READING PROCEDURE
Using the SST (Self-Diagnosis Checker)
1. Connect the SSTs to the DLC located in the engine
compartment and GND the black (negative) lead to
the body.

Using the Voltmeter


1. Turn the engine switch off.
2. Connect the DLC located in the engine
compartment terminal TEN and GND using a
jumper wire.
Caution
D Connecting the wrong DLC terminals may
possibly cause a malfunction. Carefully
connect the specified terminals only.

49 B019 9A0
DLC

3. Connect the negative battery lead of voltmeter


(20V range) to the DLC terminal FEN, and the
positive lead to the DLC terminal +B.

49 H018 9A1A
FEN

2. Set the select switch on the SST (self-diagnosis


checker) to A.
3. Turn the dial switch on the SST (system selector)
to 1, and the test switch to SELF TEST.
4. Turn the engine switch on.
5. Verify that the buzzer sounds for approximately
3 seconds and code 88 flashes for 5 seconds. If
DTC is not detected, 00 will then be indicated.
Note
D If the 88 does not flash, inspect +B terminal of
the data link connector, and the related
harnesses and connectors.
D If the 88 flashes and the buzzer sounds more
than 20 seconds, inspect the harness between
the PCM terminal and the DLC. If the harness
is normal, replace the PCM and inspect.
6. If any DTCs are indicated, inspect the appropriate
areas and repair as necessary.
Note
D A DTC consists of four numbers. They are
flashed one by one in the right window on the
display. (1 is always shown on the left
window.)
D When there are multiple malfunctions, the
codes are displayed in numerical order.
7. After completion of repairs, erase all DTCs from
the memory. (Refer to AFTER REPAIR
PROCEDURE.)
8. Remove the SSTs.

DLC
TEN

+B

GND

4. turn the engine switch on.


5. The voltmeter indicates the battery positive voltage
for approximately 3 seconds, then indicates 0V.
6. Read the DTCs indicated by the movement of the
voltmeters needle. If DTC is not detected, the
needle does not move.
7. If any DTCs are indicated, inspect the appropriate
areas and repair as necessary.
8. After completion of repairs, erase all DTCs from
the memory. (Refer to AFTER REPAIR
PROCEDURE.)
9. Remove the voltmeter and the jumper wire.
AFTER REPAIR PROCEDURE
1. After repairs, disconnect the negative battery cable
for at least 20 seconds, and depress the brake
pedal. Reconnect the negative battery cable.
2. Warm up the engine to normal operating
temperature.
Note
D If the engine will not start, keep the starter
operated for 5-6 seconds.
3. Perform the DTC READING PROCEDURE
again.
4. Verify that the DTC is not detected.

F262

ON-BOARD DIAGNOSTIC SYSTEM


.
DTC INSPECTION
DTC Table
DTC No.

Indicator Pattern

Condition

09

Engine coolant temperature (ECT) sensor


malfunction

12

Control lever position sensor malfunction

36

Glow plug relay malfunction

DTC 09
DETECTION
CONDITION
POSSIBLE
CAUSE

ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION


Input value to PCM is excessively high or low for more than 2.0 sec.
D ECT sensor malfunction
D Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E
D Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B

STEP

INSPECTION

ACTION

Does ECT sensor or PCM connector have


poor connection?

Yes

Repair or replace connector, then go to Step 6.

No

Go to next step.

Disconnect ECT sensor connector.


Turn engine switch on. Is there 5 V at
connector terminal A?

Yes

Go to next step.

No

Inspect for open or short circuit in wiring harness. (PCM


terminal BECT sensor terminal B)

Is there continuity between connector


terminal A and PCM terminal E?

Yes

Go to next step.

No

Repair or replace wiring harness, then go to Step 6.

Is ECT sensor okay?


+ CONTROL SYSTEM, ENGINE
COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION

Yes

Go to next step.

No

Replace ECT sensor, then go to Step 6.

Clear DTC from memory.


Is same code No. present after performing
After Repair Procedure?

Yes

Go to Step 1.

No

Intermittent poor connection in harnesses or connector.


Repair connectors and/or harnesses, then go to next step.

Clear DTC from memory.


Is there any DTC present after performing
After Repair Procedure?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

PCM (20 PIN)


ECT SENSOR
E
J

HARNESS SIDE CONNECTOR


(VIEW FROM HARNESS SIDE)

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

F263

ON-BOARD DIAGNOSTIC SYSTEM

DTC 12
DETECTION
CONDITION

CONTROL LEVER POSITION SENSOR MALFUNCTION


D Input voltage from control lever positIon sensor is below 0.1 V or above 4.75 V when continued for 1.0

sec.
D When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V.
D Control lever position sensor malfunction
D Idle switch malfunction
D Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-

POSSIBLE
CAUSE

nal B
D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to

PCM terminal J
D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to

PCM terminal A
D Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H

STEP
1

INSPECTION

ACTION

Does control lever position sensor connector


or PCM connector have poor connection?

Yes

Repair or replace connectors, then go to Step 7.

No

Go to next step.

Disconnect control lever position sensor


connector. Turn engine switch on. Is there
5 V at connector terminal B?

Yes

Go to next step.

No

Inspect for open or short circuit in wiring harness. (PCM


terminal Acontrol lever position sensor terminal B)

Is there continuity between connector


terminal A and PCM terminal J?

Yes

Go to next step.

No

Repair or replace wiring harness, then go to Step 7.

Is there continuity between connector


terminal C and PCM terminal B?

Yes

Replace control lever position sensor, then go to Step 7.

No

Repair or replace wiring harness, then go to Step 7.

Is there continuity between connector


terminal E and PCM terminal H?

Yes

Go to next step.

No

Repair or replace wiring harness, then go to Step 7.

Is idle switch okay?


+ CONTROL SYSTEM, IDLE SWITCH INSPECTION

Yes

Go to next step.

No

Replace idle switch.

Clear DTC from memory.


Is same code No. present after performing
After Repair Procedure?

Yes

Go to Step 1.

No

Intermittent poor connection in harness or connector.


Repair connector and/or harness, then go to next step.

Clear DTC from memory.


Is there any DTC present after performing
After Repair Procedure?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

3
4

CONTROL LEVER POSITION SENSOR


PCM (20 PIN)
A
J

HARNESS SIDE CONNECTOR


(VIEW FROM HARNESS SIDE)

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

F264

ON-BOARD DIAGNOSTIC SYSTEM

DTC 36

GLOW PLUG RELAY MALFUNCTION


D When the glow plug relay is on, current voltage signal of the relay below 1.0 V is inputted to the PCM

DETECTION
CONDITION

continuously for more than 1.0 sec.


D When the glow plug relay is off, signal of the relay current voltage above 4.0 V is inputted to the PCM

continuously for more than 1.0 sec.


POSSIBLE
CAUSE
STEP
1
2

3
4
5

D
D
D
D

Glow plug relay malfunction


Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR)
Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B)
Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse
INSPECTION

ACTION

Does glow plug relay connector or PCM


connector have poor connection?

Yes

Repair or replace connectors, then go to Step 5.

No

Go to next step.

Remove glow plug relay.


Is there continuity between connector
terminal A and PCM terminal O?
Is there continuity between connector
terminal A (B) and PCM terminal I?

Yes

Go to next step.

No

Repair or replace wiring harness.

Is there continuity between connector


terminal B and body GND?

Yes

Go to next step.

No

Repair or replace wiring harness.

Is there continuity between connector


terminal A (R) and glow fuse?

Yes

Go to next step.

No

Repair or replace wiring harness.

Is glow plug relay okay?


+ INTAKE-AIR SYSTEM, GLOW PLUG
RELAY INSPECTION

Yes

Go to next step.

No

Replace glow plug relay.

Clear DTC from memory.


Is same code No. present after performing
After Repair Procedure?

Yes

Go to Step 1.

No

Intermittent poor connection in harnesses or connectors.


Repair connectors and/or harnesses, then go to next step.

Clear DTC from memory.


Is there any DTC present after performing
After Repair Procedure?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.
GLOW PLUG RELAY

PCM (20 PIN)

A
A
O

A
B

HARNESS SIDE CONNECTOR


(VIEW FROM HARNESS SIDE)

(WIRE
COLOR: R)

(WIRE
COLOR: B)

HARNESS SIDE CONNECTOR


(VIEW FROM TERMINAL SIDE)

F265

ON-BOARD DIAGNOSTIC SYSTEM


Euro 3 Regulation Models
D When the customer reports a vehicle malfunction, check the warning light indication and diagnostic trouble
code (DTC), then diagnose the malfunction according to following flowchart.
If a DTC exists, diagnose the applicable DTC inspection. (See 67 DTC TABLE.)
If no DTC exists and the warning light does not illuminate or flash, diagnose the applicable symptom troubleshooting. (See TROUBLESHOOTING ITEM TABLE)

YMU102WBX

*: Generator Warning Light, Security Light and Glow Indicator Light Flashing
OBD READ/CLEAR DIAGNOSTIC TEST RESULTS
Euro 3 Regulation Models
D This retrieves all stored DTCs in PCM and clears
the DTC.
OBD PARAMETER IDENTIFICATION (PID) ACCESS
Euro 3 regulation Models
D The PID mode allows access to certain data
values, analog and digital inputs/outputs,
calculated values and system status information.
Since PID values for output devices are PCM
internal data values, inspect each device to identify
which output device has a malfunction.

F266

ON-BOARD DIAGNOSTIC SYSTEM


ON-BOARD DIAGNOSTIC TEST
Euro 3 Regulation Models
DTCs retrieving procedure
1. Perform the necessary vehicle preparation and
visual inspection.
2. Connect WDS or equivalent to the vehicle DLC
located the engine room.

PID/DATA monitor and record procedure


1. Perform the necessary vehicle preparation and
visual inspection.
2. Connect WDS or equivalent to the vehicle DLC
located the engine room.

ZCF4070W012

ZCF4070W012

3. Access and monitor PIDs by WDS or equivalent.

3. Retrieve DTC by WDS or equivalent.


DTC TABLE
DTC

Output pattern

Possible cause

P0100

MAF circuit malfunction

(See 69
DTC
P0100)

Boost sensor circuit malfunction

(See 72
DTC
P0105)

IAT No.1circuit malfunction

(See 74
DTC
P0110)

ECT circuit malfunction

(See 77
DTC
P0115)

Accelerator position sensor


circuit malfunction

(See 80
DTC
P0120)

Fuel temperature sensor


malfunction

(See 83
DTC
P0180)

Injection amount control system


malfunction

(See 86
DTC
P0251)

TDC sensor circuit malfunction

(See 88
DTC
P0335)

EGR system malfunction

(See 89
DTC
P0400)

Vehicle speed sensor (VSS)


circuit malfunction

(See 91
DTC
P0500)

WALTPX0100

P0105
WALTPX0105

P0110
WALTPX0110

P0115
WALTPX0115

P0120
WALTPX0120

P0180
WALTPX0180

P0251
WALTPX0251

P0335
WALTPX0335

P0400
WALTPX0400

P0500
WALTPX0500

F267

Page

ON-BOARD DIAGNOSTIC SYSTEM

DTC

Output pattern

Possible cause

Page

Idle switch malfunction

(See 93
DTC
P0510)

PCM malfunction

(See 94
DTC
P0606)

IAT No.2 circuit malfunction

(See 95
DTC
P1110)

Fuel shut off (FSO) solenoid


malfunction

(See 98
DTC
P1182)

Pump speed sensor circuit


malfunction

(See 99
DTC
P1189)

BARO circuit malfunction

(See 100
DTC
P1195)

Control sleeve (CS) sensor


circuit malfunction

(See 101
DTC
P1226)

Timer control valve circuit


malfunction

(See 103
DTC
P1312)

Timer position sensor circuit


malfunction
WALTPX1318

(See 105
DTC
P1318)

WALTPX1402TIF

(See 107
EGR valve position sensor circuit
DTC
malfunction
P1402)

P0510
WALTPX0510

P0606
WALTPX0606

P1110
WALTPX1110

P1182
WALTPX1182

P1189
WALTPX1189

P1195
WALTPX1195

P1226
WALTPX1226

P1312
WALTPX1312

P1318

P1402

P1602
*

Immobilizer unitPCM
communication error

(See 110
DTC
P1602)

Code word is not registered in


PCM

(See 112
DTC
P1603)

Key ID numbers are not


registered in PCM

(See 113
DTC
P1604)

Code word does not match after


engine cranking

(See 113
DTC
P1621)

Key ID number does not match

(See 114
DTC
P1622)

Code word or key ID number


read/write error in PCM

(See 114
DTC
P1623)

WALTPX1602

P1603
*
WALTPX1603

P1604
*
WALTPX1604

P1621
*
WALTPX1621

P1622
*
WALTPX1622

P1623
*
WALTPX1623

F268

ON-BOARD DIAGNOSTIC SYSTEM

DTC

Output pattern

Possible cause

P1624
*

Immobilizer system
communication counter = 0

(See 115
DTC
P1624)

Injection pump EPROM circuit


malfunction

(See 115
DTC
P1649)

WALTPX1624

P1649
WALTPX1649

Page

: With immobilizer system

DTC P0100
DTC P0100
DETECTION
CONDITION

POSSIBLE
CAUSE

MAF circuit malfunction


D PCM monitors input voltage from MAF/IAT sensor when engine is running. If PCM detects either of
following conditions, PCM determines that MAF circuit has a malfunction.
Input voltage at PCM terminal 4E is below 0.25 V.
Input voltage at PCM terminal 4E is above 4.90 V.
D
D
D
D
D
D
D

MAF/IAT sensor malfunction


Connector or terminal malfunction
Short to GND in wiring between MAF/IAT sensor terminal C and PCM terminal 4E
Open circuit in wiring between MAF/IAT sensor terminal C and PCM terminal 4E
Open circuit in wiring between MAF/IAT sensor terminal B and PCM terminal body GND
PCM malfunction
Open circuit in wiring between MAF/IAT sensor terminal A and PCM control relay terminal D

LOW INPUT

ZCF4070W001

F269

ON-BOARD DIAGNOSTIC SYSTEM

DTC P0100

MAF circuit malfunction

HIGH INPUT

ZCF4070W002

ZCF4070W003

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY CURRENT INPUT SIGNAL STATUS


D Turn engine switch (engine OFF).
D Connect WDS or equivalent.
D Start engine.
D Access MAF PID using WDS or equivalent.
D Is MAF PID within 0.25 4.90 V?

Yes

Go to Step 11.

No

Go to next step.

INSPECT MAF/IAT SENSOR CONNECTOR


FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect MAF/IAT sensor connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminals, then go to Step 9.

No

If MAF PID is below 0.25 V in previous step, go to next


step.
If MAF PID is above 4.90 V in previous step, go to Step 8.

CHECK POWER SUPPLY CIRCUIT FOR OPEN


CIRCUIT
D Turn engine switch to ON (Engine OFF).
D Check voltage at MAF/IAT sensor terminal A
(harnessside).
D Is voltage B+?

Yes

Go to next step.

No

Inspect for open circuit in wiring harness between


MAF/IAT sensor terminal A (harnessside) and PCM
control relay terminal D (harnessside).
Repair or replace harness, then go to Step 11.

F270

ON-BOARD DIAGNOSTIC SYSTEM

STEP
5

11

12

13

INSPECTION

ACTION

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Is there a malfunction?

Yes

Repair terminal, then go to Step 11.

No

Go to next step.

INSPECT MAF SENSOR SIGNAL CIRCUIT


FOR OPEN CIRCUIT
D Check for continuity between MAF/IAT
sensor terminal C (harnessside) and PCM
connector terminal 4E (harnessside).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 11.

INSPECT MAF SENSOR SIGNAL CIRCUIT


FOR SHORTS
D Check for continuity between following
circuits:
MAF/IAT sensor terminal C (harnessside)
and body GND
MAF/IAT sensor connector terminals B and
C (harnessside)
D Is there continuity?

Yes

Repair or replace suspected harness, then go to Step 11.

No

Inspect MAF/IAT sensor, then go to Step 11.


(See NO TAG MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR INSPECTION)

INSPECT MAF SENSOR GROUND CIRCUIT


FOR OPEN CIRCUIT
D Check for continuity between MAF/IAT
sensor terminal B (harnessside) and body
GND.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 11.

INSPECT MAF SENSOR SIGNAL CIRCUIT


FOR SHORT TO POWER CIRCUIT
D Turn engine switch to ON (Engine OFF).
D Measure voltage between MAF/IAT sensor
terminal C (harnessside) and body GND.
D Is voltage 0 V?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 11.

INSPECT POOR CONNECTION OF PCM


CONNECTOR
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection at terminals 4E
and 4A (damaged, pulledout terminals,
corrosion, etc.).
D Is there a malfunction?

Yes

Repair terminal, then go to next step.

No

Inspect MAF/IAT sensor, then go to next step.


(See NO TAG MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR INSPECTION)

VERIFY TROUBLESHOOTING OF DTC P0100


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F271

ON-BOARD DIAGNOSTIC SYSTEM


DTC P0105
DTC P0105
DETECTION
CONDITION

POSSIBLE
CAUSE

Boost sensor circuit malfunction


D PCM monitors input voltage from boost sensor when engine switch is turned ON. If PCM detects either
of following conditions, PCM determines that boost sensor circuit has a malfunction.
Input voltage at PCM terminal 1P is below 0.19 V.
Input voltage at PCM terminal 1P is above 4.90 V.
D
D
D
D
D
D
D

Boost sensor malfunction


Connector or terminal malfunction
Short to GND in wiring between boost sensor terminal B and PCM terminal 1P
Open circuit in wiring between boost sensor terminal B and PCM terminal 1P
Open circuit in wiring between boost sensor terminal A and PCM terminal 1B
Open circuit in wiring between boost sensor terminal C and PCM terminal 1A
PCM malfunction

LOW INPUT

ZCF4070W004

HIGH INPUT

ZCF4070W005

ZCF4070W006

F272

ON-BOARD DIAGNOSTIC SYSTEM


Diagnostic procedure
STEP
1

10

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY CURRENT INPUT SIGNAL STATUS


D Turn engine switch to ON (engine OFF).
D Connect WDS or equivalent.
D Start engine.
D Access MAP PID using WDS or equivalent.
D Is MAP PID within 0.19 4.90 V?

Yes

Go to Step 11.

No

Go to next step.

INSPECT POOR CONNECTION OF BOOST


SENSOR CONNECTOR
D Turn engine switch to OFF.
D Disconnect boost sensor connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminals, then go to Step 9.

No

If MAP PID is below 0.19 V in previous step, go to next


step.
If MAP PID is above 4.90 V in previous step, go to Step 8.

CHECK POWER SUPPLY CIRCUIT FOR OPEN


CIRCUIT
D Turn engine switch to ON (Engine OFF).
D Check voltage at boost sensor terminal C
(harnessside).
D Is voltage B+?

Yes

Go to next step.

No

Inspect for open circuit in wiring harness between boost


sensor terminal C (harnessside) and PCM terminal 1A
(harnessside).
Repair or replace harness, then go to Step 11.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Is there a malfunction?

Yes

Repair terminal, then go to Step 11.

No

Go to next step.

INSPECT BOOST SENSOR SIGNAL CIRCUIT


FOR OPEN CIRCUIT
D Check for continuity between boost sensor
terminal B (harnessside) and PCM
connector terminal 1P (harnessside).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 11.

INSPECT BOOST SENSOR SIGNAL CIRCUIT


FOR SHORTS
D Check for continuity between following
circuits:
Boost sensor terminal B (harnessside)
and body GND
Boost sensor connector terminals A and B
(harnessside)
D Is there continuity?

Yes

Repair or replace suspected harness, then go to Step 11.

No

Inspect boost sensor, then go to Step 11.


(See NO TAG BOOST SENSOR INSPECTION)

INSPECT BOOST SENSOR GROUND CIRCUIT


FOR OPEN CIRCUIT
D Check for continuity between boost sensor
terminal A (harnessside) and PCM
connector terminal 1B (harnessside).
D Is there continuity?

Yes

Replace boost sensor, then go to Step 11.

No

Repair or replace suspected harness, then go to Step 11.

INSPECT BOOST SENSOR SIGNAL CIRCUIT


FOR SHORT TO POWER CIRCUIT
D Turn engine switch to ON (Engine OFF).
D Measure voltage between boost sensor
terminal B (harnessside) and body GND.
D Is voltage 0 V?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 11.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection at terminals 1A,
1B and 1P (damaged, pulledout terminals,
corrosion, etc.).
D Is there a malfunction?

Yes

Repair terminal, then go to next step.

No

Inspect boost sensor, then go to next step.


(See NO TAG BOOST SENSOR INSPECTION)

F273

ON-BOARD DIAGNOSTIC SYSTEM

STEP
11

12

INSPECTION

ACTION

VERIFY TROUBLESHOOTING OF DTC P0105


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P0110
DTC P0110
DETECTION
CONDITION

POSSIBLE
CAUSE

IAT No. 1 circuit malfunction


D PCM monitors IAT sensor No. 1 signal at PCM terminal 1J. If voltage at PCM terminal 1J is below 0.13
V or above 4.90 V, PCM determines that IAT sensor No. 1 circuit has a malfunction.
D
D
D
D
D
D
D
D
D

IAT sensor No. 1 malfunction


Short to GND circuit between IAT sensor No. 1 terminal D and PCM terminal 3D
IAT No. 1 signal and IAT GND circuit are shorted each other.
Poor connection at IAT sensor No. 1 or PCM connector
PCM malfunction
Open circuit between IAT sensor No. 1 terminal D and PCM terminal 3D
Short to power circuit between IAT sensor No. 1 terminal D and PCM terminal 3D
Open circuit between IAT sensor No. 1 terminal E and PCM terminal 1B
Short to power circuit between IAT sensor No. 1 terminal E and PCM terminal 1B

LOW INPUT

ZCF4070W052

F274

ON-BOARD DIAGNOSTIC SYSTEM

DTC P0110

IAT No. 1 circuit malfunction

HIGH INPUT

ZCF4070W053

ZCF4070W060

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CLASSIFY IF INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Clear DTC from PCM memory.
D Turn engine switch to OFF then ON (Engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

VERIFY CURRENT INPUT SIGNAL


STATUS-HIGH OR LOW INPUT
D Start engine.
D Access IATDC PID using WDS or equivalent.
D Is IATDC PID within 0.134.90 V?

Yes

Go to Step 16.

INSPECT IAT SENSOR No. 1 TERMINAL


D Turn engine switch to OFF.
D Disconnect IAT sensor No. 1 connector.
D Check for bent terminal of IAT sensor No. 1
terminals D and E (partside).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 16.

No

Go to next step.

No

D IF IATDC PID is below 0.13 V, go to next step.


D IF IATDC PID is above 4.90 V, go to Step 9.

F275

ON-BOARD DIAGNOSTIC SYSTEM

STEP
5

10

11

12

13

14

INSPECTION

ACTION

CLASSIFY IF IAT SENSOR No. 1


MALFUNCTION OR HARNESS MALFUNCTION
D Turn engine switch to ON (Engine OFF).
D Access IATDC PID using WDS or equivalent.
D Is IATDC PID below 0.13 V?

Yes

Go to next step.

No

Go to Step 10.

INSPECT IAT SENSOR No. 1 SIGNAL CIRCUIT


FOR SHORT TO GND
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for continuity between IAT sensor No.
1 terminal D (harnessside) and body GND.
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 16.

No

Go to next step.

INSPECT IAT SENSOR No. 1 CIRCUITS FOR


SHORT
D Check for continuity between IAT sensor No.
1 terminals D and E (harnessside).
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 16.

No

Go to Step 16.

INSPECT IAT SENSOR No. 1 CONNECTOR


FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect IAT sensor No. 1 connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 16.

No

Go to next step.

INSPECT IAT SENSOR No. 1


D Inspect IAT sensor No. 1.
(See NO TAG MASS AIR FLOW
(MAF)/INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION)
D Is it okay ?

Yes

Go to next step.

No

Replace IAT sensor No. 1, then go to Step 16.

INSPECT IAT SENSOR No. 1 SIGNAL CIRCUIT


FOR SHORT TO POWER
D Turn engine switch to ON (Engine OFF).
D Measure voltage between IAT sensor No. 1
terminal D (harnessside) and body GND.
D Is voltage B+?

Yes

Repair or replace shorted harness, then go to Step 16.

No

Go to next step.

INSPECT IAT SENSOR No. 1 GND CIRCUIT


FOR SHORT TO POWER
D Measure voltage between IAT sensor No. 1
terminal E (harnessside) and body GND.
D Is voltage B+?

Yes

Repair or replace shorted harness, then go to Step 16.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Inspect PCM terminals 3D and 1B (damaged,
pulled-out pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 16.

No

Go to next step.

INSPECT IAT SENSOR No. 1 SIGNAL CIRCUIT


FOR OPEN
D Check for continuity between IAT sensor No.
1 terminal D (harnessside) and PCM
terminal 3D.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 16.

INSPECT IAT SENSOR No. 1 GND CIRCUIT


FOR OPEN
D Check for continuity between IAT sensor No.
1 terminal E (harnessside) and PCM
terminal 1B (harness-side).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to next step.

F276

ON-BOARD DIAGNOSTIC SYSTEM

STEP
15

16

INSPECTION

ACTION

VERIFY TROUBLESHOOTING OF DTC P1110


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Clear DTC from PCM memory.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P0115
DTC P0115
DETECTION
CONDITION

POSSIBLE
CAUSE

ECT circuit malfunction


D PCM monitors ECT sensor signal at PCM terminal 1T. If voltage at PCM terminal 1Tis below 0.19 V or
above 4.90 V, PCM determines that ECT sensor circuit has a malfunction.
D
D
D
D
D
D
D
D
D

ECT sensor malfunction


Short to GND circuit between ECT sensor terminal A and PCM terminal 1T
ECT signal and ECT GND circuit are shorted each other.
Poor connection at ECT sensor or PCM connector
PCM malfunction
Open circuit between ECT sensor terminal A and PCM terminal 1T
Short to power circuit between ECT sensor terminal A and PCM terminal 1T
Open circuit between ECT sensor terminal B and PCM terminal 1B
Short to power circuit between ECT sensor terminal B and PCM terminal 1B

LOW INPUT

ZCF4070W016

F277

ON-BOARD DIAGNOSTIC SYSTEM

DTC P0115

ECT circuit malfunction

HIGH INPUT

ZCF4070W007

ZCF4070W017

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service information available?

Yes

Perform repair or diagnosis according to available Service


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CLASSIFY INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Turn engine switch ON (engine OFF).
D Connect the WDS or equivalent.
D Clear DTC from PCM memory.
D Turn engine switch to OFF then ON (Engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern is existing. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

VERIFY CURRENT INPUT SIGNAL


STATUSCIRCUIT MALFUNCTION
D Start engine.
D Access ECT PID using WDS or equivalent.
D Is ECT PID within 0.194.90 V?

Yes

Go to Step 13.

INSPECT TERMINAL FOR BENDING


D Turn engine switch to OFF.
D Disconnect ECT sensor connector.
D Check for bent of ECT sensor terminals A
and B (partside).
D Is there any concerns?

Yes

Repair or replace terminal, then go to Step 13.

No

Go to next step.

INSPECT ECT SIGNAL CIRCUIT FOR SHORT


TO GND
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check continuity between ECT sensor
terminal A (harnessside) and body GND.
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 13.

No

Go to next step.

INSPECT ECT CIRCUIT FOR SHORT


D Check continuity between ECT sensor
terminals A and B (harnessside).
D Is there continuity?

Yes

Repair or replace shorted harness, then go to step 13.

No

Go to Step 13.

No

D If ECT PID is below 0.19 V, go to next step.


D If ECT PID is above 4.90 V, go to Step 7.

F278

ON-BOARD DIAGNOSTIC SYSTEM

STEP
7

10

11

12

13

14

INSPECTION

ACTION

INSPECT ECT SENSOR CONNECTOR FOR


POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect ECT sensor connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Are there any concerns?

Yes

Repair or replace terminal, then go to Step 13.

No

Go to next step.

CLASSIFY ECT SENSOR OR HARNESS


MALFUCNTION
D Connect jumper wire between terminals A
and B (harnessside).
D Access ECT PID using WDS or equivalent.
D Is ECT PID approx. 0 V?

Yes

Replace ECT sensor, then go to Step 13.

No

Go to next step.

INSPECT ECT SENSOR SIGNAL CIRCUIT FOR


SHORT TO POWER
D Turn engine switch to ON (Engine OFF).
D Measure voltage between ECT sensor
terminal A (harnessside) and body GND.
D Is voltage B+?

Yes

Repair or replace shorted harness, then go to Step 13.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Disconnect PCM connector.
D Check for poor connection at terminals 1T
and 1B (damaged, pulledout terminals,
corrosion, etc.).
D Are there any concerns?

Yes

Repair or replace terminal, then go to Step 13.

No

Go to next step.

INSPECT ECT SENSOR SIGNAL CIRCUIT FOR


OPEN CIRCUIT
D Check continuity between ECT sensor
terminal A (harnessside) and PCM terminal
1T.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 13.

INSPECT ECT SENSOR GROUND CIRCUIT


FOR OPEN CIRCUIT
D Check continuity between ECT sensor
terminal B (harnessside) and PCM terminal
1B.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to next step.

VERIFY TROUBLESHOOTING OF DTC P0115


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F279

ON-BOARD DIAGNOSTIC SYSTEM


DTC P0120
DTC P0120

DETECTION
CONDITION

POSSIBLE
CAUSE

Accelerator position sensor circuit malfunction


D PCM monitors accelerator position sensor signal at PCM terminal 1R. If PCM detects either of following
conditions, PCM determines that accelerator position sensor circuit has a malfunction.
Input voltage at PCM terminal 1R is below 0.29 V.
Input voltage at PCM terminal 1R is above 4.80 V.
Input voltage at PCM terminal 1R is above 1.35 V with idle switch ON.
D PCM monitors difference voltage between main circuit and monitor circuit of accelerator position sensor.
If difference voltage between PCM terminal 1R and 2C is above 0.90 V, PCM determines that
accelerator position sensor has a malfunction.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Accelerator position sensor malfunction


Poor connection at accelerator position sensor or PCM connector
Open circuit between accelerator position sensor terminal B and PCM terminal 1R
Short to GND circuit between accelerator position sensor terminal B and PCM terminal 1R
Open circuit between accelerator position sensor terminal A and PCM terminal 1A
Short to GND circuit between accelerator position sensor terminal A and PCM terminal 1A
Open circuit between accelerator position sensor terminal C and PCM terminal 2C
Short to GND circuit between accelerator position sensor terminal C and PCM terminal 2C
PCM malfunction
Open circuit between accelerator position sensor terminal D and PCM terminal 1B
Short to reference voltage (Vref) supply circuit between accelerator position sensor terminal B and PCM
terminal 1R
Short to reference voltage (Vref) supply circuit between accelerator position sensor terminal C and PCM
terminal 2C
Electrical corrosion in accelerator position signal circuit
Voltage drops in reference voltage (Vref) supply circuit
Idle switch malfunction

F280

ON-BOARD DIAGNOSTIC SYSTEM

DTC P0120

Accelerator position sensor circuit malfunction

ZCF4070W18

Diagnostic procedure
STEP
1

INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

ACTION
Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

F281

ON-BOARD DIAGNOSTIC SYSTEM

STEP
2

INSPECTION

ACTION

CLASSIFY IF INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Turn engine switch ON (engine OFF).
D Connect the WDS or equivalent.
D Clear DTC from PCM memory.
D Turn engine switch to OFF then ON (Engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

INSPECT ACCELERATOR POSITION SENSOR


CONNECTOR FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect accelerator position sensor
connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace connector, then go to next step.

No

Go to next step.

INSPECT ACCELERATOR POSITION SENSOR


TERMINAL
D Check for bent terminal of accelerator
position sensor terminals (partside).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 11.

No

Go to next step.

CHECK TERMINAL VOLTAGE AT


ACCELERATOR POSITION SENSOR
D Check voltage at accelerator position sensor
terminals A, B and C (partside).
D Is voltage approx. 5 V?

Yes

Go to next step.

No

D If voltage is approx. B+, repair or replace appropriate


harnesses.
Then, go to Step 11.
D If voltage is approx. 0V, go to Step 8

VERIFY ACCELERATOR POSITION SENSOR


CIRCUIT FOR SHORT TO REFERENCE
VOLTAGE (VREF) SUPPLY CIRCUIT
D Check continuity between following terminals:
Accelerator position sensor terminals A
and B (partside)
Accelerator position sensor terminals A
and C (partside)
D Is there continuity?

Yes

Repair or replace appropriate harnesses, then go to Step


11.

No

Go to next step.

VERIFY ACCELERATOR POSITION SENSOR


CIRCUIT FOR SHORT TO GND
D Check continuity between following terminals:
Accelerator position sensor terminal A
(partside) and body GND
Accelerator position sensor terminal B
(partside) and body GND
Accelerator position sensor terminal C
(partside) and body GND
D Is there continuity?

Yes

Repair or replace appropriate harnesses, then go to Step


11.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Disconnect PCM connector.
D Inspect PCM terminals 1A, 1R, 1B and 2C
(damaged, pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 11.

No

Go to next step.

VERIFY ACCELERATOR POSITION SENSOR


MAIN CIRCUIT,MONITOR CIRCUIT AND GND
CIRCUIT FOR OPEN CIRCUIT
D Check continuity between following terminals:
Accelerator position sensor terminal A
(harnessside) and PCM terminal 1A
Accelerator position sensor terminal B
(harnessside) and PCM terminal 1R
Accelerator position sensor terminal C
(harnessside) and PCM terminal 2C
Accelerator position sensor terminal D
(harnessside) and PCM terminal 1B
D Is there continuity?

Yes

Go to next step.

No

Repair or replace appropriate harnesses, then go to Step


11.

F282

ON-BOARD DIAGNOSTIC SYSTEM

STEP
10

11

12

INSPECTION

ACTION

INSPECT ACCELERATOR POSITION SENSOR


D Make sure to reconnect all disconnected
connectors.
D Inspect accelerator position sensor.
(See NO TAG ACCELERATOR POSITION
SENSOR INSPECTION)
D Is it okay?

Yes

Go to next step.

No

Replace accelerator position sensor, then go to Step 11.

VERIFY TROUBLESHOOTING OF DTC P0120


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch ON (engine OFF).
D Connect the WDS or equivalent.
D Clear DTC from PCM memory.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P0180
DTC P0180
DETECTION
CONDITION

POSSIBLE
CAUSE

Fuel temperature sensor malfunction


D PCM monitors fuel temperature sensor signal at PCM terminal 1L. If voltage at PCM terminal 1L is
below 0.19 V or above 4.59 V, PCM determines that fuel temperature sensor circuit has malfunction.
D
D
D
D
D
D
D
D
D

Fuel temperature sensor malfunction


Short to GND circuit between fuel temperature sensor terminal K and PCM terminal 1L
Fuel temperature signal and fuel temperature GND circuit are shorted each other.
Poor connection at fuel temperature sensor or PCM connector
PCM malfunction
Open circuit between fuel temperature sensor terminal K and PCM terminal 1L
Short to power circuit between fuel temperature sensor terminal K and PCM terminal 1L
Open circuit between fuel temperature sensor terminal E and PCM terminal 1B
Short to power circuit between fuel temperature sensor terminal E and PCM terminal 1B

LOW INPUT

ZCF4070W008

F283

ON-BOARD DIAGNOSTIC SYSTEM

DTC P0180

Fuel temperature sensor malfunction

HIGH INPUT

ZCF4070W009

ZCF4070W019

Diagnostic procedure
STEP

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CLASSIFY INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Turn engine switch to ON (engine OFF).
D Connect the WDS or equivalent.
D Clear DTC from PCM memory.
D Turn engine switch to OFF then ON (Engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

VERIFY CURRENT INPUT SIGNAL


STATUS-HIGH OR LOW INPUT
D Start engine.
D Access FLT V PID using WDS or equivalent.
D Is FLT V PID within 0.194.59 V?

Yes

Go to Step 15.

INSPECT FUEL TEMPERATURE SENSOR


TERMINAL
D Turn engine switch to OFF.
D Disconnect fuel temperature sensor
connector.
D Check for bent terminal of fuel temperature
sensor terminals K and E (partside).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 15.

No

Go to next step.

CLASSIFY FUEL TEMPERATURE SENSOR


MALFUNCTION OR HARNESS MALFUNCTION
D Turn engine switch to ON (Engine OFF).
D Access FLT V PID using WDS or equivalent.
D Is FLT V PID below 0.19 V?

Yes

Go to next step.

No

Inspect fuel temperature sensor, then go to Step 15.


(See NO TAG FUEL TEMPERATURE SENSOR
INSPECTION)

No

D IF FLT V PID is below 0.19 V, go to next step.


D IF FLT V PID is above 4.59 V, go to Step 8.

F284

ON-BOARD DIAGNOSTIC SYSTEM

STEP
6

10

11

12

13

14

INSPECTION

ACTION

INSPECT FUEL TEMPERATURE SENSOR


SIGNAL CIRCUIT FOR SHORT TO GND
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for continuity between fuel
temperature sensor terminal K
(harnessside) and body GND.
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to next step.

INSPECT FUEL TEMPERATURE SENSOR


CIRCUITS FOR SHORT
D Check for continuity between fuel
temperature sensor terminals K and E
(harnessside).
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to Step 16.

INSPECT FUEL TEMPERATURE SENSOR


CONNECTOR FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect fuel temperature sensor
connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 15.

No

Go to next step.

INSPECT FUEL TEMPERATURE SENSOR


D Inspect fuel temperature sensor.
(See NO TAG FUEL TEMPERATURE
SENSOR INSPECTION)
D Is it okay ?

Yes

Go to next step.

No

Replace fuel temperature sensor, then go to Step 15.

INSPECT FUEL TEMPERATURE SENSOR


SIGNAL CIRCUIT FOR SHORT TO POWER
D Turn engine switch to ON (Engine OFF).
D Measure voltage between fuel temperature
sensor terminal K (harnessside) and body
GND.
D Is voltage B+?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to next step.

INSPECT FUEL TEMPERATURE SENSOR GND


CIRCUIT FOR SHORT TO POWER
D Measure voltage between fuel temperature
sensor terminal E (harnessside) and body
GND.
D Is voltage B+?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Inspect PCM terminals 1L and 2E(damaged,
pulled-out pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 15.

No

Go to next step.

INSPECT FUEL TEMPERATURE SENSOR


SIGNAL CIRCUIT FOR OPEN CIRCUIT
D Check for continuity between fuel
temperature sensor terminal K
(harnessside) and PCM terminal 2E.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 15.

INSPECT FUEL TEMPERATURE SENSOR GND


CIRCUIT FOR OPEN CIRCUIT
D Check for continuity between fuel
temperature sensor terminal E
(harnessside) and PCM terminal 1L
(harness-side).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to next step.

F285

ON-BOARD DIAGNOSTIC SYSTEM

STEP
15

16

INSPECTION

ACTION

VERIFY TROUBLESHOOTING OF DTC P0180


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P0251
DTC P0251
DETECTION
CONDITION

POSSIBLE
CAUSE

Injection amount control system malfunction


D PCM monitors difference voltage between target injection amount and actual injection amount while
engine running. If difference voltage is above threshold for 0.5 s, PCM determines that injection amount
control system is malfunctioning.
D
D
D
D
D
D
D

Connector or terminal malfunction


Open circuit in wiring between injection pump connector A terminal I and PCM control relay terminal D
Open circuit in wiring between injection pump connector A terminal I and PCM terminal 4X
Open or Short to GND in wiring between injection pump connector A terminal L and PCM terminal 4Y
Electronic governor malfunction
Injection pump (injection amount control) malfunction
PCM malfunction

ZFC4070W205

Diagnostic procedure
STEP
1

INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

ACTION
Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

F286

ON-BOARD DIAGNOSTIC SYSTEM

STEP
2

INSPECTION

ACTION

VERIFY CURRENT INPUT SIGNAL STATUSIS


CONCERN INTERMITTENT OR CONSTANT?
D Turn engine switch to ON (Engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING Procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

VERIFY OTHER DTC IS PRESENT


D Is other DTC present?

Yes

Perform appropriate DTC troubleshooting procedure.


(See 67 DTC TABLE)
then go to Step 8.

No

Go to next step.

INSPECT INJECTION PUMP CONNECTOR


FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect injection pump connector A.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT ELECTRONIC GOVERNOR POWER


CIRCUIT
D Turn engine switch to ON (Engine OFF).
D Measure voltage between injection pump
connector A terminal I (harnessside) and
body GND.
D Is voltage B+?

Yes

Go to next step.

No

Repair or replace electronic governor power circuit for


open, then go to Step 9.

INSPECT ELECTRONIC GOVERNOR


CONTROL CIRCUIT FOR SHORT TO GND
D Turn engine switch to OFF.
D Check for continuity between injection pump
connector A terminal L (harnessside) and
body GND.
D Is there continuity?

Yes

Repair or replace electronic governor control circuit for


short to GND, then go to Step 9.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT ELECTRONIC GOVERNOR


CONTROL CIRCUIT FOR OPEN CIRCUIT
D Check for continuity between injection pump
connector A terminal L (harnessside) and
PCM terminal 4Y (harnessside).
D Is there continuity?

Yes

Injection pump may have malfunction. Consult your


distributor for inspection of injection pump.
Go to next step.

No

Repair or replace electronic governor control circuit for


open, then go to next step.

INSPECT ELECTRONIC GOVERNOR


D Perform electronic governor Inspection.
(SeeNO TAG ELECTRONIC GOVERNOR
INSPECTION)
D Is electronic governor okay?

Yes

Injection pump may have mechanical malfunction. Consult


your distributor for inspection of injection pump.
Then go to next step.

No

Consult your distributer for replacement of electronic


governor.
Then go to next step.

VERIFY TROUBLESHOOTING OF DTC P0251


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (Engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

10

11

F287

ON-BOARD DIAGNOSTIC SYSTEM


DTC P0335
DTC P0335
DETECTION
CONDITION

POSSIBLE
CAUSE

TDC sensor circuit malfunction


D If PCM does not receive input signal from TDC sensor when engine is running, PCM determines that
TDC sensor circuit has a malfunction.
D
D
D
D
D
D
D
D

TDC sensor malfunction


Poor connection at TDC sensor or PCM connector
PCM malfunction
Short to GND circuit between TDC sensor terminal B and PCM terminal 1H
Open circuit between TDC sensor terminal B and PCM terminal 1H
Open circuit between TDC sensor terminal A and PCM control relay terminal D
Open circuit between TDC sensor terminal C and PCM terminal 1B
TDC sensor pulse wheel malfunction

ZCF4070W050

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

INSPECT TDC SENSOR


D Inspect TDC sensor.
(See NO TAG TDC SENSOR INSPECTION)
D Is it okay?

Yes

Check for poor connection (damage/pulledout terminals,


corrosion, etc), bent terminals of TDC sensor connector or
plate.
D Repair if necessary, then go to Step 9

No

Replace TDC sensor, then go to Step 9.

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection at terminals 1B
and 1H (damaged, pulledout terminals,
corrosion, etc.).
D Is there a malfunction?

F288

ON-BOARD DIAGNOSTIC SYSTEM

STEP
4

10

INSPECTION

ACTION

INSPECT TDC SENSOR TERMINAL


D Turn engine switch OFF.
D Disconnect TDC sensor connector.
D Check bent terminal of TDC sensor terminals
A, B and C (partside).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Inspect for open circuit in wiring harness between TDC


sensor terminal A (harnessside) and PCM control relay
terminal D (harnessside).
Repair or replace harness, then go to Step 9.

CHECK POWER SUPPLY CIRCUIT FOR OPEN


CIRCUIT
D Turn engine switch to ON (Engine OFF).
D Check voltage at TDC sensor terminal A
(harnessside).
D Is voltage B+?

Yes

Go to next step.

No

Inspect for open circuit in wiring harness between TDC


sensor terminal A (harnessside) and PCM control relay
terminal D (harnessside).
Repair or replace harness, then go to Step 9.

INSPECT TDC CIRCUIT FOR OPEN CURCUIT


D Check for continuity between TDC sensor
terminal B (harnessside) and PCM
connector terminal 1H (harnessside).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 9.

INSPECT TDC CIRCUIT FOR SHORT TO GND


D Check for continuity between TDC sensor
terminal B (harnessside) and body GND.
D Is there continuity?

Yes

Repair or replace suspected harness, then go to Step 9.

No

Go to next step.

INSPECT TDC SENSOR GROUND CIRCUIT


FOR OPEN CIRCUIT
D Check for continuity between TDC sensor
terminal C (harnessside) and PCM
connector terminal 1B (harnessside).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 9.

VERIFY TROUBLESHOOTING OF DTC P0335


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P0400
DTC P0400
DETECTION
CONDITION
POSSIBLE
CAUSE

EGR system malfunction


D PCM monitors EGR valve position sensor signal at PCM terminal 1F. If voltage at PCM terminal 1F is
below 0.66 V when engine is idle, PCM determines that EGR system has a malfunction.
D
D
D
D
D

EGR valve malfunction


EGR solenoid valve (vacuum) malfunction
EGR solenoid valve (vent) malfunction
EGR control solenoid valve malfunction
PCM malfunction

Diagnostic procedure
STEP
1

INSPECTION
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
D Check for related Service Bulletins and/or
online repair information availability.
D Is any related repair information available?

ACTION
Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

F289

ON-BOARD DIAGNOSTIC SYSTEM

STEP
2

INSPECTION

ACTION

INSPECT FOR APPROPRIATE SOLENOID


VALVES
D Inspect for following solenoid valves.
EGR solenoid valve (vacuum)
(See NO TAG EGR SOLENOID VALVE
(VACUUM) INSPECTION)
EGR solenoid valve (vent)
(See NO TAG EGR SOLENOID VALVE
(VENT) INSPECTION)
EGR control solenoid valve
(See NO TAG EGR CONTROL SOLENOID
VALVE INSPECTION)
D Are solenoid valves okay?

Yes

Go to next step.

No

Replace appropriate solenoid valves, then go to next step.

INSPECT VACUUM HOSE CONDITION


D Inspect vacuum hoses for clogging, any
damages, freeze, or vacuum leakage.
D Is there any concern?

Yes

Replace vacuum hoses, then go to Step 5.

No

Go to next step.

INSPECT EGR VALVE MALFUNCTION


D Turn ignition key to OFF.
D Remove EGR valve.
D Inspect EGR valve.
(See NO TAG EGR VALVE INSPECTION)
D Is EGR valve okay?

Yes

Go to next step.

No

Replace EGR valve, then go to Step 5.

VERIFY TROUBLESHOOTING OF DTC P0400


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch ON (engine OFF).
D Clear DTC from memory using WDS or
equivalent.
D Start the engine.
D Warmup engine until ECT PID is above 70
C {158 F}.
D Is same DTC present?

Yes

Go to next step.

No

Replace PCM, then go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE
(See section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F290

ON-BOARD DIAGNOSTIC SYSTEM


DTC P0500
DTC P0500
DETECTION
CONDITION

POSSIBLE
CAUSE

Vehicle speed sensor (VSS) circuit malfunction


D PCM detects after following conditions, PCM determines that VSS sensor circuit has a malfunction:
Gear is in position other than neutral.
Engine speed is avobe 4,000 rpm.
Vehicle speed is below 3.76 km/h {2.33 mph}.
D
D
D
D
D
D
D
D
D

PCM malfunction
Instrument cluster (vehicle speedometer sensor) malfunction
Open circuit between PCM terminal 1N and instrument cluster terminal 1M
Short to ground between PCM terminal 1N and instrument cluster terminal 1M
VSS malfunction
Open circuit between vehicle speed sensor terminal A and instrument cluster terminal 1L
Short to ground between vehicle speed sensor terminal A and instrument cluster terminal 1L
Open circuit between vehicle speed sensor terminal B and instrument cluster terminal 1M
Short to ground between vehicle speed sensor terminal B and instrument cluster terminal 1M

ZCF4070W059

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service information available?

Yes

Perform repair or diagnosis according to available Service


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CHECK SPEEDOMETER
D Check speedometer.
D Does vehicle speedometer needle move?

Yes

Go to next step.

No

Inspect speedometer, then go to next step.


(See Section T.)

F291

ON-BOARD DIAGNOSTIC SYSTEM

STEP
3

INSPECTION

ACTION

CLASSIFY INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Turn engine switch ON (engine OFF).
D Clear DTC from PCM using WDS or
equivalent.
D Turn engine switch to OFF then ON (engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(SeeNO TAG INTERMITTENT CONCERN
TROUBLESHOOTING.)

INSPECT POOR CONNECTION OF PCM


CONNECTOR
D Disconnect PCM connector.
D Check for poor connection at terminal 1N
(damaged/pulledout terminals, corrosion,
etc.).
D Are there any concerns?

Yes

Repair or replace terminal, then go to Step 8.

No

Go to next step.

INSPECT INSTRUMENT CLUSTER CIRCUIT


FOR OPEN CIRCUIT
D Check continuity between PCM terminal 1N
and instrument cluster 1M (harnessside).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace harness, then go to Step 8.

INSPECT INSTRUMENT CLUSTER CIRCUIT


FOR SHORT TO GROUND
D Check for continuity between PCM terminal
1N (harnessside) and body ground.
D Is there continuity?

Yes

Repair or replace harness, then go to Step 8.

No

Go to next step.

INSPECT INSTRUMENT CLUSTER


CONNECTOR FOR POOR CONNECTION
D Disconnect instrument cluster connector.
D Check for poor connection at terminal 1M
(damaged/pulledout terminals, corrosion,
etc.).
D Are there any concerns?

Yes

Repair or replace terminal, then go to Step 8.

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P0500


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch ON (engine OFF).
D Clear DTC from memory using WDS or
equivalent.
D Start engine.
D Warm up engine.
D Drive vehicle under following conditions for
10 seconds or more.
Engine speed: 4,000 rpm or above
Gear: other than neutral.
Vehicle speed: 3.76 km/h {2.33 mph} or
above
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure.
(See Section F2.)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

F292

ON-BOARD DIAGNOSTIC SYSTEM


DTC P0510
DTC P0510
DETECTION
CONDITION

POSSIBLE
CAUSE

Idle switch malfunction


D PCM detects after following conditions, PCM determines that idle switch has a malfunction:
Output voltage from accelerator position sensor is avobe 1.35 V with idle switch ON.
Output voltage from accelerator position sensor is below 0.86 V with idle switch OFF.
D
D
D
D
D
D

Idle switch malfunction


Short to GND circuit between idle switch terminal A and PCM terminal 3O
Poor connection at idle switch or PCM connector
PCM malfunction
Open circuit between idle switch terminal A and PCM terminal 3O
Open circuit between idle switch terminal B and body GND

ZFC4070W051

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CLASSIFY IF INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Clear DTC from PCM memory.
D Turn engine switch to OFF then ON (Engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

CHECK IDLE SWITCH


D Inspect idle switch.
(See NO TAG IDLE SWITCH INSPECTION)
D Is it okay?

Yes

Go to next step.

No

Replace idle switch, then go to Step 9

INSPECT IDLE SWITCH TERMINAL


D Turn engine switch to OFF.
D Disconnect idle switch connector.
D Check for bent terminal of idle switch
terminals A and B (partside).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

F293

ON-BOARD DIAGNOSTIC SYSTEM

STEP
5

10

INSPECTION

ACTION

INSPECT IDLE SWITCH SIGNAL CIRCUIT FOR


SHORT TO GND
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for continuity between idle switch
terminal A (harnessside) and body GND.
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 9.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Inspect PCM terminals 3O (damaged,
pulled-out pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT IDLE SWITCH SIGNAL CIRCUIT FOR


OPEN CIRCUIT
D Check for continuity between idle switch
terminal A (harnessside) and PCM terminal
3O.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 9.

INSPECT IDLE SWITCH GND CIRCUIT FOR


OPEN CIRCUIT
D Check for continuity between idle switch
terminal B (harnessside) and body GND.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to next step.

VERIFY TROUBLESHOOTING OF DTC P0510


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch ON (engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P0606 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn engine switch to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P0606
DTC P0606
DETECTION
CONDITION
POSSIBLE
CAUSE

PCM malfunction
D PCM detects internal malfunction.
D PCM malfunction

Diagnostic procedure
STEP
1

INSPECTION

ACTION

F294

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1110
DTC P1110
DETECTION
CONDITION

POSSIBLE
CAUSE

IAT sensor No.2 circuit malfunction


D PCM monitors IAT sensor No.2 signal at PCM terminal 1J. If voltage at PCM terminal 1J is below 0.14 V
or above 4.90 V, PCM determines that IAT sensor No.2 circuit has a malfunction.
D
D
D
D
D
D
D
D
D

IAT sensor No.2 malfunction


Short to GND circuit between IAT sensor No.2 terminal A and PCM terminal 1J
IAT No.2 signal and IAT GND circuit are shorted each other
Poor connection at IAT sensor No.2 or PCM connector
PCM malfunction
Open circuit between IAT sensor No.2 terminal A and PCM terminal 1J
Short to power circuit between IAT sensor No.2 terminal A and PCM terminal 1J
Open circuit between IAT sensor No.2 terminal B and PCM terminal 1B
Short to power circuit between IAT sensor No.2 terminal B and PCM terminal 1B

LOW INPUT

ZCF4070W013

HIGH INPUT

ZCF4070W014

ZCF4070W015

Diagnostic procedure
STEP
1

INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

ACTION
Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

F295

ON-BOARD DIAGNOSTIC SYSTEM

STEP
2

10

11

INSPECTION

ACTION

CLASSIFY IF INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Turn engine switch ON (engine OFF).
D Connect the WDS or equivalent.
D Clear DTC from PCM memory.
D Turn engine switch to OFF then ON (Engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

VERIFY CURRENT INPUT SIGNAL


STATUS-HIGH OR LOW INPUT
D Start engine.
D Access IAT PID using WDS or equivalent.
D Is IAT PID within 0.144.90 V?

Yes

Go to Step 15.

No

D If IAT PID is below 0.14 V, go to next step.


D If IAT PID is above 4.90 V, go to Step 8.

INSPECT IAT SENSOR No.2 TERMINAL


D Turn engine switch to OFF.
D Disconnect IAT sensor No.2 connector.
D Check for bent terminal of IAT sensor No.2
terminals A and B (partside).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 17.

No

Go to next step.

CLASSIFY IAT SENSOR No.2 MALFUNCTION


OR HARNESS MALFUNCTION
D Turn engine switch to ON (Engine OFF).
D Access IAT PID using WDS or equivalent.
D Is IAT PID below 0.14 V?

Yes

Go to next step.

No

Go to Step 9.

INSPECT IAT SENSOR No.2 SIGNAL CIRCUIT


FOR SHORT TO GND
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for continuity between IAT sensor
No.2 terminal A (harnessside) and body
GND.
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to next step.

INSPECT IAT SENSOR No.2 CIRCUITS FOR


SHORT
D Check for continuity between IAT sensor
No.2 terminals A and B (harnessside).
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to Step 15.

INSPECT IAT SENSOR No.2 CONNECTOR


FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect IAT sensor No.2 connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 15.

No

Go to next step.

INSPECT IAT SENSOR No.2


D Inspect IAT sensor No.2.
(See NO TAG MASS AIR FLOW
(MAF)/INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION)
D Is it okay ?

Yes

Go to next step.

No

Replace IAT sensor No.2, then go to Step 15.

INSPECT IAT SENSOR No.2 SIGNAL CIRCUIT


FOR SHORT TO POWER
D Turn engine switch to ON (Engine OFF).
D Measure voltage between IAT sensor No.2
terminal A (harnessside) and body GND.
D Is voltage B+?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to next step.

INSPECT IAT SENSOR No.2 GND CIRCUIT


FOR SHORT TO POWER
D Measure voltage between IAT sensor No.2
terminal B (harnessside) and body GND.
D Is voltage B+?

Yes

Repair or replace shorted harness, then go to Step 15.

No

Go to next step.

F296

ON-BOARD DIAGNOSTIC SYSTEM

STEP
12

13

14

15

16

INSPECTION

ACTION

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Inspect PCM terminals 1J and 1B (damaged,
pulled-out pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 15.

No

Go to next step.

INSPECT IAT SENSOR No.2 SIGNAL CIRCUIT


FOR OPEN CIRCUIT
D Check for continuity between IAT sensor
No.2 terminal A (harnessside) and PCM
terminal 1J.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 15.

INSPECT IAT SENSOR No.2 GND CIRCUIT


FOR OPEN CIRCUIT
D Check for continuity between IAT sensor
No.2 terminal B (harnessside) and PCM
terminal 1B (harness-side).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to next step.

VERIFY TROUBLESHOOTING OF DTC P0110


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F297

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1182
DTC P1182
DETECTION
CONDITION
POSSIBLE
CAUSE

Fuel shut off (FSO) solenoid malfunction


D When the engine switch is turned off while the engine is running, if the decrease in engine speed is 200
rpm or less 2 seconds after the engine switch is turned off, PCM determines that FSO solenoid has
malfunction.
D FSO solenoid malfunction
D Short to power circuit between injection pump connector A terminal J and PCM terminal 4W
D PCM malfunction

ZCF4070W102

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CLASSIFY IF INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Clear DTC from PCM memory.
D Start engine.
D Turn engine switch to OFF and wait for 2
seconds or more, then ON (Engine OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

INSPECT FSO SOLENOID CIRCUIT FOR


SHORT TO POWER
D Inspect the voltage between injection pump
connector A terminal J and body ground.
D Is voltage B+?

Yes

Repair or replace harness, then go to Step 5.

No

Go to next step.

INSPECT FSO SOLENOID


D Perform FSO solenoid inspection.
(See NO TAG FUEL SHUT OFF (FSO)
SOLENOID INSPECTION)
D Is FSO solenoid okay?

Yes

Go to next step.

No

Replace FSO solenoid, then go to next step.

F298

ON-BOARD DIAGNOSTIC SYSTEM

STEP
5

INSPECTION

ACTION

VERIFY TROUBLESHOOTING OF DTC P0110


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Clear DTC from PCM memory.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P1189
DTC P1189

DETECTION
CONDITION

POSSIBLE
CAUSE

Pump speed sensor circuit malfunction


D PCM monitors pump speed sensor signal at PCM terminal 2D and 2K. If difference between engine
speeds detected by the pump speed sensor and the TDC sensor is 500 rpm or more for 1 second
continuously under the following conditions, PCM determines that pump speed sensor circuit has
malfunction.
Engine speed detected by the pump speed sensor is lower than that detected by the TDC sensor
Engine is running
D
D
D
D
D
D
D
D

Pump speed sensor malfunction


Poor connection at pump speed sensor or PCM connector
Pump speed sensor circuits are shorted each other.
Short to GND circuit between pump speed sensor terminal A and PCM terminal 2K
Short to GND circuit between pump speed sensor terminal B and PCM terminal 2D
Open circuit between pump speed sensor terminal A and PCM terminal 2K
Open circuit between pump speed sensor terminal B and PCM terminal 2D
PCM malfunction

ZCF4070W100

Diagnostic procedure
STEP
1

INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

ACTION
Yes

Perform repair or diagnosis according to available Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

F299

ON-BOARD DIAGNOSTIC SYSTEM

STEP
2

INSPECTION

ACTION

VERIFY PUMP SPEED SENSOR VOLTAGE


D Disconnect pump speed sensor connector.
D Connect voltmeter pump speed sensor
terminals A and B (partside).
D Check voltage in AC range while cranking
engine.
D Is any voltage reading?

Yes

Go to Step 4.

No

Go to next step.

VERIFY PUMP SPEED SENSOR


D Perform pump speed sensor inspection.
(See NO TAG PUMP SPEED SENSOR
INSPECTION)
D Is pump speed sensor okay?

Yes

Check for poor connection (damaged, pulledout


terminals, corrosion, etc.) or bent terminal of pump speed
sensor.
D Repair or replace if necessary, then go to Step 8.

No

Go to next step.

INSPECT PCM CONNECTOR POOR


CONNECTION
D Turn engine switch OFF.
D Disconnect PCM connector.
D Check for poor connection at terminals 2K
and 2D (damaged, pulledout terminals,
corrosion, etc.).
D Is there any malfunction?

Yes

Repair or replace terminal, then go to Step 8.

No

Go to next step.

INSPECT PUMP SPEED SENSOR CIRCUIT


FOR OPEN CIRCUIT
D Inspect the following terminals for continuity:
Between pump speed sensor terminal A
and PCM terminal 2K
Between pump speed sensor terminal B
and PCM terminal 2D
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 8.

INSPECT PUMP SPEED SENSOR CIRCUIT


FOR SHORT TO GROUND
D Inspect the following terminals for continuity:
Between pump speed sensor terminal A
and body ground
Between pump speed sensor terminal B
and body ground
D Is there continuity?

Yes

Repair or replace harness, then go to Step 8.

No

Go to next step.

INSPECT PUMP SPEED SENSOR CIRCUIT


FOR SHORT TO EACH OTHER
D Check continuity between pump speed
sensor terminals A and B (harnessside).
D Is there continuity?

Yes

Repair or replace harness, then go to next step.

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P1189


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Clear DTC from PCM memory.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P1195
DTC P1195
DETECTION
CONDITION
POSSIBLE
CAUSE

BARO circuit malfunction


D PCM monitors input voltage from BARO sensor integrated in PCM. If input voltage from BARO sensor is
below 1.50 V or above 4.50 V, PCM determines that BARO sensor circuit is malfunctioning.
D BARO sensor malfunction (integrated in PCM)
D PCM malfunction

F2100

ON-BOARD DIAGNOSTIC SYSTEM


Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1195 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn engine switch to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

DTC P1226
DTC P1226
DETECTION
CONDITION

POSSIBLE
CAUSE

Control sleeve (CS) sensor circuit malfunction


D PCM monitors input voltage from CS sensor. If input voltage from CS sensor is below 0.23 V or above
4.68 V, PCM determines that CS sensor circuit is malfunctioning.
D
D
D
D

CS sensor malfunction
PCM malfunction
Connector or terminal malfunction
Open or short to ground circuit between CS sensor terminal (injection pump connector A) F and PCM
terminal 1Q
D Open or short to ground circuit between CS sensor terminal (injection pump connector A) G and PCM
terminal 1O
D Open circuit between CS sensor terminal (injection pump connector A) H and PCM terminal 1M

ZCF4070W101

F2101

ON-BOARD DIAGNOSTIC SYSTEM


Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1226 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn engine switch to OFF, then start engine.
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

INSPECT CS SENSOR CONNECTOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect CS sensor connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 8.

No

Go to next step.

INSPECT PCM CONNECTOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 8.

No

Go to next step.

INSPECT CS SENSOR CIRCUIT FOR SHORT


TO GROUND
D Inspect the following terminals for continuity:
Between injection pump connector A
terminal F and body ground
Between injection pump connector A
terminal G and body ground
D Is there continuity?

Yes

Repair or replace harness, then go to Step 8.

No

Go to next step.

INSPECT CS SENSOR CIRCUIT FOR OPEN


CIRCUIT
D Inspect the following terminals for continuity:
Between injection pump connector A
terminal F and PCM terminal 1Q
Between injection pump connector A
terminal G and PCM terminal 1O
Between injection pump connector A
terminal H and PCM terminal 1M
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 8.

INSPECT CS SENSOR
D Perform CS sensor inspection.
(See NO TAG CONTROL SLEEVE (CS)
SENSOR INSPECTION)
D Is CS sensor okay?

Yes

Injection pump may have a malfunction. Consult your


distributer for inspection of injection pump.
Then go to next step.

No

Consult your distributer for replace of CS sensor.


Then go to next step.

VERIFY TROUBLESHOOTING OF DTC P1226


COMPLETED
D Turn engine switch to OFF and ON (Engine
OFF).
D Clear DTC from memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F2102

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1312
DTC P1312
DETECTION
CONDITION

POSSIBLE
CAUSE

Timer control valve circuit malfunction


D PCM monitors difference voltage between target injection timing and actual injection timing while ECT is
above 80C {176F} and engine running. If difference voltage is above threshold for 5 s, PCM
determines that injection timing control system is malfunctioning.
D
D
D
D
D
D
D

Connector or terminal malfunction


Open circuit in wiring between injection pump connector A terminal C and PCM control relay terminal D
Short to GND in wiring between injection pump connector A terminal B and PCM terminal 4U
Open circuit in wiring between injection pump connector A terminal B and PCM terminal 4U
TCV malfunction
Injection pump (injection timing control) malfunction
PCM malfunction

ZCF4070W201

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY IF CURRENT INPUT SIGNAL


STATUSIS CONCERN INTERMITTENT OR
CONSTANT?
D Turn engine switch to ON (Engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Access ECT PID using WDS or equivalent.
D Wait until ECT PID is above 80C {176F}.
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING Procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

VERIFY OTHER DTC IS PRESENT


D Is other DTC present?

Yes

Perform appropriate DTC troubleshooting procedure.


(See 67 DTC TABLE)
then go to Step 8.

No

Go to next step.

F2103

ON-BOARD DIAGNOSTIC SYSTEM

STEP
4

10

11

INSPECTION

ACTION

INSPECT INJECTION PUMP CONNECTOR


POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect injection pump connector A.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT TCV POWER CIRCUIT


D Turn engine switch to ON (Engine OFF).
D Measure voltage between injection pump
connector A terminal C (harnessside) and
body GND.
D Is voltage B+?

Yes

Go to next step.

No

Repair or replace TCV power circuit for open, then go to


Step 9.

INSPECT TCV CONTROL CIRCUIT FOR


SHORT TO GND
D Turn engine switch to OFF.
D Check for continuity between injection pump
connector A terminal C (harnessside) and
body GND.
D Is there continuity?

Yes

Repair or replace TCV control circuit for short to GND,


then go to Step 9.

No

Go to next step.

INSPECT PCM CONNECTOR POOR


CONNECTION
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT TCV CONTROL CIRCUIT FOR OPEN


D Check for continuity between injection pump
connector A terminal C (harnessside) and
PCM terminal 4U (harnessside).
D Is there continuity?

Yes

Injection pump may have malfunction. Consult your


distributor for inspection of injection pump.
Go to next step.

No

Repair or replace TCV control circuit for open, then go to


next step.

INSPECT TCV
D Perform TCV Inspection.
(SeeNO TAG TIMER CONTROL VALVE
(TCV) INSPECTION)
D Is TCV okay?

Yes

Injection pump may have mechanical malfunction. Consult


your distributor for inspection of injection pump.
Then go to next step.

No

Consult your distributor for replacement of TCV.


Then go to next step.

VERIFY TROUBLESHOOTING OF DTC P1312


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Turn engine switch to ON (Engine OFF).
D Clear DTC from PCM memory using WDS or
equivalent.
D Start engine.
D Access ECT PID using WDS or equivalent.
D Wait until ECT PID is above 80C {176F}.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F2104

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1318
DTC P1318
DETECTION
CONDITION

POSSIBLE
CAUSE

Timer position sensor circuit malfunction


D PCM monitors input voltage from timer position sensor. If input voltage from timer position sensor is
below 0.25 V or above 4.90 V, PCM determines that timer position sensor circuit is malfunctioning.
D
D
D
D

Timer position sensor malfunction


PCM malfunction
Connector or terminal malfunction
Open or short to ground circuit between timer position sensor terminal (injection pump connector B) A
and PCM terminal 1K
D Open or short to ground circuit between timer position sensor terminal (injection pump connector B) C
and PCM terminal 1I
D Open circuit between timer position sensor terminal (injection pump connector B) B and PCM terminal
1G

ZCF4070W203

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1318 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn engine switch to OFF, then start engine.
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

INSPECT TIMER POSITION SENSOR


CONNECTOR FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect timer position sensor connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 8.

No

Go to next step.

F2105

ON-BOARD DIAGNOSTIC SYSTEM

STEP
4

INSPECTION

ACTION

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 8.

No

Go to next step.

INSPECT TIMER POSITION SENSOR CIRCUIT


FOR SHORT TO GROUND
D Inspect the following terminals for continuity:
Between injection pump connector B
terminal A and body ground
Between injection pump connector B
terminal C and body ground
D Is there continuity?

Yes

Repair or replace harness, then go to Step 8.

No

Go to next step.

INSPECT TIMER POSITION SENSOR CIRCUIT


FOR OPEN
D Inspect the following terminals for continuity:
Between injection pump connector B
terminal A and PCM terminal 1K
Between injection pump connector B
terminal C and PCM terminal 1I
Between injection pump connector B
terminal B and PCM terminal 1G
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 8.

INSPECT TIMER POSITION SENSOR


D Perform timer position sensor inspection.
(See NO TAG TIMER POSITION SENSOR
INSPECTION)
D Is timer position sensor okay?

Yes

Injection pump may have a malfunction. Consult your


distributor for inspection of injection pump.
Then go to next step.

No

Consult your distributor for replace of timer position


sensor.
Then go to next step.

VERIFY TROUBLESHOOTING OF DTC P1318


COMPLETED
D Turn engine switch to OFF and ON (Engine
OFF).
D Clear DTC from memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F2106

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1402
DTC P1402
DETECTION
CONDITION

POSSIBLE
CAUSE

EGR valve position sensor circuit malfunction


D If PCM detects EGR valve position sensor voltage at PCM terminal 1F below 0.10 V or above 4.90 V
after engine start, PCM determines that EGR valve position circuit has a malfunction.
D
D
D
D
D
D
D
D
D
D
D
D

EGR valve position sensor malfunction


Connector or terminal malfunction
Open circuit between EGR valve position sensor terminal C and PCM terminal 1F.
Short to ground circuit between EGR valve position sensor terminal C and PCM terminal 1F.
Open circuit between EGR valve position sensor terminal B and PCM terminal 1A.
Short to ground circuit between EGR valve position sensor terminal B and PCM terminal 1A.
Open circuit between EGR valve position sensor terminal A and PCM terminal 1B
Short to reference voltage (Vref) supply circuit between EGR valve position sensor terminal C and PCM
terminal 1F
PCM malfunction
MAF sensor malfunction
Electrical corrosion in EGR valve position signal circuit
Voltage drops in ground circuit or reference voltage (Vref) supply circuit

ZCF4070W202

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CLASSIFY IF INTERMITTENT CONCERN OR


CONTINUOUS CONCERN
D Turn engine switch to OFF then ON (Engine
OFF).
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern is existing. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

F2107

ON-BOARD DIAGNOSTIC SYSTEM

STEP
3

10

11

INSPECTION

ACTION

INSPECT EGR VALVE POSITION SENSOR


CONNECTOR
D Turn engine switch to OFF.
D Disconnect EGR valve position sensor
connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Are there any concerns?

Yes

Repair terminal, then go to Step 18.

No

Go to next step.

CHECK POWER SUPPLY CIRCUIT VOLTAGE


AT EGR VALVE POSITION SENSOR
CONNECTOR
D Turn engine switch to ON (Engine OFF).
D Measure voltage between EGR valve
position sensor terminal B (harnessside)
and body ground.
D Is voltage within 4.5 5.5 V?

Yes

Go to Step 9.

No

D If voltage is B+, repair or replace shorted harness,


then go to Step 18.
D If voltage is approx. 0 V, go to next step.

INSPECT EGR VALVE POSITION SENSOR


POWER SUPPLY CIRCUIT FOR SHORT TO
GROUND
D Check continuity between EGR valve position
sensor terminal B (harnessside) and body
ground.
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 18.

No

Go to next step.

INSPECT EGR VALVE POSITION SENSOR


POWER SUPPLY AND GROUND CIRCUIT FOR
SHORT TO EACH OTHER
D Check continuity between EGR valve position
sensor terminals B (harnessside) and A
(harnessside).
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 18.

No

Go to next step.

CHECK PCM CONNECTOR


D Disconnect PCM connector.
D Check for poor connection at terminal 1A
(damaged, pulledout pins, corrosion, etc.).
D Is there any concern?

Yes

Repair terminal, then go to Step 18.

No

Go to next step.

VERIFY EGR VALVE POSITION SENSOR


POWER SUPPLY CIRCUIT FOR OPEN
CIRCUIT
D Check continuity between EGR valve position
sensor terminal B (harnessside) and PCM
terminal 1A (harnessside).
D Is there continuity?

Yes

Go to Step 18.

No

Repair or replace suspected harness, then go to Step 18.

CHECK SIGNAL CIRCUIT VOLTAGE AT EGR


VALVE POSITION SENSOR CONNECTOR
D Turn engine switch to ON (Engine OFF).
D Measure voltage between EGR valve
position sensor terminal C (harnessside)
and body ground.
D Is voltage within 4.5 5.5 V?

Yes

Go to Step 15.

No

D If voltage is B+, repair or replace shorted harness,


then go to Step 18.
D If voltage is approx. 0 V, go to Step 11.

INSPECT EGR VALVE POSITION SENSOR


POWER SUPPLY AND SIGNAL CIRCUIT FOR
SHORT TO EACH OTHER
D Check continuity between EGR valve position
sensor terminals B (harnessside) and C
(harnessside).
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 18.

No

Go to next step.

INSPECT EGR VALVE POSITION SENSOR


SIGNAL CIRCUIT FOR SHORT TO GROUND
D Check continuity between EGR valve position
sensor terminal C (harnessside) and body
ground.
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 18.

No

Go to next step.

F2108

ON-BOARD DIAGNOSTIC SYSTEM

STEP
12

13

14

15

16

17

18

19

INSPECTION

ACTION

INSPECT EGR VALVE POSITION SENSOR


SIGNAL AND GROUND CIRCUIT FOR SHORT
EACH OTHER
D Check continuity between EGR valve position
sensor terminals C (harnessside) and A
(harnessside).
D Is there continuity?

Yes

Repair or replace shorted harness, then go to Step 18.

No

Go to next step.

CHECK PCM CONNECTOR


D Disconnect PCM connector.
D Check for poor connection at terminal 1F
(damaged, pulledout pins, corrosion, etc.).
D Is there any concern?

Yes

Repair terminal, then go to Step 18.

No

Go to next step.

VERIFY EGR VALVE POSITION SENSOR


SIGNAL CIRCUIT FOR OPEN CIRCUIT
D Disconnect PCM connector.
D Check continuity between EGR valve position
sensor terminal C (harnessside) and PCM
terminal 1F (harnessside).
D Is there continuity?

Yes

Go to Step 18.

No

Repair or replace suspected harness, then go to Step 18.

CHECK PCM CONNECTOR


D Disconnect PCM connector.
D Check for poor connection at terminal 1B
(damaged, pulledout pins, corrosion, etc.).
D Is there any concern?

Yes

Repair terminal, then go to Step 18.

No

Go to next step.

VERIFY EGR VALVE POSITION SENSOR


GROUND CIRCUIT FOR OPEN CIRCUIT
D Check continuity between EGR valve position
sensor terminal A (harnessside) and PCM
terminal 1B (harnessside).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace suspected harness, then go to Step 18.

INSPECT EGR VALVE POSITION SENSOR


D Perform EGR valve position sensor
inspection.
(See section F2)
D Is EGR position sensor okay?

Yes

Go to next step.

No

Replace EGR valve position sensor, then go to next step.

VERIFY TROUBLESHOOTING OF DTC P1402


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Start engine.
D Clear DTC from PCM memory using WDS or
equivalent.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F2109

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1602
DTC P1602
DETECTION
CONDITION

Immobilizer unitPCM communication error


D Command transmission from the PCM to the immobilizer unit exceeds limit.
D No response from immobilizer unit
D Immobilizer unit malfunction

POSSIBLE
CAUSE

D
D
D
D
D
D
D
D
D
D

Coil (immobilizer system) malfunction


Key (transponder) malfunction
PCM malfunction
Open circuit in wiring between immobilizer unit terminal A and PCM terminal 2L
Open circuit in wiring between immobilizer unit terminal C and body ground
Open circuit in wiring between immobilizer unit terminal F and coil terminal A
Open circuit in wiring between immobilizer unit terminal D and coil terminal C
Short to ground circuit in wiring between immobilizer unit terminal A and PCM terminal 2L
Short to ground circuit in wiring between immobilizer unit terminal F and coil terminal A
Short to ground circuit in wiring between immobilizer unit terminal D and coil terminal C

ZCF4070W301

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related repair information available?

Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

CLASSIFY IF NO DTC DETECTED OR SOME


DTC DETECTED
D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF and ON (Engine
OFF).
D Has DTC P1624 been detected?

Yes

Go to step 10.

No

Go to next step.

INSPECT IMMOBILIZER UNIT CONNECTOR


FOR POOR CONNECTION
D Turn ignition key to OFF.
D Disconnect immobilizer unit connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Is there any malfunction?

Yes

Repair or replace terminals, then go to Step 19.

No

Go to next step.

F2110

ON-BOARD DIAGNOSTIC SYSTEM

STEP
4

INSPECTION

ACTION

INSPECT GROUND CIRCUIT OF IMMOBILIZER


UNIT FOR OPEN CIRCUIT
D Measure resistance between immobilizer unit
terminal C (harnessside) and body ground.
D Is there any continuity?

Yes

Go to next step.

No

Repair or replace harness for open, then go to Step 19.

INSPECT COIL TERMINAL


D Disconnect coil connector.
D Check for bent terminals.
D Is there any malfunction?

Yes

Repair or replace terminals, then go to Step 19.

No

Go to next step.

INSPECT COIL FOR SHORT CIRCUIT


D Check continuity between coil terminal A
(partside) and body ground.
D Is there any continuity?

Yes

Replace coil, then go to Step 19.

No

Go to next step.

INSPECT COIL CIRCUIT FOR SHORT


D Connect coil connector.
D Check continuity between immobilizer unit
terminal F (harnessside) and body ground.
D Is there any continuity?

Yes

Repair or replace harness for short circuit, then go to Step


19.

No

Go to next step.

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Is there any malfunction?

Yes

Repair or replace harness, then go to Step 19.

No

Go to next step.

INSPECT COMMUNICATION LINE FOR OPEN


CIRCUIT
D Connect break out box with PCM
disconnected.
D Measure continuity between immobilizer unit
terminal A (harnessside) and PCM terminal
2L.
D Is there any continuity?

Yes

Go to step 19.

No

Repair or replace harness for open circuit, then go to Step


19.

CLASSIFY MALFUNCTION BY ANOTHER


DETECTED DTCS
D Has DTC P1602 detected?

Yes

Go to Step 14.

No

Go to next step.

INSPECT COIL CONNECTOR FOR POOR


CONNECTION
D Disconnect coil connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Are there any malfunctions?

Yes

Repair or replace harness, then go to Step 19.

No

Go to next step.

INSPECT COIL FOR OPEN CIRCUIT


D Disconnect coil connector.
D Measure resistance between coil terminals
(partside).
D Is there any continuity?

Yes

Go to next step.

No

Replace coil, then go to Step 19.

INSPECT COIL CIRCUIT FOR OPEN CIRCUIT


D Connect coil connector.
D Measure the resistance between immobilizer
connector F and D (harnessside).
D Is there any continuity?

Yes

Go to Step 19.

No

Repair or replace harness for open circuit, then go to Step


19.

14

CLASSIFY MALFUNCTION BY ANOTHER


DETECTED DTCS.
D Has immobilizer unit DTC 03 detected?

Yes

Key has not transponder, change to registered key.


Then go to Step 19.

No

Go to next step.

15

CLASSIFY MALFUNCTION BY ANOTHER


DETECTED DTCS.
D Has immobilizer unit DTC 01 detected?

Yes

Key that using for ignition is not registered.


Reprogram key or using another registered key, then go to
next step.
(See NO TAG IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE)

No

Go to next step.

10

11

12

13

F2111

ON-BOARD DIAGNOSTIC SYSTEM

STEP
16

17

18

19

20

INSPECTION

ACTION

INSPECT IMMOBILIZER UNIT CONNECTOR


FOR POOR CONNECTION
D Turn ignition key to OFF.
D Disconnect immobilizer unit connector.
D Check for poor connection (damaged,
pulledout terminals, corrosion, etc.).
D Are there any malfunctions?

Yes

Repair or replace harness, then go to next step.

No

Go to next step.

INSPECT IMMOBILIZER UNIT POWER


CIRCUIT FOR OPEN CIRCUIT
D Turn ignition key to ON (Engine OFF).
D Measure voltage between immobilizer
connector J (harnessside) and body ground.
D Is there voltage B+?

Yes

Go to next step.

No

Repair or replace harness for open circuit, then go to Step


19.

INSPECT COMMUNICATION LINE FOR SHORT


HARNESS
D Measure resistance between immobilizer unit
terminal A (harnessside) and body ground.
D Is there any continuity?

Yes

Repair or replace harness for short, then go to next step.

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P1602


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE.)

No

Troubleshooting completed.

DTC P1603
DTC P1603
DETECTION
CONDITION
POSSIBLE
CAUSE

Code word is not registered in PCM


D Code word is not registered in PCM.
D Immobilizer system reprogram procedure (code word) was not performed after replacing PCM.

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any repair information available?

Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1603 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Perform code word reprogram procedure.


(See NO TAG IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE)

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P1603


COMPLETED
D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE.)

No

Troubleshooting completed.

F2112

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1604
DTC P1604
DETECTION
CONDITION
POSSIBLE
CAUSE

Key ID numbers are not registered in PCM


D Key ID numbers are not registered in PCM.
D Immobilizer system reprogram procedure (key IDs) was not performed after replacing PCM.

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any repair information available?

Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1604 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Perform key ID number reprogram procedure.


(See NO TAG IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE)

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P1604


COMPLETED
D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE.)

No

Troubleshooting completed.

DTC P1621
DTC P1621
DETECTION
CONDITION
POSSIBLE
CAUSE

Code word does not match after engine cranking


D Code word stored in PCM and immobilizer unit does not match
D Immobilizer system reprogram procedure (code word) was not performed correctly after replacing
immobilizer unit or PCM.

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any repair information available?

Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1621 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Perform code word reprogram procedure.


(See NO TAG IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE)

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P1621


COMPLETED
D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE.)

No

Troubleshooting completed.

F2113

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1622
DTC P1622
DETECTION
CONDITION
POSSIBLE
CAUSE

Key ID number does not match


D ID number stored in immobilizer unit (IU) and PCM does not match. This DTC is indicated only after
immobilizer unit is replaced and reprogramming system.
D Transformation of key ID number stored in PCM.

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any repair information available?

Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1622 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Go to next step.

No

Go to Step 4.

CHECK IF ENGINE STARTS NORMALLY


USING ANOTHER REGISTERED KEY
D Does engine start with another registered
key?

Yes

Previous key is defective. Discard it.

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P1622


COMPLETED
D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE.)

No

Troubleshooting completed.

DTC P1623
DTC P1623

Code word or key ID number read/write error in PCM

DETECTION
CONDITION

D PCM internal EEPROM damaged.

POSSIBLE
CAUSE

D PCM internal EEPROM damaged.

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any repair information available?

Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1623 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE.)

No

Troubleshooting completed.

F2114

ON-BOARD DIAGNOSTIC SYSTEM


DTC P1624
DTC P1624
DETECTION
CONDITION
POSSIBLE
CAUSE

Immobilizer system communication counter = 0


D PCM detected immobilizer system communication malfunction three times or more
D Attempted to start engine three times or more under malfunction.
D Code word mismatch

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED REPAIR INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any repair information available?

Yes

Perform repair or diagnosis according to available repair


information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

FOLLOW OTHER DETECTED DTC FIRST


D Turn ignition key to OFF and to START.
D Has P1602 been detected?

Yes

Go to DTC P1602 inspection.


(See 110 DTC P1602.)

No

Go to next step.

INSPECT IMMOBILIZER UNIT CONNECTOR


FOR POOR CONNECTION
D Has P1621 been detected?

Yes

Go to DTC P1621 inspection.


(See 113 DTC P1621.)

No

Go to next step.

VERIFY TROUBLESHOOTING OF DTC P1624


COMPLETED
D Make sure to reconnect all disconnected
connectors.
D Clear DTC from memory using WDS or
equivalent.
D Turn ignition key to OFF, then start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform After Repair Procedure
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE.)

No

Troubleshooting completed.

DTC P1649
DTC P1649
DETECTION
CONDITION

Injection pump EPROM circuit malfunction


D If PCM cannot access to injection pump EPROM, PCM determines that the injection pump EPROM
circuit has malfunction.
D
D
D
D

POSSIBLE
CAUSE

D
D
D
D

Injection pump EPROM malfunction


PCM malfunction
Connector or terminal malfunction
Open circuit between injection pump EPROM terminal (injection pump connector B) D and PCM terminal
1A
Open or short to ground circuit between injection pump EPROM terminal (injection pump connector B) F
and PCM terminal 2E
Open or short to ground circuit between injection pump EPROM terminal (injection pump connector B) G
and PCM terminal 2L
Open or short to ground circuit between injection pump EPROM terminal (injection pump connector B) E
and PCM terminal 1S
Open circuit between injection pump EPROM terminal (injection pump connector B) H and PCM terminal
1B

F2115

ON-BOARD DIAGNOSTIC SYSTEM

DTC P1649

Injection pump EPROM circuit malfunction

ZCF4070W204

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY RELATED SERVICE INFORMATION


AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?

Yes

Perform repair or diagnosis according to Service


Information.
D If vehicle is not repaired, go to next step.

No

Go to next step.

VERIFY DTC P1649 DETECTED AGAIN


D Clear DTC from memory using WDS or
equivalent.
D Turn engine switch to OFF, then start engine.
D Is same DTC present?

Yes

Go to next step.

No

Intermittent concern exists. Go to INTERMITTENT


CONCERN TROUBLESHOOTING procedure.
(See NO TAG INTERMITTENT CONCERN
TROUBLESHOOTING)

INSPECT INJECTION PUMP EPROM


CONNECTOR FOR POOR CONNECTION
D Turn engine switch to OFF.
D Disconnect injection pump EPROM
connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT INJECTION PUMP EPROM POWER


CIRCUIT FOR OPEN CIRCUIT
D Measure voltage between injection pump
connector B terminal D (harnessside) and
body GND.
D Is voltage approx. 5V?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 9.

F2116

ON-BOARD DIAGNOSTIC SYSTEM

STEP
5

10

INSPECTION

ACTION

INSPECT PCM CONNECTOR FOR POOR


CONNECTION
D Turn engine switch to OFF.
D Disconnect PCM connector.
D Check for poor connection (damaged,
pulledout pins, corrosion, etc.).
D Is there a malfunction?

Yes

Repair or replace terminal, then go to Step 9.

No

Go to next step.

INSPECT INJECTION PUMP EPROM CIRCUIT


FOR SHORT TO GND
D Inspect the following terminals for continuity:
Between injection pump connector B
terminal F and body ground
Between injection pump connector B
terminal G and body ground
Between injection pump connector B
terminal E and body ground
D Is there continuity?

Yes

Repair or replace harness, then go to Step 9.

No

Go to next step.

INSPECT INJECTION PUMP EPROM CIRCUIT


FOR OPEN CIRCUIT
D Inspect the following terminals for continuity:
Between injection pump connector B
terminal F and PCM terminal 2E
Between injection pump connector B
terminal G and PCM terminal 2L
Between injection pump connector B
terminal E and PCM terminal 1S
Between injection pump connector B
terminal H and PCM terminal 1B
D Is there continuity?

Yes

Go to next step.

No

Repair or replace open harness, then go to Step 9.

INSPECT INJECTION PUMP EPROM


D Perform injection pump EPROM inspection.
(See NO TAG INJECTION PUMP EPROM
INSPECTION)
D Is injection pump EPROM okay?

Yes

Injection pump may have a malfunction. Consult your


distributer for inspection of injection pump.
Then go to next step.

No

Consult your distributer for replace of injection pump


EPROM.
Then go to next step.

VERIFY TROUBLESHOOTING OF DTC P1649


COMPLETED
D Turn engine switch to OFF and ON (Engine
OFF).
D Clear DTC from memory using WDS or
equivalent.
D Start engine.
D Is same DTC present?

Yes

Replace PCM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Perform AFTER REPAIR PROCEDURE.
(See Section F2)
D Is there any DTC present?

Yes

Go to applicable DTC inspection.


(See 67 DTC TABLE)

No

Troubleshooting completed.

F2117

TROUBLESHOOTING

TROUBLESHOOTING
FOREWORD
D Before proceeding with the following
troubleshooting:
See Section GI to understand the basic troubleshooting procedure.
Perform the DTC inspection.
If a DTC is displayed, proceed with inspection
steps for the code.
When the engine can be started, perform ENGINE TUNEUP. (See ENGINE TUNEUP.)

Y3U103WN3

Inspection Method for Sensor Connectors or Wires


1. Connect SSTs (WDS or equivalent) to DLC.
2. Turn engine switch to ON (Engine OFF).

INTERMITTENT CONCERN TROUBLESHOOTING


Vibration Method
D If malfunction occurs or becomes worse while
driving on a rough road or when engine is
vibrating, perform the steps below.
Note
D There are several reasons vehicle or engine
vibration could cause an electrical malfunction.
Some of the things to check for are:
Connectors not fully seated.
Wire harnesses not having full play.
Wires laying across brackets or moving
parts.
Wires routed too close to hot parts.
D An improperly routed, improperly clamped, or
loose harness can cause wiring to become
pinched between parts.
D The connector joints, points of vibration, and
places where wire harnesses pass through the
fire wall, body panels, etc. are the major areas
to be checked.
Inspection Method for Switch Connectors or Wires
1. Connect SSTs (WDS or equivalent) to DLC.
2. Turn engine switch to ON (Engine OFF).
Note
D If engine starts and runs, perform the following
steps at idle.
3. Access PIDs for the switch you are inspecting.
4. Turn switch on manually.
5. Shake each connector or wire harness a bit
vertically and horizontally while monitoring the PID.
D If PID value is unstable, check for poor
connection.

Note
D If engine starts and runs, perform the following
steps at idle.
3. Access PIDs for the switch you are inspecting.
4. Shake each connector or wire harness a bit
vertically and horizontally while monitoring the PID.
D If PID value is unstable, check for poor
connection.

Y3U103WN4

Inspection Method for Sensors


1. Connect SSTs (WDS or equivalent) to DLC.
2. Turn engine switch to ON (Engine OFF).
Note
D If engine starts and runs, perform the following
steps at idle.
3. Access PIDs for the switch you are inspecting.
4. Vibrate the sensor slightly with your finger.
D If PID value is unstable or malfunction occurs,
check for poor connection and/or poorly
mounted sensor.
Inspection Method for Actuators or Relays
1. Connect SSTs (WDS or equivalent) to DLC.
2. Turn engine switch to ON (Engine OFF).
Note
D If engine starts and runs, perform the following
steps at idle.
3. Prepare the SIMULATION TEST for actuators or
relays that you are inspecting.
4. Vibrate the actuator or relay with your finger for 3 s
after SIMULATION TEST is activated.

F2118

TROUBLESHOOTING
D If variable click sound is heard, check for poor
connection and/or poorly mounted actuator or
relay.

When testing a vehicle with a water leakage


problem, special caution must be used.
1. Connect SSTs (WDS or equivalent) to DLC if you
are inspecting sensors or switches.
2. Turn engine switch to ON (Engine OFF).
Note
D If engine starts and runs, perform the following
steps at idle.

Y3U103WN5

Note
D Vibrating relays too strongly may result in open
relays.

3. Access PIDs for sensor or switch if you are


inspecting sensors or switches.
4. If you are inspecting the switch, turn it on manually.
5. Spray water onto the vehicle or run it through a car
wash.
D If PID value is unstable or malfunction occurs,
repair or replace part as necessary.

Water Sprinkling Method


If malfunction occurs only during high humidity or
rainy/snowy weather, perform the following steps.
Caution
D Indirectly change the temperature and
humidity by spraying water onto the front of
the radiator.
D If a vehicle is subject to water leakage, the
leakage may damage the control module.

F2119

Y3U103WTJ

TROUBLESHOOTING
TROUBLESHOOTING ITEM TABLE
D Confirm trouble symptom by using the following
diagnostic index, then go to appropriate
troubleshooting chart.
No.

D If a diagnostic trouble code is displayed, proceed

with inspection steps for the code.

TROUBLESHOOTING ITEM

DESCRIPTION

Melting of main or other fuses

Starter does not work.

Will not crank

Starter does not work.

Hard to start/long crank/erratic start/erratic crank

Starter cranks engine at normal speed but engine requires


excessive cranking time before starting.

Engine stalls.

Engine stops unexpectedly at idle and/or after start.

Cranks normally but will not start

Starter cranks engine at normal speed but engine will not run.

Slow return to idle/fast idle

Engine takes more time than normal to return to idle speed.


Engine speed continues at fast idle after warmup.

Engine runs rough/rolling idle

Engine speed fluctuates between specified idle speed and lower


speed and engine shakes excessively. Idle speed is too slow and
engine shakes excessively.

Runs on

Engine runs after engine switch is turned off.

After start/at idle

7
8

Engine stalls/quits.

Acceleration/cruise

Engine stops unexpectedly at beginning of acceleration, during


acceleration or while cruising.

Engine runs rough.

Acceleration/cruise

Engine speed fluctuates during acceleration or cruising.

Misses

Acceleration/cruise

Engine misses during acceleration or cruising.

Buck/jerk

Acceleration/cruise/
deceleration

Vehicle bucks/jerks during acceleration, cruising, or deceleration.

Hesitation/stumble
Surges

Acceleration

Momentary pause at beginning of acceleration or during


acceleration

Acceleration/cruise

Momentary minor irregularity in engine output

Acceleration/cruise

Performance is poor under load (e.g., power down when climbing


hills).

10

Lack/loss of power

11

Poor fuel economy

12

High oil consumption/leakage

13

Cooling system concerns

Overheating

Engine runs at higher than normal temperature/overheats.

14

Cooling system concerns

Runs cold

Engine does not reach normal operating temperature.

15

Excessive black smoke

Excessive black smoke is observed in exhaust gas.

16

Engine noise

Engine noise from under hood

17

Vibration concerns (engine)

Vibration from under hood or drive line

18

A/C does not work sufficiently.

A/C does not work sufficiently.

19

A/C is always on or A/C compressor runs


continuously.

A/C compressor magnetic clutch does not disengage.

20

Intermittent concerns

Intermittent concerns

21

Constant voltage

Incorrect constant voltage

Fuel economy is unsatisfactory.


Oil consumption is excessive.

F2120

TROUBLESHOOTING
QUICK DIAGNOSIS CHART

Y6E4080W002

F2121

TROUBLESHOOTING

ZCF4080W001

F2122

TROUBLESHOOTING

ZCF4080W002

F2123

TROUBLESHOOTING
NO.1 MELTING OF MAIN OR OTHER FUSES
1

Melting of main or other fuses

[TROUBLESHOOTING HINTS]
Inspect condition of fuse.

Y6E4080W001

Damaged fuse

Related wiring harness

MAIN (80 A)

MAIN fuse
D Generator
D Engine switch
ENG fuse
D Blower relay
Blower fan
motor
D A/C relay
Refrigerant
pressure switch
D FIP fuse

BTN (30 A)

BTN fuse
D ROOM fuse

GLOW (60 A)

ENG (15 A)
FIP (15 A)

ROOM (10 A)

GLOW fuse
D Glow plug relay
Glow plug
ENG fuse
D PCM
FIP fuse
D PCM control relay
PCM
ROOM fuse
D PCM

NO.2 WILL NOT CRANK


2

Will not crank

DESCRIPTION
POSSIBLE
CAUSE

D Starter does not work.


D Open starter circuit between battery and starter through engine switch
D Starter malfunction
D Seized/hydrolocked engine or flywheel

Diagnostic procedure
STEP
1

INSPECTION

ACTION

D Verify following:
Battery connection
Battery condition
Fuses
D Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

D Is clicking sound heard from starter when


engine switch is turned to START?

Yes

Go to next step.

No

Go to Step 6.

F2124

TROUBLESHOOTING

STEP

INSPECTION

ACTION

D Do any other electrical accessories work?

Yes

Go to next step.

No

Inspect charging system.


(See Section G)

D Disconnect battery negative cable.


D Disconnect engine switch and starter
connectors.
D Inspect for electrical connections, loose
wire, bent or corroded terminals.
D Inspect for continuity on following circuits
Engine switch and starter
Battery cable and starter magnetic switch
D Are all circuits okay?

Yes

Go to next step.

No

Repair or replace open circuits.

D Inspect engine switch.


(See Section T)
D Are all circuits okay?

Yes

Go to next step.

No

Replace engine switch.

D Inspect starting system.


(See section G)
D Is starting system okay?

Yes

Inspect for seized/hydrolocked engine, flywheel or drive


plate.
(See Section H)

No

Repair or replace components as required.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.3 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK


3

Hard to start/long crank/erratic start/erratic crank

DESCRIPTION

POSSIBLE
CAUSE

D Starter cranks engine at normal speed but engine requires excessive cranking time before start.
D Battery is in normal condition.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Poor fuel quality


Starting system malfunction
Intakeair system restriction
Incorrect idle speed
Engine overheating
Glow system malfunction
Fuel filter clogging
Fuel line restriction
Fuel leakage
Exhaust system restriction
Incorrect fuel injection timing
Injection pump malfunction
Injection nozzle malfunction
Low engine compression
Injection pump EPROM malfunction
EGR system malfunction

Diagnostic procedure
STEP
1

INSPECTION

ACTION

D Inspect for following:


Fuel quality including water
contamination
Fuel line/fuel filter clogging
Intakeair system restriction
D Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

D Is engine overheating?

Yes

Go to symptom troubleshooting NO.13 COOLING


SYSTEM CONCERNSOVERHEATING.

No

Go to next step.

Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

Yes

Inspect glow plug and glow plug relay.


(SeeNO TAG GLOW PLUG INSPECTION)
(See Section F2)
Replace any malfunctioning part as necessary.
If glow system is okay, go to next step.

No

Go to next step.

D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON position.
Retrieve any DTC.
Is DTC displayed?

D Does engine start normally after warmup?

F2125

TROUBLESHOOTING

STEP

INSPECTION
D Is idle speed correct?

ACTION
Yes

Go to next step.

No

Adjust idle speed.


(See NO TAG ENGINE TUNEUP)

D Is there any restriction in exhaust system?

Yes

Repair or replace as necessary.

No

Go to next step.

D Inspect for fuel leakage from fuel pipe.


D Is any fuel leakage found on fuel pipe?

Yes

Repair or replace as necessary.

No

Go to next step.

D Measure engine compression.


D Is compression okay?

Yes

Go to Step 10.

No

Go to next step.

D Inspect timing belt for following:


Chipping of gear teeth
Breakage, damage or cracks
Low tension
D Is timing belt okay?

Yes

Inspect for following:


D Burnt valve
D Worn piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve stem or valve guide
Repair or replace as necessary.

No

If timing is incorrect, adjust timing


If timing belt is not okay, replace timing belt.

D Inspect injection timing.


D Is injection timing okay?

Yes

Go to next step.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

D Remove and injection nozzle for following:


Clogged nozzle
Faulty nozzle gasket
Incorrect valve opening pressure
D Is injection nozzle okay?

Yes

Inspect following:
D Starting signal (PCM terminal 1U)
If okay, remove and inspect injection pump.

No

Repair or replace injection nozzle.

10

11

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

12

NO.4 ENGINE STALLS-AFTER START/AT IDLE


4
DESCRIPTION

POSSIBLE
CAUSE

Engine stallsafter start/at idle


D Engine stops unexpectedly at idle and/or after start.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Poor fuel quality


Intakeair system restriction
Incorrect idle speed
Engine overheating
A/C system improper operation
Immobilizer system activation or malfunction
FSO solenoid malfunction
PCM control relay malfunction
Glow system malfunction
Fuel leakage
Fuel line restriction
Fuel filter clogging
Incorrect fuel injection timing
Injection pump malfunction
Injection nozzle malfunction
Low engine compression
EGR system malfunction
MAF/IAT sensor malfunction
IAT sensor N0.2 malfunction
VSS malfunction

F2126

TROUBLESHOOTING
Diagnostic procedure
STEP
1

INSPECTION
Note
D Following test should be performed on
vehicles with immobilizer system.
D Go to Step 12 for vehicles without
immobilizer system.

ACTION
Yes

Both conditions appear:


D Go to Step 4.

No

Either or other condition appear:


D Go to next step.

D Does engine stall approx. 2 s after engine


is started?

Yes

Go to next step.

No

Immobilizer system is okay.


Go to Step 12.

D Is immobilizer unit connector securely


connected to immobilizer unit?

Yes

Go to next step.

No

Connect immobilizer unit connector securely.


Return to Step 2.

D Does immobilizer indicator light flash and


indicate any of following immobilizer
system DTCs?
DTC: 01, 02, 03, 11, 21

Yes

Go to ON-BOARD DIAGNOSTIC FUNCTION of


immobilizer system.
(See DTC TABLE)

No

Go to next step.

D Does immobilizer indicator light illuminate?

Yes

Go to Step 8.

No

Go to next step.

D Does immobilizer indicator light flash and


indicate following immobilizer system DTC
more than 135 s after engine switch is
turned to ON?
DTC: 24, 30

Yes

Go to ON-BOARD DIAGNOSTIC FUNCTION of


immobilizer system.
(See DTC TABLE)

No

Go to next step.

D Turn engine switch to OFF.


D Disconnect immobilizer unit connector.
D Connect jumper wire between immobilizer
unit connector terminal M and GND.
D Turn engine switch to ON.
D Does immobilizer indicator light illuminate?

Yes

Reconnect immobilizer unit connector.


Go to next step.

No

Inspect for open circuit between immobilizer unit connector


terminal M and instrument cluster.
If okay, inspect immobilizer indicator light bulb. Repair or
replace if necessary. Reconnect immobilizer unit
connector, then return to Step 4.

D Connect WDS or equivalent to DLC and


retrieve DTC.
D Is any of following DTC displayed?
DTC: P1602, P1603, P1604, P1621,
P1622, P1624

Yes

Go to appropriate DTC test.

No

Go to next step.

D Disconnect accelerator position sensor


connector.
D Inspect continuity between GND terminal at
accelerator position sensor vehicle harness
connector and body GND.
D Is there continuity?

Yes

Go to next step.

No

Access PCM connector.


Inspect for continuity between PCM connector 4A and 4B
terminals and body GND.
Repair or replace as necessary.

D Turn engine switch to ON.


D Access B+ PID.
D Is B+ PID okay?

Yes

Go to next step.

No

Repair or replace wiring harness.

Yes

Inspect for open circuit between PCM connector terminal


2I and immobilizer unit connector terminal A.

No

Repair or replace wiring harness between immobilizer unit


connector terminal J and fuse panel.

D Connect WDS or equivalent to DLC.


D Do following conditions appear?
Engine is not completely started
DTC P1624 is displayed
2

10

B+ PID
Battery positive voltage
11

D Disconnect immobilizer unit connector.


D Turn engine switch to ON.
D Is there battery voltage at immobilizer unit
connector terminal J?

F2127

TROUBLESHOOTING

STEP
12

13

INSPECTION

ACTION

D Inspect for following:


Fuel quality including water
contamination
Fuel line restriction
Loose bands on intakeair system
Cracks on intakeair system parts
Intakeair system restriction
D Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 12.

D Is engine overheating?

Yes

Go to symptom troubleshooting NO.13 COOLING


SYSTEM CONCERNSOVERHEATING.

14

Note
D Ignore DTC P0120 while performing this
test.
D Disconnect accelerator position sensor
connector.
D Measure voltage at accelerator position
sensor connector VREF terminal with
engine switch ON.

No

Go to next step.

Yes

Go to next step.

No

Go to symptom troubleshooting NO.21 CONSTANT


VOLTAGE.

Yes

DTC is displayed:
D Go to appropriate DTC test.
Communication error message is displayed:
D Inspect for following:
Open circuit between PCM control relay and PCM
terminal 4C
Open PCM control relay GND circuit
PCM control relay is stuck open
Open PCM GND circuit (terminal 4A or 4B)
Poor connection of vehicle body GND

No

No DTC is displayed:
D Go to next step.

Specification
4.55.5 V
D Is voltage okay?
15

D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

16

D Does engine run normal after warmup?

Yes

Go to next step.

No

Go to Step 18.

17

D Inspect for glow plug and glow plug relay.


(See NO TAG GLOW PLUG INSPECTION)
(See Section F2)
D Is glow system operation normal?

Yes

Go to next step.

No

Repair or replace any malfunctioning parts according to


glow system operation results.

D Access RPM PID.


D Is RPM PID indicating engine speed during
cranking engine?

Yes

Go to next step.

No

Inspect for following:


D Open or short circuit in pump speed sensor
D Open or short circuit in pump speed sensor harnesses
D Open or short circuit between pump speed sensor and
PCM terminals 2K and 2D

Yes

Go to next step.

No

A/C is always on:


D Go to symptom troubleshooting NO.19 A/C IS
ALWAYS ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY.
Other symptoms:
D Inspect following:
Refrigerant charging amount
Cooling fan and/or condenser fan operation

Yes

Inspect and adjust idle speed.


(See ENGINE TUNEUP)
If symptom still appears, go to next step.

No

Go to next step.

18

19

Note
D The following test should be performed
on the vehicles with A/C system. If the
following test cannot be performed due
to engine stalls, go to next step.
D Go to next step for the vehicles without
A/C system.
D Connect pressure gauge to A/C lines.
D Turn blower switch on.
D Is pressure within specifications?
(See Section U)

20

D Depress accelerator pedal slightly.


D Crank engine.
D Does engine start now?

F2128

TROUBLESHOOTING

STEP
21

22
23

24

25
26

27
28

29

30

INSPECTION

ACTION

D Perform FSO solenoid inspection.


(See NO TAG FUEL SHUT OFF (FSO)
SOLENOID INSPECTION)
D Is FSO solenoid okay?

Yes

Go to next step.

No

Inspect for following:


D Stuck FSO solenoid
D Open circuit in FSO solenoid
D Poor GND of FSO solenoid
D Open circuit between FSO solenoid and PCM
connector terminal 4W
Repair or replace any malfunctioning parts.

D Inspect fuel leakage from fuel pipe.


D Is any fuel leakage found on fuel pipe?

Yes

Repair or replace as necessary.

No

Go to next step.

D Access EGR PID.


D Read EGR PID during cranking engine.
(See PCM INSPECTION)
D Is EGR PID okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid valve (vent)
D EGR solenoid valve (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoid valve (vacuum)
and PCM terminal 4T
Repair or replace as necessary.

D Inspect injection timing.


D Is injection timing okay?

Yes

Go to next step.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

D Inspect fuel filter for clogging.


D Is fuel filter okay?

Yes

Go to next step.

No

Replace fuel filter cartridge.

D Remove injection nozzle.


D Inspect injection nozzle for following:
Clogged nozzle
Seized needle valve
Incorrect valve opening pressure
Faulty nozzle gasket
D Is injection nozzle okay?

Yes

Go to next step.

No

Repair or replace injection nozzle.

D Measure engine compression.


D Is compression okay?

Yes

Go to Step 29.

No

Go to next step.

D Inspect timing belt for following:


Chipping of gear teeth
Low tension
Breakage, damage or cracks
D Is timing belt okay?

Yes

Inspect for following:


D Burnt valve
D Worn piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve seat or valve guide
Repair or replace as necessary.

No

If timing is incorrect, adjust timing.


If timing belt is not okay, replace timing belt.

Yes

Inspect following:
D Idle switch
D Neutral switch
D Start signal (PCM terminal 1U)
D MAF/IAT sensor
D IAT sensor No.2
D VSS
D Pump speed sensor
If okay, remove and inspect injection pump.

No

Adjust valve clearance.

D Is valve clearance correct?

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

F2129

TROUBLESHOOTING
NO.5 CRANKS NORMALLY BUT WILL NOT START
5

Cranks normally but will not start

DESCRIPTION

D
D
D
D

Starter cranks engine at normal speed but engine will not run.
Refer to No.4 ENGINE STALLS if this symptom appears after engine stall.
Fuel is in tank.
Battery is in normal condition.

POSSIBLE
CAUSE

D
D
D
D
D
D
D
D
D
D
D
D
D
D

Poor fuel quality


Intakeair system restriction
Fuel line restriction
EGR system malfunction
FSO solenoid malfunction
Glow system malfunction
Fuel leakage
Fuel filter clogging
Incorrect fuel injection timing
Injection pump malfunction
Injection nozzle malfunction
Immobilizer system activation or malfunction
Low engine compression
PCM control relay malfunction

Diagnostic procedure
STEP
1

INSPECTION
Note
D The following test should be performed
on the vehicles with immobilizer system.
D Go to Step 12 for vehicles without
immobilizer system.

Yes

Both conditions appear:


D Go to Step 4.

No

Either of other condition appears:


D Go to next step.

D Does engine stall after approx. 2 s since


engine is started?

Yes

Go to next step.

No

Immobilizer system is okay.


Go to Step 12.

D Is immobilizer unit connector securely


connected to immobilizer unit?

Yes

Go to next step.

No

Connect immobilizer unit connector securely.


Return to Step 2.

D Does immobilizer indicator light flash and


indicate any of following immobilizer
system DTC?
DTC: 01, 02, 03, 11, 21

Yes

Go to ON-BOARD DIAGNOSTIC FUNCTION of


immobilizer system.
(See DTC TABLE)

No

Go to next step.

D Does immobilizer indicator light illuminate?

Yes

Go to Step 8.

No

Go to next step.

D Does immobilizer indicator light flash and


indicate any of following immobilizer
system DTCs after more than 135 s after
engine switch is turned to ON?
DTC: 24, 30

Yes

Go to ON-BOARD DIAGNOSTIC FUNCTION of


immobilizer system.
(See DTC TABLE)

No

Go to next step.

D Turn engine switch to OFF.


D Disconnect immobilizer unit connector.
D Connect jumper wire between immobilizer
unit connector terminal M and GND.
D Turn engine switch to ON.
D Does immobilizer indicator light illuminate?

Yes

Reconnect immobilizer unit connector.


Go to next step.

No

Inspect for open circuit between immobilizer unit connector


terminal M and instrument cluster.
If okay, inspect immobilizer indicator light bulb.
Repair or replace if necessary.
Reconnect immobilizer unit connector, then return to Step
4.

D Connect WDS or equivalent to DLC and


retrieve DTC.
D Is any of following DTC displayed?
DTC: P1602, P1603, P1604, P1621,
P1622, P1624

Yes

Go to appropriate DTC test.

No

Go to next step.

D Connect WDS or equivalent to DLC.


D Do following conditions appear?
Engine is not completely started.
DTC P1624 is displayed.
2

5
6

ACTION

F2130

TROUBLESHOOTING

STEP
9

10

11

12

INSPECTION
Yes

Go to next step.

No

Access PCM connector.


Inspect for continuity between PCM connector 4A/4B
terminals and body GND.
Repair or replace as necessary.

D Turn engine switch to ON.


D Access B+ PID.
D Is B+ PID okay?
B+ PID
Battery positive voltage

Yes

Go to next step.

No

Repair or replace wiring harness.

D Disconnect immobilizer unit connector.


D Turn engine switch to ON.
D Is there battery voltage at immobilizer unit
connector terminal J?

Yes

Inspect for open circuit between PCM connector terminal


2I and immobilizer unit connector terminal A.

No

Repair or replace wiring harness between immobilizer unit


connector terminal J and fuse panel.

D Inspector for following:


Fuel quality including water
contamination
Fuel line restriction
Loose bands on intakeair system
Cracks on intakeair system parts
Intakeair system restriction
D Inspect fuses.
D Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 12.

Yes

Go to next step.

No

Go to symptom troubleshooting NO.21 CONSTANT


VOLTAGE.

Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

D Turn engine switch to ON.


D Is FSO solenoid operation sound heard?

Yes

Go to Step.

No

Inspect for following:


D Stuck FSO solenoid
D Open circuit in FSO solenoid
D Poor GND of FSO solenoid
D Open circuit between FSO solenoid and PCM
connector terminal 4W
Repair or replace any malfunctioning parts.

D Inspect glow plug and glow plug relay.


(See NO TAG GLOW PLUG INSPECTION)
(See Section F2)
D Is glow system operation normal?

Yes

Go to next step.

No

Repair or replace any malfunctioning part according to


glow system operation results.

D Inspect for fuel leakage from fuel pipe.


D Is any fuel leakage found on fuel pipe?

Yes

Repair or replace as necessary.

No

Go to next step.

D Measure engine compression.


D Is compression okay?

Yes

Go to Step 20.

No

Go to next step.

13

Note
D Ignore DTC P0120 while performing this
test.
D Turn engine switch to ON.
D Disconnect accelerator position sensor
connector.
D Measure voltage at accelerator position
sensor connector VREF terminal.
Specification
4.55.5 V
D Is voltage okay?

14

15

16

17
18

ACTION

D Disconnect accelerator position sensor


connector.
D Inspect for continuity between GND
terminal at accelerator position sensor
vehicle harness connector and body GND.
D Is there continuity?

D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON position.
Retrieve any DTC.
Is DTC displayed?

F2131

TROUBLESHOOTING

STEP

INSPECTION
D Inspect timing belt for following
Chipping of gear teeth
Low tension
Breakage, damage or cracks
D Is timing belt okay?

19

ACTION
Yes

Inspector for following:


D Burnt valve
D Worn piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve system or valve guide
Repair or replace as necessary.

No

If timing is incorrect, adjust timing.


If timing belt is not okay, replace timing belt.

D Inspect injection timing


D Is injection timing okay?

Yes

Go to next step.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

21

D Inspect fuel filter for clogging.


D Is fuel filter okay?

Yes

Go to next step.

No

Replace fuel filter cartridge.

22

D Access EGR PID.


D Read EGR PID during cranking engine.
(See NO TAG PCM INSPECTION)
D Is PID value okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid valve (vent)
D EGR solenoid valve (vacuum)
D EGR valve
D Vacuum hose between EGR solenoid valve
D Wiring harness between EGR solenoid valve (vacuum)
and PCM terminal 4T
Repair or replace as necessary.

D Remove injection nozzle.


D Inspect injection nozzle for following:
Clogged nozzle
Seized needle valve
Incorrect valve operating pressure
Faulty nozzle okay?
D Is injection nozzle okay?

Yes

Go to next step.

No

Repair or replace injection nozzle.

D Is valve clearance correct?

Yes

Inspect following:
D Pump speed sensor
If okay, remove and inspect injection pump.

No

Adjust valve clearance.

20

23

24

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

25

NO.6 SLOW RETURN TO IDLE/FAST IDLE


6

Slow return to idle/fast idle

DESCRIPTION

POSSIBLE
CAUSE

D Engine takes more time than normal to return to idle speed.


D Engine speed continues at fast idle after warmup
D
D
D
D
D
D

Malfunction of ECT sensor


Thermostat is stuck open.
Air leakage from intakeair system
Fuel injection timing is incorrect.
Incorrect adjustment of accelerator cable free play
Incorrect adjustment of idle speed

Diagnostic procedure
STEP
1

INSPECTION
D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

ACTION
No

No DTC is displayed:
D Go to next step.

Yes

DTC is displayed:
D Go to appropriate DTC test.

D Inspect injection timing.


D Is injection timing okay?

Yes

Go to next step.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

D Inspect for air leakage from intakeair


system components while racing engine to
higher speed.
D Is there any air leakage?

Yes

Repair or replace as necessary.

No

Go to next step.

F2132

TROUBLESHOOTING

STEP

INSPECTION

ACTION

D Remove thermostat and inspect operation.


(See Section E)
D Is thermostat okay?

Yes

Inspect and adjust idle speed.


(See ENGINE TUNEUP)

No

Replace thermostat.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.7 ENGINE RUNS ROUGH/ROLLING IDLE


7

Engine runs rough/rolling idle

DESCRIPTION

POSSIBLE
CAUSE

D Engine speed fluctuates between specified idle speed and lower speed and engine shakes
excessively.
D Idle speed is too slow and engine shakes excessively.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Poor fuel quality


Air leakage from intakeair system
Intakeair system restriction
Incorrect idle speed
Engine overheating
A/C system improper operation
EGR system improper operation
Glow system malfunction
Fuel leakage
Fuel filter clogging
Fuel line restriction
Incorrect fuel injection timing
Injection pump malfunction
Injection nozzle malfunction
Low engine compression

Diagnostic procedure
STEP

INSPECTION

ACTION

D Inspect for following:


Proper fuel quality including water
contamination
Loose bands on intakeair system
Cracks on intakeair system parts
Intakeair system restriction
D Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

D Is engine overheating?

Yes

Go to symptom troubleshooting NO.13 COOLING


SYSTEM CONCERNSOVERHEATING.

No

Go to next step.

D
D
D
D

Yes

No DTC is displayed:
D Go to next step.

No

DTC is displayed:
D Go to appropriate DTC test.

Yes

Go to next step.

No

Go to step 6.

Yes

Go to step 7.

No

Repair or replace any malfunctioning part according to


glow system operation results.

Yes

Go to next step.

No

A/C is always on:


D Go to symptom troubleshooting NO 19. A/C IS
ALWAYS ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY.
For other symptoms:
D Inspect following:
Refrigerant charging amount
Cooling fan and/or condenser fan operation

4
5

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

D Does engine run normal after warmup?


D Inspect glow plug and glow plug relay.
(SeeNO TAG GLOW PLUG INSPECTION)
(See Section F2)
D Is glow system operation normal?
Note
D The following test should be performed
on the vehicles with A/C system. If the
following test cannot be performed due
to engine stalls, go to next step.
D Go to next step for the vehicle without
A/C system.
D Connect pressure gauge to A/C lines.
D Turn blower switch on.
D Is pressure within specifications?
(See Section U)

F2133

TROUBLESHOOTING

STEP

INSPECTION
D Depress accelerator pedal slightly.
D Crank engine.
D Does engine start now?

ACTION
Yes

Inspect and adjust idle speed.


(See ENGINE TUNEUP)
If symptom still appears, go to next step.

No

Go to next step.

D Inspect fuel leakage from fuel pipe.


D Is any fuel leakage found on fuel pipe?

Yes

Repair or replace as necessary.

No

Go to next step.

D Perform EGR system inspection.


D Is EGR system okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid valve (vent)
D EGR solenoid valve (vacuum)
D EGR valve
D Vacuum hose connection
D Wiring harness between EGR solenoid valve (vacuum)
and PCM terminal 4T
Repair or replace as necessary.

D Measure engine compression.


D Is compression okay?

Yes

Go to Step 12.

No

Go to next step.

D Inspect timing belt for following:


Chipping of gear teeth
Low tension
Breakage, damage or cracks
D Is timing belt okay?

Yes

Inspect for following:


D Burnt valve
D Worm piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve stem or valve guide
Repair or replace as necessary

No

If timing is incorrect, adjust timing.


If timing belt is not okay, replace timing belt.

D Inspect injection timing.


D Is injection timing okay?

Yes

Go to next step.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

D Inspect fuel filter for clogging.


D Is fuel filter okay?

Yes

Go to next step.

No

Replace fuel filter cartridge.

D Inspect fuel line for restriction.


D Is any restriction found in fuel line?

Yes

Repair or replace as necessary.

No

Go to next step.

D Remove injection nozzle.


D Inspect injection nozzle for following:
Clogged nozzle
Seized needle valve
Incorrect valve opening pressure
Faulty nozzle gasket
D Is injection nozzle okay?

Yes

Go to next step.

No

Repair or replace injection nozzle.

16

D Is valve clearance correct?

Yes

Inspect following:
D VSS
D Pump speed sensor
If okay, remove and inspect injection pump.

No

Adjust valve clearance.

17

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

8
9

10
11

12

13
14
15

NO.8 RUNS ON
8
DESCRIPTION
POSSIBLE
CAUSE

Runs on
D Engine runs after engine switch is turned to OFF.
D FSO solenoid malfunction.

F2134

TROUBLESHOOTING
Diagnostic procedure
STEP

INSPECTION
D
D
D
D

ACTION

Run engine at idle speed.


Disconnect FSO solenoid connector.
Make sure engine stops.
Does engine stop?

Yes

Inspect for following:


D Short to power line between engine switch and FSO
solenoid
Inspect circuit between FSO solenoid and PCM terminal
4W.
Repair or replace wiring harness.

No

Inspect FSO solenoid for being stuck open.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.9 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE,


SURGES
Engine stalls/quitsacceleration/cruise
Engine runs roughacceleration/cruise
Missesacceleration/cruise
Buck/jerkacceleration/cruise/deceleration
Hesitation/stumbleacceleration
Surgesacceleration/cruise

DESCRIPTION

D
D
D
D
D
D

Engine stops unexpectedly at beginning of acceleration or during acceleration or while cruising.


Engine speed fluctuates during acceleration or cruising.
Engine misses during acceleration or cruising.
Vehicle bucks/jerks during acceleration, cruising or deceleration.
Momentary pause at beginning of acceleration or during acceleration
Momentary minor irregularity in engine output

POSSIBLE
CAUSE

D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Poor fuel quality


Glow system malfunction
Air leakage from intakeair system
Purge solenoid valve malfunction
Intakeair system restriction
Air cleaner restriction
Engine overheating
A/C system improper operation
Turbocharger malfunction
EGR system malfunction
Fuel line restriction
Fuel filter clogging
Incorrect fuel injection timing
Incorrect idle speed
Injection pump malfunction
Injection nozzle malfunction
Low engine compression
Exhaust system restriction
Clutch slippage

Diagnostic procedure
STEP
1

4
5

INSPECTION
D Is idle speed stable?

D Is engine overheating?

D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

D Does symptom disappear after warmup?


D Inspect glow plug and glow plug relay.
(See NO TAG GLOW PLUG INSPECTION)
(See Section F2)
D Is glow system operation normal?

ACTION
Yes

Go to next step.

No

Go to symptom troubleshooting NO.7 ENGINE RUNS


ROUGH/ROLLING IDLE.

Yes

Go to symptom troubleshooting NO.13 COOLING


SYSTEM OVERHEATING.

No

Go to next step.

Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

Yes

Go to next step.

No

Go to Step 6.

Yes

Go to next step.

No

Repair or replace any malfunctioning part according to


glow system operation results.

F2135

TROUBLESHOOTING

STEP
6

INSPECTION
Note
D The following test should be performed
on the vehicles with A/C system.
D Go to next step for the vehicles without
A/C system.

ACTION
Yes

Go to next step

No

A/C is always on:


D Go to symptom troubleshooting NO.19 A/C IS
ALWAYS ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY.
For other symptoms:
D Inspect following:
Refrigerant charging amount
Cooling fan and condenser fan operation

Yes

Go to next step.

No

Clean or replace as necessary.

Yes

Retighten hose bands.


If concern is resolved, complete inspection.
If concern still exists, go to next step.

No

Turbocharger is okay.
Go to next step.

D Perform EGR system inspection.


D Is EGR system okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harnesses between EGR solenoids and PCM
terminals
Repair or replace as necessary.

D Is there any restriction in exhaust system?

Yes

Repair or replace as necessary.

No

Go to next step.

D Remove injection nozzle.


D Inspect injection nozzle for following:
Clogged nozzle
Seized needle valve
Incorrect valve opening pressure
Faulty nozzle gasket
D Is injection nozzle okay?

Yes

Go to next step.

No

Repair or replace injection nozzle.

12

D Inspect fuel line for restriction.


D Is any restriction found in fuel line?

Yes

Repair or replace as necessary.

No

Go to next step.

13

D Inspect fuel filter for clogging.


D Is fuel filter okay?

Yes

Go to next step.

No

Replace fuel filter cartridge.

D Measure engine compression.


D Is compression okay?

Yes

Go to Step 16.

No

Go to next step.

D Inspect timing belt for following:


Chipping of gear teeth
Low tension
Breakage damage or cracks
D Is timing belt okay?

Yes

Inspect for following:


D Burnt valve
D Worn piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve stem and valve guide
Repair or replace as necessary.

No

If timing is incorrect, adjust timing.


If timing belt is not okay, replace timing belt.

D Connect pressure gauge to A/C lines.


D Turn blower switch on.
D Is pressure within specifications?
(See Section U)
7

D Inspect air cleaner and/or intakeair


system for clogging or restriction.
D Are air cleaner and intakeair system
okay?
Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Inspect hose bands between following
parts:
Turbocharger compressor housing and
air cleaner
Turbocharger compressor housing and
charge air cooler
D Are hose bands loose?

10
11

14
15

F2136

TROUBLESHOOTING

STEP
16

17

INSPECTION

ACTION

D Inspect injection timing.


D Is injection timing okay?

Yes

Inspect following:
D Clutch for slippage
D Pump speed sensor
If okay, remove and inspect injection pump.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.10 LACK/LOSS OF POWER


10

Lack/loss of poweracceleration/cruise

DESCRIPTION

POSSIBLE
CAUSE

D Performance is poor under load (e.g., power down when climbing hills).
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Poor fuel quality


Air leakage from intakeair system
Intakeair system restriction
Air cleaner restriction
Engine overheating
A/C system improper operation
EGR system malfunction
Clutch slippage
Exhaust system restriction
Fuel line restriction
Fuel filter clogging
Incorrect fuel injection timing
Incorrect idle speed
Injection pump malfunction
Injection nozzle malfunction
Low engine compression pressure
Turbocharger malfunction
Brake system dragging
Intake shutter valve malfunction

Diagnostic procedure
STEP
1

INSPECTION
D Is idle speed stable?

ACTION
Yes

Go to next step.

No

Go to symptom troubleshooting NO.7 ENGINE RUNS


ROUGH/ROLLING IDLE.

D Is engine overheating?

Yes

Go to symptom troubleshooting NO.13 COOLING


CONCERNSOVERHEATING.

No

Go to next step.

D Is engine overheating?

Yes

Go to symptom troubleshooting No.16 COOLING


SYSTEM CONCERNSOVERHEATING.

No

Go to next step.

Yes

Go to next step.

No

A/C is always on:


D Go to symptom troubleshooting NO.19 A/C IS
ALWAYS ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY.
For other symptoms:
D Inspect following:
Refrigerant charging amount
Cooling fan and condenser fan operation

D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

D Inspect A/C cutoff operation.


D Does A/C cutoff work properly?

Yes

Go to next step.

No

Inspect A/C cutoff system components.

D Inspect air cleaner and/or intakeair


system for clogging or restriction.
D Are air cleaner and intakeair system
okay?

Yes

Go to next step.

No

Clean or replace as necessary.

F2137

TROUBLESHOOTING

STEP
7

INSPECTION
Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Go to Step 16 for the vehicles without
turbocharger system.

Retighten hose bands.


If concern is resolved, complete inspection.
If concern still exists, go to next step.

No

Turbocharger is okay.
Go to next step.

D Remove parts necessary to inspect


turbocharger. Do not remove turbocharger.
D Inspect if turbocharger compressor wheel
is bent, damaged, or interfering with
housing on vehicle.
(See NO TAG TURBOCHARGER
INSPECTION)
D Is there any problem?

Yes

Replace turbocharger.

No

Go to next step.

D Inspect if turbocharger compressor wheel


locknut is loose or has fallen down inside
turbocharger.
D Is there any problem?

Yes

Replace turbocharger.

No

Go to next step.

D Turn turbocharger compressor wheel by


hand.
D Does wheel turn easily and smoothly?

Yes

Go to next step.

No

Replace turbocharger.

D Inspect if turbocharger turbine wheel is


damaged, cracked or interfering with
housing on vehicle.

Yes

Replace turbocharger.

No

Go to next step.

D Inspect hose bands between following


parts:
Turbocharger compressor housing and
air cleaner
Turbocharger compressor housing and
charge air cooler
D Are hose bands loose?
8

10

11

ACTION
Yes

Note
D Inspect all fins on each turbine wheel.
D Is there any problem?
12

D Is any engine oil found inside turbocharger


turbine housing?

Yes

Excessive amount of oil is found:


D Replace turbocharger.
Small amount of oil is found:
D Wipe oil out of vehicle, then go to next step.

No

Go to next step.

13

D Is any engine oil found inside turbocharger


compressor housing?

Yes

Wipe oil out of vehicle and install all removed parts in Step
8. Then, go to next step.

No

Turbocharger is okay.
Install all removed parts in Step 8.
Then, go to next step.

D Perform EGR system inspection.


D Is EGR system okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harnesses between EGR solenoids and PCM
terminals
Repair or replace as necessary.

D Is there any restriction in exhaust system?

Yes

Repair or replace as necessary.

No

Go to next step.

14

15

F2138

TROUBLESHOOTING

STEP

INSPECTION

ACTION

D Remove injection nozzle.


D Inspect injection nozzle for following:
Clogged nozzle
Seized needle valve
Incorrect valve opening pressure
Faulty nozzle gasket
D Is injection nozzle okay?

Yes

Go to next step.

No

Repair or replace injection nozzle.

17

D Inspect fuel filter for clogging.


D Is fuel filter okay?

Yes

Go to next step.

No

Replace fuel filter cartridge.

18

D Measure engine compression.


D Is compression okay?

Yes

Go to Step 20.

No

Go to next step.

D Inspect timing belt for following:


Chipping of gear teeth
Low tension
Breakage, damage or cracks
D Is timing belt okay?

Yes

Inspect following:
D Burnt valve
D Worn piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve stem and valve guide
Repair or replace as necessary.

No

If timing is incorrect, adjust timing.


If timing belt is not okay, replace timing belt.

Yes

Inspect following:
D Boost sensor
D Brake system for dragging
D Clutch for slippage
If okay, remove and inspect injection pump.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

16

19

20

21

D Inspect injection timing.


D Is injection timing okay?

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.11 POOR FUEL ECONOMY


11

Poor fuel economy

DESCRIPTION

POSSIBLE
CAUSE

D Fuel economy is unsatisfactory.


D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Incorrect adjustment of idle speed


Accelerator pedal misadjustment
Air cleaner restriction
Engine cooling system malfunction
Poor fuel quality
Improper coolant level
Turbocharger malfunction
Improper engine compression
Exhaust system clogging
Injection timing is incorrect
Injection nozzle malfunction
Injection pump malfunction
Fuel leakage
Brake dragging
EGR system malfunction

Diagnostic procedure
STEP
1

INSPECTION

ACTION

D Inspect for following:


Fuel quality including water
contamination
Air cleaner element restriction
D Inspect coolant level
D Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

D
D
D
D

Yes

DTC is displayed:
Go to appropriate DTC test.

No

No DTC is displayed:
Go to next step.

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

F2139

TROUBLESHOOTING

STEP
3

6
7

INSPECTION
Yes

Go to next step.

No

Inspect for coolant leakage, cooling fan and condenser fan


operations or thermostat operation.

D Inspect idle speed.


(See ENGINE TUNEUP)
D Is idle speed okay?

Yes

Go to next step.

No

Go to symptom troubleshooting NO.6 SLOW RETURN


TO IDLE/FAST IDLE.

D Perform EGR system inspection.


D Is EGR system okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoids and PCM
terminals
Repair or replace as necessary.

D Inspect fuel leakage from fuel pipe.


D Is any fuel leakage found on fuel pipe?

Yes

Repair or replace as necessary.

No

Go to next step.

D Remove injection nozzle.


D Inspect injection nozzle for following:
Clogged nozzle
Seized needle valve
Incorrect valve opening pressure
Faulty nozzle gasket
D Is injection nozzle okay?

Yes

Go to next step.

No

Repair or replace injection nozzle.

Yes

Go to next step.

No

Replace turbocharger.

Yes

Inspect exhaust system.

No

Go to next step.

Yes

Go to next step.

No

Inspect for cause.

Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Perform turbocharger inspection.
(See TURBOCHARGER INSPECTION)
D Is turbocharger okay?

9
10

ACTION

D Access ECT PID.


D Drive vehicle while monitoring PID.
(See PCM INSPECTION)
D Is PID within specification?

D Is there restriction in exhaust system?


D Is brake system functioning properly?

11

D Measure engine compression.


D Is compression okay?

Yes

Go to Step 13.

No

Go to next step.

12

D Inspect timing belt for following:


Chipping or gear teeth
Low tension
Breakage, damage or cracks
D Is timing belt okay?

Yes

Inspect for following:


D Burnt valve
D Worn piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve stem and valve guide
Repair or replace as necessary.

No

If timing is incorrect, adjust timing.


If timing belt is not okay, replace timing belt.

Yes

Inspect following:
D Boost sensor
D Injection pump

No

Adjust injection timing.

13

14

D Inspect injection timing.


D Is injection timing okay?

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

F2140

TROUBLESHOOTING
NO.12 HIGH OIL CONSUMPTION/LEAKAGE
12

High oil consumption/leakage

DESCRIPTION

POSSIBLE
CAUSE

D Oil consumption is excessive.


D
D
D
D
D
D

Improper engine oil level


Improper dipstick
Improper engine oil viscosity
Engine internal parts malfunction
Oil leakage
Turbocharger malfunction

Diagnostic procedure
STEP
1

INSPECTION
D Verify following:
Proper dipstick
Proper engine viscosity
Engine oil level
D Are all items okay?

Go to next step.

No

Service as necessary.
Repeat Step 1.

Yes

Replace turbocharger.

No

Go to next step.

D Inspect if turbocharger compressor wheel


locknut is loose or has fallen down inside
turbocharger.
D Is there any problem?

Yes

Replace turbocharger.

No

Go to next step.

D Turn turbocharger compressor wheel by


hand.
D Does wheel turn easily and smoothly?

Yes

Go to next step.

No

Replace turbocharger.

D Inspect if turbocharger turbine wheel is


damaged, cracked or interfering with
housing on vehicle.

Yes

Replace turbocharger.

No

Go to next step.

Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Remove parts necessary to inspect
turbocharger.
D Do not remove turbocharger.
D Inspect if turbocharger compressor wheel
is bent, damaged, or interfering with
housing on vehicle.
D Is there any problem?

ACTION
Yes

Note
D Inspect all fins on each turbine wheel.
D Is there any problem?
6

D Is any engine oil found inside turbocharger


turbine housing?

Yes

Excessive amount of oil is found:


D Replace turbocharger.
Small amount of oil is found:
D Wipe oil of vehicle, then go to next step.

No

Go to next step.

D Is any engine oil found inside turbocharger


compressor housing?

Yes

Wipe oil out of vehicle, then go to next step.

No

Go to next step.

D Is any engine oil found around oil pipes


attached on turbocharger centre housing?

Yes

If oil leaks from damaged pipe, replace oil pipe.


Then, go to next step.

No

Go to next step.

D Is any engine oil found inside air intake


pipes or hoses?

Yes

Wipe engine oil out.

No

Turbocharger is okay.
Install all removed parts in Step 2.
Then go to next step.

F2141

TROUBLESHOOTING

STEP
10

11

INSPECTION
D Measure engine compression.
D Is compression okay?

ACTION
Yes

Inspect oil leakage from outside of engine.

No

Inspect for following:


D Damaged valve seat
D Worn valve stem and valve guide
D Worn or stuck piston ring
D Worn piston, piston ring or cylinder
Service as necessary.

D Verify test results. If okay, return to diagnostic index to service any advice additional symptoms.

NO.13 COOLING SYSTEM CONCERNS-OVERHEATING


13

Cooling system concernsoverheating

DESCRIPTION

POSSIBLE
CAUSE

D Engine runs at higher than normal temperature/overheats.


D
D
D
D
D
D
D
D
D
D
D
D
D

Cooling fan malfunction


Condenser fan malfunction
Low drive belt tension
Drive belt damage
Improper coolant level
Thermostat malfunction
Radiator clogging
Improper water/antifreeze mixture
Improper or damaged radiator cap
Radiator hose damage
Coolant leakage (engine internal, turbocharger, external)
A/C system malfunction
EGR system malfunction

Diagnostic procedure
STEP
1

INSPECTION

ACTION

D Inspect following:
Engine coolant level
Coolant leakage
Water and antifreeze mixture
Radiator condition
Collapsed or restricted radiator hoses
Radiator pressure cap
Drive belt tension
Drive belt
Fan rotational direction
Cooling fan
D Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTCs.
Is DTC displayed?

Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

Note
D The following test should be performed
on the vehicles with A/C system. Go to
Step 5 for vehicles without A/C system.

Yes

Go to next step.

No

Go to symptom troubleshooting NO.19 A/C IS ALWAYS


ON OR A/C COMPRESSOR RUNS CONTINUOUSLY.

D Start engine and run it at idle speed.


D Turn A/C switch on if equipped.
D Do condenser fan and/or cooling fan
operate?

Yes

Go to next step.

No

Condenser fan does not operate:


D Inspect for following:
Condenser fan relay is stuck open.
Condenser fan motor malfunction
Condenser fan motor GND open
Open circuit between condenser fan motor and relay
Open circuit between condenser fan relay and PCM
terminal 3C
Open battery power circuit of condenser fan relay

D Is drive belt okay?

Yes

Go to next step.

No

Replace drive belt.

D Start engine and run it at idle speed.


D Turn A/C switch off.
D Does A/C compressor disengage?
4

F2142

TROUBLESHOOTING

STEP
6
7
8

10

INSPECTION

ACTION

D Is there any leakage around heater unit in


passenger compartment?

Yes

Inspect and service heater for leakage.

No

Go to next step.

D Is there any leakage at coolant hoses


and/or radiator?

Yes

Replace malfunctioning parts.

No

Go to next step.

D Perform EGR system inspection.


D Is EGR system okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoid and PCM
terminals
Repair or replace as necessary.

D Cool down engine.


D Remove thermostat and inspect operation.
D Is thermostat okay?

Yes

Thermostat is okay.
Inspect cylinder block for leakage or blockage.

No

Replace thermostat.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms

NO.14 COOLING SYSTEM CONCERNS-RUNS COLD


14

Cooling system concernsruns cold

DESCRIPTION
POSSIBLE
CAUSE

D Engine normal operating temperature.


D Thermostat malfunction
D Condenser fan system malfunction
D Cooling fan system malfunction

Diagnostic procedure
STEP

INSPECTION

ACTION

D Is customer complaint Lack of passenger


compartment heat only?

Yes

Inspect A/C and heater system.

No

Go to next step.

D Does engine speed continue at fast idle?

Yes

Go to symptom troubleshooting NO.6 SLOW RETURN


TO IDLE/FAST IDLE.

No

Go to next step.

D Remove thermostat and inspect operation.


(See Section E)
D Is thermostat okay?

Yes

Inspect cooling fan and condenser fan operation.


If both or either fan operate abnormally, inspect for
following:
D Condenser fan relay is stuck closed
D Short to GND between condenser fan relay and PCM
terminal 3C
D Circuit between condenser fan relay and fan motor
shorts to battery supply line

No

Replace thermostat.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.15 EXCESSIVE BLACK SMOKE


15

Excessive black smoke

DESCRIPTION

POSSIBLE
CAUSE

D Excessive black smoke is observed in exhaust gas.


D
D
D
D
D
D
D

Air cleaner element restriction


Incorrect fuel injection timing
Injection nozzle malfunction
Injection pump malfunction
Low engine compression
EGR System Malfunction
Intake shutter valve malfunction

Diagnostic procedure
STEP
1

INSPECTION
D
D
D
D

Connect WDS or equivalent to DTC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

ACTION
Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

F2143

TROUBLESHOOTING

STEP
2
3
4

INSPECTION

ACTION

D Does any other symptom exist?

Yes

Go to appropriate flow chart.

No

Go to next step.

D Inspect air cleaner element for clogging.


D Is air cleaner element okay?

Yes

Go to next step.

No

Repair or replace air cleaner element.

D Inspect injection timing.


D Is injection timing okay?

Yes

Go to next step.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

D Remove injection nozzle.


D Inspect injection nozzle for following:
Clogged nozzle
Seized needle valve
Incorrect valve opening pressure
Faulty nozzle gasket
D Is injection nozzle okay?

Yes

Go to next step.

No

Repair or replace injection nozzle.

D Perform EGR system inspection.


D Is EGR system okay?

Yes

Go to next step.

No

Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoids and PCM
terminals
Repair or replace as necessary.

D Measure engine compression.


D Is compression okay?

Yes

Inspect following:
D Boost sensor
D Injection pump

No

Inspect following:
D Damaged valve seat
D Worn valve stem and valve guide
D Worn or stuck piston ring
D Worn piston, piston ring or cylinder
Service as necessary.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.16 ENGINE NOISE


16
DESCRIPTION

POSSIBLE
CAUSE

Engine noise
D Engine noise from under hood
D
D
D
D
D
D
D
D
D
D
D
D

Engine internal damage


Timing belt displacement
Injection nozzle malfunction
Loose attaching bolts or worn parts
Improper drive belt tension
Air leakage from intakeair system
Turbocharger operating noise
Improper injection timing
ECT sensor malfunction
EGR system malfunction
IAT sensor No.2 malfunction
Injection pump malfunction

Diagnostic procedure
STEP
1
2
3

INSPECTION
D Is squeal, click or chirp sound present?
D Is rumble or grind sound present?
D Is rattle sound present?

ACTION
Yes

Inspect engine oil level or drive belts.

No

Go to next step.

Yes

Inspect drive belt.

No

Go to next step.

Yes

Inspect location of rattle for loose parts.

No

Go to next step.

F2144

TROUBLESHOOTING

STEP
4
5
6

10

11

INSPECTION
D Is hiss sound present?

Inspect for vacuum leakage.

No

Go to next step.

Yes

Inspect exhaust system for loose parts.

No

Go to next step.

Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

D Access ECT PID.


D Inspect ECT PID while warming up engine.
D Is PID value correct?

Yes

Go to next step.

No

Inspect ECT sensor and related wiring harnesses.

D Access IAT PID.


D Inspect IAT PID while running engine.
D Is PID value correct?

Yes

Go to next step.

No

Inspect IAT sensor and related wiring harnesses.

D Inspect injection timing.


D Is injection timing okay?

Yes

Go to next step.

No

Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.

Yes

Go to next step.

No

Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harnesses between EGR solenoids and PCM
terminals
Repair or replace as necessary.

Yes

Replace turbocharger.

No

Go to next step.

D Inspect if turbocharger compressor wheel


locknut is loose or has fallen down inside
turbocharger.
D Is there any problem?

Yes

Replace turbocharger.

No

Go to next step.

D Turn turbocharger compressor wheel by


hand.
D Does wheel turn easily and smoothly?

Yes

Go to next step.

No

Replace turbocharger.

D Inspect if turbocharger turbine wheel is


damaged, cracked or interfering with
housing on vehicle.
D Is there any problem?

Yes

Replace turbocharger.

No

Go to next step.

D Is any engine oil found inside turbocharger


turbine housing?

Yes

Excessive amount of oil is found:


D Replace turbocharger.
Small amount of oil is found:
D Wipe oil out of vehicle, then, go to next step.

No

Go to next step.

Yes

Wipe oil out of vehicle.


Then, go to next step.

No

Go to next step.

Yes

Remove turbocharger.
Inspect for cracks on centre housing inlet surface.
If cracks are found, replace turbocharger.

No

Go to next step.

D Is rap or roar sound present?


D
D
D
D

Connect WDS or equivalent to DTC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

D Perform EGR system inspection.


Is EGR system okay?

Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Remove parts necessary to inspect
turbocharger.
D Inspect if turbocharger compressor wheel
is bent, damaged, or interfering with casing
on vehicle.
D Is there any problem?

12

13

14

15

16

17

ACTION
Yes

D Is any engine oil found inside turbocharger


compressor housing?
D Is any exhaust gas leakage found around
location where turbocharger is attached to
exhaust manifold?

F2145

TROUBLESHOOTING

STEP
18

19

20

INSPECTION
D Are any centre housing and turbine
housing attaching bolts loose?

D Remove injection nozzle.


D Inspect for following:
Clogged nozzle
Seized needle valve
Incorrect valve opening pressure
Faulty nozzle gasket
Afterdripping
D Is injection nozzle okay?

ACTION
Yes

Retighten loose bolts.


If a bolt is found to be missing, attach appropriate new bolt.

No

Turbocharger is okay.
Install all removed parts in Step 11.
Go to next step.

Yes

Inspect for following:


D Metal flow
D Bent connecting rod
D Damaged valve seat

No

Replace injection nozzle or gasket.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.17 VIBRATION CONCERNS (ENGINE)


17

Vibration concerns (engine)

DESCRIPTION
POSSIBLE
CAUSE

D Vibration from under hood or driveline


D Loose attaching bolts or worn parts
D Components malfunction such as worn parts

Diagnostic procedure
STEP
1

INSPECTION
D Inspect following components for loose
attaching bolts or worn parts:
Cooling fan
Drive belt and pulley
Engine mounts
Exhaust system
D All items okay?

ACTION
Yes

Inspect following systems:


D Wheels
D Transmission and amounts
D Driveline
D Suspension
Service as necessary.

No

Readjust or retighten engine mount installation position.


Service as necessary for other parts.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.18 A/C DOES NOT WORK SUFFICIENTLY


18

A/C does not work sufficiently.

DESCRIPTION

POSSIBLE
CAUSE

D A/C compressor magnetic clutch does not engage when A/C switch is turned on.
D
D
D
D
D
D
D
D
D
D

Improper refrigerant charging amount


Open A/C magnetic clutch
Open circuit in related wire harnesses
Poor GND of A/C magnetic clutch
A/C low/high pressure switch is stuck open.
A/C relay is stuck open.
Seized A/C compressor
ECT sensor malfunction
Improper magnetic clutch clearance
Accelerator position sensor malfunction

Diagnostic procedure
STEP
1

INSPECTION
D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

ACTION
Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

F2146

TROUBLESHOOTING

STEP
2

INSPECTION

ACTION

D Turn engine switch on.


D Set the fan switch to 1st, 2nd, 3rd, or 4th
position.
D Verify the blower motor is operating.
D Is blower motor okay?

Yes

Go to next step.

No

Inspect for following:


D Poor ground of fan switch
D Open circuit in blower resistor
D Poor contact of fan switch
D Blower relay is stuck open
D Open circuit in blower relay coil
D Seized blower motor
D Open circuit in blower motor coil
D Open circuit between blower motor and resistor
D Open circuit between fan switch and resistor
Repair or replace as necessary.

D
D
D
D

Connect WDS or equivalent to DTC.


Access ACSW PID.
Turn engine switch on.
Set the fan switch to 1st, 2nd, 3rd, or 4th
position.
D Turn A/C switch on.
D Dose ACSW PID read ON?

Yes

Go to next step.

No

Inspect for following:


D Frost switch is stuck open.
D Poor contact of microswitch in heater control unit
D Open circuit between PCM connector terminal 3C and
frost switch connector terminal
D Open circuit between frost switch connector terminal
and fan switch connector terminal
Repair or replace as necessary.

D Start the engine and run it at idle speed.


D Set the fan switch to 1st position.
D Measure the voltage at terminal of A/C
relay connector terminal C.
Specification
More than 10.5 V
D Is voltage correct?

Yes

Go to next step.

No

Inspect for following:


D Open circuit A/C relay coil
D Poor connect in A/C relay
D A/C relay stuck open
D Open circuit between PCM connector terminal 4L and
A/C relay connector terminal
D Open circuit in battery supply line
D Open circuit between engine switch and A/C relay
connecter terminal
D Engine coolant temperature sensor malfunction
Repair or replace as necessary.

D Disconnect the A/C magnetic clutch


connector.
D Measure the A/C magnetic clutch
connector terminal voltage.
Specification
More than 10.5 V
D Is voltage correct?

Yes

Inspect for following:


D Poor ground of A/C magnetic clutch
D Open circuit in magnetic clutch coil
D Refrigerant charging amount
Repair or replace as necessary.

No

Inspect for following:


D Open circuit between pressure switch connector
terminal and A/C magnetic clutch connector terminal
D Refrigerant changing amount
D A/C pressure switch is stuck open.
D Magnetic clutch clearance
D A/C compressor is seized
Repair or replace as necessary.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.19 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY


19

A/C always ON or A/C compressor runs continuously

DESCRIPTION

D A/C compressor magnetic clutch does not disengage.

POSSIBLE
CAUSE

D
D
D
D
D
D

Improper magnetic clutch clearance


Short to GND circuit between PCM and A/C relay
Short to GND circuit between PCM and A/C switch
Short to power line between A/C relay and pressure switch
A/C low/high pressure switch is stuck closed.
A/C relay is stuck closed.

Diagnostic procedure
STEP
1

INSPECTION
D
D
D
D

Connect WDS or equivalent to DLC.


Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?

ACTION
Yes

DTC is displayed:
D Go to appropriate DTC test.

No

No DTC is displayed:
D Go to next step.

F2147

TROUBLESHOOTING

STEP
2

INSPECTION
D
D
D
D
D

ACTION

Connect WDS or equivalent to DLC.


Access ACSW PID.
Turn engine switch on.
Turn blower switch off.
Dose ACSW PID read ON?

Yes

Go to next step.

No

Inspect for following:


D Short to ground circuit between PCM connector
terminal 3C and frost switch
D Short to ground circuit between frost switch and
blower switch connector terminal
Repair or replace as necessary.

D Start engine and run it at idle speed.


D Turn blower switch off.
D Measure the voltage at terminal of A/C
relay connector terminal C.
Specification
0V
D Is voltage correct?

Yes

Inspect for magnetic clutch clearance.


Adjust it as necessary.

No

Inspect for following:


D Short to ground circuit between PCM connector
terminal 4L and A/C relay terminal C
D A/C relay is stuck to close.
D Short to power line between A/C relay connector
terminal C and A/C pressure switch
D Short to power line between pressure switch and A/C
compressor magnetic clutch connector
Repair or replace as necessary.

D Verify test results. If okay, return to diagnostic index to service any additional symptoms.

NO.20 INTERMITTENT CONCERNS


20
DESCRIPTION

Intermittent concerns
D Symptom occurs randomly and is difficult diagnose.

POSSIBLE
CAUSE

Diagnostic procedure
STEP
1

INSPECTION

ACTION

D Talk to customer.
D Retrieve vehicle service history.
D Does vehicle have a number of previous
repairs and components replaced for a
certain symptom?

Yes

Go to appropriate flow chart.

No

Go to next step.

D Connect WDS or equivalent to DLC.


D If input is switchtype component, turn on
manually.
D Turn engine switch to ON.
D Access PIDs for suspect component.
D Lightly tap on suspect component, wiggle
and pull each wire/connector at suspect
component or PCM.
D Are any PID values out of range, or do they
suddenly change and go back into range?

Yes

Inspect each wire for corrosion, bent or loose terminal


crimps.

No

Go to Symptom Index.

D Start engine.
D Lightly tap on suspect component, wiggle
and pull each wire/connector at suspect
component or PCM.
D Are any PID values out of range, or do they
suddenly change and go back into range?

Yes

Inspect each wire for corrosion, bent or loose terminals


and poor wire terminal crimps.

No

Go to next step.

D Accurately spray water on suspect


component wire, component or vacuum
line related to possible fault area.
D Are any PID values out of range, or
suddenly change and go back into range,
or was there a noticeable engine
misfire/stumble?

Yes

Fault occurred while spraying on component:


D Replace part and verify repair.
Fault occurred while spraying wiring:
D Inspect each wire for corrosion, bent or loose
terminals and poor wire terminal crimps.
Fault occurred while spraying vacuum line:
D Repair vacuum hoses.

No

Inspect wire and connector at suspect component for


corrosion, bent or loose terminals, poor wire terminal
crimps and high tension of wire.
Repair as necessary.

F2148

TROUBLESHOOTING
NO.21 CONSTANT VOLTAGE
21

Constant voltage

DESCRIPTION

D Incorrect constant voltage


D Constant voltage circuit malfunction

POSSIBLE
CAUSE

Note
D Accelerator position sensor and boost sensor use constant voltage.

Diagnostic procedure
STEP
1

2
3

INSPECTION

ACTION

D Disconnect accelerator position sensor


connector.
D Turn engine switch to ON position.
D Measure voltage between following
accelerator position sensor connector
terminals:
Constant voltage terminal and GND
terminal
D Is constant voltage above 6.0 V?

Yes

Repair constant voltage circuit short to power in harness.

No

Go to next step.

D Is voltage across battery terminals above


10.5 V?

Yes

Go to next step.

No

Inspect charging system.

D Turn engine switch to OFF.


D Disconnect sensor where constant voltage
inspection failed.
D Measure voltage between battery positive
post and GND circuit at appropriate sensor
vehicle harness connector.
D Is voltage above 10.5 V and within 1.0 V
of battery voltage?

Yes

Go to next step.

No

Go to Step 9.

D
D
D
D

Yes

Inspect for open constant voltage supply circuit between


PCM connector terminal 1A and suspect sensor connector.

No

Go to next step.

D Turn engine switch to OFF.


D Disconnect accelerator position sensor
connector.
D Disconnect EGR solenoid valve (vacuum)
connector.
D Turn engine switch to ON.
D Measure voltage between power supply
circuit at EGR solenoid valve (vacuum)
connector and battery negative post.
D Is voltage above 10.5 V?

Yes

Reconnect EGR solenoid valve (vacuum).


Go to next step.

No

Battery power is not present.


Inspect following:
D MAIN fuse and/or PCM fuse
D PCM control relay
D Open circuit between MAIN fuel and PCM control relay
D Open circuit between PCM control relay and EGR
solenoid valve (vacuum)
D Open circuit between PCM control relay and PCM
terminal 3B
D Open circuit between PCM control relay and PCM
terminal 4C/4D

D Turn engine switch to OFF.


D Leave accelerator position sensor
disconnected.
D Disconnect MAF/IAT sensor connector.
D Turn engine switch to ON.
D Measure voltage between following
accelerator position sensor connector
terminals:
Constant voltage terminal and GND
terminal
D Is voltage 4.06.0 V?

Yes

Replace MAF/IAT sensor.

No

Go to next step.

Turn engine switch to ON.


Connect WDS or equivalent to DTC.
Attempt to access ECT PID.
Can ECT PID be accessed?

F2149

TROUBLESHOOTING

STEP

INSPECTION

D Turn engine switch to OFF.


D Leave accelerator position sensor and
MAF/IAT sensor connectors disconnected.
D Disconnect boost sensor connector.
D Turn engine switch to ON.
D Measure voltage between constant voltage
and GND terminals at accelerator position
sensor connector.
D Is voltage 4.06.0 V?

Yes

Replace boost sensor.

No

Go to next step.

D Turn engine switch to OFF.


D Leave accelerator position sensor
disconnected.
D Disconnect MAF/IAT sensor and boost
sensor connectors.
D Turn engine switch to ON.
D Connect WDS or equivalent to DLC.
D Access B+ PID.
D Is B+ PID above 10.5 V?

Yes

Inspect constant voltage circuit for shorting to GND.

No

Inspect for open battery power supply circuit between PCM


control relay and PCM terminal 4C/4D.

D
D
D
D

Yes

Go to next step.

No

Go to Step 11.

D Are DTCs present for two or more following


sensors connected to PCM 1B terminal?
D Boost sensor
D MAF/IAT sensor
D Accelerator position sensor
D ECT sensor
D IAT sensor No.2
D Fuel temperature sensor
D EGR position sensor

Yes

Go to next step.

No

Inspect for poor GND circuit of sensor where constant


voltage inspection failed.

D Turn engine switch to OFF.


D Disconnect WDS or equivalent from DLC.
D Disconnect sensor where constant voltage
inspection failed.
D Inspect for continuity between GND circuit
at appropriate sensor connector and body
GND.
D Is there continuity?

Yes

Go to next step.

No

Inspect for open GND circuit between following terminals:


D PCM connector 4A/4B terminals and GND
D PCM connector 4A/4B and 1B terminals

10

11

Turn engine switch to ON.


Connect WDS or equivalent to DLC.
Attempt to access ECT PID.
Can ECT PID be accessed?

ACTION

F2150

TROUBLESHOOTING
SYSTEM INSPECTION
FICD System Inspection
Fast-Idle Function
1. Verify that the FICD actuator rod is not pulled.
2. Verify that the engine is cold (ECT is below 20 C
{68 F}).
3. Turn fan switch off.
4. Start the engine.
5. Verify that the FICD actuator rod is pulled.

11. If not, disconnect vacuum hose A from the FICD


actuator and inspect if there is vacuum.
VACUUM HOSE A

6. If not, disconnect the vacuum hoses from the FICD


actuator and inspect if there is vacuum as shown.
FICD ACTUATOR

Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.

Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.
7. If there is vacuum, consult your distributor for
replacement of the FICD actuator.
8. If there is no vacuum, inspect the following.
D FICD solenoid valve No.1 and No.2
D Loose or damaged vacuum hoses between
FICD actuator, FICD solenoid valve No.1 and
No.2, and vacuum pump.
D PCM terminal C, E and P voltages (Refer to
CONTROL SYSTEM, POWERTRAIN
CONTROL MODULE (PCM) INSPECTION.)
D Wiring harness between FICD solenoid valve
No.1 and PCM terminal C.
D Wiring harness between FICD solenoid valve
No.2 and PCM terminal P.
9. Warm up the engine. (ECT above 20 C {68 F}).
10. Verify that the FICD actuator rod returns for one
notch.

12. If there is no vacuum, consult your distributor for


replacement of the FICD actuator.
13. If there is vacuum, inspect the following.
D FICD solenoid valve No.1
D PCM terminal C, E voltages (Refer to
CONTROL SYSTEM, POWERTRAIN
CONTROL MODULE (PCM) INSPECTION.)
D Wire harness between FICD solenoid valve
No.1 and PCM terminal C
14. Warm up the engine (ECT is above 60 C {140
F}).
15. Verify that the FICD actuator rod returns
completely.

16. If not, disconnect vacuum hose B from the FICD


actuator and inspect if there is vacuum.

F2151

TROUBLESHOOTING
7. If there is no vacuum, inspect the following:
D FICD solenoid valve No.2
D PCM terminal G and P voltages (Refer to

VACUUM HOSE B

CONTROL SYSTEM, POWERTRAIN CONTROL


MODULE (PCM) INSPECTION)
D Wiring harness between FICD solenoid valve No.2
connector terminal B and PCM terminal P
Turbocharger Boost Pressure
1. Disconnect the air hose between the intake pipe
and the boost compensator.
2. Connect a pressure gauge (range of measurement
is 93.3 kPa {700 mmHg, 27.6 inHg}).
BOOST COMPENSATOR
PRESSURE GAUGE

Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.
17. If there is no vacuum, consult your distributor for
replacement of the FICD actuator.
18. If there is vacuum, inspect the following.
D FICD solenoid valve No.2
D PCM terminal E, G and P voltages (Refer to
CONTROL SYSTEM, POWERTRAIN
CONTROL MODULE (PCM) INSPECTION.)
D Wiring harness between FICD solenoid valve
No.2 and PCM terminal P.
A/C Idle-up Function
1. Start the engine.
2. Warm up the engine to normal operating
temperature and run it at idle speed.
3. Set the fan switch at 1st position.
4. Verify that the FICD rod is pulled for one notch.
5. If not, disconnect the vacuum hose B from the
FICD actuator and inspect if there is vacuum as
shown.

TO INTAKE
PIPE

3. Warm up the engine.


4. With the accelerator at the wide open throttle,
increase the engine speed to 48005000 rpm and
verify that the boost pressure is within the
specification.
Specification
60.073.3 kPa
{0.620.74 kgf/cm2, 8.8210.52 psi}
5. If not as specified, inspect the exhaust system.
(Refer to EXHAUST SYSTEM, EXHAUST
SYSTEM INSPECTION.)
6. If the exhaust system is normal, inspect the
wastegate actuator. (Refer to INTAKE-AIR
SYSTEM, TURBOCHARGER INSPECTION,
Wastegate Actuator Inspection.)
7. If the wastegate actuator is normal, inspect the
turbocharger. (Refer to INTAKE-AIR SYSTEM,
TURBOCHARGER INSPECTION.)

VACUUM HOSE B

TCV Control Inspection (Europe and UK)


1. Crank the engine and verify that the TCV operation
sound is heard.
WL
Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.
6. If there is vacuum, consult your distributor for
replacement of the FICD actuator.

F2152

TCV

TROUBLESHOOTING
WL Turbo

TCV

2. If no operation sound is heard, inspect the TCV (in


the FIP).
3. If the TCV is normal, inspect the following:
D PCM terminal Q voltage (Refer to CONTROL
SYSTEM, POWERTRAIN CONTROL
MODULE (PCM) INSPECTION)
D Wire harness between TCV and PCM terminal
Q
EGR System Inspection (if equipped)
1. Make sure that all hoses are securely connected in
the proper position.
2. Disconnect the vacuum hose from the EGR valve.
3. Start the engine at cold condition.
4. Verify that there is no vacuum at vacuum hose.
5. If there is vacuum, inspect the following:
D EGR solenoid valve
D PCM terminal R voltage (Refer to CONTROL
SYSTEM, POWERTRAIN CONTROL
MODULE (PCM) INSPECTION.)
D Wire harness between EGR solenoid valve and
PCM terminal R
6. Warm up the engine to the normal operating
temperature and run it at idle speed.
7. Verify that there is vacuum at vacuum hose.
8. If there is no vacuum, inspect the following:
D EGR solenoid valve
D PCM terminal R voltage (Refer to CONTROL
SYSTEM, POWERTRAIN CONTROL
MODULE (PCM) INSPECTION.)
D Wire harness between EGR solenoid valve and
PCM terminal R
9. Connect the vacuum pump to the EGR valve.
10. Apply the vacuum to the EGR valve and inspect if
the engine speed becomes unstable or the engine
stalls.
11. If the engine speed does not change, stop the
engine and inspect the EGR valve.

F2153

TROUBLESHOOTING
Glow System Inspection
STEP
1

INSPECTION

ACTION

RESULTS

Connect NGS tester to DTC.


Turn engine switch on and retrieve DTC.
Are any of the following DTCs displayed?
D 09 (ECT sensor)
D 12 (Control lever position sensor)
D 36 (Glow plug relay)

Yes

Go the appropriate DTC test.


After repair is completed, go to next step.

No

Go to next step.

Turn engine switch on while engine is cold.


Does glow indicator light illuminate for approx.
19 seconds.?

Yes

Go to next step.

No

Inspect the following according to indication condition


of glow indicator light:
1. Will not go out
D Short circuit between glow indicator light and PCM
connector terminal M
D Short circuit in instrument cluster print plate
2. Illuminates for approx. 1 second (same condition
after engine is warmed up and cold)
D Extremely low resistance of engine coolant temperature sensor
D Short circuit between engine coolant temperature
sensor and PCM connector terminal E
3. Will not illuminate
D Glow indicator light
D Open circuit between glow indicator light and PCM
connector terminal M
D Open circuit in instrument cluster print plate
4. Illuminates for approx. 9 seconds (same condition
after engine is warmed up and cold)
D Extremely high resistance of engine coolant temperature sensor
D Open circuit between engine coolant temperature
sensor and PCM connector terminal E

Leave engine switch on while engine is cold.


Does glow plug voltage indicate B+ for
approx. 15 seconds.?

Yes

Go to next step.

No

Inspect for open or short circuit in harnesses and connectors between battery, glow plug relay, and glow
plug.
Inspect if glow plug relay is stuck open or closed.
Inspect glow plug relay ground circuit.
Inspect for open circuit between glow relay and PCM
terminal O.

Does glow plug voltage indicate B+ while


cranking engine?

Yes

Go to next step.

No

Inspect for open or short to ground circuit in harness


and connectors between engine switch (starter) and
PCM connector terminal D.

Is power supplied to the glow plug for maximum 10 minutes after engine started when
engine is cold?

Yes

Go to next step.

No

Inspect for open or short circuit in harnesses and connectors between NE sensor and PCM connector terminal F.

Remove the glow plug wire from glow plugs.


Measure resistance between glow plug and
body ground.
Is glow plug resistance approx. 1 or less?
+ INTAKE-AIR SYSTEM, GLOW PLUG INSPECTION

Yes

Glow system is okay.

No

Replace glow plug.

F2154

ENGINE ELECTRICAL SYSTEM


CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
BATTERY REMOVAL/INSTALLATION . . . . . .
BATTERY INSPECTION . . . . . . . . . . . . . . . . . .
BATTERY RECHARGING . . . . . . . . . . . . . . . . .
GENERATOR REMOVAL/INSTALLATION . . .
GENERATOR INSPECTION . . . . . . . . . . . . . .
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
IGNITER INSPECTION . . . . . . . . . . . . . . . . . . .
IGNITION COIL REMOVAL/INSTALLATION .

G
G
G
G
G
G
G
G
G

1
1
1
2
2
3
5
5
5

IGNITION COIL INSPECTION . . . . . . . . . . . . .


DISTRIBUTOR REMOVAL/INSTALLATION . .
DISTRIBUTOR DISASSEMBLY/ASSEMBLY .
DISTRIBUTOR INSPECTION (F2 CARB) . . .
HIGH-TENSION LEAD
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
STARTER REMOVAL/INSTALLATION . . . . . .
STARTER INSPECTION . . . . . . . . . . . . . . . . . .

G
G
G
G

G 9
G10
G10
G10

Battery Clamp Installation Note (RH)


 Install the battery clamp as shown.

CHARGING SYSTEM
BATTERY REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

3.54.9
{3550, 3143}

FRONT

75D26R

FRONT
Nm {kgfcm, inlbf}

Negative battery cable

Positive battery cable

Battery clamp
+ Installation Note (RH)

Battery

Battery tray

BATTERY INSPECTION
Battery
ST
 Inspect the battery in the following procedure.
Step

G1

Inspection

Measure open circuit


voltage of battery.

Quick charge for 30


minutes and recheck
voltage.

Apply test load (see test


load chart) to battery using
a battery
y load tester and
record battery voltage after
15 seconds. Is voltage
more than specification?

5
6
8
9

Action
Above
12.4 V

Go to
Step 3.

Below
12.4 V

Go to
next step.

Above
12.4 V

Go to
next step.

Below
12.4 V

Replace
battery.

Yes

Battery is
okay.

No

Replace
battery.

CHARGING SYSTEM
1. Place a battery in a pan of water to prevent it from
overheating. The water level should come up about
halfway on the battery. Keep water off the top of
the battery.

Test load chart


Battery

Load (A)

34B19R

110

55D23R

180

75D26L

195

75D26R

195

80D26R

195

95D31R

250

BATTERY

Battery positive voltage with load


Approximate
battery temp.

Minimum voltage(V)

21 C {70 F}

9.6

15 C {60 F}

9.5

10 C {50 F}

9.4

4 C {40 F}

9.3

1 C {30 F}

9.1

Battery type
(5hour rate)

Slow charge
(A)

Quick charge
(A)/(30 min.)

7 C {20 F}

8.9

34B19R (27)

3.04.0

20

12 C {10 F}

8.7

55D23R (48)

4.55.5

30

18 C { 0 F}

8.5

2. Connect a battery charger to the battery.


3. Adjust the charging current as follows.

Back-up Current
1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed.
2. Disconnect the negative battery cable.

5.56.5

35

5.56.5

35

80D26R (55)

5.56.5

35

95D31R (64)

6.58.0

40

4. After the battery has been recharged, measure the


battery positive voltage and verify that the battery
keeps specified voltage for more than 1 hour.

Caution
 Operating electrical loads while measuring
the back-up current can damage the circuit
tester.

Specification
Above 12.4 V

3. Measure the back-up current between the negative


battery terminal and the negative battery cable.
Back-up current
20 mA max.

75D26L (52)
75D26R (52)

5. If not as specified, replace the battery.


GENERATOR REMOVAL/INSTALLATION
Warning
 When the battery cables are connected,
touching the vehicle body with generator
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.

4. If the current exceeds the maximum, remove the


fuse in the main fuse block and the fuse block one
by one while measuring the back-up current.
5. Inspect and repair harnesses and connectors of
the fuse at which the current reduces.
BATTERY RECHARGING

1. Disconnect the negative battery cable.


2. Remove the fresh-air duct, air intake pipe and air
hose. (WL, WL Turbo)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the drive belt deflection/tension. (Refer to
Section B1B3, DRIVE BELT, DRIVE BELT
INSPECTION.)

Caution
 When disconnecting the battery, remove
the negative cable first and install it last to
prevent damage to electrical components
or the battery.
 To avoid deformation or damage to the
battery, remove the battery plugs while
charging the battery.
 Do not quick charge for over 30 minutes. It
will damage the battery.

G2

CHARGING SYSTEM
1. Place a battery in a pan of water to prevent it from
overheating. The water level should come up about
halfway on the battery. Keep water off the top of
the battery.

Test load chart


Battery

Load (A)

34B19R

110

55D23R

180

75D26L

195

75D26R

195

80D26R

195

95D31R

250

BATTERY

Battery positive voltage with load


Approximate
battery temp.

Minimum voltage(V)

21 C {70 F}

9.6

15 C {60 F}

9.5

10 C {50 F}

9.4

4 C {40 F}

9.3

1 C {30 F}

9.1

Battery type
(5hour rate)

Slow charge
(A)

Quick charge
(A)/(30 min.)

7 C {20 F}

8.9

34B19R (27)

3.04.0

20

12 C {10 F}

8.7

55D23R (48)

4.55.5

30

18 C { 0 F}

8.5

2. Connect a battery charger to the battery.


3. Adjust the charging current as follows.

Back-up Current
1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed.
2. Disconnect the negative battery cable.

5.56.5

35

5.56.5

35

80D26R (55)

5.56.5

35

95D31R (64)

6.58.0

40

4. After the battery has been recharged, measure the


battery positive voltage and verify that the battery
keeps specified voltage for more than 1 hour.

Caution
 Operating electrical loads while measuring
the back-up current can damage the circuit
tester.

Specification
Above 12.4 V

3. Measure the back-up current between the negative


battery terminal and the negative battery cable.
Back-up current
20 mA max.

75D26L (52)
75D26R (52)

5. If not as specified, replace the battery.


GENERATOR REMOVAL/INSTALLATION
Warning
 When the battery cables are connected,
touching the vehicle body with generator
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.

4. If the current exceeds the maximum, remove the


fuse in the main fuse block and the fuse block one
by one while measuring the back-up current.
5. Inspect and repair harnesses and connectors of
the fuse at which the current reduces.
BATTERY RECHARGING

1. Disconnect the negative battery cable.


2. Remove the fresh-air duct, air intake pipe and air
hose. (WL, WL Turbo)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the drive belt deflection/tension. (Refer to
Section B1B3, DRIVE BELT, DRIVE BELT
INSPECTION.)

Caution
 When disconnecting the battery, remove
the negative cable first and install it last to
prevent damage to electrical components
or the battery.
 To avoid deformation or damage to the
battery, remove the battery plugs while
charging the battery.
 Do not quick charge for over 30 minutes. It
will damage the battery.

G2

CHARGING SYSTEM
1. Place a battery in a pan of water to prevent it from
overheating. The water level should come up about
halfway on the battery. Keep water off the top of
the battery.

Test load chart


Battery

Load (A)

34B19R

110

55D23R

180

75D26L

195

75D26R

195

80D26R

195

95D31R

250

BATTERY

Battery positive voltage with load


Approximate
battery temp.

Minimum voltage(V)

21 C {70 F}

9.6

15 C {60 F}

9.5

10 C {50 F}

9.4

4 C {40 F}

9.3

1 C {30 F}

9.1

Battery type
(5hour rate)

Slow charge
(A)

Quick charge
(A)/(30 min.)

7 C {20 F}

8.9

34B19R (27)

3.04.0

20

12 C {10 F}

8.7

55D23R (48)

4.55.5

30

18 C { 0 F}

8.5

2. Connect a battery charger to the battery.


3. Adjust the charging current as follows.

Back-up Current
1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed.
2. Disconnect the negative battery cable.

5.56.5

35

5.56.5

35

80D26R (55)

5.56.5

35

95D31R (64)

6.58.0

40

4. After the battery has been recharged, measure the


battery positive voltage and verify that the battery
keeps specified voltage for more than 1 hour.

Caution
 Operating electrical loads while measuring
the back-up current can damage the circuit
tester.

Specification
Above 12.4 V

3. Measure the back-up current between the negative


battery terminal and the negative battery cable.
Back-up current
20 mA max.

75D26L (52)
75D26R (52)

5. If not as specified, replace the battery.


GENERATOR REMOVAL/INSTALLATION
Warning
 When the battery cables are connected,
touching the vehicle body with generator
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.

4. If the current exceeds the maximum, remove the


fuse in the main fuse block and the fuse block one
by one while measuring the back-up current.
5. Inspect and repair harnesses and connectors of
the fuse at which the current reduces.
BATTERY RECHARGING

1. Disconnect the negative battery cable.


2. Remove the fresh-air duct, air intake pipe and air
hose. (WL, WL Turbo)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the drive belt deflection/tension. (Refer to
Section B1B3, DRIVE BELT, DRIVE BELT
INSPECTION.)

Caution
 When disconnecting the battery, remove
the negative cable first and install it last to
prevent damage to electrical components
or the battery.
 To avoid deformation or damage to the
battery, remove the battery plugs while
charging the battery.
 Do not quick charge for over 30 minutes. It
will damage the battery.

G2

CHARGING SYSTEM

G6

WL, WL Turbo

5.06.8 Nm
{5070 kgfcm, 4460 inlbf}

2030
{2.03.1, 1522}

A
B
C
1925
{1.92.6,
1418}

3851
{3.85.3,
2838}

A
5.06.8 Nm
{5070 kgfcm,
4460 inlbf}

3851
{3.85.3, 2838}

C
3851
{3.85.3, 2838}
Nm {kgfm, ftlbf}

Nm {kgfm, ftlbf}

F2 CARB, F2 CIS
5.06.8 Nm
{5070 kgfcm, 4460 inlbf}
1622
{1.62.3,
1216}

Terminal B wire

Connector

Drive belt (generator)

Generator strap (G6)

Generator

GENERATOR INSPECTION
Generator Warning Light
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B1B3, DRIVE BELT,
DRIVE BELT INSPECTION.)
3. Turn the ignition switch (engine switch) on and
verify that the generator warning light illuminates.
4. If not, inspect the generator warning light and
wiring harnesses between the battery and
generator warning light and between the battery
and generator terminal L (G6, F2 CARB, F2 CIS), I
(WL, WL Turbo).
3851
{3.85.3, 2838}

ST
G6, F2 CARB, F2 CIS

Nm {kgfm, ftlbf}

G3

CHARGING SYSTEM

G6

WL, WL Turbo

5.06.8 Nm
{5070 kgfcm, 4460 inlbf}

2030
{2.03.1, 1522}

A
B
C
1925
{1.92.6,
1418}

3851
{3.85.3,
2838}

A
5.06.8 Nm
{5070 kgfcm,
4460 inlbf}

3851
{3.85.3, 2838}

C
3851
{3.85.3, 2838}
Nm {kgfm, ftlbf}

Nm {kgfm, ftlbf}

F2 CARB, F2 CIS
5.06.8 Nm
{5070 kgfcm, 4460 inlbf}
1622
{1.62.3,
1216}

Terminal B wire

Connector

Drive belt (generator)

Generator strap (G6)

Generator

GENERATOR INSPECTION
Generator Warning Light
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B1B3, DRIVE BELT,
DRIVE BELT INSPECTION.)
3. Turn the ignition switch (engine switch) on and
verify that the generator warning light illuminates.
4. If not, inspect the generator warning light and
wiring harnesses between the battery and
generator warning light and between the battery
and generator terminal L (G6, F2 CARB, F2 CIS), I
(WL, WL Turbo).
3851
{3.85.3, 2838}

ST
G6, F2 CARB, F2 CIS

Nm {kgfm, ftlbf}

G3

CHARGING SYSTEM
Standard voltage

WL, WL Turbo

Engine switch ON (V)

Idle (V) [20C {68F}]

WL, WL Turbo

WL, WL Turbo

B+

14.0514.85

B+

14.0514.85

7.0257.425

2.04.0

13.0014.85

Terminal

6. If not as specified, disassemble and inspect the


generator.
5. Verify that the generator warning light goes out
after engine starts.
6. If not, inspect the wiring harness between the S
terminals of the generator (WL, WL Turbo) and the
generator.
Generator
Voltage
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is within
the specification. (Refer to Section B1B3, DRIVE
BELT, DRIVE BELT INSPECTION.)
3. Turn off all electrical loads.
4. Turn the ignition switch (engine switch) to START
position and verify that the generator turns
smoothly without any noise while the engine is
running.
5. Measure the voltage at the terminals shown in the
table.

Current
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B1B3, DRIVE BELT,
DRIVE BELT INSPECTION.)
3. Disconnect the negative battery cable.
4. Connect an ammeter, capable of reading 120 A or
over, between generator terminal B and the wiring
harness.
5. Connect the negative battery cable.
6. Turn all electrical loads off.
7. Start the engine and increase the engine speed to
2,0002,500 rpm.
8. Turn the following electrical loads on and verify that
the current reading increases.
 Headlights
 Blower motor
 Rear window defroster
Note
 Current required for generating power varies
with electrical loads applied.

G6, F2 CARB, F2 CIS

Standard current (Reference)


S

Measuring conditions
Room temperature: 20 C {68 F}
Voltage: 13.5 V
Engine hot
Engine speed
(rpm)

Standard voltage
Ignition switch ON (V)

Idle [20C {68F}] (V)

G6, F2 CARB, F2 CIS

G6, F2 CARB, F2 CIS

B+

14.114.7

Approx. 1

13.014.0

B+

14.114.7

Terminal

*:

G6, F2 CARB,
F2 CIS

WL, WL Turbo

1,000

Approx. 043

Approx. 058

2,000

Approx. 062

Approx. 074

Must not be 0 A.

9. If generator terminal B current will not increase,


disassemble and inspect the generator.

WL, WL Turbo

Terminal B current (A)*

G4

IGNITION SYSTEM

IGNITION SYSTEM

G6, F2 CIS
8.912.7
{90130, 79112}

IGNITER INSPECTION
G6, F2 CIS
1. Disconnect the igniter connector.
2. Turn the ignition switch on and measure the
voltage at connector terminal A using the
voltmeter.

1.51.9
{1520, 1417}

G6, F2 CIS

Specification
Battery positive voltage

6.879.80
{70100, 60.886.8]
Nm {kgfcm, inlbf}

3. Turn the ignition switch off and verify that there is


continuity between terminal B and the body
ground.
4. While cranking the engine, measure the voltage at
terminal C using the voltmeter.

F2 CARB
8.912.7
{90130, 79112}

Specification
Approx. 0.5 V
5. If voltage and continuity are okay, replace the
igniter. (Refer to IGNITION SYSTEM, IGNITION
COIL REMOVAL/INSTALLATION.)

2.02.9
{2030, 1826}

IGNITION COIL REMOVAL/INSTALLATION


G6, F2 CARB, F2 CIS
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

6.879.80
{70100, 60.886.8]

ST
Nm {kgfcm, inlbf}

Center lead

Connector

Ignition coil bracket

Condenser

Ignition coil

Igniter

IGNITION COIL INSPECTION


G6, F2 CARB, F2 CIS
Primary Coil Winding
1. Disconnect the ignition coil connector.

G5

IGNITION SYSTEM

IGNITION SYSTEM

G6, F2 CIS
8.912.7
{90130, 79112}

IGNITER INSPECTION
G6, F2 CIS
1. Disconnect the igniter connector.
2. Turn the ignition switch on and measure the
voltage at connector terminal A using the
voltmeter.

1.51.9
{1520, 1417}

G6, F2 CIS

Specification
Battery positive voltage

6.879.80
{70100, 60.886.8]
Nm {kgfcm, inlbf}

3. Turn the ignition switch off and verify that there is


continuity between terminal B and the body
ground.
4. While cranking the engine, measure the voltage at
terminal C using the voltmeter.

F2 CARB
8.912.7
{90130, 79112}

Specification
Approx. 0.5 V
5. If voltage and continuity are okay, replace the
igniter. (Refer to IGNITION SYSTEM, IGNITION
COIL REMOVAL/INSTALLATION.)

2.02.9
{2030, 1826}

IGNITION COIL REMOVAL/INSTALLATION


G6, F2 CARB, F2 CIS
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

6.879.80
{70100, 60.886.8]

ST
Nm {kgfcm, inlbf}

Center lead

Connector

Ignition coil bracket

Condenser

Ignition coil

Igniter

IGNITION COIL INSPECTION


G6, F2 CARB, F2 CIS
Primary Coil Winding
1. Disconnect the ignition coil connector.

G5

IGNITION SYSTEM
2. Measure the resistance at the primary coil using an
ohmmeter.

F2 CARB

Specification [20 C {68 F}]


G6, F2 CIS: 0.810.99
F2 CARB: 1.0351.265

(+)

G6, F2 CIS

4. If not as specified, replace the ignition coil. (Refer


to IGNITION SYSTEM, IGNITION COIL
REMOVAL/INSTALLATION.)
DISTRIBUTOR REMOVAL/INSTALLATION
G6, F2 CARB, F2 CIS
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Adjust the ignition timing. (Refer to Section F1,
F3F4, ENGINE TUNE-UP, IGNITION TIMING
ADJUSTMENT.)

F2 CARB

G6

3. If not as specified, replace the ignition coil. (Refer


to IGNITION SYSTEM, IGNITION COIL
REMOVAL/INSTALLATION.)
Secondary Coil Winding
1. Disconnect the ignition coil connector.
2. Disconnect the center lead.
3. Measure the resistance at the secondary coil using
an ohmmeter.
Specification
1016 k [20 C {68 F}]
1925 {1.92.6, 1418}
G6, F2 CIS
Nm {kgfm, ftlbf}

G6

IGNITION SYSTEM
2. Measure the resistance at the primary coil using an
ohmmeter.

F2 CARB

Specification [20 C {68 F}]


G6, F2 CIS: 0.810.99
F2 CARB: 1.0351.265

(+)

G6, F2 CIS

4. If not as specified, replace the ignition coil. (Refer


to IGNITION SYSTEM, IGNITION COIL
REMOVAL/INSTALLATION.)
DISTRIBUTOR REMOVAL/INSTALLATION
G6, F2 CARB, F2 CIS
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Adjust the ignition timing. (Refer to Section F1,
F3F4, ENGINE TUNE-UP, IGNITION TIMING
ADJUSTMENT.)

F2 CARB

G6

3. If not as specified, replace the ignition coil. (Refer


to IGNITION SYSTEM, IGNITION COIL
REMOVAL/INSTALLATION.)
Secondary Coil Winding
1. Disconnect the ignition coil connector.
2. Disconnect the center lead.
3. Measure the resistance at the secondary coil using
an ohmmeter.
Specification
1016 k [20 C {68 F}]
1925 {1.92.6, 1418}
G6, F2 CIS
Nm {kgfm, ftlbf}

G6

IGNITION SYSTEM
Distributor Installation Note
 Verify that the No.1 cylinder is at top dead center,
and align the distributor matching marks.

