BT-50 Manual Taller

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Training Manual
Mazda BT-50
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http://eshops.mercadolibre.com.ve/bodoshop
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No part of this hardcopy may be reproduced in any form without prior permission of
Mazda Motor Europe GmbH.
The illustrations, technical information, data and descriptive text in this issue, to the best of our
knowledge, were correct at the time of going to print.
No liability can be accepted for any inaccuracies or omissions in this publication, although every
possible care has been taken to make it as complete and accurate as possible.
© 2006
Mazda Motor Europe GmbH
Training Services
Table of Contents
General Information ..........................................................................00-1

Product Concept....................................................................................................00-1
Vehicle Identification Number................................................................................00-7
Engine Identification Number ................................................................................00-8
Other Vehicle Information Labels ..........................................................................00-9
Model Plate.....................................................................................................00-9
Tyre Pressure Label .......................................................................................00-9
Technical Data.....................................................................................................00-10
Jacking and Lifting...............................................................................................00-11
Towing .................................................................................................................00-12
Scheduled Maintenance Table ............................................................................00-13
Remarks .......................................................................................................00-15
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Cooling System ........................................................................................................01-15

Features ..............................................................................................................01-15
Specifications ......................................................................................................01-15
Parts Location......................................................................................................01-16
System Overview.................................................................................................01-17
Intake-Air System .....................................................................................................01-18
Features ..............................................................................................................01-18
Parts Location......................................................................................................01-19
System Overview.................................................................................................01-20
MAF Sensor.........................................................................................................01-21
MAF Learning Function .......................................................................................01-21
MAF Data Reset ..................................................................................................01-21
MAP Sensor / IAT Sensor No.1...........................................................................01-21
Variable Geometry Turbocharger ........................................................................01-22
Intake Manifold ....................................................................................................01-23
Variable Swirl Control Shutter Valves...........................................................01-24
Vacuum Chamber................................................................................................01-24
Service Training BT-50

Table of Contents
Exhaust System........................................................................................................01-31
Features ..............................................................................................................01-31
Parts Location......................................................................................................01-31
Warm up system..................................................................................................01-32
Wiring Diagram.............................................................................................01-32
Exhaust Shutter Valve Solenoid Valve .........................................................01-33
Exhaust Shutter Valve Unit...........................................................................01-33
Operating Conditions....................................................................................01-33
Emission System......................................................................................................01-34
Features ..............................................................................................................01-34
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Parts Location......................................................................................................01-34
System Overview.................................................................................................01-36
EGR Solenoid Valve............................................................................................01-37
EGR Control ........................................................................................................01-37
Intake Shutter Valve ............................................................................................01-38
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Charging and Starting System ................................................................................01-39
Parts Location......................................................................................................01-39
Control System .........................................................................................................01-40
Features ..............................................................................................................01-40
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Specifications ......................................................................................................01-40
Parts Location......................................................................................................01-41
System Overview.................................................................................................01-42
Block Diagram .....................................................................................................01-44
Relationship Chart ...............................................................................................01-45
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Crankshaft Position Sensor .................................................................................01-46

Camshaft Position Sensor ...................................................................................01-47
Powertrain Control Module ..................................................................................01-48
Features .......................................................................................................01-48
A/C Cut-Off Control ......................................................................................01-49
Glow Plug Relay ...........................................................................................01-50
On-Board Diagnostic System ..............................................................................01-51
Features .......................................................................................................01-51
Malfunction Indicator Lamp ..........................................................................01-51
Self Test .......................................................................................................01-51
PID Monitor..........................................................................................................01-52
Simulation Test....................................................................................................01-53
Maintenance and Repair .....................................................................................01-54
MAF Sensor Learning Function....................................................................01-54
Replacing the MAF Sensor...........................................................................01-54
PCM Replacement .......................................................................................01-55

Table of Contents
Suspension ........................................................................................02-1
Features ................................................................................................................02-1
Specifications ........................................................................................................02-1
Parts Location........................................................................................................02-2
Front Suspension 2WD ..................................................................................02-2
Front Suspension 4WD ..................................................................................02-2
Rear Suspension ............................................................................................02-3
Wheels and Tyres .......................................................................................................02-4
Specifications ........................................................................................................02-5
Driveline / Axle...................................................................................03-1
Features ................................................................................................................03-1
Specifications ........................................................................................................03-1
RFW System .........................................................................................................03-2
Parts Location.................................................................................................03-2
System Overview............................................................................................03-3
On-Board Diagnostic System .........................................................................03-4
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Transmission .....................................................................................05-1
Clutch ..........................................................................................................................05-1
Features ................................................................................................................05-1
Specifications ........................................................................................................05-1
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Parts Location........................................................................................................05-2
Clutch Master Cylinder ..........................................................................................05-3
Dual Mass Flywheel ..............................................................................................05-4
S15M(X)-D Manual Transmission..............................................................................05-5
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Features ................................................................................................................05-5
Specifications ........................................................................................................05-6
Overview................................................................................................................05-7
Power Flow............................................................................................................05-8
Shift Mechanism ..................................................................................................05-10
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Shift Mechanism Unit....................................................................................05-11

5th / Reverse Gear Mechanism .....................................................................05-12
Reverse Gear Lockout Mechanism ..............................................................05-14
HVAC ..................................................................................................07-1
Basic System ..............................................................................................................07-1
Features ................................................................................................................07-1
Specifications ........................................................................................................07-1
Parts Location........................................................................................................07-2
Refrigerant System................................................................................................07-3
Control System ...........................................................................................................07-4
Features ................................................................................................................07-4
Parts Location........................................................................................................07-4
Wiring Diagram......................................................................................................07-5
Climate Control Unit ..............................................................................................07-6

Table of Contents
Restraints...........................................................................................08-1
Airbag System ............................................................................................................08-1
Features ................................................................................................................08-1
Parts Location........................................................................................................08-2
Wiring Diagram......................................................................................................08-3
SAS Control Module ..............................................................................................08-4
Side Airbag Sensors..............................................................................................08-5
Side Airbags ..........................................................................................................08-5
Seat Belt Pretensioners.........................................................................................08-6
On-Board Diagnostic System ................................................................................08-7
Features .........................................................................................................08-7
Self Test .........................................................................................................08-7
PID Monitor.....................................................................................................08-8
Body & Accessories..........................................................................09-1

Body Panels ................................................................................................................09-1
Cabin .....................................................................................................................09-1
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Ladder Frame ........................................................................................................09-2
Cargo Box..............................................................................................................09-3
Anti-Corrosion Measures.......................................................................................09-3
Glass/Windows/Mirrors..............................................................................................09-4
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Security and Locks.....................................................................................................09-5
Features ................................................................................................................09-5
Theft Deterrent System .........................................................................................09-5
Wiring Diagram...............................................................................................09-6
Exterior Trim ...............................................................................................................09-7
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Features ................................................................................................................09-7
Parts Location........................................................................................................09-7
Front and Rear Bumper.........................................................................................09-8
Interior Trim ................................................................................................................09-9
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Features ................................................................................................................09-9
Parts Location........................................................................................................09-9
Lighting System........................................................................................................09-10
Features ..............................................................................................................09-10
Parts Location......................................................................................................09-10
Front Combination Light ...............................................................................09-10
Rear Combination Light................................................................................09-11
Overview..............................................................................................................09-12
Daytime Running Light ........................................................................................09-12
Wiring Diagram....................................................................................................09-13
Wiper / Washer System............................................................................................09-14
Features ..............................................................................................................09-14
Parts Location......................................................................................................09-14
Wiring Diagram....................................................................................................09-15

Control System WL-C Engine
Notes:
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01-56 Service Training BT-50

Suspension
Suspension
Features
• The front and rear suspension of the BT-50 have the following new features:
– Enlarged diameter and modified damper valve tuning of the double acting low
pressurised shock absorbers
– Enlarged diameter of the front stabiliser
– Extended leaf springs on the rear axle
– Modified wheel alignment values
Specifications
Specification
Item
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2WD 4WD
Front suspension
Suspension type Double wishbone
Spring type Torsion bar spring
Type Torsion bar
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Stabilizer
Diameter mm 27 28
Shock absorber type Cylindrical, double-acting
Maximum steering Inner 33°00'-37°00' 31°30'-35°30'
angle Outer 30°00'-35°00' 27°00'-32°00'
Total toe-in mm 2-8 3-9
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Front wheel RAP cab: 0°44' ±1°

alignment Camber angle (reference value) 0°35' ±1°
DBL cab: 0°45' ±1°
(Unloaded
RAP cab: 2°07' ±1°
condition*) Caster angle (reference value) 1°56' ±1°
DBL cab: 2°06' ±1°
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RAP cab: 10°37'

Steering axis inclination 8°25'
DBL cab: 10°35'
Rear suspension
Suspension type Leaf spring
Spring type Semi elliptic leaf spring
Shock absorber type Cylindrical, double-acting
* : Fuel tank full; engine coolant and engine oil at specified level, and spare tire, jack and tools in designated position.
BT-50_T02001
Service Training BT-50 02-1

Suspension
Parts Location
Front Suspension 2WD
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1 Front shock absorber 4 Lower arm
2 Torsion bar spring 5 Tension rod
3 Upper arm 6 Front stabiliser
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Front Suspension 4WD

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BT-50_02003
1 Shock absorber 4 Lower arm

2 Torsion bar spring 5 Front stabiliser
3 Upper arm

Suspension
Rear Suspension
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BT-50_02004
1 4WD 3 Shock absorber

2 2WD 4 Leaf spring

Wheels and Tyres Suspension
Wheels and Tyres

• The wheels and tyres have the following new features:
– Modified wheel and tyre sizes
– Modified wheel offset
– New designs for 15- and 16-inch aluminium alloy wheels and 15-inch steel wheels.
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1 15-inch standard steel rim (2WD) 3 15-inch aluminium alloy rim (2WD)
2 15-inch design steel rim (4WD) 4 16-inch aluminium alloy rim (4WD)
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Suspension Wheels and Tyres
Specifications
Item Specification
Size 15 x 61/2J 15 x 61/2JJ 16 x 7J
Offset mm 20 25 10
Wheel Pitch circle diameter mm 139.7
Aluminium Aluminium
Material Steel Steel
alloy alloy
235/75R15 245/70R16
Size 215/70R15C 106/104S
109S 111S
Up to four
Front persons 220 210 210
Air
Tyre Full load
pressure
kPa Up to four
210 210 210
Rear persons
Full load 375 290 270
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Remaining tread mm 1.6
Wheel nut tightening
Nm 88.2-117.6
torque
Wheel
Radial
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and 1.5 max.
Wheel and tyre direction
tyre
runout mm Axial
2.0 max.
direction
BT-50_T02002
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Wheels and Tyres Suspension
Notes:
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Driveline / Axle
Driveline / Axle
Features
• The driveline / axle of the BT-50 has the following new features:
– Modified transfer case due to increased engine torque and new transmission
– RFW control with OBD function integrated in PCM (separate RFW module has been
dropped)
NOTE: Further information can be found in the Training Manuals ‘B-Series’ (NMT-005) and
in ‘Manual transmission and 4WD’ (CT-L1002).
Specifications
Item Specification
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Drive type 2WD 4WD
Transmission type S15M-D S15MX-D
Front axle
Bearing type Taper roller bearing
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Rear axle
Bearing type Taper roller bearing
Support type Semi-floating
Casing Banjo type
Length mm 739
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Diameter mm 35.0
Rear differential
Reduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inch) 8.9
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Final gear ratio 3.416 3.727

Grade API service GL-5
Differential oil Type Viscosity SAE 90
Capacity L 2.45 2.35
Front differential
Reduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inch) 8.00
Final gear ratio 3.727
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Grade API service GL-5
Above -18°C: SAE 90
Differential oil Type Viscosity
Below -18°C: SAE 80
Capacity L 1.9
BT-50_T03001

RFW System Driveline / Axle
RFW System
• The RFW system is controlled by the PCM. The input and output components are the
same as used for the B-Series with separate RFW control module.
Parts Location
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BT-50_03001
1 RFW main switch 7 RFW vacuum actuator

2 Transfer neutral switch 8 Joint shaft component
3 4WD switch 9 Lock solenoid valve
4 One-way check valve 10 Free solenoid valve
5 RFW switch 11 PCM
6 RFW unit

Driveline / Axle RFW System
System Overview
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1 4WD indicator light 11 One-way check valve

2 RFW indicator light 12 Lock solenoid valve
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3 To battery 13 Free solenoid valve

4 Front differential 14 RFW main switch
5 Lock 15 PCM
6 Free 16 Vehicle battery
7 RFW vacuum actuator 17 Engine switch
8 RFW unit 18 Selector lever
9 RFW switch 19 4WD switch
10 To vacuum pump 20 Transfer neutral switch

RFW System Driveline / Axle
On-Board Diagnostic System
• Detected malfunctions are stored as 4-digit DTCs in the PCM memory and can be
retrieved by means of M-MDS.
DTC Table
DTC Malfunction
P1812 RFW lock solenoid valve circuit failure
P1813 RFW lock solenoid valve open circuit
P1814 RFW lock solenoid valve circuit/short to battery
P1815 RFW lock solenoid valve circuit/short to ground
P1878 RFW free solenoid valve circuit failure
P1879 RFW free solenoid valve open circuit
P1880 RFW free solenoid valve circuit/short to battery
P1885 RFW free solenoid valve circuit/short to ground
BT-50_T03002
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Simulation Test
• A simulation test has been adopted to check the function of certain output components
by means of M-MDS.
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PID Applicable component Condition Test condition
4WDMODE_L # 4WD indicator light OFF/ON
HUBLOCK # RFW lock solenoid valve OFF/ON Engine switch at
HUBLOCK_L # RFW free solenoid valve OFF/ON ON
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NTFLAMP # RFW indicator light OFF/ON

BT-50_T03003
NOTE: Further diagnosis is supported by the symptom troubleshooting section in the W/M.
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Transmission Clutch
Clutch
Features
• The clutch system of the BT-50 has the following new features:
– Clutch master cylinder with one-way valve and pulsation damper
– Dual mass flywheel
Specifications
Item Specification
Manual transmission type S15M-D, S15MX-D
Clutch control Hydraulic
Spring type Diaphragm
Clutch cover
Set load N 10,100
Outer diameter mm 250
Clutch disc
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Inner diameter mm 155
Type Suspended
Clutch pedal Pedal ratio 5.2
Full stroke mm 152
Clutch master cylinder inner diameter mm 15.87
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Clutch release cylinder inner diameter mm 22.23
Clutch fluid type SAE J1703, FMVSS 116 DOT-3
BT-50_T05001
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Clutch Transmission
Parts Location
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BT-50_05013
1 Dual-mass flywheel 5 Clutch release cylinder

2 Clutch disc 6 Clutch release collar
3 Clutch cover 7 Clutch pedal
4 Clutch release fork 8 Clutch master cylinder

Transmission Clutch
Clutch Master Cylinder
• The one-way valve prevents harsh clutch engagement by a throttle, which prevents too
quick back flowing of the fluid when the clutch is engaged thus ensuring smooth driving
off.
• The pulsation damper reduces pressure fluctuations in the hydraulic line during clutch
operation, minimizing operation noise and vibration transmission to the clutch pedal.
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BT-50_05001
1 One-way valve 2 Pulsation damper

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Clutch Transmission
Dual Mass Flywheel
• The dual mass flywheel compensates torque fluctuations thus reducing rattle noises of
the transmission gears.
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BT-50_05014
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1 Torsional-vibration damping spring 3 Primary flywheel

2 Secondary flywheel

Transmission S15M(X)-D Manual Transmission
S15M(X)-D Manual Transmission

• Due to the increased engine torque the newly developed three-shaft 5-speed manual
transmission S15M-D has been adopted for the 2WD version, while the S15MX-D
transmission with an additional transfer case has been adopted for the 4WD version.
• Except for the transfer case the construction and operation of both transmissions are
basically the same. They have superseded the R15M(X)-D transmission used on the B-
Series.
Features
• Construction and operation of the S15M(X)-D transmission are quite similar to the P66M-
D transmission introduced on the MX-5 (NC). It has the following features:
– Triple-cone synchroniser mechanism for the 1st and 2nd gear
– Double-cone synchroniser mechanism for the 3rd gear
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– Single-cone synchroniser mechanism for 4th, 5th and reverse gear
– Integrated shift mechanism unit comprising shift rods and forks, detent balls, and pin-
type interlock mechanism
– Cam-type reverse lockout mechanism
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S15M(X)-D Manual Transmission Transmission
Specifications
Item Specification
Transmission type S15M-D, S15MX-D
Transmission/Transfer control Floor-shift
Shift assist Synchromesh
1GR 3.905
2GR 2.248
3GR 1.491
Gear ratio
4GR 1.000
5GR 0.800
Reverse 3.391
Type Manual Transmission fluid type A
Transmission case oil Capacity
L 3.55
(approx.quantity)
Shift control case oil
Capacity
[S15M-D] ml 220-260
(approx.quantity)
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High 1.000
Transfer ratio
Low 2.020
Transfer case oil
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Capacity
[S15MX-D] L 1.85
(approx.quantity)
BT-50_T05002
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Overview
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BT-50_05002
A Extension housing (S15M-D) 5 Reverse idler gear

B Transfer case (S15MX-D) 6 Reverse gear
1 Output shaft 7 5th gear
2 3rd gear 8 Counter shaft
3 2nd gear 9 Input shaft
4 1st gear

Power Flow
BT-50_05003
1st Gear
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BT-50_05004
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2nd Gear
BT-50_05005
3rd Gear

BT-50_05006
4th Gear
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BT-50_05007
5th Gear
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BT-50_05008
Reverse Gear

Shift Mechanism
• Most of the shift mechanism components are accommodated in the shift mechanism
unit. Due to its five speed layout the S15M(X)-D transmission requires four shift rods in
total (three in the shift mechanism unit and one in the transmission housing).
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BT-50_05009
1 Section A-A 3 Control rod

2 Shift mechanism unit 4 Shift rod
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Shift Mechanism Unit
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BT-50_05010
1 Transmission breather 11 Interlock pin

2 Spring 12 1st/2nd shift rod
3 Plastic spring seat 13 3rd/4th shift rod
4 Detent ball 14 Retaining ring
5 Oil baffle plate 15 Plain washer
6 Retaining bolt 16 Push pin
7 3rd/4th shift fork 17 5th/reverse shift rod end
8 Stopper block 18 Rubber plug
9 1st/2nd shift fork 19 3rd/4th shift rod end
10 5th/reverse shift rod 20 1st/2nd shift rod end

5th / Reverse Gear Mechanism
• The shift fork for the 5th / reverse gear is mounted on an additional shift rod inside the
gearbox. It is operated by the 5th / reverse shift rod in the shift mechanism unit via the
counter lever.
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BT-50_05011

