Electrical Wiring Diagrams LHD PDF

HOW TO READ ELECTRICAL WIRING DIAGRAM
1. HOW TO READ ELECTRIC WIRING DIAGRAM
1) CONTENTS OF ELECTRICAL WIRING DIAGRAM (CIRCUIT)

POSITION EXPLANATION
A - Upper horizonal lines : Power supply- Power supply lines : 30, 15, 15A, 15C
- Ef7 or Af3 or F2
 Ef7 : Fuse No #20 in Engine Fuse Block

B
 Af3 : Fuse No #3 in Engine Fuse Block Aux.
 F2 : Fuse No #2 in I/P Fuse Block
- Connector(X101~X902)
C  Connector No X401 terminal No 6

 Refer to Major Connector Position (Section 2)
- Wiring Harness Splice
D  J201 : Wiring Harness Splice

 JX202 : Wiring Harness Splice Pack
E - Internal circuit of component (Relay)(Component name, terminal number)

- Internal circuit of component (Module)(Component name, terminal number and
F
connecting wiring circuit)
- Wiring Harness Color
G
 Refer to wiring harness color abbreviation
- Ground Harness Pack

H
 Ground Harness Pack Position (GX101~GX402)
- Lower horizonal line : Ground Line
I  Ground Position (G103~G302)

 B : Body Ground
2. CIRCUIT IDENTIFICATION SYMBOL

IDENTIFICATION
MEANING
SYMBOL
X Connector
E Fuse in engine fuse block.
A Fuse in engine fuse block. Aux
F Fuse in I/P fuse block
G Ground
J Splice pack
3. FUNCTION OF POWER SUPPLY LINE (NUMBER)

Power supply No. Power supply condition
15 Battery Voltage(B+) supply in Ignition "ON" and "ST" (IGN II/III) Position
15A Battery Voltage(B+) supply in Ignition "ON" (IGN II) Position
30 Battery Voltage(B+) supply directly regardless of Ignition Position
31 Ground connected to battery(–)
4. WIRING HARNESS COLOR IDENTIFICATION
Abbreviation Color Abbreviation Color
BN Brown L-BU Light Blue
GN Green RD Red
VT Violet BU Blue
PK Pink YE Yellow
WH White GY Gray
OR Orange BK Black
L-GN Light Green . .
5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR

- Terminal number is given based on Female Terminal Connector
ex) Terminal Number 4 of X405 connection
POSITION OF CONNECTORS AND GROUNDS
1. CONNECTOR, GROUND AND GROUND PACK INFORMATION

1) FAMII 2.4D ENGINE (LD9)
2) 2.0 DIESEL ENGINE (LLW)
3) HVF-6 3.2 ENGINE (LUI)
4) CONNECTOR INFORMATION
Connector Terminal
Color Connecting Wiring Harness Connecting Position
Number Number
Behind the Engine Fuse
X101 36 Black Engine - Body
Block
Connector Terminal
Color Connecting Wiring Harness Connecting Position
Number Number
Behind the left side Head
X102 12 Black Front JPR - Front
Lamp
X103 8 Black Engine - Fuel Heater (DSL) Right side upper Cylinder
X104 4 Black Engine - Glow Plug (DSL) Left side upper Cylinder
X106 7 Black Engine - Fuel Injector (HVF6) Upper the cylinder Head
X201 92 Black Body - I.P Below to the "A" pillar
X202 12 Colorless I.P - Body Behind the Audio
X203 6 Colorless I.P - Air Bag Below the floor console
X204 16 Black I.P - FATC Behind the FATC
X301 12 Colorless Console - Body Below the floor console
X302 2 Yellow Body - Air Bag Inside left "B" Pillar
X303 2 Yellow Body - Air Bag Inside right "B" Pillar
X304 12 Black Fuel Sender - Body Below the right "C" pillar
Body - Rear Wheel Speed
X305 4 Black Behind the "2nd" Seat
Sensor
X401 18 Colorless Roof - Body Inside the left "C" pillar
X402 18 Colorless Lift Gate - Body Behind the left "C" pillar
X403 2 Black Curtain Air Bag - Body Behind the left "C" pillar
X404 2 Black Curtain Air Bag - Body Behind the right "C" pillar
Body - Rear Objective Alarm
X405 6 Black Behind the right Tail Lamp
Sensor
X501 18 Gray Body - Front LH Door Under the left "A" Pillar
X502 18 Colorless Body - Front LH Door Under the left "A" Pillar
X601 18 Gray Body - Front RH Door Under the right "A" Pillar
X602 18 Colorless Body - Front RH Door Under the right "A" Pillar
X701 15 Colorless Body - Rear LH Door Under the left "B" Pillar
X801 15 Colorless Body - Rear RH Door Under the right "B" Pillar
X901 18 Colorless Lift Gate - Lift Gate JPR Behind the "2nd" Seat
5) GROUND/ GROUND PACK INFORMATION
Ground/Ground Pack
Color Wiring Harness Ground Position
Number
GX101 Black/Gray Front Behind the left HeadLamp
Behind the Engine Fuse
G103 - Battery
Block
G105 - Battery On the Cylinder Block
GX106 Black/Gray Engine (DSL/HFV6) Upper the Cylinder Head
G107 - Fuel Injector (HFV6) On the Cylinder Block
G108 - Engine (FAM II) On the Cylinder Block
G111 - Engine (FAM II) On the Cylinder Block
G112 Black/Gray Engine (DSL) On the Cylinder Block
Behind Steering Column -
GX201 Black/Gray I/P
Lower
G202 - I/P On the I/P Fuse Block braket
Inside the left instrument
G203 - FATC
panel
G204 - Body Under the left "A" pillar
Ground/Ground Pack
Color Wiring Harness Ground Position
Number
GX301 Black/Gray Body Under the right seat cushion
Left the luggage
GX401 Black/Gray Body
compartment
Right the luggage
GX402 Black/Gray Body
compartment
6) SPLICE PACK INFORMATION
Splice Pack Number Color Wiring Harness Splice Pack Position
JX103 Black Engine (FAM II) Upper the cylinder Head
JX202 Black/Pink I/P Behind Steering Column - Lower
JX303 Black/Brown BODY Inside Front Rocker Panel-LH
JX305 Black BODY Inside Front Rocker Panel-RH
JX306 Black/Blue BODY Inside Front Rocker Panel-RH
2. WIRING HARNESS, CONNECTOR & GROUND LOCATION

1) W/H I/P
2) W/H BODY
3) W/H ENGINE
 2.4D GASOLINE
 2.0S DIESEL
 3.2D HFV-6
4) W/H FRONT
5) W/H FRONT DOOR
6) W/H REAR DOOR
7) W/H LIFT GATE
8) W/H AIR BAG
9) W/H CONSOLE
10) W/H ROOF
11) SPLICE PACK
SECTION 3
WIRING DIAGRAM FOR POWER SUPPLIES
1. IGNITION SWITCH CIRCUIT

1) BATTERY & IGN II CIRCUIT
2) IGN I/II & IGN II/III CIRCUIT
2. ENGINE FUSE BLOCK CIRCUIT
3. ENGINE FUSE BLOCK. AUX CIRCUIT
4. I/P FUSE BLOCK CIRCUIT
5. GROUND & GROUND PACK
SECTION 4
USAGE AND CAPACITY OF FUSES IN FUSE BOX

1. ENGINE ROOM RELAY AND FUSE BLOCK
1) POSITION OF RELAY AND FUSE
2) USAGE OF FUSE IN ENGINE FUSE BLOCK
Power Supply Fuse No. Capacity Usage
Ef1 20A REAR WIPER MOTOR
Ef2 60A I/P FUSE BLOCK(BATTERY MAIN)
I/P FUSE BLOCK(IGN II), BLOWER
Ef3 40A
MOTOR
Ef4 40A ABS MODULE
30 B(+) Ef5 20A STARTER RELAY
Ef6 30A LIFT GATE GLASS DEFOG
I/P FUSE BLOCK(ACC/RAP RELAY,
Ef7 40A
RUN/CRANK RELAY)
Ef8 30A COOLING FAN AUX.
Ef9 30A COOLING FAN MAIN.
Ef10 20A ECM
LD9 : CANISTER PURGE SOLENOID,
. .
LEGR VALVE, CMP SENSOR
LLW : THROTTLE PLATE ACTUATOR,
Ef11 15A BOOST PRESSURE ACTUATOR,
CMP SENSOR
LU1 : IGNITION COIL,
MAIN RELAY . .
INJECTOR(#2,4.6)
. . LD9 : FRT HO2S, REAR HO2S
Ef12 15A LLW : ECM
LU1 : HO2S, IMRC, CAMSHAFT
POSITION ACTUATOR,
. .
INTAKE/EXHAUST, CANISTER
PURGE SOLENOID
Ef13 10A STARTER RELAY, MAIN RELAY
30 B(+)
Ef14 10A A/C COMP. RELAY
LD9 : INJECTOR, COOLING FAN
. . (AUX., MAIN, CONTROL), A/C COMP.
RELAY
LLW : GLOW PLUG CONTROL UNIT,
COOLING FAN(AUX., MAIN,
Ef15 15A
MAIN RELAY CONTROL), A/C COMP RELAY,
ENGINE FUSE BLOCK AUX.
LU1 : IGNITION COIL,
INJECTOR(#1,3,5), COOLING
. .
FAN(AUX., MAIN, CONTROL), A/C
COMP. RELAY
Ef16 15A COUPLING CONTROL MODULE
Ef17 15A FUEL PUMP RELAY
30 B(+) Ef18 20A ABS MODULE, OIL FEEDING CONN.
Ef19 - NOT USED
Ef20 15A BRAKE SWITCH
Ef21 25A COOLING FAN CONTROL RELAY
.
Ef22 15A HORN RELAY
POWER SEAT & HEATING MAT
30 B(+) Ef23 30A
SWITCH POWER SEAT TEST CONN.
HEAD LAMP LH, TAIL LAMP LH,
PARK LAMP RELAY Ef24 15A TURN/PARK LAMP LH, LICENSE
LAMP
DEGOG RELAY Ef25 20A SUN ROOF MODULE
HEAD LAMP RH, MIRROR CONTROL
Ef26 15A
SWITCH
HEAD LAMP RELAY
Ef27 15A HEAD LAMP LH
Ef28 15A HEAD LAMP
30 B(+) Ef29 15A FRT FOG LAMP RELAY
DEGOG RELAY Ef30 10A HEAD LAMP. LH, TAIL LAMP. LH
PARK LAMP RELAY Ef31 10A HEAD LAMP. RH, TAIL LAMP. RH
Ef32 15A TCM
30 B(+)
Ef33 20A Head Lamp Washer
- Ef34 - Not Used
Ef35 20A Not Used
Ef36 25A Not Used
Spare
Ef37 10A Not Used
Ef38 15A Not Used
2. ENGINE FUSE BLOCK, AUX (ONLY DIESEL)

1) POSITION OF FUSE AND RELAY
2) USAGE OF FUSES IN I/P FUSE BLOCK
30 B(+) Af1 60A GLOW PLUG CONTROL UNIT
30 B(+) Af2 30A FUEL FILTER HEATER RELAY
30 B(+) Af3 40A PTC-1 RELAY
3. I/P FUSE BLOCK

1) POSITION OF FUSE
2) USAGE OF FUSES IN ISU
POWER WINDOW MAIN SWICH,
F1 20A
ACC/RAP RELAY SUNROOF MODULE
F2 20A POWER WINDOW MAIN SWICH
Ef2(60A) F3 10A FRT WASHER PUMP RELAY
. F4 - NOT USED
Ef2(60A) F5 10A SDM
RUN/CRANK RELAY F6 10A SDM
. F7 - NOT USED
Ef2(60A) F8 10A REAR FOG LAMP RELAY
REAR FOG LAMP RELAY, FUEL
RUN/CRANK RELAY F9 10A PUMP, FUEL TANK LEVEL SENSOR,
ECM MIRROR, CLUTCH SWITCH
ACC/RAP RELAY F10 10A AUDIO, CLOCK
Ef2(60A) F11 10A BCM
Ef2(60A) F12 2A IGNITION SWITCH, IMMOBILIZER.
CLUSTER, DRIVER INFORMATION
RUN/CRANK RELAY F13 10A CENTER, PASSENGER SEATBELT
INDICATOR
Ef2(60A) F14 15A BCM, XBCM
Ef3(40A) F15 10A SSPS MODULE
Ef2(60A) F17 15A OSRVM HEATING RELAY
MANUAL A/C CONT. , FATC, AQS
SENSOR, BLOWR HIGH RELAY,
Ef3(40A) F18 10A
PARK ASSIST MODULE, ENGINE
AUX. FUSE BLOCK(PTC RELAY)
Ef2(60A) F19 15A MANUAL A/C CONT. , FATC, DLC
Ef2(60A) F20 10A LIFT GATE GLASS RELAY
. F21 - NOT USED
. F22 - NOT USED
. F23 - NOT USED
RUN/CRANK RELAY F25 10A XBCM
RUN/CRANK RELAY F27 15A FRT FOG RELAY
CLUSTER, CLOCK, AUDIO, RFA
Ef2(60A) F28 15A RECEIVER, DRIVER INFORMATION
CENTER
RUN/CRANK RELAY F29 15A TCM
Ef3(40A) F30 20A HEATING MAT SWITCH
Ef2(60A) F32 20A EXTRA POWER JACK CARGO
ACC/RAP RELAY F33 20A CIGAR LIGHTER
Ef2(60A) F34 20A EXTRA POWER JACK CARGO
. F36 15A DOOR DEAD LACK RELAY
. F37 - NOT USED
Ef2(60A) F38 20A DOOR LOCK/UNLOCK RELAY
MIRROR CONTROL SWITCH,
ACC/RAP RELAY F39 10A
FOLDING MIRROR UNIT
SECTION 5
ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM

1) BATTERY, STARTER MOTOR, GENERATOR & NSBU SWITCH CIRCUIT : FAM II 2.4D
(LD9)
a. CONNECTOR INFORMATION
CONNECTOR NO CONNECTING WIRING
CONNECTOR POSITION
(PIN NO, COLOR) HARNESS
G103 Battery Behind the Engine Fuse Block
G105 Battery On the Cylinder Block
G108 Engine (FAM II) On the Cylinder Block
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
c. POSITION OF CONNECTORS AND GROUNDS
 W/H ENGINE (LD9)
2) BATTERY, STARTER MOTOR, GENERATOR & NSBU SWITCH CIRCUIT ; 2.0 DIESEL
(LLW)
CONNECTOR POSITION
GX106 (Black/Gray) Engine (DSL/HFV6) Upper the Cylinder Head
 W/H ENGINE (LLW)
3) BATTERY, STARTER MOTOR, GENERATOR & NSBU SWITCH CIRCUIT : HFV6 3.2
(LU1)
CONNECTOR POSITION
X106 (7 Pin, Black) Engine - Fuel Injector (HVF6) Upper the Cylinder Head

 W/H ENGINE (LUI)
4) IGNITION SWITCH CIRCUIT

CONNECTOR POSITION
X101 (36 Pin, Black) Engine - Body Behind the Engine Fuse Block
 W/H INSTRUMENT PANEL

d. SPLICE PACK
5) POWER MODE CIRCUIT

CONNECTOR POSITION
GX101 (Black/Gray) Front Behind the left HeadLamp
GX301 (Black/Gray) Body Under the right seat cushion
 W/H BODY
2. ECM (ENGINE CONTROL MODULE) : ME7.9.9 (FAM II 2.4D)

1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM, GENERATOR & CKP SENSOR
CIRCUIT
CONNECTOR POSITION

2) FUEL PUMP, INJECTOR & HEATED O2 SENSOR CIRCUIT
CONNECTOR POSITION
X304 (12 Pin, Black) Fuel Sender - Body Below the right "C" pillar
GX402 (Black/Gray) Body Right the luggage compartment
 W/H BODY
d. SPLICE PACK
3) ETC MODULE, SENSOR (MAP, ECT, KNOCK, ACP & ACCELERATOR PEDAL), OIL
PRESSURE SWITCH & LEGR CIRCUIT
CONNECTOR POSITION
X201 (92 Pin, Black) Body - I.P Below to the "A" pillar
CONNECTOR POSITION
d. SPLICE PACK
4) EVAP CANISTER PURGE SOLENOID, SENSOR (CMP, ACCELERATOR PEDAL, FUEL
LEVEL) & CLUTCH SWITCH CIRCUIT
CONNECTOR POSITION

d. SPLICE PACK
5) BRAKE SWITCH, BACK UP SWITCH, NSBU SWITCH CIRCUIT

CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
6) DLC (DATA LINK CONNECTOR) CIRCUIT
CONNECTOR POSITION
X203 (6 Pin, Colorless) I.P - Air Bag Below the floor console
X204 (16 Pin, Black) I.P - FATC Behind the FATC
CONNECTOR POSITION
GX201 (Black/Gray) I/P Behind Steering Column - Lower
 W/H BODY

d. SPLICE PACK
3. ECM (ENGINE CONTROL MODULE) : EDC16C39 (2.0 DIESEL)

1) BATTERY POWER SUPPLY, GROUND, GLOW PLUG CONTROL UNIT, FUEL HEATER,
GENERATOR & CKP SENSOR CIRCUIT
CONNECTOR POSITION
X103 (8 Pin, Black) Engine - Fuel Heater (DSL) Right side upper Cylinder
X104 (4 Pin, Black) Engine - Glow Plug (DSL) Left side upper Cylinder
CONNECTOR POSITION
G112 (Black/Gray) Engine (DSL) On the Cylinder Block

2) INJECTOR, FUEL PUMP SENSOR (EXHAUST GAS TEMPERATURE, FUEL
TEMPERATURE) CIRCUIT
CONNECTOR POSITION
Engine - Exhaust Gas Temp.
X105 (4 Pin, Black) Behind the Cylinder Head
Sensor (DSL)
CONNECTOR POSITION
G112 (Black/Gray) Engine (DSL) On the Cylinder Block
 W/H BODY
3) SENSOR (WIF, MAF/IAT, DPF PRESSURE, RAIL PRESSURE, ECT,ACP), SWITCH (OIL
PRESSURE), RAIL PRESSURE CONTROL VALVE & FUEL METERING UNIT CIRCUIT
CONNECTOR POSITION


4) SENSOR (ACCELERATOR PEDAL, BOOST PRESSURE, FUEL LEVEL,CMP),
ACTUATOR (THROTTLE PLATE, BOOST PRESSURE), CLUTCH SWITCH & EGR VALVE
CIRCUIT
CONNECTOR POSITION


5) BRAKE SWITCH, BACK UP SWITCH & NSBU SWITCH CIRCUIT
CONNECTOR POSITION

d. SPLICE PACK

CONNECTOR POSITION

 W/H BODY
d. SPLICE PACK
4. ECM (ENGINE CONTROL MODULE) : E77 (HFV6 3.2D)

1) BATTERY POWER SUPPLY, GROUND, GENERATOR & CKP SENSOR CIRCUIT
CONNECTOR POSITION
 W/H ENGINE (LU1)
 W/H INSTRUMENT PANNEL

2) INJECTOR & HEATED O2 SENSOR CIRCUIT
CONNECTOR POSITION
3) IGNITION COIL, BRAKE SWITCH CIRCUIT

CONNECTOR POSITION
G107 Fuel Injector (HFV6) On the Cylinder Block
d. SPLICE PACK
4) SENSOR (MAF/IAT, FUEL LEVEL), FUEL PUMP & SWITCH (CLUTCH, BACK UP,
NSBU) CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H INSTRUMENT PANNEL

5) INTAKE MANIFOLD RUNNING CONTROL (IMRC), CAMSHIFT POSITION ACTUATOR,
EVAP CANISTER PURGE SOLENOID & CMP SENSOR CIRCUIT
CONNECTOR POSITION
6) ETC MODULE, SENSOR (ECT, KNOCK, ACP & ACCELERATOR PEDAL) & BCM
CIRCUIT
CONNECTOR POSITION

d. SPLICE PACK
7) ENGINE OIL PRESSURE (EOP) SENSOR & ENGINE OIL LEVEL SWITCH CIRCUIT
CONNECTOR POSITION
 W/H BODY
CONNECTOR POSITION

 W/H BODY
d. SPLICE PACK
5. TCM (TRANSMISSION CONTROL MODULE)

1) POWER SUPPLY, GROUND, BRAKE SWITCH & SOLENOID VALVE CIRCUIT
CONNECTOR POSITION
GX401 (Black/Gray) Body Left the luggage compartment

 W/H BODY

d. SPLICE PACK
2) SENSOR (INPUT SPEED,OUTPUT SPEED), NSBU SWITCH & HIGH SPEED CAN
CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H BODY

d. SPLICE PACK
3) GEAR SHIFT LEVER, WINTER MODE SWITCH & CLUSTER CIRCUIT

CONNECTOR POSITION
d. SPLICE PACK
6. BCM (BODY CONTROL MODULE)

1) POWER SUPPLY, GROUND, IGNITION SWITCH CIRCUIT
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
2) POWER MODE, RAIN SENSOR & REAR WIPER SWITCH CIRCUIT
CONNECTOR POSITION
X401 (18 Pin, Colorless) Roof - Body Inside the left "C" pillar
 W/H BODY

 W/H ROOF
3) HEAD LAMP, ILLUMINATION, FRONT/REAR FOG, BRAKE SWITCH & DIMMER
CONTROL CIRCUIT
CONNECTOR POSITION
X301 (12 Pin, Colorless) Console - Body Below the floor console
 W/H BODY

d. SPLICE PACK
4) INTERIOR LAMP, BACK UP LAMP, GEAR SHIFT LEVEL, SWITCH(WINTER MODE,
CRUISE, HAZARD, TURN SIGNAL) CIRCUIT

 W/H BODY
5) FRONT WIPER, LIFT GATE WIPER, RAIN SENSOR & EVAP CORE TEMP. SENSOR
CIRCUIT
CONNECTOR POSITION
X402 (18 Pin, Colorless) Lift Gate - Body Behind the left "C" pillar
CONNECTOR POSITION
X901 (18 Pin, Colorless) Lift Gate - Lift Gate JPR Behind the "2nd" Seat
 W/H BODY
 W/H ROOF
 W/H LIFT GATE
6) DOOR LOCK/UNLOCK, HORN, DOOR LATCH, PARKING ASSIST & SWITCH (PARK
BRAKE, HOOD OPEN, DOOR LOCK) CIRCUIT
CONNECTOR POSITION
X102 (12 Pin, Black) Front JPR - Front Behind the left side Head Lamp
X501 (18 Pin, Gray) Body - Front LH Door Under the left "A" Pillar
 W/H BODY
 W/H FRONT DOOR

 W/H FRONT
d. SPLICE PACK
7) POWER WINDOW, LIFT GATE GLASS, COUPLING CONTROL MODULE, ESP SWITCH
& MANUAL A/C CONTROLLER CIRCUIT
CONNECTOR POSITION
X502 (18 Pin, Colorless) Body - Front LH Door Under the left "A" Pillar

 W/H BODY
 W/H FRONT DOOR
d. SPLICE PACK
7. AIR CONDITIONER
1) AIR CONDITIONER CONTROL SWITCH & BLOWER MOTOR CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
G203 FATC Inside the left instrument panel

2) INTAKE MOTOR, MODE MOTOR & EVAP CORE TEMP. SENSOR CIRCUIT
CONNECTOR POSITION
 W/H BODY

d. SPLICE PACK
8. FATC (FULL AUTOMATIC TEMPERATURE CONTROL)

1) MOTOR (BLOWER, INTAKE, MODE, TEMPERATURE) & POWER MODULE CIRCUIT
CONNECTOR POSITION
2) SENSOR (AQS, DUCT TEMP., EVAP CORE TEMP., INCAR, COMBI), ECM & BCM
CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT
 W/H BODY
d. SPLICE PACK
9. AIR CONDITIONER COMPRESSOR CIRCUIT

CONNECTOR POSITION
X106 (7 Pin, Black) Engine - Fuel Injector (HVF6) Upper the cylinder Head

10. RADIATOR COOLING FAN CIRCUIT
1) COOLING FAN CIRCUIT : FAM II 2.4D (LD9)
CONNECTOR POSITION
 W/H FRONT
2) COOLING FAN CIRCUIT : 2.0 DIESEL (LLW)
CONNECTOR POSITION
 W/H FRONT
3) COOLING FAN CIRCUIT : HFV6 3.2 (LU1)
CONNECTOR POSITION
 W/H FRONT
11. PTC-HEATER CIRCUIT : 2.0 DIESEL (LLW)
CONNECTOR POSITION

12. HEAD LAMP CIRCUIT
1) W/O HEAD LAMP LEVELING
CONNECTOR POSITION
 W/H BODY
 W/H FRONT
2) W/ HEAD LAMP LEVELING
CONNECTOR POSITION
 W/H BODY
 W/H FRONT
d. SPLICE PACK
13. HEAD LAMP SWITCH CIRCUIT

1) W/O AUTO LIGHT
CONNECTOR POSITION
 W/H BODY

d. SPLICE PACK
2) W/ AUTO LIGHT
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
14. ILLUMINATION CIRCUIT

1) ILLUMINATION, DIMMER CONTROL SWITCH & HEATING MAT SWITCH CIRCUIT
CONNECTOR POSITION

 W/H CONSOLE
d. SPLICE PACK
2) LAMP (LICENSE PLATE & FRONT/REAR PARKING) CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT
 W/H BODY
15. FRONT & REAR FOG LAMP CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT
d. SPLICE PACK
16. HAZARD & TURN SIGNAL LAMP CIRCUIT
CONNECTOR POSITION
X602 (18 Pin, Colorless) Body - Front RH Door Under the right "A" Pillar
CONNECTOR POSITION
 W/H BODY
 W/H FRONT
17. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL),
BACK UP LAMP & ECM MIRROR CIRCUIT
CONNECTOR POSITION
X901(18 Pin, Colorless) Lift Gate - Lift Gate JPR Behind the "2nd" Seat
CONNECTOR POSITION
 W/H BODY
 W/H ROOF
d. SPLICE PACK
18. INTERIOR LAMP CIRCUIT
1) LAMPS (MAP, ROOM, DOOR STEP, SUNVISOR, LUGGAGE, GLOVE BOX, KEY HOLE)
CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H BODY
 W/H ROOF
 W/H FRONT DOOR
d. SPLICE PACK
19. WIPER CIRCUIT

1) FRONT WIPER CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H BODY
 W/H FRONT
 W/H ROOF
2) LIFT GATE WIPER CIRCUIT & HEAD LAMP WASHER CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H LIFT GATE

 W/H FRONT
20. FRONT/REAR WINDOW DEFROSTER & OSRV MIRROR
HEATING SYSTEM CIRCUIT
CONNECTOR POSITION
Below to the "A" pillarX204 (16
X201 (92 Pin, Black) Body - I.P
Pin, Black)
CONNECTOR POSITION
 W/H BODY
 W/H FRONT DOOR

 W/H LIFT GATE
21. ELECTRIC OSRV (OUTSIDE REAR VIEW) MIRROR & FOLDING
MIRROR CIRCUIT
CONNECTOR POSITION
Pin, Black)
CONNECTOR POSITION
 W/H BODY

 W/H FRONT DOOR
d. SPLICE PACK
22. POWER WINDOW CIRCUIT

CONNECTOR POSITION
X601 (18 Pin, Gray) Body - Front RH Door Under the right "A" Pillar
X701 (15 Pin, Colorless) Body - Rear LH Door Under the left "B" Pillar
CONNECTOR POSITION
X801 (15 Pin, Colorless) Body - Rear RH Door Under the right "B" Pillar
 W/H FRONT DOOR
 W/H BODY
 W/H REAR DOOR
d. SPLICE PACK
23. LIFT GATE GLASS CIRCUIT

CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT DOOR
 W/H REAR DOOR

 W/H LIFT GATE
24. HORN, EXTRA POWER JACK & CIGAR LIGHTER CIRCUIT
CONNECTOR POSITION
Pin, Colorless)
CONNECTOR POSITION
 W/H FRONT
 W/H BODY
 W/H CONSOLE
25. DRIVER INFORMATION CENTER & CLOCK CIRCUIT
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
26. DOOR LOCKING SYSTEM CIRCUIT

1) ACTUATOR CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT DOOR
 W/H REAR DOOR

d. SPLICE PACK
2) LATCH CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT
 W/H FRONT DOOR

 W/H REAR DOOR
d. SPLICE PACK
3) DEAD LOCK CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT DOOR
 W/H REAR DOOR

d. SPLICE PACK
26. DOOR LOCKING SYSTEM CIRCUIT
1) ACTUATOR CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT DOOR
 W/H REAR DOOR

d. SPLICE PACK
2) LATCH CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT
 W/H FRONT DOOR

 W/H REAR DOOR
d. SPLICE PACK
3) DEAD LOCK CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT DOOR
 W/H REAR DOOR

d. SPLICE PACK
28. CLUSTER
1) TEMPERATURE GAUGE, TACHOMETER, FUEL GAUGE, ODDOMETER,
SPEEDOMETER, PASSENGER SEATBELT INDICATOR & SINGLE WIRE CAN CIRCUIT
CONNECTOR POSITION
 W/H AIR BAG

d. SPLICE PACK
2) WARNING (COOL TEMP., LOW FUEL, CHARGE, OIL, SERVICE VEHICLE) LAMP,
INDICATOR (CRUISE ACTIVE, GLOW PLUG, WINTER MODE TRAILER) & OAT SENSOR
CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H FRONT
d. SPLICE PACK
3) WARNING (SEAT BELT, LOW WASH FLUID, WATER IN FUEL, AWD, PARKING
BRAKE) LAMP, INDICATOR (ESC OFF, FRONT/REAR FOG) LAMP CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
4) WARNING (ABS, ESC ACTIVE&FAULT, ENGINE CHECK, AIR BAG CHANGE OIL)
LAMP, INDICATOR (ESC NOT READY, DCS, DISEEL FILTER) LAMP CIRCUIT
CONNECTOR POSITION
d. SPLICE PACK
5) WARNING (SSPS, PARKING ASSIST) LAMP, INDICATOR (HIGH BEAM,,LEFT TURN,
RIGHT TURN, DOOR OPEN, LIFT GATE OPEN) LAMP & ILLUMINATION CIRCUIT
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
29. AUDIO CIRCUIT

1) POWER SUPPLY, GROUND, REMOTE CONTROL SWITCH, ANTENNA MODULE
CIRCUIT
CONNECTOR POSITION
G202 I/P On the I/P Fuse block Braket
d. SPLICE PACK
2) FRONT/REAR SPEAKER & TWEETER CIRCUIT
CONNECTOR POSITION
CONNECTOR POSITION
 W/H BODY
 W/H FRONT DOOR

 W/H REAR DOOR
30. ABS (ANTILOCK BRAKE SYSTEM)
1) POWER SUPPLY, OIL FEEDING CONNECTOR, ESC SWITCH, BCM & HIGH SPEED
CAN CIRCUIT
CONNECTOR POSITION
G204 Body Under the left "A" pillar
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
2) SENSOR (WHEEL SPEED, STEERING ANGLE, YAW), DECENT CONTROL SYSTEM
SWITCH & SSPS MODULE CIRCUIT
CONNECTOR POSITION
X305 (4 Pin, Black) Body - Rear Wheel Speed Sensor Behind the "2nd" Seat
CONNECTOR POSITION
 W/H BODY

d. SPLICE PACK
31. AIR BAG (SDM: SENSING & DIAGNOSTIC MODULE) CIRCUIT
1) POWER SUPPLY, DRIVER/PASSENGER AIR BAG MODULE, SEATBELT SWITCH,
SEATBELT REMINDER SENSOR & CLUSTER CIRCUIT
CONNECTOR POSITION
 W/H AIR BAG

d. SPLICE PACK
2) SIDE AIR BAG MODULE, SEATBELT PRETENSIONER, CURTAIN AIR BAG MODULE &
SIDE IMPACT SENSOR CIRCUIT
CONNECTOR POSITION
X302 (2 Pin, Yellow) Body - Air Bag Inside left "B" Pillar
X303 (2 Pin, Yellow) Body - Air Bag Inside right "B" Pillar
 W/H BODY
 W/H AIR BAG
32. SUN ROOF CIRCUIT
CONNECTOR POSITION
 W/H BODY
 W/H ROOF
33. SSPS (SPEED SENSITIVE POWER STEERING) CIRCUIT
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
34. PARKING ASSIST MODULE CIRCUIT

CONNECTOR POSITION
Body - Rear Objective Alarm
X405 (6 Pin, Black) Behind the right Tail Lamp
Sensor
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
35. COUPLING CONTROL MODULE CIRCUIT
CONNECTOR POSITION
 W/H BODY
36. CRUISE CONTROL SYSTEM CIRCUIT
CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
37. RKE & IMMOBILIZER SYSTEM CIRCUIT

CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
38. POWER SEAT SYSTEM CIRCUIT

CONNECTOR POSITION
 W/H BODY
d. SPLICE PACK
39. HEATING MAT CIRCUIT
CONNECTOR POSITION
 W/H CONSOLE
 W/H BODY
40. TRAILER SYSTEM CIRCUIT
1) V92
CONNECTOR POSITION
X201 (96 Pin, Black) Body - I.P Below to the "A" Pillar
 W/H BODY
d. SPLICE PACK
2) V2S
CONNECTOR POSITION
X201 (96 Pin, Black) Body - I.P Below to the "A" Pillar
 W/H BODY
d. SPLICE PACK
41. GMLAN CIRCUIT
1) HIGH SPEED CAN CIRCUIT : AWD
CONNECTOR POSITION
 W/H BODY
2) HIGH SPEED CAN CIRCUIT : FWD
CONNECTOR POSITION
 W/H BODY
3) SINGLE WIRE CAN CIRCUIT
CONNECTOR POSITION
 W/H AIR BAG

d. SPLICE PACK
ECTION 1C
ENGINE (DOHC ENGINE MECHANICAL)
DOHC ENGINE MECH. - DOHC ENGINE UNIT (111)

OPERATION C
NO. OPERATION DESCRIPTION
CODE 2.4D 3.2D .
1 . ENGINE ASSEMBLY (M/T) - OVERHAUL 1110100 12.0 11.5 .
OPERATION C
CODE 2.4D 3.2D .
INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold
. . . .
ass'y, Timing belt, Engine adjust.
C - With transfer case 111010C 0.4 0.4 .
. ENGINE ASSEMBLY (A/T) - OVERHAUL 1110300 11.9 11.4 .
INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold
. . . .
ass'y, Timing belt, Engine adjust.
2 . ENGINE ASSEMBLY (M/T) - REPLACE 1110800 8.9 7.8 .
INC : R & I Engine ass'y, Intake and exhaust manifold ass'y, Engine
. . . .
adjust.
. ENGINE ASSEMBLY (A/T) - REPLACE 1110900 8.8 7.7 .
INC : R & I Engine ass'y, Intake and exhaust manifold ass'y, Engine
. . . .
adjust.
C: C-100 / C105
DOHC ENGINE MECH. - BELT SYSTEM (113)
OPERATION C
CODE 2.4D 3.2D .
1 . BELT, ACCESSORY - REPLACE 1132200 0.4 1.0 .
2 . IDLE, ACCESSORY BELT - REPLACE 1132300 — 1.2 .
3 . AUTO TENSIONER, ACCESSORY BELT - REPLACE 1132400 0.5 1.0 .
C: C-100 / C105
DOHC ENGINE MECH. - ENGINE BLOCK (121)
OPERATION C
CODE 2.4D 3.2D .
1 . OIL LEVEL INDICATOR - REPLACE 1210200 0.2 0.2 .
2 . TUBE, OIL LEVEL INDICATOR - REPLACE 1210300 0.3 0.3 .
3 . PLUG, CYLINDER BLOCK - REPLACE 1210600 — 0.9 .
OPERATION C
CODE 2.4D 3.2D .
4 . PLUG, EXPANSION - REPLACE 1210700 0.4 — .
NOTE : Add appropriate labor MODEL(s) for removal if necessary
. . . .
components to gain access to plug to regular labor hours column
5 . PLUG, OIL GALLERY - REPLACE 1210900 1.8 — .
6 . BLOCK, CYLINDER - REPLACE 1211100 12.9 12.4 .
INC : Overhaul Engine ass'y, R & I Crankshaft, Piston . . . .
C: C-100 / C105
DOHC ENGINE MECH. - CRANKSHAFT & PISTON (122)
OPERATION C
CODE 2.4D 3.2D .
1 . SEAL(S), CRANKSHAFT REAR MAIN (AUTO TRANSAXLE) -
1220200 4.4 9.1 .
REPLACE
. SEAL(S), CRANKSHAFT REAR MAIN (MANUAL TRANSAXLE) -
1220400 4.0 9.0 .
REPLACE
OPERATION C
CODE 2.4D 3.2D .
INC : R & I Flywheel . . . .
2 . BEARING, CRANKSHAFT MAIN (ONE) - REPLACE 1220600 12.7 11.0 .
INC : R & I Engine ass'y, Flywheel, Crankshaft balance unit, Engine
. . . .
adjust.
A - Replace each additional 122060A 0.1 0.1 .
E - With transfer case 122060E 0.4 0.4 .
3 . BEARING, CONNECTING ROD (ONE) - REPLACE 1220800 5.2 — .
INC : R & I Cylinder head, Crankshaft balance unit . . . .
A - Replace each additional 122080A 0.2 — .
B - Replace all 122080B 0.6 — .
4 . BEARING, BANK 1 CONNECTING ROD (ONE) - REPLACE 1220900 — 9.2 .
INC : R & I Cylinder head, Oil pan . . . .
A - Replace each Additional 122090A — 0.2 .
B - Replace all 122090B — 0.5 .
5 . BEARING, BANK 2 CONNECTING ROD (ONE) - REPLACE 1220910 — 9.3 .
A - Replace each additional 122091A — 0.2 .
B - Replace all 122091B — 0.5 .
6 . CRANKSHAFT (M/T) - REPLACE 1221100 12.7 11.0 .
INC : R & I Engine ass'y, Cylinder head ass'y, Flywheel, Crankshaft
. . . .
balance unit, Engine adjust.
D - Replace one piston rings 122110D 0.1 0.1 .
E - Replace all piston rings 122110E 0.4 0.6 .
F - Replace one connecting rod 122110F 0.3 0.1 .
G - Replace all connecting rods 122110G 1.2 0.6 .
H - Replace one piston 122110H 0.3 0.1 .
J - Replace all pistons 122110J 1.2 0.6 .
K - With transfer case 122110K 0.4 0.4 .
C: C-100 / C105
DOHC ENGINE MECH. - CRANKSHAFT & PISTON (122)
OPERATION C
CODE 2.4D 3.2D .
6 . CRANKSHAFT (A/T) - REPLACE 1221200 12.4 10.9 .
INC : R & I Engine ass'y, Cylinder head ass'y, Flywheel, Crankshaft
. . . .
balance unit, Engine adjust.
D - Replace one piston rings 122120D 0.1 0.1 .
OPERATION C
CODE 2.4D 3.2D .
E - Replace all piston rings 122120E 0.4 0.6 .
F - Replace one connecting rod 122120F 0.3 0.1 .
G - Replace all connecting rods 122120G 1.2 0.6 .
H - Replace one piston 122120H 0.3 0.1 .
J - Replace all pistons 122120J 1.2 0.6 .
K - With transfer case 122120K 0.4 0.4 .
7 . CRANKSHAFT TARGET WHEEL - REPLACE 1221300 12.5 11.1 .
A - With manual transaxle 122130A 0.3 0.1 .
8 . UNIT, CRANKSHAFT BALANCE - REPLACE 1221400 1.6 — .
9 . PISTON, ROD AND/OR RINGS (ONE) - REPLACE 1221500 5.5 — .
INC : R & I Cylinder head, Crankshaft balance unit, Engine adjust. . . . .
C - Replace each additional 122150C 0.4 — .
D - Replace all 122150D 1.2 — .
10 . BANK 1 PISTON, ROD AND/OR RINGS (ONE) - REPLACE 1221600 — 9.8 .
B - Replace all 122160B — 0.5 .
11 . BANK 2 PISTON, ROD AND/OR RINGS (ONE) - REPLACE 1221610 — 10.0 .
B - Replace all 122161B — 0.5 .
12 . FLYWHEEL (MANUAL T/M) - REPLACE 1221700 3.9 3.9 .
INC : R & I Transaxle ass'y, Clutch cover ass'y . . . .
13 . FLYWHEEL (AUTO T/M) - REPLACE 1221900 4.4 4.4 .
C: C-100 / C105
DOHC ENGINE MECH. - OIL PAN & PUMP (123)
OPERATION C
CODE 2.4D 3.2D .
1 . FILTER, OIL - REPLACE 1231100 0.4 0.4 .
2 . ADAPTER, OIL FILTER - REPLACE 1231200 — 0.6 .
3 . PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE 1231300 0.3 0.3 .
4 . PAN AND/OR GASKET, OIL - REPLACE 1231500 1.2 8.9 .
OPERATION C
CODE 2.4D 3.2D .
INC : Front exhaust pipe ass'y, Drive axle intermshaft . . . .
5 . PUMP, ENGINE OIL - REPLACE 1231700 3.0 6.9 .
INC : R & I Timing belt, Oil pan, Engine adjust . . . .
. SENSOR, FUEL SWITCH & ENGINE OIL PRESSURE GAGE -
6 1231900 0.3 0.3 .
REPLACE
7 . SENSOR, ENGINE OIL LEVEL - REPLACE 1231910 — 0.3 .
8 . TUBE, OIL SUCTION - REPLACE 1232100 1.3 9.0 .
9 . OIL SEAL, CRANKSHAFT (FRONT) - REPLACE 1232300 1.2 0.6 .
10 . VALVE, OIL PRESSURE RELIEF - REPLACE 1232700 1.6 6.9 .
11 . GASKET, OIL PUMP - REPLACE 1232900 3.0 6.9 .
12 . PIPE AND/OR GASKET, INTERNAL PCV - REPLACE 1233100 0.9 — .
C: C-100 / C105
DOHC ENGINE MECH. - CYLINDER HEAD (131)
OPERATION C
CODE 2.4D 3.2D .
1 . FOLLOWER, CAM (ONE CYLINDER) - REPLACE 1312100 — 7.1 .
A - Cam follower (Each additional) 131210A — 0.1 .
B - Cam followers (All) 131210B — 0.2 .
2 . GASKET, CYLINDER HEAD - REPLACE 1312300 3.0 7.2 .
OPERATION C
CODE 2.4D 3.2D .
INC : R & I Cylinder head ass'y, Engine adjust. . . . .
3 . HEAD, CYLINDER - REPLACE 1312500 3.9 — .
INC : R & I Intake & exhaust manifold, Engine adjust. . . . .
. HEAD, CYLINDER - OVERHAUL 1312600 5.1 — .
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Valves,
. . . .
Engine adjust.
4 . HEAD, BANK 1 CYLINDER - REPLACE 1312610 — 7.4 .
. HEAD, BANK 1 CYLINDER - OVERHAUL 1312620 — 8.2 .
. . . .
Engine adjust.
5 . HEAD, BANK 2 CYLINDER - REPLACE 1312640 — 7.6 .
. HEAD, BANK 2 CYLINDER - OVERHAUL 1312650 — 8.4 .
. . . .
Engine adjust.
6 . VALVE (ONE CYLINDER) - REPLACE 1312700 4.4 — .
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Camshaft,
. . . .
Valves recondition, Engine adjust.
C - One cylinder valve (Each additional) 131270C 0.3 — .
D - Valves (All) 131270D 0.7 — .
7 . VALVE, BANK 1 (ONE CYLINDER) - REPLACE 1312710 — 7.7 .
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Camshaft,
. . . .
Valves recondition, Engine adjust.
C - One cylinder valve (Each additional) 131271C — 0.2 .
D - Valves (All) 131271D — 0.5 .
C: C-100 / C105
DOHC ENGINE MECH. - CYLINDER HEAD (131)
OPERATION OPERATION C
NO.
DESCRIPTION CODE 2.4D 3.2D .
8 . VALVE, BANK 2 (ONE
1312720 — 7.9 .
CYLINDER) - REPLACE
INC : R & I Cylinder head
. . . .
ass'y, Intake & exhaust
OPERATION OPERATION C
NO.
DESCRIPTION CODE 2.4D 3.2D .
manifold, Camshaft, Valves
recondition, Engine adjust.
C - One cylinder valve (Each
131272C — 0.2 .
additional)
D - Valves (All) 131272D — 0.5 .
9 . SPRING CAP AND/OR
SEAL, VALVE (ONE 1312900 4.4 7.1 .
CYLINDER) - REPLACE
INC : R & I Camshaft,
. . . .
Engine adjust.
C - One cylinder valve spring
131290C 0.3 0.2 .
(Each additional)
D - Springs (All) 131290D 0.7 0.5 .
. ADJUSTER, VALVE -
10 REPLACE (ONE 1313100 — 7.1 .
CYLINDER)
A - Valve adjuster (Each additional) 131310A — 0.1 .
B - Valve adjusters (All) 131310B — 0.2 .
11 . LIFTER, VALVE (ONE
1313800 4.2 — .
CYLINDER) - REPLACE
C - One cylinder valve lifter
131380C 0.1 — .
(Each additional)
D - Lifters (All) 131380D 0.2 — .
. SENSOR, ENGINE
12 COOLANT TEMP - 1314100 0.2 0.3 .
REPLACE
C: C-100 / C105
DOHC ENGINE MECH. - CAM SUPPORT & SHAFT (132)
OPERATION C
CODE 2.4D 3.2D .
1 . COVER AND/OR GASKET, CAMSHAFT HOUSING (ONE PIECE) -
1322100 0.4 0.8 .
REPLACE
B - Replace all 132210B — 0.4 .
2 . CAMSHAFT, EXHAUST/INTAKE - REPLACE 1322400 1.9 7.1 .
OPERATION C
CODE 2.4D 3.2D .
INC : R & I Camshaft gear, Ignition timing adjust. . . . .
3 . CAP, OIL FILLER - REPLACE 1322700 0.2 0.2 .
4 . COVER, CAMSHAFT UPPER - REPLACE 1322800 0.2 0.2 .
5 . OIL SEAL, CAMSHAFT - REPLACE 1323000 1.4 7.1 .
C: C-100 / C105
DOHC ENGINE MECH. - TIMING COVER (133)
OPERATION C
CODE 2.4D 3.2D .
1 . PULLEY, CRANKSHAFT - REPLACE 1332100 0.5 0.5 .
2 . COVER AND/OR GASKET, TIMING - REPLACE 1332200 — 6.6 .
3 . COVER TIMING BELT REAR - REPLACE 1332300 1.8 — .
4 . BELT, TIMING - REPLACE 1332500 1.1 — .
. BELT, TIMING - ADJUST 1332700 1.1 — .
5 . TENSIONER, TIMING BELT - REPLACE 1332900 1.1 — .
INC : R & I Timing belt, Engine adjust. . . . .
6 . SPROCKET, CRANKSHAFT TIMING - REPLACE 1333100 1.1 6.9 .
7 . SPROCKET, CAMSHAFT TIMING - REPLACE 1333300 1.4 — .
8 . PUMP AND/OR GASKET, COOLANT - REPLACE 1333500 1.8 1.3 .
9 . PULLEY, COOLANT PUMP - REPLACE 1333600 — 1.1 .
10 . SENSOR, CRANKSHAFT POSITION - REPLACE 1333700 1.3 0.5 .
A - With Transfer Case 133370A 1.3 1.4 .
11 . SENSOR, CAMSHAFT POSITION - REPLACE 1333800 1.1 0.4 .
. SOLENOID, BANK 1 CAMSHAFT POSITION ACTUATOR -
12 1333810 — 0.3 .
REPLACE
. SOLENOID, BANK 2 CAMSHAFT POSITION ACTUATOR -
13 1333820 — 0.9 .
REPLACE
14 . PULLEY, IDLER - REPLACE 1333900 1.1 — .
15 . COVER, TIMING BELT FRONT - REPLACE 1334800 1.0 — .
16 . CHAIN, BANK 1 SECONDALY TIMING - REPLACE 1335100 — 6.7 .
17 . CHAIN, BANK 2 SECONDALY TIMING - REPLACE 1335200 — 7.0 .
C: C-100 / C105
DOHC ENGINE MECH. - TIMING COVER (133)
OPERATION C
CODE 2.4D 3.2D .
18 . CHAIN, PRIMALY TIMING - REPLACE 1335300 — 6.9 .
. TENSIONER AND/OR GASKET, SECONDALY TIMING CHAIN -
19 1335400 — 6.7 .
REPLACE
OPERATION C
CODE 2.4D 3.2D .
. TENSIONER AND/OR GASKET, PLIMALY TIMING CHAIN -
20 1335500 — 6.7 .
REPLACE
21 . GUIDE, SECONDALY TIMING CHAIN - REPLACE 1335600 — 6.7 .
22 . GUIDE, SECONDALY TIMING CHAIN INNER - REPLACE 1335700 — 6.7 .
23 . GUIDE, PLIMALY TIMING CHAIN UPPER - REPLACE 1335800 — 6.7 .
24 . SPROCKET, BANK 1 CAMSHAFT TIMING - REPLACE 1335900 — 6.8 .
25 . SPROCKET, BANK 2 CAMSHAFT TIMING - REPLACE 1336100 — 6.8 .
26 . SPROCKET, BANK 1 CAMSHAFT IDLER - REPLACE 1336200 — 6.9 .
27 . SPROCKET, BANK 2 CAMSHAFT IDLER - REPLACE 1336300 — 7.0 .
C: C-100 / C105
DOHC ENGINE MECH. - ENGINE & TRANSAXLE MOUNT (138)
OPERATION C
CODE 2.4D 3.2D .
1 . MOUNT, ENGINE (RH-FRONT) - REPLACE 1380100 0.8 0.8 .
OPERATION C
CODE 2.4D 3.2D .
2 . BRACKET, ENGINE MOUNT (RH-FRONT) - REPLACE 1380300 1.8 1.0 .
3 . MOUNT, TRANSAXLE (LH-FRONT) - REPLACE 1380500 1.3 1.3 .
4 . MOUNT, TRANSAXLE (CENTER-REAR) - REPLACE 1380700 0.5 0.5 .
5 . BRACKET, TRANSAXLE MOUNT - REPLACE 1380900 0.5 0.5 .
6 . MOUNT, TRANSAXLE (CENTER-FRONT) - REPLACE 1381200 0.6 0.6 .
7 . SHIELD, SPLASH - REPLACE . . . .
Right 1382100 0.2 0.2 .
Left 1382200 0.2 0.2 .
Both 1382400 0.3 0.3 .
8 . COVER, ENGINE LOWER - REPLACE 1382800 0.3 0.3 .
C: C-100 / C105
SECTION 1D
ENGINE (ENGINE COOLING)