F2 CARB

MATCHING MARKS

1925 {1.92.6, 1418}

Nm {kgfm, ftlbf}

F2 CIS

1925 {1.92.6, 1418}

ST
Nm {kgfm, ftlbf}

Vacuum hose

High-tension lead
+ HIGH-TENSION LEAD
REMOVAL/INSTALLATION

Connector

Distributor
+ Installation Note

G7

IGNITION SYSTEM
DISTRIBUTOR DISASSEMBLY/ASSEMBLY
G6, F2 CARB, F2 CIS
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
F2 CIS

G6

F2 CARB

Cap

Coupling set

Rotor

Governor set

Cover

10

Oil seal

Signal rotor

11

Bearing

Pick-up coil with igniter

12

Distributor body

Vacuum control unit

13

O-ring

Breaker

G8

IGNITION SYSTEM
DISTRIBUTOR INSPECTION (F2 CARB)
Centrifugal Spark Advance Control
1. Warm up the engine to the normal operating
temperature.
2. Check to be sure that the idle speed and ignition
timing are correct. (Refer to Section F4, ENGINE
TUNE-UP.)
3. Turn off all electrical loads.
4. Disconnect the vacuum hose to the vacuum control
unit, and plug the end of the hose.

TIMING LIGHT
DIAPHRAGM A

( ) 1115

VACUUM HOSE

02
20
0
53.3
ADVANCE (DEGREE)
{150, 5.9} {400, 15.7}

5. While gradually increasing the engine speed, use


the timing light to check the advance angle on
crankshaft pulley.

VACUUM ( kPa { mmHg , inHg })

6. If necessary, disassemble and inspect the


distributor.

1923

Pick-up Coil With Igniter Inspection


1. Connect an ohmmeter to the pick-up coil.

()
913

02
ADVANCE 0(DEGREE)
1,200 2,200
6,000
ENGINE SPEED ( rpm )

(1) Excess advance . . . weak governor spring (if


the governor spring is
broken, the advance will
rise very high)
(2) Insufficient advance . governor weight or cam
malfunction
6. If necessary, disassemble and inspect the
distributor.

2. Measure the resistance.

ST Resistance
9001,200

Vacuum Spark Advance Control


1. Warm up the engine to normal operating
temperature.
2. Check to be sure that the idle speed and ignition
timing are correct. (Refer to section F4, ENGINE
TUNE-UP.)
3. Turn off all electrical loads.
4. Disconnect the vacuum hose to the vacuum control
unit, and plug the end of the hose.
5. Attach a vacuum pump to the diaphragm A and
check using the timing light while applying vacuum.

3. If it is not within specification, replace it.


HIGH-TENSION LEAD REMOVAL/INSTALLATION

G9

Caution
 The high-tension leads must be reinstalled
to their original positions. Incorrect
installation can damage the leads and
cause power loss, and negatively affect the
electronic components.

STARTING SYSTEM

STARTING SYSTEM
WL, WL Turbo

STARTER REMOVAL/INSTALLATION
9.911.7 Nm
{100120 kgfcm,
87104 inlbf}

Warning
 When the battery cables are connected,
touching the vehicle body with starter
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.
1. Disconnect the negative battery cable.
2. Remove the battery. (WL, WL Turbo) (Refer to
CHARGING SYSTEM, BATTERY
REMOVAL/INSTALLATION.)
3. Remove the intake manifold bracket. (G6)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
G6, F2 CARB, F2 CIS
3851 {3.85.3, 2838}

3851 {3.85.3, 2838}

9.911.7 Nm
{100120 kgfcm,
87104 inlbf}

Nm {kgfm, ftlbf}

Terminal B wire

Terminal S wire

Starter

STARTER INSPECTION
On-vehicle Inspection
1. Verify that the battery is fully charged.
2. Crank the engine and verify that the starter turns
smoothly without any noise.
3. If not as specified, measure the voltage at
terminals S and B when the ignition switch (engine
switch) is at START position.
Specification
Above 8 V
4. If the voltage is within the specification, remove the
starter and inspect the magnetic switch and the
starter.
5. If the voltage is not as specified, inspect the wiring
harness, ignition switch (engine switch).

Nm {kgfm, ftlbf}

No Load Test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, voltmeter, and
ammeter as shown.
A
B
M

IGNITION
SWITCH
(ENGINE
SWITCH)

V
STARTER
BATTERY

TERMINAL S

G10

STARTING SYSTEM

STARTING SYSTEM
WL, WL Turbo

STARTER REMOVAL/INSTALLATION
9.911.7 Nm
{100120 kgfcm,
87104 inlbf}

Warning
 When the battery cables are connected,
touching the vehicle body with starter
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.
1. Disconnect the negative battery cable.
2. Remove the battery. (WL, WL Turbo) (Refer to
CHARGING SYSTEM, BATTERY
REMOVAL/INSTALLATION.)
3. Remove the intake manifold bracket. (G6)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
G6, F2 CARB, F2 CIS
3851 {3.85.3, 2838}

3851 {3.85.3, 2838}

9.911.7 Nm
{100120 kgfcm,
87104 inlbf}

Nm {kgfm, ftlbf}

Terminal B wire

Terminal S wire

Starter

STARTER INSPECTION
On-vehicle Inspection
1. Verify that the battery is fully charged.
2. Crank the engine and verify that the starter turns
smoothly without any noise.
3. If not as specified, measure the voltage at
terminals S and B when the ignition switch (engine
switch) is at START position.
Specification
Above 8 V
4. If the voltage is within the specification, remove the
starter and inspect the magnetic switch and the
starter.
5. If the voltage is not as specified, inspect the wiring
harness, ignition switch (engine switch).

Nm {kgfm, ftlbf}

No Load Test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, voltmeter, and
ammeter as shown.
A
B
M

IGNITION
SWITCH
(ENGINE
SWITCH)

V
STARTER
BATTERY

TERMINAL S

G10

STARTING SYSTEM
3. Operate the starter and verify that it turns
smoothly.
4. Measure the voltage and current while the starter
is operating.
Specification
Engine type
Item

G6

F2 CARB,
F2 CIS

WL,
WL Turbo

Voltage (V)

11.5

11.5

11

Current (A)

Below 100

Below 60

Below 130

5. If not as specified, repair or replace the inner parts


as necessary.

G11

CLUTCH
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . .
CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH FLUID INSPECTION . . . . . . . . . . . . .
CLUTCH FLUID REPLACEMENT/AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL INSPECTION/
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .

H 1
H 1
H 1
H 1
H 2
H 2
H 3
H 4
H 5

CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . H 7


CLUTCH RELEASE CYLINDER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . H 7
CLUTCH RELEASE CYLINDER
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . H 7
CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H 8
CLUTCH UNIT REMOVAL/INSTALLATION . . . H 8
CLUTCH COVER INSPECTION . . . . . . . . . . . . H10
CLUTCH DISC INSPECTION . . . . . . . . . . . . . . . H11
CLUTCH RELEASE COLLAR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . H11
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11
PILOT BEARING INSPECTION . . . . . . . . . . . . . H11
FLYWHEEL INSPECTION . . . . . . . . . . . . . . . . . H11

H 5
H 5

GENERAL PROCEDURES

CLUTCH FLUID

Clutch Pipe Removal/Installation


1. If any clutch pipe has been disconnected any time
during the procedure, add brake fluid, bleed the air,
and inspect for leakage after the procedure has
been completed.
2. If removing the clutch pipe, remove it using the
SST (49 0259 770B). If installing the clutch pipe,
modify the clutch pipe tightening torque to allow for
the use of a torque wrenchSST (49 0259 770B)
combination, and then tighten the clutch pipe using
the SST (49 0259 770B).

CLUTCH FLUID INSPECTION


Note
 The fluid in the reservoir must be maintained
between the MIN/MAX level during
replacement.
CLUTCH FLUID REPLACEMENT/AIR BLEEDING
Caution
 Clutch fluid will damage painted surfaces,
be careful not to spill clutch fluid on a
painted surface. If this should happen,
wash it off immediately.
 Do not mix different brands of clutch fluid.
 Do not reuse the clutch fluid that was
drained out.
1. Draw the fluid from the reserve tank with a suction
pump.
2. Remove the bleeder cap from the clutch release
cylinder and attach a vinyl hose to the bleeder plug.
3. Place the other end of the vinyl hose into a
container.
4. Slowly pump the clutch pedal several times.
5. With the clutch pedal depressed, loosen the
bleeder screw using the SST to let fluid escape.
Close the bleeder screw using the SST.
BLEEDER SCREW

49 0259 770B

H1

CLUTCH FLUID, CLUTCH PEDAL


1.Repeat steps 4 and 5 until only clean fluid is seen.
2.Tighten the bleeder screw.
Tightening torque
5.98.8 Nm {6090 kgfcm, 5278 inlbf}

CLUTCH PEDAL
CLUTCH PEDAL INSPECTION/ADJUSTMENT
Clutch Pedal Height
1. Measure the distance from the upper surface of the
pedal pad to the carpet.

3.Add fluid to the MAX mark.


4.Check for correct clutch operation.

Pedal height
241.6246.6 mm {9.529.70 in}

A 1417
{1.41.8, 1113}

PEDAL HEIGHT

CARPET

Nm {kgfm, ftlbf}

2.If necessary, adjust the pedal height by turning


stopper bolt A and clutch switch (or adjust bolt) B.

H2

CLUTCH FLUID, CLUTCH PEDAL


1.Repeat steps 4 and 5 until only clean fluid is seen.
2.Tighten the bleeder screw.
Tightening torque
5.98.8 Nm {6090 kgfcm, 5278 inlbf}

CLUTCH PEDAL
CLUTCH PEDAL INSPECTION/ADJUSTMENT
Clutch Pedal Height
1. Measure the distance from the upper surface of the
pedal pad to the carpet.

3.Add fluid to the MAX mark.


4.Check for correct clutch operation.

Pedal height
241.6246.6 mm {9.529.70 in}

A 1417
{1.41.8, 1113}

PEDAL HEIGHT

CARPET

Nm {kgfm, ftlbf}

2.If necessary, adjust the pedal height by turning


stopper bolt A and clutch switch (or adjust bolt) B.

H2

CLUTCH PEDAL
CLUTCH PEDAL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2.Remove in the order indicated in the table.
3.Install in the reverse order of removal.
4.After installation, adjust the clutch pedal.
(Refer to CLUTCH PEDAL
INSPECTION/ADJUSTMENT)

Clutch Pedal Free Play


1. Depress the clutch pedal by hand until clutch
resistance is felt, and measure the pedal free play.
Pedal free play
3.08.0 mm {0.120.31 in}

L.H.D.
D
1925
{1.92.6,
1418}

C
1216
{1.21.7,
8.712.3}

1925
{1.92.6,
1418}

PEDAL
FREE PLAY
Nm {kgfm, ftlbf}

6.99.80 Nm
{70100 kgfcm,
6186.8 inlbf}

2.If necessary, adjust the pedal free play by turning


locknut C and adjusting push rod D.
Clutch Release Point Inspection
1. Without depressing the clutch pedal, slowly shift
the shift lever into reverse position until the gears
contact.
2.Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops
(release point) up to the full stroke end position.

Clutch switch connector (G6, F2 CIS)

Spring pin

Clevis pin

Nut

Clutch pedal component

R.H.D.
G6, F2 CIS, F2 Carb
 Refer to section F1, F3, or F4, INTAKE-AIR
SYSTEM, ACCELERATOR PEDAL
REMOVAL/INSTALLATION.

Standard distance
A: 14.637.5 mm {0.581.47 in}
(reference value)
A

WL, WL Turbo
 Refer to section F2, INTAKE-AIR SYSTEM,
ACCELERATOR PEDAL
REMOVAL/INSTALLATION.

RELEASE
POINT
FULL
STROKE
END
POSITION

Nm {kgfm, ftlbf}

PEDAL STROKE

3.If the clutch pedal disengagement stroke is outside of


the specification, adjust the pedal height and pedal
free play, and verify the pedal stroke.
Pedal stroke
146.5151.5 mm {5.85.9 in}
(reference value)

H3

CLUTCH PEDAL
CLUTCH PEDAL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2.Remove in the order indicated in the table.
3.Install in the reverse order of removal.
4.After installation, adjust the clutch pedal.
(Refer to CLUTCH PEDAL
INSPECTION/ADJUSTMENT)

Clutch Pedal Free Play


1. Depress the clutch pedal by hand until clutch
resistance is felt, and measure the pedal free play.
Pedal free play
3.08.0 mm {0.120.31 in}

L.H.D.
D
1925
{1.92.6,
1418}

C
1216
{1.21.7,
8.712.3}

1925
{1.92.6,
1418}

PEDAL
FREE PLAY
Nm {kgfm, ftlbf}

6.99.80 Nm
{70100 kgfcm,
6186.8 inlbf}

2.If necessary, adjust the pedal free play by turning


locknut C and adjusting push rod D.
Clutch Release Point Inspection
1. Without depressing the clutch pedal, slowly shift
the shift lever into reverse position until the gears
contact.
2.Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops
(release point) up to the full stroke end position.

Clutch switch connector (G6, F2 CIS)

Spring pin

Clevis pin

Nut

Clutch pedal component

R.H.D.
G6, F2 CIS, F2 Carb
 Refer to section F1, F3, or F4, INTAKE-AIR
SYSTEM, ACCELERATOR PEDAL
REMOVAL/INSTALLATION.

Standard distance
A: 14.637.5 mm {0.581.47 in}
(reference value)
A

WL, WL Turbo
 Refer to section F2, INTAKE-AIR SYSTEM,
ACCELERATOR PEDAL
REMOVAL/INSTALLATION.

RELEASE
POINT
FULL
STROKE
END
POSITION

Nm {kgfm, ftlbf}

PEDAL STROKE

3.If the clutch pedal disengagement stroke is outside of


the specification, adjust the pedal height and pedal
free play, and verify the pedal stroke.
Pedal stroke
146.5151.5 mm {5.85.9 in}
(reference value)

H3

CLUTCH PEDAL
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
Note
 Apply lithium-based grease to the spring and
bush when assembling.
2. Assemble in the reverse order of disassembly.

1216
{1.21.7, 8.712.3}

1417
{1.41.8,
1113}

Nm {kgfm, ftlbf}

Clutch switch (G6, F2 CIS)

Adjustment bolt (WL, WL Turbo, F2 Carb)

Nut

Stopper rubber

Retaining ring

Washer

Bush

Pin

Fork

10

Push rod

11

Nut

12

Pedal pad

13

Clutch pedal component

H4

CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER


CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
6.99.8 {70100, 60.886.7}

SST *
12.821.5
{130220, 113190}

* 49 0259 770B

Nm {kgfcm, inlbf}

Clutch pipe

Clutch master cylinder

Nut

Gasket

CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

84112 Nm
{8.511.5 kgfm,
61.583.1 ftlbf}

H5

CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER


CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
6.99.8 {70100, 60.886.7}

SST *
12.821.5
{130220, 113190}

* 49 0259 770B

Nm {kgfcm, inlbf}

Clutch pipe

Clutch master cylinder

Nut

Gasket

CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

84112 Nm
{8.511.5 kgfm,
61.583.1 ftlbf}

H5

CLUTCH MASTER CYLINDER

Snap ring
+ Disassembly Note
+ Assembly Note

Piston

Protector

Primary cap

Return spring

Tank cap

Reservoir

Bushing

Joint bolt

10

Gasket

11

One-way valve piston

12

Return spring

13

One way valve pin

14

Clutch master cylinder body

Snap Ring Disassembly Note


 Hold the piston down using a cloth-wrapped pin
punch.

Snap Ring Assembly Note


 Hold the piston down using a cloth-wrapped pin
punch.

H6

CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER


CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

2226 {2.22.7, 1619}

1622 {1.62.3, 1216}

(LITHIUM BASED GREASE)

E-clip

Bolt

Clutch hose

Clutch release cylinder

Nm {kgfm, ftlbf}

CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

G6

5.98.8 Nm
{6090 kgfcm,
5378 inlbf}

EXCEPT
G6

Boot

Bleeder cap

Push rod

Bleeder screw

Piston and cap

Steel ball

Return spring

Clutch release cylinder body

H7

CLUTCH UNIT

CLUTCH UNIT
CLUTCH UNIT REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

G6
:9298 {9.310.0, 67.372.3}
EXCEPT G6 :97102 {9.810.5, 70.975.9}
ENGINE SIDE

TRANSMISSION SIDE

SST

1826 {1.82.7, 1419}

SST
SST
SST

(MOLYBDENUM SULFIDE)
Nm {kgfm, ftlbf}

Transmission
+ Section J1, MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION
+ Section J2, MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION

Clutch disc
+ Installation Note

Pilot bearing
+ Removal Note
+ Installation Note

Clutch release collar

Clutch release fork

Clutch cover
+ Removal Note
+ Installation Note

Flywheel
+ Removal Note
+ Installation Note

H8

CLUTCH UNIT
Clutch Cover Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross
pattern until spring tension is released.
49 E011 1A0

Flywheel Installation Note


1. Install the flywheel to the crankshaft.
2. Hand-tighten the flywheel lock bolts.
3. Install the SST to the flywheel.
4. Apply sealant to the bolt threads before installing
the bolt to prevent oil leakage from the bolt.
5. Gradually tighten the flywheel lock bolts in a
crisscross pattern.
G6
1

49 SE01 310A

49 E011 1A0

4
6

Pilot Bearing Removal Note


Note
 The pilot bearing does not need to be removed
unless you are replacing it.

EXCEPT G6

 Use the SSTs to remove the pilot bearing.


3

1
6

49 E011 1A0
4

5
2

49 1285 071

Flywheel Removal Note


1. Hold the flywheel using the SST.
2. Remove the bolts evenly and gradually in a
crisscross pattern.

Pilot Bearing Installation Note


G6, F2 CIS, F2 Carb
 Install a new pilot bearing using a pipe until depth
is as follows:
Depth
4.0 mm {0.16 in}

G6
PILOT BEARING
CRANK
SHAFT

49 E011 1A0

EXCEPT G6

1
6

49 E011 1A0

5
2

H9

CLUTCH UNIT
WL, WL Turbo
 Install a new pilot bearing using a pipe until
protrusion height is as follows:

CLUTCH COVER INSPECTION


1. Measure the wear of the diaphragm spring figures.
Depth
0.6 mm {0.024 in} min.

Protrusion height
00.2 mm {00.008 in}

DEPTH
PILOT BEARING
FLY WHEEL

2. Measure the flatness of the pressure plate using a


straight edge and a feeler gauge.

Clutch Disc Installation Note


 Hold the clutch disc in position using the SST.

Clearance
0.5 mm {0.020 in} max.

49 SE01 310A

Clutch Cover Installation Note


1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a
crisscross pattern.

3. When checking the diaphragm spring fingers,


mount a dial indicator on the cylinder block.
4. Rotate the flywheel and check for misaligned
diaphragm spring fingers.

49 E011 1A0

Misalignment
0.6 mm {0.030 in} max.

49 SE01 310A

5. Replace the clutch cover if not as specified.

H10

CLUTCH UNIT
WL, WL Turbo
 Install a new pilot bearing using a pipe until
protrusion height is as follows:

CLUTCH COVER INSPECTION


1. Measure the wear of the diaphragm spring figures.
Depth
0.6 mm {0.024 in} min.

Protrusion height
00.2 mm {00.008 in}

DEPTH
PILOT BEARING
FLY WHEEL

2. Measure the flatness of the pressure plate using a


straight edge and a feeler gauge.

Clutch Disc Installation Note


 Hold the clutch disc in position using the SST.

Clearance
0.5 mm {0.020 in} max.

49 SE01 310A

Clutch Cover Installation Note


1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a
crisscross pattern.

3. When checking the diaphragm spring fingers,


mount a dial indicator on the cylinder block.
4. Rotate the flywheel and check for misaligned
diaphragm spring fingers.

49 E011 1A0

Misalignment
0.6 mm {0.030 in} max.

49 SE01 310A

5. Replace the clutch cover if not as specified.

H10

CLUTCH UNIT
CLUTCH DISC INSPECTION
1. Using vernier calipers, measure the thickness of
the lining at a rivet head on both sides.
2. If clutch disc thickness is less than the minimum,
replace the clutch disc.

FLYWHEEL
PILOT BEARING INSPECTION
1. Without removing the pilot bearing from the
flywheel, turn the bearing while applying force in
the axial direction.

Thickness
0.3 mm {0.012 in} min.
0.3 mm
{0.012 in}

2. If the bearing sticks or has excessive resistance,


replace it.
3. Measure the clutch disc runout using a dial
indicator.

FLYWHEEL INSPECTION
1. Install a dial indicator on the cylinder block.
2. Measure the flywheel runout using a dial indicator.

Runout
0.7 mm {0.027 in} max.

Runout
0.2 mm {0.079 in} max.

4. If runout is excessive, replace the clutch disc.


CLUTCH RELEASE COLLAR INSPECTION

3. If runout is excessive, replace the flywheel.

Caution
 Cleaning the clutch release collar with
cleaning fluids or a steam cleaner can wash
the grease out of the sealed bearing.
Otherwise, clutch release collar may not
operate properly.
1. Turn the collar while applying force in the axial
direction.

2. If the collar sticks or has excessive resistance,


replace the clutch release collar.

H11

MANUAL TRANSMISSION
(R15MD, R15MXD)
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . .
TRANSMISSION OIL INSPECTION . . . . . . . . .
TRANSMISSION OIL REPLACEMENT . . . . . .
OIL SEAL (R15MD) REPLACEMENT . . . . . .
VEHICLE SPEEDOMETER SENSOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .

J21
J21
J21
J22

VEHICLE SPEEDOMETER SENSOR


INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . J22
MANUAL TRANSMISSION
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . J23

J22
TRANSMISSION OIL REPLACEMENT
1. Remove drain plugs A and B, and drain the oil into
a container.
2. Clean the drain plug A.
3. Install the drain plug A with new washer and a new
drain plug B.

MANUAL TRANSMISSION
TRANSMISSION OIL INSPECTION
1. Remove the filler plug.
FILLER PLUG

Tightening torque
A: 4058 Nm {4.06.0 kgfm, 2943 ftlbf}
B: 2131 Nm {2.13.2 kgfm, 1623 ftlbf}
FILLER PLUG

2. Verify that the oil is at the brim of the filler plug hole
as shown. If it is low, add the specified oil from the
filler plug hole.
DRAIN PLUG A

Specified oil
Grade:
API service GL4 or GL5
Viscosity:
SAE 75W90 (All season) or
SAE 80W90 (Above 10C {50F})

DRAIN PLUG B

4. Remove the filler plug and add the specified oil


through the filler plug port until the level rises to the
bottom of the port.
Specified oil
Grade:
API service GL4 or GL5
Viscosity:
SAE 75W90 (All season) or
SAE 80W90 (Above 10C {50F})
Capacity:
2.8 L {3.0 US qt, 2.5 lmp qt} (R15MD)
3.2 L {3.4 US qt, 2.8 lmp qt} (R15MXD)

FILLER PLUG HOLE

FILLER PLUG HOLE

3. Install a new filler plug.


Tightening torque
2539 Nm {2.64.0 kgfm, 1928 ftlbf}

J21

MANUAL TRANSMISSION
1. Install a new filler plug.
Tightening torque
2539 Nm {2.64.0 kgfm, 1928 ftlbf}
OIL SEAL (R15MD) REPLACEMENT
1. Drain the transmission oil.
2. Remove the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2),
PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the oil seal using a screwdriver.

4. Apply the specified oil to the new oil seal.


5. Install the oil seal until it touches the case using a
suitable piece of pipe.

PIPE

6. Install the propeller shaft.


(Refer to section L, PROPELLER SHAFT (4x2),
PROPELLER SHAFT REMOVAL/INSTALLATION.)
7. Add the transmission oil.
(Refer to MANUAL TRANSMISSION,
TRANSMISSION OIL REPLACEMENT.)
VEHICLE SPEEDOMETER SENSOR
REMOVAL/INSTALLATION
(Refer to section J1, MANUAL TRANSMISSION,
VEHICLE SPEEDOMETER SENSOR
REMOVAL/INSTALLATION.)
VEHICLE SPEEDOMETER SENSOR INSPECTION
(Refer to section J1, MANUAL TRANSMISSION,
VEHICLE SPEEDOMETER SENSOR INSPECTION.)

J22

MANUAL TRANSMISSION
MANUAL TRANSMISSION REMOVAL/INSTALLATION
4 2 (R15MD)
1. Disconnect the negative battery cable.
2. Drain the transmission oil into a container.
3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT
REMOVAL/INSTALLATION.)
4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Add the specified amount and type of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION
OIL REPLACEMENT.)
8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

F2

6988
{7.09.0,
5165}

1925 {1.92.6, 1418}

6988
{7.09.0,
5165}
1622
{1.62.3,
1216}

3851
{3.85.3,
2838}

6988
{7.09.0,
5165}
6988
{7.09.0,
5165}

1622
{1.62.3,
1216}

ST
3851
{3.85.3,
2838}

3851
{3.85.3,
2838}

7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}

3846
{3.84.7,
2833}

3246 {3.24.7, 2433}


2228 {2.22.9, 1620}

Nm {kgfm, ftlbf}

Shift lever knob

12

Vehicle speedometer sensor connector

Console

13

Backup light switch connector

Dust boot

14

Neutral switch connector (F2 CIS)

Change boot upper plate

15

Front pipe bracket

Boot

16

Clutch release cylinder

Dust boot

17

Gasket

Crossmember
+ Removal Note

Wave washer

18

Transmission lower mount

Change bush

19

10

Change lever

Transmission
+ Removal note
+ Installation note

11

Change seat

J23

MANUAL TRANSMISSION

WL, WL TURBO
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

3851
{3.85.3,
2838}

1925 {1.92.6, 1418}

3851 {3.85.3, 2838}

A
1622
{1.62.3,
1216}

1622
{1.62.3,
1216}

3246 {3.24.7, 2433}


2228 {2.22.9, 1620}

3846
{3.84.7, 2833}

Nm {kgfm, ftlbf}

Shift lever knob

11

Change seat

Console

12

Vehicle speedometer sensor connector

Dust boot

13

Back-up light switch connector

Change boot upper plate

14

Front pipe bracket

Boot

15

Clutch release cylinder

Dust boot

16

Gasket

Crossmember
+ Removal Note

Wave washer

17

Transmission lower mount

Change bush

18

10

Change lever

Transmission
+ Removal note
+ Installation note

J24

MANUAL TRANSMISSION

ZCF5210W001

Shift lever knob

12

Vehicle speedometer sensor connector

Console

13

Backup light switch connector

Dust boot

14

Neutral switch connector

Change boot upper plate

15

Front pipe bracket

Boot

16

Clutch release cylinder

Dust boot

17

Gasket

Crossmember
See NO TAG Crossmember removal note

Wave washer

18

Transmission lower mount

Change bush

19

10

Change lever

Transmission
See NO TAG Transmission removal note
See NO TAG Transmission installation note

11

Change seat

J25

MANUAL TRANSMISSION
Crossmember removal note
D Securely support the transmission on a
transmission jack, then remove the crossmember.
Transmission removal note
Warning
D Do not allow the transmission to fall from
the transmission jack.
D Maintain the stability of the transmission while

removing it.

Transmission installation note


Warning
D A transmission that is not securely
supported on a transmission jack is
dangerous. It can slip or fall, causing
serious injury. Never work without the
transmission jack until crossmember
installation is finished.
1. Place the transmission on a transmission jack.
2. Maintain the stability of the transmission while
installing the jacks.

ST

J26

MANUAL TRANSMISSION
4 4 (R15MXD)
1. Disconnect the negative battery cable.
2. Drain the transmission and transfer oil into a container.
3. Remove the front and rear propeller shaft.
(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT
REMOVAL/INSTALLATION.)
(Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT
REMOVAL/INSTALLATION.)
4. Remove the front pipe. (G6 engine)
(Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Add the specified type and amount of transmission and transfer oil.
(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)
(Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)
9. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
G6
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

R
R

3851 {3.85.3, 2838}

1925
{1.92.6,
1418}

A
3851 {3.85.3, 2838}

1622
{1.62.3,
1216}

6988
{7.09.0,
5165}

3851 {3.85.3, 2838}

3246 {3.24.7, 2433}

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

3750
{3.75.1,
2736}

4453 {4.45.3, 3239}

3851 {3.85.3, 2838}

Nm {kgfm, ftlbf}

J27

MANUAL TRANSMISSION

Shift lever knob

14

Backup light switch connector

Console

15

Neutral switch connector

Dust boot

16

4x4 indicator switch connector

Change boot upper mount

17

Transfer neutral switch connector (RFW model)

Boot

18

Front pipe bracket

Dust boot

19

Clutch release cylinder

Gasket

20

Wave washer

Crossmember
+ MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION,
4 2 (R15MD), Crossmember removal note

Change bush

10

Change lever

21

Transmission lower mount

11

Change seat

22

12

Transfer under cover

13

Vehicle speedometer sensor connector

Transmission and transfer


+ Removal note
+ Installation note

WL, WL TURBO

7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}

R
R

3851
{3.85.3,
2838}

1925
{1.92.6, 1418}

ST

3851
{3.85.3, 2838}

A
3246
{3.24.7, 2433}
1622
{1.62.3,
1216}

3750
{3.75.1,
2736}

4453
{4.45.3, 3239}
2228
{2.22.9, 1620}

Nm {kgfm, ftlbf}

J28

MANUAL TRANSMISSION

Shift lever knob

14

Backup light switch connector

Console

15

Transfer neutral switch connector (RFW model)

Dust boot

16

4x4 indicator switch connector

Change boot upper mount

17

Front pipe bracket

Boot

18

Clutch release cylinder

Dust boot

19

Gasket

Wave washer

Crossmember
+ MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION,
4 2 (R15MD), Crossmember removal note

Change bush

20

Transmission lower mount

10

Change lever

21

11

Change seat

12

Transfer under cover

Transmission and transfer


+ Removal note
+ Installation note

13

Vehicle speedometer sensor connector

ZCF5210W003

Shift lever knob

Dust boot

Console

Change boot upper plate

J29

MANUAL TRANSMISSION

Boot

16

4x4 indicator switch connector

Dust boot

17

Neutral switch connector

Gasket

18

Front pipe bracket

Wave washer

19

Clutch release cylinder

Change bush

20

Crossmember

10

Change lever

21

Transmission lower mount

11

Change seat

22

12

Transfer under cover

13

Vehicle speedometer sensor connector

14

Backup light switch connector

Transmission and transfer


See NO TAG Transmission and transfer removal
note
See NO TAG Transmission and transfer installation
note

15

Transfer neutral switch connector (RFW model)

Transmission and transfer removal note


Warning
D Do not allow the transmission to fall from
the transmission jack.
D Maintain the stability of the transmission and

transfer while removing the jacks.

Transmission and transfer installation note


Warning
D A transmission and transfer that are not
securely supported on a transmission jack
are dangerous. They can slip or fall,
causing serious injury. Never work without
the transmission jack until crossmember
installation is finished.
1. Place the transmission and transfer on a
transmission jack.
2. Maintain the stability of the transmission and
transfer while installing the jacks.

J210

PROPELLER SHAFT
PROPELLER SHAFT (42) . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT INSPECTION . . . . . . . . . .
FRONT PROPELLER SHAFT (44) . . . . . . . . . . .
FRONT PROPELLER SHAFT REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

L1
L1
L2
L2
L2

FRONT PROPELLER SHAFT INSPECTION . .


FRONT PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . .
REAR PROPELLER SHAFT (44) . . . . . . . . . . . .
REAR PROPELLER SHAFT REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR PROPELLER SHAFT INSPECTION . . . .

L3
L3
L5
L5
L5

PROPELLER SHAFT (42)


PROPELLER SHAFT REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
5058
{5.06.0, 3743}

SST

3752 {3.75.4, 2739}


Nm {kgfm, ftlbf}

Bolt, nut

Nut
+ Installation Note

Propeller shaft
+ Removal Note
+ Installation Note

WL TURBO, G6:

49 S120 440

WL, F2 CIS, F2 CARB:

49 0259 440

Propeller Shaft Installation Note


 Align the marks made during removal, and install
the propeller shaft. If installing a new propeller
shaft, align the differential companion flange
precast marking with the tag on the propeller shaft.
TAG

MARK

Propeller Shaft Removal Note


1. Before removing the propeller shaft, put marks on
the yoke and the companion flange on the
propeller shaft tag side for proper reinstallation.
TAG

MARK

Nut Installation Note


ST
 Tighten the center bearing installation nuts with the
vehicle *unloaded.
*unloaded...Fuel tank is full; engine coolant and engine
oil are at specified levels; spare tire, jack and tools are
in designated position.

2. Remove the propeller shaft from the extension


housing and immediately install the SST to prevent
oil leakage.

L1

PROPELLER SHAFT (42), FRONT PROPELLER SHAFT (44)


PROPELLER SHAFT INSPECTION
1. Measure the propeller shaft runout using a dial
indicator.

FRONT PROPELLER SHAFT (44)


FRONT PROPELLER SHAFT REMOVAL/
INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Runout
0.4 mm {0.016 in} max.

2830
{2.83.1, 2122}

2. If the runout is excessive, replace the propeller


shaft.
3. Move the universal joint in the direction shown, and
inspect joint play.
Note
 Starting torque
0.31.1 Nm
{3.012.0 kgfcm, 2.710.4 inlbf}

Nm {kgfm, ftlbf}

Bolt, nut

Front propeller shaft


+ Removal Note
+ Installation Note

Front Propeller Shaft Removal Note


 Before removing the front propeller shaft, put
marks on the yoke and the companion flange on
the propeller shaft tag side for proper reinstallation.
4. If there is excessive play or the starting torque is
not within the specification, replace the propeller
shaft.

TAG

MARK

Front Propeller Shaft Installation Note


 Align the marks made during removal, and install
the front propeller shaft. If installing a new
propeller shaft, align the precast marking with the
tag on the front propeller shaft.

L2

PROPELLER SHAFT (42), FRONT PROPELLER SHAFT (44)


PROPELLER SHAFT INSPECTION
1. Measure the propeller shaft runout using a dial
indicator.

FRONT PROPELLER SHAFT (44)


FRONT PROPELLER SHAFT REMOVAL/
INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Runout
0.4 mm {0.016 in} max.

2830
{2.83.1, 2122}

2. If the runout is excessive, replace the propeller


shaft.
3. Move the universal joint in the direction shown, and
inspect joint play.
Note
 Starting torque
0.31.1 Nm
{3.012.0 kgfcm, 2.710.4 inlbf}

Nm {kgfm, ftlbf}

Bolt, nut

Front propeller shaft


+ Removal Note
+ Installation Note

Front Propeller Shaft Removal Note


 Before removing the front propeller shaft, put
marks on the yoke and the companion flange on
the propeller shaft tag side for proper reinstallation.
4. If there is excessive play or the starting torque is
not within the specification, replace the propeller
shaft.

TAG

MARK

Front Propeller Shaft Installation Note


 Align the marks made during removal, and install
the front propeller shaft. If installing a new
propeller shaft, align the precast marking with the
tag on the front propeller shaft.

L2

FRONT PROPELLER SHAFT (44)

TAG

MARK

FRONT PROPELLER SHAFT


DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
R

FRONT PROPELLER SHAFT INSPECTION


1. Measure the front propeller shaft runout using a
dial indicator.
Runout
0.4 mm {0.016 in} max.

Snap ring
+ Disassembly Note

Universal joint yoke

Universal joint
+ Disassembly Note
+ Assembly Note

Sliding yoke

Propeller shaft

Snap ring Disassembly Note


1. Mark the yoke and propeller shaft for proper
reassembly.
2. If the runout is excessive, replace the front
propeller shaft.
3. Move the universal joint in the direction shown,
and inspect the joint play.

MARK

Note
 Starting torque
0.30.7 Nm
{3.08.0 kgfcm, 2.76.9 inlbf}

2. Clamp the propeller shaft in a vise.


3. Remove the snap ring.

ST

Universal joint Disassembly Note


1. Push one bearing cup out of the propeller shaft by
tapping the yoke with a plastic hammer.

BEARING CUP

4. If there is excessive play or the starting torque is


not within the specification, repair the front
propeller shaft.
(Refer to FRONT PROPELLER SHAFT (44),
FRONT PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY.)
YOKE

L3

FRONT PROPELLER SHAFT (44)

TAG

MARK

FRONT PROPELLER SHAFT


DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
R

FRONT PROPELLER SHAFT INSPECTION


1. Measure the front propeller shaft runout using a
dial indicator.
Runout
0.4 mm {0.016 in} max.

Snap ring
+ Disassembly Note

Universal joint yoke

Universal joint
+ Disassembly Note
+ Assembly Note

Sliding yoke

Propeller shaft

Snap ring Disassembly Note


1. Mark the yoke and propeller shaft for proper
reassembly.
2. If the runout is excessive, replace the front
propeller shaft.
3. Move the universal joint in the direction shown,
and inspect the joint play.

MARK

Note
 Starting torque
0.30.7 Nm
{3.08.0 kgfcm, 2.76.9 inlbf}

2. Clamp the propeller shaft in a vise.


3. Remove the snap ring.

ST

Universal joint Disassembly Note


1. Push one bearing cup out of the propeller shaft by
tapping the yoke with a plastic hammer.

BEARING CUP

4. If there is excessive play or the starting torque is


not within the specification, repair the front
propeller shaft.
(Refer to FRONT PROPELLER SHAFT (44),
FRONT PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY.)
YOKE

L3

FRONT PROPELLER SHAFT (44)

TAG

MARK

FRONT PROPELLER SHAFT


DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
R

FRONT PROPELLER SHAFT INSPECTION


1. Measure the front propeller shaft runout using a
dial indicator.
Runout
0.4 mm {0.016 in} max.

Snap ring
+ Disassembly Note

Universal joint yoke

Universal joint
+ Disassembly Note
+ Assembly Note

Sliding yoke

Propeller shaft

Snap ring Disassembly Note


1. Mark the yoke and propeller shaft for proper
reassembly.
2. If the runout is excessive, replace the front
propeller shaft.
3. Move the universal joint in the direction shown,
and inspect the joint play.

MARK

Note
 Starting torque
0.30.7 Nm
{3.08.0 kgfcm, 2.76.9 inlbf}

2. Clamp the propeller shaft in a vise.


3. Remove the snap ring.

ST

Universal joint Disassembly Note


1. Push one bearing cup out of the propeller shaft by
tapping the yoke with a plastic hammer.

BEARING CUP

4. If there is excessive play or the starting torque is


not within the specification, repair the front
propeller shaft.
(Refer to FRONT PROPELLER SHAFT (44),
FRONT PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY.)
YOKE

L3

FRONT PROPELLER SHAFT (44)


1. Remove the opposite bearing cup in the same
manner.
2. Separate the propeller shaft and yoke.
3. Clamp the yoke in a vise.
4. Remove the bearing cups and the spider from the
yoke in the same manner as in Steps 1 and 2.
Universal joint Assembly Note
1. Verify that the inside of the bearing cup is filled with
1.151.45g {0.040.05 oz} grease. Add the
specified amount of disulphide molybdem grease
as necessary.
2. Set the new spider into the yoke and tap in a new
bearing cup until the snap ring groove is exposed.

SPIDER

3. Measure the snap ring clearance, then select and


install two new snap rings of equal thickness.
Snap ring thicknesses
mm {in}
1.22 {0.0480}

1.32 {0.0520}

1.24 {0.0488}

1.34 {0.0528}

1.26 {0.0496}

1.36 {0.0536}

1.28 {0.0504}

1.38 {0.0543}

1.30 {0.0512}
BEARING CUP
YOKE

SNAP RING
CLEARANCE

SPIDER

4. Install the remaining bearing cups and snap rings


as in Steps 13.
5. Move the universal joint in the direction shown, and
inspect joint play.
Note
 Starting torque
0.30.7 Nm
{3.08.0 kgfcm, 2.76.9 in lbf}

L4

6. If there is excessive play or the starting torque is


not within the specification, replace the front
propeller shaft.

REAR PROPELLER SHAFT (44)

REAR PROPELLER SHAFT (44)

TAG

MARK

REAR PROPELLER SHAFT


REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

5058
{5.06.0, 3743}

REAR PROPELLER SHAFT INSPECTION


1. Measure the rear propeller shaft runout using a dial
indicator.
Runout
0.4 mm {0.016 in} max.

3752
{3.75.4, 2739}
5058
{5.06.0, 3743}
Nm {kgfm, ftlbf}

Bolt, nut

Nut
+ PROPELLER SHAFT (42), PROPELLER
SHAFT REMOVAL/INSTALLATION, Nut
Installation Note

Rear propeller shaft


+ Removal Note
+ Installation Note

Dynamic damper (WL Turbo)

2. If the runout is excessive, replace the rear


propeller shaft.
3. Move the universal joint in the direction shown.
Inspect starting torque and joint play.
Note
 Starting torque
0.31.1 Nm
{3.012.0 kgfcm, 2.710.4 inlbf}

Rear Propeller Shaft Removal Note


1. Before removing the rear propeller shaft, put marks
on the yoke and the companion flange on the rear
propeller shaft tag side for proper reinstallation.
TAG

ST

MARK

4. If there is excessive play or the starting torque is


not within the specification, replace the rear
propeller shaft.

Rear Propeller Shaft Installation Note


 Align the marks made during removal, and install
the rear propeller shaft. If installing a new propeller
shaft, align precast marking with the tag on the
rear propeller shaft.

L5

FRONT AND REAR AXLES


GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . M2
FRONT AXLE (4 2) . . . . . . . . . . . . . . . . . . . . . . . . M2
WHEEL HUB, STEERING KNUCKLE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . M2
WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . M3
WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . M6
FRONT AXLE (4 4) . . . . . . . . . . . . . . . . . . . . . . . . M8
WHEEL HUB, STEERING KNUCKLE
INSPECTION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . M8
WHEEL HUB, STEERING KNUCKLE
PREINSPECTION (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . . M8
WHEEL HUB BOLT REPLACEMENT
(VEHICLES BUILT FROM 08/2002) . . . . . . . M8
WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . M9
WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . M12
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16
REAR AXLE INSPECTION . . . . . . . . . . . . . . . . M16
AXLE SHAFT REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . M16
AXLE SHAFT (WITH ABS) REMOVAL/
INSTALLATION (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . M19
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M23
DRIVE SHAFT REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . M23
DRIVE SHAFT REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . M24
DRIVE SHAFT DISASSEMBLY/ASSEMBLY
(VEHICLES BUILT UP TO 07/2002) . . . . . . . M26
DRIVE SHAFT DISASSEMBLY/ASSEMBLY
(VEHICLES BUILT FROM 08/2002) . . . . . . . M29
OUTPUT SHAFT (MFW)
REMOVAL/INSTALLATION . . . . . . . . . . . . . . M32
OUTPUT SHAFT
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . M33
REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . M35
REAR DIFFERENTIAL OIL INSPECTION . . . . M35
REAR DIFFERENTIAL OIL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . M35
REAR DIFFERENTIAL REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . M36

STANDARD DIFFERENTIAL
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD DIFFERENTIAL ASSEMBLY . . .
LIMITED SLIP DIFFERENTIAL
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
LIMITED SLIP DIFFERENTIAL
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL FREEEWHEEL (MFW)
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . .
REMOTE FREEWHEEL (RFW)
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 4 INDICATOR SWITCH INSPECTION . . .
TRANSFER NEUTRAL SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
RFW SWITCH INSPECTION . . . . . . . . . . . . . .
RFW MAIN SWITCH REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .
RFW MAIN SWITCH INSPECTION . . . . . . . .
ONE-WAY CHECK VALVE INSPECTION . . .
LOCK AND FREE SOLENOID VALVES
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
RFW ACTUATOR INSPECTION . . . . . . . . . . .
RFW CONTROL MODULE INSPECTION . . . .
RFW CONTROL MODULE
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
JOINT SHAFT COMPONENT
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
JOINT SHAFT COMPONENT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
JOINT SHAFT INSPECTION . . . . . . . . . . . . . .
JOINT SHAFT COMPONENT ASSEMBLY . . .
CONTROL BOX REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT FORK INSPECTION . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL OIL
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL OIL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL OIL SEAL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL REMOVAL
/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL DISASSEMBLY . . . .
FRONT DIFFERENTIAL ASSEMBLY . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .
REMOTE FREEWHEEL (RFW) . . . . . . . . . . . .

M1

M37
M40
M44
M46
M48
M48
M48
M48
M48
M49
M49
M49
M50
M50
M50
M51
M51
M53
M54
M55
M56
M58
M59
M60
M61
M61
M61
M61
M62
M64
M67
M72
M72

GENERAL PROCEDURES, FRONT AXLE (4 2)

GENERAL PROCEDURES

FRONT AXLE (4 2)

Wheel and tire removal/installation


D The removal and installation procedures for the
wheels and tires are not mentioned in this section.
When a wheel is removed, retighten the wheel nuts
to the specified torque. (See TD Wheels and
Tires.)

WHEEL HUB, STEERING KNUCKLE INSPECTION


Wheel Bearing Play Inspection
D After jacking up the vehicle and supporting it at the
specified places with safety stands, inspect for
noticeable bearing play by holding the top and
bottom of the tire.

Brake line disconnection/connection

Wheel bearing axial play


0 mm {0 in}

Caution
D Brake fluid will damage painted surfaces. If
brake fluid gets on a painted surface, wipe
it off immediately.

Preload Adjustment
1. Verify that the tire rotates smoothly when rotated
strongly, and that there is no rough feeling or is
abnormal noise from the bearing.
2. Remove the brake caliper component and suspend
it by a rope.
3. Remove the hub cap, pull out the cotter pin and
remove the set cover.
4. Loosen the locknut to the extent that it can be
turned by hand.
5. Attach a pull scale to a hub bolt and measure the
frictional force.
6. Tighten the locknut until the reading reaches the
specified amount.

D If any brake line has been disconnected any time

during the procedure, add brake fluid, bleed the


brakes, and inspect leakage after the procedure
has been completed.
Brake Pipe Flare Nut Installation
D Tighten the brake pipe flare nut using the SST (49
0259 770B). Be sure to modify the brake
pipe fIare nut tightening torque to allow use of a
torque wrench-SST combination. (Refer to section
GI, FUNDAMENTAL PROCEDURES, TORQUE
FORMULAS.)
Suspension arm removal/installation
D Tighten any part of the suspension that uses
rubber bushings only after vehicle has been
lowered and unloaded.

Preload
Frictional force plus
5.910.7 N {0.61.1 kgf, 1.42.4 lbf}
7. Install the set cover, and secure with a new cotter
pin.
8. Install the hub cap and brake caliper component.

Note
D Unloaded: Fuel tank is full. Engine coolant and
engine oil are at a specified level. Spare tire,
jack and tools are in designated position.
Connectors disconnection/connection
D Disconnect the negative battery cable before doing
any work that requires the handling of connectors.
Reconnect the negative battery cable only after the
work is completed.

M2

FRONT AXLE (4 2)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION (VEHICLES BUILT UP 07/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

5468 {5.57.0, 4050}

SST

108127 {1113, 8094}

SST

3050 {3.05.2, 2250}


80100
{8.110.2,
5973}

R
SST

R
SST
R
R

R
SST

SST

4558 {4.56.0, 3343}


118156 {1216, 87115}

1925
{1.92.6,
1418}

Nm {kgfm, ftlbf}

Hub cap

Cotter pin

11

Lower arm ball joint


+ section R, FRONT SUSPENSION, TORSION
BAR SPRING AND LOWER ARM (4 2)
REMOVAL/INSTALLATION, Lower Arm Ball
Joint/Knuckle Removal Note

Set cover

Locknut

Washer

12

Hub and disc plate component


+ Installation Note

Upper arm ball joint


+ section R, FRONT SUSPENSION, UPPER
ARM REMOVAL/INSTALLATION, Upper Arm
Ball Joint/Knuckle Removal Note

Brake caliper component


+ Removal Note

13

Steering knuckle

Dust cover

14

Tie-rod end ball joint


+ section N, MANUAL STEERING, STEERING
GEAR AND LINKAGE REMOVAL/
INSTALLATION, Tie-rod End Ball Joint
Removal Note

Disc plate
+ Removal Note

15

Wheel hub
+ Removal Note

16

Hub bolt
+ Removal Note
+ Installation Note

10

Knuckle arm

M3

FRONT AXLE (4

17

Outer bearing inner race

18

Oil seal
+ Installation Note

19

Inner bearing inner race

20

Inner bearing outer race


+ Removal Note
+ Installation Note

21

Outer bearing outer race


+ Removal Note
+ Installation Note

Brake Caliper Component Removal Note


D Remove the brake caliper component, and
suspend it by a rope.

2)

Outer Bearing Outer Race, Inner Bearing Outer


Race Installation Note
D Install the bearing outer race using the SSTs and a
press. For the other side, reverse the wheel hub
and install the outer race.

OUTSIDE BEARING

49 H033 101
INSIDE BEARING

49 B025 001

Disc Plate, Wheel Hub, Hub Bolt Removal Note


Note
D The hub bolt does not need to be removed
unless it is being replaced.
1. After putting markings on the disc plate and the
wheel hub, remove the bolt and disassemble the
plate and hub.

Oil Seal Installation


1. After inserting the bearing in the hub, use the SST
to tap in the oil seal until it is flush with the hub end
surface.
2. Apply grease to the oil seal lip.

49 F019 001
MARK

2. Remove the hub bolt using a press as necessary.

Hub Bolt Installation Note


D Press new hub bolts into the wheel hub using a
press.

Inner Bearing Outer Race, Outer Bearing Outer


Race Removal Note
Note
D When the inner bearing outer race is removed,
the inner race and oil seal are removed
together.
D Remove the bearing outer race using a suitable

round bar and a hammer. For the other side,


reverse the wheel hub and remove the outer race.

M4

FRONT AXLE (4
Hub and Disc Plate Component Installation Note
1. Apply grease to the areas indicated in the figure.

2. Install the hub and disc plate component, then


adjust the preload. (Refer to FRONT AXLE (4 2),
WHEEL HUB, STEERING KNUCKLE
INSPECTION, Preload Adjustment.)

M5

2)

FRONT AXLE (4

2)

WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION (VEHICLES BUILT FROM 08/2002)


Caution
D Performing the following procedures without first removing the ABS wheelspeed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheelspeed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.
Note
D For this procedure, only the tightening torque of the ABS wheel speed sensor and ABS sensor rotor
removal/installation procedures have been added from the current models. No change has been made for
other procedures, SSTs and notes from the current models.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Hub cap

11

Lower arm ball joint

Cotter pin

12

Upper arm ball joint

Set cover

13

Steering knuckle

Locknut

14

Disc plate

Washer

15

Wheel hub

Brake caliper component

16

Hub bolt

Hub and disc plate component

17

Outer bearing inner race

Dust cover

18

Oil seal

Tie-rod end ball joint

19

Inner bearing innner race

10

Knuckle arm

20

Inner bearing outer race

M6

FRONT AXLE (4

21

Outer bearing outer race

22

ABS sensor rotor


+ See ABS Sensor Removal Note
+ See ABS Sensor Installation Note

ABS Sensor Rotor Removal Note


Note
D The sensor rotor does not need to be removed
unless it is being replaced.
1. Remove the sensor rotor using a chisel.

ABS Sensor Rotor Installation Note


1. Set the SST as shown in the figure.

2. Press the new sensor rotor in until flush with the


end of the wheel hub using the SST and a press.

M7

2)

FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE
PREINSPECTION (VEHICLES BUILT FROM
08/2002)
Wheel Bearing Play Inspection
1. Position a dial indicator against the wheel hub.

FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE INSPECTION
(VEHICLES BUILT UP TO 07/2002)
Wheel Bearing Play Inspection
(Refer to FRONT AXLE (4 2), WHEEL HUB,
STEERING KNUCKLE INSPECTION, Wheel Bearing
Play Inspection.)
Preload Adjustment
Caution
D When replacing the locknut, tighten it using
the SST and turn the wheel hub a few times
to seat the bearing. Then, perform the
preload adjustment.
1. For RFW model, remove the hub cap and drive
shaft end flange. For MFW model, remove the
freewheel hub component.
2. Remove the spacer and set plate.
3. Remove the brake caliper component, and
suspend it by a rope.
4. Loosen the locknut to the extent that it can be
turned by hand using the SST.

2. Push and pull the wheel hub by hand in the axial


direction and measure the wheel bearing play.
Maximum wheel bearing play
0.05 mm {0.002 in}
3. If the bearing play exceeds the specification,
replace and tighten the locknut to the specified
torque and retest.
D
IReplace the wheel bearing as necessary.

49 S231 635

WHEEL HUB BOLT, (4X4) REPLACEMENT


(VEHICLES BUILT FROM 08/2002)
1. Remove the hub bolt using the SSTs.

5. Attach a pull scale to a hub bolt and measure the


frictional force.
6. Tighten the locknut until the reading reaches the
specified amount.
Preload
Frictional force plus
5.910.7 N {0.61.1 kgf, 1.42.4 lbf}

2. Install the hub bolt into the wheel hub and install a
washer and hub nut on the hub bolt.
3. Tighten the hub nut while holding the wheel hub
using a brass bar.

7. Install the set plate, spacer, freewheel hub or drive


shaft end flange, hub cap and brake caliper
component.

M8

FRONT AXLE (4

4)

WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION (VEHICLES BUILT UP TO 07/2002)


1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

5580 {5.68.2, 4159}

R
SST

R
SST

SST

5567
{5.66.9,
4149}

5468 {5.57.0}

SST

3051
{3.05.2,
2237}

R
SST
R

R
R

SST
SST
SST

R
SST
R

1925 {1.92.6, 1418}


118156 {1216, 87115}
4044 {4.04.5, 2932}
4558 {4.56.0, 3343}

(RFW MODEL)

(MFW MODEL)
2529 {2.53.0, 1921}

Nm {kgfm, ftlbf}

Hub cap

Dust cover

Drive shaft end flange

10

Freewheel hub component

Spacer

Set plate

Tie-rod end ball joint


+ Section N, MANUAL STEERING, STEERIG
GEAR AND LINKAGE REMOVAL/
INSTALLATION, Tie-rod End Ball Joint
Removal Note

Locknut
+ Removal Note
+ Installation Note

11

Brake caliper component


+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Brake
Caliper Component Removal Note.

Disc plate
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Disc Plate
Removal Note

12

Wheel hub
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Wheel
Hub Removal Note

Hub and disc plate component

M9

FRONT AXLE (4 4)

13

Hub bolt
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Hub Bolt
Removal Note
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Hub Bolt
Installation Note

14

Outer bearing inner race

15

Oil seal
+ Installation Note

16

Inner bearing inner race

17

Inner bearing outer race


+ FRONT AXLE (4 2) WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Inner
Bearing Outer Race, Outer Bearing Outer Race
Removal Note
+ Installation Note

18

Outer bearing outer race


+ FRONT AXLE (4 2) WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Inner
Bearing Outer Race, Outer Bearing Outer Race
Removal Note
+ Installation Note

19

Nut
+ Section R, FRONT SUSPENSION, TORSION
BAR SPRING AND LOWER ARM (4 2)
REMOVAL/INSTALLATION, Nut Installation Note

20

Shock absorber bolt

21

Upper arm ball joint


+ Section R, FRONT SUSPENSION, UPPER
ARM REMOVAL/INSTALLATION, Upper Arm
Ball Joint/Knuckle Removal Note

22

Steering knuckle component


+ Removal Note

23

Lower arm ball joint

24

Oil seal
+ Removal Note
+ Installation Note

25

Spacer

26

Needle bearing
+ Removal Note
+ Installation Note

27

Steering Knuckle Component Removal Note


1. Remove the lower arm ball joint from the knuckle
using the SST. (Refer to section R, FRONT
SUSPENSION, TORSION BAR SPRING AND
LOWER ARM (4 2) REMOVAL/INSTALLATION,
Lower Arm Ball Joint/Knuckle Removal Note.)
2. Remove the lower arm installation bolt and remove
the lower arm with the knuckle.
Oil Seal Removal Note
D Remove the oil seal using a screwdriver.

Needle Bearing Removal Note


D Remove the needle bearing using the SST.
49 S231 660

Needle Bearing Installation Note


1. Install the needle bearing using the SST and a
press.
2. Apply grease to the needle bearing.

49 S033 108

Steering knuckle

Locknut Removal Note


D Remove the locknut using the SST.
49 S231 635

M10

FRONT AXLE (4
Oil Seal Installation Note
1. Install the new oil seal using the SST and a press.
2. Apply grease to the oil seal lip.

4)

Locknut Installation Note


1. Install the locknut using the SST.
49 S231 635

49 S033 107

2. Adjust the preload. (Refer to FRONT AXLE (4


WHEEL HUB, STEERING KNUCKLE
INSPECTION, Preload Adjustment)

Outer Bearing Outer Race Installation Note


D Install the outer bearing outer race using the SST
and press.

49 F027 005

Inner Bearing Outer Race Installation Note


D Install the inner bearing outer race using the SST
and a press.

49 F027 007

Oil Seal Installation Note


D Install the new oil seal using the SST and a press.

49 S033 106

M11

4)

FRONT AXLE (4

4)

WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION (VEHICLES BUILT FROM 08/2002)


Caution
D Performing the following procedures without first removing the ABS wheelspeed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheelspeed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Locknut
+ See Locknut Removal Note
+ See Locknut Installation Note
Brake caliper component
+ See Brake Caliper Component Removal Note

Disc plate

Tierod end ball joint


+ See Oil Seal Removal Note

Bolt (stabilizer)

M12

Bolt (shock absorber)

Upper arm ball joint

Lower arm ball joint

Wheel hub, steering knuckle, dust cover

10

Oil seal
+ See Oil Seal Removal Note
+ See Oil Seal Installation Note

FRONT AXLE (4

11

Wheel hub component


+ See Wheel Hub Component Removal Note
+ See Wheel Hub Component Installation Note

12

Retaining ring

13

Wheel Bearing
+ See Wheel Bearing Removal Note
+ See Wheel Bearing Installation Note

14

Dust cover
+ See Dust Cover Removal Note
+ See Dust Cover Installation Note

15

Steering Knuckle

16

Hub bolt
+ See Hub Bolt Removal Note
+ See Hub Bolt Installation Note

4)

Oil Seal Removal Note


1. Remove the oil seal by using a screwdriver.

Locknut Removal Note


1. Knock the crimped portion of the locknut outward
using a small chisel and hammer.

Wheel Hub Component Removal Note


1. Remove the wheel hub component using the SSTs
and a press.
2. Lock the hub by applying the brakes.
3. Remove the locknut.
Brake Caliper Component Removal Note
1. Remove the brake caliper component, and
suspend it with rope.

2. If the bearing inner race remains on the front wheel


hub component, grind a section of the bearing
inner race until approx. 0.5 mm {0.02 in) remains.
Then remove it using a chisel.

Tierod End Ball Joint Removal Note


1. Remove the tie rodnut.
2. Separate the tierod end from the steering knuckle
using the SSTs.

Wheel Bearing Removal Note


1. Remove the wheel bearing using the SSTs and a
press.

M13

FRONT AXLE (4

4)

Hub Bolt Installation Note


1. Install the new hub bolts using a press.

Dust Cover Removal Note


Note
D The dust cover does not need to be removed
unless it is being.
1. Mark the dust cover and steering knuckle for
proper installation.

Dust Cover Installation Note


1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.

3. Install the new dust cover using the SSTs and a


press.

2. Remove the dust cover using a chisel.

Hub Bolt Removal Note


Note
D The hub bolts do not need to be removed
unless they are being replaced.

Wheel Bearing Installation Note


1. Install the new wheel nearing using the SSTs and
a press.

1. Remove the hub bolts using a press.

M14

FRONT AXLE (4
Wheel Hub Component Installation Note
1. Install the wheel hub component using the SSTs
and a press.

Oil Seal Installation Note


1. Apply grease to the new oil seal lip.
2. Install the new oil seal flush with the knuckle using
the SSTs.

Locknut Installation Note


1. Install a new locknut and stake it as shown.

M15

4)

REAR AXLE
4. If not as specified, adjust the bearing play. (Refer
to REAR AXLE, AXLE SHAFT
REMOVAL/INSTALLATION, Bearing Inner Race,
Bearing Locknut Installation Note, Bearing play
adjustment.)

REAR AXLE
REAR AXLE INSPECTION
Wheel Bearing Play Inspection
1. Jack up the rear end and support it with safety
stands.
2. Verify that there is no abnormal noise and that the
tire rotates smoothly when forcefully rotated by
hand.
3. With a hand on top of the tire, inspect the bearing
play.
Wheel bearing axial play
0.050.25 mm {0.0020.010 in}

AXLE SHAFT REMOVAL/INSTALLATION (VEHICLES BUILT UP TO 07/2002)


1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

SST
*

SST

1621 Nm
{1.62.2 kgfcm,
1215 inlbf}

275313 {2832, 203231}

SST

R
SST
SST

SST
R

108127
{1113, 8094}

SST
R

*49

0259 770B
Nm {kgfm, ftlbf}

M16

REAR AXLE
Bearing Housing Removal Note
D Remove the bearing and bearing housing using the
SSTs.

Brake drum

Parking brake connecting pin

Brake pipe

Nut

Axle shaft and back plate component

Shim

Bearing locknut
+ Removal Note
+ Installation Note

Lock washer

Bearing housing
+ Removal Note

10

Bearing inner race


+ Installation Note

11

Bearing spacer

12

Oil seal (bearing housing side)


+ Installation Note

13

Bearing outer race


+ Removal Note
+ Installation Note

14

Back plate component

15

Axle shaft

16

Hub bolt

17

Baffle

18

Oil seal (axle casing side)


+ Removal Note
+ Installation Note

49 S026 204
49 S026 205

49 S026 208

Bearing Outer Race Removal Note


D After removing the bearing inner race and oil seal
from the rear wheel hub, tap lightly using a suitable
round bar to force out the outer race.

Oil Seal (Axle Casing Side) Removal Note


D Remove the oil seal from the axle casing using a
screwdriver.

Bearing Locknut Removal Note


Note
D Be careful when removing or installing the
bearing locknuts for the left wheels because
they are left threaded (tightened by turning
counterclockwise).

OIL SEAL

D Set the SSTs as shown in the figure, and remove

the bearing locknut from the rear axle shaft.


AXLE CASING

49 0603 635A
49 S120 645A

Oil Seal (Axle Casing Side) Installation Note


1. Use the SST to tap the oil seal in until it is flush
with the end of the axle casing.
2. After installation, apply grease to the oil seal lip.
OIL SEAL

49 H025 001

M17

AXLE CASING

REAR AXLE
Bearing Outer Race, Oil Seal
(Bearing Housing Side) Installation Note
D Press the bearing outer race and the oil seal using
the SSTs.
OIL SEAL

BEARING
OUTER
RACE

49 U027 003
49 F027 004

Bearing play adjustment


D Adjust the bearing play in the axial direction (only
when the bearing is replaced).
(1) First insert one side of the rear axle shaft
component and push the end of the shaft to the
thrust block, then insert a shim(s) at point A so
that the clearance between the end of the shaft
and the thrust block becomes 0.650.95 mm
{0.0260.037 in}.
(2) Next insert the opposite shaft component and
push the end of the shaft to the thrust block.
(3) Use a shim(s) at point A so that the clearance
between the end of the shaft and the thrust block
becomes 0.050.25 mm {0.0020.010 in}.
Bearing play in axial direction
0.050.25 mm {0.0020.010 in}

Bearing Inner Race, Bearing Locknut Installation


Note
Caution
D The torque wrench must be attached
perpendicular to the SST.

PINION SHAFT
A

1. Set the SST and then press the bearing inner race
in until 3 to 5 threads of the bearing locknut
mounting screw of the axle shaft are visible above
the top of the bearing outer race.

49 S120 748

2. Remove the SST, and then install the bearing


locknut to the axle shaft.
3. Tighten the bearing locknut using the SST to press
in the bearing inner race.
4. Remove the SST and install the lock washer so
that its tab fits into the groove of the axle shaft.
5. Tighten the bearing locknut to the specified torque.
Bearing locknut tightening torque
275313 Nm
{28.032.0 kgfm, 203231 ftlbf}

49 0603 635A
49 S120 645A

M18

SHIM

THRUST
BLOCK

REAR AXLE
AXLE SHAFT (WITH ABS) REMOVAL/INSTALLATION (VEHICLES BUILT FROM 08/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Brake drum

Parking brake connecting pin

Brake pipe

4
5

Bearing locknut
+ See Bearing Locknut Removal Note
+ See Bearing Inner Race, Bearing Locknut
Installation Note

Nut

Lock washer

Axle shaft and back plate component


+ See Axle Shaft and Back Plate Component,
Shim Installation Note (Bearing play adjustment)

10

Bearing housing
+ See Bearing Housing Removal Note

11

Bearing inner race


+ See Bearing Inner Race, Bearing Locknut
Installation Note

12

Bearing spacer

13

Oil seal (bearing housing side)


+ See Bearing Outer Race, Oil Seal (Bearing
Housing Side) Installation Note

14

Bearing outer race


+ See Bearing Outer Race, Removal Note
+ See Bearing Outer Race, Oil Seal (Bearing
Housing Side) Installation Note

Shim
+ See Axle Shaft and Back Plate Component,
Shim Installation Note (Bearing play adjustment)
ABS sensor rotor
+ See ABS Sensor Rotor Removal Note
+ See ABS Sensor Rotor Installation Note

M19

REAR AXLE

15

Back plate component

16

Axle shaft

17

Hub bolt

18

Baffle

19

Oil seal (axle casing side)


+ See Oil Seal (Axle Casing Side) Removal Note
+ See Oil Seal (Axle Casing Side) Installation
Note

Bearing Housing Removal Note


1. Remove the bearing and bearing housing using the
SSTs.

ABS Sensor Rotor Removal Note


Warning
D When grinding, be careful of debris coming
from the grinder or bearing collar. Always
wear eye protectors.
Caution
D Because the ABS sensor rotor and rear
wheel hub edge are almost flush even if the
axle shaft is moved as far as it will go, be
careful not to damage the rear wheel hub
when grinding.

Bearing Outer Race Removal Note


1. After removing the bearing inner race and oil seal
from the rear wheel hub, tap lightly using a suitable
round bar to force out the outer race.

1. Grind a part of the ABS sensor rotor using a


grinder until 0.5 mm {0.02 in} remains, and then
brake it using a chisel and remove from the shaft.

Oil Seal (Axle Casing Side) Removal Note


1. Remove the oil seal from the axle casing using a
screwdriver.

Bearing Locknut Removal Note


Note
D Be careful when removing or installing the
bearing locknuts for the left wheels because
they are left threaded (tightened by turning
counterclockwise).
1. Set the SSTs as shown in the figure, and remove
the bearing locknut from the rear axle shaft.

M20

REAR AXLE
Oil Seal (Axle Casing Side) Installation Note
1. Tap the oil seal in until it is flush with the end of the
axle casing using the SST.

2. Remove the SST, and then install the bearing


locknut to the axle shaft.
3. Tighten the bearing locknut using the SST to press
in the bearing inner race.
4. Remove the SST and install the lock washer so
that its tab fits in the groove of the axle shaft.
5. Tighten the bearing locknut to the specified torque.
Bearing locknut tightening torque
275313 Nm
{28.032.0 kgfm, 203231 ftlbf}

2. After installation, apply grease to the oil seal lip.


Bearing Outer Race, Oil Seal (Bearing Housing
Side) Installation Note
1. Press the bearing outer race and the oil seal using
the SSTs.
Axle Shaft and Back Plate Component, Shim
Installation Note (Bearing play adjustment)
D Adjust the bearing play in the axial direction (only
when the bearing is replaced).
(1) First insert one side of the rear axle shaft
component, insert a shim(s) at point A so that
the clearance between the end of the shaft and
the thrust block becomes 0.650.95 mm
{0.0260.037 in}.
(2) Next insert the opposite shaft component and
push the end of the shaft to the thrust block.
(3) Use a shim(s) at point B so that the clearance
between the end of the shaft and the thrust block
becomes 0.050.25 mm {0.0020.010 in}.

Bearing Inner Race, Bearing Locknut Installation


Note
Caution
D The torque wrench must be attached
perpendicular to the SST

Bearing play in axial direction


0.050.25 mm {0.0020.009 in}

1. Set the SST and then press the bearing in until 3 to


5 threads of the bearing locknut mounting screw of
the axle shaft are visible above the top of the
bearing outer race.

M21

REAR AXLE
ABS Sensor Rotor Installation Note
Note
D Install the ABS sensor rotor in the direction
shown in the figure

1. Press the ABS sensor rotor in until it is flush with


the end of the bearing lock nut using the SST.

M22

DRIVE SHAFT

DRIVE SHAFT
DRIVE SHAFT REMOVAL/INSTALLATION (VEHICLES BUILT UP TO 07/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Wheel hub, steering knuckle


+ FRONT AXLE (4 4), WHEEL HUB,
STEERING KNUCKLE
REMOVAL/INSTALLATION

Snap ring

Clip
+ Installation Note

Drive shaft
+ Removal Note
+ Installation Note

Drive Shaft Removal Note


Caution
D Do not damage the dust cover or oil seal.
D Remove the drive shaft by prying with a bar

inserted between the differential casing and the


drive shaft.

Clip Installation Note


Left side
D Install a new clip to the output shaft clip groove
with the opening facing upward.
Right side
D Install a new clip to the clip groove of the drive
shaft end with the opening facing upward.
CLIP

OPENING
28 mm {1.1 in}

Drive Shaft Installation Note


D Be careful not to damage the oil seal with the shaft
spline when installing the drive shaft.

M23

DRIVE SHAFT
DRIVE SHAFT REMOVAL/INSTALLATION (VEHICLES BUILT FROM 08/2002)
Caution
D Performing the following procedures without first removing the ABS wheelspeed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheelspeed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. If removing the RH drive shaft, drain the front differential oil.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Wheel hub, steering knuckle


+ See WHEEL HUB, STEERING KNUCKLE (4x4)
REMOVAL/INSTALLATION

Drive shaft
+ See Drive Shaft Removal Note
+ See Drive Shaft Installation Note

Clip

Drive Shaft Removal Note


Caution
D Do not damage the dust cover or the ABS
sensor rotor on the drive shaft. These parts
cannot be purchased separately. Replace
the assembled unit if the dust cover or the
ABS sensor rotor is damaged.
D The sharp edges of the drive shaft can

splice or puncture the oil seal. Be careful


when removing the drive shaft from the
front differential.

M24

1. Remove the drive shaft by prying with a bar


inserted between the differential casing and and
the drive shaft, as shown in the figure.

DRIVE SHAFT
Drive Shaft Installation Note

28 mm {1.1 in}

Caution
D The sharp edges of the drive shaft can slice
or puncture the oil seal. Be careful when
installing the drive shaft to the front
differential.
D The oil seals are damaged easily if this

procedure is not done correctly.


D (LH)

1. Install a new clip onto the output shaft with the


opening facing upward. Ensure that the diameter of
the clip does not exceed the specification for
installation.

2. After installation, measure the outer diameter.


D If it exceeds the specification, repeat Steps 12

using a new clip.


Outer diameter specification
28 mm {1.1 in}
3. Apply differential oil to the oil seal lip.
4. Insert the drive shaft into the output shaft.
5. Push the drive shaft into the wheel hub.
6. After installation, pull the output shaft side outer
ring forward to confirm that the drive shaft is
securely held by the clip.
D (LH)

1. Install a new clip onto the drive shaft with the


opening of a new clip facing upward.

2. After installation, measure the outer diameter.


D If it exceeds the specification, repeat Steps 12

using a new clip.


Outer diameter specification

M25

3. Install the drive shaft into the front differential.


4. Push the drive shaft into the wheel hub.
5. After installation, pull the front differential side
outer ring forward to confirm that the drive shaft is
securely held by the clip.

DRIVE SHAFT
DRIVE SHAFT DISASSEMBLY/ASSEMBLY (VEHICLES BUILT UP TO 07/2002)
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of removal.

R
RIGHT SIDE

R
R

R
R

LEFT SIDE

Boot band
+ Disassembly Note
+ Assembly Note

Inner ring
+ Disassembly Note
+ Assembly Note

Clip

Outer ring
+ Disassembly Note
+ Assembly Note

Cage
+ Disassembly Note
+ Assembly Note

Snap ring
+ Assembly Note

Boot
+ Disassembly Note
+ Assembly Note

Balls
+ Disassembly Note
+ Assembly Note

Bell joint component

10

Drive shaft

M26

DRIVE SHAFT
Boot Band Disassembly Note

3. Disassemble the balls, inner ring, cage from the


drive shaft as component.
4. Turn the cage by approximately 30 degrees and
pull the cage and balls away from the inner ring.

Note
D The wheel side boot band does not need to be
removed unless replacing it.

30_

1. Pry up the locking clip using a screwdriver and


remove the band using pliers.
2. Slide the boot along the shaft to expose the joint.

Boot Disassembly Note


Note
D The wheel side boot does not need to be
removed unless it is being replaced.
Outer Ring Disassembly Note
1. Wrap the shaft splines with tape.
2. Remove the boot.

Caution
D Mark with paint; do not use a punch.
1. Mark the cage and outer ring for proper assembly.
2. Remove the clip using a screwdriver.
3. Remove the outer ring from the inner ring and the
balls.
4. Clean the grease away.

TAPE

MARKS

Boot Assembly Note


Note
D The wheel side and differential side boots are
different.
Balls, Inner Ring, Cage Disassembly Note
Caution
D Mark with paint; do not use a punch.
100.5 mm
{4.0 in}

1. Mark the drive shaft and inner ring for proper


assembly.

WHEEL SIDE

99.2 mm
{3.9 in}

DIFFERENTIAL SIDE

1. With the splines of the shaft still wrapped in tape


from disassembly, assemble the boot.
2. Temporarily assemble the wheel side boot, new
boot bands, and differential side boot to the drive
shaft.
3. Remove the tape.

MARKS

2. Disassemble the snap ring from the drive shaft


using a snap-ring pliers.

M27

DRIVE SHAFT
Cage, Inner Ring, Balls, Snap Ring Assembly Note
1. Align the marks, and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution
D Install the cage with the offset facing the
snap ring groove. If incorrectly installed,
the drive shaft may become disengaged.

LEFT SIDE

RIGHT SIDE

2. Install a new snap ring.


BALLS
CAGE

Standard length
Right side : 619.0629.0 mm {24.424.7 in}
Left side : 551.0561.0 mm {21.722.0 in}
3. Release trapped air from inside the boot using a
screwdriver covered with a rag.
SNAP RING
GROOVE

INNER
RING

Outer Ring Assembly Note


Note
D Use the specified grease supplied in the boot
kit.
1. Apply grease to the cage, inner ring, balls, and the
outer ring.
4. Set the new boot band to the boot groove.
5. Fold the band back and use pliers to pull it tight.
6. Lock the end of the band by bending the locking
clips.

Wheel side
: 110130 g {3.84.6 oz}
Differential side : 95105 g {3.43.7 oz}
2. Align the marks, and install the outer ring onto the
shaft.
3. Install a new clip.
MARKS

Boot Band Assembly Note


Caution
D Do not damage the boot.
D For wheel side, apply grease only when
assembling the boot.
1. Apply grease to the inside of the boot.
2. Set the drive shaft to the standard length.

M28

DRIVE SHAFT
DRIVE SHAFT DISASSEMBLY/ASSEMBLY (VEHICLES BUILT FROM 08/2002)
Caution
D Do not damage and remove the dust cover or the ABS sensor rotor on the drive shaft. These parts
cannot be purchased separately. Replace the assembled unit if the dust cover or the ABS sensor
rotor is damaged and removed.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of removal.

Boot band
+ See Boot Band Disassembly Note
+ See Boot Band Assembly Note

Clip

Outer ring
+ See Outer Ring Disassembly Note
+ See Outer Ring Assembly Note

Snap ring
+ See Cage, Inner Ring, Balls, Snap Ring Assembly Note

Balls
+ See Balls, Inner Ring, Cage Disassembly Note
+ See Cage, Inner Ring, Balls, Snap Ring Assembly Note

Boot Band Disassembly Note


Note
D The wheel side boot band does not need to be
removed unless replacing it.
1. Pry up the locking clip using a screwdriver.
2. Remove the band using pliers.
3. Slide the boot along the shaft to expose the joint.

M29

Inner ring
+ See Balls, Inner Ring, Cage Disassembly Note
+ See Cage, Inner Ring, balls, Snap Ring Assembly Note

Cage
+ See Balls, Inner Ring, Cage Disassembly Note
+ See Inner ring, Balls, Snap Ring Assembly
Note

Boot
+ See Boot Disassembly Note
+ See Boot Assembly Note

Bell joint component

10

Drive shaft

DRIVE SHAFT
D Do not strip the tape until the boot is

assembled.
1. Wrap the shaft splines with tape.

Outer Ring Disassembly Note


1. Mark the cage and outer ring for proper assembly.
2. Remove the boot.
Caution
D Mark with paint; do not use a punch.

Boot Assembly Note


1. Fill the boot (wheel side) with the specified grease
from a tube, not by hand.

2. Remove the clip using a screwdriver.


3. Remove the outer ring from the inner ring and the
balls.
4. Clean the grease away.

Caution
D Do not touch the grease with your hand.
Apply it from the tube to prevent foreign
matter from entering the boot.
Note
D The wheel side and differential side boots are
different.
D Use the specified grease supplied in the boot.
Grease amount
110130 g {3.884.58 oz}
2. With the splines of the shaft still wrapped in tape
from disassembly, install the boot.
3. Remove the tape.

Balls, Inner Ring, Cage Disassembly Note


1. Mark the inner ring and cage.
Caution
D Mark with paint; do not use a punch.
2. Remove the snap ring using snapring pliers.
3. Disassemble the balls, inner ring, cage from the
drive shaft as component.
4. Turn the cage approximately 30 degrees and pull
the cage and balls away from the inner ring.

Cage, Inner Ring, Balls, Snap Ring Assembly Note


1. Align the marks and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution
D Install the cage with the offset facing the
snap ring groove. If incorrectly installed,
the drive shaft may become disengaged.
2. Install a new snap ring.

Boot Disassembly Note


Note
D The wheel side boot does not need to be
removed unless replacing it or the bell joint and
shaft component.

M30

DRIVE SHAFT
Outer Ring Assembly Note
1. Fill the outer ring and boot with the specified
grease.
Caution
D Do not touch the grease with your hand.
Apply it from the tube to prevent foreign
matter from entering the boot.
Note
D Use the specified grease supplied in the boot
kit.
2. Lock the end of the band by bending the locking
clips.

Grease amount
95115 g {3.364.05 oz}
2. Align the marks, and install the outer ring on to the
shaft.
3. Install a new clip.
4. Install the boot,
5. Set the drive shaft to the standard length.
Standard length
Right side: 593.5603.5 mm {23.3723.75 in}
Left side: 525.5535.5 mm {20.6921.08 in}
6. Release any trapped air from the boots by carefully
lifting up the small end of each boot with a cloth
wrapped screwdriver.
Caution
D Be careful not to allow the grease to leak.
D Do not damage the boot.

7. Verify that the drive shaft length is within the


specification.
Boot Band Assembly Note
Note
D Always use new bands.
D The band should be folded in the direction
opposite to the forward revolving direction of
the drive shaft.
1. Fold the band back and use pliers to pull it tight.

M31

DRIVE SHAFT
OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

3757
{3.75.5, 2739}

Nm {kgfm, ftlbf}

Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION
Bolt

Output Shaft Component Removal Note


D Remove the output shaft by prying with a bar
inserted between the bearing housing of the output
shaft and the differential casing.

M32

Screw

Output shaft component


+ Removal Note

DRIVE SHAFT
OUTPUT SHAFT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

R
SST
R
R
R

Clip
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Clip Assembly Note

Bearing
+ Disassembly Note
+ Assembly Note

Output shaft component


+ Disassembly Note
+ Assembly Note

Output shaft

Bearing housing

Oil seal
+ Assembly Note

O-ring

Oil seal
+ Assembly Note

Output Shaft Component Disassembly Note


D Disassemble the output shaft component using a
press.

M33

DRIVE SHAFT
Bearing Disassembly Note
D Remove the bearing from the output shaft
component using a press.

Oil Seal Assembly Note


D Assemble the new oil seal by lightly tapping it
using a plastic hammer.

Oil Seal Assembly Note


D Use the SST to assemble the new oil seal until it is
flush with the bearing housing end using the SST.

Output Shaft Component Assmebly Note


D Press the output shaft and bearing to the bearing
housing.

49 M005 796

Bearing Assembly Note


Caution
D Press the bearing center and shaft center
vertically.
D Press the new bearing to the output shaft.

M34

REAR DIFFERENTIAL
Specified oil
Type
Standard differential:
API service GL5, SAE 90
LSD:
API service GL6, SAE 90
Capacity:
4 2:
1.40 L {1.48 US qt, 1.23 lmp qt}
4 4:
1.85 L {1.96 US qt, 1.63 lmp qt}

REAR DIFFERENTIAL
REAR DIFFERENTIAL OIL INSPECTION
Caution
D Position the vehicle level.
1. Remove the filler plug.
2. Verify that the oil is at the brim of the filler plug
hole. If it is low, add the specified oil.
Specified oil
Type
Standard differential:
API service GL5, SAE 90
LSD:
API service GL6, SAE 90
Capacity
4 2:
1.40 L {1.48 US qt, 1.23 lmp qt}
4 4:
1.85 L {1.96 US qt, 1.63 lmp qt}

6. Install a new washer and the filler plug.


Tightening torque
4053 Nm {4.05.5 kgfm, 2939 ftlbf}

FILLER PLUG

WASHER

3. Install a new washer and the filler plug.


Tightening torque
4053 Nm {4.05.5 kgfm, 2939 ftlbf}
REAR DIFFERENTIAL OIL REPLACEMENT
1. Remove the filler and drain plugs.
2. Drain the differential oil into a container.

3. Wipe the plugs clean.


4. Install a new washer and the drain plug.
Tightening torque
4053 Nm {4.05.5 kgfm, 2939 ftlbf}
5. Add the specified oil from the filler plug hole until it
reaches the brim of the hole.

M35

REAR DIFFERENTIAL
REAR DIFFERENTIAL REMOVAL/INSTALLATION
Caution
D Clean away the old sealant before applying the new sealant.
D Install the differential carrier within 10 minutes after applying sealant.
D Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oil.
1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.)
2. Remove the rear propeller shaft. (Refer to section L, REAR PROPELLER SHAFT (4 4), REAR PROPELLER
SHAFT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

2628 {2.62.9, 1920}

5058
{5.06.0, 3743}

Nm {kgfm, ftlbf}

Axle shaft and back plate component


+ REAR AXLE, AXLE SHAFT REMOVAL/
INSTALLATION

Differential Removal Note


D To prevent the differential from dropping, leave the
two bolts loosely tightened. Then hit the differential
carrier using a wooden hammer.

M36

Differential
+ Removal Note

REAR DIFFERENTIAL
STANDARD DIFFERENTIAL DISASSEMBLY
D Disassemble in the order indicated in the table.

SST
SST

SST
SST

SST

Differential component
+ Disassembly Note

14

Adjusting shim

15

Front bearing cup


+ Disassembly Note

Bearing cap
+ Disassembly Note

16

Oil buffle

Adjusting shim

17

Side bearing cup

Rear bearing cup


+ Disassembly Note

Side bearing cone


+ Disassembly Note

18

Carrier

19

Hex screw

Pinion nut
+ Disassembly Note

20

Ring gear

21

Roll pin
+ Disassembly Note

22

Pinion shaft

23

Thrust block

Companion flange
+ Disassembly Note

Oil seal
+ Disassembly Note

Thrust washer

24

Pinion gear

10

Drive pinion
+ Disassembly Note

25

Pinion gear thrust washer

26

Side gear

11

Front bearing cone

27

Side gear thrust washer

12

Collapsible spacer

28

Case

13

Rear bearing cone


+ Disassembly Note

M37

REAR DIFFERENTIAL
Differential Component Disassembly Note
D Mount a carrier component to the SST or
equivalent.

Pinion Nut Removal Note


D Hold the companion frange and remove the pinion
nut.

T57L500B

Bearing Cap Disassembly Note


D Place a mark on one of the bearing caps so that
the left and right bearing caps wont get mixed up.
Use the mark for matching at the time of assembly.

Companion Flange Disassembly Note


D Remove the companion flange using universal
puller.

MARK

Oil Seal Disassembly Note


D Pull out the oil seal using the SST.

Side Bearing Cone Disassembly Note


Warning
D When pulling the side bearing cone, do not
allow differential component to fall. It can
strike legs or feet and may cause serious
injury.
Caution
D Mark the left bearing in order to install in
the same position.

308047
T77F1102A

D Remove the side bearing cone using a press and

the SST.

Drive Pinion Disassembly Note


D Remove the drive pinion by tapping with a plastic
hammer.
205D064
D84L1123A

M38

REAR DIFFERENTIAL
Rear Bearing Cone Disassembly Note
Note
D Mark or otherwise distinguish between the front
and rear cones so that they are not mixed up at
the time of reassembly.
D Remove the rear bearing cone using the SST.

205D064
D84L1123A

Front Bearing Cup, Rear Bearing Cup Disassembly


Note
Note
D Mark or otherwise distinguish between the front
and rear cups so that they are not mixed up at
the time of reassembly.
D Remove the bearing races using the SSTs (308

047 T77F1102A and 100 001 T50T100A).


100001
T50T100A

3308047
T77F1102A

Roll Pin Disassembly Note


Caution
D Insert the bar from the knock pin hole at the
opposite side from where the ring gear is
installed.
D Secure the gear case in a vise and remove the roll

pin using a small drift.

M39

REAR DIFFERENTIAL
STANDARD DIFFERENTIAL ASSEMBLY
D Assemble in the order indicated in the table.

7595 {7.69.7, 5570}

SST

SST

SST
130150
{13.215.3,
96110}

R
SST

R
R

SST

R
SST

R
R

SST

298500
{30.350.9, 220368}

Nm {kgfm, ftlbf}

Case
+ Assembly Note

16

Adjusting shim
+ Assembly Note

Side gear thrust washer


+ Assembly Note

17

Rear bearing cone


+ Assembly Note

Side gear

18

Pinion gear thrust washer

Drive pinion
+ Assembly Note

Pinion gear

19

Collapsible spacer

Thrust block

20

Front bearing cone

Pinion shaft

21

Thrust washer

Roll pin

22

Ring gear

Oil seal
+ Assembly Note

10

Hex screw

23

Companion flange

11

Side bearing cone


+ Assembly Note

24

Pinion nut

25

12

Carrier

Side bearing cup


+ Assembly Note

13

Oil buffle

26

Adjusting shim
+ Assembly Note

14

Front bearing cup


+ Assembly Note

27

Bearing cap
+ Assembly Note

15

Rear bearing cup


+ Assembly Note

M40

REAR DIFFERENTIAL
Adjusting Shim Assembly Note
Pinion height Adjustment
1. Assemble the rear bearing cone over the SST and
insert it into the rear bearing cup of the carrier.
2. Assemble the front bearing cone into the front
bearing cup and assemble the SSTs.

6. This measurement is the thickness needed for the


selective shim if there was no marking on the drive
pinion. If the drive pinion is marked with a plus (+)
reading, the amount marked should be subtracted
from the feeler gauge measurement. If the drive
pinion is marked with a minus () reading, the
amount marked should be added to the feeler
gauge measurement.

205456

Rear Bearing Cone Assembly Note


D Assemble the selected spacer on the drive pinion
and press the rear bearing inner race until it is
firmly seated on the shaft.

205110, T76P4020A10
205457

205105, T76P4020A3

205090
T75L1165B

205109, T76P4020A9

Drive Pinion Assembly Note


Drive pinion preload adjustment

205111, T76P4020A11

3. Roll the SST component back and forth a few


times to seat the bearings while tightening the SST
by hand.
Tightening torque
27 Nm {2.8 kgfm, 20 ftlbf}

1. Install the drive pinion, collapsible spacer and


companion flange to the carrier, and tighten the
pinion nut until all end play is removed.
2. Continue to tighten in small increments until the
specified preload can be obtained.

4. Center the SST (205456) into the side bearing


bore. Install the bearing caps and tighten the bolt.
Tightening torque
7595 Nm {7.69.7 kgfm, 5570 ftlbf}

Drive pinion preload


1.21.5 Nm
{12.215.3 kgfcm, 10.613.2 inlbf}

Note
D There should be drag on the feeler gauge
when it is inserted between the SSTs
(205110, T76P4020A10 and 205456).

3. If the specified preload cant be obtained within the


specified tightening torque range, replace the
collapsible spacer and inspect again.

5. Insert the thickest feeler gauge possible between


the SSTs (205110, T76P4020A10 and
205456).
205110
T76P4020A10
FEELER GAUGE

Caution
D Never loosen pinion nut to decrease drive
pinion preload torque, and never exceed
specified preload torque. If preload torque
is exceeded, a new collapsible spacer must
be installed and the torque sequence
repeated.

205456

M41

REAR DIFFERENTIAL
Case Assembly Note
D Assemble the side gears, thrust washer, thrust
block, pinion gears, pinion shaft and knock pin.
After assembling the knock pin, make a crimp so
that the pin will not come out of the gear case.

Front Bearing Cup, Rear Bearing Cup Assembly


Note
1. Install the oil baffle in the outer bearing cup bore of
the carrier.
2. Install the outer bearing cup and inner bearing cup
using the SST.
205024
T76P4616A

Side Gear Thrust Washer Assembly Note


D Adjust the backlash of the side gears and pinon
gear as follows.
(1) Set a dial gauge to the pinion gear as shown in
the figure.
(2) Secure one of the side gears.
(3) Move the pinion gear and measure the
backlash at the end of the pinion gear.

Oil Seal Assembly Note


1. Apply a light coat of oil to the lip of a new oil seal.
2. Assemble the new oil seal using the SST.

205007
T56T4676B

Standard backlash
00.1 mm {00.004 in}
(4) If the backlash exceeds the standard, use the
thrust washers to adjust.
Side Bearing Cone Assembly Note
Caution
D Bearings should be assembled to the
original positions.
D Press the side bearings into the gear case using

the SST.

205092
T75L1165DA

Side Bearing Cup, Adjusting Shim, Bearing Cap


Assembly Note
Ring gear backlash adjustment
1. Install the gear case component on the carrier.
2. Push the gear case component to the left side of
the carrier and measure the clearance between the
side bearing and carrier. This measurement is the
left and right total shim thickness.
3. Divide the amount of shim in step 2 appropriately
between the right and left side, then install the
bearing cap.
4. Adjust the drive pinion, ring gear backlash and the
side bearing preload as follows.
(1) Mark the ring gear at four points at approx. 90
intervals and mount a dial indicator to the
carrier so that the feeler comes in contact at a
90 angle with one of the ring gear teeth.

M42

REAR DIFFERENTIAL
DIAL INDICATOR
WITH BRACKETRY
RING
GEAR

5. Inspect the backlash at the three other marked


points and make sure that the minimum backlash
is more than 0.12 mm {0.005 in} and difference of
the maximum and minimum backlash value is less
than 0.08 mm {0.003 in}.

6. If backlash is not as specified, correct the backlash


by switching shims from one side of the differential
case to the other.
7. Using a torque wrench, inspect the total rotating
torque of the pinion and differential component by
rotating the pinion three complete revolutions, and
then reading the rotating torque. The readings
should not exceed 2.4 Nm {24.0 kgfcm,
20.8 inlbf}. If the backlash is within specification
but the rotating torque is to high, the preload may
be adjusted by removing an equal amount of shims
from both sides of the differential.
8. Inspect the drive pinion and ring gear tooth
contact.
(1) Coat both surfaces of 68 teeth of the ring
gear uniformly with a thin red lead coating.
(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) If the tooth contact is good, wipe off the red
lead coating.
(4) If it is not good, adjust the pinion height, then
adjust the backlash.

M43

REAR DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL DISASSEMBLY
D Disassemble in the order indicated in the table.

SST

SST
SST

SST
SST

SST

SST

Differential component
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Differential
Component Disassembly

Bearing cap
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Bearing Cap
Disassembly Note

SST

Oil seal
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Oil Seal
Disassembly Note

Thrust washer

10

Drive pinion
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Drive Pinion
Disassembly Note

Adjusting shim

Side bearing cup

11

Front bearing cone

Side bearing cone


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Side Bearing
cone Disassembly Note

12

Collapsible spacer

13

Rear bearing cone


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Rear Bearing
Inner Race Disassembly Note

14

Adjusting shim

15

Front bearing cup


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Front
Bearing cup Disassembly Note

16

Oil buffle

Pinion nut
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Pinion nut
Disassembly Note
Companion frange
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Companion
Frange Disassembly Note

M44

REAR DIFFERENTIAL

17

Rear bearing cup


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Rear Bearing
cup Disassembly Note

18

Carrier

19

Hex screw

20

Ring gear

21

Roll pin
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Roll Pin
Disassembly Note

22

Pinion shaft

23

Thrust block

24

Pinion gear thrust washer

25

Pinion gear

26

Side gear

27

Side gear thrust washer

28

Limited slip differential component


+ Disassembly Note

T83T4205A3

T83T4205A2

T83T4205A4

4. Tighten the SST to move the side gears away from


the pinion gears and relieve the normal loaded
condition.
T83T4205A3
T83T4205A4
T83T4205A2

Limited Slip Differential Component Disassembly


Note
1. Place one of the axle shafts, which was removed
from the component, into a vise, with the splines
extending above the jaws of the vise far enough to
engage the side gears of the differential case
component, and position the differential case onto
the axle shaft as a holding fixture by aligning the
splines of the side gear with those of the axle shaft.

5. Push out the thrust washers located behind the


pinion gears.
6. Momentarily, loosen the SST. Retighten the SST until
a very slight movement of the pinion gears is seen.
7. Insert SST into the bore of the pinion shaft and
rotate the differential case until the pinion gears
can be removed through the large openings in the
differential case.
T83T4205A1

2. Install the SST into the bottom of the side gear,


and apply grease to the centering hole of it.

8. Retain the top side gear and clutch pack in the


differential case by hand and remove the SSTs.

T83T4205A4
RETAINING CLIP

DIFFERENTIAL
CLUTCH PACK

3. Install the SSTs into the differential case.

9. Remove the top side gear and clutch pack. Keep the
stack of clutch plates and clutch discs in exact order.
10. Remove the retainer clips from both clutch packs
to allow separation of the clutch discs and clutch
plates for cleaning and inspection.

M45

REAR DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL ASSEMBLY
D Assemble in the order indicated in the table.

7595 {7.69.7, 5570}

SST

SST

SST
130150
{13.215.3,
96110}

R
R

SST

SST

R
R
R

SST

SST

SST
R

R
298500
{30.350.9, 220368}

Nm {kgfm, ftlbf}

Case

14

Oil buffle

Limited slip differential component


+ Assembly Note

15

Side gear thrust washer

Side gear

Front bearing cup


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Front Bearing
Cup Assembly Note

Pinion gear

16

Pinion gear thrust washer

Thrust block

Rear bearing cup


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Rear Bearing Cup
Assembly Note

Pinion shaft

17

Roll pin
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Roll Pin
Assembly Note

Adjusting shim
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Adjusting Shim
Assembly Note

18

Ring gear
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Ring Gear
Assembly Note

Rear bearing cone


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Rear Bearing
Cone Assembly Note

19

Drive pinion
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Drive Pinion
Assembly Note

20

Collapsible spacer

10

11

Hex screw

12

Side bearing cone


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Side Bearing
Cone Assembly Note

13

Carrier

M46

REAR DIFFERENTIAL

21

Front bearing cone

22

Thrust washer

23

Oil seal
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Oil Seal
Assembly Note

24

Companion frange

25

Pinion nut

26

Side bearing cup


+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Side Bearing Cup
Assembly Note

27

Adjusting shim
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Adjusting Shim
Assembly Note

28

Bearing cap
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Bearing Cap
Assembly Note

6. Tighten the SST so the side gears move away from


the pinion gears and relieve the loaded condition.
7. While holding the pinion gears in place, insert SST
into the hole of pinion shaft in the differential case.
Pull on the SST rotating differential case allowing
the differential pinion gears to rotate and enter into
the differential case.
T83T4205A1

8. Adjust the SST by very slightly loosening or


tightening until the required load is applied to allow
the side gears and pinion gears to rotate.
9. Rotate the differential case until the holes of both
pinion gears are aligned with those of the
differential case.
10. Apply torque to the SST for clearance to assemble
the differential thrust washers.

Limited Slip Differential Component Assembly


Note
Note
D Always replace the entire disc and plate kits,
even if only one component requires it.

THRUST WASHER

1. Assemble the retainer clips to the ears of the clutch


plates. Make sure both clips are completely
assembled or seated onto the ears of the clutch
plates.
2. Place the differential case on a bench. Assemble
the clutch pack and side gear into the differential
case. Make sure the clutch pack stays assembled
to the splines of side gear, and the retainer clips
are completely seated into the pockets of
differential case.
3. Install the SSTs to the differential case.

Note
D During assembly, be sure the holes of the
thrust washers and gears are lined up exactly
with those of the differential case.

T83T4205A3
T83T4205A4

11. Assemble thrust washers into the differential case.


Use a very small screwdriver or shim stock to push
the washers into place.

T83T4205A2

4. With tools assembled to the differential case,


position the differential case onto the axle shaft by
aligning the splines of the differential side gear with
those of the axle shaft.
5. Position both pinion gears opposite one another
through the openings in the differential case. Align
holes of the differential pinion gears with each
other. Hold the pinion gears by hand.

M47

MANUAL FREEWHEEL (MFW) MECHANISM


REMOTE FREEWHEEL (RFW) MECHANISM

MANUAL FREEWHEEL (MFW)


MECHANISM

REMOTE FREEWHEEL
(RFW) MECHANISM

ON-VEHICLE INSPECTION
1. Jack up the front of the vehicle and support it on
safety stands.
2. Set the select lever in 2H position.
3. Set the freewheel hub control handle to the FREE
position, then turn the handle clockwise and
counterclockwise by hand, and inspect that it turns
smoothly.
4. Set the freewheel hub control handle to LOCK
position and inspect that the wheel turns with
considerable force applied to make it turn.
5. If not as specified, replace the freewheel hub
component as necessary.

4 4 INDICATOR SWITCH INSPECTION


1. Jack up the vehicle and support it on safety stands.
2. Remove the transfer case switch
(4 4 indicator switch).

3. Inspect for continuity between the terminals as


shown using an ohmmeter.
Continuity

Switch

Yes

Depressed (ON)

No

Released (OFF)

4. If not correct, replace the switch.


TRANSFER NEUTRAL SWITCH INSPECTION
1. Jack up the vehicle and support it on safety stands.
2. Remove the transfer case switch (neutral switch).

M48

REMOTE FREEWHEEL (RFW) MECHANISM


RFW MAIN SWITCH REMOVAL/INSTALLATION
1. Remove the meter hood.
(Refer to Section S, DASHBOARD AND
CONSOLE, METER HOOD
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

1. Inspect for continuity at the switch using an


ohmmeter.
Continuity

Switch

Yes

Depressed (ON)

No

Released (OFF)

OFF

ON

12 mm {0.472 in}
13 mm {0.512 in}

2. If not correct, replace the switch.

RFW SWITCH INSPECTION


1. Jack up the vehicle and support it on safety stands.
2. Disconnect the RFW switch connector and remove
the switch.

RFW main switch

RFW MAIN SWITCH INSPECTION


1. Remove the RFW main switch.
2. Inspect for continuity between the terminals as
shown using an ohmmeter.
: Continuity
Switch

Terminal
A

OFF
ON

3. Inspect for continuity at the switch using an


ohmmeter.
Continuity

Switch

Yes

Depressed (ON)

No

Released (OFF)

123456567

3. If not correct, replace the switch.

4. If not correct, replace the switch.

M49

REMOTE FREEWHEEL (RFW) MECHANISM


ONEWAY CHECK VALVE INSPECTION
1. Remove the oneway check valve.
2. Blow through A and inspect that air flows from B.
3. Blow through B and inspect that air does not flow
from A.
B

RFW ACTUATOR INSPECTION


1. Jack up the vehicle and support it on safety stands.
2. Disconnect the vacuum hoses from the actuator.
3. Connect a vacuum pump tester to the actuator
(free side) as shown.
4. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum,
and verify that the rod moves toward the left
(drivers side).

4. If not correct, replace the oneway check valve.


LOCK AND FREE SOLENOID VALVES INSPECTION
1. Disconnect the vacuum hoses and the connector
from each solenoid valve.
2. Blow through each valve from port B.
3. Inspect that air flows from the air filter.
BLOW
B

5. Disconnect the vacuum pump tester.


6. Connect the vacuum pump tester to the actuator
(lock side) as shown.
7. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum,
and inspect that the rod moves toward the right
(passenger side).

AIR FILTER

4. Connect 12V and a ground to the terminals of each


valve.
5. Blow through each valve from port B.
6. Inspect that air flows from port A.
B

7. If not correct, replace the solenoid valve(s).

M50

8. If not correct, replace the actuator.

REMOTE FREEWHEEL (RFW) MECHANISM


RFW CONTROL MODULE INSPECTION
1. Remove the scuff plate. (Refer to section S, TRIM,
SCUFF PLATE REMOVAL/INSTALLATION.)
2. Remove the front side trim. (Refer to section S,
TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Turn the ignition switch on and inspect the RFW
control module terminal voltages, referring to the
Terminal Voltage Chart.
RFW CONTROL MODULE

4. If not correct, replace the component(s), wiring,


and/or RFW control module.
REW CONTROL MODULE REMOVAL/INSPECTION
1. Remove the scuff plate. (Refer to section S, TRIM,
SCUFF PLATE REMOVAL/INSTALLATION.)
2. Remove the front side trim. (Refer to section S,
TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Connector

Nut

Bolt

RFW control module

M51

REMOTE FREEWHEEL (RFW) MECHANISM


Terminal Voltage Chart

RFW CONTROL MODULE TERMINAL

B+: Battery positive voltage


Terminal

Signal name

Connected to

Lock solenoid

Lock solenoid

Ground

Body

Free solenoid

Free solenoid

Condition

Inspection point

Solenoid OFF

B+

D Harness (Lock solenoidRFW

Solenoid ON

Below 0.5 V

D Lock solenoid

CM)

Voltage

Below 0.5 V

Harness to ground point

Solenoid OFF

B+

D Harness (Free solenoidRFW

Solenoid ON

Below 0.5 V

D Free solenoid

CM)

D Harness (4

4 4 indicator
light

4 4 indicator
light

4 4 indicator light OFF

B+

4 4 indicator light ON

Below 0.5 V

4 indicator
lightRFW CM)
D 4 4 indicator light

Lock indicator
light

LOCK
indicator light

Lock indicator light OFF

B+

D Harness (Lock indicator

Lock indicator light ON

Below 0.5 V

D Lock indicator light

Battery

Battery

Ignition swtich ON

B+

Ignition swtich OFF

Below 0.5 V

RFW main
switch

RFW main switch


released (OFF)

B+

D Harness (RFW main

RFW main
switch

RFW main switch


depreased (ON)

Below 0.5 V

D RFW main switch

RFW switch

RFW switch

RFW switch OFF

B+

RFW switch ON

Below 0.5 V

D Harness (RFW switchRFW CM)


D RFW switch

4 4 indicator switch
OFF

B+

D Harness (4

4 4 indicator switch
ON

Below 0.5 V

4 indicator
switchRFW CM)
D 4 4 indicator switch

Transfer neutral switch


OFF

B+

D Harness (Transfer neutral

Transfer neutral switch


ON

Below 0.5 V

D Transfer neutral switch

4 4 indicator
switch

4 4 indicator
switch

Transfer
neutral switch

Transfer
neutral switch

lightRFW CM)

M52

Harness, Fuse (Battery-Ignition


switchRFW CM)

switchRFW CM)

switchRFW CM)

REMOTE FREEWHEEL (RFW) MECHANISM


JOINT SHAFT COMPONENT REMOVAL/INSTALLATION
1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, DIFFERENTIAL OIL REPLACEMENT.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

2326 {2.32.7, 1719}

SST

3753 {3.75.5, 2739}


3753 {3.75.5, 2739}

Nm {kgfm, ftlbf}

Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION

Vacuum hose

RFW switch connector

Output Shaft Removal Note


D Remove the output shaft using the SST.

49 0813 215A

M53

Snap pin

Joint shaft component, control box component

Gear sleeve

Output shaft
+ Removal Note

REMOTE FREEWHEEL (RFW) MECHANISM


JOINT SHAFT COMPONENT DISASSEMBLY
D Disassemble in the order indicated in the table.

SST

SST

SST

Control box

Clip

Bearing
+ Disassembly Note

Remote freewheel hub


+ Disassembly Note

10

Oil seal
+ Disassembly Note

Spacer

11

Joint shaft

Retaining ring

12

Needle bearing

Ball bearing
+ Disassembly Note

13

Clip

14

Casing

Adjustment shim (s)

15

Output shaft and gear sleeve

Dust seal

M54

REMOTE FREEWHEEL (RFW) MECHANISM


Remote Free Wheel Hub Disassembly Note
D Remove the remote free wheel hub using the SST.

Oil Seal Disassembly Note


D Remove the oil seal using the SST.

49 U027 004

49 0710 520

Ball Bearing Disassembly Note


1. Remove the ball bearing and the joint shaft using a
press.

JOINT SHAFT INSPECTION


1. Measure the joint shaft runout.
Maximum runout
0.03 mm {0.0012 in}

2. Remove the ball bearing using a press.


2. If not correct, replace the joint shaft.

Bearing Disassembly Note


D Remove the dust seal and bearing using the SST
and a suitable bar.

49 W027 001

M55

REMOTE FREEWHEEL (RFW) MECHANISM


JOINT SHAFT COMPONENT ASSEMBLY
D Assemble in the order indicated in the table.

1622 {1.62.3, 1216}

SST
SST

SST
R
R
SELECTIVE

SST
SELECTIVE
SST

SST

SST
Nm {kgfm , ftlbf}

Output shaft and gear sleeve

Casing

Spacer
+ Assembly Note

Oil seal
+ Assembly Note

10

Remote freewheel hub


+ Assembly Note

Adjustment shim(s)
+ Assembly Note

11

Clip

12

Ball bearing
+ Assembly Note

Dust seal
+ Assembly Note

13

Needle bearing

14

Clip

15

Control box

Joint shaft
+ Assembly Note

Bearing
+ Assembly Note

Retaining ring

M56

REMOTE FREEWHEEL (RFW) MECHANISM


Oil Seal Assembly Note
1. Apply differential oil to a new oil seal.
2. Install the new oil seal using the SST and a press.

Joint Shaft Assembly Note


D Install the joint shaft using the SST and a press.

49 U027 006
49 U027 006

Bearing Assembly Note


D Install the bearing using the SSTs and a press.

Ajustment Shim(s), Ball Bearing Assembly Note


1. Install the removed shim(s) and the ball bearing
using the SST and a press.

49 U027 005

49 U027 006

49 U027 006

Spacer, Remote FreeWheel Hub Assembly Note


1. Install the removed spacer and the remote
freewheel hub using a suitable pipe and the SST
and a press.

2. Install a new retaining ring.


3. Measure the clearance between the ball bearing
and the retaining ring.

49 U027 005

4. If not as specified, adjust by adding or removing


shims. Use no more than two shims on either side.
Maximum clearance
0.15 mm {0.0059 in}
Available shim thickness
0.15 mm {0.0059 in}, 0.30 mm {0.0118 in},
0.35 mm {0.0138 in}, 0.40 mm {0.0157 in},
0.50 mm {0.0197 in}
5. Remove the retaining ring.

M57

2. Install a new clip.


3. Measure the clearance between the remote
freewheel hub and the clip.

REMOTE FREEWHEEL (RFW) MECHANISM


4. If not as specified, adjust by adding or removing
spacers. Use no more than two spacers on either
side.
Maximum clearance
0.15 mm {0.0059 in}
Available shim thickness
0.15 mm {0.0059 in}, 0.30 mm {0.0118 in},
0.35 mm {0.0138 in}, 0.40 mm {0.0157 in},
0.50 mm {0.0197 in}
Dust Seal Assembly Note
1. Install the new dust seal using the SST and a press.

49 M005 796

CONTROL BOX REMOVAL/INSTALLATION


1. Drain the front differential oil. (Refer to FRONT
DIFFERENTIAL, FRONT DIFFERENTIAL OIL
REPLACEMENT.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
2326 {2.32.7, 1719}

1622
{1.62.3, 1216}

Vacuum hose

RFW switch connector

Control box

Nm {kgfm , ftlbf}

M58

REMOTE FREEWHEEL (RFW) MECHANISM


CONTROL BOX DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
R

R
SST

Nm {kgfm , ftlbf}

Snap pin

Change rod

Washer

10

Shift fork

RFW actuator

11

RFW switch and washer

Boot
+ Assembly Note

Spring cap

12

Spring and ball

Oil seal
+ Assembly Note

Washer

13

Control box

Roll pin
+ Disassembly Note
+ Assembly Note

M59

REMOTE FREEWHEEL (RFW) MECHANISM


Roll Pin Disassembly Note
D Remove the roll pin as shown in the figure.

SHIFT FORK INSPECTION


1. Measure the clearance between the gear sleeve
and the shift fork.
Standard clearance
0.10.40 mm {0.00400.0157 in}
Maximum clearance
0.50 mm {0.0197 in}

Oil Seal Assembly Note


D Install a new oil seal using the SST and a press.

49 U027 007

2. Inspect the output shaft and gear sleeve of the


splines for damage and wear.
3. If not correct, replace the output shaft and gear
sleeve as necessary.

Boot Assembly Note


D Install the boot as shown in the figure.

Roll Pin Assembly Note


D Install a new roll pin as shown in the figure.

M60

FRONT DIFFERENTIAL

FRONT DIFFERENTIAL
FRONT DIFFERENTIAL OIL INSPECTION
(Refer to REAR DIFFERENTIAL, REAR
DIFFERENTIAL OIL INSPECTION.)
Specified oil
Type
Above 18 C {0 F}: API GL5, SAE 90
Below 18 C {0 F}: API GL5, SAE 80
Capacity
MFW: 1.2 L {1.3 US qt, 1.1 lmp qt}
RFW: 1.5 L {1.6 US qt, 1.3 lmp qt}
FRONT DIFFERENTIAL OIL REPLACEMENT
(Refer to REAR DIFFERENTIAL, REAR
DIFFERENTIAL OIL REPLACEMENT.)
Specified oil
Type
Above 18 C {0 F}: API GL5, SAE 90
Below 18 C {0 F}: API GL5, SAE 80
Capacity
MFW: 1.2 L {1.3 US qt, 1.1 lmp qt}
RFW: 1.5 L {1.6 US qt, 1.3 lmp qt}
FRONT DIFFERENTIAL OIL SEAL REPLACEMENT
1. Remove the drive shaft.
(Refer to DRIVE SHAFT, DRIVE SHAFT
REMOVAL/INSTALLATION, Drive shaft removal
Note.)
2. Drain the differential oil.
(Refer to REAR DIFFERENTIAL, REAR
DIFFERENTIAL OIL REPLACEMENT.)
3. Remove the oil seal using a screwdriver.
4. Tap in the new oil seal to the differential using the
SST.
49 G030 795

5. Install the drive shaft.


(Refer to DRIVE SHAFT, DRIVE SHAFT
REMOVAL/INSTALLATION, Drive Shaft Installation
Note.)
6. Add the differential oil to the specified level.
(Refer to FRONT DIFFERENTIAL, FRONT
DIFFERENTIAL OIL REPLACEMENT.)

M61

FRONT DIFFERENTIAL
FRONT DIFFERENTIAL REMOVAL/INSTALLATION
1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)
2. Remove the propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (4 4), FRONT PROPELLER
SHAFT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
MFW

APPLY SCREW LOCK AGENT


95115 {9.511.8, 6985}

3753 {3.75.5, 2739}

6393 {6.49.5, 4768}

5580 {5.68.2, 4159}


Nm {kgfm, ftlbf}

Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Drive Shaft Removal Note

M62

Front differential component


+ Removal Note

Differential bracket

FRONT DIFFERENTIAL

RFW

APPLY LOCKING COMPOUND


94.2115.7
{9.511.8, 68.885.3}

2830
{2.83.1, 2122}

2326
{2.32.7, 1719}

94.2115.7
{9.511.8, 68.885.3}

62.893.1
{6.49.5, 46.368.7}
3753
{3.75.5, 2739}

APPLY SCREW
LOCK AGENT

Nm {kgfm, ftlbf}

Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Drive Shaft Removal Note

Front differential, joint shaft component


+ Removal Note

Joint shaft, crossmember

Vacuum hose

Front differential

RFW switch component

Front Differential, Joint Shaft Component Removal


Note
1. Set the transmission jack on the differential.
2. Remove the bolts and nuts indicated by arrows.

M63

3. Remove the front differential and joint shaft


component from the vehicle using the transmission
jack.

FRONT DIFFERENTIAL
FRONT DIFFERENTIAL DISASSEMBLY
D Disassemble in the order indicated in the table.
SST

SST

SST
SST

SST

SST

Bolt

Adjusting screw

Differential casing

Side bearing outer race

Oil baffle

Differential component
+ Disassembly Note

Locknut
+ Disassembly Note

10

Washer

Lock plate

11

Bearing cap
+ Disassembly Note

Companion flange
+ Disassembly Note

M64

FRONT DIFFERENTIAL
Locknut Disassembly Note
D Hold the companion flange using the SST and
remove the locknut.

12

Oil seal
+ Disassembly Note

13

Drive pinion
+ Disassembly Note

14

Front bearing inner race

15

Collapsible spacer

16

Rear bearing inner race


+ Disassembly Note

17

Spacer

18

Front bearing outer race


+ Disassembly Note

19

Rear Bearing outer race


+ Disassembly Note

20

Carrier

21

Bolt

22

Ring gear

23

Knock pin
+ Disassembly Note

24

Pinion shaft

25

Pinion gear

26

Thrust washer

27

Side gear

28

Thrust washer

29

Side bearing inner race


+ Disassembly Note

30

Gear case

49 S120 710

Companion Frange Disassembly Note


D Pull the companion flange out using the SST.

49 0839 425C

Oil Seal Disassembly Note


D Remove the oil seal using a screw driver.

Differential Component Disassembly Note


D Install the differential component on the SSTs.
49 M005 561

49 0107 680A

Bearing Cap Disassembly Note


D Place a mark on one of the bearing caps so that
the left and right bearing caps wont get mixed up.
Use the mark for matching at the time of assembly.

Drive Pinion Disassembly Note


D Remove the drive pinion by tapping with a plastic
hammer.

MARK

M65

FRONT DIFFERENTIAL
Rear Bearing Inner Race Disassembly Note
Note
D Mark or otherwise distinguish between the front
and rear inner races so that they are not mixed
up at the time of reassembly.
D Remove the rear bearing inner race using the SST.

Side Bearing Inner Race Disassembly Note


Caution
D Mark the left bearing in order to install in
the same position.

49 H027 002

D Remove the side bearing inner race from the gear

case using the SST.


Front Bearing Outer Race, Rear Bearing Outer
Race Disassembly Note

49 0839 425C

Note
D Mark or otherwise distinguish between the front
and rear outer races so that they are not mixed
up at the time of reassembly.
D Remove the bearing outer races using the two

grooves on the carrier and tapping the outer races


alternately.

Knock Pin Disassembly Note


Caution
D Insert the bar from the knock pin hole at the
opposite side from where the ring gear is
installed.
D Secure the gear case in a vise and remove the

knock pin using a 4 mm {0.16 in} diameter bar.

M66

FRONT DIFFERENTIAL
FRONT DIFFERENTIAL ASSEMBLY
Caution
D Clean away the old sealant before applying the new sealant.
D Install the differential carrier within 10 minutes after applying sealant.
D Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oll.
D Assemble in the order indicated in the table.
184284
{1329, 95209}
2327
{2.32.7, 1719}

R
SST

1451
{3.85.3, 2838}

R
R

1825
{1.82.6, 1418}

SST

SST
R
SST
6983
{7.08.5,
5161}

SST

SST

SST

R
SST
SST
R

Nm {kgfm, ftlbf}

Gear case
+ Assembly Note

Side bearing inner race


+ Assembly Note

Thrust washer
+ Assembly Note

10

Bolt

11

Carrier

Side gear

12

Thrust washer

Front Bearing outer Race


+ Assembly Note

Pinion gear

13

Pinion shaft

Rear bearing outer race


+ Assembly Note

Knock pin

14

Ring gear
+ Assembly Note

Spacer
+ Assembly Note

15

Rear bearing inner race


+ Assembly Note

M67

FRONT DIFFERENTIAL

16

Drive pinion
+ Assembly Note

17

Collapsible spacer

18

Front bearing inner race

19

Oil seal
+ Assembly Note

20

Companion flange

21

Washer

22

Locknut
+ Assembly Note

23

Side bearing outer race


+ Assembly Note

24

Adjusting screw
+ Assembly Note

25

Bearing cap
+ Assembly Note

26

Lock plate

27

Baffle plate

28

Differential casing

29

Bolt

Standard backlash
00.1 mm {00.004 in}
4. If the backlash exceeds the standard, use the
thrust washers to adjust.
Ring Gear Assembly Note
1. Coat the ring gear and gear case facing surfaces
with locking agent.
2. Install the ring gear and tighten the bolt to the
specified torque.
Side Bearing Inner Race Assembly Note
Caution
D Bearings should be assembled to the
original positions.
D Press the side bearings into the gear case using

the SST.

49 G030 338

Gear Case Assembly Note


D Assemble the side gears, thrust washer, pinion
gears, pinion shaft and knock pin.
After assembling the knock pin, make a crimp so
that the pin will not come out of the gear case.
Front Bearing Outer Race Assembly Note
D Press the front bearing outer race into the carrier
using the SST and a press.

49 F027 005

Thrust Washer Assembly Note


1. Set a dial gauge to the pinion gear as shown in the
figure.
2. Secure one of the side gears.
3. Move the pinion gear and measure the backlash at
the end of the pinion gear.

Rear Bearing Outer Race Assembly Note


D Press the rear bearing outer race into the carrier
using the SST and a press.

49 F027 004

M68

FRONT DIFFERENTIAL
Spacer Assembly Note
Pinion height adjustment

49 0727 570

Notes
D Use the same spacer and nut.
D Be careful to install collars A and B in the
correct position and facing in the correct
direction.
1. Assemble the spacer, rear bearing inner race and
SST (49 8531 568) on to the SST (49 8531 565).
Secure the collar with the O-ring. Then install this
to the carrier.
2. Assemble the front bearing inner race, SST (49
8531 567), companion flange, washer and nut to
the SST (49 8531 565).
3. Tighten the nut to the extent that the SST (49 8531
565) can be turned by hand.

49 0350 555

7. Add the two (left and right) values obtained by the


measurements taken in Step 6 and then divide the
total by 2. From this result, subtract the result
obtained by dividing the number inscribed on the
end surface of the drive pinion by 100. (If there is
no figure inscribed, use 0.) This is the pinion height
adjustment value.
Note
D For example, the measured results obtained at
Step 6 are 0.06 mm and 0.04 mm, and the
figure inscribed on the end of the drive pinion is
2:

49 0350 555
49 8531 565

pinion height
0.06+0.04
2 = 0.07 =
adjustment value
2
100

SPACER
REAR BEARING

Therefore, replace it with a spacer 0.07 mm


{0.003 in} thicker than the currently used one.

49 8531 568
O RING

49 8531 567
FRONT BEARING

4. Place the SST on the surface plate and set the dial
indicator to zero.

Rear Bearing Inner Race Assembly Note


Caution
D Press in until the force required suddenly
increases.
D Install the spacer selected for the pinion
height adjustment, confirm that the
installation direction is correct.
D Press the rear bearing inner race in using the

49 0727 570

SSTs.
SPACER

5. Place the SST (49 0350 555) on top of the SST (49
8531 565), and then set the SST (49 0727 570) on
top of the SST (49 0350 555).
6. Place the measuring probe of the dial indicator so
that it contacts the place where the side bearing is
installed in the carrier. Then measure left and right
side of the lower position.

M69

49 F401 331
49 G030 338

FRONT DIFFERENTIAL
Drive Pinion Assembly Note
Drive pinion preload adjustment

Locknut Assembly Note


1. Assemble the companion flange and washer.
2. Tighten the new locknut using the SST with the
determined torque while performing drive pinion
preload adjustment.
3. Verify that the preload is within the specification.

Caution
D Do not install the oil seal.
1. Install the drive pinion, spacer, front bearing,
collapsible spacer and companion flange to the
carrier, and temporarily tighten the locknut.
2. Adjust the preload of the drive pinon bearing as
follows.
(1) Turn the companion flange by hand to seat the
bearing.
(2) Use a torque wrench to tighten the locknut
temporarily tightened in Step 1, and confirm
that the specified preload can be obtained
within the specified tightening torque range.
The torque applied at this time will be used
after the oil seal is installed.
Locknut tightening torque
128284 Nm {1329 kgfm, 95209 fflbf}
Drive pinion preload
0.913.4 Nm {914 kgfcm, 7.912.1 inlbf}
49 S120 710

Preload
0.91.3 Nm {914 kgfcm, 7.912.1 inlbf}

49 S120 710

Side Bearing Outer Race, Adjusting Screw, Bearing


Cap Assembly Note
Ring gear backlash adjustment
1. Install the differential gear component to the
carrier. After loosely tightening the bearing outer
race and bearing cap mounting bolts, completely
tighten the adjustment screw by hand. Then, while
turning the ring gear, alternately tighten the left and
right adjustment screws using the SST.

49 0259 720

(3) If the specified preload cant be obtained within


the specified tightening torque range, replace
the collapsible spacer and inspect again.
(4) Remove the locknut, washer and companion
flange.
Oil Seal Assembly Note
D Apply differential oil to the oil seal lip and press the
oil seal in until it touches the end of the differential
carrier using the SST.

2. Adjust the drive pinion, ring gear backlash and the


side bearing preload as follows.
(1) Mark the ring gear at four points at approx. 90
intervals and mount a dial indicator to the
carrier so that the feeler comes in contact at a
90 angle with one of the ring gear teeth.
(2) Turn both bearing adjusters equally until the
backlash becomes 0.090.11 mm
{0.00350.0043 in} using the SST.

49 0259 720
49 U027 003

M70

FRONT DIFFERENTIAL
(3) Inspect for the backlash at the three other
marked points and make sure that the
minimum backlash is more than 0.05 mm
{0.002 in} and difference of the maximum and
minimum backlash value is less than 0.07 mm
{0.0028 in}.

Toe and flank contact


Replace the spacer with a thinner one, and move the
drive pinion outward.
TOE CONTACT

FLANK CONTACT

Heel and face contact


Replace the spacer with a thicker one.
Bring the drive pinion inward.
(4) After adjusting the backlash, tighten the
adjustment screws equally until the distance
between both pilot sections on the bearing
caps (L) become as specified.

HEEL CONTACT

Bearing cap bolt tightening torque


3851 Nm {3.85.3 kgfm, 2838 ftlbf}

Standard distance
185.43185.50 mm {7.3007.303 in}
3. The inspection and adjustment procedure is as
follows:
(1) Coat both surfaces of 68 teeth of the ring
gear uniformly with a thin red lead coating.
(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) If the tooth contact is good, wipe off the red
lead coating.
(4) If it is not good, adjust the pinion height, then
adjust the backlash.
RED LEAD

M71

FACE CONTACT

TROUBLESHOOTING

TROUBLESHOOTING
REMOTE FREEWHEEL (RFW)
Foreword
D Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read
and understand the basic flow of troubleshooting in order to properly perform the basic procedures.
Precaution
D This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary
for trouble caused by other sources.
D Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the
malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.)
Diagnostic Index
No

TROUBLESHOOTING ITEM

DESCRIPTION

No RFW operation from free to lock


(RFW indicator light does not illuminate)

D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

Free solenoid valve malfunction


RFW indicator light bulb malfunction
RFW actuator malfunction
RFW switch malfunction
Print plate in instrument cluster malfunction
METER 15 A fuse malfunction
ENGINE 15 A fuse malfunction
Transfer neutral switch malfunction
4 4 indicator switch malfunction
RFW control module malfunction
Lock solenoid valve malfunction
RFW control box malfunction
Air leakage from vacuum hose
One-way check valve malfunction
Related fuses and/or harness malfunction

No RFW operation from lock to free


(RFW indicator light does not go off)

D
D
D
D
D
D
D
D
D
D
D
D
D
D

Lock solenoid valve malfunction


RFW switch malfunction
RFW actuator malfunction
Print plate in instrument cluster malfunction
Engine 15 A fuse malfunction
RFW main switch malfunction
Transfer neutral switch malfunction
4 4 indicator switch malfunction
RFW control module malfunction
Free solenoid valve malfunction
RFW control box malfunction
Air leakage from vacuum hose
One-way check valve malfunction
Related fuses and/or harness malfunction

Noise

D Joint shaft bearing abrasion or damage


D RFW hub abrasion
D Joint shaft abrasion

Oil leakage

D RFW control box is poorly installed.

M72

TROUBLESHOOTING

No RFW operation from lock to free

Oil leakage

Symptom Troubleshooting
1

NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)

DESCRIPTION

RFW does not change from free to lock.

[TROUBLESHOOTING HINTS]
D
D
D
D
D
D
D

Transfer neutral switch malfunction


4 4 indicator switch malfunction
RFW control module malfunction
Lock solenoid valve malfunction
Free solenoid valve malfunction
RFW indicator light bulb malfunction
RFW control box malfunction

STEP
1

D
D
D
D
D
D
D

METER 15 A fuse and/of ENGINE 15 A fuse malfunction


Print plate in instrument cluster malfunction
RFW switch malfunction
RFW actuator malfunction
Air leakage from vacuum hose
One-way check valve malfunction
Related fuses and/or harnesses malfunction

INSPECTION

ACTION

Disconnect RFW control module connector.


Turn ignition (engine) switch on.
Measure voltage between RFW control module
connector terminal F and ground.
Is the voltage greater than 10 V?

Yes

Go to Step 6.

No

Turn ignition (engine) switch off.


Then go to next step.

Is the METER 15 A fuse okay?

Yes

Go to next step.

No

Replace 15 A METER fuse.


Then go to Step 31.

Inspect RFW indicator light bulb.


Is it okay?

Yes

Go to next step.

No

Replace RFW indicator light bulb.


Then go to Step 31.

Measure voltage between instrument cluster


connector terminal 1J and ground.
Is the voltage greater than 10 V?

Yes

Go to next step.

No

Repair wiring harness between METER 15 A fuse


and instrument cluster.
Then go to Step 31.

Measure voltage between instrument cluster


connector terminal 2H and ground.
Is the voltage greater than 10 V?

Yes

Repair wiring harness between instrument cluster


and RFW control module.
Then go to Step 31.

No

Replace print plate in instrument cluster.


Then go to Step 31.

Yes

Go to Step 8.

No

Turn ignition (engine) switch off.


Then go to next step.

Measure voltage between RFW control module


connector terminal H and ground.
Is the voltage greater than 10 V?

M73

Related fuse and / or harnesses

Noise

Vacuum hose

Joint shaft

RFW hub

Joint shaft bearing

Oneway check valve

RFW control box

Free solenoid valve

Lock solenoid vallve

RFW control module

RFW main switch

4 x4 indicator swiitch

Transfer neutral switch

METER 15 A fuse

ENGINE 15 A fuse

RFW actuator

No RFW operation from free to lock

RFW switch

Troubleshooting item

RFW indicator light bulb

Print plate in instrument cluster

Possible factor

Conventional front differential parts

Quick Diagnosis Chart

TROUBLESHOOTING

STEP
7

INSPECTION

ACTION
Yes

Repair wiring harness between ENG 15 A fuse and


RFW control module.
Then go to Step 31.

No

Replace the ENG 15 A fuse.


Then go to Step 31.

Disconnect free solenoid valve connector.


Measure voltage between free solenoid valve
connector terminal A and ground.
Is the voltage greater than 10 V?

Yes

Connect free solenoid valve.


Then go to next step.

No

Repair wiring harness between ENG 15 A fuse and


RFW control module.
Then go to Step 31.

Measure voltage between free solenoid valve


connector terminal B and ground.
Is the voltage greater than 10 V?

Yes

Go to next step.

No

Inspect free solenoid valve.


Then go to Step 31.

Measure voltage between RFW control module


connector terminal C and ground.
Is the voltage greater than 10 V?

Yes

Go to next step.

No

Repair wiring harness between free solenoid valve


and RFW control module.
Then go to Step 31.

Disconnect lock solenoid valve connector.


Measure voltage between lock solenoid valve
connector terminal A and ground.
Is the voltage greater than 10 V?

Yes

Connect lock solenoid valve.


Then go to next step.

No

Repair wiring harness between ENG 15 A fuse and


RFW control module.
Then go to Step 31.

Measure voltage between lock solenoid valve


connector terminal B and ground.
Is the voltage greater than 10 V?

Yes

Go to next step.

No

Inspect lock solenoid valve.


Then go to Step 31.

Measure voltage between RFW control module


connector terminal A and ground.
Is the voltage greater than 10 V?

Yes

Go to next step.

No

Repair wiring harness between lock solenoid valve


and RFW control module.
Then go to Step 31.

Turn ignition (engine) switch off.


Is there continuity between RFW control module
connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between RFW control


module and ground.
Then go to Step 31.

Shift select lever to N position.


Is there continuity between RFW control module
connector terminal L and ground?

Yes

Go to Step 19.

No

Go to next step.

16

Is there continuity between transfer neutral switch


connector terminal A and ground?

Yes

Repair wiring harness between RFW control


module and transfer neutral switch.
Then go to Step 31.

No

Go to next step.

17

Inspect transfer neutral switch.


Is it okay?

Yes

Go to next step.

No

Replace transfer neutral switch.


Then go to Step 31.

Is there continuity between transfer neutral switch


connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between transfer neutral


switch and ground.
Then go to Step 31.

Shift select lever to 4 4 indicator position.


Is there continuity between RFW control module
connector terminal K and ground?

Yes

Go to Step 23.

No

Go to next step.

Is there continuity between 4 4 indicator switch


connector terminal A and ground?

Yes

Repair wiring harness between 4


switch and RFW control module.
Then go to Step 31.

No

Go to next step.

10

11

12

13

14

15

18

19

20

Is the ENG 15 A fuse okay?

M74

4 indicator

TROUBLESHOOTING

STEP
21

22

23

24

25

26

27

28

29

30

31

INSPECTION

ACTION

Inspect 4 4 indicator switch.


Is it okay?

Yes

Go to next step.

No

Replace 4 4 indicator switch.


Then go to Step 31.

Is there continuity between 4 4 indicator switch


connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between 4


switch and ground.
Then go to Step 31.

Shift select lever to 4H position.


Is there continuity between RFW control module
connector terminal J and ground?

Yes

Go to Step 27

No

Go to next step.

Is there continuity between RFW switch


connector terminal A and ground?

Yes

Repair wiring harness between RFW control


module and RFW switch.
Then go to Step 31.

No

Go to next step.

Inspect RFW switch.


Is it okay?

Yes

Go to next step.

No

Replace RFW switch.


Then go to Step 31.

Is there continuity between RFW switch


connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between RFW switch and


ground.
Then go to Step 31.

Inspect one-way check valve.


Is it okay?

Yes

Go to next step.

No

Replace one-way check valve.


Then go to Step 31.

Inspect RFW control box.


Is it okay?

Yes

Go to next step.

No

Replace RFW control box.


Then go to Step 31.

Inspect vacuum in vacuum hoses.


Is it okay?

Yes

Go to next step.

No

Repair vacuum in vacuum hoses.


Then go to Step 31.

Inspect RFW control module.


Is it okay?

Yes

Go to next step.

No

Repair or replace RFW control module.


Then go to next step.

Turn ignition (engine) switch on.


Shift select lever from 2H to 4H position.
Does RFW operate from free to lock?

Yes

Troubleshooting completed.
Explain repairs to customer.

No

Inspect malfunction symptoms again, then repeat


from Step 1 if malfunction occurs again.

4 indicator

NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)

DESCRIPTION

RFW does not change from lock to free.

[TROUBLESHOOTING HINTS]
D
D
D
D
D
D
D

D
D
D
D
D
D
D
D

RFW main switch malfunction


Transfer neutral switch malfunction
4 4 indicator switch malfunction
RFW control module malfunction
Free solenoid valve malfunction
Lock solenoid valve malfunction
RFW control box malfunction

STEP
1

ENGINE 15 A fuse malfunction


RFW main switch malfunction
RFW actuator malfunction
RFW switch malfunction
Air leakage from vacuum reservoir or actuator system
One-way check valve
Print plate in instrument cluster malfunction
Related fuses and/or harnesses malfunction

INSPECTION

ACTION

Disconnect RFW control module connector.


Is there continuity between RFW control module
connector terminal F and ground?

Yes

Go to next step.

No

Go to Step 3.

M75

TROUBLESHOOTING

STEP
2

INSPECTION

ACTION
Yes

Repair wiring harness between RFW control module


and instrument cluster.
Then go to Step 32.

No

Inspect for no continuity between Instrument cluster


terminal 2H and ground.

Turn ignition (engine) switch off.


Disconnect RFW control module connector.
Turn ignition (engine) switch on.
Measure voltage between RFW control module
connector terminal H and ground.
Is the voltage greater than 10 V?

Yes

Go to Step 5.

No

Turn ignition (engine) switch off.


Then go to next step.

Is the ENG 15 A fuse okay?

Yes

Repair wiring harness between ENG 15 A fuse and


RFW control module.
Then go to Step 32.

No

Replace the ENG 15 A fuse.


Then go to Step 32.

Disconnect free solenoid valve connector.


Measure voltage between free solenoid valve
connector terminal A and ground.
Is the voltage greater than 10 V?

Yes

Connect free solenoid valve.


Then go to next step.

No

Repair wiring harness between ENG 15 A fuse and


RFW control module.
Then go to Step 32.

Measure voltage between free solenoid valve


connector terminal B and ground.
Is the voltage greater than 10 V?

Yes

Go to next step.

No

Inspect free solenoid valve.


Then go to Step 32.

Measure voltage between RFW control module


connector terminal C and ground.
Is the voltage greater than 10 V?

Yes

Go to next step.

No

Repair wiring harness between free solenoid valve


and RFW control module.
Then go to Step 32.

Disconnect lock solenoid valve connector.


Measure voltage between lock solenoid valve
connector terminal A and ground.
Is the voltage greater than 10 V?

Yes

Connect lock solenoid valve.


Then go to next step.

No

Repair wiring harness between ENG 15 A fuse and


RFW control module.
Then go to Step 32.

Measure voltage between lock solenoid valve


connector terminal B and ground.
Is the voltage greater than 10 V?

Yes

Go next step.

No

Inspect lock solenoid valve.


Then go to Step 32.

Measure voltage between RFW control module


connector terminal A and ground.
Is the voltage greater than 10 V?

Yes

Go next step.

No

Repair wiring harness between lock solenoid valve


and RFW control module.
Then go to Step 32.

Turn ignition (engine) switch off.


Is there continuity between RFW control module
connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between RFW control module


and ground.
Then go to Step 32.

Shift select lever to N position.


Is there continuity between RFW control module
connector terminal L and ground?

Yes

Go to Step 16.

No

Go to next step.

13

Is there continuity between transfer neutral switch


connector terminal A and ground?

Yes

Repair wiring harness between RFW control module


and transfer neutral switch.
Then go to Step 32.

No

Go to next step.

14

Inspect transfer neutral switch.


Is it okay?

Yes

Go to next step.

No

Replace transfer neutral switch.


Then go to Step 32.

10

11

12

Disconnect instrument cluster connector No.2.


Is there continuity between instrument cluster
terminal 2H and ground?

M76

TROUBLESHOOTING

STEP
15

16

17

18

19

20

21

22

23

24

25

INSPECTION

ACTION

Is there continuity between transfer neutral switch


connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between transfer neutral


switch and ground.
Then go to Step 32.

Shift select lever to 2H position.


Is there continuity between RFW control module
connector terminal K and ground?

Yes

Go to Step 20.

No

Go to next step.

Is there continuity between 4 4 indicator switch


connector terminal A and ground?

Yes

Repair wiring harness between RFW control module


and 4 4 indicator switch.
Then go to Step 32.

No

Go to next step.

Inspect 4 4 indicator switch.


Is it okay?

Yes

Go to next step.

No

Replace 4 4 indicator switch.


Then go to Step 32.

Is there continuity between 4 4 indicator switch


connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between 4


and ground.
Then go to Step 32.

Shift select lever to 4H position.


Is there continuity between RFW control module
connector terminal J and ground?

Yes

Go to Step 28.

No

Go to next step.

Is there continuity between RFW switch


connector terminal A and ground?

Yes

Repair wiring harness between RFW switch.


Then go to Step 32.

No

Go to next step.

Inspect RFW switch.


Is it okay?

Yes

Go to next step.

No

Replace RFW switch.


Then go to Step 32.

Is there continuity between RFW switch


connector terminal B and ground?

Yes

Go to next step.

No

Repair wiring harness between RFW switch and


ground.
Then go to Step 32.

Push RFW main switch on.


Is there continuity between RFW main switch
connector terminal I and ground?

Yes

Go to Step 28.

No

Go to next step.

Is there continuity between RFW main switch


connector terminal F and ground?

Yes

Repair wiring harness between RFW main switch


and RFW control module.
Then go to Step 32.

No

Go to next step.

4 indicator switch

26

Inspect RFW main switch.


Is it okay?

Yes

Go to next step.

No

Replace RFW main switch.

27

Is there continuity between RFW main switch


connector terminal D and ground?

Yes

Go to next step.

No

Repair wiring harness between RFW main switch


and ground.
Then go to Step 32.

Inspect one-way check valve.


Is it okay?

Yes

Go to next step.

No

Replace one-way check valve.


Then go to Step 32.

Inspect RFW actuator.


Is it okay?

Yes

Go to next step.

No

Replace RFW actuator.


Then go to Step 32.

Inspect vacuum in vacuum hoses.


Is it okay?

Yes

Go to next step.

No

Repair vacuum in vacuum hoses.


Then go to Step 32.

28

29

30

M77

TROUBLESHOOTING

STEP
31

32

INSPECTION

ACTION

Inspect RFW control module.


Is it okay?

Yes

Go to next step.

No

Repair or replace RFW control module.


Then go to next step.

Turn ignition (engine) switch on.


Move selector lever from 2H to 4H position.
Does RFW operate from free to lock?

Yes

Troubleshooting completed.
Explain repairs to customer.

No

Inspect malfunction symptoms again, then repeat


from Step 1 if malfunction occurs again.

NOISE

DESCRIPTION

Noise is heard from front differential.

[TROUBLESHOOTING HINTS]
D Joint shaft bearing abrasion or damage
D RFW hub abrasion

STEP
1
2
3
4

D Joint shaft abrasion


D Conventional front differential parts malfunction

INSPECTION

ACTION

Inspect joint shaft bearing.


Is it okay?

Yes

Go to next step.

No

Replace joint shaft bearing.

Inspect RFW hub.


Is it okay?

Yes

Go to next step.

No

Replace RFW hub.

Inspect joint shaft.


Is it okay?

Yes

Go to next step.

No

Replace joint shaft.

Malfunction is caused by other than RFW.


Inspect conventional front differential parts.
Are they okay?

Yes

Go to next step.

No

Replace defective part(s).

Has front differential noise stopped?

Yes

Troubleshooting completed.
Explain repairs to customer.

No

Inspect malfunction symptoms again, then repeat


from Step 1 if malfunction occurs again.

OIL LEAKAGE

DESCRIPTION

The oil leaks from front differential.

[TROUBLESHOOTING HINTS]
D Poor installation of the RFW control box

STEP
1

D Malfunction of conventional front differential parts

INSPECTION
Is RFW control box installed completely?

ACTION
Yes

Go to next step.

No

Install RFW control box securely.


Then go to Step 3.

Malfunction is caused by something other than


RFW.
Inspect conventional front differential parts.
Are they okay?

Yes

Go to next step.

No

Replace defective part(s).

Is there any oil leakage from front differential?

Yes

Inspect malfunction symptoms again, then repeat


from Step 1 if malfunction still occurs.

No

Troubleshooting completed.
Explain repairs to customer.

M78

STEERING SYSTEM
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N11
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N12
STEERING SHAFT INSPECTION . . . . . . . . . . . N12
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N13
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N14
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N15
POWER STEERING OIL PUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N16
POWER STEERING OIL PUMP (F2 CIS, F2 CARB,
G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N18
POWER STEERING OIL PUMP (WL, WL TURBO)
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N20

GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N 1
MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N 3
STEERING SHAFT INSPECTION . . . . . . . . . . . N 4
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N 5
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N 7
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 9
ENGINE SPEED SENSING POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
POWER STEERING FLUID INSPECTION . . . N10

GENERAL PROCEDURES

MANUAL STEERING

Wheels and tires removal/installation


 The removal and installation procedures for the
wheels and tires are not mentioned in this section.
When a wheel is removed, retighten it to the
specified torque. (Refer to section TD,
SUSPENSION, Wheels and Tires.)

STEERING WHEEL AND COLUMN INSPECTION


Steering Wheel Play Inspection
 If the play exceeds specification, either the steering
joints are worn or the backlash of the steering gear
is excessive. With the wheels in the straight-ahead
position, gently turn the steering wheel to the left
and right and verify that the play is within
specification.

Power steering components removal/installation


 If any power steering fluid line has been
disconnected anytime during the procedure, add
ATF MIII or equivalent (e.g. Dexron II), bleed
the fluid lines, and inspect for leakage after the
procedure has been completed.

Steering wheel play


030 mm {01.18 in}

Connectors disconnection/connection
 Disconnect the negative battery cable before doing
any work that requires handling of connectors.
Reconnect the negative battery cable only after the
work is completed.

Steering Wheel Looseness Inspection


 Move the steering wheel as shown in the figure to
inspect for column bearing wear, steering shaft
joint play, steering wheel looseness, and column
looseness.

N1

STEERING SYSTEM
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N11
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N12
STEERING SHAFT INSPECTION . . . . . . . . . . . N12
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N13
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N14
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N15
POWER STEERING OIL PUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N16
POWER STEERING OIL PUMP (F2 CIS, F2 CARB,
G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N18
POWER STEERING OIL PUMP (WL, WL TURBO)
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N20

GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N 1
MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N 3
STEERING SHAFT INSPECTION . . . . . . . . . . . N 4
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N 5
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N 7
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 9
ENGINE SPEED SENSING POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
POWER STEERING FLUID INSPECTION . . . N10

GENERAL PROCEDURES

MANUAL STEERING

Wheels and tires removal/installation


 The removal and installation procedures for the
wheels and tires are not mentioned in this section.
When a wheel is removed, retighten it to the
specified torque. (Refer to section TD,
SUSPENSION, Wheels and Tires.)

STEERING WHEEL AND COLUMN INSPECTION


Steering Wheel Play Inspection
 If the play exceeds specification, either the steering
joints are worn or the backlash of the steering gear
is excessive. With the wheels in the straight-ahead
position, gently turn the steering wheel to the left
and right and verify that the play is within
specification.

Power steering components removal/installation


 If any power steering fluid line has been
disconnected anytime during the procedure, add
ATF MIII or equivalent (e.g. Dexron II), bleed
the fluid lines, and inspect for leakage after the
procedure has been completed.

Steering wheel play


030 mm {01.18 in}

Connectors disconnection/connection
 Disconnect the negative battery cable before doing
any work that requires handling of connectors.
Reconnect the negative battery cable only after the
work is completed.

Steering Wheel Looseness Inspection


 Move the steering wheel as shown in the figure to
inspect for column bearing wear, steering shaft
joint play, steering wheel looseness, and column
looseness.

N1

MANUAL STEERING
Steering Wheel Effort Inspection
1. With the vehicle on a hard, level surface, put the
wheels in the straight-ahead position.
2. Remove the air bag module, if equipped.
(Refer to section T, AIR BAG SYSTEM,
DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
3. Measure the steering wheel effort using a torque
wrench.

Steering wheel effort


4.5 Nm {460 kgfcm, 399 inlbf} max.
4. If not as specified, inspect the following: rotation
starting torque of pinion, rotation torque of each
ball joint, and steering joints.

N2

MANUAL STEERING
STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
4050
{4.05.0,
2936}

4050
{4.05.0, 2936}

AIR BAG MODEL

1622
{1.62.3, 1216}
1622
{1.62.3, 1216}
2026
{2.02.7,
1519}
1824
{1.82.5, 1418}

2026
{2.02.7, 1519}

Nm {kgfm, ftlbf}

Horn cap

Combination switch

Air bag module (with air bag)


+ section T, AIR BAG SYSTEM, DRIVER-SIDE
AIR BAG MODULE REMOVAL/INSTALLATION

Steering shaft
+ Installation Note

Universal joint

Locknut

Boot

Steering wheel
+ Removal Note
+ Installation Note

10

Intermediate shaft

11

Steering lock component


+ Removal Note
+ Installation Note

Column cover

N3

MANUAL STEERING
Steering Wheel Removal Note
Caution
 Do not try to remove the steering wheel by
hitting the shaft with a hammer. The column
will collapse.
 Set the wheels in the straight-ahead position,

remove the steering wheel using a suitable puller.


Steering Lock Component Removal Note
 Use a chisel to make a groove in the heads of the
steering lock mounting bolts. Remove the bolts
using a screwdriver. Remove the steering lock
component.

Steering Lock Component Installation Note


 Install the new steering lock mounting bolts.
Tighten the bolts until the heads break off.

Steering Wheel Installation Note


1. For vehicles with air bags, adjust the clock spring.
(Refer to section T, CLOCK SPRING, CLOCK
SPRING ADJUSTMENT.)
2. Install the steering wheel with the vehicle in the
straight-ahead position.
STEERING SHAFT INSPECTION
 Inspect the following, and replace the column
component as necessary.
1. Needle and ball bearing damage.
2. Steering shaft length.
Length
816.9819.9 mm {32.1732.27 in}

Steering Shaft Installation Note


1. Temporarily tighten the bolt A.
2. Tighten the nut B to the specified torque.
3. Tighten the bolt A to the specified torque.
Tightening torque
1622 Nm {1.62.3 kgfm, 1216 ftlbf}
3. Dust boot damage.

N4

MANUAL STEERING
Steering Wheel Removal Note
Caution
 Do not try to remove the steering wheel by
hitting the shaft with a hammer. The column
will collapse.
 Set the wheels in the straight-ahead position,

remove the steering wheel using a suitable puller.


Steering Lock Component Removal Note
 Use a chisel to make a groove in the heads of the
steering lock mounting bolts. Remove the bolts
using a screwdriver. Remove the steering lock
component.

Steering Lock Component Installation Note


 Install the new steering lock mounting bolts.
Tighten the bolts until the heads break off.

Steering Wheel Installation Note


1. For vehicles with air bags, adjust the clock spring.
(Refer to section T, CLOCK SPRING, CLOCK
SPRING ADJUSTMENT.)
2. Install the steering wheel with the vehicle in the
straight-ahead position.
STEERING SHAFT INSPECTION
 Inspect the following, and replace the column
component as necessary.
1. Needle and ball bearing damage.
2. Steering shaft length.
Length
816.9819.9 mm {32.1732.27 in}

Steering Shaft Installation Note


1. Temporarily tighten the bolt A.
2. Tighten the nut B to the specified torque.
3. Tighten the bolt A to the specified torque.
Tightening torque
1622 Nm {1.62.3 kgfm, 1216 ftlbf}
3. Dust boot damage.

N4

MANUAL STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
1. With the wheels in the straight-ahead position, remove in the order indicated in the table.
2. Install in the reverse order of removal.

3754
{3.75.5, 2739}
2026
{2.02.7, 1519}

4558
{4.56.0,
3343}

SST
6978
{7.08.0, 5157}

4558
{4.56.0,
3343}

SST

79157
{8.016.0,
58115}

4558
{4.56.0, 3343}

SST

3754
{3.75.5,
2739}
4558
{4.56.0, 3343}

SST

SST
Nm {kgfm, ftlbf}

Cotter pin

Washer

Nut

10

Bolt, nut, washer

Ball joint
+ Removal Note

11

Idler arm bracket

12

Bolt, nut, washer

Locknut

13

Bolt

Tie rod

14

Center link

Steering gear and pitman arm


+ Removal Note

Idler arm
+ Removal Note

15

Bushing

Dust boot
+ Removal Note
+ Installation Note

N5

MANUAL STEERING
Ball Joint, Idler Arm, Steering Gear and Pitman
Arm Removal Note
 Remove the ball joint from the knuckle and center
link, the idler arm from the center link, and steering
gear and pitman arm from the center link using the
SST.
49 T028 3A0

Dust Boot Removal Note


1. Place the chisel against the boot and hold it at the
angle shown.
2. Remove the dust boot by tapping it with a hammer.

Dust Boot Install Note


1. Wipe the grease off the ball joint.
2. Put a small amount of lithium-based grease into a
new dust boot.
3. Install the dust boot using the SST and a press.

49 1243 785A

N6

MANUAL STEERING
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
2534
{2.53.5, 2534}
1521
{1.52.2, 1115}

1524
{1.52.5, 1118}

128166
{13.017.0, 95122}

R
SST

R
R

197235
{20.024.0, 145173}

SST

Nut

Adjusting screw

Pitman arm
+ Disassembly Note

10

Oil seal

11

Retaining ring

Clip

12

Dust boot
+ Assembly Note

Locknut
+ Disassembly Note

13

Oil seal

Locknut (side cover)


+ Disassembly Note

14

Adjusting nut
+ Disassembly Note

Sector shaft
+ Disassembly Note
+ Assembly Note

15

Bearing

16

Worm ball nut


+ Assembly Note

17

Bearing

Side cover

Adjusting shim

N7

Nm {kgfm, ftlbf}

MANUAL STEERING
Pitman Arm Disassembly Note
 Separate the pitman arm from the steering gear
using the SST.

Adjusting Nut Disassembly Note


 Remove the adjusting nut using the SST.

49 UB39 585A

49 U032 3A0

Locknut (Side Cover), Sector Shaft Disassembly


Note
1. Loosen the locknut.
2. Remove the side cover attaching bolts.
3. Set the sector shaft in the middle position.
4. Tap the sector shaft lower end using a plastic
hammer to loosen the sector shaft.
5. Lift and remove the sector shaft with the locknut
and the side cover from the gear housing.

Worm Ball Nut Assembly Note


1. Inspect the worm ball nut preload using the SST.

49 0180 510B

Worm ball nut preload


1.01.3 Nm {1014 kgfcm, 8.712.1 inlbf}
[Without the sector shaft]
2. If not as specified, adjust the preload.
(1) Loosen the locknut and turn the adjusting
screw using the SST.
Locknut Disassembly Note
 Remove the locknut using the SST.

49 U032 201
49 U032 201

N8

MANUAL STEERING
(2) Tighten the locknut to the specified torque
using the SST.
Tightening torque
128166 Nm {1317 kgfm, 95122 ftlbf}
49 U032 201
49 U034 209

5. Wipe away excessive grease.


STEERING GEAR AND LINKAGE INSPECTION
Steering Gear Backlash Adjustment
Caution
 Adjust the backlash while keeping the
steering gear in the center position.
Otherwise, the backlash becomes
excessively small and gears may be
damaged.

(3) Inspect the worm ball nut preload again.


Sector Shaft Assembly Note
1. Set the adjusting screw and shim, in the T
groove.
2. Measure the clearance in the axial direction.

 Turn the adjusting screw to adjust steering gear

backlash.
Backlash
0 mm
ADJUSTING
SHIM

3. Adjust the clearance to the specified value if the


clearance is more than the specified value.
Clearance
00.1 mm (00.004 in)
Adjusting shim thickness
1.97 mm {0.077 in} 2.00 mm {0.079 in}
2.03 mm {0.079 in} 2.06 mm {0.081 in}
2.09 mm {0.082 in}
Caution
 Be careful not to damage the oil seal and
bearing.
4. Assemble the sector shaft in such a way that the
teeth of the sector shaft mesh with the center part
of the teeth of the worm ball nut.
Dust Boot Assembly Note
1. Wipe the grease off the ball joint.
2. Put a small amount of lithium-based grease into a
new dust boot.
3. Install the dust boot onto the ball joint.
4. Set the SST over the boot and install a new clip.

N9

MANUAL STEERING
(2) Tighten the locknut to the specified torque
using the SST.
Tightening torque
128166 Nm {1317 kgfm, 95122 ftlbf}
49 U032 201
49 U034 209

5. Wipe away excessive grease.


STEERING GEAR AND LINKAGE INSPECTION
Steering Gear Backlash Adjustment
Caution
 Adjust the backlash while keeping the
steering gear in the center position.
Otherwise, the backlash becomes
excessively small and gears may be
damaged.

(3) Inspect the worm ball nut preload again.


Sector Shaft Assembly Note
1. Set the adjusting screw and shim, in the T
groove.
2. Measure the clearance in the axial direction.

 Turn the adjusting screw to adjust steering gear

backlash.
Backlash
0 mm
ADJUSTING
SHIM

3. Adjust the clearance to the specified value if the


clearance is more than the specified value.
Clearance
00.1 mm (00.004 in)
Adjusting shim thickness
1.97 mm {0.077 in} 2.00 mm {0.079 in}
2.03 mm {0.079 in} 2.06 mm {0.081 in}
2.09 mm {0.082 in}
Caution
 Be careful not to damage the oil seal and
bearing.
4. Assemble the sector shaft in such a way that the
teeth of the sector shaft mesh with the center part
of the teeth of the worm ball nut.
Dust Boot Assembly Note
1. Wipe the grease off the ball joint.
2. Put a small amount of lithium-based grease into a
new dust boot.
3. Install the dust boot onto the ball joint.
4. Set the SST over the boot and install a new clip.

N9

ENGINE SPEED SENSING POWER STEERING

ENGINE SPEED SENSING POWER


STEERING
AIR BLEEDING
1. Inspect the fluid level. (Refer to ENGINE SPEED
SENSING POWER STEERING, POWER
STEERING FLUID INSPECTION, Fluid Level
Inspection.)
2. Jack up the front of the vehicle and support it on
safety stands.
3. Turn the steering wheel fully to the left and right
several times with the engine not running.
4. Reinspect the fluid level. If it has dropped, add
fluid.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.
6. Lower the vehicle.
7. Start the engine and let it idle.
8. Turn the steering wheel fully to the left and right
several times.
9. Verify that the fluid is not foamy and that the fluid
level has not dropped.
10. Add fluid as necessary and repeat Steps 8 and 9.

POWER STEERING FLUID INSPECTION


Fluid Level Inspection
 Inspect the power steering fluid level. Add fluid to
the specified level as necessary.
Fluid specification
ATF MIII or equivalent (e.g. Dexron II)
Fluid Leakage Inspection
Caution
 To prevent damage to the steering system,
do not keep the steering wheel in the fully
turned position for more than 5 seconds.
1. Start the engine and let it idle. Turn the steering
wheel fully to the left and right to apply fluid
pressure.
Note
 The points where fluid leakage may occur are
indicated in the figure.
2. Inspect for fluid leakage.

R.H.D.

L.H.D.

F2 CIS
F2 CARB

F2 CIS
F2 CARB

WL
WL TURBO

WL
WL TURBO

G6

G6

N10

ENGINE SPEED SENSING POWER STEERING

ENGINE SPEED SENSING POWER


STEERING
AIR BLEEDING
1. Inspect the fluid level. (Refer to ENGINE SPEED
SENSING POWER STEERING, POWER
STEERING FLUID INSPECTION, Fluid Level
Inspection.)
2. Jack up the front of the vehicle and support it on
safety stands.
3. Turn the steering wheel fully to the left and right
several times with the engine not running.
4. Reinspect the fluid level. If it has dropped, add
fluid.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.
6. Lower the vehicle.
7. Start the engine and let it idle.
8. Turn the steering wheel fully to the left and right
several times.
9. Verify that the fluid is not foamy and that the fluid
level has not dropped.
10. Add fluid as necessary and repeat Steps 8 and 9.

POWER STEERING FLUID INSPECTION


Fluid Level Inspection
 Inspect the power steering fluid level. Add fluid to
the specified level as necessary.
Fluid specification
ATF MIII or equivalent (e.g. Dexron II)
Fluid Leakage Inspection
Caution
 To prevent damage to the steering system,
do not keep the steering wheel in the fully
turned position for more than 5 seconds.
1. Start the engine and let it idle. Turn the steering
wheel fully to the left and right to apply fluid
pressure.
Note
 The points where fluid leakage may occur are
indicated in the figure.
2. Inspect for fluid leakage.

R.H.D.

L.H.D.

F2 CIS
F2 CARB

F2 CIS
F2 CARB

WL
WL TURBO

WL
WL TURBO

G6

G6

N10

ENGINE SPEED SENSING POWER STEERING


Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.

7. Close the gauge valve completely. Increase the


engine speed to 1,0001,500 rpm and measure
the fluid pressure generated by the oil pump. If the
pressure is not within the specification, replace the
oil pump component.

49 1232 670A

Oil pump fluid pressure


8.99.3 MPa
{9095 kgf/cm2, 12801350 psi}
THERMOMETER
5060 C {122140 F}

49 H002 671

GAUGE
CLOSE VALVE
COMPLETELY

2. Mark both hose connections to ensure that the


hose is reinstalled in its original position.
3. Disconnect the pressure hose from the oil pump.
Attach the SST (49 G032 304).
Tightening torque
G6:
3247 Nm {3.24.8 kgfm, 2434 ftlbf}
F2 CIS, F2 CARB, WL, WL Turbo:
3044 Nm {3.04.5 kgfm, 2232 ftlbf}

Caution
 If the steering wheel is kept in the fully
turned position for more than 5 seconds,
the fluid temperature will rise excessively
and adversely affect the oil pump.

4. Connect the SSTs (49 1232 670A and 49 H002 671)


to the SST (49 G032 304).
G6

8. Open the gauge valve fully and increase the


engine speed to 1,0001,500 rpm.
9. Turn the steering wheel fully to left and right and
measure the fluid pressure generated at the gear
housing. If the pressure is not within the
specification, repair or replace the steering gear
component.

49 B032 304

Gear housing fluid pressure


8.99.3 MPa
{9095 kgf/cm2, 12801350 psi}
F2 CIS, F2 CARB, WL, WL TURBO

THERMOMETER
5060 C {122140 F}

49 G032 3A4

GAUGE
OPEN VALVE
COMPLETELY

49 H002 671

5. Bleed the air from the system.


6. Open the gauge valve fully. Start the engine and
turn the steering wheel fully left and right to raise
the fluid temperature to 5060 C {122140 F}.
Caution
 If the valve is left closed for more than 5
seconds, the fluid temperature will increase
excessively and adversely affect the oil
pump.

10. Remove the SSTs. Install and tighten the pressure


pipe to the specified torque.
Tightening torque
3044 Nm {3.04.5 kgfm, 2232 ftlbf}
11. Bleed the air from the system.

N11

ENGINE SPEED SENSING POWER STEERING


Note
 To determine whether the steering effort is
satisfactory or not, perform the inspection on
another vehicle of the same model and under
the same conditions, and compare the results.
 The steering wheel effort varies with conditions
as shown below.
1. Road conditions, such as dry or wet, and
asphalt or concrete.
2. Tire conditions, such as brand, wear, and
tire pressure.
12. If not as specified, inspect the following points:
 Air in system
 Fluid leakage at hose or connectors
 Function of oil pump and steering gear
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION
(Refer to MANUAL STEERING, STEERING WHEEL
AND COLUMN REMOVAL/INSTALLATION.)
STEERING SHAFT INSPECTION
(Refer to MANUAL STEERING, STEERING SHAFT
INSPECTION.)
STEERING WHEEL AND COLUMN INSPECTION
Steering Wheel Play Inspection
(Refer to MANUAL STEERING, STEERING WHEEL
AND COLUMN INSPECTION, Steering Wheel Play
Inspection.)
Steering Wheel Looseness Inspection
(Refer to MANUAL STEERING, STEERING WHEEL
AND COLUMN INSPECTION, Steering Wheel
Looseness Inspection.)
Steering Wheel Effort Inspection
1. Inspect the following points:
 Tire size and tire pressure
 Fluid level
2. With the vehicle on a hard, level surface, put the
wheels in the straight-ahead position.
3. Start the engine and warm the power steering fluid
to 5060 C {122140 F}.
4. Remove the air bag module, if equipped. (Refer to
section T, AIR BAG SYSTEM, DRIVER-SIDE AIR
BAG MODULE REMOVAL/INSTALLATION.)
5. Measure the steering wheel effort using a torque
wrench.

Steering wheel effort


7.8 Nm {80 kgfcm, 69 inlbf} max.

N12

ENGINE SPEED SENSING POWER STEERING


Note
 To determine whether the steering effort is
satisfactory or not, perform the inspection on
another vehicle of the same model and under
the same conditions, and compare the results.
 The steering wheel effort varies with conditions
as shown below.
1. Road conditions, such as dry or wet, and
asphalt or concrete.
2. Tire conditions, such as brand, wear, and
tire pressure.
12. If not as specified, inspect the following points:
 Air in system
 Fluid leakage at hose or connectors
 Function of oil pump and steering gear
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION
(Refer to MANUAL STEERING, STEERING WHEEL
AND COLUMN REMOVAL/INSTALLATION.)
STEERING SHAFT INSPECTION
(Refer to MANUAL STEERING, STEERING SHAFT
INSPECTION.)
STEERING WHEEL AND COLUMN INSPECTION
Steering Wheel Play Inspection
(Refer to MANUAL STEERING, STEERING WHEEL
AND COLUMN INSPECTION, Steering Wheel Play
Inspection.)
Steering Wheel Looseness Inspection
(Refer to MANUAL STEERING, STEERING WHEEL
AND COLUMN INSPECTION, Steering Wheel
Looseness Inspection.)
Steering Wheel Effort Inspection
1. Inspect the following points:
 Tire size and tire pressure
 Fluid level
2. With the vehicle on a hard, level surface, put the
wheels in the straight-ahead position.
3. Start the engine and warm the power steering fluid
to 5060 C {122140 F}.
4. Remove the air bag module, if equipped. (Refer to
section T, AIR BAG SYSTEM, DRIVER-SIDE AIR
BAG MODULE REMOVAL/INSTALLATION.)
5. Measure the steering wheel effort using a torque
wrench.

Steering wheel effort


7.8 Nm {80 kgfcm, 69 inlbf} max.

N12

ENGINE SPEED SENSING POWER STEERING


STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3247
{3.24.8, 2434}
2435
{2.43.6, 1826}
3754
{3.75.5, 2739}

2026
{2.02.7, 1519}

SST
6978
{7.08.0, 5157}

SST

79157
{7.016.0, 58115}

R
3754
{3.75.5, 2739}

4558
{4.56.0, 3343}

SST

R
4558
{4.56.0, 3343}

SST

SST
Nm {kgfm, ftlbf}

Cotter pin

11

Idler arm bracket

Locknut

12

Pressure pipe

Ball joint
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Ball
Joint Removal Note

13

Return pipe

14

Bolt

15

Bolt, nut, washer

Locknut

16

Tie rod

Center link

Steering gear and pitman arm


+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Steering
Gear and Pitman Arm Removal Note

Idler arm
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Idler
Arm Removal Note

17

Bushing

Washer

Dust boot
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Dust
Boot Disassembly Note
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Dust
Boot Assembly Note

10

Bolt, nut, washer

N13

ENGINE SPEED SENSING POWER STEERING


STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
5764
{5.76.5, 4247}
3044
{3.04.5, 2232}

R
R

R
R

R
R

R
R
5663
{5.76.5, 4247}

SST
R

197235
{20.024.0,
145173}

SST

Nut

O-ring

Pitman arm
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Pitman
Arm Disassembly Note

Y packing

10

Back up ring

11

Oil seal

Clip

12

Back up ring

Dust boot
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Dust
Boot Assembly Note

13

Y packing

14

Dust cover

15

Snap ring

16

Washer

17

Oil seal

18

Valve and piston component


+ Assembly Note

19

O-ring

20

Seal ring

21

Gear housing

Locknut
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut
(Side Cover), Sector Shaft Disassembly Note
Sector shaft
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut
(Side Cover) Sector Shaft Disassembly Note
Side cover

N14

Nm {kgfm, ftlbf}

ENGINE SPEED SENSING POWER STEERING


Valve and Piston Component Assembly Note
Caution
 Do not scratch the seal ring and O-ring on
the piston against the entrance to the
housing.
 Insert the piston by slightly turning to the
left and right so as not to create flection at
the O-ring and seal ring.
 Insert the valve and piston component to the gear

housing.

STEERING GEAR AND LINKAGE INSPECTION


(Refer to MANUAL STEERING, STEERING GEAR
AND LINKAGE INSPECTION, Steering Gear Backlash
Adjustment.)

N15

ENGINE SPEED SENSING POWER STEERING


Valve and Piston Component Assembly Note
Caution
 Do not scratch the seal ring and O-ring on
the piston against the entrance to the
housing.
 Insert the piston by slightly turning to the
left and right so as not to create flection at
the O-ring and seal ring.
 Insert the valve and piston component to the gear

housing.

STEERING GEAR AND LINKAGE INSPECTION


(Refer to MANUAL STEERING, STEERING GEAR
AND LINKAGE INSPECTION, Steering Gear Backlash
Adjustment.)

N15

ENGINE SPEED SENSING POWER STEERING


POWER STEERING OIL PUMP REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. For F2 CIS, F2 Carb and G6 engine model, adjust the drive belt. (Refer to Section B1 or B3, DRIVE BELT,
DRIVE BELT ADJUSTMENT.)
F2 CIS, F2 CARB

3044
{3.04.5, 2232}

3039
{3.04.0, 2228}

SST
5059
{5.06.0, 3743}
Nm {kgfm, ftlbf}

N16

ENGINE SPEED SENSING POWER STEERING

G6

1925
{1.92.6, 1418}

3246
{3.24.7, 2433}

3247
{3.24.8, 2434}

5059
{5.06.0, 3743}

SST

CLAMP
POSITION

30 mm
{1.2 in}

Nm {kgfm, ftlbf}

Drive belt

Return hose

Locknut
+ Removal Note

Power steering fluid pressure switch connector


(except F2 Carb)

Oil pump pulley

Power steering oil pump component

Pressure pipe (F2 CIS, F2 Carb), pressure hose


(G6)

Locknut Removal Note


 Secure the pulley using the SST and remove the
locknut.

49 G032 354

N17

ENGINE SPEED SENSING POWER STEERING

WL, WL TURBO

3044
{3.04.5, 2232}

1925
{1.92.6, 1418}

1925
{1.92.6,
1418}

Nm {kgfm, ftlbf}

Pressure pipe

Power steering oil pump

Return hose

O-ring

Bolt and nut

N18

ENGINE SPEED SENSING POWER STEERING


POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY
1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs
are necessary.
2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of disassembly.

9.913.7 Nm
{100140 kgfcm,
87121 inlbf}

1519
{1.52.0,
1114}

7.911.7 Nm
{80120 kgfcm,
70104 inlbf}

G6

2225
{2.22.6, 1618}

R
F2 CIS
5068
{5.07.0,
3750}

F2 CARB

1821
{1.82.2, 1416}

1623
{1.62.4, 1217}

2225
{2.22.6, 1618}

Nm {kgfm, ftlbf}

SST

Power steering oil pump component


+ Disassembly Note

13

Rear body
+ Assembly Note

Pressure switch component

14

O-ring

O-ring

15

Nut (G6)

Cam ring
+ Assembly Note

Connector (G6)

16

Rotor

Connector bolt

17

O-ring

Vane
+ Assembly Note

Control valve component

18

Pin

Spring

19

Side plate
+ Assembly Note

10

Suction pipe

20

O-ring

11

O-ring

21

Oil seal

12

Shaft component

22

Front body

N19

ENGINE SPEED SENSING POWER STEERING


Power Steering Oil Pump Disassembly Note

3. Install the vanes in the rotor with the rounded edges


outward.

Caution
 To secure the oil pump in a vise, use the SST
as shown to prevent damage to the pump.

ROUND EDGE

49 F032 301

Rear Body Assembly Note


 After installing the rear body, manually turn the shaft
to verify that it rotates smoothly.
Side Plate Assembly Note
1. Install a new O-ring and the side plate to the front
body.
2. Position the side plate using the rear body.

Vane, Cam Ring Assembly Note


1. Install the cam ring with the marks facing the front
body.

2. Install the rotor with the mark facing the rear body.
MARK

N20

ENGINE SPEED SENSING POWER STEERING


POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY
1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs
are necessary.
2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of disassembly.
R

7.911.7 Nm
{80120 kgfcm,
69.5104.1 inlbf}

2225
{2.22.6, 1618}

R
SST

R
R

5068
{5.07.0, 3750}
Nm {kgfm, ftlbf}

Power steering oil pump component


+ ENGINE SPEED SENSING POWER
STEERING, POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Power Steering
Oil Pump Component Disassembly Note

10

Cam ring
+ ENGINE SPEED SENSING POWER
STEERING POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Cam Ring
Assembly Note

2
3

Suction pipe

11

Rotor

O-ring

12

Vane
+ ENGINE SPEED SENSING POWER
STEERING, POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Vane
Assembly Note

Connector

O-ring

Control valve

7
8

Spring

13

Rear body
+ ENGINE SPEED SENSING POWER
STEERING, POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Rear Body
Assembly Note

Side plate
+ ENGINE SPEED SENSING POWER
STEERING, POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Side Plate
Assembly Note

14

O-ring

O-ring

15

Front body

N21

BRAKING SYSTEM
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . .
CONVENTIONAL BRAKE SYSTEM . . . . . . . . . . .
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . .
VACUUM LINE INSPECTION . . . . . . . . . . . . . .
BRAKE PEDAL INSPECTION . . . . . . . . . . . . . .
BRAKE PEDAL REMOVAL/INSTALLATION . .
BRAKE SWITCH INSPECTION . . . . . . . . . . . . .
MASTER CYLINDER REMOVAL/
INSTALLATION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER REMOVAL/
INSTALLATION (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
FLUID LEVEL SENSOR INSPECTION . . . . . .
MASTER CYLINDER DISASSEMBLY/
ASSEMBLY (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER DISASSEMBLY/
ASSEMBLY (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
POWER BRAKE UNIT INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
POWER BRAKE UNIT INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
POWER BRAKE UNIT REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
VACUUM SWITCH INSPECTION (DIESEL) . .
VACUUM SWITCH
REMOVAL/INSTALLATION (DIESEL) . . . . . .
VACUUM PUMP INSPECTION (DIESEL) . . . .
VACUUM PUMP REMOVAL/INSTALLATION
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE INSPECTION (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE INSPECTION (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE ADJUSTMENT
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE ADJUSTMENT
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
FRONT BRAKE (DISC) INSPECTION . . . . . . .
FRONT BRAKE (DISC) REMOVAL/
INSTALLATION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
DISC PAD (FRONT) REPLACEMENT
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
FRONT BRAKE (DISC) REMOVAL/
INSTALLATION (4x4) (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . . . .

P
P
P
P
P
P
P

2
3
3
3
3
4
5

P 5
P 8
P10
P11
P13
P14
P15
P16
P16
P17
P17
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27

DISC PAD (FRONT) REPLACEMENT


(4x4) (VEHICLES BUILT FROM 08/2002) . . . P29
CALIPER (FRONT) DISASSEMBLY/
ASSEMBLY (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P29
CALIPER (FRONT) DISASSEMBLY/
ASSEMBLY (4x4) (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P30
REAR BRAKE (DRUM) INSPECTION . . . . . . . P31
REAR BRAKE (DRUM) REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . P31
BRAKE DRUM INSPECTION . . . . . . . . . . . . . . . P32
WHEEL CYLINDER DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P32
PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . P32
PARKING BRAKE (STICK TYPE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . P32
PARKING BRAKE (STICK TYPE)
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . P32
PARKING BRAKE LEVER (STICK TYPE)
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P33
PARKING BRAKE CABLE (STICK TYPE)
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P34
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . P35
ABS LOCATION INDEX . . . . . . . . . . . . . . . . . . . P35
ABS HU/CM SYSTEM INSPECTION . . . . . . . . P36
ABS HU/CM REMOVAL/INSTALLATION . . . . . P38
ABS HU/CM INSPECTION . . . . . . . . . . . . . . . . . P39
FRONT ABS WHEELSPEED SENSOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P42
FRONT ABS WHEELSPEED SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . P43
REAR ABS WHEELSPEED SENSOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P45
REAR ABS WHEELSPEED SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . P46
G SENSOR REMOVAL/INSTALLATION . . . . . P47
G SENSOR INSPECTION . . . . . . . . . . . . . . . . . P47
ONBOARD DIAGNOSTIC (ANTILOCK BRAKE
SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P48
ABS SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . P48
ABS ONBOARD DIAGNOSTIC . . . . . . . . . . . . P49
DTC TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P51
DTC PID/DATA MONITOR TABLE . . . . . . . . . . P53
ACTIVE COMMAND MODES TABLE . . . . . . . . P55
DTC B1318 (63) . . . . . . . . . . . . . . . . . . . . . . . . . . P56
DTC B1342 (61) . . . . . . . . . . . . . . . . . . . . . . . . . . P57
DTC C1095 (54), C1096 (53) . . . . . . . . . . . . . . . P58
DTC C1140 (30) . . . . . . . . . . . . . . . . . . . . . . . . . . P59
DTC C1145 (11), C1155 (12), C1165 (13),
C1175 (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P60
DTC 1148 (41), C1158 (42), C1168 (43),
C1178 (44), C1233 (46), C1234 (45)
C1235 (47), C1236 (48) . . . . . . . . . . . . . . . . . . P62
DTC 1186 (51), C1266 (52) . . . . . . . . . . . . . . . . P65
DTC C1194 (24), C1198 (25), C1202 (26)
C1206 (27), C1210 (22), C1214 (23) . . . . . . . P67
DTC C1414 (64) . . . . . . . . . . . . . . . . . . . . . . . . . . P67
DTC C1510 (32), C1511 (33), C1512 (34),
C1513 (35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P68

P1

DTC C1949 (03), C1950 (04) . . . . . . . . . . . . . . .


TROUBLESHOOTING (ANTILOCK BRAKE
SYSTEM) (2003 MY ONWARDS) . . . . . . . . . . . .
ABS SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . .
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYMPTOM TROUBLESHOOTING . . . . . . . . . .
NO.1 ABS WARNING LIGHT DOES NOT
ILLUMINATE WITH IGNITION SWITCH
(ENGINE SWITCH) ON . . . . . . . . . . . . . . . . . . .
NO.2 ABS WARNING LIGHT STAYS ON FOR
MORE THAN 4 SECONDS WITH IGNITION
SWITCH (ENGINE SWITCH) ON . . . . . . . . . .

P69

NO.3 THERE IS A MALFUNCTION IN


SYSTEM EVEN THOUGH ABS WARNING
LIGHT INDICATES THAT THE SYSTEM
IS NORMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P78

P71
P71
P72
P72
P73
P73
P74

GENERAL PROCEDURES
Wheel and tires removal/installation
D The removal and installation procedures for the
wheels and tires are not mentioned in this section.
When a wheel is removed, retighten the wheel nuts
to the specified torque. (See TD Wheels and Tires.
Brake lines disconnection/connection
Caution
D Brake fluid will damage painted surfaces. If
brake fluid get on a painted surface, wipe it
off immediately.
D If any brake line has been disconnected anytime

during the procedure, add brake fluid, bleed the


brakes, and inspect leakage after the procedure
has been completed.

Brake pipe flare nut tightening


D Tighten the brake pipe flare nut by using the SST
(49 0259 770B). Be sure to modify the brake pipe
flare nut tightening torque to allow for use of a
torque wrench-SST combination. (Refer to section
GI, FUNDAMENTAL PROCEDURES, TORQUE
FORMULAS.)
Connectors disconnection
D Disconnect the negative battery cable before
performing any work that requires handling of
connectors. Reconnect the negative battery cable
only after the work is completed.
ABS components operation Note
D Make sure that there are no DTCs in the ABS
memory after working on ABS components. If there
are any DTCs in the memory, clear them.

Fluid specification
SAE J1703 or FMVSS116 DOT3 or DOT4

P2

CONVENTIONAL BRAKE SYSTEM

CONVENTIONAL BRAKE SYSTEM


AIR BLEEDING
Note
D The reservoir should be kept 3/4 full during
bleeding.
D The brakes should be bled whenever a brake
line is disconnected. If a hydraulic line is
disconnected at the master cylinder, start at the
slave cylinder farthest from the brake master
cylinder, and move to the next farthest slave
cylinder until all four cylinders have been bled.
If the disconnection point is anywhere except
the master cylinder, start at the point closest to
the disconnection, and move to the next
closest slave cylinder until all four cylinders
have been bled.
1. Remove the bleeder cap and attach a vinyl tube to
the bleeder screw.
2. Place the other end of the vinyl tube in a clear
fluid-filled container.
3. One person should depress the brake pedal a few
times, and then hold it in the depressed position.
4. A second person should loosen the bleeder screw,
drain out the fluid and retighten the screw using the
SST.

VACUUM LINE INSPECTION


1. Remove the clamps and the vacuum hose.
2. Apply both suction and pressure to the engine-side
hose (Gasoline) or vacuum pump side of the hose
(Diesel), and verify that air blows only toward that
side. If air flows in both directions or not at all,
replace the vacuum hose.

CHECK VALVE

ENG

BRAKE PEDAL INSPECTION


Brake Pedal Height Inspection
D Verify that the distance from the center of the
upper surface of the pedal pad to the floor panel is
as specified.

Tightening torque
Front:
914 Nm {92142 kgfcm, 80123 inlbf}
Rear:
5.98.8 Nm {6090 kgfcm, 5378 inlbf}

Pedal height
L.H.D.: 214219 mm {8.438.81 in}
R.H.D.:219224 mm {8.638.81 in}

PEDAL HEIGHT

49 0259 770B

5. Repeat steps 3 and 4 until no air bubbles are seen.


6. After air bleeding, inspect the following:
(1) brake operation
(2) fluid leakage
(3) fluid level

P3

CONVENTIONAL BRAKE SYSTEM


Brake Pedal Height Adjustment
1. Disconnect the brake switch connector.
2. Loosen locknut B and turn switch A until it does not
contact the pedal.
3. Loosen locknut D and turn rod C to adjust the height.
4. Tighten the bolt with locknut B so that clearance
between the bolt for brake light switch A and pedal
stopper is within the specification.

Specification
0.11.0 mm {0.0040.039 in}
Tightening torque
1417 Nm {140180 kgfcm, 122156 inlbf}
5. Connect the brake switch connector.
6. After adjustment, inspect the pedal play and the
brake light operation.

5. After adjustment, inspect the pedal height and the


brake light operation.
Pedal-to-floor Clearance Inspection
1. Start the engine and verify that the distance from
the floor panel to the pedal pad center is as
specified when the pedal is depressed with a force
of 589 N {60 kgf, 132 lbf}.

Clearance
105 mm {4.2 in} min.
C

Brake Pedal Play Inspection


1. Depress the pedal a few times to eliminate the
vacuum in the system.
2. Remove the snap pin, verify that the holes in the
fork and in the pedal are aligned, and reinstall the
pin.
3. Gently depress the pedal by hand until resistance
is felt (approx. 20N {2 kgf, 4.4 lbf}) and inspect
the free play.

PEDAL-TO-FLOOR
CLEARANCE

2. If the distance is less than specified, inspect the


following:
(1) Air in brake system
(2) Malfunction of the automatic adjuster
(3) Excessive shoe clearance

Pedal play
38 mm {0.120.31 in}

Brake Pedal Play Adjustment


1. Remove the snap pin and clevis pin.
2. Loosen locknut D and turn rod C to align the holes
in the fork and in the pedal.
3. Install the clevis pin and the snap pin.
4. Tighten locknut D.

BRAKE PEDAL REMOVAL/INSTALLATION


R.H.D.
The brake pedal is mounted on the bracket
integrated with the clutch pedal and accelerator
pedal. Refer to section F1F4, INTAKE AIR
SYSTEM, ACCELERATOR PEDAL
REMOVAL/INSTALLATION for the brake pedal
removal/installation.
L.H.D.
The brake pedal is mounted on the bracket
integrated with the clutch Pedal. Refer to section
H, CLUTCH PEDAL REMOVAL/INSTALLATION for
the brake pedal removal/installation.

Tightening torque
2434 Nm {2.43.5 kgfm, 1825 ftlbf}

P4

CONVENTIONAL BRAKE SYSTEM


BRAKE SWITCH INSPECTION
1. Disconnect the brake switch connector.
2. Inspect for continuity between the terminals of the
brake switch connector using the circuit tester.
: Continuity

R.H.D.

Terminal

Condition

SST

When the brake pedal is


depressed.
When the brake pedal is
not depressed.

SST *
12.921.5
{130220, 113190}

9.8115.6
{100160, 87138}

B
* 49 0259 770B

3. If not as specified, replace the brake switch.


MASTER CYLINDER REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
L.H.D.

Nm {kgfcm, inlbf}

Brake fluid level sensor connector

Brake pipe

Bracket (R.H.D.)

Master cylinder
+ Installation Note

O-ring

Master Cylinder Installation Note


1. Loosen the adjusting nut of the SST.
2. Place the SST on the power brake unit and tighten
the nut and washer.
Tightening torque
9.8115.6 Nm
{100160 kgfcm, 87138 inlbf}

SST

3. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum to


the power brake unit using a vacuum pump.

9.8115.6
{100160, 87138}

SST *
12.921.5
{130220, 113190}

* 49 0259 770B

Nm {kgfcm, inlbf}

49 B043 001

P5

CONVENTIONAL BRAKE SYSTEM


4. Turn the adjusting nut of the SST counterclockwise
until the gauge rod just contacts the push rod end
of the power brake unit. Push lightly on the end of
the gauge rod to be sure it is seated. Verify that
there is no gap between the adjusting nut and SST
body.
5. Remove the SST from the power brake unit.

Clearance at B
1. Measure and record the height D1 of the gauge
rod.

(D1)

TOUCHING

49 B043 001

49 B043 001

2. Turn the adjusting nut until the SST body sets


closely on the master cylinder. Turn only enough
for the body to touch.
3. Measure and record height D2 of the gauge rod.