1 Counter lever 18 Reverse gear

2 Washer 19 Countershaft rear bearing
3 Retaining ring 20 Locknut
4 5th/reverse clutch hub and shift fork 21 Synchronizer key spring
component
5 Steel ball 22 Clutch hub sleeve
6 5th gear bearing inner race 23 Detent spring
7 Needle bearing 24 Detent ball
8 5th gear 25 5th/reverse shift rod
9 Synchronizer ring 26 5th/reverse shift fork
10 Retaining bolt 27 Synchronizer key
11 Reverse idler gear shaft component 28 5th/reverse clutch hub
12 Reverse idler gear shaft 29 Output rear bearing
13 Thrust washer 30 Reverse counter gear
14 Reverse idler gear 31 Spacer
15 Friction damper 32 5th counter gear
16 Thrust washer (Selective) 33 Counter lever shaft component
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17 Spacer (Selective)
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Reverse Gear Lockout Mechanism
• To prevent accidental shifting into reverse gear while downshifting from the 5th to the 4th
gear a cam-type lockout mechanism is installed in the extension housing (2WD) or in the
transfer case (4WD). The figure below shows the variant of the 4WD version.
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BT-50_05012
A Shifting directly from 5th to reverse gear 2 Selector in 5th gear position
(locked)
B Shifting from 5th to reverse gear via neutral 3 Lockout mechanism released
(released)
1 Selector locked 4 Selector in Neutral position

HVAC Basic System
Basic System
Features
• The HVAC (Heating, Ventilation, Air Conditioning) basic system of the BT-50 has the
following new features:
– Modified blower unit to reduce fan noise
– Condenser with sub-cooling function and integrated receiver / drier
Specifications
Item Specification
Heating capacity kW 4.86
Cooling capacity kW 4.012
Type R-134a
Refrigerant
Regular amount approx. 475
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Type Swash plate
Discharge capacity ml 154
Max. allowable speed rpm 7,000
A/C compressor PAG oil type FD46XG
Lubrication
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Sealed volume ml 180
Magnetic clutch clearance mm 0.35-0.75
Fusible plug Melting point °C 102-107
Type Multiflow (sub-cooling type)
Radiated heat kW 10.46
Condenser
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Receiver/drier capacity ml 220

Desiccant Synthetic zeolite
Expansion valve Type Internal regulating type
Evaporator Type Single tank drawn cup
Temperature control Reheat full air mix type
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Electrical consumption (during Blower motor W 220

A/C operation) Magnetic clutch W 48
Blower motor Type Sirocco
Refrigerant Condition ON OFF
pressure
Operating High 390 - 790 2940 - 3340
Magnetic clutch switch
pressure kPa Low 176 - 216 20 or less
control
Evaporator Condition ON OFF
temperature Evaporator
°C 3.0 +/- 0.6 1.0 +/- 0.6
sensor temperature
BT-50_T07001

Basic System HVAC
Parts Location
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1 Heater / air distribution unit 6 High pressure charging valve

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2 Cooling unit 7 Condenser

3 Blower unit 8 Receiver / drier
4 Low pressure charging valve 9 Compressor
5 Refrigerant pressure switch

HVAC Basic System
Refrigerant System
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BT-50_07006
1 Low-pressure charging valve 5 Condenser

2 Expansion valve 6 Evaporator
3 High-pressure charging valve 7 A/C Compressor
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4 Receiver / drier
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Control System HVAC
Control System
Features
• The HVAC control of the BT-50 has the following new features:
– Newly designed control panel with larger dials
Parts Location
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BT-50_07003
1 A/C relay 5 Blower motor

2 Climate control unit 6 Refrigerant pressure switch
3 Evaporator temperature sensor 7 Magnetic clutch
4 Blower resistor

HVAC Control System
Wiring Diagram
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BT-50_07004
1 PCM 7 A/C switch

2 A/C relay 8 Fan switch
3 Refrigerant pressure switch 9 Blower resistor
4 Magnetic clutch 10 Blower motor
5 Climate control unit 11 Blower relay
6 A/C Amplifier / Thermoswitch (incl.
evaporator temperature sensor)

Control System HVAC
Climate Control Unit
• A new designed cable operated climate control unit has been adopted.
1 A/C switch op 5 Fan switch

BT-50_07005
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2 Rear window defroster switch 6 Rec/Fresh lever
3 Airflow mode selector dial 7 Temperature control dial
4 Climate control unit
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Restraints Airbag System
Airbag System
Features
• The airbag system of the BT-50 has the following new features:
– Side airbags integrated in the backrests of the front seats (depending on grade) *1)
– Side airbag sensors installed on the door sills
– SAS (Sophisticated Airbag Sensor) control module with enhanced OBD system
– Rack-type seatbelt pretensioners, height-adjustable on front seats of DBL cab
version *1)
*1) Similar to MX-5 (NC)
NOTE: Further information can be found in the Training Manual of the ‘B-Series’ (NMT-005)
and ‘MX-5’ (NMT-008), and ‘Supplemental Restraint System’ (CT-L1003).
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Airbag System Restraints

Parts Location
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1 Airbag system warning light 5 Side airbag sensor

2 Clock spring 6 Side airbag module
3 Seat belt pretensioner 7 SAS control module
4 Driver-side airbag module 8 Passenger-side airbag module
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Wiring Diagram
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BT-50_08002
1 Clock spring 9 SAS control module

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2 Driver-side airbag module 10 Twisted pair wire

3 Passenger-side airbag module 11 Passenger-side side airbag sensor
4 Driver-side seat belt pretensioner 12 Driver-side side airbag sensor
5 Driver-side side airbag module 13 IC
6 Passenger-side seat belt pretensioner 14 Airbag system warning light
7 Passenger-side side airbag module 15 DLC-2
8 Poor connection detection bar (connector 16 Poor connection detection bar (connector
no.2) no.1)

SAS Control Module
• The SAS control module is located on the centre tunnel, in front of the shift lever.
• The SAS control module processes the signals it receives from the internal micro-
mechanical sensor and the side airbag sensors. If the acceleration/deceleration caused
by a frontal or side impact exceeds a predetermined threshold, the SAS control module
triggers the airbags / pre-tensioners or only the side airbags with a DC signal.
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BT-50_08003
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1 SAS control module 3 Connector

2 Driving direction
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Side Airbag Sensors
• The side airbag sensors are installed under the vehicle on the door sills, close to the B-
pillar. A rigid metal cover protects the sensors against any damage during off-road
driving.
• The side airbag sensor measures the acceleration / deceleration of the vehicle during a
side impact and transmits this information to the SAS control module.
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BT-50_08004
1 Protection cover 2 Side airbag sensor
Side Airbags
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• The BT-50 is equipped with side airbags, which protect the head and chest area of the
occupants during a side impact. The operation is similar to that of the MX-5 (NC).
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BT-50_08005
1 Inflator 3 Airbag
2 Module cover 4 Side airbag module

Seat Belt Pretensioners
• The BT-50 is equipped with rack-type seat belt pretensioners, which remove the excess
slack from the seat belt in case of an accident. The operation is similar to that of the MX-
5 (NC) seat belt pretensioners.
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BT-50_08006
1 Spindle 8 Clutch roller

2 Spring seat 9 Cylinder
3 Spring shaft 10 Gas generator
4 Spring 11 Cap nut
5 Spring case 12 Rack
6 Cover 13 Base
7 Gear


Features
• The OBD system of the airbag system allows bi-directional communication with M-MDS,
enabling a quicker and more precise diagnosis. It has the following new features:
– Selftest (retrieving four digit DTCs stored for present and past malfunctions)
– PID monitor
Self Test
• The self-test function comprises displaying present and past four-digit DTCs by means of
M-MDS. To read out the DTCs of the SAS control module connect the M-MDS to the
vehicle and select the option ToolboxÆSelf TestÆModulesÆRCM.
• The excerpt of the DTC table below shows that a malfunction, which is indicated by the
airbag system warning light with only one flashing pattern e.g. DTC 22, can actually have
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several different root causes. A more detailed description of the root cause is only
displayed when performing the self test with M-MDS.
• When a malfunction of the airbag system is present the warning light flashes a two-digit
DTC for ten times. Then the light stays illuminated. The flashing starts again when the
ignition is switched off and on.
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DTC
Air bag system warning light
M-MDS Malfunction
Priority
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display Flashing pattern

ranking
Passenger-side air bag module circuit

B1933 21 7
resistance high
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Driver-side air bag module circuit

B1934 19 8
resistance low
Passenger-side air bag module circuit
B1935 21 7
resistance low
Driver-side side air bag module circuit short
B1992
to power supply
Driver-side side air bag module circuit short
B1993
to ground
22 12
Driver-side side air bag module circuit
B1994
resistance high
Driver-side side air bag module circuit
B1995
resistance low
BT-50_T08001

PID Monitor
• The PID monitor function allows monitoring the PIDs of the SAS control module.
Therefore, connect the M-MDS to the vehicle and select the option ToolboxÆ
DataloggerÆModulesÆ RCM.
PID Definition Unit/Condition

CONT_RCM Number of continuous DTCs Num
CRSH_ST_D1 Driver-side airbag sensor communication state OK/FAULT
CRSH_ST_D2 Driver-side airbag sensor circuit state OK/FAULT
CRSH_ST_P1 Passenger-side airbag sensor communication state OK/FAULT
CRSH_ST_P2 Passenger-side airbag sensor circuit state OK/FAULT
D_PTENSFLT Driver-side seat belt pretensioner circuit state *1)
DABAGR Driver-side airbag module resistance ohm
DR_PTENS Driver-side seat belt pretensioner resistance ohm
DS_AB Driver-side, side airbag module resistance ohm
DS_AB_ST Driver-side, side airbag module circuit state *1)
DS1_STAT Driver-side airbag module circuit state *1)
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DSB_P_ST Driver-side seat belt pretensioner circuit state *1)
IG_V_2 System IG1 voltage value V
On-demand driver-side, side airbag sensor
OD_CRST_D1 OK/FAULT
communication state
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OD_CRST_D2 On-demand driver-side, side airbag sensor circuit state OK/FAULT
On-demand passenger-side, side airbag sensor
OD_CRST_P1 OK/FAULT
communication state
OD_CRST_P2 On-demand passenger-side, side airbag sensor circuit state OK/FAULT
OD_DAB1_ST On-demand driver-side airbag module circuit state *1)
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OD_DSAB_ST On-demand driver-side, side airbag circuit state *1)

OD_PAB1_ST On-demand passenger-side airbag module circuit state *1)
OD_PSAB_ST On-demand passenger-side, side airbag sensor circuit state *1)
P_PTENSFLT Passenger-side seat belt pretensioner circuit state *1)
PABAGR Passenger-side airbag module resistance ohm
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PS_AB Passenger-side, side airbag module resistance ohm

PS_AB_ST Passenger-side, side airbag sensor circuit state *1)
PS_PTENS Passenger-side seat belt pretensioner resistance ohm
PS1_STAT Passenger-side airbag module circuit state *1)
PSB_P_ST Passenger-side seat belt pretensioner circuit state *1)
BT-50_T08002
*1) SQ_LOWRES / OPEN / SHRT_B+ / SHRT_GND / Normal

Body & Accessories Body Panels
Body Panels
Cabin
• The cabin structure of the BT-50 (DBL cab version) with its triple-H structure, the side-
door beams, and the use of high-tensile steel, provide a class top level of passive safety
in conjunction with the rigid ladder frame satisfying stringent European collision-safety
standards.
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BT-50_09001
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• Despite having no B-pillars the RAP cab version satisfies the European collision-safety
standards by reinforcements in the rear access panel.
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BT-50_09002

Body Panels Body & Accessories
Ladder Frame
• The cross-braced ladder frame of the BT-50 is essentially carried over from the B-Series,
just as four cabin mounts, which minimise lateral movement, but allow for compliance in
vertical movement providing comfortable driving.
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BT-50_09003
DBL Cab Frame

Body & Accessories Body Panels
Cargo Box
• The cargo box of the BT-50 has the following new features allowing a more versatile
usage of the cargo box:
– Taller cargo box walls to increase the load capacity.
– New structure of the inner cargo box walls with one horizontal and several vertical
guiding grooves that allow splitting up the cargo space with boards.
– Inner rope hooks that are placed closer to the floor to ease firm securing of load.
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BT-50_09004
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1 Vertical guiding grooves 3 Inner rope hook

2 Horizontal guiding groove
Anti-Corrosion Measures
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• The body of the BT-50 features improved anti-corrosion measures:

– Organic-resin coated steel is used on body panels that are regularly exposed to
weather, such as the cowl, bonnet and outer door panels. Undercoating, PVC and
wax coatings are used extensively to protect the underbody, frame and other
exposed areas, against corrosion.
– Galvanized steel is used for fenders, rocker panels, outer cargo box panels, the
cargo box floor panel, wheel wells and load gate.

Glass/Windows/Mirrors Body & Accessories
Glass/Windows/Mirrors
• The glass/windows/mirrors of the BT-50 have following new features:
– Rear window defroster switch installed in centre panel
– Power outer mirror switch installed in driver door trim
– Enlarged power outer mirrors
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1 Rear window defroster switch
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BT-50_09007
1 Power outer mirror switch

Body & Accessories Security and Locks
Security and Locks

Features
• The security and locks system of the BT-50 has the following features:
– Power door lock system (without double lock)
– Keyless entry system (keyless transmitter with retractable key)
– Mazda immobiliser system with separate immobiliser module
– Theft-deterrent system (for vehicles with U.K. specification)
NOTE: Further information can be found in the Training Manuals of the ‘B-Series’ (NMT-005)
and ‘Immobiliser System’ (CT-L 1007).
Theft-Deterrent System
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• The theft-deterrent system activates the turn lights and the theft-deterrent horn when the
bonnet or a door is opened by means of other than the key or the keyless transmitter.
The system is deactivated when a door is opened with the key or the unlock button of
the keyless transmitter.
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BT-50_09008
1 Engine switch 6 Theft-deterrent horn

2 Front door latch and lock actuator 7 Bonnet switch
3 Rear door latch and lock actuator 8 Door lock control module
4 Door switch 9 Theft-deterrent control module
5 Keyless control module

Security and Locks Body & Accessories
Wiring Diagram
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BT-50_09009
1 Instrument cluster 9 Theft-deterrent horn

2 Door ajar warning light 10 Theft-deterrent control module
3 Security light 11 Door key cylinder switches
4 Door switches 12 Door lock control module
5 Driver’s door lock-link switch 13 Keyless control module
6 Rear door lock-link switches 14 Hazard warning switch
7 Bonnet switch 15 Flasher control module
8 Theft-deterrent horn relay 16 Key reminder switch

Body & Accessories Exterior Trim
Exterior Trim
Features
• The exterior trim of the BT-50 has the following new features (depending on grade):
– Painted front bumper with integrated front grille
– New designed chrome door handles
– Larger wheel arch extensions
– Modified side steps
Parts Location
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BT-50_09026
1 Side step 5 Side protector

2 Wheel arch extension 6 Front flap
3 Rear bumper 7 Front bumper
4 Rope hook

Exterior Trim Body & Accessories
Front and Rear Bumper
• The front bumper is completely new designed, while the rear bumper is the same as
used on the B-Series.
• The plastic front bumper is installed on a steel reinforcement. The bumper also
accommodates the front grille, newly designed front fog lights and the lower wheel arch
extensions (if equipped).
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BT-50_09005
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1 Bumper reinforcement 4 Front bumper

2 Lower wheel arch extension 5 Front hole cover (without front fog lights)
3 Front hole cover (with front fog lights)

Body & Accessories Interior Trim
Interior Trim
Features
• The interior trim of the BT-50 has the following new features:
– Newly designed dashboard installed on a steel crossmember
– Front door pockets with bottle holder
– Sliding upper glove compartment
– Newly designed centre console
Parts Location
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BT-50_09010
1 Sliding upper glove compartment 5 Cup holder

2 Glove compartment 6 Cup holder (except REG cab)
3 Storage compartment 7 Centre console
4 Door pocket

Lighting System Body & Accessories
Lighting System
Features
• The lighting system of the BT-50 has the following new features:
– Front combination light with multi-reflector headlight type, turn and parking light
– Rear combination light with stepped reflector
– Front and rear fog light switch incorporated in light switch
– Rear fog light integrated in rear combination light or in rear bumper (depending on
market)
– Centre console illumination light
– Room light incorporating spot lights
– DRL (Daytime Running Light) (depending on market)
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Parts Location
Front Combination Light
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BT-50_09012
1 Headlight bulb 4 Section B-B

2 Front turn light bulb 5 Section A-A
3 Parking light bulb

Body & Accessories Lighting System
Rear Combination Light
1 Brake/taillight bulb op 4 Section A-A

BT-50_09013
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2 Turn light bulb 5 Rear combination light
3 Back-up light bulb (LH)
Rear fog light bulb (RH)
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Lighting System Body & Accessories
Overview
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BT-50_09014
1 Combination switch 5 Centre console illumination

2 Light switch 6 Glove compartment light
3 Panel light control switch 7 Hazard warning switch
4 Headlight levelling switch 8 Interior light
Daytime Running Light
• Since some countries outlaw driving vehicles without switched on headlights during
daytime, a DRL system is available for these markets. On the BT-50, a DRL control
module automatically switches on the headlights when the ignition is in IG1 position.

Body & Accessories Lighting System
Wiring Diagram
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BT-50_09028

Wiper / Washer System Body & Accessories
Wiper / Washer System

Features
• The wiper / washer system of the BT-50 has the following new features:
– Intermittent wiper function with adjustable interval
Parts Location
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BT-50_09016
1 Wiper and washer switch 5 Wiper arm and blade

2 Washer nozzle 6 Washer motor
3 Washer hose 7 Washer tank
4 Wiper motor

Body & Accessories Wiper / Washer System
Wiring Diagram
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BT-50_09024
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1 Wiper switch 5 Auto-stop switch

2 Washer switch 6 Interval relay
3 Washer motor 7 Interval control switch
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4 Wiper motor 8 One-touch switch

Entertainment Body & Accessories
Audio System
Features
• The modular audio system of the BT-50 is available in two different variants: Radio with
CD player or with 6-CD changer. It has the following features:
– AM/FM tuner with RDS (Radio Data System) and ALC (Audio Level Control)
– Single CD player or 6-CD changer with MP3 compatibility
– I-Pod adapter compatibility (16-pin connector)
– 6-Loudspeaker system comprising four door speakers and two tweeters
– OBD system
Specifications
Audio Unit
Item
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Specification
Type A
Without RDS
Type B
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Rated voltage V 12
LW kHz 153-279 –
AM
Frequency band MW kHz 531-1602 522-1629 531-1629
FM MHz 87.5-108
Audio amplifier maximum output
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W 35×4
power
Output impedance ohm 4
BT-50_T09004
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Speakers
Specification
Item Rear speaker
Front speaker Tweeter
DBL cab RAP cab
Maximum input W 25
Impedance ohm 4
Size mm 160 100 160 30
BT-50_T09005

Body & Accessories Entertainment
Parts Location
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BT-50_09017
1 Roof antenna 6 Audio unit

2 Tweeter LH 7 Antenna cable
3 Rear speaker RH 8 Front speaker RH
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4 Rear speaker LH 9 Tweeter RH
5 Front speaker LH
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System Overview
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BT-50_09019
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1 Roof antenna 8 Rear speaker (LH)

2 Audio unit 9 Base unit
3 Tweeter (RH) 10 Lower module
4 Front speaker (RH) 11 Vehicle speed signal
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5 Front speaker (LH) 12 TNS signal

6 Tweeter (LH) 13 Centre panel unit
7 Rear speaker (RH)
NOTE: A telephone mute function is only available by using an appropriate connector

adapter, which is provided as accessory part by Mazda Motor Europe.

