Trooper (2002) PDF

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SECTION
TABLE OF CONTENTS GENERAL INFORMATION
0A 0B
General Information Maintenance and Lubrication HEATING, VENTILATION AND AIR CONDITIONING HVAC System STEERING Power-Assisted System SUSPENSION Front Suspension Rear Suspension Wheel and Tire System DRIVELINE/AXLE Differential (Front) Differential (Rear) Driveline Control System (SHIFT ON THE FLY) Driveline Control System (TOD) Drive Shaft System Transfer Case (Standard Type) Transfer Case (TOD) BRAKE Brake Control System Anti-Lock Brake System Power-Assisted Brake System Parking Brake System ENGINE Engine Mechanical Engine Cooling Engine Fuel Engine Electrical Ignition System Starting and Charging System Driveability and Emissions Engine Exhaust Engine Lubrication Engine Speed Control System Induction TRANSMISSION Automatic Transmission Transmission Control System Manual Transmission Clutch BODY AND ACCESSORIES Lighting System Wiper/Washer System Entertainment Wiring System Meter and Gauge Body Structure Seats Security and Locks Sun Roof/Convertible Top Exterior/Interior Trim RESTRAINTS Seat Belt System Supplemental Restraint System (SRS) Restraint Control System CONTROL SYSTEM Cruise Control System
WORKSHOP MANUAL TROOPER (UX)
1A 2A 3C 3D 3E 4A1 4A2 4B1 4B2 4C 4D1 4D2
FOREWORD
This manual includes special notes, important points, service data, precautions, etc. That are needed for the maintenance, adjustments, service, removal and installation of vehicle components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without notice. Arrangement of the material is shown in the table of contents on the right-hand side of this page. A black spot on the first page of each section can be seen on the edge of the book below each section title. These point to a more detailed table of contents preceding each section. 5A 5B 5C 5D 6A 6B 6C 6D1 6D2 6D3 6E 6F 6G 6H 6J 7A 7A1 7B 7C 8A 8B 8C 8D 8E 8F 8G 8H 8I 8J 9A 9J 9J1 10A
This manual applies to 2002 models.
SECTION
GENERAL INFORMATION
TROOPER
0A1
GENERAL INFORMATION
CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . Maintenance and Lubrication . . . . . . . . . . . . . 0A 0B
General Information
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . . Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theft Prevention Standard . . . . . . . . . . . . . . . . 0A1 0A2 0A3 0A6 Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . Standard Bolts Torque Specifications . . . . . . Abbreviations Charts . . . . . . . . . . . . . . . . . . . . Service Parts Identification Plate . . . . . . . . . . 0A12 0A14 0A15 0A16
General Repair Instruction

1. If a floor jack is used, the following precautions are recommended. Park vehicle on level ground, block front or rear wheels, set jack against the recommended lifting points (see Lifting Instructions in this section), raise vehicle and support with chassis stands and then perform the service operations. 2. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 3. Use a cover on body, seats and floor to protect them against damage and contamination. 4. Brake fluid and antifreeze solution must be handled with reasonable care, as they can cause paint damage. 5. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 7. Used cotter pins, plastic clips, gaskets, Orings, oil seals, lock washers and selflocking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused. 8. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation.
9. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 10. Lubricate rotating and sliding faces of the parts with oil or grease before installation. 11. When necessary, use a sealer on gaskets to prevent leakage. 12. Carefully observe all specifications for bolt and nut torques. 13. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant134a. 14. When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 15. SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental Restraint System (SRS) Air Bags. This system is not to be serviced without consulting the appropriate service information. Consult Section 9J SRS System if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by: 1. AIR BAG warning light on the instrument panel. 2. A Code J or K for fifth digit of Vehicle Identification Number.
0A2
GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations. Arrow Type Application Arrow Type Application D Ambient/Clean air flow D Cool air flow
Front of vehicle
Up Side
D Gas other than ambient air D Hot air flow
Task Related
D Ambient air mixed with another gas D Can indicate temperature change
View Detail
Motion or direction
View Angle
Lubrication point oil or fluid
Dimension (1:2)
Lubrication point grease
Sectioning (1:3)
Lubrication point jelly
GENERAL INFORMATION
0A3
Identification
Vehicle Identification Number (VIN)
This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle.
905R200005
F00R200010
0A4
GENERAL INFORMATION
Engine Serial Number

The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter.
F06R200001
Transmission Serial Number

Manual : Stamped into the lower side of the transmission.
220RW084
GENERAL INFORMATION
Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode switch.
0A5
240R200028
0A6
GENERAL INFORMATION
Theft Prevention Standard

The 11 major components listed below will be marked with 17 digit VIN at the stage of production. In addition its service parts will be marked with manufacturer s trade mark, R mark and DOT mark. Reference Figure No. 0A-10 ENGINE COMPONENT 1 6VE1 INDICATION PRODUCTION VIN plate SERVICE PARTS
0A-11
TRANSMISSION
2 Manual transmission Automatic transmission 3 Engine hood 4 Front door 5 Rear door 6 Fender 7 Rear Quarter panel 8 Front bumper 9 Back door left side 10 Back door right side 11 Rear bumper
VIN plate
0A-11
BODY
VIN label
Anti Theft Stamping/Plate/Label

STAMPING/PLATE LABEL
PRODUCTION
SERVICE PARTS
GENERAL INFORMATION
0A7
Anti Theft Stamping/Label/Plate Location

The stamping, label and plate locations are indicated by arrows in the illustration below. NOTE: A. VIN plate locations for production. B. Stamping locations for service parts. Engine
901RW195
Manual Transmission (AR5)
901RX021
0A8
GENERAL INFORMATION
Automatic Transmission (THM)
901RW197
GENERAL INFORMATION
Body
0A9
901RW113
Legend (3) Engine Hood (4) Front Door (5) Rear Door
(6) Fender (7) Rear Quarfer Panel (8) Front Bumper
0A10
Body
GENERAL INFORMATION
901RW114
Legend (9) Back Door Left Side
(10) Back Door Right Side (11) Rear Bumper
GENERAL INFORMATION
0A11
Body Label Instructions

Do not peel off the masking tape until completion of paint work when replacing these parts, as the tape is affixed on the label attached to service parts for body of the antitheft component. NOTE: Be sure to pull off the masking tape after paint work has been completed. Do not attempt to remove this label for any reason.
901RW083
Precautions in pulling off the masking tape 1. Use only your finger nail or a similar blunt instrument to peel off the masking tape. Use of a sharp object will damage the underlying antitheft label. 2. Be careful not to damage the paint around the label.
901RY00057
0A12
GENERAL INFORMATION
D When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance.
Lifting Instructions
CAUTION: D If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage.
Lifting Points and Supportable Point Locations
C00RW003
Lifting Point: Front D When using a floor jack, lift on the center of the skid plate.
545RS001
GENERAL INFORMATION
Supportable Point: Front D Position the chassis stands at the bottom of the frame sidemember, behind the front wheel. Supportable Point: Rear
0A13
D Position the chassis stands at the bottom of the frame sidemember, just behind the trailing link bracket.
501RS003
501RW002
Lifting Point: Rear D Position the floor jack at the center of the rear axle case when lifting the vehicle.
Legend (1) Trailing Link Bracket Supportable Point: Rear D Position the chassis stands at the bottom of the rear axle case.
420RS002
420RS001
0A14
GENERAL INFORMATION
Standard Bolts Torque Specifications

The torque values given in the following table should be applied where a particular torque is not specified. Strength Class 4.8 Refined 8.8 Non-Refined 9.8
Bolt Identification
Bolt Diameter Pitch (mm)

M 6X1.0 M 8X1.25 M 10X1.25 * M10X1.5 M12X1.25 * M12X1.75 M14X1.5 * M14X2.0 M16X1.5 * M16X2.0 M18X1.5 M20X1.5 M22X1.5 M24X2.0 48 (36) 818 Nm (613 lb ft) 2134 Nm (1525 lb ft) 2033 Nm (1425 lb ft) 4974 Nm (3654 lb ft) 4569 Nm (3351 lb ft) 77115 Nm (5685 lb ft) 72107 Nm (5379 lb ft) 104157 Nm (77116 lb ft) 100149 Nm (74110 lb ft) 151226 Nm (111166 lb ft) 206310 Nm (152229 lb ft) 251414 Nm (185305 lb ft) 359539 Nm (265398 lb ft) 510 Nm (47 lb ft) 1223 Nm (917 lb ft) 2846 Nm (2034 lb ft) 2845 Nm (2033 lb ft) 6191 Nm (4567 lb ft) 5784 Nm (4262 lb ft) 93139 Nm (69103 lb ft) 88131 Nm (6597 lb ft) 135204 Nm (100150 lb ft) 130194 Nm (95143 lb ft) 195293 Nm (144216 lb ft) 270405 Nm (199299 lb ft) 363544 Nm (268401 lb ft) 431711 Nm (318524 lb ft) 1730 Nm (1222 lb ft) 3763 Nm (2746 lb ft) 3660 Nm (2744 lb ft) 76114 Nm (5684 lb ft) 72107 Nm (5379 lb ft) 114171 Nm (84126 lb ft) 107160 Nm (79118 lb ft) 160240 Nm (118177 lb ft) 153230 Nm (113169 lb ft) 230345 Nm (169255 lb ft) 317476 Nm (234351 lb ft) 425637 Nm (313469 lb ft) 554831 Nm (409613 lb ft)
The asterisk * indicates that the bolts are used for femalethreaded parts that are made of soft materials such as casting, etc.
GENERAL INFORMATION
0A15
Abbreviations Charts
List of automotive abbreviations which may be used in this manual A Ampere(s) ABS Antilock Brake System AC Alternating Current A/C Air Conditioning ACCEL Accelerator ACC Accessory ACL Air Cleaner Adj Adjust A/F Air Fuel Ratio AIR Secondary Air Injection System Alt Altitude AMP Ampere(s) ANT Antenna ASM Assembly A/T Automatic Transmission/Transaxle ATDC After Top Dead Center ATF Automatic Transmission Fluid Auth Authority Auto Automatic BARO Barometric Pressure Bat Battery B+ Battery Positive Voltage Bbl Barrel BHP Brake Horsepower BJ Birfield Universal Joint BPT Backpressure Transducer BTDC Before Top Dead Center C Degrees Celsius CAC Charge Air Cooler Calif California cc Cubic Centimeter CID Cubic Inch Displacement CKP Crankshaft Position CL Closed Loop CLCC Closed Loop Carburetor Control CMP Camshaft Position CO Carbon Monoxide Coax Coaxial Conn Connector Conv Converter Crank Crankshaft Cu. In. Cubic Inch CV Constant Velocity Cyl Cylinder(s) DI Distributor Ignition Diff Differential Dist Distributor DLC Data Link Connector DOHC Double Overhead Camshaft DOJ Double Offset Universal Joint DTC Diagnostic Trouble Code DTM Diagnostic Test Mode DTT Diagnostic Test Terminal DVM Digital Voltmeter (10 meg.) DVOM Digital Volt Ohmmeter EBCM Electronic Brake Control Module ECM Engine Control Module ECT Engine Coolant Temperature EEPROM Electronically Erasable Programmable Read Only Memory EGR Exhaust Gas Recirculation EI Electronic Ignition
ETC Electronic Throttle Control ETR Electronically Tuned Receiver EVAP Evaporation Emission Exh Exhaust F Degrees Fahrenheit Fed Federal (All States Except Calif.) FF Front Drive Front Engine FL Fusible Link FLW Fusible Link Wire FP Fuel Pump FRT Front ft Foot FWD Front Wheel Drive 4WD Four Wheel Drive 4 x 4 Four Wheel Drive 4 A/T Four Speed Automatic Transmission/Transaxle Gal Gallon GEN Generator GND Ground Gov Governor g Gram Harn Harness HC Hydrocarbons HD Heavy Duty Hg Hydrargyrum (Mercury) HiAlt High Altitude HO2S Heated Oxygen Sensor HVAC HeaterVentAirConditioning IAC Idle Air Control IAT Intake Air Temperature IC Integrated Circuit / Ignition Control ID Identification / Inside Diameter IGN Ignition INJ Injection IP Instrument Panel IPC Instrument Panel Cluster Int Intake ISC Idle Speed Control J/B Junction Block kg Kilograms km Kilometers km/h Kilometer per Hour kPa Kilopascals kV Kilovolts (thousands of volts) kW Kilowatts KS Knock Sensor L Liter lb ft Foot Pounds lb in Inch Pounds LF Left Front LH Left Hand LR Left Rear LS Left Side LWB Long Wheel Base L4 InLine Four Cylinder Engine MAF Mass Air Flow MAN Manual MAP Manifold Absolute Pressure Max Maximum MC Mixture Control MFI Multiport Fuel Injection MIL Malfunction Indicator Lamp Min Minimum mm Millimeter MPG Miles Per Gallon
0A16
GENERAL INFORMATION
TFT Transmission Fluid Temprature TOD Torque On Demand TP Throttle Position TRANS Transmission/Transaxle TURBO Turbocharger TVRS Television & Radio Suppression TVV Thermal Vacuum Valve TWC Three Way Catalytic Converter 3 A/T Three Speed Automatic Transmission/Transaxle 2WD Two Wheel Drive 4 x 2 Two Wheel Drive Ujoint Universal Joint V Volt(s) VAC Vacuum VIN Vehicle Identification Number VRRRE Vehicle Refrigerant Recovery and Recycling Equipment Vref ECM Reference Voltage VSS Vehicle Speed Sensor VSV Vacuum Switch Valve V6 Six Cylinder V Engine V8 Eight Cylinder V Engine W Watt(s) w/ With w/b Wheel Base w/o Without WOT Wide Open Throttle
MPH Miles Per Hour M/T Manual Transmission/Transaxle MV Millivolt N Newtons NA Natural Aspirated NC Normally Closed NM Newton Meters NO Normally Open NOX Nitrogen, Oxides of OBD On-Board Diagnostic OD Outside Diameter O/D Over Drive OHC Overhead Camshaft OL Open Loop O2 Oxygen O2S Oxygen Sensor PAIR Pulsed Secondary Air Injection System P/B Power Brakes PCM Powertrain Control Module PCV Positive Crankcase Ventilation PRESS Pressure PROM Programmable Read Only Memory PNP Park/Neutral Position P/S Power Steering PSI Pounds per Square Inch PSP Power Steering Pressure Pt. Pint Pri Primary PWM Pulse Width Modulate Qt. Quart REF Reference RF Right Front RFI Radio Frequency Interference RH Right Hand RPL Reduced Power Lamp RPM Revolutions Per Minute RPM Sensor Engine Speed Sensor RPO Regular Production Option RR Right Rear RS Right Side RTV Room Temperature Vulcanizing RWAL Rear Wheel Antilock Brake RWD Rear Wheel Drive SAE Society of Automotive Engineers Sec Secondary SFI Sequential Multiport Fuel Injection SI System International SIR Supplemental Inflatable Restraint System SOHC Single Overhead Camshaft Sol Solenoid SPEC Specification Speedo Speedometer SRS Supplemental Restraint System ST Start / Scan Tool Sw Switch SWB Short Wheel Base SYN Synchronize Tach Tachometer TB Throttle Body TBI Throttle Body Fuel Injection TCC Torque Converter Clutch TCM Transmission Control Module TDC Top Dead Center Term Terminal TEMP Temperature
Service Parts Identification Plate

The Vehicle Information Plate (Service Parts ID plate) is provided on all vehicle models. It is located on the center dash wall inside the engine compartment. The plate lists the VIN (Vehicle Identification Number), paint information and all production options and special equipment on the vehicle when it was shipped from the factory.
905RW007
SECTION
MAINTENANCE AND LUBRICATION
TROOPER
0B1
GENERAL INFORMATION
Maintenance and Lubrication
CONTENTS
Maintenance Schedule List . . . . . . . . . . . . . . . Explanation of Complete Vehicle Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Fluids and Lubricants . . . . 0B1 0B5 0B8 Lubricant Viscosity Chart . . . . . . . . . . . . . . . . . Recommended Liquid Gasket . . . . . . . . . . . Recommended Thread Locking Agents . . . Maintenance Service Data . . . . . . . . . . . . . . . . 0B9 0B11 0B11 0B12
Maintenance Schedule List

Normal Vehicle Use
The maintenance instructions in this Maintenance Schedule are based on the assumption that the vehicle will be used as designed: D to carry passengers and cargo within the limitations specified on the tire placard located on the inside of the glove compartment door; D to be driven on reasonable road surfaces within legal operating limits; D to be driven on a daily basis, as a general rule, for at least several miles/kilometers; D to be driven on unleaded fuel Unusual or severe operating conditions will require more frequent vehicle maintenance, as specified in the following sections. [Severe Driving Condition] ITEMS REPLACE AIR CLEANER FILTER CHANGE ENGINE OIL AND OIL FILTER CHANGE AUTOMATIC TRANSMISSION FLUID CHANGE FRONT AND REAR AXLE OIL REPLACE TIMING BELT CHANGE POWER STEERING FLUID
Severe Driving Conditions

If the vehicle is usually operated under any of the severe driving conditions listed below, it is recommended that the applicable maintenance services be performed at the specified interval shown in the chart below. Severe driving conditions: D Towing a trailer, using a camper or car top carrier. D Repeated short trips of less than 8 Km (5 miles) with outside temperature remaining below freezing. D Extensive idling and/or low speed driving for long distances, such as police, taxi or doortodoor delivery use. D Operating on dusty, rough, muddy or salt spread roads.
INTERVAL See explanation of service, page 0B5 Every 3,000 miles (4,800 km) or 3 months Every 20,000 miles (32,000 km) Every 15,000 miles (24,000 km) Every 100,000 miles (160,000 km) Every 30,000 miles (48,000 km)
0B2
Mileage Only Items
02UBSOM51
0B3
Mileage/Months
02UBSOM31
0B4
02UBSOM41
0B5
Explanation of Complete Maintenance Schedule
Vehicle
Valve Clearance Adjustment

Incorrect valve clearance will result in increased engine noise and reduced engine output. Retorque the camshaft bracket bolts before checking and adjusting the valve clearance. Check and adjust the valve clearance whenever excessive engine noise occurs.
Brief explanations of the services listed in the preceding Maintenance Schedule are presented below. Replace all questionable parts and note any necessary repairs as you perform these maintenance procedures.
Front and Rear Axle Lubricant Replacement

Check the lubricant level after every 7,500 miles (12,000 km) of operation and add lubricant to level of filler hole if necessary. Replace the front and rear axle lubricant at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) of operation thereafter.
Tire Rotation
Rotate tires every 7,500 miles (12,000 km).
Front Wheel Bearings Lubricant Replacement

Clean and repack the front wheel bearings at 30,000 miles (48,000 km) intervals. Refer to DRIVE SHAFT SYSTEM (SEC. 4C).
Manual Transmission Lubricant Replacement

Check the lubricant level after every 7,500 miles (12,000 km) of operation and add lubricant to level of filler hole if necessary. Replace the transmission lubricant at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) of operation thereafter.
Radiator Core and Air Conditioning Condenser Cleaning

Clean the front of the radiator core and air conditioning condenser, at 60,000 miles (96,000 km) intervals.
Fluid Level Check

A fluid loss in any system (except windshield washer) may indicate a problem. Repair the system at once. Engine oil level Check level and add if necessary. The best time to check the engine oil level is when the oil is warm. After stopping the engine with the vehicle on a level surface, wait a few minutes for the oil to drain back to the oil pan. Pull out the oil level indicator (dipstick). Wipe it clean and push the oil level indicator back down all the way. Pull out the oil level indicator, keeping the tip down, and look at the oil level on it. Add oil, if needed, to keep the oil level above the ADD mark and between the ADD and FULL marks in the operating range area. Avoid overfilling the engine since this may cause engine damage. Push the oil level indicator back down all the way after taking the reading. If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain back to the pan fast enough to give a true oil level. Engine coolant level and condition Check engine coolant level in the coolant reservoir and add engine coolant if necessary. Inspect the engine coolant and replace it if dirty or rusty. Windshield washer fluid level Check washer fluid level in the reservoir and add if necessary. Power steering system reservoir level Check and keep at the proper level. Brake master cylinder reservoir level Check fluid. Keep fluid at proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced. Hydraulic clutch system Check fluid level in the reservoir. Add fluid as required.
Transfer Case Lubricant Replacement

Check the lubricant level after every 7,500 miles (12,000 km) of operation and add lubricant to level of filler hole if necessary. Replace the transfer case lubricant at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) of operation thereafter.
Extension Lubricant Level Check (2WD only)

Check oil level at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) or operation thereafter.
Air Cleaner Element Replacement

Replace the air cleaner under normal operating conditions every 30,000 miles (48,000 km). Operation of the vehicle in dusty areas will necessitate more frequent replacement.
Spark Plug Replacement

Replace the plugs at 100,000 miles (160,000 km) intervals with the type specified at the end of this section.
Cooling System Service

Drain, flush and refill system with new engine coolant. Refer to Recommended Fluids and Lubricants in this section, or ENGINE COOLING (SEC.6B).
Timing Belt Replacement

Replace the timing belt at every 100,000 miles (160,000 km). Failure to replace the timing belt may result in serious damage to the engine.
0B6

normal highway speeds means a wheel balancing is needed. Check tire pressure when the tires are cold (include the spare). Maintain pressure as shown in the tire placard, which is located on the driver s door lock pillar.
Battery fluid level Check fluid level in the battery.
Fluid Leak Check

Check for fuel, water, oil or other fluid leaks by looking at the surface beneath the vehicle after it has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice gasoline fumes or fluid at any time, locate the source and correct it at once.
Steering System Operation

Be alert for any changes in steering action. An inspection or service is needed when the steering wheel is harder to turn or has too much free play, or if there are unusual sounds when turning or parking.
Engine Oil and Oil Filter Replacement

Always use API SE, SF, SG, SH or ILSAC GF-1, GF-2 quality oils of the proper viscosity. When choosing an oil, consider the range of temperatures the car will be operated in before the next oil change. Then, select the recommended oil viscosity from the chart. Always change the oil and the oil filter as soon as possible after driving in a dust storm.
Brake Systems Operation

Watch for the BRAKE light coming on. Other signs of possible brake trouble are such things as repeated pulling to one side when braking, unusual sounds when braking or between brake applications, or increased brake pedal travel. If you note one of these conditions, repair the system at once. For convenience, the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, bindings, leaks, crack, chafing etc. Inspect disc brake pads for wear and rotors for surface condition. Inspect other brake parts, including parking brake drums, linings etc., at the same time. Check parking brake adjustment. Inspect the brakes more often if habit or conditions result in frequent braking.
Engine Cooling System Inspection

Inspect the coolant/antifreeze. If the coolant is dirty or rusty, drain, flush and refill with new coolant. Keep coolant at the proper mixture for proper freeze protection, corrosion inhibitor level and best engine operating temperature. Inspect hoses and replace if cracked, swollen or deteriorated. Tighten the hose clamps if equipped with screwtype clamps. Clean outside of radiator and air conditioning condenser. Wash filler cap and neck. To help ensure proper operation, a pressure test of both the cooling system and the cap is also recommended.
Parking Brake and Transmission Park Mechanism Operation

Park on a fairly steep hill and hold the vehicle with the parking brake only. This checks holding ability. On automatic transmission vehicles, shifting from P position to the other positions cannot be made unless the brake pedal is depressed when the key switch is in the ON position or the engine is running. WARNING: BEFORE CHECKING THE STARTER SAFETY SWITCH OPERATION BELOW, BE SURE TO HAVE ENOUGH ROOM AROUND THE VEHICLE. THEN FIRMLY APPLY BOTH THE PARKING BRAKE AND THE REGULAR BRAKE. DO NOT USE THE ACCELERATOR PEDAL. IF THE ENGINE STARTS, BE READY TO TURN OFF THE KEY PROMPTLY. TAKE THESE PRECAUTIONS BECAUSE THE VEHICLE COULD MOVE WITHOUT WARNING AND POSSIBLY CAUSE PERSONAL INJURY OR PROPERTY DAMAGE.
Exhaust System Inspection

Visually inspect the exhaust pipes, muffler, heat shields and hangers for cracks, deterioration, or damage. Be alert to any changes in the sound of the exhaust system or any smell of fumes. These are signs the system may be leaking or overheating. Repair the system at once, if these conditions exist. (See also Engine Exhaust Gas Safety and Three Way Catalytic Converter in the Owner s manual.)
Fuel Cap, Fuel Lines, and Fuel Tank Inspection

Inspect the fuel tank, the fuel cap and the fuel lines every 60,000 miles (96,000 km) for damage which could cause leakage. Inspect the fuel cap and the gasket for correct sealing and physical damage. Replace any damaged parts.
Drive Belt Inspection

Check the serpentine belt driving for cracks, fraying, wear, and correct tension every 30,000 miles (48,000 km). Replace as necessary.
Starter Safety Switch Operation (Automatic Transmission)

Check by trying to start the engine in each gear while setting the parking brake and the foot brake. The starter should crank only in P (Park) or N (Neutral).
Wheel Alignment, Balance and Tires Operation

Uneven or abnormal tire wear, or a pull right or left on a straight and level road may show the need for a wheel alignment. A vibration of the steering wheel or seat at
Starter Safety Switch Operation (Manual Transmission)

To check, place the shift lever in Neutral, push the clutch pedal halfway and try to start. The starter should not

crank. The starter should crank only when the clutch pedal is fully depressed.
0B7
Clutch Control Lubrication

Lubricate the clutch pedal bushing, the clevis pin, and pedal spring every 15,000 miles (24,000 km) or 6 months. If a squeaking noise arises from around the bushing or the clevis pin at the clutch pedal arm when the clutch pedal is depressed, lubricate them.
Accelerator Linkage Lubrication

Lubricate the accelerator pedal fulcrum pin with chassis grease.
Steering and Suspension Inspection

Inspect the front and rear suspension and steering system for damaged, loose or missing parts or signs of wear. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc.
Clutch Pedal Free Play Inspection

Note the clutch pedal free play. It should be 5 15 mm (0.2 0.6 in). Adjust clutch control when there is little or no free play.
Body and Chassis Lubrication

Lubricate the key lock cylinders, the hood latch, the hood and door hinges, the door check link, the parking cable guides, the underbody contact points, and the linkage.
Accelerator Linkage Inspection

Inspect for interference, binding, and damaged or missing parts. Check accelerator pedal for smooth operation and even pedal effort. Replace parts as needed.
Propeller Shaft Inspection and Lubrication

Except TOD model : yoke and universal joints with grease containing MOS2 (disulfide molybdenum type grease) at the interval shown in the Maintenance Schedule. All models : check for play in normal direction of rotation of sliding yoke and universal joints. Also check the propeller shaft flangetopinion bolts for proper torque to 63 Nm (46 lb ft) for front and rear propeller shaft.
Automatic Transmission Fluid Replacement

Under harsh operating conditions, such as constant driving in heavy city traffic during hot weather, or in hilly or mountainous terrain, change the transmission fluid and service the sump filter after every 20,000 miles (32,000 km) of operation. More over, the remaining life percentage of ATF can be estimated by using TECHII as an auxiliary tool to judge the right time for ATF replacement. The remaining life percentage is calculated from ATFS heat history. When it is close to 0%, ATF replacement is recommended.
Auto Cruise Control Inspection

Check to see if the clearance between cruise link and accelerator link is normal. Also, check that their properly connected.
Brake Pedal Free Play Inspection

Note the brake pedal free play. It should be 610 mm (0.230.39 in). Adjust brake control when there is little or no free play.
Clutch Lines and Hoses Inspection

Check lines and hoses for proper attachment, binding, leaks, cracks, chafing, deterioration, etc. Any questionable parts should be replaced or repaired at once. When abrasion or wear is evident on lines or hoses, the cause must be corrected.
0B8
Recommended Fluids and Lubricants

USAGE Engine Engine coolant Brake system Power steering system Automatic transmission Manual transmission Rear axle and front axle FLUID/LUBRICANT API SE, SF, SG, SH or ILSAC GF-1, GF-2 Engine oil (See oil chart on the following page for proper viscosity) Mixture of water and good quality ethylene glycol base type antifreeze. DOT-3 hydraulic brake fluid. DEXRON -III Automatic transmission fluid. DEXRON -III Automatic transmission fluid. Engine oil (See oil chart on following page for proper viscosity) GL-5 gear lubricant (Standard differential) GL-5 Limited slip differential gear lubricant together with limited slip differential lubricant additive (Part No. 8-01052-358-0) or equivalent (If equipped with optional limited slip differential) (See oil chart in this section for proper viscosity) Engine Oil Chassis grease DOT-3 hydraulic brake fluid Engine oil Chassis grease Engine oil Chassis grease Chassis grease Wheel bearing grease GL-5 gear lubricant (SAE 75W-90) SAE40 (Areas where ambient temperatures of 32C (90F) and higher are regularly encountered.) SAE5W30SF (Other areas) DEXRON -III Automatic transmission fluid. DEXRON -III Automatic transmission fluid. Grease containing MoS2 or multipurpose type grease NLGI No.2 Engine oil Washer fluid Synthetic light weight engine oil (SAE 5W-30) Chassis grease
Clutch system a. Pivot points b. Clutch fork joint c. Master cylinder Hood latch assembly a. Pivots and spring anchor b. Release pawl Hood and door hinges Chassis lubrication Parking brake cables Front wheel bearings Shift on the fly system Transfer Case (Except TOD and 2WD model)
TOD system Extension assembly Propeller shafts (Except TOD model) Sliding yoke and Univeral joint Body door hinge pins and linkage, fuel door hinge, rear compartment lid hinges Windshield washer solvent Key lock cylinder Accelerator linkage
0B9
Lubricant Viscosity Chart

Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following table.
Oil Viscosity Chart for Gasoline Engine
905RT011
Oil Viscosity Chart for Manual Transmission and Transfer Case
B00RW002
0B10
Oil Viscosity Chart for Front Axle
B00RW003
Oil Viscosty Chart for Rear Axle
B00RW004
0B11
Recommended Liquid Gasket

Type RTV* Silicon Base Water Base Solvent Brand Name Three Bond 1207B Three Bond 1207C Three Bond 1215 Three Bond 1280 Three Bond 1281 Three Bond 1141E Three Bond 1104 Belco Bond 4 Belco Bond 401 Belco Bond 402 LOCTITE 515 LOCTITE 518 LOCTITE 17430 Manufacturer Three Bond Three Bond Three Bond Three Bond Three Bond Three Bond Three Bond Isuzu Isuzu Isuzu Loctite Loctite Loctite Remarks For Engine Repairs For Axle Case Repairs T/M Repairs T/M For Engine Repairs For Engine Repairs
Anaerobic
All
* RTV: Room Temperature Vulcanizer NOTE: 1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle. 2. Be careful to use the specified amount of liquid gasket. Follow the manufacturer s instructions at all times. 3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket. The connecting surfaces must be perfectly dry. 4. Do not apply LOCTITE 17430, LOCTITE 515 and LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result. Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry. 2. Apply LOCTITE to the bolts.
Recommended Thread Locking Agents

LOCTITE Type LOCTITE 242 LOCTITE 262 LOCTITE 271 LOCTITE Color Blue Red Red
F00RW014
3. Tighten the bolts to the specified torque. After tightening, be sure to keep the bolts free from vibration and torque for at least an hour until LOCTITE hardens. NOTE: When the application procedures are specified in this manual, follow them.
0B12
Maintenance Service Data

Service Data and Specifications
ENGINE Valve clearance (cold) Spark plug type Spark plug gap CLUTCH BRAKE WHEEL ALIGNMENT Clutch pedal free play Brake pedal free play Parking brake travel Toe-in Camber Caster PROPELLER SHAFT WHEEL AND TIRES Flange torque Size Wheel nut torque Tire inflation pressure (Front) * Tire inflation pressure (Rear) * Unless otherwise specified on tire information label on the vehicle. Intake 0.280.05 mm (0.0110.002 in) Exhaust 0.30.05 mm (0.0120.002 in) K16PR-P11/PK16PR11/RC10PYP4 1.05 mm (0.04 in) 515 mm (0.200.59 in) 610 mm (0.240.39 in) 67 notches 02 mm (00.08 in) 030 21045 63 Nm (46 lb ft) (Except TOD model) 43 Nm (32 lb ft) (TOD model) P245/70R16 118 Nm (87 lb ft) 210 kPa (30 psi) 240 kPa (35 psi)
Approximate Capacities
Items Fuel tank * Crankcase Coolant Transmission Transfer Transfer with TOD Extention Axle Shift on the fly system Power steering Air conditioning (R-134a) Rear Front (4WD vehicle only) Oil Change with Filter Oil Change without Filter M/T A/T Manual Automatic Metric Measure 85 L 4.7 L 4.0 L 8.5 L 8.8 L 2.7 L 8.6 L 1.45 L 1.9 L 0.185 L 3.0 L 1.4 L 0.12 L 1.0 L 0.8 L U.S. Measure 22.5 Gal. 5.0 Qt 4.2 Qt 9.0 Qt 9.3 Qt 2.86 Qt 9.1 Qt 1.5 Qt 2.0 Qt 0.195 Qt 3.2 Qt 1.5 Qt 0.13 Qt 1.1 Qt 1.76 lb
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
SECTION
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
TROOPER
1A1

HVAC SYSTEMS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Heating and Ventilation System . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Inspection . . . . . . . . . . . . . . . . . . . Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Unit and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Core and / or Mode Door . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Mode Control Link Unit . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Temperature Control Link Unit . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . Blower Assembly and Associated Parts . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Link Unit and / or Mode door . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Heater Duct, Defroster Nozzle and Ventilation Duct . . . . . . . . . . . . . . . . . . . . . . . . . Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center and / or Drive Side Vent . . . . . . . . . . . 1A3 1A3 1A3 1A8 1A9 1A12 1A14 1A14 1A15 1A15 1A16 1A16 1A16 1A17 1A17 1A18 1A18 1A18 1A19 1A19 1A19 1A19 1A19 1A20 1A20 1A20 1A21 1A21 1A21 1A21 1A22 1A23 1A23 1A23 1A23 1A24 1A24 1A24 1A25 1A25 Center Vent, Drive Side Vent and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Lever Assembly and / or Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Lever Assembly, Control Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Illumination Bulb . . . . . . . . . . . . Control Panel Illumination Bulb and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor and Associated Parts . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning System . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Inspection . . . . . . . . . . . . . . . . . . . General Repair Procedure . . . . . . . . . . . . . . Compressor Assembly . . . . . . . . . . . . . . . . . . . Compressor Assembly and Associated Parts (6VE1) . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . New Compressor Installation . . . . . . . . . . . . Condenser Assembly . . . . . . . . . . . . . . . . . . . . Condenser Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . . . . Receiver / Drier and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator Assembly . . . . . . . . . . . . . . . . . . . . 1A25 1A25 1A25 1A26 1A26 1A26 1A28 1A29 1A29 1A29 1A29 1A30 1A30 1A30 1A30 1A31 1A31 1A39 1A47 1A48 1A56 1A56 1A56 1A57 1A57 1A58 1A58 1A58 1A58 1A59 1A59 1A59 1A59 1A60 1A60 1A60 1A60 1A61
1A2

1A61 1A61 1A62 1A62 1A62 1A63 1A63 1A64 1A64 1A64 1A64 1A65 1A65 1A65 1A66 1A67 1A70 1A70 1A70 1A71 1A72 1A72 1A72 1A74 1A74 1A76 1A76 1A76 1A76 1A76 1A76 1A77 1A77 1A77 1A78 1A80 1A81 1A81 1A81 1A82 1A83 1A88 1A89 1A90 1A91 1A92 Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System . . . . . . . . . . . . . . . . . . . Overview of Automatic Control of Automatic Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting, Its Overview and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Air Conditioner Control Unit Power Supply Diagnosis . . . . . . . . . . . . . . . . . . . . . Performance and Movement checklist for Automatic Air Conditioner Related Parts . Troubleshooting With Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection By Failed Location . . . . . . . . . . . . . Inspection of the Sensors . . . . . . . . . . . . . . . Inspection of the Intake Actuator System . Inspection of the Mix Actuator System . . . . Inspection of the Mode Actuator System . . Inspection of the Fan Motor System . . . . . . Inspection of the Magnetic Clutch System Condenser Fan Diagnosis . . . . . . . . . . . . . . Individual Inspection . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . Power Transistor . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Heater/Air Conditioner Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Car Sensor . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duct Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Actuator . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Actuator . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Thermostat, Evaporator Core and/or Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch and Illumination Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch, Illumination Bulb and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data And Specifications . . . . . . . . . . . . . Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Clutch Assembly (DKV-14G Type) Parts Location View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . Oil Specification . . . . . . . . . . . . . . . . . . . . . . . Handling of Oil . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil Check . . . . . . . . . . . . . . . . . Checking and Adjusting Oil Quantity for Used Compressor . . . . . . . . . . . . . . . . . . . . . Checking and Adjusting for Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . Contamination of Compressor Oil . . . . . . . . Oil Return Operation . . . . . . . . . . . . . . . . . . . Replacement of Component Parts . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Air Conditioning System . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Full Automatic Air Conditioner Parts Configuration . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line and Associated Parts . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . Functions and Features . . . . . . . . . . . . . . . . Automatic Air Conditioner Block Diagram . Control Panel Layout . . . . . . . . . . . . . . . . . . . Air Control Functions . . . . . . . . . . . . . . . . . . . Operation and Functions of Control Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A94 1A98 1A102 1A102 1A103 1A105 1A107 1A111 1A111 1A115 1A118 1A121 1A124 1A126 1A129 1A132 1A135 1A135 1A135 1A135 1A135 1A135 1A135 1A136 1A136 1A136 1A136 1A136 1A136 1A137 1A137 1A137 1A137 1A137 1A137 1A138 1A138 1A138 1A138 1A138 1A138 1A139 1A139 1A139
1A3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Heating and Ventilation System

General Description
Heater
When the engine is warming up, the warmed engine coolant is sent out into the heater core. The heater system supplies warm air into the passenger compartment to warm it up. Outside air is circulated through the heater core of the heater unit and then back into the passenger compartment. By controlling the mixture of outside air and heater core air, the most comfortable passenger compartment temperature can be selected and maintained. The temperature of warm air sent to the passenger compartment is controlled by the temperature control knob. This knob acts to open and close the air mix door, thus controlling the amount of air passed through the heater core. The air selector knob, with its different modes, also allows you to select and maintain the most comfortable passenger compartment temperature. The air source select lever is used to select either FRESH for the introduction of the outside air, or RECIRC for the circulation of the inside air. When the lever is set to FRESH, the outside air is always taken into the passenger compartment. When setting the lever to RECIRC position, the circulation of air is restricted only to the inside air with no introduction of the outside air and the air in the passenger compartment gets warm quickly. However, the lever is normally set to FRESH to prevent the windshield from clouding.
1A4
640R200001
Legend (1) Side Defroster Hose (2) Vent Box (3) Upper Center Vent Box (4) Lower Center Vent Box (5) Blower Assembly (6) Control Lever Assembly (7) Evaporator Assembly
(8) (9) (10) (11) (12) (13) (14)
Duct Heater Unit Rear Heater Duct Lap Vent Nozzle Vent Box Side Defroster Hose Defroster Nozzle
1A5
Control Lever Assembly

The vehicle has cable-type-control to control the mode and temperature of the heater unit and the mode door for the air source of the blower assembly. The fan control is used to control the amount of air sent out by the resistor at four levels from LOW to HIGH.
865RW007
Legend (1) Air Source Select Lever (2) Air Select Knob
(3) Fan Control Knob (Fan Switch) (4) Air Conditioning (A/C) Switch (W/ A/C) (5) Temperature Control Knob
1A6
Ventilation
Set AIR SOURCE SELECT LEVER to FRESH position and turn on the blower fan. Heating can be done in this lever position, sending in fresh air from outside. The blower fan also serves to deliver fresh outside air to the vehicle interior to assure adequate ventilation.
C01RS001
1A7
Air Select Knob

The air select knob allows you to direct heated air into the passenger compartment through different outlets. 1. Vent In this position, air is discharged from the upper air outlet. Air quantity is controlled by the fan control knob. 2. Bi-Level In this position, air flow is divided between the upper air outlets and the floor air outlets, with warmer air delivered to the floor outlets than the air delivered to the upper air outlets. 3. Foot In this position, air flow is delivered to the foot while sending approx 30% op total amount air to the wind shield. 4. Def/Foot In this position, air flow is delivered to the foot, while sending approx. 40% of total amount of air to the windshield. Selecting this mode allows air conditioning system to work when the fan switch is turned to on position, even if the A/C switch is off. 5. Defrost In this position, most of the air is delivered to the windshield and a small amount is delivered to the side windows. Moving the air source select lever to the CIRC position provides quickest heat delivery by closing the blower assembly mode door. In this position, outside air is not delivered to the passenger compartment. Selecting this mode allows air conditioning system to work when the fan switch is turned to on position, even if the A/C switch is off.
C01RW001
Air Source Select Lever

The intake of outside air and the circulation of inside air are controlled by sliding this lever left or right.
Temperature Control Knob

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

This knob controls the blower motor speed to regulate the amount of air delivered to the defrost, foot, and ventilation ducts: 1. Low 2. Medium Low 3. Medium High 4. High
1A8
Wiring Diagram
D01R200019
1A9
Diagnosis
Heating Cycle diagnosis
Condition No heating or insufficient heating. Possible cause Blower motor does not run or runs improperly. Engine coolant temperature is low. Correction Refer to FAN CONTROL LEVER (FAN SWITCH) DIAGNOSIS. Check the engine coolant temperature after warming up the engine and check the thermostat. Replace as necessary. Add engine coolant as required. Check if the water hose to the heater core is clogged, collapsed or twisted. Repair or replace as necessary. Clean or replace as necessary. Repair the temperature control link unit or mode doors. Repair or replace as necessary. Repair Repair Repair. Adjust.
Insufficient engine coolant. Circulation volume of engine coolant is insufficient. Heater core clogged or collapsed. The heater cores is not provided with air sent from the blower motor. Duct connections unsealing. Control lever moves but mode door does not operate. The mode door cannot be set to the mode selected. defective or
Cable attaching clip is not correct. Link unit of heater assembly defective. or blower
Link unit of heater unit or blower assembly defective. Control cable is not adjusted.
1A10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Fan Control Lever (Fan Switch) Diagnosis

Current flows to the blower motor through the heater and the A/C relay (B-36) to activate the rotation of the blower motor by turning ON the fan control knob (fan switch). Blower motor speed is controlled in stages by the resistor, by operating the switch from LOW to HIGH. For the inspection of the relays, switches and units in each table, refer to INDIVIDUAL INSPECTION in this section.
D01R200020
Condition Blower motor does not run. Blower motor does not run in certain position (s). Blower motor does not stop at OFF position.
Possible cause
Correction Refer to Chart A Refer to Chart B, C, D and E Refer to Chart F
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A11
Chart A Blower Motor Dose Not Run

Step 1 2 3 4 5 6 Is relay (B-36) OK? Is fuse C-19 (25A) OK? Is resistor OK? Is fan control knob OK? Go to Step 5 Is blower motor OK? 1. Turn the ignition switch ON. 2. Turn fan control knob ON. 3. Check to see if battery voltage is present at chassis side connector terminal No. B5-1 Is there a battery voltage? Go to Step 6 Poor ground or open circuit either between chassis side connector terminal No. B5-2 and No. I41-2 or No. I18-1 and body ground (No. B-2). Action Yes Go to Step 2 Go to Step 3 Go to Step 4 No Replace Replace Replace Replace control lever assembly. Replace
Open circuit between No. C-19 (25A) fuse and No. B5-1.
Chart B Blower Motor Does Not Run At Low Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between chassis side connector terminal No. I41-1 and No.I18-2. No Replace
Replace control lever assembly.
Chart C Blower Motor Dose Not Run At Medium Low Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between the chassis side connector terminal No. I41-4 and No. I18-5. No Replace
Chart D Blower Motor Dose Not Run At Medium High Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between chassis side connector terminal No. I41-6 and No. I18-3. No Replace
Chart E Blower Motor Dose Not Run At High Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between Chassis side connector terminal No. I41-3 and No. I18-6. No Replace
Chart F Blower Motor Does Not Stop In The OFF Position

Step 1 Action Is the fan control knob (Fan Switch) OK? Yes Short circuit between chassis side connector terminal No. B5-2 and No. I41-2,No. I41 -3 and No. I18-6, No. I41-6 and No. I18-3, No. I41-4 and No. I18-5 or No. I41-1 and No. I18-2 No
Individual Inspection
Blower Motor
1. Disconnect the blower motor (B-5) connector from the blower motor. 2. Connect the battery positive terminal to the No. 1 terminal of the blower motor and the negative to the No. 2. 3. Be sure to check to see if the blower motor operates correctly.
Resistor
1. Disconnect the resistor (I-41) connector. 2. Check for continuity and resistance between the terminals of the resistor.
840R200011
873RS005

Fan switch position 1 2 3 4 Resistor terminals with continuity 12 24 26 23 Resistance 2.4 W 0.90 W 0.28 W
Heater & A/C Relay

1. Disconnect the heater and the A/C relay (B-36). D When removing the connector for relay, unfasten the tang lock of the connector by using a screwdriver, then pull the relay (1) out.
Fan Control Knob (Fan Switch)

1. Check for continuity between the terminals of the fan switch.
825RS001
2. Check for continuity between the heater and the A/C relay (B-36) terminals.
865RS001
Fan switch position OFF 1 2 3 4
Switch connector terminals with continuity No continuity 124 145 134 146
825RS002
Condition Normal When battery voltage is applied between 1 3
Relay terminals with continuity 1 3 (Approx 85105W) 24
Heater Unit
Heater Unit and Associated Parts
860RY00005
Legend (1) Instrument Panel Assembly (2) Instrument Panel Center Bracket (3) Resistor (4) Duct (5) Evaporator Assembly (A/C only) (6) Rear Heater Duct
(7) (8) (9) (10) (11) (12)
Heater Unit Assembly Center Ventilation Lower Duct Driver Lap Vent Nozzle Water Hose Electro Thermo Connector (With A/C) Resistor Connector
Removal
1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning) D Refer to Refrigerant Recovery in this section. 4. Remove the Instrument panel assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 5. Disconnect the water hoses at the heater unit. 6. Disconnect resistor connector. 7. Remove duct. 8. Remove evaporator assembly (A/C only). D Refer to Evaporator Assembly in this section. 9. Remove instrument panel center bracket. D Refer to Cross Beam Assembly in Body and Accessories section. 10. Remove rear heater duct. 11. Remove heater unit assembly. 12. Remove driver lap vent nozzle. 13. Remove center ventilation lower duct.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. When handling the PCM and the control unit, be careful not to make any improper connection of the connectors. 2. Adjust the control lever assembly cables. D Refer to Control Lever Assembly in this section. 3. When installing the heater unit, defroster nozzle and center vent duct, be sure that the proper seal is made, without any gap between them.
Heater Core and / or Mode Door

Disassembled View
860RS001
Legend (1) Case (Temperature Control) (2) Mode Door (3) Duct
(4) Heater Unit (5) Case (Mode Control) (6) Heater Core
Removal
1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with conditioning). D Refer to Refrigerant Recovery in this section. 4. Remove heater unit. D Refer to Heater Unit in this section. 5. Remove duct.
6. Remove case (Mode control) and do not remove link unit at this step.
air

7. Remove case (Temperature control). Separate two halves of core case. 9. Pull out the mode door while raising up the catch of the door lever.
860R200007
860RS004
8. Remove heater core (1).
Inspection
Check for foreign matter in the heater core, stains or core fin damage.
Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. Check that each mode door operates properly.
860R200006
Heater Mode Control Link Unit

Disassembled View
860RS005
Legend (1) Case (Mode Control) (2) Heater Unit (3) Mode Sub-lever
(4) (5) (6) (7)
Clip Door Lever Rod Washer and Mode Main Lever
Removal
1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning). D Refer to Refrigerant Recovery in this section. 4. Remove heater unit. D Refer to Heater Unit in this section. 5. Remove the case (Mode control) from heater unit. 6. Remove washer and the mode main lever. 7. Remove rod. 8. Press the tab of the sub-lever inward, and take out the sub-lever. 9. Pull out the door lever while raising up the catch of the door lever.
860RS006
10. Remove clip.
Installation
To install, follow the remove steps in the reverse order, noting the following points: 1. Apply grease to the mode sub-lever and to the abrasive surface of the heater unit.
2. After installing the link unit, check to see if the link unit operates correctly.
Heater Temperature Control Link Unit

Disassembled View
860RS007
Legend (1) Case (Temperature control) (2) Clip (3) Door Lever
(4) (5) (6) (7)
Clip Heater Unit Rod Sub-lever
Removal
1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning). D Refer to Refrigerant Recovery in this section. 4. Remove heater unit. D Refer to Heater Unit in this section. 5. Remove the case (Temperature control) from the heater unit. 6. Remove rod. 7. Remove sub-lever.
8. Pull out the door lever while raising up the catch of the door lever. 9. Remove clip.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Apply grease to the sub-lever and to the abrasive surface of the heater unit. 2. After installing the link unit, check to see if the link unit operates correctly.
Blower Assembly
Blower Assembly and Associated Parts
873RY00003
Legend (1) Electro Thermo Connector (2) Blower Motor Connector (3) Resistor Connector (4) Dash Side Trim Panel (RH)
(5) (6) (7) (8) (9)
Blower Assembly Duct Evaporator Assembly (A/C only) Heater Unit Instrument Panel Assembly
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with air conditioning). D Refer to Refrigerant Recovery in this section. 3. Remove instrument panel assembly. D Refer to Instrument Panel Assembly in Body and Accessories section.
4. Disconnect resistor connector. 5. Remove duct. 6. Remove evaporator assembly (A/C only). D Refer to Evaporator Assembly in this section. 7. Remove dash side trim panel (RH). 8. Disconnect blower motor connector. 9. Remove blower assembly.
Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. Adjust the control lever assembly cables. D Refer to Control Lever Assembly in this section.
Blower Link Unit and / or Mode door

Disassembled View
873RS001
Legend (1) Upper Case (2) Mode Door (3) Lower Case
(4) Sub Lever (5) Door Lever (6) Blower Assembly
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with conditioning). D Refer to Refrigerant Recovery in this section. 3. Remove blower assembly. D Refer to Blower Assembly in this section. air

4. Remove lower case. 5. Separate the upper case and slit the lining parting face with a knife.
873RS002
6. Pull out the mode door while lifting up the catch of door lever. 7. Remove sub-lever. 8. Remove door lever.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Apply grease to the door lever and to the abrasive surface of the upper case. 2. Apply an adhesive to the parting face of the lining when assembling the upper case.
Blower Motor
Blower Motor and Associated Parts
873R200006
Legend (1) Blower Motor Connector
(2) Blower Motor Assembly (3) Attaching Screw
Removal
1. Disconnect the battery ground cable. 2. Remove blower motor connector. 3. Remove attaching screw. 4. Remove blower motor assembly.
Installation
To install, follow the removal steps in the reverse order.
Rear Heater Duct, Defroster Nozzle and Ventilation Duct

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
874RS017
Legend (1) Center Defroster Nozzle (2) Side Defroster Nozzle (3) Side Ventilation Duct (4) Center Ventilation Upper Duct (5) Center Ventilation Lower Duct
(6) (7) (8) (9) (10)
Center Console Rear Heater Duct Driver Lap Duct Cross Beam Assembly Instrument Panel Assembly
Removal
1. Disconnect the battery ground cable. 2. Remove instrument panel assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 3. Remove center ventilation upper duct. 4. Remove side ventilation duct. 5. Remove center ventilation lower duct.
6. Remove driver lap duct. 7. Remove center console. 8. Remove rear heater duct. D Refer to Consoles in Body and Accessories section. 9. Remove cross beam assembly. D Refer to Cross Beam Assembly in Body and Accessories section.

10. Remove side defroster nozzle. 11. Remove center defroster nozzle.
Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching.
Center and / or Drive Side Vent

Center Vent, Drive Side Vent and Associated Parts
740RS003
Legend (1) Center Vent (2) Meter Cluster Assembly (3) Lower Cluster Assembly
(4) Front Console Assembly (5) Instrument Panel Driver Lower Cover Assembly (6) Side Vent
Removal
1. Disconnect the battery ground cable. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove instrument panel driver lower cover assembly. 5. Remove meter cluster assembly. D Refer to Instrument Panel Assembly in Body and Accessories section.
6. Remove screws and the center vent from center cluster while prying up the center vent catch portions. 7. Remove screws and the side vent from the center cluster while prying up the vent catch portions.
Installation
Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts
865RS011
Legend (1) Instrument Panel Passenger Lower Cover Assembly (2) Glove Box (3) Fan Switch and Air Conditioning Switch Connector (4) Temp Control Link Connection (5) Control Cable (6) Blower Assembly Connection
(7) (8) (9) (10) (11) (12)
Attaching Screws Control Lever Assembly Mode Control Link Connection Front Console Assembly Lower Cluster Assembly Instrument Panel Driver Lower Cover Assembly (13) Meter Cluster Assembly
Removal
1. Disconnect the battery ground cable. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove glove box.
5. Remove instrument panel passenger lower cover assembly. 6. Remove instrument panel driver lower cover assembly. 7. Remove meter cluster assembly. D Refer to Instrument Panel Assembly in Body and Accessories section.

8. Remove attaching screws. D Remove the four attaching screws.
865RS010
9. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors.
865RS009
10. Remove control lever assembly. 11. Remove control cable.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Adjust the control cable.
865RY00013
D Air source control cable. 1. Slide the control lever to the left (CIRC position). 2. Connect the control cable at the CIRC position of the link unit of the blower assembly and secure it with the clip. D Temperature control cable. 1. Turn the control knob to the left (MAX COLD position). 2. Connect the control cable at the COLD position of the temperature control link of the heater unit and secure it with the clip. D Air select control cable 1. Turn the control knob to the right (DEFROST position). 2. Connect the control cable at the DEFROST position of the mode control link of the heater unit and secure it with the clip. 2. Check the control cable operation.
Control Panel Illumination Bulb

Control Panel Illumination Bulb and Associated Parts
865RS007
Legend (1) Control Lever Assembly
(2) Bulb Socket (3) Illumination Bulb
Removal
1. Disconnect the battery ground cable. 2. Remove control lever assembly. D Refer to Control Lever Assembly in this section. 3. Pull out the bulb socket from the panel by turning it counterclockwise. 4. Pull the illumination bulb from the socket.
Installation
Resistor
Resistor and Associated Parts
874RW005
Legend (1) Glove Box (2) Duct (Heater only) (3) Resistor Connector (4) Resistor
(5) Front Console (6) Lower Cluster (7) Instrument Panel Passenger Lower Cover Assembly
Removal
1. Disconnect the battery ground cable. 2. Remove front console. 3. Remove lower cluster. 4. Remove glove box. 5. Remove instrument panel passenger lower cover assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 6. Remove resistor connector. 7. Remove duct (heater only). 8. Remove resistor.
Installation
Air Conditioning System

General Description
Air Conditioning Refrigerant Cycle Construction
C01RS003
Legend (1) Electronic Thermostat (2) Evaporator Core (3) Evaporator Assembly (4) Temperature Sensor (5) Expansion Valve (6) Blower Motor (7) Dual Pressure Switch (8) Receiver/Drier
(9) (10) (11) (12) (13) (14) (15) (16) (17)
Condenser Compressor Magnetic Clutch Mode (HEAT) Control Door Temp. Control Door (Air Mix Door) Heater Core Mode (VENT) Control Door Heater Unit Mode (DEF) Control Door

The refrigeration cycle includes the following four processes as the refrigerant changes repeatedly from liquid to gas and back to liquid while circulating.
Compressor
The compressor performs two main functions: It compresses low-pressure and low-temperature refrigerant vapor from the evaporator into high-pressure and high-temperature refrigerant vapor to the condenser. It pumps refrigerant and refrigerant oil through the air conditioning system. This vehicle is equipped with six-cylinder axle plate compressor (3). The specified amount of the compressor oil is 240cm3 (8.0 fl. oz.). The oil used in the HFC-134a system compressor differs from that used in R-12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction. The magnetic clutch connector is a waterproof type.
Evaporation
The refrigerant is changed from a liquid to a gas inside the evaporator. The refrigerant mist that enters the evaporator vaporizes readily. The liquid refrigerant removes the required quantity of heat (latent heat of vaporization) from the air around the evaporator core cooling fins and rapidly vaporizes. Removing the heat cools the air, which is then radiated from the fins and lowers the temperature of the air inside the vehicle. The refrigerant liquid sent from the expansion valve and the vaporized refrigerant gas are both present inside the evaporator as the liquid is converted to gas. With this change from liquid to gas, the pressure inside the evaporator must be kept low enough for vaporization to occur at a lower temperature. Because of that, the vaporized refrigerant is sucked into the compressor.
Compression
The refrigerant is compressed by the compressor until it is easily liquefied at normal temperature. The vaporized refrigerant in the evaporator is sucked into the compressor. This action maintains the refrigerant inside the evaporator at a low pressure so that it can easily vaporize, even at low temperatures close to 0C(32F). Also, the refrigerant sucked into the compressor is compressed inside the cylinder to increase the pressure and temperature to values such that the refrigerant can easily liquefy at normal ambient temperatures.
Magnetic Clutch
The compressor is driven by the drive belt from the crank pulley of the engine. If the compressor is activated each time the engine is started, this causes too much load to the engine. The magnetic clutch (1) transmits the power from the engine to the compressor and activates it when the air conditioning is ON. Also, it cuts off the power from the engine to the compressor when the air conditioning is OFF. Refer to Compressor in this section for magnetic clutch repair procedure.
Condensation
The refrigerant inside the condenser is cooled by the outside air and changes from gas to liquid. The high temperature, high pressure gas coming from the compressor is cooled and liquefied by the condenser with outside air and accumulated in the receiver/drier. The heat radiated to the outside air by the high temperature, high pressure gas in the compressor is called heat of condensation. This is the total quantity of heat (heat of vaporization) the refrigerant removes from the vehicle interior via the evaporator and the work (calculated as the quantity of heat) performed for compression.
Expansion
The expansion valve lowers the pressure of the refrigerant liquid so that it can easily vaporize. The process of lowering the pressure to encourage vaporization before the liquefied refrigerant is sent to the evaporator is called expansion. In addition, the expansion valve controls the flow rate of the refrigerant liquid while decreasing the pressure. That is, the quantity of refrigerant liquid vaporized inside the evaporator is determined by the quantity of heat which must be removed at a prescribed vaporization temperature. It is important that the quantity of refrigerant be controlled to exactly the right value.
871R200002
Condenser
Also, it functions to cool and liquefy the high-pressure and high-temperature vapor sent from the compressor by the radiator fan or outside air. A condenser may malfunction in two ways: it may leak, or it may be restricted. A condenser restriction will result in excessive compressor discharge pressure. If a partial restriction is present, the refrigerant expands after passing through the restriction. Thus, ice or frost may form immediately after the restriction. If air flow through the condenser or radiator is

blocked, high discharge pressures will result. During normal condenser operation, the refrigerant outlet line will be slightly cooler than the inlet line. The vehicle is equipped with the parallel flow type condenser. A larger thermal transmission area on the inner surface of the tube allows the radiant heat to increase and the ventilation resistance to decrease. The refrigerant line connection has a bolt at the block joint, for easy servicing. The condenser assembly (3) is located in front of the radiator. It provides rapid heat transfer from the refrigerant to the cooling fins.
875R200025
Triple Pressure Switch

Triple pressure switch is installed on the upper part of the receiver/drier. This switch is constructed with a unitized type of two switches. One of them is a low and high pressure switch (Dual pressure switch) to switch ON or OFF the magnetic clutch as a result of irregularly highpressure or low pressure of the refrigerant. The other one is a medium pressure switch (Cycling switch) to switch ON or OFF the condenser fan sensing the condenser high side pressure.
875R200025
Receiver / Drier
The receiver/drier (2) performs four functions: D As the quantity of refrigerant circulated varies depending on the refrigeration cycle conditions, sufficient refrigerant is stored for the refrigeration cycle to operate smoothly in accordance with fluctuations in the quantity circulated. D The liquefied refrigerant from the condenser is mixed with refrigerant gas containing air bubbles. If refrigerant containing air bubbles. Is sent to the expansion valve, the cooling capacity will decrease considerably. Therefore, the liquid and air bubbles are separated and only the liquid is sent to the expansion valve. D The receiver/drier utilizes a filter and drier to remove the dirt and water mixed in the cycling refrigerant. D The sight glass, installed on top of the receiver/drier, shows the state of the refrigerant. A receiver/drier may fail due to a restriction inside the body of the unit. A restriction at the inlet to the receiver/drier will cause high pressure. Outlet restrictions will be indicated by low pressure and little or no cooling. An excessively cold receiver/drier outlet may indicate a restriction. The receiver/drier of this vehicle is made of aluminum with a smaller tank. It has a 300cc refrigerant capacity. The refrigerant line connection has a bolt at the block joint, for easy servicing.
Compressor Low-pressure control High-pressure control
ON (kPa/psi) 206.030.0 (29.84.3) 2353.6196.1 (341.328.4) ON (kPa/psi) 1471.098.1 (213.314.2)
OFF (kPa/psi) 176.524.5 (25.63.6) 2942.0196.1 (426.628.4) OFF (kPa/psi) 1078.7117.7 (156.417.1)
Condenser fan Medium-pressure control
875R200025
874RY00003
Expansion Valve
This expansion valve (1) is an internal pressure type and it is installed at the evaporator intake port. The expansion valve converts the high pressure liquid refrigerant sent from the receiver/drier to a low pressure liquid refrigerant by forcing it through a tiny port before sending it to the evaporator (2). This type of expansion valve consists of a temperature sensor, diaphragm, ball valve, ball seat, spring adjustment screw, etc. The temperature sensor contacts the evaporator outlet pipe, and converts changes in temperature to pressure. It then transmits these to the top chamber of the diaphragm. The refrigerant pressure is transmitted to the diaphragms bottom chamber through the external equalizing pressure tube. The ball valve is connected to the diaphragm. The opening angle of the expansion valve is determined by the force acting on the diaphragm and the spring pressure. The expansion valve regulates the flow rate of the refrigerant. Accordingly, when a malfunction occurs to this expansion valve, both discharge and suction pressure get low, resulting in insufficient cooling capacity of the evaporator. The calibration has been changed to match the characteristics of HFC-134a.
Evaporator
The evaporator cools and dehumidifies the air before the air enters the passenger compartment. High-pressure liquid refrigerant flows through the expansion valve (2) into the low-pressure area of the evaporator. The heat in the air passing through the evaporator core (1) is lost to the cooler surface of the core, thereby cooling the air. As heat is lost between the air and the evaporator core surface, moisture in the vehicle condenses on the outside surface of the evaporator core and is drained off as water. When the evaporator malfunctions, the trouble will show up as an inadequate supply of cool air. The cause is typically a partially plugged core due to dirt, or a malfunctioning blower motor. The evaporator core with a laminate louver fin is a single-sided tank type where only one tank is provided under the core.
874RY00007
Electronic Thermostat
The thermostat consists of the thermo sensor (1) and thermostat unit (4) which functions electrically to reduce the noises being generated while the system is in operation. The electronic thermo sensor (1) is mounted at the evaporator core (2) outlet and senses the temperature of the cool air from the evaporator (3). Temperature signals are input to the thermostat unit. This information is compared by the thermo unit and results in the output to operate the A/C thermostat relay and turn the magnetic clutch ON or OFF to prevent evaporator freeze-up. A characteristic of the sensor is that the resistance decreases as the temperature increases and the resistance increases as the temperature decreases.
Refrigerant Line
Restriction in the refrigerant line will be indicated by: 1. Suction line A restricted suction line will cause low suction pressure at the compressor, low discharge pressure and little or no cooling. 2. Discharge line A restriction in the discharge line generally will cause the discharge line to leak. 3. Liquid line A liquid line restriction will be evidenced by low discharge and suction pressure and insufficient cooling. Refrigerant flexible hoses that have a low permeability to refrigerant and moisture are used. These low permeability hoses have a special nylon layer on the inside.
852RW011
Legend (1) Pressure Resistance Layer (Polyester Braid) (2) Moisture Resistance AND Outer Protector Layer (3) Heat Resistance Layer (4) Heat Resistance Core Layer (Neoprene) (5) Low Permeation Layer (Nylon Barner)
874RX022
Air Conditioning Parts
852R200014
Legend (1) Liquid Line (High-Pressure Pipe) (2) O-ring (3) Discharge Line (High-Pressure Hose) (4) Pressure Switch (5) Receiver Drier (6) Condenser Assembly
(7) (8) (9) (10) (11) (12) (13)
Drive Belt Relay Compressor Drain Hose Suction Line (Low-Pressure Hose) Evaporator Assembly A/C Switch
Wiring Diagram
D01R200017
D01R200018
Diagnosis
Air Conditioning Cycle Diagnosis
Condition No cooling or insufficient cooling. Possible cause Magnetic clutch does not run. Compressor is not rotating properly. Drive belt is loose or broken. Compressor is not rotating properly. Magnetic clutch face is not clean and slips. Compressor is not rotating properly. Incorrect clearance between magnetic drive plate and pulley. Compressor is not rotating properly. Compressor oil leaks from the shaft seal or shell. Compressor is not rotating properly. Compressor is seized. Insufficient or excessive charge of refrigerant. Leaks in the refrigerant system. Correction Refer to Magnetic Clutch Diagnosis in this section. Adjust the drive belt to the specified tension or replace the drive belt. Clean the magnetic clutch face or replace. Adjust the clearance. Refer to Compressor in this section. Replace the compressor
Replace the compressor Discharge and recover the refrigerant. Recharge to the specified amount. Check the refrigerant system for leaks and repair as necessary. Discharge and recover the refrigerant. Recharge to the specified amount. Clean the condenser or replace as necessary. Repair the link unit. Replace the expansion valve. Check the electronic thermostat and replace as necessary. Check the evaporator core and replace or clean the core. Check the evaporator and duct connection, then repair as necessary. Refer to Fan Control Knob (Fan Switch) Diagnosis in this section.
Condenser is clogged or insufficient radiation. Temperature control link unit of the heat unit is defective. Unsteady operation due to a foreign substance in the expansion valve. Poor operation of the electronic thermostat. Insufficient velocity of cooling air. Evaporator clogged or frosted. Air leaking from the cooling unit or air duct. Blower motor properly. *For the execution of the charging and discharging operation in the table above, refer to Recovery, Recycling, Evacuating and Charging in this section. does not rotate
Checking The Refrigerant System With Manifold Gauge

Since Refrigerant-134a (HFC-134a) is used in the air conditioning system in this vehicle, be sure to use manifold gauges, charging hoses and other air conditioning service tools for HFC-134a when checking the refrigerant system. Conditions: D D D D D D D Run the engine at idling Air conditioning switch is ON Run the blower motor at HIGH position Temperature control lever set to MAX COLD Air source selector lever at CIRC Open the engine hood Close all the doors
Normal Pressure: D At ambient temperature: approx. 2530C (7786F). D At low-pressure side: approx. 147.1294.2 kPa (21.342.7 psi). D At high-pressure side: approx. 1372.91863.3 kPa (199.1270.2 psi). Refer to the table on the refrigerant pressure-temperature relationship in this section. HFC-134a Pressure-Temperature Relationship Pressure (kPa) 36 67 104 147 196 255 314 392 471 569 677 785 912 1059 1216 (psi) 5.3 9.7 15 21 28 37 45 57 68 82 98 114 132 154 176 Temperature (C) 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 (F) 4.4 5 14 23 32 41 50 59 68 77 86 95 104 113 122

Connect The Manifold Gauge Low-pressure hose (LOW) Suction side High pressure hose (HI) Discharge side
901RS137
Legend (1) Low Side (2) High Side
Condition Discharge (High Gauge) Pressure Abnormally High Discharge (High Gauge) Pressure Abnormally High. Insufficient cooling. Discharge (High Gauge) Pressure Abnormally High. High pressure gauge drop. (After stopping A/C, the pressure drops approx. 196 kPa (28 psi) quickly) Discharge (High Gauge) Pressure Abnormally Low. Insufficient cooling Discharge (High Gauge) Pressure Abnormally Low. Low pressure gauge indicates vacuum.
Possible cause Condenser clogged or dirty. Cooling fan properly. does not operate
Correction Clean the condenser fins Check the cooling fan operation. Discharge and recover refrigerant. Recharge to specified amount. Evacuate and charge refrigerant system.
Excessive refrigerant in system.
Air in system.
Insufficient refrigerant in system.
Check for leaks. Discharge and recover the refrigerant. Recharge to the specified amount. Replace the expansion valve.
Clogged or defective expansion valve.

Condition Discharge (High Gauge) Pressure Abnormally Low. Frost or dew on refrigerant line before and after the receiver/drier or expansion valve, and low pressure gauge indicates vacuum. Discharge (High Gauge) Pressure Abnormally Low. High and low pressure gauge balanced quickly. (After turned off A/C) Suction (Low Gauge) Pressure Abnormally High. Low pressure gauge (Low pressure gauge is lowered after condenser is cooled by water.) Suction (Low Gauge) Pressure Abnormally High. Low pressure hose temperature. (Low pressure hose temperature around the compressor refrigerant line connector is lower than around evaporator.) Suction (Low Gauge) Pressure Abnormally High. High and low pressure gauge balanced quickly. (After turned off A/C) Suction (Low Gauge) Abnormally Low. Insufficient cooling. Pressure Possible cause Restriction caused by debris or moisture in the receiver/drier. Correction Check system for restriction and replace the receiver/drier.
Compressor seal defective Poor compression due to a defective compressor gasket. Excessive refrigerant in system.
Repair or replace the compressor. Repair or replace the compressor.
Discharge and recover refrigerant Recharge to specified amount.
Unsatisfactory valve operation due to defective temperature sensor of expansion valve. Expansion valve opens too long. Compressor gasket is defective.
Replace the expansion valve.
Replace the expansion valve. Repair or replace the compressor.
Check for leaks. Discharge and recover the refrigerant. Recharge to specified amount. Replace the expansion valve.
Suction (Low Gauge) Pressure Abnormally Low. Frost on the expansion valve inlet line Suction (Low Gauge) Pressure Abnormally Low Receiver/drier inlet and outlet refrigerant line temperature. (A distinct difference in temperature develops.) Suction (Low Gauge) Pressure Abnormally Low. Expansion valve outlet refrigerant line. (Not cold and low pressure gauge indicates vacuum.) Suction (Low Gauge) Pressure Abnormally Low. When the refrigerant line is clogged or blocked, the low pressure gauge reading will decrease, or a vacuum reading may be shown. Suction (Low Gauge) Pressure Abnormally Low. Evaporator core is frozen.
Expansion valve clogged.
Receiver/Drier clogged.
Replace the receiver/drier.
Expansion valve temperature sensor is defective.
Replace the expansion valve.
Clogged or blocked refrigerant line.
Replace refrigerant line.
Thermo switch defective.
Replace thermo switch.

Condition Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Insufficient cooling. Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Suction (Low) pressure hose (Not cold). Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally Low. Insufficient cooling A/C Air Conditioning Possible cause Excessive refrigerant in system. Correction Discharge and recover the refrigerant, the Recharge to the specified amount. Clean the condenser fins. Evacuate and charge refrigerant.
Condenser clogged or dirty. Air in system.
Check for leaks. Discharge and recover refrigerant. Recharge to specified amount.
Magnetic Clutch Diagnosis
D08R200260
When the air conditioning switch and the fan control knob (fan switch) are turned on with the engine running, current
flows through the thermostat and the compressor relay to activate the magnetic clutch.

The air conditioning can be stopped by turning off the air conditioning switch or the fan control knob (fan switch). However, even when the air conditioning is in operation, the electronic thermostat, the pressure switch or the Powertrain Control Module (PCM) is used to stop the air conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to reduce the engine load which is being caused by the rise in the engine coolant temperature, and the acceleration of the vehicle, etc. For the inspection of the relays, switches and units in the table, refer to Individual Inspection in this section.
Magnetic Clutch Does Not Run

Step 1 2 3 Action Are No. C-20 (10A) fuse and No. C-19 (25A) fuse OK? Are heater and A/C (B-36), thermostat (X-5), and compressor (X-7) relays OK? Is pressure switch (triple pressure switch) OK? Go to Step 4 4 5 Are air conditioning switch and fan control knob (Fan Switch) OK? 1. Turn the ignition switch ON (Engine is running). 2. Air conditioning switch and fan control knob (Fan Switch) ON. 3. Check to see if battery voltage is present at chassis side connector terminal No. E3-1. Is there a battery voltage? 6 Check to see if continuity between compressor side connector terminal No. E3-1 and the magnetic clutch side connector terminal. Is there a continuity? 7 Check to see if battery voltage is present at chassis side connector terminal No. C89-2 Is there a battery voltage? 8 1. Disconnect thermostat relay (X-5). 2. Check to see if battery voltage is present at the chassis side relay terminal NO. X5-2 Is there a battery voltage? 9 Check to see if voltage (approx. 10V) is present between chassis side relay terminal No. X5-1 and No. X5-3. Is there a battery voltage? 10 1. Reconnect thermostat relay and disconnect compressor relay (X-7). 2. Check to see if battery voltage is present at the chassis side relay terminal No. X7-2. Is there a battery voltage? 11 Check to see if continuity between chassis side relay terminal No. X7-4 and the chassis side connector terminal No. E3-1. Is there a continuity? 12 Check to see if battery voltage is present between chassis side relay terminal No. X7-1 and No. X7-3. Is there a battery voltage? 13 Check to see if battery voltage is present at chassis side relay terminal No. X7-1. Is there a battery voltage? Go to Step 15 Go to Step 13 Go to Step 14 Open circuit between No. C-20 (10A) fuse and No. X7-1. Go to Step 12 Open circuit. Go to Step 11 Go to Step 10 Go to Step 16 Open circuit between No. X5-4 and No. X7-2. Go to Step 9 Go to Step 8 Go to Step 6 Go to Step 7 Go to Step 5 Yes Go to Step 2 Go to Step 3 No Replace Replace Switch defective or insufficient refrigerant. Replace
Magnetic clutch defective.
Compressor defective. Open circuit between No.C-20 (10A) fuse and No. C89-2. Open circuit between No. C89-1 and No.X5-2.
Magnetic Clutch Does Not Run (Contd)

Step 14 Action Check to see if battery voltage is present at chassis side connector terminal No. E21-F4. Is there a battery voltage? Yes Power train control module (PCM) defective. Refer to Driveability and Emissions in Engine section. Power train control module (PCM) defective. Refer to Driveability and Emissions in Engine section. No
Open circuit between No. X7-3 and No. E21-F4.
15
Check to see if continuity between chassis side relay terminal No. X5-4 and chassis side connector terminal No. E21-F45. Is there a continuity?
Open circuit
16
Check to see if battery voltage is present at chassis side relay terminal No. X5-1. Is there a battery voltage? Go to Step 17 Go to Step 20 Open circuit between No.I23-6 and No.B4-3. Open circuit between No. X5-3 and No. B4-1. Open circuit between No. B4-2 and No. I18-4 or poor ground (Fan Switch Ground Circuit). Open circuit between No. C-20 (10A) fuse and No.I23-2. 1. Reconnect thermostat relay. 2. Check to see if battery voltage is present at chassis side connector terminal No. B4-3. Is there a battery voltage? Go to Step 18 Check to see if battery voltage (appox 10V) is present at chassis side connector terminal No. B4-1. Is there a battery voltage? Go to Step 19
17
18
19
Check to see if continuity between chassis side connector terminal No. B4-2 and No. I18-4. Is there a continuity? Electronic thermostat defective.
20
Check to see if battery voltage is present at chassis side connector terminal No. I23-2. Is there a battery voltage?
Open circuit between X5-1 and No.I23-6.
Fan Control Knob (Fan Switch) And Air Conditioning (A/C) Switch
1. Check for continuity between the fan switch and the A/C switch side connector terminals.
Heater And A/C (B-36), Thermostat (X-5) And Compressor (X-7) Relay
1. Disconnect relays and check for continuity and resistance between relay terminals. D For handling of these relays, refer to Heater &A/C Relay in this section.
865RS002
825RS003
Fan swtich position OFF 1 2 3 4 A/C switch position OFF ON
Fan switch connector terminals with continuity No continuity 124 145 134 146 A/C switch connector terminals with continuity 16 126
Condition Normal When battery voltage is applied between 1 3
Relay terminals with continuity 1 3 (Approx 85105W) 24
Pressure Switch
1. Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2). 2. Reconnect the connector to active the A/C switch, and check to see if there is continuity between the chassis side connector terminal (3) and (4) and the fan operates.
D When disconnecting or reconnecting the lines, use two wrenches to support the line fitting, to prevent from twisting or other damage. D Always install new O-rings whenever a connection is disassembled. D Before connecting any hoses or lines, apply new specified compressor oil to the O-rings. D When removing and replacing any parts which require discharging the refrigerant circuit, the operations described in this section must be performed in the following sequence: 1. Use the J-39500 (ACR4: HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent to thoroughly discharge and recover the refrigerant. 2. Remove and replace the defective part. 3. After evacuation, charge the air conditioning system and check for leaks.
Repair Of Refrigerant Leaks

Refrigerant Line Connections Install new O-rings, if required. When disconnecting or connecting lines, use two wrenches to prevent the connecting portion from twisting or becoming damaged.
875R200033
General Repair Procedure

Precautions For Replacement or Repair of Air Conditioning Parts
There are certain procedures, practices and precautions that should be followed when servicing air conditioning systems: D Keep your work area clean. D Always wear safety goggles and protective gloves when working on refrigerant systems. D Beware of the danger of carbon monoxide fumes caused by running the engine. D Beware of discharged refrigerant in enclosed or improperly ventilated garages. D Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system. D When discharging and recovering the refrigerant, do not allow refrigerant to discharge too fast; it will draw compressor oil out of the system. D Keep moisture and contaminants out of the system. When disconnecting or removing any lines or parts, use plugs or caps to close the fittings immediately. Never remove the caps or plugs until the lines or parts are reconnected or installed.
852RS003
When connecting the refrigerant line at a block joint, securely insert the projecting portion of the joint portion into the connecting hole on the unit side and secure with a bolt. Apply the specified compressor oil to the O-rings prior to connecting.
Condenser Fan
1. Disconnect the condenser fan connector. 2. Connect the battery positive terminal to the condenser fan side connector terminal No.C-75-1 and negative to the No.C-75-2.

3. Check that condenser fan is rotating correctly. O-rings (2) must be closely aligned with the raised portion (1) of refrigerant line.
875R200026
CAUTION: Compressor (PAG) oil to be used varies according to the compressor model. Be sure to apply oil specified for the model of compressor.
850RW003
Insert the nut into the union. First, tighten the nut by hand as much as possible, then tighten the nut to the specified torque.
850RW002 850RW004
Leak Check
Inspection of refrigerant leak Refrigerant leak may cause an adverse effect not only on the performance and durability of each component of the air-conditioner, but also on the global atmosphere. Therefore, it is most important to repair refrigerant leak when there is any leak found.
Inspection flow of refrigerant leak

Step 1 Action 1. Evacuate the refrigerant system. 2. Charge the refrigerant. Is there any refrigerant leak? 2 1. Operate the compressor for more than 5 minutes to raise the pressure on the high pressure side. Is there any refrigerant leak at high pressure components? Inspection steps Check the components of the air conditioner to see if there occurs any refrigerant leak along the flow of refrigerant. NOTE: D To avoid an error in the detection of refrigerant leak, make sure there is no refrigerant vapor or cigarette smoke around the vehicle before conducting the inspection. Also, select a location where the refrigerant vapor will not be blown off by wind. D Inspection should be conducted chiefly on the pipe connections and sections where a marked oil contamination is found. When refrigerant is leaking, oil inside is also leaking at the same time. D It is not possible to visually check the leak from inside the cooling unit. Follow the method below when checking. Remove the drain hose or resistor of the cooling unit, and insert a leak detector to see if there occurs any leak. High pressure side 1. Discharger section of compressor 2. Inlet/outlet section of condenser 3. Inlet/outlet section of receiver driver 4. Inlet section of cooling unit Low pressure side 1. Outlet section of cooling unit 2. Intake section of compressor Major checking points of refrigerant leak Compressor D Pipe connection D Sealing section of shaft Yes Repair refrigerant system Repair refrigerant system No
Go To Step 2 Compressor operation to be confirmed
D Mating section of cylinder Condenser D Pipe connection D Welds of condenser body Receiver drier D Pipe connection D Attaching section of pressure switch D Section around the sight glass Evaporator unit (cooling unit) D Pipe connection D Connections of expansion valve D Brazed sections of evaporator NOTE: D The evaporator and expansion valve are contained in the case. Remove the drain hose or the resistor of the cooling unit and insert a leak detector when checking for any leak. Flexible hose D Pipe connection D Caulking section of the hose D Hose (cracks, pinholes, flaws) Pipe D Pipe connection D Pipe (cracks, flaws) Charge Valve NOTE: D The charge valve, which is used to connect the gauge manifold, is normally provided with a resin cap. When the valve inside gets deteriorated, refrigerant will leak out.
Leak at Refrigerant Line Connections

1. Check the torque on the refrigerant line fitting and, if too loose, tighten to the specified torque. D Use two wrenches to prevent twisting and damage to the line. D Do not over tighten. 2. Perform a leak test on the refrigerant line fitting. 3. If the leak is still present, discharge and recover the refrigerant from the system. 4. Replace the O-rings. D O-rings cannot be reused. Always replace with new ones. D Be sure to apply the specified compressor oil to the new O-rings. 5. Retighten the refrigerant line fitting to the specified torque. D Use two wrenches to prevent twisting and damage to the line. 6. Evacuate, charge and retest the system.
D HFC-134a and R-12 should never be mixed as their compositions are not the same. D HFC-134a PAG oil tends to absorb moisture more quickly than R-12 mineral oil and, therefore, should be handled more carefully. D Keep HFC-134a containers stored below 40C (100F). WARNING: D SHOULD HFC-134A CONTACT YOUR EYE(S), CONSULT A DOCTOR IMMEDIATELY. D DO NOT RUB THE AFFECTED EYE(S). INSTEAD, SPLASH QUANTITIES OF FRESH COLD WATER OVER THE AFFECTED AREA TO GRADUALLY RAISE THE TEMPERATURE OF THE REFRIGERANT ABOVE THE FREEZING POINT. D OBTAIN PROPER MEDICAL TREATMENT AS SOON AS POSSIBLE. SHOULD THE HFC-134A TOUCH THE SKIN, THE INJURY MUST BE TREATED THE SAME AS SKIN WHICH HAS BEEN FROSTBITTEN OR FROZEN.
Leaks In The Hose

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

Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury. D Always wear safety goggles and protective gloves. D Always work in a well-ventilated area. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components. D If HFC-134a should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical help. D If it is necessary to transport or carry any container of HFC-134a in a vehicle, do not carry it in the passenger compartment. D If it is necessary to fill a small HFC-134a container from a large one,never fill the container completely. Space should always be allowed above the liquid for expansion.
Refrigerant Recovery
The refrigerant must be discharged and recovered by using the J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent before removing or mounting air conditioning parts. 1. Connect the high and low charging hoses of the ACR4(or equivalent) as shown below.
Evacuation of The Refrigerant System
901RS142
Legend (1) Low Side (2) High Side NOTE: Explained below is a method using a vacuum pump. Refer to the ACR4(or equivalent) manufacturer s instructions when evacuating the system with a ACR4(or equivalent). Air and moisture in the refrigerant will cause problems in the air conditioning system. Therefore, before charging the refrigerant, be sure to evacuate air and moisture thoroughly from the system. 1. Connect the gauge manifold. D High-pressure valve (HI) Discharge-side.
901RS141
D Low-pressure valve (LOW) Suction-side. 2. Discharge and recover the refrigerant. 3. Connect the center hose of the gauge manifold set to the vacuum pump inlet. 4. Operate the vacuum pump, open shutoff valve and then open both hand valves. 5. When the low-pressure gauge indicates approximately 750 mmHg (30 inHg), continue the evacuation for 5 minutes or more. 6. Close both hand valves and stop the vacuum pump. 7. Check to ensure that the pressure does not change after 10 minutes or more. D If the pressure changes, check the system for leaks. D If leaks occur, retighten the refrigerant line connections and repeat the evacuation steps. 8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the gauge manifold pressure is at 750 mmHg (30 inHg), close both hand valves. 9. Close positive shutoff valve. Stop the vacuum pump and disconnect the center hose from the vacuum pump.
Legend (1) Low Side (2) High Side 2. Recover the refrigerant by following the Manufacturer s Instructions. 3. When a part is removed, put a cap or a plug on the connecting portion so that dust, dirt or moisture cannot get into it.
Refrigerant Recycling
Recycle the refrigerant recovered by J-39500 (ACR4:HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent. For the details of the actual operation, follow the steps in the ACR4(or equivalent) Manufacturer s Instructions.
Charging The Refrigerant System

There are various methods of charging refrigerant into the air conditioning system. These include using J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent and direct charging with a weight scale charging station. Charging Procedure D ACR4(or equivalent) Method For the charging of refrigerant recovered by ACR4(or equivalent), follow the manufacturer s instruction.
D Direct charging with a weight scale charging station method 1. Make sure the evacuation process is correctly completed. 2. Connect the center hose of the manifold gauge to the weight scale. 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle. 4. Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle.
901RS141 901RS143
Legend (1) Low Side (2) High Side
Legend (1) Low Side (2) High Side (3) Refrigerant Container (4) Weight Scale

5. Place the refrigerant container(3) up right on a weight scale(4). Note the total weight before charging the refrigerant. a. Open the refrigerant container valve. b. Open the low side vale on the manifold gauge set. Refer to the manufacturer s instructions for a weight scale charging station. 8. When finished with the refrigerant charging, close the low pressure valve of the manifold gauge and container valve. 9. Check for refrigerant leaks.
Checking The A/C System

1. Run the engine and close all the vehicle doors. 2. Turn A/C switch ON, set the fan switch to its highest position. 3. Set the air source lever to CIRC, set the temperature lever to the full cool position. 4. Check the high and low pressure of the manifold gauge. D Immediately after charging refrigerant, both high and low pressures might be slightly high, but they settle down to the pressure guidelines shown below: D The ambient temperature should be between 2530C (7786F). D The pressure guideline for the high-pressure side is approximately 1372.91863.3 kPa (199.1270.2 psi). D The pressure guideline for the low-pressure side is approximately 147.1294.2 kPa (21.342.7 psi). D If an abnormal pressure is found, refer to Checking The Refrigerant System With Manifold Gauge in this section. 5. Put your hand in front of the air outlet and move the temperature control lever of the control panel to different positions. Check if the outlet temperature changes as selected by the control knob. Reading Sight Glass The sight glass provides accurate diagnosis only under the following conditions. If the vehicle can be tested under these conditions, check the sight glass appearance and compare to the chart below. D Engine speed idle D A/C switch ON D Blower fan operating at highest speed D Air source selector lever at RECIRC D Temperature control lever at coldest position D Ambient temperature below 30C (86F) and humidity below 70% (See NOTE 1) D High side pressure less than 1667.1 kPa (241.7 psi) (See NOTE 2) NOTE: 1. If the vehicle cannot be moved to a testing location that meets these specifications, then the sight glass cannot be used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue checking the system performance. NOTE: 2. If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue checking system performance.
901RS144
6. Perform a system leak test: D Charge the system with approximately 200 g (0.44 lbs) of HFC-134a. D Make sure the high pressure valve of the manifold gauge is closed. D Check to ensure that the degree of pressure does not change. D Check for refrigerant leaks by using a HFC-134a leak detector. D If a leak occurs, recover the refrigerant. Repair the leak and start all over again from the first step of evacuation. 7. If no leaks are found, continue charging refrigerant to the air conditioning system. D Charge the refrigerant until the scale reading decreases by the amount of the charge specified. Specified amount: 800 g (1.76 lbs) D If charging the system becomes difficult: 1. Run the engine at idle and close all the vehicle doors. 2. Turn A/C switch ON. 3. Set the fan switch to its highest position. 4. Set the air source selector lever to CIRC. 5. Slowly open the low side valve on the manifold gauge set. WARNING: BE ABSOLUTELY SURE NOT TO OPEN THE HIGH PRESSURE VALVE OF THE MANIFOLD GAUGE. SHOULD THE HIGH PRESSURE VALVE BE OPENED, THE HIGH PRESSURE REFRIGERANT WOULD FLOW BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT CONTAINER TO BURST.

High and low pressure pipe temperature The high pressure pipe is hot and the low pressure pipe is cold. There is a distinct difference in temperature between them. Almost transparent. A flow of bubbles can be seen, but they disappear when the throttle is opened. The high pressure pipe is warm and the low pressure pipe is cool. There is no great difference in temperature between them. A flow of bubbles always can be seen. It appears sometimes transparent, and sometimes frothy. There is litttle difference in temperature between the high pressure pipe and the low pressure pipe. Something like fog faintly can be seen. The high pressure pipe is hot and the low pressure pipe is slightly warm. There is a defference in temperature between them. Even at idle with the fan at HI” (with the window fully open), the bubbles cannnot be seen.
Slight glass condition
Air conditioning cycle condition
OK
NG (Not enough refrigerant)
NG (Almost no refrigerant)
NG (Too much refrigerant)
Compressor Assembly
Compressor Assembly and Associated Parts (6VE1)
852R200013
Legend (1) Compressor Bracket (2) Magnetic Clutch Harness Connector (3) Compressor (4) O-ring
(5) (6) (7) (8) (9)
To Evaporator Suction Line (Low-Pressure Hose) Discharge Line (High-Pressure Hose) To Condenser Serpentine Belt
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant D Refer to Refrigerant Recovery in this section. 3. Disconnect magnetic clutch harness connector.

4. Remove serpentine belt. D Move serpentine belt tensioner to loose side using wrench then remove serpentine belt. 4. Connect magnetic clutch harness connector.
New Compressor Installation

The new compressor is filled with 150cm3 (5.0fl.oz.)of compressor oil and nitrogen gas. When mounting the compressor on the vehicle, perform the following steps; 1. Gently release nitrogen gas from the new compressor. D Take care not to let the compressor oil flow out. D Inspect O-rings and replace if necessary.
850R200001
Legend (1) Auto Tensioner (2) Idle Pulley (3) Cooling Fan Pulley (4) Serpentine Belt (5) Power Steering Oil Pump (6) Air Conditioner Compressor (7) Crankshaft Pulley (8) Generator 5. Disconnect refrigerant line connector. D When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 6. Remove compressor.
871R200003
2. Turn the compressor several times by hand and release the compressor oil in the rotor. 3. When installing on a new system, the compressor should installed as it is. When installing on a used system, the compressor should be installed after adjusting the amount of compressor oil. (Refer to Compressor in this section)
Installation
1. Install compressor. D Tighten the compressor fixing bolts to the specified torque. Torque: 19 Nm (14 lbft) 2. Connect refrigerant line connector. D Tighten the refrigerant line connector fixing bolts to the specified torque. Torque: 15 Nm (11 lbft) D O-rings cannot be reused. Always replace with new ones. D Be sure to apply new compressor oil to the O-rings when connecting refrigerant lines. 3. Install serpentine belt. D Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position.
871R200004
Condenser Assembly
Condenser Assembly and Associated Parts
875R200027
Legend (1) Refrigerant Line (2) Pressure Switch Connector (3) Front Bumper Assembly
(4) Radiator Grille (5) Engine Hood Front End Stay (6) Condenser Assembly
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Remove front bumper assembly. D Refer to Bumpers in Body and Accessories section. 5. Remove engine hood front end stay. 6. Disconnect pressure switch connector. 7. Disconnect refrigerant line. D When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 8. Remove condenser assembly. D Handle with care to prevent damaging the condenser or radiator fin.
Installation
1. Install condenser assembly. D If installing a new condenser, be sure to add 30cm3 (1.0 fl. oz.) of new compressor oil to a new one. D Tighten the condenser fixing bolts to the specified torque. Torque: 6 Nm (52 lbin) 2. Connect refrigerant line. D Tighten the inlet line connector fixing bolt to the specified torque. Torque: 15 Nm (11 lbft) D Tighten the outlet line connector fixing bolt to the specified torque. Torque: 6 Nm (52 lbin) D O-rings cannot be reused. Always replace with new ones.

D Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line. 3. Connect pressure switch connector. 4. Install engine hood front end stay. 5. Install front bumper assembly. 6. Install radiator grille.
Receiver / Drier
Receiver / Drier and Associated Parts
875R200034
Legend (1) Pressure Switch Connector (2) Refrigerant Line
(3) Radiator Grille (4) Receiver / Drier
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect refrigerant line. D When removing the line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 6. Remove receiver/drier. D Loosen the bolt, then, using care not to touch or bend the refrigerant line, carefully pull out the receiver/drier.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. If installing a new receiver/drier, be sure to add 30cm3 (1.0 fl. oz.) of new compressor oil to a new one. 2. Put the receiver/drier in the bracket and connect with the refrigerant line. Check that no excessive force is imposed on the line. Fasten the bracket bolt to the receiver/drier. 3. Tighten the refrigerant line to the specified torque. Torque: 6 Nm (52 lbin) 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line.
Pressure Switch
Pressure Switch and Associated Parts
875R200028
Legend (1) Pressure Switch Connector
(2) Pressure Switch (3) Radiator Grille
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect pressure switch. D When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.
Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. O-ring cannot be reused. Always replace with a new one. 2. Be sure to apply new compressor oil to the O-ring when connecting pressure switch. 3. Tighten the pressure switch to the specified torque. Torque: 13 Nm (113 lbin)
Evaporator Assembly
Evaporator Assembly and Associated Parts
874RT002
Legend (1) Resistor and Electronic Thermostat Connector (2) Drain Hose (3) Refrigerant Line (4) Passenger Knee Bolster Reinforcement Assembly
(5) Instrument Panel Passenger Lower Cover Assembly (6) Glove Box (7) Front Console Assembly (8) Lower Cluster Assembly (9) Evaporator Assembly
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove front console assembly. 4. Remove lower cluster assembly. 5. Remove glove box. 6. Remove instrument panel passenger lower cover assembly. 7. Remove passenger knee bolster reinforcement assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 8. Disconnect resistor (2) and electronic thermostat connector (1).
874RY00009

9. Disconnect drain hose. 10. Disconnect refrigerant line. D Use a back-up wrench when disconnecting and reconnecting the refrigerant lines. D When removing the refrigerant line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 11. Remove evaporator assembly. 1. To install a new evaporator assembly, add 50cm3 (1.7 fl. oz.) of new compressor oil to the new core. 2. Tighten the refrigerant outlet line to the specified torque. Torque: 25 Nm (18 lbft) 3. Tighten the refrigerant inlet line to the specified torque. Torque: 15 Nm (11 lbft) 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting lines.
Installation
To install, follow the removal steps in the reverse order, noting the following points:
Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View
874R200016
Legend (1) Lining (2) Expansion Valve (3) O-ring (4) Evaporator Assembly (5) Lower Case
(6) (7) (8) (9) (10)
Lining Evaporator Core Electronic Thermostat Attaching Screw Upper Case
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove evaporator assembly. D Refer to Evaporator Assembly in this section. 4. Remove the electronic thermostat sensor. D Pull the sensor from the evaporator assembly. 5. Remove attaching screw. 6. Remove upper case. 7. Remove lower case. D Slit the case parting face with a knife since the lining is separated when removing the evaporator.
8. Remove evaporator core.
874RY00006
9. Remove expansion valve. D Tear off the insulator carefully. D Remove the sensor fixing clip. D Use a back-up wrench when disconnecting all refrigerant pipes.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. The sensor is installed on the core with the clip. 2. The sensor must not interfere with the evaporator core. 3. When installing the new evaporator core, install the thermo sensor (2) to the evaporator core (1) specified position with the clip in the illustration.
874RS006
D Lift to remove the upper case.
874RY00005
874RX021

4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cm3 (1.7 fl. oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications in this section. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly.
Air Conditioning Switch and Illumination Bulb

Air Conditioning Switch, Illumination Bulb and Associated Parts
865RS003
Legend (1) Control Lever Assembly
(2) Illumination Bulb (3) A/C Switch
Removal
1. Disconnect the battery ground cable. 2. Remove control lever assembly. D Refer to Control Lever Assembly in this section. 3. Lift up the catch portion (1) of the switch and remove the air conditioning switch (2) while pushing it toward the outside.
865RS004
4. Turn the illumination bulb counterclockwise to remove.
Installation
Refrigerant Line
Refrigerant Line and Associated Parts
852R200016
Legend (1) Clip and Clamp (2) Suction Line (Low Pressure Hose) (3) Liquid Line (High-Pressure Pipe)
(4) (5) (6) (7)
Discharge Line (High Pressure Hose) Air Cleaner Radiator Grille Suction Line (Low-Pressure Pipe)
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Remove air cleaner. 5. Remove clip and clamp. 6. Disconnect liquid line (High-pressure pipe).
7. Disconnect suction line (Low-pressure pipe) using a back-up wrench. 8. Disconnect suction line (Low-pressure hose) using a back-up wrench. 9. Disconnect discharge line (High-pressure hose) using a back-up wrench. D Use a backup wrench when disconnecting and reconnecting the refrigerant lines.

D When removing the refrigerant line connecting part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. O-rings cannot be reused. Always replace with new ones. 2. Be sure to apply new compressor oil to the O-rings when connecting lines. 3. Tighten the refrigerant line to the specified torque. Refer to Main Data and Specifications for Torque Specifications in this section.
Main Data And Specifications

General Specifications
Heater Unit Temperature control Capacity Air flow HEATER CORE Type Element dimension Radiating area EVAPORATOR ASSEMBLY Capacity Air flow EVAPORATOR CORE Type Element dimension EXPANSION VALVE Type THERMOSTAT SWITCH Type Electronic thermostat OFF: Below 1.00.5C (33.80.9F) ON: Above DIFF 2.00.5C (35.60.9F) Parallel flow type 16.3 kw (14000 Kcal./hr.) 800 m3/h f252 Assembly includes sight glass with triple pressure switch 300 cm3 (10 fl.oz.) Triple pressure switch Low pressure control ON: 206.030.0 kPa (29.84.3 psi) OFF: 176.519.6 kPa (25.62.8 psi) Medium pressure control ON: 1471.098.1 kPa (213.314.2 psi) OFF: 1078.7117.7 kPa (156.417.7 psi) High pressure control ON: 2353.6196.1 kPa (341.328.4 psi) OFF: 2942.0196.1 kPa (426.628.4 psi) Internal pressure equalizer type Al-laminate louver fin type 235 mm (9.3 in.) 225.3 mm (8.9 in.) 60 mm (2.4 in.) 4.9 kw (4200 Kcal./hr.) 470 m#/hr Plate and corrugate fin type 171 mm (6.7 in.) 161 mm (6.3 in.) 25 mm (0.98 in.) Approx. 0.75 m@ Reheat air mix system 4.3 kw (3700 Kcal./hr.) 280 m#/h
CONDENSER Type Radiation performance CONDENSER FAN Air flow Fan size RECEIVER/DRIER Type Internal volume PRESSURE SWITCH Type

REFRIGERANT Type Specified amount HFC-134a 800 g (1.76 lbs.)
Torque Specifications
852R200015
874R200018
Compressor
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS ON-VEHICLE SERVICE INFORMATION. FAILURE TO FOLLOW CAUTIONS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. see if the drive plate can be rotated. If rotation is impossible, the compressor is seized. Low discharge pressure may be due to a faulty internal seal of the compressor, or a restriction in the compressor. Low discharge pressure may also be due to an insufficient refrigerant charge or a restriction elsewhere in the system. These possibilities should be checked prior to servicing the compressor. If the compressor is inoperative, but is not seized, check to see if current is being supplied to the magnetic clutch coil terminals. The compressor oil used in the HFC134a system compressor differs from that used in R12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction.
DKV-14G Type Compressor

DKV14G is equipped with fivevane rotary compressor. These vanes are built into a rotor which is mounted on a shaft. When the shaft rotates, the vanes built into the cylinder block assembly are operated by centrifugal force. This changes the volume of the spare formed by the rotor and cylinder, resulting in the intake and compression of the refrigerant gas. The discharge valve and the valve stopper, which protects the discharge valve, are built into the cylinder block assembly. There is no suction valve but a shaft seal is installed between the shaft and head; a trigger valve, which applies back pressure to the vanes, is installed in the cylinder block and a refrigerant gas temperature sensor is installed in the front head. The specified quantity of compressor oil is contained in the compressor to lubricate the various parts using the refrigerant gas discharge pressure.
General Description
When servicing the compressor, keep dirt or foreign material from getting on or into the compressor parts and system. Clean tools and a clean work area are important for proper service. The compressor connections and the outside of the compressor should be cleaned before any OnVehicle repair, or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichloroethane, naphtha, kerosene, or equivalent solvent, and dried with dry air. Use only lint free cloths to wipe parts. The operations described below are based on bench overhaul with compressor removed from the vehicle, except as noted. They have been prepared in order of accessibility of the components. When the compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be discarded and new compressor oil added to the compressor. Compressor malfunction will appear in one of four ways: noise, seizure, leakage or low discharge pressure. Resonant compressor noises are not cause for alarm; however, irregular noise or rattles may indicate broken parts or excessive clearances due to wear. To check seizure, deenergize the magnetic clutch and check to
871RX002
Diagnosis
Condition Noise from compression Possible cause Defective rotor/piston Defective shaft Noise from magnetic clutch Defective bearing Defective clutch Clearance between drive plate and pulley not standard Insufficient cooling Defective gasket Defective rotor/reed valve Defective trigger valve/suction valve Not rotating Defective rotor/piston Defective shaft Rotating parts insufficient oil Oil and/or gas leakage Defective seal Defective O-ring seized due to Correction Replace compressor/cylinder and shaft assembly Replace compressor/cylinder and shaft assembly Replace magnetic clutch Replace magnetic clutch Adjust the clearance or replace magnetic clutch Replace compressor/gasket Replace compressor/valve plate Replace compressor/suction valve Replace compressor/cylinder and shaft assembly Replace compressor/cylinder and shaft assembly Replace compressor Replace compressor/shaft seal Replace
Magnetic Clutch Assembly (DKV-14G Type)

Parts Location View
871R200001
Legend (1) Drive Plate bolt (2) Drive Plate (3) Snap Ring
(4) (5) (6) (7)
Pulley Assembly Field Coil Shim (s) Lead Wire
Removal
1. Using drive plate holder J-7624 (1) to prevent the drive plate from rotating, then remove the drive plate bolt.
2. Remove drive plate by using drive plate puller J-33944-A (2) and forcing screw J-33944-4 (1).
871R200014
3. Remove shim (s).

871R200013

4. Remove snap ring (1) by using snap ring pliers. 6. Loosen screw and disconnect the field coil wire connector.
871R200012
5. Remove pulley assembly by using pulley puller pilot J-38424 (2), pulley puller J-8433 (1) and pulley puller leg J-24092-2 (3).
871R200009
7. Loosen three screws and remove the field coil.
871R200010 871R200008
Inspection and Repair

Drive Plate
If the frictional surface shows signs of damage due to excessive heat, the drive plate and pulley should be replaced.
3. Install pulley assembly by using pulley installer J-33940-A (2) and drive handle J-8092 (1).
Pulley Assembly
Check the appearance of the pulley assembly. If the frictional surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and drive plate should be replaced. The frictional surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.
Coil
Check coil for loose connector or cracked insulation.
Installation
1. Install field coil. D Align the located portion (1) of the field coil and compressor.
871R200011
4. Install snap ring. 5. Install shim (s). 6. Install the drive plate to the compressor drive shaft together with the original shim(s)(1). Press the drive plate by hand.
871R200006
D Tighten the mounting screw to the specified torque. Torque: 5Nm (44 lb in) 2. Connect the lead wire connector with the rubber hold and tighten the screw.
871R200007

7. Install drive plate bolt by using drive plate holder J-7624 (1) to prevent the drive plate from rotating. D Check to be sure that the clutch clearance is between 0.3-0.6 mm (0.01-0.02 in.)
871R200013
D Tighten the drive plate bolt to the specified torque. Torque: 13 Nm (113 lb in) D After tightening the drive plate bolt, check to be sure the pulley rotates smoothly.
871R200015
Legend (1) Dial Gauge (2) Pulley Assembly (3) Field Coil Wire Connector D If necessary, install adjusting shim(s). D Adjusting shims are available in the following thickness. Thickness D 0.1 mm (0.0039 in.) D 0.3 mm (0.0118 in.) D 0.5 mm (0.0197 in.)
Compressor Oil
Oil Specification
D The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires a mineral compressor oil. The two oils must never be mixed. D Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor. D Always use HFC-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0) (Charging Amount) more than 90 cm3 (3.0 fl.oz) less than 90 cm3 (3.0 fl.oz) (Collected Amount) same as collected amount 90 cm3 (3.0 fl.oz)
7. Install the compressor, then evacuate, charge and perform the oil return operation. 8. Check system operation. When it is impossible to preform oil return operation, the compressor oil should be checked in the following order: 1. Discharge and recover refrigerant and remove the compressor. 2. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 3. Check the oil for contamination. 4. If more than 90 cm3 (3.0 fl. oz.) of oil is extracted from the compressor, supply the same amount of oil to the compressor to be installed. 5. If the amount of oil extracted is less than 90 cm3 (3.0 fl. oz.), recheck the compressor oil in the following order. 6. Supply 90 cm3 (3.0 fl. oz.) of oil to the compressor and install it onto the vehicle. 7. Evacuate and recharge with the proper amount of refrigerant. 8. Perform the oil return operation. 9. Remove the compressor and recheck the amount of oil. 10. Adjust the compressor oil, if necessary. (Collected Amount) more than 90 cm3 (3.0 fl.oz) less than 90 cm3 (3.0 fl.oz) (Charging Amount) same as collected amount 90 cm3 (3.0 fl.oz)
Handling of Oil
D The oil should be free from moisture, dust, metal powder, etc. D Do not mix with other oil. D The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC-134a Vane Rotary Compressor Oil absorbs moisture very easily.) D The compressor oil must be stored in steel containers, not in plastic containers.
Compressor Oil Check

The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil Capacity Capacity total in system: 150cm3 (5.0 fl.oz) Compressor (Service parts) charging amount: 150 cm3 (5.0 fl.oz)
Checking and Adjusting Oil Quantity for Used Compressor

1. Perform oil return operation. Refer to Oil Return Operation in this section. 2. Discharge and recover refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 4. If the amount of oil drained is much less than 90 cm3 (3.0 fl. oz.), some refrigerant may have leaked out. Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts. 5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil in this section.) 6. Adjust the oil level following the next procedure below.
Checking and Adjusting for Compressor Replacement

150 cm3 (5.0 fl.oz.) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the new compressor. 1. Perform oil return operation. 2. Discharge and recover the refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil. 4. Check the compressor oil for contamination.

5. Adjust the oil level as required. (Amount of oil drained from used compressor) less than 90 cm3 (3.0 fl.oz) more than 90 fl.oz) cm3 (3.0 (Draining amount of oil from new compressor) Same as drained amount 90 cm3 (3.0 fl.oz)
Replacement of Component Parts

When replacing the system component parts, supply the following amount of oil to the component parts to be installed. (Component parts to be installed) Evaporator Condenser Receiver/dryer Refrigerant line (one piece) (Amount of Oil) 50 cm3 (1.7 fl. oz.) 30 cm3 (1.0 fl. oz.) 30 cm3 (1.0 fl. oz.) 10 cm3 (0.3 fl. oz.)
6. Evacuate, charge and perform the oil return operation. 7. Check the system operation.
Contamination of Compressor Oil

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

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

COMPRESSOR Model Type Number of vanes Rotor diameter Stroke Displacement Maximum speed Direction of rotation Lubrication system Lubricant DKV-14G Vane rotary type 5 64 mm (2.52 in.) 8.75 mm (0.34 in.) 140 cm3 (47.3 fl.oz.) 7,000 rpm (up to 8,500 rpm) Clockwise (Front-side view) Pressure differential type R-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0) 150 cm3 (5.0 fl.oz.) Refrigerant Shaft seal Weight MAGNETIC CLUTCH Type Rated voltage Current consumption Starting torque Direction of rotation Weight Electromagnetic single-plate dry clutch 12 Volts D.C. 3.7 A 49 Nm (36 lbft) Clockwise (Front-side view) 2.8 kg Refrigerant-134a (R-134a), 700 g (1.54 lbs.) Lip type 3.5 kg
871R200005
Special Tools
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME
J-7624 Drive plate holder
J-33940-A Pulley installer
J-33944-A Drive plate puller
J-8092 Drive handle
J-33944-4 Forcing screw
J-38424 Pulley puller pilot
J-8433 Pulley puller
J-24092-2 Pulley puller leg
Automatic Air Conditioning System

General Description
Using a variety of sensors, this automatic heater and air conditioner accurately senses outside air temperature, solar radiation quantity, evaporators blowing temperature, and interior temperature, then enters these data to the automatic heater/air conditioner control unit (equipped with the built-in micro-computer). The data provided to the control unit enables to automatically control blow temperature and blow air quantity, turn on or off the compressor and switch the blow port as well as switching between the fresh air intake and interior air circulation. Resetting the automatic function allows you to switch to the manual control mode. The self-diagnoisis function of the automatic heater and air conditioner control unit (with the builtin microcomputer) allows the unit to access and diagnose a failed part easier and quicker.
Full Automatic Air Conditioner Parts Configuration
865R200051
Legend (1) Sun Sensor (2) Lower Center Vent Box (3) Evaporator Assembly (4) Duct Sensor (5) Intake Actuator
(6) (7) (8) (9) (10) (11)
Blower Unit Automatic Air Conditioner Control Unit In Car Sensor Heater Unit Mode Actuator Mix Actuator
Refrigerant Line and Associated Parts
852R200017
Legend (1) Liquid Line (High Pressure Pipe) (2) O Ring (3) Discharge Line (High Pressure Hose) (4) Pressure Switch (5) Receiver Drier (6) Ambient Sensor
(7) (8) (9) (10) (11) (12) (13)
Condenser Assembly Drive Belt Compressor Drain Hose Suction Line (Low-Pressure Hose) Evaporator Assembly A/C Switch
Circuit Diagram
6VE1 Engine
D01R200012
D01R200013
D01R200021
D01R200015
D01R200016
Functions and Features

Automatic interior temperature control This function enables to maintain the interior temperature at the level specified from the temperature control switch despite of changes in factors such as vehicle speeds, outside air temperature and number of passengers. Maximum cooling and heating function You can select FC (Full cool, namely maximum cooling temperature) or FH (Full heat, maximum heating temperature) from the temperature control lever. Automatic air flow control Air flow is automatically and consecutively fine tuned according to the specified interior temperature and changes in aperture of the heater unit mix door. Mode (blow port) control This function automatically selects either one of the VENT, BI-LEVEL, FOOT or DEF mode for the blow port according to changes of temperature on the blow port. Using the mode switch allows you to select a desired blow port manually. Intake (switching between the fresh air intake and circulation of interior air) control The intake (switching between fresh air intake and circulation of interior air) mode automatically selects either FRESH (fresh air intake), MIX or RECIRC (interior air circulation) according to changes of the blow port temperature. Using the intake switch allows you to select a desired intake port manually (in the manual operation, FRESH and RECIRC modes alone are available). Pressing the DEF (defrost) mode switch selects the FRESH (fresh air intake). Cooler start-up timing control This function is used for maintaining the air flow at LOW level until the evaporator is sufficiently cooled down. It is intended to prevent a large volume of hot air being blowing into inside of a vehicle when the cooler is turned on in hot summer season. Heater start-up timing control This function is used for maintained the air flow at LOW level and also for maintaining the defrost mode until temperature of coolant in the heater core is sufficiently heated. It is intended to prevent a large volume of cool air being blown into inside of a vehicle when the heater is turned on in cold winter season. Solar radiation quantity offset control The photodiode on the sun sensor determines solar radiation quantity accurately to offset interior temperature quickly. Switch position storing function This function is used for storing switch positions being selected in the immediately preceding operation, namely the last time the ignition has been turned off. It simplifies the setup procedures when restarting
the system. Self-diagnosis function The self-diagnosis function turned on from the panel switch makes your troubleshooting easier (for detail of this function, refer to the section titled Self-Diagnosis).
Automatic Air Conditioner Block Diagram
F01R200006
Control Panel Layout
865RY00024
Legend (1) Auto Switch (2) Mode Switch (3) DEF/FOOT Switch (4) DEF Switch
(5) (6) (7) (8)
Intake Switch Fan Switch Air Conditioning Switch Temperature Control Knob
Air Control Functions
C01RY00004
Legend (1) Interior Air Intake (2) Fresh Air Intake (3) Evaporator Core (4) Air Mix Door (5) DEF Door (6) VENT Door
(7) (8) (9) (10) (11) (12)
FOOT Door Sub Air Mix Door Heater Unit Heater Core Evaporator Unit Blower Unit
Operation and Functions of Control Panel Switches

Auto Switch
1. Pressing this switch turns on the automatic control mode. It resets all manual switches except that for the fan control. However, when the Manual REC is selected for the intake or the Manual Open is selected, the modes are maintained. 2. It causes the A/C (air conditioner) to the ON mode (this function, however, available only when the fan is turned on and also the compressor is turned on because of the given outside air temperature level). Indication D The AUTO LED is turned off. D Currently selected mode for the Mode and Intake are respectively indicated. D The A/C LED remains turned on even if the compressor has been turned off because of the given outside air temperature level. Pressing the air conditioning switch in this state turns off the A/C LED.
Mode Switch
1. Pressing the VENT, B/L or FOOT switch selects the corresponding mode. 2. When the Auto is selected for the Mode and Intake, pressing the mode switch fixes the Intake to the immediately preceding status. Indication D The AUTO LED is turned off. D Currently selected blow port is indicated.
DEF Switch
Press this switch to select the DEF mode. Blow port DEF Intake port Auto FRESH *1 A/C ON mode *2 MIX Auto
*1: When the manual REC is selected for the Intake, the manual REC is maintained. *2: The ON mode is enabled only when the fun is turned on, and also the compressor is turned on because of the given outside air temperature level. Indication D The AUTO LED is turned off.
D The DEF LED and the A/C LED are turned on. D The indication of the intake LED depends on the system condition.
F01RX006
Intake Switch
Pressing this switch sequentially selects a different intake port in the following order.
F01RX005
Indication D The Auto LED maintains unaffected. D Currently selected intake port is indicated.
Fan Switch
1. Sets the fan to the specified mode. 2. Even when the fan switch is turned off, status display for the Mode, Intake is maintained.
Temperature Control Knob

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

Indication D As long as the MAX control is selected, the immediately preceding indication shall be maintained for the AUTO. D Status display is provided for others.
Air Conditioning Switch

Pressing this switch turns on or off the A/C (air conditioning) control. (The compressor remains turned off if the fan is turned off and also the compressor has been turned off because of the given outside air temperature level.) Indication 1. The A/C LED remains turned on even if the compressor has been turned off because of the given outside air temperature level. In this case, however, the AUTO or DEF switch must be turned on and the A/C ON mode must also be turned on (by the MAX/C mode). 2. Pressing the A/C switch from the above state (1) turns off the A/C LED.
865RY00020
Legend (1) In Car Sensor (2) Automatic Air Conditioner Control Unit
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System
Automatic Air Conditioner Control Unit
Equipped with the built-in micro-computer, this control unit operates on signals from sensors and input signals from switches to offer total control of the blower fan, and actuators used for the mode door, intake door and air mix door. Its self-diagnosis function enables quicker access to a failed part and its more accurate troubleshooting.
Ambient Sensor
This sensor is used for detecting temperature outside the vehicle. It converts a given outside air temperature into a resistance value before entering the data to the automatic air conditioner control unit. Thermal effects from the condenser and radiator during idling after a run can be measured and offset the automatic amplifier. This sensor is provided on the side plate situated at upper right side of the condenser.
In Car Sensor
It is a sensor used for detecting room temperature of a vehicle. This sensor converts a given room temperature into a resistance value before entering the data to the automatic air conditioner control unit. This in car sensor unites the power driven aspirator and the motor fan so that a small amount of room air may be constantly fed to the sensor. This sensor is provided on the control panel.
875R200029
Legend (1) Ambient Sensor (2) Condenser Assembly
Duct Sensor
The duct sensor is the sensor to detect temperature change of the side of evaporator blower coming by fresh recirculation of intake door or on off of compressor. The temperature is converted to resistant rate. And it works as thermostat to control to prevent freezing of evaporator. This sensor is installed in the upper case of evaporator.
Sun Sensor
It is a photodiode used for detecting quantity of solar radiation. This sensor converts the offset signal generated by changes in the interior temperature (which results from fluctuations in solar radiation) into photoelectric current to enter into the automatic heater/air conditioner control unit. This sensor is provided at top of the defroster grill.
860RY00007
826RY00012
Legend (1) Sensor Part (2) Duct Sensor Assembly (3) Evaporator Assembly
Legend (1) Sun Sensor
Power Transistor
Receiving base current from the automatic air conditioner control unit, the power transistor implements stageless speed change of the blower fan motor. This transistor is provided on the evaporator.
874RY00011
Legend (1) Evaporator Assembly (2) Power Transistor
Actuator
The actuators are power driven type containing a small motor. Receiving output current from the automatic air conditioner control unit, actuators drive the heater and blower unit mode doors. Actuators consist of the mode actuator used for switching the mode (blow port selection), the mix actuator used for changing aperture of the air mix door, the intake actuator used for switching the intake mode(fresh air/interior air) and the cold air bypassing actuator.
The actuator changes the motor speed using the gear and drives each door rotating the output axis united with the sliding contact.
860RW026
Legend (1) Output Axis (2) Motor (3) Printed Circuit Board (4) Sliding Contact
860R200008
Legend (1) Mix Actuator (2) Intake Actuator (3) Blower Unit (4) Mode Actuator (5) Heater Unit
The mode and mix actuators are common actuators with the builtin potentiometer. For the intake actuator, the contact switch type is selected. The potentiometer is a register assembled to the printed circuit board of the mix and mode actuators. It detects the air mix door position specified by rotation of the output axis as a ratio of the variable terminal (VM) voltage against the reference voltage (VDD: 5V), then signals the value to the automatic air conditioner control unit.
C01RX016
Movement of Mix Actuator

Position of the air mix door is determined by the controller on the automatic air conditioner control unit. As the heat or cool side of the controller is grounded, the transistor on the driver is activated and, thus, the motor rotation is turned on. The sliding contact connected to the motor sends the position detection signal from the potentiometer to the automatic air conditioner control unit. As the set temperature and interior temperature are balanced, the controller returns to the neutral and the motor rotation is stopped. I-45 (+) side 8 6 (-) side 6 8 Rotation direction Clockwise Counter clockwise Remarks Full heat side Full cool side
Movement of Mode Actuator

As target position of the mode door is decided on the controller of the control unit, the control unit reads the position detection signal from the actuator to select the clockwise or counter clockwise motor rotation direction. Grounding the controller VENT or DEF side after the direction selection activates the transistor on the driver, thus turning on the motor rotation. Accompanying the motor rotation, the sliding contact rotates, too. When the target position is reached, the controller on the control unit returns to the neutral and the motor stops. Conduction pin (+) side 5 1 (-) side 1 5 Rotation direction Clockwise Counter clockwise Remarks VENT to DEF direction DEF to VENT direction
C01RX005
C01RX017
Movement of Intake Actuator

The controller on the automatic air conditioner control unit selects an intake mode to be used. As the Terminal No.5 I-49 is grounded via the sliding contact on the terminal plate, the transistor on the driver is activated, thus turning on the motor rotation. Then, accompanying move of the motor, the sliding contact rotates until grounding of the Terminal No.5 I-49 is removed, thus stopping the motor. Grounding terminal No.5 I-49 Rotation direction Clockwise Remarks RE-CIRCULATIONMIXF RESH
Interior Temperature Control

The automatic air conditioner control unit operates on the setup temperature signal from the temperature control switch and other sensor signals to derive the total signal. Then, the control unit compares this signal against the signal from the potentiometer to determine rotation direction of the mix actuator. The mix actuator moves the air mix door to the aperture specified by the total signal so that the specified interior temperature is achieved. If the compressor is turned off in the A/C (air conditioning) mode, aperture of the air mix door is offset according to the outside air temperature or the specified interior temperature. This function removes the difference in the blowing temperature in this state and that of when the compressor is turned on. When FH or FC is selected for the setup temperature, the air mix door is accordingly fixed to the Full Heat or Full Cool mode. When the VENT mode is selected, aperture of the air mix door is controlled so that excessively heated air may not be blown from the VENT blow port.
C01RX006
Overview of Automatic Control of Automatic Air Conditioner

The full automatic heater and air conditioner on this vehicle has the following features: D Interior temperature control. D Air flow control. D Mode (blow port) control. D Intake (switching between fresh air and interior air) control. D Heater start timing control. D Cooler start timing control. D Evaporator anti-freeze control.
C01RY00011
Air Flow Control

In the Auto Mode D The automatic air conditioner control unit operates on the setup temperature signal and other sensor signals to derive the total signal. Then, the control unit adjusts base potential of the power transistor to match it to the voltage pattern of the target fan so that stage-less fan speed control can be achieved. When solar radiation quantity is detected in the VENT or B/L mode, the control unit increases the minimum fan voltage to offset. When FH or FC is selected from the temperature control switch, air flow is accordingly fixed to MAX HI or AUTO HI. In the Manual Mode D Air flow specified from the fan switch is entered to the automatic air conditioner control unit as the manual signal. The signal modifies the air flow to the level specified from the fan switch so that the required fan voltage is attained.
Mode (Blow Port) Control

The automatic air conditioner control unit operates on the setup temperature from the control switch, and temperature and solar radiation quantify from the sensors to determine the total mode control signal. According to the pattern specified by this signal, the control unit selects either one of the VENT, BI-LEVEL, FOOT or DEF/FOOT mode. The mode actuator determines the rotation direction comparing the target position against the current position being determined by the position detection signal. When FH or FC is selected for the temperature from the temperature control switch, mode is accordingly fixed to the VENT or FOOT. D In the manual operation of the mode switch, you can select a desired blow port mode pressing the corresponding mode switch. D Operating the DEF mode switch selects the DEF for the blow port mode.
C01RY00009
C01RY00008
Intake (Fresh air/interior air switching) Control

In the Full Auto mode, the automatic air conditioner control unit operates on the setup temperature signal and other sensor input signals to derive the total signal. According to the pattern specified by this signal, the control unit provides the intake control. When the fan is turned off or the A/C (air conditioning) is turned off, the intake is fixed to the FRESH mode. When FC or FH is selected from the control switch, the intake mode is accordingly fixed to the RECIRC or FRESH. In the Manual Operation D Pressing the FRESH (fresh air intake) or the RECIRC (room air circulation) accordingly selects the FRESH or RECIRC mode. When the DEF Mode Switch is depressed D The intake mode is fixed to the FRESH. When the MANU REC is selected, however, the mode is fixed the RECIRC. When the Mode Switch is depressed D If the automatic intake control is selected, the intake is fixed to the currently selected mode.
Compressor Control
In the automatic control mode, the automatic air conditioner control unit turns on or off the compressor with the evaporator antifreeze mechanism using the duct sensor. And, when outside air is detected to be low through the ambient sensor signal, the control unit turns off the compressor using the compressor control function. Manual Control D In the automatic control mode, pressing the A/C (air conditioning) switch turns off the compressor. D Pressing the DEF mode switch automatically turns on the compressor.
C01R200019
Heating Start Timing Control

When the automatic air conditioner is started, heating is turned on under following conditions. D The detected temperature of thermo unit is 58C (136F) or less. D The temperature setting signal and the total signal by each sensor meet the condition of heating. When the detected temperature by the coolant temperature sensor is 58C (136F) or less, the blower fan motor is set to work at low speed and the DEF mode is selected. When the detected temperature by the coolant temperature sensor is 25C (77F) or more, the blow mode changes automatic control. And the blower fan speed is controlled to be lineally up from LO to MAX HI.
C01RY00012
840R200012
Cooling Start Timing Control

When the automatic air conditioner is started, cooling is turned on under following conditions. D The in car sensor is 30C (86F) or more. D The temperature setting signal and the signals from each sensor meet the specified condition. The blower fan speed is set to LO for maximum 7 seconds when cooling start conditions meet, and then, is controlled to be lineally up to MAX HI by 5.32%/S.
C06RY00001
Troubleshooting
Troubleshooting, Its Overview and Procedures
The full automatic heater and air conditioner equips with the Self-Diagnosis Function to check its major components. This function makes access to the sensors, actuators and blower fan motor system easier when checking them up and, when a failed part is located, this function restores its original performance. When implementing the troubleshooting, this self-diagnosis function narrows the range to be searched at the first step, then check relevant parts one by one according to the Checking Procedures by Failed Location. As for a location this function is unappreciable, the system accurately determines characteristics of a given trouble and checks relevant parts according to the Checking Procedures by Failed Location. The following illustrates basic troubleshooting flow.
Basic Troubleshooting Flow
F01RX009
Auto Air Conditioner Control Unit Power Supply Diagnosis

This check is required because a trouble on the auto amplifier (control unit) power supply circuit or grounding circuit prevents accurate troubleshooting.
D08R200263
Condition Power source does not supply to auto air conditioner control unit.
Possible cause
Correction Refer to Chart A
Chart A: Check of Auto Amplifier Power Supply System

Step Action Value(s) Yes No
1 2 3
Is the fuse C16 normal? Is the fuse C20 normal? Disconnect the auto A/C control unit connector I32. Is the battery voltage applied between the harness side connector terminal No.I328 and the ground? Approx. 12V Go to Step 5 Go to Step 3 Go to Step 2
Replace the fuse Replace the fuse
Go to Step 4
Repair an open circuit between the fuse C16 and terminal No.I328. Is the action complete? Go to Step 4 Go to Step 7 Go to Step 6 Is there continuity between the harness side connector terminal No.I3216 and the ground? Repair an open circuit between terminal No.I3216 and the ground No.B2. Is the action complete? Go to Step 5 Turn the lighting switch on. Is the battery voltage applied between the harness side connector terminal No.I3210 and the ground? Approx. 12V Go to Step 9 Go to Step 8
5 6
Repair an open circuit between the lighting switch and terminal No.I3210. Is the action complete? Go to Step 7 Turn the starter switch on. Is the battery voltage applied between the harness side connector terminal No.I327 and the ground? Approx. 12V Go to Step 10
10
Repair an open circuit between the fuse C20 and terminal No.I327. Is the action complete? Verify repair
Performance and Movement checklist for Automatic Air Conditioner Related Parts
Start the engine, and when the engine coolant reached 50C (122F) check performance and movement of the related parts according the following checklist.
Performance Check Using the Manual Switch

No. Item Blowing temperature (check movement of air mix door) Checking Approach Condition Auto switch must be turned on(FANAUTOMODE AUTO) Operation 1. Select FC for the setup temperature. 2. Select FH for the setup temperature. Then, select the MAX Control. 1. Turn the fan knob off. 2. Turn the fan knob from LOW to HI. Push the mode switch to change the blow port mode sequentially from the VENT through BI-LEVEL, FOOT up to DEF. Turn the LED off using the interior/outside air switch (this introduces the outside air intake mode). Then, the set fan knob to HI and press the interior/outside switch to turn on the LED. Push the OFF switch. 1. Push the Auto switch. 2. Push the Air Conditioner switch. Acceptance criteria 1. Cold air shall be blown out. 2. Hot air shall be blown out.
Airflow volume(check movement of the mode door) Blowing temperature(chec k movement of the mode door)
Set temperature to 25C (77F).
1. The fan shall be stopped, thus stopping air blow, too. 2. Airflow volume shall change from LOW to HI. LED corresponding to each mode shall be turned on and the blow port mode shall be switched smoothly.
Set temperature to 25C (77F). Set the fan knob to HI.
The interior/outside air switching mode (check movement of intake door)
Set temperature to 25C (77F).
The LED indication shall be switched from OFF to ON accompanying a change in air blowing sound.
Compressor 5
Set the temperature to 18C (64.4F) (FC). (Outside air temperature is 0C (32F) or above and interior temperature at ordinary temperature.)
1. As the fan knob is set to the Auto position, the A/C switch LED shall come on and the compressor shall be turned on. 2. As the A/C LED comes off, the compressor shall be turned off.
Check of Auto Function

No. Item Checking Approach Condition Operation Acceptance criteria The LED shall come on. Cold air shall be blown out. The following LEDs shall come on: Select FC for the temperature. D Blow port mode: D Intake mode D Fan speed: MAX Hi D A/C
The following phenomena shall be recognized.