TOUCHING
ADJUSTING NUT

6. Remove the SST from the power brake unit without


disturbing the adjusting nut. Set the SST onto the
master cylinder as shown in the figure.
7. Push lightly on the end of the SST gauge rod to be
sure that it is contacting the bottom of the master
cylinder piston, but do not push so hard that the
piston moves. Note any clearance between the
SST body and the adjusting nut: clearance B, or
between the body and the master cylinder:
clearance C. Adjust the push rod as necessary as
outlined in Adjustment below.
Adjustment
Measurement

Push rod

Clearance at B

Too long

Clearance at C

Too short

No clearance at B or C

Okay

ADJUSTING NUT
(D2)

CLEARANCE (B)

49 B043 001

4. Subtract D1 from D2. Using the SST, turn the nut


to shorten the power brake unit push rod an
amount equal to the difference.
49 B043 004

CLEARANCE (C)

49 B043 001
49 E043 003A

CLEARANCE (B)

P6

CONVENTIONAL BRAKE SYSTEM


Clearance at C
1. Push lightly on the end of the SST gauge rod, and
measure the clearance between the adjusting nut
and the SST body.

CLEARANCE (C)

49 B043 001

2. Using the SSTs, turn the nut to lengthen the power


brake unit push rod an amount equal to the
clearance measured at B.
49 B043 004

49 E043 003A

P7

CONVENTIONAL BRAKE SYSTEM


MASTER CYLINDER REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Brake fluid level sensor connector

Bracket

Brake pipe

Master cylinder
(See Master Cylinder Installation Note)

Master Cylinder Installation Note


1. Turn the nut of the SST clockwise to fully retract
the SST gauge rod. Attach the SST to the power
brake unit.
Tightening torque
9.915 Nm {1.01.6 kgfm, 7.311 ftlbf}
2. Apply vacuum of 66.7 kPa {500 mmHg, 19.7
inHg} using a vacuum pump.

Caution
D When pushing the SST gauge rod into the
master cylinder piston, only use enough
pressure to push the rod to the bottom of
the piston. If too much pressure is applied,
a false reading will occur.

3. Turn the adjusting nut of the SST counterclockwise


until the gauge rod just contacts the push rod end
of the power brake unit. Push lightly on the end of
the gauge rod to be sure it is seated. Verify that
there is no gap between the adjusting nut and SST
body.
4. Remove the SST from the power brake unit without
disturbing the adjusting nut. Set the SST onto the
master cylinder as shown in the figure.

P8

CONVENTIONAL BRAKE SYSTEM


5. Push lightly on the end of the SST gauge rod to be
sure it has contacted the bottom of the master
cylinder piston, but do not push so hard that the
piston moves. Take note of any clearance between
the SST body and the adjusting nut (clearance B)
or between the body and the master cylinder
(clearance C).
Measurement
Clearance at (B)
Clearance at (C)
No clearance at (B) or (C)

Push rod
Too short
Too long

Adjusting the push rod clearance at C or no


clearance at B or C
Note
D The threads of the push rod are specially
designed so that the bolt becomes harder to
turn past a certain point. This is to prevent the
bolt from coming loose. Turn the bolt only
within this range when adjusting.
1. Measure and record height D1 of the gauge rod.
2. Turn the adjusting nut until the SST body sets
squarely on the master cylinder. (Turn only enough
for the body to touch.)

Adjusting the push rod clearance at B


3. Measure and record height D2 of the gauge rod.

Note
D The threads of the push rod are specially
designed so that the bolt becomes harder to
turn past a certain point. This is to prevent the
bolt from coming loose. Turn the bolt only
within this range when adjusting.
1. Push lightly on the end of the SST gauge rod, and
measure the clearance between the adjusting nut
and the SST body.

2. Using the SST, turn the nut to lengthen the power


booster push rod an amount equal to the sum
subtracting 0.10.4 mm {0.0040.016 in} from
the clearance measured at B.

P9

CONVENTIONAL BRAKE SYSTEM


4. Subtract D1 from D2 and add 0.10.4 mm
{0.0040.016 in}. Using the SST, turn the nut to
shorten the power booster push rod an amount
equal to the sum.

FLUID LEVEL SENSOR INSPECTION


1. Disconnect the sensor connector.
2. Connect an ohmmeter to the connector.
3. Starting with the fluid level above MIN, verify that
there is no continuity.
4. Remove the brake fluid and verify that there is
continuity when the level is below MIN.
: Continuity
Terminal

Fluid level

Below MIN.
Above MIN.

5. If not as specified, replace the sensor.

A
B

P10

CONVENTIONAL BRAKE SYSTEM


MASTER CYLINDER DISASSEMBLY/ASSEMBLY (VEHICLES BUILT UP TO 07/2002)
Caution
D If the master cylinder body is damaged, replace the unit as a component. When securing the master
cylinder in a vise, tighten only the flange of the master cylinder.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

1.01.5
{1015, 8.713}

R
2.02.4 {2025, 1821}

Nm {kgfcm , inlbf}

Cap set

10

Cup

2
3

Screw

11

Primary piston stopper

Reservoir

12

Primary piston

Joint bushing

13

Fluid level sensor

Stop screw
+ Assembly Note

Snap ring

14

O-ring

Spacer

15

Secondary piston

Piston guide

16

Master cylinder body

O-ring

P11

CONVENTIONAL BRAKE SYSTEM


Stop Screw and O-ring Assembly Note
1. Install a new O-ring onto the stop screw.
2. Push the primary piston component in full.
3. Install and tighten the stop screw.
Tightening torque
2.02.4 Nm {2025 kgfcm, 1821 inlbf}

P12

CONVENTIONAL BRAKE SYSTEM


MASTER CYLINDER DISASSEMBLY/ASSEMBLY
(VEHICLES BUILT FROM 08/2002)
1. After removing the brake fluid, disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Cap set

11

Cup

Pin

12

Primary piston stopper

Reservoir

13

Primary piston

Joint bushing

14

Brake fluid level sensor

Stop screw (without ABS)


(See Stop Screw (without ABS) Assembly Note)

Seal and plate assembly

15

Snap ring

Stop pin (with ABS)


(See Stop Pin (with ABS) Assembly Note)

Spacer

16

Gasket

Piston guide

17

Secondary piston

10

Oring

18

Master cylinder body

Stop Screw (without ABS) Assembly Note


1. Push the primary piston component in fully.
2. Install and tighten a new gasket and the stop
screw.
3. Push and release the piston to verify that it is held
by the stop screw.

P13

CONVENTIONAL BRAKE SYSTEM


Stop Pin (with ABS) Assembly Note
1. Install the secondary piston component with the
piston hole facing the stop pin.
2. Install and tighten a new gasket and the stop pin.
3. Push and release the piston to verify that it is held
by the stop pin.

49 U043 004

A
A

49 U043 006

49 U043 005

PEDAL DEPRESSION
FORCE
GAUGE
VACUUM GAUGE

2. After bleeding the air from the SST, conduct the


test as described in the following steps.
a) Inspection for vacuum loss
Unloaded condition
1. Start the engine.
2. Stop the engine when the vacuum gauge reading
reaches 66.7 kPa {500 mmHg, 19.7 inHg}.
3. Observe the vacuum gauge for 15 seconds. If the
gauge shows 63.366.7 kPa {475500 mmHg,
18.719.7 inHg}, the unit is operating.

POWER BRAKE UNIT INSPECTION


(VEHICLES BUILT UP TO 07/2002)
Power Brake Unit Function Inspection
(Simple method)
Note
D Replace power brake unit component as
necessary.
Step 1
1. With the engine stopped, depress the pedal a few
times.
2. With the pedal depressed, start the engine.
3. If the pedal moves down slightly, immediately after
the engine starts, the unit is operating.
Step 2
1. Start the engine.
2. Stop the engine after it has run for 1 or 2 minutes.
3. Depress the pedal with the usual force.
4. If the first pedal stroke is long and becomes shorter
with subsequent strokes, the unit is operating.

Loaded condition
1. Start the engine.
2. Depress the brake pedal with a force of 196 N {20
kgf, 44 lbf}.
3. With the brake pedal depressed, stop the engine
when the vacuum gauge reading reaches 66.7 kPa
{500 mmHg, 19.7 inHg}.
4. Observe the vacuum gauge for 15 seconds. If the
gauge shows 63.366.7 kPa {475500 mmHg,
18.719.7 inHg}, the unit is operating.
b) Inspection for hydraulic pressure
1. When the engine is stopped (vacuum 0 kPa {0
mmHg, 0 inHg}) and the fluid pressure is within
the specification, the unit is operating.

Note
D If a problem is found, inspect for damage on
the check valve or vacuum hose, and examine
the installation. Repair as necessary, and
inspect it again.
Step 3
1. Start the engine.
2. Depress the pedal with the usual force.
3. Stop the engine with the pedal held depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is
operating.
(Inspection using the testers)
1. Connect the SSTs, vacuum gauge, and pedal
depression force gauge as shown in the figure.
Note
D Use commercially available gauges and pedal
depression force gauge.
D Bleed the air from the SST at gauge A.

P14

Pedal force

Fluid pressure

196 N
{20 kgf, 44 lbf}

790 kPa {8 kgf/cm2, 114 psi} min

2. Start the engine. Depress the brake pedal when


the vacuum reaches 66.7 kPa {500 mmHg, 19.7
inHg}. If the fluid pressure is within the
specification, the unit is operating.
Pedal force

Fluid pressure

196 N
{20 kgf, 44 lbf}

8,240 kPa
{84 kgf/cm2, 1,200 psi} min

CONVENTIONAL BRAKE SYSTEM


POWER BRAKE UNIT INSPECTION
(VEHICLES BUILT FROM 08/2002)
Power Brake Unit Function Inspection (Inspection
using gauges)
1. Connect the SST gauges, a vacuum gauge, and a
pedal depression gauge as shown in the figure.
Bleed the air from the SST gauges before
performing the following tests.

Checking for vacuum loss (unloaded condition)


1. Start the engine.
2. Stop the engine when the vacuum gauge indicates
66.7 kPa {500 mmHg, 19.7 inHg).
3. Observe the vacuum gauge for 15 seconds.
D If the gauge indicates 63.466.6 kPa
475500 mmHg, 18.819.6 inHg, the unit is
operating.
Checking for vacuum loss (loaded condition)
1. Start the engine.
2. Depress the brake pedal with a force of 196 N {20
kgf, 44 lbf}.
3. With the brake pedal held depressed, stop the
engine when the vacuum gauge indicates 66.7 kPa
{500 mmHg, 19.7 inHg).
4. Observe the vacuum gauge for 15 seconds.
D If the gauge indicates 63.466.6 kPa
475500 mmHg, 18.819.6 inHg, the unit is
operating.
Checking for hydraulic pressure
1. If the engine is stopped (vacuum 0 kPa {0 mmHg,
0 inHg}) and the fluid pressure is within the
specification, the unit is operating.
Pedal force

Fluid pressure

196 N
{20 kgf, 44 lbf}

790 kPa {8 kgf/cm2, 114 psi}

2. Start the engine. Depress the brake pedal when


the vacuum reaches 66.7 kPa {500 mmHg, 19.7
inHg}.
D If the fluid pressure is within specification, the
unit is operating.
Pedal force

Fluid pressure

196 N
{20 kgf, 44 lbf}

8,040 kPa {82 kgf/cm2, 1,166 psi}

P15

CONVENTIONAL BRAKE SYSTEM


POWER BRAKE UNIT REMOVAL/INSTALLATION
1. Remove the master cylinder. (Refer to
CONVENTIONAL BRAKE SYSTEM, MASTER
CYLINDER REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

VACUUM SWITCH INSPECTION (DIESEL)


1. Remove the vacuum hose from the power brake unit.
2. Set the vacuum pump hose (commercially
available on the market) onto the power brake unit
as shown.

L.H.D.

3. Turn the engine switch on.


4. Release the parking brake.
5. Apply vacuum to the power brake unit using the
vacuum pump (commercially available on the
market) and verify the operating condition of the
brake light warning light.

1925
{1.92.6, 1418}

2434
{2.43.5, 1825}

Vacuum kPa {mmHg, inHg}

Brake warning
light

Below 10.7"1.3 {80"10, 3.2"0.4}

ON

Above 10.7"1.3 {80"10, 3.2"0.4}

OFF

Nm {kgfm, ftlbf}

6. The vacuum switch is functioning normally if it


corresponds to the above specifications. Replace
the vacuum switch as necessary.

R.H.D.

1925
{1.92.6, 1418}

2434
{2.43.5, 1825}

Nm {kgfm, ftlbf}

Vacuum switch connector (Diesel)

Vacuum hose

Snap pin

Clevis pin

Nut

Power brake unit

Gasket

Fork

Nut

P16

CONVENTIONAL BRAKE SYSTEM


VACUUM SWITCH REMOVAL/INSTALLATION
(DIESEL)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

VACUUM PUMP INSPECTION (DIESEL)


1. Warm up the engine.
2. Disconnect the vacuum hose from the vacuum
pump and connect a vacuum gauge as shown in
the figure, then inspect the vacuum.

L.H.D.

Vacuum specification (In 20 seconds)


Engine speed 1,500 rpm
73.3 kPa {550 mmHg, 21.7 inHg}
Maximum vacuum
Engine speed 3,000 rpm
93.3 kPa {700 mmHg, 27.6 inHg}

2024
{2.02.5, 1518}

Nm {kgfm, ftlbf}

R.H.D.

3. If the pressure is less than the specification,


inspect for the following.
(1) Malfunction of the vacuum pump
(2) Shortage of the lubrication oil pressure

2024
{2.02.5, 1518} Nm {kgfm, ftlbf}

Vacuum switch connector

Vacuum switch
+ Installation Note

VACUUM PUMP REMOVAL/INSTALLATION


(DIESEL)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Vacuum Switch Installation Note


1. Remove the old sealant.
Caution
D Do not apply sealant to the tip of the
vacuum switch as a malfunction may occur.
2. Apply sealant to the area shown before installation
of the vacuum switch onto the power brake unit,
and then tighten it to the specified torque.
Tightening torque
2024 Nm {2.02.5 kgfm, 1518 ftlbf}

R
DO NOT APPLY
SEALANT ON
THIS AREA

1925 {1.92.6, 1418}


Nm {kgfm, ftlbf}

P17

Vacuum hose

Bolt

Vacuum pump

O-ring

CONVENTIONAL BRAKE SYSTEM


LOAD SENSING PROPORTIONING VALVE
INSPECTION (VEHICLES BUILT UP TO 07/2002)
1. Place the vehicle on level ground.
2. Inspect the tire inflations and set them to the
recommended pressure as necessary.
3. Prepare the vehicle with a person in the drivers
seat; include the standard vehicle tools, the spare
wheel and tire, and a full tank of fuel.
4. Connect pressure gauges (commercially available)
to the front and rear calipers.

Note
D When applying the specified pressure, the brake
pedal must not be double pumped or released.
D Approximately two seconds after setting the front
wheel cylinder fluid pressure, read the rear pressure.
5. Bleed the air from the brake system.
6. Slowly depress the brake pedal until the front
pressure gauge indicates the specified pressure
shown in the table, then note the reading on the
rear pressure gauge.
kPa {kgf/cm2, psi}
Front pressure

Rear pressure

4,900 {50, 711}

2,550 {26, 370}

9,810 {100, 1,422}

3,530 {36, 512}

LOADED
A PERSON IN
DRIVERS SEAT

REAR PRESSURE
4,900 {50, 711} 9,810 {100, 1,422}
FRONT PRESSURE
kPa {kgf/cm2, psi}

7. If not as specified, replace and adjust the LSPV.

P18

CONVENTIONAL BRAKE SYSTEM


LOAD SENSING PROPORTIONING VALVE (LSPV)
INSPECTION (VEHICLES BUILT FROM 08/2002)
1. Place the vehicle on level ground.
2. Check the tire inflations and set them to the
recommended pressure if necessary.
D If not as specified, replace or adjust.
3. Check the vehicle with a person in the drivers seat;
include the standard vehicle tools, the spare wheel
and tire, and a full tank of fuel.
4. Install the SST to the front wheel cylinder and rear
wheel cylinder, then bleed the air in the brake line
and load sensing proportioning valve (LSPV) using
a air bleed valve A.

5. Inspect the fluid pressure of rear wheel cylinder


while the fluid pressure of front wheel cylinder is
4,900 kPa {50 kgf/cm2, 711 psi} and 9,800 kPa
{100 kgf/cm2, 1,422 psi}.
D If not as specified, adjust the LSPV.

Specification
kPa {kgf/cm2, psi}
Type
Without ABS
4x2
With ABS
Without ABS
4x4
With ABS

Front wheel cylinder


fluid pressure

Rear wheel cylinder

4,900 {50, 711}

2,2502,850 {22.9529.06, 327413}

9,800 {100, 1,422}

3,1303,930 {31.9240.07, 454569}

4,900 {50, 711}

2,9103,710 {29.6837.83, 423538}

9,800 {100, 1,422}

4,9706,170 {50.6862.91, 721894}

4,900 {50, 711}

2,2502,850 {22.9529.06, 327413}

9,800 {100, 1,422}

3,1303,930 {31.9240.07, 454569}

4,900 {50, 711}

2,6503,450 {27.0335.18, 385500}

9,800 {100, 1,422}

4,7005,900 {47.9360.16, 682855}

P19

CONVENTIONAL BRAKE SYSTEM


LOAD SENSING PROPORTIONING VALVE
ADJUSTMENT (VEHICLES BUILT UP TO 07/2002)
1. Place the unloaded vehicle on level ground.
Unloaded condition: Fuel tank is full. Engine
coolant and engine oil are at
specified levels. Spare tire,
jack, and tools are in
designated position.
Note
D A change of 5 mm {0.197 in} dimension L
results in a change of 853 kPa {8.7 kgf/cm2,
124 psi} for 4 2 and 1020 kPa {10.4 kgf/cm2,
148 psi} for 4 4.
2. Adjust main spring dimension L between the LSPV
and the adjustment link by loosening and
repositioning the LSPV.
(1) Decrease dimension L if the fluid pressure is
low.
(2) Increase dimension L if the fluid pressure is
high.
Reference value
Dimension L
4 2: 147.5154.5 mm {5.8086.082 in}
4 4: 175.5182.5 mm {6.9107.185 in}

MAIN SPRING

ADJUSTMENT LINK

AXLE CASING

BOLT

3. After adjustment, recheck the fluid pressure. If not


as specified, replace the LSPV as a component.

P20

CONVENTIONAL BRAKE SYSTEM


kPa {kgf/cm2, psi}

LOAD SENSING PROPORTIONING VALVE (LSPV)


ADJUSTMENT (VEHICLES BUILT FROM 08/2002)

Type

1. Place the unloaded vehicle on level ground.


Unloaded: Fuel tank is full. Engine coolant and tire,
jack and tools are in designated position.

4x4

Note
D A change of 5mm {0.197 in} in dimension L
results in a change of the following.

Specification
Dimension L
mm {in}

4x2
4x4

without ABS

Dimension L

with ABS

147.5154.5
{5.816.08}

without ABS

175.5182.5

with ABS

{6.917.18

without ABS

850 {8.67, 123}

with ABS

1,020 {10.40, 148}

without ABS

1,060 {10.81, 154}

with ABS

1,080 {11.01, 157}

2. Adjust main spring dimension L between the LSPV


and the adjustment link loosening and
repositioning the LSPV.

D Decrease dimension L if the fluid pressure is low.


D Increase dimension L if the fluid pressure is high.

Type

4x2

Change

3. Tighten the nut.


Specification
18.625.4 Nm {1.892.60 kgfm, 13.718.8
ftlbf}
4. After adjustment, recheck the fluid pressure.
D If not as specified, replace the LSPV as a
component

P21

CONVENTIONAL BRAKE SYSTEM


LOAD SENSING PROPORTIONING VALVE
REMOVAL/INSTALLATION (VEHICLES BUILT UP
TO 07/2002)
Caution
D Do not disassemble the LSPV.
D Do not move the nut A.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, adjust the main spring dimension.
(Refer to CONVENTIONAL BRAKE SYSTEM,
LOAD SENSING PROPORTIONING VALVE
ADJUSTMENT.)
12.821.5 Nm
{130220 kgfcm, 113190 inlbf}

SST * 12.821.5 Nm

SST *

{130220 kgfcm,
113190 inlbf}

1925 {1.92.6, 1418}

1925
{1.92.6, 1418}

* 49 0259 770B

Brake pipe

Nut

Bolt

Load sensing proportioning valve

Nm {kgfm, ftlbf}

P22

CONVENTIONAL BRAKE SYSTEM


LOAD SENSING PROPORTIONING VALVE (LSPV)
REMOVAL/INSTALLATION (VEHICLES BUILT FROM
08/2002)
Caution
D Do not disassemble the LSPV.

Brake pipe
(See Brake Pipe Installation Note)

Nut

Brake Pipe Installation Note


1. Install the brake pipe to the load sensing
proportioning valve (LSPV) and align yellow
painting on the brake pipe and LSPV.

P23

D Do not move nut A.

1. Remove in the order indicated in the table.


2. Install in the reverse order of removal.
3. After installation, adjust the main spring dimension.
(See LOAD SENSING PROPORTIONING VALVE
(LSPV) ADJUSTMENT.)

Bolt

Load sensing proportioning valve (LSPV)

CONVENTIONAL BRAKE SYSTEM


FRONT BRAKE (DISC) INSPECTION
Disc Pad Thickness Inspection
1. Jack up the front of the vehicle and support it on safety stands.
2. Remove the wheel and tires.
3. Look through the caliper inspection hole and
inspect the remaining thickness of the pads.
Thickness
2.0 mm {0.08 in} min.
4. Replace the pads as a set (right and left wheels) if
either is at or less than the minimum thickness.

Disc Plate Runout Inspection (Vehicles built up to


07/2002)
1. Verify that there is no wheel bearing looseness.
2. Measure the runout at the outer edge of the
contact surface of the disc pad.
Runout
0.05 mm {0.002 in} max.
3. If the runout is not within the specification, repair or
replace the disc plate.

Disc Plate Thickness Inspection


1. Measure the thickness of the disc plate.
Caution
D When it is necessary to machine the disc
plate, if the disc plate is removed from the
vehicle then machined, excessive runout
may result. Machine the disc plate with it
installed on the vehicle.
(Vehicles built up to 07/2002)
Standard
24 mm {0.94 in}
Minimum
22 mm {0.87 in}
Minimum thickness after machining by using a
brake lathe on-vehicle
22.8 mm {0.90 in}

Disc Plate Runout Inspection (Vehicles built from


08/2002)
1. Tighten the disc plate to the wheel hub using two
wheel nuts. When measuring runout, measure at
the outer edge of the disc plate surface.

(Vehicles built from 08/2002)


Standard thickness:
28.0 mm {1.10 in)
Minimum thickness:
26.0 mm {1.02 in)
Minimum thickness after machining by using a
brake lathe on-vehicle
26.8 mm {1.06 in}
2. If the thickness is not within the specification,
replace the disc plate.

P24

Runout limit
0.05 mm {0.002 in} max.

CONVENTIONAL BRAKE SYSTEM


FRONT BRAKE (DISC) REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.

2229
{2.23.0, 1629}

R
2934
{2.93.5, 2125}

108127
{10.414.0, 8094}

SST

Nm {kgfm, ftlbf}

Brake hose

Bolt

3
4
5

Disc pad
+ Installation Note

Guide pin

Plate

Dust boot

Guide plate

Caliper

Mounting support

P25

CONVENTIONAL BRAKE SYSTEM


Disc Pad Installation Note
1. Push the piston fully inward using the SST.
2. Install the disc pad.

49 0221 600C

DISC PAD (FRONT) REPLACEMENT (VEHICLES


BUILT UP TO 07/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

2934
{2.93.5, 2125}

SST

Nm {kgfm, ftlbf}

Bolt

Caliper

Disc pad
+ CONVENTIONAL BRAKE SYSTEM, FRONT
BRAKE (DISC) REMOVAL/INSTALLATION,
Disc Pad Installation Note

Plate

Guide plate

P26

CONVENTIONAL BRAKE SYSTEM


FRONT BRAKE (DISC) REMOVAL/INSTALLATION (4X4)
(VEHICLES BUILT FROM 08/2002)
Caution
D Performing the following procedures without first removing the ABS wheelspeed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheelspeed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.

Flexible hose

Inner shim (cover shim)


(See Outer Shim, Inner shim Installation Note)

Guide pin

Caliper

Disc pad
(See Disc Pad Installation Note)

Inner shim (rubber coated shim)


(See Outer Shim, Inner shim Installation Note)

Outer shim (cover shim)


(See Outer Shim, Inner shim Installation Note)

Guide plate
(See Guide Plate Removal Note)

10

Mounting support

11

Disc plate
(See Disc Plate Removal Note)
(See Disc Plate Installation Note)

Outer shim (rubber coated shim)


(See Outer Shim, Inner shim Installation Note)

P27

CONVENTIONAL BRAKE SYSTEM


Guide Plate Removal Note
1. Pull up and at a slant on the supporting part of the
guide plate in the direction indicated by the arrow
(1) and (2) as shown in the figure, to remove the
guide plate from the mounting support.
Caution
D If the guide plate is removed by pulling in
the direction indicated by the arrow as
shown in the figure, the stopper may be
deformed and not able to be reused. Do not
remove in this manner
3. Assemble the covershim to the greaseapplied
rubber coated shim.
Caution
D Be careful not to get any grease on the pad
lining surface.

Disc Pad Installation Note


1. Push the piston fully inward using the SST.
2. Install the disc pad.

Disc Plate Removal Note


1. Mark the wheel hub bolt and disc plate before
removal for reference during installation.

Disc Plate Installation Note


1. Remove any rust or grime on the contact face of
the disc plate and wheel hub.
2. Install the disc plate and align the marks made
before removal.
Outer Shim, Inner shim Installation Note
1. Assemble the rubber coated shim to the back plate
of the disc pad.
2. Apply brake grease to the rubber coated shim as
shown in the figure.

P28

CONVENTIONAL BRAKE SYSTEM


DISC PAD (FRONT) REPLACEMENT (4X4)
(VEHICLES BUILT FROM 08/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

CALIPER (FRONT) DISASSEMBLY/ASSEMBLY


(VEHICLES BUILT UP TO 07/2002)
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

*
SST
914
{92143, 80123}

SST

*49 0259 770B

Bolt

Caliper

Guide pin

Disc pad
(See Disc Pad Installation Note)

Outer shim (cover shim)


(See Outer Shim, Inner shim Installation Note)

Outer shim (rubber coated shim)


(See Outer Shim, Inner shim Installation Note

Inner shim (cover shim)


(See Outer Shim, Inner shim Installation Note)

Inner shim (rubber coated shim)


(See Outer shim, Inner shim Installation Note)

Guide plate
(See Guide Plate Removal Note)

Piston
+ Disassembly Note

Dust seal

Piston seal
+ Disassembly Note

Bleeder cap, screw

Caliper body

Nm {kgfcm, inlbf}

Piston Disassembly Note


Caution
D Blow the compressed air slowly to prevent
the piston from suddenly popping out.
D Place a piece of wood in the caliper, then blow

compressed air through the hole to force the piston


out of the caliper.
WOOD

P29

CONVENTIONAL BRAKE SYSTEM


Piston Seal Disassembly Note
D Remove the piston seal from the brake caliper
using the SST.

Dust seal

Piston
(See Piston Disassembly Note)

Piston seal
(See Piston Seal Disassembly Note)

Bleeder cap

Bleeder screw

Caliper

Piston Disassembly Note


Caution
D Blow the compressed air slowly to prevent
the piston from suddenly popping out.

CALIPER (FRONT) DISASSEMBLY/ASSEMBLY


(4X4) (VEHICLES BUILT FROM 08/2002)

1. Place the SST in the caliper, the blow compressed


air through the hole to force the piston out of the
caliper.

1. Disassemble in the order indicated in the table.


2. Assemble in the reverse order of removal.

Piston Seal Disassembly Note


1. Remove the piston seal from the brake caliper
using the SST.

P30

CONVENTIONAL BRAKE SYSTEM


REAR BRAKE (DRUM) INSPECTION
Brake Lining Thickness Inspection
1. Remove the brake drum.
2. Inspect the remaining thickness of the lining.
Thickness
1.0 mm {0.04 in} min.
3. Replace both left and right brake shoes if either is
at or less than the minimum thickness.
REAR BRAKE (DRUM) REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation.
(1) Depress the brake pedal a few times, then verify that the brakes do not drag.
(2) Inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK
TYPE) INSPECTION, Parking Brake Lever Stroke Inspection.)

9.812.7
{100130, 87112}

* SST
12.821.5
{130220, 113190}

APPLY

*49 0259 770B

TO SHADED EREA

Nm {kgfcm, inlbf}

Brake drum

Adjust strut

Hold spring, washer

Brake shoe

Hold pin

10

Parking brake cable

Lower return spring

11

Operating lever

Upper return spring

12

Brake pipe

Pawl lever spring

13

Wheel cylinder

Pawl lever

14

Gasket

P31

CONVENTIONAL BRAKE SYSTEM


BRAKE DRUM INSPECTION
1. Measure the inner diameter of the drum.

PARKING BRAKE SYSTEM


PARKING BRAKE (STICK TYPE) INSPECTION
Parking Brake Lever Stroke Inspection
1. Pull the parking brake lever a few times.
2. Verify that the stroke is within the specification
when the parking brake lever is pulled with a force
of 98 N {10 kgf, 22 ibf}.

Maximum diameter
4 2: 271.5 mm {10.68 in}
4 4: 296.5 mm {11.67 in}
2. Apply chalk to the inside of the brake drum.
3. Inspect for scratches and uneven or abnormal
wear inside the drum as shown in the figure.

Stroke
17 notches
3. If not as specified, adjust the parking brake lever
stroke.
PARKING BRAKE (STICK TYPE) ADJUSTMENT
Parking Brake Lever Stroke Adjustment
1. Before adjustment, depress the brake pedal
several times while the vehicle is moving in
reverse.
2. Loosen the locknut A and turn the adjustment nut
B so that the stroke is within the above range.
3. After adjustment, tighten the locknut A.

4. Repair or replace the drum as necessary. Repair if


the problem is minor.
5. When repairing or replacing the drum, check the
contact with the shoes.
6. Wipe the chalk off after inspection.
WHEEL CYLINDER DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Tightening torque
6.99.8 Nm {70100 kgfcm, 4386 inlbf}

B
A

R
SST *

4. After adjustment, inspect the following points.


(1) Turn the ignition (engine) switch on, pull the
parking brake lever one notch, and verify that
the brake warning light illuminates.
(2) Verify that the rear brakes do not drag when
the wheels are turned by hand.

5.98.8
{ 6090 , 5378 }

* 49 0259 770B

Dust boot

Piston

Piston cap

Spring

Bleeder cap, screw

Cylinder body

Nm { kgfcm , inlbf }

P32

PARKING BRAKE SYSTEM


PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING
BRAKE (STICK TYPE) INSPECTION.)

12.818.6 {130190, 113164}

6.99.8
{70100, 4386}

Nm {kgfcm, inlbf}

Clip

Pin and clip

Joint pin

10

Spring

Cable connector

11

Rachet pawl

Parking brake switch

12

Stopper

Clip

13

Fork joint

Pin

14

Spring

Clip and joint pin

15

Guide

Lever

16

Rod

P33

PARKING BRAKE SYSTEM


PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION
1. Remove the under guard. (Refer to section F1F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING
BRAKE (STICK TYPE) INSPECTION.)
4x2

1622 {1.62.3, 1216}

1622
{1.62.3,
1216}

6.99.8 Nm
{70100 kgfcm,
4386 inlbf}

4x4

1622
{1.62.3, 1216}

6.99.8 Nm
{70100 kgfcm,
4386 inlbf}

1622
{1.62.3, 1216}

1622
{1.62.3, 1216}

1622
{1.62.3,
1216}

1622
{1.62.3, 1216}

Nut

Grommet

Bolt

Bolt

Spring

Spring (4

Front brake cable

10

Clip

Bolt (4

11

Rear cable (left)

Bracket (4

12

Rear cable (right)

4)
4)

P34

4)

Nm {kgfm, ftlbf}

ANTILOCK BRAKE SYSTEM

ANTILOCK BRAKE SYSTEM


ABS LOCATION INDEX

ABS HU/CM
(See ABS HU/CM SYSTEM INSPECTION)
(See ABS HU/CM REMOVAL/
INSTALLATION)
(See ABS HU/CM INSPECTION)
ABS wheel speed (front)
(See FRONT ABS WHEELSPEED SENSOR
REMOVAL/INSTALLATION)
(See FRONT ABS WHEELSPEED SENSOR
INSPECTION)

P35

ABS wheel speed sensor (rear)


(See REAR ABS WHEELSPEED SENSOR
REMOVAL/INSTALLATION)
(See REAR ABS WHEELSPEED SENSOR
INSPECTION)

G sensor (4x4)
(See G SENSOR REMOVAL/INSTALLATION)
(See G SENSOR INSPECTION)

ANTILOCK BRAKE SYSTEM


ABS HU/CM SYSTEM INSPECTION
System Inspection
Preparation
1. Verify that the battery is fully charged. With the ignition switch (engine switch) on, verify that the ABS warning
lights goes out after 3 seconds.
2. If the lights stays on after 3 seconds elapse, the ABS HU/CM detects a failure. Follow the troubleshooting
procedures.
3. Turn the ignition switch (engine switch) off.
4. Jack up the vehicle on level ground and support it evenly on safety stands. Shift the transmission to N position.
5. Release the parking brake.
6. Rotate the wheels by hand, and inspect for brakedrag.
Using the SST (WDS or equivalent)
1. Perform the Preparation. (See Preparation.)
2. Connect the SST (WDS or equivalent) to the data
link connector (DLC).
3. Set up an active command mode inspection
according to the combination of commands below.
(See ABS ONBOARD DIAGNOSTIC.)

COMMAND NAME
OPERATION

PMP
MOTOR

RF
OUTLET

RF
INLET

Pressure
retention

OFF

OFF

ON

Pressure
reduction

ON

COMMAND
TYPE

Manual
ON

OFF

The chart above shows an example of a right wheel inspection.


Note
D When working with two people, one should depress the brake pedal, the other should attempt to rotate the
wheel being inspected.
4. Send the command while depressing on the brake pedal and attempting to rotate the wheel being inspected.
5. When pressure is being maintained, and a click sound indicating the solenoid is operating is heard from the
ABS HU/CM, confirm that the wheel does not rotate. When pressure is being reduced, and the click sound
indicating the solenoid is operating is heard from the ABS HU/CM, confirm that the wheel rotates, even though
the brake pedal is being depressed.
Note
D To protect the ABS HU/CM, the solenoid valve used for simulations and the ABS motor stay on for 10
seconds each time they are switched on.
D Performing the inspections above determines the following.
The ABS HU/CM brake lines are normal.
The ABS HU/CM hydraulic system is not significantly abnormal.
The ABS HU/CM wiring is normal.
D However, the following items cannot be checked.
ABS HU/CM input system harness and parts.
Extremely small leaks in the ABS HU/CM internal hydraulic system.
Unusual intermittent occurrences in the above items.

P36

ANTILOCK BRAKE SYSTEM


6. Turn the ignition switch (engine switch) off and
remove the jumper wire.

Without using the SST (WDS or equivalent)


1. Perform the Preparation (See Preparation.)
Caution
D Connecting to the wrong data link
connector (DLC) terminal may cause a
malfunction. Carefully connect only to the
specified terminal only.
2. Use a jumper wire to short terminal TBS of the
DLC to body ground.
3. Depress the brake pedal, and have an assistant
verify that the right front wheel does not turn.
4. With the brake pedal still depressed, turn the
ignition switch on and verify that the brake is
released momentarily (approx. 0.5 seconds) and
that the wheel turns when pressurereduction
operates.

5. Inspect the operation of the remaining wheels in


order: right front, left front, rear.
D Replace the ABS HU/CM if wheels do not
rotate.
D Inspect brake piping to ABS HU/CM if
operation of the remaining wheel order is not
within specified.

Note
D If Steps 4 and 5 show correct operation, the
following systems are okay:
Brake piping to ABS HU/CM.
Braking system, including ABS HU/CM.
Electrical system in ABS HU/CM (solenoid,
ABS motor, etc.)
D The following are not inspected with above
steps:
Input system and harness of ABS HU/CM.
Intermittent failure.
Fluid leakage from brake including the ABS
HU/CM and master cylinder.

P37

ANTILOCK BRAKE SYSTEM


ABS HU/CM REMOVAL/INSTALLATION
Caution
D Do not drop the ABS HU/CM, Replace it if it is subjected to an impact.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Connector
(See Connector Removal Note)
(See Connector Installation Note)

Stud

Bushing

Brake pipe(See Brake Pipe Removal Note)(See


Brake Pipe Installation Note)

Joint bolt

Gasket

ABS HU/CM component


(See ABS HU/CM Removal/Installation Note

10

Joint
(See Joint Installation Note)

Nut

11

Gasket

Bracket

12

ABS HU/CM

P38

ANTILOCK BRAKE SYSTEM


Connector Removal Note
1. Pull the lock lever to disconnect the connector.

Connector Installation Note


1. Verify that the connection part and waterproof
packing are free of foreign material, then connect
the connector.
2. Verify that the lock lever is completely pushed in.

Brake Pipe Removal Note


1. Mark the brake pipe connecting positions before
removal for reference during installation.

ABS HU/CM INSPECTION


1. Disconnect the negative battery cable.
2. Connect the SST between the ABS HU/CM and
harness connector with the ignition (engine switch)
off.
3. Attach the tester leads to the SST and inspect
voltage referring to the table below.

ABS HU/CM Removal/Installation Note


1. When removing/installing the ABS HU/CM from/to
the vehicle, attach a strip of protective tape on the
ABS HU/CM connector to prevent brake fluid from
entering.
Joint Installation Note
1. Install the Joint with the ABS HU/CM as shown in
the figure.

Brake Pipe Installation Note


1. When install the brake pipe, align the marks made
before removal with the ABS HU/CM DSC HU as
shown in the figure.

P39

ANTILOCK BRAKE SYSTEM


Terminal Voltage Table (Reference)
(Engine is idling, and connector is connected unless otherwise indicated)

Terminal
A
B

Signal

Connected to

RR wheelspeed

RR wheel
speed sensor

C
F

LR wheelspeed

LR wheel
speed sensor

C
F

LR wheelspeed

LR wheel
speed sensor

Test condition

Voltage (V)

Vehicle is stopped.

0 (AC)

D Inspect using the wave profile.

(See Inspection Using An Oscilloscope (Reference))


Vehicle is stopped.

RF wheelspeed

RF wheel
speed sensor

(See Inspection Using An Oscilloscope (Reference))


D Inspect using the wave profile.

(See Inspection Using An Oscilloscope (Reference))

LR wheelspeed

LR wheel
speed sensor

G sensor input

G sensor

sensor.

0 (AC)

(See Inspection Using An Oscilloscope (Reference))


0 (AC)

D Inspect using the wave profile.

(See Inspection Using An Oscilloscope (Reference))


Vehicle is stopped
or driving with
constant speed.

H*1

D Inspect related harness.


D Inspect ABS wheelspeed

D Inspect using the wave profile.

Vehicle is stopped.
I
E

0 (AC)

D Inspect using the wave profile.

Vehicle is stopped.
G
D

Action

2.42.6

Vehicle driving with


acceleration.

2.51.0

Vehicle driving with


deceleration.

2.54.0

D Inspect related harness.


D Inspect G sensor.

J*1

G sensor ground

Onboard
diagnostic

KLN terminal of
DLC

No need to
check

DLC

No need to
check

U*2

G sensor

D Inspect related harness.

Onboard
diagnostic

TBS terminal of
DLC

1014

D Inspect related harness.

Power supply

Ignition switch
(engine switch)

B+

D Inspect related harness.

P40

ANTILOCK BRAKE SYSTEM

Terminal

*1:
*2:

Signal

Connected to

Test condition

Voltage (V)

AA

Power supply
(Solenoid valve)

Battery

B+

AB

Power supply
(ABS motor)

Battery

B+

AC

Ground

Ground

AD

Ground

Ground

4x4 only.
Use this terminal at factory only, not used for inspection and repair at field.

Inspection Using An Oscilloscope (Reference)


Wheel speed
D ABS HU/CM terminal:
RF: G (+)D ()
RR: A (+)B ()
LF: I (+)E ()
LR: C (+)F ()
D Oscilloscope setting: 1 VDIV (Y), 2 msDIV (X), AC
range.
D Vehicle condition: Driving 30 kmh {18.6 mph}

Note
D As vehicle speed increases, period of wave
shortens.
D There is a malfunction is in the sensor rotor,
the wave profile warps.

P41

Action
D Inspect related harness.

D Inspect related harness.


D Inspect related harness.

ANTILOCK BRAKE SYSTEM


FRONT ABS WHEELSPEED SENSOR REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
4x2

Connector

Bolt

P42

Front ABS wheelspeed sensor

ANTILOCK BRAKE SYSTEM


4x4

Connector

Bolt

FRONT ABS WHEELSPEED SENSOR


INSPECTION
Visual Inspection
1. Remove the wheel and tire, and inspect the sensor
for looseness and damage. Replace the sensor if
necessary.

Resistance Inspection
1. Disconnect the ABS wheelspeed sensor
connector.
2. Inspect the resistance at the ABS wheelspeed
sensor.
D If not as specified, replace the ABS
wheelspeed sensor.

Clearance Inspection
1. Inspect the clearance between the wheelspeed
sensor and the sensor rotor.
Clearance
0.31.1 mm {0.0120.043 in}

Front ABS wheelspeed sensor

Resistance
1.21.6 kilohm
Voltage Inspection
1. Jack up the vehicle on level ground and support it
evenly on safety stands.
2. Disconnect the ABS wheelspeed sensor
connector.
3. Inspect each sensor by rotating each wheel one
revolution per second.
D If not as specified, replace the ABS
wheelspeed sensor.
Voltage
0.151.2 V (AC)

P43

ANTILOCK BRAKE SYSTEM


Voltage Pattern Inspection
1. Jack up the vehicle on level ground and support it
evenly on safety stands.
2. Disconnect the ABS wheelspeed sensor
connector.
3. Using an oscilloscope, inspect voltage pattern for
distortion and noise by rotating each wheel.
D If there is distortion or noise, inspect the ABS
sensor rotor.

P44

ANTILOCK BRAKE SYSTEM


REAR ABS WHEELSPEED SENSOR REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Connector

Bolt

P45

Rear ABS wheelspeed sensor

ANTILOCK BRAKE SYSTEM


REAR ABS WHEELSPEED SENSOR INSPECTION
Visual Inspection
1. Inspect the sensor for looseness and damage.
Replace the sensor if necessary.
Clearance Inspection
1. Remove the ABS wheelspeed sensor.
2. Measure the length A and B shown in the figure
using vernier calipers.
3. Subtract B from A then verify the clearance
between the wheelspeed sensor and the sensor
rotor.
Clearance
0.31.1mm {0.0120.043 in}

Resistance Inspection
1. Disconnect the ABS wheelspeed sensor
connector.
2. Inspect the resistance at the ABS wheelspeed
sensor.
D If not as specified, replace the ABS
wheelspeed sensor..
Resistance
1.21.6 kilohm
Voltage Inspection
1. On level ground, jack up the vehicle and support it
evenly on safety stands.
2. Disconnect the ABS wheelspeed sensor
connector.
3. Inspect each sensor by rotating each wheel one
revolution per second.
D If not as specified, replace the ABS
wheelspeed sensor.
Voltage
0.151.2 V (AC)
Voltage Pattern Inspection
1. Jack up the vehicle on level ground and support it
evenly on safety stands.
2. Disconnect the ABS wheelspeed sensor
connector.
3. Using an oscilloscope, inspect voltage pattern for
distortion and noise by rotating each wheel.
D If there is distortion or noise, inspect the ABS
sensor rotor.

P46

ANTILOCK BRAKE SYSTEM


(2) Facing up (inclined 90 from horizontal)

G SENSOR REMOVAL/INSTALLATION
Caution
D Do not drop the G sensor, Replace it if it is
subjected to an impact.

Voltage
1.31.7 V

1. Slide the RH front seat fully backward.


2. Remove in the order indicated in the table.

(3) Facing down (declined 90 from horizontal)


Voltage
3.33.7 V

Connector

G sensor and bracket

G sensor

3. Install in the reverse order of removal.


G SENSOR INSPECTION
1. Connect the connector.
2. Turn ignition switch (engine switch) on, and verify
the voltage between terminals A and B under the
following conditions.
D If not within the specification, replace the G
sensor.
(1) Horizontal
Voltage
2.42.6 V

P47

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


ABS SYSTEM DIAGRAM

Ignition switch (engine switch)

10

ABS wheelspeed sensor

Instrument cluster

11

ABS HU/CM

ABS warning light

12

4x4 only

ABS motor relay (FET)

13

G sensor

Valve relay (FET)

14

DLC

Solenoid valve

15

KLN

ABS motor

16

TBS

Brake switch

17

GND

Battery

P48

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


ABS ONBOARD DIAGNOSTIC

(3) After the ABS warning light illuminates for 3


seconds, the ABS warning light indicates
DTCs.
(4) After completion of repairs, clear DTCs.

OnBoard Diagnostic (OBD) Test Description


D The OBD test inspects the integrity and function of
the ABS and outputs the results when requested
by the specific tests.
D Onboard diagnostic test also:
Provides a quick inspection of the ABS.
Is usually performed at the start of each diagnostic procedure.
Provides verification after repairs to ensure
that no other faults occurred during service.
D The OBD test is divided into 3 tests:
Read/clear diagnostic results, PID monitor and
record and active command modes.
Read/clear diagnostic results
D This function allows you to read or clear DTCs in
the ABS HU/CM memory.

Clearing DTCs Procedures


Using SST (WDS or equivalent)
(1) After repairs have been made, perform the
DTCs reading procedure.
(2) Erase DTCs by SST (WDS or equivalent).
(3) Ensure that the customers concern has been
resolved.

PID/data monitor and record


D This function allows you to access certain data
values, input signals, calculated values, and
system status information.
Active command modes
D This function allows you to control devices through
the SST (WDS or equivalent).

Without using SST (WDS or equivalent)

DTCs Retrieving Procedure


Using SST (WDS or equivalent)
(1) Connect SST (WDS or equivalent) to the
vehicle data link connector (DLC) located in the
left side of the engine compartment.
(2) Retrieve DTC by SST (WDS or equivalent).

Caution
D Connecting to the wrong DLC terminal may
cause a malfunction. Carefully connect
only to the specified terminal.
(1) Connect the TBS terminal at the DLC to body
ground using a jumper wire.
(2) Turn the ignition key (engine key) to ON
(engine OFF).
(3) Output all stored DTCs.
(4) After verifying that the first code is repeated,
depress the brake pedal 10 times or more at
intervals of less than 1 second.
(5) Turn the ignition key (engine key) to OFF and
disconnect the jumper wire.

Without using SST (WDS or equivalent)


(1) Connect the TBS terminal at DLC to body
ground using a jumper wire.
(2) Turn the ignition key (engine key) to ON
(engine OFF).

Note
D DTCs cannot be cleared if the following occur:
If intervals of depressing the brake pedal
exceed 1 second.
The brake switch has failed.

P49

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


PID/Data Monitor and Record Procedure
(1) Connect SST (WDS or equivalent) to the
vehicle DLC located in the left side of the
engine compartment.
(2) Access and monitor PIDs by SST (WDS or
equivalent).

Active Command Modes Procedure


Note
D When driving, the ABS motor and each valve
forcibly turn ABS_POWER on, and then each
command on. ABS_POWER regulates the
power supply for the ABS motor and 6 valves.
(1) Connect SST (WDS or equivalent) to the
vehicle DLC located in the left side of the
engine compartment.
(2) Turn the ignition key (engine key) to ON
(Engine OFF) or start engine.
(3) Activate active command modes using SST
(WDS or equivalent).

P50

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC Table
DTC
SST
(WDS
or
equivalent)

ABS
warning
light

B1318

63

ABS HU/CM
power supply

(See DTC B1318 (63))

B1342

61

ABS HU/CM

(See DTC B1342 (61))

C1095

54

Motor relay,
pump motor

(See DTC C1095 (54),


C1096 (53))

C1096

53

Motor relay,
pump motor

(See DTC C1095 (54),


C1096 (53))

C1140

30

ABS HU/CM
(pump)

(See DTC C1140 (30))

C1145

11

Right front ABS


wheelspeed
sensor

(See DTC C1145 (11),


C1155 (12), C1165 (13),
C1175 (14))

C1148

41

Right front ABS


wheel speed
sensor/sensor
rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (47), C1236
(48))

C1155

12

Left front ABS


wheelspeed
sensor

(See DTC C1145 (11),


C1155 (12), C1165 (13),
C1175 (14))

C1158

42

Left front ABS


wheelspeed
sensor/sensor
rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (47), C1236
(48))

C1165

13

Right rear ABS


wheelspeed
sensor

(See DTC C1145 (11),


C1155 (12), C1165 (13),
C1175 (14))

C1168

43

Right rear ABS


wheel speed
sensor/sensor
rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (57), C1236
(48))

C1175

14

Left rear ABS


wheelspeed
sensor

(See DTC C1145 (11),


C1155 (12), C1165 (13),
C1175 (14))

C1178

44

Left rear ABS


wheelspeed
sensor/sensor
rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (47), C1236
(48))

ABS warning light flashing pattern

P51

Diagnostic
system
component

Action

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC
SST
(WDS
or
equivalent)

ABS
warning
light

C1186

51

Valve relay

(See DTC C1186 (51),


C1266 (52))

C1194

24

Left front outlet


solenoid valve

(See DTC C1194 (24),


C1198 (25), C1202
(26), C1206 (27),
C1210 (22), C1214
(23))

C1198

25

Left front inlet


solenoid valve

(See DTC C1194 (24),


C1198 (25), C1202
(28), C1206 (27),
C1210 (22), C1214
(23))

C1202

26

R outlet solenoid
valve

(See DTC C1194 (24),


C1198 (25), C1202
(26), C1206 (27),
C1210 (22), C1214
(23))

C1206

27

R inlet solenoid
valve

(See DTC C1194 (24),


C1198 (25), C1202
(25), C1206 (27),
C1210 (22), C1214
(23))

C1210

22

Right front outlet


solenoid valve

(See DTC C1194 (24),


C1198 (25), C1202
(26), C1206 (27),
C1210 (22), C1214
(23))

C1214

23

Right front inlet


solenoid valve

(See DTC C1194 (24),


C1198 (25), C1202
(26), C1206 (27),
C1210 (22), C1214
(23))

C1233

46

Left front wheel


speed sensor/
sensor rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (47), c1236 (48))

C1234

45

Right front
wheelspeed
sensor/sensor
rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (47), C1236
(48))

C1235

47

Right rear
wheelspeed
sensor/sensor
rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (47), C1236
(48))

ABS warning light flashing pattern

P52

Diagnostic
system
component

Action

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC

*:

SST
(WDS
or
equivalent)

ABS
warning
light

C1236

48

Left rear wheel


speed sensor/
sensor rotor

(See DTC C1148 (41),


C1158 (42), C1168 (43),
C1178 (44), C1233
(46), C1234 (45),
C1235 (47), C1236
(48))

C1266

52

Valve relay

(See DTC C1186 (51),


C1266 (52))

C1414

64

ABS HU/CM
mismatched
installation

(See DTC C1414 (64))

C1510

32

Right front solenoid valve, motor


or wheelspeed
sensor/sensor
rotor

(See DTC C1510 (32),


C1511 (33), C1512
(34), C1513 (35))

C1511

33

Left front solenoid valve, motor


or wheelspeed
sensor/sensor
rotor

(See DTC C1510 (32),


C1511 (33), C1512
(34), C1513 (35))

C1512

34

R solenoid
valve, motor or
right rear wheel
speed sensor/
sensor rotor

(See DTC C1510 (32),


C1511 (33), C1512
(34), C1513 (35))

C1513

35

R solenoid
valve, motor or
left rear wheel
speed sensor/
sensor rotor

(See DTC C1510 (32),


C1511 (33), C1512
(34), C1513 (35))

C1949*

03*

G sensor

(See DTC C1949 (03),


C1950 (04))

C1950*

04*

G sensor

(See DTC C1949 (03),


C1950 (04))

ABS warning light flashing pattern

Diagnostic
system
component

Action

4x4 only

PID/DATA Monitor Table


PID Name
(Definition)
ABS_LAMP
(ABS warning lamp
driver output state)
ABS_VOLT (System
battery voltage value)

Unit/Condition

Condition/Specification
D ABS warning light is

ON/OFF

illuminated: ON.
D ABS warning light is not
illuminated: OFF.
D Ignition key at ON: B+
D Idle: Approx. 1316 V

P53

Action

ABS HU/CM
terminal

Inspect ABS warning


light.
W
Inspect power supply
circuit. (See ABS HU/CM
INSPECTION)

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

PID Name
(Definition)

Unit/Condition

Condition/Specification
D During ABS control: ON/

ABSLF_I
(LF ABS inlet valve
output state)

ON/OFF

OFF (solenoid valve is


activated/deactivated.)
D Not ABS control: OFF
(solenoid valve is
deactivated.)
D During ABS control: ON/

ABSLF_O (LF ABS


outlet valve output
state)

ABSPMPRLY
(ABS pump motor
relay output state)

ON/OFF

OFF (solenoid valve is


activated/deactivated.)
D Not ABS control: OFF
(solenoid valve is
deactivated.)
D Motor relay is activated:

ON/OFF

ON.
D Motor relay is deactivated:
OFF.
D During ABS control: ON/

ABSR_I
(R ABS inlet valve
output state)

ON/OFF

OFF (solenoid valve is


activated/deactivated.)
D Not ABS control: OFF
(solenoid valve is
deactivated.)
D During ABS control: ON/

ABSR_O
(R ABS outlet valve
output state)

ON/OFF

OFF (solenoid valve is


activated/deactivated.)
D Not ABS control: OFF
(solenoid valve is
deactivated.)
D During ABS control: ON/

ABSR_I
(RF ABS inlet valve
output state)

ON/OFF

OFF (solenoid valve is


activated/deactivated.)
D Not ABS control: OFF
(solenoid valve is
deactivated.)
D During ABS control: ON/

ABSRF_O
(RF ABS inlet valve
output state)

ABSVLVRLY
(ABS valve relay
output state)

ON/OFF

OFF (solenoid valve is


activated/deactivated.)
D Not ABS control: OFF
(solenoid valve is
deactivated.)
D Valve relay is activated:

ON/OFF

ON.
D Valve relay is deactivated:
OFF
D Vehicle is stopped or

ACCLMTR*
(Accelerometer)

ACCELERATION

driving at a constant
speed: 0 G.
D Vehicle is driving at a
acceleration: Changes
between 0 1.28 G.
D Vehicle is driving at a
deceleration: Changes
between 0 1.27 G.
D Brake pedal is depressed:

BOO_ABS
(Brake pedal switch

ON/OFF

ON.
D Brake pedal is released:
OFF.

P54

Action
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Inspect ABS HU/CM.
(See ABS HU/CM
INSPECTION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Inspect ABS HU/CM.
(See ABS HU/CM
INSPECTION

ABS HU/CM
terminal

Inspect G sensor. (See G


SENSOR INSPECTION)

H, J

Inspect brake switch.


Y

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

PID Name
(Definition)

Unit/Condition

CCNTABS
(Number of continuous
trouble code set)
LF_WSPD
(LF wheelspeed
sensor input)
LR_WSPD
(LR wheelspeed
sensor input)

Condition/Specification
D DTC is detected: 1255.
D DTC is not detected: 0.
D Vehicle is stopped: 0 KPH

KPH or MPH

{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.
D Vehicle is stopped: 0 KPH

KPH or MPH

{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.
D Pump motor is activated:

PMPSTAT
(ABS motor status)

RF_WSPD
(RF wheelspeed
sensor input)
RR_WSPD
(RR wheelspeed
sensor input)
*:

ON/OFF

{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.
D Vehicle is stopped: 0 KPH

KPH or MPH

{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.

ABS HU/CM
terminal

Perform inspection using


appropriate DTC.
(See ABS ONBOARD
DIAGNOSTIC)

Inspect wheelspeed
sensor/sensor rotor.

Inspect wheelspeed
sensor/sensor rotor.

E, I

C, F

Inspect ABS HU/CM.


(See ABS HU/CM
INSPECTION)

ON.
D Pump motor is
deactivated: OFF
D Vehicle is stopped: 0 KPH

KPH or MPH

Action

Inspect wheelspeed
sensor/sensor rotor.

Inspect wheelspeed
sensor/sensor rotor.

D, G

A, B

4x4 only

Active Command Modes Table


SST (WDS or equivalent) display
Output part
Menu

ABS OUTPUT
CONTROL

Command name

Operation/unit
(SST (WDS or
equivalent display))

ABS_POWER

Valve relay

ON/OFF

LF_INLET

LF inlet solenoid valve

ON/OFF

LF_OUTLET

LF outlet solenoid valve

ON/OFF

PMP_MOTOR

ABS motor

ON/OFF

REAR_INLET

R inlet solenoid valve

ON/OFF

REAR_OUTLET

R outlet solenoid valve

ON/OFF

RF_INLET

RF inlet solenoid valve

ON/OFF

RF_OUTLET

RF outlet solenoid valve

ON/OFF

P55

Note

Ignition key (engine


key) at ON (Engine
OFF)

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC B1318 (63)
Caution
D When attaching the tester lead to the ABS HU/CM or the ABS HU/CM harness connector, the SST
(49 G066 001) must be used. (See ABS HU/CM INSPECTION.)
DTC B1318 (63)
DETECTION
CONDITION
POSSIBLE
CAUSE

ABS HU/CM power supply


D Voltage at Z terminal of ABS HU/CM drops below 10 V when driving vehicle.
D Low power supply
D Battery and/or generator malfunction
D Poor ground or open circuit of ground

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT ABS HU/CM POWER SUPPLY


CIRCUIT FOR OPEN CIRCUIT
D Turn ignition key (engine key) to OFF.
D Disconnect ABS HU/CM connector.
D Connect SST (adapter harness) to ABS HU/
CM connector (harness side) with ABS HU/CM
disconnected.
D Start engine.
D Measure voltage between terminal Z of SST
(harness side) and ground.
D Is voltage above 10 V?

Yes

Go to next step.

No

Go to Step 3.

INSPECT ABS HU/CM GROUND CIRCUIT FOR


POOR GROUND AND OPEN CIRCUIT
D Turn ignition key (engine key) to OFF.
D Measure resistance between terminal AA of
SST and ground.
D Is resistance within 01 ohm?

Yes

Go to Step 5.

No

If there is no continuity:
D Repair or replace harness for open between
ABS HU/CM and ground, then go to Step 5.
D Repair or replace harness for poor ground then
go to Step 5.

INSPECT BATTERY POWER


D Inspect battery.
D Is it okay?

Yes

Go to next step.

No

Replace battery, then go to Step 5.

INSPECT GENERATOR
D Inspect generator.
D Is it okay?

Yes

Go to next step.

No

Repair or replace generator, then go to Step 5.

P56

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

STEP
5

INSPECTION

ACTION

VERIFY TROUBLESHOOTING COMPLETED


D Make sure to connect all disconnected
connectors.
D Clear DTC from memory.
(See Clearing DTCs Procedures)
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

DTC B1342 (61)


DTC B1342 (61)
DETECTION
CONDITION
POSSIBLE
CAUSE

ABS HU/CM
D The onboard diagnostic program detects computer malfunction.
D Malfunction of ABS HU/CM (CM part)

Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY CURRENT STATUS OF MALFUNCTION


D Clear DTC memory.
(See Clearing DTCs Procedures)
D Start engine and drive vehicle at 10 km/h
{6.2 mph} or above.
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

DTC C1095 (54), C1096 (53)


Caution
D When attaching the tester lead to the ABS HU/CM or the ABS HU/CM harness connector, the SST
(49 G066 001) must be used. (See ABS HU/CM INSPECTION.)
DTC B1095 (54), C1096 (53)

Motor relay, ABS motor

D C1095 (54): ABS motor is stuck OFF when vehicle is started or during ABS operation, ABS motor ON is

DETECTION
CONDITION

commanded.
D C1096 (53): ABS motor is stuck ON when vehicle is started or during ABS operation, ABS motor OFF is

commanded.
POSSIBLE
CAUSE

D
D
D
D

Open circuit, or short power or short to ground of motor relay and/or ABS motor in ABS HU/CM
Stuck motor relay and/or ABS motor
Open circuit of ABS motor power supply
Open circuit of ABS motor ground

P57

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

Diagnostic procedure
STEP
1

2
3

INSPECTION

ACTION

VERIFY OTHER DTC HAS RECORDED


D If any of DTC C1186 (51) and/or C1266 (52)
also stored?

Yes

Go to applicable DTC inspection.

No

Go to next step.

INSPECT ABS FUSE CONDITION


D Is ABS fuse (60 A) okay?

Yes

Go to next step.

No

Replace fuse, then go to Step 5.

INSPECT MOTOR RELAY POWER SUPPLY


CIRCUIT FOR OPEN
D Turn ignition key (engine key) to OFF.
D Disconnect ABS HU/CM connector.
D Connect SST (adapter harness) to ABS HU/
CM connector (harness side) with ABS HU/CM
disconnected.
D Turn ignition key (engine key) to ON (engine
OFF).
D Measure voltage between ABS HU/CM
terminal AB (harness side) and ground.
D Is voltage B+?

Yes

Go to next step.

No

Repair or replace harness for open circuit between


battery positive terminal and ABS HU/CM terminal
AB, then go to Step 5.

P58

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

STEP
4

INSPECTION

ACTION

INSPECT ABS HU/CM GROUND CIRCUIT FOR


OPEN CIRCUIT
D Turn ignition key (engine key) to OFF.
D Inspect continuity between ABS HU/CM
terminal AD of SST and ground.
D Is there continuity?

Yes

Go to next step.

No

Repair or replace harness for open circuit between


ABS HU/CM terminal AD and ground, then go to
next step.

VERIFY TROUBLESHOOTING COMPLETED


D Make sure to connect all disconnected
connectors.
D Clear DTC from memory.
(See Clearing DTCs Procedures)
D Start engine and drive vehicle at 10 km/h
{6.2 mph} or above.
D Gradually slow down and stop vehicle.
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

DTC C1140 (30)


DTC C1140 (30)
DETECTION
CONDITION
POSSIBLE
CAUSE

ABS HU/CM (pump)


D Left and right front wheels, or left and/or right rear wheel(s) lock is detected during ABS operation.
D Stuck ABS pump in ABS HU/CM

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT ABS HU/CM OPERATION


D Perform ABS HU/CM system inspection.
(See System Inspection)
D Is it okay?

Yes

Go to next step.

No

Replace ABS HU/CM, then go to Step 4.

INSPECT CONVENTIONAL BRAKE


OPERATION
D Inspect brake fluid level.
D Start engine.
D Perform a road test to verify conventional
vehicle braking performance.
D Is there a concern.

Yes

Inspect conventional brake line, then go to Step 4.

No

Go to next step.

INSPECT REAR BRAKE DRAGGING


D Turn ignition key (engine key) to OFF.
D Jack up vehicle and support it with safety
stand.
D Release parking brake.
D Turn rear wheel by hand and inspect for rear
brakedrag.
D Is rear brake dragging?

Yes

Repair parking brake system, then go to next step.

No

Go to next step.

VERIFY TROUBLESHOOTING COMPLETED


D Clear DTC from memory.
(See Clearing DTCs Procedures)
D Start engine and drive vehicle at 10 km/h
{6.2 mph} or above at least 1 min.
D Gradually slow down and stop vehicle.
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

P59

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC C1145 (11), C1155 (12), C1165 (13), C1175 (14)
Caution
D When attaching the tester lead to the ABS HU/CM or the ABS HU/CM harness connector, the SST
(49 G066 001) must be used. (See ABS HU/CM INSPECTION.)
DTC
DTC
DTC
DTC

C1145 (11)
C1155 (12)
C1165 (13)
C1175 (14)

DETECTION
CONDITION
POSSIBLE
CAUSE

RF ABS wheelspeed sensor


LF ABS wheelspeed sensor
RR ABS wheelspeed sensor
LR ABS wheelspeed sensor
D When open or short circuit is detected.
D Open circuit or short to power circuit of ABS wheelspeed sensor(s) circuit
D ABS wheelspeed sensor(s) malfunction

P60

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT ABS WHEELSPEED SENSOR


CIRCUIT FOR OPEN CIRCUIT
D Turn ignition key (engine key) to OFF.
D Disconnect ABS HU/CM connector.
D Connect SST (adapter harness) to ABS HU/
CM connector (harness side) with ABS HU/CM
disconnected.
D Measure resistance between suspected
sensor terminals of SST.
RF ABS wheelspeed sensor: GD
LF ABS wheelspeed sensor: IE
RR ABS wheelspeed sensor: AB
LR ABS wheelspeed sensor: CF
D Is resistance within 1.31.7 kilohm?

Yes

Go to next step.

No

Go to Step 3.

INSPECT ABS WHEELSPEED SENSOR


CIRCUIT FOR SHORT TO POWER
D Turn ignition key (engine key) to ON (engine
OFF).
D Inspect voltage between suspected sensor
terminal(s) of SST (adapter harness) and
ground(s).
RF ABS wheelspeed sensor: G, D
LF ABS wheelspeed sensor: I, E
RR ABS wheelspeed sensor: A, B
LR ABS wheelspeed sensor: C, F
D Is voltage B+?

Yes

Repair or replace harness for short to power circuit


between ABS HU/CM and ABS wheelspeed
sensor(s), then go to Step 5.

No

Go to Step 5.

INSPECT ABS WHEELSPEED SENSOR


D Turn ignition key (engine key) to OFF.
D Disconnect suspected sensor connector(s)
and inspect resistance between sensor
terminals (part side).
D Is resistance within 1.31.7 kilohm?

Yes

Go to next step.

No

Replace ABS wheelspeed sensor, then go to Step


5.

INSPECT ABS HU/CM TO ABS


WHEELSPEED SENSOR CIRCUIT FOR
OPEN CIRCUIT
D Inspect continuity between suspected sensor
terminal(s) of SST and ABS wheelspeed
sensor connector. (vehicle harness side)
RF ABS wheelspeed sensor (+): GA
RF ABS wheelspeed sensor (): DB
LF ABS wheelspeed sensor (+): IA
LF ABS wheelspeed sensor (): EB
RR ABS wheelspeed sensor (+): AA
RR ABS wheelspeed sensor (): BB
LR ABS wheelspeed sensor (+): CA
LR ABS wheelspeed sensor (): FB
D Is there continuity?

Yes

Repair or replace poor connections of ABS HU/CM


connector and/or ABS wheelspeed sensor
connector(s), then go to next step.

No

Repair or replace harness for open circuits


between ABS HU/CM and ABS wheelspeed
sensor(s), then go to next step.

VERIFY TROUBLESHOOTING COMPLETED


D Make sure to reconnect all disconnected
connectors.
D Clear DTC from memory
(See Clearing DTCs Procedures)
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

P61

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC C1148 (41), C1158 (42), C1168 (43), C1178 (44), C1233 (46), C1234 (45), C1235 (47), C1236 (48)
Caution
D When attaching the tester lead to the ABS HU/CM or the ABS HU/CM harness connector, the SST
(49 G066 001) must be used. (See ABS HU/CM INSPECTION.)
DTC
DTC
DTC
DTC

C1148 (41), C1234 (45)


C1158 (42), C1233 (46)
C1168 (43), C1235 (47)
C1178 (44), C1236 (48)

RF ABS wheelspeed sensor/sensor rotor


LF ABS wheelspeed sensor/sensor rotor
RR ABS wheelspeed sensor/sensor rotor
LR ABS wheelspeed sensor/sensor rotor

D C1148 (41), C1158 (42), C1168 (43), C1178 (44): ABS wheelspeed signal is out of specification when

DETECTION
CONDITION

just after vehicle has started to move.


D C1234 (45), C1233 (46), C1235 (47), C1236 (48): ABS wheelspeed signal malfunction (distortion/

sudden change) is detected during driving.


POSSIBLE
CAUSE

D
D
D
D

Short to ground circuit of ABS wheelspeed sensor(s) circuit


ABS wheelspeed sensor(s) malfunction
Damaged ABS sensor rotor(s)
Incorrect clearance between ABS sensor and sensor rotor

P62

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


Diagnostic procedure
STEP
1

INSPECTION

ACTION

VERIFY CURRENT INPUT SIGNAL STATUS OF


CONCERN IS INTERMITTENT OR CONSTANT
D Turn ignition key (engine key) to OFF.
D Connect SST (WDS or equivalent) to DLC.
D Start engine and drive vehicle.
D Access LF_WSPD, LR_WSPD, RF_WSPD
and RR_WSPD PID using SST (WDS or
equivalent)
D Are PIDs display vehicle speed and 4 PIDs
equal?

Yes

Go to Step 5.

No

Go to next step.

INSPECT ABS WHEELSPEED SENSOR


CIRCUIT FOR SHORT TO GROUND
D Turn ignition key (engine key) to OFF.
D Disconnect ABS HU/CM connector.
D Connect SST (adapter harness) to ABS HU/
CM connector (harness side) with ABS HU/CM
disconnected.
D Inspect continuity between suspected sensor
terminal(s) of SST (adapter harness) and
ground(s).
RF ABS wheelspeed sensor: G
LF ABS wheelspeed sensor: I
RR ABS wheelspeed sensor: A
LR ABS wheelspeed sensor: C
D Is there continuity?

Yes

Go to next step.

No

Go to Step 4.

INSPECT ABS WHEELSPEED SENSOR FOR


SHORT TO GROUND
D With ignition key (engine key) at OFF,
disconnected suspected sensor connector(s),
inspect continuity between suspected sensor
terminal(s) A (part side) and ground(s).
D Is there continuity?

Yes

Replace ABS wheelspeed sensor(s), then go to


Step 8.

No

Repair or replace harness (short to ground)


between ABS HU/CM and ABS wheelspeed
sensor connector(s), then go to Step 8.

INSPECT SENSOR ROTOR CLEARANCE


D Jack up vehicle and support it with safety
stands.
D Remove suspected wheel(s).
D Inspect clearance between sensor and rotor.
D Is clearance within 0.31.1 mm {0.012
0.043 in}?

Yes

Go to Step 8.

No

Replace ABS wheelspeed sensor(s), then go to


Step 8.

INSPECT ABS WHEELSPEED SENSOR


OUTPUT PULSE
D Start engine and drive vehicle.
D Inspect output voltage pattern using an
oscilloscope.

Yes

Go to Step 8.

No

Go to next step.

P63

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

STEP
6

INSPECTION

ACTION

INSPECT SENSOR ROTOR FOR DAMAGE


D Jack up vehicle and support it with safety
stands.
D Remove suspected wheel(s).
D Visually inspect sensor rotor for missing,
deformed and obstructed teeth.
Number of teeth: 44
D Is sensor rotor okay?

Yes

Go to next step.

No

Replace rotor, then go to Step 8.

INSPECT SENSOR ROTOR CLEARANCE


D Inspect clearance between sensor and rotor.
D Is clearance within 0.31.1 mm {0.012
0.043 in}?

Yes

Go to next step.

No

Replace ABS wheelspeed sensor(s), then go to


next step.

VERIFY TROUBLESHOOTING COMPLETED


D Make sure to reconnect all disconnected
connectors.
D Clear DTC from memory
(See Clearing DTCs Procedures)
D Start engine and drive vehicle at 10 kmh
{6.2 mph} or above.
D Gradually slow down vehicle and stop.
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

P64

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC C1186 (51), C1266 (52)
Caution
D When attaching the tester lead to the ABS HU/CM or the ABS HU/CM harness connector, the SST
(49 G066 001) must be used. (See ABS HU/CM INSPECTION.)
DTC C1186 (51), C1266 (52)

Valve relay

D C1186 (51): Valve relay in ABS HU/CM is stuck OFF when ignition switch (engine switch) is turned ON,

DETECTION
CONDITION

valve relay ON is commanded.


D C1266 (52): Valve relay in ABS HU/CM is stuck ON when ignition switch (engine switch) is turned ON,

valve relay OFF is commanded.


POSSIBLE
CAUSE

D Open circuit, short to power or short to ground circuit of valve relay in ABS HU/CM
D Stuck ON or OFF of valve relay in ABS HU/CM
D Open circuit of valve relay power supply circuit

P65

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


Diagnostic procedure
STEP

INSPECTION

ACTION

INSPECT ABS FUSE CONDITION


D Is ABS fuse (60 A ) okay?

Yes

Go to next step.

No

Replace fuse, then go to Step 3.

INSPECT FAILSAFE RELAY POWER SUPPLY


CIRCUIT FOR OPEN CIRCUIT
D Turn ignition key (engine key) to OFF.
D Disconnect ABS HU/CM connector.
D Connect SST (adapter harness) to ABS HU/
CM connector (harness side) with ABS HU/CM
disconnected.
D Turn ignition key (engine key) to ON (engine
OFF).
D Measure voltage between terminal AC of
SST (adapter harness) and ground.
D Is voltage B+?

Yes

Go to next step.

No

Repair or replace harness for open circuit between


battery positive terminal and ABS HU/CM terminal
AC, then go to next step.

VERIFY TROUBLESHOOTING COMPLETED


D Make sure to reconnect all disconnected
connectors.
D Clear DTC from memory
(See Clearing DTCs Procedures)
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

P66

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


DTC C1194 (24), C1198 (25), C1202 (26), C1206 (27), C1210 (22), C1214 (23)
DTC
DTC
DTC
DTC
DTC
DTC

C1202 (26)
C1206 (27)
C1210 (22)
C1214 (23)
C1194 (24)
C1198 (25)

DETECTION
CONDITION
POSSIBLE
CAUSE

R outlet solenoid valve


R inlet solenoid valve
RF outlet solenoid valve
RF inlet solenoid valve
LF outlet solenoid valve
LF inlet solenoid valve
D Solenoid monitor signal is not output in response to solenoid ON command.
D Solenoid monitor signal is output in response to solenoid OFF command.
D Open circuit, short to power or short to ground of solenoid valve circuit in ABS HU/CM
D Stuck solenoid valve in ABS HU/CM

Diagnostic Procedure
STEP
1

INSPECTION

ACTION

VERIFY CURRENT STATUS OF MALFUNCTION


D Clear DTC from memory
(See Clearing DTCs Procedures)
D Start engine and drive vehicle at 10 kmh
{6.2 mph} or above at least 1 min.
D Gradually slow down vehicle and stop.
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

DTC C1414 (64)


DTC C1414 (64)
DETECTION
CONDITION
POSSIBLE
CAUSE

ABS HU/CM unit mismatched installation


D When G sensor signal input for more than 400 ms to 4x2 vehicletype ABS HU/CM.
D Mismatched installation of ABS HU/CM

4x2 vehicle type ABS HU/CM is mismatched installed on 4x4 vehicle.

P67

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT ABS HU/CM FOR MISMATCHED


INSTALLATION
D Verify ABS HU/CM part number.
D Has a ABS HU/CM with the correct part
number been installed?

Yes

Go to next step.

No

Replace with correct ABS HU/CM part number,


then go to next step.

VERIFY CURRENT STATUS OF MALFUNCTION


D Clear DTC from memory
(See Clearing DTCs Procedures)
D Is same DTC present?

Yes

Replace ABS HU/CM

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

DTC C1510 (32), C1511 (33), C1512 (34), C1513 (35)


RF solenoid valve, ABS motor or RF ABS wheelspeed sensor/
sensor rotor
LF solenoid valve, ABS motor or LF ABS wheelspeed sensor/
sensor rotor
R solenoid valve, ABS motor or RR ABS wheelspeed sensor/
sensor rotor
R solenoid valve, ABS motor or LR ABS wheelspeed sensor/
sensor rotor

DTC C1510 (32)


DTC C1511 (33)
DTC C1512 (34)
DTC C1513 (35)
DETECTION
CONDITION

POSSIBLE
CAUSE

D Wheel lock is detected during ABS operation (pressure reduction inoperative).


D
D
D
D
D
D

Low electrical power supply


Malfunction of solenoid valve in ABS HU/CM
Malfunction of ABS wheelspeed sensor
Damaged ABS sensor rotor
Stuck ABS motor in ABS HU/CM
Malfunction of hydraulic unit of ABS HU/CM

Diagnostic procedure
STEP
1
2

INSPECTION

ACTION

VERIFY OTHER DTC HAS RECORDED


D Is DTC B1318 (63) also stored?

Yes

Go to DTC B1318 (63) inspection.

No

Go to next step.

VERIFY OTHER DTC HAS RECORDED


D Is any of DTC C1202 (26), C1206 (27),
C1214 (22), C1210 (23), C1198 (24) and/or
C1194 (25) also stored?

Yes

Go to applicable DTC inspection.

No

Go to next step.

VERIFY OTHER DTC HAS RECORDED


D Is any of DTC C1145 (11), C1148 (41),
C1155 (12) C1158 (42), C1165 (13),
C1168 (43), C1175 (14), C1178 (44),
C1233 (46), C1234 (45), C1235 (47) and/or
C1236 (48) also stored?

Yes

Go to applicable DTC inspection.

No

Go to next step.

VERIFY OTHER DTC HAS RECORDED


D Is any of DTC C1095 (54) and/or C1096 (53)
also stored?

Yes

Go to applicable DTC inspection.

No

Go to next step.

INSPECT ABS HU/CM OPERATION


D Perform ABS HU/CM system inspection.
(See System Inspection)
D Is it okay?

Yes

Go to next step.

No

Replace ABS HU/CM, then go to next step.

P68

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

STEP
6

INSPECTION

ACTION

VERIFY CURRENT STATUS OF MALFUNCTION


D Clear DTC from memory
(See Clearing DTCs Procedures)
D Start engine and drive vehicle at 10 kmh
{6.2 mph} or above at least 1 min.
D Gradually slow down vehicle and stop.
D Is same DTC present?

Yes

Replace ABS HU/CM.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

DTC C1949 (03), C1950 (04)


DTC C1949 (03), C1950 (04)

G sensor

D C1949 (03):

DETECTION
CONDITION

POSSIBLE
CAUSE

Monitor voltage of G sensor is detected at 4.5 V or more, or 0.5 V or less.


Monitor voltage difference of 0.4 V or more within1 cycle is detected 8 times in 1second.
D C1950 (04):
G sensor 0point correction value is default or more
Output voltage value from G sensor remains absolutely unchanged
Difference between estimated G force calculated from steering sensor and value output from G sensor
exceeds specification
D Malfunction of fuse (ENGINE 15 A)
D Open circuit in harness between G sensor terminal C and ignition switch (engine switch)
D Open, short to power, or short to ground circuit in harness between ABS HU/CM terminal H and G

sensor terminal B
D Open circuit in harness between ABS HU/CM terminal J and G sensor terminal A
D Malfunction of G sensor

P69

ONBOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)


Diagnostic procedure
STEP

INSPECTION

ACTION

INSPECT ENGINE FUSE CONDITION


D Is ENGINE fuse (15 A) okay?

Yes

Go to next step.

No

Replace fuse, then go to Step 8.

INSPECT G SENSOR POWER SUPPLY


CIRCUIT FOR OPEN CIRCUIT
D Turn ignition switch (engine switch) to ON
(engine OFF).
D Measure voltage between G sensor terminal
C (harness side) and ground.
D Is voltage B+?

Yes

Go to next step.

No

Repair or replace harness for open circuit between


G sensor terminal C and ignition switch, then go to
Step 8.

INSPECT G SENSOR GROUND CIRCUIT FOR


OPEN CIRCUIT
D Turn ignition switch (engine switch) to OFF.
D Disconnect ABS HU/CM and G sensor
connectors.
D Inspect continuity between ABS HU/CM
terminal J (harness side) and G sensor
terminal A (harness side).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace harness for open circuit between


ABS HU/CM terminal J and G sensor terminal A,
then go to Step 8.

INSPECT G SENSOR SIGNAL CIRCUIT FOR


OPEN CIRCUIT
D Inspect continuity between ABS HU/CM
terminal H (harness side) and G sensor
terminal B (harness side).
D Is there continuity?

Yes

Go to next step.

No

Repair or replace harness for open circuit between


ABS HU/CM terminal H and G sensor terminal B,
then go to Step 8.

INSPECT G SENSOR SIGNAL CIRCUIT FOR


SHORT TO POWER
D Turn ignition switch (engine switch) to ON
(engine OFF).
D Measure voltage between ABS HU/CM
terminal H (harness side) and ground.
D Is voltage B+?

Yes

Repair or replace harness for short to power


between ABS HU/CM terminal H and G sensor
terminal B, then go to Step 8.

No

Go to next step.

INSPECT G SENSOR SIGNAL CIRCUIT FOR


SHORT TO GROUND
D Turn ignition switch (engine switch) to OFF.
D Inspect continuity between ABS HU/CM
terminal H (harness side) and ground.
D Is there continuity?

Yes

Repair or replace harness for short to ground circuit


between ABS HU/CM terminal H and G sensor
terminal B, then go to Step 8.

No

Go to next step.

INSPECT G SENSOR
D Inspect G sensor.
(See G SENSOR INSPECTION)

Yes

Go to next step.

No

Replace G sensor, then go to next step.

VERIFY TROUBLESHOOTING COMPLETED


D Clear DTC from memory
(See Clearing DTCs Procedures)
D Is same DTC present?

Yes

Replace ABS HU/CM, then go to next step.

No

Go to next step.

VERIFY AFTER REPAIR PROCEDURE


D Is there any other DTC present?

Yes

Go to applicable DTC inspection.

No

Troubleshooting completed.

P70

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)

ABS SYSTEM DIAGRAM

Ignition switch (engine switch)

10

ABS wheelspeed sensor

2
3

Instrument cluster

11

ABS HU/CM

ABS warning light

12

4x4 only

ABS motor relay (FET)

13

G sensor

Valve relay (FET)

14

DLC

Solenoid valve

15

KLN

ABS motor

16

TBS

Brake switch

17

GND

Battery

P71

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)


FOREWORD
(1) Before performing the steps in Symptom Troubleshooting, perform the Onboard Diagnostic Inspection. To
check the DTC, follow the DTC Inspection steps.
PRECAUTION
When inspecting or servicing the ABS, note the following points:
(1) The ABS warning light illuminates even when the system is normal.
Cases
Under the following conditions:
When the rear wheels are jacked up, stuck, or placed
on a chassis roller, and only the rear wheels ABS
wheel speed sensors are spun for more than
20 seconds

Remedy

ABS control when


warning light
illuminates

After turning ignition switch (engine


switch) off, vehicle is driven at speed
greater than 10 kmh {6.2 mph} and
normal operation is confirmed.

If ABS is operating,
stop control after
operation. If ABS is not
operating, stop control
immediately.

Battery voltage rises above


about 10 V.

Operate control.

Parking brake is not fully released while driving.


Brake drag.
Sudden acceleration/deceleration.
Left/right or front/rear tires are different. (Size, radius,
tire pressure, or wear is other than that listed on tire
label.)
Battery voltage at ABS HU/CM ignition terminal Z drops
below about 9 to10 V. (*)

* : If battery voltage drops below about 9 to 10 V while vehicle speed is greater than 6 kmh {3.7 mph}, ABS
HU/CM records DTC B1318 (DTC 63).
(2) Precautions during servicing of ABS
The ABS is composed of electrical and mechanical parts. It is necessary to categorize malfunctions as
being either electrical or hydraulic when performing troubleshooting.
D Malfunction in electrical system
The ABS control module (ABS HU/CM) has an onboard diagnostic function. With this function, the ABS
warning light will turn on when there is a problem in the electrical system. Also, past and present
malfunctions are recorded in the ABS HU/CM. This function can find malfunctions that do not occur during
periodic inspections. Turn the ignition switch (engine switch) to ON position, shorting the TBS terminal of
the data link connector and the body ground, or connecting the SST (WDS or equivalent) to the DLC, and
approximately 5 seconds later the stored malfunctions will be displayed in the order of occurrence. To
find out the causes of ABS malfunctions, use these onboard diagnostic results.
If a malfunction occurred in the past but is now normal, the cause is likely a temporary poor connection of
the harness. The ABS HU/CM usually operates normally. Be careful when searching for the cause of
malfunction.
After repair, it is necessary to erase the DTC from the ABS HU/CM memory. Also, if the ABS related parts
have been replaced, verify that the no DTC has been displayed after repairs.
After repairing the ABS wheelspeed sensor or ABS sensor rotor, or after replacing the ABS HU/CM (ABS
motor or ABS motor relay or solenoid valve), the ABS warning light may not go off even when the ignition
switch (engine switch) is turned to ON position. IN this case, drive the vehicle at a speed of more than 10
kmh {6.2 mph}, make sure the ABS warning light goes off, and then erase the DTC.
When repairing, if the ABS related connectors are disconnected and the ignition switch (engine switch) is
turned to ON position, the ABS HU/CM will mistakenly detect a fault and record it as a malfunction.
To protect the ABS HU/CM, make sure the ignition is off before connecting or disconnecting the ABS HU/
CM connector.
D Malfunctions in hydraulic system
Symptoms in a hydraulic system malfunction are similar to those in a conventional brake malfunction.
However, it is necessary to determine if the malfunction is in an ABS component or the conventional brake
system.
The ABS hydraulic unit contains delicate mechanical parts. If foreign materials get into the component, the
ABS may fail to operate. Also, it will likely become extremely difficult to find the location of the malfunction
in the event that the brakes operate but the ABS does not. Make sure foreign materials do not get inside
when servicing the ABS (e.g. brake fluid replacement, pipe removal).

P72

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)


SYMPTOM TROUBLESHOOTING
Verify the symptom, and perform troubleshooting according to the appropriate number.
No.

Symptom

ABS warning light does not illuminate with ignition switch (engine switch) on.

ABS warning light stays on for more than 4 seconds with ignition switch (engine switch) on.

There is a malfunction in the system even though ABS warning light indicates that the system is normal.

Quick Diagnostic Chart

NO.1 ABS WARNING LIGHT DOES NOT ILLUMINATE WITH IGNITION SWITCH (ENGINE SWITCH) ON
D When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals, and wiring harness are
connected correctly and undamaged.
1

Air bag system warning light does not illuminate when ignition switch is turned to ON position.

[TROUBLESHOOTING HINTS]
D ABS warning light circuit open or shorted to ground

Diagnostic procedure
STEP
1

INSPECTION

ACTION

CHECK TO SEE WHETHER MALFUNCTION IS


IN COMMON POWER SUPPLY FOR ABS
WARNING LIGHT OR OTHER WARNING
LIGHTS
Does either of the following warning lights
illuminate when ignition switch (engine switch) is
turned to ON position?
D Air bag system warning light
D Generator warning light

Yes

Go to step 4.

No

Go to next step.

INSPECT INSTRUMENT CLUSTER POWER


SUPPLY FUSE
Is instrument cluster ignition power supply fuse
okay?

Yes

Go to next step.

No

Check for a short to ground on blown fuse circuit.


Repair or replace if necessary. Install appropriate
amperage fuse.

P73

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)

STEP
*3

*7

INSPECTION

ACTION

INSPECT WIRING HARNESS BETWEEN


INSTRUMENT CLUSTER POWER SUPPLY
AND INSTRUMENT CLUSTER FOR
CONTINUITY
Turn ignition switch (engine switch) to ON
position.
Measure voltage at instrument cluster connector
terminal 1J.
Is voltage approximately 12 V?

Yes

Inspect warning light circuits in instrument cluster


(open circuit in instrument cluster).

No

Repair wiring harness between fuse block and


instrument cluster (Terminal 1J).

CHECK FOR OPEN CIRCUIT IN ABS HU/CM


Does ABS warning light illuminate when the
ignition switch (engine switch) is at ON position
and the ABS HU/CM is disconnected?

Yes

Go to next step.

No

Go to step 6.

CONFIRM THAT MALFUNCTION SYMPTOMS


DO NOT REOCCUR AFTER ABS HU/CM IS
CONNECTED
Reconnect ABS HU/CM.
Does ABS warning light illuminate when the
ignition switch (engine switch) is at ON position?

Yes

Temporary poor connection at ABS HU/CM


connector Terminal W.
Inspect ABS HU/CM connector and Terminal W.

INSPECT ABS WARNING LIGHT BULB


Remove instrument cluster.
Inspect ABS warning light bulb.
Is it okay?

Yes

Go to next step.

No

Replace ABS warning light bulb.

CHECK TO SEE WHETHER MALFUNCTION


(LACK OF CONTINUITY) IS IN WIRING
HARNESS (BETWEEN INSTRUMENT
CLUSTER AND ABS HU/CM) OR INSTRUMENT
CLUSTER

Yes

Replace instrument cluster (open circuit in


instrument cluster).

No

Repair wiring harness between instrument cluster


and ABS HU/CM (Terminal W).

No

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Disconnect ABS HU/CM connector and
instrument cluster connectors. Is there continuity
between instrument cluster connector terminal 2B
and ABS HU/CM connector terminal W?

NO.2 ABS WARNING LIGHT STAYS ON FOR MORE THAN 4 SECONDS WITH IGNITION SWITCH (ENGINE
SWITCH) ON
Using SST (WDS or equivalent)
D When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals, and wiring harness are
connected correctly and undamaged.
2

ABS warning stays on for more than 4 seconds with ignition switch (engine switch) on.

[TROUBLESHOOTING HINTS]
D ABS HU/CM detects ABS system malfunction
D ABS HU/CM detects low voltage in power supply (ABS HU/CM ignition terminal Z voltage is below about 9 to 10 V)
D ABS HU/CM does not operate
D ABS warning light circuit open or shorted to high voltage (approximately 12 V)

Diagnostic procedure
STEP
1

INSPECTION
INSPECT ABS HU/CM IGNITION POWER
SUPPLY FUSE
Is ABS HU/CM power supply fuse okay?

ACTION
Yes

Go to next step.

No

Check for a short to ground on blown fuse circuit.


Repair or replace if necessary.
Install appropriate amperage fuse.

P74

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)

STEP
2

INSPECTION

ACTION

INSPECT WIRING HARNESS BETWEEN ABS


HU/CM AND DLC (DATA LINK CONNECTOR)
FOR CONTINUITY OR SHORTS
Perform DTC inspection.
Is error message displayed regarding
communication between ABS HU/CM and SST
(WDS or equivalent)?

Yes

If a communication error message is displayed


even after inspecting according to procedures
displayed on the SST (WDS or equivalent), go to
Step 6.

No

Go to next step.

CHECK FOR DTCS IN ABS HU/CM


Have DTCs been recorded in memory?

Yes

Perform inspection using appropriate DTC.

No

Go to next step.

INSPECT PID/DATA IN ABS HU/CM


Inspect the following items using SST (WDS or
equivalent).
D ABS_LAMP (ABS warning light)
D ABS_VOLT (power supply voltage)
Is ABS_LAMP ON after more than 4 seconds
with ignition switch (engine switch) to ON position.

Yes

Go to next step.

No

ABS system is normal.

INSPECT ABS HU/CM IGNITION POWER


SUPPLY SYSTEM (TERMINAL Z)
Check the voltage for PID/DATA monitor
ABS_VOLT item.
Specification: above 10 V
Is voltage within specification?

Yes

Go to Step 16.

No

Go to next step.

INSPECT BATTERY
Is battery voltage normal?

Yes

If a communication error message is displayed on


SST (WDS or equivalent) in Step 2 inspection, go
to next step.
If a communication error message is not displayed
on SST (WDS or equivalent) in Step 2 inspection,
go to Step 9.

No

Perform inspection of battery and charging system.

VERIFY THAT ABS HU/CM IS CONNECTED


Is ABS HU/CM securely connected?

Yes

Go to Step 9.

No

Connect ABS HU/CM connector securely, then go


to next step.

CONFIRM THAT MALFUNCTION SYMPTOMS


DO NOT REOCCUR AFTER ABS HU/CM IS
CONNECTED
Does ABS warning light go out after more than 4
seconds with ignition switch (engine switch) at
ON position?

Yes

Temporary poor connection in ABS HU/CM


connector.
Inspect connector and terminal.

No

Go to next step.

VERIFY THAT ABS HU/CM CONNECTOR


TERMINALS Z AND AC ARE CONNECTED
Does malfunction symptom reoccur when ABS
HU/CM connector terminals Z and AC are shaken
while the ignition switch (engine switch) is at ON
position?

Yes

Connect ABS HU/CM connector terminals Z and


AC securely, then go to next step.

No

Go to Step 11.

CONFIRM THAT MALFUNCTION SYMPTOMS


DO NOT REOCCUR AFTER ABS HU/CM
CONNECTOR TERMINALS Z AND AC ARE
CONNECTED
Does ABS warning light go out after more than 4
seconds with ignition switch (engine switch) at
ON position?

Yes

Temporary poor connection at terminal.


Inspect ABS HU/CM connector and terminal.

No

Go to next step.

3
4

*9

10

P75

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)

STEP
*11

INSPECTION

ACTION

INSPECT WIRING HARNESS BETWEEN FUSE


BLOCK AND ABS HU/CM (TERMINAL Z) FOR
CONTINUITY

Yes

Go to next step.

No

Repair wiring harness between fuse block and ABS


HU/CM (Terminal Z).

Yes

If a communication error message is displayed on


SST (WDS or equivalent) in Step 2 inspection, go
to next step.
If a communication error message is not displayed
on SST (WDS or equivalent) in Step 2 inspection,
recheck malfunction symptoms.

No

Repair wiring harness between ABS HU/CM


(terminal AC) and ground.

Yes

Go to next step.

No

Repair wiring harness between ABS HU/CM


(Terminal T) and data link connector (DLC).

Yes

Repair wiring harness between ABS HU/CM


(Terminal T) and data link connector (DLC).

No

Go to next step.

Yes

Repair wiring harness between ABS HU/CM


(Terminal T) and data link connector (DLC).

No

Replace ABS HU/CM (communication circuit or


ABS HU/CM power supply circuit malfunction in
ABS HU/CM).

Yes

Connect ABS HU/CM connector terminal W


securely, then go to next step.

No

Go to Step 18.

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Turn ignition switch (engine switch) to LOCK
position.
Disconnect ABS HU/CM connector.
Is voltage approximately 12 V at ABS HU/CM
terminal Z?
*12

INSPECT WIRING HARNESS BETWEEN ABS


HU/CM (TERMINAL AC) AND GROUND FOR
CONTINUITY

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal AC and ground?
*13

INSPECT WIRING HARNESS BETWEEN ABS


HU/CM AND DLC (DATA LINK CONNECTOR)
FOR CONTINUITY

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal T and data link connector
(DLC)?
*14

INSPECT WIRING HARNESS BETWEEN ABS


HU/CM AND DLC (DATA LINK CONNECTOR)
FOR SHORT TO B+

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Turn ignition switch (engine switch) to ON
position.
Is voltage approximately 12 V at ABS HU/CM
connector terminal T?
*15

INSPECT WIRING HARNESS BETWEEN ABS


HU/CM AND DLC (DATA LINK CONNECTOR)
FOR SHORT TO GROUND

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal T and ground?
16

VERIFY THAT ABS HU/CM CONNECTOR


TERMINAL W IS CONNECTED
Does malfunction symptom happen again when
ABS HU/CM connector terminal W is shaken
while the ignition switch (engine switch) is ON
position?

P76

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)

STEP
17

*18

*19

INSPECTION

ACTION

CONFIRM THAT MALFUNCTION SYMPTOMS


DO NOT REOCCUR AFTER ABS HU/CM
CONNECTOR TERMINAL W IS CONNECTED
Does ABS warning light go out after more than 4
seconds with ignition switch (engine switch) to
ON position?

Yes

Temporary poor connection at terminal.


Inspect ABS HU/CM connector and terminal.

No

Go to next step.

CHECK TO SEE WHETHER MALFUNCTION IS


IN INSTRUMENT CLUSTER (SHORT TO
GROUND) OR ELSEWHERE
Disconnect all instrument cluster connectors.
Is there continuity between instrument cluster
connector terminal 2B and ground?

Yes

Go to next step.

No

Replace instrument cluster (short to ground circuit


in instrument cluster).

INSPECT WIRING HARNESS BETWEEN


INSTRUMENT CLUSTER AND ABS HU/CM
FOR SHORT TO GROUND
Disconnect ABS HU/CM
Is there continuity between instrument cluster
connector terminal 2B and ground?

Yes

Repair wiring harness between ABS HU/CM


(Terminal W) and instrument cluster.

No

Replace ABS HU/CM (short to ground or B+ circuit


in ABS HU/CM).

Without using SST (WDS or equivalent)


D When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals, and wiring harness are
connected correctly and undamaged.
2

ABS warning stays on for more than 4 seconds with ignition switch (engine switch) on.

[TROUBLESHOOTING HINTS]
D ABS HU/CM detects ABS system malfunction
D ABS HU/CM detects low voltage in power supply (ABS HU/CM ignition terminal Z voltage is below 10 V)
D ABS HU/CM does not operate
D ABS warning light circuit open or shorted to high voltage (approximately 12 V)

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT ABS HU/CM IGNITION POWER


SUPPLY FUSE
Is ABS HU/CM power supply fuse okay?

Yes

Go to next step.

No

Check for a short to ground on blown fuse circuit.


Repair or replace if necessary.
Install appropriate amperage fuse.

CHECK FOR DTCS IN ABS HU/CM


Have DTCs been recorded in memory?

Yes

Perform inspection using appropriate DTC.

No

Go to next step.

INSPECT BATTERY
Is battery voltage normal?

Yes

Go to next step.

No

Perform inspection of battery and charging system.

VERIFY THAT ABS HU/CM IS CONNECTED


Is ABS HU/CM securely connected?

Yes

Go to Step 6.

No

Connect ABS HU/CM connector securely, then go


to next step.

VERIFY THAT MALFUNCTION SYMPTOMS


DO NOT REOCCUR AFTER ABS HU/CM IS
CONNECTED
Does ABS warning light go out after more than 4
seconds with ignition switch (engine switch) at
ON position?

Yes

Temporary poor connection in ABS HU/CM


connector.
Inspect connector and terminal.

No

Go to next step.

VERIFY THAT ABS HU/CM CONNECTOR


TERMINALS W, AC AND Z ARE CONNECTED
Does malfunction symptom happen again when
ABS HU/CM connector terminals W, AC and Z
are shaken while the ignition switch (engine
switch) is at ON position?

Yes

Connect ABS HU/CM connector terminals W. AC


and Z securely, then go to next step.

No

Go to Step 8.

*6

P77

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)

STEP
7

*8

INSPECTION

ACTION

VERIFY THAT MALFUNCTION SYMPTOM


OCCURS AFTER ABS HU/CM CONNECTOR
TERMINALS W, AC AND Z ARE CONNECTED
Does ABS warning light go out after more than 4
seconds with ignition switch (engine switch) at
ON position?

Yes

Temporary poor connection at terminal.


Inspect ABS HU/CM connector and terminal.

No

Go to next step.

INSPECT WIRING HARNESS BETWEEN FUSE


BLOCK AND ABS HU/CM (TERMINAL Z) FOR
CONTINUITY

Yes

Go to next step.

No

Repair wiring harness between fuse block and ABS


HU/CM (Terminal Z).

Yes

Go to next step.

No

Repair wiring harness between ABS HU/CM


(terminal AC) and ground.

CHECK TO SEE WHETHER MALFUNCTION


(SHORT TO GROUND) IS IN ABS HU/CM AND
WIRING HARNESS (BETWEEN INSTRUMENT
CLUSTER AND ABS HU/CM) OR INSTRUMENT
CLUSTER
Turn ignition switch (engine switch) to LOCK
position.
Disconnect instrument cluster connector.
Connect ABS HU/CM connector.
Is there continuity between instrument cluster
connector terminal 2B and ground?

Yes

Go to next step.

No

Replace instrument cluster (short to ground circuit


in instrument cluster).

INSPECT WIRING HARNESS BETWEEN


ABS HU/CM AND INSTRUMENT CLUSTER
FOR SHORT TO GROUND
Disconnect ABS HU/CM connector.
Is there continuity between instrument cluster
connector terminal 2B and ground?

Yes

Repair wiring harness between ABS HU/CM


(Terminal W) and instrument cluster.

No

Replace ABS HU/CM (short to ground or B+ circuit


in ABS HU/CM).

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Turn ignition switch (engine switch) to LOCK
position.
Disconnect ABS HU/CM connector.
Is voltage approximately 12 V at ABS HU/CM
terminal Z?
*9

INSPECT WIRING HARNESS BETWEEN ABS


HU/CM (TERMINAL AC) AND GROUND FOR
CONTINUITY

Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal AC and ground?
*10

*11

NO.3 THERE IS A MALFUNCTION IN SYSTEM EVEN THOUGH ABS WARNING LIGHT INDICATES THAT
THE SYSTEM IS NORMAL
3

There is a malfunction in the system even though ABS warning light indicates that the system is normal.

[TROUBLESHOOTING HINTS]
There is a mechanical malfunction in system.

Diagnostic procedure
STEP
1

INSPECTION
CHECK FOR DTCS IN ABS HU/CM
Have DTCs been recorded in memory?

ACTION
Yes

Perform inspection using appropriate DTC.

No

Go to next step.

P78

TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)

INSPECT ABS HYDRAULIC UNIT


Perform ABS hydraulic unit system inspection.
Is system okay?

Yes

Inspect conventional brake system.

No

If wheels do not rotate:


Replace ABS HU/CM
If wheels rotate but order in which wheels rotate
is incorrect:
Inspect brake pipe passage to ABS HU/CM.

P79

SUSPENSION
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . .
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . .
WHEEL ALIGNMENT PREINSPECTION . . . . .
FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . .
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . .
VEHICLE HEIGHT ADJUSTMENT . . . . . . . . . .
FRONT SHOCK ABSORBER REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SHOCK ABSORBER INSPECTION . .
FRONT SHOCK ABSORBER DISPOSAL
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
TORSION BAR SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2) . . . . . . . . .

R
R
R
R
R
R

1
1
1
2
3
3

R 5
R 6
R 6
R 7

TORSION BAR SPRING AND LOWER ARM


REMOVAL/INSTALLATION (4 4) . . . . . . . . . R10
LOWER ARM INSPECTION . . . . . . . . . . . . . . . . R12
UPPER ARM REMOVAL/INSTALLATION . . . . R13
UPPER ARM INSPECTION . . . . . . . . . . . . . . . . R14
STABILIZER AND TENSION ROD
REMOVAL/INSTALLATION (4 2) . . . . . . . . . R14
STABILIZER REMOVAL/INSTALLATION (4 4) . R15
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . R16
REAR SHOCK ABSORBER AND LEAF
SPRING REMOVAL/INSTALLATION . . . . . . . R16
REAR SHOCK ABSORBER DISPOSAL
(VEHICLES BUILT FROM 08/2002) . . . . . . . . R18

GENERAL PROCEDURES

WHEEL ALIGNMENT

Wheels and tires removal/installation


D The removal and installation procedures for the
wheels and tires are not mentioned in this section.
If a wheel is removed, retighten it to the specified
tightening torque, referring to section TD.

WHEEL ALIGNMENT PREINSPECTION


1. Inspect the inflation of each tire, and set to the
recommended pressure, as necessary.
2. Inspect the front wheel bearing play. Adjust the
bearing preload or replace bearing(s) as
necessary.
(Refer to section M, FRONT AXLE (4 2), WHEEL
HUB, STEERING KNUCKLE INSPECTION or
FRONT AXLE (4 4), WHEEL HUB, STEERING
KNUCKLE INSPECTION.)
3. Inspect the wheel and tire runout at all wheels.
(Refer to section TD, SUSPENSION, Wheels and
Tires.)
4. Inspect the ball joints and steering linkage for
excessive looseness.
5. Place the vehicle on level ground with no luggage
and passenger load.
6. The difference in height between the left and right
sides from the center of the wheel to the fender
brim must not exceed 10 mm {0.39 in}. If not
within the specification, adjust the vehicle height.
(Refer to FRONT SUSPENSION, VEHICLE
HEIGHT ADJUSTMENT.)

Suspension arms removal/installation


D Tighten any part of the suspension that uses
rubber bushings only after the vehicle has been
lowered and unloaded*.
* Unloaded condition: Fuel tank is full. Engine
coolant and engine oil are at specified levels.
Spare tire, jack, and tools are in designated
position.

7. Shake the vehicle to settle the suspension.

R1

WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
Specifications
Specification

Item

4 2
(mm {in})

Total toe-in

Front wheel alignment


(*1Unloaded
condition)

Maximum steering
angle

3"3 {0.12"0.12}
0 16 "16

(degree)
Inner

35 00

+2
3

Outer

33 00

+2
3

Camber angle*2
Caster

angle*3

Steering axis inclination


(reference value)
*1
*2
*3

4 4
0 14 "14
33 30

+2
3

30 00

+2
3

0 56 "30

1 06 "30

1 37 "45

2 02 "45

8 04

10 15

Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated
position.
Difference between left and right must not exceed 30.
Difference between left and right must not exceed 45.

Maximum Steering Angle Adjustment


1. Loosen the adjusting bolt locknut.
2. Turn the adjusting bolt to provide the correct
turning angle.
3. After adjustment, tighten the locknut to the
specified torque.

Total Toe-in Adjustment


1. Loosen the tie-rod end locknuts.
2. Turn the tie rods by the same amount in the
opposite direction.
Note
D One turn of the tie rod (both sides) changes the
toe-in by about 30 mm {1.18 in}.
D The left and right tie rods are both right
threaded. To increase the toe-in, turn the right
tie rod toward the front of the vehicle and the
left tie rod equally toward the rear.

Tightening torque
4058 Nm {4.06.0 kgfm, 2943 ftlbf}
4 2

3. Tighten the tie-rod end locknuts.


Tightening torque
6978 Nm {7.08.0 kgfm, 5157 ftlbf}
TIE ROD

ADJUSTING BOLT
4 4

ADJUSTING BOLT

R2

WHEEL ALIGNMENT, FRONT SUSPENSION


Caster and Camber Adjustment
1. Loosen the upper arm shaft bolt and insert or
remove adjustment shims to provide the correct
angle.

FRONT SUSPENSION
VEHICLE HEIGHT ADJUSTMENT

No.15

Caution
D If the vehicle height on a winch or towbar
(bullbar or similar accessory) equipped
vehicle is adjusted, it is possible that the
vehicle height will drop below specification
again or the tires will be subject to uneven
wear. Without adjusting the vehicle height,
adjust only the difference between the left
and right sides and perform a wheel
alignment to specification.

No.611

FRONT

1. Place the vehicle on level ground.


2. Inspect the front and rear tire pressure and adjust it
as necessary.
3. Measure the distance from the center of each front
wheel to the fender brim.

Adjustment shim
No.

Thickness (mm {in})

No.

Thickness (mm {in})

1.0 {0.039}

1.0 {0.039}

1.6 {0.063}

1.6 {0.063}

2.0 {0.079}

2.0 {0.079}

3.2 {0.126}

10

3.2 {0.126}

4.0 {0.157}

11

4.0 {0.157}

0.6 {0.024}

Left/right difference
10 mm {0.39 in} max.
Standard vehicle height
Drive
type

Note
D Shims No.15 are used on either side. Do not
use more than two.
D Shims No.611 are used at the front and rear
of either sides. Do not use more than one.
D Camber: A change of shim thickness (at front
and rear) of 1 mm {0.039 in} results in a
change of about 15.
D Caster: A change of shim thickness (at front or
rear only) of 1 mm {0.039 in} results in a
change of about 30.

4x2

Cab type

Tire size

Regular
Cab,
Stretch Cab*

ALL

Double Cab

2. After adjustment, tighten the upper arm shaft bolt


to the specified torque.

4x4

Tightening torque
94116 Nm {9.511.9 kgfm, 6986 ftlbf}

Double Cab

427.0 {16.81}
422.0 {16.61}

205R16
Regular
Cab,
Stretch Cab*

Vehicle
height (mm
{in})

235/75R15
P235/75R15

519.0 {20.43}
515.0 {20.28}

265/70R15

518.0 {20.39}

205R16

510.0 {20.08}

235/75R15
P235/75R15
265/70R15

506.0 {19.92}
509.0 {20.04}

* :Includes Stretch Cab (with Rear Access System)


model.

R3

WHEEL ALIGNMENT
Caution
D Adjust the vehicle height at the left and
right wheels at the same time. Otherwise,
the vehicle height may not be adjusted
correctly.
4. If the difference between left and right is not within
the specification, adjust the vehicle height by
turning the torsion bar spring anchor bolt.
Note
D Vehicle height increasedecreases per one
anchor bolt rotation as follows:
4x2: 3.5 mm {0.14 in}
4x4: 3.3 mm {0.13 in}
4 2

4 4

ANCHOR BOLT

ANCHOR BOLT

5. Move the vehicle forward and back to seat each


part.
6. Verify that the vehicle height is within the standard.
D
If not, readjust the vehicle height.

R4

FRONT SUSPENSION
FRONT SHOCK ABSORBER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

68 mm
{0.240.31 in}

5580 {5.68.2, 4159}

Nm {kgfm, ftlbf}

Nut
+ Installation Note

Bolt

Washer and nut

Retainer, bushing

Shock absorber

Nut Installation Note


D Tighten the nut so that the exposed thread of the
shock absorber piston is 68 mm {0.240.31 in}.

R5

FRONT SUSPENSION
FRONT SHOCK ABSORBER INSPECTION
1. Remove the front shock absorber from the vehicle.
2. Inspect for damage and oil leakage.
3. Inspect the rubber bushing for deterioration and
wear.
4. Compress and extend the shock absorber piston at
least three (3) times. Verify that the operational
force does not change and that there is no unusual
noise.
5. Compress the shock absorber piston and release
it. Verify that the piston extends fully at a normal
speed.
FRONT SHOCK ABSORBER DISPOSAL (VEHICLES
BUILT FROM 08/2002)
Warning
D Whenever drilling into a shock absorber,
wear protective eye wear. The gas in the
shock absorber is pressurized, and could
spray metal chips into the eyes and face
when drilling.
1. Clamp a shock absorber on a flat surface or with
the piston pointing downwards.
2. Drill a 23 mm {0.080.12 in) hole at a point
2030 mm {0.81.2 in} from the bottom of the
tube, so that the gas can escape.

3. Turn the hole downwards.


4. The oil can be collected by moving the piston rod
several times up and down and cutting the tube at
the end.
5. Dispose of waste oil according to the waste diposal
law.
Note
D Shock absorber gas is nitrogen gas.
D Shock absorber oil is mineral oil.

R6

FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the vehicle height and adjust it as necessary.

APPLY THREAD
LOCKING COMPOUND

APPLY THREAD
LOCKING COMPOUND

118156 {12.016.0, 87115}


118156 {12.016.0, 87115}

SST
R

Nm {kgfm, ftlbf}

Cotter pin

11

Torque plate

Nut

12

Lower arm spindle, washer, and nut

Lower arm ball joint/Knuckle arm


+ Removal Note

13

Bolt, washer, and nut (shock absorber)

Rubber bushing
+ Removal Note
+ Installation Note

Anchor bolt
+ Removal Note
+ Installation Note

14

Tension rod bolt

15

Stabilizer bolt, bushing, retainer, spacer, and nut


+ Installation Note

Anchor swivel

16

Lower arm

Bolt and washer

17

Bound bumper, washer, and nut

Torsion bar component

18

Bolts and washer (ball joint)

Anchor arm

19

Lower arm ball joint

10

Torsion bar spring


+ Removal Note
+ Installation Note

20

Clip
+ Installation Note

21

Lower arm ball joint boot

R7

FRONT SUSPENSION
Lower Arm Ball Joint/Knuckle Arm Removal Note
D Separate the ball joint from the knuckle arm using
the SST.

Clip Installation Note


1. Install the SST to the ball joint stud with the stud
stands straight up.
2. Install the clip in the dust boot groove.

KNUCKLE

49 T028 3A0

Anchor Bolt Removal Note


D Mark the anchor bolt and swivel for reference
during installation.

49 U034 208

Stabilizer Bolt, Bushing, Retainer, Spacer And Nut


Installation Note
D Tighten the nuts so that 1821 mm {0.710.82 in}
of thread is exposed at the end of the bolt.

MATCHING MARK

1821 mm
{0.710.82 in}

Torsion Bar Spring Removal Note


D Mark the torsion bar spring and anchor arm and
the torsion bar spring and torque plate for
reference during installation.

MATCHING MARK

Rubber Bushing Installation Note


D Install a new bushing using the SST.

MATCHING MARK

49 UB39 615

Rubber Bushing Removal Note


D Remove the rubber bushing from the body using
the SST.

49 UB39 615

R8

FRONT SUSPENSION
Torsion Bar Spring Installation Note
1. Before installation, check the identification mark on
the end of the torsion bar spring.
L: Left bar, R: Right bar
2. Align the marks made during removal, and connect
the torsion bar spring to the torque plate.

MATCHING MARK

MATCHING MARK

Anchor Bolt Installation Note


D Install the anchor bolt, and tighten it until the marks
made during removal are aligned.

MATCHING MARK

Note
D If the anchor bolt was not marked during
removal, install it as follows:
(1) Lower the front suspension until the upper
arm contacts the rebound stopper.
(2) Install the anchor arm so that the angle A is
34 "4.5.
(3) Install the anchor bolt and tighten it 27.3
turns.

R9

FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4)
1. Remove the driveshaft snap ring.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Inspect the vehicle height and adjust it as necessary.

118156
{12.016.0, 87115}

118156 {12.016.0, 87115}

SST

APPLY THREAD
LOCKING COMPOUND

Cotter pin

13

Lower arm spindle (front), washer and nut

Nut

14

Lower arm ball joint/Knuckle arm


+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2), Lower Arm
Ball Joint/Knuckle Arm Removal Note

Stabilizer bolt, bushing, retainer, spacer and nut


+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2), Stabilizer
Bolt, Bushing, Retainer, Spacer, And Nut
Installation Note

Bolt, washer and nut (shock absorber)

15

Lower arm

Anchor bolt and washer


+ Installation Note

16

Bound bumper, washer, and nut

17

Bolt, washer and nut

Anchor swivel

18

Lower arm ball joint

Bolt and washer

19

Torsion bar spring component

Anchor arm
+ Removal Note
+ Installation Note

Clip
+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2), Clip
Installation Note

10

Torsion bar spring


+ Removal Note
+ Installation Note

20

Lower arm ball joint boot

21

11

Torque plate

Lower arm bushing


+ Removal Note
+ Installation Note

12

Lower arm spindle (rear), washer and nut

R10

FRONT SUSPENSION
Anchor Arm Removal Note
D Mark the anchor arm and body for reference during
installation.

Lower Arm Bushing Installation Note


1. Apply soapy water to the new bushing.
2. Install the bushing using the SST.
49 U034 2A0

Torsion Bar Spring Removal Note


D Mark the torsion bar spring and anchor arm and
the torsion bar spring and torque plate for
reference during installation.

Torsion Bar Spring Installation Note


1. Before installation, inspect the identification mark
on the end of the torsion bar spring.
L: Left bar, R: Right bar
2. Align the marks made during removal, and connect
the torsion bar spring to the torque plate.

Anchor Arm Installation Note


D Align the marks made during removal, and install
the anchor arm onto the torsion bar spring.

Lower Arm Bushing Removal Note


D Remove the lower arm bushing using the SST.
49 U034 2A0

R11

FRONT SUSPENSION
Anchor Bolt Installation Note
D Install the anchor bolt, and tighten it until the marks
made during removal are aligned.

Note
D If the anchor bolt was not marked during
removal, install it at follows:
(1) Lower the front suspension until the upper
arm contacts the rebound stopper.
(2) Install the anchor arm so that the angle A is
60"4.5.
(3) Install the anchor bolt and tighten it 26.9
turns.

LOWER ARM INSPECTION


1. Remove the lower arm from the vehicle.
2. Inspect for damage, cracks, and bending.
3. Check the ball joint rotation torque.
(1) Rotate the ball joint five times.
(2) Connect the SST to the ball stud, and measure
the rotation torque using a pull scale.
(3) Replace it if not within the specification.
Pull scale reading
2034 N {2.03.5 kgf, 4.47.7 lbf}
49 0180 510B

R12

FRONT SUSPENSION
UPPER ARM REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the wheel alignment and adjust it as necessary.

R
SST

Clip

Upper arm component

Cotter pin and nut

Bolt and washer

Upper arm ball joint/Knuckle arm


+ Removal Note

Upper arm ball joint

Bolt and washer

Clip
+ Installation Note

Adjustment shim
+ Removal Note

10

Upper arm ball joint boot

Upper Arm Ball Joint/Knuckle Arm Removal Note


D Separate the upper arm ball joint from the knuckle
arm using the SST.

Clip Installation Note


1. Install the SST to the ball joint stud with the stud
stands straight up.
2. Install the clip in the dust boot groove.

49 T028 3A0

49 U034 209

KNUCKLE

Adjustment Shim Removal Note


D Note the number, amount and position of the shims
so that they are reinstalled in the correct positions.

R13

FRONT SUSPENSION
UPPER ARM INSPECTION
1. Remove the upper arm from the vehicle.
2. Inspect for damage, cracks, and bending.
3. Check the ball joint rotation torque.
(1) Rotate the ball joint five times.
(2) Connect the SST to the ball stud, and measure
the rotation torque using a pull scale.
(3) Replace it if not within the specification.

49 0180 510B

Pull scale reading


5.024 N {0.52.5 kgf, 1.25.5 lbf}
STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

2226 {2.22.7, 1619}

APPLY THREAD
LOCKING COMPOUND

94116 {9.511.9, 6986}

94127 {9.513.0, 6994}


Nm {kgfm, ftlbf}

Nut
+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2), Stabilizer
Bolt, Bushing, Retainer, Spacer, And Nut
Installation Note

Stabilizer bracket

Bushing

Stabilizer bar

Tension rod nut


+ Installation Note

Retainer

10

Bushing and retainer

Bolt

11

Bolt

Bushing, retainer and spacer

12

Tension rod

Bolt

R14

FRONT SUSPENSION
Tension Rod Nut Installation Note
D Tighten the tension rod nuts so that length L is 98.5
mm {3.88 in}.

STABILIZER REMOVAL/INSTALLATION (4 4)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

2226 {2.22.7, 1619}

Nm {kgfm, ftlbf}

Nut
+ FRONT SUSPENSION, STABILIZER AND
TENSION ROD REMOVAL/INSTALLATION
(4 2), Nut Installation Note

Retainer, bushing, and spacer

Bolt

Stabilizer bracket

Retainer and bushing

Bushing

Bolt

Stabilizer bar

Retainer and bushing

R15

REAR SUSPENSION

REAR SUSPENSION
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION
1. Support the frame with safety stands and place a jack under the differential casing. Remove in the order
indicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary.
2. Install in the reverse order of removal.
4 2

6478
{6.58.0, 4857}

5978 {6.08.0, 4457}

APPLY THREAD LOCKING


COMPOUND

7898
{8.010.0, 5872}

R
2026 {2.02.7, 1519.5}

5473 {5.57.5, 4054}

Nm {kgfm, ftlbf}

Nut, washer, retainer, and bushing

10

Spring pin

Nut, washer, retainer, and bushing

11

Nut and washer

Shock absorber

12

Shackle pin

Nut and washer

13

Shackle plate

Nut and washer

14

Leaf spring component

U-bolt

15

Spring clamp

Stopper rubber

Leaf spring bushing


+ Removal Note
+ Installation Note

Bolt and washer

R16

REAR SUSPENSION

4 4

99.1112 {10.111.5, 73.183.1}

APPLY THREAD
LOCKING COMPOUND

6478
{6.58.0, 4857}

5978 {6.08.0, 4457}

R
7898 {8.010.0, 5872}

2026 {2.02.7, 1519.5}

Nm {kgfm, ftlbf}

Bolt and nut

11

Bolt and washer

Washer, retainer, and bushing

12

Spring pin

Nut, washer, retainer, and bushing

13

Nut and washer

Shock absorber

14

Shackle pin

Nut and washer

15

Shackle plate

Nut and washer

16

Leaf spring component

U-bolt

17

Set plate

Spring clamp

Leaf spring bushing


+ Removal Note
+ Installation Note

10

Stopper rubber

R17

REAR SUSPENSION
Leaf Spring Bushing Removal Note
D Secure the leaf spring in a vise and remove the
bushing using a chisel.

Leaf Spring Bushing Installation Note


D Press in the bushing using a suitable pipe.

REAR SHOCK ABSORBER DISPOSAL (VEHICLES


BUILT FROM 08/2002)
1. Dispose the rear shock absorber in the same way
as the front shock absorber. (See FRONT SHOCK
ABSORBER DISPOSAL).

R18

BODY
BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S 3
BONNET REMOVAL/INSTALLATION . . . . . . . . S 3
BONNET ADJUSTMENT . . . . . . . . . . . . . . . . . . S 4
FRONT FENDER PANEL . . . . . . . . . . . . . . . . . . . . S 4
FRONT FENDER PANEL
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S 4
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S 5
FRONT DOOR REMOVAL/INSTALLATION . . . S 5
FRONT DOOR DISASSEMBLY/ASSEMBLY . . S 6
FRONT DOOR ADJUSTMENT . . . . . . . . . . . . . S 7
REAR DOOR REMOVAL/INSTALLATION . . . . S 7
REAR DOOR DISASSEMBLY/ASSEMBLY . . . S 8
REAR DOOR ADJUSTMENT . . . . . . . . . . . . . . . S 9
DOOR LOCK STRIKER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S 9
REGULATOR HANDLE REMOVAL . . . . . . . . . . S 9
REGULATOR HANDLE INSTALLATION . . . . . S 9
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . S10
POWER WINDOW MAIN SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S10
POWER WINDOW MAIN SWITCH
INSPECTION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . S10
POWER WINDOW MAIN SWITCH
INSPECTION (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . . S13
POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S15
POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . S15
POWER WINDOW SUBSWITCH INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S16
POWER WINDOW SUBSWITCH INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . S16
FRONT POWER WINDOW REGULATOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S16
FRONT POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S17
REAR POWER WINDOW REGULATOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S17
REAR POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S17
POWER WINDOW MOTOR INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S18
POWER WINDOW MOTOR INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . S18
POWER DOOR LOCK SYSTEM . . . . . . . . . . . . . . S20
DOOR KEY CYLINDER SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S20
DOOR KEY CYLINDER SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S20
DOOR LOCK-LINK SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . S20
DOOR LOCK-LINK SWITCH INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S20
DOOR LOCK-LINK SWITCH INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . . S21

DOOR LOCK ACTUATOR


REMOVAL/INSTALLATION . . . . . . . . . . . . . . . .
DOOR LOCK ACTUATOR INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
DOOR LOCK ACTUATOR INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . .
DOOR LOCK TIMER UNIT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . .
DOOR LOCK TIMER UNIT INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
DOOR LOCK TIMER UNIT INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
KEYLESS UNIT REMOVAL/INSTALLATION . .
KEYLESS UNIT DISASSEMBLY/ASSEMBLY .
KEYLESS UNIT INSPECTION . . . . . . . . . . . . . .
TRANSMITTER BATTERY REPLACEMENT .
TRANSMITTER BATTERY INSPECTION . . . .
FUEL-FILLER LID AND OPENER . . . . . . . . . . . .
FUEL-FILLER LID
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FUEL-FILLER LID ADJUSTMENT . . . . . . . . . .
BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BUMPER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT BUMPER
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . .
REAR BUMPER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR BUMPER DISASSEMBLY/ASSEMBLY . .
EXTERIOR ATTACHMENT . . . . . . . . . . . . . . . . . . .
RADIATOR GRILLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
COWL GRILLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
WINDSHIELD GARNISH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
SIDE PROTECTOR REMOVAL . . . . . . . . . . . . .
SIDE PROTECTOR INSTALLATION . . . . . . . .
SIDE PROTECTOR INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
OVER FENDER REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
OVER FENDER REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
TAILGATE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
TAILGATE ADJUSTMENT . . . . . . . . . . . . . . . . .
ROPE HOOK REMOVAL/INSTALLATION . . . .
MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD UPPER MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD UPPER MOLDING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD SIDE MOLDING REMOVAL . . .
WINDSHIELD SIDE MOLDING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BELTLINE MOLDING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR BELTLINE MOLDING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .

S1

S16
S22
S22
S22
S23
S24
S25
S25
S26
S27
S27
S29
S29
S29
S29
S29
S29
S30
S30
S30
S30
S30
S30
S32
S32
S33
S33
S34
S35
S35
S36
S36
S36
S36
S36
S36
S36
S37

ROOF MOLDING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . .
OUTSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL OUTSIDE MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
POWER OUTSIDE MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
POWER OUTSIDE MIRROR INSPECTION . .
POWER OUTSIDE MIRROR SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
POWER OUTSIDE MIRROR SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . . .
REARVIEW MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILAMENT INSPECTION . . . . . . . . . . . . . . . . . .
FILAMENT REPAIR . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER RELAY
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD REMOVAL . . . . . . . . . . . . . . . . . .
WINDSHIELD INSTALLATION . . . . . . . . . . . . . .
QUARTER WINDOW GLASS
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
QUARTER WINDOW GLASS
REMOVAL/INSTALLATION (STRETCH CAB
4 DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW GLASS REMOVAL . . . . . . . .
REAR WINDOW GLASS INSTALLATION . . . .
DASHBOARD AND CONSOLE . . . . . . . . . . . . . . .
DASHBOARD REMOVAL/INSTALLATION . . .
DASHBOARD DISASSEMBLY/ASSEMBLY . .
DASHBOARD MEMBER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
COLUMN COVER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT CONSOLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT CONSOLE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
REAR CONSOLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR CONSOLE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
GLOVE COMPARTMENT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
METER HOOD
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
A-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
B-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .

S37
S37
S37
S37
S37
S38
S38
S39
S39
S39
S39
S39
S39
S40
S40
S40
S41
S41
S42
S44
S45
S45
S45
S47
S47
S48
S49
S49
S49
S49
S49
S50
S50
S50
S51
S51
S51
S51

B-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
B-PILLAR UPPER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
ROOF SIDE TRIM
REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
FRONT SIDE TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT SCUFF PLATE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR SCUFF PLATE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR SCUFF PLATE
REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
C-PILLAR TRIM REMOVAL/INSTALLATION . .
QUARTER UPPER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
QUARTER LOWER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
BACK UPPER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
BACK LOWER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT DOOR TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR DOOR TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR ACCESS PANEL TRIM
REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLINER REMOVAL/INSTALLATION . . . . .
FLOOR COVERING . . . . . . . . . . . . . . . . . . . . . . . . .
FLOOR COVERING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT BELT REMOVAL/INSTALLATION . . . . . .
SEAT BELT REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
SEAT BELT INSPECTION . . . . . . . . . . . . . . . . .
BUCKLE REMOVAL/INSTALLATION . . . . . . . . .
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SEAT REMOVAL/INSTALLATION . . . .
FRONT SEAT DISASSEMBLY/ASSEMBLY . . .
CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . .
REAR SEAT REMOVAL/INSTALLATION . . . . .
REAR SEAT DISASSEMBLY/ASSEMBLY . . . .
SEAT WARMER SWITCH REMOVAL . . . . . . .
SEAT WARMER SWITCH INSTALLATION . . .
SEAT WARMER SWITCH INSPECTION . . . . .
SEAT WARMER UNIT INSPECTION . . . . . . . .
BODY SHELL (STRETCH CAB 4 DOOR) . . . .
REAR ACCESS PANEL
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR ACCESS PANEL
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
STRIKER REMOVAL/INSTALLATION . . . . . . .
TROUBLESHOOTING (POWER WINDOW
SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMITTENT CONCERN
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .

S2

S51
S52
S52
S52
S52
S53
S53
S53
S53
S53
S54
S54
S54
S55
S55
S55
S56
S56
S56
S56
S58
S58
S60
S60
S60
S62
S62
S63
S65
S65
S65
S68
S68
S68
S68
S69
S69
S70
S70
S71
S71

BASIC POWER WINDOW SYSTEM


INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC MODE FUNCTION
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC WINDOW RETURN
FUNCTION INSPECTION . . . . . . . . . . . . . . . .
IG OFF TIMER
FUNCTION INSPECTION . . . . . . . . . . . . . . . .
IG OFF TIMER
FUNCTION INSPECTION . . . . . . . . . . . . . . . .
TROUBLESHOOTING INDEX . . . . . . . . . . . . . .
NO.1 DRIVERSIDE FRONT WINDOW
DOES NOT GO UP AND DOWN
IN AUTOMATIC MODE . . . . . . . . . . . . . . . . . . .
NO.2 DRIVERSIDE FRONT WINDOW
DOES NOT REVERSE, EVEN WHEN
ENCOUNTERING A FOREIGN OBJECT
IN ITS PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NO.3 DRIVERSIDE FRONT WINDOW
REVERSES, EVEN THOUGH THE GLASS

S72
S72
S73
S73
S73
S74
S74

S76

DOES NOT ENCOUNTER A FOREIGN


OBJECT WHILE IT IS GOING UP
IN AUTOMATIC MODE . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING (KEYLESS ENTRY
SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM CHECK
SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM PRELIMINARY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
ONBOARD DIAGNOSTIC FUNCTION . . . . . .
TROUBLESHOOTING INDEX . . . . . . . . . . . . . .
NO.1 ONE OR MORE ONBOARD
DIAGNOSTIC FUNCTIONS
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . .
NO.2 ALL ONBOARD DIAGNOSTIC
FUNCTIONS INOPERATIVE . . . . . . . . . . . . . .
NO.3 TRANSMITTER CODE CANNOT
BE REPROGRAMMED . . . . . . . . . . . . . . . . . . .

S77
S78
S78
S78
S79
S80
S81
S81
S82
S84

BONNET
3.03.9
{3040,
2734}

Warning
D Removing the bonnet without supporting it
can be dangerous. The bonnet may fall and
injure you. Always perform these
procedures together with at least another
person.

A
A

BONNET REMOVAL/INSTALLATION
1. Pull out the windshield washer pipe.
2. To remove the bonnet hinge, remove the front
fender panel. (Refer to FRONT FENDER PANEL,
FRONT FENDER PANEL
REMOVAL/INSTALLATION.)
3. To remove the bonnet lock, remove the radiator
grille.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Adjust the bonnet. (Refer to BONNET
ADJUSTMENT.)

7.910.7
{80110,
69.595.4}

Nm {kgfcm, inlbf}

S3

Shroud seal weatherstrip

Bonnet

Bonnet hinge

Bonnet stay

Bonnet lock

Bonnet release lever

Bonnet release cable

BONNET/FRONT FENDER PANEL


BONNET ADJUSTMENT
1. Measure the gap and height between the bonnet
and the body.

Height Adjustment
1. Loosen the bonnet lock installation bolts and move
the bonnet lock to reposition the bonnet.
BOLT

Clearance
a: 2.75.3 mm {0.110.20 in}
b: 1.80.8 mm {0.070.03 in} (sec. AA)
c: 2.30.8 mm {0.090.03 in} (sec. BB)
d: 2.30.3 mm {0.090.01 in} (sec. CC)
e: 6.010.0 mm {0.240.39 in}
f: 7.013.0 mm {0.280.51 in}

50 {2.0}

A A

30 {1.2}
E

D
D

B B

2. Tighten the bonnet lock installation bolts.

C C

FRONT FENDER PANEL

FRONT FENDER PANEL REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the front side turn light.
3. Remove the front bumper.
4. Remove the front turn light.
5. Remove the front flap.
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.

a
e
b , c, d

SEC. AA
SEC. BB
SEC. CC

f
SEC. DD

SEC. EE
B

mm {in}

2. If not as specified, adjust the gap and height.


(Refer to Gap Adjustment.) (Refer to Height
Adjustment.)

Gap Adjustment
1. Loosen the bonnet installation bolts and reposition
the bonnet.
A

BOLT

6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}

Mud guard

Front fender panel

2. Tighten the bonnet installation bolts.

S4

12345678

DOOR

DOOR
FRONT DOOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the door screen. (Refer to FRONT DOOR
DISASSEMBLY/ASSEMBLY.)
3. To remove the front door hinge, remove the front
fender panel. (Refer to FRONT FENDER PANEL,
FRONT FENDER PANEL
REMOVAL/INSTALLATION.)
4. To remove the checker, remove the speaker.
(Refer to section T, AUDIO, SPEAKER
REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Adjust the front door. (Refer to FRONT DOOR
ADJUSTMENT.)

Front Door Harness Removal Note


1. Disconnect the connectors indicated in the table, if
equipped.
Connector name

Symbol

Drivers side

Passengers side

Door lock-link switch

Door lock actuator

Power window main


switch

Power window
subswitch

Power outside
mirror

Front power window


regulator

Speaker

2. Disengage the clips.

DOOR HARNESS

CLIP
C

2230
{2.23.1, 1622}

CLIP CLIP
(WITHOUT
SPEAKER)

(WITH SPEAKER)

Nm {kgfm, ftlbf}

Front door harness


+ Removal Note

Checker pin

Front door hinge

Front door

Checker

CLIP

CLIP

8.912.7 Nm
{90130 kgfcm, 79112 inlbf}

3. Remove the rubbber boot and pull out the door


harness.

S5

DOOR
FRONT DOOR DISASSEMBLY/ASSEMBLY
1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position.
2. Disconnect the negative battery cable.
3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. To remove the inner handle, peel off the door screen partially.
5. Disassemble in the order indicated in the table.
6. Assemble in the reverse order of disassembly.
WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM

B
B
A
D

6.879.80
{70100, 60.886.7}

4.36.1
{4363,
3854}

C
6.879.80 {70100, 60.886.7}

D
H

WITH POWER WINDOW SYSTEM AND


POWER DOOR LOCK SYSTEM

8.912.7
{90130, 79112}

G
I

4.36.1
{4363,
3854}

2.02.9 {2030, 1826}

6.879.80
{70100, 60.886.7}

J
I

Nm {kgfcm, inlbf}

Inner handle

Front power window regulator

Door screen

Outer handle

Front door glass

10

Retainer

Glass run channel

11

Door key cylinder

Front glass guide

12

Front door lock (manual)

Rear glass guide

13

Front door lock (power)

Front manual window regulator

14

Door lock knob

S6

DOOR
FRONT DOOR ADJUSTMENT
1. Measure the clearance between the door and the
body.

2230
{2.23.1, 1622}

Clearance
a: 4.06.0 mm {0.160.23 in}
b: 1.51.0 mm {0.0590.039 in}
c: 2.00.5 mm {0.0780.019 in}
d: 4.58.5 mm {0.180.33 in}
e: 1.2 mm {0.047 in}
f: 3.56.5 mm {0.140.25 in}
g: 2.7 mm {0.11 in}
h: 5.5 mm {0.22 in}

E E

8.912.7 Nm
{90130 kgfcm,
79112 inlbf}

A A
B B

(+)

Nm {kgfm, ftlbf}

F
F

e
(+)

a
b

()
SEC. BB

SEC. AA

(+)
b

()

SEC. CC

g
()
SEC. DD

h
SEC. EE

SEC. FF

2. If not as specified, loosen the door hinge


installation bolts or the door lock striker installation
screws, and move them to reposition the door.
(Refer to FRONT DOOR
REMOVAL/INSTALLATION.) (Refer to DOOR
LOCK STRIKER REMOVAL/INSTALLATION.)
3. Tighten the bolts or the screws.
REAR DOOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the door screen. (Refer to REAR DOOR
DISASSEMBLY/ASSEMBLY.)
3. To remove the checker, remove the ashtray
bracket. (Refer to REAR DOOR
DISASSEMBY/ASSEMBLY.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Adjust the rear door. (Refer to REAR DOOR
ADJUSTMENT.)

S7

Connector

Checker pin

Rear door hinge

Rear door

Checker

DOOR
REAR DOOR DISASSEMBLY/ASSEMBLY
1. Close the rear door glass completely.
2. Disconnect the negative battery cable.
3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.)
4. Disassemble in the order indicated in the table.
5. Assemble in the reverse order of disassembly.
WITH POWER WINDOW SYSTEM

6.879.80
{70100, 60.886.7}

E
WITHOUT POWER WINDOW SYSTEM

6.879.80
{70100,
60.886.7}

2.53.5
{2536, 2231}

4.36.1
{4363, 3854}

D
A
C

6.879.80
{70100, 60.886.7}

Nm {kgfcm, inlbf}

Inner handle

Door screen

Rear door glass


+ Removal Note

Ashtray bracket

Glass run channel

Glass hole lid

Glass guide

Rear manual window regulator

10

Door lock knob

Rear power window regulator

11

Rear door lock

12

Outer handle

S8

DOOR
Rear Door Glass Removal Note
D Draw out the rear door glass through the glass
hole.

DOOR LOCK STRIKER REMOVAL/INSTALLATION


1. Remove the screws.
2. Remove the door lock striker.
DOOR LOCK
STRIKER

SCREW

1826
{1.82.7,
1419}

REAR DOOR

REAR DOOR GLASS


Nm {kgfm, ftlbf}

REAR DOOR ADJUSTMENT


1. Measure the clearance between the door and the
body.
Clearance
a: 3.56.5 mm {0.140.25 in}
b: 1.51.0 mm {0.0590.039 in}
c: 5.5 mm {0.22 in}

3. Install in the reverse order of removal.


REGULATOR HANDLE REMOVAL
1. Remove the regulator handle clip using a rag as
shown.

DD
A A
E E
B B
RAG

C
C

2. Remove the regulator handle.


a

(+)

(+)

b
()

b
()

SEC. AA

SEC. BB
a

(+)
b

CLIP

(+)

c
SEC. CC

REGULATOR HANDLE INSTALLATION


1. Install the clip in the regulator handle.
2. Set the door glass at the fully raised position and
push the regulator handle on as shown.

b
()

()

SEC. DD

SEC. EE

2. If not as specified, loosen the door hinge


installation bolts or the door lock striker installation
screws, and move them to reposition the door.
(Refer to REAR DOOR
REMOVAL/INSTALLATION.) (Refer to DOOR
LOCK STRIKER REMOVAL/INSTALLATION.)
3. Tighten the bolts or screws.

CLIP

S9

FRONT

POWER WINDOW SYSTEM


(Vehicles built up to 07/2002)

POWER WINDOW SYSTEM


POWER WINDOW MAIN SWITCH
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Disengage the clip using tapewrapped flathead
screw driver.
3. Pull the switch panel forward to disengage the
hook.

SWITCH PANEL

POWER
WINDOW
MAIN SWITCH

(Vehicles built up to 07/2002)

SWITCH PANEL

BODY
SCREW

BODY
CLIP

HOOK

(Vehicles built from 08/2002)

(Vehicles built from 08/2002)

6. Install in the reverse order of removal.


POWER WINDOW MAIN SWITCH INSPECTION
(VEHICLES BUILT UP TO 07/2002)
Regular Cab, Stretch Cab
1. Remove the switch panel. (Refer to POWER
WINDOW MAIN SWITCH
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the power window
main switch terminals using an ohmmeter.
3. When inspecting the drivers side, connect the
battery positive voltage to terminal F and connect
the ground to terminal D.
4. When inspecting the passengers side, turn the
power-cut switch to ON.

4. Disconnect the power window main switch


connector.
5. Remove the screws to remove the power window
main switch from the switch panel.

S10

POWER WINDOW SYSTEM


Power window switch
Drivers side
: Continuity
Terminal

Switch
position

A (H)

B (I)

Manual close
Off
Auto open
Manual open

Double Cab
1. Remove the switch panel. (Refer to POWER
WINDOW MAIN SWITCH
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the power window
main switch terminals using an ohmmeter.
3. When inspecting the drivers side, connect the
battery positive voltage to terminal A (L.H.D.) or F
(R.H.D.) and connect the ground to terminal H.
4. When inspecting the passengers side and rear,
turn the power-cut switch to ON.
Power window switch
Drivers side

( ): R.H.D.

: Continuity

Passengers side
: Continuity

Switch
position

Terminal

Switch
position

H (A)

I (B)

Terminal
A (F)

L (D)

J (B)

Manual close

Close

Off

Off

Auto open
Manual open

Open

( ): R.H.D.

( ): R.H.D.

Passengers side
: Continuity

Power-cut switch
Switch
position

: Continuity
Switch
position

Terminal
D

A (H)

B (I)

H (A)

I (B)

Terminal
A (F)

D (L)

B (J)

Close

ON
Off

OFF

( ): R.H.D.

Open

( ): R.H.D.
Rear left
F

: Continuity

POWER-CUT SWITCH

Switch
position

MANUAL
OPEN

MANUAL
CLOSE

OPEN

CLOSE

Close

AUTO
OPEN

AUTO
CIRCUIT

Terminal

Off
Open

I (B)
H (A)
PASSENGERS
SIDE

( ): R.H.D.
Rear right

OPEN

CLOSE

: Continuity
Switch
position

A (H) B (I)
DRIVERS SIDE
H
I

A
D

Close

Off

( ) : R.H.D.

5. If not as specified, replace the power window main


switch.

Open

( ): R.H.D.

S11

Terminal
A

POWER WINDOW SYSTEM


Power-cut switch
: Continuity
Terminal
Switch
position

L
(D
)

J
(B
)

D
(L
)

B
(J)

ON
OFF

( ): R.H.D.
L.H.D.

A
H

D
B
PASSENGERS

C
RIGH
T

R.H.D.

F
H

J
PASSENGERS
D

5. If not as specified, replace the power window main


switch.

S12

POWER WINDOW SYSTEM


POWER WINDOW MAIN SWITCH INSPECTION
(VEHICLES BUILT FROM 08/2002)
Drivers Side
1. Remove the driverside front door trim.
2. Connect the power window main switch connector.
3. Measure the voltage at the power window main switch terminals as indicated below.
4. Disconnect the power window main switch connector before inspecting for continuity at terminals 1M and 1F.
D If not as specified, inspect the parts listed under Action.
D If the parts and wiring harnesses are okay but the system still does not work properly, replace the power
window main switch.
Terminal voltage list (Reference)

Terminal

1F

1H

Signal

Door
switch

IG1

Connected to

Door switch

P. WIND 30 A
fuse

Power
supply

P. WIND 15 A
fuse

1L
(1D)

Close
output

Power window
motor

1M

Ground

GND

1N
(1B)

Close
output

Power window
motor

1J

2A

2B

Ground

SEN2

Test condition
Any door is open (door switch is
on): inspect for continuity to
ground

Yes

All doors are closed (door switch is


off): inspect for continuity to ground

No

Ignition switch is at ON position

B+

Ignition switch is at LOCK position

Under any condition

SEN1

Below 1.0

While door glass is closing

B+

Under any condition: inspect for


continuity to ground

Yes

While door glass is opening

Below 1.0

While door glass is closing

B+

Under any condition: inspect for


continuity to ground

Power window
motor

Door glass is in motion

Door glass in motion


Door glass is not in motion

2D

Power
supply

Power window
motor

B+

While door glass is opening

Door glass is not in motion

2C

Below 1.0

Action

D Inspect door switch


D Inspect related

harness
D Inspect P.WIND 30 A

fuse
D Inspect relate

harness
D P. WIND 15 A fuse
D Inspect related

harness

Power window
motor

Power window
motor

Voltage (V)/
Continuity

Under any condition

Yes

D Power window motor


D Inspect related

harness
D Inspect GND
D Power window motor
D Inspect related

harness
D Power window motor
D Inspect related

harness
Alternates
between 0
and 9
0 or 9
Alternates
between 0
and 9
0 or 9
9

D Power window motor


D Inspect related

harness
D Power window motor
D Inspect related

harness
D Power window motor
D Inspect related

harness

( ) : R.H.D.

S13

POWER WINDOW SYSTEM


Except Drivers Side
1. Remove the power window main switch.
2. Turn the powercut switch to UNLOCK.
3. Inspect for continuity between the power window main switch terminals using an an ohmmeter.
D If not as specified, replace the power window main switch.
Passengers side

Rear right

Rear left

Powercut switch

S14

POWER WINDOW SYSTEM


POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION (VEHICLES BUILT UP
TO 07/2002)
Passengers side
1. Disconnect the negative battery cable.
2. Disengage the clip using a tape-wrapped flathead
screwdriver.
3. Pull the power window subswitch forward, and
disengage the hook.

4. Remove the power window subswitch.


5. Install in the reverse order of removal.
BODY

Rear
1. Disconnect the negative battery cable.
2. Disengage the clip using a tape-wrapped flathead
screwdriver.
3. Pull the power window subswitch panel forward to
disengage the hook.

CLIP
POWER
WINDOW
SUBSWITCH

BODY

HOOK

4. Disconnect the power window subswitch


connector.
5. Install in the reverse order of removal.
Rear
1. Disconnect the negative battery cable.
2. Remove the hook by inserting a tape-wrapped,
flathead screwdriver between the switch and the
rear door trim.

4. Remove the screw.


5. Remove the power window subswitch.

HOOK

POWER WINDOW
SUBSWITCH

3. Disconnect the connector, and remove the power


window subswitch.
4. Install in the reverse order of removal.
POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION (VEHICLES BUILT FROM
08/2002)
Passengers side
1. Disconnect the negative battery cable.
2. Remove the screw.
3. Remove the switch panel.

S15

6. Install in the reverse order of removal.

POWER WINDOW SYSTEM


POWER WINDOW SUBSWITCH INSPECTION
(VEHICLES BUILT UP TO 07/2002)
1. Remove the power window subswitch. (Refer to
POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the power window
subswitch terminals using an ohmmeter.
Passengers side
: Continuity
Terminal

Switch position

Off
Close
Open

E
CLOSE
OPEN

Rear
: Continuity
Terminal

Switch position

FRONT POWER WINDOW REGULATOR


REMOVAL/INSTALLATION
1. Raise the rear edge of the front door glass 80 mm
{3.1 in} from the fully lowered position.
2. Disconnect the negative battery cable.
3. Remove the front glass guide and the rear glass
guide. (Refer to DOOR, FRONT DOOR
DISASSEMBLY/ASSEMBLY.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

Close
B

Off

Open

8.912.7
{90130, 79112}

D
C

B
A

B
F

CLOSE
OPEN
E

D
C
6.879.80
{70100, 60.886.7}

3. If not as specified, replace the power window


subswitch.
Nm {kgfcm, inlbf}

POWER WINDOW SUBSWITCH INSPECTION


(VEHICLES BUILT FROM 08/2002)
1. Inspect for continuity between the power window
subswitch terminals.
D If not as specified, replace the power window
subswitch.

S16

Front power window regulator connector

Bolt

Nut

Front power window regulator

POWER WINDOW SYSTEM


FRONT POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
A

D
C

3.04.9 Nm
{3050 kgfcm,
2743 inlbf}

Bolt

Power window motor


+ Disassembly Note
+ Assembly Note

Frame

6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}

Rear power window regulator connector

Bolt

Rear power window regulator

REAR POWER WINDOW REGULATOR


DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3.14.8 Nm
{3149 kgfcm, 2742 inlbf}

Power Window Motor Disassembly Note


D Make marks on the gear and base of the frame
before disassembling the power window motor.
BASE
MARK

GEAR

Power Window Motor Assembly Note


D Align the marks of the gear and the frame to install
the power window motor.
REAR POWER WINDOW REGULATOR
REMOVAL/INSTALLATION
1. Raise the rear door glass completely.
2. Disconnect the negative battery cable.
3. Remove the door screen. (Refer to DOOR, REAR
DOOR DISASSEMBLY/ASSEMBLY.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

S17

Bolt

Power window motor


+ Disassembly Note
+ Assembly Note

Frame

POWER WINDOW SYSTEM


D If not as specified, replace the power window
motor.

Power Window Motor Disassembly Note


D Make marks on the gear and base of the frame
before disassembling the power window motor.

Voltage
Pulse wave: MAX. 5V, MIN. 0V
MARK

Motor operation

BASE

Terminal
2A

2B

UP

GND

B+

DOWN

B+

GND

GEAR

Power Window Motor Assembly Note


D Align the marks of the gear and base of the frame
to install the power window motor.
POWER WINDOW MOTOR INSPECTION
(VEHICLES BUILT UP TO 07/2002)
1. Remove the power window motor. (Refer to
FRONT POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY.) (Refer to REAR
POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY.)
2. Apply battery positive voltage to the power window
motor terminals and inspect the operation of the
power window motor.
B+: Battery positive voltage
Connection

Motor operation

B+

GND

Up

Down

UP

Except Drivers Side


1. Apply battery positive voltage to the power
window motor terminals and inspect the power
window motor.
D If not as specified, replace the power window
motor.
Terminal

Motor operation

UP

GND

B+

DOWN

B+

GND

DOWN

A
B

3. If not as specified, replace the power window


motor.

INITIAL POSITION SETTING

POWER WINDOW MOTOR INSPECTION


(VEHICLES BUILT FROM 08/2002)
Drivers side
1. Disconnect the power window motor connector.
2. Apply battery positive voltage to the power
window motor terminals 2A and 2B and inspect the
power window motor operation.
D If not as specified, replace the power window
motor.
3. Apply battery positive voltage to the power
window motor terminal 1D and connect terminal 1A
to ground.
4. Measure the voltage at terminal 1B and 1C while
performing Step 3.

S18

Note
D A driverside window will not fully close
automatically under the following conditions:
The battery has been disconnected during
vehicle maintenance or for other reasons.
The power window main switch connector,
or driverside power window motor
connector has been disconnected.
Carry out the following procedure to
resume operation:
1. Turn the ignition switch to the ON position.
2. Press the driver side power window main switch
and fully open the driverside window.

POWER WINDOW SYSTEM


3. Pull up the driver side power window main switch
to manualup position to fully close the driver side
window, and keep holding the switch up at the
position for about 2 seconds to complete initial
setting.

S19

POWER DOOR LOCK SYSTEM

POWER DOOR LOCK SYSTEM


DOOR KEY CYLINDER SWITCH
REMOVAL/INSTALLATION
UK Only
1. Raise the door glass fully.
2. Disconnect the negative battery cable.
3. Remove the door screen. (Refer to DOOR, FRONT
DOOR DISASSEMBLY/ASSEMBLY.)
4. Disconnect the door key cylinder switch connector.
5. Remove the door key cylinder switch.
6. Install in the reverse order of removal.
DOOR KEY CYLINDER SWITCH INSPECTION
UK Only
1. Raise the door glass fully.
2. Disconnect the negative battery cable.
3. Remove the door screen. (Refer to DOOR, FRONT
DOOR DISASSEMBLY/ASSEMBLY.)
4. Disconnect the door key cylinder switch connector.
5. Inspect for continuity between the door key
cylinder switch terminals using an ohmmeter.
: Continuity
: Resistance

FRONT DOOR LOCK

SCREW

Terminal

Key cylinder
position

5. Install in the reverse order of removal.

Neutral
Lock

Rear
UK only

Unlock

Note
D The rear door lock-link switch is mounted to the
rear door lock actuator.

R: 9501050
B

UNLOCK

FRONT DOOR
LOCK-LINK SWITCH

1. Remove and install the rear door lock actuator.


(Refer to DOOR LOCK ACTUATOR
REMOVAL/INSTALLATION, Rear.)

LOCK

DOOR LOCK-LINK SWITCH INSPECTION


(VEHICLES BUILT UP TO 07/2002)
Front
1. Disconnect the negative battery cable.
2. Remove the driver-side door screen. (Refer to
DOOR, FRONT DOOR
DISASSEMBLY/ASSEMBLY.)
3. Disconnect the front door lock-link switch
connector.
4. Inspect for continuity between the front door
lock-link switch terminals using an ohmmeter.
: Continuity

6. If not as specified, replace the door key cylinder


switch.
DOOR LOCK-LINK SWITCH
REMOVAL/INSTALLATION
Front

Lock knob
position

Note
D The front door lock-link switch is mounted to
the driver-side door lock.

Lock
Unlock

1. Disconnect the negative battery cable.


2. Remove the driver-side door lock. (Refer to DOOR,
FRONT DOOR DISASSEMBLY/ASSEMBLY.)
3. Remove the screws.
4. Remove the front door lock-link switch from the
front door lock.

S20

Terminal
A

POWER DOOR LOCK SYSTEM

UNLOCK

LOCK

5. If not as specified, replace the front door lock-link


switch.

DOOR LOCK ACTUATOR


REMOVAL/INSTALLATION
Front

Rear
UK only
1. Disconnect the negative battery cable.
2. Remove the door screen.(Refer to DOOR, REAR
DOOR DISASSEMBLY/ASSEMBLY.)
3. Disconnect the rear door lock-link switch
connector.
4. Inspect for continuity between the rear door
lock-link switch terminals using an ohmmeter.
: Continuity

Note
D The front door lock actuator is mounted to the
passenger-side door lock.
1. Disconnect the negative battery cable.
2. Remove the passenger-side door lock. (Refer to
DOOR, FRONT DOOR
DISASSEMBLY/ASSEMBLY.)
3. Remove the screws.
4. Remove the front door lock actuator from the front
door lock.

Terminal

Lock knob position

Lock
Unlock
FRONT DOOR LOCK
UNLOCK

123456567

5. If not as specified, replace the rear door lock


actuator.

FRONT DOOR LOCK ACTUATOR

DOOR LOCK-LINK SWITCH INSPECTION


(VEHICLES BUILT FROM 08/2002)
1. Disconnect the front door lock actuator connector.
2. Inspect for continuity between the door locklink
switch terminals using an ohmmeter.
D If not as specified, replace the front door lock
actuator.

SCREW

5. Install in the reverse order of removal.


Rear
Note
D The rear door lock actuator is mounted to the
rear door lock.
1. Disconnect the negative battery cable.
2. Remove the rear door lock. (Refer to DOOR,
REAR DOOR DISASSEMBLY/ASSEMBLY.)
3. Remove the screws.
4. Disconnect the rod.

S21

POWER DOOR LOCK SYSTEM


D If not as specified, replace the front door lock
actuator.

5. Remove the rear door lock actuator from the rear


door lock.

Actuator operation

REAR DOOR LOCK

Connectio
B+

GND

Lock

Unlock

SCREW

ROD
REAR DOOR
LOCK ACTUATOR

6. Install in the reverse order of removal.


DOOR LOCK ACTUATOR INSPECTION
(VEHICLES BUILT UP TO 07/2002)
1. Disconnect the negative battery cable.
2. Remove the door screen. (Refer to DOOR, FRONT
DOOR DISASSEMBLY/ASSEMBLY.) (Refer to
DOOR, REAR DOOR
DISASSEMBLY/ASSEMBLY.)
3. Disconnect the door lock actuator connector.
4. Apply battery positive voltage to the door lock
actuator terminals and inspect the operation of the
door lock actuator.
B+: Battery positive voltage
Terminal
A

DOOR LOCK TIMER UNIT


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the flasher unit. (Refer to section T,
EXTERIOR LIGHTING SYSTEM, FLASHER UNIT
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Actuator operation

GND

B+

Lock

B+

GND

Unlock
FRONT, REAR

UNLOCK

LOCK
A

REAR (WITH DOOR-LOCK


LINK SWITCH)

5. If not as specified, replace the door lock actuator.


DOOR LOCK ACTUATOR INSPECTION
(VEHICLES BUILT FROM 08/2002)
Drivers side
1. Disconnect the door lock actuator connector.
2. Apply battery positive voltage to the operation of
the door lock actuator.

S22

Door lock timer unit connector

Nut

Bracket

Door lock timer unit

POWER DOOR LOCK SYSTEM


DOOR LOCK TIMER UNIT INSPECTION (VEHICLES BUILT UP TO 07/2002)
1. Remove the flasher unit. (Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT
REMOVAL/INSTALLATION.)
2. Measure the voltage at the door lock timer unit terminals as indicated below.
3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals A, C, D, and H.
4. If not as specified, inspect the parts listed under Inspection area and the related wiring harnesses.
5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock
timer unit.
Terminal Voltage List (Reference)
B+: Battery positive voltage

Terminal

Signal

Connection

Test condition

Voltage (V)
/Continuity

Inspection area

GND

Body ground

Constant: inspect for continuity to


ground

Yes

Power supply

D/L 30 A fuse

Constant

B+

Door lock-link switch is at lock:


inspect for continuity to terminal H

No

Unlock input

Door lock-link
switch

Door lock-link switch is at unlock:


inspect for continuity to terminal H

Yes

Door lock-link switch is at lock: inspect


for continuity to terminal H

Yes

Door lock-link switch is at unlock:


inspect for continuity to terminal H

No

E
F

Lock input

Lock output
Unlock output

G
H

GND

Door lock-link
switch
Door lock
actuator

Door lock actuators are locked

Door lock
actuator

Door lock actuators are unlocked

Other
Other

Not used
Terminal A of
door lock timer
unit

Constant: inspect for continuity to


terminal A

S23

D/L 30 A fuse
Door lock-link
switch

Door lock-link
switch

Door lock
actuator

Door lock
actuator

Yes

POWER DOOR LOCK SYSTEM


DOOR LOCK TIMER UNIT INSPECTION (VEHICLES BUILT FROM 08/2002)
1. Remove the door lock timer unit without disconnecting the connector.
2. Measure the voltage at the door lock timer unit terminals as indicated below.
3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals K, L, M, and N.
D If not as specified, inspect the parts listed under Action.
D If the parts and wirring harnesses are okay but the system still does not work properly, replace the door lock
timer unit.
Terminal voltage list (Reference)

Terminal

Signal
Power
supply

Unlock
output

Lock
output

Lock/
Unlock
input

Connected to

D/L 30 A fuse

Test condition

Under any condition

Voltage (V)/
Continuity
B+

Action
D Inspect D/L 30 A fuse
D Inspect related har-

ness

Door lock
actuator

Door lock
actuator

Keyless unit

Door lock actuator is unlocked

0 B+ 0

Other

Below 1.0

Door lock actuator is locked

0 B+ 0

Other

Below 1.0

Transmitter lock button is pressed

B+ 5 B+

Transmitter unlock button is


pressed

B+ 0 B+

No transmitter unlock buttons are


pressed

B+

D Inspect door lock

actuator
D Inspect related

harness
D Inspect door lock

actuator
D Inspect related

harness
D Inspect keyless unit
D Inspect transmitter
D Inspect related

harness

Yes

D Inspect door locklink

Lock
input

Unlock
input

Power
ground

Door locklink
switch

Door locklink
switch

GND

Drivers side door is locked:


inspect for continuity to ground
Drivers side door is unlocked:
inspect for continuity to ground

No

Drivers side door is locked:


inspect for continuity to ground

No

Drivers side door is unlocked:


inspect for continuity to ground

Under any condition: inspect for


continuity to ground

S24

Yes

Yes

switch
D Inspect related

harness
D Inspect door locklink

switch
D Inspect related

harness

D Inspect GND

POWER DOOR LOCK SYSTEM


KEYLESS UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Nut

Keyless unit connector

Keyless unit

KEYLESS UNIT DISASSEMBLY/ASSEMBLY


1. Remove the screw.
Note
D The screw which fixes the keyless unit bracket
is for a body ground connection. Be sure to
secure the screw when installing.
2. Slide the bracket the arrow and remove it.
3. Assemble in the reverse order of disassembly.

S25

POWER DOOR LOCK SYSTEM


KEYLESS UNIT INSPECTION
1. Remove the keyless unit without disconnecting the connector.
2. Measure the voltage at the keyless unit terminals (other than terminal L) as indicated below.
D If not as specified, inspect the parts listed under Action.
3. Disconnect the negative battery cable.
4. Disconnect the keyless unit connector and inspect for continuity between terminal L and the bracket.
5. Inspect for continuity at terminal L as indicated below.
6. If the parts and wiring harnesses are okay but the system still does not work properly, perform the
troubleshooting.
Terminal voltage list (Reference)

Terminal

Signal

Connected to

Test condition
Ignition switch is at ON position

IG1

METER 15 A
fuse

Voltage (V)/
Continuity

Action

B+

D Inspect METER 15 A

fuse
Ignition switch is at LOCK or ACC
position

Below 1.0

D Inspect related

harness
D Inspect ROOM 10 A

Power
supply

ROOM 10 A
fuse

Under any condition

B+

fuse
D Inspect related

harness

Door
open/
closed

Door switch

Any door is open (any door switch


is on)

Below 1.0

All door are closed (door swityches


are off)

B+

D Inspect door switches


D Inspect related

harness

*1 H

Hazard

Flasher unit

Transmitter LOCK button is


pressed

B+ Below
1.0 B+

Transmitter UNLOCK button is


pressed

B+ Below
1.0 B+
Below
1.0 B+

No transmitter buttons are pressed

B+

D Inspect flasher unit


D Inspect related

harness

Yes

Under any condition: inspect for


continuity to ground

Ground

GND

S26

POWER DOOR LOCK SYSTEM

Terminal

Signal

Connected to

Test condition
Transmitter LOCK button is
pressed

Lock/
unlock
output

Door lock timer


unit

Transmitter UNLOCK button is


pressed
No transmitter buttons are pressed

Voltage (V)/
Continuity

Action

B+ 6 B+

*2 5

2.5 5

B+ Below
1.0 B+
*25 Below
1.0 5

D Inspect door lock

timer unit
D Inspect related

harness

B+
*2 5

*1 :Except vehicles with theftdeterrent system.


*2 :Vehicles with theftdeterrent system.

TRANSMITTER BATTERY REPLACEMENT


1. Insert a small screwdriver in to the slot and gently
pry open the transmitter.

Battery specification
Lithium CR2025 X 1
Note
D The batteries will last about 2 years when used
10 times a day.
TRANSMITTER BATTERY INSPECTION
Caution
D Since the battery voltage does not drop
fully if the button is pushed for only 4
seconds or less, it can not be properly
examined to see whether it is good or bad.
Always push the button for 5 seconds.

2. Press the portion of the battery indicated by A and


remove the battery.
3. Install a new (CR2025) into the front portion of the
holder with the positive pole (+) facing up. Press
on the B portion of the battery to set the battery.

Note
D A correct measurement can not be obtained if
the battery temperature is low. Make sure the
battery is at 18 _C {64 _F} or more for at least
30 minutes before reinspecting if a
measurement value is under the standard
voltage.
1. Remove the transmitter cover.
2. Apply the circuit tester leads to the positions
indicated in the figure.

4. Align the front and back covers and snap the


transmitter shut.

S27

POWER DOOR LOCK SYSTEM


3. While pressing the battery as shown in the figure,
press the LOCK and UNLOCK buttons on the
transmitter at the same time to start measurement
of the voltage.
4. Release the buttons after 5 seconds.

5. Verify that the minimum voltage is the standard


voltage or more for 10 seconds after starting
measurement.
D If the voltage is under the standard voltage,
replace the battery
Standard voltage
2.7 V

S28

FUEL-FILLER LID AND OPENER, BUMPER

FUEL-FILLER LID AND OPENER

BUMPER

FUEL-FILLER LID REMOVAL/INSTALLATION


1. Remove as indicated in the table.
2. Install in the reverse order of removal.

FRONT BUMPER REMOVAL/INSTALLATION


1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

6393 {6.49.5, 4768}


6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}

Fuel-filler lid

FUEL-FILLER LID ADJUSTMENT


1. Measure the gap and height between the fuel-filler
lid and the body.

6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}

Clearance
a: 3.55.5 mm {0.140.21 in}
b: 0.52.0 mm {0.010.07 in}

6393 {6.49.5, 4768}


Nm {kgfm, ftlbf}

A
a

b
A

Front bumper

Front bumper stay

FRONT BUMPER DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
0.20.8 {29, 27}

SEC.AA

2. If not as specified, loosen the fuel-filler lid


installation bolts and reposition the fuel-filler lid.
3. Tighten the fuel-filler lid installation bolts.

6.879.80 {70100, 60.886.7}

0.20.3 {24, 23}

12345678

Nm {kgfcm, inlbf}

S29

Front bumper side fascia

Front bumper upper fascia

Front bumper lower fascia

BUMPER
REAR BUMPER REMOVAL/INSTALLATION
With Step
1. Remove the bolts, then remove the rear bumper.

REAR BUMPER DISASSEMBLY/ASSEMBLY


With Step
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}
3246
{3.24.7,
2433}
A
A

A
B

BOLT
79116
{8.011.9,
58.086.0}

6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}

REAR BUMPER

A
B

0.300.78 Nm
{3.08.0 kgfcm,
2.76.9 inlbf}

Nm {kgfm, ftlbf}

Nm {kgfm, ftlbf}

2. Install in the reverse order of removal.


Without Step
1. Disconnect the negative battery cable.
2. Disconnect the rear fog light connector.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Side bumper step


+ Removal Note

Center bumper step


+ Removal Note

Rear bumper fascia

Rear bumper stay

Rear bracket

Set plate

Side Bumper Step Removal Note


1. Disengage clips A using pliers.
2. Pull the side bumper step upward, then remove it.

SIDE BUMPER STEP

79116
{8.011.9,
58.086.0}

1622
{1.62.3,
1216}
Nm {kgfm, ftlbf}

Rear bumper stay

Rear bumper fascia

CLIP A

Center Bumper Step Removal Note


1. Remove the screws.
2. Disengage clips A using pliers.
3. Disengage clips B, then remove the center bumper
step.
12345678

S30

BUMPER, EXTERIOR ATTACHMENT


B

SCREW

B
A

SCREW
A

CENTER BUMPER STEP

SCREW

CLIP B

EXTERIOR ATTACHMENT
RADIATOR GRILLE REMOVAL/INSTALLATION
1. Pull the radiator grille toward you, then disengage
clips A to remove the radiator grille.

SCREW

CLIP A

A
CLIP

RADIATOR GRILLE

2. Install in the reverse order of removal.


COWL GRILLE REMOVAL/INSTALLATION
1. Remove the windshield wiper arm and blade.
(Refer to section T, WIPER AND WASHER,
WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
2. Remove the weatherstrip.
3. Remove the screws, then remove the cowl grille.

SCREW

COWL GRILLE

WEATHERSTRIP

4. Install in the reverse order of removal.


WINDSHIELD GARNISH REMOVAL/INSTALLATION
1. Remove the screws.
2. Pull the windshield garnish upward, then
disengage hook A from the cowl grille.

S31

EXTERIOR ATTACHMENT
CENTER SIDE
PROTECTOR
(REGULAR CAB)

FRONT SIDE PROTECTOR


d

b
c

d
ca

a
e

SCREW

c
DOUBLE-SIDED ADHESIVE TAPE
CENTER SIDE
REAR SIDE PROTECTOR
PROTECTOR
(STRETCH CAB)
d
d
d
b
c
c a
a

WINDSHIELD
GARNISH
COWL GRILLE

e e

a c
c

HOOK

1. Install in the reverse order of removal.

4. Peel off the backing paper from the double-sided


adhesive tape and attach the side protector onto
the body as shown.

SIDE PROTECTOR REMOVAL


Warning
D Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.

Clearance
a : 4.85.8 mm {0.190.22 in}
b : 5.06.0 mm {0.200.23 in}
c : 13.014.0 mm {0.510.55 in}
d : 16.517.0 mm {0.650.66 in}
e : 12.313.3 mm {0.490.52 in}
f : 6.08.0 mm {0.240.31 in}

1. Pry the side protector end 2030 mm {0.791.18


in} using a flathead screwdriver or a razor.
2. Pull the side protector forward, then remove it.

Regular Cab
Note
D The side protector is installed with
double-sided adhesive tape. If the side
protector is difficult to remove, soften the
double-sided adhesive tape using a hot air
blower.

CENTER SIDE PROTECTOR

Clearance
a : 03.0 mm {00.11 in}
b : 37.5 mm {1.48 in}
c : 10.0 mm {0.39 in}
d : 2.05.0 mm {0.080.19 in}
e : 25.0 mm {0.98 in}

A
A

SIDE PROTECTOR INSTALLATION


1. Remove the adhesive remaining on the side
protector (if it will be reused) and the body using a
razor knife.
2. Remove any grease or dirt from the adhesion
surface of the side protector (if it will be reused)
and the body.
3. Attach double-sided adhesive tape to the side
protector as shown (if it will be reused).

REAR SIDE
PROTECTOR

FRONT SIDE PROTECTOR

SEC. AA

Stretch Cab 2 Door


CENTER SIDE PROTECTOR
REAR SIDE
PROTECTOR

FRONT SIDE PROTECTOR


a

A
A

SEC. AA

S32

EXTERIOR ATTACHMENT
Clearance
a : 4.85.8 mm {0.190.22 in}
b : 5.06.0 mm {0.200.23 in}
c : 3.977.97 mm {0.160.31 in}

Double Cab

FRONT SIDE PROTECTOR


A
A

REAR SIDE PROTECTOR


f
e
b

SEC. AA

5. After installing the side protector to the body, apply


pressure of 50 Nm {5.0 kgfm, 37 ftlbf} or more
with a roller, etc.
SIDE PROTECTOR INSTALLATION
(STRETCH CAB 4 DOOR)
1. Remove the adhesive remaining on the side
protector (if to be reused) and the body using a
razor.
2. Remove any grease or dirt from the adhesion
surface of the side protector (if to be reused) and
body.
3. Attach doublesided adhesive tape to the side
protector as shown (if to be reused).
Clearance
a : 03.0 mm {00.11 in}
b : 23.0 mm {0.91 in}
c : 8.0 mm {0.31}
d : 2.05.0 mm {0.080.19 in}
e : 25.0 mm {0.98 in}
f : 6.0 mm {0.24 in}
g : 27.0 mm {1.06 in}
h : 1.0 mm {0.04 in}

OVER FENDER REMOVAL/INSTALLATION


(VEHICLES BUILT UP TO 07/2002)
1. Remove the screws.
2. Remove the fasteners.
3. Disengage clips A of the over fender using a
fastener remover, then remove the over fender.
FRONT
CLIP
A

A
A
A

OVER FENDER
FASTENER
REAR
A
A

SCREW
A

CLIP
A

OVER FENDER

SCREW
FASTENER

4. Install in the reverse order of removal.

4. Peel off the wax paper from the doublesided


adhesive tape and attach the side protector onto
the body as shown.

S33

EXTERIOR ATTACHMENT
OVER FENDER REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/20002)
Front
1. To remove the front over fender No.1, remove the
front bumper.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Rear
1. To remove the front over fender No.1, remove the
front bumper.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

CLIP A
A

A
A

A
A

7
3

VUE0035454

DOUBLE CAB

2
7

EXCEPT
DOUBLE CAB

CLIP A

5
A

8
1

Rivet

VUE0035455

Fastener

Rivet A

Screw A

Screw A

Screw B

Rear over fender No. 2

Front over fender No. 2

Screw B

Nut

Fastener

Front over fender No. 1

Screw C (except double cab)

Screw D

Rear over fender No. 1

Screw E (B Series only)

10

Screw F (B Series only)

11

Rivet B

12

Rear flap (B Series only)


(See Rear flap removal note)
(See Rear flap installation note)

S34

5
A

EXTERIOR ATTACHMENT
Rear flap removal note
1. While cutting the doublesided adhesive tape
using a screw driver or a razor, separate the rear
flap from the rear over fender No. 2.

TAILGATE DISASSEMBLY/ASSEMBLY
1. Remove the cover.
2. Remove the nuts attaching the tailgate lock.
3. Disconnect the rods from the tailgate lock.
4. Remove the tailgate lock.

Warning
D Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.

NUT

TAILGATE LOCK

ROD

5. Remove the bolts, then remove the latch guide,


latch and rod.
BOLT

ROD

Rear flap installation note


LATCH GUIDE

Note
D Doublesided adhesive tape has already been
attached to the new rear flap.

LATCH

Warning
D Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.
1. When installing a new rear flap, follow the
procedure below:
(1) Remove the adhesive remaining on the rear
over fender No. 2 using a razor.
(2) Remove any grease or dirt from the adhesion
surface of the rear over fender No. 2.
2. When reusing the rear flap, follow the procedure
below:
(1) Remove the adhesive remaining on the rear
flap and the rear over fender No. 2 using a
razor.
(2) Remove any grease or dirt from the adhesion
surface of the rear flap and the rear over
fender No. 2.
(3) Apply primer to the bonding area of the rear
flap.
(4) Attach doublesided adhesive tape to the rear
flap as shown.
3. Peel off the backing of the doublesided adhesive
tape, install the rear flap to the rear over fender No.
2.

6. Remove the handle.


7. Assemble in the reverse order of disassembly.
TAILGATE ADJUSTMENT
1. Loosen the bolts.
2. Move the striker forward and rearward until the
tailgate will lock properly.
3. After the correct adjustment is made, tighten the
bolts securely.

S35

BOLT
STRIKER

EXTERIOR ATTACHMENT, MOLDING


ROPE HOOK REMOVAL/INSTALLATION
1. Remove the screws and bolts, then remove the
rope hook.

ROPE HOOK
SCREW

MOLDING
WINDSHIELD UPPER MOLDING REMOVAL
D Remove the windshield upper molding from the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD REMOVAL.)
WINDSHIELD UPPER MOLDING INSTALLATION
D Install the windshield upper molding to the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD INSTALLATION.)
WINDSHIELD SIDE MOLDING REMOVAL
D Remove the windshield side molding from the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD REMOVAL.)

ROPE HOOK

WINDSHIELD SIDE MOLDING INSTALLATION


D Install the windshield side molding to the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD INSTALLATION.)

BOLT

2. Install in the reverse order of removal.

FRONT BELTLINE MOLDING


REMOVAL/INSTALLATION
1. Lower the front door glass fully.
2. Remove the manual outside mirror or the power
outside mirror. (Refer to OUTSIDE MIRROR,
MANUAL OUTSIDE MIRROR
REMOVAL/INSTALLATION.) (Refer to OUTSIDE
MIRROR, POWER OUTSIDE MIRROR
REMOVAL/INSTALLATION.)
3. Pull the rear end of the front beltline molding to
disengage the hook.
FRONT BELTLINE MOLDING

HOOK

4. Pull the front beltline molding upward, then remove


clips A.
A

BELTLINE
MOLDING

CLIP
A

5. Install in the reverse order of removal.

S36

MOLDING, OUTSIDE MIRROR


REAR BELTLINE MOLDING
REMOVAL/INSTALLATION
1. Lower the rear door glass fully.
2. Pull the rear end of the rear beltline molding to
disengage the hook.

OUTSIDE MIRROR
MANUAL OUTSIDE MIRROR
REMOVAL/INSTALLATION
1. Remove the inner garnish.
2. Remove the front door trim. (Refer to TRIM,
FRONT DOOR TRIM REMOVAL/INSTALLATION.)
3. Remove the screws.
4. Remove the manual outside mirror.

REAR BELTLINE MOLDING

MANUAL OUTSIDE MIRROR


SCREW

HOOK

3. Pull the rear beltline molding upward, then remove


clips A.
5. Install in the reverse order of removal.

BELTLINE
MOLDING
CLIP
A

4. Install in the reverse order of removal.

POWER OUTSIDE MIRROR


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the inner garnish.
3. Remove the front door trim. (Refer to TRIM,
FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. Partially peel off the door screen.
5. Disconnect the power outside mirror connector.
6. Remove the screws.
7. Remove the power outside mirror.

ROOF MOLDING REMOVAL/INSTALLATION


1. Pull the rear edge of roof molding upward, then
disengage clips A.

SCREW

POWER OUTSIDE MIRROR

ROOF MOLDING
ROOF MOLDING

POWER OUTSIDE MIRROR


CONNECTOR

CLIP
BODY
A

2. Install in the reverse order of removal.

8. Install in the reverse order of removal.


POWER OUTSIDE MIRROR INSPECTION
1. Disconnect the negative battery cable.
2. Remove the inner garnish.
3. Remove the front door trim. (Refer to TRIM,
FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. Partially peel off the door screen.
5. Disconnect the power outside mirror connector.
6. Apply battery positive voltage to the power outside
mirror and inspect the operation of the power
outside mirror.

S37

OUTSIDE MIRROR
B+: Battery positive voltage
Connection
B+

GND

Mirror
operation

Up

Down

Left

Right

: Continuity
Switch
position

Terminal
I

Up
Down
LH
Left

Right
Up

DOWN UP

M
LEFT

Down
*

123456567

RH

RIGHT

Left

Right

1. If not as specified, replace the power outside


mirror.
POWER OUTSIDE MIRROR SWITCH
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the fuse block cover.
3. Remove the fuse block installation screws, and
push the fuse block into the dashboard.
4. Insert your hand into the hole for the fuse block,
and press the hooks of the power outside mirror
switch.
5. Push the power outside mirror switch out, then
remove it.
6. Disconnect the power outside mirror switch
connector.
POWER OUTSIDE
MIRROR SWITCH
POWER
OUTSIDE
MIRROR
SWITCH
CONNECTOR

3. If not as specified, replace the power outside mirror


switch.

7. Install in the reverse order of removal.


POWER OUTSIDE MIRROR SWITCH INSPECTION
1. Remove the power outside mirror switch. (Refer to
POWER OUTSIDE MIRROR SWITCH
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the power outside
mirror switch terminals using an ohmmeter.

S38

REARVIEW MIRROR, REAR WINDOW DEFROSTER

REARVIEW MIRROR

REAR WINDOW DEFROSTER

REARVIEW MIRROR REMOVAL/INSTALLATION


Regular Cab

REAR WINDOW DEFROSTER SWITCH


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the meter hood.
3. Press the hooks of the rear window defroster
switch and push the switch out.

Note
D The rearview mirror is attached to the interior
light. (Refer to section T, INTERIOR LIGHTING
SYSTEM, INTERIOR LIGHT
REMOVAL/INSTALLATION, Regular Cab.)
Stretch Cab, Double Cab
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

HOOK

REAR WINDOW
DEFROSTER
SWITCH

2.03.9
{2040, 1834}

Nm {kgfcm, inlbf}

Cover

Screw

Rearview mirror

METER HOOD

4. Install in the reverse order of removal.


REAR WINDOW DEFROSTER SWITCH
INSPECTION
1. Remove the rear window defroster switch.
2. Inspect for continuity between the rear window
defroster switch terminals using an ohmmeter.
: Continuity
: Bulb
Switch
position

Terminal
A

ON
OFF

3. If not as specified, replace the rear window


defroster switch.
FILAMENT INSPECTION
1. Turn the ignition switch to ON position.
2. Turn the rear window defroster switch on.
Caution
D Directly touching the rear window defroster
filament with the lead of the circuit tester
will damage it. Wrap aluminum foil around
the end of the lead and test the filament by
touching it with the foil.

S39

REAR WINDOW DEFROSTER


Caution
D Do not use the rear window defroster until
the paint is completely dry. It may cause
other malfunctions if it is used before the
paint is dry.

LEAD OF THE CIRCUIT TESTER


PUSH

5. Use a hot air blower heated to 150C {302F} for


30 minutes or let the paint set for 24 hours at
25C {77F} to allow it to dry completely.

FILAMENT

ALUMINUM FOIL

1. Connect the positive ()) lead of the voltmeter to


the positive side of each filament and the negative
(*) lead to ground.
2. Gradually, slide the positive ()) lead from the
positive side to the negative side and measure the
voltage. Verify that the voltage decreases
accordingly.
Measurement place

Voltage (Reference value)

(1) (2)

Approx. 12 V Approx. 0 V

(2)
NEGATIVE
SIDE

REAR WINDOW DEFROSTER RELAY


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Disconnect the rear window defroster relay
connector.
3. Slide the rear window defroster relay upward, then
remove it.

REAR
WINDOW
DEFROSTER
RELAY

REAR WINDOW
DEFROSTER RELAY CONNECTOR

(1)
POSITIVE
SIDE

4. Install in the reverse order of removal.


REAR WINDOW DEFROSTER RELAY INSPECTION
1. Remove the rear window defroster relay. (Refer to
REAR WINDOW DEFROSTER RELAY
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the rear window
defroster relay terminals using an ohmmeter.
: Continuity B+: Battery positive voltage

3. If the voltage is not as specified or it changes


rapidly, the filament is faulty. Repair the filament.
FILAMENT REPAIR
1. Use white gasoline to clean around the damaged
section of the filament.
2. Attach tape above and below the damaged section
of the filament.
BROKEN FILAMENT

Terminal

Step

B)

GND

1
2

TAPE

SECTION TO BE REPAIRED

3. Using a small brush or marking pen, repair the


filament with silver paint or equivalent.
4. After approximately 23 minutes, carefully
remove the tape without disturbing the repaired
area.

3. If not as specified, replace the rear window


defroster relay.

S40

WINDOW GLASS
Reusing Windshield
1. Make a hole through the sealant from the inside of
the vehicle using an awl.
2. Pass the SST (piano wire) through the hole.

WINDOW GLASS
WINDSHIELD REMOVAL
1. Remove the cowl grille.(Refer to EXTERIOR
ATTACHMENT, COWL GRILLE
REMOVAL/INSTALLATION.)
2. Apply protective tape to the headliner, the body
and the dashboard.

PROTECTIVE TAPE

WINDSHIELD UPPER
MOLDING
R

Warning
D Using a razor knife with bare hands can
cause injury. Always wear gloves when
using a razor knife.

SEALANT

HEADLINER
PROTECTIVE TAPE

3. Wind each end of the wire around a bar.

3. Cut the lip of the windshield upper molding using a


razor knife.

PROTECTIVE
TAPE

WINDSHIELD
DAM

Note
D The windshield upper molding and windshield
side molding are replacement parts.

49 0305 870A

WINDSHIELD
UPPER MOLDING

Note
D Use the entire length of piano wire to prevent it
from breaking when cutting through the
sealant.
4. Working with another person, saw through the
sealant around the edge of the glass, being careful
not to damage the body.

LIP

Not Reusing Windshield


Warning
D Using a piano wire with bare hands can
cause injury. Always wear gloves when
using a piano wire.

49 0305 870A

Note
D For the areas of the sealant that are difficult to
cut, use a piano wire and follow the procedures
under Reusing Windshield.

5. Remove the windshield.


6. Remove the spacers from the body.
7. Remove the spacer and the dam from the glass.
CENTER

1. Use a tool like that shown in the figure, and insert


the blade into the sealant.
2. Pull through the sealant around the edge of the
glass.

DAM

SPACER

8. Remove the windshield upper molding and the


windshield side molding from the windshield.

3. Remove the windshield.


4. Remove the spacers from the body.

S41

WINDOW GLASS

WINDSHIELD UPPER MOLDING

GLASS MARK

WINDSHIELD

WINDSHIELD SIDE MOLDING

WINDSHIELD
SIDE MOLDING

WINDSHIELD

WINDSHIELD INSTALLATION

7. Securely bond a dam along the circumference of


the glass 8.5 mm {0.33 in} from the upper edge
and 14.5 mm {0.57 in} from the lower and side
edge.
8. Install the spacer to the glass.

Warning
D Using a razor knife with bare hands can
cause injury. Always wear gloves when
using a razor knife.

CENTER
8.5 {0.33}

Caution
D To prevent the sealant from cracking or the
glass from being pushed out by air
pressure if a door is closed, open all of the
windows and leave them open until the
sealant has hardened.
1. Cut away the old sealant using a razor knife so that
12 mm {0.040.07 in} thickness of sealant
remains around the circumference of the frame. If
all the sealant has come off in any one place, apply
some primer after degreasing, and allow it 30
minutes to dry. Then put on new sealant to create
a 2 mm {0.08 in} layer.
2. Clean and degrease an approximately 50 mm
{1.97 in} wide strip around the circumference of
the glass and the bonding area on the body.
3. Align the center mark on the windshield upper
molding with the glass mark.
4. Install the windshield upper molding from the
center toward both sides.