ENGINE COOLING - RADIATOR (141)
OPERATION C
CODE 2.0DSL 2.4D 3.2D
1 . COCK OR PLUG, RADIATOR DRAIN - REPLACE 1410300 0.6 0.6 0.6
2 . RADIATOR ASSEMBLY - REPLACE 1410500 2.6 1.4 1.4
A - With automatic transaxle 141050A 2.7 1.5 1.5
3 . COOLING SYSTEM - FLUSH 1411700 0.8 0.8 0.8
4 . INTER COOLER ASSEMBLY - REPLACE 1411800 1.6 — —
C : C-100
ENGINE COOLING - COOLING FAN (143)
OPERATION C
1 . SUPPORT, RADIATOR (UPPER) - REPLACE 1430300 0.4 0.4 0.4
2 . DEFLECTOR AND/OR SEAL, RADIATOR (LOWER) - REPLACE 1430500 0.6 0.6 0.6
3 . SHROUD, RADIATOR FAN (ONE PIECE) - REPLACE 1430700 1.1 0.4 0.8
OPERATION C
4 . MOTOR AND/OR BLADE, ELECTRIC COOLING FAN -
. . . .
REPLACE
Right 1431100 1.1 0.4 0.8
Left 1431200 1.1 0.4 0.8
Both 1431300 1.2 0.5 0.9
C : C-100
ENGINE COOLING - RADIATOR HOSE & PIPE (145)
OPERATION C
1 . TUBE, OVERFLOW - REPLACE 1450300 0.4 0.2 0.2
2 . RESERVOIR, RADIATOR COOLANT - REPLACE 1450400 0.4 0.4 0.4
3 . CLAMP, RADIATOR HOSE - REPLACE 1450500 0.8 0.8 0.8
A - Replace each additional 145050A 0.1 0.1 0.1
4 . HOSE, UPPER ENGINE COOLANT - REPLACE 1450700 0.6 0.6 0.6
. HOSE, LOWER ENGINE COOLANT - REPLACE 1450800 0.8 0.8 0.8
. HOSE, BOTH ENGINE COOLANT - REPLACE 1450900 1.0 1.0 1.0
5 . HOSE, COOLANT (PIPE TO PUMP) - REPLACE 1451100 0.9 0.7 0.7
. HOSE, COOLANT (PIPE TO RESERVOIR) - REPLACE 1451200 0.5 0.4 0.3
. HOSE, COOLANT (THERMOSTAT TO RESERVOIR) - REPLACE 1451300 0.4 — —
. HOSE, THERMOSTAT BY - PASS - REPLACE 1451400 1.7 — —
. HOSE, COOLANT (WATER PUMP TO RESERVOIR) - REPLACE 1451600 — — 0.3
. HOSE, RADIATOR BY-PASS - REPLACE 1451900 — 0.7 —
6 . PIPE, COOLANT - REPLACE 1452100 0.9 0.9 0.6
. PIPE, COOLANT (THERMOSTAT OT RESERVOIR) - REPLACE 1452200 0.4 — —
. PIPE, COOLANT (WATER PUMP TO RESERVOIR) - REPLACE 1452300 — — 0.4
. PIPE AND/OR SEAL, COOLANT (HOSE TO PUMP) - REPLACE 1452400 2.8 — 0.4
7 . HOSES, INLET HEATER - REPLACE 1453100 0.5 0.5 0.5
. HOSES, OUTLET HEATER - REPLACE 1453200 0.5 0.5 0.5
. HOSES, ALL HEATER - REPLACE 1453300 0.6 0.6 0.6
8 . CAP, RADIATOR - REPLACE 1454100 0.2 0.2 0.2
9 . DISTRIBUTOR, WATER - REPLACE 1454500 — 0.5 —
10 . HOSE, HEATER, FDG - REPLACE 1454600 — 0.2 —
11 . HOSE, THROTTLE BODY - REPLACE 1454700 — 0.4 —
C : C-100
ENGINE COOLING - THERMOSTAT (148)
OPERATION C100/C105
1 . THERMOSTAT, OUTLET AND/OR GASKET - REPLACE . . . .
SOHC 1480300 0.4 - -
DOHC 1480500 - 0.4 0.4
2 . HOUSING, THERMOSTAT - REPLACE . . . .
OPERATION C100/C105
SOHC 1480700 0.4 - -
DOHC 1480900 - 0.4 0.4
C : C-100
SECTION 1E
ENGINE (ENGINE ELECTRICAL)

ENGINE ELECTRICAL - IGNITION CABLE (151)
OPERATION C
1 . WIRES, SPARK PLUG - REPLACE (ONE OR TWO) 1510200 — 0.2 —
. WIRES, SPARK PLUG - REPLACE (ALL) 1510500 — 0.3 —
2 . PLUGS, GLOW - REPLACE (ONE OR TWO) 1510600 0.8 — —
. PLUGS, GLOW - REPLACE (ALL) 1510700 1.0 — —
3 . PLUGS, SPARK - REPLACE (ONE OR TWO) 1510900 — 0.3 0.2
. PLUGS, SPARK - REPLACE (ALL) 1511200 — 0.4 0.6
4 . COIL, ELECTRONIC IGNITION CONTROL - REPLACE 1511400 — 0.4 0.6
5 . WIRING, GLOW PLUG - REPLACE 1511500 0.8 — —
C : C-100
ENGINE ELECTRICAL - ALTERNATOR UNIT (154)
OPERATION C
1 . PULLEY AND/OR FAN, ALTERNATOR - REPLACE 1540200 1.6 0.8 1.3
2 . BEARING, REAR ALTERNATOR - REPLACE 1540600 2.0 1.2 1.7
3 . RECTIFIER, ALTERNATOR - TEST AND REPLACE 1541400 2.3 1.5 2.0
4 . ALTERNATOR ASSEMBLY - REPLACE 1541800 1.5 0.7 1.2
OPERATION C
5 . STATOR, ALTERNATOR - REPLACE 1542200 2.1 1.3 1.8
6 . FRAME & BEARING - REPLACE 1542400 1.9 1.1 1.6
7 . REGULATOR, ALTERNATOR - REPLACE 1542700 2.3 1.5 2.0
8 . BRACKET, ALTERNATOR MOUNTING - REPLACE 1544200 2.8 0.7 —
9 . SHACKLE, ALTERNATOR - REPLACE 1544600 — 0.4 —
10 . SUPPORT, ALTERNATOR - REPLACE 1544700 — 0.4 —
C : C-100
ENGINE ELECTRICAL - STARTER (156)
OPERATION C
1 . SOLENOID, STARTER MOTOR - REPLACE 1560200 0.8 1.0 0.8
2 . DRIVE ASSEMBLY, STARTER MOTOR - REPLACE 1560500 0.6 0.8 0.6
3 . MOTOR ASSEMBLY, STARTER - REPLACE 1560900 0.5 0.7 0.5
C : C-100
ENGINE ELECTRICAL - BATTERY (157)
OPERATION C
1 . BATTERY . . . .
Charge and Test 1570200 0.3 0.3 0.3
Replace 1570300 0.3 0.3 0.3
2 . RETAINER AND/OR BOLTS, BATTERY - REPLACE 1570500 0.2 0.2 0.2
3 . COVER, BATTERY TERMINAL (ONE OR TWO) - REPLACE 1570900 0.2 0.2 0.2
4 . TRAY, BATTERY - REPLACE 1571200 0.7 0.7 0.7
OPERATION C
5 . SHIELD, BATTERY HEAT - REPLACE 1571300 0.3 0.3 0.3
C : C-100
ENGINE ELECTRICAL - FUSE & RELAY (158)

OPERATION C
1 . RELAY - REPLACE 1581600 0.2 0.2 0.2
2 . COVER, FUSE BLOCK - REPLACE 1582300 0.2 0.2 0.2
3 . BOX, RELAY & FUSE - REPLACE 1582700 0.4 0.4 0.4
4 . FUSE - REPLACE 1583700 0.2 0.2 0.2
5 . BOX, INSTRUMENT PANEL RELAY & FUSE - REPLACE 1584900 0.5 0.5 0.5
6 . BOX, AUXILIARY RELAY & FUSE - REPLACE 1585100 0.6 — —
C : C-100
SECTION 1F
ENGINE (ENGINE CONTROLS)

ENGINE CONTROLS - FUEL TANK (171)
OPERATION C
1 PUMP, FUEL AND/OR GAGE, O-RING (IN TANK) - REPLACE 1710300 0.6 0.6 0.6
PUMP, SUB FUEL AND/OR GAGE, O-RING (IN TANK) -
2 1710400 0.5 0.5 0.5
REPLACE
3 HOSES, FUEL TANK FILLER NECK VENT - REPLACE 1710700 0.9 0.9 0.9
OPERATION C
4 TANK, FUEL - REPLACE 1710900 1.2 1.2 1.2
A - With rear drive module 171090A 1.5 1.5 1.5
5 RING, FUEL PUMP - REPLACE 1711100 0.5 0.5 0.5
A - To replace sub fuel pump ring 171110A 0.1 0.1 0.1
6 SENDER, FUEL - REPLACE 1711700 0.6 0.6 0.6
A - To replace sub fuel sender 171170A 0.1 0.1 0.1
ENGINE CONTROLS - FUEL LINE (172)
OPERATION C
. FUEL SYSTEM - CLEAN AND FLUSH 1720100 1.2 1.2 1.2
1 LOCKER AND/OR SEAL, FUEL ELEMENT FILTER - REPLACE 1720200 0.4 — —
2 FILTER, FUEL ELEMENT - REPLACE 1720300 0.4 — —
3 PIPE, FUEL RETURN OR FEED - REPLACE 1720500 0.5 0.5 0.5
4 HOSE, FUEL FEED - REPLACE . . . .
Filter to pipe 1720910 0.3 — —
Injector to pipe 1720930 — 0.4 0.4
Tank to pipe 1720940 0.5 0.5 0.5
Filter to fuel injection pump 1720950 0.3 — —
5 HOSE, FUEL RETURN - REPLACE . . . .
Tank to pipe 1721300 0.5 — —
Function block to pipe 1721400 0.4 — —
6 BRACKET, FUEL FILTER - REPLACE 1722900 0.3 — —
7 HEATER, FUEL - REPLACE 1723500 0.4 — —
8 SENSOR, FUEL TEMPERATURE - REPLACE 1723600 0.4 — —
9 SENSOR, WATER - REPLACE 1723700 0.4 — —
ENGINE CONTROLS - CANISTER & FUEL VACUUM (173)
OPERATION C
1 SOLENOID, EVAP. EMISSION CANISTER PURGE - REPLACE 1730300 — 0.3 0.3
2 HOSE, EVAP. EMISSION CONTROL - REPLACE . . . .
Pipe to throttle Body 1730700 — 0.3 0.3
Pipe to Canister 1730900 — 0.4 0.4
OPERATION C
3 BRACKET, FUEL VAPOR CANISTER MOUNTING - REPLACE 1731300 — 0.4 0.4
4 CANISTER, FUEL VAPOR - REPLACE 1731500 — 0.4 0.4
TUBE, FUEL VAPOR RETURN - REPLACE (TANK TO
5 1731600 — 0.8 0.8
CANISTER)
6 PIPE, EVAPORATIVE EMISSION CONTROL - REPLACE 1731900 — 0.5 0.5
7 FILTER, CANISTER - REPLACE 1732800 — 0.4 0.4
ENGINE CONTROLS - FUEL INJECTION (181)
OPERATION C
1 BODY, THROTTLE - REPLACE & REINSTALL 1810300 0.4 0.4 0.3
2 GASKET(LIQUID), THROTTLE BODY - REPLACE 1810600 0.4 0.4 0.3
3 INJECTOR, FUEL - REPLACE 1811100 0.4 0.4 0.6
A - To replace each additional 181110A 0.2 0.1 0.1
B - To replace all 181110B 0.4 0.2 0.2
4 RAIL, FUEL - REPLACE 1811400 0.6 0.4 0.5
5 PUMP, FUEL INJECTION - REPLACE 1811500 3.5 — —
PIPE, FUEL RAIL (FUEL INJECTION PUMP TO FUEL RAIL) -
6 1811610 0.3 — —
REPLACE
7 PIPE, FUEL RAIL (FUEL INJECTOR TO FUEL RAIL) - REPLACE 1811620 0.3 — —
A - To replace each additional 181162A 0.1 — —
B - To replace all 181162B 0.2 — —
8 BLOCK AND/OR HOSE, FUEL RETURN FUNCTION - REPLACE 1811630 0.3 — —
9 SENSOR, FUEL RAIL PRESSURE - REPLACE 1811640 0.7 — —
10 REGULATOR, FUEL RAIL PRESSURE - REPLACE 1811650 0.7 — —
ENGINE CONTROLS - ACCELERATOR CONTROL (182)
OPERATION C
1 SWITCH, CRUISE CONTROL - REPLACE 1821700 0.3 0.3 0.3
2 MODULE, ACCELERATOR PEDAL - REPLACE 1821800 0.5 0.5 0.5
ENGINE CONTROLS - EMISSION CONTROL (186)
OPERATION C
1 CONTROLLER, ECM / PCM - REPLACE 1860100 0.9 0.6 0.9
OPERATION C
INC : Reprogram . . . .
2 CONTROLLER, ECM / PCM - REPROGRAM ONLY 1860300 0.8 0.4 0.8
3 CONTROLLER, TCM - REPLACE 1860500 0.6 0.6 0.6
INC : Reprogram . . . .
4 CONTROLLER, TCM - REPROGRAM ONLY 1860600 0.4 0.4 0.4
5 BRACKET, CONTROLLER - REPLACE 1860700 0.3 0.3 0.3
6 SENSOR, MAP - REPLACE 1860900 0.3 0.4 —
7 SENSOR, VEHICLE SPEED - REPLACE 1861100 0.2 0.2 0.2
8 SENSOR, KNOCK - REPLACE 1861300 — 0.3 —
9 SENSOR, BANK 1 KNOCK - REPLACE 1861700 — — 0.5
A - With transfer case 186170A — — 1.3
10 SENSOR, BANK 2 KNOCK - REPLACE 1861800 — — 0.5
11 UNIT, GLOW PLUG CONTROL - REPLACE 1863100 0.2 — —
DIAGNOSTIC TIME - DTC RELATED DIAGNOSIS FOR ALL
12 1869900 0.2 0.2 0.2
DIAGNOSIS ECUS
SECTION 1G
ENGINE (ENGINE INTAKE & EXHAUST)

ENGINE INTAKE & EXHAUST - AIR INTAKE SYSTEM (191)
OPERATION C
1 AIR CLEANER - REPLACE 1910300 0.3 0.3 0.3
2 FILTER, AIR CLEANER - REPLACE 1910500 0.2 0.2 0.2
3 DUCT AND/OR HOSE, OUTLET AIR - REPLACE 1910700 0.2 0.2 0.2
4 SENSOR, MAT - REPLACE 1910900 0.2 0.2 0.4
5 DUCT, LOWER INTERNAL AIR - REPLACE 1911200 0.4 0.4 0.4
OPERATION C
6 RESONATOR, AIR CLEANER FRONT - REPLACE 1911400 — 0.2 —
7 RESONATOR, AUXILIARY - REPLACE 1911500 — 0.2 —
8 RESONATOR, AIR CLEANER REAR - REPLACE 1911800 0.7 0.7 0.7
9 SEAL, AIR CLEANER RESONATOR DUCT - REPLACE 1911900 0.3 0.3 0.3
10 HOSE, BREATHER - REPLACE 1912900 — 0.2 —
11 SENSOR, MAF - REPLACE 1913100 0.2 — 0.2
12 DUCT, AIR CLEANER RESONATOR - REPLACE 1913200 0.4 0.4 0.4
13 SNORKEL, AIR CLEANER - REPLACE 1913300 0.4 0.4 0.4
14 DUCT, TURBO INLET - REPLACE 1913400 0.3 — —
15 DUCT, CHARGING AIR INLET - REPLACE 1913500 0.4 — —
16 DUCT, CHARGING AIR OUTLET - REPLACE 1913600 0.3 — —
17 PIPE, CHARGING AIR OUTLET DUCK - REPLACE 1913700 0.3 — —
18 DUCT, CHARGING AIR OUTLET FRONT - REPLACE 1913800 0.4 — —
19 DUCT, CHARGING AIR OUTLET REAR - REPLACE 1913900 0.4 — —
ENGINE INTAKE & EXHAUST - INTAKE MANIFOLD (193)
OPERATION C
1 MANIFOLD AND/OR GASKET, INTAKE - REPLACE 1930200 1.8 1.4 0.4
2 BLOCK AND/OR GASKET, MANIFOLD - REPLACE 1930300 — — 0.6
VALVE AND/OR SEAL, INTAKE MANIFOLD TUNING CONTROL
3 1930310 — — 0.3
- REPLACE
4 BRACE, INTAKE MANIFOLD - REPLACE 1930500 — 0.2 —
OPERATION C
5 SOLENOID, EGR - REPLACE 1930600 0.3 — —
6 VALVE AND/OR GASKET, EGR - REPLACE 1930700 0.6 0.3 —
7 HOSE AND/OR VALVE, PCV - REPLACE 1932600 0.3 — 0.3
8 PIPE AND/OR GASKET, EGR - REPLACE . . . .
EGR cooler to intake manifold 1933100 0.5 — —
EGR to exhaust manifold 1933200 1.5 — —
9 COOLER, EGR - REPLACE 1933300 2.0 — —
10 HOSE, EGR COOLING FEED - REPLACE 1933400 0.5 — —
11 HOSE, EGR COOLING RETURN - REPLACE 1933500 0.4 — —
ENGINE INTAKE & EXHAUST - EXHAUST MANIFOLD (194)
OPERATION C
1 MANIFOLD AND/OR GASKET EXHAUST - REPLACE 1940300 1.5 1.1 —
2 MANIFOLD, BANK 1 EXHAUST - REPLACE 1940310 — — 2.5
3 MANIFOLD, BANK 2 EXHAUST - REPLACE 1940320 — — 0.9
4 SENSOR, FRONT HEATED OXYGEN - REPLACE 1940400 — 0.3 —
5 SENSOR, REAR HEATED OXYGEN - REPLACE 1940410 — 0.4 —
OPERATION C
6 COVER, EXHAUST MANIFOLD - REPLACE 1940800 0.6 0.3 —
7 COVER, BANK 1 EXHAUST MANIFOLD - REPLACE 1940900 — — 2.2
8 COVER, BANK 2 EXHAUST MANIFOLD - REPLACE 1940910 — — 0.4
9 SHIELD, EXHAUST MANIFOLD INNER - REPLACE 1940920 0.7 — —
10 SENSOR, OXYGEN - REPLACE . . . .
Bank 1 Upper 1941200 — — 2.5
Bank 1 Lower 1941300 — — 0.4
Bank 2 Upper 1941400 — — 0.4
Bank 2 Lower 1941500 — — 0.4
11 CHARGER AND/OR GASKET, TURBO - REPLACE 1941600 1.5 — —
PIPE AND/OR GASKET, TURBO CHARGER OIL FEED -
12 1941700 0.4 — —
REPLACE
PIPE AND/OR GASKET, TURBO CHARGER OIL RETURN -
13 1941800 0.5 — —
REPLACE
14 HOSE, TURBO CHARGER OIL RETURN - REPLACE 1941900 0.2 — —
ENGINE INTAKE & EXHAUST - VACUUM HOSE (195)
OPERATION C
1 HOSE, VACUUM - REPLACE . . . .
Vacuum pump to EGR sol. 1950800 0.2 — —
EGR valve to EGR sol. 1950810 0.2 — —
VALVE, FILTER, HOSE AND/OR PIPE, VACUUM POWER BRAKE
2 1950900 0.4 0.2 0.2
- REPLACE
3 PUMP, VACUUM - REPLACE 1951400 0.8 — —
ENGINE INTAKE & EXHAUST - EXHAUST PIPE LINE (196)
OPERATION C
. EXHAUST SYSTEM - ALIGN 1960100 0.3 0.3 0.3
1 HANGER AND/OR CLAMP, EXHAUST SYSTEM - REPLACE 1960300 0.4 0.4 0.4
2 SEAL, EXHAUST PIPE - REPLACE 1960500 0.3 0.3 0.3
3 SEAL, FRONT EXHAUST PIPE - REPLACE 1960700 0.3 0.5 0.4
OPERATION C
PIPE, FRONT EXHAUST - REPLACE (MANIFOLD TO
4 1960900 0.4 0.4 0.5
CONVERTER)
5 HANGER AND/OR BRACKET, CONVERTER - REPLACE 1961100 0.3 0.3 —
6 SHIELD, CONVERTER - REPLACE 1961300 0.3 0.3 0.3
7 FILTER, DIESEL PARTICULATER(DPF) - REPLACE 1961400 0.8 — —
8 CONVERTER - REPLACE 1961500 0.4 0.4 0.4
CONVERTER, PUP - REPLACE 1961600 — 0.6 —
9 CONVERTER, BANK 1 PUP - REPLACE 1961610 — — 0.4
10 CONVERTER, BANK 2 PUP - REPLACE 1961620 — — 0.4
11 SHIELD, RESONATOR AND EXHAUST PIPE - REPLACE 1961700 0.3 0.3 0.3
12 SHIELD, MUFFLER - REPLACE 1961900 0.3 0.3 0.3
13 MUFFLER, FRONT - REPLACE 1962100 0.5 0.5 0.5
14 MUFFLER, REAR - REPLACE . . . .
Right 1962210 0.4 0.4 0.4
Left 1962220 0.4 0.4 0.4
Both 1962230 0.6 0.6 0.6
15 EXHAUST SYSTEM (COMPLETE) - REPLACE (SINGLE) 1962500 0.7 0.7 0.7
16 SHIELD, FUEL TANK - REPLACE 1962600 0.8 0.8 0.8
A - With rear drive module 196260A 1.5 1.5 1.5
ENGINE INTAKE & EXHAUST - EXHAUST PIPE LINE (196)
OPERATION C
17 SENSOR, DPF - REPLACE 1963100 0.3 — —
18 HOSE, DPF SENSOR - REPLACE 1963300 0.4 — —
19 SENSOR, EXHAUST TEMPERATURE - REPLACE . . . .
Upper 1963500 0.3 — —
Lower 1963700 0.3 — —
OPERATION C
20 DPF - REGENERATION 1963900 0.6 — —
SECTION 2C
SUSPENSION (FRONT SUSPENSION)
FRONT SUSPENSION - KNUCKLE & HUB (213)

OPERATION MODEL
CODE C100 C105
. . TOE, FRONT - ADJUST. 2130100 0.6 0.6
. . WHEEL ALIGNMENT - CHECK AND/OR ADJUST. 2130300 1.0 1.0
1 . BEARING, FRT WHEEL - REPLACE . . .
Right 2130500 1.0 1.0
Left 2130600 1.0 1.0
Both 2130700 1.8 1.8
2 . KUNCKLE, STEERING - REPLACE . . .
Right 2131100 1.0 1.0
Left 2131200 1.0 1.0
Both 2131300 1.8 1.8
3 . ROTOR, FRT WHEEL - REPLACE . . .
Right 2131500 0.4 0.4
Left 2131600 0.4 0.4
Both 2131700 0.6 0.6
. ROTOR, FRT WHEEL - GRINDING . . .
Right 2131510 0.8 0.8
Left 2131610 0.8 0.8
OPERATION MODEL
CODE C100 C105
Both 2131710 1.4 1.4
4 . SHIELD, FRT BRAKE - REPLACE . . .
Right 2132100 1.0 1.0
Left 2132200 1.0 1.0
Both 2132300 1.8 1.8
5 . NUT, FRT WHEEL DRIVE SHIFT - REPLACE . . .
Right 2134100 0.4 0.4
Left 2134200 0.4 0.4
Both 2134300 0.6 0.6
FRONT SUSPENSION - FRONT SHOCK ABSORBER (214)
OPERATION MODEL
CODE C100 C105
1 . SPRING, FRONT COIL - REPLACE . . .
Right 2140100 1.2 1.2
Left 2140200 1.2 1.2
Both 2140300 2.2 2.2
2 . STRUT, FRONT SUSPENSION - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Right 2140900 0.6 0.6
Left 2141100 0.6 0.6
Both 2141200 1.0 1.0
3 . MOUNT ASSEMBLY, FRONT STRUT BEARING - REPLACE . . .
Right 2141900 1.0 1.0
Left 2142100 1.0 1.0
Both 2142200 1.8 1.8
4 . BUMPER, FRONT SUSPENSION - REPLACE . . .
Right 2142400 1.0 1.0
Left 2142500 1.0 1.0
Both 2142600 1.8 1.8
5 . INSULATION, FRONT SPRING (UPPER/LOWER) - REPLACE . . .
Right 2142700 1.2 1.2
Left 2142800 1.2 1.2
Both 2142900 2.2 2.2
6 . SHOCK ABSORBER - REPLACE . . .
Right 2143100 1.2 1.2
Left 2143200 1.2 1.2
Both 2143300 2.2 2.2
FRONT SUSPENSION - CONTROL ARM (215)
OPERATION MODEL
CODE C100 C105
1 . SHAFT, FRONT STABILIZER - REPLACE 2150500 1.4 1.4
2 . INSULATION, FRONT STABILIZER SHAFT - REPLACE 2150700 0.5 0.5
3 . ARM, FRONT LOWER CONTROL - REPLACE . . .
Right 2151500 0.6 0.6
Left 2151600 0.6 0.6
OPERATION MODEL
CODE C100 C105
Both 2151700 1.0 1.0
4 . LINK, FRONT STABILIZER SHAFT - REPLACE . . .
Right 2152700 0.4 0.4
Left 2152800 0.4 0.4
Both 2152900 0.6 0.6
5 . FRAME, DRIVE TRAIN & FRONT SUSPENSION - REPLACE 2153200 1.9 1.9
A - With Propeller Shaft 215320A 0.3 0.3
SECTION 2D
SUSPENSION (REAR SUSPENSION)

REAR SUSPENSION - FOUR LINK TYPE (231)
OPERATION MODEL
CODE C100 C105
1 SHAFT, REAR STABILIZER - REPLACE 2310100 0.6 0.6
2 INSULATION, REAR STABILIZER SHAFT - REPLACE 2310300 0.4 0.4
3 ARM, REAR SUSPENSION LOWER CONTROL - REPLACE . . .
INC : Rear Wheel Alignment . . .
Right 2311800 1.6 1.6
Left 2311900 1.6 1.6
Both 2312000 2.2 2.2
4 LINK, REAR STABILIZER SHAFT - REPLACE . . .
Right 2314100 0.4 0.4
Left 2314200 0.4 0.4
Both 2314300 0.6 0.6
5 KNULKCE, REAR SUSPENSION - REPLACE . . .
Right 2315100 1.6 1.6
Left 2315200 1.6 1.6
Both 2315300 2.2 2.2
A - With RDM (Rear Drive Module) . . .
Right 231510A 0.2 0.2
Left 231520A 0.2 0.2
Both 231530A 0.2 0.2
6 ARM, REAR SUSPENSION TRAILING - REPLACE . . .
Right 2315400 0.5 0.5
Left 2315500 0.5 0.5
Both 2315600 0.8 0.8
7 BRACKET, REAR SUSPENSION TRAILING - REPLACE . . .
Right 2315700 0.4 0.4
Left 2315800 0.4 0.4
Both 2315900 0.6 0.6
8 SUPPORT, REAR SUSPENSION - REPLACE 2316100 3.4 3.4
A - With RDM (Rear Drive Module) 231610A 0.8 0.8
REAR SUSPENSION - FOUR LINK TYPE (231)
OPERATION MODEL
CODE C100 C105
9 ARM, REAR SUSPENSION UPRER CONTROL - REPLACE . . .
Right 2318100 1.5 1.5
Left 2318200 1.5 1.5
Both 2318300 1.8 1.8
OPERATION MODEL
CODE C100 C105
10 BEARING AND HUB ASSEMBLY REAR WHEEL - REPLACE . . .
Right 2318400 0.6 0.6
Left 2318500 0.6 0.6
Both 2318600 1.0 1.0
Right 231840A 0.1 0.1
Left 231850A 0.1 0.1
Both 231860A 0.2 0.2
11 LINK, REAR SUSPENSION - REPLACE . . .
Right 2318700 1.3 1.3
Left 2318800 1.3 1.3
Both 2318900 1.6 1.6
REAR SUSPENSION - REAR SHOCK ABSORBER (232)

OPERATION MODEL
CODE C100 C105
1 SPING, REAR - REPLACE . . .
Right 2320100 1.5 1.5
Left 2320300 1.5 1.5
Both 2320500 2.0 2.0
2 INSULATION, REAR SPRING UPPER AND/OR LOWER - REPLACE . . .
Right 2320700 1.5 1.5
Left 2320800 1.5 1.5
Both 2320900 2.0 2.0
3 ABSORBER, REAR SHAFT - REPLACE . . .
Right 2321100 0.5 0.5
Left 2321200 0.5 0.5
Both 2321300 0.8 0.8
4 BUMPER, REAR SUSPENSION JOUNCE - REPLACE . . .
Right 2321400 1.6 1.6
Left 2321500 1.6 1.6
Both 2321600 2.2 2.2
SECTION 2E
SUSPENSION (TIRES & WHEEL)

TIRES & WHEEL - WHEELS & WHEEL COVER (241)
OPERATION MODEL
CODE C100 C105
1 COVER, WHEEL (FRONT) - REPLACE 2410100 0.2 0.2
COVER, WHEEL (REAR) - REPLACE 2410300 0.2 0.2
COVER, WHEEL (ALL) - REPLACE 2410500 0.2 0.2
2 WHEEL - BALANCE . . .
One 2410700 0.4 0.4
OPERATION MODEL
CODE C100 C105
Two 2410800 0.7 0.7
Four 2410900 1.2 1.2
3 WHEEL - REPLACE . . .
One 2411100 0.6 0.6
Two 2411110 1.0 1.0
Three 2411120 1.4 1.4
Four 2411130 1.8 1.8
4 TIRE - REPLACE . . .
One 2411300 0.6 0.6
Two 2411310 1.0 1.0
Three 2411320 1.4 1.4
Four 2411330 1.8 1.8
5 STEM, TIRE VALVE - REPLACE . . .
One 2411500 0.4 0.4
Two 2411510 0.6 0.6
Three 2411520 0.8 0.8
Four 2411530 1.0 1.0
6 NUT, WHEEL - REPLACE 2411700 0.2 0.2
7 CAP, HUB - REPLACE 2412900 0.2 0.2
TPMS - TIRE PRESSURE MONITORING SYSTEM (242)

OPERATION MODEL
CODE C100 C105
1 LIGH, LOW TIRE PRESSURE WARNING - DAGNOSIS TIME 2421000 — 0.2
2 SENSOR, LOW TIRE PRESSURE WARNING SENSOR - REPLACE . . .
INC : ID REGISTRATION . . .
One 2421100 — 0.8
Two 2421110 — 1.2
Three 2421120 — 1.6
Four 2421130 — 2.0
SECTION 3A
DRIVE LINE / AXLE

DRIVE AXLE - AXLE SHIFT PARTS (FRONT) (321)
OPERATION MODEL
CODE C .
1 . BOOT (SEAL), AXLE SHAFT JOINT(FRONT) - REPLACE . . .
One 3210100 1.1 .
Two 3210200 1.4 .
Three 3210300 2.4 .
OPERATION MODEL
CODE C .
Four 3210400 2.7 .
2 . JOINT, AXLE SHAFT CV(FRONT) - REPLACE . . .
One 3210600 1.0 .
Two 3210700 1.3 .
Three 3210800 2.1 .
Four 3210900 2.3 .
3 . AXLE ASSEMBLY, FRONT DRIVE - REPLACE . . .
Right 3211100 0.8 .
Left 3211200 0.8 .
Both 3211300 1.2 .
4 . SHAFT, AXLE(FRONT) - REPLACE 3211500 1.4 .
5 . SHAFT ASSEMBLY, FRT WHV DRV INTERMEDIATE - REPLACE 3211600 0.8 .
C : C-100
DRIVE AXLE - AXLE SHIFT PARTS (REAR) (322)
OPERATION MODEL
CODE C .
1 . BOOT (SEAL), AXLE SHAFT JOINT(REAR) - REPLACE . . .
One 3220100 1.1 .
Two 3220200 1.4 .
Three 3220300 2.4 .
OPERATION MODEL
CODE C .
Four 3220400 2.7 .
2 . JOINT, AXLE SHAFT CV(REAR) - REPLACE . . .
One 3220600 1.0 .
Two 3220700 1.3 .
Three 3220800 2.1 .
Four 3220900 2.3 .
3 . AXLE ASSEMBLY, REAR DRIVE - REPLACE . . .
Right 3221100 0.8 .
Left 3221200 0.8 .
Both 3221300 1.2 .
4 . SHAFT, AXLE(REAR) - REPLACE 3221500 1.4 .
C : C-100
SECTION 3C
REAR DRIVE MODULE

DRIVE AXLE / AXLE/ RDM - RDM PARTS (331)
OPERATION MODEL
CODE C100 C105
1 . MODULE ASSEMBLY, REAR WHEEL DRIVE - REPLACE 3310100 1.9 1.9
. OIL, REAR DRIVE MODULE - REPLACE 3310300 0.3 0.3
2 . SEAL, DIFFERENTIAL DRIVE PINION GEAR - REPLACE 3310500 2.0 2.0
. HOUSING ASM, REAR WHEEL DRIVE DIFFERENTIAL CARRIER -
3 3310700 2.0 2.0
REPLACE
OPERATION MODEL
CODE C100 C105
. BUSHING ASSEMBLY, REAR WHEEL DRIVE DIFFERENTIAL
4 3310900 1.9 1.9
CARRIER - REPLACE
5 . SEAL, DIFFERENTIAL CARRIER COVER - REPLACE 3311100 2.0 2.0
. HOUSING ASM, ASSEMBLY REAR WHEEL DRIVE MODULE
6 3311300 1.9 1.9
CLUTCH - REPLACE
7 . SEAL, REAR AXLE SHAFT - REPLACE 3311500 1.9 1.9
8 . MODULE, REAR DIFFERENTIAL CLUTCH CONTROL - REPLACE 3316100 1.9 2.1
INC : REPROGRAM
. MODULE, REAR DIFFERENTIAL CLUTCH CONTROL -
9 3317100 0.3 0.3
REPROGRAM ONLY
DRIVE AXLE / AXLE/ RDM - RDM PARTS (332)
OPERATION MODEL
CODE C100 C105
1 . SHAFT ASM, PROPELLER - REPLACE 3320100 0.5 0.5
SECTION 4A
BRAKE (HYDRAULIC BRAKE)

HYDRAULIC BRAKE – BRAKE PIPE (425)
OPERATION MODEL
CODE C .
1 . HOSE, FRONT BRAKE – REPLACE . . .
Right 4250100 0.6 .
Left 4250200 0.6 .
OPERATION MODEL
CODE C .
Both 4250300 1.0 .
2 . HOSE, REAR BRAKE – REPLACE . . .
Right 4250400 0.6 .
Left 4250500 0.6 .
Both 4250600 1.0 .
3 . PIPE, REAR BRAKE (JUNCTION BLOCK TO HOSE – RR) – REPLACE . . .
Right 4250800 2.8 .
Left 4251100 2.8 .
Both 4251300 3.0 .
4 . PIPE, BRAKE PRESS MODULATOR VALVE FRONT – REPLACE 4251500 1.2 .
5 . PIPE, BRAKE PRESS MODULATOR VALVE REAR – REPLACE 4251600 1.2 .
6 . PIPE, FRONT BRAKE – REPLACE - RIGHT 4251900 1.7 .
7 . PIPE, FRONT BRAKE – REPLACE - LEFT 4252100 1.5 .
8 . PIPE, BRAKE MODULATOR TO JUNCTION BLOCK – REPLACE . . .
Right Rear 4252400 1.2 .
Left Rear 4252500 1.2 .
HYDRAULIC BRAKE – BRAKE PEDAL and MOUNT (428)
OPERATION MODEL
CODE C .
1 . PEDAL AND/OR BUSHING, BRAKE – REPLACE 4280100 0.4 .
2 . PAD, BRAKE PEDAL – REPLACE 4280500 0.2 .
3 . SWITCH, STOP LAMP – REPLACE 4280700 0.2 .
4 . SHAFT, BRAKE PEDAL – REPLACE 4280900 0.4 .
SECTION 4B
BRAKE (MASTER CYLINDER & POWER

BOOSTER)
MASTER CYLINDER & POWER BOOSTER - MASTER CYLINDER &
BOOSTER (431)
OPERATION MODEL
CODE C .
1 . CYLINDER, BRAKE MASTER - REPLACE . . .
OH 4310100 — .
Replace 4310200 1.1 .
OPERATION MODEL
CODE C .
. BRAKE SYSTEM - BLEED 4310400 0.4 .
2 . BOOSTER, VACUUM POWER BRAKE - REPLACE 4310600 1.6 .
3 . RESERVOIR KIT, BRAKE MASTER CYLINDER - REPLACE 4310800 0.6 .
4 . SWITCH, BRAKE RESERVOIR - REPLACE 4311100 0.2 .
5 . VALVE, BRAKE PROPORTIONER - REPLACE 4311300 0.7 .
6 . CYLINDER ASS'Y, BRAKE MASTER - REPLACE 4311500 1.6 .
7 . HOSE, BRAKE BOOSTER VACUUM - REPLACE 4312100 0.2 .
C : C-100
SECTION 4D
BRAKE (FRONT BRAKES)

FRONT BRAKES - FRONT BRAKE (445)
OPERATION MODEL
CODE C .
1 . PAD KIT, FRT DISC BRAKE - REPLACE . . .
Right 4450100 0.4 .
Left 4450110 0.4 .
Both 4450120 0.6 .
2 . BRAKE CALIPER ASSEMBLY, FRT - REPLACE . . .
Right Front 4450300 0.6 .
Left Front 4450400 0.6 .
Both Front 4450500 1.0 .
3 . HOUSING KIT, FRT BRAKE CALIPER - REPLACE 4451000 0.6 .
4 . PIN KIT, FRT BRAKE CALIPER GUIDE - REPLACE . . .
Right 4451100 0.5 .
Left 4451200 0.5 .
Both 4451300 0.8 .
5 . VALVE KIT, FRT BRAKE CALIPER BLEEDER - REPLACE 4451500 0.2 .
C : C-100
SECTION 4E
BRAKE (REAR BRAKES)

REAR BRAKES (W/ABS) - REAR BRAKE (456)
OPERATION MODEL
CODE C .
1 . BACKING PLATE, PARK BRAKE - REPLACE . . .
Right 4563800 0.6 .
Left 4563900 0.6 .
Both 4564100 1.0 .
OPERATION MODEL
CODE C .
Right 456380A 0.1 .
Left 456390A 0.1 .
Both 456410A 1.2 .
2 . BRAKE CALIPER ASSEMBLY, REAR - REPLACE . . .
Right 4564300 0.6 .
Left 4564400 0.6 .
Both 4564500 1.0 .
3 . ROTOR, REAR WHEEL - REPLACE . . .
Right 4565100 0.4 .
Left 4565200 0.4 .
Both 4565300 0.6 .
4 . PIN KIT, REAR BEAR BRAKE CALIPER - REPLACE . . .
Right 4565500 0.5 .
Left 4565600 0.5 .
Both 4565700 0.8 .
5 . HOUSING KIT, REAR BRAKE CALIPER - REPLACE 4566000 0.6 .
6 . VALVE KIT, REAR BRAKE CALIPER BLEEDER - REPLACE 4566100 0.2 .
7 . PAD KIT, REAR DISC BRAKE - REPLACE . . .
Right 4566300 0.5 .
Left 4566400 0.5 .
Both 4566500 0.8 .
C : C-100
SECTION 4F
BRAKE (ANTI-LOCK BRAKES SYSTEM)

SECTION 4G
BRAKE (PARKING BRAKES)

PARKING BRAKES - PARKING BRAKE (478)
OPERATION MODEL
CODE C .
. . PARKING BRAKE - ADJUST 4780100 0.3 .
1 . CONTROL ASSEMBLY, PARKING BRAKE - REPLACE 4780300 0.5 .
2 . CABLE, PARKING BRAKE - REPLACE . . .
Front 4780500 0.6 .
Rear, Both 4780600 0.7 .
OPERATION MODEL
CODE C .
3 . SWITCH, PARK BRAKE LAMP - REPLACE 4780800 0.3 .
4 . SHOE, PARKING BRAKE - REPLACE 4781100 0.8 .
. A - WITH RDM (REAR DRIVE MODULE) 478110A 0.1 .
5 . SHOE ASS'Y, PARKING BRAKE - REPLACE 4781300 0.6 .
. A - WITH RDM (REAR DRIVE MODULE) 478130A 0.1 .
6 . MODULE, REAR OBJECT ALARM – REPLACE 4781700 0.6 .
7 . SENSOR, REAR OBJECT – REPLACE 4781800 0.9 .
. A – REPLACE EACH ADDITIIONAL 478180A - .
. B – REPLACE ALL 478180B 0.1 .
8 . ALARM, REAR OBJECT – REPLACE 4781900 0.3 .
C : C-100
SECTION 5A3
TRANSMISSION / TRANSAXLE / TRANSFER