1 Auto function FAN KNOB AUTO MODE SW AUTO Change the temperature gradually starting with 20C (68F) up to 30C (86F). D Temperature of blown air: Cold air is changed to hot air. D Change in the air flow volume. D The blow port mode LED indication changes in the following sequence:
Cold air shall be blown out. The following LEDs shall come on. Select FH for the temperature. D Blow port mode: D Fan speed: Max Hi.
Troubleshooting With Self-Diagnosis Function

Overview of Self-Diagnosis Function
The self-diagnosis is implemented in 3 steps for each target. For detail of check procedure contained in each step, refer to the relevant section of Check Procedure by Failed Location listed in the SelfDiagnosis Operation Procedure. For turning on the self-diagnosis function and switching of the check step, refer to the flow chart given below. You can reset the selfdiagnosis function by turning the ignition switch off or turning the DEF switch on for 5 seconds.
Self-Diagnosis Operation Procedure

1. Set the IG to the OFF position. 2. Apply 60W bulb light to the sun sensor. 3. Set the temperature setting lever on the automatic heater/air conditioner panel to the center position 25C (77F). 4. Set the fan switch on the same panel to the Auto position. Is the action complete? Go to Step 2 While pushing both the Auto switch and the DEF switch on the automatic heater/air conditioner panel, start the engine. Is the current trouble diagnosing function turned on approximately in 10 seconds? Go to Step 3 Go to Step 4 Go to Step 5 Refer to *1. Refer to *2. Repair or replace the output equipment or repair the harness
3 4 5
Does the A/C LED flash every 0.5 second interval? Push the A/C switch once. Does the A/C LED flash every 0.5 second interval? Refer to *3 chart Check of Output Equipment. Does each output equipment function normally according to operation of the temperature setting level?
6 Push the DEF switch for 5 seconds consecutively or turn on and off the IG. Is the action complete?
Go to Step 6
Go to Step 1
*1Displaying the Current Trouble Diagnosing Table

Start the engine while holding down both the Auto switch and the DEF switch on the control panel, and the table will appear in approximately 10 seconds to the indicator lamp (LED) of the air conditioning switch. Result of the diagnosis along the following 9 items will be shown one by
one in 0.5 second interval irrespective of presence or absence of a trouble for a given item. When the display 9 items is completed, it is repeated with 3 seconds of interval in between. A failed item is indicated by flashing of the LED that is repeated 3 times within 0.5 seconds. If a trouble is indicated, you can locate the failed section by knowing when in the total sequence it has been displayed.
F01RX010
Item for Current Trouble Diagnosis
F01RY00008

As shown above, display of result along nine items is repeated with 3-second interval in between. Note 1: When checking the sun sensor, apply sufficient light using a 60W bulb. Otherwise, it can be diagnosed as failed. Note 2: If the temperature setting lever is set on both ends {one set to 18C (64.4F), blue scale = Full cool and the other to 31C (87.8F), red scale = Full hot}, they can be diagnosed as failed. Note 3: Likewise, the fan switch can be diagnosed as failed if set on both ends. past trouble diagnosis will appear on the indicator lamp (LED) of the air conditioning switch. Results of the diagnosis along the following five items are displayed one by one in 0.5 second interval irrespective of presence or absence of a trouble. A failed item is indicated by flashing of the LED that is repeated 3 times within 0.5 seconds. You can locate the failed section by counting in what sequence it has been displayed. Past trouble code can be cleared by disconnecting one of the following sources for at least thirty (30) seconds. NOTE: To prevent system damage, the ignition key must be OFF when disconnecting or reconnecting battery power. D The No.16 fuse (Room lamp, Clock) D The negative battery cable. (Disconnecting the negative battery cable will result in the loss of other on-board memory data, such as preset radio tuning).
*2Displaying the Past Trouble Diagnosing Table

The past trouble diagnosis displays only the items on which trouble has recurred 16 times in the past. If you press the air conditioning switch once while the current trouble diagnosis is taking place, display of the
F01RX011
F01RY00007
*3Check of Output Equipment
F01R200005
Inspection By Failed Location

Inspection of the Sensors
When the self-diagnosis function has determined that trouble is present on the sensors, check them according to the following flow chart.
F01RY00005
Chart 1: In Car Sensor
D08R200264
Step
Action
Value(s)
Yes
No
Disconnect the in car sensor connector. (No.I-34) Is performance of the sensor normal? (Refer to the later section on Individual Inspection) Go to Step 2 Go to Step 4 Replace the in car sensor Go to Step 3
2 3
Is there continuity between the harness side connector No.I331 and No.I343? Repair an open circuit between terminal No.I331 and No.I343. Is the action complete?
Go to Step 2 Go to Step 6
Go to Step 5
4 5
Is there continuity between the harness side connector No.I3311 and No.I344? Repair an open circuit between terminal No.I3311 and No.I344. Is the action complete?
Go to Step 4 Verify repair
Replace the auto air conditioner control unit. Is the action complete?
Chart 2: Ambient Sensor
D08R200265
Step
Action
Value(s)
Yes
No
Disconnect ambient sensor connector. (No.C86) Is performance of the ambient sensor normal? (Refer to the later section on Individual inspection) Go to Step 2
Replace the ambient sensor
Connect the ambient sensor connector.
Refer to the later section Is resistance between the harness side connector on Individual No.I332 and No.I3311 normal? inspection Repair an open circuit between terminal No.I332 and No.C861 or No.I3311 and No.C862. Is the action complete?
Go to Step 4
Go to Step 3
Verify repair Verify repair
Chart 3: Sun Sensor
D08R200266
Step
Action
Value(s)
Yes
No
Disconnect the sun sensor connector. (No.I35) Is performance of the sun sensor normal? (Refer to the later section on individual inspection) Go to Step 2 Go to Step 4 Replace the sun sensor. Go to Step 3
2 3
Is there continuity between the harness side connector terminal No.I333 and No.I351? Repair an open circuit between terminal No.I333 and No.I351. Is the action complete?
Go to Step 5
4 5
Is there continuity between the harness side connector terminal No.I3311 and No.I352? Repair an open circuit between terminal No.I3311 and I352. Is the action complete?
Inspection of the Intake Actuator System
D08R200267
Condition Does not work at all Control failure
Possible cause
Correction Refer to Chart A Refer to Chart B
Chart A: Does Not Work At All

1 2 3 4
Is the fuse FL1 normal? Is the fuse C20 normal? Is the relay B36 normal? Turn on the ignition switch. (the engine is run.) Is the battery voltage applied between the harness side connector terminal No.I493 and ground? Approx 12V Go to Step 6 Go to Step 4 Go to Step 3 Go to Step 2
Replace the fuse Replace the fuse Replace the relay
Go to Step 5
Repair an open circuit between terminal No.I493 and No.B364. Is the action complete? Approx 12V Go to Step 4 Go to Step 8 Go to Step 6 Go to Step 10 Verify repair Verify repair Go to Step 7 Go to Step 9 Is the battery voltage applied between the harness side connector terminal No.I494 and ground? Replace the intake actuator motor. Is the action complete? Is there continuity between the harness side connector terminal No.I3211 and No.I494? Repair an open circuit between No.I3211 and I494. Is the action complete? Replace the auto air conditioner control unit. Is the action complete?
6 7 8 9 10
Chart B: Failure on the Intake Control

1 2 3 4 5 6
Is the fuse No.C20 normal? Is the relay No.B36 normal? Turn on the ignition switch. (the engine is run.) Is the intake actuator stopped? Replace or repair the auto air conditioner control unit. Is the action complete? Is there continuity between the harness side connector terminal No.I495 and No.I3311? Repair an open circuit between terminal No.I495 and No.I3311. Is the action complete? Go to Step 5 Go to Step 9 Verify repair Go to Step 7 Go to Step 5 Go to Step 3 Go to Step 2
Replace the fuse Replace the relay Go to Step 4 Go to Step 6
Go to Step 8
7 8
Is there continuity between the harness side connector terminal No.I496 and No.I3312? Repair an open circuit between terminal No.I496 and No.I3312. Is the action complete?
Go to Step 10
9 10
Is there continuity between the harness side connector terminal No.I491 and No.I3313? Repair an open circuit between terminal No.I491 and I33-13. Is the action complete?
Go to Step 12
11 12
Is there continuity between the harness side connector terminal No.I492 and No.I3314? Repair an open circuit between harness No.I492 and No.I3314. Is the action complete?
Go to Step 11
13
1. Disconnect the intake actuator connector No.I49. 2. Is the battery voltage applied between harness side connector terminal No.I496 and ground? No.I492 and ground? No.I491 and ground? Replace or repair the intake actuator. Is the action complete?
Go to Step 14 Verify repair Verify repair
Go to Step 15
14 15
Replace or repair the air conditioner control unit. Is the action complete?
Inspection of the Mix Actuator System
D08R200268
Possible cause
Chart A: Does Not work At All

1. Turn on the ignition switch (the engine is run). 2. Disconnect the mix actuator connector (I45). 3. Short-circuit the chassis harness side connector terminal No.I453 and No.I457. 4. Using the temperature control lever, select FH for the temperature. Is the battery voltage applied on a regular interval basis between the harness side connector terminal No.I456 (-) and No.I458 (+)?
Go to Step 3 Varify repair
Go to Step 2
2 3
Replace the auto air conditioner control unit. Using the temperature control lever, select FC for the temperature. Is the battery voltage applied on a regular interval basis between the harness side connector terminal No.I456 (+) and No.I458 (-)?
Go to Step 5 Verify repair Go to Step 7
4 5 6
Replace the auto air conditioner control unit. Is there continuity between the harness side connector terminal No.I326 and No.I456? Repair an open circuit between terminal No.I326 and No.I456. Is the action complete? Go to Step 5 Go to Step 9 Go to Step 8 Is there continuity between the harness side connector terminal No.I325 and No.I458? Repair an open circuit between terminal No.I325 and No.I458. Is the action complete? Verify repair Verify repair Replace the mix actuator. Is the action complete?
7 8
Chart B: Mix Actuator Control Failure

Turn the ignition switch (the engine is run). Dose the mix actuator fully stroke when FH and FC of the temperature control lever? Go to Step 3 Varify repair Go to Step 5 Go to Step 2 Go to Step 4
2 3 4
Repair or replace the air mix door or the link unit. Is the action complete? Is there continuity between the harness side connector terminal No.I453 and No.I3311? Repair an open circuit between terminal No.I453 and No.I3311. Is the action complete? Go to Step 3 Go to Step 7 Go to Step 6 Is there continuity between harness side connector terminal No.I457 and No.I335? Repair an open circuit between terminal No.I457 and No.I335. Is the action complete? Go to Step 5 Is there continuity between the harness side connector terminal No.I452 and No.I3315? Go to Step 9 Go to Step 8 Repair an open circuit between terminal No.I452 and No.I3315. Is the action complete? Go to Step 7 Is sum of the voltage between the following chassis harness side connector terminals approximately 5V? No.I3315 and No.I335, No.I335 and No.I3311 Replace the actuator. Is the action complete? Verify repair Verify repair Replace the auto air conditioner control unit. Is the action complete?
5 6
Go to Step 11
Go to Step 10
10 11
Inspection of the Mode Actuator System
D08R200269
Possible cause
Chart A: Does Not Work At All

1. Turn on the ignition switch (the engine is run). 2. Disconnect the mode actuator connector (B69) 3. Select VENT pressing the mode actuator. Is the battery voltage provided on a regular interval between the harness side connector terminal No.B691 (+) and No.B695 (-)?
Go to Step 3 Varify repair
Go to Step 2
2 3
Replace the auto air conditioner control unit. Is the action complete? Turn on the DEF mode switch. Is the battery voltage provided on a regular interval between the chassis side connector terminal No.B695 (+) and No.B691 (-)?
Go to Step 5 Varify repair Go to Step 7
4 5 6
Replace the auto air conditioner control unit. Is there continuity between the harness side connector terminal No.B691 and No.I324? Repair an open circuit between terminal No.B691 and No.I324. Is the action complete? Go to Step 5 Go to Step 9 Go to Step 8 Is there continuity between the harness side connector terminal No.B695 and No.I323? Repair an open circuit between terminal No.B695 and No.I323. Is the action complete? Verify repair Verify repair Replace the mode actuator.
7 8
Chart B: Mode Actuator Control Failure

Turn on the ignition switch (the engine is run). Dose the mode actuator fully stroke when the defrost mode and the vent mode are selected? Go to Step 3 Go to Step 1 Go to Step 5 Go to Step 2 Go to Step 4
2 3 4
Repair or replace the mode door or the link unit. Is the action complete? Is there continuity between the harness side connector terminal No.B699 and No.I3311? Repair an open circuit between terminal No.B699 and No.I3311. Is the action complete? Go to Step 3 Go to Step 7 Go to Step 6 Is there continuity between the harness side connector terminal No.B693 and No.I3310? Repair an open circuit between terminal No.B693 and No.I3310. Is the action complete? Go to Step 5 Go to Step 9 Go to Step 8 Is there continuity between harness side connector terminal No.B694 and No.I338? Repair an open circuit between terminal No.B694 and No.I338. Is the action complete? Go to Step 7 Is sum of the voltage between the following harness side connector terminal approximately 5V? Voltage between No.I338 and No.I3310 plus voltage between No.I338 and No.I3311 Replace the actuator. Is the action complete? Verify repair Go to Step 13 Verify repair Verify repair Go to Step 12 Dose the mode actuator work normally through manual operation? Replace the sensor. Is the action complete? Replace the auto air conditioner control unit. Is the action complete?
5 6
7 8
5V
Go to Step 11
Go to Step 10
10 11 12 13
Inspection of the Fan Motor System
D08R200270
Condition The fan dose not rotate at all The fan dose not stop
Possible cause
Chart A: Fan Does Not Rotate At All

1 2 3
Are the fuse No.C19 normal? Are the relay No.B36 normal? Turn on the ignition switch (the engine is run). Is the battery voltage applied between the harness side connector terminal No.B51 and ground? Go to Step 5 Go to Step 3 Go to Step 2
Replace the fuse Replace the relay
Go to Step 4
Repair an open circuit between terminal No.B51 and No.C19 fuse. Is the action complete? Go to Step 3 Go to Step 7 Go to Step 6 Is there continuity between the harness side connector terminal No.B52 and ground (No.B2)? Repair an open circuit between terminal No.B52 and ground. Is the action complete? Go to Step 8 Verify repair Verify repair Go to Step 9 Is the battery voltage applied between the harness side connector terminal No.B52 and No.B51? Replace the blower motor. Is the action complete? Refer to chart B and C. Is the action complete?
5 6
7 8 9
Chart B: Fan Does Not Stop

1. Disconnect the power transistor connector I50 and the auto A/C control unit connector I33. 2. Turn on the ignition switch. Does the blower motor stop? Go to Step 3 Go to Step 2 Repair a short circuit between connector, No.B52 and No.I501, or No.B52 and I3317. Is the action complete? Verify repair Replace the power transistor Is the power transistor normal? (Refer to the later section on individual inspection.) Go to Step 4 Replace the auto A/C control unit Reinstall the power transistor. Does the blower motor start operating?
Inspection of the Magnetic Clutch System

6VE1 Engine
D08R200272

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

1 2 3
Is the fuse No.C20 normal? Is the relay No.X7 (compressor relay) No.X5 (A/C thermo relay) and No.B36 (heater relay) normal? Is the pressure switch normal? Go to Step 4 Go to Step 2 Go to Step 3
Replace the fuse Replace the relay Replace the pressure switch
1. Turn the ignition switch on. (the engine is run.) 2. Turn the fun switch and the air conditioner switch on. Is the battery voltage applied between the harness side connector terminal No.E31 and the ground? Go to Step 5 Verify repair Go to Step 8 Go to Step 6 Go to Step 7
5 6 7
Repair or replace the magnetic clutch. Is the action complete? Is there continuity between the harness side connector terminal No.X74 and No.E31? Repair an open circuit between terminal No.X74 and No.E31. Is the action complete? Go to Step 6 Is the battery voltage applied between the harness side connector terminal No.X72 and ground, No.X71 and ground? Repair an open circuit between terminal No.X72 and fuse No.C20, No.X71 and fuse No.C20. Is the action complete? Go to Step 8 Go to Step 12 Go to Step 11 Is the battery voltage applied between the harness side connector terminal No.I3318 and ground? Repair an open circuit between terminal No.I3318 and No.X73. Is the action complete? Go to Step 10 Go to Step 14 Go to Step 13 Is the battery voltage applied between the harness side connector terminal No.C892 and ground? Repair an open circuit between terminal No.C892 and fuse No.C20. Is the action complete? Go to Step 12 Is the battery voltage applied between the harness side connector terminal No.X53 and ground, No.X52 and ground? Repair an open circuit between terminal No.X53 and No.C891, No.X52 and fuse No.C20. Is the action complete? Go to Step 14 Go to Step 18 Go to Step 17 Is the battery voltage applied between the harness side connector terminal No.I3214 and ground?
Go to Step 10
Go to Step 9
10 11
12 13
14
Go to Step 16
Go to Step 15
15
16
Chart A: Magnetic Clutch Does Not work (Contd)

17
Repair an open circuit between terminal No.X51 and I3214. Is the action complete? Go to Step 16 Go to Step 20 Go to Step 19 Is there continuity between the harness side connector terminal No.I334 and PCM (S47)? Repair an open circuit between terminal No.I334 and PCM (S47). Is the action complete? Go to Step 18 Go to Step 22 Go to Step 21 Is there continuity between the harness side connector terminal No.X51 and No.I3214? Repair an open circuit between terminal No.X51 and No.I3214. Is the action complete? Go to Step 20 Go to Step 24 Go to Step 23 Is there continuity between the harness side connector terminal No.X54 and PCM (F45)? Repair an open circuit between terminal No.X54 and PCM (F45). Is the action complete? Go to Step 22 Go to Step 26 Go to Step 25 Is there continuity between the harness side connector terminal No.X73 and PCM (F4)? Repair an open circuit between terminal No.X73 and PCM (F4). Is the action complete? Go to Step 24 1. Disconnect the auto A/C control unit connectors and connect the PCM connectors. 2. Ground the auto A/C control unit connector terminal No.I3214. Does the magnetic clutch work? Go to Step 28 Verify repair Verify repair Go to Step 27 Replace the PCM. Is the action complete? Replace the auto A/C control unit. Is the action complete?
18 19
20 21
22 23
24 25
26
27 28
CAUTION: There are conditions which air conditioner system dose not operate except trouble as follows. 1. The throttle is griater than 90%. 2. The ignition voltage is below 10.5 volts. 3. The engine speed greater than 4500 RPM for 5 seconds or 5400 RPM. 4. The engine coolant temperature (ECT) is greater than 125C (257F). 5. The intake air temperature (IAT) is less than 5C (41F). 6. The power steering pressure switch signals a high pressure condition.
Condenser Fan Diagnosis

While the air conditioning is ON, the cycling switch in the triple pressure switch senses the refrigerant pressure, and activates the condenser fan to improve the cooling
capacity of the condenser when the refrigerant pressure exceeds a set pressure value. The condenser fan stops when the air conditioning is turned OFF or when the pressure goes down below the set pressure value.
D08R200271
Condition Condenser fan does not run.
Possible cause
Chart A Condenser Fan Does Not Run

1 2 3
Are 30A fuse normal? Is relay (X-19) normal? Is pressure switch normal?
Replace Replace Switch defective or insufficient refrigerant. Replace Repair open circuit between Condenser Fan fuse (30A) and No.X19-1. Repair open circuit between fuse (10A) and C89-3.
4 5 Is fan motor normal? 1. Disconnect condenser fan relay (X-19). 2. Check to see if battery voltage is present at the chassis side relay terminal NO. X19-1. Is there a battery voltage? 6 1. Reconnect condenser fan relay (X-19). 2. Check to see if battery voltage is present at chassis side connector terminal No.C89-3. Is there a battery voltage? 7 Check to see if continuity between chassis side relay terminal No.X19-4 and the chassis side connector terminal No.C89-4. Is there a continuity? 8 Check to see if continuity between chassis side connector terminal No. C75-1 and chassis side relay terminal No.X19-3. Is there a continuity?
Go to Step 6
Go to Step 7
Go to Step 8 Poor ground or open circuit between chassis side connector terminal No.X19-5 (or No.C75-2) and body ground (No.C39).
Repair open circuit.
Repair open circuit.
Chart B Condenser Fan Does Not Stop

1. Disconnect the triple pressure connector. Does condenser fan stop?
Replace the triple pressure switch.
Replace the condenser fan relay.
In Car Sensor
1. Disconnect the in car sensor connector (I34). 2. Measure resistance between the in car sensor side terminal No.I343 and No.I344.
Sun Sensor
1. Disconnect the sun sensor connector (I35). 2. Measure the current value on the sun sensor when placed it approximately 15 cm away from 60W incandescent lamp.
D06R200101
Ambient Sensor
1. Disconnect the connector (C86) on the ambient sensor. 2. Measure resistance between the ambient sensor side terminals.
C01R200018
C01R200014
Power Transistor
1. Remove the power transistor connector (I50) from the evaporator assembly. 2. Check the conduction between the power transistor side terminals.
In Car Sensor
1. Dismount the in car sensor from the automatic heater/air conditioner control unit. Connect (+) end and () end of the battery to the aspirator motor side terminals No.I341 and No.I342, respectively, then check if the motor runs normally.
C01R200017
In Car Sensor
1. Turn on the ignition switch (the engine is started). Start the air conditioner in Full Auto. 2. Make sure that the in car sensor suctions cigarette smokes and such.
C01RY00005
Heater (B36), Thermostat (X5), And Compressor (X7) Relay

1. Disconnect relays and check for continuity and resistance between relay terminals. D For handling of these relays, refer to Heater Relay in this section.
901RY00041
Triple Pressure Switch (V6, A/T)

1. Disconnect the connector and check for continuity between pressure switch side connector terminals (1) and (2). 2. Reconnect the connector to activate the A/C switch, and check to see if there is continuity between the chassis side connector terminal (3) and (4) and the fan operates.
875R200031
On-Vehicle Service
Power Transistor Automatic Heater/Air Control Unit Conditioner
874RY00010
Legend (1) Evaporator Assembly (2) Power Transistor (3) Power Transistor Connector (4) Instrument Panel Passenger Lower Cover (5) Glove Box (6) Front Console (7) Lower Cluster (8) Passenger Knee Bolster Reinforcement
865RY00012
Legend (1) Connector (2) Set Screw (3) Instrument Panel Cluster (4) Automatic Air Conditioner Control Unit
Removal
1. Disconnect the battery ground cable. 2. Remove instrument panel cluster. D Refer to Instrument Panel Assembly in Body Stractur section. 3. Disconnnect the automatic heater/air conditioner control unit connector. 4. Remove automatic heater/air conditioner control unit.
Removal
1. Remove front console. 2. Remove lower cluster. 3. Remove glove box. 4. Remove instrument panel passenger lower cover. 5. Remove passenger knee bolster reinforcement. 6. Disconnect the power transistor connector. 7. Remove power transistor.
Installation
To install, follow the removal step in the reverse order.
Installation
In Car Sensor
Ambient Sensor
865RY00020
875R200030
Legend (1) In Car Sensor (2) Automatic Air Conditioner Control Unit
Legend (1) Ambient Sensor (2) Sensor Connector (3) Radiator Grille
Removal
1. Disconnect the battery ground cable. 2. Remove the automatic air conditioner control unit. D Refer to the automatic air conditioner control unit section. 3. Remove in car sensor.
Removal
1. Disconnect the battery ground cable. 2. Remove radiator grille. D Refer to Radiator Grille in Body Structure section. 3. Disconnect the ambient sensor connector. 4. Remove the ambient sensor.
Installation
Installation
Sun Sensor
Duct Sensor
826RY00012
Legend (1) Sun Sensor
Removal
1. Disconnect the battery ground cable. 2. Remove the sun sensor. 3. Disconnect the sun sensor connector.
874R200019
Installation
Legend (1) Sensor Part (2) Evaporator Core (3) Evaporator Assembly (4) Duct Sensor Assembly
Removal
1. Disconnect the battery ground cable. 2. Remove the evaporator assembly. D Refer to the evaporator assembly in this section. 3. Remove the duct sensor assembly.
Installation
Mode Actuator
Mix Actuator
860R200009
860RY00009
Legend (1) Driver Knee Bolster Assembly (2) Instrument Panel Driver Lower Cover Assembly (3) Mode Actuator (4) Actuator Rod
Legend (1) Instrument Panel Assembly (2) Actuator Rod (3) Mix Actuator (4) Instrument Panel Center Bracket
Removal
1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover assembly. 3. Remove the driver knee bolster assembly. D Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the actuator rod. 5. Remove the mode actuator.
Removal
1. Disconnect the battery ground cable. 2. Remove the instrument panel assembly. D Refer to the Instrument Panel Assembly in Body and Accessories section. 3. Remove the instrument panel center bracket. 4. Remove the actuator rod. 5. Remove the mix actuator.
Installation
To install, follow the remove step in the reverse order.
Installation
Intake Actuator
873RY00004
Legend (1) Evaporator Assembly (2) Intake Actuator (3) Intake Actuator Connector
Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove the evaporator assembly. D Refer to Evaporator Assembly section. 4. Disconnect the intake actuator connector. 5. Remove the intake actuator.
Installation
SECTION
POWER ASSISTED SYSTEM
TROOPER
2A1
STEERING
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering System Test . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding The Power Steering System . . . . . . Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . Flushing The Power Steering System . . . . . . Steering Wheel Free Play Adjustment . . . . . . Front End Alignment Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Gear . . . . . . . . . . . . . . . . . . . . Power Steering Gear and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Gear Disassembled View . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . . . Power Steering Pump and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Disassembled View Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1Main Data and Specifications . . . . . . . . . . Center Track Rod Assembly . . . . . . . . . . . . . . Center Track Rod Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer Track Rod Assembly . . . . . . . . . . . . . . . Outer Track Rod Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A2 2A2 2A5 2A11 2A12 2A12 2A12 2A12 2A12 2A13 2A13 2A18 2A19 2A20 2A20 2A20 2A21 2A22 2A23 2A24 2A25 2A27 2A28 2A28 2A28 2A29 2A30 2A30 2A31 2A32 2A33 2A34 2A34 2A35 2A35 2A35 2A36 2A36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Lever and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Linkage and Associated Parts . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Supplemental Restraint System Steering Wheel & Column . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . SRS Connectors . . . . . . . . . . . . . . . . . . . . . . Inflator Module . . . . . . . . . . . . . . . . . . . . . . . . . . Inflator Module and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combination Switch . . . . . . . . . . . . . . . . . . . . . Combination Switch and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock Cylinder and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Inspection . . . . . . . . . . . . . . . . . . . . . Steering Column . . . . . . . . . . . . . . . . . . . . . . . . Steering Column and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Inspection . . . . . . . . . . . . . . . . . . . . . Supplemental Restraint System Steering Wheel & Column and Associated Parts . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2A37 2A37 2A38 2A39 2A39 2A39 2A40 2A41 2A41 2A42 2A43 2A43 2A43 2A45 2A45 2A45 2A46 2A46 2A47 2A47 2A47 2A49 2A50 2A50 2A50 2A52 2A54 2A54 2A54 2A56 2A57 2A58 2A58 2A58 2A60 2A62 2A63 2A64 2A64 2A65
2A2

Service Precaution
General Description
The hydraulic power steering system consists of a pump, an oil reservoir, a steering gear, a pressure hose and a return hose.
Power Steering Gear
A03RS001
The power steering gear has a recirculating ball system which acts as a rolling thread between the worm shaft and the rack piston. When the worm shaft is turned right, the rack piston moves up in gear. Turning the worm shaft left moves the rack piston down in gear. The rack piston teeth mesh with the sector gear, which is part of the sector shaft. Turning the worm shaft turns the sector shaft, which turns the wheels through the steering linkage.
The control valve in the steering gear directs the power steering fluid to either side of the rack piston. The rack piston converts the hydraulic pressure into a mechanical force. If the steering system becomes damaged and loses hydraulic pressure, the vehicle can be controlled manually.
2A3
Hydraulic Pump
442RV006
The hydraulic pump is a vane-type design. There are two openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly, and end plate. The smaller opening contains the pressure line union, flow control valve and spring.
Pressure Switch
When hydraulic pressure reaches 3650 350 kPa (530 50 psi), the pressure switch of the power steering pump closes causing the Powertrain Control Module (PCM) to actuate the throttle valve, which increases the engine rpm to prevent the overload-induced engine speed slow down. The switch opens when hydraulic pressure drops to 3150 350 kPa (460 50 psi).
2A4
Steering Linkage
433RS007
Legend (1) Center Track Rod Assembly (2) Outer Track Rod Assembly (3) Pitman Arm
(4) (5) (6) (7)
Relay Lever Rod End,Outer Track Rod Rod End,Inner
The steering linkage consists of a pitman arm, relay lever, center track rod, and two adjustable outer track rods. When the steering wheel is turned, the gear rotates the pitman arm which forces the center track rod to one side. The outer track rods, connected to the center track rod by ball studs, transfers the steering force to the wheels. The outer track rods are adjustable and are used for toe-in adjustments. The center track rod is supported by the pitman arm and relay lever. The relay lever pivots on a support attached to the frame. The overall condition of the steering linkage affects steering performance. If parts are bent, damaged, worn or poorly lubricated, improper and possibly dangerous steering action will result. Whenever any steering linkage components are repaired or replaced, check the steering geometry and front end alignment. Refer to Front End Alignment Inspection and Adjustment in this section.
2A5
Steering Column
WARNING: TO AVOID DEPLOYMENT WHEN TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT USE ELECTRICAL TEST EQUIPMENT, SUCH AS BATTERY-POWERED OR A/C-POWERED VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED IN THIS MANUAL. DO NOT USE A NON-POWERED PROBE-TYPE TESTER. INSTRUCTION IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. When servicing a vehicle equipped with Supplemental Restraint System, pay close attention to all WARNINGS and CAUTIONS. For detailed explanation about SRS, refer to Restraints section. The steering column has three important features in addition to the steering function: 1. The column is energy absorbing, designed to compress in a front-end collision to minimize the possibility of injury to the driver of the vehicle. 2. The ignition switch and lock are mounted conveniently on the column.
3. With the column mounted lock, the ignition and steering operation can be locked to prevent theft of the vehicle. The column can be disassembled and reassembled. However, to ensure the energy absorbing action, use only the specified screws, bolts and nuts as designated, and tighten them to the specified torque. Handle the column with care when it is removed from the vehicle. A sharp blow on the end of steering shaft or shift lever, or dropping the assembly could shear or loosen the fasteners that maintain column rigidity.
Diagnosis
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To identify the symptom, always road test the vehicle first. Proceed with the following preliminary inspections and correct any defects which are found. 1. Inspect tires for proper pressure and uneven wear. 2. Raise vehicle on a hoist, then inspect front and rear suspension and steering linkage for loose or damaged parts. 3. Spin the front wheels. Inspect for out-of-round tires, out-of-balance tires, loose and/or rough wheel bearings.
General Diagnosis
Condition Vehicle Pulls Possible cause Mismatched or uneven tires. Tires not adequately inflated. Broken or sagging springs. Radial tire lateral force. Improper wheel alignment. Brake dragging in one wheel. Loose, bent or broken front or rear suspension parts. Faulty shock absorbers. Abnormal or Excessive Tire Wear Sagging or broken spring. Tire out of balance. Improper wheel alignment. Faulty shock absorber. Hard driving. Overloaded vehicle. Tires not rotated periodically. Worn or loose road wheel bearings. Wobbly wheel or tires. Tires not adequately inflated. Wheel Hop Blister or bump on tire. Improper shock absorber operation. Correction Replace tire. Adjust tire pressure. Replace spring. Replace tire. Adjust wheel alignment. Repair brake. Tighten or replace the appropriate suspension part(s). Replace shock absorber. Replace spring. Balance or replace tire. Check front end alignment. Replace shock absorber. Replace tire. Replace tire and reduce load. Replace or rotate tire. Replace wheel bearing. Replace wheel or tire. Adjust the pressure. Replace tire. Replace shock absorber.
2A6

Condition Possible cause Tire or wheel out of balance. Loose wheel bearings. Worn steering linkage ball joints. Worn upper or lower ball joints. Excessive wheel runout. Blister or bump on tire. Excessive loaded radial runout of tire/wheel assembly. Improper wheel alignment. Loose or worn steering linkage. Loose steering gear. Tires not adequately inflated. Loose, bent or broken front or rear suspension parts. Faulty shock absorber. Hub bearing preload misadjustment. Correction Balance wheels or replace tire/or wheel. Replace wheel bearing. Replace ball joints. Replace ball joints Repair or replace wheel and/or tire. Replace tire. Replace tire or wheel. Check wheel alignment. Tighten or replace steering linkage. Tighten housing bolts. Adjust tire pressure. Tighten or replace the appropriate suspension parts. Replace shock absorber. Adjust preload. Replace ball joint. Check wheel alignment. Check and adjust pinion torque. Inflate tires to proper pressure. Repair or replace. Repair or replace. Refer to Power steering system diagnosis Replace wheel bearings. Retighten or repair. Inspect and adjust steering gear preload. shaft Retighten or replace steering shaft. Replace ball joints. Replace ball joints. Replace ball joints. Replace ball joints. Repair or replace. Check and repair steering gear. Adjust wheel alignment. Adjust tire pressure. Retighten. Replace.
Shimmy, Shake or Vibration
Hard Steering
Bind in steering linkage ball studs, upper or lower ball joint. Improper wheel alignment. Steering gear misadjustment. Tire not adequately inflated. Bind in steering column or shaft. Improper power steering system operation.
Too Much Play In Steering
Wheel bearings worn. Loose steering gear or linkage. Steering gear misadjustment. Worn or loose universal joint. steering
Worn steering linkage ball joints. Worn upper or lower ball joints. Poor Steering Wheel Returnability Bind in steering linkage ball joints. Bind in upper or lower ball joints. Bind in steering column and shaft. Bind in steering gear. Improper wheel alignment. Tires not adequately inflated. Loose steering wheel nut. Worn wheel bearing.

Condition Abnormal Noise Possible cause Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Worn upper or lower control arm bushing. Loose stabilizer bar. Loose wheel nuts. Replace. Correction
2A7
Replace. Replace. Retighten bolts or replace bushings. Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required.
Loose suspension bolts or nuts. Broken or otherwise damaged wheel bearings. Broken suspension springs. Loose steering gear. Faulty steering gear. Wandering or Poor Steering Stability Mismatched or unevenly worn tires. Loose steering linkage ball joints. Faulty shock absorbers. Loose stabilizer bar. Broken or sagging springs. Steering gear misadjustment. Improper wheel alignment. Erratic Steering When Braking Worn wheel bearings. Broken or sagging springs. Leaking caliper. Warped discs. Badly worn brake pads. Tires are inflated unequally.
Retighten suspension bolts or nuts. Replace wheel bearing. Replace spring. Retighten mounting bolt. Check and adjust steering gear. Replace tire or inflate tires to proper pressure. Replace ball joints. Replace shock absorber. Tighten or replace stabilizer bar or bushings. Replace spring (pairs). Check or adjust steering gear. Adjust wheel alignment. Replace wheel bearings. Replace spring (pairs). Repair or replace caliper. Replace brake disc. Replace brake pads. Inflate tires to proper pressure.
2A8

between this noise and steering performance. Do not replace the valve unless the hissing noise is extremely objectionable. A replacement valve will also have a slight noise, and is not always a cure for the condition. Correction Adjust hose position. Do not bend tubing by hand. Tighten or replace tie rod end. Tighten steering gear mounting. Check and adjust steering gear preload. Adjust front wheel alignment. Replace front wheel bearing. Replace tie rod end. Replace ball joint. steering shaft Replace steering assembly. Adjust the steering gear. Repair or replace steering gear valve. Bleed the system. Repair steering gear. Replenish fluid. Repair pump assembly. Repair or replace steering gear. Replenish fluid. Bleed hydraulic system. Tighten tie rod end. Replace wheel bearing. Repair or replace steering gear valve. Repair pump assembly. Repair pump assembly. Repair steering gear. Replenish fluid. Repair or replace.
Power Steering System

There is some noise in all power steering systems. One of the most common is a hissing sound when the steering wheel is fully turned and the car is not moving. This noise will be most evident when the steering wheel is operated while the brakes are applied. There is no relationship Condition Rattle or Chucking Noise
Possible cause Pressure hose touching other parts of vehicle. Tie rod ends loose. Loose steering gear mounting. Steering gear misadjustment.
Poor Return of Steering Wheel to Center
Improper front wheel alignment. Wheel bearing worn. Tie rod end binding. Ball joint binding. Tight or bearing. frozen
Steering gear misadjustment. Sticky or plugged steering gear valve. Entry of air in the power steering system. Momentary Increase In Effort When Turning Wheel Fast To Right or Left Steering Wheel Surges or Jerks When Turning Especially During Parking Excessive Wheel Kick Back or Loose Steering High internal leakage. Power steering fluid level low. Insufficient pump pressure. Sticky steering gear valve. Power steering fluid level low. Air in system. Tie rod end loose. Wheel bearing worn. Hard Steering or Lack of Power Assist Sticky steering gear valve. Insufficient pump pressure. Excessive internal pump leakage. Excessive internal steering gear leakage. Power steering fluid level low. Unstable Engine Idling or Stalling When Turning Pressure switch of the power steering pump or its harness is faulty.
2A9
Power Steering Pump

Foaming milky power steering fluid, low fluid level, and possible low pressure can be caused by air in the fluid, or loss of fluid due to internal pump leakage. Check for leak and correct. Bleed the system. Extremely cold temperatures will cause air bubbles in the system if the fluid level Condition Low Pressure Due to Steering Pump is low. If the fluid level is correct and the pump still foams, remove the pump from the vehicle and check the housing for cracks. If the housing is cracked, replace the pump housing. Correction Replace relief valve. Replace side plate. Replace cam ring. Replace side plate or rotor. Repair or replace vanes and rotor. Replace side plate. Repair internal leakage. Replace housing. Repair steering unit or pump. Replace side plate or rotor. Replace cam ring. Bleed hydraulic system. Replenish fluid. Tighten mounting bolt. Repair or replace vanes and rotor. Repair rotor and vane. Replace relief valve. Replace side plate and vanes.
Possible cause Relief valve sticking or inoperative. Side plate not flat against cam ring. Extreme wear of cam ring. Scored side plate or rotor. Vanes sticking in rotor slots. Cracked or broken side plate. High internal leakage.
Low Pressure Due to Steering Gear Growling Noise In Steering Pump
Scored housing bore. Excessive back pressure in hoses or steering unit caused by restriction. Scored side plate or rotor. Worn cam ring.
Groaning Noise In Steering Pump
Air in the fluid. Low fluid level. Pump mounting loose.
Rattling Noise In Steering Pump Swishing Noise In Steering Pump Whining Noise In Steering Pump
Vanes sticking in rotor slots. Vane improperly installed. Damaged relief valve. Scored side plate and vanes.
Steering Column Lock System

Condition Will Not Unlock Will Not Lock Possible cause Damaged lock cylinder. Damaged park lock cable. Lock spring broken or worn. Damaged lock cylinder. Ignition switch stuck. Park lock cable damaged. Key Cannot OFF-LOCK be Removed in Ignition switch is not set correctly. Damaged lock cylinder. Faulty shift lock mechanism. Correction Replace lock cylinder. Replace park lock cable. Replace lock cylinder. Replace lock cylinder. Repair or replace ignition switch. Replace park lock cable. Correct ignition switch. Replace lock cylinder. Repair or replace the shift lock mechanism.
Column
Condition Noise in Column Possible cause Universal joint loose. Shaft lock snap ring not seated. Correction Tighten joint. Place snap ring in proper position.
2A10
Turn Signal Switch

This diagnosis covers mechanical problems only. Refer to Turn Signal Switch in Electrical section for electrical diagnosis. Condition Turn Signal Will Not Stay In Turn Position Possible cause Foreign material or loose parts preventing movement of yoke. Broken or missing canceling spring. Turn Signal Will Not Cancel detent or Correction Repair or replace signal switch. Replace signal switch. Tighten mounting screws. Replace turn signal switch. Replace turn signal switch. Replace turn signal switch. Tighten arm screw. Replace turn signal switch. Replace turn signal switch. Repair turn signal switch. Tighten mounting screws. Replace turn signal switch. Replace turn signal switch. Replace turn signal switch. Repair or replace hazard switch. Refer to Electrical section. Replace flasher unit. Repair loose connector. Replace bulb. Repair bulb socket. Repair loose connector.
Loose switch mounting screws. Switch or anchor bosses broken. Broken, missing or out of position detent, return or canceling spring. Worn canceling cam.
Turn Signal Difficult To Operate
Turn signal switch arm loose. Broken or distorted yoke. Loose or misplaced springs. Foreign parts and/or material. Loose turn signal switch mounting screws.
Turn Signal Will Not Indicate Lane Change
Broken lane change pressure pad or spring hanger. Broken, missing or misplaced lane change spring. Base of wire damaged.
Hazard Switch Cannot Be Turned Off No Turn Signal Lights
Foreign material between hazard switch to turn signal switch body. Electrical failure in chassis harness. Inoperative turn signal flasher unit. Loose chassis harness connector.
Front or Rear Turn Signal Lights Not Flashing
Burned-out or damaged turn signal bulb. High resistance connection ground at bulb socket. Loose chassis harness connector. to
2A11
Power Steering System Test

Test Procedure
F02RX001
Legend (1) Bolt (M16 1.5) (2) Hose (Vehicle Side)
(3) To Power Steering Gear (4) To Power Steering Pump
Test of fluid pressure in the power steering system is performed to determine whether or not the oil pump and power steering unit are functioning normally. The power steering system test is the method used to identify and isolate hydraulic circuit difficulties. Prior to performing this test, the following inspections and corrections, if necessary, must be made. D Inspect pump reservoir for proper fluid level. D Inspect pump belt for proper tension. D Inspect pump driver pulley condition. 1. Place a container under the pump to catch the fluid when disconnecting or connecting the hoses. 2. With the engine NOT running,disconnect the pressure hose at the power steering pump and install power steering tester J-29877-A. The gauge must be between the shutoff valve and pump. Open the shutoff valve. 3. Check the fluid level. Fill the reservoir with power steering fluid, to the Full mark. Start the engine, then turn the steering wheel and momentarily hold it against a stop (right or left). Turn the engine off and check the connections at tester for leakage. 4. Bleed the system. Refer to Bleeding the Power Steering System in this section. 5. Start the engine and check the pump fluid level. Add power steering fluid if required. When the engine is at normal operating temperature, increase engine speed to 1500 rpm. CAUTION: Do not leave shutoff valve fully closed for more than 5 seconds, as the pump could become damaged internally.
6. Fully close the shutoff valve. Record the highest pressures. D If the pressure recorded is within 93009800 kPa (13501420 psi), the pump is functioning within its specifications. D If the pressure recorded is higher than 9800 kPa (1420 psi), the valve in the pump is defective. D If the pressure recorded is lower than 9300 kPa (1350 psi), the valve or the rotating group in the pump is defective. 7. If the pump pressures are within specifications, leave the valve open and turn (or have someone else turn) the steering wheel fully in both directions. Record the highest pressures and compare with the maximum pump pressure recorded in step 6. If this pressure cannot be built in either side of the power steering gear, the power steering gear is leaking internally and must be disassembled and repaired. 8. Shut the engine off, remove the testing gauge. 9. Reconnect the pressure hose, check the fluid level and make the needed repairs. 10. If the problem still exists, the steering and front suspension must be thoroughly examined.
2A12
Maintenance
The hydraulic system should be kept clean and fluid level in the reservoir should be checked at regular intervals and fluid added when required. Refer to Recommended Fluids and Lubricants in General Information section for the type of fluid to be used and the intervals for filling. If the system contains some dirt, flush it as described in this section. If it is exceptionally dirty, both the pump and the gear must be completely disassembled before further usage. All tubes, hoses, and fittings should be inspected for leakage at regular intervals. Fittings must be tight. Make sure the clips, clamps and supporting tubes and hoses are in place and properly secured. Power steering hoses and lines must not be twisted, kinked or tightly bent. Air in the system will cause spongy action and noisy operation. When a hose is disconnected or when fluid is lost, for any reason, the system must be bled after refilling. Refer to Bleeding the Power Steering System in this section. D Inspect belt for tightness. D Inspect pulley for looseness or damage. The pulley should not wobble with the engine running. D Inspect hoses so they are not touching any other parts of the vehicle. D Inspect fluid level and fill to the proper level.
Bleeding Procedure
When bleeding the system, and any time fluid is added to the power steering system, be sure to use only power steering fluid as specified in General Information. 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes. 2. Start the engine and let it run for a few seconds. Do not turn the steering wheel. Then turn the engine off. 3. Add fluid if necessary. 4. Repeat the above procedure until the fluid level remains constant after running the engine. 5. Raise and support the front end of the vehicle so that the wheels are off the ground. 6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 7. Add power steering fluid if necessary. 8. Lower the vehicle, set the steering wheel at the straight forward position after turning it to its full steer positions 2 or 3 times, and stop the engine. 9. Check the fluid level and refill as required. 10. If the fluid is extremely foamy, allow the vehicle to set a few minutes, then repeat the above procedure.
Flushing The Power Steering System

1. Raise and support the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump inlet connector and plug the connector port on the pump. Position the line toward a large container to catch the draining fluid. 3. While running the engine at idle, fill the reservoir with new power steering fluid. Turn the steering wheel in both directions. Do not contact or hold the steering wheel to the wheel stops. This will cause the pump to go to pressure relief mode, which may cause a sudden fluid overflow at the reservoir. 4. Install all the lines and hoses. Fill the system with new power steering fluid and bleed the system as described in Bleeding The Power Steering System. Operate the engine for about 15 minutes. Remove the pump return line at the pump inlet and plug the connection on the pump. While refilling the reservoir, check the draining fluid for contamination. If foreign material is still evident, replace all lines, disassemble and clean or replace the power steering system components. Do not re-use any drained power steering fluid.
Fluid Level
1. Run the engine until the power steering fluid reaches normal operating temperature, about 55C (130F), then shut the engine off. 2. Check the level of fluid in the reservoir. 3. If the fluid level is low, add power steering fluid as specified in General Information to the proper level and install the receiver cap. 4. When checking the fluid level after the steering system has been serviced, air must be bled from the system. Refer to Bleeding the Power Steering System in this section.
Bleeding The Power Steering System

When a power steering pump or gear has been installed, or an oil line has been disconnected, the air that has entered the system must be bled out before the vehicle is operated. If air is allowed to remain in the power steering fluid system, noisy and unsatisfactory operation of the system may result.
2A13
Steering Wheel Free Play Adjustment

Inspection
1. Align the front wheels properly in the straight ahead position. 2. Loosen the lock nut on the adjusting screw of the steering gear. 3. Turn the adjust screw clockwise to decrease free play or counter-clockwise to increase. 4. After check of specified free play, tighten the lock nut to specified torque. Torque: 41 Nm (30 lb ft)
Front End Alignment Inspection and Adjustment

General Description
Front End Alignment refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Proper front end alignment must be maintained in order to insure efficient steering, good directional stability and to prevent abnormal tire wear. The most important factors of front end alignment are wheel toe-in, wheel camber and axle caster. Camber: This illustration is viewed from the front of the vehicle.
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1. With the tires in the straight-ahead position, check the amount of steering wheel play by turning the wheel in both directions until the tires begin to move. NOTE: The wheel free play should be checked with the engine running. Free play: 0 30 mm (0 1.18 in) 2. Also check the steering wheel for play and looseness in the mount by moving it back and forth and sideways. When test driving, check for hard steering, steering shimmy and tendency to pull to one side.
Adjustment
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Camber is the vertical tilting inward or outward of the front wheels. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (). The amount of tilt measured in degrees from the vertical is called the camber angle (1). If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside.
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2A14

Toe-in is the measured amount the front wheels are turned in. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure.
Caster: This illustration is viewed from the side of the vehicle.
Inspection
Before making any adjustments affecting caster, camber or toe-in, the following front end inspection should be made. 1. Inspect the tires for proper inflation pressure. Refer to Main Data and Specifications in Wheel and Tire System section. 2. Make sure that the vehicle is unladen condition (With no passenger or loading). 3. Make sure that the spare tire is installed at the normal position. 4. Inspect the front wheel bearings for proper adjustment. Refer to Front Hub and Disc Overhaul in Suspension section. 5. Inspect the ball joints, tie rod ends and relay rods. If excessive looseness is noted, correct before adjusting. Refer to Steering Linkage in this section. 6. Inspect the wheels and tires for run-out. Refer to Wheel Replacement in Wheel and Tire System section. 7. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster. 8. Inspect the steering gear for looseness at the frame. 9. Inspect the shock absorbers for leaks or any noticeable noise. Refer to Shock Absorber Replacement in Suspension section. 10. Inspect the control arms or stabilizer bar attachment for looseness. Refer to Suspension section. 11. Inspect the front end alignment using alignment equipment. Follow the manufacturer s instructions. 12. Park the vehicle must be on a level surface.
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Caster(1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the vehicle). A backward tilt is positive(+) and a forward tilt is negative (). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Toe-in: This illustration is viewed from the top of the vehicle.
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2A15
Trim Height Adjustment

Adjust the trim height(1) by means of the adjusting bolt on the height control arms. CAUTION: When adjusting front end alignment, be sure to begin with trim height first, as it may change other adjusted alignments.
Caster Adjustment
The caster angle can be adjusted by means of the caster shims(1) installed between the chassis frame(2) and fulcrum pins. Caster angle: 210 45 CAUTION: Left and right side must be equal within 30.
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450RS001
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1. Check and adjust the tire inflation pressures. 2. Park the vehicle on a level ground and move the front of the vehicle up and down several times to settle the suspension. 3. Make necessary adjustment with the adjusting bolt on the height control arms. Trim height: 129 mm (5.08 in)
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NOTE: Difference of the caster shim front/rear thickness should be 3.6 mm (0.142 in) or less. Overall thickness of caster shim and camber shim should be 10.8 mm (0.425 in) or less. Tighten the fulcrum pin bolt to the specified torque. Torque: 152 Nm (112 lb ft)
2A16
Camber Adjustment
The camber angle can be adjusted by means of the camber shims(2) installed in position between the chassis frame(1) and fulcrum pins Camber angle: 0 30 King pin inclination: 1230 30 CAUTION: Left and right side must be equal within 30.
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NOTE: Overall thickness of caster shim and camber shim should be 10.8 mm (0.425 in) or less. Tighten the fulcrum pin bolt to the specified torque. Torque: 152 Nm (112 lb ft)
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Position of shims Front side When added Caster shim When removed Camber shim Rear side When removed When added When removed When added When added When removed
Camber angle Decreases Increases Unchanged Unchanged Decreases Increases
Caster angle Decreases Increases Decreases Increases Unchanged Unchanged
2A17
Toe-in Adjustment
1. To adjust the toe-in angle, loosen the lock nuts(2) on the outer track rods(1) and turn the outer track rods. Turn both rods the same amount, to keep the steering wheel centered . Toe-in: 0 2 mm (0 0.08 in)
3. Adjust the inside wheel angle of each side with the stop bolts. NOTE: The maximum protruding length(1) of stop bolt(3) from the lock nut(2) should be 10 mm or less
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4. Similarly adjust the inside wheel angle of the other side with stop bolt.
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2. Tighten the lock nut to the specified torque. Torque: 118 Nm (87 lb ft)
Inside wheel: 34 (+0 to 2) Outside wheel: 32 NOTE: Maximum steering angles should be set after adjusting front wheel alignment. 5. If the stop between the lower link end and the knuckle comes ahead of the stop bolt, adjust the stop bolt so that inner stop bolt touches the drop arm (relay lever).
Maximum Steering Angle Adjustment

The maximum steering angle of the front wheels can be adjusted with the stop bolts under the frame side members.
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1. Position each front wheel on the turning radius gauge in a straight-ahead position. 2. Set the parking brake firmly.
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6. Tighten the lock nut to the specified torque. Torque: 23 Nm (17 lb ft)
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General Specification
Caster Camber King pin inclination Toe-in Max. steering angle inside outside 210 45 0 30 1230 30 0 2 mm (0 0.08 in) 34 (+0 to 2) 32
Torque Specification
E03RS001
2A19
Special Tools
ILLUSTRATION TOOL NO. TOOL NAME
J29877A Tester: Power steering
J39213 Adapter: Power steering tester
J29107 Remover: Pitman arm
J26508 Installer: Extension housing oil seal
2A20
Power Steering Gear

Power Steering Gear and Associated Parts
431RS002
Legend (1) Pipe (2) Universal Joint Bolt (3) Pitman Arm
(4) Nut (5) Gear Box Mounting Bolt and Nut (6) Gear Box
Removal
1. Remove the stone guard. 2. Remove the lower fan shroud. Refer to Radiator in Engine section. 3. Disconnect stabilizer bar at the stabilizer links. Loosen stabilizer bracket fixing nuts. 4. Remove pipe. 5. Remove nut. 6. Use Pitman arm remover J29107 to remove pitman arm.
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7. Make a setting mark(1) across the coupling flange and worm shaft to ensure reassembly of the parts in the original position, then remove universal joint bolt.
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Installation
1. Align the setting marks(1) made at removal, then install gear box.
431RW004
8. Push the stabilizer bar aside and remove the gear box mounting bolts and nuts.
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2. Tighten gear box mounting bolt and nut to specified torque. Torque: 44 Nm (33 lb ft) 3. Tighten gear universal joint bolt to specified torque. Torque: 25 Nm (18 lb ft) 4. Align the notched tooth and install pitman arm.
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9. Remove gear box.
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5. Install nut and tighten Nut to specified torque. Torque: 216 Nm (159 lb ft) 6. Install Pipe and tighten to specified torque. Torque: 44 Nm (33 lb ft)
2A22
Steering Gear Disassembled View
440RS001
Legend (1) Dust Cover (2) Retaining Ring (3) Back Up Ring (4) Oil Seal (5) Ball-nut and Valve Housing Assembly (6) O-ring
(7) (8) (9) (10) (11) (12)
Seal Ring O-ring Gear Box Sector Shaft Top Cover Assembly Lock Nut
2A23
Disassembly
CAUTION: Do not clamp the steering gear assembly in a vise by the power cylinder housing. 1. Remove dust cover. 2. Remove retaining ring. 3. Remove back up ring. 4. Remove oil seal. D Clean the faces of the extended stub shaft. D Plug the hose fitting on the inlet side. D Remove the oil seal by blowing compressed air through the hole in the outlet side.
D Holding the top cover stationary, turn the adjusting screw clockwise to raise and free to cover, then remove the cover with O-ring. 7. Bring the stub shaft into straight-ahead position. Do not force the sector shaft off the gear box with a hammer or other impact tools then remove sector shaft.
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8. Remove ball-nut and valve housing assembly.
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5. Remove lock nut. D Remove the adjusting screw lock nut and turn the adjusting screw counter-clockwise to remove the preload between the sector gear and the rack piston. 6. Remove the top cover bolts and the top cover assembly.
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D Always keep the ball nut and valve housing assembly in a horizontal position to prevent them from traveling to the end of the worm shaft and damaging the ball tubes. 9. Remove O-ring. 10. Remove seal ring. 11. Remove O-ring. 12. Remove gear box.
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2A24

D Check sector shaft outside diameter. Limit: 31.7 mm (1.25 in)

Inspect the following parts for wear, damage or any other abnormal conditions. D Bearing D Ball-nut and valve housing D Sector shaft D Top cover D Gear box D Needle bearing D Dust seal D Seal ring D Gasket
Ball-nut Rotation
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Dust Seal and Seal Ring Setting
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Hold the ball nut and valve housing assembly vertically and see if the ball-nut lowers by turning smoothly. If the ball-nut does not lower smoothly, check the worm shaft for bending and foreign matter. NOTE: When testing the ball nut and valve housing assembly, do not let it travel all the way to the end of worm shaft, or damage to the ball tubes will result.
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D Note the dust seal (1) and the seal ring(2) installation direction. Always install a new part. D Apply a thin coat of power steering fluid to lip of each part.
2A25
Gasket Setting
5. Install ball-nut and valve housing assembly. D Always keep the ball screw and valve housing assembly in a horizontal position (avoid holding it vertically), or the rack piston will fall off onto the end of the worm, causing the rack piston to slip out of the worm shaft and ball to fall out.
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D Note the gasket(1) installation direction. D Apply a thin coat of power steering fluid to lip of each part.
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Reassembly
1. Install gear box. 2. Apply a thin coat of power steering fluid to the new O-ring(2) and be sure to discard used part, then install o-ring. 3. Apply a thin coat of power steering fluid to the new seal ring(1) and be sure to discard used part, then install seal ring. 4. Apply a thin coat of power steering fluid to the new O-ring and be sure to discard used part, then install o-ring.
D Be careful not to drop the O-ring into the valve housing. D Tighten the valve housing bolts to the specified torque. Torque: 47 Nm (35 lb ft) 6. Install sector shaft. D Tape the sector shaft serrations to protect the seal ring from damage. D Align the center tooth of ball nut with that of the sector shaft.
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7. Install O-ring.
2A26

11. Install back up ring and position the chamfered face (outer circumference) towards the oil seal. 12. Install retaining ring and position the chamfered face (outer circumference) towards the oil seal. 13. Install dust cover.
8. Install top cover assembly and tighten the fixing bolts to specified torque. Torque: 47 Nm (35 lb ft) 9. Adjust the backlash between the worm gear and the ball nut.
440RS011
D With the worm gear rotating, set it to the straight ahead position. D Set the worm shaft preload to below 10kgcm with the sector shaft adjusting screw. D Measure the worm shaft preload with the worm gear turned 450 both to the right and to the left. The worm gear preload in these positions should be 0.40.6 Nm (46 kgcm) lower than in the straight ahead position. D Lock the sector shaft adjusting screw with the lock nut. Lock nut torque: 41 Nm (30 lb ft) 10. Apply a thin coat of power steering fluid to oil seal lip of each part, then use installer J26508 to install oil seal.
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2A27

Steering unit Type Gear ratio Integral, ball screw 16.3 : 1
E03RS003
2A28
Power Steering Pump

Power Steering Pump and Associated Parts
436R200001
Legend (1) Hose, Suction (2) Hose, Flexible (3) Bolt
(4) Belt (5) Pulley (6) Pump Assembly
Removal
1. Drain the engine coolant. 2. Place a drain pan below the pump. 3. Remove the air cleaner duct (1) and the radiator upper hose (2).
436RW004

4. Remove the drive belt. 5. Remove the pulley from the power steering pump. 6. Disconnect the suction hose. 7. Disconnect the flexible hose. 8. Remove the power steering pump fixing bolt. 9. Remove the pump assembly. CAUTION: When removing the prmp assembly, be careful not to damage the wiring harnessunder the pump housing.
2A29
Installation
1. Install the adjust plate and tighten the mounting bolts to the specified torque. Torque: 56 Nm (41 lb ft) 2. Install the pump assembly. Connect the harness under the pump housing. 3. Tighten the fixing bolt to the specified torque. Torque: 46 Nm (34 lb ft) 4. Connect the flexible hose, then tighten the eye bolt to specified torque. Torque: 54 Nm (40 lb ft) 5. Connect the suction hose. 6. Install the pulley onto the power steering pump and tighten the nut to the specified torque. Torque: 78 Nm (58 lb ft) 7. Install the air cleaner duct and the radiator upper hose. 8. Refill the engine coolant. 9. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System in this section.
2A30
Power Steering Pump Disassembled View
442R200001
Legend (1) Bolt (2) Suction Pipe (3) O-ring (4) Front Housing (5) Snap Ring (6) Shaft Assembly (7) Bearing (8) Shaft (9) Retaining Ring (10) Oil Seal (11) O-ring (12) O-ring (13) Gasket
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27)
Rear Housing Assembly and Pump Cartridge Side Plate Rotor and Vane Pin Cam Rear Housing Bolt Spring Retaining Ring Filter Valve O-ring Connector Pressure Switch
Disassembly
1. Clean the oil pump with solvent (plug the discharge and suction ports to prevent the entry of solvent). Be careful not to expose the oil seal of shaft assembly to solvent. 2. Remove the bolt. 3. Remove the suction pipe. 4. Remove the O-ring. 5. Remove the connector. 6. Remove the O-ring.
7. Remove the valve. 8. Remove the retaining ring. 9. Remove the filter. 10. Remove the spring. 11. Remove the snap ring. 12. Remove the shaft assembly. 13. Remove the retaining ring. 14. Remove the oil seal. CAUTION: When removing the oil seal, be careful not to damage the housing.

15. Remove the bolt. 16. Remove the rear housing assembly and the pump cartridge. 17. Remove the gasket. 18. Remove the O-ring. 19. Remove the O-ring. 20. Remove the front housing. 21. Remove the side plate. 22. Remove the rotor and vane. 23. Remove the cam. 24. Remove the pin. 25. Remove the rear housing. 26. Remove the pressure switch.
2A31
Vane

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered during inspection.
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Rotor
Sliding faces of the vane should be free from wear. (Particularly the curved face at the tip that contact with the cam should be free from wear and distortion). When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly.
Cam
The inner face of the arm should have a uniform contact pattern without a sign of step wear. When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly.
Side Plate
The sliding faces of parts must be free from step wear (more than 0.01 mm), which can be felt by the finger nail. The parts with minor scores may be reused after lapping the face.
Valve
442RS002
Check that the groove in the vane is free from excessive wear and that the vane slides smoothly. When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly.
The sliding face of the valve must be free from burrs and damage. The parts with minor scores may be reused after smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear which can be felt by the finger nail. Needle bearing fitting face must be free from damage and wear.
O-ring, Oil Seal, Retaining Ring

Be sure to discard used parts, and always use new parts for installation. Prior to installation, lubricate all seals and rings with power steering fluid.
2A32

6. Install side plate. CAUTION: When installing side plate, be careful not to damage its inner surface. Damaged side plate may cause poor pump performance, pump seizure or oil leakage. 7. Install front housing. 8. Install a new o-ring and be sure to discard used parts. 9. Install a new o-ring and be sure to discard used parts. 10. Install a new gasket and be sure to discard used parts. 11. Install rear housing and pump cartridge. 12. Install bolt and tighten it to the specified torque. Torque: 17.6 Nm (12.8 lb ft) 13. Install a new oil seal and be sure to discard used parts. CAUTION: When installing the oil seal, be careful not to damage the oil seal contacting surface of the housing. 14. Install shaft assembly. 15. Install snap ring. 16. Install spring. 17. Install retaining ring. 18. Install filter. 19. Install valve. 20. Install retaining ring. 21. Install a new o-ring and be sure to discard used parts. 22. Install connector and tighten it to the specified torque. Torque: 19.6 Nm (14.3 lb ft) 23. Install a new o-ring and be sure to discard used parts. 24. Install suction pipe. 25. Install bolt and tighten it to the specified torque.
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Pressure Switch
Check the switch operation as follows: With engine idling and A/C on, turn the steering wheel fully to the left; compressor should interrupt and engine idle speed will increase. Shut off A/C and again turn steering fully to the left; engine idle will increase. If system fails to function properly, disconnect connector at the pressure switch and repeat system check while testing continuity across disconnected SW connector.
Reassembly
1. Install rear housing. 2. Install pin. 3. Install cam. 4. Install the rotor with punch mark facing the front housing.
Torque: 15.7 Nm (11.5 lb ft) 26. Install pressure switch and tighten it to the specified torque. Torque: 20 Nm (14 lb ft)
5. Install the vanes with curved face in contact with the inner wall of the cam.
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2A33
1Main Data and Specifications

Oil pump Type Operating fluid Vane ATF DEXRONIII
E02R200002
2A-34 POWER ASSISTED SYSTEM
Center Track Rod Assembly

Center Track Rod Assembly and Associated Parts
433RW001
Legend (1) Nut and Cotter Pin (2) Nut and Cotter Pin, Pitman Arm
(3) Nut and Cotter Pin, Relay Lever (4) Center Track Rod Assembly
2A35
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove nut and cotter pin, then use remover J36831 to disconnect outer track rod assembly from the center track rod. CAUTION: Be careful not to damage the ball joint boot.
4. Remove nut and cotter pin then use remover J36831 to remove relay lever from the center track rod. CAUTION: Be careful not to damage the ball joint boot.
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5. Remove center track rod assembly.

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3. Remove nut and cotter pin then use remover J36831 to remove pitman arm from the center track rod. CAUTION: Be careful not to damage the ball joint boot.
Make necessary correction or parts replacement if wear, damage, corrosion, bending, deteriorations or any other abnormal condition are found through inspection. Check the ball joint (Boot, screws and tapered surfaces).
Installation
1. Install center track rod assembly. 2. Install nut, cotter pin and relay lever, then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 59 Nm (43 lb ft) 3. Install nut, cotter pins and pitman arm, then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 4. Install nut and cotter pins, then tighten the nut to the specified torgue, with fust enough additional torgue to align cotter pen holes. Install new cotter pin. Torque: 98 Nm (72 lb ft)
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Outer Track Rod Assembly

Outer Track Rod Assembly and Associated Parts
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Legend (1) Rod End Assembly, Inner (2) Lock Nut, Inner (Left-hand threads) (3) Lock Nut, Outer
(4) Rod End Assembly, Outer (5) Nut and Cotter Pin, Knuckle Arm (6) Nut and Cotter Pin, Center Track Rod
2A37
Removal
1. Remove wheel and tire assembly. Refer to Wheel Replacement in Suspension section. 2. Remove nut and cotter pin, then use remover J36831 to disconnect outer track rod assembly at the center track rod. CAUTION: Be careful not to damage the ball joint boot.
5. Apply setting marks (1) to ensure reassembly of the parts in their original position, then remove outer rod end assembly.
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6. Remove inner lock nut. NOTE: For either outer rod, the screw on the right side of the vehicle is threaded counterclockwise. 7. Apply setting marks (1) to ensure reassembly of the parts in their original position, then remove inner rod end.
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3. Remove nut and cotter pin then use remover J36831 to remove outer track rod assembly from the knuckle arm. CAUTION: Be careful not to damage the ball joint boot.
433RS015

433RS013
4. Remove outer lock nut.
Make necessary correction or parts replacement if wear, damage, corrosion, bending, deteriorations or any other abnormal condition are found through inspection. Check the following parts: D Rod end assembly D Ball joint (Boot, screws and tapered surfaces)
Installation
1. Install inner rod end and align the setting marks applied during disassembly. 2. Tighten the inner lock nut to specified torque. Torque: 118 Nm (87 lb ft) NOTE: For either outer rod, the screw on the right side of the vehicle is threaded counterclockwise. 3. Install outer rod end assembly and align the setting marks applied during disassembly. 4. Tighten the outer lock nut to specified torque. Torque: 118 Nm (87 lb ft) 5. Install knuckle arm nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 6. Install center track rod and nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) NOTE: If replacing the track rod, adjust the new track rod length. Rod length: 328.3 mm (12.93 in)
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NOTE: Adjust the toe-in. Refer to Front End Alignment Inspection and Adjustment in this section.
2A39
Relay Lever
Relay Lever and Associated Parts
433RS017
Legend (1) Bolt and Nut (2) Relay Lever and Bracket (3) Bracket
(4) Relay Lever (5) Nut and Washer (6) Nut and Cotter Pin
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove nut and cotter pin then use remover J36831 to disconnect relay lever at the center track rod.
433RS011

3. Remove stabilizer bar bolt and nut and push the stabilizer bar aside, then remove the relay lever bolts and nuts.
Installation
1. Install bracket. 2. Install relay lever. 3. Install nut and washer and tighten the nut to the specified torque. Torque: 118 Nm (87 lb ft) 4. Install relay lever and bracket. 5. Install bolt and nut and tighten it to the specified torque. Torque: 44 Nm (33 lb ft) 6. Install nut and cotter pin and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 59 Nm (43 lb ft)
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4. Remove relay lever and bracket. 5. Remove relay lever nut and washer. 6. Remove relay lever, use remover J2291201 to remove relay lever from the bracket.
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7. Remove bracket.
2A41
Steering Linkage and Associated Parts

E03RS004
Special Tools
J36831 Tie rod end remover
J2291201 Relay lever remover
2A43
Supplemental Restraint System Steering Wheel & Column

Service Precaution
This steering wheel and column repair section covers the Supplemental Restraint System (SRS) steering column. The following repair procedures are specific to SRS components. When servicing a vehicle equipped with Supplemental Restraint System, pay close attention to all WARNINGS and CAUTIONS. For detailed explanation about SRS, refer to Restraints section. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. SAFE HANDLING OF INFLATOR MODULES REQUIRES FOLLOWING THE PROCEDURES DESCRIBED BELOW FOR BOTH LIVE AND DEPLOYED MODULES. SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY (AIR BAG) SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY (AIR BAG) IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AN AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. TO AVOID DEPLOYMENT WHEN TROUBLE SHOOTING THE SRS SYSTEM, DO NOT USE ELECTRICAL TEST EQUIPMENT, SUCH AS BATTERY-POWERED OR A/C-POWERED VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED IN THIS MANUAL. DO NOT USE A NON-POWERED PROBE-TYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.)
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SRS Connectors
CAUTION: The special tellow color connectors are used for supplemental restraint system-air bag circuit. When removing the cable harness, do not pull the cables. Otherwise, cable disconnection may occur.

When connect the SRS connector, insert the connector completely. Imperfect locking may cause malfunction of SRS circuit.
Installation
To install the connector, hold the soket insulator(1) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2).
Removal
To remove the connector, hold the cover insulator(1) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2).
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Inflator Module
Inflator Module and Associated Parts
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Legend (1) Module Connector
(2) Inflator Module (3) Steering Wheel
Removal
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to LOCK. 3. Disconnect the battery terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. 5. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly .
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6. Disconnect the yellow 2-way SRS connector located behind the inflator module. D Check for defects such as damage and breakage in the lead wire for the igniter. If an abnormality is found as the result of the inspection, replace the inflator module with a new one.
Installation
1. Install inflator module. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) 2. Support the module and carefully connect the module connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 3. Secure the module with one bolt to relieve weight on the wire connector and tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)
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7. Remove inflator module.

WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT .
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The inflator module consists of a cover, air bag, inflator, and retainer. Inspect the inflator module mainly for the following: D Check for holes, cracks, severe blemishes and deformation on the cover. D Check that the retainer is not deformed.
4. Connect the yellow 2-way SRS connector located under the steering column. 5. Connect the battery terminal cable. 6. Set ignition to ON while watching warning light. Light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.
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Steering Wheel
Steering Wheel and Associated Parts
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Legend (1) Horn Lead (2) Steering Wheel Fixing Nut
(3) Inflator Module (4) Steering Wheel
CAUTION: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on its end could collapse the steering shaft or loosen the slide block which maintains column rigidity. Leaning on the column assembly could cause the jacket to bend or deform. Any of the above damage could impair the column s collapsible design. If it is necessary to remove the steering wheel, use only the specified steering wheel puller. Under no conditions should the end of the shaft be hammered upon, as hammering could loosen slide block which maintains column rigidity.
Removal
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to LOCK. 3. Disconnect the battery terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column.

5. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position, then remove steering wheel.
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6. Disconnect the yellow 2-way SRS connector located behind the inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.
10. Move the front wheels to the straight ahead position, then use steering wheel remover J29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.
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7. Disconnect horn lead. 8. Remove steering wheel fixing nut.
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Installation
1. Install steering wheel by aligning the setting marks made when removing. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 2. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 3. Connect horn lead. 4. Support the module and carefully connect the module connector. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinches. D Secure the module with one bolt to relieve weight on the wire connector. D Tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)
7. Turn the ignition switch to ON while watching warning light. Light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.
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5. Connect the yellow 2-way SRS connector located under the steering column. 6. Connect the battery terminal cable.
Combination Switch
Combination Switch and Associated Parts
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Legend (1) Steering Column Cover (2) Steering Wheel (3) Inflator Module
(4) (5) (6) (7)
Combination Switch and SRS Coil Assembly Front Console Assembly Steering Lower Cover Lower Cluster Assembly
Removal
CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the transmission (for M/T) and transfer control lever knob. Disconnect the wiring harness connectors then remove front console assembly. 6. Remove lower cluster assembly. 7. Remove the engine hood opening lever, then remove steering lower cover.

8. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. Disconnect the yellow 2-way SRS connector located behind the inflator module, then remove inflator module.
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9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead posision, then use steering wheel remover J29752 to remove the steering wheel.
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WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.
CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil.
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10. Remove steering column cover. 11. Disconnect the wiring harness connectors located under the steering column, then remove combination switch and SRS coil assembly. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly.
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2. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch on any moving parts.
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Installation
1. Install combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. Then turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark.
Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 3. Align the setting marks made when removing then install steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 5. Support the inflator module and carefully connect the module connector. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 6. Secure the module with one bolt to relieve weight on the wire connector. 7. Tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)
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8. Install steering lower cover then Install the engine hood opening lever. 9. Install lower cluster assembly 10. Install the transmission (for M/T) and transfer control lever knob, then install front console assembly. 11. Connect the wiring harness connectors. 12. Connect the battery terminal cable. 13. Turn the ignition switch to ON while watching warning light and check the light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.
Lock Cylinder
Lock Cylinder and Associated Parts
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Legend (1) Inflator Module (2) Steering Wheel (3) Steering Column Cover (4) Combination Switch and SRS Coil Assembly (5) Snap Ring
(6) (7) (8) (9) (10) (11)
Cushion Rubber Lock Cylinder Assembly Front Console Assembly Lower Cluster Assembly Steering Lower Cover Shift Lock Cable (for A/T)
Removal
CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the transmission (for M/T) and transfer control lever knob and disconnect the wiring harness connectors, then remove front console assembly. 6. Remove lower cluster assembly. 7. Remove the engine hood opening lever and steering lower cover.

8. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly.
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10. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position.
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9. Disconnect the yellow 2-way SRS connector located behind the inflator module.
11. Move the front wheels to the straight ahead position, then use steering wheel remover J29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.
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WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. 15. Remove snap ring. 16. Remove cushion rubber. 17. Remove shift lock cable (for A/T). 18. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly.
Installation
1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil.
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12. Remove steering column cover. 13. Disconnect the wiring harness connectors located under the steering column. 14. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly.
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7. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch on any moving parts.
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12. Tighten fixing bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)
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Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 10. Support inflator module and carefully connect the module connector, then install inflator module. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Secure the inflator module with one bolt to relieve weight on the wire connector.
13. Install steering lower cover, then install the engine hood opening lever. 14. Install lower cluster assembly. 15. Connect the wiring harness connectors, then install front console assembly and install the transmission (for M/T) and transfer control lever knob. 16. Connect the yellow 2-way SRS connector located under the steering column. 17. Connect the battery terminal cable.
System Inspection
Turn the ignition switch to ON while watching warning light.The light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.
Steering Column
Steering Column and Associated Parts
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Legend (1) Inflator Module (2) Steering Wheel (3) Steering Column Cover (4) Combination Switch and SRS Coil Assembly (5) Snap Ring (6) Cushion Rubber
(7) (8) (9) (10) (11) (12) (13)
Lock Cylinder Assembly Shift Lock Cable (For A/T) Steering Column Assembly Front Console Assembly Lower Cluster Assembly Steering Lower Cover Driver Knee Bolster (reinforcement)
Removal
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to LOCK. 3. Disconnect the battery terminal cable, and wait at least 5 minutes.
4. Disconnect the yellow 2-way SRS connector located under the steering column.

CAUTION: The wheel of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column from the steering gear. Failure to do so will cause the SRS coil assembly to become uncentered which will cause damage to the SRS coil assembly. 5. Disconnect the transmission (for M/T) and transfer control lever knob. 6. Disconnect the wiring harness connectors. 7. Remove front console assembly. 8. Remove lower cluster assembly. 9. Remove the engine hood opening lever, then remove steering lower cover. 10. Remove driver knee bolster (reinforcement). 11. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly.
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14. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead position, then use steering wheel remover J29752 to remove the steering wheel.
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12. Disconnect the yellow 2-way SRS connector located behind the inflator module. 13. Remove inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.
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22. Apply a setting mark (1) across the universal joint and steering shaft to reassemble the parts in their original position, then remove steering column assembly. NOTE: A setting mark can be easily made if the shaft is withdrawn a little by loosening the steering shaft universal joint.
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15. Remove steering column cover. 16. Disconnect the wiring harness connectors located under the steering column. 17. Remove the combination switch assembly with SRS coil. NOTE: SRS coil is a part of combination switch assembly, which can not be replaced singly. Therefore, be sure not to remove the SRS coil from the combination switch assembly.
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Inspection
If the abnormal conditions are found through inspection, replace the steering column assembly.
Column Capsule
Check capsules on steering column bracket assembly; all must be securely seated in bracket slots and checked for any loose conditions when pushed or pulled by hand.
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18. Remove snap ring. 19. Remove cushion rubber. 20. Remove shift lock cable (For A/T). 21. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly.
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Check clearance between capsule and bracket. It must be within 1 mm (0.039 in).
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Sheared Injected Plastic Pin

Check the sheared injected plastic pins for any loose conditions or damage.
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Column Tube
Check for collapse by measuring the distance as shown in the figure. Standard distance: 162.2165.8 mm (6.3866.528 in)
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Shaft Length
Check the shaft length from the upper end of the slide joint to the end of the shaft. If column length is not in specifications, steering column should be replaced. Standard length: 308310 mm (12.12612.205 in)
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Column Universal Joint for Tilt Mechanism

If the resistance is felt when checked by rotate the joint, replace the steering column assembly.
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Shaft Universal Joint (Lower End)

If the resistance is felt when checked by rotate the joint, replace the steering column assembly.
Shaft Bellows Pipe

Check the shaft bellows pipe for bend by using straight edge. Measure the clearance between the bellows pipe and the straight edge (at center of the bellows pipe). Standard: Less than 1 mm (0.039 in)
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Tilt Mechanism
Tilt mechanism should moves smoothly. While locked the tilt mechanism, be sure the steering column latch securely by pushing the steering wheel upward and downward.
12. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch any moving parts.
Installation
1. Install steering column assembly. 2. Align the setting marks on the universal joint and steering shaft made during removal. 3. Tighten the steering column fixing bolt (dash panel) to the specified torque. Torque: 19 Nm (14 lb ft) 4. Tighten the steering column fixing bolt bracket) to the specified torque. Torque: 17 Nm (13 lb ft) 5. Tighten the universal joint to the specified torque. Torque: 25 Nm (18 lb ft) 6. Install lock cylinder assembly. 7. Install shift lock cable (For A/T). 8. Install cushion rubber. 9. Install snap ring. 10. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 11. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil.
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(pedal
Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 13. Install steering wheel and align the setting marks made when removing. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 14. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 15. Support the module and carefully connect the module connector then install inflator module.

CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 16. Secure the module with one bolt to relieve weight on the wire connector. 17. Tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)
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18. Install driver knee bolster (reinforcement). 19. Install steering lower cover. 20. Install the engine hood opening lever. 21. Install lower cluster assembly. 22. Connect the wiring harness connectors then install front console assembly. 23. Install the transmission (for M/T) and transfer control lever knob. 24. Connect the yellow 2-way SRS connector located under the steering column. 25. Connect the battery terminal cable.
System Inspection
Turn the ignition switch ON while watching warning light. The light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.
Supplemental Restraint System Steering Wheel & Column and Associated Parts
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Special Tools
J29752 Steering wheel remover
SECTION
FRONT SUSPENSION
TROOPER
3C1
SUSPENSION
CONTENTS
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . Wheel and Tire System . . . . . . . . . . . . . . . . . . 3C1 3D1 3E1
FRONT SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsion Bar and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knuckle and Associated Parts . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C1 3C2 3C3 3C6 3C6 3C6 3C6 3C6 3C7 3C7 3C7 3C7 3C7 3C8 3C8 3C8 3C9 3C9 3C11 3C11 3C11 3C12 3C12 Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . Upper Control Arm and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . Lower Control Arm and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . Upper Ball Joint and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . Lower Ball Joint and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C14 3C14 3C14 3C15 3C16 3C18 3C18 3C18 3C19 3C20 3C21 3C21 3C21 3C22 3C22 3C23 3C23 3C23 3C24 3C24 3C25 3C26
Service Precaution
3C2
FRONT SUSPENSION
General Description
C03RW001
Legend (1) Shock Absorber (2) Upper Control Arm (3) Height Control Arm
(4) (5) (6) (7)
Torsion Bar Link Lower Control Arm Stabilizer Bar
The front suspension is designed to allow each wheel to compensate for changes in the road surface level without greatly affecting the opposite wheel. Each wheel is independently connected to the frame by a steering knuckle, ball joint assemblies, and upper and lower control arms. The front wheels are held in proper relationship to each other by two outer track rods which are connected to steering arms on the knuckles, and to a center track rod. All models have a front suspension system consisting of control arms, stabilizer bar, shock absorber and a torsion bar. The front end of the torsion bar is attached to the lower control arm. The rear of the torsion bar is mounted
into a height control arm at the crossmember. Vehicle trim height is controlled by adjusting this arm. Shock absorbers are mounted between the brackets on the frame and the lower control arms. The lower portion of each shock absorber is attached to the lower control arm. The upper portion of each shock absorber extends through a frame bracket and is secured with two rubber bushings, three retainers and a nut. Ball joint assemblies are bolted to the outer end of the upper and lower control arm and are attached to the steering knuckle. The inner ends of the upper control arm have pressed in bushings. Bolts, passing through the bushing, attach the control arm to the frame. The inner ends of the lower
FRONT SUSPENSION
control arm are attached to the frame by bolts passing through the bushings, which are pressed in the frame. Side roll of the front suspension is controlled by a spring steel stabilizer bar. It is mounted in rubber bushings,
3C3
which are held to the crossmember by brackets. The ends of the stabilizer bar are connected to the lower control arms by links.
General Diagnosis
Condition Vehicle Pulls Possible cause Mismatched or uneven tires. Tires not adequately inflated. Broken or sagging springs. Radial tire lateral force. Improper wheel alignment. Brake dragging in one wheel. Loose, bent or broken front or rear suspension parts. Faulty shock absorbers. Abnormal or Excessive Tire Wear Sagging or broken spring. Tire out of balance. Improper wheel alignment. Faulty shock absorber. Hard driving. Overloaded vehicle. Tires not rotated periodically. Worn or loose road wheel bearings. Wobbly wheel or tires. Tires not adequately inflated. Wheel Hop Shimmy, Shake or Vibration Blister or bump on tire. Improper shock absorber operation. Tire or wheel out of balance. Loose wheel bearings. Worn steering linkage ball joints. Worn upper or lower ball joints. Excessive wheel runout. Blister or bump on tire. Excessive loaded radial runout of tire/wheel assembly. Improper wheel alignment. Loose or worn steering linkage. Loose steering gear. Tires not adequately inflated. Loose, bent or broken front or rear suspension parts. Faulty shock absorber. Hub bearing preload misadjustment. Correction Replace tire. Adjust tire pressure. Replace spring. Replace tire. Adjust wheel alignment. Repair brake. Tighten or replace the appropriate suspension part(s). Replace shock absorber. Replace spring. Balance or replace tire. Check front end alignment. Replace shock absorber. Replace tire. Replace tire and reduce load. Replace or rotate tire. Replace wheel bearing. Replace wheel or tire. Adjust the pressure. Replace tire. Replace shock absorber. Balance wheels or replace tire/or wheel. Replace wheel bearing. Replace ball joints. Replace ball joints. Repair or replace wheel and/or tire. Replace tire. Replace tire or wheel. Check wheel alignment. Tighten or replace steering linkage. Tighten housing bolts. Adjust tire pressure. Tighten or replace the appropriate suspension parts. Replace shock absorber. Adjust preload.
3C4
FRONT SUSPENSION
Condition Possible cause Bind in steering linkage ball studs, upper or lower ball joint. Improper wheel alignment. Steering gear misadjustment. Tire not adequately inflated. Bind in steering column or shaft. Improper power steering system operation. Correction Replace ball joint. Check wheel alignment. Check and adjust pinion torque. Inflate tires to proper pressure. Repair or replace. Repair or replace. Refer to Steering section. Replace wheel bearings. Retighten or repair. Inspect and adjust steering gear preload. shaft Retighten or replace steering shaft. Replace ball joints. Replace ball joints. Replace ball joints. Replace ball joints. Repair or replace. Check and repair steering gear. Adjust wheel alignment. Adjust tire pressure. Retighten. Replace. Replace.
Hard Steering
Too Much Play In Steering
Wheel bearings worn. Loose steering gear or linkage. Steering gear misadjustment. Worn or loose universal joint. steering
Worn steering linkage ball joints. Worn upper or lower end ball joints. Poor Steering Wheel Returnability Bind in steering linkage ball joints. Bind in upper or lower ball joints. Bind in steering column and shaft. Bind in steering gear. Improper wheel alignment. Tires not adequately inflated. Loose steering wheel nut. Worn wheel bearing. Abnormal Noise Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Worn upper or lower control arm bushing. Loose stabilizer bar. Loose wheel nuts.
Replace. Replace. Retighten bolts or replace bushings. Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required. Retighten suspension bolts or nuts. Replace wheel bearing. Replace spring. Retighten mounting bolt. Check and adjust steering gear.
Loose suspension bolts or nuts. Broken or otherwise damaged wheel bearings. Broken suspension springs. Loose steering gear. Faulty steering gear.
FRONT SUSPENSION
Condition Wandering or Poor Steering Stability Possible cause Mismatched or unevenly worn tires. Loose steering linkage ball joints. Faulty shock absorbers. Loose stabilizer bar. Broken or sagging springs. Steering gear misadjustment. Improper wheel alignment. Erratic Steering When Braking Worn wheel bearings. Broken or sagging springs. Leaking caliper. Warped discs. Badly worn brake pads. Tires are inflated unequally. Low or Uneven Trim Height Broken or sagging springs. Vehicle overloaded. Incorrect springs. Suspension Bottoms Vehicle overloaded. Faulty shock absorber. Incorrect, broken or sagging springs. Body Leans Loose stabilizer bar. Faulty shock absorber, struts or mounting. Broken or sagging springs. Vehicle overloaded. Cupped Tires Worn wheel bearings. Excessive tire or wheel run out. Worn ball joints. Tire out of balance. Correction
3C5
Replace tire or inflate tires to proper pressure. Replace ball joints. Replace shock absorber. Tighten or replace stabilizer bar or bushings. Replace spring (pairs). Check or adjust steering gear. Adjust wheel alignment. Replace wheel bearings. Replace spring (pairs). Repair or replace caliper. Replace brake disc. Replace brake pads. Inflate tires to proper pressure. Replace springs (In pairs). Reduce load. Adjust or replace torsion bar. Reduce load. Replace shock absorber. Replace springs. Tighten stabilizer bar bolts or replace bushings. Replace shock absorber. Replace springs (In pairs). Reduce load. Replace wheel bearing. Replace tire or wheel. Replace ball joints. Adjust tire balance.
3C6
FRONT SUSPENSION
Shock Absorber
Shock Absorber and Associated Parts
450RS006
Legend (1) Nut (2) Rubber Bushing and Washer
(3) Bolt, Nut and Washer (4) Shock Absorber (5) Rubber Bushing and Washer
Removal
1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove bolt,nut and washer. 4. Remove nut. 5. Remove rubber bushing and washer. 6. Remove shock absorber. 7. Remove rubber bushing and washer.
Installation
1. Install rubber bushing and washer. 2. Install shock absorber. 3. Install rubber bushing and washer. 4. Install nut, then tighten it to the specified torque. Torque: 20 Nm (14 lb ft) 5. Install bolt, nut and washer, then tighten to the specified torque. Torque: 82 Nm (61 lb ft)

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Shock absorber D Rubber bushing
FRONT SUSPENSION
3C7
Stabilizer Bar
Stabilizer Bar and Associated Parts
410RS002
Legend (1) Nut and Washer (2) Link
(3) Bracket, Nut and Washer (4) Rubber Bushing (5) Stabilizer Bar
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove the stone guard. 3. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 4. Remove nut and washer. CAUTION: Be careful not to break the ball joint boot. 5. Remove link. 6. Remove bracket. 7. Remove stabilizer bar. 8. Remove rubber bushing.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Stabilizer bar D Rubber bushing D Link ball joint
Installation
1. Install rubber bushing. 2. Install stabilizer bar. 3. Install bracket, then tighten it to the specified torque. Torque: 22 Nm (16 lb ft) 4. Install link. 5. Install nut and washer, then tighten the nut to the specified torque. Torque: 50 Nm (37 lb ft)
3C8
FRONT SUSPENSION
Torsion Bar
Torsion Bar and Associated Parts
410RS003
Legend (1) Adjust Bolt, End Piece and Seat
(2) Height Control Arm (3) Torsion Bar
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Apply the setting marks(1) to the adjust bolt and end piece, then remove adjust bolt, end piece and seat.
410RS004
FRONT SUSPENSION
3. Apply the setting marks(2) to the height control arm and torsion bar, then remove height control arm.
3C9
Installation
1. Apply grease to the serrated portions, then install torsion bar. Make sure the bars are on their correct respective sides and align the setting marks(3).
410RS005
4. Apply the setting marks(3) to the torsion bar and lower control arm, then remove torsion bar.
410RS007
410RS006 410RS006

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Torsion bar D Height control arm D Adjust bolt D Rubber seat
3C10
FRONT SUSPENSION
5. Install adjust bolt and seat, then turn the adjust bolt to the setting mark(1) applied during disassembly. NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.
2. Apply grease to the portion that fits into the bracket then install height control arm and align the setting marks(2).
410RS005
3. Apply grease to the bolt portion of the end piece(4). Apply grease to the portion of the seat(5) that fits into the bracket.
410RS004
410RS008
4. Apply grease to the serrated portions.
FRONT SUSPENSION
3C11
Knuckle
Knuckle and Associated Parts
410RW001
Legend (1) Torsion Bar (2) Lower Ball Joint, Nut and Cotter Pin (3) Back Plate (4) Knuckle Assembly (5) Knuckle
(6) (7) (8) (9) (10)
Needle Bearing Thrust Washer Oil Seal Upper Ball Joint, Nut and Cotter Pin Wheel Speed Sensor
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove the brake caliper. Refer to Disc Brakes in Brake section.
4. Remove the hub assembly. Refer to Front Hub and Disk in Driveline/Axle section. 5. Remove outer track rod from the knuckle. Refer to Outer Track Rod Assembly Replacement in Steering section. 6. Remove the speed sensor from the knuckle. 7. Loosen torsion bar by height control arm adjust bolt, then remove torsion bar. Refer to Torsion Bar Replacement in this section.
3C12
FRONT SUSPENSION
14. Remove needle bearing by using remover J23907.
8. Remove back plate. 9. Remove lower ball joint by using remover J29107. CAUTION: Be careful not to damage the ball joint boot.
901RW044

901RW042
10. Remove upper ball joint by using remover J36831. CAUTION: Be careful not to damage the ball joint boot.
Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Knuckle D Knuckle arm D Needle bearing D Thrust washer
Installation
1. Apply appropriate amount of multipurpose type grease to the new bearing (Approx. 5 g)and install needle bearing by using installer J36838 and J8092.
901RW043
11. Remove knuckle assembly. 12. Remove oil seal. 13. Remove washer.
901RW045
FRONT SUSPENSION
2. Apply multipurpose type grease to the thrust washer, and install washer with chamfered side facing knuckle. 3. Use a new oil seal, and apply multipurpose type grease to the area surrounded by the lip (approx. 2 g). Then use installer J41468 and J8092 to install oil seal. After fitting the oil seal to the installer, drive it to the knuckle using a hammer or bench press until the tool front face contacts with the thrust washer.
3C13
901RW046
4. Install knuckle assembly. 5. Install upper ball joint and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 6. Install lower ball joint and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 147 Nm (108 lb ft) 7. Install back plate. 8. Install wheel speed sensor. 9. Install torsion bar, refer to Torsion Bar Replacement in this section. NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.
3C14
FRONT SUSPENSION
Upper Control Arm

Upper Control Arm and Associated Parts
450RS007
Legend (1) Bolt and Plate (2) Camber Shims (3) Caster Shims (4) Nut Assembly (5) Upper Control Arm Assembly (6) Fulcrum Pin
(7) (8) (9) (10) (11) (12)
Bushing Plate Nut Speed Sensor Cable Nut and Cotter Pin Upper Ball Joint, Bolt Washer and Nut
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section.
3. Remove the brake caliper and disconnect brake pipe. Refer to Disc Brakes in Brake section. 4. Support lower control arm with a jack. 5. Remove speed sensor cable. 6. Remove nut and cotter pin then use remover J36831.
FRONT SUSPENSION
CAUTION: Be careful not to break the ball joint boot.
3C15
901RW048
901RW043
16. Remove fulcrum pin.
7. Remove upper ball joint. 8. Remove bolt and plate. 9. Remove nut assembly. 10. Remove camber shims and note the positions and number of shims. 11. Remove caster shims and note the positions and number of shims. 12. Remove upper control arm assembly. 13. Remove nut. 14. Remove plate. 15. Remove bushing by using remover J29755.

Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Upper control arm D Bushing D Fulcrum pin
901RW047
3C16
FRONT SUSPENSION
4. Install nut and tighten fulcrum pin nut fingertight. NOTE: Torque fulcrum pin nut after adjusting buffer clearance. Buffer clearance: 20 mm (0.79 in) Torque: 108 Nm (80 lb ft)
Installation
1. Install fulcrum pin. 2. Install bushing by using installer J29755 and J39376.
901RW049 450RS012
5. Install upper control arm assembly with the fulcrum pin projections turned inward.
901RW050
3. Install plate.
450RS013
Legend (1) Projection (2) Outward
FRONT SUSPENSION
6. Install the caster shims(2) between the chassis frame and fulcrum pin. 7. Install the camber shims(1) between the chassis frame and fulcrum pin.
3C17
450RS014
8. Install nut assembly. 9. Install bolt and plate, then tighten the bolt to the specified torque. Torque: 152 Nm (112 lb ft) 10. Install upper ball joint and tighten it to the specified torque. Torque: 57 Nm (42 lb ft) 11. Install nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 12. Install speed sensor cable.
3C18
FRONT SUSPENSION
Lower Control Arm

Lower Control Arm and Associated Parts
450R200010
Legend (1) Nut and Washer, Front (2) Bush, Front (3) Bolt, Front (4) Nut and Washer, Rear (5) Bush, Rear (6) Bolt, Rear (7) Bolt, Lower Ball Joint
(8) (9) (10) (11) (12) (13) (14)
Bolt, Torsion Bar Arm Torsion Bar Arm and Nut Torsion Bar Lower Control Arm Lower Ball Joint and Nut Shock Absorber, Bolt Washer and Nut Stabilizer Link, Washer and Nut
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section.
3. Remove the outer track rod from the knuckle. Refer to Steering Linkage in Steering section. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub. Refer to Front Hub and Disc in Driveline/Axle section. 5. Support lower control arm with a jack. 6. Remove front nut and washer.
FRONT SUSPENSION
7. Remove rear nut and washer. 8. Remove torsion bar, refer to Torsion Bar Replacement in this section. 9. Remove torsion bar arm. 10. Disconnect the stabilizer link at the lower control arm. 11. Remove the shock absorber lower end from the lower control arm. 12. Remove the lower ball joint from the lower control arm. 13. Remove front bolt. 14. Remove rear bolt. 15. Remove lower control arm. 16. Remove torsion bar arm bolt. 17. Remove lower ball joint bolt. 18. Remove front bushing by using remover J36833.
3C19
19. Remove rear bushing by using remover J36834.
901RW051
901RW034
901RW052

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Lower control arm D Bushing
901RW035
3C20
FRONT SUSPENSION
11. Install torsion bar arm bracket and tighten it to the specified torque. Torque: 116 Nm (85 lb ft) 12. Install Torsion bar, refer to Torsion Bar Replacement in this section. 13. Install rear nut and washer and tighten lower link nut fingertight. NOTE: Torque lower control arm nut after adjusting buffer clearance. Buffer clearance: 20 mm (0.79 in) Torque: 196 Nm (145 lb ft)
Installation
1. Install rear bushing by using installer J36834.
901RW053
2. Install front bushing by using installer J36833.
450RS012
14. Install front nut and washer then tighten lower link nut finger-tight. NOTE: Torque lower control arm nut after adjusting buffer clearance . Buffer clearance: 20 mm (0.79 in) Torque: 157 Nm (116 lb ft) NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.
901RW036
3. Install lower ball joint bolt. 4. Install torsion bar arm bolt. 5. Install lower control arm. 6. Install rear bolt. 7. Install front bolt. 8. Install lower ball joint and tighten it to the specified torque. Torque: 103 Nm (76 lb ft) 9. Install shock absorber and tighten it to the specified torque. Torque: 82 Nm (61 lb ft) 10. Install stabilizer link and tighten it to the specified torque. Torque: 50 Nm (37 lb ft)
450RS012
FRONT SUSPENSION
3C21
Upper Ball Joint

Upper Ball Joint and Associated Parts
450RS022
Legend (1) Bolt, Nut and Washer
(2) Upper Ball Joint (3) Nut and Cotter Pin
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove the speed sensor from the knuckle.
3C22
FRONT SUSPENSION
D After moving the ball joint 4 or 5 times, attach nut then measure the preload. Starting torque: 0.5 3.2 Nm (0.42.4 lb ft)
3. Remove upper ball joint nut and cotter pin, then use remover J36831 to remove the upper ball joint from the knuckle. CAUTION: Be careful not to break the ball joint boot.
450RS024 901RW043
4. Remove bolt and washer. 5. Remove upper ball joint.
If the above limits specified are exceeded, replace the ball joint assembly.
Installation Inspection and Repair

Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. D Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement. D Inspect screw/taper area of ball for damage. D If any defects are found by the above inspections, replace the ball joint assembly with new one. 1. Install upper ball joint. 2. Install bolt and nut, then tighten them to the specified torque. Torque: 57 Nm (42 lb ft) 3. Install nut and cotter pin, then tighten the nut to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft)
450RS023
FRONT SUSPENSION
3C23
Lower Ball Joint

Lower Ball Joint and Associated Parts
450RS025
Legend (1) Bolt (2) Lower Ball Joint
(3) Nut (4) Nut and Cotter Pin
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove the outer track rod from the knuckle. Refer to Steering Linkage in Steering section. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub. Refer to Front Hub and Disc in Driveline/Axle section. 5. Support lower control arm with a jack. 6. Remove lower ball joint nut and cotter pin, then use remover J29107 to remove the lower ball joint from the knuckle. CAUTION: Be careful not to damage the ball joint boot.
901RW042
3C24
FRONT SUSPENSION
7. Remove nut. 8. Remove lower ball joint. 9. Remove bolt.
Installation
1. Install bolt. 2. Install lower ball joint. 3. Install nut and tighten it to the specified torque. Torque: 103 Nm (76 lb ft) 4. Install nut, then tighten it to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 147 Nm (108 lb ft)

Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. D Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement . D Inspect screw/taper area of ball for damage. D If any defects are found by the above inspections, replace the ball joint assembly with new one.
450RS026
D After moving the ball joint 4 or 5 times, attach nut the measure the preload. Starting torque: 0.56.4 Nm (0.44.7 lb ft)
450RS024
D If the above limits specified are exceeded, replace the ball joint assembly.
FRONT SUSPENSION
3C25

Front suspension Torsion bar spring Front shock absorber Type Length Diameter Type Piston diameter Stroke Compressed length Extended length Stabilizer bar Diameter Independent wishbone arms, torsion bar spring with stabilizer bar. 1217 mm (47.9 in) 26.6 mm (1.05 in) Hydraulic, double acting, telescopic 30.0 mm (1.18 in) 130.0 mm (5.12 in) 390.0 mm (15.35 in) 260.0 mm (10.24 in) 26.0 mm (1.02 in)
E03R200008
3C26
FRONT SUSPENSION
Special Tools
J23907 Remover; Needle bearing
J36833 Remover and Installer kit; Lower arm front bushing
J36838 Installer; Needle bearing
J36834 Remover and Installer kit; Lower arm rear bushing
J8092 Grip
J36831 Tie rod end remover
J41468 Installer; Oil seal
J29107 Lower end remover
J39376 Installer; Upper arm bushing
J29755 Remover and Installer Upper arm bushing
SECTION
REAR SUSPENSION
TROOPER
3D1
SUSPENSION
REAR SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Spring and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D1 3D2 3D3 3D3 3D3 3D4 3D4 3D5 3D5 3D5 3D5 3D5 3D6 3D6 3D6 3D6 3D7 Center Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Link and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D8 3D8 3D8 3D8 3D9 3D10 3D10 3D10 3D10 3D11 3D12 3D12 3D12 3D12 3D13 3D14 3D16
Service Precaution
3D2
REAR SUSPENSION
General Description
C03RS003
Legend (1) Stabilizer Bar (2) Lateral Rod
(3) Shock Absorber (4) Trailing Link (5) Center Link
The rear suspension is a 4-link, coil spring type suspension with a stabilizer bar, consisting of two trailing links, center link, lateral rod, shock absorber, and stabilizer. In this suspension, the links are specially arranged to enable the rear axle to move freely, thereby expanding suspension stroke, reducing friction, and improving lateral rigidity and roll control. All these result in improved stability, riding comfort, and rough road maneuverability. Each link connects the axle housing with the frame through a runner bushing. The axle housing is supported by the trailing links and center link longitudinally and by the lateral rod latitudinally.
REAR SUSPENSION
3D3
Coil Spring
Coil Spring and Associated Parts
460RS001
Legend (1) Parking Brake Cable Bracket (2) Shock Absorber
(3) Coil Spring (4) Insulator (5) Stabilizer Bar, Link and Nut
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Support the rear axle case with a jack. 3. Remove the parking brake cable bracket from the trailing link. 4. Disconnect the stabilizer bar at the stabilizer link. 5. Remove the shock absorber from the axle case. 6. Remove spring insulator. 7. Remove coil spring while lowering the rear axle case.
CAUTION: Be sure not to let the brake hose, parking brake cable, and breather hose extend to their full length.
3D4
REAR SUSPENSION
3. Install the insulator on the coil spring. Jack up the axle case gently with the top of the coil spring set to the spring seat on the frame side.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Coil spring D Insulator
Installation
1. Install coil spring and make sure that the coil spring is installed in the proper position. Paint mark(1) should be downward.
460RS004
4. Install shock absorber and tighten the nut lightly,then retighten it to the specified torque after the vehicle is at curb height. NOTE: When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. Torque: 78 Nm (58 lb ft) 5. Install stabilizer bar. Torque: 50 Nm (37 lb ft)
460RW001
6. Install parking brake cable bracket.
2. Fit the end of the coil spring to the coil spring seat and mount the coil spring on the rear axle case.
460RS003
REAR SUSPENSION
3D5
Shock Absorber
Shock Absorber and Associated Parts
461RW002
Legend (1) Bolt and Nut
(2) Shock Absorber (3) Nut and Washer
Removal
1. Remove shock absorber fixing nut and washer. 2. Remove shock absorber fixing bolt and nut. 3. Remove shock absorber.
Installation
1. Install shock absorber. When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. 2. Install bolt and nut, then tighten the bolt and nut lightly. Retighten to the bolt and nut specified torque after the vehicle is at curb height. Torque: 95 Nm (70 lb ft) 3. Install nut and washer, then tighten the nut lightly. Retighten to the nut specified torque after the vehicle is at curb height. Torque: 78 Nm (58 lb ft)

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Shock absorber D Rubber bushing (Axle side) NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.
3D6
REAR SUSPENSION
Trailing Link
Trailing Link and Associated Parts
460RW017
Legend (1) Parking Brake Cable
(2) Bolt and Nut (3) Trailing Link
Removal
1. Remove the parking brake cable from the trailing link. 2. Remove the trailing link fixing bolt and nut. 3. Remove trailing link.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. 1. Trailing link 2. Rubber bushing D Remove the rubber bushing by using remover J39214.
901RW058
REAR SUSPENSION
D Install the rubber bushing by using installer J39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.
3D7
901RW059
Installation
1. Install trailing link. Make sure that the trailing link is in its correct position. NOTE: When mounting trailing link, be sure not to use grease on bushings or any other nearby part.
460RS008
2. Install bolt and nut. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 Nm (101 lb ft) 3. Install parking brake cable. CAUTION: The parking brake cable should not be overstrained or slackened.
3D8
REAR SUSPENSION
Center Link
Center Link and Associated Parts
460RX001
Legend (1) Center Link (2) Bolt and Nut
(3) Speed Sensor Cable Bracket (4) Speed Sensor Cable
Removal
1. Remove the speed sensor cable from the center link. 2. Remove the speed sensor cable bracket from the frame. 3. Remove bolt and nut. 4. Remove center link.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. 1. Center link 2. Rubber bushing D Remove the rubber bushing by using remover J39214.
901RW058
REAR SUSPENSION
D Install the rubber bushing by using to installer J39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.
3D9
901RW059
Installation
1. Install center link. Make sure that the center link is in its correct position. NOTE: When mounting center link, be sure not to use grease bushings or any other nearby part.
460RS010
2. Install bolt and nut. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 Nm (101 lb ft) 3. Install speed sensor cable bracket. 4. Install speed sensor cable.
3D10
REAR SUSPENSION
Lateral Rod
Lateral Rod and Associated Parts
460RW019
Legend (1) Bolt and Nut
(2) Nut and Washer (3) Lateral Rod
Removal
1. Remove nut and washer. 2. Remove bolt and nut. 3. Remove lateral rod.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Lateral rod 2. Rubber bushing (Frame side) D Remove the rubber bushing (Frame side) by using remover J39214.
901RW060
REAR SUSPENSION
D Install the rubber bushing (Frame side) by using Installer J39215. NOTE: When mounting rubber bushings, do not use grease on bushings or any other nearby parts.
3D11
901RW063
Installation
901RW061
1. Install lateral rod and make sure that the lateral rod is in its correct position. NOTE: When mounting lateral rod, be sure not to use grease on bushings or any other nearby part.
3. Rubber bushing (Axle side) D Remove the rubber bushing (Axle side) by using remover J39792.
460RS016 901RW062
D Install the rubber bushing (Axle side) by using installer J39792.
Legend (1) Frame Side (2) Axle Side 2. Install bolt and nut. Tighten the bolt and nut lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 Nm (101 lb ft) 3. Install nut and washer. Tighten the nut lightly, then retighten the nut to the specified torque after the vehicle is at curb height. Torque: 78 Nm (58 lb ft)
3D12
REAR SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts
460RW020
Legend (1) Nut and Washer (2) Link
(3) Bracket and Bolt (4) Rubber Bushing (5) Stabilizer Bar
Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove nut and washer. 4. Remove link. CAUTION: Be careful not to damage the ball joint boot. 5. Remove bracket.
6. Remove stabilizer bar. 7. Remove rubber bushing.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Stabilizer bar D Rubber bushing D Link ball joint
REAR SUSPENSION
3D13
Installation
1. Install rubber bushing. 2. Install stabilizer bar. 3. Install bracket and tighten to the specified torque. Torque: 22 Nm (16 lb ft) 4. Install link. 5. Install nut and washer, then tighten the nut to the specified torque. Torque: 50 Nm (37 lb ft)
460RS018
3D14
REAR SUSPENSION

Rear suspension Coil spring Type Free length Spring diameter Coil diameter (inner) Effective No. of turns Total No. of turns Shock absorber Type Piston diameter Stroke Extended length Compressed length Stabilizer bar Diameter 4Link, coil spring type with stabilizer bar. 402mm (15.83in) 12.7mm (0.5in) 105mm (4.13in) 5.32 6.82 Hydraulic, double acting, telescopic 25.0mm (0.98in) 175mm (6.89in) 489mm (19.25in) 314mm (12.36in) 19.0mm (0.75in)
REAR SUSPENSION
3D15
E03RW006
3D16
REAR SUSPENSION
Special Tools
J39214 Remover and Installer; Trailing center link bushing
J39792 Remover and Installer; Lateral rod bushing (axle side)
J39215 Remover and Installer; Lateral rod bushing (frame side)
SECTION
WHEEL AND TIRE SYSTEM
TROOPER
3E1
SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel and Associated Parts . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E1 3E2 3E3 3E9 3E9 3E9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Replacement . . . . . . . . . . . . . . . . . . . . . . General Balance Procedure . . . . . . . . . . . . . . Balancing Wheel and Tire . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 3E9 3E10 3E10 3E10 3E11 3E12
Service Precaution
3E2
General Description
480R200012
Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear.
3E3
Diagnosis
480RS001
Irregular and Premature Wear

Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures.
If the following conditions are noted, rotate the tires: D Front tire wear is different from rear. D Uneven wear exists across the tread of any tire. D Left and right front tire wear is unequal. D Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: D Left and right front tire wear is unequal. D Wear is uneven across the tread of any front tire. D Front tire treads have a scuffed appearance with feather edges on one side of the tread ribs or blocks.
Tire Rotation
Tire rotation is recommended to equalize wear for longer tire life.
Tread Wear Indicators
480RS006
480RS002
Legend (1) Spare Tire
The original equipment tires have built-in tread wear indicators(1) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended.
3E4

6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration.
Inflation of Tires
Radial Tire Waddle
710RS003
Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile), should be checked monthly or before any extended trip. Tire pressure increases approximately 15% when the tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar. NOTE: Check the tire pressure whenever irregular wear is found. Tire inflation greatly affects tire wear. If the alignment check does not reveal any alignment problems, check the condition of the shock absorbers and wheel/tire balance.
480RS007
Diagnosis List
If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with feather edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage.
Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will waddle. From the driver s seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver s seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found.
3E5
Radial Tire Lead/Pull

Lead/Pull is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3. Wheel alignment. The way in which a tire is built can produce lead in a car. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The Radial Tire Lead/Pull Correction chart should be used to make sure that front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead/pull.
3E6
Radial Tire Lead/Pull Correction Chart

Step 1 Action 1. Inflate tires to recommended pressure. 2. Road test vehicle on level uncrowned road. Was a problem corrected? 2 Switch front tires side to side and road test again. Was a problem corrected? 3 4 5 Did the vehicle lead in same direction? Put tires back in original position and check alignment. Was a problem corrected? Install known good tire on one front side. Was a problem corrected? Replace tire Typical examples of abnormal tire ahead wear and major causes: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty wear wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. Tread wear one-sided. End Go to Step 5 Install a known good tire in place of other front tire If lead corrected, replace tire End If roughness results,replace tires Go to Step 4 Go to Step 2 Yes No
480RW003
1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted.
480RW002
1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance.

Localized tread wear.
3E7
Wear in shoulders at points opposed to each other.
480RW004
480RW006
1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder wear (generally wear develops in outer shoulder):
1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Premature wear in shoulders.
480RW007
1. Flexing of tire excessive due to under-inflation.

480RW005
1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering.
3E8
One sided feather edging.
480RW008
1. Wear caused by repeated hard-cornering. 2. Camber or toe-in incorrect.
3E9
Wheel
Wheel and Associated Parts
480RW001
Legend (1) Wheel Lug Nut (2) Wheel and Tire
Removal
1. Loosen wheel lug nut by approximately 180 g (half a rotation), then raise the vehicle and remove the nuts. 2. Remove wheel and tire. NOTE: Never use heat to loosen a tight wheel lug nut. The application of heat to the hub can shorten the life of the wheel and may cause damage to wheel bearings.
Installation
1. Install wheel and tire. 2. Install wheel lug nut, and lower the vehicle. Tighten the wheel lug nuts to the specified torque in numerical order. Torque: 118 Nm (87 lb ft) CAUTION: Before installing wheels, remove any build-up of corrosion on the wheel mounting surface and brake disc mounting surface by scraping and wire brushing. Installing wheels without good metal-to-metal contact at mounting surfaces can cause wheel nuts to loosen, which can later allow a wheel to come off while the vehicle is moving. NOTE: Valve caps should be on the valve stems to keep dust and water out.
480RS020
3E10
Tire
Tire Replacement
When replacement is necessary, the original metric the size should be used. Most metric tire sizes do not have exact corresponding alphanumeric tire sizes. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with tire having the most tread, to equalize braking traction. CAUTION: Do not mix different types of tires such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control. Steel 1 Vertical play: Less than 1.5 mm (0.059 in) 2 Horizontal play: Less than 1.5 mm (0.059 in) Aluminum 1 Vertical play: Less than 0.7 mm (0.028 in) 2 Horizontal play: Less than 0.7 mm (0.028 in)
Tire Dismounting
Remove valve cap on valve step and deflate the tire. Then use a tire changing machine to mount or dismount tires. Follow the equipment manufacturer s instruction. Do not use hand tools or tire lever alone to change tires as they may damage the tire beads or wheel rim.
Tire Mounting
Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, and light rust. Before mounting a tire, the bead area should be well lubricated with an approved tire lubricant. After mounting, inflate the tire to 196kPa (28 psi) so that beads are completely seated. Inflate the air to specified pressure and install valve cap to the stem. WARNING: NEVER STAND OVER TIRE WHEN INFLATING. BEAD MAY BREAK WHEN BEAD SNAPS OVER RIMS SAFETY HUMP AND CAUSE SERIOUS PERSONAL INJURY. NEVER EXCEED 240 KPA (35 PSI) PRESSURE WHEN INFLATING. IF 240 KPA (35 PSI) PRESSURE WILL NOT SEAT BEADS, DEFLATE, RE-LUBRICATE AND RE-INFLATE. OVER INFLATION MAY CAUSE THE BEAD TO BREAK AND CAUSE SERIOUS PERSONAL INJURY.
480RS012
General Balance Procedure

Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer s recommendations. There are two types of wheel and tire balance. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear.
Tire Repair
There are many different materials on the market used to repair tires. Manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer if they are not included with the repair kit.
Wheel Inspection
Damaged wheels and wheels with excessive run-out must be replaced. Wheel run out at rim (Base on hub Bore):
3E11
Balancing Wheel and Tire

On-vehicle Balancing
On-Vehicle balancing methods vary with equipment and tool manufacturers. Be sure to follow each manufacturer s instructions during balancing operation.
Off-vehicle Balancing
Most electronic off-vehicle balancers are more accurate than the on-vehicle spin balancers. They are easy to use and give a dynamic balance. Although they do not correct for drum or disc unbalance (as onvehicle spin balancing does), they are very accurate.
480RS013
Legend (1) Heavy Spot Wheel Shimmy (2) Add Balance Weights Here Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy.
480RS015
480RS014
Legend (1) Heavy Spot Wheel Hop (2) Add Balance Weights Here WARNING: STONES SHOULD BE REMOVED FROM THE TREAD TO AVOID OPERATOR INJURY DURING SPIN BALANCING AND TO OBTAIN A GOOD BALANCE.
3E12

Wheels Size Offset P.C.D., wheel studs Standard tire Size Pressure(Front) Pressure(Rear) 16 x 7JJ 38.0 mm (1.50 in) 139.7 mm (5.50 in) P245/70R16 210 kPa (30 psi) 240 kPa (35 psi)
E03RW002
SECTION
DIFFERENTIAL (FRONT)
TROOPER
4A11
DRIVELINE/AXLE
CONTENTS
Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . . Driveline Control System (Shift on the fly) . . Driveline Control System (TOD) . . . . . . . . . . . Drive Shaft System . . . . . . . . . . . . . . . . . . . . . . Transfer Case (Standard Type) . . . . . . . . . . . Transfer Case (TOD) . . . . . . . . . . . . . . . . . . . . 4A1 4A2 4B1 4B2 4C 4D1 4D2
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . Pinion Shaft Oil Seal and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive Axle Assembly . . . . . . . . . . . . . . . Front Drive Axle Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A11 4A12 4A12 4A13 4A13 4A13 4A14 4A14 4A15 4A15 4A15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Assembly . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Cage Assembly . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4A17 4A19 4A19 4A110 4A112 4A121 4A121 4A121 4A122 4A123 4A125 4A127
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM(SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE REFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED , do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally,such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specification. Following these instructions can help you avoid damage to parts and systems.
4A12
Front Drive Axle

Diagnosis
Condition Oil Leak At Front Axle Oil Leak At Pinion Shaft Possible cause Worn or defective oil seal. Front axle housing cracked. Too much gear oil. Oil seal worn or defective. Pinion flange loose or damaged. Noises In Front Axle Drive Shaft Joint Clank When Accelerating From Coast Shudder or Acceleration Vibration During Broken or worn drive shaft joints and bellows (BJ and DOJ). Loose drive shaft joint to output shaft bolts. Damaged inner drive shaft joint. Excessive drive shaft joint angle. Worn or damaged drive shaft joints. Sticking spider assembly (inner drive shaft joint). Sticking joint assembly (outer drive shaft joint). Vibration At Highway Speeds Noises in Front Axle Out of balance or out of round tires. Front end out of alignment. Insufficient gear oil. Wrong or poor grade gear oil. Drive pinion to ring gear backlash incorrect. Worn or chipped ring gear, pinion gear or side gear. Pinion shaft bearing worn. Wheel bearing worn. Differential bearing loose or worn. Wanders and Pulls Wheel bearing preload too tight. Incorrect front alignment. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Front or rear suspension parts loose or broken. Front Wheel Shimmy Wheel bearing worn or improperly adjusted. Incorrect front alignment. Worn ball joint or bush. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Shock absorber worn. Correction Replace the oil seal. Repair or replace. Correct the oil level. Replace the oil seal. Tighten or replace. Replace the drive shaft joints and bellows. Tighten. Replace. Repair. Replace. Lubricate or replace. Lubricate or replace. Balance or replace. Align. Replenish the gear oil. Replace the gear oil. Adjust the backlash. Replace the ring gear, pinion gear or side gear. Replace the pinion shaft bearing. Replace the wheel bearing. Tighten or replace. Adjust the wheel bearing preload. Adjust the front alignment. Tighten or replace. Adjust or replace the steering gear. Adjust the inflation or replace. Tighten or replace. Adjust or replace. Adjust the front alignment. Replace the ball joint or bush. Tighten or replace. Tighten or replace. Replace or adjust the inflation. Replace the shock absorber.
4A13
Pinion Shaft Oil Seal

Pinion Shaft Oil Seal and Associated Parts
415RW015
Legend (1) Flange Nut (2) Flange
(3) Oil Seal (4) Outer Bearing (5) Collapsible Spacer
Removal
1. Raise the vehicle and support it at the frame. The hoist must remain under the front axle housing. 2. Drain the front axle oil by loosening the drain plug(1).
412RS001
4A14
3. Remove the front propeller shaft. Refer to Front Propeller Shaft in this section. 4. Remove flange nut by using pinion flange holder J37221.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Seal surface of the pinion. 2. Cage bore for burns.
Installation
1. Install collapsible spacer. Discard the collapsible spacer and install a new one. 2. Install outer bearing. used
NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut. 3. Install oil seal, use oil seal installer J24250 to install a new oil seal that has been soaked in axle lubricant.
425RW039
5. Remove flange. 6. Remove oil seal. 7. Remove outer bearing by using remover J39602.
415RS002
4. Install flange. 5. Install flange nut, refer to Differential Assembly Overhaul for flange nut reassembly in this section. NOTE: Discard the used nut and install a new one.
415RW016
8. Remove collapsible spacer.
4A15
Front Drive Axle Assembly

Front Drive Axle Assembly and Associated Parts
412RW001
Legend (1) Mounting Bolt and Nut (2) Washer and Spacer (3) Breather Hose (4) Shift Switch Connector (5) Protector
(6) Front Axle Case Assembly and Front Drive Shaft Assembly (LH side) (7) Hub Assembly (Disc, Back Plate and Knuckle) (8) Front Drive Shaft Assembly (RH side) (9) Propeller Shaft (with TOD) (10) Propeller Shaft (11) Bolt
Removal
1. Jack up the vehicle and support it using jack stands. 2. Remove the tire and wheel.
4A16
14. Disconnect shift switch connector.
3. Remove the drain bolt to drain differential oil. NOTE: a. During the work, be sure that the diff case is supported by the jack.
412RS031
15. Remove VSV assembly (1). NOTE: Be sure not to remove hose and connector from VSV asm.
412RS003
b. Remove the brake caliper fixing bolt and hang the caliper. Refer to Disc Brakes in Brake section. c. Remove the antilock brake system speed sensor. Refer to Front Wheel Speed in Brake section. 4. Remove the hub assembly (Disc, back plate and knuckle), refer to Front Hub and Disc in this section. 5. Disconnect the knuckle and the suspension arm. Refer to Suspension section. 6. Remove steering link and arm assembly, refer to Steering Linkage in Steering section. 7. Remove suspension crossmember. 8. Remove propeller shaft, refer to Front Propeller Shaft in this section. 9. Remove protector. 10. Remove breather hose. 11. Remove the hose clip. 12. Disconnect breather hose from front drive axle tube and disconnect housing. 13. Disconnect vacuum hose from actuator.
412RW002
16. Remove mounting bolt and nut.
4A17
19. Lower the vehicle and disconnect the RH front drive shaft assembly, then remove the front axle case assembly and front drive shaft assembly (LH).
412RS004
17. Remove washer and spacer. 18. Remove the mounting bracket fixing bolt.
412RS006
20. Remove front drive shaft assembly (RH).
Installation
1. Install front drive shaft assembly (RH) and lay the assembly on the lower arm. 2. Install front axle case assembly and front drive shaft assembly (LH) and place the axle case on the jack, connect to the front drive shaft assembly (RH) before installing to the vehicle. 3. Install bolt and tighten the mounting bracket fixing bolt to the specified torque. Torque: 116 Nm (85lb ft) 4. Install washer and spacer.
412RS005
4A18
5. Tighten the mounting bolt and nut to the specified torque. Torque: 152 Nm (112lb ft)
412RW005
Legend (1) Frame (2) Spacer (3) Washer (4) Bolt (5) Nut 6. Install VSV assembly and tighten nuts to specified torque. Torque: 8 Nm (69lb in) 7. Install the shift switch connector. NOTE: Be careful not to permit the entry of dust into the connector. 8. Install the actuator side of vacuum hose. NOTE: Be careful not to permit the entry of dust into the hose. 9. Connect breather hose and install the hose clip. 10. Install protector and tighten bolts to specified torque. Torque: 26 Nm (20lb ft) 11. Install propeller shaft, refer to Front Propeller Shaft in this section. 12. Install suspension crossmember. 13. Steering link and arm assembly, refer to Steering Linkage in Steering section. 14. Install hub assembly (Disc, back plate and knuckle), refer to Front Hub and Disc in this section.
4A19
Differential Assembly
Disassembled View
415RW001
Legend (1) Differential Assembly (2) Flange Nut (3) Flange (4) Dust Cover (5) Oil Seal (6) Outer Bearing (7) Outer Bearing Outer Race (8) Damper (9) Bracket (10) Differential Carrier (11) Bearing Cap
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)
Bolt Inner Bearing Outer Race Collapsible Spacer Pinion Gear Inner Bearing Adjust Shim Diff Cage Assembly Side Bearing Outer Race Side Bearing Adjust Shim Bolt Axle Case
4A110 DIFFERENTIAL (FRONT)
Disassembly
1. Remove differential carrier fixing bolt. 2. Remove differential assembly. 3. Using holding fixture J37264 and holding fixture base J328920, fix the differential assembly to the bench.
7. Remove side bearing outer race, after removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations. 8. Remove side bearing, using remover J22888 and adapter J81072.
415RS005 425RS008
4. Remove bearing cap bolt. 5. Apply a setting mark to the side bearing cap and the differential carrier then remove bearing cap.
9. Remove adjust shim, note the thickness and position of the shims removed. 10. Remove the flange nut using holding wrench J37221 after raising up its staked parts completely.
425RS009
425RW040
6. Remove differential cage assembly.
11. Remove flange. 12. Remove dust cover.
13. Remove the drive pinion assembly using a soft metal rod and a hammer.
4A111
20. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a hammer.
425RW041
14. Remove collapsible spacer. 15. Remove the inner bearing using a separator J2291201 and a press.
425RS014
425RS015
415RS006
16. Remove adjust shim. 17. Remove inner bearing outer race. 18. Remove oil seal. 19. Remove outer bearing.

21. Remove damper and bracket. 2. Using installer J24252 and grip J8092, install Inner bearing outer race.
425RW042 415RS008
Reassembly
1. Using installer J24256 and grip J8092, install outer bearing outer race.
3. Install adjust shim and adjust drive pinion mounting distance 1. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings. 2. Tighten the nut to the specified torque. Torque: 2.3 Nm (20 lb in)
415RS007
415RS009
Legend (1) Pilot : J2177742 (2) Nut and Bolt : J235979 (3) Gauge Plate : J235977
3. Clean the side bearing bores. Install the dial indicator with the discs and arbor. Install and tighten the bearing caps to the specified torque. Torque: 98 Nm (72 lb ft) Legend (1) Dial Indicator (2) Ganging Arbor (3) Plunger (4) Gauge Plate
4A113
5. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to 0. Repeat the procedure to verify the 0 setting.
415RS010
Legend (1) Dial Indicator: J8001 (2) Disc (2 pcs.): J235978 (3) Arbor: J235971 (4) Gauge Plate: J2359742 4. Set the dial indicator to 0. Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position.
425RS021
6. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.
425RS020 425RS022
Legend (1) Example=Dial indicator reading of 0.085

7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code 0, the pinion is nominal.
425RS023
8. Select the shim using the chart;
Pinion marking Dial indicator reading (Inches) 0.081 0.082 0.083 0.084 0.085 0.086 0.087 0.088 0.089 0.090 0.091 0.092 0.093 0.094 0.095 0.096 0.097 0.098 0.099 0 0.001 0.002 0.003 0.004 0.005 0.006 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) +10 mm (Inches) +8 mm (Inches) +6 mm (Inches) +4 mm (Inches) +2 mm (Inches) 0 mm (Inches) 2 mm (Inches) 4 mm (Inches) 6 mm (Inches) 8 mm (Inches)
4A115
10 mm (Inches) 2.18 (0.0858) 2.20 (0.0866) 2.23 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)
NOTE: When ordering shims, find the part number in the parts catalog by using the thickness of shims listed in the above table.
4. Place the shim on the drive pinion, with the chamfered side turned towards the pinion head then install the inner bearing onto the pinion using an installer J613301 and a press.

NOTE: Do not apply pressure to the roller cage and apply pressure only to the inner race. 2. Tighten the nut to the specified torque using the pinion flange holder J37221. Torque: 177275Nm (130203 lb ft) NOTE: Discard used flange nut and install new one and do not over tighten the flange nut.
425RS024
5. Discard the used collapsible spacer and install a new one. 6. Install pinion gear. 7. Install outer bearing. 8. Use oil seal installer J24250 to install a new oil seal that has been soaked in rear axle lubricant. NOTE: Take care to use a front differential oil seal, NOT the rear differential oil seal.
425RW040
3. Adjust pinion bearing preload. a. Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange. b. Continue tightening flange nut until the specified starting torque is obtained. Starting torque: New bearing 0.71.1 Nm(5.649.98 lb in) Used bearing 0.40.5Nm(2.864.94Ib in)
415RS011
9. Install dust cover. 10. Install flange. 11. Install flange nut. 1. Apply lubricant to the pinion threads.
425RS027
4. Using punch J39209, stake the flange nut at two points.
NOTE: When staking, be sure to turn the nut to insure that there is no change in bearing preload. Make sure of preload again as instructed in 3).
4A117
2. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.
415RS012
425RS030
Legend (1) 1.3mm or less 12. Install adjust shim. 1. Attach the side bearing to the differential assembly without shims. Support the opposite side using a pilot to prevent bearing damage.
3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores. Mount the dial indicator J8001 on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.
425RS029 425RS031
Legend (1) Drive handle:J8092 (2) Installer:J24244 (3) Pilot:J81072

4. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range. Backlash: 0.130.18 mm(0.005 0.007 in) 13. Install the side bearings together with the selected shims.
425RS029
425RS032
With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 in) to each shim pack to provide side bearing preload. Always use new shims. 5. Use bearing remover J22888 and pilot J81072 to remove side bearing.
Legend (1) Drive Handle:J8092 (2) Installer: J24244 (3) Pilot: J81072 14. Install side bearing outer race. 15. Install differential cage assembly. 16. Install bearing cap then align the setting marks(1) applied at disassembly.
415RS013
425RS035
17. Tighten the cap bolt to the specified torque. Torque: 98 Nm (72 lb ft)
4A119
Gear Tooth Contact Pattern Check and Adjustment 1. Apply a thin coat of prussian blue or equivalent to the faces of the 78 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described in illustration if the contact is abnormal.
425RS036
1. Measure the amount of runout of the ring gear at its rear face. Standard: 0.02 mm ( 0.001 in) Limit: 0.05 mm ( 0.002 in) Legend (1) Heel (2) Toe (3) Concave Side(Coast) (4) Convex Side(Drive)
425RS038
425RS037
425RS039
18. Install differential assembly. 1. Clean the faces of the front axle case and differential carrier. Apply Three Bond TB1215 or equivalent to the sealing side of the axle case and the carrier. 2. Attach the differential case and the carrier assembly to the front axle case and tighten the nuts and bolts. Torque: 25 Nm (19 lb ft)
3. Fill the axle case with hypoid gear lubricant, to just below the filler hole. Lubricant capacity: 1.4 liter(1.5 US qt) 19. Install damper. 1. Clean the faces and bolt thread hole of differential carrier. 2. Install the bracket with new bolts. 3. Install the damper to the bracket with new bolts. Torque: 22 Nm (16 lb ft)
415RS014
425RW042
4A121
Differential Cage Assembly

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

4. Remove the cross pin, using a soft metal rod and a hammer. 5. Tighten the fixing bolts in a diagonal sequence as illustrated.
425RS043
415RS016
5. Remove pinion gear. 6. Remove side gear. 7. Remove thrust washer.
Clearance between the differential pinion and the cross pin measurement:
Standard: 0.06 0.12 mm (0.0020.005 in) Limit: 0.2 mm (0.008 in)

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Ring gear, pinion gear 2. Bearing 3. Side gear, pinion gear, cross pin 4. Differential cage, carrier 5. Thrust washer 6. Oil seal
Ring gear replacement:

1. The ring gear should always be replaced with the drive pinion as a set. 2. Clean the ring gear threaded holes to remove the locking agent. 3. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt. 4. Discard used bolts and install new ones. Torque: 108 Nm (80 lb ft)
425RS045
4A123
Clearance between the side gear and the differential box:

Standard: 0.030.10 mm (0.0010.004 in) Limit: 0.15 mm(0.006 in)
Reassembly
1. Install thrust washer. 2. Install side gear. 3. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction.
425RS046
Legend (1) Side Gear (2) Differential Box
425RS048
Play in splines between the side gear and the axle shaft:
Standard: 0.080.36 mm(0.003 0.014 in) Limit:0.5m (0.02 in)
4. Install cross pin. 1. Be sure to install the cross pin so that it is in alignment with the lock pin hole in the differential cage.
425RS049
2. Adjust the backlash between the side gear and the pinion gear. Backlash:0.03 0.08 mm (0.001 0.003 in)
425RS047

Thickness of thrust washers available: 1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in, 0.043 in) 7. Tighten the bolts in diagonal sequence as illustrated. Torque: 108 Nm (80 lb ft) NOTE: Discard used bolts and install new ones.
425RS050
5. Install lock pin. After lock pin installation, stake the cage to secure the lock pin.
415RS016
425RS051
Legend (1) Staked Portion (2) Lock Pin 6. Clean the ring gear threaded holes to remove the locking agent. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt.
4A125

Axle tube Type Gear type Gear ratio Differential type Oil capacity Type of lubricant Axle shaft type Hub locking Type liter (US qt) (to 1) It consists of the duct, a cast iron housing and the axle tube. Hypoid 4.300 Two pinion 1.4 (1.5) (Differential) 0.12 (0.13) (Actuator Housing: Shift on the fly) 75W90 GL5 (Multi grade type) Refer to General Information Constant velocity joint (Birfield joint type and double offset joint) Rigid
E04RW002
E04R200005
4A127
Special Tools
J37221 Holder; Pinion flange
J2291201 Separator
J24256 Installer; Outer bearing outer race
J37264 Differential holding fixture (Use with J328920 base)
J8092 Driver handle
J328920 Holding fixture base
J24252 Installer; Inner bearing outer race
J22888 Puller; Side bearing
J2177742 Pilot
J81072 Adapter; Side bearing plug
J235979 Nut and bolt

J235977 Gauge plate
J24244 Installer; Side bearing
J8001 Dial indicator
J39602 Remover; Outer bearing
J235978 Disc
J235971 Arbor
J613301 Installer; Pinion bearing
J39209 Punch; End nut lock
SECTION
DIFFERENTIAL (REAR)
TROOPER
4A21
DRIVELINE/AXLE
DIFFERENTIAL (REAR)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Housing and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Seal Replacement . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Shaft and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Oil Seal Replacement . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Oil Seal and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A21 4A23 4A24 4A25 4A25 4A25 4A26 4A26 4A27 4A27 4A27 4A28 4A29 4A29 4A210 4A210 4A210 4A211 4A211 Differential Assembly . . . . . . . . . . . . . . . . . . . . Differential Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Cage Assembly . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Slip Differential . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A212 4A212 4A212 4A213 4A214 4A215 4A217 4A224 4A224 4A225 4A225 4A226 4A228 4A228 4A229 4A229 4A231 4A235 4A236
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM(SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE REFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED , do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally,such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specification. Following these instructions can help you avoid damage to parts and systems. The f244 differential has two N types A-type and Btype. A-type: the sticker with bar code is attached. B-type: the sticker with no bar code on the lower part of carrier is attached.
4A22
DIFFERENTIAL (REAR)
In case of Work Shop Manual;

A-type: Refer to 98 UBS Work Shop Manual. B-type: Described in This Work Shop Manual.
425RY00018
DIFFERENTIAL (REAR)
4A23
General Description
The rear axle assembly is of the semifloating type in which the vehicle weight is carried on the axle housing . The center line of the pinion gear is below the center line of the ring gear (hypoid drive). All parts necessary to transmit power from the propeller shaft to the rear wheels are enclosed in a banjo type axle housing. The 9.61 inch ring gear rear axle uses a conventional ring and pinion gear set to transmit the driving force of the engine to the rear wheels. This gear set transfers this driving force at a 90 degree angle from the propeller shaft to the drive shafts. The axle shafts are supported at the wheel end of the shaft by a roller bearing. The pinion gear is supported by two tapered roller bearings. The pinion depth is set by a shim pack located between the gear end of the pinion and the roller bearing that is pressed onto the pinion. The pinion bearing preload is set by crushing a collapsible spacer between the bearings in the axle housing.
420RY00003
The ring gear is bolted onto the differential cage with 12 bolts. The differential cage is supported in the axle housing by two tapered roller bearings. The differential and ring gear are located in relationship to the pinion by using selective shims and spacers between the bearing and the axle housing. To move the ring gear, shims are deleted from one side and an equal amount are added to the other side. These shims are also used to preload the bearings which
are pressed onto the differential cage. Two bearing caps are used to hold the differential into the rear axle housing. The differential is used to allow the wheels to turn at different rates of speed while the rear axle continues to transmit the driving force. This prevents tire scuffing when going around corners and prevents premature wear on internal axle parts. The rear axle is sealed with a pinion seal, a seal at each axle shaft end, and by a liquid gasket between the differential carrier and the axle housing.
4A24
DIFFERENTIAL (REAR)
Diagnosis
Many noises that seem to come from the rear axle actually originate from other sources such as tires, road surface, wheel bearings, engine, transmission, muffler, or body drumming. Investigate to find the source of the noise before disassembling the rear axle. Rear axles, like any other mechanical device, are not absolutely quiet but should be considered quiet unless some abnormal noise is present. To make a systematic check for axle noise, observe the following: 1. Select a level asphalt road to reduce tire noise and body drumming. 2. Check rear axle lubricant level to assure correct level, and then drive the vehicle far enough to thoroughly warm up the rear axle lubricant. 3. Note the speed at which noise occurs. Stop the vehicle and put the transmission in neutral. Run the engine speed slowly up and down to determine if the noise is caused by exhaust, muffler noise, or other engine conditions. 4. Tire noise changes with different road surfaces; axle noises do not. Temporarily inflate all tires to 344 kPa (50 psi) (for test purposes only). This will change noise caused by tires but will not affect noise caused by the rear axle. Rear axle noise usually stops when coasting at speeds under 48 km/h (30 mph); however, tire noise continues with a lower tone. Rear axle noise usually changes when comparing pull and coast, but tire noise stays about the same. Distinguish between tire noise and rear axle noise by noting if the noise changes with various speeds or sudden acceleration and deceleration. Exhaust and axle noise vary under these conditions, while tire noise remains constant and is more pronounced at speeds of 32 to 48 km/h (20 to 30 mph). Further check for tire noise by driving the vehicle over smooth pavements or dirt roads (not gravel) with the tires at normal pressure. If the noise is caused by tires, it will change noticeably with changes in road surface. 5. Loose or rough front wheel bearings will cause noise which may be confused with rear axle noise; however, front wheel bearing noise does not change when comparing drive and coast. Light application of the brake while holding vehicle speed steady will often cause wheel bearing noise to diminish. Front wheel bearings may be checked for noise by jacking up the wheels and spinning them or by shaking the wheels to determine if bearings are loose. 6. Rear suspension rubber bushings and spring insulators dampen out rear axle noise when correctly installed. Check to see that there is no link or rod loosened or metaltometal contact. 7. Make sure that there is no metaltometal contact between the floor and the frame. After the noise has been determined to be in the axle, the type of axle noise should be determined, in order to make any necessary repairs.
Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to 55 mph) under four driving conditions. 1. Driving under acceleration or heavy pull. 2. Driving under load or under constant speed. 3. When using enough throttle to keep the vehicle from driving the engine while the vehicle slows down gradually (engine still pulls slightly). 4. When coasting with the vehicle in gear and the throttle closed. The gear noise is usually more noticeable between 48 and 64 km/h (30 and 40 mph) and 80 and 89 km/h (50 and 55 mph).
Bearing Noise
Bad bearings generally produce a rough growl or grating sound, rather than the whine typical of gear noise. Bearing noise frequently wowwows at bearing rpm, indicating a bad pinion or rear axle side bearing. This noise can be confused with rear wheel bearing noise.
Rear Wheel Bearing Noise

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

Low speed knock can be caused by worn universal joints or a side gear hub counter bore in the cage that is worn oversize. Inspect and replace universal joints or cage and side gears as required.
Backlash Clunk
Excessive clunk on acceleration and deceleration can be caused by a worn rear axle pinion shaft, a worn cage, excessive clearance between the axle and the side gear splines, excessive clearance between the side gear hub and the counterbore in the cage, worn pinion and side gear teeth, worn thrust washers, or excessive drive pinion and ring gear backlash. Remove worn parts and replace as required. Select closefitting parts when possible. Adjust pinion and ring gear backlash.
DIFFERENTIAL (REAR)
4A25
Axle Housing
Axle Housing and Associated Parts
420RY00001
Legend (1) Coil Spring and Insulator (2) Axle Housing Assembly (3) ABS Speed Sensor and Harness (4) Nut (5) Parking Brake Cable (6) Bolt and Nut (7) Antilock Brake System (ABS) Connector and Bracket (8) Bolt and Nut
(9) (10) (11) (12) (13) (14) (15) (16) (17)
Nut Differential Assembly Axle Shaft Assembly Brake Disc Brake Pipe Brake Caliper Nut Breather Hose Flare Nut
Removal
1. Raise the vehicle and support it with suitable safety stands. The hoist must remain under the rear axle housing. 2. Remove brake fluid. Refer to Hydraulic Brakes in Brake section. 3. Remove rear wheels and tires. Refer to Wheel in Suspension section.
4. Remove propeller shaft. Refer to Rear Propeller Shaft in this section. 5. Drain the rear axle oil into a proper container. 6. Remove parking brake cable, release the connection between the cable fixing clip equalizer. Refer to Parking Brakes in Brake section. 7. Move the clip aside and pull out the breather hose. 8. Disconnect the ABS connectors (1) and remove the brackets (2) attached to the frame and center link.
4A26
DIFFERENTIAL (REAR)
20. Remove the brake pipe clip and fixing bolt on the axle housing and take out the brake pipe. 21. Remove the bearing holder fixing nut and take out the axle shaft assembly, be sure not to damage the oil seal by the spline of the shaft, Refer to Axle Shaft in this section. 22. Remove differential assembly, refer to Differential Assembly in this section.
Oil Seal Replacement

Remove the oil seal, carefully not to damage the housing, and mount new oil seal using oil seal installer J39210.
350RS001
9. Loosen the brake tube flare nut, remove the clip and take out the brake tube. 10. Remove the shock absorber fixing nut from the axle housing. 11. Remove the stabilizer linkage mounting nut from the axle housing. 12. Remove the lateral rod fixing nut from the axle housing. 13. Remove the center link mounting bolt and nut from the axle housing. 14. Remove the trailing link fixing bolt and nut from the axle housing. 15. Jack down and remove the coil spring and insulator. 16. Axle housing assembly can be separated from the vehicle on completion of steps 1 11. 17. Remove the brake caliper fixing bolt (3), loosen the flare nut (1), release the clip (2) and take out the brake caliper together with the flexible hose.
420RS004
Installation
1. Install differential assembly, refer to Differential Assembly in this section. 2. Install axle shaft assembly then tighten the bearing holder mounting nut to the specified torque. Be sure not to damage the oil seal by the spline of the shaft. Torque: 74Nm (54lb ft) 3. Install brake pipe. 4. Connect antilock brake system (ABS) speed sensor and harness, refer to 4Wheel AntiLock Brake System (ABS) in Brake section. 5. Install brake disc. 6. Install brake caliper. Refer to Disk Brakes in Brake section. 7. Install axle housing assembly. 8. Install coil spring and insulator. 9. Install the trailing link fixing bolt and nut to the axle housing. For the procedures in items 913, refer to Suspension section. 10. Install the center link bolt and nut to the axle housing. 11. Install the lateral rod fixing nut to the axle housing. 12. Install the stabilizer linkage mounting nut to the axle housing. 13. Install the shock absorber fixing nut to the axle housing.
306RS001
18. Remove brake disc. 19. Remove antilock brake system speed sensor fixing bolt and the clip and bracket on the axle housing.
DIFFERENTIAL (REAR)
14. Install brake tube flare nut, Refer to Disk Brakes in Brake section. 15. Install ABS connector and bracket. 16. Connect breather hose.
4A27
17. Install parking brake cable, Refer to Parking Brakes in Brake section. 18. Bleed brakes. Refer to Hydraulic Brakes in Brake section.
Axle Shaft
Axle Shaft and Associated Parts
420RY00005
Legend (1) Brake Caliper (2) Brake Disc (3) Wheel Pin (4) Axle Shaft Assembly (5) Back Plate (6) Parking Brake Assembly
(7) (8) (9) (10) (11) (12) (13)
Bearing Holder Bearing Retainer Snap Ring Bolt Nut Antilock Brake System (ABS) Speed Sensor
Removal
1. Raise the vehicle. 2. Remove tires and wheels. Refer to Wheel in Steering section.
3. Remove brake caliper. Use a wire to attach the brake caliper to the frame. Refer to Disk Brakes in Brake section. 4. Remove brake disc. 5. Remove ABS sensor. 6. Remove Parking brake assembly. Refer to Parking Brakes in Brake section.
4A28
DIFFERENTIAL (REAR)
cable mounting 14. Remove back plate. 15. Remove the wheel pins using a remover J6627A.
7. Remove the parking brake bolts(Behind the back plate)(1).
311RS001
420RS007
8. Remove the bearing holder mounting nuts. 9. Remove axle shaft assembly. NOTE: Be sure not to damage the oil seal. 10. Remove snap ring. 11. Using a bearing remover J39211 and press, remove retainer together with the bearing holder.