14.5 {0.57}
6.0 {0.24}

DAM

SPACER

14.5 {0.57}

14.5 {0.57}

CERAMIC
PARTING
LINE
mm {in}

9. Install spacers into the hole of the body.


10. Temporarily install the glass onto the body and
adjust the glass to body clearance.
11. Make a mark on the glass directly above the
V-notch of spacers.
12. Verify that the gap along the upper edge is
7.5 mm {0.30 in}.
7.5 {0.30}

CENTER

MARKING

BODY

WINDSHIELD UPPER MOLDING


MARK

SPACER

GLASS MARK

mm {in}

13. Remove the windshield.


WINDSHIELD

Caution
D Keep the area free of dirt and grease, and
do not touch the surface or the primer may
not properly bond to the surface of the
glass and body, which may cause leaks to
occur.

5. Align the upper edge of the windshield side


molding with the glass mark.
6. Install the windshield side molding from the upper
part towards the lower part.

14. Use a brush to apply primer to the bonding area of


the glass and body within the region shown. Use
only glass primer on the glass and body primer on
the body and molding. Allow it to dry for
approximately 30 minutes.

S42

WINDOW GLASS

8.5 {0.33}

UPPER

GLASS
PRIMER

14.5 {0.57}

BODY

WINDSHIELD

GLASS
PRIMER
BODY
PRIMER

BODY
PRIMER

13.0 {0.51}

UPPER

SEALANT

SIDE

14.5 {0.57}

ADJUST SEALANT
IN THIS AREA

SIDE

GLASS
PRIMER
BODY
PRIMER

DAM

19.0 {0.75}

BODY
PRIMER
19.0
{0.75}

WINDSHIELD

BODY

16.0 {0.63}

LOWER

DAM

WINDSHIELD
SIDE MOLDING
WINDSHIELD
UPPER MOLDING

BODY PRIMER

ADJUST SEALANT
IN THIS AREA
mm {in}

15. Once the primer is dry, apply a 11.0 mm {0.43 in}


high, 5.0 mm {0.20 in} wide bead of sealant along
the dam around the entire circumference to fill the
gap between the dam and the edge of the
windshield.

Hardening time of sealant

5.0
{0.20}

11.0
{0.43}

Temperature

Surface
hardening time

Time required
until car can be
put into service

5 C {41 F}

Approx. 1.5 h

Approx. 12 h

20 C {68 F}

Approx. 1 h

Approx. 4 h

35 C {95 F}

Approx. 10 min

Approx. 2 h

20. Use white gasoline to remove any sealant that


oozes out.
21. Install the cowl grille. (Refer to EXTERIOR
ATTACHMENT, COWL GRILLE
REMOVAL/INSTALLATION.)

DAM

mm {in}

16. Align the glass marks with the V-notches in


spacers and install the glass onto the body.
17. Press firmly inward on the glass to compress the
sealant.
18. Verify that the gap along the upper and side edge
is 7.5 mm {0.30 in}.
19. Adjust the sealant as indicated in the figure.

S43

WINDOW GLASS
QUARTER WINDOW GLASS REMOVAL/INSTALLATION
(STRETCH CAB 2 DOOR)
1. To remove the quarter window hinge, remove the quarter upper trim. (Refer to TRIM, QUARTER UPPER TRIM
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Hinge cover

Quarter window glass

Quarter window hinge

Quarter window glass weatherstrip

Quarter window lock

S44

WINDOW GLASS
QUARTER WINDOW GLASS REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR)
1. Remove the rear access panel trim. (See REAR ACCESS PANEL TRIM REMOVAL/INSTALLATION.)
2. Remove the upper latch. (See REAR ACCESS PANEL DISASSEMBLY/ASSEMBLY.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of the removal.

Quarter window hinge

Quarter window glass

Quarter window lock

Weatherstrip

REAR WINDOW GLASS REMOVAL


1. Remove the headliner. (Refer to HEADLINER,
HEADLINER REMOVAL/INSTALLATION.)
2. Remove the rear window defroster connector if
equipped.
3. While another person presses the rear window
glass, use the SST to push the lip of the rear
window weatherstrip from the inside.
REAR WINDOW WEATHERSTRIP

remove it with the rear window weatherstrip


attached.
5. Remove the rear window weatherstrip from the
rear window glass.
REAR WINDOW GLASS INSTALLATION
1. Clean and degrease the body and the rear window
glass.
2. Install the rear window weatherstrip to the rear
window glass.
REAR WINDOW WEATHERSTRIP

LIP

49 0259 866A

4. After the top of the rear window weatherstrip is


removed, push the rear window glass outside and

S45

WINDOW GLASS
3. Fit the SST into the rear window weatherstrip and
cross the ends as shown, leave 200 mm {7.87 in}.
REAR WINDOW WEATHERSTRIP

49 0259 866A
200 {7.87}

mm {in}

4. Apply soapy water as shown.


REAR WINDOW WEATHERSTRIP
BODY

SOAPY WATER

5. Align the rear window glass with the rear window


weatherstrip and body.
6. While another person lightly taps the outside of the
rear window glass near the rear window
weatherstrip all around its circumference, pull one
end of the SST and install the rear window glass.

49 0259 866A

7. Install the rear window defroster connector if


equipped.
8. Install the headliner. (Refer to HEADLINER,
HEADLINER REMOVAL/INSTALLATION.)

S46

DASHBOARD AND CONSOLE

DASHBOARD AND CONSOLE


DASHBOARD REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the driver-side air bag module. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG
MODULE REMOVAL/INSTALLATION.)
3. Remove the passenger-side air bag module. (Refer to section T, AIR BAG SYSTEM, PASSENGER-SIDE AIR
BAG MODULE REMOVAL/INSTALLATION.)
4. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION.)
5. Remove the installation bolts then lower the assembled steering shaft from the dashboard. (Refer to section N,
MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
6. Remove the meter hood.
7. Remove the instrument cluster.
8. Remove the front console. (Refer to FRONT CONSOLE REMOVAL/INSTALLATION.)
9. Remove the glove compartment.
10. Remove the bonnet release cable installation nut.
11. Remove the A-pillar trims. (Refer to TRIM, A-PILLAR TRIM REMOVAL/INSTALLATION.)
12. Disconnect the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM,
CLIMATE CONTROL UNIT REMOVAL.) (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT
INSTALLATION.)
13. Remove the fuse block.
14. Remove in the order indicated in the table.
15. Install in the reverse order of removal.
16. Adjust the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM,
CLIMATE CONTROL UNIT ADJUSTMENT.)

7.911.7
{80120, 70104}

7.911.7 {80120, 70104}

7.911.7 {80120, 70104}

Nm {kgfcm, inlbf}

Bolt

S47

Dashboard

DASHBOARD AND CONSOLE


DASHBOARD DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Defroster nozzle

Duct

Side demister nozzle

Dashboard crash pad

Center duct

S48

DASHBOARD AND CONSOLE


DASHBOARD MEMBER REMOVAL/INSTALLATION
1. Remove the dashboard. (Refer to DASHBOARD
REMOVAL/INSTALLATION.)
2. Remove the bolts, then remove the dashboard
member.

FRONT CONSOLE DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

DASHBOARD MEMBER
1622
{1.62.3, 1216}

1622
{1.62.3,
1216}

1622
{1.62.3,
1216}

BOLT

1622
{1.62.3, 1216}
Nm {kgfm, ftlbf}

3. Install in the reverse order of removal.


COLUMN COVER REMOVAL/INSTALLATION
1. Remove the screws, then remove the column
cover.

COLUMN
COVER

Screw

Front console

Boot

Set plate

REAR CONSOLE REMOVAL/INSTALLATION


1. Remove the screws.
2. Pull the rear console upward, then remove it.

SCREW

2. Install in the reverse order of removal.


FRONT CONSOLE REMOVAL/INSTALLATION
1. Remove the rear console.
2. For manual transaxle vehicle, remove the shift
lever knob.
3. Remove the screws, then remove the front
console.

REAR CONSOLE

Caution
D In order to prevent noise caused by
interference with the dashboard, install the
screws to the rear of the front console
before installing the front of the front
console.
FRONT CONSOLE
SCREW

SCREW

3. Install in the reverse order of removal.


4. Install in the reverse order of removal.

S49

DASHBOARD AND CONSOLE


REAR CONSOLE DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

METER HOOD REMOVAL/INSTALLATION


1. Remove the screws.
2. Pull the meter hood toward you, then disengage
clips A and pins B.
SCREW

A B

A B
A

B A

CLIP
B PIN
A

3. Disconnect the connectors, then remove the meter


hood.
4. Install in the reverse order of removal.

Screw

Console lid outer

Console lid inner

Rear console

Console lid lock

Console lid hinge

Console lid bracket

GLOVE COMPARTMENT REMOVAL/INSTALLATION


1. Open the glove compartment and bend the sides
inward to disengage the pins.
2. Pull the glove compartment downward, then
disengage clips A.
PIN
PIN

A
CLIP
A

GLOVE COMPARTMENT

3. Install in the reverse order of removal.

S50

TRIM

TRIM
A-PILLAR TRIM REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002)
1. Remove the quarter upper trim. (Regular cab,
stretch cab) (Refer to QUARTER UPPER TRIM
REMOVAL/INSTALLATION.)
2. Remove the B-pillar upper trim. (Double cab)
(Refer to B-PILLAR UPPER TRIM
REMOVAL/INSTALLATION.)
3. Pull the A-pillar trim toward you, then disengage
clips A and pin B.
4. Pull the A-pillar trim upward, then disengage the
hook.
A

B
A A
CLIP
A
A

A
PIN

B-PILLAR TRIM

A-PILLAR TRIM

B
A
CLIP

CLIP C

PIN

A
HOOK
A

7. Install in the reverse order of removal.

5. Install in the reverse order of removal.


A-PILLAR TRIM REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002)
1. Remove the roof side trim. (See ROOF SIDE TRIM
REMOVAL/INSTALLATION.)
2. Pull the Apillar trim downward to disengage clips
A and pin B.
3. Remove the Apillar trim.

B-PILLAR TRIM REMOVAL/INSTALLATION


(VEHICLES BUILT FROM 08/2002)
1. Remove the roof side trim. (See ROOF SIDE TRIM
REMOVAL/INSTALLATION.)
2. Remove the back upper trim. (See BACK UPPER
TRIM REMOVAL/INSTALLATION.)
3. Remove the back lower trim. (See BACK LOWER
TRIM REMOVAL/INSTALLATION.)
4. Remove the fasteners B.
5. Pull the Bpillar trim to disengage clips A.
6. Remove the Bpillar trim.
7. Install in the reverse order of removal.

4. Install in the reverse order of removal.


B-PILLAR TRIM REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002)
Regular Cab
1. Turn over the seaming welt.
2. Remove the seat belt upper anchor installation
bolt.
3. Remove the back upper trim.
4. Pull the B-pillar trim toward you, then disengage
clips A and pins B.
5. Remove clip C.
6. Remove the seat belt from the B-pillar trim.

S51

TRIM
B-PILLAR LOWER TRIM REMOVAL/INSTALLATION
Double Cab
1. Remove the front scuff plate.
2. Remove the rear scuff plate.
3. Turn over the seaming welt.
4. Pull the B-pillar lower trim indicated by the arrow,
then disengage clips A and pin B.
5. Remove the seat belt from B-pillar trim.
6. Pull the B-pillar lower trim upward, then disengage
hooks C from the body.

FRONT SIDE TRIM REMOVAL/INSTALLATION


1. Remove the scuff plate.
2. Loosen the nut.
3. Pull the front side trim in the direction indicated by
the arrow, then remove it.

NUT

CLIP

FRONT SIDE
TRIM

A
A

4. Install in the reverse order of removal.

PIN
A

ROOF SIDE TRIM REMOVAL/INSTALLATION


(STRETCH CAB 4 DOOR)
1. Remove the screw on the hook.
2. Remove the hook.
3. Pull the roof side trim downward to disengage clips
A and pin B.
4. Remove the roof side trim.

B
A
B-PILLAR
LOWER TRIM
HOOK
C
C

7. Install in the reverse order of removal.


B-PILLAR UPPER TRIM REMOVAL/INSTALLATION
Double Cab
1. Remove the B-pillar lower trim. (Refer to B-PILLAR
LOWER TRIM REMOVAL/INSTALLATION.)
2. Remove the front seat belt upper anchor
installation bolt.
3. Remove the C-pillar trim. (Refer to C-PILLAR
TRIM REMOVAL/INSTALLATION.)
4. Remove the fastener.
5. Pull the B-pillar upper trim toward you, then
disengage clips A and pins B from the body.
A

A
B

CLIP
A
HOOK

A
B

B-PILLAR
UPPER TRIM

FASTENER

6. Install in the reverse order of removal.

S52

5. Install in the reverse order of removal.

TRIM
FRONT SCUFF PLATE REMOVAL/INSTALLATION
1. Remove the screws.
2. Pull the front scuff plate upward, then disengage
pin A.

SCREW
A

3. Install in the reverse order of removal.


C-PILLAR TRIM REMOVAL/INSTALLATION
Double Cab
1. Turn over the seaming welt.
2. Remove the rear seat. (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Double Cab, Rear.)
3. Remove the rear seat belt upper anchor installation
bolt.
4. Remove the fasteners.
5. Pull the C-pillar trim toward you, then disengage
clips A and pin B.
6. Remove the seat belt from C-pillar trim.

PIN

A
FRONT SCUFF PLATE

3. Install in the reverse order of removal.


A

REAR SCUFF PLATE REMOVAL/INSTALLATION


Double Cab
1. Remove the screw.
2. Pull the rear scuff plate upward, then disengage
clips A and pin B.

A
B

CLIP
A
PIN

B
SCREW
REAR SCUFF PLATE

C-PILLAR TRIM

CLIP

PIN
FASTENER

3. Install in the reverse order of removal.


REAR SCUFF PLATE REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR)
1. Pull the scuff plate upward to disengage clips A
and pin B.
2. Remove the scuff plate.

7. Pull the C-pillar trim upward, then remove it from


the body.
8. Install in the reverse order of removal.
QUARTER UPPER TRIM REMOVAL/INSTALLATION
Stretch Cab
1. Remove the back upper trim.
2. Remove the upper anchor of the seat belt.
3. Remove the quarter window lock. (Refer to
WINDOW GLASS, QUARTER WINDOW GLASS
REMOVAL/INSTALLATION.)
4. Remove the hook.
5. Remove the fasteners.
6. Pull the quarter upper trim toward you, then
disengage clips A and pins B.

S53

TRIM

BACK UPPER TRIM REMOVAL/INSTALLATION


1. Insert a flathead screwdriver or equivalent in the
gap between the rear window weatherstrip and
back upper trim, then pull the back upper trim to
disengage clips A and pins B.
2. Remove the back upper trim.

B
CLIP

HOOK
A

PIN
A
A

B
FASTENER

QUARTER UPPER TRIM

7. Install in the reverse order of removal.


QUARTER LOWER TRIM REMOVAL/INSTALLATION
Stretch Cab
1. Remove the quarter upper trim. (Refer to
QUARTER UPPER TRIM
REMOVAL/INSTALLATION.)
2. Remove the back lower trim.
3. Remove the fasteners.
4. Pull the quarter lower trim toward you, then
disengage clips A and pins B.
QUARTER LOWER TRIM

3. Install in the reverse order of removal.


BACK LOWER TRIM REMOVAL/INSTALLATION
1. Remove the back upper trim. (See BACK UPPER
TRIM REMOVAL/INSTALLATION.)
2. Remove the fasteners.
3. Remove the back lower trim.

FASTENER

B
A

A
A
A

CLIP
PIN

5. Install in the reverse order of removal.


4. Install in the reverse order of removal.

S54

TRIM
FRONT DOOR TRIM REMOVAL/INSTALLATION
1. Disconnect the negative battery cable if equipped
with a power window system.
2. Remove the regulator handle if equipped.
3. Remove the inner garnish.
4. Remove the power window switch if equipped.
5. Remove the screws and the fastener.
6. Pull the front door trim toward you, then disengage
clips A.
7. Pull the front door trim upward, then disengage
hook B.
FASTENER

FRONT DOOR TRIM

REAR ACCESS PANEL TRIM


REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR)
1. Remove the lower anchor bolt and upper anchor
bolt. (See FRONT SEAT BELT
REMOVAL/INSTALLATION.)
2. Remove the fastener.
3. Remove the screw.
4. Remove pins A.
5. Pull the rear access panel trim to disengage clips
A.
6. Remove the rear access panel trim with the seat
belt pulled out through the seat belt hole.

A
A

CLIP

A
A

A
SCREW

A
A

FASTENER

HOOK

FRONT DOOR TRIM

7. Install in the reverse order of removal.

A
A
A

SCREW

CLIP
A

A
B

A
A

A
A

HOOK

8. Install in the reverse order of removal.


REAR DOOR TRIM REMOVAL/INSTALLATION
Double cab
1. Disconnect the negative battery cable if equipped
with power window.
2. Remove the regulator handle if equipped.
3. Remove the power window switch if equipped.
4. Remove the screws.
5. Remove the ashtray.
6. Pull the door trim toward you, then disengage clips
A.
INNER HANDLE
B

SCREW
A

CLIP
A

A
A
ASHTRAY

A
A
A

A
A

B
HOOK

REAR DOOR TRIM

7. Extract the inner handle from the rear door trim.


8. Pull the rear door trim upward, then disengage
hooks B.
9. Install in the reverse order of removal.

S55

HEADLINER, FLOOR COVERING

HEADLINER

FLOOR COVERING

HEADLINER REMOVAL/INSTALLATION
1. Remove the A-pillar trims.
2. Remove the B-pillar upper trims. (Refer to TRIM,
B-PILLAR UPPER TRIM
REMOVAL/INSTALLATION, Double Cab.)
3. Remove the quarter upper trims. (Refer to TRIM,
QUARTER UPPER TRIM
REMOVAL/INSTALLATION, Stretch Cab.)
4. Remove the C-pillar trims. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION,
Double Cab.)
5. Remove the assist handle.
6. Remove the rearview mirror.
7. Remove the sunvisors and adapters.
8. Remove the interior light. (Refer to section T,
INTERIOR LIGHTING SYSTEM, INTERIOR
LIGHT REMOVAL/INSTALLATION.)
9. Remove the fasteners, then remove the headliner.

FLOOR COVERING REMOVAL/INSTALLATION


Regular Cab, Stretch Cab
1. Remove the dashboard member. (Refer to
DASHBOARD AND CONSOLE, DASHBOARD
MEMBER REMOVAL/INSTALLATION.)
2. Remove the quarter lower trims. (Refer to TRIM,
QUARTER LOWER TRIM
REMOVAL/INSTALLATION, Stretch Cab.)
3. Remove the back lower trim.
4. Remove the front seats. (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Regular Cab.) (Refer
to SEAT, SEAT REMOVAL/INSTALLATION, Stretch
Cab, Double cab, Front.)
5. Remove the rear seat. (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Stretch Cab, Double
cab, Rear.)
6. Remove the rear console bracket.
7. Remove the lower anchor installation bolts of front
seat belts.
8. Remove the front side trims.
9. Remove the air outlet ducts. (Refer to section U,
BASIC SYSTEM, AIR OUTLET DUCT
REMOVAL/INSTALLATION.)
10. Remove the footrest.
11. Remove the fasteners, then remove the floor
covering.

HEADLINER

FASTENER

ASSIST HANDLE
FASTENER

ADAPTER
SUNVISOR

10. Remove the headliner from the vehicle through the


passenger-side door.

FLOOR COVERING

12. Install in the reverse order of removal.

HEADLINER

11. Install in the reverse order of removal.

Double cab
1. Remove the dashboard member. (Refer to
DASHBOARD AND CONSOLE, DASHBOARD
MEMBER REMOVAL/INSTALLATION.)
2. Remove the B-pillar lower trims. (Refer to TRIM,
B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION.)
3. Remove the C-pillar trims. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION.)

S56

FLOOR COVERING
4. Remove the front seats and rear seat. (Refer to
SEAT, SEAT REMOVAL/INSTALLATION, Stretch
Cab, Double cab, Front.) (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Stretch Cab, Double
cab, Rear.)
5. Remove the rear console bracket.
6. Remove the lower anchor installation bolts of front
seat belts and rear seat belts.
7. Remove the front side trim.
8. Remove the air outlet duct. (Refer to section U,
BASIC SYSTEM, AIR OUTLET DUCT
REMOVAL/INSTALLATION.)
9. Remove the footrest.
10. Remove the fasteners, then remove the floor
covering.
Type 1

FASTENER

FLOOR COVERING
Type 2
FLOOR COVERING
FASTENER

11. Install in the reverse order of removal.

S57

SEAT BELT

SEAT BELT
SEAT BELT REMOVAL/INSTALLATION
Caution
D The ELR has a spring that will unwind if the
retractors cover is removed. The spring
cannot be rewound by hand. If this occurs,
the ELR will not work properly. Therefore,
do not disassemble the retractor.

Stretch Cab
Front
1. Remove the quarter lower trim. (Refer to TRIM,
QUARTER LOWER TRIM
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
3978
{3.98.0, 2957}

Regular Cab
Drivers side and passengers side
1. Remove the B-pillar trim if equipped with a B-pillar
trim. (Refer to TRIM, B-PILLAR TRIM
REMOVAL/INSTALLATION, Regular Cab.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

3978
{3.98.0, 2957}

3978
{3.98.0, 2957}

3978
{3.98.0, 2957}

Nm {kgfm, ftlbf}

Anchor cover

Retractor cover (if equipped)

Seat belt

Anchor cover

Seat belt

Rear
1. Remove the quarter lower trim. (Refer to TRIM,
QUARTER LOWER TRIM
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Except drivers side and passengers side


Except Europe and UK
1. Remove as indicated in the table.
2. Install in the reverse order of removal.

3978
{3.98.0, 2957}

Nm {kgfm, ftlbf}

Nm {kgfm, ftlbf}

Seat belt

S58

SEAT BELT
Rear
1. Remove the C-pillar trim. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

3978
{3.98.0, 2957}

3978
{3.98.0, 2957}

3978
{3.98.0, 2957}

3978
{3.98.0, 2957}

Nm {kgfm, ftlbf}

Anchor cover

Seat belt
Nm {kgfm, ftlbf}

Double Cab
Front
1. Remove the B-pillar lower trim. (Refer to TRIM,
B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION, Double Cab.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
3978
{3.98.0, 2957}

3978
{3.98.0, 2957}

Anchor cover

Seat belt

Nm {kgfm, ftlbf}

S59

Anchor cover

Seat belt

SEAT BELT
FRONT SEAT BELT REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR)
1. Remove the cover.
2. Remove the lower anchor bolt.
3. Remove the anchor cover.
4. Remove the upper anchor bolt.
5. Rear access panel trim. (See REAR ACCESS
PANEL TRIM REMOVAL/INSTALLATION.)
6. Remove the front seat belt through the seat belt
hole.
7. Remove the bolts from the retractor.
3. Remove the retractor.
4. Make sure that the seat belt does not lock when
the retractor is tilted slowly up to 15 from the
mounted position. Make sure that the seat belt
locks when the retractor is tilted 40 or more.

RETRACTOR

5. If any of the above-mentioned steps are not as


specified, replace the seat belt.
BUCKLE REMOVAL/INSTALLATION
Bench Seat
Drivers side and passengers side
1. Disconnect the negative battery cable.
2. Remove as indicated in the table.
3. Install in the reverse order of removal.

8. Remove the retractor.

3978
{3.98.0, 2957}

9. Install in the reverse order of removal.


Nm {kgfm, ftlbf}

SEAT BELT INSPECTION


Belt
1. Inspect the webbing for scars, tears, and wear.
2. Inspect the fitting for deformation or damage.
3. If a problem is found, replace the seat belt.

ELR
1. Verify that the belt can be pulled out smoothly, and
that it moves smoothly when worn.
2. Verify that the retractor locks when the belt is
quickly pulled.

S60

Buckle

SEAT BELT
Except drivers side and passengers side
Except Europe and UK
1. Remove as indicated in the table.
2. Install in the reverse order of removal.

3978
{3.98.0, 2957}

3978
{3.98.0, 2957}

Nm {kgfm, ftlbf}

1
Nm {kgfm, ftlbf}

Buckle

Bucket Seat
Front
1. Disconnect the negative battery cable.
2. Remove the side cover. (Refer to SEAT, FRONT
SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.)
3. Remove as indicated in the table.
4. Install in the reverse order of removal.

3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}

Front buckle

Stretch Cab
Rear
1. Remove as indicated in the table.
2. Install in the reverse order of removal.
3978
{3.98.0, 2957}

Nm {kgfm, ftlbf}

Rear buckle

Double Cab
Rear
1. Remove the seat cushion. (Refer to SEAT, REAR
SEAT REMOVAL/INSTALLATION, Double Cab.)
2. Remove as indicated in the table.
3. Install in the reverse order of removal.

S61

Rear buckle

SEAT
Bucket Seat
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

SEAT
FRONT SEAT REMOVAL/INSTALLATION
Bench Seat
1. Remove as indicated in the table.
2. Install in the reverse order of removal.

3563
{3.56.5, 2647}
3563
{3.56.5, 2647}

3563
{3.56.5, 2647}
3563
{3.56.5, 2647}

Nm {kgfm, ftlbf}

Nm {kgfm, ftlbf}

Front seat
+ Installation note

Front seat installation note


1. To install the seat, tighten the bolts in the order
indicated in the figure.
FRONT

LEFT
SIDE

Connector

Cover

Front seat
+ Installation note

Front seat installation note


1. To install the seat, tighten the bolts in the order
indicated in the figure.
FRONT

RIGHT
SIDE

DOOR
SIDE

2. Verify that the seat slider is securely locked in


position before fully tightening the bolts.
3. After installing the seat, slide it forward and
backward and verify that the seat slider securely
locks in position.

TUNNEL
SIDE

2. Verify that the seat slider is securely locked in


position before fully tightening the bolts.
3. After installing the seat, slide it forward and
backward and verify that the seat slider securely
locks in position.

S62

SEAT
FRONT SEAT DISASSEMBLY/ASSEMBLY
Bench Seat
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

A
3246
{3.24.7, 2433}

Nm {kgfm, ftlbf}

Headrest

Seat back frame

Pole guide

Seat cushion trim

Recliner lever

10

Seat cushion pad

Side cover

11

Seat cushion frame

Lower cover

12

Cable

Seat back trim

13

Slide adjuster

Seat back pad

14

Connecting rod

S63

SEAT
Bucket Seat
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. When removing the cable (passengers seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)

3978 {3.98.0, 2957}

PASSENGERS SEAT

3753
{3.75.5, 2739}

B
A

C
B
3978
{3.98.0, 2957}

Nm {kgfm, ftlbf}

Headrest

11

Slide adjuster No.3

Recliner lever

12

Pole guide

Side cover

13

Seat back trim

Front buckle

14

Seat back warmer unit (Europe only)

Spring (stretch cab)

15

Seat back pad

Cable (stretch cab)

16

Seat cushion trim

Wire

17

Seat cushion warmer unit (Europe only)

Connecting rod

18

Seat cushion pad

Slide adjuster No.1

19

Seat cushion frame

10

Slide adjuster No.2

S64

SEAT
CABLE ADJUSTMENT
D Verify the slide adjuster slides and locks smoothly
when the slide adjuster lever is operated.

SEAT BACK

LEVER

BOLT
1622
{1.62.3, 1216}

SLIDE
LOCK

SCREW
2.02.9 Nm
{2030 kgfcm,
1826 inlbf}

LEVER

Nm {kgfm, ftlbf}

REAR SEAT REMOVAL/INSTALLATION


Stretch Cab
Seat back
1. Remove the back upper trim.
2. Remove the bolts.
3. Lift the seat back up in the direction of the arrow,
then unhook it from the body.

Hinge
1. Remove the back lower trim. (Refer to TRIM,
BACK LOWER TRIM REMOVAL/INSTALLATION.)
2. Remove the fasteners, and then turn over the floor
covering.
3. Remove the bolts, and then remove the hinge.
BOLT
1622
{1.62.3, 1216}

SEAT BACK

HOOK

HOOK

HOOK
HINGE

BOLT
6.879.80
{70100, 60.886.7}

Nm {kgfm, ftlbf}

Nm {kgfcm, inlbf}

Seat cushion
1. Lift up the rear seat cushion.
2. Remove the screws.
3. Remove the bolts, and then remove the seat
cushion.

S65

SEAT
Double Cab
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3563
{3.56.5,
2647}

1622
{1.62.3,
1216}

PULL

1622
{1.62.3,
1216}

1622
{1.62.3, 1216}

3563
{3.56.5,
2647}
Nm {kgfm, ftlbf}

Seat cushion

Seat back
+ Installation note

Hinge

Striker

Seat back installation note


D After installing the seat back, verify that it securely
locks to the striker.
REAR SEAT DISASSEMBLY/ASSEMBLY
Stretch Cab
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

S66

Seat cushion trim

Seat cushion pad

SEAT
Double Cab
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Headrest

Side cover

Pole guide

Stopper

Seat back trim

Seat back frame

Seat back pad

Seat cushion trim

Rear back catch

10

Seat cushion pad

S67

SEAT
SEAT WARMER SWITCH REMOVAL
1. Disconnect the negative battery cable.
2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the seat warmer
switch and pull it forward to remove it.
3. Disconnect the seat warmer switch connector, and
then remove the seat warmer switch.

SEAT WARMER UNIT INSPECTION


1. Remove the front seat. (Refer to FRONT SEAT
REMOVAL/INSTALLATION, Bucket Seat.)
2. Inspect seat warmer unit at roor temperature of 20
C {68 F}.
3. Apply battery positive voltage to the seat warmer
unit terminal A, connect the ground to terminal B,
and measure the temperature of the thermometal
switch with a thermometer.
A

HOOK

A
B
SEAT WARMER
SWITCH

CONNECTOR

SEAT WARMER SWITCH INSTALLATION


1. Connect the seat warmer switch connector.
2. Insert the seat warmer switch in the hole to install
it.
3. Connect the negative battery cable.

THERMOMETER

SEAT WARMER SWITCH INSPECTION


1. Remove the seat warmer switch. (Refer to SEAT
WARMER SWITCH REMOVAL.)
2. Inspect for continuity between the seat warmer
switch terminals using an ohmmeter.
: Continuity

: Bulb

Terminal

Switch position

On
Off

3. If not as specified, replace the seat warmer switch.

S68

THERMOMETAL
SWITCH

4. When the temperature of the thermometal switch is


approximately 40 C {104 F}, inspect the
resistance between the seat warmer unit terminals
using an ohmmeter. Verify that the resistance
changes from approximately 4.8 to
approximately 13.0 .
5. Remove battery positive voltage from seat warmer
unit terminals.
6. When the temperature of the thermometal switch is
approximately 30 C {86 F}, inspect the
resistance between the seat warmer unit terminals
using an ohmmeter. Verify that the resistance
changes from approximately 13.0 to
approximately 4.8 .
7. If any of the above-mentioned steps are not as
specified, replace the seat back pad (with seat
warmer unit) and seat cushion pad (with seat
warmer unit).

BODY SHELL (STRETCH CAB 4 DOOR)

BODY SHELL
REAR ACCESS PANEL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.

Checker

Connector

Rear access panel hinge

Rear access panel

3. Install in the reverse order of removal.

S69

BODY SHELL (STRETCH CAB 4 DOOR)


REAR ACCESS PANEL DISASSEMBLY/ASSEMBLY
1. Remove the door (See REAR ACCESS PANEL REMOVAL/INSTALLATION
2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of removal.

Upper latch

Outer handle

Lower latch

Weatherstrip

Rear access panel remote controller

STRIKER REMOVAL/INSTALLATION
Upper striker
1. Remove the bolts.
2. Remove the upper lock striker.

Lower Striker
1. Remove the screw.
2. Remove the lower striker.

3. Install in the reverse order of removal.


3. Install in the reverse order of removal.

S70

TROUBLESHOOTING [POWER WINDOW SYSTEM]

TROUBLESHOOTING [POWER
WINDOW SYSTEM]
INTERMITTENT CONCERN TROUBLESHOOTING
Vibration Method
D If malfunction occurs or becomes worse while
driving on a rough road or when engine is
vibrating, perform the steps below.
Note
D There are several reasons why vehicle or
engine vibration could cause an electrical
malfunction. Some of the things to check for:
Connectors not fully seated.
Wire harnesses not having full play.
Wires laying across brackets or moving
parts.
Wires routed too close to hot parts.
D An improperly routed, improperly clamped, or
loose harness can cause wiring to become
pinched between parts.
D The connector joints, points of vibration, and
places where wire harnesses pass through the
firewall, body panels, etc. are the major areas
to be checked.
D Check for DTCs or malfunctions by shaking
harnesses and connectors that are suspected
to be causing malfunction.

Connector Terminal Check Method


1. Check the connection condition of each female
terminal.
2. Insert male terminal into the female terminals to
check for looseness.

FOREWORD
D Always perform basic power window system
inspection before troubleshooting.
D Troubleshooting gives content unique to trouble
caused by problems in the automatic window
return function.

S71

TROUBLESHOOTING [POWER WINDOW SYSTEM]


BASIC POWER WINDOW SYSTEM INSPECTION
Manual Mode Function Inspection
STEP
1

INSPECTION

ACTION

D Turn ignition switch to ON position.


D Do all windows go up and down in manual

mode using power window main switch?

D Does each window go up and down in manual

mode using power window subswitch?

D Turn powercut switch UNLOCK.


D Push/pull power window main switch (switches

for all doors in manual mode).


D Does only driverside front window go up and

Yes

Go to next step.

No

D Inspect the following items:


Power window main switch power supply
fuses
Power window main switch ground wiring
harness
Power window main switch power supply
wiring harnesses
Wiring harness between power window main
switch and power window motor
Power window main switch
Power window motor
Each power window motor wire installation
point
Each window installation point on its carrier
plate
Each power window regulator installation
point on each door
D Repair or replace the problem area, then go to
Step 4.

Yes

D Go to next step.

No

D Inspect the following items:


Power window main switch (powercut switch
system malfunction)
Power window subswitch
Subswitch power supply wiring harnesses
D Repair or replace the problem area, then go to
automatic mode function inspection.

Yes

D Manual mode function is normal.


D Go to automatic mode function inspection.

No

Replace power window main switch, then go to


automatic mode function inspection (powercut
switch system malfunction).

down?

Automatic Mode Function Inspection


STEP
1

INSPECTION

ACTION

D Turn ignition switch to ON position.


D Operate power window main switch for

Yes

Go to next step.

No

Driverside front window does not go up and


down in automatic mode:
D Go to Step 1 of NO. 1 DRIVERSIDE FRONT
WINDOW DOES NOT GO UP AND DOWN IN
AUTOMATIC MODE.
Driverside front window go up and down in
automatic mode, but driverside front window
reverses:
D Go to Step 1 of NO. 3 DRIVERSIDE FRONT
WINDOW REVERSES EVEN THOUGH THE
GLASS DOES NOT ENCOUNTER A FOREIGN
OBJECT WHILE IT IS GOING UP IN
AUTOMATIC MODE.

Yes

D Go to next step.

No

Replace power window main switch, then go to


automatic window return function inspection.

D Gently press the driverside front power

Yes

window switch while driverside front window


is going up in automatic mode.
D Does the glass stop?

D Automatic mode function is normal.


D Go to automatic window return function
inspection.

No

Replace power window main switch, then go to


automatic window return function inspection.

driverside front door in automatic mode.


D Does driverside front window go up and
down?

D Gently pull the driverside front power window

switch while driverside front window is going


down in automatic mode.
D Does the glass stop?
3

S72

TROUBLESHOOTING [POWER WINDOW SYSTEM]


Automatic Window Return Function Inspection
STEP
1

INSPECTION

ACTION

D Turn ignition switch to ON position.


D Lower driverside front window completely.
D Use power window main switch to close

Yes

Go to Step 1 of NO. 3 DRIVERSIDE FRONT


WINDOW REVERSES EVEN THOUGH THE
GLASS DOES NOT ENCOUNTER A FOREIGN
OBJECT WHILE IT IS GOING UP IN AUTOMATIC
MODE.

No

Go to next step.

Yes

D Automatic window return function inspection is


normal.
D Go to IG OFF timer function inspection.

No

Go to Step 1 of NO. 2 DRIVERSIDE FRONT


WINDOW DOES NOT REVERSE, EVEN WHEN
ENCOUNTERING A FOREIGN OBJECT IN ITS
PATH.

drivers window in automatic mode.


D Does window automatically reverse even

though the glass does not encounter a foreign


object while it is going up in automatic mode?
2

D Lower driverside front window completely.


D Take a hammer and hold it against the inside

of the top of the window frame so that the


window will hit its handle when it is closed.
D Raise the window using automatic mode.
D When the window hits the hammer handle,
does it immediately reverse and go down to
approximately 200 mm {7.87 in} from the
completely closed position?

IG OFF Timer Function Inspection


STEP
1

INSPECTION

ACTION

D Turn ignition switch to ON position.


D In automatic mode, push down power window

main switch for driverside front window. Window should go down within approximately 42
seconds from ignition switch OFF position.
D In manual mode (finger continuously
depressing power window main switch),
window should go down within approximately
42 seconds from ignition switch OFF position.
D Does driverside front window go down?
2

D Turn ignition switch to ON position.


D In automatic mode, pull up power window main

switch for driverside front window. Window


cannot go up within approximately 4 seconds
from ignition switch OFF position.
D Verify that driverside front window does not
operate.
D Does driverside front window go down?
3

D Turn ignition switch to ON position.


D Lower driverside front window completely.
D Take a hammer and hold it against the inside

of the top of the window frame so that the


window will hit its handle when it is closing.
D Raise the window using manual mode.
D When the window hits the hammer handle,
does it immediately reverse and go down to
approximately 200 mm {7.87 in} from the
completely raised position?
4

D Open any door.


D Turn ignition switch to ON position.
D Push/pull power window main switch for

driverside front window within approximately


42 seconds from ignition switch OFF position.
D Verify that driverside front window does not
go up or down.
D Does driverside front window go up or down?

Yes

Go to next step.

No

Replace power window main switch, then go to


next step.

Yes

Replace power window main switch, then go to


next step.

No

Go to next step.

Yes

Go to next step.

No

Replace power window main switch, then go to


next step.

Yes

D Inspect door switch and related warning


harness.
D If above parts are okay, replace power window
main switch, then go to next step.
D If above parts are incorrect, repair or replace
malfunction part(s), then go to next step.

No

D Go to next step.

S73

TROUBLESHOOTING [POWER WINDOW SYSTEM]

STEP

INSPECTION

ACTION

D Close all doors.


D Turn ignition switch to ON position.
D Push/pull power window main switch for

driverside front window after approximately


60 seconds from ignition switch OFF position.
D Verify that driverside front window does not
go up or down.
D Does driverside front window go up or down?

Yes

Replace power window main switch, then go to


twostep down function inspection.

No

D IG OFF timer function is normal.


D Go to twostep down function inspection.

TROUBLESHOOTING INDEX
No.

TROUBLESHOOTING ITEM

PAGE

Driverside front window does not go up and down in


automatic mode.

(See NO. 1 DRIVERSIDE FRONT WINDOW DOES NOT


GO UP AND DOWN IN AUTOMATIC MODE.)

Driverside front window does not reverse, even


when encountering a foreign object in its path.

(See NO. 2 DRIVERSIDE FRONT WINDOW DOES NOT


REVERSE, EVEN WHEN ENCOUNTERING A FOREIGN
OBJECT IN ITS PATH.)

Driverside front window reverses even though the


glass does not encounter a foreign object while it is
going up in automatic mode.

(See NO. 3 DRIVERSIDE FRONT WINDOW REVERSES


EVEN THOUGH THE GLASS DOES NOT ENCOUNTER A
FOREIGN OBJECT WHILE IT IS GOING UP IN
AUTOMATIC MODE.)

NO. 1 DRIVERSIDE FRONT WINDOW DOES NOT GO UP AND DOWN IN AUTOMATIC MODE
1

Driverside front window does not go up and down in automatic mode

POSSIBLE
CAUSE

D Open or short to B+ circuit in position sensor 1 signal, ground signal from wiring harness (between
power window main switch and driverside front power window motor), inner power window main
switch, or inner motor: Steps 36
D Open or short to B+/ground circuit in position sensor 2 signal from wiring harness (between power
window main switch and driverside front power window motor), inner power window main switch, or
inner motor: Steps 711
Note
D The automatic function and the ignition off timer function do not operate while power window main
switch is in failsafe mode. The failsafe operates when position sensor 1, and/or position sensor 2,
and/or position sensor 2 power supply malfunctions.
D Position sensor 1 and/or 2 malfunction
When driverside front window is kept up down, main switch can not sense a pulse signal from
position sensor 1 during that can sense 5 pulses (2.5 cycles) from position 2.
When driverside front window is kept up down, main switch can not sense a pulse signal from
position sensor 2 during that can sense 5 pulses (2.5 cycles) from position 1.
There are 3 abnormal pulse from a pulse signal during driverside front window is kept up or down.
There are 20 cycle pulses from a close position during driverside front window is kept up.
There is no pulse signal during 1 sec. after down is operated.

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT WHETHER POWER WINDOW MAIN


SWITCH ENTERS FAILSAFE MODE OR NOT
D Did driverside front window go up or down in
automatic mode?

Yes

Recheck malfunction symptoms.

No

Go to next step. (Power window main switch may


enter failsafe mode.)

VERIFY WHETHER MALFUNCTION IS IN


WIRING HARNESS (BETWEEN POWER
WINDOW MAIN SWITCH AND DRIVERSIDE
FRONT POWER WINDOW MOTOR) OR
ELSEWHERE
D Turn ignition switch ON position.
D Test voltage at power window main switch
connector terminal 2C (position sensor 1
signal).
D Is voltage alternate between 0 V and
approximately 5 V when driverside front
window is being gone up and down?

Yes

Go to Step 7.

No

Go to next step.

S74

TROUBLESHOOTING [POWER WINDOW SYSTEM]

STEP
3

INSPECTION

ACTION

VERIFY POSITION SENSOR 1 OUTPUT


SIGNAL
D Turn ignition switch to ON position.
D Test voltage at driverside front power window
motor connector terminal 1C (position sensor 1
signal).
D Is voltage alternate between 0 V and
approximately 12 V when driverside front
window is being gone up and down at manual
mode?

Yes

Go to next step.

No

Replace driverside front power window motor,


then go to Step 12.

INSPECT WIRING HARNESS BETWEEN


POWER WINDOW MAIN SWITCH AND
DRIVERSIDE FRONT POWER WINDOW
MOTOR FOR CONTINUITY
D Turn ignition switch to LOCK position.
D Disconnect power window main switch
connector.
D Is there continuity between the following power
window main switch connector terminals and
driverside front power window motor
connector terminals?
2C1C (position sensor 1 signal)
2D1D (position sensor power supply)
2A1A (ground signal)

Yes

Go to next step.

No

Repair wiring harness between power window


main switch and driverside front power window
motor, then go to Step 12.

VERIFY WHETHER MALFUNCTION IS IN


WIRING HARNESS (BETWEEN POWER
WINDOW MAIN SWITCH AND DRIVERSIDE
FRONT POWER WINDOW MOTOR) OR
POWER WINDOW MAIN SWITCH
D ignition switch to ON position.
D Measure voltage at the following power
window main switch connector terminals:
2C (position sensor 1 signal)
2A (ground signal)
D Is voltage approximately 12 V?

Yes

Repair wiring harness between power window


main switch and driverside front power window
motor, then go to Step 12.

No

Replace power window main switch (open or short


to B in power window main switch).

VERIFY WHETHER MALFUNCTION IS IN


WIRING HARNESS (BETWEEN POWER
WINDOW MAIN SWITCH AND DRIVERSIDE
FRONT POWER WINDOW MOTOR) OR
ELSEWHERE
D Is continuity between following power window
main switch connector terminals and ground?
2C (position sensor 1 signal)
2D (position sensor power supply)

Yes

Replace wiring harness between power window


main switch and driverside front power window
motor, then go to Step 12.

No

Go to next step.

VERIFY WHETHER MALFUNCTION IS IN


POWER WINDOW MAIN SWITCH OR
ELSEWHERE
D Turn ignition switch to ON position.
D Test voltage at power window main switch
connector terminal 2B (position sensor 2
signal).
D Does voltage alternate between 0 V and
approximately 12 V when driverside front
window is being gone up down?

Yes

Replace power window main switch. (malfunction


in power window main switch automatic mode
control), then go to Step 11.

No

Go to next step.

VERIFY POSITION SENSOR 2 OUTPUT


SIGNAL
D Turn ignition switch to ON position.
D Test voltage at driverside front power window
motor connector terminal 1B (position sensor 2
signal).
D Is voltage alternate between 0 V and
approximately 12 V when driverside front
window is being gone up down?

Yes

Go to next step.

No

Replace driverside front power window motor,


then go to Step 12.

S75

TROUBLESHOOTING [POWER WINDOW SYSTEM]

STEP

INSPECTION

10

11

12

ACTION

VERIFY WHETHER MALFUNCTION IS IN


WIRING HARNESS (BETWEEN POWER
WINDOW MAIN SWITCH AND DRIVERSIDE
FRONT POWER WINDOW MOTOR) OR
ELSEWHERE
D Turn ignition switch to LOCK position.
D Disconnect power window main switch
connector and driverside front power window
motor connector.
D Is there continuity between power window
main switch connector terminal 2B (position
sensor 2 signal) and driverside front power
window motor connector terminal 1B (position
sensor 2 signal)?

Yes

Go to next step.

No

Repair wiring harness between power window


main switch and driverside front power window
motor, then go to Step 12.

VERIFY WHETHER MALFUNCTION IS IN


WIRING HARNESS (BETWEEN POWER
WINDOW MAIN SWITCH AND DRIVERSIDE
FRONT POWER WINDOW MOTOR) OR
ELSEWHERE
D Is there continuity between power window
main switch connector terminal 2B (position
sensor 2 signal) and ground?

Yes

Repair wiring harness between power window


main switch and driverside front power window
motor, then go to Step 12.

No

Go to next step.

VERIFY WHETHER MALFUNCTION IS IN


WIRING HARNESS (BETWEEN POWER
WINDOW MAIN SWITCH AND DRIVERSIDE
FRONT POWER WINDOW MOTOR) OR
POWER WINDOW MAIN SWITCH
D Turn ignition switch to ON position.
D Measure voltage at power window main switch
connector terminal 2B (position sensor 2
signal).
D Is voltage approximately 12 V?

Yes

Repair wiring harness between power window


main switch and front driverside power window
motor, then go to next step.

No

Replace power window main switch (open or short


to B+/ground in power window main switch), then
go to next step.

RECHECK MALFUNCTION SYMPTOM AFTER


REPAIR
D Did malfunction disappear?

Yes

D Troubleshooting completed.
D Explain repairs to customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

NO. 2 DRIVERSIDE FRONT WINDOW DOES NOT REVERSE, EVEN WHEN ENCOUNTERING A FOREIGN
OBJECT IN ITS PATH
2

Driverside front window does not reverse, even when encountering a foreign object in its path.

POSSIBLE
CAUSE

D Automatic window return range did not reset after battery disconnect: Step 2

Diagnostic procedure
STEP

INSPECTION

ACTION

CHECK FOR CUSTOMER COMPLAINT


D Did customer complain that driverside front
window did not reverse when nearing complete
close?

Yes

D System normal.
D Explain to customer that automatic window
return power window system does not operate
when nearing of complete close.

No

Go to next step.

RESET REVERSE AREA STORED IN


DRIVERSIDE FRONT WINDOW MOTOR
D Reset the main switch to recognize driverside
front window fully closed position.
D Did malfunction disappear?

Yes

D Troubleshooting completed.
D Explain to customer that misadjustment of
automatic window return range was the
problem.

No

Replaced power window main switch.

S76

TROUBLESHOOTING [POWER WINDOW SYSTEM]


NO. 3 DRIVERSIDE FRONT WINDOW REVERSES EVEN THOUGH THE GLASS DOES NOT ENCOUNTER A
FOREIGN OBJECT WHILE IT IS GOING UP IN AUTOMATIC MODE
Driverside front window reverses even though the glass does not encounter a foreign object
while it is going up in automatic mode.

3
POSSIBLE
CAUSE

D Too much driverside front window friction resistance: Steps 15


D Short to ground in position sensor 1 signal from wiring harness (between power window main switch
and driverside front power window motor), inner driverside front power window motor, or inner
power window main switch: Steps 6, 7

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT FOR FOREIGN OBJECT IN


DRIVERSIDE FRONT WINDOW
D Is there a foreign object in driverside front
window?

Yes

Remove the object.

No

Go to next step.

INSPECT ACRYLIC VISOR BRACKET


INSTALLATION
D Is acrylic visor bracket properly installed?

Yes

Go to next step.

No

Reinstall acrylic visor bracket properly.

INSPECT TO SEE IF GLASS RUN CHANNEL


INTERFERES WITH DRIVERSIDE FRONT
WINDOW
D Remove driverside front door trim.
D Does glass run channel interfere with
driverside front window?

Yes

Repair or replace glass run channel, then go to


Step 9.

No

Go to next step.

INSPECT LUBRICANT ON DRIVERSIDE


CARRIER PLATE
D Is there lubricant on driverside carrier plate?

Yes

Go to next step.

No

Apply lubricant (mineral oil).

INSPECT INSTALLATION OF DRIVERSIDE


FRONT POWER WINDOW SYSTEM
COMPONENTS
D Are the following parts properly installed?
Driverside front door glass
Driverside power window motor wire
Driverside power window motor
Driverside power window regulator frame
Driverside carrier plate
Driverside glass run channel

Yes

Go to next step.

No

Reinstall part(s) properly, then go to Step 9.

VERIFY POSITION SENSOR 1 OUTPUT


SIGNAL
D Turn ignition switch to ON position.
D Test voltage at driverside front power window
motor connector terminal 1C (position sensor
1 signal).
D Is voltage alternate between 0 V and
approximately 12 V when driverside front
window is being gone up and down at manual
mode?

Yes

Go to next step.

No

Replace driverside front power window motor,


then go to Step 8.

VERIFY WHETHER MALFUNCTION IS IN


WIRING HARNESS (BETWEEN POWER
WINDOW MAIN SWITCH AND DRIVERSIDE
FRONT POWER WINDOW MOTOR) OR
POWER WINDOW MAIN SWITCH
D Turn ignition switch to LOCK position.
D Disconnect power window main switch.
D Is there continuity between power window
main switch connector terminal 2C (position
sensor 1 signal) and ground?

Yes

Repair wiring harness between power window


main switch and driverside front power window
motor, then go to next step.

No

Replace power window main switch (short to


ground in power window main switch), then go to
next step.

RECHECK MALFUNCTION SYMPTOM AFTER


REPAIR
D Did malfunction disappear?

Yes

D Troubleshooting completed.
D Explain repairs to customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

S77

TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]

TROUBLESHOOTING [KEYLESS
ENTRY SYSTEM]
FOREWORD
D Go to troubleshooting after identifying the specific
malfunction by doing a keyless entry system
preliminary inspection.
Flowchart

KEYLESS ENTRY SYSTEM CHECK SHEET


D Use the sheet below as a customer interview sheet

when accepting a vehicle for service.


D If the symptom is Power door lock system does not oper-

ate with transmitter at all, find out how the customer


uses the keyless entry system by following the check
sheet below.

S78

TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]

KEYLESS ENTRY SYSTEM PRELIMINARY INSPECTION


D Perform the following preliminary inspection before troubleshooting.

STEP

INSPECTION

ACTION

D Is system an aftermarket one?

Yes

Perform troubleshooting according to aftermarket


keyless entry system manual.

No

Go to next step.

D Did customer activate keyless entry system

Yes

Go to next step.

when ignition switch was in LOCK position?

No

D Explain to customer that system does not work


when ignition is in ON position.
D Turn ignition switch to LOCK position, then go to
next step.

Yes

Attempt to lock/unlock doors with transmitter in


noninterference area.
If system operates:
D Area of operation is bad. Explain effect of
outside interference on transmitter to customer.
If system does not operate:
D Go to next step.

D Did customer use keyless entry system in

particular area, such as being near TV towers,


power plants, power lines, or factories?

No

S79

TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]

STEP
4

INSPECTION

ACTION

D Are any of the following aftermarket electrical

Yes

parts on the vehicle?


Cellular phone
Radiowave equipment
Remote engine starter
TV.etc.

Disconnect aftermarket electrical part connectors


and attempt to lock/unlock doors with transmitter.
If system operates:
D Aftermarket electrical parts are interfering with
keyless entry system.
If system does not operate:
Go to next step.

No
5

D Perform onboard diagnostic function.

Yes

Go to next step.

(See ONBOARD DIAGNOSTIC FUNCTION)


D Does onboard diagnostic function work?

No

D Go to Step 1 of NO. 1 ONE OR MORE


ONBOARD DIAGNOSTIC FUNCTIONS
INOPERATIVE.
D Go to Step 1 of NO. 2 ALL ONBOARD
DIAGNOSTIC FUNCTIONS INOPERATIVE.

D Attempt to reprogram transmitter ID code.


D Can transmitter ID code be reprogrammed?

Yes

System is in normal now

No

Go to Step 1 of troubleshooting NO. 3


TRANSMITTER ID CODE CANNOT BE
REPROGRAMMED.

ONBOARD DIAGNOSTIC FUNCTION

S80

TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]


TROUBLESHOOTING INDEX
No.
1

TROUBLESHOOTING ITEM

DESCRIPTION

One or more onboard


diagnostic functions
inoperative.

D Malfunction in hazard warning light system

All onboard diagnostic


functions inoperative.

D Malfunction in keyless unit power supply

Transmitter ID code cannot be


reprogrammed.

D Malfunction in transmitter battery,

(except vehicle with theftdeterrent


system), or door lock linkage system,
drivers door key cylinder switch system.
circuit, door switch circuit or keyless unit
ground circuit.
transmitter, keyless unit bracket, keyless
unit bracket ground screw or keyless unit
circuit.

ACTION
(See NO. 1 ONE OR MORE
ONBOARD DIAGNOSTIC
FUNCTIONS INOPERATIVE)
(See NO. 2 ALL ONBOARD
DIAGNOSTIC FUNCTIONS
INOPERATIVE)
(See NO. 3 TRANSMITTER ID
CODE CANNOT BE
REPROGRAMMED)

NO. 1 ONE OR MORE ONBOARD DIAGNOSTIC FUNCTIONS INOPERATIVE


D When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and
undamaged.
1

One or more onboard diagnostic functions inoperative

DESCRIPTION

POSSIBLE
CAUSE

D Malfunction in hazard warning light system (except vehicle with theftdeterrent system), or door lock
linkage system, drivers door key cylinder switch system.
D Malfunction in hazard warning light system (except vehicle with theftdeterrent system)
Hazard warning light circuit
Keyless unit malfunction
Malfunction in wiring harness between keyless unit and flasher unit
D Malfunction in door lock linkage
D Malfunction in keyless unit door lock/unlock signal circuit
Keyless unit malfunction
Malfunction in wiring harness between keyless unit and door lock timer unit

Diagnostic procedure
Note
D For with theftdeterrent system, follow the procedure from Step 4.
STEP
1

*3

INSPECTION

ACTION

CHECK HAZARD WARNING LIGHT


OPERATION DURING ONBOARD DIAGNOSIS
D Did hazard warning lights flash during
onboard diagnostic function operation?

Yes

Go to Step 4.

No

Go to next step.

INSPECT HAZARD WARNING LIGHT CIRCUIT


D Do hazard warning lights flash when hazard
warning switch is on?

Yes

Go to next step.

No

Inspect hazard warning light circuit.

CHECK TO SEE WHETHER MALFUNCTION IS


IN WIRING HARNESS (BETWEEN KEYLESS
UNIT AND FLASHER UNIT) OR KEYLESS
UNIT
D Measure voltage at keyless unit connector
terminal H during onboard diagnostic function
operation.
When hazard warning light flashed:
B+below 1.0 V
D Is voltage as above?

Yes

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

No

D Inspect wiring harness between keyless unit and


flasher unit.
If wiring harness is OK, replace keyless unit
and reprogram transmitter ID code, then go to
Step 8.
If wiring harness malfunction, repair wiring
harness, then go to Step 8.

MAKE SURE THAT ALL DOORS LOCK AND


UNLOCK DURING ONBOARD DIAGNOSIS
D Did all doors unlock and lock during onboard
diagnostic function operation?

Yes

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

No

Go to next step.

INSPECT DOOR LOCK LINKAGE


D Operate inner door lock knob and make sure
door locks and unlocks manually.
D Does every door lock system work?

Yes

Go to next step.

No

Inspect door lock linkage.

S81

TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]

STEP

INSPECTION

*6

*7

ACTION

CHECK TO SEE WHETHER MALFUNCTION IS


IN DOOR LOCK ACTUATOR, DOOR LOCK
TIMER UNIT GROUND CIRCUIT OR
ELSEWHERE
D Measure voltage at keyless unit connector
terminal O during onboard diagnostic function
operation.
With double locking system or
theftdeterrent system
All doors locked: 5 2.5 5 V
All door unlocked: 5 below 1.0 V 5V
Other
All door locked: B+ 6 V B+
All door unlocked: B+ below 1.0 V B+
D Is voltage as above?

Yes

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

No

D Inspect door lock timer unit connector.


D Inspect wiring harness between keyless unit and
door lock timer unit.
If above parts are OK, go to next step.
If above parts malfunction, repair malfunction
part.

CHECK TO SEE WHETHER MALFUNCTION IS


IN KEYLESS UNIT OR DOOR LOCK TIMER
UNIT
D Measure voltage at door lock timer unit
connector terminal F.
D Is voltage as following?
With double locking system or
theftdeterrent system: 5 V
Other: B+

Yes

Replace keyless unit and reprogram transmitter ID


code, then go to next step.

No

Replace door lock timer unit, then go to next step.

RECHECK MALFUNCTION SYMPTOM AFTER


REPAIR
D Does keyless entry system operate properly?

Yes

Troubleshooting completed.
Explain repairs to customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

NO. 2 ALL ONBOARD DIAGNOSTIC FUNCTIONS INOPERATIVE


D When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and
undamaged.
2

All onboard diagnostic functions inoperative

DESCRIPTION

POSSIBLE
CAUSE

D Malfunction in keyless unit power supply circuit, door switch circuit or keyless unit ground

circuit.

D Malfunction in IG1, B+ signal circuit of keyless unit


Keyless unit power supply fuse malfunction
Malfunction in wiring harness between keyless unit power supply fuse(s) and keyless unit itself
D Malfunction in keyless units door open/closed signal circuit
D Door switch system malfunction
Keyless unit malfunction
Malfunction in wiring harness between keyless unit and door switch
D Malfunction in keyless unit GND signal circuit
Malfunction in wiring harness between keyless unit and ground

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT KEYLESS UNIT POWER SUPPLY


FUSES
D Are keyless unit power supply fuses okay?

Yes

Go to next step.

No

Check for a short to ground on blown fuses circuit.


Repair or replace as necessary.
Install appropriate amperage fuse.

INSPECT DOOR SWITCH INSTALLATION


D Are door switches installed securely?

Yes

Go to next step.

No

Install door switch(es) securely, then go back to


Step 5 of keyless entry system preliminary
inspection.

S82

TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]

STEP
*3

*4

*5

INSPECTION

ACTION

CHECK TO SEE WHETHER MALFUNCTION IS


IN WIRING HARNESS (LACK OF CONTINUITY
BETWEEN FUSE BLOCK AND KEYLESS
UNIT) OR ELSEWHERE
D Turn ignition switch to ON position.
D Measure voltage at following keyless unit
terminals:
IG1 signal (Terminal A)
B signal (Terminal B)
D Is voltage B+?

Yes

Go to next step.

No

Repair wiring harness between fuse block and


keyless unit, then go to Step 8.

CHECK TO SEE WHETHER MALFUNCTION IS


IN WIRING HARNESS (SHORT TO B+
BETWEEN FUSE BLOCK AND KEYLESS UNIT,
OR BETWEEN KEYLESS UNIT AND GROUND)
OR ELSEWHERE
D Turn ignition switch to LOCK position.
D Disconnect keyless unit connector.
D Measure voltage at following keyless unit
connector terminals:
IG1 signal (Terminal A)
D Is voltage B+?

Yes

Repair malfunctioning wiring harness, then go to


Step 8.

No

Go to next step.

CHECK TO SEE WHETHER MALFUNCTION IS


IN WIRING HARNESS (LACK OF CONTINUITY
BETWEEN KEYLESS UNIT AND GROUND) OR
ELSEWHERE
D Is there continuity between keyless unit
connector terminal L and ground?

Yes

Go to next step.

No

Repair wiring harness between keyless unit and


ground, then go to Step 8.

CHECK FOR CHECK CODE 04 IN


INSTRUMENT CLUSTER
D Inspect door switch using instrument cluster
input/output check mode.
(See Section T)
D Does DTC 04 function properly?

Yes

Go to next step.

No

Repair door switch system using DTC 04


inspection procedure, then go to Step 8.

INSPECT KEYLESS UNIT OR WIRING


HARNESS (BETWEEN KEYLESS UNIT AND
DOOR SWITCHES FOR CONTINUITY)
D Open the driverside door.
D Is there continuity between keyless unit
connector terminal C, D and ground?

Yes

Replace keyless unit and reprogram keyless unit


ID code, then go to next step.

No

Repair wiring harness between keyless unit and


door switch(es) then go to next step.

RECHECK MALFUNCTION SYMPTOM AFTER


REPAIR
D Does keyless entry system operate properly?

Yes

Troubleshooting completed.
Explain repairs to customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

S83

TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]


NO. 3 TRANSMITTER ID CODE CANNOT BE REPROGRAMMED
3

Transmitter ID code cannot be reprogrammed

DESCRIPTION

D Malfunction in transmitter battery, transmitter keyless unit bracket, keyless unit bracket ground screw
or keyless unit circuit.

POSSIBLE
CAUSE

D Malfunction in transmitter battery, transmitter, keyless unit bracket, keyless unit bracket ground screw
or keyless unit circuit
Transmitter battery, transmitter, keyless unit bracket, keyless unit bracket ground screw or keyless
unit malfunction

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT TRANSMITTER BATTERY


INSTALLATION AND TYPE
D Visually inspect transmitter battery.
D Are below items okay?
Transmitter battery installation (correct
polarity)
Battery type (CR2025)

Yes

Go to next step.

No

Set transmitter battery properly or replace with


specified transmitter battery (CR2025), then go to
Step 8.

INSPECT TRANSMITTER BATTERY


TERMINALS FOR RUST AND POOR
CONNECTION
D Visually inspect transmitter.
Is there rust on transmitter battery terminals
(positive or negative pole)?
Is there poor connection between terminals
and battery?

Yes

Replace transmitter battery or repair transmitter


battery terminal, then go to Step 8.

No

Go to next step.

INSPECT TRANSMITTER BATTERY


D Inspect transmitter battery.
D Is battery voltage normal?

Yes

Go to next step.

No

Replace transmitter battery, then go to Step 8.

INSPECT KEYLESS UNIT BRACKET


INSTALLATION
D Is keyless unit bracket installed securely?

Yes

Go to next step.

No

Install bracket securely, then go back to Step 6 of


keyless entry system preliminary inspection.

INSPECT GROUND SCREW INSTALLATION


BETWEEN KEYLESS UNIT AND KEYLESS
UNIT BRACKET
D Are keyless unit and keyless unit bracket
connected securely to ground screw?

Yes

Go to next step.

No

Install screw securely, then go back to Step 6 of


keyless entry system preliminary inspection.

CHECK TO SEE WHETHER MALFUNCTION IS


IN TRANSMITTER BATTERY OR ELSEWHERE
D Replace with a known good transmitter battery.
D Does keyless entry system operate properly?

Yes

Replace transmitter battery, then go to Step 8.

No

Go to next step.

CHECK TO SEE WHETHER MALFUNCTION IS


IN TRANSMITTER OR KEYLESS UNIT
D Reprogram keyless unit ID code by using
another known good transmitter.
D Does keyless entry system operate okay?

Yes

Replace transmitter and reprogram transmitter ID


code, then go to next step.

No

Replace keyless unit and reprogram keyless unit


ID code, then go to next step.

RECHECK MALFUNCTION SYMPTOM AFTER


REPAIR
D Does keyless entry system operate properly?

Yes

Troubleshooting completed.
Explain repairs to customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

S84

BODY ELECTRICAL SYSTEM


POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . T 3
FUSE SERVICE CAUTION . . . . . . . . . . . . . . . . . T 3
MAIN FUSE REMOVAL/INSTALLATION . . . . . T 3
IGNITION SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 3
IGNITION SWITCH INSPECTION . . . . . . . . . . . T 3
KEY REMINDER SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 3
KEY REMINDER SWITCH INSPECTION . . . . T 4
CIGARETTE LIGHTER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 4
CIGARETTE LIGHTER INSPECTION . . . . . . . T 4
RELAY LOCATION . . . . . . . . . . . . . . . . . . . . . . . . T 5
RELAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . T 6
EXTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . T 7
FRONT COMBINATION LIGHT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 7
HEADLIGHT AIMING . . . . . . . . . . . . . . . . . . . . . . T 7
HEADLIGHT BULB
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 7
PARKING LIGHT BULB
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 8
FRONT TURN LIGHT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 8
FRONT TURN LIGHT BULB
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 8
FRONT SIDE TURN LIGHT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 8
REAR COMBINATION LIGHT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 9
REAR COMBINATION LIGHT BULB
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 9
REAR FOG LIGHT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 9
REAR FOG LIGHT BULB
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T 9
LICENSE PLATE LIGHT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . T 10
COMBINATION SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . T 10
COMBINATION SWITCH
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . T 10
LIGHT SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . T 10
LIGHT SWITCH INSPECTION . . . . . . . . . . . . . T 10
HAZARD WARNING SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . T 11
HAZARD WARNING
SWITCH INSPECTION . . . . . . . . . . . . . . . . . . T 11
REAR FOG LIGHT SWITCH REMOVAL . . . . . T12
REAR FOG LIGHT SWITCH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . T12
REAR FOG LIGHT SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T12
HEADLIGHT LEVELING SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T12
HEADLIGHT LEVELING SWITCH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . T12
HEADLIGHT LEVELING SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T12

BACK-UP LIGHT SWITCH


REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
BACK-UP LIGHT SWITCH INSPECTION . . . .
FLASHER UNIT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FLASHER UNIT INSPECTION (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . . . .
FLASHER UNIT INSPECTION (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . . . .
HEADLIGHT LEVELING ACTUATOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
HEADLIGHT LEVELING ACTUATOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR FOG LIGHT RELAY
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR FOG LIGHT RELAY INSPECTION . . . .
RUNNING LIGHT RELAY
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
RUNNING LIGHT RELAY INSPECTION . . . . .
INTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . .
INTERIOR LIGHT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
INTERIOR LIGHT INSPECTION . . . . . . . . . . . .
DOOR SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
DOOR SWITCH INSPECTION . . . . . . . . . . . . . .
PANEL LIGHT CONTROL SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
PANEL LIGHT CONTROL SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIPER AND WASHER . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WIPER MOTOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
WINDSHIELD WIPER MOTOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
WINDSHIELD WIPER ARM AND BLADE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WIPER LINK
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
WINDSHIELD WASHER TANK
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
WINDSHIELD WASHER MOTOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
WINDSHIELD WASHER MOTOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER NOZZLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER NOZZLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER NOZZLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER PIPE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
WINDSHIELD WIPER AND WASHER
SWITCH REMOVAL/INSTALLATION . . . . . . .
WINDSHIELD WIPER AND WASHER
SWITCH INSPECTION . . . . . . . . . . . . . . . . . . .
WARNING AND INDICATOR SYSTEM . . . . . . . .

T1

T13
T13
T13
T14
T14
T15
T16
T17
T17
T17
T17
T19
T19
T19
T20
T20
T20
T21
T22
T21
T22
T22
T22
T23
T23
T23
T23
T23
T24
T24
T24
T24
T24
T25

BODY ELECTRICAL SYSTEM


INSTRUMENT CLUSTER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
INSTRUMENT CLUSTER
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
INSTRUMENT CLUSTER INSPECTION . . . . .
INSTRUMENT CLUSTER REPAIR . . . . . . . . . .
WARNING AND INDICATOR LIGHT
BULB REMOVAL/INSTALLATION . . . . . . . . . .
FUEL GAUGE SENDER UNIT
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE SENDER UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE SENDER UNIT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE SENDER UNIT
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE SWITCH INSPECTION . . . . .
HORN REMOVAL/INSTALLATION . . . . . . . . . .
HORN RELAY REMOVAL/INSTALLATION . . .
HORN RELAY INSPECTION . . . . . . . . . . . . . . .
CLOCK REMOVAL/INSTALLATION . . . . . . . . .
AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUDIO UNIT REMOVAL . . . . . . . . . . . . . . . . . . .
AUDIO UNIT INSTALLATION . . . . . . . . . . . . . . .
FRONT SPEAKER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT SPEAKER INSPECTION . . . . . . . . . . .
REAR SPEAKER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR SPEAKER INSPECTION . . . . . . . . . . . .
ROOF ANTENNA REMOVAL . . . . . . . . . . . . . . .
ROOF ANTENNA INSTALLATION . . . . . . . . . .
ROOF ANTENNA INSPECTION . . . . . . . . . . . .
ANTENNA FEEDER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
ANTENNA FEEDER INSPECTION . . . . . . . . . .
CONDENSER REMOVAL/INSTALLATION . . .
THEFT-DETERRENT SYSTEM . . . . . . . . . . . . . . .
STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . .
BONNET SWITCH REMOAL/INSTALLATION
BONNET SWITCH INSPECTION . . . . . . . . . . .
THEFT-DETERRENT HORN RELAY
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
THEFT-DETERRENT HORN RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEFT-DETERRENT RELAY
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
THEFT-DETERRENT RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEFT-DETERRENT CONTROL MODULE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .

T25
T25
T25
T27
T27
T27
T28
T28
T28
T28
T28
T28
T29
T29
T29
T29
T29
T29
T30
T30
T30
T31
T31
T31
T31
T32
T32
T33
T33
T33
T33
T33
T33
T33
T33
T33

THEFT-DETERRENT CONTROL MODULE


INSPECTION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
THEFT-DETERRENT CONTROL MODULE
INSPECTION (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
THEFT-DETERRENT HORN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . . . .
IMMOBILIZER UNIT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
IMMOBILIZER UNIT INSPECTION . . . . . . . . . .
COIL REMOVAL/INSTALLATION . . . . . . . . . . .
IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . .
CODE WORD INPUT PROCEDURE . . . . . . . .
AIR BAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . .
DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
SAS UNIT REMOVAL/INSTALLATION . . . . . . .
CLOCK SPRING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
CLOCK SPRING ADJUSTMENT . . . . . . . . . . . .
CLOCK SPRING INSPECTION . . . . . . . . . . . . .
AIR BAG MODULE DEPLOYMENT
AUTHORIZATION PROCEDURE . . . . . . . . . .
AIR BAG MODULE DEPLOYMENT
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG MODULE DISPOSAL
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION OF SST
(DEPLOYMENT TOOL) . . . . . . . . . . . . . . . . . .
ON-BOARD DIAGNOSTIC
(IMMOBILIZER SYSTEM) . . . . . . . . . . . . . . . . . . .
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-BOARD DIAGNOSTIC
(AIR BAG SYSTEM) . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

T2

T36
T38
T41
T42
T41
T42
T43
T44
T50
T52
T52
T53
T53
T54
T55
T55
T55
T56
T56
T59
T60
T61
T61
T61
T62
T62
T62
T63
T64
T64
T65
T66
T66
T73
T73

POWER SYSTEM

POWER SYSTEM
FUSE SERVICE CAUTION
Caution
D Determine and correct the cause of the
burnt fuse before replacing it with the
specified type. If the fuse is replaced before
doing this, it may burn again.

IGNITION SWITCH INSPECTION


1. Remove the column cover.
2. Disconnect the ignition switch connectors.
3. Inspect for continuity between the ignition switch
terminals using an ohmmeter.
: Continuity
Ignition key
position

Terminal
2A

2B

1D

1C

1B

1A

LOCK

MAIN FUSE REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

ACC
ON
START

G6, WL, WL TURBO, F2 CIS

2A

2B

2B

2A

123456567

START
START
LOCK
LOCK
ON
ON ACC
ACC
1A 1B
1C 1D

1C

1A

1D

1B

F2 CARB

4. If not as specified, replace the ignition switch.


KEY REMINDER SWITCH REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the column cover.
3. Disconnect the key reminder switch connector.
4. Remove the key reminder switch.
KEY REMINDER
SWITCH

Nut

Bolt

Main fuse

IGNITION SWITCH REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the column cover.
3. Disconnect the ignition switch connectors.
4. Remove the screw to remove the ignition switch.

STEERING
LOCK

5. Install in the reverse order of removal.

IGNITION
SCREW
SWITCH
CONNECTOR

IGNITION
SWITCH

5. Install in the reverse order of removal.

T3

POWER SYSTEM
KEY REMINDER SWITCH INSPECTION
1. Remove the column cover.
2. Disconnect the key reminder switch connector.
3. Inspect for continuity between the key reminder
switch terminals using an ohmmeter.
: Continuity
Key position

Socket Removal Note


1. Pry up the stopper with a tape-wrapped
screwdriver.
2. Pull the socket by prying up the stopper.

Terminal
A

Inserted
Removed
A

CIGARETTE LIGHTER INSPECTION


D Verify that the cigarette lighter plug will move
normally within 1020 seconds, after pressing
the plug into the socket. If the plug does not move,
replace the cigarette lighter.

4. If not as specified, replace the key reminder switch.


CIGARETTE LIGHTER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the center panel.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Cigarette lighter plug

Connector

Socket
+ Removal Note

Ring

T4

POWER SYSTEM
RELAY LOCATION

ZCF8110W101

T5

POWER SYSTEM
D If not as specified, replace the relay.

RELAY INSPECTION
Relay Type
Terminal type
Fourterminal

Parts name

Type A

Starter relay

Type B

PCM control relay

Note
D The inspection of theftdeterrent relay has not
been changed.

Y5A8110W151

Fourterminal
Type A
1. Remove the relay.
2. Inspect for continuity between the relay terminals
using an ohmmeter.

ZCF8110W102

D If not as specified, replace the relay.

Z5U914WAK

Type B
1. Remove the relay.
2. Inspect for continuity between the relay terminals
using an ohmmeter.

ZCF8110W103

T6

EXTERIOR LIGHTING SYSTEM


If it is difficult to remove front combination light
with pliers
D Remove the adjusting screws and the screw by
loosening them.

EXTERIOR LIGHTING SYSTEM


FRONT COMBINATION LIGHT
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the radiator grille. (Refer to section S,
EXTERIOR ATTACHMENT, RADIATOR GRILLE
REMOVAL/INSTALLATION.)
3. Remove the front turn light. (Refer to FRONT
TURN LIGHT REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Adjust the headlight aiming. (Refer to HEADLIGHT
AIMING.)

ADJUSTING
SCREW
SCREW

ADJUSTING
SCREW

HEADLIGHT AIMING
1. Adjust the tire air pressure to the specification.
2. Position the unloaded vehicle on a level surface.
3. Seat one person in the drivers seat.
4. Start the engine and charge the battery fully.
5. Position the vehicle straight ahead and
perpendicularly to a wall.
6. Set the headlights 7.6 m {25 ft} from the wall.
7. While adjusting one headlight, disconnect the
connector of the other.
1

Front combination light connector

Front combination light


+ Removal Note

Spring

Caution
D Always tighten the adjusting screws last.
When loosening the adjusting screws, loosen
the screws first and then tighten them.
If the adjusting screws are tightened first,
then loosened, they will continue to loosen
when the vehicle is in motion and may
cause the headlights to become misaligned.

Front Combination Light Removal Note


Removal with pliers
Caution
D When pressing the hook of the adjusting
screws and the screw with the pliers, do not
damage the front combination light
mounting.

8. Adjust the headlights by turning the adjusting


screws as shown in the figure. Loosen the screws
first, then tighten them.

1. Press the hook of the adjusting screws and the


screw with the pliers.
2. Pull the front combination light out of the adjusting
screws and the screw.

ADJUSTING
SCREW

OUTWARD

INWARD

UP

HOOK

DOWN
SCREW

HEADLIGHT BULB REMOVAL/INSTALLATION


Caution
D A halogen bulb generates extremely high
heat when it is used. If the surface of the
bulb is soiled, excessive heat will build up
and the lights life will be shortened. When
replacing the bulb, hold the metal flange,
not the glass.

FRONT COMBINATION LIGHT MOUNTING

T7

EXTERIOR LIGHTING SYSTEM


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Headlight bulb connector

Cover
+ Installation Note

Headlight bulb

Cover Installation Note


D Align the TOP mark with top side.

Screw

Front turn light

Front turn light connector

FRONT TURN LIGHT BULB


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

TOP MARK

PARKING LIGHT BULB REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Socket

Front turn light bulb

FRONT SIDE TURN LIGHT


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

FRONT

Socket

Parking light bulb

REAR

FRONT TURN LIGHT REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

T8

Front side turn light

Front side turn light connector

Socket

Front side turn light bulb

EXTERIOR LIGHTING SYSTEM


REAR COMBINATION LIGHT
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

REAR FOG LIGHT REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
WITHOUT REAR BUMPER

Screw

Rear combination light

Rear combination light connector

REAR COMBINATION LIGHT BULB


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the rear combination light.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Screw

Lens
+ Removal Note

Rear turn light bulb

Back-up light bulb

Brake light/taillight bulb

Rear fog light connector

Nut

Spring washer

Rear fog light

WITH REAR BUMPER

Rear fog light connector

Screw

Rear fog light

REAR FOG LIGHT BULB


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Lens Removal Note


D Push the hook upward with your finger.
HOOK

T9

Screw

Lens

Rear fog light bulb

EXTERIOR LIGHTING SYSTEM


LICENSE PLATE LIGHT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

COMBINATION SWITCH
DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Screw

Screw

License plate light

Windshield wiper and washer switch

License plate light bulb

Light switch

Socket

Body

License plate light connector

COMBINATION SWITCH REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. For vehicles without air bag system, remove the
horn cap. For vehicles with air bag system, remove
the driver-side air bag module. (Refer to AIR BAG
SYSTEM, DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
3. Remove the steering wheel. (Refer to section N,
MANUAL STEERING, STEERING WHEEL AND
COLUMN REMOVAL/INSTALLATION.)
4. For vehicles with air bag system, remove the clock
spring. (Refer to AIR BAG SYSTEM, CLOCK
SPRING REMOVAL/INSTALLATION.)
5. Remove the column cover.
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.

LIGHT SWITCH REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the column cover.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Light switch connector

Screw

Light switch

LIGHT SWITCH INSPECTION


Headlight Switch
1. Remove the light switch. (Refer to LIGHT SWITCH
REMOVAL/INSTALLATION.)

Screw

Combination switch

Combination switch connector

Note
D When the flash-to-pass switch is on, the
contact of the low-high switch is at neutral.
2. Inspect for continuity between the light switch
terminals using an ohmmeter.

T10

EXTERIOR LIGHTING SYSTEM


: Continuity
Switch position
Light

Dimmer

OFF

TNS

Headlight

Low

Terminal

Flashto-pass

P
(B)

D
(N)

L
(H)

F
(J)

3. If not as specified, replace the light switch.


HAZARD WARNING SWITCH
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the meter hood. (Refer to section S,
DASHBOARD AND CONSOLE, METER HOOD
REMOVAL/INSTALLATION.)
3. Remove as indicated in the table.
4. Install in the reverse order of removal.

H
(L)

Off
On
Off
On
Off
On

High

( ): Light switch right side lever


(J)

(N)

OFF
OFF
TNS
FLASH
-TO
-PASS

HIGH

HOOK

HEADLIGHT

HEADLIGHT TNS

(L)

(H)

(B)

*
(O)

*
(M)

*
(K)

P
(*)

Hazard warning switch

LOW

(*)

*
(J)

F
(*)

HAZARD WARNING SWITCH INSPECTION


1. Remove the meter hood. (Refer to section S,
DASHBOARD AND CONSOLE, METER HOOD
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the hazard warning
switch terminals using an ohmmeter.
: Continuity
: Bulb

(*)

*
(B)

Terminal

Switch
position

(*)

Off
On

( ): LIGHT SWITCH RIGHT SIDE LEVER

3. If not as specified, replace the light switch.


Turn Switch
1. Remove the light switch. (Refer to LIGHT SWITCH
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the light switch
terminals using an ohmmeter.
: Continuity
Switch position

Terminal
C (M)

A (K)

E (O)

Right
Off

Left

( ): Light switch right side lever


(M)
C

*
*
* (M)
(O)
(K)
* H
P
N
L (J)
(*)
A

(*)

F
(*)

(*)

(*)

*
(B)

3. If not as specified, replace the hazard warning


switch.

(K)
(O)
( ): LIGHT SWITCH RIGHT SIDE LEVER

T11

EXTERIOR LIGHTING SYSTEM


REAR FOG LIGHT SWITCH REMOVAL
1. Disconnect the negative battery cable.
2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the rear fog light
switch and pull it forward to remove it.
3. Disconnect the connector to remove the rear fog
light switch.

HEADLIGHT LEVELING SWITCH REMOVAL


1. Disconnect the negative battery cable.
2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the headlight
leveling switch and pull it forward to remove it.
3. Disconnect the connector to remove the headlight
leveling switch.

HOOK

HOOK
CONNECTOR

CONNECTOR
REAR FOG
LIGHT SWITCH

HEADLIGHT
LEVELING SWITCH

REAR FOG LIGHT SWITCH INSTALLATION


1. Connect the rear fog light switch connector.
2. Insert the rear fog light switch in the hole to install
it.
3. Connect the negative battery cable.

HEADLIGHT LEVELING SWITCH INSTALLATION


1. Connect the headlight leveling switch connector.
2. Insert the headlight leveling switch in the hole to
install it.
3. Connect the negative battery cable.

REAR FOG LIGHT SWITCH INSPECTION


1. Remove the rear fog light switch. (Refer to REAR
FOG LIGHT SWITCH REMOVAL/INSTALLATION.)
2. Inspect for continuity between the rear fog light
switch terminals using an ohmmeter.
: Continuity

HEADLIGHT LEVELING SWITCH INSPECTION


1. Remove the headlight leveling switch. (Refer to
HEADLIGHT LEVELING SWITCH
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the headlight
leveling switch terminals using an ohmmeter.
: Continuity
: Resistance
: Bulb

Switch position

Terminal
A

Terminal

Switch position

Off
Neutral

0
1
2

R3

R1:1600

R2+R3

R1+ R2+ R3

On

3. If not as specified, replace the rear fog light switch.

3:300

3
*

R1 R2 R3

560

2:

3. If not as specified, replace the headlight leveling


switch.

T12

EXTERIOR LIGHTING SYSTEM


BACK-UP LIGHT SWITCH
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

FLASHER UNIT REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

2534 {2.53.4, 1924}

DRIVER-SIDE
FRONT SIDE TRIM

Nm {kgfm, ftlbf}

Back-up light switch connector

Back-up light switch

Gasket

BACK-UP LIGHT SWITCH INSPECTION


1. Disconnect the back-up light switch connector.
2. Inspect for continuity between the back-up light
switch terminals using an ohmmeter.
: Continuity
Terminal

Shift lever
position

Reverse
Other

3. If not as specified, replace the back-up light switch.

T13

Nut

Flasher unit

Flasher unit connector

EXTERIOR LIGHTING SYSTEM


FLASHER UNIT INSPECTION
(VEHICLES BUILT UP TO 07/2002)
1. Measure the voltage at the flasher unit terminals as indicated below.
2. Disconnect the flasher unit connector before inspecting for continuity at terminal C.
3. If not as specified, inspect the parts listed under Inspection area and the related wiring harnesses.
4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the flasher unit.
Terminal Voltage List (Reference)
B+: Battery positive voltage
A
B

Terminal

Signal

Connection

Voltage (V)
/Continuity

Test condition

Alternates
B+ and 0

Hazard warning switch on


A

Flasher unit
output

Hazard warning
switch

Hazard warning
switch off

Ignition switch at
ON position

B+

Ignition switch at
LOCK or ACC
position

Hazard warning switch on


B

Power supply

Flasher unit
ground

Hazard warning
switch

GND

Hazard warning
switch off

Ignition switch at
LOCK or ACC
position

Constant: inspect for continuity to


ground

D Hazard

warning switch
D Turn signal

light

B+

Ignition switch at
ON position

Inspection area

B+

D HAZARD 10 A

fuse
D METER 15 A

fuse
0
Yes

D Hazard

warning switch
GND

FLASHER UNIT INSPECTION


(VEHICLES BUILT FROM 08/2002)
1. Connect the connector to the flasher unit.
2. Connect the negative battery cable.
3. Measure the voltage at the flasher unit using voltmeter.
D When inspecting terminal F for continuity, disconnect the flasher unit connector.
4. If the value are not as specified in the Terminal Voltage List (Reference), inspect the parts under Action and
related wiring harnesses.
5. If the system does not work properly even though the parts or related wiring harnesses do not have any
malfunction, replace the flasher unit.
Terminal Voltage List (Reference)

Terminal

Signal

Power supply

Connected to
HAZARD 10 A
fuse

Test condition
Under any
condition

T14

Voltage (V)/
Continuity

Action
D Inspect HAZARD 10 A

B+

fuse
D Inspect related harness

EXTERIOR LIGHTING SYSTEM

Terminal

Signal

Connected to

Test condition
Turn signal light
(LH) flashes

Turn signal
flasher (LH)

Turn signal
light (LH)

Hazard warning
switch at on
position
Other

Flasher unit
ground

Turn signal light


(RH) flashes
G

Turn signal
flasher (RH)

Turn signal
light (RH)

Hazard warning
on

Turn switch on/off


(RH)

Hazard warning switch

Combination
switch

Hazard warning
switch at on
position

Combination
switch

Yes

Alternates
below 1.0 and
B+

Other

Below 1.0

Hazard warning
switch at on
position

Below 1.0

B+

Ignition switch is at
ON and turn switch
(RH) on

B+

HEADLIGHT LEVELING ACTUATOR


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the radiator grille. (Refer to section S,
EXTERIOR ATTACHMENT, RADIATOR GRILLE
REMOVAL/INSTALLATION.)
3. Remove the front turn light. (Refer to FRONT
TURN LIGHT REMOVAL/INSTALLATION.)
4. Remove the front combination light. (Refer to
FRONT COMBINATION LIGHT
REMOVAL/INSTALLATION.)
5. Remove the headlight leveling actuator connector
from the bracket.
6. Disconnect the headlight leveling actuator
connector.
7. Remove the nuts.
8. Remove the headlight leveling actuator.

(LH)
D Inspect related harness

D Inspect GND

D Inspect turn signal light

(RH)
D Inspect related harness

D Inspect hazard warning


D Inspect related harness

D Inspect combination switch


D Inspect related harness

Below 1.0

Ignition switch is at
ON and turn switch
(LH) on
Other

D Inspect turn signal light

switch

Hazard warning
switch at off
position

Other
Turn switch on/off
(LH)

Alternates
below 1.0 and
B+

Action

Below 1.0

Constant: inspect
for continuity to
ground

GND

Voltage (V)/
Continuity

B+

D Inspect combination switch


D Inspect related harness

Below 1.0

9. Install in the reverse order of removal.

HEADLIGHT
LEVELING
ACTUATOR

HEADLIGHT LEVELING
ACTUATOR CONNECTOR

T15

EXTERIOR LIGHTING SYSTEM


HEADLIGHT LEVELING ACTUATOR INSPECTION
1. Measure the voltage at the headlight leveling actuator terminals as indicated below.
Note
D Because the headlight leveling actuator connector is waterproof, it is impossible to measure the voltage at
the headlight leveling actuator terminals. When inspecting, measure the voltage at the terminal of the part
which is connected to the headlight leveling actuator.
(1) To measure the voltage at the terminal A of the headlight leveling actuator, remove the column cover and
measure the voltage at the terminal N of the light switch connector. (Refer to LIGHT SWITCH
INSPECTION.)
(2) To measure the voltage at the terminal B of the headlight leveling actuator, remove the headlight leveling
switch with the connector connected and measure the voltage at the terminal C of the headlight leveling
switch connector. (Refer to HEADLIGHT LEVELING SWITCH INSPECTION.)
(3) Disconnect the headlight leveling actuator connector before inspecting for continuity at terminal C.
2. If not as specified, inspect the parts listed under Inspection area and the related wiring harnesses.
3. If the parts and wiring harnesses are okay but the system still does not work properly, replace the headlight
leveling actuator.
Terminal Voltage List (Reference)
B+: Battery positive voltage

Terminal

Signal

Headlight
leveling
actuator
power supply

Headlight
leveling switch
position

Headlight
leveling
actuator
ground

Connection

Combination
switch

Headlight
leveling switch

GND

Test condition
Headlight illuminated

Voltage ( V )
/Continuity

Inspection area

B+
Combination switch

Headlight unilluminated

Headlight
switch on

Headlight leveling
switch at 0

6.2

Headlight leveling
switch at 1

4.2

Headlight leveling
switch at 2

2.1

Headlight leveling
switch at 3

Constant : inspect for continuity


to ground

T16

Headlight leveling switch

Yes

GND

EXTERIOR LIGHTING SYSTEM


REAR FOG LIGHT RELAY
REMOVAL/INSTALLATION

RUNNING LIGHT RELAY REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the washer tank from the bracket.
3. Remove the running light relay with the cover
attached.

Note
D Because the lock section of the relay is
damaged easily, do not remove the relay from
the bracket unless replacement is necessary.
Always perform an inspection of the rear fog
light relay before removal.

NUT

1. Disconnect the negative battery cable.


2. Disconnect the rear fog light relay connector.
3. Remove the rear fog light relay by prying the lock
section of the upper part with a flathead
screwdriver.

RUNNING LIGHT
RELAY WITH COVER

4. Remove the cover.


5. Disconnect the running light relay connector.

REAR FOG
LIGHT RELAY

COVER

BRACKET

REAR FOG LIGHT


RELAY CONNECTOR

RUNNING LIGHT
RELAY

4. Install in the reverse order of removal.


REAR FOG LIGHT RELAY INSPECTION
1. Remove the bracket and pull it toward you.
2. Inspect for continuity between the rear fog light
relay terminals using an ohmmeter.
: Continuity B+: Battery positive voltage
Terminal

Step

B+

GND

1
2

RUNNING LIGHT
RELAY CONNECTOR

6. Install in the reverse order of removal.


RUNNING LIGHT RELAY INSPECTION
1. Remove the running light relay. (Refer to
RUNNING LIGHT RELAY
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the running light
relay terminals using an ohmmeter.
: Continuity
: Diode

Test
condition

Constant

Terminal
A

B
B

3. If not as specified, replace the rear fog light relay.

T17

EXTERIOR LIGHTING SYSTEM


3. Connect the terminal A to the positive battery
terminal and the terminal D to the negative battery
terminal.
4. Verify that there is continuity between terminals A
and E, and that there is no continuity between
terminals B and F.
B

5. Connect the terminal C to the positive battery


terminal and the terminal D to the negative battery
terminal.
6. Verify that there is no continuity between terminals
B and F, and between terminals A and E.
B

7. If not as specified, replace the running light relay.

T18

INTERIOR LIGHTING SYSTEM

INTERIOR LIGHTING SYSTEM


INTERIOR LIGHT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
ALL VEHICLES EXCEPT
REGULAR CAB

Interior Light Installation Note


Regular cab
Note
D The spacer acts as a ground. If the spacer is
not installed in the position shown in the figure,
the interior light may not illuminate.
REGULAR CAB

1. Tighten the screw fully. (More than 4 mm {0.2 in}


of thread should be exposed.)
2. Install the interior light.
SCREW

4.0 mm
{0.2 in}

Lens
+ Removal Note

Interior light bulb

Screw

Spacer

Interior light
+ Installation Note

Interior light connector

SPACER
INTERIOR LIGHT

INTERIOR LIGHT INSPECTION


1. Remove the interior light. (Refer to INTERIOR
LIGHT REMOVAL/INSTALLATION.)
2. Inspect for continuity between the interior light
terminals using an ohmmeter.
: Bulb

Lens Removal Note


All vehicles except regular cab
1. Insert a tape-wrapped flathead screwdriver into the
lens.
2. Twist the screwdriver to remove the lens.

Terminal

Step

Body GND

ON
DOOR
OFF
B

A
OFF

ON

DOOR
A

Regular cab
D Push the areas indicated by the arrows to pull out
the lens.

3. If not as specified, replace the interior light.

T19

INTERIOR LIGHTING SYSTEM


DOOR SWITCH REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

Screw

Door switch

Door switch connector

DOOR SWITCH INSPECTION


1. Remove the door switch.
2. Inspect for continuity between the door switch
terminals using an ohmmeter.
: Continuity
Terminal

Switch condition

Body GND

Pressed
Released

BODY GND

3. If not as specified, replace the door switch.


PANEL LIGHT CONTROL SWITCH
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the meter hood. (Refer to section S,
DASHBOARD AND CONSOLE, METER HOOD
REMOVAL/INSTALLATION.)
3. Remove as indicated in the table.
4. Install in the reverse order of removal.

HOOK

T20

Panel light control switch

INTERIOR LIGHTING SYSTEM


PANEL LIGHT CONTROL SWITCH INSPECTION
1. Remove the meter hood without disconnecting the panel light control switch connector. (Refer to section S,
DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)
2. Measure the voltage at the panel light control switch as indicated below.
3. Disconnect the panel light control switch connector before inspecting for continuity at terminal G.
4. If not as specified, inspect the parts listed under Inspection area and the related wiring harnesses.
5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the panel light
control switch.
Terminal Voltage List (Reference)
B+: Battery positive voltage
G
H

Terminal
A
B
D
F
G
H

Signal
Panel light
control
output

Connection
Each
illumination

Power
supply

Light switch

Voltage (V)/
Continuity

Test condition
Inspect using an oscilloscope
+ A terminal inspection

Not used

Headlight switch at TNS or


headlight position

Not used

Not used

D Light switch
D TAIL 10 A fuse

A Terminal Inspection
1. Measure the wave pattern of the A terminal on the
panel light control switch using an oscilloscope.

Each illumination

B+

Constant: Inspect for continuity to


ground

GND

Inspection area

Headlight switch at OFF position

Panel light
control
switch
ground

Yes

GND

PANEL LIGHT
CONTROL SWITCH

5. Verify that the pattern on the screen matches the


pattern shown in the figure as the panel light
control switch is gradually turned to the darkest
position.

OSCILLOSCOPE

2. Set the headlight switch to either the TNS or


headlight position.
3. Set the panel light control switch to the brightest
position.
4. Verify that the pattern of the screen is as shown in
the figure.

V
B+
0

13.2 ms
515.4 ms

T21

WIPER AND WASHER


WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Adjust the windshield wiper arm and blade. (Refer
to WINDSHIELD WIPER ARM AND BLADE
ADJUSTMENT.)

WIPER AND WASHER


WINDSHIELD WIPER MOTOR
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Disconnect the connector.
3. Loosen the bolts.
4. Pull the windshield wiper motor forward until the
connection between the windshield wiper motor
and windshield wiper link is in the engine room.
5. Pry off the connection between the windshield
wiper motor and windshield wiper link.
6. Remove the windshield wiper motor.

1619
{1.62.0,
1214}

WINDSHIELD WIPER MOTOR

Nm {kgfm, ftlbf}

CONNECTOR

WINDSHIELD
WIPER LINK

BOLT
4.06.8 {4070, 3560}

Cap

Nut

Windshield wiper arm


+ Installation Note

Windshield wiper blade

Rubber brush

Nm {kgfcm, inlbf}

7. Install in the reverse order of removal.


WINDSHIELD WIPER MOTOR INSPECTION
1. Disconnect the windshield wiper motor connector.
2. Connect battery positive voltage and inspect the
operation of the windshield wiper motor as
indicated below.
Terminal

Operation

High

Low

A
B

Windshield Wiper Arm Installation Note


D Clean the windshield wiper arm connector shafts
with a wire brush before installing the windshield
wiper arms.

WINDSHIELD WIPER
ARM CONNECTOR SHAFT

C
D

3. Connect battery positive voltage to terminal C of


the windshield wiper motor to operate the
windshield wipers at low speed.
4. Disconnect battery positive voltage from terminal C
of the motor while the wipers are operating.
5. Verify that the wipers do not stop in the park
position.
6. Short between terminal C and B of the motor, and
connect battery positive voltage to terminal D of
the motor.
7. Verify that the wipers operate at low speed again,
then stop in the park position.
8. If not as specified, replace the windshield wiper
motor.

WINDSHIELD WIPER ARM AND BLADE


ADJUSTMENT
1. Operate the windshield wiper motor to set the
windshield wipers in the park position.
2. Align both ends of the wiper blades to the marks
on the ceramic section.

T22

CERAMIC SECTION

MARK

WIPER AND WASHER


WINDSHIELD WIPER LINK
REMOVAL/INSTALLATION
1. Remove the windshield wiper arm and blade.
(Refer to WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
2. Remove the cowl grille.
3. Remove the windshield wiper motor.
(Refer to WINDSHIELD WIPER MOTOR
REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Adjust the windshield wiper arm and blade.
(Refer to WINDSHIELD WIPER ARM AND BLADE
ADJUSTMENT.)
6.879.80
{70100, 60.886.7}

Windshield washer motor

Grommet

WINDSHIELD WASHER MOTOR INSPECTION


1. Disconnect the windshield washer motor
connector.
2. Connect battery positive voltage to terminal B and
ground to terminal A of the motor.
3. Verify that the windshield washer motor operates.
B
Nm {kgfcm, inlbf}

Bolt

Windshield wiper link

M
A

WINDSHIELD WASHER TANK


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Disconnect the connector.
3. Disconnect the windshield washer pipe from the
windshield washer motor.
4. Pull the windshield washer tank up and slide it off
the bracket.

WINDSHIELD
WASHER TANK

CONNECTOR
WINDSHIELD
WASHER PIPE

B
A

4. If the motor does not operate, replace the


windshield washer motor.
WINDSHIELD WASHER NOZZLE REMOVAL
1. Disconnect the windshield washer pipe from the
windshield washer nozzle.
2. Remove the windshield washer nozzle using a 10
mm {0.4 in} deep socket wrench from underneath
the bonnet.
DEEP SOCKET WRENCH

WINDSHIELD WASHER NOZZLE

BRACKET

5. Install in the reverse order of removal.


WINDSHIELD WASHER MOTOR
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the windshield washer tank.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

WINDSHIELD WASHER NOZZLE INSTALLATION


1. Connect the windshield washer pipe to the
windshield washer nozzle.
2. Push the windshield washer nozzle into the
installation hole.
3. Adjust the windshield washer nozzle. (Refer to
WINDSHIELD WASHER NOZZLE ADJUSTMENT.)

T23

WIPER AND WASHER


WINDSHIELD WASHER NOZZLE ADJUSTMENT
D Insert a needle or equivalent tool into the spray
holes of the windshield washer nozzle and adjust
the nozzle direction as shown.

SCREW

WINDSHIELD
WIPER AND
WASHER
SWITCH

CENTER

320 {12.6}

CONNECTOR

390 {15.4}

6. Install in the reverse order of removal.

100 100
{3.9} {3.9}

290
{11.4} 290
{11.4}

270
{10.6}

180
{7.1}

WINDSHIELD WIPER AND WASHER SWITCH


INSPECTION
1. Remove the column cover.
2. Remove the windshield wiper and washer switch.
3. Inspect for continuity between the windshield wiper
and washer switch terminals using an ohmmeter.
: Continuity

WINDSHIELD
GLASS END LINE

MOLDING
END LINE

Switch position

WINDSHIELD WASHER PIPE


REMOVAL/INSTALLATION
1. Disconnect the windshield washer pipe from the
windshield washer nozzle and the windshield
washer motor.
2. Remove the clips.
3. Remove the windshield washer pipe.

Wiper
switch

L(F)

G(E
)

M(C
)

N(D
)

C(M
)

123

Off

OFF

mm {in}

Terminal

Onetouch

On

INT
LO
HI

Washer
switch

On

( ): Wiper and washer switch left side lever


(D)
N
ONE-TOUCH WIPER
SWITCH
HI
OFF

OFF

HI
LO

INT
INT

LO
CLIP

INT
RELAY

WINDSHIELD
WASHER PIPE

L
(F)

H
(J)

4. Install in the reverse order of removal.

M
(C)

G
(E)

C
(M)
WASHER
SWITCH

WINDSHIELD WIPER AND WASHER SWITCH


REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the column cover.
3. Disconnect the connector.
4. Remove the screws.
5. Remove the windshield wiper and washer switch.

0
(*)
*

G
(*)

M
N
(*)

L
(*)

*
(J)

H
(*)

*
(E)
*
(F)

*
(A)

*
(D)

( ): WIPER AND WASHER SWITCH LEFT SIDE LEVER

4. If not as specified, replace the windshield wiper


and washer switch.

T24

WARNING AND INDICATOR SYSTEM

WARNING AND INDICATOR SYSTEM


INSTRUMENT CLUSTER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the meter hood. (Refer to section S,
DASHBOARD AND CONSOLE, METER HOOD
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Screw

Instrument cluster connector

Instrument cluster

INSTRUMENT CLUSTER INSPECTION


Speedometer
1. Adjust the tire air pressure to the specification.
2. Using a speedometer tester, verify that the
speedometer indication is within the allowable
range indicated in the table.
Allowable range (km/h)

20

1822

40

3644

60

5466

80

7288

100

90110

120

108132

140

126154

160

144176

180

162198

3. Verify that fluctuation of the speedometer needle is


within the allowable range.
Needle fluctuation allowable range
Within 0.5 km/h

INSTRUMENT CLUSTER
DISASSEMBLY/ASSEMBLY

4. If the speedometer needle does not move or if the


indication is outside of the allowable range, inspect
the vehicle speedometer sensor and related wiring
harness.
5. If the vehicle speedometer sensor and related
wiring harness are normal, replace the instrument
cluster.

Caution
D If the print plate on the back of the
instrument cluster is damaged, the system
will not operate properly and it may become
the cause of trouble or malfunction.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Speedometer tester
indication (km/h)

Tachometer
Using the SSTs (NGS kit) or a dwell tacho tester
Caution
D If the engine speed exceeds the allowable
range, the engine could be damaged.
Therefore, when inspecting the tachometer,
do not allow the engine speed to exceed the
allowable range indication on the
tachometer.
1. Follow the appropriate procedure for using the
SSTs (NGS kit) or dwell tacho tester.

Screw

Bulb

Alarm

Front lens

Instrument cluster

Using the SSTs (NGS kit)


(1) Connect the SSTs (NGS kit) to the data link
connector and battery.

DIAGNOSTIC PROGRAM CARD

NGS KIT

T25

WARNING AND INDICATOR SYSTEM


(2) Select VEHICLE & ENGINE SELECTION and
press TRIGGER. (Select the model and
specifications of the vehicle you are testing.)
(3) Select PCM-POWERTRAIN CTRL MODULE
and press TRIGGER.
(4) Select PID/DATA MONITOR AND RECORD
and press TRIGGER.
(5) Select RPM and press TRIGGER.
(6) Press START.

: Resistance
Step
1

FUEL

GND

COM

R1
R2

R1, R2: 140200

Using a dwell tacho tester


D Connect a dwell tacho tester to the terminals K and
B of the PCM connector.

GND
FUEL+
COM

2. Verify that the tachometer indication is within the


allowable range indicated in the table.
Dwell tacho tester
indication (rpm)

Terminal
FUEL +

FUEL

Allowable range (rpm)

650

583705

1000

9261060

2000

19542120

3000

29803180

4000

40084240

12. Verify that the difference in resistance between R1


and R2 is less than 6 .
13. If not as specified, replace the instrument cluster.

3. If the tachometer needle does not move or if the


indication is outside of the allowable range, inspect
the PCM and related wiring harness.
4. If the PCM and related wiring harness are normal,
replace the instrument cluster.

Water Temperature Gauge


1. Disconnect the water temperature sender unit
connector.
2. Turn the ignition switch to ON position.
3. Verify that the needle is below C.
4. Ground terminal A of the water temperature sender
units vehicle side connector.

Fuel Gauge
1. Disconnect the fuel gauge sender unit connector.
2. Connect the red lead of SST (Fuel And
Thermometer checker) to terminal B of the fuel
gauge sender unit connector and black lead to
ground.
3. Set the resistance of SST (Fuel And Thermometer
checker) to 180 .

49 N088 0A0
49 0839 285

5. Verify that the needle is above H.


6. If the needle does not move or moves irregularly,
remove the instrument cluster.
(Refer to INSTRUMENT CLUSTER
REMOVAL/INSTALLATION.)
7. Measure the resistance between the water
temperature gauge terminals using an ohmmeter.
: Resistance

4. Turn the ignition switch to ON position.


5. Verify that the needle is below E.
6. Turn the ignition switch to LOCK position.
7. Set the resistance of SST (Fuel And Thermometer
checker) to 10 .
8. Turn the ignition switch to ON position.
9. Verify that the needle is above F.
10. If the needle does not move or moves irregularly,
remove the instrument cluster.
(Refer to INSTRUMENT CLUSTER
REMOVAL/INSTALLATION.)
11. Measure the resistance between the fuel gauge
terminals using an ohmmeter.

T26

Step
1
2

Terminal
TEMP +

TEMP

V+

COM

R1
R2

R1, R2: 140200

WARNING AND INDICATOR SYSTEM


WARNING AND INDICATOR LIGHT BULB
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the instrument cluster.
(Refer to INSTRUMENT CLUSTER
REMOVAL/INSTALLATION.)
3. Turn the socket counterclockwise to remove the
bulb as shown in the figure.

TEMP+
COM

V+

TEMP

8. Verify that the difference in resistance between R1


and R2 is less than 6 .
9. If not as specified, replace the instrument cluster.

BULB

INSTRUMENT CLUSTER REPAIR


Note
D The needle of speedometer or tachometer may
continue to rotate clockwise until it rests on the
mask plate. If a customer complains of this
concern, repair the needle position according
to the following steps.
1. Verify the concern.
TACHOMETER

SPEEDOMETER

2. Turn the ignition switch to LOCK position.


3. Remove the ROOM fuse, then wait for 10 minutes
or more until the power supply in the instrument
cluster is spent.
4. Turn the ignition switch to ON position.
5. Verify that the needle returns to zero.
TACHOMETER

SPEEDOMETER

4. Install in the reverse order of removal.


FUEL GAUGE SENDER UNIT INSPECTION
1. For G6, F2 CIS, or F2 Carb engine vehicles, remove
the fuel pump unit. (Refer to section F1, FUEL
SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
(Refer to section F3, FUEL SYSTEM, FUEL TANK
REMOVAL/INSTALLAITON.) (Refer to section F4,
FUEL SYSTEM, FUEL TANK
REMOVAL/INSTALLATION.) For WL or WL Turbo
engine vehicles, remove the fuel gauge sender unit.
(Refer to section F2, FUEL SYSTEM, FUEL TANK
REMOVAL/INSTALLATION.)
2. Using an ohmmeter, measure and verify that the
resistance between terminals B and C (WL, WL
Turbo) or A and B (G6, F2 CIS, F2 Carb) of the fuel
gauge sender unit is as shown in the following
chart while slowly moving the unit arm from empty
to full.
Measuring point

Resistance ()

Full

18.426.4

1/2

81.593.5

Empty

136154

WL, WL TURBO
87.0 {3.43} *
65.5 {2.58}

* DOUBLE CAB
2WD, STRETCH
CAB 2WD

FULL

169.7 {6.681} *
158.1 {6.224}

1/2
253.7 {9.988}

EMPTY

6. After the needle returns to zero, install the ROOM


fuse with the ignition switch at ON position. If the
needle does not return to zero, remove the front
lens and carefully move the needle to zero by
hand. (Refer to INSTRUMENT CLUSTER
DISASSEMBLY/ASSEMBLY.)

T27

*
B C
mm {in}

WARNING AND INDICATOR SYSTEM


WATER TEMPERATURE SENDER UNIT
INSPECTION
1. Remove the water temperature sender unit.
2. Place the sender unit in a container of water.
3. Heat the water gradually.
4. Using an ohmmeter, measure and verify that the
resistance between terminal of the sender unit and
the sender unit body is as shown below.

G6, F2 CIS, F2 CARB


67.5 {2.66}

FULL

160.1 {6.303}

1/2
A B

255.7 {10.067}

EMPTY

Water temperature (C {F })

Resistance ()

49.850.2 {121.7122.3}

189.4259.6

mm {in}

3. If not as specified, replace the fuel gauge sender


unit. (Refer to section F1, FUEL SYSTEM, FUEL
PUMP UNIT DISASSEMBLY/ASSEMBLY.) (Refer
to section F2, FUEL SYSTEM, FUEL TANK
REMOVAL/INSTALLATION.) (Refer to section F3,
FUEL SYSTEM, FUEL PUMP UNIT
DISASSEMBLY/ASSEMBLY.) (Refer to section F4,
FUEL SYSTEM, FUEL PUMP UNIT
REMOVAL/INSTALLATION.)
WATER TEMPERATURE SENDER UNIT REMOVAL
1. Disconnect the negative battery cable.
2. Disconnect the connector.
3. Remove the water temperature sender unit.
CONNECTOR

WATER
TEMPERATURE
SENDER UNIT

WATER TEMPERATURE SENDER UNIT


INSTALLATION
1. Apply sealant from the third thread to the top
thread.

5. If not as specified, replace the water temperature


sender unit.
OIL PRESSURE SWITCH INSPECTION
1. Verify that the oil pressure warning light illuminates
when the ignition switch is turned to ON position.
2. Verify that the oil pressure warning light goes off
when the engine is started.
3. If the oil pressure warning light does not illuminate
or remains illuminated, inspect the oil pressure
warning light bulb and related wiring harness.
4. If the oil pressure warning light bulb and related
wiring harness are normal, inspect the oil pressure.
(Refer to section D, LUBRICATION SYSTEM, OIL
PRESSURE INSPECTION.)
5. If the oil pressure is normal, replace the oil
pressure switch.
HORN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Disconnect the horn connector.
3. Remove the bolt.
4. Remove the horn.

BOLT
THIRD THREAD

68
{0.240.31}

mm { in }

HORN

2. Install the water temperature sender unit.


Tightening torque
11.817.6 Nm
{120180 kgfcm, 105156 inlbf}
3. Connect the water temperature sender unit
connector.
4. Connect the negative battery cable.

HORN
CONNECTOR

5. Install in the reverse order of removal.


HORN RELAY REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the driver-side front side trim. (Refer to
section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)

T28

WARNING AND INDICATOR SYSTEM, AUDIO


1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

AUDIO
AUDIO UNIT REMOVAL
1. Disconnect the negative battery cable.
2. With the beveled parts of the SST (Removing tool)
facing inward, insert them into the unit.
3. Pull the SST (Removing tool) outward and
rearward to slide out the unit.
49 D066 801A

Nut

Horn relay connector

Horn relay

HORN RELAY INSPECTION


1. Remove the horn relay. (Refer to HORN RELAY
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the horn relay
terminals using an ohmmeter.
: Continuity B+: Battery positive voltage

4. Disconnect the connectors and antenna jack.


AUDIO UNIT INSTALLATION
Caution
D If the harness or the antenna feeder is
caught between the unit and dashboard, it
may become the cause of trouble or
malfunctions. Make certain that the wiring
harness and antenna feeder are not caught
between the unit and dashboard.

Terminal

Step

B+

GND

1
2

1. Connect the connectors and antenna jack.


2. Insert the unit until each clip clicks.
3. Connect the negative battery cable.

A
C

FRONT SPEAKER REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the front door trim. (Refer to section S,
TRIM, FRONT DOOR TRIM
REMOVAL/INSTALLATION.)
Caution
D When removing or installing a speaker,
touching the radio cone paper could cause
poor sound quality. When removing or
installing a speaker, hold the speakers
bracket and handle with care.

3. If not as specified, replace the horn relay.


CLOCK REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the meter hood. (Refer to section S,
DASHBOARD AND CONSOLE, METER HOOD
REMOVAL/INSTALLATION.)
3. Remove the screws and remove the clock.
SCREW

CLOCK

3. Remove in the order indicated in the table.


4. Install in the reverse order of removal.

SCREW

4. Install in the reverse order of removal.

P29

AUDIO

Screw

Screw

Speaker
+ Installation Note

Connector

Rear speaker

Connector

Double cab
1. Disconnect the negative battery cable.
2. Remove the rear door trim.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Speaker Installation Note


D When installing the speakers, position the
speakers so that the terminals face downward.
FRONT SPEAKER INSPECTION
1. Remove the speaker. (Refer to SPEAKER
REMOVAL/INSTALLATION.)
2. Inspect for resistance between the speaker
terminals using an ohmmeter.
: Resistance
Test condition

Terminal
A

B
R

Constant

R: 4

123456567

Armrest

Connector

Rear speaker

REAR SPEAKER INSPECTION


1. Remove the rear speaker.
2. Inspect for resistance between the rear speaker
terminal using an ohmmeter.
D If not as specified, replace the rear speaker.

3. Touch the leads of an ohmmeter to the speaker


terminals and verify that the speaker clicks.
Range
1
4. If not as specified, replace the speaker.
REAR SPEAKER REMOVAL/INSTALLATION
Stretch cab 4 door
1. Disconnect the negative battery cable.
2. Remove the rear access panel trim.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

T30

AUDIO
5. Inspect for continuity between the roof antenna
terminals using an ohmmeter.
: Continuity

ROOF ANTENNA REMOVAL


1. Disconnect the negative battery cable.
2. Remove the driver-side front side trim. (Refer to
section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Disconnect the connection between the roof
antenna and the antenna feeder.

Terminal

Step

2
C
D
D

B
B

A
A

123456567

4. Remove the screws and pull out the roof antenna.


6. If not as specified, replace the roof antenna.

SCREW

ROOF ANTENNA

ANTENNA FEEDER REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the driver-side front side trim. (Refer to
section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Disconnect the connection between the antenna
feeder and the roof antenna.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

ROOF ANTENNA INSTALLATION


1. Tape the antenna jack to the antenna drain hose.

2. Pass the roof antenna and antenna drain hose


through the A-pillar from the hole in the roof.
3. Connect the antenna feeder.
4. Install the screws.
5. Install the driver-side front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
6. Connect the negative battery cable.
ROOF ANTENNA INSPECTION
1. Disconnect the negative battery cable.
2. Remove the driver-side front side trim. (Refer to
section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Disconnect the connection between the roof
antenna and the antenna feeder.
4. Verify that there is no continuity between roof
antenna terminals A and B using an ohmmeter.

T31

Clip

Antenna feeder

AUDIO
ANTENNA FEEDER INSPECTION
1. Disconnect the negative battery cable.
2. Remove the driver-side front side trim. (Refer to
section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Disconnect the connection between the antenna
feeder and the roof antenna.
4. Verify that there is no continuity between the
antenna feeder terminals A and B using an
ohmmeter.
5. Inspect for continuity between the antenna feeder
terminals using an ohmmeter.
: Continuity
Terminal

Step

1
2

B
D
A

123456567

6. If not as specified, replace the antenna feeder.


CONDENSER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

IGNITION
COIL

Screw

Clip

Nut

Condenser

T32

THEFT-DETERRENT SYSTEM

THEFT-DETERRENT SYSTEM
STRUCTURAL VIEW

Theft-deterrent control module

10

Flasher unit

2
3

Theft-deterrent relay

11

Security light

Key reminder switch

12

Drivers door key cylinder switch

Ignition switch

13

Passengers door key cylinder switch

Door switch

14

Door lock timer unit

Bonnet switch

15

Front turn light

Door lock-link switch

16

Front side turn light

Theft-deterrent horn

17

Rear combination light

Theft-deterrent horn relay

BONNET SWITCH REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove the theft-deterrent horn relay. (Refer to
THEFT-DETERRENT HORN RELAY
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

BONNET SWITCH INSPECTION


1. Disconnect the bonnet switch connector.
2. Inspect for continuity between the bonnet switch
terminals using an ohmmeter.
: Continuity
Switch position

Terminal
A

Closed
Open

Bolt

Nut

Connector

Bonnet switch

3. If not as specified, replace the bonnet switch.

T33

123

THEFT-DETERRENT SYSTEM
THEFT-DETERRENT HORN RELAY
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the washer tank from the bracket.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Nut

Connector

Theft-deterrent horn relay

Bolt

Connector

Theft-deterrent relay

THEFT-DETERRENT RELAY INSPECTION


1. Remove the theft-deterrent relay.
2. Inspect for continuity between the theft-deterrent
relay terminals using an ohmmeter.
: Continuity B+: Battery positive voltage
Terminal

Step

THEFT-DETERRENT HORN RELAY INSPECTION


1. Remove the theft-deterrent horn relay.
2. Inspect for continuity between the theft-deterrent
horn relay terminals using an ohmmeter.
: Continuity B+: Battery positive voltage

B+

GND

1
2

Terminal

Step

B+

GND

1
2

E
F

C
C

F E

A
:

123456567

3. If not as specified, replace the theft-deterrent relay.


D

123456567

THEFT-DETERRENT CONTROL MODULE


REMOVAL/INSTALLATION
Note
D Because the lock section of the relay is
damaged easily, do not remove the relay from
the bracket unless replacement is necessary.
Always perform an inspection of the relay
before removal.

3. If not as specified, replace the theft-deterrent horn


relay.
THEFT-DETERRENT RELAY
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the front side trim. (Refer to section S,
TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

1. Disconnect the negative battery cable.


2. Remove the flasher unit. (Refer to EXTERIOR
LIGHTING SYSTEM, FLASHER UNIT
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

T34

THEFT-DETERRENT SYSTEM

Theft-deterrent control module connector

Nut

Bracket

Theft-deterrent control module


+ Removal Note

Theft-deterrent Control Module Removal Note


D Remove the theft-deterrent control module by
prying the lock section of side part with a flathead
screwdriver.

T35

THEFT-DETERRENT SYSTEM
THEFT-DETERRENT CONTROL MODULE INSPECTION
(VEHICLES BUILT UP TO 07/2002)
1. Remove the theft-deterrent control module without disconnecting the connectors.
2. Measure the voltage at the theft-deterrent control module terminals as indicated below.
3. Disconnect the theft-deterrent control module connectors before inspecting for continuity at terminals 1F, 2K,
2M, 2N and 2R.
4. If not as specified, inspect the parts listed under inspection area and related wiring harnesses.
5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the theft-deterrent
control module.
Terminal Voltage List (Reference)
B+: Battery positive voltage

1F 1E 1D 1C 1B 1A

Terminal

Signal

2S 2Q 2O 2M 2K 2I 2G 2E 2C 2A
2T 2R 2P 2N 2L 2J 2H 2F 2D 2B

Connection

Test condition
Ignition switch at ON position

1A
1B

IG1
Power supply

ENGINE 15 A fuse
ROOM 10 A fuse

Ignition switch at LOCK or ACC


position
Constant
Ignition
switch
at ON
position

1C

Flasher input

D Turn switch
D Hazard warning

switch
D Flasher unit

Turn (LH)

Turn light (LH)

1F

Turn (RH)

Theft-deterrent
control module
ground

Turn light (RH)

GND

0
B+

Turn switch on

Alternates 0
and B+

Turn switch off

0
Alternates 0
and B+

Hazard warning switch off

Theft-deterrent system alarm 1:


Active

Alternates 0
and B+

Theft-deterrent system alarm 1:


Other

Turn switch on

Alternates 0
and B+

Turn switch off

Inspection area
D Ignition switch
D ENGINE 15 A

fuse
ROOM 10 A fuse

D Turn switch
D Hazard warning

switch
D Flasher unit

Hazard warning switch off

Alternates 0
and B+
Turn light (LH)
0

Theft-deterrent system alarm 1:


Active

Alternates 0
and B+

Theft-deterrent system alarm 1:


Other

Hazard warning switch on

Ignition
switch
at ON
position
1E

B+

Hazard warning switch on

Ignition
switch
at ON
position
1D

Voltage ( V )
/Continuity

Turn switch on

Alternates 0
and B+

Turn switch off

Hazard warning switch off

Alternates 0
and B+
Turn light (RH)
0

Theft-deterrent system alarm 1:


Active

Alternates 0
and B+

Theft-deterrent system alarm 1:


Other

Hazard warning switch on

Constant: inspect for continuity to


ground

T36

Yes

THEFT-DETERRENT SYSTEM
B+: Battery positive voltage
Terminal

Signal

Connection

2A

Not used

2B

Not used

2C

Theft-deterrent
horn on/off

Theft-deterrent horn
relay

2D

Key reminder
switch on/off

Key reminder switch

Test condition

Voltage ( V )
/Continuity

Inspection area

Theft-deterrent system alarm 1:


Active
Theft-deterrent system alarm 1:
Other

Alternates 0
and B+
Theft-deterrent horn
relay
B+

Key reminder switch on

B+

Key reminder switch off

Key reminder switch

2E

Not used

2F

Not used

2G

Not used

2H

Not used

2I

Not used

2J

Not used

D Door lock timer

2K

Lock/unlock

unit
D Drivers door

lock-link switch
2L

2M

2N

Lock/unlock

Bonnet
open/closed

2O

2P
2Q

2R

2S

2T

Security light
on/off

Door open/closed

Theft-deterrent
relay on/off

No

Drivers door lock-link switch


unlocked: inspect for continuity to
ground

Yes

Not used

Rear door lock-link


switch

Bonnet switch

D Drivers door key

Door key cylinder


switch

Drivers door lock-link switch


locked: inspect for continuity to
ground

cylinder switch
D Passengers
door key cylinder
switch

Rear door lock-link switch locked:


inspect for continuity to ground

No

Rear door lock-link switch


unlocked: inspect for continuity to
ground

Yes

Bonnet switch on: inspect for


continuity to ground

Yes

Bonnet switch off: inspect for


continuity to ground

No

Drivers or passengers door


locked with key

2.5

Drivers or passengers door


unlocked with key

Other

Not used
Security light

Door switch

Theft-deterrent relay

Drivers door lock-link


switch

Security light off

B+

Any door open: inspect for


continuity to ground

Yes

All doors closed: inspect for


continuity to ground

No
0

Theft-deterrent system alarm 1:


Other

B+

T37

D Drivers or

passengers door
key cylinder
switch

Security light

Door switch

Theft-deterrent system alarm 1:


Active

Rear door lock-link


switch

Bonnet switch

Security light on

Not used

Theft-deterrent relay

THEFT-DETERRENT SYSTEM
THEFT-DETERRENT CONTROL MODULE INSPECTION
(VEHICLES BUILT FROM 08/2002)
1. Remove the theft-deterrent control module without disconnecting the connectors.
2. Measure the voltage at the theft-deterrent control module terminals as indicated below.
3. Disconnect the theft-deterrent control module connectors before inspecting for continuity at terminals 1F, 2K,
2M, 2N and 2R.
4. If not as specified, inspect the parts listed under Action.
D If the parts and wiring harnesses are okay but the system still does not work properly, replace the theft-deterrent
control module.
Terminal Voltage List (Reference)

Terminal

1A

1B

Signal

Connected to

ENGINE 15 A
fuse

IG1

Power supply

ROOM 10 A
fuse

Test condition
Engine switch at ON
position
Engine switch a
LOCK or ACC
position
Under any condition

Voltage (V)/
Continuity
B+

Below 1.0

B+

Action

D Inspect engine switch


D ENGINE 15 A fuse
D Inspect related harness

D ROOM 10 A fuse

1C

1D

1E

Yes

1F

Theftdeterrent
control module
ground

Under any condition:


inspect for continuity
to ground

GND

2A

2B

2C

2D

Theftdeterrent
horn on/off

Theftdeterrent
horn relay

Key reminder
switch on/off

Key reminder
switch

Theftdeterrent
system alarm 1:
Other

B+

Theftdeterrent
system alarm 1:
Active

Alternates
below 1.0
and
B+

Key reminder switch


on
Key reminder switch
off

D Inspect theftdeterrent

B+

horn relay
D Inspect related harness

D Inspect key reminder

switch
Below 0.1

D Inspect related harness

2E

2F

2G

2H

2I

T38

THEFT-DETERRENT SYSTEM

Terminal

2J

2K

2L

Signal
Keyless entry
system
discemment
signal input

Lock/unlock

Connected to

Test condition

Keyless unit

Under any condition

D Door lock

Drivers door lock


link switch unlocked:
inspect for continuity
to ground

No

timer unit
D Drivers
door lock
link switch

Drivers door lock


link switch unlocked:
inspect for continuity
to ground

D Passengers

2M

2N

Lock/unlock

Bonnet open/
closed

door lock
link switch
D Rear door
locklink
switch

Bonnet switch

D Drivers

2O

Door key cylinder


switch
D
D
D

2P

2Q

Security light on/


off

2R

Door open/closed

Voltage (V)/
Continuity

door key
cylinder
switch
Passengers
door key
cylinder
switch
keyless unit
Instrument
cluster
Door lock
timer unit

Security light

Door switch

Rear
door
closed

locklink switch
D Inspect related harness

Yes

Passengers
and rear
door lock
link switch
locked:
inspect for
continuity to
ground

No

D Inspect passengers or

rear door locklink switch

Passengers
and rear
door lock
link switch
unlocked:
inspect for
continuity to
ground

Yes

Bonnet switch on:


inspect for continuity to
ground

Yes

Bonnet switch off:


inspect for continuity to
ground

No

Drivers or passengers
door locked with key or
transmitter

2.5

Other

D Inspect keyless unit


D Inspect related harness

D Inspect drivers door

Drivers or passengers
door unlocked with key
or transmitter

Action

D Inspect related harness

D Inspect bonnet switch


D Inspect related harness

D Inspect drivers or

Below 1.0

passengers door key


cylinder switch
D Inspect keyless unit
(See KEYLESS UNIT
INSPECTION)
D Inspect related harness

Security light on

Below 0.1

Security light off

B+

Any door open: inspect


for continuity to ground

Yes

All doors closed:


inspect for continuity to
ground

No

T39

D Inspect security light


D Inspect related harness

D Inspect door switch


D Inspect related harness

THEFT-DETERRENT SYSTEM

Terminal

2S

2T

Signal

Hazard warning
signal output

Connected to

Flasher unit

Test condition

Voltage (V)/
Continuity

Theftdeterrent system
alarm 1: Active

Below 1.0

Theftdeterrent system
alarm 1: Other

B+

T40

Action
D Inspect flasher unit

(See FLASHER UNIT


INSPECTION)
D Inspect related harness

THEFTDETERRENT SYSTEM, IMMOBILIZER SYSTEM


THEFT-DETERRENT HORN
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

IMMOBILIZER SYSTEM
IMMOBILIZER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Caution
D After replacing the immobilizer unit with a
new one, the engine cannot be started
without reprogramming the ID number of
the keys of the new immobilizer unit. Input
the ID number. (Refer to IMMOBILIZER
SYSTEM REPROGRAM PROCEDURE.)

Bolt

Connector

Theft-deterrent horn

P41

Immobilizer unit connector

Immobilizer unit

IMMOBILIZER SYSTEM
IMMOBILIZER UNIT INSPECTION
1. Measure the voltage at the immobilizer unit terminals as indicated below.
2. Disconnect the immobilizer unit connector before inspecting for continuity at terminal C.
D If not as specified, inspect the parts listed under Action.
D If the parts and wiring harnesses are okay but the system still does not work properly, replace the
immobilizer unit.
Terminal Voltage Table (Reference)

ZCF8170W103

Terminal

Signal
Communication with
PCM

B
C

Connected to

PCM

GND

GND

Power supply to coil

Coil

Key ID number input

Coil

Key reminder switch


input

Key reminder
switch

Back-up power supply

Battery

M
N

Starter relay output

Power supply

Security light output

Starter relay

Engine switch

Security light

Test condition

Voltage
(V)/continuity

Engine switch at
ON position

B+

Engine switch at
LOCK position

Below 1.0

Under any
condition: inspect
for continuity to
ground

Yes

Key removed from


key cylinder

Below 1.0

Key inserted into


key cylinder

Cannot be
measured

Key removed from


key cylinder

Below 1.0

Key inserted into


key cylinder

Cannot be
measured

Key removed from


key cylinder

Below 1.0

Key inserted into


key cylinder

B+

Under any condition

B+

Engine switch at
ON position

Below 1.0

Engine switch at
LOCK position

Engine switch at
ON position

B+

Engine switch at
OFF position

Below 1.0

Security light
neither illuminates
nor blinks

T42

B+

Action
D Inspect PCM
D Inspect related harness

D Inspect GND

D Inspect coil
D Inspect related harness

D Inspect coil
D Inspect related harness

D Inspect key reminder switch


D Inspect related harness
D Inspect ROOM 10 A fuse
D Inspect related harness
D Inspect starter relay
D Inspect related harness

D Inspect ENGINE 15 A fuse


D Inspect related harness
D Inspect security light
D Inspect related harness

IMMOBILIZER SYSTEM
COIL REMOVAL/INSTALLATION
Note
D Do not remove the coil unless you are
replacing it.
D When the coil only is replaced, the immobilizer
system reprogram procedure is not necessary.

Coil Installation Note


1. Install hook 1 to the steering lock.
2. Install hook 2 to the steering lock.
HOOK 2

1. Disconnect the negative battery cable.


2. Remove the column cover.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
HOOK 1

Connector

Coil
+ Installation Note

T43

IMMOBILIZER SYSTEM
VEHICLES BUILT BEFORE SEPTEMBER 2001
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE
Note
D The DDS1 is installed to the FIP with set bolts and cannot be removed. If there is a possibility that the
DDS1 is faulty, be sure to ask your distributor to repair it.
D When an error occurs during the reprogram procedures, except when both the immobilizer unit and the
DDS1 are replaced, repeat the procedure from Step 1. If you still cannot reprogram, confirm how many
keys can start the engine.
Then, perform the key replacement or addition reprogram procedure according to the valid key number.
D To make a copy of the key or replace the immobilizer system component parts (the key(s), steering lock,
immobilizer unit and/or the DDS1), the customer should bring all keys she/he has to the dealer. This is
because the previously programmed key IDs are erased when reprogramming the key IDs into the
immobilizer unit and the DDS1.
D To replace the DDS1, there should be at least one valid key. Otherwise, both the immobilizer unit and the
DDS1 should be replaced.
D The immobilizer unit and the DDS1 cannot be changed from one car to another. If an immobilizer unit or the
DDS1 is replaced with one from another car, the engine will not start. Reprogramming of the IDs and code
word of an immobilizer unit that has already been programmed as a set is not possible.
D The immobilizer unit and the DDS1 should not be replaced with a new one as a trial during troubleshooting.
If this is done, the ID and code word will be programmed into the new unit and it cannot be used for other
cars even if you find that the old unit was normal.
D The immobilizer system cannot be deactivated.
D Confirm that all keys registered can start the engine after the reprogramming procedure. When confirming,
wait for more than 5 seconds before inserting the next key.
D When the customer does not need to register more than two keys, the following procedures can be stopped
after registering two keys.
Key Replacement or Addition
When customer has brought two or more valid keys

VALID KEYS

KEY 1

NEW KEY
KEY 3

KEY 2

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s).
2. Using key 1, turn ignition switch to ON position then back to LOCK position five times. The key should not
remain at ON position or LOCK position for more than one second.
(1) Turn key 1 back to ON position. Observe illumination of security light in instrument cluster.
(2) Turn key 1 to LOCK position and remove key 1 from steering lock. Observe security light goes out.
3. Using key 2, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
4. Repeat Step 3 with key 3.
5. If there are 48 keys (valid and/or new keys), repeat Step 3.
6. Wait for 30 seconds to quit reprogram mode.

T44

IMMOBILIZER SYSTEM
When customer has brought only one or no valid key (code word is required)

KEY 1

NEW KEYS

KEY 2
VALID KEY OR
NEW KEY
KEY 3

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s).
2. Using key 1, turn ignition switch to ON position then back to LOCK position five times. The key should not
remain at ON position or LOCK position for more than one second.
(1) Turn key 1 back to ON position. Observe flashing of security light (300 ms ON300 ms OFF) in instrument
cluster.
(2) Turn key 1 to LOCK position and wait for 5 minutes until security light decreases in flashing frequency to
1.2 seconds.
(3) Input code word. (Refer to CODE WORD INPUT PROCEDURE.)
(4) Observe security light stops flashing and illuminates (1 second), then goes out.
(5) Turn key 1 to LOCK position and remove from steering lock.
3. Using key 2, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
4. Repeat Step 3 with key 3.
5. If there are 48 keys (valid and/or new keys), repeat Step 3.
6. Wait for 30 seconds to quit reprogram mode.
Steering Lock Replacement
When customer has brought two or more valid keys for old steering lock
Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
IMMOBILIZER UNIT

KEY 3, 4, 5

KEY 1, 2
DDS1
VALID KEYS
(ORIGINAL
KEYS)

NEW KEYS

OLD

NEW

TO VEHICLE HARNESS

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Remove old steering lock.
2. Connect new steering lock to ignition switch connector.
3. Connect old steering lock to coil connector as shown in figure.
4. Insert key 1 into old steering lock.

T45

IMMOBILIZER SYSTEM
5. Insert key 3 into new steering lock and turn to ON position then back to LOCK position five times. The key
should not remain at ON position or LOCK position for more than one second.
(1) Turn key 3 back to ON position. Observe illumination of security light in instrument cluster.
(2) Turn key 3 to LOCK position. Observe that security light goes out.
Note
D Perform next two steps within 30 seconds of Step 5(2).
6. Remove key 1 from old steering lock and insert key 2 into old steering lock.
7. Using key 3 of new steering lock, turn to ON position. Observe that security light illuminates (for 12 seconds)
and goes out.
(1) Turn key 3 to LOCK position.
Note
D Perform next two steps within 30 seconds of Step 7(1).
8. Disconnect coil connector from old steering lock, and reconnect coil connector to new steering lock.
9. Using key 3 of new steering lock, turn to ON position. Observe that security light illuminates (for 12 seconds)
and goes out.
(1) Turn key 3 to LOCK position and remove from steering lock.
10. Repeat Step 9 with key 4.
11. Repeat Step 9 with key 5.
12. Wait for 30 seconds to quit reprogram mode.
13. Install new steering lock.
When customer has brought only one or no valid key (code word is required)

KEY 1
NEW KEYS
KEY 2

KEY 3

Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Replace steering lock.
2. Using key 1, turn ignition switch to ON position then back to LOCK position five times. Key should not remain
at ON position or LOCK position for more than one second.
(1) Turn key 1 back to ON position. Observe flashing of security light (300 ms ON300 ms OFF) in instrument
cluster.
(2) Turn key 1 to LOCK position and wait for 5 minutes until security light decreases in flashing frequency to
1.2 seconds.
(3) Input code word. (Refer to CODE WORD INPUT PROCEDURE.)
(4) Observe the security light stops flashing and illuminates (1 second), then goes out.
(5) Turn key 1 to LOCK position and remove from steering lock.
3. Using key 2, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
4. Repeat Step 3 with key 3.
5. Wait for 30 seconds to quit reprogram mode.

T46

IMMOBILIZER SYSTEM
Immobilizer Unit Replacement
When customer does not have valid key or when customer has brought at least one valid key
KEY 1

VALID OR
NEW KEYS

KEY 2

KEY 3

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s) if necessary.
2. Replace immobilizer unit. (Refer to IMMOBILIZER UNIT REMOVAL/INSTALLATION.)
3. Using key 1, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Wait for 16 minutes until security light begins to blink with a flashing frequency of 300 ms. (The light will
blink for 60 seconds.)
(2) Turn key 1 to LOCK position while the light is flashing and remove from steering lock.
4. Using key 2, turn to ON position while the light is flashing. Observe that security light illuminates (for 12
seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
5. Repeat Step 4 with key 3.
6. If there are 48 keys (valid and/or new keys), repeat Step 4.
7. Wait for 30 seconds to quit reprogram mode.
DDS1 Replacement
Note
D The DDS1 is installed to the FIP with set bolts and cannot be removed. If there is a possibility that the
DDS1 is faulty, be sure to ask your distributor to repair it.
When customer does not have valid key
D Immobilizer unit needs to be replaced with the DDS1. Perform Replacement of Both Immobilizer unit and
DDS1 of the immobilizer system reprogram procedure.
When customer has brought at least one valid key

VALID KEY
KEY 1

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Replace the DDS1. (Refer to section F2, FUEL SYSTEM, FUEL INJECTION PUMP (FIP)
REMOVAL/INSTALLATION.)
2. Using key 1, turn ignition switch to ON position, and observe that security light illuminates (for 12 seconds) in
instrument cluster.
(1) Turn key 1 to LOCK position.
3. Wait for 30 seconds to quit reprogram mode.

T47

IMMOBILIZER SYSTEM
Replacement of Both Immobilizer Unit and DDS1
Note
D Keys may be valid or new keys.
D When an error occurs in Steps 1 to 4, repeat the procedure from Step 1.
D When an error occurs in Step 5, perform the Reprogram error recovery procedure for replacement of both
immobilizer unit and DDS1.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s) if necessary.
2. Replace immobilizer unit (Refer to IMMOBILIZER UNIT REMOVAL/INSTALLATION.) and DDS1. (Refer to
section F2, FUEL SYSTEM, FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION.)
3. Using key 1, turn ignition switch to ON position. Observe security light illuminates and then goes out in
instrument cluster.
(1) Turn key 1 to LOCK position. Observe security light blinks once repeatedly.
4. Using key 2, turn ignition switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 2 to LOCK position. Observe security light blinks twice repeatedly.
5. Using key 3, turn ignition switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 3 to LOCK position. Observe security light blinks three times repeatedly.
6. If there are 48 keys (valid and/or new keys), repeat Step 4.
7. Wait for 30 seconds to quit reprogram mode.
Reprogram error recovery procedure for replacement of both immobilizer unit and DDS1
Note
D If no specific time interval is given, step should be performed within 30 seconds of the previous step.
1. Using key 1, turn ignition switch to ON position then back to LOCK position five times. Key should not remain
at ON position or LOCK position for more than one second.
2. Using key 1, turn ignition switch to ON position (Security light illuminates).
3. Turn key 1 to LOCK position and remove from steering lock (Security light goes out).
4. Using key 2, turn to ON position. Observe that security light illuminates (about 12 seconds) and goes out.
5. Turn key 2 to LOCK position and remove from steering lock.
6. Repeat Step 4 and 5 with key 3.
7. If there are 48 keys (valid and/or new keys), repeat Step 4 and 5.
8. Wait for 30 seconds to quit reprogram mode.

T48

IMMOBILIZER SYSTEM
VEHICLES BUILT FROM SEPTEMBER 2001
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE
Note
D When an error occurs during the reprogram procedures, except when both the immobilizer unit and PCM
are replaced, repeat the procedure from Step 1. If you still cannot reprogram, confirm how many keys can
start the engine. Then, perform the key replacement or additional reprogram procedure according to the
valid key number.
D To make a copy of the key or replace the immobilizer system component parts (the key(s), steering lock,
immobilizer unit, and/or PCM), the customer should bring all keys to the dealer. This is because the
previously programmed key IDs are erased when reprogramming the key IDs into the immobilizer unit and
PCM.
D If the customer has only one valid key when replacing the immobilizer system component parts, the dealer
should contact a distributor to obtain the code word.
D To replace the immobilizer unit or PCM, there should be at least one valid key. Otherwise, both the
immobilizer unit and PCM should be replaced.
D The immobilizer unit and PCM cannot be changed from one car to another. If an immobilizer unit or PCM is
replaced with one from another car, the engine will not start. Reprogramming of the IDs and code word of
an immobilizer unit that has already been programmed is not possible.
D The immobilizer unit and PCM should not be newly replaced as a trial during troubleshooting. If this is done,
the ID and code word will be programmed into the new unit and it cannot be used for other cars even if you
find that the old unit was normal.
D The immobilizer system cannot be deactivated.
D Confirm that all keys registered can start the engine after the reprogram procedure. When confirming, wait
for more than 5 seconds before inserting the next key.
D When the customer does not need to register more than two keys, the following procedures can be stopped
after registering two keys.
D If the key cannot be registered in spite of the fact that the immobilizer system operates normally, there may
be a malfunction with the key reminder switch or wiring harness.
Key Replacement or Addition
When the customer has two or more valid keys

Y5A8122W102

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s).
2. Insert key 1 into the steering lock and hold for 1 second or more.
3. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
4. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
5. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
6. If there are 48 keys (valid and/or new keys), repeat Step 5 with each key.
7. Wait for 30 seconds.

T49

IMMOBILIZER SYSTEM
When the customer has only one or no valid key (code word is required)

Y5A8122W103

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s).
2. Insert key 1 into the steering lock and hold for 1 second or more.
3. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
4. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
5. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
6. If there are 48 keys (valid and/or new keys), repeat Step 5 with each key.
7. Wait for 30 seconds.
8. After reprogramming, clear DTCs stored in the PCM.
Steering Lock Replacement
When the customer has two or more valid keys from the old steering lock

ZCF8122W101

Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Remove the steering lock.
2. Connect the engine switch connector and key reminder switch connector to a new steering lock.
3. Connect the coil connector to the removed steering lock as shown in the figure.
4. Insert key 1 into the removed steering lock.
5. Insert key 3 into the new steering lock and hold for 1 second or more.
6. Remove and insert key 3 five times at no more than 1second intervals.

T50

IMMOBILIZER SYSTEM
(1) After the final key insertion, verify that the
security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
Note
D Perform Steps 7, 8 and 9 within 30 seconds after Step 6(2).
7. Remove key 1 from the steering lock.
8. Insert key 2 into the removed steering lock.
9. Insert key 3 into the new steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
10. After verifying that the security light goes off, turn the key to the LOCK position.
Note
D Perform Steps 11 and 12 within 30 seconds after Step 10.
11. Disconnect the coil connector from the removed steering lock and connect to the new steering lock.
12. Turn key 3 to the ON position and verify that the security light illuminates.
13. After verifying that the security light goes off, turn key 3 to the LOCK position and remove from the steering
lock.
14. Insert key 4 into the new steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
15. Insert key 5 into the new steering lock and turn the key to the ON position.
(1) After verifying that the security light goes off, turn the key to the LOCK position.
16. Wait for 30 seconds.
17. Install the new steering lock to the vehicle.
When the customer has only one or no valid key (code word is required)

Y5A8122W105

Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Replace the steering lock.
2. Insert key 1 into the steering lock and hold for 1 second or more.
3. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
4. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12
seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
5. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.

T51

IMMOBILIZER SYSTEM
6. If there are 48 keys (valid and/or new keys), repeat Step 5 with each key.
7. Wait for 30 seconds.
8. After reprogramming, clear DTCs stored in the PCM.
Immobilizer Unit Replacement
When the customer does not have valid key
D PCM needs to be replaced with immobilizer unit. Perform Both Immobilizer unit and PCM Replacement of the
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE. (See 54 Both Immobilizer Unit and PCM
Replacement.)
When the customer has at least one valid key (code word is required)

Y5A8122W106

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s) if necessary.
2. Replace immobilizer unit.
3. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
4. After the security light goes off, turn key 1 to the LOCK position.
(1) Remove the key from the steering lock and wait for 2 seconds or more.
5. Insert key 2 into the steering lock and hold 1 second or more.
6. Remove and insert key 2 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
7. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
8. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After the security light goes off, turn the key to the LOCK position.
9. If there are 48 keys (valid and/or new keys), repeat Step 8 with each key.
10. Wait for 30 seconds.
11. After reprogramming, clear DTCs stored in the PCM.

T52

IMMOBILIZER SYSTEM
PCM Replacement
When the customer does not have valid key
D Immobilizer unit needs to be replaced with PCM. Perform Both Immobilizer Unit and PCM Replacement of the
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE. (See 54 Both Immobilizer Unit and PCM
Replacement.)
When the customer has two or more valid keys

Y5A8122W107

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s) if necessary.
2. Replace the PCM.
3. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
4. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
5. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
6. Repeat Step 5 with key 1.
7. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
8. If there are 48 keys (valid and/or new keys), repeat Step 7 with each key.
9. Wait for 30 seconds.
When the customer has only one valid key (code word is required)

Y5A8122W108

Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s) if necessary.
2. Replace the PCM.
3. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.

T53

IMMOBILIZER SYSTEM
4. After verifying that the security light goes off, turn key 1 to the LOCK position.
(1) Remove the key from the steering lock and wait for 2 seconds or more.
5. Insert key 2 into the steering lock and wait for 1 second or more.
6. Remove and insert key 2 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
7. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
8. If there are 48 keys (valid and/or new keys), repeat Step 8 with each key.
9. Wait for 30 seconds.
10. After reprogramming, clear DTCs stored in the PCM.
Both Immobilizer Unit and PCM Replacement
When the customer has two or more valid keys
Note
D Keys may be valid or new.
D When an error occurs in Steps 1 to 3, repeat the procedure from Step 1.
D When an error occurs in Step 4, perform the Reprogram error recovery procedure for both immobilizer unit
and PCM replacement.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s) if necessary.
2. Replace immobilizer unit and PCM.
3. Using key 1, turn engine switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 1 to LOCK position. Observe security light blinks once repeatedly.
4. Using key 2, turn engine switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 2 to LOCK position. Observe security light blinks twice repeatedly.
5. Using key 3, turn engine switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 3 to LOCK position. Observe security light blinks three times repeatedly.
6. If there are 48 keys (valid and/or new keys), repeat Step 4.
7. Wait for 30 seconds to quit reprogram mode.
Reprogram error recovery procedure for both immobilizer unit and PCM replacement
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
2. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
3. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
4. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
5. Wait for 30 seconds.

T54

IMMOBILIZER SYSTEM
VEHICLES BUILT BEFORE SEPTEMBER 2001
CODE WORD INPUT PROCEDURE
Note
D A code word is composed of five digits from 19 and is part of the immobilizer unit from the manufacturer.
Each unit has its own code word. To obtain the code word, you need to have the immobilizer serial number,
then ask the distributor.
D To input the code word into the DDS1, turn the ignition key and count the number of flashes of the security
light. The calculation of the number of flashes of the security light comes with the timing of the turning of the
key.
1. Wait for 5 minutes until security light flashes slowly. (300 ms ON, 300 ms OFF
2. Input the code word as in the example shown below.

ONE CYCLE OR MORE

INPUTTING THE CODE WORD 3 AND 1

SECURITY LIGHT

1.2 s ON, 1.2 s OFF)

ON
OFF
ON

IGNITION SWITCH
LOCK

WITHIN 30 SECONDS

(1) Turn ignition switch to ON position while security light is off and count three illumination cycles. As the light
goes out after the third illumination, turn key to LOCK position.
(2) Wait at least one illumination cycle and within 30 seconds of turning key to LOCK position, turn ignition
switch to ON position while security light is off and count one illumination cycle. As the light goes out after
the first illumination, turn key to LOCK position.
(3) Repeat Step (2) for rest of three digits.
3. When code word is registered correctly in the DDS1. The security light stops flashing and illuminates.
4. As soon as the security light stops flashing and illuminates, the following immobilizer system reprogram
procedure should be started.
Note
D If the code word is not input correctly, the security light goes out after all five digits are input. In this case,
perform the Code Word Input Error Recovery Procedure.

T55

IMMOBILIZER SYSTEM
VEHICLES BUILT FROM SEPTEMBER 2001
CODE WORD INPUT PROCEDURE
Note
D A code word is composed of eight digits from 19 and is part of the immobilizer unit from the manufacturer.
Each unit has its own code word. To obtain the code word, you need to have the immobilizer serial number,
then ask the distributor.
D To input the code word into the PCM, turn the engine key and count the number of flashes of the security
light. The calculation of the number of flashes of the security light comes with the timing of the turning of the
key.
1. Wait for 5 minutes until security light flashes slowly. (300 ms ON300 ms OFF
2. Input the code word as shown in the example below.

1.2 s ON1.2 s OFF)

ZCF8122W102

(1) Turn engine switch to ON position while security light is off and count three illumination cycles. As the light
goes out after the third illumination, turn key to LOCK position.
(2) Wait at least one illumination cycle and within 30 seconds of going to LOCK position, turn engine switch to
ON position while security light is off and count one illumination cycle. As the light goes out after the first
illumination, turn key to LOCK position.
(3) Repeat Step (2) for rest of six digits.
3. When code word is registered correctly in the PCM, the security light stops flashing and illuminates.
4. As soon as the security light stops flashing and illuminates, the following immobilizer system reprogram
procedure should be started.
Note
D If the code word is not input correctly, the security light goes out after all eight digits are input. In this case,
perform the Code Word Input Error Recovery Procedure.
Examples of Incorrect Input of Code Word
Note
D The security light must flash one or more times between the digits of the code word.
D If the code word is input incorrectly, the security light goes out. Remove and insert key five times and
repeat the procedure to input all eight figures for the code word.
D When an error occurs during the reprogram procedures except when both the immobilizer unit and PCM
are replaced, repeat the procedure from Step 1. If you still cannot reprogram, confirm how many keys can
start the engine. Then, perform the key replacement or addition reprogram procedure according to the valid
key number.
D The security light flashes ten or more times while the engine switch is at ON position.

ZCF8122W103

T56

IMMOBILIZER SYSTEM
D The engine switch is turned to ON position and LOCK position while the security light is off.

ZCF8122W104

D The engine switch is turned to LOCK position and ON position while the security light is on.

ZCF8122W105

D The engine switch is turned to LOCK position and ON position while the security light is off.

ZCF8122W106

D An unmatched code word is input to the immobilizer unit.


Code Word Input Error Recovery Procedure
1. Remove and insert key five times at no more than 1second intervals.
2. Repeat the CODE WORD INPUT PROCEDURE.

T57

AIR BAG SYSTEM


Air Bag Module Handling
D A live (undeployed) air bag module may
accidentally deploy when it is handled and
cause serious injury. When carrying a live
(undeployed) air bag module, point the front
surface away from your body to lessen the
chance of injury in case it deploys.

AIR BAG SYSTEM


SERVICE WARNINGS
Component Disassembly
D Disassembling and reassembling the
components of the air bag system can render
the system inoperative, which may result in
serious injury or death in the event of an
accident. Do not disassemble any air bag
system component.

RIGHT

WRONG

D A live (undeployed) air bag module placed face

down on a surface is dangerous. If the air bag


module deploys, the motion of the module can
cause serious injury. Always face the front
surface up to reduce the motion of the module
in case it accidentally deploys.

Wiring Harness Repair


D Incorrectly repairing an air bag system wiring
harness can accidentally deploy the air bag
module, which can cause serious injury. If a
problem is found in the system wiring, replace
the wiring harness. Do not try to repair it.

RIGHT

Air Bag Module Inspection


D Inspecting an air bag module using an
ohmmeter can deploy the air bag module,
which may cause serious injury. Do not use an
ohmmeter to inspect an air bag module. Always
use the on-board diagnostic function to
diagnose the air bag for malfunctions. (Refer to
ON-BOARD DIAGNOSTIC FUNCTION, AIR BAG
SYSTEM.)

WRONG

SAS Unit Handling


D Disconnecting the SAS unit connector or
removing the SAS unit with the ignition switch
at ON position can cause the air bag modules
to deploy, which may seriously injure you.
Before disconnecting the SAS unit connector
or removing the SAS unit, turn the ignition
switch to LOCK position, then disconnect the
negative battery cable and wait for more than 1
minute to allow the backup power supply of the
SAS unit to deplete its stored power.
D Connecting the SAS unit connector without
firmly installing the SAS unit to the vehicle is
dangerous. The crash sensor inside the unit
may send an electrical signal to the air bag
modules. This will deploy the air bag modules,
which may result in serious injury. Therefore,
before connecting the connector, firmly mount
the unit to the vehicle.

T58

AIR BAG SYSTEM


D For vehicles with a single point sensor, once an

air bag is deployed due to an accident or other


causes, the SAS unit must be replaced with a
new one even if the used one does not have
any external signs of damage. The used SAS
unit may have been damaged internally which
may cause improper operation, resulting in
major injuries or even death. The used single
point SAS unit cannot be bench-checked or
self-checked.
Component Handling
D Oil, grease, water, etc., on components may
cause an air bag module to fail to deploy in an
accident, which may cause serious injury. Do
not allow oil, grease, water, etc., on
components.
D Inserting a screwdriver, etc., into the connector
of an air bag module may damage the
connector and cause the air bag module to
deploy improperly, which may cause serious
injury. Do not insert any foreign objects into
the connector.

7.911.7 Nm
{80120 kgfcm, 70104 inlbf}

Bolt
+ Installation Note

Connector
+ Installation Note

Driver-side air bag module

Connector Installation Note


D Install the connector as shown in the figure.

Component Reusing
D Even if an air bag module does not deploy in a
collision and does not have any external signs
of damage, it may have been damaged
internally, which may cause improper
operation. Improper operation may cause
serious injury. Always self-check the
undamaged air bag module to determine
whether it can be reused. (Refer to ON-BOARD
DIAGNOSTIC FUNCTION, AIR BAG SYSTEM.)
Bolt Installation Note
D Tighten the bolts in the order shown in the figure.

DRIVER-SIDE AIR BAG MODULE


REMOVAL/INSTALLATION
Warning
D Handling the air bag module improperly can
accidentally deploy the air bag module,
which may seriously injure you. Read
SERVICE WARNINGS before handling the
air bag module. (Refer to SERVICE
WARNINGS.)
1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable and wait for
more than 1 minute.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Turn the ignition switch to ON position.
6. Verify that the air bag system warning light
illuminates for approximately 6 seconds then
goes off.
7. If the air bag system warning light remains on, off,
or repeats flashing after servicing, there are
malfunctions in the system. Perform the inspection
again. (Refer to ON-BOARD DIAGNOSTIC
FUNCTION, AIR BAG SYSTEM.)

PASSENGER-SIDE AIR BAG MODULE


REMOVAL/INSTALLATION

T59

Warning
D Handling the air bag module improperly can
accidentally deploy the air bag module,
which may seriously injure you. Read
SERVICE WARNINGS before handling the
air bag module. (Refer to SERVICE
WARNINGS.)
1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable and wait for
more than 1 minute.
3. Remove the glove compartment.
4. Remove in the order indicated in the table.

AIR BAG SYSTEM


5. Install in the reverse order of removal.
6. Turn the ignition switch to ON position.
7. Verify that the air bag system warning light
illuminates for approximately 6 seconds then
goes off.
8. If the air bag system warning light remains on, off,
or repeats flashing after servicing, there are
malfunctions in the system. Perform the inspection
again. (Refer to ON-BOARD DIAGNOSTIC
FUNCTION, AIR BAG SYSTEM.)

Note
D When a new SAS unit has been installed, the
air bag system warning light flashes
continuously if there arent any malfunctions in
the system. Perform the air bag module
deployment authorization procedure. (Refer to
AIR BAG MODULE DEPLOYMENT
AUTHORIZATION PROCEDURE.)
8. If the air bag system warning light remains on, off,
or repeats flashing after servicing, there are
malfunctions in the system. Perform the inspection
again. (Refer to ON-BOARD DIAGNOSTIC
FUNCTION, AIR BAG SYSTEM.)
6.879.80 Nm
{70100 kgfcm, 60.886.7 inlbf}

A
B
A

6.879.80 Nm
{70100 kgfcm, 60.886.7 inlbf}

Connector

Bolt

Passenger-side air bag module

SAS UNIT REMOVAL/INSTALLATION


Warning
D Handling the SAS unit improperly can
accidentally deploy the air bag module,
which may seriously injure you. Read
SERVICE WARNINGS before handling the
SAS unit. (Refer to SERVICE WARNINGS.)

Connector

Nut
+ Installation Note

SAS unit

Nut Installation Note


D Tighten the nuts in the order shown in the figure.

1. Turn the ignition switch to LOCK position.


2. Disconnect the negative battery cable and wait for
more than 1 minute.
3. Remove the front console. (Refer to section S,
DASHBOARD AND CONSOLE, FRONT
CONSOLE REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Turn the ignition switch to ON position.
7. Verify that the air bag system warning light
illuminates for approximately 6 seconds then
goes off.

T60

AIR BAG SYSTEM


CLOCK SPRING REMOVAL/INSTALLATION
1. Remove the driver-side air bag module.
(Refer to DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
2. Remove the steering wheel. (Refer to section N,
MANUAL STEERING, STEERING WHEEL AND
COLUMN REMOVAL/INSTALLATION.)
3. Remove the column cover.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

3. Turn the clock spring counterclockwise 2.75 turns.

0.81.1 Nm
{812 kgfcm, 710 inlbf}

Connector

Screw
+ Installation Note

Clock spring

4. Align the mark on the clock spring with that on the


outer housing.

Screw Installation Note


D Fasten the screws in the order in the figure.

CLOCK SPRING ADJUSTMENT


1. Set the front wheels straight ahead.
Caution
D The clock spring will break if over-wound.
Do not forcibly turn the clock spring when
turning it.

ALIGNMENT MARKS

CLOCK SPRING INSPECTION


1. Remove the driver-side air bag module. (Refer to
DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
2. Disconnect the clock spring connector.
3. Inspect for continuity between the clock spring
terminals using an ohmmeter.
: Continuity
Test condition

2. Turn the clock spring clockwise until it stops.

Terminal
1A

1B

2D

3A

3B

4D

Constant

123456567

T61

AIR BAG SYSTEM


Note
D If the SSTs (Deployment Tool and Adapter
Harness) are not available, consult the nearest
Ford representative for assistance.

HORN CIRCUIT
2D
VEHICLESIDE

4D
AIR BAG CIRCUIT (GND)

1B
1A

AIR BAG CIRCUIT


(POWER SUPPLY)

3B

1A

Deployment Procedures for Inside of Vehicle


1. Inspect the SST (Deployment Tool). (Refer to
INSPECTION OF SST (DEPLOYMENT TOOL).)
2. Move the vehicle to an open space, away from
strong winds, and close all doors and windows.
3. Turn the ignition switch to LOCK position.
4. Disconnect the negative battery cable and wait for
more than 1 minute.
5. Follow the appropriate procedure for deploying the
driver-side air bag module or passenger-side air
bag module.

2D 2C 2B 2A

AIR BAG MODULE-SIDE


3B

3A

bag modules inside the vehicle. (Refer to


Deployment Procedure for Inside of Vehicle.)
D When the vehicle is not to be scrapped, deploy the
air bag modules outside the vehicle. (Refer to
Deployment Procedure for Outside of Vehicle.)

3A

VEHICLE-SIDE
1B

D When the vehicle is to be scrapped, deploy the air

AIR BAG
MODULESIDE

4D 4C 4B 4A

Note
D When the vehicle-side connector of clock
spring is disconnected, terminals 1A and 1B
are shorted to prevent unexpected deployment
of the air bag module.

Driver-side air bag module


D Remove the column cover, disconnect the clock
spring connector, then connect the SST (Adapter
Harness) to the clock spring as shown in the figure.

4. If not as specified, replace the clock spring.


AIR BAG MODULE DEPLOYMENT
AUTHORIZATION PROCEDURE
1. Install a new SAS unit. Turn the ignition switch to
ON position and verify that the air bag system
warning light illuminates for approximately 6
seconds, goes out, and then flashes continuously.
2. If a diagnostic trouble code is indicated (the air bag
system warning light doesnt flash continuously),
perform the appropriate ON-BOARD DIAGNOSTIC
FUNCTION. (Refer to ON-BOARD DIAGNOSTIC
FUNCTION, AIR BAG SYSTEM.) When the
malfunctions have been repaired and the air bag
system warning light flashes continuously, go to
Step 3.
3. If the air bag system warning light flashes
continuously, turn the ignition switch to LOCK
position then back to ON position after more than
approximately 1 second.
4. Verify that the air bag system warning light
illuminates for approximately 6 seconds and then
goes off.
5. If the light stays on, perform the deployment
authorization procedure again.

CLOCK SPRING
CONNECTOR

49 D066 002

Passenger-side air bag module


D Remove the glove compartment, disconnect the
passenger-side air bag module connector, then
connect the SST (Adapter Harness) to the
passenger-side air bag module as shown in the
figure.
PASSENGER-SIDE
AIR BAG MODULE
CONNECTOR

49 D066 002

AIR BAG MODULE DEPLOYMENT PROCEDURE


6. Connect the SST (Deployment Tool) to the SST
(Adapter Harness).

Caution
D Deploying the air bag modules inside the
vehicle may cause damage to the vehicle
interior. When the vehicle is not to be
scrapped, always deploy the air bag
modules outside the vehicle.

T62

AIR BAG SYSTEM


Warning
D If the air bag module is not properly
installed to the wheel, serious injury may
occur when the module is deployed. When
installing the air bag module to the wheel,
make sure the module is facing up.

49 D066 002

3. Place the driver-side air bag module on the center


of the wheel with the module facing up. To secure
the module to the wheel, wrap the wire harness
through the wheel and around the bolt at least
four times.

49 H066 002

7. Connect the red clip of the SST (Deployment Tool)


to the positive battery terminal and the black clip to
the negative battery terminal.
8. Verify that the red light on the SST (Deployment
Tool) is illuminated.

DRIVER-SIDE
AIR BAG MODULE

WIRE
HARNESS

49 H066 002
ACTIVATION
SWITCH
GREEN LIGHT
RED LIGHT

4. Connector the SST (Adapter Harness) to the


driver-side air bag module as shown.

49 D066 002

9. Make sure all persons are standing at least 6 m


{20 ft} from the vehicle.
10. Press the activation switch on the SST
(Deployment Tool) to deploy the air bag module.
Deployment Procedures for Outside of Vehicle
1. Inspect the SST (Deployment Tool). (Refer to
INSPECTION OF SST (DEPLOYMENT TOOL).)
2. Turn the ignition switch to LOCK position.
3. Disconnect the negative battery cable and wait for
more than 1 minute.
4. Follow the appropriate procedure for deploying the
driver-side air bag module or passenger-side air
bag module.

5. Stack three tires on top of the tire with the air bag
module. Stack another tire that has a wheel on top
of the four tires.
TIRE WITH
WHEEL

Driver-side air bag module


1. Remove the driver-side air bag module.
(Refer to DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
2. Install the bolts to the driver-side air bag module.
TIRE

BOLT

DRIVER-SIDE
AIR BAG MODULE

TIRE WITH
DRIVER-SIDE
AIR BAG
MODULE

6. Tie all tires together with wire.

T63

AIR BAG SYSTEM

PASSENGER-SIDE
AIR BAG MODULE

BOLT

7. Connect the SST (Deployment Tool) to the SST


(Adapter Harness).

Warning
D If the air bag module is not properly
installed to the tire, serious injury may
occur when the module is deployed.
When installing the air bag module to the
tire, make sure the module is facing the
center of the tire.

49 H066 002

3. Tie the passenger-side air bag module to the tire


with the module facing the center of the tire. Wrap
the wire harness through the tire and around the
bolts at least four times.

49 D066 002

8. Connect the red clip of the SST (Deployment Tool)


to the positive battery terminal and the black clip to
the negative battey terminal.
9. Verify that the red light on the SST (Deployment
Tool) is illuminated.
TIRE

49 H066 002
ACTIVATION
SWITCH

WIRE HARNESS

GREEN LIGHT
RED LIGHT

10. Make sure all persons are standing at least 6 m


{20 ft} from the tire.
11. Press the activation switch on the SST
(Deployment Tool) to deploy the driver-side air bag
module.
Passenger-side air bag module
1. Remove the passenger-side air bag module.
(Refer to PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
2. Install the bolts to the passenger-side air bag
module.

PASSENGER-SIDE
AIR BAG MODULE

4. Connector the SST (Adapter Harness) to the


passenger-side air bag module as shown.
49 D066 002

T64

AIR BAG SYSTEM


5. Stack the tire with the passenger-side air bag
module on top of two tires. Stack a tire on top of
the three tires. Stack another tire that has a wheel
on top of the four tires.

49 H066 002
ACTIVATION
SWITCH

TIRE WITH
WHEEL

GREEN LIGHT
RED LIGHT

10. Make sure all persons are standing at least 6 m


{20 ft} from the tire.
11. Press the activation switch on the SST
(Deployment Tool) to deploy the passenger-side air
bag module.
TIRE

AIR BAG MODULE DISPOSAL PROCEDURE


Warning
D Before scrapping a vehicle with an
undeployed air bag module, deploy the air
bag module. The undeployed air bag
module may deploy by accident causing
injury. Never dispose of an undeployed air
bag module.

TIRE WITH
PASSENGER-SIDE
AIR BAG MODULE

6. Tie all tires together with wire.

Warning
D The air bag module is very hot immediately
after it deploys. You can get burned. Do not
touch the air bag module for at least 15
minutes after deployment.
Warning
D Pouring water on a deployed air bag
module is dangerous. The water will mix
with residual gases to form a gas that can
make breathing difficult. Do not pour water
on the deployed air bag module.
Warning
D A deployed air bag module may contain
deposits of sodium hydroxide, a caustic
byproduct of the gas-generated
combustion. If this substance gets into
your eyes or on your hands, it can cause
irritation and itching. When handling the
deployed air bag module, wear gloves and
safety glasses.

7. Connect the SST (Deployment Tool) to the SST


(Adapter Harness).
49 H066 002

1. Put on gloves and safety glasses.


2. Place the deployed air bag module in a plastic bag,
seal it, and then dispose of it.
3. Wash your hands after removing your gloves.

49 D066 002

8. Connect the red clip of the SST (Deployment Tool)


to the positive battery terminal and the black clip to
the negative battery terminal.
9. Verify that the red light on the SST (Deployment
Tool) is illuminated.

T65

AIR BAG SYSTEM


INSPECTION OF SST (DEPLOYMENT TOOL)
D Use the SST (Deployment Tool) to deploy a live air
bag module before disposing of it.
D Before connecting the SST (Deployment Tool) to
the clock spring, driver-side air bag module or
passenger-side air bag module, inspect the
operation of the SST (Deployment Tool).
49 H066 002

CLIP
CONNECTOR A

GREEN LIGHT
CONNECTOR B
ACTIVATION SWITCH
RED LIGHT

Inspection Procedure
1. Follow the steps below to verify that the SST
(Deployment Tool) is operating correctly.
Step

Light condition

Inspection procedure

Green

Red

Connect red clip to positive


battery terminal and black
clip to negative battery
terminal.

On

Off

Connect connectors A and B


of SST (Deployment Tool).

Off

On

Press activation switch.

On

Off

RED
BLACK

49 H066 002

ACTIVATION
SWITCH

CONNECTOR A

49 H066 002

CONNECTOR B

2. If not as specified, do not use the SST


(Deployment Tool) because it may cause the air
bag module to unexpectedly deploy upon
connection to the air bag module.

T66

ON-BOARD DIAGNOSTIC (IMMOBILIZER SYSTEM)

ONBOARD DIAGNOSTIC [IMMOBILIZER SYSTEM]


FOREWORD
Caution
D When the engine does not start or stalls and the following DTCs are not indicated, go to engine
symptom troubleshooting.
Note
D If engine condition is normal but light stays on, inspect for short circuit between security light and
immobilizer unit connector terminal M. Repair or replace the wiring harness if necessary.
1. Turn the engine switch to START position for 2 seconds, then back to ON position.
2. Wait for 2 minutes.
3. Verify the security light condition and read the DTC if indicated.
4. Verify the DTC with WDS or equivalent.
5. If the DTC is indicated, go to troubleshooting referring to the DTC table.
DTC TABLE
DTC

Output pattern

Description

01
WALTPX0001

02

Page

ID number unregistered in immobilizer unit is


input after engine switch is turned to ON
position or engine cranking.

(See 68 DTC 01)

ID number format error (voltage range,


frequency)

(See 68 DTC 02)

ID number is not input into immobilizer unit


after engine switch is turned to ON position or
cranking engine.

(See 68 DTC 03)

Coil or wiring harness between immobilizer


unit and coil is open circuit.

(See 69 DTC 11)

Code word/ID number stored in immobilizer


unit EEPROM cannot be read.

(See 70 DTC 21)

Open or short circuit in wiring harness


between immobilizer unit and PCM.

(See 70 DTC 24)

Immobilizer unitPCM communication error

(See 71 DTC 30)

WALTPX0002

03
WALTPX0003

11
WALTPX0011

21
WALTPX0021

24
WALTPX0024

30
WALTPX0030

Note
D Perform the following if the security light stays on:
If engine stalls, go to symptom troubleshooting NO.7 ENGINE RUNS ROUGH/ROLLING IDLE. (See
NO.7 ENGINE RUNS ROUGH/ROLLING IDLE.)
If engine will not start, go to symptom troubleshooting NO.5 CRANKS NORMALLY BUT WILL NOT
START. (SeeNO.5 CRANKS NORMALLY BUT WILL NOT START)
If engine condition is normal but light stays on, inspect for continuity between the following wiring
harness and body ground: security light and immobilizer unit connector terminal M. Repair or replace
the wiring harness.

T67

ON-BOARD DIAGNOSTIC (IMMOBILIZER SYSTEM)


DTC 01
DTC 01
POSSIBLE
CAUSE

ID number unregistered in immobilizer unit is input after engine switch is turned to ON position or
engine cranking.
D ID number is unregistered in immobilizer unit.

Diagnostic procedure
STEP

INSPECTION

ACTION

Go to ID number input procedure.


(See NO TAG Key Replacement or Addition )

DTC 02
DTC 02
POSSIBLE
CAUSE

ID number format error (voltage range, frequency)


D Defective transponder in the key

Diagnostic procedure
STEP

INSPECTION

ACTION

Dispose of defective key.


Duplicate key if necessary.
(See NO TAG Key Replacement or Addition )

DTC 03
DTC 03
POSSIBLE
CAUSE

ID number is not input into immobilizer unit after engine switch is turned to ON position or
cranking engine.
D
D
D
D

No transponder in the key


Defective transponder in the key (ID number is not output.)
Defective coil at steering lock
Defective wiring harness between coil and immobilizer unit

ZCF8170W102

Diagnostic procedure
STEP

INSPECTION

ACTION

D Does security light indicate DTC 11?

Yes

Go to DTC 11.

No

Go to next step.

D Does security light indicate DTC 30?

Yes

Go to DTC 30.

No

Go to next step.

Yes

Dispose of defective key.


Duplicate key if necessary.
(See NO TAG Key Replacement or Addition .)

No

Go to next step.

Yes

Repair the wiring harness connected to terminals A and/or


C.

No

Troubleshooting is completed.

INSPECT FOR OTHER PROPER KEYS


D Does engine start with other proper keys?

INSPECT COIL CIRCUIT FOR SHORT TO


GND OR COIL CIRCUIT FOR CONTINUITY
D Disconnect the coil connector.
D Inspect for short circuits between coil
connector terminals A and C and ground,
and also between coil connector terminals
A and C.
D Is there a short?

T68

ON-BOARD DIAGNOSTIC (IMMOBILIZER SYSTEM)


DTC 11
DTC 11
POSSIBLE
CAUSE

Coil or wiring harness between immobilizer unit and coil is open circuit.
D
D
D
D

Open circuit in coil


Poor connection of coil connector
Poor connection of immobilizer unit
Defective wiring harness between immobilizer unit and coil

ZCF8170W101

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT CONNECTOR CONNECTION


D Is connector of coil or immobilizer unit
connected securely?

Yes

Go to next step.

No

Connect connector securely.

INSPECT COIL CIRCUIT FOR CONTINUITY


D Is there continuity between coil terminals A
and C?

Yes

Go to next step.

No

Replace coil.

INSPECT COIL CIRCUIT FOR OPEN


CIRCUIT
D Disconnect coil connector and immobilizer
unit connector.
D Inspect for open circuit in wiring harness:
Immobilizer unit D to coil C, and
immobilizer unit F to coil A
Immobilizer unit D to coil A, and
immobilizer unit F to coil C
D Is there an open?

Yes

Replace immobilizer unit and reprogram immobilizer


system.
(See NO TAG Immobilizer Unit Replacement)

No

Repair wiring harness between coil and immobilizer unit.

Note
D Vehicle harness which is connected to
immobilizer unit terminals D and F, uses
a twisted pair wire. Because twisted pair
wire does not have polarity, immobilizer
unit connector terminal D may be
connected to coil connector terminal A
or C. Likewise, immobilizer unit
connector terminal F may be connected
to coil connector terminal A or C.

T69

ON-BOARD DIAGNOSTIC (IMMOBILIZER SYSTEM)


DTC 21
DTC 21
POSSIBLE
CAUSE

Code word/ID number stored in immobilizer unit EEPROM cannot be read.


D Defective immobilizer unit

Diagnostic procedure
STEP

INSPECTION
INSPECT IMMOBILIZER UNIT
D Turn engine switch from LOCK position to
START position for 2 seconds.
D Does security light indicate DTC 21 again?

ACTION
Yes

Replace immobilizer unit and reprogram immobilizer


system.
(See NO TAG Immobilizer Unit Replacement )

No

Immobilizer system is okay.

DTC 24
DTC 24
POSSIBLE
CAUSE

Open or short circuit in wiring harness between immobilizer unit and PCM
D
D
D
D

Defective immobilizer unit


Defective PCM
Poor connection of connector
Defective wiring harness

ZCF8170W103

Diagnostic procedure
STEP
1

INSPECTION

ACTION

INSPECT CONNECTOR CONNECTION


D Are both immobilizer unit and PCM
connectors connected properly?

Yes

Go to next step.

No

Connect connectors properly.

INSPECT COMMUNICATION CIRCUIT FOR


CONTINUITY
D Disconnect immobilizer unit and PCM
connectors.
D Is there continuity between immobilizer unit
connector terminal A and following PCM
connector terminal?
Terminal 3S

Yes

Go to next step.

No

Repair wiring harness between PCM and immobilizer unit.

INSPECT IMMOBILIZER UNIT FOR SHORT


TO GND
D Is there continuity between immobilizer unit
connector terminal A and ground?

Yes

Repair short circuit in wiring harness between PCM and


immobilizer unit.

No

Go to next step.

T70

ON-BOARD DIAGNOSTIC (IMMOBILIZER SYSTEM)

STEP
4

INSPECTION
INSPECT COMMUNICATION CIRCUIT
D Connect PCM connector.
D Turn engine switch to ON position.
D Measure voltage at immobilizer unit
connector terminal A.
D Is voltage more than 10 V?

ACTION
Yes

Replace immobilizer unit and reprogram immobilizer


system.
(See NO TAG Immobilizer Unit Replacement)
Note
D Confirm that voltage at immobilizer unit connector
terminal L is more than 10 V when turning engine
switch to ON position after repairing malfunction of
DTC 24. If not as specified, repair wiring harness
between ENGINE 15 A fuse and immobilizer unit.

No

Replace PCM and reprogram immobilizer system.


(See NO TAG PCM Replacement)
Note
D Confirm that voltage at immobilizer unit connector
terminal L is more than 10 V when turning engine
switch to ON position after repairing malfunction of
DTC 24. If not as specified, repair wiring harness
between ENGINE 15 A fuse and immobilizer unit.

DTC 30
DTC 30
POSSIBLE
CAUSE

Immobilizer unitPCM communication error


D Defective immobilizer unit
D Defective PCM

Diagnostic procedure
STEP

INSPECTION
INSPECT INNER CIRCUIT OF IMMOBILIZER
UNIT
D Replace immobilizer unit and reprogram
immobilizer system.
(See NO TAG Immobilizer Unit
Replacement )
D Does engine start?

ACTION
Yes

Immobilizer unit was defective.

No

Replace PCM and reprogram immobilizer system.


(See NO TAG PCM Replacement )

T71

ON-BOARD DIAGNOSTIC (AIR BAG SYSTEM)

ONBOARD DIAGNOSTIC [AIR BAG SYSTEM]


AIR BAG SYSTEM
Diagnostic Trouble Code
D The SAS unit has an on-board diagnostic function that flashes or illuminates the air bag system warning light to
indicate trouble in the air bag system. The trouble can be determined by the warning light illumination or
flashing pattern.
Flowchart
START

Turn ignition switch to ON position.


Does air bag system warning light illuminate?

No

Troubleshoot warning light circuit.


+ TROUBLESHOOTING, AIR BAG SYSTEM

Yes
Does air bag system warning light illuminate for
approximately 6 seconds and then go off?

No

Yes
No
Does air bag system warning light remain off?
Yes
END

Refer to diagnostic trouble code table and


inspect system starting from small service
code.
+ Diagnostic trouble code table
+ Inspection of Diagnostic Trouble Codes

Note
D When a malfunction has occurred in the air bag system and the air bag system warning light doesnt turn on
after the ignition switch is turned to ON position, the warning buzzer built into the SAS unit sounds 5 times
for 5 cycles.
Diagnostic trouble code table
DTC

Output pattern

Diagnosed circuit

ON

SAS unit connector poor connection


OFF
ON

SAS unit
OFF
ON

Power supply of SAS unit


OFF
ON

Driver-side air bag module


OFF
ON

Passenger-side air bag module


OFF

Continuously flashes

Deployment authorization standby code

Caution
D When the output pattern continuously flashes (standby code), perform the deployment
authorization procedure. (Refer to AIR BAG SYSTEM, AIR BAG MODULE DEPLOYMENT
AUTHORIZATION PROCEDURE.)

T72

ON-BOARD DIAGNOSTIC (AIR BAG SYSTEM)


Inspection of Diagnostic Trouble Codes
DTC 1

DETECTION
CONDITION

SAS UNIT CONNECTOR POOR CONNECTION


Warning
D Detection conditions are for understanding DTC outline before performing inspection.
Performing inspection with only detection conditions may cause injury due to operating error
or damage the system. When performing inspection, always follow inspection procedure.
No continuity between poor connection detector bar terminals of SAS unit

POSSIBLE
CAUSE
STEP
1

D Poor connection of connector


D SAS unit connector malfunction
D Damaged SAS unit

INSPECTION
VERIFY THAT SAS UNIT CONNECTOR IS
CONNECTED WITH SAS UNIT
Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS

ACTION
Yes

Go to next step.

No

Reconnect connector properly.

Yes

Replace SAS unit.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

No

Replace wiring harness.

Turn ignition switch to LOCK position.


Disconnect negative battery cable and wait for
more than 1 minute.
Remove front console.
Is SAS unit connecor securely connected?
2

INSPECT SAS UNIT CONNECTOR


Remove column cover.
Disconnect clock spring connector.
Remove glove compartment. (Vehicles with
passenger-side air bag)
Disconnect passenger-side air bag module
connector. (Vehicles with passenger-side air
bag)
Disconnect SAS unit connector.
Is SAS unit connector okay?

DTC 2

DETECTION
CONDITION

SAS UNIT
Warning
D Detection conditions are for understanding DTC outline before performing inspection.
Performing inspection with only detection conditions may cause injury due to operating error
or damage the system. When performing inspection, always follow inspection procedure.
Malfunction in SAS unit inner circuit

POSSIBLE
CAUSE

Damaged SAS unit

STEP

INSPECTION

ACTION
Replace SAS unit.
+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

T73

ON-BOARD DIAGNOSTIC (AIR BAG SYSTEM)

DTC 3

DETECTION
CONDITION

POWER SUPPLY OF SAS UNIT


Warning
D Detection conditions are for understanding DTC outline before performing inspection.
Performing inspection with only detection conditions may cause injury due to operating error
or damage the system. When performing inspection, always follow inspection procedure.
Voltage supplied to SAS unit is 9 V or less.

POSSIBLE
CAUSE

Note
D Diagnostic trouble code 3 is indicated when voltage simultaneously drops in the harness of both of
following circuits.
1. Harness between METER 15 A fuse and terminal AB of SAS unit connector.
2. Harness between ENGINE 15 A fuse and terminal Z of SAS unit connector.
D Weak battery
D Malfunction in wiring harness between battery and SAS unit
D Damaged SAS unit

STEP
1

INSPECTION

ACTION

INSPECT BATTERY
Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS

Yes

Go to next step.

No

Battery is weak.
Inspect charge/discharge system.
+ Section G, CHARGING SYSTEM, BATTERY
INSPECTION

Yes

Replace SAS unit.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

No

Repair wiring harness.


(Ignition switch-Fuse block)

Is battery voltage more than 9 V?


2

INSPECT WIRING HARNESS BETWEEN


BATTERY AND SAS UNIT
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove column cover.
Disconnect clock spring connector.
Remove glove compartment. (Vehicles with
passenger-side air bag)
Disconnect passenger-side air bag module
connector. (Vehicles with passenger-side air
bag)
Remove front console.
Disconnect SAS unit connector.
Turn ignition switch to ON position.
Measure voltage at terminal AB or Z of SAS
unit connector.
Is voltage more than 9 V?

SAS UNIT CONNECTOR

AA

AB

T74

ON-BOARD DIAGNOSTIC (AIR BAG SYSTEM)

DTC 6

DETECTION
CONDITION

DRIVER-SIDE AIR BAG MODULE


Warning
D Detection conditions are for understanding DTC outline before performing inspection.
Performing inspection with only detection conditions may cause injury due to operating error
or damage the system. When performing inspection, always follow inspection procedure.
Resistance detected between terminals M and O of SAS unit is other than 1.873.42 .

POSSIBLE
CAUSE
STEP
1

D
D
D
D

Damaged driver-side air bag module


Damaged clock spring
Open or short circuit in wiring harness between clock spring and SAS unit
Damaged SAS unit
INSPECTION

INSPECT CLOCK SPRING PIN

ACTION
Yes

Go to next step.

No

Replace clock spring.


+ AIR BAG SYSTEM, CLOCK SPRING
REMOVAL/INSTALLATION

VERIFY WHETHER MALFUNCTION IS IN


DRIVER-SIDE AIR BAG MODULE OR
OTHER PARTS
Connect SST (Air bag simulator) to clock
spring.
Connect negative battery cable.
Is diagnostic trouble code 6 indicated when
ignition switch is turned to ON position?

Yes

Go to next step.

No

Replace driver-side air bag module.


+ AIR BAG SYSTEM, DRIVER-SIDE AIR BAG
MODULE REMOVAL/INSTALLATION

INSPECT CLOCK SPRING CONNECTOR


PIN
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove column cover.
Disconnect clock spring connector.
Is clock spring connector pin okay?

Yes

Go to next step.

No

Replace wiring harness.

VERIFY WHETHER MALFUNCTION IS IN


CLOCK SPRING OR OTHER PARTS
Connect SST (Air bag simulator) to clock
spring connector.
Connect negative battery cable.
Is diagnostic trouble code 6 indicated when
ignition switch is turned to ON position?