CASE (AISIN AUTO TRANSAXLE : 55-51LE)
AISIN AUTO T/A : 55-51LE - AUTOMATIC TRANSAXLE (531)
OPERATION MODEL
CODE C100 C105
1 TORQUE CONVERTER - REPLACE 5310100 4.3 4.3
OPERATION MODEL
CODE C100 C105
A - With Transfer Case 531010A 0.6 0.6
2 BOLTS, TORQUE CONVERTER TO FLYWHEEL - REPLACE . . .
DOHC(2.4) 5310200 0.8 0.8
DOHC(3.2) 5310210 0.8 0.8
2.0 DSL 5310220 0.4 0.4
A - With Transfer Case . . .
DOHC(2.4) 531020A 0.6 0.6
DOHC(3.2) 531021A — —
2.0 DSL 531022A — —
3 AUTO TRANSAXLE ASSEMBLY - REPLACE 5310300 4.3 4.3
AUTO TRANSAXLE ASSEMBLY - OVERHAUL 5310400 8.8 8.8
INC : Assembly replacement . . .
4 STICK, OIL GAUGE - REPLACE 5310600 0.2 0.2
AISIN AUTO T/A : 55-51LE - CASE & RELATED PARTS (532)
OPERATION MODEL
CODE C100 C105
1 SENSOR, INPUT SHAFT SPEED (ISS) - REPLACE 5320100 0.3 0.3
2 SENSOR, OUTPUT SHAFT SPEED(OSS) - REPLACE 5320200 0.3 0.3
3 SENSOR, TRANSMISSION FLUID TEMPERATURE(TFTS) - REPLACE 5320400 1.2 1.2
OPERATION MODEL
CODE C100 C105
4 SWITCH, PARK/NEUTRAL POSITION (PNP) - REPLACE 5320500 0.5 0.5
5 HARNESS, TRANSAXLE WIRING - REPLACE 5320600 1.2 1.2
6 HOUSING, TRANSAXLE - REPLACE 5320700 6.8 6.8
7 HOUSING, TORQUE CONVERTER - REPLACE 5320800 4.8 4.8
8 TUBE, DIFFERENTIAL BEARING LUBE APPLY - REPLACE 5320900 5.0 5.0
9 PLATE, TRANSAXLE HOUSING OIL RESERVOIR - REPLACE 5321100 5.0 5.0
10 TUBE, LUBRICATION APPLY - REPLACE . . .
C-3 5321400 4.6 4.6
Lubrication 5321500 4.6 4.6
A - With Transfer Case . . .
C-3 532140A 0.6 0.6
Lubrication 532150A 0.6 0.6
11 FILTER, TRANSAXLE OIL - REPLACE 5321600 4.8 4.8
12 REAR CASE, TRANSAXLE - REPLACE 5321800 4.9 4.9
AISIN AUTO T/A : 55-51LE - CASE & RELATED PARTS (532)
OPERATION MODEL
CODE C100 C105
13 SEAL, DRIVE AXLE FLUID - REPLACE . . .
Right 5321900 1.0 1.0
Left 5322100 1.0 1.0
OPERATION MODEL
CODE C100 C105
Both 5322200 1.6 1.6
14 PARKING SYSTEM - REPLACE 5322300 5.6 5.6
15 COVER, T/A SIDE - REPLACE 5322400 0.6 0.6
16 HOSE BREATHER - REPLACE 5322500 0.2 0.2
17 PISTONS, ACCUMULATOR - REPLACE 5322600 4.6 4.6
18 RACE, TAPER ROLLER BRARING, OTR - REPLACE 5322900 5.1 5.1
19 TUBE, BRAKE APPLY - REPLACE 5323000 4.6 4.6
20 SEAL RING, REAR CASE - REPLACE 5323100 4.9 4.9
21 PISTON, B-5 BRAKE - REPLACE 5323200 5.0 5.0
22 PLATE AND/OR DISC, B-5 BRAKE - REPLACE 5323300 5.0 5.0
AISIN AUTO T/A : 55-51LE - INTERNAL POWER TRAIN PARTS
(533)
OPERATION MODEL
CODE C100 C105
1 OIL PUMP - REPLACE 5330100 4.9 4.9
2 CLUTCH ASSEMBLY, SECOND BRAKE - REPLACE 5330200 4.7 4.7
3 CLUTCH ASSEMBLY, SECOND COAST BRAKE - REPLACE 5330300 4.7 4.7
4 RACE, CLUTCH, INNER - REPLACE 5330400 4.5 4.5
5 ONE-WAY CLUTCH, NO, 1 - REPLACE 5330500 4.5 4.5
6 RACE, CLUTCH, OUTER - REPLACE 5330600 4.5 4.5
7 CLUTCH ASSEMBLY, FORWARD - REPLACE 5330700 4.8 4.8
8 CLUTCH ASSEMBLY, DIRECT - REPLACE 5330800 4.6 4.6
AISIN AUTO T/A : 55-51LE - GEAR ASSEMBLY (534)
OPERATION MODEL
CODE C100 C105
1 GEAR ASSEMBLY, PLANETARY - REPLACE 5340100 4.6 4.6
2 GEAR ASSEMBLY, REAR PLANETARY RING - REPLACE 5340200 4.6 4.6
OPERATION MODEL
CODE C100 C105
3 GEAR ASSEMBLY, PLANETARY SUN - REPLACE 5340300 4.6 4.6
4 CLUTCH ASSEMBLY, LOW/REVERSE BRAKE - REPLACE 5340400 4.9 4.9
5 ONE-WAY CLUTCH, NO.2 - REPLACE 5340500 4.9 4.9
6 GEAR ASSEMBLY, FRONT PLANETARY RING - REPLACE 5340600 4.9 4.9
7 CLUTCH ASSEMBLY, UNDERDRIVE - REPLACE 5340700 5.6 5.6
8 ONE-WAY CLUTCH, UNDERDRIVE - REPLACE 5340800 5.5 5.5
9 PISTON, UNDERDRIVE BRAKE - REPLACE 5340900 1.0 1.0
10 BAND ASSEMBLY, UNDERDRIVE BRAKE - REPLACE 5341100 5.4 5.4
11 GEAR ASSEMBLY, COUNTER DRIVE - REPLACE 5341200 5.2 5.2
12 GEAR ASSEMBLY, UNDERDRIVE PLANETARY AND DIFFERENTIAL
5341300 5.2 5.2
DRIVE PINION - REPLACE
13 GEAR ASSEMBLY, DIFFERENTIAL - REPLACE 5341400 4.9 4.9
14 GEAR, REAR PLANETARY SUN - REPLACE 5341500 5.2 5.2
AISIN AUTO T/A : 55-51LE - CONTROL VALVE (535)
OPERATION MODEL
CODE C100 C105
1 VALVE BODY - REPLACE 5350100 1.2 1.2
OPERATION MODEL
CODE C100 C105
2 COVER, VALVE BODY - REPLACE 5350500 0.9 0.9
3 VALVE BODY SOLENOID - REPLACE . . .
Linear 5350600 1.0 1.0
Lockup 5350700 1.0 1.0
Shift 1~5 5350800 1.0 1.0
AISIN AUTO T/A : 55-51LE - FLUID COOLER PIPE (536)

OPERATION MODEL
CODE C100 C105
1 FLUID COOLER PIPE - REPLACE . . .
Inlet 5360100 0.7 0.7
Outlet 5360200 0.7 0.7
Both 5360300 0.9 0.9
2 FLUID COOLER PIPE AND HOSE - REPLACE . . .
DOHC(2.4 D, 3.2D) 5360400 0.8 0.8
2.0 DSL 5360500 0.8 0.8
3 COOLER, TRANS FLUID AUXILIARY - REPLACE 5361000 1.2 1.2
AISIN AUTO T/A : 55-51LE - AUTOMATIC TRANSAXLE

CONTROLS (537)
OPERATION MODEL
CODE C100 C105
1 KNOB, SHIFT LEVER - REPLACE 5370100 0.2 0.2
2 CABLE, SHIFT CONTROL - REPLACE 5370200 0.9 0.9
3 LEVER, SHIFT CONTROL (AT TRANSMISSION) - REPLACE 5370300 0.8 0.8
4 COVER, SHIFT CONTROL - REPLACE 5370500 0.7 0.7
5 BRACKET, A/T CONTROL - REPLACE 5371100 0.8 0.8

CASE (FIVE-SPEED MANUAL TRANSAXLE : D33)
FIVE-SPEED M/T(D33) - MANUAL TRANSAXLE (561)

OPERATION MODEL
CODE C .
1 . TRANSAXLE ASSEMBLY - REPLACE 5610100 3.7 .
INC : Replace concentric slave cylinder necessary . . .
A - With Transfer Case 561010A 4.3 .
OPERATION MODEL
CODE C .
. TRANSAXLE ASSEMBLY - OVERHAUL 5610300 7.6 .
. TRANSAXLE OIL - REPLACE 5610500 0.4 .
C : C-100
FIVE-SPEED M/T(D33) - TRANSAXLE GEAR (563)
OPERATION MODEL
CODE C .
1 . GEAR, OUTPUT - 5TH SPEED (DRIVEN) - REPLACE 5630100 5.9 .
2 . GEAR, INPUT - 5TH SPEED (DRIVING) - REPLACE 5630200 5.8 .
3 . GEAR, OUTPUT - 4TH SPEED (DRIVEN)- REPLACE 5630300 5.7 .
5 . GEAR, OUTPUT - 3TH SPEED (DRIVEN)- REPLACE 5630500 5.8 .
7 . GEAR, INTERMEDIATE-2TH SPEED (DRIVING) - REPLACE 5630700 5.7 .
8 . GEAR, INTERMEDIATE-1TH SPEED (DRIVING) - REPLACE 5630900 5.7 .
9 . SHAFT, TRANSAXLE INPUT - REPLACE 5631000 5.9 .
10 . SHAFT, TRANSAXLE OUTPUT - REPLACE 5631100 6.1 .
11 . GEAR, REVERSE (DRIVEN ) - REPLACE 5631200 6.0 .
C : C-100
FIVE-SPEED M/T(D33) - TRANSAXLE GEAR (563)
OPERATION MODEL
CODE C .
12 . SYNCHRONIZERS ( 5TH / REVERSE ) - REPLACE 5631300 5.9 .
13 . GEAR, INTERMEDIATE - REPLACE 5631400 5.7 .
OPERATION MODEL
CODE C .
14 . SYNCHRONIZERS (3RD-4TH) - REPLACE 5631500 5.7 .
15 . SYNCHRONIZERS (1ST-2ND) - REPLACE 5631700 5.7 .
C : C-100
FIVE-SPEED M/T(D33) - BEARING PLATE (565)

OPERATION MODEL
CODE C .
1 . REAR COVER, TRANSAXLE - REPLACE 5650100 0.6 .
2 . TRANSMISSION FLUID COLLECTOR PIPE - REPLACE 5650200 0.6 .
3 . BEARING, BALL GROOVE - REPLACE 5650400 4.8 .
4 . OIL DRAIN CHAINNEL - REPLACE 5650600 4.5 .
OPERATION MODEL
CODE C .
5 . MAGNET, T/A HOUSHING - REPLACE 5650800 4.5 .
6 . RAIL, IDLE SHIFT - REPLACE 5651000 4.7 .
C : C-100
FIVE-SPEED M/T(D33) - GEAR SHIFT COVER & FORK (566)
OPERATION MODEL
CODE C .
1 . SHIFT SHAFT ASSEMBLY - REPLACE 5660200 4.5 .
2 . CONTROL LEVER, SELECT - REPLACE 5660400 0.5 .
3 . TRANSAXLE CASE - REPLACE 5661100 5.0 .
4 . CLUTCH CASE - REPLACE 5661300 4.5 .
C : C-100
FIVE-SPEED M/T(D33) - DIFFERENTIAL GEAR (567)
OPERATION MODEL
CODE C .
1 . DIFFERENTIAL ASSEMBLY - REPLACE 5670100 4.7 .
OPERATION MODEL
CODE C .
2 . SEALS, AXLE (TRANSAXLE) - REPLACE (RIGHT) . . .
Right 5671300 1.0 .
Left 5671400 1.0 .
Both 5671500 1.6 .
3 . DIFFERENTIAL RACE AND/OR SHIM - REPLACE 5671700 5.0 .
4 . DRAIN PLUG, TRANSAXLE FLUID - REPLACE 5671800 0.2 .
C : C-100
FIVE-SPEED M/T(D33) - SHIFT CONTROL (569)

OPERATION MODEL
CODE C .
1 . LEVER, GEARSHIFT CONTROL ASSEMBLY - REPLACE 5690500 0.9 .
2 . CABLE LOCK PIN, CONTROL ASSEMBLY - REPLACE 5690600 0.3 .
3 . CONTROL ASSEMBLY, FLOOR MOUNTED GEARSHIFT - REPLACE 5690900 1.0 .
INC : Adjust Linkage . . .
C : C-100
CASE (CLUTCH)
CLUTCH - CLUTCH PARTS (581)

OPERATION MODEL
CODE C100 C105
1 CYLINDER, CONCENTRIC SLAVE - REPLACE 5810700 3.9 3.9
2 PIPE, CONCENTRIC SLAVE CYLINDER REAR - REPLACE 5810800 4.0 4.0
3 CONNECTOR, CONCENTRIC SLAVE CYLINDER - REPLACE 5811000 4.0 4.0
4 DISC AND/OR CLUTCH COVER, CLUTCH - REPLACE 5811100 3.9 3.9
A - To Replace Clutch Fork Shaft and/or Bushings 581110A — —
B - To Replace Flywheel 581110B — —
C - With Transfer Case 581110C 0.6 0.6
5 SWITCH, BACK-UP LAMP - REPLACE 5811300 0.4 0.4
CLUTCH - HYDRAULIC CLUTCH (582)

OPERATION MODEL
CODE C100 C105
1 CYLINDER, CLUTCH M/CYNLINDER - REPLACE 5820100 0.8 0.8
2 HOSE, HYDRAULIC CLUTCH RESERVOIR - REPLACE 5820300 0.4 0.4
3 PIPE, CLUTCH ACTUATOR CYLINDER FRT - REPLACE 5820500 1.1 1.1
4 HOSE, HYDRAULIC CLUTCH - REPLACE 5821300 0.5 0.5
CLUTCH - CLUTCH PEDAL (583)
OPERATION MODEL
CODE C100 C105
1 PEDAL, SHAFT AND/OR BUSHING, CLUTCH - REPLACE 5830100 0.5 0.5
2 SPRING, CLUTCH PEDAL RETURN - REPLACE 5830300 0.5 0.5
3 COVER, PEDAL PLATE - REPLACE 5830700 0.2 0.2
4 SHAFT, CLUTCH PEDAL - REPLACE 5830900 0.4 0.4
5 SWITCH, CLUTCH START - REPLACE 5831100 0.3 0.3
6 BRACKET, CLUTCH PEDAL - REPLACE 5831300 0.7 0.7
7 PEDAL UNIT, CLUTCH - REPLACE 5831500 0.7 0.7
TRANSFER CASE
TRANSFER CASE - TRANSFER CASE PARTS (591)
OPERATION MODEL
CODE C .
1 . TRANSFER CASE ASSEMBLY - REPLACE 5910100 1.5 .
. OIL, TRANSFER CASE MODULE - REPLACE 5910200 0.3 .
2 . O - RING, TRANSFER CASE INPUT SHAFT - REPLACE 5910300 1.5 .
3 . SEAL, TRANSFER CASE INPUT SHAFT - REPLACE 5910400 2.0 .
OPERATION MODEL
CODE C .
. O - RING, TRANSFER CASE REAR OUTPUT DRIVE SHAFT HOUSING
4 5910500 0.6 .
- REPLACE
5 . FLANGE, TRANSFER CASE REAR OUTPUT SHAFT - REPLACE 5910600 0.7 .
6 . SEAL, FRONT WHEEL DRIVE INTERMEDIATE SHAFT - REPLACE 5910700 2.0 .
. SEAL, FRONT WHEEL DRIVE INTERMEDIATE SHAFT HOUSING -
7 5910800 2.0 .
REPLACE
8 . SEAL, TRANSFER CASE - REPLACE 5910900 1.8 .
9 . SHAFT, FRONT WHEEL DRIVE INTERMEDIATE - REPLACE 5911000 1.9 .
10 . BEARING, FRONT WHEEL DRIVE INTERMEDIATE SHAFT - REPLACE 5911100 1.9 .
11 . SEAL, FRONT WHEEL DRIVE INTERMEDIATE SHAFT - REPLACE 5911200 0.6 .
12 . SHIDELD, TRANSFER CASE - REPLACE 5911300 0.3 .
C : C-100
SECTION 6A
STEERING (POWER STEERING SYSTEM)

POWER STEERING SYSTEM - POWER STEERING GEAR (621)
OPERATION MODEL
CODE C100 C105
1 . LINE, POWER STEERING GEAR CYLINDER - REPLACE . . .
Right 6210100 0.7 0.7
Left 6210200 0.7 0.7
Both 6210300 0.8 0.8
2 . COUPLING, STEERING FLEXIBLE - REPLACE 6210500 0.5 0.5
OPERATION MODEL
CODE C100 C105
3 . GEAR ASSEMBLY, POWER STEERING . . .
adjust 6210700 0.4 0.4
Replace 6210800 1.7 1.7
. GEAR ASSEMBLY, POWER STEERING (RHD) - REPLACE 6211100 1.7 1.7
4 . SHIELD, STEERING GEAR HEAT - REPLACE 6211300 0.3 0.3
POWER STEERING SYSTEM - POWER STEERING PIPE LINE (623)
OPERATION MODEL
CODE C100 C105
1 . CAP, POWER STEERING PUMP RESERVOIR - REPLACE 6230100 0.2 0.2
2 . PIPE, POWER STEERING PUMP INLET - REPLACE . . .
DOHC(2.4D) 6230500 0.5 0.5
DOHC(3.2D) 6230510 0.9 0.9
2.0 DSL 6230520 0.5 0.5
3 . HOSE, POWER STEERING GEAR INLET - REPLACE . . .
DOHC(2.4D) 6230900 0.8 0.8
DOHC(3.2D) 6230910 0.9 0.9
2.0 DSL 6230920 1.0 1.0
4 . PIPE, POWER STEERING GEAR OUTLET - REPLACE . . .
DOHC(2.4D) 6231500 0.7 0.7
DOHC(3.2D) 6231510 1.2 1.2
2.0 DSL 6231520 1.2 1.2
5 . PUMP ASSEMBLY, POWER STEERING - REPLACE . . .
DOHC(2.4D) 6231900 0.9 0.9
DOHC(3.2D) 6231910 0.8 0.8
2.0 DSL 6231920 1.0 1.0
6 . RESERVOIR ASSEMBLY, PS FLUID (REMOTE) - REPLACE 6232100 0.4 0.4
7 . PIPE, POWER STEERING FLUID COOLING - REPLACE 6232200 0.9 0.9
8 . BRACKET, POWER STEERING PUMP - REPLACE . . .
DOHC(2.4D) 6232400 0.4 0.4
DOHC(3.2D) 6232410 0.8 0.8
2.0 DSL 6232420 1.0 1.0
SECTION 6E
STEERING (STEERING WHEEL & COLUMN)

STEERING WHEEL & COLUMN - STEERING WHEEL (641)
OPERATION MODEL
CODE C .
1 . WHEEL, STEERING (W/AIR BAG) - REPLACE 6410100 0.6 .
2 . SWITCH (W/AIR BAG) - REPLACE . . .
Windshield Wiper 6410600 0.5 .
Multifunction 6410700 0.5 .
3 . NUT, STEERING WHEEL (W/AIR BAG) - REPLACE 6411500 0.2 .
C : C-100
STEERING WHEEL & COLUMN - STEERING COLUMN COVER
(642)
OPERATION MODEL
CODE C .
1 . COVER, STEERING WHEEL - REPLACE . . .
Lower 6420100 0.4 .
Upper 6420300 0.4 .
OPERATION MODEL
CODE C .
Both 6420500 0.4 .
C : C-100
STEERING WHEEL & COLUMN - STEERING COLUMN (643)

OPERATION MODEL
CODE C .
1 . COLUMN ASSEMBLY, TILT AND/OR TELESCOPING STEERING -
. . .
REPLACE
A - With Driver's Air Bag 6430300 1.0 .
2 . MODULE, P/S CONT - REPLACE 6432100 0.2 .
3 . SENSOR, STEERING ANGLE - REPLACE 6432300 0.3 .
4 . SWITCH ASM, IGN & START - REPLACE 6432700 0.5 .
5 . CYLINDER ASM, IGN LOCK - REPLACE 6432900 1.3 .
6 . SWITCH ASM, IGN KEY ALARM - REPLACE 6433000 0.5 .
C : C-100
STEERING WHEEL & COLUMN - TIRE ROD (647)

OPERATION MODEL
CODE C .
1 . TIE ROD END AND/OR ADJUSTER SLEEVE - REPLACE . . .
Right 6470500 0.6 .
Left 6470600 0.6 .
Both 6470700 0.8 .
2 . TIE ROD - REPLACE . . .
Right 6471100 0.8 .
Left 6471200 0.8 .
OPERATION MODEL
CODE C .
Both 6471300 1.2 .
3 . BOOT, RACK & PINION - REPLACE . . .
Right 6472100 0.8 .
Left 6472200 0.8 .
Both 6472400 1.2 .
C : C-100
SECTION 7A
HEATING & VENTILATION

HEATING & VENTILATION - AIR DISTRIBUTION (711)
OPERATION C
1 . DUCT, AIR OUTLET - REPLACE . . . .
Right 7110600 0.3 0.3 0.3
Left 7110610 0.3 0.3 0.3
Both 7110620 0.4 0.4 0.4
OPERATION C
2 . DUCT, AIR DISTRIBUTION - REPLACE 7111300 3.6 3.6 3.6
3 . DUCT, AUXILIARY AIR OUTLET - REPLACE 7111800 2.7 2.7 2.7
4 . COVER, AIR INLET - REPLACE 7112200 0.3 0.3 0.3
5 . DUCT, FLOOR REAR AIR OUTLET - REPLACE 7113400 0.6 0.6 0.6
6 . DUCT, FLOOR REAR AIR OUTLET REAR - REPLACE 7113500 1.2 1.2 1.2
C : C-100
HEATING & VENTILATION - EVAPORATOR (713)
OPERATION C
1 . COVER, HEATER CORE (A/C) - REPLACE 7130100 4.4 4.4 4.4
A - Recover/Recharge A/C system 713010A 0.7 0.7 0.7
2 . MODULE, HEATER - REPLACE 7130300 4.4 4.4 4.4
3 . CORE, HEATER - REPLACE 7130500 4.4 4.4 4.4
4 . EVAPORATOR - REPLACE 7130700 4.6 4.6 4.6
5 . EVAPORATOR CORE - REPLACE 7130900 4.7 4.7 4.7
6 . O RING, EVAPORATOR INLET - REPLACE 7131100 1.1 1.1 1.1
INC : Recover/Recharge A/C system . . . .
7 . O RING, EVAPORATOR OUTLET - REPLACE 7131200 1.1 1.1 1.1
8 . VALVE, EXPANSION - REPLACE 7131600 1.1 1.1 1.1
. VALVE, EXPANSION (RHD) - REPLACE 7131700 1.1 1.1 1.1
9 . AIR INLET - REPLACE 7131800 3.7 3.7 3.7
10 . MODULE, AIR CON - REPLACE 7132100 4.9 4.9 4.9
C : C-100
HEATING & VENTILATION - EVAPORATOR (713)
OPERATION C
11 . MOTOR, AIR INLET - REPLACE 7132800 3.7 3.7 3.7
12 . MOTOR, MODE - REPLACE 7132900 0.3 0.3 0.3
13 . MOTOR, AIR MIX - REPLACE 7133200 0.5 0.5 0.5
14 . SENSOR, DUCT - REPLACE 7133600 0.4 0.4 0.4
OPERATION C
15 . RELAY, HIGH - REPLACE 7133700 0.6 0.6 0.6
16 . THERMISTER - REPLACE 7133800 4.4 4.4 4.4
17 . HEATER, FREE - REPLACE 7133900 0.3 — —
18 . ADHESIVE, AIR OUTLET DUCT SEAL - REPLACE 7134200 2.7 2.7 2.7
C : C-100
HEATING & VENTILATION - BLOWER (714)

OPERATION C
1 . RESISTOR, BLOWER MOTOR - REPLACE 7140100 0.2 0.2 0.2
2 . TUBE, BLOWER MOTOR COOLING - REPLACE 7140500 0.3 0.3 0.3
3 . MOTOR AND/OR FAN, BLOWER - REPLACE 7140700 0.4 0.4 0.4
4 . HOUSING, BLOWER MOTOR - REPLACE 7140900 4.6 4.6 4.6
A - Recover/Recharge AC system 714090A 0.7 0.7 0.7
5 . FILTER, AIR - REPLACE 7141100 0.3 0.3 0.3
6 . COVER, AIR FILTER - REPLACE 7141300 0.3 0.3 0.3
C : C-100
SECTION 7B
HVAC CONTROL
HVAC CONTROL - COMPRESSOR (732)
OPERATION C
1 . CLUTCH PLATE AND HUB ASSEMBLY, COMPRESSOR -
7320400 1.1 1.2 1.3
REPLACE
2 . COIL AND/OR PULLEY RIM, COMPRESSOR CLUTCH -
7320800 1.5 1.6 1.7
REPLACE
3 . COMPRESSOR ASSEMBLY - REPLACE 7322100 0.9 1.0 1.1
C : C-100
HVAC CONTROL - COMPRESSOR MOUNT (733)
OPERATION C
1 . BRACKET, COMPRESSOR LOWER SUPPORT - REPLACE 7330100 2.8 1.6 1.2
2 . BRACKET, COMPRESSOR REAR - REPLACE 7330300 — 0.8 —
C : C-100
HVAC CONTROL - A/C HOSE & PIPE LINE (734)
OPERATION C
1 . SEALS, COMPRESSOR MANIFOLD REFRIGERANT O-RING -
7340300 0.2 0.2 0.2
REPLACE
Compressor Line 7340410 0.2 0.2 0.2
Pressure Switch 7340500 0.2 0.2 0.2
OPERATION C
Condenser Line 7340600 0.2 0.2 0.2
Evaporator Inlet Line 7340700 0.3 0.3 0.3
Evaporator Outlet Line 7340800 0.3 0.3 0.3
2 . LINE, REFRIGERANT (EVAPORATOR TO CONDENSER) -
7341200 0.6 0.6 0.6
REPLACE
3 . LINE, REFRIGERANT (COMPRESSOR SUCTION/DISCHARGE)
7341300 0.4 0.4 0.4
- REPLACE
4 . CONDENSER - REPLACE 7341400 0.6 0.6 0.6
5 . TRANSDUCER, A/C PRESSURE - REPLACE 7341900 0.2 0.2 0.2
6 . LINE, REFRIGERANT (EVAPORATOR TO COMPRESSOR
7342200 0.4 0.4 0.4
HOSE) - REPLACE
C : C-100
HVAC CONTROL - A/C CONTROL SWITCH (735)
OPERATION C
1 . SWITCH, CONTROL ASSEMBLY - REPLACE 7350100 0.4 0.4 0.4
OPERATION C
2 . CABLE, TEMPERATURE - REPLACE 7350500 0.6 0.6 0.6
3 . SENSOR, OUTSIDE TEMPERATURE - REPLACE 7351700 0.4 0.4 0.4
4 . SWITCH, ATC - REPLACE 7351900 0.4 0.4 0.4
5 . SENSOR, SUN - REPLACE 7352100 0.2 0.2 0.2
6 . SENSOR, INCAR - REPLACE 7352300 0.5 0.5 0.5
7 . SENSOR, ANTI POLLUTION - REPLACE 7352500 0.4 0.4 0.4
8 . DIAGNOSTIC TIME - DTC RELATED DIAGNOSIS 7352600 0.2 0.2 0.2
C : C-100
SECTION 8A
RESTRAINTS (SEAT BELTS)

SEAT BELTS - FRONT SEAT BELT (812)
OPERATION MODEL
CODE C .
1 . BUCKLE, FRONT SEAT BELT - REPLACE . . .
Right 8120100 0.3 .
Left 8120200 0.3 .
Both 8120300 0.5 .
OPERATION MODEL
CODE C .
2 . BELT, SAFETY FRONT - REPLACE . . .
Right 8120500 0.4 .
Left 8120600 0.4 .
Both 8120700 0.7 .
3 . GUIDE AND/OR COVER, SAFEY BELT - REPLACE . . .
Right 8120900 0.2 .
Left 8121100 0.2 .
4 . ADJUSTER, FRONT SAFETY BELT - REPLACE . . .
Right 8121300 0.4 .
Left 8121400 0.4 .
. . 0.7 .
C : C-100
SEAT BELTS - REAR SEAT BELT (822)
OPERATION MODEL
CODE C .
1 . BELT, SAFETY REAR - REPLACE . . .
Right 8220400 0.4 .
Left 8220500 0.4 .
2 . BUCKLE, REAR SEAT BELT - REPLACE . . .
OPERATION MODEL
CODE C .
Right 8220910 0.3 .
Left 8220920 0.3 .
3 . BELT, SAFETY 3TH REAR - REPLACE . . .
Right 8220930 0.4 .
Left 8220940 0.4 .
C : C-100
SECTION 8B
RESTRAINTS S. I. R (SUPPLEMENTAL
INFLATABLE RESTRAINTS)
S. R. S (SUPPLEMENTAL INFLATABLE RESTRAINTS) - AIR BAG
SYSTEM (832)
OPERATION MODEL
CODE C100 C105
1 . COIL, SRS - REPLACE 8320100 0.6 0.6
2 . SDM, AIR BAG - REPLACE 8320300 0.6 0.6
INC : REPROGRAM . . .
3 . SDM, AIR BAG - REPROGRAM ONLY 8320400 0.3 0.3
4 . MODULE, STEERING WHEEL INFLATOR - REPLACE 8320700 0.2 0.2
5 . MODULE, PASSENGER INFLATABLE CUSHION - REPLACE 8320900 3.4 3.4
6 . SENSOR, SIDE AIR BAG - REPLACE . . .
Right 8321000 0.3 0.3
Left 8321100 0.3 0.3
Both 8321200 0.5 0.5
7 . MODULE, SIDE AIR BAG - REPLACE . . .
Right 8321300 0.4 0.4
Left 8321400 0.4 0.4
Both 8321500 0.7 0.7
8 . CURTAIN, SIDE AIR BAG - REPLACE . . .
Right 8321600 2.2 2.2
Left 8321700 2.2 2.2
Both 8321800 2.5 2.5
S. R. S (SUPPLEMENTAL INFLATABLE RESTRAINTS) -
IMMOBILIZER (833)
OPERATION MODEL
CODE C100 C105
1 . VEHICLE THEFT MODULE - REPLACE 8330500 0.8 0.8
2 . VEHICLE THEFT DETERRENT(IMMOBILIZER) - REPROGRAM ONLY 8330600 0.5 0.5
SECTION 9A
BODY & ACCESSORIES (BODY WIRING

SYSTEM)
BODY WIRING SYSTEM - WIRING HARNESS (911)
OPERATION MODEL
CODE C100 C105
1 CABLES, BODY - REPLACE . . .
Negative 9110300 0.6 0.6
2 WIRING, FLOOR (BOOY) - REPLACE 9110500 5.1 5.1
3 WIRING, CONSOL - REPLACE 9110600 0.5 0.5
4 WIRING, INST PANEL - REPLACE 9110700 4.0 4.0
5 WIRING, ROOF - REPLACE 9110900 2.1 2.1
6 WIRING, FRONT - REPLACE 9111300 1.0 1.0
7 WIRING, FRONT DOOR - REPLACE 9112300 0.9 0.9
8 WIRING, REAR DOOR - REPLACE 9112500 0.9 0.9
9 WIRING, ENGINE CONTROL - REPLACE 9112900 2.1 2.1
10 WIRING, FULE PUMP - REPLACE 9113100 0.5 0.5
11 WIRING, REAR ABS - REPLACE 9113300 0.6 0.6
12 WIRING, AIR BAG - REPLACE 9113400 2.5 2.5
13 WIRING, TAILGATE - REPLACE 9114500 0.6 0.6
SECTION 9B
BODY & ACCESSORIES (LIGHTING SYSTEM)

LIGHTING SYSTEM - FRONT LAMP (916/917)
OPERATION MODEL
CODE C100 C105
1 HEADLAMP/COMPOSITE ASSEMBLY - REPLACE . . .
Right 9160100 0.4 0.4
Left 9160200 0.4 0.4
OPERATION MODEL
CODE C100 C105
Both 9160300 0.5 0.5
2 BULB, COMPOSITE HEADLAMP - REPLACE . . .
Right 9160400 0.4 0.4
Left 9160500 0.4 0.4
Both 9160600 0.5 0.5
3 CAP, HEADLAMP - REPLACE . . .
Right 9160800 0.4 0.4
Left 9160900 0.4 0.4
4 BULB, TURN SIGNAL - REPLACE . . .
Right 9161100 0.4 0.4
Left 9170100 0.4 0.4
Both 9170200 0.5 0.5
5 BULB, POSTION - REPLACE . . .
Right 9161300 0.4 0.4
Left 9170300 0.4 0.4
Both 9170400 0.5 0.5
6 LAMP, FOG - REPLACE . . .
Right 9161500 1.0 1.0
Left 9170500 1.0 1.0
Both 9170600 1.0 1.0
7 BULB LAMP, FOG - REPLACE . . .
Right 9161700 0.4 0.4
Left 9170700 0.4 0.4
Both 9170800 0.5 0.5
LIGHTING SYSTEM - FRONT LAMP (916/917)
OPERATION MODEL
CODE C100 C105
8 LAMP, TURN SIGNAL SIDE - REPLACE . . .
Right 9162100 0.4 0.4
Left 9171200 0.4 0.4
OPERATION MODEL
CODE C100 C105
Both 9171300 0.5 0.5
9 BULB, TURN SIGNAL SIDE LAMP - REPLACE . . .
Right 9162200 0.4 0.4
Left 9171400 0.4 0.4
Both 9171500 0.5 0.5
LIGHTING SYSTEM - REAR LAMP (918)

OPERATION MODEL
CODE C100 C105
1 LAMP, REAR COMBINATION - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Right 9180100 0.2 0.2
Left 9180200 0.2 0.2
Both 9180300 0.3 0.3
2 BULB, COMBINATION LAMP - REPLACE . . .
Right 9180500 0.2 0.2
Left 9180600 0.2 0.2
Both 9180700 0.3 0.3
3 LAMP, LICENSE - REPLACE 9180800 0.2 0.2
4 BULB LAMP, LICENSE - REPLACE 9180900 0.2 0.2
5 BULB, BACK-UP LAMP - REPLACE 9181100 0.2 0.2
BULB TURN SIGNAL - REPLACE 9181200 0.2 0.2
6 LAMP, HIGH MOUNTED STOP - REPLACE 9181700 0.4 0.4
7 APPLIQUE, LIFTGATE UPPER - REPLACE 9181800 0.4 0.4
8 BULB, REAR FOG LAMP - REPLACE 9182700 0.2 0.2
SECTION 9D
BODY & ACCESSORIES (WIPER/WASHER

SYSTEM)
WIPER / WASHER SYSTEM - WINDSHIELD WIPER (921)
OPERATION MODEL
CODE C100 C105
1 . MOTOR, WIPER - REPLACE 9210200 0.5 0.5
. MOTOR, BACK WINDOW - REPLACE 9210300 0.5 0.5
2 . BLADE, WIPER (WINDSHIELD) - REPLACE 9210700 0.2 0.2
. BLADE, WIPER (BACK WINDOW) - REPLACE 9210710 0.2 0.2
3 . ARM, WIPER (WINDSHIELD) - REPLACE 9210900 0.2 0.2
. ARM, WIPER (BACK WINDOW) - REPLACE 9211000 0.2 0.2
4 . LINKAGE, WIPER - REPLACE 9211100 0.5 0.5
5 . RAMP, RR/WDO WPR ARM PARK - REPLACE 9211500 0.3 0.3
WIPER / WASHER SYSTEM - WINDSHIELD WASHER (921)
OPERATION MODEL
CODE C100 C105
1 . RESERVOIR, WASHER FLUID - REPLACE 9230100 0.5 0.5
2 . HOSES, NOZZLES, WASHER - REPLACE 9230300 0.6 0.6
. HOSES, NOZZLES, REAR WASHER - REPLACE 9230400 1.7 1.7
3 . TUBE, HEAD LAMP WASHER NOZZLE - REPLACE 9230600 0.4 0.4
4 . PUMP, WASHER - REPLACE 9230700 0.4 0.4
BODY & ACCESSORIES (INSTRUMENT DRIVER
SYSTEM)
INSTRUMENT DRIVER SYSTEM - INSTRUMENT CLUSTER (925)

OPERATION MODEL
CODE C100 C105
1 . CLUSTER ASSEMBLY, I/P - REPLACE 9250300 0.6 0.3
2 . I/P CLUSTER - REPROGRAM ONLY 9250800 0.4 0.4
SECTION 9F
BODY & ACCESSORIES (AUDIO & ANTI-THEFT

SYSTEM)
AUDIO SYSTEM - ELECTRICAL PARTS (928)
OPERATION MODEL
CODE C100 C105
1 . SPEAKER, RADIO CENTER FRONT - REPLACE 9280200 0.3 0.3
2 . SPEAKER, RADIO FRONT SIDE DOOR - REPLACE . . .
Right 9280300 0.4 0.4
Left 9280400 0.4 0.4
OPERATION MODEL
CODE C100 C105
Both 9280500 0.6 0.6
3 . SPEAKER, RADIO REAR SIDE DOOR - REPLACE . . .
Right 9280600 0.4 0.4
Left 9280700 0.4 0.4
Both 9280800 0.6 0.6
4 . AMPLIFIER, RADIO SPEAKER - REPLACE 9280810 0.5 0.5
5 . HORN ASSAY - REPLACE 9281100 0.4 0.4
6 . LAMP, ROOM (READING) - REPLACE 9281500 0.2 0.2
7 . BULB, LAMP (READING) - REPLACE 9281600 0.2 0.2
8 . LAMP, DOME - REPLACE 9281700 0.2 0.2
9 . BULB, DOME LAMP - REPLACE 9281800 0.2 0.2
10 . LAMP, GLOVE BOX - REPLACE 9281900 0.2 0.2
11 . BULB, GLOVE BOX - REPLACE 9282000 0.2 0.2
12 . SWITCH, GLOVE BOX - REPLACE 9282100 0.2 0.2
13 . PLAYER, COMPACT DISK - REPLACE 9283300 0.2 0.2
. SWITCH, AUDIO REMOTE CONTROL 9283800 0.2 0.2
14 . SENSOR, RAIN - REPLACE 9284200 0.2 0.2
15 . COVER, RAIN SENSOR - REPLACE 9284300 0.2 0.2
16 . DISPLAY, DRIVER, INFORMATION - REPLACE 9284400 0.3 -
AUDIO & ANTI-THEFT SYSTEM - ANTENNA PARTS (929)
OPERATION MODEL
CODE C100 C105
1 . CABLE, ANTENNA - REPLACE . . .
ANTENNA TO CONNECTOR 9290300 0.2 0.2
CONNECTOR TO MODULE 9290400 2.0 2.0
MODULE TO EXTN END 9290500 2.1 2.1
2 . MODULE, R.F.A - REPLACE 9291160 0.5 0.5
3 . MODULE, RADIO ANTENNA - REPLACE 9291600 0.7 0.7
4 . EXPORT B.C.M - REPLACE 9292500 1.0 1.0
5 . EXPORT B.C.M - REPROGRAM ONLY 9292600 0.5 0.5
6 . BODY CONTROL MODULE - REPLACE 9292800 1.2 1.2
7 . B.C.M - REPROGRAM ONLY 9292900 0.4 0.4
OPERATION MODEL
CODE C100 C105
8 . R.F.A (UNIT RECEIVER) - REPROGRAM ONLY 9293700 0.4 0.4
SECTION 9G
BODY & ACCESSORIES (INTERIOR TRIM)
INTERIOR TRIM - INSTRUMENT PANEL (931)

OPERATION MODEL
CODE C100 C105
1 . LOCK, COMPARTMENT I/P - REPLACE 9310100 0.2 0.2
2 . BOX, GLOVE - REPLACE 9310700 0.2 0.2
3 . PANEL, INSTRUMENT ASSEMBLY - REPLACE 9310900 3.2 3.2
4 . PANEL, KICK PAD - REPLACE . . .
Right 9311100 0.2 0.2
Left 9311200 0.2 0.2
5 . COVER, INSTRUMENT LOWER - REPLACE 9311400 0.2 0.2
6 . NOZZLE, VENTILATION CENTER - REPLACE . . .
Right 9311800 0.2 0.2
Left 9311810 0.2 0.2
OPERATION MODEL
CODE C100 C105
7 . BOX, COIN - REPLACE 9313000 0.2 0.2
INTERIOR TRIM - MOLDING & SWITCH (932)

OPERATION MODEL
CODE C100 C105
1 . PLATE I/P CLUSTER TRIM - REPLACE 9320100 0.3 0.3
2 . SWITCH ASSY - REPLACE . . .
Hazard Warning 9320300 0.2 0.2
Fog Lamp 9320400 0.2 0.2
Rear Defogger 9320450 0.3 0.3
3 . CLOCK - REPLACE 9320600 0.2 0.2
4 . SWITCH, ELECTRIC REMOTE MIRROR - REPLACE 9320800 0.2 0.2
5 . HOUSING, SWICH - REPLACE 9321100 0.2 0.2
6 . SWITCH, HEAD LAMP LEVELING - REPLACE 9321500 0.2 0.2
OPERATION MODEL
CODE C100 C105
7 . MOLDING, CENTER UPPER I/P - REPLACE 9322800 0.3 0.3
8 . MOLDING, INSTRUMENT PANEL GARNISH - REPLACE 9323000 0.3 0.3
INTERIOR TRIM - INSTRUMENT & PARTS (933)

OPERATION MODEL
CODE C100 C105
1 . PLATE, I/P CENTER TRIM - REPLACE 9330100 0.2 0.2
2 . BOX, DEPOSIT - REPLACE 9330900 0.2 0.2
INTERIOR TRIM - CONSOLE (934)
OPERATION MODEL
CODE C100 C105
1 . CONSOLE ASSEMBLY, FRONT - REPLACE . . .
Auto 9340100 0.9 0.9
Manual 9340200 0.9 0.9
2 . CONSOLE ASSEMBLY, REAR - REPLACE . . .
Auto 9340400 0.4 0.4
OPERATION MODEL
CODE C100 C105
Manual 9340500 0.4 0.4
3 . HOUSING, CIGARETTE LIGHTER - REPLACE 9340700 0.2 0.2
4 . LIGHTER, CIGARETTE - REPLACE 9340900 0.2 0.2
5 . ASHTRAY, F/FLR CNSL - REPLACE 9341400 0.2 0.2
6 . JACK, EXTRA POWER SUPPLY - REPLACE 9341700 0.4 0.4
7 . COVER, CONSOLE - REPLACE 9342400 0.2 0.2
8 . BOX,REAR CONSOLE - REPLACE 9342500 0.2 0.2
9 . LID,REAR CONSOLE - REPLACE 9342600 0.2 0.2
10 . HOLDER CUP REAR CONSOLE - REPLACE 9342800 0.5 0.5
11 . TRAY, REAR CONSOLE - REPLACE 9342900 0.5 0.5
INTERIOR TRIM - FRONT DOOR TRIM (935)
OPERATION MODEL
CODE C100 C105
1 . TRIM ASSEMBLY, FRONT DOOR - REPLACE . . .
Right 9350100 0.4 0.4
Left 9350200 0.4 0.4
Both 9350300 0.7 0.7
2 . HANDLE, FRONT DOOR INSIDE - REPLACE . . .
Right 9350500 0.6 0.6
Left 9350600 0.6 0.6
Both 9350700 1.1 1.1
3 . SEAL, FRONT DOOR TRIM - REPLACE 9350800 0.4 0.4
4 . SWITCH, WINDOW LIFTER MAIN - REPLACE 9351300 0.4 0.4
Passenger 9351310 0.4 0.4
. SWITCH, TAILGATE GLASS OPEN - REPLACE 9351320 0.4 0.4
5 . SWITCH, HEATING MAT - REPLACE . . .
Right 9351400 0.2 0.2
Left 9351410 0.2 0.2
Both 9351420 0.2 0.2
6 . GRILLE, FRONT SPEAKER - REPLACE . . .
Right 9351800 0.4 0.4
Left 9351900 0.4 0.4
Both 9352000 0.7 0.7
7 . HANDLE, GRIP FRONT INNER - REPLACE . . .
Right 9352700 0.5 0.4
Left 9352800 0.5 0.5
Both 9352810 0.9 0.9
8 . TWEETER, FRONT DR SPEAKER - REPLACE . . .
Right 9353600 0.5 0.5
Left 9353700 0.5 0.5
Both 9353800 0.9 0.9
INTERIOR TRIM - REAR DOOR TRIM (936)
OPERATION MODEL
CODE C100 C105
1 . TRIM ASSEMBLY, REAR DOOR - REPLACE . . .
Right 9360300 0.4 0.4
Left 9360400 0.4 0.4
Both 9360500 0.7 0.7
2 . HANDLE, REAR DOOR INSIDE - REPLACE . . .
Right 9360700 0.6 0.6
Left 9360800 0.6 0.6
Both 9360900 1.1 1.1
OPERATION MODEL
CODE C100 C105
3 . SEAL, REAR DOOR TRIM - REPLACE 9361100 0.4 0.4
4 . GRILLE, REAR SPEAKER - REPLACE . . .
Right 9361200 0.4 0.4
Left 9361210 0.4 0.4
Both 9361220 0.7 0.7
5 . TWEETER, REAR DR SPEAKER - REPLACE . . .
Right 9361600 0.4 0.4
Left 9361610 0.4 0.4
Both 9361620 0.7 0.7
6 . SWITCH, WINDOW LIFTER MAIN REAR - REPLACE . . .
Right 9361700 0.5 0.5
Left 9361800 0.5 0.5
Both 9361900 0.9 0.9
7 . HANDLE, GRIP REAR INNER - REPLACE . . .
Right 9363800 0.5 0.5
Left 9363810 0.5 0.5
Both 9363820 0.9 0.9
INTERIOR TRIM - PILLAR TRIM (938)
OPERATION MODEL
CODE C100 C105
1 . TRIM, CENTER PILLAR - REPLACE . . .
Upper Right 9380100 0.4 0.4
Lower Right 9380200 0.3 0.3
. TRIM, CENTER PILLAR - REPLACE . . .
Upper Left 9380400 0.4 0.4
OPERATION MODEL
CODE C100 C105
Lower Left 9380500 0.3 0.3
2 . COVER, ROCKER PANEL FRONT - REPLACE . . .
Right 9380700 0.3 0.3
Left 9380800 0.3 0.3
3 . COVER, ROCKER PANEL REAR - REPLACE . . .
Right 9381100 0.2 0.2
Left 9381200 0.2 0.2
4 . TRIM, TAILGATE - REPLACE 9381500 0.3 0.3
5 . MOLDING, WINDSHELD GARNISH - REPLACE . . .
Right 9381600 0.3 0.3
Left 9381620 0.3 0.3
Both 9381630 0.5 0.5
6 . COVER, TAILGATE UPPER TRIM - REPLACE 9381700 0.2 0.2
7 . TRIM, QUARTER SIDE UPPER - REPLACE . . .
Right 9382810 0.7 0.7
Left 9382820 0.7 0.7
Both 9382830 1.2 1.2
8 . TRIM, QUARTER SIDE LOWER - REPLACE . . .
Right 9382840 0.5 0.5
Left 9382850 0.5 0.5
Both 9382860 0.8 0.8
INTERIOR TRIM - FLOOR CARPET (939)
OPERATION MODEL
CODE C100 C105
1 . CARPET, ONE PIECE FLOOR - REPLACE 9390100 2.3 2.3
2 . COVER, LOAD FLOOR COMPARTMENT - REPLACE 9390300 0.2 0.2
3 . HANDLE, LOAD FLR COVER - REPLACE 9390310 0.2 0.2
4 . COVER, SPARE TIRE - REPLACE 9390500 - 0.2
5 . SHELF, LOAD, COMPARTMENT - REPLACE 9390700 0.2 0.2
6 . NET, LOAD COMPARTMENT - REPLACE 9390900 0.2 0.2
7 . BOX, LOAD COMPARTMENT SIDE - REPLACE 9391100 0.2 0.2
8 . COMPARTMENT, LOAD FLOOR - REPLACE 9391200 0.2 -
OPERATION MODEL
CODE C100 C105
9 . COVER, REAR FLOOR DEPOSITBOX - REPLACE 9392100 0.2 0.2
10 . TRAY, FRONT SEAT STORAGE - REPLACE 9392000 0.2 0.2
11 . DEPOSIT BOX, TOOL KIT - REPLACE 9392900 0.2 0.2
SECTION 9H
BODY & ACCESSORIES (SEATS)