Body & Accessories Entertainment

• The modular audio system consists of the base unit, the lower module (if equipped) and
the centre panel. The base unit with CD player is different from the one with 6-CD
changer.
BT-50_09018
1
2
3
Base unit
Audio unit
Lower module op 4
5
Cover
Centre panel
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NOTE: MC (Music Cassette) drive or MD (Mini Disc) player are currently not available for
Europe.
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BT-50_09025
Operating key layout of the 6-CD changer

• The OBD system of the modular audio system comprises a self-test and a diagnostic
assist function.
Self-Test Function
• The fault memory of the audio module can store up to three DTCs. If a fourth fault is
detected when three DTCs are already stored, the oldest DTC is deleted and the new
one stored.
• Once a DTC is stored in the non-volatile memory of the audio unit it can be displayed on
the information display when the test mode has been activated. In addition, the self-test
function allows deleting the stored DTCs.
Diagnostic Assist Function
• The diagnostic assist function allows checking of the following components:
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– Information display
– Speakers
– Radio reception condition
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– Antenna condition
NOTE: For further information about the self-test and diagnostic assist function refer to the
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W/M.
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Body & Accessories Power Systems
Power Systems
Parts Location
BT-50_09020
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1 Main fuse block 2 Fuse block
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Instrumentation / Driver Info Body & Accessories
Instrumentation / Driver Information System

Features
• The instrumentation / driver information system of the BT-50 has the following new
features:
– LED-type warning and indicator lights
– Front and rear fog light indicator lights incorporated in the IC
– Key reminder warning alarm
– Extended input / output check code functions
Specifications
Item Specification
Meter type Stepper motor type
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Indication range km/h 0–180
Speedometer
Input signal source Speedometer sensor
Rated voltage V DC 12
Meter type Stepper motor type
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Indication range rpm 0–5,500
Tachometer Red zone rpm 4,500–5,000
Input signal source PCM
Meter type Stepper motor type (Reset-to-zero type)
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Fuel level
Input signal source Fuel gauge sender unit
gauge
Stepper motor type
Water Meter type
(Medium range stabilised type)
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temperature
Input signal source ECT sensor
gauge
Display LCD
Odometer/
Indication digits Odometer: 6 digits, Tripmeter: 4 digits
Tripmeter
Sound frequency Hz 2,000–2,200
Warning
alarms Output sound
dB 67.5
pressure level
Clock accuracy (reference value)* s/day -1.5–1.5
BT-50_T09009
* : If the clock accuracy varies largely from the reference value, battery deterioration or an audio unit
(base unit) malfunction may have occurred.

Body & Accessories Instrumentation / Driver Info
Instrument Cluster Overview
No.
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BT-50_09023
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1 RFW indicator light PCM
2 4x4 indicator light RFW main switch
3 Red Zone
4 Turn indicator light Flasher control module
5 Speedometer gauge VSS
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6 Water temperature gauge ECT sensor

7 High-beam indicator light Headlight switch
8 Front fog light indicator light Front fog light relay
9 Rear fog light indicator light Rear fog light relay
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10 Fuel level gauge Fuel gauge sender unit

11 Fuel-level warning light Fuel gauge sender unit
12 ABS warning light ABS HU/CM
• Parking brake switch
13 Brake system warning light
• Brake fluid level sensor
14 Airbag system warning light SAS control module
15 Generator warning light Generator
• Immobilizer module
16 Security light
• Theft deterrent control module
17 Oil pressure warning light Oil pressure switch
18 Door ajar warning light Door switches
19 Sedimentor warning light Sedimentor switch
20 MIL PCM
21 Glow indicator light PCM
22 Tachometer gauge CKP sensor
BT-50_T09010

Instrumentation / Driver Info Body & Accessories
Key Reminder Warning Alarm
• This function warns with an intermittent sound from the buzzer in the IC that the key is in
the steering lock in position ACC or LOCK when any door is opened. Additionally a
permanent sound warns when a door is opened and the lights are switched on.
Input / Output Check Mode
• This function allows checking the input and output circuits of the instrument cluster. It
can be activated in the following way:
1. Press and hold the odometer/tripmeter switch, and turn the ignition switch to the ON
position.
2. Continue holding the odometer/tripmeter switch for approx. 5 s. until tESt is
displayed on the LCD.
3. Release the odometer/tripmeter switch within 3 s after tESt is displayed.
4. When the odometer/tripmeter indicates check code 00, push the odometer/tripmeter
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switch to select a check code.
5. Inspect the check codes according to the W/M.
Check code Check item Related items

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• Key reminder warning alarm
04 Door switch
• Lights-on reminder warning alarm
• Lights-on reminder warning alarm
08 TNS relay
• Each illumination light
• Headlight
09 Headlight switch
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• Rear fog light control system

10 Speedometer sensor Speedometer
11 PCM Tachometer
12 Speedometer Speedometer
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13 Tachometer Tachometer
14 Buzzer Buzzer
15 Rear fog light relay Rear fog light indicator light
16 Fuel-level warning light Fuel-level warning light
18 Engine key illumination Engine key illumination
22 Fuel gauge sender unit Fuel gauge
23 Fuel gauge Fuel gauge
24 ECT sensor Water temperature gauge
25 Water temperature gauge Water temperature gauge
• Odometer/tripmeter (LCD) • Odometer/tripmeter (LCD)
26
• Warning and indicator lights • Warning and indicator lights
29 Rear fog light switch Rear fog light control system
31 Key reminder switch Key reminder warning alarm
40 Front fog light relay Front fog light relay
BT-50_T09011

Body & Accessories Control System
Control System
Features
• The control system of the BT-50 has the following new features:
– DLC-2
– HS-CAN connection between PCM and DLC-2 for communication with M-MDS
Data Link Connector
• The DLC-2 is located under the dashboard next to the centre panel.
• The 17-pin DLC-1, known from the previous B-Series, is installed on the left rear side in
the engine compartment. It cannot be used for communication with M-MDS.
NOTE: For communication with M-MDS the control modules of the ABS (Antilock-Brake
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System) and the SAS are connected to DLC-2 via ISO (International Standard
Organisation) bus.
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Control System Body & Accessories
Wiring Diagram
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BT-50_09027

List of Abbreviations
ABS Anti-lock Brake System HU/CM Hydraulic Unit/Control
Module
A/C Air Conditioning IAT Intake Air Temperature
APP Accelerator Pedal Position IC Instrument Cluster
CAN Controller Area Network ISO International Standard

Organisation
CKP CranKshaft Position ISV Intake Shutter Valve
CMP CaMshaft Position KLN K-LiNe
CPP
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Clutch Pedal Position LCD Liquid Crystal Display
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DBL DouBLe LED Light Emitting Diode
Data Link Connector LSD Limited Slip Differential

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DLC
DLR Daytime Running Light MAF Mass Air Flow

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DTC Diagnostic Trouble Code MAP Manifold Absolute Pressure
ECT Engine Coolant Temperature MIL Malfunction Indicator Lamp
EGR Exhaust Gas Recirculation MC Music Cassette
FEN Fault ENgine MD Mini Disc
HVAC Heating, Ventilation, Air M-MDS Mazda-Modular Diagnostic

Conditioning System
Service Training Mazda BT-50

List of Abbreviations
OBD On-Board Diagnostics VSC Variable Swirl Control
PCM Powertrain Control Module VSS Vehicle Speed Sensor
PID Parameter IDentification VIN Vehicle Identification Number
RAP Random Access Panel
REG REGular
RFW Remote FreeWheel
RWD
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Rear Wheel Drive
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SAS Sophisticated Airbag Sensor
Supplemental Restraint
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SRS
System
SST Special Service Tool

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TEN Test ENgine
W/D Wiring Diagram
W/M Workshop Manual
VBC Variable Boost Control
VGT Variable Geometry

Turbocharger
Service Training Mazda BT-50

Created in Master PDF Editor - Demo Version RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.MAIN.INDEX TO. MODEL .INDEX
GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . GI-1 DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . GI–10
RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . . GI-1 INSTALLATION OF RADIO SYSTEM . . . . . . . . GI–10
SERVICING PROCEDURE . . . . . . . . . . . . . . . GI-1/2 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . GI–11
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-3 ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . GI–11
ADVISORY MESSAGES . . . . . . . . . . . . . . . . . . GI-3 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–11/13
TROUBLESHOOTING PROCEDURE . . . . . . GI-3/6 ELECTRICAL TROUBLESHOOTING
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . GI-6 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–13
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-7 JACKING POSITIONS . . . . . . . . . . . . . . . . . . . . . . GI–14
FUNDAMENTAL PROCEDURES . . . . . . . . . . . . GI-8 VEHICLE LIFT (2 SUPPORTS) POSITIONS . . . GI–14
PROTECTION OF THE VEHICLE . . . . . . . . . . GI-8 SAFETY STAND POSITIONS . . . . . . . . . . . . . . . GI–14
PREPARATION OF TOOLS AND TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–15
MEASURING EQUIPMENT . . . . . . . . . . . . . . GI-8 TOWING HOOKS . . . . . . . . . . . . . . . . . . . . . . . . GI–16
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . GI-8 TIEDOWN HOOKS . . . . . . . . . . . . . . . . . . . . . . . GI–16
DISCONNECTION OF THE NEGATIVE IDENTIFICATION NUMBER LOCATIONS . . . . . GI–16
BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . GI-8 VEHICLE IDENTIFICATION NUMBER . . . . . . GI–16
REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . . GI-8 ENGINE IDENTIFICATION NUMBER . . . . . . . GI–16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . GI-8 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI–17/19
INSPECTION DURING REMOVAL, ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–19
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . GI-8 PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI-20
ARRANGEMENT OF PARTS . . . . . . . . . . . . . . GI-8/9 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20
CLEANING OF PARTS . . . . . . . . . . . . . . . . . . . GI-9
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . GI-9
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ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . GI-9
RUBBER PARTS AND TUBING . . . . . . . . . . . GI–19
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . GI–19
TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . . GI–10
VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–10
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HOW TO USE THIS MANUAL SERVICING PROCEDURE
Inspection, Adjustment
RANGE OF TOPICS The procedures for inspections and adjustments
This manual contains the procedures for performing are divided into steps. Important points in regard
all of the required service operations. The to the location and contents of the procedures are
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procedures are divided into the following five basic explained in detail and are shown in the
operations. illustrations.
(1) Removal/Installation
(2) Disassembly/Assembly
(3) Replacement SHOWS PROCEDURE ORDER
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(4) Inspection FOR SERVICE

(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.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
CONTINUED
GI–1 Created in Master PDF Editor - Demo Version
BACK.TO.CHAPTER.INDEX TO. MODEL .INDEX
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
Procedure ITEM (S) Indicates any relevant
references which need to be
followed during installation.
“Removal/Installation”
Portion
“Inspection After SHOWS SPECIAL

Installation” Portion SERVICE TOOL (SST)
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
FOR SERVICE
Install the parts SHOWS APPLICATION

by performing POINTS OF GREASE, ETC.
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Steps 1—3 in
reverse order SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS EXPENDABLE PARTS
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SHOWS DETAILS
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SHOWS TIGHTENING
TORQUE UNITS
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
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SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE
CONTINUED
SYMBOLS
TROUBLESHOOTING PROCEDURE
There are eight symbols indicating oil, grease, Basic Flow of Troubleshooting
sealant, and the use of SSTs. These symbols
show the points of applying or using such materials
during service.
Symbol Meaning Kind
SECTION F ONLY
Appropriate new
Apply oil engine oil or ACTUAL TROUBLESHOOTING PROCEDURES
gear oil
SECTION K
ONLY
Appropriate new
Apply brake fluid
brake fluid
Apply automatic Appropriate new

transaxle/ automatic
transmission transaxle/ IF
MENTIONED
fluid transmission fluid
Appropriate
Apply grease
grease
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Appropriate SECTION F
Apply sealant
sealant ONLY
Apply petroleum Appropriate On-board diagnosis

jelly petroleum jelly The service codes are important hints for repairing
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malfunctions that are difficult to simulate. By
following the service code, perform the inspection
O-ring, gasket, to quickly and accurately diagnose the malfunction.
R Replace part
etc. The self-diagnostic function is used during
inspection. When a service code is shown,
specifying the cause of a malfunction, continue the
do
SST Use SST Appropriate SST inspection according to the items indicated by the
self-diagnostic function.
Engine tune-up (Section F)

ADVISORY MESSAGES
Any necessary adjustments are made after starting
You’ll find several Warnings, Cautions, Notes,
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the engine.
Specifications and Upper and lower limits in this
manual.
Basic inspection (Section K)
The basic inspection is performed to quickly
Warning narrow down the possible causes after a
A Warning indicates a situation in which
malfunction occurs regardless of the symptoms.
serious injury or death could result if the ST The basic inspection is performed to also locate
warning is ignored. the region of many malfunction symptoms.
Caution Diagnostic index
A Caution indicates a situation in which The diagnostic index lists the symptoms of the
damage to the vehicle could result if the malfunctions. Select the symptoms pertaining or
caution is ignored. most closely pertaining to the actual malfunction.
Note Quick diagnosis chart (If mentioned)
A Note provides added information that will The quick diagnosis chart lists the diagnosis and
help you to complete a particular procedure. inspection procedures to be performed specifically
relating to the cause of the malfunction.
Specification
The values indicate the allowable range when Symptom troubleshooting
performing inspections or adjustments. Symptom troubleshooting quickly determines the
location of the malfunction according to the type of
Upper and lower limits symptoms.
The values indicate the upper and lower limits
that must not be exceeded when performing
inspections or adjustments. CONTINUED
Procedures For Use

Using the basic inspection
Perform the basic inspection before the symptom troubleshooting.
Perform each step in the order shown.
The reference column lists the location of the detailed procedure for each basic inspection.
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 SHOWS ITEM NAMES FOR

ORDER THE DETAILED PROCEDURES SHOW POINTS REQUIRING
ATTENTION IN REGARD TO
INSPECTION RESULTS
Perform malfunction diagnosis according to No. 26

“HOLD INDICATOR LIGHT DOES NOT ILLUMI-
NATE WHEN HOLD SWITCH IS TURNED ON” or
No. 27 “HOLD INDICATOR LIGHT ILLUMINATES
WHEN HOLD SWITCH IS NOT TURNED ON”
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Using the diagnostic index

The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting.
The exact malfunction symptoms can be selected using the details.
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CONTINUED
Using the quick diagnosis chart

The chart lists the relation between the symptoms and cause of the malfunction.
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.
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
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CHOOSE THE ACTUAL

SYMPTOM
ST
CONTINUED
Using the symptom troubleshooting

Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for each
trouble symptom.
TROUBLESHOOTING
HINTS describes TROUBLE SYMPTOM
possible point of
malfunction.
STEP shows the ACTION describes the

order of appropriate action to
troubleshooting. 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.
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How to perform ACTION
is described in the relative
material shown.
TEXT SEQUENCE
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The text sequence is as indicated by the arrows shown below.

Example:
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CONTINUED
GI–6
UNITS
UNITS The actual converted values for 2.7 kgf/cm2 are

264 kPa and 38.4 psi. In the top specification, 2.7
Electric current A (ampere)
is used as an upper limit, so its converted values
Electric power W (watt) are rounded down to 260 and 38. In the bottom
Electric resistance (ohm) specification, 2.7 is used as a lower limit, so its
converted values are rounded up to 270 and 39.
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
kgf/cm2 (kilogram force per square
Positive pressure
centimeter)
psi (pounds per square inch)
Number of
rpm (revolutions per minute)
revolutions
N·m (Newton meter)
kgf·m (kilogram force per meter)
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Torque kgf·cm (kilogram force per centimeter)
ft·lbf (foot pound) force
in·lbf (inch pound) force
L (liter)
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US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
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cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)
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Conversion to SI Units
(Système International d’Unités)
All numerical values in this manual are based on SI
units. Numbers shown in conventional units are
converted from these values.
ST
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:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
CONTINUED
GI–7
FUNDAMENTAL PROCEDURES
FUNDAMENTAL PROCEDURES REMOVAL OF PARTS

While correcting a problem, try also to determine
PROTECTION OF THE VEHICLE its cause. Begin work only after first learning which
Always be sure to cover fenders, seats, and floor parts and subassemblies must be removed and
areas before starting work. disassembled for replacement or repair. After
removing the part, plug all holes and ports to
prevent foreign material from entering.
PREPARATION OF TOOLS AND MEASURING

EQUIPMENT
Be sure that all necessary tools and measuring DISASSEMBLY
equipment are available before starting any work. If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be
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marked in a place that will not affect their
performance or external appearance and identified
so that reassembly can be performed easily and
efficiently.
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SPECIAL SERVICE TOOLS

Use special tools when they are required.
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INSPECTION DURING REMOVAL, DISASSEMBLY

When removed, each part should be carefully
inspected for malfunctioning, deformation,
damage, and other problems.
DISCONNECTION OF THE NEGATIVE BATTERY

CABLE
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 ARRANGEMENT OF PARTS
memories of the clock, audio, and DTCs, etc. All disassembled parts should be carefully
Therefore, it is neccessary to verify those arranged for reassembly.
memories before disconnecting the cable. Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
CONTINUED
GI–8
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.
CLEANING OF PARTS
All parts to be reused should be carefully and
thoroughly cleaned using the appropriate method.
SXU00012
Warning
Using compressed air can cause dirt and ADJUSTMENT
other particles to fly out, causing injury to Use suitable gauges and/or testers when making
the eyes. Wear protective eye wear adjustments.
whenever using compressed air.
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SXU00013
RUBBER PARTS AND TUBING

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REASSEMBLY Prevent gasoline or oil from spilling on rubber parts

Standard values, such as torques and certain or tubing.
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with new
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ones:
1 Oil seals 2 Gaskets
3 O-rings 4 Lockwashers
5 Cotter pins 6 Nylon nuts
ST
SXU00014
HOSE CLAMPS
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 leaks.
SXU00015
CONTINUED
GI–9
FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM
TORQUE FORMULAS INSTALLATION OF RADIO SYSTEM

When using a torque wrench-SST combination, the If a radio system is installed improprerly or if a high-
written torque must be recalculated due to the powered type is used, the CIS and other systems may
extra length that the SST adds to the torque be affected.
wrench. Recalculate the torque using the following When the vehicle is to be equipped with a radio,
formulas. Choose the formula that applies to you. observe the following precautions.
Torque Unit Formula 1. Install the antenna at the farthest point from control
kgf·m kgf·m [L/(L+A) ] modules.
2. Install the antenna feeder as far as possible from
kgf·cm kgf·cm [L/(L+A) ]
the control modules harness, and perpendicular to
ft·lbf ft·lbf [L/(L+A) ] wiring harnesses.
in·lbf in·lbf [L/(L+A) ] 3. Do not install a high-powered radio system.
A: The length of the SST past the torque wrench drive. 4. After installing the radio system, start and idle the
L: The length of the torque wrench. engine, then confirm that the engine is not
influenced by output waves from the system.
VISE op
SXU00016
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When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.
do
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SXU00017
DYNAMOMETER
When test-running a vehicle on dynamometer :
Place a fan, preferably a vehicle-speed
proportional type, in front of the vehicle.
Connect an exhaust gas ventilation unit.
Cool the exhaust pipes with a fan.
Keep the area around the vehicle uncluttered.
Watch the water temperature gauge.
CONTINUED
GI–10
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM Disconnecting Connectors