Yes

Go to next step.

No

Replace clock spring.


+ AIR BAG SYSTEM, CLOCK SPRING
REMOVAL/INSTALLATION

Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove driver-side air bag module.
+ AIR BAG SYSTEM, DRIVER-SIDE AIR
BAG MODULE REMOVAL/INSTALLATION
Is clock spring pin okay?
2

T75

ON-BOARD DIAGNOSTIC (AIR BAG SYSTEM)

STEP
5

INSPECTION

ACTION

INSPECT WIRING HARNESS BETWEEN


CLOCK SPRING AND SAS UNIT
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove glove compartment. (Vehicle with
passenger-side air bag)
Disconnect passenger-side air bag module
connector. (Vehicle with passenger-side air
bag)
Remove front console.
Disconnect SAS unit connector.
Inspect wiring harness between terminal O of
SAS unit connector and terminal A of clock
spring connector, and between terminal M of
SAS unit connector and terminal B of clock
spring connector for following.
D Short to ground
D Short to power supply
D Open circuit
Is wiring harness okay?
CLOCK SPRING

3A

Replace SAS unit.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

No

Replace wiring harness.

SAS UNIT CONNECTOR

CLOCK SPRING CONNECTOR

3B

DTC 7

DETECTION
CONDITION

Yes

AA

AB

PASSENGER-SIDE AIR BAG MODULE


Warning
D Detection conditions are for understanding DTC outline before performing inspection.
Performing inspection with only detection conditions may cause injury due to operating error
or damage the system. When performing inspection, always follow inspection procedure.
Resistance detected between terminals I and K of SAS unit is other than 1.632.71 .

POSSIBLE
CAUSE
STEP
1

D
D
D
D

Damaged passenger-side air bag module (With passenger-side air bag)


Damaged false resistance (Without passenger-side air bag)
Open or short circuit in wiring harness between passenger-side air bag module and SAS unit
Damaged SAS unit
INSPECTION

Is vehicle equipped with passenger-side air


bag module?

ACTION
Yes

Go to next step.

No

Go to step 5.

T76

ON-BOARD DIAGNOSTIC (AIR BAG SYSTEM)

STEP
2

INSPECTION
INSPECT PASSENGER-SIDE AIR BAG
MODULE CONNECTOR PIN

ACTION
Yes

Go to next step.

No

Replace wiring harness.

VERIFY WHETHER MALFUNCTION IS IN


PASSENGER-SIDE AIR BAG MODULE OR
OTHER PARTS
Connect SST (Air bag simulator) to
passenger-side air bag module connector.
Connect negative battery cable.
Is diagnostic trouble code 7 indicated when
ignition switch is turned to ON position?

Yes

Go to next step.

No

Replace passenger-side air bag module.


+ AIR BAG SYSTEM, PASSENGER-SIDE AIR BAG
MODULE REMOVAL/INSTALLATION

INSPECT WIRING HARNESS BETWEEN


PASSENGER-SIDE AIR BAG MODULE AND
SAS UNIT
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove column cover.
Disconnect clock spring connector.
Remove front console.
Disconnect SAS unit connector.
Inspect wiring harness between terminal K of
SAS unit connector and terminal A of
passenger-side air bag module connector,
and between terminal I of SAS unit connector
and terminal B of passenger-side air bag
module connector for following.
D Short to ground
D Short to power supply
D Open circuit
Is wiring harness okay?

Yes

Replace SAS unit.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

No

Replace wiring harness.

Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove glove compartment.
Disconnect passenger-side air bag module
connector.
Is passenger-side air bag module connector
pin okay?
3

T77

ON-BOARD DIAGNOSTIC (AIR BAG SYSTEM)

STEP
5

INSPECTION

ACTION

VERIFY WHETHER MALFUNCTION IS IN


FALSE RESISTANCE OR OTHER PARTS
Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS

Yes

Go to next step.

No

Replace false resistance.

Yes

Replace SAS unit.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

No

Replace wiring harness.

Turn the ignition switch to LOCK position.


Disconnect negative battery cable and wait for
more than 1 minute.
Remove glove compartment.
Remove false resistance.
Connect SST (Air bag simulator) to
passenger-side air bag module connector.
Connect negative battery cable.
Is diagnostic trouble code 7 indicated when
ignition switch is turned to ON position?
6

INSPECT WIRING HARNESS BETWEEN


FALSE RESISTANCE AND SAS UNIT
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove column cover.
Disconnect clock spring connector.
Remove front console.
Disconnect SAS unit connector.
Inspect wiring harness between terminal K of
SAS unit connector and terminal A of
passenger-side air bag module connector,
and between terminal I of SAS unit connector
and terminal B of passenger-side air bag
module connector for following.
D Short to ground
D Short to power supply
D Open circuit
Is wiring harness okay?
PASSENGER-SIDE AIR BAG
MODULE CONNECTOR

SAS UNIT CONNECTOR

AA

AB

T78

TROUBLESHOOTING

TROUBLESHOOTING
AIR BAG SYSTEM
Foreword
D Refer to section GI and thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures.
D For the steps that have an asterisk (*) , inspect the connector/terminal connection for continuity and damage. If
the connection is poor, reconnect it, or repair or replace the appropriate parts if necessary.
Troubleshooting Index
D Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area.
No.

Malfunction symptom

Air bag system warning light does not illuminate when ignition switch is turned to ON position.

Air bag system warning light illuminates immediately after ignition switch is turned to ON position and remains illuminated.

Symptom Troubleshooting
Note
D The following may be the cause of trouble if the symptom does not go away after the symptom
troubleshooting steps are followed.
1. Poor contact at terminal G of short connector (6pin) between instrument cluster and SAS unit.
2. Simultaneous poor contact at terminals D and F of short connector (6pin) between METER 15 A fuse and SAS
unit, and ENGINE 15 A fuse and SAS unit, respectively.
3. Simultaneous poor contact at terminals S and X of SAS unit connector (21pin).
4. Simultaneous poor contact at terminals AB and Z of SAS unit connector (21pin).
5. Simultaneous poor contact in wiring harness between terminal S of SAS unit connector (21pin) and ground,
terminal X of SAS unit connector (21pin) and ground.
6. Simultaneous poor contact in wiring harness between METER 15 A fuse and SAS unit, ENGINE 15 A fuse and
SAS unit.
1

Air bag system warning light does not illuminate when ignition switch is turned to ON position.

TROUBLESHOOTING HINTS
Malfunction in SAS unit power supply/ground circuit
1 Air bag system warning light does not illuminate
D SAS unit malfunction
D Instrument cluster (print plate) malfunction
D Terminal 1J of instrument cluster connector (16pin) malfunction
D Terminal 2J of instrument cluster connector (14pin) malfunction
D Terminal Q of SAS unit connector (21pin) malfunction
D Air bag system warning light bulb malfunction
D Poor installation of air bag system warning light bulb
D Poor connection at terminal 1J of instrument cluster connector (16pin)
D Poor connection at terminal 2J of instrument cluster connector (14pin)
D Poor connection at terminal Q of SAS unit connector (21pin)
D Poor contact in instrument cluster connectors (14, 16pin)
D Open or short circuit in wiring harness between instrument cluster and SAS unit
STEP
1
2
3
4

INSPECTION

ACTION

Are instrument cluster connectors (14, 16pin)


securely connected?

Yes

Go to next step.

No

Reconnect connector properly, then go to Step 10.

Is air bag system warning light bulb securely


installed?

Yes

Go to next step.

No

Reinstall properly, then go to Step 10.

Is air bag system warning light bulb functional?

Yes

Reinstall properly, then go to next step.

No

Replace bulb, then go to Step 10.

Yes

Go to next step.

No

Reconnect properly, then go to Step 10.

Are terminal 1J of instrument cluster connector


(16pin) and terminal 2J of instrument cluster
connector (14pin) securely connected?

T79

TROUBLESHOOTING

STEP

INSPECTION

ACTION

Are terminal 1J of instrument cluster connector


(16pin) and terminal 2J of instrument cluster
connector (14pin) damaged?

Yes

Replace air bag harness for malfunctioning


terminal, then go to Step 10.

No

Go to next step.

Is there continuity between terminals 1J and 2J of


print plate of instrument cluster?

Yes

Go to next step.

No

Replace instrument cluster, then go to Step 10.


+ WARNING AND INDICATOR SYSTEM,
INSTRUMENT CLUSTER
REMOVAL/INSTALLATION

Turn ignition switch to LOCK position.


Disconnect negative battery cable and wait for
more than 1 minute.
Remove column cover.
Disconnect clock spring connector.
Remove glove compartment. (Vehicle with
passenger-side air bag)
Disconnect passenger-side air bag module
connector. (Vehicle with passenger-side air bag)
Remove front console.
Disconnect SAS unit connector (21pin).
Is terminal Q of SAS unit connector (21pin)
securely connected?

Yes

Go to next step.

No

Reconnect properly, then go to Step 10.

Is terminal Q of SAS unit connector (21pin)


damaged?

Yes

Replace air bag harness, then go to Step 10.

No

Go to next step.

*9

Disconnect instrument cluster connector (14pin).


Is there continuity between terminal Q of SAS unit
connector (21pin) and terminal 2J of instrument
cluster connector (14pin)?

Yes

Replace SAS unit, then go to next step.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

No

Replace air bag harness, then go to next step.

10

Connect SAS unit connector (21pin).


Connect passenger-side air bag module
connector. (Vehicle with passenger-side air bag)
Connect clock spring connector.
Connect instrument cluster connector.
Connect negative battery cable.
When turning ignition switch to ON position, does
air bag system warning light operate properly?

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

T80

TROUBLESHOOTING

Air bag system warning light illuminates immediately after ignition switch is turned to ON position and
remains illuminated.

TROUBLESHOOTING HINTS
Malfunction in air bag system warning light circuit
1 Air bag system warning light remains illuminated
D SAS unit malfunction
D Malfunction of short bar between terminals Q and S of SAS unit connector (21pin)
D No connection in SAS unit connector (21pin)
D Short circuit in wiring harness between instrument cluster and SAS unit
STEP
1

INSPECTION

ACTION

Turn ignition switch to LOCK position.


Disconnect negative battery cable and wait for
more than 1 minute.
Remove front console.
Is SAS unit connector (21pin) securely
connected?

Yes

Go to next step.

No

Reconnect properly, then go to Step 5.

Is short bar between terminals Q and S of SAS


unit connector (21pin) bent?

Yes

Replace air bag harness, then go to Step 5.

No

Go to next step.

Is SAS unit short bar hook okay?

Yes

Go to next step.

No

Replace SAS unit, then go to Step 5.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

Remove column cover.


Disconnect clock spring connector.
Remove glove compartment. (Vehicle with
passenger-side air bag)
Disconnect passenger-side air bag module
connector. (Vehicle with passenger-side air bag)
Disconnect SAS unit connector (21pin).
Disconnect instrument cluster connector (14pin).
Insert insulating material between terminals Q
and S of SAS unit connector (21pin) so short bar
cannot function.
Is there continuity between terminal Q and
ground?

Yes

Replace air bag harness, then go to next step.

No

Replace SAS unit, then go to next step.


+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION

Connect SAS unit connector (21pin).


Connect passenger-side air bag module
connector. (Vehicle with passenger-side air bag)
Connect clock spring connector.
Connect instrument cluster connector.
Connect negative battery cable.
When turning ignition switch to ON position, does
air bag system warning light operate properly?

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction reoccurs.

*4

T81

HEATER AND AIR


CONDITIONER SYSTEMS
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . U 2
HANDLING REFRIGERANT . . . . . . . . . . . . . . . . U 2
STORING REFRIGERANT . . . . . . . . . . . . . . . . . U 2
SERVICE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . U 2
HANDLING COMPRESSOR OIL . . . . . . . . . . . . U 2
REFRIGERANT SYSTEM SERVICE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 3
MANIFOLD GAUGE SET INSTALLATION . . . . U 3
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 3
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 3
REFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 5
REFRIGERANT CHARGE CHECK . . . . . . . . . . U 6
REFRIGERANT PRESSURE CHECK . . . . . . . U 7
PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . U 7
BASIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 8
STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U 8
BLOWER UNIT REMOVAL/INSTALLATION . . U10
BLOWER UNIT DISASSEMBLY/ASSEMBLY . U10
COOLING UNIT REMOVAL/INSTALLATION . . U10
COOLING UNIT DISASSEMBLY/ASSEMBLY . U12
EVAPORATOR INSPECTION . . . . . . . . . . . . . . U13
HEATER UNIT REMOVAL/INSTALLATION . . . U13
HEATER UNIT DISASSEMBLY/ASSEMBLY . . U14
HEATER CORE INSPECTION . . . . . . . . . . . . . . U15
A/C COMPRESSOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U15
CONDENSER REMOVAL/INSTALLATION . . . U16
CONDENSER INSPECTION . . . . . . . . . . . . . . . U16
RECEIVER/DRIER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U16
REFRIGERANT LINES
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U17
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . U19

STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U19


MAGNETIC CLUTCH
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U20
MAGNETIC CLUTCH CLEARANCE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U20
MAGNETIC CLUTCH INSPECTION . . . . . . . . . U21
A/C RELAY No.1
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U21
A/C RELAY No.1 INSPECTION . . . . . . . . . . . . . U22
A/C RELAY No.2
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U22
A/C RELAY No.2 INSPECTION . . . . . . . . . . . . . U22
REFRIGERANT PRESSURE SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U22
REFRIGERANT PRESSURE SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . U23
THERMOSWITCH INSPECTION . . . . . . . . . . . U23
BLOWER MOTOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U24
BLOWER MOTOR INSPECTION . . . . . . . . . . . U24
RESISTOR REMOVAL/INSTALLATION . . . . . . U24
RESISTOR INSPECTION . . . . . . . . . . . . . . . . . . U25
CLIMATE CONTROL UNIT REMOVAL . . . . . . U25
CLIMATE CONTROL UNIT INSTALLATION . . U25
CLIMATE CONTROL UNIT
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U25
CLIMATE CONTROL UNIT WIRE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U26
CLIMATE CONTROL UNIT INSPECTION . . . . U27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . U28
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U28
TROUBLESHOOTING INDEX . . . . . . . . . . . . . . U28
SYMPTOM TROUBLESHOOTING . . . . . . . . . . U28

U1

SERVICE WARNINGS, SERVICE CAUTIONS

SERVICE WARNINGS

SERVICE CAUTIONS

HANDLING REFRIGERANT
 Avoid breathing air conditioning refrigerant or
lubricant vapor. Exposure may irritate eyes,
nose and throat. If accidental system discharge
occurs, ventilate work area before resuming
service.
 Do not pressure test or leak test R-134a service
equipment and/or vehicle air conditioning
system with compressed air. Some mixtures of
air and R-134a have been shown to be
combustible at elevated pressures. These
mixtures, if ignited, may cause injury or
property damage. Additional health and safety
information may be obtained from refrigerant
manufacturers.
 Do not allow the refrigerant to leak near fire or
any kind of heat. A poisonous gas may be
generated if the refrigerant gas contacts fire or
heat such as from cigarettes and heaters.
When carrying out any operation that can
cause refrigerant leakage, extinguish or
remove the above-mentioned heat sources and
maintain adequate ventilation.
 Handling liquid refrigerant is dangerous. A
drop of it on the skin can result in localized
frostbite. When handling the refrigerant, wear
gloves and safety goggles. If refrigerant
splashes into the eyes, immediately wash them
with clean water and consult a doctor.

HANDLING COMPRESSOR OIL


 Use FD46XG (G6, WL, WL turbo) or ZXL 100PG
(F2, F2 Cab) compressor oil for this vehicle.
Using a PAG oil other than FD46XG (G6, WL,
WL turbo) or ZXL 100PG compressor oil can
damage the A/C compressor.
 Do not spill compressor oil on the vehicle. A
drop of compressor oil on the vehicle surface
can eat away at the paint. If oil gets on the
vehicle, wipe it off immediately.
 FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2,
F2 Cab) compressor oil (PAG oil) has a higher
moisture absorption efficiency than the
previously used mineral oil. If moisture mixes
with the compressor oil, the refrigerant system
could be damaged. Therefore, install caps
immediately after using the compressor oil or
removing refrigerant system parts to prevent
moisture absorption.

STORING REFRIGERANT
 The refrigerant container is highly pressurized.
If it is subjected to high heat, it could explode,
scattering metal fragments and liquid
refrigerant that can seriously injure you. Store
the refrigerant at temperatures below 40 C
{104 F}.

FD46XG (G6, WL, WL turbo) or ZXL


100PG (F2, F2 Cab) COMPRESSOR
OIL

MINERAL OIL

MOISTURE ABSORPTION

U2

TIME

REFRIGERANT SYSTEM SERVICE PROCEDURES

REFRIGERANT SYSTEM SERVICE


PROCEDURES

TAP PIN SIDE

49 C061 001
49 C061 005

MANIFOLD GAUGE SET INSTALLATION


1. Fully close the valves of the SST (49 C061 001).
2. Connect the SSTs (49 C061 002, 49 C061 003) to
the high- and low-pressure side joints of the SST
(49 C061 001).
3. Connect the SSTs (49 C061 006A, 49 C061 007)
to the ends of the SSTs (49 C061 002, 49 C061
003).
4. Connect the SSTs (49 C061 006A, 49 C061 007)
to the charging valves.

49 C061 004
REFRIGERANT
TANK
SCALE
VACUUM PUMP

7. Open all the valves of the SST (49 C061 001).

49 C061 001

Caution
 Close the SST (49 C061 001) valve
immediately after stopping the vacuum
pump. If the valve is left open, the vacuum
pump oil will flow back into the refrigeration
cycle and cause a decrease in the efficiency
of the air conditioner.

49 C061 002
49 C061 003

49 C061 006A
CAP

49 C061 007
CAP
CHARGING VALVE OF
LOW-PRESSURE SIDE

AIR PURGE VALVE

CHARGING
VALVE OF
HIGH-PRESSURE
SIDE

8. Start the vacuum pump and let it operate for


15 minutes.
49 C061 001

RECOVERY
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.

CLOSE

CHARGING
Charging Recycled R-134a Refrigerant
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.
Charging New R-134a Refrigerant

9. Verify that high- and low-pressure side readings of


the SST (49 C061 001) are at 101 kPa
{760 mmHg, 29.9 inHg}. Close each valve of
the SST (49 C061 001).

Caution
 Do not exceed the specification when
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration
cycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.
6. Place the refrigerant tank on the scale.
Regular amount of refrigerant
550 g {19.4 oz}

49 C061 001

10. Stop the vacuum pump and wait for 5 minutes.


11. Check the high- and low-pressure side readings of
the SST (49 C061 001). If the reading has
changed, inspect for leakage and then repeat from
step 7. If the reading has not changed, go to step
12.
12. Open the valve of the refrigerant tank.
13. Weigh the refrigerant tank.

U3

REFRIGERANT SYSTEM SERVICE PROCEDURES

REFRIGERANT SYSTEM SERVICE


PROCEDURES

TAP PIN SIDE

49 C061 001
49 C061 005

MANIFOLD GAUGE SET INSTALLATION


1. Fully close the valves of the SST (49 C061 001).
2. Connect the SSTs (49 C061 002, 49 C061 003) to
the high- and low-pressure side joints of the SST
(49 C061 001).
3. Connect the SSTs (49 C061 006A, 49 C061 007)
to the ends of the SSTs (49 C061 002, 49 C061
003).
4. Connect the SSTs (49 C061 006A, 49 C061 007)
to the charging valves.

49 C061 004
REFRIGERANT
TANK
SCALE
VACUUM PUMP

7. Open all the valves of the SST (49 C061 001).

49 C061 001

Caution
 Close the SST (49 C061 001) valve
immediately after stopping the vacuum
pump. If the valve is left open, the vacuum
pump oil will flow back into the refrigeration
cycle and cause a decrease in the efficiency
of the air conditioner.

49 C061 002
49 C061 003

49 C061 006A
CAP

49 C061 007
CAP
CHARGING VALVE OF
LOW-PRESSURE SIDE

AIR PURGE VALVE

CHARGING
VALVE OF
HIGH-PRESSURE
SIDE

8. Start the vacuum pump and let it operate for


15 minutes.
49 C061 001

RECOVERY
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.

CLOSE

CHARGING
Charging Recycled R-134a Refrigerant
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.
Charging New R-134a Refrigerant

9. Verify that high- and low-pressure side readings of


the SST (49 C061 001) are at 101 kPa
{760 mmHg, 29.9 inHg}. Close each valve of
the SST (49 C061 001).

Caution
 Do not exceed the specification when
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration
cycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.
6. Place the refrigerant tank on the scale.
Regular amount of refrigerant
550 g {19.4 oz}

49 C061 001

10. Stop the vacuum pump and wait for 5 minutes.


11. Check the high- and low-pressure side readings of
the SST (49 C061 001). If the reading has
changed, inspect for leakage and then repeat from
step 7. If the reading has not changed, go to step
12.
12. Open the valve of the refrigerant tank.
13. Weigh the refrigerant tank.

U3

REFRIGERANT SYSTEM SERVICE PROCEDURES


Warning
 If the refrigerant system is charged with a
large amount of refrigerant when checking
for gas leakage, and if any leakage should
occur, the refrigerant will be released into
the atmosphere. In order to prevent the
accidental release of refrigerant which can
destroy the ozone layer in the stratosphere,
follow the proper procedures and charge
with only a small amount of refrigerant
when checking for gas leakage.
 If charging the system with refrigerant
using service cans, running the engine with
the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure
you. Therefore, do not open the
high-pressure side valve while the engine is
running.

Warning
 If charging the system with refrigerant
using service cans, running the engine with
the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure
you. Therefore, do not open the
high-pressure side valve while the engine is
running.
17. Open the high-pressure side valve of the SST (49
C061 001) and charge with refrigerant until the
weight of refrigerant tank has decreased 300 g
{10.6 oz} from the amount in step 13.
49 C061 001
OPEN

14. Open the high-pressure side valve of the SST (49


C061 001).
49 C061 001
OPEN

18. Close the high-pressure side valve of the SST (49


C061 001).
49 C061 001

15. When the low-pressure side reading increases to


0.098 MPa {1.0 kgf/cm2, 14 psi}, close the
high-pressure side valve of the SST (49 C061
001).
49 C061 001

16. Inspect for leakage from the cooler pipe/hose


connections using the SST (Gas leak tester). If
there is no leakage, go to step 17. If a leakage is
found at a loose joint, tighten the joint and inspect
for leakage again. If there is still leakage at the
same joint, discharge the refrigerant and then
repair the joint. Repeat the charging procedure
from step 7. If there is no leakage after tightening
the joint, go to step 17.

Warning
 If charging the system with refrigerant
using service cans, running the engine with
the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure
you. Therefore, do not open the
high-pressure side valve while the engine is
running.
19. Start the engine and actuate the A/C compressor.
20. Open the low-pressure side valve of the SST (49
C061 001) and charge with refrigerant until the
refrigerant tank is empty.

U4

REFRIGERANT SYSTEM SERVICE PROCEDURES

49 C061 001

TAP PIN SIDE

AIR PURGE VALVE

49 C061 001

OPEN

49 C061 005
49 C061 004
REFRIGERANT
TANK

VACUUM PUMP

21. Close the low-pressure side valve of the SST (49


C061 001) and the valve of the refrigerant tank.
22. Stop the engine and A/C compressor.
23. Inspect for leakage using the SST (Gas leak
tester). If there is no leakage, go to step 24. If
leakage is found at a loose joint, tighten the joint
and inspect for leakage again. If there is still a leak
at the same joint, discharge the refrigerant and
then repair the joint. Repeat the charging
procedure from step 7. If there is no leakage after
tightening the joint, go to step 24.
24. Disconnect the SSTs (49 C061 006A, 49 C061
007) from the charging valves.
25. Install the caps to the charging valves.

6. Open only the center valve of the SST (49 C061


001).
Caution
 Close the SST (49 C061 001) valve
immediately after stopping the vacuum
pump. If the valve is left open, the vacuum
pump oil will flow back into the refrigeration
cycle and cause a decrease in the efficiency
of the air conditioner.
7. Start the vacuum pump and let it run for 1 minute.
49 C061 001
CLOSE

49 C061 006A
49 0061 007
CAP

CAP

8. Close the center valve of the SST (49 C061 001).


REFILLING

49 C061 001

Caution
 Do not exceed the specification when
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration
cycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.

9. Stop the vacuum pump.


10. Open the valve of the refrigerant tank.
Warning
 If charging the system with refrigerant
using service cans, running the engine with
the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure
you. Therefore, do not open the
high-pressure side valve while the engine is
running.

U5

REFRIGERANT SYSTEM SERVICE PROCEDURES

49 C061 001

TAP PIN SIDE

AIR PURGE VALVE

49 C061 001

OPEN

49 C061 005
49 C061 004
REFRIGERANT
TANK

VACUUM PUMP

21. Close the low-pressure side valve of the SST (49


C061 001) and the valve of the refrigerant tank.
22. Stop the engine and A/C compressor.
23. Inspect for leakage using the SST (Gas leak
tester). If there is no leakage, go to step 24. If
leakage is found at a loose joint, tighten the joint
and inspect for leakage again. If there is still a leak
at the same joint, discharge the refrigerant and
then repair the joint. Repeat the charging
procedure from step 7. If there is no leakage after
tightening the joint, go to step 24.
24. Disconnect the SSTs (49 C061 006A, 49 C061
007) from the charging valves.
25. Install the caps to the charging valves.

6. Open only the center valve of the SST (49 C061


001).
Caution
 Close the SST (49 C061 001) valve
immediately after stopping the vacuum
pump. If the valve is left open, the vacuum
pump oil will flow back into the refrigeration
cycle and cause a decrease in the efficiency
of the air conditioner.
7. Start the vacuum pump and let it run for 1 minute.
49 C061 001
CLOSE

49 C061 006A
49 0061 007
CAP

CAP

8. Close the center valve of the SST (49 C061 001).


REFILLING

49 C061 001

Caution
 Do not exceed the specification when
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration
cycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.

9. Stop the vacuum pump.


10. Open the valve of the refrigerant tank.
Warning
 If charging the system with refrigerant
using service cans, running the engine with
the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure
you. Therefore, do not open the
high-pressure side valve while the engine is
running.

U5

REFRIGERANT SYSTEM SERVICE PROCEDURES


11. Start the engine and actuate the A/C compressor.
12. Open the low-pressure side valve of the SST (49
C061 001).

49 C061 007

49 C061 006A

CAP

49 C061 001
OPEN
CAP

REFRIGERANT CHARGE CHECK


Caution
 The FD46XG (G6, WL, WL turbo) or ZXL
100PG (F2, F2 Cab) compressor oil will
separate from refrigerant at high
temperatures of 50 C {122 F} or more. If
this happens, the sight glass will change to
a milky-white color, and there is a
possibility that you might mistakenly
believe the refrigerant amount to be
insufficient and recharge with additional
refrigerant.
If the system is overcharged with
refrigerant, the sight glass will become
clear and give a false indication. You will
mistakenly believe that the refrigerant
amount is correct.
Therefore, when checking the refrigerant
amount, verify the refrigerant pressure and
cooler pipe temperature in addition to the
sight glass condition.

13. Refer to refrigerant charge check and refill with


refrigerant.
L.H.D.

SIGHT GLASS

R.H.D. (WL, G6, F2 Cab)

1. Warm up the engine and run it at a constant


1,500 rpm.
2. Set the fan switch at 4th.
3. Set the temperature control dial to MAX COLD.
4. Close all the doors and windows.
5. Check the refrigerant amount condition according
to the following table.

SIGHT GLASS

R.H.D.
(WL turbo)

SIGHT GLASS

14. Close the low-pressure side valve of the SST (49


C061 001) and the valve of the refrigerant tank.
15. Stop the engine and the A/C compressor.
16. Disconnect the SSTs (49 C061 006A, 49 C061
007) from the charging valves.
17. Install the caps to the charging valves.

U6

REFRIGERANT SYSTEM SERVICE PROCEDURES


11. Start the engine and actuate the A/C compressor.
12. Open the low-pressure side valve of the SST (49
C061 001).

49 C061 007

49 C061 006A

CAP

49 C061 001
OPEN
CAP

REFRIGERANT CHARGE CHECK


Caution
 The FD46XG (G6, WL, WL turbo) or ZXL
100PG (F2, F2 Cab) compressor oil will
separate from refrigerant at high
temperatures of 50 C {122 F} or more. If
this happens, the sight glass will change to
a milky-white color, and there is a
possibility that you might mistakenly
believe the refrigerant amount to be
insufficient and recharge with additional
refrigerant.
If the system is overcharged with
refrigerant, the sight glass will become
clear and give a false indication. You will
mistakenly believe that the refrigerant
amount is correct.
Therefore, when checking the refrigerant
amount, verify the refrigerant pressure and
cooler pipe temperature in addition to the
sight glass condition.

13. Refer to refrigerant charge check and refill with


refrigerant.
L.H.D.

SIGHT GLASS

R.H.D. (WL, G6, F2 Cab)

1. Warm up the engine and run it at a constant


1,500 rpm.
2. Set the fan switch at 4th.
3. Set the temperature control dial to MAX COLD.
4. Close all the doors and windows.
5. Check the refrigerant amount condition according
to the following table.

SIGHT GLASS

R.H.D.
(WL turbo)

SIGHT GLASS

14. Close the low-pressure side valve of the SST (49


C061 001) and the valve of the refrigerant tank.
15. Stop the engine and the A/C compressor.
16. Disconnect the SSTs (49 C061 006A, 49 C061
007) from the charging valves.
17. Install the caps to the charging valves.

U6

REFRIGERANT SYSTEM SERVICE PROCEDURES

Amount

Condition of
sight glass

Other conditions

Mpa
{kgf/cm2, psi}

 High-pressure side cooler

Insufficient
Bubbles

2.0
{21, 299}

pipe is warm;
low-pressure side cooler
pipe is cool.
 High- and low-pressure
side readings are lower
than normal.
 Air cooling ability is low.

1.5
{15, 213}
1.0
{10, 142}

0.2
{2.0, 28}

 High-pressure side cooler

Clear
Correct

Milky white

pipe is hot; low-pressure


side cooler pipe is cold.
 High- and low-pressure
side readings are normal.
* If sight glass is
milky-white, pour water
into condenser for
approximately 20
seconds to cool it off,
then the sight glass will
clear.

Over
Clear

LOW-PRESSURE SIDE

0.1
{1.0, 14}

PRESSURE READING OF MANIFOLD GAUGE


20
{68}

25
{77}

30
{86}

35
{95}

40
C
{104} {F}

AMBIENT TEMPERATURE

 High-pressure side cooler

pipe is hot; low-pressure


side cooler pipe is cold.
 High- and low-pressure
side reading are higher
than normal.
 Air cooling ability is low.

HIGH-PRESSURE SIDE

9. If not as specified, troubleshoot the refrigerant


system. (Refer to TROUBLESHOOTING.)
PERFORMANCE TEST
Note
 After servicing the refrigerant system, the test
is performed.

6. If not as specified, troubleshoot the refrigerant


system. (Refer to TROUBLESHOOTING.)

1. Install the SSTs (manifold gauge set). (Refer to


MANIFOLD GAUGE SET INSTALLATION.)
2. Open the bonnet.
3. Close all the doors and windows.
4. Warm up the engine and run it at a constant
1,500 rpm.
5. Set the fan switch at 4th.
6. Set the temperature control dial to MAX COLD.
7. Record center ventilator right side temperature.
8. Determine and record ambient temperature.
9. Verify that the temperature reading is in the shaded
zone.

REFRIGERANT PRESSURE CHECK


1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Open the bonnet.
3. Close all the doors and windows.
4. Warm up the engine and run it at a constant
1,500 rpm.
5. Set the fan switch at 4th.
6. Set the temperature control dial to MAX COLD.
7. Measure the ambient temperature and the highand low-pressure side reading of the SST (49
C061 001).
8. Verify that the intersection of the pressure reading
of the SST (49 C061 001) and ambient
temperature is in the shaded zone.

C {F}
6 {43}
5 {41}
4 {39}
3 {37}
2 {36}
1 {34}
0 {32}
20
{68}

25
{77}

30
{86}

35
{95}

CENTER VENTILATOR
TEMPERATURE
AMBIENT TEMPERATURE

40
C
{104} {F}

10. If the performance is not within the shaded zone,


troubleshoot the refrigerant system. (Refer to
TROUBLESHOOTING.)

U7

REFRIGERANT SYSTEM SERVICE PROCEDURES

Amount

Condition of
sight glass

Other conditions

Mpa
{kgf/cm2, psi}

 High-pressure side cooler

Insufficient
Bubbles

2.0
{21, 299}

pipe is warm;
low-pressure side cooler
pipe is cool.
 High- and low-pressure
side readings are lower
than normal.
 Air cooling ability is low.

1.5
{15, 213}
1.0
{10, 142}

0.2
{2.0, 28}

 High-pressure side cooler

Clear
Correct

Milky white

pipe is hot; low-pressure


side cooler pipe is cold.
 High- and low-pressure
side readings are normal.
* If sight glass is
milky-white, pour water
into condenser for
approximately 20
seconds to cool it off,
then the sight glass will
clear.

Over
Clear

LOW-PRESSURE SIDE

0.1
{1.0, 14}

PRESSURE READING OF MANIFOLD GAUGE


20
{68}

25
{77}

30
{86}

35
{95}

40
C
{104} {F}

AMBIENT TEMPERATURE

 High-pressure side cooler

pipe is hot; low-pressure


side cooler pipe is cold.
 High- and low-pressure
side reading are higher
than normal.
 Air cooling ability is low.

HIGH-PRESSURE SIDE

9. If not as specified, troubleshoot the refrigerant


system. (Refer to TROUBLESHOOTING.)
PERFORMANCE TEST
Note
 After servicing the refrigerant system, the test
is performed.

6. If not as specified, troubleshoot the refrigerant


system. (Refer to TROUBLESHOOTING.)

1. Install the SSTs (manifold gauge set). (Refer to


MANIFOLD GAUGE SET INSTALLATION.)
2. Open the bonnet.
3. Close all the doors and windows.
4. Warm up the engine and run it at a constant
1,500 rpm.
5. Set the fan switch at 4th.
6. Set the temperature control dial to MAX COLD.
7. Record center ventilator right side temperature.
8. Determine and record ambient temperature.
9. Verify that the temperature reading is in the shaded
zone.

REFRIGERANT PRESSURE CHECK


1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Open the bonnet.
3. Close all the doors and windows.
4. Warm up the engine and run it at a constant
1,500 rpm.
5. Set the fan switch at 4th.
6. Set the temperature control dial to MAX COLD.
7. Measure the ambient temperature and the highand low-pressure side reading of the SST (49
C061 001).
8. Verify that the intersection of the pressure reading
of the SST (49 C061 001) and ambient
temperature is in the shaded zone.

C {F}
6 {43}
5 {41}
4 {39}
3 {37}
2 {36}
1 {34}
0 {32}
20
{68}

25
{77}

30
{86}

35
{95}

CENTER VENTILATOR
TEMPERATURE
AMBIENT TEMPERATURE

40
C
{104} {F}

10. If the performance is not within the shaded zone,


troubleshoot the refrigerant system. (Refer to
TROUBLESHOOTING.)

U7

BASIC SYSTEM

BASIC SYSTEM
STRUCTURAL VIEW
BLOWER UNIT

L.H.D. (G6)

COOLING UNIT
HEATER UNIT

COOLER
PIPE
(LOW)
COOLER
PIPE
(HIGH)

HEATER
HOSE
A/C
COMPRESSOR

L.H.D. (WL, WL turbo)

COOLER
HOSE
(LOW)

BLOWER UNIT
COOLING UNIT

CONDENSER

HEATER UNIT

RECEIVER/DRIER

COOLER
PIPE
(LOW)

HEATER
HOSE
COOLER
PIPE
(HIGH)

A/C
COMPRESSOR

COOLER
HOSE
(HIGH)
CONDENSER

RECEIVER/DRIER

L.H.D. (F2, F2 Cab)


BLOWER UNIT
COOLING UNIT
HEATER UNIT

COOLER
PIPE
(LOW)

HEATER
COOLER
HOSE
PIPE
A/C
(HIGH) COMPRESSOR
COOLER
HOSE
(HIGH)

CONDENSER

RECEIVER/DRIER

U8

BASIC SYSTEM

R.H.D. (G6)
HEATER UNIT
COOLING UNIT

HEATER
HOSE
A/C
COMPRESSOR

BLOWER UNIT
COOLER
HOSE
(LOW)

COOLER
PIPE
(HIGH)

CONDENSER
COOLER
HOSE (HIGH)

RECEIVER/DRIER

R.H.D. (WL, WL turbo)


HEATER UNIT
HEATER
HOSE

COOLING UNIT

A/C
COMPRESSOR

BLOWER UNIT
COOLER
HOSE (LOW)

COOLER
PIPE
(HIGH)

SIGHT GLASS

CONDENSER

R.H.D. (F2 Cab)

RECEIVER/DRIER
HEATER UNIT
HEATER
HOSE

COOLING UNIT

A/C
COMPRESSOR

BLOWER UNIT
COOLER
HOSE (LOW)

COOLER
PIPE
(HIGH)
CONDENSER
RECEIVER/DRIER

U9

COOLER
HOSE (HIGH)

WL turbo

BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove the cooling unit. (Refer to COOLING UNIT
REMOVAL/INSTALLATION.)
4. Remove the passengers side front side trim
(L.H.D. only.)
5. Remove as indicated in the table.
6. Install in the reverse order of removal.

R.H.D.

B
C
A

A
B
C

Connector

Blower unit

BLOWER UNIT DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
L.H.D.

Blower motor

Resistor

Blower harness

Polyurethane protector

Inlet duct case (front)

Inlet duct case (rear)

Blower case (upper)

Blower case (lower)

Air intake door

10

Air intake link

11

Air intake crank

COOLING UNIT REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer
to REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
3. Remove the glove compartment.
4. Disconnect the air intake wire from the cooling unit.
(Refer to CONTROL SYSTEM, CLIMATE
CONTROL UNIT WIRE ADJUSTMENT.)
Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

B
C
A

B
C

U10

BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove the cooling unit. (Refer to COOLING UNIT
REMOVAL/INSTALLATION.)
4. Remove the passengers side front side trim
(L.H.D. only.)
5. Remove as indicated in the table.
6. Install in the reverse order of removal.

R.H.D.

B
C
A

A
B
C

Connector

Blower unit

BLOWER UNIT DISASSEMBLY/ASSEMBLY


1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
L.H.D.

Blower motor

Resistor

Blower harness

Polyurethane protector

Inlet duct case (front)

Inlet duct case (rear)

Blower case (upper)

Blower case (lower)

Air intake door

10

Air intake link

11

Air intake crank

COOLING UNIT REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer
to REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
3. Remove the glove compartment.
4. Disconnect the air intake wire from the cooling unit.
(Refer to CONTROL SYSTEM, CLIMATE
CONTROL UNIT WIRE ADJUSTMENT.)
Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

B
C
A

B
C

U10

BASIC SYSTEM
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
6. Install in the reverse order of removal.
7. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

Cooler hose (low)


+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Removal Note
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

Cooler pipe (high)


+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Removal Note
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

Connector

Cooling unit
+ Removal Note
+ Installation Note

L.H.D.

1521 Nm
{1.52.2 kgfm,
130.2190.9 inlbf}

6.99.8 Nm
{0.71.0 kgfm,
60.886.7 inlbf}

R.H.D.
2029 Nm
{2.03.0 kgfm,
1521 ftlbf}

Cooling Unit Removal Note (R.H.D. only)


 Turn the cooling unit 90 degrees to the right, and
remove the cooling unit.

R
9.8119.61 Nm
{100200 kgfcm,
86.8173.5 inlbf}

Cooling Unit Installation Note


 When installing a new cooling unit (evaporator),
add FD46XG (G6, WL, WL turbo) or ZXL 100PG
(F2, F2 Cab) compressor oil into the refrigeration
cycle.
Supplement amount
40 ml {40 cc, 1.4 fl oz}

U11

BASIC SYSTEM
COOLING UNIT DISASSEMBLY/ASSEMBLY
Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
L.H.D.

Cooler case (upper)

Cooler case (lower)

Thermoswitch clip

Thermoswitch
+ Assembly Note

Evaporator

Expansion valve
+ Assembly Note

High pressure pipe

Expansion Valve Assembly Note


 Replace the O-rings at the expansion valve joints
and apply compressor oil to the O-rings and
connect the joints.
 Tighten the joint to the specified torque using two
open-end wrenches.
 Assemble the heat-sensing tube as shown in the
figure.
2024 Nm
{2.02.5 kgfm,
1518 ftlbf}

11.814.7 Nm
{120150 kgfcm,
105130 inlbf}

R.H.D.

HEAT-SENSING TUBE

Thermoswitch Assembly Note


1. Insert the thermoswitch probe in location as shown
in the figure.
EVAPORATOR

40 mm
{1.6 in}

U12

BASIC SYSTEM
EVAPORATOR INSPECTION
1. Remove the cooling unit. (Refer to COOLING UNIT
REMOVAL/INSTALLATION.)
2. Remove the evaporator from the cooling unit.
3. Inspect for cracks, damage, and oil leakage. If any
problems are found, replace the evaporator.
4. Inspect for bent fins. If they are bent, use a
flat-head screwdriver to straighten them.
HEATER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (Refer to section E,
ENGINE COOLANT, ENGINE COOLANT
REPLACEMENT.) (With heater core only)
3. Remove the dashboard. (Refer to section S,
DASHBOARD AND CONSOLE, DASH BOARD
REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

WITH HEATER CORE ONLY

Heater hose

Heater unit

U13

BASIC SYSTEM
HEATER UNIT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

*
*
*

WITH HEATER CORE ONLY

Heater core

Airflow mode crank (2)

Air mix rod

10

Airflow mode crank (3)

Air mix link

11

Airflow mode crank (4)

Air mix crank (1)

12

Airflow mode sub link (1)

Air mix crank (2)

13

Airflow mode sub link (2)

Air mix shaft

14

Heater case (1)

Airflow mode main link

15

Heater case (2)

Airflow mode crank (1)

16

Heater case (3)

U14

BASIC SYSTEM
HEATER CORE INSPECTION
1. Remove the heater unit. (Refer to HEATER UNIT
REMOVAL/INSTALLATION.)
2. Remove the heater core from the heater unit.
3. Inspect for cracks, damage, and coolant leakage. If
any are found, replace the heater core.
4. Inspect for bent fins. If any are bent, use a flathead
screwdriver to straighten them.
5. Verify that the heater core inlet and outlet are not
distorted or damaged. Repair with pliers if necessary.

G6, WL, WL turbo


1521
{1.52.2,
1115}

A/C COMPRESSOR REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE PROCEDURES,
RECOVERY.) (Refer to REFRIGERANT SYSTEM
SERVICE PROCEDURES, CHARGING.)
3. Remove the drive belt (P/S + A/C).
4. Remove the air cleaner and air hose. (WL turbo
only) (Refer to section F2, INTAKE-AIR SYSTEM,
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
5. Loosen the A/C compressor bolts, then slide the
A/C compressor. (WL turbo only)
Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings after
removing any refrigeration cycle parts to keep
moisture or foreign material out of the cycle.

2435
{2.43.6,
1826}

Nm {kgfm, ftlbf}

F2, F2 Cab

R
3039
{3.04.0,
2228}

6. Remove in the order indicated in the table. Do not


allow compressor oil to spill.
7. Install in the reverse order of removal.
8. Adjust the drive belt (P/S + A/C). (Refer to section
B1, DRIVE BELT, DRIVE BELT ADJUSTMENT.)
(Refer to section B2, DRIVE BELT, DRIVE BELT
ADJUSTMENT.) (Refer to section B3, DRIVE
BELT, DRIVE BELT ADJUSTMENT.)
9. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

Nm {kgfm, ftlbf}

Connector

Cooler hose (high)


+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

Cooler hose (low)


+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

A/C compressor
+ Installation Note

A/C Compressor Installation Note


 Remove the following amount of compressor oil
from the new A/C compressor when replacing the
A/C compressor.
Compressor oil to be removed = 180 ml
{180 cc, 6.08 fl oz} [compressor oil from old
A/C compressor + 15 ml {15 cc, 0.5 fl oz} ]

U15

BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
3. Remove the radiator grille.
4. Remove the charge air cooler and air hose. (WL
turbo only)
(Refer to section F2, INTAKE-AIR SYSTEM,
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
5. Remove the receiver/drier. (Refer to
RECEIVER/DRIER REMOVAL/INSTALLATION.)

Condenser Installation Note


 When installing a new condenser, add FD46XG
(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)
compressor oil into the refrigeration cycle.
Supplemental amount
30 ml {30 cc, 1.0 fl oz}
CONDENSER INSPECTION
1. Inspect for cracks, damage, and oil leakage. If any
problems are found, replace the condenser.
2. Inspect for fins clogged by dust. If any are clogged,
remove the dust from the fins.
3. Inspect for bent fins. If any are bent, use a flathead
screwdriver to straighten them.

Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

RECEIVER/DRIER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE PROCEDURES,
RECOVERY.) (Refer to REFRIGERANT SYSTEM
SERVICE PROCEDURES, CHARGING.)
3. Remove the radiator grille.

6. Remove in the order indicated in the table. Do not


allow compressor oil to spill.
7. Install in the reverse order of removal.
8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

4. Remove in the order indicated in the table. Do not


allow compressor oil to spill.
5. Install in the reverse order of removal.
6. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

1521 Nm
{1.52.2 kgfm,
1115 ftlbf}

Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

6.859.80 Nm
{70100 kgfcm, 60.886.7 inlbf}

B
C
C

D
R

Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

Bonnet lock stay

Condenser
+ Installation Note

U16

BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
3. Remove the radiator grille.
4. Remove the charge air cooler and air hose. (WL
turbo only)
(Refer to section F2, INTAKE-AIR SYSTEM,
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
5. Remove the receiver/drier. (Refer to
RECEIVER/DRIER REMOVAL/INSTALLATION.)

Condenser Installation Note


 When installing a new condenser, add FD46XG
(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)
compressor oil into the refrigeration cycle.
Supplemental amount
30 ml {30 cc, 1.0 fl oz}
CONDENSER INSPECTION
1. Inspect for cracks, damage, and oil leakage. If any
problems are found, replace the condenser.
2. Inspect for fins clogged by dust. If any are clogged,
remove the dust from the fins.
3. Inspect for bent fins. If any are bent, use a flathead
screwdriver to straighten them.

Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

RECEIVER/DRIER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE PROCEDURES,
RECOVERY.) (Refer to REFRIGERANT SYSTEM
SERVICE PROCEDURES, CHARGING.)
3. Remove the radiator grille.

6. Remove in the order indicated in the table. Do not


allow compressor oil to spill.
7. Install in the reverse order of removal.
8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

4. Remove in the order indicated in the table. Do not


allow compressor oil to spill.
5. Install in the reverse order of removal.
6. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

1521 Nm
{1.52.2 kgfm,
1115 ftlbf}

Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

6.859.80 Nm
{70100 kgfcm, 60.886.7 inlbf}

B
C
C

D
R

Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

Bonnet lock stay

Condenser
+ Installation Note

U16

BASIC SYSTEM

Connector

Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

Condenser
+ CONDENSER REMOVAL/INSTALLATION,
Condenser Installation Note

Receiver/drier
+ Installation Note

Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.
3. Remove the radiator grille.
4. Remove the front bumper. (Refer to section S,
BUMPER, FRONT BUMPER
REMOVAL/INSTALLATION.)
5. Remove the radiator. (WL turbo only)
6. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
7. Install in the reverse order of removal.
8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

Receiver/drier Installation Note


 When installing a new receiver/drier, add FD46XG
(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)
compressor oil into the refrigeration cycle.
Supplemental amount
35 ml {35 cc, 1.2 fl oz}
REFRIGERANT LINES REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer
to REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
L.H.D.

B
C

D
F

R
R

D
F

A
C

B
A
R

R
R

B
A

U17

BASIC SYSTEM

Connector

Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note

Condenser
+ CONDENSER REMOVAL/INSTALLATION,
Condenser Installation Note

Receiver/drier
+ Installation Note

Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.
3. Remove the radiator grille.
4. Remove the front bumper. (Refer to section S,
BUMPER, FRONT BUMPER
REMOVAL/INSTALLATION.)
5. Remove the radiator. (WL turbo only)
6. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
7. Install in the reverse order of removal.
8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

Receiver/drier Installation Note


 When installing a new receiver/drier, add FD46XG
(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)
compressor oil into the refrigeration cycle.
Supplemental amount
35 ml {35 cc, 1.2 fl oz}
REFRIGERANT LINES REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer
to REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
L.H.D.

B
C

D
F

R
R

D
F

A
C

B
A
R

R
R

B
A

U17

BASIC SYSTEM

R.H.D.

B
R

R
D

E
B
R
B

C
A
R
A

D
B
A

D
C

A: 6.859.80 Nm {70100 kgfcm, 60.886.7 inlbf}


B: 1521 Nm {1.52.2 kgfm, 1115 ftlbf}
C: 2029 Nm {2.03.0 kgfm, 1521 ftlbf}
D: 9.8119.61 Nm {100200 kgfcm, 86.8173.5 inlbf}
E: 2435 Nm {2.43.6 kgfm, 1826 ftlbf}

Cooler hose (low)


+ Removal Note
+ Refrigerant Lines Removal Note
+ Refrigerant Lines Installation Note

Cooler hose (high)


+ Removal Note
+ Refrigerant Lines Installation Note

Cooler pipe (high)


+ Refrigerant Lines Removal Note
+ Refrigerant Lines Installation Note

Refrigerant Lines Installation Note


1. When installing a new cooler pipe or hose, add
FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2
Cab) compressor oil into the refrigeration cycle.
Supplemental amount
Cooler hose (low): 8 ml {8 cc, 0.3 fl oz}
Cooler hose (high): 5 ml {5 cc, 0.2 fl oz}
Cooler pipe: 3 ml {3 cc, 0.1 fl oz}
2. Apply compressor oil to the O-rings and connect
the joints.
3. Tighten the joints.
(1) Tighten the nut or bolt of the joint by hand.
(2) Tighten the joint to the specified torque. If it is a
nut joint, tighten the nut using a spanner and
torque wrench.

Cooler Hose Removal Note


WL turbo only
 Loosen the A/C compressor bolts, then slide the
A/C compressor, and remove the cooler hose bolt
from the A/C compressor.
Refrigerant Lines Removal Note
 Loosen the nut using two spanners, then remove
the cooler pipe or hose.

U18

CONTROL SYSTEM

CONTROL SYSTEM
STRUCTURAL VIEW
L.H.D.
A/C RELAY No.2*

A/C RELAY No.1

REFRIGERANT PRESSURE SWITCH

MAGNETIC CLUTCH

CLIMATE
CONTROL UNIT

THERMOSWITCH
RESISTOR

BLOWER MOTOR

R.H.D.

REFRIGERANT PRESSURE SWITCH


MAGNETIC CLUTCH
A/C RELAY No.2*

A/C RELAY No.1

CLIMATE
CONTROL UNIT

THERMOSWITCH

RESISTOR
BLOWER MOTOR

* F2 Cab only

U19

CONTROL SYSTEM
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. Adjust the magnetic clutch clearance. (Refer to
MAGNETIC CLUTCH CLEARANCE
ADJUSTMENT.)

Stator Removal Note


 Set a straight-socket (17 mm {0.67 in}) on the shaft
of the A/C compressor to protect it.
 Remove the stator using a pulley puller as shown
in the table.
STRAIGHT-SOCKET
(17 mm {0.67 in})

10.115.0 N
{102153
89132
kgf
inlbf}

Stator Installation Note


 Install the stator perpendicularly using the SST and
a pulley puller as shown in the table.

49 H061 005

Bolt
+ Removal/Installation Note

Pressure plate
+ Installation Note

Shim

Snap ring

A/C compressor pulley

Stator
+ Removal Note
+ Installation Note

Pressure Plate Installation Note


 When installing the pressure plate, carry out
magnetic clutch clearance adjustment.

Bolt Removal/Installation Note


 When removing or installing the bolt, hold the
pressure plate in place as shown in the table.
BOLT

A/C COMPRESSOR

MAGNETIC CLUTCH CLEARANCE ADJUSTMENT


G6, WL, WL turbo Only
1. Set the A/C compressor on a level block.
2. Turn on the magnetic clutch by connecting the
battery positive voltage to the magnetic clutch
connector terminal and the ground to the A/C
compressor body.
3. Fix a dial gauge on a magnetic base and set the
measuring probe onto point A on the pressure
plate surface.

U20

CONTROL SYSTEM
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. Adjust the magnetic clutch clearance. (Refer to
MAGNETIC CLUTCH CLEARANCE
ADJUSTMENT.)

Stator Removal Note


 Set a straight-socket (17 mm {0.67 in}) on the shaft
of the A/C compressor to protect it.
 Remove the stator using a pulley puller as shown
in the table.
STRAIGHT-SOCKET
(17 mm {0.67 in})

10.115.0 N
{102153
89132
kgf
inlbf}

Stator Installation Note


 Install the stator perpendicularly using the SST and
a pulley puller as shown in the table.

49 H061 005

Bolt
+ Removal/Installation Note

Pressure plate
+ Installation Note

Shim

Snap ring

A/C compressor pulley

Stator
+ Removal Note
+ Installation Note

Pressure Plate Installation Note


 When installing the pressure plate, carry out
magnetic clutch clearance adjustment.

Bolt Removal/Installation Note


 When removing or installing the bolt, hold the
pressure plate in place as shown in the table.
BOLT

A/C COMPRESSOR

MAGNETIC CLUTCH CLEARANCE ADJUSTMENT


G6, WL, WL turbo Only
1. Set the A/C compressor on a level block.
2. Turn on the magnetic clutch by connecting the
battery positive voltage to the magnetic clutch
connector terminal and the ground to the A/C
compressor body.
3. Fix a dial gauge on a magnetic base and set the
measuring probe onto point A on the pressure
plate surface.

U20

CONTROL SYSTEM
3. If not within the specification, remove the pressure
plate and adjust the clearance by changing the
shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5
mm {0.020 in}) or the number of shims.

4. Turn off the magnetic clutch by disconnecting the


ground from the A/C compressor body, then
measure the dial gauge readings.
5. Measure the clearance for point B and C on the
pressure plate surface by repeating the above
steps 2 through 4.

MAGNETIC CLUTCH INSPECTION


1. Disconnect the magnetic clutch connector.
2. Connect battery positive voltage to terminal A of
magnetic clutch and ground to the A/C compressor
body.

Clearance
0.350.75 mm {0.0140.029 in}
MEASURING POINT
A

6. If the clearance is not as specified, adjust it by


changing the shim.

Note
 The seven shim sizes from 0.7 mm {0.028 in}
to 1.3 mm {0.051 in} differ in 0.1 mm {0.004 in}
increments.

3. Verify that the magnetic clutch operates.


4. If not as specified, replace the stator.
A/C RELAY No.1 REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
F2, F2 Cab Only
1. Measure the clearance around the entire
circumference between the pressure plate and A/C
compressor pulley using a thickness gauge.

2. Verify that the clearance is within the specification.


Clearance
0.30.6 mm {0.010.02 in}

U21

Connector

A/C relay No.1

CONTROL SYSTEM
3. If not within the specification, remove the pressure
plate and adjust the clearance by changing the
shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5
mm {0.020 in}) or the number of shims.

4. Turn off the magnetic clutch by disconnecting the


ground from the A/C compressor body, then
measure the dial gauge readings.
5. Measure the clearance for point B and C on the
pressure plate surface by repeating the above
steps 2 through 4.

MAGNETIC CLUTCH INSPECTION


1. Disconnect the magnetic clutch connector.
2. Connect battery positive voltage to terminal A of
magnetic clutch and ground to the A/C compressor
body.

Clearance
0.350.75 mm {0.0140.029 in}
MEASURING POINT
A

6. If the clearance is not as specified, adjust it by


changing the shim.

Note
 The seven shim sizes from 0.7 mm {0.028 in}
to 1.3 mm {0.051 in} differ in 0.1 mm {0.004 in}
increments.

3. Verify that the magnetic clutch operates.


4. If not as specified, replace the stator.
A/C RELAY No.1 REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
F2, F2 Cab Only
1. Measure the clearance around the entire
circumference between the pressure plate and A/C
compressor pulley using a thickness gauge.

2. Verify that the clearance is within the specification.


Clearance
0.30.6 mm {0.010.02 in}

U21

Connector

A/C relay No.1

CONTROL SYSTEM
A/C RELAY No.1 INSPECTION
1. Remove the A/C relay No.1.
2. Inspect for continuity between the A/C relay No.1
terminals using an ohmmeter.
: Continuity B+: Battery positive voltage

B
C

Terminal

Step

B+

GND

3. If not as specified, replace the A/C relay No.2.

REFRIGERANT PRESSURE SWITCH REMOVAL/


INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer
to REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
3. Remove the radiator grille.

B
123456567

3. If not as specified, replace the A/C relay No.1.

Caution
 If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

A/C RELAY NO.2 REMOVAL/INSTALLATION


1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

4. Remove as indicated in the table.


5. Install in the reverse order of removal.
6. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)

5.97.8 Nm
{6080 kgfcm,
5369 inlbf}

Connector

A/C relay No.2

A/C RELAY NO.2 INSPECTION


1. Remove the A/C relay No.2.
2. Inspect for continuity between the A/C relay No.2
terminals using an ohmmeter.
: Continuity B+: Battery positive voltage
Step

Terminal
B

1
2

B+

GND

Connector

Refrigerant pressure switch


+ Installation Note

Refrigerant Pressure Switch Installation Note


 Apply compressor oil to the O-ring and connect the
joint.

123456567

U22

CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH INSPECTION
1. Install the SSTs (manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Disconnect the refrigerant pressure switch
connector.
3. Verify the high-pressure side reading of the SST
(Manifold gauge).
4. Inspect for continuity between the terminals of the
refrigerant pressure switch using an ohmmeter.
0.180.21
{1.82.2, 2631}

WITH HEATER
CORE
A

WITHOUT
HEATER CORE
A

3.03.3
{3034, 427483}

CONTINUITY

7. If not as specified, inspect on/off points of the


thermoswitch.

NO CONTINUITY
0.02 {0.25, 3.56}
OR LESS

0.40.7
{4.08.0, 57113}
MPa { kgf/cm2 , psi }

5. If not as specified, replace the refrigerant pressure


switch.
THERMOSWITCH INSPECTION
To Determine if the Switch is Functioning
1. Remove the glove compartment.
2. Start the engine.
3. Turn the fan switch on.
4. Turn the A/C switch on.
5. Connect the positive (+) and negative () probes of
the voltmeter to terminal A and terminal B of the
thermoswitch respectively. (The wiring harness
connector must be connected to the thermoswitch
connector.)
6. Inspect the voltage as shown below.

To Inspect On/Off Points of the Thermoswitch


1. Disconnect the negative battery cable.
2. Remove the cooling unit (Refer to BASIC
SYSTEM, COOLING UNIT
REMOVAL/INSTALLATION.)
3. Remove the thermoswitch. (Refer to BASIC
SYSTEM, COOLING UNIT
DISASSEMBLY/ASSEMBLY.)
4. Connect the negative battery cable.
5. Connect the thermoswitch connector to the wiring
harness connector.
6. Turn the ignition switch to ON position.
7. Turn the A/C switch on.
8. Turn the fan switch on.
9. Immerse the sensor part of thermoswitch in a
container of ice water.
10. Connect the positive (+) and negative () probes of
the voltmeter to terminal A and terminal B of the
thermoswitch respectively.
11. Inspect the voltage as shown below.
WITH HEATER CORE

: Continuity
Water temperature
temperat re

WITHOUT HEATER CORE

: Continuity
Temperature
control dial
position
MAX COLD

Terminal
A

1C {34F} or less

: Continuity
Magnetic clutch
cl tch

Terminal

3C {37F} or more

WITH HEATER CORE

1/2

On
Off

MAX WARM

Water temperature
temperat re

Terminal
A

03C {3237F}
3C {37F} or more
711C {4552F}

123456567

11C {52F} or more


1418C {5764F}
18C {64F} or more

WITHOUT HEATER CORE

: Continuity
Magnetic clutch
cl tch

Terminal
A

B
123456567

On
Off
123456567

U23

CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH INSPECTION
1. Install the SSTs (manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Disconnect the refrigerant pressure switch
connector.
3. Verify the high-pressure side reading of the SST
(Manifold gauge).
4. Inspect for continuity between the terminals of the
refrigerant pressure switch using an ohmmeter.
0.180.21
{1.82.2, 2631}

WITH HEATER
CORE
A

WITHOUT
HEATER CORE
A

3.03.3
{3034, 427483}

CONTINUITY

7. If not as specified, inspect on/off points of the


thermoswitch.

NO CONTINUITY
0.02 {0.25, 3.56}
OR LESS

0.40.7
{4.08.0, 57113}
MPa { kgf/cm2 , psi }

5. If not as specified, replace the refrigerant pressure


switch.
THERMOSWITCH INSPECTION
To Determine if the Switch is Functioning
1. Remove the glove compartment.
2. Start the engine.
3. Turn the fan switch on.
4. Turn the A/C switch on.
5. Connect the positive (+) and negative () probes of
the voltmeter to terminal A and terminal B of the
thermoswitch respectively. (The wiring harness
connector must be connected to the thermoswitch
connector.)
6. Inspect the voltage as shown below.

To Inspect On/Off Points of the Thermoswitch


1. Disconnect the negative battery cable.
2. Remove the cooling unit (Refer to BASIC
SYSTEM, COOLING UNIT
REMOVAL/INSTALLATION.)
3. Remove the thermoswitch. (Refer to BASIC
SYSTEM, COOLING UNIT
DISASSEMBLY/ASSEMBLY.)
4. Connect the negative battery cable.
5. Connect the thermoswitch connector to the wiring
harness connector.
6. Turn the ignition switch to ON position.
7. Turn the A/C switch on.
8. Turn the fan switch on.
9. Immerse the sensor part of thermoswitch in a
container of ice water.
10. Connect the positive (+) and negative () probes of
the voltmeter to terminal A and terminal B of the
thermoswitch respectively.
11. Inspect the voltage as shown below.
WITH HEATER CORE

: Continuity
Water temperature
temperat re

WITHOUT HEATER CORE

: Continuity
Temperature
control dial
position
MAX COLD

Terminal
A

1C {34F} or less

: Continuity
Magnetic clutch
cl tch

Terminal

3C {37F} or more

WITH HEATER CORE

1/2

On
Off

MAX WARM

Water temperature
temperat re

Terminal
A

03C {3237F}
3C {37F} or more
711C {4552F}

123456567

11C {52F} or more


1418C {5764F}
18C {64F} or more

WITHOUT HEATER CORE

: Continuity
Magnetic clutch
cl tch

Terminal
A

B
123456567

On
Off
123456567

U23

CONTROL SYSTEM

WITH HEATER
CORE
A

BLOWER MOTOR INSPECTION


1. Remove the glove compartment.
2. Disconnect the blower motor connector.
3. Connect battery positive voltage to terminal B and
ground to terminal A of the blower motor, and verify
its operation.

WITHOUT
HEATER CORE
A

12. If not as specified, replace the thermoswitch.


(Refer to BASIC SYSTEM, COOLING UNIT
DISASSEMBLY/ASSEMBLY.)
BLOWER MOTOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove as indicated in the table.
4. Install in the reverse order of removal.

Connector

Blower motor

4. If not as specified, replace the blower motor.


RESISTOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove as indicated in the table.
4. Install in the reverse order of removal.

U24

Connector

Resistor

CONTROL SYSTEM

WITH HEATER
CORE
A

BLOWER MOTOR INSPECTION


1. Remove the glove compartment.
2. Disconnect the blower motor connector.
3. Connect battery positive voltage to terminal B and
ground to terminal A of the blower motor, and verify
its operation.

WITHOUT
HEATER CORE
A

12. If not as specified, replace the thermoswitch.


(Refer to BASIC SYSTEM, COOLING UNIT
DISASSEMBLY/ASSEMBLY.)
BLOWER MOTOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove as indicated in the table.
4. Install in the reverse order of removal.

Connector

Blower motor

4. If not as specified, replace the blower motor.


RESISTOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove as indicated in the table.
4. Install in the reverse order of removal.

U24

Connector

Resistor

CONTROL SYSTEM
RESISTOR INSPECTION
1. Remove the glove compartment.
2. Disconnect the resistor connector.
3. Verify that the resistance between the terminals of
the resistor is as shown in the table.
Terminal

Resistance ()

1A1B (2A)

R1: 0.430.47

1A1C

R2: 1.041.16

1C1D

R3: 1.471.63

R3

1D

R2

1C

R1

1A

1B

2A

1C

1A

1D

1B

CLIMATE CONTROL UNIT INSTALLATION


1. Connect the climate control unit connectors.
2. Insert the climate control unit until each clip clicks.

3. Adjust the wire of the climate control unit. (Refer to


CLIMATE CONTROL UNIT WIRE ADJUSTMENT.)
4. Install the glove compartment.
5. Connect the negative battery cable.

2A

Climate Control Unit Removal/Installation Note


With heater core
 Set the temperature control dial at MAX COLD, the
airflow mode control dial at DEF.

4. If not as specified, replace the resistor.


CLIMATE CONTROL UNIT REMOVAL
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Disconnect the air intake wire from the blower unit.
4. Disconnect the air mix wire and airflow mode wire
from the heater unit.
5. With the beveled parts of the SST facing inward,
insert them into the climate control unit.
6. Pull the SST outward and rearward to slide out the
climate control unit.

CLIMATE CONTROL UNIT


DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
WITH HEATER CORE

49 D066 801A

7. Disconnect the climate control unit connectors.

U25

CONTROL SYSTEM
RESISTOR INSPECTION
1. Remove the glove compartment.
2. Disconnect the resistor connector.
3. Verify that the resistance between the terminals of
the resistor is as shown in the table.
Terminal

Resistance ()

1A1B (2A)

R1: 0.430.47

1A1C

R2: 1.041.16

1C1D

R3: 1.471.63

R3

1D

R2

1C

R1

1A

1B

2A

1C

1A

1D

1B

CLIMATE CONTROL UNIT INSTALLATION


1. Connect the climate control unit connectors.
2. Insert the climate control unit until each clip clicks.

3. Adjust the wire of the climate control unit. (Refer to


CLIMATE CONTROL UNIT WIRE ADJUSTMENT.)
4. Install the glove compartment.
5. Connect the negative battery cable.

2A

Climate Control Unit Removal/Installation Note


With heater core
 Set the temperature control dial at MAX COLD, the
airflow mode control dial at DEF.

4. If not as specified, replace the resistor.


CLIMATE CONTROL UNIT REMOVAL
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Disconnect the air intake wire from the blower unit.
4. Disconnect the air mix wire and airflow mode wire
from the heater unit.
5. With the beveled parts of the SST facing inward,
insert them into the climate control unit.
6. Pull the SST outward and rearward to slide out the
climate control unit.

CLIMATE CONTROL UNIT


DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
WITH HEATER CORE

49 D066 801A

7. Disconnect the climate control unit connectors.

U25

CONTROL SYSTEM
WITHOUT HEATER CORE

CLIMATE CONTROL UNIT WIRE ADJUSTMENT


Air Intake Wire
1. Set the air intake lever at FRESH.
2. Set the air intake link to FRESH in the direction of
the arrow and insert a screwdriver into the set hole.
L.H.D.

AIR INTAKE WIRE

SET HOLE

R.H.D.
AIR INTAKE WIRE

Dial

Knob
+ Removal Note

A/C switch

Panel

Fan switch

Climate control unit harness

Illumination bulb

A/C amplifer

Air mix wire

10

Airflow mode wire

11

Air intake wire

11

Cap

13

Body

SET HOLE

3. Connect the air intake wire to the air intake link.


4. Clamp the air intake wire to wire clamp.
5. Verify that the air intake lever moves its full stroke.
Air Mix Wire (With heater core only)
1. Set the temperature control dial at MAX COLD.
2. Set the air mix link to MAX COLD in the direction of
the arrow and insert a screwdriver into the set hole.

SET HOLE

Knob Removal Note


 Use a wire to push the knob from the reverse side
and remove it as shown in the figure.

AIR MIX WIRE

WIRE

3. Connect the air mix wire to the air mix link.


4. Clamp the air mix wire to wire clamp.
5. Verify that the temperature control dial moves its
full stroke.

KNOB

U26

CONTROL SYSTEM
WITHOUT HEATER CORE

CLIMATE CONTROL UNIT WIRE ADJUSTMENT


Air Intake Wire
1. Set the air intake lever at FRESH.
2. Set the air intake link to FRESH in the direction of
the arrow and insert a screwdriver into the set hole.
L.H.D.

AIR INTAKE WIRE

SET HOLE

R.H.D.
AIR INTAKE WIRE

Dial

Knob
+ Removal Note

A/C switch

Panel

Fan switch

Climate control unit harness

Illumination bulb

A/C amplifer

Air mix wire

10

Airflow mode wire

11

Air intake wire

11

Cap

13

Body

SET HOLE

3. Connect the air intake wire to the air intake link.


4. Clamp the air intake wire to wire clamp.
5. Verify that the air intake lever moves its full stroke.
Air Mix Wire (With heater core only)
1. Set the temperature control dial at MAX COLD.
2. Set the air mix link to MAX COLD in the direction of
the arrow and insert a screwdriver into the set hole.

SET HOLE

Knob Removal Note


 Use a wire to push the knob from the reverse side
and remove it as shown in the figure.

AIR MIX WIRE

WIRE

3. Connect the air mix wire to the air mix link.


4. Clamp the air mix wire to wire clamp.
5. Verify that the temperature control dial moves its
full stroke.

KNOB

U26

CONTROL SYSTEM
Airflow Mode Wire
1. Set the airflow mode control dial at DEF.
2. Set the airflow mode link to DEF in the direction of
the arrow and insert a screwdriver into the set hole.
SET HOLE

Fan Switch
1. Remove the climate control unit. (Refer to
CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the fan switch
terminals using an ohmmeter.
: Continuity
Terminal

Switch
position

0
1
2
3

AIRFLOW
MODE
WIRE

3. Connect the airflow mode wire to the airflow mode


link.
4. Clamp the airflow mode wire to wire clamp.
5. Verify that the airflow mode control dial moves its
full stroke.
CLIMATE CONTROL UNIT INSPECTION
A/C Switch
1. Remove the climate control unit. (Refer to
CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the A/C switch
terminals using an ohmmeter.
: Continuity
Terminal

Switch
position

OFF
ON

123456567

3. Connect battery positive voltage to terminal C and


ground to the terminal A.
4. Turn the A/C switch on.
5. Verify that the LED illuminaltes.
6. If not as specified, replace the A/C switch.

U27

B C

123456567
E C A

3. If not as specified, replace the fan switch.

CONTROL SYSTEM
Airflow Mode Wire
1. Set the airflow mode control dial at DEF.
2. Set the airflow mode link to DEF in the direction of
the arrow and insert a screwdriver into the set hole.
SET HOLE

Fan Switch
1. Remove the climate control unit. (Refer to
CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the fan switch
terminals using an ohmmeter.
: Continuity
Terminal

Switch
position

0
1
2
3

AIRFLOW
MODE
WIRE

3. Connect the airflow mode wire to the airflow mode


link.
4. Clamp the airflow mode wire to wire clamp.
5. Verify that the airflow mode control dial moves its
full stroke.
CLIMATE CONTROL UNIT INSPECTION
A/C Switch
1. Remove the climate control unit. (Refer to
CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the A/C switch
terminals using an ohmmeter.
: Continuity
Terminal

Switch
position

OFF
ON

123456567

3. Connect battery positive voltage to terminal C and


ground to the terminal A.
4. Turn the A/C switch on.
5. Verify that the LED illuminaltes.
6. If not as specified, replace the A/C switch.

U27

B C

123456567
E C A

3. If not as specified, replace the fan switch.

TROUBLESHOOTING

TROUBLESHOOTING
FOREWORD
 Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures.
 When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and
undamaged.
 The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to
verify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEX
No.

Malfunction symptom

Insufficient blown air volume and/or no blown air depending on airflow mode.

No blown air in any airflow mode.


Blown air volume does not change at any fan speed.

Airflow mode does not change.

Improper air circulation and/or no air circulation.

No temperature control.(For climate control unit without variable thermistor only)

Air from vent not cold enough.

No cool air.

Noise while operating A/C system.

SYMPTOM TROUBLESHOOTING
1

Insufficient blown air volume and/or no blown air depending on airflow mode.

TROUBLESHOOTING HINTS
1 Malfunction in VENT mode system
Steps 14
2 Malfunction in HEAT mode system
Step 5
3 Malfunction in DEFROSTER mode system
Steps 68
STEP
1

2
3
4

INSPECTION

ACTION

When airflow mode control dial is operated, is


appropriate resistance felt and can it be moved
throughout its full range?

Yes

Go to next step.

No

Go to Step 1 of troubleshooting index No. 3.

Does air blow out when in VENT mode?

Yes

Go to Step 5.

No

Go to next step.

Yes

Remove obstruction, then go to Step 9.

No

Go to next step.

Yes

Inspect duct for clogging, deformity and air


leakage, then go to Step 9.

No

Install duct securely in the proper position, then


go to Step 9.

Is vent clogged?
Is duct in dashboard properly installed?

Does air blow out when in HEAT mode?

Yes

Go to next step.

No

Inspect vent for clogging, then go to Step 9.

Does air blow out when in DEFROSTER mode?

Yes

Operation is okay. Recheck malfunction


symptoms.

No

Go to next step.

Is vent clogged?

Yes

Remove obstruction, then go to Step 9.

No

Go to next step.

Is defroster duct properly installed?

Yes

Inspect duct for clogging, deformity, and air


leakage, then go to next step.

No

Install duct securely in the proper position, then


go to next step.

U28

TROUBLESHOOTING

TROUBLESHOOTING
FOREWORD
 Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures.
 When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and
undamaged.
 The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to
verify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEX
No.

Malfunction symptom

Insufficient blown air volume and/or no blown air depending on airflow mode.

No blown air in any airflow mode.


Blown air volume does not change at any fan speed.

Airflow mode does not change.

Improper air circulation and/or no air circulation.

No temperature control.(For climate control unit without variable thermistor only)

Air from vent not cold enough.

No cool air.

Noise while operating A/C system.

SYMPTOM TROUBLESHOOTING
1

Insufficient blown air volume and/or no blown air depending on airflow mode.

TROUBLESHOOTING HINTS
1 Malfunction in VENT mode system
Steps 14
2 Malfunction in HEAT mode system
Step 5
3 Malfunction in DEFROSTER mode system
Steps 68
STEP
1

2
3
4

INSPECTION

ACTION

When airflow mode control dial is operated, is


appropriate resistance felt and can it be moved
throughout its full range?

Yes

Go to next step.

No

Go to Step 1 of troubleshooting index No. 3.

Does air blow out when in VENT mode?

Yes

Go to Step 5.

No

Go to next step.

Yes

Remove obstruction, then go to Step 9.

No

Go to next step.

Yes

Inspect duct for clogging, deformity and air


leakage, then go to Step 9.

No

Install duct securely in the proper position, then


go to Step 9.

Is vent clogged?
Is duct in dashboard properly installed?

Does air blow out when in HEAT mode?

Yes

Go to next step.

No

Inspect vent for clogging, then go to Step 9.

Does air blow out when in DEFROSTER mode?

Yes

Operation is okay. Recheck malfunction


symptoms.

No

Go to next step.

Is vent clogged?

Yes

Remove obstruction, then go to Step 9.

No

Go to next step.

Is defroster duct properly installed?

Yes

Inspect duct for clogging, deformity, and air


leakage, then go to next step.

No

Install duct securely in the proper position, then


go to next step.

U28

CONTROL SYSTEM

STEP
9

INSPECTION

ACTION

Does air blow out?

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

No blown air in any airflow mode.


Blown air volume does not change at any fan speed.

TROUBLESHOOTING HINTS
1 Blower motor, resistor, fan switch malfunction
Step 1
2 Blower unit malfunction
Steps 24
STEP
1

INSPECTION

ACTION

Inspect the following systems and electrical parts:


 Blower motor, resistor, fan switch.
Are they okay?

Yes

Go to next step.

No

Repair or replace malfunctioning part, then go to


Step 5.

Turn ignition switch to ON position.


Turn fan switch on.
on
Is noise coming from blower unit?

Yes

Go to next step.

No

Go to Step 4.

Inspect fan in blower unit.


 Is fan free of interference from blower unit
case?
 Is fan free of foreign material and
obstructions?
Is fan okay?

Yes

Go to next step.

No

Remove obstruction, repair or replace fan and


blower unit case, then go to Step 5.

Is blower unit intake vent clogged?

Yes

Remove obstruction, then go to next step.

No

Inspect if there are any obstructions in passage


between blower unit and heater unit, then go to
next step.

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

Does air blow out?

Airflow mode does not change.

TROUBLESHOOTING HINTS
1 Malfunction in heater units airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow
mode wire or wire clamp
Steps 1, 2
2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunction
Step 3
3 Malfunction in one or more heater unit doors
Steps 4, 5
STEP
1

INSPECTION

ACTION

Inspect heater units airflow mode main link,


airflow mode rod, airflow mode cranks, airflow
mode sub links, airflow mode wire and wire
clamp.
 Is there g
grease on airflow mode main link,,
airflow mode cranks and airflow mode sub
links?
 Are airflow mode main link, airflow mode rod,
airflow mode cranks, and airflow mode sub
links installed securely and in the proper
position?
 Is wire clamp free of deformation?
Are above items all okay?

Yes

Go to next step.

No

Apply grease or install airflow mode main link,


airflow mode rod, airflow mode cranks and airflow
mode sub links securely in their proper positions,
repair wire clamp, then go to Step 6.

U29

TROUBLESHOOTING

STEP
2

4
5

INSPECTION

ACTION

Is airflow mode wire positioned securely and


correctly in relation to the heater units airflow
mode main link?

Yes

Go to next step.

No

Adjust airflow mode wire or install it correctly, then


go to Step 6.

Inspect climate control unit.


 Is bevel g
gear set properly
y engaged?
g g
 Is airflow mode wire properly installed in
correct direction on bevel gear?
 Is wire clamp free of deformation?
Are above items okay?

Yes

Go to next step.

No

Properly engage bevel gear set or install airflow


mode wire in correct direction, repair or replace
wire clamp, then go to Step 6.

Is there any foreign material or obstruction in any


of heater units doors?

Yes

Remove obstruction, then go to Step 6.

No

Go to next step.

Are all doors within heater unit securely and


properly positioned?

Yes

Inspect each door for cracks or damage, then go


to next step.

No

Install malfunction doors securely in proper


position, then go to next step.

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

Does airflow mode change?

Improper air circulation and/or no air circulation.

TROUBLESHOOTING HINTS
1 Malfunction in blower units air intake crank, air intake link, air intake wire or wire clamp
Steps 1, 2
2 Climate control unit air intake wire or wire clamp malfunction
Step 3
3 Blower unit air intake door malfunction
Steps 4, 5
STEP
1

INSPECTION

ACTION

Inspect blower units air intake crank, air intake


link and wire clamp.
 Is there grease
g
on air intake crank and air
intake link?
 Are air intake crank and air intake link securely
and properly positioned?
 Is wire clamp free of deformation?
Are above items okay?

Yes

Go to next step.

No

Apply grease or install air intake crank and air


intake link properly and securely, repair wire
clamp, then go to Step 6.

Is air intake wire positioned securely and correctly


in relation to the blower units air intake link?

Yes

Go to next step.

No

Adjust air intake wire or install securely in correct


position, then go to Step 6.

Inspect climate control unit.


 Is air intake wire properly installed in correct
direction in relation to the air intake lever of
climate control unit?
 Is wire clamp free of deformation?
Are above items okay?

Yes

Go to next step.

No

Install air intake wire securely in correct position,


repair or replace wire clamp, then go to Step 6.

Is there any foreign material or obstruction in


blower units air intake door?

Yes

Remove obstruction, then go to Step 6.

No

Go to next step.

Is blower units air intake door securely and


properly positioned?

Yes

Inspect air intake door for cracks or damage, then


go to next step.

No

Install air intake door securely in proper position,


then go to next step.

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

Does air circulate?

U30

CONTROL SYSTEM

No temperature control.(Without variable thermistor in climate control unit only)

TROUBLESHOOTING HINTS
1 Malfunction in heater units air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp
Steps 2, 3
2 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction
Step 4
3 Heater unit air mix door malfunction
Steps 5, 6
STEP

INSPECTION

ACTION

Is coolant sufficiently warmed up?

Yes

Go to next step.

No

Warm engine up, then go to Step 7.

Inspect heater units air mix rod, air mix link, air
mix cranks, air mix shaft and wire clamp.
 Is there grease
g
on air mix rod,, air mix link and
air mix cranks?
 Are air mix rod, air mix link, air mix cranks, and
air mix shaft securely installed in their proper
positions?
 Is wire clamp free of deformation?
Are above items okay?

Yes

Go to next step.

No

Apply grease or install air mix rod, air mix link, air
mix cranks, and air mix shaft securely in their
proper positions, repair wire clamp, then go to
Step 7.

Is air mix wire securely installed in the correct


position in relation to heater units air mix link?

Yes

Go to next step.

No

Adjust air mix wire or install securely in correct


position, then go to Step 7.

Inspect climate control unit.


 Is bevel g
gear set properly
y engaged?
g g
 Is air mix wire properly installed in correct
position in relation to bevel gear?
 Is wire clamp free of deformation?
Are above items okay?

Yes

Go to next step.

No

Properly engage bevel gear set or install air mix


wire in correct position, repair or replace wire
clamp, then go to Step 7.

Is there any foreign material or obstruction in


heater units air mix door?

Yes

Remove obstruction, then go to Step 7.

No

Go to next step.

Is heater units air mix door securely and properly


installed?

Yes

Inspect door for cracks or damage, then go to


next step.

No

Install door securely in proper position, then go to


next step.

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

Does unit operate in every temperature setting?

Air from vent not cold enough.

TROUBLESHOOTING HINTS
1 Drive belt malfunction
Step 1
2 Malfunction in blower unit or condenser
Steps 4, 5
3 Malfunction in receiver/drier or expansion valve (valve closes too much)
Steps 8, 9
4 Malfunction in refrigerant lines
Steps 10, 11
5 Malfunction in piping connections
Steps 1, 2, 13
6 A/C compressor system malfunction, insufficient compressor oil
Steps 15, 16
7 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system
Steps 1720

U31

TROUBLESHOOTING

STEP
1

INSPECTION

ACTION

Inspect drive belt.


+ Section B1, DRIVE BELT, DRIVE BELT
INSPECTION
+ Section B2, DRIVE BELT, DRIVE BELT
INSPECTION
+ Section B3, DRIVE BELT, DRIVE BELT
INSPECTION
Is it okay?

Yes

Go to next step.

No

Adjust or replace drive belt, then go to Step 21.


+ Section B1, DRIVE BELT, DRIVE BELT
ADJUSTMENT
+ Section B2, DRIVE BELT, DRIVE BELT
ADJUSTMENT
+ Section B3, DRIVE BELT, DRIVE BELT
ADJUSTMENT

Carry out refrigerant system performance test.


+ REFRIGERANT SYSTEM SERVICE
PROCEDURES PERFORMANCE TEST
PROCEDURES,
Is operation normal?

Yes

Operation is normal. (Recheck malfunction


symptoms.)

No

Go to next step.

Are refrigerants high-pressure and low-pressure


values both high?

Yes

Go to next step.

No

Go to Step 6.

Is blower unit intake clogged?

Yes

Remove obstruction, then go to Step 21. (If air


does not reach evaporator within cooling unit,
heat exchange does not occur and refrigerant
pressure rises. Therefore, removal of obstruction
is necessary.)

No

Go to next step.

Inspect condenser.
+ BASIC SYSTEM, CONDENSER INSPECTION
Is it okay?

Yes

Add or subtract refrigerant to make specified


amount, then go to Step 21. (Excessive amount
of refrigerant.)

No

Replace condenser, or repair and clean


condenser fins, then go to Step 21.

Are refrigerants high-pressure and low-pressure


values both low?

Yes

Go to next step.

No

Go to Step 14.

Immediately after A/C compressor operates, does


refrigerants
high-pressure
value momentarily
g
g
y rise
to correct value, then fall and stay below it? (Is
there negative pressure on low-pressure side?)

Yes

Go to next step.

No

Go to Step 10.

Turn A/C switch off and let air conditioner stop for
10 minutes.
min tes
Start engine.
Turn both A/C switch and fan switch on.
Does malfunction occur after A/C compressor
turns on?

Yes

Go to next step.

No

Start vacuum pump for 30 minutes and replace


receiver/drier, then go to Step 21. (Since
receiver/drier has become saturated with water,
replacement is necessary.)

Is expansion valve heat-sensing tube within


cooling unit securely installed in proper position?

Yes

Replace expansion valve, then go to Step 21.


(Since valve closes too much, replacement is
necessary.)

No

Install heat-sensing tube securely in proper


position, then go to Step 21.

Yes

Go to next step.

No

If piping or an A/C component is damaged or


cracked, replace it. Then go to Step 21. If there is
no damage, go to Step 13.

6
7

10

Inspect refrigerant lines.


 Is piping free of damage and cracks?
 Are piping connections free of oil grime?
(Visual inspection)
 Are piping connections free of gas leakage?
 Are piping installation points on condenser free
of gas
g leakage?
g
 Are piping installation points on receiver/drier
free of gas leakage?
 Are piping installation points on A/C
compressor free of gas leakage?
 Are piping installation points on cooling unit
free of gas leakage?
*Perform gas leak inspection using gas leak
tester.
Are above items okay?

U32

CONTROL SYSTEM

STEP
11

12

13

14
15
16

17
18

INSPECTION

ACTION

Are piping connections for evaporator in cooling


unit free of gas leakage?

Yes

If the A/C compressor is making noise, add


10 ml {10 cc, 0.34 fl oz} of compressor oil and
verify that malfunction does not occur.
Add or subtract refrigerant to make specified
amount, then go to Step 21.

No

If piping is damaged or cracked, replace it. Then


go to Step 21. If there is no damage, go to next
step.

Yes

Tighten connections to specified torque. If the A/C


compressor is making noise, add 10 ml {10 cc,
0.34 fl oz} of compressor oil and verify that
malfunction does not occur.
Tighten connections to specified torque, add or
subtract refrigerant to make specified amount,
then go to Step 21.

No

If the A/C compressor is making noise, add


10 ml {10 cc, 0.34 fl oz} of compressor oil and
verify that malfunction does not occur.
Replace O-ring on piping, add or subtract
refrigerant to make specified amount, then go to
Step 21.

Yes

Tighten connections to specified torque. If the A/C


compressor is making noise, add 10 ml {10 cc,
0.34 fl oz} of compressor oil and verify that
malfunction does not occur.
Tighten connections to specified torque, add or
subtract refrigerant to make specified amount,
then go to Step 21.

No

If the A/C compressor is making noise, add 10 ml


{10 cc, 0.34 fl oz} of compressor oil and verify
that malfunction does not occur.
Replace O-ring on piping, add or subtract
refrigerant to make specified amount, then go to
Step 21.

Does refrigerants high-pressure value hardly


increase?

Yes

Go to next step. (Pressure hardly increases.)

No

Go to Step 17.

When engine is racing, does high-pressure value


increase?

Yes

Return to Step 3.

No

Go to next step.

After compressor oil is replenished each 10 ml


{10 cc, 0.34 fl oz}, does high-pressure value
increase?

Yes

Troubleshooting completed. (Explain to customer


that cause was insufficient compressor oil.)

No

Replace A/C compressor, then go to Step 21.


(Cause is defective A/C compressor.)

Is only refrigerant low-pressure value high?

Yes

Go to Step 20.

No

Go to next step.

Yes

Go to next step.

No

Repair or install air mix rod, air mix link, air mix
cranks and air mix shaft securely in proper
position, then go to Step 21.

Are piping connections for evaporator in cooling


unit loose?

Are piping connections loose?

Are heater units air mix rod, air mix link, air mix
cranks and air mix shaft securely and properly
installed?

U33

TROUBLESHOOTING

STEP
19

20

21

INSPECTION

ACTION

1.
2.
3.
4.
5.
6.

Set the fan switch at 4th position.


Turn the A/C switch on.
Set to FRESH mode.
Set the temperature control to MAX COLD.
Set to VENT mode.
Run engine at a constant 1,500 rpm for
10 minutes.
7. Run engine at idle speed for 1 minute.
8. 1 engine speed cycle is defined as going from
idle speed to 4,000 rpm and back to idle speed
over a period of 12 seconds.
Perform 5 cycles
cycles.
9. Run engine at idle speed for 30 seconds.
10. Remove all compressor oil from A/C
compressor and verify that it is 105 ml {105 cc,
3.55 fl oz}.
11. If it is more than 105 ml {105 cc, 3.55 fl oz},
put only 105 ml {105 cc, 3.55 fl oz}
back into A/C compressor.
12. Carry out above steps 1 to 10 again and verify
that compressor oil is 105 ml {105cc, 3.55 fl
oz}.
Is there 105 ml {105 cc, 3.55 fl oz} of
compressor oil in A/C compressor?

Yes

Go to Step 21.

No

Carry out 1 to 10 of step 19 again until


compressor oil is 105 ml {105 cc, 3.55 fl oz}.

Is expansion valve heat-sensing tube within


cooling unit securely installed in proper position?

Yes

Replace expansion valve, then go to next step.


(Since valve opens too much, replacement is
necessary.)

No

Install heat-sensing tube securely in proper


position, then go to next step.

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

Does cool air blow out? (Are results of refrigerant


system performance test okay?)

No cool air.

TROUBLESHOOTING HINTS
1 A/C compressor system malfunction
Step 2
2 Incorrect amount of refrigerant
Step 3
3 A/C switch indicator light malfunction
Steps 46
4 A/C relay system malfunction
(WL, WL turbo, F2 Cab) Steps 7, 1113
(G6, F2) Steps 7, 11, 12
5 Refrigerant pressure switch malfunction
Step 8
6 PCM A/C cut-off control system
(WL, WL turbo) Steps 9, 26
(G6, F2) Step 9
7 PCM (IG1 signal) system malfunction
Steps 10, 25
8 Magnetic clutch system malfunction
Step 14
9 PCM (A/C signal) system malfunction
(WL, WL turbo) Steps 15, 20
(G6, F2) Steps 15, 19, 20
(F2 Cab) Step 15
10 Thermoswitch, A/C switch malfunction
(WL, WL turbo, G6, F2) Steps 2124
(F2 Cab) Steps 1618

U34

CONTROL SYSTEM

STEP
1
2

4
*5

*6

*8

*9

*10

INSPECTION

ACTION

Does air blow out?

Yes

Go to next step.

No

Go to Step 1 of troubleshooting indexes 1, 2.

Start engine.
Turn both A/C switch and fan switch on
on.
Does A/C compressor operate?

Yes

Go to Step 1 of troubleshooting index 6.

No

Go to next step.

Inspect refrigerant amount.


+ REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST
Is it okay?

Yes

Go to next step.

No

Add or subtract refrigerant to specified level, then


go to Step 27.

Does A/C switch indicator light illuminate?

Yes

Go to Step 7.

No

Go to next step

Turn ignition switch to ON position.


(With air mix wire) Remove airflow mode wire, air
intake wire and air mix wire. Remove climate
control unit.
(Without air mix wire) Remove airflow mode wire
and air intake wire. Remove climate control unit.
Remove A/C switch from climate control unit and
connect A/C switch connector.
Test voltage at A/C switch terminal C (IG2 signal).
Is voltage approximately 12 V?

Yes

Go to next step.

No

Repair wiring harness between fuse block and


A/C switch, then go to Step 27.

Inspect A/C switch.


+ CONTROL SYSTEM, CLIMATE CONTROL
UNIT INSPECTION
Is it okay?

Yes

Inspect wiring harness between A/C switch and


resistor, then go to Step 27.

No

Replace A/C switch, then go to Step 27.

Are A/C relay power supply fuses okay?

Yes

Go to next step.

No

Check for a short to ground on blown fuses


circuit.
Repair or replace as necessary.
Install appropriate amperage fuse.

Remove radiator grille. Disconnect refrigerant


pressure switch connector. When refrigerant
pressure switch connector terminals A and B (on
wiring harness side) are shorted, does cool air
blow out?

Yes

Inspect refrigerant pressure switch, then go to


Step 27.

No

WL for ISRAEL: Undo short, reconnect


refrigerant pressure switch connector, then go to
Step 10.
Other models: Undo short, reconnect refrigerant
pressure switch connector, then go to next step.

Check the DTC for the PCM ON-BOARD


DIAGNOSTIC SYSTEM.
Are the following DTCs displayed?
 DTC 09 (WL or WL turbo)
 DTC 0120 (F2 or G6)
+ Section F1, ON-BOARD DIAGNOSTIC
SYSTEM, DIAGNOSTIC TROUBLE CODE
INSPECTION
+ Section F2, ON-BOARD DIAGNOSTIC
SYSTEM, DIAGNOSTIC TROUBLE CODE
INSPECTION
+ Section F3, ON-BOARD DIAGNOSTIC
SYSTEM, DIAGNOSTIC TROUBLE CODE
INSPECTION

Yes

Go to appropriate inspection procedure. (The


engine coolant temperature sensor (DTC 09) or
throttle position sensor (DTC 0120), which sends
the PCMs A/C cut off control input signal, may be
the cause of the trouble.)

No

Go to next step.

Turn ignition switch to ON position.


Does magnetic clutch operate when A/C relay
connector terminal B (IG2 signal) is grounded?

Yes

Go to Step 15.

No

Go to next step.

U35

TROUBLESHOOTING

STEP
*11

*12

*13

*14

*15

*16

*17

*18

*19

INSPECTION

ACTION

Turn ignition switch to ON position.


Test voltage at the following A/C relay connector
terminals:
 Terminal A (IG2 signal)
 Terminal C (A/C control signal)
Is voltage approximately 12 V?

Yes

Go to next step.

No

Repair wiring harness between fuse block and


A/C relay, then go to Step 27.

Test voltage at A/C relay terminal D (A/C control


signal).
Is voltage approximately 12 V?

Yes

G6 or F2: Go to Step 14.


Other models: Go to next step.

No

Inspect A/C relay, then go to Step 27.

Disconnect refrigerant pressure switch connector.


Test voltage at refrigerant pressure switch
connector (on wiring harness side) terminal A
(A/C control signal).
Is voltage approximately 12 V?

Yes

Reconnect refrigerant pressure switch connector,


then go to next step.

No

Repair wiring harness between A/C relay and


refrigerant pressure switch, then go to Step 27.

Test voltage at magnetic clutch connector


terminal A (A/C control signal).
Is voltage approximately 12 V?

Yes

Inspect magnetic clutch, then go to Step 27.

No

G6 or F2: Repair wiring harness between A/C


relay and magnetic clutch, then go to Step 27.
Other models: Repair wiring harness between
refrigerant pressure switch and magnetic clutch,
then go to Step 27.

Turn A/C switch off. Remove glove compartment.


Turn ignition switch to ON position. Test voltage
at the following thermoswitch connector terminal
(A/C signal):
 Terminal B (with variable thermistor in climate
control unit)
 Terminal A (without variable thermistor in
climate control unit)
Is voltage approximately 12 V?

Yes

F2 Cab: Go to next step.


Other models: Go to Step 21.

No

F2 Cab: Repair wiring harness between A/C relay


and thermoswitch, then go to Step 27.
G6 or F2: Go to Step 19.
Other models: Go to Step 20.

Turn ignition switch to LOCK position.


Disconnect thermoswitch connector.
Start engine.
Turn both A/C switch and fan switch on.
When following thermoswitch connector terminals
shorted does cool
(on wiring harness side) are shorted,
air blow out?
 Terminal AC (with variable thermistor in
climate control unit)
 Terminal BC (without variable thermistor in
climate control unit)

Yes

Undo short, then go to next step.

No

Undo short, then go to Step 18.

Turn ignition switch to ON position.


Test voltage at the following thermoswitch
connector terminals (IG2 signal):
 Terminal B (with variable thermistor in climate
control unit)
 Terminal A (without variable thermistor in
climate control unit)
Is voltage approximately 12 V?

Yes

Inspect thermoswitch, then go to Step 27.

No

Repair wiring harness between fuse block and


thermoswitch, then go to Step 27.

Turn ignition switch to ON position.


Turn A/C switch on.
Turn fan switch off.
Test voltage at A/C switch connector terminal A
(A/C signal).
Is voltage approximately 12 V?

Yes

Inspect wiring harness between thermoswitch


and A/C switch, then go to Step 27.

No

Inspect A/C switch, then go to Step 27.

Disconnect refrigerant pressure switch connector.


Test voltage at refrigerant pressure switch
connector ((on wiring
g harness side)) terminal A
(A/C control signal).
Is voltage approximately 12 V?

Yes

Repair wiring harness between thermoswitch and


refrigerant pressure switch, then go to Step 27.

No

Go to next step.

U36

CONTROL SYSTEM

STEP
*20

*21

22

*23

*24

*25

*26

27

INSPECTION

ACTION

Turn ignition switch to ON position.


Test voltage at the following PCM connector
terminals (A/C signal):
 Terminal G (WL or WL turbo)
 Terminal Q (G6 or F2)
Is voltage approximately 12 V?

Yes

G6 or F2: Repair wiring harness between PCM and


refrigerant pressure switch, then go to Step 27.
Other models: Repair wiring harness between
PCM and thermoswitch, then go to Step 27.

No

Inspect PCM, then go to Step 27.

Turn ignition switch to LOCK position.


Disconnect thermoswitch connector.
Start engine.
Turn both A/C switch and fan switch on.
When following thermoswitch connector terminals
(on wiring harness side) are shorted,
shorted does cool
air blow out?
 Terminal BC (without variable thermistor in
climate control unit)
 Terminal AC (with variable thermistor in
climate control unit)

Yes

Undo short, then go to next step.

No

Go to Step 23.

Turn ignition switch to ON position.


Test voltage at the following thermoswitch
(
g )
connector terminals (IG2
signal):
 Terminal A (without variable thermistor in
climate control unit)
 Terminal B (with variable thermistor in climate
control unit)
Is voltage approximately 12 V?

Yes

Inspect thermoswitch, then go to Step 27.

No

Repair wiring harness between fuse block and


thermoswitch, then go to Step 27.

Turn ignition switch to ON position.


Turn A/C switch on.
Turn fan switch off.
Test voltage at A/C switch connector terminal A
(A/C signal).
Is voltage approximately 12 V?

Yes

Go to next step.

No

Inspect A/C switch, then go to Step 27.

Test voltage at thermoswitch connector terminal


C (A/C signal).
Is voltage approximately 12 V?

Yes

Go to next step.

No

Repair wiring harness between thermoswitch and


A/C switch, go to Step 27.

Test voltage at the following PCM connector


terminals (A/C signal):
 Terminal L (WL or WL turbo)
 Terminal J (G6 or F2)
Is voltage approximately 12 V?

Yes

WL or WL turbo: Go to next step.


Other models: Recheck malfunction symptoms.

No

Repair wiring harness between A/C relay and


PCM, then go to Step 27.

Inspect the following input signal components:


 Engine coolant temperature sensor and PCM
wiring harness (A/C cut-off control).
Are they okay?

Yes

Recheck malfunction symptoms.

No

Replace input signal components, then go to next


step.

Does cool air blow out? (Is refrigerant system


performance test result correct?)

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

U37

TROUBLESHOOTING

Noise while operating A/C system.

TROUBLESHOOTING HINTS
1 Magnetic clutch operation noise
Step 3
2 A/C compressor operation noise
Steps 48
3 A/C compressor slippage noise
Steps 911
4 Hose or refrigerant line interference noise
Step 12
STEP
1

INSPECTION

ACTION

Is there a squeaking or whirling sound (A/C


compressor slippage noise)?

Yes

Go to Step 9.

No

Go to next step.

Is there a rattling or vibrating sound (interference


noise)?

Yes

Go to Step 12.

No

Go to next step.

Is there a clicking sound (magnetic clutch


operation noise)?

Yes

Adjust clearance between magnetic clutch


pressure plate and A/C compressor pulley, then
go to Step 13.
+ CONTROL SYSTEM, MAGNETIC CLUTCH
CLEARANCE ADJUSTMENT

No

Go to next step.

Is noise heard continuously for more than 3


seconds after A/C compressor comes on?

Yes

Go to next step.

No

Condition is normal. (Noise normally occurs for


23 seconds immediately after A/C compressor
turns on.)

Inspect idle speed.


+ Section F1, ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT
+ Section F2, ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT
+ Section F3, ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT
+ Section F4, ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT
Is it okay?

Yes

Go to next step.

No

Adjust idle speed, then go to Step 13.

Drain compressor oil.


Is it contaminated with metal particles?

Yes

Go to next step.

No

Replace A/C compressor, then go to Step 13.

Is compressor oil whitish and mixed with water?

Yes

Replace entire A/C system (excluding heater),


then go to Step 13.

No

Go to next step.

Is compressor oil darker than normal and


contaminated with aluminum chips?

Yes

Replace A/C compressor and receiver/drier, then


go to Step 13. (Since A/C compressor may be
worn and receiver/drier may be clogged,
replacement of receiver/drier is necessary.)

No

Condition is normal. Recheck malfunction


symptoms.

Inspect drive belt.


+ Section B1, DRIVE BELT, DRIVE BELT
INSPECTION
+ Section B2, DRIVE BELT, DRIVE BELT
INSPECTION
+ Section B3, DRIVE BELT, DRIVE BELT
INSPECTION
Is it okay?

Yes

Go to next step.

No

Adjust or replace drive belt, then go to Step 13.

Is drive belt worn? Does it have foreign material


imbedded in it, or have oil on it?

Yes

Remove obstruction, remove oil, or replace drive


belt, then go to Step 13.

No

Go to next step.

10

U38

CONTROL SYSTEM

STEP

INSPECTION

ACTION

11

Inspect magnetic clutch.


+ CONTROL SYSTEM, MAGNETIC CLUTCH
INSPECTION
Is it okay?

Yes

Replace A/C compressor (excluding pressure


plate, A/C compressor pulley, and stator), then go
to Step 13.

No

Replace magnetic clutch, then go to Step 13.

12

Is noise coming from A/C compressor?

Yes

Visually inspect A/C compressor, replace


appropriate parts if necessary, then go to next
step.

No

If noise is coming from refrigerant lines, repair


any detached or missing clips, tighten loose bolts,
then go to next step.

Yes

Troubleshooting completed. Explain repairs to


customer.

No

Recheck malfunction symptoms, then repeat from


Step 1 if malfunction recurs.

13

Has A/C compressor noise stopped?

U39

TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . .
FUEL AND EMISSION CONTROL
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ELECTRICAL SYSTEM . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSMISSION . . . . . . . . . . . . . . .
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . .
FRONT AND REAR AXLES (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
FRONT AND REAR AXLES (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .

TD
TD
TD
TD

1
1
4
4

TD 5
TD 6
TD10
TD10
TD11
TD11

STEERING SYSTEM . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
BRAKING SYSTEM (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEELS AND TIRES (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
WHEELS AND TIRES (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
BODY ELECTRICAL SYSTEM . . . . . . . . . . .
HEATER AND AIR
CONDITIONER SYSTEMS . . . . . . . . . . . . .

TD12

TECHNICAL DATA
ENGINE
Engine

Item
Generator
Drive belt deflection
[Applied pressure
98 N {10 kgf, 22 lbf}]
(mm {in})

P/S
A/C
Generator

Drive belt tension


(N {kgf, lbf})

P/S
A/C

Compression

(kPa {kgf/cm2, psi} [rpm])

Pushing distance of the front oil seal


(from the edge of the chain cover)
Pushing distance of the rear oil seal
(from the edge of the rear cover)

G6
New

10.012.0 {0.400.47}

Used

12.014.0 {0.480.55}

New

6.67.2 {0.260.28}

Used

7.28.0 {0.290.31}

New

8.510.0 {0.340.39}

Used

10.011.5 {0.400.45}

New

491588 {5060, 110132}

Used

393490 {4050, 88110}

New

412470 {4248, 93105}

Used

354402 {3641, 8090}

New

557641 {56.765.4, 125143}

Used

471556 {48.056.7, 106124}

Standard

1255 {12.8, 182} [270]

Minimum

882.6 {9.0, 128} [270]

(mm {in})
(mm {in})

TD1

00.7 {00.027}
00.5 {00.019}

TD13
TD13
TD14
TD15
TD15
TD17
TD18
TD18

TECHNICAL DATA

Specification

Item

WL

WL Turbo

Type

WLT3

Diesel, 4-cycle

Cylinder arrangement and number

Inline, 4-cylinder

Combustion chamber

Swirl type

Valve system

OHC, timing gear and belt driven,12 valves

Displacement
Bore

WL3

(ml {cc, cu in})

stroke

2,499 {2,499, 152.4}

(mm {in})
Generator

93.0

92.0 {3.66

3.62}

New

7.09.0 {0.280.35}

Used

8.010.0 {0.320.39}

Limit

16.0 {0.63}

A/C (measuring
Drive belt deflection
[Applied pressure 98 N {10 kgf, point a)
22 lbf}]
(mm {in})

New

5.06.2 {0.200.24}

Used

6.06.5 {0.240.25}

Limit

11.3 {0.44}

A/C (measuring
point b)

New

9.511.8 {0.380.46}

Used

11.012.5 {0.440.49}

Limit

18.0 {0.71}

New

442637 {4565, 99143}

Used

383539 {3955, 86121}

Limit

177 {18, 40}

New

403519 {4153, 91116}

Used

354431 {3644, 8096}

Limit

181 {18.5, 41}

Generator

Drive belt tension


(N {kgf, lbf})

A/C

Timing belt deflection


[Applied pressure 98 N {10 kgf, 22 lbf}]

(mm {in})

Bolt head mark W


Cylinder head bolt length
(mm {in})
Bolt head mark N

Standard

9.010.0 {0.360.39}

Standard

101.2101.8 {3.9854.007}

Minimum

102.5 {4.035}

Standard

113.2113.8 {4.4574.480}

Minimum

114.5 {4.508}

Camshaft oil seal tapping amount

(mm {in})

0.51.0 {0.020.03}

Front oil seal tapping amount

(mm {in})

00.4 {00.01}

Rear oil seal tapping amount

(mm {in})

Compression ratio

21.9,

Compression pressure
IN
Valve timing
EX

(kPa

{kgf/cm2,

psi} [rpm])

20.1, 19.8*1

21.6

19.9

2,942 {30, 427} [200]

Open

BTDC ()

10

Close

ABDC ()

28

24

23

Open

BBDC ()

61

Close

ATDC ()

IN
Valve
clearance

00.5 {00.01}
21.6*1

(mm {in})
EX

Engine cold

0.050.15 {0.00200.0059}
(0.10 0.05 {0.0039 0.0019})

Engine hot
(Reference)

0.15 {0.0059}

Engine cold

0.150.25 {0.00600.0098}
(0.20 0.05 {0.0078 0.0019})

Engine hot
(Reference)

0.25 {0.0098}

TD2

TECHNICAL DATA

Engine

Item
Generator
Drive belt deflection
[Applied pressure
98 N {10 kgf, 22 lbf}]
(mm {in})

P/S
A/C
Generator

Drive belt tension


(N {kgf, lbf})

P/S
A/C

Compression

(kPa {kgf/cm2, psi} [rpm])

Timing belt deflection


[Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in})
Pushing distance of the front oil seal
(from the edge of the chain cover)
Pushing distance of the rear oil seal
(from the edge of the rear cover)

F2 CARB

F2 CIS

New

7.08.0 {0.280.31}

Used

8.09.0 {0.320.35}

New

5.06.0 {0.200.23}

Used

5.56.5 {0.220.25}

New

10.012.0 {0.400.47}

Used

12.014.0 {0.480.55}

New

510588 {5260, 115132}

Used

432509 {4452, 97114}

New

393490 {4050, 88110}

Used

344441 {3545, 7799}

New

373490 {3850, 84110}

Used

275372 {2838, 6283}

Standard

1196 {12.2, 173} [300]

1226 {12.5, 178} [300]

Minimum

837 {8.54, 121} [300]

858 {8.75, 124} [300]

New

8.09.0 {0.320.35}

Used

9.010.0 {0.360.39}

(mm {in})
(mm {in})

TD3

0 {0}
00.5 {00.019}

TECHNICAL DATA
LUBRICATION SYSTEM
Engine

Item

F2

G6

WL

WL Turbo

295392
{3.04.0,
4356}
[3000]

305402
{3.14.1,
4558}
[3000]

452529
{4.65.4,
6676}
[3000]

402480
{4.14.9,
5969}
[3000]

Oil replacement

3.9 {4.1, 3.4}

4.5 {4.8, 4.0}

5.6 {5.9, 4.9}

Oil and oil filter replacement

4.2 {4.4, 3.7}

4.7 {5.0, 4.4}

6.3 {6.7, 5.5}

Total (dry engine)

4.6 {4.9, 4.0}

5.5 {5.8, 4.8}

Oil pressure

(kPa

Oil capacity
(L {US qt, lmp qt})

{kgf/cm2,

psi} [rpm])

Engine oil

API service CD

SAE 40

0C40_C {32_F104F}

SAE 30

10C20_C {14_F68F}

SAE 20W-20

Above 30_C {86F}

Above 25_C {13F}


Viscosity

6.7 {7.1, 5.9}

API service SG

SAE

10W-30*,

10W-40, 10W-50

Above 10_C {14F)

SAE 20W-40, 20W-50

Below 20_C {4_F}

SAE 5W-20

Below 0_C {32_F}

SAE

15C40_C {5_F104F}

5W-30*

SAE 10W-30

Below 10_C {50_F}

D European specification vehicles use only those oils marked with an asterisk

SAE 5W-30

COOLING SYSTEM
Engine

Item

F2

G6

Cooling system
Coolant capacity (Approximate
quantity)
(L {US qt, lmp qt})
Water
pump

WL

7.5 {7.9, 6.6}

9.4 {9.9,8.3}

Without
heater

6.9 {7.3, 6.1}

8.8 {9.3, 7.7}

Type

Centrifugal,
timing belt
driven

Type

Wax, flow
control

Wax,
twostage

Wax, bottom bypass

83.589.5
{183193}

Sub:
83.589.5
{183193}
Main:
86.589.5
{188193}

8084 {176183}

Opening
temperature

(_C {_F})

Full-open
temperature

(_C {_F})

WLT3

Centrifugal, Vbelt driven

100 {212}
8.5 {0.33}
min

Full-open lift
(mm {in})

95 {203}

Sub: 1.5
{0.06} min
Main: 8.0
{0.31} min

Type

8.5 {0.33} min.


Corrugated fin

Cap valve opening pressure


(kPa {kgf/cm2, psi})

74102
{0.751.05, 10.714.9}

Type
Cooling
fan

WL turbo

With
heater

Thermo
stat

Radiator

WL3

Water-cooled, force circulation

94122 {0.951.25, 13.617.7}


Thermo-modulation

Outer diameter
Blade

(mm {in})
Number

380 {15.0}

410 {16.1}

440 {17.3}

10

TD4

TECHNICAL DATA
FUEL AND EMISSION CONTROL SYSTEMS
CIS vehicles
Engine

Item
Idle speed

(rpm)

F2

730770 (750"20)

730770 (750"20)

46/750

57/750

(BTDC /rpm)

Injection timing
Idle speed*1

G6

(rpm)

A/C

ON*2

700800 (750"50)

P/S ON*3

780880 (830"50)

700800 (750"50)

CO concentration

Within the regulation

HC concentration

Within the regulation

Fuel pressure
(kPa {kgf/cm2, psi})

Hold pressure

More than 340 {3.5, 50}

Fuel pump maximum pressure

500630 {5.06.5, 7292}

Fuel leakage

Less than 1

(drop/2 minutes)
Injection volume
(ml {cc, fl oz}/15 sec.)

Fuel injector

5571 {5571, 1.92.3}

Resistance

1216

() [20C {68F}]

Pressure regulator
*1:
*2:
*3:
*4:

4660 {4660, 1.62.0}

Fuel pressure (at vacuum ON)


(kPa {kgf/cm2, psi})

210250 {2.12.6, 3036}

Fuel pressure (at vacuum OFF*4)


(kPa {kgf/cm2, psi})

270310 {2.73.2, 3945}

Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on.
A/C switch and fan switch are turned on.
Steering wheel is fully turned.
Hot condition at start.

DIESEL vehicles
Engine

Item

WL Turbo

WL

(780"20)*1

(rpm)

760800
700740 (720"20)*2

(kPa {kgf/cm2, psi})

107115 {1.091.18,
15.516.8}

When A/C is operated

825875 (850"25)

805855 (830"25)
825875 (850"25)*3

When P/S is operated

Idle speed
Injection timing

ATDC 10

Boost relief pressure

Idle-up speed
(rpm)

When engine is cold


Injection pump

Injection nozzle

Cam lift

12001500 (1350"150)
(mm {in})

Diesel smoke

2.48 {0.098}

Injection starting pressure


(MPa {kgf/cm2, psi})

New: 11.412.2 {116124, 16501760}


Inspection: More than 10.0 {102, 1450}
No leakage when pressure of 8.8 MPa {90 kgf/cm2, 1280 psi})
is applied.

Nozzle leakage
*1:
*2:
*3:

700740 (720"20)

(%)

Within the regulation

General (L.H.D.)
Europe and UK
Europe

TD5

TECHNICAL DATA
CARB vehicles
Engine

Item

F2 CARB

Idle speed

800850 (800 +50


0 )

(rpm)

Injection timing

(BTDC)

Idle-up speed

(rpm)

57 (6"1)

A/C Operated

14001600 (1500"100)

P/S Operated

D/P Operated

19002100 (2000"100)

T/P Operated
CO concentration
HC concentration
Fuel pump

Carburetor

(ppm)
Discharge pressure

(kPa

Discharge amount
Float level

(mm {in})

{kgf/cm2,

psi})

2025 {0.20.25, 2.83.6}

cc {cu in} min.

1150 {70.2}

89 {0.3150.354}

Primary throttle opening angle


*1:
*2:

10501250 (1150"100)
1
2
2.02.5 (2.0 +0.5
0 )* , 2.03.0 (2.5"0.5)*

(%)

4445 {1.7321.772}
()

4852 {50"2}

GULF
General

ENGINE ELECTRICAL SYSTEM


Engine

Item

G6

Electrolyte gravity

1.271.29

Back-up current *1
Test load chart

(mA)

Max. 20

Battery type

80D26R

(A)

Battery type
(5-hour rate)

80D26R (55)

5.56.5

Quick charge
(A/30 min.)

Battery type
(5-hour rate)

80D26R (55)

35

(A)

Battery
Slow charge

195

Rotor resistance (Between slip rings)

()

Standard

Brush length
Brush spring force

(mm {in})

Standard

(N {kgf, lbf})

4.86.0 {0.480.62, 1.061.36}

Minimum

(N {kgf, lbf})

2.2 {0.22, 0.48}

Terminal

Standard voltage
(V)
Idle
[20_C {68_F}]
Generated current*2
(Reference)
(A)

18.5 {0.73}

Minimum

Ignition switch
ON

Generator

(mm {in})

3.74.4

Engine speed

Terminal

5.0 {0.20}

B+

Approx. 1

B+

14.114.7

13.014.0

14.114.7

1000

Approx. 043

2000

Approx. 062

(rpm)

*1:

Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
*2: Must not be 0 A.

TD6

TECHNICAL DATA

Engine

Item
Ignition
coil

G6

Primary coil

Resistance
[20_C {68_F}]

()

Secondary coil

(k)
NGK
DENSO

KJ16CR11*3, *5, KJ20CR11*4, *5


K16PRU*3, K20PRU*4

Plug gap

(mm {in})
(k)
)

Resistance
Tightening torque

Hightension
lead

) [20 _C {68 _F}]


(k

Commutator
diameter
Brush length
Starter

Brush spring force

1.01.1 {0.0400.043}*5,
0.70.8 {0.0280.031}
3.07.5

DENSO

1522 {1.52.3, 1116}

No.1 lead

2.97.7

No.2 lead

4.310.8

No.3 lead

5.413.5

No.4 lead

6.616.2

Center lead

4.511.2

Standard

(mm {in})

29.4 {1.16}

Minimum

(mm {in})

28.8 {1.14}

Standard

(mm {in})

12.3 {0.48}

Minimum

(mm {in})

Standard

(N {kgf, lbf})

180243 {18.324.8, 40.354.5}

Minimum

(N {kgf, lbf})

57.7 {5.88, 12.9}

Pinion gap
No load test

NGK
(Nm {kgfm, ftlbf})

Resistance

1016
ZFR5F11*3, *5, ZFR6F11*4, *5,
BKR5E*3, BKR6E*4

Type
Spark
plug

0.810.99

(mm {in})

7.0 {0.28}

3.0 {1.118}

Voltage

(V)

11.5

Current

(A)

Below 100

*3:

Standard plug
*4: Cold type plug
*5: Europe

TD7

TECHNICAL DATA

Engine

Item

F2 CARB

F2 CIS

Electrolyte gravity
Back-up current
Test load chart
(A)

Battery

1.271.29

*1

(mA)
Battery type

34B19R

180

(A)

Battery type
(5-hour rate)

Quick charge
(A/30 min.)

Battery type
(5-hour rate)

34B19R (27)

3.04.0

Brush spring force

4.55.5
20
30
()

18.5 {0.73}

Minimum

(mm {in})

5.0 {0.20}

Standard

(N {kgf, lbf})

4.86.0 {0.480.62, 1.061.36}

Minimum

(N {kgf, lbf})

2.2 {0.22, 0.48}

B+

Approx. 1

B+

14.114.7

13.014.0

14.114.7

Terminal

(V)
Idle
[20_C {68_F}]

Ignition
coil

Engine speed

Terminal

1000

Approx. 043

2000

Approx. 062

(rpm)

Primary coil

Resistance
[20_C {68_F}]

()

Secondary coil

02/1200, 913/2200,
1923/6000

/kPa {mmHg, inHg}

02/20 {150, 5.9},


1115/53.3 {400, 15.7}

BKR5E*5
BKR6E*3
BKR7E*4

BPR5ES11*3
BPR6ES11*4

K16PRU*5
K20PRU*3
K22PRU*4

W16EXRU11*3
W20EXRU11*4

0.70.8 {0.0280.031}

1.01.1 {0.0400.043}

NGK
Type
DENSO

Spark
plug
Plug gap

(mm {in})
(k)
)

Tightening torque

Hightension
lead

Resistance
(k
) [20 _C {68 _F}]

NGK

*2:
*3:
*4:
*5:

3.07.5

DENSO
(Nm {kgfm, ftlbf})

1522 {1.52.3, 1116}

No.1 lead

2.757.07

No.2 lead

4.1910.43

No.3 lead

4.3810.88

No.4 lead
Center lead

*1:

0.810.99
1016

/rpm

Distributor
Vacuum spark advance

1.0351.265

(k)

Centrifugal spark advance

Resistance

3.74.4

(mm {in})

Standard voltage

Generated current*2
(Reference)
(A)

55D23R (48)

Standard

Ignition switch
ON

Generator

55D23R (48)

Rotor resistance (Between slip rings)


Brush length

55D23R
34B19R (27)

Slow charge

Max. 20
110

5.7314.08
2.005.33

3.99.9

Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
Must not be 0 A.
Standard plug
Cold type plug
Hot type plug

TD8

TECHNICAL DATA

Engine

Item
Commutator
diameter
Brush length
Starter

Brush spring force

F2 CARB

Standard

(mm {in})

32.0 {1.26}

Minimum

(mm {in})

31.4 {1.24}

Standard

(mm {in})

17.0 {0.67}

Minimum

(mm {in})

Standard

(N {kgf, lbf})

19.2 {1.95, 4.25}

Minimum

(N {kgf, lbf})

8.83 {0.90, 1.98}

Pinion gap

11.5 {0.46}

(mm {in})

No load test

0.52.0 {0.0200.078}

Voltage

(V)

11.5

Current

(A)

Below 60
Engine

Item

WL, WL Turbo

Electrolyte gravity

1.271.29

Back-up current *1
Test load chart
(A)

(mA)
Battery type

Battery
Slow charge
(A)

Quick charge
(A/30 min.)

Battery type
(5-hour rate)

Battery type
(5-hour rate)

195

75D26R

195

95D31R

250

75D26L (52)

5.56.5

75D26R (52)

5.56.5

95D31R (64)

6.58.0

75D26L (52)

35

75D26R (52)

35

95D31R (64)

Brush spring force

40
()
(mm {in})

17.9 {0.70}

Minimum

(mm {in})

5.0 {0.20}

Standard

(N {kgf, lbf})

2.65 {0.27, 0.59}

(N {kgf, lbf})

1.18 {0.12, 0.26}

Minimum

B+

B+

2.04.0

14.0514.85

14.0514.85

7.0257.425

13.0014.85

1000

Terminal B
current

Approx. 058

2000

Terminal B
current

Approx. 074

Terminal

Standard voltage
(V)
Idle
[20_C {68_F}]

Generated current*2
(Reference)
(A)

2.50

Standard

Engine switch
ON
Generator

20 max.

75D26L

Rotor resistance (Between slip rings)


Brush length

F2 CIS

Engine speed
(rpm)

Terminal

*1: Back-up

current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine
switch is at OFF position and the engine key is removed.
*2: Must not be 0 A.

TD9

TECHNICAL DATA

Engine

Item
Commutator
diameter
Brush length
Starter

Brush spring force

WL, WL Turbo

Standard

(mm {in})

29.5 {1.16}

Minimum

(mm {in})

27.3 {1.07}

Standard

(mm {in})

17.7 {0.70}

Minimum

(mm {in})

Standard

(N {kgf, lbf})

27.033.0 {2.753.37, 6.057.41}

Minimum

(N {kgf, lbf})

Pinion gap

(mm {in})

No load test

8.7 {0.34}

3.0 {0.12}

Voltage

(V)

11

Current

(A)

Below 130

CLUTCH
Item

Specification

Clutch pedal
Height

(mm {in})

241.6246.6 {9.529.70}

Pedal free play

(mm {in})

3.08.0 {0.120.31}

(mm {in})

0.7 {0.027} max.

Clutch disc
Runout limit
Clutch fluid
Type

SAE J1703 or FMVSS116 DOT-3 or DOT-4

MANUAL TRANSMISSION
M15M-D
Item

Specification

Type
Transmission oil

Viscosity
Capacity

API service GL-4 or GL-5


All-season

SAE 75W-90

Above
10 _C {50 _F}

SAE 80W-90

(L {US qt, lmp qt})

2.0 {2.1, 1.8}

M15MX-D
Item

Specification

Type
Transmission oil

Viscosity
Capacity

API service GL-4 or GL-5


All-season

SAE 75W-90

Above
10 _C {50 _F}

SAE 80W-90

(L {US qt, lmp qt})

Type
Transfer oil

Viscosity
Capacity

2.5 {2.6, 2.2}


API service GL-4 or GL-5

All-season

SAE 75W-90

Above
10 _C {50 _F}

SAE 80W-90

(L {US qt, lmp qt})

2.0 {2.1, 1.8}

R15M-D
Item

Specification

Type
Transmission oil

Viscosity
Capacity

API service GL-4 or GL-5


All-season

SAE 75W-90

Above
10 _C {50 _F}

SAE 80W-90

(L {US qt, lmp qt})

TD10

2.8 {3.0, 2.5}

TECHNICAL DATA
R15MX-D
Item

Specification

Type
Transmission oil

API service GL-4 or GL-5

Viscosity

All-season

SAE 75W-90

Above
10 _C {50 _F}

SAE 80W-90

Capacity

(L {US qt, lmp qt})

3.2 {3.4, 2.8}

Type
Transfer oil

API service GL-4 or GL-5

Viscosity

All-season

SAE 75W-90

Above
10 _C {50 _F}

SAE 80W-90

Capacity

(L {US qt, lmp qt})

2.0 {2.1, 1.8}

PROPELLER SHAFT
Item

Front propeller shaft


(4 4)

Rear propeller shaft


(4 4)

0.4 {0.016}

0.4 {0.016}

0.4 {0.016}

0.31.1
{3.012.0, 2.710.4}

0.30.7
{3.08.0, 2.76.9}

0.31.1
{3.012.0, 2.710.4}

Propeller shaft (4

Runout limit

(mm {in})

Starting torque of universal


(Nm {kgfcm, inlbf})

2)

FRONT AND REAR AXLES (VEHICLES BUILT UP TO 07/2002)


Item

4 2
Play

0 {0}

Preload
Front axle

Wheel bearing

0.40.7 {4.08.0, 3.56.9}

(Nm {kgfcm, inlbf})


Pull scale reading

5.910.7 {0.61.1, 1.42.4}

(N {kgf, lbf})
Rear axle

Wheel bearing play

Drive shaft

Shaft length
(mm {in})

(mm {in})

0.050.25 {0.0020.010}

Left side

551.0561.0 {21.722.0}

Right side

619.0629.0 {24.424.7}

Pinion height

(mm {in})

Backlash of side gear and differential


pinion
(mm {in})
Drive pinion preload (Nm {kgfcm, inlbf})
Backlash of drive
pinion and ring
gear
(mm {in})

Front

0.0320.032 {0.0010.001}

Rear

0.2540.254 {0.0100.010}

Front

00.1 {00.003}

Rear

Front

0.91.3 {9.014.0, 7.912.1}

Rear

1.82.6 {18.027.0, 15.723.4}

Standard

0.090.11 {0.00360.0043} [Front]


0.120.20 {0.0050.008} [Rear]

Minimum

0.05 {0.002} [Front], 0.12 {0.008} [Rear]

Allowance variation

0.07 {0.003} [Front], 0.08 {0.005} [Rear]


3.909

Differential

Final gear ratio

4.444
4.100

WL3
F2 CIS
F2 CARB
WL

Grade
Front

Viscosity

SAE 90
1.20 {1.27, 1.06} [MFW]
1.50 {1.59, 1.32} [RFW]

Front

Rear

1.40 {1.48, 1.23}

Grade

1.85 {1.96, 1.63}

API service GL-6

Viscosity
Capacity

4.777

WLT3
WL TURBO
G6
WL

Above-18_C {0_F}: SAE 90


Below-18_C {0_F}: SAE 80

Rear
Capacity
(L {US qt, lmp qt})

LSD

4.444

API service GL-5

Standard
Oil

4 4

(mm {in})

SAE 90
(L {US qt, lmp qt})

TD11

1.40 {1.48, 1.23}

1.85 {1.96, 1.63}

TECHNICAL DATA
FRONT AND REAR AXLES (VEHICLES BUILT FROM 08/2002)
Item

Specification

Drive type
Play

(mm {in})

Preload
Front axle

Wheel bearing

Drive shaft

Shaft length (Air


in boot at
atmospheric
pressure)
(mm {in})

(mm {in})

0.050.25 {0.0020.010}

525.5535.5
{20.6921.08}

Right side

593.5603.5
{23.3723.75}

(mm {in})

Backlash of side gear and differential


pinion
(mm {in})
Drive pinion preload (Nm {kgfcm, inlbf})

Front

0.0320.032 {0.0010.001}

Rear

0.2540.254 {0.0100.010}

Front

00.1 {00.003}

Rear

Front

0.91.3 {9.014.0, 7.912.1}

Rear

1.82.6 {18.027.0, 15.723.4}

Standard

0.090.11 {0.00360.0043} [Front]


0.120.20 {0.0050.008} [Rear]

Minimum

0.05 {0.002} [Front], 0.12 {0.008} [Rear]

Allowance variation

0.07 {0.003} [Front], 0.08 {0.005} [Rear]


3.909

Differential

0.05 {0.002}

Left side

Pinion height

Backlash of drive
pinion and ring
gear
(mm {in})

0 {0}

5.910.7 {0.61.1, 1.42.4}

(N {kgf, lbf})
Wheel bearing play

4x4

0.40.7 {4.08.0, 3.56.9}

(Nm {kgfcm, inlbf})


Pull scale reading

Rear axle

4x2

Final gear ratio

4.444
4.100

WL3
F2 CIS
F2 CARB
WL

Grade
Front

Standard

Above-18_C {0_F}: SAE 90


Below-18_C {0_F}: SAE 80

Rear
Capacity
(L {US qt, lmp qt})

SAE 90
1.20 {1.27, 1.06} [MFW]
1.50 {1.59, 1.32} [RFW]

Front

Rear

1.40 {1.48, 1.23}

Grade
LSD

1.85 {1.96, 1.63}

API service GL-6

Viscosity
Capacity

4.777

WLT3
WL TURBO
G6
WL

API service GL-5

Viscosity

Oil

4.444

SAE 90
(L {US qt, lmp qt})

TD12

1.40 {1.48, 1.23}

1.85 {1.96, 1.63}

TECHNICAL DATA
STEERING SYSTEM
Item
Play

Steering wheel

(mm {in})

Effort

030 {01.18}

(Nm {kgfcm, inlbf})

Backlash

45 {460, 399} max.

(mm {in})

Worm shaft preload

Steering gear

(Nm {kgfcm, inlbf})

Grade
Capacity

Power steering
oil pump

7.8 {80, 69} max.


0 {0}

1.01.3
{1014, 8.712.1}

0.71.2
{6.512.5, 5.710.8}

8.99.3
{9095, 12801350}

API service GL-4, SAE 90

ATF M-III or equivalent


(e.g. DexronRII)

0.34 {0.36, 0.30}

1.1 {1.2, 1.0}

8.99.3
{9095, 12801350}

Gear housing pressure


(MPa {kgf/cm2, psi})
Oil

Engine speed sensing


power steering

Manual steering

(L {US qt, lmp qt})

Oil pump fluid pressure


(MPa {kgf/cm2, psi})

BRAKING SYSTEM (VEHICLES BUILT UP TO 07/2002)


4 2

Item

F2, G6

4 4

WL, WL Turbo

Brake pedal
Brake pedal height

(mm {in})

L.H.D.: 214219 {8.438.81}


R.H.D.: 219224 {8.638.81}

Brake pedal play

(mm {in})

38 {0.120.31}

Brake pedal-to-floor clearance

(mm {in})

105 {4.2} min.

Power brake unit


Fluid pressure when
pedal depressed at
196 N {20 kgf ,44 lbf})
(kPa {kgf/cm2, psi})

Power brake unit


at 0 kPa {0 mmHg,
0 in Hg}

790 {8, 114} min.

Power brake unit at


66.7 kPa {500
mmHg, 19.7 in Hg}

8,240 {84, 1,200} min.

Vacuum pump
Vacuum specification [In 20 seconds]
[When engine speed 1,500 rpm]
(kPa {mmHg, in Hg})

73.3 {550, 21.7}

Maximum vacuum
[When engine speed 3,000 rpm]
(kPa {mmHg, in Hg})

93.3 {700, 27.6}

Braking force control device


Type

LSPV

Rear fluid pressure when front pressure is


4,900 kPa {50 kgf/cm2, 711 psi}
(kPa {kgf/cm2, psi})

2,550 {26, 370}

Front disc brake


Disc pad thickness limit

(mm {in})

2.0 {0.08}

Thickness limit

(mm {in})

22 {0.87}

Runout limit

(mm {in})

0.05 {0.002}

Brake lining thickness limit

(mm {in})

1.0 {0.04}

Drum maximum diameter

(mm {in})

Disc plate

Rear drum brake


271.5 {10.68}

296.5 {11.67}

Parking brake
Parking brake lever stroke
[When pulled at 98 N {10 kgf, 22 lbf}]
(notches)

17

Brake fluid
Type

SAE J1703 or FMVSS116 DOT-3 or DOT-4

TD13

TECHNICAL DATA
BRAKING SYSTEM (VEHICLES BUILT FROM 08/2002)
Item

Specification

Drive type

4x2

4x4

Brake pedal
Brake pedal height

(mm {in})

L.H.D.: 214219 {8.438.81}


R.H.D.: 219224 {8.638.81}

Brake pedal play

(mm {in})

38 {0.120.31}

Brake pedal-to-floor clearance

(mm {in})

105 {4.2} min.

Power brake unit


Fluid pressure when
pedal depressed at
196 N {20 kgf ,44 lbf})
(kPa {kgf/cm2, psi})

Power brake unit


at 0 kPa {0 mmHg,
0 in Hg}

790 {8, 114} min.

Power brake unit at


66.7 kPa {500
mmHg, 19.7 in Hg}

8,040 {82, 1,166} min.

Vacuum pump
Vacuum specification [In 20 seconds]
[When engine speed 1,500 rpm]
(kPa {mmHg, in Hg})

73.3 {550, 21.7}

Maximum vacuum
[When engine speed 3,000 rpm]
(kPa {mmHg, in Hg})

93.3 {700, 27.6}

Load sensing proportioning valve (LSPV)

Fluid pressure
(kPa {kgf/cm2, psi})

When front
pressure is 4,900
kPa {50 kgf/cm2,
711 psi}

Without ABS: 2,2502,850


{22.9529.06, 327413}
With ABS: 2,9103,710
{29.6837.83, 423538}

Without ABS: 2,2502,850


{22.9529.06, 327413}
With ABS: 2,6503,450
{27.0335.18, 385500}

When front
pressure is 9,800
kPa {100 mmHg,
19.7 in Hg}

Without ABS: 3,1503,930


{31.9240.07, 454569}
With ABS: 4,9706,170
{50.6862.91, 721894}

Without ABS: 3,1303,930


{31.9240.07, 454569}
With ABS: 47005,900
{47.9360.16, 682855}

Front disc brake


Disc pad thickness limit

(mm {in})

2.0 {0.08}

Thickness limit

(mm {in})

Runout limit

(mm {in})

0.05 {0.002}

Brake lining thickness limit

(mm {in})

1.0 {0.04}

Drum maximum diameter

(mm {in})

271.5 {10.68}

Disc plate

22 {0.87}

26 {1.02}

Rear drum brake

Parking brake
Parking brake lever stroke
[When pulled at 98 N {10 kgf, 22 lbf}]
(notches)

17

Brake fluid
Type

SAE J1703 or FMVSS116 DOT-3 or DOT-4

TD14

TECHNICAL DATA
SUSPENSION
Suspension
Item

4 2
(mm {in})

Total toe-in
Front wheel
alignment
[unloaded*1]

4 4
3"3 {0.12"0.12}

0_16 "16

(Degree)

0_14 "14

Camber angle

+2_
35_00 3_
33_00 +2_
3_
0_56"30

33_30 +2_
3_
30_00 +2_
3_
1_ 06"30

Caster angle*2

1_37"45

2_02"45

Inner

Maximum
steering angle

Outer

Exposed thread of shock absorber piston

(mm {in})

Lower arm ball joint rotation torque


(Pull scale reading)

(N {kgf, lbf})

Upper arm ball joint rotation torque


(Pull scale reading)

(N {kgf, lbf})

Exposed thread of stabilizer control link bolt

68 {0.240.31}
1444 {0.74.5, 1.69.9}
3.432.5 {0.43.2, 0.97.0}

(mm {in})

1821 {0.710.82}

*1:

Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in
designated positions.
Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 45.
Wheels and Tires
(Vehicles built up to 07/2002)
Europe
Item

4 2
Front

Size

Front
Tire

195R14C-8PR

Rear

Air pressure
(kPa {kgf/cm2, psi})
Rear
Wear limit

Up to full
passenger
Full
loaded
Up to full
passenger
Full
loaded

Offset

(mm {in})

Pitch circle diameter

(mm {in})

(Nm {kgfcm, inlbf})


Runout limit (mm {in})

235/75R15 105S

200 {2.0, 28}


180 {1.8, 26}

180 {1.8, 26}

205R16C-8PR
180 {1.8, 26}

180 {1.8, 26}


220 {2.2, 31}
200 {2.0, 28}

450 {4.5, 63}

200 {2.0, 28}


180 {1.8, 26}

180 {1.8, 26}

250 {2.5, 35}

450 {4.5, 63}

1.6 {0.06}
14 5J
14 5 1/2J

Tightening torque
Wheel
and tire

205/75R14C

(mm {in})

Size
Wheel

4 4

14 5 1/2J

40 {1.57}

15 6 1/2JJ

16 6JJ

25 {0.98}

35 {1.38}

139.7 {5.45}
Standard wheel: 89117 {912, 6586}
Styled wheel (16 6JJ): 118147 {1215, 87108}

Horizontal

2.0 {0.078}

Vertical

1.5 {0.059}

Imbalance limit
(g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}.
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on either side of the wheel.

TD15

TECHNICAL DATA
General
Item

4 2
Front

Size

185R14C8PR

Rear
Unloaded
(Up to
full
passenger
Front )

Tire

Air pressure
(kPa {kgf/cm2, psi})

Loaded
(Full
loaded)

200
{2.0, 28}

180
{1.8, 26}
180 {1.8, 26}
200
{2.0, 28}

180 {1.8, 26}

Size
(mm {in})

Pitch circle diameter

(mm {in})

Tightening torque
(Nm {kgfcm, inlbf})

240
{2.4, 34}

260
{2.6, 36}

1.6 {0.06}
14 5J

Offset

250
{2.5, 35}

450 {4.5, 63}

(mm {in})

(mm

205R16C- 235/75R15 P235/75R1 P235/75R1


8PR
105S
5 105S
5 106S

Unloaded
(Up to
full
passenger
Rear )

Wheel

Wheel
and tire Runout limit
{in})

195R14C8PR

180
{1.8, 26}

Loaded
(Full
loaded)
Wear limit

4 4

14 5J
14 5
1/2J

40 {1.57}

16 6JJ

15 6 1/2JJ

35 {1.38}

25 {0.98}

139.7 {5.45}
Standard wheel: 89117 {912, 6586}
Styled wheel (16 6JJ): 118147 {1215, 87108}

Horizontal

2.0 {0.078}

Vertical

1.5 {0.059}

Imbalance limit
(g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}.
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on the inner or outer side of the wheel.

TD16

TECHNICAL DATA
Wheels and Tires
(Vehicles built from 08/2002)
L.H.D
Item

Specification

Drive type

4x2
Front

195R14
C8PR

Size
Rear
Air Pressure

Front

Tire
(kPa {kgf/cm2,
psi})

Wheel

Wheel
and
tire

4x4
205/75
R14C

235/75
R15
105S

205R16
C8PR

P235/7
5R15
108S

265/70
R15
110S

Unloaded
Loaded

210 {2.1, 30}


210 {2.1, 30}

Unloaded
Rear

Loaded

Wear limit

(mm {in})

Size

(mm {in})

Offset

(mm {in})

Pitch circle diameter

(mm {in})

240
{2.4, 35}

1.6 {0.06}
14x5
1/2JJ

14x5J

40 {1.57}

16x6JJ

15x6 1/2JJ

16x7JJ

35
{1.38}

25 {0.98}

10 {0.39}

139.7 {5.50}
Standard wheel: 89117 {912, 6586}
Styled wheel (16x6JJ): 118147 {1215, 87108}
Vertical: 1.5 {0.059} max.
Horizontal: 2.0 {0.079} max.

(mm {in})

imbalance limit

250
{2.5, 36}

450 {4.6, 65}

Tightening torque
(Nm {kgfcm, ftlbf})
Runout limit

265/70
R15
112S

(g {oz})

10 {0.35} max.

D One balance weight: max. 60 g {2.0 oz}.


D If the total weight exceeds 100 g {3.5 oz} on each side, rebalance after moving the tire around the rim.
D Do not use more than two balance weights on the inner or outer side of the wheel.

R.H.D
Item

Specification

Drive type
Size
Air Pressure

4x2
Front

Tire
(kPa {kgf/cm2,
psi})

Wheel
and
tire

235/75
R15 105S

P235/75
R15 108S

265/70
R15 110S

Rear

265/70
R15 112S

Unloaded
Loaded

210 {2.1, 30}


210 {2.1, 30}

Unloaded

Wear limit
Wheel

205/75
R14C

Rear
Front

4x4

Loaded

450
{4.6, 65}

250
{2.5, 36}

(mm {in})

240
{2.4, 35}
1.6 {0.06}

Size

(mm {in})

14x5 1/2JJ

15x6 1/2JJ

15x7JJ

Offset

(mm {in})

40 {1.57}

25 {0.98}

10 {0.39}

Pitch circle diameter

(mm {in})

139.7 {5.50}

Tightening torque
(Nm {kgfcm, ftlbf})
Runout limit
imbalance limit

89117 {912, 6586}


Vertical: 1.5 {0.059} max.
Horizontal: 2.0 {0.079} max.

(mm {in})
(g {oz})

10 {0.35} max.

D One balance weight: max. 60 g {2.0 oz}.


D If the total weight exceeds 100 g {3.5 oz} on each side, rebalance after moving the tire around the rim.
D Do not use more than two balance weights on the inner or outer side of the wheel.

TD17

TECHNICAL DATA
BODY ELECTRICAL SYSTEM
Item

Specification

Headlight

Exterior light bulb capacity

Interior light bulb capacity

Warning and indicator light


bulb capacity

(W)

(W)

(W)

High beam/Low beam*

60/55 2

Parking light

5 2

Front turn light

21 2

Brake light/taillight

21/5 2

Rear turn light

21 2

Back-up light

21 2

Rear fog light

21 1

License plate light

5 2
Stretch cab, Double cab

Interior light

10 1

Regular cab

8 1

Instrument cluster illumination

3.4 4

Oil pressure warning light

1.4 1

Generator warning light

1.4 1

Sedimentor warning light

1.4 1

Brake system warning light

1.4 1

Rear window defroster indicator light

1.4 1

Glow indicator light

1.4 1

High beam indicator light

1.4 1

Turn indicator light

1.4 2

Air bag system warning light

1.4 1

4 4 indicator light

1.4 1

LOCK indicator light

1.4 1

*: Also remains illuminated when high beam turned on.


HEATER AND AIR CONDITIONER SYSTEMS
Specification

Item
Refrigerant

Regular amount
Lubricating oil

A/C compressor

G6, WL
(g {oz})
Sealed volume
(ml {cc, fl oz})

Magnetic clutch clearance


(mm {in})

F2
550 {19.4}
180 {180, 6.08}

0.350.75 {0.0140.029}

TD18

0.30.6 {0.0120.023}

SPECIAL TOOLS
SPECIAL TOOLS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST2
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . ST6
TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . ST10
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . ST15
REMOTE FREE WHEEL (4x4) . . . . . . . . . . . ST18
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . ST20

ST1

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST21
ST30
ST32
ST33
ST34
ST35

SPECIAL TOOLS

Engine
Mazda Tool Number
49 L010 1A0

Ford Tool Number


Mounting Stand
303-435 (21-187)

Mounting Plate for 303-435-06


303-435-11 (21-146C)

49 S013 102
Commercially available
Not
applicable

49 S010 1A0
Commercially available
Not
applicable

49 9014 001
Commercially available
Not
applicable

49 0636 100B

Compressor, Valve Spring


303-060 (21-024)

49 B012 0A2

Adapter for 303-060


303-060-02 (21-024-02)

ST2

SPECIAL TOOLS

49 S120 170

Pliers, Valve Stem Oil Seal


303-508 (21-211)

49 L012 0A0A

Installer, Intake Valve Stem Oil Seal


303-247 (21-130A)

49 0249 010A
Commercially available
Not
applicable

49 G011 001
Commercially available
Not
applicable

49 S015 1A1
Commercially available
Not
applicable

49 S120 215A

Remover, Crankshaft Timing Pulley


303-249 (21-132)

49 S010 301

Installer, Driver Pinion Oil Seal


204-088 (14-030)

ST3

SPECIAL TOOLS

49 0259 749
Commercially available
Not
applicable

49 S010 001

Installer, Timing Cover Oil Seal


303-427 (21-178)

49 S011 103

Installer, Wheel Speed Sensor Ring


205-307 (15-089)

49 S011 102A

Locking Tool, Flywheel


303-254 (21-135)

Socket, Cylinder Head Bolt


303-393 (21-168)

49 E011 1A0

Universal Flange Holding Wrench


205-072 (15-030A)_

49 0187 280
Commercially available
Not
applicable

ST4

SPECIAL TOOLS

49 G014 001

Wrench, Oil Filter


Use OTC tool GV 6883
Not
applicable

49 L011 2A0

Adapter for 205-047-07


205-047-05 (15-011-06)
Graphic
not
available

Adapter for 205-047-07


205-047-06 (15-011-07)

Adapter for 205-047-07


205-047-07 (15-011-08)

49 S120 710

Universal Flange Holding Wrench


205-072 (15-030A)

49 S011 103

Installer, Wheel Speed Sensor Ring


205-307 (15-089)

ST5

Graphic
not
available

Graphic
not
available

SPECIAL TOOLS

Transmission
Mazda Tool Number

Ford Tool Number

49 SE01 310A

Aligner, Clutch Plate


308-204 (16-067)

49 0839 425C

Remover, Mainshaft Needle Bearing


Sleeve
308-191 (16-056)

Remover, Bearing/Gear
205-310 (15-091)

Thrust Pad for 205-071


307-115 (17-019)

Remover, Drop Arm


204-015 (14-008)

Remover, Bearing/Gear
205-311 (15-092)

Center Screw
205-034 (15-002)

ST6

Graphic
not
available

SPECIAL TOOLS

49 H017 101

Adapter for 307-272


307-272-01 (17-061-01)

49 1243 465A

Socket, Output Shaft Nut


308-108 (16-039)

49 0710 520

Remover, Bearing/Gear
205-310 (15-091)

49 F027 005

Adapter for 205-066


205-066-03 (15-033-03)

49 F027 007

Installer, Drive Pinion Oil Seal


204-088 (14-030)

ST7

Graphic
not
available

SPECIAL TOOLS

49 F401 331

Installer, Extension Housing Oil Seal


307-028 (17-002)

Installer, Drive Pinion Bearing


205-068 (15-042)

Remover/Installer, Lower Arm Bushing


204-058 (14-027)

Installer, Drive Pinion Oil Seal


204-088 (14-030)

49 0862 350
Commercially available
Not
applicable

49 F017 101

49 G030 795

Holding Tool, Synchronizer Ring


308-422 (16-093)

Installer, Oil Pump Oil Seal


307-032 (17-010A)

ST8

Graphic
not
available

SPECIAL TOOLS

49 F401 335A

Installer, Input Shaft Oil Seal


307-210 (17-041)

49 U027 003

Installer, Oil Pump Oil Seal


307-032 (17-010A)

49 S120 440

Screwdriver
Not
applicable

49 S017 401

Gears
Not
applicable

ST9

SPECIAL TOOLS

Transfer Box
Mazda Tool Number

Ford Tool Number

49 S120 710

Universal Flange Holding Wrench


205-072 (15-030A)

49 0839 425C

Remover, Bearing/Gear
205-310 (15-091)

Remover, Bearing/Gear
205-311 (15-092)

ST10

SPECIAL TOOLS

49 F401 331

Installer, Extension Housing Oil Seal


307-028 (17-002)

Remover/Installer, Lower Arm Bushing


204-058 (14-027)

Remover, Bearing/Gear
205-310 (15-091)

Installer, Driver Pinion Bearing


205-068 (15-042)

Installer, Differential Double Lip Oil Seal


308-203 (16-066)

49 0727 415

Installer, Differential Bearing


205-082 (15-037)

Installer, Torque Converter Oil Seal


307-273 (17-052)

ST11

SPECIAL TOOLS

49 0727 415

Installer, Halfshaft Oil Seal


308-119 (16-071)

Socket, Output Shaft Nut


308-108 (16-039)

49 0727 415

Installer, Drive Pinion Bearing


205-068 (15-042)

Installer, Extension Housing Oil Seal


307-028 (17-002)

49 G030 370

Support Plate, Gear Removal


308-198 (16-063)

49 G030 797

Socket, Guide Sleeve


308-109 (16-040A)

49 G026 102

Socket, Guide Sleeve


308-109 (16-040A)

ST12

SPECIAL TOOLS

49 0258 749

Installer, Torque Converter Oil Seal


307-273 (17-052)

49 S231 395A

Spreader, Transfer Chain


308-423 (16-094)

49 0500 330

Graphic
not
available

Remover, Bearing/Gear
205-310 (15-091)

Depth Gauge
Commercially available
Not
applicable

49 U017 3A0A

Adjustment Tool, Transfer Case


308-424 (16-095)

Graphic
not
available

Commercially available
Not
applicable

49 F401 336B

Installer, Differential Double Lip Oil Seal


308-203 (16-066)

ST13

SPECIAL TOOLS

49 0636 145

Remover, Bearing/Gear
205-310 (15-091)

ST14

SPECIAL TOOLS

Front Differential
Mazda Tool Number

Ford Tool Number

49 M005 581

Mounting Bracket, Engine/Differential


205-329 (15-105A)

49 S120 710

Universal Flange Holding Wrench


205-072 (15-030A)

49 H027 002

Remover, Bearing/Gear
205-310 (15-091)

49 0727 570

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

49 8531 565

Gauge, Master Pinion


205-059 (15-020)

49 0305 555

Preload Sleeve
205-060 (15-023)

49 0259 720

Universal Flange Holding Wrench


205-072 (15-030A)

ST15

SPECIAL TOOLS

49 0839 425C

Remover, Bearing/Gear
205-310 (15-091)

Thurst Pad for 205-071


307-115 (17-019)

Remover, Mainshaft Needle Bearing


Sleeve
308-191 (16-056)

49 G030 338

Installer, Front Differential Bearing Cup


204-281 (14-056)

Graphic
not
available

49 F027 004
Commercially available
Not
applicable

49 F027 005

Installer, Front Differential Oil Seal


204-282 (14-057)

ST16

Graphic
not
available

SPECIAL TOOLS

49 U027 003

Installer, Drive Pinion Bearing


205-082 (15-037)

Installer, Drive Pinion Bearing


205-068 (15-042)

49 G030 795

Installer, Front Differential Oil Seal


204-283 (14-058)

49 0350 555

Gauge, Master Pinion


205-059 (15-020)

49 0350 565

Gauge, Master Pinion


205-059 (15-020)

49 0350 567

Gauge, Master Pinion


205-059 (15-020)

49 0350 568

Gauge, Master Pinion


205-059 (15-020)

ST17

Graphic
not
available

SPECIAL TOOLS

Remote Free Wheel (4x4)


Mazda Tool Number
49 U027 005

49 U027 006

Ford Tool Number


Installer, Remote Freewheel Bearing
204-284 (14-059)

Installer, Remote Freewheel Bearing


204-285 (14-060)

49 U027 004

Remover, Rear Wheel Hub Oil Seal


205-174 (15-072)

49 U027 004

Remover, Oil Seal


303-112 (21-051)

49 M005 796

Installer, Remote Freewheel Dust Seal


204-286 (14-061)

Graphic
not
available

Graphic
not
available

Graphic
not
available

49 0813 215 A
Commercially available
Not
applicable

49 W027 001

Remover/Installer, Pivot Bushing


205-342 (15-110)

ST18

SPECIAL TOOLS

49 U027 007

Installer, Remote Freewheel Oil Seal


204-287 (14-062)

ST19

Graphic
not
available

SPECIAL TOOLS

Front Axle
Mazda Tool Number
49 T028 3A0

Ford Tool Number


Separator, Ball Joint
211-020 (13-006)

Remover, Mainshaft Needle Bearing


Sleeve
308-191 (16-056)

49 H033 101

Installer, Rear Wheel Hub Bearing


Cone/Oil Seal
205-101 (15-051)

49 B025 001

Installer, Input Shaft Bearing Cone


308-041 (16-020)

49 F019 001

Installer, Timing Cover Oil Seal


303-427 (21-178)

ST20

SPECIAL TOOLS

Rear Axle
Mazda Tool Number
49 S120 645A

49 0603 635A

Ford Tool Number


Holding Tool, Rear Axle Shaft
205-496 (15-112)

Wrench, Rear Axle Shaft Bearing


205-497 (15-113)

49 S126 204

Remover, Bearing/Gear
205-311 (15-092)

T57L-500-B

Mounting Bracket, Engine/Differential


205-329 (15-105-A)

308-047 (T77F-1102-A)

Remover, Rear Wheel Hub Oil Seal


205-174 (15-072)

Remover, Oil Seal


303-112 (21-051)

ST21

Graphic
not
available

Graphic
not
available

SPECIAL TOOLS

205-D064 (D84L-1123-A)

Remover, Bearing/Gear
205-310 (15-091)

Remover, Bearing/Gear
205-311 (15-092)

205-456

Adjustment Gauge, Drive Pinion


205-058 (15-019)

205-110 (T76P-4020-A10)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


205-044-02 (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST22

SPECIAL TOOLS

205-457

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST23

SPECIAL TOOLS

205-105 (T76P-4020-A3)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST24

SPECIAL TOOLS

205-109 (T76P-4020-A9)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

ST25

SPECIAL TOOLS

205-111 (T76P-4020-A11)

Gauge, Master Pinion


205-059 (15-020)

Holding Fixture, Dial Indicator Gauge


205-044 (15-008)

Adapter for 205-044 (Step Gauge)


204-044-03A (15-008-03A)

Installer, Differential Bearing


205-062 (15-023)

205-090 (T75L-1165-B)

Installer, Drive Pinion Bearing


205-068 (15-042)

ST26

SPECIAL TOOLS

205-024 (T76P-4616-A)

Installer, Differential Bearing Cone


205-066 (15-033)

Adapter for 205-066


205-066-02 (15-033-02A)

Adapter for 205-066


205-066-03 (15-033-03)

205-092 (T57L-1165-DA)

Installer, Differential Bearing


205-081 (15-032)

205-007 (T56T-4676-B)

Installer, Drive Pinion Oil Seal


205-077 (15-047A)

Installer, Drive Pinion Oil Seal


205-115 (15-058)

ST27

SPECIAL TOOLS

49 S126 205

Adapter for 205-311 (Extension)


205-311-02 (15-092-02)

Adapter for 205-311 (Extension)


205-311-03 (15-092-03)

49 S126 208

Remover, Bearing/Gear
205-310 (15-091)

Adapter for 205-311 (Extension)


205-311-04 (15-092-04)

49 S120 748
Commercially available
Not
applicable

49 F027 004
Commercially available
Not
applicable

49 U027 003

Installer, Differential Bearing


205-082 (15-037)

ST28

SPECIAL TOOLS

49 H025 001
Commercially available
Not
applicable

T83T-4205-A1
Not essential
Not
applicable

T83T-4205-A2
Not essential
Not
applicable

T83T-4205-A3
Not essential
Not
applicable

T83T-4205-A4
Not essential
Not
applicable

ST29

SPECIAL TOOLS

Steering
Mazda Tool Number

Ford Tool Number

49 T028 3A0

Separator, Ball Joint


211-020 (13-006)

49 1232 670 A

Pressure Gauge, Power Steering


211-190 (13-018)

49 H002 671

Pressure Gauge, Power Steering


211-190 (13-018)

Adapter for 211-190 (Connector)


211-190-01 (13-018-01)

49 G032 3A4

Adapter for 211-190 (Connector)


211-190-01 (13-018-01)

49 T028 3A0

Remover, Mainshaft Bearing


308-200 (16-056)

49 B032 304

Pressure Gauge, Power Steering


211-190 (13-018)

ST30

SPECIAL TOOLS

49 0180 510B

Clamp Connector, Preload Gauge


211-021 (13-004A)

Clamp Connector, Preload Gauge


211-041 (13-008A)

49 0223 695E

Remover, Mainshaft Bearing


308-200 (16-056)

ST31

Graphic
not
available

SPECIAL TOOLS

Brakes
Mazda Tool Number

Ford Tool Number

49 0259 770B
Commercially available
Not
applicable

49 U043 0A0
Commercially available
Not
applicable

49 0221 600C

Retractor, Brake Caliper Piston


206-005 (12-014)

49 0208 701A

Remover, O-Ring Seal


100-010 (17-063)

49 B043 001

Setter, Brake Servo Push Rod


206-016 (12-010)

49 EC43 003A
Commercially available
Not
applicable

49 B043 004
Commercially available
Not
applicable

ST32

SPECIAL TOOLS

Suspension
Mazda Tool Number
49 U034 2AO

Ford Tool Number


Remover/Installer, Pivot Bushing
205-342 (15-110)

Installer, Crankshaft Rear Oil Seal


303-395 (21-171)

49 U039 615

Remover/Installer, Pivot Bushing


205-342 (15-110)

Remover/Installer, Rear Axle Bush


205-035 (15-003)

ST33

Graphic
not
available

SPECIAL TOOLS

Air Conditioning
Mazda Tool Number

Ford Tool Number

49 C081 0A0A
Commercially available
Not
applicable

49 C061 012
Commercially available
Not
applicable

49 C061 013
Commercially available
Not
applicable

49 H061 005

Installer, Drive Pinion Oil Seal


205-046 (15-010A)

ST34

SPECIAL TOOLS

General
Mazda Tool Number

Ford Tool Number

49 0305 870A
Commercially available
Not
applicable

49 9140 074

Holding Fixture, Dial Indicator Gauge


310-017 (23-018)

49 9200 146

Adapter for 303-396


303-396-02 (24-001-02)

49 9200 147

Pressure Tester, Cooling System


303-396 (24-001A)

49 0259 888A
Commercially available
Not
applicable

49 01670280
Commercially available
Not
applicable

49 N088 0A0
Commercially available
Not
applicable

ST35

SPECIAL TOOLS

49 L018 901
Commercially available
Not
applicable

ST36

Z
SECTION TITLE

RANGER
2000 2002
lefthanddrive
(LHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.

SECTION

General Information

GI

Ground points

Schematic

System circuit diagrams /


Component Location Views

A~U

Connectors

Parts index

PI

As all information in this manual was the best


available at the time of printing, vehicle
specification an other information will be updated
in Service Information.
Ford Motor Company

APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN) and
related materials shown on the following page.

E2002 Ford Motor Company


All rights reserved. Reproduction by any means,
electronic or mechanical including photocopying,
recording or by any information storage and retrieval
system or translation in whole or part is not permitted
without written authorisation from Ford Motor Company.

Z
Vehicle identification numbers (VIN)
(Chassis numbers)
European specifications (LHD)
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0

BMF:30WW
BME:30WW
DMF:30WW
DME:30WW
LMF:30WW
LME:30WW
BMD:30WW
BMC:30WW
DMD:30WW
DMC:30WW
LMD:30WW
LMC:30WW
BMB:30WW
BMA:30WW
DMB:30WW
DMA:30WW
LMB:30WW
LMA:30WW

100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001-

WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0

BMFE:40WW 100001BMEE:40WW 100001DMFE:40WW 100001DMEE:40WW100001LMFE:40WW 100001LMEE:40WW 100001BMD:40WW 100001BMC:40WW 100001DMD:40WW 100001DMC:40WW 100001LMD:40WW 100001LMC:40WW 100001BMB:40WW 100001BMA:40WW 100001DMB:40WW 100001DMA:40WW 100001LMB:40WW 100001LMA:40WW 100001-

MNC
MNC
MNC
MNC

BSB:30WW
BSA:30WW
BSB:3WWW
BSA:3WWW

General specifications (LHD)


MNC
MNC
MNC
MNC

BSF:30WW
BSE:30WW
BSF:3WWW
BSE:3WWW

100001100001100001100001-

WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0

BMBD20:W
BMDD20:W
BMDE40:W
LMAD20:W
LMBD20:W
LMBE40:W
LMDE40:W
LMFE40:W

100001100001100001100001100001100001100001100001-

100001100001100001100001-

Z
Note:
Euro 3 regulation models (WL3, WLT3 engines) are equipped with an EGR cooler in
the engine compartment.
Non Euro 3 regulation models are not equipped with an EGR cooler in the engine compartment.

EGR cooler

Wire colours
Colour

Code

Colour

Code

Black

Orange

Blue

Pink

Brown

BR

Purple

Dark blue

DL

Red

Dark green

DG

Sky blue

Green

PU
R
SB

Tan

Grey

GY

Violet

Light blue

LB

White

Light green

LG

Yellow

Natural

TOCB1UK

TOCB1UK

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . Z2
Ground points (WL, WL Turbo, before
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Ground points (F2 CIS, G6) . . . . . . . . . . . . . .
Ground points (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Schematic (WL, WL Turbo, before
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Schematic (F2 CIS, G6) . . . . . . . . . . . . . . . . .
Schematic (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Engine
Starting System / Charging System
(WL, WL Turbo, before model
year 2002) . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System / Charging
System (F2 CIS, G6) . . . . . . . . . . . . . . . . .
Starting System / Charging
System (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . .
Powertrain / Quickstart system
(WL, WL Turbo: General specifications,
before model year 2002) . . . . . . . . . . . . . .
Powertrain / Preglow system
(WL, WL Turbo: European specifications,
before model year 2002) . . . . . . . . . . . . . .
Powertrain / Ignition (G6) . . . . . . . . . . . . . .
Powertrain / Ignition (F2 CIS) . . . . . . . . . .
Powertrain / Preglow system
(WL3, WLT3, as of model year 2002) .
Fuel system (before model year 2002) . .
Fuel system (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . .

Z12
Z14
Z16
Z18
Z19
Z20

Z21
Z23

Z25

Z27

Z31
Z35
Z41
Z49
Z47
Z55

Chassis
Remote freewheel control system
(before model year 2002) . . . . . . . . . . . . Z101
Remote freewheel control system
(WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . Z103
Instrument cluster
Instrument cluster (WL, WL Turbo,
before model year 2002) . . . . . . . . . . . . . . Z57
Instrument cluster (F2 CIS, G6) . . . . . . . . Z63
Instrument cluster (WL3, WLT3,
as of model year 2002) . . . . . . . . . . . . . . . Z69
Body
Front wiper/washer . . . . . . . . . . . . . . . . . . . Z75
Horns (before model year 2002) . . . . . . . . Z89

Horns (WL3, WLT3, as of


model year 2002) . . . . . . . . . . . . . . . . . . . . Z93
Rear defrost . . . . . . . . . . . . . . . . . . . . . . . . Z107
Power windows (Regular cabin,
Stretch cabin) . . . . . . . . . . . . . . . . . . . . . . . Z113
Power windows (Double cabin) . . . . . . . Z115
Central door locking . . . . . . . . . . . . . . . . . Z117
Power mirrors . . . . . . . . . . . . . . . . . . . . . . Z119
Heated seats (before model
year 2002) . . . . . . . . . . . . . . . . . . . . . . . . . Z121
Heated seats (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . Z123
Air bags Service warnings . . . . . . . . . . Z125
Air bags (before model year 2002) . . . . . Z127
Air bags (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . Z129
Immobiliser system (before model
year 2002) . . . . . . . . . . . . . . . . . . . . . . . . . Z131
Immobiliser system (WL3, WLT3,
as of model year 2002) . . . . . . . . . . . . . . Z133
Interior Lighting
Instrument illumination . . . . . . . . . . . . . . . . Z97
Interior lamps . . . . . . . . . . . . . . . . . . . . . . . Z109
Exterior Lighting
Headlamps (without daytime running
lamps, without headlamp levelling,
before model year 2002) . . . . . . . . . . . . . .
Headlamps (with daytime running
lamps, with headlamp levelling, before
model year 2002) . . . . . . . . . . . . . . . . . . . .
Headlamps (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . .
Licence plate lamps / Parking Lamps /
Tail lamps / Rear fog lamps (before
model year 2002) . . . . . . . . . . . . . . . . . . . .
Licence plate lamps / Parking Lamps /
Tail lamps / Rear fog lamps
(WL3, WLT3, as of model year 2002) .
Turn Signal and Hazard Lamps
(before model year 2002) . . . . . . . . . . . . .
Turn Signal and Hazard Lamps
(WL3, WLT3, as of model year 2002) .
Reversing lamps / Stop Lamps /
Horns (before model year 2002) . . . . . . . .
Reversing lamps / Stop Lamps /
Horns (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . .

Z77

Z79
Z83

Z81

Z85
Z87
Z91
Z89

Z93

Air conditioning
Heating / Air conditioning (WL, WL
Turbo, before model year 2002) . . . . . . . . Z95
Heating / Air conditioning (F2 CIS, G6) . . Z97

TOCB1UK

Heating / Air conditioning (WL3,


WLT3, as of model year 2002) . . . . . . . . Z99
Accessory
Cigar lighter / Clock / Outlet /
Rear defrost . . . . . . . . . . . . . . . . . . . . . . . . Z107
Audio Systems . . . . . . . . . . . . . . . . . . . . . . Z111
Other
Data Link Connector (DLC) (before
model year 2002) . . . . . . . . . . . . . . . . . . . Z135
Data Link Connector (DLC) (WL3,
WLT3, as of model year 2002) . . . . . . . Z137
Connectors (before model year 2002) . . Z139
Connectors (WL3, WLT3,
as of model year 2002) . . . . . . . . . . . . . . . . Z141
Parts index . . . . . . . . . . . . . . . . . . . . . . . . . . Z143

Z-GI

Wiring Diagrams

Contents of wiring diagrams


D This document comprises the 6 groups shown below.

GI

General Information

A how-to on using and reading wiring diagrams, using


test equipment, checking harnesses and connectors,
and finding trouble spots

Ground points

Ground routes from and to the battery

Schematic

Shows main fuses and other fuses for each system

A~U

System circuit diagrams /


Component Location Views

Shows circuit and connector diagrams and


component and connector location diagrams

Connectors

Shows connectors common throughout system

PI

Parts index

Gives page number of circuit diagram for each


component

Z-2

Z-GI

Reading Wiring Diagrams


Ground points
D This shows ground points of the harness.
GROUND POINTS (4SD)
3

JC01 JOINT CONNECTOR


D
B
C
A
E
B
B
B
B
B
B

8
B

10

12

B /O

B
6

B /W

JC02 JOINT CONNECTOR


D
B
C
A
E
B
B
B
B
B
B
B
B
C

JC03 JOINT CONNECTOR


D
B
C
A
E
B
B
B
B
B
B
D
C
E
B
A
WITHOUT
AIRBAG
T A I RSYSTEM
IT H O U
BAG
D
B
C
A
E
B
B
B
B
B
B
B

D
C
E
B
A
WITH AIRBAG SYSTEM

WITH ABS
B (E M )

B (D )

B (E M )

B (E M )

B (F )

B (E M )

B (F )

TO EACH
UNIT

B (E M )

TO EACH
UNIT

B (D )

EMISSION
HARNESS
(EM)

J C 02

11

B (D )
B (D )
B (D )

B /W ( E M )

DASH
HARNESS
(D)

B (D )
WITH AIRBAG SYSTEM

TO EACH
UNIT

FRONT
HARNESS
(F)

B
(F )

10

B (D )

B (F )
B (F )

B (D )
J C 03
B (D )

B (E M )

J C 01
B (F )

B (D )

B / O (D )
3
WITHOUT AIRBAG SYSTEM

B (F )
B (F )
B (F )

B ( I)

B ( I)

B (F )

INSTRUMENT
PANEL
HARNESS
(I)

B (F )
B ( I)

B (F )

B (IN )

INTERIOR
LIGHT
HARNESS
(IN)

12

SHORT
CORD

B (F )

Ground indication
On vehicle

Indication

On system circuit diagrams and ground points


The ground connection numbers in system circuit diagrams
correspond to those in the ground point diagram.
To circuit

ENGINE CONTROL SYSTEM


BATTERY

IG

MAIN
100 A

F B 0 9

K E Y

X 01

F B 07

60 A

B (E )

B /W (D )

B /W ( F )
B

F B 0 5

A
B T N
40 A

IN J OR
FIP
30 A

B (F )

B (D )
J B 0 5

G
W /R ( F )

J B 0 3

W /R ( D )
R OO

1 B

10 A

X 03

8
F B 0 3

F B 0 3

Y /L (F )

X 0 6

F B 0 4

F B 0 3

L G /R
(E M )

X 09

Y
L /R ( E )

J B 0 4

L /R (E M )

SPV RELAY
(SECTION B_1b)

W /Y
(E M )

I G1I G2

A C C

X 0 3
L (D )

A A

X 0 6

O F F

S T

E N G IN E
10 A
14 J B 01

B / L (D )

MAIN
RELAY

F B 0 4

ENGINE SWITCH

L /R
(D )

F B 0 4

W /G (E M )

B /L
(E M )

L /R
(E M )

B 1 0 1

B /W
(F )

1 E

3 W

B 1 0 3

1 B

1 A

B 1 0 2

1 F

P C M
2 M

GLOW
PLUG
RELAY

3 R

3 P

L G

B R /B
( E M )

1 S

1 N

1 Q

B 1 0 1
L

B 1 02

(E M )

L
(E )

F B 0 1

F B 0 3

(E M )

L (E )
I
L

L /B
( E M )

G /B
(E M )

G /W
(E M )

B
(E )

(E )
J

B 1 0 5

X 0 9

1 1
23

22

14

A/C RELAY
(SECTION G2)

B
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)

DATA LINK CONNECTOR (DLC)

B
(E M )

B 1 0 4

(SECTION U)

31
AD FAN RELAY
(SECTION G2)

GLOW
PLUG

G
G

B 1 01

P C M (E M )

1 U
1 S
Y
W /G
1 V

B 1 0 3

G L O W

P L U G

B /W

1 O

1 M

1 K

P /L

L /W

L /R

1 I

1 G

1 Q

W /R L /B
W /L

V /W

1 T

1 R

R E L A Y

1 C

1 A

2 O

R /Y

L /R

G /R

B /L

W /Y

1 F

1 D

1 B

2 P

1 E
L G /R

G /W
1 P

1 N

1L

1 J

1 0 4 G L O W P L U G
(S H O R T C O RD )

1 H

2 K

2 I

2 G

2 E

2 A

2 M

B 1 05

L /W
2 N

2L

E N G I N E ( E ) S H O R T
(E )

3 Y

2 C
L G / BB R / W R / L

2 J

R /Y

B R /Y L / Y
2 H

2 F

2 D

B /W

C O R D )

Z-3

3 Q

3 Z

3 X

3 O

3 M

3 K

3 G
R /B
L G

3 V

3 T

3 A

3 I

3 S

L /R
R /L

O
2 B

C O RD
(S H O R T

3 U
3 W

G Y /RP /B

3 R

V
B R / BY / B
3 P

3 N

3 E

3 C
G /Y

G /R

3L

3 J

3 H

3 F

B /O
3 D

3 B

B 1 0 2
(E)

G L O W

P L U G

R E L A Y

L /R
L
B

Z-GI

Reading Wiring Diagrams

System circuit diagram/connector diagram


D These diagrams show the circuits for each system, from the power supply to the ground. The power supply side is on the
upper part of the page, the ground side on the lower part. The diagrams describe circuits with the ignition switch off.
Below is an explanation of the various points in the diagram.
ENGINE CONTROL SYSTEM
B A TT E R Y
+
F B 0 9

B (E )
A

System name

M A IN
100A

IG KE Y
60A

X 0 1

F B 0 7 D
B /W ( F )

F B 0 5
B (F )

IN J O R
F IP
30A

F B 0 3
GLOW
40A

F B 0 3
W /G ( E M )

F B 0 4
Y /L (F )
S
F B 0 4
M A IN R E L A Y
F B 0 3

G
D

F B 0 4

L /R ( E )

L /R ( E M )
B 1 0 1

1E

3W

B 1 0 3

B 1 0 2
2M

GLOW
PLUG
RELA Y

3R

B 1 0 1
L
(E M )

B 1 0 2
F B 0 1 F B 0 3

B
(E )

LG
(E M )

L (E )
I

L
(E )

B 1 0 5

X 0 9

L G /R
(E M )

X 0 9

B /W
(F )

23

B
B
(E M )

D A T A L IN K
( S E C T IO N U

B 1 0 4
GLOW
PL UG

G
G

B 1 0 1 P C M ( E M ) 1 U

Connector code

1O
1S

1V
B103

Y : Ground connector
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air conditioning system connectors
H : Transmission control system connectors
I : Interior light system connectors
J : Audio/radio system connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
N : Power steering/4-wheel steering system
connectors
O : Anti-lock brake system connectors
P : Power seat/seat heater system connectors
Q : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
U : Data link connector
X : Common connectors
JB: Joint box connections

1K

1T

GLOW PLUG RELAY (F)

1I

1C

1G

1A

W /Y

1P

1N

B /L
1L

1J

1H

B 1 0 4 G L O W P L U G
( S H O R T C O RD )

1F

G / Y W /Y
1D

L /W

1B

2P

2N

2L

2J

Ground numbers
A harness ground is represented differently than
a unit ground.
Types of grounds

Symbol

Harness

G
G
Unit

G
G
Sensor

Z-4

2G

L G /BB R /WR /L
B
2H

B 1 0 5 E N G IN E ( E )S H O R T C O RD
(E )
(S

B /W

2I

2M
G /R

L G /R R / Y R /W

G /W

1R

2K

2O

1E

W /G W /L V / W

The prefix letter indicates the system in which


the connector is used.

1M

1Q

W /R L /B P /L L /W L /R

Z-GI

Reading Wiring Diagrams

The number indicates that the circuit


continues to the related system circuit
diagram.

System code

B-1A

Current symbol
DATA LINK
CONNECTOR (DLC)
(SECTION U)

B /W (D )

Current flows in the direction of the arrow.

B (D )
1B
ENGINE SWITCH

17

18

G /Y
(E M )

W /Y
(E M )

R /W
(E M )

O FF

ST

A CC

IG 1 IG 2

E N G IN E
J B 0 4 1 0 A 1 4 J B 0 1

X 0 6

16
X 0 3

X 0 3
L (D )

B /L (D )
AA

Indicates shielded wire.*

B /L
(E M )
B 1 0 1
1F

1D

1I

1A

* Shielded wire:
Prevents signal disturbances from
electrical interference. Wire is
covered by a metal meshing for
grounding.

PCM
2C

2A

1S

2B

2E

R /Y
(E M )

SHIELD WIRE

B 1 0 7
W /R
(E M )
P /B G Y /R O
(E M ) (E M ) (E M )

INTAKE AIR
TEMPERATURE
SENSOR NO.1
1
B 1 0 7
O
(E M )

B
(E M )

14
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)

B 1 0 6

Connector symbols
BOOST SENSOR

D Male and female connectors are represented as follows in


the system circuit and connector diagrams.

3Y

3Q

3U
3W

3K

3I

L G B R /BY / B G /R
3V

3T

3A
3G

R /B

R /L
3X

3M

3S

B / W L /R

3Z

3O

3R

3P

3N

B106 BOOST SENSOR (EM)

3L

3E

B102 GLOW PLUG RELAY (E)

3C

G /Y

3J

3H

3F

Circuit
diagram symbol

L /R
L

B /O
3D

Connector
diagram symbol

3B

B107 INTAKE AIR TEMPERATURE


SENSOR NO.1 (EM)

P / B G Y /R O

R /Y

Male
Male

Female
Female

L
R

Wire color code (harness symbol)


D Like connectors are linked by dashed lines between the
connector symbols.

D Two-colour wires are indicated by a two-letter symbol.


The first indicates the base colour of the wire, the
second the colour of the stripe. For example:

D Connector diagrams show connectors on the harness


side. The terminal indicates the view from the harness
side.

W/R is a white wire with a red strip


BR/Y is a brown wire with a yellow strip

(Example)
Connector on harness side

Symbol
(Example)
Solid colour wire

B
(F)

Black

Striped wire

W/R
(F)

White
(base
colour)

View from
harness side

Red
(stripe)
D Colours for connectors except milk-white are given in
locations.
D The harness symbol is in ( ) following the harness
symbols (refer to P-7).

D Unused terminals are indicated by :.

Z-5

Z-GI

Reading Wiring Diagrams

Routing diagram
D The routing diagram shows where electrical components are on the system circuit diagram by call out line and connector
symbols.

Connector symbol

Component name

Ground symbol

Shows the system that uses the


connector.

Shows the names of


components in routing diagrams.

Shows the ground in system


circuit diagrams.

(Example)
Connector

Symbol

Common connectors

X-9

System connectors

I-03

HARNESS SYMBOL

(F)

(E)

(R)

INSTRUMENT
CLUSTER

VACUUM
SWITCH

C-01

C-05
(F)-(I)

X-02

(F)-(I)

X-02

C-06
PARKING BRAKE SWITCH

Z-6

Z-GI

Reading Wiring Diagrams


Harness symbols
DESCRIPTION OF HARNESS

SYMBOL

DESCRIPTION OF HARNESS

SYMBOL

FRONT HARNESS

(F)

DOOR NO.1 HARNESS

(DR1)

FRONT NO.2 HARNESS

(F2)

DOOR NO.2 HARNESS

(DR2)

ENGINE HARNESS

(E)

DOOR NO.3 HARNESS

(DR3)

DASH HARNESS

(D)

DOOR NO.4 HARNESS

(DR4)

REAR HARNESS

(R)

FLOOR HARNESS

(FR)

REAR NO.2 HARNESS

(R2)

INTERIOR LIGHT HARNESS

(IN)

REAR A HARNESS

(RA)

A/C HARNESS

(AC)

INSTRUMENT PANEL HARNESS

(I)

EMISSION HARNESS

(EM)

EMISSION NO.2 HARNESS

(EM2)

EMISSION NO.3 HARNESS

(EM3)

Z-7

Z-GI

Reading Wiring Diagrams

Symbols
Symbol

Meaning

Symbol

D Generates electricity through chemical


reaction.

Battery

D Emits light and generates heat when


current flows through filament.

Light

D Supplies direct current to circuits.

Ground (1)

Meaning

3.4 W

Resistance

D Connecting point to vehicle body or other


ground wire where current flows from
positive to negative terminal of battery.

D A resistor with constant value.


D Mainly used to protect electrical
components in circuits by maintaining
rated voltage.

D Ground (1) indicates a ground point to


body through wire harness.

D Ground (2) indicates point where


component is grounded directly to body.
Ground (2)

Motor

D Converts electrical energy into mechanical


energy.

Pump

D Pulls in and discharges gases and liquids.

Remarks
D Current will not flow through a circuit if
ground is faulty.

D Melts when current flow exceeds that


specified for circuit, interrupts current flow.

Fuse (1)

Precautions

Cigarette lighter

D Do not replace with fuses exceeding


specified capacity.

(Box)

D Electrical coil that generates heat.

Fuse (2)
<Blade type>

<Tube type>
D Generates sound when current flows.

Horn
(Cartridge)
Main fuse/
Fusible link

<Cartridge type>

<Fusible link>
Speaker

Transistor (1)
Collector (C)
Base (B)

D Electrical switching component.


D Turns on when voltage is applied to the
base (B).
Collector
indication
mark

NPN

Emitter (E)

C
B

Transistor (2)
Collector (C)

EC B
C

PNP

Emitter (E)

Speed sensor

D Movement of magnet in speedometer turns


contact within sensor on and off.

Ignition switch

D Turning ignition key switches circuit to


operate various components.

E
B

D Reading code.
2 S C 828 A

Base (B)

D Generates heat when current flows.

Heater

Semiconductor
Number of
terminals

Revision mark
A: High-frequency PNP
B: Low-frequency PNP
C: High-frequency NPN
D: Low-frequency NPN

B 1

B 2
S T

IG 2

O FF
IG 1

Z-8

O FF
A C C

Z-GI

Reading Wiring Diagrams


Symbol
Switch (1)

Meaning

Symbol

D Allows or breaks current flow by opening


and closing circuits.

Meaning

Harness
Connection
D
B

When circuit C-D is


connected to circuit
A-B, the connection
D is indicated by a
black dot.

Normally open (NO)

For vehicles with ABS, use the A-B circuit.

Selection

WITH ABS

Switch (2)
A

Diversion point D
for the different
circuits according to
the vehicles
specification is
indicated by a white
dot.

Normally closed (NC)

Relay (1)

D
B

WITHOUT ABS
C

For vehicles without ABS, use the C-B


circuit.

D Current flowing through coil produces electromagnetic force causing contact to open or close.
No current to coil

Current to coil

No Flow

Flow

Normally open (NO)


Relay (2)

D Current flowing through coil produces electromagnetic force causing contact to close.
No current to coil

Current to coil
Flow

No Flow

Normally closed (NC)


Sensor (variable)

D Resistance changes with other


components operation.

Diode

D Known as a semiconductor rectifier, the


diode allows current to flow in one
direction only.
Cathode (K)
K

Sensor (thermistor)

Capacitor

D Resistance changes with temperature.

Light-emitting diode
(LED)

D A diode that lights when current flows.


D Unlike ordinary bulbs, the diode does not
generate heat when lit.

Cathode (K)

D Component that temporarily stores


electrical charge.

Anode (A)
Flow of direct current
A K
A

Anode (A)
Cathode (K)
Anode (A)
Flow of current

Solenoid

D Current flowing through coil generates


electromagnetic force to operate plungers.

Z-9

Reference diode
(Zener diode)

D Allows current to flow in one direction up


to a certain voltage; allows current to flow
in the other direction once that voltage is
exceeded.

Z-GI

Reading Wiring Diagrams


Symbol

Meaning
D The wiring position can be exchanged freely within the
connector.

Extent of the change in the wiring position (1)

D The wiring position can be exchanged according to the following


combinations only:
Between A and B, between C and D, between E and F.

Extent of the change in the wiring position (2)

D The wiring position can be exchanged according to the following


combinations only:
Between A, C and E, between B, D and F.