SEATS - FRONT SEAT (941)
OPERATION MODEL
CODE C100 C105
1 . GUIDE RAIL, FRONT SEAT MANUAL - REPLACE . . .
Passenger 9410100 0.7 0.7
Driver 9410300 0.7 0.7
. GUIDE RAIL, FRONT SEAT POWER - REPLACE 9410400 0.8 0.8
2 . KNOB, FRONT SEAT BACK - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Passenger 9410500 0.2 0.2
Driver 9410600 0.2 0.2
3 . PAD, D/SEAT BK CUSH - REPLACE 9410700 0.7 0.7
4 . PAD, F/SEAT CUSH - REPLACE 9411000 0.7 0.7
5 . COVER, FRONT SEAT SIDE - REPLACE . . .
Passenger 9412100 0.2 0.2
Driver 9412200 0.2 0.2
6 . HEADREST FRONT SEAT - REPLACE . . .
Passenger 9412700 0.2 0.2
Driver 9412800 0.2 0.2
7 . COVER, FRONT SEAT CUSHION - REPLACE . . .
Passenger 9413100 0.7 0.7
Driver 9413200 0.7 0.7
8 . COVER, FRONT SEAT BACK - REPLACE . . .
Passenger 9413400 0.7 0.7
Driver 9413500 0.7 0.7
9 . RECLINING FRONT SEAT - REPLACE . . .
Passenger 9413700 0.8 0.8
Driver 9413800 0.8 0.8
10 . GUIDE, F/SEAT BK H/RST ADJ ROD - REPLACE . . .
Passenger 9414100 0.3 0.3
Driver 9414200 0.3 0.3
. SEAT, FRONT ASSEMBLY - REPLACE . . .
11 Passenger 9414600 0.3 0.3
Driver 9414700 0.3 0.3
12 . SWITCH, D/SEAT ADJR & RECL - REPLACE 9414900 0.3 0.3
SEATS - REAR SEAT (942)
OPERATION MODEL
CODE C100 C105
13 . TABLE, FRONT SEAT BACK - REPLACE 9415100 - -
14 . FRONT, HEATING MAT CUSHION - REPLACE . . .
Passenger 9415800 0.8 0.8
Driver 9415900 0.8 0.8
15 . FRONT, HEATING MAT BACK - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Passenger 9416100 0.8 0.8
Driver 9416200 0.8 0.8
. LUMBAR SUB, D/SEAT - REPLACE . . .
16 Passenger 9416500 - -
Driver 9416600 0.7 0.7
OPERATION MODEL
CODE C100 C105
. SEAT ASS'Y, REAR - REPLACE . . .
1 LH 9420110 0.2 0.2
RH 9420120 0.2 0.2
. PAD, R/SEAT CUSH - REPLACE . . .
2 LH 9420200 0.5 0.5
RH 9420210 0.5 0.5
. PAD, R/SEAT CUSH BK CUSH - REPLACE . . .
3 LH 9420400 0.5 0.5
RH 9420410 0.5 0.5
. COVER, R/SAET CUSH - REPLACE . . .
4 LH 9420710 0.5 0.5
RH 9420720 0.5 0.5
5 . CAP, R/SEAT ADJR HDL BOLT - REPLACE 9420800 0.2 0.2
. COVER, R/SEAT BK CUSH - REPLACE . . .
6 LH 9420910 0.5 0.5
RH 9420920 0.5 0.5
7 . ARMREST, R/SEAR - REPLACE 9421100 0.3 0.3
. CABLE, R/SEAT RECL ACTR - REPLACE . . .
8 RH 9421300 0.5 0.5
LH 9421400 0.5 0.5
. KNOB, R/SEAT BK - REPLACE . . .
9 RH 9421600 0.2 0.2
LH 9421700 0.2 0.2
. COVER, R/SEAT CUSH SI/NS OTR - REPLACE . . .
10 LH 9421800 0.2 0.2
RH 9421900 0.2 0.2
11 . RESTRAINT, R/SEAT CTR HD - REPLACE 9422500 0.2 0.2
12 . RESTRAINT, R/SEAT HD - REPLACE 9422510 0.2 0.2
13 . GUIDE, R/SEAT H/RST ADJ ROD - REPLACE 9422600 0.3 0.3
OPERATION MODEL
CODE C100 C105
14 . BRACKET, R/SEAT CUSH - REPLACE 9423800 0.5 0.5
15 . COVER, R/SAET BK CUSH CHILD ST BRKT F/N - REPLACE 9425000 0.4 0.4
16 . RECLINER, R/SEAT - REPLACE . . .
LH 9425100 0.4 0.4
RH 9425110 0.4 0.4
17 . COVER, R/SEAT CUSH - REPLACE . . .
LH 9425200 0.3 0.3
RH 9425210 0.3 0.3
18 . STRUT, R/SEAT - REPLACE 9425300 0.2 0.2
19 . FRAME, R/SEAT CUSH - REPLACE . . .
LH 9425400 0.5 0.5
RH 9425410 0.5 0.5
. RISER, R/SEAT - REPLACE . . .
20 LH 9425500 0.4 0.4
RH 9425510 0.4 0.4
. PANEL, R/SEAT CUSH - REPLACE . . .
21 LH 9425600 0.3 0.3
RH 9425610 0.3 0.3
SEATS - REAR SEAT #2 (943)
OPERATION MODEL
CODE C100 C105
1 . SEAT #2 ASS'Y, REAR - REPLACE . . .
Right 9430100 0.2 0.2
Left 9430110 0.2 0.2
2 . COVER, R/SEAR #2 BK CUSH - REPLACE 9430300 0.4 0.4
3 . COVER, R/SEAR #2 CUSH - REPLACE 9430500 0.4 0.4
4 . PAD, R/SEAT #2 BK CUSH - REPLACE 9430700 0.7 0.7
5 . PAD, R/SEAT #2 CUSH - REPLACE 9430900 0.7 0.7
6 . COVER, R/SEAT #2 H/RST - REPLACE 9431000 0.3 0.3
7 . PANEL, R/SEAT #2 BK CUSH - REPLACE 9431100 0.2 0.2
8 . FRAME, R/SEAT H/RST SUPT(#2) - REPLACE 9431200 0.3 0.3
9 . HANDLE, R/SEAT #2 BK CUSH LAT REL - REPLACE 9431300 0.2 0.2
10 . BRACKET, R/SEAT #2 - REPLACE 9431400 0.3 0.3
OPERATION MODEL
CODE C100 C105
11 . FRAME, R/SEAT #2 BK CUSH - REPLACE 9431500 0.7 0.7
12 . FRAME, R/SEAT #2 CUSH - REPLACE 9431600 0.7 0.7
13 . LINK, R/SEAT #2 HGE FRT - REPLACE 9431700 0.3 0.3
SECTION 9L
BODY & ACCESSORIES (GLASS & MIRRORS)

GLASS & MIRRORS - GLASS & OUTSIDE MIRRORS (946)
OPERATION MODEL
CODE C100 C105
1 GLASS, WINDSHIELD - REPLACE 9460100 1.2 1.2
2 MOLDING, WINDSHIELD FRONT - REPLACE 9460600 0.6 0.6
3 GLASS, FRONT DOOR - REPLACE . . .
Right 9461100 0.5 0.5
OPERATION MODEL
CODE C100 C105
Left 9461200 0.5 0.5
4 GLASS, REAR DOOR - REPLACE . . .
Right 9461400 0.6 0.6
Left 9461500 0.6 0.6
5 MIRROR, OUTSIDE REAR VIEW - REPLACE . . .
Right 9462300 0.3 0.3
Left 9462400 0.3 0.3
6 GLASS, QUARTER WINDOW - REPLACE . . .
Right 9463100 0.7 0.7
Left 9463200 0.7 0.7
7 WINDOW, L/FTGATE - REPLACE 9463700 0.4 0.4
8 WEATHERSTRIP L/GATE WINDOW - REPLACE 9463800 0.4 0.4
SECTION 9M
BODY & ACCESSORIES (EXTERIOR PARTS)

EXTERIOR PARTS - EMBLEM & LETTERING (951)
OPERATION MODEL
CODE C100 C105
1 EMBLEM - REPLACE 9510100 0.2 0.2
2 LETTERING - REPLACE 9510300 0.2 0.2
SECTION 9O
BODY & ACCESSORIES (BUMPERS & FASCIAS)

BUMPERS & FASCIAS - FRONT BUMPER (956)
OPERATION MODEL
CODE C100 C105
1 . FASCIA, FRONT BUMPER - REPLACE 9560100 1.0 1.0
2 . BEAM, IMPACT FRONT - REPLACE (ONE PIECE) 9560300 1.2 1.2
3 . BRACKET, BUMPER. FRONT - REPLACE 9560900 1.0 1.0
4 . STAY, FRONT BUMPER - REPLACE 9561500 1.3 1.3
BUMPERS & FASCIAS - REAR BUMPER (957)
OPERATION MODEL
CODE C100 C105
1 . FASCIA, REAR BUMPER - REPLACE 9570100 0.8 0.8
3 . PAD, REAR BUMPER STEP - REPLACE 9570500 0.2 0.2
3 . BEAM, IMPACT REAR - REPLACE 9570600 0.9 0.9
OPERATION MODEL
CODE C100 C105
4 . BRACKET, BUMPER REAR - REPLACE
EXTERIOR TRIM - MUD GUARD (952)

OPERATION MODEL
CODE C100 C105
1 GUARD, MUD FRONT - REPLACE . . .
Right 9520100 0.2 0.2
Left 9520200 0.2 0.2
Both 9520300 0.3 0.3
2 GUARD, MUD REAR - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Right 9520600 0.2 0.2
Left 9520700 0.2 0.2
Both 9520800 0.3 0.3
3 MOLDING, ROCKER PANEL - REPLACE . . .
Right 9520900 0.5 0.5
Left 9520910 0.5 0.5
Both 9520920 0.9 0.9
4 MOLDING, FRONT WHEEL ARCH - REPLACE . . .
Right 9521100 0.3 0.3
Left 9521200 0.3 0.3
Both 9521300 0.5 0.5
5 MOLDING, GARNISH FRONT DOOR - REPLACE . . .
Right 9521500 0.3 0.3
Left 9521600 0.3 0.3
Both 9521700 0.5 0.5
6 MOLDING, GARNISH REAR DOOR - REPLACE . . .
Right 9522100 0.3 0.3
Left 9522200 0.3 0.3
Both 9522300 0.5 0.5
7 MOLDING, REAR WHEEL ARCH - REPLACE . . .
Right 9522500 0.3 0.3
Left 9522600 0.3 0.3
Both 9522700 0.5 0.5
8 STEP. ASSIST - REPLACE . . .
Right 9523100 0.3 0.3
Left 9523200 0.3 0.3
Both 9523300 0.5 0.5
SECTION 9P
BODY & ACCESSORIES (DOORS)

DOORS - FRONT DOOR & LOCK (961A)
OPERATION MODEL
CODE C100 C105
1 . DOOR ASSEMBLY, FRONT - REPLACE . . .
Right 9610100 1.8 1.8
Left 9610200 1.8 1.8
. DOOR ASSEMBLY, FRONT - ALIGN . . .
OPERATION MODEL
CODE C100 C105
Right 9610400 0.4 0.4
Left 9610500 0.4 0.4
2 . HINGE, FRONT DOOR - REPLACE . . .
Right Upper 9610700 1.4 1.4
Left Upper 9610800 1.4 1.4
Right Lower 9610900 1.4 1.4
Left Lower 9611100 1.4 1.4
Both Right 9611200 1.5 1.5
Both Left 9611300 1.5 1.5
3 . LINK, FRONT DOOR HOLD OPEN - REPLACE . . .
Right 9611500 0.5 0.5
Left 9611600 0.5 0.5
4 . HANDLE, FRONT DOOR OUTSIDE - REPLACE . . .
Right 9612100 0.5 0.5
Left 9612200 0.5 0.5
5 . STRIKER, FRONT DOOR LOCK - REPLACE . . .
Right 9612500 0.2 0.2
Left 9612600 0.2 0.2
6 . LATCH, FRONT DOOR - REPLACE . . .
Right 9612800 0.6 0.6
Left 9612900 0.6 0.6
Both 9613000 1.1 1.1
DOORS - FRONT WINDOW LIFTER (961B)
OPERATION MODEL
CODE C100 C105
1 . RAIL, FRONT DOOR GUIDE - REPLACE . . .
Right 9615100 0.5 0.5
Left 9615200 0.5 0.5
2 . REGULATOR, FRONT DOOR WINDOW POWER - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Right 9616400 0.6 0.6
Left 9616500 0.6 0.6
3 . MOTOR, FRONT DOOR WINDOW - REPLACE . . .
Right 9616700 0.6 0.6
Left 9616800 0.6 0.6
DOORS - FRONT WEATHER STRIP (961C)
OPERATION MODEL
CODE C100 C105
1 . WEATHER STRIP, FRONT DOOR - REPLACE . . .
Right 9618100 0.4 0.4
Left 9618200 0.4 0.4
2 . SECOND WEATHER STRIP, FRONT DOOR - REPLACE . . .
Right 9618300 0.8 0.8
Left 9618400 0.8 0.8
3 . MOLDING, FRONT DOOR OUTER - REPLACE . . .
Right 9618600 0.3 0.3
Left 9618700 0.3 0.3
4 . WEATHER STRIP, FRONT DOOR GLASS - REPLACE . . .
Right 9618800 0.6 0.6
Left 9618900 0.6 0.6
5 . GLASS RUN, FRONT DOOR - REPLACE . . .
Right 9619100 0.6 0.6
Left 9619200 0.6 0.6
6 . MOULDING, FRONT SIDE DOOR - REPLACE 9619300 0.3 0.3
7 . WEATHER STRIP, FRONT DOOR, LOWER - REPLACE . . .
Right 9619400 0.2 0.2
Left 9619410 0.2 0.2
DOORS - REAR DOOR & LOCK (963A)
OPERATION MODEL
CODE C100 C105
1 . DOOR ASSEMBLY, REAR - REPLACE . . .
Right 9630100 1.7 1.7
Left 9630200 1.7 1.7
. DOOR ASSEMBLY, REAR - ALIGN . . .
OPERATION MODEL
CODE C100 C105
Right 9630400 0.4 0.4
Left 9630500 0.4 0.4
2 . HINGE, FRONT DOOR - REPLACE . . .
Right Upper 9630700 0.3 0.3
Left Upper 9630800 0.3 0.3
Right Lower 9630900 0.3 0.3
Left Lower 9631100 0.3 0.3
Both Right 9631200 0.4 0.4
Both Left 9631300 0.4 0.4
3 . LINK, FRONT DOOR HOLD OPEN - REPLACE . . .
Right 9631500 0.5 0.5
Left 9631600 0.5 0.5
4 . HANDLE, FRONT DOOR OUTSIDE - REPLACE . . .
Right 9631800 0.5 0.5
Left 9631900 0.5 0.5
5 . STRIKER, FRONT DOOR LOCK - REPLACE . . .
Right 9632100 0.2 0.2
Left 9632200 0.2 0.2
6 . LATCH, FRONT DOOR - R&R OR REPLACE . . .
Right 9632400 0.6 0.6
Left 9632500 0.6 0.6
Both 9632600 1.1 1.1
DOORS - REAR WINDOW LIFTER (963B)
OPERATION MODEL
CODE C100 C105
1 . REGULATOR, REAR DOOR WINDOW POWER - REPLACE . . .
Right 9636300 0.6 0.6
Left 9636400 0.6 0.6
2 . MOTOR, REAR DOOR WINDOW - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Right 9636600 0.6 0.6
Left 9636700 0.6 0.6
DOORS - REAR WEATHER STRIP (963C)

OPERATION MODEL
CODE C100 C105
1 . WEATHERSTRIP, REAR DOOR - REPLACE . . .
Right 9638100 0.4 0.4
Left 9638200 0.4 0.4
2 . SECOND WEATHER STRIP, REAR DOOR - REPLACE . . .
Right 9638300 0.8 0.8
Left 9638400 0.8 0.8
3 . GARNISH, REAR DOOR - REPLACE . . .
Right 9638500 0.2 0.2
Left 9638510 0.2 0.2
4 . MOLDING, REAR DOOR OUTER - REPLACE . . .
Right 9638600 0.3 0.3
Left 9638700 0.3 0.3
5 . WEATHER STRIP, REAR DOOR GLASS - REPLACE . . .
Right 9638800 0.6 0.6
Left 9638900 0.6 0.6
6 . GLASS RUN, REAR DOOR - REPLACE . . .
Right 9639100 0.7 0.7
Left 9639200 0.7 0.7
7 . MOLDING, REAR SIDE DOOR - REPLACE 9639300 0.3 0.3
8 . WEATHER STRIP, REAR DOOR, LOWER - REPLACE . . .
Right 9639400 0.2 0.2
Left 9639410 0.2 0.2
DOORS - FUEL FILLER LOCK & QUARTER WINDOW LOCK (966)
OPERATION MODEL
CODE C100 C105
1 . DOOR, FUEL FILLER - REPLACE 9660100 0.2 0.2
2 . CAP, FUEL TANK - REPLACE 9660300 0.2 0.2
3 . ACTUATOR, FUEL FILLER DOOR - REPLACE 9661900 0.6 0.6
DOORS - TRUNK LID LOCK & TAILGATE LOCK (967)
OPERATION MODEL
CODE C100 C105
1 . STRIKER, REAR COMPARTMENT LID LOCK - REPLACE 9670300 0.2 0.2
2 . ACTUATOR, TAILGATE - REPLACE 9671100 0.4 0.4
3 . LATCH, L/GATE WINDOW - REPLACE 9671400 0.4 -
4 . ROD, TAILGATE LOCK - REPLACE 9671500 0.4 0.4
5 . LATCH, L/GATE - REPLACE 9671600 0.5 0.5
6 . HANDLE A RELEASE T/GATE - REPLACE 9671700 0.5 -
7 . HANDLE A LIFTGATE - REPLACE 9671710 0.5 0.5
OPERATION MODEL
CODE C100 C105
8 . CAMERA, REAR VIEW - REPLACE 9671800 0.5 -
DOORS - CAR LOCK (968)

OPERATION MODEL
CODE C100 C105
1 . CYLINDER, FRONT DOOR LOCK - REPLACE . . .
Right 9680100 0.5 0.5
Left 9680200 0.5 0.5
OPERATION MODEL
CODE C100 C105
2 . CYLINDER, TAILGATE LOCK - REPLACE 9680400 0.4 0.4
3 . CYLINDER, IGNITION LOCK - REPLACE 9680600 0.5 0.5
4 . CAR LOCK SET - REPLACE 9680700 1.8 1.8
5 . BLANK KEY - CUTTING 9681100 0.2 0.2
A - Immo. Coding 968110A 0.2 0.2
B - Immo. or/and RKE Coding 968110B 0.2 0.2
C - RKE Coding 968110C 0.1 0.1
6 . KEY OR TRANSMITTER - REPLACE 9681600 0.1 0.1
A - Immo. or/and RKE Coding 968160A 0.2 0.2
B - RKE Coding 968160B 0.1 0.1
SECTION 9Q
BODY & ACCESSORIES (ROOF)

ROOF - HEADLINING & ROOF PANEL (971)
OPERATION MODEL
CODE C100 C105
1 HEADLINING ASSEMBLY - REPLACE 9710100 1.9 1.9
2 HANDLE, ASSIST - REPLACE . . .
Right Front 9710200 0.2 0.2
OPERATION MODEL
CODE C100 C105
Left Front 9710300 0.2 0.2
Right Rear 9710400 0.2 0.2
Left Rear 9710500 0.2 0.2
3 ROOF, RACK (ONE OR TWO) - REPLACE 9711500 0.4 0.4
4 HOLDER A SUNGLASS - REPLACE 9712400 0.2 0.2
5 en @@ ROOF PANEL – REPLACE 9712500 9.0 9.0
ROOF - SUNSHADE & INSIDE MIRROR (972A)

OPERATION MODEL
CODE C100 C105
1 MIRROR, VISOR VANITY - REPLACE 9720100 0.2 0.2
2 SUNSHADE - REPLACE . . .
Right 9720300 0.2 0.2
OPERATION MODEL
CODE C100 C105
Left 9720400 0.2 0.2
3 MIRROR, INSIDE REAR VIEW - REPLACE 9720600 0.3 0.3
ROOF - SUN ROOF (972B)

OPERATION MODEL
CODE C100 C105
1 MOTOR, SUN ROOF - REPLACE 9725100 2.0 2.0
2 GLASS, SUN ROOF - REPLACE 9725200 0.4 0.4
3 FRAME, SUN ROOF ASSY - REPLACE 9725400 2.2 2.2
SECTION 9R
BODY & ACCESSORIES (BODY FRONT END)

BODY FRONT END - HOOD PANEL (973)
OPERATION MODEL
CODE C100 C105
1 PANNEL, HOOD - REPLACE 9730100 0.5 0.5
PANNEL, HOOD - ALIGN 9730300 0.3 0.3
2 MOLDING, HOOD - REPLACE 9730400 0.3 —
3 CABLE, HOOD LATCH - REPLACE 9730500 0.4 0.4
4 HINGE, HOOD - REPLACE . . .
Right 9731100 1.3 1.3
Left 9731200 1.3 1.3
Both 9731300 1.6 1.6
5 INSULATION, ENGINE HOOD - REPLACE 9731700 0.3 0.3
6 WEATHER STRIP, HOOD - REPLACE 9731900 0.2 0.2
7 SPRING, HOOD GAS - REPLACE . . .
Right 9732100 0.2 0.2
Left 9732110 0.2 0.2
Both 9732120 0.3 0.3
BODY FRONT END - FRONT PANEL (974)

OPERATION MODEL
CODE C100 C105
1 LATCH, HOOD - REPLACE 9740100 0.3 0.3
2 HANDLE, HOOD LATCH RELEASE - REPLACE 9740200 0.3 0.3
3 BUMPERS, HOOD - REPLACE 9740500 0.2 0.2
BODY FRONT END - FENDER PANEL (975)
OPERATION MODEL
CODE C100 C105
1 SKIRT, FRONT FENDER INNER - REPLACE . . .
Right 9750100 0.3 0.3
Left 9750200 0.3 0.3
2 FENDER, FRONT - REPLACE . . .
Right 9750400 1.3 1.3
Left 9750500 1.3 1.3
FENDER, FRONT - ALIGN . . .
Right 9750700 0.3 0.3
Left 9750800 0.3 0.3
3 TRAY, BATTERY - REPLACE 9751100 0.4 0.4
4 PANEL, WHEELHOUSE - REPLACE . . .
Right 9751300 4.7 4.7
OPERATION MODEL
CODE C100 C105
Left 9751400 4.7 4.7
BODY FRONT END - DASH PANEL & COWL (976)

OPERATION MODEL
CODE C100 C105
1 PANEL, AIR INLET GRILLE - REPLACE 9760100 0.4 0.4
2 PANEL, DASH ASSEMBLY - REPLACE 9760200 3.7 3.7
3 WEATHER STRIP, AIR INLET GRILLE - REPLACE 9760900 0.2 0.2
BODY FRONT END - GRILLE (977)
OPERATION MODEL
CODE C100 C105
1 GRILLE ASSEMBLY - REPLACE 9770100 0.4 0.4
SECTION 9S
BODY REAR END - TRUNK LID PANEL & SPOILER (978)
OPERATION MODEL
CODE C100 C105
1 . HINGE, LIFT GATE - REPLACE . . .
Right 9780100 0.8 0.8
Left 9780200 0.8 0.8
Both 9780300 1.5 1.5
2 . SUPPORT, REAR COMPARTMENT - REPLACE . . .
OPERATION MODEL
CODE C100 C105
Right 9782500 0.2 0.2
Left 9782600 0.2 0.2
Both 9782700 0.3 0.3
3 . TAILGATE - REPLACE 9782900 1.2 1.2
4 . WEATHER STRIP, REAR COMPARTMENT 9783100 0.4 0.4
5 . WEATHER STRIP, L/GATE WINDOW 9783200 0.4 —
6 . HINGE, LIFT GATE WINDOW - REPLACE . . .
Right 9784700 0.4 —
Left 9784800 0.4 —
Both 9784900 0.7 —
7 . SUPPORT, LIFT GATE WINDOW - REPLACE . . .
Right 9785100 0.2 —
Left 9785200 0.2 —
Both 9785300 0.3 —
SECTION 2
ENGINE COMPARTMENT
1. COMPONENTS CONNECTION LOOSE
Check engine compartment for components which may be loose; kinked or pinched vacuum
hoses or electrical connections, and for any other missing or disconnected components as
below.
1. Air Cleaner
2. Engine oil filter cap
3. Brake fluid reservoir*
4. Clutch fluid reservoir*
5. Coolant reservoir
6. fuse and relay box
7. battery
8. Washer fluid reservoir
9. Power steering fluid reservoir
10. Engine oil level dipstick
*Kalos/Aveo, Nubira/Lacetti and Evanda have one reservoir for both the brake and clutch fluid.
 Check engine components for missing or disconnection.

 Check electrical connections for loose or misconnection.
 Check vacuum hoses for kink, pinch, damage, twist and swelling.
 Check hose clamps and pipe connections for leak or loose for following systems.
o – Fuel system
o – Cooling system
o – Power steering system
o – Airconditioning system
 Check engine components which may be loose.
If remedy is required, tighten clamps, connections, bolts and nuts, and replace or repair
defective hose and its connections.
2. HOSE AND ELECT. WIRES ROUTING
Check to assure that following hoses and electrical wires are properly routed to provide
sufficient clearance with adjacent moving or hot parts.
 Fuel hose
 Airconditioning hose
 Vacuum hoses
 High-tension cable for ignition system
 Electric wires
3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER

COMPONENTS
Observe the movement or freeness of movement of linkage, valves and other components.
 Accelerator cable
o Check the accelerator cable free play when the engine is warm as follow.
o 1) Pull the accelerator cable toward the throttle lever.
o 2) Push the cable away from the throttle lever until the lever begins to move. (free
play)
o If adjustment is required, refer to "9. Throttle linkage" of this section.
 Clutch pedal
o Check the clutch pedal free play when depress the clutch pedal.
 Steering linkage system

o The best method for checking condition is with the vehicle on a flat surface and
two mechanics working as a team.
o One of the mechanics turns the steering wheel one way and then the other, and
checks its function mounting and condition, also the mounting for the steering
column (with or without power assistance) while the other mechanic checks for
play in the following places;
o – Tie rods (there must be no looseness)
o – Steering gear mounting on frame
o – Steering shaft universal joints from steering gear and upwards (there must be no
looseness)
o – Check all clamps for proper mounting and tightness
 Starter motor assembly
 1) Check that starting switch and contacts are securely fitted.

 2) Run starter motor, and check for followings.
o Starter motor should crank engine at normal speed.
o Starter motor should function without abnormal noise.
Note : Do not run the starter motor too long as this puts a severe strain on the battery.
 Engine starting response

o Starting the engine, and check if the engine will function normally.
o If the engine does not start or if it stops again, check following items. For further
informations, refer to service manual.
o – Ignition system
o – IAC operation
o – Sensors and ECM, if necessary
4. UNUSUAL NOISES
Check for unusual noises within engine compartment.
Run the engine and check if there are some unusual noises. If unusual noises are heard,
fasten or fix the loosen parts and adjust the clearance between components.
5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS,
ETC.
Visually inspect for seepage and leaks at hoses and pipe connection, seals, gaskets and
plugs. Tighten clamps and connection as necessary.
 Fuel system
 Airconditioning system
 Cooling system
 Brake system
 Clutch system
 Power steering system
 Engine assembly
o – Camshaft support housing
o – Cylinder head
o – Cylinder block
o – Oil pan
o – Seals for camshaft etc.
6. POWER STEERING SYSTEM

Check power steering gear, lines and hoses for leaks and clearance with adjacent panels,
moving or hot parts.
Tighten clamps and connectors as necessary.
7. ENGINE COOLANT PROTECTION
Test engine coolant protection
 The cooling fans are actuated by the ECM using a low-speed cooling fan relay and a
high speed cooling fan relay on non-A/C model or a series/parallel cooling fan relay on
A/C model as below;
<Example: TACUMA(REZZO)>
Fan operating Temp.(°C)
Description Cooling fan Operating Mode
ON OFF
Low speed 96 93
A/C OFF or Non-A/C model
High speed 100 97
Low speed when the A/C system id ON
A/C ON
High speed 100 97
 Check all hoses and connection.

 Check for leaks of cooling system as following procedure.
o – Correct coolant level and run engine at idle speed.
o – Mount radiator tester on expansion tank instead of screw cap.
o – Leaks can be recognized by escaping coolant.
o – If pressure drops or even rises without coolant escaping, this indicates an
internal coolant leak in the engine caused by a defective cylinder head gasket or a
crack in the block.
8. ALL FLUID LEVELS CHECK
Check all fluid levels; engine oil, transmission oil, power steering oil, brake and cooling system.
 Engine oil
o – Engine oil level should be checked with the vehicle standing on level ground
(before the operation of engine). If the engine is running, stop the engine and wait
5 minutes for the oil to drain back to the oil pan before checking the oil level.
o – Pull out the oil level indicator (dipstick), wipe and clean it, and reinsert it.
o Again pull it out and check that the oil level is within MAX. and MIN. level marks.
Also check the oil on the dipstick for contamination.
o – The oil should not go above the "Max" mark on the dip-stick, since this may
cause engine damage.
 Automatic Transaxle Fluid (ATF)

o – The automatic transaxle equipped with ZF 4HP 16 does not have a dipstick. So,
check the fluid level by removing the fluid level plug when the fluid is warmed to
approx. 40°C after driving the vehicle for about 10 minutes with the vehicle on a
level surface.The fluid level should be up to the bottom of the plug hole.If the fluid
level is low, replenish the ATF until it reaches the bottom of the plug hole.
o Reinstall the filler plug and tighten it securely.
Note : Removal of the fluid level plug when the transaxle fluid is hot may cause injury if
fluid drains from the fluid level plug.
 – The automatic transaxle equipped with AISIN 81-40LE or 80-40LE has a dipstick and
the fluid level should be checked when the transaxle reaches normal operting
remperature (70°C ~ 80°C) with the selector lever in position P after operating the
vehicle for about 20 km. Make sure the vehicle is level.
 Pull out the dipstick, wipe and clean it, and reinsert it. Again pull it out and check that the
fluid level is between the MIN and the MAX notches of hot area on the dipstick. Also
check the oil on the dipstick for contamination.
Note : Use only special fluid as given in the fluid chart in owner's manual.
 ZF 4HP 16 : ESSO LT 71141 or ISU H50235

 AISIN 81-40LE or 80-40LE : ESSO JWS 3309 or ISU DEXRON III
 Manual Transaxle oil

o – With the vehicle on a level surface and the fluid in the transaxle cold, remove the
filler plug and check the fluid level. The fluid should come to the bottom edge of
the plug hole.
o – If the level is low, add SAE 80 (1.2S : SAE 75W-85) manual transaxle fluid
through the filler plug hole until the fluid begins to run out.
o – Reinstall the filler plug and tighten it securely.
 Brake/clutch fluid
o – The fluid level in the container should be between the MIN and MAX mark.
o – If the level falls below the MIN mark, add the fluid to the MAX mark and tighten
the cap securely afterwards.
Note : Fluid specification DOT 3 or DOT 4
 Coolant
o Check the coolant level in surge tank.
o – The coolant should be full in the radiator and the fluid level should be between
the "MIN" and "MAX" marks on the outside of the surge tank when the engine is
cool.
o – If the level falls below the "MIN" mark, add enough 50/50 water and ethylene
glycol anti-freeze mix to bring level to a little over the "MAX" mark.
o – For protection in extremely cold weather conditions, use 40% water and 60%
ethylene glycol antifreeze mix.
Note : Do not overfill and remove the coolant surge tank cap when the engine and
radiator are hot.
Note : The antifreeze content of the coolant should be maintained at a minimum of 50%
and maximum of 60%.
 Windshield washer fluid

o Check the windshield washer fluid level in the reservoir tank.
o – Windshield washer level in the reservoir tank should be at 2/3-3/4 level.
Note : Do not use radiator antifreeze for windshield washer solution. Because this may
result in damage to the paint work.
 Power steering oil
o Check fluid level with engine turned off.
o – The fluid level should be between the MIN and MAX marks on the reservoir.
o If it drops to or below the MIN mark, top up with the specified fluid.
Note : Fluid specification DEXRON® II D or DEXRON® III
9. THROTTLE LINKAGE
Check throttle linkage for interference or binding, damage and freeness at wide open and
closed throttle.
 Depressing accelerator pedal several times. check the throttle linkage for freeness.
* Allowable limit for flexure of accelerator cable : 2-10 mm (0.08-0.39 inch).
10. BELTS TENSION

 Check that the belt is worn, cracked or frayed.
 check tension for following belts and adjust if necessary.
Note : to check belt tension easily, apply moderate thumb pressure (Approx. 10 Kg)
midway between pulleys, and check the deflection. If the belt goes down by 10 mm, it is
normal.
SECTION 1A2
GENERAL ENGINE INFORMATION - FAM II 2.4D

Caution : Disconnect the negative battery cable before removing or installing any
electrical unit or when a tool or equipment could easily come in contact with exposed
electrical terminals. Disconnecting this cable will help to prevent personal injury and
damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
SPECIFICATIONS
General Specifications
Application Description
Engine 4–Cylinder/In–Line
Bore x Stroke 87.5 x 100 mm (3.44 x 3.94 in.)
Displacement 2,405 cm³ (147 in³)
Ignition Sequence 1–3–4–2
Engine Performance Compression Ratio 9.6 : 1
Maximum Power 100 kW @ 5,000 rpm
Maximum Torque 220 N•m 2,200 rpm
Air Conditioning System
Idle Speed 690 rpm
(ON/OFF)
Ignition Type Direct Ignition System (DIS)
Starter Type PG 260D (M/T, A/T)
. Capacity 1.4 kW (M/T, A/T)
Spark–Plug Type FLR8LDCU (Bosch)
. Cap 0.9~1.1 mm (0.035~0.043 in.)
Fuel Injection Type MPI
Fuel Pump Type Electric Motor Pump
Fuel Filter Type Cartridge
Lubricating Type Forced Feed Type
Oil Pump Type Rotary (Trochoid) Pump
Cooling Type Forced Water Circulation
Radiator Type Cross – Flow
Water Pump Type Centrifugal
Thermostat Type Pellet Type
Battery Type MF
Engine Part
. Rating (V-AH) 12V–60AH
Cold Cranking Ampere
. 650
(CCA)
Generator Type AD 237
. Rating (V-AH) 14.6 ± 0.25 V-120AH
API SL (ILSAC GF-III) grade SAE
Engine Oil Type 5W-30
* Hot area : SAE 10W-30
. Engine Disassembly 4.5 L (4.75 qt)
Oil Change (Including Oil
. 4.5 L (4.75 qt)
Filter)
Oil Change (Excluding Oil
. 4.3 L (4.54 qt)
Filter)
Coolant Type Dexcool/Silicate Based Coolant
. Capacity 9 L (9.51 qt)
Fuel Tank Capacity 65 L (17.2 gal)
COMPONENT LOCATOR
Engine Compartment
1. Air Cleaner Assembly
2. Camshaft Position (CMP) Sensor
3. Engine Oil Filler Cap
4. Electronic Throttle Body
5. Internal PCV Pipe
6. Exhaust Gas Recirculation (EGR) Valve
7. Direct Ignition System (DIS)
8. Engine Control Module (ECM)
9. Washer Fluid Tank
10. Battery
11. Engine Fuse Block
12. Surge Tank Cap
13. Power Steering Fluid Reservoir
14. Brake Oil Tank
15. Ignition Wires
16. Resonator
17. Intake Air Temperature (IAT) Sensor
DIAGNOSIS
General Diagnosis
Condition Probable Cause Correction
Hard Starting Malfunction of Faulty fuse. Replace the fuse.
(With normal IgnitionSystem
cranking) . Faulty spark plug. Clean or replace the spark plug.
. Electric leakage at the high- Replace the cable.
tension cable.
. Poor connection of the high- Replace the cable or wires.
tension cable or lead wires.
. Improper ignition timing. Adjust the ignition timing.
. Faulty ignition coil. Replace the ignition coil.
Malfunction of Fuel System Lock of fuel in the fuel tank. Feed the fuel.
. Dirty or clogged fuel filter. Replace the fuel pump assembly.
. Clogged fuel pipe. Clean the fuel pipe.
. Malfunction of the fuel pump. Replace the fuel pump assembly.
. Malfunction of the fuel injector. Replace the injector.
. The foreign material in the fuel Clean the fuel tank and replace
tank. the fuel pump assembly.
Decline of Compression Poor tightening spark plug. Tighten to the specified torque.
Pressure
. Cracked cylinder head gasket. Replace the gasket.
. Inadequate the valve clearance. Adjust the clearance.
. Leakage of the valve clearance. Repair the valve.
. Interference of the valve stem. Replace the valve or the valve
guide.
. Low elasticity or damage of the Replace the valve spring.
valve spring.
. Abnormal interference of pistons Replace the piston ring.
and cylinders.
. Excessive wear of pistons, rings, Replace the ring or the piston and
or cylinders. boring or replace the cylinder.
Others Broken timing belt. Replace the belt.
. Malfunction of Positive Check and replace Positive
Crankcase Ventilation(PCV) Crankcase Ventilation(PCV)
valve. valve if needed.
. Loosening, damage or leakage of Connect the hose correctly or
the vacuum hose. replace it.
. Leakage of intake system. Replace intake system.
Lack of Engine Decline of Compression Refer to Section 1C1, Engine Mechanical Refer to Section 1C1,
Power Pressure – FAM II 2.4D. Engine Mechanical –
FAM II 2.4D.
Malfunction of Ignition Improper ignition timing. Adjust the ignition timing.
System
. Faulty spark plug. Adjust or replace the spark
plug.
. Electric leakage or poor connection of Connect the cable
the high-tension cable. correctly or replace it.
Malfunction of Fuel System Clogged fuel pipe. Clean the pipe.
. Clogged or contaminated fuel filter. Replace the fuel pump
assembly.
Others Clogged exhaust system. Check and repair the
system.
. Clogged or contaminated air cleaner Clean or replace the air
element. cleaner element.
. Leak of the intake manifold gasket. Replace the gasket.
. Dragging brakes. Repair or replace the
brakes.
. Slipping clutch. Adjust or replace the
clutch.
Rough Engine Decline of Compression Refer to Section 1C1, Engine Mechanical Refer to Section 1C1,
Idling Pressure – FAM II 2.4D. Engine Mechanical –
FAM II 2.4D.
Malfunction of Fuel System Clogged fuel pipe. Clean the pipe.
. Clogged or contaminated fuel filter. Replace the fuel pump
assembly.
Malfunction of Ignition Malfunction of the spark plug. Adjust or replace the spark
System plug.
. Worn DIS terminal or accumulated Replace or clean the DIS.
carbon in the DIS.
. Poor ignition timing. Adjust the ignition timing.
. Malfunction of the ignition coil. Replace the ignition coil.
Others Clogged or contaminated air cleaner Clean or replace the air
element. cleaner element.
. Leak of the intake manifold gasket. Replace the gasket.
. Malfunction of PositiveCrankcase Check the valve or replace
Ventilation(PCV) valve. it if needed.
. Poor connection or damage or leakage of Connect the hose correctly
the vacuum hose. or replace it.
Engine Hesitation (Upon Decline of Compression Refer to Section 1C1, Engine Refer to Section 1C1,
pressing accelerating Pressure Mechanical – FAM II 2.4D. Engine Mechanical –
pedal, the engine makes FAM II 2.4D.
delayed response. This Malfunction of Ignition Poor ignition timing. Adjust the ignition timing.
situation is remarkable System
when cruising or starting.) . Poor spark plug or inadequate Replace the spark plug.
spark plug gap.
. Electric leakage or poor Connect the cable
connection of the high-tension correctly or replace it.
cable.
Others Malfunction of the air cleaner Clean or replace the air
system. cleaner system.
. Leak of the intake manifold Replace the gasket.
gasket.
Engine Surging (Engine Decline of Compression Refer to Section 1C1, Engine Refer to Section 1C1,
power makes fluctuation in Pressure Mechanical – FAM II 2.4D. Engine Mechanical –
a fixed speed and speed FAM II 2.4D.
changes without operating Malfunction of Fuel System Clogged fuel pipe. Clean the pipe.
the accelerating pedal.) . Clogged or contaminated fuel Replace the fuel pump
filter. assembly.
Malfunction of Ignition Malfunction of the spark plug. Adjust or replace the spark
System plug.
connection of the high tension correctly or replace it.
cable.
. Loosening or damage of the Replace the DIS.
DIS.
. Poor ignition timing. Adjust the ignition timing.
Others Leak of the intake manifold Clean or replace the
gasket. gasket.
. Leakage of the vacuum hose. Connect the hose correctly
or replace it.
Excessive Detonation Overheated Engine Refer to "Overheat" in this Refer to "Overheat" in this
(According to the opening page. page.
range of throttle valve, Malfunction of Ignition Abnormal spark plug. Replace the spark plug.
knocking sound of metallic System
is made with abnormal . Poor ignition timing. Adjust the ignition timing.
explosion.)
connection of the high-tension correctly or replace it.
cable.
Malfunction of Fuel System Clogged or contaminated fuel Clean or replace the fuel
filter and fuel pipe. pump assembly and the
fuel pipe.
Others Leak of the intake manifold Replace the gasket.
gasket.
. Excessive carbon deposit due Remove the carbon.
to abnormal combustion.
Overheat Malfunction of Cooling Lack of coolant. Refill coolant.
System
. Malfunction of the thermostat. Replace the thermostat.
. Malfunction of the cooling fan. Check or replace the cooling
fan.
. Poor water pump performance. Replace the pump.
. Clogged or leaky radiator. Clean, repair or replace the
radiator.
Malfunction of Lubrication Poor engine oil. Replace engine oil with the
System specified one.
. Blocking oil filter or strainer. Clean or replace the oil filter
or the strainer.
. Lack of engine oil. Refill oil.
. Poor oil pump performance. Replace or repair the pump.
Other Leakage of oil. Repair.
. Damaged cylinder head gasket. Replace the gasket.
Poor Fuel Consumption Decline of Compression Pressure Refer to Section 1C1, Refer to Section 1C1,
Engine Mechanical – Engine Mechanical –
FAM II 2.4D. FAM II 2.4D.
Malfunction of Fuel System Leakage of the fuel tank Repair or replace the fuel
or the fuel pipe. tank or the fuel pipe.
Malfunction of Ignition System Improper ignition timing. Adjust the ignition
timing.
. Abnormal spark plug Replace the spark plug.
(Excessive carbon deposit,
inadequate gap, burnt
electrode).
connection of the high- normally or replace it.
tension cable.
Malfunction of CoolingSystem Malfunction of the Replace the thermostat.
thermostat.
Others Improperly installed Repair or replace the
valve. valve.
. Slipping clutch. Repair or replace the
clutch.
. Low pressure of tires. Adjust the pressure of
tires.
Excessive Consumption of Leakage of Engine Oil Loosened oil drain plug. Tighten the plug.
Engine Oil . Loosened oil pan bolt. Tighten the bolt.
. Loosened oil filter. Tighten the filter.
. Loosened oil pressure Tighten the switch.
switch.
. Leakage of camshaft Replace the seal.
front oil seal.
. Leakage of crankshaft Replace the seal.
front oil seal.
. Leakage at the cylinder Replace the gasket.
head cover gasket.
. Damage of the cylinder Replace the gasket.
head gasket.
Oil Mixing in Combustion Stuck piston ring. Remove carbon and
Chamber replace the ring.
. Worn piston or cylinder. Replace the piston or the
cylinder.
. Worn piston ring or ring Replace the piston or ring.
groove.
. Inadequate position of the Adjust the position.
piston ring cutting part.
. Abrasion or damage of Replace the valve system.
the valve system.
Low Oil Pressure Malfunction of Lubrication Inadequate oil viscosity. Replace with the specified
System one.
. Loosening of the oil Tighten the switch.
pressure switch.
. Lack of engine oil. Refill oil.
. Blocking oil strainer. Clean the strainer.
. Lowered function of the Replace the pump.
oil pump.
. Abrasion or damage of Replace the valve.
the oil pump relief valve.
Engine Noise Valve Noise Inadequate valve clearance. Adjust the valve clearance.
. Abrasion of valve stem or Replace the valve stem or the
guide. guide.
. Weak valve spring. Replace the spring.
Piston, Ring, Cylinder Noise Abrasion of the piston, the Boring the cylinder or replace
ring or the cylinder. the piston, the ring or the
cylinder.
Connecting Rod Noise Abrasion of the connecting Replace the bearing.
rod bearing.
. Loosened the connecting rod Tighten to the specified torque.
nut.
Crankshaft Noise Abrasion of the crankshaft Replace the bearing.
bearing.
. Abrasion of the crankshaft Grind or replace the crankshaft
journal. journal.
. Loosened bearing cap bolt. Tighten to the specified torque.
. Excessive clearance of the Adjust or replace.
crankshaft thrust bearing.
. Low oil pressure. Refer to "Low Oil Pressure" in
this section.
Checking Engine Oil Level
Check the engine oil level or condition. If needed, refill or replace the oil.
Check the engine oil level within normal engine operating temperature as follows ;
1. After stopping the engine, wait for a few minutes to accumulate oil into the oil pan.
2. After pulling out the oil level gauge, check the oil level.
3. Clean the oil level gauge and insert the gauge into the guide.
4. After pulling out the oil level gauge again, recheck the oil level and insert the gauge into
guide again.
Important : Oil level should be between "MIN" mark and "MAX" mark.
5. If oil level is below the "MIN" mark, refill the engine oil as much as the demanded
quantity.
Important : If checking the oil level under the engine cold condition, oil is not
accumulated into oil pan quickly and correct level checking cannot be performed.
Therefore, wait until temperature reaches the normal operating condition and check the
engine oil level.
Checking Engine Oil and Oil Filter
When checking engine oil level or condition, if needed, change the engine oil (including the oil
filter) as follows ;
1. After stopping the engine, wait for a few minutes to accumulate oil into the oil pan.
2. Remove the oil filler cap.
3. Remove the oil drain plug and drain the oil off.
4. After draining the oil completely, tighten the oil drain plug to 30~40 N•m (22~30 lb-ft).
5. Replace the oil filter using the oil filter wrench.
Important : Whenever changing the engine oil, replace the oil filter together. When
replacing the new oil filter, apply the engine oil on the oil filter sealing.
Checking Accessory Drive Belt
After checking the accessory drive belt for looseness, crack, wear or tension, replace the belt if
necessary.
 Inspect : Figures below show the various stages of belt wear to aid in belt replacement
decisions. Condition of the belt ribs is best judged where the belt is bent over one of the
larger accessory drive system pulleys.
A - New belt
B - Moderately used belt : few cracks, some wear on ribs and in grooves. Replace is not
required.
C - Severely used belt : several cracks per 30 mm. Should be replaced before chunking
occurs.
D - Failed belt : separation of rib material from the backing (chunking). Replace belt
immediately.
Checking Spark Plug
Caution : Under no circumstances should the spark plug/s gap be adjusted. If the gap is
not within specifications, replace the spark plug.
After checking the spark plug for bad clearance, excessive carbon deposit, worn electrode or
damaged insulator, replace the new one if necessary.
Remove and check the spark plug as follows ;
1. Pull the ignition wire cap portion and disconnect the ignition wires from the spark plug. If
pulling the ignition wires, circuit could be disconnected. Therefore, the cap portion should
be used.
2. Remove the spark plugs from the cylinder head using a wrench.
3. Measure the spark plug clearance with the filler gauge. If measured value is not within
the specified value, adjust the grounding electrode. When installing a new spark plug,
check the equality and then install it.
4. Inspect the spark plug as below.
Poor Spark Plug Performance