Make necessary correction or parts replacement if wear, corrosion or any other abnormal conditions are found through inspection.
Visual Check:
Check the following parts for wear, damage, noise or any other abnormal conditions: 1. Axle shaft 2. Bearing When checking the axle shaft, pay special attention to the splined portions and replace the shaft if distortion or step wear is noticeable. Correct slight step wear with a grinder.
420RS006
12. Remove bearing. 13. Remove bearing holder.
420RS008
DIFFERENTIAL (REAR)
4A29
Axle Shaft Runout

Limit: 1.0 mm (0.039 in)
Oil Seal Replacement

Remove the oil seal carefully not to damage the bearing holder bore . When installing, use oil seal installer J39379.
420RS009
Axle Shaft Flange Runout

Limit: 0.08 mm (0.003 in)
420RS011
Installation
1. Install wheel pin. 2. Install back plate. 3. Install bearing holder. 4. Install bearing. 5. Install retainer by using a bearing installer J39212, press fit together with the bearing.
420RS010
420RS012
4A210 DIFFERENTIAL (REAR)

6. Install snap ring. 7. Install axle shaft assembly. NOTE: Be sure not to damage the oil seal. 8. Tighten the bearing holder mounting nut to the specified torque. Torque: 74Nm (54 Ib ft) 9. Fix the parking brake cable mounting bolt (Behind the back plate). 10. Install parking brake assembly, refer to Parking Brakes in Brake section. 11. Install antilock brake system sensor. 12. Install brake disc. 13. Install brake caliper, refer to Disk Brakes in Brake section.
Pinion Oil Seal

Pinion Oil Seal and Associated Parts
425RY00010
Legend (1) Flange Nut and Washer (2) Flange
(3) Oil Seal (4) Outer Bearing (5) Collapsible Spacer
Removal
1. Remove the rear propeller shaft. Propeller Shaft in this section. 2. Drain the rear axle oil. Refer to Rear
DIFFERENTIAL (REAR)
3. Remove flange nut and washer by using pinion flange holder J861401 after raising up its staked parts completely.
4A211

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Seal surface of the pinion. 2. Cage bore for burns.
Installation
1. Install collapsible spacer, discard the used collapsible spacer and install a new one. 2. Install outer bearing. NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut. 3. By using the seal installer J37263, install a new oil seal (1) that has grease on seal lip.
415RS018
4. Remove flange. 5. Remove oil seal. 6. Remove outer bearing by using remover J39602.
425RS004
4. Install flange. 5. Install flange nut and washer. Refer to Differential Assembly in this section for flange nut reassembly. NOTE: Discard the used nut and install a new one.
425RY00003
7. Remove collapsible spacer.
Differential Assembly
Differential Assembly and Associated Parts
425RY00004
Legend (1) Bolt and Nut (2) Axle Shaft Assembly
(3) Parking Brake Cable (4) Differential Assembly (5) Nut
Removal
1. Jack up and support the frame with stands. 2. Remove the wheel and tire. Refer to Wheel in Steering section. 3. Drain the differential oil. 4. Remove the propeller shaft. Refer to Rear Propeller Shaft in this section. 5. Remove the ABS speed sensor. Refer to 4Wheel Antilock Brake System (ABS) in Brake section.
6. Remove the parking brake cable fastening clip and disconnect the equalizer section. Refer to Parking Brakes in Brake section. 7. Remove the bearing holder fixing nuts. 8. Remove axle shaft assembly, be sure not to damage the oil seal by axle shaft. 9. Remove differential carrier mounting bolts and nuts. 10. Remove differential assembly.
DIFFERENTIAL (REAR)
4A213
Installation
1. Clean the contact surfaces of the axle and differential carrier. As shown in the drawing, apply Three Bond TB1215 or equivalent then install differential assembly.
425RS006
2. Install bolt and nut. Tighten the differential carrier mounting bolts and nuts to the specified torque. Torque:Nuts 44Nm (33lb ft) Bolts 66Nm (48lb ft) 3. Install axle shaft assembly. Be sure not to damage the oil seal by axle shaft. 4. Install nut, refer to Axle Shaft in this section. 5. Install parking brake cable, refer to Parking Brakes in Brake section. NOTE: After completing the assembling work, fill the prescribed gear oil to the filler hole. Lubricant capacity: 3.0 liter (3.2 US qt) 6. Tighten the oil filler plug to the specified torque. Torque: 78Nm (58lb ft)
Disassembled View
415RY00002
Legend (1) Flange Nut and Washer (2) Flange (3) Oil Seal (4) Outer Bearing (5) Outer Bearing Outer Race (6) Diff Carrier (7) Bearing Cap (8) Bolt
(9) (10) (11) (12) (13) (14) (15) (16) (17)
Inner Bearing Outer Race Collapsible Spacer Inner Bearing Adjust Shim (Pinion Position) Drive Pinion Shaft Differential Cage Assembly Adjust Shim (Diff Cage Assembly) Side Bearing Side Bearing Outer Race
DIFFERENTIAL (REAR)
4A215
Disassembly
1. Using holding fixture J42832 and holding fixture base J328920, fix the differential assembly to the bench.
5. Remove side bearing by using remover J42379 and adapter J81073. Select collet halves 44803 in remover kit J42379 for side bearing removal and insert is not required for this operation.
415RW003 425RW035
2. Apply a setting mark to the side bearing cap and the differential carrier then remove bearing cap.
6. Note the thickness and position of the shims then remove adjust shim. 7. Remove the flange nut and washer by using pinion flange holder J861401 after raising up its staked parts completely.
425RS009
3. Remove differential cage assembly. 4. Remove side bearing outer race. After removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations.
415RS018
8. Removed flange assembly.

9. Remove the drive pinion assembly using a soft metal rod and a hammer. 15. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a hammer.
425RY005
10. Remove collapsible spacer. 11. Remove the inner bearing by using remover J42379.Select insert 303174 and collet halves 44803 in remover kit J42379 for inner bearing removal.
425RS014
425RS015
415RW004
12. Remove adjust shim. 13. Remove oil seal. 14. Remove outer bearing.
DIFFERENTIAL (REAR)
4A217
Reassembly
1. Install outer bearing outer race by using installer J44461 and grip J8092.
2. Tighten the nut to the specified torque. Torque: 2.3 Nm (20 lb in)
425RW030 425RY00011
2. Install inner bearing outer race by using installer J44462 and grip J8092.
3. Clean the side bearing bores. Place discs and dial indicator on to arbor, and place tool into position in side bearing bores. Install and tighten the bearing caps to the specified torque.
425RY00012
3. Adjust the drive pinion mounting distance as follows: 1. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings. Install gauge plate J42826 (3), inner pilot J42827 (2) ,stud and nut J2177743 (4) and outer pilot J42824 (1) through inner and outer bearings.
425RW031
Legend (1) Dial Indicator: J8001 (2) Gauge Plate: J44451 (3) Disc (2 pcs.): J44452 (4) Arbor: J235971

4. Set the dial indicator J8001 to 0. Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position. 6. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.
425RS022
425RS020
Legend (1) Example=Dial indicator reading od 0.085 7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code 0, the pinion is nominal.
Legend (1) Dial Indicator (2) Ganging Arbor (3) Plunger (4) Gauge Plate 5. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to 0. Repeat the procedure to verify the 0 setting.
425RS023
425RS021
DIFFERENTIAL (REAR)
8. Select the shim thickness using the chart;
Pinion marking Dial indicator reading (inches)
4A219
+10
+9
+8
+7
+6
+5
+4
+3
+2
+1
10
0.080 0.081 0.082 0.083 0.084 0.085 0.086 0.087 0.088 0.089 0.090 0.091 0.092 0.093 0.094 0.095 0.096 0.097 0.098 0.099 0.000 0.001 0.002 0.003 0.004 0.005 0.006 2.14
(0.0843)
2.12
(0.0835)
2.12
(0.0835)
2.12
(0.0835)
2.12
(0.0835)
2.14
(0.0843)
2.14
(0.0843)
2.16
(0.0850)
2.12
(0.0835)
2.12
(0.0835)
2.14
(0.0843)
2.14
(0.0843)
2.16
(0.0850)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.12
(0.0835)
2.12
(0.0835)
2.14
(0.0843)
2.14
(0.0843)
2.16
(0.0850)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.12
(0.0835)
2.12
(0.0835)
2.14
(0.0843)
2.14
(0.0843)
2.16
(0.0850)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.12
(0.0835)
2.12
(0.0835)
2.14
(0.0843)
2.14
(0.0843)
2.16
(0.0850)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.24
(0.0822)
2.24
(0.0822)
2.26
(0.0890)
2.12
(0.0835)
2.12
(0.0835)
2.14
(0.0843)
2.14
(0.0843)
2.16
(0.0850)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.24
(0.0882)
2.24
(0.0882)
2.26
(0.0890)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.12
(0.0835)
2.12
(0.0835)
2.14
(0.0843)
2.14
(0.0843)
2.16
(0.0850)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.24
(0.0882)
2.24
(0.0882)
2.26
(0.0890)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.14
(0.0843)
2.16
(0.0850)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.24
(0.0882)
2.24
(0.0882)
2.26
(0.0890)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.16
(0.0850)
2.18
(0.0858)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.24
(0.0882)
2.24
(0.0882)
2.26
(0.0890)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.18
(0.0858)
2.20
(0.0866)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.24
(0.0882)
2.24
(0.0882)
2.26
(0.0890)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.20
(0.0866)
2.22
(0.0874)
2.22
(0.0874)
2.24
(0.0882)
2.24
(0.0882)
2.26
(0.0890)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.24
(0.0882)
2.24
(0.0882)
2.26
(0.0890)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.26
(0.0890)
2.28
(0.0898)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.28
(0.0898)
2.30
(0.0905)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.30
(0.0905)
2.32
(0.0914)
2.32
(0.0914)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.50
(0.0987)
2.50
(0.0987)
2.34
(0.0921)
2.34
(0.0921)
2.36
(0.0929)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.50
(0.0987)
2.50
(0.0987)
2.52
(0.0992)
2.52
(0.0992)
2.54
(0.1000)
2.36
(0.0929)
2.38
(0.0937)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.50
(0.0984)
2.50
(0.0984)
2.52
(0.0992)
2.52
(0.0922)
2.54
(0.1000)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.38
(0.0937)
2.40
(0.0945)
2.40
(0.0945)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.50
(0.0984)
2.50
(0.0984)
2.52
(0.0992)
2.52
(0.0922)
2.54
(0.1000)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.42
(0.0953)
2.42
(0.0953)
2.44
(0.0961)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.50
(0.0984)
2.50
(0.0984)
2.52
(0.0992)
2.52
(0.0922)
2.54
(0.1000)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.44
(0.0961)
2.46
(0.0969)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.50
(0.0984)
2.50
(0.0984)
2.52
(0.0992)
2.52
(0.0922)
2.54
(0.1000)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.46
(0.0969)
2.48
(0.0977)
2.48
(0.0977)
2.50
(0.0984)
2.50
(0.0984)
2.52
(0.0992)
2.52
(0.0922)
2.54
(0.1000)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.48
(0.0977)
2.50
(0.0984)
2.50
(0.0984)
2.52
(0.0992)
2.52
(0.0922)
2.54
(0.1000)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.52
(0.0992)
2.52
(0.0922)
2.54
(0.1000)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.54
(0.1000)
2.56
(0.1008)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.56
(0.1008)
2.58
(0.1016)
2.58
(0.1016)
2.58
(0.1016)

4. Place the shim (1) on the drive pinion, then install the inner bearing (2) onto the pinion by using installer J42828 and a press . NOTE: Do not apply pressure to the roller cage. Apply pressure only to the inner race. 10. Install flange nut and washer. 1. Apply lubricant to the pinion threads. 2. Using the pinion flange holder J861401, tighten the nut only enough to remove the shaft end play. NOTE: Discard used flange nut and install new one.
425RW024
5. Install collapsible spacer. Discard the used collapsible spacer and install a new one. 6. Install drive pinion shaft assembly. 7. Install outer bearing. 8. Use oil seal installer J37263 to install a new oil seal that has grease on seal lip.
415RW006
3. Adjust pinion bearing preload. a. Measure the bearing preload by using a torque meter and note the scale reading required to rotate the flange. b. Continue tightening flange nut until the specified starting torque is obtained. Starting torque: 1.11.6 Nm (1014 lb in) NOTE: a. Do not overtighten or loosen and then retighten the nut. b. Pinion nut torque should be in the range of 298380 Nm (220281 Ib ft).
425RS025
9. Install flange assembly.
425RW018
DIFFERENTIAL (REAR)
4. Using punch J39209, stake the flange nut at two points. NOTE: When staking, be sure to turn the nut to ensure that there is no change in bearing preload. Make sure of preload again as instructed in 3).
4A221
2. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.
425RS030
425RS028
11. Adjust ring gear backlash. 1. Attach the side bearing to the differential assembly without shims by using installer J42829 and grip J8092.
3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores. Mount the dial indicator J8001 on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.
425RW003
425RS031

4. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range. Backlash: 0.13 0.2mm (0.005 0.008in) 12. Install the side bearings together with the selected shims by using installer J42829 (2) and grip J8092 (1).
425RW032 425RS032
With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 in) to each shim pack to provide side bearing preload. Always use new shims. 5. Remove side bearing by using remover J42379 and adapter J81073.
13. Install side bearing outer race. 14. Install differential cage assembly. 15. Align the setting marks (1) applied at disassembly then install the bearing cap.
425RS035
415RW003
DIFFERENTIAL (REAR)
16. Tighten the bolt to the specified torque. Torque:108Nm (80lb ft)
4A223
425RS038
425RS036
Gear Tooth Contact Pattern Check and Adjustment 1. Apply a thin coat of Prussian blue or equivalent to the faces of the 78 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described in illustration if the contact is abnormal.
Legend (1) Heel (2) Toe (3) Concave Side(Coast) (4) Convex Side(Drive)
425RS039
Differential Cage Assembly

Disassembled View
415RY00001
Legend (1) Pinion Mate Gear (2) Thrust Washer(for Side Gear) (3) Side Gear (4) Differential Shaft
(5) (6) (7) (8)
Ring Gear Bolt Differention Cage Lock Pin
DIFFERENTIAL (REAR)
4A225
Disassembly
1. Remove bolt. 2. Remove ring gear. 3. Remove lock pin using a small drift.
D D D D
Side gear, pinion mate gear, differential shaft Differential cage, carrier Thrust washer Oil seal
Ring gear replacement: 1. The ring gear should always be replaced with the drive pinion as a set. 2. Clean the ring gear threaded holes to remove the locking agent. 3. Discard used bolts and install new ones. 4. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt. Torque: 127Nm (94 lb ft)
425RY00002
4. Remove the differential shaft by using a soft metal rod and a hammer.
425RW033
Clearance between the differential pinion and the pinion shaft measurement. Standard: 0.07 0.13 mm (0.003 0.005 in) Limit: 0.2 mm (0.008 in)
425RS043
5. Remove pinion mate gear. 6. Remove side gear and thrust washer.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Ring gear, pinion gear D Bearing
425RY00007

Clearance between the side gear and the differential box. Standard: 0.032 0.105 mm (0.001 0.004 in) Limit: 0.105 mm (0.004 in)
Reassembly
Differential cage Thrust washer Side gear Pinion gear 1. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction. 2. Install the pinion mate gear with thrust washer by engaging it with the side gears while turning both pinion mate gears simultaneously in the same direction.
425RY00005
Legend (1) Side gear (2) Differential box Play in splines between the side gear and the axle shaft. Standard: 0.07 0.38 mm (0.003 0.014 in) Limit: 0.5 mm (0.02 in)
425RS048
3. Install differential shaft. 1. Be sure to install the differential shaft so that it is in alignment with the lock pin hole in the differential cage.
425RY00006
425RS049
DIFFERENTIAL (REAR)
2. Adjust the backlash between the side gear and the pinion gear. Backlash: 0.10 0.20 mm (0.004 0.008 in) Thickness of thrust washers available mm in 0.80 0.031 0.90 0.035 1.00 0.039 1.10 0.043 1.20 0.047 1.30 0.051 Torque: 127Nm (94 lb ft)
4A227
5. Tighten the bolts in diagonal sequence as illustrated. NOTE: Discard used bolts and install new ones.
425RW033
425RY00008
4. Install lock pin. D Install the lock pin using small drift.
425RY00009
Limited Slip Differential

Disassembled View
425RY001
Legend (1) Screw (2) Differential cage A (3) Thrust washer (4) Spring disc (5) Friction Plate (6) Friction plate (7) Friction Plate (8) Friction disc (9) Friction Plate (10) Friction disc (11) Friction Plate (12) Pressure ring (13) Side gear
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)
Pinion and Pinion shaft Side gear Pressure ring Friction Plate Friction disc Friction Plate Friction disc Friction Plate Friction Plate Friction Plate Spring disc Thrust washer Differential cage B
DIFFERENTIAL (REAR)
4A229
Disassembly
Differential Cages A and B 1. To ensure installation of the parts in original position apply a setting mark before removing the differential cages A and B. 2. Using special tool, J44450, grip it with a vice, and set the differential.
9. Remove Friction plate. 10. Remove Friction disc. 11. Remove Friction plate. 12. Remove Friction disc. 13. Remove Friction plate. 14. Remove Pressure ring. 15. Remove Side gear. 16. Remove Pinion and pinion shaft. 17. Remove Side gear. 18. Remove Pressure ring. 19. Remove Friction plate. 20. Remove Friction disc. 21. Remove Friction plate. 22. Remove Friction disc. 23. Remove Friction plate. 24. Remove Friction plate. 25. Remove Friction plate. 26. Remove Spring disc. 27. Remove Thrust washer. 28. Remove Differential cage B.

425RS054
3. Gradually and evenly loosen the 3 fixing screws of the differential cages A and B.
Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection.
Visual check
Check the following parts for wear, damage, noise or any other abnormal conditions. D Friction disc, friction plate and spring disc
425RS055
4. Remove Differential cage A. 5. Remove Thrust washer. 6. Remove Spring disc. NOTE: When removing the spring disc, friction disc, and friction plate, place them in order for clear distinction of left and right use. 7. Remove Friciton plate. 8. Remove Friction plate.
425RS056
Legend (1) Sliding surfaces (2) Projections

D Pressure ring D Case
425RY003
425RS059
Legend (3) Sliding surface with the friction disc. When nicks or scratches are found, polish with an oil stone and repair on a level block using a compound. (4) Sliding spherical surface with the pinion gear. (5) Sliding surface with the side gear. (6) Vshaped groove of the pressure ring and V shaped section of the pinion shaft. (7) Fitting section with the case. (8) Face contacting the inner surface of the differential case. Repair burrs and nicks using an oil stone. D Thrust washer
Legend (11) Contact surface with the spring disc. (12) Inner groove of the differential cage B. Repair light nicks and burrs using an oil stone.
425RS060
Legend (7) Fitting section with the case. (8) Face contacting the inner surface of the differential case. Repair burrs and nicks using an oil stone. (9) Sliding surface with the side gear or case. (11) Contact surface with spring disc.
425RS058
Legend (9) Sliding surface with the side gear or case. (10) Peripheral groove of the side gear. Repair light nicks and burrs using an oil stone.
DIFFERENTIAL (REAR)
Measure the Deformation of the friction disc & plate. Limit: 0.08 mm (0.003 in) Measure the wear of the thrust washer Limit: 1.3 mm (0.05 in)
4A231
425RS061
425RS063
Measure the wear of the friction plate & disc Limit(AB): 0.1 mm (0.004 in) Remarks: A=Inner or outer projections B=Sliding surface subjected to abrasion
Reassembly
Adjust the clearance between the friction disc and plate. 1. Measuring the depth of the differential cage. Standard (AB): (C): 89.13 mm (3.51 in) 9.13 mm (0.36 in)
425RS062
425RS064

2. Measuring the overall length of the pressurering, friction disc and friction plate. D Mount the pinion shaft in the pressurering and then install the friction disc & plate. D Measure the length between the plates over the Vgroove. (D)
425RS066
2. Measuring the dimension between the thrust washers at both ends. D Assemble the side gear, pinion, pinion shaft, pressure ring and thrust washer, and pressing the pressure ring tothe pinion shaft in the direction of the shaft to make the clearance 0.
425RS065
3. After measuring dimensions A,B,C and D, make adjustment in the following manner: D Measure the thickness (E) of the spring disc. 1.75mm (0.069in) 2 discs 4. Select the friction disc & plate so as to satisfy the following equation: {(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in) Also, the total size difference of the friction disc & plate and spring disc should be 0.05mm (0.02in) or less. Thickness :1.651.751.85mm(0.0650.0690.073 in)
D Have the side gear contact to the pinion to make the backlash 0. D Measure the dimension washers at both ends. (H) between thrust
Backlash adjustment of the side gear in the direction of the shaft

1. Measuring the depth of the differential cage. (FB): 95.63 mm (3.76 in) (G): 15.63 mm (0.62 in)
425RS067
DIFFERENTIAL (REAR)
3. After measuring dimensions of each of the above sections, proceed with the adjustment in the following manner: Adjust the clearance to satisfy the equation below. {(F B) + G H}=0.05 0.20 mm Also, select the thrust washers so that the dimensional difference between the back surfaces of the left and right pressure rings to the thrust washers is 0.05mm or less. Thickness : 1.5mm (0.059 in) 1.6 mm(0.063 in) 1.7 mm(0.067 in) NOTE: When assembling the parts, apply recommended gear oil sufficiently to each of the parts, especially, to the contact surfaces and sliding surfaces. 1. Install Differential cage B. 2. Install Thrust washer. 3. Install Spring disc. D When assembling the spring disc, make sure the mounting direction is correct as shown in figure.
4A233
6. Install Friction plate. 7. Install Friction disc. 8. Install Friction plate. 9. Install Friction disc. 10. Install Friction plate. 11. Install Pressure ring. 12. Install Side gear. 13. Install Pinion and pinion shaft. 14. Install Side gear. 15. Install Pressure ring. 16. Install Friction plate. 17. Install Friction disc. 18. Install Friction plate. 19. Install Friction disc. 20. Install Friction plate. 21. Install Friction plate. 22. Install Friction plate. 23. Install Spring disc. D When assembling the spring disc, make sure the mounting direction is correct. 24. Install Thrust washer. 25. Install Differential cage A. 26. Install Screw. D Matching the guide marks of the differential cages A and B, tighten the screws evenly in the diagonal order.
425RY004
Legend (1) Friction Plate (2) Spring Disc (3) Friction Disc 4. Install Friction plate. 5. Install Friction plate.
425RS055

27. Check the operation. D Measure the starting torque using the side gear holder. Starting torque: 29 45 Nm (3.0 4.6 kgm/ 22 33Ib ft)
425RW065
Legend (1) Side Gear Holder : J44450
DIFFERENTIAL (REAR)
4A235

Rear axle Type Rear axle Size Gear type Gear ratio (to 1) Differential type Lubricant Grade Locking Differential Lubricant Banjo, Semifloating 244 mm (9.61 in) Hypoid 4.300 Two pinion GL5: (Standard differential) GL5, LSD: (Limited slip differential) 80W90 GL5 (USE Limited Slip Differential Gear Lubricant or Friction Modifier Organic Additive) 3.0 liter (3.2 US qt)
Capacity
420RY00002
Special Tools
J39210 Installer; Axle shaft inner seal
J37263 Installer; Pinion oil seal
J6627A Wheel pin remover
J42832 Holding fixture
J39211 Remover; Axle shaft bearing
J39212 Installer; Axle shaft bearing
J42379 Remover; Bearing
J39379 Installer; Outer axle seal
J81073 Adapter; Side bearing plug
J861401 Pinion flange holder
J44461 Installer; Outer bearing outer race
DIFFERENTIAL (REAR)
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION
4A237
TOOL NO. TOOL NAME
J8092 Grip
J44451 Gage plate
J44462 Installer; Inner bearing outer race
J8001 Dial indicator
J42824 Pilot;Outer
J44452 Disc (2 required)
J2177743 Nut & Stud
J235971 Arbor
J44453 Pilot;Inner
J42828 Installer; Pinion bearing
J44449 Pilot;Outer bearing
J39209 Punch; End nut lock

J42829 Installer; Side bearing
J39602 Remover; Outer bearing
J39858 Clutch pack unloading tool kit Includes J341741/J341742 Screw cap and Cap J2234215 Forcing screw
J44450 Side gear holder
SECTION
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
TROOPER
4B11
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Shift On The Fly System . . . . . . . . . . . . . . . . . Outline of Shift on The Fly System . . . . . . . . . Functions of Indicator Lamp . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle Diagnosis . . . . . . . . . . . . . . . . . . . . . Shift On The Fly Vacuum Piping And Electric Equipment . . . . . . . . . . . . . . . . . . . . . . 4B11 4B12 4B12 4B16 4B17 4B117 4B119 Vacuum piping diagram . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . . 4WD Control Unit . . . . . . . . . . . . . . . . . . . . . . . 4WD Control Unit Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B119 4B120 4B123 4B123 4B124 4B124
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
4B12
Shift On The Fly System

Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel drive (2WD) and 4 wheel drive (4WD) electrically by drivers pressing the 4WD switch (push button type) on instrument panel. This system controls below operations. (Shifting between 4H and 4L must be performed by transfer control lever on the floor.) 1. Shifting the transfer front output gear (Connecting to, and disconnecting from, front propeller shaft by motor actuator). 2. Retrial of shifting the transfer front output gear. 3. Connecting front wheels to, and disconnecting them from, the front axles by vacuum actuator. 4. Indicator on instrument panel. 5. 4WD out signal to other Electronic Hydraulic Control Unit.
System Diagrams
412RX003
4B13
Normal Operation
The motor actuator mounted on transfer rear case is driven by signal from 4WD switch on instrument panel. After complete the connecting transfer front output gear to, or disconnecting it from, front propeller shaft, condition Time Chart of Shifting Under Normal Condition of the transfer position switch changes. The vacuum solenoid valve (VSV) is driven by the signal from transfer position switch and the vacuum actuator connects front wheels to, or disconnect them from, front axles.
F04RW002
4B14

gear. This procedure is repeated 3 times in maximum. While this procedure, 4WD indicator lamp blinks by 2 Hz. If the transfer position switch does not turn on after aforementioned procedure has been repeated 3 times, the gear shifting is stopped and 4WD indicator lamps blinking changes from 2Hz to 4Hz to notify driver that the gear shifting is stopped. This blinking of indicator lamp continues until 4WD switch is returned from 4WD to 2WD.
Retrial
The motor actuator starts transfer gear shifting after signal from 4WD switch on instrument panel has been received. But the shifting may be impossible in cold weather or under high speed condition. When 2 seconds have passed since transfer gear shifting started and the transfer position switch dose not turn on (the gear engagement is not completed), the motor reverses its rotation for 1.2 seconds and tries again to shift transfer Time Chart of Shifting Under Severe Condition (retrial)
F04RX001

Warning at 4L position :In view of the shifting mechanism of transfer, the gear shifting from 4WD to 2WD at 4L condition is impossible. Therefore, the transfer position switch can not be turned off by 4WD
4B15
switch when vehicle is in 4L condition. In the case this condition continues for 2 seconds, the shifting to 2WD is stopped and the indicator lamps blinking changes from 2Hz to 4Hz to notify driver of wrong operation.
Time Chart of Shifting from 4WD to 2WD at 4L Condition
F04RX002
4WD out signal to other Electronic Hydraulic Control Unit : 4WDcontrol unit sends 4WD out signal to other Electronic Hydraulic Control Unit as below. 4WD out signal (Period) 120 ms 240 ms Vehicle Condition 2WD 4WD Transfer position switch 2WD (Open) 4WD (Close) Front axle switch 2WD (Open) 4WD (Close)
4B16
Functions of Indicator Lamp

Indication of vehicle condition : Indicator lamp is controlled by 4WD control unit and shows vehicle conditions as below. Indicator Off On Blink (2Hz) Blink (4Hz) Vehicle condition 2WD 4WD Operating Stop operating 4WD switch Off (Close) On (Open) On (Open) Off (Close) On (Open) Off (Close) Bulb check : Transfer position switch 2WD (Open) 4WD (Close) 4WD (Close) 2WD (Open) 2WD (Open) 4WD (Close) Front axle switch 2WD (Open) 4WD (Close) 2WD (Open) 4WD (Close) 2WD (Open) 4WD (Close)
F04RX003
Retrials from 2WD to 4WD :In cold weather or under high speed condition, the gear shifting (engagement) sometimes does not complete by 3 trials. In such case, the indicator lamp inform driver of this incident as aforementioned chart (shown at Retrial in Outline of shift on the fly system).
4B17
Diagnosis
Before Judging That Troubles Occur (Unfaulty mode)
When Switching from 2WD to 4WD 1. In case that blinking frequency of the 4WD indicator changes from 2Hz to 4Hz. When heavy synchronization load is needed, the motor actuator tries the shifting transfer gear three times including the activation shifting. While the motor actuator tries shifting, the indicator blinks by 2Hz. If the third shifting fails, the indicators blinking changes from 2Hz to 4Hz at the same time that the motor actuator shifted back to 2WD. Heavy synchronization load occurs by: D extremely lower temperature. D higher speed, rotation difference of wheels during cornering. Solution 1: Operate again after stop the vehicle or slow down. 2. In case that the 4WD indicator continues blinking by 2Hz for more than 11.5 seconds. When there is rotation difference of wheels or there is phase difference between front wheels and axles, it is difficult to connect front wheels to front axles. The blinking by 2Hz shows that shifting the transfer gear or connecting the front wheels is in the middle of operating. In above case, the indicators blinking by 2Hz shows that connecting the front wheels is not completed (because the indicators blinking changes to 4Hz when the shifting transfer gear is impossible.). And removal of rotation or phase difference make connecting the front wheels possible. Solution 2: When vehicle is running, drive straight ahead while accelerating and decelerating. When vehicle is at a stop, move the vehicle forward and backward from 2 to 3 meters. When switching from 4WD to 2WD 1. In case that the 4WD indicator continues blinking by 2Hz . The 4WD indicator continues blinking by 2Hz until both shifting the transfer gear and disconnecting the front wheels are completed when switching 4WD to 2WD. When driveline is loaded with torsional torque, the shifting transfer gear and disconnecting front wheels are impossible. In this case, removal of torsional torque on driveline make the shifting transfer gear and disconnecting front wheels possible. Solution 3: When vehicle is running, drive straight ahead while accelerating and decelerating. When vehicle is at a stop, move the vehicle forward and backward from 2 to 3 meters. 2. In case that the 4WD indicators blinking changes from 2Hz to 4Hz. Check the position of transfer lever. Is it at 4L position? In view of the shifting mechanism of transfer, the gear shifting from 4WD to 2WD at 4L condition is impossible. Solution 4: Push the 4WD switch to 4WD, shift the transfer lever to High position and reoperate the 4WD switch to 2WD.
4B18
Parts Location
D08RX005
Legend (1) I12 (2) I9 (3) H7, H24, H25 (4) Fuse Box (5) C16 (6) C94 (7) M11, M12
(8) (9) (10) (11) (12) (13) (14)
M22 M23 M24 H10 M26 Relay & Fuse Box H12, H16
4B19
Wiring Diagram
D08RW028
4B110
D08RW029
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B111
Connector List
D04RW030
4B112
Diagnosis of The Faults Based on the Status of 4WD Indicator Lamp, 4WD Switch and T/F Change Lever
Diagnosis charts are shown on below. If troubles can not be solved after every chart was traced, troubles may occur in the 4WD control unit. In this case, replace the 4WD control unit and trace every chart again. Fault on switching from 2WD to 4WD 1. In case that 4WD indicators blinking changes from 2Hz to 4Hz after Solution 1 is carried out. Faults occur in the motor actuator or the transfer case assembly. Remove the motor actuator and check function. If problem was found and it was repaired, try Solution 1 again. After that, disassemble the transfer case assembly for check and repair or replace. If incident is not improved after above mentioned actions were taken, replace the 4WD control unit. 2. In case that 4WD indicator does not blink nor light, when switching from 2WD to 4WD. Step 1 Is ignition turned on? Go to Step 2 2 Does the indicator light comes on when the engine is not started? Action Yes No Turn on the ignition and trace this chart from start. Burning out of indicator lamp or disconnection of harness wire. Trace this chart from the start after repair or replace.
Go to Step 3 3 Start the engine. Is the 4WD switch turned from 2WD to 4WD? Short-circuit (body short) on harness of the 4WD switch. Fault of the 4WD switch (holding the closed condition). Trace this chart from the start after repair or replace.
Push the 4WD switch to 4WD.

3. Case that the indicator keeps blinking by 2Hz after aforementioned Solution 2 is carried out. Step 1 Were problems found? Action Check the air pressure and wear of all tires. Yes Try Solution 2 after adjust the air pressure and replace worn tires. No
Go to Step 2 Disconnection of the motor actuator harness wiring. Trace this chart from the start after repair or replace. Faults on the motor actuator. Trace this chart from the start after replace. Internal faults of transfer case. Disassemble the transfer case for check. Trace this chart from the start after repair or replace. Faults on the transfer position switch or its harness. Trace this chart from the start after repair or replace. Faults on the VSV main body, its harness or vacuuming system. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start. Disconnection on the axle harness. Trace this chart from the start after repair or replace. Faults on Front Axle ASM. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start.
2 Can the transfer lever be operated from High to 4L or vice versa?
Go to Step 3 3 Pull out the hoses from vacuum actuator and operate 4WD switch. Is there negative pressure on either of hoses?
Go to Step 4 4 Check the axle switch. Were problems found?
Internal faults on axle switch. Trace this chart from the start after replace.
4B114
Fault on switching from 4WD to 2WD 1. Case that indicator does not blink nor turn out. Step 1 Does the indicator turn out by ignition off? 2 Is the 4WD switch on 2WD position? Go to Step 2 Disconnection on the 4WD switch harness or breakdown of the 4WD switch in open state. Trace this chart from the start after repair or replace. Action Yes No Short circuit of the indicator harness.
Turn the 4WD switch to 2WD position. Trace this chart from the start.

2. Case that indicator keeps 2Hz blinking after aforementioned Solution 3 is carried out. Step 1 Were problems found? Action Check the air pressure and wear of all tires. Yes Try Solution 3 after adjust the air pressure and replace worn tires. Faults on the harness wiring of motor actuator. Trace this chart from the start after repair or replace. Internal faults on transfer case. Disassemble the transfer case for check. Trace this chart from the start after repair or replace. Faults on the motor actuator. Trace this chart from the start after or replace. No
Go to Step 2
2 Can the transfer lever be operated from High to 4L or vice versa?
Go to Step 3 Faults on the transfer position switch or its harness. Trace this chart from the start after repair or replace. Faults on the VSV main body, its harness or vacuuming system. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start.
Pull out the hoses from vacuum actuator and operate 4WD switch. Is there negative pressure on either of hoses?
Go to Step 4 4 Check the axle switch. Were problems found? Internal faults on axle switch. Trace this chart from the start after replace. Faults on Front Axle ASM. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start.
Short circuit (body short) or disconnection of the axle harness. Trace this chart from the start after repair or replace.
4B116
3. Case that indicators blinking changes to 4Hz after aforementioned Solution 4 is carried out. Step 1 Can the transfer lever be operated from High to 4L or vice versa? Action Yes Faults on the harness wiring of motor actuator. Trace this chart from the start after repair or replace. Faults on the motor actuator. Trace this chart from the start after replace. Internal faults on transfer case. Disassemble the transfer case for check. Trace this chart from the start after repair or replace. No
Faults on the 4WD control unit. Trace this chart from the start after replace.
Front Axle Diagnosis

D When the 4WD switch is operated from 4WD to 2WD, indicator light does not go out. Step 1 2 Action Drive slow 100 200m after a few minutes idling. Has indicator light gone out? Jack up front tires. Does the right side of front wheel rotate when the left side of front wheel is rotated? 3 1. Check the actuator switch. 2. Check the circuit to indicator. Was a problem found? Trace this chart from the start after repair or replace. Trace this chart from the start after repair or replace. Go to Step 4 Go to Step 3 Disassemble axle ASM for check. Trace this chart from the start after repair or replace. All right. Go to Step 2 Yes No
1. Check the VSV valve. 2. Check the circuit to VSV valve. Was a problem found?
Go to Step 5 Trace this chart from the start after repair or replace. Disassemble axle ASM for check. Trace this chart from the start after repair or replace.
Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Go to Step 6
Does actuator work all right?
Trace this chart from the start.
4B118
D When the 4WD switch is operated from 2WD to 4WD, indicator light is not actuated. Step 1 2 Action Drive slow 100 200m after a few minutes idling. Has indicator light actuated? Jack up front tires. Does not the right side of front wheel rotate when the left side of front wheel is rotated? 3 1. Check the actuator switch. 2. Check the circuit to indicator. Was a problem found? Trace this chart from the start after repair or replace. Trace this chart from the start after repair or replace. Go to Step 4 Go to Step 3 Disassemble axle ASM for check. Trace this chart from the start after repair or replace. All right. Go to Step 2 Yes No
1. Check the VSV valve. 2. Check the circuit to VSV valve. Was a problem found?
Go to Step 5 Trace this chart from the start after repair or replace. Disassemble axle ASM for check. Trace this chart from the start after repair or replace.
Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Go to Step 6
Does actuator work all right?
Trace this chart from the start.
Shift On The Fly Vacuum Piping And Electric Equipment

Vacuum piping diagram
C04RW007
VSV Assembly, Actuator Assembly
Vacuum Tank
412RS032
412RS033
4B120
Inspection And Repair

Vacuum Piping
C04RW008
1. Pull out the Hose A in figure and install a vacuum gauge. 2. Plug up Hose B in figure to prevent the leak of vacuum. 3. Start the engine and measure vacuum 2 or 3 minutes afterward. 4. Repeat 1) and 2) but with Hose A plugged and Hose B pulled out. 5. If vacuum measures 400mmHg, or if it shows a sudden drop immediately after engine stop, inspect the hose, tank, and pipe for damage. NOTE: Be careful not to permit the entry of dust and water during inspection. 6. Pull out Hose D in above illustration. 7. Plug Hose E in above illustration. 8. Make sure that Hose D in above illustration is under atmospheric pressure. 9. Pull out Hose E and plug Hose D, and make sure that Hose E is under atmospheric pressure. 10. If Check 8) or 9) has revealed stoppage, check and see that there is no bend, foreign matter in the hose or in the filter. If there is trouble, repair or replace.
Check Valve
C04RS004
1. Apply vacuum from the orange colored side(1). Vacuum:400mmHg 2. Check leakage of vacuum. 3. Make sure that vacuum cannot be applied from the black colored side(2). 4. If vacuum is not applicable as much as 400mmHg, and if there is resistance on the intake side, replace with a new check valve.
VSV Assembly
Inspect the vehicle side harness as follows:
2. With battery connected A B:There is continuity C:Closed 3. If 1) and 2) fail, replace with a new VSV.
Axle Position Switch
412RS071
Legend (1) Grey (2) Blue

412RS048
1. Remove connector. 2. Shift transfer lever to 2H and start the engine. NOTE: Do not move the vehicle while inspection. 3. Make sure that there is continuity in the vehicle side of harness. If there is no continuity, check transfer shift switch and wiring. Inspect both VSVs as follows:
1. With ball (1) being free A B:There is continuity 2. With ball forced into the switch A B:No continuity 3. If 1) and 2) fail, replace with a new switch.
Motor Actuator Assembly

Inspect the function of the motor actuator assembly as follows:
F04RS004
1. With battery not connected (Usual). AC:There is continuity B:Closed
4B122

Shift rod of the motor actuator moves and stops at 2WD position.
1. Disassemble the motor actuator from transfer rear case.
412RW037
412RX002
Legend (3) Shift Rod (4) Connector 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position.
Legend (1) 2WD (2) 4WD (3) Shift Rod (4) Connector 4. If 2) and 3) fail, replace with a new motor actuator.
Transfer Position Switch
412RX001
Legend (1) 2WD (2) 4WD (3) Shift Rod (4) Connector 3. Connect the terminals as shown in figure.
412RW040
Legend (1) Ball 1. With ball being free. AB : There is continuity. 2. With ball forced into the switch. AB : No continuity. 3. If 1) and 2) fail, replace with a new switch.
4WD Control Unit

4WD Control Unit Associated Parts
412RW044
Legend (1) Lower Cluster Assembly (2) Front Console Assembly
(3) Harness Connector (4) Nut (5) 4WD Control Unit
4B124
Removal
1. Remove lower cluster assembly and front console assembly. Refer to Interior Trim in Body and Accessories section. 2. Remove nut. 3. Remove 4WD control unit. 4. Disconnect harness connector (1).
412RW045
Legend (1) Harness Connector
Installation
1. Connect harness connector, then install 4WD control unit. 2. Install lower cluster assembly and front console assembly.
SECTION
DRIVE LINE CONTROL SYSTEM (TOD)
TROOPER
4B21
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . System Components . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Functions of Indicator Lamp . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Diagnostic Flow Chart . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4B21 4B22 4B24 4B24 4B28 4B212 4B216 4B217 4B218 Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Failed Pin . . . . . . . . . . . . . . . . . . . . . Checking Failed TOD Control Unit Pin . . . . . Diagnostic Trouble Codes . . . . . . . . . . . . . . . . Diagnosis from Trouble Codes . . . . . . . . . . . . Trouble Diagnosis Depending on The Status of TOD Indicator . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis from Symptom . . . . . . . . . . . . . . . . . 4B221 4B223 4B226 4B231 4B232 4B256 4B285
Service Precaution
4B22 DRIVE LINE CONTROL SYSTEM (TOD)
General Description
C07RY00003
TOD (Torque on Demand) system is traction state control system to vehicle.
Transfer Position and Drive Mode

Three drive modes can be selected through operation of 4WD switch and transfer lever. Transfer Position HIGH 4WD AUTO SWITCH ON OFF 4L ON/OFF Mode 2H TOD 4L Drive mode Rear wheel drive Electronically controlled torque split four wheel drive Low-speed mechanical lock-up four wheel drive
The electronic control unit (ECU) judges the signals from the transfer lever and controls the transfer drive mode and shift-on-the-fly system status.
TOD Control
The TOD position usually drives the rear wheels, and transmits the torque to the front wheels with the help of electronically controlled torque split mechanism according to running conditions encountered. The driving force is directly transmitted to the rear wheels. This force is split by the transfer and delivered to the front wheels. The magnitude of the torque transmitted to the front wheels is controlled by changing the pressing force of the multi plate disk clutch built in the transfer unit. The
pressing force of the clutch is controlled by changing the voltage to the electromagnetic coil mounted to the rear of the clutch. When the clutch is completely disengaged, the rear wheels are driven. When the clutch is completely engaged, a rigid four wheel drive mode is obtained. The torque split status is controlled continuously between the rear wheel and four wheel drive modes. This system includes front and rear speed sensors, and receives throttle position sensor information from the PCM. The control unit receives signals sent from these sensors and changes the pressing force of the multi plate disk clutch to determine the torque distribution on the front and rear wheels. Therefore, when the slip of the rear wheels is increased against the current torque level in the normal

rear wheel drive mode, the control unit detects the slip condition, determines the optimum torque based on the feedback control logic, and increases the torque to the front wheels. The control unit uses the signal from the throttle position sensor to predict the future vehicle condition and the intention of the driver with respect to acceleration and deceleration, and determines the initial torque distribution using these data and the information from the speed sensors. In case of small circle turning in the parking lot, for example, the control unit minimizes the clutch pressing force to restrict a braking phenomenon. When the ABS becomes active, the control unit optimizes the clutch pressing force to ensure stable braking.
4B23
TOD Indicator Control

The TOD indicator on the instrument panel informs the driver of the current working status of the transfer unit. The information consists of two items: the drive mode (2H, TOD, 4L, transition) and the torque split status of the TOD (torque distribution level). The indicator can display occasional errors and corresponding error codes.
System Components
Parts Location
A07RY00002
Legend (1) T/F Connector (2) 4H Switch and 4L Switch (3) High-Low Planetary Gear Set (4) Mechanical Lock
(5) (6) (7) (8)
Multi Plate Disk Clutch Pack Electromagnetic Coil Rear Speed Sensor Front Speed Sensor
4B25
Front and Rear Speed Sensors

The sensors are built in the transfer case, and detect the rotation of rotors directly coupled to the propeller shafts. Thirty rectangular pulses are output per one rotation of the propeller shaft.
Multi Plate Disk Clutch Pack

Transmits the torque determined by the clutch pressing force to the front propeller shaft via the front drive chain.
262RW029
261RW045
Mechanical Lock Sleeve

Couples the front and rear propeller shaft mechanically when the transfer shaft is in the 4L position.
Electromagnetic Coil
Receives the duty signals from the TOD control unit and controls the pressing force of the clutch pressure cam.
262RW028
261RW044
High-Low Planetary Gear Set

Establishes an auxiliary transmission mechanism. When the transfer shift lever is set to the 2H or TOD position, the reduction gear ratio is 1.000 and the corresponding driving force is generated. When the transfer shift lever is set to the 4L position, the reduction gear ratio is 2.480 and the corresponding driving force is generated.
Transfer Connector
Transmits the input and output signals of the speed sensors, electromagnetic coil, and 4H and 4L switche to the vehicle harness. A waterproof 12-pin type is used.
261RW046
262RW030
TOD Indicator Lamps (on the instrument panel)

Inform the following items. D Bulb check D Drive mode D ABS IN status D BRAKE ON status
4H and 4L Switch
Detects the shift position of the transfer from the movement of the transfer lever and outputs signals to the TOD control unit.
261RW002 821RW049
4B27
Check Lamp
Inform the following items. D Bulb check D Fail (fail alarm) D Trouble code
821RW078
TOD ECU
This control unit is mounted to the front right hand seat via a special bracket.
F07RW029
Functions of Indicator Lamp

TOD Indicator Lamps
C07RY00017

Indication During Transition of Transfer Lever When the transfer lever is shifted, and the signals from the AXLE switch do not comply with the signal conditions of the 4H and 4L switch, the transfer lever position signals generated by the 4H and 4L switch and the N position signals are repeatedly output at an interval of 0.8 second. NOTE: After the transfer lever is set to the specified position and the AXLE switch generates compliant signals, the normal output status is returned.
4B29
C07RW015
Bulb Check When the starter switch is turned on, the TOD indicator lamps go on as shown below. NOTE: Once the starter switch is turned on, all the TOD indicator lamps are lit for two seconds even if the transfer lever is in any position.
C07RW016

Simplified checking method of ABS IN and BRAKE ON signals: In the event that any of the signal inputs listed below are observed while the self-diagnostic code is being displayed (the self-diagnostic connector is short-circuited to GND), you can simply check the ABS IN and BRAKE ON signals as shown in the figures below.
C07RW0171
DRIVE LINE CONTROL SYSTEM (TOD) 4B211
Check Lamp
Check Lamp Bulb Check When the starter switch is turned on in the normal state, the control unit turns on the CHECK lamp to check the bulb.
C07RW019
Diagnosis
General Information Diagnosis
The troubles on TOD are classified into the group that can be identified by the lighting status of the TOD indicator lamps and those that can be recognized as abnormal phenomena of the vehicle by the driver. The troubles that can be identified by the lighting status of the TOD indicator lamps are examined by the procedures Diagnosis from Trouble Codes and Trouble Diagnosis Depending on The Status of TOD Indicator. The troubles that can be recognized as abnormal phenomena of the vehicle by the driver are examined by the procedure Diagnosis from symptom.
Self-diagnosis
The control unit has a function of self-diagnosis. If a trouble occurs in the course of system startup, the control unit blinks the CHECK lamp and saves the trouble code.
C07RW021
NOTE: If an intermittent fault occurs, the control unit stops blinking upon removal of the fault. The trouble code is saved to the control unit.

Indication Method of Trouble Code D Short-circuit terminal 8 of the self-diagnostic connector to GND to display the trouble code on the CHECK lamp. D If no trouble codes exist, code 12 is displayed continuously. D If trouble codes exist, code 12 is displayed three times, and the trouble codes, starting from the smaller code number, are displayed three times respectively.
821RW021
C07RY00018

How to Clear The Trouble Code The trouble codes saved to the control unit can be deleted by the following procedure if the starter switch is being in the OFF position. 1. Shift the transfer lever to the neutral position between HIGH and 4L, and short-circuit the self-diagnostic connector. NOTE: The neutral position between HIGH and 4L refers to the point that turns off the TOD indicator lamps. (However, be sure to check the position before short-circuiting the self-diagnostic connector.) Trouble Intermittently Observed Troubles intermittently observed are mostly attributable to temporary imperfect connection of harnesses and connectors. When such troubles are found, check the associated circuit according to the following procedure. 1. Check whether improper connectors are plugged in or connector terminals are completely engaged. 2. Check whether the terminals are deformed or damaged. If yes, remove the deformation or damage and connect the terminals securely. 3. It is likely that wires in the harness are falsely broken. Therefore, in examination of failed harness circuit, shake the harness for check to such extent that the harness will not be damaged. Test Run of Failed TOD Vehicle If the TOD indicator lamps experienced faulty operation even once in the past, the failed portion can be identified by use of the procedure Diagnosis from Trouble Codes or Trouble Diagnosis Depending on The Status of TOD Indicator. If the troubles that are only recognized as abnormal phenomena of the vehicle by the driver are observed, conduct the test run in the following procedure to reproduce the faulty phenomena and diagnose the fault for each phenomenon. 1. Start the engine, and check that the TOD indicator lamps are turned on for about two seconds for initial check; the CHECK lamp goes off; and the TOD indicator lamps display the specified drive mode. (If the CHECK lamp starts blinking, read the trouble codes and identify the failed portion.) 2. While keeping the vehicle standstill, operate the 4WD switch and shift the transfer lever to change the modes: 2H modeTOD mode4L modeTOD mode2H mode. Check that the TOD indicator lamps correctly display the status whenever the mode is changed. If the transition status is displayed during the shift operation, run the vehicle a little to complete shifting. 3. Slowly start the vehicle in the TOD mode, and add the power to accelerate to at least 40 km/h and maintain the speed for about two minutes. Apply the brake to completely stop the vehicle. Repeat this test pattern at least three times. 4. Turn the steering to the right end (or left end) in the TOD mode, and slowly start the vehicle and make a circle five times. Next, conduct the same test in the 2H mode. 5. Slowly start the vehicle in the TOD mode, and accelerate to at least 40 km/h. Keep the established speed, carefully change the mode in the sequence TOD mode2H mode TOD mode while checking that the shift is complete in each mode change. After the test, apply the brake to completely stop the vehicle. 6. Slowly start the vehicle in the TOD mode, and accelerate to at least 40 km/h. Apply the brake strongly so that the ABS works, and completely stop the vehicle.
C07RW011
2. Turn on the starter switch while maintaining the state of step 1, and step on the brake pedal five times within five seconds from the first step on. (Note that five times includes the first step on). (The TOD indicator lamps display the 4L mode whenever the brake pedal is stepped on.) 3. If the conditions shown in steps 1 and 2 are met, the trouble codes saved to the control unit are cleared. (After the codes are completely deleted, the code 12 that indicates the normal condition is continuously displayed.)
Precautions on Diagnosis
Replacement of Control Unit The control unit itself rarely fails. In most cases, the harnesses have failed (i.e. short-circuit) to cause secondary troubles. Other cases include that the cause has been unknown due to intermittent occurrence of troubles and the troubles are removed accidentally along with replacement of control unit, resulting in misjudgment of cause. Therefore, before replacing the control unit, check the connector joints and whether the unspecified current flows in the control unit due to short-circuit between harnesses.

7. Slowly start the vehicle in the 4L mode, and accelerate to at least 20 km/h. Apply the brake to completely stop the vehicle. If the CHECK lamp starts blinking during the test run, read the trouble codes and give appropriate maintenance according to the diagnostic procedure. If the TOD indicator lamps are lit abnormally during the run, check the lighting condition and give appropriate maintenance according to the diagnostic procedure. Even if the phenomena are not observed, try to reproduce the abnormal state reported by the customer to the possible extent. Post-Repair Check As long as the starter is not turned off, the TOD indicator lamps continue blinking even after the failed portion is repaired. Therefore, upon completion of repair, be sure to turn off the starter switch once and then turn on it to conduct the test run sequence specified in steps 1 through 7 above and check that the TOD indicator lamps no longer show any faulty status.
Basic Diagnostic Flow Chart
C07RW0231
Parts Location
D08RW367
Legend (1) I9 (2) C63 (3) H7, H8, H25 (4) H33 (5) Fuse Box (6) C16 (7) B13 (8) H55, H57 (9) M22 (10) M23
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)
M24 H10 H17 E54 E29 Relay & Fuse Box H12 B48, B49 H33, H36 M27 I12
Circuit Diagram
D04RY00003
D04RY00002
D04RY00010
Connector List
No. B-13 Connector face No. H-8 Connector face
B-48
H-10
B-49
H-12
C-16
H-17
C-63
H-25
C-94
H-33
E-29
H-36
E-54
H-55
H-7
H-57

No. I-9 Connector face
I-12
M-22
M-23
M-24
M-27
Checking Failed Pin

Connector Pin Assignment
D ECU pin assignment
D04RY00011
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
NAME N.C N.C N.C DG MAP N.C IND. b N.C IND. Rr N.C N.C SOL (+) Ref COM () VIG TPS TECH 2 IND. a IND. c IND. AUTO CHECK N.C PGND ADC (+) N.C N.C Not used Not used Not used Gas/Diesel Not used Display FrontB Not used Display RearE Not used Not used EMC Speed Reference Speed Return Ignition TPS (PWM) TECH2 Display FrontA Display FrontC Display AutoD Check T/F Not used Power Ground Axle Disconnect Output Not used Not used
CONTENTS

No. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 NAME N.C N.C N.C DIAG TOD SW 4H SW Frt. Sig ABS IN VIG N.C 4WD OUT BRAKE N.C N.C LIGHTING SW N.C AXLE SW N.C 4L SW Rr. Sig GND GND. 2 N.C Not used Not used Not used Diagnostic Input TOD Switch 4H Switch Input Front Speed Signal ABS In Ignition Not used 4WD Signal Output Brake Switch Input Not used Not used Lighting Switch Input Not used Axle Switch Input Not used 4L Switch Input Rear Speed Signal ECU Ground 1 ECU Ground 2 Not used CONTENTS
Reference
D Transfer connector pin assignment (connector on the transfer case) for inspection of transfer pins.
810RW310
No. 1 2 3 4 5 6 7 8 9 10 11 12
NAME Ref. (Rer. ) Ref. (Frt. ) SW GND 4H SW (+) Rer. (+) Frt. (+) POWER GND SOL (+) COM () (Rer. ) COM () (Frt. ) NC 4L SW (+)
CONTENTS Rear speed sensor reference output Front speed sensor reference output SW GND 4H SW plus terminal Rear speed sensor plus Front speed sensor plus Power GND Electromagnetic solenoid Rear speed sensor GND Front speed sensor GND Not used 4L SW plus terminal
Checking Failed TOD Control Unit Pin

NOTE: 1. Unplug the ECU connector and the pins, unless otherwise specified. 2. Before removing the ECU, turn off the ignition switch. 3. If the standard values are not observed, check the pins with other testers. Che ck Pin No. 4 22 46 31 Circuit to be tested Ignition Engine Switch State Position OFF OFF OFF OFF STOP STOP STOP STOP Multimeter Scale/ Range W W W W Measure between Pin Number 4, 46 22, 46 46, GND 31, 46 Standard Valve Note
D-G MAP P-GND GND 4H SW
Continuity : OK Continuity : OK Continuity : OK No continuity (high, 4L) and continuity (N) : OK No continuity (high) and continuity (4L, N) : OK Continuity : OK Remove ECU and start the engine. Move the vehicle forth and back to connect axle surely. DLC connector terminal 8
44
4L SW
OFF
STOP
44, 46
42
AXLE SW
ON
RUN
42, 46
29
DIAG
OFF
STOP
29 (TOD), 8 (DLC Connector) 17 (+), 46 () 6 (+), 46 () 18 (+), 46 () 20 (+), 46 () 33 (+), 46 () 12 (+), 46 () 32 (+), 46 ()
Continuity : OK
17 6 18 20 33 12 32
IND.a IND.b IND.c CHECK LAMP ABS IN Ref. Ft.(+)
ON ON ON ON ON ON ON
STOP STOP STOP STOP STOP STOP STOP
DCV DCV DCV DCV DCV DCV DCV
8.0 14.5 V 8.0 14.5 V 8.0 14.5 V 8.0 14.5 V 11.5 14.5 V 5 9 V 0.7 6 V
When the indicator lamp is turned off. When the indicator lamp is turned off. When the indicator lamp is turned off.
Connect ECU Connect ECU and move the vehicle (off one tooth of speed sensor ring) making sure of voltage change. Connect ECU and move the vehicle (off one tooth of speed sensor ring) making sure of voltage change. Connect ECU
45
Rr.(+)
ON
STOP
DCV
45 (+), 46 ()
0.7 6 V
13 14
COM(-) Vig
ON ON
STOP STOP
DCV DCV
13 (+), 46 () 14 (+), 46 ()
0V 8 14.5 V

Che ck Pin No. 37 15 Circuit to be tested Ignition Engine Switch State Position OFF ON STOP STOP Multimeter Scale/ Range DCV DCV Measure between Pin Number 37 (+), 46 () 15 (+), 46 () 36, 46 23, 46 11, 46 30 (+), 46 () 40 (+), 46 () 19 (+), 46 () 8 (+), 46 () 34 (+), 46 () Standard Valve Note
BRAKE TPS
8 14.5 V PWM duty cycle 10% 90% 7 12 kW 10 30 W 1.0 5.0 W SW OFF : 0 V SW ON : 8.0 14.5 V SW OFF : 8.0 14.5 V SW ON : 0 V TOD : 0 V 2H&4L : 8.0 14.5 V 0V 8 14.5 V
Press brake pedal Step on the accelerator pedal and make sure that duty cycle changes. Disconnect battery GND terminal Disconnect battery GND terminal Disconnect battery GND terminal SW OFF : Contact point open SW ON : Contact point close
36 23 11 30
4WD OUT ADC(+) SOL(+) 4WD SW
OFF OFF OFF ON
STOP STOP STOP STOP
W W W DCV
40
LIGHTING AUTO INDI RR INDI VIG
ON
STOP
DCV
19
ON
STOP
DCV
Connect ECU.
8 34
ON ON
STOP STOP
DCV DCV
Connect ECU. When the indicator lamp is turned on.
Tech 2 Scan Tool

From 98 MY, Isuzu dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide.
901RW257
Legend (1) PCMCIA Card (2) SAE 16/19 Adaptor
(3) DLC Cable (4) Tech 2
Getting Started
D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (4) 4. Mark sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC connector.
Operating Procedure
The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.
821RW021
6. The vehicle ignition turns on. 7. Power up the Tech 2. 8. Verify the Tech 2 power up display.
060RY027
060RW009
060RX062
Diagnostic Trouble Codes

Code 12 13 14 15 16 21 23 24 26 27 28 31 32 33 36 37 38 Item Start code Ref Front speed sensor Ref Front speed sensor TPS ECU Rear speed sensor EMC (+) Rear speed sensor ADC (+) & AXLE SW EMC (+) ADC (+) ADC (+) ECU ECU ECU Tech 2 code (P code) P1735 P1731 P1736 P1737 P1716 P1733 P1738 P1760 P1721 P1761 P1762 P1712 P1714 Normal Shorted GND Input abnormality (open, sig or com) Shorted VB Input abnormality Shorted or disconnected wiring, abnormality in input CPU abnormality Input abnormality (open, sig or com) Shorted GND Input abnormality Output abnormality Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted GND CPU abnormality CPU abnormality CPU abnormality Diagnosis Check flow No. 6 2 6 3 7 1 5 10 4 11 9 12 13 1 1 1
TPS : Throttle Position Sensor EMC : Electromagnetic coil ADC : Shift on the fly (Axle Dis Connect)
Diagnosis from Trouble Codes

D Diagnose the based on the fault that have been saved to the control unit according to the system self-diagnostic function.
Check flow 1
Trouble code 23, 36, 37(P1712), 38(P1714)
Phenomenon The ECU has failed.
Standard
Step 1 Turn on the starter switch. Is the trouble reproduced?
Action
Yes Replace the ECU and conduct the test run. Go to Step 3
No
Go to Step 2 The trouble is not reproduced. Refer to Troubles intermittently observed. Go to Step 3
1. Clear the trouble codes. 2. Conduct the test run. Is the trouble reproduced during the test run? Replace the ECU and conduct the test run. Go to Step 3 Repeat the Diagnosis Flow.
1. Check that all the parts are mounted. 2. Clear the trouble codes. Is this step complete?
Return to Step 3
Check flow 2
Trouble code 14 (P1731)
Phenomenon Front speed sensor signal open or GND short, speed sensor com open.
Standard 0.3 > sensor voltage
NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken.
D04RY00004

Step 1 1. Start the engine. 2. Select TOD mode. Is there the memory except DTC 14(P1731)? 2 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 10 and 25? 3 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 10 and the connector (M27) terminal 6, the connector (B49) terminal 12 and connector (M27) terminal 2, and the connector (B49) terminal 13 and connector (M27) terminal 10? 4 Is the memory DTC 24(P1733)? Go to Step 5 5 6 Is there the continuity between harnesses of terminal 32 and 45 (vehicle side terminal of the front and rear speed sensor)? Is there the continuity between harnesses of terminal 12 and 13 (vehicle side terminal of the speed sensor COM() and ref)? Go to Step 6 Replace front and rear speed sensor. Go to Step 7 Replace the front speed sensor. Go to Step 7 Repair the circuit. Go to Step 7 Go to Step 3 Go to Step 4 Go to Step 2 Action Yes No
Repair the circuit. Go to Step 7 Refer to other trouble check flow. Repair the circuit. Go to Step 7
Repair the circuit. Go to Step 7
1. Check that all the parts are mounted. 2. Clear the trouble code. Is the step complete? Verify the repair. Return to Step 7
Check flow 3
Phenomenon The front speed sensor no pulse.
Standard Hi level : 4.5 6.0 V Lo level : 0.7 2.0 V Frequency (F) = 700 850 Hz (at 30 mile/h)
NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.
D04RY00004

Step 1 1. Connect TECH 2. While running in TOD mode, does TECH2s front speed sensor indication change with vehicle speed? Go to Step 2 2 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? Go to Step 3 3 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 10 and 25? 4 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 10 and the connector (M27) terminal 6, the connector (B49) terminal 12 and connector (M27) terminal 2, and the connector (B49) terminal 13 and connector (M27) terminal 10? 5 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? 6 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete? Replace ECU. Go to Step 6 Repeat the Diagnosis Flow. Go to Step 6 Replace the front speed sensor. Go to Step 5 Repair the circuit. Go to Step 6 Go to Step 4 Action Yes No Repair and inspection front speed sensor tone wheel. Go to Step 6 The trouble is not reproduced. Refer to Troubles intermittently observed.
Return to Step 6
Check flow 4
Phenomenon The front speed sensor no pulse.
Standard Hi level : 4.5 6.0 V Lo level : 0.7 2.0 V Frequency (F) = 700 850 Hz (at 30 mile/h)
NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.
D04RY00004

Step 1 1. Connect TECH 2. While running in TOD mode, does TECH2s rear speed sensor indication change with vehicle speed? Go to Step 2 2 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? Go to Step 3 3 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 23 and 25? 4 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 23 and the connector (M27) terminal 5, the connector (B49) terminal 12 and connector (M27) terminal 1, and the connector (B49) terminal 13 and connector (M27) terminal 9? 5 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? 6 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete? Replace ECU. Go to Step 6 Repeat the Diagnosis Flow. Go to Step 6 Replace the rear speed sensor. Go to Step 5 Repair the circuit. Go to Step 5 Go to Step 4 Action Yes No Repair and inspection front speed sensor tone wheel. Go to Step 6 The trouble is not reproduced. Refer to Troubles intermittently observed.
Return to Step 6
Check flow 5
Phenomenon Rear speed sensor signal open or GND short, speed sensor COM open.
Standard 0.3 V > sensor voltage
NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken.
D04RY00004

Step 1 1. Start the engine. 2. Select TOD mode. Is there the memory except DTC 24(P1733)? 2 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 23 and 25? 3 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 23 and the connector (M27) terminal 5, the connector (B49) terminal 12 and connector (M27) terminal 1, and the connector (B49) terminal 13 and connector (M27) terminal 9? 4 Is the memory DTC 14(P1731)? Go to Step 5 5 6 Is there the continuity between harnesses of terminal 32 and 45 (vehicle side terminal of the front and rear speed sensor)? Is there the continuity between harnesses of terminal 12 and 13 (vehicle side terminal of the speed sensor COM() and ref)? Go to Step 6 Replace front and rear speed sensor. Go to Step 7 Replace the rear speed sensor. Go to Step 7 Repair the circuit. Go to Step 7 Go to Step 3 Go to Step 4 Go to Step 2 Action Yes No
Repair the circuit. Go to Step 7 Refer to other trouble cheek flow. Repair the circuit Go to Step 7
1. Check that all the parts are mounted. 2. Clear the trouble code. Is the step complete? Verify the repair Return to Step 7
Check flow 6
Trouble code 13 (P1735) 15 (P1736)
Phenomenon The reference is short-circuited to GND. The reference Vb is short-circuited.
Standard Reference ] 5 V
If the reference wire (15) is short-circuited to GND, the speed signal is not generated. If the wire is short-circuited to the battery voltage, the signal level becomes faulty.
D04RY00004

Step 1 1. Start the engine. Does the voltage between terminals 12 and 13 meet the standard 5V? Action Yes The phenomenon is not respoduced. Refer to Troubles intermittently observed. Go to Step 3 No
Go to Step 2 Go to Step 7 The ECU is failed. Replace the ECU. Go to Step 8 Short to GND between (B49) 12 and (H17) 1. Repair the sircuit. Go to Step 8 The reference harness for the front speed sensor is shortcircuited to GND. Repair the circuit. Go to Step 6 The reference harness for the front speed sensor is shortcircuited to GND. Repair the circuit. Go to Step 8 The ECU has failed. Replace the ECU. Go to Step 8
2 3
Is the voltage below the standard? 1. Turn off the starter switch. 2. Disconnect the ECU connector. Is the continuity established between vehicle harness terminals (B49)12 and (B48)24?
Go to Step 4
1. Disconnect the H-17 connector. Is the continuity established between floor harness connector terminals (H-17)1 and (H-17)8? Go to Step 5
1. Disconnect the M-27 connector. Is the continuity established between transfer harness connector terminals (M27)2 and (M27)7? Replace the front speed sensor. Go to Step 8
1. Disconnect the M-27 connector. Is the continuity established between transfer harness connector terminals (M27)1 and (M27)7? Replace the rear speed sensor. Go to Step 8
1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. Is the battery voltage observed between harness connector terminals (B49)12 and (B48)24?
Repair the harness circuit. Go to Step 8 Repeat the Diagnosis Flow
1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?
Go to Step 8
Check flow 7
Phenomenon The voltage of the throttle position sensor (TPS) is faulty.
Standard See below table.
NOTE: The signal voltage from the TPS deviates from the standard range.
D04RY00004
D04RY00012

Step 1 Action 1. Turn off the starter switch. Is the battery voltage normal? Go to Step 2 2 1. Turn on the starter switch. Does the voltage between terminals 15 and 46 fall within the standard range? 3 1. Clear the trouble code. 2. Turn on the starter switch. Is there DTC21 (P1716)? 4 1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. Does the voltage between terminals (B49)15 and (B48)24 fall within the standard range above? 5 Is the harness healthy? Go to Step 6 6 7 Is the TPS healthy? Go to Step 7 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete? Repeat the Diagnosis Flow. Go to Step 4 The ECU has failed. Replace the ECU. Go to Step 7 Go to Step 3 Go to Step 4 Refer to Trouble intermittently observed. Yes No Charge or replace the battery. Go to Step 7
Go to Step 5 Repair the harness. Go to Step 7 Replace the TPS. Go to Step 7
Go to Step 7
Check flow 9
Phenomenon The electromagnetic coil is broken or shorted to the battery.
Standard
D04RY00008

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the continuity established between terminals (B49)11 and (B49)22? 2 1. Connect the ECU connector. 2. Start the engine. 3. Set the TOD mode. Does the voltage between terminals 11 and 22 indicate at least 0.4V? 3 Is the battery voltage always observed between terminals 11 and 22? Go to Step 3 Go to Step 2 Go to Step 4 The ECU has failed. Replace the ECU. Go to Step 5 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Replace the transfer electromagnetic coil (solenoid clutch). Go to Step 5 Yes No
The harness is shortcircuited on the battery. Repair the circuit. Go to Step 5
1. Disconnect the M27 connector. Is the continuity established between transfer connector terminals (M27)8 and (M27)7? The harness is broken. Repair the circuit. Go to Step 5 Repeat the Diagnosis Flow.
Return to Step 5
Check flow 10
Trouble code 26
Phenomenon The electromagnetic coil GND is short-circuited.
Standard Resistance: 1.0 to 5.0 ohm (at ordinary temperature)
D04RY00008

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Does the resistance between terminals (B49)11 and (B49)22 indicate 1.0 to 5.0 ohm? 2 1. Connect the ECU connector. 2. Start the engine. 3. Set the TOD mode. When the throttle is operated between full close and full open positions, does the voltage between terminals 11 and 22 indicate at least 0.1 to 1.0 V? 3 1. Disconnect the connector (M27). Does the resistance between transfer connector terminals (M27)8 and (M27)7 indicate 1.0 to 5.0ohm? The harness is broken. Repair the circuit. Go to Step 4 Repeat the Diagnosis Flow. Go to Step 2 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 3 Yes No
The ECU has failed. Replace the ECU. Go to Step 4 Replace the transfer electromagnetic coil. Go to Step 4
Return to Step 4
Check flow 11
Phenomenon The shift on the fly system (front axle disconnect) works incorrectly.
Standard
NOTE: The shift on the fly system is not changed between 2WD and 4WD modes normally. CAUTION: If code 32 or 33 is also observed, remove the trouble associated with code 32 or 33 first.
D04RY00008

Step 1 Action 1. Turn on the starter switch. 2. Set the transfer to the 2H mode. Is the battery voltage observed between terminals 23 and 46? 2 3 Is 5V observed between terminals 42 and 46? 1. Set the transfer to the high (TOD) mode. Does the voltage between terminals 23 and 46 indicate 0V? Go to Step 4 4 Does the voltage between terminals 42 and 46 indicate 0V? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 6 The ECU has failed. Replace the ECU. Go to Step 7 The shift on the fly system is failed (refer to Section Drive Line Control System and Front Axle). See Trouble Diagnosis Depending on The Status of TOD Indicator. The ECU has failed. Replace the ECU. Go to Step 7 Yes No
Does the TOD indicator show the 2H mode? The ECU has failed. Replace the ECU.
Set the transfer to the high (TOD) mode. Does the voltage between terminals 23 and 46 indicate 0V?
The shift on the fly system has failed (refer to Section Driveline Control System). Repeat the Diagnosis Flow.
Return to Step 7
Check flow 12
Phenomenon The on/off signal (ADC) line of the shift on the fly system (front axle disconnect) is broken, or the line is short-circuited to the battery.
Standard
NOTE: The on/off signal line of the shift on the fly system is broken, or the line is shortcircuited to the battery.
D04RY00008

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the continuity established between terminals (B48)1 and (B48)24? 2 Does the voltage between terminals (B48)1 and (B48)24 indicate 0V? Go to Step 3 3 1. 2. 3. 4. Turn off the starter switch. Connect ECU connector. Turn on the starter switch. Set the transfer to the 2H mode. The phenomenon is not reproduced Refer to Troubles intermittently observed. Repeat the Diagnosis Flow. Go to Step 2 Yes No The harness is broken. Repair the circuit. Go to Step 3 The battery is short-circuited. Repair the circuit. Go to Step 4
Is the battery voltage observed between terminals 23 and 46? 4 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?
The ECU has failed. Replace the ECU. Go to Step 4
Return to Step 4
Check flow 13
Phenomenon The ADC line is short-circuited to GND.
Standard
NOTE: D The on/off signal line of the shift on the fly system is shortcircuited to GND. D The system enters into the fail-safe mode because of fusing or system protection. (If a shortcircuit is observed on GND, the output to the on/off signal line becomes 0V.)
D04RY00008

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Does the resistance between terminals (B48)1 and (B48)24 meet the standard, R = 21 4 ohms? Yes The phenomenon is not reproduced. Refer to Troubles intermittently observed. The signal line circuit of the shift on the fly system is short-circuited to GND. Repair the circuit. Go to Step 4 The signal line circuit of the shift on the fly system is layer short-circuited*. Replace the valve (VSV). Go to Step 4 Repeat the Diagnosis Flow. No
Go to Step 2
Is the resistance between terminals (B48)1 and (B48)24 R<2 ohms?
Go to Step 3
Is the resistance between terminals (B48)1 and (B48)24 R= 97ohms?
Go to Step 4
Return to Step 4
*Layer short-circuit : The coil is damaged by overcurrent.
Trouble Diagnosis Depending on The Status of TOD Indicator

Functional check with TOD indicator light is conducted prior to check on Charts AH. D After the starter is switched on, check and see if the status has become as tabulated below.
C07RY00019
D If the status is as tabulated above, there is no problem. If not as tabulated above, inspect the harness.
Chart A Function of circuit Fail condition Indicator lamp status
Indicator drive circuit The circuit informs the indicator of the working condition of the ECU. All the TOD indicator lamps and CHECK lamp are lit, and go off momentarily at an interval of about two seconds.
Transfer lever position 4WD Auto Switch
High/4L
D04RY00015

Step 1 Turn on the starter switch. Is the battery voltage observed between terminals 14 and 46 or 34 and 46? 2 Check that all the parts are mounted. Is this step complete? Action Yes The ECU has failed. Replace the ECU. Go to Step 2 Repeat the Diagnosis Flow. No Check the battery circuit. Go to Step 2 Return to Step 2
Chart B1 Function of circuit Fail condition Indicator lamp status
The 4WD switch circuit wires are broken or short-circuited to the GND Even after the transfer position is select from TOD to 2H, the indicator lamp status is not changed.
High
D04RY00015

Step 1 Action 1. Turn on the starter switch. When the 4WD Auto Switch is select to the 4WD position, is 0 V observed between terminal 30 and 46? 2 When the 4WD Auto Switch is select to the 2WD position, is 12 V observed between terminals 30 and 46? Go to Step 3 3 When the transfer lever is shifted to the 4L position, is battery boltage observed between terminals 19 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Repeat the Diagnosis Flow. Yes No Repair the 4WD Auto Switch circuit. Go to Step 4 Repair the 4WD Auto Switch circuit. Go to Step 4
Go to Step 2
Replace the ECU. Go to Step 4 Return to Step 4
Check that all the parts are mounted. Is this step complete?
Chart B2 Function of circuit Fail condition Indicator lamp status
The 4WD AUTO SWITCH circuit is short to battery. Even after the transfer mode is select from 2H to TOD the indicator lamp status does not change.
High
D04RY00015

Step 1 Action When the 4WD Auto Switch is select to the 4WD position, is 0 V observed between terminal 30 and 46? Go to Step 2 2 When the 4WD Auto Switch is select to the 2WD position, is 12 V observed between terminals 30 and 46? Go to Step 3 3 1. Disconnect the ECU connector. Is the continuity established between terminals (B49)14 and (B49)17? Go to Step 4 4 Is the continuity established between terminals (B49)14 and (B49)6? Yes No Repair the 4WD Auto Switch circuit. Go to Step 7 Repair the 4WD Auto Switch circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Return to Step 7
Go to Step 5 5 Is the continuity established between terminals (B49)14 and (B49)18?
Go to Step 6 6 Is the continuity established between terminals (B49)14 and (B49)19? Replace ECU. Go to Step 7 7 Check that all the parts are mounted. Is this step complete? Repeat the Diagnosis Flow.
Chart C1 Function of circuit Fail condition
4H switch circuit wires are broken or the battery is short-circuited. When the 4WD Auto Switch is 4WD mode. When the lever is shifted from 4L to TOD, the 4L mode remains on the indicator and the TOD mode is displayed without turning off the previous mode.
Indicator lamp status
4L <> Middle between 4L and High <> High
D04RY00015

Step 1 Action 1. Turn on the starter switch. When the transfer lever is shifted to the high position, is 12V observed between terminals 31 and 46 (4H switch)? 2 3 When the transfer lever is shifted to the 4L position, is 12V observed between terminals 31 and 46 (4H switch)? When the transfer lever is shifted to the middle position between 4L and High, is 0V observed between terminals 31 and 46 (4H switch)? 1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. When the transfer lever is shifted to the high position between 4L and High, is 12V observed between terminals (B48)9 and (B48)24 (4H switch)? 5 6 When the transfer lever is shifted to the middle position, is 0V observed between terminals (B48)9 and (B48)24 (4H switch)? When the transfer lever is shifted to the 4L position, is 12V observed between terminals (B48)9 and (B48)24 (4H switch)? Go to Step 2 Go to Step 3 Replace the ECU. Go to Step 14 Go to Step 4 Go to Step 4 Yes No
Go to Step 4
Go to Step 5 Go to Step 6 The 4H switch circuit battery is short-circuited between ECU and transfer. Repair the circuit. Go to Step 14
Go to Step 7
Turn off the starter switch. When the transfer lever is shifted to the middle position between 4L and High, is the continuity established between terminals (B48)9 and (B48)24 (4H switch)?
Go to Step 8 Go to Step 11 The phenomenon is not reproduced. Refer to Troubles intermittently observed. The 4H switch circuit is broken between ECU and transfer. Repair the circuit. Go to Step 14 Repair the transfer assembly. Go to Step 14 Repair the transfer assembly. Go to Step 14
8 9
When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)9 and (B48)24? When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)9 and (B48)24?
The ECU has tailed. Replace the ECU. Go to Step 14
10
When the transfer lever is shifted to the middle position between 4L and High, is the continuity established between terminals (M27)4 and (M27)7?
Repair the transfer assembly. Go to Step 14
11
When the transfer lever is shifted to the high position, is the continuity established between transfer connector terminals (M27)4 and (M27)7? When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (B48)9 and (M27)7?
Go to Step 12
12
Go to Step 13

Step 13 Action Is the continuity established between transfer terminals (M27)4 and body? Yes The harness is shorted between terminal (M-27)4 and GND. Repair the circuit. Go to Step 14 Repeat the Diagnosis Flow. No
The ECU has failed. Replace the ECU. Go to Step 14 Return to Step 14
14
Chart C2 Function of circuit Fail condition Indicator lamp status
The 4H switch circuit is short-circuited to GND. When the transfer lever is shifted to 4L, the indicator lamp status is not changed.
4L
D04RY00015

Step 1 2 3 4 Action When the transfer lever is shifted to the High position, is 5V observed between terminals 31 and 46 (4H switch)? When the transfer lever is shifted to the neutral position, is 0V observed between terminals 31 and 46 (4H switch)? When the transfer lever is shifted to the 4L position, is 5V observed between terminals 31 and 46 (4H switch)? 1. Turn off the starter switch. Is the continuity established between terminals 14 and 17? Go to Step 5 5 Is the continuity established between terminals 14 and 6? Yes Go to Step 2 Go to Step 3 Go to Step 4 No Go to Step 14 Go to Step 14 Go to Step 14 Replace TOD indcator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23
Go to Step 6 6 Is the continuity established between terminals 14 and 18?
Go to Step 9 9 1. Turn on the starter switch. 2. Shift the transfer lever is shifted to the 4L position. Is 0 V observed between terminals 17 and 22? 10 Is 0 V observed between terminals 6 and 22? Go to Step 10
Go to Step 11 11 Is 0 V observed between terminals 18 and 22?
Go to Step 12 12 Is 12 V observed between terminals 19 and 22?
Go to Step 13 13 Is 0 V observed between terminals 8 and 22? The phenomenon is not reproduced. Refer to Troubles intermittently observed.
The ECU has failed. Replace the ECU.

Step 14 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector. When the transfer lever is shifted to the neutral position, is the continuity established between terminals (B48)9 and (B48)24 (4H switch)? 15 16 When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)9 and (B48)24? When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)9 and (B48)24? Go to Step 17 17 1. Disconnect the H17 connector. When the transfer lever is shifted to the neutral position between high and 4L, is the continuity established between terminals (H-17)3 and (B-49)22? 18 When the transfer lever is shifted to the high position, is the continuity established between transfer connector terminals (H-17)3 and (B-49)22? When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (H-17)3 and (B-49)22? Yes No
Go to Step 17 Go to Step 16 The ECU has failed. Replace the ECU. Go to Step 23
Go to Step 18
Go to Step 20
Go to Step 21
Go to Step 19 GND is short-circuited between terminals (B-49)22 and (H-17)3. Repair the circuit. Go to Step 23 Repair the transfer assembly. Go to Step 23
19
Go to Step 22 20 1. Disconnect the M27 connector. When the transfer lever is shifted to the neutral position between high and 4L, is the continuity established between terminals (M-27)4 and (M-27)7? 21 1. Disconnect the M27 connector. When the transfer lever is shifted to the high position, is the continuity established between terminals (M-27)4 and (M-27)7? 22 1. Disconnect the M27 connector. When the transfer lever is shifted to the 4L position, is the continuity established between terminals (M-27)4 and (M-27)7? Repair the transfer assembly. Go to Step 23 Repeat the Diagnosis Flow.
Go to Step 21 Repair the transfer assembly. Go to Step 23
Go to Step 22 GND is short-circuited between terminals (B-48)9 and (M27)4. Repair the circuit. Go to Step 23 Return to Step 23
23
Chart D1 Function of circuit Fail condition Indicator lamp status
4L switch circuit wires are broken or the battery is short-circuited. The TOD mode is displayed in the neutral position between high and 4L. When the lever is shifted to the 4L position, the TOD mode is displayed.
4L
Middle between 4L and High
D04RY00004

Step 1 Turn on the starter switch. When the transfer lever is shifted to the high position, is 12V observed between terminals 44 and 46 (4L switch)? 2 When the transfer lever is shifted to the middle position between 4L and High, is 0V observed between terminals 44 and 46 (4L switch)? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 44 and 46 (4L switch)? Go to Step 2 Go to Step 4 Action Yes No
Go to Step 3 The ECU has failed. Replace the ECU. Go to Step 13
Go to Step 4
Go to Step 4
1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. When the transfer lever is shifted to the high position, is 12V observed between terminals (B48)22 and (B48)24 (4L switch)? Go to Step 5 Go to Step 7
When the transfer lever is shifted to the middle position between 4L and High, is 0V observed between terminals (B48)22 and (B48)24 (4L switch)? When the transfer lever is shifted to the 4L position, is 0V observed between terminals (B48)22 and (B48)24 (4L switch)?
Go to Step 6 The 4L switch circuit battery is short-circuited between ECU and transfer. Repair the circuit Go to Step 13
Go to Step 7
Go to Step 7
Turn off the starter switch. When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)22 and (B48)24 (4L switch)?
Go to Step 12
Go to Step 8
When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (B48)22 and (B48)24 (4L switch)? When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)22 and (B48)24 (4L switch)?
Go to Step 9 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Wires are broken between transfer connector (M-27)12 and connector (B-48)22. Repair the circuit. Go to Step 13 Wire are broken between transfer connector (M-27)12 and (B-48)22. Repair the circuit. Go to Step 13
Go to Step 10
Go to Step 11
10
1. Disconnect the M27 connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between transfer connector terminals (M-27)12 and GND?
11
When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (M-27)12 and GND?

Step 12 Action When the transfer lever is shifted to the high position, is the continuity established between transfer connector terminals (M-27)12 and GND? Repair the transfer assembly. Go to Step 13 13 Check that all the parts are mounted. Is this step complete? Repeat the Diagnosis Flow. Yes No Wires are broken between transfer connector (M-27)12 and connector (B-48)22. Repair the circuit. Go to Step 13 Return to Step 13
Chart D2 Function of circuit Fail condition Indicator lamp status
The 4L switch circuit is short-circuited to GND. The 4L mode is displayed even in the 2H or TOD.
High (2H or TOD)
D04RY00006

Step 1 2 3 4 Action When the transfer lever is shifted to the high position, is 12V observed between terminals 44 and 46 (4L switch)? When the transfer lever is shifted to the neutral position, is 0V observed between terminals 44 and 46 (4L switch)? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 44 and 46 (4L switch)? 1. Select the 4WD Auto Switch to the 2H position. Is 12V observed between terminals 17 and 46? Go to Step 5 5 Is 12V observed between terminals 6 and 46? Yes Go to Step 2 Go to Step 3 Go to Step 4 No Go to Step 7 Go to Step 7 Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 16 The ECU has failed. Replace the ECU. Go to Step 16
Go to Step 6 6 Is 12V observed between terminals 18 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed.
1. Turn off the starter switch. 2. Disconnect the ECU connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (B48)22 and (B48)24?
Go to Step 8
Go to Step 10
When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)22 and (B48)24? When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)22 and (B48)24?
Go to Step 9
Go to Step 11 The ECU has failed. Replace the ECU. Go to Step 16
Go to Step 12 10 1. Disconnect the H-17 connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (H-17)6 and (B-48)24? 11 When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (H-17)6 and (B-48)24? When the transfer lever is shifted to the high position, is the continuity established between terminals (H-17)6 and (B-48)24?
Go to Step 11
Go to Step 13
Go to Step 12
Go to Step 14 GND is short-circuited between terminals (B48)22 and (H-17)6. Repair the circuit. Go to Step 16 Repair the transfer assembly. Go to Step 16
12
Go to Step 15 13 1. Disconnect the M-27 connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (M-27)12 and GND?
Go to Step 14

Step 14 Action 1. Disconnect the M-27 connector. When the transfer lever is shifted to the 4L position, is the continuity established between terminals (M-27)12 and GND? 15 1. Disconnect the M-27 connector. When the transfer lever is shifted to the high position, is the continuity established between terminals (M-27)12 and GND? Repair the transfer assembly. Go to Step 16 Repeat the Diagnosis Flow. Yes No Repair the transfer assembly. Go to Step 16 GND is short-circuited between terminals (H17)6 and (M-27)12. Repair the circuit. Go to Step 16 Return to Step 16
Go to Step 15
16
Chart E1 Function of circuit Fail condition Indicator lamp status
AXLE switch circuit wires are broken. Both the TOD and 4L modes are disabled. (The transition status is not removed.)
Hight
4L
D04RY00007

Step 1 Start the engine. When the transfer lever is shifted to the neutral position between high and 4L, is 5V observed between terminals 42 and 46? 2 When the transfer lever is shifted to the high position and 4WD Auto switch selected to 4WD position, is 0V observed between terminals 42 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 42 and 46? Shift the transfer lever to the 4L position. Is 0V observed between terminals 17 and 46? Go to Step 5 5 Is 0V observed between terminals 6 and 46? Go to Step 2 Go to Step 7 Action Yes No
Go to Step 7 Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 19 The ECU has failed. Replace the ECU. Go to Step 19
3 4
Go to Step 6 6 Is 0V observed between terminals 18 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 19
When the transfer lever is shifted to the high position and 4WD Auto Switch selected to the 2WD position, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the high position (TOD mode), is 0V observed between terminals 23 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 23 and 46? Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?
Go to Step 8
Go to Step 11
Go to Step 9 Go to Step 10 Go to Step 12 Examine the trouble based on Diagnosis from Trouble Codes.
Go to Step 11 Go to Step 11 Go to Step 11 The ECU has failed. Replace the ECU. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19
9 10 11
12
1. Turn off the starter switch. 2. Disconnect the ECU connector. Does the resistance between terminals (B48)1 and (B48)24 meet the standard, 17< R < 25 ohm? Go to Step 13
13
1. Turn on the starter switch. When the 4WD Auto Switch is select to the 2WD position, is the battery voltage supplied to each VSV?
Go to Step 14
14
When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage supplied to each VSV? Go to Step 15
15
When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed on each VSV? Go to Step 16

Step 16 Action When the transfer lever is shifted to the 4L position, is 0V observed on each VSV? Go to Step 17 17 Is the vacuum pressure supplied to the VSV? Go to Step 18 18 Can the single AXLE switch enable and disable the continuity? Repair the shift on the fly system (refer to Driveline Control System). Go to Step 19 Repeat the Diagnosis Flow. Yes No Repair the circuit or replace the VSV. Go to Step 19 Repair the vacuum system. Go to Step 19 Replace the AXLE switch (refer to Driveline Control System). Go to Step 19 Return to Step 19
19
Chart E2 Function of circuit Fail condition Indicator lamp status
The AXLE switch circuit is short-circuited to GND. Even after the 4WD Auto Switch is select to the 2WD position, the 2WD mode is not enabled. (The transition status is not removed.)
High
D04RY00007

Step 1 Start the engine. When the transfer lever is shifted to the middle position between High and 4L, is 5V observed between terminals 42 and 46? 2 When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed between terminals 42 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 42 and 46? Select the 4WD Auto Switch to the 2WD position. Is 12V observed between terminals 17 and 46? Go to Step 5 5 Is 12V observed between terminals 6 and 46? Go to Step 6 6 Is 12V observed between terminals 18 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 8 Go to Step 2 Go to Step 7 Action Yes No
Go to Step 7 Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 19 The ECU has failed. Replace the ECU. Go to Step 19
3 4
The ECU has failed. Replace the ECU. Go to Step 19 Go to Step 11
7 8
When the 4WD Auto Switch is select to the 2WD position, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed between terminals 23 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 23 and 46? Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?
Go to Step 9
Go to Step 11
Go to Step 10 Go to Step 12 Examine the trouble based on Diagnosis from Trouble Codes.
Go to Step 11 Go to Step 11 The ECU has failed. Replace the ECU. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19
10 11
12
1. Turn off the starter switch. 2. Disconnect the ECU connector. Does the resistance between terminals (B48)1 and (B48)24 meet the standard, 17< R < 25 ohm? Go to Step 13
13
1. Connect the ECU connector. 2. Turn on the starter switch. When the 4WD Auto Switch is select to the 2WD position, is the battery voltage supplied to each VSV? Go to Step 14
14
When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage supplied to each VSV? Go to Step 15
15
When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed on each VSV? Go to Step 16

Step 16 Action When the transfer lever is shifted to the 4L position, is 0V observed on each VSV? Go to Step 17 17 Is the vacuum pressure supplied to the VSV? Go to Step 18 18 Can the single AXLE switch enable and disable the continuity? Repair the shift on the fly system (refer to Driveline Control System). Go to Step 19 Repeat the Diagnosis Flow. Yes No Repair the circuit or replace the VSV. Go to Step 19 Repair the vacuum system. Go to Step 19 Replace the AXLE switch (refer to Driveline Control System). Go to Step 19 Return to Step 19
19
Chart G Function of circuit Fail condition
The trouble codes are displayed.
Indicator lamp status
D04RY00009
Step 1
Action Disconnect the ECU connector from ECU. Is the continuity established between terminals (B48)7 and (B48)24?
Yes
No The ECU has failed. Replace the ECU. Go to Step 3 Repair the self-diagnostic connector circuit. Go to Step 3
Go to Step 2
Is the self-diagnostic connector short-circuited?
Go to Step 3 3 1. Check that all the parts are mounted. 2. Clear the trouble codes. Is this step complete? Repeat the Diagnosis Flow.
Repeat to Step 3
Chart H Function of circuit Fail condition Indicator lamp status
lighting switch circuit Reads in the status of lighting switch, reducing the indicator at night. Even if the lighting switch is pressed on and off, brightness does not change.
All position (exsample TOD mode)
D04RY00009

Step 1 Action 1. Disconnect ECU terminal. 2. Turn on the starter switch. Is battery voltage observed between ECU terminals (B48)18 and (B48)24? 2 Turn lighting SW ON. Is 0 V observed between ECU terminal (B48)18 and (B48)24? Go to Step 3 3 Connect ECU terminal. While the lighting switch is pressed on and off, does the brightness of the indicator change? The phenomenon is not reproduced. Refer to Troubles intermittently observed Repeat the Diagnosis Flow. Yes No Wires are broken lighting SW circuit. Repair the circuit. Go to Step 4 Lighting SW circuit battery short. Repair the circuit. Go to Step 4
Go to Step 2
Diagnosis from Symptom

Troubles that are not indicated by the warning lamp are listed in the table below. These troubles are caused by the faults that cannot be detected by the self-diagnostic function of the control unit. If this type of trouble is observed, interview the customer and conduct test runs to reproduce the trouble, cross-check the reported trouble with the listed phenomena, and diagnose and analyze the trouble on the item by item basis. Phenomena 1 The tight corner braking is observed when the vehicle is subject to full steering. D D D D Major cause The standard tires are not used. The tire pressure is incorrect. The tires are worn inuniformity. The transfer or wiring is imperfect. D The limited slip differential is failed. D The transfer or wiring is imperfect. D The shift on the fly system is failed. D D D D The standard tires are not used. The tire pressure is incorrect. The tires are worn inuniformity. The transfer or wiring is imperfect. D The limited slip differential is failed. D The wiring is imperfect. D The shift on the fly system is failed. D The wiring is imperfect. D The ABS is failed. Corrective action Check and recondition the vehicle according to Chart 1.
Even if the 4WD Auto Switch is select to the 4WD position, the 4WD mode is not active, resulting in remarkable rear wheel spin. D When the 4WD Auto Switch is select to the 4WD position, the drive resistance of the 4WD system is too large to get sufficient running speed. D Noised drive line. The shift on the fly system (front axle) generates gear noises. The braking distance gets long even when the ABS is active.
Check and recondition the vehicle according to Chart 2.
Check and recondition the vehicle according to Chart 1.
Check and recondition the vehicle according to Chart 3. Check and recondition the vehicle according to Chart 4.
Chart 1 Function of circuit Fail condition
The tight corner braking is observed. When the vehicle is subject to full steering in the TOD mode, the drive resistance gets large or the judder occurs. Otherwise, the above phenomenon is observed only when the brake is applied.
D04RY00009

Step 1 Action Are the front and rear tires in specified size? Yes No Replace the tires with specified ones, and service the new tires. Go to Step 16 Inflate the tires to recommended pressure. Go to Step 16 Replace the tires with specified ones, and service the new tires. Go to Step 16 Replace the tires with specified ones, and service the new tires. Go to Step 16
Go to Step 2 2 Is the tire pressure correct?
Go to Step 3 3 Are the tires free from abnormal wear?
Go to Step 4 4 Are different types of tires used?
Go to Step 5 5 1. Start the engine. 2. Shift the transfer lever to the high (TOD) position and switch the 4WD AUTO switch to the 4WD position. 3. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the tight corner braking occur? Is the judder with chug-chug sound observed? * Use caution on the operation. 6 1. Shift the transfer lever to the high position and switch the 4WD AUTO switch to the 2H position. 2. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the tight corner braking occur? Is the judder with chug-chug sound observed? * Use caution on the operation. 7 8 Is an LSD mounted to the rear differential? Is the genuine LSD oil used in the rear differential? Go to Step 9 9 Does the engine output the power correctly? Go to Step 10 10 Do the speed sensors work correctly? (Check trouble codes.) The ECU has failed. Replace the ECU. Go to Step 16 Go to Step 7 Go to Step 8 Go to Step 6
Go to Step 11
Go to Step 14 Go to Step 9 Replace the differential oil. Go to Step 16 Check the engine. Go to Step 16 Replace the speed sensors. Go to Step 16 Conduct full steering under WOT. Go to Step 5 Repair the circuit of terminal 33 (ABS IN). Go to Step 16
11
Is the tight corner braking observed only when the brake is applied? Go to Step 12
12
Turn on the starter switch. Is the battery voltage observed between terminals 33 and 46? Go to Step 13

Step 13 Action 1. Apply the brake and fully turn the steering to the left (or right) end, and start the creep run. Does the voltage between terminals 11 and 22 range between 0.1 and 1.0V? 14 1. Shift the transfer lever to the high (TOD) position and switch the 4WD AUTO switch to 4WD position. 2. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the voltage between terminals 11 and 22 range between 0.1 and 1.0V? 15 1. Select the 4WD Auto Switch to the 2WD position. 2. Jack up the right front wheel. Does the front tire rotate smoothly? Go to Step 15 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Repeat the Diagnosis Flow. Go to Step 10 Yes Repair the transfer assembly. Go to Step 16 No The ECU has failed. Replace the ECU. Go to Step 16
Repair the transfer assembly. Go to Step 16 Return to Step 16
16
*NOTE: Before checking this item, run the vehicle more than 10 meters with the steering wheel in straight position so that the 4L mechanical lock sleeve can be released certainly.
The 4WD mode is not active. The rear wheels spin in the TOD mode, so the driving torque is not transmitted to the front wheels. The indicator lamps will not show the 4L and TOD status.
D04RY00009

Step 1 Action Is the trouble code 31(P1721) or 26 recorded? Yes Examine the trouble based on Diagnosis from Trouble Codes. Go to Step 7 Examine the trouble based on Diagnosis from Trouble Codes. No
Go to Step 2
Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?
Go to Step 3 Examine the trouble based on Trouble Diagnosis Depending on The Status of TOD Indicator. Repair the transfer assembly. Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 7 Return to Step 7
When the transfer lever and 4WD switch are in the specified position, do the TOD indicator lamps show the correct status?
Go to Step 4 4 Shift the transfer lever to the 4L position, fully turn the steering to the left (or right) end, and start the creep run. Does the tight corner braking occur? Go to Step 5 5 1. Shift the transfer lever to the high (TOD) position. 2. Turn on the starter switch. Does the voltage between terminals 11 and 22 indicate at least 3V while the throttle is completely open? 6 Does the voltage between terminals 11 and 22 indicate at least 0.1V while the throttle is completely closed? Go to Step 6 The TOD clutch is worn. Repair the transfer assembly. Go to Step 7 Repeat the Diagnosis Flow.
The shift on the fly system generates gear noises. (The fuel economy is bad in the 2H mode.) When the vehicle is run in the 2H mode, the shift on the fly system generates gear noises or the front wheel gears are engaged to generate a shock.
D04RY00015

Step 1 Action Do the indicator lamps show the correct status? Yes No Examine the trouble based on Trouble Diagnosis Depending on The Status of TOD Indicator. Go to Step 2
Go to Step 2 2 Is any of the trouble codes 28(P1760), 32(1761) and 33(P1762) recorded? Examine the trouble based on Diagnosis from Trouble Codes. Go to Step 4 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Repair the battery circuit. Go to Step 6 6 Check that all the parts are mounted. Is this step complete? Repeat the Diagnosis Flow.
Go to Step 3 Go to Step 5 The shift on the fly system is failed (refer to Section 4B1 and 4C). Go to Step 6 Repair the battery and charging system. Go to Step 6 Return to Step 6
3 4
Turn on the starter switch. Is the battery voltage observed between terminals 14 and 22? When the 4WD Auto Switch is select to the 2WD position, are the front axle gears correctly disengaged (and when the left front tire is jacked up and turned, is the front propeller shaft standstill)?
Does the battery voltage maintain the correct level?
The braking distance gets long even when the ABS is active. Enough deceleration is not obtained and the braking distance gets long even when the ABS is active in the 2H mode.
D04RY00009
4B294
Step 1

Action Are the brake and ABS systems healthy? Go to Step 2 Yes No Repair the brake and ABS. Go to Step 4 Repair the battery system. Go to Step 4
Turn on the starter switch. Is the battery voltage observed between terminals 14 and 22? Go to Step 3 1. Select the 4WD SW to the 2WD position. 2. The voltage between terminals 36 and 46 ranges between 7.5 and 16V (0.12 seconds make a cycle)
Does the voltage within the range specified? 4 Check that all the parts are mounted. Is this step complete?
Go to Step 4 Repeat the Diagnosis Flow".
SECTION
DRIVE SHAFT SYSTEM
TROOPER
4C1
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (2WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (4WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joints Replacement . . . . Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . . Front Axle Drive Shaft and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Bushing Replacement . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Shift On The Fly System . . . . . . . . . . . . . . . . . 4C2 4C2 4C3 4C4 4C4 4C4 4C6 4C6 4C9 4C10 4C11 4C11 4C11 4C12 4C12 4C16 4C17 4C18 4C18 4C19 4C19 4C20 4C21 4C21 4C22 4C24 Shift On The Fly System and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly (Except TOD 44) . . . . . . . . . Universal Joint Disassembly . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Universal Joint Reassembly . . . . . . . . . . . . . Reassembly (Except TOD 44) . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Rear Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Joint Disassembly . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Universal Joint Reassembly . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 4C24 4C24 4C26 4C31 4C32 4C33 4C33 4C34 4C34 4C35 4C36 4C37 4C38 4C41 4C42 4C43 4C44 4C44 4C44 4C44 4C45 4C46 4C47 4C48 4C49 4C50 4C51
4C2
DRIVE SHAFT SYSTEM
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM(SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED , do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
General Description
This publication contains essential removal, installation, adjustment and maintenance procedures. The front axle utilizes a central disconnect type front axle/transfer case system. The drive axles are completely flexible assemblies, consisting of inner and outer constant velocity (CV) drive shaft joints connected by an axle shaft. For description of front propeller shaft and universal joint, refer to Front Propeller Shaft in this section.
DRIVE SHAFT SYSTEM
4C3
Diagnosis
Condition Oil Leak At Front Axle Oil Leak At Pinion Shaft Possible cause Worn or defective oil seal. Front axle housing cracked. Too much gear oil. Oil seal worn or defective. Pinion flange loose or damaged. Noises In Front Axle Drive Shaft Joint Clank When Accelerating From Coast Shudder or Acceleration Vibration During Broken or worn drive shaft joints and bellows (BJ and DOJ). Loose drive shaft joint to output shaft bolts. Damaged inner drive shaft joint. Excessive drive shaft joint angle. Worn or damaged drive shaft joints. Sticking spider assembly (inner drive shaft joint). Sticking joint assembly (outer drive shaft joint). Vibration At Highway Speeds Noises in Front Axle Out of balance or out of round tires. Front end out of alignment. Insufficient gear oil. Wrong or poor grade gear oil. Drive pinion to ring gear backlash incorrect. Worn or chipped ring gear, pinion gear or side gear. Pinion shaft bearing worn. Wheel bearing worn. Differential bearing loose or worn. Wanders and Pulls Wheel bearing preload too tight. Incorrect front alignment. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Front or rear suspension parts loose or broken. Front Wheel Shimmy Wheel bearing worn or improperly adjusted. Incorrect front alignment. Worn ball joint or bush. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Shock absorber worn. Correction Replace the oil seal. Repair or replace. Correct the oil level. Replace the oil seal. Tighten or replace. Replace the drive shaft joints and bellows. Tighten. Replace. Repair. Replace. Lubricate or replace. Lubricate or replace. Balance or replace. Align. Replenish the gear oil. Replace the gear oil. Adjust the backlash. Replace the ring gear, pinion gear or side gear. Replace the pinion shaft bearing. Replace the wheel bearing. Tighten or replace. Adjust the wheel bearing preload. Adjust the front alignment. Tighten or replace. Adjust or replace the steering gear. Adjust the inflation or replace. Tighten or replace. Adjust or replace. Adjust the front alignment. Replace the ball joint or bush. Tighten or replace. Tighten or replace. Replace or adjust the inflation. Replace the shock absorber.
4C4
DRIVE SHAFT SYSTEM
Front Hub and Disc (2WD Model)

Disassembled View
411RY00003
Legend (1) Bolt (2) Cover and Gasket (3) Packing (4) Lock Washer (5) Hub Nut (6) Outer Bearing
(7) (8) (9) (10) (11) (12)
Hub and Disc Assembly ABS Sensor Ring Inner Bearing Oil Seal Bolt Wheel Pin
Disassembly
1. Before disassembly, jack up the front of vehicle and support frame with jack stands. 2. Remove the two bolts from the rear side of the knuckle arm, then remove the brake caliper, with the brake hose attached. Use a wire to attach the brake caliper to the upper link. Refer to Disk Brakes in Brake section.
DRIVE SHAFT SYSTEM

3. Remove cover bolt. 4. Remove cover and gasket. 5. Remove lock washer. 6. Remove hub nut, using front hub nut wrench J36827.
4C5
11. Remove bolt. 12. If necessary, replace the wheel pin in the following manner. D Scribe mark(1) on hub to disc before disassembly to insure proper assembly.
901RW054
411RS003
7. Remove outer bearing. 8. Remove oil seal. 9. Remove inner bearing. 10. Use a brass bar to remove the outer bearing outer race(1), oil seal, inner bearing and inner bearing outer race(2) from the hub.
D Clamp hub and disc assembly in vise, using protective pads. Remove six(6) disc-to-hub retaining bolts.
411RS021
411RS002
4C6
DRIVE SHAFT SYSTEM

NOTE: Be sure wheel stud is started squarely and seats completely.
D Place hub on a suitable work surface and remove wheel studs, as required, using a hammer.
411RS004
411RS005
2. Align index marks(1) and install hub to disc.

Check the following parts for wear, damage or other abnormal conditions. D Hub D Hub bearing D Bearing outer race D Disc D Oil seal
Reassembly
1. Install wheel pin. D Place hub on a wood workbench or a block of wood approx. 6 by 6 to protect the wheel stud ends and threads. D Install wheel stud, using a hammer.
411RS003
DRIVE SHAFT SYSTEM

3. Install bolt. Tighten the bolts to the specified torque. Torque: 103 Nm (76 lb ft)
4C7
5. Install inner bearing. Install the outer race by driving it into the hub by using installer J36829 and grip J8092.
411RS023 411RS021
4. Install outer bearing. Install the outer race by driving it into the hub by using installer J36828 and grip J-8092.
6. Install oil seal by using installer J36830 and grip J8092. Apply Multipurpose grease NLGI No. 2 or equivalent to the lip portion.
901RW056 901RW057
4C8
DRIVE SHAFT SYSTEM
7. Apply Multipurpose grease NLGI No.2 in the hub and bearing. Hub Outer bearing Inner bearing 35 g (1.23 oz) 10 g (0.35 oz) 15 g (0.53 oz)
8. Install hub nut by using wrench J36827. Turn the place where there is a chamfer in the tapped hole to the outer side, and attach the nut.
411RS011
9. Install lock washer. D Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. Screw is to be fastened tightly so its head may come lower than the surface of the washer.
901RW054
Preload Adjustment 1. Tighten the hub nut to 29.4 Nm (21.7 lb ft), then loosen the nut to the full. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. Bearing Preload New bearing and New oil seal Used bearing and New oil seal 19.6 24.5 N (4.4 5.5 lb) 11.8 17.7 N (2.6 4.0 lb)
If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut.
411RS012
10. Install the paking. 11. Install cover and tighten the cover bolt. 12. Install brake caliper and tighten fixing bolt.
DRIVE SHAFT SYSTEM
4C9

E04RW00001
4C10
DRIVE SHAFT SYSTEM
Special Tools
J36827 Wrench; Hub nut
J36829 Installer; Inner bearing
J36828 Installer; Outer bearing
DRIVE SHAFT SYSTEM
4C11
Front Hub and Disc (4WD Model)

Disassembled View
411RW001
Legend (1) Bolt (2) Cap (3) Snap Ring and Shim (4) Hub Flange (5) Lock Washer and Lock Screw (6) Hub Nut
(7) (8) (9) (10) (11) (12) (13)
Outer Bearing Bolt Hub and Disc Assembly Wheel Pin ABS Sensor Ring Inner Bearing Oil Seal
Disassembly
1. Before disassembly, select the 2WD position with the 4WD switch. 2. Jack up the front of vehicle and support frame with jack stands.
3. Remove the disc brake caliper assembly and hang it on the frame with wires. Refer to Disk Brakes in Brake section. 4. Remove Bolt. 5. Remove cap. 6. Remove snap ring and shim. 7. Remove hub flange.
4C12
DRIVE SHAFT SYSTEM

D Place hub on a suitable work surface and remove the studs by using a hammer.
8. Remove lock washer and lock screw. 9. Use wrench J36827, remove hub nut.
901RW054
411RS004
10. Remove hub and disc assembly. 11. Remove ABS sensor ring. 12. Remove outer bearing. 13. Remove oil seal. 14. Remove inner bearing. 15. Remove bolt , if necessary, replace the wheel pin in the following manner. D Apply a scribe mark(1) to disc to hub. D Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disctohub retaining bolts.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. D Hub D Hub bearing oil seal D Knuckle spindle D Disc D Caliper D Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) D ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Disc Brakes in Brake section.
Reassembly
1. Install wheel pin. D Place the hub on a wood workbench or a block of wood approx. 6 by 6 to protect the wheel stud ends and threads.
411RS003
DRIVE SHAFT SYSTEM

D Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats completely.
4C13
3. Use installer J36829 and grip J8092, then install the inner bearing by driving it into the hub.
901RW055
411RS005
2. Align scribe marks(1) and attach the hub to the disc, then tighten the bolts to the specified torque. Torque: 103 Nm (76 lb ft)
4. Use installer J36828 and grip J8092 then install the outer bearing by driving it into the hub.
901RW056
411RS003
4C14
DRIVE SHAFT SYSTEM

8. Install hub nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J36827.
5. Apply grease (NLGI No.2 or equivalent) to the lip portion, then install oil seal by using installer J36830 and grip J8092.
901RW057
6. Install ABS sensor ring, then tighten the bolts to the specified torque. Torque: 18 Nm (13 lb ft) 7. Install hub and disc assembly. D Apply grease in the hub. D Apply wheel bearing type grease NLGI No. 2 or equivalent to the outer and inner bearing. Grease Amount D Hub: 35 g (1.23 oz) D Outer bearing: 10 g (0.35 oz) D Inner bearing: 15 g (0.53 oz)
901RW054
Preload Adjustment 1. Tighten the hub nut to 29 Nm (22 lb ft), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New bearing and New oil seal Bearing Preload: 20 N 25 N (4.4 lb 5.5 lb) Used bearing and New oil seal Bearing Preload: 12 N 18 N (2.6 lb 4.0 lb) If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut.
411RS009
Legend (1) Inner Bearing (2) Hub (3) Outer Bearing
411RS011
DRIVE SHAFT SYSTEM

9. Install lock washer and lock screw in the following manner. D Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. D If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. D If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. D Screw is to be fastened tightly so its head may come lower than the surface of the washer. 12. Install hub cap. 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 lb ft)
4C15
411RS012
10. Apply adhesive (LOCTITE 515 or equivalent) to both joining flange faces then install hub flange. 11. Install snap ring and shim. D Adjust the clearance between the free wheeling hub body and the snap ring. Clearance: 0 mm0.3 mm (0 in0.012 in) Shims Available: 0.2 mm, 0.3 mm, 0.5 mm, 1.0 mm (0.008 in, 0.012 in, 0.020 in, 0.039 in)
411RW002
4C16
DRIVE SHAFT SYSTEM

E04RW001
DRIVE SHAFT SYSTEM
4C17
Special Tools
J36827 Wrench; Hub nut
J36829 Installer; Inner bearing
J36828 Installer; Outer bearing
4C18
DRIVE SHAFT SYSTEM
Front Drive Shaft Joint

Front Drive Shaft Joints Replacement
D Refer to Front Drive Axle Assembly Replacement in this section, and refer to Front Hub and Disc in Suspension section. 1. Open filler plug and make sure that the oil is up to the plug port. If the level oil is low, replenish with gear oil GL5 grade. 2. Tighten the filler plug to specified torque. Torque: 78 Nm (58 lb in)
Front Hub Bearing Preload Check

Check the hub bearing preload at the wheel pin. New bearing and new oil seal: 19.6 24.5 N (4.4 5.5 lb) Used bearing and new oil seal: 11.8 17.7 N (2.6 4.0 lb)
411RS001
Inspection Of Shift On The Fly System Gear Oil
412RT002
DRIVE SHAFT SYSTEM
4C19
Front Axle Drive Shaft

Front Axle Drive Shaft and Associated Parts
412RW003
Legend (1) Axle Case and Differential (2) DOJ Case Assembly (3) Snap Ring (4) Bearing (5) Snap Ring (6) Oil Seal (7) Bracket (8) DOJ Case (9) Circlip (10) Bolt (11) Drive Shaft Joint Assembly (12) Snap Ring
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)
Spacer Ball Snap Ring Ball Retainer Ball Guide Band Bellows Band Band Bellows Band BJ Shaft Dust Seal
4C20
DRIVE SHAFT SYSTEM

4. Remove drive shaft joint assembly. 5. Using snap ring pliers, remove the snap ring.
Disassembly
NOTE: For the left side, follow the same steps as right side. 1. Raise the hooked end of the band (1) with a screwdriver or equivalent.
412RS011
6. Remove spacer. 7. Remove the six balls (1) with a screwdriver or equivalent.
412RS009
2. Remove band. 3. Pry off circlip (1) with a screwdriver or equivalent.
412RS012
412RS010
DRIVE SHAFT SYSTEM

8. Using snap ring pliers, remove the snap ring (1) fastening the ball retainer to the center shaft.
4C21

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Drive shaft joint assembly 2. DOJ case, ball, ball guide, ball retainer 3. Bellows 4. Bearing 5. Dust seal, oil seal
Bushing Replacement
D Remove the bushings using a remover J393781 and hammer.
412RS013
9. Remove ball retainer, ball guide and bellows. 10. Raise the hooked end of the band (1) with a screwdriver or equivalent.
412RS015
D By using installer J393782 and base J393783, press fit the bushings into the bracket.
412RS014
11. Remove band. 12. Remove bellows. 13. Remove dust seal. 14. Remove BJ shaft assembly. 15. Remove the mounting bracket fixing bolts, and then remove DOJ case assembly from the axle case. 16. Remove snap ring and bearing. 17. Remove snap ring and oil seal. 18. Remove bracket.
412RS016
4C22
DRIVE SHAFT SYSTEM

12. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft.
Reassembly
1. Install DOJ case to bracket. 2. Install oil seal and fix snap ring. 3. Install bearing and fix snap ring. 4. Install bracket to axle case. Tighten the bracket bolt to the specified torque. Torque: 116 Nm (85 lb ft) 5. Apply 150g of the specified grease in BJ . 6. Install dust seal . 7. Apply a thin coat of grease to the shaft for smooth installation then install bellows. 8. Install band. Note the setting direction. After installation, check that the bellows is free from distortion.
412RS013
13. Align the track on the ball (1) retainer with the window in the cage, and install the six balls into position.
412RS017
9. Install another bellows and fix band. 10. Install the ball guide with the smaller diameter side ahead onto the shaft. 11. Install ball retainer.
412RS018
DRIVE SHAFT SYSTEM

14. Install spacer. 15. Install snap ring. 16. Enclose 150g of the specified grease in DOJ case, then install drive shaft joint assembly. After reassembly, move the DOJ longitudinally several times to get to fit. 17. Install the circlip (1) so that open ends are positioned away from the ball groove.
4C23
18. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure.
412RS021
19. Install Band. After installation, check that the bellows is free from distortion.
412RS019
412RS020
Legend (1) Outer Case (2) Circlip (3) Open Ends
4C24
DRIVE SHAFT SYSTEM
Shift On The Fly System

Shift On The Fly System and Associated Parts
412RW004
Legend (1) Filler Plug (2) Bolt (3) Oil Seal (4) Snap Ring(External) (5) Inner Shaft Bearing (6) Snap Ring(Internal) (7) Inner Shaft
(8) (9) (10) (11) (12) (13) (14) (15)
Needle Bearing Clutch Gear Sleeve Housing Front Axle Drive Shaft (LH side)with Bracket Bolt Actuator Assembly Bolt
Disassembly
1. Remove filler plug and gasket, drain oil. 2. Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case. 3. Remove Actuator Assembly and draw out actuator ASM.
4. Remove housing. 5. Remove sleeve.
DRIVE SHAFT SYSTEM

6. Remove clutch gear. 7. Remove snap ring from front axle case by using snap ring pliers.
4C25
10. Remove inner shaft bearing by using a remover J37452 and press. NOTE: Be careful not to damage the shaft.
412RW017
8. Take out inner shaft from front axle case. 9. Remove snap ring from inner shaft by using snap ring pliers.
412RW015
11. Remove needle bearing from inner shaft by using a remover J26941 and sliding hammer J261901. NOTE: Be careful not to damage the shaft.
412RW016 412RS045
12. Remove oil seal from front axle case. NOTE: Be careful not to damage the front axle case.
4C26
DRIVE SHAFT SYSTEM

Inspect the removed parts. If there are abnormalities such as wear and damage, take corrective action or replace.
Inner Shaft RunOut

With both end centers supported, rotate the shaft slowly and measure deflection with a dial gauge. Limit: 0.5 mm (0.02 in) NOTE: Do not heat the shaft to correct its bend.
Visual Check
1. Check and see if the inner shaft has any abnormalities such as wear and damage.
412RS026
412RW014
Inner Shaft Bearing
2. When inspecting the inner shaft, be sure to check and see if its splined part is twisted, worn, or cracked. If so, replace with a new shaft. In case of an abnormality in its gear part (a slide with sleeve), replace the shaft.
412RW006
420RS008
Legend (1) Inner Shaft Bearing (2) Inner Shaft (3) Clutch Gear 1. Inspect the state of inner shaft bearing. If any abnormality such as roughness is found, replace with a new inner shaft bearing. 2. Insert a clutch gear and check the state of needle bearing. 3. If there is an abnormality such as roughness, replace the needle bearing.
DRIVE SHAFT SYSTEM
4C27
Sleeve Condition
Check and see that there is no wear, damage, or cracking in the sleeve. NOTE: Close inspection of the groove and inner gear are required because those are important parts.
Clutch Gear Condition

Check and see that there is no wear, damage, cracking, or any other abnormality in the clutch gear.
Clutch Gear Function
Sleeve Function
412RW010
412RW011
Operate the sleeve with the inner shaft combined with the clutch gear. If roughness is felt, replace the sleeve. NOTE: Gear oil should be applied to the contact surface of gear. Check the width of sleeve center groove. Limit: 7.1 mm (1.28 in)
If there is an abnormality such as roughness when operated in combination with sleeve, replace the clutch gear. NOTE: When inspecting, gear oil should be applied to the contact surface of gear.
Clutch Gear Journal Diameter

Make sure of the size illustrated. Limit: 36.98 mm (1.456 in)
412RW022 412RW009
4C28
DRIVE SHAFT SYSTEM
Actuator
Check and see that there is no damage, cracking, or other abnormality. Functional Check
412RW007
Disconnect the shift position switch and make sure of function with a vacuum of 400 mmHg applied to Ports A and B, in accordance with the table below.
412RW021
State C D
Port A 400 mmHg A/P
Port B A/P 400 mmHg
Function E F
If there is an abnormality, replace the actuator as an assembly. NOTE: 1. If the actuator works under 400mmHg or less, there is no functional problem.
412RW013
DRIVE SHAFT SYSTEM

2. Be careful not to permit the entry of water or dust into the ports of the actuator. Dimensional Check Measure illustrated sizes 1, 2, and 3. Limit 1=64.1 mm (2.52 in) 2=6.7 mm (0.26 in) 3=6.7 mm (0.26 in)
4C29
2. Force a new needle bearing into inner shaft by using a installer J41694 and grip J8092.
412RS051
3. Place a new snap ring(internal) in inner shaft. Force a new inner shaft bearing into the inner shaft by using a installer J37452 and press.
412RS037
Reassembly
1. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer J41693 and grip J8092.
412RS044
4. Install snap ring(external). NOTE: Be careful not to damage the inner shaft. 5. Clean the housing contact surface of the front axle case and insert inner shaft assembly into the front axle case. NOTE: Be careful not to damage seal.
412RS043
4C30
DRIVE SHAFT SYSTEM

10. Tighten bolts to specified torque. Torque: 116Nm(85 lb ft) 11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to specified torque. Torque: 39Nm (29 lb ft) 12. Apply liquid gasket to the contact surface on the actuator side.
6. Install snap ring (internal) in the groove of front axle case. NOTE: Be sure to install the snap ring properly.
412RW017
7. Apply differential gear oil to clutch gear, then install clutch gear. 8. Apply differential gear oil to sleeve, then install sleeve. 9. Clean contact surface with the front axle and actuator mounting surface. Apply liquid gasket to the contact surface on the front axle case, then install in the housing.
412RW012
13. Align shift arm with the groove of sleeve and install the actuator. 14. Tighten bolts to specified torque. Torque: 13Nm(113 lb ft) 15. Install front axle drive shaft and mounting bracket. Tighten fitting bolts to specified torque. Torque: 116Nm (85 lb ft) 16. Pour specified amount of differential gear oil to filler plug. Front Differential Oil Capacity: 1.4lit (1.48US qt) Actuator Housing Oil Capacity: 0.12lit(0.13US qt) 17. Install filler plug through gasket and tighten to specified torque. Torque: 7.8Nm (58lb ft)
412RW023
DRIVE SHAFT SYSTEM
4C31

Front drive axle oil capacity Type of lubricant Axle shaft type 1.4 liter (1.48 US qt)(Differential) 0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly) GL5 (Multi grade type) Refer to chart in General Information Constant velocity joint(Birfield joint type and double offset joint)
E04RW004
4C32
DRIVE SHAFT SYSTEM
Special Tools
J39378 Remover and Installer; Front Axle mount bushing
J8092 Grip
J37452 Remover and Installer; Inner shaft bearing
J 26941 Remover;Bearing needle
J261901 Hammer; Sliding
J41694 Installer; Bearing needle
DRIVE SHAFT SYSTEM
4C33
Front Propeller Shaft

General Description
Since the propeller shaft is balanced carefully, welding or any other modifications are not permitted. Alignment marks should be applied to each propeller shaft before removal.
401RW002
4C34
DRIVE SHAFT SYSTEM
Front Propeller Shaft and Associated Parts
401RW058
Legend (1) Bolt, Nut and Washer (Front Axle Side) (2) Front Propeller Shaft (3) Bolt, Nut and Washer (Transfer Side)
(4) (5) (6) (7)
Front Propeller Shaft (with TOD) Coupling LJ Constant Velocity Joint BJ Constant Velocity Joint
Removal
1. Jack up the vehicle and support it on the chassis stands. 2. Gear shift lever should be placed in neutral position and parking brake released. 3. Remove the exhaust and transfer protectors. NOTE: Apply alignment marks on the flange at the front propeller shaft both front and rear side.
401RS020
DRIVE SHAFT SYSTEM
4C35
401RW053
401RW051
Installation
NOTE: Never install the shaft assembly backwards. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 1. Align the mark which was applied at removal. Install front propeller shaft and tighten the bolts to the specified torque. Torque: 63 Nm (46 lb ft) 2. Install the exhaust and transfer protectors. 3. After installing the propeller shaft, be sure to apply black paint (1) to exposed area (other than connecting surface) of the entire surface of flange coupling .
401RW052
4. Remove bolt, nut and washer (Front axle side). 5. Remove bolt, nut and washer (Transfer side). 6. Remove front propeller shaft. NOTE: If equipped with torque on demand (TOD), when removing, installing or carring for front propeller shaft, be sure to wind a piece of cloth round the part of the boot with which fittings may interfere so that the boot can be protected. The boot may be damaged if bending force is applied to the constant velocity joint of the shaft.
401RS019
4C36
DRIVE SHAFT SYSTEM
Disassembly (Except TOD 44)
401RW057
Legend (1) Sleeve Yoke
(2) Seal (3) Tube Assembly
1. Apply alignment marks (1) on the sleeve yoke and tube assembly then remove sleeve yoke.
2. Remove seal. 3. Remove tube assembly.
401RW056
DRIVE SHAFT SYSTEM
4C37
Universal Joint Disassembly
401RW055
Legend (1) Flange Yoke (2) Spider
(3) Snap Ring (4) Needle Roller Bearing (5) Grease Fitting
1. Apply alignment marks (1) on the yokes of the universal joint, then remove snap ring.
2. Tap out the needle roller bearing by gently striking the shoulder of the yoke, using a mallet or a copper hammer.
401RS028 401RS006
4C38
DRIVE SHAFT SYSTEM
3. Make sure of proper position for reinstallation by applying setting marks, then remove spider .

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection. NOTE: When any part of the journal assembly (spider, needle roller bearing) requires replacement, be sure to replace the entire assembly. Check the following parts for wear, damage, noise or any other abnormal conditions: 1. Spider 2. Needle roller bearing 3. Yoke 4. Flange 5. Constant velocity joint
401RS027
Outside Diameter of Spider Pin

Standard: 17.00 mm (0.669 in) Limit: 16.90 mm (0.665 in)
Play in Splines in Normal Direction of Rotation

Check the amount of play between the sleeve yoke (1) and the propeller shaft spline (2) in the direction of rotation, using a pointed feeler gauge. Standard: 0.073 0.156 mm (0.003 0.006 in) Limit: 0.3 mm (0.012 in)
401RS007
Propeller Shaft Runout

Support the ends of the propeller shaft on V-blocks (2) and check for runout by holding the probe of a dial indicator (1) in contact with the center part of the shaft. If the amount of runout is beyond the standard value for assembly, correct with a bench press or replace the shaft with a new propeller shaft assembly. Standard: 0.3 mm (0.012 in) Limit: 0.5 mm (0.02 in)
401RS009
DRIVE SHAFT SYSTEM
4C39
Play in Universal Joint

Limit: Less than 0.1 mm (0.004 in)
401RW049
Boot of Constant Velocity Joint

401RS010
Constant Velocity Joint

NOTE: LJ and BJ constant velocity joints are unremovable types. Check the joint for play and the boot for damage, wear, and leak of grease. If abnormality is found, replace propeller shaft as an assembly.
Check the boot (2) for crack, damage and grease leak, and the boot band (1) for loosening and damage. Check the both sides of the joint and make sure that there is no leak of grease from the cover press-in parts(3).
Play in Constant Velocity Joint

Fix the shaft in a vise throrgh pieces of wood, and try to move the joint vertically, right and left, and back and forth to make sure of smooth motions and no remarkable play.
401RW048
401RW050
4C40
DRIVE SHAFT SYSTEM

2. Set a dial gage at right angle near the inner circumference and check the run-out of the flange. Limit: 0.15 mm (0.006 in)
401RW047
Front Axle Flange Run-out

1. Set a dial gage at right angle near the outer circumference of the flange face and check the run-out of the flange face. Limit: 0.15 mm (0.006 in)
401RW045
3. If vibration is felt during the 4H AUTO drive, disconnct the propeller shaft at the front axle. Reinstall the propeller shaft at 60, 120, 180, 240, and 300 and conduct test drive in each position and check if there is vibration.
401RW046
401RW044
DRIVE SHAFT SYSTEM
4C41
Universal Joint Reassembly

1. Install spider to flange yoke. Be sure to install the spider by aligning the setting marks made during disassembly. 2. Apply a molybdenumdisulfide grease or a multipurpose type grease NLGI No. 2 to inside of the bearing cap. Grease Amount: Approx. 1.2 g (0.042 oz)
4. Align setting marks (1) and join the yokes.
401RS028
5. Install snap ring. NOTE: Discard used snap rings and install new ones. When the bearing cap is in position, select and attach a snap ring of suitable thickness so that the end play of the spider pin is held within 0.1 mm (0.004 in). Snap ring thickness and Identification color 1.5 mm (0.059 in); Blue 1.53 mm (0.060 in); White 1.59 mm (0.063 in); Yellow 1.62 mm (0.064 in); Green 1.68 mm (0.066 in); Not colored NOTE: Be sure to use snap rings of the same thickness on both sides.
401RS011
3. Using either a mallet (or copper hammer) or a press, install the needle roller bearing into the yoke so that the snap ring can be installed in its groove. CAUTION: The needle roller bearing cannot be installed smoothly if it is set at an incorrect angle with the flange and excessive hammering will damage the needle roller bearing.
401RS012
4C42
DRIVE SHAFT SYSTEM
Reassembly (Except TOD 44)
401RW057
1. Discard used seal and install new one. 2. Align the alignment marks and install tube assembly to sleeve yoke.
DRIVE SHAFT SYSTEM
4C43

Engine Transmission Construction Outside diameter Length M/T 6VE1(3.5 L) A/T A/T with TOD Hollow steel tube with constant velocty joints. 40.0 mm (1.57 in) 577 mm (22.72 in) Hollow steel tube with yoke and spider type universal joints. 40.0 mm (1.57 in) 559 mm (22.01 in) 40.0 mm (1.57 in) 559 mm (22.01 in)
E04RW005
4C44
DRIVE SHAFT SYSTEM
Rear Propeller Shaft

General Description
Since the propeller shaft is balanced carefully, welding or any other modifications are not permitted. Alignment marks should be applied to each propeller shaft before removal.
401RW003
Rear Propeller Shaft and Associated Parts
401RW059
Legend (1) Bolt, Nut and Washer
(2) Rear Propeller Shaft (3) Bolt, Nut and Washer
Removal
1. Jack up the vehicle and support it on the chassis stands.
2. Gear shift lever should be placed in neutral position and parking brake released. NOTE: Apply alignment marks on the flange at the rear propeller shaft both front and rear side.
DRIVE SHAFT SYSTEM
4C45
401RS023
3. Remove bolt, nut and washer (Rear axle side). 4. Remove bolt, nut and washer (Transfer side). 5. Remove rear propeller shaft.
Installation
NOTE: Never install the shaft assembly backwards. 1. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 2. Align the mark which is applied at removal . Install rear propeller shaft and tighten the bolts to the specified torque. Torque: 63 Nm (46 lb ft) 3. After installing the propeller shaft, be sure to apply black paint (1) to exposed area (other than connecting surface) of the entire surface of flange coupling .
401RS022
4C46
DRIVE SHAFT SYSTEM
Disassembly
401RW057
1. Apply alignment marks (1) on the sleeve yoke and tube assembly then remove sleeve yoke.
2. Remove seal. 3. Remove tube assembly.
401RW056
DRIVE SHAFT SYSTEM
4C47
Universal Joint Disassembly
401RW054
Legend (1) Flange Yoke (2) Spider with Grease Fitting
(3) Snap Ring (4) Needle Roller Bearing (5) Grease Fitting
1. Apply alignment marks (1) on the yokes of the universal joint, then remove snap ring.
2. Tap out the needle roller bearing by gently striking the shoulder of the yoke, using a mallet or a copper hammer.
401RS028 401RS006
4C48
DRIVE SHAFT SYSTEM
3. Make sure of proper position for reinstallation by applying setting marks, then remove spider with grease fitting.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection. NOTE: When any part of the journal assembly (spider, needle roller bearing, grease fitting) requires replacement, be sure to replace the entire assembly. Check the following parts for wear, damage, noise or any other abnormal conditions: 1. Spider 2. Needle roller bearing 3. Yoke 4. Flange
Outside Diameter of Spider Pin

Standard: 17.00 mm (0.669 in) Limit: 16.90 mm (0.665 in)
401RS008
Play in Splines in Normal Direction of Rotation

Check the amount of play between the sleeve yoke (1) and the propeller shaft spline (2) in the direction of rotation, using a pointed feeler gauge. Standard: 0.073 0.156 mm (0.003 0.006 in) Limit: 0.3 mm (0.012 in)
401RS007
Propeller Shaft Run-out

Support the ends of the propeller shaft on V-blocks (2) and check for run-out by holding the probe of a dial indicator (1) in contact with the center part of the shaft. If the amount of run-out is beyond the standard value for assembly, correct with a bench press or replace the shaft with a new propeller shaft assembly . Standard: 0.3 mm (0.012 in) Limit: 0.5 mm (0.02 in)
401RS009
DRIVE SHAFT SYSTEM
4C49
Play in Universal Joint

Limit: Less than 0.1 mm (0.004 in)
401RS012
4. Align setting marks (1) and join the yokes.