Extent of the change in the wiring position (3)

Abbreviations
3GR

Third Gear

CCT

Circuit

4GR

Fourth Gear

CIGAR

Cigarette

Ampere

CIS

Continuous Fuel Injection System

A/C

Air Conditioning

CKP

Crankshaft Position Sensor

A/F

Air Fuel

CLS

Closed Loop System

A/R

Auto Reverse

CMP

Camshaft Position Sensor

AAS

Auto Adjusting Suspension

COMBI

Combination

ABS

Anti-lock Braking System

CON

Conditioner

ACC

Accessories

CONT

Control

ACV

Air Control Valve

CPU

Central Processing Unit

ADD

Additional

CSD

Cold Start Device

AIR

Secondary Air Injection

CTP

Closed Throttle Position

AIS

Air Injection System

DEF

Defroster

ALL

Automatic Load Levelling

DI

Distributor Ignition

AM

Amplitude Modulation

DLC

Data Link Connector

AMP

Amplifier

DLI

Distributorless Ignition

ANT

Antenna

DOHC

Double-Overhead Camshaft

AP

Accelerator Pedal

DTC

Diagnostic Trouble Code(s)

AS

Autostop

DTM

Diagnostic Test Mode

ASV

Air Supply Valve

ECM

Engine Control Module

AT

Automatic Transmission

ECPS

Electronically Controlled Power Steering

ATX

Automatic Transaxle

ECT

Engine Control Temperature

B+

Battery Positive Voltage

EGR

Exhaust Gas Recirculation

BAC

Bypass Air Control

EI

Electronic Ignition

BARO

Barometric Pressure

ELEC

Electric

CAC

Charge Air Cooler

ELR

Emergency Locking Retractor

CARB

Carburetor

ETR

Electronic Tuner

Z-10

Reading Wiring Diagrams

Z-GI

Front

OBD

On-board Diagnostic

F/I

Fuel Injector

OFF

Switch Off

FC

Fan Control

ON

Switch On

FICB

Fast-Idle Cam Breaker

Power

FM

Frequency Modulation

P/S

Power Steering

FP

Fuel Pump

PAIR

Pulsed Secondary Air Injection

FPR

Fuel Pump Relay

PCM

Powertrain Control Module

GEN

Generator

PNP

Park/Neutral Position

GND

Ground

PRCV

Pressure Regulator Control Solenoid Valve

H/D

Heater/Defroster

PRG

Purge Solenoid Valve

HEAT

Heater

PSP

Power Steering Pressure

HEI

High-Energy Ignition

PTC

Positive Temperature Coefficient Heater

HI

High

QSS

Quicik-Start System

HO2S

Heated Oxygen Sensor

Rear

IAC

Idle Air Control

REC

Recirculation

IAT

Intake Air Temperature

RF

Right Front

ICM

Ignition Control Module

RFW

Remote Freewheel

IG

Ignition

RH

Right Hand

ILLUMI

Illumination

RPM

Engine Speed

INT

Intermittent

RR

Rear Right

JB

Joint Box

SAPV

Secondary Air Pulse Valve

KS

Knock Sensor

SFI

Sequential Multipoint Fuel Injection

LCD

Liquid Crystal Display

SOL

Solenoid

LF

Left Front

ST

Start

LH

Left Hand

SW

Switch

LO

Low

TC

Turbocharger

LR

Left Rear

TCM

Transmission (Transaxle) Control Module

Motor

TCV

Twin Scroll Turbocharger Solenoid Valve

MAF

Mass Air Flow Sensor

TEMP

Temperature

MAP

Manifold Absolute Pressure

TICS

Triple Induction Control System

MFI

Multiport Fuel Injection

TP

Throttle Position Sensor

Middle

TR

Transmission Range

MID
MIL

Malfunction Indicator Lamp

TWS

Total Wiring System

MIN

Minute

Volt

MIX

Mixture

VAF

Volume Air Flow Sensor

MPX

Multiplex

VENT

Ventilation

MT

Manual Transmission

VOL

Volume

MTR

Mechanical Tuning Radio

VR

Voltage regulator

MTX

Manual Transaxle

VRIS

Variable Resonance Induction System

NC

Normally Closed

VSS

Vehicle Speed Sensor

NO

Normally Open

Watt(s)

O2S

Oxygen Sensor

WOT

Wide Open Throttle

Z-11

p12nUK

Y-1

Ground points (WL, WL Turbo, before model year 2002)

10

14

3
B
4

B
7

15

17

B/R

6
B

B/R

16

B/R

11

B/R

With fuel injection,


European specifications

B(F)

B(F)

B(F)

B(F)

B(F)

Z12

3
B/R(F)

B(F)

Front harness

with air bag

B(F)

B(F)

with immobiliser
unit

16

4
B/R(F)

to each
unit

Front harness

B(F)

to each
unit

with immobiliser unit

with door harness

B(F)

B/R(F)

B(R2)

10

B(R2)

11

Rear harness 2

14

Rear window heater grid

15

Short cord

B(FR)

17

Floor harness

6
B(R2)

B/R(F)

With fuel injection,


European specifications

Wiring Diagram

p13nUK

Y-1

Harness symbol

11

14

17

Z13

WL Turbo

16

WL

15

Wiring Diagram

10
16

p14nUK

Y-2

Ground points (F2 CIS, G6)

2
5

Wiring Diagram

7
8

10

11

14

12

13

B/O

15
17

B(F)

B(R2)

10

11

B(F)

B(R2)

B(F)

B(R2)

Rear harness
2

Z14

B(F)
B(INJ)
B(F)

B(F)

12

Injection harness

B
(INJ)

to each unit

Front harness

B(F)

B(F)

to each unit

5
B/O(INJ)

13

14

Rear window
heater grid

15

Short cord

B(FR)

17

Floor harness

with air bag


B(F)

B(F)

B(F)

p15nUK

Y-2

Harness symbol

10
12

11

13

14

17

G6

Z15

13

12

15

F2 CIS

Wiring Diagram

Y-3

Ground points (WL3, WLT3, as of model year 2002)


3

10

14

15

11
B

B/ R

16

B/ R
B/ R

B /R

B/ R

B /R

19
E

B( F)

B( F)

B/ R( F )
B( F)
B/ R( F )
B( F)

B( F)

B/ R( F )

B/ R( F )
B( F)

Front harness

B/ R( F )

Z16

B( F)

B( F)

20

B/ R( F )

B/ R( F )

to each unit

Front harness

to each unit

B/ R( F )

B/ R( F )
B( F)

JC

01

with air bag

B( F )

B/ R (F)

B( R2 )

10

B( R2 )

11

Rear harness
2

14

Rear window
heater grid

15

Short cord

B( FR)

17

Floor harness

16
B( R2 )

B( F )

18

B( F )

B( F )

B( F )

19

B/ R

B/ R
B/ R

B/ R

18

17

Joint connector (F)


I

B
5

01

Wiring Diagram

JC

p17UK

Y-3

Harness symbol

Z
Wiring Diagram

10

16

19

11

14
Stretch cabin
Regular cabin
18

Z17

17

10

11

20
14

JC-01

17
15

Double cabin

p18nUK

W-1

Schematic (WL, WL Turbo, before model year 2002)

current from battery


T

I2

I2

I2

I2

I3

Immobiliser system

Heated Seats

Rear defrost

Outlet

Data Link Connector


(DLC)

Clock

Cigar lighter

Interior lamps

Air Bags

Heating

Air conditioning

Remote freewheel
control system

Powertrain
Quickstart system

Powertrain
Glow System

Starting System
Charging System

Fuel system

Central door locking

current from IG1 terminal of ignition switch


current from IG2 terminal of ignition switch
current from ACC terminal of ignition switch
Other

System

Section

Audio Systems

B/Y
30A

(PTC)

60A

GLOW

30A

HEAD

80A

MAIN

30A

BTN

G/B

R
10A
B/W

B/W

W/R

W/R

B/Y
W/R

Z18

Reversing Lamps

F2

Turn Signal and Hazard Lamps

F1

Stop Lamps

F2

Horns

F2

Instrument Illumination

I1

Licence plate lamps


Parking Lamps
Tail lamps

E3

Headlamps
(without daytime running lamps / without
headlamp levelling)

E1

R/B

10A

(A/C)

30A

(D/L)

20A

R.DEF

HAZARD

L/Y

LG/R
W/G
W

B/W
10A

ROOM

15A

STOP

L/R
10A

G/W

Y/R

TAIL

Ignition switch
ST

OFF
R/B

IG1 IG2

ACC

Headlamp
switch
15A
L

CIGAR

40A

(HEATER)

15A

WIPER

B/R

L/W

R/Y

R/L
R/W

L
10A
L

R.FOG

R/G

Instrument cluster

Power Mirrors
R/L
15A
W
15A

ENGINE
(S.WARM)

15A

METER

30A

(P.WIND)

B/W

R/W

BR/Y

B/Y
R/G

Headlamps
(with daytime running
lamps / with headlamp levelling)
Rear fog lamps

C1a
C1b
C1c

E2

E3

R/L

Windshield Wiper/
Washer
Power Windows

D
K1
K2

Wiring Diagram

S1

G1

B1a
B1b

B2a
B2b

A1

B5

K3

Battery

p19nUK

W-2

Schematic (F2 CIS, G6)

current from battery


P

I2

I2

I2

I2

I3

Heated Seats

Rear defrost

Data Link Connector


(DLC)

Outlet

Clock

Cigar lighter

Interior lamps

Air Bags

Heating

Air conditioning

Fuel system

Remote freewheel
control system

Powertrain
Ignition
(F2 CIS, G6)

Starting System
Charging System

current from IG1 terminal


of ignition switch
current from IG2 terminal
of ignition switch
current from ACC terminal of ignition switch
Other

System

Section

Audio Systems

B/Y

30A

FUEL INJ

30A

HEAD

80A

MAIN

30A

BTN

F2

Turn Signal and


Hazard Lamps

F1

Stop Lamps

F2

Horns

F2

Instrument Illumination

I1

R/B

Licence plate lamps


Parking Lamps
Tail lamps

E3

R/L

Headlamps
(without daytime running lamps / without
headlamp levelling)

E1

R
10A
B/W

B/W

W/R

W/R

B/Y
W/R

Z19

Reversing Lamps

L/W

10A

(A/C)

30A

(D/L)

20A

R.DEF

HAZARD

L/Y

LG/R
W/G
W

B/W

ST
IG1 IG2

10A

ROOM

15A

STOP

L/R
10A

G/W

Y/R

TAIL

OFF
ACC

Ignition switch

Headlamp switch
15A

CIGAR

40A

(HEATER)

15A

WIPER

B/R

L/W

R/Y

R/W
L

10A

R.FOG

R/G

Instrument cluster

Central door locking


Power Mirrors
R/L
R/W
15A
W

ENGINE

15A

(S.WARM)

15A

METER

30A

(P.WIND)

B/W
BR/Y

Headlamps
(with daytime running lamps / with
headlamp levelling)

C2a
C2b
C2c
K3
L

E2

L
R/G

Rear fog lamps

E3

B/Y
R/L

Windshield Wiper/
Washer
Power Windows

D
K1
K2

Wiring Diagram

S1

G2

B5

B3a
B3b
B3c
B4a
B4b
B4c

A2

Battery

W-3

Schematic (WL3, WLT3, as of model year 2002)

current from battery


2

T 2

I 2

I 2

I 2

I 2

I 3

6a
6b
6c

B
B
B

K 3

Battery

current from IG2 terminal of ignition switch


current from ACC terminal of ignition switch
Other

System
B

30A

PT C

60A

GLOW

30A

H EAD

80A

MA IN

30A

BT N

Z20

IG 2

Reversing Lamps

R
B/ W

W/ R

W/ R

B/ W

IG 1

G/B

B/ W

W/ R

ST

Audio Systems

F 4

R/B

B/ Y

OF F

B/ Y

Section

Ignition
switch

10A

A/ C

30A

D/L

20A

R.DE F

15A

FI P

10A

ROOM

15A

ST O P

10 A HAZ A RD

L/Y

LG/R

Turn Signal and Hazard Lamps

F 3

Stop Lamps

F 4

Horns

F 4

W/ G
W
L/ W

Instrument Illumination
10A
Y/ R

L/R

I1

TA IL

G/W
R/B

Licence plate lamps


Parking Lamps
Tail lamps

C
C
C

3a
3b
3c

Headlamp
switch

AC C

B/ R

15 A CIGA R

40 A H E AT ER
15 A WI PE R

L/W

R/ Y

R/W
L
10 A R.F O G
L

Instrument cluster

R/G

Power Mirrors
L
R/L
15 A
W
15 A

E N GINE

B/ W

R/W

BR /Y

Headlamps
E

S. WAR M

15 A

ME TE R

30 A

P. WI ND

B/ Y
R/G

Rear fog lamps

E 5

Windshield Wiper/
Washer

K
K

1
2

R/L

Power Windows

Wiring Diagram

Immobiliser system

Heated Seats

Rear defrost

Data Link Connector


(DLC)

Outlet

Clock

Cigar lighter

Interior lamps

Air Bags

Heating

Air conditioning

Remote freewheel
control system

Powertrain
Glow System

Starting System
Charging System

Fuel system

Central door locking

current from IG1 terminal of ignition switch

p21nUK

A-1

Starting System / Charging System (WL, WL Turbo, before model year 2002)

Battery

Main fuse box


+

HEAD
B(E)

R(E)
30A
MAIN
B/W(E)

B(E)
80A

X01
B/W
(E)
A

B/W(F)

X07
ST
X02

IG1 IG2

Instrument cluster
(Section C1a)

X02

Ignition
switch

OFF

ACC

W/B
(F)

B/Y
(F)

B
(E)

X09

B/W
(E)

A101

R
(E)

W/B
(E)

A102

Z21

B/Y(E)
A101

B/Y(F)

X08

Powertrain control
module (PCM)
(Section B1b, 2b)

Regulator

Starter
A102

1B
W/R
(E)

A101

Starter (E)

A102

Generator (E)
1B
W/R

B/Y

W/B

W/R

2A
B/W

2A
W/R
(E)

Generator

Wiring Diagram

X01

p22nUK

A-1

Harness symbol

[ Black ]
(F)(E)

Wiring Diagram

[ Black ]
(F)(E)

X08

X07
Main fuse box

[ Black ]
(F)(E)

X01

X09

A101
Starter

Z22
A102
Generator

X02
Ignition switch

X02
Ignition switch
[ Blue ]

[ White ]

p23nUK

A-2

Starting System / Charging System (F2 CIS, G6)

Battery

Main fuse box

HEAD
B(E)

R(E)
30A
MAIN

B(E)

B/W(E)
80A

X01
B/W
(E)
A

B/W(F)

X07
ST

OFF

B/Y(F)
X02

IG1 IG2

Instrument cluster
(Section C2a)

X02

Ignition switch

ACC

B/Y
(F)
W/B
(F)
B
(E)
X09
X08
B/W
(E)

A201

R
(E)

W/B
(E)

B/Y
(E)
A202

Z23

B/Y(E)
A201

Regulator

Starter

A2-01

A2-02

Starter (E)

B/Y

Generator (E)

B/W

W/B

Generator

Wiring Diagram

X01

p24nUK

A-2

Harness symbol

X01

X09

X01

X09

Starter

A201

X07
(F)(E)
[ Black ]

X08
(F)(E)
[ Black ]

Z24

A202

X07
(F)(E)
[ Black ]

Generator
[ Grey ]

X08

A201

(F)(E)
[ Black ]

A202
[ Grey ]

G6
A202

Generator

X02

Generator

F2 CIS

Starter

Generator

A202

X02

Ignition switch

Ignition switch

[ Blue ]

[ White ]

Wiring Diagram

Main fuse box

[ Black ]
(F)(E)

Main fuse box

[ Black ]
(F)(E)

A-3

Starting System / Charging System (WL3, WLT3, as of model year 2002)

Battery

HE AD
B( E)

R( E )
30A
MA IN

B( E)

B/ W( E)
80A

01
B/ W
(E )
A
X

B/ W( F )

AB

07
X

Instrument cluster
(Section C-3a)

02

Ignition switch

02

OF F

ST

IG 1

IG 2

AC C

X 0 2

W
(F)

B
(E )

W/ B
(F )

X 0 3

B/ Y
(F )
15A

E N GINE
X

09

03

B/ W
(F )

B/ W
(E )

R
(E )

W/ B
(E )

A3 03

Starter relay
A3 0 2

Z25

A3 0 1
A3 03
B/ L
(F )
B/ L (F )

B/ L (E )
A3 0 1

R( F )

54

B/ L (F )

Immobiliser module
(Section T-2)
Regulator

Powertrain control module


(PCM)
(Section B-6c)

08

Starter

A 3 0 1

Starter (E)

A3 0 2

B/ L

Generator (E)

B/ W

A3 0 3

Starter relay (F)

W/ B
B/ W

R
B/ Y
B/ L

Generator

Wiring Diagram

X 0 1

p26UK

A-3

Harness symbol

Z
Wiring Diagram

[Grey]
(F)(E)
[Black]

X08

(F)(E)

X09

(F)(E)

X07
Main fuse box

X01

Z26

A3-01
Starter

A3-02
Generator

X02
X02

A3-03
Starter relay

Ignition switch
[Blue]

X03
Fuse block

Ignition switch
[White]

p27nUK

B-1a

Powertrain / Quickstart system (WL, WL Turbo: General specifications, before model year 2002)

Battery

Main fuse box

MAIN

B(E)

X07

X01

X02

Ignition
switch

OFF

ST
GLOW
IG1

IG2

60A

Wiring Diagram

X01
X01

B/W(F)

B/W(E)
80A

B/W
(F)

B/W
(F)

B/W
(F)

ACC

X02

B105

W
(F)

ENGINE

FICD solenoid valve 2

B105

B/W(F)
15A

X03

B106

FICD solenoid valve 1

Fuse block

B106

X03
B/W
(F)

G
(F)

P
(F)

B101
J

Powertrain control module (PCM)


O

BR
(F)

R
(F)

G/R
(F)

W
(F)

B/R
(F)

B101
R/B
(E)

B/W
(F)
B/R(F)

Z27

X09
B102

B103

B109
G/R
(E)

Glow plug
relay

R(F)

Engine Coolant Temperature (ECT) sensor

R(F)
No.4

No.3

B
(F)

No.2

No.1

B104

Fuel shutoff
valve

B/R
(F)

B/R(E)

B107

Glow plugs

B102

B/R
(E)

W
(E)

B108

Diesel pump
unit

B107

NE sensor
B/R(E)
6

B101

Powertrain control module (PCM) (F)

I
O

BR

GY

W/L

R/B

B/W

P
P

B106

FICD solenoid valve 2 (F)

B107

B102

G
E

R/W

G/R

B/Y

B/R

Engine Coolant Temperature (ECT) sensor (E)

Glow plug relay (F)

B103

Glow plug relay (E)

B/W

B/R

G/R

Glow plugs (F)

B105

FICD solenoid valve 1


(F)

BR
R

R/B

B108

NE sensor (E)

B109

B/R
P

B104

Diesel pump unit (F)

B/W

B/W

p28nUK

B-1a

Harness symbol

(F)(E)
(F)(E) X09
X07

[Brown]
Glow plug relay

[Black]

FICD solenoid valve 1

[Black]
Glow plug
relay

B105

B103

B102

Main fuse box

[Black]
FICD solenoid valve 1

(F)(E)
B105
X09

FICD solenoid valve 2

FICD solenoid valve 2

B106

Main fuse box

B106

X01

[Black]

(F)(E)
X07

X01

B107

B107

Engine Coolant Temperature (ECT) sensor

Engine Coolant Temperature (ECT) sensor

B104
Glow plugs

Z28

B109
Diesel pump unit

B103

[Black]

Glow plug relay

B108

[Brown]

NE sensor

WL Turbo

B102
Glow plug relay

B104

[Grey]

B108
NE sensor
[Grey]

B109
Diesel pump unit
[Black]

B101
Powertrain control
module (PCM)

X02
Ignition switch

X03
Fuse block

X02
Ignition switch
[Blue]

[White]

Glow plugs

WL

Wiring Diagram

B102

[Black]

B102

[Brown]
Glow plug relay

[Brown]
Glow plug relay

p29nUK

Powertrain (WL, WL Turbo: General specifications) / Quickstart system (WL, WL Turbo)

B-1b
Z

A/C Relay 1
(Section G1)

B/Y
(F)

R/W
(F)

R/B
(F)

B101
D

GY
(F)

W/L
(F)

Powertrain control module (PCM)

B101

Z29
4

Instrument cluster
(Section C1c)

B101

Powertrain control module (PCM) (F)


O

BR

GY

W/L

R/B

B/W

P
P

G
R/W

G/R

B/Y

B/R

Instrument cluster
(Section C1a)

Wiring Diagram

Thermo switch
(Section G1)

Ignition switch
(Section A1)

p30nUK

B-1b

Harness symbol

Z
Wiring Diagram

Z30
B101

p31nUK

B-2a

Powertrain / Preglow system (WL, WL Turbo: European specifications, before model year 2002)

< >...WL Turbo

Main fuse box


+

MAIN
B(E)

X07

X01

X02
OFF

Ignition
switch

B/W
(F)

GLOW
IG1 IG2
60A

B/W
(F)

B/W
(F)
B/W
(F)

ACC

X02
W
(F)

B205

FICD solenoid valve 1

Fuse block
ENGINE
15A

FICD solenoid valve 2

B205

B/W(F)
X03

B206

B206
49

X03
B/W
(F)

G
(F)

P
(F)

Immobiliser module
(Section T)

B201
L

with immobiliser unit

Powertrain control module (PCM)


O

BR
(F)

R
(F)

G/R
(F)

W
(F)

B/R
(F)

BR/W
(F)

R/L
(F)

G/W
(F)

L/B
(F)

B201
R/B
(E)

B/W
(F)

B/R(F)

B209

Z31

X09
B203

B202

G/R
(E)

Glow plug
relay

W
(E)

R(F)

Engine Coolant
Temperature (ECT)
sensor

Glow plugs

B204

B/R
(F)

B209

No.4

No.3

No.2

No.1

Fuel
shutoff
valve

NE sensor

Diesel
pump
unit

C
B/R
(F)

B207
B
(F)

Injection
timing
control
valve

Fuel Lever Variable Resistor (FLVR) sensor

B/R(E)
B208

B207

B202

B/R
(E)

Idle
switch

without immobiliser
unit

B/R(F)

B/R(E)
3

B201

Powertrain
control module (PCM) (F)

K
S
BR/R
Y/B

L/B

BR

GY

W/L

R/B

B/W

<Y>

B206

FICD solenoid valve 2 (F)

B/W

B207

B202

I
G

R/W

R/L

G/W
H

G/R

BR/W

B/Y

B/R

Engine Coolant Temperature (ECT) sensor (E)

B/R

G/R

Glow plug relay (F)

B203

Glow plug relay (E)

B204

Glow plugs (F)

B205

FICD solenoid valve 1 (F)

BR
R

R/B

B208

NE sensor (E)

B209

B/R

Diesel pump unit (F)

C
R/L

B/R

BR/W L/B

G/W

B/W

(B/R) (V/W)
F

B/W

Wiring Diagram

A
ST

X01

with immobiliser unit

B/W(F)

B/W(E)
80A

X01

( )...

Battery

p32nUK

B-2a

Harness symbol

[ Black ]
(F)(E)

X07

B202

[ Black ]
(F)(E)

[ Brown ]
Glow plug relay

[ Black ]
FICD solenoid valve
1

X09

Glow plug
relay

B205

X07

B203

FICD solenoid valve


2

[ Black ]
FICD solenoid valve
1

B205
FICD solenoid valve
2

B206

Main fuse box

B206

X01

[ Black ]
(F)(E)

X09

B202
Main fuse box

[ Black ]
(F)(E)

X01

B207

B207

Engine Coolant Temperature (ECT) sensor

Engine Coolant Temperature (ECT) sensor

B204
Glow plugs

Z32

B209
Diesel pump
unit
[ Grey ]

B203
B202

Glow plug
relay
[ Brown]

Glow plug
relay

B204

[ Grey ]

B208
NE sensor
[ Grey]

WL Turbo

B208

NE sensor

B209
Diesel pump unit
[ Grey]

B201
Powertrain control
module (PCM)
[ Black ]

X02
X03
Fuse block

X02
Ignition switch
[ Blue ]

Ignition switch
[ White ]

Glow plugs

WL

Wiring Diagram

B202

[ Brown ]
Glow plug relay

[ Brown ]
Glow plug relay

p33nUK

Powertrain / Preglow system (WL, WL Turbo: European specifications, before model year 2002)

B-2b

Thermo switch
(Section G1)

A/C Relay 1
(Section G1)

12

10

B/Y
(F)

BR/R
(F)

Y/B
(F)

R/W
(F)

R/B
(F)

B201
D

Powertrain control module (PCM)

B201

GY
(F)

Y
(F)

W/L
(F)

Z33

B210
B/R
(F)

Exhaust Gas Recirculation (EGR) valve


WL Turbo
4

Instrument cluster
(Section C1c)

Instrument cluster
(Section C1a)

B201

Powertrain
control module (PCM) (F)

K
S
BR/R
Y/B
T

L/B

BR

GY

W/L

R/B

B/W

<Y>
R

B210

R/W

R/L

G/W
H

G/R

BR/W

B/Y

B/R

Exhaust Gas Recirculation (EGR) valve (F)


B/R

Wiring Diagram

< >...WL Turbo

Data Link Connector


(DLC)
(Section U)

Ignition switch
(Section A1)

p34nUK

B-2b

Harness symbol

Z
Wiring Diagram

[ Green ]
Exhaust Gas Recirculation
(EGR) valve

B210

Z34
B201
Powertrain control module (PCM)
[ Black ]

p35nUK

B-3a

Powertrain (G6) / Ignition (G6)

X01

X01

MAIN

B/W(E)

B/W(F)

FUEL INJ

X01

BTN

L/W(E)
30A

Fuse block
X03

30A

Ignition switch

L/R(F)
X03

10A

IG1 IG2

X03

ACC

X02

X03

ENGINE

OFF

ST

ROOM
W/R(F)

specifications (LHD)

X02

Fuse block

X08
W/R(E)

W(F)
15A
B301

B/W
(F)

L/W
(F)

1A

2F

B302
W
(F)

Main relay

1E

1D

1K

Powertrain control module (PCM)

2U

1B

2V

2W

2E

2C

LG/B
(F)

L/W
(F)

P
(F)

B/O
(F)

B301
LG/R
(F)

X05
W
(F)

B302

W
(F)

O
(F)

LG/R
(INJ)

B304

R/W
(F)

O
(F)

O
(F)

Y/B
(F)

Y
(F)

BR/R
(F)

B/Y
(F)

Ignition coil
9

Capacitor

Z35

Ignition
module
B305

10

11

12

Fuel injector 1

B/Y
(INJ)

B/Y
(INJ)

1T

Ignition coil (F)

B/Y

B310

B311

B309
B/O(F)

B/Y
(INJ)

B/Y
(F)

X05

B/Y(INJ)

B/Y(INJ)

B/O
(INJ)

X05

B/Y(F)

B/Y(F)

13

B302

1O

R/G

W/G

G/R

BR/R

BR

1P

1N

(B)
1L

1R

B305

Idle air control valve


(IAC) (INJ)
L/G

1M

1Q

G/B

Camshaft
position
sensor

1S

1V

Idle air control valve


(IAC)

Fuel injector 4

B/Y
(INJ)

Powertrain control module (PCM) (F)


1U

B311

B309

Fuel injector 2
B308

B/Y
(INJ)

B
(F)

B310

B308

B307

B/Y(F)

B304

LG/B
(INJ)

Fuel injector 3

B306

B(F)

B301

LG/B
(INJ)
B307

B306

B
(F)

Canister purge solenoid valve,


Fuel pressure solenoid valve,
Mass Air Flow (MAF) sensor
(Section B3b)

LG/R
(INJ)

Data Link Connector


(DLC)
(Section U)

B303

B/Y(F)

LG/R
(INJ)

L/G
(INJ)

B310

B303
B
(F)

B/Y
(F)

LG/B
(INJ)

1K

1I

1G

1E

1C

Y/B
R/B

L/O

1J

1H

2Y

L/R
Y

1F

B/Y

W/L

1B

2Z

1D

Ignition module (F)

2W

2U

L/W

LG/R

L/Y

LG/B

2X

2V

2S

2Q

2O

2M

G/W

G/B

G/Y

L
2T

2R

B306

B311

1A

R/W

Camshaft position sensor (F)


P

B/Y

B/O

2P

2K

2I

2E

2C

Main relay (F)

BR/W

B/O

L/W

B/W

R/W

BR/B

B/Y

2N

2L

2F

2D

2B

2J

B/Y

2H

B307

B303

Capacitor (F)

2A

Fuel injector 1 (INJ)

LG/R

2G

Fuel injector 3 (INJ)

LG/R

B/Y

B308

Fuel injector 2 (INJ)

LG/B

B/Y

B309

Fuel injector 4 (INJ)

LG/B

B/Y

Wiring Diagram

X01

80A
X08

( )... European

X07

B(E)

Main fuse box

Battery

p36nUK

B-3a

Harness symbol

Z
Wiring Diagram

[ Black ]

(F)(E)
X08
Main fuse box

X01

[ Black ]

(F)(INJ)
X05

[ Black ]
Idle air control valve (IAC)

B310

B309
Fuel injector 4
[ Grey ]

B307
Fuel injector 3
[ Grey ]

B303

Z36

Capacitor
[ Black ]

B304

B302

Ignition coil

Main relay

B305
X07
(F)(E)

Ignition module

B311
Camshaft position sensor

13

[ Black ]
[ Grey ]

B306
Fuel injector 1

[ Grey ]

B308
Fuel injector 2
[ Grey ]

[ Grey ]

B301
Powertrain control module (PCM)
[ Yellow ]

X02
Ignition switch
[ White ]

X03
Fuse block

X02
Ignition switch
[ Blue ]

p37nUK

B-3b

Powertrain (G6) / Ignition (G6)

European specifications
(LHD)

1N

2N

1P

2D

2L

2Q

2K

2O

2M

2X

2T
B301

V
(F)

W
(F)

BR
(F)

BR/B
(F)

G
(F)

G/W
(F)

BR/W
(F)

G/Y
(F)

X09

G/B
(F)

L/Y
(F)

L
(F)

X05
B319

BR
(E)

BR/W
(INJ)

B320

Canister purge
solenoid valve

G/Y
(INJ)

Fuel pressure solenoid valve


B320

B319
B312

B317

B313

Power
steering
pressure
switch

Door ajar
switch, tailgate

B314

Z37

Heated
oxygen
sensor
(HO2S),
front

B317

B315

Intake air temperature sensor


B314

BR/B
(F)

B316

Engine Coolant
Temperature
(ECT) sensor

Throttle Position
Sensor (TPS)

B/Y
(F)
B/Y(F)

B316

B315

BR/B
(F)

BR/B
(F)

B/Y
(F)

BR/B
(INJ)

B/Y
(F)

B/Y
(F)

G/B
(F)

B318

X05

B318
BR/B(F)

BR/B(F)

BR/B(F)

Mass Air Flow (MAF) sensor

BR/B(F)

Main relay
(Section B3a)

B301

Powertrain control module (PCM)


(F)
1U
1S
1Q
1O
R/G

B312
1M

W/G

G/R

BR

1P

1N

1K

1I

1G

BR/R

1E

1C

Y/B

2Y

1A
L/R

2W

2U

L/W

LG/R

L/Y

LG/B

2S

2Q

2O

2M

G/W

G/B

G/Y

2K

2G

2I

2E

2C

2A

BR/W

B/O

R/W

BR/B

2N

2L

2F

2D

2B

B313

Door ajar switch, tailgate (F)

Power steering pressure switch (E)

V
G/B
1V
B314

1T

1R

L/O

1J

1H

B315 Engine

Y
1F

Coolant Temperature
(ECT) sensor (F)

Intake air temperature


sensor (F)
BR/B

(B)
1L

R/B

BR/B

1D

B/Y

W/L

1B
B316

2Z

2X

2V

Throttle Position Sensor


(TPS) (INJ)

L
2T
B317

BR/W BR/B

Canister purge solenoid


valve (F)

B320

L/Y

B/Y

2P

2J

2H

B318

G/W
G/Y

B319

2R

Heated oxygen sensor


(HO2S), front (F)

Fuel pressure solenoid


valve (F)

B/Y

BR/B

BR

Mass Air Flow (MAF)


sensor (F)
B/Y

G/B

BR/B

Wiring Diagram

Powertrain control module (PCM)

( )...

p38nUK

B-3b

Harness symbol

Wiring Diagram

B317

B320

[ Black ]
(F)(E)

X09

[ Black ]
Heated oxygen sensor (HO2S), front

[ Blue ]
Evaporative emission
(EVAP) canister vent
valve

[ Black ]
Intake air temperature sensor

B314

[ Black ]
Canister purge solenoid valve

Throttle Position
Sensor (TPS)

B319

B316

X05
(F)(INJ)
[ Black ]

Z38

B315

Engine Coolant Temperature (ECT) sensor

[ Black ]

B312

B318

Door ajar switch, tailgate


[ Black ]

B313

Power steering
pressure switch

Mass Air Flow (MAF) sensor


[ Black ]

B301
Powertrain control module
(PCM)
[ Yellow ]

p39nUK

B-3c

Powertrain (G6) / Ignition (G6)

specifications (LHD)

Wiring Diagram

Powertrain control module


(PCM)
1H

1Q

1J

1M

2Z

1O

L/O
(F)

R/G
(F)

R/B
(F)

G/R
(F)

W/L
(F)

W/G
(F)

2A

2B

1L

1V

B
(F)

B
(F)

B
(F)

G/B
(F)

B301

B
(F)

G/B(F)

X05

European
specifications
(LHD)

X09
G/B
(E)

G/B
(F)

Z39

B321
6

14

Fuel pump relay


(Section B5)

Coolant pressure
switch
(Section G2)

15

A/C Relay 1
(Section G2)

Brake pressure
switch
(Section F2)

Instrument cluster
(Section C2a)

B322

Clutch
switch

16

Neutral
position
switch

B321
B
(INJ)

B322

B
(F)

B
(E)
X09
B
(F)

12

B301

Powertrain control module (PCM)


(F)
1U
1S
1Q
1O
R/G
G/B
1V

1T

1R

B321
1M

W/G

G/R

BR

1P

1N

1K

1I

1G

BR/R
(B)
1L

1E

1C

L/O

1J

1H

Y
1F

2Y

L/R

Y/B
R/B

1A

1D

B/Y

W/L

1B

2Z

2W

2U

2S

L/W

LG/R

L/Y

LG/B

2V

2T

2X

2Q

2O

2M

G/W

G/B

G/Y

2R

2P

2K

2I

2G

2E

2C

BR/W

B/O

R/W

BR/B

2N

2L

2F

2D

2B

2H

Clutch switch (F)

2A

2J

B322

Neutral position switch


(E)

B
B

G/B

( )... European

G/B

p40nUK

B-3c

Harness symbol

[ Black ]
(F)(INJ)

X09

X05

Wiring Diagram

[ Black ]
(F)(E)

Neutral position switch

B322

Z40
12

B301

Powertrain control module (PCM)


[ Yellow ]

B321

p41nUK

B-4a

Powertrain (F2 CIS) / Ignition (F2 CIS)

Battery

Main fuse box


X01

X01

MAIN

X07

B(E)

B/W(E)

B/W(F)

X01

FUEL INJ

X01

BTN

L/W(E)

X08

30A

X02

30A

OFF

ST

ROOM
W/R(F)

W/R(E)

Fuse block

Ignition switch

L/R(F)
X03

10A

IG1 IG2

X03

ACC

X02

Fuse block
X03

X03

ENGINE

W(F)

W(F)

B/W(F)
15A

L/W
(F)

L/W
(F)

B401
1A
L/B(F)
B401

1G
2F

B402

Main
relay

W
(F)

1E

1D

1I

Powertrain control
module (PCM)

1K

2U

2V

2W

2E

2C

LG/R
(F)

LG/B
(F)

L/W
(F)

P
(F)

B/O
(F)

LG/R
(INJ)

LG/B
(INJ)

L/G
(INJ)

1B

B401

X05
W
(F)

B402

W
(F)

O
(F)

B404
L/B(F)

R/W
(F)

O
(F)

O
(F)

Y/B
(F)

Y
(F)

BR/R
(F)

B/Y
(F)

Ignition coil

Capacitor

Z41

Ignition
module

O(F)

B403
B405

B
(F)

O
(F)

10

11

12

B406

Canister purge solenoid valve,


Fuel pressure solenoid valve,
Mass Air Flow (MAF) sensor
(Section B4b)

LG/B
(INJ)

B
(F)

B407

Fuel injector
1

Data Link Connector (DLC)


(Section U)

LG/B
(INJ)

B411

Idle air
control
valve (IAC)

B409

B408

Fuel injector
3

Fuel injector
2

Fuel injector
4

Camshaft
position
sensor

B410
B406

B407

B/Y
(INJ)

B(F)

B/Y(F)

LG/R
(INJ)

B410

B403
B/Y
(F)

LG/R
(INJ)

B/Y
(INJ)

B/Y
(INJ)

B411

B409

B408
B/Y
(INJ)

B/O(F)

B/Y
(INJ)

B/Y
(F)

X05

50
B/Y(INJ)

B/Y(INJ)

Instrument cluster
(Section C2a)

B/O
(INJ)

X05

B/Y(F)

B/Y(F)
1

B401

Powertrain control module (PCM)


(F)
1U
1S
1Q
1O
R/G
G/B
1V

B404

B410

1T

1R

Ignition coil (F)

L/G

B402
1M

W/G
BR

1P

1N

B405

1K

1I

BR/R

B/W

L/B

R/B

L/O

1J

1H

1L

B/Y

1G

1E

1C

Y/B
Y
1F

1A

2Y

2U

L/W

LG/R

B/Y

L/Y

LG/B

1D

1B

2Z

2X

2V

2S

R/W

position sensor (F)

B/Y

B/O

2Q

2O

2M

G/W

G/B

G/Y

2P

2N

2L

L
2T
B406

B411 Camshaft

2W

L/R

Ignition module (F)

Idle air control valve (IAC)


(INJ)

13

2R

2K

B/Y

2G

2E
P

B/O

G/O

R/W

BR/B

2H

2F

2D

2B

BR/W

Fuel injector 1 (INJ)

LG/R

2I

2J

B407

2C

2A

B403 Capacitor

L/W

L/W

B/Y

L/B

Fuel injector 3 (INJ)

LG/R

Main relay (F)

B/Y

B408

Fuel injector 2 (INJ)

LG/B

B/Y

(F)

B409

Fuel injector 4 (INJ)

LG/B

B/Y

Wiring Diagram

X08

80A

p42nUK

B-4a

Harness symbol

[ Black ]
(F)(E)

Wiring Diagram

X08

[ Black ]
Idle air control valve (IAC)

B410
Main fuse box

X01
13

B409

Fuel injector 4
[ Grey ]

B407
Fuel injector 3
[ Grey ]

B403
Capacitor

Z42

[ Black ]

B402

B404

Main relay

Ignition coil

X07
(F)(E)
[ Black ]

X05
(F)(INJ)
[ Black ]

B405
Ignition module

B406
Fuel injector 1
[ Grey ]

[ Grey ]

B408
Fuel injector 2
[ Grey ]

B411
Camshaft position sensor

B401

[ Grey ]

Powertrain control module (PCM)


[ Yellow ]

X02
Ignition switch
[ White ]

X03

X02

Fuse block

Ignition switch
[ Blue ]

p43nUK

B-4b

Powertrain (F2 CIS) / Ignition (F2 CIS)

1N

1P

2N

2D

2L

2K

2Q

2M

2H

2O

2P

2T

2X

B401
V
(F)

W
(F)

BR
(F)

BR/B
(F)

G
(F)

G/W
(F)

BR/W
(F)

G/Y
(F)

BR/W
(INJ)

G/Y
(INJ)

X05

L/Y
(F)

L
(F)

X05
B419

G/W
(INJ)

G
(INJ)

G/W
(INJ)

B420

Canister
purge solenoid valve

Fuel pressure solenoid valve

B419
B412

B413

Door ajar
switch, tailgate

B417

Power steering pressure


switch

B414

Z43

Heated
oxygen
sensor
(HO2S),
front

B415

Intake air temperature sensor

B416

Engine Coolant
Temperature (ECT)
sensor

B414

B415

G/O
(F)

Throttle
Position
Sensor
(TPS)

B416

G/B
(F)

O
(F)

B420

B/Y
(F)

B/Y
(F)
B/Y(F)

X05

B417
BR/B
(F)

BR/B
(INJ)

BR/B
(INJ)

BR/B
(INJ)

B/O
(INJ)

B/O
(F)

B/Y
(F)

B/Y
(F)

BR/B(INJ)
B418

X05

Mass Air Flow (MAF) sensor

BR/B(F)

Main relay
(Section B4a)
13

B401

Powertrain control module (PCM) (F)


1U

1S

1Q

1O

R/G

W/G

G/B
1V
B414

1T

1R

Intake air temperature


sensor (INJ)

BR/B

B412
1M

1K

1I

BR/R

BR

1P

1N

B415

1L

B/W

L/B

R/B

L/O

1J

1H

1E

1C

Y/B
Y
1F

Engine Coolant Temperature


(ECT) sensor (INJ)

BR/B

1G

1D

2Y

1A

2W

2U

2S

L/R

L/W

LG/R

B/Y

L/Y

LG/B

2V

2T

2Z

1B
B416

2X

Throttle Position Sensor


(TPS) (INJ)

B417

BR/W BR/B

Canister purge solenoid


valve (F)

B420

L/Y

B/Y

2O

2M

G/W

G/B

G/Y

2P

2N

2L

2R

2K

2G

2E
P

B/O

G/O

R/W

BR/B

2H

2F

2D

2B

2I

BR/W

2J

Heated oxygen sensor


(HO2S), front (F)

Fuel pressure solenoid


valve (F)

B/Y

2C

2A

BR/B

Door ajar switch, tailgate (INJ)

B413

Power steering pressure switch (F)

B
G/W

B418

G/W
G/Y

B419

2Q

BR

Mass Air Flow (MAF)


sensor (F)

B/O

G/B

G/O

B/Y

Wiring Diagram

Powertrain control
module (PCM)

p44nUK

B-4b

Harness symbol

[ Black ]
Engine Coolant Temperature (ECT)
sensor

B415

B419

Intake air temperature


sensor

B414

Wiring Diagram

[ Black ]
Canister purge solenoid
valve

Door ajar switch, tailgate

B412
Throttle Position Sensor (TPS)

[ Blue ]
Fuel pressure solenoid valve

B416

B420

13

Z44

X05
(F)(INJ)
[ Black ]

B417
Heated oxygen sensor
(HO2S), front
[ Black ]

B418
B413

Mass Air Flow (MAF)


sensor
[ Black ]

Power steering pressure switch

B401
Powertrain control
module (PCM)
[ Yellow ]

p45nUK

B-4c

Powertrain (F2 CIS) / Ignition (F2 CIS)

Z
Wiring Diagram

Powertrain control module (PCM)


1H

1Q

1J

L/O
(F)

R/G
(F)

R/B
(F)

1O

2A

2B

1V

W/G
(F)

B
(F)

B
(F)

G/B
(F)

B401

B
(F)

G/B(F)

X09

X05
G/B
(E)

G/B
(F)

Z45

B421
6

14

Fuel pump relay


(Section B5)

Coolant pressure switch


(Section G2)

A/C Relay 1
(Section G2)

B422

Clutch switch

16

Brake pressure switch


(Section F2)

Neutral position
switch

B421
B
(INJ)

B
(F)

B422
B
(E)
X09
B
(F)

12

B401

Powertrain control module (PCM) (F)


1U

1S

1Q

1O

R/G

W/G

G/B
1V

1T

1R

B421
1M

1K
BR/R

BR

1P

1N

1L

1I

1G

B/W

L/B

R/B

L/O

1J

1H

1E

1C

Y/B
Y
1F

1D

1A

2Y

2W

2U

2S

L/R

L/W

LG/R

B/Y

L/Y

LG/B

2V

2T

1B

2Z

2X

2K

2Q

2O

2M

G/W

G/B

G/Y

2P

2N

2L

2R

2I

Clutch switch (F)

2A

2E
P

B/O

G/O

R/W

BR/B

2H

2F

2D

2B

BR/W

2J

2C

2G

B422

Neutral position switch


(E)

B
B

G/B

G/B

p46nUK

B-4c

Harness symbol

Z
Wiring Diagram

12
[ Black ]
(F)(E)

X09

Neutral position switch

B422

Z46
X05
(F)(INJ)
[ Black ]

B401
Powertrain control module
(PCM)
[ Yellow ]

B421
Clutch switch

p47nUK

B-5

Fuel system (before model year 2002)

Battery

Main fuse box


+

MAIN

B(E)

B/W(E)
X01

B/W(F)

X01

X02

X07
OFF

ST

Fuse block

F2 CIS,G6

WL,WL Turbo

IG1 IG2

ENGINE

Main fuse box

W(F)

B/W(F)

(PTC)
30A

Instrument cluster
(Section C1a)

X01

B502

B/W
(F)
A

B/W
(F)
C

X03

15A

X03

Instrument cluster
(Section C2a)

Fuel pump relay

48
G/B
(E)

19

B502
Y
(F)

L/O
(F)

B503

Fuel heater

L/O(F)

X04

X18
18

B503
Y
(R2)

Z47

Data Link
Connector
(DLC)
(Section U)

B501

Fuel pump/fuel
gauge sender

14

Powertrain control module


(PCM)
(Section B3c,
4c)
Fuel
pump

B501

X09

Y
(F)

G/R
(R)

Y
(R)

G/R
(R2)

Y
(R2)

L/O
(F)

Y
(R)

B/R
(E)

G/R
(F)

X04

X18

B501

Fuel
gauge

Fuel pump/fuel
gauge sender

B/R
(R2)
B501

B/R
(F)

X18
B/R(R)

B
(R2)

B/R(F)
X04

X18
16

B501

Fuel pump/fuel gauge sender (R2)

WL,
WL Turbo

B502

10 11

Fuel pump relay (F)

B/R

C B/W

B/W

G/R

G/R

L/O

F2 CIS,G6
B/R

B/R(R)

B/R(R2)

B503

Fuel heater (E)

A
G/B

B/R

B/O(F)
X04

ACC

X02

B/O(INJ)
X05
13

Ignition switch

Wiring Diagram

80A

p48nUK

B-5

Harness symbol

Main fuse box

10
(R)(R2)

X05

X18

(F)(R)
X04
11

X07

B501

(F)(E)
[ Black ]

Fuel pump/fuel gauge sender

F2 CIS,G6

Z48

13

Fuel heater
Main fuse box

B503

[ Black ]
(F)(E)

X09

X01

X04
(F)(R)

X02
Ignition switch
[ White ]

X02

16

B502
WL,WL Turbo

Fuel pump relay

X03
Fuse block

Ignition switch
[ Blue ]

Wiring Diagram

X01

[ Black ]
(F)(INJ)

B-6a

Powertrain / Preglow system (WL3, WLT3, as of model year 2002)

B T N 30A

X 0 8

01
W/ R( E)

B( E)

B /L(F )

B/ W( F )

B/ W( E)

F IP 15A
A

X 0 2

07

L/W (F )

Ignition
switch

OF F

ST

B/ W( F)
X 0 3

B6 02

B/ W
(E )

X 0 3

IG 1

07
X

PCM module relay

IG 2

ROOM
10A

AC C

02

15A

X 0 3

B /L(F )

LG
(F )

B/ L
(F )

B/ L
(F )

4C

4D

4X

B6 0 8

B/ W
(F)

B6 0 1

B6 0 7

G/O
(F )

Y/ G
(F )

4Z

4T

B6 0 8
L G/R
(F )

2K

4V

R/B
(E )

1C

1V

2D

4A

3O

4B

1D

Shield

BR
(F)

Fuel pump
(Section B-6c)

G/B
(F )
X

Z49

B6 0 4

P
(F )

B6 0 3

Glow plug relay

B/ R
(F )

L
(F )

G/W
(F)

B/ R
(F)

B6 1 1

B6 1 3

Clutch
switch

No .1

No .2

No .3

No .4

Glow plugs

B 6 0 8

L/W

B/ L

LG

1K

1I

1G

1Q

1C

20

1A

2K

B/ L

L/Y

BR/Y

R/L

GY /L

G/R

G Y /B

G/Y

P/ B

G/ B

1V

1T

1R

1P

1N

1L

1J

1H

1F

1D

B 6 03

L /R

B6 0 4

Glow plug relay (F)

2G

BR /W

BR /B

L/W

W/ L

1B

2L

2J

3K

2C

R/Y

2H

Glow plug relay (E)

2F

P/ L

BR /R

Y/ R

2D

B6 0 5

3I

3G

3E

3M

3A

3P

3N

Glow plugs (F)

3L

3J

3H

B6 06

3F

3D

4U

LG
3B

4Q

LG /B

L/B

GY

(G /O )

B/ L

BR

Y/ G

4Z

4X

Intake air control valve (F)

4V

B6 07

09

B/ R
(F )
20

4O

4M

4K

4I

4S

4W

R/W
B/ L

2B

B
(F )

4Y

3C

G/W

B6 1 3
B/ R
(E )

B6 1 2

B
(F )

20

3O

2A

2E

2I

1E

B/ W

PCM module relay (F)


C

1M

1O
1S

B/ R
(F)

Fuel pump
3

1U

B6 1 1

B/ R
(F )

B
(F )

Neutral
position
switch

B6 1 2

Idle switch

B6 0 5

G/B (E )

G/B
(F )

B6 1 0

B6 0 3

09

G/B (F )

R
(F)

L/W

4I

4Q

B6 0 1
55

B 6 0 2

B6 09
W/ R
(F )

Powertrain control module (PCM)

3B

Powertrain
control module (PCM)
(F)

Exhaust
Gas Recirculation
(EGR)
valve

B6 0 1

01
B/ L
(F)

B 6 01

B6 09

Exhaust gas recirculation (EGR)


solenoid valve
(vent)

L/R
(F )

03

B /L( F)

B/ L
(F )

B/ L
(F )

Exhaust gas recirculation (EGR)


solenoid valve
(vacuum)

B6 0 6
B/ L(F)

GL OW
60 A

B/ L
(F )

B6 0 7

Intake air
control
valve

E N GINE

B6 02

B/ L
(F )

B6 0 6

B/ L
(F )

X 0 3

W
(F )

B/ L
(F )

B/ L
(F )

03

4G

B/ Y

LG/ R

W/ R

G/B

R/B
4R

4T

4P

4N

4L

4J

4H

4C

4A

B/ L

B/ R

B/ L

B/ R

4D

4B

4E

4F

Exhaust gas recirculation (EGR) solenoid valve (vacuum) (F)

BR
R

R/B

G/O

Y/ G

B /L

B/ L

Exhaust gas recirculation (EGR) solenoid valve (vent) (F)

LG/R

B/ L

B6 0 9

Exhaust Gas Recirculation


(EGR) valve (F)
W/ R

B /L

B 6 10

Fuel pump (F)

B6 11

Idle switch (F)

G/W

B6 12

Clutch switch (F)

G/B

B6 13

Neutral position switch (E)

G/B

B /R

Wiring Diagram

B/ L (F)
A

B/ W( E)

)... W LT 3

WL T 3

W/ R( F )

MA IN 8 0 A

Battery

p50UK

B-6a

Harness symbol

[Black]
(F)(E)

X07

B604
[Brown]
Glow plug relay

(F)(E)

[Black]

X08
[Grey]
(F)(E)

Wiring Diagram

[Brown]
Glow plug
relay

Exhaust gas recirculation (EGR) solenoid


valve (vacuum)

B607

X09
[Black]
Exhaust gas recirculation (EGR) solenoid valve (vent)

B603
Main fuse box

Neutral position switch

B608

X01

B613

B606
Intake air control valve
[Black]

B609

Z50

Exhaust Gas Recirculation (EGR)


valve

B603
Glow plug relay

Idle switch

B611
Clutch switch

B612

B605
Glow plugs

B610
Fuel pump
[Grey]
20

B601
Powertrain control
module (PCM)

X02
Ignition switch
[White]

X03
B602
PCM module relay

Fuse
block

X02
Ignition switch
[Blue]

B-6b

Powertrain / Preglow system (WL3, WLT3, as of model year 2002)

12

58

Immobiliser module
(Section T-2)

10

11

59

B/ Y
(F )

Y/ R
(F )

W
(F)

4K

2B

Wiring Diagram

Data Link Connector


(DLC)
(Section U-2)

W/ L
(F )
W/ L (F )
BR/ R
(F )

W/ L
(F)
B6 0 1
2J

Reference
voltage
1G

1I

1K

1S

2L

2A

2I

Powertrain control module (PCM)


2E

1F

1J

1T

1A

1P

2C

1R

B6 01

BR /W
(F )

BR /B (F )

BR/ B (F )

56

Shield
BR /W (F )

BR/ W (F )
W
(F )

B
(F)

R
(F )

L/Y
(F )

L/ W
(F )

R/Y
(F )

Z51

BR /W
(F )

BR/ B
(F )

G/Y
(F )

BR/ B
(F )

BR /Y
(F )

V
(F )

BR/ W
(F )

V
(E )

BR/ W
(E )

09

BR/ B
(E )
B6 14

BR/ B (E )

10

B/ R
(F )

BR /B
(E )

B6 1 5

B6 1 5

Fuel pump
20

B6 0 1

1U

Powertrain
control module (PCM) (F)

B 6 14

1K

1I

1G

1Q

1C

L/Y

BR/Y

R/L

GY /L

G/R

G Y /B

G/Y

P/ B

G/ B

L /R

1V

1T

1R

1P

1N

1L

1J

1H

1F

1D

BR /B

L/W

W/ L

1B

2L

B 61 5

Fuel pump (F)


R

L/ Y

BR /W

/Y

2F

BR /R

Y/ R

2D

2B

BR/ B

P/ L

(F )

(F )

(F)

B6 1 8

3O

3K

EGR valve position


sensor

3I

3G

3E

B6 1 9

G/W

3A

3N

4Y

3L

3J

3H

B 6 1 6

Engine Coolant
Temperature (ECT)
sensor (E)

3F

3D

4U

LG
3B

BR /Y

LG /B

L/B

GY

(G /O )

B/ L

BR

Y/ G

4Z

4X

4V

Intake Air Temperature (IAT) sensor 2

BR /B

Boost pressure sensor (F)

BR /W

GY /L

BR /B

BR /B

BR /B

B 61 9

Accelerator pedal position sensor (F)

BR /B

P/ L

R/L

BR /W

4Q

4O

4M

4K

4I

4S

4W

R/W
B/ L

3P

Boost pressure sensor

3C

3M

P/ L

R/L

(F )

L /W

B 61 8

BR /W

2H

BR /B

EGR valve
position sensor
(E)
V

R/Y

BR/ W

(F )

B6 1 6

2C

BR /W

2J

2A

BR/ B

(F )

Accelerator pedal position sensor

Intake Air Temperature (IAT) sensor 2

2E

2G
2I

B/ L

BR

2K

1A

1E

B/ W

B6 1 7

1M

1O
1S

B6 1 6

Engine Coolant
Temperature
(ECT) sensor

GY /L

(F )

BR/ B
(E )

G/Y
(E )

EPROM

BR /W

Powertrain control module


(PCM)
(Section B-6c)

BR /B (E )
B6 1 7

BR/ Y
(E )

( )...W LT 3
Instrument
cluster
(Section C-3a)

G/Y

4T

4G

B/ Y

LG/ R

W/ R

G/B

R/B
4R

4P

4N

4L

4J

4H

4C

4A

B/ L

B/ R

B/ L

B/ R

4D

4B

4E

4F

p52UK

B-6b

Harness symbol

Z
Wiring Diagram

[Grey]
(F)(E)

X10

B615
Engine Coolant Temperature (ECT) sensor

Z52
B616
Intake Air Temperature (IAT) sensor 2
[Black]

B614
B617
EGR valve position sensor

Fuel pump
[Grey]

B618
Boost pressure sensor

[Grey]

20

B601
Powertrain
control
module
(PCM)

B619
Accelerator
pedal position sensor

B-6c

Powertrain / Preglow system (WL3, WLT3, as of model year 2002)


Thermo switch
(Section G3)

A/C Relay 1
(Section G3)

Instrument cluster
(Section C3a)

( )... W LT 3

Instrument cluster
(Section C3b)

60

B/ L
(F )

R/W
(F )

R/B
(F )

G/R
(F )

GY
(F )

1U

3C

4L

1N

4S

Wiring Diagram

Starter relay
(Section A3)

B6 0 1

Powertrain control module (PCM)


1L

4U

4W

1M

4E

3D

4Y

1O

1Q

1H

1B

B6 0 1

Shield
Fuel pump
(Section B6b)

56

PCM module relay


(Section B6a)

55

BR /B (F )

B/ L(F)

BR /B (F )

B/ L(F)

B/ L (F)

B/ L (F)
B/ L
(F )

LG/B
(F )

BR/ B (F )

L/B
(F )

GY /B
(F )

R
(F )

BR/ B
(F )

B
(F )

W
(F )

B/ L
(F)

BR/ B
(F )

P
(F )

Z53

B/ R
(F )

Fuel temperature
sensor

Intake Air Temperature (IAT)


sensor 1

20

1U

Powertrain
control module (PCM) (F)

B 6 2

1O
1S

1Q

1M

1K

1I

1G

1C

2K

1A

2G

B/ L

L/Y

L /R

BR /W

B/ W

BR/Y

R/L

GY /L

G/R

G Y /B

G/Y

P/ B

G/B

BR /B

L/W

W/ L

1V

1T

1R

1P

1N

1L

1J

1H

1F

1D

1B

2L

B6 2 1

Fuel pump (F)

LG /B

L/ B

BR /B

GY /B

B/ L

B/ L

2J

B/ L
D

G/B

B/ R

B/ L
A

3O

2A

3K

R/Y

2H

2F

P/ L

BR /R

Y/ R

2D

3I

3G

3E

3M

2C

Mass Air Flow (MAF) sensor / Intake Air Temperature (IAT) sensor
(F)
BR /B

2E

2I

1E

B6 2 2

3A

B/ L
3N

TDC sensor (F)

B/ L

P/ B

BR /B

3L

3J

3H

3F

3D

TDC sensor
20

4U

LG
3B

4Q

4O

4M

4K

4I

4S

4W

R/W

3P

4Y

3C

G/W

2B

Mass Air Flow


(MAF) sensor

Mass Air Flow (MAF) sensor / Intake


Air Temperature (IAT) sensor

Fuel pump

B6 0 1

BR/ B
(F )

B6 2 2

B/ R
(F )

Fuel shutoff valve

P/ B
(F )

B/ L
(F )

G/ B
(F )

D A

B6 2 1

B6 2 0

B/ L
(F )

B/ L
(F )

LG /B

L/B

GY

(G /O )

B/ L

BR

Y/ G

4Z

4X

4V

4T

4G

B/ Y

LG/ R

W/ R

G/B

R/B
4R

4P

4N

4L

4J

4H

4C

4A

B/ L

B/ R

B/ L

B/ R

4D

4B

4E

4F

p54UK

B-6c

Harness symbol

Z
Wiring Diagram

Z54

B622
TDC sensor
[Grey]

B620
Fuel pump
[Grey]

B621
Mass Air Flow (MAF)
sensor / Intake Air Temperature (IAT) sensor

20

B601
Powertrain control
module (PCM)

B-7

Fuel system (WL3, WLT3, as of model year 2002)

Battery
+

PT C
X 0 1

30 A

Instrument cluster
(Section C3a)

01

48
G/ B
(E )

Y
(F )

B7 0 2

04

18

Y
(R )

Fuel heater
Y
(R 2)

B7 0 1

Fuel gauge
sensor

B7 0 2

with fuel heater

B7 0 1
B
(E )

B/ R
(R 2)

Z55

18

04

10
B/ R
(R )

B
(F )
B/ R
(F )

B7 01

Fuel gauge sensor (R2)

B7 0 2

Fuel heater (E)

G/B
B/ R

16

Wiring Diagram

B( E)

p56UK

B-7

Harness symbol

Z
Wiring Diagram

(R)(R2)
Fuel heater

B702

X18
[Grey]
(F)(E)

(F)(R)

X10

Main fuse box

X04

X01

B701
Fuel gauge sensor

Z56

Regular cabin
Stretch cabin
(R)(R2)

X18
16

(F)(R)

X04

X04
(F)(R)

B701
Fuel gauge sensor
Double cabin

p57nUK

C-1a

Instrument cluster (WL, WL Turbo, before model year 2002)

MAIN
B(E)

B/W(E)
X01

B/W(F)

X02

X07

BTN

Ignition switch
OFF

ST

W/R(E)
30A

X08

X01
W/R
(F)

IG1 IG2

Fuse block

ACC

4x4 with remote freewheel control system


4x4 without remote freewheel control system
with air bag
European specifications (LHD)
with immobiliser unit
not used

Fuse block

X02

METER

ROOM

W(F)

B/Y(F)

L/R(F)
10A

X03

...
...
...
...
...
...

15A

X03

B/Y
(F)

X03

X03

Instrument cluster

C101
1K

1J
22

Safety

Water temperature gauge

1.4W

Fuel gauge

1I

2K

Tachometer

Microprocessor

1F

1L

1P

1N

1G

Charge

Speedometer

1M

Sedimentor
1.4W

1.4W

2C

2I
C101

L
(F)
BR/B
(F)

L/W
(F)

Y
(F)

B/R
(F)

X09

Y/B
(F)

R/Y
(F)

W/L
(F)

W/B
(F)

21

W
(F)

Z57

C104
L
(E)
51

L
(E)

L/W
(E)

48

L/W
(E)

C103

Door entry
switches
(Section I3)

C103

Fuel pump/fuel
gauge sender
(Section B5)

Immobiliser module
(Section T)

Powertrain control
module (PCM)
(Section B1b, 2b)

C102

with immobiliser unit

Speedometer sensor

Speedometer sensor

except 4x4

4x4
5

Instrument cluster (F)

L/W
1P
C103

L/Y
1O

R/Y
1N

W/L
1M

Speedometer sensor
(E)
except 4x4

L/W

C102

L
1L

C104

B
(F)

Coolant temperature sensor

16

C101

Sedimentor
switch

Generator
(Section A1)

L/R

B/Y

B/R

1K

1J

1I

Y/B
1H

R/B

1F

1E

B
1D
C104

4x4

L/W

1G

R/G

G/B

G/W

1C

1B

1A

O
B/L
2N

Sedimentor switch (F)

<<R/L>>

2M

GY
2L

((BR/B))

(Y/G)

2K

2J

W
2I

<BR>

2H

[GY/R]
<LG/R>

BR

2G

2F

L/Y
2E

Y/R
2D

W/B
2C

2B

R/W
2A

Coolant temperature sensor (F)


Y/B

Instrument cluster
(Section C1b)

Wiring Diagram

<>
[ ]
()
<< >>
(( ))

Main fuse box


+

Battery

p58nUK

C-1a

Harness symbol

Main fuse box

X08

Wiring Diagram

[ Black ]
(F)(E)

[ Black ]
(F)(E)

X09

X01

[ Grey ]
Speedometer sensor

C103

Z58

16
Instrument cluster

C101

C104
Sedimentor switch
[ Black ]
Instrument cluster

X07
(F)(E)
[ Black ]

C101
C102

Coolant temperature
sensor

X02
X03
Fuse block

X02

Ignition switch

Ignition switch

[ White ]

[ Blue ]

p59nUK

C-1b

Instrument cluster (WL, WL Turbo, before model year 2002)

4x4 with remote freewheel control system


4x4 without remote freewheel control system
with air bag
European specifications (LHD)
with immobiliser unit
not used

Instrument cluster
Instrument cluster
(Section C1a)

22

26

Instrument cluster
(Section C1c)

Brake fluid

Air bag

4x4

4x4

1.4W

1.4W

2G

RFW
1.4W

2G

Rear fog
lamp

Oil pressure

1.4W

1.4W

1.4W

1.4W

2H

2D

2J

2M

2M

2E

C101
GY/R
(F)
LG/R
(F)

X09

BR
(F)

Y/R
(F)

Y/G
(F)

GY/R
(E)

Z59

4x4 without remote freewheel


control system

4x4 Mode
switch
23
C109

Remote freewheel control system


(Section H)

B/R
(E)

C106

Air bag module


(Section S1)

C105

C101

L/Y

R/Y

W/L

1P

1O

1N

1M

C107

Park brake switch (F)

C106

with air
bag

B
(F)

C105

L
1L

L/R

B/Y

B/R

1K

1J

1I

C108

Y/B
1H

1G

R/B

1F

1E

Vacuum warning switch


(F)

B
1D
C109

R/G

G/B

G/W

1C

1B

1A

4x4 Mode switch (E)

L/Y
L/Y

B/R

GY/R

O
B/L
2N

<<R/L>>

2M

GY
2L

((BR/B))

2K

(Y/G)

2J

W
2I

Brake
fluid
sensor

Vacuum
warning
switch

B
(F)

Instrument cluster (F)

L/W

C106

C108

C106

Rear fog lamp


switch
(Section E3)

4x4 with remote


freewheel control
system

Park
brake
switch

52

Oil pressure
switch

L/Y
(F)

L/Y
(F)

C107

Brake
fluid
sensor

X09
B/R
(F)

L/Y
(F)

Y/R
(E)

25

24

O
(F)

R/L
(F)

X09

C109

European specifications (LHD)

except
European
specifications
(LHD)

European
specifications
(LHD)

<BR>

[GY/R]
<LG/R>

BR

L/Y

Y/R

W/B

2H

2G

2F

2E

2D

2C

R/W
2B

2A

Oil pressure switch (E)

Y/R

C106

Brake fluid sensor (F)


O
<<L/Y>
B

Wiring Diagram

...
...
...
...
...
...

<>
[ ]
()
<< >>
(( ))

p60nUK

C-1b

Harness symbol

Wiring Diagram

4x4 Mode switch

C109

C108
Vacuum warning switch
[ Black ]

C106

Brake fluid sensor

Z60

Instrument cluster

C101

[ Black ]
Instrument cluster

X09
(F)(E)
[ Black ]

C101

C105

Oil pressure switch


[ Black ]

C107
Park brake switch

p61nUK

C-1c

Instrument cluster (WL, WL Turbo, before model year 2002)


Headlamp switch
(Section E1, 2)

27

28

29

30

45

R/B
(F)

R/W
(F)

G/B
(F)

G/W
(F)

B/L
(F)

GY
(F)

Illumination
3.4x4

1B

High
beam
1.4W

1A

RH
direction
indicator
1.4W

LH direction indicator
1.4W

2N

2L

Rear
window
heater
on
1.4W

Pre
glow indicator
1.4W

26
1D

1C
C101

B
(F)

R/G
(F)

Z61

38

Instrument illumination
potentiometer
(Section I1)

Instrument cluster (F)

L/W
1P

L/Y

1O

R/Y

W/L

1N

1M

L
1L

L/R

B/Y

B/R

1K

1J

1I

4x4 with remote freewheel control system

[ ]

...

4x4 without remote freewheel control system


with air bag
European specifications (LHD)
with immobiliser unit
not used

Instrument cluster
2A

1E

C01

...

()
...
<< >> ...
(( ))
...
...

C101

Instrument cluster
(Section C1b)

< >

Y/B
1H

1G

R/B

1F

1E

B
1D

R/G

G/B

G/W

1C

1B

1A

B/L
2N

O
<<R/L>>

2M

GY
2L

((BR/B))

(Y/G)

2K

2J

W
2I

<BR>

2H

[GY/R]
<LG/R>

2G

BR

2F

L/Y
2E

Y/R

W/B

2D

2C

R/W
2B

2A

Wiring Diagram

Powertrain control module (PCM)


(Section B1b, 2b)

Rear window heater


relay
(Section I2)

Direction indicator
switch
(Section F1)

Headlamp switch
(Section I1)

p62nUK

C-1c

Harness symbol

Z
Wiring Diagram

Instrument cluster
[ Black ]
Instrument cluster

C101

Z62
5

C101

p63nUK

C-2a

Instrument cluster (F2 CIS, G6)


Main fuse box
+

MAIN
B(E)

B/W(E)

B/W(F)

X02

Ignition switch
OFF

ST

W/R(E)
30A

X07

BTN
X08

X01

IG1 IG2

W/R
(F)

Fuse block

ACC

METER

ROOM

15

10A

X03

G/R(F)

4x4 with remote freewheel control system


4x4 without remote freewheel control system
with air bag
European specifications (LHD)
with immobiliser unit
not used

Fuse block

X02
W(F)

B/Y(F)

L/R(F)

Powertrain control module (PCM)


G6 (Section B3c)

...
...
...
...
...
...

15A

X03

B/Y
(F)

X03

X03

C201
1H

1K

Instrument cluster

1J
22

Water temperature gauge

Fuel gauge
Tachometer

Microprocessor

1I

1L

1F

1P

1N

1G

Charge
1.4W

Speedometer

1M

Sedimentor
1.4W

2C
C201

Y
(F)

L
(F)

L/W
(F)

B/O
(F)

X09

R/Y
(F)

Y/B
(F)

Z63

W/L
(F)
X05

L
(E)
19

B/O
(INJ)

L
(E)

L/W
(E)

Door entry
switches
(Section I3)

C203

Fuel pump/fuel gauge


sender
(Section B5)

Coolant temperature sensor

Speedometer sensor

except 4x4

50

C202

Speedometer sensor

W/B
(F)

21

L/W
(E)

C203

O
(F)

4x4

Powertrain
control
module
(PCM)
(Section
B3c)

Ignition module,
Ignition coil
(Section B4a)

G6

F2 CIS

Generator
(Section A2)

13

C201 Instrument

L/W
1P
C203

cluster (F)

R/Y
1O

1N

O
((W/L))

1M

C202

L
1L

Speedometer sensor (E)


except 4x4

L/W

L/R

B/Y

B/O

1K

1J

1I

((G/R))

1H

4x4

L/W

Y/B
1G

R/B

1F

1E

B
1D

R/G

G/B

G/W

1C

1B

1A

B/L
2N

O
[GY/R]

<<R/L>>

2M

2L

2K

2J

<BR>

2I

2H

L/Y

[GY/R]
<LG/R>

2G

2F

2E

Y/R

W/B

2D

2C

R/W
2B

2A

Coolant temperature sensor (T)

Y/B

Instrument
cluster
(Section C2b)

Wiring Diagram

80A

X01

<>
[ ]
()
<< >>
(( ))

Battery

p64nUK

C-2a

Harness symbol

X09
13

Main fuse box

Wiring Diagram

[ Black ]
(F)(E)
[ Grey ]
Speedometer sensor

C203
X01
[ Black ]
(F)(E)

X08
X07
(F)(E)
[ Black ]

X05
Instrument cluster

(F)(INJ)
[ Black ]

C201

C202
Crash sensor centre radiator
[ Black ]

F2 CIS

[ Black ]
Instrument cluster

C201

Z64

Main fuse box


13

X01

[ Grey ]
Speedometer sensor

C203

X02
Ignition switch
[ Blue ]

X03
Fuse block

X07

X05

(F)(E)
[ Black ]

(F)(INJ)
[ Black ]

X08
(F)(E)
[ Black ]

G6
X09
(F)(E)
[ Black ]

C202
Crash sensor centre radiator
[ Black ]

X02
Ignition switch
[ White ]

p65nUK

C-2b

Instrument cluster (F2 CIS, G6)

Instrument cluster
Instrument cluster
(Section C2a)

22

26

4x4
1.4W

4x4
1.4W

RFW
1.4W

2G

2G

Air bag
1.4W

2J

2H

Brake
fluid
1.4W

Rear
fog
lamp
1.4W

Oil
pressure
1.4W

2M

2D

Instrument
cluster
(Section C2c)

2E

2M

C201
GY/R
(F)
LG/R
(F)

X09
GY/R
(E)

Z65

4x4 without remote freewheel


control system

European
specifications
(LHD)

Y/R
(F)

Y/G
(F)

BR
(F)

C207

C207

25

24

Air bag module


(Section S1)

Remote freewheel
control system
(Section H)

B
(E)

Y/R
(E)

Brake
fluid sensor

52

Rear fog lamp


switch
(Section E3)

C204

Oil pressure
switch

C205 Brake

R/Y
1N

O
((W/L))

1M

fluid sensor (F)


O
<<L/Y>>
B

B
(F)

with air
bag

C204

L
1L

L/R

B/Y

B/O

1K

1J

1I

C206

C205

B
(F)

Instrument cluster (F)

1O

Brake
fluid
sensor

4x4 with remote


freewheel control
system

B
(F)

1P

C205

Park
brake
switch (F)

C205

X09

L/W

L/Y
(F)
C206

C205

4x4 Mode
switch
23

C201

L/Y
(F)

O
(F)

R/L
(F)

X09

European
specifications
(LHD)

except European specifications (LHD)

((G/R))

1H

Y/B
1G

Park brake switch (F)

R/B

1F

1E

B
1D

R/G

G/B

G/W

1C

1B

1A

C207 4x4

Mode switch (E)

L/Y
B

GY/R

B/L
2N

O
(Y/G)

<<R/L>>

2M

2L

2K

2J

<BR>

2I

2H

L/Y

[GY/R]
<LG/R>

2G

2F

2E

Y/R

W/B

2D

2C

R/W
2B

2A

Oil pressure
switch (E)

Y/R

Wiring Diagram

4x4 with remote freewheel control system


4x4 without remote freewheel control system
with air bag
G6
European specifications (LHD)

< >...
[ ]...
( )...
(( ))...
<< >>...

p66nUK

C-2b

Harness symbol

[ Black ]

Wiring Diagram

(F)(E)

X09

C205
Brake fluid sensor

Instrument cluster

C201
F2 CIS

Z66

C204

C201

Oil pressure switch

[ Black ]
Instrument cluster

Oil pressure switch

C204
[ Black ]
4x4 Mode switch

C207
C206
Park brake switch

C205
Brake fluid sensor

G6
X09
(F)(E)
[ Black ]

p67nUK

C-2c

Instrument cluster (F2 CIS, G6)


Headlamp switch
(Section E1, 2))

Rear window heater


relay
(Section 12)
30

29

28

< >...
[ ]...
( )...

45

(( ))...
<< >>...
R/B
(F)

G/B
(F)

R/W
(F)

G/W
(F)

Instrument cluster
2A

1E

High
beam
1.4W

Illumination
3.4x4

1B

1A

2N

LH
direction
indicator
1.4W

RH
direction
indicator
1.4W

Rear
window
heater
on 1.4W

26
1D

1C
C201

B
(F)

R/G
(F)

Z67

38

Instrument illumination
potentiometer
(Section I1)

Instrument cluster
(F)

L/W
1P

R/Y
1O

1N

O
((W/L))

1M

1L

L/R

B/Y

B/O

1K

1J

1I

((G/R))

1H

Y/B
1G

R/B

1F

1E

B
1D

R/G

G/B

G/W

1C

1B

1A

B/L
2N

O
<R/L>

2M

2L

2K

(Y/G)
2J

<B/R>

2I

2H

C201

G6
European specifications (LHD)

B/L
(F)

C201

Instrument cluster
(Section C2b)

4x4 with remote freewheel control system


4x4 without remote freewheel
control system
with air bag

L/Y

[GY/R]
<LG/R>

2G

2F

2E

Y/R

W/B

2D

2C

R/W
2B

2A

Wiring Diagram

27

Direction indicator
switch
(Section F1)

Headlamp switch
(Section I1)

p68nUK

Harness symbol

C-2c
Z
Wiring Diagram

Instrument cluster
[ Black ]
Instrument cluster

C201

Z68
5

C201

C-3a

Instrument cluster (WL3, WLT3, as of model year 2002)


+

MA IN

< >. ..4 X 4


( )... with air bag

B( E)

B/ W (E)

B /W (F )
A

80 A

01

BT N
X

01

Immobiliser module
(Section T2)

02

OF F

ST

10A

08

03

C3 1 0

C3 1 0

P( F)

61

ROO M

W/ R( F )

W/ R( E)
30 A

07

03

L/R
(F )

IG 2

IG 1

Ignition
switch

AC C

X 0 2

ME TE R
B/ Y (F )

W( F )

L/R (F)

15A

X 03

L/R
(F )

Key warning switch

X 03

Instrument cluster

C3 0 1
1J

1K

Safety
1.4W

Coolant temp.
gauge

Fuel gauge

Tachometer

(Section C3c)

Speedometer

Charge
1.4W

Sedimentor
1.4W

Microprocessor

2K

1I

1F

1L

1P

1N

1G

1H

2C

1M

2I
C3 0 1

L
(F )
BR/ B
(F )

L/W
(F )

Y
(F )

B/ R
(F )

R/Y
(F )

Y/ B
(F )

X 0 9

W/ B
(F )

W/ L
(F )

G/ R
(F )

W
(F )

Z69

C3 0 4
L
(E )
51

L/W
(E )

48

Immobiliser
module
(Section T2)

21

L/W
(E )

L
(E )
C3 0 3

Door lock
switch
(Section I3)

C3 0 3

Fuel gauge
sensor
(Section B7)

Powertrain control module


(PCM)
(Section B6c)

Powertrain con- Generator


trol module
(Section A3)
(PCM)
(Section B6b)
B
(F )

Coolant temperature sensor


Speedometer
sensor

except 4X4

4X4
3

16

1P

C3 0 3

C3 0 2

Instrument cluster (F)

L/W

R/Y
1O

1N

W/ L

L/R

1M

1L

1K

B /Y

B /R

G/R

Y/ B

R/B

R/ G

G/B

G/W

1J

1I

1H

1G

1F

1E

1D

1C

1B

1A

Speedometer sensor (E)


except 4X4
L

L/W

C3 0 4

C3-02

Speedometer
sensor

C3 0 1

Sedimentor
switch

60

C3 0 4
4X 4

L/W

B/ L

R/ L

2N

2M

Sedimentor switch (F)

GY

BR/ B

(Y /G )

2L

2K

2J

C 31 0

W
2I

<B R >

<L G /R >

2H

2G

Key warning switch (F)

L/R

2F

L/ Y

Y/ R

W/ B

2E

2D

2C

R/W
2B

2A

Coolant temperature sensor (F)

Y/ B

(Section C3b)

Wiring Diagram

Battery

p70UK

C-3a

Harness symbol

(F)(E)

[Grey]
(F)(E)

X08

X07

X09

Main fuse box

Wiring Diagram

[Black]
(F)(E)

[Grey]
Speedometer sensor

C303

X01

Z70

Instrument cluster

C301
[Black]
Instrument cluster

C304

C301

Sedimentor switch
Key warning switch

C310
16

C302
Coolant temperature
sensor

X02
Ignition switch
[White]

X02
X03
Fuse block

Ignition switch
[Blue]

C-3b

Instrument cluster (WL3, WLT3, as of model year 2002)


(

)...

AI R BAG

1.4W

2H

2G

GLOW
1. 4 W

OIL
1.4W

1. 4 W

RF W
LOC K
1.4W

4W D

2J

2D

B R AKE
1. 4 W

2L

2E

C3 01
Y/ G
(F )
LG/R
(F )

Z71

24

Y/ G
(F )

Y/ G
(F )

47

25

Data Link Connector (DLC)


(Section U2)

Remote freewheel
control module
(Section H2)

L/Y
(F )

Y/ R
(F)

BR
(F )

23

GY
(F )

X 0 9

C3 0 6

Y/ R
(E )

Air bag module


(Section S2)

L/ Y
(F )

L/Y
(F )

C3 0 7

Brake fluid
sensor

Park brake
switch

C3 0 5

Oil pressure
switch

Powertrain control
module (PCM)
(Section B6c)

with air bag

4X 4

C3 0 6
B
(F )

C3 0 1

1P

C3 0 6

C3 0 5

Instrument cluster (F)

L/W

R/Y
1O

1N

W/ L

L/R

1M

1L

1K

Brake fluid sensor (F)

B /Y

B /R

G/R

Y/ B

R/B

R/ G

G/B

G/W

1J

1I

1H

1G

1F

1E

1D

1C

1B

1A

C3 0 7

L/Y
B

with air bag

Wiring Diagram

Instrument cluster
(Section C3a)

< > ...4 X 4

B/ L

R/ L

2N

2M

Park brake switch (F)

L/Y

GY

BR/ B

(Y /G )

2L

2K

2J

W
2I

<B R >

<L G /R >

2H

2G

2F

L/ Y

Y/ R

W/ B

2E

2D

2C

R/W
2B

2A

Oil pressure switch (E)

Y/ R

p72UK

C-3b

Harness symbol

Z
Wiring Diagram

[Grey]
(F)(E)

X09

C306
Brake fluid sensor

Z72

Instrument cluster

C301
[Black]
Instrument cluster

C301

C305
Oil pressure switch

C307
Park brake switch

C-3c

Instrument cluster (WL3, WLT3, as of model year 2002)


Direction indicator switch
(Section F3)

Rear window
heater relay
(Section I2)

Rear fog lamp


switch
(Section E5)

27

28

29

30

45

52

R/B
(F )

R/W
(F )

G/B
(F )

G/W
(F)

B/ L
(F )

R/L
(F )

Instrument cluster

C3 0 1
1E

2A

1B

2N

1A

2M

(Section C3a)

ILLU M I
3.4X 4

T URN
RH
1. 4 W

T URN
LH
1.4W

B EAM
1. 4W

1C

R.DEF
1. 4 W

1D

C3 0 1

R/G
(F )

B
(F )

Z73

38

Panel illumination switch


(Section I1)

C3 01

Instrument
cluster (F)

L/W
1P

R/Y
1O

1N

W/ L

L/R

1M

1L

1K

B /Y

B /R

G/R

Y/ B

R/B

R/ G

G/B

G/W

1J

1I

1H

1G

1F

1E

1D

1C

1B

1A

B/ L

R/ L

2N

2M

GY

BR/ B

(Y /G )

2L

2K

2J

W
2I

<B R >

<L G /R >

2H

2G

2F

L/ Y

Y/ R

W/ B

2E

2D

2C

R/W
2B

2A

R. F O G
1.4 W

)...

with air bag

Wiring Diagram

Headlamp
switch
(Section E4)

< > ...4 X 4

Headlamp
switch
(Section I1)

p74UK

C-3c

Harness symbol

Z
Wiring Diagram

Instrument cluster
[Black]
Instrument cluster

C301

Z74

C301

p75nUK

Windshield Wiper/Washer

Main fuse box


+

()

MAIN

B/W(E)

B(E)
80A

B/W(F)

X07

X01

Fuse block

IG1 IG2

WIPER
B/R(F)
15A

X03

L
(F)

X02
OFF

ST

without air bag

Wiring Diagram

X01

...

Ignition switch

ACC
X02

X03

Wiper/washer switch

L(F)
D02

Onetouch wipe
High speed

L
(F)

Intermittent
wipe
Low speed

Washer switch

Off

High speed

Off

Low speed

Intermittent wipe

Intermittent
wiper relay
D02

L(F)
L
(F)

L/O
(F)

L/B
(F)

L/Y
(F)

L/W
(F)

Z75

D03
D01

Windshield washer
pump motor

D01

Circuit
breaker

Windshield wiper
motor

WL3, WLT3 as of model year 2002


3

D01

Windshield washer
pump motor (F)
B
L/O

D02

Wiper/washer switch
(F)
(G/R)

D03 Windshield

wiper motor

(F)

L/Y

L/W
L/B

B
(F)

Stop switch

B
(F)

L/O

L/W

L/Y

L/B

Battery

p76nUK

Harness symbol

Windshield washer pump motor

D01

D03

Main fuse box

Windshield wiper motor

Main fuse box

D03

X01
X01

D01

Windshield washer pump


motor

X07

Z76

(F)(E)
[ Black ]

F2 CIS, G6

X07
3

[ White ]
Ignition switch

X02

D02

Wiper/washer switch
5

X02
Ignition switch

X03
Fuse block

[ Blue ]

(F)(E)
[ Black ]

WL,WL Turbo

Wiring Diagram

Windshield wiper motor

p77nUK

Headlamps (without daytime running lamps / without headlamp levelling, before model year 2002)

Main fuse box

Fuse block
TAIL

BTN
W/R(E)

B(E)

W/R(F)

Y/R(F)
10A

X03

X03

HEAD
R(E)
30A

X01

R(F)
X08
E101

Light
switch
Off
TNS

Headlamp
switch
Headlamp
flasher

Headlamps

Dimmer switch
Low
beam

High beam

R/B(F)

E101
R/W
(F)

Z77

Instrument cluster
(Section C1c, 2c)

R/L
(F)

R/W(F)

28

R/W
(F)

R/L
(F)

R/W
(F)

R/L
(F)

E102

Headlamp, LH
side

E103
60/55W

60/55W

E102

E103
B(F)
1

E101

Headlamp switch (F)

R/B

E102 Headlamp,

R/L

R/W

G/W

G/O

Y/R

LH side (F)

G/B

E103

Headlamp, RH side (F)

R/L
B

R/L
R/W

R/B(F)

39

Instrument Illumination
(Section I1)

R/B(F)

40

Licence plate lamps, Parking Lamps, Tail lamps


(Section E3)

R/B(F)

41

E101

R/W

Headlamp, RH
side

Wiring Diagram

30A

X01

Battery

E-1

p78nUK

E-1

Harness symbol

Z
Wiring Diagram

[ Black ]
(F)(E)

Main fuse box

X08

X01

Z78

E103
Headlamp, RH side
[ Black ]

E102

Headlamp, LH side
[ Black ]

E101
Headlamp switch

X03
Fuse block

p79nUK

E-2

Headlamps (with daytime running lamps / with headlamp levelling, before model year 2002)

Battery

Main fuse box

MAIN

A
B/W(E)

B(E)

B/W(F)

X01

Fuse block

X07

BTN
W/R(E)

Ignition switch

W/R(F)

Y/R(F)
10A

X03
R(E)

30A

X03

IG1 IG2

Headlamp switch

X08

B/R
(F)

E201

Light
switch

R.FOG

TNS

E201
R/Y(F)

R/G(F)
10A

E206

Headlamp
levelling
motor LH

Headlamp
levelling
motor RH

Headlamps

Fuse block

R
(F)

Dimmer
switch

Headlamp
flasher

X03

R/G(F)
E207

X03

Off

Fuse block

X03

ACC

X02

R(F)

X01

OFF

ST

HEAD

53

X02

TAIL

30A

Rear fog lamp


switch
(Section E3)

High beam

WIPER
15A

X03

Low
beam

L
(F)

E201
R/B(F)
R/G(F)

E207

E206
B
(F)

B(F)

W
(F)
E205

E204

Z79

E208

Instrument cluster
(Section C1c, 2c)

W/L
(F)
28

R/W(F)
R/W
(F)

B
(F)

R/L
(F)

R/W
(F)

R/L
(F)

E202
E208

Headlamp, LH
side

B
(F)

B
(F)

W/L(F)

41

W/L(F)

40

E203

Headlamp, RH
side

60/55W

60/55W

B
(F)

E203

E202
B(F)

E201

Headlamp switch (F)

R/B

E205

R/Y

E202

R/G

G/W

G/O

Y/R

R/W

Daytime Running
Lamps (DRL) relay (F)
W/L

R/W

R/B

Headlamp, LH side (F)

G/B

E203

E208

Headlamp levelling
switch (F)
G
B

Headlamp, RH side (F)

E204

R/L
R/W

Headlamp levelling
motor RH (F)

E207

B
W

R/L

E206

Instrument Illumination
(Section I1)

Daytime Running
Lamps (DRL) relay

E204

G(F)

39

E205

Headlamp
relay

R/W
(F)

Headlamp
levelling
switch

Wiring Diagram

80A

R/G

Headlamp relay (F)

R
R/W

R/G

Headlamp levelling
motor LH (F)

R/G

R/L

W
B

Licence plate lamps,


Parking Lamps,
Tail lamps
(Section E3)

p80nUK

E-2

Harness symbol

[ Black ]
(F)(E)

Wiring Diagram

Daytime Running Lamps


(DRL) relay
E205
[ Blue ]
Headlamp relay

X07
[ Black ]
(F)(E)

E204

X08

Main fuse box

X01

Z80

E203

Headlamp, RH
side
[ Black ]

Headlamp levelling
switch

E208

E206

Headlamp levelling motor RH

E207
[ Grey ]

Headlamp levelling motor LH

E202
[ Grey ]

Headlamp, LH
side
[ Black ]

E201
Headlamp switch

X02
X03
Fuse block

X02

Ignition switch

Ignition switch

[ Blue ]

[ White ]

p81nUK

E-3

Licence plate lamps / Parking Lamps / Tail lamps / Rear fog lamps (before model year 2002)
...

<>

with daytime running lamps / with headlamp levelling

European specifications (LHD)


E308
53

R/G(F)

X04

E308

R/G(F)

R/L(F)

R/L(F)

Wiring Diagram

Headlamp switch
(Section E2)

R/L(R)

B(F)

Rear fog lamp relay


Headlamp switch
(Section E1)
< Daytime Running
Lamps (DRL) relay
(Section E2) >

R/B
(F)
<W/L>

41

R/G
(F)

X04

R/W
(F)

R/B
(F)
<W/L>

40

R/L
(F)
E309
E309

R/B
(R)

R/G(F)

R/L(F)

R/L(F)

Instrument cluster
(Section C1b, 2b)

52

Rear fog lamp switch

X18

R/B
<W/L>
(F)

R/B
<W/L>
(F)

E301

X18

R/B
(R2)

E302

LH parking lamp

E303

RH parking lamp

5W

5W
E301

E303

Z81

B
(F)

E305

RH Licence plate
lamp

5W

R/B
(R2)

R/B
(R2)

E304

LH Licence plate
lamp

5W
E302

B
(F)

R/B
(R2)

R/L
(R2)

E306

Tail lamp, LH side


5W

E304

B
(F)

5W
E305

E307

Tail lamp, RH
side
E306

B
(R2)

B
(R2)

B
(R2)

B
(R2)

11

10 11

11

10 11

Rear fog
lamp

21W

E307

B
(R2)

B
(F)

E301

E306

LH parking lamp (F)

E302

RH parking lamp (F)

R/B
<W/L>

R/B
<W/L>

Tail lamp, RH side (R2)

R/W

G/W

R/B

W/G

E307

E303

LH Licence plate lamp (R2)

Rear fog lamp (R2)

R/L
B

E304

RH Licence plate lamp (R2)

R/B

Rear fog lamp relay (F)


R/W

R/L

11

lamp, LH side (R2)

E309 Rear

R/G

E305 Tail

R/B

E308

fog lamp switch (F)


R/G

B
R/L

R/W

R/W

G/B

R/B

W/G

p82nUK

E-3

Harness symbol
E306

E304

10
(R)(R2)

Rear fog lamp

E307

X18

Wiring Diagram

RH Licence plate lamp

(F)(R)

X04

E305

Tail lamp, LH side

E303
LH Licence plate
lamp

E302

11

RH parking lamp

Z82

E301
LH parking lamp

X04
(F)(R)

E308
Rear fog lamp relay

E309
Rear fog lamp switch

Tail lamp, RH side

E-4

Headlamps (WL3, WLT3, as of model year 2002)

Battery
+

MA IN
B/ W( E)

B( E)

B/ W( F )

X 0 1

X 0 7

TA IL

BT N
W/ R( E )

W/ R( F )

30A

10A

03

X 0 3

IG 1

HE AD
R( E)
30A

01

Headlamp switch

X 0 8

IG 2

Ignition switch

AC C

02

R( F )

02

OF F

ST

Y/ R( F)

Wiring Diagram

80A

B/ R
(F )

E4 0 1

Light switch
03

R.F O G

Rear fog lamp


switch
(Section E5)

53

E4 0 1

Off

R/Y (F )

R/G(F )
R/G
(F )

10 A

03

TN S

X 0 3

R/G
(F )
E4 07

WI PE R
15A

R
(F )

Dimmer switch

Headlamp
flasher

R/ G (F )

Head

High
beam

03

Low
beam

L
(F )

E4 0 6

Headlamp
levelling
motor LH

E4 0 1

Headlamp levelling motor RH

R/B( F )

R/ B (F )

R/G( F )
E4 0 6

E4 0 7

R/W
(F )

G
(F )

Daytime Running
Lamps (DRL)
relay

W
(F )

Headlamp relay

G(F )

Z83

B
(F)

Instrument cluster
(Section C3c)

28

R/ W( F )
R/W
(F )

Headlamp, LH
side

R/B

E4 0 5

E4 0 8

R/Y

19

E 4 0 2

R/G

G/W

G/O

Y/ R

R /W

Daytime Running Lamps (DRL) relay (F)


W/ L

R/W

R/B

G/B

G
B

E 4 03
B
(F )

18

19

E 4 0 6

B
(F )

4
E4 0 4

Headlamp, RH side (F)

B
E 4 0 7

Headlamp levelling motor RH (F)

R/G

Headlamp relay (F)

R/L

R/W

40

B
(F )

60 /55W

B
(F )

R/L

W/ L(F )
E4 0 3

Headlamp, RH
side

E 4 03

Headlamp, LH side (F)

Headlamp levelling switch (F)

R/L
(F )

E 4 0 2

Headlamp switch (F)

R/W
(F )

60/ 55W

B
(F )
18

R/L
(F)

E4 0 2

B
(F )

E4 0 8

E 4 01

E4 0 5

E4 04

E4 0 8

Headlamp
levelling
switch

Instrument illumination
(Section I1)

E4 0 5

E4 0 4

G
(F)

39

R/W( F )

R/W

R/G

Headlamp levelling motor LH (F)

R/G

R/L

W
B

Licence plate lamps,


Parking Lamps, Tail
lamps,
(Section E5)

p84UK

E-4

Harness symbol

[Black]
(F)(E)

X07

E404

Wiring Diagram

[Blue]
Headlamp relay

(F)(E)

Daytime Running
Lamps (DRL) relay

X08

E405
Main fuse box

X01

19

Z84
E403

Headlamp levelling switch

Headlamp, RH side
[Black]

E408

E406
Headlamp levelling
motor RH

E407

[Grey]

Headlamp levelling
motor LH
[Grey]

18

E402
Headlamp, LH side
[Black]

E401
Headlamp switch

X02
X02
X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

E-5

Licence plate lamps / Parking Lamps / Tail lamps / Rear fog lamps (WL3, WLT3, as of model year 2002)

Rear fog lamp relay


53

R/G( F )

R /L(F )

R/G( F )

04

R /L(F )

Wiring Diagram

Headlamp switch
(Section E4)

R /L(R )

B( F)
E5 0 8

E5 0 8

X 0 4

Daytime Running
Lamps (DRL)
relay
(Section E4)

40

R/G
(F )

W /L( F)

W/ L (F )

R/ W
(F )

R/B
(R )

W/ L
(F )
X

R/L
(F )
E5 0 9
E5 0 9
R/L (F )

18

R/B
(R 2 )

W/ L (F )

52

R/L (F )

Rear fog lamp switch

Instrument
cluster
(Section C3c)
X 1 8

R/B( R2 )

R/B( R2 )

R/L
(R 2 )

B
(F )
W/ L
(F )

W/ L
(F )

R/B
(R 2)

R/B
(R 2)

R/B
(R 2)

R/B
(R 2)

E5 07

Rear fog lamp


21W
E5 07
E5 01

LH parking
lamp

Z85

5W

E5 0 2
5W

E5 01

E 501

LH parking lamp (F)

E5 0 2

E5 04

E5 0 3

RH parking
lamp
E5 0 2

LH Licence
plate lamp

5W

B
(R 2 )

18

19

10 11

10 1 1

11

10 1 1

RH parking lamp (F)

E5 0 3

LH Licence plate lamp (R2)

E 5 0 4

11

E 5 05

RH Licence plate lamp (R2)

Tail lamp, LH side (R2)

E 5 08 Rear

Rear fog lamp (R2)

E 5 09

fog lamp relay (F)


R/G

R /W

R/L

R/W

G/ B

R/B

W/ G

R/B
B

G/W
W/ G

R/B

B
(R 2)

E5 0 6

B
(R 2)

R/B

5W

B
(R 2)

R/L
B

E5 0 5

Tail lamp,
RH side

B
(R 2)

W/ L

R/W

5W

E5 04

E5 0 6

Tail lamp,
LH side

B
(F)

E 507

E5 0 5

B
(F )

W/ L

Tail lamp, RH side (R2)

5W

E5 0 3

E 506

RH Licence
plate lamp

Rear fog lamp switch (F)


R/G

B
R/ L

R /W

p86UK

E-5

Harness symbol

Tail lamp, RH side

10

[Black]
RH Licence plate lamp

E504

(R)(R2)

X18

Rear fog lamp

E507

19

E505
(F)(R)

Tail lamp, LH side

X04
E503
LH Licence plate
lamp
[Black]

11

Z86
E502
RH parking lamp

18

E501
LH parking lamp

X04
(F)(R)

E508
Rear fog lamp
relay

E509
Rear fog lamp
switch

Wiring Diagram

E506

p87nUK

F-1

Turn Signal and Hazard Lamps (before model year 2002)

Fuse block

Main fuse box


+

MAIN
B(E)

B/W(E)

daytime running lamps

B/W(F)

L/Y(F)
10A

X01
A

B/W(E)

B/W(F)

X07

X02

Ignition
switch

OFF

ST
IG1 IG2

ACC
METER

X02

W(F)

B/Y(F)
X03

15A

F103

X03

F104

Hazard flasher
switch

G/R(F)
F103

Electronic
flasher
module

F104
G/O
(F)

F103
G/B
(F)

G/O(F)

G/W
(F)

G/B(F)

G/B(F)

G/W(F)

G/W(F)

LH direction indicator
RH direction indicator

E101
<E201>
X18

X04

X04

G/B(R)

G/B(F)

G/B
(R2)

Z87

21W

21W

E305

Direction indicator lamp, LH


side front (F)

F102

F103

R/W

G/B

R/B

W/G

G/W(R)

G/W
(F)

F106
5W

21W

F106

Hazard flasher switch (F)

E306

Direction indicator lamp, RH


side front

R/G

E306

R/B

B/Y

G/W

G/B

L/Y

G/R

RH Rear direction indicator lamp (R2)

R/W

G/W

R/B

W/G

RH Rear direction indicator


lamp

E306

B
(F)

F104 Electronic

G/O

21W

F102

B
(F)

Direction
indicator
switch

F102

Side direction
indicator lamp,
RH side

B
(R2)

B
(F)

10 11

E101 Direction
<E201>

flasher mod-

indicator switch (F)

G/O
B

F105

E101
<E201>

G/W
(R2)

ule (F)

LH Rear direction indicator lamp (R2)

30

F105

G/W

29

B
(F)

Direction indicator lamp, RH


side front (F)

G/B

G/W
(F)

Instrument cluster
(Section C1c, 2c)

Side direction
indicator lamp,
LH side

5W

B
(F)

11

E305

F105

Direction indicator lamp, LH


side front

F101

B
(R2)

G/B
(F)

X18

G/W(F)

G/W
(F)

F101

LH Rear direction indicator


lamp

G/W(F)

G/B
(F)

G/B
(F)

E305

F101

G/B(F)

G/O
(F)

R/B

G/R

Side direction indicator lamp, LH side (F)

G/B

R/L
<R/Y> <R/G>

F106

G/W

G/O

Y/R

R/W

G/B

Side direction indicator lamp, RH side (F)

G/W

Wiring Diagram

80A

X01

...with

<>

HAZARD

Battery

p88nUK

F-1

Harness symbol

RH Rear direction indicator lamp


Main fuse box
[ Black ]
Side direction indicator
lamp, RH side

10

(R)(R2)

E306

Wiring Diagram

X01

X18

F106

[ Black ]
Side direction indicator
lamp, LH side

F105

(F)(R)

X04

E305
LH Rear direction indicator lamp

F102
Direction indicator lamp,
RH side front

11

X07

Z88

(F)(E)
[ Black ]

F101
Direction indicator lamp,
LH side front
3
Hazard flasher switch

F103
[ White ]
Ignition switch

X02

X04
(F)(R)
4

E201(with daytime running lamps)


E101(without daytime running lamps)
Direction indicator switch

F104
Electronic
flasher module

X03

X02
Ignition switch

Fuse block
[ Blue ]

p89nUK

F-2

Reversing Lamps / Stop Lamps / Horns (before model year 2002)

<>

Main fuse box


+

MAIN
B(E)

B/W(E)

B/W(F)

BTN

STOP
X08

X01

X02

15A

X03

G/W
(F)

X03

Ignition switch

OFF

ST

W/R(F)

W/R(E)
30A

Fuse block

X07

IG1 IG2

Fuse block

ACC

METER

X02

X03

Stop lamp
switch

F201

X09

F201

F206

<L>

F205
16

Reversing
lamps
switch

F2 CIS,G6

F2 CIS,G6

Powertrain control module (PCM)


(Section B3c, 4c)

R/W(F)

W/G(F)

R/W(E)
X09

W/G
(F)
G/R
(F)

Dual horn

B/Y(E)

X03

F205

Horn relay

Single
horn

15A

F206

G/W
(F)
A

B/Y(F)

W(F)

G/W(F)

G/W(F)

with remote
freewheel control system

R/W(E)

R/W(F)
X08

X04
R/W(F)

R/W(E)

R/W
(R)

W/G
(R)

WL,WL Turbo
X18
B/R
(F)

B/R
(F)

G/R
(F)

B/R
(F)

W/G
(R2)

R/W
(R2)

S102

Z89

F204

F203

F202

Horn

Horn
LH

Horn
RH

G/R
(F)

G/R
(F)

R/W
(R2)

F207

W/G
(R2)

Reversing
lamp,
left

21W

Clock
spring
D02

Horn
switch

Horn
switch

with air bag


Horn relay (F)

F202

D02

E305

21W

Stop
lamp
RH

21W

Reversing
lamp,
right

E306
B
(R2)

B
(R2)

11

10 11

RH (F)

F204

Horn (F)

F205

Stop lamp switch (F)

F206

Reversing lamps switch (E)

F207 Horn

switch (F)

(with air bag)


(Clock spring)

C
A
G/W
G/W
G/W
B/R

21W

E306

Stop
lamp
LH

without air bag

F203 Horn

Horn LH (F)

R/W
(R2)

E305

G/R

F201

W/G
(R2)

B/R

B/R

Horn switch (F)

E305 Reversing

lamp, left / Stop


lamp LH (R2)

(without air bag)


L/O
B

L/W

L/Y

L/B

G/R
B

G/W

B/Y

W/G

R/W

B/R

G/R

R/W

G/B

R/B

W/G

E306

Reversing lamp, right / Stop


lamp RH (R2)

R/W

G/W

R/B

W/G

S102 Shorting

G/R

bar connector (F)

G/R
B/Y

B/W

Y/G

Y/G

R/G

R/G

G/R
B/W

B/Y

Wiring Diagram

80A

X01

...G6

Battery

p90nUK

F-2

Harness symbol
Reversing lamp, right

X01

X09

Stop lamp RH

10
Reversing lamps switch

E306
(R)(R2)

F206

Reversing lamp, left

X18

Stop lamp LH

E305

[ Black ]
(F)(E)

X07
(F)(R)

X04

F204
Horn
[ Black ]

F203
Horn RH

Z90

[ Black ]

11

X08
(F)(E)
[ Black ]

F2 CIS, G6

F202
Horn LH
[ Black ]

Main fuse box


[ Black ]
(F)(E)

X01

Shorting bar connector

S102

X09
Reversing lamps switch

F206

[ Black ]

[ White ]
Ignition switch

(F)(E)

X07

X02

F205

X04

Stop lamp switch

F204

D02

Horn
[ Black ]

F203
Horn RH
[ Black ]

Horn switch

F201

X02

Horn relay

Ignition switch

X08
(F)(E)
[ Black ]

X03
F202
Horn LH
[ Black ]

WL, WL Turbo

Fuse block

[ Blue ]

(F)(R)

F207
Horn switch

Wiring Diagram

[ Black ]
(F)(E)

Main fuse box

F-3

Turn Signal and Hazard Lamps (WL3, WLT3, as of model year 2002)
MA IN
B( E)
X

L/Y (F )

B/ W( F)

01
A

B/ W (E)

B /W (F )

X 0 7

10A

03

03

X 0 2

Ignition switch
OF F

ST

IG 1

IG 2

AC C

X 0 2

X 03

X 03

ME TE R

W( F )

B/ Y( F)
15 A

F3 0 3

Flasher unit

Hazard flasher
switch

F3 04
F3

F3

F3 04

G/R( F )
03

G/O
(F )

03
G/B
(F )

G/ W
(F )

G/O(F )

left
G/B (F )
G/W (F )
X

18

G/B
(F )

X 0 4

G/B (R)

G/B (F )

G/B (F )

G/B (F )

Z91

G/ B
(F )

G/W
(F)
29

21 W

Direction indicator lamp,


LH rear

21 W

E5 0 5

F 3 0 1 Direction

indicator lamp, LH

B
(F )

11

18

F 3 0 2

G/B

F 3 0 3

F3

Side direction indicator lamp, RH (F)

G/W

Hazard flasher switch (F)

B
E4 01

R/Y

21 W

B /Y

G/W

G/B

L/Y

G/R

R /G

G/W

G/O

Y /R

21 W

Direction
indicator
lamp, RH
rear

E5 0 6

B
(F )

B
(R 2)

19

10 11

F 3 0 5

Side direction indicator lamp, LH (F)

G/O
B
B

E5 0 5

R /W

Direction indicator lamp, RH


front

Flasher unit (F)

B
(F )

E5 0 6

F3 02

F3 04

Direction indicator switch (F)

R/B

Side direction
indicator lamp,
RH

5W

F3 06

R /B

G/W
(R 2)

F3 02

B
(F)

R/G

right
Direction indicator
switch

G/W (R)

G/W
(F )

F3 06

05

G/O

X 1 8

30

Instrument
cluster
(Section C3c)

B
(F )

G/W

B
F 3 06

Direction indicator lamp, RH


front (F)

05

Side direction
indicator lamp,
LH

5W

F3 01

B
(R 2 )

front (F)

F3

Direction indicator lamp,


LH front

G/W (F )

G/W (F )

04

G/ W
(F )

G/B
(F )

F3 01

E5 0 5

G/W (F )
G/B
(F )

G/ B
(R 2 )

E4 0 1
E4 0 1

G/ W
(F )

G/B

G/R

Direction indicator lamp, LH rear (R2)

G/B

R/W
B

R/B

E5 0 6

Direction indicator lamp, RH rear (R2)

G/B
W/G

G/O
(F )

R/W

G/W

R/B

W/G

Wiring Diagram

X 0 1

HAZ A RD

B/ W (E)
80 A

Battery

p92UK

F-3

Harness symbol

Side direction indicator lamp, RH

F306

10

Direction indicator lamp, RH rear

Main fuse box

(R)(R2)

X01

X18

Direction indicator
lamp, LH rear

E505
19

(F)(R)
Side direction indicator lamp, LH

F305

X04

11

F302
Direction indicator lamp, RH front

Z92

[Black]

18

X07
(F)(E)
[Black]

F301

Hazard flasher switch

F303

Direction indicator lamp, LH front

[Black]

X04
(F)(R)

E401

F304

X02

Flasher unit

X02
X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

Direction indicator switch

Wiring Diagram

E506

F-4

Reversing lamps / Stop Lamps / Horns (WL3, WLT3, as of model year 2002)

Battery
+

MA IN
B( E)

B/ W( E)

B/ W( F )

X 0 1

X 0 2

X 0 7

BT N

ST O P
W/ R( E)

30A

OF F

ST

Ignition switch

W/ R( F )

01

X 0 8

03

15 A

G/W
(F)

X 0 3

IG 1

IG 2

AC C

ME TE R

X 0 2

G/W (F )

B/ Y( F)
X

G/W (F )

G/W
(F )
A

W( F )
15A

03

03

X 0 9

F4 04

Stop lamp switch

B/ Y
(E )

F4 0 1

Horn relay
F4 04
X

F4 0 1
W/ G
(F )
G/R
(F )

F4

05

Reversing lamps switch


R/W
(R )

18

G/R
(F )

B/ R
(F )

F4 05
R/W( E )

04
W/ G
(R )

B/ R
(F )

08

R/W( F )

W/ G
(R 2)

R/W
(R 2)

W/ G
(R 2)

R/W
(R 2)

S2 0 2
F4

02

F4

Z93

Horn LH

03

Horn
RH

G/R
(F )

G/R
(F )
F4 06

R/W
(R 2)

W/ G
(R 2 )

E5 0 5

G/R

Clock
spring

21W

Stop
lamp LH

21W

E5 0 6

Reversing
lamp, LH

21W

Reversing
lamp, RH

D2 0 2

Horn
switch

with air bag


F 40 1

D2 0 2

F4 02

Horn relay (F)

Horn LH (F)

F 40 3

Horn
switch

E5 0 5

E5 0 6
B
(R 2)

B
(R 2)

11

10 11

without air bag


F 4 0 4

Horn RH (F)

Stop lamp switch (F)

F 4 0 5

Reversing lamps switch (E)

G/ W
G/ W

G/ W

B/ R

G /R

B/ R

Horn switch (F)


(without air bag)

L/ W

L/ Y

L/ B

B/ Y

W/ G

R/W

Horn switch (F)


(with air bag)
(Clock spring)

B/ R

E 5 05

L/O

G/W

F 4 0 6

Reversing lamp, LH / Stop


lamp LH (R2)

G/ R
B

R/W

G/B

R/B

W/ G

E5 0 6

Reversing lamp, RH / Stop


lamp RH (R2)

R/W

G/W

R/B

W/G

S 20 2

G/R

Shorting bar connector (F)

G/R

B /Y

B /W

Y /G

Y/ G

B /W

B /Y

G/R

Stop lamp RH
21 W

Wiring Diagram

80A

p94UK

F-4

Harness symbol
[Grey]
(F)(E)

Reversing lamp, RH / Stop lamp RH


10

X07

E506

(R)(R2)

X18

Reversing lamp, LH / Stop


lamp LH

Main fuse box

X01

E505
Reversing lamps switch

(F)(R)

F405

X04

11

F403

Z94

Horn RH
[Black]

X08

Shorting bar connector

(F)(E)

S202
F402
Horn LH
[Black]

X04
(F)(R)

F404
Stop lamp switch

F406
Horn switch

F401

D202

Horn relay

X02
X02
X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

Horn switch

Wiring Diagram

X09

[Black]
(F)(E)

p95nUK

G-1

Heating / Air conditioning (WL, WL Turbo, before model year 2002)

X01

( )...
X07

X01

MAIN

B(E)

B/W(E)

B/W(F)

B/W(E)

X02
OFF

ST

(A/C)
LG/R(F)

IG1 IG2

10A

ACC
X02

WIPER
L(F)

Ignition switch

B/W(F)

Wiring Diagram

80A

WL, WL Turbo with remote freewheel control


system

L(F)

B/R(F)
15A
(HEATER)
B/R(F)

LG/R
(F)

40A

X03

L
(F)

X03

Fuse block
L(F)
L
(F)

G106

A/C Relay
1
G106

Resistor

Powertrain control
module (PCM)
(Section B1b, 2b)
7

R/B
(F)

LG/B
(F)

A/C switch

L
G105

M
G103

G110
G108

L/Y

L/Y
(F)

A/C pressure
switch

Z95

R/W
(F)

L
(F)

G108

G104

L/W
(F)

R/G
(F)

L/R

L/Y
(F)

L/B

L/B

G102

G109

Blower
motor
G105

L/B

L(F)

L
(F)

L/R
(F)

L/B
(F)

X09

(L)

G102

Blower assembly

G101

R/G
(E)

AMP

2
3

Off

G107

A/C Compressor
clutch

B
(F)

Fan switch

Heater control module

Thermo switch

G101 C

Heater control module


(F)

G102

L/R
B

G106

A/C Relay 1 (F)


LG/R

LG/B

R/B

L/Y
L/B

G107

(F) Blower assembly


E

(F)

L/R

L/Y

A/C Compressor clutch


(E)
R/G

G108

L/B

G103

(Blower assembly)
L/R

A/C pressure switch (F)

L/B

L/Y

G109

R/G

LG/B

Resistor
(Short cord)
L

L/R

L/Y

L/B

R/W

Resistor

G105 Blower

motor
(Short cord)

(Short cord)
L/B

L/B

Thermo switch (F)

L/W

G104

G110

A/C switch (F)

L/Y

L/W

Main fuse box

Battery

p96nUK

G-1

Harness symbol

X01

[ Black ]
(F)(E)

Wiring Diagram

Main fuse box

X07
[ Black ]
(F)(E)

X09

(F) Blower assembly

G102

Z96

A/C switch

G110

G106
G108

[ White ]
Ignition switch

A/C Relay 1

A/C pressure switch


[ Black ]

Resistor

G103

G107

X02

A/C Compressor clutch

G104
Resistor

G105

Blower motor

G109

Thermo switch

G101
Heater control module

X02
Ignition switch

X03
Fuse block

[ Blue ]

p97nUK

G-2

Heating / Air conditioning (F2 CIS, G6 )


Main fuse box
X01

Battery

X07

X01

MAIN

B(E)

B/W(E)

B/W(F)

B/W(E)

X02

Ignition switch

B/W(F)

OFF

ST

(A/C)
LG/R(F)

IG1 IG2

10A

ACC
X02

WIPER
L(F)

Wiring Diagram

80A

L(F)

B/R(F)
15A
(HEATER)
B/R(F)

LG/R
(F)

X03

L
(F)

G206

A/C Relay
1

Powertrain control
module (PCM)
(Section B3c, 4c)
7

40A

Fuse block

X03

Thermo switch
L(F)

L
(F)

Resistor

A/C switch

Blower assembly

G202

G206

R/B
(F)

LG/B
(F)

G205
M

R/G
(F)
G203

G210
G208

G204
L/B

L(F)

G208

L/Y

L/Y
(F)

A/C pressure switch

Z97

L
(F)

R/W
(F)

L/W
(F)

L/R

L/Y
(F)

G209

G205
L/B

L/B

G202

G207

A/C Compressor
clutch

Blower
motor

L
(F)

L/R
(F)

L/B
(F)
G201

AMP

2
3

Off

Thermo switch

B
(F)

Fan
switch

Heater control module


5

G201 Heater

control module

G202 (F)

(F)

G206

A/C Relay 1 (F)


LG/R

LG/B

R/B

Blower assembly
E

(F)

L/R

L/Y

L/R

L/B

L/Y

L/B

G207

A/C Compressor
clutch (E)
LG/B

G208

G203

(Blower assembly)

A/C pressure switch (F)

L/R

L/B

L/Y

G209

R/W

R/G

Resistor
(Short cord)
L

L/R

L/Y

L/B

G204 Resistor

(Short cord)

R/W

Blower motor
(Short cord)
L/B

L/B

Thermo switch (F)

L/W

G205

G210

A/C switch (F)

L/Y

L/W

p98nUK

G-2

Harness symbol

Main fuse box

Wiring Diagram

X01

G206

(F) Blower assembly

A/C Relay 1

X07

G202

Z98

(F)(E)
[ Black ]

G208

A/C switch

A/C pressure switch


[ Black ]

G210
G207
A/C Compressor clutch

[ White ]
Ignition switch

G203

Resistor

X02

G204

Resistor

G205

Blower motor

G209

Thermo switch

G201
Heater control module

X02
Ignition switch

X03
Fuse block

[ Blue ]

G-3

Heating / Air conditioning (WL3, WLT3, as of model year 2002)


X

01

MA IN

01

B( E)

B/ W( E)

Battery

07
B/ W (F )

B/ W( E)

B/ W (F )

02

Ignition switch

OF F

ST

Wiring Diagram

80A

A/ C
LG/R(F )

IG 1

IG 2

AC C

10A
X 0 2

WI PER
L(F)

L(F )

B/ R (F)
15A

L
(F )

LG/R
(F )

HEAT ER
B/ R (F)
40A

X 0 3

03

G3 0 6

A/C Relay

L(F )

G3 0 6

7
G30

G3 0 4

G3 03

05

Blower
motor
G3

G310

L/B

L( F)
L/Y

L/ Y
(F )

Z99

R/W
(F)

L
(F )

G
(F )

L/W
(F )

09

L/R

G3 02

L
(F )

L/Y
(F )

L/R
(F )

05

L/B

L /B

L/Y
(F )
G309

G
(E )

Blower assembly

L/B
(F )

G3 01
AM P
1

G30

G3

A/C pressure
switch
G30

G30

Resistor

A/C switch
Powertrain control
module (PCM)
(Section B6c)

R/B
(F )

LG/B
(F )

L
(F )

B
(F )

A/C Compressor
clutch

OF F
4

Thermo switch

Fan
switch

Heater control module


5

G301

G302

Heater control module (F)


L/ R
B

L/Y
L/B

G303

Blower assembly (F)


E

(F )

L/R

L/Y

L/B

L/R
L

A/C Relay (F)

G307

LG/R

LG/B

R/B

A/C Compressor clutch (E)

G3 0 8

L/B

(Short cord)

L/R

L/Y

L /B

G3 05

Resistor

(Short cord)

B
G306

G304

Resistor

A/C pressure switch (F)

G309

LG/ B

G 3 1 0

Thermo switch (F)

L/W

R/W

(Short cord)
L/B

L/B

L/Y

Blower motor

A/C switch (F)

L/Y

L/W

p100UK

G-3

Harness symbol

[Grey]
(F)(E)

Wiring Diagram

X09
[Black]
(F)(E)

X07
Main fuse box

X01

Blower assembly

G302
A/C switch

Z100

G310

G303
Resistor

G306
A/C Relay

G308
A/C pressure switch
[Black]

G307
A/C Compressor
clutch

G304
Resistor

G305
Blower motor

G309
Thermo switch

G301
X02
X02
X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

Heater control module

p101nUK

Remote freewheel control system (before model year 2002)

Main fuse box


+

< >...

MAIN

B(E)

B/W(E)
80A

X01

B/W(F)

X02

X07

Lock solenoid

Ignition switch

Free solenoid

OFF

ST
IG1 IG2

H04

ACC

X02
W
(F)

H02
B/W
(F)

Fuse block

B
(F)

Remote freewheel main


switch

H03
B/W
(F)

H04

ENGINE
B/W(F)
15A

X03

X03
B/W
(F)

R
(F)

LG
(F)

G/O
(F)

H01

Remote freewheel control


module
B

R/G
(F)

GY/R
(F)

LG/B
(F)

E
H01

Z101

B
(F)

X09
R/G
(E)

H06

Remote freewheel
switch
H05

H07

4x4 Mode switch

H06

B/R
(E)
<B>

LG/R
(F)

24

23

LG/B
(E)

GY/R
(E)
H05

BR
(F)

Neutral position
switch

B/R
(E)
<B>

H07

Instrument cluster
(Section C1b, 2b)

B/R
(E)
<B>

B/R
(F)
<B>
X09
B/R
(F)

H01 Remote

6
WL,
WL Turbo

freewheel control module (F)


K

GY/R G/O
LG/B

R/G

H05 Remote

freewheel
switch (E)
R/G
B/R
<B>

H02

LG/R

LG

B/W

BR

Lock solenoid (F)

B
D

H06 4x4

Mode switch (E)

B/R
GY/R
<B>

H03

H07 Neutral

position
switch (E)
B/R
LG/B
<B>

B/W

Free solenoid (F)

B
(F)

G6
H04

LG

B/W

Remote freewheel
main switch (F)

G/O

Wiring Diagram

X01

G6

Battery

p102nUK

Harness symbol

[ Grey ]
Lock solenoid

H02

H02

[ Yellow ]
Free solenoid

X01

[ Yellow ]
Free solenoid

[ Black ]
Neutral position switch

H03

H07

[ Black ]
4x4 Mode switch

H06

H03
[ Black ]
Neutral position
switch

Main fuse box

X01

H07
[ Black ]
Remote freewheel
switch

H05

H06

4x4 Mode switch


[ Black ]

X07

Z102

(F)(E)
[ Black ]

X07
H05

(F)(E)
[ Black ]

Remote freewheel switch


[ Black ]

WL, WL Turbo

G6
3
Ignition switch
[ White ]

X02

X02

Ignition switch

H01
Remote freewheel control
module

[ Blue ]

H04
Remote freewheel main
switch
[ Blue ]

X03
Fuse block

Wiring Diagram

Main fuse box

[ Blue ]
Lock solenoid

H-2

Remote freewheel control system (WL3, WLT3, as of model year 2002)

Battery
+

MA IN

B( E)

B/ W (E )
X 0 1

B/ W( F)

X 0 2

X 0 7

IG 1

G2

Lock solenoid

Free solenoid

Ignition switch

OF F

ST

Wiring Diagram

X 0 1

80 A

AC C

X 0 2

H 2 02

W
(F )

H 2 03

B/ W
(F )

B/ W
(F )

E N GINE
B/ W( F)
X

03

15A

X 0 3

B/ W
(F )

R
(F )

LG
(F )

H2 0 1

Remote freewheel control module


B

H2 0 1
GY /R
(F )

R/G
(F)

L G/B
(F )

LG/ R
(F)

X 0 9

B
(F )

R/G
(E )

GY /R
(E )

Z103

H2 0 5

LG /B
(E )

H2 0 6

Remote freewheel switch

H2 0 4

H2 0 7

4x4 Mode
switch

H2 0 5

23

Neutral position switch

H2 0 6

B/ R (E)

B
(F )
B/ R (E)

B /R (E )
X

H2 0 5

20

GY /R

G/O

LG /B

R/G

B/ W

BR

Remote freewheel switch


(E)

H 2 02

LG/ R

H2 0 6

LG

H2 04

Free solenoid (F)

Remote freewheel main switch (F)

R
B

H 2 03

Lock solenoid (F)

B/ W

4x4 Mode switch (E)

H2 0 7

Neutral position switch (E)

R/G
B/ R
B/ R

09

Remote freewheel control module (F)

H2 0 4

B/ R
(E )

B/ R( E)

H2 0 1

Remote freewheel main


switch

24

Instrument cluster
(Section C3b)

H2 0 7

B/ R
(E )

G/O
(F )

BR
(F )

GY /R

B/ R

LG /B

LG

B/ W

G/O

p104UK

H-2

Harness symbol

[Grey]
(F)(E)

Main fuse box

X07

[Blue]
Lock solenoid

H202
[Yellow]
Free solenoid

H203

X01

Wiring Diagram

X09
[Black]
(F)(E)

[Black]
Neutral position switch

H207

H206
4x4 Mode switch
[Black]

Z104

[Blue]
Remote freewheel main switch

H204
H205
Remote freewheel switch
[Black]

20

X02
H201
Remote freewheel control module

X02
X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

p105nUK

I-1

Instrument Illumination

39

R/B(F)

R/B(F)

Instrument illumination potentiometer


R/B
(F)

R/B
(F)

Oscillator

R/B
(F)

R/B
(F)
27

Instrument cluster
(Section C1c, 2c, 3c)

R/B
(F)

44

Clock
(Section I2)

F103

G211(F2 CIS,G6)
G111(WL,WL Turbo)

J01

F103

Audio illumination

Hazard flasher
switch illumination

G211(F2 CIS,G6)
G111(WL,WL Turbo)

J01

1E

1F

R/G
(F)

R/G
(F)

I101

Heater and A/C


control assembly
illumination

R/B(F)

B
(F)

R/G
(F)

Instrument cluster
(Section C1c, 2c, 3c)

R/G
(F)

Z105

38

R/G
(F)

R/G(F)

R/G(F)

R/G(F)

I101

Instrument illumination potentiometer (F)

F103

Hazard flasher switch illumination (F)

G111(WL,WL Turbo)

Heater and A/C control assembly illumination (F)

G211(F2 CIS,G6)
B

G/O

R/G

R/G

R/B

J01

Audio illumination (F)


1M

1K

L/R

L/Y

L/W

1N

1L

1E
R/B

1C
L/R

1A
L/W

R/G
1J

1H

1F

1D

1B

R/B

B/Y

G/W

G/B

L/Y

G/R

R/G

R/B

Wiring Diagram

Headlamp switch
(Section E1, 2, 4)

p106nUK

I-1

Harness symbol

Z
Wiring Diagram

Hazard flasher switch illumination

F103
Instrument illumination
potentiometer

I101

Z106

J01
Audio illumination

G111 ( WL, WL Turbo )


G211 ( F2 CIS, G6 )
Heater and A/C control assembly illumination

p107nUK

I-2

Cigar lighter / Clock / Outlet / Rear defrost

Battery

Main fuse box


+

BTN
B(E)

W/R(E)

W/R(F)
X08

MAIN

X03

A
B/W(E)

80A

B/W(E)

B/W(F)

X01

X02
OFF

ROOM
10A

ACC

X03

Ignition switch
B
B/W(E)

ST

B/W(F)

IG1 IG2

X07

R.DEF
W(F)

W
(F)

B/W(F)
X03

Instrument cluster
(Section C1c, 2c, 3c)

20A

Fuse block

X02

Fuse block
L
(F)

X03

Fuse block
METER

X03

Instrument Illumination
(Section I1)

CIGAR
15A

44

B/Y(F)
15A

X03

I204

45

Wiring Diagram

30A

X01

X03

Rear window
heater relay

X03
I204
L/W
(F)

B/L
(F)

B/L
(F)

Z107

L/W
(F)

Rear window
heater switch

B/L
(F)

I203

I206

14

B
R/B

L/R

lighter (F)

I202
I201

I203 Outlet

(F)

B
(F)

I204

L/W

L/W

Clock

Cigar lighter

B
(F)

I202 Cigar

Clock (F)

I202

I203
B
(F)

I201

I201

I205

B/L(R)
I207

L/W
(F)

Outlet

X04

R/B
(F)

L/W(F)

I205

Rear window heater grid

L/R
(F)

G
(F)

L/W
B

Rear window heater


relay (F)

B
(F)

I205 Rear

window heater
switch (F)

B/Y

B/L

I206

Rear window heater


grid (R)
B/L

I207

Rear window heater grid


(Short cord)
B

p108nUK

I-2

Harness symbol

Main fuse box


Rear window heater
grid

I206

(F)(R)

X04

I207
Rear window heater
grid
14

X07
(F)(E)
[ Black ]

X08
(F)(E)
[ Black ]

Z108

WL, WL Turbo
Clock
Rear window heater
switch

Main fuse box

I201

I205

X01
[ White ]
Ignition switch

X02
(F)(R)

X04

[ Black ]
Rear window heater
relay

I202
Cigar lighter

I204

[ Black ]

I203
Outlet
[ Black ]

X07
(F)(E)
[ Black ]

X02
Ignition switch

X08
(F)(E)
[ Black ]

X03
F2 CIS, G6

Fuse block

[ Blue ]

Wiring Diagram

X01

p109nUK

I-3

Interior lamps

Fuse block

Main fuse box


+

BTN

ROOM

B(E)

W/R(E)
X01

W/R(F)
X08

X01

10A

X03

Wiring Diagram

30A

Battery

X03
L/R
(F)
X11
L/R
(IN)
I301

Interior lamp

Off

On

Door

Instrument cluster
(Section C1a, 2a)

I301
21
R/Y
(IN)
X11
R/Y
(F)
I306

R/Y
(F)

X19

Z109

R/Y(FR)

R/Y(FR)

R/Y(F)

R/Y(F)
X04
R/Y(R)

R/Y
(FR)

R/Y
I304

R/Y
(R)

I302

LH Rear
door
entry
switch

I305

LH Front
door
entry
switch

RH Rear
door entry
switch

Double cabin
I301

Interior lamp (IN)

I302

R/Y

(Regular cabin)

R/Y

L/R
L/R

I306

(FR) Short cord


(FR)
R/Y

(Short cord)
R/Y

I303

RH Front
door entry
switch

Double cabin
LH Front door entry switch
(FR)

I303

RH Front door entry switch


(R)

I304

LH Rear door entry switch

I305

RH Rear door entry switch (R)

(Short cord)

(Stretch cabin)
(Double cabin)

R/Y
(R)

R/Y

R/Y

R/Y

R/Y

p110nUK

I-3

Harness symbol

Interior lamp
Main fuse box

X01

I301

Wiring Diagram

[ Black ]
RH Front door entry
switch

I303
(F)(R)

X04

I302
LH Front door entry
switch
[ Black ]

Z110

X08

X11

(F)(E)
[ Black ]

(F)(IN)

Regular cabin,

X19

Stretch cabin

(F)(FR)

[ Black ]
RH Rear door entry
switch
[ Black ]
RH Front door entry
switch

Interior lamp

I301

I305

I303
(F)(IN)

X11
(F)(R)

X04

X04

(F)(IN)

(F)(R)

X11

I304

LH Rear door entry


switch
[ Black ]

I306
(FR) Short cord

X03
Fuse block

X19
(F)(FR)

I302

LH Front door entry


switch

X19
(F)(FR)

Double cabin

p111nUK

Audio Systems

Battery

Main fuse box


+

MAIN

B(E)

B/W(E)

B/W(F)

X01

X07

X02

BTN
W/R(E)
30A

Wiring Diagram

80A

OFF

ST

Ignition switch

X08

X01

IG1 IG2

W/R
(F)

Fuse block

ACC
X02

ROOM
L/R(F)

L
(F)

10A

CIGAR
L/W(F)
X03
L/R
(F)

L/W
(F)

1C

1A

15A

X03

J01

Audio unit

3A

1K

J04

1L

1M

1N

J01

Z111

L
(F)

L/W
(F)

X15
L/R
(DR1)

L/Y
(DR1)

L
(DR2)

J03

Speaker,
left

Speaker,
right

1E

L/R

R/B

L/Y

L/W

R/G

1C
L/R

L/W
(F)

L/R
(F)

L/Y
(F)

J06

Speaker,
right

without audio harness


J02 Speaker,

1K

L
(F)

Speaker,
left

Audio unit (F)


1M

1N

J05

with audio harness


J01

1M

L/W
(DR2)

J02

15

1L

L/Y
(F)

L/R
(F)

X12
B

1K
J01

left (DR1)

J03

(with audio harness)

1A

Speaker, right (DR2)


(with audio harness)

L/W
L/Y

1N
J04

Audio unit

1L

1J

1H

1F

1D

L/W

L/R

1B
J05

Speaker, left (F)

L
J06

(without audio harness)

Speaker, right (F)


(without audio harness)

3A

(Short cord)

L/W

L/Y

L/R

p112nUK

Harness symbol

Z
Wiring Diagram

Speaker, right

J03
(F)(DR2)

X15

Main fuse box

X01

J02

Speaker, left

X12
(F)(DR1)

Z112

Audio unit
Audio unit

J01

J04

(F)(DR2)

X15

[ White ]
Ignition switch

X07
(F)(E)
[ Black ]

X02

J06
Speaker, right

X08
(F)(E)
[ Black ]

(F)(DR1)

X12

15

X02
Ignition switch

X03
J05
Speaker, left

Fuse block

[ Blue ]

p113nUK

K-1

Power Windows (Regular cabin, Stretch cabin)

Battery

Main fuse box


+

MAIN

B(E)

B/W(E)
X01

B/W(F)

X01

X07

X02

Wiring Diagram

80A

Ignition switch
OFF

ST
IG1 IG2

ACC
X03

X02

Fuse block
(P.WIND)

X03

W(F)
30A

Power window main switch

Power cutoff switch


Close
Close

Open

Open

R/L
(F)

K101
G/W
(DR1)

Auto circuit

R/L
(DR1)

R/W
(DR1)

X13
R/L
(F)

X14

G/W
(F)

R/W
(F)

G/W
(DR2)

R/W
(DR2)

R/L
(F)

X17

X16

K101
R/L
(DR2)

Z113

K102
G/B
(DR1)

B
(DR1)

Power window switch,


RH side front

R/B
(DR1)

Close

Open
K102

X14
B
(F)

G/B
(DR2)

K103
M

Open

Close

LH Front
window
motor

R/B
(DR2)
K104

RH Front window
motor

Open

Close

K101

Power window main switch (DR1)

K102

G/W
R/W

R/L

Power window switch, RH side front


(DR2)

G/B

R/B

R/B

G/W

G/B

K103 LH

Front window motor (DR1)

K104

RH Front window motor (DR2)

R/W

G/B

G/B

R/L

R/B

R/B

p114nUK

K-1

Harness symbol

Z
Wiring Diagram

Main fuse box

X01

Power window switch, RH


side front

K102
RH Front window
motor

K104
(F)(DR2)

X16
(F)(DR2)

X07

X17

Z114

(F)(E)
[ Black ]

[ White ]
Ignition switch

K101
Power window main switch

X02
X16

K103

(F)(DR2)

LH Front window motor


[ Blue ]

X17
(F)(DR2)

(F)(DR1)

X03

X13

Fuse block

X14
(F)(DR1)

X02
Ignition switch
[ Blue ]

X13

X14

(F)(DR1)

(F)(DR1)

p115nUK

K-2

Power Windows (Double cabin)

Main fuse box


+

MAIN

B(E)

B/W(E)
X01

X01

Ignition switch

X07

Fuse block

IG1 IG2

(P.WIND)

ACC

X02

W(F)
30A

OFF

ST

R/L(F)
X03

X02

B/W(F)

Wiring Diagram

80A

Battery

X03

R/L(F)

Power window main switch


Power
cutoff
switch
Auto circuit

Close

Close

Open

Close

Open

Close

Open
K201

Open

K201

G/W
(DR1)

R/W
(DR1)

R/L
(DR1)

G/W
(F)

R/W
(F)

R/L
(F)

X14

W
(DR1)

L/W
(DR1)

W/R
(DR1)

W
(F)

L/W
(F)

W/R
(F)

G/Y
(DR1)

X13

R/L(F)

X14

G/Y
(F)

R/L(F)
X06

X20

R/L(F)
W
(R)

L/W
(R)

R/L
(R)

W
(DR3)

L/W
(DR3)

R/L
(DR3)

R/L
(F)
X17

Z115

B
(DR1)

X16
R/W
(DR2)

G/W
(DR2)
R/B
(DR1)

Close

X14

Open

B
(F)

Close

Open

G/B
(DR3)

Close

Open

R/L
(DR4)

Open

K206

Power window switch,


RH side rear

Close

Open

Close

Open

R/B
(DR4)
K208

RH Rear window
motor
Close

LH Rear window motor

Open

Close

K201

K205

Power window main switch (DR1)

W/R

G/Y

G/B

R/B

W
B

K202

L/W

R/L

R/B

G/W

R/W

G/W

Power window switch, RH side rear (DR3)

G/B

R/L

Power window switch, RH side front (DR2)

L/W

K206

R/B

G/B

K203

G/B

R/L

K204

RH Front window motor (DR2)

R/W

G/B

G/B

R/L

R/B

R/B

Power window switch, LH side rear (DR4)

LH Front window motor (DR1)

L/W

K207

RH Rear window motor (DR3)

Power window switch,


LH side rear

K206
G/B
(DR4)

K207

RH Front window motor

L/W
(DR4)

X22

R/B
(DR3)

K204

LH Front window motor

W
(DR4)

K205

R/B
(DR2)

K203

R/L
(FR)

K205

Power window
switch, RH side
front

K202
G/B
(DR2)

G/Y
(FR)

X21

R/L
(DR2)
K202

G/B
(DR1)

W/R
(FR)

K208

LH Rear window motor (DR4)

G/B

G/B

R/B

R/B

R/B

p116nUK

K-2

Harness symbol

Z
Wiring Diagram

Main fuse box

X01

Power window switch, RH


side front

K202
[ Blue ]
RH Front window
motor

Power window switch,


RH side rear

RH Rear window
motor

K207

K205

(R)(DR3)

X21

K204
(F)(DR2)

X16

Z116

X07
(F)(E)
[ Black ]

(F)(R)

K208

X06

LH Rear window
motor

K206
[ White ]
Ignition switch

X22
(FR)(DR4)

X02
X17
X16
(F)(DR2)

X17
(F)(DR2)

K201

(F)(DR2)

X20
(F)(FR)

Power window main


switch

X13
(F)(DR1)

X14
(F)(DR1)

K203
LH Front window
motor
[ Blue ]

X06
(F)(R)

X13
X03

(F)(DR1)

Fuse block

X20
(F)(FR)

X14
(F)(DR1)

X02
Ignition switch
[ Blue ]

Power window switch,


LH side rear

p117nUK

K-3

Central door locking

Fuse block

Main fuse box


+

MAIN
B(E)

(D/L)

B/W(E)
X01

Double cabin

B/W(F)
X07

30A

X03

X03
G(F)

G(F)
G
(F)

G
(F)

G
(F)

X04

X14
W/G
(F)

G/O(F)

G
(FR)

X17

G/R(F)

X21
K301

G
(DR2)

Door lock timing unit

K303

G
(DR4)

K304

K305

Lock

Lock

Central door
locking

Lock
K302

G/Y
(DR1)

Lock
M

Unlock

Unlock

Unlock

RH Front
door lock
motor

Door lock
motor, LH
side rear

Door lock
motor, RH
side rear

K303

K304

R
(DR2)

Z117

K301

X22

G
(DR3)

K302

X14

X19

G
(R)

G
(F)

G/O
G/R
(DR1) (DR1)

Unlock

K305
R
(DR4)

R
(DR3)

X21
X17

G/Y
(F)

G/Y
(F)

B
(F)

R
(F)

X22

R
(R)

R
(F)

R
(FR)
X04

X19

R
(F)
G/Y(F)

K301

Door lock timing unit (F)

K302

G/O

G/R

W/G

Central door locking (DR1)

G/O

R(F)

K303

RH Front door lock motor


(DR2)

K304

Door lock motor, LH side


rear (DR3)

K305

Door lock motor, RH side


rear (DR4)

G/Y
G

G/Y

R
(F)

R(F)

Wiring Diagram

80A

X01

Battery

G/R

p118nUK

K-3

Harness symbol

Main fuse box

Wiring Diagram

X01

Door lock motor, RH


side rear

K305
(R)(DR3)
RH Front door lock
motor

X21

K303

X07

Z118

(F)(E)
[ Black ]

(F)(R)

X04
3

K304
Door lock motor, LH
side rear

X22
(FR)(DR4)

X17

K302

(F)(DR2)

Central door locking

X14
(F)(DR1)

X17
(F)(DR2)

X19
(F)(FR)

X04
(F)(R)

K301
Door lock timing
unit

X03
Fuse block

X19
(F)(FR)

X14
(F)(DR1)

p119nUK

Power mirrors

Battery

Main fuse box


+

MAIN

B(E)

B/W(E)
X01

B/W(F)

X01

X07

Power mirror switch


Left

Right

ST
IG1 IG2

Down

X02
OFF
ACC

Up

X02

Down

Up
Left

Select LH mirror

Right

Select RH mirror

Select LH mirror

Select RH mirror

L01
L
(F)

BR
(F)
BR/Y
(F)

L/B
(F)

Z119

BR
(F)

BR
(F)

LG/B
(F)

BR/B
(F)

L/W
(F)

X13
B
(F)

BR/B
(DR1)

LG/B
(DR1)

BR
(DR2)

L/B
(DR2)

X03

L03

Power mirror, RH
side

Power mirror, LH
side
M

CIGAR

BR/Y
(DR2)

L02

Left
Right

Fuse block

X16

BR
(DR1)

Up
Down

Up
Down

Left
Right

L01

Power mirror switch (F)


BR
B

L/W

L02

LG/B

L/B

BR/Y BR/B

Power mirror, LH side (DR1)


LG/B
BR/B

L03

BR

Ignition
switch

Power mirror, RH side (DR2)


L/B
BR/Y

BR

15A

X03

Wiring Diagram

80A

p120nUK

Harness symbol

Z
Wiring Diagram

Main fuse box

X01

Power mirror, RH side

L03

(F)(DR2)

X16

Z120

X07
(F)(E)
[ Black ]

[ White ]
Ignition switch

X02
L02

Power mirror, LH side

Power mirror switch

L01

X16
(F)(DR2)

X13
(F)(DR1)

X02
X03
X13
(F)(DR1)

Fuse block

Ignition switch
[ Blue ]

p121nUK

Heated seats (before model year 2002)

Battery

Main fuse box


+

MAIN
B(E)

B/W(E)
X01

X01

B/W(F)
A

X07

Wiring Diagram

80A

X02

Ignition switch
OFF

ST
IG1 IG2

ACC

X02

Fuse block
S.WARM
W(F)

BR/Y(F)
X03

15A

X03
BR/Y
(F)

P01

Heated seat
switch

P01

P01
BR/B
(F)
X19

B
(F)

Z121

BR/B
(FR)
P02

Heater
P02

B
(FR)

17

P01

Heated seat switch (F)

P02

Heater (FR)

BR/B

BR/B

BR/Y

p122nUK

Harness symbol

Main fuse box

Wiring Diagram

X01

X07

Z122

(F)(E)
[ Black ]

[ White ]
Ignition switch

P02

Heated Seats

X02
[ Blue ]
Heated seat switch

17

P01
X19
(F)(FR)

X02
Ignition switch

X03
Fuse block

X19
(F)(FR)

[ Blue ]

P-2

Heated seats (WL3, WLT3, as of model year 2002)


A

MA IN
B (E )

B/ W( E)
X 01

X 01

B/ W( F)
B

X 0 7

IG 1

02

OF F

ST

G2

Wiring Diagram

80 A

Battery

Ignition switch

AC C

02

S. WARM
W( F )

BR/ Y (F )
X

03

15 A

03

BR/ Y
(F )
P2 0 1

Heated seat switch


P2 0 1

P2 0 1
BR/ B
(F )
BR /B (F )
BR/ B
(F )
X 1 9

04

B
(F )

BR
(R )

Z123

BR/ B
(F R )
P2 0 2

P2 0 3

Heated seat element, driver


side front

Heated seat element, driver


side front

P2 0 2

P2 0 3
B
(R )

B
(F R )

17

P2 0 1

P2 0 2

Heated seat switch (F)

Heated seat element, driver


side front (FR)

P2 0 3

Heated seat element, passenger side front (R)

BR /B

BR /B

BR

BR /Y

04

B
(F )
3

p124UK

P-2

Harness symbol

Z
Wiring Diagram

[Black]
(F)(E)

X07
Main fuse box

Heated seat element, passenger side front

X01

P203
(F)(R)

X04

Z124

P202
17

X19
3

[Blue]
Heated seat switch

P201

X04
(F)(R)

X02
X02

(F)(FR)

X19

X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

(F)(FR)

Heated seat element, driver side


front

Z-S

Wiring Diagram

Air Bags
Service Warnings
Component Disassembly
D
Disassembling and reassembling the components of
the air bag system can render the system inoperative,
which may result in serious injury or death in the
event of an accident. Do not disassemble any air bag
system component.

Air Bag Handling


D
A live (undeployed) air bag may accidentally deploy
when it is handled and cause serious injury. When
carrying a live (undeployed) air bag, point the front
surface away from your body to lessen the chance of
injury in case it deploys.

RIGHT
Wiring Harness Repair
D
Incorrectly repairing an air bag system wiring harness
can accidentally deploy the air bag, which can cause
serious injury. If a problem is found in the system
wiring, replace the wiring harness. Do not try to repair
it.

D
A live (undeployed) air bag placed face down on a
surface is dangerous. If the air bag deploys, the
motion of the air bag can cause serious injury. Always
face the front surface up to reduce the motion of the
air bag in case it accidentally deploys.

RIGHT

Air Bags Service Warnings

WRONG

Air Bag Inspection


D
Inspecting an air bag using an ohmmeter can deploy
the air bag, which may cause serious injury. Do not
use an ohmmeter to inspect an air bag. Always use
the on-board diagnostic function to diagnose the air
bag for malfunctions. (Refer to ON-BOARD
DIAGNOSTIC FUNCTION; AIR BAG SYSTEM.)

Z-125

WRONG

Wiring Diagram

Air Bag Module Handling


D
Disconnecting the air bag module connector or
removing the air bag module with the ignition switch
in the ON position can cause the air bags to deploy,
which may seriously injure you. Before disconnecting
the air bag module connector or removing the air bag
module, turn the ignition switch to the LOCK position,
then disconnect the negative battery cable and wait
for more than 1 minute to allow the backup power
supply of the air bag module to deplete its stored
power.
D
Connecting the air bag module connector without
firmly installing the air bag module to the vehicle is
dangerous. The crash sensor inside the module may
send an electrical signal to the air bags. This will
deploy the air bags, which may result in serious injury.
Therefore, before connecting the connector, firmly
mount the module to the vehicle.
D
For vehicles with a single point sensor, once an air
bag is deployed due to an accident or other causes,
the air bag module must be replaced with a new one
even if the used one does not have any external signs
of damage. The used air bag module may have been
damaged internally, which may cause improper
operation, resulting in major injuries or even death.
The used single point air bag module cannot be
benchchecked or selfchecked.
Component Handling
D
Oil, grease, water, etc. on components may cause the
air bags to fail to deploy in an accident, which may
cause serious injury. Do not allow oil, grease, water,
etc. on components.
D
Inserting a screwdriver etc. into the connector of an
air bag may damage the connector and cause the air
bag to deploy improperly, which may cause serious
injury. Do not insert any foreign objects into the
connector.

Air Bags Service Warnings

Component Reusing
D
Even if an air bag does not deploy in a collision and
does not have any external signs of damage, it may
have been damaged internally, which may cause
improper operation. Improper operation may cause
serious injury. Always selfcheck the undamaged air
bag to determine whether it can be reused. (Refer to
ON-BOARD DIAGNOSTIC FUNCTION, AIR BAG
SYSTEM.)

Z-126

Z-S

p127nUK

S-1

Air bags (before model year 2002)

MAIN
B(E)

B/W(E)

B/W(F)
A

X07

X01

Wiring Diagram

80A

X01

with passenger air bag

< >...

Main fuse box


+

Battery

X02

Ignition switch
OFF

ST
IG1 IG2

ACC

Fuse block

X02

METER
W(F)

B/Y(F)

B/Y(F)

15A

X03

ENGINE
B/W(F)
15A

B/W(F)
S102

X03

S101
Z

Air bag module


AA

R/G
(F)

Y/G
(F)

L
(F)

LG
(F)

R
(F)

Y/R
(F)

AB

B
(F)

B
(F)

S101

S102
R/G
(F)

S103

Shorting bar
B
(F)

Y/G
(F)

Z127

Shorting
bar

S104

LG

Shorting
bar

Clock spring
Y/G
(F)

Y/G
(F)

LG
S105

Inflator
46

47

Shorting bar

25

Data Link Connector


(DLC)
(Section U)

Instrument cluster
(Section C1b, 2b)

Passenger air bag


unit
with passenger air
bag

Inflator
Driver air bag unit
8

S101

Air bag module (F)

S102 Shorting

bar connector (F)

S103 (F)

Clock spring
(Clock spring)

(F)
W
AA

G/R

R/G

Y/G

LG

Y/R

B/Y

AB

B/W

R/G

R/G

G/R

B/W

B/W

B/Y

R
S104

B/Y

Y/G

LG
C

Y/G

Passenger air bag unit (F)

S105

Driver air bag unit


(Clock spring)

B
Y/R

LG

LG

p128nUK

S-1

Harness symbol

Z
Wiring Diagram

Main fuse box

X01

Passenger air bag unit

S104
[ White ]
Ignition switch

Shorting bar connector

S102

X02

Z-128

(F) Clock spring

S103
9

X07
(F)(E)
[ Black ]

S101

Air bag module

S105

Driver air bag unit

X02
X03
Fuse block

Ignition switch
[ Blue ]

S-2

Air bags (WL3, WLT3, as of model year 2002)

Battery
+

MA IN
B/ W (E)

B( E)
X 0 1

B/ W( F)

01

AB

X 0 7

IG 1

02

OF F

ST

G2

Wiring Diagram

80A

Ignition switch

AC C

X 0 2

ME TE R
B/ Y (F )

W( F )
X

B/ Y( F )

15A

03

E N GINE
B/ W (F )
15A

B/ W( F)
S2 0 2

03

S2 01

Air bag module


S

L
(F)

LG
(F)

R
(F )

Y/ R
(F )

AB
X

S2 0 1
Y/ G
(F )

S2 0 3

Shorting bar

B
(F )

S2 0 2

S2 0 4

LG

B
(F )

Shorting bar

Z129

Y/ G
(F )

Clock spring
L

Shorting bar

LG
S2 0 5

Inflator
25

Shorting bar

Passenger air bag


unit

Instrument cluster
(Section C3b)
Inflator

with passenger air


bag

Driver air bag unit


9

S2 0 1

S2 02

Air bag module (F)

S 2 03

Shorting bar connector (F)

(F) Clock spring


(F )

WU
AA

G/R

BY

B/ W

AB

B /Y

B /W

Y /G

Y/ G

B /W

B /Y

LG

G/R

R
S 2 0 4

B/ Y

(Clock spring)

S2 0 5

Passenger air bag unit (F)

Driver air bag unit


(Clock spring)

Y/ R

R
LG

LG

p130UK

S-2

Harness symbol

Z
Wiring Diagram

Main fuse box

X01

[Yellow]
Passenger air bag
unit
Shorting bar connector

S204

S202

Z130

Clock spring

S203

X07
(F)(E)
[Black]

S201
Air bag module

S205
Driver air bag unit
[Yellow]

X02
Ignition switch

X02
Ignition switch

X03
Fuse block

[Blue]

[White]

p131nUK

Immobiliser system (before model year 2002)

X01

X01

MAIN

Main fuse box

Battery

B(E)

B/W(E)

B/W(F)
A

X07

X02

BTN
W/R(E)

Instrument cluster
(Section C1a)

Ignition switch

W/R(F)

30A

X08

Fuse block

IG1 IG2

ROOM
10A

ACC

X02

W/R(F)
X03

OFF

ST

L/R(F)
51

Wiring Diagram

80A

X03

Fuse block
ENGINE
W(F)
15A

X03
BR/B
(F)

L/R
(F)

X03

B/W
(F)

T01
L

Coil

Immobiliser module
C

T01

T02

B/R
(F)

V/W
(F)

B/W(F)

GY(F)

Z131

Y(F)
B209

Diesel pump
unit
DDS1

49

Powertrain control
module (PCM)
(Section B2a)

B209

B/R
(F)

T01

Immobiliser module (F)


M

16

T02
I

BR/B

C
B/R

Coil (F)

B209

L/R
J

GY

C
R/L

V/W
GY

B/W

Diesel pump unit (F)

B/R

BR/W L/B

G/W

B/W

B/R

V/W

p132nUK

Harness symbol

Z
Wiring Diagram

Main fuse box

X01

Z132

[ White ]
Ignition switch

16

X07
(F)(E)
[ Black ]

X02
X08
(F)(E)
[ Black ]

Immobiliser module

T01

B209
Diesel pump unit
[ Grey ]

T02
X02
X03
Fuse block

Ignition switch
[ Blue ]

Coil

T-2

Immobiliser system (WL3, WLT3, as of model year 2002)


X

01

MA IN

Battery
+

01

B( E)

A
B/ W( F)

B/ W( F )
X

07

X 0 2

BT N
W/ R( E)

W/ R( F )

30 A

Wiring Diagram

80 A

OF F

ST

Ignition switch

08
IG 1

IG 2

AC C

02

W
(F )

X 0 3

X 0 3

ROOM
10A
X 0 3

T2

E N GINE
15A
X 0 3

L/ R
(F )

B/ W
(F )

01

Immobiliser module

T2

B/ R
(F)

W
(F )

R
(F )

BR/ B
(F )

P
(F )

Y
(F )

GY
(F )

59

54

51

61

01

Z133

T2

02

Coil
Powertrain control
module (PCM)
(Section B6b)

Starter relay
(Section A3)

20

T 2 01

Immobiliser module (F)


M
BR /B

B/ R

L/R
J

Coil (F)

R
B/ W

T 2 02
I

W
GY

GY
D

Instrument cluster
(Section C3a)

Key warning switch


(Section C3a)

p134UK

T-2

Harness symbol
(F)(E)

X08

Wiring Diagram

X07

[Black]
(F)(E)

Main fuse box

X01

Z134

Immobiliser module

T201

20

T202
Coil

X02
X02
X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

p135nUK

Data Link Connector (DLC) (before model year 2002)

< >...

Main fuse box

MAIN
B(E)

B/W(E)
X01

B/W(F)
A

X07

Wiring Diagram

80A

X01

X02

Ignition switch
OFF

ST
IG1 IG2

ACC

Fuse block

X02

METER
W(F)
15A

X03

Powertrain control module (PCM)


(Section B2b, 3a, 4a)

12

BR/R(F)

10

Y/B(F)

11

Y(F)

X03

B/Y(F)

Powertrain control
module (PCM)
(Section B3a, 4a)

B/O
(F)

Y/G(F)

47

R/G(F)

46

Z135

Data Link
Connector
(DLC)

Air bag module


(Section S1)

with air bag

X05
B
(F)

B/R
(F)

B/O
(INJ)

L/O(F)

18

O(F)

Fuel pump relay


(Section B5)
Ignition coil
(Section B3a, 4a)

F2 CIS,G6

13
F2 CIS,G6
U01 Data

WL,WL Turbo

Link Connector (DLC) (F)

WL, WL Turbo (European specifications)

FEN

KLN

TEN

+B

GND

FAB

GND

F/P

TAB

<Y/G>

F2 CIS, G6

BR/R B/Y

Y/B
B/R

IG

with air bag

Battery

Y/B

BR/R B/Y

B/O

<R/G>

Note: This is the connector as seen from the terminal side.

<Y/G>

L/O

<R/G>

p136nUK

Harness symbol

X01

Main fuse box

X01

2
2
13

U01
Data Link Connector
(DLC)

U01
Data Link Connector
(DLC)

X07

Z136

(F)(E)
[ Black ]

X07
(F)(E)
[ Black ]

X05

(F)(INJ)
[ Black ]

WL, WL Turbo

F2 CIS, G6

[ White ]
Ignition switch

X02

X02
Ignition switch

X03
Fuse block

[ Blue ]

Wiring Diagram

Main fuse box

U-2

Data Link Connector (DLC) (WL3, WLT3, as of model year 2002)

< > ...

MA IN
B/ W (E )
X 0 1

80A

B/ W( F)
A

01

B
X

X 0 7

IG 1

02

OF F

ST

G2

Ignition switch

AC C

02
ME TE R
W( F )
X

Powertrain control module


(PCM)
(Section B6b)

12

B R /R (F )

11

Y /R (F )

10

B /Y (F )

03

15 A

03

B/ Y
(F)

U201

Data Link Connector


(DLC)

Instrument cluster
(Section C3b)

47

Y /G(F )

Z137

with air bag

B/ R
(F )

Powertrain control module (PCM)


(Section B6b)

58

B
(F )

W /L( F)

20

U2 0 1

Data Link Connector


(DLC) (F)
A
FE N KL N
GND

FA B

TE N

+B

B/ Y

BR /R

Y/ R

B/ R

IG

GND

<Y /G >

Note: This is the connector as seen from the terminal side.

W/ L

with air bag

Wiring Diagram

B( E)

Battery

B/ Y

p138UK

U-2

Harness symbol

Z
Wiring Diagram

Main fuse box

X01

U201

Z138

Data Link Connector (DLC)

X07
(F)(E)
[Black]

20

X02
X02
X03
Fuse block

Ignition switch
[Blue]

Ignition switch
[White]

p139nUK

Connectors (before model year 2002)


Main fuse box (E)

X02

Ignition switch (F)

X03

Fuse block (F)

X01

(L/W)

with central
locking

(R)
30A

R
R

W/R

30A

30A

10A

R/B
80A

60A
<G/B>

B/W

B/W

10A

B/W

30A

LG/R

L/Y
W/G

HEAD

GLOW (FUEL INJ)

BTN

<PTC>

MAIN

B/Y

B/R

X04

B/R

10

11

20A

( )...

17

15A

L/W

18

12

19

13

20

15A

G/W

B/Y

15A

10A

Y/R

B/W

15A

18

S.WARM

(D/L)

14

METER

R.DEF

15

ENGINE

16

STOP

17

(HEATER)

TAIL

18

CIGAR

ROOM

19

WIPER

20

10

21

R.FOG

11

22

(P .WIND)

21

14

13

10A

L/R

with rear fog lamp

15
W

16

30A

R/L

22
R/G

10A

21

with power windows

Note: This is the connector as


seen from the terminal side.

with fuel heater (Diesel)

40A

12

HAZARD

R/Y

Note: This is the connector as seen from


the terminal side.
< >...

B/R

(A/C)

W
W/R

15A

L/Y

15A

with heated
seats
BR/Y

10A

B/W

LG/R

B/W

<30A>

B/W

10A

F2 CIS, G6

(F) (R)

X05

Z139

WL, WL Turbo

(F) (INJ)

F2 CIS

G6
(F)

F2 CIS, G6

(F)

I
B/R

W/G

R/W

B/L

<G>

R/B
<<W/L>>

<R>

G/W

G/B

G/R

(BR/B)

R/Y

(F)

[R/L]

B/O

W/G

R/W

R/Y

(F)
R/B
<<W/L>>

B/L

(( B ))

G/W

G/B

[R/L]

(BR/B)

B/Y

L/W

G/Y

BR/B

(( B ))

B/Y

B/O

BR/W LG/R

LG/B

G/W

B/Y

L/W

G/Y

BR/B LG/B

B/O BR/W LG/R

J
(INJ)

BR

RY

R/W

W/G

BR

B/R

RY

R/W

W/G

B/R

G/R

R/B

<R>

<G>

B/L

(R)

(R)
B

[ R/L ]

G/B

G/W

R/B

<R>

<G>

B/L

[ R/L ]

G/B

G/W

(INJ)

LG/B BR/B

G/Y

L/G

B/Y

LG/B BR/B

LG/R BR/W

B/O

B/Y

LG/R BR/W B/O

G/Y

L/G

B/Y

G/W

G/W

X06

Heated Seats
... RH Front door entry switch

( ( ) )...
< >...

not used

<< >>...

Double cabin

(F) (R)

( )...

X07 (F)

]...

with daytime running lamps


European specifications (LHD)

(E)

X08

(F)

R/L
L/W

R/L

(R)
W

(F) (E)

B/Y
(F)

L/W

B/W

B/W

(E)

B/W

B/W

W/R

(F)

W/R

B/Y

R/W

(F)
R/W
( L/W )

( L/W )

( )...

F2 CIS, G6

Wiring Diagram

(30A)

p140nUK

Connectors (before model year 2002)


X11 (F)

(F) (E)

(IN)

X12 (F)

(DR1)

X09

Y/R

W/B

R/G

L/W

B/Y
L

W
G/R

WL, WL Turbo with remote


freewheel control system

G6 without remote freewheel control system

L/W

(F)

(F)

L/R

F2 CIS

(F)

(F)

I
Y/R

B/R

R/G

R/G
LG/B
(R/W)

<GY/R>

W
W/G B/Y
B/R
(G/B) (W/B) (B/Y) (B)
L/W
L
G/R
GY/R
(BR) (L/W) (L)

R/Y

Y/R

G/B

W/B

B/Y

G/B

W/B

B/Y

R/W

BR

L/W

GY/R

Y/R

L/W

R/W

L/Y

(IN)

(DR1)

L/R

L/R

L
X13 (F)
(E)

(E)

B/R

W
G/R

<GY/R>

B/Y
L

W/B
L/W

B/R
(B)

W
B/Y
W/B
R/G
(B/Y) (W/B) (G/B)
G/R
L/W
L
GY/R
LG/B
(L) (L/W) (BR)

Y/R
R/G

(E)

Y/R

R/G
(R/W)

B/Y

W/B

<GY/R>

L/W

(DR1)

X15

(E)

G/B
BR

Y/R

R/W

W/B

B/Y

R/W

G/B

L/W

R/L

BR/Y

L/B

BR

Y/R

BR/B
BR

Z140

( )...

( )...G6 < >...4X4

(F) (DR1)

X16 (F)

C
<G/Y>

(F)

G/Y
G/W

(B)

<G/Y>

L/R

L/W

(R/L)
(DR2)

LG/B

with power windows


X18 (R) (R2)

BR/B

LG/B

<W>

R/W

BR

G/W

B/R

G/O

BR/Y

( )...

(R/L)

(DR2)

with power windows

( )...
X20

(R2)

(DR2)
G

L/B

BR

(G/W) (R/W) <W/R>

Double cabin with power windows


(F) (FR)

with power windows

(F) (FR)

R/Y

G/W

R/W

R/B

W/G

(R/L)

W/R

( )... European
< >...F2 CIS,G6

with power windows

(DR3)

Double cabin

R/Y

R/L

X22 (FR)

L/W

(DR4)
Double cabin

L/W

R/L

(R)

<G>

G/Y

W/R

R/L

(FR)

G/Y
(FR)
R/L

W/R

(DR3)

B/R

(G/W) (R/W)

( )...
X21 (R)

<R>
BR/B

( )...

G/W

(F)

BR/B
(BR)

(FR)

not used

<G/R>

R/W

G/Y

R
(F)

( )...

W/G

<G/R> G/B
Y

Double cabin

G/B
R/B

(R/L)

(R)

(F)

< >...
X19

(DR2)

(F)

G/R

G/Y

<W> G/R

R/L

<L/W>

G/O

K
(DR1)

X17 (F)

(F)

K
B

<W/R> R/W

<L/W>

(DR2)

L/Y

(F)

(DR1)

X14

(F) (DR2)

R/L

L/W

(DR4)

R/L

specifications (LHD)

Wiring Diagram

R/Y
(F)

WL, WL Turbo without remote freewheel control sys(F)


tem

Connectors (WL3, WLT3, as of model year 2002)


Main fuse box (E)

01

1
R
R

W/ R

30A

Ignition switch (F)

Fuse block (F)

X 0 3

5
10A

LG/ R

10A

L/Y

10

W/ G

11

15A

B/ R

B/ R

R /B

30 A

80A

60A

<G /B >

B/ W

B/ W

B /W

30A

< 30A >

20A

15A

L/W

40A

15A

L/W

17

18

12

19

13

20

B/ W
B

B/ W

HEAD

GLOW

BTN

PT C

MA IN

B/ Y

B/ R

W/ R

Note: This is the connector as seen from the


terminal side.
<

15A

G/W

B/ Y

15A

10A

Y/ R

B/ W

15A

10A

L/R

(F) (R)

Z141

B/ R
B/ L

W/ G

R /W

W/ L

14

G/B

X 07

(F) (R)

10A

R/G

13

S. W A R M

D/L

14

ME TE R

R.DEF

15

E N GINE

FI P

16

ST O P

17

HE AT ER

TA IL

18

CIGA R

ROOM

19

WI PE R

20

10

21

R.F O G

11

22

P. W IN D

21

15
W

30A

R/L 22

X 08 F

(F) (E)

R/Y

(F )
L/W

R/L

R /W

W/G

B/ R

(G/R)

<G>

B /L

(F)

B/ W

B /W

(E )

B/ W

B/ W

(R )
W

not used

R/L

G/B

< >...Double

G/W

R/B

<R>

X 10

<R /G >

(F )

<L G /B >

L/W

B/ Y

W/ B

BR/ Y Y/ R
L

(F) (E)

X 14

BR /W

G/B

(F) (DR1)

G/Y

(F )

BR/ R G/Y

B/ R

BR /B

K
B

G/Y

L/W

G/O

G/R

(B )

<G /Y >

(F )
W/ R

R/W

G/W

K
<G Y /R >

(E )

L/W
B/ R

> ...4X 4

W/ B

B/ Y

Y/ R

BR/ Y

G/B

<R /G >

(DR1 )
G/Y

<L G /B >

(E )
BR /B

<

> ...

BR /W

<B>

<L/ W >
<W >

G/Y
G/R

G/O

(G /W ) (R/ W ) <W /R >

with fuel heater (Diesel)

W/ R
R

W/ R

B /L

R/W

(E )

<G Y /R >

L/W

B/ L
R/ W

(F )

cabin

(F) (E)

(F) (E)

R/L

BR/ B

R/Y
G/W

06

(R )

<

R/Y

16

R/L
BR

( )...

12

HAZ A RD

Note: This is the connector as seen from the terminal side.

(F )

X 09

15A

A/ C

with fuel heater (Diesel)

> ...

X 04

BR /Y

( )... with power windows


< > ... Double cabin with power windows

Wiring Diagram

02

Connectors (WL3, WLT3, as of model year 2002)


X 19

(R) (R2)

G/B

(F) (FR)

(G/R)

R
(F )

B/ R

W/ G

R/B

R/W

R/W

R /B

G/B

G/W

R/Y

BR /B

R/L

(R2)

G/W

W /G B/ R

<R>

(F R )
(B R/ B )

)...

not used

( )...

with heated seats

R/Y

<G >

Wiring Diagram

R/L
(R )

X 1 8

Z142

Parts index
4x4 Mode switch . . . . . . . . . Z59, 65, 101, 103
A/C Compressor clutch . . . . . . . . Z95, 97, 99
A/C pressure switch . . . . . . . . . . . Z95, 97, 99
A/C Relay . . . . . . . . . . . . . . . . . . . . Z95, 97, 99
A/C switch . . . . . . . . . . . . . . . . . . . . Z95, 97, 99
Accelerator pedal position sensor . . . . . . Z51
Air bag module . . . . . . . . . . . . . . . . . . . . . . Z129
Audio illumination . . . . . . . . . . . . . . . . . . . Z105
Audio unit . . . . . . . . . . . . . . . . . . . . . . . . . . Z111
Blower assembly . . . . . . . . . . . . . . Z95, 97, 99
Blower motor . . . . . . . . . . . . . . . . . Z95, 97, 99
Boost pressure sensor . . . . . . . . . . . . . . . . Z51
Brake fluid sensor . . . . . . . . . . . . . Z59, 65, 71
Camshaft position sensor . . . . . . . . . . Z35, 41
Canister purge solenoid valve . . . . . . . Z37, 43
Capacitor . . . . . . . . . . . . . . . . . . . . . . . . Z35, 41
Central door locking . . . . . . . . . . . . . . . . . Z117
Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . Z107
Clock spring . . . . . . . . . . . . . . . . . . . . . . . . Z129
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z107
Clutch switch . . . . . . . . . . . . . . . . . Z39, 45, 49
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z131, 133
Coolant temperature sensor . . . . Z57, 63, 69
Data Link Connector (DLC) . . . . . . . Z135, 137
Daytime Running Lamps
(DRL) relay . . . . . . . . . . . . . . . . . . . . . . . Z79, 83
Diesel pump unit . . . . . . . . . . . . . Z27, 31, 131
Direction indicator lamp, LH front . . . . Z87, 91
Direction indicator lamp, LH rear . . . . . . . Z91
Direction indicator lamp, RH front . . . Z87, 91
Direction indicator lamp, RH rear . . . . . . . Z91
Direction indicator switch . . . . . . . . . . . Z87, 91
Door lock motor, LH side rear . . . . . . . . . Z117
Door lock motor, RH side rear . . . . . . . . . Z117
Door lock timing unit . . . . . . . . . . . . . . . . . Z117
Driver air bag unit . . . . . . . . . . . . . . . Z127, 129
EGR valve position sensor . . . . . . . . . . . . Z51
Electronic flasher module . . . . . . . . . . . . . . Z87
Engine Coolant Temperature
(ECT) sensor . . . . . . . . . . . Z27, 31, 37, 43, 51
Exhaust gas recirculation
(EGR) solenoid valve (vacuum) . . . . . . . . Z49
Exhaust gas recirculation
(EGR) solenoid valve (vent) . . . . . . . . . . . Z49
Exhaust Gas Recirculation
(EGR) valve . . . . . . . . . . . . . . . . . . . . . . . . . Z33
FICD solenoid valve 1 . . . . . . . . . . . . . Z27, 31
FICD solenoid valve 2 . . . . . . . . . . . . . Z27, 31
Flasher unit . . . . . . . . . . . . . . . . . . . . . . . . . . Z91
Free solenoid . . . . . . . . . . . . . . . . . . . Z101, 103
Fuel gauge sensor . . . . . . . . . . . . . . . . . . . Z55
Fuel heater . . . . . . . . . . . . . . . . . . . . . . . Z47, 55
Fuel injectors . . . . . . . . . . . . . . . . . . . . . Z35, 41
Fuel pressure solenoid valve . . . . . . . . Z37, 43
Fuel pump/fuel gauge sender . . . . . . . . . . Z47

Z143

Fuel pump relay . . . . . . . . . . . . . . . . . . . . . . Z47


Fuel pump . . . . . . . . . . . . . . . . . . . . Z49, 51, 53
Generator . . . . . . . . . . . . . . . . . . . . Z21, 23, 25
Glow plug relay . . . . . . . . . . . . . . . Z27, 31, 49
Glow plugs . . . . . . . . . . . . . . . . . . . Z27, 31, 49
Hazard flasher switch illumination . . . . . Z105
Hazard flasher switch . . . . . . . . . . . . . . Z87, 91
Headlamp, LH side . . . . . . . . . . . . . . . . Z79, 83
Headlamp, RH side . . . . . . . . . . . . . . . . Z79, 83
Headlamp levelling motor LH . . . . . . . Z79, 83
Headlamp levelling motor RH . . . . . . . Z79, 83
Headlamp levelling switch . . . . . . . . . . Z79, 83
Headlamp relay . . . . . . . . . . . . . . . . . . . Z79, 83
Headlamp switch . . . . . . . . . . . . . . Z77, 79, 83
Heated oxygen sensor (HO2S),
front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z37, 43
Heated seat element, driver side front . . Z123
Heated seat element, passenger
side front . . . . . . . . . . . . . . . . . . . . . . . . . . . Z123
Heated seat switch . . . . . . . . . . . . . . Z121, 123
Heater and A/C control assembly
illumination . . . . . . . . . . . . . . . . . . . . . . . . . Z105
Heater control module . . . . . . . . . Z95, 97, 99
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z121
Horn LH . . . . . . . . . . . . . . . . . . . . . . . . . . Z89, 93
Horn relay . . . . . . . . . . . . . . . . . . . . . . . . Z89, 93
Horn RH . . . . . . . . . . . . . . . . . . . . . . . . . Z89, 93
Horn switch . . . . . . . . . . . . . . . . . . . . . . . Z89, 93
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z89
Idle air control valve (IAC) . . . . . . . . . . Z35, 41
Idle switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Z49
Ignition coil . . . . . . . . . . . . . . . . . . . . . . . Z35, 41
Ignition module . . . . . . . . . . . . . . . . . . . Z35, 41
Immobiliser module . . . . . . . . . . . . . . Z131, 133
Instrument cluster . . . . . . . . . . . . . Z57 Z73
Instrument illumination potentiometer . . Z105
Intake air control valve . . . . . . . . . . . . . . . . Z49
Intake air temperature sensor . . . . . . . Z37, 43
Intake air temperature sensor 2 . . . . . . . . Z51
Interior lamp . . . . . . . . . . . . . . . . . . . . . . . . Z109
Key warning switch . . . . . . . . . . . . . . . . . . . Z69
LH Front door entry switch . . . . . . . . . . . . Z109
LH Front window motor . . . . . . . . . . Z113, 115
LH Licence plate lamp . . . . . . . . . . . . . Z81, 83
LH parking lamp . . . . . . . . . . . . . . . . . . Z81, 83
LH Rear direction indicator lamp . . . . . . . Z87
LH Rear door entry switch . . . . . . . . . . . . Z109
LH Rear window motor . . . . . . . . . . . . . . . Z115
Lock solenoid . . . . . . . . . . . . . . . . . . . Z101, 103
Main relay . . . . . . . . . . . . . . . . . . . . . . . . Z35, 41
Mass Air Flow (MAF) sensor / Intake
air temperature sensor . . . . . . . . . . . . . . . . Z53
Mass Air Flow (MAF) sensor . . . . . . . . Z37, 43
NE sensor . . . . . . . . . . . . . . . . . . . . . . . . Z27, 31

Parts index
Neutral position switch . Z39, 45, 49, 101, 103
Oil pressure switch . . . . . . . . . . . . Z59, 65, 71
Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z107
Park brake switch . . . . . . . . . . . . . Z59, 65, 71
Passenger air bag unit . . . . . . . . . . . . . . . Z129
PCM module relay . . . . . . . . . . . . . . . . . . . . Z49
Power mirror, LH side . . . . . . . . . . . . . . . . Z119
Power mirror, RH side . . . . . . . . . . . . . . . Z119
Power mirror switch . . . . . . . . . . . . . . . . . Z119
Power steering pressure switch . . . . . Z37, 43
Powertrain control module (PCM) Z27 Z53
Power window main switch . . . . . . . Z113, 115
Power window switch, LH side rear . . . . Z115
Power window switch, RH side
front . . . . . . . . . . . . . . . . . . . . . . . . . . . Z113, 115
Power window switch, RH side rear . . . . Z115
Rear fog lamp relay . . . . . . . . . . . . . . . . Z81, 85
Rear fog lamp switch . . . . . . . . . . . . . . Z81, 85
Rear fog lamp . . . . . . . . . . . . . . . . . . . . Z81, 85
Rear window heater grid . . . . . . . . . . . . . Z107
Rear window heater relay . . . . . . . . . . . . Z107
Rear window heater switch . . . . . . . . . . . Z107
Remote freewheel control module . Z101, 103
Remote freewheel main switch . . . . Z101, 103
Remote freewheel switch . . . . . . . . . Z101, 103
Resistor . . . . . . . . . . . . . . . . . . . . . . Z95, 97, 99
Reversing lamp, left / Stop lamp LH . Z89, 93
Reversing lamp, right /
Stop lamp RH . . . . . . . . . . . . . . . . . . . . . Z89, 93
Reversing lamps switch . . . . . . . . . . . . Z89, 93
RH Front door entry switch . . . . . . . . . . . Z109
RH Front door lock motor . . . . . . . . . . . . . Z117
RH Front window motor . . . . . . . . . . Z113, 115
RH Licence plate lamp . . . . . . . . . . . . . Z81, 83
RH parking lamp . . . . . . . . . . . . . . . . . . Z81, 83
RH Rear direction indicator lamp . . . . . . . Z87
RH Rear door entry switch . . . . . . . . . . . . Z109
RH Rear window motor . . . . . . . . . . . . . . Z115
Sedimentor switch . . . . . . . . . . . . . . . . . Z57, 69
Short cord . . . . . . . . . . . . . . . . . . . . . . . . . . Z109
Shorting bar connector . . . . . . . . Z89, 93, 129
Side direction indicator lamp, LH side . . . Z87
Side direction indicator lamp, LH . . . . . . . Z91
Side direction indicator lamp, RH side . . . Z87
Side direction indicator lamp, RH . . . . . . . Z91
Speaker, left . . . . . . . . . . . . . . . . . . . . . . . . Z111
Speaker, right . . . . . . . . . . . . . . . . . . . . . . . Z111
Speedometer sensor . . . . . . . . . . Z57, 63, 69
Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . Z25
Starter . . . . . . . . . . . . . . . . . . . . . . . Z21, 23, 25
Stop lamp switch . . . . . . . . . . . . . . . . . . . . . Z93
Tail lamp, LH side . . . . . . . . . . . . . . . . . Z81, 85
Tail lamp, RH side . . . . . . . . . . . . . . . . . Z81, 85
TDC sensor . . . . . . . . . . . . . . . . . . . . . . . . . Z53

Z144

Thermo switch . . . . . . . . . . . . . . . . Z95, 97, 99


Throttle Position Sensor (TPS) . . . . . . Z37, 43
Throttle position switch . . . . . . . . . . . . . Z37, 43
Vacuum warning switch . . . . . . . . . . . . . . . Z59
Windshield washer pump motor . . . . . . . . Z75
Windshield wiper motor . . . . . . . . . . . . . . . Z75
Wiper/washer switch . . . . . . . . . . . . . . . . . . Z75

SECTION TITLE

RANGER
2003
lefthanddrive
(LHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.

SECTION

General Information

GI

Ground points

Schematic

System circuit diagrams /


Component Location Views

A~U

Connectors

Parts index

PI

As all information in this manual was the best


available at the time of printing, vehicle
specification an other information will be updated
in Service Information.
Ford Motor Company

E 2002 Ford Motor Company


All rights reserved. Reproduction by any means,
electronic or mechanical including photocopying,
recording or by any information storage and retrieval
system or translation in whole or part is not permitted
without written authorisation from Ford Motor Company.

Note:
Euro 3 regulation models (WL3, WLT3 engines) are equipped with an EGR cooler in
the engine compartment and with a timer control valve (TCV) on the fuel injection pump
(FIP).
Euro 2 regulation models (WL, WL Turbo engines) are not equipped with an EGR cooler
in the engine compartment, but with a timer control valve (TCV) on the fuel injection
pump (FIP).
Euro 1 regulation models (WL, WL Turbo engines) are neither equipped with an EGR
cooler in the engine compartment nor with a timer control valve (TCV) on the fuel injection pump (FIP).

EGR cooler

TCV

FIP

Wire colours
Colour

Code

Colour

Code

Black

Orange

Blue

Pink

Brown

BR

Purple

Dark blue

DL

Red

Dark green

DG

Sky blue

Green

PU
R
SB

Tan

Grey

GY

Violet

Light blue

LB

White

Light green

LG

Yellow

Natural

TOCB3UK

TOCB3UK

Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . 2
Ground points . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine
Charging System . . . . . . . . . . . . . . . . . . . . . . .
Starting System . . . . . . . . . . . . . . . . . . . . . . . .
Engine control
Euro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preglow system
Euro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel heater . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18
18
20
24
28
20
24
28
34

Chassis
Remote freewheel control system . . . . . . . . 60
AntiLock Control 4Wheel . . . . . . . . . . . . 82
Instrument cluster
Instrument cluster . . . . . . . . . . . . . . . . . . . . . . 36
Body
Front wiper/washer . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear defrost . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote keyless entry . . . . . . . . . . . . . . . . . . .
Power windows . . . . . . . . . . . . . . . . . . . . . . . .
Central door locking . . . . . . . . . . . . . . . . . . . .
Power mirrors . . . . . . . . . . . . . . . . . . . . . . . . .
Heated seats . . . . . . . . . . . . . . . . . . . . . . . . . .
Air bags Service warnings . . . . . . . . . . . . .
Air bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Immobiliser system . . . . . . . . . . . . . . . . . . . . .

42
56
62
68
74
76
80
84
86
88
90

Interior Lighting
Instrument illumination . . . . . . . . . . . . . . . . . . 64
Interior lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Exterior Lighting
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daytime Running Lamps . . . . . . . . . . . . . . . .
Licence plate lamps . . . . . . . . . . . . . . . . . . . .
Parking Lamps . . . . . . . . . . . . . . . . . . . . . . . . .
Tail lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamp levelling . . . . . . . . . . . . . . . . . . . . .
Rear fog lamps . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Lamps . . . . . . . . . .
Reversing lamps . . . . . . . . . . . . . . . . . . . . . . .
Stop Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . .

44
44
46
46
46
48
50
52
54
56

Air conditioning
Heating / Air conditioning . . . . . . . . . . . . . . . . 58

Accessory
Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Audio Systems
with audio harness . . . . . . . . . . . . . . . . . . .
without audio harness . . . . . . . . . . . . . . . .

62
64
70
72

Other
Data Link Connector (DLC)
Euro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Euro 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Parts index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

GI

Wiring Diagrams

Contents of wiring diagrams


D This document comprises the 6 groups shown below.

GI

General Information

A how-to on using and reading wiring diagrams, using


test equipment, checking harnesses and connectors,
and finding trouble spots

Ground points

Ground routes from and to the battery

Schematic

Shows main fuses and other fuses for each system

A~U

System circuit diagrams /


Component Location Views

Shows circuit and connector diagrams and


component and connector location diagrams

Connectors

Shows connectors common throughout system

PI

Parts index

Gives page number of circuit diagram for each


component

GI

Reading Wiring Diagrams


Ground points
D This shows ground points of the harness.
GROUND POINTS (4SD)
3

JC01 JOINT CONNECTOR


D
B
C
A
E
B
B
B
B
B
B

8
B

10

12

B /O

B
6

B /W

JC02 JOINT CONNECTOR


D
B
C
A
E
B
B
B
B
B
B
B
B
C

JC03 JOINT CONNECTOR


D
B
C
A
E
B
B
B
B
B
B
D
C
E
B
A
WITHOUT
AIRBAG
T A I RSYSTEM
IT H O U
BAG
D
B
C
A
E
B
B
B
B
B
B
B

D
C
E
B
A
WITH AIRBAG SYSTEM

WITH ABS
B (E M )

B (D )

B (E M )

B (E M )

B (F )

B (E M )

B (F )

TO EACH
UNIT

B (E M )

TO EACH
UNIT

B (D )

EMISSION
HARNESS
(EM)

J C 02

11

B (D )
B (D )
B (D )

B /W ( E M )

DASH
HARNESS
(D)

B (D )
WITH AIRBAG SYSTEM

TO EACH
UNIT

FRONT
HARNESS
(F)

B
(F )

10

B (D )

B (F )
B (F )

B (D )
J C 03
B (D )

B (E M )

J C 01
B (F )

B (D )

B / O (D )
3
WITHOUT AIRBAG SYSTEM

B (F )
B (F )
B (F )

B ( I)

B ( I)

B (F )

INSTRUMENT
PANEL
HARNESS
(I)

B (F )
B ( I)

B (F )

B (IN )

INTERIOR
LIGHT
HARNESS
(IN)

12

SHORT
CORD

B (F )

Ground indication
On vehicle

Indication

On system circuit diagrams and ground points


The ground connection numbers in system circuit diagrams
correspond to those in the ground point diagram.
To circuit

ENGINE CONTROL SYSTEM


BATTERY

IG

MAIN
100 A

F B 0 9

K E Y

X 01

F B 07

60 A

B (E )

B /W (D )

B /W ( F )
B

F B 0 5

A
B T N
40 A

IN J OR
FIP
30 A

B (F )

B (D )
J B 0 5

G
W /R ( F )

J B 0 3

W /R ( D )
R OO

1 B

10 A

X 03

8
F B 0 3

F B 0 3

Y /L (F )

X 0 6

F B 0 4

F B 0 3

L G /R
(E M )

X 09

Y
L /R ( E )

J B 0 4

L /R (E M )

SPV RELAY
(SECTION B_1b)

W /Y
(E M )

I G1I G2

A C C

X 0 3
L (D )

A A

X 0 6

O F F

S T

E N G IN E
10 A
14 J B 01

B / L (D )

MAIN
RELAY

F B 0 4

ENGINE SWITCH

L /R
(D )

F B 0 4

W /G (E M )

B /L
(E M )

L /R
(E M )

B 1 0 1

B /W
(F )

1 E

3 W

B 1 0 3

1 B

1 A

B 1 0 2

1 F

P C M
2 M

GLOW
PLUG
RELAY

3 R

3 P

L G

B R /B
( E M )

1 S

1 N

1 Q

B 1 0 1
L

B 1 02

(E M )

L
(E )

F B 0 1

F B 0 3

(E M )

L (E )
I
L

L /B
( E M )

G /B
(E M )

G /W
(E M )

B
(E )

(E )
J

B 1 0 5

X 0 9

1 1
23

22

14

A/C RELAY
(SECTION G2)

B
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)

DATA LINK CONNECTOR (DLC)

B
(E M )

B 1 0 4

(SECTION U)

31
AD FAN RELAY
(SECTION G2)

GLOW
PLUG

G
G

B 1 01

P C M (E M )

1 U
1 S
Y
W /G
1 V

B 1 0 3

G L O W

P L U G

B /W

1 O

1 M

1 K

P /L

L /W

L /R

1 I

1 G

1 Q

W /R L /B
W /L

V /W

1 T

1 R

R E L A Y

1 C

1 A

2 O

R /Y

L /R

G /R

B /L

W /Y

1 F

1 D

1 B

2 P

1 E
L G /R

G /W
1 P

1 N

1L

1 J

1 0 4 G L O W P L U G
(S H O R T C O RD )

1 H

2 K

2 I

2 G

2 E

2 A

2 M

B 1 05

L /W
2 N

2L

E N G I N E ( E ) S H O R T
(E )

3 Y

2 C
L G / BB R / W R / L

2 J

R /Y

B R /Y L / Y
2 H

2 F

C O R D )

B /W

3 Q

3 Z

3 X

3 O

3 M

3 K

3 G
R /B
L G

3 V

3 T

3 A

3 I

3 S

L /R
R /L

O
2 B

2 D

C O RD
(S H O R T

3 U
3 W

G Y /RP /B

3 R

V
B R / BY / B
3 P

3 N

3 E

3 C
G /Y

G /R

3L

3 J

3 H

3 F

B /O
3 D

3 B

B 1 0 2
(E)

G L O W

P L U G

R E L A Y

L /R
L
B

GI

Reading Wiring Diagrams

System circuit diagram/connector diagram


D These diagrams show the circuits for each system, from the power supply to the ground. The power supply side is on the
upper part of the page, the ground side on the lower part. The diagrams describe circuits with the ignition switch off.
Below is an explanation of the various points in the diagram.
ENGINE CONTROL SYSTEM
B A TT E R Y
+
F B 0 9

B (E )
A

System name

M A IN
100A

IG KE Y
60A

X 0 1

F B 0 7 D
B /W ( F )

F B 0 5
B (F )

IN J O R
F IP
30A

F B 0 3
GLOW
40A

F B 0 3
W /G ( E M )

F B 0 4
Y /L (F )
S
F B 0 4
M A IN R E L A Y
F B 0 3

G
D

F B 0 4

L /R ( E )

L /R ( E M )
B 1 0 1

1E

3W

B 1 0 3

B 1 0 2
2M

GLOW
PLUG
RELA Y

3R

B 1 0 1
L
(E M )

B 1 0 2
F B 0 1 F B 0 3

B
(E )

LG
(E M )

L (E )
I

L
(E )

B 1 0 5

X 0 9

L G /R
(E M )

X 0 9

B /W
(F )

23

B
B
(E M )

D A T A L IN K
( S E C T IO N U

B 1 0 4
GLOW
PL UG

B 1 0 1 P C M ( E M ) 1 U

Connector code

1O
1S

1V
B103

Y : Ground connector
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air conditioning system connectors
H : Transmission control system connectors
I : Interior light system connectors
J : Audio/radio system connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
N : Power steering/4-wheel steering system
connectors
O : Anti-lock brake system connectors
P : Power seat/seat heater system connectors
Q : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
U : Data link connector
X : Common connectors
JB: Joint box connections

1K

1T

GLOW PLUG RELAY (F)

1I

1C

1G

1A

W /Y

1P

1N

B /L
1L

1J

1H

B 1 0 4 G L O W P L U G
( S H O R T C O RD )
B

B /W

1F

2I

G / Y W /Y
1D

1B

G /R

L G /BB R /WR /L
L /W

R
2P

2N

2L

2J

A harness ground is represented differently than


a unit ground.
Symbol

Harness

9
Unit

Sensor

B
2H

B 1 0 5 E N G IN E ( E )S H O R T C O RD
(E )
(S

Ground numbers

Types of grounds

2G

2M

L G /R R / Y R /W

G /W

1R

2K

2O

1E

W /G W /L V / W

The prefix letter indicates the system in which


the connector is used.