When disconnecting two connectors, grasp the
ELECTRICAL PARTS connectors, not the wires.
Battery Cable
Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
cable.
SXU00020
Connectors can be disconnected by pressing or

pulling the lock lever as shown.
SXU00018
Wiring Harness
To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
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flathead screwdriver.
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SXU00021
Locking Connector
When locking connectors, listen for a click that will
indicate they are securely locked.
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CONNECTORS
Data Link Connector
Insert the probe into the service hole when
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connecting a jumper wire to the data link

connector.
Caution
Inserting a jumper wire probe into the data
link connector terminal may damage the SXU00022
terminal.
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.
CONTINUED
GI–11
ELECTRICAL SYSTEM
Caution
To prevent damage to the terminal, wrap a
thin wire around the lead before inserting it
into the terminal.
SXU00027
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code
SXU00024
symbol.
Terminals The first letter indicates the base color of the wire
Inspection and the second the color of the stripe.
Pull lightly on individual wires to check that they CODE COLOR CODE COLOR
are secured in the terminal. B Black O Orange
BR Brown P Pink
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G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
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LG Light Green
B/R BR/Y
SXU00025 BLACK BROWN
Replacement
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Use the appropriate tools to remove a terminal as

shown. When installing a terminal, be sure to insert RED YELLOW
it until it locks securely.
Insert a thin piece of metal from the terminal side
of the connector, and then, with the terminal
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locking tab pressed down, pull the terminal out

SXU00028
from the connector.
TYPE A
Fuse
Replacement
TYPE B
1. When replacing a fuse, be sure to replace it with
one of the specified capacity. If a fuse again fails
after it has been replaced, the circuit probably has
a short and the wiring should be checked.
2. Be sure the negative battery terminal is
disconnected before replacing a main fuse.
SXU00026
Sensors, Switches, and Relays

Handle sensors, switches, and relays carefully. Do
not drop them or strike them against other objects.
SXU00029
CONTINUED
GI–12
ELECTRICAL SYSTEM
3. When replacing a pullout fuse, use the fuse puller. Ohmmeter

The ohmmeter is used to measure the resistance
PULLER between two points in a circuit, and to check for
continuity and short circuits.
Caution
Do not connect the ohmmeter to any circuit
to which voltage is applied. This will
damage the ohmmeter.
POWER SOURCE LINE
FUSE
SXU00030
ELECTRICAL TROUBLESHOOTING TOOLS

Jumper Wire
A jumper wire is used to create a temporary circuit. GROUND LINE
Connect the jumper wire between the terminals of
a circuit to bypass a switch.
OHMMETER SXU00034
Caution
Do not connect a jumper wire from the
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power source line to a body ground; this
may cause burning or other damage to
wiring harnesses or electronic components.
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SXU00032
Voltmeter
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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.
VOLTMETER POWER SOURCE LINE
BLACK LEAD
RED LEAD
GROUND
CONTINUED
GI–13
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS,

SAFETY STAND POSITIONS
JACKING POSITIONS REAR
Warning
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 op
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REAR
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VEHICLE LIFT (2 SUPPORTS)

POSITIONS
FRONT
CONTINUED
GI–14
TOWING
TOWING (With Manual Transmission)

If the transmission, rear axle, and steering system are
Proper lifting and towing are necessary to prevent not damaged, the vehicle may be towed on all four
damage to the vehicle. wheels. If any of these components are damaged, use
Government and local laws must be followed. wheel dollies.
(With Automatic Transmission)
If excessive damage or other conditions prevent
towing the vehicle with the driving wheels off the
ground, use wheel dollies.
If all four wheels are on the ground, the vehicle may be

Wheel dollies 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:
Place the rear wheels on dollies.
Tow with the rear wheels off the ground.
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Disconnect the propeller shaft.
Wheel dollies
If the transmission or rear axle is inoperative, tow with
the rear wheels off the ground.
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Caution
Follow these instructions when towing the
vehicle with all wheels on the ground or
with the front wheels on the ground and the
Caution rear wheels raised.
Do not tow with sling-type equipment. This
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could damage your vehicle. Use wheel-lift (44 Model)

or flatbed equipment. 1. Put the transfer case in 2H.
2. Set the transfer case at 2H and the hubs
at FREE.
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(All Models)
1. Set the transmission in neutral.
2. Turn the engine switch to ACC position.
3. Release the parking brake.
Remember that power assist for the brakes

and steering will not be available when the
engine is not running.
If your Ford/Mazda has 44, change to 2-wheel drive

before having the vehicle towed. If this is not possible,
tow with all four wheels raised.
CONTINUED
GI–15
TOWING, IDENTIFICATION NUMBER LOCATIONS
TOWING HOOKS IDENTIFICATION NUMBER

Caution LOCATIONS
The towing hooks should be used only in VEHICLE IDENTIFICATION NUMBER
an emergency (e.g. to get the vehicle out of
a ditch or a snow bank).
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
44
ENGINE IDENTIFICATION NUMBER

G6
TIEDOWN HOOKS
Caution op
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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 WL, WL Turbo
damage the bumper.
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FRONT
42
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F2 CIS
F2 CARB
44
CONTINUED
GI–16
NEW STANDARDS
NEW STANDARDS
Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal — Accelerator Pedal

ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B Battery Positive Voltage VB Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP
Camshaft Position Sensor — Crank Angle Sensor
sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
— Closed Throttle Position Switch — Idle Switch
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CPP Clutch Pedal Position — Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
CSP
CS sensor Control Sleeve Sensor Control Sleeve Position Sensor #6
sensor
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CKP
Crankshaft Position Sensor — Crank Angle Sensor 2
sensor
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
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DI Distributor Ignition — Spark Ignition

DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
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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
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air Control — Idle Speed Control
— Incorrect Gear Ratio — —
#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
CONTINUED
GI–17
NEW STANDARDS

Remark
— Injection Pump FIP Fuel Injection Pump #6

— 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
Mass Air Flow Sensor — Airflow Sensor
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
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— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
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Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Injection with
AIR Secondary Air Injection — Secondary Air Injection System
air pump
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SAPV Secondary Air Pulse Valve — Reed Valve

SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— 1–2 Shift Solenoid Valve
— Shift Solenoid A
— Shift A Solenoid Valve
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— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 3–4 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lock-up Position
Transmission (Transaxle) Control
TCM — EC-AT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
#4: Device that controls engine and powertrain
CONTINUED
GI–18
NEW STANDARDS, ABBREVIATIONS

Remark
VAF
Volume Air Flow Sensor — Air flow Sensor
sensor
Warm Up Three Way Catalytic
WU-TWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open
#5: Directly connected to exhaust manifold
ABBREVIATIONS
ACC . . . . . . . . . . . . . . Accessories
ATDC . . . . . . . . . . . . . After top dead center
ATF . . . . . . . . . . . . . . . Automatic transmission fluid
BTDC . . . . . . . . . . . . . Before top dead center
CARB . . . . . . . . . . . . . Carburetor
ELR . . . . . . . . . . . . . . Emergency locking retractor
EX . . . . . . . . . . . . . . . Exhaust
FIP . . . . . . . . . . . . . . . Fuel injection pump
HI . . . . . . . . . . . . . . . . High
op
HLA . . . . . . . . . . . . . . Hydraulic lash adjuster
IG . . . . . . . . . . . . . . . . Ignition
IN . . . . . . . . . . . . . . . . Intake
INT . . . . . . . . . . . . . . . Intermittent
LH . . . . . . . . . . . . . . . . Left hand
L.H.D. . . . . . . . . . . . . . Left hand drive
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LO . . . . . . . . . . . . . . . Low
LSD . . . . . . . . . . . . . . Limited slip differential
LSPV . . . . . . . . . . . . . Load sensing proportioning valve
M ................ Motor
MAX . . . . . . . . . . . . . . Maximum
MFW . . . . . . . . . . . . . Manual freewheel
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MIN . . . . . . . . . . . . . . Minimum
P/S . . . . . . . . . . . . . . . Power steering
RFW . . . . . . . . . . . . . . Remote freewheel
RH . . . . . . . . . . . . . . . Right hand
R.H.D. . . . . . . . . . . . . Right hand drive
SAS . . . . . . . . . . . . . . Sophisticated air bag sensor
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SST . . . . . . . . . . . . . . Special service tool

TNS . . . . . . . . . . . . . . Tail number side lights
2WD . . . . . . . . . . . . . . 2 wheel drive
4WD . . . . . . . . . . . . . . 4 wheel drive
42 . . . . . . . . . . . . . . 4 wheel – 2 drive
44 . . . . . . . . . . . . . . 4 wheel – 4 drive
CONTINUED
GI–19
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to
delivery to your customer.
EXTERIOR UNDER BONNET-ENGINE RUNNING AT
OPERATING TEMPERATURE
INSPECT and ADJUST, if necessary, the following
items to the specifications: CHECK the following items:
Glass, exterior bright metal and paint for damage Operation of dashpot
Initial ignition timing
Wheel lug nuts
Injection timing
Tire pressures
Idle speed
All weatherstrips for damage or detachment Operation of throttle position sensor
Operation of bonnet release and lock
Door operation and alignment ON HOIST
Headlight aiming CHECK the following items:
INSTALL the following parts:
Operation of freewheel hubs
Wheel caps Manual transmission oil level
UNDER BONNET-ENGINE OFF Transfer oil level
Front differential oil level
INSPECT and ADJUST, if necessary, the following
Rear differential oil level
items to the specifications:
Underside fuel, coolant and hydraulic lines, fittings,
p
Fuel, coolant and hydraulic lines, fittings, connections
connections and components for leaks
and components for leaks
Tires for cuts or bruises
Engine oil level ho Steering linkage, suspension, exhaust system and
Power steering fluid level (if equipped)
all underside hardware for looseness or damage
Brake and clutch master cylinder fluid levels
Windshield washer reservoir fluid level ROAD TEST
Radiator coolant and specific gravity CHECK the following items:
Tightness of water hose clamps
oS
Brake operation
Tightness of battery terminals, electrolyte level and
Clutch operation
specific gravity Steering control
Drive belt tensions
Operation of meters and gauges 3 Squeaks, rattles
Accelerator cable and linkage for free movement
or unusual noise
CLEAN the spark plugs Engine general performance
d
INTERIOR Emergency locking retractors

Operation of transfer
INSTALL the following parts
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Fuse for accessories

CHECK the operation of the following items: AFTER ROAD TEST
Seat controls (sliding and reclining) and headrest REMOVE seat and floor mat protective covers
Door locks CHECK for necessary owner's information material,
Ignition switch (Engine switch) and steering lock tools and spare tire in vehicle
All lights including warning and indicator lights
Horn, windshield wipers and washers (if equipped)
Wiper blades performance Clean the wiper blades and
windshield
Antenna
Cigarette lighter and clock
Tilt steering (if equipped)
Air conditioner at various modes (if equipped)
CHECK the following items:
Presence of spare fuse
Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
Operation and fit of windows
Pedal height and free play of brake and clutch pedals
Parking brake CONTINUED
Gl-20
ENGINE
(G6)
DRIVE BELT ................................................................B1-1 HLA REMOVAL/INSTALLATION .....................B1-10/11
DRIVE BELT INSPECTION ................................B1-1/2 HLA TROUBLESHOOTING .............................B1-12
DRIVE BELT ADJUSTMENT .............................B1-2 FRONT OIL SEAL.......................................................B1-13
COMPRESSION INSPECTION ..................................B1-2 FRONT OIL SEAL REPLACEMENT.................B1-13
TIMING CHAIN .............................................................B1-3 REAR OIL SEAL .........................................................B1-14
TIMING CHAIN REMOVAL/ REAR OIL SEAL REPLACEMENT ..................B1-14
INSTALLATION ....................................................B1-3/5 ENGINE .......................................................................B1-15
CYLINDER HEAD GASKET ..................................B1-6 ENGINE REMOVAL/INSTALLATION ..............B1-15/16
CYLINDER HEAD GASKET ENGINE DISASSEMBLY/ASSEMBLY ..............B1-17
REPLACEMENT .................................................B1-6/9
HYDRAULIC LASH ADJUSTER (HLA).................B1-10
DRIVE BELT Deflection

mm {in}
DRIVE BELT INSPECTION
Drive belt *New Used
Drive Belt Deflection Check
10.0—12.0 12.0—14.0
1. Check the drive belt deflection when the engine Generator
{0.40—0.47} {0.48—0.55}
is cold, or at least 30 minutes after the engine 6.6—7.2 7.2—8.0
has been stopped. Apply pressure 98 N {10 kgf, P/S
{0.26—0.28} {0.29—0.31}
22 Ibf} midway between the specified pulleys. 8.5—10.0 10.0—11.5
A/C
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{0.34—0.39} {0.40—0.45}
*: A belt that has been on a running engine for less than five
minutes.
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(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
Drive Belt Tension Check
1. Belt tension can be checked in place of belt deflection.
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Check the drive belt tension when the engine is cold, or
at least 30 minutes after the engine has been stopped.
Using the SST, check the belt tension between any two
pulleys.
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N {kgf, Ibf}
Drive belt *New Used
491-588 393-490
Generator
{50-60,110-132} {40-50,88-110}
412—470 354—402
P/S {42-48,93—105} {36-41, 80—90}
557—641 471—556
A/C {56.7—65.4, {48.0—56.7,
125—143} 106—124}
* A belt that has been on a running engine for less than five minutes.
CONTINUED
B1-1
DRIVE BELT, COMPRESSION INSPECTION

2. If the tension is not within the specification, adjust it. COMPRESSION INSPECTION
(Refer to DRIVE BELT, DRIVE BELT Warning
ADJUSTMENT.) • When the engine and the oil are hot, they
DRIVE BELT ADJUSTMENT can badly burn. Be careful not to burn
1. Loosen mounting bolts A and B, and locknut C. yourself during removal/installation of each
2. Adjust the belt deflection or tension by turning the component.
adjusting bolt D. 1. Verify that the battery is fully charged. Recharge it
(Refer to DRIVE BELT, DRIVE BELT if necessary.
INSPECTION.) (Refer to section G, CHARGING SYSTEM,
3. Tighten mounting bolts A and B and locknut C. 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.
4. Perform "Fuel Line Safety Procedure". Leave the
fuel pump relay removed.
(Refer to section F1, FUEL SYSTEM, BEFORE
REPAIR PROCEDURE.)
5. Disconnect the igniter connector.
(Refer to section G, IGNITION SYSTEM,
IGNITION COIL REMOVAL/INSTALLATION.)
6. Remove the spark plugs.
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7. Connect a compression gauge into the No.1 spark
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8. Fully depress the accelerator pedal and crank the
engine.
9. Note the maximum gauge reading.
10. Inspect compression of each cylinder.
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Compression
kPa {kgf/cm2, psi} [rpm]
Engine type
Item
G6
Standard 1255 {12.8, 182} [270]
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Minimum 882.6 {9.0, 128} [270]

Maximum
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196 kPa {2.0 kgf/cm 2, 28 psi}

difference between
11. If the compression in one or more cylinders is low
or the compression difference between cylinders
exceeds the maximum, 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.
(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.
12. Disconnect the compression gauge.
13. Install the spark plugs.
Tightening torque
15—22 N.m {1.5—2.3 kgf.m, 11—l6ft.lbf}
14. Connect the igniter connector.
15. Install the fuel pump relay.
CONTINUED
B1-2
TIMING CHAIN
TIMING CHAIN
TIMING CHAIN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the generator.
3. 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.
(Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP
REMOVAL/INSTALLATION.)
4. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the
way.
5. Remove the cylinder head.
(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
6. Remove the water pump. (Refer to section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.)
7. Remove the oil pan. (Refer to section D, OIL PAN, OIL PAN REMOVAL/INSTALLATION.)
8. Disconnect the oil strainer stay.
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Start the engine and check for engine oil and engine coolant leakage.
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1 A/C compressor bracket 10 Balancer chain, idler sprocket, crankshaft sprocket

2 Generator strap ☞ Installation Note
3 P/S oil pump bracket 11 Timing chain, timing sprocket, camshaft sprocket
☞ Installation Note
4 Generator bracket
12 Chain adjuster
5 Pulley lock bolt ☞ Installation Note
☞ Removal/Installation Note 13 Key
6 Crankshaft pulley
14 Timing chain lever
7 Chain cover ☞ Installation Note
8 Spacer 15 Timing chain guide
9 Balancer chain guide
CONTINUED
B1-3
TIMING CHAIN
Pulley Lock Bolt Removal/Installation Note 2. Assemble the camshaft sprocket to the timing
• Hold the crankshaft using the SST. chain so that the timing mark of camshaft
sprocket is aligned with the white link of timing
chain as shown.
Timing Chain Lever Installation Note 3. Secure the camshaft sprocket and the timing
chain with a wire to prevent disengagement.
• Install the chain lever and verify that it
Balancer Chain, Idler Sprocket, Crankshaft
moves smoothly in the direction indicated.
Sprocket Installation Note
1. Install the crankshaft sprocket as shown.
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2. Assemble the idler sprocket on to the idler shaft.
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Chain Adjuster Installation Note
• Push the chain adjuster sleeve in (toward the
left) and insert the pin as shown into the lever to
hold the sleeve.
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3. Set the balancer chain on the idler sprocket so

that the timing mark of the idler sprocket is
aligned with the brown link of the balancer chain
as shown.
Timing Chain, Timing Sprocket, Camshaft

Sprocket Installation Note
1. Install the timing chain and timing sprocket so
that the white link of the timing chain is aligned
with the timing mark of the timing sprocket as
shown.
CONTINUED
B1-4
TIMING CHAIN
4. Install the balancer chain so that the five 4. Loosen the chain guide C by adjusting bolt E.
alignment marks on the chain, sprocket and 5. Push the chain guide C with a force of 49 N
cylinder block align, and attach the idler sprocket {5.0 kgf, 11 Ibf} in the direction of the arrow,
to the cylinder block. then pull back the chain guide 3.2—3.8 mm
{0.13—0.14 in] and tighten the adjusting bolt E.
5. Hand-tighten the idler sprocket lock bolt.

Balancer Chain Guide Installation Note Note
1. Install the chain guide A and B. • The balancer chain must be replaced if chain
guide C bottoms when adjusting.
6. Measure the timing chain slack.
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Specification
Approx. 3.0 mm {0.12 in}
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2. Install the chain guide C, and tighten the bolt D
and hand-tighten the adjusting bolt E.
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3. Tighten the idler sprocket lock bolt.
CONTINUED
B1-5
CYLINDER HEAD GASKET

CYLINDER HEAD GASKET REPLACEMENT
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• 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 Procedure" in section F1.
(Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
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 drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
4. Remove the cooling fan.
5. Remove the front pipe.
6. Remove the air intake pipe and resonance chamber.
7. Disconnect the accelerator cable and bracket.
8. S. Disconnect the vacuum hoses, water hoses, and engine harness connectors.
9. Disconnect the fuel hoses.
(Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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10. Remove the intake manifold bracket.
11. Remove the distributor.
(Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.)
12. Remove the high-tension lead.
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(Refer to section G, IGNITION SYSTEM, HIGH-TENSION LEAD REMOVAL/INSTALLATION.)
13. Remove the spark plug.
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16. Inspect for fuel leakage.
17. Inspect the compression.
(Refer to COMPRESSION INSPECTION.)
18. Start the engine and
(1) check the pulleys and drive belt for runout and contact.
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(2) check the ignition timing and idle speed.