401RS010
NOTE: Assemble the spider and spline yoke so that their grease fittings are arranged on the same side.
Universal Joint Reassembly

1. Install spider to flange yoke. Be sure to install the spider by aligning the setting marks made during disassembly. 2. Before installing needle roller bearing, apply a molybdenumdisulfide grease or a multipurpose type grease NLGI No. 2 to inside of the bearing cap. Grease Amount: Approx. 1.2 g (0.042 oz)
401RS028
5. Install snap ring. NOTE: Discard used snap rings and install new ones. When the bearing cap is in position, select and attach a snap ring of suitable thickness so that the end play of the spider pin is held within 0.1 mm (0.004 in). Snap ring thickness and identification color 1.5 mm (0.059 in): Blue 1.545 mm (0.061 in): White 1.59 mm (0.063 in): Yellow 1.635 mm (0.064 in): Green 1.68 mm (0.066 in): Not colored NOTE: Be sure to use snap rings of the same thickness on both sides.
401RS011
3. Using either a mallet (or copper hammer) or a press, install the needle roller bearing into the yoke so that the snap ring can be installed in its groove. CAUTION: The needle roller bearing cannot be installed smoothly if it is set at an incorrect angle with the flange and excessive hammering will damage the needle roller bearing.
4C50
DRIVE SHAFT SYSTEM
Reassembly
401RW057
1. Discard used seal and install new one. 2. Align the alignment marks and install tube assembly to sleeve yoke.
DRIVE SHAFT SYSTEM
4C51

Engine Transmission Construction Outside diameter Length M/T 68.9 mm (2.71 in) 1093 mm (43.03 in) 6VE1(3.5 L) A/T 68.9 mm (2.71 in) 1093 mm (43.03 in) A/T with TOD 68.9 mm (2.71 in) 1075 mm (42.32 in) Hollow steel tube with yoke and spider type universal joints.
E04RW006
SECTION
TRANSFER CASE (STANDARD TYPE)
TROOPER
4D11
DRIVELINE/AXLE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Rear Case Assembly . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D11 4D12 4D14 4D14 4D14 4D16 4D16 4D17 4D19 4D19 4D110 4D113 4D114 4D114 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly) . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D116 4D116 4D117 4D118 4D118 4D120 4D120 4D121 4D123 4D127 4D133 4D136
Service Precaution
4D12 TRANSFER CASE (STANDARD TYPE)
General Description
M/T model
A07RW019

A/T model
4D13
A07RW001
The transfer case is used to provide a means of providing power flow to the front axle. The transfer case also provides a means of disconnecting the front axle, providing better fuel economy and quieter operation when the vehicle is driven on improved roads where four wheel drive is not required. In addition, the transfer case provides an additional gear reduction when placed in low range, which is useful when difficult offroad conditions are encountered. A floor mounted shift lever is used to select the operating range. When four wheel drive has been selected, the four wheel drive indicator light is designed to come on when the front axle has been engaged.
Transfer Rear Oil Seal

Removal
1. Disconnect the rear propeller shaft from the transfer case side. 2. Remove end nut and rear companion flange, use the companion flange holder J861411 to remove the end nut.
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Install oil seal and apply engine oil to the oil seal outer surfaces. 2. Apply the recommended grease (BESCO L2) or equivalent to the oil seal lip. 3. Use the oil seal installer J39208 to install the rear seal to the transfer rear case.
266RW001
3. Use the universal puller to remove the rear companion flange and Oring. 4. Remove the oil seal from the transfer case.
220RS016
4. Rear companion flange and end nut. 5. Install the rear companion flange and Oring. 6. Use the companion flange holder J37221 to install a new end nut and tighten to the specified torque. Torque: 167 Nm (123 lb ft) 7. Use the punch J39209 to stake the end nut at two spots. NOTE: Be sure to confirm that there is no crack at the staked portion of the end nut after staking.
266RS001
4D15
266RW002
8. Connect the rear propeller shaft to the transfer case and tighten to the specified torque. Torque: 63 Nm 46 (lb ft)
Transfer Case Assembly
260R200002
Legend (1) Transfer Protector (2) Rear Propeller Shaft (3) Front Propeller Shaft (4) Front Console
(5) Select Lever Assembly (A/T) Grommet Assembly (M/T) (6) Transfer Control Lever (7) Wiring Harness Connector (8) Transmission Transfer Bolt (9) Transfer Case Assembly
Removal
NOTE: Before removing transmission & transfer assembly from vehicle, change the transfer mode to 2WD by pushing button switch on dash panel. 1. Disconnect the battery ground cable. 2. Drain the transfer case fluid. 3. Remove transfer protector. 4. Remove rear propeller shaft.
5. Remove the rear and front propeller shaft from the transfer case side. 6. Disconnect the four oxygen sensor connectors from the transmission harness. 7. Remove the right and left catalytic converter assemblies and exhaust pipe. 8. Remove the transfer control lever knob. 9. Remove the selector lever assembly. Refer to Selector Lever in the Section 7A.

10. Remove transfer control lever. 11. Disconnect the 4WD switch and speed sensor harness connector and 2WD4WD actuator harness connector from the transmission harness. 12. Remove transmissiontransfer bolt and support the transfer case with a transmission jack. 13. Remove four transmissiontransfer bolts and the three nuts. 14. Remove the transfer case assembly from the vehicle.
4D17
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Install transfer case assembly and apply a thin coat of molybdenum disulfide grease to the input shaft spline. 2. Tighten the transmissiontransfer bolt to the specified torque. Torque: 46 Nm (34 lb ft)
260RW001
3. Tighten the exhaust pipe to exhaust manifold bolt to the specified torque. Torque: 67 Nm (49 lb ft) 4. Tighten the exhaust pipe flange bolt to the specified torque. Torque: 43 Nm (32 lb ft) 5. Tighten the propeller shaft bolt to the specified torque. Torque: 63 Nm (46 lb ft)

6. Tighten the transfer protector bolt to the specified torque. Torque: 37 Nm (27 lb ft)
256RW026
4D19
Transfer Rear Case Assembly

Removal
1. Remove the speedometer sensor. 2. Remove the plate. 3. Remove the speedometer driven gear bushing and driven gear. NOTE: Apply a reference mark to the driven gear bushing before removal. 4. Remove front companion flange. 5. Remove rear companion flange, use the flange companion holder J861411 to remove the end nut. 10. Pull the 2WD4WD 2WD4WD shift rod. actuator assembly with
262RW009
6. Remove the front and rear companion flange. NOTE: Use the universal puller to remove the rear companion flange. 7. Remove control box assembly. 8. Disconnect the actuator breather hose from the 2WD4WD actuator assembly. Legend (1) Shift Rod: 2WD4WD (Position: 2WD) (2) 2WD4WD Actuator Assembly (3) Pull (4) Rear Case Assembly (5) Position: 4WD (6) Mode: 2WD
220RW027
220RW085
9. Remove the 2WD4WD actuator assembly bolts.

11. Off set the actuator assembly.
Installation
1. Install transfer rear case assembly. 2. Install transfer case assembly and apply the recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer rear case fitting faces.
220RW028
12. Remove the actuator assembly.
220RS017
3. Perform the following steps before fitting the transfer rear case: 1. Shift the highlow shift to the 4H side. 2. Turn the select rod counterclockwise so that the select block projection A may enter into the 2WD4WD shift block. 3. The cutaway portion of the select rod head (9) should align with that of the rear case holes stopper (10).
220RW029
Legend (7) Position: 4WD (8) Mode: 2WD 13. Remove transfer case assembly. 14. Remove transfer rear case assembly.
230RW004
4. Tighten the transfer rear case bolts to the specified torque. Torque: 37 Nm (27 lb ft) 5. Shift the 2WD4WD shift rod (11) to the 4WD side.

6. Join the rod grooves of 2WD4WD actuator assembly (12) and shift rod (11).
4D111
8. Tighten the 2WD4WD actuator bolts to the specified torque. Torque: 19 Nm (14 lb ft) 9. Connect the actuator breather hose to actuator. 10. Install control box assembly. Torque: 19 Nm (14 lb ft) 11. Install rear companion flange. 12. Install front companion flange, use the companion flange holder J861411 to tighten the flange nuts to the transfer case.
220RW030
Legend (11) Shift Rod: 2WD4WD (Position: 4WD) (12) 2WD4WD Actuator Assembly (Mode: 2WD) (13) Rear Case Assembly 7. Push the 2WD4WD actuator assembly (12) with 2WD4WD shift rod (11) till the shift rod (11) reaches the 2WD position.
262RW009
13. Tighten the new transfer flange nuts to the specified torque. Torque Rear companion flange: 167 Nm (123 lb ft) Front companion flange: 137 Nm (101 lb ft)
220RW031
Legend (14) Position: 2WD (15) Mode: 2WD

14. Use the punch J39209 to stake the rear companion flange nut at two spots. 15. Stake the front companion flange nut at one spot. NOTE: Be sure to confirm that there is no crack at the staked portion of the flange nut after staking. 16. Install the Oring (8) to the speedometer driven gear bushing (7). 17. Install the driven gear to the speedometer driven gear bushing (7). 18. Install the speedometer driven gear assembly to the transfer rear cover. 19. Install the plate (6) to the transfer rear case and tighten to the specified torque. Torque: 15 Nm (11 lb ft) 20. Install the speedometer sensor and tighten to the specified torque. Torque: 27 Nm (20 lb ft)
266RS001
225RW005
266RW002
4D113
Disassembly
226RW131
Legend (1) Rear Output Shaft Assembly (2) Rear Output Shaft (3) Bearing Snap Ring (4) Ball Bearing
(5) (6) (7) (8) (9)
Bearing Snap Ring Ball Speedometer Drive Gear Ball Bearing Transfer Rear Case (with oil seal)
1. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring.
226RS060

2. Remove the rear output shaft assembly from the transfer rear case. 3. Remove ball bearing, use a bench press and the bearing remover J2291201 to remove the ball bearing.
Reassembly
1. Install transfer rear case (with oil seal). Oil seal replacement D Remove the oil seal from the transfer rear case. D Apply engine oil to the oil seal outer surfaces. D Fill in recommended grease (BESCO L2) or equivalent in the oil seal lip. D Use the oil seal installer to install J39208 to the rear oil seal to the transfer rear case.
226RS061
4. Remove speedometer drive gear. 5. Remove ball. 6. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring. 7. Remove ball bearing. 8. Remove rear output shaft, use a bench press and the bearing remover J2291201 to remove the ball bearing.
220RS019
2. Install rear output shaft. 3. Install ball bearing, use the ball bearing installer J37223 and the adapter J37486A to install the ball bearing.
226RS062
9. Remove transfer rear case (with oil seal).

262RW021

Refer to TRANSFER CASE ASSEMBLY in this section for inspection and repair.
4. Install bearing snap ring. 5. Install ball.

6. Install speedometer drive gear.
4D115
226RS064
7. Install ball bearing, use the ball bearing installer J37223 to install the ball bearing.
226RS065
8. Install the rear output shaft assembly to the transfer rear case. 9. Install bearing snap ring. NOTE: The snap ring must be fully inserted into the transfer rear case snap ring groove.
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)

Disassembled View
262R200004
Legend (1) Transfer Case (2) Detent Ball, Spring, Spacer and Plug (3) Spring (4) Interlock Pin (5) 4WD Indicator Switch (6) Shift Block (7) Spring Pin (8) Spring
(9) (10) (11) (12) (13) (14) (15) (16)
Shift Arm 2WD4WD Shift Rod Spring Pin and Bridge Select Rod Assembly Spring Pin HighLow Shift Rod Shift Arm Shift Block
4D117
Disassembly
1. Remove detent ball, spring and plug. 2. Remove spring pin and bridge, use a spring pin remover to remove the spring pin from the bridge.
8. Remove 4WD indicator switch. 9. Remove interlock pin. 10. Remove spring, use a magnetic tool to remove the interlock pin from the transfer case.
262RS005 262RW011
3. Remove spring pin. 4. Remove spring. 5. Engage the 2WD4WD sleeve with front output gear. Remove the spring pin from the block. Remove the shift rod.
11. Remove select rod assembly. 12. Remove spring pin. 13. Remove highlow shift rod, use a spring pin remover to remove the shift arm spring pin from the shift arm and shift block. Remove the highlow shift rod.
262RS006 262RW022
6. Remove shift arm. 7. Remove shift block.
14. Remove shift arm. 15. Remove shift block. 16. Remove transfer case.

Refer to TRANSFER CASE ASSEMBLY in this section for inspection and repair.
10. Install the shift rod: 2WD4WD (2) with interlock pin pushed in.
Reassembly
1. Install transfer case. 2. Install shift block. 3. Install shift arm. 4. Install highlow shift rod. 5. Engage the HighLow sleeve with the 4H (1) side. 6. Install the spring pin to the shift block and shift arm.
262RW013 262RW012
7. Install select rod assembly. 8. Install spring. 9. Engage the HighLow sleeve with the 4H side and install the interlock pin (4) in the proper direction.
Legend (2) 2WD4WD (3) 4H Side (4) Interlock pin (5) 2WD (6) 4WD (7) Rod: 24 (8) Rod: HL (9) 4H (10) 4L (11) 42 (12) 44 11. Install 4WD indicator switch and tighten to the specified torque. Torque: 39 Nm (29 lb ft) 12. Install shift block. 13. Install shift arm. 14. Install 2WD4WD shift rod. 15. Install spring.

16. Engage the 2WD4WD sleeve with the 4WD side and install the spring pin.
4D119
262RW022
17. Install spring pin and bridge. 18. Install detent ball, spring and plug and tighten the plug to the specified torque. Torque: 25 Nm (18 lb ft)

Disassembled View
226RW132
Legend (1) Transfer Case (with oil seal) (2) Bearing Snap Ring (3) Front Output Gear Assembly (4) Ball Bearing (5) Front Output Shaft (6) Stopper Plate (7) 2WD4WD Clutch Hub and Assembly (8) Block Ring (9) Outside Ring (10) Inside Ring (11) Front Output Gear (12) Needle Bearing (13) SubGear (antilash plate) (M/T) (14) Belleville Spring (M/T) (15) Spacer (M/T) (16) SubGear Snap Ring (M/T) (17) Bearing Collar (18) Ball Bearing (19) Bearing Snap Ring (20) Snap Ring (21) Ball Bearing
(22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42)
Counter Gear SubGear (antilash plate) Belleville Spring Spacer Ball Bearing Snap Ring Counter Gear Assembly Bearing Snap Ring Input Shaft Assembly Input Shaft Ball Bearing Snap Ring Plate Ball Bearing Collar Needle Bearing Transfer Input Gear HighLow Clutch Hub and Sleeve Assembly Lock Nut Ball Bearing Bearing Snap Ring
4D121
Disassembly
1. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring. 2. Remove ball bearing, use a bearing remover J37217 and puller J37487 to remove the ball bearing.
5. Remove the front companion flange. 6. Remove snap ring. 7. Remove the input shaft assembly from the transfer case.
265RW001
262RW016
3. Install the front companion flange temporarily. 4. Use the Companion flange holder J861411 and lock nut wrench J37219 to remove the lock nut.
8. Remove highlow clutch hub and sleeve. 9. Remove transfer input gear, use the universal puller to remove the highlow clutch hub and sleeve, and transfer input gear.
226RS070 226RW130

10. Remove needle bearing. 11. Remove bearing collar. 17. Remove front output gear assembly, use a pair of snap ring pliers to expand the bearing snap ring and use a plastic hammer to tap the front output gear assembly free.
226RS071
12. Remove ball. 13. Remove plate. 14. Remove ball bearing, use a bench press and the ball bearing remover J2291201 to remove the ball bearing.
262RS009
18. Remove bearing snap ring. 19. Remove ball bearing. 20. Remove bearing collar. 21. Remove subgear snap ring. (M/T) 22. Remove spacer.(M/T) 23. Remove belleville spring.(M/T) 24. Remove subgear (antilash plate).(M/T) 25. Remove front output gear. 26. Remove needle bearing, use a bench press and the bearing remover J2291201 to remove the parts above.
265RS002
15. Remove input shaft. 16. Remove bearing snap ring.
262RS010

27. Remove inside ring. 28. Remove outside ring. 29. Remove block ring. 30. Disassemble the 2WD4WD clutch hub and sleeve assembly. D Springs (1) D Inserts (2) D Clutch Hub (3) D Sleeve (4)
4D123
33. Remove front output shaft. 34. Remove bearing snap ring. 35. Remove the counter gear assembly from the transfer case. 36. Remove snap ring, use a pair of snap ring pliers to remove the snap ring. 37. Remove ball bearing, use a bench press and the bearing remover J2291201 to remove the ball bearing. 38. Remove snap ring, use a pair of snap ring pliers to remove the snap ring. 39. Remove ball bearing, use a bench press and the bearing remover J2291201 to remove the ball bearing.
226RW133
31. Remove stopper plate. NOTE: Do not reuse the stopper plate. 32. Remove ball bearing, use the ball bearing remover J2291201 to remove the ball bearing.
226RS073
40. Remove spacer. 41. Remove belleville spring. 42. Remove subgear (antilash plate). 43. Remove counter gear.

1. Make the necessary repair or parts replacement if wear, damage or any other abnormal conditions are found during inspection. 2. Wash all parts thoroughly in clean solvent. Be sure all old lubricant, metallic particles, dirt, or foreign material are removed from the surfaces of every part. Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue.
Gears
262RS011
1. Inspect all the gear teeth for signs of excessive wear or damage and check all the gear splines for burrs, nicks, wear or damage. Remove the minor nicks or scratches on an oil stone. Replace any part exhibiting excessive wear or damage.

Gear Inside Diameter 1. Use an inside dial indicator to measure the gear inside diameter. 2. If the measured value exceeds the specified limit, the gear must be replaced. Gear inside diameter Standard : 48.00048.013 mm (1.88981.8903 in) Limit : 48.10 mm (1.894 in)
Bearings
1. Inspect the condition of all the needles and ball bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to the bearings. NOTE: Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers. 2. Lubricate the bearings with a light oil and check them for roughness by slowly turning the race by hand. Ball Bearing Play 1. Use a dial indicator to measure the ball bearing play. 2. If the measured value exceeds the specified limit, the ball bearing must be replaced. Limit : 0.2 mm (0.008 in)
226RS040
Clutch Hub Spline Play

1. Set a dial indicator to the clutch hub to measured. 2. Move the clutch hub as far as possible to both the right and the left. Note the dial indicator reading. 3. If the measured value exceeds the specified limit, the clutch hub must be replaced. Clutch hub spline play Standard : 00.1 mm (00.004 in) Limit : 0.2 mm (0.008 in)
226RS043
226RS042
4D125
Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance between the block ring and the insert. 2. If the measured value exceeds the specified limit, the block ring and the insert must be replaced. Block ring and insert clearance Standard : 3.463.74 mm (0.1360.147 in) Limit : 4.0 mm (0.158 in)
Clutch Hub and Insert Clearance

1. Use a thickness gauge to measure the clearance between the clutch hub and the insert. 2. If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced. Clutch hub and insert clearance Standard : 0.010.19 mm (0.00040.0075 in) Limit : 0.3 mm (0.012 in)
226RS037
226RS038
2WD4WD Synchronizer (3Cone)

1. Use a thickness gauge to measure the clearance between the block ring and the dog teeth. 2. If the measured value exceeds the specified limit, the 2WD4WD synchronizer assembly must be replaced. Block ring and insert clearance Standard : 1.5 mm (0.059 in) Limit : 0.8 in (0.031 in)
Detent Springs
1. Inspect the springs for distortion, cracks or wear. Replace if these conditions are present.
226RW142

Detent Spring Free Length 1. Use a vernier caliper to measure the detent spring free length. 2. If the measured value is less than the specified limit, the detent spring must be replaced. Detent spring free length Detent spring Standard Inner : 23.2 mm (0.913 in) Outer : 26.2 mm (1.06 in) Limit Inner : 22.6 mm (0.890 in) Outer : 26.2 mm (1.03 in) Interlock pin Standard : 1.59 mm (0.063 in) Limit : 1.53 mm (0.060 in)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring. Replace if these conditions are present. Shift Arm Thickness 1. Use a micrometer to measure the shift arm thickness. 2. If the measured value is less than the specified limit, the shift arm must be replaced. Shift arm thickness Standard : 9.609.85 mm (0.3780.388 in) Limit : 9.0 mm (0.354 in)
220RW035
Detent Spring Tension 1. Use a spring tester to measure the detent spring tension. 2. If the measured value is less than the specified limit, the detent spring must be replaced. Detent spring set length Detent spring Compressed height : 19.7 mm (0.776 in) Standard Inner : 22.632.4 N (5.087.29 Ib)
230RS006
Outer : 91.2101 N (20.522.7 Ib) Interlock pin Compressed height : 11.5 mm (0.453 in) Standard : 9.8 N (2.2 lb)
4D127
Reassembly
1. Install transfer case (with oil seal). Input shaft oil seal (1) replacement 1. Remove the oil seal from the transfer case. 2. Apply engine oil to the oil seal outer surfaces. 3. Apply recommended grease (BESCO L2) or equivalent to the oil seal lip. 4. Use the oil seal installer J38592 to install the oil seal to the transfer case.
4. Use the oil seal installer J38594 to install the oil seal to the transfer case.
220RW033
2. Install counter gear. 3. Install subgear and apply chassis grease (3) to the subgear and the counter gear thrust surfaces.
220RW032
Front output shaft oil seal (2) replacement 1. Remove the oil seal from the transfer case. 2. Apply engine oil to the oil seal outer surfaces. 3. Apply recommended grease (BESCO L2) or equivalent to the oil seal lip.
226RW134

4. Install belleville spring. 5. Install spacer. 6. Install ball bearing. 7. Select a snap ring that will allow the minimum axial play. Clearance : 00.1 mm (00.004 in) Snap ring availability: Thickness 1.50 mm (0.059 in) 1.55 mm (0.061 in) 1.60 mm (0.063 in) Colorcoding White Yellow Blue SubGear (antilash plate) Preload 1. Hook a length of piano wire (4) over one of the subgear (5) teeth. 2. Attach the other end of the piano wire (4) to a spring balancer. 3. Measure the subgear preload. Preload : 5998 N (1322 lb)
8. Use a pair of snap ring pliers to install the snap ring to the counter gear.
226RS075
9. Install ball bearing. 10. Install snap ring. 11. Install the counter gear assembly to the transfer case. 12. Install bearing snap ring, use a pair of snap ring pliers to install the snap ring to the transfer case. NOTE: The snap ring must be fully inserted into the transfer case snap ring groove.
226RS170
13. Install front output shaft. 14. Install ball bearing, use a bench press to install the ball bearing to the front output shaft.
226RS021
262RS012

15. Install stopper plate. 16. Assemble the clutch sleeve and hub assembly.
4D129
18. Install a new stopper plate and the clutch sleeve and hub assembly to the front output shaft.
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226RW135
17. Engage the springs in the same insert with the open ends away from each other.
Legend (6) Front Output Gear 19. The clutch hub face (with the heavy boss) must be facing the front output gear side. 20. Use a bench press to slowly force the clutch sleeve and hub assembly together with the stopper plate into place. 21. Align the inserts with the block ring insert grooves. Install the block ring to the clutch sleeve and hub assembly. 22. Install outside ring. 23. Install the outside ring, inside ring and needle bearing to the front output gear and bearing collar. NOTE: Coat all parts with transmission oil before installing them.
226RW141
226RW139
24. Install needle bearing. 25. Install front output gear. 26. Install subgear (antilash plate). (M/T)

27. Install belleville spring. (M/T) 28. Install spacer and apply engine oil to the thrust surfaces of the subgear, the belleville spring, and the spacer. (M/T) 32. Install bearing snap ring and select a snap ring that will allow the minimum axial play. Clearance : 00.1 mm (00.004 in) Snap ring availability: Snap ring thickness 1.55 mm (0.061 in) 1.60 mm (0.063 in) 1.65 mm (0.065 in) 1.70 mm (0.067 in) 1.75 mm (0.069 in) 1.80 mm (0.071 in) 1.85 mm (0.073 in) 1.90 mm (0.075 in) Color coding White Yellow Blue Pink Green Brown Red Orange
262RW060
29. Install subgear snap ring. (M/T) 30. Install bearing collar, use a bench press to install the needle bearing collar together with the front output gear.
262RS015
262RS014
31. Install ball bearing.
226RS021

33. Use a pair of snap ring pliers to install the snap ring to the output shaft. Sub gear (anti lash plate) preload (M/T) 1. Hook a length of piano wire (4) over one of the subgear (5) teeth. 2. Attach the other end of the piano wire to (4) a spring balancer. 3. Measure the subgear preload. Preload: 5998 N (1322 lb) (M/T)
4D131
38. Install plate. 39. Install ball. 40. Install bearing collar. 41. Install needle bearing. 42. Install transfer input gear. 43. Install highlow clutch hub and sleeve and the clutch hub face (with the heavy boss) must be facing the transfer input gear side (7).
226RW136
226RS075
34. Install front output gear assembly. 35. Install bearing snap ring, use a pair of snap ring pliers to install the snap ring to the transfer case. NOTE: The snap ring must be fully inserted into the transfer case snap ring groove. 36. Input shaft. 37. Install ball bearing, use a bench press to install the ball bearing to the input shaft.
44. Install input shaft assembly. 45. Install the snap ring to the input shaft. 46. Install the input shaft assembly to the transfer case. 47. Install the snap ring to the transfer case. NOTE: The snap ring must be fully inserted into the transfer case snap ring groove. 48. Install the front companion flange temporarily and use the flange holder J861411 and lock nut wrench J37219 to install the lock nut. Torque: 137 Nm (101 lb ft)
226RW137 265RS003

49. Use the punch to stake the lock nut at one spot. 50. Install ball bearing, use a suitable drift and hammer to install the ball bearing.
226RS079
51. Install bearing snap ring.
4D133

Type Control method Synchronized type gears shifting between the 2 and 4 wheel drive mode. Constant mesh type gears shifting between low and high. Remote control with the gear shift lever on the floor for gear shifting between low and high . Electric control with the button switch on the instrument panel for gear shifting between the 2 and 4 wheel drive mode. High; 1.000 Low; 2.050 1.45 lit. (1.53 U.S. quart) Besco Transaxle Oil Refer to chart in Section 0
Gear ratio Oil capacity Type of lubricant
E07RW008
E07RW009
4D135
E07RW010
Special Tools
ILLUSTRATION PART NO. PART NAME ILLUSTRATION PART NO. PART NAME
J2291201 Bearing remover/installer
J39208 Rear oil seal installer
J38592 Transfer case oil seal installer
J37486A Bearing installer adapter
J37219 Mainshaft nut wrench
J861411 Flange holder
J37223 Rear output shaft and bearing installer
J37217 Mainshaft end bearing remover
J39209 Punch, end nut
J37487 Puller
J38594 Front output shaft oil seal installer
J8092 Driver handle
SECTION
TRANSFER CASE (TOD)
TROOPER
4D21
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . Transfer Rear Oil Seal and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOD ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Cover Assembly . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly Clutch Pack and Clutch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . 4D21 4D22 4D22 4D23 4D25 4D25 4D25 4D25 4D27 4D27 4D27 4D28 4D28 4D29 4D29 4D29 4D210 4D212 4D212 4D212 4D214 4D216 4D216 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Sprocket and Mechanical Lock . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Output Shafts and Shift Control Shaft . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Output Shafts and Shift Control Shaft . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Sprocket and Mechanical Lock . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Pack and Clutch Cam . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D216 4D218 4D218 4D218 4D220 4D220 4D221 4D223 4D223 4D223 4D226 4D230 4D230 4D230 4D234 4D234 4D235 4D237 4D237 4D237 4D239 4D239 4D239 4D241 4D243
Service Precaution
4D22 TRANSFER CASE (TOD)

Removal
F07RW083
Legend (1) Transfer Protector (2) Rear Propeller Shaft (3) Front Propeller Shaft (4) Front Console (5) Selector Lever Assembly (6) Transfer Control Lever
(7) (8) (9) (10) (11) (12) (13)
Breather Hose Exhaust Pipe Seat Belt Tension Rod Speed Sensor Harness Connector Transfer Harness Connector Transfer Case Bolt Transfer Case
1. Disconnect the ground cable (-). 2. Remove the transfer protector. 3. Remove the rear propeller shaft from the transfer case.
4. Remove the front propeller shaft from the transfer case. 5. Remove the shift control rod from the selector lever assembly.
TRANSFER CASE (TOD)

6. Disconnect the wiring harness, transfer control lever knob, and shift lock cable and then remove the front console.
4D23
Installation
To install, follow the removed steps in the reverse order, noting the following points. 1. Apply a thin coat of grease (Besco L2) or equivalent to the input shaft spline.
256RW028
7. Remove the selector lever assembly and put it aside. 8. Remove the transfer control lever. 9. Disconnect the breather hose. 10. Remove the left exhaust pipe fixing bolts and nuts, and put the exhaust pipe aside. 11. Remove the left seat belt tension rod and put the rear proper shaft aside.
261RW024
2. Mount the transfer case.
260RW006
12. Disconnect the transfer harness connector from the top of the transfer case. 13. Disconnect the speed sensor harness connector. 14. Remove the fuel pipe clip fixing bolt on the transfer case. 15. Support the transfer case with a jack. 16. Remove the seven bolts from the transfer case. 17. Remove the transfer case assembly.

3. Tighten the transfer case bolts (see the figure below). Torque : 46 Nm (34 lb ft)
261RW0041
4. Tighten propeller shaft bolt. Torque : 63 Nm (46 lb ft)
TRANSFER CASE (TOD)
4D25
Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts
261RW005
Legend (1) Oil Seal (2) End Nut and Rear Companion Flange
Removal
1. Remove the rear propeller shaft from the transfer case. 2. Using the flange holder J-8614-11, remove the end nut. 3. Using the universal puller, remove the rear companion flange and O-ring. 4. Remove the oil seal from the transfer rear case.
Installation
1. Apply engine oil to the circumference of the oil seal. Fill the oil seal lip with grease (Besco L2).
261RW006
Legend (1) Inside (2) Outside

2. Using the oil seal installer J-42804, install the oil seal. NOTE: When installing the oil seal, pay attention to the direction. 5. Stake the end nut at one place so that there is no gap between a flat portion on the shaft and the nut staked portion. NOTE: Check the staked end nut is free from cracks.
261RW035
Rear Output Shaft Oil Seal

Distance between the transfer case and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Distance : 9.8510.35 mm (0.390.41 in)
266RY00003
260R200005
6. Install the rear propeller shaft to the transfer case and tighten to the specified torque. Torque : 63 Nm 46 (lb ft)
A04RW004
3. Mount the rear companion flange, O-ring , washer, and nuts to the transfer in this order. 4. Using the flange holder J-8614-11, install a new end nut. Torque : 167 Nm (123 lb ft)
TRANSFER CASE (TOD)
4D27
TOD ECU
Removal
1. Disconnect the ground cable (-). 2. Move the right-hand seat forward and remove the second seat foot rest (1). 3. Disconnect the connector from the ECU (2). 4. Remove the set bolts and detach the ECU (2) from the bracket.
F07RW021
Installation
1. Perform the removal steps in reverse order.
Unit Repair
Inspection
Before disassembling and after assembling, check the following items on the transfer connector terminals. No. 1 2 3 4 5 6 7 8 9 10 11 12 NAME Ref . (Rr . ) Ref . (Frt . ) SW GND 4H SW (+) Rer . (+) Frt . (+) POWER GND EMC (+) COM () (Rr .) COM () (Frt .) NC 4L SW (+) CONTENTS Rear speed sensor reference output Front speed sensor reference output SW GND 4H SW plus terminal Rear speed sensor plus Front speed sensor plus Power GND Electromagnetic solenoid Rear speed sensor GND Front speed sensor GND Not used 4L SW plus terminal COLOR LG LG B R B/LG LB B Y GR/ R GR/ R Y
4H and 4L switch
Check whether the 4H switch (terminals 4 and 7) and 4L switch (terminals 12 and 3 ) work as specified in the table below. If yes, the continuity is established on these switches. If not, check the switches, shift rails, transfer case, and rear cover, and replace the failed parts. Position 4H SW 4L SW High OFF OFF Neutral ON ON 4L OFF ON
Power GND
Check that there is a continuity between the power GND pin (terminal 7) and transfer case. If not, replace the grounding wire.
Resistance of electromagnetic coil

Check the resistance between electromagnetic coil (terminal 8) and power GND (terminal 7). If not, replace the electromagnetic coil. Standard : 1.4 2.0W Allowable : 1.0 5.0W
810RW002
TRANSFER CASE (TOD)
4D29
Transfer Case
Disassembled View
266RW004
Legend (1) Front Companion Flange (2) 4H and 4L Switch, Ground Cable, and Center Connector (3) Offset Lever
(4) (5) (6) (7)
Spring Pin Transfer Case Assembly Transfer Cover Assembly Rear Companion Flange
Disassembly
1. Remove the drain plug from the transfer case and drain the oil. 2. Disconnect the 4H and 4L switch and ground cable. 3. Remove the clip fixing the harness. 4. Remove the flange nut, using the flange holder J-8614-11, and remove the front companion flange. 5. Remove the flange nut, using the flange holder J-8614-11, and remove the rear companion flange.
266RW005

6. Remove the offset lever set bolt on the right side. 8. Remove the offset lever.
261RW015
261RW017
7. Remove the offset lever lock spring pin. NOTE: When removing the spring pin, note the recess position of the pin.
9. Remove the sixteen bolts and detach the transfer cover assembly from the transfer case assembly. NOTE: When removing the transfer cover assembly, be careful not to damage the oil seal.
Reassembly
1. Apply liquid gasket (Loctite 598 or equivalent) uniformly to the mating face that contacts the transfer case.
261RW016
261RW023
2. Tighten the sixteen bolts with the specified torque. Torque : 31 Nm (23 lb ft) 3. Wind the sealing tape around the drain plug thread and tighten the plug with the specified torque. Torque : 25 Nm (18 lb ft)
TRANSFER CASE (TOD) 4D211

4. Mount the offset lever to the transfer shift and install the spring pin.
266R200005
261RW016
9. Fix the harness with the clip. 10. Tighten the 4L and 4H switch to the specified torque. Torque : 24 Nm (17 lb ft) 11. Fill the transfer case with ATF II or III (1.9 liters). 12. Wind the sealing tape around the filler plug thread and tighten the plug to the specified torque. Torque : 25 Nm (18 lb ft)
5. Attach the O-ring and washer to the companion flange. NOTE: Securely push the O-ring to the hollow of the companion flange, and then attach the washer. 6. Use the flange holder J-8614-11 to tighten the flange nut. 7. Tighten the flange nut with the specified torque. Torque : 167 Nm (123 lb ft) 8. Securely stake the flange nut at one place so that there is no gap between a flat poriton on the shaft and the nut staked portion. NOTE: Check the staked flange nut is free from cracks.
266RY00003
Transfer Cover Assembly

Disassembled View
261RW007
Legend (1) Coil Assembly (2) Snap Ring (3) Ball Bearing
(4) (5) (6) (7)
Speed Gear and Tone Wheel Ball Bearing Transfer Cover Assembly Front and Rear Speed Sensors
Disassembly
1. Using snap ring pliers, remove the snap ring.
261RW047

2. Strike the speed gear and tone wheel with a rod or other appropriate tool from the outside of the transfer cover assembly, and remove the ball bearing and speed gear and tone wheel. NOTE: Be careful not to damage the speed gear teeth. 4. Using a terminal pull-out tool or an equivalent tool, push down the lock to unlatch the terminal for the coil assembly, and pull the terminal out. NOTE: Pay attention not to damage other terminals.
261RW032 266RW018
3. Remove the stopper plate on the back with a precision screwdriver or other appropriate tool starting from the small lock of the plate. NOTE: Be careful not to damage the stopper plate during the work.
5. Remove the fixing nuts of the coil assembly from the outside of the transfer cover assembly. Remove the coil assembly from the transfer cover.
261RW030
261RW042

6. Using the bearing remover J-42805 and slide hammer J-2619-01, remove the ball bearing for the front output shaft. 3. Using the oil seal installer J-42804, install the oil seal to the transfer cover assembly.
261RW035 901RW087
7. Remove the bolts and front and rear speed sensors. NOTE: Be careful not to damage the speed sensors during the work.
Rear Output Shaft Oil Seal

Distance between the transfer case end and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Dimension : 9.8510.35 mm (0.390.41 in)
261RW033
Reassembly
1. Remove the oil seal from the transfer cover assembly. 2. Apply oil to the circumference of the new oil seal and fill the lip with grease (Besco L2 or equivalent).
A04RW004
4. Apply a thin coat of grease to the seal ring of each front and rear speed sensor, and mount the sensor carefully. 5. Tighten the bolt to the specified torque. Torque : 5 Nm (43 lb in) NOTE: Pay attention not to mount the front (or rear) sensor to the rear (or front) sensor position. 6. Install the ball bearing (1) for the front output shaft as flat as shown in the figure. 7. Mount the coil assembly and tighten the set nuts to the specified torque. Torque : 10 Nm (87 lb in)

8. Connect the terminal in the central connector. NOTE: Be careful not to damage other terminals. 9. Install speed gear and tone wheel. 10. Install the ball bearing (2) as flat as shown in the figure.
261RW0091
11. Using snap ring pliers, install the snap ring to the transfer cover assembly. NOTE: Securely install the snap ring to the groove of the transfer cover assembly.
Transfer Case Assembly Clutch Pack and Clutch Cam

Disassembled View
266RW006
Legend (1) Clutch Pack Assembly (2) Insulator Washer (3) Armature Plate (4) Snap Ring
(5) (6) (7) (8) (9)
Wave Spring Cam Pulley Cam Ball Cam and Coil Housing Thrust Bearing
Disassembly
1. Remove the thrust bearing. 2. Remove the cam and coil housing. NOTE: When the cam and coil housing is removed, the cam balls may be detached together with the housing. Be careful not to lose the ball. 3. Remove the cam ball.
266RW013

4. Remove the cam pulley. 5. Remove the wave spring. 6. Using snap ring pliers, remove the snap ring. NOTE: Be careful not to damage the snap ring.
266RW009
7. Remove the armature plate. 8. Remove the insulator washer. 9. Remove the clutch pack assembly as a package.
266RW017
Sprocket and Mechanical Lock

Disassembled View
266RW008
Legend (1) Strainer (2) Hose (3) Oil Pump Assembly (4) Thrust Washer (5) Mechanical Lock Hub (6) Lock-up Sleeve
(7) (8) (9) (10) (11) (12)
Lock-up Fork Chain Lower Driven Sprocket Front Tone Wheel Drive Sprocket Sprocket Spacer
Disassembly
1. Remove the sprocket spacer. 2. Remove the front tone wheel.

3. Remove the drive sprocket, lower driven sprocket, and chain together from the front and rear output shafts.
266RW010
4. Remove the mechanical lock hub. 5. Remove the lock-up fork. 6. Remove the spring retainers from the connection between the rail shaft and lock-up fork. 7. Remove the lock-up sleeve.
261RW018
8. Remove the thrust washer. 9. Remove the magnet from the strainer set position together with the oil pump assembly. 10. Remove the strainer from the oil pump assembly. 11. Remove the hose from the oil pump assembly.
Output Shafts and Shift Control Shaft

Disassembled View
261RW0101
Legend (1) Transfer Case Assembly (2) Detent Spring (3) Front Output Shaft (4) Reduction Hub (5) Output Shaft (6) Reduction Fork Assembly (7) Lock-up shaft (8) Spring Pin (9) Reduction Fork
(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)
Cam Assembly Snap Ring Washer Cam Cam Pilot Block Shifter Shaft Assembly Shifter Lever Shaft Snap Ring Reduction Lever Assembly Snap Ring
Disassembly
1. Remove the output shaft.
6. Remove the spring pin that fixes the reduction fork to the lock-up shaft.
261RW020 266RW011
2. Remove the detent spring. 3. Remove the cam pilot block bolts. 4. Remove the shifter shaft assembly and cam assembly. 5. Remove the reduction fork assembly together with the reduction hub.
7. Remove the reduction fork. 8. Remove the lock-up shaft. 9. Using snap ring pliers, remove the snap ring from the cam pilot block.
261RW029
261RW019
10. Remove the washer. 11. Remove the cam. 12. Remove the cam pilot block.

13. Using snap ring pliers, remove the snap ring from the shifter shaft assembly.
261RW021
14. Remove the reduction lever assembly. 15. Remove the snap ring. 16. Remove the shifter lever shaft. 17. Remove the front output shaft.
266RW012
18. Remove the transfer case assembly.
Transfer Case
Disassembled View
265RW015
Legend (1) Transfer Case (2) Ball Bearing (3) Ring Gear (4) Snap Ring (5) Input Shaft and Carrier Assembly (6) Snap Ring
(7) (8) (9) (10) (11) (12) (13)
Ball Bearing Snap Ring Thrust Plate Carrier Assembly Snap Ring Circular Hub Input Shaft
Disassembly
1. Remove ball bearing (for front output shaft). 2. Expand the snap ring through the opening in the planetary gear assembly.
4. Remove the snap ring from the transfer case.
261RW036
5. Using snap ring pliers, remove the snap ring before the ball bearing.
265RY00002
3. While expanding the snap ring, remove the input shaft, ball bearing, carrier assembly, and thrust plate from the transfer case.
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6. Using the bearing remover J-22912-01, remove the ball bearing from the input shaft. 10. Remove the circular hub. 11. Remove the snap ring before the ring gear.
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7. Remove the thrust plate. 8. Remove the carrier assembly. 9. Remove the snap ring from the carrier assembly.
12. Using the special tool J-42806, remove the ring gear. NOTE: Removing the ring gear needs a high-load press. This means the transfer case may be damaged. To remove and replace the ring gear, it is recommended that the transfer case assembly should be replaced.
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Thickness of Reduction Hub D Measure the thickness with a micrometer. D If the measurement exceeds the limit, replace the reduction hub. Standard : 3.05-3.30 mm (0.120-0.130 in) Allowable limit : 2.5 mm (0.098 in)
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When wear, damage, or any other defects are observed during the inspection, the part or parts must be repaired or replaced. Wash all the parts with clean solvent, and check that old oil, metallic particles, dirt, or foreign materials are completely removed. Blow the air into oil holes and grooves to remove foreign materials or residual solvent.
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Lock-up Sleeve Mount the lock-up hub, drive sprocket assembly, and lock-up sleeve to the output shaft. If the lock-up sleeve does not move smoothly, replace the sleeve. NOTE: Apply ATF to the area engaging the gear. Thickness of Lock-up Sleeve D If the measurement exceeds the limit, replace the lock-up sleeve. Standard : 7.16-7.32 mm (0.282-0.288 in) Allowable limit : 7.9 mm (0.311 in)
Chain
D Check whether the face that contacts the sprocket is free from excessive wear or damage. If defects are observed, replace the part. D If the chain interference mark is found on the inside wall of the transfer cover or the chain is so slack that a skipped engagement occurs between the chain and sprocket, replace the chain.
Sprocket
D Check whether the sprocket tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline. Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part. D If excessive wear or damage is observed on the sprocket inside sliding surface, replace the part.
Gear
Check whether the gear tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline. Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part.
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Reduction Fork Check the reduction fork and shaft for wear, distortion, and scratches. If defects are observed, replace the parts. Thickness of Reduction Fork D If the measurement exceeds the limit, replace the reduction fork. Standard : 3.41-3.79 mm (0.134-0.149 in) Allowable limit : 4.4 mm (0.173 in)
Bearing
Check the profile of the needle, roller, ball, and thrust bearings. Wash the bearings with clean solvent completely, and dry with air. NOTE: If the bearing is rotated excessively, the rollers may be damaged. So, rotate the bearing slowly with your hand. Apply grease to the bearing, and check the smoothness of the bearing while slowly rotating the race with your hand. Allowable limit : 0.23 mm (0.009 in)
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Lock-up Fork D Check the lock-up fork and shaft for wear, distortion, and scratches. If defects are observed, replace the parts. Thickness Lock-up Fork If the measurement exceeds the limit, replace the lock-up fork. Standard : 6.99-7.09 mm (0.275-0.279 in) Allowable limit : 6.3 mm (0.248 in)
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Lock-up Fork Spring Check the lock-up fork spring for distortion, cracking, and wear. If defects are observed, replace the part. Free Length of the Lock-up Fork Spring D If the measurement exceeds the limit, replace the spring. Standard : 60.96 mm (2.40 in) Allowable limit : 55.0 mm (2.17 in)
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Tension of Lock-up Fork Spring D If the measurement exceeds the limit, replace the spring. (When compressed to 41.4 mm) Standard : 27.1-33.8 N {2.76-3.45 kg} Allowable limit : 24.5 N {2.5 kg}
Multi Plate Disk Clutch

D If the burned, mirror-surfaced clutch facing, or scraping is observed on the clutch plates, clutch housing, armature plate, and insulator washer, replace the part or parts.
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Tension of Detent Spring Assembly D If the measurement exceeds the limit, replace the spring. N {kg} (When compressed by 3 mm from the free length) Standard : 139 N -203 {14.2-20.7 kg} Allowable limit : 130 N {13.3 kg}
Coil Assembly
D Check the resistance of the coil with a tester. If defects are observed, replace the assembly. * (ordinary temperature) Standard : 1.42.0 W Allowable limit : 1.05.0 W
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Oil Pump
D Remove foreign materials from the strainer. If the strainer is damaged, replace it. D If the area into which the shaft is inserted is excessively worn or damaged, replace the pump.
Cam Pulley, Cam Ball, and Cam&Coil Housing

D Check the cam balls and cam for excessive wear or damage. If defective, replace the parts.
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Switch Stroke
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4H Switch Signal B to Switch Body
4L Switch Signal A to C
The Parts 4H and 4L Switch

D Check the continuity of 4H and 4L switch. 1 2 3
The correspo nding position of transfer lever High 4L Neutral
Open Open Close
Open Close Close
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Transfer Case
Disassembled View
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Legend (1) Transfer Case (2) Ball Bearing (3) Ring Gear (4) Snap Ring (5) Input Shaft and Carrier Assembly (6) Snap Ring
(7) (8) (9) (10) (11) (12) (13)
Ball Bearing Snap Ring Thrust Plate Carrier Assembly Snap Ring Circular Hub Input Shaft
Reassembly
1. Remove the oil seal from the transfer case. 2. Apply engine oil to the circumference of the new oil seal and fill the lip with grease (Besco L2 or equivalent).

3. Using the front output shaft oil seal installer J-42807, install the oil seal to the transfer case. 4. Using the input shaft (main) oil seal installer J-42808, install the oil seal to the transfer case.
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Front Output Shaft Oil Seal

Distance between the transfer case end and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Distance : 0.931.43 mm (0.0370.056 in)
Input Shaft Oil Seal

Distance between the transfer case end and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Distance : 3.253.75 mm (0.130.15 in)
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5. Using the special tool J-42809, press-fit the ring gear. Pay attention to the following points. D Identify the correct direction of gear. D Do not damage the gear. D Do not press-fit the ring gear slantingly. D Press-fit the ring gear to the innermost. D Remove burrs generated by press-fitting. D If the transfer case has serrations, match them with those of the gear and press-fit the gear. 6. Install the snap ring. 7. Install the circular hub. 8. Install the snap ring to the carrier. 9. Mount the carrier assembly to the input shaft. 10. Check the direction of thrust plate and mount it to the input shaft.
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11. Mount the ball bearing to the input shaft so that the snap ring will be installed to the input shaft.
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12. Install the snap ring to the input shaft. 13. Install the snap ring to the transfer case.
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14. Using the snap ring pliers, expand the snap ring through the opening between the ring gear and carrier assembly and securely install the input shaft and carrier assembly.
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15. Install the ball bearing (for front output shaft)
Output Shafts and Shift Control Shaft

Disassembled View
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Legend (1) Transfer Case Assembly (2) Detent Spring (3) Front Output Shaft (4) Reduction Hub (5) Output Shaft (6) Reduction Fork Assembly (7) Lock-up Shaft (8) Spring Pin (9) Reduction Fork
(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)
Cam Assembly Snap Ring Washer Cam Cam Pilot Block Shifter Shaft Assembly Shifter Lever Shaft Snap Ring Reduction Lever Assembly Snap Ring
Reassembly
1. Apply ATF to the inside of the ball bearing for the front output shaft. 2. Mount the front output shaft to the transfer case.
6. Mount the cam to the cam pilot block. 7. Attach the washer to the cam pilot block and fix the washer with the snap ring.
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3. Mount the shifter lever shaft in the transfer case assembly. 4. Install the snap ring to the shifter lever shaft. 5. Mount the reduction lever assembly to the shifter lever shaft and fix the assembly with the snap ring.
8. Mount the reduction fork to the lock-up shaft. 9. Install the spring pin to the reduction fork and lock-up shaft.
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10. Install the reduction fork assembly together with the reduction hub to the transfer case assembly.
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11. Install the cam assembly and tighten the cam pilot block set bolts to the specified torque. Torque : 12 Nm (104 lb in) 12. Tighten the detent spring to the specified torque. Torque : 24 Nm (17 lb ft)
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13. Apply ATF to the needle bearing inside the output shaft assembly. 14. Install the output shaft to the transfer case assembly.
Sprocket and Mechanical Lock

Disassembled View
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Legend (1) Strainer (2) Hose (3) Oil Pump Assembly (4) Thrust Washer (5) Mechanical Lock Hub (6) Lock-up Sleeve
(7) (8) (9) (10) (11) (12)
Lock-up Fork Chain Lower Driven Sprocket Front Tone Wheel Drive Sprocket Sprocket Spacer
Reassembly
1. Connect the hose and strainer to the oil pump assembly. 2. Install the oil pump assembly to the output shaft and set the magnet to the strainer position. 3. Install thrust washer. 4. Install the spring to the lock-up fork. 5. Mount the lock-up sleeve together with the lockup fork to the output shaft and lock-up shaft.

6. Install the spring retainer to the lock-up fork.
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7. Install mechanical lock hub. 8. Apply ATF to the chain. 9. Engage the chain to both sprockets. 10. Install the chain and sprocket assembly to both the output shafts.
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11. Install the front tone wheel and sprocket spacer.
Clutch Pack and Clutch Cam

Disassembled View
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Legend (1) Clutch Pack Assembly (2) Insulator Washer (3) Armature Plate (4) Snap Ring
(5) (6) (7) (8) (9)
Wave Spring Cam Pulley Cam Ball Cam and Coil Housing Thrust Bearing
Reassembly
1. Mount the clutch pack assembly to which the multi plate disk clutch is already installed to the output shaft. NOTE: Mount the clutch pack assembly while adjusting the phase of both the clutch housing and drive sprocket. 2. Install the insulator washer. 3. Install the armature plate. 4. Using snap ring pliers, attach the snap ring.
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5. Install the wave spring. 6. Install the cam pulley. 7. Place a ball on each groove of the cam pulley.
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8. Install the cam and coil housing. 9. Install the thrust bearing.

Leading Particulars
Type 2H TOD 4L Control system Gear ratio Oil quantity, Lit Oil H L Transfer case with low range reduction mechanisn Rear wheel drive Electronically controlled torque split four wheel drive Low-speed mechanical lock-up four wheel drive Floor direct control 1.000 2.480 1.9 ATF DEXRON-IIE or ATF DEXRON-III
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Special Tools
J861411 Flange Holder
J42806 Ring Gear Replacer
J42804 Rear Oil Seal Installer
J42807 Front Out Oil Seal Installer
J39209 Punch
J42808 Input Shaft Oil Seal Installer
J42805 Bearing Remover
J42809 Ring Gear Installer
J261901 Slide Hammer
J2291201 Bearing Remover
SECTION
BRAKE CONTROL SYSTEM
TROOPER
5A1
BRAKES
CONTENTS
Brake Control System . . . . . . . . . . . . . . . . . . . . Antilock Brake System . . . . . . . . . . . . . . . . . . 5A1 5B1 Power-Assisted Brake System . . . . . . . . . . . . Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 5C1 5D1

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . System Components . . . . . . . . . . . . . . . . . . . Electronic Hydraulic Control Unit (EHCU) . ABS Warning Light . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor . . . . . . . . . . . . . . . . . . G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal and Anti-lock Braking . . . . . . . . . . . Brake Pedal Travel . . . . . . . . . . . . . . . . . . . . Acronyms and Abbreviations . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . ABS Service Precautions . . . . . . . . . . . . . . . Computer System Service Precautions . . . General Service Precautions . . . . . . . . . . . . Note on Intermittents . . . . . . . . . . . . . . . . . . . Test Driving ABS Complaint Vehicles . . . . . ABS Warning Light . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . Basic Diagnostic Flow Chart . . . . . . . . . . . . Basic Inspection Procedure . . . . . . . . . . . . . Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . Getting Started . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure . . . . . . . . . . . . . . . . . . . Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EHCU Connector Pin-out Checks . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . Connector List . . . . . . . . . . . . . . . . . . . . . . . . Part Location . . . . . . . . . . . . . . . . . . . . . . . . . Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . Chart A1 ABS Works Frequently But Vehicle Does Not Decelerate . . . . . . . . . . . Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2) . . . . . . . . . . . . . . . . . . . . . . . . Chart A-2 Uneven Braking Occurs While ABS Works . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart A-3, TA-3 The Wheels Are Locked . Chart A-4 Brake Pedal Feed Is Abnormal . Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking Diagnostic Trouble Codes . . . . . . . . . . . . . . . . Diagnosis By ABS Warning Light Illumination Pattern . . . . . . . . . . . . . . . . . . . . . 5A2 5A3 5A3 5A3 5A4 5A4 5A4 5A4 5A4 5A4 5A5 5A5 5A5 5A5 5A5 5A5 5A5 5A6 5A6 5A6 5A7 5A8 5A9 5A9 5A11 5A12 5A13 5A16 5A18 5A19 5A19 5A20 5A20 5A21 5A21 5A22 5A23 5A24 Diagnostic Trouble Codes (DTCs) . . . . . . . Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated. . . . . . . . . . . . . . . . . . Chart B-2 EHCU Abnormality (DTC 14) . . . Chart B-3 Power Voltage Drop (DTC 15) . . Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16) . . . . . . . . . . . . . . . . . Chart B-5 G-Sensor Circuit (DTC 21) . . . . . Chart B-6 Abnormal Transmission Input (DTC 23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-7 Transfer Monitor (DTC 24) . . . . . Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32) . . . . . . . . . . . . . . . . . Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35) . . . . . . . . . . . . . . . . . Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41) . . . . . . . . . . . . . . . . . Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42) . . . . . . . . . . . . . . . . . Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43) . . . . . . . . . . . . . . . . . Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44) . . . . . . . . . . . . . . . . . Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45) . . . . . . . . . . . . . . . . . Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46) . . . . . . . . . . . . . . . . . Chart B-16 FL Speed Sensor Disconnection (DTC 51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-17 FR Speed Sensor Disconnection (DTC 52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-18 RL Speed Sensor Disconnection (DTC 53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-19 RR Speed Sensor Disconnection (DTC 54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-20 FL Speed Sensor Short Circuit (DTC 61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-21 FR Speed Sensor Short Circuit (DTC 62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-22 RL Speed Sensor Short Circuit (DTC 63) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-23 RR Speed Sensor Short Circuit (DTC 64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-24 Sensor Signal Input Abnormality (DTC 65) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Signal Abnormality Criteria using TECH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Inspection Procedure . . . . . . . . . . . . . . . . 5A24 5A27 5A27 5A28 5A28 5A28 5A29 5A30 5A30 5A31 5A31 5A31 5A32 5A32 5A32 5A33 5A33 5A34 5A34 5A35 5A36 5A37 5A38 5A39 5A40 5A40 5A41
5A2

5A41 5A42 5A42 5A43 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2) . . . . . . . . . . . . . . Chart C-2 Transmission Input Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2) . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A43 5A44 5A44 5A46
Chart C-1-1 FL Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-2 FR Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-3 RL Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-4 RR Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
5A3
General Description
The Anti-lock Brake System (ABS) works on all four wheels. A combination of wheel speed sensor and Electronic Hydraulic Control Unit (EHCU) can determine when a wheel is about to stop turning and adjust brake pressure to maintain best braking. This system helps the driver maintain greater control of the vehicle under heavy braking conditions.
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Legend (1) Electronic (2) Hydraulic (3) Electronic Hydraulic Control Unit (EHCU)
(4) (5) (6) (7)
Front Wheel Speed Sensor Rear Wheel Speed Sensor G-Sensor Proportioning and Bypass (P&B) Valve
System Components
Electronic Hydraulic Control Unit (EHCU), four Wheel Speed Sensors, Warning Light, and G-sensor.
Electronic Hydraulic Control Unit (EHCU)

The EHCU consists of ABS control circuits, fault detector, and a fail-safe. It drives the hydraulic unit according to the signal from each sensor, cancelling ABS to return to normal braking when a malfunction has occurred in the ABS. The EHCU has a self-diagnosing function which can indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment front right side. It consists of a Motor, Plunger Pump, Solenoid Valves and Check Valve. On the outside, the relay box containing a motor relay and a valve relay is installed. Solenoid Valves: Reduces or holds the caliper fluid pressure for each front disc brake or both rear disc brakes according to the signal sent from the EHCU. Reservoir: Temporarily holds the brake fluid that returns from the front and rear disc brake caliper so that pressure of front disc brake caliper can be reduced smoothly. Plunger Pump: Feeds the brake fluid held in the reservoir to the master cylinder.
5A4

The G-sensor judges whether the friction coefficient of road surface is low or high, and changes the EHCUs operating system to ensure ABS control.
Motor: Drives the pump according to the signal from EHCU. Check Valve: Controls the brake fluid flow.
ABS Warning Light
Normal and Anti-lock Braking

Under normal driving conditions, the Anti-lock Brake System functions the same as a standard power assisted brake system. However, with the detection of wheel lock-up, a slight bump or kick-back will be felt in the brake pedal. This pedal bump will be followed by a series of short pedal pulsations which occurs in rapid succession. The brake pedal pulsation will continue until there is no longer a need for the anti-lock function or until the vehicle is stopped. A slight ticking or popping noise may be heard during brake applications when the Anti-lock features is being used. When the Anti-lock feature is being used, the brake pedal may rise even as the brakes are being applied. This is also normal. Maintaining a constant force on the pedal will provide the shortest stopping distance.
Brake Pedal Travel

Vehicles equipped with the Anti-lock Brake System may be stopped by applying normal force to the brake pedal. Although there is no need to push the pedal beyond the point where it stops or holds the vehicle, by applying more force the pedal will continue to travel toward the floor. This extra brake pedal travel is normal.
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Vehicles equipped with the Anti-lock Brake System have an amber ABS warning light in the instrument panel. The ABS warning light will illuminate if a malfunction in the Anti-lock Brake System is detected by the Electronic Hydraulic Control Unit (EHCU). In case of an electronic malfunction, the EHCU will turn ON the ABS warning light and disable the Anti-lock braking function. The ABS light will turn ON for approximately three seconds after the ignition switch is to the ON position. If the ABS light stays ON after the ignition switch is the ON position, or comes ON and stays ON while driving, the Anti-lock Brake System should be inspected for a malfunction according to the diagnosis procedure.
Acronyms and Abbreviations

Several acronyms and abbreviations are commonly used throughout this section: ABS Anti-lock Brake System CKT Circuit DLC Data Link Connector EHCU Electronic Hydraulic Control Unit FL Front Left FR Front Right GEN Generator MV Millivolts RL Rear Left RR Rear Right RPS Revolution per Second VDC Volts DC
Wheel Speed Sensor

It consists of a sensor and a rotor. The sensor is attached to the knuckle on the front wheels and to the axle shaft bearing holder on the rear wheels. The rotor is press-fit in the axle shaft. The flux generated from electrodes magnetized by a magnet in the sensor varies due to rotation of the rotor, and the electromagnetic induction generates alternating voltage in the coil. This voltage draws a sine curve with the frequency proportional to rotor speed and it allows detection of wheel speed.
G-Sensor
The G-sensor installed inside the center console detects the vehicle deceleration speed and sends a signal to the EHCU. In 4WD operation, all four wheels may be decelerated in almost the same phase, since all wheels are connected mechanically. This tendency is noticeable particularly on roads with low friction coefficient, and the ABS control is adversely affected.

VAC Volts AC W/L Warning Light WSS Wheel Speed Sensor
5A5
General Diagnosis
General Information
ABS malfunction can be classified into two types, those which can be detected by the ABS warning light and those which can be detected as a vehicle abnormality by the driver. In either case, locate the fault in accordance with the BASIC DIAGNOSTIC FLOWCHART and repair. Please refer to Section 5C for the diagnosis of mechanical troubles such as brake noise, brake judder (brake pedal or vehicle vibration felt when braking), uneven braking, and parking brake trouble.
D If welding work is to be performed on the vehicle using an electric arc welder, the EHCU and valve block connectors should be disconnected before the welding operation begins. D The EHCU and valve block connectors should never be connected or disconnected with the ignition ON . D EHCU of the Anti-lock Brake System are not separately serviceable and must be replaced as assemblies. Do not disassemble any component which is designated as non-serviceable in this Section. D If only rear wheels are rotated using jacks or drum tester, the system will diagnose a speed sensor malfunction and the ABS warning light will illuminate. But actually no trouble exists. After inspection stop the engine once and re-start it, then make sure that the ABS warning light does not illuminate. If the battery has been discharged The engine may stall if the battery has been completely discharged and the engine is started via jumper cables. This is because the Anti-lock Brake System (ABS) requires a large quantity of electricity. In this case, wait until the battery is recharged, or set the ABS to a non-operative state by removing the fuse for the ABS (40A). After the battery has been recharged, stop the engine and install the ABS fuse. Start the engine again, and confirm that the ABS warning light does not light.
ABS Service Precautions

Required Tools and Items: D Box Wrench D Brake Fluid D Special Tool Some diagnosis procedures in this section require the installation of a special tool. J-39200 High Impedance Multimeter When circuit measurements are requested, use a circuit tester with high impedance.
Note on Intermittents
As with virtually any electronic system, it is difficult to identify an intermittent failure. In such a case duplicating the system malfunction during a test drive or a good description of vehicle behavior from the customer may be helpful in locating a most likely failed component or circuit. The symptom diagnosis chart may also be useful in isolating the failure. Most intermittent problems are caused by faulty electrical connections or wiring. When an intermittent failure is encountered, check suspect circuits for: D Suspected harness damage. D Poor mating of connector halves or terminals not fully seated in the connector body (backed out). D Improperly formed or damaged terminals.
Computer System Service Precautions

The Anti-lock Brake System interfaces directly with the Electronic Hydraulic Control Unit (EHCU) which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the EHCU circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools as described in this section. Power should never be removed or applied to any control module with the ignition in the ON position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the OFF position.
Test Driving ABS Complaint Vehicles

In case that there has been an malfunction in the lighting pattern of ABS warning light, the fault can be located in accordance with the DIAGNOSIS BY ABS WARNING LIGHT ILLUMINATION PATTERN . In case of such trouble as can be detected by the driver as a vehicle symptom, however, it is necessary to give a test drive following the test procedure mentioned below, thereby reproducing the symptom for trouble diagnosis on a symptom basis: 1. Start the engine and make sure that the ABS W/L goes OFF. If the W/L remains ON, it means that the Diagnostic Trouble Code (DTC) is stored. Therefore, read the code and locate the fault. 2. Start the vehicle and accelerate to about 30 km/h (19 mph) or more.
General Service Precautions

The following are general precautions which should be observed when servicing and diagnosing the Anti-lock Brake System and/or other vehicle systems. Failure to observe these precautions may result in Anti-lock Brake System damage.
5A6

to the trouble is stored in the EHCU. Only the ordinary brake system is available when the ABS is turned off. When the ABS warning light is actuated, if the starter switch is set ON after setting it OFF once, the EHCU checks up on the entire system and, if there is no abnormality, judges ABS to work currently and the warning light works normally even though the trouble code is stored. NOTE: Illumination of the ABS warning light indicates that anti-lock braking is no longer available. Power assisted braking without anti-lock control is still available.
3. Slowly brake and stop the vehicle completely. 4. Then restart the vehicle and accelerate to about 40 km/h (25 mph) or more. 5. Brake at a time so as to actuate the ABS and stop the vehicle. 6. Be cautious of abnormality during the test. If the W/L is actuated while driving, read the DTC and locate the fault. 7. If the abnormality is not reproduced by the test, make best efforts to reproduce the situation reported by the customer. 8. If the abnormality has been detected, repair in accordance with the SYMPTOM DIAGNOSIS . NOTE: D Be sure to give a test drive on a wide, even road with little traffic. D If an abnormality is detected, be sure to suspend the test and start trouble diagnosis at once.
Normal Operation
ABS Warning Light When the ignition is first moved from OFF to ON , the amber ABS warning light will turn ON . The ABS warning light will turn ON during engine starting and will usually stay ON for approximately three seconds after the ignition switch is returned to the ON position. The warning light should remain OFF at all other times.
ABS Warning Light

When ABS trouble occurs and actuates when possible the ABS warning light, the trouble code corresponding
Basic Diagnostic Flow Chart

Step 1 Action 1. Customer complaint. 2. Questioning to customer. 3. Basic inspection (Refer to Basic inspection procedure) Using TECH 2? 2 3 Make sure of DTC by mode F0 : Diagnostic Trouble Codes. Is EHCU including DTC? 1. Repair of faulty part. 2. Elimination of DTC. 3. Inspection of ABS W/L Illumination pattern with ignition SW ON. 4. Test drive. Dose repeat trouble? 4 Check if the DTC is stored. Is EHCU including DTC? Go to Step 3 Repeat the diagnosis it the symptom or DTC appears again Go to Step 1 Go to Step 5 Go to Step 2 Go to Step 4 Yes No
Go to Step 5 Trouble diagnosis based on symptom (Refer to SYMPTOM DIAGNOSIS) Go to Step 3
Go to Step 3 5 1. Reconnect all components and ensure all component are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Finished
Go to Step 5
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Basic Inspection Procedure 1. Basic Inspection of System Brake

Step 1 Is the fluid level normal? Go to Step 2 2 3 4 5 Does fluid leak? Is the booster functioning normal? Go to Step 4 Is the pad and rotor normal? Go to Step 5 Reconnect all components and ensure all component are properly mounted. Was this step finished? Finished Go to Step 5 Repair. Go to Step 3 Action Yes No Replenish with fluid. Go to Step 2 Go to Step 3 Repair. Go to Step 4 Repair. Go to Step 5
2. Inspection of Front Axle Switch

Step 1 Action Turn the key switch on and shift to 4WD position by pressing the 4WD switch. Does the 4WD light come on? 2 Reconnect all components and ensure all components are properly mounted. Was this step finished? Finished Go to Step 2 Go to Step 2 Yes No
Repair. Go to Step 2
3. Ground Inspection
Step 1 2 Action Are ABSrelated ground points ok? Go to Step 2 Reconnect all components and ensure all components are properly mounted. Was this step finished? Finished Go to Step 2 Yes No Repair. Go to Step 2
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Tech 2 Scan Tool

901RW257
(3) DLC Cable (4) Tech2
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Getting Started
D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (3). 3. Connect the DLC cable to the Tech 2 (4). 4. Make sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC connector.
Operating Procedure
821RW021
6. The vehicle ignition turns on. 7. Power up the Tech 2. 8. Verify the Tech 2 power up display.
060RX065
060RW009
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060RX064
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Data List
Display Battery Voltage Brake Light Switch Front Left Wheel Speed Front Right Wheel Speed R Rear Left L ft Wheel Wh l Speed S d Rear Left Wheel Speed Wheel Sensor Status Gsensor Transfer Monitor(TOD) OffRoad Switch (Transmission Input) Valve Relay ABS State ABS Relay Return Pump Relay Front Left Isolation Valve Front Left Dump Valve Front Right Isolation Valve Front Right Dump Valve Rear Isolation Valve Rear Dump Valve ABS Warning Lamp ON/OFF To be ON usually (while engine stopped) Content Voltage Open/Close MPH(km/h) OK/NG Criteria for Data Between 1016.9V Open(0V) when pedal is released Closed(12V) when pedal is depressed. Start the vehicle and make sure of linear change in each wheel speed. Turn each wheel by hand and make sure that each speed data change. OK/NG Low/High 2 Wheel Drive 4 Wheel Drive Active/Inactive Active/Inactive ON/OFF Active/Inactive Active/Inactive Active/Inactive To be OK usually To be Low usually When 2WD: 2 Wheel Drive When 4WD: 4 Wheel Drive When shift lever position is 1, 2 and R : Active (M/T) When shift lever position is L and R : Active (A/T) To be Active usually To be OFF usually To be Active usually To be Inactive usually To be Inactive usually
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EHCU Connector Pin-out Checks

D Disconnect Electronic Brake Control Module. D Perform checks with high impedance digital multimeter J-39200 or equivalent. No. Circuit to be Tested Ignition Switch Position OFF ON 2 3 4 Stop light switch Ground connection FL speed sensor OFF OFF OFF OFF OFF 5 FR speed sensor OFF OFF OFF 6 RL speed sensor OFF OFF OFF 7 RR speed sensor OFF OFF OFF 8 9 G-sensor Transmission Input ON ON 20DCV Multimeter Scale/Range 20DCV 20DCV 20DCV 200m 2km 200km 200mACV 2km 200km 200mACV 2km 200km 200mACV 2km 200km 200mACV Measure between Pin Number 8 (+), 15 () 8 (+), 15 () 10, 15 12, Ground 15, Ground 20, 21 20, 15 20, 21 4, 5 4, 15 4, 5 22, 23 22, 15 22, 23 2, 3 2, 15 2, 3 26, 8 6 (+), 15 () Nominal Value Note
Ignition enable
0V to 0.1V 11.5V to 14.5V 10.5V to 14.5V Less than 2m 1.3k to 1.9km more than 100km more than 200mV 1.3k to 1.9km more than 100km more than 200mV 1.3k to 1.9km more than 100km more than 200mV 1.3k to 1.9km more than 100km more than 200mV 1k to 2km Less than 6V (shift lever position L, R) 6.6 to 9.0V (other shift position) More than 9.6V (shift lever position 1, 2, R) 6.6 to 9.0V (other shift position) Internal Resistance Insulation Resistance Turn wheel at 1RPS Internal Resistance Insulation Resistance Turn wheel at 1RPS Insulation Resistance Internal Resistance Turn wheel at 1RPS Internal Resistance Insulation Resistance Turn wheel at 1RPS Horizontal vehicle A/T Battery voltage 12V Press brake pedal
M/T Battery voltage 12V
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Circuit Diagram
D08RW033
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D08RW034
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D08RW035
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Connector List
D05RW002
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D05RW003
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Part Location
D08RW369
Legend (1) F2 (2) F3 (3) I9 (4) C63 (5) H7, H8, H24, H25 (6) B25 (7) C16 (8) Fuse Box (9) B13 or B14 (10) C13 (11) H10, H11
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
C41 H41, H42 C4 C85 Relay & Fuse Box (X15) H12, H15, H16 C39 M1 M8 H33 I10
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Symptom Diagnosis
The symptoms that cannot be indicated by the warning light can be divided in the following five categories: 1. ABS works frequently but vehicle does not decelerate. 2. Uneven braking occurs while ABS works. 3. The wheels lock during braking. No No. 1 2 3 4 5 Symptom Sym tom
4. Brake pedal feel is abnormal. 5. Braking sound (from EHCU) is heard while not braking. These are all attributable to problems which cannot be detected by EHCU self-diagnosis. Use the customer complaint and a test to determine which symptom is present. Then follow the appropriate flow chart listed below. Diagnostic Flow Charts Without TECH 2 Chart A1 Chart A2 Chart A3 Chart A4 Chart A5 With TECH 2 Chart TA1 Chart TA3 Chart TA5
ABS works frequently but vehicle does not decelerate. Uneven braking occurs while ABS works. The wheels are locked. Brake pedal feel is abnormal. Braking sound (from EHCU) is heard while not braking.
Chart A1 ABS Works Frequently But Vehicle Does Not Decelerate

Step 1 Action 1. Turn key off. 2. G Sensor connector and EHCU connector disconnected. Is there continuity between EHCU terminals 26 and 8? 2 3 Connect EHCU connector. Is there continuity between the G sensor and the EHCU? Is the G sensor normal? (Refer to chart B-5) Go to Step 4 4 Is braking force distribution normal between the front and rear of the vehicle? Go to Step 5 5 6 Are axle parts installed normally? Is there play in each wheel speed sensor? Go to Step 6 Repair wheel speed sensor. Go to Step 11 Replace sensor or sensor ring. Go to Step 11 Go to Step 3 Go to Step 2 Go to Step 3 Repair circuit. Go to Step 1 Replace G sensor. Go to Step 11 Repair brake parts. Go to Step 11 Repair axle parts. Go to Step 11 Yes No
Go to Step 7
Is there damage, or powered iron sticking to each wheel speed sensor/sensor ring? Is the output of each wheel speed sensor normal? (Refer to chart C-1 or TC-1)
Go to Step 8 Replace wheel speed sensor or repair harness. Go to Step 11 Replace switch or repair harness. Go to Step 11
Go to Step 9 9 Is the input of transmission normal? (Refer to chart C-2 or TC-2) Go to Step 10
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Step 10

Action Is the input of 4WD controller normal? Yes No Replace controller or repair harness. Go to Step 11
Go to Step 11 11 Reconnect all components and ensure all components are properly mounted. Was this step finished? Repeat the Basic diagnostic flow chart.
Go to Step 11
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step 1 Action 1. Connect TECH 2. 2. Make sure of the output conditions of each wheel speed sensor by mode F1: Data Display. Is the output of each sensor normal? 2 3 Return to Chart A-1. Was the Chart A-1 finished? Reconnect all components, ensure all components are properly mounted. Was this step finished? Go to Step 3 Repeat the Basic diagnostic flow chart. Go to Step 2 Go to Step 2 Yes No Replace wheel speed sensor. Go to Step 3
Go to Step 3
Chart A-2 Uneven Braking Occurs While ABS Works

Step 1 2 3 Action Is there play in each sensor? Is there damage or powdered iron sticking to each sensor/sensor ring? Is the output of each sensor normal? (Refer to chart C-1 or TC-1) Go to Step 4 4 Is brake pipe connecting order correct? Replace EHCU. Go to Step 5 5 Reconnect all components, ensure all components are properly mounted. Was this step finished? Repeat the Basic diagnostic flow chart. Yes Repair. Go to Step 5 Repair. Go to Step 5 No Go to Step 2 Go to Step 3 Replace sensor or repair harness. Go to Step 5 Reconnect brake pipe correctly. Go to Step 5
Go to Step 5
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Chart A-3, TA-3 The Wheels Are Locked

Step 1 2 3 Is ABS working? Is vehicle speed under 10 km/h (6mph)? Is sensor output normal? (Chart C-1 or TC-1) Go to Step 4 4 Is transmission input normal? (Chart C-2 or TC-2) Go to Step 5 5 Is front 4WD controller normal? Replace EHCU. Go to Step 9 6 Is transmission input normal? (Chart C-2 or TC-2) Go to Step 7 7 Is front 4WD controller normal? Action Yes Go to Step 2 Normal. No Go to Step 6 Go to Step 3 Replace sensor or repair harness. Go to Step 9 Replace SW or repair harness. Go to Step 9 Replace 4WD controller or repair harness. Go to Step 9 Replace SW or repair harness Go to Step 9 Replace 4WD controller or repair harness. Go to Step 9 Correct. Go to Step 9
Go to Step 8 8 9 Is hydraulic unit grounded properly? Reconnect all components, ensure all components are properly mounted. Was this step finished? Replace EHCU. Go to Step 9 Repeat the Basic diagnostic flow chart.
Go to Step 9
Chart A-4 Brake Pedal Feed Is Abnormal

Step 1 2 Action Is the stop light actuated when the brake pedal is depressed? 1. Turn the ignition switch off. 2. Disconnected EHCU connector. 3. Measure voltage between the EHCU connector terminal 10 and 15 when brake pedal is depressed. Is the voltage equal to the battery voltage? 3 Is stop light fuse C-14 normal? Go to Step 5 4 Is there continuity between EHCU connector terminals, 12 and 15 to body ground? Go to Step 6 5 Is the brake SW normal? Repair stop light harness. Go to Step 7 Go to Step 4 Yes Go to Step 2 No Go to Step 3 Harness NG between brake SW and EHCU. Go to Step 7 Replace fuse C-14. Go to Step 7 Repair body grounded harness. Go to Step 7 Replace brake SW. Go to Step 7
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Step 6

Action Is the check harness/connector for suspended disconnection? Yes Hydraulic system leakage or air entry (Refer to servicing Leakage or brake fluid ) Go to Step 7 Repeat the Basic diagnostic flow chart. No
Repair harness. Go to Step 7
Reconnect all components and ensure all components are properly mounted. Was this step finished?
Go to Step 7
Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
Step 1 Action Is this the first time the vehicle is being driven after starting the engine? Is vehicle speed under 10 km/h (6 mph)? Yes It is self checking sound. Normal. It is self checking sound. Normal. No
Go to Step 2
Go to Step 3
Check for the following condition: D At the time of shift down or clutch operation. D At the time of low m drive (ice or snow road) or rough road drive. D At the time of high-speed turn. D At the time of passing curb. D At the time of operating electrical equipment switches. D At the time of racing the engine (over 5000 rpm). Did it occur under any one condition above? Is there play in each sensor/wheel speed sensor rings?
ABS may sometime be actuated even when brake pedal is not applied. Go to Step 5
Go to Step 4 Repair. Go to Step 7 Repair. Go to Step 7
4 5 6
Damage or powdered iron sticking to each sensor/wheel speed sensor ring? Is each sensor output normal?(Refer to chart C-1 or TC-1).
Go to Step 6 Check harness/ connector for suspected disconnection. If no disconnection is found, replace EHCU. Go to Step 7 Repeat the Basic diagnostic flow chart.
Repair. Go to Step 7
Reconnect all components, ensure all components are properly mounted. Was this step finished?
Go to Step 7
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Choose and trace an appropriate flowchart by the numbers listed below to find fault and repair. Code 12 14 15 16 21 23 24 32 35 41 42 43 44 45 46 51 52 53 54 61 62 63 64 65 Start Code EHCU Function Power Voltage Drop CLASS2 Communication Line Abnormality G-sensor Transmission Input Transfer Monitor Motor & Motor Relay Valve Relay FL Holding Solenoid Valve FL Decompression Solenoid Valve FR Holding Solenoid Valve FR Decompression Solenoid Valve Rear Holding Solenoid Valve Rear Decompression Solenoid Valve FL Wheel Speed Sensor FR Wheel Speed Sensor RL Wheel Speed Sensor RR Wheel Speed Sensor FL Wheel Speed Sensor FR Wheel Speed Sensor RL Wheel Speed Sensor RR Wheel Speed Sensor Sensor Signal Input Shorted or disconnected coil Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Disconnected coil/wiring Disconnected coil/wiring Disconnected coil/wiring Disconnected coil/wiring Shorted coil/wiring Shorted coil/wiring Shorted coil/wiring Shorted coil/wiring Wrong number of teeth Wiring disconnection Input abnormality Item Normal Abnormality in input/output, operational and control circuits Diagnosis Chart No. B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9 B-10 B-11 B-12 B-13 B-14 B-15 B-16 B-17 B-18 B-19 B-20 B-21 B-22 B-23 B-24
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or if the warning light is actuated during driving, trouble should be diagnosed on a illumination pattern basis as follows:
Diagnosis By ABS Warning Light Illumination Pattern

In the event that there is abnormality in the ABS warning light illumination pattern while the key is in the ON position No. 1 Condition Warning light is actuated normally
ABS Warning Light Illumination Pattern Normal
Diagnostic
Warning light is not lit
Warning light lighting circuit troubleGo to Chart B-1
Warning light remains ON
Diagnostic trouble codes are stored. Display diagnostic trouble codes and diagnose on a code basis according to the flow charts.
Warning light is actuated while driving
Diagnostic trouble codes are stored. Display diagnostic trouble codes and diagnose on a code basis according to the flow charts.
Diagnostic Trouble Codes (DTCs)

When the warning light in the meter remains ON, the EHCU stores the fault identification and disables the ABS. 1. How to display and erase DTCs: NOTE: D If DTCs are not displayed, harness C-4 connector terminal 30 and I-10 connector terminal 2 may be disconnected. Repair the harness and try DTC display again.
D DTCs can be displayed also by TECH 2. Select mode F0: Diagnostic Trouble Codes from Application Menu. 1. How to start DTC display: D Confirm that the vehicle has come to a complete stop (with the wheels standing still) and that the brake pedal is not depressed. (Unless these two conditions are satisfied, DTC display cannot be started.) D With IGN OFF, connect #12 terminal with #4 terminal or # 5 terminal (GND) . Then turn IGN ON.

The DLC is located behind the driver side kick panel
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350RT001
D Keep #12 terminal connected with #4 terminal or # 5 terminal (GND) during DTC display. (If #12 terminal is separated from #4 terminal or # 5 terminal (GND) during display, display will stop.) 2. DTC display: D DTC is displayed by blinking warning light. D Double-digit display. D First, normal DTC 12 is displayed three times and then any other DTCs are displayed three times. (If no other DTCs have been stored, the display of DTC 12 will be repeated.) 3. How to erase code: D Conduct brake switch ON/OFF operation 6 or more times within 3 seconds of self-diagnosis startup. D The code cannot be erased if more than 3 seconds have passed since self-diagnosis startup, or if self-diagnosis has started with brake switched on (brake pedal depressed).
B05RW005
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4. Notes D If the following should occurs during Diagnostic Trouble Code (DTC) display the display will be discontinued. After initial check, the status that is under the control of ABS will be returned : The vehicle starts (The wheels turn) or the brake pedal is depressed. D Up to 3 different codes can be stored. D If the ABS should turn OFF due to an intermittent defect, the system will be restored at the next key cycle, if the initial check finds no abnormality (when IGN is switched from OFF to ON). 5. An example of DTC display Display of DTC 23
B05RW006
After displaying DTC 12 three times, one DTC after another is displayed, starting with the most recent one. (However, display is discontinued after about 5 minutes.)
B05RS005
The DTC 12 is displayed repeatedly. (display is discontinued after about 5 minutes)
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Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.
Step 1 2 Action Is W/L fuse C-10 disconnected? Is W/L burnt out? Yes Replace fuse. Go to Step 5 Replace W/L bulb. Go to Step 5 No Go to Step 2
Go to Step 3
1. 2. 3. 4.
Turn the key off. Disconnect EHCU connector. Turn the key ON. Measure the voltage between EHCU connector terminal 16 and 15. Go to Step 4 Check harness for suspected disconnection. No fault found: Replace EHCU. Go to Step 5 Repeat the Basic diagnostic flow chart.
Is the voltage equal to the battery voltage? 4 Is there continuity between EHCU connector terminals, 12 and 15 and body ground.
Repair harness and connector. Go to Step 5
Repair harness and connector. Go to Step 5
Reconnect all components, ensure all components are properly mounted. Was this step finished?
Go to Step 5
Chart B-2 EHCU Abnormality (DTC 14)

Step 1 Action 1. Turn the key off. 2. Disconnect the EHCU connector. 3. Inspect EHCU ground. Is there resistance between the EHCU connector terminals, 12 and 15 and body ground? 2 1. 2. 3. 4. Turn the key off, connect the EHCU. Erase the trouble code. Turn Ignition off, then on, to perform system self-check. If warning light remains on, display trouble codes once again. Go to Step 2 Yes No
Repair the body ground harness. Go to Step 3 Inspect in accordance with the DTC displayed.
Is the check trouble code 14? 3 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?
Replace EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart.
Go to Step 3
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Chart B-3 Power Voltage Drop (DTC 15)

Step 1 Action Is the battery voltage normal? (Battery capacity check) Go to Step 2 2 1. Turn the key off. 2. Disconnect EHCU connector. 3. Turn the key on. Is the voltage between EHCU connector terminals 8 and 15, higher than 10V? Check harness connector for suspected disconnection. Fault found: Repair, and perform system self-check. No fault found: replace EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart. Yes No Charge or replace battery. Go to Step 2
Repair harness or connector. Go to Step 3
1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?
Go to Step 3
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU and PCM connector. Is there continuity between EHCU connector terminals 25 and ground? 2 1. Connect EHCU connector. 2. Clear diagnostic trouble code. 3. Turn the key on. Is the diagnostic trouble code 16 shown on the displayed? 3 1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Go to Step 2 Check the PCM harness. Refer to 6E section. Go to Step 3 Repeat the Basic diagnostic flow chart. Yes No Repair harness or connector. Go to Step 3
Replace EHCU. Go to Step 3
Go to Step 3
Chart B-5 G-Sensor Circuit (DTC 21)

Step 1 Vehicle placed horizontal. Is the resistance between the G sensor connector terminals 1 and 2 within 4.0-6.0 kW? Action Yes Check harness connector for short. Fault found : Repair , and perform system self-check. No fault found : replace EHCU. Go to Step 3 No
Go to Step 2 Repair or replace bracket. Go to Step 4
Is the bracket installed horizontally? Go to Step 4

Step 3 Remove G sensor. Is the resistance between the G sensor connector terminals 1 and 2 within 1.0-2.0 kW when G sensor is horizontal? 4 Measure resistance between G sensor connector terminals 1 and 2 within 4.0-6.0 kW when G sensor tilted to 30 or more? Go to Step 4 Harness between EHCU and G sensor is faulty and short. Repair the harness Go to Step 5 Repeat the Basic diagnostic flow chart. Action Yes No
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Replace G sensor. Go to Step 5
Replace G sensor. Go to Step 5
1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?
Go to Step 5
Chart B-6 Abnormal Transmission Input (DTC 23)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. Is there continuity between EHCU connector terminal 6 to 15 (Gear position-P(A/T), N(M/T))? 2 3 Is the vehicle an A/T model? Turn the key on and measure the voltage between EHCU connector terminal 6 and 15. Is the 6V under when the gear position is L, and R(Battery voltage 12V)? Yes Shorted switch harness. Repair switch or harness. Go to Step 6 Go to Step 3 No
Go to Step 2 Go to Step 4 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6
Go to Step 5 4 Turn the key on and measure the voltage between EHCU connector terminal 6 and 15. Is the 9.6V over when the gear position is 1, 2, R(Battery voltage 12V)?
Go to Step 5
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Step 5

Action Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or 2,3,D,N and P(A/T)(Battery voltage 12V)? Yes Suspected harness/ connector short power source/GND. Suspected shorted transmission SW. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat the Basic diagnostic flow chart. No
Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6
Go to Step 6
Chart B-7 Transfer Monitor (DTC 24)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. Is the EHCU connector terminal 9 line normally? 2 Is the TOD ECU or 4WD controler normal? Replace EHCU. Go to Step 3 3 1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat the Basic diagnostic flow chart. Go to Step 2 Yes No Repair Go to Step 3 Repair or replace TOD ECU or 4WD contrder. Go to Step 3
Go to Step 3
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)
Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure voltage between EHCU connector terminal 13 and body ground. Is the voltage equal to battery voltage? Go to Step 2 2 Is there continuity between EHCU connector terminal 12 and ground? Yes No Repair fuse/harness between battery and EHCU connector terminal 13. Go to Step 3 Repair between EHCU connector terminal 12 and ground. Go to Step 3
Go to Step 3 3 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat the Basic diagnostic flow chart.
Go to Step 3
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Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)
Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure voltage between EHCU connector terminal 14 and body ground. Is the voltage equal to battery voltage? 2 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Replace EHCU. Go to Step 2 Repeat the Basic diagnostic flow chart. Yes No Repair fuse and harness EHCU connector terminal 14 and battery. Go to Step 2
Go to Step 2
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)

Step 1 Action Was the EHCU Connector Pinout Checks perfomed? Go to Step 2 2 Is the EHCU connector free from damage or corrosion? Yes No Go to EHCU Connector Pin-out Checks. Repair the connector. Repeat the Basic Diagnostic Flow Chart.
Go to Step 3 3 1. Replace the EHCU. 2. Reconnect all component, ensure all component are properly mounted. Was this step finished? Repeat the Basic Diagnostic Flow Chart.
Go to Step 3
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)

Go to Step 3
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Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)

Go to Step 3
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)

Go to Step 3
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)

Go to Step 3
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Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)

Go to Step 3
Chart B-16 FL Speed Sensor Disconnection (DTC 51)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the resistance between EHCU connector terminals 20 and 21. Is the resistance between 1.3k and 1.9k ohms? Yes Check for faults in harness between speed sensor and EHCU. Fault found: Repair, and perform system self-check. No fault found: Replace EHCU. Go to Step 3 Repair harness abnormality between sensors and EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart. No
Go to Step 2
Measure the FL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms?
Replace sensor. Go to Step 3
Go to Step 3
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Chart B-17 FR Speed Sensor Disconnection (DTC 52)

Go to Step 2
Measure the FR speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms?
Go to Step 3
Chart B-18 RL Speed Sensor Disconnection (DTC 53)

Go to Step 2
Measure the RL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms?
Go to Step 3
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Chart B-19 RR Speed Sensor Disconnection (DTC 54)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the resistance between EHCU connector terminals 2 and 3. Is the resistance between 1.3K and 1.9k ohms? Yes Check for faults in harness between speed sensor and EHCU. Fault found: Repair, and perform system self-check. No fault found: Replace EHCU. Go to Step 3. Repair harness abnormality between sensors and EHUC. Go to Step 3 Repeat the Basic diagnostic flow chart. No
Go to Step 2
Measure the RR speed sensor resistance at the sensor connector. Is the sensor resistance between 1.3k and 1.9k ohms?
Go to Step 3
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Chart B-20 FL Speed Sensor Short Circuit (DTC 61)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector 3. Measure the FL speed sensor resistance between EHCU connector terminals 20 and 21. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the FL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2) Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat the Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No
Replace sensor. Go to Step 6 Repair. Go to Step 6
Damage and powdered iron sticking to sensor/sensor ring?
Go to Step 6
NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h or higher to make sure that the warning light goes out.
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Chart B-21 FR Speed Sensor Short Circuit (DTC 62)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the FR speed sensor resistance between EHCU connector terminals 4 and 5. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the FR speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2) Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No
Go to Step 6
5A38
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector 3. Measure the RL speed sensor resistance between EHCU connector terminals 22 and 23. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the RL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2)? Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat the Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No
Go to Step 6
5A39
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the RR speed sensor resistance between EHCU connector terminals 2 and 3. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the RR speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2) Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No
Go to Step 6
5A40
Chart B-24 Sensor Signal Input Abnormality (DTC 65)

Step 1 2 Using TECH 2? 1. Connect TECH 2. 2. Select Snap shot manual trigger. 3. With wheel speed data displayed, run the vehicle when speed has arrived at 30 km/h (18 mph). 4. Check speed data on each wheel (refer to the criterion given below). *1 Is the abnormal sensor condition found? 3 4 5 Is there play in sensor/sensor ring? Is there powdered iron sticking to sensor/sensor ring? Is there a broken tooth or indentation in sensor ring? Action Yes Go to Step 2 No Go to Step 3 Go to Step 3 All the sensors should follow the following flowchart (without using TECH 2). Go to Step 4 Go to Step 5
Replace. Go to Step 8 Repair. Go to Step 8 Repair. Go to Step 8 Replace sensor ring. Go to Step 8 Adjust or repair. Go to Step 8
Go to Step 6 Go to Step 7 Repair, and perform system self-check. Go to Step 8
6 7
Is there play in wheel bearing? Is the check wiring between sensor and EHCU normal?
Replace EHCU. Go to Step 8 8 1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat Basic diagnostic flow chart.
Go to Step 8
Sensor Signal Abnormality Criteria using TECH 2

1. While driving, the speed of one or two wheels 25% or more higher than that of the other wheels. 2. The speed of one or two wheels is 10 km/h (6 mph) or more higher than that of the other wheels. 3. During steady driving, wheel speed changes abruptly. *1 The vehicle must run on a level paved road. NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h or higher to make sure that the warning light goes out. It is important to verify that the correct tires are installed on vehicle.
5A41
Unit Inspection Procedure

This section describes the following inspection procedures referred to during SYMPTOM DIAGNOSIS and
DIAGNOSIS BY ABS WARNING LIGHT ILLUMINATION PATTERN :
without TECH 2 Wheel Speed Sensor Output Inspection Transmission SW Inspection Chart C-1-1 to C-1-4 Chart C-2
with TECH 2 Chart TC-1 Chart TC-2
Chart C-1-1 FL Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle, With all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning FL wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 20 and 21 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (C-13) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit in harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No
Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3
Go to Step 3
5A42
Chart C-1-2 FR Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning FR wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 4 and 5 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (C-41) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No
Go to Step 3
Chart C-1-3 RL Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning RL wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 22 and 23 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (F-3) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No
Go to Step 3
5A43
Chart C-1-4 RR Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning RR wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 2 and 3 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (F-2) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No
Go to Step 3
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

Step 1 Action 1. Connect TECH 2. 2. While driving the vehicle, check the wheel speed of each sensor by Data List. Is the vehicle speed value is normal? 2 Check the sensor harness for suspected disconnection (Check while shaking harness/connector). Is the sensor harness connection normal? 3 While driving the vehicle, check the wheel speed of each sensor by Data List. Is the vehicle speed value is normal? 4 Check sensor roter. Is the sensor roter normal? 5 While driving the vehicle, check the wheel speed of each sensor by Data List. Is the vehicle speed value is normal? Go to Step 6 6 Reconnect all components, ensure all components are properly mounted. Was this step finished? Repeat the Basic diagnostic flow chart. Go to Step 6 Go to Step 6 Go to Step 4 Replace sensor roter. Go to Step 5 Repair harness or connector between EHCU and speed sensor. Go to Step 6 Go to Step 6 Replace speed sensor. Go to Step 3 Go to Step 2 Repair. Go to Step 6 Yes No
Go to Step 6
5A44
Chart C-2 Transmission Input Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. Is there continuity between EHCU connector terminals 6 and 15 (Gear position-P(A/T), N(M/T))? 2 3 Is the vehicle an A/T model? Turn the key on and measure voltage between EHCU connector terminals 6 and 15. Is there less than 6V when the gear position is L, and R(Battery voltage 12V)? Yes Shorted switch harness. Repair switch or harness. Go to Step 6 Go to Step 3 No
Go to Step 2 Go to Step 4 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6
Go to Step 5 4 Turn the key on and measure the voltage between EHCU connector terminal 6 and 15. Is there more than 9.6V when the gear position is 1, 2, R(Battery voltage 12V)?
Go to Step 5 5 Measure the voltage between EHCU connector terminals 6 and 15. Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or 2,3,D,N and P(A/T)(Battery voltage 12V)?
Go to Step 6 6 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat the Basic diagnostic flow chart.
Go to Step 6
5A45
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)

Step 1 1. Connect TECH 2. 2. Select Data List. Is this vehicle an A/T model ? 2 3 4 5 6 Is OffRoad Switch(Transmission Input): Active when the shift lever is the L and R? Is OffRoad Switch(Transmission Input): Inactive when the shift lever is other than the L and R? Is OffRoad Switch(Transmission Input): Active when the shift lever is in 1, 2 and R? Is OffRoad Switch(Transmission Input): Inactive when the shift lever is other than the 1, 2 and R? 1. Abnormal T/M SW, inhibitor SW, or harness. 2. Repair T/M SW, inhibitor SW, or harness. Is the T/M SW, inhibitor SW, or harness repaired? 7 Reconnect all components, ensure all components are properly mounted. Was this step finished? Go to Step 7 Repeat the Basic diagnostic flow chart. Go to Step 6 Go to Step 2 Go to Step 3 Go to Step 7 Go to Step 5 Go to Step 7 Go to Step 4 Go to Step 6 Go to Step 6 Go to Step 6 Go to Step 6 Action Yes No
Go to Step 7
5A46
Special Tools
J35616 Connector test adapter kit
J39200 High impedance multimeter
7000086ISU Tech 2 Set (1) PCMCIA Card (2) SAE 16/19 Adapter (3) DLC Cable (4) Tech 2
SECTION
ANTILOCK BRAKE SYSTEM
TROOPER
5B1
BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Electronic Hydraulic Control Unit . . . . . . . . . . Electronic Hydraulic Control Unit and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Speed Sensor . . . . . . . . . . . . . . . 5B1 5B2 5B2 5B2 5B2 5B3 5B3 5B3 5B3 5B4 Front Wheel Speed Sensor and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Speed Sensor . . . . . . . . . . . . . . . Rear Wheel Speed Sensor and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B4 5B4 5B5 5B5 5B6 5B6 5B6 5B6 5B6
Service Precaution
5B2
Electronic Hydraulic Control Unit

Electronic Hydraulic Control Unit and Associated Parts
350RW013
Legend (1) Connector (2) Hydraulic Unit ASM
(3) Bolts (4) Nut (5) Bolt
Removal
1. Remove battery ASM. 2. Remove harness connector. 3. Remove EHCU fixing nuts. 4. Remove brake pipes. D After disconnecting brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 5. Remove hydraulic unit fixing nuts.
Installation
To install, follow the removal steps in the reverse order, noting the following points: Torque Hydraulic unit fixing nuts : 22 Nm (16 lb ft) Ground cable : 14 Nm (10 lb ft) Brake pipe (joint bolts) : 16 Nm (12 lb ft) D After installing the hydraulic unit, bleed brakes completely. See Section 5A Hydraulic Brakes.
5B3
G-Sensor
Removal Installation
1. Install G-sensor assembly (3). D Care should be taken so that the G-sensor is not installed in the wrong direction. 2. Install G-sensor assembly fixing bolt (2). D Tighten the fixing bolt to the specified torque. Torque : 10 Nm (87 lb in) 3. Install G-sensor wiring connector (1). 4. Install center console. D Refer to Consoles in Body and Accessories section.
350RX001
1. Remove center console. D Refer to Consoles in Body and Accessories section. 2. Remove clip from G-sensor connector, then disconnect connector. 3. Remove G-sensor assembly fixing bolt (2). 4. Remove G-sensor assembly (3).

Refer to Chart B-5 in this Section.
5B4
Front Wheel Speed Sensor

Front Wheel Speed Sensor and Associated Parts
350RW012
Legend (1) Speed Sensor Connector (2) Sensor Cable Fixing Bolt (Upper side)
(3) Sensor Cable Fixing Bolt (Lower side) (4) Sensor Cable Fixing Bolt (Sensor side) (5) Speed Sensor
Removal
1. Remove speed sensor connector. 2. Remove sensor cable fixing bolt (Upper side). 3. Remove sensor cable fixing bolt (Lower side). 4. Remove the speed sensor cable fixing bolts (1) and caliper fixing bolt (2) from caliper side speed sensor cable bracket (3).
350RW010
5. Remove speed sensor.
5B5

1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage; replace speed sensor if necessary. 3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the sensor ring assembly. Refer to removal of the sensor ring in Section 4C Front hub and disc.
NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 5. Install speed sensor connector.
Installation
1. Install speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install speed sensor fixing bolt and tighten the fixing bolt to the specified torque. Torque Sensor side : 8 Nm (69 lb in) Caliper side : 155 Nm (115 lb ft)
350RW011
Legend (1) Caliper Fixing Bolt (2) Bracket (3) Sensor Fixing Bolt (4) Sensor (5) Knuckle (6) Brake Caliper 3. Install speed sensor cable fixing bolt (Lower side) and tighten the fixing bolt to the specified torque. Torque : 24 Nm (18 lb ft) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque : 6 Nm (52 lb ft)
5B6
Rear Wheel Speed Sensor

Rear Wheel Speed Sensor and Associated Parts
350RW008
Legend (1) Speed Sensor Connector (2) Sensor Cable Fixing Bolt
(3) Clip (11 pieces) (4) Speed Sensor (5) Sensor Fixing Bolt
Removal
1. Remove speed sensor connector. 2. Remove clip. 3. Remove sensor cable fixing bolt. 4. Remove sensor fixing bolt. 5. Remove speed sensor.
2. Check the pole piece for damage, and replace the speed sensor if necessary. 3. Check the speed sensor cable for a short or an open, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping. If damaged replace the axle shaft assembly. Refer to removal of the sensor ring in Section 4B Rear Axle.
Installation
1. Install the speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install the sensor fixing bolt and tighten it to the specified torque. Torque : 18 Nm (13 lb ft) 3. Install the sensor cable fixing bolt and tighten it to the specified torque. Torque : 24 Nm (18 lb ft) NOTE: Confirm that the cable is not twisted when connecting the speed sensor cable. 4. Install clip. 5. Install speed sensor connector.
350RS035

1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc.
SECTION
POWER ASSISTED BRAKE SYSTEM
TROOPER
5C1
BRAKES
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . Filling Master Cylinder Reservoir . . . . . . . . Deterioration of Brake Fluid . . . . . . . . . . . . . Leakage of Brake Fluid . . . . . . . . . . . . . . . . . Bleeding Brake Hydraulic System . . . . . . . . Flushing Brake Hydraulic System . . . . . . . . Brake Pipes and Hoses . . . . . . . . . . . . . . . . Brake Hose Inspection . . . . . . . . . . . . . . . . . Front / Rear Caliper Brake Hose . . . . . . . . . . Front / Rear Caliper Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . P & B (Proportioning and Bypass) Valve . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Pedal Height . . . . . . . . . . . . . . . . . Checking Pedal Travel . . . . . . . . . . . . . . . . . Brake Pedal and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Fluid Reservoir Tank . . . . . . . . . . . . . . . . . . . . . Fluid Reservoir Tank and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder Assembly . . . . . . . . . . . . . . . . 5C2 5C2 5C5 5C6 5C9 5C9 5C9 5C9 5C9 5C10 5C10 5C10 5C11 5C11 5C11 5C11 5C12 5C12 5C12 5C12 5C13 5C13 5C13 5C14 5C14 5C14 5C15 5C16 5C16 5C16 5C17 5C17 5C17 5C18 5C18 5C18 5C19 5C20 5C20 5C20 5C20 5C21 Master Cylinder Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Booster Assembly . . . . . . . . . . . . . . . Vacuum Booster Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior Components . . . . . . . . . . . . . . . . . . . . Exterior Components and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Booster Overhaul . . . . . . . . . . . . . . . . Vacuum Booster . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Pads . . . . . . . . . . . . . . . . . . . Front Disc Brake Pads Inspection . . . . . . . . Front Disc Brake Pads and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Rotor . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Front Disc Brake Caliper Assembly . . . . . . . . Front Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Caliper . . . . . . . . . . . . . . . . . Front Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 5C21 5C21 5C21 5C22 5C23 5C24 5C25 5C25 5C25 5C25 5C26 5C28 5C28 5C28 5C29 5C29 5C29 5C29 5C30 5C31 5C32 5C32 5C32 5C33 5C33 5C35 5C35 5C35 5C35 5C37 5C37 5C37 5C38 5C40 5C40 5C40 5C41 5C41 5C43
5C2

5C44 5C44 5C44 5C45 5C45 5C47 5C47 5C47 5C47 5C48 5C49 Rear Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 5C49 5C49 5C50 5C52 5C52 5C52 5C53 5C53 5C55
Rear Disc Brake Pads . . . . . . . . . . . . . . . . . . . Brake Pads Inspection . . . . . . . . . . . . . . . . . Brake Pads and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Rotor . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Rear Drum (In Disc) Inside Diameter Check Rear Disc Brake Caliper Assembly . . . . . . . .
Service Precaution
General Description
Master Cylinder Assembly
330RW013
The master cylinder contains two pistons that supply the hydraulic pressure for a dualcircuit braking system. The primary piston provides the fluid pressure to the front brakes, while the secondary piston provides the fluid pressure to the rear brakes. If the pressure is lost from either system, the remaining system will function to stop the vehicle.

CAUTION: 1. The master cylinder is not repairable. If found defective, it must be replaced as a complete assembly. 2. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. (Refer to OnVehicle Service in this section.) 3. The torque values specified un-lubricated fasteners. are
5C3
for dry,
4. Perform service operations on a clean bench free from all mineral oil materials.
Brake Booster
331RS001
This booster is a tandem vacuum unit with a diaphragm effective diameter 205mm + 230mm. In normal operating mode, with the service brakes in the released position, the tandem vacuum booster operates with vacuum on both sides of its diaphragms. When the brakes are applied, air at atmospheric pressure is admitted to one side of each diaphragm to provide the power assist. When the service brake is released, the atmospheric air is shut off from the one side of each diaphragm. The air is then drawn from the booster through the vacuum check valve to the vacuum source. CAUTION: 1. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 2. The torque values specified unlubricated fasteners. are for dry,
Disc Brake
The disc brake assembly consists of a caliper, piston, rotor, pad assembly and support bracket. The caliper assembly has a single bore and is mounted to the support bracket with two mounting bolts. The support bracket allows the caliper to move laterally against the rotor. The caliper is a onepiece casting with the inboard side containing the piston bore. A square cut rubber seal is located in a groove in the piston bore which provides the hydraulic seal between the piston and the cylinder wall. NOTE: 1. Replace all components included in repair kits used to service this caliper. 2. Lubricate rubber parts with clean brake fluid to ease assembly. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. Replace pads in axle sets only.
3. The vacuum booster is not repairable and must be replaced as a complete assembly.
5C4

6. Perform the service operation on a clean bench free from all mineral oil materials.
5. The torque values specified are for dry, unlubricated fasteners. Operation Front Disc Brake
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Rear Disc Brake
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Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward resulting in a clamping action on the rotor. This clamping action forces the linings against the rotor, creating friction to stop the vehicle.
5C5
Diagnosis
Road Testing The Brakes
Brake Test Brakes should be tested on a dry, clean, reasonably smooth and level roadway. A true test of brake performance cannot be made if the roadway is wet, greasy or covered with loose dirt so that all tires do not grip the road equally. Testing will also be adversely affected if the roadway is crowned so as to throw the weight of the vehicle toward wheels on one side or if the roadway is so rough that wheels tend to bounce. Test the brakes at different vehicle speeds with both light and heavy pedal pressure; however, avoid locking the wheels and sliding the tires. Locked wheels and sliding tires do not indicate brake efficiency, since heavily braked but turning wheels will stop the vehicle in less distance than locked wheels. More tiretoroad friction is present with a heavily braked turning tire then with a sliding tire. The standard brake system is designed and balanced to avoid locking the wheels except at very high deceleration levels. It is designed this way because the shortest stopping distance and best control is achieved without brake lockup. Because of high deceleration capability, a firmer pedal may be felt at higher deceleration levels. External Conditions That Affect Brake Performance 1. Tires: Tires having unequal contact and grip on the road will cause unequal braking. Tires must be equally inflated, identical in size, and the thread pattern of right and left tires must be approximately equal. 2. Vehicle Loading: A heavily loaded vehicle requires more braking effort.
3. Wheel Alignment: Misalignment of the wheels, particularly in regard to excessive camber and caster, will cause the brakes to pull to one side.
Brake Fluid Leaks

With engine running at idle and the transmission in Neutral, depress the brake pedal and hold a constant foot pressure on the pedal. If pedal gradually falls away with the constant pressure, the hydraulic system may be leaking. Check the master cylinder fluid level. While a slight drop in the reservoir level will result from normal lining wear, an abnormally low level in reservoir indicates a leak in the system. The hydraulic system may be leaking internally as well as externally. Refer to Master Cylinder Inspection. Also, the system may appear to pass this test but still have slight leakage. If fluid level is normal, check the vacuum booster push rod length. If an incorrect length push rod is found, adjust or replace the push rod. Check the brake pedal travel and the parking brake adjustment. When checking the fluid level, the master cylinder fluid level may be low from the MAX mark if the front and rear linings are worn. This is not abnormal.
Warning Light Operation

When the ignition switch is in the START position, the BRAKE warning light should turn on and go off when the ignition switch returns to the ON position. The following conditions will turn on the BRAKE light: 1. Parking brake applied. The light should be on whenever the parking brake is applied and the ignition switch is on. 2. Low fluid level. A low fluid level in the master cylinder will turn the BRAKE light on. 3. During engine cranking the BRAKE light should remain on. This notifies the driver that the warning circuit is operating properly.
5C6
General Diagnosis
Condition Brake Pull Possible cause Tire inflation pressure is unequal. Front wheel alignment is incorrect. Unmatched tires on same axle. Adjust Adjust Tires with approx. the same amount of tread should be used on the same axle. Check for soft hoses and damaged lines. Replace with new hoses and new doublewalled steel brake piping. Clean or replace. Replace Replace Grind or replace. Clean or replace. Adjust or replace. Check all suspension mountings. Check and tighten the bolts to specifications. Check per instructions. If not within specifications, replace or machine the rotor. Check per instructions. If not within specifications, replace or machine the rotor. Adjust wheel bearings to correct specifications Replace the brake pad and machine rotor to within specifications. Check the vacuum booster operation and repair, if necessary. Check the front and rear brake system for failure and repair. Also, check the brake warning light. If a failed system is found, the light should indicate failure. Check and replace pads in sets. Remove caliper and rebuild. Remove and replace with original equipment pad or equivalent. Check for ruptured or loose hose. Correct vacuum hose direction. Replace or clean. Correction
Restricted brake pipes or hoses.
Water or oil on the brake pads. Brake pads hardened. Brake pads worn excessively. Brake rotor worn or scored. Disc brake caliper malfunctioning. Front hub bearing preload incorrect. Loose suspension parts. Loose calipers. Brake Roughness (Pulsates) or Chatter Excessive lateral runout.
Parallelism not within specifications.
Wheel bearings not adjusted. Pad reversed (steel against iron). Excessive Pedal Effort Malfunctioning vacuum booster. Partial system failure.
Excessively worn pad. Piston in caliper stuck or sluggish. Fading brakes due to incorrect pad. Vacuum leak to vacuum booster. Check the direction of check valve within vacuum hose. Grease on the brake pads.

Condition Excessive Brake Pedal Travel Possible cause Air in hydraulic circuit. Level of brake fluid in the reservoir too low. Master cylinder push rod clearance excessive. Leakage in hydraulic system. Brake Drag Master cylinder pistons not returning correctly. Restricted brake pipes or hoses. Correction Bleed the hydraulic circuit.
5C7
Replenish brake fluid reservoir to specified level and bleed hydraulic circuit as necessary. Adjust Correct or replace defective parts. Adjust the stop light switch and vacuum booster push rod. If necessary, rebuild. Check for soft hoses or damaged pipes, and replace with new hoses and new doublewalled steel brake piping. Adjust Adjust Adjust the brake pedal height or power cylinder operating rod. Replace Replace piston seals. Clean Replace Overhaul the parking brakes and correct. Adjust or replace. Correct or replace the brake back plate and brake shoe as necessary. Clean Grind or replace. Grind or replace. Grind or replace. Check operation and correct as necessary. Check and lubricate, if necessary. Clean and lubricate. Replace Replace Correct Grind or replace. Replace Adjust or replace. Grind or replace.
Parking brake misadjusted. Parking brake insufficient. lining clearance
Brake pedal free play insufficient. Piston in the master cylinder sticking. Piston in the disc brake caliper sticking. Brake pads sticking in caliper. Return spring weakened. Parking brake binding. Front hub bearing preload incorrect. Parking brake shoes not returning. Obstructions in hydraulic circuit. Brake disc warped excessively. Rear brake drum distorted. Parking cable sticking. Grabbing or Uneven Braking Action (All conditions listed under Pulls) Malfunctioning vacuum booster. Binding brake pedal mechanism. Corroded caliper assembly. Brake Noisy Brake pads are worn. Brake pads are hardened. Brake pads are in poor contact with rotor. Brake disc(s) warped, worn or damaged. Disc brake fatigued. antisqueak shims
Front hub bearings are loose or preload is incorrect. Brake disc is rusted.
5C8

Condition Possible cause Master cylinder faulty. Vacuum booster faulty. Level of brake fluid in reservoir too low. Air in hydraulic circuit. Disc brake caliper faulty. Water or oil on brake pads. Brake pads in poor contact with the brake disc. Brake pads worn. Brake disc rusted. Check valve in vacuum hose faulty. Correction Correct or replace. Correct or replace. Replenish and bleed. Bleed Clean or replace. Clean or replace. Correct Replace Grind or replace. Correct or replace.
Poor Brake Action
5C9
Hydraulic Brakes
Filling Master Cylinder Reservoir
CAUTION: Use only specified brake fluid. Do not use any fluid which contains a petroleum base. Do not use a container which has been used for petroleum based fluids or a container which is wet with water. Petroleum based fluid will cause swelling and distortion of rubber parts in the hydraulic brake system. Water mixed with brake fluid lowers the fluid boiling point. Keep all fluid containers capped to prevent contamination. Always fill the master cylinder reservoir when the engine is cold. Never allow the brake fluid to come in contact with the painted surfaces. The master cylinder reservoir must be kept properly filled to ensure adequate reserve and to prevent air and moisture from entering the hydraulic system. However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir must not be overfilled. The brake fluid reservoir is on the master cylinder, which is located under the hood on the left side of the cowl. Thoroughly clean reservoir cap before removal to avoid getting dirt into reservoir. Remove cup and diaphragm. Add fluid as required to bring level to the MAX mark on the reservoir tank. Use DOT 3 Hydraulic Brake Fluid. If the fluid cap diaphragm is stretched, return it to the original position before installing. cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 40A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine. NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. In replenishing brake fluid, take care that air bubbles do not enter the brake fluid. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures described below. Bleeding the Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 7 through 9 until the brake fluid comes out of the delivery port during step 7. NOTE: Do not allow the fluid level in the reservoir to go below the halfway mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly.
Deterioration of Brake Fluid

Using any other brake fluid than specified or brake fluid with mineral oil or water mixed in will drop the boiling point of brake fluid. It may, in turn, result in vapor lock or deteriorated rubber parts of the hydraulic system. Be sure to change the brake fluid at specified intervals. If the rubber parts are deteriorated, remove all the system parts and clean them with alcohol. Prior to reassembly, dry the cleaned parts with air to remove the alcohol. Replace all the hoses and rubber parts of the system.
Leakage of Brake Fluid

With engine idling, set shift lever in the neutral position and continue to depress brake pedal at a constant pedal application force. Should the pedal stroke become deeper gradually, a leakage from the hydraulic pressure system is possible. Make sure by visual check that there is no leak.
Bleeding Brake Hydraulic System

A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are disconnected at any fitting located between the master
5C10 POWER ASSISTED BRAKE SYSTEM

16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces. 27. Depress the brake pedal to check if you feel sponginess after the air has been removed from all wheel cylinders and calipers. If the pedal feels spongy, the entire bleeding procedure must be repeated. 28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the MAX level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine.
Flushing Brake Hydraulic System

It is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Approximately one quart of fluid is required to flush the hydraulic system. The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used when it contains the slightest trace of mineral oil. All rubber parts that have been subjected to a contaminated fluid must be replaced.
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17. Bleed the air from the front wheel brake pipe connection (2) by repeating steps 7 through 16. Bleeding the Caliper 18. Bleed the air from each wheel in the order listed below: D Right rear caliper D Left rear caliper D Right front caliper D Left front caliper Conduct air bleeding from the wheels in the above order. If no brake fluid comes out, it suggests that air is mixed in the master cylinder. In this case, bleed air from the master cylinder in accordance with steps 7 through 17, and then bleed air from the caliper. 19. Place the proper size box end wrench over the bleeder screw. 20. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a transparent container containing brake fluid. 21. Pump the brake pedal slowly three (3) times (once/sec), then hold it depressed. 22. Loosen the bleeder screw until fluid flows through the tube. 23. Retighten the bleeder screw. 24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level.
Brake Pipes and Hoses

The hydraulic brake system components are interconnected by special steel piping and flexible hoses. Flexible hoses are used between the frame and the front calipers, the frame and rear axle case and the rear axle and the rear calipers. When the hydraulic pipes have been disconnected for any reason, the brake system must be bled after reconnecting the pipe. Refer to Bleeding the Brake Hydraulic System in this section.
Brake Hose Inspection

The brake hose should be inspected at least twice a year. The brake hose assembly should be checked for road hazard, cracks and chafing of the outer cover, and for leaks and blisters. Inspect for proper routing and mounting of the hose. A brake hose that rubs on suspension components will wear and eventually fail. A light and mirror may be needed for an adequate inspection. If any of the above conditions are observed on the brake hose, adjust or replace the hose as necessary. CAUTION: Never allow brake components such as calipers to hang from the brake hoses, as damage to the hoses may occur.
5C11
Front / Rear Caliper Brake Hose

Front / Rear Caliper Brake Hose and Associated Parts Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque Torque: 16 Nm (12 lb ft) 2. Tighten the bolt to the specified torque. Torque: 35 Nm (26 lb ft) NOTE: Always use new gaskets and be sure to put the hooked edge of the flexible hose end into the antirotation cavity. After installing the brake hoses, bleed the brakes as described in this section.
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Legend (1) Bolt and Gasket (2) Clip (3) Hose (4) Brake Pipe
Removal
1. Raise the vehicle and support it with suitable safety stands. 2. Remove the wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove bolt and gasket. 7. Remove hose.
Rear Axle Brake Hose

Rear Axle Brake Hose and Associated Parts Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque Torque: 16 Nm (12 lb ft) 2. Tighten the bolt to the specified torque. Sems bolts Torque: 13 Nm (113 lb in) Flange bolts Torque: 15 Nm (11 lb ft) After installing the brake hoses, bleed the brakes as described in this section.
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Legend (1) Brake Pipe (2) Clip (3) Bolt (4) Brake Pipe (5) Hose
Removal
1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove brake pipe. 7. Remove bolt. 8. Remove hose.
5C13
Brake Pipe
Removal
1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly as necessary. 3. Clean dirt, grease, and other foreign material off the pipe fittings at both ends. 4. Remove brake pipe (1).
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque. Master cylinder side Torque: 12 Nm (104 lb in) Other Torque: 16 Nm (12 lb ft) After installing the brake pipes, bleed the brakes as described in this section.
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5. Remove plastic clip (2).
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P & B (Proportioning and Bypass) Valve

P & B (Proportioning and Bypass) Valve Sectional View Removal
1. The P&B valve is not repairable and must be replaced as a complete assembly. Care must be taken to prevent brake fluid from contacting any painted surface. 2. Remove hydraulic pipes (1) and plug (1) the pipes to prevent the loss of fluid or the entrance of dirt. 3. Remove bolt (3). 4. Remove P&B valve (2).
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Legend (1) Master Cylinder (Secondary) (2) Master Cylinder (Primary) (3) Rear Brake (4) Front Brake The P&B valve contains two sections, each serving a different function. The proportioning section of the P&B valve proportions outlet pressure to the rear brakes after a predetermined rear input pressure has been reached. This is done to prevent rear wheel lock up on the vehicles with light rear wheel loads. The valve has a pass feature which assures full system pressure to the rear brakes in the event of front brake system malfunction. Also full front pressure is retained in the event of rear brake malfunction. The combination valve has a pressure differential warning switch which is designed to constantly compare front and rear brake pressure from the master cylinder and turn on the brake system warning light on the instrument panel in the event of a front or rear system malfunction. The valve and switch are so designed that the switch will latch in the warning position once a malfunction has occured. The only way the light can be turned off is to repair the malfunction and apply a pedal forced required to developed line pressure. The P&B valve is not repairable and must be replaced as a complete assembly.
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Installation
1. Install P&B valve (2). 2. Install bolt (3) and tighten the bolt to the specified torque. Torque: 13 Nm (113 lb in) 3. Install hydraulic pipes (1) and tighten the bolt to the specified torque. Torque: 16 Nm (12 lb ft) 4. After installing the brake pipes, bleed the brakes refering to Bleeding Brake Hydraulic System in this section.
5C15

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Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when the pedal is fully released. Brake pedal height adjustment should be performed as follows:
Adjust Brake Pedal
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NOTE: While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal. h. Tighten the stoplight switch lock nut. i. Connect the stoplight switch connector.
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1. Measure the brake pedal height after making sure the pedal is fully returned by the pedal return spring. Pedal height must be measured after starting the engine and receiving it several times. Pedal Free Play : 6-10 mm (0.23-0.39 in) Pedal Free Play : 208-218 mm (8.19-8.58 in) NOTE: Pedal free play must be measured after turning off the engine and stepping on the brake pedal firmly five times or more. 2. If the measured value is not within the above range, adjust the brake pedal as follows: a. Disconnect the stoplight switch connector. b. Loosen the stoplight switch lock nut (1). c. Rotate the stoplight switch so that is moves away from the brake pedal. d. Loosen the lock nut on the push rod. e. Adjust the brake pedal to the specified height by rotating the push rod in the appropriate direction. f. Tighten the lock nut to the specified torque. Torque: 20 Nm (15 lb ft) g. Adjust the stoplight switch to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. Clearance : 00.2 mm (00.008 in)
Checking Pedal Travel
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1. Pedal height (3) must be measured after starting the engine and revving it several times to apply vacuum to the vacuum booster fully. NOTE: Pedal height (3) must be 100 mm (3.9 in) or more when about 50 kg (110.25 lb) of stepping force is applied. 2. If the measured value is lower than the above range, air existing in the hydraulic system is suspected. Perform the bleeding procedure.
5C17
Brake Pedal and Associated Parts
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Legend (1) Nut (2) Stoplight Switch Connector (3) Fulcrum Pin (4) Driver Knee Bolster Assembly (5) Lower Cluster Assembly (6) Shift Knob
(7) (8) (9) (10) (11) (12) (13)
Front Console Assembly Instrument Panel Driver Lower Cover Return Spring Brake Pedal Snap Pin Pin Antitheft Controller
Removal
1. Remove shift knob. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove instrument panel driver lower cover. 5. Remove driver knee bolster assembly. 6. Remove antitheft controller. 7. Remove stoplight switch connector. 8. Remove return spring. 9. Remove snap pin. 10. Remove pin. 11. Remove nut. 12. Remove fulcrum pin. 13. Remove brake pedal.
Installation
1. Install brake pedal. 2. Install fulcrum pin and apply grease to the entire circumference of the fulcrum pin. Torque: 33 Nm (24 lb ft) 3. Install nut and tighten the nut to the specified torque. Torque: 33 Nm (24 lb ft) 4. Install pin and apply grease to the entire circumference of the push rod pin. 5. Install snap pin and adjust the pedal free travel Refer to Brake Pedal Adjustment previously in this section. 6. Install return spring. 7. Connect stoplight switch connector. 8. Connect antitheft connector. 9. Install driver knee bolster assembly. 10. Install instrument panel driver lower cover.

11. Install lower cluster assembly. 12. Install front console assembly. 13. Install shift knob.
Stoplight Switch
Removal
1. Remove shift knob. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove instrument panel driver lower cover. 5. Remove driver knee bolster assembly. 6. Remove stoplight switch connector (3). 7. Remove lock nut (1). 8. Remove switch (2).
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2. Install lock nut. 3. Connect stoplight switch connector. 4. Install driver knee bolster assembly. 5. Install instrument panel driver lower cover. 6. Install lower cluster assembly. 7. Install front console assembly. 8. Install shift knob.
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Installation
1. Install switch and adjust the stoplight switch to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. Clearance (1): 0-0.2 mm (0-0.009 in) NOTE: While adjusting the installation of the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal.
5C19

Pedal free play Pedal Height 610 mm (0.23 0.39 in) 208218 mm (8198.58 in)
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Fluid Reservoir Tank

Fluid Reservoir Tank and Associated Parts
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Legend (1) Fluid Reservoir (2) Electrical Connector
(3) Oring (4) Retainer
Removal
NOTE: Before removing the fluid reservoir, remove the brake fluid from the fluid reservoir. 1. Disconnect electrical connector. 2. Remove retainer (1).
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Oring (1) must be set onto the fluid reservoir (2), before installing fluid reservoir.
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3. Remove fluid reservoir and the fluid lever sensor built into the fluid reservoir . The fluid level sensor cannot be removed for servicing. 4. Remove Oring.
5C21
Master Cylinder Assembly

Master Cylinder Assembly and Associated Parts
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Legend (1) Electrical Connector (2) Master Cylinder (3) 2 attaching Nuts
(4) P&B Valve and Bracket (5) Brake Pipes (6) Spacer and 2 gaskets
Removal
CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. While removing the master cylinder, further, do not hold the piston as it can be easily pulled out. Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 1. Disconnect electrical connector. 2. Remove brake pipes after disconnecting the brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 3. Remove 2 attaching nuts.
4. Remove P&B valve and bracket. 5. Remove master cylinder. 6. Remove spacer and the 2 gaskets.

Master Cylinder
The master cylinder is not repairable and must be replaced as a complete assembly if found defective.
Inspection
Excessive brake pedal travel, malfunction or dragging brake suggests that the master cylinder is defective. In such cases perform the following visual check. Visual Check Make parts replacement as required if wear, distortion, nicks, cuts, corrosion, or other abnormal conditions are found through the following parts inspection: D Master cylinder body D Fluid reservoir

D Oring There should be a pressure increase of 0.5 kg/cm@ or more.
Functional Inspection of Master Cylinder Piston

Push the primary piston (1) with your fingers to check that it travels smoothly. If the motion is questionable, replace the master cylinder as a complete assembly.
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NOTE: When checking the front (or primary) side, be sure to mount the master cylinder plug in the rear (or secondary) port.
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0 Line Apply air pressure to the front and rear ports Remarks No pressure rise. Checks port into the atmospheric pressure chamber
5 Line Pressure increase of 0.5 kg/cm@ or more Checks air tightness of the pressure chamber
Functional Inspection of Master Cylinder

Inspect the master cylinder for function as follows. If any abnormal function is found, replace with a new one. (including the master cylinder attachment and master cylinder plug (7)) Install the primary piston holder (3) J39242 onto the master cylinder (4). Make sure the spacer (2) (2 bolts) with its adjusting bolt is screwed in up to the 0 line
NOTE: 1. Do not use an air compressor, as the air from the compressor is mixed with compressor oil. 2. When installing the master cylinder onto the vacuum booster, always adjust the vacuum booster push rod. (Refer to Vacuum Booster in this section). 3. After the master cylinder is installed onto the vehicle, check for leakage, pedal travel and pedal free play.
Installation
1. Install spacer and the 2 gaskets. 2. Install master cylinder, when replacing the master cylinder or vacuum booster or both, always measure the vacuum booster push rod protrusion and adjust it as necessary (Refer to Vacuum Booster in section). 3. Install P&B valve and bracket. 4. Install 2 attaching nuts and tighten the attaching nuts to the specified torque. Torque: 13 Nm (113 lb in)
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Connect the master cylinder attachment (5) J39242 with the end of the radiator cap tester (6) J2446001, and apply air pressure with the cap tester. Make sure there is no rise in pressure and that with the adjusting bolt further screwed in 5 mm (align the adjusting bolt to the 5 line).

5. Install brake pipes and tighten the brake pipe to the specified torque. Master cylinder side Torque: 12 Nm (104 lb in) Others Torque: 16 Nm (12 lb ft) 6. Connect electrical connector.
5C23

Type Piston bore diameter Dualcircuit 25.4 mm (1.000 in)
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Special Tools
J-39242 Primary Piston Holder (including master cylinder attachment and master cylinder plug
J-24460-01 Radiator Cap Tester
5C25
Vacuum Booster Assembly

Vacuum Booster Assembly and Associated Parts
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Legend (1) Pin (2) Vacuum Booster Fixing Nut (3) Vacuum Hose
(4) Master Cylinder (5) Vacuum Booster (6) Snap Pin
Removal
1. Before removing the vacuum booster assembly, disconnect and remove the brake pipes. 2. Remove master cylinder, refer to Master Cylinder Removal in this section. CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. While removing the master cylinder, further, do not hold the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 3. Remove vacuum hose. 4. Disconnect the yoke clevis from the brake pedal. 5. Remove vacuum booster fixing nut. 6. Remove vacuum booster.

Vacuum Hose
1. Inspect the check valve (2), which is installed inside the vacuum hose. 2. Air should pass freely from the vacuum booster (3) to the engine (1).

3. Air should not pass from the engine (1) to the vacuum booster (3). If it does, the check valve is inoperative and must be replaced. 3. Set push rod gauge J39216 on vacuum booster, and apply negative pressure by means of vacuum pump J23738A so that the pressure in the vacuum booster becomes 500 mm Hg. NOTE: Be sure to apply NEGATIVE pressure after installing a push rod gauge on the vacuum booster.
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Installation
1. Install vacuum booster and vacuum booster push rod adjustment. NOTE: When replacing either the master cylinder or vacuum booster, be sure to measure push rod, and adjust if required. 2. Remove retainer from vacuum booster front shell using a small screwdriver. Then gently draw plate and seal assembly out of the shell inside.
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4. Measure dimension (4). Dimension (4) (Standard): 0.10.1 mm (0.00390.0039 in)
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5. If dimension (4) is out of the standard range, adjust push rod using the Push Rod Support J39241.
5C27
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6. Mount plate and seal assembly in vacuum booster front shell. Then install the retainer. 7. Install vacuum booster fixing nut and tighten the specified torque. Torque: 21 Nm (16 lb ft) 8. Install yoke clevis. 9. Connect vacuum hose and make sure that the arrow on the hose points in the direction of the engine. 10. Install master cylinder, refer to Master Cylinder Installation in this section.
Exterior Components
Exterior Components and Associated Parts
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Legend (1) Yoke Clevis (2) Lock Nut (3) Retaining Clip (4) Valve Body Guard (5) Silencer
(6) (7) (8) (9) (10) (11)
Filter 2 Gaskets and Spacer Vacuum Booster Retainer Plate and Seal Assembly Master Cylinder
Removal
1. Remove master cylinder, refer to Master Cylinder in this section. 2. Remove vacuum booster, refer to Vacuum Booster in this section. 3. Remove yoke clevis. 4. Remove lock nut. 5. Remove retaining clip. 6. Remove valve body guard. 7. Remove silencer. 8. Remove filter. 9. Remove 2 gaskets and spacer. 10. Remove retainer, use a small screwdriver to pry out the retainer. Gently pull out the plate and seal assembly from the shell.
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11. Remove plate and seal assembly.
5C29

Visual Check
Make necessary parts replacement if cuts, nicks, excessive wear, or other abnormal conditions are found through inspection. Check the following parts: D Yoke clevis D Valve body guard D Silencer D Filter plate and seal assembly
2. Install retainer. 3. Install 2 gaskets and spacer. 4. Install filter. 5. Install silencer. 6. Install valve body guard. 7. Install retainer. 8. Install lock nut and tighten to the specified torque. Torque: 20 Nm (15 lb ft) 9. Install yoke clevis. 10. Install vacuum booster, refer to Vacuum Booster in this section. 11. Install master cylinder, refer to Master Cylinder in this section and after installation, perform brake pedal check and adjustment. Refer to Brake Pedal in this section.
Installation
1. Install plate and seal assembly.
Vacuum Booster Overhaul

Vacuum Booster
The vacuum booster cannot be disassembled for repair. Replace a defective vacuum booster with a new one.

Vacuum booster diaphragm diameter (Front) Vacuum booster diaphragm diameter (Rear) Push rod stroke Plunger diameter Push rod diameter 205 mm (8.07 in) 230 mm (9.06 in) More than 32.0 mm (1.26 in) 10.25 mm (0.40 in) 27.4 mm (1.08 in)
C05RT003
5C31
Special Tools
J-39216 Push Rod Gauge
J-23738-A Vacuum Pump
J-39241 Push Rod Support
Front Disc Brake Pads

Front Disc Brake Pads Inspection
Check the outer pad by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.00 mm (0.039 in) of the pad itself. The disc pads have a wear indicator that makes a noise when the pad wears to where replacement is required. Minimum limit (1): 1.0 mm (0.039 in)
302RS002
Front Disc Brake Pads and Associated Parts
302RW003
Legend (1) Lock Bolt (2) Caliper Assembly
(3) Pad Assembly (4) Clip (5) Outer Side
5C33
Removal
NOTE: If a squealing noise occurs from the front brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced. D Draw out twothirds of the brake fluid from the reservoir. D Raise the vehicle and support it with suitable safety stands. 1. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 2. Remove lock bolt (1).
302RS005
2. Install pad assembly with shim and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (2). Wipe off extruded grease after installing.
302RW004
3. Remove caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove Clip.
Installation
1. Install clip.
302RW005
Legend (2) Inner Shim (3) Wear Indicator (4) Inner Side
302RW006
302RW007
3. Install caliper assembly, use adjustable pliers to bottom the piston into the caliper bore. Be careful do not damage the piston boot and do not damage the flexible hose by twisting or pulling it.
5. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft)
5C35
Front Disc Brake Rotor

Inspection
In the manufacturing of the brake rotor, all the tolerances regarding surface finish, parallelism and lateral runout are held very closely. Maintaining these tolerances provides the surface necessary to assure smooth brake operation. The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. Maximum runout: 0.010 mm (0.0004 in)
Lateral Runout
Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as rotor wobble. This movement causes the piston to be knocked back into its bore. This results in additional pedal travel and a vibration during braking.
Checking Lateral Runout

1. Adjust the wheel bearing correctly, refer to Differential in Section 4A. 2. Attach a dial indicator to some portion of the suspension so that the stem contacts the rotor face about 29 mm (1.14 in) from the rotor edge. 3. Move the rotor one complete rotation and the lateral runout should not exceed 0.13 mm (0.005 in). Maximum runout: 0.13 mm (0.005 in)
411RS018
Replacing Brake Rotors

When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.
Refinishing Brake Rotors

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 24.60 mm (0.969 in). The minimum refinish dimension is 24.97 mm (0.983 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish.
411RS019
Parallelism
Parallelism is the measurement of thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made 29 mm (1.14 in) from the edge of the rotor.

After refinishing, replace any rotor that does not meet the minimum thickness of 24.97 mm (0.983 in). Do not use a brake rotor that will not meet the specification. Minimum wear dimension: 24.60 mm (0.969 in) Refinish dimension: 24.97 mm (0.983 in)
411RW003
5C37
Front Disc Brake Caliper Assembly

Front Disc Brake Caliper Assembly and Associated Parts
302RW008
Legend (1) Guide Bolt (2) Brake Flexible Hose (3) Lock Bolt
(4) (5) (6) (7)
Caliper Assembly Clip Support Bracket with Pad Assembly Pad Assembly
Removal
1. Raise the vehicle and support with suitable safety stands. 2. Wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material.
302RW009

4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove guide bolt (2). 6. Remove lock bolt (3). 2. Install pad assembly with shim and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (6). Wipe off extruded grease after installing.
302RW011 302RW010
7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 9. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 10. Remove clip.
Legend (4) Inner Shim (5) Wear Indicator (6) Inner Side 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 155 Nm (115 lb ft)
Installation
1. Install clip.
302RW012
4. Install caliper assembly.

302RS005

5. Install lock bolt (9) and guide bolt (8) and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft)
5C39
302RW013
6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the antirotation cavity then tighten the Ibolt (10) to the specified torque. Torque: 35 Nm (26 lb ft)
302RW014
7. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.
Front Disc Brake Caliper

Front Disc Brake Caliper Disassembled View
302RW015
Legend (1) Guide Bolt (2) Lock Bolt (3) Bleeder with Cap (4) Caliper Body
(5) (6) (7) (8) (9)
Dust Boot: Guide Bolt and Lock Bolt Piston Seal Piston Dust Boot: Piston Dust Boot Ring
Disassembly
1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot: guide bolt and lock bolt. 4. Remove dust boot ring, using a small screwdriver, remove the dust boot ring.
302RS016

5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF THE PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT WHEN APPLYING COMPRESSED AIR. THIS COULD RESULT IN PERSONAL INJURY. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.
5C41
Reassembly
1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 Nm (69 lb in) 3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.
302RS018
302RS017
6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body.
4. Install piston. 5. Install piston dust boot; when inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result.

Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Rotor D Cylinder body D Cylinder bore D Piston D Guide bolt, lock bolt D Support bracket NOTE: The piston seal, boot ring and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace them with new ones.
302RS019

6. Install dust boot ring and apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.
302RS020
7. Install guide bolt and lock bolt dust boot. 8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft) 9. Install the dust boot on the support bracket after applying special grease (approximately 1 g) onto the dust boot inner surface. Apply special grease onto the lock bolt and guide bolt setting hole of the support bracket.
302RS021
5C43

Type Pad dimension Adjusting method Piston diameter Disc type Disc thickness Disc effective diameter Floating, pin slide 55 cm@ (8.52 in@) Selfadjusting 60.33 mm (2.38 in) Ventilated 26 mm (1.02 in) 222 mm (8.74 in)
E05RW004
Rear Disc Brake Pads

Brake Pads Inspection
Check the outer pads by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.0 mm (0.039 in) of the pad itself. The disc pads have a wear indicator that makes a noise when the pad wears to where replacement is required. Minimum limit (1): 1.0 mm (0.039 in)
302RW016
Brake Pads and Associated Parts
306RW001
Legend (1) Caliper Assembly (2) Clip
(3) Lock Bolt (4) Pad Assembly
5C45
Removal
NOTE: If a squealing noise occurs from the rear brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced. D Draw out twothirds of the brake fluid from the reservoir. D Raise the vehicle and support it with suitable safety stands. 1. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 2. Remove lock bolt (1)
306RW003
2. Install pad assembly with shim and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims. Wipe off extruded grease after installing.
306RW002
3. Remove caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove clip.
Installation
1. Install clip (2).
306RW004
Legend (3) Inner Shim (4) Wear Indicator
306RW005
306RW006
3. Install caliper assembly, use adjustable pliers to bottom the piston into the caliper bore. Be careful not to damage the piston dust boot and do not damage the flexible hose by twisting or pulling it.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 44 Nm (32 lb ft) 5. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes.
5C47
Rear Disc Brake Rotor

Inspection
In the manufacturing of the brake rotor, all the tolerances regarding surface finish, parallelism and lateral runout are held very closely. Maintaining these tolerances provides the surface necessary to assure smooth brake operation. The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. Maximum parallelism: 0.001 mm (0.0004 in)
Lateral Runout
Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as rotor wobble. This movement causes the piston to be knocked back into its bore. This results in additional pedal travel and a vibration during braking.
Checking Lateral Runout

1. Adjust the wheel bearing correctly, refer to Differential in Section 4A. 2. Attach a dial indicator to some portion of the suspension so that the stem contacts the rotor face about 29 mm (1.14 in) from the rotor edge. 3. Move the rotor one complete rotation. 1. The lateral runout should not exceed 0.13 mm (0.005 in) Maximum runout: 0.13 mm (0.005 in)
420RS013
Replacing Brake Rotors

When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.
Refinishing Brake Rotors

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 16.6 mm (0.654 in). The minimum refinish dimension is 16.97 mm (0.668 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish.
411RS019
Parallelism
Parallelism is the measurement of thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made 22 mm (0.87 in) from the edge of the rotor.