1M

1Q

W /R L /B P /L L /W L /R

GI

Reading Wiring Diagrams


The number indicates that the circuit
continues to the related system circuit
diagram.

System code

B-1A

Current symbol
DATA LINK
CONNECTOR (DLC)
(SECTION U)

B /W (D )

Current flows in the direction of the arrow.

B (D )
1B
ENGINE SWITCH

17

18

G /Y
(E M )

W /Y
(E M )

R /W
(E M )

O FF

ST

A CC

IG 1 IG 2

E N G IN E
J B 0 4 1 0 A 1 4 J B 0 1

X 0 6

16
X 0 3

X 0 3
L (D )

B /L (D )
AA

Indicates shielded wire.*

B /L
(E M )
B 1 0 1
1F

1D

1I

1A

* Shielded wire:
Prevents signal disturbances from
electrical interference. Wire is
covered by a metal meshing for
grounding.

PCM
2C

2A

1S

2B

2E

R /Y
(E M )

SHIELD WIRE

B 1 0 7
W /R
(E M )
P /B G Y /R O
(E M ) (E M ) (E M )

INTAKE AIR
TEMPERATURE
SENSOR NO.1
1
B 1 0 7
O
(E M )

B
(E M )

14
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)

B 1 0 6

Connector symbols
BOOST SENSOR

D Male and female connectors are represented as follows in


the system circuit and connector diagrams.

3Y

3Q

3U
3W

3K

3I

L G B R /BY / B G /R
3V

3T

3A
3G

R /B

R /L
3X

3M

3S

B / W L /R

3Z

3O

3R

3P

3N

B106 BOOST SENSOR (EM)

3L

3E

B102 GLOW PLUG RELAY (E)

3C

G /Y

3J

3H

3F

Circuit
diagram symbol

L /R
L

B /O
3D

Connector
diagram symbol

3B

B107 INTAKE AIR TEMPERATURE


SENSOR NO.1 (EM)

P / B G Y /R O

R /Y

Male
Male

Female
Female

L
R

Wire color code (harness symbol)


D Like connectors are linked by dashed lines between the
connector symbols.

D Two-colour wires are indicated by a two-letter symbol.


The first indicates the base colour of the wire, the
second the colour of the stripe. For example:

D Connector diagrams show connectors on the harness


side. The terminal indicates the view from the harness
side.

W/R is a white wire with a red strip


BR/Y is a brown wire with a yellow strip

(Example)
Connector on harness side

Symbol
(Example)
Solid colour wire

B
(F)

Black

Striped wire

W/R
(F)

White
(base
colour)

View from
harness side

Red
(stripe)
D Colours for connectors except milk-white are given in
locations.
D The harness symbol is in ( ) following the harness
symbols (refer to P-7).

D Unused terminals are indicated by :.

GI

Reading Wiring Diagrams

Routing diagram
D The routing diagram shows where electrical components are on the system circuit diagram by call out line and connector
symbols.

Connector symbol

Component name

Ground symbol

Shows the system that uses the


connector.

Shows the names of


components in routing diagrams.

Shows the ground in system


circuit diagrams.

(Example)
Connector

Symbol

Common connectors

X-9

System connectors

I-03

HARNESS SYMBOL

(F)

(E)

(R)

INSTRUMENT
CLUSTER

VACUUM
SWITCH

C-01

C-05
(F)-(I)

X-02

(F)-(I)

X-02

C-06
PARKING BRAKE SWITCH

GI

Reading Wiring Diagrams


Harness symbols
DESCRIPTION OF HARNESS

SYMBOL

DESCRIPTION OF HARNESS

SYMBOL

FRONT HARNESS

(F)

DOOR NO.1 HARNESS

(DR1)

FRONT NO.2 HARNESS

(F2)

DOOR NO.2 HARNESS

(DR2)

ENGINE HARNESS

(E)

DOOR NO.3 HARNESS

(DR3)

DASH HARNESS

(D)

DOOR NO.4 HARNESS

(DR4)

REAR HARNESS

(R)

FLOOR HARNESS

(FR)

REAR NO.2 HARNESS

(R2)

INTERIOR LIGHT HARNESS

(IN)

REAR NO.3 HARNESS

(R3)

A/C HARNESS

(AC)

INJECTION HARNESS

(INJ)

INSTRUMENT PANEL HARNESS

(I)

EMISSION HARNESS

(EM)

EMISSION NO.2 HARNESS

(EM2)

EMISSION NO.3 HARNESS

(EM3)

GI

Reading Wiring Diagrams

Symbols
Symbol

Meaning

Symbol

D Generates electricity through chemical


reaction.

Battery

D Emits light and generates heat when


current flows through filament.

Light

D Supplies direct current to circuits.

Ground (1)

Meaning

3.4 W

Resistance

D Connecting point to vehicle body or other


ground wire where current flows from
positive to negative terminal of battery.

D A resistor with constant value.


D Mainly used to protect electrical
components in circuits by maintaining
rated voltage.

D Ground (1) indicates a ground point to


body through wire harness.

D Ground (2) indicates point where


component is grounded directly to body.
Ground (2)

Motor

D Converts electrical energy into mechanical


energy.

Pump

D Pulls in and discharges gases and liquids.

Remarks
D Current will not flow through a circuit if
ground is faulty.

D Melts when current flow exceeds that


specified for circuit, interrupts current flow.

Fuse (1)

Precautions

Cigarette lighter

D Do not replace with fuses exceeding


specified capacity.

(Box)

D Electrical coil that generates heat.

Fuse (2)
<Blade type>

<Tube type>
D Generates sound when current flows.

Horn
(Cartridge)
Main fuse/
Fusible link

<Cartridge type>

<Fusible link>
Speaker

Transistor (1)
Collector (C)
Base (B)

D Electrical switching component.


D Turns on when voltage is applied to the
base (B).
Collector
indication
mark

NPN

Emitter (E)

C
B

Transistor (2)
Collector (C)

EC B
C

PNP

Emitter (E)

Speed sensor

D Movement of magnet in speedometer turns


contact within sensor on and off.

Ignition switch

D Turning ignition key switches circuit to


operate various components.

E
B

D Reading code.
2 S C 828 A

Base (B)

D Generates heat when current flows.

Heater

Semiconductor
Number of
terminals

Revision mark
A: High-frequency PNP
B: Low-frequency PNP
C: High-frequency NPN
D: Low-frequency NPN

B 1

B 2
S T

IG 2

O FF
IG 1

O FF
A C C

GI

Reading Wiring Diagrams


Symbol
Switch (1)

Meaning

Symbol

D Allows or breaks current flow by opening


and closing circuits.

Meaning

Harness
Connection
D
B

When circuit C-D is


connected to circuit
A-B, the connection
D is indicated by a
black dot.

Normally open (NO)

For vehicles with ABS, use the A-B circuit.

Selection

WITH ABS

Switch (2)
A

Diversion point D
for the different
circuits according to
the vehicles
specification is
indicated by a white
dot.

Normally closed (NC)

Relay (1)

D
B

WITHOUT ABS
C

For vehicles without ABS, use the C-B


circuit.

D Current flowing through coil produces electromagnetic force causing contact to open or close.
No current to coil

Current to coil

No Flow

Flow

Normally open (NO)


Relay (2)

D Current flowing through coil produces electromagnetic force causing contact to close.
No current to coil

Current to coil
Flow

No Flow

Normally closed (NC)


Sensor (variable)

D Resistance changes with other


components operation.

Diode

D Known as a semiconductor rectifier, the


diode allows current to flow in one
direction only.
Cathode (K)
K

Sensor (thermistor)

Capacitor

D Resistance changes with temperature.

Light-emitting diode
(LED)

D A diode that lights when current flows.


D Unlike ordinary bulbs, the diode does not
generate heat when lit.

Cathode (K)

D Component that temporarily stores


electrical charge.

Anode (A)
Flow of direct current
A K
A

Anode (A)
Cathode (K)
Anode (A)
Flow of current

Solenoid

Reference diode
(Zener diode)

D Current flowing through coil generates


electromagnetic force to operate plungers.

D Allows current to flow in one direction up


to a certain voltage; allows current to flow
in the other direction once that voltage is
exceeded.

GI

Reading Wiring Diagrams


Symbol

Meaning
D The wiring position can be exchanged freely within the
connector.

Extent of the change in the wiring position (1)

D The wiring position can be exchanged according to the following


combinations only:
Between A and B, between C and D, between E and F.

Extent of the change in the wiring position (2)

D The wiring position can be exchanged according to the following


combinations only:
Between A, C and E, between B, D and F.

Extent of the change in the wiring position (3)

Abbreviations
3GR

Third Gear

CCT

Circuit

4GR

Fourth Gear

CIGAR

Cigarette

Ampere

CIS

Continuous Fuel Injection System

A/C

Air Conditioning

CKP

Crankshaft Position Sensor

A/F

Air Fuel

CLS

Closed Loop System

A/R

Auto Reverse

CMP

Camshaft Position Sensor

AAS

Auto Adjusting Suspension

COMBI

Combination

ABS

Anti-lock Braking System

CON

Conditioner

ACC

Accessories

CONT

Control

ACV

Air Control Valve

CPU

Central Processing Unit

ADD

Additional

CSD

Cold Start Device

AIR

Secondary Air Injection

CTP

Closed Throttle Position

AIS

Air Injection System

DEF

Defroster

ALL

Automatic Load Levelling

DI

Distributor Ignition

AM

Amplitude Modulation

DLC

Data Link Connector

AMP

Amplifier

DLI

Distributorless Ignition

ANT

Antenna

DOHC

Double-Overhead Camshaft

AP

Accelerator Pedal

DTC

Diagnostic Trouble Code(s)

AS

Autostop

DTM

Diagnostic Test Mode

ASV

Air Supply Valve

ECM

Engine Control Module

AT

Automatic Transmission

ECPS

Electronically Controlled Power Steering

ATX

Automatic Transaxle

ECT

Engine Control Temperature

B+

Battery Positive Voltage

EGR

Exhaust Gas Recirculation

BAC

Bypass Air Control

EI

Electronic Ignition

BARO

Barometric Pressure

ELEC

Electric

CAC

Charge Air Cooler

ELR

Emergency Locking Retractor

CARB

Carburetor

ETR

Electronic Tuner

10

Reading Wiring Diagrams


F

Front

OBD

On-board Diagnostic

F/I

Fuel Injector

OFF

Switch Off

FC

Fan Control

ON

Switch On

FICB

Fast-Idle Cam Breaker

Power

FM

Frequency Modulation

P/S

Power Steering

FP

Fuel Pump

P/W CU

Power Window Control Unit

FPR

Fuel Pump Relay

PAIR

Pulsed Secondary Air Injection

GEN

Generator

PCM

Powertrain Control Module

GND

Ground

PNP

Park/Neutral Position

H/D

Heater/Defroster

PRCV

Pressure Regulator Control Solenoid Valve

HEAT

Heater

PRG

Purge Solenoid Valve

HEI

High-Energy Ignition

PSP

Power Steering Pressure

HI

High

PTC

Positive Temperature Coefficient Heater

HO2S

Heated Oxygen Sensor

QSS

Quicik-Start System

IAC

Idle Air Control

Rear

IAT

Intake Air Temperature

REC

Recirculation

ICM

Ignition Control Module

RF

Right Front

IG

Ignition

RFW

Remote Freewheel

ILLUMI

Illumination

RH

Right Hand

INT

Intermittent

RPM

Engine Speed

JB

Joint Box

RR

Rear Right

KS

Knock Sensor

SAPV

Secondary Air Pulse Valve

LCD

Liquid Crystal Display

SFI

Sequential Multipoint Fuel Injection

LF

Left Front

SOL

Solenoid

LH

Left Hand

ST

Start

LO

Low

SW

Switch

LR

Left Rear

TC

Turbocharger

Motor

TCM

Transmission (Transaxle) Control Module

MAF

Mass Air Flow Sensor

TCV

Twin Scroll Turbocharger Solenoid Valve

MAP

Manifold Absolute Pressure

TEMP

Temperature

MFI

Multiport Fuel Injection

TICS

Triple Induction Control System

MID

Middle

TP

Throttle Position Sensor

MIL

Malfunction Indicator Lamp

TR

Transmission Range

MIN

Minute

TWS

Total Wiring System

MIX

Mixture

Volt

MPX

Multiplex

VAF

Volume Air Flow Sensor

MT

Manual Transmission

VENT

Ventilation

MTR

Mechanical Tuning Radio

VOL

Volume

MTX

Manual Transaxle

VR

Voltage regulator

NC

Normally Closed

VRIS

Variable Resonance Induction System

NO

Normally Open

VSS

Vehicle Speed Sensor

O2S

Oxygen Sensor

Watt(s)

WOT

Wide Open Throttle

11

GI

Y-a

Ground points
except
Euro 1

with air bag

without air bag

without
central
locking

B( F )

with central locking

B/ R

B
B
6

6
B

without air bag


B

3
B/ R
B/ R

B
B

B
B

with air bag


B/ R

Euro 1
B/ R

B (F )

Freestyle cabin / Stretch


cabin (with rear access)
Ground
(Section Yb)

12

B( F )

B( F )

4
B( F )
B( F )

with air bag


B( F )

with air bag

12

B( F )

to each
unit

Front harness
5

B( F )

Front harness

B( F )

B( F )

B( F )

to each unit

B( F )

B( F )

B( F )

with central locking

B( F )

B( F )

B( F )
B/ R (F )
B( F )
3

B/ R (F )

06

B( F R )

Freestyle cabin / Stretch


cabin (with rear access)

10
Ground
(Section Yb)
B/ R (F )

except Euro 1

11

(F )

(E)

(R)

Y-a

Harness symbol
3

6
5

[Euro 1, Euro 2]

X06
(F)-(FR)

13
2

[Euro 3]
3

X06
2

(F)-(FR)

Y-b

Ground points
B
7

B
B

10

11

12

13

B( F R )

10

B (D R 3)

11

Door harness 3

12

Door harness 4

13

Heated rear
screen ground

14

audio
ground

14

B( R 2 )

B( R 2 )

B( R 2 )

Ground
(Section Ya)

Rear harness 2
B( F R )

B( F R )

Floor harness

B( R 2 )

14

to each unit

B( F R )

to each
unit

B( F 2 )
9

27

Front harness 2

Ground
(Section
Ya)

B( F 2 )

04

B( F )

26

B( R )

B (D R 4 )

AntiLock Control
4Wheel
Freestyle cabin / Stretch
cabin (with rear access)

B( F R )

10

Floor harness

except Freestyle cabin /


Stretch cabin (with rear access)

audio ground

(F )

(E)

(R)

Y-b

Harness symbol
7

[Double cabin]

14

13

10

15

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

(R)-(DR4)
X2 6
12

04

(F)-(R)
8

X04
X27

(F)-(R)

13

(FR)-(DR3)
11

10

Schematic
current from battery

current from IG1 terminal of ignition switch


current from IG2 terminal of ignition switch

Battery
B

current from ACC terminal of ignition switch


Other

W/ R

L/ R

B T N 60A

M A IN 8 0 A

IG

KEY

1 40A

IG

KEY

2 40A

R O OM 10A

System

F IP / IN J 20A

Ignition
switch

B/ L

A /C 10A

B/ W

LG/R
OF F

ST

GLOW

HE A T E R 40 A

60A

System

IG 1

IG 2

AC C

B/ W
B/ R

HE A D 20A

W
R. DE F O G 20A

B/ Y
B/ W

TA IL 1 0A

Headlamp
switch

L/ R
R/ B
CIG A R 15A

Euro 3

Off

Euro 3

Headlamp
TNS
flasher

L/ R
B

2,

L/ W
R/ B

L/ R

Head

16

High beam
B4

Fuel heater

G /B

B/ Y

L/ R

Low
beam

Interior lamps

I 3

Remote keyless entry

I 4

Audio Systems

J1

J2

P/ W 1 5 A
G
P .W IND 30A

Power windows
K

R/ L

R/ W

M E T E R 15A

B/ Y

Front wiper/washer

I 2

L/ W

P T C 30A

Clock
Instrument illumination

L/ R

L/ R

Instrument cluster

I 1

S T OP 15A

Dimmer
switch

B/ W

Cigar lighter
Rear defrost

L/ W

Light switch

B/ Y

Engine control
Preglow system

B/Y

Y/ R

except
Euro 3

1,

Remote freewheel control


system

L/ W
W

B/ W

A / C2 10A

Charging System
Starting System

Heating / Air conditioning

R/ W
HE A D 3 0 A

OF F

B/ Y

Section

Section

WI P E R 15A

W/ G

Central door locking

D/ L 30A

R/ G

L/ W

Power mirrors

R
E

Daytime Running Lamps

L/ R
R/ W

AntiLock Control
4Wheel

A BS 6 0 A

Y
B/ W
R/ B

E N GI NE 15A
R/ Y

Headlamp levelling

BR /Y
R/ G

Heated seats

S .WA R M 15A
R .F OG 10A

Rear fog lamps

R /G

B/ Y

B/ W

Turn Signal and Hazard


Lamps

B/ Y

Reversing lamps

Air bags

L/ Y
HA Z A RD 10A

L/ R

Immobiliser system

B/ Y

T
B/ W

Stop Lamps
Horn

G/ W

B/ Y

Data Link Connector (DLC)

U1,
U2

This page is intentionally left blank.

17

Charging System / Starting System


Battery

01

01

03

03

R/ W

(E )

09

& .

(F )

Cold area
@ Euro 3
Euro 1, Euro 2, not cold area

(F )

HE A D 30A

HE A D 20A

M A IN 8 0 A

Cold area

B/ L
(F )
IG KE

Y1

4 0A

IG KE

Y2

4 0A

B /W (E)

R (E)

B/ W
A

(F )

B( E)

Euro 1
Powertrain control
module (PCM)
(Section B1b)

B( E )

B/ Y

B/ Y

B/ Y

B/Y

(F )

(F )

(F )

(F )

02

OF F

ST

IG 2

(F )

B/ Y

03

03
W

B/ W

(F )

(F )

(F )

(F )
E N GI NE 15A

03

except Euro 3

01

02

B/ Y
B/ Y

Starter

Ignition
switch

AC C

Euro 1
Powertrain control
module (PCM)
(Section B2b)

02

OF F

IG 1

Starter
relay

Regulator

Generator
A

18

(F )

W/ B (E )

Immobiliser module
(Section T)

(F )
01

B/ L
&B /Y

08

B/ Y
@B /L

B/ L
(F )

B/ L
(F )

(F )

(E )

02

03

B/ L
A

02

Powertrain control module (PCM)


(Section B3c)

09

W/ B
(F )

Euro 3
M
5

Instrument cluster
(Section Cb)

01

A 02

Starter (E)

B
B
B

A 03

Generator (E)

Starter relay (F)

B/L
&B /Y
R

B/ W

W/ B

B /W

B/ Y
B/ L

(F )

(E)

(R)

Harness symbol
[Grey]
(F)(E)
X08

[Grey]
(F)(E)
X09

Main fuse box


X01

19

A02
Generator
[Grey]

A01
Starter
A02
Generator

X03
Fuse block
X02
Ignition
switch
A03
Starter
relay

B-1a

Engine control / Preglow system (Euro 1)


Battery

01

01
B/ L

(F )

(E )
MA IN 80 A

IG KE

Y1

4 0A

IG KE

Y2

40A

B/W

B/ W

(F )

(F )

GLOW
60A

B/ W
(F )

OF F

OF F

ST

02

01
IG 2

IG 1

(F )
B1 0 6

B1 0 5

AC C

02

03

B1 0 9

FICD solenoid
valve 2

FICD solenoid
valve 1

03

B/ W
(F )

B/ W
B/ W (F )

Ignition
switch

Fuel shutoff
valve

B/ W

(F )

(F )

B1 0 6

B1 0 5

E N GI N E 15A
B/ W

(F )

(F )

(F )

B1 0 1

Powertrain control
module (PCM)
I

B
B1 0 1

R/ B

BR

BR /Y

(F )

(F )

(F )

(F )

W
(F )

B/ R (F )

B1 0 2
B/ R (F )

20

Glow plug
relay

B1 0 2

08

BR /Y

(E )

(E )

(F )

(E )

Engine Coolant
Temperature
(ECT) sensor

R( F )
B1 0 4
B
No. 4

No. 3

No. 2

No. 1

(F )

B/ R

B1 08

B1 0 7

(F )

B/ R (E )
B/ R

Glow plugs

B1 0 7

Pump speed sensor


B/ R
(E )

B101 Powertrain control module (PCM) (F)


I

B102 Glow plug relay (F)

B104 Glow plugs (F)

GY

W /L
R /B

R /W

B/ W

BR /Y

R/ B

B/ Y

B /R

B106 FICD solenoid valve 2 (F)

BR
R

B
BR

B105 FICD solenoid valve 1 (F)

B107 Engine Coolant Temperature


(ECT) sensor (E)

B/ R

BR /Y

B108 Pump speed sensor (E)

B/ R

B109 Fuel shutoff valve (F)

B/ W

B /W

B /W

B-1a

Harness symbol
Glow plug relay
B102

WL T u rbo

[Brown]
Glow plug relay
B102

[Grey]
(F)(E)

[Black]
Fuel shutoff valve
B109

FICD solenoid valve 2


B106

X08

Main fuse box

X01

B107
Engine Coolant
Temperature
(ECT) sensor
[Grey]

21

B108

B105

Pump speed sensor

FICD solenoid
valve 1

[Grey]

[Black]
B104
WL

B109

Glow plugs

Fuel shutoff
valve
[Black]
4

X03
Fuse block

X03
Ignition switch

B101
Powertrain control module
(PCM)

B-1b

Engine control / Preglow system (Euro 1)


Ignition switch (ST)
(Section A)

A/C Amplifier
(Section G)

A/C Relay
(Section G)

B/ Y

R/ W

R/B

(F )

(F )

(F )

B1 0 1

Powertrain control
module (PCM)

K
B1 0 1

GY

W/ L

(F )

(F )

22
7

Instrument cluster
(Section Cb)

B101 Powertrain control module (PCM) (F)


I

BR

GY

W /L

R /B

B /W

R/ W

BR /Y

B/ Y

B /R

Instrument cluster
(Section Ca)

B-1b

Harness symbol

23
B101
Powertrain control module
(PCM)

B-2a

Engine control / Preglow system (Euro 2)


Battery

01

01
B/ L

B
(E )

(F )
M A IN 8 0 A

IG

K EY

1 40A

IG

K EY

2 40A

B/ W
(F )

B/ W
(F )

GLOW
60A

B/ W
(F )

Ignition switch

OF F

OF F

ST
X

02
B/ W
(F )

B/W (F )

01
B2 0 6

B2 0 5
IG 2

IG 1

AC C

02

03

FICD solenoid
valve 1

03

FICD solenoid
valve 2

B/ W

(F )

(F )

B2 0 5

B2 0 6

E N GI NE 15A
B/ W

(F )

(F )

(F )

B2 0 1

Powertrain control module


(PCM)
O

BR /Y

(F )

(F )

(F )

BR /W

R/L

G/ W

L/ B

B/ W

(F )

(F )

(F )

(F )

(F )

B2 0 1
R/ B

BR

(F )

(F )

B/ R (F )

B2 0 2
B2 0 9

Glow plug
relay

B/ R (F )
X

08

24

B/ R

(E )

(E )

B2 0 8

B2 0 7
R( F )
B2 0 4

Fuel pump

Fuel
shutoff
valve

B2 0 9

Engine Coolant
Temperature
(ECT) sensor

Glow plugs

B
No.4

No.3

No.2

No.1

(F )

Position sensor

(E )

R
(F )

TCV

Idle
switch

B/ R (E )

BR /Y

B2 0 2

B/ R
(F )
B/ R
(F )

B2 0 7

Pump speed sensor

B/ R
(F )

B/R
(E )
4

B201 Powertrain control module (PCM) (F)


K

Q
BR /R

L /B

BR

B /Y

M
GY

W /L

R/ B

B /W

B202 Glow plug relay (F)


A

R /W

BR /Y

R/ L

G /W

B /Y

B /R

C
G

B206 FICD solenoid valve 2 (F)

BR
R

B205 FICD solenoid valve 1 (F)

B204 Glow plugs (F)

R /B

B /W

B
B R /W

B207 Engine Coolant Temperature (ECT) sensor (E)

B208 Pump speed sensor (E)

B209 Fuel pump (F)


C

C
B/ R

BR /Y

B/ R

R/L

B /R

G /W

B /W

BR /W

L/ B

B /R

W
F
F

B /W

B-2a

Harness symbol
Glow plug relay
B202
[Grey]
(F)(E)

[Grey]
Fuel pump
B202

X08
[Brown]
Glow plug relay
B202

Main fuse box

X01

B206
FICD solenoid valve 2

25

B208
Pump speed sensor
[Grey]

B207
Engine Coolant Temperature (ECT) sensor
[Grey]
B204
Glow plugs

B205
FICD solenoid valve 1
[Black]

X03
Fuse block

X02
Ignition switch

B201
Powertrain control
module (PCM)

B2-b

Engine control / Preglow system (Euro 2)


Ignition switch
(ST)
(Section A)

Data Link Connector (DLC)


(Section U2)

A/C Amplifier
(Section G)

A/C Relay
(Section G)

10

11

B/ Y

BR /R

B/ Y

R/W

R/ B

(F )

(F )

(F )

(F )

(F )

B2 0 1

Powertrain control module (PCM)


M

B2 0 1

W/ L
(F )
GY

(F )

(F )

26

W/ L
(F )

W/ L
(F )

12

B2 1 0
7

Instrument cluster
(Section Cb)

Instrument cluster
(Section Ca)

B/ R
(F )

Data Link Connector (DLC)


(Section U2)
Exhaust Gas Recirculation (EGR)
valve

B201 Powertrain control module (PCM) (F)


K

Q
BR /R

L /B

BR

GY

B210 Exhaust Gas Recirculation (EGR) valve (F)

G
W /L

B/ Y

R/ B

B /W

R /W

R /L

G /W

E
BR /Y

B/ R

C
G

B R /W

B /Y

B /R

B2-b

Harness symbol
[Green]
3

Exhaust Gas Recirculation (EGR)


valve
B210

27
B210
Powertrain control module
(PCM)

B-3a

Engine control / Preglow system (Euro 3)


Battery
X

01

01

W/ R

(E )

(F )
M A IN 8 0 A

03

03
B/ L
(F )

L/ R
(F )

BT N 60 A
X

B/ L
(F )

R OOM 10A

01
L/ W

B/ L

(F )

(F )

FI P / IN J 2 0A

IG
L/ W

L/ W

(F )

(F )

K EY

1 40A

B/ L

B/ L

B/ L

B/ L

B/ L

(F )

(F )

(F )

(F )

(F )

B/ W
(F )

IG

K EY

2 40A

02

B3 0 6

B3 0 2

PCM module
relay

OFF

OF F

ST

IG 2

IG 1

Exhaust gas
recirculation
(EGR) solenoid valve
(vacuum)

AC C

B3 0 6
X

B3 0 2

B3 0 8

B3 0 7

Intake air control valve

Ignition
switch

B3 0 7

B3 0 9

Exhaust gas
recirculation
(EGR) solenoid valve
(vent)

B3 0 8

Exhaust Gas
Recirculation
(EGR) valve
B3 0 9

02
X

03

03

W
B/ L (F )

B/ L(F )

(F )
B/ L

B/ L

B/ L

(F )

(F )

(F )

LG(F )

G/ O

Y/ G

LG/ R

W/ R

(F )

(F )

(F )

(F )

4Z

4T

4Q

4I

E N GI N E 15A

B/ L (F )

B/ L (F )

B/ L (F )

4C

4D

4X

B/ W (F )
B3 0 1

3B

41

4V

2K

Powertrain
control module (PCM)

2D

1C

1V

4A

4B

3O

1D

Fuel pump
(Section B-3c)

B3 0 1
G/ B

BR (F )

R/ B

(F )

(F )
GLOW

60A

B3 0 3

B/ R

B/ R

G/ W

(F )

(F )

(F )

28

P( F )

(E )

B3 1 3

Neutral
position
switch

(F )

L(F )

Shield

B3 1 1

B3 1 2

Clutch
switch

Idle switch
B3 0 3

G/ B

(F )
G/ B

B/ R (F )

Glow plug
relay

09

G/ B

28

B3 1 3
B/ R (E )

B( F )

R( F )

B3 1 1

B3 1 0

B3 1 2

B/ R (F )
No.1

No.2

No.3

No.4

Glow plugs

(F )

(F )

1U

B301
Powertrain control module
(PCM) (F)

1O
1S

B/L

L/Y

B/ W

BR /Y

1V

1T

1K

1I

1G

1A
1E

R/ L

GY /L

G/ R

GY /B

1R

1P

1N

1L

B302 PCM module relay (F)


C

1M

1Q

2K

2G

2E

BR /W

L/ W
2L

G /Y

P /B

G /B

BR /B

1J

1H

1F

1D

1B

R/Y

L/R

3O

2A

W /L
2J

B303 Glow plug relay (F)

2H

2F

P/L

3K

3I

3G

3E

3M

2C
BR /R

Y /R

2D

2B

B305 Glow plugs (F)

3L

3J

3H

3F

C
L /W

B/ L

LG

4U

LG/ B

L/ B

GY

B/ L

LG

G /O

B /L

BR

Y/ G

3D

3B

4Z

4X

4V

4T

B306 Intake air control valve (F)

4O

28

4M

4K

4A

4I

4S

L/ W

4Q
4W

R /W

3N

4Y

3A
3C

G/ W

3P

2I

1C

08

B/ R (F )

Fuel pump
4

B/ R (F )

B3 0 5

4G
LG/ R

B/ Y

W /R

4E

4C

G /B

B /L

B/ R

B/ L

B /R

4D

4B

R /B
4R

4P

4N

B307 Exhaust gas recirculation


(EGR) solenoid valve
(vacuum) (F)

4L

4J

B308

4H

4F

Exhaust gas recirculation


(EGR) solenoid valve
(vent) (F)

BR
R

R/B

G/ O

B /L

B
Y/ G

B309 Exhaust Gas Recirculation


(EGR) valve (F)
W/ R

B/ L

B310 Fuel pump (F)

B311 Idle switch (F)

G/W

B312 Clutch switch (F)

G/B

B313 Neutral position switch (E)

G/ B

B /R

B /L

LG/ R

B/ L

B-3a

Harness symbol
[Grey]
(F)(E)

X08
[Grey]
(F)(E)

Glow plug relay


B303
[Grey]
Fuel pump
B310

X09
Main fuse box

X01

[Brown]
Glow plug relay

[Black]
Exhaust gas recirculation
(EGR) solenoid valve (vent)
B308
Neutral position switch
B313

B303

B307
Exhaust gas recirculation (EGR) solenoid
valve (vacuum)
[Black]

29

Clutch switch
B312

B305
Glow plugs

B309
Exhaust Gas
Recirculation
(EGR) valve

B306
Intake air control
valve

Joint connector

X28

X03
4

Fuse block

X02
Ignition switch

B302
PCM module
relay

B311
Idle switch

B301
Powertrain control module
(PCM)

B-3b

Engine control / Preglow system (Euro 3)

Instrument cluster
(Section Ca)

Data Link Connector (DLC)


(Section U2)

12

W/ L

W/ L

(F )

(F )

Immobiliser module
(Section T)

10

11

13

14

BR /R
(F )

B/ Y
(F )

Y/ R
(F )

(F )

2A

4K

2B

2I

W/ L
(F )

B3 0 1
2J

1G

1K

1I

1S

2L

2E

1T

1A

Powertrain control module (PCM)

1J

1P

1F

1R

2C
B3 0 1

BR /W

BR /B

BR /B

BR /B

(F )

(F )

(F )

(F )

Shield

L/ Y

L/ W

R/ Y

(F )

(F )

(F )

(F )

(F )

(F )

BR /W

30

BR /W

BR /B

BR /Y

(F )

(F )

(F )

B3 1 4

BR /W

(F )
BR /B (F )

(F )

G/ Y (F)

V( F )

BR /W (F )

V( E )

BR /W (E )

X
X

BR /B (E )

08

B/R

BR /B

BR /B

(F )

(E )

(E )

BR /Y

BR /B

G/ Y

BR /B

(E )

(E )

(E )

(E )

09

BR /W

GY /L

BR /B

BR /W

R/ L

BR /B

P/ L

(F )

(F )

(F )

(F )

(F )

(F )

(F )

B3 1 7

B3 1 8

28

EPROM

B 3 1 5

B3 16

B 315

Engine Coolant
Temperature
(ECT) sensor

B/R
(F )

B3 1 9

Accelerator pedal position sensor

B3 1 6

Intake air temperature sensor 2

EGR valve position sensor

Boost pressure
sensor

Fuel pump
3

B301

1U

Powertrain control module


(PCM) (F)

1O

B/L

L/Y

B/ W

BR /Y

1V

1M

1K

1I

1G

1Q

1S

1T

1A
1E

R/ L

GY /L

G/ R

GY /B

1R

1P

1N

1L

G /Y

P /B

1J

1H

1F

B314
Fuel pump (F)

2G

L/R

BR /W

G /B

BR /B

L/ W

W /L

1D

2E

2I

1B

2L

2J

2A

B317 EGR valve position sensor (E)

BR /W

B R /B

R
BR /W

L/Y
R/Y

4Y

R /Y

2H

2F

4Q
4W

2C

4U

BR /R

LG/ B

L/ B

GY

Y /R

G /O

B /L

BR

Y/ G

2B

4Z

4X

4V

4T

2D

4O

4M

4K

4I

4S

P /L

B315 Engine Coolant Temperature (ECT) sensor (E)


W

2K

1C

4A
4G

LG/ R

B/ Y

W /R

4E

4C

G /B

B /L

B /R

B/ L

B /R

R /B
4R

4P

4N

4L

4J

4H

4F

B316 Intake air temperature sensor 2 (E)

L/W
BR /Y

BR /B

B318 Boost pressure sensor (F)

B319 Accelerator pedal position sensor (F)


D

BR /W

G Y /L

BR /B

BR /B

B R /B

BR /B

P/ L

R /L

BR /W

42

G/ Y

4D

4B

Powertrain control
module (PCM)
(Section B3c)

B-3b

Harness symbol
[Grey]
Fuel pump
[Grey]
[Grey]
(F)(E)

X09

[Grey]

B314

(F)(E)

X08
3

Engine Coolant Temperature (ECT) sensor


B315

[Black]
Intake air temperature
sensor 2
B316

31

Joint connector

X28
B317
EGR valve
position sensor

B318
Boost pressure
sensor

[Grey]

[Black]

B319
Accelerator pedal position sensor
[Black]

B301
Powertrain control module
(PCM)

B-3c

Engine control / Preglow system (Euro 3)


Starter relay
(Section A)

A/C Amplifier
(Section G)

A/C Relay
(Section G)

Instrument cluster
(Section Ca)

Instrument cluster
(Section Cb)

15

B/ L

R/ W

R/ B

G/ R

GY

(F )

(F )

(F )

(F )

(F )

1U

3C

4L

1N

4S

B3 0 1

4W

4U

1L

1M

1Q

Powertrain control module


(PCM)

1O

4Y

3D

4E

1H

1B
B3 0 1
BR /B
(F )

Shield

Fuel pump
(Section B3b)

32

PCM module relay


(Section B3a)

BR /B

BR /B
(F )

42

41

BR /B
(F )

(F )

B/ L

B/ L

(F )

(F )

LG/ B

B/ L

L/ B

(F )

(F )

(F )

B/ L
(F )
GY /B
(F )

BR /B

(F )

(F )

(F )

(F )

B/ L
(F )

BR /B

B/ L

B/ L

G/ B

B/ L

P/ B

BR /B

(F )

(F )

(F )

(F )

(F )

(F )

(F )

(F )

B3 2 0

Fuel shutoff valve

B/ R

B3 2 1

B/ R
(F )

Fuel temperature
sensor

28

Mass Air Flow (MAF) sensor / Intake


air temperature sensor

B/ R

Fuel pump

(F )

1U

1O

1M

1K

1I

1G

1Q

1S

BR /Y

R/ L

GY /L

G/ R

GY /B

G /Y

P /B

1V

1T

1R

1P

1N

1L

1J

1H

1F

L/ Y

L/R

BR /W

G /B

BR /B

3I

3G

3E

3A

1D

1B

3P

(F )

3L

3J

3H

3F

B/ L

L/ B
B/ L

BR /B
W

LG/ B

GY /B

B /L

BR /B

B/ L

G /B

B/ R

B /L

LG/ B

L/ B

GY

LG

G /O

B /L

BR

Y /G

3D

3B

4Z

4X

4V

4T

P /B

BR /B

4O

4M

4K

4I

4S

B/ L

B322 TDC sensor (F)

4Q
4U

4W

R /W

3N

4Y

3C

G/ W

B321 Mass Air Flow (MAF) sensor / Intake air temperature


sensor (F)

B320 Fuel pump (F)

3K
3M

1C

B/ W

B/ L

3O

1A
1E

28

B/ R

B301
Powertrain control module
(PCM) (F)

B3 2 2

(F )
E

4A
4E

4C

G /B

B /L

B /R

B /L

B/ R

4D

4B

4G
LG/ R

B/ Y

W /R

R/ B
4R

4P

4N

4L

4J

4H

4F

TDC sensor

Harness symbol

B-3c

[Grey]
Fuel pump
B320
[Black]
Mass Air Flow (MAF)
sensor / Intake air
temperature sensor
B321

33

B322
TDC sensor
[Grey]
Joint connector

X28

B301
Powertrain control module
(PCM)

B-4

Fuel heater
Battery

01

01

B
(E )
M A IN 80A

PTC 30A

G/ B (F )

B4 0 1

Fuel
heater

B4 0 1

34

B( F )

B401

Fuel
heater (F)

G/ B

(F )

(E)

(R)

B-4

Harness symbol

Main fuse box


X01

B401
Fuel heater
[Grey]

35
4

C-a

Instrument cluster
Battery

01

# .. with

remote freewheel control system


with air bag
% ..with ABS
& .. Euro 3
( ). with immobiliser unit

01

B/ L

B
(E )
MA IN 8 0 A

01

03

IG

03

KEY

(F )

1 40A

B/ W

L/ R

W/ R

(F )

(F )

IG

R OOM 10A

B T N 60A

KEY

(F )

2 40A

ST

E URO 3

Powertrain control
module (PCM)
(Section B3c)

IG 2

G/ R

15

02

Ignition switch

OF F

OF F

IG 1

AC C

(F )
X

02

03

03
B/ Y

W
(F )

(F )
M E T E R 15A

Instrument cluster

C01

1H

1J

1K

Low fuel
indicator
1.4W

Water temperature
gauge

Speedometer

Tachometer

Microprocessor

Safety
1.4W

Fuel indicator
gauge
(Section I2)

b
1F

1I

1L

1P

1N

1G

1M

2K
C

Y( F )
X

(Section Cb)

(Section Cc)

L/ W

(F )

(F )

04

08

R/ Y

W/ L

Y/ B

(F )

(F )

(F )

01

Y( R )

36

19
Y( R 2 )

B/ R

L/ W

(E )

(E )

C04

(F )

L
(E )
C0

L/ W
(E )

BR /B
(F )

C03

Fuel pump/fuel
gauge sender
29

04

19

B/ R

B/ R

B/ R

(F )

(R)

(R 2)

Speedometer
sensor

Speedometer
sensor

4x2

except 4x2

Door entry
switches
(Section I3)

Coolant temperature sensor

Powertrain control
module (PCM)
(Section B1b,
B2b, B3b)

B/ R (F )

16

C02

C04
X

Immobiliser
module
(Section T)

01

Instrument cluster (F)

L /W
1P

02

Coolant temperature sensor (F)

C 03

1O

R /Y

W /L

L /R

B /Y

1N

1M

1L

1K

1J

1I

&G /R
1H

Y /B

R /B

1G

1F

1E

1D

Speedometer sensor (E)


4

Y/ B

B /R

L/W

except 4x2

L/ W

R/ G

G /B

G /W

B/ L

R/ L

GY

1C

1B

1A

2N

2M

2L

C 04

Fuel pump/fuel gauge sender


(R2)

L
B/ R

(B R/ B ) @Y /G
2K

2J

W
2I

#B R

#LG/ R

2H

2G

2F

L /Y

Y /R

W /B

B
%L G

R /W

2E

2D

2C

2B

2A

with immobiliser
unit

(F )

(E)

(R)

C-a

Harness symbol

[Euro 1, Euro 2]

Fuel pump/fuel gauge sender


C04

[Grey]
Speedometer sensor
C03
4x2

[Grey]
(F)-(E)

(R)-(R2)

X08

X19

Main fuse box

[Double cabin]

[Grey]
Speedometer sensor

X01

C03

except 4x2

(F)-(R)
X04
Instrument cluster
C01

[Black]
Instrument cluster
C01

C02
Coolant temperature sensor

37

[Grey]
(F)-(E)

Fuse block

(R)-(R2)
X19

X02

[Euro 3]

X01

Fuel pump/fuel gauge sender


C04

X03

X08

Main fuse box

03

[Grey]
Speedometer sensor
C03 4x2

Ignition switch

[Grey]
Speedometer sensor
C03
except 4x2

X04
(F)-(R)

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

C02
Coolant temperature sensor

X04
(F)-(R)

C-b

Instrument cluster
remote freewheel control system
with air bag
with ABS
( ) ...
with immobiliser unit
#

. with

Instrument cluster
(Section
Ca)

Park
brake
1.4W

RF W

4WD

LOCK

1. 4W

Air bag
1.4W

Preglow
indicator
1.4W

ABS
1.4W

1. 4W

d
2E

2G

2H

L/ Y

Y/ G (F )

(F )

38

L/ Y

LG/ R

BR

(F )

(F )

L/ Y

Charge
1.4W

2D

2C

2L

2I

Y/ G

Y/ G

(F )

(F )

%L G

GY

Y/ R

W/ B

(F )

(F )

(F )

(F )

(F )

C0

Brake
fluid sensor

BR /W
C0

36

Remote freewheel control


module
(Section H)

Park brake
switch
C0

with remote freewheel control


system

B( F )

01

09

R/ L

GY

2M

2L

(B R /B ) @Y /G
2K

2J

W
2I

#B R

#LG/ R

2H

2G

(F) Short cord

L/ Y

Air bag module


(Section
S1)

(Short cord)
B R/ W

without
ABS

Data Link
Connector
(DLC)
(Section
U1, U2)

B
(F )

2F

L /Y

Y /R

W /B

B
%L G

R/ W

2E

2D

2C

2B

2A

17

ABS control
module
(Section O)

with air bag

C 05

B/ L

(F )

35

34

Powertrain
control module (PCM)
(Section
B1b, B2b,
B3c)

Y/ R

05

(E )

Generator
(Section A)

Sedimentor
switch
C

05

C06

Oil pressure switch

B
(F )

with ABS
4

Instrument cluster (F)

2N

(F )

37

01

09

LG
C0

(F )

(F )

Sedimentor
1.4W

(Section Cc)

2B

2J

Low oil
pressure
1.4W

Sedimentor switch (F)

C 06

Oil pressure switch (E)

C 07

Brake fluid sensor (F)

C 08

Park brake switch (Short


cord)

L/ Y
B

BR /W

Y/ R
B

(F )

(E)

[Grey]
(F)-(E)

(R)

C-b

Harness symbol

[Grey]
Sedimentor switch
C05
Brake fluid sensor
C07

X09

C06
Oil pressure switch

39

Instrument cluster
C01
[Black]
Instrument cluster
C01
(F) Short cord
C09

C08
Park brake switch

C-c

Instrument cluster
Headlamp
switch
(Section E1)

Flasher unit
(Section F1)

Rear window
heater relay
(Section I1)

Rear fog lamp


switch
(Section E4)

. .with

( ).
19

20

18

21

22

G/ B

G/ W

R/ W

B/ L

R/ L

(F )

(F )

(F )

(F )

(F )

Instrument cluster

C01

1B

1A

LH
direction
indicator
1.4W

(Section Cb)

(Section Ca)

2A

RH direction indicator
1.4W

2N

High
beam
1.4W

2M

Rear window heater


ON indicator 1.4W

Rear fog
lamp
1.4W

1D
C01

40
B
(F )

01

Instrument cluster (F)

L/ W
1P

1O

R/ Y

W /L

L /R

B /Y

B/ R

1N

1M

1L

1K

1J

1I

&G /R
1H

Y /B

R /B

R/ G

G /B

G /W

B/ L

R/ L

GY

1G

1F

1E

1D

1C

1B

1A

2N

2M

2L

(B R/ B ) @Y /G
2K

2J

#B R

#LG/R

2I

2H

2G

remote freewheel control system


with air bag

% ..with ABS
& ..Euro 3

2F

L/ Y

Y /R

W/ B

2E

2D

2C

B
%L G

R/ W

2B

2A

with immobiliser unit

(F )

(E)

(R)

C-c

Harness symbol

Instrument cluster
C01
[Black]
Instrument cluster
C01

41

Front wiper/washer
Battery

01

01

# .. without

B/ L
(F )

B
(E )
M A IN 8 0 A

IG KE

Y1

40A

IG KE

Y2

40A

B/ W
(F )
X

02

Ignition switch
ST

OF F

OF F

IG 1

AC C

IG 2
X

(F )

(F )

03

03

W
(F )
WI P E R 15A

L( F )

Wiper/washer switch

D02

Wiper
switch (2)

HI G H
IN T

02

Wiper switch (1)

Onetouch

OF F
HI GH
OF F

IN T

LO W

Washer
switch

LO W

Intermittent wiper relay

L/ Y (F )

02

L/ W(F )

01

L/ B

B
(F )

42

L/ O (F )

D0

(F )

Windshield wiper
motor

Stop
switch

D03

Windshield
washer pump
motor

M
LO
HI

M
Circuit
breaker

D 01

Windshield washer pump


motor (F)
B

02

Wiper/washer switch (F)

#G/ R

L/B

D 03

L/ W

L/ Y

L
L/ O

L /O

B( F )

Windshield wiper motor (F)

L/ W

L /Y

L/B

01

air bag

(F )

(E)

(R)

Harness symbol
Windshield wiper motor
D03

Main fuse box


X01

43

D01
Windshield washer
pump motor

D02
Wiper/washer
switch

X02
X03
Fuse block

Ignition switch

E-1

Headlamps / Daytime Running Lamps


Battery

01

01
B/ L

(F )

(E )

IG

M A IN 8 0 A

K EY

1 40A
B/ W
(F )

IG

K EY

2 40A

03

03

W/ R

Y/ R

(F )

R/ W

(F )

HE A D 20A

(F )

R( F )

Rear fog lamp


switch
(Section E4)

(F )

Light
switch

Headlamp
flasher

R/G

R/ G

(F )

(F )

03

03

02

03

B/R

(F )

(F )
A/C 2 1 0A

E1 0 1

Head

Off

03

TNS
Dimmer switch
High beam

R/ Y
(F )
R .FOG 10A

AC C

E1 0 1

R/ G

27

IG 1

IG 2

Headlamp switch
26

OF F

(F )

Headlamp levelling
switch
(Section E3)

OF F

ST

HE A D 30A

02

Ignition switch

(F )

T A IL 10A

B T N 60A

E1 0 1

R/ B

R/ B

(F )

(F )

25

Instrument illumination
(Section I2)

Low beam
R/ B
(F )

E1 01

R/ G

R/ W (F )

(F )

R/ W
(F )

E1 0 4

Headlamp relay
E1 0 5
R/W
(F )

Daytime Running
Lamps (DRL) relay

E1 04
W

R/ L(F )

44

Instrument cluster
(Section Cc)

(F )
R/W

18

(F )
R/ W

R/ L

R/ W

R/L

(F )

(F )

(F )

(F )

E1 0 2

E1 0 5

E1 0 3

Headlamp,
LH side

60/ 55 W

Headlamp,
RH side

B( F )

60/ 55W

W/ L( F )
W/ L
(F )

E 103

E 1 02
B( F )

W/ L( F )

R/ B

(R)

(F )

(F )

B( F )
B( F )
1

E 1 01

Headlamp switch (F)

E 1 02

W/ R

B /Y

Y /R

Headlamp, LH side (F)

W/ B

E 103

Headlamp, RH side (F)

E 1 04

Headlamp relay (F)

E 105

Daytime Running Lamps


(DRL) relay (F)

R/ L

R/ L

W/ L
R/ B

R /Y

R /G

R /W

R/W

R/W

R /B

R/ W
W

R/ G

R
R/ L

24

Parking Lamps
(Section E2)

23

Tail lamps
(Section E2)

04

(F )

(E)

E-1

Harness symbol

(R)

Daytime Running Lamps (DRL) relay


E105

[Double cabin]

Main fuse box


X01

(F)-(R)
X04

E103
Headlamp,
RH side

E104
Headlamp relay

45

E102
Headlamp, LH side

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

2
6

X03
Fuse block
X02
Ignition switch

E101
Headlamp switch

X04
(F)-(R)
X04
(F)-(R)

E-2

Licence plate lamps / Parking Lamps / Tail lamps


Daytime Running Lamps (DRL)
relay
(Section E1)
24

23

R/ B
(R )
W/ L
X

(F )

19
R/ B
(R2)
R/ B

R/ B

(R 2 )

(R 2)

W/ L

W/ L

R/ B

R/ B

(F )

(F )

(R2)

(R2)

E2 0 1

E2 0 5

E2 0 2

LH parking lamp

RH parking lamp

5W

5W
E2 0 1

E2 0 2

R/ B
(R 2 )

E2 0 6

Tail lamp, LH
side

5W

R/ B
(R2)

E2 0 4

Tail lamp, RH
side

5W

5W

E2 0 6

E2 0 5

E2 0 7

RH Licence
plate lamp

LH Licence plate
lamp

5W

E2 0 4

E2 0 7

46

(F )

(F )

(R2)

(R2)

(R2 )

(R2)

B
(R2)

E 2 01

LH parking lamp (F)

E 2 02

RH parking lamp (F)

W/ L

W/ L

E 2 04

RH Licence plate lamp (R2)

E 2 05

Tail lamp, LH side (R2)

R/W

E 2 06

Tail lamp, RH side (R2)

G /B

R/W

E 2 07

LH Licence plate lamp (R2)

G /W

R/B

R/B

W/G

R/B

W/G

R/B

(F )

(E)

(R)

E-2

Harness symbol
(R)-(R2)
X19

Tail lamp, RH side


E206
[Grey]
RH Licence plate lamp
E204
7

[Double cabin]

[Grey]
LH Licence plate lamp
E207

E205
Tail lamp, LH
side

8
1

Tail lamp, RH
side
E206

[Grey]
RH Licence plate lamp
E204

47

(R)-(R2)

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

E202
RH parking
lamp

X19

[Grey]
LH Licence plate lamp
E207

E201
LH parking
lamp
2

E205
Tail lamp, LH side
8

E-3

Headlamp levelling

Headlamp switch
(Section E1)

26

R/G

R/ G

(F )

(F )

R/ G (F )

E3 0 1

0
1
G
(F )
E3 0 1

2
3

R/ G

R/ G

(F )

(F )

(F )

(F )

E3 0 2

48

Headlamp levelling
switch

E 303

Headlamp levelling motor LH

Headlamp levelling motor RH

E3 0 1
C

C
E3 0 3

E3 0 2
B
(F )

E 3 01

Headlamp levelling switch (F)

E 3 02

Headlamp levelling motor LH (F)

E3 0 3

(F )

(F )

Headlamp levelling motor RH (F)

R/ G

R/ G

R/ G

(F )

(E)

(R)

E-3

Harness symbol

E303
Headlamp levelling motor RH

49
E302
Headlamp levelling motor LH

E301
Headlamp levelling switch

E-4

Rear fog lamps


Headlamp switch
(Section E1)

27

R/ G
(F )
R/ G
(F )
R/ G
R/ W

(F )

(F )
E4 0 1

E4 0 2

Rear fog lamp


switch

Rear fog lamp


relay

E 402

E 4 01
R/ L

R/L

(F )

(F )
R/ L
(F )

R/ L
(F )

R/L
(F )
C

04

19

R/ L

22

(R )

50

Instrument
cluster
(Section Cc)

R/ L
(R2 )

E4 0 3

Rear fog lamp


21W

E4 0 3

B( F )

E 4 01

Rear fog lamp switch (F)

E 4 02

Rear fog lamp relay (F)

E 4 03

B( R 2 )

Rear fog lamp (R2)

R/ G
R/ L
R/ L

R /W

R /W

R/G
R/L

(F )

(E)

(R)

E-4

Harness symbol
(R)-(R2)
X19

[Double cabin]

E403
Rear fog lamp

X04
E401
Rear fog lamp
switch

(F)-(R)

51

(R)-(R2)

E402
Rear fog lamp relay

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

X19

E403
Rear fog lamp
X04
(F)-(R)

X04
(F)-(R)

F-1

Turn Signal and Hazard Lamps


Battery

01

01

W/ R

(E )

(F )

03

B T N 60A

M A IN 8 0 A

03

HA Z A RD 10A

Direction indicator switch


B/ L
(F )

IG

K EY

1 40A

IG

K EY

2 40A

B/ W
LH

(F )
X

OF F

ST

IG 2

Ignition
switch

OF F

IG 1

E1 0 1

AC C

RH

02

B/ Y( F )

W/ B (F )

W/ R( F )

L/ Y (F )

02
W
(F )
M E T E R 15A

F1 0 1
A

Flasher unit
G

G/ W( F )

G/ B (F)

F1 01

with keyless entry

G/ R (F)

G/ W
(F )

G/ W
(F )

G/ R
G/ B
(F )
G/ W( F)

G/ B (F)
G/ W( F)

G/ B (F )

52
F1 0 5

Side direction
indicator lamp,
RH

Direction indicator lamp, RH


front

21W

F1 0 5

F1 0 3

F1 0 6

Direction indicator lamp, LH


front

21W

Side direction
indicator lamp,
LH

5W

F1 0 4

B( F )

F1 0 6

B( F )

G/ W (R 2 )

Flasher unit
(F)

W/ R

G /W

W /B

G /R

Side direction indicator lamp,


LH (F)

F 1 02

G/ B

19

F1 02

Direction indicator lamp,


RH rear

21W

G/ W( F)

G/ B (F)

20

19

Hazard flasher
switch

B( F )

F1 02

B( F )

E2 0 5

Direction indicator lamp,


LH rear

21W

Instrument cluster
(Section Cc)

B( F )

E2 0 5

B( R 2 )

F1 0 6

Remote keyless
entry
(Section I4)

G/ B (R 2 )

E2 0 6

E2 0 6

04

G/ B (F)

F1 0 4

F1 0 3

B( F )

F1 0 1

G/ R (F)
X

G/ B (R )

G/ W( R )

32

G/ W (F )

G/ B (F)

5W

(F )

B( R 2 )
8

Hazard flasher switch (F)

F 1 03

Direction indicator lamp, RH


front (F)

F 1 04

Direction indicator lamp, LH


front (F)

F1 0 5

Side direction indicator lamp,


RH (F)

L/ Y
B
F

G /B
D
E 1 01

R/ G

R/ B

G/ R

G/ W

G/ B

Direction indicator switch (F)

R/ B

R/ Y

R/ L

E 2 05

R/ W

W/ R

B/ Y

Y/ R

Direction indicator lamp, LH


rear (R2)

W/ B

R/W
B

R/B

E 2 06

Direction indicator lamp, RH


rear (R2)

G /B
W/G

R/W
B

R/B

G /W
W/G

G/W

(F )

(E)

F-1

Harness symbol

(R)

Direction indicator lamp, RH rear


E206

Side direction indicator lamp, RH


F105
(R)-(R2)

[Double cabin]

Main fuse box

X19
7

X01

E205
Direction indicator
lamp, LH rear

F103
Direction indicator
lamp, RH front
[Black]

F106
Side direction indicator lamp, LH
Direction indicator lamp, RH rear
E206

X04

53

F104
Direction indicator lamp, LH front
[Black]

(F)-(R)
Flasher unit
F101
2

Hazard flasher switch


F102

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

(R)-(R2)
X19

E205
Direction indicator
lamp, LH rear

X03
Fuse block
X02

Ignition switch
E101
Direction indicator
switch

X04
(F)-(R)

X04
(F)-(R)

F-2

Reversing lamps

< >. ..B

Battery

01

01

B/ L

(E )

(F )

IG

M A IN 8 0 A

KEY

1 40A
B/ W
(F )

IG

KEY

2 40A

02

Ignition switch
OF F

ST

IG 2

OF F

IG 1

AC C

Reversing lamps switch


X

08

R/ W
(F )

R/ W
(E )
F2 0 1

04

19

F2 0 1

R/W
(R )

R/W
(R 2)

54

R/ W

R/W
(R 2)

(R2)
E2 0 6

E2 0 5
21W
<18W>

Reversing lamp, left

21W
<18W>

E2 0 5
B
(R2)

F 2 01

Reversing lamps switch


(E)

E 2 05

Reversing lamp, left (R2)

R/ W

B/ Y
R/ W

R/B

E 2 06

Reversing lamp, right


(R2)

G /B

R/ W

W/G

R/B

G /W
W/G

08

Reversing lamp, right

E2 0 6
B
(R 2)

03

03
W
(F )

B/ Y
(F )

B/ Y
(E )

M E T E R 15A

02

S e ries

(F )

(E)

(R)

F-2

Harness symbol
(R)-(R2)

[Grey]
(F)-(E)
X01

Reversing lamp, right


E206

X19

Reversing lamps switch

F201

Main fuse box

[Double cabin]

X01

E205
Reversing lamp,
left
8

X04
(F)-(R)

55

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

Reversing lamp, right


E206
(R)-(R2)
X19

Reversing lamp, left


E205

X03
Fuse block

X02
Ignition switch
X04
(F)-(R)

X04
(F)-(R)

F-3

Stop Lamps / Horn


Battery

01

01

03

# ..

03
G/ W

W/ R

(F )

(F )

(E )
M A IN 80A

(F )

S T OP 15A

B T N 60A

without air bag

G/ W
G/ W
G/ W

G/ W

(F )

(F )
C

(F )

A
F3 0 1

Horn relay

F3 0 3

Stop lamp switch

F3 0 1

F3 0 3

W/ G
(F )

ABS control module


(Section O)

G/ R (F)

W/ G

28

(F )
W/ G
(F )

AntiLock Control 4Wheel

04

19

W/ G
B/ R

(R )

G/ R (F)

(F )

S1 0 2

W/ G
(R 2 )

with air bag

without air bag

G/ R (F)

56

F3 0 4
W/ G

W/ G

B/ R

B/ R

(R2)

(R 2 )

(F )

(F )

E2 0 5

E2 0 6

Stop lamp LH

F 3 02

Horn LH (F)

Horn switch

(R2)

(R 2 )

F 3 03

Stop lamp switch (F)

F 3 04

Horn switch (F)

F 3 05

Horn RH (F)

Horn switch (F)


L/ Y

Stop lamp LH (R2)

E 2 06

Stop lamp RH (R2)

S 102

Shorting bar connector (F)

B/ R
R/ W

G /B

R/ B

W /G

R/ W

G /W

R/B

W/G

G /R
B

Horn switch

L/ W

B/ R
G/ R

W/ G

E 2 05

02

#G/ R

B/ R

G /W

G/ W

02

G/ W

A
G/ R

Horn RH

E2 0 6

Horn relay (F)

(F )

F3 0 5

Horn LH

21W

E2 0 5

F301 H

F3 0 2

Stop lamp RH

21 W

G/ R

Clock
spring

B /Y

B/ W

Y /G

Y/ G

B /W

B/ Y

G /R

L/ B

L /O

(F )

(E)

(R)

F-3

Harness symbol
(R)-(R2)
X19

Stop lamp RH
E206

Main fuse box

X01

[Double cabin]

E205
Stop lamp LH

F305
Horn RH
[Black]
X04
(F)-(R)

57

F302
Horn LH
[Black]

Stop lamp RH

Horn relay
F301

Shorting bar connector

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

(R)-(R2)

E206
7

X19

S102

D02
Horn switch

X03

E205
Stop lamp LH

Fuse block

F304
Horn switch

F303
Stop lamp
switch

X04
(F)-(R)

X04
(F)-(R)

Heating / Air conditioning


Battery
X

01

01

B/ L

(E )

(F )
X

03

M A IN 8 0 A

IG

KEY

1 40A

B T N 60A

IG

KEY

2 40A

03
W/ R

B/ W
(F )

(F )
A/C 1 0 A

03

Ignition switch

03

B/ R

(F )

IG 2

IG 1

AC C

(F )
A/C 2 10 A

/
LG R
(F )

02

OFF

OF F

ST

02

(F )
B/ R (F )
G

07

B/ R

(F )

(F )

A/C Relay

HE A T E R 40A
Y( F )

03

06

LG/ B

R/ B

(F )

(F )

07

06

Powertrain control
module (PCM)
(Section B1b,
B2b, B3c)

L/ B

Blower motor

Blower assembly

04

Resistor
Y

09

(F )

A/C pressure
switch

04

09

58

R/ W

(F )

(F )

G
(F )
G
X

09

L/ W

L/ Y

(F )

(F )

10
G

05

03

L/B

E
L/ Y

L/R

L/ Y

(F )

11

L/ R

L/ B

(F )

(F )

(F )
G

01

A/C Amplifier

(E )
G

08

L/ Y

L/ B

(F )

Fan switch
4

Evaporator discharge air


temperature sensor

L/ R

B
3

Off

A/C Compressor clutch

G01 Heater control module (F)

G02 (F) Blower assembly

A/C switch

Heater control module


5

G04 Resistor (Short cord)


Blower assembly

(F )

L/ R

L/ Y

L /B

G05 Resistor (Short cord)

G06 Blower motor (Short cord)

G07 A/C Relay (F)

L/ B
L/ B

E
L
G 08

L/ R

L/ R

A/C Compressor clutch (E)

G09 A/C pressure switch (F)


L/ Y

L/ B

L/ B

R/ B

L
LG/ R

G10 A/C Amplifier (F)

L/ Y
LG/ B

G11 A/C switch (F)

L/Y

L/W

LG/ B

L/ W

R /W

Harness symbol
[Grey]
(F)(E)

X09

Main fuse box

X01

G07
A/C Relay

59

G09
A/C pressure
switch
[Black]

Resistor
G04

G08
A/C Compressor clutch

X03
Fuse block

X02
Ignition switch

G11
A/C switch
G01
Heater control
module

G05
Resistor
G10
A/C Amplifier
G06
Blower
motor

G03
(F) Blower assembly

Remote freewheel control system


Battery
X

01

01
B/ L

(E )

(F )
M A IN 8 0 A

IG

KEY

1 40A

IG

KEY

2 40A

B/ W
(F )
X

ST

IG 1

IG 2

02

Lock solenoid

Ignition switch

OF F

OF F

Free solenoid

AC C

H0
X

H03

02

03

B/ W

B/ W

(F )

(F )

03

B/ W

(F )

(F )
E N GI NE 15A

B/ W

LG

(F )

(F )

(F )

H01

Remote freewheel control module


B

R/ G

GY /R

(F )

(F )

F
H

LG

(F )
X

R/ G

(E )

60

05

(F )

05

B/ R
(E )

06

B/ R (E )

G/ O
(F )

H07

4x4 Mode
switch

Remote
freewheel
switch

09

/
LG B
(E )

GY /R

(E )

01

/B
/R
(F )

BR
(F )

36

37

H04

Remote
freewheel
main switch

Transfer
neutral
switch

06

H07

B/ R

LG

Instrument cluster
(Section Cb)

H04

B/ R (E )

(E )

B
(F )

B/ R (E )
X

08

B/ R (F )

H01 Remote freewheel control module (F)


K

GY /R

G/ O

LG/ B

R/ G

B /W

LG/ R
BR

H07 Transfer neutral switch (E)

B/ R

LG/ B

H02 Lock solenoid (F)


C

LG

R
B

H03 Free solenoid (F)

H04 Remote freewheel main


switch (F)

H05 Remote freewheel switch (E)

H06 4x4 Mode switch (E)

R/ G

B/W

LG

B/W
G/ O

B/ R

B/ R

GY /R

Harness symbol
Free solenoid
H03

[Grey]
(F)(E)
[Grey]
(F)(E)

X09

X08

[Blue]
Lock solenoid
H02

Main fuse box

[Black]
Transfer neutral switch
H07
[Black]
4x4 Mode switch
H06

X01

61

H05
Remote freewheel switch
[Black]

H04
Remote freewheel main
switch
[Blue]

X03
Fuse block

X02
Ignition switch

H01
Remote freewheel control
module

I-1

Cigar lighter / Rear defrost


Battery
X

01

01

B/ L

(E )

(F )
M A IN 8 0 A

IG KE

Y1

40A
B/ W
(F )

IG KE

Y2

40A

03

03

02

W/ R
(F )
R .D E FOG 20A

B T N 60A

OFF

ST

IG 2

B/ Y

(F )

(F )

03

Ignition switch

OF F

IG 1

AC C

02

03

03
W

(F )

(F )

M E T E R 15A

I1 0 4

Rear window heater


relay

CI G A R
15A

03

I1 0 4
L/ W
B/ L

(F )

(F )

(F )

B/ L

L/ W
I1 0 5

(F )

62

B/ L
(F )

Rear window heater


switch

04

B/ L

L/ W

(F )

(F )
I1 0 1

I1 0 2

Outlet

Cigar
lighter

I1 0 5

(R )

I1 0 1

I1 0 3

I1 0 2

Rear window heater


grid

21

(F )

(F )

B
(F )
B

Instrument
cluster
(Section Cc)

I1 0 3

(F )
B

(F )

13

I101 Cigar lighter (F)

I102 Outlet (F)

I103 Rear window heater grid

I104 Rear window heater relay (F)

(R )
L/ W
B

L/ W
B

I105 Rear window heater


switch (F)

(Short cord)
B/ L

B /Y
B
W
G
B/ L

I-1

Harness symbol
Main fuse box

[Double cabin]

[Black]
Rear window
heater grid
I103

X01

I103
Rear window
heater grid
[Black]

X04

13

(F)(R)

63

Rear window
heater switch
I105

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

[Black]
Rear window
heater grid
I103

X03
Fuse block
I103
Rear window
heater grid
[Black]

X02
Ignition switch

X04
I104
Rear window
heater relay

(F)(R)

I102
Outlet
[Black]

I101
Cigar lighter
[Black]

X04
(F)(R)

13

I-2

Clock / Instrument illumination


Battery

01

01

03

# ..without
& ..Euro 3

03

W/ R

B
(E )

(F )
B T N 60A

M A IN 8 0 A

R OOM 10 A
B/ L
(F )

IG

KEY

1 40A

IG

KEY

2 40A

B/ W
(F )

Headlamp switch
(Section E1)

25

OF F

ST

IG 2

02

Ignition
switch

OF F

IG 1

AC C

R/ B
(F )

02

L/ R
(F )

L
R/ B

R/ B

(F )

R/ B

(F )

R/ B

(F )

(F )

R/ B

(F )

(F )

R/ B
X

(F )
C

(Section
Ca)

R/ B
(F )

01

1E
b

R/B
(F )

Cluster illumination

R/B
(F )

R/ B
(F )

J1 0 1

Hazard flasher
switch illumination

I2 0 3

Audio illumination

F1 0 2

1C
C

15A

# J 201
F1 0 2

Heater panel illumination lamp

J1 0 1

03

L/ W
(F )

I2 0 3

# J 201

I2 0 1

01
R/G

R/G

R/ G

(F )

(F )

(F )

R/ G

03

CI G A R

Clock

(F )

64

R/ G

R/ G

(F )

(F )

R/ G (F )

I2 0 1
I2 0 2

Illumination dimmer
B
OS C

(F )
I2 0 2
B
(F )

I2 01

Clock (F)

01

Cluster illumination (F)

L/ W

B
R/ B

L/R

1P

1O

F 1 02

R/ Y

W/ L

L/ R

B /Y

B /R

1N

1M

1L

1K

1J

1I

&G /R
1H

Y/B

R /B

R/ G

G /B

G /W

1G

1F

1E

1D

1C

1B

1A

Hazard flasher switch illumination (F)

R/ G

L/W
I2 02
D

Illumination dimmer (F)

I2

03

Heater panel illumination


lamp (F)

J101
# J201

Audio illumination (F)


1M

1K

1E

1C

1A

L/ R

R /B

L /R

L/W

L/ Y

L/ W

1N

1L

1D

1B

B
B

R /G
R/ G
R/ B

R /B
R/ G
1J

1H

1F

R/ B

G/ R

audio harness

(F )

(E)

(R)

I-2

Harness symbol

Main fuse box


X01

Cluster illumination
C01
[Black]
Cluster illumination
C01

Hazard flasher switch illumination


F102

65

[Black]
Audio illumination
J101
J201

Clock
I201

Audio illumination
J101
J201

X03
Fuse block

X02
Ignition switch

I202

I203

Illumination
dimmer

Heater panel illumination lamp

I-3

Interior lamps
Battery

01

01

W/ R

(E )

(F )
M A IN 80 A

03

03

10

L/ R
(F )

B T N 60 A

R OOM 10A

L/ R
(I N)

with power
windows

I3 0 1

with keyless
entry

Power window
main switch
(Section K1)

Remote keyless
entry module
(Section I4)

31

Interior lamp

Instrument cluster
(Section Ca)

30

29

ON

OF F
D OOR

R/ Y

B/ L

R/ Y

(F )

(F )

(F )

I3 0 1
R/Y ( IN )

R/ Y

Freestyle cabin /
Stretch cabin
(with rear access)

(F )
X

10

04

R/ Y
X

R/ Y (F )

(F )

06

R/Y

R/ Y

R/ Y

(F R )

(F )

(F )
R/ Y (F )

R/ Y
(F R)

R/ Y (R )
DO UB LE CA B

R/ Y
(F R)

R/ Y

66

(F R)
X

R/ Y (R )

27
I3 0 6
X

26
R/ Y

R/Y

R/ Y

(DR3)

R/ Y (R)

R/ Y (F R )

(R)
R/Y (DR 4)

I3 0 5

I3 0 3

Door
entry
switch, LH
front

Door
entry
switch,
LH rear

I3 0 3

Door entry
switch, LH
front

Door
entry
switch,
RH rear

except Freestyle
cabin / Stretch
cabin (with rear access)

R/ Y (R )

I3 0 2

I3 0 4

Door entry
switch, RH
front

I3 0 2

Door entry
switch, RH
front

Freestyle cabin /
Stretch cabin
(with rear access)

except Freestyle
cabin / Stretch
cabin (with rear
access)

Double cabin
I3 01

Interior lamp (IN)


Regular cabin

except
Regular cabin

I302

Door entry
switch, RH
front

(DR4) Freestyle cabin / Stretch cabin (with rear access)

I3 06

(FR) Short cord

(R) except Freestyle cabin / Stretch cabin (with rear access)

R/ Y
R/ Y

I3 0 3

L /R

Door entry switch, LH


front

L/ R

(DR3) Freestyle cabin / Stretch cabin (with rear access)

(F R)

R/ Y

I3 04

Door entry switch, RH rear (R)

I3 05

Door entry switch, LH rear


(Short cord)

(FR) except Freestyle cabin / Stretch cabin (with rear access)


R/ Y

R/ Y

R /Y

R/ Y

(Short cord)

R /Y

(F )

(E)

(R)

I-3

Harness symbol
[Black]
Door entry switch, RH rear
I304

Interior lamp
I301

[Double cabin]
Main fuse box
[Black]
Door entry switch, RH front
I302

X01

(F)-(IN)
X10

X04
(F)-(R)

I305
Door entry switch, LH rear
[Black]
I306
(FR) Short cord

(F)-(IN)

67

I303
Door entry switch, LH front
[Black]

X06

X10

(F)-(FR)

*
**

(R)-(DR4)
X26

Freestyle cabin / Stretch cabin (with rear access)


except Freestyle cabin / Stretch cabin (with rear access)

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

[Black]
Door entry switch, RH front
* I302
[Black]
Door entry switch, RH front
I302

**

(FR)-(DR3)
X27
X03
Fuse block

X06
(F)-(FR)
I301
Interior lamp

X10
(F)-(IN)

I303
*
Door entry switch, LH front
[Black]

X04
X04
(F)-(R)

(F)-(R)
X06
(F)-(FR)

I303 **
Door entry switch, LH front
[Black]

I-4

Remote keyless entry


Battery
X

01

01

B/L

(E )

(F )
M A IN 8 0 A

IG

KEY

1 40A

IG

KEY

2 40A

B/ W
(F )
X

02

Ignition switch
ST

03

IG 2

03

OF F

OF F

IG 1

AC C

W/ R
X

(F )
B T N 60A

ROOM

03

03
W

10A

(F )
M E T E R 15A

L/ R

B/ Y

(F )

(F )

I4 0 1

Remote keyless entry module


C

I4 0 1

68

B/ L

G/ R

LG/ R

(F )

(F )

(F )

(F )

30

Door entry
switches
(Section I3)

32

Flasher unit
(Section F1)

33

Door lock timing


unit
(Section K2a)

I4

01

Remote keyless entry module (F)

O
LG

/R

B/ L
B

L/ R

G/ R
J

B/ Y

02

(F )

(E)

(R)

I-4

Harness symbol

Main fuse box


X01

69
4

X03
Fuse block

X02
Ignition switch

I401
Remote keyless
entry module

J-1

Audio Systems (with audio harness)


# .. with power windows

Battery
X

01

01

B
(E )

@ ..

B/ L

with central locking

(F )
M A IN 8 0 A

IG

KEY

1 40A

IG

KEY

2 40A

B/ W
(F )

02

Ignition switch
ST

IG 2

03

OFF

OF F

IG 1

03

AC C

02

W/ R
X

(F )

03

03

R OOM 10 A

B T N 60A

L/ W

(F )

L/ R (F )

(F )
C IGA

R 15A
J1 0 1

1C

Audio unit
2A

2B

2F

2H

P/ L (F )

GY /L (F )

GY /R (F )

GY (F )

P /L(F R )

G Y /L( F R )

GY /R (R )

GY (R )

P/ L (F R )

GY /L (F R )

GY /R (R )

GY (R )

GY /R

GY

(DR4)

(DR 4 )

3A

1A

1L

1N

1K

1M
J1 0 1

06

04
L/ W

L/ Y

(F )

(F )

(F )

70

GY /L

P/ L

(F R )

(F R)

GY

GY /R

GY /R

GY

(DR3)

(DR 3 )

(DR 3 )

(D R3)

24

J1 0 5

27

J1 0 5

Door speaker, LH side,


rear

Door
speaker, LH
side, rear

Double cabin

GY (R )

GY /R (R )

GY

GY /R

(DR4)

(DR 4 )

26

J1 0 4

Freestyle cabin / Stretch cabin


(with rear access)

Door speaker, RH
side, rear

22

L/ R
(F )

13

L/Y
#L/W

L/ R

L/ Y

#L

@L /W

@L

(DR 1 )

(D R1)

(D R2)

(D R2)

L/ R

J1 0 2

J1 0 4

J1 0 3

Door
speaker, LH
side, front

Door speaker,
RH side, rear
Double cabin

16

Door
speaker,
RH side,
front

14

with rear door speakers


J101

Audio unit

J102

(F )
1M

1K

L/ R

(F )
1E

1C

1A

R/ B

L /R

L/ W

L/ Y

L /W

R/ G

1N

1L

2I

(Short cord)
2C

2A
P/ L

3A
B

1J

1H

1F

1D

1B

2J

GY

GY /R

2H

2F

GY /L
2D

2B

Door speaker, LH side, front


(DR1)

J103

Door speaker, RH side, front


(DR2)

J104

Door speaker, RH side, rear


(DR4)

J105

Door speaker, LH side, rear


(DR3)

L/ Y
#L/ W

L/ Y
@L/ W

GY

GY

L/ R
#L

L/ R
@L

GY /R

GY /R

J-1

Harness symbol
(R)(DR4)

X22

Main fuse box

Door speaker, RH
side, rear
J104

Door speaker, LH
side, rear
J105

Door speaker, RH
side, front
J103

X01

[Double cabin]
(F)(DR2)

X16

X04
X24

(F)(R)

(FR)(DR3)
J102
Door speaker,
LH side, front

X13

71

(F)(DR1)
(F)(DR1)

X13

(R)(DR4)

X06

[Black]
Audio unit
J101
14

Audio unit
J101

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

X26

(F)(FR)

Door speaker, RH
side, rear
J104
Door speaker, RH
side, front
J103

(F)(DR2)
(FR)(DR3)

X16

X27

(F)(DR2)

X16
X03
Fuse block

X02
Ignition switch
J105
Door speaker,
LH side, rear

X04

X06

(F)(R)

(F)(FR)

X04
(F)(R)

J102
Door speaker,
LH side, front

X13
(F)(DR1)

X06
(F)(FR)

J-2

Audio Systems (without audio harness)


Battery
X

01

01

B/ L

(E )

(F )
M A IN 8 0 A

IG

K EY

1 40A

IG

K EY

2 40A

B/ W
(F )

ST

IG 2

03

IG 1

03

02

Ignition switch

OFF

OF F

AC C

02

W/ R
X

(F )
B T N 60A

03

03

R OOM 10A

L/ W

(F )

L/ R (F )

(F )
CI G A R 15A
J2 0 1

1C

1A

Audio unit
3A

2A

2B

2F

2H

P/L (F )

GY /L (F )

GY /R (F )

GY (F )

P/ L (F R )

G Y/ L (F R )

GY /R (R )

GY (R )

P/ L (F R )

GY /L (F R )

GY /R (R )

GY (R )

1L

1K

1N

1M
J2 0 1

72

GY /L

P/ L

(F R)

(F R )
X

24

GY

GY /R

GY /R

GY

(DR 3 )

(DR3)

(D R3)

(DR 3 )

J2 0 5

06

27

J2 0 5

GY

(DR 4 )

(DR4)

GY (R )

GY /R (R )

GY

GY /R

(DR4)

(DR 4 )

26

J2 0 4

Door speaker,
LH side, rear

Door speaker, LH
side, rear
Double cabin

GY /R

04

Door speaker, RH
side, rear
Freestyle cabin / Stretch cabin
(with rear access)

L/ W

L/ Y

L/ R

(F )

(F )

(F )

(F )

22

J2 0 4

Door speaker,
RH side, rear

J2 0 2

J2 0 3

Door speaker, LH
side, front

Door speaker, RH
side, front

Double cabin

14

with rear door speakers


J201 Audio unit (F)

J202 Door speaker, LH side, front


(F)
(F )

1M

(Short cord)

(F )

1K

1E

1C

1A

L/ R

R/B

L/R

L/W

L/ Y

L/W

R/G

1N

1L

2I

2C

2A
P/ L

3A
B

1J

1H

1F

1D

1B

2J

GY

GY /R

2H

2F

GY /L
2D

2B

J203 Door speaker, RH side, front


(F)

J202 Door speaker, RH side, rear


(DR4)

J205 Door speaker, LH side, rear


(DR3)

L/ W

L/ Y

GY

GY

L/ R

GY /R

GY /R

J-2

Harness symbol

(FR)(DR3)

Door speaker, RH
side, rear
J204

Main fuse box

X01

X24

(R)(DR4)

[Double cabin]

X22

X04
(F)(R)
J205
Door speaker,
LH side, rear

73

14

[Black]
Audio unit
J201

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

X06

(FR)(DR3)

(R)(DR4)

(F)(FR)

X27

X26
Door speaker, RH
side, rear
J204

Audio unit
J201

X03
Fuse block
J202
Door speaker,
LH side, front

X02
Ignition switch

X06
(F)(FR)

X04

J205
Door speaker,
LH side, rear

X04
(F)(R)

(F)(R)

X06
J203
Door speaker,
RH side, front

(F)(FR)

K-1

Power windows
# .. with

Battery
X

01

01

03

03

W/ R

(E )

rear power windows


Door entry switches
(Section I3)

(F )
M A IN 8 0 A

B T N 60A

B/ W
(F )
IG KE

Y2

40A

IG KE

Y1

40A

P / W 15A

31
G( F )

B/ L
X

OF F

ST

(F )

02

01

R/ Y (F )
X

Ignition switch

OF F

13

15

R/ L
IG 2

IG 1

(F )

AC C
X

Close

02

Open

03

03

13

G( D R 1)

R/ L

R/ L

R/ L

(F )

(F )

(F )

(D R1)

P .WI ND 30A

Close

with rear power windows

Open

K1 0 1

Close

Power
cutoff
switch

Open

Close

G /Y (DR1)

L/ W(DR 1)

W( DR1)

G /W (DR1)

G/ Y (F)

W(F )
X

07

06
X

05

23

R/ L(F R )

G Y (FR )
X

W(D R 3)

25

W(R)
X

L/W( DR3)

24

R /L (DR 3 )

Vc c

R/ L

R/ L

R/L

(R )

(F )

(F )

04

R /W( F )

W (DR4)

L/ W(D R 4)

22
G /W (DR2)

R/ L(DR4 )

18

R /W (DR 2 )

74

Close

K1 0 1

K1 0 2

Power window switch,


RH side
rear

Open

16

Close

K1 0 9

R /L( DR2)

K1 0 3

Open

Power window switch,


RH side
front

G/ B

R/ B

(DR1 )

(DR 1 )

with auto return function

K1 0 5

B
K1 0 4
G /B (D R 3)

K1 0 3
G /B (DR4 )

R/ B (DR3)

G /B (DR2 )

Close

Open

15

Power window motor,


right front

Close

Open

IC 1
X

K1 0 6

Power window
motor, RH side
rear

(DR 1 )

R/ B (D R 2)

K1 0 7

Power window
motor, LH side rear

Open

K1 0 2

R/B (DR 4)

K1 0 8

IC 2
Close

Open

B
(F )

Power window motor, left front

Close
6

with rear power windows


K101 Power window main switch (DR1)
B

#W/ R

#G/ Y

G /B

K102 Power window switch, RH side front (DR2)

#L/ W

#W

G /W

R/W

R/ L
R /B

R /L

R/ Y

K104 Power window switch, LH side rear (DR3)

R/ L

L/ W

R/ B

G/ B

R /B

G /B

K103 Power window switch, RH side rear (DR4)

R/ L

G /W

K106 Power window motor, right


front (DR2)

L/ W

K107 Power window motor, RH


side rear (DR4)

R/ B

G/ B

K108 Power window motor, LH


side rear (DR3)

G/ B

G/ B

G/ B

G/ B

R/ B

R/ B

R/B

R/ B

K109 Power window main switch Power window motor, left front

R /W

K105 Power window motor, left


front (DR1)

(Power window main switch)

(Power window motor, left front)


Note: This is the connector as seen from the
terminal side.

R/ L(F )

L/ W( R)

Power window switch,


LH side rear

Open

R/ L
(F )

K1 0 4

Close

15

L/ W( F )

G/ W(F )
W /R (FR )

Auto
circuit

R/ W(DR 1)
X

W /R (F)

Open

Power window control


unit

K1 0 1
W/R( DR1)

R/ Y (DR1)

K-1

Harness symbol
(R)(DR4)

Power window switch,


RH side front
K102

X22

Power window switch,


RH side rear
K103

(F)(DR4)
[Blue]
Power window
motor, right front
K106

Main fuse box

X01

X23

(F)(DR2)

X16
(F)(DR2)

[Double cabin]

X18
K107
Power window
motor, RH side
rear

X04
K108
Power window motor, LH side
rear
K104
Power window switch, LH
side rear

(F)(R)

K101
Power winX25
dow main
switch
(FR)(DR3)
K109
X24
Power window main
(FR)(DR3)
switch Power window
motor, left front

X05
(F)(R)

X13
(F)(DR1)

X15
(F)(DR1)

75

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

(F)(DR1)
(F)(DR1)

X13

X06
X07

(F)(FR)

(F)(FR)

K105
Power window motor,
left front
[Blue]

[Blue]
Power window
motor, right front
K106

X15
(F)(DR2)

X16
(F)(DR2)

X03

X18

Fuse block
(F)(DR2)

X02

X16

Ignition switch

X04

X07

(F)(R)

(F)(FR)

X06

X18

(F)(FR)

(F)(DR2)

X04
(F)(R)

X05
(F)(R)

K101
Power window
main switch

K109
Power window main switch
Power window motor, left front
K105
Power window
motor, left front
[Blue]

X13
(F)(DR1)

X15
(F)(DR1)

X06
(F)(FR)

K102
Power window
switch, RH side
front

K-2a

Central door locking


Battery
X

01

01
W/ R
(F )

M A IN 80A

03

B
(E )

03
W/ G
(F )

B T N 60A

D/ L 30A

K2 0 1
A

Door lock timing unit


N

G/ R

G/ O

(F )

(F )

F
K2 0 1

15

with keyless
entry

(F )

LG/ R (F )

G/ R

G/ O

(DR1)

(D R1)
K2 0 2

Lock

Unlock

Door lock
switch

Remote keyless entry


module
(Section I4)

K2 0 2

76

B
(DR 1 )

with keyless entry


X

B
(F )

K201 Door lock timing unit (F)

K202 Door lock switch (DR1)


with keyless
entry

G/ R

without keyless
entry

MK

B
G/ O

G/O
L

W/G

LG/ R

R
G/ R

G/ R

G/ O

15

33

K-2a

Harness symbol

[Double cabin]
Main fuse box

X01

K202
Door lock switch

77

(F)(DR1)

X15

X03

Door lock timing


unit
K201

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

X15
(F)(DR1)

Fuse block

K202
Door lock switch

X15
(F)(DR1)

K-2b

Central door locking


G

(F )

(F )

(F )

G
(F )

K2 0 1

(F )

(F )

G
(F )
X

Door lock timing unit

07

G
X

(F R)

15
X

K2 0 1

G
(DR 2 )

K2 0 2

with keyless entry

23

(R )

G
(D R4)

K2 0 4

Door lock
motor, RH
front

Unlock

25

(DR3)

K2 0 3

Door lock
motor, LH
front

05

18
X

(D R1)

K2 0 5

Door lock
motor, LH
rear

Unlock

Door lock
motor, RH
rear

Unlock

Unlock

R
(F )

Lock

Lock

K2 0 2

78

(D R1)

(DR2 )

R
(D R4)

(F )

K202 Door lock motor, LH front


(DR1)

I
M

K203 Door lock motor, RH front


(DR2)

05

(F )

(F )

K204 Door lock motor, LH rear


(DR3)

K205 Door lock motor, RH rear


(DR4)

G/O
L

(F )

K
G/ R

(F )

23

(R )
07

K201 Door lock timing unit (F)

25

(F R)

(F )

with central locking, rear

18

15

Lock
K2 0 5

(DR3)
X

X
X

Lock
K2 0 4

K2 0 3

LG/ R
J

W/G

G
D

B
G

G/ R

G /O

K-2b

Harness symbol
Door lock motor,
RH rear
K205
Door lock timing
unit
K201

(F)(DR1)

(R)(DR4)

Door lock motor,


RH front
K203

X23

X15

[Double cabin]
(F)(DR2)

X18
(F)(R)

X05

X07

K204
Door lock motor, LH rear

(F)(FR)

X25

X18

(FR)(DR3)
K202
Door lock motor,
LH front

(F)(DR2)

79

X15
X05

(F)(DR1)

X07

(F)(R)

(F)(FR)

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

Door lock motor,


RH front
K203

(F)(DR2)

X18

K202
Door lock motor,
LH front

X15
(F)(DR1)

Power mirrors
Battery
X

01

# ..

01

with power windows

B/ L

(E )

(F )
IG KE

M A IN 8 0 A

Y1

40A
B/ W
(F )

IG KE

Y2

40A
ST

Power mirror switch

IG 2
X

03

L/ W
Up

Down

Up

Right

Down

L01
Right

Left

Select RH mirror

Select RH
mirror

Select LH mirror

Select LH mirror

L01
BR

LG/ B

BR /B

L/ B

(F )

(F )

(F )

(F )

BR /Y
(F )

BR

BR

(F )

(F )

17

80

L/ B

BR /Y

BR

(D R2)

(DR2)

(D R2)

L03

LG/ B

BR /B

#L /B

#B R/ Y

(DR1)

(DR1)

14

BR

(DR 1 )

(F )

L02

Power mirror,
RH

M2
M1

Power mirror, LH

M2

Left/right

M1

Up/down

Left/right

Up/down

Right

Left

Right

Left

Up

Down

Up

Down
5

L01 Power mirror switch (F)


BR
B

L/ W

L02 Power mirror, LH (DR1)


LG/ B

L/ B

BR /Y

BR /B
LG/ B
#L/ B
BR/B
#B R/ Y

BR

L03 Power mirror, RH (DR2)

L/ B
BR /Y

B
R

(F )
CI G A R 15 A

02

OF F

IG 1

AC C

03
L

(F )

Left

OFF

02

Ignition switch

Harness symbol

Power mirror,
RH
L03

Main fuse box

X01

[Double cabin]

(F)(DR2)

X17

81

X14

L02
Power mirror,
LH

(F)(DR1)
(F)(DR1)

X14

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

Power mirror,
RH
L03
(F)(DR2)

X17
L01
Power mirror
switch
[Grey]

X03
Fuse block

X02
Ignition switch

X17
(F)(DR2)

X14
(F)(DR1)

L02
Power mirror,
LH

AntiLock Control 4Wheel


Battery
X

01

01
B/ L

B
MA IN 80 A

IG

KE Y

Data Link Connector


(DLC)
(Section U1, U2)

Yaw rate acceleration sensor

(F )

(E )

1 40A
C

B/ W
(F )

IG

KE Y

06

2 40A
X

OFF

ST

02

Ignition switch

OF F

(R)

L/ R

(F 2)

IG 2

ABS 6 0 A

IG 1

38

39

40

G/ B

Y/ R

V/ Y

(F )

(F )

(F )

B/ W

04

G/ W

W/ L

(R )

(R )

AC C

B/ W (F )
X

02
X

03

03

B/ W

(F )

(F )
E N GI NE 15A

L/ R

L/ R

(F 2)

(F 2)

21

11

12

B/ W (F )
X

11

G/ W
(F 2)

W/ L
(F 2 )

G/ B
(F 2 )

Y/ R
(F 2)

V/ Y
(F 2)

B/ W (F 2 )
O

AB

AC

AA

AD

ABS control
module

BR /W

BR /R

BR /Y

BR

(F 2)

(F 2 )

(F 2)

(F 2)

W
O

(F 2)

(F 2 )

(F 2 )

(F 2)
X

82

(F 2)

(F 2)

12

BR /W

BR /R

BR /Y

BR

(R)

(R)

(R )

(R )

(F )

(F )

(F )

BR /W

BR /R

BR /Y

BR

(R2)

(R 2)

(R 2)

(R 2)

02

03

04

W/ G

LG

(F 2)

(F 2)

12

20

LG

(F )

(F )

05
28

Wheel speed sensor, RH


side front

Wheel speed sensor, LH


side front

Wheel speed sensor, LH


side rear

11

W/ G

Stop lamp
switch
(Section F3)

01

21
X

G
(F )

01

17

Instrument
cluster
(Section Cb)

Wheel speed sensor, RH


side rear

O02 Wheel speed sensor, LH


side front (F)

O01 ABS control module (F2)


W

AC

AA

L/ R

L/ R

W/ G

G/ B

W/ L

BR /Y

LG

Y/ R

AD

AB

AC

AA

AD

AB

G/ W

V/ Y

L
H

O05 Wheel speed sensor, RH


side rear (R2)

O04 Wheel speed sensor, LH


side rear (R2)

BR /R

O06 Yaw rate acceleration sensor (R)

BR
BR

B/ W

O03 Wheel speed sensor, RH


side front (F)

BR /R

BR /W

BR /Y
B/ W

G /W

W /L

B R /W

Harness symbol
(R)(R2)

X20

[Grey]
ABS control module
O01
Main fuse box

[Grey]
Wheel speed sensor, RH side rear
O05

X01

[Double cabin]

(R)(F2)

X21

O04
Wheel speed
sensor, LH side
rear
[Grey]

X04

83

O03
Wheel speed
sensor, RH side
front
[Grey]

(F)(R)
O06
Yaw rate acceleration sensor
[Black]

O02
Wheel speed
sensor, LH side
front
[Grey]

(R)(R2)

X20
[Grey]
Wheel speed sensor, RH side rear
O05

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

X03
Fuse block
O04
Wheel speed
sensor, LH side
rear
[Grey]

X21

X02
9

Ignition switch

(F2)(R)

(R)(F2)

X21

X12

X04

(F)(F2)

(F)(R)

X11
(F)(F2)

X04
(F)(R)

O06
Yaw rate acceleration sensor
[Black]

Heated seats
Battery
X

01

# ..

01

B/ L

(E )

(F )
M A IN 8 0 A

IG KE

Y1

40A
B/ W
(F )

IG KE

Y2

40A

OF F

ST

IG 1

AC C

IG 2
X
P

01

01

BR /B

BR /Y

(F )

(F )

03

W
(F )
S .WA RM 15A

BR /B (F )

BR /B (F )

06

Heated seat
switch

04

BR /W

BR /B

#B R/ B

(F R)

(R)

03

02

Seat cushion
heater, RH
front

Seat cushion
heater, LH
front

84

03

B
(F )

02

B( R )

B( F R )

04

B( F )

10

P01 Heated seat switch (F)


BR /B
B

P02 Seat cushion heater, RH


front (R)

P03 Seat cushion heater, LH


front (FR)

BR /W
#B R /B

BR /B

BR /Y

03

02

OF F

02

Ignition
switch

Regular cabin

Harness symbol

Main fuse box

X01

[Double cabin]

P03
Seat cushion
heater, LH front

X04
(F)(R)
10

P02
Seat cushion
heater, RH front

85

[Blue]
Heated seat switch
P01

X06

[Regular cabin / Stretch cabin


(without rear access)
Freestyle cabin / Stretch cabin
(with rear access)]

X03

(F)(FR)

Fuse block

X02
Ignition switch
P03
Seat cushion
heater, LH front

X06
X04

(F)(FR)

10

(F)(R)
P02
Seat cushion
heater, RH front

X04
(F)(R)

X06
(F)(FR)

Wiring Diagram

Air Bags
Service Warnings
Component Disassembly
D Disassembling and reassembling the components of
the air bag system can render the system inoperative,
which may result in serious injury or death in the
event of an accident. Do not disassemble any air bag
system component.

Air Bag Handling


D A live (undeployed) air bag may accidentally deploy
when it is handled and cause serious injury. When
carrying a live (undeployed) air bag, point the front
surface away from your body to lessen the chance of
injury in case it deploys.

RIGHT
Wiring Harness Repair
D Incorrectly repairing an air bag system wiring harness
can accidentally deploy the air bag, which can cause
serious injury. If a problem is found in the system
wiring, replace the wiring harness. Do not try to repair
it.

D A live (undeployed) air bag placed face down on a


surface is dangerous. If the air bag deploys, the
motion of the air bag can cause serious injury. Always
face the front surface up to reduce the motion of the
air bag in case it accidentally deploys.

RIGHT

Air Bags Service Warnings

WRONG

Air Bag Inspection


D Inspecting an air bag using an ohmmeter can deploy
the air bag, which may cause serious injury. Do not
use an ohmmeter to inspect an air bag. Always use
the on-board diagnostic function to diagnose the air
bag for malfunctions. (Refer to ON-BOARD
DIAGNOSTIC FUNCTION; AIR BAG SYSTEM.)

86

WRONG

Wiring Diagram

Air Bag Module Handling


D Disconnecting the air bag module connector or
removing the air bag module with the ignition switch
in the ON position can cause the air bags to deploy,
which may seriously injure you. Before disconnecting
the air bag module connector or removing the air bag
module, turn the ignition switch to the LOCK position,
then disconnect the negative battery cable and wait
for more than 1 minute to allow the backup power
supply of the air bag module to deplete its stored
power.
D Connecting the air bag module connector without
firmly installing the air bag module to the vehicle is
dangerous. The crash sensor inside the module may
send an electrical signal to the air bags. This will
deploy the air bags, which may result in serious injury.
Therefore, before connecting the connector, firmly
mount the module to the vehicle.
D For vehicles with a single point sensor, once an air
bag is deployed due to an accident or other causes,
the air bag module must be replaced with a new one
even if the used one does not have any external signs
of damage. The used air bag module may have been
damaged internally, which may cause improper
operation, resulting in major injuries or even death.
The used single point air bag module cannot be
benchchecked or selfchecked.
Component Handling
D Oil, grease, water, etc. on components may cause the
air bags to fail to deploy in an accident, which may
cause serious injury. Do not allow oil, grease, water,
etc. on components.
D Inserting a screwdriver etc. into the connector of an
air bag may damage the connector and cause the air
bag to deploy improperly, which may cause serious
injury. Do not insert any foreign objects into the
connector.

Air Bags Service Warnings

Component Reusing
D Even if an air bag does not deploy in a collision and
does not have any external signs of damage, it may
have been damaged internally, which may cause
improper operation. Improper operation may cause
serious injury. Always selfcheck the undamaged air
bag to determine whether it can be reused. (Refer to
ON-BOARD DIAGNOSTIC FUNCTION, AIR BAG
SYSTEM.)

87

S-1

Air bags
Battery
X

01

01

B/ L

(F )

(E )
M A IN 80A

IG

KEY

1 40A
B/ W
(F )

IG

KEY

2 40A
OF F

ST

Driver air bag


unit

Passenger air
bag unit
Inflator

IG 2

02

OF F

Ignition
switch

ACC

IG 1

Inflator

Shorting bar

Y/ R

Y/ R
(F )

03

S1 0 5

S1 0 4

02

W( F )

Shorting bar

(F )

Clock spring

EN G IN E
15A

ME T E R
15A

Y/ B

S1 0 3

B/ Y( F )

B/ W (F )

B/ Y( F )

B/ W (F )

AB

03

S1 0 2
L( F )

LG(F )
S1 0 1

Air bag module


X

S
S1 0 1

88

Y/ G (F )

Shorting bar

S1 0 2
Y/ G (F )
B

(F )

(F )
34

Instrument
cluster
(Section Cb)
5

S101 Air bag module (F)

S102 Shorting bar connector (F)

S103 (F) Clock spring


(Clock spring)

(F )

W
AA

Y/G

LG

Y/R

B/ Y

B /W

AB

G /R

B /Y

B/ W

Y /G

Y/ G

S104 Passenger air bag unit (F)


V

B /W

B/ Y

G /R

LG

Y /R

S105 Driver air bag unit (Clock spring)

Y/ B
Y/ R

Y /R

Y /B

S-1

Harness symbol

Main fuse box

X01

89

[Yellow]
Passenger air
bag unit
S104

S103
(F) Clock
spring
[Yellow]

X03
S105
Driver air bag
unit

Shorting bar
connector
S102

Fuse block

X02
Ignition switch
S101
Air bag module

Immobiliser system
Battery
X

01

# ..

01

B/ L

(E )

(F )
M A IN 8 0 A

IG

KEY

1 40A

IG

KEY

2 40A

Euro 3

B/ W
(F )
X

03

03

02

L/ R

W/ R

(F )

(F )
B T N 60A

OF F

ST

OF F

Ignition switch

R OOM 10A
L/ R

IG 2

IG 1

AC C

(F )
T

03

X
X

Keyless
switch

Euro 3
T

03
W

E N GI NE 15A

03
B/ W (F )
T

Immobiliser module
F

(F )

L/ R (F )

P( F )

03

02

01

C
T

W(F )

B/ R

B/ R
(F )

(F )

90

R
(F )

Y
(F )

BR /B

B2 0 9

GY
(F )
X

(F )
T

Starter relay
(Section A)

28

Fuel pump

Euro 3

(F )

B2 0 9

14
B/ R
(F )

Coil

B/ R (F )

Powertrain control module


(PCM)
(Section B3b)

T01 Immobiliser module (F)

T02 Coil (F)

T03 Keyless switch (F)

B209 Fuel pump (F)


C

B/ R

L/R
C

BR /B

B/ W

L /R

#P

GY

GY

R/ L

B /R

G /W

B /W

BR /W

L/ B

B /R

W
F

Euro 2

DD S 1

02

16

Instrument
cluster
(Section Ca)

01

B
F

Harness symbol
[Grey]
Fuel pump
B209

[Euro 1, Euro 2]
3

Main fuse box

X01

Coil
T02
Joint connector

X28

X03
Fuse block

91

X02
Ignition switch
T03
Keyless switch

[Euro 3]
3

Main fuse box

X01

T01
Immobiliser
module

U-1

Data Link Connector (DLC) (Euro 1)


Battery
X

01

# ..

01
B/ L

% ..

(F )

(E )
M A IN 8 0 A

IG KE

Y1

40A

IG KE

Y2

40A

B/ W
(F )
X

OF F

ST

IG 2

IG 1

AC C

X
X

03

03

B/ Y
(F )

W
(F )
M E T E R 15A

39

Y/ R
(F )

ABS control
module
(Section O)

38

G/ B
(F )

AntiLock Control
4Wheel

B/ R
(F )

Instrument
cluster
(Section Cb)

35

Y/ G
(F )

92

with air bag


V/ Y
(F )

U101
Data Link
Connector
(DLC)

B
(F )

U101 Data Link Connector (DLC) (F)

KL N

+B

GN D
TB S

FA B

B/ Y

%Y/ R
B/R

%G /B
GN D

#Y /G
BU SB

Note: This is the connector as seen from the terminal side.

%V /Y

40

ABS control
module
(Section O)

AntiLock Control
4Wheel

02

OF F

02

Ignition
switch

with air bag


AntiLock Control
4Wheel

U-1

Harness symbol

Main fuse box

X01

[Grey]
Data Link Connector (DLC)
U101

93
2

X03
Fuse block

X02
Ignition switch

U-2

Data Link Connector (DLC) (Euro 2, Euro 3)


Battery
X

01

# ..

01

with air bag

B/ L

(F )

(E )

IG

M A IN 8 0 A

KE Y

1 40A
B/W
(F )

IG

Euro 3
Powertrain control
module (PCM)
(Section B3b)

KE Y

2 40A

ST

IG 2

13

11

12

IG 1

03

03
W
(F )

M E T E R 15A

W/ L(F )

Y/ R
(F )

B/ Y

BR /R

(F )

(F )

ABS control
module
(Section O)

38

G/ B
(F )

B/ R
(F )

Instrument cluster
(Section Cb)

35

Y/ G
(F )

94

with air bag


V/ Y
(F )

U201
Data Link Connector (DLC)
B
(F )

U201 Data Link Connector (DLC) (F)

FE N

KLN

TE N

+B

GN D

B/ Y

B/ Y

B/ R
TB S

FA B

BR /R

Y/ R

IG

G/ B

GN D

#Y /G
BU SB

Note: This is the connector as seen from the terminal side.

W/ L

B
V/ Y

AC C

X
X

Y/ R (F )

OF F

10
B/Y
(F )

39

02

Ignition switch
Powertrain control module (PCM)
(Section B2b, B3b)

OF F

40

ABS control
module
(Section O)

02

U-2

Harness symbol
[Euro 2]

Main fuse box


[Grey]
Data Link Connector (DLC)
U201

X01
1

X03

95

Fuse block

X02

[Euro 3]

Ignition switch

Main fuse box

X01

[Grey]
Data Link Connector (DLC)
U201

X-1

Connectors
X01 Main fuse box
#... Euro 3
... with fuel heater

(E )
(E )

<3 0A

60A

40A

40A

B/ W

A
60A

80A
7

30A

60A

B /L

W /R

G/ B

L/ R
J

A
B/ W

#2 0A

(F 2)

(F )

X02 Ignition switch (F)

#L /W
G

R/ W

R /B

B/ L

B/ Y

B/ W

B/R

( )... if equipped
1

MAIN

IG KE

IG KE

BT N

(F IP /I N J)

Y2

(P T C )

H EAD

Y1

(A B S )

(G LO W)

96

X03 Fuse block (F)


#... without power windows,
without central locking

W/ R

R/ Y

10A

LG/ R

W/ G
#

30A

10A

L/ Y

G
#

15A

20A

10A

R/ G

W/R
#

B/ R

40A

17

10

11

20A

15A

L /W

(A /C )

12

HA Z A R D

13

(S .W A R M )

18

(R .D E F OG)

14

ME T E R

19

(R .F OG)

15

E N GI N E

20

HE A D

16

W IPER

12
R/ W

20A

15A

W/ R

G/ W

5
BR /Y

15A

B/ Y

15A

13
B/ R

10A

Y/ R

10A

L/ R

B/ W

15A

15A

Note: This is the connector


as seen from the terminal
side.

10A

21

ST O P

17

(HE A T E R)

TA IL

18

CI G A R

R OOM

19

(D /L )

20

10

(P /W )

21

(A /C 2 )

(A B S )

22

(P .WI ND)

14

15

16

W
#

30A

R/L
#

22

11

( )... if equipped

X-2

Connectors
X04 (F) (R)

#... Regular cabin


@... with rear door speakers
%... with rear power windows
&... not used
(F )

(R )

C
%/R/L
B/W

R/L

W/G

R/W

B/L

BR /B

W/L

G/W

R/Y

GY/R

B/R

B/R

GY

G/B

%... with rear power windows


&... with power locks, rear

X05 (F) (R)

(F )

@GY/R

R/W

R/Y

&GY/R

@G Y

G/B

G/W

R/B

W/G
BR / W
#BR / B

R/L
B/L

A
%R /L
B/ W

X06 (F) (FR)

@... with rear power windows


#... with rear door speakers
%... Freestyle cabin / Stretch
cabin (with rear access)

(R)
(F )

L/ W

%W

&G

%L /W

&R

97

@... with rear power windows


%... with power locks, rear

@R /L
BR /B

X07 (F) (FR)

(F R )

GY/L

R/Y

%B

P/L

@R/L

#P/L

R/Y

#GY/L

X08 (F) (E)

#... Euro 3
@... Euro 1, Euro 2, not cold
area
(F )

(F )

B/Y

G/Y

@G Y

X09 (F) (E)

%G

W
#

L/ W
B/Y
#B /L

L/W

X10 (F) (IN)

(E )
(I N)

(F )

#GY/R
%G/B
%BR/B

W/B
Y/R
%G/Y

B/R
W
#

B/L
@B/Y

%R

%... Euro 3
#... with remote freewheel control system
(F )

B/R

BR/Y

@W/R
R/W

(E )

(F R )

W/R

R
G

%BR/W

#R/G
#LG/B
%V

#R/G
#LG/B
%V

BR /B

W/B

Y/R

%BR/W

%G /Y

#GY/R
%/G/B
%BR/B

L/R

R /Y

R/Y

L /R

R/W

BR/Y

B/Y

X-3

Connectors
X11 (F) (F2)

X12 (F) (F2)

#... not used

X13 (F) (DR1)


#... with power windows

(F )

(F )

(F 2)

LG

B /W

B/ W

#B

G/ B

G/ B

LG

Y/ R

Y /R
G

(F )

(F 2)

W/G

V/Y

V/ Y

W /G

(DR1)

R/ L

L/ W

L/ R
#L

#R/ L

#G

L/ Y
#L/ W

X15 (F) (DR1)

X14 (F) (DR1)

@... with rear power windows


%... with keyless entry
&... with power windows

#... with power windows


(F )

(DR1)
(F )

L/B

BR/Y

BR

BR

BR/B
#BR/Y

LG/B
#L/B

G/ Y

G
R/ Y

W/ R

98

X17 (F) (DR2)

X16 (F) (DR2)

(DR 1 )

G/ W
B

R/W

G/ O

L/ W
G/ R

@L/ W

@W

& G /W
G/ R

R/ L

L/ R
@L

(F )

(F )

@W/ R &R /Y

%R

#R/ L

LG/ B

B R /B

BR

BR

BR /Y

L/ B
R/ W

X20 (R) (R2)

X19 (R) (R2)

(DR 2 )

(DR2)

L/ Y
@L/ W

L/Y

@... with power windows

(D R2)

L/ R

%G

@G /Y
&R /W

X18 (F) (DR2)

#... with power windows


@... with central locking

(F )

G/ O

G /W

@G/W

@R/W

X21 (R) (F2)

@... not used

(R2)
(R)

@G/R

G/ B

G /W

(R)

R/L
R /W

R /B

W /G

G /B

R/ L
B /R

B/R

W /G

(R )

(R 2 )

R /B

R /W

G /W

BR /Y
Y

BR/Y

BR

BR/W B R /R

BR /R

BR /W

BR

BR /Y

BR

B R /W

BR /R

(F 2 )

G/ W

G/ W

W/ L

W/ L

BR/Y
BR /R

BR/W

BR

X-4

Connectors
X22 (R) (DR4)

X23 (R) (DR4)


#... with rear door speakers

#... with rear power windows


(D R4)

(R)
(DR4 )

(R)

GY

GY/R

R /L

R /L

#G Y

#GY/R

X24 (FR) (DR3)

L/W

#L/ W

#W

X25 (FR) (DR3)


#... with rear door speakers

#... with rear power windows


(DR 3 )

(F R)
(DR3)

(F R)

P/ L

GY /L

R/L

R /L

#G Y

GY

W/R

#L/ W

#GY/R

99

X26 (R) (DR4)

#W

X27 (FR) (DR3)

(R )

(F R)

(DR4)

R/Y

GY

GY

GY/R

R /Y

R/ Y
P/ L

GY/R

(D R3)

GY/L

GY

X28 Joint connector (F)

B/ R

B/ R

B/ R

B /R

B/ R

B /R

B/ R

R /Y
GY/R

Parts index
Heater panel illumination lamp . . . . . . . . . . . 64
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Horn relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Idle switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Illumination dimmer . . . . . . . . . . . . . . . . . . . . . 64
Immobiliser module . . . . . . . . . . . . . . . . . . . . . 90
Instrument cluster . . . . . . . . . . . . . . . . 36, 38, 40
Intake air control valve . . . . . . . . . . . . . . . . . . 28
Intake air temperature sensor . . . . . . . . . 30, 32
Interior lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Keyless switch . . . . . . . . . . . . . . . . . . . . . . . . . 90
Licence plate lamps . . . . . . . . . . . . . . . . . . . . 46
Lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mass Air Flow (MAF) sensor . . . . . . . . . . . . . 32
Neutral position switch . . . . . . . . . . . . . . . . . . 28
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . 38
Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Park brake switch . . . . . . . . . . . . . . . . . . . . . . 38
Parking Lamps . . . . . . . . . . . . . . . . . . . . . . . . . 46
Passenger air bag unit . . . . . . . . . . . . . . . . . . 88
PCM module relay . . . . . . . . . . . . . . . . . . . . . . 28
Power mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Power mirror switch . . . . . . . . . . . . . . . . . . . . 80
Powertrain control module
(PCM) . . . . . . . . . . . . 20, 22, 24, 26, 28, 30, 32
Power window main switch . . . . . . . . . . . . . . 74
Power window motors . . . . . . . . . . . . . . . . . . 74
Power window switches . . . . . . . . . . . . . . . . . 74
Pump speed sensor . . . . . . . . . . . . . . . . . 20, 24
Rear fog lamp . . . . . . . . . . . . . . . . . . . . . . . . . 50
Rear fog lamp relay . . . . . . . . . . . . . . . . . . . . . 50
Rear fog lamp switch . . . . . . . . . . . . . . . . . . . 50
Rear window heater grid . . . . . . . . . . . . . . . . 62
Rear window heater relay . . . . . . . . . . . . . . . 62
Rear window heater switch . . . . . . . . . . . . . . 62
Remote freewheel control module . . . . . . . . 60
Remote freewheel main switch . . . . . . . . . . . 60
Remote freewheel switch . . . . . . . . . . . . . . . . 60
Remote keyless entry module . . . . . . . . . . . . 68
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Reversing lamps . . . . . . . . . . . . . . . . . . . . . . . 54
Reversing lamps switch . . . . . . . . . . . . . . . . . 54
Sedimentor switch . . . . . . . . . . . . . . . . . . . . . . 38
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 72
Speedometer sensor . . . . . . . . . . . . . . . . . . . 36
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Stop Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Stop lamp switch . . . . . . . . . . . . . . . . . . . . . . . 56
Tail lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TDC sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Transfer neutral switch . . . . . . . . . . . . . . . . . . 60
Wheel speed sensors . . . . . . . . . . . . . . . . . . . 82

4x4 Mode switch . . . . . . . . . . . . . . . . . . . . . . . 60


A/C Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . 58
A/C Compressor clutch . . . . . . . . . . . . . . . . . 58
A/C pressure switch . . . . . . . . . . . . . . . . . . . . 58
A/C Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
A/C switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ABS control module . . . . . . . . . . . . . . . . . . . . 82
Accelerator pedal position sensor . . . . . . . . 30
Air bag module . . . . . . . . . . . . . . . . . . . . . . . . . 88
Audio illumination . . . . . . . . . . . . . . . . . . . . . . 64
Audio unit . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 72
Blower assembly . . . . . . . . . . . . . . . . . . . . . . . 58
Blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Boost pressure sensor . . . . . . . . . . . . . . . . . . 30
Brake fluid sensor . . . . . . . . . . . . . . . . . . . . . . 38
Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cluster illumination . . . . . . . . . . . . . . . . . . . . . 64
Clutch switch . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Coolant temperature sensor . . . . . . . . . . . . . 36
Data Link Connector (DLC) . . . . . . . . . . . 92, 94
Daytime Running Lamps (DRL) relay . . . . . 44
Direction indicators . . . . . . . . . . . . . . . . . . . . . 52
Direction indicator switch . . . . . . . . . . . . . . . . 52
Door entry switches . . . . . . . . . . . . . . . . . 66, 76
Door lock motors . . . . . . . . . . . . . . . . . . . . . . . 78
Door lock timing unit . . . . . . . . . . . . . . . . . 76, 78
Driver air bag unit . . . . . . . . . . . . . . . . . . . . . . 88
EGR valve position sensor . . . . . . . . . . . . . . 30
Engine Coolant Temperature
(ECT) sensor . . . . . . . . . . . . . . . . . . . . 20, 24, 30
Exhaust Gas Recirculation
(EGR) valve . . . . . . . . . . . . . . . . . . . . . . . . 26, 28
FICD solenoid valve . . . . . . . . . . . . . . . . . 20, 24
Flasher unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Free solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel pump/fuel gauge sender . . . . . . . . . . . . 36
Fuel pump . . . . . . . . . . . . . . . . 24, 28, 30, 32, 90
Fuel shutoff valve . . . . . . . . . . . . . . . . . . . . . . 20
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Glow plug relay . . . . . . . . . . . . . . . . . . 20, 24, 28
Glow plugs . . . . . . . . . . . . . . . . . . . . . . 20, 24, 28
Hazard flasher switch . . . . . . . . . . . . . . . . . . . 52
Hazard flasher switch illumination . . . . . . . . 64
Headlamp levelling motors . . . . . . . . . . . . . . 48
Headlamp levelling switch . . . . . . . . . . . . . . . 48
Headlamp relay . . . . . . . . . . . . . . . . . . . . . . . . 44
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Headlamp switch . . . . . . . . . . . . . . . . . . . . . . . 44
Heated seats . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Heated seat switch . . . . . . . . . . . . . . . . . . . . . 84
Heater control module . . . . . . . . . . . . . . . . . . 58

100

Windshield washer pump motor . . . . . . . . . .


Windshield wiper motor . . . . . . . . . . . . . . . . .
Wiper/washer switch . . . . . . . . . . . . . . . . . . . .
Yaw rate acceleration sensor . . . . . . . . . . . .

42
42
42
82

101

Z
SECTION TITLE

RANGER
2000 2002
Right-hand-drive
(RHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.

SECTION

General Information

GI

Ground points

Schematic

System circuit diagrams /


Component Location Views

A~U

Connectors

Parts index

PI

As all information in this manual was the best


available at the time of printing, vehicle
specification an other information will be updated
in Service Information.
Ford Motor Company

APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN) and
related materials shown on the following page.

E 2002 Ford Motor Company


All rights reserved. Reproduction by any means,
electronic or mechanical including photocopying,
recording or by any information storage and retrieval
system or translation in whole or part is not permitted
without written authorisation from Ford Motor Company.

Z
Vehicle identification numbers (VIN)
(Chassis numbers)
WF0
WF0
WF0
WF0
WF0

LMBD20*W 100001LMBE40*W 100001LMDD20*W 100001LMDE40*W 100001LMFE40*W 100001-

Note:
Euro 3 regulation models (WL3, WLT3 engines) are equipped with an EGR cooler in
the engine compartment.
Non Euro 3 regulation models are not equipped with an EGR cooler in the engine compartment.

EGR cooler

Wire colours
Colour

Code

Colour

Code

Black

Orange

Blue

Pink

Brown

BR

Purple

Dark blue

DL

Red

Dark green

DG

Sky blue

Green

PU
R
SB

Tan

Grey

GY

Violet

Light blue

LB

White

Light green

LG

Yellow

Natural

TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . Z2
GROUND POINTS (WL, WL TURBO,
BEFORE MODEL YEAR 2002) . . . . . . . . . . . . . . Z12
GROUND POINTS (F2 CARB) . . . . . . . . . . . . . . . Z14
GROUND POINTS (WL3, WLT3, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . Z16
SCHEMATIC ( WL, WL TURBO, BEFORE
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . Z18
SCHEMATIC (F2 CARB) . . . . . . . . . . . . . . . . . . . . Z19
SCHEMATIC (WL3, WLT3, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . Z20
ENGINE-RELATED SYSTEMS
STARTING SYSTEM / CHARGING
SYSTEM (WL, WL TURBO, BEFORE
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM / CHARGING
SYSTEM (F2 CARB) . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM / CHARGING
SYSTEM (WL3, WLT3, AS OF MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWERTRAIN (WL: GENERAL SPECS) /
QUICKSTART SYSTEM (WL) . . . . . . . . . . .
POWERTRAIN (WL: U.K. SPECS, WL
TURBO) / GLOW SYSTEM (WL, WL
TURBO, BEFORE MODEL YEAR 2002) . . .
IGNITION SYSTEM (F2 CARB) . . . . . . . . . . .
POWERTRAIN / IGNITION (F2 CARB) . . . .
FUEL CONTROL SYSTEM . . . . . . . . . . . . . . .
POWERTRAIN CONTROL SYSTEM /
GLOW SYSTEM (WL3, WLT3, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . .

Z21
Z23

Z25
Z27

Z31
Z35
Z37
Z39

Z41

CHASSIS-RELATED SYSTEMS
REMOTE FREEWHEEL CONTROL
SYSTEM (BEFORE MODEL YEAR 2002) . . Z91
REMOTE FREEWHEEL CONTROL
SYSTEM (WL3, WLT3, AS OF MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z93
INSTRUMENT CLUSTER-RELATED SYSTEMS
INSTRUMENT CLUSTER (WL, WL
TURBO, BEFORE MODEL YEAR 2002) . . . Z47
INSTRUMENT CLUSTER (F2 CARB) . . . . . . Z53
INSTRUMENT CLUSTER (WL3, WLT3,
AS OF MODEL YEAR 2002) . . . . . . . . . . . . . . Z57
BODY-RELATED SYSTEMS
WINDSCREEN WIPER / WASHER
(BEFORE MODEL YEAR 2002) . . . . . . . . . . . Z63

WINDSCREEN WIPER / WASHER (AS OF


MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . Z65
HORNS (BEFORE MODEL YEAR 2002) . . . Z79
HORNS (AS OF MODEL YEAR 2002) . . . . . Z83
REAR WINDOW DEFROSTER . . . . . . . . . . . Z97
POWER WINDOWS (REGULAR CAB,
STRETCH CAB) . . . . . . . . . . . . . . . . . . . . . . . Z103
POWER WINDOWS (DOUBLE CAB) . . . . . Z105
POWER DOOR LOCKS . . . . . . . . . . . . . . . . Z107
POWER OUTSIDE MIRRORS . . . . . . . . . . . Z109
AIR BAG SYSTEM SERVICE
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . Z111
AIR BAG SYSTEM (BEFORE MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . Z113
AIR BAG SYSTEM (WL3, WLT3, AS
OF MODEL YEAR 2002) . . . . . . . . . . . . . . . . Z115
IMMOBILISER SYSTEM (BEFORE
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . Z117
THEFTDETERRENT SYSTEM
(BEFORE MODEL YEAR 2002) . . . . . . . . . . Z119
IMMOBILISER SYSTEM (WL3, WLT3,
AS OF MODEL YEAR 2002) . . . . . . . . . . . . . Z121
THEFTDETERRENT SYSTEM (WL3,
WLT3, AS OF MODEL YEAR 2002) . . . . . Z123
INTERIOR LIGHTING SYSTEMS
ILLUMINATION LIGHT . . . . . . . . . . . . . . . . . . . Z95
CIGARETTE LIGHTER / CLOCK / OUTLET /
REAR WINDOW DEFROSTER . . . . . . . . . . . Z97
INTERIOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . Z99
EXTERIOR LIGHTING SYSTEMS
HEADLIGHTS (WITHOUT HEADLIGHT
LEVELING SYSTEM) . . . . . . . . . . . . . . . . . . . .
HEADLIGHTS (WITH HEADLIGHT
LEVELING SYSTEM, BEFORE MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LICENCE PLATE LIGHTS / PARKING
LIGHTS / TAIL LIGHTS / REAR FOG
LIGHT (BEFORE MODEL YEAR 2002) . . . .
HEADLIGHTS (WL3, WLT3, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . .
LICENCE PLATE LIGHTS / PARKING
LIGHTS / TAIL LIGHTS / REAR FOG LIGHT
(WL3, WLT3, AS OF MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN AND HAZARD WARNING
LIGHTS (BEFORE MODEL YEAR 2002) . . .
BACKUP LIGHTS / BRAKE LIGHTS /
HORNS (BEFORE MODEL YEAR 2002) . . .

Z67

Z69

Z71
Z73

Z75
Z77
Z79

TURN AND HAZARD WARNING LIGHTS


(WL3, WLT3, AS OF MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z81
BACKUP LIGHTS / BRAKE LIGHTS /
HORNS (WL3, WLT3, AS OF MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z83
AIR CONDITIONING-RELATED SYSTEMS
HEATER AND AIR CONDITIONER (WL,
WL TURBO, BEFORE MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z85
HEATER AND AIR CONDITIONER
(F2 CARB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z87
HEATER AND AIR CONDITIONER
(WL, WL TURBO, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . Z89

ACCESSORIES
CIGAR LIGHTER / CLOCK / OUTLET . . . . . Z97
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . Z101
OTHER
DATA LINK CONNECTOR (BEFORE
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . Z125
DATA LINK CONNECTOR (WL3, WLT3,
AS OF MODEL YEAR 2002) . . . . . . . . . . . . . Z127
COMMON CONNECTORS LIST
(BEFORE MY 2002) . . . . . . . . . . . . . . . . . . . . . . . Z129
COMMON CONNECTORS LIST
(WL-3, WLT-3, AS OF MY 2002) . . . . . . . . . . . . Z131
PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z133

Z-GI

Wiring Diagrams

Contents of wiring diagrams


D This wiring diagram comprises the 6 groups shown below.

GI

General information

A how-to on using and reading wiring diagrams, using


test equipment, checking harnesses and connectors,
and finding trouble spots

Ground points

Ground routes from and to the battery

Schematic

Shows main fuses and other fuses for each system

A~U

System circuit diagrams /


Component location views

Shows circuit and connector diagrams and


component and connector location diagrams

Connectors

Shows connectors common throughout system

PI

Parts index

Gives page number of circuit diagram for each


component

Z-2

Y-1
GROUND POINTS (WL, WL Turbo, before model year 2002)

10

14

3
7
8

15

B/R

B/R

16

B/R

17
11

B/R
WI T H F UE L
I NJ E CT I O N
P UM P

B( F )

B( F )

B( F )

WI T H
IMMOBILIZER
UNI T

B (F )

B (F )

B (F )

9
F RO NT
HA RNE S S

WI T H A I R B A G

Z-12

TO
EACH
UNIT

B( F )

B( F )

B / R(F )
FRONT
HARNESS

B / R(F )

B( F )
TO
EACH
UNIT
B( F )

16

WI T H I M M O B I L Z E R UNI T

5
B (R2 )

10

B (R2 )

11

RE A R
NO . 2
HA RNE S S

14

F I L A M E NT

15

S HO RT CO RD

B (F R)

17

FLOOR
HA RNE S S

B( F )

B/ R ( F )

B/ R ( F )

B (R2 )

W I H T F U EL I N J EC T I ON PU MP

WIRING DIAGRAM

HARNESS SYMBOL :

(F)

(E)

(R)

10

6
1

11

14
17

Z-13

DOUBLE CAB
2

16

10
3
5
7
4

11

WIRING DIAGRAM

8
15

14

REGULAR CAB,STRETCH CAB

Z
Y-1

Y-2
GROUND POINTS (F2 CARB)

Z
WIRING DIAGRAM

1
2

10

14

B/O

11

15

Z-14

B( F )

B (R2 )

10

B( F )

B (R2 )

11

RE A R
NO . 2
HA RNE S S

14

F I L A M E NT

15

S HO RT CO RD

TO
EACH
UNIT

B( F )

TO
EACH
UNIT

B( F )

B( F )

B( F )

B( F )

B/ O( F )

FRONT
HARNESS

B (R2 )

HARNESS SYMBOL :

(F)

(E)

(R)

10

Z-15

11
2

3
5

14

WIRING DIAGRAM

15

Z
Y-2

Y-3

GROUND POINTS (WL-3, WLT-3, as of model year 2002)


14

4
B

15

11

B/R

16

B/R

B/R

B/R

B/R

18
19

A
E

B(F)

B(F)

B/R(F)
B(F)
B/R(F)
B(F)

B(F)

B/R(F)
B/R(F)
B(F)
B/R(F)

Z-16

B(F)

TO
EACH
UNIT

FRONT
HARNESS

B/R(F)

B(F)

20

B/R(F)

B(F)

B(F)

B(F)

FRONT
HARNESS

TO
EACH
UNIT

B/R(F)
B/R(F)

B/R(F)

16

B(F)

18

B(F)
B(F)
B(F)

19

B/R

B/R
B/R

B/R

17

B/R

JC-01

B(R2)

10

B(R2)

11

REAR
NO.2
HARNESS

14

FILAMENT

15

SHORT CORD

17

FLOOR
HARNESS

B(R2)

B(FR)
DOUBLE CAB

WIRING DIAGRAM

10

JC-01 JOINT CONNECTOR(F)

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

10
16

18

11

14

STRETCH CAB
REGULAR CAB

19

Z-17

JC-01
20

10

7
5

11

WIRING DIAGRAM

14
8
15
9

DOUBLE CAB
17

Z
Y-3
From No.
F175-30-01I

W-1
ELECTRICAL WIRING SCHEMATIC (WL, WL Turbo, before model year 2002)

T -1

REAR W IN D O W
DEFR O STER

IMMO BIL IZER SYSTEM

CURRENT F ROM IG1 T ERMINAL


OF ENGINE SWIT CH
CURRENT F ROM IG2 T ERMINAL
OF ENGINE SWIT CH
CURRENT F ROM ACC T ERMINAL
OF ENGINE SWIT CH
OT HERS

SYST EM CIRCUIT

SECT ION

B/Y
6 0 A GL OW
3 0 A H EAD
8 0 A M AI N
3 0 A BT N

B/ W

B/W

W/R

W /R

W/R

2 0 A R . D EF

Z-18

1 0 A R OOM
1 5 A ST OP

OFF

10A HAZARD

L/Y

LG/R

F -2

T URN AND HAZ ARD


WARNING LIGHT S

F -1

BRAKE LIGHT S

F -2

HORN

F -2

ILLUMINAT ION
LIGHT S

I-1

LICENCE PLAT E
LIGHT S/
PARKING LIGHT S/
T AILLIGHT S

E-3

HEADLIGHT S
(WIT HOUT HEADLIGHT
LEVELING SYST EM)

E-1

W /G
W

B/W

IG2

BACK-UP LIGHT S

1 0 A ( A/ C )
30A (D/L)

ST

R/B

B /Y

IG1

AUDIO SYST EM

L/Y
L/R
G/W

Y/R

10A TAIL

EN GI N E
SW I T C H

R/ B

ACC

B/ R

1 5 A C I GAR

4 0 A ( H EAT ER )
1 5 A W I PER

HE A DL I G HT
S WI T CH
L/W

R/ Y

R/ L
R/ W
1 0 A R. F O G

R/ G

C-1a
INST RUMENT CLUST ER C-1b
C-1c

POWER OUT SIDE


MIRRORS

R/ L
R/ W
15A
W
15A

EN GI N E
M ET ER

3 0 A ( P. W I N D )

B/W

HEADLIGHT S
(WIT H HEADLIGHT
LEVELING SYST EM)

E-2

REAR F OG LIGHT

E-3

B/Y
R/ G
R/L
WINDSHIELD WIPER
AND WASHER
POWER WINDOWS

D
K-1
K-2

WIRING DIAGRAM

I-2

CL O C K

I-2

CIG AR ETTE L IG H TER

O U TL ET

I-2

IN TER IO R L IG H T

DATA L IN K
CO N N EC TO R

I-3

AIR BAG SYSTEM

I-2

S-1

PO W ER TR AIN C O N TR O L
SYSTEM/
Q U IC K-STAR T
SYSTEM

HEATER AN D AIR
CO N D ITIO N ER

B-1a
B-1b

PO W ER TR AIN C O N TR O L
SYSTEM/
G L O W SYSTEM

G -1

B-2a
B-2b

STAR TIN G SYSTEM/


CH AR G IN G SYSTEM

REMO TE FR EEW H EEL


CO N TR O L SYSTEM

A-1

T H EFT-D ETER R EN T
SYSTEM

CURRENT F ROM BAT T ERY


H

T -2

PO W ER D O O R L O C KS

K-3

BATTERY
+

ELECTRICAL WIRING SCHEMATIC (F2 CARB)


CUR RENT F ROM BAT TER Y
A-2

B-3
B-4

B-5

G -2

I-3

I-2

I-2

I-2

STAR TIN G SYSTEM/


C H AR G IN G SYSTEM

IG N ITIO N SYSTEM/
PO W ER TR AIN C O N TR O L
SYSTEM

FU EL C O N TR O L
SYSTEM

H EATER AN D
AIR C O N D ITIO N ER

IN TER IO R L IG H T

C IG AR ETTE L IG H TER

R EAR W IN D O W
D EFR O STER

O U TL ET

BAT T ERY
+

CUR RENT F ROM IG1 TER MINAL


OF IGNITI ON SWIT CH
CUR RENT FROM IG2 T ERM INAL
OF I GNI TION SWIT CH
CUR RENT FROM ACC TER MINAL
OF I GNI TION SWIT CH
OTHER S

SYST EM CI RCUI T

SECTI ON

BAC K-U P LIGH TS

F- 2

C LOCK

I- 2

B/Y
AU DIO SY STEM

3 0 A HEAD
8 0 A M AIN

10A
B/W

B/W

3 0 A BT N

Z-19

10A

(A/C)

20A

R.DEF

30A
B/W

IG1

OFF
IG2

HAZ ARD

L/Y

T URN AND HAZ ARD


WARN ING L IGHT S

F- 1

L ICEN CE PLA TE
L IGHT S/
PAR KING L IGHT S/
T AILL IGHT S

E -3

I LLUM INAT ION


L IGHT S

I- 1

H EADLI GH TS
( WITH OUT HEADL IGHT
LEVELI NG SYST EM)

E -1

W/R
W/R

ST

10A

RO O M

15A

ST O P

(D/L )

L G /R
W

10A
Y/R

W/G

TAIL

R/B

L /R
G /W

IG NIT IO N
SWIT CH

HE A DLI GHT
S WI T CH
R/L

A CC

R/W
15A
L

CIG AR

L /W
I NST RUMEN T
C LUST ER

C-2 a
C-2 b

(HEAT ER)

15A

(WIPER)

15A

ENG INE

W
15A

M ET ER

30A

(P.WIND)

F- 2

BR AKE L IGHTS

F- 2

L
L

WI NDSHI ELD WI PER


AN D WASH ER

B/W
B/Y

POWER WINDOWS

K-1

POWER DOOR LOC KS

K- 3

R/L

POWER OU TSI DE
MI RRORS

WIRING DIAGRAM

40A
B/R

H ORN

Z
W-2

W-3

ELECTRICAL WIRING SCHEMATIC (WL-3, WLT-3, as of model year 2002)

CURRENT FROM BATTERY

OTHERS

SYSTEM CIRCUIT

B/Y

80A MAIN
30A BTN

R/B
B/W

B/W

W/R

W/R
10A A/C
30A D/L
W/R

Z-20

B/W

20A R.DEF
15A FIP
10A ROOM
15A STOP

OFF

IG1

IG2

BACK-UP LIGHTS

F-4

TURN AND HAZARD


WARNING LIGHTS

F-3

BRAKE LIGHTS

F-4

HORNS

F-4

ILLUMINATION
LIGHTS

I-1

LICENCE PLATE
LIGHTS /
PARKING LIGHTS /
TAILLIGHTS

E-5

B/Y

ST

AUDIO SYSTEM

SECTION

10A HAZARD

L/Y

LG/R
W/G

L/Y

W
L/W
Y/R

L/R

10A TAIL

G/W

ENGINE
SWITCH

R/B

ACC

HEADLIGHT
SWITCH
L

15A CIGAR

L/W

R/Y
R/W

B/R

40A HEATER
15A WIPER

10A R.FOG

R/G
INSTRUMENT
CLUSTER

POWER OUTSIDE
MIRRORS

C-3a
C-3b
C-3c

R/L

15A ENGINE

B/W

15A METER

B/Y

30A P.WIND

R/L

R/W

HEADLIGHTS

E-4

R/G

REAR FOG LIGHT

E-5

WINDSHIELD WIPER
AND WASHER

D-2

POWER WINDOWS

K-1
K-2

WIRING DIAGRAM

IMMOBILIZER SYSTEM

REAR WINDOW
DEFROSTER

OUTLET

DATA LINK
CONNECTOR

CLOCK

CIGARETTE LIGHTER

INTERIOR LIGHT

AIR BAG SYSTEM

HEATER AND AIR


CONDITIONER

REMOTE FREEWHEEL
CONTROL SYSTEM

STARTING SYSTEM/
CHARGING SYSTEM

CURRENT FROM IG1 TERMINAL


OF ENGINE SWITCH
CURRENT FROM IG2 TERMINAL
OF ENGINE SWITCH
CURRENT FROM ACC TERMINAL
OF ENGINE SWITCH

60A GLOW
30A HEAD

T-3

I-2

U-2

I-2

I-2

I-2

I-3

S-2

G-3

H-2

B-6a POWERTRAIN
B-6b CONTROL SYSTEM /
B-6c GLOW SYSTEM

A-3

THEFT-DETERRENT
SYSTEM

POWER DOOR LOCKS

T-4

K-3

BATTERY
+

From No.
F175-30-01I

A-1
STARTING SYSTEM / CHARGING SYSTEM (WL, WL Turbo, before model year 2002)

BATTERY
+
-

MAIN FUSE BLOCK


HEAD
X-01

WIRING DIAGRAM

R(E)

B(E)
30A
MAIN

B/W(E)

B(E)
80A

X-01
B/W
(E)
A

B/W(F)

X-07

OFF

ST

X-02

IG1

IG2

INSTRUMENT
CLUSTER
(SECTION C-1a)

X-02
ENGINE
SWITCH

ACC

W/B
(F)

B/Y
(F)

B
(E)

X-09

B/W
(E)

A1-01

R
(E)

W/B
(E)

A1-02

B/Y(F)

Z-21

B/Y(E)
A1-01

PCM
(SECTION B-1b,2b)

X-08

VOLTAGE
REGULATOR

STARTER
A1-02

1B
W/R
(E)

A1-01 STARTER(E)

A1-02 GENERATOR(E)
1B

W/R
B

B/Y

W/B

W/R

2A

B/W

2A
W/R
(E)

GENERATOR

(F)

HARNESS SYMBOL :

(E)

[BLACK]
(F)-(E)

(R)

[BLACK]
(F)-(E)

X-09

X-08
[BLACK]
(F)-(E)

X-07
MAIN FUSE BLOCK

X-01

Z-22
A1-02

A1-01
STARTER

GENERATOR

X-02
ENGINE SWITCH
[WHITE]

X-02

WIRING DIAGRAM

ENGINE SWITCH
[BLUE]

Z
A-1

A-2
STARTING SYSTEM (F2 CARB) / CHARGING SYSTEM (F2 CARB)

BATTERY
+

MAIN FUSE BLOCK


HEAD
B(E)

WIRING DIAGRAM

R(E)
X-01

30A
MAIN

B(E)

B/W(E)
80A

X-01
B/W
(E)
A

B/W(F)

X-07

OFF

ST

B/Y(F)
X-02

IG1

IG2

INSTRUMENT
CLUSTER
(SECTION C-2a)

X-02
IGNITION
SWITCH

ACC

B/Y
(F)
W/B
(F)
B
(E)
X-09
X-08
B/W
(E)

A2-01

R
(E)

W/B
(E)

B/Y
(E)
A2-02

Z-23

B/Y(E)
A2-01
VOLTAGE
REGULATOR

STARTER

A2-01 STARTER(E)

A2-02 GENERATOR(E)

B/Y

B/W

W/B

GENERATOR

HARNESS SYMBOL :

(F)

(E)

(R)

[BLACK]
(F)-(E)

X-09
MAIN FUSE BLOCK

X-01

Z-24
X-07
(F)-(E)
[BLACK]

X-08
(F)-(E)
[BLACK]

A2-02

A2-02

GENERATOR
[GRAY]

GENERATOR

X-02
A2-01
STARTER

IGNITION SWITCH
[WHITE]

WIRING DIAGRAM

X-02
IGNITION SWITCH
[BLUE]

Z
A-2

A-3

STARTING SYSTEM / CHARGING SYSTEM (WL-3, WLT-3, as of model year 2002)

BATTERY
+

R(E)
X-01

30A
MAIN

B(E)

B/W(E)
80A

X-01
B/W
(E)
A

B/W(F)

X-07
X-02

INSTRUMENT
CLUSTER
(SECTION C-3a)
2

X-02
OFF

ST
IG1 IG2

ENGINE
SWITCH

ACC

X-02
W
(F)

B
(E)

W/B
(F)

X-03

B/Y
(F)
15A

ENGINE

X-09

X-03
B/W
(F)

B/W
(E)

R
(E)

W/B
(E)

A3-03
STARTER
RELAY

A3-01

A3-02

A3-03

Z-25

R(F)

B/L
(F)
B/L(E)
A3-01

B/L(F)

B/L(F)

X-08

66 IMMOBILIZER UNIT
(SECTION T-3)
IC REGULATOR

1 PCM
(SECTION B-6c)

STARTER

A3-01 STARTER(E)

A3-03 STARTER RELAY(F)

A3-02 GENERATOR(E)

B/L

B/W

W/B
R

B/W
B/Y
B/L

GENERATOR

WIRING DIAGRAM

HEAD
B(E)

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(F)-(E)
[BLACK]
(F)-(E)

X-08

(R)

[GRAY]
(F)-(E)

X-09

X-07
MAIN FUSE
BLOCK

X-01

Z-26

A3-01
STARTER

A3-03
STARTER RELAY

A3-02
GENERATOR

X-02
ENGINE SWITCH
[WHITE]

X-03
FUSE BLOCK

WIRING DIAGRAM

X-02
ENGINE SWITCH
[BULE]

Z
A-3
From No.
F175-30-01I

B-1a
POWERTRAIN CONTROL SYSTEM (WL: GENERAL SPECS.) / QUICK-START SYSTEM (WL)

BATTERY
+
-

MAIN FUSE BLOCK


MAIN

A
B/W(E)

80A

X-01
X-01

B/W(F)

X-01

X-07

X-02
OFF

ST

GLOW
IG1

IG2

60A

WIRING DIAGRAM

B(E)

B/W
(F)

ENGINE
SWITCH

B/W
(F)

B/W
(F)

ACC

X-02
W
(F)

B1-05
FICD
SOLENOID VALVE
No.1
B1-05

FUSE BLOCK
ENGINE
B/W(F)
15A

X-03

B1-06
FICD
SOLENOID VALVE
No.2
B1-06

X-03
B/W
(F)

G
(F)

P
(F)

B1-01

PCM
O

BR
(F)

R
(F)

G/R
(F)

W
(F)

B/R
(F)

B1-01
R/B
(E)

B/W
(F)
B/R(F)
B1-09

X-09

Z-27

B1-03

B1-02

G/R
(E)

GLOW PLUG
RELAY

W
(E)

GLOW PLUG

ENGINE COOLANT
TEMPERATURE
SENSOR
B1-07

R(F)

R(F)

No.4

No.3

No.2

No.1

B1-04
B
(F)

FUEL
CUT
VALVE

B/R
(F)

FUEL
INJECTION
PUMP

B/R(E)

B1-07

B1-02

B/R
(E)

B1-08

NE SENSOR
B/R(E)
6

B1-01 PCM(F)

I
O

BR

GY

P
P

B1-06 FICD SOLENOID VALVE


No.2(F)

B/W

W/L

R/B

B/W

R/W

B1-03 GLOW PLUG RELAY(E)

B1-02 GLOW PLUG RELAY(F)

G/R

B/Y

B1-05 FICD SOLENOID VALVE


No.1(F)

BR
B/R

R/B

B1-07 ENGINE COOLANT TEMPERATURE SENSOR(E)

B/R

B1-04 GLOW PLUG(F)

G/R

B1-08 NE SENSOR(E)

B1-09 FUEL INJECTION PUMP(F)

B/R

B/W

B/W

(F)

HARNESS SYMBOL :

(E)

[BROWN]
GLOW PLUG RELAY

B1-02
GLOW PLUG
RELAY

(R)

[BLACK]
(F)-(E)

X-07

[BROWN]
GLOW PLUG RELAY

B1-03

B1-02

[BLACK]
(F)-(E)

X-09
6

MAIN FUSE BLOCK

FICD SOLENOID
VALVE No.2
[BLACK]
FICD SOLENOID
VALVE No.1

B1-06

B1-05

X-01

ENGINE COOLANT
TEMPERATURE SENSOR

B1-07

Z-28

B1-09
FUEL INJECTION PUMP
[BLACK]

B1-08
NE SENSOR
[GRAY]

B1-04
GLOW PLUG

X-02
ENGINE SWITCH
[WHITE]

ENGINE SWITCH
[BLUE]

B1-01
PCM

WIRING DIAGRAM

X-02

X-03
FUSE BLOCK

Z
B-1a

B-1b
POWERTRAIN CONTROL SYSTEM (WL: GENERAL SPECS.) / QUICK-START SYSTEM (WL)

THERMOSWITCH
(SECTION G-1)

A/C RELAY No.1


(SECTION G-1)

B/Y
(F)

R/W
(F)

R/B
(F)

B1-01
D
PCM
M

GY
(F)

W/L
(F)

B1-01

Z-29
B1-01 PCM(F)

W/L

R/W

R/B

B/W

BR

GY

P
P

G/R

B/Y

B/R
B

INSTRUMENT CLUSTER
(SECTION C-1c)

INSTRUMENT CLUSTER
(SECTION C-1a)

WIRING DIAGRAM

ENGINE SWITCH
(SECTION A-1)

HARNESS SYMBOL :

(F)

(E)

(R)

Z-30
B1-01
PCM

WIRING DIAGRAM

Z
B-1b

B-2a
POWERTRAIN CONTROL SYSTEM (WL: U.K. SPECS., WL Turbo) / GLOW SYSTEM (WL, WL Turbo, before model year 2002)
< >...WL-T

MAIN FUSE BLOCK


MAIN

80A

B/W(F)

X-01

X-07

X-02
OFF

ST

X-01

GLOW
IG1

IG2

60A

B/W
(F)

ENGINE
SWITCH

B/W
(F)

B/W
(F)

B/W
(F)

ACC

X-02
W
(F)

B2-05
FICD
SOLENOID VALVE
No.1
B2-05

FUSE BLOCK
ENGINE
B/W(F)
X-03

15A

B2-06
FICD
SOLENOID VALVE
No.2
B2-06
49

X-03
B/W
(F)

G
(F)

P
(F)

IMMOBILIZER
UNIT
(SECTION T-1)

B2-01

PCM
O

BR
(F)

R
(F)

G/R
(F)

W
(F)

B/R
(F)

BR/W
(F)

R/L
(F)

G/W
(F)

L/B
(F)

B2-01
R/B
(E)

B/R(F)

B2-09

X-09

Z-31

B2-03

B2-02

G/R
(E)

GLOW PLUG
RELAY

W
(E)

ENGINE COOLANT
TEMPERATURE
SENSOR
B2-07

R(F)

TIMER
CONTROL
VALVE

IDLE
SWITCH

CONTROL LEVER
POSITION SENSOR
B2-09

FUEL
INJECTION
PUMP

C
B/R
(F)

No.4

No.1

B
(F)

No.3

GLOW PLUG

No.2

B2-04

B/R
(F)

B/R(E)
B2-08

B2-07

B2-02

B/R
(E)

NE SENSOR
B/R(F)
B/R(E)
6

B2-01 PCM(F)

K
S

BR/R

Y/B
T

B2-06 FICD SOLENOID VALVE


No.2(F)

B/W

L/B
<Y>
R

BR

GY

P
P

W/L

B/W

R/L

B2-03 GLOW PLUG RELAY(E)

B2-02 GLOW PLUG RELAY(F)

I
E

BR/W

G/R

G/W

B/Y

B/R

G/R

BR
R/B

B2-07 ENGINE COOLANT TEMPERATURE SENSOR(E)

B/R

B2-05 FICD SOLENOID VALVE


No.1(F)

B2-04 GLOW PLUG(F)

B2-08 NE SENSOR(E)

B2-09 FUEL INJECTION PUMP(F)

B/R

R/L

B/R

G/W B/W

BR/W

L/B

B/R
F

V/W

B/W

WIRING DIAGRAM

B/W(E)

B(E)
X-01

BATTERY
+

HARNESS SYMBOL :

(F)

(E)

[BROWN]
GLOW PLUG RELAY

B2-02
GLOW PLUG
RELAY

(R)

[BLACK]
(F)-(E)

X-07

[BROWN]
GLOW PLUG RELAY

B2-03

B2-02

[BLACK]
(F)-(E)

X-09
6

MAIN FUSE BLOCK

FICD SOLENOID
VALVE No.2
[BLACK]
FICD SOLENOID
VALVE No.1

B2-06

B2-05

X-01

ENGINE COOLANT
TEMPERATURE SENSOR

B2-07

Z-32

B2-09
FUEL INJECTION
PUMP
[GRAY]

B2-08
NE SENSOR
[GRAY]

B2-04
GLOW PLUG

X-02

X-02

X-03

ENGINE SWITCH
[BLUE]

FUSE BLOCK

B2-01
PCM
[BLACK]

WIRING DIAGRAM

ENGINE SWITCH
[WHITE]

Z
B-2a

B-2b
POWERTRAIN CONTROL SYSTEM (WL: U.K. SPECS., WL Turbo) / GLOW SYSTEM (WL, WL Turbo)
WIRING DIAGRAM

ENGINE SWITCH
(SECTION A-1)

DATA LINK CONNECTOR


(SECTION U)

12

10

B/Y
(F)

BR/R
(F)

Y/B
(F)

GY
(F)

W/L
(F)

B2-01

PCM
R

B2-01
Y
(F)

B2-10

Z-33

B/R
(F)
EGR SOLENOID
VALVE
WL Turbo
4

INSTRUMENT CLUSTER
(SECTION C-1c)

INSTRUMENT CLUSTER
(SECTION C-1a)

B2-01 PCM(F)

K
S

BR/R

Y/B
T

L/B
<Y>
R

BR

GY

P
P

B2-10 EGR SOLENOID VALVE(F)

I
G

W/L

B/W

R/L

BR/W

G/R

G/W

B/Y

B/R
B

B/R

< >...WL Turbo

HARNESS SYMBOL :

(F)

(E)

(R)

[GRAY]
EGR SOLENOID VALVE

B2-10

Z-34
WIRING DIAGRAM

B2-01
PCM
[BLACK]

Z
B-2b

B-3
IGNITION SYSTEM (F2 CARB)

BATTERY
+

MAIN FUSE BLOCK


A

MAIN
B/W(E)
X-01

80A

B/W(F)

X-01

X-07

IG1

X-02
OFF

ST
IG2

WIRING DIAGRAM

B(E)

IGNITION
SWITCH

ACC

X-02
W(F)

W
(F)

Y/G

W(F)

W(F)

54

B3-04

PCM
(SECTION B-4)

NOISE
FILTER

B3-01

B3-02
+

W(F)

B3-03

IGNITION
COIL
B

Z-35

CONDENSER

B3-01 IGNITION COIL


(F)
(SHORT
CORD)

B3-02 IGNITION COIL


(SHORT CORD)
W

B3-03 CHECK CONNECTOR


(TACHOMETER)(F)

B3-04 FRONT(F)-NOISE FILTER


(F)

(SHORT CORD)
W

(NOISE FILTER)
Y/G

CHECK
CONNECTOR
(TACHOMETER)

(F)

HARNESS SYMBOL :

(E)

(R)

IGNITION COIL

B3-01

MAIN FUSE BLOCK

X-01

Z-36
B3-02
IGNITION COIL

X-07
(F)-(E)
[BLACK]

B3-04
(F)-NOISE FILTER

B3-03

X-02

CHECK CONNECTOR
(TACHOMETER)

IGNITION SWITCH
[WHITE]

WIRING DIAGRAM

X-02
IGNITION SWITCH
[BLUE]

Z
B-3

B-4
POWERTRAIN CONTROL SYSTEM (F2 CARB)

MAIN FUSE BLOCK

BATTERY
+

MAIN

A
B/W(E)

80A

X-01

B/W(F)

X-01

X-07

OFF

ST

X-03

FUSE BLOCK
ENGINE

IG1

X-03

IG2

IGNITION
SWITCH

ACC

X-02

W(F)

B/W(F)

X-02

15A
B/W(F)
B/W
(F)
C

B/W(F)

B/W(F)

B/W
(F)
A
B4-05
POSITIVE
TEMPERATURE
COEFFICIENT
HEATER RELAY
B4-05

B/W
(F)

Y/R
(F)

B/Y
(F)

W
(F)

B/W
(F)

R/L
(F)

IGNITION
COIL
(SECTION B-3)

B4-02

B/W
(E)

B/W
(E)

X-09

54

FAST IDLE
CAM BREAKER
SOLENOID VALVE
B4-02

Y/R(F)

B4-01
J

PCM

X-08
H

B4-01
R/L
(E)

Y/R
(F)

Y/R
(F)

SLOW
FUEL
CUT
SOLENOID
VALVE

B/L
(F)
B/L(E)

Z-37

B4-04

X-09

FUEL PUMP
RELAY
(SECTION B-5)

B
(F)
X-09

B
(F)
4

B4-01 PCM(F)

B4-02 FAST IDLE CAM BREAKER SOLENOID VALVE(F)


G

B/L

B4-04 WATER THERMOSWITCH(E)

B4-03 CARBURETOR(E)

B/Y

B/W
B/Y

Y/R

B/W

CARBURETOR

B4-04
B/O
(E)

55

Y/R

AIR
VENT
SOLENOID
VALVE

WATER
THERMOSWITCH

B4-06
POSITIVE
TEMPERATURE
COEFFICIENT
HEATER

B4-03

B4-05 POSITIVE TEMPERATURE COEFFICIENT HEATER RELAY(F)


C

B/W

B/W

R/L

Y/R

B/W
F

B4-06 POSITIVE TEMPERATURE COEFFICIENT HEATER(F)

R/L

B/L

B/W
B/O

WIRING DIAGRAM

B(E)

HARNESS SYMBOL :

(F)

(E)

(R)

[GREEN]
FAST IDLE CAM BREAKER
SOLENOID VALVE
[BLACK]
B4-02
(F)-(E)
POSITIVE TEMPERATURE
X-09
COEFFICIENT
HEATER RELAY

CARBURETOR

B4-03

B4-05
MAIN FUSE BLOCK

X-01
[BLACK]
(F)-(E)

X-07
5

Z-38

X-08

[WHITE]
IGNITION SWITCH

(F)-(E)
[BLACK]

X-02
B4-06
POSITIVE TEMPERATURE
COEFFICIENT
HEATER

X-02
IGNITION SWITCH
[BLUE]

B4-04

WIRING DIAGRAM

WATER THERMOSWITCH

X-03
FUSE BLOCK

B4-01
PCM

Z
B-4

B-5
FUEL CONTROL SYSTEM

MAIN FUSE BLOCK


MAIN

BATTERY
+

A
B/W(E)

80A

X-01

B/W(F)

X-01

X-02

X-07
OFF

ST

FUSE BLOCK

F2 CARB

IG1

ENGINE
W(F)

B/W(F)
B/W
(F)
A
B5-02

B/W
(F)
D

X-03

15A

IG2

IGNITION
SWITCH

ACC

X-02
WL Turbo

X-03
INSTRUMENT
CLUSTER
(SECTION C-1a)

INSTRUMENT
CLUSTER
(SECTION C-2a)

FUEL
PUMP
RELAY

WIRING DIAGRAM

B(E)

48

19

B5-02

Y
(F)
Y/R
(F)

G/R
(F)

Y
(F)
X-04

G/R
(R)

X-04

Y
(R)

X-18

Y
(R2)

Y
(R)

X-18

55
PCM
(SECTION
B-4)

G/R
(R2)

Y
(R2)

B5-01
FUEL GAUGE
SENDER
UNIT
B5-01

Z-39

B5-01

FUEL
PUMP

FUEL
GAUGE
SENDER
UNIT

FUEL
GAUGE

B/R
(R2)

B5-01
X-18
B
(R2)

B/R(R)

B/R(R2)
X-18

WL,
WL Turbo

B5-02 FUEL PUMP RELAY(F)

B/R

G/R

F2 CARB
B/R

B/R(R)

X-04

G/R

B/W

B/W

Y/R

B/R(F)
X-04

10 11

B5-01 FUEL GAUGE SENDER UNIT(R2)

B/O(F)

16

(F)

HARNESS SYMBOL :

(E)

(R)

10
(R)-(R2)

X-18

(F)-(R)

X-04
11

16

B5-01

Z-40

FUEL GAUGE
SENDER UNIT

WL,WL Turbo

MAIN FUSE BLOCK

X-01

X-02
IGNITION SWITCH
[WHITE]

WIRING DIAGRAM

X-02
IGNITION SWITCH
[BLUE]

X-04
X-07

X-03

(F)-(E)
[BLACK]

(F)-(R)

FUSE BLOCK

F2 CARB

B5-02

FUEL PUMP RELAY

B-5

B-6a

POWERTRAIN CONTROL SYSTEM / GLOW SYSTEM (WL-3, WLT-3, as of model year 2002)
BTN 30A

W/R(E)

WLT-3

W/R(F)

B/L(F)
MAIN 80A

B/L(F)

B/W(E)

X-07

B/W
(E)
B

L/W(F)

X-02

X-03

IG1

X-07

IG2

ENGINE

B/L
(F)

15A

X-03
B/L(F)

B/L(F)

LG
(F)

L/R
(F)

X-03

B/L(F)

B/L
(F)

B/L
(F)

B/L
(F)

4C

4D

4X

B/L
(F)

B/W
(F)

B6-01

Y/G
(F)

LG/R
(F)

W/R
(F)

4Z

4T

4Q

4I

2K

4V

2D

4A

4B

3O

1D

B6-01
SHIELD
WIRE

BR
(F)

B6-04

Z-41

P
(F)

B6-03
GLOW PLUG
RELAY

G/B
(F)
B/R
(F)

L
(F)

B6-11

1O
1S

1Q

L/Y

1V

1T

1I

1R

1G
1E

1P

1N

1L

1J

B
P/B

1H

1F

B6-03 GLOW PLUG RELAY(F)

B6-13
B/R
(E)

B6-12

B
(F)

B
(F)

X-09
B/R
(F)

1C

1A

20

2K

2G

L/R BR/W

G/B BR/B

L/W

W/L

2L

2J

1D

1B

2E

2I

2A

20

3O

3K

R/Y

2H

B6-04 GLOW PLUG RELAY(E)

2F

3I

3G

3E

3M

2C

P/L

BR/R

Y/R

2D

2B

G/W

3P

3A

B6-05 GLOW PLUG(F)

3L

3J

3H

3F

4U

B/L

LG

3D

3B

B6-06 INTAKE SHUTER


SOLENOID VALVE(F)

(G/O)
4Z

4O

4Q

4M

4K

4I

4S

4W

R/W

3N

4Y

3C

20

LG/B

L/B

GY

B/L

BR

Y/G

4X

4V

4T

4G

B/Y W/R

LG/R

4E

G/B

R/B
4R

4P

4N

4L

4J

4H

4F

4C

4A

B/L

B/R

B/L

B/R

4D

4B

B6-07 EGR SOLENOID VALVE(VACUUM)(F)

BR

L/W L/W
B/L

1K

R/L GY/L G/R GY/B G/Y

B6-02 PCM CONTROL RELAY(F)


{MAIN RELAY}
C

1M

B/R
(F)

NEUTRAL
SWITCH

CLUTCH
SWITCH

B6-11

B/R
(F)

B6-13

INJECTION PUMP
3

1U

PUMP SPEED
SENSOR

B
(F)

G/B(E)

B6-12

IDLE
SWITCH

No.1

No.2

No.3

No.4

GLOW PLUG

G/B(F)
G/B
(F)

R
(F)
B6-05

X-09

G/W
(F)

B/R
(F)

B6-10

B6-03

BR/Y

B6-09
EGR
CONTROL
SOLENOID
VALVE
B6-09

PCM

67

B/L

B6-08
EGR
SOLENOID
VALVE
(VENT)
B6-08

G/O
(F)

1C

1V

3B

INJECTION PUMP
(SECTION B-6c)

B/W

B/L
(F)

B6-01

B/L
(F)
R/B
(E)

B6-01 PCM(F)

B/L
(F)

B6-07
EGR
SOLENOID
VALVE
(VACUUM)
B6-07

B6-06
INTAKE
SHUTER
SOLENOID
VALVE
B6-06

B/L
(F)

X-03

W
(F)

B6-02

GLOW
60A

ROOM
10A

ACC

X-02

PCM CONTROL RELAY


{MAIN RELAY}

B/L
(F)

X-03
ENGINE
SWITCH

OFF

ST

B/W(F)
X-03

B6-02

B/W(F)

B/W(E)

FIP 15A

X-01

)...WLT-3
}...CAUTION LABEL TITLE

R/B

G/O

Y/G B/L

B/L

LG

B6-08 EGR SOLENOID VALVE(VENT)(F)

LG/R B/L

B6-09 EGR CONTROL


SOLENOID VALVE(F)
W/R

B/L

B6-10 INJECTION PUMP(F)

B6-11 IDLE SWITCH(F)

G/W

B6-12 CLUTCH SWITCH(F)

G/B

B6-13 NEUTRAL SWITCH(E)

G/B

B/R

WIRING DIAGRAM

(
{

X-08

X-01

B(E)

BATTERY
+

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

[BROWN]
GLOW PLUG
RELAY

[BLACK]
(F)-(E)

B6-04

X-07

[BROWN]
GLOW PLUG
RELAY

(R)

(F)-(E)

X-08
[GRAY]
(F)-(E)

[BLACK]
EGR SOLENOID
VALVE (VACUUM)

B6-07

X-09

B6-03

[BLACK]
EGR SOLENOID
VALVE (VENT)

MAIN FUSE
BLOCK

NEUTRAL SWITCH

B6-08

X-01

B6-13

B6-06
INTAKE SHUTER
SOLENOID VALVE
[BLACK]

B6-09
EGR CONTROL
SOLENOID VALVE

B6-03

Z-42

GLOW PLUG RELAY

CLUTCH SWITCH

20

B6-12

5
4

B6-05
GLOW PLUG

B6-10

X-02

INJECTION PUMP
[GRAY]

ENGINE SWITCH
[WHITE]

B6-01
PCM

X-03
FUSE BLOCK

B6-11
IDLE SWITCH

B6-02
PCM CONTROL RELAY

WIRING DIAGRAM

X-02
ENGINE SWITCH
[BULE]

Z
B-6a
From No.
F175-30-01I

B-6b

POWERTRAIN CONTROL SYSTEM / GLOW SYSTEM (WL-3, WLT-3, as of model year 2002)
DATA LINK CONNECTOR
(SECTION U-2)

WIRING DIAGRAM

INSTRUMENT CLUSTER
(SECTION C-3a)
5
68

)...WLT-3

IMMOBILIZER UNIT
(SECTION T-3)

12

10

69

70

BR/R
(F)

B/Y
(F)

Y/R
(F)

W
(F)

2A

4K

2B

W/L
(F)
W/L(F)
W/L
(F)
B6-01
2J

REFERENCE
VOLTAGE(Vref)
1G

1K

1I

1S

2L

2I
PCM

2E

1F

1J

1T

1A

1P

2C

1R

B6-01
BR/W
(F)

PCM
71 (SENSOR GROUND)
(SECTION B-6c)

BR/B(F)

BR/B(F)

SHIELD WIRE

BR/W(F)

BR/W(F)
W
(F)

B
(F)

L/Y
(F)

R
(F)

L/W
(F)

R/Y
(F)

Z-43

BR/W
(F)

BR/B
(F)

G/Y
(F)

BR/B
(F)

BR/Y
(F)

BR/B(E)

V
(E)

BR/W
(E)

BR/B
(E)

INJECTION PUMP EPROM


B6-15
INJECTION PUMP

B6-16

BR/W
(F)

BR/B
(F)

R/L
(F)

BR/B
(F)

P/L
(F)

B6-18

B6-19

BR/B
(E)

G/Y
(E)

B6-15
ENGINE COOLANT
TEMPERATURE
SENSOR

BR/W GY/L
(F)
(F)

BR/B(E)
B6-17

BR/Y
(E)
TIMER POSITION
SENSOR

BR/W
(F)
X-10

BR/B
(E)

B/R
(F)

V
(F)

X-09

B6-14

ACCELERATOR
POSITION SENSOR

B6-16
INTAKE AIR
TEMPERATURE
SENSOR No.2

EGR VALVE
POSITION SENSOR

BOOST SENSOR

20
B6-01 PCM(F)

1O

1U
1S

1Q

B/L

L/Y

B/W

BR/Y

1V

1T

1M

1K

1I

1G
1E

R/L GY/L G/R GY/B G/Y


1P

1R

1N

B6-14 INJECTION PUMP(F)

1L

1J

B
P/B

1H

1F

1C

1A

2K

2G

L/R BR/W

G/B BR/B

L/W

W/L

2L

2J

1D

1B

2E

2I

2A

3O

R/Y

2H

2F

3K

3I

BR/W

L/Y

P/L

BR/R

Y/R

2D

2B

G/W

3P

3A

3L

3J

3H

3F

4U

B/L

LG

3D

3B

(G/O)
4Z

LG/B

L/B

GY

B/L

BR

Y/G

4X

4V

4T

B6-16 INTAKE AIR TEMPERATURE SENSOR No.2

BR/W BR/B

BR/B

BR/Y BR/B

B6-18 BOOST SENSOR(F)

BR/W GY/L BR/B

4Q

B6-19 ACCELERATOR POSITION SENSOR(F)

BR/B

P/L

R/L BR/W

4O

4M

4K

4I

4S

4W

R/W

3N

4Y

L/W

R/Y BR/B

B6-17 EGR VALVE POSITION SENSOR(E)

3E
3C

B6-15 ENGINE COOLANT TEMPERATURE SENSOR(E)


W

3G

3M

2C

G/Y

4G

B/Y W/R

LG/R

4E

G/B

R/B
4R

4P

4N

4L

4J

4H

4F

4C

4A

B/L

B/R

B/L

B/R

4D

4B

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

[GRAY]
(F)-(E)

X-10

B6-15
ENGINE COOLANT
TEMPERATURE SENSOR

Z-44

20

B6-16
INTAKE AIR
TEMPERATURE SENSOR NO.2
[BLACK]

B6-14
B6-17

INJECTION PUMP
[GRAY]

B6-18
BOOST SENSOR

EGR VALVE
POSITION SENSOR
[GRAY]

WIRING DIAGRAM

B6-01
PCM

B6-19
ACCELERATOR
POSITION SENSOR

Z
B-6b
From No.
F175-30-01I

B-6c

POWERTRAIN CONTROL SYSTEM / GLOW SYSTEM (WL-3, WLT-3, as of model year 2002)
THERMOSWITCH
(SECTION G-3)

INSTRUMENT
CLUSTER
(SECTION C-3a)

( )...WLT-3
{ }...CAUTION LABEL TITLE

INSTRUMENT
CLUSTER
(SECTION C-3b)

72

B/L
(F)

R/W
(F)

R/B
(F)

G/R
(F)

GY
(F)

1U

3C

4L

1N

4S

B6-01
SENSOR GROUND

PCM
1L

4U

4W

1M

4E

3D

4Y

1O

1Q

1H

1B

P/B
(F)

BR/B
(F)

B6-01
SHIELD
WIRE
INJECTION PUMP 71
(SECTION B-6b)
PCM CONTROL RELAY
67
{MAIN RELAY}
(SECTION B-6a)

BR/B(F)
B/L(F)

BR/B(F)

B/L(F)

B/L(F)

B/L(F)
B/L
(F)

LG/B
(F)

BR/B(F)

L/B
(F)

R
(F)

GY/B BR/B
(F)
(F)

W
(F)

B
(F)

B/L
(F)

BR/B
(F)

P
(F)

Z-45

FUEL
SHUT
OFF
SOLENOID

FUEL
TEMP
SENSOR

CONTROL
SLEEVE
POSITION
SENSOR

1O
1Q

B/L

L/Y

B/W

BR/Y

1V

1T

1M

1K

1I

R/L GY/L G/R GY/B G/Y


1R

B6-20 INJECTION PUMP(F)

1G

1C

1E

1P

1N

1L

1J

B
P/B

1H

1F

2K

1A

2G

ELECTRONIC
GOVERNOR

L/R BR/W

G/B BR/B

L/W

W/L

2L

2J

1D

BR/B
LG/B

L/B

BR/B

GY/B

B/L

B/L

B/L

1B

G/B B/R

2E

2I

B6-22

INTAKE AIR
TEMPERATURE
SENSOR No.1

B/L
A

2A

3O

R/Y

2H

2F

P/L

BR/R

Y/R

2D

2B

3K

3I

3G

3E

3N

P/B BR/B

4Y

3L

3J

3H

3F

B/L

LG

3D

3B

(G/O)
4Z

TDC SENSOR
20

4U

4Q

4O

4M

4K

4I

4S

4W

R/W

B6-22 TDC SENSOR(F)

B/L

3A
3C

G/W

3P

MASS AIR
FLOW SENSOR

MASS AIR FLOW /


INTAKE AIR TEMPERATURE SENSOR

3M

2C

B6-21 MASS AIR FLOW / INTAKE AIR TEMPERATURE SENSOR(F)

B/R
(F)

20

1S

B/L
(F)

G/B
(F)

B/R
(F)
TIMER
CONTROL
VALVE

INJECTION PUMP

1U

B/L
(F)

B6-21

B6-20

B6-01 PCM(F)

B/L
(F)

LG/B

L/B

GY

B/L

BR

Y/G

4X

4V

4T

4G

B/Y W/R

LG/R

4E

G/B

R/B
4R

4P

4N

4L

4J

4H

4F

4C

4A

B/L

B/R

B/L

B/R

4D

4B

WIRING DIAGRAM

A/C RELAY
No.1
(SECTION G-3)

STARTER
RELAY
(SECTION A-3)

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

20

Z-46

B6-22
TDC SENSOR
[GRAY]

B6-20
INJECTION PUMP
[GRAY]

B6-21
MASS AIR FLOW /
INTAKE AIR TEMPERATURE SENSOR

WIRING DIAGRAM

B6-01
PCM

Z
B-6c
From No.
F175-30-01I

C-1a
INSTRUMENT CLUSTER (WL, WL Turbo, before model year 2002)
B/W(E)

B/W(F)

80A

BTN
W/R(E)
30A

FUSE BLOCK
ROOM
10A

X-03

X-03

ENGINE
SWITCH

ACC

FUSE BLOCK
METER
W(F)

L/R(F)
C1-10

C1-10

IG2

X-02

KEY REMINDER
SWITCH
L/Y(F)

OFF

IG1

WITH THEFT-DETERRENT SYSTEM


THEFT-DETERRENT
58
CONTROL MODULE
(SECTION T-2)

X-02

ST

W/R(F)
X-08

X-01

>...4X4 WITH REMOTE FREEWHEEL CONTROL SYSTEM


] ...4X4 WITHOUT REMOTE FREEWHEEL CONTROL SYSTEM
) ...WITH AIR BAG
>> ...U.K. SPECS.
...NOT USED

B/Y(F)

L/R(F)

15A

X-03

B/Y
(F)

X-03

C1-01

INSTRUMENT CLUSTER

1J

1K

22
WATER
TEMPERATURE
GAUGE

SECURITY
1.4W

2K

FUEL
GAUGE

1I

1F

1L

B/R
(F)

BR/B
(F)

1G

1P

L
(F)
BR/B
(F)

TACHO
METER

MICROCOMPUTER

L/W
(F)

Y
(F)

X-09

SPEEDOMETER

1M

1N

Y/B
(F)

CHARGE
1.4W

SEDIMENTOR
1.4W

2C

R/Y
(F)

W/L
(F)

W/B
(F)

21

INSTRUMENT
CLUSTER
(SECTION C-1b)

2I
C1-01

W
(F)

C1-04

Z-47

56

L
(E)

THEFTDETERRENT
CONTROL
MODULE
(SECTION
T-2)

51
IMMOBILIZER
UNIT
(SECTION T-1)

L/W
(E)

48

L
(E)

L/W
(E)

C1-03

C1-03

FUEL GAUGE
SENDER UNIT
(SECTION B-5)

WITH
THEFTDETERRENT
SYSTEM

VEHICLE
SPEEDOMETER
SENSOR
EXCEPT 4X4

PCM
(SECTION
B-1b,2b)

DOOR
SWITCHES
(SECTION
I-3)
C1-02
WATER
TEMPERATURE
SENDER UNIT

VEHICLE
SPEEDOMETER
SENSOR
4X4

C1-01 INSTRUMENT CLUSTER(F)

1P

1O

C1-02 WATER TEMPERATURE SENDER UNIT(F)

R/Y

W/L

L/R

1N

1M

1L

1K

B/Y

B/R

1J

1I

1H

C1-03 VEHICLE SPEEDOMETER SENSOR(E)


EXCEPT 4X4

L/W

C1-04

B
(F)

16

L/W

SEDIMENTOR
SWITCH

GENERATOR
(SECTION A-1)

Y/B

R/B

R/G

G/B

G/W

1G

1F

1E

1D

1C

1B

1A

B/L
2N

C1-04 SEDIMENTOR SWITCH(F)

O
<<R /L>>
2M

GY BR/B
2L

2K

(Y/G)
2J

W
2I

[GY/R]
<LG/R>
2G

C1-04 KEY REMINDER SWITCH(F)

4X4

L/W

<BR>
2H

L/Y

L/R

BR
2F

L/Y

Y/R

W/B

2E

2D

2C

R/W
2B

2A

Y/B

WIRING DIAGRAM

B(E)
X-01

<
[
(
<<

X-07

MAIN FUSE BLOCK


MAIN

BATTERY
+

(F)

HARNESS SYMBOL :

[BLACK]
(F)-(E)

X-07

(E)

[BLACK]
(F)-(E)

X-08

(R)

[BLACK]
(F)-(E)

X-09

[GRAY]
VEHICLE SPEEDOMETER SENSOR

C1-03

MAIN FUSE BLOCK

X-01

INSTRUMENT CLUSTER

Z-48

C1-01

C1-04

[BLACK]
INSTRUMENT CLUSTER

SEDIMENTOR SWITCH

C1-01
WL,WL Turbo
C1-02
WATER TEMPERATURE
SENDER UNIT

KEY REMINDER SWITCH

16

C1-10

X-02
ENGINE SWITCH
[WHITE]

X-03
FUSE BLOCK

WIRING DIAGRAM

X-02
ENGINE SWITCH
[BLUE]

Z
C-1a

C-1b
INSTRUMENT CLUSTER (WL, WL Turbo, before model year 2002)

INSTRUMENT CLUSTER
INSTRUMENT
22
CLUSTER
(SECTION C-1a)

26

4WD
1.4W

RFW
LOCK
1.4W

4WD
1.4W

2G

2G

BRAKE
1.4W

R.FOG
1.4W

OIL
1.4W

INSTRUMENT
CLUSTER
(SECTION C-1c)

AIR BAG
1.4W

2J

2H

2M

2D

2M

2E

C1-01
GY/R
(F)

U.K. SPECS.
LG/R
(F)

X-09

Y/R
(F)

Y/G
(F)

BR
(F)

GY/R
(E)

Z-49

4X4
WITHOUT
REMOTE
FREEWHEEL
CONTROL
SYSTEM

R/L
(F)

X-09

C1-09
4X4
INDICATOR
SWITCH
C1-09

SAS UNIT
(SECTION
S-1)

RFW
CONTROL MODULE
(SECTION H)

B/R
(E)
X-09

C1-05

52

OIL
PRESSURE
SWITCH

REAR FOG
LIGHT
SWITCH
(SECTION
E-3)

4X4 WITH REMOTE


FREEWHEEL
CONTROL SYSTEM

B/R
(F)
6

WITH
AIR BAG

1P

1O

5
EXCEPT
U.K. SPECS.

U.K. SPECS.