A spark plug can perform poorly due to wear, dirt, carbon fouling, excessive electrode wear, a
broken insulator or excessive gap.
Worn or Dirty Plugs
Worn or dirty plugs can give satisfactory operation while the vehicle is idling, but break down
under load.This can cause :
 poor fuel economy,

 power loss,
 acceleration loss,
 difficult starting, or
 poor engine performance.
Carbon Fouling
Carbon fouling is indicated by black carbon deposits. The black deposits are usually the result
of slow-speed driving and short runs. In these circumstances, the optimum engine operating
temperature is seldom reached.Fouling can also be caused by :
 worn piston rings,

 faulty ignition,
 rich fuel mixture, or spark plugs that are rated too cold.
Excessive Electrode Wear

This often indicates :
 the engine is operating at high speeds,

 the engine is operating at levels that are consistently greater than normal,
 a plug that is rated too hot,
 excessively lean fuel mixture, or plug/s overheating due to insufficient tightening (caused
by combustion gases leaking past the threads).
Broken Insulator
Broken insulators are usually the result of improper installation or carelessness.
Breaks in the upper insulator can result from a poor fitting spark plug socket or impact. The
cracked insulator may not show up until oil or moisture penetrates the crack. The crack is often
just below the crimped part of the shell and may not be visible.
Breaks in the lower insulator often result from careless re-gapping and are usually visible.
This can also result from the plug operating too hot. For example, in periods of high speed
operation or under heavy loads.
a - Normal : Brown or grayish-tan deposits and slight electrode wear indicate correct spark
plug heat range and mixed periods of high and low speed driving.
b - Carbon Fouled : Dry, fluffy black carbon deposits possibly due to poor ignition output, a
weak coil, excessive idling or slow speeds under light load. If spark plug temperatures remain
too low for normal combustion, the deposits are not burned off.
c - Oil Fouled : Wet, oily deposits with minor electrode wear possibly due to oil leaking past
worn piston rings. Breaking in a new or recently overhauled engine before the rings are fully
seated may also result in this condition.
d - Deposit Fouling A : Red brown, yellow and white colored coatings on the insulator tip which
are by-products of combustion. They come from fuel and lubricating oil which generally contain
additives. Most powdery deposits have no adverse effect on spark plug operation, however,
they may cause intermittent missing under severe operating conditions.
e - Deposit Fouling B : Deposits similar to those identified in deposit fouling A (4). These are
also by-products of combustion from fuel and lubricating oil. Excessive valve stem clearances
and / or defective intake valve seals allow too much oil to enter the combustion chamber. The
deposits will accumulate on the portion of the spark plug that projects into the chamber and will
be heaviest on the side facing the intake valve. If this condition is only detected in one or two
cylinders, check the valve stem seals.
f - Deposit Fouling C : Most powdery deposits identified in deposit fouling A (4) have no
adverse effect on the operation of the spark plug as long as they remain powdery. Under
certain conditions of operation however, these deposits melt and form a shiny glaze coating on
the insulator. When hot, this acts as a good electrical conductor allowing the current to flow
along the deposit instead of sparking across the gap.
g - Detonation : Commonly referred to as engine knock or pinging, detonation causes severe
shocks inside the combustion chamber causing damage to parts.
h - Pre-ignition : Burnt or blistered insulator tip and badly eroded electrodes probably due to
the excessive heat. This is often caused by a cooling system blockage, sticking valves,
improperly installed spark plugs or plugs that are the wrong heat rating (too hot). Sustained
high speed with a heavy load can produce temperatures high enough to cause pre-ignition.
i - Heat Shock Failure : A rapid increase in spark plug tip temperature under severe operating
conditions can cause heat shock and result in fractured insulators. This is a common cause of
broken and cracked insulator tips.
j - Insufficient Installation Torque : Poor contact between the spark plug and the cylinder head
seat. The lack of proper heat transfer that results from poor seat contact causes overheating of
the spark plug. In many cases, severe damage occurs. Dirty threads in the cylinder head can
cause the plug to seize before it is seated. Ensure the cylinder head and spark plug threads
are free of deposits, burrs and scale before installation.
Checking Air Cleaner Element
If the air cleaner element becomes dirty, engine efficiency could be deteriorated. Be sure to
check the element often and replace a new one within the specified period. Especially, if a
vehicle frequently runs on a dusty road, check and replace the element often.
Checking Fuel System
Check the fuel system as follows ;
 Check the fuel line or line connection portion for damage or leakage.
 Check the fuel hose surface for damage
 Check the fuel cap for looseness.
Checking Hose System

Check the engine vacuum hoses, PCV hose or canister hose as follows ;
 Check the hose surface for damage by heat or machine.

 Check the hose for hardening, crack, tear or coming off.
GENERAL INFORMATION
Cleanliness and Care
An automobile engine is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in thousandths of a millimeter. When any material
engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil
should be applied to friction areas during assembly, to protect and lubricate the surfaces on
initial operation. Proper cleaning and protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard shop practice even if not specifically
stated.
Whenever valve train components are removed for service, they should be kept in order. They
should be installed in the same locations and within the same mating surfaces, as when they
were removed. Battery cables should be disconnected before any major work is performed on
the engine. Failure to disconnect cables may result in damage to wire harness or other
electrical parts.
On-Engine Service
Notice : Any time the air cleaner is removed, the intake opening should be covered. This
will protect against accidental entrance of foreign material which could follow the intake
passage into the cylinder and cause extensive damage when the engine is started.
SECTION 1C1
ENGINE MECHANICAL - FAM II 2.4D

SPECIFICATIONS
Engine Specifications
Application Description Unit FAM II 2.4D
Engine Type - 4 Cylinder (In-Line)
Displacement cm³ 2,405
Bore Stroke mm (in.) 87.5 x 100 (3.44 x 3.94)
General Data Compression Ratio - 9.6 : 1
Firing Order - 1-3-4-2
Maximum Power kw 100 kw @ 5,000 rpm
Maximum Torque N•m 220 N•m @ 2,200 rpm
Diameter mm (in.) 87.485~87.505 (3.444~3.445)
Out of Round (MAX) mm (in.) 0.013 (0.0005)
Taper (MAX) mm (in.) 0.013 (0.0005)
Cylinder Bore Piston Protrusion mm (in.) 0
Oversize (Measure Replacement Piston Available in 0.50 mm (0.019
mm (in.)
before Re-boring) in.) to suit bore
Block Face Distortion mm (in.) 0.01 MAX (0.00039)
Diameter mm (in.) 87.465~87.485 (3.443~3.445)
Clearance to Bore mm (in.) 0.010~0.030 (0.00039~0.0020)
1.230 ~ 1.250 (0.04842 ~
Ring Groove Width Top mm (in.)
0.04921)
Pistion 1.510 ~ 1.530 (0.05945 ~
. 2nd mm (in.)
0.0602)
2.530 ~ 2.550 (0.09961 ~
. Oil mm (in.)
0.10040)
Ring Groove Inner 79.96 ~ 80.66 (3.1480 ~
Top mm (in.)
Diameter 3.1756)
78.40 ~ 79.10 (3.0866 ~
. 2nd mm (in.)
3.1142)
80.06 ~ 80.76 (3.15197 ~
. Oil mm (in.)
3.17953)
0.21 ~ 0.36 (0.00827 ~
Top Compression Ring End Gap mm (in.)
0.01417)
0.36 ~ 0.61 (0.01417 ~
Second Compression Ring End Gap mm (in.)
0.02402)
Oil Ring End Gap mm (in.) 0.16 ~ 0.76 (0.0063 ~ 0.02992)
1.170 ~ 1.190 (0.04606 ~
Piston Ring Width Top mm (in.)
0.04685)
1.466 ~ 1.490 (0.05772 ~
. 2nd mm (in.)
0.05866)
. Oil mm (in.) 2.5 (0.09842)
Piston Rings
2.86 ~ 3.15 (0.11260 ~
Piston Ring Thickness Top mm (in.)
0.12402)
3.50 ~ 3.70 (0.13780 ~
. 2nd mm (in.)
0.14567)
. Oil mm (in.) 2.159 ~ 2.337 (0.085 ~ 0.092)
Ring Groove 0.040 ~ 0.080 (0.00157 ~
Top mm (in.)
Clearance 0.00315)
0.020 ~ 0.064 (0.00079 ~
. 2nd mm (in.)
0.00252)
. Oil mm (in.) 0.3 ~ 0.5 (0.01181 ~ 0.01969)
20.9910~20.9970
Diameter mm (in.)
(0.82641~0.82665)
0.7~0.9 (0.0275~0.0354)
Pin Offset mm (in.)
Toward Thrust Side
Piston Pin
0.011~0.014
Clearance : In Piston mm (in.)
(0.00043~0.00055)
Clearance : In Rod mm (in.) Interference Fit in Rod
Length mm (in.) 61.5 (2.42)
Valve Lift Intake mm (in.) 9.2 (0.36)
. Exhaust mm (in.) 9.2 (0.36)
Camshaft Camshaft Cap to Bearing Journal
mm (in.) 0.04~0.144 (0.0015~0.0056)
Clearance
42.455~43.470
Bearing Journal OD mm (in.)
(1.6714~1.7114)
57.974 - 57.995
Main Journal – Diameter (All) mm (in.)
(2.2824~2.2833)
Main Journal - Radial Runout (Shaft
Support on No. 1 and No. 5 Bearings mm (in.) 0.03 (0.00118)
Measured at No. 3 Journal)
Crankshaft
0.015~0.040
Main Bearing Clearance (All) mm (in.)
(0.00059~0.00157)
End Play mm (in.) 0.070~0.302 (0.0027~0.0118)
0.25 and 0.5 (0.00098 and
Service Oversize (Available in 2 sizes) mm (in.)
0.019)
48.970~48.988
Connecting Rod Diameter (All) mm (in.)
(1.9279~1.9287)
Journal
Out of Round (MAX) mm (in.) 0.004 (0.00015)
0.006~0.031
Rod Bearing Play mm (in.)
(0.00023~0.00122)
Rod Bearing Clearance mm (in.) 0.013~0.041 (0.0005~0.0016)
Valve Stem Protrusion mm (in.) 39.2 MAX (1.544)
Valve Guide Height mm (in.) 13.7~14.0 (0.53~0.55)
Cylinder Head 133.975~134.025
Overall Height mm (in.)
(5.2741~5.2759)
Minimum Overall Height After Machining mm (in.) 133.9 (5.271)
Valve Lash Compensators - Hydraulic
Seat Runout (MAX, All) mm (in.) 0.03 (0.0018)
Face Runout (MAX, All) mm (in.) 0.03 (0.0018)
Valve Diameter Intake mm (in.) 32 ± 0.1 (1.2598 ± 0.0039)
. Exhaust mm (in.) 29 ± 0.1 (1.1417 ± 0.00039)
Valve Stem Diameter Intake mm (in.) 5.955~5.970 (0.234~0.235)
Valve System
. Exhaust mm (in.) 5.945~5.960 (0.2346~0.2360)
Valve Seat Width Intake mm (in.) 1.0~1.5 (0.039~0.059)
. Exhaust mm (in.) 1.7~2.2 (0.066~0.086)
Valve Face Angle mm (in.) 44°
Valve Seat Angle mm (in.) 45°
Valve Guide Inside Diameter mm (in.) 6.000~6.012 (0.2362~0.2367)
Type - Rotary (Trochoild)
Gear Lash - 0.10~0.20 (0.0040~0.008)
Outer Gear to Body mm (in.) 0.11~0.19 (0.0043~0.0074)
Oil Pump
Outer Gear to Crescent mm (in.) 0.11~0.24 (0.0043~0.009)
Inner Gear to Crescent mm (in.) 0.18~0.26 (0.007~0.010)
End Clearance mm (in.) 0.03~0.10 (0.001~0.004)
Rear Main Bearing Cap - Three-Bond 1217F
Camshaft Carrier-to-Cylinder Head - HN 1581 (Loctite® 515)
Oil Pan Bolts - HN 1256 (Loctite® 542)
Oil Pump Bolts - HN 1256 (Loctite® 542)
Sealants and
Adhesives Oil Pan Pickup Tube Bolts - HN 1256 (Loctite® 542)
Oil Gallery Plug - HN 1256 (Loctite® 542)
Coolant Jacket Caps and Plugs (Freeze
- HN 1756 (Loctite® 176)
Plugs)
Exhaust Manifold Studs/Nuts - Anti-seize Compound
Type - Forced Feed
Oil Pump Type - Rotary (Trochoid)
Oil Filter Type - Cartridge
Lubricating System Oil Pan Capacity (Including Oil Filter) L 4.5L
Oil Pan Capacity (Excluding Oil Filter) L 4.3L
API SL (ILSAC GF-III) grade
Engine Oil Type - SAE 5W-30
* Hot area : SAE 10W-30
Fastener Tightening Specifications
Application N•m Lb-Ft Lb-In
Air Cleaner Element Cover Screws 2 - 18
Air Cleaner Housing Bolts 6 - 53
Battery Hold-Down Bar Bracket Retaining Nuts 10 - 89
Battery Tray Retaining Bolts 10 - 89
Camshaft Bearing Cap Bolts 8 - 71
Connecting Rod Cap Bearing Bolts 35 + 45° + 15° 26 + 45° + 15° -
Coolant Bypass Housing Bolts 15 11 -
Crankshaft Balancer Unit Assembly Bolts 20 + 45° 15 + 45° -
Crankshaft Bearing Cap Bolts 50 + 45° + 15° 37 + 45° + 15° -
Crankshaft Pulley Bolts 20 15 -
135 + 30° + 100 + 30° +
Crankshaft Timing Belt Drive Gear Bolt -
10° 10°
25 + 90° + 90° 18 + 90° + 90°
Cylinder Head Bolts -
+ 90° + 90°
Cylinder Head Cover Bolts 8 - 71
Direct Ignition System and EGR Mounting Bracket Bolts 25 18 -
Engine Beautification Cover Bolts and Nuts 8 - 71
Engine Beautification Cover Bracket Retaining Bolt 20 15 -
Engine Fuse Block Lower Cover Bolts 10 - 89
Engine Fuse Block Retaining Bolts 3 - 27
Engine Mount Adapter Bolts 50 37 -
Engine Mount Adapter Support Bracket Bolts 45 33 -
Engine Mount Frame Side Bracket Bolt 100 74 -
Engine Mount Frame Side Bracket Nuts 90 66 -
Evaporative Emission Canister Purge Solenoid Brakcet
5 - 44
Bolt
Exhaust Camshaft Gear Bolt 50 + 60° + 15° 37 + 60° + 15° -
Exhaust Front Pipe Mounting Bracket Bolt and Nut 40 30 -
Exhaust Manifold Heat Shield Bolts 15 11 -
Exhaust Manifold Retaining Nuts 22 16 -
Flexible Plate Bolts 65 48 -
Flywheel Bolts 65 + 30° + 15° 48 + 30° + 15° -
Front Timing Belt Cover Bolts 6 - 53
Fuel Rail Assembly Retaining Bolts 25 18 -
Generator-to-Generator Lower Support Bracket Through
40 30 -
Bolt & Nut
Generator-to-Intake Manifold Strap Bracket Bolt at Intake
25 18 -
Manifold
Generator-to-Intake Manifold Strap Bracket Bolt at
35 26 -
Generator
Generator Lower Support Bracket Bolts 25 18 -
Generator Upper Bracket Bolts at Intake Manifold &
25 18 -
Coolant Bypass housing
Generator Upper Bracket Bolt at Generator 35 26 -
Intake Camshaft Gear Bolt 50 + 60° + 15° 37 + 60° + 15° -
Intake Manifold Retaining Bolt & Nuts 18 13 -
Intake Manifold Support Bracket Bolt 25 18 -
Interm Shaft Support Bracket Bolts 70 52 -
Oil Filter Adapter –to-Oil Pump Bolts 8 - 71
Oil Pan Drain Plug 18 13 -
Oil Pan Flange-to-Cradle Retaining Bolts 50 37 -
Oil Pan Retaining Bolts 20 15 -
Oil Pressure Switch 40 30 -
Oil Pump Rear Cover Bolts 20 15 -
Oil Pump Retaining Bolts 10 - 89
Oil Suction Pipe Retaining Bolts 8 - 71
Pup Converter-to-Exhaust Front Pipe Retaining Nuts 40 30 -
Rear Timing Belt Cover Bolts 7 - 62
Safety Relief Valve Bolt 30 22 -
Spark Plugs 25 18 -
Starter-to-Engine Block Mounting Bolt 75 55 -
Starter-to-Transmission Mounting Bolt 75 55 -
Timing Belt Automatic Tensioner Bolt 25 18 -
Timing Belt Idler Pulley Bolt & Nut 25 18 -
Transaxle Front Mount Retaining Bolts 50 37 -
Transaxle Front Mount-to-Transaxle Through Bolt 90 66 -
Transaxle Mount Assembly Retaining Bolts 37 27 -
Transaxle Mount Bracket Retaining Bolts 50 37 -
Transaxle Rear Mount Retaining Bolts 90 66 -
Transaxle Rear Mount Bracket Retaining Bolts 90 66 -
Transaxle Rear Mount-to-Bracket Through Bolt 90 66 -
Transaxle-to-Oil Pan Flange Bolt 50 37 -
Transaxle Torque Coverter Bolts 45 33 -
SPECIAL TOOLS
Special Tools Table
KM-653
Valve Spring Compressor Adapter
KM-135
Oil Pressure Gauge Adapter
KM-805
Valve Guide Reamer
J-36972
Crankshaft Rear Oil Seal Installer
KM-571-B
Gauge
DW110-060
Engine Assembly Support Fixture
DW100-030
Engine Overhaul Stand
KM-348
Valve Spring Compressor
KM-635
Crankshaft Rear Oil Seal Installer
KM-427
Piston Pin Service Set
J-8087
Cylinder Bore
Check Gauge
KM-340-0
Cutter Set
Includes:KM-340-7
Guide Drift
KM-340-13
Cutters
KM-340-26
Cutters
KM-470-B
Angular Torque Gauge
KM-498-B
Oil Pressure Gauge
J-8037
Universal Piston Ring Compressor
EN-48243
Engine Assembly Remove/Install Pallet
EN-48244
Engine Assembly Remove/Install Pallet Supporter
COMPONENT LOCATOR
Upper End
1. Nut
2. Engine Beautification Cover
3. Bolt
4. Oil Filler Cap
5. Bolt
6. Cylinder Head Cover
7. Cylinder Head Cover Gasket
8. Tappet Adjuster
9. Valve Key
10. Valve Spring Cap
11. Valve Spring
12. Valve Stem Seal
13. Valve Spring Seat
14. Valve Guide
15. Intake Valve Seat Ring
16. Exhaust Valve Seat Ring
17. Intake Valve
18. Exhaust Valve
19. Bolt
20. Front Camshaft Cap
21. Head Bolt
22. Bolt
23. Intermediate Camshaft Cap
24. Exhaust Gas Recirculation Adapter
25. Exhaust Gas Recirculation Adapter Gasket
26. Bolt
27. Exhaust Gas Recirculation Valve
28. Exhaust Gas Recirculation Valve Gasket
29. Cylinder Head
30. Exhaust Manifold Gasket
31. Exhaust Manifold
32. Nut
33. Exhaust Manifold Heat Shield
34. Cylinder Head Gasket
35. Bolt
36. Thermostat Housing
37. Thermostat Housing Gasket
38. Stud
39. Sleeve
40. Plug
41. Bolt
42. Camshaft Position Sensor
43. Oil Gallery Plug
44. Exhaust Camshaft
45. Seal Ring
46. Camshaft Gear
47. Washer
48. Camshaft Gear Bolt
49. Intake Camshaft
50. Intake Manifold Gasket
51. Intake Manifold
52. Throttle Body Gasket
53. Throttle Body
54. Nut
55. Evaporative Emission Canister Purge Solenoid
Lower End
1. Connecting Rod Cap
2. Bearing Set
3. Connecting Rod Bolt
4. Piston Ring Set
5. Piston Pin
6. Piston
7. Engine Block
8. Sleeve
9. Water Jacket Cap
10. Bolt (Manual Transaxle)
11. Flywheel (Manual Transaxle)
12. Flexible Plate (Automatic Transaxle)
13. Bolt (Automatic Transaxle)
14. Seal Ring
15. Crankshaft
16. Reluctor Ring
17. Screw
18. Crankshaft Balancer Unit Assembly
19. Bolt
20. Oil Pan Scraper

21. Oil Pan Scraper
21. Bolt
22. Bolt
23. Oil Suction Pipe
24. Oil Pan
25. Oil Pan Drain Plug
30. Sleeve
31. Sleeve
31. Gasket
32. Gasket
32. Bolt
33. Bolt
34. Oil Pump Cover
35. Ring Gear
36. Gear
37. Oil Pressure Switch
38. Washer
39. Washer
40. Oil Duct Outlet Plug
41. Connecting Piece
42. Seal Ring
43. Oil Filter
44. Bypass Valve
45. Pressure Relief Valve Plunger
46. Pressure Relief Valve Spring
47. Seal Ring
48. Pressure Relief Valve Plug
49. Rear Timing Belt Cover
50. Bolt
51. Special Bolt
52. Idler Pulley
53. Stud
54. Nut
55. Bolt
56. Tensioner
57. Bolt
58. Thrust Inner Washer
59. Woodruff Key
60. Crankshaft Gear
61. Thrust Outer Washer
62. Bolt
63. Camshaft Drive Belt
64. Gasket
65. Front Timing Belt Cover
66. Bolt
67. Bushing Plug
68. Bushing
69. Oil Gallery Plug
70. Bolt
71. Water Pump
72. Seal Ring
73. Crankshaft Position Sensor
74. Bolt
75. Knock Sensor
76. Bolt
77. Oil Filter Adapter
Air Intake System

1. Air Cleaner Upper Housing
2. Air Cleaner Element Seal
3. Air Cleaner Element
4. Air Cleaner Lower Housing
5. Air Cleaner Snorkel Assembly
6. Lower Intake Air Duct
7. Air Cleaner Resonator Duct Seal
8. Air Cleaner Resonater Duct Assembly
9. Air Cleaner Front Resonator
10. Air Cleaner Resonator Seal
11. Air Cleaner Rear Resonator
12. Air Cleaner Outlet Resonator Seal
13. Air Cleaner Outlet Resonator Lower Housing
14. Air Cleaner Outlet Resonator Upper Housing
15. PCV Hose
16. Intak Air Temperature (IAT) Sensor
17. Air Cleaner Outlet Resonator Tunning Tube
Engine Mount System

1. Transaxle Front Mount Assembly
2. Engine Mount Adapter Support Bracket
3. Engine Mount Assembly
4. Cradle Assembly
5. Transaxle Mount Assembly
6. Transaxle Rear Mount Bracket
7. Transaxle Rear Mount
DIAGNOSIS
Engine Diagnosis
Begin engine mechanical system diagnosis by reviewing the disassembled views. Reviewing
the description and operation information provided will assist in determining whether the
condition described by the customer is a fault or normal engine operation.
Symptoms
Strategy Based Diagnosis
1. Review the system operations to familiarise yourself with the system functions.
2. Perform an engine management Diagnostic System Check.
All diagnosis on a vehicle should follow a logical process. Strategy based diagnosis is a
uniform approach for repairing all vehicle systems. The strategy based diagnostic flow chart
may always be used to resolve a system problem. The diagnostic flow chart is the place to
start when repairs are required.
Visual / Physical Inspection
1. Inspect the vehicle for aftermarket accessories which may adversely affect engine
operation.
2. Inspect the easily accessible or visible system components for obvious signs of damage
or conditions that may cause the symptom.
3. Check the engine lubrication system for the following:
o correct oil level,
o correct lubricant viscosity,
o correct oil filter application, and
o contaminated or burnt oil.
4. Confirm the exact operating conditions under which the fault occurs. Note factors such
as:
o engine speed (rpm),
o ambient temperature,
o engine temperature,
o engine warm-up time, and
o vehicle road speed.
5. Compare the engine sounds, if applicable, to a known good engine, and ensure you are
not trying to diagnose a normal operating condition.
Intermittent
For intermittent faults, test the vehicle under the same conditions the customer reported in
order to confirm whether the system is operating correctly.
Compression Pressure Check
1. Ensure that the vehicle battery is in good condition, and fully charged.
2. Operate the vehicle until the engine is at normal operating temperature.
3. Disconnect the ignition wires from the spark plug.
4. Disconnect the fuel injector electrical connector.
5. Remove all of the spark plugs.
Notice : Do not insert objects into the throttle plate opening. Damage to the electronic
throttle body can result, requiring replacement of the electronic throttle body assembly.
6. Block the throttle linkage wide open.
7. Install the engine cylinder compression gage to the cylinder being tested.
8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or
puffs, for the cylinder being tested. If the engine rotates for more than 4 compression
strokes, test the cylinder again.
9. Record the compression reading.
10. Remove the engine cylinder compression gage from the cylinder being tested.
11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to
obtain valid test results.
12. If any cylinders have low compression, inject approximately 15 ml of engine oil into
the cylinder through the spark plug hole.
13. Repeat steps 8-11 for all low compression cylinders.
14. The minimum compression in any one cylinder should not be less than 70 percent
of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For
example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the
highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70
percent = 105 psi), in order to determine the lowest allowable pressure in any other
cylinder.
o Normal : The compression builds up quickly and evenly to the specified
compression.
o Piston rings leaking : Compression is low on the first compression stroke. The
compression builds up on the following strokes, but does not reach normal.
Compression improves considerably when you add oil.
o Valves leaking : Compression is low on the first compression stroke. The
compression does not build up on the following strokes, and does not reach
normal. Compression does not improve much, if at all, when you add oil.
o Head gasket leaking : Compression is low on the first stroke. The compression
does not build up on the following strokes, and does not reach normal.
Compression does not improve much, if at all, when you add oil. Adjacent
cylinders have the same, or similar, low compression readings.
15. If one or more cylinders fail to meet the minimum specified compression, repair or
replace all damaged or worn components and test the engine again.
Oil Pressure Check
1. With the vehicle on a level surface, allow adequate drain down time, 2-3 minutes, and
measure for a low engine oil level. Add the recommended grade engine oil, and fill the
crankcase until the oil level measures FULL on the oil level indicator.
2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or
the oil indicator light. Listen for a noisy valve train or a knocking noise.
3. Inspect for the following :
o Engine oil diluted by moisture or unburned fuel mixtures
o Improper engine oil viscosity for the expected temperature
o Incorrect or faulty oil pressure gage sensor
o Incorrect or faulty oil pressure gage
o Plugged oil filter
o Malfunctioning oil filter bypass valve
1. Remove the oil pressure switch from the oil filter adapter.
1. Install the oil pressure gage adapter KM-135 and the oil pressure gauge KM-498-B
at the place of the oil pressure switch.
2. Start the engine and then allow the engine to reach normal operation temperature.
3. Measure the engine oil pressure at idle speed.
4. The minimum oil pressure should be 200 kPa (29 psi).
4. If the engine oil pressure is below minimum specifications, inspect the engine for one or
more of the following :
o Oil pump worn or dirty
o Malfunctioning oil pump pressure relief valve
o Oil pump screen loose, plugged, or damaged
o Excessive bearing clearance
o Cracked, porous or restricted oil galleries
o Engine block oil gallery plugs missing or incorrectly installed
o Broken valve lifters
o Loose oil filter adapter
5. After checking the oil pressure, remove the oil pressure gauge and adapter and then
install the oil pressure switch to 40 N•m (30 lb-ft).
6. Check the oil level. Add oil until it reaches the MAX mark if needed.
Oil Leak Diagnosis

Important : You can repair most fluid leaks by first visually locating the leak, repairing
or replacing the component, or by resealing the gasket surface. Once the leak is
identified, determine the cause of the leak. Repair the cause of the leak as well as the
leak itself.
Step Action Value(s) Yes No
1. Operate the vehicle until it reaches normal
operating temperature.
2. Park the vehicle on a level surface, over a
large sheet of paper or other clean surface.
1 -
3. Wait 15 minutes.
4. Inspect for drippings.
Are drippings present? Go to Step 2 System OK

Can you identify the type of fluid and the
2 -
approximate location of the leak? Go to Step 10 Go to Step 3
1. Visually inspect the suspected area. Use a
small mirror to assist in looking at hard to
see areas.
2. Inspect for leaks at the following locations :
o Sealing surfaces
3 -
o Fittings
o Cracked or damaged components

1. Completely clean the entire engine and
surrounding components.
2. Operate the vehicle for several kilometers,
miles, at normal operating temperature and
4 -
at varying speeds.
3. Park the vehicle on a level surface, over a
large sheet of paper or other clean surface.
4. Wait 15 minutes. Go to Step 10 Go to Step 5
5. Identify the type of fluid, and the
approximate location of the leak.

approximate location of the leak?
see areas.
o Sealing surfaces
5 -
o Fittings

1. Completely clean the entire engine and
surrounding components.
2. Apply an aerosol-type powder, baby powder,
foot powder, etc., to the suspected area.
3. Operate the vehicle for several kilometers,
miles, at normal operating temperature and
6 at varying speeds. -
4. Identify the type of fluid, and the
approximate location of the leak, from the
discolorations in the powder surface.

see areas.
o Sealing surfaces
7 -
o Fittings

Use the black light kit in order to identify the type of
fluid, and the approximate location of the leak.
Refer to the manufacturer's instructions when using
8 -
the tool.
see areas.
o Sealing surfaces
9 -
o Fittings

approximate location of the leak? Go to Step 10 System OK
1. Inspect the engine for mechanical damage.
Special attention should be shown to the
following areas :
o Higher than recommended fluid levels
o Higher than recommended fluid
pressures
o Plugged or malfunctioning fluid filters
or pressure bypass valves
o Plugged or malfunctioning engine
ventilation system
o Improperly tightened or damaged
fasteners
10 -
o Cracked or porous components
o Improper sealants or gaskets, where
required
o Improper sealant or gasket
installation
o Damaged or worn gaskets or seals
o Damaged or worn sealing surfaces
2. Inspect the engine for customer
modifications.
Is there mechanical damage, or customer

modifications to the engine? Go to Step 11 System OK
Repair or replace all damaged or modified
11 components. -
Does the engine still leak oil? Go to Step 11 System OK
Crankcase Ventilation System Inspection/Diagnosis
Results Of Incorrect Operation
 A plugged positive crankcase ventilation (PCV) orifice or hose may cause the following
conditions :
- Rough idle
- Stalling or slow idle speed
- Oil leaks
- Oil in air cleaner
- Sludge in engine
 A leaking PCV orifice or hose may cause the following conditions :
- Rough idle
- Stalling
- High idle speed
Functional Check
With these systems, any blow-by in excess of the system capacity, from a badly worn engine,
sustained heavy load, etc., is exhausted into the air cleaner and is drawn into the engine.
Proper operation of the crankcase ventilation system depends upon a sealed engine. If oil
slugging or dilution is noted and the crankcase ventilation system is functioning properly, check
the engine for a possible cause. Correct any problems.
If an engine is idling rough, inspect for a clogged PCV orifice, a dirty vent filter, air cleaner
element, or plugged hose. Replace as required. Use the following procedure :
 Remove the PCV hose from the cylinder head cover.

 Operate the engine at idle.
 Place your thumb over the end of the hose in order to check for a vacuum. If there is no
vacuum at the hose, inspect for the following items :
- Plugged hoses
- The manifold port
 Turn OFF the engine.

 Inspect the PCV orifice in the cylinder head cover for debris or blockage.
Base Engine Misfire without Internal Engine Noises

Cause Correction
 Verify oil pressure. Refer to "Oil Pressure
Check" in this section.
High oil pressure.  Repair or replace damaged components as
required.
 Inspect the accessory drive system

Worn, damaged, or improperly installed accessory
components.
drive belt - severe cracking, bumps or missing
 Repair or replace damaged components as
segments.
required. Refer to Section 1C1, Engine
A misfire DTC may be present without an actual
Mechanical - FAM II 2.4D.
misfire condition.
 Inspect the accessory drive system
Worn, damaged, or improperly installed accessory
components.
drive system components.
required.
misfire condition.
 Inspect the crankshaft pulley.
Damaged, loose or improperly installed crankshaft
pulley.
required. Refer to Section 1C1, Engine
misfire condition.
Worn, damaged, or improperly installed crankshaft
reluctor wheel.
A worn or damaged crankshaft reluctor wheel can
result in different symptoms depending on the
severity and location of the wear or damage.
 Systems with electronic communications, DIS

or coil per cylinder, and severe reluctor ring  Inspect the crankshaft position sensor.
damage may exhibit periodic loss of  Inspect the crankshaft reluctor wheel.
crankshaft position, stop delivering a signal,  Inspect the crankshaft.
and then re-sync the crankshaft position.  Repair or replace damaged components as
 Systems with electronic communication, DIS required.
or coil per cylinder, and slight reluctor ring
damage may exhibit no loss of crankshaft
position and no misfire may occur.
 Systems with mechanical communications,
high voltage switch, and severe reluctor ring
damage may cause additional pulses and
effect fuel and spark delivery.
Damaged, loose or improperly installed engine

 Inspect the flywheel.
flywheel.
Cause Correction
A misfire DTC may be present without an actual  Repair or replace damaged components as
misfire condition. required. Refer to Section 1C1, Engine
Damaged, improperly installed or restricted exhaust

 Inspect the exhaust system components.
system, collapsed or dented pipes, plugged mufflers
or malfunctioning catalytic converters.
required.
A DTC may be present without an actual fault
condition.
 Inspect the vacuum system components.
Worn, damaged or improperly installed vacuum  Repair or replace damaged components as
hoses. required.
 Inspect the MAP sensor.

Damaged or improperly installed MAP sensor,  Repair or replace damaged components as
sealing grommet nicked, torn or missing. required.
 Inspect the electronic throttle body.

Damaged or improperly installed electronic throttle  Repair or replace damaged components as
body. required.
 Inspect the intake manifold.

Damaged or improperly installed intake manifold.
required.
 Inspect the spark plugs. Refer to "Checking

Spark Plug" in this section in Engine
Controls.
 Verify engine compression. Refer
Damaged or improperly installed cylinder head. to "Compression Pressure Check" in this
Oil consumption may or may not cause the engine to section.
misfire.  Inspect the cylinder heads.
 Inspect the engine block.
required.
 Inspect the valve springs.

Worn, damaged, loose or broken valve spring.
required.
 Inspect the valves.

 Inspect the valve guides.
Worn, damaged or stuck valve, carbon on the valve
stem or valve seat.
required.

 Inspect the valve guides.Inspect the valves.
Worn or damaged valve guide.  Repair or replace damaged components as
required.
 Inspect the valve lifters.

 Inspect the camshaft.
Worn, damaged or dirty valve lifter.  Repair or replace damaged components as
required.
Cause Correction
Worn or damaged camshaft lobe.  Repair or replace damaged components as
required.
 Inspect the timing belt and sprockets.

Worn, damaged or loose timing belt and sprockets.
required.
 Inspect the spark plugs. Refer to "Checking

Spark Plug" in this section.
 Verify engine compression. Refer
Worn, damaged or improperly installed piston.
to "Compression Pressure Check" in this
Pistons must be installed with the mark, or dimple,
section.
on the top of the piston, facing the front of the
 Inspect the cylinder bores.
engine; piston pins must be centered in the
 Inspect the pistons.
connecting rod pin bore.
 Inspect the piston pins.
Oil consumption may or may not cause the engine to
 Inspect the connecting rods.
misfire.
required.
Base Engine Misfire with Abnormal Internal Lower Engine Noises

Cause Correction
Worn, damaged, or improperly
installed accessory drive belt - severe  Inspect the accessory drive system components.
cracking, bumps or missing  Repair or replace damaged components as required. Refer
segments. to Section 1C1, Engine Mechanical - FAM II 2.4D.
A misfire DTC may be present
without an actual misfire condition.
 Inspect the accessory drive system components.
installed accessory drive system
 Repair or replace damaged components as required. Refer
components.
to Section 1C1, Engine Mechanical - FAM II 2.4D.
A misfire DTC may be present
Worn, damaged, improperly installed  Inspect the crankshaft pulley.
or loose crankshaft pulley.  Repair or replace damaged components as required. Refer
A misfire code may be present to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged, improperly installed  Inspect the engine flywheel.
or loose engine flywheel.  Repair or replace damaged components as required. Refer
A misfire code may be present to Section 1C1, Engine Mechanical - FAM II 2.4D.
 Inspect the spark plugs. Refer to Section 1A2, General
Worn, damaged or improperly Engine Information – FAM II 2.4D.
installed piston.  Verify engine compression. Refer to "Compression Pressure
Pistons must be installed with the Check" in this section.
mark, or dimple, on the top of the  Inspect the cylinder bores.
piston, facing the front of the engine;  Inspect the pistons.
piston pins must be centered in the  Inspect the piston pins.
connecting rod pin bore.  Inspect the connecting rods.
Oil consumption may or may not  Repair or replace damaged components as required. Refer
cause the engine to misfire. to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged or improperly  Inspect the crankshaft.

installed crankshaft thrust bearing.  Inspect the crankshaft thrust bearing.
Cause Correction
A misfire code may be present  Repair or replace damaged components as required.
Base Engine Misfire with Abnormal Valve Train Noise
Cause Correction
Worn, damaged or stuck valve,
carbon on the valve stem or valve
 Repair or replace damaged components as required.
seat.
Worn, damaged or dirty valve lifter.

Worn or damaged camshaft lobe.

Worn, damaged or loose timing belt
and sprockets.
Base Engine Misfire with Coolant Consumption

Cause Correction
 Inspect the spark plugs. Refer to Section 1C1, Engine
Damaged or improperly installed  Verify engine compression. Refer to "Compression Pressure
cylinder head. Check" in this section.
Coolant consumption may or may not  Inspect the cylinder heads.
cause the engine to misfire.  Inspect the engine block.
Base Engine Misfire with Excessive Oil Consumption

Cause Correction
Worn or damaged valve.
 Inspect the spark plugs. Refer to Section 1A2, General Engine

Information - FAM II 2.4D.
 Verify engine compression. Refer to "Compression Pressure
Worn, damaged or improperly
Check" in this section.
installed piston rings.
 Inspect the cylinder bores.
Piston rings must be installed
 Inspect the pistons.
with the mark, or dimple, on the
 Inspect the piston pins.
top of the piston ring, facing up.
 Inspect the connecting rods.
Engine Noise on Start-Up, but Only Lasting a Few Seconds

Cause Correction
 Install the correct engine oil and oil filter. Refer to Section
Incorrect engine oil, viscosity. 1C1, Engine Mechanical - FAM II 2.4D.
 Install the correct engine oil and oil filter. Refer to Section
Incorrect oil filter, without anti-
1C1, Engine Mechanical - FAM II 2.4D.
drainback feature.
Cause Correction
1. Inspect the oil filter by-pass valve.
2. Repair or replace damaged components as required.
installed oil filter by-pass valve.
1. Inspect the valve lifters.
High valve lifter leak down rate. 2. Repair or replace damaged components as required.
1. Inspect the crankshaft.

Worn, damaged, or improperly 2. Inspect the crankshaft thrust bearing.
installed crankshaft thrust bearing. 3. Repair or replace damaged components as required.
Upper Engine Noise, Regardless of Engine Speed

Cause Correction
 Verify oil pressure. Refer to "Oil Pressure Check" in this
section.
Low oil pressure.
 Verify oil pressure. Refer to "Oil Pressure Check" in this

section.
Improper lubrication of the valve train  Inspect the oil filter bypass valve.
components.  Inspect the oil pump and pump screen.
 Inspect the engine block oil galleries.
 Inspect the valve springs.

Broken valve spring.  Repair or replace damaged components as required.

Worn, damaged or stuck valves, carbon  Inspect the valve guides.
on the valve stem or valve seat.  Repair or replace damaged components as required.

Worn or damaged valve guide.

Worn, damaged or dirty valve lifter.  Repair or replace damaged components as required.
 Inspect the engine camshaft lobes.

Worn or damaged camshaft lobes.  Repair or replace damaged components as required.

Worn, damaged, improperly installed or
loose timing belt and sprockets.
 Inspect the timing belt tensioner.
Worn, damaged or improperly installed
timing belt tensioner, if equipped.
Lower Engine Noise, Regardless of Engine Speed

Cause Correction
1. Verify oil pressure. Refer to "Oil Pressure Check" in this
section.
Low oil pressure.
Cause Correction
1. Verify the operation of the ignition controls system.
Refer to Section 1F2, Engine Controls - FAM II 2.4D in
Detonation or spark knock. Vehicle DTC Information.
Worn, damaged, or improperly installed

1. Inspect the accessory drive system components.
accessory drive belt - severe cracking,
bumps or missing segments in the
accessory drive belt.
1. Inspect the accessory drive system components.
accessory drive system components.
1. Inspect the crankshaft pulley.
Worn, damaged, or improperly installed 2. Inspect the crankshaft.
crankshaft pulley. 3. Repair or replace damaged components as required.
1. Inspect the engine flywheel.

2. Inspect the engine flywheel bolts.
3. Inspect the torque converter.
4. Inspect the torque converter bolts.
engine flywheel.

torque converter.
Damaged oil pan, contacting the oil pump

1. Inspect the oil pan.
screen - an oil pan that has been
2. Inspect the oil pump screen.
damaged may loosen, improperly position,
or restrict oil flow at the oil pump screen,
preventing proper oil flow to the oil pump.
Worn, damaged, improperly installed or
restricted oil pump screen - an oil pan that 1. Inspect the oil pan.
has been damaged may loosen, 2. Inspect the oil pump screen.
improperly position, or restrict oil flow at 3. Repair or replace damaged components as required.
the oil pump screen, preventing proper oil
flow to the oil pump.
1. Inspect the spark plugs. Refer to Section 1A2, General
Engine Information – FAM II 2.4D.
Worn, damaged, or improperly installed 2. Verify engine compression. Refer to "Oil Pressure
piston - pistons must be installed with the Check" in this section.
mark, or dimple, on the top of the piston, 3. Inspect the cylinder bores.
facing the front of the engine.Piston pins 4. Inspect the pistons.
must be centered in the connecting rod pin 5. Inspect the piston pins.
bore. 6. Inspect the connecting rods.
1. Inspect the connecting rods.

2. Inspect the connecting rod bearings.
3. Inspect the crankshaft connecting rod journals.
connecting rod bearing.
Cause Correction
1. Inspect the crankshaft bearings.
Worn, damaged, or improperly installed 2. Inspect the crankshaft journals.
crankshaft bearing. 3. Repair or replace damaged components as required.
Engine Noise Under Load

Cause Correction
1. Verify oil pressure. Refer to "Oil Pressure Check" in
this section.
Low oil pressure.
2. Repair or replace as required.
1. Verify the correct operation of the ignition controls.

Refer to Section 1F2, Engine Controls - FAM II
Detonation or spark knock. 2.4D in Vehicle DTC Information.

2. Inspect the engine flywheel bolts.
engine flywheel.

torque converter.
Worn, damaged, or improperly installed 1. Inspect the cylinder bores.

pistons-pistons must be installed with the 2. Inspect the pistons.
mark, or dimple, on the top of the piston, 3. Inspect the piston pins.
facing the front of the engine.Piston pins 4. Inspect the connecting rods.
must be centered in the connecting rod pin 5. Repair or replace damaged components as required.
bore.
1. Inspect the connecting rods.
2. Inspect the connecting rod bearings.
3. Inspect the crankshaft connecting rod journals.
connecting rod bearing.
1. Inspect the crankshaft bearings.