(Refer to section F1, ENGINE TUNE-UP.)
CONTINUED
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B1-6
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1 Upper radiator hose 5 Cylinder head

2 Cylinder head cover ☞ Removal Note
☞ Installation Note ☞ Installation Note
3 Distributor drive gear 6 Cylinder head gasket
☞ Removal Note ☞ Installation Note
4 Camshaft sprocket
☞ Removal Note
CONTINUED
B1-7

Distributor Drive Gear Removal Note
1. Turn the crankshaft clockwise so that the No.1
piston is at TDC of the compression stroke.
3. Secure the camshaft sprocket and the chain with a

wire as shown.
2. Verify that the camshaft sprocket mark is aligned
with the horizontal surface on the cylinder head.
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ho 4. Remove the camshaft sprocket off the camshaft
3. Remove the seal cover. dowel pin.
4. Hold the crankshaft using the SST. Cylinder Head Removal Note
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1. Remove the bolts A.
2. Loosen the cylinder head bolts a few turns in the
order shown.
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5. Remove the lock bolt.

Camshaft Sprocket Removal Note
1. Remove the service cover on the chain cover. Cylinder Head Gasket Installation Note
• Apply silicone sealant to the areas shown.
Thickness
Ø3.0 mm {0.12 in}
2. Push the chain adjuster sleeve in (toward the left)

and insert a pin as shown into the lever hole to
hold the sleeve.
CONTINUED
B1-8

Cylinder Head Installation Note Distributor Drive Gear Installation Note
1. Tighten the cylinder head bolts a few turns in the 1. Install the distributor drive gear with a new washer
order shown. and lock bolt.
2. Hold the camshaft with a screwdriver as shown.
2. Tighten the bolts A.

Camshaft Sprocket Installation Note
1. Install the camshaft sprocket onto the camshaft 3. Tighten the lock bolt.
dowel pin. 4. Apply silicone sealant to the areas shown.
2. Remove the wire securing the camshaft sprocket
and chain.
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5. Install the new seal cover.
Cylinder Head Cover Installation Note
3. Remove the retaining pin from the chain adjuster. 1. Verify that the grooves on the cylinder head cover
4. Install the service cover with a new gasket. are free of oil, water, and other foreign material.
Tightening torque 2. Coat a new gasket with silicone sealant, and install
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7.9—10.7 it onto the cylinder head cover.

N.m {80—110 kgf.cm, 69.5—95.4 in.lbf} 3. Apply silicone sealant to the cylinder head as
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shown.
4. Install the cylinder head cover.
CONTINUED
B1-9
HYDRAULIC LASH ADJUSTER (HLA)

HLA REMOVAL / INSTALLATION
Caution
• Removal and installation of the HLA must be carried out only when the problem cannot be solved by
the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)

2. Remove the distributor.
(Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.)
3. Remove the cylinder head cover.
(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
6. Check the engine oil level,
(Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.)
(1) check the engine oil.
(2) check the idle speed, (Refer to section F1, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
8. Check the HLA troubleshooting.
(Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
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1 Distributor drive gear 2 Rocker arm

☞ CYLINDER HEAD GASKET, CYLINDER HEAD ☞ Removal Note & Installation Note
GASKET REPLACEMENT, Distributor Drive
Gear Removal Note 3 HLA
☞ CYLINDER HEAD GASKET, CYLINDER HEAD ☞ Installation Note
GASKET REPLACEMENT, Distributor Drive Gear
Installation Note
CONTINUED
B1-10

Rocker Arm Removal Note Rocker Arm Installation Note
1. Loosen the bolts a few turns in the order shown. Note
• The intake side shaft has twice as many oil
holes as the exhaust side shaft.
1. Assemble the rocker arm and shaft assembly as
shown in the figure according to the cap number
and mark.
2. Identify the rocker arm and shaft assembly parts

so that they can be reinstalled in the same
locations from which they were removed.
3. Remove the rocker arm and shaft assembly
together with the bolts.
2. Install the rocker arm and shaft.
HLA Installation Note
1. Place each HLA in a container filled with clean 3. Tighten the bolts a few turns in the order shown.
engine oil.
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Caution
• Do not push the pin too hard. It may damage
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the HLA.
2. Bleed the air from the HLA by inserting a pin into
the plunger hole and pressing the plunger until it
no longer moves.
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3. Pour engine oil into the oil reservoir in the rocker

arm.
4. Apply clean engine oil to HLA O-ring

CONTINUED
B1-11

HLA TROUBLESHOOTING
Problem Possible Cause Action
1. Noise when engine is started Oil leakage in oil passage or Run engine at 2,000—3,000 rpm.
immediately after oil is changed. in HLA If noise stops within 20 minutes*, HLA is normal.
If not, replace HLA.
2. Noise when engine is started after
Time required for engine oil to circulate within
sitting one day or more.
HLA includes tolerance for engine oil condition
and ambient temperature.
3. Noise when engine is started after Oil leakage in HLA (Refer to HYDRAULIC LASH ADJUSTER
new HLA is installed. (HLA), HLA TROUBLESHOOTING,
Valve Clearance Inspection.)
4. Noise continues more than 10 Insufficient oil pressure Check oil pressure.
minutes. If lower than specification, check for cause.
(Refer to section D, OIL PRESSURE INSPECTION)
Faulty HLA Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
(Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA
Measure valve clearance.
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(Refer to HLA, HLA TROUBLESHOOTING, Valve
Clearance Inspection.)
5. Noise during idle after high speed
running.
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Incorrect oil amount Check oil level.
(Refer to section D, ENGINE OIL, ENGINE OIL
INSPECTION.)
Deteriorated oil Replace new engine oil.
(Refer to section D, ENGINE OIL, ENGINE OIL
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REPLACEMENT.)
Valve Clearance Inspection

1. Remove the cylinder head cover.
(Refer to CYLINDER HEAD GASKET, CYLINDER
HEAD GASKET REPLACEMENT.)
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2. Measure valve clearance.
Valve clearance
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0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in},

replace the HLA. (Refer to HYDRAULIC LASH
ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.)
4. Install the cylinder head cover.
(Refer to CYLINDER HEAD GASKET, CYLINDER
HEAD GASKET REPLACEMENT, Cylinder Head Cover
Installation Note.) CONTINUED
B1-12
FRONT OIL SEAL

FRONT OIL SEAL
FRONT OIL SEAL REPLACEMENT
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 drive belt.
(Refer to DRIVE BELT, DRIVE BELT
ADJUSTMENT.)
4. Remove the cooling fan and water pump pulley.
5. Remove the radiator cowling.
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1 Pulley lock bolt
☞ TIMING CHAIN, TIMING CHAIN
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☞ REMOVAL/INSTALLATION, Pulley Lock Bolt
☞ Removal/Installation Note
2 Crankshaft pulley
3 Front oil seal
☞ Removal Note
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Front Oil Seal Removal Note

1. Cut the oil seal lip using a razor knife.
2. Remove the oil seal using a screwdriver protected
with a rag.
Front Oil Seal Installation Note

1. Apply clean engine oil to the oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.
CONTINUED
B1-13
REAR OIL SEAL

REAR OIL SEAL
REAR OIL SEAL REPLACEMENT
2. Remove the flywheel.
(Refer to section H, CLUTCH UNIT, CLUTCH
UNIT REMOVAL/INSTALLATION.)
1 Rear oil seal

☞ Removal Note
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Rear Oil Seal Removal Note
1. Cut the oil seal lip using a razor knife. ho
2. Remove the oil seal using a screwdriver
protected with a rag.
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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 using the SST and a
hammer. CONTINUED
B1-14
ENGINE
ENGINE
ENGINE REMOVAL/INSTALLATION
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• 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 Procedure" in section F1.

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 air cleaner and fresh-air duct.
4. Remove the front pipe.
5. Disconnect the accelerator cable, bracket, heater hoses, and vacuum hoses.
6. Remove the radiator.
(Refer to section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)
7. Remove the drive belt.
(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
8. Disconnect the fuel hoses.
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(Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
9. Remove the transmission. ho
(Refer to section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.)
10. 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.
(Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP
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11. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of
the way.
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(1) check the engine oil, engine coolant, transmission oil, and fuel leakage.
(2) check the ignition timing, idle speed and idle mixture. (Refer to section F1, ENGINE TUNE-UP.)
15. Perform a road test.
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CONTINUED
B1-15
ENGINE
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1 Engine mount nut 2 Engine

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CONTINUED
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B1-16
ENGINE
ENGINE DISASSEMBLY/ASSEMBLY
1. Remove the oil cooler. (Refer to section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.)
2. Remove the thermostat. (Refer to section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.)
3. Remove the spark plug.
4. Remove the oil pressure switch. (Refer to section D, OIL PRESSURE INSPECTION.)
5. Remove the intake-air system.
(Refer to section F1, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
6. Remove the exhaust system.
(Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
7. Remove the oil filter. (Refer to section D, OIL FILTER, OIL FILTER REPLACEMENT)
8. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.)
9. Remove the generator.
10. Disassemble in the order indicated in the table.
11. Assemble in the reverse order of disassembly.
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1 Water bypass pipe 6 A/C idler

2 Water inlet pipe 7 P/S idler
3 A/C compressor bracket 8 Oil cooler bypass pipe
4 Generator bracket 9 Generator strap
5 P/S oil pump bracket 10 Engine mount
CONTINUED
B1-17
Created in Master PDF Editor - Demo Version RANG.DRFT.OVERHAUL MANUAL PAGES FROM SUPPLEMENT
GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . GI–11 ARRANGEMENT OF PARTS . . . . . . . . . . . . . . GI–15
RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . . GI–11 CLEANING OF PARTS . . . . . . . . . . . . . . . . . . . GI–15
SERVICING PROCEDURE . . . . . . . . . . . . . . . GI–11/2 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . GI–15/6
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–13 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . GI–16
ADVISORY MESSAGES . . . . . . . . . . . . . . . . . . GI–13 RUBBER PARTS AND TUBING . . . . . . . . . . . GI–16
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . GI–13 HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . GI–16
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–14 TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . . GI–16
FUNDAMENTAL PROCEDURES . . . . . . . . . . . . GI–15 VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–16
PREPARATION OF TOOLS AND ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . GI–17
MEASURING EQUIPMENT . . . . . . . . . . . . . . GI–15 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–17
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . GI–15 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI–18/10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . GI–15 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–10
INSPECTION DURING REMOVAL,
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . GI–15
HOW TO USE THIS MANUAL SERVICING PROCEDURE

Inspection, Adjustment
RANGE OF TOPICS The procedures for inspections and adjustments
This manual contains the procedures for are divided into steps. Important points in regard to
performing all of the required service operations. the location and contents of the procedures are
The procedures are divided into the following five explained in detail and are shown in the
op
basic operations. illustrations.
(1) Removal/Installation
(2) Disassembly/Assembly
(3) Replacement
(4) Inspection SHOWS PROCEDURE ORDER
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(5) Adjustment FOR SERVICE
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.
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SHOWS TIGHTENING
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TORQUE
SPECIFICATIONS
CONTINUED
GI–1
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
Procedure ITEM (S) Indicates any relevant
references which need to be
followed during installation.
“Removal/Installation”
Portion
“Inspection After SHOWS SPECIAL

Installation” Portion SERVICE TOOL (SST)
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
op
FOR SERVICE
Install the parts SHOWS APPLICATION

by performing POINTS OF GREASE, ETC.
steps 1—3 in
reverse order SHOWS TIGHTENING
TORQUE
Sh
SPECIFICATIONS SHOWS EXPENDABLE PARTS
do
SHOWS DETAILS
SHOWS TIGHTENING
TORQUE UNITS
Bo
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE CONTINUED
GI–2
SYMBOLS TEXT SEQUENCE
There are eight symbols indicating oil, grease, The text sequence is as indicated by the arrows
sealant, and the use of SSTs. These symbols shown below.
show the points of applying or using such materials Example:
during service.
Symbol Meaning Kind À
New appropriate
Apply oil engine oil or
gear oil
New appropriate
Apply brake fluid
brake fluid Á
Apply automatic New appropriate
transaxle/ automatic
transmission transaxle/
fluid transmission fluid
Appropriate
Apply grease
grease
Appropriate
Apply sealant
op
sealant
Apply petroleum Appropriate

jelly petroleum jelly
Sh
O-ring, gasket,
R Replace part À Á
etc.
do
SST Use SST Appropriate SST
ADVISORY MESSAGES
You’ll find several Warnings, Cautions, Notes,
Bo
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.

The values indicate the upper and lower limits
that must not be exceeded when performing
inspections or adjustments.
CONTINUED
GI–3
UNITS
UNITS The actual converted values for 2.7 kgf/cm2 are

Electric current A (ampere) 264 kPa and 38.4 psi. In the top specification, 2.7
Electric power W (watt) is used as an upper limit, so its converted values
are rounded down to 260 and 38. In the bottom
Electric resistance (ohm)
specification, 2.7 is used as a lower limit, so its
Electric voltage V (volt) converted values are rounded up to 270 and 39.
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
kgf/cm2 (kilogram force per square
Positive pressure
centimeter)
psi (pounds per square inch)
Number of
rpm (revolutions per minute)
revolutions
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
op
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Sh
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
do
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)
Bo
Conversion to SI Units
(Système International d’Unités)
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.
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:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
CONTINUED
GI–4
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.
op
49 SE01 310
Sh
SXU00009
CLEANING OF PARTS
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
DISASSEMBLY
do
If the disassembly procedure is complex, requiring Warning

many parts to be disassembled, all parts should be Using compressed air can cause dirt and
marked in a place that will not affect their other particles to fly out, causing injury to
performance or external appearance and identified the eyes. Wear protective eye wear
so that reassembly can be performed easily and whenever using compressed air.
Bo
efficiently.
SXU00010
SXU00007
REASSEMBLY
INSPECTION DURING REMOVAL, DISASSEMBLY Standard values, such as torques and certain
When removed, each part should be carefully adjustments, must be strictly observed in the
inspected for malfunctioning, deformation, reassembly of all parts.
damage, and other problems. If removed, these parts should be replaced with new
ones:
1 Oil seals 2 Gaskets

3 O-rings 4 Lockwashers
5 Cotter pins 6 Nylon nuts
CONTINUED
GI–5
HOSE CLAMPS
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.
SXU00015
Hardened sealant causes leakage.
Oil should be applied to the moving components of
TORQUE FORMULAS
parts. When using a torque wrench–SST combination,
Specified oil or grease should be applied at the
the written torque must be recalculated due to the
prescribed locations (such as oil seals) before extra length that the SST adds to the torque
reassembly. wrench. Recalculate the torque using the following
formulas. Choose the formula that applies to you.
op Torque Unit
N·m
kgf·m
Formula
N·m [L/(L+A) ]
kgf·m [L/(L+A) ]
Sh
kgf·cm kgf·cm [L/(L+A) ]
ft·lbf ft·lbf [L/(L+A) ]
in·lbf in·lbf [L/(L+A) ]
SXU00012 A: The length of the SST past the torque wrench

drive.
do
ADJUSTMENT L: The length of the torque wrench.

Use suitable gauges and/or testers when making
adjustments.
SST
Bo
SXU00016
SXU00013 VISE
When using a vise, put protective plates in the jaws
RUBBER PARTS AND TUBING of the vise to prevent damage to parts.
Prevent gasoline or oil from getting on rubber parts
or tubing.
SXU00017
SXU00014
CONTINUED
GI–6
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM 2. Inspect the terminals of waterproof connectors

from the connector side, as they cannot be
CONNECTORS accessed from the wiring harness side.
Disconnecting Connectors
When disconnecting two connectors, grasp the Caution
connectors, not the wires. 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.
op
Sh
SXU00021
do
Locking Connector
When locking connectors, listen for a click that will
indicate they are securely locked.
Bo
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.
CONTINUED
SXU00023
GI–7
NEW STANDARDS
NEW STANDARDS
Following is a comparison of the previous standard and the new standard.
Abbrevi- Abbrevi- Remark
Name Name
ation ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B Battery Positive Voltage VB Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP
Camshaft Position Sensor — Crank Angle Sensor
sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
— Closed Throttle Position Switch — Idle Switch
op
CPP Clutch Pedal Position — Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
CSP
CS sensor Control Sleeve Sensor Control Sleeve Position Sensor #6
sensor
Sh
CKP
Crankshaft Position Sensor — Crank Angle Sensor 2
sensor
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
do
DI Distributor Ignition — Spark Ignition

DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
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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
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air Control — Idle Speed Control
— Incorrect Gear Ratio — —
#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).
CONTINUED
GI–8
NEW STANDARDS

Name Name
ation ation
— Injection Pump FIP Fuel Injection Pump #6
— 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
Mass Air Flow Sensor — Airflow Sensor
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
op
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
Sh
Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Inject with
AIR Secondary Air Injection — Secondary Air Injection System
compressor
do
SAPV Secondary Air Pulse Valve — Reed Valve

SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— Shift Solenoid A
— Shift A Solenoid Valve
Bo

— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 3–4 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lock-up Position
Transmission (Transaxle) Control
TCM — EC-AT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
#4: Device that controls engine and powertrain
CONTINUED
GI–9
NEW STANDARDS, ABBREVIATIONS

Name Name
ation ation
VAF
Volume Air Flow Sensor — Air flow Sensor
sensor
Warm Up Three Way Catalytic
WU-TWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open
#5: Directly connected to exhaust manifold
ABBREVIATIONS
1ST . . . . . . . . . . . . . . . . . First
2ND . . . . . . . . . . . . . . . . . Second
2W . . . . . . . . . . . . . . . . . . 2-wheel
3RD . . . . . . . . . . . . . . . . . Third
4TH . . . . . . . . . . . . . . . . . Fourth
4W . . . . . . . . . . . . . . . . . . 4-wheel
5TH . . . . . . . . . . . . . . . . . Fifth
BTDC . . . . . . . . . . . . . . . . Before top dead center
CARB . . . . . . . . . . . . . . . Carburetor
op
CIS . . . . . . . . . . . . . . . . . . Continuous fuel injection
system
EX . . . . . . . . . . . . . . . . . . Exhaust
FIP . . . . . . . . . . . . . . . . . . Fuel injection pump
HLA . . . . . . . . . . . . . . . . . Hydraulic lash adjuster
H.................... High
Sh
IN . . . . . . . . . . . . . . . . . . . Intake
L .................... Low
max. . . . . . . . . . . . . . . . . . Maximum
min. . . . . . . . . . . . . . . . . . Minimum
SST . . . . . . . . . . . . . . . . . Special service tool
do
TDC . . . . . . . . . . . . . . . . . Top dead center

CONTINUED
Bo
GI–10
TRANSFER
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3– 1 OUTPUT SHAFT COMPONENT
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . J3– 1 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . J3– 5/6
TRANSFER COMPONENT TRANSFER COMPONENT ASSEMBLY . . . . J3– 7/10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . J3– 2/3 TRANSFER INSPECTION . . . . . . . . . . . . . . . . J3–10
FRONT DRIVE SPROCKET COMPONENT
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . 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.
op
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.
Sh
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.
CONTINUED
do
Bo
J3–1
TRANSFER
TRANSFER COMPONENT DISASSEMBLY

Disassemble in the order indicated in the table.
SST
op
Sh
SST
do
Bo
SST
1 Stopper pin 14 Oil passage