W/L

L/R

1N

1M

1L

1K

B/Y

B/R

1J

1I

1H

Y/B

R/B

R/G

G/B

G/W

B/L

1G

1F

1E

1D

1C

1B

1A

2N

C1-08 VACUUM SWITCH(F)

C1-09 4X4 INDICATOR


SWITCH(E)

L/Y
L/Y

B/R

GY/R

O
<<R/L>>
2M

GY BR/B
2L

2K

(Y/G)
2J

W
2I

<BR>
2H

[GY/R]
<LG/R>
2G

BR
2F

L/Y

Y/R

W/B

2E

2D

2C

R/W
2B

2A

L/Y
(F)
C1-06
BRAKE
FLUID
LEVEL
SENSOR
C1-06

C1-08
VACUUM
SWITCH

B
(F)

C1-05 OIL PRESSURE SWITCH


(E)

R/Y

C1-07 PARKING BRAKE


SWITCH(F)

C1-07
PARKING
BRAKE
SWITCH

B
(F)

C1-01 INSTRUMENT CLUSTER(F)

L/W

L/Y
(F)

L/Y
(F)

C1-06
BRAKE
FLUID
LEVEL
SENSOR
C1-06

Y/R
(E)

25

24

23

O
(F)

Y/R

C1-06 BRAKE FLUID LEVEL


SENSOR(F)
O
<<L/Y>>

WIRING DIAGRAM

>...4X4 WITH REMOTE FREEWHEEL CONTROL SYSTEM


] ...4X4 WITHOUT REMOTE FREEWHEEL CONTROL SYSTEM
) ...WITH AIR BAG
>> ...U.K. SPECS.
...NOT USED

<
[
(
<<

(F)

HARNESS SYMBOL :

BRAKE FLUID
LEVEL SENSOR

C1-06

(E)

(R)

[BLACK]
VACUUM SWITCH

C1-08
4X4 INDICATOR
SWITCH

C1-09

INSTRUMENT CLUSTER

C1-01

Z-50

[BLACK]
INSTRUMENT CLUSTER

C1-01
X-09
(F)-(E)
[BLACK]

C1-05
OIL PRESSURE SWITCH

WIRING DIAGRAM

C1-07
PARKING BRAKE SWITCH

Z
C-1b

C-1c
INSTRUMENT CLUSTER (WL, WL Turbo, before model year 2002)
TURN SWITCH
(SECTION F-1)

PCM
(SECTION B-1b,2b)

27

28

29

30

45

R/B
(F)

R/W
(F)

G/B
(F)

G/W
(F)

B/L
(F)

GY
(F)

C1-01

INSTRUMENT CLUSTER
1E

2A

ILLUMI
3.4X4

BEAM
1.4W

INSTRUMENT
CLUSTER
26
(SECTION C-1b)

1B

TURN
LH
1.4W

1C

2N

1A

TURN
RH
1.4W

2L

R.DEF
1.4W

GLOW
1.4W

1D

C1-01

R/G
(F)

B
(F)

Z-51

38
PANEL LIGHT
CONTROL SWITCH
(SECTION I-1)

C-01 INSTRUMENT CLUSTER(F)

L/W
1P

1O

R/Y

W/L

L/R

1N

1M

1L

1K

B/Y

B/R

1J

1I

1H

Y/B

R/B

R/G

G/B

G/W

1G

1F

1E

1D

1C

1B

1A

B/L
2N

O
<<R/L>>
2M

GY BR/B
2L

2K

(Y/G)
2J

W
2I

<BR>
2H

[GY/R]
<LG/R>
2G

BR
2F

L/Y

Y/R

W/B

2E

2D

2C

R/W
2B

2A

WIRING DIAGRAM

HEADLIGHT
SWITCH
(SECTION E-1,2)

< >...4X4 WITH REMOTE FREEWHEEL


CONTROL SYSTEM
[ ] ...4X4 WITHOUT REMOTE
FREEWHEEL CONTROL SYSTEM
( ) ...WITH AIR BAG
<< >> ...U.K. SPECS.
...NOT USED

HEADLIGHT
SWITCH
(SECTION I-1)

REAR WINDOW
DEFROSRTER
RELAY
(SECTION I-2)

HARNESS SYMBOL :

(F)

(E)

(R)

INSTRUMENT CLUSTER

C1-01

[BLACK]
INSTRUMENT CLUSTER

C1-01

Z-52
WIRING DIAGRAM

Z
C-1c

C-2a
INSTRUMENT CLUSTER (F2 CARB)

BATTERY
+

MAIN FUSE BLOCK


MAIN

A
B/W(E)

B/W(F)

80A
BTN

X-01

X-02
OFF

ST

W/R(E)
30A

X-07
X-08

X-01

IG1

W/R
(F)

IG2

IGNITION
SWITCH

ACC

FUSE BLOCK

X-02

FUSE BLOCK
ROOM

METER
W(F)

B/Y(F)

L/R(F)
10A

X-03

15A

X-03

B/Y
(F)

X-03

X-03

C2-01
1K

INSTRUMENT CLUSTER

1J
22

WATER
TEMPERATURE
GAUGE

FUEL
GAUGE

1I

TACHO
METER

MICROCOMPUTER

1L

1F
Y
(F)

1P

L
(F)

X-09

Z-53

L
(E)

R/Y
(F)

Y/B
(F)

W/B
(F)
21

L/W
(E)

19

SEDIMENTOR
1.4W

2C
C2-01

X-09
B/O
(F)

CHARGE
1.4W

1N

1G

L/W
(F)

SPEEDOMETER

Y/B
(E)

DOOR SWITCHES
(SECTION I-3)

C2-03

FUEL GAUGE
SENDER UNIT
(SECTION B-5)

2
GENERATOR
(SECTION A-2)

C2-02
WATER
TEMPERATURE
SENDER UNIT

VEHICLE
SPEEDOMETER
SENSOR
5

C2-02 WATER TEMPERATURE SENDER UNIT(E)

C2-01 INSTRUMENT CLUSTER(F)

L/W
1P

R/Y
1O

1N

1M

L/R

1L

1K

B/Y

B/O

1J

1I

C2-03 VEHICLE SPEEDOMETER SENSOR(E)

L/W

1H

Y/B

R/B

R/G

G/B

G/W

1G

1F

1E

1D

1C

1B

1A

B/L

2N

2M

2L

2K

2J

2I

2H

2G

2F

L/Y

Y/R

W/B

2E

2D

2C

R/W
2B

2A

Y/B

INSTRUMENT
CLUSTER
(SECTION C-2b)

WIRING DIAGRAM

B(E)

(F)

HARNESS SYMBOL :

(E)

(R)

[BLACK]
(F)-(E)
MAIN FUSE BLOCK

X-09

X-01

[GRAY]
VEHICLE SPEEDOMETER SENSOR

C2-03

INSTRUMENT CLUSTER

C2-01

[BLACK]
INSTRUMENT CLUSTER

C2-01

Z-54
X-07
(F)-(E)
[BLACK]

X-08
(F)-(E)
[BLACK]

C2-02

X-02

WATER TEMPERATURE
SENDER UNIT

IGNITION SWITCH
[WHITE]

X-03
FUSE BLOCK

WIRING DIAGRAM

X-02
IGNITION SWITCH
[BLUE]

Z
C-2a

C-2b
INSTRUMENT CLUSTER (F2 CARB)
REAR WINDOW
DEFROSRTER
RELAY
(SECTION I-2)

TURN SWITCH
(SECTION F-1)

27

28

29

30

45

R/B
(F)

R/W
(F)

G/B
(F)

G/W
(F)

B/L
(F)

C2-01
1E

2A

1B

1A

2N

ILLUMI
3.4X4

BEAM
1.4W

TURN
LH
1.4W

TURN
RH
1.4W

R.DEF
1.4W

INSTRUMENT
22
CLUSTER
(SECTION C-2a)
OIL
1.4W

BRAKE
1.4W

2D

2M

2E

1D

1C

C2-01

Y/R
(F)

X-08

Z-55

C2-06

C2-05
BRAKE
FLUID
LEVEL
SENSOR
C2-05

Y/R
(E)
C2-04
OIL
PRESSURE
SWITCH

B
(F)

R/G
(F)

L/Y
(F)

O
(F)

PARKING
BRAKE
SWITCH

38
PANEL LIGHT
CONTROL SWITCH
(SECTION I-1)

B
(F)

C2-01 INSTRUMENT CLUSTER(F)

L/W
1P

R/Y
1O

1N

1M

C2-05 BRAKE FLUID LEVEL


SENSOR(F)
O
B

C2-04 OIL PRESSURE SWITCH(E)

L/R

1L

1K

B/Y

B/O

1J

1I

1H

Y/B

R/B

R/G

G/B

G/W

1G

1F

1E

1D

1C

1B

1A

C2-06 PARKING BRAKE


SWITCH(F)
L/Y

B/L

2N

2M

2L

2K

2J

2I

2H

2G

2F

L/Y

Y/R

W/B

2E

2D

2C

R/W
2B

2A

Y/R

WIRING DIAGRAM

INSTRUMENT CLUSTER

HEADLIGHT
SWITCH
(SECTION E-1)

HEADLIGHT
SWITCH
(SECTION I-1)

(F)

HARNESS SYMBOL :

(E)

(R)

BRAKE FLUID
LEVEL SENSOR

C2-05

INSTRUMENT CLUSTER

C2-01

[BLACK]
INSTRUMENT CLUSTER

C2-01

Z-56

X-08
(F)-(E)
[BLACK]

C2-04
OIL PRESSURE SWITCH

WIRING DIAGRAM

C2-06
PARKING BRAKE
SWITCH

Z
C-2b

C-3a

INSTRUMENT CLUSTER (WL-3, WLT-3, as of model year 2002)

< >...4X4

X-07

MAIN
B/W(E)

B/W(F)
A

80A
BTN

X-01

IMMOBILIZER UNIT
73
(SECTION T-3)

X-01

W/R(F)
X-03

C3-10

IG2

ENGINE
SWITCH

ACC

X-02

METER

W(F)

L/R(F)

P(F)

P(F)

IG1

L/R
(F)

C3-10

X-02
OFF

ST

10A

X-03

X-08

P(F)

THEFT-DETERRENT
CONTROL MODULE 58
(SECTION T-4)

ROOM
W/R(E)

30A

KEY REMINDER
SWITCH

B/Y(F)

15A

X-03

L/R
(F)

X-03
C3-01

1K

INSTRUMENT CLUSTER

1J
b (SECTION C-3b)

WATER
TEMPERATURE
GAUGE

SECURITY
1.4W

TACHO
METER

a (SECTION C-3c)

FUEL
GAUGE

SPEEDOMETER

CHARGE
1.4W

SEDIMENTOR
1.4W

MICROCOMPUTER

2K

1I

BR/B
(F)

Z-57

X-18
Y(R2)
C3-11
FUEL GAUGE
SENDER
UNIT
C3-11

B/R
(F)

BR/B
(F)

56
51

X-04

1G

1P

L
(F)

Y(F)

Y(R)

L/W
(F)
X-09

Y/B
(F)

L/W
(E)

L
(E)

L/W
(E)

C3-03

X-18

C3-03

R/Y
(F)

G/R
(F)

W/L
(F)

W/B
(F)

21

72

VEHICLE
SPEEDOMETER
SENSOR
EXCEPT 4X4

B/R
(F)

PCM
(SECTION B-6c)

PCM
(SECTION
B-6b)

1P

R/Y W/L
1O

1N

1M

L
1L

L/W

W
(F)

VEHICLE
SPEEDOMETER
SENSOR
4X4

SEDIMENTOR
SWITCH

GENERATOR
(SECTION A-3)

C3-04

16

C3-02 WATER TEMPERATURE SENDER UNIT(F)

L/R

B/Y

B/R

1K

1J

1I

C3-03 VEHICLE SPEEDOMETER SENSOR(E)


EXCEPT 4X4
L

2I
C3-01

B
(F)

C3-01 INSTRUMENT CLUSTER(F)

L/W

2C

C3-02
WATER
TEMPERATURE
SENDER UNIT

X-04

16

1M

1H

DOOR
SWITCHES
(SECTION I-3)

B/R
(R)

WITH
THEFTDETERRENT
SYSTEM

1N

C3-04
L
(E)

B/R
(R2)

THEFTDETERRENT
CONTROL
MODULE
(SECTION
T-4)

IMMOBILIZER
UNIT
(SECTION T-3)

1L

1F

G/R Y/B
1H

Y
1F

R/B
1E

B
1D

R/G G/B G/W


1C

1B

1A

B/L

R/L

2N

2M

C3-04 SEDIMENTOR SWITCH(F)

4X4

L/W

1G

GY BR/B Y/G
2L

2K

2J

W
2I

<BR> <LG/R>
2H
2G

C3-10 KEY REMINDER SWITCH(F)

L/Y
2F

2E

R/W

Y/R W/B
2D

2C

2B

Y/B

2A

C3-11 FUEL GAUGE SENDER UNIT(R2)

L/R
B/R

WIRING DIAGRAM

B(E)

BATTERY
+

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

[BLACK]
(F)-(E)

(E)

(F)-(E)

X-08

X-07

(R)

(R)-(R2)

[GRAY]
(F)-(E)

X-09

X-18
[GRAY]
VEHICLE SPEEDOMETER SENSOR

C3-03

MAIN FUSE BLOCK

X-01
(F)-(R)

X-04

C3-11
FUEL GAUGE SENDER UNIT

Z-58

C3-04
SEDIMENTOR
SWITCH

INSTRUMENT CLUSTER

C3-01
[BLACK]
INSTRUMENT CLUSTER

C3-01

16

C3-02
WATER TEMPERATURE
SENDER UNIT

KEY REMINDER
SWITCH

C3-10

WIRING DIAGRAM

X-02
ENGINE SWITCH
[WHITE]

X-04
(F)-(R)

X-02
X-03

ENGINE SWITCH
[BLUE]

FUSE BLOCK

Z
C-3a
From No.
F175-30-01I

C-3b

INSTRUMENT CLUSTER (WL-3, WLT-3, as of model year 2002)

WIRING DIAGRAM

INSTRUMENT CLUSTER
(SECTION C-3a)

2G

OIL
1.4W

AIR BAG
1.4W

RFW
LOCK
1.4W

4WD
1.4W

2H

2J

GLOW
1.4W

BRAKE
1.4W

2L

2E

2D

C3-01
Y/G
(F)

L/Y
(F)

Y/R
(F)

BR
(F)

LG/R
(F)

GY
(F)

X-09

Z-59

Y/G
(F)

Y/G
(F)
23

25

47
DATA LINK
CONNECTOR
(SECTION U-2)

L/Y
(F)

SAS UNIT
(SECTION S-2)

C3-05
OIL
PRESSURE
SWITCH

L/Y
(F)

C3-06
BRAKE
FLUID
LEVEL
SENSOR

Y/R
(E)

24

RFW
CONTROL MODULE
(SECTION H-2)

PCM
(SECTION B-6c)

C3-07
PARKING
BRAKE
SWITCH

C3-06
B
(F)

4X4

5
C3-01 INSTRUMENT CLUSTER(F)

L/W
1P

R/Y W/L
1O

1N

1M

L
1L

C3-05 OIL PRESSURE SWITCH (E)

L/R

B/Y

B/R

1K

1J

1I

C3-06 BRAKE FLUID LEVEL SENSOR(F)

L/Y
B

G/R Y/B
1H

< >...4X4

1G

Y
1F

R/B
1E

B
1D

R/G G/B G/W


1C

1B

1A

B/L

R/L

2N

2M

GY BR/B Y/G
2L

C3-07 PARKING BRAKE SWITCH(F)

L/Y

2K

2J

W
2I

<BR> <LG/R>
2H
2G

L/Y
2F

2E

R/W

Y/R W/B
2D

2C

2B

2A

Y/R

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

BRAKE FLUID
LEVEL SENSOR

C3-06

(R)

[GRAY]
(F)-(E)

X-09

INSTRUMENT CLUSTER

C3-01
[BLACK]
INSTRUMENT CLUSTER

Z-60

C3-01
5

C3-05
OIL PRESSURE SWITCH

WIRING DIAGRAM

C3-07
PARKING BRAKE SWITCH

Z
C-3b
From No.
F175-30-01I

C-3c

INSTRUMENT CLUSTER (WL-3, WLT-3, as of model year 2002)


REAR WINDOW
DEFROSRTER
RELAY
(SECTION I-2)

TURN SWITCH
(SECTION F-3)

REAR FOG
LIGHT SWITCH
(SECTION E-5)

27

28

29

30

45

52

R/B
(F)

R/W
(F)

G/B
(F)

G/W
(F)

B/L
(F)

R/L
(F)

C3-01

INSTRUMENT CLUSTER
1E

2A

1B

1A

2N

2M

ILLUMI
3.4X4

BEAM
1.4W

TURN
LH
1.4W

TURN
RH
1.4W

R.DEF
1.4W

R.FOG
1.4W

(SECTION C-3a) a

1D

1C
C3-01

B
(F)

R/G
(F)

Z-61

38
PANEL LIGHT
CONTROL SWITCH
(SECTION I-1)

C3-01 INSTRUMENT CLUSTER(F)

L/W
1P

R/Y W/L
1O

1N

1M

L
1L

L/R

B/Y

B/R

1K

1J

1I

G/R Y/B
1H

1G

Y
1F

R/B
1E

B
1D

R/G G/B G/W


1C

1B

1A

B/L

R/L

2N

2M

GY BR/B Y/G
2L

2K

2J

W
2I

<BR> <LG/R>
2H
2G

L/Y
2F

2E

R/W

Y/R W/B
2D

2C

2B

2A

WIRING DIAGRAM

HEADLIGHT
SWITCH
(SECTION E-4)

< >...4X4
HEADLIGHT
SWITCH
(SECTION I-1)

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

INSTRUMENT CLUSTER

C3-01
[BLACK]
INSTRUMENT CLUSTER

C3-01

Z-62
WIRING DIAGRAM

C-3c
From No.
F175-30-01I

D
WINDSHIELD WIPER AND WASHER (before model year 2002)
B/W(E)
X-01

80A

B/W(F)

X-07

X-01

FUSE BLOCK
WIPER

IG1

B/R(F)
15A

X-03

L
(F)

X-02
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)

OFF

ST
IG2

WIRING DIAGRAM

B(E)

ACC

X-02

X-03
WINDSHIELD WIPER AND WASHER SWITCH

L(F)
D-02

ONE-TOUCH
SWITCH
HIGH
WASHER
SWITCH

L
(F)

HIGH

OFF
LOW INT

OFF

LOW

INT

INT
RELAY

D-02

L(F)
L
(F)

L/O
(F)

L/B
(F)

L/Y
(F)

L/W
(F)

D-03

Z-63

D-01
WINDSHIELD
WASHER
MOTOR

D-01

AUTOSTOP
SWITCH

B
(F)

B
(F)
CIRCUIT
BREAKER

WINDSHIELD WIPER MOTOR

D-01 WINDSHIELD WASHER


MOTOR(F)
B

D-02 WINDSHIELD WIPER AND WASHER SWITCH(F)


L/Y
<L/O>

L/W
<
>

L/O

<

L/B
>

<

D-03 WINDSHIELD WIPER MOTOR(F)

<L/W>

L/O
<L/Y>

<L/B>

<L>

(G/R)

L/W

L/Y

L/B

B
>

<B>

<

>

( )...WITHOUT AIR BAG


< >...F2 CARB

MAIN FUSE BLOCK


MAIN

BATTERY
+
-

HARNESS SYMBOL :

(F)

(E)

WINDSHIELD
WASHER MOTOR

D-01

(R)

[BLACK]
(F)-(E)

X-07
MAIN FUSE BLOCK

X-01

MAIN FUSE BLOCK


WINDSHIELD
WIPER MOTOR

X-01

D-03
1

D-03
WINDSHILD
WIPER MOTOR

D-01
WINDSHILD
WASHER MOTOR

Z-64

X-07
(F)-(E)
[BLACK]

F2 CARB
WL,WL Turbo

WIRING DIAGRAM

D-02
WINDSHIELD WIPER AND
WASHER SWITCH

X-02
X-02
X-03
FUSE BLOCK

ENGINE SWITCH (WL,WL Turbo)


[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

ENGINE SWITCH (WL,WL Turbo)


[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]

Z
D

D-2

WINDSHIELD WIPER AND WASHER (WL-3, WLT-3, as of model year 2002)

BATTERY
+

MAIN
X-01

80A

B/W(F)
A

X-07

X-01

IG1

WIPER
B/R(F)
15A

X-03

L
(F)

X-02
OFF

ST
IG2

ENGINE
SWITCH

ACC

X-02

X-03

WINDSHIELD WIPER AND WASHER SWITCH

L(F)
D2-02

ONE-TOUCH
SWITCH
HIGH
LOW INT

WASHER
SWITCH

L
(F)

HIGH

OFF

OFF

LOW

INT

INT
RELAY
D2-02

L(F)
L
(F)

L/O
(F)

L/B
(F)

L/Y
(F)

L/W
(F)

Z-65

D2-03
D2-01
M

WINDSHIELD
WASHER
MOTOR

B
(F)

D2-01

AUTOSTOP
SWITCH

B
(F)
WINDSHIELD WIPER MOTOR
4

5
D2-01 WINDSHIELD WASHER
MOTOR(F)

D2-02 WINDSHIELD WIPER AND WASHER SWITCH(F)

L/Y

L/O

L/W
L/B

L/O

D2-03 WINDSHIELD WIPER MOTOR(F)


L/W

L/Y

L/B

CIRCUIT
BREAKER

WIRING DIAGRAM

B/W(E)

B(E)

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

WINDSHIELD
WASHER MOTOR
[BLACK]
(F)-(E)

D2-01

X-07
WINDSHIELD
WIPER MOTOR
MAIN FUSE BLOCK

D2-03

X-01

Z-66

5
4

D2-02
WINDSHIELD WIPER AND
WASHER SWITCH

X-02
ENGINE SWITCH
[WHITE]

X-03
FUSE BLOCK

WIRING DIAGRAM

X-02
ENGINE SWITCH
[BLUE]

Z
D-2
From No.
F175-30-01I

E-1
HEADLIGHTS (WITHOUT HEADLIGHT LEVELING SYSTEM)
FUSE BLOCK

MAIN FUSE BLOCK


BTN

TAIL
W/R(F)

W/R(E)
30A

Y/R(F)
10A

X-03

WIRING DIAGRAM

B(E)
X-01

BATTERY
+

X-03

HEAD
R(E)
30A

X-01

R(F)
X-08
E1-01
LIGHT
SWITCH
OFF
TNS HEAD
LIGHT

HEADLIGHT
SWITCH

DIMMER
SWITCH

FLASHTO-PASS

HI

LO

R/B(F)

R/W
(F)

Z-67

INSTRUMENT
CLUSTER
(SECTION C-1c,2b, 3c)

28

R/L
(F)

R/W(F)
R/W
(F)

R/L
(F)

R/W
(F)

R/L
(F)

E1-02
LH

E1-03
60/55W

HEADLIGHTS

60/55W

E1-02

E1-03
B(F)
1

E1-01 HEADLIGHT SWITCH(F)


G/W

G/O

G/B

Y/R

R/W

E1-02 HEADLIGHT LH(F)

E1-03 HEADLIGHT RH(F)

R/L
R

R/L

R/B

R/L
R/W

R/B(F)

39

R/B(F)

40

R/B(F)

41

E1-01

E1-01

R/W

RH

ILLUMINATION LIGHTS
(SECTION I-1)

LICENSE PLATE LIGHTS,


PARKING LIGHTS,
TAILLIGHTS
(SECTION E-3)

(F)

HARNESS SYMBOL :

(E)

(R)

[BLACK]
(F)-(E)

MAIN FUSE BLOCK

X-01

X-08
MAIN FUSE BLOCK

X-01

E1-03

Z-68

HEADLIGHT RH
[BLACK]

E1-03
HEADLIGHT RH
[BLACK]

X-08
(F)-(E)
[BLACK]
HEADLIGHT LH
[BLACK]

E1-02
HEADLIGHT LH
[BLACK]

E1-02

F2 CARB

WL,WL Turbo

WIRING DIAGRAM

E1-01
HEADLIGHT SWITCH

X-03
FUSE BLOCK

Z
E-1

E-2
HEADLIGHTS (WITH HEADLIGHT LEVELING SYSTEM, before model year 2002)
FUSE BLOCK

MAIN FUSE BLOCK


BTN

TAIL
W/R(F)

Y/R(F)

30A

10A

X-03

WIRING DIAGRAM

W/R(E)

B(E)
X-01

BATTERY
+
-

X-03

HEAD
R(E)
30A

R(F)

X-01

X-08

HEADLIGHT SWITCH

E2-01
LIGHT
SWITCH
OFF
TNS HEAD
LIGHT

FUSE BLOCK
REAR FOG LIGHT
SWITCH
(SECTION E-3)

R.FOG
53

E2-01

R/G(F)

R/Y(F)
10A

X-03
R/G(F)

E2-05

DIMMER
SWITCH

FLASHTO-PASS

X-03

HI

E2-04

LO

E2-01
HEADLIGHT
LH LEVELING
ACTUATOR

R/B(F)

HEADLIGHT
LEVELING
ACTUATOR

E2-05

39

R/B(F)

41

R/B(F)

40

ILLUMINATION
LIGHTS
(SECTION I-1)

R/L(F)
E2-04

B
(F)

R/B(F)

RH

R/L
(F)

R/W
(F)

G(F)

LICENSE PLATE
LIGHTS,
PARKING LIGHTS,
TAILLIGHTS
(SECTION E-3)

B(F)

Z-69

E2-06

B
(F)

HEADLIGHT
LEVELING
SWITCH

INSTRUMENT
CLUSTER
(SECTION
C-1c)

28

R/W(F)
R/W
(F)

R/L
(F)

R/W
(F)

R/L
(F)

E2-02

E2-06

E2-03
60/55W

LH
B
(F)

60/55W

HEADLIGHTS

E2-02

RH

E2-03
B(F)

E2-01 HEADLIGHT SWITCH(F)

R/B

R/Y

E2-02 HEADLIGHT LH(F)

R/L

G/W

G/O

Y/R

R/W

E2-05 HEADLIGHT LEVELING ACTUATOR LH(F)

G/B

E2-04 HEADLIGHT LEVELING ACTUATOR RH(F)

E2-03 HEADLIGHT RH(F)

R/L

R/L
B

R/W

E2-06 HEADLIGHT LEVELING SWITCH(F)

G
B

R/G
B

R/W

R/G

(F)

HARNESS SYMBOL :

(E)

(R)

[BLACK]
(F)-(E)

MAIN FUSE BLOCK

X-01

X-08

Z-70

E2-03

HEADLIGHT RH
[BLACK]

E2-04
HEADLIGHT
LEVELING ACTUATOR RH
[GRAY]

E2-05
HEADLIGHT
LEVELING ACTUATOR LH
[GRAY]

E2-02
HEADLIGHT LH
[BLACK]

E2-06
HEADLIGHT LEVELING
SWITCH

HEADLIGHT SWITCH

X-03
FUSE BLOCK

WIRING DIAGRAM

E2-01

Z
E-2

E-3
LICENSE PLATE LIGHTS / PARKING LIGHTS / TAILLIGHTS / REAR FOG LIGHT (before model year 2002)

U.K. SPECS.

HEADLIGHT SWITCH
(SECTION E-2)

53

R/G(F)

WIRING DIAGRAM

REAR FOG
LIGHT RELAY

X-04

R/G(F)

R/L(F)

R/L(F)

R/L(R)

B(F)
E3-08

E3-08

X-04
41

R/B(F)

40

R/B(F)

R/G
(F)

HEADLIGHT
SWITCH
(SECTION E-1,2)

R/W
(F)

R/L
(F)
E3-09

R/B
(F)

PARKING
LIGHT
LH
E3-01

5W

Z-71

B
(F)

PARKING
LIGHT
RH
E3-02

B
(F)

R/L(F)

52

REAR FOG
LIGHT SWITCH

R/B
(R2)

R/B
(R2)

LICENSE
PLATE LIGHT
LH
E3-03

5W

X-18

R/B
(R2)

E3-04

E3-03

E3-02

E3-01
5W

R/L(F)

R/G(F)

X-18

R/B
(F)

INSTRUMENT
CLUSTER
(SECTION
C-1b)

E3-09

R/B
(R)

LICENSE
PLATE LIGHT
RH
E3-04

5W

E3-05

E3-07

E3-06

TAILLIGHT
LH

5W

R/L
(R2)

B
(F)

R/B
(R2)

TAILLIGHT
RH

5W

E3-05

21W

E3-07

E3-06

B
(R2)

B
(R2)

B
(R2)

B
(R2)

11

10 11

11

10 11

REAR FOG
LIGHT

B
(R2)

B
(F)

E3-01 PARKING LIGHT LH(F)

E3-02 PARKING LIGHT RH(F)

R/B

R/B

R/B

R/W

G/W

R/B

W/G

R/L

11

E3-05 TAILLIGHT LH(R2)

E3-07 REAR FOG LIGHT(R2)

E3-04 LICENSE PLATE LIGHT RH(R2)

E3-03 LICENSE PLATE LIGHT LH(R2)

R/B

E3-06 TAILLIGHT RH(R2)

E3-08 REAR FOG LIGHT RELAY(F)

B
E3-09 REAR FOG LIGHT SWITCH(F)

R/G

R/W

R/L

R/G

B
R/L

R/W

R/W

G/B

R/B

W/G

HARNESS SYMBOL :

(F)

(E)

(R)
TAILLIGHT RH

E3-06
10

[BLACK]
LICENSE PLATE LIGHT RH

E3-04

(R)-(R2)

[BLACK]
LICENSE PLATE LIGHT LH

X-18

E3-03
(F)-(R)

TAILLIGHT LH

X-04

E3-05

11

E3-02

E3-07

PARKING LIGHT RH

REAR FOG LIGHT LH

Z-72

E3-01

DOUBLE CAB

PARKING LIGHT LH
TAILLIGHT RH

10

E3-06

[BLACK]
LICENSE PLATE LIGHT RH

E3-04
[BLACK]
LICENSE PLATE LIGHT LH

(R)-(R2)

X-18

E3-03
TAILLIGHT LH

E3-05
E3-09
REAR FOG
LIGHT RELAY

REAR FOG
LIGHT SWITCH

WIRING DIAGRAM

E3-08

11

X-04
(F)-(R)

E3-07
REAR FOG LIGHT LH

REGULAR CAB,
STRETCH CAB

Z
E-3

E-4

HEADLIGHTS (WL-3, WLT-3, as of model year 2002)

BATTERY
+

BTN

TAIL
W/R(F)

Y/R(F)

30A

X-01

10A

X-03

WIRING DIAGRAM

W/R(E)

B(E)

X-03

HEAD
R(F)

R(E)
30A

X-08

X-01

HEADLIGHT SWITCH
R/G(F)

R/Y(F)

R/G(F)
X-03

R/G
(F)

10A

OFF
TNS HEAD
LIGHT

X-03

R/G(F)

DIMMER
SWITCH

FLASHTO-PASS

R/G
(F)
E4-05

E4-01
LIGHT
SWITCH

E4-01

R.FOG

REAR FOG LIGHT


SWITCH
53
(SECTION E-5)

HI

LO

E4-04
E4-01

HEADLIGHT
LH LEVELING
ACTUATOR
E4-05
G(F)

R/W
(F)

Z-73

INSTRUMENT
28
CLUSTER
(SECTION C-3c)

E4-06
0

R/W
(F)

3
1

2
LH

E4-01 HEADLIGHT SWITCH(F)

18
E4-02 HEADLIGHT LH(F)

G/W G/O G/B


R/W

E4-05 HEADLIGHT LEVELING ACTUATOR LH(F)

Y/R

HEADLIGHTS

LICENSE PLATE
LIGHTS,
40 PARKING LIGHTS,
TAILLIGHTS
(SECTION E-5)

R/L
(F)

60/55W

B
(F)

B
(F)

19

18
E4-04 HEADLIGHT LEVELING ACTUATOR RH(F)
R/L

R/L
B

RH

E4-03

E4-03 HEADLIGHT RH(F)

B
B

R/W

E4-06 HEADLIGHT LEVELING SWITCH(F)


G

R/B(F)

E4-03
60/55W

E4-02

19

R/L

R/W
(F)

R/L
(F)

E4-02
B
(F)

B
(F)

R/Y

R/L
(F)

R/W(F)

E4-06

R/B

ILLUMINATION
39 LIGHTS
(SECTION I-1)

G(F)
G
(F)

HEADLIGHT
LEVELING
SWITCH

R/B(F)

R/L(F)

E4-04

B
(F)

R/B(F)

HEADLIGHT
RH
LEVELING
ACTUATOR

R/G
B

R/W

R/G

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

(F)-(E)

X-08
MAIN FUSE BLOCK

X-01

18

HEADLIGHT LEVELING SWITCH

E4-06

Z-74

E4-03
HEADLIGHT RH
[BLACK]

E4-04
HEADLIGHT LEVELING
ACTUATOR RH
[GRAY]

19

E4-05
HEADLIGHT LEVELING
ACTUATOR LH
[GRAY]

E4-02
HEADLIGHT LH
[BLACK]

HEADLIGHT SWITCH

X-03
FUSE BLOCK

WIRING DIAGRAM

E4-01

Z
E-4
From No.
F175-30-01I

E-5

LICENSE PLATE LIGHTS / PARKING LIGHTS / TAILLIGHTS / REAR FOG LIGHT

R/G(F)

X-04
R/L(F)

R/G(F)

WIRING DIAGRAM

REAR FOG
LIGHT RELAY
HEADLIGHT SWITCH
53
(SECTION E-4)

R/L(F)

R/L(R)

B(F)
E5-08
HEADLIGHT
SWITCH
40
(SECTION E-4)

E5-08

X-04
R/G
(F)

R/B(F)

R/B(F)

R/B
(R)

R/B
(F)

R/W
(F)

R/L
(F)

E5-09
E5-09

X-18

R/L(F)
REAR FOG
LIGHT SWITCH

R/B
(R2)

R/B(F)

R/L(F)

R/B(R2)

INSTRUMENT
52 CLUSTER
(SECTION C-3c)
X-18

R/B(R2)

B
(F)
R/B
(F)

R/B

(F)

R/B
(R2)

R/B
(R2)

R/B
(R2)

R/L
(R2)

R/B
(R2)

E5-07
21W REAR FOG
LIGHT
E5-07

Z-75
E5-01 PARKING LIGHT LH(F)

E5-01
PARKING
5W LIGHT
LH
E5-01

E5-02
PARKING
5W LIGHT
RH
E5-02

B
(F)

B
(F)

B
(R2)

B
(R2)

B
(R2)

B
(R2)

18

19

10 11

10 11

11

10 11

E5-02 PARKING LIGHT RH(F)

R/B

R/B

E5-03
LICENSE
5W PLATE LIGHT
LH
E5-03

W/G

TAILLIGHT
LH

E5-05

5W

TAILLIGHT
RH

B
(R2)

E5-06

E5-04 LICENSE PLATE LIGHT RH(R2)

11
E5-05 TAILLIGHT LH(R2)
R/W G/B

E5-07 REAR FOG LIGHT(R2)

R/B

R/B

E5-08 REAR FOG LIGHT RELAY(F)

E5-09 REAR FOG LIGHT SWITCH(F)


R/G

R/G R/W
R/L

R/B

5W

E5-06

R/W G/W
B

E5-05

E5-03 LICENSE PLATE LIGHT LH(R2)

E5-06 TAILLIGHT RH(R2)

E5-04
LICENSE
5W PLATE LIGHT
RH
E5-04

R/L

R/L

R/W

R/B

W/G

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

TAILLIGHT RH

E5-06
10

[BLACK]
LICENSE PLATE
LIGHT RH

E5-04

[BLACK]
LICENSE PLATE
LIGHT LH

E5-03

(R)-(R2)

X-18
TAILLIGHT LH

E5-05

18

(F)-(R)

X-04

11

Z-76

E5-07

E5-02

REAR FOG LIGHT

PARKING LIGHT RH

19
3

E5-01
PARKING LIGHT LH

E5-09
REAR FOG LIGHT
SWITCH

WIRING DIAGRAM

X-04
(F)-(R)

E5-08
REAR FOG LIGHT
RELAY

Z
E-5
From No.
F175-30-01I

F-1
TURN AND HAZARD WARNING LIGHTS (before model year 2002)
MAIN FUSE BLOCK
MAIN
80A

X-01

B/W(F)

L/Y(F)

WITH THEFT-DETERRENT SYSTEM

10A

X-01
A

B/W(E)

B/W(F)

IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)

OFF

ST
IG1

THEFT-DETERRENT
RELAY
(SECTION T-2)

X-02

X-07

IG2

ACC

METER

X-02

W(F)

B/Y(F)

WITH
THEFT-DETERRENT
SYSTEM

X-03

15A

59

THEFT-DETERRENT
CONTROL MODULE
(SECTION T-2)

61

62

G/R
(F)

G/Y
(F)

63

G/O(F)

F1-03

X-03

F1-04

HAZARD
WARNING
SWITCH

THEFT-DETERRENT
CONTROL MODULE
(SECTION T-2)

F1-03

60

G/B
(F)

F1-04

FLASHER
UNIT

G/R(F)
WITHOUT
THEFT-DETERRENT
SYSTEM

F1-03

G/O
(F)

G/O(F)

G/W
(F)

G/O
(F)

LH
G/B(F)
G/W(F)
X-18

G/B(F)

G/B
(R2)

G/B
(F)

G/B
(F)

E3-05
REAR
21W TURN LIGHT
LH

F1-01
FRONT
21W TURN LIGHT
LH

F1-05
FRONT SIDE
5W TURN LIGHT
LH

Z-77

F1-01

E3-05

B
(R2)

11

F1-02 FRONT TURN LIGHT RH (F)

G/W
B

E3-05 REAR TURN LIGHT LH(R2)

R/W

G/B

R/B

W/G

F1-06
FRONT SIDE
5W
TURN LIGHT
RH

F1-02
FRONT
21W TURN LIGHT
RH

E3-06
REAR
21W TURN LIGHT
RH

F1-03 HAZARD WARNING SWITCH(F)

E3-06

F1-02

B
(F)

B/Y

L/Y

G/O
B

R/W

G/W

R/B

W/G

E1-01 TURN SWITCH(F)


<E2-01>
<

>

G/R
<R/B>

(G/Y)

F1-05 FRONT SIDE TURN LIGHT LH(F)

10 11

G/W

G/B
G/R

B
(F)

B
(R2)

F1-04 FLASHER UNIT(F)


G/W

R/B

TURN SWITCH

30

B
(F)

R/G

X-18

G/W
(R2)

F1-06

G/O

E1-01
<E2-01>

RH

G/W(R)

G/W
(F)

B
(F)

E1-01
<E2-01>

G/W
(F)

INSTRUMENT
CLUSTER
(SECTION
C-1c,2b, 3c)

E3-06 REAR TURN LIGHT RH(R2)

G/W(F)

G/W
(F)

F1-05

B
(F)

G/W(F)

G/W(F)

G/W(F)

29

G/B

G/B(F)

X-04
G/B(F)

G/B
(F)

F1-01 FRONT TURN LIGHT LH (F)

G/B(F)

X-04
G/B(R)

WIRING DIAGRAM

B/W(E)

B(E)

< >...WITH HEADLIGHT LEVELING SYSTEM


( ( ...WITH THEFT-DETERRENT SYSTEM

FUSE BLOCK
HAZARD

G/B

G/O
<
>

G/B
<
>

Y/R

R/W

<R/Y>

<R/L>

<G/W>
R
<

<G/O> <G/B>

R/L
> <R/W>

R/B
<R>

<Y/R>

F1-06 FRONT SIDE TURN LIGHT RH (F)

G/W

<

>

BATTERY
+

(F)

HARNESS SYMBOL :

(E)

(R)

FRONT SIDE
TURN LIGHT RH

F1-06
MAIN FUSE BLOCK

REAR TURN LIGHT RH


[BLACK]
(F)-(E)

(R)-(R2)

X-07

X-18

E3-06
10

X-01

REAR TURN LIGHT LH

E3-05

1
FRONT SIDE
TURN LIGHT LH

F1-05

(F)-(R)

X-04
11

F1-02
FRONT TURN LIGHT RH
[BLACK]

WL,WL Turbo

Z-78

F1-01
FRONT TURN LIGHT LH
[BLACK]

MAIN FUSE BLOCK

FRONT SIDE
TURN LIGHT RH

X-01

HAZARD WARNING
SWITCH

F1-06

FLASHER UNIT

F1-04

F1-03

1
TURN SWITCH
E2-01(WITH HEADLIGHT

LEVELING SYSTEM)

FRONT SIDE
TURN LIGHT LH

E1-01(WITHOUT HEADLIGHT
LEVELING SYSTEM)

F1-05

F1-02
FRONT TURN LIGHT RH
[BLACK]

F1-01

FUSE BLOCK

X-04
(F)-(R)

X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

FRONT TURN LIGHT LH


[BLACK]

X-07
(F)-(E)
[BLACK]

X-03

F2 CARB

WIRING DIAGRAM

X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]

Z
F-1

F-2
BACK-UP LIGHTS / BRAKE LIGHTS / HORN (before model year 2002)

MAIN FUSE BLOCK

BATTERY
+

MAIN

A
B/W(F)

B/W(E)
80A

X-01

BTN
X-08

X-01

X-03

15A

X-02
OFF

ST

W/R(F)

W/R(E)
30A

FUSE BLOCK
STOP

X-07

G/W
(F)

X-03

IG1

IG2

ACC

IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)

X-02

B/Y(F)
15A

X-03

G/W(F)

G/W(F)

FUSE BLOCK
METER

W(F)

B/Y(E)
X-09

X-03

F2-06

G/W
(F)
A

F2-05

BACK-UP
LIGHT
SWITCH
F2-06

BRAKE
SWITCH

F2-01
HORN
RELAY

F2-05

F2-01

F2 CARB

W/G
(F)

G/R
(F)

WL,WL Turbo

R/W(F)

R/W(F)

R/W(E)

R/W(E)

X-08

X-04
W/G
(R)

R/W
(R)

W/G
(R2)

R/W
(R2)

X-18
B/R
(F)

G/R
(F)

B/R
(F)

B/R
(F)

S1-02
F2-04
HORN

Z-79

F2-03
HORN
RH

F2-02
HORN
LH

G/R
(F)

G/R
(F)

R/W
(R2)

F2-07

HORNS

W/G
(R2)

E3-05

G/R

E3-06
BACK-UP
LIGHT
LH

21W

CLOCK
SPRING

R/W
(R2)

W/G
(R2)

21W

BRAKE
LIGHT
LH

21W

BRAKE
LIGHT
RH

21W

BACK-UP
LIGHT
RH

D-02

WITH AIR BAG


F2-01 HORN RELAY(F)
C

G/W
G/W

G/W

B/R

G/R

F2-02 HORN LH(F)

B/R

L/W

L/Y

L/B

11

10 11

G/R

R/W
B

R/B

F2-05 BRAKE SWITCH(F)

F2-06 BACK-UP LIGHT


SWITCH(E)

G/W

B/Y

W/G

R/W

F2-07 HORN SWITCH(F)


(WITH AIR BAG)
(CLOCK SPRING)

B/R

E3-05 BACK-UP LIGHT LH/


BRAKE LIGHT LH(R2)

(WITHOUT AIR BAG)

B
(R2)

F2-04 HORN(F)

F2-03 HORN RH(F)

D-02 HORN SWITCH(F)

E3-06
B
(R2)

WITHOUT AIR BAG

B/R

L/O

E3-05

HORN
SWITCH

HORN
SWITCH

E3-06 BACK-UP LIGHT RH/


BRAKE LIGHT RH(R2)

G/B
W/G

R/W
B

R/B

G/W
W/G

G/R

S1-02 SHORT CONNECTOR(F)

G/R
B/Y

B/W

Y/G

Y/G

R/G

R/G

G/R
B/W

B/Y

WIRING DIAGRAM

B(E)

(F)

HARNESS SYMBOL :

(E)

[BLACK]
(F)-(E)

(R)

[BLACK]
(F)-(E)

[BLACK]
(F)-(E)

X-08

X-09

BACK-UP LIGHT RH /
BRAKE LIGHT RH

E3-06
(R)-(R2)

10

X-18

X-07
MAIN FUSE BLOCK

BACK-UP LIGHT LH /
BRAKE LIGHT LH

E3-05

BACK-UP LIGHT SWITCH

X-01

F2-06
(F)-(R)

X-04
11

F2-03
HORN RH

Z-80

WL,WL Turbo
F2-02
HORN LH
MAIN FUSE BLOCK

BACK-UP LIGHT SWITCH

X-01

F2-06

HORN RELAY

F2-01

SHORT CONNECTOR

S1-02

F2-07
HORN SWITCH

D-02
HORN SWITCH

F2-04
HORN

X-03

X-07

F2-05

(F)-(E)
[BLACK]

X-08
(F)-(E)
[BLACK]

BRAKE SWITVCH
[BLACK]

X-09

X-04
(F)-(R)

X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

F2 CARB

(F)-(E)
[BLACK]

FUSE BLOCK

WIRING DIAGRAM

X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]

F-2

F-3

TURN AND HAZARD WARNING LIGHTS (WL-3, WLT-3, as of model year 2002)
MAIN
X-01

L/Y(F)

B/W(F)
X-03

X-01
A

B/W(E)

B/W(F)

X-07

IG1

IG2

X-03
THEFT-DETERRENT
RELAY
(SECTION T-4)

X-02
OFF

ST

10A

ENGINE
SWITCH

F3-03

FLASHER
UNIT

F3-03

F3-03

60

G/B
(F)

G/W
(F)

G/W(F)

G/W(F)
X-04

G/W
(F)

G/B
(F)

G/W
(F)

G/B(F)

G/B(F)

Z-81

G/B
(R2)

G/B
(F)

G/B
(F)

E5-05
REAR
21W TURN LIGHT
LH
E5-05

F3-01
FRONT
21W TURN LIGHT
LH
F3-01

F3-05
FRONT SIDE
5W TURN LIGHT
LH
F3-05

B
(R2)

B
(F)

B
(F)

11

19

F3-02 FRONT TURN LIGHT RH(F)

B
F3-06 FRONT SIDE TURN LIGHT RH (F)

G/W
(F)

G/W
(R2)

F3-06
FRONT SIDE
5W TURN LIGHT
RH
F3-06

F3-02
FRONT
21W TURN LIGHT
RH
F3-02

E5-06
REAR
21W TURN
LIGHT
RH
E5-06

B
(F)

B
(F)

B
(R2)

18

10 11

B/Y

L/Y G/R

E4-01 TURN SWITCH(F)

G/W

R/B

R/Y

R/W

Y/R

G/B

G/Y

E5-05 REAR TURN LIGHT LH(R2)

R/G

G/O
B

G/W G/O G/B


B

B
(F)

F3-05 FRONT SIDE TURN LIGHT LH(F)

F3-04 FLASHER UNIT(F)


G/W G/B

R/G R/B

G/W
(F)

G/O

G/W(R)

30

F3-03 HAZARD WARNING SWITCH(F)

G/W

G/B

G/W(F)

G/W(F)

INSTRUMENT
CLUSTER
(SECTION C-3c)

G/O
(F)

E5-06 REAR TURN LIGHT RH(R2)

R/W G/B
B

R/B W/G

G/O
(F)

E4-01
E4-01 RH
TURN SWITCH

X-18

X-04
G/W(F)

29

LH

G/B(F)
G/B
(F)

F3-04

G/O(F)

G/B(F)

F3-01 FRONT TURN LIGHT LH(F)

G/Y
(F)
F3-04

HAZARD
WARNING
SWITCH

THEFT-DETERRENT
CONTROL MODULE
(SECTION T-4)

G/B(F)

G/R
(F)

63

G/O(F)
B/Y(F)

15A

G/B(R)

62

METER X-03

X-03
W(F)

X-18

61

THEFT-DETERRENT
CONTROL MODULE
(SECTION T-4)

ACC

X-02

59

WIRING DIAGRAM

80A

HAZARD

B/W(E)

B(E)

BATTERY
+

R/W G/W
B

R/B W/G

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

FRONT SIDE TURN


LIGHT RH

REAR TURN LIGHT RH

E5-06

F3-06
10
(R)-(R2)

MAIN FUSE BLOCK

X-18

X-01

REAR TURN LIGHT LH

E5-05

18
1
(F)-(R)

FRONT SIDE TURN


LIGHT LH

X-04

F3-05

11

F3-02

Z-82

FRONT TURN LIGHT RH


[BLACK]

19

X-07
(F)-(E)
[BLACK]

HAZARD WARNING
SWITCH

F3-01

F3-03

FRONT TURN LIGHT LH


[BLACK]

F3-04

FLASHER UNIT

E4-01
TURN SWITCH

WIRING DIAGRAM

X-02
ENGINE SWITCH
[WHITE]

X-02
ENGINE SWITCH
[BLUE]

X-04
X-03

(F)-(R)

FUSE BLOCK

Z
F-3
From No.
F175-30-01I

F-4

BACK-UP LIGHTS / BRAKE LIGHTS / HORNS (WL-3, WLT-3, as of model year 2002)

BATTERY
+

MAIN

A
B/W(F)

B/W(E)
80A

X-01

BTN

STOP
W/R(E)

30A

X-07

X-01

W/R(F)
X-08

X-03

15A

G/W
(F)

X-03

X-02
OFF

ST
IG1

IG2

ENGINE
SWITCH

ACC

METER

X-02

W(F)

G/W(F)
G/W
(F)

F4-01

G/W
(F)
A

B/R
(F)

Z-83

F4-03
HORN
RH

S2-02

F4-06

W/G
(R2)

R/W
(R2)

W/G
(R2)

R/W
(R2)

R/B W/G

BACK-UP
21W LIGHT
RH

BRAKE
21W LIGHT
RH

E5-06
B
(R2)

B
(R2)

11

10 11

F4-04 BRAKE SWITCH(F)

F4-05 BACK-UP LIGHT SWITCH(E)

G/W

B/Y

W/G

R/W

F4-06 HORN SWITCH(F)


(CLOCK SPRING)

B/R

E5-06 BACK-UP LIGHT RH / BRAKE LIGHT RH(R2)

R/W G/B
B

21W

BACK-UP
LIGHT
LH

E5-05

F4-03 HORN RH(F)

W/G
(R2)

E5-06
BRAKE
21W LIGHT
LH

B/R G/R
E5-05 BACK-UP LIGHT LH / BRAKE LIGHT LH(R2)

R/W
(R2)

E5-05

HORN
SWITCH

B/R

R/W
(R)

BACK-UP
LIGHT
SWITCH

G/R
(F)

CLOCK
SPRING

G/W

X-08
W/G
(R)

F4-05

R/W(E)

X-18

G/R

F4-02 HORN LH(F)

R/W(F)

X-04

B/R
(F)

F4-02
HORN
LH

F4-05

W/G
(F)

G/R
(F)

G/W
G/W

B/Y
(E)

F4-04

B/R
(F)

X-09

BRAKE
SWITCH

F4-01

X-03

F4-04

HORN
RELAY

F4-01 HORN RELAY(F)

B/Y(F)
15A

X-03

G/R

S2-02 SHORT CONNECTOR(F)

R/W G/W
B

R/B W/G

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

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

WIRING DIAGRAM

B(E)

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

BACK-UP LIGHT RH /
BRAKE LIGHT RH

[GRAY]
(F)-(E)

[BLACK]
(F)-(E)

10

E5-06

X-09

X-07
MAIN FUSE BLOCK

BACK-UP LIGHT LH /
BRAKE LIGHT LH

(R)-(R2)

X-01

E5-05

X-18
BACK-UP LIGHT SWITCH

F4-05

(F)-(R)

X-04

11

F4-03

Z-84

HORN RH
[BLACK]

X-08
(F)-(E)

HORN RELAY

F4-02

F4-01

HORN LH
[BLACK]
SHORT CONNECTOR

S2-02

HORN SWITCH

F4-06

WIRING DIAGRAM

X-02
ENGINE SWITCH
[WHITE]

X-04
(F)-(R)

X-02
X-03
F4-04

ENGINE SWITCH
[BLUE]

FUSE BLOCK

BRAKE SWITCH

Z
F-4
From No.
F175-30-01I

G-1
HEATER AND AIR CONDITIONER (WL, WL Turbo, before model year 2002)

MAIN FUSE BLOCK

BATTERY
+

X-01

X-07

X-01

MAIN

B/W(E)

B/W(F)

80A
B/W(E)

X-02

IG2

ACC

B/W(F)

OFF

ST

(A/C)
IG1

LG/R(F)
10A

ENGINE
SWITCH

X-02

WIPER
L(F)

WIRING DIAGRAM

B(E)

B/R(F)

L(F)
15A
(HEATER)

B/R(F)
LG/R
(F)

L
(F)

40A

X-03

X-03

FUSE BLOCK
L(F)

L
(F)

G1-06

G1-06

L
PCM
(SECTION B-1b)
7

R/B
(F)

LG/B
(F)

G1-02

BLOWER UNIT
RESISTOR

A/C
RELAY No.1
A/C
SWITCH

G1-05

M
G1-03

G1-10
G1-08

L/Y

L/Y
(F)

REFRIGERANT
PRESSURE
SWITCH

L
(F)

G1-08

G1-04

G1-05

L/B

L(F)

R/W
(F)

L/W
(F)

Z-85

R/G
(F)

L/R

L/Y
(F)

L/B

L/B

G1-02

G1-09

BLOWER
MOTOR

L
(F)

L/R
(F)

L/B
(F)

X-09

G1-01

R/G
(E)

AMP

2
3

G1-07

OFF
4

MAGNETIC
CLUTCH
THERMOSWITCH

B
(F)

FAN
SWITCH

CLIMATE CONTROL UNIT


4

WITH AIR CONDITIONER


G1-01 CLIMATE CONTROL UNIT(F)

G1-06 A/C RELAY No.1(F)

LG/R

LG/B

R/B

G1-02 FRONT(F)-BLOWER UNIT


E

(F)

L/R

L/Y

L/R

L/B

L/Y

L/B

G1-07 MAGNETIC CLUTCH(E)

R/G

G1-04 RESISTOR

G1-03 RESISTOR
(BLOWER UNIT)

G1-08 REFRIGERANT PRESSURE SWITCH(F)

R/G

LG/B

L/R

L/B

L/Y

G1-05 BLOWER MOTOR

(SHORT CORD)

(SHORT CORD)
(SHORT CORD)

L/R

L/Y

L/B

G1-09 THERMOSWITCH(F)

L/W

R/W

L/B

L/B

G1-10 A/C SWITCH(F)

L/Y

L/W

HARNESS SYMBOL :

(F)

(E)

(R)

[BLACK]
(F)-(E)

X-07
[BLACK]
(F)-(E)

X-09
MAIN FUSE BLOCK

X-01
A/C RELAY No.1

G1-06

Z-86

(F)-BLOWER UNIT

G1-02

X-02
ENGINE SWITCH
[WHITE]

X-02

G1-08
REFRIGERANT
PRESSURE SWITCH
[BLACK]

ENGINE SWITCH
[BLUE]

G1-07

X-03

MAGNETIC CLUTCH

WIRING DIAGRAM

FUSE BLOCK

G1-09

G1-01

THERMOSWITCH

G1-05
G1-03
RESISTOR

BLOWER MOTOR

CLIMATE CONTROL UNIT

G1-10
A/C SWITCH

G1-04
RESISTOR

Z
G-1

G-2
HEATER AND AIR CONDITIONER (F2 CARB)

MAIN FUSE BLOCK

BATTERY
+

X-01

X-07

X-01

MAIN

B/W(E)

B/W(F)

80A
B/W(E)

WIRING DIAGRAM

B(E)

X-02

B/W(F)

OFF

ST

(A/C)
LG/R(F)

IG1

10A

IG2

IGNITION
SWITCH

ACC

X-02

ENGINE
B/W(F)

W(F)
15A
WIPER

L(F)
LG/R
(F)

L(F)

B/R(F)
15A

L
(F)

(HEATER)
B/R(F)

A/C
RELAY No.1

X-03

FUSE BLOCK
L(F)

R/W
(F)

L
A/C
SWITCH

G2-05
M

LG
(F)

REFRIGERANT
PRESSURE
SWITCH
G2-08

G2-03

G2-10
L(F)

L/Y

R/W(F)
LG
(F)

Z-87

R/G(F)

L
(F)

R/W
(F)

L/R

L/Y
(F)

L/R
(F)

L/B
(F)
G2-01

G2-11

AMP

2
3

B
(F)

4
THERMOSWITCH

G2-06 A/C RELAY No.1(F)

LG/R

LG/B

R/W

G2-02 FRONT(F)-BLOWER UNIT

L/Y

L/R

L/B

L/Y

L/B

G2-07 MAGNETIC CLUTCH(E)

LG

B/W

G2-04 RESISTOR

G2-03 RESISTOR
(BLOWER UNIT)

(F)

L/R

G2-08 REFRIGERANT PRESSURE SWITCH(F)

L/R

L/B

L/Y

G2-05 BLOWER MOTOR

(SHORT CORD)

(SHORT CORD)
(SHORT CORD)

L/R

L/Y

L/B

L/B

L/B

G2-09 THERMOSWITCH(F)

G2-10 A/C SWITCH(F)

G2-11 A/C RELAY No.2(F)

R/G

G2-12 FICD SOLENOID VALVE (F)

CLIMATE CONTROL UNIT

B
(F)

FAN
SWITCH

OFF

G2-01 CLIMATE CONTROL UNIT(F)

G2-05
L/B

G2-02

L
(F)

B(F)

G2-04
L/B

L/B

G2-09

A/C
No.2

MAGNETIC
CLUTCH

BLOWER
MOTOR

L/Y
(F)

L/W
(F)

G2-11

G2-07

G2-02

BLOWER UNIT
RESISTOR

G2-12

G2-08

L
(F)

G2-12
FICD
SOLENOID
VALVE

G2-06
LG/B
(F)

40A

X-03

B/W
(F)

G2-06

R/G

LG/B

L/W

R/W

L/Y

LG

L/W
D

R/G

(F)

HARNESS SYMBOL :

(E)

(R)

FICD SOLENOID VALVE

G2-12
MAIN FUSE BLOCK

X-01

A/C RELAY No.2

G2-11
1

Z-88

G2-06
A/C RELAY No.1

X-07

(F)-BLOWER UNIT

(F)-(E)
[BLACK]

G2-02
X-02
IGNITION SWITCH
[WHITE]

G2-08
PEFRIGERANT
PRESSURE SWITCH
[BLACK]

X-02
G2-07

IGNITION SWITCH
[BLUE]

MAGNETIC CLUTCH

X-03
FUSE BLOCK

WIRING DIAGRAM

G2-01
CLIMATE CONTROL UNIT

G2-09
THERMOSWITCH

G2-10
A/C SWITCH

G2-03

G2-04

G2-05

RESISTOR

RESISTOR

BLOWER MOTOR

Z
G-2

G-3
HEATER AND AIR CONDITIONER (WL-3, WLT-3, as of model year 2002)
X-01

X-07

X-01

MAIN

BATTERY
+

B/W(E)

B/W(F)

80A
B/W(E)

B/W(F)

B
A/C

LG/R(F)

X-02
OFF

ST
IG1

IG2

10A
L(F)

ENGINE
SWITCH

ACC

X-02

WIPER
L(F)

WIRING DIAGRAM

B(E)

B/R(F)

15A
HEATER

LG/R
(F)

L
(F)

B/R(F)

40A

X-03

X-03
L(F)
B

L
(F)

G3-06

RESISTOR

A/C
RELAY
G3-06

R/B
(F)

LG/B
(F)

PCM
(SECTION B-6c)

G3-02
L

A/C
SWITCH

G3-05

BLOWER
MOTOR

M
G3-03

G3-10

Z-89

G3-08
REFRIGERANT
PRESSURE
SWITCH
G3-08

L/Y

L/Y
(F)
L
(F)

G3-04

G3-05

L/B

L(F)

R/W
(F)

L/W
(F)

G
(F)

L/R

L/Y
(F)

L/B
G3-02

G3-09

L/B

L
(F)

L/R
(F)

BLOWER UNIT

L/B
(F)

X-09

G3-01

G
(F)

AMP

2
3

G3-07

OFF
4

MAGNETIC
CLUTCH

B
(F)

FAN
SWITCH

CLIMATE CONTROL UNIT

THERMOSWITCH

4
WITH AIR CONDITIONER
G3-01 CLIMATE CONTROL UNIT(F)

B
G3-06 A/C RELAY (F)
LG/R

G3-02 FRONT(F)-BLOWER UNIT


(F)
E
L/R

L/Y

L/R

L/B

L/Y

L/B

G3-07 MAGNETIC CLUTCH(E)

G3-03 RESISTOR
(BLOWER UNIT)

G3-08 REFRIGERANT PRESSURE SWITCH(F)

L/R

L/B

L/Y

G3-04 RESISTOR

(SHORT CORD)
E

L/R

L/Y

L/B

G3-05 BLOWER MOTOR

(SHORT CORD)

L/B

L/B

G3-09 THERMOSWITCH(F)

G3-10 A/C SWITCH(F)

LG/B R/B

LG/B

L/W R/W

(SHORT CORD)

L/Y

L/W

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

[GRAY]
(F)-(E)

X-09
[BLACK]
(F)-(E)

X-07
MAIN FUSE BLOCK

X-01

G3-06
A/C RELAY

Z-90
4

(F)-BLOWER UNIT

G3-02
G3-08
REFRIGERANT
PRESSURE SWITCH
[BLACK]

G3-07
MAGNETIC CLUTCH

X-02
ENGINE SWITCH
[WHITE]

G3-09
THERMOSWITCH

G3-10
A/C SWITCH

X-02
ENGINE SWITCH
[BLUE]

G3-01
CLIMATE
CONTROL UNIT

G3-05

G3-03
RESISTOR

WIRING DIAGRAM

X-03
FUSE BLOCK

BLOWER MOTOR

G3-04

RESISTOR

G-3
From No.
F175-30-01I

H
REMOTE FREEWHEEL CONTROL SYSTEM (before model year 2002)

BATTERY
+
-

MAIN FUSE BLOCK


MAIN

A
B/W(E)

X-01

80A

X-01

B/W(F)

X-02

X-07

OFF

ST
IG1

IG2

LOCK
SOLENOID

ENGINE
SWITCH

FREE
SOLENOID
H-04
RFW
MAIN
SWITCH
H-04

ACC

X-02
W
(F)

H-02

H-03
B/W
(F)

B/W
(F)

FUSE BLOCK
ENGINE

B
(F)

B/W(F)
X-03

15A

X-03
B/W
(F)

R
(F)

LG
(F)

G/O
(F)

H-01

RFW CONTROL MODULE


B

E
H-01

R/G
(F)

LG/B
(F)

GY/R
(F)

X-09
B
(F)

R/G
(E)

Z-91

H-06

H-07

4X4
INDICATOR
SWITCH
H-06

RFW
SWITCH
H-05

LG/R
(F)

24

23

LG/B
(E)

GY/R
(E)

H-05

BR
(F)

B/R(E)

NEUTRAL
SWITCH

INSTRUMENT
CLUSTER
(SECTION C-1b)

H-07
B/R(E)

B/R(E)

B/R(E)
X-09
B/R
(F)

H-01 RFW CONTROL MODULE(F)

H-05 RFW SWITCH(E)

H-02 LOCK SOLENOID(F)

GY/R

G/O

LG/B

R/G

B/W

BR

LG/R

LG

R
B

H-03 FREE SOLENOID(F)

H-06 4X4 INDICATOR SWITCH(E)

H-07 NEUTRAL SWITCH(E)

R/G
B/R
B/R

GY/R

B/R

LG/B

B/W

H-04 RFW MAIN SWITCH(F)

LG

B/W

G/O

WIRING DIAGRAM

B(E)

(F)

HARNESS SYMBOL :

(E)

[BLACK]
(F)-(E)

[BLACK]

X-07

X-09

MAIN FUSE BLOCK

X-01

(F)-(E)

(R)

[BLUE]
LOCK SOLENOID

H-02
[YELLOW]
FREE SOLENOID

H-03
6
[BLACK]
NEUTRAL SWITCH

H-07

H-06
5

4X4 INDICATOR SWITCH


[BLACK]

3
RFW MAIN SWITCH

Z-92

H-04
4

H-05
RFW SWITCH
[BLACK]

X-02
ENGINE SWITCH
[WHITE]

X-03

X-02
ENGINE SWITCH
[BLUE]

WIRING DIAGRAM

FUSE BLOCK

H-01
RFW CONTROL MODULE

Z
H

H-2
REMOTE FREEWHEEL CONTROL SYSTEM (WL-3, WLT-3, as of model year 2002)

BATTERY
+

MAIN

B/W(E)
X-01

80A

X-01

B/W(F)

X-02

X-07

OFF

ST
IG1

IG2

LOCK
SOLENOID

ENGINE
SWITCH

WIRING DIAGRAM

B(E)

FREE
SOLENOID

ACC

X-02

H2-02

W
(F)

H2-03

B/W
(F)

B/W
(F)

ENGINE
B/W(F)
15A

X-03

X-03
B/W
(F)

R
(F)

LG
(F)

H2-01

RFW CONTROL MODULE


L

I
H2-01

R/G
(F)

GY/R
(F)

LG/B
(F)

LG/R
(F)

X-09
B
(F)

R/G
(E)

GY/R
(E)

Z-93

RFW
SWITCH
H2-05

G/O
(F)

LG/B
(E)

H2-06
4X4
INDICATOR
SWITCH
H2-06

H2-05

BR
(F)

H2-07

23

NEUTRAL
SWITCH

24

INSTRUMENT
CLUSTER
(SECTION C-3b)

H2-07

B/R
(E)

B
(F)

B/R
(E)

B/R(E)

B/R(E)

H2-04
RFW
MAIN
SWITCH
H2-04

B/R(E)

B/R(E)
X-09

20

H2-01 RFW CONTROL MODULE(F)

H2-02 LOCK SOLENOID(F)

GY/R

G/O

LG/R

LG

LG/B

R/G B/W

H2-05 RFW SWITCH(E)

BR
F

B
D

B/W

H2-06 4X4 INDICATOR SWITCH(E)

H2-07 NEUTRAL SWITCH(E)

R/G
B/R

H2-03 FREE SOLENOID(F)

B/R GY/R

B/R LG/B

LG

4
H2-04 RFW MAIN SWITCH(F)

B/W

G/O

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

[GRAY]
(F)-(E)

X-09
[BLACK]
(F)-(E)

X-07
MAIN FUSE BLOCK

X-01

[BLUE]
LOCK SOLENOID

H2-02
[YELLOW]
FREE SOLENOID

H2-03

[BLACK]
NEUTRAL SWITCH

H2-07

H2-06
4X4 INDICATOR
SWITCH
[BLACK]
[BLUE]
RFW MAIN SWITCH

H2-04
20

Z-94

H2-05
RFW SWITCH
[BLACK]

X-02
ENGINE SWITCH
[WHITE]

X-02

WIRING DIAGRAM

ENGINE SWITCH
[BLUE]

X-03
FUSE BLOCK

H2-01
RFW CONTROL MODULE

Z
H-2
From No.
F175-30-01I

I-1
ILLUMINATION LIGHTS

R/B(F)

R/B(F)

PANEL LIGHT CONTROL SWITCH


R/B
(F)

R/B
(F)
OSC

R/B
(F)

R/B
(F)
27
INSTRUMENT
CLUSTER
(SECTION C-1c,2b, 3c)

R/B
(F)

44
CLOCK
(SECTION I-2)

G2-13(F2 CARB)
G1-11(WL,WL Turbo)

1E

J-01

F1-03

1F

J-01

F1-03

AUDIO
ILLUMINATION

HAZARD
WARNING
SWITCH
ILLUMINATION

R/G
(F)

R/G
(F)

I1-01

G2-13(F2 CARB)
G1-11(WL,WL Turbo)
CLIMATE
CONTROL UNIT
ILLUMINATION

R/B(F)

B
(F)

R/G
(F)

R/G
(F)

INSTRUMENT
CLUSTER
(SECTION C-1c,2b, 3c)
38

Z-95

R/G
(F)

R/G(F)

R/G(F)

R/G(F)

F1-03 HAZARD WARNING SWITCH ILLUMINATION(F)

I1-01 PANEL LIGHT CONTROL SWITCH(F)

G/O

R/G

R/G

R/B
J-01 AUDIO ILLUMINATION(F)
1M

1K

1E

1C

1A

L/R

R/B

L/R

L/W

L/Y

L/W

1D

1B

1N

1L

R/G
1J

1H

1F

G1-11(WL,WL Turbo) CLIMATE CONTROL UNIT ILLUMINATION(F)


G2-13(F2 CARB)

R/B

B/Y

G/W

G/B

L/Y

G/R

R/G

R/B

WIRING DIAGRAM

HEADLIGHT
SWITCH
39
(SECTION E-1,2, 4)

HARNESS SYMBOL :

(F)

(E)

(R)

HAZARD WARNING
SWITCH ILLUMINATION

F1-03
AUDIO
ILLUMINATION

J-01

Z-96
I1-01
PANEL LIGHT CONTROL SWITCH

G1-11(WL,WL Turbo)
G2-13(F2 CARB)
CLIMATE CONTROL UNIT
ILLUMINATION

WIRING DIAGRAM

Z
I-1

I-2
CIGARETTE LIGHTER / CLOCK / OUTLET / REAR WINDOW DEFROSTER

MAIN FUSE BLOCK


BTN

BATTERY
+
-

W/R(F)

W/R(E)
30A

X-01

X-08

MAIN

X-03

A
B/W(E)

80A

B/W(F)

B/W(E)

X-01
B
B/W(E)

B/W(F)

IG2

ACC

W
(F)

B/W(F)

FUSE
BLOCK

X-03

L
(F)

X-03
FUSE BLOCK
METER

INSTRUMENT CLUSTER
(SECTION C-1c,2b,3c)

ROOM
10A

IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)

X-02

W(F)
20A

OFF

IG1

FUSE BLOCK
R.DEF
X-03

X-02

ST

X-07

ILLUMINATION
LIGHTS
(SECTION I-1)

X-03

B/Y(F)
15A

X-03

I2-04

45

WIRING DIAGRAM

B(E)

CIGAR
15A

X-03

REAR WINDOW
DEFROSTER
RELAY

44

X-03

I2-04

B/L
(F)

G
(F)
L/W
(F)

L/W
(F)

Z-97

I2-03

I2-05

I2-01 CLOCK(F)

I2-02 CIGARETTE LIGHTER (F)

I2-02
I2-01

B
(F)

14

CLOCK

CIGARETTE
LIGHTER

I2-03

B/L(R)

I2-01
I2-02

OUTLET

FILAMENT
I2-06

R/B
(F)

L/W(F)

I2-05
REAR WINDOW
DEFROSTER
SWITCH

X-04

I2-07

L/R
(F)

L/W
(F)

WITH OUTLET

B/L
(F)

I2-03 OUTLET(F)

B
(F)

B
(F)

I2-04 REAR WINDOW


DEFROSTER RELAY(F)

B
(F)

I2-05 REAR WINDOW


DEFROSTER SWITCH(F)

I2-06 FILAMENT(R)

I2-07 FILAMENT
(SHORT CORD)

B
R/B

L/R

L/W

L/W
B

L/W
B

B/Y

B/L
B/L

B/L

(F)

HARNESS SYMBOL :

(E)

(R)

[BLACK]
(F)-(E)

X-07

[BLACK]

FILAMENT

I2-07

FILAMENT

(F)-(E)

I2-06

X-08
MAIN FUSE BLOCK

X-01

(F)-(R)

X-04

14

Z-98

WL,WL Turbo

MAIN FUSE BLOCK

REAR WINDOW
DEFROSTER SWITCH

X-01

I2-05

[BLACK]
REAR WINDOW
DEFROSTER RELAY

CLOCK

I2-01

I2-04
4
[WHITE]
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)

X-02

X-03
FUSE BLOCK

X-07

I2-03

(F)-(E)
[BLACK]

OUTLET

X-08
(F)-(E)
[BLACK]

X-04
(F)-(R)

I2-02
F2 CARB

CIGARETTE LIGHTER

WIRING DIAGRAM

X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

Z
I-2

I-3
INTERIOR LIGHT
FUSE BLOCK
ROOM
W/R(E)
30A

W/R(F)
X-08

X-01

X-03

10A

WIRING DIAGRAM

B(E)
X-01

MAIN FUSE BLOCK


BTN

BATTERY
+
-

X-03
L/R
(F)
X-11
L/R
(IN)
I3-01

WITH THEFT-DETERRENT SYSTEM


OFF
THEFT-DETERRENT
CONTROL MODULE
(SECTION T-2,-4)

65

R/Y(F)

ON

INTERIOR
LIGHT

DOOR
I3-01

INSTRUMENT
CLUSTER
21
(SECTION C-1a,2a,3a)

R/Y
(IN)

R/Y
(F)

X-11
R/Y
(F)
I3-06

R/Y
(F)

X-19
R/Y(FR)

R/Y(FR)

R/Y(F)

R/Y(F)

R/Y(F)

Z-99

X-04
R/Y(R)

I3-05
DOOR
SWITCH
LR

I3-04
DOOR
SWITCH
RR

I3-03
DOOR
SWITCH
LF

R/Y
(R)

R/Y
(R)

R/Y
(FR)

R/Y

I3-02
DOOR
SWITCH
RF

WITH DOOR SWITCH


I3-01 INTERIOR LIGHT(IN)

I3-02 DOOR SWITCH RF(R)

I3-03 DOOR SWITCH LF(FR)

I3-04 DOOR SWITCH RR(R)

I3-05 DOOR SWITCH LR(R)


(SHORT CORD)

R/Y
(REGULAR CAB)

R/Y

L/R
L/R

(STRETCH CAB)
(DOUBLE CAB)

I3-06 FLOOR(FR)-SHORT CORD


(FR)
R/Y

(SHORT CORD)
R/Y

R/Y

R/Y

R/Y

R/Y

(F)

HARNESS SYMBOL :

(E)

(R)
[BLACK]
(F)-(E)

INTERIOR LIGHT

I3-01

X-08
[BLACK]
DOOR SWITCH RF

MAIN FUSE BLOCK

X-01

(F)-(IN)

I3-02

X-11

(F)-(R)

X-04
(F)-(FR)

X-19

I3-03
DOOR SWITCH LF
[BLACK]

Z-100

(F)-(IN)

X-11

INTERIOR LIGHT

[BLACK]
DOOR SWITCH RR

I3-01

I3-04

[BLACK]
DOOR SWITCH RF

I3-02
(F)-(IN)

X-11

(F)-(R)

X-04

I3-05

X-19
X-03
FUSE BLOCK

DOOR SWITCH LR
[BLACK]

X-04
(F)-(R)

I3-06
(FR)-SHORT CORD

I3-03
X-19
(F)-(FR)

DOOR SWITCH LF
[BLACK]

WIRING DIAGRAM

(F)-(FR)

Z
I-3

J
AUDIO SYSTEM

BATTERY
+
-

MAIN FUSE BLOCK


MAIN

A
B/W(E)

B/W(F)

80A
BTN

X-01

X-07
W/R(E)

30A

X-02
OFF

ST

X-08

X-01

FUSE BLOCK
ROOM

W/R
(F)

L/R(F)

IG1

IG2

WIRING DIAGRAM

B(E)

ACC

IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)

X-02
L
(F)

10A
CIGAR
L/W(F)
X-03
L/R
(F)

L/W
(F)

1C

1A

15A

X-03

J-01

AUDIO UNIT
3A

Z-101

1K

1L

1M

1N

L
(F)

L/W
(F)

L/R
(F)

L/Y
(F)

J-01

J-04

X-15
B

X-12
L
(DR2)

L/W
(DR2)

L/R
(DR1)

L/Y
(DR1)

J-02

J-03
LH

RH
SPEAKERS

15

J-01 AUDIO UNIT(F)

J-02 SPEAKER LH(DR2)


1M

1K

1E

1C

1A

L/R

R/B

L/R

L/W

L/Y

L/W

R/G

1N

J-04 AUDIO UNIT


3A
(SHORT CORD)

1L

1J

1H

1F

1D

1B

J-03 SPEAKER RH(DR1)

L/W

L/Y

L/R

(F)

HARNESS SYMBOL :

(E)

[BLACK]
(F)-(E)

(R)

[BLACK]
(F)-(E)

SPEAKER RH

J-03

X-08

X-07
MAIN FUSE BLOCK

X-01
[GREEN]
(F)-(DR1)

X-12

J-02
X-15

SPEAKER LH

Z-102

(F)-(DR2)
[GREEN]

[GREEN]
(F)-(DR1)
AUDIO UNIT

X-12

15

J-04
AUDIO UNIT

J-01

[GREEN]
(F)-(DR2)

X-02

X-03
FUSE BLOCK

WIRING DIAGRAM

ENGINE SWITCH (WL,WL Turbo)


[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]

X-15

X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

Z
J

K-1
POWER WINDOWS (REGULAR CAB, STRETCH CAB)

BATTERY
+
-

MAIN FUSE BLOCK


MAIN

A
B/W(F)

B/W(E)
80A

X-01

X-01

X-07

IG1

X-02
OFF

ST
IG2

ACC

IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)

X-02

X-03

FUSE BLOCK
(P.WIND)

X-03

W(F)
POWER WINDOW MAIN SWITCH

30A

POWER-CUT SWITCH
CLOSE
CLOSE

OPEN

OPEN

K1-01
G/W
(DR1)

AUTO
CIRCUIT

R/L
(F)

R/L
(DR1)

R/W
(DR1)

X-13
R/L
(F)

X-14

G/W
(F)

R/W
(F)

G/W
(DR2)

R/W
(DR2)

R/L
(F)

X-17

X-16

K1-01
R/L
(DR2)
K1-02

Z-103

G/B
(DR1)

B
(DR1)

R/B
(DR1)

CLOSE

OPEN

POWER
WINDOW
SUBSWITCH

K1-02
X-14
B
(F)

G/B
(DR2)

K1-03
M
OPEN

CLOSE

R/B
(DR2)
K1-04

POWER WINDOW
REGULATOR
RH

M
OPEN

CLOSE

POWER WINDOW
REGULATOR
LH

K1-01 POWER WINDOW MAIN SWITCH(DR1)

K1-02 POWER WINDOW SUBSWITCH (DR2)

G/B
R/B

R/L

K1-03 POWER WINDOW REGULATOR RH(DR1)

K1-04 POWER WINDOW REGULATOR LH(DR2)

G/W

R/B

R/W

G/B

G/B

R/W

G/W G/B

R/L

R/B

R/B

WIRING DIAGRAM

B(E)

(F)

HARNESS SYMBOL :

(E)

(R)

POWER WINDOW
MAIN SWITCH

[BLACK]
(F)-(E)

[BLUE]
POWER WINDOW
REGULATOR RH

X-07

K1-01

K1-03

MAIN FUSE BLOCK

X-01
(F)-(DR1)

X-13

K1-02
X-16
(F)-(DR2)

Z-104

X-17

X-14

(F)-(DR2)

(F)-(DR1)

POWER WINDOW
SUBSWITCH LH

K1-04
POWER WINDOW
REGULATOR LH
[BLUE]

(F)-(DR1)

X-13
X-14
(F)-(DR1)

WIRING DIAGRAM

X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]

(F)-(DR2)

X-16
X-03
FUSE BLOCK

X-17
(F)-(DR2)

X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

Z
K-1

K-2
POWER WINDOWS (DOUBLE CAB)
MAIN FUSE BLOCK
MAIN

A
B/W(E)

X-01

80A

X-01

OFF

ST

X-07

FUSE BLOCK
(P.WIND)

IG1

R/L(F)

IG2

30A

ENGINE
SWITCH

ACC

X-02

W(F)
X-03

X-02

B/W(F)

WIRING DIAGRAM

B(E)

BATTERY
+
-

X-03

R/L(F)
POWER WINDOW MAIN SWITCH

POWER-CUT
SWITCH

CLOSE

OPEN

CLOSE
F

OPEN

CLOSE

OPEN

A
K2-01

AUTO
CIRCUIT

CLOSE

OPEN

K2-01

G/W
(DR1)

R/W
(DR1)

R/L
(DR1)

G/W
(F)

R/W
(F)

R/L
(F)

X-14

R/L
(DR1)

W
(DR1)

L/W
(DR1)

W/R
(DR1)

G/Y
(DR1)

W
(F)

L/W
(F)

W/R
(F)

C
G/Y
(F)

W/R
(FR)

G/Y
(FR)

R/L
(FR)

W
(DR4)

L/W
(DR4)

R/L
(DR4)

X-13

R/L(F)

X-14

R/L(F)
X-06

X-20

R/L(F)
R/L
(F)
X-17
B
(DR1)

L/W
(R)

R/L
(R)

W
(DR3)

L/W
(DR3)

R/L
(DR3)

X-16
G/W
(DR2)

Z-105

G/B
(DR1)

W
(R)

R/W
(DR2)

R/L
(DR2)
K2-02

R/B
(DR1)

X-14

CLOSE

OPEN

CLOSE

OPEN

B
(F)

K2-03
M
OPEN

CLOSE

M
OPEN

CLOSE

POWER WINDOW
REGULATOR
LF

CLOSE

OPEN

G/B
(DR4)

R/B
(DR4)

K2-07
M
OPEN

CLOSE

POWER
WINDOW
SUBSWITCH
LR

K2-06

R/B
(DR3)

K2-04

POWER WINDOW
REGULATOR
RF

POWER
WINDOW
SUBSWITCH
RR

K2-05
G/B
(DR3)

R/B
(DR2)

K2-06

K2-05

POWER
WINDOW
SUBSWITCH
LF

K2-02
G/B
(DR2)

X-22

X-21

K2-08

POWER WINDOW
REGULATOR
RR

M
OPEN

CLOSE

POWER WINDOW
REGULATOR
LR

K2-01 POWER WINDOW MAIN SWITCH(DR1)

K2-02 POWER WINDOW SUBSWITCH LF(DR2)

K2-03 POWER WINDOW REGULATOR RF(DR1)

K2-04 POWER WINDOW REGULATOR LF(DR2)

W/R

G/Y

G/W R/W

L/W

R/L

R/B

R/W

G/B

G/B

R/L

G/B

R/B

G/W G/B

R/L

R/B

R/B

K2-05 POWER WINDOW SUBSWITCH RR(DR3)

G/B

R/L

K2-06 POWER WINDOW SUBSWITCH LR(DR4)

L/W

R/B

G/B

R/L

K2-07 POWER WINDOW REGULATOR RR(DR3)

L/W

K2-08 POWER WINDOW REGULATOR LR(DR4)

G/B

G/B

R/B

R/B

R/B

HARNESS SYMBOL :

(F)

(E)

(R)

[BLACK]
(F)-(E)

X-07
POWER WINDOW
SUBSWITCH RR

MAIN FUSE BLOCK

X-01

POWER WINDOW
MAIN SWITCH

K2-05

POWER WINDOW
REGULATOR RR

K2-07

K2-01
(R)-(DR3)

X-21
[BLUE]
POWER WINDOW
REGULATOR RF

K2-03
(F)-(DR1)

X-13
(F)-(R)

K2-08

X-06

POWER WINDOW
REGULATOR LR

Z-106

K2-06
(F)-(DR1)

X-22

X-14

POWER WINDOW
SUBSWITCH LR

(FR)-(DR4)

X-16
(F)-(DR2)
(F)-(DR1)

X-20

K2-02
POWER WINDOW
SUBSWITCH LF

(F)-(FR)

X-13
X-17
X-14
(F)-(DR1)

(F)-(DR2)

K2-04
POWER WINDOW
REGULATOR LF
[BLUE]

WIRING DIAGRAM

X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]

(F)-(DR2)

X-16
X-03
FUSE BLOCK

X-17

X-06
(F)-(R)

X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]

(F)-(DR2)

X-20

(F)-(FR)

K-2

K-3
POWER DOOR LOCKS
MAIN FUSE BLOCK

FUSE BLOCK
(D/L)

MAIN
B/W(E)
80A

X-01

B/W(F)
X-07

X-01

DOUBLE CAB
30A

X-03

X-03
G(F)

WITH THEFT-DETERRENT
SYSTEM
THEFT-DETERRENT
CONTROL MODULE 64
(SECTION T-2,4)

G(F)
G
(F)

G
(F)

G
(F)

G/O
(F)
W/G
(F)

G/O(F)

X-04
G
(FR)

X-17
X-21
K3-01

X-14

G
(DR2)
K3-03

LOCK

G
(DR4)

K3-04

K3-05
LOCK

LOCK
DOOR
LOCK-LINK
SWITCH

X-22

G
(DR3)

K3-02
UNLOCK

X-19

G
(R)

G
(F)

G/R(F)
G/O G/R
(DR1) (DR1)

WIRING DIAGRAM

B(E)

BATTERY
+

M
DOOR LOCK
TIMER UNIT

LOCK
M

UNLOCK

UNLOCK

UNLOCK

K3-02

G/Y
(DR1)

R
(DR3)

R
(DR2)

K3-01
X-14

DOOR LOCK
ACTUATOR
RR
K3-04

DOOR LOCK
ACTUATOR
LF
K3-03

R
(DR4)
X-21

Z-107

X-17
B
(F)

G/Y
(F)

G/Y
(F)

R
(F)

X-22

R
(R)

R
(FR)

R
(F)

X-04

X-19

R
(F)
G/Y(F)

K3-02 DOOR LOCK-LINK SWITCH(DR1)

G/O

G/R

W/G

G/O

R(F)

K3-03 DOOR LOCK ACTUATOR


LF(DR2)

K3-04 DOOR LOCK ACTUATOR RR(DR3)

G/Y
G

G/Y

R
(F)

R(F)

K3-01 DOOR LOCK TIMER UNIT(F)

G/R

B
G

LG/R

(WITHOUT
THEFT-DETERRENT
SYSTEM)
B

R
LG/R

(WITHOUT
THEFT-DETERRENT
SYSTEM)

(WITH
THEFT-DETERRENT
SYSTEM)

K3-05 DOOR LOCK ACTUATOR LR(DR4)

DOOR LOCK
ACTUATOR
LR
K3-05

(WITH
THEFT-DETERRENT
SYSTEM)

HARNESS SYMBOL :

(F)

(E)

(R)
DOOR LOCK
ACTUATOR RR

K3-04

[BLACK]
(F)-(E)

DOOR LOCK-LINK
SWITCH

X-07

K3-02

(R)-(DR3)

X-21

MAIN FUSE BLOCK

X-01
(F)-(R)

X-04

K3-05
DOOR LOCK
ACTUATOR LR

X-22
(FR)-(DR4)

K3-03
X-17

Z-108

X-14

DOOR LOCK
ACTUATOR LF

(F)-(DR2)

(F)-(DR1)

X-19
(F)-(FR)
DOOR LOCK TIMER UNIT

K3-01
3

X-14
(F)-(DR1)

X-17

WIRING DIAGRAM

X-03
FUSE BLOCK

X-04
(F)-(R)

(F)-(DR2)

X-19
(F)-(FR)

Z
K-3

L
POWER OUTSIDE MIRRORS

BATTERY
+
-

MAIN FUSE BLOCK


MAIN

A
B/W(E)

80A

X-01

B/W(F)

X-01

X-07

RIGHT

X-02
OFF

ST

LEFT
IG1

IG2

ACC

UP

DOWN

X-02

DOWN

UP
LEFT

LH

POWER
OUTSIDE
MIRROR
SWITCH

RIGHT

LH

RH

RH

L-01
L
(F)

BR
(F)
L/B
(F)

BR/Y
(F)

BR
(F)

BR
(F)

LG/B
(F)

BR/B
(F)

Z-109

X-16
B
(F)

BR/Y
(DR2)

BR
(DR1)

LEFT

UP

RIGHT

DOWN

FUSE BLOCK
CIGAR

BR/B
(DR1)

LG/B
(DR1)

X-03

L-02

L-03

L/W
(F)
X-13

BR
(DR2)

L/B
(DR2)

POWER
OUTSIDE
MIRROR
LH

UP

LEFT

DOWN

RIGHT

POWER
OUTSIDE
MIRROR
RH

L-01 POWER OUTSIDE MIRROR SWITCH(F)

BR
B

L/W

L-02 POWER OUTSIDE MIRROR RH(DR1)

LG/B

L/B

LG/B

BR/Y

BR/B

BR/B

L-03 POWER OUTSIDE MIRROR LH(DR2)

BR

IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)

L/B
BR/Y

BR

15A

X-03

WIRING DIAGRAM

B(E)

HARNESS SYMBOL :

(F)

(E)

(R)

POWER OUTSIDE
MIRROR RH

[BLACK]
(F)-(E)

L-02

X-07
MAIN FUSE BLOCK

X-01
(F)-(DR1)

X-13

L-03

Z-110

POWER OUTSIDE
MIRROR LH

X-16
(F)-(DR2)

(F)-(DR1)

X-13
L-01
POWER OUTSIDE
MIRROR SWITCH

X-02
(F)-(DR2)

X-16

WIRING DIAGRAM

ENGINE SWITCH (WL,WL Turbo)


[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]

X-02
X-03
FUSE BLOCK

ENGINE SWITCH (WL,WL Turbo)


[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

Z
L

WIRING DIAGRAM

AIR BAG SYSTEM


SERVICE WARNINGS
Component Disassembly

Air Bag Mudule Handling

Diisassembling and reassembling the


components of the air bag system can render
the system inoperative, which may result in
serious injury or death in the event of an
accident. Do not disassemble any air bag
system component.

A live (undeployed) air bag module may


accidently deploy when it is handled and
cause serious injury. When carrying a live
(undeployed) air bag module, point the front
surface away from your body to lessen the
chance of injury in case it deploys.

RIGHT

Wiring Harness Repair

Incorrectly repairing an air bag system wiring


harness can accidently deploy the air bag
module, which can cause serious injury. If a
problem is found in the system wiring , replace
the wiring harness. Do not try to repair it.

A live (undeployed) air bag module placed face


down on a surface is dangerous. If the air bag
module deploys, the motion of the module can
cause serious injury. Always face the front
surface up to reduce the motion of the module
in case it accidentaly deploys.

AIR BAG SYSTEM SERVICE CAUTIONS/SERVICE WARNINGS

RIGHT

Air Bag Module Inspection

Inspecting an air bag module using an


ohmmeter can deploy the air bag module,
which may cause serious injury. Do not use an
ohmmeter to inspec an air bag module.
Always use the on-board diagnostic function
to diagnose the air bag for malfunctions.
(Refer to ON-BOARD DIAGNOSTIC FUNCTION,
AIR BAG SYSTEM.)

*The references in this section can be found in Repair Manual [F161-10-99A (1999-1)]

Z-111

WRONG

WRONG

WIRING DIAGRAM

SAS Unit Handling

Discannecting the SASunit connector or


removing the SAS unit with the ignition switch
at ON position can cause the air bag modules
to deploy, which may seriously injure you.
Before disconnecting the SAS unit connector
or removing the SAS unit, turn the ignition
switch to LOCK position, then disconnect the
negative battery cable and wait for more than 1
minute to allow the backup power supply of
the SAS unit to deplete its stored power.
Connecting the SAS unit connector without
firmly installing the SAS unit to the vehicle is
dangerous. The crash sensor inside the unit
may send an electrical signal to the air bag
modules. This will deploy the air bag modules,
which may result in serious injury. Therefore,
before connecting the connector, firmly mount
the unit to the vehicle.
For vehicles with a single point sensor, once
an air bag is deployed due to an accident or
other causes, the SAS unit must be replaced
with a new one even if the used one does not
have any external signs of damage. The used
SAS unit may have been damaged internally
which may cause improper operation,
resulting in major injuries or even death. The
used single point SAS unit cannot be
bench-checked or self-checked.

Component Handling

AIR BAG SYSTEM SERVICE CAUTIONS/SERVICE WARNINGS

Oil, grease, water, etc on components may


cause the air bag modules to fail to deploy in an
accident, which may cause serious injury. Do
not allow oil, grease, water, etc on components.
Inserting a screwdriver, etc into the connector
of an air bag module may damage the
connector and cause the air bag module to
deploy improperly, which may cause serious
injury. Do not insert any foreign objects into
the connector.

Component Reusing

Even if an air bag madule does not deploy in a


collision and does not have any external signs
of damage, it may have been damaged
internally, which may cause improper
operation. Improper operation may cause
serious injury. Always self-check the
undamaged air bag module to determine
whether it can be reused. (Refer to ON-BOARD
DIAGNOSTIC FUNCTION, AIR BAG SYSTEM.)

*The references in this section can be found in Repair Manual [F160-10-99A (1999-1)]

Z-112

S-1

AIR BAG SYSTEM (before model year 2002)

< >...WITH PASSENGER-SIDE AIR BAG MODULE

MAIN FUSE BLOCK


MAIN

80A

B/W(F)
A

X-07

X-01

IG1

X-02
OFF

ST
IG2

WIRING DIAGRAM

B/W(E)

B(E)
X-01

ENGINE
SWITCH

ACC

FUSE BLOCK
METER

X-02
W(F)

B/Y(F)

B/Y(F)

15A

X-03

ENGINE
B/W(F)
15A

B/W(F)
S1-02

X-03

S1-01
Z

AB

SAS UNIT
S

AA

R/G
(F)

Y/G
(F)

L
(F)

LG
(F)

R
(F)

Y/R
(F)

B
(F)

B
(F)

S1-01

S1-03
SHORT BAR

S1-02
R/G
(F)

B
(F)

Y/G
(F)

SHORT
BAR

S1-04

LG

Z-113

CLOCK
SPRING
Y/G
(F)

Y/G
(F)

47

25

SHORT
BAR

LG
S1-05
INFLATOR

46

PASSENGER-SIDE
AIR BAG MODULE

SHORT BAR

INSTRUMENT CLUSTER
(SECTION C-1b)

DATA LINK CONNECTOR


(SECTION U)

WITH
PASSENGER-SIDE
AIR BAG MODULE

INFLATOR
DRIVER-SIDE
AIR BAG MODULE
8

S1-01 SAS UNIT(F)

S1-02 SHORT CONNECTOR(F)

S1-03 FRONT(F)-CLOCK SPRING


(F)

W
AA

G/R

Y/G

LG

Y/R

Y/G

Y/G

B/Y

B/W

R/G

R/G

AB

B/W

B/W

B/Y

S1-04 PASSENGER-SIDE AIR BAG MODULE(F)


B/Y

(CLOCK SPRING)

G/R
LG

R/G

S1-05 DRIVER-SIDE AIR BAG MODULE


(CLOCK SPRING)

BATTERY
+
-

Y/R

LG

LG

HARNESS SYMBOL :

(F)

(E)

(R)

[BLACK]
(F)-(E)

X-07

MAIN FUSE BLOCK

X-01

Z-114
7

(F)-(CLOCK SPRING)

S1-03

SHORT CONNECTOR

S1-02
PASSENGER-SIDE
AIR BAG MODULE

S1-05

S1-04

DRIVER-SIDE
AIR BAG MODULE

X-02

X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]

8
9

S1-01
SAS UNIT

WIRING DIAGRAM

X-03
FUSE BLOCK

ENGINE SWITCH (WL,WL Turbo)


[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]

Z
S-1

S-2
AIR BAG SYSTEM (WL-3, WLT-3, as of model year 2002)

BATTERY
+

MAIN
B/W(E)
80A

X-01

X-01

B/W(F)
X-07

IG1

X-02
OFF

ST
IG2

WIRING DIAGRAM

B(E)

ENGINE
SWITCH

ACC

X-02
METER
W(F)

B/Y(F)
X-03

B/Y(F)

15A
ENGINE
B/W(F)
15A

B/W(F)
S2-02

X-03

S2-01
Z

AB

SAS UNIT
Q

L
(F)

LG
(F)

R
(F)

Y/R
(F)

S2-01
Y/G
(F)

S2-03
SHORT BAR

B
(F)

S2-02

Z-115

Y/G
(F)

SHORT
BAR

S2-04

LG
CLOCK
SPRING

B
(F)

SHORT
BAR

LG
S2-05
INFLATOR

25

PASSENGER-SIDE
AIR BAG MODULE

SHORT BAR

INSTRUMENT
CLUSTER
(SECTION C-3b)

WITH
PASSENGER-SIDE
AIR BAG MODULE

INFLATOR

8
S2-01 SAS UNIT(F)

DRIVER-SIDE
AIR BAG MODULE

S2-02 SHORT CONNECTOR(F)

S2-03 FRONT(F)-CLOCK SPRING


(F)

W
AA

G/R B/Y
C

Y/G

LG

Y/R

B/W Y/G

Y/G B/W B/Y

AB

LG

R
S2-04 PASSENGER-SIDE AIR BAG MODULE(F)

B/Y B/W

G/R

(CLOCK SPRING)

S2-05 DRIVER-SIDE AIR BAG MODULE


(CLOCK SPRING)

Y/R

LG

LG

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

MAIN FUSE BLOCK

X-01

(F)-CLOCK SPRING

S2-03

Z-116

7
SHORT CONNECTOR
[YELLOW]
PASSENGER-SIDE
AIR BAG MODULE

[YELLOW]
DRIVER-SIDE
AIR BAG MODULE

S2-02

S2-05

S2-04
X-07
(F)-(E)
[BLACK]

X-02
ENGINE SWITCH
[WHITE]

WIRING DIAGRAM

X-02
X-03

ENGINE SWITCH
[BLUE]

FUSE BLOCK

S2-01
SAS UNIT

Z
S-2
From No.
F175-30-01I

T-1

IMMOBILIZER SYSTEM (before model year 2002)

MAIN FUSE BLOCK

BATTERY
+
-

X-01

X-01

MAIN

A
B/W(F)

B/W(F)

80A

X-07

WIRING DIAGRAM

B(E)

X-02

BTN
W/R(E)

W/R(F)

30A

INSTRUMENT
CLUSTER
(SECTION C-1a)

X-08

FUSE BLOCK
ROOM

IG1

L/R(F)
10A
FUSE BLOCK
ENGINE

X-03

IG2

ENGINE
SWITCH

ACC

X-02

W/R(F)

51

OFF

ST

X-03

W(F)
15A

X-03
BR/B
(F)

L/R
(F)

B/W
(F)

X-03

T1-01
IMMOBILIZER UNIT
C

COIL

D
T1-02

T1-01

B/R
(F)

V/W
(F)

B/W(F)

GY(F)

Y(F)
B2-09

Z-117

FUEL
INJECTION
PUMP

DDS1

49
PCM
(SECTION B-2a)

B2-09
B/R
(F)

T1-01 IMMOBILIZER UNIT(F)


M

16

T1-02 COIL(F)
I

B/R

BR/B

V/W
GY

B/W
N

L/R
J

GY

B2-09 FUEL INJECTION PUMP(F)

R/L

B/R

G/W B/W

BR/W

L/B

B/R
F

V/W

(F)

HARNESS SYMBOL :

(E)

(R)

6
MAIN FUSE BLOCK

X-01

Z-118

X-07
(F)-(E)
[BLACK]

X-08
(F)-(E)
[BLACK]

COIL

T1-02
B2-09
FUEL INJECTION PUMP
[GRAY]

16

X-02

X-03
FUSE BLOCK

X-02
ENGINE SWITCH
[BLUE]

T1-01
IMMOBILIZER UNIT

WIRING DIAGRAM

ENGINE SWITCH
[WHITE]

Z
T-1

T-2

THEFT-DETERRENT SYSTEM (before model year 2002)


MAIN
B/W(E)
80A

X-01

B/W
(E)

BTN

B/W(F)

X-01

X-07

X-08

B/W
(F)

FUSE BLOCK

61

G/R(F)

T2-02
THEFTDETERRENT
RELAY

15A
X-03
G/W
(F)
A
T2-03
THEFTDETERRENT
HORN RELAY

X-03

HAZARD
WARNING
SWITCH
(SECTION
F-1)

IG1

IG2

X-02

ENGINE
SWITCH
FUSE BLOCK
ENGINE

ACC

15A

ROOM
10A

X-03

KEY LEMINDER
SWITCH
(SECTION
C-1a)

TURN SWITCH
(SECTION F-1)

W(F)
X-03

G/W(F)
15A

X-03

X-02
OFF

X-03

STOP

L/Y(F)
L/Y
(F)

W/R
(F)

W/R
(F)

FUSE BLOCK

HAZARD

L/Y
(F)

ST

W/R(F)

W/R(E)
30A

X-07

DOOR LOCK
TIMER UNIT
(SECTION
K-3)

INTSRUMENT
CLUSTER
(SECTION
C-1a)

60

59

58

64

56

G/B
(F)

G/W
(F)

L/Y
(F)

G/O
(F)

BR/B
(F)

2K

2Q

X-03

FUSE
BLOCK
B/W
(F)

X-03
L/R
(F)

T2-01

T2-03

T2-02

P/L(F)
Y/R(F)

2D
1A
1D
1E
THEFT-DETERRENT CONTROL MODULE
2O

1B

2C
2S

1F

2N

2M

1C

2R

T2-01
T2-01

G/Y
(F)

LG/R(F)
GY/B
(F)

BR/W
(F)

B
(F)

LG/R
(FR)

LG/R
(R)

Z-119

FLASHER UNIT
(SECTION F-1)

T2-04

T2-05
THEFT-DETERRENT
HORN

BONNET
SWITCH
T2-04

B
(F)

X-23

K3-04

DOOR
LOCK-LINK
SWITCH LR
K3-05

DOOR
LOCK-LINK
SWITCH RR
K3-04

X-24

X-14
B
(F)

B
(F)

B(F)

65
DOOR SWITCHS
(SECTION I-3)

B
(DR1)
X-17

B(R)

63
FLASHER UNIT
(SECTION F-1)

T2-06

T2-07
B
(DR2)

X-23

B
(FR)

DOOR KEY
CCYLINDER
SWITCH
RF

DOOR KEY
CCYLINDER
SWITCH
LF

B
(DR3)

B
(DR4)

T2-06

T2-07

K3-05

R/Y
(F)

G/O
(F)

BR/R
(DR1)

BR/R
(DR2)

LG/R
(DR3)

LG/R
(DR4)

X-14

X-17

X-24
62

BR/R(F)

X-04

X-19

X-04
3

17

DOUBLE CAB
T2-01 THEFT-DETERRENT CONTROL MODULE(F)
1F

1E

G/W

1D

1C

G/B

G/O

1B

1A

L/R

B/W

2M
2S

2Q

2O

Y/R

BR/B

BR/R

2T

BR/R

2R

(LG/R)

2G

G/O

2P

BR/R

2N

2C

2A

P/L

2L

2J

2H

2F

2D

K3-04 DOOR LOCK-LINK


SWITCH RR(DR3)

T2-02 THEFT-DETERRENT
RELAY(F)

L/Y

G/W
G/W

G/W

Y/R

GY/B

G/Y

G/R

T2-03 THEFT-DETERRENT
HORN RELAY(F)
C

L/Y

L/Y

BR/W

T2-07 DOOR KEY CYLINDER


SWITCH LF(DR2)

2I

2E

R/Y

T2-06 DOOR KEY CYLINDER


SWITCH RF(DR1)

2K

2B

K3-05 DOOR LOCK-LINK


SWITCH LR(DR4)

LG/R

LG/R

P/L

T2-04 BONNET SWITCH(F)

BR/W

T2-05 THEFT-DETERRENT
HORN(F)

GY/B

WIRING DIAGRAM

B(E)

( )...DOUBLE CAB

MAIN FUSE BLOCK

BATTERY
+
-

(F)

HARNESS SYMBOL :

(E)

(R)
(R)-(DR3)

[BLACK]
BONNET
SWITCH

X-23

THEFT-DETERRENT
HORN RELAY

DOOR LOCK-LINK
SWITCH RR

K3-04

DOOR KEY CYLINDER


SWITCH RF

T2-03

T2-06

T2-04
MAIN FUSE BLOCK

(F)-(R)

X-01

X-04

K3-05
DOOR LOCK-LINK
SWITCH LR

X-24
(FR)-(DR4)

17

X-14

T2-07

(F)-(DR1)

X-17

Z-120

X-19

DOOR KEY CYLINDER


SWITCH LF

(F)-(DR2)

(F)-(FR)

T2-05

[BLACK]
THEFT-DETERRENT
CONTROL MODULE

THEFT-DETERRENT HORN

T2-01

X-07
(F)-(E)
[BLACK]

X-08

(F)-(DR1)

(F)-(E)
[BLACK]

X-14

T2-01
THEFT-DETERRENT
CONTROL MODULE

WIRING DIAGRAM

X-02
ENGINE SWITCH
[WHITE]
THEFT-DETERRENT
RELAY

T2-02
X-02

X-03
FUSE BLOCK

X-04

ENGINE SWITCH
[BLUE]

(F)-(R)

X-17
(F)-(DR2)

X-19
(F)-(FR)

T-2

T-3
IMMOBILIZER SYSTEM (WL-3, WLT-3, as of model year 2002)
X-01

X-01

A
B/W(F)

B(E)
80A

WIRING DIAGRAM

MAIN

BATTERY
+

B/W(F)
A

X-07

X-02

BTN
W/R(E)
30A

W/R(F)

OFF

ST

X-08
IG1

IG2

ENGINE
SWITCH

ACC

X-02
W
(F)
X-03

X-03
ROOM
10A

X-03

ENGINE
15A
X-03

L/R
(F)

B/W
(F)

T3-01

IMMOBILIZER UNIT
C

B/R
(F)

W
(F)

R
(F)

BR/B
(F)

P
(F)

Y
(F)

GY
(F)

70

66

51

73

PCM
(SECTION B-6b)

STARTER
RELAY
(SECTION A-3)

INSTRUMENT
CLUSTER
(SECTION C-3a)

KEY REMINDER
SWITCH
(SECTION C-3a)

T3-01

Z-121

T3-02

20
T3-01 IMMOBILIZER UNIT(F)
M
BR/B

T3-02 COIL(F)
I

B/W

L/R

GY

B/R

W
GY

COIL

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

[BLACK]
(F)-(E)

(R)

(F)-(E)

X-08

X-07
MAIN FUSE BLOCK

X-01

20

Z-122
COIL

T3-02

X-02
ENGINE SWITCH
[WHITE]

WIRING DIAGRAM

X-02
X-03

ENGINE SWITCH
[BLUE]

FUSE BLOCK

T3-01
IMMOBILIZER UNIT

Z
T-3
From No.
F175-30-01I

T-4
THEFT-DETERRENT SYSTEM (WL-3, WLT-3, as of model year 2002)

BATTERY
+

MAIN

B/W(E)
80A

X-01

BTN

B/W(F)

W/R(E)
30A

X-01

X-03
HAZARD
61 WARNING
G/R(F)
SWITCH
T4-02
(SECTION
THEFTF-3)
DETERRENT
RELAY
T4-02

Y/R(F)

ENGINE
SWITCH
ENGINE

X-02

2S

KEY LEMINDER
SWITCH
(SECTION
C-3a)

TURN SWITCH
(SECTION F-3)

ACC

W(F)
15A

X-03

DOOR LOCK
TIMER UNIT
(SECTION
K-3)

INTSRUMENT
CLUSTER
(SECTION C-3a)

60

59

58

64

56

G/B
(F)

G/W
(F)

P
(F)

G/O
(F)

BR/B
(F)

2K

2Q

X-03

ROOM
10A

15A
X-03
X-03
G/W
(F)
A
T4-03
THEFTDETERRENT
HORN RELAY
T4-03
P/L(F)
2C

15A

IG2

X-03

G/W(F)
X-03

X-02
OFF

IG1

W/R
(F)

W/R
(F)

STOP

L/Y(F)
L/Y L/Y
(F)
(F)
A
E

X-08

B/W
(F)

HAZARD

ST

W/R(F)

X-07

X-07

B/W
(E)

B/W
(F)

X-03
L/R
(F)

T4-01
1A
2D
1D
1E
THEFT-DETERRENT CONTROL MODULE
2O

1B

1F

2N

2M

2R

1C

T4-01

T4-01

G/Y
(F)

LG/R(F)

X-19
GY/B
(F)

B
(F)

BR/W
(F)

LG/R
(FR)

62

Z-123

T4-04

T4-05
THEFT-DETERRENT
HORN

B
(F)

B
(DR4)
X-24

BR/R
(DR1)

T4-07

K3-04
DOOR
LOCK-LINK
SWITCH RR
K3-04

T4-06

DOOR KEY
CCYLINDER
SWITCH
LF
T4-07
B
(DR2)

B
(DR3)
X-23

B
(FR)

X-14

BR/R
(DR2)

LG/R
(DR3)

K3-05
DOOR
LOCK-LINK
SWITCH LR
K3-05

T4-04

X-17
X-23

LG/R
(DR4)

BONNET
SWITCH

BR/R(F)

LG/R
(R)

X-24
FLASHER UNIT
(SECTION F-3)

BR/R
(F)

X-04

DOOR KEY
CCYLINDER
SWITCH
RF
T4-06
B
(DR1)

X-17

B(R)

B(F)

R/Y
(F)

G/O
(F)

65

63
FLASHER UNIT
(SECTION F-3)

DOOR SWITCHS
(SECTION I-3)

X-14

B
(F)

B
(F)

X-04
3

17

DOUBLE CAB
T4-01 THEFT-DETERRENT CONTROL MODULE(F)
1F

1E

G/W

1D

1C

2S
1B

G/B G/O L/R

2Q

2O

BR/R

2I

2G

2E

2R

2N

T4-07 DOOR KEY CYLINDER


SWITCH LF(DR2)
B

BR/R

2A

2L

2J

2H

2F

2D

K3-04 DOOR LOCK-LINK


SWITCH RR(DR3)

T4-02 THEFT-DETERRENT
RELAY(F)
E

L/Y

BR/W
2P

2C

P/L

Y/R BR/B BR/R LG/R G/O

2T

2K

1A

B/W

R/Y
T4-06 DOOR KEY CYLINDER
SWITCH RF(DR1)

2M

G/Y

G/R

L/Y

G/W
G/W

G/W

Y/R

2B

K3-05 DOOR LOCK-LINK


SWITCH LR(DR4)

LG/R

LG/R

T4-03 THEFT-DETERRENT
HORN RELAY(F)

GY/B P/L

T4-04 BONNET SWITCH(F)

BR/W

T4-05 THEFT-DETERRENT HORN(F)

GY/B

WIRING DIAGRAM

B(E)

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

THEFT-DETERRENT
HORN RELAY
THEFT-DETERRENT
RELAY

T4-02

[BLACK]
BONNET
SWITCH

T4-03

DOOR LOCK-LINK
SWITCH RR

T4-04

K3-04
(R)-(DR3)
DOOR KEY CYLINDER
SWITCH RF

MAIN FUSE BLOCK

X-23

T4-06

X-01

(F)-(R)

X-04

K3-05
DOOR LOCK-LINK
SWITCH LR

X-24
(FR)-(DR4)

Z-124

X-14
17

(F)-(DR1)

X-07

T4-07

(F)-(E)
[BLACK]

T4-05
X-08

X-17

[BLACK]
THEFT-DETERRENT
CONTROL MODULE

THEFT-DETERRENT HORN

T4-01

(F)-(E)

X-19
3

DOOR KEY CYLINDER


SWITCH LF

(F)-(DR2)

(F)-(FR)

5
4

(F)-(DR1)

X-14
T4-01
THEFT-DETERRENT
CONTROL MODULE

WIRING DIAGRAM

X-02
ENGINE SWITCH
[WHITE]

X-02
ENGINE SWITCH
[BLUE]

X-03

X-04
(F)-(R)

FUSE BLOCK

X-19

X-17
(F)-(DR2)

(F)-(FR)

T-4
From No.
F175-30-01I

DATA LINK CONNECTOR (before model year 2002)

BATTERY
+

MAIN FUSE BLOCK


MAIN

X-01

80A

B/W(F)
A

X-07

X-01

X-02
OFF

ST
IG1

WIRING DIAGRAM

B/W(E)

B(E)

IG2

ENGINE
SWITCH

ACC

FUSE BLOCK
METER

X-02
W(F)

15A

X-03
12

BR/R(F)

10

Y/B(F)

X-03

PCM
(SECTION B-2b)

B/Y(F)

Y/G(F)

47

R/G(F)

46

SAS UNIT
(SECTION S-1)
U-01
DATA LINK
CONNECTOR

Z-125

B
(F)

B/R
(F)

U-01 DATA LINK CONNECTOR(F)

WL,WL Turbo

FEN

TEN

+B

GND

FAB

Y/B

BR/R

B/Y

B/R

GND

TAB

Y/G

NOTE:THIS IS THE CONNECTOR AS SEEN FROM THE TERMINAL SIDE.

R/G

HARNESS SYMBOL :

(F)

(E)

(R)

[BLACK]
(F)-(E)

X-07

MAIN FUSE BLOCK

X-01

DATA LINK CONNECTOR

U-01

Z-126
2

X-02
ENGINE SWITCH
[WHITE]

WIRING DIAGRAM

X-02
ENGINE SWITCH
[BLUE]

X-03
FUSE BLOCK

Z
U

U-2

DATA LINK CONNECTOR (WL-3, WLT-3, as of model year 2002)

MAIN
B(E)

B/W(E)
X-01

80A

X-01

B/W(F)

X-07

X-02
OFF

ST
IG1

WIRING DIAGRAM

BATTERY
+

IG2

ENGINE
SWITCH

ACC

X-02
METER
W(F)
X-03

PCM
(SECTION B-6b)

12

BR/R(F)

69

Y/R(F)

10

B/Y(F)

15A

X-03

B/Y
(F)

INSTRUMENT
47
CLUSTER
(SECTION C-3b)

Z-127

B/R
(F)

PCM
68
(SECTION B-6b)

Y/G(F)
U2-01
DATA LINK
CONNECTOR

B
(F)

W/L(F)

20

U2-01 DATA LINK CONNECTOR(F)


A
FEN KLN
GND

TEN

+B

B/Y

D
BR/R

Y/R

B/R

FAB IG- GND

Y/G W/L

NOTE:THIS IS THE CONNECTOR AS SEEN FROM THE TERMINAL SIDE.

B/Y

From No.
F175-30-01I

HARNESS SYMBOL :

(F)

(E)

(R)

MAIN FUSE BLOCK

X-01

U2-01
DATA LINK CONNECTOR

20

Z-128
X-07
(F)-(E)
[BLACK]

X-02
2

ENGINE SWITCH
[WHITE]

X-03
FUSE BLOCK

WIRING DIAGRAM

X-02
ENGINE SWITCH
[BLUE]

Z
U-2
From No.
F175-30-01I

X-1

COMMON CONNECTOR LIST (before model year 2002)

X-03 FUSE BLOCK(F)

WITH
AIR CONDITIONER

(R)
30A

1
R
R
30A

W/R
30A

B/W

R/B
80A

10A

B/W
B

60A

15A

B/R

LG/R

10A

L/Y

10

W/G

11

B/R

40A

17

A
30A

B/W B/W

15A

L/W

18

(A/C)

12

HAZARD

13

(D/L)

14

METER

R.DEF
-

15

ENGINE

16

STOP

17

(HEATER)

TAIL
ROOM

18

WIPER
-

20

B/W

20A

12

19

13

20

9
10
11

B/W

B/Y

15A

G/W

B/Y

14

15A

L
HEAD

BTN

MAIN

B/R

W/R

GLOW

10A

Y/R

10A

L/R

B/W

16

30A

R/L

R.FOG

22

(P.WIND)

22

R/Y

NOTE: THIS IS THE CONNECTOR AS SEEN


FROM THE TERMINAL SIDE.
( )...F2 CARB

21

WITH
REAR FOG LIGHT

15

15A

CIGAR
-

21

W
1

19

10A

R/G

21

NOTE: THIS IS THE CONNECTOR AS SEEN FROM THE TERMINAL SIDE.

X-04 FRONT(F)-REAR(R)

WL,WL Turbo

W/G R/W

R/Y

(F)
B/L

<G>

BR
(R)
B

<R>

(LG/R)
R/L]

R/B

G/W G/B

G/R

( L G / R ) ((B R))
[R/L]

B/L

(B)

R/W W/G B/R

R/Y

R/L

G/B

G/W R/B

<R>

<G>

B/L

(F)

(R)
L/W

R/L

(F)
W

L/W

W/G R/W
R/B

R/Y

BR

R/Y

G/W G/B

R/W W/G B/R

G/R

(R)
Y

G/B

G/W R/B

B/L

( )...WITH THEFT-DETERRENT SYSTEM


(( )) . . . N O T U S E D
X-08 FRONT(F)-ENGINE(E)

X-07 FRONT(F)-ENGINE(E)

X-06 FRONT(F)-REAR(R)

B/O

(F)

B/W B/W

(E)

< >...DOUBLE CAB

Z-129

B/R

F2 CARB

]...U.K. SPECS.

B/W B/W

(F)

B/Y

W/R

R/W
(R/L)

W/R

B/Y

(E)
(Y/R)

(R/W)

(R/W) (Y/R)

R/W
(R/L)

( )...F2 CARB

WIRING DIAGRAM

X-02 ENGINE SWITCH(F)


(WL,WL Turbo)
IGNITION SWITCH(F)
(F2 CARB)

X-01 MAIN FUSE BLOCK(E)

COMMON CONNECTOR LIST (before model year 2002)


X-09 FRONT(F)-ENGINE(E)

X-12 FRONT(F)-DOOR NO.1(DR1)

X-11 FRONT(F)-INTERIOR LIGHT(IN)

R/Y

L/Y

(F)
WL,WL-T.WITHOUT RFW
(F)

(F)

R/L

BR/B

LG/B

BR

(F)

(F)

L/R

F2 CARB

WL,WL-T,WITH RFW

X-13 FRONT(F)-DOOR NO.1(DR1)

L/R

(F)
I

Y/R
(R/G)

W/B

B/Y

L/W

W
G/R

B/R

Y/R

<GY/R>

R/G

W/B

B/Y

LG/B

L/W

W
G/R

B/R

B/W

B/L

W/B

B/Y

GY/R

B/W

Y/B

L/W

R/Y

BR/B

L/Y

(IN)

(DR1)

(DR1)

L/R

BR

L/R

(R/L)

LG/B

( )...WITH POWER WINDOWS


X-15 FRONT(F)-DOOR NO.2(DR2)

X-14 FRONT(F)-DOOR NO.1(DR1)


(E)

(E)

(E)
I

B/R
<GY/R>

B/Y

G/R

Y/R

W/B
L/W

(R/G)

B/R
GY/R

B/Y

G/R

W/B

L/W

R/G

Y/R

B/O

B/Y
L

LG/B

W/B
L/W

B/L
Y/B

B/W

[BR/R] <G/Y>

(F)

<W/R>

B/W

<W>

BR/Y

(F)
L/B

BR/Y

(R/L)

(DR2)
BR

(DR2)

G/W

[BR/R]

G/B

(R/L)

(R)
B/R

G/R

W/G

L/W
(F)

<W>

G/Y
G/R

<L/W>

G/O

<G/Y>

L/W

[BR/R]

(DR2)
L

(G/W) (R/W) <W/R>

R/B

R/W

G/W

<G/R>

<R>

(F)

(R2)

<G/R>

G/B
G/W

R/B

W/G B/R

<R>

(FR)
[LG/R]

[ ]...U.K.SPECS. ( )...WITH POWER WINDOWS

( )...U.K. SPECS. < >...F2 CARB


X-23 REAR(R)-DOOR No.3(DR3)

X-22 FLOOR(FR)-DOOR NO.4(DR4)

DOUBLE CAB

[LG/R]

(R/L)

R/W

(G/W) (R/W)

X-21 REAR(R)-DOOR NO.3(DR3)

((R/Y))

<G>

R/Y

<G>

(( ))...WITH DOOR SWITCH


[ ]...U.K.SPECS. < >...DOUBLE CAB
X-24 FLOOR(FR)-DOOR No.4(DR4)

DOUBLE CAB

G/Y
(F)
W/R

R/L

L/W

L/W

R/L

(R)

G/Y

W/R

L/W

(R)

LG/R

(FR)

(DR4)

LG/R

R/L

(FR)

G/Y
(FR)
R/L

W/R

(DR3)

R/L

(DR4)

(DR3)

LG/R

LG/R

R/L

WIRING DIAGRAM

X-20 FRONT(F)-FLOOR(FR)

[B]

[B]

L/B

( )...WITH POWER WINDOWS

BR/R]

R/W

BR

X-18 REAR(R)-REAR NO.2(R2)

Z-130

R/L
(F)

G/W G/O

( )...WITH POWER WINDOWS


[ ]...U.K. SPECS.
< >...DOUBLE CAB WITH POWER WINDOWS
X-19 FRONT(F)-FLOOR(FR)

( )...WITH AIR CONDITIONER < >...4X4


X-17 FRONT(F)-DOOR NO.2(DR2)

R/W

G/Y

K
<L/W>

(DR1)

X-16 FRONT(F)-DOOR NO.2(DR2)

Z
X-2

X-3

COMMON CONNECTOR LIST (WL-3, WLT-3, as of model year 2002)


X-02 ENGINE SWITCH(F)

X-01 MAIN FUSE BLOCK(E)

X-03 FUSE BLOCK(F)

3
10A LG/R

R
R

W/R

30A

30A

R/B
80A

60A

B/W B/W

15A

B/R

B/R 40A

17

4
5

10

B/W 10A L/Y

30A

W/G

11

20A

12

19

15A

L/W

13

20

14

15A

L/W

18

7
8

B/W

9
10
11

B/W

L
1

HEAD

BTN

MAIN

B/Y

15A

B/R

Z-131

R/B G/W G/B

(R)
B

<LG/R>

R/Y

R/L

16

30A

R/L

R/L

X-07 FRONT(F)-ENGINE(E)

(F)
W

L/W

G/B G/W R/B

L/W

(E)

B/W B/W

(F)

<LG/B>

W/B

G/B

<GY/R>

L/W

(F)

(B) BR/W G/Y

B/R

(F)

BR/B

BR/R G/Y

G/Y L/W

R/W G/W G/O G/R

K
<GY/R>

(E)

L/W

Y/R BR/Y

B/R

G/B

21
22

22

(DR1)

<R/G>

(E)

<LG/B>

< >...4X4

G/Y

<G/Y>

BR/R

G/R G/O G/W R/W <W/R>


<W>

G/Y BR/W
BR/B

<L/W>

( )...NOT USED

B/L

W/R

R/W

W/R

B/L

R/W

(E)

X-14 FRONT(F)-DOOR NO.1(DR1)

<W/R>

W/B B/Y

19
20

<R> <G> B/L

X-10 FRONT(F)-ENGINE(E)

B/Y

18

(F)

( )...NOT USED < >...DOUBLE CAB

BR/Y Y/R

16
17

21

B/W B/W

(R)

R/W W/G B/R (G/R)

X-09 FRONT(F)-ENGINE(E)

<R/G>

15

X-08 FRONT(F)-ENGINE(E)

(F)

R/L
(BR)

14

METER
ENGINE
HEATER
CIGAR
R.FOG
P.WIND

15

B/W 15A

R/L

R/Y LG/R

W/G R/W

R/Y 10A R/G

13

NOTE: THIS IS THE CONNECTOR AS SEEN FROM THE TERMINAL SIDE.

X-06 FRONT(F)-REAR(R)

L/R

10A

(F)
G

W/R 10A Y/R

GLOW

X-04 FRONT(F)-REAR(R)

B/R

B/Y 15A

12

NOTE: THIS IS THE CONNECTOR AS SEEN


FROM THE TERMINAL SIDE.

B/L

G/W

A/C
HAZARD
D/L
R.DEF
FIP
STOP
TAIL
ROOM
WIPER
-

< >...DOUBLE CAB

WIRING DIAGRAM

From No.
F175-30-01I

COMMON CONNECTOR LIST (WL-3, WLT-3, as of model year 2002)


X-17 FRONT(F)-DOOR NO.2(DR2)

BR/R

(F)
R/W G/W

BR/R

B
R

R/L

G/W R/W

G/B (G/R)

(R)
B/R W/G R/B R/W G/W

(DR2)
G

X-19 FRONT(F)-FLOOR(FR)

X-18 REAR(R)-REAR NO.2(R2)

G/B

Z-132

(R)

(DR3)

R/Y

(LG/R)

R/L

(R2)
Y

G/W R/W R/B W/G

B/R

(R)

(FR)
(LG/R)

(
X-23 REAR(R)-DOOR No.3(DR3)

R
(F)

)...NOT USED

R/Y

(G)

( )...DOUBLE CAB

X-24 FLOOR(FR)-DOOR No.4(DR4)

LG/R

LG/R

(FR)

(DR4) LG/R

LG/R

WIRING DIAGRAM

Z
X-4
From No.
F175-30-01I

PARTS INDEX
4

H
4X4 INDICATOR SWITCH...............................Z-49,91,93

HAZARD WARNING SWITCH .............................Z-77


HAZARD WARNING SWITCH ILLUMINATION
...............................................................................Z-95
HEADLIGHTS...................................................Z-67,69
HEADLIGHT LEVELING ACTUATOR...................Z-69
HEADLIGHT LEVELING SWITCH ........................Z-69
HEADLIGHT SWITCH......................................Z-69
HORN....................................................................Z-79,83
HORN RELAY.......................................................Z-79,83
HORN SWITCH.....................................................Z-79,83

A
A/C RELAY .......................................................Z-85,87
A/C SWITCH.....................................................Z-85,87
AUDIO ILLUMINATION .........................................Z-95
AUDIO UNIT..........................................................Z-101

B
BACK-UP LIGHTS.................................................Z-79,83
BACK-UP LIGHT SWITCH....................................Z-79,83
BLOWER MOTOR............................................Z-85,87
BONNET SWITCH.................................................Z-119
BRAKE FLUID LEVEL SENSOR......................Z-49,55
BRAKE LIGHTS.....................................................Z-79,83
BRACK SWITCH...................................................Z-79,83

I
IGNITION COIL .....................................................Z-35
IMMOBILIZER UNIT..............................................Z-117
INSTRUMENT CLUSTER.................Z-47,49,51,53,55
INTERIOR LIGHT ..................................................Z-99

K
CARBURETOR......................................................Z-37
CHECK CONNECTOR ..........................................Z-35
CIGARETTE LIGHTER..........................................Z-97
CLIMATE CONTROL UNIT ..............................Z-85,87
CLIMATE CONTORL UNIT ILLUMINATION .........Z-95
CLOCK ..................................................................Z-97
CLOCK SPRING....................................................Z-113
COIL......................................................................Z-117

KEY REMINDER SWITCH ....................................Z-47

L
LICENSE PLATE LIGHTS.....................................Z-71,75
LOCK SOLENOID .................................................Z-91

M
MAGNETIC CLUTCH .......................................Z-85,87

N
DATA LINK CONNECTOR....................................Z-125
DOOR KEY CYLINDER SWITCH..........................Z-119
DOOR LOCK ACTUATORS..................................Z-107
DOOR LOCK TIMER UNIT....................................Z-107
DOOR LOCK-LINK SWITCH............................Z-107,119
DOOR SWITCHES ................................................Z-99
DRIVER-SIDE AIR BAG MODULE........................Z-113

NE SENSOR.....................................................Z-27,31
NEUTRAL SWITCH...............................................Z-91
NOISE FILTER ......................................................Z-35

O
OIL PRESSURE SWITCH................................Z-47
OUTLET.................................................................Z-97

P
EGR SOLENOID VALVE.......................................Z-33
ENGINE COOLANT TEMPERATURE SENSOR..........
..........................................................................Z-27,31

PANEL LIGHT CONTROL SWITCH......................Z-95


PARKING BRAKE SWITCH .............................Z-49,55
PARKING LIGHTS.................................................Z-71,75
PASSENGER-SIDE AIR BAG MODULE...............Z-113,115
PCM...................................................Z-27,29,31,33,37
POSITIVE TEMPERATURE COEFF ICIENT HEATER
...............................................................................Z-37
POSITIVE TEMPERATURE COEFF ICIENT HEATER
RELAY ...................................................................Z-37
POWER OUTSIDE MIRRORS..............................Z-109
POWER OUTSIDE MIRROR SWITCH.................Z-109
POWER WINDOW MAIN SWITCH..................Z-103,105
POWER WINDOW REGULATORS..................Z-103,105
POWER WINDOW SUBSWITCH.....................Z-103,105

F
FAST IDLE CAM BREAKER SOLENOID VALVE
...............................................................................Z-37
FICD SOLENOID VALVES..........................Z-27,31,87
FILAMENT .............................................................Z-97
FLASHER UNIT.....................................................Z-77,81
FREE SOLENOID..................................................Z-91
FRONT SIDE TURN LIGHTS................................Z-77,81
FRONT TURN LIGHTS.........................................Z-77,81
FUEL GAUGE SENDER UNIT ..............................Z-39
FUEL INJECTION PUMP............................Z-27,31,117
FUEL PUMP RELAY .............................................Z-39

G
GENERATOR ...................................................Z-21,23
GLOW PLUG ....................................................Z-27,31
GLOW PLUG RELAY .......................................Z-27,31

R
REAR FOG LIGHT................................................Z-71,75
REAR FOG LIGHT RELAY....................................Z-71,75
REAR FOG LIGHT SWITCH.................................Z-71,75
REAR TURN LIGHT..............................................Z-77,81

Z-133

PARTS INDEX
REAR WINDOW DEFROSTER RELAY ................Z-97
REAR WINDOW DEFROSTER SWITCH..............Z-97
REFRIGERANT PRESSURE SWITCH ............Z-85,87
RESISTOR........................................................Z-85,87
RFW CONTROL MODULE....................................Z-91
RFW MAIN SWITCH .............................................Z-91
RFW SWITCH .......................................................Z-91

S
SAS UNIT..............................................................Z-113
SEDIMENTOR SWITCH........................................Z-47
SHORT CONNECTOR ....................................Z-79,113
SPEAKERS...........................................................Z-101
STARTER .........................................................Z-21,23

T
TAILLIGHTS..........................................................Z-71,75
THEFT-DETERRENT CONTROL MODULE.........Z-119
THEFT-DETERRENT HORN................................Z-119
THEFT-DETERRENT HORN RELAY....................Z-119
THEFT-DETERRENT RELAY...............................Z-119
THEFT-DETERRENT UNIT...................................Z-119
THERMOSWITCH ............................................Z-85,87
TURN SWITCH......................................................Z-77,81

V
VACUUM SWITCH ................................................Z-49
VEHICLE SPEEDOMETER SENSOR..............Z-47,53

W
WATER TEMPERATURE SENDER UNIT .......Z-47,53
WATER THERMOSWITCH ...................................Z-37
WINDSHIELD WASHER MOTOR .........................Z-63
WINDSHIELD WIPER AND WASHER SWITCH ..........
...............................................................................Z-63
WINDSHIELD WIPER MOTOR .............................Z-63

Z-134

SECTION TITLE

RANGER
2003
Righthanddrive
(RHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.

SECTION

General Information

GI

Ground points

Schematic

System circuit diagrams /


Component Location Views

A~U

Connectors

Parts index

PI

As all information in this manual was the best


available at the time of printing, vehicle
specification an other information will be updated
in Service Information.
Ford Motor Company

E 2002 Ford Motor Company


All rights reserved. Reproduction by any means,
electronic or mechanical including photocopying,
recording or by any information storage and retrieval
system or translation in whole or part is not permitted
without written authorisation from Ford Motor Company.

Wire colours
Colour

Code

Colour

Code

Black

Orange

Blue

Pink

Brown

BR

Purple

Dark blue

DL

Red

Dark green

DG

Sky blue

Green

PU
R
SB

Tan

Grey

GY

Violet

Light blue

LB

White

Light green

LG

Yellow

Natural

TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
GROUND POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL WIRING SCHEMATIC . . . . . . . . . . . 16

INTERIOR LIGHTING SYSTEMS


ILLUMINATION LIGHT . . . . . . . . . . . . . . . . . . . . . 54
INTERIOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . 56

ENGINE-RELATED SYSTEMS
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
ENGINE CONTROL SYSTEM . . . . . . . . . . . . . .
GLOW SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTERIOR LIGHTING SYSTEMS


HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LICENSE PLATE LIGHT . . . . . . . . . . . . . . . . . . .
PARKING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . .
TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT LEVELING SYSTEM . . . . . . . . . .
REAR FOG LIGHT . . . . . . . . . . . . . . . . . . . . . . . .
TURN AND HAZARD WARNING LIGHT . . . . .
BACK-UP LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18
18
20
20

CHASSIS-RELATED SYSTEMS
REMOTE FREEWHEEL CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 WHEEL ANTILOCK BRAKE
SYSTEM (4WABS) . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTRUMENT CLUSTER-RELATED SYSTEMS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 26
BODY-RELATED SYSTEMS
WINDSHIELD WIPER AND WASHER . . . . . . .
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER . . . . . . . . . . . . .
KEYLESS UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER WINDOW SYSTEM . . . . . . . . . . . . . . .
POWER DOOR LOCK SYSTEM . . . . . . . . . . . .
POWER OUTSIDE MIRROR . . . . . . . . . . . . . . .
AIR BAG SYSTEM SERVICE CAUTIONS /
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . .
AIR BAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . .
THEFT-DETERRENT SYSTEM . . . . . . . . . . . . .

32
46
52
58
62
64
68
72
74
76
78

34
36
36
36
38
40
42
44
46

AIR CONDITIONING-RELATED SYSTEMS


HEATER AND AIR CONDITIONER . . . . . . . . . . 48
ACCESSORY
CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . 52
CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 60
OTHER
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . 82
COMMON CONNECTOR LIST . . . . . . . . . . . . . . . . 84
PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Z-GI
Contents of wiring diagrams
D This wiring diagram comprises the sections shown below.

GI

General information

A how-to on using and reading wiring diagrams, using


test equipment, checking harnesses and connectors,
and finding trouble spots

Ground points

Ground routes from and to the battery

Schematic

Shows main fuses and other fuses for each system

A~U

System circuit diagrams /


Component location views

Shows circuit and connector diagrams and


component and connector location diagrams

Connectors

Shows connectors common throughout system

PI

Parts index

Gives page number of circuit diagram for each


component

Reading Wiring Diagrams

GI

Ground points
This shows ground points of the harness.
GROUND POINTS(4SD)
3

10

12

JC-01 JOINT CONNECTOR(F)


B/O

JC-02 JOINT CONNECTOR(F)

B/W

B
B

E
B
B

B
B

C
B
B

B
B

JC-03 JOINT CONNECTOR(D)


D
B
C
A
E
B
B
B
B
B
B

E
D
C
B
A
(WITHOUT AIR BAG SYSTEM)
D
B
C
A
E
B
B
B
B
B
B
B
E
D
C
B
A
(WITH AIR BAG SYSTEM)

WITH ABS
B(EM)

B(F)

B(F)

B(F)
B(F)
TO
EACH
UNIT
B
(F)

B(EM)

B(EM)

B(EM)

B(D)
B(D)

EMISSION
HARNESS
(EM)

B(D)

11

B(D)
B(D)

DASH
HARNESS
(D)

B(D)

B/W(EM)

B(D)
WITH AIR BAG SYSTEM

TO
EACH
UNIT

FRONT
HARNESS
(F)

JC-02

10
JC-03

B(D)

B(EM)

B(F)

TO
EACH
UNIT

B(D)

B(EM)

JC-01

B(F)

B(D)

B/O(D)

WITHOUT AIR BAG SYSTEM

B(F)
B(F)

B(I)

B(I)

B(I)

B(F)
B(F)
B(F)

INSTRUMENT
PANEL
HARNESS
(I)

B(IN)

B(F)

12

INTERIOR
LIGHT
HARNESS
(IN)
SHORT
CORD

Ground indication
On vehide

Indication

On circuit diagrams and ground points


The ground connection numbers in system circuit diagrams
correspond to those in the ground point diagram.
To circuit

ENGINE CONTROL SYSTEM


BATTERY
-

MAIN
100A

FB-09

IG KEY
60A

X-01

FB-07

B(E)

B/W(F)
A
INJ OR
FIP
30A

B/W(D)

FB-05
BTN
40A

B(F)

JB-05

G
W/R(F)

W/R(D)

1B
L/R
(D)
X-06

FB-04
FB-03

2
D

X-09
L/R(E)

L/R(EM)

LG/R
(EM)

W/Y
(EM)

1E

1B

SPV RELAY
(SECTION B-1b)

L/R
(EM)

B/L
(EM)

1A

1F

ACC

X-03
L(D)

AA

X-06

IG1 IG2

ENGINE
10A
14 JB-01

JB-04
B/L(D)

MAIN RELAY

X-03
OFF

ENGINE SWITCH ST

Y/L(F)
S

B(D)

FB-04

W/G(EM)
I

FB-04

ROOM
10A
8

FB-03

FB-03

JB-03

B1-01

B/W
(F)

3W

B1-03

B1-02

PCM
2M

GLOW
PLUG
RELAY

3R

3P

1S

LG
(EM)

BR/B
(EM)

G/B
(EM)

1N

1Q

B1-01
L
(EM)

B1-02
L
(E)

FB-01

FB-03

L(E)
L
(E)

B
(E)
J

B1-05

X-09

11
22

23

B
B1-04

L/B
(EM)
G/W
(EM)

14

DATA LINK CONNECTOR(DLC)


(SECTION U)

B
(EM)

A/C RELAY
(SECTION G-2)

REFRIGERANT
PRESSURE SWITCH
(SECTION G-1)

31
AD FAN RELAY
(SECTION G-2)

GLOW
PLUG

B1-01 PCM(EM)

1U

1O
1S

W/L

V/W

1V

1T

1R

B1-03 GLOW PLUG RELAY(F)

B/W

1M

1K

L/W

L/R

1I

1G

1Q

W/R L/B

W/G

1A

2O

LG/R

R/Y

L/R

G/R

B/L

1C

W/Y

1F

1D

1B

2P

1E
P/L

G/W
1P

1N

1L

1J

B1-04 GLOW PLUG


(SHORT CORD)

1H

2K

2I

2G

2E

2A

3Y

R/Y

GY/R P/B

B/W

2M
L

L/W
2N

2L

B1-05 ENGINE(E)-SHORT CORD


(E)

2J

BR/Y L/Y
2H

2F

2D

3
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

2B

3Q

3Z

3X

3M

3K
V

LG BR/B Y/B

3O

G/R

3I

3L

3J

3H

3F

3S

3V

3T

3A
3G

R/B

L/R
R/L

(SHORT CORD)
B

3U
3W

2C
LG/B BR/W R/L

3R

3P

3N

3E

B1-02 GLOW PLUG RELAY(E)

3C
G/Y
B/O
3D

3B

L/R
L
B

GI

Reading Wiring Diagrams

System circuit diagram/connector diagram


These diagrams show the circuits for each system, from the power supply to the ground. The power supply side
is on the upper part of the page, the ground side on the lower part. The diagrams describe circuits with the
ignition switch off.
Below is an explanation of the various points in the diagram.

ENGINE CONTROL SYSTEM

System name

BATTERY
-

MAIN
100A

FB-09

IG KEY
60A

X-01

FB-07

B(E)

B/W(F)
A

FB-05
B(F)

INJ OR
FIP
30A

FB-03

FB-03

FB-04
Y/L(F)

W/G(EM)
GLOW
40A

FB-04

MAIN RELAY

FB-03
U

D
FB-04

X-09

Y
L/R(E)

L/R(EM)

LG/R
(EM)

W/Y
(EM)

1E

1B

B1-01

B/W
(F)

3W

B1-03

B1-02
2M

GLOW
PLUG
RELAY

LG
(EM)

BR/B
(EM)

23

22

L
(EM)
FB-01

FB-03

L(E)
L
(E)
B1-05

X-09

3P

B1-01

B1-02

B
(E)

3R

B
B
(EM)

DATA LINK CONNECTOR(DLC)


(SECTION U)

B1-04
GLOW
PLUG

Connector code

B1-01 PCM(EM)

1U

The prefix letter indicates the system in which the


connector is used.

1S

1Q

W/R

L/B

W/G

W/L

V/W

1V

1T

1R

B1-03 GLOW PLUG RELAY(F)

Y : Ground connector
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air-conditioning system connectors
H : Transmission control/Key interlock/
Shift-lock system connectors
I : Interior light system connectors
J : Audio/radio connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
O : Anti-lock brake system connectors
P : Power seat/seat warmer system connectors
Q : Auto cruise control system connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
U : Data link connector
X : Common connectors
JB : Joint box connections
FB : Main fuse block

B/W

1M

L/W L/R

1K

1I

1G

1C

1A

2O

LG/R

R/Y

R/W

G/R

B/L

G/Y W/Y

1E
W/Y

G/W
1P

1N

1L

1J

1H

B1-04 GLOW PLUG


(SHORT CORD)

1F

2K

2I

2G

2E

2A

2M

1D

1B

2C
LG/B BR/W R/L
L/W

R
2P

2N

2L

2J

BR/Y L/Y
2H

B1-05 ENGINE(E)-SHORT CORD


(E)

R/Y GY/R P/B

2F

2D

A harness ground is represented differently than a


unit ground.
Types of grounds

Symbol

Harness

9
Unit

Sensor

O
2B

(SHORT CORD)

Ground numbers

4
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

1O
P/L

Reading Wiring Diagrams


The number indicates that the circuit
continues to the related system
diagram.

GI

System code

Multiplex communication
B-1a

Indicates communication with connected parts.


Signals are transmitted back and forth between
connected parts.

DATA LINK
CONNECTOR(DLC)
(SECTION U)

B/W(D)
B(D)
1B

IG1 IG2

ENGINE
10A
14 JB-01

JB-04

G/Y
(EM)

W/Y
(EM)

R/W
(EM)

OFF

ENGINE SWITCH ST
X-06

16
X-03

ACC

X-03

Current symbol

L(D)

B/L(D)
AA

Current flows in the direction of the arrow.

B/L
(EM)
B1-01
1F

1D

1I

1A

PCM
2C

2A

1S

2B

Indicates shielded wire.*

2E

R/Y
(EM)

SHIELD WIRE

W/R
(EM)
P/B
(EM)

O
(EM)

GY/R
(EM)

* Shielded wire :
Prevents signal disturbances from
electrical interference.
Wire is covered by a metal meshing for
grounding.

B1-07
INTAKE AIR
TEMPERATURE
SENSOR NO.1
B1-07
O
(EM)

B
(EM)

14
REFRIGERANT
PRESSURE SWITCH
(SECTION G-1)

B1-06

Connector symbols
BOOST SENSOR

Male and female connectors are represented as follows

3Y

3U
3W

B/W

3Q

3M

3K

3I

3S
V

LG BR/B Y/B

3X

3V

3T

3A
3G

R/B

L/R
R/L

3Z

3O

3R

3P

3N

3E

G/Y

3L

3J

3H

3F

in the circuit and connector diagrams.

3C

G/R

B1-06 BOOST SENSOR(EM)

P/B GY/R

B1-02 GLOW PLUG RELAY(E)

Circuit diagram
symbol

L/R
L

B/O
3D

Connector
diagram symbol

3B

B1-07 INTAKE AIR TEMPERATURE


SENSOR NO.1(EM)

Male

R/Y

Male

Female
L

Female

Wire color code (harness symbol)

Like connectors are linked by dashed lines between the


connector symbols.

Two-color wires are indicated by a two-letter

Connector diagrams show connectors on the harness

symbol.The first indicates the base color of the


wire, the second the color of the stripe.
For example:

side. The terminal indicates the view from the harness


side.
(Example)

W/R is a white wire with a red strip


BR/Y is a brown wire with a yellow strip
Symbol
(Example)

Solid color wire

B Black
(F)

Connector on harness side

Striped wire

W/R
(F)

View from harness side

White
(base color)
Red(stripe)

Colors for connectors except white are given in locations.


Unused terminals are indicated by .

The harness symbol is in ( ) following the harness


symbols (refer to P-7.).

5
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

Reading Wiring Diagrams

GI
Routing diagram

The routing diagram shows where electrical components are on the system circuit diagram by call out line
and connector symbols.

Connector symbol

Component name

Ground symbol

Shows the system that uses the


connector.

Shows the names of components


in routing diagrams.

Shows the ground in system


diagrams.

(Example)
Connector

Symbol

Common connectors

X-19

System connectors

I-03

HARNESS SYMBOL :

(F)

(E)

(R)

INSTRUMENT
CLUSTER

VACUUM
SWITCH

C-01

C-05
6

(F)-(I)

X-02

(F)-(I)

X-02

C-06
PARKING BRAKE SWITCH

6
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

Reading Wiring Diagrams

GI

Harness symbols
DESCRIPTION OF HARNESS

SYMBOL

DESCRIPTION OF HARNESS

SYMBOL

FRONT HARNESS

(F)

DOOR NO.1 HARNESS

(DR1)

FRONT NO.2 HARNESS

(F2)

DOOR NO.2 HARNESS

(DR2)

ENGINE HARNESS

(E)

DOOR NO.3 HARNESS

(DR3)

DASH HARNESS

(D)

DOOR NO.4 HARNESS

(DR4)

REAR HARNESS

(R)

FLOOR HARNESS

(FR)

REAR NO.2 HARNESS

(R2)

INTERIOR LIGHT HARNESS

(IN)

REAR NO.3 HARNESS

(R3)

A/C HARNESS

(AC)

INSTRUMENT PANEL HARNESS

(I)

INJECTION HARNESS

(INJ)

HAND BRAKE HARNESS

(HB)

EMISSION HARNESS

(EM)

EMISSION NO.2 HARNESS

(EM2)

EMISSION NO.3 HARNESS

(EM3)

7
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

Reading Wiring Diagrams

GI
Symbols
Symbol

Meaning

Symbol

Meaning

Battery

Generates electricity through chemical


reaction.
Supplies direct current to circuits.

Light

Emits light and generates heat when


current flows through filament.

Ground (1)

1
Ground (2)

3.4W

Resistance

Connecting point to vehicle body or


other ground wire where current flows
from positive to negative terminal of
battery.
Ground (1) indicates a ground point to
body through wire harness.
Ground (2) indicates point where
component is grounded directly to body.

A resistor with a constant value.


Mainly used to protect electrical
components in circuits by maintaining
rated voltage.

Motor

Converts electrical energy into


mechanical energy.

Pump

Pulls in and discharges gases and


liquids.

Cigarette lighter

Electrical coil that generates heat.

Remarks
Current will not flow through a circuit if
ground is faulty.
Melts when current flow exceeds that
specified for circuit, interrupts current
flow.

Fuse (1)

Precautions
Do not replace with fuses exceeding
specified capacity.

(box)
Fuse (2)

<Blade type>

<Tube type>

Generates sound when current flows.

Horn
(Cartridge)
Main fuse/
Fusible link

<Cartridge type>

<Fusible link>

Speaker

Transistor (1)
Collector (C)
Base (B)

Electrical switching component.


Turns on when voltage is applied to the
base (B).
Collector
indication
mark

NPN

Emitter (E)

B
E

Transistor (2)

C
EC B

Generates heat when current flows.

Heater

E
B

Speed sensor

Movement of magnet in speedometer


turns contact within sensor on and off.

Ignition switch

Turning ignition key switches circuit to


operate various component.
(NOTE)
Ignition switch is called engine switch
on diesel vehicles.

Reading code.

Collector (C)
2 S C 828 A
Base (B)

PNP

Emitter (E)

Semiconductor
Number of
terminals

Revision mark
A:High-frequency PNP
B:Low-frequency PNP
C:High-frequency NPN
D:Low-frequency NPN

B2

IG2

8
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

B1

ST
OFF
IG1

OFF
ACC

Reading Wiring Diagrams


Symbol
Switch (1)

Meaning

GI

Symbol

Allows or breaks current flow by


opening and closing curcuits.

Meaning

Harness
Connection
D
B

When circuit C-D


is connected to
circuit A-B, the
connection D is
indicated by a
black dot.

Normally open (NO)

Switch (2)

For vehicles with ABS, use the A-B


circuit.

Selection

WITH ABS
A

Diversion point D
for the different
circuits according to the vehicles specification
is indicated by a
white dot.

Normally closed
(NC)

Relay (1)

WITHOUT ABS
C

For vehicles without ABS, use the C-B


circuit.

Current flowing through coil produces electromagnetic force causing contact to open or close.
No current to coil

Current to coil
Flow

No flow

Normally open (NO)


Relay (2)

Current flowing through coil produces electromagnetic force causing contact to close.
No current to coil

Current to coil
Flow

No flow

Normally closed (NC)


Sensor (variable)

Resistance changes with other


components operation.

Diode

Known as a semiconductor rectifier,


the diode allows current flow in one
direction only.
Cathode(K)
K

Sensor
(thermistor)

Capacitor

Resistance changes with temperature.

Light-emitting
diode
(LED)

A K

A K

A diode that lights when current flows.


Unlike ordinary bulbs, the diode does
not generate heat when lit.

Cathode(K)

Component that temporarily stores


electrical charge.

Anode(A)
Flow of electric current

Anode(A)
Cathode(K)
Anode(A)
Flow of current

Solenoid

Current flowing through coil generates


electromagnetic force to operate
plungers.

9
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

Reference diode
(Zener diode)

Allows current to flow in one direction


up to a certain voltage; allows current
to flow in the other direction once that
voltage is exceeded.

Reading Wiring Diagrams

GI

Symbol

Meaning
The wiring position can be exchanged freely within the
connector.

Extent of the change in the wiring position (1)


E
B
B
F

C
B

A
B

B
D

B
B

The wiring position can be exchanged according to the


following combinations only.
Between A and B, Between C and D, Between E and F

Extent of the change in the wiring position (2)


E
B
B
F

C
B

A
B

B
D

B
B

The wiring position can be exchanged according to the


following combinations only.
Between A, C and E, Between B, D and F

Extent of the change in the wiring position (3)


E
B
B
F

C
B

A
B

B
D

B
B

Abbreviations used in this booklet


3GR

Third Gear

CCT

Circuit

4GR

Fourth Gear

CIGAR

Cigarette

Ampere

CIS

Continuous Fuel Injection System

A/C

Air Conditioning

CKP

Crankshaft Position Sensor

A/F

Air Fuel

CLS

Closed Loop System

A/R

Auto Reverse

CMP

Camshaft Position Sensor

AAS

Auto Adjusting Suspension

COMBI

Combination

ABS

Anti-lock Braking System

CON

Conditioner

ACC

Accessories

CONT

Control

ACV

Air Control Valve

CPU

Central Processing Unit

ADD

Additional

CSD

Cold Start Device

AIR

Secondary Air Injection

CTP

Closed Throttle Position

AIS

Air Injection System

DEF

Defroster

ALL

Automatic Load Leveling

DI

Distributor Ignition

AM

Amplitude Modulation

DIS

Drive Information System

AMP

Amplifier

DLC

Data Link Connector

ANT

Antenna

DLI

Distributorless Ignition

AP

Accelerator Pedal

DOHC

Double-Overhead Camshaft

AS

Autoshop

DTC

Diagnostic Trouble Code(s)

ASV

Air Supply Valve

DTM

Diagnostic Test Mode

AT

Automatic Transmission

ECPS

Electronically Controlled Power Steering

ATX

Automatic Transaxle

ECT

Engine Control Temperature

B+

Battery Positive Voltage

EGR

Exhaust Gas Recirculation

BAC

Bypass Air Control

EI

Electronic Ignition

BARO

Barometric Pressure

ELEC

Electric

CAC

Charge Air Cooler

ELR

Emergency Locking Retractor

CARB

Carburetor

ETR

Electronic Tuner

10
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

Reading Wiring Diagrams


F

Front

Power

F/I

Fuel Injector

P/S

Power Steering

FC

Fan Control

P/W CU

Power Window Control Unit

FICB

Fast-Idle Cam Breaker

PAIR

Pulsed Secondary Air Injection

FM

Frequency Modulation

PCM

Powertrain Control Module

FP

Fuel Pump

PNP
PRCV

Park/Neutral Position

GI

Pressure Regulator Control Solenoid

FPR

Fuel Pump Relay

GEN

Generator

GND

Ground

PRG

Purge Solenoid Valve

H/D

Heater/Defroster

PSP

Power Steering Pressure

HEAT

Heater

PTC

Positive Temperature Coefficient Heater

HEI

High-Energy Ignition

QSS

Quick-Start System

HI

High

Rear

HO2S

Heated Oxygen Sensor

REC

Recirculation

IAC

Idle Air Control

RF

Right Front

IAT

Intake Air Temperature

RH

Right Hand

ICM

Ignition Control Module

RPM

Engine Speed

IG

Ignition

RR

Right Rear

ILLUMI

Illumination

SAPV

Secondary Air Pulse Valve

INT

Intermittent

SFI

Sequential Multipoint Fuel Injection

JB

Joint Box

SOL

Solenoid

KS

Knock Sensor

SPV

Spill Valve

LCD

Liquid Crystal Display

ST

Start

LF

Left Front

SW

Switch

LH

Left Hand

TC

Turbocharger

LO

Low

TCM

Transmission(Transaxle)Control Module

LR

Left Rear

TCS

Traction control system

Motor

TCV

Twin Scroll Turbocharger Solenoid Valve

MAF

Mass Air Flow Sensor

TDC

Top dead center

MAP

Manifold Absolute Pressure

TEMP

Temperature

MFI

Multiport Fuel Injection

TICS

Triple Induction Control System

MID

Middle

TP

Throttle Position Sensor

MIL

Malfunction Indicator Lamp

TR

Transmission Range

MIN

Minute

TR

Transmission(Transaxle)Range

MIX

Mixture

TWS

Total Wiring System

MPX

Multiplex

Volt

MT

Manual Transmission

VAF

Volume Air Flow Sensor

MTR

Mechanical Tuning Radio

VENT

Ventilation

MTX

Manual Transaxle

VOL

Volume

NC

Normally Closed

VR

Voltage Regulator

NO

Normally Open

VRIS

Variable Resonance Induction System

O2S

Oxygen Sensor

VSS

Vehicle Speed Sensor

OBD

On-board Diagnostic

Watt(s)

OFF

Switch Off

WOT

Wide Open Throttle

ON

Switch On

OSC

Oscillator

Valve

11
Form No.5561-1E-02H
5561-10-02H
F180-30-02H

Y-a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

GROUND POINT

12

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3

13
2

X-06

;
;;;;;
;;;;;
;;;;;
;;;;;

(F)-(FR)

X-06
(F)-(FR)

Y-a

Y-b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

GROUND POINT

14

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;
;;;;;
;;;;;
;;;;;
;;;;;

[DOUBLE CAB]

13
9

X-04
(F)-(R)

10

15

(R)-(DR3)

X-28

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

11

(F)-(R)

X-04

13

X-29
(FR)-(DR4)

12

10

Y-b

W
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

ELECTRICAL WIRING SCHEMATIC

16

THIS PAGE INTENTIONALLY


LEFT BLANK

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

A
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

CHARGING SYSTEM / STARTING SYSTEM

18

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[GRAY]
(F)-(E)

[GRAY]
(F)-(E)

X-08

X-09

MAIN FUSE BLOCK

X-01

19

A-02
GENERATOR
[GRAY]

A-01
STARTER

A-02
GENERATOR

;
;;;;;
;;;;;
;;;;;
;;;;;

X-03
FUSE BLOCK

A-03
STARTER RELAY

X-02
ENGINE SWITCH

B-a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

ENGINE CONTROL SYSTEM / GLOW SYSTEM

20

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

[BLACK]
EGR SOLENOID VALVE
(VACUUM)
[BLACK]

GLOW PLUG RELAY

B-03
[GRAY]
(F)-(E)

B-03

B-07

EGR SOLENOID VALVE


(VENT)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
X-08

[BROWN]
GLOW PLUG RELAY

[GRAY]
INJECTION PUMP

B-10

[GRAY]
(F)-(E)

X-09

B-08
[BLACK]
INTAKE SHUTTER
SOLENOID VALVE

B-06

NEUTRAL SWITCH

B-13

MAIN FUSE BLOCK

X-01

21

;
;;;;;
;;;;;
;;;;;
;;;;;
4

B-09

EGR CONTROL
SOLENOID VALVE

B-05
GLOW PLUG

X-03
FUSE BLOCK

X-02
ENGINE SWITCH

B-01
PCM

X-30
JOINT CONNECTOR

B-02
PCM CONTROL RELAY

B-11
IDEL SWITCH

B-12
CLUTCH SWITCH

B-a

B-b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

ENGINE CONTROL SYSTEM / GLOW SYSTEM

22

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3

[GRAY]
(F)-(E)

[GRAY]
(F)-(E)

[GRAY]
ENGINE COOLANT
TEMPERATURE SENSOR

X-08

B-15

X-09

23

B-14

INJECTION PUMP
[GRAY]

B-16
INTAKE AIR
TEMPERATURE
SENSOR No.2
[BLACK]

B-17

B-18

EGR VALVE
BOOST SENSOR
POSITION SENSOR [BLACK]
[GRAY]

;
;;;;;
;;;;;
;;;;;
;;;;;

B-01
PCM

X-30
JOINT CONNECTOR

B-19
ACCELERATOR
POSITION SENSOR
[BLACK]

B-b

B-c
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

ENGINE CONTROL SYSTEM / GLOW SYSTEM

24

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[GRAY]
INJECTION PUMP

B-20

[GRAY]
TDC SENSOR

B-22

B-21

25

MASS AIR FLOW/


INTAKE AIR
TEMPERATURE SENSOR
[BLACK]

;
;;;;;
;;;;;
;;;;;
;;;;;

B-01
PCM

X-30
JOINT CONNECTOR

B-c

C-a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

INSTRUMENT CLUSTER

26

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3

[GRAY]
(F)-(E)

X-08

FUEL GAUGE SENDER UNIT

[GRAY]
VEHICLE SPEEDOMETER SENSOR
2WD

(R)-(R2)

X-19

C-03

MAIN FUSE BLOCK

C-04

X-01

C-03

4WD
VEHICLE SPEEDOMETER SENSOR
[GRAY]

[DOUBLE CAB]
(F)-(R)

X-04

C-02

WATER TEMPERATURE
SENDER UNIT

FUEL GAUGE SENDER UNIT

27

(R)-(R2)

C-04

X-19

;
;;;;;
;;;;;
;;;;;
;;;;;
INSTRUMENT CLUSTER

C-01

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

[BLACK]
INSTRUMENT CLUSTER

C-01

(F)-(R)

X-04

X-03
FUSE BLOCK

X-04
(F)-(R)

X-02
ENGINE SWITCH

C-a

C-b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

INSTRUMENT CLUSTER

28

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
BRAKE FLUID
LEVEL SENSOR

SEDIMENTOR SWITCH

C-07

C-05

[GRAY]
(F)-(E)

X-09

29

;
;;;;;
;;;;;
;;;;;
;;;;;

INSTRUMENT CLUSTER

C-01

[BLACK]
INSTRUMENT CLUSTER

C-01

(F)-SHORT CORD

C-06
OIL PRESSURE SWITCH

C-09

C-08

PARKING BRAKE SWITCH

C-b

C-c
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

INSTRUMENT CLUSTER

30

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;
;;;;;;
;;;;;;
;;;;;;
;;;;;;
INSTRUMENT CLUSTER

C-01

[BLACK]
INSTRUMENT CLUSTER

31
6

C-01

C-c

D
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

WINDSHIELD WIPER AND WASHER

32

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK

X-01

WINDSHIELD
WIPER MOTOR

D-03

33

D-01

WINDSHIELD
WASHER MOTOR

;
;;;;;
;;;;;
;;;;;
;;;;;
5

X-03
FUSE BLOCK

X-02
ENGINE SWITCH

D-02
WINDSHIELD
WIPER AND WASHER SWITCH

E-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

HEADLIGHT

34

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK

X-01

[DOUBLE CAB]

(F)-(R)

HEADLIGHT RH

E1-03

X-04

E1-02

35

HEADLIGHT LH

;
;;;;;
;;;;;
;;;;;
;;;;;

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]
(F)-(R)

X-04
E1-01
X-03

HEADLIGHT SWITCH

FUSE BLOCK

X-04
(F)-(R)

E-1

E-2
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

LICENCE PLATE LIGHT / PARKING LIGHT / TAILLIGHT

36

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

TAILLIGHT RH

E2-06
(R)-(R2)
[GRAY]
LICENSE PLATE LIGHT RH

X-19
7

E2-04

[GRAY]
LICENSE PLATE LIGHT LH

E2-07

E2-02

E2-05
TAILLIGHT LH

[DOUBLE CAB]
8

PARKING LIGHT RH

TAILLIGHT RH

37

E2-01

(R)-(R2)

PARKING LIGHT LH

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

E2-06

X-19
7

[GRAY]
LICENSE PLATE LIGHT RH

E2-04

[GRAY]
LICENSE PLATE LIGHT LH

E2-07

TAILLIGHT LH

E2-05

E-2

E-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

HEADLIGHT LEVELING SYSTEM

38

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
1

E3-03

HEADLIGHT
LEVELING
ACTUATOR RH

39
E3-02

;
;;;;;
;;;;;
;;;;;
;;;;;
5

HEADLIGHT
LEVELING
ACTUATOR LH

E3-01
HEADLIGHT
LEVELING SWITCH

E-3

E-4
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

REAR FOG LIGHT

40

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

(R)-(R2)

;
;;;;;
;;;;;
;;;;;
;;;;;

X-19
7

REAR FOG LIGHT

E4-03

REAR FOG LIGHT SWITCH

E4-01

[DOUBLE CAB]
8

(F)-(R)

X-04

X-04
(F)-(R)

41

E4-02

(R)-(R2)

REAR FOG LIGHT


RELAY

X-19

REAR FOG LIGHT

E4-03

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]
8
(F)-(R)

X-04

E-4

F-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

TURN AND HAZARD WARNING LIGHT

42

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

REAR TURN LIGHT RH

FRONT SIDE TURN LIGHT RH

F1-05

(R)-(R2)

E2-06

X-19
7

MAIN FUSE BLOCK

X-01
1

F1-03

[DOUBLE CAB]
E2-05

(F)-(R)

REAR TURN LIGHT LH

X-04
8

FRONT TURN LIGHT RH


[BLACK]

F1-06
FRONT SIDE TURN LIGHT LH
REAR TURN LIGHT RH

43

(R)-(R2)

F1-04

;
;;;;;
;;;;;
;;;;;
;;;;;
HAZARD
WARNING SWITCH

F1-02

7
REAR TURN LIGHT LH

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

FLASHER UNIT

X-19

FRONT TURN LIGHT LH


[BLACK]

E2-06

F1-01

(F)-(R)

E2-05

X-04

X-03

E1-01
TURN SWITCH

FUSE BLOCK

X-04

X-02
ENGINE SWITCH

(F)-(R)

F-1

F-2
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

BACK-UP LIGHT

44

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

BACK-UP LIGHT RH

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

(R)-(R2)

E2-06

X-19
7

[GRAY]
(F)-(E)

X-08

BACK-UP LIGHT SWITCH

MAIN FUSE BLOCK

F2-01

X-01

E2-05

[DOUBLE CAB]

BACK-UP LIGHT LH

(F)-(R)

X-04

BACK-UP LIGHT RH

E2-06

45

(R)-(R2)

X-19

;
;;;;;
;;;;;
;;;;;
;;;;;

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]
(F)-(R)

7
BACK-UP LIGHT LH

E2-05

X-04

X-03
FUSE BLOCK

X-04
(F)-(R)

X-02
ENGINE SWITCH

F-2

F-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

BRAKE LIGHT / HORN

46

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

BRAKE LIGHT RH
(R)-(R2)

E2-06

X-19
7

MAIN FUSE BLOCK

X-01

[DOUBLE CAB]

E2-05
BRAKE LIGHT LH

(F)-(R)

X-04
8

F3-05

HORN RH
[BLACK]

47

BRAKE LIGHT RH
(R)-(R2)

F3-02

X-19

HORN LH
[BLACK]

;
;;;;;
;;;;;
;;;;;
;;;;;

HORN RELAY

F3-01

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]
(F)-(R)

SHORT CONNECTOR

E2-06
7
BRAKE LIGHT LH

E2-05

X-04

S1-02

X-03
FUSE BLOCK

F3-04
HORN SWITCH

X-04
(F)-(R)

F3-03
BRAKE SWITCH

F-3

G
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

HEATER AND AIR CONDITIONER

48

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[GRAY]
(F)-(E)

X-09

A/C RELAY

G-07

MAIN FUSE BLOCK

X-01

49

G-09

;
;;;;;
;;;;;
;;;;;
;;;;;
5

REFRIGERANT
PRESSURE SWITCH
[BLACK]

A/C SWITCH

G-11

G-08

RESISTOR

MAGNETIC CLUTCH

G-04

X-03
FUSE BLOCK

X-02
ENGINE SWITCH

G-05

RESISTOR

G-01
CLIMATE
CONTROL UNIT

G-03

G-10

(F)-BLOWER UNIT

G-06

A/C AMPLIFIER

BLOWER MOTOR

H
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

REMOTE FREEWHEEL CONTROL SYSTEM

50

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3

[GRAY]
(F)-(E)

X-09

[GRAY]
(F)-(E)

X-08

[BLUE]
LOCK SOLENOID

H-02

FREE SOLENOID

H-03

[BLACK]
TRANSFER NEUTRAL SWITCH

H-07
[BLACK]
4 4 INDICATOR SWITCH

H-06

MAIN FUSE BLOCK

X-01

51

;
;;;;;
;;;;;
;;;;;
;;;;;
5

H-05
RFW SWITCH
[BLACK]

X-03
X-02

FUSE BLOCK

ENGINE SWITCH

H-04

RFW MAIN SWITCH

H-01
RFW CONTROL
MODULE

I-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

CIGARETTE LIGHTER / REAR WINDOW DEFROSTER

52

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

[BLACK]
FILAMENT

I1-03

MAIN FUSE BLOCK

X-01

[DOUBLE CAB]
(F)-(R)

X-04

I1-03
FILAMENT
[BLACK]

13

53

[BLACK]
FILAMENT

I1-03

;
;;;;;
;;;;;
;;;;;
;;;;;

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

REAR WINDOW
DEFROSTER SWITCH

I1-05

[BLACK]
OUTLET

I1-02
6

X-04

(F)-(R)

I1-01

(F)-(R)

X-04

I1-03

X-03
FUSE BLOCK

13

FILAMENT
[BLACK]

X-02
ENGINE SWITCH

I1-04
REAR WINDOW
DEFROSTER RELAY

CIGARETTE LIGHTER
[BLACK]

I-1

I-2
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

CLOCK / ILLUMINATION LIGHT

54

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK

X-01

HAZARD
WARNING SWITCH
ILLUMINATION

55

;
;;;;;
;;;;;
;;;;;
;;;;;
F1-02

AUDIO UNIT
ILLUMINATION
(OPTION)

CLOCK

[BLACK]
INSTRUMENT CLUSTER
ILLUMINATION

C-01

I2-01 C-01

J-01

INSTRUMENT CLUSTER
ILLUMINATION

X-03
FUSE BLOCK

I2-02

X-02

ENGINE SWITCH
PANEL LIGHT
CONTROL SWITCH

I2-03
HEATER CONTROL
ILLUMINATION

I-2

I-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

INTERIOR LIGHT

56

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

INTERIOR LIGHT

I3-01

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

[BLACK]
DOOR SWITCH RF

I3-02

MAIN FUSE BLOCK

X-01

[DOUBLE CAB]

X-10

I3-04
DOOR SWITCH RR
[BLACK]

(F)-(IN)

X-04

I3-05

(F)-(R)

I3-06

DOOR SWITCH LR
[BLACK]

(FR)-SHORT CORD

I3-03
DOOR SWITCH LF
[BLACK]

X-06
(F)-(FR)

57

(R)-(DR3)

;
;;;;;
;;;;;
;;;;;
;;;;;

[BLACK]
FREESTYLE CAB/
DOOR SWITCH RF
STRETCH CAB
(WITH REAR ACCESS SYSTEM)
[BLACK]
EXCEPT FREESTYLE CAB/
DOOR SWITCH RF
STRETCH CAB
(WITH REAR ACCESS SYSTEM)

X-28

I3-02

(F)-(IN)

X-10

INTERIOR LIGHT

I3-01

I3-02

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]
(F)-(IN)

X-10
X-03
FUSE BLOCK

X-04
(F)-(R)

X-04
(F)-(R)

X-29
(FR)-(DR4)

I3-03
DOOR SWITCH LF
[BLACK]

X-06
(F)-(FR)

X-06
(F)-(FR)

FREESTYLE CAB/
STRETCH CAB
(WITH REAR ACCESS SYSTEM)

I3-03
DOOR SWITCH LF
[BLACK]

EXCEPT FREESTYLE CAB/


STRETCH CAB
(WITH REAR ACCESS SYSTEM)

I-3

I-4
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

KEYLESS UNIT

58

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK

X-01

59

;
;;;;;
;;;;;
;;;;;
;;;;;
5

X-03
FUSE BLOCK

X-02
ENGINE SWITCH

I4-01
KEYLESS UNIT

I-4

J
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

AUDIO SYSTEM

60

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

REAR DOOR
SPEAKER RH

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

J-04
(R)-(DR3)

X-22

[DOUBLE CAB]

MAIN FUSE BLOCK

X-01

(F)-(DR1)

X-13

FRONT DOOR
SPEAKER RH

J-03
REAR DOOR
SPEAKER LH

(F)-(R)

J-05

X-04

X-25
(FR)-(DR4)

J-02
FRONT DOOR
SPEAKER LH

X-16
(F)-(DR2)

61

X-06
(F)-(FR)

;
;;;;;
;;;;;
;;;;;
;;;;;

(R)-(DR3)

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

(F)-(DR1)

X-13

AUDIO UNIT
(OPTION)

J-01

(F)-(DR2)

X-16

(F)-(DR1)

X-13

REAR DOOR
SPEAKER RH

X-28

J-04

FRONT DOOR
SPEAKER RH

J-03

(F)-(R)

X-04
X-03
FUSE BLOCK

X-04
(F)-(R)

X-02

X-29

ENGINE SWITCH

J-05

(FR)-(DR4)

REAR DOOR
SPEAKER LH

J-02
FRONT DOOR
SPEAKER LH

X-06
(F)-(FR)

X-16
(F)-(DR2)

X-06
(F)-(FR)

K-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

POWER WINDOW SYSTEM

62

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

POWER WINDOW
SUBSWITCH RR

(R)-(DR3)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

POWER WINDOW
SUBSWITCH LR

K1-03

X-22

K1-04

(R)-(DR3)
[BLUE]
FRONT POWER
WINDOW
REGULATOR RH

MAIN FUSE BLOCK

X-01

POWER WINDOW
MAIN SWITCH

X-23

REAR POWER
WINDOW REGULATOR LH

K1-01

K1-08

K1-05

[DOUBLE CAB]
X-13
(F)-(DR1)

X-26
(FR)-(DR4)

X-15
(F)-(DR1)

X-25
(FR)-(DR4)

K1-02
POWER WINDOW
SUBSWITCH LF

X-04

K1-06

(F)-(R)

FRONT POWER
WINDOW
REGULATOR LH
[BLUE]

X-05
(F)-(R)

X-16

K1-09

(F)-(DR2)

X-18

63

(F)-(DR2)
POWER WINDOW
MAIN SWITCHFRONT POWER WINDOW
REGULATOR RH
(F)-(FR)

K1-07
REAR POWER
WINDOW REGULATOR RH

X-07
(F)-(FR)

X-06

;
;;;;;
;;;;;
;;;;;
;;;;;
4

(F)-(DR2)

X-16

X-05

(F)-(R)

X-18

POWER WINDOW
MAIN SWITCH[BLUE]
FRONT POWER WINDOW
FRONT POWER
WINDOW REGULATOR RH REGULATOR RH

(F)-(DR1)

X-13

K1-05

POWER WINDOW
MAIN SWITCH

K1-01

K1-09

(F)-(DR1)

X-15
(F)-(DR1)
[REGULAR CAB,STRETCH CAB
(WITHOUT REAR ACCESS SYSTEM), X-13
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

X-02
ENGINE SWITCH

X-03
FUSE BLOCK

X-04
(F)-(R)

X-15
K1-02

(F)-(DR1)

POWER WINDOW
SUBSWITCH LF

(F)-(DR2)

K1-06
X-06

FRONT POWER
WINDOW REGULATOR LH
[BLUE]

X-16

(F)-(FR)

(F)-(DR2)

X-07
(F)-(FR)

X-18
(F)-(DR2)

K-1

K-2a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

POWER DOOR LOCK SYSTEM

64

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK

DOOR LOCK-LINK SWITCH

X-01

K2-02
(F)-(DR1)

X-15

[DOUBLE CAB]

65

;
;;;;;
;;;;;
;;;;;
;;;;;
DOOR LOCK
TIMER UNIT

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
DOOR LOCK-LINK SWITCH
(WITH REAR ACCESS SYSTEM)] K2-02

K2-01

(F)-(DR1)

X-15

(F)-(DR1)

X-15

X-03
FUSE BLOCK

K-2a

K-2b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

POWER DOOR LOCK SYSTEM

66

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;
;;;;;
;;;;;
;;;;;
;;;;;

DOOR LOCK
ACTUATOR RR

K2-04

DOOR LOCK TIMER UNIT

K2-01

(R)-(DR3)
(F)-(DR1)

X-23
DOOR LOCK
ACTUATOR RF

X-15

K2-02
(F)-(DR1)

X-15

[DOUBLE CAB]
X-05
(F)-(R)

K2-05
X-26

X-18
(F)-(DR2)

DOOR LOCK
ACTUATOR LR

(FR)-(DR4)

K2-03

X-05

DOOR LOCK
ACTUATOR LF

(F)-(R)

X-07
(F)-(FR)

67

X-18
(F)-(DR2)

X-07
(F)-(FR)

DOOR LOCK
ACTUATOR RF

K2-02
(F)-(DR1)

[REGULAR CAB,STRETCH CAB


X-15
(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

K2-03
DOOR LOCK
ACTUATOR LF

X-18
(F)-(DR2)

K-2b

L
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

POWER OUTSIDE MIRROR

68

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

POWER OUTSIDE
MIRROR RH

L-02
(F)-(DR1)

MAIN FUSE BLOCK

X-14

X-01

[DOUBLE CAB]

L-03
POWER
OUTSIDE MIRROR LH

69

X-17
(F)-(DR2)

;
;;;;;
;;;;;
;;;;;
;;;;;
5

X-17

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

(F)-(DR1)

X-14

POWER OUTSIDE
MIRROR RH

L-02

(F)-(DR1)

X-14
L-01
POWER OUTSIDE
MIRROR SWITCH

X-03
FUSE BLOCK

X-02
ENGINE SWITCH

L-03
POWER
OUTSIDE MIRROR LH

(F)-(DR2)

X-17
(F)-(DR2)

O
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

4 WHEEL ANTILOCK BRAKE SYSTEM (4WABS)

70

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

(R)-(R2)

X-20

[GRAY]
ABS HU/CM

O-01

[GRAY]
ABS WHEEL-SPEED
SENSOR RR

MAIN FUSE BLOCK

O-05

X-01

[GRAY]
ABS WHEELSPEED SENSOR RF

O-03

(R)-(F2)

X-21
(F)-(R)

X-04

[DOUBLE CAB]

O-04
ABS WHEEL-SPEED
SENSOR LR
[GRAY]

O-06

71

G SENSOR
[BLACK]
(R)-(R2)

O-02
ABS WHEELSPEED SENSOR LF
[GRAY]

;
;;;;;
;;;;;
;;;;;
;;;;;

(F)-(F2)

X-12

(F)-(F2)

X-20

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

X-11

[GRAY]
ABS WHEEL-SPEED
SENSOR RR

O-05

(R)-(F2)

X-21

ENGINE SWITCH

X-02
(F)-(R)
FUSE BLOCK

X-04
O-04

X-03

ABS WHEEL-SPEED
SENSOR LR
[GRAY]

X-21
(R)-(F2)

X-04
(F)-(R)

O-06
G SENSOR
[BLACK]

S
AIR BAG SYSTEM
SERVICE WARNINGS
Component Disassembly

Air Bag Mudule Handling

Disassembling and reassembling the components


of the air bag system can render the system
inoperative, which may result in serious injury or
death in the event of an accident. Do not
disassemble any air bag system component.

A live (undeployed) air bag module may


accidentally deploy when it is handled and cause
serious injury. When carrying a live (undeployed)
air bag module, point the front surface away from
your body to lessen the chance of injury in case it
deploys.

RIGHT

Wiring Harness Repair

AIR BAG SYSTEM SERVICE CAUTIONS / SERVICE WARNINGS

Incorrectly repairing an air bag system wiring


harness can accidentally deploy the air bag
module, which can cause serious injury. If a
problem is found in the system wiring, replace the
wiring harness. Do not try to repair it.

WRONG

A live (undeployed) air bag module placed face


down on a surface is dangerous. If the air bag
module deploys, the motion of the module can
cause serious injury. Always face the front surface
up to reduce the motion of the module in case it
accidentally deploys.

RIGHT

WRONG

Air Bag Module Inspection


Inspecting an air bag module using an ohmmeter
can deploy the air bag module, which may cause
serious injury. Do not use an ohmmeter to inspect
an air bag module. Always use the on-board
diagnostic function to diagnose the air bag for
malfunctions. (Refer to ON-BOARD DIAGNOSTIC
FUNCTION, AIR BAG SYSTEM.)

*The references in this section can be found in B Series Workshop Manual [1644-10-99A (1999-1)] or
RANGER Repair Manual [F161-10-99A (1999-1)]

72
Form No. 5561-1E-02H
5561-10-02H
F180-30-02H

S
SAS Unit Handling
Disconnecting the SAS unit connector or removing
the SAS unit with the ignition switch at ON position
can cause the air bag modules to deploy, which
may seriously injure you. Before disconnecting the
SAS unit connector or removing the SAS unit, turn
the ignition switch to LOCK position, then
disconnect the negative battery cable and wait for
more than 1 minute to allow the backup power
supply of the SAS unit to deplete its stored power.
Connecting the SAS unit connector without firmly
installing the SAS unit to the vehicle is dangerous.
The crash sensor inside the unit may send an
electrical signal to the air bag modules. This will
deploy the air bag modules, which may result in
serious injury. Therefore, before connecting the
connector, firmly mount the unit to the vehicle.
For vehicles with a single point sensor, once an air
bag is deployed due to an accident or other causes,
the SAS unit must be replaced with a new one even
if the used one does not have any external signs of
damage. The used SAS unit may have been
damaged internally which may cause improper
operation, resulting in major injuries or even death.
The used single point SAS unit cannot be benchchecked or self-checked.

AIR BAG SYSTEM SERVICE CAUTIONS / SERVICE WARNINGS

Component Handling
Oil, grease, water, etc on components may cause
the air bag modules to fail to deploy in an accident,
which may cause serious injury. Do not allow oil,
grease, water, etc on components.
Inserting a screwdriver, etc into the connector of
an air bag module may damage the connector and
cause the air bag module to deploy improperly,
which may cause serious injury. Do not insert any
foreign objects into the connector.

Component Reusing
Even if an air bag madule does not deploy in a
collision and does not have any external signs of
damage, it may have been damaged internally,
which may cause improper operation. Improper
operation may cause serious injury. Always selfcheck the undamaged air bag module to determine
whether it can be reused. (Refer to ON-BOARD
DIAGNOSTIC FUNCTION, AIR BAG SYSTEM.)

*The references in this section can be found in B Series Workshop Manual [1644-10-99A (1999-1)] or
RANGER Repair Manual [F161-10-99A (1999-1)]

73
Form No. 5561-1E-02H
5561-10-02H
F180-30-02H

S-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

AIR BAG SYSTEM

74

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK

X-01

75

;
;;;;;
;;;;;
;;;;;
;;;;;

[YELLOW]
(F)-CLOCK SPRING

[YELLOW]
PASSENGER-SIDE
AIR BAG MODULE

S1-04
6

S1-03

SHORT CONNECTOR

S1-02

X-03
FUSE BLOCK

S1-05
DRIVER-SIDE
AIR BAG MODULE

X-02
ENGINE SWITCH

S1-01
SAS UNIT

S-1

T-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

IMMOBILIZER SYSTEM

76

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3

MAIN FUSE BLOCK

X-01

77

;
;;;;;
;;;;;
;;;;;
;;;;;

IMMOBILIZER UNIT

T1-01
COIL

T1-02

X-03
FUSE BLOCK

T1-03
KEY REMINDER
SWITCH

X-02
ENGINE SWITCH

X-30
JOINT CONNECTOR

T-1

T-2a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

THEFT-DETERRENT SYSTEM

78

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

(F)

HARNESS SYMBOL:

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[BLACK]
BONNET SWITCH

T2-05

DOOR KEY
CYLINDER SWITCH RF

MAIN FUSE BLOCK

T2-06

X-01

(F)-(DR1)

X-15

[DOUBLE CAB]

T2-07
DOOR KEY
CYLINDER SWITCH LF

79

X-18
(F)-(DR2)

;
;;;;;
;;;;;
;;;;;
;;;;;
THEFT-DETERRENT
CONTROL MODULE

T2-01

[REGULAR CAB,STRETCH CAB


(WITHOUT REAR ACCESS SYSTEM),
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]

(F)-(DR1)

(F)-(DR1)

X-15

X-15

DOOR KEY
CYLINDER SWITCH RF

T2-06

X-03

T2-07
DOOR KEY
CYLINDER SWITCH LF

FUSE BLOCK

T2-01
THEFT-DETERRENT
CONTROL MODULE
[BLACK]

X-02
ENGINE SWITCH

X-18
(F)-(DR2)

X-18
(F)-(DR2)

T-2a

T-2b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

THEFT-DETERRENT SYSTEM

80

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;

DOOR LOCK-LINK
SWITCH RR

K2-04

MAIN FUSE BLOCK

(R)-(DR3)

X-01

X-24

(F)-(R)

X-04

K2-05
X-27

DOOR LOCK-LINK
SWITCH LR

(FR)-(DR4)

T2-03
THEFT-DETERRENT HORN RELAY

X-05

10

(F)-(R)

81

T2-04
THEFT-DETERRENT HORN

;
;;;;;
;;;;;
;;;;;
;;;;;
THEFT-DETERRENT
CONTROL MODULE

X-07
(F)-(FR)

T2-01

X-05

X-03
FUSE BLOCK

X-04
(F)-(R)

T2-01
THEFT-DETERRENT
CONTROL MODULE
[BLACK]

(F)-(R)

X-07
(F)-(FR)

T-2b

U
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

DATA LINK CONNECTOR

82

;
;
;

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

HARNESS SYMBOL:

(F)

(E)

(R)

;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3

MAIN FUSE BLOCK

X-01

[GRAY]
DATA LINK CONNECTOR

U-01

83

;
;;;;;
;;;;;
;;;;;
;;;;;

X-03
FUSE BLOCK

X-02
ENGINE SWITCH

X-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

COMMON CONNECTOR LIST

84

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

COMMON CONNECTOR LIST

85

X-2

X-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

COMMON CONNECTOR LIST

86

Form No. 5561-1E-02H


Form No. 5561-10-02H
Form No. F180-30-02H

COMMON CONNECTOR LIST

87

X-4

PARTS INDEX
4

HEADLIGHT LEVELING SWITCH ....................... 38


HEADLIGHT SWITCH .......................................... 34
HORN ................................................................... 46
HORN RELAY ...................................................... 46
HORN SWITCH .................................................... 46

4X4 INDICATOR SWITCH .................................... 50

A
A/C AMPLIFIER ................................................... 48
A/C RELAY ........................................................... 48
A/C SWITCH ........................................................ 48
ABS HU/CM ......................................................... 70
ABS WHEEL-SPEED SENSOR ........................... 70
ACCELERATOR POSITION SENSOR ................. 22
AUDIO UNIT ......................................................... 60

I
IDLE SWITCH ...................................................... 20
ILLUMINATION
AUDIO UNIT ....................................................... 54
HAZARD WARNING SWITCH ........................... 54
HEATER CONTROL .......................................... 54
INSTRUMENT CLUSTER .................................. 54
IMMOBILIZER UNIT ............................................. 76
INJECTION PUMP ................................... 20, 22, 24
INSTRUMENT CLUSTER ........................ 26, 28, 30
INTAKE AIR TEMPERATURE SENSOR ........ 22, 24
INTAKE SHUTER SOLENOID VALVE .................. 20
INTERIOR LIGHT ................................................. 56

B
BACK-UP LIGHT .................................................. 44
BACK-UP LIGHT SWITCH ................................... 44
BLOWER MOTOR ................................................ 48
BONNET SWITCH ............................................... 78
BOOST SENSOR ................................................. 22
BRAKE FLUID LEVEL SENSOR ......................... 28
BRAKE LIGHT ...................................................... 46
BRAKE SWITCH .................................................. 46

K
KEYLESS UNIT .................................................... 58
KEY REMINDER SWITCH ................................... 76

C
CIGARETTE LIGHTER ........................................ 52
CLIMATE CONTROL UNIT .................................. 48
CLUTCH SWITCH ................................................ 20
CLOCK ................................................................. 54
COIL ..................................................................... 76

L
LICENSE PLATE LIGHT ...................................... 36
LOCK SOLENOID ................................................ 50

M
D
DATA LINK CONNECTOR .................................... 82
DOOR KEY CYLINDER SWITCH ........................ 78
DOOR LOCK ACTUATOR .................................... 66
DOOR LOCK TIMER UNIT ............................ 64, 66
DOOR LOCK-LINK SWITCH ......................... 64, 80
DOOR SWITCH ................................................... 56
DRIVER-SIDE AIR BAG MODULE ...................... 74

MAGNETIC CLUTCH ........................................... 48


MASS AIR FLOW SENSOR ................................. 24

N
NEUTRAL SWITCH ............................................. 20

O
OIL PRESSURE SWITCH .................................... 28
OUTLET ............................................................... 52

E
EGR CONTROL SOLENOID VALVE .................... 20
EGR SOLENOID VALVE ...................................... 20
EGR VALVE POSITION SENSOR ........................ 22
ENGINE COOLANT TEMPERATURE
SENSOR ............................................................ 22

P
PANEL LIGHT CONTROL SWITCH ..................... 54
PARKING BRAKE SWITCH ................................. 28
PARKING LIGHT .................................................. 36
PASSENGER-SIDE AIR BAG MODULE .............. 74
PCM ......................................................... 20, 22, 24
PCM CONTROL RELAY ...................................... 20
POWER OUTSIDE MIRROR ............................... 68
POWER OUTSIDE MIRROR SWITCH ................ 68
POWER WINDOW MAIN SWITCH ...................... 62
POWER WINDOW SUBSWITCH ......................... 62

F
FILAMENT ............................................................ 52
FLASHER UNIT ................................................... 42
FREE SOLENOID ................................................ 50
FRONT DOOR SPEAKER ................................... 60
FRONT POWER WINDOW REGULATOR ........... 62
FRONT SIDE TURN LIGHT ................................. 42
FRONT TURN LIGHT ........................................... 42
FUEL GAUGE SENDER UNIT ............................. 26

G
G SENSOR .......................................................... 70
GENERATOR ....................................................... 18
GLOW PLUG ........................................................ 20
GLOW PLUG RELAY ........................................... 20

H
HAZARD WARNING SWITCH ............................. 42
HEADLIGHT ......................................................... 34
HEADLIGHT LEVELING ACTUATOR .................. 38

88
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

R
REAR DOOR SPEAKER ...................................... 60
REAR FOG LIGHT ............................................... 40
REAR FOG LIGHT RELAY ................................... 40
REAR FOG LIGHT SWITCH ................................ 40
REAR POWER WINDOW REGULATOR .............. 62
REAR TURN LIGHT ............................................. 42
REAR WINDOW DEFROSTER RELAY ............... 52
REAR WINDOW DEFROSTER SWITCH ............. 52
REFRIGERANT PRESSURE SWITCH ................ 48
RESISTOR ........................................................... 48
RFW CONTROL MODULE .................................. 50
RFW MAIN SWITCH ............................................ 50
RFW SWITCH ...................................................... 50

PARTS INDEX
S
SAS UNIT ............................................................. 74
SEDIMENTOR SWITCH ...................................... 28
STARTER ............................................................. 18
STARTER RELAY ................................................. 18

T
TAILLIGHT ............................................................ 36
TDC SENSOR ...................................................... 24
THEFT-DETERRENT
CONTROL MODULE ................................... 78, 80
THEFT-DETERRENT HORN ................................ 80
THEFT-DETERRENT HORN RELAY ................... 80
TRANSFER NEUTRAL SWITCH ......................... 50
TURN SWITCH .................................................... 42

V
VEHICLE SPEEDOMETER SENSOR ................. 26

W
WATER TEMPERATURE
SENDER UNIT ................................................... 26
WINDSHIELD WASHER MOTOR ........................ 32
WINDSHIELD WIPER AND
WASHER SWITCH ............................................ 32
WINDSHIELD WIPER MOTOR ............................ 32

89
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H

Вам также может понравиться