Worn, damaged, or improperly installed 2. Inspect the crankshaft journals.
crankshaft bearing. 3. Repair or replace damaged components as required.
Engine Will Not Crank - Crankshaft Will Not Rotate

Cause Correction
1. Remove accessory drive belts.
2. Rotate crankshaft by hand at the
Seized accessory drive system component.
pulley or flywheel location.
Hydraulically locked cylinder.

1. Remove spark plugs and check for
fluid.
 Coolant/antifreeze in cylinder
2. Inspect for broken head gasket.
 Oil in cylinder
3. Inspect for cracked engine block or
 Fuel in cylinder
cylinder head.
Cause Correction
4. Inspect for a sticking fuel injector.
1. Remove the torque converter bolts.

Seized automatic transaxle torque converter.
1. Disengage the clutch.

Seized manual transaxle.
 Inspect timing belt and gears.

Broken timing belt and/or gears.  Repair as required.
 Inspect crankshaft.
Seized crankshaft.  Repair as required.
Material in cylinder.
 Inspect cylinder for damaged
 Broken valve components and/or foreign materials.
 Piston material  Repair or replace as required.
 Foreign material
 Inspect crankshaft and connecting rod

bearings.
Seized crankshaft or connecting rod bearings.
 Repair as required.
 Inspect connecting rods.

Bent or broken connecting rod.  Repair as required.
 Inspect crankshaft.
Broken crankshaft.  Repair as required.
Coolant in Combustion Chamber

Definition : Excessive white smoke and/or coolant type odor coming from the exhaust pipe may
indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or
a faulty thermostat may lead to an "over temperature" condition which may cause engine
component damage.
Cause Correction
1. A slower than normal cranking speed may indicate coolant entering the combustion chamber.
Refer to Engine Will Not Crank - Crankshaft Will Not Rotate.
2. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder
bore.
3. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the
coolant may indicate a faulty gasket or damaged component.
4. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block, with low compression, may indicate a failed cylinder head gasket. Refer to "Compression
Pressure Check" in this section.
Cracked intake manifold or failed gasket. Replace the components as required.

Replace the head gasket and components as required. Refer
Faulty cylinder head gasket.
Machine the cylinder head to the proper flatness, if applicable
Warped cylinder head. and replace the cylinder head gasket. Refer to Section 1C1,
Engine Mechanical - FAM II 2.4D.
Cause Correction
Cracked cylinder head. Replace the cylinder head and gasket.
Cracked cylinder liner or engine block. Replace the components as required.
Cylinder head or engine block porosity. Replace the components as required.
Coolant in Engine Oil
Definition : Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant
entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty
thermostat may lead to an "over temperature" condition which may cause engine component
damage. Contaminated engine oil and oil filter should be changed.
Cause Correction
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not properly
lubricate the crankshaft bearings and may lead to component damage. Refer to Lower Engine
Noise, Regardless of Engine Speed.
2. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the
cooling system may indicate a faulty gasket or damaged component.
3. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block with low compression may indicate a failed cylinder head gasket. Refer to "Compression
Pressure Check" in this section.
Replace the head gasket and components as required. Refer

Faulty cylinder head gasket.
Machine the cylinder head to proper flatness, if applicable,
Warped cylinder head. and replace the cylinder head gasket. Refer to Section 1C1,
Cracked cylinder head. Replace the cylinder head and gasket.
Cracked cylinder liner or engine block. Replace the components as required.
Cylinder head or engine block porosity. Replace the components as required.
Accessory Drive Belt Diagnosis
Drive Belt Chirping Diagnosis
Definition : Accessory drive belt chirping can be defined as a high-pitched noise that is heard
once per revolution of the drive belt or a pulley. The following items are indications of chirping :
 A high pitched noise that is heard once per revolution of the drive belt or a accessory
drive pulley.
 Chirping may occur on cold damp startup conditions and will subside once the vehicle
reaches normal operating temperature.
Diagnostic Aids
The chirping noise may be intermittent due to moisture on the drive belt or the accessory drive
pulley(s). In order to duplicate the customer's concern, It may be necessary to spray a small
amount of water onto the drive belt. If spraying water onto the drive belt duplicates the
symptom, cleaning the accessory belt pulley(s) may be the most probable solution.
A loose or improper installation of a body or suspension component, or other item(s) on the
vehicle may also cause the chirping noise.
Test Description
The number(s) below refer to the step(s) in the diagnostic table.
2. The chirping noise may not be engine related. This step is to verify that the engine is
making the noise. If the engine is not making the noise do not proceed further with his
table.
3. The noise may be an internal engine noise. Remove the drive belt and operate the
engine for a few seconds, this will verify if the chirping noise is related to the drive belt or
not. With the drive belt removed the water pump will not operate and the engine may
overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated
with the drive belt removed.
4. Inspect the drive belt for signs of pilling. Pilling is the small balls, pills, or strings in the
drive belt grooves caused by the accumulation of rubber dust.
6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or
incorrect installation of an accessory drive component, or the pulley may be bent inward
or outward from a previous repair. Test for a misaligned pulley using a straight edge in
the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to
that accessory drive component for the proper removal and installation procedure for
that pulley.
10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut,
spacer, or washer was installed.
12. Inspect the accessory drive pulley(s) should include inspecting for bends, dents or
other damage to the pulley(s) that would prevent the drive belt from seating properly in
the pulley grooves, or on the smooth surface of the pulley when the back side of the
drive belt is used to drive the pulley.
14. Replacing the drive belt when it is not damaged or there is not excessive pilling will
only be a temporary repair.

Did you review the Symptoms - Engine Mechanical
1 diagnostic information, and perform the necessary - Go
inspections? Go to Step 2 to Symptoms
Verify that there is a chirping noise. Go to
2 Does the engine make the chirping noise? - Diagnostic
Go to Step 3 Aids
1. Remove the drive belt. Refer to Section 1C1,
Engine Mechanical - FAM II 2.4D. Go to Engine
2. Operate the engine for no longer than 30 to Noise on Start-
3 -
40 seconds. Up, but Only
Lasting a Few
Does the chirping noise still exist? Seconds Go to Step 4
Inspect for severe drive belt pilling exceeding 1/3 of
4 the drive belt groove depth. -
Does the drive belt grooves have pilling? Go to Step 5 Go to Step 6
Clean the accessory drive belt pulley(s) with a
5 suitable wire brush. -
Were the accessory drive belt pulley(s) cleaned? Go to Step 15 -
Inspect for a misaligned accessory drive pulley(s).
6 -
Is there a misaligned pulley(s)? Go to Step 7 Go to Step 8
Replace and/or repair the misaligned accessory
drive pulley(s).
7 -
Were the misaligned accessory drive pulley(s)
replaced and/or repaired? Go to Step 15 -
Inspect for a bent or cracked accessory drive
bracket(s).
8 -
Is there a bent and/or cracked accessory drive
bracket(s)? Go to Step 9 Go to Step 10
Replace the bent and/or cracked accessory drive
bracket(s).
9 -
Was the bent and/or cracked accessory drive
bracket(s) replaced? Go to Step 15 -
Inspect for incorrect, loose and/or missing
fasteners.
10 -
Were there any incorrect, loose, and/or missing
fasteners found? Go to Step 11 Go to Step 12
1. Replace any incorrect and/or missing
fasteners.
2. Tighten any loose fasteners. Refer
11 to "Fastener Tightening Specifications" in -
this section.
Were the fasteners replaced and/or tightened? Go to Step 15 -

Inspect for a bent accessory drive pulley(s).
12 -
Was a bent accessory drive pulley(s) found? Go to Step 13 Go to Step 14
Replace the bent accessory drive pulley(s).
13 -
Was the bent accessory drive pulley(s) replaced? Go to Step 15 -
Replace the drive belt. Refer to Section 1C1,
14 Engine Mechanical - FAM II 2.4D. -
Was the drive belt replaced? Go to Step 15 -
1. Clear any codes.
2. Run the engine in order to verify the repair.
15 -
Does the chirping noise still exist? - System OK
Drive Belt Squeal Diagnosis
Definition : Accessory drive belt squealing can be defined as a loud screeching noise caused
by a slipping drive belt. Belt squeal is unusual in multi-rib belts. Drive belt squeal generally
occurs when a heavy load is applied to the drive belt, such as an air-conditioning compressor
engagement, snapping the throttle, seized pulley or a faulty accessory drive component.
 A loud screeching noise that is caused by a slipping drive belt (this is unusual for a drive
belt with multiple ribs)
 The squeal occurs when a heavy load is applied to the drive belt, such as an A/C
compressor engagement, snapping the throttle, slipping on a seized pulley, or a faulty
accessory drive component.
Diagnostic Aids
A loose or improper installation of a body or suspension component, or other item(s) on the
vehicle may cause the squeal noise.
If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying
their load(s), making sure they are operating to their maximum capacity. An overcharged air
conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing
generator is suggested items to inspect.
Test Description
2. The squeal may not be engine related. This step is to verify that the engine is making the
noise. If the engine is not making the noise do not proceed further with this table.
3. The squeal may be an internal engine noise. Remove the drive belt and operate the
engine for a few seconds, this will verify if the squealing noise is related to the drive belt
or an accessory drive component. With the drive belt removed the water pump will not
operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set
when the engine is operated with the drive belt removed.
4. This test is to verify that an accessory drive component(s) does not have a seized
bearing. With the belt removed test the bearings in the accessory drive component(s) for
smooth operation. Also test the accessory drive components with the engine operating
by varying the load on the accessory drive component(s) to verify that the component(s)
is operating properly.
5. This test is to verify that the drive belt tensioner is operating properly. If the drive belt
tensioner is not operating properly, proper belt tension may not be achieved to keep the
drive belt from slipping which could cause a squealing noise.
6. This test is to verify that the drive belt is not too long, which would prevent the drive belt
tensioner from operating properly. Also if the incorrect length drive belt was installed, it
may not be routed correctly and may be turning an accessory drive component in the
incorrect direction.
incorrect installation of a accessory drive component, or the pulley may be bent inward
that accessory drive component for the proper removal and installation procedure for
that pulley.
8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width.
Using a known good vehicle, compare the accessory drive pulleys.

Did you review the Symptoms - Engine Mechanical Go
diagnostic information, and perform the necessary to Symptoms -
1 -
inspections? Engine
Go to Step 2 Mechanical
Verify that there is a squealing noise. Go to
2 Does the engine make the squeal noise? - Diagnostic
Go to Step 3 Aids
1. Remove the drive belt. Refer to Section 1C1,
Engine Mechanical - FAM II 2.4D. Go to Engine
3 -
Lasting a Few
Inspect for a seized accessory drive component
4 bearing or a faulty accessory drive component. -
Did you find and correct the condition? Go to Step 9 Go to Step 5
Inspect the drive belt tensioner for proper
5 operation. Refer to Drive Belt Tensioner Diagnosis. -
Check for the correct length drive belt.
6 -
Inspect for a misaligned pulley.
7 -
8 Inspect for an incorrect size pulley. - Go to Step 9 -
Did you find and correct the condition?
1. Install the drive belt. Refer to Section 1C1,
2. Clear any codes.
9 -
Does the squealing noise still exist? - System OK

Drive Belt Whine Diagnosis
Definition : Accessory drive belt whine can be defined as a high-pitched continuous noise that
is most likely to be caused by a failed bearing in one of the accessory drive components.
Diagnostic Aids
The drive belt will not cause the whine.
If the whine is intermittent, verify that it is not the accessory drive component(s) by varying
their loads, making sure they are operating to their maximum capacity. An overcharged air
conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing
generator are suggested items to inspect.
Test Description
3. This test is to verify that the whine is being caused by the accessory drive component(s).
Remove the drive belt and operate the engine for a few seconds, this will verify if the
whining noise is related to the accessory drive component. With the drive belt removed
the water pump will not operate and the engine may overheat. Also diagnostic trouble
codes (DTCs) may set when the engine is operated with the drive belt removed.
4. This inspection should include checking the drive belt tensioner and the drive belt idler
pulley bearings. The drive belt may have to be installed and the accessory drive
component(s) operated separately by varying their loads. Refer to the suspected
accessory drive component for the proper removal and replacement procedure.

1 -
inspections? Engine
Verify that there is a whining noise. Go to
2 Does the engine make the whine noise? - Diagnostic
Go to Step 3 Aids
1. Remove the drive belt. Drive Belt
Replacement. Go to Engine
3 -
Lasting a Few
Does the whining noise still exist? Seconds Go to Step 4
1. Inspect for a failed accessory drive
component bearing.
2. Install the drive belt. Drive Belt
4 -
Replacement.
Did you find and correct the condition? Go to Step 5 -

1. Clear any codes.
5 2. Run the engine in order to verify the repair. -
- System OK
Does the whining still exist?
Drive Belt Rumbling Diagnosis
Definition : Accessory drive belt rumble can be defined as a low pitch tapping, knocking or
thumping noise heard at or just above idle, once per rotation of the drive belt or a specific
component. Drive belt rumble is generally caused by one of the following :
 A low pitch tapping, knocking, or thumping noise heard at or just above idle.
 Heard once per revolution of the drive belt or a pulley(s).
 Rumbling may be caused from :
1. Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in
the drive belt pulley groove
2. The separation of the drive belt
3. A damaged drive belt
Diagnostic Aids
Vibration from the engine operating may cause a body component or another part of the
vehicle to make a rumbling noise.
The drive belt may have a condition that cannot be seen or felt. Sometimes replacing the drive
belt may be the only repair for the symptom.
If after replacing the drive belt and completing the diagnostic table, the rumbling is only heard
with the drive belt is installed, there might be an accessory drive component failure. Varying
the load on the accessory drive component(s) may aid in identifying which component is
causing the rumbling noise.
Test Description
2. This test is to verify that the symptom is present during diagnosing. Other vehicle
components may cause a similar symptom.
3. This test is to verify that the drive belt is causing the rumbling. Rumbling may be
confused with an internal engine noise due to the similarity in the description. Operate
the engine for a few seconds, this will verify if the rumbling noise is related to the drive
belt or not. With the drive belt removed the water pump will not operate and the engine
may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is
operated with the drive belt removed.
4. Inspect the drive belt to ensure that the drive belt is not the cause of the noise. Small
cracks across the ribs of the drive belt will not cause the noise. Belt separation is
identified by the plies of the belt separating, this may be seen at the edge of the belt or
felt as a lump in the belt.
5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe
the drive belt does not have a smooth surface for proper operation.

1 -
inspections? Engine
Verify that there is a rumbling noise. Go to
2 Does the engine make the rumbling noise? - Diagnostic
Go to Step 3 Aids
1. Remove the drive belt(s). Refer to Section
1C1, Engine Mechanical - FAM II 2.4D. Go to Engine
3 -
Lasting a Few
Inspect the drive belt for damage, separation, or
4 sections of missing ribs. -
Were any of these conditions found? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the
5 drive belt groove depth. -
Do the drive belt grooves have pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable
wire brush.
2. Install the drive belt. Refer to Section 1C1,
6 -
Did you complete the repair? Go to Step 8 -

Install a new drive belt. Refer to Section 1C1,
Did you complete the replacement? Go to Step 8 -
1. Clear any codes.
8 -
Does the rumbling noise still exist? - System OK
Drive Belt Vibration Diagnosis
Definition : Accessory drive belt vibration can be defined as a drive belt that jumps, shakes or
rattles. Accessory drive belt vibration is usually indicated by one of the following :
 The vibration is engine-speed related.

 The vibration may be sensitive to accessory load.
Diagnostic Aids
The accessory drive components may have an affect on engine vibration. An overcharged air
conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an
extra load placed on the generator is suggested items to inspect. To help identify an
intermittent or an improper condition, vary the loads on the accessory drive components.
Test Description
2. This test is to verify that the vibration is present during diagnosing. Other vehicle
components may cause a similar symptom such as the exhaust system, or the drive
train.
3. This test is to verify that the drive belt or accessory drive components may be causing
the vibration. Remove the drive belt and operate the engine for a few seconds, this will
verify if the vibration is related to the drive belt or not. With the drive belt removed the
water pump will not operate and the engine may overheat. Also diagnostic trouble codes
(DTCs) may set when the engine is operated with the drive belt removed.
4. The drive belt may cause a vibration. While the drive belt is removed this is the best time
to inspect the condition of the drive belt.
6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer,
or washer was installed.
8. This step should only be performed if the fan is driven by the drive belt. Inspect the
engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for
smooth operation. Inspect for a bent fan shaft or bent mounting flange.
9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings
for smooth operation and excessive play. Compare the water pump with a known good
water pump.
10. Accessory drive component brackets that are bent, cracked, or loose may put an
extra strain on that accessory drive component causing it to vibrate.

1 -
inspections? Engine
Verify that the vibration is engine related. Go to
2 Does the engine make the vibration? - Diagnostic
Go to Step 3 Aids
1. Remove the drive belt. Refer to Section 1C1, Go to
Engine Mechanical - FAM II 2.4D. Diagnostic
2. Operate the engine for no longer than 30 to Starting Point -
40 seconds. Vibration
3 - Diagnosis and
Does the engine still make the vibration? Correction in
Vibration
Diagnosis and
Correction Go to Step 4
Inspect the drive belt for wear, damage, debris
4 build-up and missing drive belt ribs. -
6 fasteners. -
Replace any incorrect and/or missing
fastener.Tighten any loose fasteners. Refer
7 to "Fastener Tightening Specifications" in this -
section.
Were the fasteners replaced and/or tightened? Go to Step 11 -
Inspect for damaged fan blades or a bent fan clutch
8 shaft. -
Inspect for a bent water pump shaft.
9 -
Inspect for bent or cracked accessory drive
10 bracket(s). -
Did you find and correct the condition? Go to Step 11 -
11 1. Clear any codes. - - System OK
Does the vibration still exist?

Drive Belt Falls Off Diagnosis
Definition : The drive belt falls off the pulleys or may not ride correctly on the pulleys.
Diagnostic Aids
If the drive belt repeatedly falls off the accessory drive belt pulley(s), this may be caused by a
pulley misalignment.
An extra load that is quickly applied or released by an accessory drive component may also
cause the drive belt to fall off. Verify that the accessory drive component(s) are operating
properly.
If the drive belt is the incorrect length, the drive belt tensioner may not maintain the proper
tension on the drive belt.
Test Description
The number(s) below refer to the step(s) on the diagnostic table.
2. This inspection is to verify the condition of the drive belt. Damage may have occurred to
the drive belt when the drive belt fell off. Inspect the belt for cuts, tears, sections of ribs
missing, or damaged belt plies.
incorrect installation of a accessory drive component, or the pulley may be bent inward
that accessory drive component for the proper removal and installation procedure of that
pulley.
5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents or
other damage to the pulleys that would prevent the drive belt from seating properly in the
pulley grooves or on the smooth surface of a pulley when the back side of the drive belt
is used to drive the pulley.
6. Accessory drive component brackets that are bent or cracked will also cause the drive
belt to fall off.
7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut , spacer,
or washer was installed. Missing, loose, or incorrect fasteners may cause pulley
misalignment from the accessory drive bracket(s) moving under load. Over tightening the
fasteners may cause misalignment of the accessory component bracket(s).

1 -
inspections? Engine
Inspect for a damaged drive belt.
2 -
Was a damaged drive belt found? Go to Step 3 Go to Step 4
Does the drive belt continue to fall off? Go to Step 4 System OK
Inspect for misaligned accessory drive pulley.
4 -
Inspect for a bent or dented accessory drive pulley.
5 -
Inspect for a bent or a cracked accessory drive
6 bracket(s). -
fasteners.
7 -
Were there any incorrect, loose and/or missing
fasteners? Go to Step 8 Go to Step 9
1. Replace any incorrect and/or missing
fasteners.
2. Tighten any loose fasteners. Refer
8 to "Fastener Tightening Specifications" in -
this section.

Test the drive belt tensioner for correct operation.
9 Refer to Drive Belt Tensioner Diagnosis. -
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt
10 Tensioner Replacement. -
Inspect for a failed drive belt idler and/or tensioner
11 pulley bearings. -
Did you find and repair the condition? Go to Step 12 -
Run the engine in order to verify the repair.
12 -
Does the drive belt still fall off? - System OK
Drive Belt Excessive Wear Diagnosis
Definition : Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
Diagnostic Aids
Excessive wear on a drive belt is usually caused by incorrect installation or the incorrect drive
belt for the application.
Minor misalignment of the accessory drive belt pulley(s) will not cause excessive wear, but will
probably cause the drive belt to make a noise or fall off.
Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may
also make the drive belt fall off.
Test Description
2. This inspection is to verify that the drive belt is correctly installed on all of the accessory
drive pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by
one groove on a pulley(s).
3. The installation of a drive belt that is too wide or too narrow will cause wear on the drive
belt. The drive belt ribs should match all of the grooves on the pulleys.
4. This inspection is to verify the drive belt is not contacting any part of the engine or body
while the engine is operating. There should be sufficient clearance when the accessory
drive components load varies. The drive belt should not come in contact with an engine
or a body component when snapping the throttle.
1 -
inspections? Engine
Inspect the drive belt(s) for proper installation.
2 -
Is the drive belt installed properly? Go to Step 5 Go to Step 3
Inspect for the correct drive belt.
3 -
Is the correct drive belt installed? Go to Step 5 Go to Step 4
Inspect the drive belt for signs of rubbing against a Go to
4 bracket, hose, or wiring harness. - Diagnostic
Was the drive belt rubbing against anything? Go to Step 5 Aids
Replace the drive belt. Refer to Section 1C1,
Run the engine in order to verify the repair.
6 -
Is there still excessive drive belt wear? - System OK
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Air Cleaner Assembly

Removal Procedure
1. Disconnect the negative battery cable.

2. Disconnect the Intake Air Temperature (IAT) sensor connector.
3. Loosen the clamp and disconnect the air cleaner outlet hose from the resonator.
4. Remove the air cleaner housing bolts.
5. Unclip the housing from the ball stud and then remove the air cleaner assembly.
Installation Procedure
1. Install the air cleaner assembly.

2. Install the air cleaner housing to the ball stud and connect the air cleaner outlet hose to
the resonator.
3. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 6 N•m (53 lb-in.).
Air Cleaner Element
Removal Procedure
1. Loosen the clamp and disconnect the air cleaner outlet hose from the air cleaner
housing.
2. Remove the air cleaner element cover screws.
3. Remove the air cleaner element.
1. Install the air cleaner element cover.

2. Tighten the air cleaner element cover screws.
Tighten
Tighten the air cleaner element cover screws to 2 N•m (18 lb-in.).
Cylinder Head Cover

Removal Procedure

2. Remove the engine beautification cover bolts and nuts.
3. Remove the engine beautification cover.
4. Disconnect the breather hose and PCV hose from the cylinder head cover.
5. Disconnect the ignition wires from the spark plugs.
6. Disconnect the camshaft position sensor connector.
7. Remove the cylinder head cover bolts.
8. Remove the cylinder head cover.

9. Remove the cylinder head cover gasket from the cylinder head cover.
1. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the
top of the rear cylinder head cover-to-cylinder head seal.
2. Install the new cylinder head cover gasket to the cylinder head cover.
3. Install the cylinder head cover.
4. Install the cylinder head cover bolts.
Tighten
Tighten the cylinder head cover bolts to 8 N•m (71 lb-in.).
5. Connect the ignition wires to the spark plugs.
6. Connect the camshaft position sensor connector.

7. Connect the breather hose and PCV hose to the cylinder head cover.
8. Install the engine beautification cover.
Tighten
Tighten the engine beautification cover bolts and nuts to 8 N•m (71 lb-in.).
9. Connect the negative battery cable.

Accessory Drive Belt
Removal Procedure
1. Raise and suitably support the vehicle.

2. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
3. Remove the engine front shield at the position of right front wheel. Refer to Section 9R,
Body Front End.
4. Install a suitable tool to the drive belt tensioner.
5. Rotate the drive belt tensioner clockwise in order to relieve the belt tension.
6. Remove the drive belt.
7. Clean and inspect the belt and the mating surfaces of all the pulleys. Refer to Section
1A, General Engine Information.
1. Route the belt around all the pulleys.

2. Install a suitable tool to the drive belt tensioner.
3. Rotate the drive belt tensioner clockwise in order to relieve tension on the tensioner.
4. Install the drive belt.
5. Inspect the drive belt for proper installation and alignment.
Cylinder Head and Gasket
Tools Required
KM-470-B Angular Torque Gauge

DW110-060 Engine Assembly Support Fixture
Removal Procedure
1. Remove the fuel pump fuse.

2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of
fuel pressure.
4. Drain the engine coolant. Refer to Section 1D2, Engine Cooling - FAM II 2.4D.
5. Remove the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.
6. Remove the engine beautification cover and the engine beautification cover bracket.
8. Loosen the clamp and remove the resonator from the electronic throttle body.
9. Disconnect the Direct Ignition System (DIS) connector.
10. Disconnect the front heated oxygen sensor connector.
11. Disconnect the Electronic Throttle Control (ETC) connector.
12. Disconnect the Coolant Temperature Sensor (CTS) connector.
13. Disconnect the Exhaust Gas Recirculation (EGR) valve connector.
15. Remove the engine front shield at the position of the right front wheel.
16. Remove the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this
section.
17. Install the engine assembly support fixture DW110-060.
18. Remove the engine mount assembly. Refer to "Engine Mount Assembly" in this
section.
19. Disconnect the upper radiator hose from the thermostat housing.
20. Remove the crankshaft pulley bolts.
21. Remove the crankshaft pulley.
22. Remove the front timing belt cover bolts.

23. Remove the front timing belt cover.
24. Remove the timing belt. Refer to "Timing Belt" in this section.
25. Remove the cylinder head cover and the gasket. Refer to "Cylinder Head Cover" in
this section.
Notice : Take extreme care to prevent any scratches, nicks or damage to the
camshafts.
26. While holding the intake camshaft firmly in place, remove the intake camshaft gear
bolts.
27. Remove the intake camshaft gear.
28. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft
gear bolts.
29. Remove the exhaust camshaft gear.
30. Remove the timing belt automatic tensioner bolts.
31. Remove the timing belt automatic tensioner.
32. Remove the timing belt idler pulley bolt and nut.
33. Remove the timing belt idler pulley.
34. Remove the engine mount adapter support bracket bolts.
35. Remove the engine mount adapter support bracket.
36. Remove the crankshaft gear.
37. Remove the camshaft position (CMP) sensor.
38. Remove the rear timing belt cover bolts.

39. Remove the rear timing belt cover.
40. Remove the pup converter-to-exhaust front pipe retaining nuts.
41. Remove the exhaust front pipe mounting bracket bolt and nut.
42. Remove the exhaust front pipe from the pup converter. Refer to Section 1G2,
Engine Exhaust - FAM II 2.4D.
43. Disconnect all of the necessary vacuum hoses.
44. Remove the intake manifold support bracket bolts and the bracket.
45. Remove the ground terminal retaining bolt from the intake manifold.
46. Disconnect the fuel feed line at the fuel rail.
47. Disconnect the coolant hoses at the rear cylinder head and the exhaust gas
recirculation (EGR) valve adapter.
48. Disconnect the coolant hoses from the electronic throttle body.
49. Remove the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II
2.4D.
50. Remove the generator upper bracket bolts.
51. Remove the generator upper bracket.
52. Remove the generator-to-intake manifold strap bracket bolts on the generator and
the intake manifold.
53. Remove the evaporative (EVAP) emission canister purge solenoid valve bracket
bolt.
54. Remove the EVAP emission canister purge solenoid valve.
55. Remove the camshaft. Refer to "Camshaft" in this section.

56. Loosen all of the cylinder head bolts gradually in the sequence shown.
57. Remove the cylinder head bolts.
58. Remove the cylinder head with the intake manifold and the exhaust manifold
attached.
Notice : Prevent any engine oil or coolant from entering the cylinders when
removing the cylinder head.
59. Remove the cylinder head gasket.
Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and the engine block.
2. Make sure the gasket surfaces of the cylinder head and the engine block are free of
nicks and heavy scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to "Cylinder Head and Valve Train
Components" in this section.
Important : Before replacing the cylinder head, be sure to install the engine mount
and then remove the engine assembly support fixture DW110-060.
1. Install the new cylinder head gasket.

2. Install the cylinder head with the intake manifold and the exhaust manifold attached.
3. Install the cylinder head bolts and tighten the cylinder head bolts gradually in the
sequence shown.
Tighten
Tighten the cylinder head bolts to 25 N•m (18 lb-ft) and turn the bolts another 3 turns of
90° using the angular torque gauge KM-470-B.
4. Install the camshaft. Refer to "Camshaft" in this section.
5. Install the EAVP emission canister purge solenoid valve.
Tighten
Tighten the evaporative emission canister purge solenoid valve bracket bolt to 5 N•m (44
lb-in.).
6. Install the generator upper bracket.
Tighten
Tighten the generator upper bracket retaining bolts (1) to 25 N•m (18 lb-ft) and the bolt
(2) to 35 N·m (26 lb-ft).
7. Install the generator-to-intake manifold strap bracket.
Tighten
Tighten the generator-to-intake manifold strap bracket retaining bolt (3) to 35 N•m (26 lb-
ft) and the bolt (4) to 25 N•m (18 lb-ft).
8. Connect the coolant hoses to the electronic throttle body, rear cylinder head and the
EGR valve bracket.
9. Install the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II 2.4D.
10. Connect the fuel feed line at the fuel rail.
11. Connect all of the necessary vacuum hoses.
12. Install the ground terminal retaining bolt.
13. Install the intake manifold support bracket.
Tighten
Tighten the intake manifold support bracket bolts to 25 N•m (18 lb-ft).
14. Install the exhaust front pipe to the pup converter. Refer to Section 1G2, Engine
Exhaust - FAM II 2.4D.
Tighten
Tighten the pup converter-to-exhaust front pipe retaining nuts to 35 N•m (26 lb-ft).
Tighten the exhaust front pipe mounting bracket bolt and nut to 40 N•m (30 lb-ft).
15. Install the rear timing belt cover.
Tighten
Tighten the rear timing belt cover bolts to 7 N•m (62 lb-in.).
16. Install the engine mount adapter support bracket.
Tighten
Tighten the engine mount adapter support bracket retaining bolts to 45 N•m (33 lb-ft).
17. Install the timing belt idler pulleys.
Tighten
Tighten the timing belt idler pulleys retaining bolt and nut to 25 N•m (18 lb-ft).
18. Install the camshaft position sensor. Refer to Section 1F2, Engine Controls - FAM
II 2.4D.
19. Install the crankshaft gear.
Tighten
Tighten the crankshaft timing belt drive gear bolt to 135 N•m (100 lb-ft) and turn the bolt
another 30° and 10° using the angular torque gauge.
20. Install the timing belt automatic tensioner.
Tighten
Tighten the timing belt automatic tensioner retaining bolt to 25 N•m (18 lb-ft).
21. Install the camshaft gears with the timing marks at the front.
22. Insert the guide pin of the intake camshaft into the "IN" bore.
23. Insert the guide pin of the exhaust camshaft into the "EX" bore.
24. Install the camshaft gears by counter holding on the hex of the camshaft with an
open-ended wrench.
25. While holding the intake camshaft firmly in place, install a new intake camshaft
gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) and turn the bolt another 60°
and 15° using the angular torque gauge.
26. While holding the exhaust camshaft firmly in place, install a new exhaust camshaft
gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 50 N•m (37 lb-ft) and turn the bolt another 60°
and 15° using the angular torque gauge.
27. Apply a small amount of gasket sealant to the corners of the front camshaft caps
and to the top of the rear cylinder head cover-to-cylinder head seal.
28. Install the cylinder head cover gasket and the cylinder head cover. Refer
to "Cylinder Head Cover and Gasket" in this section.
Tighten

30. Connect the breather hose and the PCV hose to the cylinder head cover.
31. Align the timing marks on the camshaft gears to the notches on the cylinder head
cover, using the intake gear mark for the intake gear and the exhaust gear mark for the
exhaust gear.
32. Align the mark on the crankshaft gear with the notch at the bottom of the rear
timing belt cover.
33. Install the timing belt.
34. Check and adjust the timing belt tension. Refer to "Timing Belt Check and
Adjust" "Timing Belt Check and Adjust" in this section.
35. Install the front timing belt cover.
Tighten
Tighten the front timing belt cover retaining bolts to 6 N•m (53 lb-in.).
36. Install the crankshaft pulley.
Tighten
Tighten the crankshaft pulley bolts to 23 N•m (17 lb-ft).
37. Install the engine mount assembly. Refer to "Engine Mount Assembly" in this
section.
Tighten
Tighten the engine mount adapter bolts to 50 N•m (11 lb-ft).
Tighten the engine mount frame side bracket bolt to 100 N•m (74 lb-ft) and nuts to 90
N•m (66 lb-ft).
38. Remove the engine assembly support fixture DW110-060.

39. Install the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this
section.
40. Connect the upper radiator hose to the thermostat housing.
41. Install the engine front shield at the position of right front wheel.
42. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
43. Install the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.
Tighten
44. Connect the IAT sensor connector.

45. Connect the CTS sensor connector.
46. Connect the ETC sensor connector.
47. Connect the DIS coil connector.
48. Connect the O2 sensor connector.
49. Connect the EGR valve connector.
50. Install the fuel pump fuse.
52. Refill the engine cooling system. Refer to Section 1D2, Engine Cooling - FAM II
2.4D.
Camshafts
Removal Procedure

5. Remove the cylinder head cover. Refer to "Cylinder Head Cover" in this section.
Notice : Take extreme care to prevent any scratches, nicks of damage to the
camshafts.
6. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
8. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear
bolt.
10. Loosen the camshaft bearing cap bolts in stages of one-half to one turn.
11. Remove the camshaft bearing cap bolts from the cylinder head.
12. Remove the camshafts.
13. Remove the seal ring from the camshafts.
Important : The camshaft must be detached evenly from the bearing seats in the
front guide bearing.
14. Check the camshaft and bearing seats for wear and replace them if necessary.
Notice : Take extreme care to prevent any scratches, nicks of damage to the
camshafts.
1. Lubricate the camshaft journals and the camshaft caps with engine oil.
2. Install the intake and exhaust camshafts.
3. Install the intake and exhaust camshaft bearing caps in their original positions.
4. Install the intake and exhaust camshaft bearing cap bolts.
5. Tighten the camshaft bearing cap bolts gradually in the sequence shown for each
camshaft caps.
Tighten
Tighten the camshaft bearing cap bolts to 8 N•m (71 lb-in.).
6. Measure the intake and exhaust camshaft end play. Refer to "Engine Specification" in
this section.
7. Install the intake camshaft gear.
8. While holding the intake camshaft firmly in place, install a new intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) plus 60° and 15° using the
angular torque gauge KM-470-B.
9. Install the exhaust camshaft gear.

10. While holding the exhaust camshaft firmly in place, install a new exhaust camshaft
gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 50 N•m (37 lb-ft) plus 60° and 15° using the
11. Install the timing belt. Refer to "Timing Belt" in this section.
12. Install the cylinder head cover gasket and cylinder head cover.
Tighten
Tighten
Timing Belt Check and Adjust
Adjustment Procedure

2. Disconnect the intake air temperature (IAT) sensor connector.
5. Remove the engine front shield at the position of right front wheel.
6. Remove the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this
section.
8. Remove the engine mount assembly. Refer to "Engine Mount Assembly" in this section.
11. Rotate the crankshaft at least one full turn clockwise using the crankshaft gear bolt.
12. Align the mark on the crankshaft gear with the notch at the bottom of the rear
timing belt cover.
13. Align the camshaft gear timing marks. Use the exhaust gear mark for the exhaust
gear and the intake gear mark for the intake gear, since the gears are not
interchangeable.
14. Loosen the automatic tensioner bolt. To relieve the belt tension, turn the hex-key
tab counterclockwise.
15. Rotate the automatic tensioner hex-key tab clockwise until the adjust arm pointer
of the timing belt automatic tensioner is aligned with the notch in the timing belt
automatic tensioner bracket.
16. Tighten the automatic tensioner bolt.
17. Rotate the crankshaft two full turns clockwise using the crankshaft gear bolt.
18. Check the automatic tensioner pointer.
19. When the adjust arm pointer of the timing belt automatic tensioner is aligned with
the notch on the timing belt automatic tensioner bracket, the belt is tensioned correctly.
Tighten
Tighten the automatic tensioner bolt to 25 N•m (18 lb-ft).
Tighten
Tighten the front timing belt cover bolts to 6 N•m (53 lb-in.).
Tighten
Tighten the crankshaft pulley bolt to 23 N•m (17 lb-ft).
section.
section.
24. Install the engine front shield. Refer to 9R, Body Front End.
25. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
Tighten
Timing Belt
Removal Procedure

7. Remove the engine front shield at the position of right front wheel.
8. Remove the accessory drive belt. Refer to "Accessory Drive Belt" in this section.
section.
13. Using the crankshaft gear bolt, rotate the crankshaft clockwise until the timing mark
on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt
cover.
Notice : The camshaft gears must be aligned with the notch on the cylinder head
cover or damage to the engine could result.
14. Align the camshaft gears with the notch on the cylinder head cover.
Important : Use the intake gear mark for the intake camshaft gear and the exhaust
gear mark for the exhaust camshaft gear since both gears are not
interchangeable.
15. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.
16. Remove the timing belt.
1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear
timing belt cover.
2. Align the timing mark on the camshaft gears, using the intake gear mark for the intake
gear and the exhaust gear mark for the exhaust gear.
3. Install the timing belt.
4. Turn the hex-key in a clockwise direction to tension the belt. Turn until the pointer aligns
with the notch.
5. Install the automatic tensioner.
Tighten
Tighten the automatic tensioner bolt to 25 N•m (18 lb-ft).
6. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt.
7. Recheck the automatic tensioner pointer.
Tighten
Tighten the front timing belt cover bolts to 6 N•m (53 lb-in.).
9. Install the engine mount assembly. Refer to "Engine Mount Assembly" in this section.
Tighten
Tighten the crankshaft pulley bolt to 23 N•m (17 lb-ft).
section.
12. Install the engine front shield at the position of right front wheel.
13. Install the right front wheel. Refer to Section 2E, Tires and Wheels. Section 2E,
Tires and Wheels.
14. Install the air cleaner assembly.
Tighten
Oil Pan
Removal Procedure

2. Remove the engine under cover.
3. Remove the oil filler cap.
4. Remove the oil pan drain plug and drain the oil into a suitable container.
5. Remove the exhaust front pipe from the pup converter. Refer to Section 1G2, Engine
Exhaust – FAM II 2.4D.
6. Remove the oil pan flange-to-transaxle retaining bolts.
7. Remove the transaxle-to-oil pan flange retaining bolt.
8. Remove the interm shaft support bracket bolts from the oil pan and the engine block.
9. Remove the interm shaft support bracket.
10. For the AWD vehicle, remove the transfer case bracket. Refer to Section 5D,
Transfer Case.
11. Remove the oil pan retaining bolts.
12. Remove the oil pan from the engine block with pushing the engine assembly
forward.
Cleaning Procedure
1. Clean the oil pan sealing surface.

2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes on the engine block.
5. Clean the oil pan scraper.
1. Coat the oil pan mating surface with sealant.
Important : Install the oil pan within 5 minutes after applying the liquid gasket to
the oil pan.
2. Install the oil pan to the engine block.

3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 N•m (89 lb-in.).
4. Install the oil pan flange-to-transaxle retaining bolts.
Tighten
Tighten the oil pan flange-to-transaxle bolts to 50 N•m (37 lb-ft).
5. Install the transaxle-to-oil pan flange retaining bolt.
Tighten
Tighten the transaxle-to-oil pan flange bolt to 50 N•m (37 lb-ft).
6. Install the interm shaft support bracket.
Tighten
Tighten the interm shaft support bracket bolts to 70 N•m (52 lb-ft).
7. For the AWD vehicle, Install the transfer case bracket. Refer to Section 5D, Transfer
Case.
8. Install the exhaust front pipe to the pup converter. Refer to Section 1G, Engine Exhaust.
Tighten
10. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 18 N•m (13 lb-ft).
11. Install the engine under cover. Refer to Section 9N, Frame and Underbody.
12. Refill the engine crankcase with engine oil.
Oil Pump
Removal Procedure

3. Remove the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section.
4. Disconnect the oil pressure switch connector.
5. Remove the oil pan. Refer to "Oil Pan" in this section.
6. Remove the oil pump retaining bolts.
7. Carefully separate the oil pump and gasket from the engine block and oil pan.
8. Remove the oil pump.
Inspection Procedure
1. Clean the oil pump and the engine block gasket mating surface areas.
2. Remove the safety relief valve bolt.

3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.
5. Remove the oil pump rear cover.

6. Clean the oil pump housing and all the oil pump components.
7. Inspect the oil pump components for signs of wear. Replace the worn oil pump parts.
Notice : Pack the oil pump gear cavity with petroleum jelly to ensure an oil pump
prime or engine damage could result.
8. Coat all the oil pump parts with clean engine oil.
9. Apply Loctite 242 to the oil pump rear cover bolts and install the cover and bolts.
Tighten
Tighten the oil pump rear cover bolts to 20 N•m (15 lb-ft).
10. Install the safety relief valve, spring, washer and bolt.
Tighten
Tighten the safety relief valve bolt to 30 N•m (22 lb-ft).
1. Apply Loctite242 to the oil pump bolts and room temperature vulcanizing (RTV) sealant
to the new oil pump gasket.
2. Install the gasket to the oil pump and install the oil pump to the engine block with bolts.
Tighten
Tighten the oil pump retaining bolts to 10 N•m (89 lb-in.).
3. Install a new oil pump-to-crankshaft seal. Coat the lip of the seal with a thin coat of
grease.
4. Install the oil pan. Refer to "Oil Pan" in this section.

5. Connect the oil pressure switch connector.
6. Install the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section.
Engine Mount Assembly (RH Side)
Tools Required

Removal Procedure
Caution : Only lift the engine far enough to take the weight off the engine mount
assembly, or damage to the mount and lifting equipment failure may occur.
1. Support the engine assembly using the engine assembly support fixture DW110-060.
2. Remove the engine mount adapter retaining bolts from the engine mount support
bracket.
3. Remove the engine mount frame side bracket retaining bolt and nuts.
4. Remove the engine mount assembly.
1. Install the engine mount assembly.
Tighten
Tighten the engine mount frame side bracket retaining bolt to 100 N•m (74 lb-ft) and nuts
to 90 N•m (66 lb-ft).
Tighten the engine mount adapter retaining bolts to 50 N•m (37 lb-ft).

Transaxle Mount Assembly (LH Side)
Tools Required

Removal Procedure
1. Remove the battery and battery tray. Refer to Section 1E2, Engine Electrical – FAM II
2.4D.
Caution : Only lift the engine far enough to take the weight off the transaxle mount
assembly, or damage to the mount and lifting equipment failure may occur.
3. Remove the transaxle mount bracket retaining bolts from the transaxle.
4. Remove the transaxle mount assembly retaining bolts from the left front longitudinal.
5. Remove the transaxle mount assembly.
1. Install the transaxle mount assembly.
Tighten
Tighten the transaxle mount assembly retaining bolts (2) to 37 N•m (27 lb-ft).
Tighten the transaxle mount bracket retaining bolts (1) to 50 N•m (37 lb-ft).
3. Install the battery and battery tray. Refer to Section 1E2, Engine Electrical – FAM II
2.4D.
Transaxle Front Mount Assembly
Tools Required

Removal Procedure
Caution : Only lift the engine far enough to take the weight off the transaxle front
mount assembly, or damage to the mount and lifting equipment failure may occur.
2. Remove the transaxle front mount-to-cradle through bolt.
3. Remove the transaxle front mount retaining bolts from the transaxle.
4. Remove the transaxle front mount assembly.
1. Install the transaxle front mount assembly.
Tighten
Tighten the transaxle front mount retaining bolts to 50 N•m (37 lb-ft).
Caution : Before tightening the transaxle front mount through bolt swing the
engine assembly backwards and forwards or from the side to side for the proper
alignment.
2. Install the transaxle front mount through bolt.
Tighten
Tighten the transaxle front mount-to-cradle through bolt to 90 N•m (66 lb-ft).
Transaxle Rear Mount Assembly
Tools Required

Removal Procedure
Caution : Only lift the engine far enough to take the weight off the transaxle rear
mount assembly, or damage to the mount and lifting equipment failure may occur.
2. Remove the transaxle rear mount-to-bracket through bolt.
3. Remove the transaxle rear mount bracket retaining bolts from the transaxle.
4. Remove the transaxle rear mount bracket.
5. Remove the transaxle rear mount retaining bolts from the cradle.
6. Remove the transaxle rear mount.
1. Install the transaxle rear mount to the cradle.
Tighten
Tighten the transaxle rear mount retaining bolts to 90 N•m (66 lb-ft).
2. Install the transaxle rear mount bracket to the transaxle.
Tighten
Tighten the transaxle rear mount bracket retaining bolts to 90 N•m (66 lb-ft).
Caution : Before tightening the transaxle rear mount through bolt, swing the
alignment.
3. Install the transaxle rear mount through bolt.
Tighten
Tighten the transaxle rear mount-to-bracket through bolt to 90 N•m (66 lb-ft).
Intake Manifold
Removal Procedure

4. Loosen the clamp and disconnect the air cleaner outlet hose from the electronic throttle
body with resonator attached.
5. Disconnect the electronic throttle control (ETC) sensor connector.
6. Disconnect the manifold absolute pressure (MAP) sensor connector.
7. Disconnect the coolant hoses form the electronic throttle body.
8. Disconnect all of the necessary vacuum hoses, including the brake booster vacuum
hose at the intake manifold.
9. Remove the generator upper bracket.
10. Remove the generator-to-intake manifold strap bracket bolt on the intake manifold
and loosen the bolt on the generator.
11. Remove the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II
2.4D.
12. Remove the evaporative (EVAP) emission canister purge solenoid valve. Refer
to Section 1F2, Engine Controls - FAM II 2.4D.
13. Remove the intake manifold support bracket bolt at the engine block and the intake
manifold.
14. Remove the intake manifold support bracket.
15. Remove the ground terminal retaining bolt.
16. Remove the intake manifold retaining bolt and nuts in the sequence shown.
17. Remove the intake manifold.
18. Remove the intake manifold gasket.
19. Clean the sealing surfaces of the intake manifold and the cylinder head.
1. Install a new intake manifold gasket.