2 Control lever end 15 Roll pin
3 Locknut 16 Spacer
+ Disassembly Note 17 H—L shift fork
4 Companion flange 18 H—L shift rod
5 44 indicator switch 19 Roll pin
6 Transfer neutral switch (RFW model) 20 Roll pin
7 Plug (except RFW model) 21 Retainer
8 Detent ball and spring 22 Spacer
9 Snap ring 23 2W—4W shift end
10 Bearing (input shaft gear) 24 Roll pin
+ Disassembly Note
25 2W—4W shift fork
11 Adjustment shim
26 Spring
12 Chain cover
27 Spacer
13 Interlock pin
28 2W—4W shift rod
J3–2 CONTINUED
TRANSFER
29 Retainer Bearing (Input Shaft Gear) Disassembly Note

Remove the bearing by using the SST.
30 Output shaft component, chain, and front drive
sprocket component
+ Disassembly Note
31 Input shaft gear 49 0839 425C
32 Bearing
33 Adjustment shim
34 Adjustment shim
35 Lock plate
36 Counter shaft gear support
+ Disassembly Note
37 O-ring
38 Thrust washer Output Shaft Component, Chain, and Front Drive
Sprocket Component Disassembly Note
39 Counter gear Remove the output shaft and the front drive
40 Bearing sprocket from the transfer case housing by lightly
41 Spacer tapping the input shaft gear and the front drive
sprocket by using a plastic hammer.
42 Thrust washer
43 Oil seal
op
44 Snap ring
45 Bearing (front drive sprocket)
+ Disassembly Note
46 Oil seal
Sh
Locknut Disassembly Note
1. Hold the companion flange by using the SST and
remove the locknut.
Counter Shaft Gear Support Disassembly Note

do
49 S120 710 Tap out the counter shaft gear support by using a
tape-wrapped screwdriver and a plastic hummer.
Bo
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
CONTINUED
J3–3
TRANSFER
FRONT DRIVE SPROCKET COMPONENT

DISASSEMBLY/ASSEMBLY
SST
SST
1 Bearing
+ Disassembly Note
+ Assembly Note
2 Front drive sprocket
Bearing Disassembly Note
op
Remove the bearings from both sides of the front
drive sprocket by using the SST.
49 0839 425C
Sh
do
Bearing Assembly Note

Bo
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
CONTINUED
J3–4
TRANSFER
OUTPUT SHAFT COMPONENT DISASSEMBLY/ASSEMBLY

SST
op
Sh
SST
do
Bo
1 Speedometer drive gear 9 Bearing (low gear side)

2 Bearing (2W—4W clutch hub side) + Disassembly Note
+ Disassembly Note + Assembly Note
+ Assembly Note 10 Thrust lock washer
3 2W—4W clutch hub 11 Steel ball
4 2W—4W hub sleeve 12 Low gear
5 Drive sprocket 13 Needle bearing
6 Needle bearing 14 Roll pin
7 Spacer 15 H—L hub sleeve
8 Thrust washer 16 Output shaft
CONTINUED
J3–5
TRANSFER
Bearing (2W—4W 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.
op
Sh
Bearing (Low Gear Side) Assembly Note
Install the bearing by using the SST.
do
49 0727 415
Bo
Bearing (2W—4W Clutch Hub Side) Assembly Note

Install the bearing by using the SST.
49 F401 331
49 F401 336B
CONTINUED
J3–6
TRANSFER
TRANSFER COMPONENT ASSEMBLY

Assemble in the order indicated in the table.
R
R R
25—34 {2.5—3.5, 18—25}

R 25—34 {2.5—3.5, 18—25}
19—25
R {1.9—2.6,
R 14—18}
19—25 SST
{1.9—2.6,
14—18} 128—177
{13—18,
94—130}
SELECTIVE USE
R SST
SST
R
R
25—34
{2.5—3.5,
op
18—25}
19—25 19—25
{1.9—2.6, {1.9—2.6,
14—18} 14—18}
R
Sh
R
SST SST
SELECTIVE USE
SST
do
37—47 19—25
{3.7—4.8, {1.9—2.6,
27—34} 14—18}
SST R R
Bo
R
SELECTIVE USE
SST
APPLY SILICONE SEALANT
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

N·m {kgf·m, ft·lbf}
1 Bearing (front drive sprocket) 13 Adjustment shim

+ Assembly Note + Assembly Note
2 Snap ring 14 Bearing (input shaft gear)
3 Oil seal + Assembly Note
+ Assembly Note 15 Input shaft
4 Thrust washer 16 Snap ring
5 Spacer 17 Bearing
6 Bearing 18 Output shaft component
7 Counter gear 19 Front drive sprocket component
8 Thrust washer 20 Chain
9 Counter gear component + Assembly Note
10 O-ring 21 H—L shift fork
11 Counter shaft gear support 22 Spacer
12 Lock plate 23 H—L shift rod

24 Roll pin
http://eshops.mercadolibre.com.ve/bodoshop CONTINUED
J3–7
TRANSFER
25 2W—4W shift end Adjustment Shim Assembly Note

1. Measure the bearing bore depth (A) of the transfer
26 Spacer
case by using vernier calipers.
27 2W—4W shift rod
28 Retainer
29 Spacer A
30 Spring
31 2W—4W shift fork
32 Retainer
33 Roll pin
34 Oil passage TRANSFER CASE
35 Adjustment shim
+ Assembly Note
36 Adjustment shim 2. Measure height (B) of the bearing clip by using
+ Assembly Note vernier calipers and a surface plate.
37 Interlock pin
38 Chain cover
39 Detent ball and spring BEARING
40 Plug (except RFW model)
op
41 Transfer neutral switch (RFW model)
42 44 indicator switch
43 Oil seal B
+ Assembly Note
Sh
44 Companion flange
45 Locknut
+ Assembly Note 3. Calculate the difference between (A) and (B) to
46 Control lever end determine the clearance.
47 Stopper pin
Clearance=(A)–(B)
do
Bearing (Front Drive Sprocket) Assembly Note

Install the bearing to the transfer case by using the
SSTs. ADJUSTMENT SHIM
CLEARANCE
49 G030 797
Bo
TRANSFER CASE
HOUSING
49 G026 102 INPUT SHAFT
4. Select and install the proper shim to obtain the

standard clearance.
Oil Seal Assembly Note Standard clearance
Apply oil to the lip of a new oil seal and install the 0—0.1 mm {0—0.0039 in}
oil seal in the transfer case by using the SST. 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
CONTINUED
J3–8
TRANSFER
Bearing (Input Shaft Gear) Assembly Note Adjustment Shim Assembly Note
Press the bearing on the input shaft gear by using 1. Measure the bearing height and the bearing bore
the SSTs. 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
op
by using the SST to set the center to center
distance for easy installation into the transfer case.
49 S231 395A
Sh
49 U017 3A0A
3. Select the proper adjustment shim to adjust the

clearance.
Standard clearance
do
0.1—0.3 mm {0.004—0.011 in}

Adjustment shim thickness
0.5 mm {0.020 in}, 0.6 mm {0.024 in},
2. Install the front drive sprocket component into the 0.7 mm {0.028 in}, 0.8 mm {0.031 in},
transfer case by lightly tapping it with a plastic 0.9 mm {0.035 in}, 1.0 mm {0.039 in},
Bo
hammer, keeping the chain horizontal. 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}
4. Select the proper adjustment shim for the front

drive sprocket bearing in same way as for the
output shaft side.
Standard clearance
0—0.1 mm {0—0.0039 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},
3. After installing, check that the chain rotates 0.9 mm {0.035 in}, 1.0 mm {0.039 in},
smoothly. 1.1 mm {0.043 in}, 1.2 mm {0.047 in},
CONTINUED
J3–9
TRANSFER
49 U017 3A0A
Oil Seal Assembly Note 2. If not as specified, replace the shift fork and hub
Apply oil to the lip of a new oil seal and install the sleeve.
oil seal in the chain cover case by using the SST.
49 0727 415
op
Sh
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.
do
49 S120 710
Bo
TRANSFER INSPECTION
Hub Sleeve and Shift Fork Inspection
1. Measure the clearance between the hub sleeve
and shift fork.
Clearance
0.38—0.52 mm {0.015—0.020 in}
Maximum
0.8 mm {0.031 in}
CONTINUED
J3–10
FUEL AND EMISSION CONTROL SYSTEMS

(G6)
Page 1 of 2
ENGINE TUNE-UP ...............................................................F1-2 CHECK VALVE (TWO-WAY)
ENGINE TUNE-UP PREPARATION............................F1-2 INSPECTION ....................................................... F1-25/26
IGNITION TIMING ADJUSTMENT...............................F1-2/3 EVAPORATIVE CHAMBER
IDLE SPEED ADJUSTMENT .......................................F1-4 INSPECTION ....................................................... F1-26
IDLE-UP SPEED INSPECTION ..................................F1-4/5 CHARCOAL CANISTER INSPECTION ................... F1-26
IDLE MIXTURE INSPECTION .....................................F1-5 PURGE SOLENOID VALVE
INTAKE-AIR SYSTEM ........................................................F1-6 INSPECTION ....................................................... F1-26/27
VACUUM HOSE ROUTING DIAGRAM .......................F1-6 POSITIVE CRANKCASE VENTILATION
INTAKE-AIR SYSTEM (PCV) VALVE INSPECTION .............................. F1-27
REMOVAL/INSTALLATION .................................F1-6/7 CONTROL SYSTEM .......................................................... F1-28
BYPASS AIR CONTROL (BAC) VALVE CONTROL SYSTEM COMPONENT
REMOVAL/INSTALLATION .................................F1-8 LOCATION............................................................ F1-28
AIR VALVE INSPECTION ........................................... F1-8 PCM REMOVAL/INSTALLATION ............................. F1-29
IDLE AIR CONTROL (lAC) VALVE PCM INSPECTION .............................................. F1-29/37
INSPECTION ........................................................F1-8 MASS AIR FLOW (MAF) SENSOR
ACCELERATOR PEDAL INSPECTION........................................................ F1-37
REMOVAL/INSTALLATION ................................ F1-9 THROTTLE POSITION (TP) SENSOR
ACCELERATOR CABLE INSPECTION ....................................................... F1-37/38
INSPECTION/ADJUSTMENT ..............................F1-9 THROTTLE POSITION (TP) SENSOR
FUEL SYSTEM .................................................................. F1-10 ADJUSTMENT .................................................... F1-38
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BEFORE REPAIR PROCEDURE ............................. F1-10 THROTTLE POSITION (TP) SENSOR
AFTER REPAIR PROCEDURE ................................. F1-10 REMOVAL/INSTALLATION ................................ F1-38/39
FUEL TANK ho CLOSED THROTTLE POSITION (CTP)
REMOVAL/INSTALLATION ............................... F1-11/13 SWITCH INSPECTION ....................................... F1-39
NONRETURN VALVE INSPECTION ........................ F1-13 INTAKE AIR TEMPERATURE (IAT) SENSOR
FUEL PUMP UNIT INSPECTION ....................................................... F1-39
REMOVAL/INSTALLATION ............................... F1-13 INTAKE AIR TEMPERATURE (IAT) SENSOR
FUEL PUMP UNIT REMOVAL/INSTALLATION ................................ F1-40
DISASSEMBLY/ASSEMBLY .............................. F1-13/14 ENGINE COOLANT TEMPERATURE (ECT)
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FUEL PUMP UNIT INSPECTION .............................. F1-14/16 SENSOR REMOVAL/INSTALLATION ............... F1-40
FUEL FILTER (HIGH-PRESSURE) ENGINE COOLANT TEMPERATURE (ECT)
REMOVAL/INSTALLATION ............................... F1-16/17 SENSOR INSPECTION ...................................... F1-40/41
FUEL INJECTOR CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION ............................... F1-18/19 INSPECTION ....................................................... F1-41
FUEL INJECTOR INSPECTION ................................ F1-19/21 OXYGEN SENSOR O2S)
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PRESSURE REGULATOR INSPECTION ....................................................... F1-41/42

REMOVAL/INSTALLATION ............................... F1-21 OXYGEN SENSOR O2S)
PRESSURE REGULATOR REMOVAL/INSTALLATION................................. F1-42
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INSPECTION ...................................................... F1-21/22 VARIABLE RESISTOR INSPECTION........................ F1-42

PRESSURE REGULATOR CLUTCH SWITCH INSPECTION .............................. F1-42/43
CONTROL (PRC) SOLENOID CLUTCH SWITCH
VALVE INSPECTION ................................................. F1-22 REMOVAL/INSTALLATION ............................... F1-43
PULSATION DAMPER NEUTRAL SWITCH INSPECTION ............................ F1-43
REMOVAL/INSTALLATION ............................... F1-22 NEUTRAL SWITCH
PULSATION DAMPER INSPECTION ....................... F1-22 REMOVAL/INSTALLATION ................................ F1-43/44
FUEL PUMP RELAY INSPECTION .......................... F1-23 POWER STEERING PRESSURE
EXHAUST SYSTEM .......................................................... F1-24 (PSP) SWITCH INSPECTION ............................ F1-44
EXHAUST SYSTEM INSPECTION ........................... F1-24 MAIN RELAY INSPECTION ....................................... F1-44/45
EXHAUST SYSTEM MAIN RELAY REMOVAL/INSTALLATION ................ F1-45
REMOVAL/INSTALLATION ............................... F1-24 ON-BOARD DIAGNOSTIC SYSTEM ............................... F1-45
EMISSION SYSTEM .......................................................... F1-25 READ/CLEAR DIAGNOSTIC TEST
EMISSION SYSTEM (ENGINE RESULTS ............................................................. F1-45
COMPARTMENT SIDE) COMPONENT PARAMETER IDENTIFICATION (PID)
LOCATION .......................................................... F1-25 ACCESS ............................................................... F1-45
ROLLOVER VALVE INSPECTION ........................... F1-25 DIAGNOSTIC SUPPORT PROCEDURE .................. F1-45
SIMULATION TEST..................................................... F1-45
EVAPORATIVE GAS CHECK VALVE
ON-BOARD DIAGNOSTIC TEST .............................. F1-45/46
(TWO-WAY) INSPECTION ................................ F1-25
DTC READING PROCEDURE .................................. F1-46/48
F1-1 CONTINUED
FUEL AND EMISSION CONTROL SYSTEMS

Page 2 of 2
(G6 )
PID/DATA MONITOR AND RECORD TROUBLESHOOTING ...................................................F1-70
PROCEDURE ...................................................... F1-48 FOREWORD ............................................................F1-70
PLAYBACK OF STORED PIDS TROUBLESHOOTING ITEM TABLE .....................F1-70
PROCEDURE ...................................................... F1-48/49 QUICK DIAGNOSTIC CHART ...............................F1-71/74
DIAGNOSTIC SUPPORT PROCEDURE .......... F1-49 SYMPTOM TROUBLESHOOTING .......................F1-75/114
SIMULATION TEST PROCEDURE ........................ F1-50/51 DIAGNOSTIC INSPECTION..................................F1-115/120
AFTER REPAIR PROCEDURE ............................. F1-51 ENGINE SYSTEM INSPECTION .........................F1-120/127
DTC INSPECTION .................................................. F1-52/69
ENGINE TUNE-UP Not Using the SSTs (NGS tester)

ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating
Using the SSTs (NGS Tester) temperature.
1. Warm up the engine to normal operating 2. Shift the transmission into neutral.
temperature. 3. Turn off all electrical loads.
2. Shift the transmission into neutral. • A/C switch
3. Turn off all electrical loads. 4. Verify that the steering wheel is at straight ahead
• A/C switch position.
4. Verify that the steering wheel is at straight ahead Caution
position. • Connecting the wrong DLC terminals
5. Connect the SSTs (NQS tester) to the DLC and may possibly cause a malfunction.
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select "PID/DATA MONITOR AND RECORD". Carefully connect the specified
(Refer to ON-BOARD DIAGNOSTIC SYSTEM, terminals only.
ON-BOARD DIAGNOSTIC TEST, NGS Tester ho 5. Connect a dwell tachometer to the DLC terminal
Hook-up Procedure.) IG-.
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IGNITION TIMING ADJUSTMENT

Using the SSTs (NGS Tester)
1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-
UP PREPARATION.)
2. Verify that the RPM PID is within the
6. Access RPM PID. Press the trigger key to enter specification.
this selection.
(Refer to ON-BOARD DIAGNOSTIC SYSTEM, Specification
PID/DATA MONITOR AND RECORD 730—770 (750 ±20) rpm
PROCEDURE.) 3. If not as specified, adjust the idle speed.
7. Press SETUP (Key 8) and turn the test mode on. (Refer to ENGINE TUNE-UP, IDLE SPEED
8. Press CANCEL. ADJUSTMENT.)
9. Press START. 4. Connect the timing light to the high-tension lead
of the No. 1 cylinder.
5. Verify that the timing mark on the crankshaft
pulley is within the specification.
Specification
BTDC 4°—6°(5° ± 1°)
CONTINUED
F1-2
ENGINE TUNE-UP
6. If not as specified, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
7. Tighten the distributor lock bolts to the specified
torque.
Tightening torque
19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf}
8. Press SETUP (Key 8) and turn the test mode off.
9. Press CANCEL.
4. Verify that the idle speed is within the
10. Verify that the timing mark on the crankshaft specification.
Specification
730—770 (750 ± 20) RPM
5. If not as specified, adjust the idle speed.

(Refer to ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT.)
6. Connect the timing light to the high-tension lead

of the No.1 cylinder.
7. Verify that the timing mark on the crankshaft
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Specification
BTDC 1°—30°
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BTDC 4°—6° (5° ± 1°)
Not Using the SSTs (NGS Tester) 8. If not as specified, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
9. Tighten the distributor lock bolts to the specified
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(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP
PREPARATION.) torque.
2. If using the SST (System selector) to turn on the
test mode, perform the following: Tightening torque
(1) Connect the SST to the DLC. 19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf}
(2) Set switch A to position 1.
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(3) Set the test switch to SELF TEST. 10. Disconnect the SST or jumper wire. 11. Verify
that the timing mark on the crankshaft pulley is
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within the specification.
Specification
BTDC 1°—30°
3. If using a jumper wire to turn on the test mode,

perform the following:
Caution
• Connecting the wrong DLC
terminals may possibly cause a
malfunction. Carefully connect the
specified terminals only.
• Use a jumper wire to short terminal TEN
of the DLC to body GND.
CONTINUED
F1-3
ENGINE TUNE-UP
IDLE SPEED ADJUSTMENT Caution

Using the SSTs (NGS Tester) • Connecting the wrong DLC terminals
1. Perform "ENGINE TUNE-UP PREPARATION". may possibly cause a malfunction.
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP Carefully connect the specified
PREPARATION.) terminals only.
2. Verify that the RPM PID is within the • Use a jumper wire to short terminal TEN of
specification. the DLC to body GND.
Specification
730—770 (750 ± 20) RPM
Caution
• The TAS is set at the factory and must not
be adjusted. Any adjustment will
negatively affect the engine performance.
3. If not as specified, verify that the ignition timing is
within specification according to the "IGNITION
TIMING ADJUSTMENT", then adjust the idle 4. Verify that the idle speed is within the specification
speed by turning the AAS. using the dwell tachometer.
Specification
730—770 (750 ± 20) RPM
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Caution
• The TAS is set at the factory and must not
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negatively affect the engine performance.
5. If not as specified, verify that the ignition timing is
within specification according to the "IGNITION
TIMING ADJUSTMENT', then adjust the idle
speed by turning the AAS.
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4. Press SETUP (Key 8) to turn the test mode off.