After refinishing, replace any rotor that does not meet the minimum thickness of 16.97 mm (0.668 in). Do not use a brake rotor that will not meet the specification. Minimum wear dimension: 16.6 mm (0.654 in) Refinish dimension: 16.97 mm (0.668 in)
420RW002
Rear Drum (In Disc) Inside Diameter Check

Check the rear drum inside diameter by measuring at more than two portions as shown in the illustration. If the inside diameter is greater than the limit, replace the rear rotor. Standard: 210.0 mm (8.27 in) Limit: 211.4 mm (8.32 in)
420RS035
5C49
Rear Disc Brake Caliper Assembly

Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
Legend (1) Brake Flexible Hose (2) Clip (3) Lock Bolt
(4) (5) (6) (7)
Support Bracket Guide Bolt Pad Assembly with Shim Caliper Assembly
Removal
1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material.
4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove lock bolt (2). 6. Remove guide bolt (3).
306RW009
306RW008
7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 9. Remove pad assembly (with shim) and mark the lining locations if they are to be reinstalled.

10. Remove clip. 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 103 Nm (76 lb ft)
Installation
1. Install clip (4).
306RW012
306RW010
2. Install pad assembly (with shim) and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (5). Wipe off extruded grease after installing.
4. Install caliper assembly. 5. Install lock bolt and guide bolt (8) and tighten the bolt to the specified torque. Torque: 44 Nm (32 lb ft)
306RW013 306RW011
Legend (5) Inner Shim (6) Wear indicator

6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the antirotation cavity then tighten the Ibolt (9) to the specified torque. Torque: 35 Nm (26 lb ft)
5C51
302RW017
7. Install the wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.
Rear Disc Brake Caliper

Rear Disc Brake Caliper Disassembled View
306RW014
Legend (1) Guide Bolt (2) Lock Bolt (3) Bleeder with Cap (4) Caliper Body
(5) (6) (7) (8) (9)
Piston Seal Piston Dust Boot: Piston Dust Boot Ring Dust Boot: Guide Bolt and Lock Bolt
Disassembly
1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot; guide bolt and lock bolt. 4. Remove the dust boot ring using a small screwdriver.
302RS016

5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF THE PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT WHEN APPLYING COMPRESSED AIR. THIS COULD RESULT IN PERSONAL INJURY. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.
5C53
Reassembly
1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 Nm (69 lb ft) 3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.
302RS018
302RS017
6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body.
4. Install piston. 5. Install piston dust boot; when inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result.

Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Rotor D Cylinder body D Cylinder bore D Piston D Guide bolt, lock bolt D Support bracket NOTE: The piston dust seal and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace with new ones.
302RS019

6. Install dust boot ring and apply special grease (approximately 1g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.
302RS020
7. Install guide bolt and lock bolt dust boot. 8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft) 9. Install the dust boot on the support bracket after applying special grease (Approx. 1g) onto the dust boot inner surface. Also apply special grease onto the lock bolt and guide bolt setting hole of the support bracket.
302RS021
5C55

Type Pad dimension Adjusting method Piston diameter Disc type Disc thickness Disc effective diameter Floating, pin slide 33 cm@ (5.11 in@) Selfadjusting 41.3 mm (1.63 in) Ventilated 18 mm (0.71 in) 269.2 mm (10.60 in)
E05RW005
SECTION
PARKING BRAKE
TROOPER
5D1
BRAKES
PARKING BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Lever and Front Cable . . . . . . Parking Brake Lever, Front Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1 5D1 5D2 5D3 5D3 5D3 5D4 Parking Brake Rear Cable . . . . . . . . . . . . . . . . Parking Brake Rear Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Parking Brake Adjustment . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 5D5 5D5 5D5 5D6 5D7 5D7 5D8
Service Precaution
General Description
Pulling up the parking brake lever by hand will set the parking brake. Once pulled up, the lever is held by a ratchettype lock until it is released. The position of the lever is transmitted through cable/lever systems to the rear wheels. These parts are designed in order to obtain sufficient braking force when parking on slopes. When the parking brake is set, or when the ignition switch is in the ON position, the brake warning light illuminates. The rear wheel parking brake is a duoservo brake (mechanical inside expansion type) built into the rear disc brake. Parking brake adjustment is made through the adjusting hole bored through the back plate. Adjust the parking brake lever stroke to six or seven notches. Refer to Parking Brake Adjustment in this Section.
5D2 PARKING BRAKE
Operation
C05RW003
Legend (1) Strut (2) Fulcrum B (3) Parking Lever (4) Secondary Shoe (5) Adjusting Screw Notch
(6) (7) (8) (9) (10) (11)
Parking Cable Guide Primary Shoe Parking Brake Cable Guide Adjusting Hole Plug Adjusting Screw Notch Shoe Expanding Direction
When pulled in the direction A, the parking lever presses the secondary shoe against the brake drum using the lever/shoe joint B as a fulcrum and pushes the strut in the direction C. The strut ,in turn, presses the primary shoe against the brake drum. Counter force D to the primary shoe is transmitted again to the secondary shoe through the fulcrum B. The secondary shoe contacts the drum thereby producing braking effect. Clearance which may result from worn parking brake shoe lining can be adjusted by turning the adjusting screw. Refer to Parking Brake Adjustment in this Section.
PARKING BRAKE
5D3
Parking Brake Lever and Front Cable

Parking Brake Lever, Front Cable and Associated Parts
311RW001
Legend (1) Parking Brake Lever (2) Bolt (3) Adjusting Nut
(4) Equalizer (5) Parking Brake Front Cable (6) Switch Connector
Removal
1. Remove adjusting nut (3). 2. Remove equalizer (4).
311RX001
5D4 PARKING BRAKE

3. Remove center console. (Refer to Section 10 Body.) 4. Remove bolts. 5. Disconnect switch connector. 6. Remove parking brake lever. 7. Remove parking brake front cable.
Installation
1. Install parking brake front cable. 2. Install parking brake lever and apply grease (BESCO L2 or equivalent) to front cable contact point. 3. Reconnect switch connector. 4. Install bolts and tighten the parking brake lever fixing bolt to the specified torque. Torque : 15 Nm (11 lb ft) 5. Install center console. (Refer to Section 10 Body.) 6. Install equalizer. 7. Install adjusting nut and adjust the parking brake lever. (See Parking Brake Adjustment in this section.)
PARKING BRAKE
5D5
Parking Brake Rear Cable

Parking Brake Rear Cable and Associated Parts
311RW003
Legend (1) Adjust Nut (2) Back Plate (3) Bolt (4) Holding Spring (5) Return Spring; Upper (6) Shoe Assembly (7) Return Spring; Lower
(8) (9) (10) (11) (12) (13) (14) (15)
Caliper Assembly Rotor (Drum) Rear Wheels Cable Fixing Bolt Clip Clip Clip Rear Cable
Removal
1. Remove adjusting nut. 2. Remove rear wheels.
3. Remove caliper assembly, remove two bolts to remove the caliper assembly from the support bracket. (Refer to Rear Disc Brakes in Disc Brakes in Section 5C). Temporarily hang the caliper with a wire in order to avoid stretching the brake hose. 4. Remove rotor (drum). 5. Remove clip (floor side).
5D6 PARKING BRAKE

6. Remove bolt. 7. Remove back plate. 8. Remove clip (frame side). 9. Remove clip (suspension side). 10. Remove holding spring. 11. Remove return spring; upper. 12. Remove return spring; lower. 13. Remove the brake shoe assembly. Then remove the parking brake cable from the parking brake lever (1).
308RS002
4. Install return spring; lower. 5. Install return spring; upper and the parking brake lever (3) side (secondary side) return spring must be installed on the outer side (2) of the primary side return spring.
308RW001
14. Remove cable fixing bolt. 15. Remove rear cable.
Installation
1. Install rear cable and apply grease (BESCO L2 or equivalent) to the connecting portion of the rear cable and the equalizer. 2. Install cable fixing bolt and tighten the cable fixing bolt to the specified torque. Torque: 6 Nm (52 lb in) 3. Install shoe assembly and after installation of the shoe and cable assembly, apply the special grease included in the repair kit to the portions indicated in the illustration.
308RW002
6. Install holding spring. 7. Install clip (suspension side) and tighten the bolt to the specified torque. Torque: 7.8 Nm (68 lb in) 8. Install clip (frame side) and tighten the bolt to the specified torque. Torque: 15 Nm (11 lb in) 9. Install back plate. 10. Install bolt and tighten the bolt to the specified torque. Torque: 6 Nm (52 lb in) 11. Install clip (floor side) and tighten the bolt to the specified torque. Torque: 15 Nm (11 lb in) 12. Install rotor.
PARKING BRAKE
13. Install caliper assembly. 14. Install rear wheels. 15. Install adjusting nut and apply grease (BESCO L2 or equivalent) to front cable contact point. 16. Tighten the adjusting nut to the specified torque and to adjust the parking brake, refer to Parking Brake Adjustment in this section. Torque: 6 Nm (52 lb in)
5D7
2. Adjustment of parking brake cable a. Turn the equalizer nut so that the parking brake lever travels 6 or 7 notches when pulled up with a force of 30 kg (66 lb). b. Make sure that there is no brake dragging and tighten the cable lock nut. Torque : 6 Nm (52 lb in) 3. Breakin of parking brake shoe D When poor braking is felt, or just after replacement of parking brake shoes, be sure to conduct the breakin procedure by driving the vehicle as follows: a. Forward 50 km/h (30 mph) 400 m (about 30 seconds) with a lever pull force of 15 kg (33 lb). b. Backward 10 km/h (6 mph) 50 m (about 18 seconds) with a lever pull force of 15 kg (33 lb). NOTE: Breakin procedures must be performed under safe conditions and traffic rules. D If the braking effect remains poor after the breakin, wait for some time until parking brake shoe cools down and repeat procedures a. and b. noted above. D On completion of breakin, inspect the parking brake lever stroke, and if the lever does not come within the specified number of notches when pulled up, readjust. D Excessive breakin may cause premature wear of the parking brake lining.

Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the brake drum rotor. Replace the shoe assemblies if the lining thickness is less than 1.0 mm (0.039 in). Minimum limit: 1.0 m (0.039 in)
308RW003
Parking Brake Rotor (Drum) Inspection

Refer to Rear Disc Brakes in Section 5A2 for the inspection procedure of the rotor (drum).
Parking Brake Adjustment

1. Adjustment of parking brake assembly D Prior to lever stroke adjustment, adjust the rear brake shoe/rotor (drum) gap. Perform this procedure by loosening the adjusting nut of the equalizer. a. Remove the adjusting hole plug (rubber) and turn the shoe adjusting screw downward using a small screwdriver so that the shoes will expand until they get into close contact with the rotor. (Turn down the adjusting screw notch by notch until the rotor does not turn.) b. Turn the adjusting screw in the opposite direction (upward) until the rotor can be turned lightly. Standard number of notches to turn upward: 7 or 8. Turn the rotor in order to ensure that there is no brake dragging.
5D8 PARKING BRAKE

Rear parking brake Type Lining Dimension Adjusting Method Rotor (Drum) Inside Diameter Parking Brake Lever Stroke Duoservo 121.2 cm@ (18.79 in@) Manual adjusting 210 mm (8.27 in) 67 notches When pulled with a force of 30 kg (66 lb)
E05RW006
SECTION
ENGINE MECHANICAL
TROOPER
6A1
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Charging System . . . . . . . . . . . . 6A 6B 6C 6D1 6D2 6D3 Driveability and Emissions . . . . . . . . . . . . . . . . Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . Engine Speed Control System . . . . . . . . . . . . Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E 6F 6G 6H 6J
ENGINE MECHANICAL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover LH . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover RH . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Chamber . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Controller , Valve Spring and Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Piston Ring and Connecting Rod . . . 6A2 6A3 6A4 6A19 6A19 6A20 6A21 6A21 6A21 6A22 6A22 6A22 6A24 6A24 6A24 6A25 6A25 6A25 6A26 6A26 6A26 6A27 6A27 6A28 6A32 6A32 6A32 6A35 6A35 6A35 6A37 6A37 6A37 6A38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearings . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Associated Parts . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Clearance Adjustments . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Associated Parts . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Associated Parts . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A38 6A39 6A40 6A40 6A41 6A45 6A45 6A45 6A46 6A46 6A47 6A49 6A49 6A50 6A50 6A50 6A51 6A53 6A53 6A53 6A54 6A57 6A58 6A60 6A60 6A60 6A61 6A63 6A66 6A66 6A67 6A67 6A68 6A70
6A2
ENGINE MECHANICAL
6A74 6A74 6A74 6A75 6A79 6A81 Cylinder Block and Associated Parts . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specification . . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A81 6A81 6A82 6A83 6A86 6A92
Piston and Connecting Rod . . . . . . . . . . . . . . . Piston, Connecting Rod and Associate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
ENGINE MECHANICAL
6A3
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. D A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation. D Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order. D At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. D 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. D The six cylinders of this engine are identified by numbers; Right side cylinders 1, 3 and 5, Left side cylinders 2, 4 and 6, as counted from crankshaft pulley side to flywheel side.
Cylinder Head
The cylinder head, made of aluminum alloy casting employs a pentroof type combustion chamber with a spark plug in the center. The intake and exhaust valves are placed in Vtype design. The ports are crossflow type.
Valve Train
Intake and exhaust camshaft on the both side of banks are driven through an camshaft drive gear by timing belt. The valves are operated by the camshaft and the valve clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum cast common chamber and intake manifold attached with six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two compression rings and one oil ring. The piston pin is made of chromium steel is offset 1mm toward the thrust side, and the thrust pressure of piston to the cylinder wall varies gradually as the piston travels. The connecting rods are made of forged steel. The connecting rod bearings are graded for correct seze selection.
General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage and contributing to reliable engine performance: D When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pickup unit. D The 12volt electrical system is capable of damaging circuits. When performing any work where electrical terminals could possibly be grounded, the ground cable of the battery should be disconnected at the battery. D Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.
Crankshaft and Bearings

The crankshaft is made of Ductile castiron. Pins and journals are graded for correct size selection for their bearing.
Engine Lubrication
The oil discharged by a trochoidtype oil pump driven by the crankshaft is fed through fullflow oil filter and to the oil gallery provided under the crankshaft bearing cap. The oil is then led to the crankshaft journals and cylinder head. The crank pins are lubricated with oil from crankshaft journals through oil holes. Also, an oil jet is fed to each cylinder from crankshaft juornals on the connecting rod for piston cleaning. The oil pan flange is dealed with liquid packing only; do not deform or damage the flange surface during removal or installation.
Cylinder Block
The cylinder block is made of aluminum diecast casting for 75Vtype six cylinders. It has a rear plate integrated structure and employs a deep skint. The cylinder liner is cast and the liner inner diameter and crankshaft journal diameter are classified into grades. The crankshaft is supported by four bearings of which width of No.3 bearing on the body side is different in order to support the thrust bearing. The bearing cap is made of nodular cast iron and each bearing cap uses four bolts and two side bolts.
6A4
ENGINE MECHANICAL
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over Troubleshooting Procedure Turn on headlights and starter switch. Condition Headlights go considerably out or dim Possible cause Battery run down or under charged Terminals poorly connected Starting motor coil circuit shorted Starting motor defective Headlights stay bright Starting motor circuit open Starting motor coil open Correction Recharge or replace battery Clean battery posts and terminals and connect properly Overhaul or replace Overhaul or replace Refer to Starting and Charging System Replace
2. Ignition Trouble Starting Motor Turns Over But Engine Does Not Start Spark Test Disconnect an igniton coil from any spark plug. Connect the spark plug tester J26792 (ST125), start the engine, and check if a spark is generated in the spark plug tester. Before starting the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the part where insulation of the igniton coil is broken while the engine is running. Condition Spark jumps across gap Possible cause Spark plug defective Ignition timing incorrect Fuel not reaching fuel injector(s) or engine Valve timing incorrect Engine lacks compression No sparking takes place Ignition coil disconnected or broken Ion sensing module defective Ion sensing module cable broken or poor connections Poor connections in engine harness Powertrain Control Module cable disconnected or defective Correction Clean or replace Refer to Ignition System Refer to item 3 (Trouble in fuel system) Adjust Refer to item 4 (Engine lacks compression) Connect properly or replace Replace Correct or replace Correct Correct or replace
ENGINE MECHANICAL
3. Trouble In Fuel System Condition Starting motor turns over and spark occurs but engine does not start. Possible cause Fuel tank empty Water in fuel system Fuel filter clogged Fuel pipe clogged Fuel pump defective Fuel pump circuit open Evaporative Emission System circuit clogged Control Fill Clean Replace filter Clean or replace Replace Correct or replace Correct or replace Correction
6A5
Multiport Fuel Injection System faulty 4. Engine Lacks Compression Condition Engine lacks compression Possible cause Spark plug loosely fitted or spark plug gasket defective Valve timing incorrect Cylinder head gasket defective Valve incorrectly seated Valve stem seized Valve spring weakened or broken Cylinder or piston rings worn Piston ring seized
Refer to Driveability and Emissions section
Correction Tighten to specified torque or replace gasket Adjust Replace gasket Lap valve Replace valve and valve guide Replace Overhaul engine Overhaul engine.
Engine Compression Test Procedure

1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gage needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary. Limit; 1000 kPa (145 psi)
6A6
ENGINE MECHANICAL
Rough Engine Idling or Engine Stalling

Condition Trouble in fuel injection system Possible cause Throttle valve defective Throttle position sensor circuit open or shorted Fuel injector circuits open or shorted Fuel injectors damaged Fuel pump relay defective Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective Manifold Absolute Pressure Sensor circuit open or poor connections Manifold Absolute Pressure Sensor defective Engine Coolant Temperature Sensor circuit open or poor connections Engine Coolant Temperature Sensor defective Intake Air Temperature sensor circuit open or poor connections Intake Air defective Temperature sensor Correction Correct or replace Correct or replace Correct or replace Replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Replace Correct or replace Replace Correct or replace Replace Refer to Hard Start Refer to Hard Start Lap valve Replace filter element Readjust Replace
Ion sensing module cable broken or poor connections Ion sensing module defective Vehicle Speed Sensor circuit open or shorted Vehicle Speed Sensor defective Trouble in emission control system Powertrain Control Module defective Exhaust Gas Recirculation Valve circuit open or poor connections Exhaust Gas Recirculation Valve faulty Canister purge valve circuit open or poor connections Canister purge valve defective Trouble in ignition system Others Engine lacks compression Valve incorrectly seated Air Cleaner Filter clogged Valve timing incorrect Positive Crankcase Ventilation valve defective or clogged
ENGINE MECHANICAL
6A7
Rough Engine Running

Condition Engine misfires periodically Possible cause Ignition coil layer shorted Spark plugs fouling Spark plug(s) insulator nose leaking Ion sensing module or ION sensing module circuits defective Fuel injector(s) defective Powertrain control module faulty Engine knocks periodically Spark plugs running too hot Powertrain control module faulty Ion sensing module or ION sensing module circuits defective Engine lacks power Spark plugs fouled Fuel injectors defective Mass Airflow Sensor or Intake Airflow Sensor circuit defective Manifold Absolute Pressure (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective Engine Coolant Temperature Sensor or Engine Coolant Temperature Sensor circuit defective Powertrain Control Module faulty Intake Air Temperature Sensor or Intake Air Temperature Sensor circuit defective Throttle Position Sensor or Throttle Position Sensor circuit defective Ion sensing module or ION sensing module circuits defective Replace Clean or install hotter type plug Replace Correct or replace Replace Replace Install colder type spark plugs Replace Correct or replace Clean Replace Correct or replace Correct or replace Correction
Correct or replace
Replace Correct or replace
Correct circuit or replace throttle valve ASM Correct or replace
6A8
ENGINE MECHANICAL
Hesitation
Condition Hesitation on acceleration Possible cause Throttle Position Sensor adjustment incorrect Throttle Position Sensor circuit open or shorted Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective Manifold Absolute Pressure (MAP) Sensor circuit open or shorted MAP Sensor defective Intake Air Temperature (IAT) Sensor circuit open or shorted Ion sensing module Circuit open or poor connections Ion sensing module defective IAT Sensor defective Hesitation at high speeds (Fuel pressure too low) Fuel tank strainer clogged Fuel pipe clogged Fuel filter clogged Defective fuel pump system Fuel Pressure Control Valve leaking Hesitation at high speeds (Fuel injector not working normally) Power supply or ground circuit for Multiport Fuel Injection System shorted or open Fuel Injector defective Cable of Multiport Fuel Injection System circuit open or poor connections Correction Replace throttle valve assembly Correct or replace Correct or replace Replace Correct or replace Replace Correct or replace Correct or replace Replace Replace Clean or replace Clean or replace Replace Check and replace Replace Check and correct or replace
Replace Correct or replace
ENGINE MECHANICAL
Condition Hesitation at high speeds Possible cause Powertrain Control Module defective Throttle Position Sensor broken or poor connections cable Replace Correction
6A9
Correct cable or replace throttle valve ASM Replace throttle valve ASM Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Check and correct or replace Replace filter element Check and correct or replace
Throttle Position Sensor defective Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective MAP Sensor cable broken or poor connections MAP Sensor defective IAT Sensor circuit open or poor connections IAT Sensor defective Ion sensing module circuit open or poor connections Ion sensing module defective Throttle valve not fully opened Air Cleaner Filter clogged Power supply voltage too low
6A10
ENGINE MECHANICAL
Engine Lacks Power

Condition Trouble in fuel system Possible cause Fuel Pressure Control Valve not working normally Fuel injector clogged Fuel pipe clogged Fuel filter clogged or fouled Fuel pump drive circuit not working normally Fuel tank not sufficiently breathing due to clogged Evaporative Emission Control System circuit Water in fuel system Inferior quality fuel in fuel system Powertrain Control Module supplied poor voltage Throttle Position Sensor broken or poor connections cable Replace Clean or replace Clean Replace Correct or replace Clean or replace Correction
Clean Use fuel of specified octane rating Correct circuit Correct or replace Replace Replace Replace Replace Correct or replace Replace Replace Replace filter element Correct or replace Repair Refer to Hard Start Troubleshooting Guide Install spark plugs of adequate heat range Replace
Throttle Position Sensor defective Mass Airflow Sensor not working normally Manifold Absolute Pressure Sensor not working normally Intake Air Temperature Sensor not working normally Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective Powertrain Control Module defective Trouble in intake or exhaust system Air Cleaner Filter clogged Air duct kinked or flattened TWC defective Ignition failure Heat range of spark plug inadequate Ignition coil defective
ENGINE MECHANICAL 6A11

Condition Engine overheating Possible cause Level of Engine Coolant too low Fan clutch defective Incorrect fan installed Thermostat defective Engine Coolant pump defective Radiator clogged Radiator filler cap defective Level of oil in engine crankcase too low or wrong engine oil Resistance increased in exhaust system Replenish Replace Replace Replace Correct or replace Clean or replace Replace Change or replenish Clean exhaust system or replace defective parts Replace with Throttle Valve ASM Correct or replace Replace Replace (Use a thermostat set to open at 82C (180F)) Refer to Hard Start Adjust to recommended pressures Adjust Adjust or replace Correct level of engine oil Replace Correction
Throttle Position Sensor adjustment incorrect Throttle Position Sensor circuit open or shorted Cylinder head gasket damaged Engine overcooling Engine lacks compression Others Thermostat defective Tire inflation pressure abnormal Brake drag Clutch slipping Level of oil in engine crankcase too high Exhaust Gas Recirculation Valve defective
Engine Noisy
Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically. Condition Noise from crank journals or from crank bearings (Faulty crank journals and crank bearings usually make dull noise that becomes more evident when accelerating) Possible cause Oil clearance increased due to worn crank journals or crank bearings Crankshaft out of round Correction Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing Crank bearing seized. Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing
Crank bearing seized
6A12
ENGINE MECHANICAL
Troubleshooting Procedure Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out. Condition Noise from connecting rods or from connecting rod bearings (Faulty connecting rods or connecting rod bearings usually make an abnormal noise slightly higher than the crank bearing noise, which becomes more evident when engine is accelerated) Possible cause Bearing or crankshaft pin worn Correction Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing Correct or replace Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing
Crankpin out of round
Connecting rod bent Connecting rod bearing seized
Troubleshooting Procedure Abnormal noise stops when the spark plug on the cylinder with defective part is shorted out. Condition Piston and cylinder noise (Faulty piston or cylinder usually makes a combined mechanical thumping noise which increases when engine is suddenly accelerated but diminishes gradually as the engine warms up) Possible cause Piston clearance increased due to cylinder wear Piston seized Piston ring broken Piston defective Correction Replace piston and cylinder body Replace piston and cylinder body Replace piston and cylinder body Replace pistons and others
Troubleshooting Procedure Short out each spark plug and listen for change in engine noise. Condition Piston pin noise (Piston makes noise each time it goes up and down) Possible cause Piston pin or piston pin hole worn Correction Replace piston, piston pin and connecting rod assy

Troubleshooting Procedure The slapping sound stops when spark plug on bad cylinder is shorted out. Condition Timing belt noise Possible cause Timing belt tension is incorrect Tensioner bearing defective Timing belt defective Timing pulley defective Timing belt comes in contact with timing cover Valve noise Valve clearance incorrect Valve and valve guide seized Valve spring broken or weakened Valve seat offpositioned Camshaft worn out Crankshaft noise Crankshaft end play excessive (noise occurs when clutch is engaged) Preignition due to use of spark plugs of inadequate heat range Carbon deposits chambers in combustion Correction Replace pusher or adjust the tension pulley or replace timing belt Replace Replace Replace Replace timing belt and timing cover Replace adjusting shim Replace valve and valve guide Replace Correct Replace Replace thrust bearing
Engine knocking
Install Spark Plugs of adequate heat range Clean Replace fuel Refer to Section 6E Caution operator of incorrect gear selection Refer to Engine Lacks Power Replace Repair or Replace Replace auto tentioner or drive belt
Fuel too low in octane rating Wide Open Throttle enrichment system failure Selection incorrect Others of transmission gear
Engine overheating Water pump defective Exhaust system defective Drive belt slipping
6A14
ENGINE MECHANICAL
Abnormal Combustion
Condition Trouble in fuel system Possible cause Fuel pressure control valve defective Fuel filter clogged Fuel pump clogged Fuel tank or fuel pipe clogged Fuel injector clogged Fuel pump relay defective Power supply cable for fuel pump broken or poor connections Mass Airflow (MAF) sensor circuit open or defective MAF Sensor defective Manifold Absolute Pressure Sensor circuit open or shorted Manifold Absolute Pressure Sensor defective Engine Coolant Temperature (ECT) Sensor circuit open or shorted ECT Sensor defective Throttle Position Sensor adjustment incorrect Throttle Position Sensor defective Throttle Position Sensor connector poor connections Vehicle Speed Sensor cable poor connections or defective Vehicle Speed Sensor loosely fixed Vehicle Speed Sensor in wrong contact or defective Powertrain Control Module cable poor connections or defective Trouble in emission control system Heated Oxygen Sensor circuit open Heated Oxygen Sensor defective Signal vacuum hose loosely fitted or defective EGR Valve circuit open or shorted Exhaust Gas Recirculation Valve defective ECT Sensor circuit open or shorted Canister Purge Valve circuit open or shorted Canister Purge Valve defective ECT Sensor defective Positive Crankcase Ventilation (PCV) valve and hose clogged Evaporator system Trouble in ignition system Replace Replace Clean or replace Clean or replace Clean or replace Replace Reconnect, correct or replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Readjust Replace Reconnect Correct or replace Fix tightly Replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Replace Replace Correct or replace Refer to Section 6E Refer to Engine Lacks Power Correction

Condition Trouble in cylinder head parts Possible cause Carbon deposits chamber in combustion Correction Remove carbon Remove carbon
Carbon deposit on valve, valve seat and valve guide
6A16
ENGINE MECHANICAL
Engine Oil Consumption Excessive

Condition Oil leaking Possible cause Oil pan drain plug loose Crankcase fixing bolts loosened Oil pan setting bolts loosened Oil pan gasket broken Front cover retaining bolts loose or gasket broken Head cover fixing gasket broken bolts loose or Retighten Retighten Replace gasket Retighten or replace gasket Retighten or replace gasket Replace Retighten or replace oil filter Replace oil seal Retighten or replace Replace hose Clean Replace oil seal Replace Replace valve and valve guide Replace cylinder body assembly and pistons Correct Correct Replace cylinder body assembly and pistons Replace pistons and others Clean piston and replace rings Clean Use oil of recommended S.A.E. viscosity Continuous high speed operation and/or severe usage will normally cause increased oil consumption Correction Retighten or replace gasket
Oil filter adapter cracked Oil filter attaching bolt loose or rubber gasket broken Crankshaft front or rear oil seal defective Oil pressure unit loose or broken Blowby gas hose broken Positive Crankcase Ventilation Valve clogged Engine/Transmission coupling failed Oil leaking into combustion chambers due to poor seal in valve system Oil leaking into combustion chambers due to poor seal in cylinder parts Valve stem oil seal defective Valve stem or valve guide worn Cylinders and excessively Piston ring positioned pistons gaps worn
incorrectly
Piston rings set with wrong side up Piston ring sticking Piston ring and ring groove worn Return ports in oil rings clogged Positive Crankcase System malfunctioning Others Ventilation Positive Crankcase Ventilation Valve clogged Improper oil viscosity Continuous high speed driving and/or severe usage such as trailer towing
Fuel Consumption Excessive

Condition Trouble in fuel system Possible cause Mixture too rich or too lean due to trouble in fuel injection system Fuel cut function does not work Trouble in ignition system Others Misfiring or abnormal combustion due to trouble in ignition system Engine idle speed too high Fuel system leakage Clutch slipping Brake drag Selection incorrect of transmission gear Correction Refer to Abnormal Combustion Refer to Abnormal Combustion Refer to Hard Start or Abnormal Combustion Reset Idle Air Control Valve Correct or replace Correct Correct Caution operator of incorrect gear selection Refer to Abnormal Combustion
Excessive Exhaust Gas Recirculation flow due to trouble in Exhaust Gas Recirculation system
Lubrication Problems
Condition Oil pressure too low Possible cause Wrong oil in use Relief valve sticking Oil pump not operating properly Oil pump strainer clogged Oil pump worn Oil pressure gauge defective Crankshaft bearing or connecting rod bearing worn Oil contamination Wrong oil in use Oil filter clogged Cylinder head gasket damage Burned gases leaking Oil not reaching valve system Oil passage in cylinder head or cylinder body clogged Replace Correct or replace Clean or replace strainer Replace Correct or replace Replace Replace with correct engine oil Replace oil filter Replace gasket Replace piston and piston rings or cylinder body assembly Clean or correct Correction Replace with correct engine oil
Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil. a. Check the viscosity of the oil. b. Change the oil if the viscosity is outside the specified standard. c. Refer to the Maintenance and Lubrication section of this manual. 2. Check the engine oil level. The level should fall somewhere between the ADD and the FULL marks on the oil level dipstick. If the oil level does not reach the ADD mark on the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit. 4. Install an oil pressure gauge. 5. Start the engine and allow the engine to reach normal operating temperature (About 80C). 6. Measure the oil pressure. Oil pressure should be: 392550 kPa (56.980.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the oil pressure gauge. 9. Install the oil pressure unit. 10. Start the engine and check for leaks.
6A18
ENGINE MECHANICAL
Malfunction Indicator Lamp

The instrument panel CHECK ENGINE Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Condition CHECK ENGINE MIL does not illuminate at the starting of engine Possible cause Bulb defective MIL circuit open Command signal circuit to operate self diagnostic system shorted Engine Control Module (PCM) cable loosely connected, disconnected or defective PCM defective CHECK ENGINE MIL illuminates, and stays on Deterioration of heated sensor internal element oxygen Replace Correct or replace Correct or replace Correct or replace Correction
Replace Replace Reconnect properly Correct Correct or replace Replace Reconnect properly Correct Correct or replace Correct or replace Replace Correct or replace Correct or replace Correct or replace Correct or replace Correct or replace Replace PCM Replace PCM
Heated oxygen sensor connector terminal improper contact Heated oxygen sensor lead wire shorted Heated oxygen sensor circuit open Deterioration of engine coolant temperature sensor internal element Engine coolant temperature sensor connector terminal improper contact Engine coolant temperature sensor lead wire shorted Engine coolant temperature sensor circuit open Throttle position sensor open or shorted circuits Deterioration of crankshaft position sensor Crankshaft position sensor circuit open or shorted Vehicle speed sensor circuit open Manifold absolute pressure sensor circuit open or shorted Intake air temperature sensor circuit open or shorted Fuel injector circuit open or shorted PCM driver transistor defective Malfunctioning of PCM RAM (Random Access Memory) or ROM (Read Only Memory)
Cylinder Head Cover LH

Removal
1. Disconnect battery ground cable. 2. Remove engine cover from the dowels on the common chamber. 5. Ignition coil connector and ignition coil. D Disconnect the three connectors from the ignition coils. D Remove harness bracket bolt on cylinder head cover. D Remove fixing bolts on ignition coils.
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3. Disconnect positive crankcase ventilation hose. 4. Remove ground cable fixing bolt on cylinder head cover.
060R200199
Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assemblies 6. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 7. Remove eight fixing bolts, then the cylinder head cover.
010R200001
6A20
ENGINE MECHANICAL
Installation
1. Install cylinder head cover. D Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. D Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bearing cap on front and rear sides. D The cylinder head cover must be installed with in 5 minutes after sealant application to prevent hardning of sealant. D Tighten bolts to the specified torque. Torque : 9 Nm (78 lb in)
060R200199
Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assembly CAUTION: Ignition coil assembly #6 is different from ignition coil assembly from #1 to #5. Ignition coil assembly #6 is short type. So, note it when installing ignition coil assembly of #6.
010R200002
2. Install fuel injection harness bracket and tighten bolt to the specified torque. Torque : 9 Nm (78 lb in) 3. Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque. Torque : 4 Nm (35 lb in)
060RY00002
Legend (1) Long Type Ignition Coil Assemblies (# 1 # 5) (2) Short Type Ignition Coil Assembly (# 6) 4. Connect ground cable and tighten bolts to the specified torque. Torque : 9 Nm (78 lb in) 5. Install positive crankcase ventilation hose. 6. Install engine cover mating with the dowels.
Cylinder Head Cover RH

Removal
1. Disconnect battery ground cable. 2. Remove engine cover from the dowels on the common chamber.
Installation
1. Install cylinder head cover. D Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-1207B or equivalent) bead (diameter 2-3 mm) at eight places of arched areas of camshaft bracket on front and rear sides. D The cylinder head cover must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. D Tighten bolts to the specified torque. Torque : 9 Nm (78 lb in)
F06RY001
3. Disconnect ventilation hose from cylinder head cover. 4. Disconnect three ignition coil connectors from ignition coils and remove harness bracket bolts on cylinder head cover then remove ignition coil fixing bolts on ignition coils and remove ignition coils. 5. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 6. Remove eight fixing bolts then the cylinder head cover.
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2. Tighten fuel injector harness bracket bolts to specified torque then reconnect fuel injector harness connector. Torque : 9 Nm (78 lb ft) 3. Connect ignition coil connector and tighten ignition coil fixing bolts to specified torque. Torque : 4 Nm (35 lb in) 4. Connect ventilation hose to cylinder head. 5. Install engine cover mating with the dowels.
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6A22
ENGINE MECHANICAL
Common Chamber
Removal
1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 10. Remove common chamber four bolts and four nuts then remove the common chamber.
025R200001
013RY00001
Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Air Flow Sensor 3. Disconnect vacuum booster hose from common chamber. 4. Disconnect connector from manifold absolute pressure sensor, ion sensing module, throttle position sensor, solenoid valve, electric vacuum sensing valve, and EGR valve. 5. Disconnect vacuum hose on canister VSV and positive crankcase ventilation hose, fuel rail assembly with pressure control valve bracket. 6. Remove ventilation hose from throttle valve and intake duct and remove water hose. 7. Remove the four throttle body fixing bolts. 8. Remove exhaust gas recirculation valve assembly fixing bolt and nut on common chamber and remove EGR valve assembly. 9. Remove two bolts from common chamber rear side for remove fuel hose bracket.
Legend (1) Common Chamber (2) Throttle Valve Assembly (3) Bolt
Installation
1. Install common chamber and tighten bolts and nuts to the specified torque. Torque : Bolt : 25 Nm (18 lb ft) Nut : 25 Nm (18 lb ft) 2. Install fuel hose bracket and tighten bolts to specified torque. Torque : 10 Nm (87 lb in) 3. Install exhaust gas recirculation valve assembly and tighten bolt and nut to the specified torque. Torque : 25 Nm (18 lb ft) 4. Install throttle body and tighten bolts to the specified torque. Torque : 25 Nm (18 lb ft) 5. Install ventilating hose to throttle valve and intake duct. 6. Connect vacuum hoses on canister VSV and positive crankcase ventilation hose. Tighten bolts for fuel rail assembly with pressure control valve bracket. Torque : 25 Nm (18 lb ft) 7. Connect each connector without fail. 8. Connect vacuum booster hose.

9. Connect the ion sensing module connectors as shown in the illustration.
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Legend (1) Green Connector (2) Blue Connector (3) Identification Mark (6VE1 Engine Only) 10. Install air cleaner duct assembly.
013RY00001
Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Mass Air Flow Sensor
6A24
ENGINE MECHANICAL
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable. 2. Remove transfer case skid plate. 3. Remove 3rd crossmember. 4. Disconnect Heated oxygen (O2) sensor connector. 5. Remove the three stud nuts from the front exhaust pipe flange and two nuts from the rear exhaust pipe flange.
Installation
1. Install exhaust manifold and gasket and tighten exhaust manifold fixing nuts to the specified torque with new nuts. Torque: 52 Nm (38 lb ft) 2. Install heat protector. 3. Install exhaust front pipes three stud nuts and rear pipes two nuts to the specified torque. Torque : Stud nuts: 67 Nm (49 lb ft) Nuts (Exhaust front pipe LHRH): 57 Nm (42 lb ft) Nuts (Exhaust front pipe silencer): 43 Nm (32 lb ft) 4. Set A/C compressor to normal position and tighten two bolts to the specified torque. Torque : 40 Nm (30 lb ft) 5. Reconnect O2 sensor connectors. 6. Install 3rd crossmember. 7. Install transfer case skid plate.
035RX015
Legend (1) O2 Sensors (2) Exhaust Front Pipe LH (3) Transfer Case Skid Plate (4) 3rd Crossmember 6. Remove heat protector two fixing bolts then the heat protector. 7. Remove a bolt on engine LH side for air conditioner (A/C) compressor bracket and loosen two bolts for A/C compressor then move A/C compressor to front side. 8. Remove exhaust manifold eight fixing nuts and remove exhaust manifold from the engine.
Exhaust Manifold RH
Removal
035RX016
Legend (1) Exhaust Front Pipe RH (2) O2 Sensors (3) Torsion Bar
(4) Front Propeller Shaft (5) Transfer Case Skid Plate (6) 3rd Crossmember
1. Disconnect battery ground cable. 2. Remove transfer case skid plate. 3. Remove 3rd crossmember. 4. Remove torsion bar and front propeller shaft. Refer to removal procedure in Front Suspension section. 5. Disconnect front Heated oxygen (O2) sensor connectors. 6. Remove front exhaust flange pipe three stud nuts and two rear flange nuts then disconnect exhaust pipe. 7. Remove heat protector two fixing bolts then the heat protector. 8. Remove exhaust gas recirculation (EGR) pipe fixing bolt and nut from exhaust manifold, remove a nut from EGR valve and a bolt from rear side of cylinder head for bracket of EGR pipe then remove the EGR pipe. 9. Remove exhaust manifolds eight fixing nuts and the exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the specified torque. Torque : 52 Nm (38 lb ft) 2. Install the EGR pipe, tighten bolt and nut on exhaust manifold to specified torque. Torque : 28 Nm (21 lb ft) Tighten nut to EGR valve to the specified torque. Torque : 44 Nm (33 lb ft) Tighten the bolt for EGR pipe bracket to specified torque. Torque : 25 Nm (18 lb ft) 3. Install heat protector
6A26
ENGINE MECHANICAL
7. Install front propeller shaft. Refer to installation procedue in Front suspension section. 8. Install 3rd crossmember. 9. Install transfer case skid plate.
4. Install front exhaust flange pipe and tighten three stud nuts and rear two nuts to the specified torque. Torque: Stud nuts: 67 Nm (49 lb ft) Nuts: 57 Nm (42 lb ft) 5. Reconnect O2 Sensor harness connector. 6. Install the torsion bar and readjust the vehicle height. Refer to installation and vehicle height adjustment procedure for Front Suspension.
Crankshaft Pulley
Removal
1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 4. Move serpentine belt tensioner to loose side using wrench then remove serpentine belt.
850RW001
013RY00001
Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Mass Air Flow Sensor 3. Remove radiator upper fan shroud from radiator.
Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Driver Belt 5. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly. 6. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley then remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft holder, hold the crankshaft pulley and tighten center bolt to the specified torque. Torque : 167 Nm (123 lb ft)

2. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly. 3. Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position. 4. Install radiator upper fan shroud. 5. Install air cleaner assembly.
Timing Belt
Removal
1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. 4. Move drive belt tensioner to loose side using wrench then remove drive belt. 11. Remove right side timing belt cover then left side timing belt cover. 12. Remove lower timing belt cover 13. Remove pusher. CAUTION: The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.
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Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 5. Remove cooling fan assembly four nuts, then the cooling fan assembly. 6. Remove cooling fan drive pulley assembly. 7. Remove idle pulley assembly. 8. Remove serpentine belt tensioner assembly. 9. Remove power steering pump assembly. 10. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley remove center bolt, then the pulley.
Legend (1) Up Side (2) Down Side (3) Direction For Installation (4) Locking Pin 14. Remove timing belt. CAUTION: 1. Do not bend or twist the belt, otherwise its core could be damaged. The belt should not be bent at a radius less than 30 mm. 2. Do not allow oil or other chemical substances to come in contact with the belt. They will shorten the life. 3. Do not attempt to pry or stretch the belt with a screw driver or any other tool during installation. 4. Store timing belt in a cool and dark place. Never expose the belt direct sunlight or heat.
6A28
ENGINE MECHANICAL
1. Install timing belt. 1. Align groove of crankshaft timing pulley (2) with mark on oil pump (1). Align the mark on the crankshaft timing pulley (3) with alignment mark (white dotted line) on the timing belt (4). Secure the belt with a double clip or equivalent clip. NOTE: When timing marks are aligned, No.2 piston will be on Top Dead Center.
Installation
NOTE: For correct belt installation, the letter on the belt must be able to be read as viewed from the front of the vehicle.
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Legend (1) Crankshaft Timing Pulley (2) RH Bank Camshaft Drive Gear Pulley (3) Water Pump Pulley (4) Idle Pulley (5) LH Bank Camshaft Drive Gear Pulley (6) Tension Pulley (7) Alignment Mark on Oil Pump. (8) Alignment Mark on Timing Belt
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Legend (1) Alignment Mark on Oil Pump (2) Groove on Crankshaft Timing Pulley (3) Alignment Mark on Crankshaft Timing Pulley (4) Alignment Mark on Timing Belt
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Legend (1) Timing Belt (2) Engine Rotation Direction (3) Cylinder Head Side

2. Align the alignment mark on the RH bank camshaft drive gear pulley (2) to the alignment mark of the cylinder head cover RH (3). 3. Align the alignment mark (white line) on the timing belt (1) with alignment mark on the RH bank camshaft drive gear pulley (2) (on the left side as viewed from the front of the vehicle) and put the timing belt on the camshaft drive gear pulley. Secure the belt with a double clip or equivalent clip. NOTE: It is recommended for easy installation that the belt be secured with a double clip or equivalent clip after it is installed to each pulley.
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Legend (1) Alignment Mark on Timing Belt (White line). (2) Alignment Mark on Camshaft Drive Gear Pulley. (3) Alignemnt Mark on Cylinder Head Cover RH. 4. Align the alignment mark on the LH bank camshaft drive gear pulley (2) to the alignment mark of the cylinder head cover LH (3). 5. Align the alignment mark (white line) on the timing belt (1) with the alignment mark on the LH bank camshaft drive gear pulley (2). When aligning the timing marks, use a wrench to turn the camshaft drive gear pulley, then set the timing mark between timing belt and camshaft drive gear pulley and put the timing belt on the camshaft drive gear pulley. Secure the belt with a double clip or equivalent clip.
6. Install crankshaft pulley temporarily and tighten center bolt by hand (do not use a wrench). Turn the crankshaft pulley clockwise to give some belt slack between the crankshaft timing pulley and the RH bank camshaft drive gear pulley. 2. Install pusher and tighten bolt to the specified torque. 1. Install the pusher while pushing the tension pulley to the belt. 2. Pull out pin from the pusher. NOTE: When reusing the pusher, press the pusher with approximately 100Kg to retract the rod, and insert a pin (1.4 mm piano wire).
6A30
ENGINE MECHANICAL
014RW011
020RW003
Legend (1) Up Side (2) Down Side (3) Direction for Installation (4) Locking Pin 3. Remove double clips or equivalent clips from timing belt pulleys. Turn the crankshaft pulley clockwise by two turns. Torque : 25 Nm (18 lb ft) 3. Install timing belt cover. Remove crankshaft pulley that was installed in step 1 item 5. Tighten bolts to the specified torque. Torque: 19 Nm (14 lb ft)
Legend (1) Timing Belt Cover (2) Rubber Bushing (3) Sealing Rubber (4) Cylinder Body 4. Install crankshaft pulley using J-8614-01, hold the crankshaft pulley and tighten center bolt to the specified torque. Torque : 167 Nm (123 lb ft) 5. Install fan pulley bracket and tighten fixing bolts to the specified torque. Torque : 22 Nm (16 lb ft) 6. Install power steering pump assembly and tighten to the specified torque. Torque : M8 bolt : 22 Nm (16 lb ft) M10 bolt : 46 Nm (34 lb ft) 7. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly.
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Legend (1) Timing Belt Cover RH (2) Timing Belt Cover LH (3) Timing Belt Cover Lower

8. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position.
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Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Auto Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 9. Install radiator upper fan shroud. 10. Install air cleaner assembly.
6A32
ENGINE MECHANICAL
Camshaft
Removal
1. Disconnect battery ground cable. 2. Remove crankshaft pulley. D Refer to removal procedure for Crankshaft Pulley in this manual. 3. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual. 4. Remove cylinder head cover LH. D Refer to removal procedure for Cylinder Head Cover LH in this manual. 5. Remove cylinder head cover RH. D Refer to removal procedure for Cylinder Head Cover RH in this manual. 6. Remove twenty fixing bolts from inlet and exhaust camshaft bearing cap on one side bank, then camshaft bearing caps. 9. Remove three fixing bolts from camshaft drive gear retainer, then camshaft drive gear assembly.
014RW026
Legend (1) Right Bank (2) Left Bank (3) Timing Mark on Retainer
Installation
1. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque : 10 Nm (87 lb in) 2. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque : 98 Nm (72 lb ft)
014RW027
7. Remove camshaft assembly. 8. Remove fixing bolt for camshaft drive gear pulley.
3. Tighten sub gear setting bolt. 1. Use the J42686 gear spring lever to turn sub gear to right direction until it aligns with the M5 bolt hole between camshaft driven gear and sub gear. 2. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving.
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4. Install camshaft assembly and camshaft bearing caps, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).
Legend (1) Right Bank Camshaft Drive Gear (2) Left Bank Camshaft Drive Gear (3) Timing Mark on Drive Gear (4) Dowel Pin
014RW020
Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discrimination Mark (LI: Left bank intake, RI: Right bank intake) (LE: Left bank exhaust, RE: Right bank exhaust)
6A34
ENGINE MECHANICAL
014RW024
Legend (1) Right Bank (2) Left Bank
(3) Alignment Mark on Camshaft Drive Gear (4) Alignment Mark on Camshaft (5) Alignment Mark on Retainer
3. Tighten twenty bolts on numerical order an one side bank as shown in the illustration. Torque : 10 Nm (87 lb in)
5. Install cylinder head cover RH. D Refer to installation procedure for CYLINDER HEAD COVER RH in this manual. 6. Install cylinder head cover LH. D Refer to installation procedure for CYLINDER HEAD COVER LH in this manual. 7. Install timing belt. D Refer to installation procedure for TIMING BELT in this manual. 8. Install crankshaft pulley. D Refer to installation procedure for CRANKSHAFT PULLEY in this manual.
014RW031
Cylinder Head
Removal
1. Remove engine hood. 2. Disconnect battery ground cable. 3. Drain radiator coolant. 4. Drain engine oil. 5. Remove crankshaft pulley. D Refer to removal procedure for Crankshaft Pulley in this manual. 6. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual. 7. Remove cylinder head cover LH. D Refer to removal procedure for Cylinder Head Cover LH in this manual. 8. Remove cylinder head cover RH. D Refer to removal procedure for Cylinder Head Cover RH in this manual. 9. Remove common chamber. D Refer to removal procedure for Common Chamber in this manual. 10. Remove cylinder head assembly. A. Loosen head bolts in reverse of tightening sequence. B. Remove cylinder head assembly.
Installation
1. Install cylinder head assembly to cylinder block. A. Put cylinder head gasket on the cylinder block. NOTE: There is discrimination mark R for right bank and L for left bank on the cylinder head gasket as shown in the illustration. Do not reuse cylinder head gasket.
011RW005
B. Align dowel pin hole to dowel pin on the cylinder block. C. Position cylinder head on the cylinder block. D. Tighten two bolts temporarily by hand to prevent the cylinder head assembly from moving. E. Using J-24239-01 cylinder head bolt wrench, tighten bolts in numerical order as shown in the illustration to the specified torque.
014RW028
Legend (1) Cylinder Head (2) Cylinder Head Bolt (3) Camshaft
6A36
ENGINE MECHANICAL
NOTE: Do not reuse cylinder head bolts. Do not apply any lubricant to the cylinder head bolts. Torque : Temporary : 29 Nm (22 lb ft) Final : 64 Nm (47 lb ft)
014RW029
2. Install common chamber. D Refer to installation procedure for Common Chamber in this manual. 3. Install cylinder head cover RH. D Refer to installation procedure for Cylinder Head Cover RH in this manual. 4. Install cylinder head cover LH. D Refer to installation procedure for Cylinder Head Cover LH in this manual. 5. Install timing belt. D Refer to installation procedure for Timing Belt in this manual. 6. Install crankshaft pulley. D Refer to installation procedure for Crankshaft Pulley in this manual.
Valve Stem Oil Controller , Valve Spring and Valve Guide

Removal
1. Disconnect battery ground cable. 2. Drain engine oil. D Drain engine coolant. 3. Remove cylinder head assembly. D Refer to removal procedure for Cylinder Head in this manual. 4. Remove camshaft. D Refer to removal procedure for Camshaft in this manual. 5. Remove tappets with shim. NOTE: Do not damage shim surface. 6. Remove valve springs using J8062 valve spring compressor and J42898 valve spring compressor adapter then remove upper valve spring seat and lower seat.
Installation
1. Install valve guide using J42899 valve guide installer. 2. Install oil controller using J38537 oil controller installer. 3. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using J8062 valve spring compressor and J42898 valve spring compressor adapter to install the split collars.
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014RW042
7. Remove oil controller using J37281 oil controller remover, remove each valve stem oil controller. 8. Remove valve guide using J37985 valve guide replacer.
4. Install tappet with shim. 5. Install camshaft assembly. D Refer to installation procedure for Camshaft in this manual. 6. Install cylinder head assembly. D Refer to installation procedure for Cylinder Head in this manual. 7. Fill engine oil until full level. 8. Fill engine coolant.
6A38
ENGINE MECHANICAL
Piston, Piston Ring and Connecting Rod

Removal
F06RW011
Legend (1) Cylinder Head (2) Crankcase with Oil Pan (3) Oil Pipe
(4) Oil Strainer (5) Oil Gallery (6) Piston with Connecting Rod Assembly
1. Remove cylinder head assembly. D Refer to removal procedure for Cylinder Head in this manual. 2. Remove crankcase with Oil Pan. D Refer to removal procedure for Oil Pan and Crankcase in this manual.

3. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring.
015RW003
050RW002
Legend (1) Oil Pump (2) Oil Strainer (3) Oil Gallery (4) From Oil Filter (5) To Oil Filter 4. Remove three fixing bolts, oil pipe with O-ring. 5. Remove eight fixing bolts, oil gallery. 6. Remove piston with connecting rod assembly. (before removing the bearing cap, remove carbon on the top of cylinder bore and push piston with connecting rod out from the top of cylinder bore.)
Legend (1) Piston Front Mark (2) Piston Grade (3) Connecting Rod Front Mark 2. Install oil gallery and tighten the bolts in two steps, in the order shown in illustration. Torque : 1st step : 29 Nm (22 lb ft) 2nd step : 5565
Installation
1. Install piston with connecting rod assembly. D Apply engine oil to cylinder bore, connecting rod bearing and crank pin. When installing the piston, its front mark must face the engine front side. D The bearing cap number must be the same as connecting rod number. D Apply engine oil to the thread and seating surface of each nut. D Tighten nuts to the specified torque. Torque : 54 Nm (40 lb ft) D After tightening the nuts, make sure that the crankshaft rotates smoothly. NOTE: Do not apply engine oil to the bearing back faces and connecting rod bearing fitting surfaces. 3. Install oil pipe with O-ring. Torque : 10 Nm (87 lb in) 4. Install oil strainer assembly with O-ring. Torque : 25 Nm (18 lb ft) 5. Install crankcase with Oil Pan. D Refer to installation procedure for Oil Pan and Crankcase in this manual. 6. Install cylinder head assembly. D Refer to installation procedure for Cylinder Head in this manual.
051RS009
6A40
ENGINE MECHANICAL
Crankshaft and Main Bearings

Removal
F06RY002
Legend (1) Engine Assembly (2) Crankshaft Pulley (3) Timing Belt Cover (4) Timing Belt (5) Crankcase with Oil Pan (6) Oil Pipe (7) Oil Strainer
(8) (9) (10) (11) (12) (13) (14) (15)
Oil Pump Assembly Cylinder Body Side Bolt Oil Gallery Flywheel Rear Oil Seal Retainer Connecting Rod Cap Crankshaft Main Bearing Cap Crankshaft and Main Bearing
1. Remove engine assembly. D Refer to removal procedure for Engine Assembly in this manual. 2. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual.
3. Remove oil pan and crankcase. D Refer to removal procedure for Oil Pan and Crankcase in this manual. 4. Remove oil pipe with O-ring. 5. Remove oil strainer assembly with O-ring.

6. Remove oil pump assembly. D Refer to removal procedure for Oil Pump in this manual. 7. Remove cylinder body side bolts. 8. Remove oil gallery. 9. Remove flywheel. 10. Remove rear oil seal retainer. D Refer to removal procedure for Rear Oil Seal in this manual. 11. Remove connecting rod caps. 12. Remove crankshaft main bearing caps. 13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings. D Install main bearing in the cylinder block and main bearing cap respectively. Apply new engine oil to upper and lower main bearings. NOTE: D D D D D D Do not apply engine oil to the bearing back faces. Make sure that main bearings are in correct position. Install crankshaft with care. Apply engine oil to the thrust washer. Install thrust washer on No.3 journal. Oil grooves in thrust washer must face the crankshaft.
015RS013
2. Install crankshaft main bearing caps. D Apply engine oil to the thread and seating surface of each bearing cap fixing bolt. NOTE: D Do not apply engine oil to the bearing back faces. D Install bearing caps, starting with cylinder block front side. D Tighten main bearing fixing bolts to the specified torque. Torque : 39 Nm (29 lb ft) D After tightening the bolts, make sure that the crankshaft rotates smoothly. 3. Install connecting rod caps. D The cap number must be same as connecting rod number. D Apply engine oil to the thread and seating surface of each nut. D Tighten nuts to the specified torque. Torque : 54 Nm (40 lb ft) D After tightening the nuts, make sure that the crankshaft rotates smoothly. 4. Install rear oil seal retainer. D Remove oil on cylinder block and retainer fitting surface. D Apply sealant (TB1207B or equivalent) to retainer fitting surface as shown in illustration.
015RS012
6A42
ENGINE MECHANICAL
D Tighten fixing bolts to the specified torque. Torque : 54 Nm (40 lb ft)
D The oil seal retainer must be installed within 5 minutes after sealant application before the sealant hardens.
015RS018 015RW002
Legend (1) Around Bolt Holes (2) Around Dowel Pin D Apply engine oil to oil seal lip and align a dowel pin hole in the cylinder block with that in the retainer. D Tighten retainer fixing bolts to the specified torque. Torque : 18 Nm (13 lb ft)
6. Install oil gallery. D Clean contact surface of oil gallery and main bearing cap. Apply engine oil to oil gallery fixing bolts and tighten the bolts in two steps, in the order shown in illustration. Torque : 1st step : 29 Nm (22 lb ft) 2nd step : 5565 7. Install cylinder body side bolts and tighten bolts in order to the specified torque. Torque : 39 Nm (29 lb ft) NOTE: Do not apply the oil to the bolts.
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5. Install flywheel. D Clean tapped holes in the crankshaft. D Remove oil on crankshaft and flywheel fitting surface. NOTE: D Do not reuse the bolts. D Do not apply oil or thread lock to the bolts.
012RS007
8. Install oil pump assembly. D Remove oil on cylinder block and oil pump mounting surface.

D Apply sealant (TB1207B or equivalent) to the oil pump mounting surface. D The oil pump assembly must be installed within 5 minutes after sealant application before the sealant hardens. D Apply engine oil to oil seal lip. D Install oil pump in the cylinder block and tighten fixing bolts to the specified torque. Torque : 25 Nm (18 lb ft) 11. Install crankcase. D Remove oil on crankcase mounting surface and dry the surface. D Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the crankcase mounting surface. The bead must be continuous. D The crankcase must be installed within 5 minutes after sealant application before the sealant hardens. D Tighten fixing bolts to the specified torque. Torque : 10 Nm (87 lb in)
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Legend (1) Around Bolt Holes (2) Around Dowel Pin
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013RW004
051RW001
9. Install oil strainer with O-ring, tighten to the specified torque. Torque : 25 Nm (18 lb ft) 10. Install oil pipe with O-ring, tighten fixing bolts to the specified torque. Torque : 25 Nm (18 lb ft)
12. Install oil pan D Remove oil on oil pan mounting surface and dry the surface. D Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the oil pan mounting surface. The bead must be continuous. D The oil pan must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.
6A44
ENGINE MECHANICAL
013RW003
013RW002
13. Install timing belt. D Refer to installation procedure for Timing Belt in this manual. 14. Install engine assembly. D Refer to installation procedure for Engine in this manual.
Rear Oil Seal

Removal
1. Remove transmission assembly. D Refer to removal procedure for Transmission section in this manual. 2. Remove flywheel. 3. Remove rear oil seal using a seal remover. NOTE: Take care not to damage the crankshaft or oil seal retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using J-39201.
015RS018
3. Install transmission. D See Transmission section in this manual. CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission. Otherwise, the transmission may be damaged.
015RS017
2. Install flywheel. D Clean tapped holes in the crankshaft. D Remove oil on the crankshaft and flywheel mounting surface. D Tighten fixing bolts to the specified torque. NOTE: Do not reuse the bolts and do not apply oil or thread lock to the bolts. Torque : 54 Nm (40 lb ft)
012RS009
6A46
ENGINE MECHANICAL
Engine Assembly
Removal
035RY00001
1. Disconnect battery ground and positive cable. 2. Remove battery. 3. Make alignment mark on the engine hood and hinges before removal in order to return the hood to original position exactly. 4. Remove engine hood. 5. Drain radiator coolant. 6. Disconnect ion sensing module harness connectors, and manifold absolute pressure sensor harness connectors from sensors on common chamber. 7. Disconnect throttle position sensor harness connectors from throttle body. 8. Disconnect air duct with air cleaner cover. 9. Remove air cleaner assembly. 10. Disconnect canister vacuum hose. 11. Disconnect vacuum booster hose. 12. Disconnect three engine harness connectors. 13. Disconnect harness connector to transmission (left front side of engine compartment), disconnect shift on the fly harness connector from front side of front axle and remove transmission harness bracket from engine left side. 14. Disconnect ground cable between engine and frame. 15. Disconnect bonding cable connector on the back of right dash panel. 16. Disconnect bonding cable terminal on the left bank. 17. Disconnect starter harness connector from starter. 18. Disconnect generator harness connector from generator. 19. Disconnect coolant reserve tank hose from radiator. 20. Remove radiator upper and lower hoses. 21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly. 23. Move drive belt tensioner to loose side using wrench then remove drive belt. 24. Remove power steering pump fixing bolts, then power steering pump. Place the power steering pump along with piping on the body side. 25. Remove air conditioning compressor fixing bolts from bracket and place the compressor along with piping on the body side. 26. Remove four O2 sensor harness connectors (two each bank) from exhaust front pipe. 27. Remove three exhaust pipe fixing nuts from each bank. 28. Remove two exhaust pipe fixing nuts from each exhaust pipe, then move exhaust pipe to rear side of vehicle. 29. Remove flywheel dust covers. 30. Disconnect two heater hoses from engine. 31. Disconnect fuel hoses from right side of transmission. CAUTION: Plug fuel pipes on engine side and fuel hoses from fuel tank. 32. Remove transmission assembly. Refer to Transmission section in this manual. 33. Support the engine by engine hoist. 34. Remove two left side engine mount fixing bolts from engine mount on chassis side. 35. Remove two right side engine mount fixing bolts from engine mount on chassis side. 36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission. If the engine is assembled in the condition that the dowels have not been mounted in the specified positions, the transmission may be damaged the transmission.
035RW005
Legend (1) Exhaust Front Pipe RH (2) O2 Sensor
012RS009
1. Install engine assembly. Tighten engine mount fixing bolts to frame to the specified torque. Torque: 41 Nm (30 lb ft) 2. Reconnect fuel hose to fuel pipe on engine. 3. Install transmission assembly. Refer to Transmission section in this manual. 4. Reconnect two heater hoses to engine. 5. Install flywheel dust covers. 6. Install exhaust pipe and temporally tighten two (each bank) rear exhaust flange nuts then tighten three stud nuts (each bank) between exhaust manifold and exhaust pipe, finally tighten rear side nuts to the specified torque. Torque: Nuts (Exhaust front pipe LHRH): 57 Nm (42 lb ft) Nuts (Exhaust front pipe silencer): 43 Nm (32 lb ft)
035RW016
Legend (1) O2 Sensor (2) Exhaust Front Pipe LH 7. Reconnect O2 sensor connector. 8. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly. 9. Install air conditioner compressor to engine and tighten to the specified torque. Torque : M8 bolts : 22 Nm (16 lb ft)
6A48
ENGINE MECHANICAL
26. Reconnect connector. throttle position sensor harness
M10 bolts : 43 Nm (32 lb ft) 10. Install power steering pump, tighten fixing bolt to the specified torque. Torque : M8 bolts : 22Nm (16 lb ft) M10 bolts : 46 Nm (34 lb ft) 11. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position.
035R200004
Legend (1) Throttle Position Sensor Connector (2) Throttle Valve Assembly 27. Reconnect manifold absolute pressure sensor harness connectors. 28. Reconnect ion sensing module connectors as shown in the illustration.
850RW001
Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 12. Install upper fan shroud. 13. Reconnect radiator upper and lower hoses. 14. Reconnect coolant reserve tank hose to radiator. 15. Reconnect generator harness connector. 16. Reconnect starter harness connector. 17. Reconnect bonding cable terminal on left bank 18. Reconnect bonding cable terminal on the back of right dash panel. 19. Reconnect ground cable between engine and chassis. 20. Reconnect harness connector to transmission and install transmission harness bracket on engine left side. 21. Reconnect three engine harness connectors. 22. Reconnect vacuum booster hose. 23. Reconnect canister vacuum hose. 24. Install air cleaner assembly. 25. Reconnect air duct.
060RY00111
Legend (1) Green Connector (2) Blue Connector (3) Identification Mark (6VE1 Engine Only) 29. Install engine hood to the original position. D Refer to installation procedure for Body section in this manual.
Cylinder Head
Cylinder Head and Associated Parts
011RW008
Legend (1) Spark Plug (2) Cylinder Head Bolt (3) Camshaft Drive Gear Pulley Fixing Bolt (4) Camshaft Drive Gear Pulley (5) Camshaft Bearing Cap Fixing Bolt (6) Camshaft Bearing Cap (7) Camshaft Exhaust
(8) (9) (10) (11) (12) (13) (14)
Camshaft Intake Retainer Fixing Bolt Retainer Assembly Tappet with Shim Split Collar Valve Spring and Spring Upper Seat Valve
6A50
ENGINE MECHANICAL
Disassembly
NOTE: D During disassembly, be sure that the valve train components are kept together and identified so that they can be reinstalled in their original locations. D Before removing the cylinder head from the engine and before disassembling the valve mechanism, perform a compression test and note the results. 1. Remove camshaft drive gear pulley fixing bolt (3), then pulley (4). 2. Remove camshaft bearing cap fixing bolt (5), camshaft bearing cap (6), then camshaft exhaust (7), and intake side (8). 3. Remove tappet with shim (11). 4. Use the J8062 valve spring compressor and J42898 valve spring compressor adapter to remove the split collar (12), valve spring with upper seat (13) and valve (14).

1. Cylinder head gasket and mating surfaces for leaks, corrosion and blowby. If the gasket has failed, determine the cause. Insufficient torque on head bolts. Improper installation Loose or warped cylinder head Missing dowel pins Warped case surface 2. Cylinder head for cracks, especially between valve seats and in the exhaust ports. 3. Cylinder head deck for corrosion, sand particles in head and porosity. CAUTION: D Do not attempt to weld the cylinder head. Replace it. D Do not reuse cylinder head bolts. 4. Cylinder head deck, common chamber and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are out of flat by more than specification, the surface should be ground to within specifications. Replace the head if it requires machining beyond the repairable limit. Head surface and manifold surface Standard: 0.05 mm (0.002 in) or less Warpage limit: 0.2 mm (0.0079 in) Maximum Repairable limit: 0.2 mm (0.0079 in) Head height Standard height : 133.2 mm (5.2441 in) Warpage limit : 0.2 mm (0.0079 in) Maximum Repairable limit : 133.0 mm (5.2362 in)
014RW042
5. Remove spark plug (1). CAUTION: Do not remove the spark plugs when the head and plugs are hot. Clean dirt and debris from spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the bare metal. Do not use a motorized wire brush on any gasket sealing surface.
011RW019
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install Spark plug and tighten all the spark plugs to specified torque. Torque: 18 Nm (13 lb ft) 2. Tighten sub gear setting bolt. 1. Use J(42686 gear spring lever) to turn sub gear to right direction until the M5 bolt aligns with the hole between camshaft driven gear and sub gear. 2. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving .
014RW020
Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discrimination Mark LI: Left Bank Intake RI: Right Bank Intake LE: Left Bank Exhaust RE: Right Bank Exhaust
014RW025
3. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque: 10 Nm (87 lb in) 4. Install camshaft assembly and camshaft bearing cap, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).
014RW023
6A52
ENGINE MECHANICAL
014RW024
3. Tighten twenty bolts in numerical order on one side bank as shown in the illustration. Torque: 10 Nm (87 lb in)
014RW031
5. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque: 98 Nm (72 lb ft)
Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend (1) Camshaft Bearing Cap Fixing Bolts (2) Camshaft Assembly Inlet (3) Camshaft Assembly Exhaust (4) Shim (5) Tappet (6) Split Collar
(7) (8) (9) (10) (11) (12)
Spring Upper Seat Valve Spring Oil Controller Spring Lower Seat Valve Guide Valve
Disassembly
1. Remove camshaft bearing cap fixing bolts (1). 2. Remove camshaft assembly (intake).
3. Remove camshaft assembly (Exhaust side). 4. Remove shim (4) and tappet (5).
6A54
ENGINE MECHANICAL
2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit : 2 mm (0.0787 in)
5. Use J8062 valve spring compressor and J42898 valve spring compressor adapter to remove split collar.
014RW042
6. Remove valve spring. 7. Remove valve. 8. Remove oil controller and spring lower seat. 9. Remove the valve guide using the J42899 valve guide replacer.
014RS005

Valve Spring
CAUTION: Visually inspect the valve springs and replace them if damage or abnormal wear is evident. 1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard : 44.6 mm (1.7559 in) Limit : 43.6 mm (1.7165 in)
3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 in) Standard: 196 N (44 lb) Limit: Less than 181 N (41 lb)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratchs or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set.
014RS004

1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard : 5.977 mm5.959 mm (0.2353 in0.2346 in) Limit : 5.90 mm (0.2323 in) Exhaust Standard : 5.952 mm5.970 mm (0.2343 in0.2350 in) Limit : 5.90 mm (0.2323 in)
014RS008
2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 in) (Measured from the cylinder head upper face)
014RS007
2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set. Inside Diameter of the Vale Guide Inlet clearance Standard : 0.023 mm0.056 mm (0.0009 in0.0002 in) Limit : 0.20 mm (0.00787 in) Exhaust clearance Standard : 0.030 mm0.063 mm (0.0012 in0.0025 in) Limit : 0.20 mm (0.00787 in)
014RW046
3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance.
Valve Guide Replacement

1. Using Valve guide replacer: J42899, drive out the valve guide from the combustion chamber side.
Valve Seat
1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 in)
6A56
ENGINE MECHANICAL
2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle: 45
Limit: 39.47 mm (1.5539 in) Exhaust Standard: 39.30 mm (1.5472 in) Limit: 39.45 mm (1.5531 in)
014RS012
014RW047
2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit. Valve seat contact width Standard: 1.1 mm (0.0433 in) Limit: 1.7 mm (0.0669 in)
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface. 2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90
014RS011
Contact Surface Angle on Valve Seat on Valve

1. Measure contact surface angle on valve seat.
014RW059
3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while lapping it to fit the valve seat insert. 6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. 7. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression. 8. Lap the valve and the seat.
Reassembly
1. Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J42899, drive in a new valve guide from the camshaft side. 2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J37281, drive in a new oil controller.
014RS014
Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not to damage the aluminum section. 2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3. Strike the rod and pull it out.
014RW058
3. Install valve to valve guide. Before install valve guide apply engine oil to the outside of the valve stem. 4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward.
014RS015
4. Carefully clean the valve seat pressfit section on the cylinder head side. 5. Heat the pressfit section with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means. 6. Insert the pressfit section into the valve seat horizontally. Standard fitting interference: 0.14 mm0.09 mm (0.0055 in0.0035 in)
014RS020
6A58
ENGINE MECHANICAL
5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J8062 valve spring compressor and J42898 valve spring compressor adapter to install the split collars.
Valve Clearance Adjustments

NOTE: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite to maximum cam lift (1) as shown in illistration below.
014RW042
6. Install tappet with shim. 7. Install camshaft assembly. D Refer to installation procedure for Camshaft in this manual. Legend (1) Cam (2) Shim (3) Tappet
014RW081
Valve Clearance Standard Value (cold)

Intake: 0.23 mm0.33 mm (0.0091 in0.0130 in) Exhaust: 0.25 mm0.35 mm (0.0098 in0.0138 in)
Selection of Adjusting Shim

Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement Standard valve) Based on the above formula, the best suited shim should be selected from 41 sorts of shim (differently thick at 0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick). Install the shim and check valve clearance.
Replacement of Shim
Let the cam push down the edge of tappet by using J42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations below.
014RW084
014RW082
014RW083
6A60
ENGINE MECHANICAL
Camshaft
Camshaft and Associated Parts
014RW040
Legend (1) Camshaft Bearing Cap Fixing Bolt (2) Camshaft Bearing Cap (3) Camshaft Assembly Intake (4) Camshaft Assembly Exhaust (5) Pulley Fixing Bolt
(6) (7) (8) (9) (10)
Camshaft Drive Gear Pulley Retainer Fixing Bolt Retainer Camshaft Drive Gear Oil Seal
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley using the J43041 universal holder.
014RW060

2. Remove twenty fixing bolts from inlet and exhaust camshaft bearing cap on one side bank, then camshaft bearing cap (2). 2. Use a micrometer to measure the diameter and the uneven wear of the camshaft journals. Replace the camshaft if the diameter or the uneven wear exceeds the specified limit. Journal Diameter Standard : 25.972 mm25.993 mm (1.0225 in1.0233 in) Limit : 25.8 mm (1.0157 in) Uneven wear : 0.05 mm (0.0020 in)
014RW027
3. Remove camshaft assembly (3), (4). 4. Remove three fixing bolts (7) from camshaft drive gear retainer (8), then camshaft drive gear assembly.

1. Use a micrometer to measure the cam lobe height and uneven wear. Replace the camshaft if either the lobe height or the uneven wear exceeds the specified limit. Lobe height : 44.709 mm (1.7602 in) Uneven wear : 0.05 mm (0.0020 in)
014RS023
3. Place the camshaft on Vblocks. Slowly rotate the camshaft and measure the runout with a dial indicator. Replace the camshaft if the runout exceeds the specified limit. Runout Limit : 0.1 mm (0.0039 in)
014RW043
014RW044
6A62
ENGINE MECHANICAL
5. Replace the cylinder head and/or camshaft if the measured oil clearance exceeds the specified limit. 1. Carefully clean the camshaft journal, the camshaft bracket, and the cylinder head. 2. Install camshaft assembly and camshaft bearing cap (2), tighten twenty bolts (1) on one side bank to the specified torque. Torque: 10 Nm (87 lb in)
4. Measure the camshaft journal oil clearance. 1. Measure the camshaft bearing cap housing inside diameter. NOTE: Tighten camshaft bearing cap (2) to specified torque before measuring the camshaft bearing cap inside diameter. Torque : 10 Nm (87 lb in)
014RW031
2. Subtract the camshaft outside diameter from the camshaft bearing cap housing inside diameter. Oil Clearance Standard : 0.027 mm0.078 mm (0.0011 in0.0031 in) Limit : 0.11 mm (0.0043 in)
014RW031
3. Measure the camshaft thrust clearance with a dial indicator. Replace the camshaft and/or the cylinder head if the camshaft thrust clearance exceeds the specified limit. Camshaft thrust Clearance Standard : 0.03 mm0.08 mm (0.0012 in.0.0031 in.) Limit : 0.12 mm (0.0047 mm)
014RW037
014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten three bolts to specified torque. Torque: 10 Nm (87 lb in) 2. Tighten sub gear setting bolt. 1. Use J42686 to turn sub gear to right direction until the M5 bolt hole aligns between camshaft driven gear and sub gear. 2. Tighten M5 bolt suitable torque for prevent moving the sub gear.
014RW020
Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discerning Mark LI: Left Bank Intake RI: Right Bank Intake LE: Left Bank Exhaust RE: Right Bank Exhaust
014RW041
3. Install camshaft assembly and camshaft bearing caps, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).
014RW023
6A64
ENGINE MECHANICAL
014RW024
3. Tighten twenty bolts in numerical order on one side bank as shown in the illustration. Torque: 10 Nm (87 lb in)
4. If the oil seal requires replacement, use the J42985 to install the oil seal.
014RW034
014RW031

5. Tighten bolt for camshaft drive gear pulley to the specified torque using the J43041 universal holder. Torque: 98 Nm (72 lb ft)
014RW060
6A66
ENGINE MECHANICAL
Crankshaft
Crankshaft and Associated Parts
013RW009
Legend (1) Cylinder Head Assembly (2) Crankcase with Oil Pan (3) Oil Pipe and O-Ring (4) Oil Strainer and O-Ring (5) Oil Pump Assembly (6) Cylinder Block Side Bolts (7) Oil Gallery
(8) (9) (10) (11) (12) (13) (14)
Piston and Connecting Rod Assembly Flywheel Rear Oil Seal Retainer and Oil Seal Main Bearing Cap Crankshaft Main Bearing Cap Fixing Bolts Oil Gallery Fixing Bolts
Disassembly
1. Remove cylinder head assembly (1). Refer to Cylinder Head in this manual. 2. Remove crankcase with oil pan (2). Refer to Oil Pan and Crankcase in this manual. CAUTION: Take care not to damage or deform the sealing flange surface of crankcase. 3. Remove oil pipe and O-ring (3). 4. Remove oil strainer and O-ring (4). 5. Remove oil pump assembly (5). 6. Remove crankcase side bolts (6). 7. Remove oil gallery (7). 8. Remove piston and connecting rod assembly (8). Refer to Piston, Piston Ring and Connecting Rod in this manual. 9. Remove flywheel (9). 10. Remove rear oil seal retainer (10). 11. Remove main bearing cap (11). 12. Remove crankshaft (12).
2. Remove the main bearing cap fixing bolts in the sequence shown in the illustration. Arrange the removed main bearing caps in the cylinder number order. Remove the main bearings.

015RS004
1. Crankshaft Set the dial indicator as shown in the illustration and measure the crankshaft thrust clearance. If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set. Thrust Clearance Standard : 0.06 mm0.24 mm (0.0024 in0.0094 in) Limit : 0.30 mm (0.0118 in)
3. Remove the crankshaft. Remove the main bearings. 4. Clean the upper and lower bearings as well as the crankshaft main journal. 5. Check the bearings for damage or excessive wear. The bearings must be replaced as a set if damage or excessive wear is discovered during inspection. 6. Set the upper bearings and the thrust washers to their original positions. Carefully install the crankshaft. 7. Set the lower bearings to the bearing cap original position. 8. Apply plastigage to the crankshaft journal unit as shown in the illustration. NOTE: Do not set the plastigage on the oil hole.
015RS003
Main Bearing Clearance

1. Remove the bearing caps and measure the oil clearance.
015RS005
6A68
ENGINE MECHANICAL
Standard : 0.019 mm0.043 mm (0.0007 in0.0017 in) Limit : 0.08 mm (0.0031 in)
9. Install main bearing caps, oil gallery and crank case bolts in the order shown, and tighten each bolt to the specified torque. NOTE: Do not apply engine oil to the crank case side bolts. Main bearing cap bolts. Torque: 39 Nm (29lb ft) Oil gallery fixing bolts. Torque: 1st step: 29 Nm (21 lb ft) 2nd step 55 65 Crank case side bolts Torque : 39 Nm (29lb ft) NOTE: Do not allow the crankshaft to rotate.
015RS008
12. Clean the plastigage from the bearings and the crankshaft. Remove the crankshaft and the bearings.
Crankshaft (12) Inspection

Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions.

015RS006
10. Remove the main bearing caps in the sequence shown in the illustration.
1. Carefully set the crankshaft on the Vblocks. Slowly rotate the crankshaft and measure the runout. If the crankshaft runout exceeds the specified limit, the crankshaft must be replaced. Runout : 0.04 mm (0.0016 in)
015RS004
11. Measure the plastigage width and determine the oil clearance. If the oil clearance exceeds the specified limit, replace the main bearings as a set and/or replace the crankshaft.
015RS007

2. Measure the diameter and the uneven wear of main journal and crank pin. If the crankshaft wear exceeds the specified limit, crankshaft must be replaced. Main journal diameter : 63.918 mm63.933 mm (2.5165 in2.5170 in) Crank pin diameter : 53.922 mm53.937 mm (2.1229 in.2.1235 in.) Uneven wear limit : 0.005 mm (0.0002 in) 2. Crankshaft journal diameter grade mark. The diameter size marks (1) are stamped on the No.1 crankshaft balancer (2) as shown in the illustration.
015R200005
NOTE: Take care to ensure the bearings are positioned correctly.
015RS009
Crankshaft Bearing Selection

When installing new crankshaft bearings or replacing bearings, refer to the selection table below. Select and install the new crankshaft bearings, paying close attention to the cylinder block journal bore diameter grade mark and the crankshaft journal diameter grade mark. 1. Cylinder block journal bore diameter grade (1).
015R200006
Legend (1) Number 1 and 4 main bearing upper and lower (2) Number 2 and 3 main bearing upper (3) Number 2 and 3 main bearing lower (4) Size mark paint (5) Tab
015RS010
6A70
Size Mark (Cylinder block)
ENGINE MECHANICAL
Crank Shaft Main Journal Diameter 63.918-63.925 (2.5165-2.5167) 63.926-63.933 (2.5168-2.5170) 63.918-63.925 (2.5165-2.5167) 63.926-63.933 (2.5168-2.5170) 63.918-63.925 (2.5165-2.5167) 63.926-63.933 (2.5168-2.5170) Size Mark (Crankshaft) 2 1 Brown 2 1 Green 2 1 Yellow Crank Shaft Bearing Size Mark paint Blue Crank Shaft Bearing Thickness 2.527-2.530 (0.0995-0.0996) 2.524-2.527 (0.0994-0.0995) 0.019-0.043 (0.0007-0.0017) 2.521-2.524 (0.0993-0.0994) 2.518-2.521 (0.0991-0.0993)
Main Bearing Bore Diameter
Oil Clearance (Reference)
68.994-69.000 (2.7163-2.7165)
68.987-68.993 (2.7160-2.7163)
68.980-68.986 (2.7157-2.7160)
Reassembly
1. Crankshaft (12) D Install the main bearings to the cylinder block and the main bearing caps. D Be sure that they are positioned correctly. D Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the main bearing back faces.
D Carefully mount the crankshaft. D Apply engine oil to the thrust washer. D Assemble the thrust washer to the No.3 bearing journal. The oil grooves must face the crankshaft.
015RS013
2. Rear oil seal (10) D Remove the oil from the cylinder block and the retainer mounting surface. D Apply sealant (TB1207B or equivalent) to the retainer mounting surface, following the pattern shown in the illustration. The retainer must be installed within 5 minutes after sealant application befor the sealant hardens.
015RS012
Legend (1) Number 1 and 4 main bearing upper and lower (2) Number 2 and 3 main bearing upper (3) Number 2 and 3 main bearing lower
015RW002
015RS017
Legend (1) Around Bolt Holes (2) Around Dowel Pin D Apply engine oil to the oil seal lip. D Align the cylinder block dowel pin holes with the rear retainer dowel pins. D Tighten the rear retainer fixing bolts. New bolts should be used when installing rear retainer. Torque: 18 Nm (13 lb ft) NOTE: Be very careful not to disengage the oil seal garter spring during installation of the rear retainer. If the seal was removed from retainer for replacement, apply engine oil to the oil seal lip and install the oil seal using J39201 oil seal installer.
3. Flywheel (9) 1. Thoroughly clean and remove the oil from the threads of crankshaft. 2. Remove the oil from the crankshaft and flywheel mounting faces. 3. Mount the flywheel on the crankshaft and then install the washer. 4. Hold the crankshaft to prevent from rotating then install the bolts in the order shown to the specified torque. Torque: 54 Nm (40 lb ft) NOTE: Do not reuse the bolt and do not apply oil or thread lock to the bolt.
015RS018
015RW001
6A72
ENGINE MECHANICAL
4. Piston and connecting rod assembly (8) D Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Check to see that the piston ring end gaps are correctly positioned.
015RS020
5. Install oil gallery (7) and tighten the bolts in 2 steps, in the order shown. 1st step: 29 Nm (22 lb ft) 2nd step: 55 65
015RS019
Legend (1) No.1 Compression Ring (2) No.2 Compression Ring (3) Oil Ring Side Rail Upper (4) Oil Ring Side Rail Lower (5) Piston Front Mark D Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. The front marks must be facing the front of the engine. D Match the numbered caps with the numbers on the connecting rods. Align the punched marks on the connecting rods and caps. D Apply engine oil to the threads and seating faces of the nuts. D Tighten the nuts. Torque: 54 Nm (40 lb ft) After tightening the cap nuts, check to see that the crankshaft rotates smoothly. NOTE: Do not apply engine oil to the bearing back faces.
051RS009
6. Cylinder block side bolts (6) D Tighten all the bolts to the specified torque in the order shown. NOTE: Do not apply engine oil to the crank case side bolts. Torque: 39 Nm (29 lb ft)
012RS001
013RW010
7. Install oil pump assembly (5), refer to Oil pump in this manual. 8. Install oil strainer and O-ring (4). 9. Install oil pipe and O-ring (3) and tighten the bolts. Torque: 25 Nm (18 lb ft) 10. Install crankcase with oil pan (2). 1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2. Apply a correct width bead of sealant (TB 1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead. 3. The crankcase assembly must be installed within 5 minutes after sealant application to prevent premature hardening of the sealant. 4. Tighten the bolts and nuts to the specified torque. Torque : 10 Nm (87 lb in)
Legend (1) Portion Between Bolt Holes (2) Bolt Hole Portion 11. Install cylinder head assembly, refer to Cylinder head in this manual.
6A74
ENGINE MECHANICAL
Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts
015RW019
Legend (1) Cylinder Head Assembly (2) Cylinder Head Gasket (3) Crankcase with Oil Pan (4) Oil Pipe and O-Ring (5) Oil Strainer and O-Ring (6) Oil Gallery
(7) (8) (9) (10) (11) (12)
Piston and Connecting Rod Assembly Piston Ring Piston Pin Piston Connecting Rod Connecting Rod Cap
Disassembly
1. Remove cylinder head assembly (1). Refer to Cylinder Head Removal in this manual. 2. Remove cylinder head gasket (2). 3. Remove crankcase with oil pan (3). Refer toOil Pan and Crankcase in this manual. 4. Remove oil pipe and O-ring (4).
5. Remove oil strainer and O-ring (5). 6. Remove oil gallery (6). 7. Remove connecting rod cap with connecting rod lower bearing (12). 8. Remove piston and connecting rod assembly (7). NOTE: Before removing piston and connecting rod assembly, measure thrust clearance.
015RS031
015RS023
D Remove any ridge or carbon build up from the top end of the cylinder. 9. Remove the piston rings (8) with a piston ring expander. Arrange the removed piston rings in the cylinder number order.
Legend (1) Press Ram (2) Piston (3) Connecting Rod (4) Piston Pin 11. Piston (10) 12. Connecting rod (11)

Pistons (10)
Carefully clean away all the carbon adhering to the piston head and the piston ring grooves. NOTE: Never use a wire brush to clean the pistons. Damage will result. Visually check each piston for cracking, scoring, and other signs of excessive wear. If any of the above conditions are found, the piston must be replaced.
Piston Diameter
015RS022
10. Remove the piston pin (9) using J24086C piston pin service set and piston support with a press. NOTE: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin.
1. Measure the piston outside diameter with micrometer at the piston grading position and a right angle to the piston pin. Piston grading position (from piston head) Piston grading position : 43.0 mm (1.6929 in)
6A76
ENGINE MECHANICAL
015RV014
012RS002
The size mark (1) for piston outside diameter is represented as shown in illustration below. Outside Diameter Size Mark A : 93.360 mm93.370 mm (3.6756 in3.6760 in) Size Mark B : 93.371 mm93.380 mm (3.6760 in3.6764 in) Size Mark C : 93.381 mm93.390 mm (3.6764 in3.6768 in)
Piston Rings (8)

Any worn or damaged part discovered during engine overhaul must be replaced with a new one. 1. Ring end gap measurement D Insert the piston ring into the bore. D Push the ring by the piston, at a right angle to the wall, into the point at which the cylinder bore diameter is the smallest. D Measure the ring end gap. Compression Ring 1st ring Standard: Limit: 2nd ring Standard: Limit: Oil ring Standard: Limit: 0.150 mm0.450 mm (0.0059 in0.0177 in) 1.05 mm (0.0413 in) 0.450 mm0.600 mm (0.0177 in0.0236 in) 1.2 mm (0.0472 in) 0.300 mm0.400 mm (0.0118 in0.0157 in) 1.0 mm (0.0394 in)
015RS025
Measure the cylinder bore inside diameter (refer to Cylinder Block in this manual).
015RS026
015RS028
D Positioning mark (1) is painted as shown in the illustration. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring
Piston Pin (9)

NOTE: Do not reuse the old piston pin. 1. Use a micrometer to measure the new piston pin outside diameter in both directions at three different positions. 2. Measure the inside diameter of the connecting rod small end. If the fitting interference between the small end and pin does not conform to the specified value, the connecting rod must be replaced. Standard : 0.023 mm0.038 mm (0.0009 in0.0015 in)
015RS027
2. Measure the clearance between the piston ring groove and the piston ring with a feeler gauge. If the piston ring groove / piston ring clearance exceeds the specified limit, the piston must be replaced. Compression Ring Clearance Standard : 0.016 mm0.038 mm (0.0006 in.0.0015 in) Limit : 0.15mm (0.0059 in)
015RS029
6A78
ENGINE MECHANICAL
3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced. Clearance Standard : 0.010 mm0.017 mm (0.0004 in.0.0007 in) Limit : 0.040 mm (0.0016 in)
Connecting Rods (11)

1. Check the connecting rod alignment If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm (3.937 in) Limit: 0.15 (0.0059) Twist per 100 mm (3.937 in) Limit: 0.20 (0.0078)
015RS031
3. Measure the oil clearance between the connecting rod and the crankshaft. 1. Remove the connecting rod cap nuts and the rod caps (12). Arrange the removed rod caps in the cylinder number order. 2. Clean the rod bearings and the crankshaft pins. 3. Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastigage to the crank pin.
015RS030
2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the large end of the connecting rod If the clearance exceeds the specified limit, the connecting rod must be replaced. Standard : 0.16 mm0.35 mm (0.0063 in.0.0138 in) Limit : 0.40 mm (0.0157 in)
015RS032
4. Reinstall the rod caps (12) to their original positions. Tighten the rod cap nuts. Torque: 54 Nm (40 lb ft) NOTE: Do not allow the crankshaft to rotate.

5. Remove the rod caps. 6. Measure the width of the plastigage and determine the oil clearance. If the oil clearance exceeds the limit, replace the rod bearing as a set. Standard : 0.019 mm0.043 mm (0.0007 in0.0017 in) Limit : 0.08 mm (0.003 in) 7. Clean the plastigage from the bearings and the crankshaft pins.
Conrod Bearing Selection

Select and install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark (1). NOTE: Take care not to confuse the alignment mark (2) and the size mark (1) during the installation procedure.
015RS008 015RS034
1 Size Mark A B C
Big end Bore Diameter 56.994-57.000 (2.2439-2.2441) 56.988-56.994 (2.2436-2.2439) 56.982-56.988 (2.2434-2.2436)
Crankshaft Pin Diameter
Connecting Rod Bearing Thickness (Reference) 1.512-1.516 (0.0595-0.0597)
Color of Size Mark Yellow Green Pink
Oil Clearance (Reference) 0.025-0.054 (0.0010-0.0021) 0.027-0.056 (0.0011-0.0022) 0.029-0.058 (0.0011-0.0023)
53.922-53.937 (2.1229-2.1235)
1.508-1.512 (0.0594-0.0595) 1.504-1.508 (0.0592-0.0594)
Reassembly
1. Install connecting rod 2. Install piston 3. Install piston pin D Apply a thin coat of engine oil to the piston pin. Try to insert the piston pin into the piston pin hole with normal finger pressure. NOTE: When changing piston / connecting rod combinations, do not change the piston / piston pin combination and do not reuse the old piston pin. D Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side.
015RS036
6A80
ENGINE MECHANICAL
D Install piston rings in the following sequence. 1. Oil ring 1. Expander ring 2. Upper side rail 3. Lower side rail 2. 2nd compression ring 3. 1st compression ring D The compression rings must be set with the T or T2 mark facing up. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring D After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly.
D With J24086C Piston pin service set and a press, press fit the piston pin. NOTE: Heat the connecting rod small end to a suitable temperature to ensure smooth installation.
015RS037
Legend (1) Press Ram (2) Piston (3) Connecting Rod (4) Piston Pin 4. Install piston ring with the piston ring expander. The compression ring must be set with the T mark (1) facing up. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring
015RS038
5. Install piston and connecting rod assembly. D Insert the bearings into the connecting rods and caps. Apply new engine oil to the bearing faces and nuts. D Tighten the connecting rod cap nuts Torque : 54 Nm (40 lb ft) NOTE: Do not apply engine oil to the bearing back faces. 6. Oil gallery, refer to Crankshaft and main bearing in this manual. 7. Oil strainer and O-ring. 8. Oil pipe and O-ring. 9. Install crankcase with oil pan, refer to Oil pan and Crankcase in this manual. 10. Install cylinder head gasket. 11. Install Cylinder head assembly. D Refer to Cylinder head in this manual.
015RS027
Cylinder Block
Cylinder Block and Associated Parts
012R200002
Legend (1) Cylinder Head Assembly (2) Cylinder Head Gasket (3) Crankcase with Oil Pan (4) Oil Pipe and O-Ring (5) Oil Strainer and O-Ring (6) Oil Pump Assembly (7) Cylinder Block Side Bolts
(8) (9) (10) (11) (12) (13) (14)
Oil Gallery Piston and Connecting Rod Assembly Flywheel Rear Oil Seal Retainer Assembly Main Bearing Cap Crankshaft Cylinder Block
Disassembly
1. Remove cylinder head assembly. 2. Remove cylinder head gasket. 3. Remove crankcase with oil pan. 4. Remove oil pipe and O-ring.
5. Remove oil strainer and O-ring. 6. Remove oil pump assembly. 7. Remove crankcase side bolts. 8. Remove oil gallery. 9. Remove piston and connecting rod assembly. 10. Remove flywheel.
6A82
ENGINE MECHANICAL
11. Remove rear oil seal retainer assembly. 12. Remove main bearing cap. 13. Remove crankshaft. 14. Remove cylinder block.
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore diameter in both the axial and thrust directions. Each measurement should be made at six points. CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block. Cylinder Bore Inside Diameter Limit : 93.530 (3.6823) If the measurement exceed the specified limit, the cylinder block must be replaced. Diameter Grade A : 93.400 mm93.410 mm (3.6772 in3.6776 in) Grade B : 93.411 mm93.420 mm (3.6776 in3.6779 in) Grade C : 93.421 mm93.430 mm (3.6780 in3.6783 in)

1. Remove the cylinder head gasket and any other material adhering to the upper surface of the cylinder block. Be very careful not to allow any material to accidentally drop into the cylinder block. Be very careful not to scratch the cylinder block. 2. Carefully remove the oil pump, rear oil seal retainer, and crankcase assembly installation surface seal. 3. Wipe the cylinder block clean. 4. Visually inspect the cylinder block. If necessary, use a flaw detector to perform a dye penetrate and hydraulic (or air pressure) test. If cracking or other damage is discovered, the cylinder block must either be repaired or replaced.
Flatness
1. Using a straightedge and feeler gauge, check that the upper surface of the cylinder block is not warped. CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block. 2. The cylinder block must be reground or replaced if the warpage exceeds the limit. Warpage Limit : 0.15 mm (0.0059 in) Maximum repairable limit: 0.15 mm (0.0059 in)
012RS005
NOTE: For information on piston diameter, please refer to the section Inspection of the Piston and Connecting Rod Assembly in this manual.
012RS004

D The Grade mark (1) is stamped at the position illustrated. D Carefully mount the crankshaft. D Apply engine oil to the thrust washer. D Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft.
012RS006
Reassembly
015RS013
1. Install cylinder block. 2. Install crankshaft. D Install the main bearings to the cylinder block and the main bearing caps. D Be sure that they are positioned correctly. D Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the bearing back faces.
3. Install rear oil seal retainer. D Remove oil on cylinder block and retainer fitting surface. D Apply sealant (TB1207B or equivalent) to retainer fitting surface as shown in illustration. D The oil seal retainer must be installed within 5 minutes after sealant application before the sealant hardens.
015RW002 015RS012
Legend (1) Number 1 and 4 main bearing upper and lower. (2) Number 2 and 3 main bearing upper. (3) Number 2 and 3 main bearing lower.
Legend (1) Around Bolt Holes (2) Around Dowel Pin
6A84
ENGINE MECHANICAL
5. Install piston and connecting rod assembly. D Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. NOTE: Do not apply engine oil to the bearing back faces. D Check to see that the piston ring end gaps are correctly positioned.
D Apply engine oil to oil seal lip and align a dowel pin hole in the cylinder block with that in the retainer. D Tighten retainer fixing bolts to the specified torque. Torque: 25 Nm (18 lb ft)
015RW001
4. Install flywheel 1. Thoroughly clean and remove the oil from the threads of crankshaft. 2. Remove the oil from the crankshaft and flywheel mounting faces. 3. Mount the flywheel on the crankshaft and then install the washer. 4. Holding the crankshaft stationary, tighten the flywheel bolts in the order shown. Torque: 54 Nm (40 lb ft) NOTE: Do not reuse the bolts and do not apply oil or thread lock to the bolts.
015RS019
Legend (1) No.1 Compression Ring (2) No.2 Compression Ring (3) Oil Ring Side Rail Upper (4) Oil Ring Side Rail Lower (5) Piston Front Mark D Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. D The front marks (1) must be facing the front of the engine.
015RS018
015RS020

6. Install oil gallery and tighten the bolts in 2 steps in the order shown. 1st step : 29 Nm (22 lb ft) 2nd step : 55 65 8. Install oil pump assembly. Refer to Oil Pump in this manual. 9. Install oil strainer and O-ring. 10. Install oil pipe and O-ring. 11. Install crankcase with oil pan. 1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2. Apply a correct width bead of sealant (TB 1207C or its equivalent) to the contact surfaces of the crankcase. There must be no gaps in the bead. 3. The oil pan must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. 4. Tighten the bolts and nuts to the specified torque. Torque : 10 Nm (87 lb in)
012RS007
7. Install cylinder block side bolts (1) and tighten crankcase bolts in sequence shown in the illustration. Torque : 39 Nm (29 lb ft)
013RW010
Legend (1) Portion Between Both Holes (2) Bolt Hole Portions 12. Install cylinder head gasket. 13. Install cylinder head assembly. Refer to Cylinder Head in this manual.
012RW005
6A86
ENGINE MECHANICAL
Main Data and Specification

Item Engine type, number of cylinders and arrangement Form of combustion chamber Valve mechanism Cylinder liner type Total piston displacement Cylinder bore x stroke Compression ratio Compression pressure at 300rpm Engine idling speed (rpm) Valve clearance Oil capacity Ignition timing Spark plug Plug gap Specifications 6VE1 Water cooled, four cycle V6 Pent roof type 4-Cams, 4-Valves, DOHC Gear & Belt Drive Casted in cylinder drive 3494 cc 93.4mm x 85.0mm (3.677 in x 3.346 in) 9.1 : 1 1370 kPa (199 psi) Non adjustable (750) Intake: 0.28 mm (0.11 in) Exhaust: 0.30mm (0.12in) 5.3 liters (5.6 U.S. q.t.) Non adjustable (20 BTDC at idle rpm) K16PRP11, PK16PR11, RC10PYP4 1.0 mm1.1 mm(0.0394 in 0.0433 in)
Ignition coil, Spark plug, Crankshaft position sensor and Under cover
E06RY001
6A88
ENGINE MECHANICAL
Cylinder head cover, Cylinder head, Camshaft bearing cap, Common chamber, EGR valve and EGR pipe, Ion sensing module
E06R200002

Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt cover, Oil pump, Oil gallery, Oil strainer and Water pump
E06R200010
6A90
ENGINE MECHANICAL
Connecting rod and Water pump
E06RW011

Engine mount
E06RW003
6A92
ENGINE MECHANICAL
Special Tool
J2168702 Remover; tie rod end
J861401 Holder; Crankshaft
J8062 Compressor; Valve spring (1) J42898 Adapter; Compressor, Valve spring (2)
J37228 Seal cutter
J37281 Remover; Oil controller
J39201 Installer; Real oil seal
J38537 Installer; Oil controller
J242391 Cylinder head bolt wrench
J42985 Installer; Camshaft oil seal
J42899 Replacer; Valve guide (1, 2) J42687 Installer; Valve guide (1) J379851 Remover; Valve guide (2)
J39206 Installer; Pilot bearing
J42689 Adjusting Tool: Valve clearance

J42686 Lever; Gear spring
J43041 Holder; Universal
SECTION
ENGINE COOLING
TROOPER
6B1
ENGINE
ENGINE COOLING
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and Refilling Cooling System . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B1 6B2 6B5 6B6 6B7 6B7 6B7 6B7 6B7 6B8 6B8 6B8 6B8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator and Associated Parts . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt and Cooling Fan . . . . . . . . . . . . . . . Drive Belt and Associated Parts . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B8 6B9 6B9 6B9 6B10 6B11 6B12 6B12 6B12 6B12 6B13 6B14
Service Precaution
6B2
ENGINE COOLING
General Description
030RW001
Legend (1) Water Pump (2) Thermostat (3) Radiator (4) Reserve Tank (5) Cooling Fan (6) Cylinder Block
(7) (8) (9) (10) (11) (12) (13)
Cylinder Head Right Bank Throttle Body Cylinder Block Cylinder Head Left Bank Heater
The cooling system is a pressurized Engine Coolant (EC) forced circulation type which consists of a water pump, thermostat cooling fan, radiator and other components. The automatic transmission fluid is cooled by the EC in radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven by a timing belt.
030RS001
ENGINE COOLING
6B3
Thermostat
The thermostat is a wax pellet type with a air hole(1) and is installed in the thermostat housing.
Anti Freeze Solution

D Relation between the mixing ratio and freezing temperature of the EC varies with the ratio of antifreeze solution in water. Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system. D Calculating mixing ratio
031RW002
Radiator
The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a cap in which the valve is operated at 88.2 117.6 kPa (12.8 17.0 psi) pressure. (No oil cooler provided for M/T)
F06RW005
NOTE: Antifreeze solution + Water = Total cooling system capacity. D Total Cooling System Capacity D M/T 8.8Lit (2.32Us gal) D A/T 8.4Lit (2.22Us gal)
110RS001
6B4
ENGINE COOLING
B06RW002
B06RW003
D Mixing ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from 0C to 50C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. NOTE: 1. Even in the areas where the atmospheric temperature is higher than 0C, be sure not to use antifreeze solution at a mixing ratio lower than 20% so that the inside of the engine may not be corroded. 2. If antifreeze solution is used at a mixing ratio higher than 60%, the specific heat of the coolant falls and the engine may be overheated. Moreover, antifreeze performance drop and the coolant may be frozen. The density of the solution must be adjusted as occasion calls. Antifreeze solution lower than 20% may not have sufficient anticorrosive performance, and therefore, please never fail to adjust as occasion demands within the range of 20% to 60%.
ENGINE COOLING
6B5
Diagnosis
Engine Cooling Trouble
Condition Engine overheating Possible cause Low Engine Coolant level Incorrect fan installed Thermo meter unit faulty Faulty thermostat Faulty Engine Coolant temperature sensor Clogged radiator Faulty radiator cap Low engine oil level or use of improper engine oil Clogged exhaust system Faulty Throttle Position sensor Open or shorted Throttle Position sensor circuit Damaged cylinder head gasket Engine overcooling Engine slow to warmup Faulty thermostat Faulty thermostat Thermo unit faulty Replenish Replace Replace Replace Repair or replace Clean or replace Replace Replenish or change oil Clean exhaust system or replace faulty parts Replace throttle valve assembly Repair or replace Replace Replace Replace Replace Correction
6B6
ENGINE COOLING
9. After the engine has cooled, replenish with EC up to the MAX line of the reserve tank. 10. Start the engine. With the engine running at 3,000 rpm, make sure there is no running water sound from the heater core (behind the center console). 11. If the running water sound is heard, repeat steps 8 to 10.
Draining and Refilling Cooling System

Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the MIN and MAX lines of reserve tank when the engine is cold. If low, check for leakage and add EC up to the MAX line. There should not be any excessive deposit of rust or scales around the radiator cap or radiator filler hole, and the EC should also be free from oil. Replace the EC if excessively dirty. 1. Completely drain the cooling system by opening the drain plug (2) at the bottom of the radiator.
110RW002
2. Remove the radiator cap. WARNING: TO AVOID THE DANGER OF BEING BURNED, DO NOT REMOVE THE CAP WHILE THE ENGINE AND RADIATOR ARE STILL HOT. SCALDING FLUID AND STEAM CAN BE BLOWN OUT UNDER PRESSURE. 3. Disconnect all hoses from the EC reserve tank. Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it. Install the reserve tank and hoses. 4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze but no more than 70 percent antifreeze. 5. Fill the radiator to the base of the filler neck. Fill the EC reserve tank to MAX line when the engine is cold. 6. Block the drive wheels and firmly apply the parking brake. Shift an automatic transmission to P (Park) or a manual transmission to neutral. 7. Remove the radiator cap. Start the engine and warm it up at 2,500 3,000 rpm for about 30 minutes. 8. When the air comes out from the radiator filler neck and the EC level has gone down, replenish with the EC. Repeat this procedure until the EC level does not go down. Then stop the engine and install the radiator cap. Let the engine cool down.
ENGINE COOLING
6B7
Water Pump
Water Pump and Associated Parts
014R200005
Legend (1) Timing Belt (2) Idle Pulley
(3) Water Pump Assembly (4) Gasket
Removal
1. Disconnect battery ground cable. 2. Drain coolant. 3. Radiator hose (on inlet pipe side). 4. Remove timing belt. Refer to Timing Belt in this manual. 5. Remove Idle pulley. 6. Remove water pump assembly. 7. Remove gasket.
2. Install water pump assembly and tighten bolts to the specified torque. Torque: 25 Nm (18 lb ft) D Tightening order The tightening order are in the illustrate. NOTE: To prevent the oil leakage, apply the LOCTITE 262 or an equivalent, to the arrow marked fixing bolt thread.
Inspection
Make necessary repair and parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced: D Crack in the water pump body D EC leakage from the seal unit D Play or abnormal noise in the bearing D Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket before installation.
030RW008
6B8
ENGINE COOLING
4. Timing belt D Install timing belt. Refer to timing belt installation step in Timing Belt in this manual. 5. Connect radiator inlet hose and replenish EC. 6. Connect battery ground cable.
3. Idle pulley D Install idle pulley and tighten bolt to the specified torque. Torque: 52 Nm (38 lb ft)
Thermostat
Thermostat and Associated Parts Inspection
Suspend the thermostat in a waterfilled container using thin wire. Place a thermometer next to the thermostat. Do not directly heat the thermostat. Gradually increase the water temperature. Stir the water so that the entire water is same temperature.
031RW001
Legend (1) Thermostat Housing (2) Thermostat (3) Outlet Pipe
031RS003
Removal
1. Disconnect battery ground cable. 2. Drain engine coolant from the radiator and engine. 3. Disconnect radiator hose from the inlet pipe. 4. Remove thermostat housing. 5. Remove thermostat(2).
Confirm the temperature when the valve first begins to open. Valve opening temperature 74.5C 78.5C (166.1F 173.3F) Confirm the temperature when the valve is fully opened. Valve full open temperature and lift More than 8.5mm (0.33 in) at 90C (194F) Make necessary repair and parts replacement if extreme wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure that the air hole is in the up position. 2. Install thermostat housing and tighten bolts to the specified torque. Torque: 25 Nm (18 lb ft) 3. Installation rubber hose. 4. Replenish engine coolant (EC). 5. Start engine and check for EC leakage.
ENGINE COOLING
6B9
Radiator
Radiator and Associated Parts
110RW003
Legend (1) Oil Cooler Hose For Automatic Transmission (2) Radiator Hose (3) Fan Guide, Lower
(4) (5) (6) (7)
Reserve Tank Hose Bracket Radiator Assembly Reserve Tank
Removal
1. Disconnect battery ground cable. 2. Loosen a drain plug(2) to drain EC. 3. Disconnect oil cooler hose(1) on automatic transmission (A/T). 4. Disconnect radiator inlet hose and outlet hose from the engine.
5. Remove fan guide(1), clips(3) on both sides and the bottom lock, then remove lower fan guide(3) with fan shroud(4).
110RW001
110RW002
6B10
ENGINE COOLING
Valve opening vacuum kPa (psi) 1.96 4.91 (0.28 0.71)
6. Disconnect the reserve tank hose(4) from radiator. 7. Remove bracket(5).
110RW004
110RS006
8. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 9. Remove rubber cushions on both sides at the bottom.
Radiator Core
1. A bent fin may result in reduced ventilation and overheating may occur. All bent fins must be straightened. Pay close attention to the base of the fin when it is being straightened. 2. Remove all dust, bugs and other foreign material.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester. Replace the cap if the valve opening pressure is outside the standard range. Valve opening pressure kPa (psi) 88.3 117.7 (12.8 17.1) Cap tester: J2446001 Adapter: J33984A Check the condition of the vacuum valve in the center of the valve seat side of the cap. If considerable rust or dirt is found, or if the valve seat cannot be moved by hand, clean or replace the cap.
Flushing the Radiator

Thoroughly wash the inside of the radiator and the engine coolant passages with cold water and mild detergent. Remove all signs of scale and rust.
Cooling System Leakage Check

Use a radiator cap tester to force air into the radiator through the filler neck at the specified pressure of 196 kPa (28.5 psi) with a cap tester: D Leakage from the radiator D Leakage from the coolant pump D Leakage from the water hoses D Check the rubber hoses for swelling.
ENGINE COOLING 6B11

Cap tester: J2446001 Adapter: J33984A 8. Connect battery ground cable. 9. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank.
110RS005
111RS001
Installation
1. Install rubber cushions on both sides of radiator bottom. 2. Install radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 3. Install bracket (6) and support the radiator upper tank with the bracket (5) and secure the radiator. 4. Connect reserve tank hose (4). 5. Install lower fan guide (3). 6. Connect radiator inlet hose and outlet hose to the engine. 7. Connect oil cooler hose (1) to automatic transmission.
Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant.
Engine Coolant Filling Up Procedure

1. Make sure that the engine is cool. WARNING: WHEN THE COOLANT IS HEATED TO A HIGH TEMPERATURE, BE SURE NOT TO LOOSEN OR REMOVE THE RADIATOR CAP. OTHERWISE YOU MIGHT GET SCALDED BY HOT VAPOR OR BOILING WATER. TO OPEN THE RADIATOR CAP, PUT A PIECE OF THICK CLOTH ON THE CAP AND LOOSEN THE CAP SLOWLY TO REDUCE THE PRESSURE WHEN THE COOLANT HAS BECOME COOLER. 2. Open radiator cap pour coolant up to filler neck. 3. Pour coolant into reservoir tank up to MAX line. 4. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator cap. If the water level is lower, replenish. 5. After replenish the coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater adjustment to the highest temperature position, and let the coolant circulate also into heater water system. 6. Check to see the thermometer, continuously idling 5 minutes and stop the engine. 7. When the engine has been cooled, check filler neck for water level and replenish if required. Should extreme shortage of coolant is found, check the coolant system and reservoir tank hose for leakage. 8. Pour coolant into the reservoir tank up to MAX line.
110RW004
6B12
ENGINE COOLING
Drive Belt and Cooling Fan

Drive Belt and Associated Parts
015RW005
Legend (1) Crankshaft Pulley (2) Generator (3) Power Steering Pump
(4) (5) (6) (7)
Water Pump and Cooling Fan Pulley Idle Pulley Tension Pulley Drive Belt
The drive belt adjustment is not required as automatic drive belt tensioner is equipped.
Installation
Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly. NOTE: Fan belts for 6VE1 Gasoline Engine mounted on 98MY Trooper (UX) have been brought into one. As a result, the rotating direction of a fan belt is opposite to the direction of cooling fan for 92 to 97MY 6VD1 with no interchangeability. Therefore, incorrect installation of a fan may cause the air for cooling to flow in the opposite direction, this resulting in the poor performance of the air-conditioner and a rise temperature in engine cooling water.
Inspection
Check drive belt for wear or damage, and replace with a new one as necessary.
ENGINE COOLING 6B13

M/T Cooling system Radiator Heat radiation capacity Heat radiation area Radiator front area Radiator dry weight Radiator cap valve opening pressure Radiator coolant capacity Engine coolant pump Delivery Pump speed Thermostat Valve opening temperature Engine coolant total capacity 39N (8.8lb) 2.5lit (2.6U.S q.t.) A/T Engine coolant forced circulation (1 tube in row) Tube type corrugated (2 tube in row) 68,000 kcal/h 9.445m@ (0.878ft@) 0.302m@ (0.028ft@) 44N (9.9lb) 2.4lit (2.5U.S q.t.) 93.3 122.7kpa (13.5 17.8psi) Centrifugal impeller type 300 lit (79 U.S. gal)/min or more 5000 50 rpm Wax pellet type with air hole 74.5 78.5C (166.1 173.3F) 10.4lit (11.0U.S qt) 10.5lit (11.1U.S qt) 77,000 kcal/h 11.21m@ (1.04ft@)
E06R200009
6B14
ENGINE COOLING
Special Tool
J2446001 Tester; radiator cap
J33984A Adapter; radiator cap
SECTION
ENGINE FUEL
TROOPER
6C1
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Fuel Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . InTank Fuel Filter . . . . . . . . . . . . . . . . . . . . . Fuel Pump Flow Test . . . . . . . . . . . . . . . . . . . Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C1 6C2 6C3 6C4 6C4 6C4 6C4 6C4 6C5 6C5 6C5 6C6 6C6 6C6 6C6 6C6 6C6 6C7 Fuel Tank and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tube / Quick Connect Fittings . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . Cautions During Work . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reuse of QuickConnector . . . . . . . . . . . . . . . Assembling Advice . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 6C7 6C7 6C7 6C8 6C8 6C8 6C8 6C9 6C10 6C11 6C11 6C11 6C11 6C12 6C12 6C12 6C13
Service Precaution
6C2
ENGINE FUEL
General Description
140RY00002
Legend (1) Fuel Filler Cap (2) Fuel Tank (3) Rollover Valve (4) Fuel Pump (Fuel Level Sending Unit/Fuel Tank Pressure Sensor) (5) Fuel Filter (6) Fuel Rail Right (7) Right Bank
(8) (9) (10) (11) (12) (13) (14) (15) (16)
Fuel Rail Left Left Bank Fuel Pressure Control Valve Common Chamber Duty Solenoid Valve Throttle Valve Canister Evaporation Shut Off Valve Vent Solenoid Cut Valve
When working on the fuel system, there are several things to keep in mind: D Any time the fuel system is being worked on, disconnect the negative battery cable except for those tests where battery voltage is required. D Always keep a dry chemical (Class B) fire extinguisher near the work area.
D Replace all pipes with the same pipe and fittings that were removed. D Clean and inspect O rings. Replace if required. D Always relieve the line pressure before servicing any fuel system components. D Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair.
ENGINE FUEL
D Adhere to all Notices and Cautions. All gasoline engines are designed to use only unleaded gasoline. Unleaded gasoline must be used for proper emission control system operation. Its use will also minimize spark plug fouling and extend engine oil life. Using leaded gasoline can damage the emission control system and could result in loss of emission warranty coverage. All cars are equipped with an Evaporative Emission Control System. The purpose of the system is to minimize the escape of fuel vapors to the atmosphere.
6C3
Fuel Metering
The Engine Control Module (ECM) is in complete control of this fuel delivery system during normal driving conditions. The intake manifold function, like that of a diesel, is used only to let air into the engine. The fuel is injected by separate injectors that are mounted over the intake manifold. The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, which the MAP sensor converts to a voltage output. This sensor generates the voltage to change corresponding to the flow of the air drawn into the engine. The changing voltage is transformed into an electric signal and provided to the ECM. With receipt of the signals sent from the MAP sensor, Intake Air Temperature sensor and others, the ECM determines an appropriate fuel injection pulse width feeding such information to the fuel injector valves to effect an appropriate air/fuel ratio. The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft revolution. The ECM controls the injector on time so that the correct amount of fuel is metered depending on driving conditions. Two interchangeable O rings are used on the injector that must be replaced when the injectors are removed. The fuel rail is attached to the top of the intake manifold and supplies fuel to all the injectors. Fuel is recirculated through the rail continually while the engine is running. This removes air and vapors from the fuel as well as keeping the fuel cool during hot weather operation. The fuel pressure control valve that is mounted on the fuel rail maintains a pressure differential across the injectors under all operating conditions. It is accomplished by controlling the amount of fuel that is recirculated back to the fuel tank based on engine demand. See Section Driveability and Emission for more information and diagnosis.
6C4
ENGINE FUEL
Fuel Filter
Fuel Filter and Associated Parts
041RW014
Legend (1) Fuel Filler Cap (2) Fuel Hose
(3) Fuel Filter Fixing Bolt (4) Fuel Filter
Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Remove Fuel filler cap(1). 3. Disconnect fuel hoses(2) from fuel filter on both engine side and fuel tank side. 4. Fuel filter fixing bolt(3). D Remove the fuel filter fixing bolt(3) on fuel filter holder. 5. Remove fuel filter(4).
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter body or if the fuel filter body itself is damaged. 2. Replace the filter if it is clogged with dirt or sediment. 3. Check the drain of receive rubber and if it is clogged with dust, clean it up with air.
Installation
1. Install the fuel filter in the proper direction. 2. Install fuel filter holder fixing bolt.
ENGINE FUEL
3. Connect fuel hoses on engine side(1) and fuel tank side(2).
6C5
4. Connect the pump relay terminals with a jumper wire(1) as shown and start the fuel pump to measure delivery.
041RW001
4. Install fuel filler cap 5. Connect the battery ground cable.
140RW002
CAUTION: Never generate sparks when connecting a jumper wire. Delivery 15 seconds Delivery 0.38 liters minimum
Inspection
After installation, start engine and check for fuel leakage.
InTank Fuel Filter

The filter is located on the lower end of fuel pickup tube in the fuel tank. It prevents dirt from entering the fuel pipe and also stops water unless the filter is completely submerged in the water. It is a self cleaning type, not requiring scheduled maintenance. Excess water and sediment in the tank restricts fuel supply to the engine, resulting in engine stoppage. In such a case, the tank must be cleaned thoroughly.
If the measure value is out of standard, conduct the pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E Fuel System Electrical Test.
Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the following checks: 1. Make sure that there is fuel in the tank. 2. With the engine running, check the fuel feed pipe and hose from fuel tank to injector for evidence of leakage. Retighten, if pipe or hose connection is loose. Also, check pipes and hoses for squashing or clogging. 3. Insert the hose from fuel feed pipe into a clean container, and check for fuel pump flow rate.
6C6
ENGINE FUEL
Fuel Pump
Fuel Pump and Associated Parts
035RW030
Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Loosen fuel filler cap. 3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 Nm (14 lb ft) M8 4. Remove fuel tank assembly(1). Refer to Fuel Tank Removal in this section. 5. Remove fuel pump (FP) assembly(2) fixing screws and remove the FP assembly. NOTE: After removing FP, cover fuel tank to prevent any dust entering.
Installation
1. Install FP assembly(2). 2. Install fuel tank assembly(1). Refer to Fuel Tank Installation. 3. Fill the tank with fuel and tighten fuel filler cap. 4. Connect battery ground cable.
Fuel Pump Relay

General Description
In order to control the FP operation, the FP relay is provided. When the starter switch is turned to ON position, the FP relay operates the FP for 2 seconds. When it is turned to START position, the Power Train Control Module (PCM) receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FP to feed fuel.
ENGINE FUEL
6C7
Fuel Tank
Fuel Tank and Associated Parts
035RW032
Legend (1) Fender Liner (2) Fuel Filler Hose and Air Breather Hose and Evapo Hose (3) Undercover
(4) Fuel Tank Wiring Connector (5) Evapo Fuel Hose (6) Fuel Feed Tube and Fuel Return Tube/QuickConnect Fittings (7) Fuel Tank
Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Loosen fuel filler cap. 3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 Nm (14 lb ft) M8 4. Remove fender liner (1) of wheel well on rear right side. 5. Fuel filler hose, air breather hose and evapo hose (2). 6. Remove undercover fixing bolts on both sides and remove under cover(3). 7. Disconnect two fuel tank wiring connectors(4) on front right side of tank.
8. Disconnect evapo fuel hose(5). 9. Disconnect fuel feed tube and fuel return tube(6). NOTE: Handling of the fuel tube, be sure to refer Fuel Tube/QuickConnect Fittings in this section. 10. Remove fuel tank fixing bolts on both sides and remove fuel tank(7).
Installation
1. Install fuel tank(7). D Place a flange on right side of tank on the bracket. D Install a flange on left side on the bracket from the bottom, and tighten bolts to the specified torque. Torque: 36 Nm (27 lb ft) 2. Connect fuel feed tube and fuel return tube(6). 3. Connect evapo fuel hose(5). 4. Connect fuel tank wiring connector(4). 5. Install undercover(3).
6C8
ENGINE FUEL
D Fill the tank with fuel and tighten fuel filler cap. D Connect battery ground cable.
6. Connect fuel filler hose, air breather hose and evapo hose(2). 7. Install fender liner(1). D Mount fender liner to the wheel well.
Fuel Tube / Quick Connect Fittings

Precautions
D Lighting of Fires Prohibited. D Keep flames away from your work area to prevent the inflammable from catching fire. D Disconnect the battery negative cable to prevent shorting during work. D When welding or conducting other heat-generating work on other parts, be sure to provide pretreatment to protect the piping system from thermal damage or spattering. 2. For removal of the delivery pipe (feeding fuel to the engine), hold the connector in one hand, and hold the retainer tab with the other hand and pull out the connector, as illustrated. The pipe can be removed with the retainer attached.
Cautions During Work

Do not expose the assembly to battery electrolyte or do not wipe the assembly with a cloth used to wipe off spilt battery electorolyte. The piping wet with battery electrolyte cannot be used. Be careful not to give a bending or twisting force to the piping during the work. If deformed, replace with a new piping.
Removal
1. Open the fuel cap to relieve the fuel pressure in the tank. If the fuel quick-connect fittings are dusty, clean with an air blower, etc. and then remove it.
141RW019
3. For removal of the return pipe (returnig fuel to the tank), hold the pipe in one hand, and pull out the connentor with the other hand while pressing the square relieve button of the retainer, as illustrated.
141RW016
As some pressure may remain in the piping, cover the connector with a cloth, etc. to prevent the splashing of fuel in the first disconnection of the piping.
141RW020
NOTE: This work should be done by hands. Do not use any tools. Should the pipe can hardly be removed from
ENGINE FUEL
the connector, use a lubricant (light oil) and/or push and pull the connector longitudinally until the pipe is removed.
6C9
D If the retainer removed according to the removal step above is attached to the pipe, clean and insert it straight into the quick-connector till it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked. NOTE: The retainer, once removed from the pipe, cannot be reused. Just replace with a new retainer. Insert the new retainer into the connector side until it clicks, and connect the pipe as inserting it into the retainer until it clicks.
141RW021
When reusing the delivery pipe retainer, reuse without removing the retainer from the pipe. If the retainer is damaged or deformed, however, replace with a new retainer. Cover the connectors removed with a plastic bag, etc. to prevent the entry of dust or rain water.
141RW018
(Return Pipe) D Replace the pipe and connector if scratch, dent or crack is found. D Remove mud or dust from the pipe and make sure that the end including spool is free from defects, such as scratch, rust, and dent, which may cause poor sealability. If defective, replace with a new pipe. D After cleaning the pipe, insert it straight into the connector until it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked.
141RW022
Reuse of QuickConnector
(Delivery Pipe) D Replace the pipe and connector if scratch, dent or crack is found. D Remove mud and dust from the pipe and make sure that the end including spool is free of defects, such as scratch, rust, and dent, which may cause poor sealability. If defective, replace with a new pipe.
141RW017
6C10
ENGINE FUEL
Assembling Advice
Application of engine oil or light oil to the pipe facilitates connecting work. The work should be started immediately after lubrication, since dust may stick to the pipe surface to cause poor sealability if a long time passes after lubrication. Test/Inspection After Assembling 1. Reconnect the battery negative cable. 2. Turn the ignition key to the ON position and check pump startup sound. As the pump is actuated to raise fuel pressure, check and see fuel leak from the piping system. 3. Make sure of no fuel leakage by conducting the above fuel leak check a few times. 4. Start the engine and make sure of stable idling speed and normal vehicle run.The entry of dust during the work may sometimes affect the fuel injection system.
ENGINE FUEL 6C11
Fuel Gauge Unit

Fuel Gauge Unit and Associated Parts
140RS004
Legend (1) Wiring Connector (2) Fuel Gauge Unit
Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Loosen fuel filler cap. 3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 Nm (14 lb ft) M8 4. Wiring connector D Disconnect wiring connector(1) from the unit. 5. Fuel gauge unit D Remove the fixing screws, then the fuel gauge unit(2). NOTE: After removing fuel gauge unit, cover fuel tank to prevent any dust entering
Installation
1. Fuel gauge unit(2). 2. Wiring connector(1). D Connect the wiring connector to the fuel gauge unit. D Fill the tank with fuel and tighten fuel filler cap. D Connect battery ground cable.
6C12
ENGINE FUEL
Fuel Filler Cap

General Description
Fuel filler cap includes vacuum valve and pressure valve. In case any high vacuum and any high pressure happen in tank, each valve works to adjust the pressure to prevent the tank from being damaged.
140R200028
Legend (1) Vacuum Valve (2) Pressure Valve (3) Seal Ring
Inspection
Check the seal ring in the filler cap for presence of any abnormality and for seal condition. Replace the filler cap, if abnormal. CAUTION: The fuel filler cap valves have characteristics. A defective valve, no valve at all or a valve with the wrong characteristics will do a lot of harm to engine operating characteristics; be sure to use the same fuel filler cap as installed in this vehicle.
ENGINE FUEL 6C13

Torque Specification
035RW031
SECTION
ENGINE ELECTRICAL
TROOPER
6D11
ENGINE
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . . 6D11 6D11 6D11 6D12 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . Battery Removal . . . . . . . . . . . . . . . . . . . . . . Battery Installation . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 6D12 6D13 6D13 6D14
Battery
General Description
There are six battery fluid caps on top of the battery. These are covered by a paper label. The battery is completely sealed except for the six small vent holes on the side. These vent holes permit the escape of small amounts of gas generated by the battery. This type of battery has the following advantages over conventional batteries: 1. There is no need to add water during the entire service life of the battery. 2. The battery protects itself against overcharging. The battery will refuse to accept an extensive charge. (A conventional battery will accept an excessive charge, resulting in gassing and loss of battery fluid.) 3. The battery is much less vulnerable to self discharge than a conventional type battery.
Diagnosis
061RW001
1. Visual Inspection
Inspect the battery for obvious physical damage, such as a cracked or broken case, which would permit electrolyte loss. Replace the battery if obvious physical damage is discovered during inspection. Check for any other physical damage and correct it as necessary.
2. Hydrometer Check
There is a builtin hydrometer (Charge test indicator(1)) at the top of the battery. It is designed to be used during diagnostic procedures. Before trying to read the hydrometer, carefully clean the upper battery surface. If your work area is poorly lit, additional light may be necessary to read the hydrometer. a. BLUE RING OR DOT VISIBLE(5) Go to Step 4. b. BLUE RING OR DOT NOT VISIBLE(4) Go to Step 3.
6D12
ENGINE ELECTRICAL
a. VOLTAGE DOES NOT DROP BELOW THE MINIMUM LISTED IN THE TABLE The battery is good and should be returned to service. b. VOLTAGE IS LESS THAN MINIMUM LISTED Replace battery. ESTIMATED TEMPERATURE F 70 60 50 40 30 20 10 0 C 21 16 10 4 1 7 12 18 MINIMUM VOLTAGE V 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
3. Fluid Level Check

The fluid level should be between the upper level line(2) and lower level line(3) on side of battery. a. CORRECT FLUID LEVEL Charge the battery. b. BELOW LOWER LEVEL Replace battery.
The battery temperature must be estimated by feel and by the temperature the battery has been exposed to for the preceding few hours.
061RW001
4. Voltage Check
1. Put voltmeter test leads to battery terminals. a. VOLTAGE IS 12.4V OR ABOVE Go to Step 5. b. VOLTAGE IS UNDER 12.4V Go to procedure (2) below. 2. Determine fast charge amperage from specification. (See Main Data and Specifications in this section). Fast charge battery for 30 minutes at amperage rate no higher than specified value. Take voltage and amperage readings after charge. a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF AMPERAGE RATE Replace battery. b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF AMPERAGE RATE Drop charging voltage to 15V and charge for 10 15 hours. Then go to Step 5. c. VOLTAGE IS BETWEEN 12V AND 16V Continue charging at the same rate for an additional 31/2 hours. Then go to Step 5. d. VOLTAGE BELOW 12V Replace Battery.
Battery Charging
Observe the following safety precautions when charging the battery: 1. Never attempt to charge the battery when the fluid level is below the lower level line on the side of the battery. In this case, the battery must be replaced. 2. Pay close attention to the battery during charging procedure. Battery charging should be discontinued or the rate of charge reduced if the battery feels hot to the touch. Battery charging should be discontinued or the rate of charge reduced if the battery begins to gas or spew electrolyte from the vent holes. 3. In order to more easily view the hydrometer blue dot or ring, it may be necessary to jiggle or tilt the battery. 4. Battery temperature can have a great effect on battery charging capacity. 5. The sealed battery used on this vehicle may be either quick charged or slow charged in the same manner as other batteries. Whichever method you decide to use, be sure that you completely charge the battery. Never partially charge the battery.
5. Load Test
1. Connect a voltmeter and a battery load tester across the battery terminals. 2. Apply 300 ampere load for 15 seconds to remove surface charge from the battery. Remove load. 3. Wait 15 seconds to let battery recover. Then apply specified load from specifications (See Main Data and Specifications in this section). Read voltage after 15 seconds, then remove load.
Jump Starting
Jump Starting with an Auxiliary (Booster) Battery
CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result.
ENGINE ELECTRICAL
Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin. Never allow battery fluid to come in contact with fabrics or painted surfaces. Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vehicle. This will protect against a short circuit. Always keep batteries out of reach of young children.
6D13
4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned OFF. 6. Start the engine of the vehicle with the dead battery. 7. To remove the jumper cables, follow the above directions in reverse order. Be sure to first disconnect the negative cable from the vehicle with the discharged battery.
Battery Removal
Jump Starting Procedure

1. Set the vehicle parking brake. If the vehicle is equipped with an automatic transmission, place the selector level in the PARK position. If the vehicle is equipped with a manual transmission, place the shift lever in the NEUTRAL position. Turn OFF the ignition. Turn OFF all lights and any other accessory requiring electrical power.
061RS002
2. Look at the builtin hydrometer. If the indication area of the builtin hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This will cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating.
1. Remove negative cable (1). 2. Remove positive cable (2). 3. Remove retainer screw and rods (3). 4. Remove retainer (4). 5. Remove battery (5).
Battery Installation
1. Install battery (5). 2. Install retainer (4). 3. Instal retainer screw and rods (3). NOTE: Make sure that the rod is hooked on the body side. 4. Install positive cable (2). 5. Install negative cable (1).
6D14
ENGINE ELECTRICAL

Model (JIS) Voltage (V) Cold Cranking Performance (Amp) Reserve Capacity (Min) Load Test (Amp) Fast Charge Maximum Amperage (Amp) BCI Group No. 95D31RMF 12 622 159 310 20 27 80D26RMF 12 582 133 290 20 24 75D26RMF 12 490 123 245 20 24
SECTION
IGNITION SYSTEM
TROOPER
6D21
ENGINE
IGNITION SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D21 6D22 6D22 6D23 6D23 6D23 6D23 6D25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Position Sensor . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 6D25 6D25 6D25 6D26 6D26 6D26 6D27
Service Precaution
6D22
IGNITION SYSTEM
General Description
Ignition is done by the electronic ignition (El) that directly fires the spark plugs from ignition coils through spark plug wires without using a distributor. A pair of ignition coils for the cylinders having different phases by 360 (No.1 and No.4,No.2 and No.5,No.3 and No.6) are fired simultaneously. Since the cylinder on exhaust stroke requires less energy to fire its ignition plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. After additional 360 rotation, respective cylinder strokes are reversed. The EI consists of six ignition coils, ion sensing module, crankshaft position sensor, powertrain control module (PCM) and other components. The crankshaft position coils are connected with the PCM by means of a 80 pin connector. The PCM and ion sensing module turn on/off the primary circuit of ignition coils. A notch in the timing disc on the crankshaft activates the crank position sensor which then sends information such as firing order and starting timing of each ignition coil to the PCM. Further, the El employs ignition control (IC) to control similar to a distributor system. By receiving signals such as crank position,engine speed, water temperature and Manifold Absolute Pressure (MAP), combustion guality, the PCM controls the ignition timing.
D06RY00037
Diagnosis
Refer to Section Drivability and Emissions for the diagnosis to electronic ignition system (El system).
IGNITION SYSTEM
6D23
Ignition Coil
Removal
1. Disconnect battery ground cable. 2. Ignition coil connector and ignition coil. D Disconnect three connector from ignition coil. D Remove harness bracket bolt on cylinder head cover. D Remove fixing bolts on ignition coil. Measure resistance of ignition coil assembly, and replace the ignition coil assembly if its value exceeds the standard.
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Installation
1. Install the ignition coil assembly (3). Connect ignition coil connector (1) and ignition coil (3), then tighten bolt (2) to the specified torque. Torque: 4 Nm (35 lb in)
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Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assembly

Check the ignition coil assembly for insulation. Check terminals for corrosion or damage, and replace as necessary. Measuring resistance of ignition coil assembly. Terminal No. 1 to 2 Limit Resistance cannot be 0 ohm (short) or infinity (open circuit). Same as above Same as above
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1 to 3 2 to 3
6D24
IGNITION SYSTEM
CAUTION: Ignition coil assembly # 6 is different from ignition coil assembly from # 1 to # 5. Ignition coil assembly # 6 is short type. So, note it when installing ignition coil assembly of # 6.
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Legend (1) Long Type Ignition Coil Assemblies (# 1 # 5) (2) Short Type Ignition Coil Assembly (# 6) 2. Connect battery ground cable.
IGNITION SYSTEM
6D25
Spark Plug
Removal
1. Remove spark plugs.
Measuring Insulation Resistance

D Measure insulation resistance using a 500 volt megaohm meter. D Replace spark plugs if measured value is out of standard. Insulation resistance: 50 MW or more

The spark plug affects entire engine performance and therefore its inspection is very important. D Check electrode and insulator for presence of cracks, and replace if any. D Check spark plug gap. Replace spark plugs if measured value is out of standard. Spark plug gap : 1.0 1.1 mm (0.4 0.043 in)
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Cleaning Spark Plugs