2. Install the intake manifold.
3. Install the intake manifold retaining bolt and nuts in the sequence shown.
Tighten
Tighten the intake manifold retaining bolt and nuts to 22 N•m (16 lb-ft).
4. Install the ground wiring terminal retaining bolt to the intake manifold.
5. Install the intake manifold support bracket.
Tighten
Tighten the intake manifold support bracket bolts to the intake manifold and cylinder
block to 25 N•m (18 lb-ft).
6. Install the generator upper bracket.
Tighten
Tighten the generator upper bracket retaining bolts (1) to 25 N•m (18 lb-ft) and the bolt
(2) to 35 N•m (26 lb-ft).7.
7. Install the generator-to-intake manifold strap bracket.
Tighten
8. Install the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II 2.4D.
Tighten
Tighten the fuel rail assembly retaining bolts to 25 N•m (18 lb-ft).
9. Install the EVAP emission canister purge solenoid valve.

Tighten
Tighten the evaporative emission canister purge solenoid valve bracket bolt to 5 N•m (44
lb-in.).
10. Connect all of the necessary vacuum lines those were previously disconnected.
11. Connect the MAP sensor connector.
12. Connect the ETC sensor connector.
13. Connect the coolant hoses to the electronic throttle body.
14. Connect the air cleaner outlet hose to the electronic throttle body with resonator
attached.
17. Refill the engine cooling system. Refer to Section 1D2, Engine Cooling - FAM II
2.4D.
Exhaust Manifold
Removal Procedure

2. Disconnect the front heated oxygen sensor connector.
3. Remove the exhaust manifold heat shield retaining bolts.
4. Remove the exhaust manifold heat shield.
7. Remove the exhaust manifold retaining nuts in the sequence shown.

8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket.
10. Clean the sealing surfaces of the exhaust manifold and the cylinder head.
1. Install a new exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold retaining nuts and tighten in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 22 N•m (16 lb-ft).
4. Install the exhaust front pipe-to-pup converter. Refer to Section 1G, Engine Exhaust.
Tighten
5. Install the exhaust manifold heat shield.
Tighten
Tighten the exhaust manifold heat shield bolts to 15 N•m (11 lb-ft).
6. Connect the front heated oxygen sensor connector.
Camshaft Gears
Removal Procedure

5. Remove the cylinder head cover. Refer to "Cylinder Head Cover" in this section.
camshafts.
7. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
9. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear
bolt.
11. Remove the camshaft position (CMP) sensor.
1. Install the camshaft position (CMP) sensor.
Tighten
Tighten the camshaft position sensor bolt to 8 N•m (71 lb-in.).
camshafts.
2. Install the intake camshaft gear.

3. While holding the intake camshaft firmly in place, install a new intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) plus 60° and 15° using the
4. Install the exhaust camshaft gear.

5. While holding the exhaust camshaft firmly in place, install a new exhaust camshaft gear
bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 50 N•m (37 lb-ft) plus 60° and 15° using the
7. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to
the top of the rear cylinder head cover-to-cylinder head seal.
8. Install the cylinder head cover. Refer to "Cylinder Head Cover" in this section.
Tighten
Tighten

Rear Timing Belt Cover
Tools Required

Removal Procedure

3. Remove the camshaft gears. Refer to "Camshaft Gears" in this section.
4. Remove the timing belt automatic tensioner bolt.
6. Remove the timing belt idler pulley retaining bolt and nut.
7. Remove the timing belt idler pulleys.
8. Remove the engine mount adapter support bracket mounting bolts.
9. Remove the engine mount adapter support bracket.
10. Remove the camshaft position sensor. Refer to Section 1F2, Engine Controls –
FAM II 2.4D.
11. Remove the crankshaft gear.
12. Remove the rear timing belt cover bolts.
13. Remove the rear timing belt cover.
1. Install the rear timing belt cover.
Tighten
Tighten the rear timing belt cover bolts to 7 N•m (62 lb-in.).
2. Install the camshaft position sensor.
Tighten
Tighten the camshaft position sensor bolt to 8 N•m (71 lb-in.).
3. Install the engine mount adapter support bracket.
Tighten
Tighten the engine mount adapter support bracket bolts to 45 N•m (33 lb-ft).
4. Install the timing belt idler pulleys.
Tighten
Tighten the timing belt idler pulleys bolt and nut to 25 N•m (18 lb-ft).
5. Install the crankshaft timing belt drive gear.
Tighten
Tighten the crankshaft gear bolt to 135 N•m (100 lb-ft) plus 30° and plus 10° using the
6. Install the timing belt automatic tensioner.
Tighten
Tighten the timing belt automatic tensioner to 25 N•m (18 lb-ft).
7. Install the camshaft gears. Refer to "Camshaft Gears" in this section.
Engine
Tools Required
EN-48243 Engine Assembly Remove/Install Pallet

EN-48244 Engine Assembly Remove/Install Pallet Supporter
Removal Procedure
1. Remove the fuel pump fuse.

2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of
fuel pressure.
3. Drain the engine oil.
5. Drain the power steering oil.
6. Drain the transaxle oil. Refer to Section 5A, AISIN 55-51LE Automatic
Transaxle or Section 5B, Five-Speed Manual Transaxle (D33).
7. Discharge the air conditioning system, if equipped. Refer to Section 7B, Manual Control
Heating, Ventilation, and Air Conditioning System.
12. Remove the resonator from the electronic throttle body.
13. Disconnect the upper radiator hose from the thermostat.
14. Disconnect the lower radiator hose from the coolant pipe.
15. Disconnect the coolant hoses from the electronic throttle body.
16. Disconnect the surge tank hose from the cylinder block.
17. Disconnect the heater outlet hose from the coolant pipe.
18. Disconnect the heater inlet hose from the cylinder head.
19. Disconnect the fuel feed line from the fuel rail.
20. Disconnect the power steering return hose and the pressure hose from the power
steering pump. Refer to Section 6A, Power Steering System.
21. Disconnect all of the necessary electrical connectors such as A/C pressure sensor,
Exhaust Gas Recirculation valve, Direct Ignition System, Coolant Temperature Sensor,
Electronic Throttle Control system, Oxygen sensor, Crankshaft Position sensor,
Camshaft Position sensor, Manifold Absolute Pressure sensor, fuel injector, Engine
Control Module, knock sensor, alternator and starter terminal etc.
22. Remove the ground terminals from the starter, intake manifold and cylinder block.
23. Remove all the neccessary parts and disconnect all connectors and cables from
the transaxle. Refer to Section 5A, AISIN 55-51LE Automatic Transaxle or Section 5B,
Five-Speed Manual Transaxle (D33).
24. Disconnect all of the necessary vacuum lines, including the brake booster vacuum
hose.
25. Remove the A/C compressor. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.
26. Remove the engine electrical wires from the engine.
29. Remove the exhaust front pipe from the pup converter. Refer to Section 1G2,
Engine Exhaust – FAM II 2.4D.
30. For the AWD vehicle, remove the propeller shaft. Refer to Section 3B, Rear Drive
Axle.
31. Disconnect the stabilizer link. Refer to Section 2D, Rear Suspension.
32. Disconnect the tie rod end joint. Refer to Section 2D, Rear Suspension.
33. Disconnect the control arm joint. Refer to Section 2D, Rear Suspension.
34. Remove the left and right axle shaft. Refer to Section 3A, Automatic Transaxle
Drive Axle or Section 3B, Manual Transaxle Drive Axle.
35. Remove the power steering gear interm shaft. Refer to Section 6C, Power Steering
Gear.
36. Remove the cradle support bracket retaining bolts. Refer to Section 2C, Front
Suspension.
37. Remove the cradle mounting bolts.
Caution : Make sure that all components have to be set on the exact position on
the engine assembly remove/install pallet EN-48243 with the pallet supporter EN-
48244 as shown.
o 1~4 : Cradle Supporter

o A : Diesel Engine Oil Pan Supporter
o B : FAM II 2.4D Engine Oil Pan Supporter
o C & D : HFV6 3.2L Engine Oil Pan Supporter
o E : Manual Transaxle Supporter
o F : Automatic Transaxle Supporter
o G : Transfer Case Supporter (M/T & A/T)
o H : Transaxle Mount Supporter (M/T & A/T)
Caution : Only lower the vehicle far enough to take the weight off the engine and
transaxle mount, or damage to the mount and pallet/pallet supporter failure may
occur.
38. Lower the vehicle and position the engine assembly on to the engine assembly
remove/install pallet EN-48243 with the pallet supporter EN-48244 to the cradle.
section.
40. Remove the transaxle mount assembly. Refer to "Transaxle Mount Assembly" in
this section.
Caution : Make sure that all the cables, connectors and hoses are disconnected
from the engine and transaxle assembly.
41. Raise the vehicle to remove from the engine and transaxle assembly clear.
42. Install the hoist to the engine support bracket and lift the engine assembly far
enough to take the weight off the transaxle front and rear mount assembly.
43. Remove the transaxle front mount assembly from the cradle. Refer to "Transaxle
Front Mount Assembly" in this section.
44. Remove the transaxle rear mount assembly from the cradle. Refer to "Transaxle
Rear Mount Assembly" in this section.
45. Lift the engine assembly and remove the cradle from the engine and transaxle
assembly.
46. Separate the engine block from the transaxle as follows.
o Remove the torque converter bolts.
o Remove the transaxle to engine block mounting bolts.
o Remove the oil flange to transaxle mounting bolts.
o Remove the starter mounting bolts.
1. Install the torque converter bolts.
Tighten
Tighten the torque converter bolts to 45 N•m (33 lb-ft).
2. Install the transaxle to the engine block.
Tighten
Tighten the transaxle bell housing bolts to 75 N•m (55 lb-ft).
Tighten the oil pan flange-to-transaxle bolts to 50 N•m (37 lb-ft).
3. Install the starter mounting bolts.
Tighten
Tighten the starter-to-engine block mounting bolt to 75 N•m (55 lb-ft).
Tighten the transaxle-to-starter mounting bolt to 75 N•m (55 lb-ft).
Caution : Make sure that all components have to be set on the exact position on
the engine assembly remove/install pallet EN-48243 with the pallet supporter EN-
48244.
4. Install the engine and transaxle assembly onto the cradle.
Caution : Before tightening the transaxle front mount through bolt, swing the
alignment.
5. Install the transaxle front mount assembly.
Tighten
Tighten the transaxle front mount retaining bolts to 50 N•m (37 lb-ft).
Tighten the transaxle front mount-to-transaxle through bolt to 90 N•m (66 lb-ft).
Caution : Before tightening the transaxle rear mount through bolt, swing the
alignment.
6. Install the transaxle rear mount assembly to the cylinder block.
Tighten
Tighten the transaxle rear mount retaining bolts to 90 N•m (66 lb-ft).
Tighten the transaxle rear mount-to-bracket through bolt to 90 N•m (66 lb-ft).
7. Lift the vehicle.
8. Lower the vehicle and position the engine and transaxle assembly with the cradle
attached on to the engine assembly remove/install pallet EN-48243 with the pallet
supporter EN-48244 to the vehicle.
9. Install the transaxle mount. Refer to "Transaxle Mount Assembly" in this section.
Tighten
Tighten the transaxle mount assembly retaining bolts to 37 N•m (27 lb-ft).
Tighten the transaxle mount bracket retaining bolts to 50 N•m (37 lb-ft).
section.
Tighten
Tighten the engine mount frame side bracket retaining bolt to 100 N•m (74 lb-ft) and nuts
to 90 N•m (66 lb-ft).
Tighten the engine mount adapter retaining bolts to 50 N•m (37 lb-ft).
11. Remove the engine assembly remove/install pallet EN-48243 with the pallet
supporter EN-48244 from the vehicle.
12. Install the cradle-to-body mounting bolts. Refer to Section 2C, Front
Suspension. Section 2C, Front Suspension.
Tighten
Tighten the cradle mounting bolts to 155 N•m (114 lb-ft).
13. Install the cradle support bracket retaining bolts. Refer to Section 2C, Front
Suspension. Section 2C, Front Suspension.
Tighten
Tighten the cradle support bracket bolts to 50 N•m (37 lb-ft).
14. Install the power steering gear intermediate shaft. Refer to Section 6C, Power
Steering Gear.
15. Install the left and right axle shaft. Refer to Section 3A, Automatic Transaxle Drive
Axle or Section 3B, Manual Transaxle Drive Axle.
16. Install the control arm joint. Refer to Section 2D, Rear Suspension.
17. Install the tie rod end joint. Refer to Section 2D, Rear Suspension.
18. Install the stabilizer link. Refer to Section 2D, Rear Suspension.
19. Install the exhaust front pipe-to-pup converter. Refer to Section 1G2, Engine
Exhaust – FAM II 2.4D.
Tighten
20. For the AWD vehicle, install the propeller shaft. Refer to Section 3B, Rear Drive
Axle.
21. Install the engine electrical wires to the engine.
22. Connect all of the necessary vacuum lines, including the brake booster vacuum
hose.
23. Connect the ground terminals.
24. Connect all of the necessary electrical connectors.
25. Connect the power steering hoses to the power steering pump. Refer to Section
6C, Power Steering Gear.
26. Connect the fuel feed line to the fuel rail.
27. Connect the heater inlet and outlet hose to the cylinder head.
28. Connect all of the necessary cooling hoses to electronic throttle body, thermostat,
coolant pipe and cylinder block.
29. Install the resonator to the electronic throttle body.
31. Install the breather hose and PCV hose to the cylinder head cover.
32. Connect the intake air temperature (IAT) sensor connector.
34. Install the fuel pump fuse.

35. Refill the engine crankcase with engine oil.
36. Refill the engine coolant system. Refer to Section 1D2, Engine Cooling - FAM II
2.4D.
37. Refill the power steering system and bleed the system. Refer to Section 6A, Power
Steering System
38. Refill the A/C refrigerant system, if equipped. Refer to Section 7B, Manual Control
Heating, Ventilation and Air Conditioning System.
Crankshaft Balancer Unit Assembly
Removal Procedure

2. Remove the oil suction pipe with O-ring.
3. Remove the oil pan scraper.
4. Remove the crankshaft balancer unit assembly retaining bolts.
5. Remove the crankshaft balancer unit assembly and the shim.
Adjustment Procedure
1. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt
cover.
2. In this crankshaft position, the flattened side (arrows) of both balancer shafts must face
downward (oil pan side) and must be on a horizontal line.
3. Screw measuring device KM-949 (3) with long knurled bolt (1) into 1st balancer shaft
(intake side) and hand-tighten. The measuring arm (5) must point in “9 o’clock” direction
shown in the illustration.
4. Install the dial gauge holder with dial gauge (4) on the cylinder block.
5. Place pre-tensioned probe (6) of gauge on measuring arm of measuring device KM-949.
The probe must be set precisely between the notch marks, square to the plane surface
(7).
6. Determine the left and right stops by turning the knurled bolt (2).
7. Set the dial of the gauge to zero.
8. Use the knurled bolt (2) to move the 2nd balancer shaft (exhaust side) back and forth.
Again – simultaneously read off the tooth backlash from the gauge.
9. The permissible tooth backlash is : 0.02 mm to 0.06 mm (0.0008 to 0.0024 in.).
10. The tooth backlash must be measured in 4 different positions – turn the crankshaft
further at the fastening bolt of the timing belt drive gear by 45° in the engine rotational
direction until the measuring arm (2) is at “6 o’clock”.
11. Then loosen the knurled bolt (3) fix the measuring arm at “9 o’clock” again and
repeat the measurement.
12. If the value determined in one of the 4 measurements lies outside the tolerance
0.02 mm to 0.06 mm (0.0008 to 0.0024 in.), the tooth backlash must be adjusted.
13. Remove the balancer unit from the cylinder block/crankshaft bearing caps and
remove with the balancer piece. The balancer piece has a number (code), for easy
assignment. The tooth backlash can be adjusted by using a balancer piece with a
different thickness.
Code Thickness of Balancer piece in mm

55 0.535 – 0.565
58 0.565 – 0.595
61 0.595 – 0.625
64 0.625 – 0.655
67 0.655 – 0.685
70 0.685 – 0.715
73 0.715 – 0.745
76 0.745 – 0.775
79 0.775 – 0.805
82 0.805 – 0.835
85 0.835 – 0.865
Notice :
The next larger of smaller balancer alters the tooth backlash by 0.02 mm (0.0008
in.).
Example of selection of balancer piece : The installed balancer piece with the code
“70” gave a tooth backlash of 0.08 mm (0.0031 in.). If a balancer piece with the
code “67” is now installed, the tooth backlash will be approx. 0.06 mm (0.0024 in.).
Caution : Only one balancer piece may be installed.

Caution : Before installing the balancer shaft unit assembly, perform the
adjustment procedure for the proper operation.
Caution : Take care not to chip or dent teeth when meshing gear sets on
assembly.
1. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt
cover.
2. Turn the balancer shaft until the flattened side (arrows) of both balancer shafts face
downward (oil pan side) and are on a horizontal line.
3. Install the selected balancer piece with the balancer shaft unit to the cylinder block.
4. Install the crankshaft balancer shaft unit assembly retaining bolts.
Tighten
Tighten the crankshaft balancer shaft unit assembly retaining bolts to 20 N•m (15 lb-ft)
and turn the bolts another 45° using the angular torque gauge KM-470-B.
Note : If the balancer shaft unit has to be replaced, use the thickest balancer piece
with the code “85” for the initial installation to ensure a tooth backlash in any
case.
5. Install the oil pan scraper.
Tighten
Tighten the oil pan scraper retaining bolts to 8 N•m (71 lb-in.).
6. Install the oil suction pipe with the new O-ring.
Tighten
Tighten the oil suction pipe retaining bolts to 8 N•m (71 lb-in.).

Pistons And Connecting Rods
Tools Required
J-8037 Universal Piston Ring Compressor

J-8087 Cylinder Bore Check Gauge
KM-427 Piston Pin Service Set
Removal Procedure
1. Remove the cylinder head with the intake manifold and exhaust manifold attached. Refer
to "Cylinder Head and Gasket" in this section.
3. Remove the oil suction pipe and the O-ring.
4. Remove the oil pan scraper.
5. Remove the crankshaft balancer unit assembly. Refer to "Crankshaft Balancer Unit
Assembly" in this section.
6. Position the piston to the bottom of the piston stroke.

7. Mark the connecting rod cap for position.
8. Remove the connecting rod cap bolts.
9. Remove the connecting rod cap and the lower connecting rod bearing.
10. Remove the upper connecting rod bearing.
Caution : Use care when handling the piston. Worn piston rings are sharp and
may cause injury.
11. Remove the piston.

12. Expand the piston rings by using the universal piston ring compressor J-8037.
13. Remove the piston rings.
14. Remove the piston pin from the piston and connecting rod assembly using the
piston pin service set KM-427.
15. Separate the piston from the connecting rod.
Inspection Procedure
1. Inspect the pistons for the following conditions.

o Eroded areas at the top of the piston
o Worn piston pin bores or worn piston pins
o Scuffed or damaged skirt coating
o Ring grooves for cracks, nicks or burrs that may cause binding, and
o Warped or worn ring lands
2. Replace pistons that show any signs of damage or excessive wear.
3. Measure the piston width using the following procedure.

o Using an outside micrometer, measure the width of the piston at the thrust
surfaces of the piston, perpendicular to the piston pin centerline.
o Compare the measurement of the piston to its original cylinder by subtracting the
piston width from the cylinder diameter.
o If the clearance obtained through measurement is greater than the provided
specifications and the cylinder bores are within specification, replace the piston.
4. Measure the piston pin bore to piston pin (2) clearances using the following procedure.
o Piston pin bores and pins must be free of varnish or scuffing.
o Use an outside micrometer (1) to measure the piston pin in the piston contact
areas.
o Using an inside micrometer, measure the piston pin bore (1). Compare the result
with the piston pin diameter and piston pin to piston pin bore clearance. Refer
to "Engine Specifications" in this section.
o If the clearance is excessive, determine which piece is out of specification and
replace as required.
o Replace the piston if any of its dimensions are out of specification.
o If the new piston does not meet clearance specifications, the cylinder block may
need to be oversized to 0.25 ㎜. There is only one size of oversized pistons and
rings available for service.
5. Measure the piston ring end gap using the following procedure.
o Piston pin bores and pins must be free of varnish or scuffing.
o Place the piston ring (1) in the area of the bore where the piston ring will travel,
approximately 25 mm below the deck surface. Ensure the ring is square with the
cylinder bore by positioning the ring with the piston head.
o Measure the end gap of the piston ring with feeler gauges (2).
o If the clearance exceeds the provided specifications, the piston rings must be
replaced.
o Repeat the procedure for all piston rings.
6. Measure the piston ring side clearance using the following procedure.
o Roll the piston ring (1) entirely around the piston ring groove. If any binding is
caused by the ring groove, dress the groove with a fine file. If any binding is
caused by a distorted piston ring, replace the ring.
o With the piston ring on the piston, use feeler gauges (2) to check clearance at
multiple locations.
o Compare the measurements with piston ring side clearance. Refer to "Engine
Specifications" in this section.
o If the clearance is greater than specifications, replace the piston rings.
o If the new ring does not reduce the clearance to the correct specification, install a
new piston.
o If the new piston does not meet clearance specifications, the cylinder block may
need to be oversized to 0.25 mm. There is only one size of oversized pistons and
rings available for service.
7. Inspect the connecting rods for the following conditions.
o Inspect the connecting rod beam for twisting or bending.
o Inspect the rod cap for any nicks or damage caused by possible interference.
o Inspect for scratches or abrasion on the rod bearing seating surface.
o If the connecting rod bores contain minor scratches or abrasions, clean the bores
in a circular direction with a light emery paper.
o Retain the original bolts for preliminary assembly. They must be replaced for final
assembly.
8. Measure the connecting rod piston pin bore to piston pin clearance using the following
procedures.
o Using an outside micrometer (1), take two measurements of the piston pin (2) in
the area of the connecting rod contact.
o Using an inside micrometer, measure the connecting rod piston pin bore (1).
o Subtract the piston pin diameter from the piston pin bore.
o Compare the clearance measurements. Refer to "Engine Specifications" in this
section.
o If the clearance is excessive, replace the piston pin. If a new pin does not resolve
the clearance problem, replace the connecting rod.
9. Measure the connecting rod crankshaft bearing bore (1) using the following procedures.
o Using an inside micrometer, measure the connecting rod crankshaft bearing bore.
o Compare the bore measurements. Refer to "Engine Specifications" in this section.
o Replace the connecting rod if the bore is out of specification. Do not recondition
the connecting rod.
10. Inspect the engine block deck surface for flatness using a straight edge and a
feeler gauge. Refer to "Engine Specifications" in this section.
11. Inspect the bearing bore for concentricity and alignment using cylinder bore check
gauge J-8087. Refer to "Engine Specifications" in this section. If the bearing bore is
beyond the specifications, replace the engine block.
12. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a
bore gauge. Refer to "Engine Specifications" in this section.
13. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as
necessary.
Important : For ease of installation of the piston pin, the connecting rod should be
heated to 280°C. Heat the upper connecting rod only. Use commercial thermo
color material to determine the correct temperature. When the thermo color
material changes from black to green, the temperature is correct for installation.
1. Align the notch on the piston and connecting rod so that the proper sides will be facing
the front of the engine.
2. Install the piston pin guide through the piston and the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the piston.
5. Install the piston pin into the piston and connecting rod assembly using the piston pin
service set KM-427.
6. Select a set of new piston rings.
7. Install the piston oil ring, the expander, then the second piston oil ring to the bottom ring
groove of the piston.
8. Install the second compression ring to the middle ring groove of the piston.
9. Install the top compression ring to the top ring groove of the piston.
10. Use the piston ring expander to install the piston rings. Do not expand the piston
rings beyond the expansion necessary for installation.
11. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring and
the top compression ring in relation to the notch on the top of the piston.
12. Lubricate the cylinder wall and the piston rings with clean engine oil.
13. Install the piston using the universal piston ring compressor J-8037 and a wooden
handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
14. Install the connecting rod cap and bearings. Refer to "Crankshaft Bearings and
Connecting Rod Bearings - Gauging Plastic" in this section.
15. Install the connecting rod cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 35 N•m (26 lb-ft). Using the angular
torque gauge KM-470-B, tighten the bolts one turn of 45 degrees plus on turn of 15
degrees.
16. Install the crankshaft balancer unit assembly.
Tighten
Tighten the crankshaft balancer unit assembly bolts to 20 N•m (15 lb-ft) and turn the
bolts another 45° using the angular torque gauge KM-470-B.
17. Install the oil pan scraper bolts.
Tighten
Tighten the oil pan scraper bolts to 8 N•m (71 lb-in.).
18. Install the oil suction pipe with the new O-ring.
Tighten
Tighten the oil suction pipe bolts to 8 N•m (71 lb-in.).
20. Install the cylinder head with the intake manifold and exhaust manifold attached.
Refer to "Cylinder Head and Gasket" "Cylinder Head and Gasket" in this section.
GENERAL DESCRIPTION AND SYSTEM OPERATION

Cylinder Head and Gasket
The cylinder head is made of an aluminum alloy. The cylinder head uses cross-flow intake and
exhaust ports. A spark plug is located in the center of each combustion chamber. The cylinder
head houses the dual camshafts.
CrankShaft
The crankshaft has eight integral weights which are cast with it for balancing. Oil holes run
through the center of the crankshaft to supply oil to the connecting rods, the bearings, the
pistons, and the other components. The end thrust load is taken by the thrust washers installed
at the center journal.
Timing Belt
The timing belt coordinates the crankshaft and the dual overhead camshafts and keeps them
synchronized. The timing belt also turns the coolant pump. The timing belt and the pulleys are
toothed so that there is no slippage between them. There are two idler pulleys. An automatic
tensioner pulley maintains the timing belt's correct tension. The timing belt is made of a tough
reinforced rubber similar to that used on the serpentine drive belt. The timing belt requires no
lubrication.
Oil Pump
The oil pump draws engine oil from the oil pan and feeds it under pressure to the various parts
of the engine. An oil strainer is mounted before the inlet of the oil pump to remove impurities
which could clog or damage the oil pump or other engine components. When the crankshaft
rotates, the oil pump driven gear rotates. This causes the space between the gears to
constantly open and narrow, pulling oil in from the oil pan when the space opens and pumping
the oil out to the engine as it narrows.
At high engine speeds, the oil pump supplies a much higher amount of oil than required for
lubrication of the engine. The oil pressure regulator prevents too much oil from entering the
engine lubrication passages. During normal oil supply, a coil spring and valve keep the bypass
closed, directing all of the oil pumped to the engine. When the amount of oil being pumped
increases, the pressure becomes high enough to overcome the force of the spring. This opens
the valve of the oil pressure regulator, allowing the excess oil to flow through the valve and
drain back to the oil pan.
Oil Pan
The engine oil pan is mounted to the bottom of the cylinder block. The engine oil pan houses
the crankcase and is made of cast aluminum.
Engine oil is pumped from the oil pan by the oil pump. After it passes through the oil filter, it is
fed through two paths to lubricate the cylinder block and cylinder head. In one path, the oil is
pumped through oil passages in the crankshaft to the connecting rods, then to the pistons and
cylinders. It then drains back to the oil pan. In the second path, the oil is pumped through
passages to the camshaft. The oil passes through the internal passageways in the camshafts
to lubricate the valve assemblies before draining back to the oil pan.
Exhaust Manifold
A single four-port, rear-takedown manifold is used with this engine. The manifold is designed
to direct escaping exhaust gases out of the combustion chambers with a minimum of back
pressure. The oxygen sensor is mounted to the exhaust manifold.
Intake Manifold
The intake manifold has four independent long ports and utilizes an inertial supercharging
effect to improve engine torque at low and moderate speeds.
Camshafts
This engine is a dual overhead camshaft (DOHC) type, which means there are two camshafts.
One camshaft operates the intake valves, and the other camshaft operates the exhaust valves.
The camshafts sit in journals on the top of the engine (in the cylinder head) and are held in
place by camshaft caps. The camshaft journals of the cylinder head are drilled for oil
passages. Engine oil travels to the camshafts under pressure where it lubricates each
camshaft journal. The oil returns to the oil pan through drain holes in the cylinder head. The
camshaft lobes are machined into the solid camshaft to precisely open and close the intake
and the exhaust valves the correct amount at the correct time. The camshaft lobes are oiled by
splash action from pressurized oil escaping from the camshaft journals.
Exhaust Gas Recirculation (EGR) Valve
The exhaust gas recirculation (EGR) system is used to lower oxides of nitrogen (NOX)
emission levels caused by high combustion temperatures. The main element of the system is
the EGR valve which is operated electronically.
The EGR valve feeds small amounts of exhaust gas into the intake manifold to decrease the
combustion temperature. The amount of exhaust gas recirculated is controlled by the engine
control module (ECM) in response to variations in engine load. If too much exhaust gas enters,
combustion will not take place. For this reason, very little exhaust gas is allowed to pass
through the valve, especially at idle.
The EGR valve is usually open under the following conditions:
 Warm engine operation

 Above idle speed
SECTION 1D2
ENGINE COOLING - FAM II 2.4D

SPECIFICATIONS
Cooling System Specifications
Application Description Unit Standard
Cooling System Cooling Type - Pressurized
Dexcool/Silicate Based
Type -
Coolant Coolant
Capacity L (qt) 9 (9.5)
Type - Wax Pellet
Temperature (Opened Initially) °C (°F) 87°C (189°F)
Thermostat
Temperature (Completely Opened) °C (°F) 102°C (226°F)
Temperature (Completely Closed) °C (°F) 86°C (187°F)
Type - Electrical Dual Fan
Number of Blade EA 5(Main) / 7(Aux)
Main : 340 (13.4) / Aux : 320
Diameter mm (in.)
(12.6)
Cooling Fan
ON Temperature at Low Speed °C (°F) 96 (204.8)
OFF Temperature at Low Speed °C (°F) 93 (199.4)
ON Temperature at High Speed °C (°F) 100 (212)
OFF Temperature at High Speed °C (°F) 97 (206.6)
Open Pressure of the Pressure Valve kPa 140
Surge Tank
Open Pressure of the Vacuum Valve kPa 10
Type - Centrifugal
Water Pump Impeller Diameter mm (in.) 55 (2.17)
Number of Impeller Blade EA 6
Type - Cross Flow
Core Width mm (in.) 673 (26.50)
Radiator Core Height mm (in.) 511 (20.12)
Core Depth mm (in.) 27 (1.063)
Minimum Cooling Capacity Kcal/h 83,000
Type - NTC
Signal Voltage (at normal engine temp.) V 1.0~2.0
Resistance (at –40°C) kΩ 100.78
Coolant Resistance (at –20°C) kΩ 24.75~33.26
Temperature Sensor
(CTS) Resistance (at 0°C) kΩ 8.38~10.61
Resistance (at 40°C) kΩ 1.37~1.56
Fan Assembly Mounting Bolts 4 - 35
Fan Blade Retaining Nut 5.6 - 50
Fan Motor Retaining Screws 3.5 - 31
Radiator Upper Left and Right Bracket Retaining Bolts 20 15 -
Surge Tank Mounting Bolt and Nut 8 - 71
Thermostat Housing Mounting Bolts 15 11 -
Water Pump Mounting Bolts 25 18 -
COMPONENT LOCATOR
Radiator and Fan
1. Radiator Upper Bracket

2. Lower Radiator Bumper
3. Radiator
4. Main Cooling Fan
5. Auxiliary Cooling Fan
6. Main Cooling Fan Motor
7. Auxiliary Cooling Fan Motor
8. Cooling Fan Shroud Assembly
9. Coolant Drain Cock
Water Pump and Thermostat

1. Seal Ring
2. Thermostat
3. Thermostat Housing
4. Thermostat Housing Mounting Bolt
5. Water Pump Mounting Bolt
6. Water Pump
7. Seal Ring
DIAGNOSIS
Thermostat Test
1. Remove the thermostat from the vehicle. Refer to "Thermostat" in this section.
2. Make sure the valve spring is tight when the thermostat is fully closed. If the spring is not
tight, replace the thermostat.
3. Suspend the thermostat and a thermometer in a pan of 50/50 mixture of Dex-
cool/Silicate Based Coolant and water. Do not let the thermostat or the thermometer rest
on the bottom of the pan because the uneven concentration of heat on the bottom could
result in inaccurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of the heated solution.
6. The thermostat should begin to open at 87°C (189°F) and it should be fully open at
102°C (216°F). If it does not open at these temperatures, replace the thermostat.
Cooling System Diagnosis

Engine Overheats
Checks Action
Check for a loss of the coolant. Add the coolant.
Confirm that the coolant solution is a 50/50 mixture
Check for a weak coolant solution.
of ethylene glycol and water.
Check the front of the radiator for any dirt, any
Clean the front of the radiator.
leaves, or any insects.
Check for leakage from the hoses, the water pump,
the heater, the thermostat housing, the radiator, the Replace any damaged components.
core plugs, or the head gasket.
Check for a faulty thermostat. Replace a damaged thermostat.
Perform an ECM code diagnosis. Confirm the
Check for retarded ignition timing.
integrity of the timing belt.
Check for an improperly operating electric cooling
Replace the electric cooling fan.
fan.
Check for radiator hoses that are plugged or rotted. Replace any damaged radiator hoses.
Check for a faulty water pump. Replace a faulty water pump.
Check for a faulty surge tank cap. Replace a faulty surge tank cap.
Check for a cylinder head or an engine block that is Repair the damaged cylinder head or the damaged
cracked or plugged. engine block.
Loss of Coolant
Checks Action
Check for a leak in the radiator. Replace a damaged radiator.
Check for a leak in the following locations: Replace the following parts, as needed:
 Surge tank.  Surge tank.

 Hose.  Hose.
Check for loose or damaged radiator hoses, heater Reseat the hoses.
hoses, and connections. Replace the hoses or the clamps.
Check for leaks in the water pump seal. Replace the water pump seal.
Check for leaks in the water pump gasket. Replace the water pump gasket.
Check for an improper cylinder head torque. Tighten the cylinder head bolts to specifications.
Replace the cylinder head gasket, if needed.
Check for leaks in the following locations: Repair or replace any components, as needed, to
correct the leak.
 Intake manifold.
 Cylinder head gasket.
 Cylinder block plug.
 Heater core.
 Radiator drain plug.
Engine Fails to Reach Normal Operating Temperature or Cool Air from the Heater
Checks Action
Check to determine if the thermostat is stuck open Install a new thermostat of the correct type and heat
or is the wrong type of thermostat. range.
Check the coolant level to determine if it is below the Add sufficient coolant to raise the fluid to the
MIN mark on the surge tank. specified mark on the surge tank.
ON-VEHICLE SERVICE
Draining and Refilling the Cooling System
Important : The cooling sysem in the vehicle is designed to use either Dex-cool
coolant, which is red in color, or silicate based coolant, which is blue. These two
types of coolant are not compatible with each other and should never be mixed.
Even if the cooling system has been completely drained before a refill, do not
switch types of coolant.
Caution : Do not remove the surge tank cap while the engine and the radiator are
hot. Scalding fluid and steam may be blown out high pressure.
1. Place a pan below the vehicle to catch the draining coolant.

2. Remove the surge tank cap.
3. Unplug the drain cock.
Caution : Dispose of the used coolant to a used coolant holding tank to be picked
up with the used oil for disposal. Never pour the used coolant down the drain.
4. Catch the escaping fluid in a drain pan.

5. Remove all sludge and dirt from inside of the surge tank. Refer to "Surge Tank" in this
section.
6. Plug the drain cock.
7. Add the clean water to the surge tank.
8. Fill the tank slowly so that the upper reservoir hose remains above the water line. This
allows the air inside the cooling system to escape.
9. Start the engine.
10. Run the engine until the thermostat opens. You can tell the thermostat is open
when both radiator hoses are hot to the touch.
11. Stop the engine.
12. Repeat steps 1 through 9 until the drained water is clear and free of coolant and
rust.
Notice : Never use an antifreeze mixture more concentrated than 60% antifreeze to
40% water. The solution freezing point increases above this concentration.
13. Fill the cooling system through the surge tank with a mixture of Dex-cool and
water. The mixture must be at least 50% antifreeze, but not more than 60% antifreeze.
14. Fill the surge tank to the specified MAX fill mark on the outside of the tank.
Thermostat
Removal Procedure
Caution : To prevent personal injury, do not remove the surge tank cap while the
engine and the radiator are hot because the heat caused the system to remain
under pressure. Scalding fluid and steam may be blown out high pressure.
1. Drain the coolant. Refer to "Draining and Refilling the Cooling System" in this section.
2. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
3. Disconnect the upper radiator hose from the thermostat housing.
4. Remove the mounting bolts that hold the thermostat housing to the cylinder head.
5. Remove the thermostat housing from the cylinder head.
6. Remove the seal ring from the thermostat housing.
7. Remove the thermostat from the thermostat housing by pressing the thermostat
mounting flange downward and then rotating the flange clockwise.
8. Inspect the valve seat for foreign matter that could prevent the valve from sealing
properly.
9. Inspect the thermostat for proper operation. Refer to "Thermostat Test" in this section.
10. Clean the thermostat housing and the cylinder head mating surfaces.
1. Install the thermostat into the thermostat housing by pressing the thermostat mounting
flange downward and then rotating the flange counterclockwise. Rotate the thermostat
mounting flange until it is seated in the thermostat housing recesses.
2. Install a new seal ring into the recess in the thermostat housing.
3. Install the thermostat housing to the cylinder head.
4. Secure the thermostat housing to the cylinder head with the mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 15 N•m (11 lb-ft).
5. Connect the upper radiator hose to the thermostat housing.
6. Secure the upper radiator hose to the thermostat housing with a hose clamp.
7. Refill the engine cooling system. Refer to "Draining and Refilling the Cooling System" in
this section.
Water Pump
Removal Procedure
1. Drain the engine cooling system to a level below the thermostat housing. Refer
to "Draining and Refilling the Cooling System" in this section.
2. Remove the timing belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
4. Remove the water pump mounting bolts.

5. Remove the water pump from the engine block.
6. Remove the ring seal from the water pump.
Inspection Cleaning Procedure
1. Inspect the water pump body for cracks and leaks.

2. Inspect the water pump bearing for play or abnormal noise.
3. Inspect the water pump pulley for excessive wear. If the water pump is defective, replace
the water pump as a unit.
4. Clean the mating surfaces of the water pump and the engine block.
1. Install a new ring seal to the water pump.

2. Install the water pump to the engine block with the flange aligned with the recess of the
rear timing belt cover.
3. Secure the water pump to the engine block with the mounting bolts.
Tighten
Tighten the water pump mounting bolts to 25 N•m (18 lb-ft).
4. Install the timing belt automatic tensioner to the oil pump with the flange inserted into the
recess of the oil pump.
5. Install the timing belt automatic tensioner bolts. Do not fully tighten the bolt at this time.
6. Install the timing belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
7. Refill the engine cooling system. Refer to "Draining and Refilling the Cooling System" in
this section.
Electric Cooling Fan Assembly
Removal Procedure

2. Remove the engine cover and the engine cover bracket.
3. Remove the battery. Refer to Section 1E2, Engine Electrical – FAM II 2.4D.
4. Remove the air cleaner assembly. Refer to Section 1C1, Engine Mechanical – FAM II
2.4D.
5. Disconnect the both cooling fan electrical connectors and the A/C pressure sensor
connector.
6. Remove the cooling fan shroud mounting bolts.

7. Remove the power steering fluid supply hose and pipe retaining bracket and move it
away from the cooling fan assembly. Refer to Section 6A, Power Steering System.
8. Lift the fan shroud assembly upward and remove the cooling fan assembly from the
vehicle.
9. Remove the both main and auxiliary fan blades from the fan shroud assembly by
removing the nut at the center of the fan hubs.
10. Remove the both fan motor retaining screws.
11. Remove the both fan motors from the shroud.
Caution : If a fan assembly is bent or damaged in any way, no attempt should be
made to repair or reuse the damaged part. A bent or damaged fan assembly must
be replaced with a new fan assembly. It is essential to remain the fan assemblies
in proper balance. A fan assembly that is not in proper balance can fail and fly
apart during use, creating extreme danger. Proper balance cannot be assured on a
fan assembly that has been bent or damaged.
1. Install the both fan motors to the shroud.

2. Secure the motors to the shroud with the retaining screws.
Tighten
Tighten the fan motor retaining screws to 3.5 N•m (31 lb-in.).
3. Install the fan blades to the fan shroud assembly with the nuts in the center of the fan
hub.
Tighten
Tighten the fan blades retaining nuts to 5.6 N•m (50 lb-in.).
4. Install the cooling fan assembly to the radiator.
Important : Be sure to slip the tab at the bottom edge of the shroud into the
retaining clip at the radiator.
5. Secure the cooling fan assembly to the top of the radiator with the mounting bolts.
Tighten
Tighten the cooling fan assembly mounting bolts to 4 N•m (35 lb-in.).
6. Connect the cooling fan electrical connectors and the A/C pressure sensor connector.
7. Install the power steering fluid supply hose and pipe retaining bracket bolt and move it
away from the cooling fan assembly. Refer to Section 6A, Power Steering System.
8. Install the air cleaner assembly. Refer to Section 1C1, Engine Mechanical – FAM II 2.4D.
9. Install the battery. Refer to Section 1E2, Engine Electrical – FAM II 2.4D.
10. Install the engine cover and the engine cover bracket.
Surge Tank
Removal Procedure
Caution : To prevent personal injury, do not remove the surge tank cap while the
engine and the radiator are hot because the heat caused the system to remain
under pressure. Scalding fluid and steam may be blown out high pressure.
1. Drain the engine coolant to below the level of the surge tank.
Note : Do not drain the power steering fluid at this stage.
2. Remove the power steering fluid reservoir retaining bolts and move the reservoir away
from the surge tank. Refer to Section 6A, Power Steering System.
3. Loosen the return hose clamp and disconnect the return hose from the top of the surge
tank.
4. Loosen the throttle body hose clamp and disconnect the throttle body hose from the top
of the surge tank.
5. Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge
tank.
6. Remove the surge tank attaching bolt and nut.
7. Remove the surge tank.
8. Clean the inside and the outside of the surge tank and the surge tank cap with soap and
water.
9. Rinse the surge tank and the cap thoroughly.
1. Install the surge tank.

2. Secure the surge tank with the attaching bolt and nut.
Tighten
Tighten the surge tank retaining bolt and nut to 8 N•m (71 lb-in.).
3. Connect the return hose and the throttle body hose to the top of the surge tank.
4. Connect the feed hose to the bottom of the surge tank.
5. Secure the return hose, throttle body hose and the feed hose to the surge tank with the
hose clamps.
6. Fill the surge tank with the coolant to the center ridge or the MAX mark.
Radiator
Removal Procedure

2. Drain the engine cooling system. Refer to "Draining and Refilling the Cooling System" in
this section.
3. Remove the engine cover and the engine cover bracket.
4. Disconnect the both cooling fan electrical connectors and the A/C pressure sensor
connector.
5. Remove the radiator grill upper guide. Refer to Section 9R, Body Front End.
6. Remove the A/C condenser upper and lower bracket from the radiator. Refer to Section
7B, Manual Control Heating, Ventilation, and Air Conditioning System.
7. Hang the A/C condenser to prevent it from falling down.
8. Remove the radiator upper bracket retaining bolts.
9. Remove the radiator upper brackets.
10. Disconnect the transaxle cooler pipes from the lower radiator tank, if equipped.
11. Loosen the upper radiator hose clamp and then disconnect the upper radiator hose
from the radiator.
12. Loosen the lower radiator hose clamp and then disconnect the lower radiator hose
from the radiator.
13. Loosen the clamp and disconnect the coolant return hose.
14. Lift and carefully support the vehicle.
15. Remove the condenser, radiator, fan module (CRFM) assembly support bracket
mounting upper bolts.
16. Remove the CRFM assembly support bracket through bolts and nuts.
17. Remove the both CRFM assembly support brackets.
Caution : Do not to damage the radiator fins for the proper operation of the
cooling system.
18. Carefully lower the radiator and fan assembly from the vehicle.
19. Remove the radiator.
20. Remove the cooling fan assembly from the radiator if necessary.
Cleaning
Caution : NEVER spray water on a hot radiator. The resulting steam could cause
personal injury.
Notice : The radiator fins are necessary for good heat transfer. Do not brush the
fins. This may cause damage to the fins, reducing heat transfer.
Important : Remove bugs, leaves, dirt and other debris by blowing compressed air
through the engine side of the radiator.
Some conditions may require the use of warm water and a mild detergent.
o Clean the radiator cooling fins.

o Straighten any damaged cooling fins.
Caution : Do not to damage the radiator fins for the proper operation of the
cooling system.
1. Install the cooling fan assembly if necessary.

2. Install the radiator.
3. Carefully lift the radiator into the position previously removed.
4. Install the both CRFM assembly support brackets.
5. Install the CRFM assembly support bracket through bolts and nuts.
Tighten
Tighten the CRFM assembly support bracket through bolts and nuts to 50 N•m (37 lb-ft).
6. Install the CRFM assembly support bracket mounting upper bolts.
Tighten
Tighten the CRFM assembly support bracket mounting upper bolts to 50 N•m (37 lb-ft).
7. Connect the lower radiator hose to the radiator and then secure the clamp.
8. Connect the upper radiator hose to the radiator and then secure the clamp.
9. Connect the transaxle cooler pipes to the radiator, if equipped.
10. Connect the coolant return hose.
11. Install the A/C condenser to the radiator.
12. Install the radiator upper brackets.
Tighten
Tighten the radiator upper bracket retaining bolts to 20 N•m (15 lb-ft).
13. Install the radiator grill upper guide. Refer to Section 9R, Body Front End.
14. Install the engine cover bracket and then the engine cover.
15. Fill the engine cooling system. Refer to "Draining and Refilling the Cooling
System" in this section.
16. Connect the negative battery.