5. Press CLEAR to clear previously selected items.
6. Disconnect the SSTs.
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Not Using the SSTs (NGS Tester)

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PREPARATION.)
2. If using the SST (System selector) to turn on the
test mode, perform the following:
(1) Connect the SST to the DLC. 6. Disconnect the SST or a jumper wire.
(2) Set switch A to position 1. 7. Disconnect the dwell tachometer.
(3) Set the test switch to SELF TEST.
IDLE-UP SPEED INSPECTION
Using the SSTs (NGS Tester)
PREPARATION.)
2. Press SETUP (Key 8) and turn the test mode off.
3. Press CANCEL.
4. Press START.
5. Verify that the idle speed is normal.
(Refer to ENGINE TUNE-UP, IDLE SPEED
3. If using a jumper wire to turn on the test mode, ADJUSTMENT.)
perform the following: 6. Verify that the RPM PID is within the specification.
CONTINUED
F1-4
ENGINE TUNE-UP
Specification • Intake manifold vacuum
1
Load condition Idle-up speed (RPM)* (Refer to TROUBLESHOOTING, ENGINE
P/S ON*2 SYSTEM INSPECTION, Intake Manifold Vacuum
700—800 (750 ± 50) Inspection.)
A/C ON*3
• Fuel line pressure
*1: Excludes temporary idle speed drop just after the
(Refer to TROUBLESHOOTING, ENGINE
electrical loads (E/L) are turned on.
2 SYSTEM INSPECTION, Fuel Line Pressure
* : Steering wheel is fully turned.
Inspection.)
: A/C switch and fan switch are on.
• Ignition timing control
7. If not as specified with all load conditions,
inspect the IAC valve.
SYSTEM INSPECTION, Ignition Timing Control
8. If not as specified with some load condition, Inspection.)
inspect the related input switches, harnesses,
and connectors. • If the systems and devices are normal, replace
the TWC.
Not Using the SSTs (NGS Tester)
(Refer to EXHAUST SYSTEM, EXHAUST
1. Perform "ENGINE TUNE-UP PREPARATION". SYSTEM REMOVAL/INSTALLATION.)
PREPARATION.)
Vehicles Without Oxygen Sensor O2S)
2. Verify that the idle speed is normal.
(Refer to ENGINE TUNE-UP, IDLE SPEED 1. Perform "ENGINE TUNE-UP PREPARATION".
ADJUSTMENT.) 2. Verify that the idle speed and ignition timing are
3. Verify that the idle-up speed is within the within the specification.
specification. (Refer to IGNITION TIMING INSPECTION.)
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(Refer to IDLE SPEED ADJUSTMENT.)
3. Insert an exhaust gas analyzer to the tailpipe.
Specification
4. Verify that the CO and HC concentrations are
Load condition
P/S ON*2
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Idle-up speed (rpm)*
700—800 (750 ± 50)

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within the regulation.
5. If not, turn the adjust screw to adjust CO and HC
A/C ON*3 concentration using the SST.
1
* : Excludes temporary idle speed drop just after the
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electrical loads (E/L) are turned on.
2
* : Steering wheel is fully turned.
3
* : A/C switch and fan switch are on.
4. If not as specified with all load conditions, inspect
the IAC valve.
5. If not as specified with some load conditions,
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inspect the related input switches, harnesses,

and connectors.
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IDLE MIXTURE INSPECTION

Vehicles With Oxygen Sensor (O2S)
1. Perform "ENGINE TUNE-UP PREPARATION". 6. If not adjusted, inspect the following:
• On-board diagnostic system
PREPARATION.)
(Refer to ON-BOARD DIAGNOSTIC
2. Verify that the idle speed and ignition timing are
SYSTEM, ON-BOARD DIAGNOSTIC
within the specification.
TROUBLE CODE INSPECTION.)
(Refer to ENGINE TUNE-UP, IGNITION TIMING
INSPECTION.) • Variable resistor
(Refer to ENGINE TUNE-UP, IDLE SPEED (Refer to CONTROL SYSTEM, VARIABLE
ADJUSTMENT.) RESISTOR INSPECTION.)
3. Turn the test mode off. • Intake manifold vacuum
4. Warm up the engine by holding the engine speed (Refer to TROUBLESHOOTING, ENGINE
at 2500—3000 rpm for approx. 3 minutes. SYSTEM, INSPECTION, Intake Manifold
5. Insert an exhaust gas analyzer to the tailpipe. Vacuum Inspection.)
6. Verify that the CO and HC concentrations are • Fuel line pressure
within the regulation. (Refer to TROUBLESHOOTING, ENGINE
7. If not within the regulation, inspect the following: SYSTEM INSPECTION, Fuel line Pressure
• On-board diagnostic system Inspection.)
(Refer to ON-BOARD DIAGNOSTIC • Ignition timing control
SYSTEM, ON-BOARD DIAGNOSTIC (Refer to TROUBLESHOOTING, ENGINE
TROUBLE CODE INSPECTION.) SYSTEM INSPECTION, Ignition Timing
• O2S (Refer to CONTROL SYSTEM, Control Inspection.)
OXYGEN SENSOR O2S) INSPECTION.)
CONTINUED
F1-5
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
VACUUM HOSE ROUTING DIAGRAM
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INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

Warning
• When the engine and intake-air system are hot, they can badly burn. Turn off engine and wait until
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they are cool before removing the intake-air system.

• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
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sparks and flames away from fuel.

• Fuel line spills and leakage 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".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1. Complete the "BEFORE REPAIR PROCEDURE".
2. Drain the engine coolant from the radiator.
(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
6. Complete the "AFTER REPAIR PROCEDURE".
CONTINUED
F1-6
INTAKE-AIR SYSTEM
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1 Air cleaner component 5 Throttle body component

2 Air intake hose 6 Dynamic chamber
3 MAP sensor 7 Fuel injector
4 Accelerator cable ☞ FUEL SYSTEM, FUEL INJECTOR
☞ ACCELERATOR CABLE INSPECTION/ REMOVAL/ INSTALLATION
ADJUSTMENT 8 Intake manifold
CONTINUED
F1-7
INTAKE-AIR SYSTEM
BYPASS AIR CONTROL (BAC) VALVE

REMOVAL/INSTALLATION
2. Disconnect the IAC valve connector.
3. Drain the engine coolant from the radiator.
(Refer to section E, ENGINE COOLANT, ENGINE
COOLANT REPLACEMENT.)
4. Remove the BAC valve.
6. If not as specified, replace the BAC valve.

(Refer to BAC VALVE
REMOVAL/INSTALLATION.) If as specified, but
IAC valve is failed, inspect for the following:
Open circuit
• Power circuit (IAC valve connector
terminal A and main relay terminal D)
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AIR VALVE INSPECTION
Operation Inspection ho
Note
1. Perform the following test only when directed.
1. Carry out the "Idle Air Control (IAC) Inspection".
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SYSTEM INSPECTION, Idle Air Control (IAC)
Inspection.)
2. Remove the BAC valve.
(Refer to INTAKE-AIR SYSTEM, BAC VALVE
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3. Add cold water into the engine coolant passage of

the BAC valve to reduce the air valve temperature.
4. Verify that the air valve operates when hot water is
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added into the engine coolant passage of the BAC

valve. • GND circuit (IAC valve connector
5. If not as specified, replace the BAC valve, 6. Install terminal B and PCM connector terminal
the BAC valve. 2W)
IDLE AIR CONTROL (IAC) VALVE INSPECTION Short circuit
Resistance Inspection • IAC valve connector terminal B and
Note PCM connector terminal 2W to GND
2. Perform the following test only when directed, 7. Repair or replace faulty areas.
1. Carry out the "Idle Air Control (IAC) Inspection", 8. Connect the IAC valve connector.
(Refer to TROUBLESHOOTING, ENGINE 9. Connect the negative battery cable.
SYSTEM INSPECTION, Idle Air Control (IAC)
Inspection.)
2. If not as specified, perform the further inspection
for the IAC valve.
4. Disconnect the IAC valve connector.
5. Measure the resistance between the IAC valve
terminals using an ohmmeter.
Resistance
7.7—9.3 Ω [23 °C {73 °F}]
CONTINUED
F1-8
INTAKE-AIR SYSTEM
ACCELERATOR PEDAL REMOVAL/INSTALLATION
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1 Accelerator cable
☞ ACCELERATOR CABLE
2
INSPECTION/ADJUSTMENT
Accelerator pedal
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ACCELERATOR CABLE
INSPECTION/ADJUSTMENT
1. Measure the free play of the accelerator cable.
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Free play
1—3 mm {0.04—0.11 in}
2. If not as specified, adjust by turning the locknut,

CONTINUED
F1-9
FUEL SYSTEM
FUEL SYSTEM
BEFORE REPAIR PROCEDURE
Warning
• Fuel vapor is hazardous. It can easily
ignite, causing serious injury and damage.
Always keep sparks and flames away from
fuel.
• Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate
skin and eyes. To prevent this, always 3. Install a hose clamp over the fuel hose within the
complete the following "Fuel Line Safety clamp installation range as shown, avoiding the
Procedures". original clamp position.
Note
CLAMP INSTALLATION RANGE
• Fuel in the fuel system is under high pressure
when the engine is not running.
Fuel Line Safety Procedures
1. Remove the fuel-filler cap and release the pressure
in the fuel tank.
2. Disconnect the fuel pump relay connector located
under the passenger's side front side trim.
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Fuel Leakage Inspection
Warning
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• Fuel line spills and leakage are
dangerous. Fuel can ignite and cause
serious injuries or death and damage.
Always carry out the following procedure
with the engine stopped.
3. Start the engine.
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Caution
4. After the engine stalls, crank the engine several
• Connecting the wrong DLC terminal
times. may possibly cause a malfunction.
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5. Turn off the ignition switch. Carefully connect the specified terminal
6. Reconnect the fuel pump relay connector. only.
AFTER REPAIR PROCEDURE 1. Short the DLC terminal F/P to body GND using a
Warning jumper wire.
or death and damage. When installing the
fuel hose, observe "Fuel Hose Installation"
and "Fuel Leakage Inspection" described
below.
Fuel Hose Installation
1. Replace damaged or deformed fuel hoses, fuel
pipes, and hose clamps.
2. When installing the fuel hose onto the fuel pipe, fit
the hose onto the pipe over 25 mm {0.98 in}. 2. Turn the ignition switch on to operate the fuel
When the pipe has a stopper, fit the hose until it pump body.
contacts the stopper. 3. Pressurize the system this way for at least 5
minutes to be sure of no leakage.
4. If there is fuel leakage, inspect for damaged fuel
hoses, hose clamps, and fuel pipe sealing surface
and replace as necessary.
5. After repair, assemble the system and repeat
Steps 1 to 3.
F1-10 CONTINUED
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
Warning
• 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.
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
1. Level the vehicle.

4. Drain the fuel from the drain plug.
STRETCH CAB 2WD, DOUBLE CAB 2WD
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CONTINUED
F1-11
FUEL SYSTEM
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
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1 Joint hose 8 Fuel pump unit

☞ Installation Note 9 Fuel-filler pipe
2 Breather hose 10 Dust cover
☞ Installation Note 11 Fuel inlet pipe
3 Under guard
12 Nonreturn valve
4 Fuel hose
13 Evaporative gas check valve (two-way)
5 Fuel tank ☞ Installation Note
6 Evaporative hose 14 Check valve (two-way)
15 Evaporative chamber
7 Rollover valve
CONTINUED
F1-12
FUEL SYSTEM
Evaporative Gas Check Valve (Two-way)

Installation Note
• Install the arrow mark of the evaporative gas
check valve (two-way) facing the charcoal
canister.
Evaporative Hose Installation Note
• Fit each hose onto the respective fittings within the
specification, and install clamps as shown.
Length
Evaporative hose: 25—30 mm {0.99—1.18 in}
NONRETURN VALVE INSPECTION

1. Remove the nonreturn valve with the fuel inlet
pipe.
2. Verify that the nonreturn valve opening angle is
50—56° when pushed out from the fuel inlet pipe
side, and the clearance between the nonreturn
valve and the fuel inlet pipe end is within 1.5 mm
Breather Hose Installation Note {0.06 in} when the nonreturn valve is returned to
• Fit each hose onto the respective fittings within the the closed position.
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specification, and install clamp as shown.
Length Breather hose:

25—30 mm {0.99—1.18 in}
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3. If not as specified, replace the nonreturn valve.

Joint Hose Installation Note
• Fit the joint hose onto the respective fittings FUEL PUMP UNIT REMOVAL/INSTALLATION
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within the specification, and install clamps as

shown. 1. Remove the fuel pump unit.
Length (Refer to FUEL SYSTEM,FUEL TANK
Joint hose: 35—40 mm {1.4—1.5 in} REMOVAL/INSTALLATION.)
2. Install the fuel pump unit.
(Refer to FUEL SYSTEM,FUEL TANK
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY

Warning
• Fuel line spills and leakage are
dangerous. Fuel can ignite and cause
serious injuries or death and damage.
Fuel can also irritate skin and eyes. To
prevent this, do not damage the sealing
surface of the fuel pump unit when
removing or installing.
CONTINUED
F1-13
FUEL SYSTEM
STRETCH CAB 2WD, 2. If not as specified, perform the further inspection

DOUBLE CAB 2WD for the fuel pump unit.
Continuity Inspection
Note
• Perform the following test only when directed.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Remove the fuel tank. (Refer to FUEL SYSTEM,
FUEL TANK REMOVAL/INSTALLATION.)
4. Inspect for continuity between fuel pump unit
connector terminals C and D.
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STRETCH CAB 4WD,
DOUBLE CAB 4WD, 5. If there is no continuity, replace the fuel pump
REGULAR CAB
ho body. If as specified but the "Simulation Test" is
failed, inspect the following:
Fuel pump relay malfunction
Open circuit
• GND circuit (fuel pump unit connector terminal D
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and body GND)
• Power circuit (fuel pump relay connector terminal
D and fuel pump unit connector terminal B
through common connector)
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Short circuit
• Fuel pump relay connector terminal D and fuel
1 Rubber mount pump unit connector terminal B through common
2 Fuel filter (low-pressure) connector to GND
3 Clamp 6. Repair or replace faulty areas.
4 Fuel hose 7. Install the fuel tank.
5 Fuel pump body (Refer to FUEL SYSTEM, FUEL TANK
6 Fuel gauge sender unit
FUEL PUMP UNIT INSPECTION 8. Reconnect the negative battery cable.
Simulation Test 9. Complete the "AFTER REPAIR PROCEDURE".
1. Carry out the "Fuel Pump Operation Inspection", "Fuel (Refer to FUEL SYSTEM, AFTER REPAIR
Pump Control Inspection". PROCEDURE.)
(Refer to TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Pump Operation Inspection.)
INSPECTION, Fuel Pump Control Inspection.)
CONTINUED
F1-14
FUEL SYSTEM
Fuel Pump Maximum Pressure Inspection 8. If not as specified, inspect the following:
Warning • Fuel pump relay
• Fuel filter (low-pressure, high-pressure) for
clogging
Fuel can ignite and cause serious injuries • Fuel line for clogging or leakage
or death and damage. Always carry out the
following procedure with the engine
stopped.
PROCEDURE.)
Note
• Perform the following test only when directed. 11. Disconnect the fuel pressure gauge.
1. Complete the "BEFORE REPAIR PROCEDURE". 12. Connect the negative battery cable.
PROCEDURE.)
(Refer to FUEL SYSTEM, AFTER REPAIR
2. Disconnect the negative battery cable. PROCEDURE.)
3. Connect a fuel pressure gauge to the fuel hose Fuel Pump Hold Pressure Inspection
between the pulsation damper and fuel main hose,
Warning
then plug the opening as shown.
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stopped.

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PROCEDURE.)
4. Connect the negative battery cable. 2. Disconnect the negative battery cable.
Caution 3. Connect a fuel pressure gauge to the fuel hose
• between the pulsation damper and fuel main
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Connecting the wrong DLC terminal may

possibly cause a malfunction. Carefully hose, then plug the opening as shown.
connect the specified terminal only.
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5. Short the DLC terminal F/P to body GND using a

jumper wire.
4. Connect the negative battery cable.