D Clean spark plugs with a spark plug cleaner. D After spark plug is thoroughly cleaned, check insulator for presence of cracks. D Clean threads and metal body with a wire brush.
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D Check gasket for damage, and replace if necessary. D Measure insulation resistance with an ohmmeter, and replace if faulty. D Check fuel and electrical systems if spark plug is extremely dirty. D Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. D Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned.
Installation
1. Spark plugs D Tighten spark plugs to the specified torque. Torque: 18 Nm (13 lb ft)
Sooty Spark Plugs

Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: D Too rich mixture D Presence of oil in combustion chamber D Incorrect spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: D Too lean mixture D Improper heat value
6D26
IGNITION SYSTEM
Crankshaft Position Sensor

Removal
1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block.
Installation
1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the Oring. Torque: 10 Nm (87 lb in) 2. Reconnect wiring connector to crankshaft position sensor.
012RS008
IGNITION SYSTEM
6D27

Ignition System Ignition Form Spark Plug Type K16PRP11 (DENSO) RC10PYP4 (CHAMPION) PK16PR11 (DENSO) 1.0 mm (0.04 in) 1.1 mm (0.043 in) 18 Nm (13 lb ft) Electronic Ignition System (El system) with Crankshaft position Sensor
Plug gap Torque
E06R200001
SECTION
STARTING AND CHARGING SYSTEM
TROOPER
6D31
ENGINE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Starting System . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . . . . . . . . 6D31 6D32 6D32 6D34 6D35 6D35 6D35 6D36 6D37 6D39 6D313 6D315 6D318 General Description . . . . . . . . . . . . . . . . . . . . . General OnVehicle Inspection . . . . . . . . . . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 6D318 6D318 6D319 6D319 6D319 6D319 6D320 6D321 6D323 6D325 6D325 6D326
Service Precaution
6D32
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter switch, starter relay, etc. These main components are connected.
Starter
The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft. When the starter switch is turned on, the contacts of magnetic switch are closed, and the armature rotates. At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with the ring gear. Then, the ring gear runs to start the engine. When the engine starts and the starter switch is turned off, the plunger returns, the pinion is disengaged from the ring gear, and the armature stops rotation. When the engine speed is higher than the pinion, the pinion idles, so that the armature is not driven.
6D33
C06RY00002
6D34
Diagnosis
Condition Starter does not run Possible cause Charging failure Battery Failure Terminal connection failure Starter switch failure Starter failure Correction Repair charging system Replace Battery Repair or replace terminal connector and/or wiring harness Repair or replace starter switch Repair or replace starter
6D35
Starter
Removal
1. Battery ground cable. 2. Disconnect Heated O2 Sensor connector (1). 3. Remove exhaust front left pipe(2). 3. Reconnect the connectors to terminals B and S and tighten Terminals B to specified torque. Torque: 9 Nm (78 lb in) 4. Install heat protector(3).
065RW027 035RW016
4. Remove heat protector(3). 5. Disconnect starter wiring connector from terminals B and S(4). 6. Remove starter assembly mounting bolts on inside and outside(5). 7. Remove starter assembly toward the bottom of engine(6).
5. Install exhaust front left pipe (2) and tighten bolts and nuts to specified torque. Stud Nuts Torque: 67 Nm (49 lb ft) Nuts (Exhaust front left pipeRight pipe) Torque: 57 Nm (42 lb ft) Nuts (Exhaust front left pipeSilencer) Torque: 43 Nm (32 lb ft) 6. Connect Heated O2 Sensor connector (1).
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Installation
1. Install starter assembly(6). 2. Install mounting bolts and tighten bolts to specified torque(5). Torque: 40 Nm (30 lb ft) 7. Reconnect the battery ground cable.
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6D36
Disassembled View
065RW002
Legend (1) Bolt (2 pcs) (2) Ball Bearing (3) Pinion (4) Shift Lever (5) Dust Cover (6) Torsion Spring (7) Dust Cover (8) Magnetic Switch (9) Nut (10) Gear Case (11) Bearing Cover (12) ERing (13) Thrust Washer (2)
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)
Center Bracket Pinion Shaft Planet Gear (3) Internal Gear Center Bracket (A) Yoke Assembly Armature Brush Brush Holder Thrust Washer Rear Cover Screw (2 pcs) Through Bolt (2 pcs)
6D37
Disassembly
1. Loosen the nut(1) on terminal M of magnetic switch and disconnect the connector cable. 2. Remove bolt (2 pcs) (2).
7. Remove screw (2 pcs) (8). 8. Remove through bolt (2 pcs) (7). 9. Remove screws and through bolts, then the rear cover(9) then remove thrust washer(10). 10. Remove brush holder(6).
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3. Remove magnetic switch(5). 4. Remove dust cover(4). 5. Remove torsion spring bolts, then the magnetic switch assembly. 6. Remove torsion spring(3) from magnetic switch assembly(5).
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11. Raise a brush spring to detach brushes (4 pcs) from the commutator face and pull off the brush holder(12) and brush(11).
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065RW004
6D38

17. Remove ball bearing(19). 18. Remove bearing cover(20). 19. Remove a ball bearing and bearing cover from the gear case(18).
12. Remove yoke assembly(14). 13. Remove armature(15). 14. Pull off the yoke assembly, then remove armature, washer and center bracket.(A) (13). NOTE: In disassembling the yoke assembly, hold the armature and pull off slowly the yoke assembly. Because of strong magnetic force, avoid placing a metallic part near armature.
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20. Internal gear(21). 21. Remove internal gear and planet gear(3) (22).
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15. Remove dust cover(17). 16. Remove a dust cover and shift lever(16) from the gear case.
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065RW008

22. Remove an Ering(23) from the pinion shaft using a flat blade screwdriver.
6D39

Repair or replace necessary parts if extreme wear or damage is found during inspection.
Armature
Measure the outer diameter of commutator, and replace with a new one if it is out of the limit. Standard: 33.0 mm (1.30 in) Limit: 32.0 mm (1.26 in)
065RW010
23. Holding the pinion shaft, push pinion toward the center bracket. and turn the pinion clockwise or counterclockwise by one tooth of spline, then pull off the pinion. 24. Remove thrust washer(24). 25. Remove center bracket 26. Remove pinion shaft.
065RS014
Check for continuity between commutator and segment. Replace commutator if there is no continuity (i.e., disconnected).
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065RS015
6D310 STARTING AND CHARGING SYSTEM

Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core,armature core and shaft. Replace commutator if there is continuity (i.e., internally grounded). Polish the commutator surface with sandpaper #500 to #600 if it is rough.
065RW012
065RS016
Measure runout of armature core and commutator with a dial gauge. Repair or replace, if it exceeds the limit. Armature Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in) Commutator Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in)
Measure the depth of insulator in commutator. Repair, if it is below the limit. Standard: 0.5 mm to 0.8 mm (0.02 in to 0.03 in) Limit: 0.2 mm (0.008 in)
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Legend (1) Steel Saw (2) Insulator (3) Commutator Segments
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6D311
Brush
Measure the length of brush. Replace with a new one, if it is below the limit. Standard: 16 mm (0.63 in) Limit: 11 mm (0.43 in)
Magnetic Switch
Check for continuity of shunt coil between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).
065RW016 065RW014
Brush Holder
Check for continuity between brush holder (+) (4) and base (). Replace, if there is continuity (i.e., insulation is broken).
Continuity of Series Coil

Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).
065RW017 065RW015
Continuity of Contacts
With the plunger faced downward, push down the magnetic switch. In this state, check for continuity between terminals B and M. Replace, if there is no continuity (i.e., contacts are faulty).
Yoke Assembly
Check a magnet inside the yoke. Replace the yoke assembly if it is broken.
065RS026
065RW018
Ball Bearing
Clamp the inner race of the ball bearing with your finger, and check for sticking or play when rotating the outer race. Replace, if abnormality is found.
Pinion
Check if the pinion rotates smoothly in drive direction by hand, or if it is locked when it is rotated in reverse. If not, replace the pinion.
065RS027 065RS025

Measure inner diameter of bushing in the rear cover, and replace if it exceeds the limit. Standard: 12.50 mm to 12.527 mm (0.492 in to 0.4932 in) Limit: 12.60 mm (0.4961 in)
6D313
Reassembly
To install, follow the removal steps in the reverse order, noting the following points: Grease application places D D D D D Bushing in rear cover and center bracket Gears in reduction gear Shift lever operating portion Sliding portion of pinion Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly

Before reassembly, make sure that no metallic parts attach to the yoke assembly. Because of strong magnetic force, hold the yoke assembly and insert it slowly into the armature. Torque Torque for each part (See Torque Specifications in this section)
Pinion Jumpout Dimension

Connect the + cable of battery to terminal S and the cable to terminal M. Turn the switch on, and measure pinion travel dimension in thrust direction from the jumpout position. In measuring the dimension, pull the pinion out a little in the arrow direction. Dimension(L): 0.05 mm to 1.5 mm (0.002 in to 0.06 in)
065RS028
Measure inner diameter of bushing in the center bracket (P), and replace if it exceeds the limit. Standard: 18.01 mm to 18.127 mm (0.7091 in to 0.7137 in) Limit: 18.15 mm (0.7146 in)
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065RS030

If the measured value is out of standard, insert dust cover, or disassemble and adjust.
065RW019
Characteristic Test
For easily confirming the characteristics, conduct the no load test as follows: Rating as short as 30 seconds requires rapid testing. Fix the starter on the test bench, and wire as shown in illustration. When the switch is closed, the current flows and the starter runs under no load. At this time, measure current, voltage and speed to check if they satisfy the standard.
065RW020
Legend (1) Volt Meter (2) Tachometer (3) Battery (4) Ammeter (5) Switch
6D315

Model Rating Voltage Output Time Number of teeth of pinion Rotating direction(as viewed from pinion) Weight(approx.) No load characteristics Voltage /Current Speed Load characteristics Voltage/current Torque Speed Locking characteristics Voltage/current Torque 3V/750A or less 19Nm(14 lb ft) or more 8.4V/250A 7.3Nm(64lbin.) or more 1200rpm or more 11V/90A or less 2700rpm or more 12 V 1.4 Kw 30 sec 9 Clockwise 34 N (7.6 lb) HITACHI GD003138
E06RW023
6D317
060R200207
Charging System
General Description
The IC integral regulator charging system and its main components are connected as shown in the illustration. The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator installed on the rear end cover. The generator does not require particular maintenance such as voltage adjustment. The rectifier connected to the stator coil has eight diodes to transform AC voltage into DC voltage. This DC voltage is connected to the output terminal of generator.
General OnVehicle Inspection

The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on when the starter switch is turned to ON position. The charging system operates normally if the lamp goes off when the engine starts. If the warning lamp shows abnormality or if undercharged or overcharged battery condition is suspected, perform diagnosis by checking the charging system as follows: 1. Check visually the belt and wiring connector. 2. With the engine stopped, turn the stator switch to ON position and observe the warning lamp. If lamp does not come on: Disconnect wiring connector from generator, and ground the terminal L on connector side. If lamp comes on: Repair or replace the generator.
F06RY00002
6D319
Generator
Removal
1. Disconnect battery ground cable. 2. Move drive belt tensioner to loose side using wrench then remove drive belt (1). 3. Disconnect the wire from terminal B and disconnect the connector (4). 4. Remove generator fixing bolt (3). 5. Remove generator assembly (2).
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If voltage is not present, the line between battery and connector is disconnected and so requires repair. 3. Reconnect the wiring connector to the generator, run the engine at middle speed, and turn off all electrical devices other than engine. 4. Measure battery voltage. If it exceeds 16V, repair or replace the generator. 5. Connect an ammeter to output terminal of generator, and measure output current under load by turning on the other electrical devices (eg., head lights). At this time, the voltage must not be less than 13V.
060RW002
Inspection
1. Disconnect the wiring connector from generator. 2. With the engine stopped, turn starter switch to ON and connect a voltmeter between connector terminal L (2) and ground or between terminal IG (1) and ground.
Installation
1. Install generator assembly to the position to be installed. 2. Install generator assembly and tighten the fixing bolts to the specified torque. Torque: M10 bolt: 41 Nm (30 lb ft) M8 bolt: 21 Nm (15 lb ft) 3. Connect wiring harness connector and direct terminal B. 4. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position. 5. Reconnect battery ground cable.
Disassembled View
066RW007
Legend (1) Pulley Nut (2) Pulley (3) Front Cover Assembly (4) Rotor Assembly (5) Rear End Cover
(6) (7) (8) (9) (10)
Rectifier Terminal Insulator and Nut Regulator Assembly Brush Holder Assembly Rear Cover
6D321
Disassembly
1. Terminal insulator and nut(2). 2. Remove three nuts(1) on the rear cover and a nut on terminal B and insulator, then remove the rear cover(3).
4. Remove three screws on the IC regulator, then the IC regulator assembly(6).
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5. Remove four screws that fix rectifier(7) and stator lead wires.
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3. Remove two screws that fix the brush holder(5) and rectifier, then remove the brush holder assembly(4).
066RW004
060RW004

6. Secure the pulley directly in the vise between two copper plates, and remove the nut and pulley. 8. Use the puller to remove the rear end cover. 9. Rotor assembly
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066RS012
7. Remove four nuts(8) that secure the front cover assembly and rear end cover, and an insulator(9).
10. Pull the rotor assembly(10) off the front cover assembly(12) using a bench press(11).
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066RW006
6D323

Repair or replace necessary parts if extreme wear or damage is found during inspection.
3. Check resistance between slip rings, and replace if there is no continuity.
Rotor Assembly
1. Check the rotor slip ring surfaces for contamination and roughness. If rough, polish with #500600 sandpaper.
066RS016
4. Check for continuity between slip ring and rotor core. In case of continuity, replace the rotor assembly.
066RS014
2. Measure the slip ring diameter, and replace if it exceeds the limit.
066RS017
066RS015
Stator Coil
1. Measure resistance between respective phases. 2. Measure insulation resistance between stator coil and core with a megaohmmeter. If less than standard, replace the coil.
Rectifier Assembly
Check for continuity across P and E in the 100W range of multimeter.
066RW002
066RS018
Brush
Measure the brush length. If more than limit, replace the brush. Standard: 10.mm (0.4134 in) Limit: 8.4.mm (0.3307 in)
Change polarity, and make sure that there is continuity in one direction, and not in the reverse direction. In case of continuity in both directions, replace the rectifier assembly.
IC Regulator Assembly
Check for continuity across B and F in the 100W range of multimeter.
066RS021
066RS019

Change polarity, and make sure that there is continuity in one direction, and not in the reverse direction. In case of continuity in both directions, replace the IC regulator assembly.
6D325
Bench Test
Conduct a bench test of the generator.
Reassembly
To reassemble, follow the disassembly steps in the reverse order, noting the following points: 1. Using a press with a socket wrench attached, reassemble rotor and rear end cover assembly in the front cover.
066RS023
Preparation
Remove generator from the vehicle (see Generator removal). 1. Secure generator to the bench test equipment and connect wires. Terminal IG for energization Terminal L for neutral (warning lamp) Terminal B for output 2. Conduct the generator characteristic test. Characteristics of generator are shown in illustration. Repair or replace the generator if its outputs are abnormal.
066RS022
2. Install pulley on the rotor. Secure the pulley directly in the vise between two copper plates, and tighten nut to the specified torque. Torque: 111 Nm (82 lb ft)
066RS010
B06RX001

Parts Number (Nippon denso) Model Rated voltage Rated output Rotating direction (As viewed from pulled) Pulley effective diameter Weight 1022111740 ACJV74 12 V 90 A Clockwise 57.5 mm (2.26 in) 49.7 N (11.2 lb)
SECTION
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
TROOPER
6E1
ENGINE
TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening Specifications . . . . . . . . . . . . . . . Diagrams and Schematics . . . . . . . . . . . . . . . . PCM Wiring Diagram (1 of 8) . . . . . . . . . . . . PCM Wiring Diagram (2 of 8) . . . . . . . . . . . . PCM Wiring Diagram (3 of 8) . . . . . . . . . . . . PCM Wiring Diagram (4 of 8) . . . . . . . . . . . . PCM Wiring Diagram (5 of 8) . . . . . . . . . . . . PCM Wiring Diagram (6 of 8) . . . . . . . . . . . . PCM Wiring Diagram (7 of 8) . . . . . . . . . . . . PCM Wiring Diagram (8 of 8) . . . . . . . . . . . . PCM Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F1 20 . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F20 40 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F41 60 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F61 80 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S1 20 . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S21 40 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S41 60 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S61 80 . . . . . . . . . . . . . . . . . . . . . Component Locators . . . . . . . . . . . . . . . . . . . Undercarriage Component Locator . . . . . . Fuse and Relay Panel (Underhood Electrical Center) . . . . . . . . . . . . . . . . . . . . . Sensors and Miscellaneous Component Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Strategy-Based Diagnostics . . . . . . . . . . . . . Strategy-Based Diagnostics . . . . . . . . . . . . . DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . . No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Matching Symptom . . . . . . . . . . . . . . . . . Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . . No Trouble Found . . . . . . . . . . . . . . . . . . . . . Verifying Vehicle Repair . . . . . . . . . . . . . . . . General Service Information . . . . . . . . . . . . . . OBD II Serviceablity Issues . . . . . . . . . . . . . Visual / Physical Engine Compartment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Knowledge of Tools Required . . . . . . Serial Data Communications . . . . . . . . . . . . . . Class 2 Serial Data Communications . . . . . 6E6 6E6 6E7 6E7 6E8 6E9 6E10 6E11 6E12 6E13 6E14 6E15 6E15 6E16 6E18 6E20 6E22 6E24 6E26 6E28 6E30 6E32 6E33 6E34 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E37 6E37 6E38 6E38 On-Board Diagnostic (OBD II) . . . . . . . . . . . . . On-Board Diagnostic Tests . . . . . . . . . . . . . Comprehensive Component Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations . . . . . . . . . . . . . . . . . . Common OBD II Terms . . . . . . . . . . . . . . . . . The Diagnostic Executive . . . . . . . . . . . . . . . DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . . Decimal/Binary/Hexadecimal Conversions Verifying Vehicle Repair . . . . . . . . . . . . . . . . Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool . . . . . . . . . . . . . . . . . Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . . Getting Started . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure (For Example) . . . . . DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC Information Mode . . . . . . . . . . . . . . . . . Miscellaneous Test . . . . . . . . . . . . . . . . . . . . Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Test . . . . . . . . . . . . . . . . . . . . . . Instruments Test . . . . . . . . . . . . . . . . . . . . . . . EGR Control Test . . . . . . . . . . . . . . . . . . . . . . Variable Intake Manifold Solenoid Test . . . Injector Balance Test . . . . . . . . . . . . . . . . . . . Plotting Snapshot Graph . . . . . . . . . . . . . . . . . Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) . . . . . . Flow Chart for Snapshot Replay (Plotting Graph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary System-Based Diagnostic . . . . . . . . . Primary System-Based Diagnostic . . . . . . . Fuel Control Heated Oxygen Sensor . . . . . HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . . Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation . . . . . . . . . . . . . . Misfire Monitor Diagnostic Operation . . . . . . . Misfire Monitor Diagnostic Operation . . . . . Misfire Counters . . . . . . . . . . . . . . . . . . . . . . . Fuel Trim System Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Trim System Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E38 6E38 6E38
6E39 6E39 6E39 6E40 6E41 6E42 6E42 6E43 6E44 6E44 6E45 6E46 6E46 6E47 6E47 6E49 6E50 6E51 6E53 6E55 6E55 6E57 6E57 6E58 6E59 6E60 6E60 6E60 6E60 6E60 6E61 6E61 6E61 6E62 6E62
6E2

6E62 6E63 6E63 6E63 6E63 6E66 6E66 6E66 6E67 6E71 6E71 6E71 6E71 6E71 6E71 6E71 6E72 6E76 6E76 6E76 6E76 6E79 6E79 6E81 6E81 6E87 6E87 6E87 6E90 6E90 6E90 6E92 6E92 6E92 6E95 6E95 6E95 6E97 6E99 6E99 6E99 6E104 6E105 6E105 6E105 6E105 6E108 6E109 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Relief Procedure . . . . . . . . . Exhaust Gas Recirculation (EGR) System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Evaporative (EVAP) Emissions Canister Purge Valve Check . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . PCM Diagnostic Trouble Codes . . . . . . . . . . . DTC P0101 MAF System Performance . . . . DTC P0102 MAF Sensor Circuit Low Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0103 MAF Sensor Circuit High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0106 MAP System Performance . . . . DTC P0107 MAP Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0108 MAP Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0112 IAT Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0113 IAT Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0117 ECT Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0118 ECT Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0125 ECT Excessive Time to Closed Loop Fuel Control . . . . . . . . . . . . . . . . . . . . . . . DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0133 HO2S Slow Response Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E109 6E109 6E112 6E113 6E113 6E114 6E117 6E117 6E119 6E119 6E121 6E121 6E121 6E124 6E128 6E131 6E134 6E136 6E139 6E142 6E145 6E148 6E151 6E154 6E157 6E160 6E163 6E166 6E170 6E173 6E176 6E179 6E182 6E185
Fuel Trim Cell Diagnostic Weights . . . . . . . On-Board Diagnostic (OBD II) System Check Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Control Circuit Diagnosis . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . Electronic Ignition System Diagnosis . . . . . . . EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve . . . . . . . . . . . . . . . . . . . . . Visual Check of The Evaporative Emission Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System Check . . . . . . . . . . . . . Fuel System Pressure Test . . . . . . . . . . . . . . . Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) Diagnosis Multiple PCM Information Sensor DTCs Set Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation (EGR) Diagnosis Engine Tech 2 Data Definitions and Ranges Typical Scan Data Values . . . . . . . . . . . . . . . . Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . No Malfunction Indicator Lamp (MIL) . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Malfunction Indicator Lamp (MIL) ON Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . No Reduced Power Lamp (RPL) . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Reduced Power Lamp (RPL) ON Steady . . Circuit description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Engine Cranks But Will Not Run . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel System Electrical Test . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Relief Procedure . . . . . . . . . Electric Throttle Control (ETC) System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . .

DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0153 HO2S Slow Response Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0171 Fuel Trim System Lean Bank 1 . DTC P0172 Fuel Trim System Rich Bank 1 . DTC P0174 Fuel Trim System Lean Bank 2 . DTC P0175 Fuel Trim System Rich Bank 2 . DTC P0201 Injector 1 Control Circuit . . . . . . DTC P0202 Injector 2 Control Circuit . . . . . . DTC P0203 Injector 3 Control Circuit . . . . . . DTC P0204 Injector 4 Control Circuit . . . . . . DTC P0205 Injector 5 Control Circuit . . . . . . DTC P0206 Injector 6 Control Circuit . . . . . . DTC P0300 Engine Misfire Detected . . . . . . . DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault . . . . . . . . . . . . . . DTC P0336 58X Reference Signal Circuit . . DTC P0337 CKP Sensor Circuit Low Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0351 Ignition 1 Control Circuit . . . . . . . DTC P0352 Ignition 2 Control Circuit . . . . . . . DTC P0353 Ignition 3 Control Circuit . . . . . . . DTC P0354 Ignition 4 Control Circuit . . . . . . . DTC P0355 Ignition 5 Control Circuit . . . . . . . DTC P0356 Ignition 6 Control Circuit . . . . . . . DTC P0401 EGR Flow Insufficient . . . . . . . . . DTC P0402 EGR Pintle Crank Error . . . . . . . DTC P0404 EGR Open Stuck . . . . . . . . . . . . . DTC P0405 EGR Low Voltage . . . . . . . . . . . . DTC P0406 EGR High Voltage . . . . . . . . . . . DTC P0420 TWC System Low Efficiency Bank 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0430 TWC System Low Efficiency Bank 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0440 EVAP System . . . . . . . . . . . . . . . . DTC P0442 EVAP System Small Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0444 EVAP Purge Control Circuit Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E188 6E191 6E194 6E198 6E201 6E204 6E207 6E210 6E213 6E216 6E220 6E224 6E228 6E232 6E235 6E238 6E241 6E244 6E247 6E250 6E254 6E257 6E260 6E263 6E266 6E269 6E272 6E275 6E278 6E281 6E284 6E286 6E288 6E291 6E294 6E297 6E300 6E303 6E306 DTC P0445 EVAP Purge Control Circuit Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0446 EVAP Canister Vent Control Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0447 EVAP Vent Solenoid Circuit Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0448 EVAP Vent solenoid Circuit Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage . . . . . DTC P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage . . . . . DTC P0456 EVAP Very Small Leak . . . . . . . DTC P0461 Fuel Level Sensor Performance DTC P0462 Fuel Level Sensor CircuitLow Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0463 Fuel Level Sensor CircuitHigh Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0464 Fuel Level Sensor Noisy Signal DTC P0502 VSS Circuit Low Input . . . . . . . . . DTC P0506 Idle Air Control System Low RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0507 Idle Air Control System High RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0562 System Voltage Low . . . . . . . . . . DTC P0563 System Voltage High . . . . . . . . . DTC P0565 Cruise Main Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0566 Cruise Cancel Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0567 Cruise Resume Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0568 Cruise Set Switch Circuit Error . DTC P0571 No Brake Switch Signal . . . . . . . DTC P0601 PCM Memory . . . . . . . . . . . . . . . . DTC P0602 PCM Programming Error . . . . . . DTC P0604 PCM RAM Error . . . . . . . . . . . . . . DTC P0606 PCM Internal Performance . . . . DTC P0660 VIM Solenoid Circuit Open . . . . DTC P0662 VIM Solenoid Circuit Short . . . . . DTC P1106 MAP Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1107 MAP Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1111 IAT Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1112 IAT Sensor Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1114 ECT Sensor Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1115 ECT Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault . . . . . . . . . . . . . . . . . . . . . DTC P1125 ETC (Electric throttle control) Limit Performance Mode . . . . . . . . . . . . . . . . .
6E3
6E4

6E390 6E394 6E398 6E402 6E406 6E408 6E410 6E413 6E416 6E419 6E422 6E425 6E428 6E430 6E432 6E434 6E436 6E438 6E440 6E443 6E446 6E449 6E452 6E455 6E458 6E461 6E465 6E468 6E471 6E474 6E476 6E478 6E479 6E481 6E483 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . Default Matrix Table . . . . . . . . . . . . . . . . . . . . . On Vehicle Service Crankshaft Position (CKP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature (ECT) Sensor . Heated Oxygen Sensor (HO2S) . . . . . . . . . . . Intake Air Temperature (IAT) Sensor . . . . . . . ION Sensing Module . . . . . . . . . . . . . . . . . . . . . Mass Air Flow (MAF) Sensor . . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Sensor . Malfunction Indicator Lamp (MIL) . . . . . . . . . . Reduced Power Lamp . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . Removal Procedure . . . . . . . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . . . . . EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Position (TP) Sensor . . . . . . . . . . . . . Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . Air Cleaner/Air Filter . . . . . . . . . . . . . . . . . . . . . Common Chamber . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal Replacement . . . . . . . . . . . Accelerator Position Sensor Replacement . . Accelerator Position Sensor Adjustment . . . . Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System . . . . . . . . . . . . . . . . . . . . Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Body (TB) . . . . . . . . . . . . . . . . . . . . . . . Electronic Ignition System . . . . . . . . . . . . . . . . Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Thermo Relay . . . . . . . . . . . EVAP Canister Hoses . . . . . . . . . . . . . . . . . . . . EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Canister Vent Solenoid . . . . . . . . . . . . . Fuel Tank Pressure (Vapor Pressure) Sensor EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve) . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Vent Valve (Vent Solenoid Valve) . Linear Exhaust Gas Recirculation (EGR) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive Crankcase Ventilation (PCV) Valve . PCV Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring and Connectors . . . . . . . . . . . . . . . . . . . PCM Connectors and Terminals . . . . . . . . . . . Wire Harness Repair: Twisted Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . . Weather-Pack Connector . . . . . . . . . . . . . . . . . 6E486 6E515 6E518 6E518 6E519 6E522 6E522 6E523 6E524 6E525 6E525 6E525 6E525 6E525 6E526 6E527 6E527 6E528 6E529 6E529 6E530 6E531 6E531 6E532 6E532 6E534 6E534 6E535 6E536 6E536 6E537 6E538 6E538 6E540 6E541 6E541 6E541 6E542 6E543 6E544 6E545 6E545 6E545 6E546 6E547 6E547 6E548 6E548 6E549 6E550
DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1) . . . . . . . . . . . . . . . . . . . . DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2) . . . . . . . . . . . . . . . . . . . . DTC P1171 Fuel System Lean During Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1221 TPS1 TPS2 correlation (Circuit Performance) . . . . . . . . . . . . . . . . . . . DTC P1271 APS 1 2 Correlation Error . . . . DTC P1272 APS 2 3 Correlation Error . . . . DTC P1273 APS 1 3 Correlation Error . . . . DTC P1275 APS 1 Circuit Fault . . . . . . . . . . . DTC P1280 APS 2 Circuit Fault . . . . . . . . . . . DTC P1285 APS 3 Circuit Fault . . . . . . . . . . . DTC P1290 ETC Forced Idle Mode . . . . . . . . DTC P1295 Power Management Mode . . . . DTC P1299 ETC Forced Engine Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1310 ION Sensing Module Diagnosis DTC P1311 ION Sensing Module SEC Line 1 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . DTC P1312 ION Sensing Module SEC Line 2 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault . . . . . . . . . . . . . . . . DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail) . . . . . . DTC P1404 EGR Stuck Closed . . . . . . . . . . . DTC P1441 EVAP System Flow During Non-Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1514 TPS - MAF Correlation Error . . . DTC P1515 Command - Actual TPS Correlation Error . . . . . . . . . . . . . . . . . . . . . . . . DTC P1516 Command - Actual TPS Correlation Error . . . . . . . . . . . . . . . . . . . . . . . . DTC P1523 Actuator Control Return Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1574 Brake Switch No Operation . . . . DTC P1635 Reference Voltage # 1 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1636 PCM RAM Stack . . . . . . . . . . . . . DTC P1639 Reference Voltage # 2 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1640 Driver-1-Output Circuit Fault (ODM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1650 Quad Driver Module A Fault . .

Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . . Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description (PCM and Sensors) . . . 58X Reference PCM Input . . . . . . . . . . . . . . A/C Request Signal . . . . . . . . . . . . . . . . . . . . Crankshaft Position (CKP) Sensor . . . . . . . Engine Coolant Temperature (ECT) Sensor Electrically Erasable Programmable Read Only Memory (EEPROM) . . . . . . . . . . . . . . Fuel Control Heated Oxygen Sensors . . . . Catalyst Monitor Heated Oxygen Sensors Intake Air Temperature (IAT) Sensor . . . . . Linear Exhaust Gas Recirculation (EGR) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mass Air Flow (MAF) Sensor . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Sensor Powertrain Control Module (PCM) . . . . . . . PCM Function . . . . . . . . . . . . . . . . . . . . . . . . . PCM Components . . . . . . . . . . . . . . . . . . . . . PCM Voltage Description . . . . . . . . . . . . . . . PCM Input/Outputs . . . . . . . . . . . . . . . . . . . . PCM Service Precautions . . . . . . . . . . . . . . Reprogramming The PCM . . . . . . . . . . . . . . Throttle Position (TP) Sensor . . . . . . . . . . . Transmission Fluid Temperature (TFT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Range Switch (Mode Switch) Vehicle Speed Sensor (VSS) . . . . . . . . . . . . Use of Circuit Testing Tools . . . . . . . . . . . . . Aftermarket Electrical and Vacuum Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrostatic Discharge Damage . . . . . . . . . General Description (Air Induction) . . . . . . . . Air Induction System . . . . . . . . . . . . . . . . . . . General Description (Fuel Metering) . . . . . . . Acceleration Mode . . . . . . . . . . . . . . . . . . . . . Battery Voltage Correction Mode . . . . . . . . Clear Flood Mode . . . . . . . . . . . . . . . . . . . . . Deceleration Mode . . . . . . . . . . . . . . . . . . . . Engine Speed/Vehicle Speed/Fuel Disable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . . 6E551 6E552 6E553 6E553 6E553 6E553 6E553 6E553 6E553 6E554 6E554 6E555 6E555 6E555 6E556 6E556 6E556 6E556 6E556 6E557 6E557 6E557 6E557 6E557 6E557 6E557 6E558 6E558 6E558 6E558 6E559 6E559 6E559 6E559 6E559 6E559 6E559 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System Components . . . . . . Fuel Metering System Purpose . . . . . . . . . . Fuel Pressure Regulator . . . . . . . . . . . . . . . . Fuel Pump Electrical Circuit . . . . . . . . . . . . . Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Body Unit . . . . . . . . . . . . . . . . . . . . . General Description (Electronic Ignition System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Position (CKP) Sensor . . . . . . . Electronic Ignition . . . . . . . . . . . . . . . . . . . . . Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . Ignition Control PCM Output . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . . . A/C Clutch Circuit Operation . . . . . . . . . . . . A/C Clutch Circuit Purpose . . . . . . . . . . . . . A/C Request Signal . . . . . . . . . . . . . . . . . . . . General Description (Evaporative (EVAP) Emission System) . . . . . . . . . . . . . . . . . . . . . . EVAP Emission Control System Purpose . EVAP Emission Control System Operation Enhanced Evaporative Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description (Exhaust Gas Recirculation (EGR) System) . . . . . . . . . . . . . EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . . Linear EGR Valve . . . . . . . . . . . . . . . . . . . . . Linear EGR Control . . . . . . . . . . . . . . . . . . . . Linear EGR Valve Operation and Results of Incorrect Operation . . . . . . . . . . . . . . . . . . . . EGR Pintle Position Sensor . . . . . . . . . . . . . General Description (Positive Crankcase Ventilation (PCV) System) . . . . . . . . . . . . . . . Crankcase Ventilation System Purpose . . . Crankcase Ventilation System Operation . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E5
6E6
Specifications
Tightening Specifications
Application EGR Bolt Engine Coolant Temperature Sensor Fuel Drain Plug Fuel Pressure Regulator Attaching Screw Fuel Rail Bolts Fuel Tank Undercover Retaining Bolts Heated Oxygen Sensor Lower Intake Manifold to Engine Block Bolts Lower Intake Manifold to Engine Block Nuts Spark Plugs Throttle Body Mounting Bolts Common Chamber to Lower Intake Manifold Bolts VSS Retaining Bolt Nm 25 30 20 3 25 36 55 25 25 18 10 25 16 Lb Ft. 18 22 14 18 27 40 18 18 13 18 12 Lb In. 26 87
6E7
Diagrams and Schematics

PCM Wiring Diagram (1 of 8)
D06R200030
6E8
D06R200031
6E9
D06R200032
6E10
D06R200033
6E11
D06R200086
6E12
D06R200035
6E13
D06R200036
6E14
D06R200037
6E15
PCM Pinouts
PCM Pinout Table, 80-Way Blue Connector Row F1 20
060RY00045
PIN F1 F2 F3 F4
PIN Function PCM Ground 5Volt Referrence2 (AP Sensor 2) 5Volt Referrence2 (TP Sensor 2) A/C Clutch
Wire Color BLK/BLU GRN RED/WHT GRN/BLK
IGN ON 0.0V 5.0V 5.0V B+(A/C off)
ENG RUN 0.0V 5.0V 5.0V B+(A/C off)
Refer To Chassis Electrical AP Sensor AP Sensor General Description and Operation,A/C Cluch Circuit Opreation 4L30E T/Mission Chassis Electrical General Description, Mass Air Flow Sensor General Description and Operation, Catalyst Monitor HO2S 2 6D Section 6D Section
F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17
Mission Main Case Not Used Tachometer Not Used Not Used Not Used T.O.D Not Used Not Used Mass Air Flow(MAF) Not Used Not Used Bank 1 HO2S Low
GRN/RED BLK/RED RED/WHT YEL RED
0.0V 8.8V 4.9V 0.0V
0.0V 10.0V(at idle) 4.2V 0.1V
F18 F19 F20
Not Used Ignition Feed Ignition Feed
RED/BLU WHT
B+ B+
B+ B+
6E16
060RY00156
PIN F21
PIN Function Bank 1 HO2S 1 Ground
Wire Color WHT
IGN ON 0.0V
ENG RUN 0.0V
Refer To General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation,ION Sensing Module General Description and Operation,ION Sensing Module General Description and Operation, IAT General Description and Operation, Manifold Absolute Pressure
F22 F23
Not Used Bank 2 HO2S 1 Ground BLU
0.0V
0.0V
F24 F25
Not Used ION Sensing Module
RED/BLU
1.555V
1.555V
F26
ION Sensing Module
RED/BLK
1.555V
1.555V
F27 F28 F29
Intake Air Temperature (IAT)Sensor Not Used Manifold Absolute Pressure(MAP)
YEL/GRN RED
0.54.9V 3.5V4.9V (depends on altitude and barometric pressure)
0.54.9V 0.6-1.3V
F30 F31 F32 F33 F34 F35 F36 F37 F38
Not Used Not Used Power Lamp Reduse Power Lamp Winter Lamp Not Used Not Used Power Steering Pressure (PSP) Illuminated Switch
GRN/WHT RED/WHT PNK/GRN GRN/YEL GRN/YEL
B+ B+ B+ B+ B+
B+ B+ B+ B+ B+
4L30E T/Mission Chassis Electrical 4L30E T/Mission Power Steering Chassis Electrical

PIN F39 F40 PIN Function Brake Swich PCM Ground Wire Color GRN/YEL BLK/RED IGN ON 0.0V 0.0V ENG RUN 0.0V 0.0V Refer To 4L30E T/Mission Chassis Electrical
6E17
6E18
060RY00046
PIN F41 F42 F43 F44
PIN Function Throttle Position(TP) 1 Sensor Ground Fuel Pump Relay Adaptor Case Bank 1 HO2S 2 Heater Ground A/C Request Auto Cruise Brake Switch Adaptor Case Throttle Valve DC Motor() Not Used Bank 2 HO2S 2 Ground
Wire Color GRN SIL/BLK VIO/RED BLK/PNK
IGN ON 0.0V 0.0V 0.0V 0.0V
ENG RUN 0.0V B+ 0.0V 0.0V
Refer To General Description and Operation,TPS On Vehicle Service, Fuel Pump Relay 4L30E T/Mission General Description and Operation, Catalyst Monitor HO2S 2 Chassis Electrical Chassis Electrical 4L30E T/Mission General Description and Operation, ETC General Description and Operation, Catalyst Monitor HO2S 2 Chassis Electrical General Description and Operation, Catalyst Monitor HO2S 2 General Description and Operation,ECT Sensor General Description and Operation,VP Sensor General Description and Operation,Fuel Injector Chassis Electrical General Description
F45 F46 F47 F48 F49 F50
GRN/ORN ORN VIO/RED BLK ORN
0.0V 0.0V B+ Duty Cycle 0.0V
0.0V 0.0V B+ Duty Cycle 0.0V
F51 F52
DLC Serial Data Bank 1 HO2S 2 Ground
ORN RED
5.0V 0.0V
5.0V 0.0V
F53 F54 F55 F56 F57 F58
ECT Ground Vapor Pressure Sensor Ground Not Used Injector Cylinder #5 Ignition Feed Class 2 Data
GRN GRY/RED GRN/BLK WHT ORN/GRN
0.0V 0.0V B+ B+ 0.0V
0.0V 0.0V B+ B+ 0.0V

PIN F59 F60 PIN Function Not Used Not Used Wire Color IGN ON ENG RUN Refer To
6E19
6E20
060RY00047
PIN F61 F62 F63 F64 F65 F66 F67
PIN Function Throttle Position(TP) 2 Sensor Ground Injector Cylinder #2 AP Sensor 1 Sensor Ground Injector Cylinder #4 Throttle Psition(TP) 2 Sensor Signal Injector Cylinder #3 ION Sensing Module
Wire Color GRN/WHT GRN/ORN RED GRN/RED BLU/WHT GRN YEL
IGN ON 0.0V B+ 0.0V B+ 0.50.8V B+ 1.555V
ENG RUN 0.0V B+ 0.0V B+ 0.80.8V (at idle) B+ 1.555V
Refer To General Description and Operation,TPS General Description and Operation,Fuel Injector General Description and Operation,APS General Description and Operation,Fuel Injector General Description and Operation,TPS General Description and Operation,Fuel Injector General Description and Operation, ION Sensing Module General Description and Operation, ION Sensing Module General Description and Operation,Fuel Injector General Description and Operation, Catalyst Monitor HO2S 2 Chassis Electrical General Description and Operation, CKP sensor General Description and Operation, ECT Sensor Chassis Electrical Manual T/Mission 4L30E T/Mission
F68
ION Sensing Module
RED
1.555V
1.555V
F69 F70 F71
Injector Cylinder #1 Not Used Bank 2 HO2S 2 Heater Ground Auto Cruise Switch Resume Cranshaft Position Sensor ECT Sensor Ignition Feed Clutch Switch(M/T only) Mode Switch(A/T only)
GRN/WHT BLK
B+ 0.0V
B+ 0.0V
F72 F73 F74 F75 F76
BRN/YEL YEL BLU/RED RED/BLU YEL/GRN YEL/GRN
0.0V 0.3V 0.54.9V B+ B+ B+
0.0V 2.2V 0.54.9V B+ B+ B+

PIN F77 F78 F79 F80 PIN Function Mode Switch Mode Switch Mode Switch AP Sensor 2 Sensor Ground Wire Color BLU/WHT BLU/BLK BLU/YEL BLU IGN ON B+ B+ B+ 0.0V ENG RUN B+ B+ B+ 0.0V Refer To 4L30E T/Mission 4L30E T/Mission 4L30E T/Mission
6E21
General Description and Operation, APS
6E22
PCM Pinout Table, 80-Way Red Connector Row S1 20
060RY00069
PIN S1 S2
PIN Function PCM Ground Bank 1 HO2S 1 Heater Ground Not Used ATF Warning Lamp 5Volt Referrence2 (CKP Sensor/CMP Sensor) Auto Cruise Switch Cancel EVAP Parge Solenoid Valve Not Used Not Used Shift High(Band Apply) Malfunction Indicator (Check Engine) Lamp Not Used ION Sensing Module
Wire Color BLK/WHT BLK
IGN ON 0.0V 0.0V
ENG RUN 0.0V 0.0V
Refer To Chassis Electrical General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission Appropriate Sensor (CKP Sensor, CMP Sensor ,AP2 Sensor) Chassis Electrical General Description and Operation, EVAP Emission Control System 4L30E T/Mission Chassis Electrical General Description and Operation, ION Sensing Module General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation, Catalyst Monitor HO2S 2 General Description and Operation, Catalyst Monitor HO2S
S3 S4 S5
ORN/BLU YEL/RED
B+ 5.0V
B+ 5.0V
S6 S7
GRY/GRN RED/BLU
0.0V B+
0.0V 5.7V
S8 S9 S10 S11 S12 S13
BRN/YEL VIO RED/WHT
B+ 0.0V 1.555V
B+ B+ 1.555V
S14
Bank 2 HO2S 1 Ground Jump Bank 2 HO2S 2 Ground Jump Bank 2 HO2S 2 Low
BLU
0.0V
0.0V
S15
ORN
0.0V
0.0V
S16
BLU
0.0V
0.1V

PIN S17 PIN Function Bank 1 HO2S 1 Ground Jump Bank 1 HO2S 1 Low Wire Color WHT IGN ON 0.0V ENG RUN 0.0V Refer To
6E23
General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation, Catalyst Monitor HO2S General Description and Operation, ION Sensing Module 4L30E T/Mission
S18
GRN
0.0V
0.1V
S19
ION Sensing Module
RED/YEL
1.555V
1.555V
S20
Transmission Fluid Temperature Sensor Ground
RED/WHT
0.0V
0.0V
6E24
060RY00049
PIN S21 S22 S23 S24
PIN Function Not Used Transmissin Output Speed Sensor PCM Ground Bank 1 HO2S 2 Ground Jump Not Used EGR Control Low VSS Input Injector Cylinder #6 Winter Switch Auto Cruise Main Switch Transmissin Range Signal23 Ignition Feed TCC Solenoid Not Used ION Sensing Module
Wire Color RED BLK/RED RED
IGN ON 0.0V 0.0V 0.0V
ENG RUN 0.0V 0.0V 0.0V
Refer To 4L30E T/Mission Chassis Electrical General Description and Operation, Catalyst Monitor HO2S 2 General Description and Operation, EGR Control Chassis Electrical General Description and Operation, Fuel Injector 4L30E T/Mission Chassis Electrical 4L30E T/Mission Chassis Electrical T/Mission General Description and Operation, ION Sensing Module AP Sensor (Fuel Tank Pressure Sensor/MAP Sensor/EGR Posistion Sensor) Sensor TP Sensor
S25 S26 S27 S28 S29 S30 S31 S32 S33 S34 S35
BLK/YEL Light GRN/WHT GRN/YEL VIO/GRN PNK/BLK GRN RED/BLU RED/BRN RED/GRN
B+ 0.0V B+ B+ 0.0V 0.0V B+ 0.0V 1.555V
B+ 0.1V (at rest) B+ B+ 0.0V 0.0V B+ 0.0V 1.555V
S36 S37
5Volt Referrence (AP Sensor 1) 5Volt Referrence (Fuel Tank Pressure Sensor/MAP Sensor/EGR Posistion Sensor) 5Volt Referrence (TP Sensor 1)
BLK RED/BLU
5.0V 5.0V
5.0V 5.0V
S38
RED/BLU
5.0V
5.0V

PIN S39 S40 PIN Function Auto Cruise Lamp PCM Ground Wire Color BLK/ORN BLK IGN ON 0.0V 0.0V ENG RUN 0.0V 0.0V Refer To Chassis Electrical Chassis Electrical
6E25
6E26
060RY00050
PIN S41 S42
PIN Function AP Sensor 3 Sensor Ground Bank 2 HO2S 1 Heater Ground Transmissin Range Signal12 34 Not Used Antilock Brake System (ABS) Off Switch A/T Check Transmission Lamp M/T Up Shift Lamp Water Temp Gauge Fuel Gauge DLC Fuel Sender Unit TCC Solenoid Vapor Pressure Sensor Signal Power Switch Bank 2 HO2S 1 Low
Wire Color BLU/ORN BLK
IGN ON 0.0V 0.0V
ENG RUN 0.0V 0.0V
Refer To General Description and Operation, APS General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission Antilock Brake System Chassis Electrical Chassis Electrical Chassis Electrical Chassis Electrical General Description T/Mission General Description and Operation,VP Sensor 4L30E T/Mission General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission General Description and Operation, Catalyst Monitor HO2S
S43 S44 S45 S46
GRY/WHT VIO/WHT ORN/BLK ORN/BLK WHT/BLK YEL/RED ORN/BLU YEL/VIO BRN/BLU GRY VIO/RED BLU
0.0V B+ B+ B+ B+ B+ B+ 0.0V B+ 0.24.8V B+ 0.0V
0.0V B+ B+ B+ B+ B+ B+ 0.0V B+ 0.24.8V B+ 0.1V
S47 S48 S49 S50 S51 S52 S53 S54
S55 S56 S57 S58
Transmissin Output Speed Sensor Not Used Not Used Bank 2 HO2S 1 High
WHT RED
0.0V 0.3V
0.0V 0.10.9V

PIN S59 S60 PIN Function Auto Cruise Steering Set Switch Fuel Sender Unit Wire Color Light GRN GRY IGN ON 0.0V 0.54.9V ENG RUN 0.0V 0.54.9V Refer To Chassis Electrical
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ON-Vehicle Service PCM and Sensors
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060RY00051
PIN S61 S62
PIN Function Intake Air Temperature (IAT)Sensor Ground ION Sensing Module
Wire Color GRN RED
IGN ON 0.0V 1.555V
ENG RUN 0.0V 1.555V
Refer To General Description and Operation, IAT General Description and Operation, ION Sensing Module General Description and Operation, Catalyst Monitor HO2S General Description and Operation, Catalyst Monitor HO2S General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission
S63
Bank 1 HO2S 2 High
WHT
0.3V
0.10.9V
S64
Bank 2 HO2S 1 High
PNK
0.3V
0.10.9V
S65
Bank 2 HO2S 2 High
GRN
0.3V
0.10.9V
S66
Transmission Fluid Temperature Sensor Exhaust Gas Recirculation (EGR) Accelerator Position(AP) Sensor 1 Throttle Valve DC Motor(+) Not Used Not Used Ignition Feed for ETC Auto Cruise Main Lamp Variable Intake Manifold Canister Vent Valve Throttle Position(TP) 1 Sensor Signal
RED/BLK
0.54.9V (depends on temperature) 0.6V 0.410.45V Duty Cycle
0.54.9V (depends on temperature) 0.6V 0.410.45V Duty Cycle B+ B+ B+(rpm 3600 over) 5.7V Tank empty 0.50.8V (at idle)
S67 S68 S69 S70 S71 S72 S73 S74 S75 S76
YEL/RED WHT RED RED/BLU GRY/BLU WHT/BLU BLU/PNK BLU/PNK
General Description and Operation,EGR Control General Description and Operation,AP Sensor General Description and Operation,ETC Chassis Electrical Chassis Electrical General Description General Description and Operation, EVAP General Description and Operation,TPS
B+ B+ 0.0V 6.0V Tank empty 0.50.8V

PIN S77 S78 S79 S80 PIN Function 5Volt Referrence (AP Sensor 3) Accelerate Position(AP) Sensor 2 Accelerate Position(AP) Sensor 3 Manifold Absolute Pressure(MAP) Wire Color ORN YEL BLU/GRN GRN IGN ON 5.0V 0.410.45V 4.554.99V 0V ENG RUN 5.0V 0.410.45V 0.410.45V 0V Refer To Appropriate Sensor
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General Description and Operation,AP Sensor General Description and Operation,AP Sensor General Description and Operation, Manifold Absolute Pressure
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Component Locators
Engine Component Locator
060R200243

Engine Component Locator Table Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Name Linear Exhaust Gas Recirculation (EGR) Valve Throttle Position (TP) Sensor Intake Air Temperature (IAT) Sensor Check Engine (MIL) Light Positive Crankcase Ventilation (PCV) Valve Air Cleaner Mass Air Flow (MAF) Sensor Fuel Rail Fuel Pressure Regulator ION Sensing module Common Chamber EVAP Duty Solenoid Valve Fuse/Relay Box Manifold Absolute Pressure (MAP) Sensor Throttle Body Engine Coolant Temperature Sensor Power Train Control Module (PCM) Location Rear right side of the engine On the throttle body
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On the intake air duct near the throttle body On the instrument panel beneath the tachometer On the left of the cylinder head cover Left front of the engine bay Attached to the air filter box On the Common Chamber Rear side of the engine Bolted to the top of the Common Chamber Top of the engine Bolted to the front of the coolant pipe Along the inside of the right fender Bolted to the top of the Common Chamber Between the intake air duct and the Common Chamber On the coolant crossover pipe at the front of the engine, near the throttle body Along the inside of the left fender
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Undercarriage Component Locator
F00RW032
Undercarriage Component Locator Table Number 1 2 3 4 5 6 Name Fuel Pump Assembly EVAP Canister Vent Solenoid (EVAP Canister) Fuel Gauge Unit Fuel Filter Vehicle Speed Sensor (VSS) Location Installed in the top of the fuel tank On the top of the bracket that is located behind of the cross member On the top of the bracket that is located behind of the cross member Installed in the front edge of the fuel tank, on the right side Located along the inside of the right frame rail, ahead of the rear axle 2WD: Protrudes from the transmission housing, just ahead of the propeller shaft. 4WD: Protrudes from the rear output shaft housing of the transfer case. Threaded into the exhaust pipe behind the right-hand catalytic converter Threaded into the exhaust pipe ahead of the right-hand catalytic converter Threaded into the exhaust pipe ahead the left-hand catalytic converter Threaded into the exhaust pipe behind the left-hand catalytic converter
7 8 9 10
Heated Oxygen Sensor (Bank 1, HO2S 1) Heated Oxygen Sensor (Bank 1, HO2S 2) Heated Oxygen Sensor (Bank 2, HO2S 1) Heated Oxygen Sensor (Bank 2, HO2S 2)
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Fuse and Relay Panel (Underhood Electrical Center)
060R200212
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Sensors and Miscellaneous Component Locators
060RY00013
060RW111
T321067
060R200201
060R200224
055RY00002
6E35
041RW004
060R200208
025RW005
060R200209
060RY00014
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3. Use a check sheet or other method to identify the circuit or electrical system component. 4. Follow the suggestions for intermittent diagnosis found in the service documentation. Most Scan Tools, such as the Tech 2, have data-capturing capabilities that can assist in detecting intermittents.
Diagnosis Strategy-Based Diagnostics

Strategy-Based Diagnostics
The strategy-based diagnostic is a uniform approach to repair all Electrical/Electronic (E/E) systems. The diagnostic flow can always be used to resolve an E/E system problem and is a starting point when repairs are necessary. The following steps will instruct the technician how to proceed with a diagnosis: 1. Verify the customer complaint. D To verify the customer complaint, the technician should know the normal operation of the system. 2. Perform preliminary checks. D Conduct a thorough visual inspection. D Review the service history. D Detect unusual sounds or odors. D Gather diagnostic trouble code information to achieve an effective repair. 3. Check bulletins and other service information. D This includes videos, newsletters, etc. 4. Refer to service information (manual) system check(s). D System checks contain information on a system that may not be supported by one or more DTCs. System checks verify proper operation of the system. This will lead the technician in an organized approach to diagnostics. 5. Refer to service diagnostics.
No Trouble Found
This condition exists when the vehicle is found to operate normally. The condition described by the customer may be normal. Verify the customer complaint against another vehicle that is operating normally. The condition may be intermittent. Verify the complaint under the conditions described by the customer before releasing the vehicle. 1. Re-examine the complaint. When the complaint cannot be successfully found or isolated, a re-evaluation is necessary. The complaint should be re-verified and could be intermittent as defined in Intermittents section, or could be normal. 2. Repair and verify. After isolating the cause, the repairs should be made. Validate for proper operation and verify that the symptom has been corrected. This may involve road testing or other methods to verify that the complaint has been resolved under the following conditions: D Conditions noted by the customer. D If a DTC was diagnosed, verify a repair by duplicating conditions present when the DTC was set as noted in the Failure Records or Freeze Frame data.
Verifying Vehicle Repair

Verification of the vehicle repair will be more comprehensive for vehicles with OBD II system diagnostics. Following a repair, the technician should perform the following steps: IMPORTANT: Follow the steps below when you verify repairs on OBD II systems. Failure to follow these steps could result in unnecessary repairs. 1. Review and record the Failure Records and the Freeze Frame data for the DTC which has been diagnosed (Freeze Frame data will only be stored for an A or B type diagnostic and only if the MIL(Check Engine lamp) has been requested). 2. Clear the DTC(S). 3. Operate the vehicle within conditions noted in the Failure Records and Freeze Frame data. 4. Monitor the DTC status information for the DTC which has been diagnosed until the diagnostic test associated with that DTC runs.
DTC Stored
Follow the designated DTC chart exactly to make an effective repair.
No DTC
Select the symptom from the symptom tables. Follow the diagnostic paths or suggestions to complete the repair. You may refer to the applicable component/system check in the system checks.
No Matching Symptom
1. Analyze the complaint. 2. Develop a plan for diagnostics. 3. Utilize the wiring diagrams and the theory of operation. Combine technician knowledge with efficient use of the available service information.
Intermittents
Conditions that are not always present are called intermittents. To resolve intermittents, perform the following steps: 1. Observe history DTCs, DTC modes, and freeze frame data. 2. Evaluate the symptoms and the conditions described by the customer.
General Service Information

OBD II Serviceablity Issues
With the introduction of OBD II diagnostics across the entire passenger car and light-duty truck market in 1996, illumination of the MIL (Check Engine lamp) due to a non-vehicle fault could lead to misdiagnosis of the vehicle, increased warranty expense and customer

dissatisfaction. The following list of non-vehicle faults does not include every possible fault and may not apply equally to all product lines. Fuel Quality Fuel quality is not a new issue for the automotive industry, but its potential for turning on the MIL (Check Engine lamp) with OBD II systems is new. Fuel additives such as dry gas and octane enhancers may affect the performance of the fuel. If this results in an incomplete combustion or a partial burn, it will show up as a Misfire DTC P0300. The Reed Vapor Pressure of the fuel can also create problems in the fuel system, especially during the spring and fall months when severe ambient temperature swings occur. A high Reed Vapor Pressure could show up as a Fuel Trim DTC due to excessive canister loading. High vapor pressures generated in the fuel tank can also affect the Evaporative Emission diagnostic as well. Using fuel with the wrong octane rating for the vehicle may cause driveability problems. Many of the major fuel companies advertise that using premium gasoline will improve the performance of the vehicle. Most premium fuels use alcohol to increase the octane rating of the fuel. Although alcohol-enhanced fuels may raise the octane rating, the fuels ability to turn into vapor in cold temperatures deteriorates. This may affect the starting ability and cold driveability of the engine. Low fuel levels can lead to fuel starvation, lean engine operation, and eventually engine misfire. Non-OEM Parts All of the OBD II diagnostics have been calibrated to run with OEM parts. Something as simple as a high-performance exhaust system that affects exhaust system back pressure could potentially interfere with the operation of the EGR valve and thereby turn on the MIL (Check Engine lamp). Small leaks in the exhaust system near the post catalyst oxygen sensor can also cause the MIL (Check Engine lamp) to turn on. Aftermarket electronics, such as transceivers, stereos, and anti-theft devices, may radiate EMI into the control system if they are improperly installed. This may cause a false sensor reading and turn on the MIL (Check Engine lamp). Environment Temporary environmental conditions, such as localized flooding, will have an effect on the vehicle ignition system. If the ignition system is rain-soaked, it can temporarily cause engine misfire and turn on the MIL (Check Engine lamp). Refueling A new OBD II diagnostic was introduced in 1996 on some vehicles. This diagnostic checks the integrity of the entire evaporative emission system. If the vehicle is restarted after refueling and the fuel cap is not secured correctly, the on-board diagnostic system will sense this as a system fault and turn on the MIL (Check Engine lamp) with a DTC P0440.
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Vehicle Marshaling The transportation of new vehicles from the assembly plant to the dealership can involve as many as 60 key cycles within 2 to 3 miles of driving. This type of operation contributes to the fuel fouling of the spark plugs and will turn on the MIL (Check Engine lamp) with a P0300 Misfire DTC. Poor Vehicle Maintenance The sensitivity of OBD II diagnostics will cause the MIL (Check Engine lamp) to turn on if the vehicle is not maintained properly. Restricted air filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual vehicle faults that were not previously monitored prior to OBD II. Poor vehicle maintenance cant be classified as a non-vehicle fault, but with the sensitivity of OBD II diagnostics, vehicle maintenance schedules must be more closely followed. Related System Faults Many of the OBD II system diagnostics will not run if the PCM detects a fault on a related system or component. One example would be that if the PCM detected a Misfire fault, the diagnostics on the catalytic converter would be suspended until Misfire fault was repaired. If the Misfire fault was severe enough, the catalytic converter could be damaged due to overheating and would never set a Catalyst DTC until the Misfire fault was repaired and the Catalyst diagnostic was allowed to run to completion. If this happens, the customer may have to make two trips to the dealership in order to repair the vehicle.
Visual / Physical Engine Compartment Inspection

Perform a careful visual and physical engine compartment inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a problem without further steps. Use the following guidelines when performing a visual/physical inspection: D Inspect all vacuum hoses for pinches, cuts, disconnections, and proper routing. D Inspect hoses that are difficult to see behind other components. D Inspect all wires in the engine compartment for proper connections, burned or chafed spots, pinched wires, contact with sharp edges or contact with hot exhaust manifolds or pipes.
Basic Knowledge of Tools Required

NOTE: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in an incorrect diagnosis or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. A basic understanding of hand tools is necessary to effectively use this section of the Service Manual.
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powertrain components. The CARB OBD II Comprehensive Component Monitoring List Of Components Intended To illuminate MIL is a list of components, features or functions that could fall under this requirement. Input Components: Input components are monitored for circuit continuity and out-of-range values. This includes rationality checking. Rationality checking refers to indicating a fault when the signal from a sensor does not seem reasonable, i.e. Throttle Position (TP) sensor that indicates high throttle position at low engine loads or MAP voltage. Input components may include, but are not limited to the following sensors: D Vehicle Speed Sensor (VSS) D Crankshaft Position (CKP) sensor D Throttle Position (TP) sensor D Engine Coolant Temperature (ECT) sensor D Manifold Absolute Pressure (MAP) sensor D Mass Air Flow (MAF) sensor In addition to the circuit continuity and rationality check, the ECT sensor is monitored for its ability to achieve a steady state temperature to enable closed loop fuel control. Output Components: Output components are diagnosed for proper response to control module commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: D Control module controlled EVAP Canister Purge Valve D Electronic Transmission controls D A/C relays D VSS output D MIL control D Cruise control inhibit Refer to PCM and Sensors in General Descriptions. Passive and Active Diagnostic Tests A passive test is a diagnostic test which simply monitors a vehicle system or component. Conversely, an active test, actually takes some sort of action when performing diagnostic functions, often in response to a failed passive test. For example, the EGR diagnostic active test will force the EGR valve open during closed throttle decel and/or force the EGR valve closed during a steady state. Either action should result in a change in manifold pressure. Intrusive Diagnostic Tests This is any on-board test run by the Diagnostic Management System which may have an effect on vehicle performance or emission levels.
Serial Data Communications

Class 2 Serial Data Communications
Government regulations require that all vehicle manufacturers establish a common communication system. This vehicle utilizes the Class 2 communication system. Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by transmitting and receiving multiple signals over a single wire. The messages carried on Class 2 data streams are also prioritized. If two messages attempt to establish communications on the data line at the same time, only the message with higher priority will continue. The device with the lower priority message must wait. The most significant result of this regulation is that it provides Scan tool manufacturers with the capability to access data from any make or model vehicle that is sold. The data displayed on other Scan tools will appear the same, with some exceptions. Some Scan tools will only be able to display certain vehicle parameters as values that are a coded representation of the true or actual value. On this vehicle the Scan tool displays the actual values for vehicle parameters. It will not be necessary to perform any conversions from coded values to actual values.
On-Board Diagnostic (OBD II)

On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which is a pass or fail reported to the diagnostic executive. When a diagnostic test reports a pass result, the diagnostic executive records the following data: D The diagnostic test has been completed since the last ignition cycle. D The diagnostic test has passed during the current ignition cycle. D The fault identified by the diagnostic test is not currently active. When a diagnostic test reports a fail result, the diagnostic executive records the following data: D The diagnostic test has been completed since the last ignition cycle. D The fault identified by the diagnostic test is currently active. D The fault has been active during this ignition cycle. D The operating conditions at the time of the failure. Remember, a fuel trim DTC may be triggered by a list of vehicle faults. Make use of all information available (other DTCs stored, rich or lean condition, etc.) when diagnosing a fuel trim fault.
Comprehensive Component Monitor Diagnostic Operation

Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output

Warm-Up Cycle A warm-up cycle means that engine at temperature must reach a minimum of 70C (160F) and rise at least 22C (40F) over the course of a trip. Freeze Frame Freeze Frame is an element of the Diagnostic Management System which stores various vehicle information at the moment an emissions-related fault is stored in memory and when the MIL is commanded on. These data can help to identify the cause of a fault. Refer to Storing And Erasing Freeze Frame Data in this section for more detailed information. Failure Records Failure Records data is an enhancement of the OBD II Freeze Frame feature. Failure Records store the same vehicle information as does Freeze Frame, but it will store that information for any fault which is stored in on-board memory, while Freeze Frame stores information only for emission-related faults that command the MIL on. D D D D D D D D D D vehicle speed ECT MAF/MAP barometric pressure IAT TP high canister purge fuel trim TCC enabled A/C on
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System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations
I/M Ready Status means a signal or flag for each emission system test that had been set in the PCM. I/M Ready Status indicates that the vehicle on-board emissions diagnostics have been run. I/M Ready Status is not concerned whether the emission system passed or failed the test, only that on-board diagnosis is complete. Not all vehicles use all possible I/M flags.
Common OBD II Terms

Diagnostic When used as a noun, the word diagnostic refers to any on-board test run by the vehicles Diagnostic Management System. A diagnostic is simply a test run on a system or component to determine if the system or component is operating according to specification. There are many diagnostics, shown in the following list: D Misfire D Oxygen sensors D Oxygen sensor heaters D EGR D Catalyst monitoring Enable Criteria The term enable criteria is engineering language for the conditions necessary for a given diagnostic test to run. Each diagnostic has a specific list of conditions which must be met before the diagnostic will run. Enable criteria is another way of saying conditions required. The enable criteria for each diagnostic is listed on the first page of the DTC description in Section 6E under the heading Conditions for Setting the DTC. Enable criteria varies with each diagnostic, and typically includes, but is not limited to the following items: D engine speed
Trip Technically, a trip is a key on-run-key off cycle in which all the enable criteria for a given diagnostic are met, allowing the diagnostic to run. Unfortunately, this concept is not quite that simple. A trip is official when all the enable criteria for a given diagnostic are met. But because the enable criteria vary from one diagnostic to another, the definition of trip varies as well. Some diagnostics are run when the vehicle is at operating temperature, some when the vehicle first starts up; some require that the vehicle be cruising at a steady highway speed, some run only when the vehicle is idle; some diagnostics function with the TCC disabled. Some run only immediately following a cold engine start-up. A trip then, is defined as a key on-run-key off cycle in which the vehicle was operated in such a way as to satisfy the enabling criteria for a given diagnostic, and this diagnostic will consider this cycle to be one trip. However, another diagnostic with a different set of enable criteria (which were not met) during this driving event, would not consider it a trip. No trip will occur for that particular diagnostic until the vehicle is driven in such a way as to meet all the enable criteria.
The Diagnostic Executive

The Diagnostic Executive is a unique segment of software which is designed to coordinate and prioritize the diagnostic procedures as well as define the protocol for recording and displaying their results. The main responsibilities of the Diagnostic Executive are listed as the following: D Commanding the MIL (Check Engine lamp) on and off D DTC logging and clearing D Freeze Frame data for the first emission related DTC recorded D Non-emission related Service Lamp D Operating conditions Failure Records buffer, (the number of records will vary) D Current status information on each diagnostic D System Status (I/M ready) The Diagnostic Executive records DTCs and turns on the MIL when emission-related faults occur. It can also turn off the MIL if the conditions cease which caused the DTC to set.
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D It informs the driver that a fault affects vehicle emission levels has occurred and that the vehicle should be taken for service as soon as possible. D As a bulb and system check, the MIL will come ON with the key ON and the engine not running. When the engine is started, the MIL will turn OFF. D When the MIL remains ON while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD ll) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first.
Diagnostic Information The diagnostic charts and functional checks are designed to locate a faulty circuit or component through a process of logical decisions. The charts are prepared with the requirement that the vehicle functioned correctly at the time of assembly and that there are no multiple faults present. There is a continuous self-diagnosis on certain control functions. This diagnostic capability is complemented by the diagnostic procedures contained in this manual. The language of communicating the source of the malfunction is a system of diagnostic trouble codes. When a malfunction is detected by the control module, a diagnostic trouble code is set and the Malfunction Indicator Lamp (MIL) (Check Engine lamp) is illuminated. Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with (Check Engine lamp). However, OBD II requires that it illuminate under a strict set of guide lines. Basically, the MIL is turned on when the PCM detects a DTC that will impact vehicle emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if an emissions-related diagnostic test indicates a malfunction has occurred. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissions related faults. If the vehicle is experiencing a misfire malfunction which may cause damage to the Three-Way Catalytic Converter (TWC), the MIL will flash once per second. This will continue until the vehicle is outside of speed and load conditions which could cause possible catalyst damage, and the MIL will stop flashing and remain on steady. Extinguishing the MIL When the MIL is on, the Diagnostic Executive will turn off the MIL after three(3) consecutive trips that a test passed has been reported for the diagnostic test that originally caused the MIL to illuminate. Although the MIL has been turned off, the DTC will remain in the PCM memory (both Freeze Frame and Failure Records) until forty(40) warm-up cycles after no faults have been completed. If the MIL was set by either a fuel trim or misfire-related DTC, additional requirements must be met. In addition to the requirements stated in the previous paragraph, these requirements are as follows: D The diagnostic tests that are passed must occur within 375 RPM of the RPM data stored at the time the last test failed. D Plus or minus ten (10) percent of the engine load that was stored at the time the last failed. D Similar engine temperature conditions (warmed up or warming up ) as those stored at the time the last test failed. Meeting these requirements ensures that the fault which turned on the MIL has been corrected. The MIL (Check Engine lamp) is on the instrument panel and has the following function:
DTC Types
Each DTC is directly related to a diagnostic test. The Diagnostic Management System sets DTC based on the failure of the tests during a trip or trips. Certain tests must fail two (2) consecutive trips before the DTC is set. The following are the four (4) types of DTCs and the characteristics of those codes: D Type A D Emissions related D Requests illumination of the MIL of the first trip with a fail D Stores a History DTC on the first trip with a fail D Stores a Freeze Frame (if empty) D Stores a Fail Record D Updates the Fail Record each time the diagnostic test fails D Type B D Emissions related D Armed after one (1) trip with a fail D Disarmed after one (1) trip with a pass D Requests illumination of the MIL on the second consecutive trip with a fail D Stores a History DTC on the second consecutive trip with a fail (The DTC will be armed after the first fail) D Stores a Freeze Frame on the second consecutive trip with a fail (if empty) D Stores a Fail Record when the first test fails (not dependent on consecutive trip fails) D Updates the Fail Record each time the diagnostic test fails (Some special conditions apply to misfire and fuel trim DTCs) D Type C (if the vehicle is so equipped) D Non-Emissions related D Requests illumination of the Service D Stores a History DTC on the first trip with a fail D Does not store a Freeze Frame D Stores Fail Record when test fails D Updates the Fail Record each time the diagnostic test fails D Type D D Non-Emissions related

D D D D D Not request illumination of any lamp Stores a History DTC on the first trip with a fail Does not store a Freeze Frame Stores Fail Record when test fails Updates the Fail Record each time the diagnostic test fails D D D D D D D D D D D Air Flow Rate Fuel Trim Engine Speed Engine Load Engine Coolant Temperature Vehicle Speed TP Angle AP Angle MAP/BARO Injector Base Pulse Width Loop Status
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IMPORTANT: Only four Fail Records can be stored. Each Fail Record is for a different DTC. It is possible that there will not be Fail Records for every DTC if multiple DTCs are set. Special Cases of Type B Diagnostic Tests Unique to the misfire diagnostic, the Diagnostic Executive has the capability of alerting the vehicle operator to potentially damaging levels of misfire. If a misfire condition exists that could potentially damage the catalytic converter as a result of high misfire levels, the Diagnostic Executive will command the MIL to flash at a rate of once per second during those the time that the catalyst damaging misfire condition is present. Fuel trim and misfire are special cases of Type B diagnostics. Each time a fuel trim or misfire malfunction is detected, engine load, engine speed, and engine coolant temperature are recorded. When the ignition is turned off, the last reported set of conditions remain stored. During subsequent ignition cycles, the stored conditions are used as reference for similar conditions. If a malfunction occurs during two consecutive trips, the Diagnostic Executive treats the failure as a normal Type B diagnostic, and does not use the stored conditions. However, if a malfunction occurs on two non-consecutive trips, the stored conditions are compared with the current conditions. The MIL will then illuminate under the following conditions: D When the engine load conditions are within 10% of the previous test that failed. D Engine speed is within 375 rpm, of the previous test that failed. D Engine coolant temperature is in the same range as the previous test that failed. Storing and Erasing Freeze Frame Data and Failure Records Government regulations require that engine operating conditions be captured whenever the MIL is illuminated. The data captured is called Freeze Frame data. The Freeze Frame data is very similar to a single record of operating conditions. Whenever the MIL is illuminated, the corresponding record of operating conditions is recorded to the Freeze Frame buffer. Freeze Frame data can only be overwritten with data associated with a misfire or fuel trim malfunction. Data from these faults take precedence over data associated with any other fault. The Freeze Frame data will not be erased unless the associated history DTC is cleared. Each time a diagnostic test reports a failure, the current engine operating conditions are recorded in the Failure Records buffer. A subsequent failure will update the recorded operating conditions. The following operating conditions for the diagnostic test which failed typically include the following parameters: D Air Fuel Ratio
Intermittent Malfunction Indicator Lamp In the case of an intermittent fault, the MIL (Check Engine lamp) may illuminate and then (after three trips) go OFF. However, the corresponding diagnostic trouble code will be stored in memory. When unexpected diagnostic trouble codes appear, check for an intermittent malfunction. A diagnostic trouble code may reset. Consult the Diagnostic Aids associated with the diagnostic trouble code. A physical inspection of the applicable sub-system most often will resolve the problem. Data Link Connector (DLC) The provision for communication with the control module is the Data Link Connector (DLC). It is located at the lower left of the instrument panel behind a small square cover. The DLC is used to connect to the Tech 2 Scan Tool. Some common uses of the Tech 2 are listed below: D Identifying stored Diagnostic Trouble Codes (DTCs). D Clearing DTCs. D Performing output control tests. D Reading serial data.
TS24064
Decimal/Binary/Hexadecimal Conversions
Beginning in 1996, Federal Regulations require that all auto manufacturers selling vehicles in the United States provide Scan Tool manufacturers with software information to display vehicle operating parameters. All
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When a Scan Tool is not available, DTCs can also be cleared by disconnecting one of the following sources for at least thirty (30) seconds. NOTE: To prevent system damage, the ignition key must be OFF when disconnecting or reconnecting battery power. D The power source to the control module. Examples: fuse, pigtail at battery PCM connectors, etc. D The negative battery cable. (Disconnecting the negative battery cable will result in the loss of other on-board memory data, such as preset radio tuning).
Scan Tool manufacturers will display a variety of vehicle information which will aid in repairing the vehicle. Some Scan Tools will display encoded messages which will aid in determining the nature of the concern. The method of encoding involves the use of a two additional numbering systems: Binary and Hexadecimal. The binary number system has a base of two numbers. Each digit is either a 0 or a 1. A binary number is an eight digit number and is read from right to left. Each digit has a position number with the farthest right being the 0 position and the farthest left being the 7 position. The 0 position, when displayed by a 1, indicates 1 in decimal. Each position to the left is double the previous position and added to any other position values marked as a 1. A hexadecimal system is composed of 16 different alpha numeric characters. The alpha numeric characters used are numbers 0 through 9 and letters A through F. The hexadecimal system is the most natural and common approach for Scan Tool manufacturers to display data represented by binary numbers and digital code.
Verifying Vehicle Repair

Verification of vehicle repair will be more comprehensive for vehicles with OBD II system diagnostic. Following a repair, the technician should perform the following steps: 1. Review and record the Fail Records and/or Freeze Frame data for the DTC which has been diagnosed (Freeze Frame data will only be stored for an A or B type diagnostic and only if the MIL has been requested). 2. Clear DTC(s). 3. Operate the vehicle within conditions noted in the Fail Records and/or Freeze Frame data. 4. Monitor the DTC status information for the DTC which has been diagnosed until the diagnostic test associated with that DTC runs. Following these steps are very important in verifying repairs on OBD ll systems. Failure to follow these steps could result in unnecessary repairs.
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool

The procedure for reading diagnostic trouble code(s) is to use a diagnostic Scan Tool. When reading DTC(s), follow instructions supplied by tool manufacturer. Clearing Diagnostic Trouble Codes IMPORTANT: Do not clear DTCs unless directed to do so by the service information provided for each diagnostic procedure. When DTCs are cleared, the Freeze Frame and Failure Record data which may help diagnose an intermittent fault will also be erased from memory. If the fault that caused the DTC to be stored into memory has been corrected, the Diagnostic Executive will begin to count the warm-up cycles with no further faults detected, the DTC will automatically be cleared from the PCM memory. To clear Diagnostic Trouble Codes (DTCs), use the diagnostic Scan Tool clear DTCs or clear information function. When clearing DTCs follow instructions supplied by the tool manufacturer.
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Tech 2
From 98 MY, Isuzu dealer service departments are recommended to use the Tech 2 Scan Tool. Please refer to the Tech 2 user guide.
060M200031
(3) DLC Cable (4) Tech2
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7. Power the Tech 2 ON and verify the Tech 2 power up display.
Tech 2 Features
1. Tech 2 is a 12 volt system. Do not apply 24 volts. 2. After connecting and/or installing the Vehicle Communications Interface (VCI) module, PCMCIA card and DLC connector to the Tech 2, connect the tool to the vehicle DLC. 3. Make sure the Tech 2 is OFF when removing or installing the PCMCIA card. 4. The PCMCIA card has a capacity of 10 Megabytes which is 10 times greater than the memory of the Tech 1 Mass Storage Cartridge. 5. The Tech 2 has the capability of two snapshots. 6. The PCMCIA card is sensitive to magnetism and static electricity, so care should be taken in the handling of the card. 7. The Tech 2 can plot a graph when replaying a snapshot. 8. Always return to the Main Menu by pressing the EXIT key several times before shutting down. 9. To clear Diagnostic Trouble Codes (DTCs), open Application Menu and press F1: Clear DTC Info.
060RW009
Getting Started
D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. Insert the Isuzu system PCMCIA card (1) into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5) 4. Make sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC.
NOTE: The RS232 Loop back connector is only to use for diagnosis of Tech 2. Refer to user guide of the Tech 2.
821RW021
6. Turn on the vehicle ignition.
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Operating Procedure (For Example)

060R200202
060R100102
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Menu
D The following table shows which functions are used for the available equipment versions.
060RW223
060R100018
The following is a brief description of each of the sub menus in DTC Info and DTC. The order in which they appear here is alphabetical and not necessarily the way they will appear on the Tech 2.
DTC Modes
DTC Information Mode

Use the DTC info mode to search for a specific type of stored DTC information. DTC Status This selection will display any DTCs that have not run during the current ignition cycle or have reported a test failure during this ignition up to DTCs. DTC tests which run and pass will cause that DTC number to be removed from Tech 2 screen. Fail This Ignition This selection will display all DTCs that have failed during the present ignition cycle. History This selection will display only DTCs that are stored in the PCMs history memory. It will display all type A and B DTCs that have requested the MIL and have failed within the last 40 warm-up cycles. In addition, it will display all type C and type D DTCs that have failed within the last 40 warm-up cycles. Last Test Failed This selection will display only DTCs that have failed the last time the test run. The last test may have run during a previous ignition cycle if a type A or type B DTC is displayed. For type C and type D DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MILSVC or Message Request This selection will display only DTCs that are requesting the MIL. Type C and type D DTCs cannot be displayed using this option. This selection will report type B DTCs only after the MIL has been requested.
060R100077
On OBD II vehicles there are options available in Tech 2 DTC mode to display the enhanced information available. After selecting DTC, the following menu appears: 1. Read DTC Info by Priority 2. Freeze Frame 3. Fail Records (not all applications) 4. DTC Info 5. Clear Info

Not Run Since Code Cleared This option will display up to DTCs that have not run since the DTCs were last cleared. Since any displayed DTCs have not run, their condition (passing or failing) is unknown. Test Failed Since Code Cleared This selection will display all active and history DTCs that have reported a test failure since the last time DTCs were cleared. DTCs that last failed more than 40 warm-up cycles before this option is selected will not be displayed.
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4. Select F0:Lamps Test in the Miscellaneous Test.
Miscellaneous Test
This test consists of eight menus-Lights, Relays, EVAP, Fuel System, Instruments, EGR Control, Variable Intake Manifold Solenoid, and Injector Balance Tests. In these tests, Tech 2 sends operating signals to the systems to confirm their operations thereby to judge the normality of electric circuits. To judge intermittent trouble, 1. Confirm DTC freeze frame data, and match the freeze frame data as test conditions with the data list displayed by Miscellaneous Test. 2. Confirm DTC setting conditions, and match the setting conditions as test conditions with the data list displayed by Miscellaneous Test. 3. Refer to the latest Service Bulletin. Check to see if the Latest software is released or not. Down load the LATEST PROGRAMMED SOFTWARE to the replacement PCM.
060RY00080
5. Select F0:Malfunction Indicator Lamp.
Lamps Test
This test is conducted check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. Tech2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.
060RY00091
6. PushOn soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly.
060R100078
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17. Select F3:Reduced Power Lamp
9. Select F2: Up Shift Lamp
060RY00076
060RY00077
10. Push On soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2:Low Fuel Lamp
18. Push On soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5:Cruise Control Lamp
060RY00092
060RY00078
14. Push On soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly.
22. Push On soft key. 23. Make sure Lamp illuminates. 24. If Lamp illuminates, the Lamp is operating correctly.
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Relays Test
This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is On. 3. Select F3: Miscellaneous Test in the Application Menu.
5. Select F0:Fuel Pump Relay.
060RX021
6. Push On soft key.
060R100078
4. Select F1:Relay Test in the Miscellaneous Test.
060RY00093
7. Control Fuel Pump Relay and check data list. 8. If the data list changes, the Fuel Pump Relay is normal. 9. Select F1:A/C Clutch Relay. 10. Run the Engine at idle.
060RY00081
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4. Select F2: EVAP Test in the Miscellaneous Test.
11. Turn on Air Conditioning.
060RY00094
060RY00082
12. Turn On and Off A/C Switch. 13. Contol A/C Clutch Relay and check data list. 14. If the data list changes, the Fuel Pump Relay is normal.
5. Select F0: Purge Solenoid.
EVAP Test
This test is conducted to check EVAP system for its power operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.
060RX025
060R100078

6. Push Decrease or Increase soft key. 11. Push On or Off soft key.
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060RY00095
060RY00096
7. Control EVAP Purge Solenoid and check a data list. 8. If the data list changes, the Purge Solenoid is normal. 9. Turn engine off, turn ignition SW On. 10. Select F1:EVAP Vent Solenoid.
12. Control EVAP Vent Solenoid and check data list. 13. If the data list changes, the EVAP Vent Solenoid is normal.
Fuel System Test

This test is conducted check Fuel system for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is On. 3. Select F3: Miscellaneous Test in the Application Menu.
060RX025
060R100078
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6. Push Disable or Enable soft key.
4. Select F3: Fuel System in the Miscellaneous Menu.
060RY00083
060RY00097
5. Select F0: Fuel Trim Enable.
7. Control Fuel Trim and check data list. 8. If data list changes, the Fuel Trim is normal. 9. Select F1: Fuel Trim Reset.
060R200071
060R200071

10. Push Reset soft key.
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13. Push Open Loop or Closed Loop soft key.
060RY00098
060RY00099
11. Select F2: O2-Loop status.
14. Control O2-Loop and check data list. 15. If data list changes, the O2-Loop is normal.
Instruments Test
This test is conducted check Instruments for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is On. 3. Select F3: Miscellaneous Test in the Application Menu.
060R200071
12. This test is check the Closed Loop Status performance.
060R100078
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6. Push Decrease or Increase soft key.
4. Select F4: Instruments in the Miscellaneous Menu.
060RY00106
060RY00100
5. Select F0: Fuel Gauge level.
7. Control Fuel Level and check data list. 8. If data list and Fuel gauge meter changes, Fuel Gauge level is normal. 9. Select F1: Tachometer Control Test.
060RY00107
060RY00107

10. Push Inactive or active soft key.
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4. Select F5: EGR Control Test in the Miscellaneous Test.
060RY00101
11. Control tachometer and data list. 12. If data list and meter changes, the tachometer control is normal.
060RY00084
5. Control EGR Valve and check data list.
EGR Control Test

This test is conducted check EGR valve for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.
060RY00103
6. If data list changes, the EGR Control is normal.
Variable Intake Manifold Solenoid Test

This test is conducted check VIM Solenoid for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC.
060R100078
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4. Select F6: Variable Intake Manifold Solenoid Test.
2. Ignition SW is On.
060RY00104
060RY00085
3. Select F3: Miscellaneous Test in the Application Menu.
5. Push On or Off soft key.
060RX028 060R100078
6. Control VIM Solenoid check data list. 7. If data list changes, the VIM Solenoid is normal.
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Injector Balance Test

This test is conducted to make sure the appropriate electric signals are being sent to injectors Nos. 16. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.
5. Select injector number and push injector off soft key.
060RY00105
6. Make sure of engine speed change. 7. If engine speed changes, the injector electric circuit is normal. If engine speed does not change, the injector electric circuit or the injector itself is not normal.
Plotting Snapshot Graph

060R100078
4. Select F7: Injector Balance Test in the Miscellaneous Test.
This test selects several necessary items from the data list to plot graphs and makes data comparison on a long term basis. It is an effective test particularly in emission related evaluations.
060RY00086 060RX037
For trouble diagnosis, you can collect graphic data (snap shot) directly from the vehicle. You can replay the snapshot data as needed. Therefore, accurate diagnosis is possible, even though the vehicle is not available.
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Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
060R200070
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Flow Chart for Snapshot Replay (Plotting Graph)
060R200072
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Primary System-Based Diagnostic

Primary System-Based Diagnostic
There are primary system-based diagnostics which evaluate system operation and its effect on vehicle emissions. The primary system-based diagnostics are listed below with a brief description of the diagnostic function: Oxygen Sensor Diagnosis The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are diagnosed for the following conditions: D Heater performance (time to activity on cold start) D Slow response D Response time (time to switch R/L or L/R) D Inactive signal (output steady at bias voltage approx. 450 mV) D Signal fixed high D Signal fixed low The catalyst monitor heated oxygen sensors (Bank 1 HO2S 2 and Bank 2 HO2S 2) are diagnosed for the following conditions: D Heater performance (time to activity on cold start). D Signal fixed low during steady state conditions or power enrichment (hard acceleration when a rich mixture should be indicated). D Signal fixed high during steady state conditions or deceleration mode (deceleration when a lean mixture should be indicated). D Inactive sensor (output steady at approx. 438 mV). If the oxygen sensor pigtail wiring, connector or terminal are damaged, the entire oxygen sensor assembly must be replaced. DO NOT attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have clean reference air provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair the wires, connector or terminals could result in the obstruction of the reference air and degrade oxygen sensor performance. Refer to On-Vehicle Service, Heated Oxygen Sensors in this section.
HO2S Heater
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control to begin operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors (Bank 1 HO2S 1 and Bank2 HO2S 1) to become active. Oxygen sensor heaters are required by catalyst monitor and sensor (Bank 1 HO2S 2 and Bank 2 HO2S 2) to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further away from the engine.
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation
TS24067
Fuel Control Heated Oxygen Sensor

The main function of the fuel control heated oxygen sensors is to provide the control module with exhaust stream oxygen content information to allow proper fueling and maintain emissions within mandated levels. After it reaches operating temperature, the sensor will generate a voltage, inversely proportional to the amount of oxygen present in the exhaust gases. The control module uses the signal voltage from the fuel control heated oxygen sensors while in closed loop to adjust fuel injector pulse width. While in closed loop, the PCM can adjust fuel delivery to maintain an air/fuel ratio which allows the best combination of emission control and driveability. The fuel control heated oxygen sensors are also used to determine catalyst efficiency.
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The PCM has the ability to monitor this process using the pre-catalyst and post-catalyst heated oxygen sensors. The pre-catalyst sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The post-catalyst sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-catalyst signal will be far more active than that produced by the post-catalyst sensor. In addition to catalyst monitoring, the heated oxygen sensors have a limited role in controlling fuel delivery. If the sensor signal indicates a high or low oxygen content for an extended period of time while in closed loop, the PCM will adjust the fuel delivery slightly to compensate.

D For the 3.5L w/automatic transmission, the pre-catalyst sensors are designated Bank 1 HO2S 1 and Bank 2 HO2S 1. The post-catalyst sensors are Bank 1 HO2S 2 and Bank 2 HO2S 2. Catalyst Monitor Outputs The catalyst monitor diagnostic is sensitive to the following conditions: D Exhaust leaks D HO2S contamination D Alternate fuels Exhaust system leaks may cause the following: D Preventing a degraded catalyst from failing the diagnostic. D Causing a false failure for a normally functioning catalyst. D Preventing the diagnostic from running. Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants will prevent the TWC diagnostic from functioning properly. Three-Way Catalyst Oxygen Storage Capacity The Three-Way catalyst (TWC) must be monitored for efficiency. To accomplish this, the control module monitors the pre-catalyst HO2S and post-catalyst HO2S oxygen sensors. When the TWC is operating properly, the post-catalyst oxygen sensor will have significantly less activity than the pre-catalyst oxygen sensor. The TWC stores and releases oxygen as needed during its normal reduction and oxidation process. The control module will calculate the oxygen storage capacity using the difference between the pre-catalyst and post catalyst oxygen sensors voltage levels. If the activity of the post-catalyst oxygen sensor approaches that of the pre-catalyst oxygen sensor, the catalysts efficiency is degraded. Stepped or staged testing level allow the control module to statistically filter test information. This prevents falsely passing or falsely failing the oxygen storage capacity test. The calculations performed by the on-board diagnostic system are very complex. For this reason, post catalyst oxygen sensor activity should not be used to determine oxygen storage capacity unless directed by the service manual. Two stages are used to monitor catalyst efficiency. Failure of the first stage will indicate that the catalyst requires further testing to determine catalyst efficiency. The seconds stage then looks at the inputs for the pre and post catalyst HO2S sensors more closely before determining if the catalyst is indeed degraded. This further statistical processing is done to increase the accuracy of oxygen storage capacity type monitoring. Failing the first (stage 1) test DOES NOT indicate a failed catalyst. The catalyst may be marginal or the fuel sulfur content could be very high.
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Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of cerium as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC.
Misfire Monitor Diagnostic Operation

Misfire Monitor Diagnostic Operation
Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. The misfire ratio is calculated once every 100 engine cycles. For example, on a 6-cylinder engine, 600 ignition plug sparks occur every 100 cycles and if a misfire occurs 12 times during that time, the misfire is 12/600 100 = 2 %.
Misfire Counters
Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. These misfire counters are basically a file on each engine cylinder. A current and a history misfire counter are maintained for each cylinder. The misfire current counters (Misfire Cur #1-6) indicate the number of firing events out of the last 100 cylinder firing events which were misfires. The misfire current counter will display real time data without a misfire DTC stored. The misfire history counters (Misfire Hist #1-6) indicate the total number of cylinder firing events which were misfires. The misfire history counters will display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC P0300 is set, the misfire history counters will be updated every 100 cylinder firing events. A misfire counter is maintained for each cylinder. If the misfire diagnostic reports a failure, the diagnostic executive reviews all of the misfire counters before reporting DTC. This way, the diagnostic executive reports the most current information. When crankshaft rotation is erratic, a misfire condition will be detected. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. Misfires are counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the Misfire Counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic misfire rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300 Misfire Detected. Use diagnostic equipment to monitor misfire counter data on OBD II-compliant vehicles. Knowing which specific cylinder(s) misfired can lead to the root cause, even when dealing with a multiple cylinder misfire. Using the information in the misfire counters, identify which cylinders are misfiring. If the counter indicate cylinders
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numbers 1 and 4 misfired, look for a circuit or component common to both cylinders number 1 and 4. Misfire counter information is located in the Eng. menu, Misfire Data sub-menu of the data list. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: D Contaminated fuel D Low fuel D Fuel-fouled spark plugs D Basic engine fault
Fuel Trim System Monitor Diagnostic Operation

Fuel Trim System Monitor Diagnostic Operation
This system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the averages of short-term fuel trim values and long-term fuel trim values to rich and lean thresholds. If either value is within the thresholds, a pass is recorded. If both values are outside their thresholds, a rich or lean DTC will be recorded. The fuel trim system diagnostic also conducts an intrusive test. This test determines if a rich condition is being caused by excessive fuel vapor from the EVAP canister. In order to meet OBD II requirements, the control module uses weighted fuel trim cells to determine the need to set a fuel trim DTC. A fuel trim DTC can only be set if fuel trim counts in the weighted fuel trim cells exceed specifications. This means that the vehicle could have a fuel trim problem which is causing a problem under certain conditions (i.e., engine idle high due to a small vacuum leak or rough idle due to a large vacuum leak) while it operates fine at other times. No fuel trim DTC would set (although an engine idle speed DTC or HO2S DTC may set). Use the Tech 2 to observe fuel trim counts while the problem is occurring. A fuel trim DTC may be triggered by a number of vehicle faults. Make use of all information available (other DTCs stored, rich or lean condition, etc.) when diagnosing a fuel trim fault.
Fuel Trim Cell Diagnostic Weights

No fuel trim DTC will set regardless of the fuel trim counts in cell 0 unless the fuel trim counts in the weighted cells are also outside specifications. This means that the vehicle could have a fuel trim problem which is causing a problem under certain conditions (i.e. engine idle high due to a small vacuum leak or rough due to a large vacuum leak) while it operates fine at other times. No fuel trim DTC would set (although an engine idle speed DTC or HO2S DTC may set). Use the Tech 2 to observe fuel trim counts while the problem is occurring.
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On-Board Diagnostic (OBD II) System Check
D06RY00053
Circuit Description
The on-board diagnostic system check is the starting point for any driveability complaint diagnosis. Before using this procedure, perform a careful visual/physical check of the PCM and engine grounds for cleanliness and tightness. The on-board diagnostic system check is an organized approach to identifying a problem created by an electronic engine control system malfunction.
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbedthrough wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 1.The MIL (Check Engine lamp) should be ON steady with the ignition ON and the engine OFF. If not, the No MIL chart should be used to isolate the malfunction. 2.The RPL (Reduced Power lamp) should be ON steady with the ignition ON and the engine OFF. If not, the No RPLchart should be used to isolate the malfunction.
3.Checks the Class 2 data circuit and ensures that the PCM is able to transmit serial data. 4.This test ensures that the PCM is capable of controlling the MIL (Check Engine lamp) and the MIL (Check Engine lamp) driver circuit is not shorted to ground. 5.This test ensures that the PCM is capable of controlling the RPL (Reduced Power lamp) and the RPL (Reduced Power lamp) driver circuit is not shorted to ground. 7.Check the DTCs (System ,Volts Supply circuit). 8.Check the DTCs (PCM{Software} detect Errors). 11.If the engine will not start, the Cranks But Will Not Run chart should be used to diagnose the condition. 14.A Tech 2 parameter which is not within the typical range may help to isolate the area which is causing the problem. 15.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors of this section. 10. If the starter motor will not start, the starter control system chart should be used to diagnose the condition.
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On-Board Diagnostic (OBD II) System Check

1. Ignition ON, engine OFF. 2. Observe the malfunction indicator lamp (MIL or Check Engine lamp). Is the MIL (Check Engine lamp)ON? Go to Step 2 1. Ignition ON, engine OFF. 2. Observe the Reduced Power lamp. Is the RPL (Reduced Power lamp) ON? Go to Step 3
Go to No MIL(Check Engine lamp) Go to No RPL(Reduce d Power lamp)
1. 2. 3. 4.
Ignition OFF. Install Tech 2. Ignition ON. Attempt to display PCM engine data with the Tech 2. Go to Step 4 Go to Step 12
Does the Tech 2 display PCM data? 4 1. Using the Tech 2 output tests function, select MIL (Check Engine lamp) control and command the MIL (Check Engine Lamp) OFF. 2. Observe the MIL (Check Engine lamp). Did the MIL (Check Engine lamp) turn OFF? 5 1. Using the Tech 2 output tests function, select MIL (Check Engine lamp) control and command the RPL (Reduced Power lamp) OFF. 2. Observe the RPL (Reduced Power lamp). Did the MIL (Reduced Power lamp) turn OFF? 6 7 Select Display DTCs with the Tech 2. Are any DTCs stored? Stored DTCs. P0562, P0563, P0601, P0602, P0604, P0606, P1625, P1635, P1639, P1640, P1650 Are the applicable DTCs stored? 8 Stored DTCs. P1514, P1515, P1516, P1523, P1125, P1290, P1295, P1299 Are the applicable DTCs stored? 9 Stored DTCs. 1. P0425, P0106, P0107, P1107, P0401, P1404, P0405, P1120, P1221, P1515, P1516, P1275, P1635, P1271, P1273, P1285, P1272 2. P0336, P0337, P1220, P1515, P1221, P1516, P1280, P1639, P1271, P1272 Are the applicable DTCs stored? 10 Attempt to crank the starter motor Did the starter motor crank? 11 Attempt to start the engine. Did the engine start and continue to run?
Go to Step 5
Go to MIL(Check Engine lamp) On Steady Go to RPL(Reduce d Power lamp) On Steady Go to Step 11
Go to applicable DTC table
Go to Step 8
Go to applicable DTC table
Go to Step 9
Go to Multiple PCM Information sensor DTCs Set
Go to Step 10 Go to Starter control system Go to Cranks But Will Not Run
Go to Step 10
Go to Step 6
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On-Board Diagnostic (OBD II) System Check (Cont'd)

12
Compare PCM data values displayed on the Tech 2 to the typical engine scan data values. Are the displayed values normal or close to the typical values? Go to Symptom
Refer to indicated Component System Checks
13
1. Ignition OFF, disconnect the PCM. 2. Ignition ON, engine OFF. 3. Check the Class 2 data circuit for an open, short to ground, or short to voltage. Also, check the DLC ignition feed circuit for an open or short to ground and the DLC ground circuit for an open. 4. If a problem is found, repair as necessary. Was a problem found? Go to Step 2 Go to Step 14 1. Attempt to reprogram the PCM. Refer to Powertrain Control Module (PCM) in On-Vehicle Service. 2. Attempt to display PCM data with the Tech 2. Does the Tech 2 display PCM engine data? Go to Step 2 Go to Step 15 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Go to Step 2
14
15
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A/C Clutch Control Circuit Diagnosis
D06RY00159
Circuit Description
When air conditioning and blower fan are selected, and if the system has a sufficient refrigerant charge, a 12-volt signal is supplied to the A/C request input of the powertrain control module (PCM). The A/C request signal may be temporarily canceled during system operation by the electronic thermostat in the evaporator case. When the A/C request signal is received by the PCM, the PCM supplies a ground from the compressor clutch relay if the engine operating conditions are within acceptable ranges. With the A/C compressor relay energized, voltage is supplied to the compressor clutch coil. The PCM will enable the compressor clutch to engage whenever A/C has been selected with the engine running, unless any of the following conditions are present: D The throttle is greater than 90%. D The ignition voltage is below 10.5 volts. D The engine speed is greater than 4500 RPM for 5 seconds or 5400 RPM.
D The engine coolant temperature (ECT) is greater than 125 C (257 F). D The intake air temperature (IAT) is less than 5C (41F). D The power steering pressure switch signals a high pressure condition.
Diagnostic Aids
To diagnose an the intermittent fault, check for following conditions: D Poor connection at the PCMInspect connections for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harnessInspect the wiring harness for damage. If the harness appears to OK, observe the A/C clutch while moving connectors and wiring harnesses related to the A/C. A sudden clutch malfunction will indicate the source of the intermittent fault.
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A/C Clutch Diagnosis

This chart should be used for diagnosing the electrical portion of the A/C compressor clutch circuit. A Tech 2 will be used in diagnosing the system. The Tech 2 has the ability to read the A/C request input to the PCM. The Tech 2 can display when the PCM has commanded the A/C clutch ON. The Tech 2 should have the ability to override the A/C request signal and energize the A/C compressor relay.
Test Description
IMPORTANT: Do not engage the A/C compressor clutch with the engine running if an A/C mode is not selected at the A/C control switch. The numbers below refer to the step numbers on the Diagnostic Chart:
3. This a test determine is the problem is with the refrigerant system. If the switch is open, A/C pressure gauges will be used to determine if the pressure switch is faulty or if the system is partially discharged or empty. 4. Although the normal complaint will be the A/C clutch failing to engage, it is possible for a short circuit to cause the clutch to run when A/C has not been selected. This step is a test for that condition. 7. There is an extremely low probability that both relays will fail at the same time, so the substitution process is one way to check the A/C Thermostat relay. Use a known good relay to do a substitution check.
A/C Clutch Control Circuit Diagnosis

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the other DTC chart(s) first Go to Air Conditioning to diagnose the cause of the open pressure switch Are any other DTCs stored?
Go to OBD System Check
Go to Step 3
1. Disconnect the electrical connector at the pressure switch located on the receiver/drier. 2. Use an ohmmeter to check continuity across the pressure switch. Is the pressure switch open?
Go to Step 4
IMPORTANT: Before continuing with the diagnosis, the following conditions must be met: D The intake air temperature must be greater than 15C. (60F). D The engine coolant temperature must be less than 119C (246F). 1. A/C OFF. 2. Start the engine and idle for 1 minute. 3. Observe the A/C compressor. Is the A/C compressor clutch engaged even though A/C has not been requested? Go to Step 37 Check the Procedure Refer to Diagnostic Aids Go to Step 5
1. 2. 3. 4. 1. 2. 3. 4.
Idle the engine. A/C ON. Blower ON. Observe the A/C compressor. Engine idling. A/C ON. Blower ON. Observe the A/C Request display on the Tech 2. (Refer to the Miscellaneous test)
Is the A/C compressor magnetic clutch engaged? 6
Go to Step 6
Does the tool A/C Request display indicate Yes?
Go to Step 26
Go to Step 7
6E68
A/C Clutch Control Circuit Diagnosis (Cont'd)

Temporarily substitute the A/C compressor relay in place of the A/C thermostat relay, then repeat Step 5. Did the A/C Request display indicate Yes? Go to Step 8 Verify repair Go to Step 10 Verify repair Go to Step 9 Go to Step 11 Replace the original A/C thermostat relay. Is the action complete? Does the blower operate? Repair the blower. Is the action complete? Check for a faulty 10A A/C fuse in the underdash fuse panel. Was the 10A fuse OK? Go to Step 13 Go to Step 12 Check for short circuit and make repairs if necessary. Replace the 10A A/C fuse. Is the action complete? Verify repair 1. Remove the glove box to gain access to the A/C thermostat. 2. Disconnect the thermostat connector. 3. Attach a fused jumper between ground and the thermostat wire. 4. A/C ON. 5. Blower ON. Dose A/C request indicate YES on the Tech 2? Go to Step 14 Go to Step 17 1. Ignition ON. 2. Use a DVM to check voltage at the electronic A/C thermostat. Was voltage equal to the specified value? B+ Go to Step 17 Go to Step 15 Check for open wire between the thermostat and the A/C switch. Was the wire open? Go to Step 16 Go to Step 17 Repair the open wire between the thermostat and the A/C switch. Is the action complete? Verify repair Check for an open circuit between A/C thermostat relay and PCM A/C request terminal (F45). Was there an open circuit? Go to Step 18 Go to Step 19 Repair the open circuit between the PCM and A/C thermostat relay. Is the action complete? Verify repair 1. Ignition ON. 2. Use a DVM to check voltage at the A/C pressure switch. Was voltage equal to the specified value? B+ Go to Step 21 Go to Step 20 Repair the open circuit between the 10A A/C fuse and the pressure switch. Is the action complete? Verify repair
8 9 10 11
12
13
14
15
16
17
18
19
20
6E69

21
Use an ohmmeter to check continuity between the pressure switch and the A/C thermostat relay. Was the circuit open? Go to Step 22 Go to Step 23 Repair the open circuit between the pressure switch and the A/C thermostat relay. Is the action complete? Verify repair Go to Step 24 Verify repair Go to Step 25 Check for damaged pin or terminal at F45 of the PCM. Was a damaged pin or terminal found? Repair the damaged pin or terminal. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
22
23 24 25
26
1. Remove the A/C compressor relay. 2. Ignition ON. 3. Use a DVM to check voltage at both of the wires at the A/C compressor relay socket. Is the voltage equal to the specified value? B+ Go to Step 28 Go to Step 27 Repair the faulty wire between the A/C fuse and the A/C compressor relay . Is the action complete? Verify repair 1. 2. 3. 4. 5. A/C compressor relay removed. Engine idling. A/C ON. Blower ON. Use a DVM to measure voltage between the wire at the A/C compressor relay socket and battery. B+ Go to Step 32 Go to Step 29
27
28
Did the DVM indicate the specified value? 29 Check for an open wire between PCM terminal F4 and the A/C compressor relay. Was the wire open? 30 Repair the open wire between the PCM and the A/C compressor relay. Is the action complete? 31 Check for a damaged pin or terminal at F4 of the PCM. Was a damaged pin or a terminal found?
Go to Step 30
Go to Step 31
Verify repair Go to Step 24
Go to Step 25
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32
1. A/C compressor relay removed. 2. Connect a fused jumper at the A/C compressor relay socket with either wire. 3. Engine idling. 4. A/C ON. 5. Blower ON. Did the compressor magnetic clutch engage? Go to Step 33 Verify repair Go to Step 34 Repair the A/C compressor relay. Is the action complete? Check for an open circuit between the A/C compressor relay and the A/C clutch. Was an open circuit found? Go to Step 35 Go to Step 36 Repair the open circuit between the compressor Clutch and the A/C compressor relay. Is the action complete? Verify repair Service the compressor clutch or replace the compressor due to a faulty internal overheat switch. Is the action complete? Verify repair 1. Remove the A/C compressor relay. 2. Idle the engine. Is the compressor clutch still engaged when A/C is not selected? Go to Step 38 Go to Step 39
33 34
35
36
37
38
Repair the short to voltage between the A/C clutch and A/C compressor relay. Is the action complete? Verify repair 1. Reinstall the A/C compressor relay. 2. Remove the A/C thermostat relay. 3. Engine idling. Is the compressor clutch still engaged when A/C is not selected? Go to Step 40 Go to Step 42
39
40
Use a DVM to check for a short to ground between the A/C compressor relay and F4 of the PCM. Was a short detected? Go to Step 41 Go to Step 25 Repair the short to ground between the PCM and A/C compressor relay. Is the action complete? Verify repair Repair the short to ground between the A/C thermostat relay and the electronic thermostat. Is the action complete? Verify repair
41
42
6E71
Electronic Ignition System Diagnosis

If the engine cranks but will not run or immediately stalls, the Engine Cranks But Will Not Start chart must be used to determine if the failure is in the ignition system or the fuel system. If DTC P0300 through P0306, P0341, or P0336 is set, the appropriate diagnostic trouble code chart must be used for diagnosis. If a misfire is being experienced with no DTC set, refer to the Symptoms section for diagnosis.
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure
EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve

A continuous purge condition with no purge commanded by the PCM will set a DTC P1441. Refer to the DTC charts for further information.
Visual Check of The Evaporative Emission Canister

D If the canister is cracked or damaged, replace the canister. D If fuel is leaking from the canister, replace the canister and check hoses and hose routing.
T32003
Fuel Metering System Check

Some failures of the fuel metering system will result in an Engine Cranks But Will Not Run symptom. If this condition exists, refer to the Cranks But Will Not Run chart. This chart will determine if the problem is caused by the ignition system, the PCM, or the fuel pump electrical circuit. Refer to Fuel System Electrical Test for the fuel system wiring schematic. If there is a fuel delivery problem, refer to Fuel System Diagnosis, which diagnoses the fuel injectors, the fuel pressure regulator, and the fuel pump. If a malfunction occurs in the fuel metering system, it usually results in either a rich HO2S signal or a lean HO2S signal. This condition is indicated by the HO2S voltage, which causes the PCM to change the fuel calculation (fuel injector pulse width) based on the HO2S reading. Changes made to the fuel calculation will be indicated by a change in the long term fuel trim values which can be monitored with a Tech 2. Ideal long term fuel trim values are around 0%; for a lean HO2S signal, the PCM will add fuel, resulting in a fuel trim value above 0%. Some variations in fuel trim values are normal because all engines are not exactly the same. If the evaporative emission canister purge is ON, the fuel trim may be as low as 38%. If the fuel trim values are greater than +23%, refer to DTC P0131, DTC P0151, DTC P0171, and DTC 1171 for items which can cause a lean HO2S signal.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Relieve the fuel pressure by connecting the J 34730-1 Fuel Pressure Gauge to the fuel pressure connection on the fuel rail. CAUTION: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Place the fuel pressure gauge bleed hose in an approved gasoline container. With the ignition switch OFF, open the valve on the fuel pressure gauge. 3. Record the lowest voltage displayed by the DVM after the first second of the test. (During the first second, voltage displayed by the DVM may be inaccurate due to the initial current surge.) Injector Specifications: Resistance (Ohms) 11.8 12.6 Voltage Specification at 10C-35C (50F-95F) 5.7 6.6
Fuel System Pressure Test

A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis.
D The voltage displayed by the DVM should be within the specified range. D The voltage displayed by the DVM may increase throughout the test as the fuel injector windings warm and the resistance of the fuel injector windings changes.
6E72

7. The Fuel Injector Balance Test portion of this chart (Step 7 through Step 11) checks the mechanical (fuel delivery) portion of the fuel injector. An engine cool-down period of 10 minutes is necessary in order to avoid irregular fuel pressure readings due to Hot Soak fuel boiling.
D An erratic voltage reading (large fluctuations in voltage that do not stabilize) indicates an intermittent connection within the fuel injector. 5. Injector Specifications: Highest Acceptable Voltage Reading Above/Below 35C/10C (95F/50F) 9.5 Volts Acceptable Subtracted Value
0.6 Volts
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
R262001
CYLINDER 1st Reading (1) 2nd Reading (2) Amount of Drop (1st Reading2nd Reading) Av.drop = 166 kPa/24 psi 10 kPa/1.5 psi = 156 176 kPa or 22.5 25.5 psi
1 296 kPa (43 psi) 131 kPa (19 psi) 165 kPa (24 psi) OK
2 296 kPa (43 psi) 117 kPa (17 psi) 179 kPa (26 psi) Faulty, Rich (Too Much Fuel Drop)
4 296 kPa (43 psi) 145 kPa (21 psi) 151 kPa (22 psi) Faulty, Lean (Too Little Fuel Drop)
NOTE: These figures are examples only.
6E73
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Turn the engine OFF. NOTE: In order to prevent flooding of a single cylinder and possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure. 2. Relieve the fuel pressure. Refer to Test Description Number 2. 3. Connect the J 39021-5V Fuel Injector Tester to B+ and ground, and to the J 39021-90 Injector Switch Box. 4. Connect the injector switch box to the grey fuel injector harness connector located on the front of the EVAP canister bracket. 5. Set the amperage supply selector switch on the fuel injector tester to the Coil Test 0.5 amp position. 6. Connect the leads from the J 39200 Digital Voltmeter (DVM) to the injector tester. Refer to the illustrations associated with the test description. 7. Set the DVM to the tenths scale (0.0). 8. Observe the engine coolant temperature. Is the engine coolant temperature within the specified values?
10C (50F) to 35C (95F)
Go to Step 3
Go to Step 5
1. Set injector switch box injector #1. 2. Press the Push to Start Test button on the fuel injector tester. 3. Observe the voltage reading on the DVM. IMPORTANT: The voltage reading may rise during the test. 4. Record the lowest voltage observed after the first second of the test. 5. Set the injector switch box to the next injector and repeat steps 2, 3, and 4. Did any fuel injector have an erratic voltage reading (large fluctuations in voltage that did not stabilize) or a voltage reading outside of the specified values?
5.7-6.6 V
Go to Step 4
Go to Step 7
Replace the faulty fuel injector(s). Refer to Fuel Injector. Is the action complete? Go to Step 7
6E74
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd)
1. Set injector switch box injector #1. 2. Press the Push to Start Test button on the fuel injector tester. 3. Observe the voltage reading on the DVM. IMPORTANT: The voltage reading may rise during the test. 4. Record the lowest voltage observed after the first second of the test. 5. Set the injector switch box to the next injector and repeat steps 2, 3, and 4. Did any fuel injector have an erratic voltage reading (large fluctuations in voltage that did not stabilize) or a voltage reading above the specified value?
9.5 V
Go to Step 4
Go to Step 6
1. Identify the highest voltage reading recorded (other than those above 9.5 V). 2. Subtract the voltage reading of each injector from the highest voltage selected in step 1. Repeat until you have a subtracted value for each injector. For any injector, is the subtracted Value in step 2 greater than the specified value? 0.6 V Go to Step 4 Go to Step 7
CAUTION: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Connect the J 34730-1 Fuel Pressure Gauge to the fuel pressure test port. 2. Energize the fuel pump using the Tech 2. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Bleed the air out of the fuel pressure gauge. 5. With the fuel pump running, observe the reading on the fuel pressure gauge. Is the fuel pressure within the specified values?
296-376 kPa (43-55 psi)
Go to Step 8
Go to Fuel System Diagnosis Go to Fuel System Diagnosis
Turn the fuel pump OFF. Does the fuel pressure remain constant? Go to Step 9
6E75
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd)
1. Connect the J 39021-5V Fuel Injector Tester and J 39021-90 Injector Switch Box the fuel injector harness connector. 2. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.52.5 amp position. 3. Using the Tech 2 turn the fuel pump ON then OFF in order to pressurize the fuel system. 4. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure stabilizes. This is the first pressure reading. 5. Energize the fuel injector by depressing the Push to Start Test button on the fuel injector tester. 6. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure gauge needle has stopped moving. This is the second pressure reading. 7. Repeat steps 1 through 6 for each fuel injector. 8. Subtract the second pressure reading from the first pressure reading for one fuel injector. The result is the pressure drop value. 9. Obtain a pressure drop value for each fuel injector. 10.Add all of the individual pressure drop values. This is the total pressure drop. 11. Divide the total pressure drop by the number of fuel injectors. This is the average pressure drop. Does any fuel injector have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value? 10 kPa (1.5 psi) Go to OBD System Check
Go to Step 10
10
Re-test any fuel injector that does not meet the specification. Refer to the procedure in step 9. NOTE: Do not repeat any portion of this test before running the engine in order to prevent the engine from flooding. Does any fuel injector still have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value?
10 kPa (1.5 psi)
Go to Step 11
Go to Symptoms
11
Replace the faulty fuel injector(s). Injector. Is the action complete?
Refer to Fuel Verify repair
6E76

The PCM provides the following sensors with a 5volt reference and a sensor ground signal: 1 D The exhaust gas recirculating (EGR) pintle position sensor D The manifold absolute pressure (MAP) sensor D The throttle position (TP) sensor 1 D The acceleration position (AP) sensor 1 D The acceleration position (AP) sensor 3 D The Vapor Pressure Sensor 2 D The Crank position (CKP) sensor D The throttle position (TP) sensor 2 D The acceleration position (AP) sensor 2 The PCM monitors the separate feedback signals from these sensors in order to determine their operating status.
Powertrain Control Module (PCM) Diagnosis

To read and clear diagnostic trouble codes, use a Tech 2. IMPORTANT: Use of a Tech 2 is recommended to clear diagnostic trouble codes from the PCM memory. Diagnostic trouble codes can also be cleared by turning the ignition OFF and disconnecting the battery power from the PCM for 30 seconds. Turning off the ignition and disconnecting the battery power from the PCM will cause all diagnostic information in the PCM memory to be cleared. Therefore, all the diagnostic tests will have to be re-run. Since the PCM can have a failure which may affect only one circuit, following the diagnostic procedures in this section will determine which circuit has a problem and where it is. If a diagnostic chart indicates that the PCM connections or the PCM is the cause of a problem, and the PCM is replaced, but this does not correct the problem, one of the following may be the reason: D There is a problem with the PCM terminal connections. The terminals may have to be removed from the connector in order to check them properly. D EEPROM program is not correct for the application. Incorrect components or reprogramming the PCM with the wrong EEPROM program may cause a malfunction and may or may not set a DTC. D The problem is intermittent. This means that the problem is not present at the time the system is being checked. In this case, refer to the Symptoms portion of the manual and make a careful physical inspection of all component and wiring associated with the affected system. D There is a shorted solenoid, relay coil, or harness. Solenoids and relays are turned ON and OFF by the PCM using internal electronic switches called drivers. A shorted solenoid, relay coil, or harness will not damage the PCM but will cause the solenoid or relay to be inoperative.
Diagnostic Aids
IMPORTANT: Be sure to inspect PCM and engine grounds for being secure and clean. A short to voltage in one of the sensor input circuits may cause one or more of the following DTCs to be set: D P0425 D P0108, P1106 D P0406 D P1120, P1515, P1221, P1516, P1635 D P1275, P1639, P1271, P1273 D P1285, P1272, P1273 D P0336, P0337 D P1220, P1515, P1221, P1515, P1516 D P1280, P1271, P1272 IMPORTANT: If a sensor input circuit has been shorted to voltage, ensure that the sensor is not damaged. A damaged sensor will continue to indicate a high or low voltage after the affected circuit has been repaired. If the sensor has been damaged, replace it. An open in the sensor ground circuit between the PCM and the splice will cause one or more of the following DTCs to be set: D P0425 D P0108, P1106 D P0406 D P1120, P1515, P1221, P1516, P1635 D P1275, P1639, P1271, P1273 D P1285, P1272, P1273 D P0336, P0337 D P1220, P1515, P1221, P1515, P1516 D P1280, P1271, P1272 A short to ground in the 5volt reference A or B circuit will cause one or more of the following DTCs to be set: D P0453 D P0106, P0107, P1107 D P0401, P1404, P0405 D P1120, P1515, P1221, P1516, P1635
Multiple PCM Information Sensor DTCs Set

Circuit Description
The powertrain control module (PCM) monitors various sensors to determine the engine operating conditions. The PCM controls fuel delivery, spark advance, transmission operation, and emission control device operation based on the sensor inputs. The PCM provides a sensor ground to all of the sensors. The PCM applies 5 volts through a pullup resistor, and determines the status of the following sensors by monitoring the voltage present between the 5volt supply and the resistor: D The engine coolant temperature (ECT) sensor D The intake air temperature (IAT) sensor D The transmission fluid temperature (TFT) sensor

D P1275, P1639, P1271, P1273 D P1285, P1272, P1273 D P0336, P0337 D P1220, P1515, P1221, P1515, P1516 D P1280, P1271, P1272 Check for the following conditions: D Poor connection at PCM. Inspect the harness connectors for backedout terminals, improper mating, broken locks, improperly formed or damage terminals, and a poor terminaltowire connection.
6E77
D Damaged harness. Inspect the wiring harness for damage. If the harness is not damaged, observe an affected sensor fs displayed value on the Tech 2 with the ignition ON and the engine OFF while you move the connectors and the wiring harnesses related to the following sensors: D Vapor Pressure (Fuel Tank Pressure) Sensor D MAP Sensor D EGR D TPS1/TPS2 D APS1/APS2/APS3 D CKP
Multiple PCM Information Sensor DTCs Set

Was the On-Board (OBD) System Check performed? Go to Step 2
1. Turn the ignition OFF, disconnect the PCM. 2. Turn the ignition ON, check the 5 volt reference 1 and 2 circuit for the following conditions: D A poor connection at the PCM. D An open between the PCM connector and the splice. D A short to ground. D A short to voltage. Is there an open or short? Go to Step 3 Verify repair Go to Step 4 Repair the open or short. Is the action complete? Check the sensor ground circuit for the following conditions: D A poor connection at the PCM or the affected sensors. D An open between the PCM connector and the affected sensors. Is there an open or a poor connection? Go to Step 5 Verify repair Go to applicable DTC table Go to Step 6 Repair the open or the poor connection. Is the action complete? Following below the DTCs stored: P1635, P1639 Measure the resistance below the items: D Between EGR sensor supply circuit and Vapor Pressure Sensor supply circuit. D Between MAP sensor supply circuit and Vapor Pressure Sensor supply circuit. D Between Vapor Pressure Sensor supply circuit and PCM harness connector. (5Volt supply circuit) Is the resistance near the specified value? Go to Step 9 Go to Step 8
3 4
5 6
Go to Step 7
6E78
Multiple PCM Information Sensor DTCs Set (Cont'd)

Locate and repair the open circuit in the MAP or EGR or Vapor Pressure sensor supply circuit. Is the action complete? Verify repair 1. Disconnect the MAP, Vapor pressure sensor and EGR connector. 2. Ignition ON. 3. Measure the resistance of the blow areas: D MAP sensor GND circuit. D EGR GND circuit. D Vapor pressure sensor GND circuit. Does the voltage resistance near the specified value? Go to Step 11 Go to Step 10 Locate and repair the short circuit in the MAP or EGR or Vapor Pressure sensor signal or GND circuit. Is the action complete? Verify repair 1. Disconnect the CKP sensor connector. 2. Ignition ON. 3. Measure the voltage of the blow areas: D CKP sensor GND circuit and shield circuit. Does the voltage resistance near the specified value? Go to Step 13 Go to Step 12 Locate and repair the short circuit in the CKP sensor signal or GND circuit. Is the action complete? Verify repair Go to applicable DTC table Are more of the following items for DTCs stored? EGR, Vapor Pressure Sensor, MAP, CKP, TPS, APS Replace the PCM. The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
10
11
12
13
Go to Step 14
14
6E79
Exhaust Gas Recirculation (EGR) Diagnosis

An EGR flow check diagnosis of the linear EGR system is covered by DTC P0401. Pintle position error diagnosis is covered by DTC P0402, P0404, P1404, P0405, P0406. If EGR diagnostic trouble codes P0401 and/or P0402, P0404, P1404, P0405, P0406 are encountered, refer to the DTC charts.
Engine Tech 2 Data Definitions and Ranges

A/C CLUTCH Tech 2 Displays ON or OFF Indicates whether the PCM has commanded the A/C clutch ON. Used in A/C system diagnostic. A/C REQUEST Tech 2 Displays YES or NO Indicates the state of the A/C request input circuit from the HVAC controls. The PCM uses the A/C request signal to determine whether A/C compressor operation is being requested. AIR/FUEL RATIO Tech 2 Range 0.0-25.5 Air/fuel ratio indicates the PCM commanded value. In closed loop, the air/fuel ratio should normally be displayed around 14.6-14.7. A lower air/fuel ratio indicates a richer commanded mixture, which may be seen during power enrichment or TWC protection modes. A higher air/fuel ratio indicates a leaner commanded mixture. This can be seen during deceleration fuel mode. AP1 Tech 2 Range 0%-100% AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display 11-15% at idle and 85-89% at wide open throttle. AP2 Tech 2 Range 0%-100% AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display 85-89% at idle and 11-15% at wide open throttle. AP3 Tech 2 Range 0%-100% AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display 85-89% at idle and 32-36% at wide open throttle. BAROMETRIC PRESSURE Tech 2 Range 10-105 kPa/0.00-5.00 Volts The barometric pressure reading is determined from the MAP sensor signal monitored during key up and wide open throttle (WOT) conditions. The barometric pressure is used to compensate for altitude differences and is normally displayed around 61-104 depending on altitude and barometric pressure. CHECK TRANS LAMP AUTO TRANSMISSION Indicates the need to check for a DTC with the Tech 2 when the lamp is flashing 0.2 seconds ON and 0.2 seconds OFF. DESIRED EGR POS. Tech 2 Range 0%-100% Represents the EGR pintle position that the PCM is commanding. DESIRED IDLE Tech 2 Range 0-3187 RPM The idle speed that the PCM is commanding. The PCM will compensate for various engine loads based on engine coolant temperature, to keep the engine at the desired speed.
ECT (Engine Coolant Temperature) Tech 2 Range 40C to 151C (40F to 304F) The engine coolant temperature (ECT) is mounted in the coolant stream and sends engine temperature information to the PCM. The PCM applies 5 volts to the ECT sensor circuit. The sensor is a thermistor which changes internal resistance as temperature changes. When the sensor is cold (high resistance), the PCM monitors a high signal voltage and interprets that as a cold engine. As the sensor warms (decreasing resistance), the voltage signal will decrease and the PCM will interpret the lower voltage as a warm engine. EGR DUTY CYCLE Tech 2 Range 0%-100% Represents the EGR valve driver PWM signal from the PCM. A duty cycle of 0% indicates that no EGR flow is being commanded; a 100% duty cycle indicates maximum EGR flow commanded. EGR FEEDBACK Tech 2 Range 0.00-5.00 Volts Indicates the EGR pintle position sensor signal voltage being monitored by the PCM. A low voltage indicates a fully extended pintle (closed valve); a voltage near 5 volts indicates a retracted pintle (open valve). ENGINE LOAD Tech 2 Range 0%-100% Engine load is calculated by the PCM from engine speed and MAF sensor readings. Engine load should increase with an increase in RPM or air flow. ENGINE RUN TIME Tech 2 Range 00:00:00-99:99:99 Hrs:Min:Sec Indicates the time elapsed since the engine was started. If the engine is stopped, engine run time will be reset to 00:00:00. ENGINE SPEED Range 0-9999 RPM Engine speed is computed by the PCM from the 58X reference input. It should remain close to desired idle under various engine loads with engine idling. EVAP PURGE PWM Tech 2 Range 0%-100% Represents the PCM commanded PWM duty cycle of the EVAP purge solenoid valve. 0% displayed indicates no purge; 100% displayed indicates full purge. FUEL PUMP Tech 2 Displays ON or OFF Indicates the PCM commanded state of the fuel pump relay driver circuit. HO2S BANK 1, SEN. 1 Tech 2 Range 0-1132 mV Represents the fuel control exhaust oxygen sensor output voltage. Should fluctuate constantly within a range between 10 mV (lean exhaust) and 1000 mV (rich exhaust) while operating in closed loop. HO2S BANK 1, SEN. 2 Tech 2 Range 0-1000mV Monitors the exhaust oxygen sensor output voltage. The PCM monitors the operating efficiency of catalytic converter by comparing the output voltages of sensor 1 and sensor 2 in this bank. If the catalytic converter is operating efficiently, the output voltage of sensor 1 will give a greater fluctuation than that of sensor 2. If the PCM detects an abnormal level of voltage fluctuation from sensor 2, a DTC P0420 will be set, indicating that the catalytic converter for this bank is no longer operating efficiently.
6E80

INJ. PULSE BANK 1/INJ. PULSE BANK 2 Tech 2 Range 0-1000 msec. Indicates the amount of time the PCM is commanding each injector ON during each engine cycle. A longer injector pulse width will cause more fuel to be delivered. Injector pulse width should increase with increased engine load. LONG TERM FUEL TRIM BANK 1/BANK 2 The long term fuel trim is derived from the short term fuel trim values and represents a long term correction of fuel delivery for the bank in question. A value of 0% indicates that fuel delivery requires no compensation to maintain the PCM commanded air/fuel ratio. A negative value significantly below 0% indicates that the fuel system is rich and fuel delivery is being reduced (decreased injector pulse width). A positive value significantly greater than 0% indicates that a lean condition exists and the PCM is compensating by adding fuel (increased injector pulse width). Because long term fuel trim tends to follow short term fuel trim, a value in the negative range due to canister purge at idle should not be considered unusual. Fuel trim values at maximum authority may indicate an excessively rich or lean system. Fuel System STATUS Tech 2 Displays OPEN or CLOSED CLOSED indicates that the PCM is controlling fuel delivery according to oxygen sensor voltage. In OPEN the PCM ignores the oxygen sensor voltage and bases the amount of fuel to be delivered on TP sensor, engine coolant, and MAF sensor inputs only. MAF Tech 2 Range 0.0-512 gm/s MAF (mass air flow) is the MAF input frequency converted to grams of air per second. This indicates the amount of air entering the engine. MAP Tech 2 Range 10-105 kPa (0.00-4.97 Volts) The manifold absolute pressure (MAP) sensor measures the change in the intake manifold pressure from engine load, EGR flow, and speed changes. As intake manifold pressure increases, intake vacuum decreases, resulting in a higher MAP sensor voltage and kPa reading. The MAP sensor signal is used to monitor intake manifold pressure changes during the EGR flow test, to update the BARO reading, and as an enabling factor for several of the diagnostics. MIL Tech 2 Displays ON or OFF Indicates the PCM commanded state of the malfunction indicator lamp. MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 Tech 2 Range 0-255 Counts The misfire current counters increase at a rate according to the number of the possible misfires being detected on each cylinder. The counters may normally display some activity, but the activity should be nearly equal for all the cylinders.
HO2S BANK2, SEN. 1 Tech 2 Range 0-1132 mV Represents the fuel control exhaust oxygen sensor output voltage. Should fluctuate constantly within a range between 10mV (lean exhaust) and 1000 mV (rich exhaust) while operating in closed loop. HO2S BANK 2, SEN. 2Tech 2 Range 0-1000 mV Monitors the exhaust oxygen sensor output voltage. The PCM monitors the operating efficiency of catalytic converter by comparing the output voltages of sensor 1 and sensor 2 in this bank. If the catalytic converter is operating efficiently, the output voltage of sensor 1 will have a greater fluctuation than that of sensor 2. If the PCM detects an abnormal level of voltage fluctuation from sensor 2, a DTC P0430 will be set, indicating that the catalytic converter for this bank is no longer operating efficiently. HO2S BANK 1, SEN. 1Tech 2 Displays NOT READY or READY Indicates the status of the exhaust oxygen sensor. The Tech 2 will indicate that the exhaust oxygen sensor is ready when the PCM detects a fluctuating HO2S voltage sufficient to allow closed loop operation. This will not occur unless the exhaust oxygen sensor is warmed up. HO2S BANK 2, SEN. 1 Tech 2 Displays NOT READY or READY Indicates the status of the exhaust oxygen sensor. The Tech 2 will indicate that the exhaust oxygen sensor is ready when the PCM detects a fluctuating HO2S voltage sufficient to allow closed loop operation. This will not occur unless the exhaust oxygen sensor is warmed up. HO2S WARM UP TIME BANK 1, SEN. 1/BANK 1, SEN 2/BANK 2 SEN. 1/BANK 2 SEN. 2 Tech 2 Range 00:00:00-99:99:99 HRS:MIN:SEC Indicates warm-up time for each HO2S. The HO2S warm-up time is used for the HO2S heater test. The PCM will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that tool much time was required for the HO2S to become active, a DTC will set. If the engine was warm when started, HO2S warm-up will the display 00:00:00. IAT (INTAKE AIR TEMPERATURE) Tech 2 Range 40C to 151C (40F to 304F) The PCM converts the resistance of the intake air temperature sensor to degrees. Intake air temperature (IAT) is used by the PCM to adjust fuel delivery and spark timing according to incoming air density. IGNITION 1 Tech 2 Range 0-25.5 Volts This represents the system voltage measured by the PCM at its ignition feed.

MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 Tech 2 Range 0-65535 Counts The misfire history counters display the relative level of misfire that has been detected on each cylinder. The misfire history counters will not update or show any activity until a misfire DTC (P0300) has become active. MISFIRE FAILURES SINCE FIRST FAIL Tech 2 Range 0-65535 Counts Indicates the number of 200 crankshaft revolution sample periods during which the level of misfire was sufficiently high to report a fail. MISFIRE PASSES SINCE FIRST FAIL Tech 2 Range 0-65535 Counts Indicates the number of 200 crankshaft revolution sample periods during which the level of misfire was sufficiently low to report a pass. POWER ENRICHMENT Tech 2 Displays ACTIVE or INACTIVE ACTIVE displayed indicates that the PCM has detected conditions appropriate to operate in power enrichment mode. The PCM will command power enrichment mode when a large increase in throttle position and load is detected. While in power enrichment mode, the PCM will increase the amount of fuel delivered by entering open loop and increasing the injector pulse width. This is done to prevent a possible sag or hesitation from occurring during acceleration. SPARK Tech 2 Range 64 to 64 Displays the amount of spark advance being commanded by the PCM on the IC circuit. START-UP ECT Tech 2 Range 40C to 151C (40F to 304F) Indicates the engine coolant temperature at the time that the vehicle was started. Used by the HO2S diagnostic to determine if the last start-up was a cold start. START-UP IAT Tech 2 Range 40C to 151C (40F to 304F) Indicates the intake air temperature at the time that the vehicle was started. Used by the HO2S diagnostic to determine if the last start-up was a cold start. TOTAL MISFIRE CURRENT COUNT Tech 2 Range 0-255 Indicates the total number of cylinder firing events that were detected as being misfires during the last 200 crankshaft revolution sample period. TP1 Tech 2 Range 0%-100% TP (throttle position) angle is computed by the PCM from the TP sensor voltage. TP angle should display 6-12% at idle and 79-83% at wide open throttle. TP2 Tech 2 Range 0%-100% TP (throttle position) angle is computed by the PCM from the TP sensor voltage. TP angle should display 88-94% at idle and 19-23% at wide open throttle. CATALYST PROTECTION MODE Tech 2 Displays YES or NO YES displayed indicates that the PCM has detected conditions appropriate to operate in TWC protection mode. The PCM will decrease the air/fuel ratio to a value that depends on mass air flow (higher mass air flow = lower air/fuel ratio).
6E81
UPSHIFT LAMP (MANUAL TRANSMISSION) VEHICLE SPEED Tech 2 Range 0-255 km/h (0-155 mph) The vehicle speed sensor signal is converted into km/h and mph for display. WEAK CYLINDER Tech 2 Displays Cylinder Number This indicates that the PCM has detected crankshaft speed variations that indicate 2% or more cylinder firing events are misfires.
Typical Scan Data Values

Use the Typical Scan Data Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a properly-running engine may be used for comparison with the engine you are diagnosing. The typical scan data values represent values that would be seen on a normally-running engine. NOTE: A Tech 2 that displays faulty data should not be used, and the problem should be reported to the Tech 2 manufacturer. Use of a faulty Tech 2 can result in misdiagnosis and unnecessary replacement of parts. Only the parameters listed below are referred to in this service manual for use in diagnosis. For further information on using the Tech 2 to diagnose the PCM and related sensors, refer to the applicable reference section listed below. If all values are within the typical range described below, refer to the Symptoms section for diagnosis.
Test Conditions
Engine running, lower radiator hose hot, transmission in park or neutral, closed loop, accessories off, brake not applied and air conditioning off.
6E82
3.5L V-6 Engine (Automatic and Manual Transmission) Tech 2 Parameter A/C Clutch Relay A/C Request Data List Units Displayed Typical Data Values (IDLE) Off Typical Data Values (2500 RPM) Off Refer To
Engine
On/Off
General Description and Operation, A/C Clutch Circuit Operation General Description and Operation, A/C Request Signal General Description and Operation, Fuel System Metering Purpose General Description and Operation General Description and Operation General Description and Operation General Description and Operation
Engine
Yes/No
No
No
Air/Fuel Ratio
Engine
Ratio: _ to 1
14.614.7
14.614.7
APP Sensor1 APP Sensor2 APP Sensor3 Barometric Pressure
Engine Engine Engine Engine
Percent Percent Percent kPa
1115 8589 8589 61-104 (depends on altitude and barometric pressure) Open 0V Off
1624 7482 7684 61-104 (depends on altitude and barometric pressure) Open 0V Off
Brake Light Switch Check Trans Lamp (Auto Trans) Cruise Main Switch Cruise Set Switch Cruise Cancel Switch Cruise Resume Switch Decel Fuel Cutoff Desired EGR Position Desired Idle Speed ECT (Engine Coolant Temp)
Engine Engine
Open 0V/Closed 12V On/Off
Refer to Section 5 4L30-E Automatic Transmission Diagnosis Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 10
Engine Engine Engine Engine
Active/Inactive Active/Inactive Active/Inactive Active/Inactive
Inactive Inactive Inactive Inactive
Inactive Inactive Inactive Inactive
Engine
Active/Inactive
Inactive
Inactive
General Description and Operation, Deceleration Mode General Description and Operation, EGR Pintle Position Sensor General Description and Operation General Description and Operation, Engine Coolant Temperature (ECT) Sensor General Description and Operation, EGR Pintle Position Sensor
Engine
Percent
0%
0%
Engine Engine
RPM Degrees C, Degrees F
700 80-100C (176-212F)
800 80-100C (176-212F)
EGR Closed Pintle Position
Engine
Steps
20-40
20-40

Tech 2 Parameter EGR Duty Cycle Data List Units Displayed Typical Data Values (IDLE) 0% Typical Data Values (2500 RPM) 0% Refer To
6E83
Engine
Percent
General Description and Operation, Linear EGR Operation and Results of Incorrect Operation General Description and Operation, Mass Air Flow (MAF) Sensor
EGR Feedback EGR Normalized Engine Load
Engine Engine Engine
Volts Percent Percent
0.45-0.80 0% 2.0% - 5.5%
0.45-0.80 0% 8.0% - 16.0%
Time From Start Engine Speed
Engine
Sec
Varies. Resets at each engine start. Within 50 to +100 of Desired Idle 0%
Varies. Resets at each engine start. Actual engine speed 0%
Engine
RPM
Diagnosis, EVAP Emission Canister Purge Valve Check Diagnosis, EVAP Canister Purge Solenoid and EVAP Vacuum Switch and Visual Check; DTCs: P1441, P1442 General Description
EVAP Purge Solenoid EVAP Vent Valve
Engine
Percent
Engine
On/Off
Off
Off
Fuel System Status Fuel Level Fuel Level Sensor Fuel Tank (Vapor) Pressure Sensor Fuel Pump HO2S Bank 1 Sen.1 (millivolts) HO2S Bank 1 Sen.2 (millivolts) (Auto Trans) HO2S Bank 1 Sen.2 (millivolts) (Manual Trans) HO2S Bank 1 Sen.3 (millivolts) (Manual Trans)
Engine
Open Loop/Closed Loop Percent Volts Volts in. H2O
Closed Loop
Closed Loop
Engine Engine Engine
1.02 1.86 On 50-950 changing quickly 200-700 changing slowly On
1.02 2.57
Engine Fuel Engine Fuel General Description and Operation
Engine O2 Sensor Data O2 Sensor Data O2 Sensor Data
On/Off Millivolts
Engine Fuel General Description and Operation, Fuel control HO2S General Description and Operation, Fuel Metering System General Description and Operation, Fuel Metering System
50-950, always changing quickly 250-650 changing slowly
Millivolts
Millivolts
50-950 changing quickly
50-950 changing quickly
O2 Sensor Data
Millivolts
200-700 changing slowly
250-650 changing slowly
General Description and Operation, Catalyst Monitor Heated Oxygen Sensor (Manual Trans)
6E84

Data List Units Displayed Typical Data Values (IDLE) 50-950 changing quickly 200-700 changing slowly Typical Data Values (2500 RPM) 50-950 changing quickly 250-650 changing slowly Refer To
Tech 2 Parameter HO2S Bank 2 Sen.1 (millivolts) HO2S Bank 2 Sen.2 (millivolts) (Auto trans) HO2S Bank 1 Sen.1 (ready/not ready) HO2S Bank 2 Sen.1 (ready/not ready) HO2S Warm-Up Time Bank 1 Sen.1 HO2S Warm-Up Time Bank 1 Sen.2 HO2S Warm-Up Time Bank 2 Sen.1 HO2S Warm-Up Time Bank 2 Sen.2 IAT (Intake Air Temp)
O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data Engine
Millivolts
General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Metering System General Description and Operation, Fuel Control HO2S; DTC: P0135 General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Control HO2S General Description and Operation, Catalyst Monitor Heated Oxygen Sensor (Auto Trans) General Description and Operation, Intake Air Temperature (IAT) Sensor Refer to Section 8 General Description and Operation, Electronic Ignition System General Description, Fuel Metering, Fuel Injector General Description, Fuel Metering, Fuel Injector General Description and ION Sensing Module General Description and ION Sensing Module General Description and ION Sensing Module General Description Diagnosis, Fuel Trim System Monitor; DTCs: P0171, P0172
Millivolts
Ready Yes/No
Ready Yes
Ready Yes
Ready Yes/No
Ready Yes
Ready Yes
Seconds
25-45
25-45
Seconds
60-100
60-100
Seconds
25-45
25-45
Seconds
60-100
60-100
Degrees C, Degrees F
0-100C, depends on underhood temperature Closed 0V 12.8-14.1
0-80C, depends on underhood temperature Closed 0V 12.8-14.1
Illumination Switch Ignition Voltage Inj. Pulse Bank 1 Inj. Pulse Bank 2 Knock Present Knock Signal Knock Sensor Retard Knock Counter Long Term FT Bank 1 (Long Term Fuel Trim)
Engine Engine
Closed 0V/Open 12V Volts
Engine Engine Engine Engine Engine Engine Misfire
Milliseconds Milliseconds No/Yes Percent CA Counts Counts and Percentage
2.0-4.0 2.0-4.0 No 14 0 100 to 150 counts, 22% to +17%
2.5-4.0 2.5-4.0 No 14 0 100 to 150 counts, 22% to +17%

Tech 2 Parameter Long Term FT Bank 2 (Long Term Fuel Trim) MAF (Mass Air Flow) MAP kPa (Manifold Absolute Pressure) MIL Misfire Cur. Cyl #1 Misfire Cur. Cyl #2 Misfire Cur. Cyl #3 Misfire Cur. Cyl #4 Misfire Cur. Cyl #5 Misfire Cur. Cyl #6 Misfire Hist. Cyl #1 Misfire Hist. Cyl #2 Misfire Hist. Cyl #3 Misfire Hist. Cyl #4 Misfire Hist. Cyl #5 Misfire Hist. Cyl #6 Misfire Failures Since First Fail Misfire Passes Since First Fail PNP (Park/Neutral Position) Power Enrichment PSP Switch (Power Steering Pressure) Data List Units Displayed Typical Data Values (IDLE) 100 to 150 counts, 22% to +17% 3.0-7.0 Typical Data Values (2500 RPM) 100 to 150 counts, 22% to +17% 12-20 Refer To
6E85
Misfire
Counts and Percentage
Diagnosis, Fuel Trim System Monitor; DTCs: P0171 General Description and Operation, MAF; DTCs: P101, P0102, P0103 General Description and Operation, Manifold Absolute Pressure (MAP) Sensor; DTCs: P0106, P0107, P0108 On-Board Diagnostic System Check DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 4L30-E Automatic Transmission Diagnosis General Description and Operation, Acceleration Mode Refer to 2A Section
Engine
Grams per second Kilopascals Volts
Engine
25-35 0.8-1.3 Off 0-2 0-2 0-2 0-2 0-2 0-2 0 0 0 0 0 0 0 0 P-N
20-30 0.5-1.0 Off 0-2 0-2 0-2 0-2 0-2 0-2 0 0 0 0 0 0 0 0 P-N
Engine Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Engine
On/Off Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts P-N / R-D-3-2-L NO/YES
Engine
NO
NO
Engine
Normal/Hi
Normal Pressure
Normal Pressure
6E86

Data List Units Displayed Typical Data Values (IDLE) 15-22 Typical Data Values (2500 RPM) 34-44 Refer To
Tech 2 Parameter Spark (Advance) Start-Up ECT (Engine Coolant Temp) Start-Up IAT (Intake Air Temp) TCC Cruise Brake Switch Total Misfire Current Count TP Sensor 1 (Throttle Position Sensor 1) TP Sensor 2 (Throttle Position Sensor 2) Throttle at Idle
Engine
Degrees Before Top Dead Center Degrees C, Degrees F
General Description and Operation, Electronic Ignition System General Description and Operation, Engine Coolant Temperature (ECT) Sensor General Description and Operation, Intake Air Temperature (IAT) Sensor Refer to Section 10 DTC P0300 General Description and Operation, Throttle Position (TP) Sensor General Description and Operation, Throttle Position (TP) Sensor General Description and Operation, Throttle Position (TP) Sensor Manual Transmission 4L30-E Automatic Transmission Diagnosis DTC P0300
Engine
Depends on engine coolant temperature at time of start-up Depends on intake air temperature at time of start-up Active 0-5 612
Depends on engine coolant temperature at time of start-up Depends on intake air temperature at time of start-up Active 0-5 1216
Engine
Degrees C, Degrees F
Engine Misfire Engine
Active/Inactive Counts Percentage
Engine
Percentage
8894
8690
Engine
No/Yes
Yes
No
Upshift Lamp (manual trans) Vehicle Speed Weak Cylinder
Engine Engine Misfire
On/Off MPH / km/h Cylinder #
Off 0
Off 0
6E87
No Malfunction Indicator Lamp (MIL)
D06R200083
Circuit Description
The Check Engine lamp (MIL) should always be illuminated and steady with the ignition ON and the engine stopped. Ignition feed voltage is supplied to the MIL bulb through the meter fuse. The powertrain control module (PCM) turns the MIL ON by grounding the MIL driver circuit.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. A No MIL condition accompanied by a no-start condition suggests a faulty PCM ignition feed or battery feed circuit. 9. Using a test light connected to B+, probe each of the PCM ground terminals to ensure that a good ground is present. Refer to PCM Terminal End View for terminal locations of the PCM ground circuits. 12.In this step, temporarily substitute a known good relay for the PCM relay. The horn relay is nearby, and it can be verified as good simply by honking the horn. Replace the horn relay after completing this step. 17.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures Powertrain Control Module (PCM) and Sensors.
Diagnostic Aids
An intermittent MIL may be cased by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Inspect the PCM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D If the engine runs OK, check for a faulty light bulb, an open in the MIL driver circuit, or an open in the instrument cluster ignition feed. D If the engine cranks but will not run, check for an open PCM ignition or battery feed, or a poor PCM to engine ground.
6E88
No Malfunction Indicator Lamp (MIL)

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to Step 3 Attempt to start the engine. Does the engine start?
Go to OBD System Check Go to Step 6
2 3
Check the meter fuse for the instrument cluster ignition feed circuit. Is the fuse OK? Go to Step 4 Go to Step 16 Ignition ON, probe the ignition feed circuit at the cluster connector with a test light to ground. Is the test light ON? Go to Step 5 Go to Step 13 1. Ignition OFF. 2. Disconnect the PCM. 3. Jumper the MIL driver circuit at the PCM connector to ground. 4. Ignition ON. Is the MIL ON? Go to Step 10 Go to Step 11 Check the PCM ignition feed and battery feed fuses (15 A engine fuse and 15 A PCM fuse). Are both fuses OK? Go to Step 7 Go to Step 15 1. 2. 3. 4. Ignition OFF. Disconnect the PCM. Ignition ON. Probe the ignition feed circuit at the PCM harness connector with a test light to ground. Go to Step 8 Go to Step 12
Is the test light ON? 8 Probe the battery feed circuit at the PCM harness connector with a test light to ground. Is the test light ON? 9 10 11 Check for a faulty PCM ground connection. Was a problem found? Check for damaged terminals at the PCM. Was a problem found? Check for an open MIL driver circuit between the PCM and the MIL. Was a problem found? 12 Substitute a known good relay for the PCM main relay. Was the malfunction fixed? 13 14 Repair the open in the ignition feed circuit. Is the action complete? Locate and repair the open PCM battery feed circuit. Is the action complete?
Go to Step 14 Go to Step 10 Go to Step 17
Verify repair
Go to Step 18
Verify repair Verify repair Verify repair
Go to Step 13
6E89
No Malfunction Indicator Lamp (MIL) (Cont'd)

15
Locate and repair the short to ground in the PCM ignition feed circuit or PCM battery feed circuit. Is the action complete? Verify repair Locate and repair the short to ground in the ignition feed circuit to the instrument cluster, and replace the fuse. Is the action complete? Verify repair Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to PCM in ON-Vehicle Service for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Go to Instrument Panel in Electrical Diagnosis
16
17
18
Check the MIL driver circuit for a poor connection at the instrument panel connector. Was a problem found? Verify repair
6E90
Malfunction Indicator Lamp (MIL) ON Steady
D06R200083
Circuit description
The malfunction indicator lamp (MIL) should always be illuminated and steady with ignition ON and the engine stopped. Ignition feed voltage is supplied directly to the MIL indicator. The powertrain control module (PCM) turns the MIL ON by grounding the MIL driver circuit. The MIL should not remain ON with the engine running and no DTC(s) set. A steady MIL with the engine running and no DTC(s) suggests a short to ground in the MIL driver circuit.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the MIL does not remain ON when the PCM is disconnected, the MIL driver wiring is not faulty. 3. If the MIL driver circuit is OK, the instrument panel cluster is faulty. 6. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Poor connection or damaged harness Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
6E91
Malfunction Indicator Lamp (MIL) ON Steady

Was the On-Board diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition OFF, disconnect PCM. 2. Ignition ON, observe the MIL (Service Engine Soon lamp). Is the MIL ON? Go to Step 3
Go to Step 5
1. Ignition OFF, disconnect the instrument panel cluster. 2. Check the MIL driver circuit between the PCM and the instrument panel cluster for a short to ground. 3. If a problem is found, repair as necessary. Was the MIL driver circuit shorted to ground? Replace the instrument panel cluster. Is the action complete?
Go to OBD System Check Go to OBD System Check
Go to Step 4
1. Ignition OFF, reconnect the PCM. 2. Ignition ON, reprogram the EEPROM. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. 3. Using the Tech 2 output controls function, select MIL dash lamp control and command the MIL OFF. (Refer to the Miscellaneous test) Did the MIL turn OFF? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Go to Step 6
6E92
No Reduced Power Lamp (RPL)
D06R200083
Circuit Description
The Reduced Power Lamp (RPL) should be turned OFF afrer ON for 3 seconds with the ignition ON and the engine stopped. Ignition feed voltage is supplied to the RPL bulb through the meter fuse. The powertrain control module (PCM) turns the RPL ON by grounding the RPL driver circuit.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. A No RPL condition accompanied by a no-start condition suggests a faulty PCM ignition feed or battery feed circuit. 9. Using a test light connected to B+, probe each of the PCM ground terminals to ensure that a good ground is present. Refer to PCM Terminal End View for terminal locations of the PCM ground circuits. 12.In this step, temporarily substitute a known good relay for the PCM relay. The horn relay is nearby, and it can be verified as good simply by honking the horn. Replace the horn relay after completing this step. 17.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures Powertrain Control Module (PCM) and Sensors.
Diagnostic Aids
An intermittent RPL may be cased by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Inspect the PCM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D If the engine runs OK, check for a faulty light bulb, an open in the RPL driver circuit, or an open in the instrument cluster ignition feed. D If the engine cranks but will not run, check for an open PCM ignition or battery feed, or a poor PCM to engine ground.
6E93
No Reduced Power Lamp (RPL)

2 3
Check the meter fuse for the instrument cluster ignition feed circuit. Is the fuse OK? Go to Step 4 Go to Step 16 Ignition ON, probe the ignition feed circuit at the cluster connector with a test light to ground. Is the test light ON? Go to Step 5 Go to Step 13 1. Ignition OFF. 2. Disconnect the PCM. 3. Jumper the RPL driver circuit at the PCM connector to ground. 4. Ignition ON. Is the RPL ON? Go to Step 10 Go to Step 11 Check the PCM ignition feed and battery feed fuses (15 A engine fuse and 15 A PCM fuse). Are both fuses OK? Go to Step 7 Go to Step 15 1. 2. 3. 4. Ignition OFF. Disconnect the PCM. Ignition ON. Probe the ignition feed circuit at the PCM harness connector with a test light to ground. Go to Step 8 Go to Step 12
Is the test light ON? 8 Probe the battery feed circuit at the PCM harness connector with a test light to ground. Is the test light ON? 9 10 11 Check for a faulty PCM ground connection. Was a problem found? Check for damaged terminals at the PCM. Was a problem found? Check for an open RPL driver circuit between the PCM and the RPL. Was a problem found? 12 Substitute a known good relay for the PCM main relay. Was the malfunction fixed? 13 14 Repair the open in the ignition feed circuit. Is the action complete? Locate and repair the open PCM battery feed circuit. Is the action complete?
Verify repair
Go to Step 18
Verify repair Verify repair Verify repair
Go to Step 13
6E94
No Reduced Power Lamp (RPL) (Cont'd)

15
Locate and repair the short to ground in the PCM ignition feed circuit or PCM battery feed circuit. Is the action complete? Verify repair Locate and repair the short to ground in the ignition feed circuit to the instrument cluster, and replace the fuse. Is the action complete? Verify repair Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to PCM in ON-Vehicle Service for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Go to Instrument Panel in Electrical Diagnosis
16
17
18
Check the RPL driver circuit for a poor connection at the instrument panel connector. Was a problem found? Verify repair
6E95
Reduced Power Lamp (RPL) ON Steady
D06R200083
Circuit description
The Reduced Power Lamp (RPL) should be truned OFF after ON for 3 seconds with ignition ON and the engine stopped. Ignition feed voltage is supplied directly to the RPL indicator. The powertrain control module (PCM) turns the RPL ON by grounding the RPL driver circuit. The RPL should not remain ON with the engine running and no DTC(s) set. A steady RPL with the engine running and no DTC(s) suggests a short to ground in the RPL driver circuit.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the RPL does not remain ON when the PCM is disconnected, the RPL driver wiring is not faulty. 3. If the RPL driver circuit is OK, the instrument panel cluster is faulty. 6. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.
Diagnostic Aids
6E96
Reduced Power Lamp (RPL) ON Steady

Was the On-Board diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition OFF, disconnect PCM. 2. Ignition ON, observe the RPL. Is the RPL ON? Go to Step 3
Go to Step 5
1. Ignition OFF, disconnect the instrument panel cluster. 2. Check the RPL driver circuit between the PCM and the instrument panel cluster for a short to ground. 3. If a problem is found, repair as necessary. Was the RPL driver circuit shorted to ground? Replace the instrument panel cluster. Is the action complete?
Go to OBD System Check Go to OBD System Check
Go to Step 4
1. Ignition OFF, reconnect the PCM. 2. Ignition ON, reprogram the EEPROM. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. 3. Using the Tech 2 output controls function, select RPL dash lamp control and command the RPL OFF. (Refer to the Miscellaneous test) Did the RPL turn OFF? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Go to Step 6
6E97
Engine Cranks But Will Not Run
D06R200031
6E98
D06R200032
6E99
Circuit Description
The electronic Ignition system uses a coil -at-plug method of spark distribution. In this type of ignition system, the powertrain control module (PCM) triggers the correct driver outside the Ignition Current Sense System (ICSS), which then triggers the correct ignition coil based on the 58X signal received from the crankshaft position sensor (CKP). The spark plug connected to the coil fires when the ICSS opens the ground circuit for the coils primary circuit. During crank, the PCM monitors the CKP 58X signal. The CKP signal is used to determine which cylinder will fire first. After the CKP 58X signal has been processed by the PCM, it will command all six injectors to allow a priming shot of fuel for all the cylinders. After the priming, the injectors are left OFF during the next six 58X reference pulses from the CKP. This allows each cylinder a chance to use the fuel from the priming shot. During this waiting been received by the PCM. The ION sensor signal allows the PCM to operate the injectors sequentially based on camshaft position. If the camshaft position signal is not present at start - up, the PCM will begin sequential fuel delivery with a 1 -in-6 chance that fuel delivery is correct. The engine will run without a ION sensor signal, but will set a DTC code.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 5. An obvious cause of low fuel pressure would be an empty fuel tank. 6. The engine will easily start and run if a few injectors are disabled. It is not necessary to test all injectors at this time since this step is only a test to verify that all of the injectors have not been disabled by fuel contamination. 7. A blinking test light verifies that the PCM is monitoring the 58X crankshaft reference signal and is capable of activating the injectors. If there is an open or shorted driver circuit, DTCs 201 206 and a misfire DTC 300 306 should be set. 19. By using a spark tester, each ignition coils ability to produce 25,000 volts is verified. 25. If there is an open or shorted driver circuit, DTCs 201 206 and a misfire DTC 301 306 should be set. All six injector driver circuits can be checked at one time without removing the intake manifold if a J 39021 95 test light is available. This is the alternative procedure: D With the ignition OFF, disconnect the gray connector located at the rear of the air filter, attached to a bracket on the purge canister. D Connect test light J 39021 95 to the connector. Do any of the light constantly illuminate or fail to blink when the engine is cranked? If so, repair the short or open circuit, or replace the PCM if indicated. This procedure only tests the driver circuit as far as the test connection, so step 31 is added to test the circuit all the way to the injector.
Diagnostic Aids
An intermittent problem may be caused by a poor connection, rubbed - through wire insulation or a wire broken inside the insulation. Check for the following items: D Poor connection or damaged harness-Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty engine coolant temperature sensor-Using a Tech 2, compare engine coolant temperature with intake air temperature on a completely cool engine. Engine coolant temperature should be within 10 C of intake air temperature. If not, replace the ECT sensor.

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Check the ignition coil fuse, the engine fuse, and the PCM fuse. Was a fuse blown? Go to Step 3 Verify repair
Go to Step 4
Check for a short to ground and replace the fuse. Is the action complete?
6E100
Engine Cranks But Will Not Run (Cont'd)

1. Ignition OFF, install a fuel pressure gauge at the test fitting on the fuel supply line in the engine compartment. (Use a shop cloth to absorb any fuel leakage while making the connection.) 2. Ignition ON, observe the fuel pressure. Is the fuel pressure within the specified values, and 285 - 375 kPa does it hold steady? (43 55 psi) Go to Step 6 Go to Fuel System Electrical Test Go to Step 5 Go to Fuel System Diagnosis
Is any fuel pressure indicated?
Install the switch box J 390212 at the injector test connector and activate an injector. Did the fuel pressure drop when the injector was activated? Go to Step 7 Go to Step 18
Install an injector test light at the #2 cylinder injector harness connector. Does the light blink when the engine is cranked? Go to Step 8 Go to Step 24 1. Ignition OFF. 2. Disconnect the 11-pin connector at the ION sensing module. 3. With a test light to B + , probe each of the 6 exposed ION sensing module pins, one at a time, while the engine is cranked. (Use the gray narrow Metri - Pak flexible female connector from the J - 35616 kit to make the pin accessible.) Does the light flash at each pin when the engine is cranked? Go to Step 12 Go to Step 9
1. Remove the 4-pin connector at the ION sensing module. 2. Ignition ON. 3. Use a test light at the harness connector to verify that the module is being supplied with B + and ground. Was a problem found? Go to Step 10 Go to Step 11 Repair the open ignition feed circuit or ground circuit to the ION sensing module. Is the action complete? Verify repair Verify repair Repair the ION sensing module. Is the action complete? 1. Reconnect the ION sensing module 11-pin connector. 2. Remove the electrical connector from each coil. 3. With a test light to B+, probe each of the coil connectors at the wire which runs to the ION sensing module. Does the light flash at each coil connector when the engine is cranked? Go to Step 14 Go to Step 13
10
11 12
13
Check for an open circuit between the coil and ION sensing module. Is the action complete? Verify repair
6E101

14
1. Ignition ON. 2. While the coil connectors are disconnected, touch each coil connectors ignition feed terminal with a grounded test light (the ignition feed wire is YEL tracer). Did the test light illuminate? Go to Step 16 Verify repair Go to Step 15 Repair the open ignition feed circuit. Is the action complete? While the coil connectors are disconnected, touch each connectors secondary ground terminal with a test light to B +. (The ground wires are black.) Did the test light illuminate at each coil connector? Go to Step 18 Verify repair Go to Step 17 Repair the open secondary ground circuit. Is the action complete? 1. Test the fuel for contamination. 2. If a problem is found, clean the fuel system and correct the contaminated fuel condition as necessary. Replace the fuel filter and replace any injectors that are not delivering fuel (see Injector Balance Test). Was a problem found? Verify repair Go to Step 19 1. Remove any ignition coil and install a spark tester at the spark plug end of the coil. 2. Observe the tester while the engine is cranking. Was a crisp, blue spark observed? Only one or two sparks followed by no result is considered the same as No Spark.
15 16
17 18
19
Go to Step 21
Go to Step 20
20
Replace the ignition coil, and return to Step 19 to test the remaining coils. Is the action complete? Verify repair Repeat Step 19 for each coil. Remove only one coil at a time, and reinstall each coil on its spark plug after testing, but do not refasten coils with screws at this time. After all coils have passed the spark test, does the engine start?
21
Refasten all coils with their screws
Go to Step 22
22
1. Remove the spark plugs from all cylinders. 2. Visually inspect the spark plug electrodes. 3. Replace any spark plugs with loose or missing electrodes or cracked insulators. Did your inspection reveal any spark plugs exhibiting excessive fouling?
Correct the fouling condition
Go to Step 23
6E102

23
Refer to Engine Mechanical Diagnosis to diagnose the following conditions: D Faulty or incorrect camshaft drive belts D Leaking or sticky valves or rings D Excessive valve deposits D Weak valve springs D Incorrect valve timing D Leaking head gasket Is the action complete? Verify repair Go to Step 25 Observe the Engine Speed data display on the Tech 2 while cranking the engine. Is the engine RPM indicated? Go to Step 25 Go to Step 34 1. Disconnect the 7-pin gray connector at the rear of the air filter beneath the point where the air duct attaches to the MAF sensor. 2. Ignition ON. 3. Using a test light connected to ground, probe the ignition terminal at the PCM (female) side of the 7-pin connector. Is the test light ON? Go to Step 26 Go to Step 32 1. At the PCM (female) side of the connector, connect a test light between the ignition + terminal and one of the injector driver circuits at the same connector. 2. Ignition ON. 3. Observe the test light, and repeat the test for each injector driver circuit. Did the test light stay on when checking any of the 6 injector driver circuits? Go to Step 27 Go to Step 29
24
25
26
27
1. Ignition OFF, disconnect the PCM. 2. Ignition ON, observe the test light. Is the test light ON? Go to Step 28 Go to Step 33 Locate and repair the short to ground in the injector driver circuit. Is the action complete? Verify repair 1. Using the same test location as in step 26, connect a test light between the ignition terminal and one of the driver circuits. 2. Crank the engine and observe the test light. 3. Repeat for each injector driver circuit. Did the light blink during the test for each circuit? Go to Step 31 Verify repair Go to Step 30 Go to Step 33 Check for an open injector driver circuit. Was a problem found?
28
29
30
6E103

31
1. At the injector (male) side of the gray connector mentioned in step 25, connect an ohmmeter between the ignition pin and one of the driver circuit pins. 2. Check for continuity in the circuit. 3. Repeat for each injector circuit. The readings should be approximately equal to the specified value for injector resistance. Was a problem found? 12.5 m PCM must be Verify repair Verify repair Go to Step 8 Repair the ignition feed circuit. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement
32 33
Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? 34 1. Raise the vehicle and disconnect the CKP sensor harness. 2. Ignition ON. 3. With a test light to ground, probe the harness ignition feed terminal. Did the light illuminate? 35 Check the ignition feed wire between the sensor and the PCM for a short to ground or open circuit. Is the action complete? 36 1. Ignition ON. 2. At the CKP harness connector, connect a test light between the ignition and ground terminals. Did the light illuminate? 37 Check the sensor ground circuit for an open or short to voltage. Is the action complete? 38 Check the signal circuit between the sensor and the PCM for a short to ground, short to voltage, or an open. Was a problem found? 39 Replace the CKP position sensor. Is the action complete? Verify repair Go to Step 33 Verify repair Go to Step 39 Verify repair Go to Step 38 Go to Step 37 Verify repair Go to Step 36 Go to Step 35 Verify repair
6E104
Fuel System Electrical Test
D06R200031
6E105
Circuit Description
When the ignition switch is first turned ON, the powertrain control module (PCM) energizes the fuel pump relay which applies power to the in-tank fuel pump. The fuel pump relay will remain ON as long as the engine is running or cranking and the PCM is receiving 58X crankshaft position pulses. If no 58X crankshaft position pulses are present, the PCM de-energizes the fuel pump relay within 2 seconds after the ignition is turned ON or the engine is stopped. The fuel pump delivers fuel to the fuel rail and injectors, then to the fuel pressure regulator. The fuel pressure regulator controls fuel pressure by allowing excess fuel to be returned to the fuel tank. With the engine stopped and ignition ON, the fuel pump can be turned ON by using a command by the Tech 2.
Fuel Pressure Relief Procedure

1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay center. 3. Start the engine and allow it to stall. 4. Crank the engine for an additional 3 seconds.
Fuel Gauge Installation

1. Remove the shoulder fitting cap. 2. Install fuel gauge J 34730-1 to the fuel feed line located in front of and above the right side valve train cover . 3. Reinstall the fuel pump relay.
Diagnostic Aids
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the fuel pump is operating but incorrect pressure is noted, the fuel pump wiring is OK and the Fuel System Pressure Test chart should be used for diagnosis. CAUTION: To reduce the risk of fire and personal injury: D It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. D A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the procedure is completed.
6E106
Fuel System Electrical Test

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Read the Caution above. 2. Relieve the fuel system pressure and install the fuel pump pressure gauge to the test fitting. 3. Ignition ON, Engine is Off. 4. Use a Tech 2 to command the fuel pump ON. (Refer to the Miscellaneous Test.) Is there an immediate pressure build-up which indicates the pump is running? Go to Step 3
Go to Step 4
1. Verify that the pump is not running by removing the fuel filler cap and listening. 2. Command the pump ON with the Tech 2. Did the pump turn OFF after 2 seconds? 1. Ignition OFF. 2. Remove the fuel pump relay. 3. Using a test light connected to ground, probe the battery feed to the relay. Did the light illuminate?
Test completed
Go to Step 12
Go to Step 5
5 6
Repair short or open battery feed to fuel pump relay. Is the action complete? 1. Connect a test light between the two wires that connect to the fuel pump relay pull-in coil. 2. Ignition ON. Did the test light illuminate for 2 seconds and then turn off? Go to Step 12 Go to Step 7
1. With a test light connected to battery (), probe the fuel pump relay connector at the wire which runs from the relay pull-in coil to the PCM. 2. Ignition ON. Did the test light illuminate for 2 seconds and then turn off? Go to Step 8 Go to Step 9
Locate and repair open in the fuel pump relay ground circuit. Is the action complete? Verify repair Check for short or open between the PCM and the fuel pump relay. Was a problem found? Verify repair Go to Step 10 1. Check the fuel pump relay circuit for a poor terminal connection at the PCM. 2. If a problem is found, replace terminal as necessary. Was a problem found? Verify repair Go to Step 11
10
6E107
Fuel System Electrical Test (Cont'd)

11
Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
12
1. Reconnect the fuel pump relay. 2. Disconnect the fuel pump electrical connector at the fuel tank. 3. Using a test light connected to ground, probe the fuel pump feed wire (harness side). 4. Command the fuel pump ON with a Tech 2. Did the light illuminate for 2 seconds? Go to Step 15 Go to Step 13 1. Honk the horn to verify that the horn relay is functioning. 2. Substitute the horn relay for the fuel pump relay. 3. Leave the test light connected as in step 12. 4. Command the fuel pump ON with the Tech 2. Did the test light illuminate for 2 seconds when the fuel pump was commanded ON? Go to Step 17 Go to Step 14
13
14
1. Re-connect the horn relay in its proper location. 2. Check for a short circuit, blown fuse or open circuit between the relay and the fuel tank. Is the action complete? Verify repair 1. With the fuel pump electrical connector at the fuel tank disconnected, connect a test light between the feed wire and the ground wire (harness side). 2. Command the fuel pump ON with a Tech 2. Did the test light illuminate for 2 seconds? Go to Step 18 Verify repair Go to Step 16 Repair the open circuit in the fuel pump ground wire. Is the action complete? 1. Re-connect the horn relay in its proper location. 2. Replace the fuel pump relay. Is the action complete? Verify repair Verify repair Replace the fuel pump. Is the action complete?
15
16 17
18
6E108
Electric Throttle Control (ETC) System Check
D06R200033
6E109
Circuit Description
D The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in PWM (%) to adjust the throttle valve into a passage in the throttle body to allow air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle will vary about 13% at idle position to about 87% at wide open throttle(WOT). APS signal is used to determine which DC motor will adjust throttle position. After the APS signal has been processed by the PCM, it will command DC motor to allow movement of throttle position.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Visually/physically inspect for the following throttle valve conditions. 3. Visually/physically inspect for the following acceleration pedal conditions. 5. Check the following circuits for throttle valve and DC moter. Check the following TP sensor resistance and DC motor. 6. Check the following circuits for acceleration pedal. Check the following AP sensor resistance. 7. Following DTC: Error for ETC system.
Diagnostic Aids
D An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Throttle body Check for objects blocking the DC motor or throttle bore, excessive deposits in the ETC passage and on the valve spring, and excessive deposits in the throttle bore and on the throttle valve plate. D Acceleration pedal Check for objects blocking the AP sensor or pedal arm with spring, excessive deposits in the acceleration pedal arm and on the acceleration pedal and lacking the pedal stopper rabber.
6E110
Electric Throttle Control (ETC) System Check

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Visually/physically inspect for the following conditions: D Throttle body tampering. D Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. D Throttle body with lever: When check for objects to send round the throttle spring lever that lever is smooth movement by less than 9 lbm{1.0 Nm}, and spring lever has not excessive play. D Throttle function: Check for the throttle function. When ignition switch ON that throttle lever is smooth operated by step on the acceleration pedal. Did any of the above require a repair? Visually/physically inspect for the following conditions: D Acceleration pedal tampering. D Acceleration pedal : Check for objects blocking the spring or pedal arm. D Acceleration pedal : For check for objects to move the acceleration pedal that pedal is smooth movement, and acceleration pedal arm has not excessive play. Did any of the above require a repair? 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the acceleration position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found? Verify repair
Refer to appropriate section for on-vehicle service
Go to Step 3
Go to Step 4
Go to Step 5
Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Throttle position sensor 1 circuit. D Throttle position sensor 2 circuit. TPS, DC D Throttle DC motor circuit. mortor 17km TPS, DC D Throttle position sensor resistance. mortor D Throttle DC motor resistance. change If a problem is found, repair as necessary. resistance 0.3100m Was a problem found?
Verify repair
Go to Step 6
6E111
Electric Throttle Control (ETC) System Check (Cont'd)

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Acceleration position sensor 1 circuit. D Acceleration position sensor 2 circuit. VccGND D Acceleration position sensor 3 circuit. AP1 2.64km D Acceleration position sensor resistance. AP2 2.64km If a problem is found, repair as necessary. AP3 Was the prblem found? 4.26.4km Following below the DTCs stored: P1120, P1220, P1221, P1271, P1272, P1273, P1275, P1280, P1285, P1514, P1515, P1516, P1523 1. 2. 3. 4. 5. Closed throttle APS1 = 1115% APS2 = 8589% APS3 = 8589% NOTE: The value check of TPS must be performed in TPS1 = less than 15 seconds. 612% TPS2 Was a problem found? = 8894% Wide open throttle APS1 = 8589% APS2 = 1115% APS3 = 3236% TPS1 = 7983% TPS2 = 1923% 1. Replace the faulty sensor. 2. Recheck the value for APS and TPS Refer to the procedure in step 8. Was the problem found? Warming up the engine until the ECT rise at 80C Ignition OFF. Insall the Tech 2. Ignition ON but not engine run. Check the value for APS and TPS.
Verify repair Go to applicable DTC table
Go to Step 7
Go to Step 8
Go to Step 9
System O.K.
Go to Step 10
Verify repair
10
Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to OnVehicle Service in Powertrain Control Module and Sensors for Procedures. And also refer to letest Service Bulletin. Check to see if the Latest software is releasec or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Verify repair
6E112
Fuel System Diagnosis
060R200214
Legend (1) Vent Solenoid (2) EVAP Purge Solenoid (3) Throttle Body (4) Fuel Filler Neck (5) Fuel Tank (6) Rollover Valve (7) EVAP Canister (8) Ignition Feed (9) Ignition Feed
(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)
EVAP Purge Solenoid Drive Signal from PCM Vent Solenoid Driver Signal from PCM Vent Filter Fuel Tank Pressure Sensor Fuel Tank Pressure Signal to PCM 5 volt Reference A Circuit from PCM Sensor Ground Circuit from PCM Fuel Level Sensor Fuel Level Signal to PCM 5 Volt Return
6E113
Circuit Description
When the ignition switch is turned ON, the powertrain control module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving 58X crankshaft position pulses. If there are no 58X crankshaft position pulses, the PCM will turn the in-tank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return line.
16.Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. If checking the spark plug associated with a particular fuel injector for fouling or saturation does not determine that a particular fuel injector is leaking, use the following procedure: D Remove the fuel rail, but leave the fuel lines and injectors connected to the fuel rail. Refer to Fuel Rail Assembly in On-Vehicle Service. D Lift the fuel rail just enough to leave the fuel injector nozzles in the fuel injector ports. CAUTION: In order to reduce the risk of fire and personal injury that may result from fuel spraying on the engine, verify that the fuel rail is positioned over the fuel injector ports and verify that the fuel injector retaining clips are intact. D Pressurize the fuel system by connecting a 10 amp fused jumper between B+ and the fuel pump relay connector. D Visually and physically inspect the fuel injector nozzles for leaks. 17.A rich condition may result from the fuel pressure being above 376 kPa (55 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 20.This test determines if the high fuel pressure is due to a restricted fuel return line or if the high fuel pressure is due to a faulty fuel pressure regulator. 21.A lean condition may result from fuel pressure below 333 kPa (48 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold ), hesitation, poor driveability, lack of power, surging , and misfiring. 22.Restricting the fuel return line causes the fuel pressure to rise above the regulated fuel pressure. Command the fuel pump ON with the Tech 2. The fuel pressure should rise above 376 kPa (55 psi) as the fuel return line becomes partially closed. NOTE: Do not allow the fuel pressure to exceed 414 kPa (60 psi). Fuel pressure in excess of 414 kPa (60 psi) may damage the fuel pressure regulator. CAUTION: To reduce the risk of fire and personal injury: D It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. D A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the procedure is completed.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Connect the fuel pressure gauge to the fuel feed line as shown in the fuel system illustration. Wrap a shop towel around the fuel pressure connection in order to absorb any fuel leakage that may occur when installing the fuel pressure gauge. With the ignition switch ON and the fuel pump running, the fuel pressure indicated by the fuel pressure gauge should be 333-376 kPa (48-55 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that cannot maintain a constant fuel pressure has a leak in one or more of the following areas: D The fuel pump check valve. D The fuel pump flex line. D The valve or valve seat within the fuel pressure regulator. D The fuel injector(s). 4. Fuel pressure that drops off during acceleration, cruise, or hard cornering may case a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a Tech 2. If an extremely lean condition occurs, the oxygen sensor(s) will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. IMPORTANT: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside the fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in step 2 with the engine OFF.
6E114

1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay center. 3. Start the engine and allow it to stall. 4. Crank the engine for an additional 3 seconds.
Fuel Gauge Installation

1. Remove the shoulder fitting cap. 2. Install fuel gauge J 34730-1 to the fuel feed line located in front of and above the right side valve train cover. 3. Reinstall the fuel pump relay.
Fuel System Diagnosis

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Turn the ignition OFF. 2. Turn the air conditioning system OFF. 3. Relieve fuel system pressure and install the fuel pressure gauge. 4. Turn the ignition ON. NOTE: The fuel pump will run for approximately 2 seconds. Use the Tech 2 to command the fuel pump ON. (Refer to the Miscellaneous Test.) 5. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits? 290-376 kPa (42-55 psi)
Go to Step 3
Go to Step 17
NOTE: The fuel pressure will drop when the fuel pump stops running, then it should stabilize and remain constant. Does the fuel pressure indicated by the fuel pressure gauge remain constant? Go to Step 4 Go to Step 12
1. When the vehicle is at normal operation temperature, turn the ignition ON to build fuel pressure and observe the measurement on the gauge. 2. Start the engine and observe the fuel pressure gauge. Did the reading drop by the amount specified after the engine was started? 21-105 kPa (3-15 psi) Go to Step 5 Go to Step 6 Go to Step 9 Check for improper fuel
5 6
Is fuel pressure dropping off during acceleration, cruise, or hard cornering? Visually and physically inspect the following items for a restriction: D The in-pipe fuel filter. D The fuel feed line. Was a restriction found?
Verify repair
Go to Step 7
Remove the fuel tank and visually and physically inspect the following items: D The fuel pump strainer for a restriction. D The fuel line for a leak. D Verify that the correct fuel pump is in the vehicle. Was a problem found in any of these areas? Verify repair Go to Step 8
6E115
Fuel System Diagnosis (Cont'd)

8 9
Replace the fuel pump. Is the action complete? 1. Disconnect the vacuum hose from the fuel pressure regulator. 2. With the engine idling, apply 12-14 inches of vacuum to the fuel pressure regulator. Does the fuel pressure indicated by the fuel pressure gauge drop by the amount specified? 21-105 kPa (3-15 psi) Go to Step 10 Go to Step 11 Verify repair
10
Locate and repair the loss of vacuum to the fuel pressure regulator. Is the action complete? Verify repair Verify repair Replace the fuel pressure regulator. Is the action complete? 1. Run the fuel pump with the Tech 2. 2. After pressure has built up, turn off the pump and clamp the supply hose shut with suitable locking pliers which will not damage the hose. Does the fuel pressure indicated by the fuel pressure gauge remain constant? Go to Step 13 Go to Step 15
11 12
13
Visually inspect the fuel supply line and repair any leaks. Was a problem found? Verify repair Go to Step 14 Remove the fuel tank and inspect for leaky hose or in-tank fuel line. Was a problem found? Verify repair Go to Step 8 1. If the pliers are still clamped to the fuel supply hose, remove the locking pliers. 2. With suitable locking pliers, which will not damage the hose, clamp the fuel return line to prevent fuel from returning to the fuel tank. 3. Run the fuel pump with the Tech 2. 4. After pressure has built up, remove power to the pump. Does the fuel pressure indicated by the fuel pressure gauge remain constant? 376 kPa (55 psi) Go to Step 11 Verify repair Go to Step 18 Go to Step 16 Go to Step 21
14
15
16 17
Locate and replace any leaking fuel injector(s). Is the action complete? Is the fuel pressure indicated by the fuel pressure gauge above the specified limit?
6E116
Fuel System Diagnosis (Cont'd)

18
1. Relieve the fuel pressure. Refer to the Fuel Pressure Relief. 2. Disconnect the fuel return line from the fuel rail. 3. Attach a length of flexible hose to the fuel rail return outlet passage. 4. Place the open end of the flexible hose into an approved gasoline container. 5. Run the fuel pump with the Tech 2. 6. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits? Locate and correct the restriction in the fuel return line. Is the action complete?
290-376 kPa (42-55 psi)
Go to Step 20
19 20
Visually and physically inspect the fuel rail outlet passages for a restriction. Was a restriction found? 0 kPa (0 psi) Verify repair Go to Step 22 Go to Step 11 Go to Step 23 Is the fuel pressure indicated by the fuel pressure gauge above the specified value? 1. Command the fuel pump ON with the Tech 2. 2. Using suitable pliers which will not damage the fuel hose, gradually apply pressure with the pliers to pinch the flexible fuel return hose closed. CAUTION: Do not let the fuel pressure exceed the second specified value. Does the fuel pressure indicated by the fuel pressure gauge rise above the first specified value? 376 kPa (55 psi) 414 kPa (60 psi)
21 22
Go to Step 11
Go to Step 7
23
1. Command the fuel pump ON with the Tech 2. 2. Remove the fuel filler cap and listen for the sound of the fuel pump running. 3. Turn the pump off. Was the fuel pump running? Go to Step 7
Go to Fuel System Electrical Test Chart
6E117
Exhaust Gas Recirculation (EGR) System Check
D06R200087
Circuit Description
A properly operation exhaust gas recirculation (EGR) system will directly affect the air/fuel requirements of the engine. Since the exhaust gas introduced into the air/fuel mixture is an inert gas (contains very little or no oxygen), less fuel is required to maintain a correct air/fuel ratio. Introducing exhaust gas into the combustion chamber lowers combustion temperatures and reduces the formation of oxides of nitrogen (NOx) in the exhaust gas. Lower combustion temperatures also prevent detonation. If the EGR pintle were to stay closed, the inert exhaust gas would be replaced with air and the air/fuel mixture would be leaner. The powertrain control module (PCM) would compensate for the lean condition by adding fuel, resulting in higher long term fuel trim values.
Diagnostic Aids
The EGR valve chart is a check of the EGR system. An EGR pintle constantly in the closed position could cause detonation and high emissions of NOx. It could also result in high long term fuel trim values in the open throttle cell, but not in the closed throttle cell. An EGR pintle constantly in the open position would cause a rough idle. Also, an EGR mounted incorrectly (rotated 180) could cause rough idle. Check for the following items: D EGR passages Check for restricted or blocked EGR passages. D Manifold absolute pressure sensor A manifold absolute pressure sensor may shift in calibration enough to affect fuel delivery. Refer to Manifold Absolute Pressure Output Check.
6E118
Exhaust Gas Recirculation (EGR) System Check

1 2 3
Check the EGR valve for looseness. Is the EGR valve Loose? Tighten the EGR valve. Is the action complete? 1. Place the transmission selector in Park or Neutral. 2. Start the engine and idle until warm. 3. Using a Tech 2, command EGR 50% ON. (Refer to the Miscellaneous Test.) Does the engine idle rough and lose RPMs? 1. Engine OFF. 2. Ignition ON. 3. Using a test light to ground, check the EGR harness between the EGR valve and the ignition feed. Does the test light illuminate? Go to Step 6 Verify repair Go to Step 5 Go to Step 6 Repair the EGR harness ignition feed. Was the problem corrected? 1. Remove the EGR valve. 2. Visually and physically inspect the EGR valve pintle, valve passages and adapter for excessive deposits, obstructions or any restrictions. Does the EGR valve have excessive deposits, obstructions or any restrictions? Go to Step 7 Go to Step 8 Verify repair EGR system working properly. No problem found. Go to Step 2 Go to Step 3
Go to Step 4
5 6
Clean or replace EGR system components as necessary. Was the problem corrected? Verify repair Go to Step 8 1. Ground the EGR valve metal case to battery (). 2. Using a Tech 2, command EGR ON and observe the EGR valve pintle for movement. Does the EGR valve pintle move according to command? Go to Step 9 Go to DTC P1406 chart
1. Remove the EGR inlet and outlet pipes from the intake and exhaust manifolds. 2. Visually and physically inspect manifold EGR ports and EGR inlet and outlet pipes for blockage or restriction caused by excessive deposits or other damage. Do the manifold EGR ports or inlet and outlet pipes have excessive deposits, obstructions, or any restrictions?
Go to Step 10
EGR system working properly. No problem found.
10
Clean or replace EGR system components as necessary. Is the action complete? Verify repair
6E119
Manifold Absolute Pressure (MAP) Output Check
D06R200048
Circuit Description
The manifold absolute pressure (MAP) sensor measures the changes in the intake MAP which result from engine load (intake manifold vacuum) and engine speed changes; and converts these into a voltage output. The powertrain control module (PCM) sends a 5-volt reference voltage to the MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring the sensor output voltage, the PCM knows the MAP. A lower pressure (low voltage) output voltage will be about 1-2 volts at idle. Higher pressure (high voltage) output voltage will be about 4-4.8 volts at wide open throttle. The MAP sensor is also used, under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses the MAP sensor to diagnose proper operation of the EGR system, in addition to other functions.
Test Description
IMPORTANT: Be sure to used the same diagnostic test equipment for all measurements. The number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Applying 34 kPa (10 inch Hg) vacuum to the MAP sensor should cause the voltage to be 1.5-2.1 volts less than the voltage at step 1. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. 3. Check the vacuum hose to the sensor for leaking or restriction, Be sure that no other vacuum devices are connected to the MAP hose. IMPORTANT: Make sure the electrical connector remains securely fastened. 4. Disconnect the sensor from the bracket. Twist the sensor with your hand to check for an intermittent connection. Output changes greater than 0.10 volt indicate a bad sensor.
6E120
Manifold Absolute Pressure (MAP) Output Check

1. Turn the ignition OFF and leave it OFF for 15 seconds. 2. Ignition ON. Dont crank engine. 3. The Tech 2 should indicate a manifold absolute pressure (MAP) sensor voltage. 4. Compare this scan reading to scan reading of a known good vehicle obtained using the exact same procedure as in Steps 1-4. Is the voltage reading the same +/0.40 volt? Go to Step 2 Go to Step 5 1. Disconnect the vacuum hose at the MAP sensor and plug the hose. 2. Connect a hand vacuum pump to the MAP sensor. 3. Start the engine. 4. Apply 34 kPa (10 in.Hg) of vacuum and note the voltage change. Is the voltage change 1.5-2.1 volts less than Step 1? Go to Step 3 Go to Step 5 Verify repair Go to Step 6 Verify repair Verify repair Go to Step 4 Go to Step 4 Go to Step 7 Check the sensor cover for leakage or restriction. Does the hose supply vacuum to the MAP sensor only? Repair the hose blockage. Is the action complete? Check the sensor connection. Is the sensor connection good? Refer to On-Vehicle Service, MAP Sensor. Is the action complete? Repair the poor connection. Is the action complete?
3 4 5 6 7
6E121
Evaporative (EVAP) Emissions Canister Purge Valve Check
D06R200084
Circuit Description
Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge ON). The EVAP purge solenoid control is turned ON and OFF several times a second. The duty cycle (pulse width or ON time) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the purge solenoid is enabled when the appropriate conditions have been met: D The engine run time after start is more than 60 seconds. D The engine coolant temperature is above 30C (86F). D The fuel control system is operating in the closed-loop mode.
Diagnostic Aids
D Make a visual check of vacuum hoses. D Check the throttle body for cracks. D Check the malfunction indicator lamp for a possible mechanical problem.
Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 1. Check to see if the solenoid is open or closed. The solenoid is normally de-energized in this step, so it should be closed. 2. This step checks to determine if the solenoid was open due to an electrical circuit problem or a defective solenoid. 3. This should normally energize the solenoid, opening the valve and allowing the vacuum to drop (purge ON).
6E122
Evaporative (EVAP) Emissions Canister Purge Valve Check

1. Ignition OFF. 2. Ignition ON, engine OFF. 3. At the throttle body, disconnect the hose that goes to the purge solenoid. 4. Using a hand vacuum pump with an attached vacuum gauge J 23738-A, apply vacuum (10 in. Hg or 34 kPa) to the solenoid. Does the solenoid hold the vacuum? Go to Step 3 Go to Step 2 1. Disconnect the solenoid electrical connector. 2. As in Step 1, apply vacuum (10 in. Hg or 34 kPa) to the solenoid. Does the solenoid hold the vacuum? Go to Step 4 Go to Step 7 1. At the throttle body, put a cap over the vacuum port where the hose was disconnected for testing. This is to prevent a vacuum leak when the engine is started. 2. Ignition OFF. 3. Install the Tech 2. 4. Apply vacuum to the purge solenoid with the hand vacuum pump. 5. Start the engine, run at 2500 RPM. 6. Using the Tech 2, select Powertrain, 3.5V6 6VE1, F3: Misc. Tests, F2: EVAP Purge, F0: EVAP Purge. (Refer to the Misellaneous Test.) 7. Turn the purge solenoid ON. Did the vacuum drop when the purge was turned on? Go to Step 8 Go to Step 5 Verify repair Go to Step 9 Go to Step 6
4 5 6
Check for a short to ground in the S7 Pin wire. Is there a short? Repair the short to ground. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Servicein Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
Replace the faulty purge solenoid. Refer to On-Vehicle Service, EVAP Canister Purge Solenoid. Is the action complete? Verify repair
6E123
Evaporative (EVAP) Emissions Canister Purge Valve Check (Cont'd)

1. Turn the ignition OFF. 2. At the throttle body, install a vacuum gauge where the hose from the purge solenoid was disconnected for testing. 3. Start the engine. 4. Stabilize the engine speed at about 2500 RPM. 5. Momentarily snap the throttle open and let it return to idle. Is there approximately 10 in. Hg (34 kPa) of vacuum available at the EVAP emission canister purge solenoid?
No problem found in the EVAP emission canister purge valve check
Check the Procedure Refer to Diagnostic Aids
1. Disconnect the solenoid electrical connector. 2. Connect a test lamp between the harness terminals. Does the test lamp light? Go to Step 7 Go to Step 10 Probe terminal A and terminal B with a test lamp to ground. Does the test lamp light on both terminals? Go to Step 11 Verify repair Go to Step 13 Go to Step 12 Go to Step 14 Repair the short to voltage in the S7 Pin wire. Is the action complete? Does one of the terminals light the test lamp? Check for an open in the S7 Pin wire between the purge solenoid and the PCM. Was there an open circuit? Go to Step 15 Verify repair Verify repair Go to Step 6 Repair the open in the BLK/YEL wire. Is the action complete? Repair the open in the S7 Pin wire. Is the action complete?
10
11 12 13
14 15
6E124
PCM Diagnostic Trouble Codes

The following table lists the diagnostic trouble codes supported by this vehicle application. If any DTCs not listed here are displayed by a Tech 2, the Tech 2 data may be faulty; notify the Tech 2 manufacturer of any DTCs displayed that are not included in the following table. PCM Diagnostic Trouble Codes DTC Description Type Illuminate MIL (Check Engine Lamp) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No
P0101 P0102 P0103 P0106 P0107 P0108 P0112 P0113 P0117 P0118 P0125 P0131 P0132 P0133 P0134 P0135 P0137 P0138 P0140 P0141 P0151 P0152 P0153 P0154 P0155 P0157 P0158 P0160 P0161 P0171 P0172 P0174 P0175 P0201
MAF System Performance MAF Sensor Circuit Low Frequency MAF Sensor Circuit High Frequency MAP Rationality/Performance MAP Circuit Low Input Voltage MAP Circuit High Input Voltage IAT Circuit Low Input Voltage IAT Circuit High Input Voltage ECT Circuit Low Input Voltage ECT Circuit High Input Voltage ECT Insufficient for Closed Loop Fuel Control O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Heater Circuit (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) O2 Sensor Heater Circuit (Bank 1 Sensor 2) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1) O2 Sensor Circuit High Voltage (Bank 2 Sensor 1) O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1) O2 Sensor Heater Circuit (Bank 2 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2) O2 Sensor Circuit High Voltage (Bank 2 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2) O2 Sensor Heater Circuit (Bank 2 Sensor 2) O2 Sensor System too Lean (Bank 1) O2 Sensor System too Rich (Bank 1) O2 Sensor System too Lean (Bank 2) O2 Sensor System too Rich (Bank 2) Injector 1 Control Circuit
B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B A

DTC Description Type Illuminate MIL (Check Engine Lamp) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No Yes No No Yes Yes Yes No Yes Yes No Yes Yes Yes No
6E125
Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No
P0202 P0203 P0204 P0205 P0206 P0300 P0325 P0336 P0337 P0351 P0352 P0353 P0354 P0355 P0356 P0401 P0402 P0404 P0405 P0406 P0420 P0430 P0440 P0442 P0444 P0445 P0446 P0447 P0448 P0452 P0453 P0456 P0461 P0462 P0463 P0464 P0502 P0506 P0507 P0562
Injector 2 Control Circuit Injector 3 Control Circuit Injector 4 Control Circuit Injector 5 Control Circuit Injector 6 Control Circuit Engine Misfire Detected ION Sensing Module CKP Sensor Circuit Range/Performance (58X) CKP Sensor Circuit No signal (58X) Ignition 1 Control Circuit Ignition 2 Control Circuit Ignition 3 Control Circuit Ignition 4 Control Circuit Ignition 5 Control Circuit Ignition 6 Control Circuit EGR Flow Insufficient EGR Flow Excessive EGR Range/Performance (Open Valve) EGR Sensor Circuit Low Voltage EGR Sensor Circuit High Voltage Catalyst System Low Efficiency (Bank 1) Catalyst System Low Efficiency (Bank 2) EVAP Control System EVAP Control System Small Leak Detected EVAP Purge Control Circuit Open EVAP Purge Control Circuit Short EVAP Canister Vent Control Malfunction EVAP Vent Solenoid Circuit Open EVAP Vent Solenoid Circuit Short EVAP Control System Tank Pressure Sensor Low Input EVAP Control System Tank Pressure Sensor High Input EVAP Control System Very Small Leak Detected Fuel Level Sensor Circuit Range/Performance Fuel Level Sensor Circuit Low Input Voltage Fuel Level Sensor Circuit High Input Voltage Fuel Level Sensor Noisy Signal No VSS Signal Idle Speed Control RPM too Low Idle Speed Control RPM too High System Voltage is Low
A A A A A B B B B A A A A A A B B B B B A A B B D D B D D B B B D B B D B B B D
6E126
DTC

Description Type Illuminate MIL (Check Engine Lamp) Yes No No No No No Yes No No No No No No No No No No No Yes Yes Yes Yes Yes Yes No No No Yes No No No No Yes Yes Yes Yes Yes Yes Yes Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No No No No Yes No No No No No No No No No No No No No No No Yes Yes Yes No
P0563 P0565 P0566 P0567 P0568 P0571 P0601 P0602 P0604 P0606 P0660 P0662 P1106 P1107 P1111 P1112 P1114 P1115 P1120 P1125 P1133 P1134 P1153 P1154 P1167 P1169 P1171 P1220 P1221 P1271 P1272 P1273 P1275 P1280 P1285 P1290 P1295 P1299 P1310
System Voltage is High Cruise Main Switch Circuit Error Cruise Cancel Switch Circuit Error Cruise Resume Switch Circuit Error Cruise Set Switch Circuit Error No Brake Switch Signal PCM/ECM Memory Checksum PCM/ECM Programming error PCM/ECM RAM error PCM/ECM Internal Performance VIM Solenoid Circuit Open VIM Solenoid Circuit Short MAP Circuit Intermittent High Voltage) MAP Circuit Intermittent Low Input Voltage IAT Circuit Intermittent High Voltage IAT Circuit Intermittent Low Input Voltage ECT Circuit Intermittent Low Voltage ECT Circuit Intermittent High Voltage TPS1 Circuit ETC Limit Performance Mode O2 Sensor Too Few Rich/Lean and Lean/Rich Switches (Bank 1 Sensor 1) O2 Sensor Transition Switch Time ratio (Bank 1 Sensor 1) O2 Sensor Too Few Rich/Lean and Lean/Rich Switches (Bank 2 Sensor 1) O2 Sensor Transition Switch Time ratio (Bank 2 Sensor 1) Fuel supply System RICH During Decel Fuel Cut Off (Bank 1) Fuel supply System RICH During Decel Fuel Cut Off (Bank 2) Fuel supply System Lean During Power Enrichment TPS2 Circuit TPS1TPS2 Correlation (Circuit Performance) APS1APS2 Correlation (Circuit Performance) APS2APS3 Correlation (Circuit Performance) APS1APS3 Correlation (Circuit Performance) APS1 Circuit APS2 Circuit APS3 Circuit ETC Forced Idle Mode ETC Power Management Mode ETC Forced Engine Shutdown in Mode ION Sensing Module Diagnostic
B D D D D D A D D D D D D D D D D D B A B B B B D D D B D D D D B B B A A A A

DTC Description Type Illuminate MIL (Check Engine Lamp) Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No
6E127
Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No
P1311 P1312 P1326 P1340 P1404 P1441 P1514 P1515 P1516 P1523 P1574 P1635 P1636 P1639 P1640 P1650
ION Sensing Module SEC 1 Line Circuit Fault ION Sensing Module SEC 2 Line Circuit Fault ION Sensing Module Combustion Quality circuit ION Sensing Module Cylinder Synchronization EGR Range/Performance (Closed Valve) EVAP Control System Continuous Open Purge Flow TPSMAF Correlation CommandAcrual TPS Correlation CommandAcrual TPS Correlation Error Throttle Actuator Control Return Performance Brake Switch No Operation Reference Voltage #1 Circuit PCM RAM Stack Reference Voltage #2 Circuit ODM Output circuit Fault QDM Output Circuit Fault
A A A B B B A A A D D D D D D D
6E128
Diagnostic Trouble Code (DTC) P0101 MAF System Performance
D06R200047
Circuit Description
The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 3 to 7g/s at idle. DTC P0101 will be set if the signal from the MAF sensor does not match a predicted value based on throttle position and engine RPM.
D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.
Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0101 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. D DTC P0101 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. D The duct work at the MAF sensor for leaks. D An engine vacuum leak. D The PCV system for vacuum leaks. D An incorrect PCV valve. D The engine oil dip stick not fully seated. D The engine oil fill cap loose or missing. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken
Conditions for setting the DTC

D D D D The engine is running. No TP sensor and MAP sensor DTCs are set. No MAF frequency DTCs are set. System voltage is between 11.5 volts and 16 volts.
Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness- Inspect the wiring harness for damage. If the harness appears to be OK, observe the Mass Air Flow (MAF) display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. D Plugged intake air duct or filter element D A wideopen throttle acceleration from a stop should cause the mass air flow displayed on a Tech 2 to increase from about 36 g/s at idle to 100 g/s or greater at the time of the 12 shift. If not, check for a restriction.
6E129
A change in the display will indicate the location of the fault. If DTC P0101 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P001 Diagnostic Chart may isolate the cause of the fault.
DTC P0101 MAF System Performance

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition OFF. 2. Disconnect the Mass Air Flow (MAF) Sensor harness connector from the MAF Sensor. 3. Place an unpowered test lamp between the 12 volt signal circuit and the ground circuit, both at the MAF Sensor connector. 4. Ignition ON, EngineOFF. Did the test lamp illuminate? Go to Step 6
Go to Step 3
1. Ignition ON, Engine OFF. 2. Using a Digital Voltmeter (DVM), check the 12 volt signal circuit for the correct voltage. Did the DVM indicate a value within the following range? 11.5 to 12.5 Volt Go to Step 5 Go to Step 4
1. Ignition OFF. 2. Check the 12 volt signal circuit for the following conditions: D An open circuit D A short to ground Was the problem found? Verify repair Check the MAF ground circuit for the following conditions: D An open circuit D A short to voltage Was a problem found? Verify repair 1. Ignition OFF. 2. Check the MAF Sensor signal circuit between the PCM and the MAF Sensor for the following conditions: D An open circuit D A short to ground D A short to battery voltage Was a problem found? Verify repair Go to Step 7
6E130
DTC P0101 MAF System Performance (Cont'd)

1. Connect the MAF Sensor wiring harness connector to the MAF Sensor. 2. Connect the Tech 2 to the vehicle. 3. Place the Transmission in Park/Neutral, and fully apply the Parking Brake. 4. Start the engine. 5. Select the Mass Air Flow (MAF) parameter on the Tech 2. With the engine idling, does the Tech 2 display the following value(s)? 3 to 7 g/s Go to Step 8 Go to Step 9
1. 2. 3. 4.
Ignition OFF. Disconnect the MAF sensor connector. Ignition ON, engine idling. Using a Tech 2, monitor MAF Frequency. 0 g/s Go to Step 10 Verify repair Go to Step 9
Does the Tech 2 indication a MAF Frequency at the specified value? 9 10 Replace the MAF Sensor. Is the action complete? Replace the PCM. IMPORTANT: The PCM must be reprogrammed. Refer to PCM reprogramming. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Verify repair
6E131
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency
D06R200047
Circuit Description
The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity of air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 3 to 7g/s at idle. DTC P0102 will be set if the signal from the MAF sensor is below the possible range of a normally operating MAF sensor.
D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0102 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0102 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Misrouted harness Inspect the MAF sensor harness to ensure that it is not routed too close to high voltage wires. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Tech 2 while moving connectors and wiring harnesses related to the MAF sensor. A change in the display will indicate the location of the fault. D Plugged intake air duct or filter element A wide-open throttle acceleration from a stop should cause the
Conditions for Setting the DTC

D The engine is running above 500 RPM for more than 10 seconds. D System voltage is above 11.5 volts. D MAF signal frequency is below 1.6g/s for a total of 50-percent of the last 1000 samples monitored. A sample is taken every cylinder event.

D The PCM will ON the MIL after second trip with detected fault. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.
6E132

2. This step verifies that the problem is present at idle. 4. A voltage reading of less than 4 or over 5 volts at the MAF sensor signal circuit indicates a fault in the wiring or a poor connection. 5. This verifies that ignition feed voltage and a good ground are available at the MAF sensor.
mass air flow displayed on a Tech 2 to increase from about 3-6 g/second at idle to 100 g/second or greater at the time of the 1-2 shift. If not, check for a restriction. If DTC P0102 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.
DTC P0102 MAF Sensor Circuit Low Frequency

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Start the engine. 2. With the engine idling, monitor MAF Frequency display on the Tech 2. Is the MAF Frequency below the specified value? 3-7 g/s Go to Step 3
Go to Step 5
1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0102. Does the Tech 2 indicate DTC P0102 failed this ignition? Go to Step 4
1. 2. 3. 4.
Ignition OFF. Disconnect the MAF sensor connector. Ignition ON, engine OFF. Using a DVM, measure voltage between the MAF sensor signal circuit and battery ground. 11.512 V Go to Step 5 Go to Step 8
Is the voltage near the specified value? 5 Connect a test light between the MAF sensor ignition feed and ground circuits at the MAF sensor harness connector. Is the test light ON? 6 Connect a test light between the MAF sensor ignition feed circuit and battery ground. Is the test light ON? 7 1. Check for a poor connection at the MAF sensor. 2. If a poor connection is found, replace the faulty terminal(s). Was a poor connection found? 8 1. Ignition OFF. 2. Disconnect the MAF sensor. 3. Disconnect the PCM connector for the MAF signal circuit. 4. Ignition ON, engine OFF. 5. With the DVM, measure the voltage between the MAF signal terminal at the PCM and battery ground. Is the voltage under the specified value?
Go to Step 7
Go to Step 6
Go to Step 11
Go to Step 7
Verify repair
Go to Step 12
0V
Go to Step 9
Go to Step 10
6E133
DTC P0102 MAF Sensor Circuit Low Frequency (Cont'd)

1. 2. 3. 4.
Ignition OFF. Disconnect the PCM connector. Ignition ON. Check the MAF sensor signal circuit for a short to 5 volts. Verify repair Ignition OFF. Disconnect the PCM connector. Ignition ON. Check the MAF sensor signal circuit between the PCM and the MAF sensor for an open, short to ground, or short to the MAF ground circuit. Verify repair Go to Step 13
Is the action complete? 10 1. 2. 3. 4.
Is the action complete? 11 Locate and repair the open in the ground circuit to the MAF sensor. Is the action complete? 12 Locate and repair the open in the ignition feed circuit to the MAF sensor. Is the action complete? 13 14 Replace the MAF sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Verify repair
Go to Step 14
Verify repair
6E134
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency
D06R200047
Circuit Description
The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity of air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 3 to 7g/s at idle. DTC P0103 will be set if the signal from the MAF sensor is above the possible range of a normally operating MAF sensor.
Conditions for clearing the MIL/DTC

Diagnostic Aids
If DTC P0103 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

D The engine is running above 500 RPM for more than 10 seconds. D System voltage is above 11.5 volts. D MAF signal frequency is above 40g/s for a total of 50 percent of the last 200 samples monitored. A sample is taken every cylinder event.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. This step verifies that the problem is present at idle. 4. A frequency reading with the MAF sensor connector disconnected indicates an electromagnetic interference (EMI) related fault.

D The PCM will ON the MIL after second trip with detected the fault. D The PCM calculates an airflow value based on idle air control valve position, throttle position, RPM and barometric pressure.
6E135
DTC P0103 MAF Sensor Circuit High Frequency

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0103. Does the Tech 2 indicate DTC P0103 failed this ignition? Go to Step 3
1. Start the engine. 2. With the engine idling, monitor MAF Frequency display on the Tech 2. Is MAF Frequency above the specified value? 37g/s Go to Step 4 Go to Step 7 1. 2. 3. 4. Ignition OFF. Disconnect the MAF sensor connector. Ignition ON, engine idling. Using a Tech 2, monitor MAF Frequency. 0g/s Go to Step 5 Verify repair Go to Step 6 Go to Step 7
Does the Tech 2 indicate a MAF Frequency at the specified value? 5 6 Replace the MAF sensor. Is the action complete? 1. Check the MAF harness for incorrect routing near high voltage components (solenoids, relays, motors). 2. If incorrect routing is found, correct the harness routing. Was a problem found? 7 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Verify repair
Go to Step 7
Verify repair
6E136
Diagnostic Trouble Code (DTC) P0106 MAP System Performance
D06R200048
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts at wide-open throttle (low vacuum) at sea level. The MAP sensor is used to determine manifold pressure changes while the linear exhaust gas recirculation (EGR) flow test diagnostic is being run (refer to DTC P0401), engine vacuum level for some other diagnostics, and barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set.
D The MAP value must vary for a total of 10 seconds over a 20-second period of time that the samples were monitored. D The failure must occur for 2 consecutive trips.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will default to a BARO value of 79.3 kPa. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.


D D D D D D D D No TP sensor DTCs are present. Engine speed is steady, changing less then 100 RPM. Engine speed is between 1000 rpm and 4000 rpm. Throttle position is steady, throttle angle changes less than 1%. EGR flow rate is steady, changing less than 4%. No change in brake switch, A/C clutch, TCC or power steering pressure switch status. Above conditions are met for longer than 1 second. Actual MAP value varies more than 10 kPa.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection.

D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0106 cannot be duplicated, the information included in the Failure Records data can be useful in
6E137
determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1107 Diagnostic Chart may isolate the cause of the fault.
DTC P0106 MAP System Performance

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0106. Does the Tech 2 indicate DTC P0106 failed? Go to Step 4
Go to Step 3
1. Check for the following conditions: D Vacuum hoses disconnected, damaged, or incorrectly routed D Intake manifold vacuum leaks D Vacuum leaks at throttle body D Vacuum leaks at EGR valve flange and pipes D Crankcase ventilation valve faulty, missing or incorrectly installed. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair 1. Disconnect the MAP sensor electrical connector. 2. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 11 kPa Go to Step 5
Go to Step 13
1. Connect a test light between B+ and the MAP sensor signal circuit at the MAP sensor harness connector. 2. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 100 kPa Go to Step 6 Go to Step 9 1. Jumper the 5 volt reference circuit and the MAP signal circuit together at the MAP sensor harness connector. 2. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 100 kPa Go to Step 7 Go to Step 8 1. Ignition OFF. 2. Disconnect the PCM and check the sensor ground circuit for high resistance, an open between the PCM and the MAP sensor, or for a poor connection at the PCM. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11
6E138
DTC P0106 MAP System Performance (Cont'd)

1. Check the 5 volt reference circuit for high resistance, an open between the PCM and the MAP sensor, or a poor connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM, and check the MAP sensor signal circuit for high resistance, an open, a short to ground, or a short to the sensor ground circuit. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10 1. Check the MAP sensor signal circuit for a poor connection at the PCM. 2. If a problem is found, repair as necessary. Did the terminal require replacement? Verify repair Go to Step 14 1. Check for a poor connection at the MAP sensor. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Verify repair Go to Step 12 Replace the MAP sensor. Is the action complete? 1. Ignition OFF, disconnected the PCM. 2. Ignition ON, check the MAP signal circuit for a short to voltage or a short to the 5 volt reference circuit. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10
11
12 13
14
6E139
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage
D06R200048
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the exhaust gas recirculation (EGR) flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM monitors the MAP signals for voltages outside the normal range of the MAP sensor. If the PCM detects a MAP signal voltage that is excessively low, DTC P0107 will be set.

D The PCM will ON the MIL after second trip with detected fault. D The PCM will default to a BARO value of 79.3 kPa. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.


D No TP sensor DTCs present. D Engine is running. D Throttle angle is above 1% if engine speed is less than 1000 RPM. D Throttle angle is above 2% if engine speed is above 1000 RPM. D The MAP sensor indicates manifold absolute pressure at or below 11 kPa for a total of approximately 10 seconds over a 16-second period. D Ignition voltage more than 11 volts.
Diagnostic Aids
Check for the following conditions: D Check for intermittent codes. D The MAP sensor shares a 5 Volt reference with the EGR Sensor. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit . D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the
6E140

determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0107 Diagnostic Chart may isolate the cause of the fault.
MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0107 cannot be duplicated, the information included in the Failure Records data can be useful in
DTC P0107 MAP Sensor Circuit Low Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. With the throttle closed, observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0107. Does the Tech 2 indicate DTC P0107 failed? Go to Step 4 1. Ignition OFF. 2. Disconnect the MAP sensor electrical connector. 3. Jumper the 5 volt reference circuit and the MAP signal together at the MAP sensor harness connector. 4. Ignition ON. 5. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? (If no, start with diagnosis chart for other sensors in the circuit and see if 5V returns.)
5V 100kPa at sea level
Go to Step 4
Go to Step 3
0 V 11 kPa
Go to Step 10
Go to Step 5
1. Disconnect the jumper. 2. Connect a test light between B+ and the MAP sensor signal circuit at the MAP sensor harness connector. 3. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value. 5 V 100 kPa Go to Step 6 Go to Step 8 1. Ignition OFF. 2. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair it as necessary. Was the 5 volt reference circuit open or shorted to ground? Verify repair Go to Step 7
Check the 5 volt reference circuit for a poor connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 11
6E141
DTC P0107 MAP Sensor Circuit Low Voltage (Cont'd)

1. Ignition OFF. 2. Disconnect the PCM, and check the MAP signal circuit for an open, short to ground, or short to the sensor ground circuit. 3. If the MAP sensor signal circuit is open or shorted to ground, repair it as necessary. Was the MAP signal circuit open or shorted to ground? Verify repair Go to Step 9 Check the MAP sensor signal circuit for a poor connection at the PCM and the MAP sensor; replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 11 Replace the MAP sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
6E142
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage
D06R200048
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the key ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM monitors the MAP signals for voltages outside the normal range of the MAP sensor. If the PCM detects a MAP signal voltage that is excessively high, DTC P0108 will be set.
D The PCM will default to a BARO value of 79.3 kPa. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids
Check for the following conditions: D The MAP sensor shares a 5 Volt reference with the EGR sensor. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

D No TP sensor DTCs present. D Engine is running for more than 10 seconds. D Throttle position is below 3% if engine speed is below 1000 RPM. D Throttle position is below 10% if engine speed is above 1000 RPM. D The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 10 seconds over a 16-second period.

D The PCM will ON the MIL after second trip with detected fault.

If DTC P0108 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1108 Diagnostic Chart may isolate the cause of the fault.
6E143
DTC P0108 MAP Sensor Circuit High Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. If the engine idle is rough, unstable or incorrect, repair the idle problem before using this chart. Refer to Symptoms section. 2. With the engine idling, note the MAP value on the Tech 2. Is the MAP reading above the specified value? 2535 kPa Go to Step 4
Go to Step 3
1. 2. 3. 4.
Ignition OFF. Disconnect the MAP sensor electrical connector. Ignition ON. Note the MAP sensor voltage displayed on the Tech 2. (If no, start with diagnostic chart for other sensors in the circuit and see if 5V returns.) 11 kPa 0.0 V Go to Step 5 Go to Step 7 Go to Step 6 Go to Step 9
Is the MAP sensor voltage at the specified value? 5 6 Probe the sensor ground circuit with a test light to B+. Is the test light ON? 1. Check the MAP signal circuit for a short to voltage or a short to the 5 volt reference circuit. 2. If the MAP sensor signal circuit is shorted, repair circuit as necessary. Was the MAP sensor signal circuit shorted? 7 1. Check for a poor sensor ground terminal connection at the MAP sensor electrical connector. 2. If a problem is found, replace the faulty terminal. Did the terminal require replacement? 8 Check for a plugged or leaking vacuum supply to the MAP sensor. Is the vacuum supply plugged or leaking? 9 1. Check for a poor sensor ground terminal connection at the PCM. 2. If a problem is found, replace the faulty terminal. Did the terminal require replacement?
Verify repair
Go to Step 11
Verify repair
Go to Step 8
Verify repair
Go to Step 12
Verify repair
Go to Step 10
6E144
DTC P0108 MAP Sensor Circuit High Voltage (Cont'd)

10
1. Check the continuity of the MAP sensor ground circuit. 2. If the MAP sensor ground circuit measures over 5 ohms, repair open or poor connection. Was a condition found and corrected? Verify repair Go to Step 11 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify Repair Verify repair
11
12
Replace the MAP sensor. Is the action complete?
6E145
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage
D06RY00168
Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower, causing the PCM to monitor a lower voltage. DTC P0112 will set when the PCM detects an excessively low signal voltage on the intake air temperature sensor signal circuit.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-bout terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. If DTC P0112 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

D The engine has been running for over 15 seconds. D Vehicle speed is greater than 30 mph (48 km/h) . D IAT signal voltage indicates and intake air temperature greater than 148C (298F) (about 5 volts) for a total of 12.5 seconds over a 25-second period of time.

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.
6E146
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Verifies that the fault is present. 3. If DTC P0112 can be repeated only by duplicating the Failure Records condition, refer to the Temperature vs. Resistance Value table. The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be stored above or below a certain temperature. If this is the case, replace the IAT sensor. If the IAT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.
Intake Air Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700
6E147
DTC P0112IAT Sensor Circuit Low Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Using a Tech 2, monitor the intake air temperature (IAT). Is the intake air temperature greater than the specified value? 148C (283F) Go to Step 4
Go to Step 3
1. Ignition ON, engine OFF. Review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor the DTC info for DTC P0112. Does the Tech 2 indicate DTC P0112 failed this ignition? Refer to Test Description
1. 2. 3. 4.
Ignition OFF. Disconnect the IAT sensor electrical connector. Ignition ON. Observe the intake air temperature on the Tech 2.
Is the intake air temperature below the specified value? 5 1. Ignition OFF. 2. Disconnect the PCM electrical connectors. 3. Check the IAT sensor signal circuit for a short to ground. Is the IAT sensor signal circuit shorted to ground? 6 7 Replace the IAT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
38C (36F)
Go to Step 6
Go to Step 5
Go to Step 7
Verify repair
6E148
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage
D06RY00168
Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower causing the PCM to monitor a lower voltage. DTC P0113 will set when the PCM detects an excessively high signal voltage on the intake air temperature sensor signal circuit.

Diagnostic Aids
Check for the following conditions: D The IAT sensor shares a ground with the EGR position sensor and the TP sensor. Check the ground if these DTCs are set. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. If DTC P0113 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

D D D D D The engine has been running for over 30 seconds. Vehicle speed is less than 20 mph (32 km/h). ECT signal temperature is above 60C (140F). Mass air flow is less then 20 g/second. IAT signal voltage indicates an intake air temperature less than 39C (38F) for total of 12.5 seconds over a 25-second period.

6E149
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Verifies that the fault is present. 3. If DTC P0113 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Values table. The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be open above or below a certain temperature. If this is the case, replace the IAT sensor. If the IAT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

DTC P0113 IAT Sensor Circuit High Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Ignition ON, engine OFF. Observe the Intake Air Temp display on the Tech 2. Is the Intake Air Temp below the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0113. Does the Tech 2 indicate DTC P0113 failed? 1. Ignition OFF. 2. Disconnect the IAT sensor electrical connector. 3. Jumper the IAT signal circuit and the sensor ground circuit together at the IAT sensor harness connector. 4. Ignition ON. 5. Observe the Intake Air Temp display on the Tech 2. Is the Intake Air Temp at the specified value? 1. Jumper the IAT signal circuit at the IAT sensor harness connector to chassis ground. 2. Observe the Intake Air Temp display on the Tech 2. Is the Intake Air Temp at the specified value?
38C (36F)
Go to Step 4
Go to Step 3
Refer to Test Description
140C (284F)
Go to Step 6
Go to Step 5
140C (284F)
Go to Step 7
Go to Step 8
6E150
DTC P0113 IAT Sensor Circuit High Voltage (Cont'd)

Check for poor connections at the IAT sensor and replace terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM, and check the IAT sensor ground circuit for an open. 3. If the IAT sensor ground circuit is open, repair it as necessary. Was the IAT sensor ground circuit open? Verify repair Go to Step 9 1. Ignition OFF. 2. Disconnect the PCM, and check the IAT signal circuit for an open. 3. If the IAT sensor signal circuit is open, repair it as necessary. Was the IAT signal circuit open? Verify repair Go to Step 9 Check for a poor sensor ground or IAT signal circuit terminal connection at the PCM and replace terminal(s) if necessary. Did any of the terminals need to be replaced? Verify repair Verify repair Go to Step 11 Replace the IAT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
6E151
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage
D06R200049
Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted on a coolant crossover pipe at the front of the engine. The powertrain control module (PCM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes lower, and the ECT signal voltage measured at the PCM drops. With a fully warmed-up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. If DTC P0117 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1114 Diagnostic Chart may isolate the cause of the fault.

D Engine running time is longer than 120 seconds. D The ECT sensor signal indicates an engine coolant temperature greater than 150C (302F) (about 0.10 V) for a total of 50 seconds over a 100second period.

D The PCM will ON the MIL after second trip with detected fault. D The PCM will substitute the ECT reading with a default engine coolant temperature value. The default value is based on start-up intake air temperature and running time. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.
6E152
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P0117 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Values table. The table may be used to test the ECT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature. If this is the case, replace the ECT sensor. If the ECT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.
Engine Coolant Temperature Sensor

6E153
DTC P0117 ECT Sensor Low Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp below the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0117. Does the Tech 2 indicate DTC P0117 failed this ignition? 39C (38F) Go to Step 4
139C (282F)
Go to Step 4
Go to Step 3
1. Disconnect the ECT sensor electrical connector. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp at the specified value? 1. Ignition OFF. 2. Disconnect the PCM and check the ECT signal circuit for a short to ground or a short to the sensor ground circuit. 3. If the ECT signal circuit is shorted. repair it as necessary. Was the ECT signal circuit shorted to ground?
Go to Step 6
Go to Step 5
Go to Step 7
6 7
Replace the ECT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6E154
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage
D06R200049
Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in on a coolant crossover pipe at the front of the engine. The powertrain control module (PCM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed-up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts.

Diagnostic Aids
Check for the following conditions: The ECT shares a ground with the Transmission Fluid Temperature sensor, the Fuel Tank Pressure sensor, and the MAP sensor. Check the ground if these DTCs are also set. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. If DTC P0118 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,

D Engine running time is longer than 90 seconds. D The ECT sensor signal indicates an engine coolant temperature of 39C (38F) or less (about 5 volts) for a total of 50 seconds over a 100-second period.

D The PCM will ON the MIL after second trip with detected fault. D The PCM will substitute the ECT reading with a default engine coolant temperature value. The default value is based on start-up intake air temperature and running time. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

performing the DTC P1115 Diagnostic Chart may isolate the cause of the fault.
6E155

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P0118 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Value table. The table may be used to test the ECT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature. If this is the case, replace the ECT sensor. If the ECT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.
DTC P0118 ECT Sensor Circuit High Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp below the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor the DTC info for DTC P0118. Does the Tech 2 indicate DTC P0118 failed? 1. Disconnect the ECT sensor electrical connector. 2. Jumper the ECT signal circuit and the sensor ground circuit together at the ECT sensor harness connector. 3. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp at the specified value? 1. Jumper the ECT signal circuit at the ECT sensor harness connector to chassis ground. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp at the specified value? Check for poor connections at the ECT sensor and replace terminals if necessary. Did any terminals require replacement? Verify repair
39C (38F)
Go to Step 4
Go to Step 3
Refer to Test Description
140C (284F)
Go to Step 6
Go to Step 5
140C (284F)
Go to Step 7
Go to Step 8
Go to Step 10
6E156
DTC P0118 ECT Sensor Circuit High Voltage (Cont'd)

1. Ignition OFF. 2. Disconnect the PCM, and check the ECT sensor ground circuit for an open. 3. If the ECT sensor ground circuit is open, repair it as necessary. Was the ECT sensor ground circuit open? Verify repair Go to Step 9 1. Ignition OFF. 2. Disconnect the PCM, and check the ECT signal circuit for an open. 3. If the ECT sensor signal circuit is open, repair it as necessary. Was the ECT signal circuit open? Verify repair Go to Step 9 Check for a poor sensor ground or ECT signal circuit terminal connection at the PCM and replace terminal(s) if necessary. Did any of the terminals need to be replaced? Verify repair Verify repair Go to Step 11 Replace the ECT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
6E157
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control
D06R200049
Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. When the vehicle is first started, the powertrain control module (PCM) controls fuel delivery in open loop, ignoring the heated oxygen sensor (HO2S) signals and calculating air/fuel ratio based on inputs from the engine coolant temperature, throttle position, and mass air flow sensors. The PCM will begin using the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals for controlling fuel delivery under closed loop conditions when the following conditions have been met: D The HO2S output signals are varying, indicating that the sensors are hot enough to operate properly. D The engine coolant temperature sensor indicates coolant temperature above 50C (122F). D Time since start-up is at least 16 seconds for a warm engine or 23 seconds for a cold engine.
D For a warm engine (intake air temperature is greater than 10C/50F), engine coolant temperature sufficient to allow closed loop operation (50C/122F) is not achieved within 2 minutes of start-up. For a cold engine (intake air temperature between (7C and 10C), engine coolant temperature sufficient to allow closed loop operation (50C/122F) is not achieved within 10 minutes of start-up. D The above condition fails 20 consecutive times.



D D D D No active IAT, MAF or ECT DTC(s) are present. Engine is running. Vehicle speed is greater than 5 mph (8 km/h) . Intake air temperature is greater than 10C (14F) 0C (32F). D Startup engine coolant temperature is between 10C (14F) and 28C (82F).
6E158
Diagnostic Aids
DTC P0125 set indicates a faulty ECT sensor. Comparing the engine coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a thermometer may isolate this condition. If the displayed engine coolant temperature is not close to the actual coolant temperature, replace the ECT sensor. Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0125 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage wince the DTC was last set.
Engine Coolant Temperature

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Comparing the engine coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a thermometer may isolate this condition. If the displayed engine coolant temperature is not close to the actual coolant temperature, replace the ECT sensor. If the temperatures are close, the fault is intermittent; refer to Diagnostic Aids.
DTC P0125 ECT Excessive Time to Closed Loop Fuel Control

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to applicable ECT sensor DTC chart Are any ECT sensor DTCs set?
Go to Step 3
1. Allow the engine to cool completely. 2. Check the cooling system coolant level (refer to Cooling and Radiator). Is the coolant level OK? Go to Step 4 Check the Procedure Refer to Diagnostic Aids Go to Step 9 1. Start the engine. 2. With the engine idling, monitor ENG COOL TEMP display on the Tech 2. Does ENG COOL TEMP increase to above the specified value within 2 minutes? 21C (70F)
Go to Step 5
Check for proper operation of the thermostat (refer to Cooling and Radiator). Is the thermostat operating correctly? Go to Step 6 Go to Step 9
6E159
DTC P0125 ECT Excessive Time to Closed Loop Fuel Control (Cont'd)
Compare engine coolant temperature displayed on the Tech 2 to the actual coolant temperature measured with a thermometer. (Observe normal precautions when opening the cooling system.) Is the Tech 2 engine coolant temperature indication close to the measured temperature? Go to Step 9 Go to Step 7
1. Ignition OFF. 2. Disconnect the PCM. 3. Using a DVM, measure the resistance of the ECT at the PCM connector. 4. Compare the DVM reading with the chart in Test Description. Is the chart value approximately equal to the thermometer reading? Go to Step 12 Go to Step 8
Check for high resistance in wiring related to the ECT sensor. Also, check for poor connections at the ECT sensor and the PCM. Was a problem found? Go to Step 10 Go to Step 11 Refer to Cooling and Radiator for cooling system diagnosis and repair condition as necessary. Is the action complete? Verify repair Replace the faulty terminal(s) or repair faulty wiring as necessary. Is the action complete? Verify repair Verify repair Replace the ECT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10
11 12
6E160
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1
D06R200013
Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 350 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains excessively low for an extended period of time, DTC P0131 will be set.
D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.


D D D D No related DTCs. Vehicle is operating in closed loop. Engine coolant temperature is above 60C (140F). Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Bank 1 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90-second period of time.
Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be routed incorrectly and contacting the exhaust system. D Poor PCM to engine block grounds. D Fuel pressure The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, If fuel pressure is too low, a DTC P0131 may be set. Refer to Fuel System Diagnosis. D Lean injector(s) Perform Injector Balance Test. D Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system.


D Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. D MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. D Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination.
6E161
D If none of the above conditions are present, replace the affected HO2S.
Test Description
Number(s) below refer to step numbers on the diagnostic chart. 3. DTC P0131 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0131 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at normal operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Does the Bank 1 HO2S 1 voltage remain below the specified value? 22 mV Go to Step 4
Go to Step 3
1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0131 until the DTC P0131 test runs. Note test result. Does Tech 2 indicate DTC P0131 failed this ignition? Go to Step 4 1. Turn the ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 1 HO2S 1 high and low circuits for a short to ground or a short to the heater ground circuit. Are the Bank 1 HO2S 1 signal circuits shorted to ground? Go to Step 5 Verify repair
Go to Step 6
5 6
Repair the Bank 1 HO2S 1 signal circuit. Is the action complete? 1. Turn the ignition OFF, HO2S 1 and PCM disconnected. 2. Check for short circuit between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Verify repair Go to Step 8 Repair the short between the high and low circuits. Is the action complete?
6E162
DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1 (Cont'd)

1. Ignition OFF. 2. Reconnect the disconnected. 3. Ignition ON.
PCM,
leave
the
sensor
Does the Tech 2 indicate Bank 1 HO2S 1 voltage between the specified values? 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
425-475 mV
Go to Step 9
Verify repair
6E163
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1
D06R200013
Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains excessively high for an extended period of time, DTC P0132 will be set.

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.


D No related DTCs. D Engine coolant temperature is above 60C (140F) D Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Bank 1 HO2S 1 signal voltage remains above 952 mV during normal closed loop operation for a total of 77 seconds over a 90-second period. OR D Bank 1 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for 3 seconds.
Diagnostic Aids
Check the following items: D Fuel pressure The system will go rich if pressure is too high. The PCM can compensate for some increase. However, if fuel pressure is too high, a DTC P0132 may be set. Refer to Fuel System Diagnosis. D Perform Injector Balance Test Refer to Fuel System Diagnosis.
6E164

cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle by monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal circuit wiring and associated terminal conditions. D If none of the above conditions are present, replace the affected HO2S.
D Check the EVAP canister for fuel saturation If full of fuel, check canister control and hoses. Refer to Evaporative (EVAP) Emission Control System. D MAF sensor The system can go rich if MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see it the rich condition is corrected. If so, replace the MAF sensor. D Check for a leak in the fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. D An intermittent TP sensor output will cause the system to go rich due to a false indication of the engine acceleration. D Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. D Open HO2S Signal Circuit or Faulty HO2SA poor connection or open in the HO2S signal circuit can
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0132 failing during deceleration fuel cutoff mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0132 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Does the Bank 1 HO2S 1 voltage remain above the specified value?
952 mV (500 mV in deceleration fuel cutoff mode)
Go to Step 4
Go to Step 3
1. Ignition ON, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0132 until the DTC P0132 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0132 failed this ignition? Go to Step 4
1. 2. 3. 4.
Ignition OFF. Disconnect Bank 1 HO2S 1. Ignition ON. At HO2S Bank 1 Sensor 1 connector (PCM side) use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Go to Step 6
Are the voltages in the specified range?
6E165
DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1 (Cont'd)

5 6
Repair short to voltage in signal circuit. Is the action complete? 1. Ignition ON, engineOFF. 2. At Bank 1 HO2S 1 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage below the specified value? 10 mV Go to Step 7 Check the Procedure Refer to Diagnostic Aids Go to Step 8 1. Disconnect the jumpers to ground from Bank 1 HO2S 1 PCM-side connector. 2. With the HO2S 1 connector disconnected, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage between the specified values? 425-475 mV Verify repair
Go to Step 8
6E166
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1
D06R200013
Circuit Description
The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop has been enabled. During the monitoring period the PCM counts the number of times that a rich-to-lean and lean-to-rich response is indicated and adds the amount of time it took to complete all rich-to-lean transitions and lean-to-rich transitions. With this information, an average time for rich-to-lean and lean-to-rich transitions can be determined. If the average response time of either transition is too slow, a DTC P0133 will be set. A lean-to-rich transition is indicated when the HO2S voltage changes from less than 300 mV to greater than 600 mV. A rich-to-lean transition is indicated when the HO2S voltage changes from more than 600 mV to less than 300 mV. An HO2S that responds too slowly is likely to be faulty and should be replaced.
D Mass air flow is between 18 g/second and 42 g/second. D All above conditions are met for 3 seconds. D 90 seconds after closed loop has been enabled, Bank1 HO2S 1 average transition time between 300 mV and 600 mV is too slow. The lean-to-rich average transition response time was longer than 94 milliseconds or rich-to-lean average transition response time was longer than 105 milliseconds.

D The PCM will illuminate the malfunction indicator Lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.


D No related DTCs. D Engine coolant temperature (ETC) is above 60C (140F). D Engine is operating in closed loop. D Engine has been running for at least 90 seconds. D Engine speed is between 1500 RPM and 3000 RPM. D Canister purge duty cycle is greater than 2%.
6E167
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0133 cannot be duplicated, reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is currently present. 3. HO2S transition time, ratio mean volts and switching DTCs set for multiple sensors indicate probable contamination. Before replacing the sensors, isolate and correct the source of the contamination to avoid damaging the replacement sensors.
6E168
DTC P0133 HO2S Slow Response Bank 1 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If any DTCs are set (expect P0153, P1133, P1134, P1153, and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Install the Tech 2. 2. Idle the engine at normal operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC included in Diagnostic Support. 4. Using a Tech 2, monitor DTC info for DTC P0133 until the DTC P0133 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0133 failed this ignition? Go to Step 3 Go to Step 17 Go to Step 5 Go to Step 2
Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 6
3 4 5 6
Did the Tech 2 also indicate DTC P0153, P1133, P1134, P1153, and/or P1154 failed this ignition? Check for leaks at the pipe joints. Are the joints leaking? Tighten the Ubolt nuts at the leaking joints. Is the action complete? Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?
Go to Step 7
Go to Step 8
1. Replace damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is the action complete? Go to Step 2 Go to Step 9 Go to Step 2 Go to Step 11 Go to Step 2 Go to Step 13 Go to Step 10 Go to Step 12 Go to Step 14 Check for loose exhaust flange connections. Are the flange connections loose? Tighten the stud nuts or bolts to specifications. Is the action complete? Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded? Replace the exhaust pipes, as required. Is the action complete? Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications to replace the manifold if necessary. Is the action complete? Go to Step 2
8 9 10 11 12 13
6E169
DTC P0133 HO2S Slow Response Bank 1 Sensor 1 (Cont'd)

14
Visually/physically inspect the following items: D Ensure that the Bank 1 HO2S 1 is securely installed. D Check for corrosion on terminals. D Check terminal tension (at Bank 1 HO2S 1 and at the PCM). D Check for damaged wiring. Was a problem found in any of the above areas? Go to Step 18 Go to Step 15 1. Disconnect Bank 1 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Also measure the voltage between the low signal circuit and ground. Are both voltages in the specified range? 3-4 V Go to Step 16 Go to Step 19 1. With Bank 1 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition ON. 3. Using a Tech 2, monitor the Bank 1 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed?
15
16
Go to Step 21
Go to Step 22
17
Replace the affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption. Verify repair Verify repair Verify repair Verify repair Verify repair Go to Step 20
Is the action complete? 18 19 20 21 22 Repair condition as necessary. Is the action complete? Check for faulty PCM connections or terminal damage. Is the action complete? Repair open, short or grounded signal circuit. Is the action complete? Replace Bank 1 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Verify repair
6E170
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1
D06R200013
Circuit Description
D The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) high and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains at or near the 450 mV bias for an extended period of time, DTC P0134 will be set, indicating an open sensor signal or sensor low circuit. D Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. D Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

D D D D No related DTCs. Battery voltage is above 10 volts. The engine has been running for over 5 seconds. Engine coolant temperature (ETC) is above 60C (140F). D Oxygen sensor heater has been determined to be functioning properly. D Bank 1 HO2S 1 signal voltage remains between 400 mV and 500 mV for a total of 77 seconds over a 90-second period of time.
Action Take When the DTC Sets


6E171
Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty HO2S heater or heater circuit With the ignition ON, engine OFF, after a cool down period, the HO2S 1 voltage displayed on the Tech 2 is normally 455-460 mV. A reading over 1000 mV indicates a signal line shorted to voltage. A reading under 5 mV indicates a signal line shorted to ground or signal lines shorted together. Disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light for 2 seconds when the ignition is turned on, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.
D Intermittent test With the Ignition ON, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0134 test passes while the Failure Records conditions are being duplicated, an intermittent conditions is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes. Does the Tech 2 indicate Bank 1 HO2S 1 voltage varying outside the specified values? 400-500 mV Go to Step 3
Go to Step 4
1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0134 until the DTC P0134 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0134 failed this ignition? Go to Step 4 Verify repair
Check the Procedure Refer to Diagnostic Aids Go to Step 5
4 5
Check for a damaged harness. Was a problem found? Check for poor Bank 1 HO2S 1 high and low circuit terminal connections at the Bank 1 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 6 Check for poor Bank 1 HO2S 1 high and low circuit terminal connections at the PCM and replace terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 7
6E172
DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 (Cont'd)

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 high circuit. 3. If the Bank 1 HO2S 1 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 1 high circuit problem found and corrected? Verify repair Go to Step 8
1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 1 low circuit problem found and corrected? Verify repair Go to Step 9
1. Ignition ON, engine OFF. 2. Disconnect Bank 1 HO2S 1 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 1 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
6E173
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1
D06R200013
Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 1 HO2S 1 to become active, a DTC P0135 will set. The time it should take the HO2S to reach operating temperature is based on the accumulated amount of air that has passed through the MAF sensor and into the engine (more accumulated air flow = shorter time to HO2S activity).

D The engine has been running for over 120 seconds. D Heater signal is below 0.1A. D Bank 1 HO2S 1 voltage does not change more than 150 mV from the bias voltage (between 400 mV and 500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 150 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulate air flow since start-up.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

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2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. Ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. Checks the HO2S heater ground circuit. 6. Checks or an open or shorted HO2S heater element. 10.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description
DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating ,allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 1 HO2S 1 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified values?
Above 650 mV or below 250 mV
3 4
Inspect the fuse for the Bank 1 HO2S 1 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 1 HO2S 1 electrical connector. Using a test light connected to a good ground (do not use Bank 1 HO2S 1 heater ground or Bank 1 HO2S 1 low), probe the ignition feed circuit at the Bank 1 HO2S 1 electrical connector (PCM harness side). Go to Step 5 Go to Step 7
Does the test light illuminate? 5 Connect the test light between the Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1 heater ground. Does the test light illuminate?
Go to Step 6
Go to Step 8
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DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1 (Cont'd)

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure the resistance between the Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1 heater ground at the Bank 1 HO2S 1 pigtail. Is the HO2S heater resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10
Repair the open Bank 1 HO2S 1 ignition feed circuit to Bank 1 HO2S 1. Is the action complete? Verify repair Repair the open Bank 1 HO2S 1 heater ground circuit to Bank 1 HO2S 1. Is the action complete? Verify repair 1. Check for a poor connection at the Bank 1 HO2S 1 harness terminals. 2. If a poor connection is found, replace terminals. Was a poor connection found? Verify repair Go to Step 10 Check for a poor Bank 1 HO2S 1 high or low circuit terminal connection at the Bank 1 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 high circuit or HO2S low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 1 HO2S 1 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 1 HO2S 1 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace the Bank 1 HO2S 1. Is the action complete? Locate and repair the short to ground in Bank 1 HO2S 1 ignition feed circuit and replace the fault fuse. Is the action complete? Verify repair
10
11
12
13
14 15
6E176
D06RY00173
Circuit Description
The powertrain control module (PCM) supplies bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm impedance digital voltmeter, this may display as low as 350 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when the exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 2 signal voltage remains excessively low for an extended period of time, DTC P0137 will be set.
D Bank 1 HO2S 2 signal voltage remains below 400 mV during power enrichment mode fuel control operation for up to 5 seconds.

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.


D D D D No related DTCs. Engine is operating in closed loop. Engine coolant temperature is above 60C (140F). Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Throttle angle is between 3% and 19%. D Bank 1 HO2S 2 signal voltage remains below 22 mV during normal closed loop operation for a total of 106 seconds over a 125-second period of time. OR
Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be mispositioned and contacting the exhaust system. D Poor PCM to engine grounds. D Fuel pressure A condition which causes a lean exhaust can cause DTC P0137 to set. The system will go lean if pressure is too low. The PCM can

compensate for some decrease. However, if fuel pressure is too low, a DTC P0137 may be set. Refer to Fuel System Diagnosis. Lean injector(s) Perform Injector Balance Test. Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system. Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the DTC P0137 to set. Check for exhaust leaks near the Bank 1 HO2S 2 sensor. MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive
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D D D
alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for procedure to check for fuel contamination. D If none of the above conditions are present, replace the affected HO2S.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0137 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC0137 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Does the Bank 1 HO2S voltage remain below the specified value? 22 mV Go to Step 4
Go to Step 3
1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0137 until the DTC P0137 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0137 failed this ignition? Go to Step 4
1. Turn ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 1 HO2S 2 high and low signal circuits for a short to ground or a short to the heater ground circuit. Were Bank 1 HO2S 2 signal circuits shorted? Go to Step 5 Verify repair Go to Step 6 Repair the Bank 1 HO2S 2 signal circuit. Is the action complete? 1. Ignition OFF. 2. Leave the PCM and HO2S 2 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Go to Step 8
5 6
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7 8
Repair the short between the high and low circuits. Is the action complete? 1. Ignition OFF. 2. Reconnect the PCM, leave HO2S 2 disconnected. 3. Ignition ON. Does the Tech 2 indicate Bank 1 HO2S 2 voltage near the specified value? 425-475 mV Verify repair Check the Procedure Refer to Diagnostic Aids
Go to Step 9
6E179
D06RY00173
Circuit Description
The powertrain control module (PCM) supplies bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when the exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 2 voltage remains excessively high for an extended period of time, DTC P0138 will be set.
D Bank 1 HO2S 2 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.



D No related DTCs. D Engine is operating in closed loop. D Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Engine coolant temperature is above 60C (140F). D Throttle angle is between 3% and 19%. D Bank 1 HO2S 2 signal voltage remains above 952 mV during normal closed loop operation for a total of 106 seconds over a 125-second period of time. OR
Diagnostic Aids
Check for the following conditions: D Fuel pressure An excessively rich fuel mixture can cause a DTC P0138 to be set. Refer to Fuel System Diagnosis. D Rich injector(s) Perform Injector Balance Test. D Leaking injector Refer to Fuel System Diagnosis.
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D Open HO2S Signal Circuit of Faulty HO2S A poor connection or open in the HO2S signal circuit can cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal and wiring and associated terminal connections. D If none of the above conditions are present, replace the affected HO2S.
D Evaporative emissions (EVAP) canister purge Check for fuel saturation. If full of fuel, check the canister control and hoses. Refer to Evaporative Emission (EVAP) Control System. D MAF sensor The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the rich condition is corrected. If so, replace the MAF sensor. D Check for a leak in fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. D TP sensor An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. D Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0138 being set during deceleration fuel mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0138 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Does the Bank 1 HO2S voltage remain above the specified value?
952 mV (500 mV in deceleration fuel cutoff mode)
Go to Step 4
Go to Step 3
1. Ignition ON, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0138 until the DTC P0138 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0138 failed this ignition? Go to Step 4
1. 2. 3. 4.
Ignition OFF. Disconnect Bank 1 HO2S 1. Ignition ON. At the HO2S Bank 1 Sensor 2 connector (PCM side), use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Go to Step 6
Are the voltages above the specified range?
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5 6
Repair short to voltage in the signal circuit. Is the action complete? 1. Ignition ON, engineOFF. 2. At Bank 1 HO2S 2 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Is Bank 1 HO2S 2 voltage below the specified value? 10 mV Go to Step 7 Check the Procedure Refer to Diagnostic Aids Go to Step 8 1. Disconnect the jumpers to ground from Bank 1 HO2S 2 PCMside connector. 2. With the HO2S 2 connector disconnected, monitor BANK 1 HO2S 2 voltage. Is the Bank 1 HO2S 2 voltage between the specified values? 425-475 mV Verify repair
Go to Step 8
6E182
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2
D06RY00173
Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 1 HO2S 1 and the Bank 1 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 2 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If catalyst is operating efficiently, the Bank 1 HO2S 1 signal will be far more active than that produced by the Bank 1 HO2S 2 sensor. If the Bank 1 HO2S 2 signal voltage remains between 400 mV and 500 mV for an extended period of time, DTC P0140 will be set. Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to
maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

D D D D D D No related DTCs. Engine coolant temperature is above 60C (140F). The engine has been running for over 5 seconds. Oxygen sensor heater is functioning properly. Engine is operating in closed loop Bank 1 HO2S 2 signal voltage remains between 426 mV and 474 mV for a total of 106 seconds over a 125-second period of time.

Conditions for Cleaning the MIL/DTC

6E183
Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty HO2S heater or heater circuitWith the ignitionON, engine OFF, the HO2S voltage displayed on a Tech 2 should gradually drop to below 250 mV. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.
D Intermittent testWith the ignition ON, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.
Test Description
Number (s) below refer to the step number (s) on the Diagnostic Chart. 3. If the DTC P0140 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
DTC P0140 HO2S Circuit Insufficient Activity BANK 1 SENSOR 2

Go to Step 4
4 5
Check for a damaged harness. Was a problem found? Check for poor Bank 1 HO2S 2 high and low circuit terminal connections at the Bank 1 HO2S 2 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 6 Check for poor Bank 1 HO2S 2 high and low circuit terminal connections at the PCM and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 7 1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 2 high circuit. 3. If the Bank 1 HO2S 2 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 2 high circuit problem found and corrected? Verify repair Go to Step 8
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DTC P0140 HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 (Cont'd)

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 2 high circuit. 3. If the Bank 1 HO2S 2 low circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 2 low circuit problem found and corrected? Verify repair Go to Step 9
1. Ignition ON, engineOFF. 2. Disconnect Bank 1 HO2S 2 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Is Bank 1 HO2S 2 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 1 HO2S 2. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
6E185
D06RY00173
Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the Bank HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 1 HO2S 2 to become active, a DTC P0141 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the MAF sensor and into the engine (more total airflow = shorter time to HO2S activity).
D Ignition voltage is between 11 volts and 18 volts. D Bank 1 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.



D No related DTCs. D The engine has been running for over 120 seconds.
Diagnostic Aids
Check for the following conditions:
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2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. This ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. This checks the HO2S heater ground circuit. 6. This checks for an open or shorted HO2S heater element. 11.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.
D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 1 HO2S 2 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified values?
3 4
Inspect the fuse for Bank 1 HO2S 2 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 1 HO2S 2 electrical connector. Using a test light connected to a good ground (do not use Bank 1 HO2S 2 heater ground or Bank 1 HO2S 2 low), probe the ignition feed circuit at the Bank 1 HO2S 2 electrical connector (PCM harness side). Go to Step 5 Go to Step 7
Go to Step 6
Go to Step 8
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1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure the resistance between the Bank 1 HO2S 2 ignition feed and the Bank 1 HO2S 2 heater ground at the Bank 1 HO2S 2 pigtail. Is the HO2S resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10 Repair the open Bank 1 HO2S 2 ignition feed circuit to Bank 1 HO2S 2. Is the action complete? Verify repair Verify repair Repair the open Bank 1 HO2S 2 heater ground circuit. Is the action complete? 1. Check for a poor connection at the Bank 1 HO2S 2 harness terminals. 2. If a poor connection is found, replace the terminals. Was a poor connection found? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 2 signal circuit and the Bank 1 HO2S 2 low circuit. 3. If the Bank 1 HO2S 2 signal circuit or the HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 high circuit or the HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 1 HO2S 2 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 1 HO2S 2 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace Bank 1 HO2S 2. Is the action complete? Locate and repair the short to ground in Bank 1 HO2S 2 ignition feed circuit and replace the faulty fuse. Is the action complete? Verify repair
8 9
10
11
12
13
14 15
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D06RY00175
Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains excessively low for an extended period of time, DTC P0151 will be set.
D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.


D D D D No related DTCs. The engine is operating in closed loop. Engine coolant temperature is above 60C (140F). Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Bank 2 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90-second period of time.
Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be mispositioned and contacting the exhaust system. D Poor PCM to engine block grounds. D Fuel pressure The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, if fuel pressure is too low, a DTC P0151 may be set. Refer to Fuel System Diagnosis. D Lean injector(s) Perform Injector Balance Test. D Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system.


D Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. D MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. D Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination.
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D If none of the above conditions are present, replace the affected HO2S.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0151 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0151 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicate. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Does the Bank 2 HO2S 1 voltage remain below the specified value? 22 mV Go to Step 4
Go to Step 3
1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0151 until the DTC P0151 test runs. 4. Note test result. Does the Tech 2 indicate DTC P0151 failed this ignition? Go to Step 4
1. Turn ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 2 HO2S 1 high and low signal circuits for a short to ground or a short to the heater ground circuit. Were Bank 2 HO2S 1 signal circuits shorted? Go to Step 5 Verify repair Go to Step 6 Repair the Bank 2 HO2S 1 signal circuit. Is the action complete? 1. Ignition OFF. 2. Leave the PCM and HO2S 1 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Verify repair Go to Step 8 Repair the short between the high and low circuits. Is the action complete?
5 6
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1. Ignition OFF. 2. Reconnect the PCM, leave HO2S disconnected. 3. Ignition ON. Does the Tech 2 indicate Bank 2 HO2S 1 voltage near the specified value? 425-475 mV
Go to Step 9
6E191
D06RY00175
Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing the injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains excessively high for an extended period of time, DTC P0152 will be set.

D The PCM will ON the MIL after second trip with detected fault D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.


D No related DTCs. D The engine is operating in closed loop. D The engine coolant temperature is above 60C (140F). D Bank 2 HO2S 1 signal voltage remains above 952 mV during normal closed loop operation for a total of 77 seconds over a 90-second period. OR D Bank 2 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.
Diagnostic Aids
Check for the following conditions: D Fuel pressure The system will go rich if pressure is too high. The PCM can compensate for some increase. However, if fuel pressure is too high, a DTC P0152 may be set. Refer to Fuel System Diagnosis. D Rich injector(s) Perform Injector Balance Test. D Leaking injector Refer to Fuel System Diagnosis. D Evaporative emissions (EVAP) system Check the canister for fuel saturation. If the canister is full of fuel,
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cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage switch between the rich and lean thresholds can also cause the condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S is limited within a range between 300 mV to 600 mV, check the HO2S signal circuit wiring and associated terminal connections. D If none of the above conditions are present, replace the affected HO2S.
D D D
check EVAP control system components and hoses. Refer to Evaporative Emission (EVAP) Control System. MAF sensor The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if rich condition is corrected. If so, replace MAF sensor. Check for leaking fuel pressure regulator diaphragm by checking vacuum line to regulator for the presence of fuel. There should be no fuel in the vacuum line. TP sensor An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can cause a high HO2S voltage to be indicated. This condition is indicated by powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. Open HO2S Signal Circuit of Faulty HO2S A poor connection or open in the HO2S signal circuit can
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0152 failing during deceleration fuel cutoff mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0152 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Engine is at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Does the Bank 2 HO2S 1 voltage remain above the specified value?
952 mV (500 mV in deceleration fuel cut-off mode)
Go to Step 4
Go to Step 3
1. Ignition ON. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0152 until the DTC P0152 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0152 failed this ignition? Go to Step 4
1. 2. 3. 4.
Ignition OFF. Disconnect Bank 2 HO2S 1. Ignition ON. At HO2S Bank 2 Sensor 1 connector (PCM side) use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Go to Step 6
Are the voltages in the specified range?
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5 6
Repair short to voltage in signal circuit. Is the action complete? 1. Ignition ON, engineOFF. 2. At Bank 2 HO2S 1 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Is Bank 2 HO2S 1 voltage below the specified value? 10 mV Go to Step 7 Check the Procedure Refer to Diagnostic Aids Go to Step 8 1. Disconnect the jumpers to ground from Bank 2 HO2S 1 PCM-side connector. 2. With the HO2S 1 connector disconnected, monitor Bank 2 HO2S 1 voltage. Is the Bank 2 HO2S 1 voltage between the specified values? 425-475 mV Verify repair
Go to Step 8
6E194
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1
D06RY00175
Circuit Description
The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop has been enabled. During the monitoring period the PCM counts the number of times that a rich-to-lean and lean-to-rich response is indicated and adds the amount of time it took to complete all rich-to-lean transitions and lean-to-rich transitions. With this information, an average time for rich-to-lean and lean-to-rich transitions can be determined. If the average response time of either transition is too slow, a DTC P0153 will be set. A lean-to-rich transition is indicated when the HO2S voltage changes from less than 300 mV to greater than 600 mV. A rich-to-lean transition is indicated when the HO2S voltage changes from more than 600 mV to less than 300 mV. An HO2S that responds too slowly is likely to be faulty and should be replaced.
D Mass air flow is between 18 g/second and 42 g/second. D All above conditions are met for 3 seconds. D 90 seconds after closed loop has been enabled, Bank 2 HO2S 1 average transition time between 300 mV and 600 mV is too slow. The lean-to-rich average transition response time was longer than 94 milliseconds or the rich-to-lean average transition response time was longer than 105 milliseconds.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.


D No related DTCs. D Engine coolant temperature (ECT) is above 60C (140F). D The engine is operating in closed loop. D Engine has been running for over 60 seconds. D Canister purge duty cycle is above 2%. D Engine speed is between 1500 RPM and 3000 RPM.
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Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often
the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is currently present. 3. HO2S transition time, ratio mean volts and switching DTCs set for multiple sensors indicate probable contamination. Before replacing the sensors, isolate and correct the source of the contamination to avoid damaging the replacement sensors.
DTC P0153 HO2S Slow Response Bank 2 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If any DTCs are set, (except P0133, P1133, P1134, P1153, and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Install the Tech 2. 2. Idle the engine at operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor DTC info for DTC P0153 until the DTC P0153 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0153 failed this ignition? Go to Step 3 Go to Step 17 Go to Step 5 Go to Step 2
3 4 5 6
Did the Tech 2 also indicate DTC P0153, P1133, P1134, P1153, and/or P1154 test failed this ignition? Check for leaks at the pipe joints. Are the joints leaking? Tighten the U-bolt nuts at the leaking joint. Is your action complete? Check for gaskets that are damage or improperly installed. Are there damaged or misaligned gaskets?
Go to Step 7
Go to Step 8
1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete? Go to Step 2 Go to Step 9 Go to Step 2 Go to Step 11 Go to Step 10 Go to Step 12 Check for loose exhaust flange connections. Are the flange connections loose? Tighten the stud nuts or bolts to specifications. Is your action complete? Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?
8 9 10
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11 12 13
Replace the exhaust pipes, as required. Is your action complete? Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete? Go to Step 2 1. Visually/physically inspect the following items: D Ensure that the Bank 2 HO2S 1 is securely installed. D Check for corrosion on terminals. D Check terminal tension (at Bank 2 HO2S 1 and at the PCM). D Check for damaged wiring. Was a problem found in any of the above areas? Go to Step 18 Go to Step 15 1. Disconnect Bank 2 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Are both voltages in the specified range? 3-4 V Go to Step 16 Go to Step 19 1. With Bank 2 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition ON. 3. Using a Tech 2, monitor the Bank 2 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed? Go to Step 13 Go to Step 14 Go to Step 2
14
15
16
Go to Step 21
Go to Step 22
17
Replace the affected heated oxygen sensors. NOTE: Before replacing the sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination. Use of improper RV sealant. Engine oil/coolant consumption. Verify repair Verify repair Verify repair Verify repair Go to Step 20
Is the action complete? 18 19 20 Repair condition as necessary. Is the action complete? Check for faulty PCM connections or terminal damage. Is the action complete? Repair open, short or grounded signal circuit. Is the action complete?
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21 22
Replace Bank 2 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair
6E198
D06RY00175
Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) high and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains at or near the 450 mV bias for an extended period of time, DTC P0154 will be set, indicating an open sensor signal or sensor low circuit. Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.
D The engine has been running for over 5 seconds. D Oxygen sensor heater is functioning properly. D Bank 2 HO2S 1 signal voltage remains between 400 mV and 500 mV for a total of 77 seconds over a 90-second period of time.


Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals,

D No related DTCs. D Engine coolant temperature is above 60C (140F).

improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire-connection, and damaged harness. D Faulty HO2S heater or heater circuit With the ignition ON, engine OFF, the HO2S 1 voltage displayed on the Tech 2 is normally 455-460 mV. A reading over 1000 mV indicates a signal line shorted to voltage. A reading under 5 mV indicates a signal line shorted to ground or signal lines shorted together. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light for 2 seconds when the ignition is turned on, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S. D Intermittent test With the ignition ON, monitor the HO2S signal voltage while moving the wiring harness
6E199
and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0154 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Go to Step 4
1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data and note parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0154 until the DTC P0154 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0154 failed this ignition? Go to Step 4 Verify repair
4 5
Check for a damaged harness. Was a problem found? Check for a poor Bank 2 HO2S 1 high and low circuit terminal connections at the Bank 2 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 6 Check for a poor Bank 2 HO2S 1 high and low circuit terminal connections at the PCM and replace terminal(s) if necessary. Did the terminal require replacement? Verify repair Go to Step 7
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1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 1 high circuit. 3. If the Bank 2 HO2S 1 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 2 HO2S 1 high circuit problem found and corrected? Verify repair Go to Step 8
1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 1 low circuit. 3. If the Bank 2 HO2S 1 low circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 2 HO2S 1 low circuit problem found and corrected? Verify repair Go to Step 9
1. Ignition ON, engine OFF. 2. Disconnect Bank 2 HO2S 1 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Is the Bank 2 HO2S 1 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 2 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
6E201
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1
D06RY00175
Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the Bank HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 2 HO2S 1 to become active, a DTC P0155 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the mass air flow (MAF) sensor and into the engine (more total air flow = shorter time to HO2S activity).
D Ignition voltage is between 11 volts and 18 volts. D Heater signal is below 0.1A. D Bank 1 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV-500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0155 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0155 can be cleared by using the Tech 2 Clear info function or by disconnecting the PCM battery feed.

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2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. Ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. Checks the HO2S heater ground circuit. 6. Checks for an open or shorted HO2S heater element. 10.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description
DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 1 HO2S 1 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified value?
3 4
Inspect the fuse for the Bank 2 HO2S 1 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 2 HO2S 1 electrical connector. Using a test light connected to a known good ground (do not use Bank 2 HO2S 1 heater ground or Bank 2 HO2S 1 low), probe the ignition feed circuit at the Bank 2 HO2S 1 electrical connector (PCM harness side). Go to Step 5 Go to Step 7
Does the test light illuminate? 5 Connect the test light between Bank 2 HO2S 1 ignition feed and Bank 2 HO2S 1 heater ground. Does the test light illuminate?
Go to Step 6
Go to Step 8
6E203
DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1 (Cont'd)

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure resistance between the Bank 2 HO2S 1 ignition feed and the Bank 2 HO2S 1 heater ground at the Bank 2 HO2S 1 pigtail. Is the HO2S resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10 Repair the open Bank 2 HO2S 1 ignition feed circuit to Bank 2 HO2S 1. Is the action complete? Verify repair Verify repair Repair the open Bank 2 HO2S 1 heater ground circuit. Is the action complete? 1. Check for a poor connection at the Bank 2 HO2S 1 harness terminals. 2. If a poor connection is found, replace terminals. Was a poor connection found? Verify repair Go to Step 10 Check for a poor Bank 2 HO2S 1 signal or low circuit terminal connection at the Bank 2 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 1 signal circuit and the Bank 2 HO2S 1 low circuit. 3. If the Bank 2 HO2S 1 signal circuit or HO2S low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 2 HO2S 1 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 2 HO2S 1 signal circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace Bank 2 HO2S 1. Is the action complete? Locate and repair short to ground in Bank 2 HO2S 1 ignition feed circuit and replace the faulty fuse. Is the action complete? Verify repair
8 9
10
11
12
13
14 15
6E204
D06RY00177
Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains excessively low for an extended period of time, DTC P0157 will be set.
D Closed loop commanded air/fuel ratio is between 14.5 and 14.8 D Bank 2 HO2S 2 signal voltage remains below 22 mV during normal closed loop operation for a total of 106 seconds over a 125-second period of time. OR D Bank 2 HO2S 2 signal voltage remains below 400 mV during power enrichment mode fuel control operation for up to 5 seconds.



D No related DTCs. D The engine is operating in closed loop. D Engine coolant temperature is above 60C (140F).
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Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be mispositioned and contacting the exhaust system. D Poor PCM to engine grounds. D Fuel pressure A condition which causes a lean exhaust can cause DTC P0157 to set. The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, if fuel pressure is too low, a DTC P0157 may be set. Refer to Fuel System Diagnosis. D Lean injector(s) Perform Injector Balance Test. D Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system. D Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the DTC P0157 to set. Check for exhaust leaks near the Bank 1 HO2S 2 sensor. D MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow
measurement that is not correct. Disconnect the MAF sensor to see if the condition is corrected. If so, replace the MAF sensor. D Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination. D If none of above conditions are present, replace the affected HO2S 2.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0157 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0157 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated.

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Does the Bank 2 HO2S 2 voltage remain below the specified value? 22 mV Go to Step 4
Go to Step 3
1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data and note parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0157 until the DTC P0157 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0157 failed this ignition? Go to Step 4
1. Turn the ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 2 HO2S 2 high and low signal circuits for a short to ground or a short to the heater ground circuit. Were Bank 2 HO2S 2 signal circuits shorted? Go to Step 5 Verify repair Go to Step 6 Repair the Bank 1 HO2S 2 signal circuit. Is the action complete?
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1. Ignition OFF. 2. Leave the PCM and HO2S 2 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Verify repair Check the Procedure Refer to Diagnostic Aids Go to Step 8 Repair the short between the high and low circuits. Is the action complete? 1. Ignition OFF. 2. Reconnect the PCM, leave HO2S 2 disconnected. 3. Ignition ON. Does the Tech 2 indicate Bank 2 HO2S 2 voltage near the specified value? 425-475 mV
7 8
Go to Step 9
Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6E207
D06RY00177
Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains excessively high for an extended period of time, DTC P0158 will be set.
D Engine coolant temperature is above 60C (140F). D Bank 2 HO2S 2 signal voltage remains above 952 mV during normal closed loop operation for a total of 106 seconds over a 125-second period. OR D Bank 2 HO2S 2 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.



D No related DTCs. D Engine is operating in closed loop. D Closed loop commanded air/fuel ratio is between 14.5 and 14.8.
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indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. D Open HO2S signal or low circuit, or faulty HO2S A poor connection or open in the HO2S signal or low circuit can cause the DTC to set during deceleration fuel cutoff mode operation. An HO2S which is faulty and does not allow full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal and low circuit wiring and associated terminal connections. If the wiring and connections are OK, replace the HO2S. D If none of above conditions are present, replace the affected HO2S.
Diagnostic Aids
Check for the following conditions: D Fuel pressure An excessively rich fuel mixture can cause a DTC P0158 to be set. Refer to Fuel System Diagnosis. D Rich injector(s) Perform Injector Balance Test. D Leaking injector Refer to Fuel System Diagnosis. D Evaporative emissions (EVAP) canister purge Check for fuel saturation. If full of fuel, check canister control and hoses. Refer to Evaporative Emission (EVAP) Control System. D MAF sensor The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if a rich condition is corrected. If so, replace the MAF sensor. D Check for a leaking fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. D TP sensor An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. D Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0158 being set during deceleration fuel cutoff mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0158 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Does the Bank 2 HO2S 2 voltage remain above the specified value?
952 mV (500 mV in deceleration fuel cut-out mode)
Go to Step 4
Go to Step 3
1. Ignition ON. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0158 until the DTC P0158 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0158 failed this ignition? Go to Step 4
6E209

1. 2. 3. 4.
Ignition OFF. Disconnect Bank 2 HO2S 2. Ignition ON. At the HO2S Bank 2 Sensor 2 connector (PCM side), use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Verify repair Go to Step 6
Are the voltages in the specified range? 5 6 Repair short to voltage in signal circuit. Is the action complete? 1. Ignition ON, engine OFF. 2. At Bank 2 HO2S 2 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage below the specified value? 7 1. Disconnect the jumpers to ground from Bank 2 HO2S 2 PCM-side connector. 2. With the HO2S 2 connector disconnected, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage between the specified values? 8 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
10 mV
Go to Step 7 Check the Procedure Refer to Diagnostic Aids
Go to Step 8
425-475 mV
Go to Step 8
Verify repair
6E210
D06RY00177
Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains between 400 mV and 500 mV for an extended period of time, DTC P0160 will be set. Heated Oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank
2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

D D D D D D No related DTCs. Battery voltage is above 10 volts. The engine has been running for over 5 seconds. Oxygen sensor heater is functioning properly. Engine is in closed loop operation. Bank 2 HO2S 2 signal voltage remains between 426 mV and 474 mV for a total of 106 seconds over a 125-second period of time.


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0160 will clear after 40 consecutive warm-up cycles have occurred without a fault.

D DTC P0160 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
6E211
Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty HO2S heater or heater circuit With the ignition ON, engine OFF, the HO2S voltage displayed on a Tech 2 should gradually drop to below 250 mV. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.
D Intermittent test With the ignition ON, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0160 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Go to Step 4
4 5
Check for a damaged harness. Was problem found? Check for poor Bank 2 HO2S 2 high and low circuit terminal connections at the Bank 2 HO2S 2 harness connector and replace terminal(s) if necessary. Did either terminal require replacement? Verify repair Go to Step 6 Check for poor Bank 2 HO2S 2 high and low circuit terminal connections at the PCM and replace terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 7
6E212

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 2 high circuit. 3. If the Bank 2 HO2S 2 high circuit measures over 5.0 ohms, repair open or poor connections as necessary. Was a Bank 2 HO2S 2 high circuit problem found and corrected? Verify repair Go to Step 8
1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 low circuit measures over 5 ohms, repair open or poor connections as necessary. Was a Bank 2 HO2S 2 low circuit problem found and corrected? Verify repair Go to Step 9
1. Ignition ON, engine OFF. 2. Disconnect Bank 2 HO2S 2 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 2 HO2S 2. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
6E213
D06RY00177
Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started, the PCM will monitor the HO2S voltage. When the Bank 2 HO2S 2 voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 2 HO2S 2 to become active, a DTC P0161 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the MAF sensor and into the engine (more total air flow = shorter time to HO2S activity).
D Ignition voltage is between 11 volts and 18 volts. D Average mass air flow for the sample period is less than 23 g/second. D Bank 2 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV-500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.



6E214

2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. This ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. This checks the HO2S heater ground circuit. 6. This checks for an open or shorted HO2S heater element. 11.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.
Diagnostic Aids
Test Description

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 2 HO2S 2 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified values?
Above 650 mV or Below 250 mV
3 4
Inspect the fuse for the Bank 2 HO2S 2 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 2 HO2S 2 electrical connector. Using a test light connected to a known good ground (do not use Bank 2 HO2S 2 heater ground or Bank 2 HO2S 2 low), probe the ignition feed circuit at the Bank 2 HO2S 2 electrical connector (PCM harness side). Go to Step 5 Go to Step 7
Go to Step 6
Go to Step 8
6E215

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure resistance between the Bank 2 HO2S 2 ignition feed and the Bank 2 HO2S 2 heater ground at the Bank 2 HO2S 2 pigtail. Is the HO2S resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10 Repair the open Bank 2 HO2S 2 ignition feed circuit to Bank 2 HO2S 2. Is the action complete? Verify repair Verify repair Repair the open Bank 2 HO2S 2 heater ground circuit. Is the action complete? 1. Check for a poor connection at the Bank 2 HO2S 2 harness terminals. 2. If a poor connection is found, replace the terminals. Was a poor connection found? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 2 signal circuit and the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 signal circuit or HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 2 signal circuit and the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 signal circuit or HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 2 HO2S 2 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 2 HO2S 2 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace Bank 2 HO2S 2. Is the action complete? Locate and repair the short to ground in the Bank 2 HO2S 2 ignition feed circuit and replace the faulty fuse. Is the action complete? Verify repair
8 9
10
11
12
13
14 15
6E216
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1
D06R200010
Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively lean condition is detected on Bank 1, the PCM will set DTC P0171. The PCMs maximum authority to control long term fuel trim allows a range between 15% (automatic transmission) or 12% (manual transmission) and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.
D Engine coolant temperature is between 6C (42.8F) and 105C (221F). D Intake air temperature is between 40C (40F) and 120C (248F). D Manifold absolute pressure is between 24 kPa and 99 kPa. D Throttle angle is steady below 95%. D Vehicle speed is below 136 km/h (85 mph). D Engine speed is between 400 and 6,000 RPM. D Barometric pressure is greater than 72.5 kPa. D Mass air flow is between 2 g/second and 200 g/second. D Ignition voltage is above 9.5 volts. D Fuel system is in closed loop. D Canister purge duty cycle is greater than 0% if on.


D None of the following: EGR DTCs, HO2S DTCs, (response, transition, open, low volts, no activity), MAF DTCs, TP sensor DTCs, MAP DTCs, IAT DTCs, canister purge DTCs, EVAP DTCs, injector circuit DTCs, or misfire DTCs.


6E217
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0171 and P0174 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0171/P0174. 4. If the DTC P0171 test passes while the Failure Records conditions are being duplicated, the lean condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.
6E218
DTC P0171 Fuel Trim System Lean Bank 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart Are any DTCs set other than P0171 and P0174?
3 1. Start the engine and operate the vehicle in closed loop. 2. Observe the BANK 1 L.T. FUEL TRIM display on the Tech 2. Is the displayed value greater than the specified value? 4 1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0171/P0174 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0171 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0171 test runs and note the test result. Does the Tech 2 indicate DTC P0171 failed this ignition? 5 6 Was DTC P0174 also set? Visually and physically inspect the vacuum hoses for disconnections, splits, kinks, improper routing and improper connections and repair any problem found. Did your inspection reveal a problem requiring repair? 7 Visually and physically inspect the crankcase ventilation valve for proper installation and repair any problem found (refer to Crankcase Ventilation System). Did your inspection reveal a problem requiring repair? 8 1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block the air flow sample through the MAF sensor. 2. Correct any problem that is found as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair? 9 10 Start the engine and note the idle quality. Is a high or unsteady idle being experienced? 1. Visually and physically inspect the throttle body, intake manifold, EGR valve and the EGR feed pipe for vacuum leaks. 2. Repair any vacuum leaks as necessary. Did your inspection reveal a vacuum leak?
Go to Step 3
L.T. Fuel Trim: +20%
Go to Step 5
Go to Step 4
The lean condition is not present. If a driveability symptom still exists, refer to Symptoms section. Go to Step 15
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 9 Go to Step11
Verify repair
Go to Step 11
6E219
DTC P0171 Fuel Trim System Lean Bank 1 (Cont'd)

11
Check the fuel for excessive water, alcohol, or other contaminants (see Diagnosis in Engine Fuel for the procedure) and correct the contaminated fuel condition if present (see Engine Fuel). Was the fuel contaminated? Verify repair Go to Step 12 1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight, and in their proper locations. 2. If a faulty ground condition is present, correct it as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 13 1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 1 S.T. FUEL TRIM displayed on the Tech 2. Does BANK 1 S.T. FUEL TRIM value decrease to near the specified value? 0% Go to Step 19 Go to Step 14
12
13
14
Perform the procedure in the Fuel System Pressure Test and repair fuel system problem if necessary. Did Fuel System Pressure Test isolate a condition requiring repair? Verify repair Go to Step 15
15
1. Visually and physically inspect the intake manifold, injector O-rings, EGR adapter, EGR valve and the EGR feed pipes for vacuum leaks. 2. Repair any problem that is found. Did your inspection reveal a problem? Verify repair Go to Step 16 Visually and physically inspect the Bank 1 exhaust manifold for leaks and loose or missing hardware and correct any problem found. Did your inspection reveal a problem? Verify repair Go to Step 17 Perform the Injector Balance Test, and correct any problem found (refer to Fuel Metering System). Did Injector Balance Test isolate a problem? Verify repair Go to Step 18 Check the Procedure Refer to Diagnostic Aids 1. Visually and physically inspect the Bank 1 HO2S 1 to ensure that it is installed securely and that the Bank 1 HO2S 1 pigtail and wiring harness are not contacting the exhaust or otherwise damaged. 2. If a problem is found, correct it as necessary. Did your inspection reveal a problem? Verify repair Verify repair Replace the MAF sensor. Is the action complete?
16
17
18
19
6E220
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1
D06R200010
Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 heated oxygen sensors (HO2S) 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively rich condition is detected on Bank 1, the PCM will set DTC P0172. The PCMs maximum authority to control long term fuel trim allows a range between 15% (automatic transmission) or 12 (manual transmission) and +20%. The PCMs maximum authority to control short term fuel trim allows a range between 11% and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic. D D D D D D D D D D D
DTCs, canister purge DTCs, EVAP DTCs, injector circuit DTCs, or misfire DTCs. Engine coolant temperature is between 6C (42.8F) and 105C (221F). Intake air temperature is between 40C (40F) and 120C (248F). Manifold absolute pressure is between 24 kPa and 99 kPa. Throttle angle is steady below 95%. Vehicle speed is below 136 km/h (85 mph). Engine speed is between 400 and 6,000 RPM. Barometric pressure is greater than 72.5 kPa. Mass air flow is between 2 g/second and 200 g/second. Ignition voltage is above 9.5 volts. Fuel system is in closed loop. Canister purge duty cycle is greater than 0%, if ON.