General Description
The cooling system maintains the engine temperature at an efficient level during all engine
operating conditions.
When the engine is cold, the cooling system cools the engine slowly or not at all. This slow
cooling of the engine allows the engine to warm up quickly.
The cooling system includes a radiator and recovery subsystem, cooling fans, a thermostat
and housing, a water pump, and a water pump drive belt. The timing belt drives the water
pump.
All components must function properly in order for the cooling system to operate. The water
pump draws the coolant from the radiator. The coolant then circulates through water jackets in
the engine block, the intake manifold, and the cylinder head. When the coolant reaches the
operating temperature of the thermostat, the thermostat opens. The coolant then goes back to
the radiator where it cools.This system directs some coolant through the hoses to the heater
core. This provides for heating and defrosting. The surge tank is connected to the radiator to
recover the coolant displaced by expansion from the high temperatures.
The surge tank maintains the correct coolant level.
The cooling system for this vehicle has no radiator cap or filler neck. The coolant is added to
the cooling system through the surge tank.
Radiator
This vehicle has a lightweight tube–and–fin aluminum radiator. Plastic tanks are mounted on
the right and the left sides of the radiator core.
On vehicles equipped with automatic transaxles, the transaxle fluid cooler lines run through the
left radiator tank. A radiator drain cock is on this radiator. To drain the cooling system, open
the drain cock.
Surge Tank
The surge tank is a transparent plastic reservoir, similar to the windshield washer reservoir.
The surge tank is connected to the radiator by a hose and to the engine cooling system by
another hose. As the vehicle is driven, the engine coolant heats and expands. The portion of
the engine coolant displaced by this expansion flows from the radiator and the engine into the
surge tank. The air trapped in the radiator and the engine is degassed into the surge tank.
When the engine stops, the engine coolant cools and contracts. The displaced engine coolant
is then drawn back into the radiator and the engine. This keeps the radiator filled with the
coolant to the desired level at all times and increases the cooling efficiency.
Maintain the coolant level between the MIN and the MAX marks on the surge tank when the
system is cold.
Water Pump
The belt–driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley.
The water pump is mounted on the front of the transverse–mounted engine, and is driven by
the timing belt.
The impeller is supported by a completely sealed bearing. The water pump is serviced as an
assembly and, therefore, cannot be disassembled.
Thermostat
A wax pellet–type thermostat controls the flow of the engine coolant through the engine cooling
system. The thermostat is mounted in the thermostat housing to the front of the cylinder head.
The thermostat stops the flow of the engine coolant from the engine to the radiator in order to
provide faster warm–up, and to regulate the coolant temperature. The thermostat remains
closed while the engine coolant is cold, preventing circulation of the engine coolant through the
radiator. At this point, the engine coolant is allowed to circulate only throughout the heater core
to warm it quickly and evenly.
As the engine warms, the thermostat opens. This allows the engine coolant to flow through the
radiator, where the heat is dissipated through the radiator. This opening and closing of the
thermostat permits enough engine coolant to enter the radiator to keep the engine within
proper engine temperature operating limits.
The wax pellet in the thermostat is hermetically sealed in a metal case. The wax element of the
thermostat expands when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine coolant temperature increases.
When the engine coolant reaches a specified temperature, the wax pellet element in the
thermostat expands and exerts pressure against the metal case, forcing the valve open. This
allows the engine coolant to flow through the engine cooling system and cool the engine. As
the wax pellet cools, the contraction allows a spring to close the valve.
The thermostat begins to open at 87°C (189°F) and is fully opened at 102°C (216°F). The
thermostat is closed at 86°C (187°F).
Electric Cooling Fan
Caution : Keep hands, tools, and clothing away from the engine cooling fans to help
prevent personal injury. This fan is electric and can turn ON whether or not the engine
is running.
Caution : If a fan blade is bent or damaged in any way, no attempt should be made to
repair or reuse the damaged part. A bent or damaged fan assembly should always be
replaced with a new one. Failure to do so can result in personal injury.
The cooling fans are mounted behind the radiator in the engine compartment. Cooling system
on this vehicle has two cooling fans – the main fan and the auxiliary fan. The electric cooling
fans increase the flow of air across the radiator fins and across the condenser on air condition
(A/C) equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at
low speeds.
A vehicle equipped with the A/C or Non-A/C has two fans on the one shroud. The main fan
size is 340 mm (13.4 inches) in diameter with five blades, and the auxiliary fan size is 320 mm
(12.6 inches) in diameter with seven blades to aid the airflow through the radiator and the
condenser. Two electric fan motors attached to the center of each fan on the fan shroud
assembly drive the both fans.
A/C OFF or Non-A/C Model
 The cooling fans are actuated by the electronic control module (ECM) using the
serial/parallel cooling fan relay.
 The ECM will turn the cooling fans on at low speed when the coolant temperature
reaches 96°C (205°F) and at high speed when the coolant temperature reaches 100°C
(212°F).
 The ECM will change the cooling fans from high speed to low speed at 94°C (201°F) and
will turn the cooling fans off at 90°C (194°F).
A/C ON
 The ECM will turn the cooling fans on at low speed when the A/C system is on. The
ECM will change to high speed when the coolant temperature reaches 118°C (244°F) or
the high side A/C pressure reaches 1760 kPa (255 psi).
 The cooling fans will return to low speed when the coolant temperature reaches 115°C
(239°F) and the high side A/C pressure reaches 1347 kPa (195 psi).
SECTION 1E2
ENGINE ELECTRICAL - FAM II 2.4D

electrical terminals. Disconnecting this cable will help prevent personal injury and
SPECIFICATIONS
Starter Specifications
Description Unit Standard
Type - Permanent Magnet Gear Reduction
Capacity Kw 1.4
No Load Test at 12 volts Condition Drive Pinion
A 90 MAX
Speed
Pinion Gear Speed Rpm 2,600 MIN
Brush Length mm (in.) 8.25
Armature Diameter mm (in.) 45.5
Armature Runout mm (in.) 0.08
Segment Home Depth mm (in.) 0.6~1.0
Generator Specifications
Type - AD237
Capacity AH 120
Regulator Type - Multi
14.6 ± 0.25 at Tb=25°C, 6,000 rpm, 50%
Regulator Voltage V
Load
Length mm (in.) 18.8
Brush Number EA 2
Minimum Length mm (in.) 8.0
Battery Specifications
Type - LN2
Capacity AH 60
Cold Cranking Amps (CCA) CCA 650
Minimum Reserve Capacity (RC) min 90
Load Test amps 300
Minimum Voltage: . .
9.6 V 70°F (21°C) and above
9.5 V 60°F (15.6°C)
9.4 V 50°F (10°C)
9.3 V 40°F (4.4°C)
9.1 V 30°F (-1.1°C)
8.9 V 20°F (-6.7°C)
8.7 V 10°F (-12.2°C)
8.5 V 0°F (-17.8°C)
Spark Plug Specifications
Type - FLR8LDCU (BOSCH)
Gap mm (in.) 0.9~1.1 (0.0354~0.0433)
Generator Lower Support Bracket Bolts 25 18 -
Generator-to-Generator Lower Support Bracket Through
40 30 -
Bolt
Generator Upper Bracket Bolts at Intake Manifold &
25 18 -
Coolant Bypass Housing
Generator Upper Bracket Bolts at Generator 35 26 -
Generator-to-Intake Manifold Strap Bracket Bolts at
25 18 -
Intake Manifold
Generator-to-Intake Manifold Strap Bracket Bolts at
35 26 -
Generator
Starter-to-Engine Block Mounting Bolt 75 55 -
Starter-to-Transmission Mounting Bolt 75 55 -
Starter Solenoid Terminal-to-Battery Lead Wire Nut 15 11 -
Starter Solenoid Terminal-to-Generator Lead Wire Nut 15 11 -
Battery Tray Retaining Bolts 10 - 89
Engine Fuse Block Lower Cover Bolts 10 - 89
Engine Fuse Block Retaining Bolts 3 - 27
Battery Hold-Down Bar Bracket Retaining Nuts 10 - 89
SCHEMATIC AND ROUTING DIAGRAMS
Starting System
Charging System
DIAGNOSIS
General Diagnosis
No Crank
Checks Action
Low battery voltage Charging the battery or replace the battery.
Battery cable is loose, corroded, or damaged. Repair or replace the battery cable.
Checks Action
Faulty starter motor or starter motor circuit is
Repair or replace the starter motor/starter motor circuit.
open.
Faulty ignition switch or fuse Ef2 is blown. Replace the ignition switch or fuse Ef2.
Ground short Repair the ground short.
Crank OK, But Too Slow
Checks Action
Low battery voltage .
 Battery Charging the battery or replace the
 Battery cables is loose, corroded, or damaged battery.
Repair or replace the battery cable.
Faulty starter motor Repair or replace the starter motor.
Starter Motor Does Not Stop
Checks Action
Faulty starter motor Repair or replace the starter motor.
Faulty ignition switch Replace the ignition switch.
Starter Motor Running But Not Cranking
Checks Action
Broken clutch pinion gear or faulty starter motor Replace the starter motor.
Broken flywheel ring gear. Replace the flywheel.
Connected circuit is open. Repair the open circuit.
Overcharging Battery
Checks Action
Faulty IC regulator Replace the IC regulator.
Battery Discharge
Checks Action
Loosen the generator drive belt. Adjust the belt tension or replace the belt.
The circuit is open or shorted. Repair the open or shorted circuit.
Battery run down Replace the battery.
Open ground circuit Repair the open ground circuit.
Charging Indicator Lamp Does Not Work When the Ignition Switch is ON – Engine Does
Not Work
Checks Action
Fault IC regulator Replace the IC regulator.
Charging indicator lamp is blown or fuse is blown. Repair or replace the charging indicator lamp/fuse.
Faulty ignition switch Replace the ignition switch.
Generator ground circuit is open or shorted. Repair the circuit.
Charging Indicator Lamp Does Not Put Out Lights After Starting the Engine
Checks Action
Battery cable is corroded or damaged. Repair or replace the battery cable.
Loosen the generator drive belt. Adjust the belt tension or replace the belt.
Faulty wiring harness Repair the wiring harness.
Hard to Start the Engine
Checks Action
Faulty ignition coil Replace the ignition coil.
Faulty direct ignition system (DIS) Replace the DIS.
Faulty spark plug Replace the spark plug or adjust the gap.
Checks Action
Poor ignition timing Reset the valve timing.
Engine Idling State is Unstable
Checks Action
Faulty spark plug Replace the spark plug or adjust the gap.
Faulty ignition coil Replace the ignition coil.
Poor Engine Accelerating
Checks Action
Starter Motor Noise
Start the engine. If the starter does not operate normally, correction can be achieved as
following procedures. Before start the procedures below ensure that the battery is fully
charged, the battery cables are clean and tight and the grounds are clean, tight, and in the
correct location.
Start the engine while listening to the starter motor
turn.
Is there a loud "whoop", it may sound like a siren if
1 -
the engine is revved while the starter is engaged,
after the engine starts, but while the starter is still
held in the engaged position? Go to Step 4 Go to Step 2
Do you hear a "rumble", a "growl", or, in some
2 cases, a "knock" as the starter is coasting down to -
a stop after starting the engine? Go to Step 5 Go to Step 3
Important : This is often diagnosed as a starter
drive gear hang-in or a weak solenoid.
3 When the engine is cranked, do you hear a high- -
pitched whine after the engine cranks and starts
normally? Go to Step 6 Go to Step 5
Inspect the flywheel ring gear for the following :
 Chipped gear teeth

 Missing gear teeth
4 -
 Milled teeth
Is the flywheel bent, or does it have damaged

teeth? Go to Step 7 Go to Step 8
Remove the starter motor. Refer to "Starter" in this
section.
5 Inspect the starter motor bushings and clutch gear. -
Does the clutch gear have chipped or milled teeth
or worn bushings? Go to Step 8 Go to Step 7
Shim the starter motor away from the flywheel by
adding shims between the starter motor and the
engine block one at a time.
6 -
Flywheel runout may make this noise appear to be
intermittent.
Did you complete the repair? Go to Step 9 -
Replace the flywheel.
7 -
Replace the starter motor. Refer to "Starter" in this
8 -
section. Go to Step 9 -
Did you complete the replacement?
Operate the system in order to verify the repair.
9 -
Did you correct the condition? System OK Go to Step 1
Battery Load Test
1. Check the battery for obvious damage, such as a cracked or broken case or cover,
which could permit the loss of electrolyte. If obvious damage is noted, replace the
battery.
2. Check the battery for obvious damage, such as a cracked or broken case or cover,
which could permit the loss of electrolyte. If obvious damage is noted, replace the
battery.
Caution : Do not charge the battery if the hydrometer is clear or light yellow. Instead,
replace the battery. If the battery feels hot, or if violent gassing or spewing of electrolyte
through the vent hole occurs, discontinue charging or reduce the charging rate to avoid
personal injury.
2. Check the hydrometer. If the green dot is visible, go to the load test procedure. If the
indicator is dark but green is not visible, charge the battery. For charging a battery
removed from the vehicle, refer to "Charging a Completely Discharged Battery" in this
section.
3. Check the hydrometer. If the green dot is visible, go to the load test procedure. If the
indicator is dark but green is not visible, charge the battery. For charging a battery
removed from the vehicle, refer to "Charging a Completely Discharged Battery" in this
section.
4. Connect a voltmeter and a battery load tester across the battery terminals.
5. Apply a 300 A load for 15 seconds to remove any surface charge from the battery.
6. Remove the load.
7. Wait 15 seconds to let the battery recover, and apply a 270 A load.
Important : The battery temperature must be estimated by touch and by the temperature
condition the battery has been exposed for the preceding few hours.
7. If the voltage does not drop below the minimum listed, the battery is good and should be
reinstalled. If the voltage is less than the minimum listed, replace the battery. Refer
to "Battery Specifications" in this section.
8. If the voltage does not drop below the minimum listed, the battery is good and should be
reinstalled. If the voltage is less than the minimum listed, replace the battery. Refer
to "Battery Specifications" in this section.
Genrator Output Test
1. Perform the generator system test. Refer to "Generator System Check"in this section.
2. Perform the generator system test. Refer to "Generator System Check"in this section.
3. Replace the generator if it fails that test. Refer to "Generator" in the On-Vehicle Service
portion of this section. If it passes the test, perform the on-vehicle output check which
follows.
Important : Always check the generator for output before assuming that a grounded "L"
terminal circuit has damaged the regulator.
3. Attach a digital multimeter, an ammeter, and a carbon pile load to the vehicle.
4. Attach a digital multimeter, an ammeter, and a carbon pile load to the vehicle.
Important : Be sure the vehicle battery is fully charged, and the carbon pile load is
turned off.
4. With the ignition switch in the OFF position, check and record the battery voltage.
5. With the ignition switch in the OFF position, check and record the battery voltage.
6. Remove the harness connector from the generator.
7. Turn the ignition to RUN with the engine not running. Use a digital multimeter to check
for voltage in the harness connector "L" terminal.
8. The reading should be near the specified battery voltage of 12 volts. If the voltage is too
low, check the indicator “L” terminal circuits for open and grounded circuits causing
voltage loss. Correct any open wires, terminal connections, etc., as necessary. Refer
to "Charging System" in this section.
9. Attach the generator harness connector.
10. Run the engine at a moderate idle, and measure the voltage across the battery
terminals. The reading should be above that recorded in step 14, but less than 16 volts.
If the reading is over 16 V or below the previous reading, replace the generator. Refer
to "Generator" in the On-Vehicle Service section.
11. Run the engine at a moderate idle, and measure the generator amperage output.
12. Turn on the carbon pile, and adjust it to obtain the maximum amps while
maintaining the battery voltage above 13 V.
13. If the reading is within 15 amps of the generator’s rating noted on the generator,
the generator is good. If not, replace the generator. Refer to "Generator" in the On-
Vehicle Service section.
14. With the generator operating at the maximum output, measure the voltage
between the generator housing and the battery negative terminal. The voltage drop
should be 0.5 volt or less. If the voltage drop is more than 0.5 volt, check the ground
path from the generator housing to the negative battery cable.
15. Check, clean, tighten, and recheck all of the ground connections.
Generator System Check

When operating normally, the generator indicator lamp will come on when the ignition is in
RUN position and go out when the engine starts. If the lamp operates abnormally or if an
undercharged or overcharged battery condition occurs, the following procedure may be used
to diagnose the charging system. Remember that an undercharged battery is often caused by
accessories being left on overnight or by a defective switch that allows a lamp, such as a trunk
or a glove box lamp, to stay on.
Diagnose the generator with the following procedure:
1. Visually check the belt and the wiring.

2. With the ignition in the ON position and the engine stopped, the charge indicator lamp
should be ON. If not, detach the harness at the generator and ground the "L" terminal in
the harness with a 5 A jumper lead.
o If the lamp lights, replace the generator. Refer to "Generator" in the On-Vehicle
Service section.
o If the lamp does not light, locate the open circuit between the ignition switch and
the harness connector. The indicator lamp bulb may be burned out.
1. With the ignition switch in the ON position and the engine running at moderate speed,
the charge indicator lamp should be OFF. If not, detach the wiring harness at the
generator.
o If the lamp goes off, replace the generator. Refer to "Generator" in the On-Vehicle
Service section.
o If the lamp stays on, check for a short to ground in the harness between the
connector and the indicator lamp.
Important : Always check the generator for output before assuming that a grounded "L"
terminal circuit has damaged the regulator. Refer to "Generator" in the Unit Repair
section.
SECTION

ON-VEHICLE SERVICE
Generator
Removal Procedure

3. Remove the air cleaner assembly. Refer to Section 1C1, Engine Mechanical – FAM II
2.4D.
4. Disconnect the harness connector from the generator.
5. Remove the generator upper bracket mounting bolts and the generator-to-intake
manifold strap bracket bolts.
6. Raise and suitably support the vehicle.
7. Remove the serpentine accessory drive belt. Refer to Section 1C1, Engine Mechanical –
FAM II 2.4D.
8. Disconnect the generator lead-to-starer motor wire from the generator.
Notice : Do not remove the generator through bolt, nut and washers at this stage.
9. Loosen the nut and washers which hold the generator lower bracket-to-generator bolt.
10. Remove the generator lower support bracket bolts.
11. Carefully remove the generator with the lower support bracket.
12. Remove the generator-to-lower support bracket through bolt, nut and washer.
1. Install the generator lower support bracket to the generator and insert the through bolt.
Notice : Do not tighten the generator through bolt at this stage.
2. Install the generator and the lower support bracket assembly to the engine block.
Tighten
Tighten the generator lower support bracket bolts to 25 N•m (18 lb-ft).
3. Tighten the generator-to-generator lower support bracket through bolt.
Tighten
Tighten the generator through bolt to 40 N•m (30 lb-ft).
4. Connect the generator lead-to-starer motor wire to the generator.

5. Install the serpentine accessory drive belt. Refer to Section 1C1, Engine Mechanical –
FAM II 2.4D.
6. Lower the vehicle.
7. Install the generator upper bracket and the generator-to-intake manifold strap bracket.
8. Install the generator upper bracket mounting bolts and the generator-to-intake manifold
strap bracket bolts.
Tighten
Tighten the generator upper bracket retaining bolts (1) to 25 N·m (18 lb-ft) and the bolt
(2) to 35 N•m (26 lb-ft).
9. Connect the harness connector to the generator.
10. Install the air cleaner assembly and connect the IAT sensor connector. Refer
to Section 1C1, Engine Mechanical – FAM II 2.4D.
Starter
Removal Procedure

2. Remove the transaxle rear mount bracket. Refer to Section 1C1, Engine Mechanical -
FAM II 2.4D.
3. Remove the nuts which secure the battery lead wire and the generator lead wire from
the starter solenoid terminals.
4. Remove the starter-to-engine block mounting bolt and the starter-to-transmission
mounting bolt.
5. Remove the starter assembly.
1. Install the starter mounting bolts.
Tighten
Tighten the starter-to-engine block mounting bolt to 75 N•m (55 lb-ft).
Tighten the transmission-to-starter mounting bolt to 75 N•m (55 lb-ft).
2. Install the ignition solenoid nut and the generator lead wire nut to the starter solenoid
terminals.
Tighten
Tighten the starter solenoid terminal-to-battery lead wire nut to 15 N•m (11 lb-ft).
Tighten the starter solenoid terminal-to-generator lead wire nut to 15 N•m (11 lb-ft).
3. Install the transaxle rear mount bracket. Refer to Section 1C1, Engine Mechanical - FAM
II 2.4D.
Tighten
Tighten the transaxle rear mount bracket retaining bolts to 90 N•m (66 lb-ft).
Tighten the transaxle rear mount-to-bracket through bolt and nut to 90 N•m (66 lb-ft).
Battery and Battery Tray

Removal Procedure
1. Disconnect the batty negative cable and then disconnect the battery positive cable.
2. Loosen the nuts that fasten the battery hold-down bar bracket.
3. Remove the battery hold-down bar bracket with the nuts attached.
4. Remove the battery from the battery tray.
5. Remove the ECM. Refer to Section 1F2, Engine Controls – FAM II 2.4D.
6. Remove the engine fuse block upper cover.
7. Remove the engine fuse block retaining bolts.
8. Remove the engine fuse box from the lower cover.

9. Remove the engine fuse block lower cover retaining nuts.
Notice : Remove the power steering oil pump to ease to remove the engine fuse
box, if necessary.
10. Separate the engine fuse block from the welded bolts on the battery tray and the
body frame.
11. Check the battery tray for obvious cracks or damage.
12. Remove the battery tray retaining bolts.
13. Remove the battery tray.
1. Install the battery tray.

2. Install the battery tray retaining bolts.
Tighten
Tighten the battery tray bolts to 10 N•m (89 lb-in.).
3. Install the engine fuse block.
Tighten
Tighten the engine fuse block lower cover retaining nuts to 10 N•m (89 lb-in.).
4. Install the engine fuse block retaining bolts.
Tighten
Tighten the engine fuse block retaining bolts to 3 N•m (27 lb-in.).
5. Install the engine fuse block upper cover.

6. Install the ECM. Refer to Section 1F2, Engine Controls – FAM II 2.4D.
7. Install the battery.
Tighten
Tighten the battery hold-down bar bracket retaining nuts to 4 N•m (35 lb-in.).
8. Connect the positive battery cable.
UNIT REPAIR
Starter Motor
Disassembly Procedure
1. Remove the starter. Refer to "Starter" in this section.

2. Remove the starter through-bolts.
3. Remove the commutator end frame and brush holder assembly.
4. Inspect the brushes, the pop-out springs, and the brush holders for wear and damage.
Replace the assembly, if needed.
5. Check the armature to see if it turns freely. If the armature does not turn freely, break
down the assembly immediately, starting with Step 14. Otherwise, give the armature a
no-load test.
Notice : Complete the testing in a minimum amount of time to prevent overheating
and damaging the solenoid.
Important : If the specified current draw does not include the solenoid, deduct
from the armature reading the specified current draw of the solenoid hold-in
winding.
6. To begin the no-load test, close the switch and compare the rpm, the current, and the
voltage readings with the specifications. Refer to "Starter Specifications" in this section.
Make disconnections only with the switch open. Use the test results as follows:
1. Rated current draw and no-load speed indicate a normal condition for the starter
motor.
2. Low rpm combined with high current draw is an indication of excessive friction
caused by tight, dirty, or worn bearings, a bent armature shaft; a shorted armature;
or a shorted field coils.
3. Failure to operate with high current draw indicates a direct ground in the terminal
or fields, or "frozen" bearings.
4. Failure to operate with no current draw indicates an open field circuit, open
armature coils, broken brush springs, worn brushes, high insulation between the
commutator bars, or other causes which would prevent good contact between the
brushes and the commutator.
5. Low, no-load speed and low current indicate high internal resistance and high
current draw, which usually mean shorted fields.
7. Remove the solenoid assembly screws.
8. Remove the field connector nut. Disconnect the field connector.
9. Remove the plunger return spring.

Important : If the solenoid is not removed from the starting motor, the connector
strap terminals must be removed from the terminal on the solenoid before making
these tests.
10. Test the solenoid windings by checking the current draw.

1. Check the hold-in windings by connecting an ammeter in series with a 12-volt
battery, the switch terminal, and to ground.
2. Connect the carbon pile across the battery.
3. Adjust the voltage to 10 volts. The ammeter reading should be 13 to 19
amperes.Current will decrease as the windings heat up. Current draw readings
that are over specifications indicate shorted turns or a ground in the windings of
the solenoid. Both conditions require replacement of the solenoid. Current draw
readings that are under specifications indicate excessive resistance. No reading
indicates an open circuit.
Important : Current will decrease as the windings heat up. Current draw readings
that are over specifications indicate shorted turns or a ground in the windings of
the solenoid. Both conditions require replacement of the solenoid. Current draw
readings that are under specifications indicate excessive resistance. No reading
indicates an open circuit.
11. Check both windings, connecting them according to the preceding test.
1. Ground the solenoid motor terminal.
2. Adjust the voltage to 10 volts. The ammeter reading should be 59 to 79 amperes.
3. Check the connections and replace the solenoid, if necessary.
12. Slide the field frame with enclosed armature assembly away from the starter
assembly.
13. Remove the shield.
14. Separate the field frame from the armature.

15. Inspect the shaft and the pinion for discoloration, damage, or wear. Replace, if
necessary.
16. Inspect the armature commutator. If the commutator is rough, it should be turned
down. The outside diameter of the commutator must measure at least 26.9 - 27.1mm
(1.059 - 1.067 in.) after it is undercut or turned. Do not turn out-of-round commutators.
17. Inspect the points where the armature conductors join the commutator bars. Make
sure they have a good connection. A burned commutator bar is usually evidence of a
poor connection.
18. If test equipment is available, check the armature for short circuits by placing it on
a growler, and holding back a saw blade over the armature core while the armature is
rotated. If the saw blade vibrates, replace the armature.
19. Recheck the armature after cleaning between the commutator bars. If the saw
blade vibrates, replace the armature.
20. Remove the locking ring from the groove in the driveshaft.
21. Remove the pinion stop and the drive from the driveshaft.
22. If not done in the previous steps, remove the screws that hold the solenoid
assembly into the housing, and remove the nut from the field coil connector.
23. Rotate the solenoid 90 degrees and remove it along with the return spring.
24. Remove the plunger with the boot and the shift lever assembly. Test the solenoid
windings, if not done in Step 11.
Important : The pinion clearance must be correct to prevent the buttons on the
shift lever yoke from rubbing on the clutch collar during the cranking.
25. When the starter motor is disassembled and the solenoid is replaced, it is
necessary to check the pinion clearance.
26. Disconnect the motor field coil connector from the solenoid motor terminal and
carefully insulate the connector.
27. Connect one 12-volt battery lead to the solenoid switch terminal and the other to
the starter frame.
28. Flash a jumper lead momentarily from the solenoid motor terminal to the starter
frame, allowing shifting of the pinion in the cranking position, where it will remain until the
battery is disconnected.
Important : A means for adjusting the pinion clearance is not provided on the
starter motor. If the clearance does not fall within the limits, check for improper
installation and replace all worn parts.
29. Push the pinion back as far as possible to take up any movement, and check the
clearance with a feeler gauge. The clearance should be 0.25 to 3.56 mm (0.01 to 0.14
inch).
Assembly Procedure
1. Install the drive and the pinion stop on the driveshaft.

2. Install the lock ring into the groove on the driveshaft and insert the collar.
3. Install the shift lever, washer and the cushion.
4. Lubricate the drive end of the armature shaft with lubricant.

5. Position the solenoid assembly.
6. Fasten the solenoid assembly with the screws.
Tighten
Tighten the starter solenoid assembly screws to 8 N•m (71 lb-in).
7. Install the field coil connection to the starter terminal. Install the nut.
Tighten
Tighten the starter field coil connector nut to 8 N•m (71 lb-in).
8. Position the armature assembly into the field frame.
9. Place the shield on the armature and field frame assembly.
10. Install the armature and field frame assembly with the shield into the starter
housing.
11. Position the commutator end frame/brush holder assembly, lining up the end frame
holes with the through-bolt holes in the housing.
12. Install the starter through-bolts.
13. Install the starter. Refer to "Starter"in this section.
Tighten
Tighten the starter through-bolts to 6 N•m (53 lb-in).
Generator
Disassembly Procedure
1. Remove the generator. Refer to "Generator"in the On-Vehicle Service section.

2. Mark a match line that cannot easily be removed on the end frame to make assembly
easier.
3. Pry off the plastic cover to expose the stator connections.
Notice : If the stator connections are not welded, melt the lead. Avoid excessive
heating, as it can damage the diodes in the rectifier bridge.
4. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
5. Pry off the baffle.
6. Remove the rectifier/regulator/brush holder assembly screws.
7. Remove the brush holder assembly and the regulator.
Important : If the brush can be reused, reassmble the brush to the holder with the
retaining pin, after cleaning the brush with a soft, clean cloth.
8. Test the rectifier bridge by connecting the ohmmeter terminals to the brdge and the heat
sink.
9. Retest by connecting the ohmmeter terminals in reverse.
10. Replace the rectifier bridge, if each reading is the same.
11. Test the remaining two diodes after the above procedure.
Notice : Some kinds of digital ohmmeters are not suited for the test of the bridge
diode. In this case, consult the manufacturer regarding the test capacity.
12. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and
the base plate. If the reading is the same, the rectifier bridge should be replaced.
13. Remove the generator through - bolts.

Important : The fastening torque of this nut is 81 N•m (60 lb-ft) and may not
normally be unfastened using hand strength.
14. Move to the drive end of the generator and remove the drive end bearing nut.
15. Remove the pulley and the collars.
16. Test the rotor for an open circuit using the ohmmeter with the drive end frame
assembled. The reading should be sufficiently high, or the rotor must be replaced.
17. Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 Ω, or
the rotor should be replaced.
18. Remove the drive end frame from the shaft.

19. For vehicles with an internal generator fan, remove the drive end frame and the
fan.
20. Remove the rotor assembly.
21. Remove the stator.

22. Test the stator for an open circuit using the ohmmeter.
23. Remove the ring in the slip ring end frame.

Assembly Procedure
1. Install the new ring in the slip ring end frame.

2. Install the stator.
3. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly
until the gap between the outer lace and the end frame casting is 1.9 mm (0.075 inch).
4. Install the generator through-bolts.
Tighten
Tighten the generator through-bolts to 10 N•m (89 lb-in).
5. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.
Tighten
Tighten the generator drive end bearing nut to 81 N•m (60 lb-ft).
6. Install the generator. Refer to "Generator"in the On-Vehicle Service section.

7. Weld the brush holder terminal to the regulator terminal, if removed.
8. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled
terminal to the rectifier terminal.
9. Apply silicone grease between the bridge and the end frame for radiation purposes.
10. Fasten the screws holding the rectifier regulator/brush holder assembly to the end
frame.
11. Punch the new baffle with the pin into the brush.
Notice : Take care to prevent damage to the vehicle by protecting the diode in the
rectifier bridge from excessive heat while welding.
12. Weld the connectors of the rectifier bridge.

Battery
The sealed battery is standard on all cars. There are no vent plugs in the cover. The battery is
completely sealed, except for two small vent holes in the sides. These vent holes allow the
small amount of gas produced in the battery to escape. The battery has the following
advantages over conventional batteries :
 No water addition for the life of the battery.

 Overcharge protection. If too much voltage is applied to the battery, it will not accept as
much current as a conventional battery. In a conventional battery, the excess voltage will
still try to charge the battery, leading to gassing, which causes liquid loss.
 Not as liable to self–discharge as compared to a conventional battery. This is particularly
important when a battery is left standing for long periods of time.
 More power available in a lighter and smaller case.
The battery has three major functions in the electrical system. First, the battery provides a
source of energy for cranking the engine. Second, the battery acts as a voltage stabilizer for
the electrical system. Finally, the battery can, for a limited time, provide energy when the
electrical demand exceeds the output of the generator.
Ratings
A battery has two ratings: (1) a reserve capacity rating designated at 27°C (80°F), which is the
time a fully charged battery will provide 25 amperes current flow at or above 10.5 volts; (2) a
cold cranking amp rating determined under testing at –18°C (0°F), which indicates the cranking
load capacity.
Reserve Capacity
The reserve capacity is the maximum length of time it is possible to travel at night with the
minimum electrical load and no generator output. Expressed in minutes, Reserve Capacity (or
RC rating) is the time required for a fully charged battery, at a temperature of 27°C (80°F) and
being discharged at a current of 25 amperes, to reach a terminal voltage of 10.5 volts.
Cold Cranking Amperage
The cold cranking amperage test is expressed at a battery temperature of –18°C (0°F). The
current rating is the minimum amperage, which must be maintained by the battery for 30
seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2
volts. This rating is a measure of cold cranking capacity.
The battery is not designed to last indefinitely. However, with proper care, the battery will
provide many years of service.
If the battery tests well, but fails to perform satisfactorily in service for no apparent reason, the
following factors may point to the cause of the trouble :
 Vehicle accessories are left on overnight.

 Slow average driving speeds are used for short periods.
 The vehicle's electrical load is more than the generator output, particularly with the
addition of aftermarket equipment.
 Defects in the charging system, such as electrical shorts, a slipping generator belt, a
faulty generator, or a faulty voltage regulator.
 Battery abuse, including failure to keep the battery cable terminals clean and tight, or a
loose battery hold–down clamp.
 Mechanical problems in the electrical system, such as shorted or pinched wires.
Built - In Hydrometer
The sealed battery has a built–in, temperature–compensated hydrometer in the top of the
battery. This hydrometer is to be used with the following diagnostic procedure :
1. When observing the hydrometer, make sure that the battery has a clean top.
2. Under normal operation, two indications can be observed :
o GREEN DOT VISIBLE - Any green appearance is interpreted as a "green dot",
meaning the battery is ready for testing.
o DARK GREEN DOT IS NOT VISIBLE - If there is a cranking complaint, the battery
should be tested. The charging and electrical systems should also be checked at
this time.
3. Occasionally, a third condition may appear :
o CLEAR OR BRIGHT YELLOW - This means the fluid level is below the bottom of
the hydrometer. This may have been caused by excessive or prolonged charging,
a broken case, excessive tipping, or normal battery wear. Finding a battery in this
condition may indicate high charging by a faulty charging system. Therefore, the
charging and the electrical systems may need to be checked if a cranking
complaint exists. If the cranking complaint is caused by the battery, replace the
battery.
Charging Procedure
1. Batteries with the green dot showing do not require charging unless they have just been
discharged (such as in cranking a vehicle).
2. When charging sealed–terminal batteries out of the vehicle, install the adapter kit. Make
sure all the charger connections are clean and tight. For best results, batteries should be
charged while the electrolyte and the plates are at room temperature. A battery that is
extremely cold may not accept current for several hours after starting the charger.
3. Charge the battery until the green dot appears. The battery should be checked every
half–hour while charging. Tipping or shaking the battery may be necessary to make the
green dot appear.
4. After charging, the battery should be load tested. Refer to "Starter Motor" in this section.
Charging Time Required

The time required to charge a battery will vary depending upon the following factors :
 Size of Battery - A completely discharged large heavy-duty battery requires more than
twice the recharging time as a completely discharged small passenger car battery.
 Temperature - Temperature – A longer time will be needed to charge any battery at –
18°C (0°F) than at 27°C (80°F). When a fast charger is connected to a cold battery, the
current accepted by the battery will be very low at first. The battery will accept a higher
current rate as the battery warms.
 Charger Capacity - A charger which can supply only 5 amperes will require a much
longer charging period than a charger that can supply 30 amperes or more.
 State-of-Charge - A completely discharged battery requires more than twice as much
charge as a one-half charged battery. Because the electrolyte is nearly pure water and a
poor conductor in a completely discharged battery, the current accepted by the battery is
very low at first. Later, as the charging current causes the electrolyte acid content to
increase, the charging current will likewise increase.
Charging A Completely Discharged Battery (Off The Vehicle)

Unless this procedure is properly followed, a perfectly good battery may need to be replaced.
The following procedure should be used to recharge a completely discharged battery :
1. Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is
below 10 volts, the charge current will be very low, and it could take some time before
the battery accepts the current in excess of a few milli-amperes. Refer to "Charging Time
Required" in this section, which focuses on the factors affecting both the charging time
required and the rough estimates in the table below. Such low current may not be
detectable on ammeters available in the field.
2. Set the battery charger on the high setting.
Important : Some chargers feature polarity protection circuitry, which prevents charging
unless the charger leads are correctly connected to the battery terminals. A completely
discharged battery may not have enough voltage to activate this circuitry, even though
the leads are connected properly, making it appear that the battery will not accept
charging current. Therefore, follow the specific charger manufacturer’s instruction for
bypassing or overriding the circuitry so that the charger will turn on and charge a low–
voltage battery.
3. Continue to charge the battery until the charge current is measurable. Battery chargers
vary in the amount of voltage and current provided. The time required for the battery to
accept a measurable charge current at various voltages may be as follows :
4. Continue to charge the battery until the charge current is measurable. Battery chargers
vary in the amount of voltage and current provided. The time required for the battery to
accept a measurable charge current at various voltages may be as follows :
Voltage Hours
16.0 or more Up to 4 hours
Voltage Hours
14.0-15.9 Up to 8 hours
13.9 or less Up to 16 hours
o If the charge current is not measurable at the end of the above charging times, the
battery should be replaced.
o If the charge current is measurable during the charging time, the battery is good,
and charging should be completed in the normal manner.
Important : It is important to remember that a completely discharged battery must be

recharged for a sufficient number of ampere hours (AH) to restore the battery to a
usable state. As a general rule, using the reserve capacity rating (RC) as the number of
ampere hours of charge usually brings the green dot into view.
o If the charge current is still not measurable after using the charging time calculated
by the above method, the battery should be replaced.
Jump Starting Procedure
1. Position the vehicle with the good (charged) battery so that the jumper cables will reach.
2. Turn off the ignition, all the lights, and all the electrical loads in both vehicles. Leave the
hazard flasher on if jump starting where there may be other traffic and any other lights
needed for the work area.
3. In both vehicles, apply the parking brake firmly.
Notice : To avoid vehicle damage, make sure the cables are not on or near pulleys, fans,
or other parts that will move when the engine starts.
4. Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.

5. Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.
Caution : In order to avoid injury, do not use cables that have loose or missing
insulation.
5. Clamp one end of the first jumper cable to the positive terminal on the battery. Make
sure it does not touch any other metal parts. Clamp the other end of the same cable to
the positive terminal on the other battery. Never connect the other end to the negative
terminal of the discharged battery.
6. Clamp one end of the first jumper cable to the positive terminal on the battery. Make
sure it does not touch any other metal parts. Clamp the other end of the same cable to
the positive terminal on the other battery. Never connect the other end to the negative
terminal of the discharged battery.
Caution : To avoid injury do not attach the cable directly to the negative terminal of the
discharged battery. Doing so could cause sparks and a possible battery explosion.
6. Clamp one end of the second cable to the negative terminal of the booster battery. Make
the final connection to a solid engine ground (such as the engine lift bracket) at least 450
mm (18 in) from the discharged battery.
7. Clamp one end of the second cable to the negative terminal of the booster battery. Make
the final connection to a solid engine ground (such as the engine lift bracket) at least 450
mm (18 in) from the discharged battery.
8. Start the engine of the vehicle with the good battery. Run the engine at a moderate
speed for several minutes. Then start the engine of the vehicle which has the discharged
battery.
9. Remove the jumper cables by reversing the above sequence exactly. Remove the
negative cable from the vehicle with the discharged battery first. While removing each
clamp, take care that it does not touch any other metal while the other end remains
attached.
Generator
The charging system of this vehicle is the KDAC AD237 type. The number denotes the outer
diameter in millimeters of the stator lamination.
AD type generators are equipped with internal regulators. A Delta stator, a rectifier bridge, and
a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional
pulley and fan are used. There is no test hole.
Unlike three–wire generators, the AD 237 may be used with only two connections: The "L" and
"F" terminals are connected to the engine control module (ECM).
As with other charging systems, the charge indicator lamp is controlled by the ECM when the
ignition switch is turned to ON and goes out when the engine is running. If the charge indicator
lamp is ON with the engine running, a charging system defect is indicated.
This indicator light will glow at full brilliance for several kinds of defects as well as when the
system voltage is too high or too low.
The regulator voltage setting varies with temperature and limits the system voltage by
controlling rotor field current.
Charging System
AD type generators use a new type of regulator that incorporates a diode trio. A Delta stator, a
rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier
generators. A conventional pulley and fan are used. There is no test hole.
Starter
Wound field starter motors have pole pieces, arranged around the armature, which are
energized by wound field coils.
Enclosed shift lever cranking motors have the shift lever mechanism and the solenoid plunger
enclosed in the drive housing, protecting them from exposure to dirt, icy conditions, and
splashes.
In the basic circuit, solenoid windings are energized when the switch is closed. The resulting
plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear.
The solenoid main contacts close. Cranking then takes place.
When the engine starts, pinion overrun protects the armature from excessive speed until the
switch is opened, at which time the return spring causes the pinion to disengage. To prevent
excessive overrun, the switch should be released immediately after the engine starts.
Starting System
The engine electrical system includes the battery, the ignition, the starter, the generator, and
all the related wiring. Diagnostic tables will aid in troubleshooting system faults.
When a fault is traced to a particular component, refer to that component section of the service
manual. The starting system circuit consists of the battery, the starter motor, the ignition
switch, and all the related electrical wiring. All of these components are connected electrically.
SECTION 1F2
ENGINE CONTROLS - FAM II 2.4D

electrical unit o r w hen a tool or equipment could easily come in contact with exposed
electrical terminals. Disconnecting this cable will help prevent personal injury and
SPECIFICATIONS
Accessory Pedal Module Retaining Bolts 9 - 80
Accessory Mounting Bracket Bolts 37 27 -
Camshaft Position Sensor Bolts 8 - 71
Crankshaft Position Sensor Retaining Bolt 8 - 71
Electronic Ignition System Ignition Coil Retaining Bolts 10 - 89
Engine Control Module Bracket Retaining Nuts 15 11 -
Engine Coolant Temperature Sensor Bolt 20 15 -
Evaporative Emission Canister Bracket Nuts 10 - 89
Evaporative Emission Canister Purge Solenoid
5 - 44
BracketBolt
Exhaust Gas Recirculation Valve Retaining Bolts 30 22 -
EGR Valve Adapter Retaining Bolt (Left) 20 15 -
EGR Valve Adapter Retaining Bolt (Upper & Right) 30 22 -
Fuel Tank Strap Retaining Bolts 20 15 -
Fuel Rail Retaining Bolts 25 18 -
Knock Sensor Bolt 20 15 -
Manifold Absolute Pressure Sensor Retaining Bolt 4 - 35
Oxygen Sensor Bolt 50 37 -
Rear A/C Compressor Mounting Bracket Bolts 23 17 -
Throttle Body Retaining Nuts 10 - 89
Temperature Vs Resistance
°C °F ECT Sensor IAT Sensor
. . OHMS
Temperature vs Resistance Values (Approximate)
100 212 177 187
90 194 241 246
80 176 332 327
70 158 467 441
60 140 667 603
50 122 973 837
45 113 1188 991
40 104 1459 1180
35 95 1802 1412
30 86 2238 1700
25 77 2796 2055
20 68 3520 2500
15 59 4450 3055
10 50 5670 3760
5 41 7280 4651
0 32 9420 5800
-5 23 12300 7273
-10 14 16180 9200
-15 5 21450 9200
°C °F ECT Sensor IAT Sensor
. . OHMS
-20 -4 28680 15080
-30 -22 52700 25600
-40 -40 100700 45300
SPECIAL TOOLS
Special Tools Table
DW170-010
Oxygen Sensor Remover/Installer
DW100-010
Fuel Pressure Gauge
EN-48279
Main Fuel Pump Locking Ring Remover/Installer
EN-48278
Sub Fuel Pump Locking Ring Remover/Installer

Electrical Wiring Diagrams LHD PDF

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HOW TO READ ELECTRICAL WIRING DIAGRAM

1. HOW TO READ ELECTRIC WIRING DIAGRAM

1) CONTENTS OF ELECTRICAL WIRING DIAGRAM (CIRCUIT)

 Ef7 : Fuse No #20 in Engine Fuse Block

C  Connector No X401 terminal No 6

- Wiring Harness Splice

D  J201 : Wiring Harness Splice

E - Internal circuit of component (Relay)(Component name, terminal number)

- Ground Harness Pack

- Lower horizonal line : Ground Line

I  Ground Position (G103~G302)

2. CIRCUIT IDENTIFICATION SYMBOL

3. FUNCTION OF POWER SUPPLY LINE (NUMBER)

5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR

POSITION OF CONNECTORS AND GROUNDS

1. CONNECTOR, GROUND AND GROUND PACK INFORMATION

2. WIRING HARNESS, CONNECTOR & GROUND LOCATION

WIRING DIAGRAM FOR POWER SUPPLIES

1. IGNITION SWITCH CIRCUIT

USAGE AND CAPACITY OF FUSES IN FUSE BOX

2. ENGINE FUSE BLOCK, AUX (ONLY DIESEL)

3. I/P FUSE BLOCK

ELECTRICAL WIRING DIAGRAMS

1. STARTING & CHARGING SYSTEM

 W/H ENGINE (LD9)

 W/H ENGINE (LLW)

c. POSITION OF CONNECTORS AND GROUNDS

4) IGNITION SWITCH CIRCUIT

 W/H INSTRUMENT PANEL

5) POWER MODE CIRCUIT

2. ECM (ENGINE CONTROL MODULE) : ME7.9.9 (FAM II 2.4D)

 W/H INSTRUMENT PANEL

 W/H ENGINE (LD9)

 W/H INSTRUMENT PANEL

5) BRAKE SWITCH, BACK UP SWITCH, NSBU SWITCH CIRCUIT

 W/H INSTRUMENT PANEL

3. ECM (ENGINE CONTROL MODULE) : EDC16C39 (2.0 DIESEL)

 W/H INSTRUMENT PANEL

 W/H ENGINE (LLW)

c. POSITION OF CONNECTORS AND GROUNDS

 W/H INSTRUMENT PANEL

c. POSITION OF CONNECTORS AND GROUNDS

 W/H INSTRUMENT PANEL

 W/H ENGINE (LLW)

6) DLC (DATA LINK CONNECTOR) CIRCUIT

c. POSITION OF CONNECTORS AND GROUNDS

4. ECM (ENGINE CONTROL MODULE) : E77 (HFV6 3.2D)

 W/H ENGINE (LU1)

 W/H INSTRUMENT PANNEL

 W/H ENGINE (LU1)

3) IGNITION COIL, BRAKE SWITCH CIRCUIT

 W/H ENGINE (LU1)

 W/H ENGINE (LU1)

 W/H INSTRUMENT PANNEL

 W/H INSTRUMENT PANEL

c. POSITION OF CONNECTORS AND GROUNDS

5. TCM (TRANSMISSION CONTROL MODULE)

c. POSITION OF CONNECTORS AND GROUNDS

 W/H INSTRUMENT PANEL

 W/H INSTRUMENT PANEL

3) GEAR SHIFT LEVER, WINTER MODE SWITCH & CLUSTER CIRCUIT

6. BCM (BODY CONTROL MODULE)

 W/H INSTRUMENT PANEL