Caution
6. Turn the ignition switch on to operate the fuel • Connecting the wrong DLC terminal may
pump body. Measure the fuel pump maximum possibly cause a malfunction. Carefully
pressure. connect the specified terminal only.
Fuel pump maximum pressure
500—630 kPa {5.0—6.5 kgf/cm2, 72—92 psi}
jumper wire.
7. Turn the ignition switch off and disconnect the
jumper wire. CONTINUED
F1-15
FUEL SYSTEM
6. Turn the ignition switch on for 10 seconds to

operate the fuel pump body.
7. Turn the ignition switch off. Measure the fuel pump
hold pressure after 5 minutes.
Fuel pump hold pressure
More than 340 kPa {3.5 kgf/cm2, 50 psi}
8. Disconnect the jumper wire.
PROCEDURE.)
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11. Disconnect the fuel pressure gauge.
1 Fuel hose
12. Reconnect the negative battery cable. ho
13. If not as specified, carry out the "PRESSURE 2 Protector
REGULATOR INSPECTION", "FUEL INJECTOR 3 Fuel filter (high-pressure)
INSPECTION" (Refer to FUEL SYSTEM, ☞ Removal Note
PRESSURE REGULATOR INSPECTION.) ☞ Installation Note
(Refer to FUEL SYSTEM, FUEL INJECTOR
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INSPECTION.) Fuel Filter (High-pressure) Removal Note
14. Complete the "AFTER REPAIR PROCEDURE". • Before removing the fuel filter (high-pressure),
(Refer to FUEL SYSTEM, AFTER REPAIR paint marks on the fuel filter (high-pressure) and
PROCEDURE.) fuel filter bracket for correct reassembly.
FUEL FILTER (HIGH-PRESSURE)
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PROCEDURE.)
4. Install in the reverse order or removal.
(Refer to FUEL SYSTEM, AFTER REPAIR Fuel Filter (High-pressure) Installation Note
PROCEDURE.) Replacing the fuel filter (high-pressure)
1. Paint a mark on the new fuel filter (high-pressure)
at the same spot as the removed fuel filter (high-
pressure).
2. Align the paint marks and install the fuel filter
(high-pressure) as shown.
CONTINUED
F1-16
FUEL SYSTEM
Replacing the fuel filter bracket

1. Paint a mark on the new fuel filter bracket at the same
spot as the removed fuel filter bracket.
2. Align the paint marks and install the fuel filter bracket as
shown.
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CONTINUED
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F1-17
FUEL SYSTEM
FUEL INJECTOR REMOVAL/INSTALLATION
Warning
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety
Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
3. Disconnect the fuel injector connectors and remove the harness from the fuel distributor.
6. Complete the "AFTER REPAIR PROCEDURE." (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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1 Dynamic chamber 6 Fuel injector

2 Dynamic chamber gasket ☞ Installation note
7 Grommet
3 Fuel injector connector
4 Fuel hose 8 Fuel injector insulator
5 Fuel distributor CONTINUED
F1-18
FUEL SYSTEM
Fuel Injector Installation Note Open circuit

1. Use new fuel injector O-rings. • GND circuit (No.1 cylinder fuel injector connector
2. Verify that the O-rings and the fuel injector sealing terminal B and PCM connector terminal 2U)
surfaces are free of foreign materials. Clean with • GND circuit (No.2 cylinder fuel injector connector
gasoline if necessary. terminal B and PCM connector terminal 2V)
3. Apply a small amount of engine oil to the O-rings • GND circuit (No.3 cylinder fuel injector connector
and into the fuel distributor. terminal B and PCM connector terminal 2U)
4. Install the fuel injectors in the fuel distributor with a • GND circuit (No.4 cylinder fuel injector connector
light twisting motion so that the O-rings will not be terminal B and PCM connector terminal 2V)
folded.
• Power circuit (No.1 cylinder fuel injector connector
terminal A and main relay connector terminal D
FUEL INJECTOR INSPECTION • Power circuit (No.4 cylinder fuel injector connector
Simulation Test terminal A and main relay connector terminal D
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1. Carry out the "Fuel Injector Operation Inspection".
SYSTEM INSPECTION, Fuel Injector Operation
Inspection.)
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2. If not as specified, perform the further inspection for
the fuel injectors.
Resistance Inspection
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Note
1. Disconnect the negative battery cable. Short circuit
2. Disconnect the fuel injector connectors. • No.1 cylinder fuel injector connector terminal B
and PCM connector terminal 2U to GND
3. Measure the resistance of the fuel injector using
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an ohmmeter. • No.2 cylinder fuel injector connector terminal B

and PCM connector terminal 2V to GND
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• No.3 cylinder fuel injector connector terminal B

and PCM connector terminal 2U to GND
• No.4 cylinder fuel injector connector terminal B
and PCM connector terminal 2V to GND
5. Repair or replace faulty areas.
6. Reconnect the fuel injector connectors.
7. Reconnect the negative battery cable.
Resistance Fuel Leakage Test
12—16Ω[20°C {68°F}] Warning
4. If not as specified, replace the fuel injector. • Fuel line spills and leakage are dangerous.
(Refer to FUEL SYSTEM, FUEL INJECTOR Fuel can ignite and cause serious injuries
REMOVAL/INSTALLATION.) If as specified but or death and damage. Always carry out the
"Simulation Test" is failed, inspect for the following: following procedure with the engine
stopped.
Note
CONTINUED
F1-19
FUEL SYSTEM
1. Complete the "BEFORE REPAIR PROCEDURE". 9. Turn the ignition switch off and remove the
(Refer to FUEL SYSTEM, BEFORE REPAIR jumper wire.
PROCEDURE.) 10. If not as specified, replace the fuel injector.
2. Disconnect the negative battery cable. 11. Complete the "AFTER REPAIR PROCEDURE",
3. Remove the fuel injectors together with the fuel (Refer to FUEL SYSTEM, AFTER REPAIR
distributor. (Refer to FUEL SYSTEM, FUEL PROCEDURE.)
INJECTOR REMOVAL/INSTALLATION.) Volume Test
4. Fasten the fuel injectors firmly to the fuel Warning
distributor with wire.
stopped.
Note
1. Complete the "BEFORE REPAIR
5. Connect the negative battery cable. PROCEDURE",
Caution PROCEDURE.)
• Connecting the wrong DLC terminal may
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3. Remove the fuel injectors together with the fuel
possibly cause a malfunction. Carefully
distributor.
connect the specified terminal only. ho (Refer to FUEL SYSTEM, FUEL INJECTOR
6. Short the DLC terminal F/P to body GND using a REMOVAL/INSTALLATION.)
jumper wire. 4. Fasten the fuel injectors firmly to the fuel
distributor with wire.
5. Connect the SST as shown in the figure.
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7. Turn the ignition switch on to operate the fuel

6. Connect the negative battery cable.
pump body. Caution
8. Tilt the fuel injectors approx. 60 degrees and • Connecting the wrong DLC terminal may
verify that fuel leakage from the fuel injector possibly cause a malfunction. Carefully
nozzles is within the specification. connect the specified terminal only.
jumper wire.
Fuel leakage
Less than 1 drop/2 minutes
8. Turn the ignition switch on to operate the fuel

pump body.
9. Measure the injection volume of each fuel
injector using a graduated container.
F1-20 CONTINUED
FUEL SYSTEM
Injection volume 1. Complete the "BEFORE REPAIR PROCEDURE".

55—71 ml {55—71 cc, 1.9—2.3 fl oz}/15 sec. (Refer to FUEL SYSTEM, BEFORE REPAIR
10. Turn the ignition switch off and disconnect the PROCEDURE".)
jumper wire. 2. Disconnect the negative battery cable.
11. If not as specified, replace the fuel injector.
3. Connect a fuel pressure gauge between the
(Refer to FUEL SYSTEM, AFTER REPAIR pulsation damper and fuel main hose.
PROCEDURE.)
PRESSURE REGULATOR
Warning
or death and damage. Fuel can also irritate
skin and eyes. To prevent this, always
complete the "Fuel Line Safety
Procedures".
PROCEDURE.) 4. Connect the negative battery cable.
1. Complete the "BEFORE REPAIR
PROCEDURE". 5. Start the engine and let it idle.
(Refer to FUEL SYSTEM, BEFORE REPAIR 6. Measure the fuel line pressure after approx. 2
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PROCEDURE.) minutes.
2. Disconnect the negative battery cable. Fuel line pressure
ho 210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi}
7. Disconnect the vacuum hose from the pressure
(Refer to FUEL SYSTEM, AFTER REPAIR regulator and measure the fuel line pressure.
PROCEDURE.)
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Fuel line pressure

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
8. Turn the ignition switch off.
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1 Vacuum hose (Refer to FUEL SYSTEM, BEFORE REPAIR
2 Fuel hose PROCEDURE.")
3 Pressure regulator 10. Disconnect the negative battery cable.
PRESSURE REGULATOR INSPECTION 11. Disconnect the fuel pressure gauge.
Simulation Test 12. Reconnect the fuel main hose to the fuel
1. Carry out the "Fuel Line Pressure Inspection". distributor.
(Refer to TROUBLESHOOTING, ENGINE 13. Reconnect the negative battery cable.
SYSTEM INSPECTION, Fuel Line Pressure
14. If not as specified, inspect the following:
Inspection.)
• Fuel pump maximum pressure
2. If not as specified, perform the further inspection • Fuel pump hold pressure
for the pressure regulator. • Fuel filter for clogging
Operation Inspection • Fuel injector for leakage
Note • Fuel pump relay
• Perform the following test only when directed. • Fuel line for improper routing, clogging, kinks
or leakage
CONTINUED
F1-21
FUEL SYSTEM
If all items above are okay, replace the pressure

regulator.
(Refer to FUEL SYSTEM, PRESSURE
REGULATOR REMOVAL/INSTALLATION.)
PROCEDURE.)
PRESSURE REGULATOR CONTROL (PRC)
SOLENOID VALVE INSPECTION Short circuit
Simulation Test • PRC solenoid valve connector terminal B and
1. Carry out the "Pressure Regulator Control (PRC) PCM connector terminal 2T through common
Inspection". connector to GND)
(Refer to TROUBLESHOOTING, ENGINE 5. Repair or replace faulty areas.
SYSTEM INSPECTION, Pressure Regulator 6. Install the PRC solenoid valve.
Control (PRC) Inspection.)
for the PRC solenoid valve,
PULSATION DAMPER REMOVAL/INSTALLATION
Airflow Inspection
Note
• Perform the following test only when directed. PROCEDURE.)
1. Disconnect the negative battery cable. 2. Disconnect the negative battery cable.
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2. Remove the PRC solenoid valve. 3. Remove the pulsation damper.
(Refer to INTAKE-AIR SYSTEM, VACUUM HOSE
ROUTING DIAGRAM.)
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3. Inspect airflow between the ports under the following
conditions.
PROCEDURE.)
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1 Fuel hose
2 Bolt
4. If not as spec tied, replace the PRC solenoid valve. 3 Pulsation damper
If as specified but the "Simulation Test" is failed, PULSATION DAMPER INSPECTION
inspect for the following: 1. Remove the pulsation damper.
Vacuum hose improper routing, kinks or (Refer to FUEL SYSTEM, PULSATION DAMPER
leakage REMOVAL/INSTALLATION.)
Open circuit 2. Visually inspect the pulsation damper for
• GND circuit (PRC solenoid valve connector damage and cracks. Also inspect that there is no
terminal B and PCM connector terminal 2T extreme rust, which will cause fuel leakage.
through common connector) 3. If either is observed, replace the pulsation
• Power circuit (PRC solenoid valve connector damper.
terminal A and main relay connector terminal D CONTINUED
F1-22
FUEL SYSTEM
FUEL PUMP RELAY INSPECTION • Power circuit (fuel pump relay connector
Simulation Test terminal A or C and IG switch connector
1. Carry out the "Fuel Pump Operation Inspection", terminal IG1 through common connector)
"Fuel Pump Control Inspection".
SYSTEM INSPECTION, Fuel Pump Operation
Inspection.)
SYSTEM INSPECTION, Fuel Pump Control
Inspection.)
for the fuel pump relay.
Continuity Inspection
Note

2. Remove the fuel pump relay located under the
passenger's side front side trim.
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Short circuit
• Fuel pump relay connector terminal B and
PCM connector terminal 1H through common
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connector to GND
3. Inspect for continuity between the fuel pump relay • Fuel pump relay connector terminal D and fuel
terminals using an ohmmeter. pump unit connector terminal B through
common connector to GND
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6. Install the fuel pump relay.

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4. If not as specified, replace the fuel pump relay. If as

specified but the "Simulation Test" is failed, inspect
for the following:
Fuel pump unit malfunction
Open circuit
• GND circuit (fuel pump relay connector terminal
B and PCM connector terminal 1H through
common connector)
• GND circuit (fuel pump relay connector terminal
D and fuel pump unit connector terminal B
CONTINUED
F1-23
EXHAUST SYSTEM
EXHAUST SYSTEM
EXHAUST SYSTEM INSPECTION
1. Start the engine and inspect the exhaust system component for exhaust gas leakage.
2. If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION
Warning
• 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.

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1 After silencer 4 Front pipe

2 Main silencer 5 Insulator
3 TWO (Europe) 6 Exhaust manifold
Presilencer (Except Europe) CONTINUED
F1-24
EMISSION SYSTEM
EMISSION SYSTEM
EMISSION SYSTEM (ENGINE COMPARTMENT
SIDE) COMPONENT LOCATION
4. If not as specified, replace the rollover valve.

EVAPORATIVE GAS CHECK VALVE (TWO-
WAY) INSPECTION
1. Remove the evaporative gas check valve (two-
way).
(Refer to FUEL SYSTEM, FUEL TANK
2. Inspect airflow of the valve under the following
conditions.
Apply pressure below +2.9 kPa {+22

mmHg, +0.87 inHg} to port A No airflow
Apply pressure over +5.9 kPa {+44

Airflow
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mmHg, +1.7 inHg} to port A
Apply pressure over -0.98 kPa
{-7.36 mmHg, -0.29 inHg} to port A Airflow
1 Charcoal canister
2 Purge solenoid valve
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3 PCV valve
ROLLOVER VALVE INSPECTION
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1. Remove the rollover valve.
2. Hold the valve as shown. Blow air into port A and
verify that there is airflow.
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3. If not as specified, replace the evaporative gas

check valve (two-way).
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CHECK VALVE (TWO-WAY) INSPECTION

1. Remove the check valve (two-way).
2. Inspect airflow of the valve under the following
3. Turn the valve upside-down as shown. Blow conditions.
air into port A and verify that there is no
airflow. Apply pressure of -0.98—1-13.7 kPa
{-7.3—1-102 mmHg, -0.28— + 4.0 No airflow
inHg} to port A
Apply pressure over +18.6 kPa
Airflow
{+140 mmHg, +5.5 inHg} to port A
Apply pressure over -4.9 kPa
{-36.8 mmHg, -1.4 inHg} to port B Airflow
CONTINUED
F1-25
EMISSION SYSTEM
PURGE SOLENOID VALVE INSPECTION

Simulation Test
1. Carry out the "Purge Control Inspection".
INSPECTION, Purge Control Inspection.)
2. If not as specified, perform the further inspection for
the purge solenoid valve,
Airflow Inspection
Note
3. If not as specified, replace the check valve (two- 2. Remove the purge solenoid valve.
way). 3. Inspect airflow between the ports under the following
EVAPORATIVE CHAMBER INSPECTION conditions.
1. Remove the evaporative chamber.
2. Blow air into port A and verify that air flows out
from the holes B on the evaporative chamber.
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3. Visually inspect that there is no damage nor crack
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on the evaporative chamber.
4. If not as specified, replace the evaporative
chamber.
5. Install the evaporative chamber.
4. If not as specified, replace the purge solenoid valve.
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CHARCOAL CANISTER INSPECTION If as specified but the "Simulation Test" is failed,

1. Remove the charcoal canister. inspect for the following:
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2. Plug the atmosphere side port and purge solenoid Vacuum hose improper routing, kinks or leakage.
valve side port of the charcoal canister. Open circuit
3. Blow air into the charcoal canister from the fuel • GND circuit (purge solenoid valve connector
tank side port and verify that there is no air terminal B and PCM connector terminal 2X
leakage. through common connector)
• Power circuit (purge solenoid valve connector
4. If there is air leakage, replace the charcoal

canister.
CONTINUED
F1-26
EMISSION SYSTEM
Short circuit
• Purge solenoid valve connector terminal B and
PCM connector terminal 2X through common
connector to GND
6. Install the purge solenoid valve.
POSITIVE CRANKCASE VENTILATION (PCV) VALVE
INSPECTION
1. Remove the PCV valve.
2. Blow through the valve and verify that air flows as
specified.
Specification
Condition Airflow
Air applied from port A Yes
Air applied from port B No
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3. If not as specified, replace the PCV valve.
CONTINUED
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F1-27
MAZDA BT-50
CONTENTS
SECTION
TITLE
PREVIOUS
8 WIRING DIAGRAMS GI
(GENERAL INFORMATION)
w
(ELECTRICAL WIRING SCHEMAТIC)
FB
(FUSE BLOCK)
GENERAL INFORMATION JB
(JOINT BOX)
х
(COMMON CONNECTOR)
у
(GROUND POINТ)
FOREWORD u
(DATA LINK CONNECTOR)
This wiring diagram incorporates the wiring schematics А
of the BT-50 and availaЫe optional equipment. Actual (CHARGING SYSTEМ/
STARTING SYSTEM)
vehicle wiring may vary slightly depending оп optional ENGINE в
(ENGINE CONTROL SYSTEM)
equipment or local specifications, or both. Q
(CRUISE CONTROL SYSTEM)
For proper repair and maintenance, а thorough SUSPENSION

familiarization with this manual is important, and it DRIVELINE/AXLE
1/)
should always Ье kept in а handy place for quick and z о
BRAKES о (ANTI-LOCK BRAKE SYSTEM)
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easy reference. TRANSMISSION/ � н
u
TRANSAXLE о (ЕС·АТ CONTROL SYSTEM)
AII the contents of this manual, including drawings and N
printing.
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specifications, are the latest availaЫe at the time of
STEERING
HEATER, VENTILATION &

а:
u
w
(ELECTRIC POWER
STEERING SYSTEM)
G
z
As modifications affecting repair or maintenance occur,
AIR CONDITIONING (HVAC) z (AIR CONDIТIONING SYSTEM)
о
u s
RESTRAINTS
relevant information supplementary to this volume will (SEAT BELT/AIR BAG SVSTEM)
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8
::1i=
Ье made availaЫe . This manual should Ье kept up-to- а: (GAUGE CONТROL SYSTEM)
date. �
(WIPER SYSTEM)
.... Е
u (EXТERIOR LIGHTING SVSTEM)
а: F
d
ё3 (SIGNAL SYSTEM)
AII rights reserved. No part of this book may Ье ::1i= 1
w
reproduced or used in апу form or Ьу апу means, (INTERIOR UGHТING SVSTEM)
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1/)
electronic or mechanical-including photocopying and J
BODY & ACCESSORIES 1/) (AUDIO SYSTEM)
recording and the use of апу kind of information storage к
(DOOR/WINDOW SYSTEM)
and retrieval system-without permission in writing.
L
(MIRROR SVSTEM)
м
(SUNROOF SYSTEM)
·р
(POWER SEAT SYSTEM)
т
(SECURIТY AND LOCKS
SYSTEМ/OPTION)
ALPHABETICAL INDEX AI
ALPHABETICAL INDEX
APPLICATION:
This .manual is applicaЫe to vehicles beginning with
the Vehicle ldentification Numbers (VIN) shown оп
the following page. PRINTED IN THAILAND, DEC. 2005
F198-ЗО-05L
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BT-50 Manual Taller

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Created in Master PDF Editor - Demo Version

General Information ..........................................................................00-1

Cooling System ........................................................................................................01-15

Service Training BT-50

Crankshaft Position Sensor .................................................................................01-46

Service Training BT-50

Shift Mechanism Unit....................................................................................05-11

Service Training BT-50

Body & Accessories..........................................................................09-1

Service Training BT-50

Control System WL-C Engine

01-56 Service Training BT-50

Front wheel RAP cab: 0°44' ±1°

RAP cab: 10°37'

Service Training BT-50 02-1

Front Suspension 4WD

1 Shock absorber 4 Lower arm

02-2 Service Training BT-50

1 4WD 3 Shock absorber

Service Training BT-50 02-3

Wheels and Tyres Suspension

Wheels and Tyres

02-4 Service Training BT-50

Suspension Wheels and Tyres

Service Training BT-50 02-5

Wheels and Tyres Suspension

02-6 Service Training BT-50

Final gear ratio 3.416 3.727

Service Training BT-50 03-1

RFW System Driveline / Axle

1 RFW main switch 7 RFW vacuum actuator

03-2 Service Training BT-50

Driveline / Axle RFW System

1 4WD indicator light 11 One-way check valve

3 To battery 13 Free solenoid valve

Service Training BT-50 03-3

RFW System Driveline / Axle

On-Board Diagnostic System

NTFLAMP # RFW indicator light OFF/ON

03-4 Service Training BT-50

Service Training BT-50 05-1

1 Dual-mass flywheel 5 Clutch release cylinder

05-2 Service Training BT-50

Clutch Master Cylinder

1 One-way valve 2 Pulsation damper

Service Training BT-50 05-3

Dual Mass Flywheel

1 Torsional-vibration damping spring 3 Primary flywheel

05-4 Service Training BT-50

Transmission S15M(X)-D Manual Transmission

S15M(X)-D Manual Transmission

Service Training BT-50 05-5

S15M(X)-D Manual Transmission Transmission

05-6 Service Training BT-50

Transmission S15M(X)-D Manual Transmission

A Extension housing (S15M-D) 5 Reverse idler gear

Service Training BT-50 05-7

S15M(X)-D Manual Transmission Transmission

05-8 Service Training BT-50

Transmission S15M(X)-D Manual Transmission

Service Training BT-50 05-9

S15M(X)-D Manual Transmission Transmission

1 Section A-A 3 Control rod