D None of the following was set: EGR DTCs, HO2S DTCs, (response, transition, open, low volts, no activity), MAF DTCs, TPS DTCs, MAP DTCs, IAT

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

D A history DTC P0172 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0172 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
6E221
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0172 and P0175 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0172/P0175. 4. If the DTC P0172 test passes while the Failure Records conditions are being duplicated, the rich condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often
DTC P0172 Fuel Trim System Rich Bank 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart Are any DTCs set other than P0172 and P0175?
3 1. Start the engine and operate the vehicle in closed loop. 2. Observe B1 Long Term Fuel Trim display on the Tech 2. Is the displayed value more negative than the specified value? 4 1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0172/P0175 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0172 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0172 test runs and note test result. Does the Tech 2 indicate DTC P0172 failed this ignition? 5 6 Is DTC P0175 also set? Visually and physically inspect the air filter element and replace it if necessary. Did the air filter require replacement? 7 Visually and physically inspect the air intake duct for collapse or restriction and repair if necessary. Did your inspection reveal a condition requiring repair? L.T. Fuel Trim: 15% (auto. trans.) OR 12% (man. trans.)
Go to Step 3
Go to Step 5
Go to Step 4
The rich condition is not present. If a driveability symptom still exists, refer to Symptoms. Go to Step 15
Verify repair
Go to Step 7
Verify repair
Go to Step 8
6E222
DTC P0172 Fuel Trim System Rich Bank 1 (Cont'd)

Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block air flow through the screen and correct any problem found. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement? Verify repair Go to Step 10 Go to Step 9 Go to Step 11
9 10
Start the engine and note the idle quality. Is a low or unsteady idle being experienced? 1. Ignition OFF. 2. Physically inspect the throttle body bore and throttle plate for coking and foreign objects. 3. If a problem was found, repair as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 11 1. Disconnect the vacuum hose from the fuel pressure regulator and inspect the hose for the presence of fuel. 2. If fuel is present in the vacuum hose, replace the fuel pressure regulator (refer to Fuel Metering System). Did the fuel pressure regulator require replacement? Verify repair Go to Step 12 Ignition ON, engine OFF, monitor the TP1 Angle display on the Tech 2 while slowly depressing the accelerator pedal. Does the TP Angle display increase steadily and evenly from minimum value at closed throttle to maximum value at wide-open throttle? Minimum 8% Maximum 92%
11
12
Go to Step 13
Go to Step 21
13
1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 1 L.T. FUEL TRIM and BANK 1 S. T. FUEL TRIM display on the Tech 2. Did both values change to near the specified value? 0% Go to Step 22 Go to Step 14 1. Perform Fuel System Pressure Test. 2. If Fuel System Pressure Test isolates a problem, repair as necessary (refer to Engine Fuel or Fuel Metering System). Did the Fuel System Pressure Test isolate a problem requiring repair? Verify repair Go to Step 15
14
15
1. Ignition ON, engine OFF. 2. Connect a test light between the harness connector terminals of canister purge solenoid. Is the test light on? Go to Step 16 Go to Step 19 Check for short to ground in the wire (YEL/RED) between the canister purge solenoid and PCM terminal S-48. Was there a short to ground? Go to Step 17 Verify repair Go to Step 18 Repair the short to ground. Is the action complete?
16
17
6E223

18
Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
19
1. Perform the Injector Balance Test. 2. If Injector Balance Test isolates a problem, repair as necessary (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem requiring repair? Verify repair Go to Step 20
20
1. Remove and visually/physically inspect the Bank 1 HO2S 1 for silicon contamination. This will be indicated by a powdery deposit on the portion of the HO2S that is exposed to the exhaust stream. 2. If contamination is evident on the Bank 1 HO2S 1, replace the contaminated sensors. Did the sensor require replacement? Verify repair 1. Check the TP sensor mounting screws and tighten or replace them as necessary if they are loose or missing. 2. If the screws are OK, replace the TP sensor. Is the action complete? Verify repair Verify repair
21
22
Replace the MAF sensor. Is the action complete?
6E224
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2
D06R200010
Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively lean condition is detected on Bank 2, the PCM will set DTC P0174. The PCMs maximum authority to control long term fuel trim allows a range between 15%(automatic transmission) or 12%(manual transmission) and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.
D Intake air temperature is between 40C (40F) and 120C (248F). D Manifold absolute pressure is between 24 kPa and 99 kPa. D Throttle angle is steady between 3 and 95%. D Vehicle speed is below 136 km/h (85 mph). D Engine speed is between 400 and 6,000 RPM. D Barometric pressure is greater than 72.5 kPa. D Mass air flow is between 2 g/second and 200 g/second. D Ignition voltage is above 9.5 volts. D Fuel system is in closed loop. D Canister purge duty cycle is greater than 0%, if ON.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the failure is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.


D None of the following DTCs are set: idle system, EGR, HO2S, (response, transition, open, low volts, no activity), MAF, TP sensor, MAP, IAT, canister purge, EVAP, injector circuit, or misfire. D Engine coolant temperature is between 6C (42.8F) and 105C (221F).
6E225
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0171 and P0174 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0171/P0174. 4. If the DTC P0174 test passes while the Failure Records conditions are being duplicated, the lean condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.
6E226
DTC P0174 Fuel Trim System Lean Bank 2

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart. Are any DTCs set other than P0174 and P0171?
3 1. Start the engine and operate the vehicle in closed loop. 2. Observe the BANK 2 L.T. FUEL TRIM display on the Tech 2. Is the displayed values greater than the specified values? 4 1. Review and record Tech 2 Failure Records data. 2. Clear the DTC P0171/P0174 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0174 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0174 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0174 failed this ignition? 5 6 Was DTC P0171 also set? Visually and physically inspect the vacuum hoses for disconnections, splits, kinks, improper routing and improper connections and repair any problem found. Did your inspection reveal a problem requiring repair? 7 Visually and physically inspect the crankcase ventilation valve for proper installation and repair any problem found (refer to Crankcase Ventilation System). Did your inspection reveal a problem requiring repair? 8 1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block the air flow sample through the MAF sensor. 2. Correct any problem that is found as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair? 9 Start the engine and note the idle quality. Is a high or unsteady idle being experienced? L.T. Fuel Trim: +20%
Go to Step 3
Go to Step 5
Go to Step 4
The lean condition is not present. If a driveability symptom still exists, refer to Symptoms section. Go to Step 15
Verify repair
Go to Step 7
Verify repair
Go to Step 8
6E227
DTC P0174 Fuel Trim System Lean Bank 2 (Cont'd)

10
1. Visually and physically inspect the throttle body, intake manifold, EGR valve and the EGR feed pipe for vacuum leaks. 2. Repair any vacuum leaks as necessary. Did your inspection reveal a vacuum leak? Verify repair Go to Step 11 Check the fuel for excessive water, alcohol, or other contaminants (see Diagnosis in Engine Fuel for procedure) and correct the contaminated fuel condition is present (see Engine Fuel). Was the fuel contaminated? Verify repair Go to Step 12 1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight, and in their proper locations. 2. If a faulty ground condition is present, correct it as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 13 1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 2 S.T. FUEL TRIM displayed on the Tech 2. Does the BANK 2 S.T. FUEL TRIM value decrease to near the specified value? 0% Go to Step 19 Go to Step 14
11
12
13
14
Perform the procedure in the Fuel System Pressure Test and repair fuel system problem if necessary. Did the Fuel System Pressure Test isolate a condition requiring repair? Verify repair Go to Step 15
15
1. Visually and physically inspect the intake manifold, injector O-rings, EGR adapter, EGR valve and the EGR feed pipes for vacuum leaks. 2. Repair any problem that is found. Did your inspection reveal a problem? Verify repair Go to Step 16 Visually and physically inspect the Bank 2 exhaust manifold for leaks and loose or missing hardware and correct any problem found. Did your inspection reveal a problem? Verify repair Go to Step 17 Perform the Injector Balance Test and correct any problem found (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem? Verify repair Go to Step 18 Check the Procedure Refer to Diagnostic Aids 1. Visually and physically inspect the Bank 2 HO2S 1 to ensure that it is installed securely and that the Bank 2 HO2S 1 pigtail and wiring harness are not contacting the exhaust or otherwise damaged. 2. If a problem is found, correct it as necessary. Did your inspection reveal a problem? Verify repair Verify repair Replace the MAF sensor. Is the action complete?
16
17
18
19
6E228
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2
D06R200010
Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively rich condition is detected on Bank 2, the PCM will set DTC P0175. The PCMs maximum authority to control long term fuel trim allows a range between 15%(automatic transmission) or 12%(manual transmission) and +20%. The PCMs maximum authority to control short term fuel trim allows a range between 11% and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic. D D D D D D D D D D
activity), MAF, TPS, MAP, IAT, canister purge, EVAP, injector circuit, or misfire. Engine coolant temperature is between 6C (42.8F) and 105C (221F). Intake air temperature is between 40C (40F) and 120C (248F). Manifold absolute pressure is between 24 kPa and 99 kPa. Throttle angle is steady between 3 and 95%. Vehicle speed is below 136 km/h (85 mph). Engine speed is between 400 and 6,000 RPM. Barometric pressure is greater than 72.5 kPa. Mass air flow is between 2 g/second and 200 g/second. Ignition voltage is above 9.5 volts. Fuel system is in closed loop.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the failure is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

D None of the following DTCs are set: idle system, EGR, HO2S, (response, transition, open, low volts, no


6E229
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0172 and P0175 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0172/P0175. 4. If the DTC P0175 test passes while the Failure Records conditions are being duplicated, the rich condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed -out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records Vehicle mileage since the diagnostic test last failed may help determine how often
DTC P0175 Fuel Trim System Rich Bank 2

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart. Are any DTCs set other than P0172 and P0175?
3 1. Start the engine and operate the vehicle in closed loop. 2. Observe the BANK 2 L.T. FUEL TRIM display on the Tech 2. Is the displayed value more negative than the specified value? 4 1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0172/P0175 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0175 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0175 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0175 failed this ignition? 5 6 Was DTC P0172 also set? Visually and physically inspect the air filter element and replace it if necessary. Did the air filter require replacement? L.T. Fuel Trim: 15% (auto. trans.) OR 12% (man. trans.)
Go to Step 3
Go to Step 5
Go to Step 4
The rich condition is not present. If a driveability symptom still exists, refer to Symptoms. Go to Step 15
Verify repair
Go to Step 7
6E230

Visually and physically inspect the air intake duct for collapse or restriction and repair if necessary. Did your inspection reveal a problem requiring repair? Verify repair Go to Step 8 Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block air flow through the screen and correct any problem found. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement? Verify repair Go to Step 10 Go to Step 9 Go to Step 11
9 10
Start the engine and note the idle quality. Is a low or unsteady idle being experienced? 1. Turn the ignition off and physically inspect the throttle body bore, throttle plate, and IAC passages for coking and foreign objects. 2. If a problem was found, repair as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 11 1. Disconnect the vacuum hose from the fuel pressure regulator and inspect the hose for the presence of fuel. 2. If fuel is present in the vacuum hose, replace the fuel pressure regulator (refer to Fuel Metering System). Did the fuel pressure regulator require replacement? Verify repair Go to Step 12 1. Ignition ON, engine OFF. 2. Monitor the TP Angle display on the Tech 2 while slowly depressing the accelerator pedal. Does the TP Angle display increase steadily and evenly from minimum value at closed throttle to maximum value at wide-open throttle? Minimum 8% Maximum 92%
11
12
Go to Step 13
Go to Step 21
13
1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 2 L.T. FUEL TRIM and BANK 2 S.T. FUEL TRIM display on the Tech 2. Did both values change to near the specified value? 0% Go to Step 22 Go to Step 14 1. Perform the Fuel System Pressure Test. 2. If Fuel System Pressure Test isolates a problem, repair as necessary (refer to Engine Fuel or Fuel Metering System). Did the Fuel System Pressure Test isolate a condition requiring repair? Verify repair Go to Step 15
14
15
1. Ignition ON, engine OFF. 2. Connect a test light between the harness connector terminals of canister purge solenoid. Is the test light on? Go to Step 16 Go to Step 19 Check for short to ground in the wire (YEL/RED) between the canister purge solenoid and PCM terminal S-48. Was there a short to ground? Go to Step 17 Go to Step 18
16
6E231

17 18
Repair the short to ground. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair
19
1. Perform the Injector Balance Test. 2. If the Injector Balance Test isolates a problem, repair as necessary (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem requiring repair? Verify repair Go to Step 20
20
1. Remove and visually/physically inspect the Bank 2 HO2S 1 for silicon contamination. This will be indicated by a powdery deposit on the portion of the HO2S that is exposed to the exhaust stream. 2. If contamination is evident on the Bank 2 HO2S 1, replace the contaminated sensor. Did the sensor require replacement? Verify repair 1. Check the TP sensor mounting screws and tighten or replace them as necessary if they are loose or missing. 2. If the screws are OK, replace the TP sensor. Is the action complete? Verify repair Verify repair
21
22
Replace the MAF sensor. Is the action complete?
6E232
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit
D06R200014
Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When a driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

D The PCM will turn OFF the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. D A history DTC P0201 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0201 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a DTC P0201 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.
6E233
Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0201 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 1 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.
R321054
7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9. The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.
DTC P0201 Injector 1 Control Circuit

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Will the engine start? Go to Step 3
Go to OBD System Check Go to Engine Cranks But Will Not Run chart
1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0201 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0201 reset? Go to Step 5 1. Engine OFF. 2. Disconnect the injector connector. 3. Install an injector test light J-39021-65 on the injector test connector. 4. Crank the engine and note the light. Does the injector test light blink?
Check the Procedure Go to Diagnostic Aids
Go to Fuel Injector Coil Test Procedure
Go to Step 6
6E234
DTC P0201 Injector 1 Control Circuit (Cont'd)

Note whether the injector test light for cylinder 1 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine? Go to Step 7 Go to Step 9
1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate? Go to Step 8 Go to OBD System Check Go to Step 15 Repair short to ground in the injector driver circuit. Is the action complete?
1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 1 (green with white tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/white wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
12 13
14 15
6E235
D06R200014
Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When a driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

Diagnostic Aids


6E236
Test Description
R321055
7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9.The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0202 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0202 reset? Go to Step 5 1. Engine OFF. 2. Disconnect the injector test connector. 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 2 test light blink?
Go to Step 6
6E237

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 2 (green with orange tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/orange wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
12 13
14 15
6E238
D06R200014
Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.


D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by the 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.
Diagnostic Aids

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected.
Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart.

3. This step determines if DTC P0203 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 3 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.
6E239
R321056

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0203 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0203 reset? Go to Step 5
6E240

1. Engine OFF. 2. Disconnect the injector test connector . 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 3 test light blink? Note whether the injector test light for cylinder 3 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine?
Go to Step 6
Go to Step 7
Go to Step 9
1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 3 (green). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
12 13
14 15
6E241
D06R200014
Circuit Description

Diagnostic Aids


6E242
Test Description
R321057

Go to Step 6
6E243

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 4 (green/red). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/red wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
12 13
14 15
6E244
D06R200014
Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.


Diagnostic Aids

6E245
Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0205 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold.The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 5 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.
R321058

Go to Step 6
6E246

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 5 (green with black tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/black wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
12 13
14 15
6E247
D06R200014
Circuit Description

Diagnostic Aids


6E248
Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0206 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold.The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 6 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.
R321059

Go to Step 6
6E249

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 6 (green with yellow tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector Is the action complete? At the PCM side of the injector test connector, check the green/yellow wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10 11
12 13
14 15
6E250
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected

Circuit Description
Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ION Sensing Module. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0300 will determine if a multiple cylinder misfire is occurring by monitoring the Combustion Quality. D Damaged or faulty ignition coil Check for cracks or other damage. D Substitute a known good coil Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: D System grounds Ensure all connections are clean and properly tightened. D MAF A mass air flow (MAF) sensor output that causes the PCM to sense a lower than normal air flow will cause a lean condition. D Air induction system Air leaks into the induction system which bypass the MAF sensor will cause a lean condition. Check for disconnected or damaged vacuum hoses, incorrectly installed or faulty PCV valve, or for vacuum leaks at the throttle body, EGR valve, and intake manifold mounting surfaces. D Fuel pressure Perform a fuel system pressure test. A faulty fuel pump, plugged filter, or faulty fuel system pressure regulator will contribute to a lean condition. D Injector(s) Perform an injector coil/balance test to locate faulty injector(s) contributing to a lean or flooding condition. In addition to the above test, check the condition of the injector O-rings. D EGR Check for a leaking valve, adapter, or feed pipes which will contribute to a lean condition or excessive EGR flow. D Fuel quality Using fuel with the wrong octane rating for the vehicle may cause driveability problems. Although alcohol-enhanced fuels may raise the octane rating, the fuels ability to turn into vapor in cold temperatures deteriorates. This may affect the cold driveability of the engine. The Reid Vapor Pressure of the fuel can also create problems in the fuel system, especially during the spring and fall when changes by the refineries may not coincide with changes in the weather. D Vehicle marshalling The transportation of new vehicles from the assembly plant to the dealership can involve as many as 60 key cycles within 2 to 3 miles of driving. This type of operation contributes to the fuel fouling of the spark plugs and will turn on the MIL with a P0300 Misfire DTC. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D None of the following DTCs occur: TP sensor, MAF sensor, VSS, ECT sensor. D The engine speed is between 600 and 6250 RPM. D The system voltage is between 11 and 16 volts. D The engine temperature sensor (ECT) indicates an engine temperature between 7C (20F) and 110C (230F). D Throttle angle is steady and throttle changes less than 2% per 125 milliseconds.

D The PCM will ON the MIL after second trip with detected the fault. D If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. D The PCM will disable the TCC operation. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0300 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0300 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
The Tech 2 display Misfire Cur. #1 through #6 can be useful to determine whether the misfire is isolated to a single cylinder.
6E251
DTC P0300 Engine Misfire Detected

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Start the engine. Run the engine at idle. 2. Review and record the Tech 2 Freeze Frame data. 3. Operate the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data). 4. Monitor the Tech 2 Misfire Cur. # display for each cylinder. Is Misfire Cur. # display increasing for any cylinder (indicating a misfire currently occurring)? Go to Step 3
1. Visually and physically inspect the vacuum hoses for splits, kinks, and improper connections. 2. If a problem is found, repair or replace the vacuum hoses as necessary. Did your inspection reveal a problem? Verify repair Go to Step 4 1. Visually and physically inspect the following areas for vacuum leaks: D The intake manifold D The injector O-rings D The EGR adapter D The EGR feed pipes D ION Sensing Module 2. If a problem is found, repair the vacuum leak as necessary. Did your inspection reveal a vacuum leak? Verify repair Go to Step 5 1. Visually and physically inspect the crankcase ventilation valve for improper installation or damaged grommet. 2. If a problem is found, repair as necessary (refer to Crankcase Ventilation System). Did your inspection reveal a problem? Verify repair Go to Step 6 1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects that may partially block the air flow sample through the MAF sensor. 2. If a problem is found, repair or replace the MAF sensor as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement? Verify repair Go to Step 7
1. Remove the EGR valve and visually/physically inspect the valve to ensure that the pintle is not sticking partially open. Also, inspect the EGR valve pintle and seat for carbon deposits or burrs that may interfere with the pintle closing completely. 2. If a problem is found, clean the EGR valve pintle and seat or replace the EGR valve as necessary. Did your inspection reveal a problem? Verify repair Go to Step 8
6E252
DTC P0300 Engine Misfire Detected (Cont'd)

1. Install a spark tester at the spark plug end of the ignition coil for a cylinder that indicated a misfire. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present? Go to Step 14 Go to Step 9 1. Remove and visually/physically inspect the ignition coil(s) associated with the cylinders that were indicated as misfiring. Ensure that the coil(s) are free of cracks. 2. If a problem is found, replace the damaged ignition coil(s) as necessary. Did any ignition coils require replacement? Verify repair Go to Step 10 1. Remove the spark plugs from the cylinders that were indicated as misfiring. 2. Visually inspect the spark plug electrodes. Does your inspection reveal any spark plugs exhibiting excessive fouling?
10
Go to Engine Mechanical Diagnosis
Go to Step 11
11
1. Visually inspect the spark plug insulators for cracks, carbon tracking, or other damage. 2. If a problem is found, replace the faulty spark plug(s) as necessary. Did your inspection reveal a problem? Verify repair Go to Step 12 1. Disconnect the MAF sensor electrical connector. BANK 1 L.T. 2. Operate the vehicle in closed loop while FUEL TRIM monitoring the BANK 1 L.T. FUEL TRIM and below +20%; BANK 1 S.T. FUEL TRIM display on the Tech 2. BANK 1 S.T. Do both values decrease below the specified values? FUEL TRIM below +50% Replace the ignition coil control module. Is the action complete? Verify repair 1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight and in their proper locations. 2. If a problem is found, correct the faulty ground condition as necessary. Did your inspection reveal a poor ground? Verify repair Go to Step 15 1. Perform the Fuel System Pressure Test procedure. 2. If a problem is found, repair as necessary (refer to Engine Fuel or Fuel Metering System). Was a fuel system problem found? Verify repair Go to Step 16 1. Check the fuel for excessive water, alcohol, or other contaminants (refer to Diagnosis in Engine Fuel for procedure). 2. If a problem is found, correct the contaminated fuel condition as necessary. Was the fuel contaminated? Verify repair Go to Step 17
12
Go to Step 13
Replace the ignition coil of the affected cylinder
13 14
15
16
6E253
DTC P0300 Engine Misfire Detected (Cont'd)

17
1. Perform the Injector Coil/Balance Test. 2. If a problem is found, replace faulty injector(s) as necessary. Did any of the injectors require replacement? Verify repair Go to Step 18 1. Check for an engine mechanical problem. Refer to Engine Mechanical Diagnosis to diagnose the following conditions: D A faulty or incorrect camshaft D Leaking or sticky valves or rings D Excessive valve deposits D Weak valve springs D Incorrect valve timing D A leaking head gasket D A loose or broken motor mount 2. If a problem is found, repair as necessary. Was a basic engine mechanical problem found and repaired? Verify repair Go to Step 19
18
19
1. Check for a transmission TCC problem. Refer to 4L30-E Automatic Transmission Diagnosis. 2. If a problem is found, repair the transmission as necessary. Refer to 4L30-E Automatic Transmission Unit Repair. Was a transmission problem found and repaired? Verify repair Verify repair Go to Step 20 Replace the MAF sensor. Is the action complete?
20
6E254
Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault
D06R200098
Circuit Description
The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. D The test is performed to evacuate the Knock Intensity (KI) signal pulse width if it is within a predetermined range. If the KI signal pulse width is out of the predetermined range, the fail counter will be incremented. If the failure counter exceeds the calibration, then test is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the test is complete and a pass will be reported. This test will detect an open/short in the KI line circuit, ION module faults and analog input faults in the PCM.

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0325 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. D DTC P0325 can be cleared using the Tech2 Clear Info function or by disconnecting the PCM battery feed.

D D D D Ignition voltage is between 10volt and 16 volts. No Crank DTCs set. No EST DTCs set. No Misfire DTCs set.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM- Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage.

D The PCM will ON the MIL after second trip with detected the fault. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

If the harness appears to be OK, observe the Knock Present, Knock Sensor Noise Channel display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.
6E255
If DTC P0325 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0325 Diagnostic Chart may isolate the cause of the fault.
DTC P0325 - ION Sensing Module Knock Intensity Circuit Fault

1. Ignition OFF. 2. Disconnect the ION sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 4 Check the ION sensing harness between the PCM (F68) and ION sensing module circuit (RED Wire) at the KI line harness connector. Was a problem found? Verify repair Go to Step 6 Go to Step 5 1. Disconnect the ignition coil. Is the action complete? Check the ION sensing harness for open or short circuit between the ignition coil and ION sensing module circuit at the harness connector. Was a problem found? Verify repair Go to Step 7 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 9
5 6
8 9
Replace the Ignition coil. Is the action complete? Check the following items; 1. ION sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found? Go to Step 10 Verify repair Go to Step 11 Go to Step 11
10
Repair wiring harness. Is the action complete?
6E256
DTC P0325 - ION Sensing Module Knock Intensity Circuit Fault (Cont'd)
11 12
Replace the ION Sensing module. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not .And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12
6E257
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit
D06R200044
Circuit Description
The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The powertrain control module (PCM) uses the 58X reference signal to calculate engine RPM and crankshaft position. The PCM constantly monitors the number of pulses on the 58X reference circuit. If the PCM receives an incorrect number of pulses on the 58X reference circuit, DTC P0336 will set.


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0336 will clear after 40 consecutive warmup cycles have occurred without a fault. D DTC P0336 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

D Engine is running. D Extra or missing pulse is detected between consecutive 58X reference pulses. D Above condition is detected in 10 of 100 crankshaft rotations.
6E258
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for: D Poor connection - Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, disconnect the PCM, turn the ignition on and observe a voltmeter connected to the 58X reference circuit at the PCM harness connector while moving connectors and wiring harnesses related to the PCM. A change in voltage will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
6E259
DTC P0336 58X Reference Signal Circuit

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Attempt to start the engine. Does the engine start? Go to Step 3
Go to OBD System Check Go to Engine Cranks But Will Not Run chart Check the Procedure Refer to Diagnostic Aids
1. 2. 3. 4.
Review and record Failure Records information. Clear DTC P0336. Start the engine and idle for 1 minute. Observe DTCs. Go to Step 4
Is DTC P0336 set? 4 1. Disconnect the PCM and CKP sensor. 2. Check for an open or a short to ground in the 58X reference circuit between the CKP sensor connector and the PCM harness connector. 3. If a problem is found, repair as necessary. Was a problem found? 5 1. Reconnect the PCM and CKP sensor. 2. Connect a DVM to measure voltage on the 58X reference circuit at the PCM connector. 3. Observe the voltage while cranking the engine. Is the voltage near the specified value? 6 Check the connections at the CKP sensor and replace the terminals if necessary. Did any terminals require replacement? 7 Replace the CKP sensor. Use caution to avoid any hot oil that may drip out. Is the action complete? 8 Check connections at the PCM and replace the terminals if necessary. Did any terminals require replacement? 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Verify repair
Go to Step 5
2.5 V
Go to Step 8
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Verify repair
Go to Step 9
Verify repair
6E260
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency
D06R200044
Circuit Description
The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft reference pulses will be produced. The powertrain control module (PCM) uses the 58X reference signal to calculate engine RPM and crankshaft position. The PCM constantly monitors the number of pulses on the 58X reference circuit. If the PCM does not receive pulses on the 58X reference circuit, DTC P0337 will set.



D Engine cranking. D Crankshaft position (CKP) sensor signal is not present between two cam pulses. D CKP reference pulse is not detected within 8 CMP pulses.
6E261
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for: D Poor connection Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, disconnect
the PCM, turn the ignition on and observe a voltmeter connected to the 58X reference circuit at the PCM harness connector while moving connectors and wiring harnesses related to the PCM. A change in voltage will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
DTC P0337 CKP Sensor Circuit Low Frequency

Go to OBD System Check Go to Chart 3 Check the Procedure Refer to Diagnostic Aid
2 3
1. 2. 3. 4.
Review and record Failure Records information. Clear DTC P0337. Start the engine and idle for 1 minute. Observe DTCs. Go to Step 4
Is DTC P0337 set? 4 1. Disconnect the CKP sensor. 2. Ignition ON. 3. Using a DVM, verify that 5 V reference and ground are being supplied at the sensor connector (PCM side). Are 4-6 volts and ground available at the sensor? 5 1. Ignition ON. 2. With a DVM, backprobe the PCM connector 5 V reference and ground connections. Are 5 V reference and ground available at the PCM? 6 Check 5 V reference or ground between the CKP sensor and PCM and repair the open circuit, short to ground or short to voltage. Is the action complete? 7 1. Ignition OFF. 2. Disconnect the PCM and CKP sensor. 3. Check for an open or a short to ground in the 58X reference circuit between the CKP sensor connector and the PCM harness connector. 4. If a problem is found, repair as necessary. Was a problem found? 8 1. Reconnect the PCM and CKP sensor. 2. Connect a DVM to measure voltage on the 58X reference circuit at the PCM connector. 3. Observe the voltage while cranking the engine. Is the voltage near the specified value? 9 Check the connections at the CKP sensor and replace the terminals if necessary. Did any terminals require replacement?
Go to Step 7
Go to Step 5
Go to Step 6
Go to Step 11
Verify repair
Verify repair
Go to Step 8
2.5 V
Go to Step 11
Go to Step 9
Verify repair
Go to Step 10
6E262
DTC P0337 CKP Sensor Circuit Low Frequency (Cont'd)

10
Replace the CKP sensor. Use caution and avoid hot oil that may drip out. Is the action complete? Verify repair Check the connections at the PCM and replace the terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 12 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
11
12
6E263
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit
D06R200098
Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST control circuit 1, it will set a DTC P0351.
D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous spark events.



D The ignition is ON. D The engine is running, determined by the 58X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.
6E264

Tech 2 display related to DTC P0351 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the
DTC P0351 Ignition 1 Control Circuit

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the DTC information for DTC P0351 until the DTC P0351 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0351 failed this ignition cycle? Go to Step 3 Verify repair Verify repair
Check the Procedure Go to Diagnostic Aids Go to Step 4 Go to Step 5
3 4 5
Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 1 at the ION Sensing Module with a DVM. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
1. Ignition OFF. 2. Disconnect the 3-pin and connector at the ignition coil. 3. Check ignition control circuit 1 voltage at the ignition coil connector while cranking the engine. Does the voltage measure between the specified values? 200-1200 mV Go to Step 8 Verify repair Go to Step 11
8 9
Replace the ignition coil. Is the action complete? 1. Ignition OFF. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 1 for short to ground. Was a problem found? Verify repair Verify repair Go to Step 10 Go to Step 13 Check ignition control circuit 1 for short to voltage. Was a problem found?
10
6E265
DTC P0351 Ignition 1 Control Circuit (Cont'd)

11 12 13
Check for an open ignition control circuit 1. Was the ignition control circuit open? Repair the open ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13
6E266
D06R200098
Circuit Description



D The ignition is ON. D The engine is running, determined by the 58 X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.
6E267
Diagnostic Aids

3 4 5
Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 2 at the ION Sensing Module with a DVM . Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
1. Ignition OFF. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 2 voltage at the ignition coil connector while cranking the engine connector. Does the voltage measure between the specified 200-1200 mV values? Go to Step 8 Verify repair Go to Step 11
8 9
10
6E268

11 12 13
6E269
D06R200098
Circuit Description



6E270

Diagnostic Aids

3 4 5
Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 3 at the ION Sensing Module with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
1. Ignition OFF. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 3 voltage at the ignition coil connector while cranking the engine. Does the voltage measure between the specified 200-1200 mV values? Go to Step 8 Verify repair Go to Step 11
8 9
10
6E271

11 12 13
6E272
D06R200098
Circuit Description



6E273
Diagnostic Aids

3 4 5
Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 4 at the ION Sensing with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
8 9
10
6E274

11 12 13
Check for an open ignition control circuit 4. Was the ignition control circuit open? Repair the open in ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13
6E275
D06R200098
Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST in control circuit 5, it will set a DTC P0355.



6E276

Diagnostic Aids

3 4 5
8 9
10
6E277

11 12 13
6E278
D06R200098
Circuit Description
D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous circuit monitoring.



6E279
Diagnostic Aids

3 4 5
8 9
10
6E280

11 12 13
6E281
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient
D06R200087
Circuit Description
The powertrain control module (PCM) tests the exhaust gas recirculation (EGR) system during deceleration by momentarily commanding the EGR valve to open while monitoring the manifold absolute pressure (MAP) sensor signal. When the EGR valve is opened, the PCM monitors the change in MAP input signal. The PCM compares the MAP change to a RPM vs. BARO table. When the PCM interprets the change in MAP to be out of limits, the PCM will set DTC P0401. The number of test samples required to accomplish this may vary according to the severity of the detected flow error. Normally, the PCM will only allow one EGR flow test sample to be taken during an ignition cycle. To aid in verifying a repair, the PCM allows twelve test samples during the first ignition cycle following a Tech 2 Clear Info or a battery disconnect. Between nine and twelve samples should be sufficient for the PCM to determine adequate EGR flow and pass the EGR test.
D A/C clutch status is unchanged. D TCC status is unchanged.
Start Test
D D D D D D TP angle is less than 0.8%. EGR duty cycle is less than 1%. MAP is steady, changing less than 2 kPa. Engine speed is between 1100 RPM and 2000 RPM (M/T). MAP between 10 kPa and 40 kPa. Engine speed is between 900 RPM and 1500 rpm (A/T). The test will be aborted if the vehicle speed changes by more than 16 km/h (10 mph), engine speed changes by more than 100 RPM or the EGR is opened less than 95% of commanded position. The PCM will only run the EGR test during a closed throttle condition. The PCM will only run the EGR test at vehicle speeds above 24 km/h (15 mph). Several deceleration cycles will be necessary to run a sufficient number of EGR flow tests.
D D D

D No TP sensor, vehicle speed sensor (VSS), MAP sensor, IAT sensor, IAC, EGR Pintle Position sensor, ECT sensor, misfire, or automatic transmission DTCs set. D Engine coolant temperature is greater than 60C (140F). D Ignition voltage between 11.5 and 16 volts. D Vehicle speed is greater than 24 km/h (15 mph).

6E282
Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Actual EGR Position display on the Tech 2 while moving connectors and wiring harnesses related to the EGR valve. A change in the display will indicate the location of the fault. D Ensure EGR valve is correctly mounted. See On-Vehicle Service. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. NOTE: If the EGR valve shows signs of excessive heat, check the exhaust system for blockage (possibly a plugged catalytic converter) using the Restricted Exhaust System Check.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart 3. A malfunctioning MAP sensor can set an EGR DTC. The MAP sensor could send a constant signal which is not low enough to set a low MAP DTC. The constant signal from the MAP sensor also may not be high enough to set a high MAP DTC. This step verifies that the MAP sensor is responding.
6E283
DTC P0401 EGR Flow Insufficient

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC 1404 Is DTC P1404 also set? 1. Start the engine. 2. Monitor the MAP signal with a Tech 2 while idling. 3. While idling, jab the accelerator pedal about halfway down and immediately let the engine return to idle. Did the MAP value on the Tech 2 show an immediate large change? Go to Step 5 Verify repair
2 3
Go to Step 4
4 5
Replace the MAP sensor. Is the action complete? 1. Inspect the exhaust system for modification of original installed parts or leaks. 2. If a problem was found, repair exhaust system as necessary. Was a condition present that required repair? Go to Step 8 Go to Step 6 1. Remove the EGR valve. 2. Visually and physically inspect the pintle, valve passages and the adapter for excessive deposits or any kind of a restriction. 3. If a problem is found, clean or replace EGR system components as necessary. Was a condition present that required repair? Go to Step 8 Go to Step 7 1. Remove the EGR inlet and outlet pipes from the exhaust manifold and the intake manifold. 2. Inspect the manifold EGR ports and the EGR inlet and outlet pipes for a blockage caused by excessive deposits or other damage. 3. If a problem is found, correct the condition as necessary. Was a condition present that required repair? Go to Step 8 1. Review and record the Tech 2 Failure Records data. 2. Clear DTC and monitor the Tech 2 System Info Screen while operating the vehicle as specified in Diagnostic Aids. 3. Using a Tech 2, monitor DTC info for DTC P0401 until the DTC P0401 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0401 failed this ignition? Repair complete
6E284
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error
D06R200087
Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if pintle position is stuck open. If the PCM detects a pintle position signal indicates more than 21.5% and more than for 625 msec during cranking, the PCM will set DTC P0402.
Diagnostic Aids
Check for the following conditions: D Foreign material on EGR valve between pintle and seat may cause EGR stuck open. Inspect foreign material in EGR valve. D Excessive carbon deposit may cause unsmooth operation of EGR valve shaft. Inspect for carbon deposit and clean up inside of carbon deposit. D Poor connection or damaged harnessinspect the wiring harness for damage If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault. NOTE: If the EGR valve shows signs of excessive heat, check the exhaust system for blockage (possibly a plugged catalytic converter) using the Restricted Exhaust System Check.

D Ignition voltage is between 11 and 16 volts. D At Engine revolution less than 600 RPM, EGR pintle position indicates more than 21.0% and more than for 625 msecs.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

6E285
DTC P0402 EGR Pintle Crank Open Error

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0402 until the DTC P0402 test runs. Note the result. Does the Tech 2 indicates DTC P0402 failed this ignition? Go to Step 3
1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Repair the damaged pin or terminal. Is the action complete? 1. Remove EGR valve from Engine. 2. Inspect EGR valve whether there is any foreign material between seat and pintle. Was any foreign material in EGR valve? Go to Step 6 Go to Step 7 1. Remove EGR valve foreign material from EGR valve and clean up inside. 2. Visually inspect for damage of pintle and seat, which leakage may occur. Was there any severe damage which affects function? Go to Step 7 1. 2. 3. 4. 5. 6. Reconnect. Ignition OFF. Install the Tech 2. Run the engine at idle. On Tech-II, select special function for EGR. Use the UP arrow to increase the EGR from 0% to 40%. Go to Step 9 Verify repair Go to Step 8 Verify repair
4 5
Did EGR work properly? 8 9 Replace the EGR valve. Does DTC P0402 still fail DTC test on the Tech 2? Replace the PCM. Is the action complete?
6E286
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck
D06R200087
Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if pintle position is different from commanded position. If the PCM detects a pintle position signal indicates more than 15 points different between current and commanded and more than 15 seconds, the PCM will set DTC P0404.
D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.


D D D D D The engine is running. Ignition voltage is between 11 and 16 volts. Intake Air Temp is more than 3C (37.4F). Desire EGR position is less than 3%. The difference between desired EGR and current EGR is less than 3%. D Difference EGR pintle position between current and commanded position becomes more than 15% and last more than 15 seconds, and this condition meets three times in a trip. Then it trigger, the PCM lights on.
Diagnostic Aids
Check for the following conditions: D Excessive carbon deposit on EGR valve shaft may cause EGR stuck open or unsmooth operation. Those carbon deposit may occur by unusual port operation. Clean up carbon may make smooth function of EGR valve. D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

D The PCM will ON the MIL after second trip with detected the fault.
6E287
DTC P0404 EGR Open Stuck

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0404 until the DTC P0404 test runs. Note the result. Does the Tech 2 indicates DTC P0404 failed this ignition? Go to Step 3
1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Is the action complete? Repair the damaged pin or terminal. 1. Remove EGR valve from Engine. 2. Inspect EGR valve whether there is any excessive carbon deposit on EGR shaft. Was excessive carbon deposit on EGR valve shaft? Go to Step 6 Go to Step 7 1. Clean up EGR valve shaft and inside of EGR valve. 2. Visually inspect damage of pintle and seat if is bent, leakage may occur. Was there any severe damage which affects function? Go to Step 8 1. 2. 3. 4. 5. 6. Reconnect. Ignition OFF. Install the Tech 2. Run the engine at idle. On the Tech 2, select EGR Control Test. Use the UP arrow to increase the EGR from 0% to 40%. Go to Step 9 Go to Step 8 Verify repair
4 5
Did EGR work properly? 8 9 Replace the EGR valve. Does DTC P0404 still fail DTC test on the Tech 2? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Verify repair
6E288
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage
D06R200087
Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to command from the PCM. If current pintle position voltage indicates less than 0.1 V and last more than 10 seconds, then the PCM will set DTC P0405.


D Ignition voltage is between 11 and 16 volts. D Intake Air Temp is more than 3C (37.4F). D EGR pintle position is less than 2% and last more than 10 sec. Action taken when the DTC sets.
Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.
6E289
DTC P0405 EGR Low Voltage

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Repair the damaged pin or terminal. Is the action complete? 1. Disconnect the EGR harness connector. 2. Ignition ON. 3. At the EGR valve, use a DVM to check the voltage at the 5 volt reference wire (BLU/RED) and ground. Did the DVM indicate the specified value? 46 V Go to Step 6 Go to Step 7 1. Disconnect the EGR harness connector. 2. Measure resistance between terminal 5 volt reference wire and ground. Was resistance in range? 55.5 Km Go to Step 10 Go to Step 17 1. Ignition ON. 2. At the PCM connector, backprobe with a DVM at the 5 volt reference for the EGR valve. Did the DVM indicate the specified value? 46 V Go to Step 8 Verify repair Verify repair Go to Step 9 Repair the open 5 volt reference circuit. Is the action complete? Repair the damaged sensor ground wire. Is the action complete? 1. Disconnect the EGR harness 2. Use an ohmmeter to measure between the pintle position pin and the sensor ground pin on the EGR valve. NOTE: J-35616 Connector Test Adapter Kit may be useful for gaining access to the recessed pins on the valve. Was the ohmmeter reading approximately equal to the specified value? 1 to 1.25 Km Go to Step 13 Go to Step 17
4 5
8 9 10
11
1. Ignition ON. 2. Backprobe with a DVM to measure voltage at EGR valve pintle position pin and sensor ground pin. Was voltage in range?
Less than 0.1 V
Go to Step 17
Go to Step 12
6E290
DTC P0405 EGR Low Voltage (Cont'd)

12
1. Ignition ON. 2. Backprobe with a DVM to measure voltage at PCM sensor ground pin and pintle position pin. Was voltage in range? 1. Ignition OFF. 2. Disconnect the EGR harness. 3. Check short circuit between EGR pintle position circuit and EGR ground circuit. Was any short circuit?
Less than 0.1 V
Go to Step 13
Go to Step 18
13
Go to Step 14
Go to Step 18
14
Locate and repair the short to ground in the pintle position circuit Is the action complete? Verify repair 1. 2. 3. 4. Ignition OFF. Disconnect the PCM. Ignition ON. Measure the voltage between the EGR pintle position circuit and ground.
15
Is the measured voltage near the specified value? 16 Check for a short circuit between other wires and the pintle position circuit Is there any short circuit?
Less than 0.1 V
Go to Step 17 Repair short circuit and then Verify repair Go to Step 18 Go to Step 4
Go to Step 16
17 18 19 Replace the EGR valve. Does DTC P1404 still fail DTC test on the Tech 2? Examine the PCM pin and terminal connection. Was there a damaged terminal? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Go to Step 17 Verify repair Go to Step 19
Verify repair
6E291
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage
D06R200087
Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to command from the PCM. If current pintle position voltage indicates more than 4.8 V and last more than 10 seconds, then the PCM will set DTC P0406.


D Ignition voltage is between 11 and 16 volts. D Intake Air temp is more than 3C (37.4F). D EGR pintle position is more than 99% and last more than 10 sec.
Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

6E292
DTC P0406 EGR High Voltage

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Is the action complete? Repair the damaged pin or terminal. Is the action complete? 1. Disconnect the EGR harness connector. 2. Ignition ON. 3. At the EGR valve, use a DVM to check the voltage at the 5 volt reference wire (BLU/RED). Did the DVM indicate the specified value? 46 V Go to Step 8 Go to Step 6 1. Ignition ON. 2. At the PCM connector, backprobe with a DVM at the 5 volt reference for the EGR valve. Did the DVM indicate the specified value? 46 V Go to Step 7 Verify repair Go to Step 16 Repair the open 5 volt reference circuit Is the action complete? 1. Ignition OFF 2. Disconnect the EGR harness. 3. Use a DVM to check for an resistance between 5 V reference and Sensor Ground at EGR sensor terminals. NOTE: J-35616 Connector Test Adapter Kit may be useful for gaining access to the recessed pins on the valve. Was the measured resistance in range? 5 to 5 Km Go to Step 9 Go to Step 15
4 5
7 8
1. Ignition OFF. 2. Disconnect the EGR harness. 3. Use a DVM to check for an resistance between Sensor Ground and Signal Wire at EGR sensor terminal. Is there an open circuit? Go to Step 15 Go to Step 10 1. Ignition OFF. 2. Disconnect the EGR harness at PCM connector. 3. Use a DVM to check for shorted wire between S37 and F53. Is there a shorted wire? Go to Step 14 Go to Step 11
10
6E293
DTC P0406 EGR High Voltage (Cont'd)

11
1. Ignition ON. 2. Use a DVM to backprobe at terminal Connector of EGR valve for voltage. Was measured voltage more than 4.8 V? 1. Ignition ON. 2. Stay the EGR harness connected. 3. Check voltage by backprobing at PCM S37 terminal. Was voltage more than 4.8 V?
more than 4.8 V
Go to Step 12
Go to Step 12
12
4.8 V
Go to Step 16
Go to Step 13
13
1. Locate short circuit at EGR harness between BLU/RED to GRY/RED or GRY/RED to YEL, BLU/RED. 2. Replace EGR harness. Is the action complete? Verify repair Verify repair Go to Step 16 Verify repair Replace EGR harness. Is the action complete? Replace the EGR valve. Does DTC P1404 still fail DTC test on the Tech 2? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
14 15 16
6E294
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1
T321075
Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalyst (TWC) is used. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 1 HO2S 1 and the Bank 1 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 1 HO2S 1 signal will be far more active than that produced by the Bank 1 HO2S 2 sensor. If the PCM detects a level of Bank 1 HO2S 2 activity that indicates the catalyst is no longer operating efficiently, DTC P0420 will be set.
D Barometric Pressure is more than 72 kPa.


Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. The TWC Monitor Test Counter displayed on the Tech 2 may be used to monitor the progress of the TWC diagnostic. To complete the TWC diagnostic with a good catalyst, the counter must be allowed to increment to 49 samples and roll over to 0 at least twice. A failed catalyst

D D D D D D D D D D No related DTCs. The engine is operating in closed loop, Engine air load is below 99%. Engine coolant temperature is between 70C (158F) and 120C (248F). Mass air flow is between 2.5 g/second and 10 g/second. Engine speed is below 200 RPM. Catalyst temperature is above 350C (662F). The PCM determines that the catalysts oxygen storage capacity is below the acceptable threshold. Intake Air Temperature is between 10C (14F) and 70C (158F). Throttle angle is less than 1.5%.

will require three or more 50-sample tests to report a failure.
6E295
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 7. Difficulty completing the DTC P0420 Status This Ign, test may be encountered in areas where test conditions cannot be maintained easily, especially in urban areas. To minimize the amount of driving required to complete the DTC P0420 Status This Ign, test, use the following procedure: D Allow the engine to warm up completely.
D With the vehicle in Park, monitor mass air flow on the Tech 2 and hold part throttle to maintain a reading of over 12 g/second for at least 2 minutes. This will achieve the warm catalyst required for running the test. D Operate the vehicle in second or third gear to remain in the DTC P0420 test conditions described in Conditions for Setting the DTC as much as possible. If you must stop the vehicle, maintain the warm catalyst criteria as follows: Place the vehicle in Park or Neutral, Hold part throttle to maintain a mass air flow reading of over 15 g/second for the duration of the stop.
DTC P0420 TWC System Low Efficiency Bank 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Diagnose other DTC(s) first Are any other DTCs set (such as P0140)?
Go to Step 3
1. Visually and physically inspect the three-way catalytic converter for damage. Check for the following: D dents D severe discoloration caused by excessive temperatures D holes D internal rattle caused by damaged catalyst 2. Also, ensure that the three-way catalytic converter is a proper original equipment manufacturer part. Did your inspection reveal a problem? Go to Step 6 Go to Step 4 1. Visually and physically inspect the exhaust system between the three-way catalytic converter and the rear converter flange for leaks, damage, and loose or missing hardware. 2. If a problem is found, repair as necessary. Did your inspection reveal a problem? 1. Visually and physically inspect the Bank 1 HO2S 2. 2. Ensure that the Bank 1 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged. 3. If a problem is found, repair as necessary. Did your inspection reveal a problem?
Go to Step 7 to verify repair
Go to Step 5
Go to Step 6
6E296
DTC P0420 TWC System Low Efficiency Bank 1 (Cont'd)

Replace the three-way catalytic converter. NOTE: Check for conditions which may cause catalyst damage (refer to Diagnostic Aids). Is the action complete? Go to Step 7 to verify repair
1. Review and record the Tech 2 Failure Records data. 2. Clear DTC P0420. 3. Start the engine and allow it to warm up until the engine coolant temperature monitored on the Tech 2 is above the specified value. 4. Run the engine to maintain the specified mass air flow range for at least 2 minutes. Engine 5. Operate the vehicle to maintain DTC P0420 test coolant temp: conditions (refer to DTC Test Description in greater than Diagnostic Support for detailed instructions). 60C 6. Using a Tech 2, monitor DTC info for DTC P0420 (140F). until the DTC P0420 test runs. Mass air flow: 7. Note the test result. between 8 Does the Tech 2 indicate DTC P0420 passed this g/second and ignition? 50 g/second
Complete repair. If a driveability symptom still exists, refer to Symptoms.
6E297
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2
T321075
Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalyst (TWC) is used. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the PCM detects a level of Bank 2 HO2S 2 activity that indicates the catalyst is no longer operating efficiently, DTC P0430 will be set.
D Engine coolant temperature is between 70C (158F) and 120C (248F). D Mass air flow is between 2.5 g/second and 10 g/second. D Change in engine load is below 8%. D Engine speed is below 200 RPM. D Catalyst temperature is above 350C (662F). D The PCM determines that the catalysts oxygen storage capacity is below the acceptable threshold. D Intake air temperature is between 20C (4F) and 70C (158F). D Throttle angle is less than 1.5%. D Barometric Pressure is more than 72 kPa.



D No related DTCs. D The engine is operating in closed loop. D Engine air load is below 99%.
6E298

D Allow the engine to warm up completely. D With the vehicle in Park, monitor mass air flow on the Tech 2 and hold part throttle to maintain a reading of over 12 g/second for at least 2 minutes. This will achieve the warm catalyst required for running the test. D Operate the vehicle in second or third gear to remain in the DTC P0430 test conditions described in Conditions for Setting the DTC as much as possible. If you must stop the vehicle, maintain the warm catalyst criteria as follows: Place the vehicle in Park or Neutral, Hold part throttle to maintain a mass air flow reading of over 15 g/second for the duration of the stop. The TWC Monitor Test Counter displayed on the Tech 2 may be used to monitor the progress of the TWC diagnostic. To complete the TWC diagnostic with a good catalyst, the counter must be allowed to increment to 49 samples and roll over to 0 at least twice.
Diagnostic Aids
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 7. Difficulty completing the DTC P0430 Status This Ign, test may be encountered in areas where test conditions cannot be maintained easily, especially in urban areas. To minimize the amount of driving required to complete the DTC P0430 Status This Ign, test, use the following procedure:
DTC P0430 TWC System Low Efficiency Bank 2

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Diagnose other DTC(s) first Are any other DTCs set (such as P0160)?
Go to Step 3
1. Visually and physically inspect the three-way catalytic converter for damage. Check for the following: D dents D severe discoloration caused by excessive temperatures D holes D internal rattle caused by damaged catalyst 2. Also, ensure that the three-way catalytic converter is a proper original equipment manufacturer part. Did your inspection reveal a problem? Go to Step 6 Go to Step 4 1. Visually and physically inspect the exhaust system between the three-way catalytic converter and the rear converter flange for leaks, damage, and loose or missing hardware. 2. If a problem is found, repair as necessary. Did your inspection reveal a problem?
Go to Step 5
6E299
DTC P0430 TWC System Low Efficiency Bank 2 (Cont'd)

1. Visually and physically inspect the Bank 2 HO2S 2. 2. Ensure that the Bank 2 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged. 3. If a problem is found, repair as necessary. Did your inspection reveal a problem? Replace the three-way catalytic converter. NOTE: Check for conditions which may cause catalyst damage (refer to Diagnostic Aids). Is the action complete?
Go to Step 6
1. Review and record the Tech 2 Failure Records data. 2. Clear DTC P0430. 3. Start the engine and allow it to warm up until the engine coolant temperature monitored on the Tech 2 is above the specified value. 4. Run the engine to maintain the specified mass air flow range for at least 6 minutes. Engine 5. Operate the vehicle to maintain DTC P0430 test coolant temp: conditions (refer to DTC Test Description in greater than Diagnostic Support for detailed instructions). 70C 6. Using a Tech 2, monitor DTC info for DTC P0430 (158F). until the DTC P0430 test runs. Mass air flow: 7. Note the test result. between 2.5 Does the Tech 2 indicate DTC P0430 passed this g/second and ignition? 10 g/second
Complete repair. If a driveability symptom still exists, refer to Symptoms.
6E300
Diagnostic Trouble Code (DTC) P0440 EVAP System
D06R200084
Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister purge duty solenoid valve D Fuel tank (vapor) pressure sensor D Fuel pipes and hoses D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister vent valve (purge solenoid) The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module (PCM) monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system. If a sufficient vacuum level cannot be achieved, a large leak or a faulty EVAP canister purge solenoid is indicated. This can be caused by the following conditions: D Disconnected or faulty fuel tank pressure sensor D Missing or faulty fuel cap D Disconnected, damaged, pinched, or blocked EVAP purge line D Disconnected or damaged EVAP vent hose
D Disconnected, damaged, pinched, or blocked fuel tank vapor line D Disconnected or faulty EVAP canister duty solenoid D Open ignition feed circuit to the EVAP canister vent solenoid D Damaged EVAP canister D Leaking fuel sender assembly O-ring D Leaking fuel tank or fuel filler neck Any of the above conditions can set DTC P0440.

D No TP sensor, IAT sensor, ECT sensor, or MAP sensor DTCs set. D Start-up engine coolant temperature is less than 32C (90F). D Start-up engine coolant temperature is not more than 7C (13F) greater than start-up intake air temperature. D Start-up intake air temperature is greater than 4C (39F) . D Start-up intake air temperature is not more than 2C (4F) greater than start-up engine coolant temperature. D Vehicle speed is less than 5 mph (8 km/h). D Throttle position is greater than 3%. D Minimal fuel slosh. D BARO is greater than 70 kPa. D The EVAP system is unable to achieve or maintain vacuum during the diagnostic test.

D Engine speed is less than 1200 RPM. D Above conditions are present for 60 to 180 seconds.
6E301

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.
Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If an EVAP canister vent solenoid or an EVAP canister purge solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0440. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Determines whether or not the EVAP system can be sealed sufficiently to be pressurized. If not, the large leak must be located and corrected before continuing with diagnosis. 5. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes. 8. Checks for a blocked EVAP canister purge solenoid. The PCM commands the EVAP canister purge solenoid OFF (open) and the vent solenoid ON (closed) with the Tech 2 System Perf, EVAP output control function activated. Any pressure in the system should be released through the EVAP canister purge solenoid within a few seconds when System Perf, is activated. 9. Ensures that sufficient source vacuum is present at the EVAP canister purge solenoid.

D The PCM will turn the MIL OFF when the diagnostic has been run and the fault condition is no longer present. D A history DTC P0440 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0440 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
Check for the following conditions: D Cracked or punctured EVAP canister. D Damaged or disconnected source vacuum line, EVAP purge line, vent hose or fuel tank vapor line. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harnessInspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. D Kinked, pinched, or plugged vacuum source, EVAP purge, or fuel tank vapor lineVerify that the lines are not restricted.
DTC P0440 EVAP System

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to other DTC first Is DTC P0452 or P0453 also set? 1. 2. 3. 4. Ignition OFF. Remove the fuel cap. Ignition ON. Observe Fuel Tank Pressure on the Tech 2. 1.51 V Go to Step 4
2 3
Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 4 1. Replace the fuel cap. 2. Engine is running. 3. Observe Fuel Tank Vacuum on the Tech 2. Does Tech 2 indicate Fuel Tank Vacuum at the specified value?
Go to DTC P0452 or DTC P0453
1.471.51 V
Go to Step 5
Go to Step 6
6E302
DTC P0440 EVAP System (Cont'd)

Ignition OFF. 1. Disconnect the fuel tank vapor line and the EVAP purge line from the EVAP canister. 2. Block the canister fitting for the fuel tank vapor line. 3. Connect a hand vacuum pump to the canister fitting for the EVAP purge line. 4. Ensure that the EVAP canister vent solenoid is still commanded ON (closed). 5. Attempt to apply vacuum to the EVAP canister. Observe Fuel tank pressure on the Tech 2. Does the Tech 2 indicate Fuel tank pressure at the specified value? 1.471.51 V Go to Step 8 Go to Step 7
1. Visually/physically check for the following conditions: D Restricted fuel tank vapor line. D Restricted EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair 1. Visually/physically check for the following conditions: D Vent hose disconnected or the damaged. D EVAP canister damaged. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
Go to DTC P0452 or DTC P0453
Go to Step 11
1. Visually/physically check for the following conditions: D Missing or faulty fuel cap. D Disconnected or leaking fuel tank vapor line. D Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Verify repair Go to Step 9 Replace the EVAP canister purge solenoid. Is the action complete? Locate and repair cause of no source vacuum to the EVAP canister purge solenoid. Is the action complete? Verify repair Verify repair Replace the EVAP canister vent solenoid. Is the action complete?
9 10
11
6E303
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected
D06R200084
Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister vent solenoid D Fuel tank (vapor) pressure sensor D Fuel pipes and hoses D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister purge solenoid The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module (PCM) monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system. After the desired vacuum level has been achieved, the EVAP canister purge solenoid is turned OFF, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A small leak in the system will cause DTC P0442 to be set.

D No TP sensor, ECT sensor, Tank pressure sensor, IAT sensor, or MAP sensor DTCs set. D BARO is more than 70 kPa. D Engine speed is less than 1200 RPM. D Fuel level is between 15% and 85%. D Vehicle speed is less than 5 mph (8 km/h). D The DTC P0440 diagnostic test has passed. D A vacuum decay condition, indicating a small leak, is detected during the diagnostic test.


6E304

Diagnostic Aids
Check for the following conditions: D Cracked or punctured EVAP canister. D Damaged source vacuum line, EVAP purge line, EVAP vent hose or fuel tank vapor line. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harnessInspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If an EVAP canister vent solenoid or an EVAP canister purge solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0442. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes.
DTC P0442 EVAP System Leak Detected

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. 2. 3. 4. Ignition OFF. Remove the fuel cap. Ignition ON. Observe Fuel Tank Pressure on the Tech 2. 1.51V Go to Step 3
Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 3 IMPORTANT: Before continuing with diagnosis, zero the EVAP pressure and vacuum gauges on EVAP pressure/purge cart J 41413 (refer to tool operating instructions). 1. Replace the fuel cap. 2. Capture Failure Records data for DTC P0442 and clear DTCs. 3. Connect the EVAP pressure/purge cart J 41413 to the EVAP service port. 4. Using the Tech 2, command the EVAP canister vent solenoid ON (closed). 5. Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to the specified value. 6. Observe Fuel Tank Pressure on the Tech 2. Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 4 1. Ignition ON, engine idling. 2. Using the Tech 2, command the EVAP canister vent solenoid ON (closed). 3. Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to 15 in. H2O. 4. Switch the rotary switch on the cart to HOLD and observe the EVAP pressure gauge. Does the pressure decrease to less than the specified value within 2 minutes?
Go to Fuel Tank Pressure System
1.47V
Go to Step 4
1.47 1.51V
Go to Step 5
6E305
DTC P0442 EVAP System Leak Detected (Cont'd)

1. Disconnect the fuel tank vapor line and the EVAP purge line from the EVAP canister. 2. Block the canister fitting for the fuel tank vapor line. 3. Connect a hand vacuum pump to the canister fitting for the EVAP purge line. 4. Ensure that the EVAP canister vent solenoid is still commanded ON (closed). 5. Attempt to apply vacuum to the EVAP canister. Can the vacuum be maintained at the specific value? 1.46V Go to Step 8 Go to Step 6 1. Visually/physically check for the following conditions: D Vent hose disconnected or damaged. D EVAP canister damaged. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 10 Go to Step 10 Go to Step 7 Replace the EVAP canister vent solenoid. Is the action complete? 1. Visually/physically check for the following conditions: D Missing or faulty fuel cap. D Disconnected or leaking fuel tank vapor line. D Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 10 Go to Step 9 1. Using Tech 2, command the EVAP canister vent solenoid ON (closed). 2. With the cart connected to the EVAP service port, continuously attempt to pressurize the EVAP system by leaving the cart control knob in the pressurize position. 3. Using ultrasonic leak detector J 41416, locate and repair leak in EVAP system. (It may be necessary to partially lower the fuel tank to examine the connections on top of the tank.) Is the action complete? Go to Step 10 1. Ignition ON, engine not running. 2. Using the Tech 2, command the EVAP canister vent solenoid ON (closed). 3. Using the EVAP pressure/purge cart J 41413, pressurize and monitor the EVAP system to 15 in. H2O. 4. Switch the rotary switch on the cart to HOLD and observe the EVAP pressure gauge. Does the pressure decrease to less than the specified value within 2 minutes? 2.14V Go to Step 2 Verify repair
7 8
10
6E306
Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open
D06R200084
Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM).The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.
D DTC P0444 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP purge solenoid display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0444 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0444 Diagnostic Chart may isolate the cause of the fault.

D The Ignition is ON. D Engine is running. D System voltage is between 11.5 volts and 16 volts.


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0444 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault.
6E307
DTC P0444 EVAP Purge Control Circuit Open

1. Install the Tech 2. 2. Ignition is ON, 3. Engine is ON and operate the accelerator pedal for 3 or 4 times. 4. Observe the EVAP purge solenoid reading on the Tech 2. Is the EVAP purge solenoid reading near the specified More than 1% value?
Go to Step 3
Check the power supply circuit. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister purge solenoid valve. Ignition is ON. Using a DVM, measure at the EVAP purge solenoid connector between ground and voltage supply.
Was the measurement near the specified value? 4 Check the signal circuit for the EVAP purge solenoid. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister purge solenoid valve. Disconnect the PCM. Check the circuit between EVAP purge solenoid connector and PCM connector.
Battery voltage
Go to Step 4
Go to Step 5
Is the problem found? 5 6 Repair the circuit as necessary. Is the action complete? Check the canister purge solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the purge solenoid valve resistance within the specified values? 7 8 Replace the canister purge solenoid valve. Is the action complete? Replace the IMPORTANT: The programmed. replacement PCM must be
Go to Step 6
2530 m (at 68F{20C})
Go to Step 7
Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6E308
Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short
D06R200084
Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM). The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP purge solenoid display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0445 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0445 Diagnostic Chart may isolate the cause of the fault.



6E309
DTC P0445 EVAP Purge Control Circuit Short

1. Install the Tech 2. 2. Ignition is ON, 3. Observe the EVAP purge solenoid reading on the Tech 2. Is the EVAP purge solenoid reading near the specified value? 0%
Go to Step 3
Check the signal circuit for canister purge solenoid valve. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister purge solenoid valve. Disconnect the PCM. Check the circuit between EVAP purge solenoid connector and PCM connector. Go to Step 4 Verify repair Go to Step 5
Is the problem found? 4 5 Repair the circuit as necessary. Is the action complete? Check the canister purge solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the purge solenoid valve resistance within the specified values? 6 7 Replace the canister purge solenoid valve. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be
2530 (at 68F{20C})
Go to Step 6
6E310
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction
D06R200084
Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister vent solenoid D Fuel tank (vapor) pressure sensor D Fuel pipes and hoses D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister purge solenoid An incorrect fuel tank pressure sensor signal is detected by monitoring fuel tank pressure when the key is first turned ON during a cold start. If the fuel tank pressure signal is out of range, DTC P0446 will set. A restricted or blocked EVAP vent path is detected by monitoring fuel tank pressure during normal operation (EVAP canister vent solenoid open, EVAP canister purge solenoid normal). With the EVAP canister vent solenoid open, vacuum level in the system should be very low unless the vent path is blocked. A blockage can be caused by the following condition: D Faulty EVAP canister vent solenoid (stuck closed). D Plugged, kinked or pinched vent hose. D Shorted EVAP canister vent solenoid driver circuit. D Plugged evaporative canister.
If any of these conditions are present, DTC P0446 will set.

D No TP sensor, ECT sensor, Tank pressure sensor, IAT sensor, or MAP sensor DTCs set. D Start-up engine coolant temperature and start-up intake air temperature are more than 4C (39F) but less than 34C(93F). D Start-up engine coolant temperature is not more than 7C (13F) greater than start-up intake air temperature. D Fuel tank level is between 15% and 85%. D BARO is greater than 70 kPa.

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and Failure Records data.


6E311
how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harnessInspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. D Kinked, pinched, or plugged vent hoseVerify that the vent hose between the EVAP canister and EVAP canister vent solenoid is not restricted. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If a vent solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0446. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes. 6. Checks for a blocked EVAP canister.
DTC P0446 EVAP Canister Vent Control Malfunction

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON. 2. Capture Failure Records data for DTC P0446 and clear DTCs. 3. Ignition OFF. 4. Remove the fuel cap. 5. Ignition ON. 6. Observe Fuel Tank Pressure on the Tech 2. Does Tech 2 indicate Fuel Tank Pressure at the specified value? 1.51V Go to Step 3
IMPORTANT: Before continuing with diagnosis, zero the EVAP pressure and vacuum gauges on the EVAP pressure/purge cart J 41413 (refer to tool operating instructions). 7. Replace the fuel cap. 8. Using the Tech 2, command the EVAP vent solenoid ON (closed). 9. Connect the EVAP pressure/purge cart J 41413 to the EVAP service port. 10.Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to the specified value. 11. Observe Fuel Tank Pressure on the Tech 2. Does Tech 2 indicate Fuel Tank Pressure at the specified value? 1.52 1.69V Go to Step 4 Check the Procedure Refer to Diagnostic Aids
1. Maintain the EVAP pressure at 5 in. at H2O. 2. Using Tech 2, command the EVAP vent solenoid OFF (open) while observing the EVAP pressure gauge on the cart J 41413. Does the EVAP pressure return to the specified value within 5 seconds? 0 in. H2O
Go to Step 5
6E312
DTC P0446 EVAP Canister Vent Control Malfunction (Cont'd)

1. Disconnect the large vent hose (marked AIR) from the EVAP canister. 2. Switch the rotary switch on the cart J 41413 to PURGE. 3. Ignition ON, engine idling at normal operating temperature. 4. Observe vacuum gauge for 5 seconds while holding the engine speed at 2500 RPM. Does the vacuum remain less than the specified value? 30 in. H2O Go to Step 6 Go to Step 8 1. Inspect the vent hose between the EVAP canister and the EVAP canister vent solenoid for kinks, pinched areas, or any other form of blockage. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 9 Go to Step 9 Go to Step 9 Go to Step 7 Replace the EVAP canister vent solenoid. Is the action complete? Replace the EVAP canister. Is the action complete? 1. Using Tech 2, command the EVAP canister vent solenoid ON (closed). 2. Using the EVAP pressure/purge cart J 41413, pressurize and monitor the EVAP system to 15 in. H2O. 3. Switch the rotary switch on cart J 41413 to HOLD. 4. Using the Tech 2, command the EVAP canister vent solenoid OFF (open) while observing the EVAP pressure gauge on cart J 41413. Does the EVAP pressure return to the specified value within 30 seconds? 0 in. H2O Verify repair Go to Step 2
7 8 9
6E313
Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open
D06R200084
Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM).The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister vent solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP vent valve display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0447 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0447 Diagnostic Chart may isolate the cause of the fault.


D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

6E314
DTC P0447 EVAP Vent Solenoid Circuit Open

1. Install the Tech 2. 2. Ignition is ON, 3. Engine is ONand operate the acceleration pedal for 3 or 4 times. 4. Observe the EVAP vent solenoid reading on the Tech 2. Is the EVAP vent solenoid reading to ON? Check the power supply circuit. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister vent solenoid valve. Ignition is ON. Using a DVM, measure at the EVAP vent solenoid connector between ground and voltage supply.
Go to Step 3
Was the measurement near the specified value? 4 Check the signal circuit for vent solenoid valve. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister vent solenoid valve. Disconnect the PCM. Check the circuit between EVAP vent solenoid connector and PCM connector.
Battery voltage
Go to Step 4
Go to Step 5
Is the problem found? 5 6 Repair the circuit as necessary. Is the action complete? Check the canister vent solenoid valve. Using a DVM, measure resistance for vent solenoid valve connector terminal. Is the vent solenoid valve resistance within the specified values? 7 8 Replace the canister vent solenoid valve. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be
21.8-28.5m (at 68F{20C}) Verify repair
6E315
Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short
D06R200084
Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM). The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister vent solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP vent valve display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0448 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0448 Diagnostic Chart may isolate the cause of the fault.



6E316
DTC P0448 EVAP Vent Solenoid Circuit Short

1. Install the Tech 2. 2. Ignition is ON, 3. Observe the EVAP vent solenoid reading on the Tech 2. Is the EVAP vent solenoid reading near the specified value? 0%
Go to Step 3
Check the signal circuit for canister vent solenoid valve. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister vent solenoid valve. Disconnect the PCM. Check the circuit between EVAP vent solenoid connector and PCM connector. Go to Step 4 Verify repair Go to Step 5
Is the problem found? 4 5 Repair the circuit as necessary. Is the action complete? Check the canister vent solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the vent solenoid valve resistance within the specified values? 6 7 Replace the canister vent solenoid valve. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be
21.8-28.5m (at 68F{20C})
Go to Step 6
6E317
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage
D06R200087
Circuit Description
The powertrain control module (PCM) monitors fuel tank pressure sensor (Vapor pressure sensor) of the Enhanced Evap system. When the tank pressure output indicates low voltage, PCM will set DTC P0452.

D Tank sensor output is less than 0.2 volts for 12.5 sec. D 100 test failures within a 200 tests.
Diagnostic Aids
Check for the following conditions: D Open circuit of 5 volt reference line Inspect wiring harness from PCM to the sensor. The PCM turns P0452, and P0107 at the same time. D Open circuit or short circuit to ground line Inspect wiring harness from PCM to the sensor. The PCM turns P0452 and P0107 at the same time. D Tank fuel pressure sensor malfunction may cause P0452. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.


6E318
DTC P0452 Tank Pressure Sensor Low Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0452 until the DTC P0452 test runs. Note the result. Does the Tech 2 indicates DTC P0452 or P0452/P0107 failed this ignition?
P0452/P0107 turn on Go to Step 3 P0452 turns on Go to Step 6
1. 2. 3. 4.
Ignition OFF. Disconnect connector at the PCM. Ignition ON. At the PCM connector, measure voltage with a DVM at F54 and S37 terminals. 46 V Go to Step 4 Go to Step 10
Was the voltage in range? 4 1. Ignition OFF. 2. Connect the PCM connector to the PCM. 3. Backprobe with a DVM at fuel tank pressure sensor between 5 V reference terminal and sensor ground terminal. Was the voltage within range? 5 1. Locate open wiring of 5 volt reference circuit from the PCM to fuel tank pressure sensor. 2. Repair wiring harness. Is the action complete? 6 1. Ignition ON 2. At the PCM connector, backprobe with a DVM at the sensor output for the voltage. Was voltage within the range? 7 At the sensor output terminal, backprobe with a DVM at the sensor output Was voltage within range? 8 1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete?
46 V
For P0452 go to Step 5 and for P0107, go to diagnosis section.
Go to Step 5
Verify repair
Less than 0.2 V Less than 0.2 V
Go to Step 7
Go to Step 10
Go to Step 9
Go to Step 8
Verify repair
6E319
DTC P0452 Tank Pressure Sensor Low Voltage (Cont'd)

1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete? Verify repair Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10
6E320
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage
D06R200087
Circuit Description
The powertrain control module (PCM) monitors fuel tank pressure sensor (Vapor pressure sensor) of the Enhanced Evap system. When the tank pressure output indicates high voltage , PCM will set DTC P0453.
D A history DTC P0453 will clear after 40 consecutive warm-up cycles have occurred without a fault. D Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
Check for the following conditions: D Open circuit of sensor ground line Inspect wiring harness from PCM to the sensor. The PCM turns P0453, and P0108 at the same time. D Open circuit or short circuit to 5 volt reference line Inspect wiring harness from PCM to the sensor. The PCM turns P0453 and P0108 at the same time. D Tank fuel pressure sensor malfunction may cause P0453. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D Tank sensor output is more than 4.9 volts for 12.5 sec. D 100 test failures within a 200 tests.


6E321
DTC P0453 Fuel Tank Pressure Sensor High Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0453 until the DTC P0453 test runs. Note the result. Does the Tech 2 indicates DTC P0452 or P0452/P0107 failed this ignition?
P0453/P0108 turn on Go to Step 3 P0452 turns on Go to Step 6
1. 2. 3. 4.
Ignition OFF. Disconnect connector at the PCM. Ignition ON. At the PCM connector, measure voltage with a DVM at F54 and S37 terminals. 46 V Go to Step 4 Go to Step 10
Was the voltage in range of voltage? 4 1. Ignition OFF. 2. Connect the PCM connector to the PCM. 3. Disconnect sensor harness at fuel pressure sensor. Measure voltage with a DVM at the end of the tank pressure wiring between 5 V reference terminal and sensor ground terminal. Was the voltage within range? 5 1. Locate open wiring of ground line from the PCM to fuel tank pressure sensor. 2. Repair wiring harness. Is the action complete? 6 1. Ignition ON. 2. At the PCM connector, backprobe with a DVM at the sensor output for the voltage. Was voltage within range? 7 At the sensor output terminal, backprobe with a DVM at the sensor output. Was the voltage within range? 8 1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete?
46 V
For P0453 go to Step 6 and for P0108, go to diagnosis section.
Go to Step 5
Verify repair
More than 4.9 V More than 4.9 V
Go to Step 7
Go to Step 10
Go to Step 9
Go to Step 8
Verify repair
6E322
DTC P0453 Fuel Tank Pressure Sensor High Voltage (Cont'd)

9 10
Replace the tank pressure sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair
6E323
Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak
D06R200087
Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister vent solenoid D Fuel tank (vapor) pressure sensor D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister purge solenoid The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module(PCM)monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned ON, allowing engine vacuum to draw a very small look on the entire evaporative emissions system. After the desired vacuum level has been achieved, the EVAP canister purge solenoid is turned OFF, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A very small leak in the system will cause DTC P0456 to be set.

D D D D D D D D D D D No MAP DTCs set. No TPS DTCs set. No IAT DTCs set. No ECT DTCs set. No tank pressure sensor DTCs set. Baro is more than 70KPa. Fuel level is between 40% and 80%. Throttle angle is less than 3%. Engine speed is less than 1200 RPM. Vehicle speed is less than 5 mph (8 km/h). A vacuum decay condition, indicating a very small leak, is detected during the diagnostic test.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data. Warm up cycles have occurred without a fault.

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D Poor connection at PCMInspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness to the EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
D A history DTC P0456 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P0456 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
Check for the following conditions: D Cracked or punctured EVAP canister. D Damaged source vacuum line, EVAP purge line, EVAP vent hose or fuel tank vapor line. to wire connection.
Diagnostic Trouble Code(DTC)P0456 EVAP Very Small Leak

Was the On-Board(OBD)System Check performed? Go to Step 2
1. 2. 3. 4.
Ignition OFF. Remove the fuel cap. Ignition ON. Observe Fuel Tank Pressure on the Tech 2. 1.51V Go to Step 3
Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 3 1. Visually/physically check for the following conditions: D Vent hose disconnected or damaged. D EVAP canister damaged. D Fuel cap damaged 2. If a problem is found, repair as necessary. Was a problem found? 4 1. 2. 3. 4. Ignition ON, engine OFF. Install the fuel cap. Review and record Tech 2 Failure Records data. Operate the vehicle within Failure Records conditions as noted. 5. Using theTech 2,monitor the DTC info for DTC P0456. Does the Tech 2 indicate DTC P0456? 5 1. Ignition ON, engine idling. 2. Observe Fuel Tank Pressure on the Tech 2. Does the Tech 2 indicate Fuel Tank Pressure at the specified value?
Verify repair
Go to Step 4
Go to Step 6
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Diagnostic Trouble Code(DTC)P0456 EVAP Very Small Leak (Cont'd)

1. Ignition ON, engine idling. 2. Using theTech 2, command the EVAP canister vent solenoid ON (closed) 3. Observe EVAP canister vent solenoid operation second value? 4. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Visually/physically check for the following conditions: D Disconnected or leaking fuel tank vapor line. D Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
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Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance
D06R200091
Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0461 is set.
When there are 12 test failures within 80 test samples, it is stored.

Conditions for Clearing the DTC

D DTC P0461 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.

D Sensor output change is more than 2% within 200km. Or Sensor movement position change is less than 15% within 200km. D IAT is more than 0C. D MAP changing in 3 sec is less than 10kPa. D Engine speed changing in 3 sec is less than 50rpm.
Diagnostic Aids
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.
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DTC P0461 Fuel Level Sensor Performance

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. 2. 3. 4. Ignition Off, Engine Off. Install Tech 2. Ignition On, Engine Off. Check DTC P0462, P0463.
Was the DTC stored? 3 4 Check DTC P0464. Was the DTC stored? 1. Ignition Off, Engine Off. 2. Replace the fuel level sensor. Was the action complete?
Go to applicable DTC table Go to DTC P464 table
Verify repair
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Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor CircuitLow Voltage
D06R200091
Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. Several of the enhanced evaporative system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is more than 85% or less than 15% full. Fuel level DTCs should be diagnosed before other evaporative system DTCs because they can cause other DTCs to be set. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0462 is set.

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

D The PCM will turn the MIL OFF after three consecutive trips without a fault condition present. A history DTC will be cleared if no fault conditions have been detected for 40 warm-up cycles (engine coolant temperature has risen 4C (40F) from the start-up ECT, and ECT exceeds 71C (160F) during that same ignition cycle). D DTC P0462 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids

D D D D D Fuel tank level slosh test is completed. Fuel tank level main test is completed. Fuel tank level data is valid. Fuel tank level signal is less than a specified value. There are 100 test failures within a 200-test sample.
Test Description

8. The following chart can be used to check the sending unit:
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DTC P0462 Fuel Level Sensor Circuit Low Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Disconnected the fuel level sensor harness from its connector at the fuel tank. 2. Ignition ON, engine OFF. 3. Using a DVM, measure the voltage between the sensor harness positive and ground wires. Is the voltage approximately equal to the specified value? 5V Go to Step 6
Go to Step 3
1. Ignition ON, engine OFF. 2. With a DVM, backprobe the PCM connector at the terminal which supplies 5 volts to the fuel level sensor. Is the voltage approximately equal to the specified value? 5V Go to Step 4 Go to Step 9
1. Ignition ON, engine OFF. 2. Fuel level sensor disconnected from wiring harness. 3. With a DVM, probe the 5-volt supply wire at the sensor harness. Is the voltage approximately equal to the value measured in Step 4? Go to Step 5 Go to Step 9
Check for open or high resistance connection in the ground wire between the PCM and the fuel level sensor. Is the action complete? Verify repair Remove the fuel level sensor and check the following: D Does the arm move freely? D Are the wires open or intermittently open when wiggled? D Do the resistance values match the specification chart? Was a problem found? Go to Step 7 Verify repair Go to Step 9 Replace the fuel level sensor. Is the action complete?
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DTC P0462 Fuel Level Sensor Circuit Low Voltage (Cont'd)

Short to ground between the PCM connector and the fuel level sensor. Is the action complete? Verify repair
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Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor CircuitHigh Voltage
D06R200091
Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. Several of the enhanced evaporative system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is more than 85% or less than 15%, full. Fuel level DTCs should be diagnosed before other evaporative system DTCs because they can cause other DTCs to be set. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. High fuel level causes low resistance in the sending unit. This is recognized by the PCM because the circuit operates at a corresponding high voltage. When the circuit is continuously shorted to a voltage source greater than a specified value, or when the 5 volt signal is shorted to ground, DTC P0463 is set.
D Fuel tank level signal is greater than a specified value. D There are 100 test failures within a 200-test sample.


D The PCM will turn the MIL OFF after three consecutive trips without a fault condition present. A history DTC will be cleared if no fault conditions have been detected for 40 warm-up cycles (engine coolant temperature has risen 4C (40F) from the start-up ECT, and ECT exceeds 71C (160F) during that same ignition cycle) or the scan tool clearing function has been used. D DTC P0463 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.

D Fuel tank level slosh test is completed. D Fuel tank level main test is completed. D Fuel tank level data is valid.
Diagnostic Aids
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor.
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2. The ETC and MAP sensors share a ground at PCM terminal D9. 9. Equates the resistance values at various float positions to the following fuel gauge readings:
A change in the display will indicate the location of the fault.
Test Description
DTC P0463 Fuel Level Sensor Circuit High Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Disconnected the fuel level sensor harness from its connector at the fuel tank. 2. Ignition ON, engine OFF. 3. Using a DVM, measure the voltage between the sensor harness positive and ground wires. Is the voltage approximately equal to the specified value? 5V Go to Step 8
Go to Step 3
With the negative DVM lead connected to ground, use the positive DVM lead to probe the sensor ground wire with the harness still disconnected. Does the DVM indicate a short to a voltage source? Go to Step 4 Go to Step 5 Repair short to voltage between the sensor and the PCM. Is the repair complete? Verify repair With the negative DVM lead connected to ground, use the positive DVM lead to probe the sensor positive wire with the harness still disconnected. Does the DVM indicate a voltage greater than the specified value? 5V Go to Step 4 Verify repair Go to Step 6 Go to Step 7
6 7
Open circuit between the PCM connector and the fuel level sensor? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Verify repair
Remove the fuel level sensor and check the following: D Does the arm move freely? D Are the wire leads shorted together? D Do the resistance values match the specification chart? Was a problem found? Go to Step 9 Verify repair Go to Step 7 Replace the fuel level sensor. Is the repair complete?
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Diagnostic Trouble Code (DTC) P0464 Fuel Level Sensor Noisy Signal
D06R200091
Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0464 is set.
When there are 12 test failures within 80 test samples, it is stored.



D D D D D Sensor output changing is more than 15%. Fuel volume level is more than 0.01%. IAT is more than 0C. Vehicle speed is more than 1km/h. Throttle position is more than 2%.
Diagnostic Aids
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DTC P0464 Fuel Level Sensor Noisy Signal

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition Off, Engine Off. 2. Perform Visual/Physical Check for following points. D Lose harness connector D Clacked harness connector D Poor wire condition D Fuel tank condition D Poor sensor condition 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
Go to Step 3
1. Disassemble fuel tank on the vehicle. 2. Check the below items. D Fuel sender Was a problem found? Go to Step 4 Verify repair Go to Step 5 Go to Step 5 Replace the Fuel sender. Was the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Was the action completed? Verify repair
4 5
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Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input
D06RY00070
Circuit Description
The vehicle speed sensor has a magnet rotated by the transmission output shaft. Attached to the sensor is a hall effect circuit the interacts with the magnetic field treated by the rotating magnet. A 12-volt operating supply for the speed sensor hall circuit is supplied from the meter fuse. The VSS pulses to ground the 9-volt signal sent from the powertrain control module (PCM) on the reference circuit. The PCM interprets vehicle speed by the number of pulses to ground per second on the reference circuit.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 10. To avoid backprobing the VSS and possibly damaging a seal or terminal, the VSS output can be tested at the point where the transmission harness connects to the engine harness. Power and ground are applied by jumpers to the VSS through the connectors which are located to the rear of the air cleaner assembly. The VSS signal is monitored with a DVM as the rear driveshaft turns. The wheels can be turned to rotate the driveshaft, or in 2-wheels-drive vehicles the driveshaft can be turned directly.

D D D D D Engine is running. Engine speed is between 1800 RPM and 2500 RPM. Throttle angle is between 10% and 40%. Engine load is greater than 50 kPa. PCM detects no VSS signal for 12.5 seconds over a period of 15 seconds.

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DTC P0502 VSS Circuit Low Input

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to Step 10 Does the speedometer work? 1. Disconnect the VSS connector. 2. Ignition ON. 3. Using a test light to battery +, probe the connector ground wire. Did the light illuminate? Go to Step 5 Verify repair
2 3
Go to Step 4
4 5
Repair the sensor ground. Is the action complete? 1. Ignition ON, sensor disconnected. 2. Using a DVM, measure at the VSS connector between ground and voltage supply. Was the measurement near the specified value? Repair the open or short to ground which may have blown the meter fuse. Is the action complete? Verify repair 1. Ignition ON, VSS disconnected. 2. Using a DVM, measure at the VSS connector between ground and the wire from the speedometer. Was the measurement near the specified value? 7.5-8 V Go to Step 9 Go to Step 8 Check for an open or short circuit between the speedometer and the VSS. Was an open or short circuit located? Verify repair Verify repair Go to Step 9 Replace the speedometer. Is the action complete?
Battery voltage
Go to Step 7
Go to Step 6
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DTC P0502 VSS Circuit Low Input (Cont'd)

10
1. Ignition OFF. 2. Disconnect the MAF sensor. The connector attaches the VSS wires from the transmission harness to the left-side engine harness. 3. Disconnect the black 16-way connector. 4. Select a terminal adapter from kit J 35616 that can be used with a jumper to supply B+ to the blue wire with a yellow tracer (transmission side of the connector). 5. Use another terminal adapter to attach a voltmeter to the light-green wire with a white tracer (next to the wire in the previous step.) 6. Disconnect the blue connector next to the black 16-way connector, and locate the black/red tracer wire at one corner of the blue connector. The black/red wire is the VSS ground. Use a terminal adapter to attach a jumper to ground to the black/red VSS ground wire at the transmission side of the blue connector. 7. Raise the rear wheels off the ground with transmission in neutral. Does the DVM toggle back and forth between 0.6 V and 10 V as the wheels (and driveshaft) are rotated? Go to Step 11 Verify repair Go to Step 12
11 12
Replace the VSS. Is the action complete? Check for an open or short between the PCM and the speedometer. Was a problem found? Verify repair Go to Step 13 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
13
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Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM
D06RY00158
Circuit Description
The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in position (%) to adjustment the throttle valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. If the PCM detects a condition where too low of an idle speed is present and the PCM is unable to adjust idle speed by increasing the throttle position, DTC P0506 will set, indicating a problem with the idle control system.
D All conditions are met for 10 seconds. D Barometric pressure is more than 74.5 kPa. D Engine speed is more than 100-200 RPM lower than desired idle based upon coolant temperature.



D No TPS, VSS, ECT, EGR, MAF, MAP, IAT, low voltage, fuel system, canister purge, injector control, or ignition control DTCs are set. D MAP is less than 60 kPa. D Canister purge duty cycle is above 10%. D Engine running time is more than 125 seconds. D Vehicle speed is less than 1 mph. D Engine coolant temperature (ECT) is above 50C (122F). D Ignition voltage is between 9.5 volts and 16.7 volts. D The throttle is closed. D EVAP purge duty cycle more than 10%.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM or throttle DC motor Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage.

D Restricted air intake system Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body Check for objects blocking the ETC passage or throttle bore, excessive deposits in the ETC passage and on the ETC position, and excessive deposits in the throttle bore and on the throttle plate.
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D Large vacuum leak Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty PCV valve or brake booster hose disconnected. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
DTC P0506 Idle Air Control System Low RPM

Visually/physically inspect for the following conditions: D Throttle body tampering. D Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. D Throttle body with lever: Check for objects send round the throttle spring lever that lever is smooth movement, and spring lever has not excessive play Do any of the above require a repair? Visually/physically inspect for the following conditions: D Acceleration pedal tampering. D Acceleration pedal : Check for objects blocking the spring or pedal arm. D Acceleration pedal : Check for objects move the acceleration pedal that pedal is smooth movement, and acceleration pedal arm has not excessive play. Do any of the above require a repair? 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the acceleration position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found?
Refer to appropriate section for onvehicle service
Go to Step 3
Refer to appropriatese ction for on-vehicle service
Go to Step 4
Verify repair
Go to Step 5
Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Throttle position sensor 1 circuit. D Throttle position sensor 2 circuit. D Throttle DC motor circuit. Vcc-GND 17km D Throttle position sensor resistance. SIG-DND D Throttle DC motor resistance. change D If a problem is found, repair as necessary. resistance0.3 100m Was a problem found?
Verify repair
Go to Step 6
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DTC P0506 Idle Air Control System Low RPM (Cont'd)

6 7
Replace the throttle valve. Is the action complete? 1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: Accelerator position sensor 1 circuit. Accelerator position sensor 2 circuit. Sensor resistance. 2. If a problem is found, repair as necessary. Was a problem found? Vcc-GND 46km SIG-DND change resistance Go to Step 7
Verify repair Go to Step 9 Go to applicable DTC table Go to applicable DTC table
Go to Step 8
8 9
Replace the acceleration position sensor. Is the action complete? Following below the DTCs stored: P1125, P1290, P1295, P1299 Following below the DTCs stored:P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
Go to Step 10
10
Go to Step 11
11
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Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM
D06RY00158
Circuit Description
The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in position (%) to adjustment the throttle valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. If the PCM detects a condition where too high of an idle speed is present and the PCM is unable to adjust idle speed by increasing the throttle position, DTC P0507 will set, indicating a problem with the idle control system.
D All conditions are met for 10 seconds. D Engine speed is more than 100-200 RPM higher than desired idle based upon coolant temperature. D Barometric pressure is more than 74.5 kPa.



D No TPS, VSS, ECT, EGR, MAF, MAP, IAT, low voltage, fuel system, canister purge, injector control or ignition control DTCs are set. D Barometric pressure is above 75 kPa. D Canister purge duty cycle is above 10%. D Engine running time is more than 125 seconds. D Vehicle speed is less than 1 mph. D Engine coolant temperature (ECT) is above 50C (122F). D Ignition voltage is between 9.5 volts and 16.7 volts. D The throttle is closed. D EVAP purge duty cycle is more than 10%.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM or throttle DC motor Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or
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D Throttle body Check for sticking throttle plate. Also inspect the air passage for deposits or objects which will not allow the ETC position to fully extend or properly seat. If DTC P0507 cannot be duplicated, reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. D Vacuum leak Check for a condition that causes a vacuum leak, such as disconnected or damaged hoses, leaks at EGR valve and EGR pipe to intake manifold, leak at the throttle body, a faulty or incorrectly installed PCV valve, leaks at the intake manifold, etc.
DTC P0507 Idle Air Control System High RPM

Visually/physically inspect for the following conditions: D Throttle body tampering. D Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. D Throttle body with lever: Check for objects send round the throttle spring lever that lever is smooth movement, and spring lever has not excessive play Do any of the above require a repair? Visually/physically inspect for the following conditions: D Accelerator pedal tampering. D Accelerator pedal : Check for objects blocking the spring or pedal arm. D Accelerator pedal : Check for objects move the accelerator pedal that pedal is smooth movement, and accelerator pedal arm has not excessive play. Do any of the above require a repair? 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the accelerator position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found?
Go to Step 4
Go to Step 3
Verify repair
Go to Step 5
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DTC P0507 Idle Air Control System High RPM (Cont'd)

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Throttle position sensor 1 circuit. D Throttle position sensor 2 circuit. D Throttle DC motor circuit. Vcc-GND 17km D Throttle position sensor resistance. SIG-GND D Throttle DC motor resistance. change D If a problem is found, repair as necessary. resistance 0.3 100m Was a problem found? Replace the throttle valve. Is the action complete?
Go to Step 6
6 7
1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Accelerator position sensor 1 circuit. D Accelerator position sensor 2 circuit. D Sensor 3 circuit. D Sensor resistance. 2. If a problem is found, repair as necessary. Was a problem found? Replace the accelerator position sensor. Is the action complete?
Vcc-GND 46km SIG-GND change resistance
Verify repair Go to Step 9 Go to applicable DTC table Go to applicable DTC table
Go to Step 8
8 9
Stored DTCs: P1125, P1290, P1295, P1299
Go to Step 10
10
Stored DTCs: P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Go to Step 11
11
Verify repair
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Diagnostic Trouble Code (DTC) P0562 System Voltage Low
D06R200017
Circuit Description
The powertrain control module (PCM) monitors the system voltage on the ignition feed terminal to the PCM. A system voltage DTC will set whenever the voltage is below a calibrated value.


D Ignition ON. D System voltage is below 11.5 volts for 40 seconds.
Diagnostic Aids
If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw.

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store as Failure Records conditions which were present when the DTC was set. This information will not be stored as Freeze Frame data.
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DTC P0562 System Voltage Low

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Using a DVM, measure the battery voltage at the battery. Is the battery voltage greater than the specified value? 11.5 V Go to Step 3 1. Install a Tech 2. 2. Select Ignition Volts on the Tech 2. 3. Start the engine and raise the engine speed to the specified value. 4. Load the electrical system by turning on the headlights, high blower, etc. Is the ignition voltage approximately equal to the specified value? 2000 RPM 12.8-14.1 V Go to Step 4
Go to OBD System Check Charge battery, then go to Step 3
Go to Starting/Char ging
1. Ignition OFF. 2. Disconnect the PCM connector at the PCM. 3. Using a DVM, measure the battery voltage at the PCM connector F-20 and F-57. Is it approximately equal to battery voltage? Go to Step 5 Go to Step 6 1. Check for faulty connections at the PCM harness terminals. 2. Repair as necessary. Was a repair necessary? Verify repair Verify repair Go to Step 7 Go to Step 7 Check for an open battery feed circuit to the PCM. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6 7
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Diagnostic Trouble Code (DTC) P0563 System Voltage High
D06R200017
Circuit Description
The powertrain control module (PCM) monitors the system voltage on the ignition feed terminals to the PCM. A system voltage DTC will set whenever the voltage is above a calibrated value.


D Ignition ON. D System voltage is above 16 volts for 40 seconds.
Diagnostic Aids
If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw.

6E347
DTC P0563 System Voltage High

Was the ON-Board Diagnostic (OBD) System Check performed? Go to Step 2 Using a DVM, measure the battery voltage at the battery. Is the battery voltage less than the specified value? 11.5 V Go to Step 3
Go to Step 4
1. Charge the battery and clean the battery terminals. 2. Clean the battery ground cable connection if corrosion is indicated. Is the battery voltage less than the specified value? 11.5 V 1. 2. 3. 4. Turn OFF all the accessories. Install a Tech 2. Select the ignition voltage parameter on the Tech 2. Start the engine and raise the engine RPM to the specified value. 2000 RPM
Replace battery
Go to Step 4
Is the voltage more than 2.5 volts greater than the measurement taken in step 2 or 3? 5 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?
Go to Starting/ Charging
Go to Step 5
Verify repair
6E348
Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error
D06R200018
Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to power train control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up.


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0565 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P0565 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

D D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remains on for 15 seconds or more. Noises are generated by poor switch contact 60 times within 1 second.
Diagnostic Aids
An intermittent may be caused by the following:

D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the
6E349
cruise main switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0565 cannot be duplicated, the information included n the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0565 Diagnostic Chart may isolate the cause of the fault.
DTC P0565 Cruise Main Switch Circuit Error

1. Ignition ON, engine ON. 2. Observe the cruise main lamp in the switch. Is the cruise main lamp ON? Go to Step 3 Check the Procedure Refer to Diagnostic Aids Go to Step 4 1. Push the auto cruise main switch. 2. Observe the cruise main lamp in the switch. Is the cruise main lamp OFF?
Go to Step 4
Check the signal circuit for auto cruise main switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module(PCM). 3. Disconnect the cruise main switch. Check for an open cruise main switch signal circuit between the PCM and the cruise main switch. Is a problem found? Go to Step 5 Verify repair Go to Step 7 Go to Step 6 Go to Step 8
5 6 7
Repair the auto cruise main switch signal circuit. Is the action complete? Check the auto cruise main switch and lamp circuit. Is a problem found? Repair or replace the auto cruise main switch and lamp circuit. Is the action complete? PCM must be Verify repair Replace the PCM. IMPORTANT: The programmed. replacement
6E350
Diagnostic Trouble Code (DTC) P0566 Cruise Cancel Switch Circuit Error
D06R200018
Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up. When the cancel switch is ON, cruise system is OFF.
D Noises are generated by poor switch contact 100 times within 1.6 seconds.



D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remains on for 40 seconds or more.

6E351
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the cruise cancel switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0566 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0566 Diagnostic Chart may isolate the cause of the fault.
DTC P0566 Cruise Cancel Switch Circuit Error

Check the signal circuit for auto cruise cancel switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module(PCM). 3. Disconnect the cruise cancel switch. Check for cruise cancel switch signal circuit between the PCM and the cruise cancel switch. Is a problem found? PCM must be Go to Step 3 Verify repair Go to Step 5 Verify repair Go to Step 4 Go to Step 6
3 4 5 6
Repair the main cruise cancel switch signal circuit. Is the action complete? Check the auto cruise main switch. Is a problem found? Repair or replace the main cruise main switch. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement
6E352
Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error
D06R200018
Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up. When the resume switch is ON, vehicle speed is reset to the previous set speed.



D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remain on for 50 seconds or more.
6E353
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage.
If the harness appears to be OK, observe the Cruise resume switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0567 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0567 Diagnostic Chart may isolate the cause of the fault.
DTC P0567 Cruise Resume Switch Circuit Error

Check the signal circuit for auto cruise resume switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module (PCM). 3. Disconnect the cruise resume switch. Check for cruise resume switch signal circuit between the PCM and the cruise resume switch. Is a problem found? Go to Step 3 PCM must be Verify repair Go to Step 5 Verify repair Go to Step 4 Go to Step 6
3 4 5 6
Repair the main cruise resume switch signal circuit. Is the action complete? Check the auto cruise resume switch. Is a problem found? Repair or replace the main cruise resume switch. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement
6E354
Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error
D06R200018
Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module (PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up. When the set switch is ON, vehicle speed is set.



D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remain on for 120 seconds or more.

6E355
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the cruise set switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0568 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0568 Diagnostic Chart may isolate the cause of the fault.
DTC P0568 Cruise Set Switch Circuit Error

1. Ignition ON, engine ON. 2. Observe the cruise indicator lamp in the meter. Is the cruise indicator lamp ON? Go to Step 3 Check the Procedure Refer to Diagnostic Aids Go to Step 4 1. Push the auto cruise set switch. 2. Observe the cruise indicator lamp in the meter. Is the cruise indicator lamp OFF ?
Go to Step 5
Check the signal circuit for auto cruise set switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module (PCM). 3. Disconnect the cruise set switch. Check for cruise set switch signal circuit between the PCM and the cruise set switch. Is a problem found? Go to Step 5 PCM must be Verify repair Go to Step 7 Verify repair Go to Step 6 Go to Step 8
5 6 7 8
Repair the main cruise set switch signal circuit. Is the action complete? Check the auto cruise set switch. Is a problem found? Repair or replace the main cruise set switch. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement
6E356
Diagnostic Trouble Code (DTC) P0571 No Brake Switch Signal
D06R200076
Circuit Description
The brake switch has 3 functions. D Brake pedal operation check D Brake light operation (On and off) D Cruise control (Cancel) The PCM receives vehicle speed and switch position signals from the brake switch. The PCM sets brake operating conditions in response to these signals. If the brake switch is on, the brake system is in normal operation (cruise control cancelled).

D The PCM will not turn the malfunction indicator lamp (MIL) ON. D The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.


D Two brake switch signals not acknowledged after signal changed. D VSS not defective. D Engine is running. D Vehicle speed above 20km/h.
Diagnostic Aids
6E357
DTC P0571 No Brake Switch Signal

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition Off. Engine Off. 2. Check following fuses. D BACK 15A D STOP LAMP 15A Was a problem found? Verify repair
Go to Step 3
1. Make adjustment to the brake switch. The brake switch is installed to the brake pedal assembly. (Refer to Brake switch in 10A CRUISE CONTROL SYSTEM.) Was the problem found? Verify repair Go to Step 4 1. Push the shaft at brake switch. 2. Check shaft operation for smooth movements. Was the problem found? Verify repair Go to Step 5 1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Leave the shaft position at brake switch. Dont Between pin1 push it.) and pin2 is D Between pin 1 and pin 2 0m, Between D Between pin 3 and pin 4 pin3 and pin4 Was it specified value? is m 1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Push the shaft position at brake switch and hold it) Between pin1 and pin2 is D Between pin 1 and pin 2 m, Between D Between pin 3 and pin 4 pin3 and pin4 is 0m Was it specified value? 1. Probe related circuits for open or short to ground. 2. If a problem was found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Replace the ECM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Was the action completed? Verify repair Verify repair
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 9
1. Replace the brake switch. Was the action completed?
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Diagnostic Trouble Code (DTC) P0601 PCM Memory
060RY014
Circuit Description
The powertrain control module (PCM) used in this vehicle utilizes an electrically erasable programmable read-only memory (EEPROM). The EEPROM contains program information and the calibrations required for engine, transmission, and powertrain diagnostics operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. When the PCM is replaced or a calibration update is required, the PCM must be programmed using a Tech 2. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for the EEPROM programming procedure.


D The PCM detects an internal program fault (check sum error).
Diagnostic Aids
D DTC P0601 indicates that the contents of the EEPROM have changed since the PCM was programmed. The only possible repair is PCM replacement. Remember to program the replacement PCM with the correct software and calibration for the vehicle.

6E359
DTC P0601 PCM Memory

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6E360
Diagnostic Trouble Code (DTC) P0602 PCM Programming Error
060RY014
Circuit Description
The powertrain control module (PCM) uses Main CPU and Watchdog CPU software/calibration.
D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.


D This code detects inconsistencies between Main CPU and Watchdog CPU software/calibration.

D The PCM will not illuminate the malfunction indicator lamp (MIL).
6E361
DTC P0602 PCM Programming Error

6E362
Diagnostic Trouble Code (DTC) P0604 PCM RAM Error
060RY014
Circuit Description
The powertrain control module (PCM) uses Main CPU RAM and Watchdog CPU RAM.


D This code detects inconsistencies between Main CPU RAM and Watchdog CPU RAM.

6E363
DTC P0604 PCM RAM Error

6E364
Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance
060RY014
Circuit Description
The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs.



D This code detects inconsistencies between Main CPU A/D converters and Watchdog CPU A/D converters.
6E365
DTC P0606 PCM Internal Performance

6E366
Diagnostic Trouble Code (DTC) P0660 VIM Solenoid Circuit Open
D06R200089
Circuit Description
The VIM (Variable Intake Manifold) solenoid (intake air VSV) circuit controls the induction control valve that the length of a port is switched. The VIM solenoid is controlled by the Power Train Control Module (PCM). When the engine speed is less than 3600 RPM, the VIM solenoid is ON and when the engine speed is more than 3600 RPM, the VSV is OFF. The induction control valve is closed at the VIM solenoid is ON, and it is opened at the VSV is OFF. If the VIM solenoid circuit is opened, DTC P0660 will set.

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run an the fault condition is no longer present. D A history DTC P0660 will clear after 40 consecutive trip cycles during which the warm up cycles have occurs without a fault.
Diagnostic Aids
Check for following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness inspect the wiring harness to the solenoid and the fuel tank pressure sensor for an intermittent open short circuit.

D The Ignition is ON. D Ignition voltage is more than 11V. D There are 20 test failures within a 28test sample.

6E367
DTC P0660 VIM Solenoid Circuit Open

Was the OnBoard Diagnostic (OBD) System Check performed? Go to Step 2 1. Check the DTC. Was the DTC for the Mass Air Flow (MAF) sensor or the purge duty solenoid valve stored? Go to Step 3
1. Check the circuit between the ENGINE fuse and the MAD sensor or the Variable Intake Manifold solenoid (intake air VSV). 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair 1. Using the Tech 2, perform the Variable Intake Manifold Test. Refer to Variable Intake Manifold Test Was a problem found? Go to Step 7 Check the Procedure Refer to Diagnostic Aids Verify repair
Go to Step 5
1. Using the Tech 2, command the VIM solenoid ON and OFF. 2. Observe working noise for the VIM solenoid. Was working noise detected?
Go to Step 6
6 7
1. Replace the VIM solenoid. Is the action complete? 1. Check the circuit between the ENGINE fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 8 1. Check the circuit between the PCM fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6E368
Diagnostic Trouble Code (DTC) P0662 VIM Solenoid Circuit Short
D06R200089
Circuit Description
The VIM (Variable Intake Manifold) solenoid (intake air VSV) circuit controls the induction control valve that the length of a port is switched. The VIM solenoid is controlled by the Power Train Control Module (PCM). When the engine speed is less than 3600 RPM, the VIM solenoid is ON and when the engine speed is more than 3600 RPM, the VSV is OFF. The induction control valve is closed at the VIM solenoid is ON, and it is opened at the VSV is OFF. If the VIM solenoid circuit is opened, DTC P0660 will set.

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run an the fault condition is no longer present. D A history DTC P0660 will clear after 40 consecutive trip cycles during which the warm up cycles have occurs without a fault.
Diagnostic Aids
Check for following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness inspect the wiring harness to the solenoid and the fuel tank pressure sensor for an intermittent open short circuit.

D The Ignition is ON. D Ignition voltage is more than 11V. D There are 20 test failures within a 28test sample.

6E369
DTC P0662 VIM Solenoid Circuit Short

Was the OnBoard Diagnostic (OBD) System Check performed? Go to Step 2 1. Check the DTC. Was the DTC for the Mass Air Flow (MAF) sensor or the purge duty solenoid valve stored? Go to Step 3
1. Check the circuit between the ENGINE fuse and the MAD sensor or the Variable Intake Manifold solenoid (intake air VSV). 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair 1. Using the Tech 2, perform the Variable Intake Manifold Test. Refer to Variable Intake Manifold Test Was a problem found? Go to Step 7 Check the Procedure Refer to Diagnostic Aids Verify repair
Go to Step 5
1. Using the Tech 2, command the VIM solenoid ON and OFF. 2. Observe working noise for the VIM solenoid. Was working noise detected?
Go to Step 6
6 7
1. Replace the VIM solenoid. Is the action complete? 1. Check the circuit between the ENGINE fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 8 1. Check the circuit between the PCM fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6E370
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage
D06R200048
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the liner EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that is intermittently above the calculated value, DTC P1106 will set.

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Diagnostic Aids
Check for the following conditions: D Leaking or plugged vacuum supply line to the MAP sensor. D Inspect PCM harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

D No TP sensor DTCs are present. D Engine is running for at least 10 seconds. D Throttle angle is below 3% if engine speed is below 1000 RPM. D Throttle angle is below 10% if engine speed is above 1000 RPM. D The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 5 seconds over a 16-second period of time.

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. D The MAP sensor shares a 5 Volt Reference with the Fuel Tank Pressure sensor. Check the 5 Volt reference if this DTC is also set.
6E371
D The MAP sensor shares a ground with the Fuel Tank Pressure sensor and the ECT Sensor. Check the ground if these other DTCs are also set.
DTC P1106 MAP Sensor Circuit Intermittent High Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0108 chart first Go to Step 6 Is DTC P0108 also set?
3 4
Are DTC P1111, P1115, and/or P1120 also set? Check for a poor sensor ground circuit terminal connection at the MAP sensor. Was a problem found?
Go to Step 9
Go to Step 5
Check the MAP signal circuit between the MAP sensor connector and the PCM for an intermittent short to voltage. Was a problem found? Go to Step 10 Go to Step 8 Check for an intermittent short to voltage on the 5 volt reference circuit between the PCM and the following components: D MAP sensor D EGR valve D TP sensor Was a problem found? Go to Step 10 Go to Step 7 Check for a poor sensor ground circuit terminal connection at the PCM. Was a problem found? Go to Step 9 Go to Step 8 Check the Procedure Refer to Diagnostic Aids Check for an intermittent open or a faulty splice in the sensor ground circuit. Was a problem found? Go to Step 10
Replace the faulty harness connector terminal for the sensor ground circuit. Is the action complete? Verify repair Locate and repair the intermittent open/short circuit in the wiring harness as necessary. Is the action complete? Verify repair
10
6E372
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage
D06R200048
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that is intermittently below the calculated value, DTC P1107 will be set.
approximately 5 seconds over a 16-second period of time.


D A history DTC P1107 will Clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1107 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

D D D D No TP sensor DTCs are present. Engine is running. Ignition voltage is more than 11 volts. Throttle angle is above 1% if engine speed is less than 1000 RPM. D Throttle angle is above 3% if engine speed is above 1000 RPM. D The MAP sensor indicates an intermittent manifold absolute pressure below 11 kPa for a total of
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D The MAP Sensor shares a 5 Volt reference with the EGR Valve. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit or components itself. D The MAP Sensor share a ground with the EGR Valve and the IAT Sensor.

D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.
6E373
DTC P1107 MAP Sensor Circuit Intermittent Low Voltage

3 4
Are DTC P1111, P1115, and/or P1120 also set? Check for a poor sensor ground circuit terminal connection at the MAP sensor. Was a problem found?
Go to Step 9
Go to Step 5
Check the MAP signal circuit between the MAP sensor connector and the PCM for an intermittent short to voltage. Was a problem found? Go to Step 10 Go to Step 8 Check for an intermittent short to voltage on the 5 volt reference circuit between the PCM and the following components: D MAP sensor D EGR valve D TP sensor Was a problem found? Go to Step 10 Go to Step 7 Check for a poor sensor ground circuit terminal connection at the PCM. Was a problem found? Go to Step 9 Go to Step 8 Check the Procedure Refer to Diagnostic Aids Check for an intermittent open or a faulty splice in the sensor ground circuit. Was a problem found? Go to Step 10
Replace the faulty harness connector terminal for the sensor ground circuit. Is the action complete? Verify repair Locate and repair the intermittent open/short circuit in the wiring harness as necessary. Is the action complete? Verify repair
10
6E374
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage
D06RY00168
Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower causing the PCM to monitor a lower voltage. DTC P1111 will set when the PCM intermittently detects an excessively high signal voltage on the intake air temperature sensor signal circuit.
D The PCM will store conditions which were present when the DTC set as Failure Records data only. This information will not be stored as Freeze Frame data. D DTC P1111 does not illuminate the MIL.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D D D D D The engine has been running for over 30 seconds. Vehicle speed is less than 32 km/h (20 mph). Engine coolant temperature is above 60C (140F). Mass air flow is less than 20g/second. IAT signal voltage indicates and intake air temperature intermittently less than 39C (38F) (about 5 volts) for approximately 2.5 seconds over a 25-second period of time.

D The PCM will substitute a default value for intake air temperature.
6E375

6E376
DTC P1111 IAT Sensor Circuit Intermittent High Voltage

3 4
Is DTC P1115, also set? 1. Check for a poor sensor ground circuit terminal connection at the IAT sensor. 2. If a problem is found, repair as necessary. Was a problem found?
Verify repair
Go to Step 5
1. Check for a poor IAT signal circuit terminal connection at the IAT sensor. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 6 1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent open. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent short to voltage. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Check for a poor sensor ground circuit terminal connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Check the Procedure Refer to Diagnostic Aids 1. Check for an intermittent open or a faulty splice in the sensor ground circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
6E377
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage
D06RY00168
Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance becomes lower, causing the PCM to monitor a lower voltage. DTC P1112 will set when the PCM intermittently detects an excessively low signal voltage on the intake air temperature sensor signal circuit.
D The PCM will substitute a default value for intake air temperature.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D The engine has been running for over 15 seconds. D Vehicle speed is greater than 48 km/h (30 mph). D IAT signal voltage is greater than 148C (298F) (about 0.10 volt) for a total of 2.5 seconds over a 25-second period of time.

Test Description
6E378
2. Verifies that the fault is present. 3. If DTC P1112 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Value Chart. The chart may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature. If this is the case, replace the IAT sensor.

DTC P1112 IAT Sensor Circuit Intermittent Low Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0112 first Is DTC P0112 also set? 1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent short to ground. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
Go to OBD System Check Go to Step 3 Check the Procedure Refer to Diagnostic Aids
2 3
6E379
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage
D06R200049
Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM) applies a voltage (about 5.0 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts. If the PCM detects an ECT signal that is intermittently below the range of the ECT sensor, DTC P1114 will set.
D The PCM will store conditions which were present when the DTC set as Failure Records data only. This information will not be stored as Freeze Frame data.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

D Engine run time longer than 120 seconds. D The ECT sensor signal is intermittently greater than 150C (302F) (about 0.10 volt) for a total of 10 seconds over a 100-second period.

6E380

DTC P1114 ECT Circuit Intermittent Low Voltage

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0117 first Is DTC P0117 also set? 1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent short to ground. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
Go to OBD System Check Go to Step 3 Check the Procedure Refer to Diagnostic Aids
2 3
6E381
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage
D06R200049
Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM) applies a voltage (about 5.0 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts. If the PCM detects an ECT signal that is intermittently above the range of the ECT sensor, DTC P1115 will set.
D The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

D Engine running time longer than 90 seconds. D The ECT sensor signal is intermittently greater than 39C (38F) (about 5 volts) for a total of 10 seconds over a 100-second period.

6E382

6E383
DTC P1115 ECT Sensor Circuit Intermittent High Voltage

3 4
Is DTC P1111 also set? 1. Check for a poor sensor ground circuit terminal connection at the ECT sensor. 2. If a problem is found, repair as necessary. Was a problem found?
Verify repair
Go to Step 5
1. Check for a poor ECT signal circuit terminal connection at the ECT sensor. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 6 1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent open. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent short to voltage. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Check for a poor sensor ground circuit terminal connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Check the Procedure Refer to Diagnostic Aids 1. Check for an intermittent open or a faulty splice in the sensor ground circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
6E384
Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault
D06RY00088
Circuit Description
D The throttle position (TP) sensor circuit provides a voltage signal relative to throttle blade angle. The throttle blade angle will vary about 8 % at closed throttle to about 92 % at wide open throttle(WOT). This code detects a continuous short to ground or high in either the cicuit or the sensor.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D The MAP sensor shares a 5 Volt reference with the Fuel Tank Pressure, APS1, APS3 and EGR value. D The MAP sensor shares a ground with the Fuel Tank Pressure, the ECT sensor, and the Transmission Fluid. D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK,observe the TPS 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

D The Ignition is ON. D The throttle blade angle is less than 2.5 % or more tnan 97.5 % for 18 failres within 500 test samples (15.6m sec)


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A histror DTC P1120 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault.

If DTC P1120 cannot be duplicated,the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1120 Diagnostic Chart may isolate the cause of the fault.
6E385
Diagnostic Trouble Code(DTC)P1120-TPS 1 Circuit Fault

Go to OBD System Check Go to ETC System check
Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Ignition ON, engine not running. 2. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value? 100kPa Go to Step 4
Go to Step 7
1. Disconnect the MAP sensor. 2. Connect a test 5 volt reference circuit and the MAP signal at the MAP sensor harness connector. 3. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value? (If no, start with diagnosis chart forother sensors in the circuit and see if 5V returns.)
Go to Step 6
Go to Step 5
1. Check the MAP signal circuit between the PCM and MAP grund circuit. 2. If the MAP signal circuit is open or shoted, repair it as necessary. Was the MAP signal circuit open or shorted? Verify repair Verify repair Go to Step 13 Replace the MAP sensor. Is the action complete? 1. 2. 3. 4. Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
6 7
NOTE: The value check of TPS must be performed in less than 15 seconds. Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle value? 8 Was the DTC P1120 stored?
Closed throttle TPS1= 612% Wide open throttle TPS1= 7983%
Go to Step 8
Go to Step 9 Check the procedure. Refer to Diagnostic Aids
9 1. Connect a DVM between the 5Volt reference circuit and the TP sensor ground circuit at the TP1sensor harness connector. 2. Observe the voltage using a DVM. Is the voltage near the specified value? 5V
Go to Step 13
Go to Step 10
Go to Step 11
6E386
Diagnostic Trouble Code(DTC)P1120-TPS 1 Circuit Fault (Cont'd)

10
Check the following items; 1. TP1 signal circuit for a short to voltage. 2. TP1 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1 sensor ground circuit for a poor connection. 4. If a problem is found,repair wiring harness as necessary. Was a problem found? Verify repair Go to Step 11
11
Check the following items; 1. TP signal circuit or 5 volt reference circuit for a poor connection. 2. TP signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? PCM must be Verify repair Verify repair Go to Step 12 Go to Step 13
12 13
Replace the TP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The programmed. replacement
Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair
6E387
Diagnostic Trouble Code (DTC) P1125 ETC (Electric throttle control) Limit Performance Mode
D06RY00157
Circuit Description
D The acceleration position (AP1) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle will vary about 13 % at idle position to about 87 % at wide open throttle (WOT). This code detects if the system is in Limit Performance Mode (Fail safe Mode) and Multiple DTCs performance Mode.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 1, APP sensor 2, APP sensor 3 display on the Tech 2 While moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1125 cannot be duplicated,the information includedin the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,performing the DTC P1125 Diagnostic Chart may isolate the cause of the fault.

D The Ignition is ON. D Limit Performance Mode is active. (Fail safe Mode)


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P1125 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault.
6E388
DTC P1125 ETC Limit Performance Model

Warming up the engine until the ECT rise at 80C Closed throttle APS1 Ignition OFF. = 11 15% Ignition ON but not engine run. APS2 = Observe the AP angle reading on the Tech 2 while 8589% alowly opening the throttle. APS3 = Does the AP angle increase steadily and evenly from 8589% Wide the closed throttle value to the wide open throttle open throttle value? APS1 = 8589% APS2 = 1115% APS3 = 3236% 1. 2. 3. 4. Was the P1125 stored?
Go to Step 3
4 1. Connect a DVM between the 5 Voltge supply circuit and the AP1, AP2 AND AP3 sensor ground circuit at the AP sensor harness connector. 2. Observe the voltage using a DVM. Is the voltage reading near the specified value? 5 Check the following items; 1. AP1, AP2 or AP3 signal circuit for a short to voltage. 2. AP1, AP2 or AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1, AP2 or AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found? 6 Check the following items; 1. AP1, AP2 or AP3 signal circuit or 5 volge supply circuit for a poor connection. 2. AP1, AP2 or AP3 signal circuit or 5 volge supply circuit for high resistance between the PCM and the AP1, AP2 or AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? 5V
Go to Step 8
Go to Step 5
Go to Step 6
Verify repair
Go to Step 6
Verify repair
Go to Step 7
6E389
DTC P1125 ETC Limit Performance Model (Cont'd)

7 8
Replace the AP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The replacement PCM must be programmed.Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair Verify repair Go to Step 8
6E390
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1
D06R200010
Circuit Description
The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop and stoichiometric operation have been enabled. During this test period the PCM counts the number of times that the HO2S signal voltage crosses the rich-to-lean and lean-to-rich threshold. If the PCM determines that the HO2S did not switch enough times, DTC P1133 will be set. A lean-to-rich switch is determined when the HO2S voltage changes above and below 450 mV. Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.
D Mass air flow (MAF) is between 9 g/second and 42 g/second. D Above conditions are present for 3 seconds. D 90 seconds after closed loop and stoichiometric operation have been achieved, the PCM monitors the oxygen sensor as it switches above and below 450 mV. If fewer than 23 rich-to-lean and lean-to-rich switches are detected, DTC P1133 will be set.

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D Open loop fuel control will be in effect. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P1133 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1133 can be cleared by using Tech 2 Clear Info function or by disconnecting the PCM battery feed.

D Engine coolant temperature (ECT) is above 60C (140F). D Engine is operating in closed loop. D The engine has been running at least one minute. D Canister purge duty cycle is greater than 2%. D Engine speed is between 1500 RPM and 3000 RPM.
6E391
Diagnostic Aids
A malfunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1133 to set. Check HO2S heater circuitry for intermittent faults or poor connections. If connections and wiring are OK and DTC P1133 continues to set, replace the Bank 1 HO2S 1. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help to determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
3. A condition that affects other heated oxygen sensors indicates probable contamination. To avoid damaging the replacement sensors, correct the condition which caused the contamination before replacing the affected sensors. 5. This step checks for conditions which may cause the heated oxygen sensor to appear faulty. Correct any of the described conditions if present. 11.To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.
Test Description
DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 IMPORTANT: If any DTCs are set (except P1153 or P1154) refer to those DTCs before proceeding with this diagnostic chart. 1. Engine idling at operating temperature. 2. Operating the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 3. Using a Tech 2, monitor DTC info for DTC P1133 until the DTC P1133 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P1133 failed this ignition? Go to Step 3 Go to Step 20 Go to Step 5 Go to Step 2
3 4 5 6
Did the Tech 2 also indicate that the P1153 or P1154 tests failed? Check for leaks at the exhaust pipe joints. Are the joints leaking? Tighten the bolt/nuts at the leaking joints. Is your action complete? Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?
Go to Step 7
Go to Step 8
8 9 10
6E392
DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1 (Cont'd)

11 12 13
Replace the exhaust pipes, as required. Is your action complete? Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete? Go to Step 2 Visually/physically inspect the following items: D Ensure that the Bank 1 HO2S 1 is securely installed. D Check for corrosion on the terminals. D Check the terminals at Bank 1 HO2S 1 and at the PCM. D Check for damaged wiring. Was a problem found in any of the above areas? Verify repair Go to Step 15 1. Disconnect Bank 1 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the connector, check the voltage between the high signal circuit and ground. Also measure between the low signal circuit and ground. Are both voltages in the specified range? 3-4 mV Go to Step 18 Go to Step 16 1. Ignition OFF. 2. Check for damage to PCM pins or terminals. Was a problem found. Verify repair Go to Step 17 Check for a short to voltage or ground or an open in the signal circuit. Was a problem found? Verify repair Go to Step 18 1. Ignition OFF. 2. Disconnect the PCM connector. 3. With the HO2S disconnected, check for high and low signal circuits shorted together between the PCM and HO2S. Was a problem found? Verify repair Go to Step 19 With the PCM connected and Bank 1 HO2S 1 disconnected from the harness, check Bank 1 HO2S 1 with a Tech 2. Is the voltage in the specified range? 425-475 mV Go to Step 21 Go to Step 22 Replace the affected heated oxygen sensors. NOTE: Before replacing the sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination Use of improper RTV sealant. Engine oil/coolant consumption. Verify repair Go to Step 13 Go to Step 14 Go to Step 2
14
15
16
17
18
19
20
Is the action complete?
6E393

21 22
6E394
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1
D06R200010
Circuit Description
The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop and stoichiometric operation have been established. During the monitoring period the PCM counts the number of times that the HO2S responds from rich-to-lean and from lean-to-rich and adds the amount of time it took to complete all transitions. With this information, an average time for all transitions can be determined. The PCM then divides the rich-to-lean average by the lean-to-rich average to obtain a ratio. If the HO2S transition time ratio is not within this range, DTC P1134 will be set, indicating that the oxygen sensor is not responding as expected to changes in exhaust oxygen content.
D 90 seconds after closed loop and stoichiometric operation have been enabled, Bank 1 HO2S 1 transition ratio between lean-to-rich and rich-to-lean is less than 0.44 or greater than 3.8.

D The PCM will illuminate the malfunction indicator lamp (MIL) after second consecutive trip in which the fault is detected. D Open loop fuel control will be in effect. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.


D No related DTCs. D Engine coolant temperature (ECT) is above 60C (140F). D Engine is operating in closed loop, D The engine has been running at least one minute. D Canister purge duty cycle is greater than 2%. D Engine speed is between 1500 RPM and 3000 RPM. D Mass air flow (MAF) is between 18 g/second and 42 g/second. D Above conditions are present for a 3-second monitoring period.
Diagnostic Aids
A malfunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1134 to set. Check HO2S heater circuitry for intermittent faults or poor connections. If connections and wiring are OK and DTC P1134 continues to set, replace the Bank 1 HO2S 1.

6E395
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. A condition that affects other heated oxygen sensors indicates probable contamination. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.
5. This step checks for conditions which may cause the heated oxygen sensor to appear faulty. Correct any of the described conditions if present. 8. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.
DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 IMPORTANT: If any DTCs are set (except P1153 and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Idle the engine at operating temperature. 2. Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 3. Using a Tech 2, monitor DTC info for DTC P1134 until the DTC P1134 test runs. 4. Note the test result. Does Tech 2 indicate DTC 1134 failed this ignition? Go to Step 3 Go to Step 17 Go to Step 5 Go to Step 2
3 4 5 6
Did the Tech 2 also indicate P1153, and/or P1154 test failed? Check for leaks at the exhaust pipe joints. Are the joints leaking? Tighten the U-bolt nuts at the leaking joints. Is your action complete? Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?
Go to Step 7
Go to Step 8
1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete? Go to Step 2 Go to Step 9 Go to Step 2 Go to Step 11 Go to Step 2 Go to Step 10 Go to Step 12 Check for loose exhaust flange connections. Are the flange connections loose? Tighten the stud nuts or bolts to specifications. Is your action complete? Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded? Replace the exhaust pipes, as required. Is your action complete?
8 9 10 11
6E396
DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1 (Cont'd)

12 13
Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete? Go to Step 2 Visually/physically inspect the following items: D Ensure that the Bank 1 HO2S 1 is securely installed. D Check for corrosion on terminals. D Check the terminal tension (at Bank 1 HO2S 1 and at the PCM). D Check for damaged wiring. Was a problem found in any of the above areas? Go to Step 18 Go to Step 15 1. Disconnect Bank 1 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. 4. Also measure the voltage between the low signal circuit and ground. Are both voltages in the specified range? 3-4V Go to Step 16 Go to Step 19 1. With Bank 1 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition ON. 3. Using a Tech 2, monitor the Bank 1 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed? Go to Step 13 Go to Step 14
14
15
16
Go to Step 21
Go to Step 22
17
Replace affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption. Verify repair Verify repair Verify repair Verify repair Go to Step 20 Go to Step 7
6E397

21 22
6E398
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1
D06R200010
Circuit Description
The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop and stoichiometric operation have been enabled. During this test period the PCM counts the number of times that the HO2S signal voltage crosses the rich-to-lean and lean-to-rich thresholds. If the PCM determines that the HO2S did not switch enough times, DTC P1153 will be set. A lean-to-rich switch is determined when the HO2S voltage changes above and below 450 mV. Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.
D Mass air flow is between 8 g/second and 42 g/second. D Above conditions are present for a 3 seconds. D 90 seconds after closed loop and stoichiometric operation have been enabled, the PCM monitors the oxygen sensor switching above and below 450 mV. If fewer than 27 rich-to-lean and lean-to-rich switches for Bank 2 HO2S 1 are detected, DTC P1153 will set.



D The engine is operating in closed loop, D Engine coolant temperature (ECT) is above 60C (140F). D The engine has been running for over 60 seconds. D Canister purge duty cycle is greater than 2%. D Engine speed is between 1500 RPM and 3000 RPM.
6E399
Diagnostic Aids
A malfunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1153 to set. Check HO2S heater circuitry for intermittent faults or poor connections. If connections and wiring are OK and DTC P1153 continues to set, replace the Bank 2 HO2S 1. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
3. A condition that affects other heated oxygen sensors indicates probable contamination. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors. 5. This step checks for conditions which may cause the heated oxygen sensor to appear faulty. Correct any of the described conditions if present. 8. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.
Test Description
DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 IMPORTANT: If any DTCs are set, (except P1133 and/or P1134), refer to those DTCs before proceeding with this diagnostic chart. 1. Idle the engine at operating temperature. 2. Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 3. Using a Tech 2, monitor DTC info for DTC P1153 until the DTC P1153 test runs. Note the test result. Does Tech 2 indicate DTC failed this ignition? Go to Step 3 Go to Step 20 Go to Step 5 Go to Step 2
3 4 5 6
Did the Tech 2 also indicate P1133 and/or P1134 test failed? Check for leaks at the exhaust pipe joints. Are the joints leaking? Tighten the U-bolt nuts at the leaking joints. Is your action complete? Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?
Go to Step 7
Go to Step 8
8 9 10
6E400

11 12 13
Replace the exhaust pipes, as required. Is your action complete? Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete? Go to Step 2 Visually/physically inspect the following items: D Ensure that the Bank 2 HO2S 1 is securely installed. D Check for corrosion on terminals. D Check the terminal tension at Bank 2 HO2S 1 and at the PCM. D Check for damaged wiring. Was a problem found in any of the above areas? Verify repair Go to Step 15 1. Disconnect Bank 2 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the connector, check the voltage between the high signal circuit and ground. Also measure between the low signal circuit and ground. Are both voltages in the specified range? 3-4V Go to Step 18 Go to Step 16 1. Ignition ON. 2. Check for damage to PCM pins or terminals. Was a problem found? Verify repair Go to Step 17 Check for short to voltage or ground or an open in the signal circuit. Was a problem found? Verify repair Go to Step 18 1. Ignition OFF. 2. Disconnect the PCM connector. 3. With HO2S disconnected, check for high and low signal circuits shorted together between the PCM and HO2S. Was a problem found? Verify repair Go to Step 19 With the PCM connected and Bank 2 HO2S 1 disconnected from the harness, check Bank 2 HO2S 1 with a Tech 2. Is the voltage in the specified range? 425-475 mV Go to Step 21 Go to Step 22 Replace affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption. Verify repair Go to Step 13 Go to Step 14 Go to Step 2
14
15
16
17
18
19
20
Is the action complete?
6E401

21 22
6E402
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1
D06R200010
Circuit Description
The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop and stoichiometric operation have been enabled. During the monitor period the PCM counts the number of times that the HO2S responds from rich-to-lean and from lean-to-rich and adds the amount of time it took to complete all transitions. With this information, an average time for all transitions can be determined. The PCM then divides the rich-to-lean average by the lean-to-rich average to obtain a ratio. If the HO2S transition time ratio is not within this range, DTC P1154 will be set, indicating that the oxygen sensor is not responding as expected to changes in exhaust oxygen content.
D 90 seconds after closed loop and stoichiometric operation have been enabled, Bank 2 HO2S 1 transition ratio between lean to rich and rich to lean is less than 0.44 or greater than 3.8.



D No related DTCs. D Engine coolant temperature (ETC) is above 60C (140F). D The engine is operating in closed loop, D The engine has been running at least one minute. D Canister purge duty cycle is greater than 2%. D Engine speed is between 1500 RPM and 3000 RPM. D Mass air flow is between 18 g/second and 42 g/second. D Above conditions are present for a 3-second monitoring period.
Diagnostic Aids
A multifunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1154 to set. Check HO2S heater circuitry for intermittent faults or poor connections.

If connections and wiring are OK and DTC P1154 continues to set, replace the Bank 2 HO2S 1. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
6E403
Test Description
3. A condition that affects other heated oxygen sensors indicates probable contamination. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors. 5. This step checks for conditions which may cause the heated oxygen sensor to appear faulty. Correct any of the described conditions if present. 8. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.
DTC P1154 HO2S Transition Time Ratio Bank 2 Sensor 1

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 IMPORTANT: If any other DTCs are set (except P1133 and/or P1134), refer to those DTCs before proceeding with this diagnostic chart. 1. Idle the engine at operating temperature. 2. Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 3. Using a Tech 2, monitor DTC info for DTC P1154 until the DTC P1154 test runs. Note the test result. Does Tech 2 indicate DTC failed this ignition? Go to Step 3 Go to Step 17 Go to Step 5 Go to Step 2
3 4 5 6
Did the Tech 2 also indicate P1133, and/or P1134 test failed? Check for leaks at the exhaust pipe joints. Are the joints leaking? Tighten the U-bolt nuts at the leaking joints. Is your action complete? Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?
Go to Step 7
Go to Step 8
1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete? Go to Step 2 Go to Step 9 Go to Step 2 Go to Step 11 Go to Step 2 Go to Step 10 Go to Step 12 Check for loose exhaust flange connections. Are the flange connections loose? Tighten the stud nuts or bolts to specifications. Is your action complete? Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded? Replace the exhaust pipes, as required. Is your action complete?
8 9 10 11
6E404

12 13
Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete? Go to Step 2 Visually/physically inspect the following items: D Ensure that the Bank 2 HO2S 1 is securely installed. D Check for corrosion on terminals. D Check terminal tension (at Bank 2 HO2S 1 and at the PCM). D Check for damaged wiring. Was a problem found in any of the above areas? Go to Step 18 Go to Step 15 1. Disconnect Bank 2 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Also measure the voltage between the low signal circuit and ground. Are both voltages in the specified range? 3-4 V Go to Step 16 Go to Step 19 1. With Bank 2 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition ON. 3. Using a Tech 2, monitor the Bank 2 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed? Go to Step 13 Go to Step 14
14
15
16
Go to Step 21
Go to Step 22
17
Replace affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption. Verify repair Verify repair Verify repair Verify repair Go to Step 20
6E405

21 22
6E406
Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)
D06R200010
Circuit Description
The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop has been enabled. During the monitoring period the powertrain control module (PCM) counts the number of times a rich to lean response is indicated and adds the amount of time it look to complete all rich to lean transitions and lean to rich transitions. This code detects if Bank1 O2 sensor indicated rich exhaust while in Decel Fuel Cut Off (DFCO) for fuel control sensors.

D The PCM will not illuminate the malfunction malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

D A history DTC P1167 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. D DTC P1167 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

D No related DTCs. D The engine coolant temperature is more than 60 C (140 F). D Engine is operating in closed loop power enrichment mode for 3 seconds. D While in power enrichment mode the oxygen sensor voltage remains more than 600mV in DFCO.
Diagnostic Aids
D Check for faulty fuel injectors and fuel pump.
6E407
Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank1)
Was the On-Board (OBD) System Check performed? Go to Step 2 Go to component DTC charts
Are any component related DTCs set?
Go to Step 3
1. Place the transmission in Park. 2. Using a Tech 2, HO2S 1 voltage while running warm engine 75 C 95 C (167 F 203 F) at 1200 RPM. 3. HO2S 1 voltages should vary within the specified range. (100 900mV) 4. Quickly open the wide open the throttle for a few seconds. Did the voltage suddenly rise toward the low end of the 100 600 mV specified range?
Go to Step 4
1. Disconnect the fuel pump relay and crank the engine to relieve the fuel pressure. 2. Install the fuel pressure gauge. 3. Start the engine and idle at normal operating temperature. 4. Disconnect the vacuum line going to the fuel pressure regulator. With the engine running, is the fuel pressure within the 280 325Kpa specified range? (41 46psi)
Go to Step 5
1. Ignition OFF. 2. Remove the fuel pump relay and replace it with a fused jumper which will connect the relays battery terminal to the terminal leading to the fuel pump fuse. 3. While the fuel pump is operating, use pliers to slowly close the return line (do not exceed the first specified value). Using the pliers to restrict the return line, can the fuel pressure be manipulated to exceed the second value? Is the fuel pressure gauge reading near the specified value?
325KPa (46psi) 414KPa (60psi)
Go to Step 6
Check the following items; D Faulty fuel pump D Incorrect fuel pump D Incorrect fuel being used D Cold fuel If a problem is found, repair as necessary. Was a problem found? Verify repair
6E408
Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)
D06R200010
Circuit Description
The powertrain control module(PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop has been enabled. During the monitoring period the powertrain control module (PCM) counts the number of times a rich to lean response is indicated and adds the amount of time it look to complete all rich to lean transitions and lean to rich transitions. This code detects if Bank2 sensor indicated rich exhaust while in Decel Fuel Cut Off (DFCO) for fuel control sensors.

D The PCM will not illuminate the malfunction malfunction indicator lamp(MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

D A history DTC P1169 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. D DTC P1169 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

D No related DTCs. D The engine coolant temperature is more than 60 C (140 F). D Engine is operating in closed loop power enrichment mode for 3 seconds. D While in power enrichment mode the oxygen sensor voltage remains more than 600mV in DFCO.
Diagnostic Aids
D Check for faulty fuel injectors and fuel pump. D Check the pressure regulator.
6E409
Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank2)
Was the On-Board (OBD) System Check performed? Go to Step 2 Go to component DTC charts
Are any component related DTCs set?
Go to Step 3
1. Place the transmission in Park. 2. Using a Tech 2, HO2S 2 voltage while running warm engine75 C 95 C (167 F 203 F) at 1200 RPM. 3. HO2S 1 voltages should vary within the specified range. (100 900mV) 4. Quickly open the wide open the throttle for a few seconds. Did the voltage suddenly rise toward the low end of the specified range? 100 600 mV
Go to Step 4
1. Disconnect the fuel pump relay and crank the engine to relieve the fuel pressure. 2. Install the fuel pressure gauge. 3. Start the engine and idle at normal operating temperature. 4. Disconnect the vacuum line going to the fuel pressure regulator. With the engine running, is the fuel pressure within the 280 325Kpa specified range? (41 46psi)
Go to Step 5
1. Ignition OFF. 2. Remove the fuel pump relay and replace it with a fused jumper which will connect the relays battery terminal to the terminal leading to the fuel pump fuse. 3. While the fuel pump is operating, use pliers to slowly close the return line (do not exceed the first specified value). Using the pliers to restrict the return line, can the fuel pressure be manipulated to exceed the second value? Is the fuel pressure gauge reading near the specified value?
325KPa (46psi) 414KPa (60psi)
Go to Step 6
Check the following items; D Faulty fuel pump D Incorrect fuel pump D Incorrect fuel being used D Cold fuel. If a problem is found, repair one as necessary. Was a problem found? Verify repair
6E410
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration
D06R200010
Circuit Description
The powertrain control module (PCM) internal circuitry can identify if the vehicle fuel system is capable of supplying adequate amounts of fuel during heavy acceleration (power enrichment). The PCM monitors the voltage of the oxygen sensor during power enrichment. When a power enrichment mode of operation is requested during closed loop operation (by heavy acceleration), the PCM will provide more fuel to the engine. Under these conditions the PCM should detect a rich condition (high oxygen sensor voltage). If this rich exhaust is not detected at this time, a DTC P1171 will set. A plugged fuel filter, restricted fuel line, restricted in-tank filter or defective fuel pump can prevent adequate amounts of fuel from being supplied during power enrichment mode.



D No related DTCs. D Engine is operating in closed loop power enrichment mode for 3 seconds. D Engine coolant temperature is above 60C (140F). D While in power enrichment mode the oxygen sensor voltage remains below 400 mV for 3 seconds.
Diagnostic Aids
D A restricted fuel filter or fuel line, restricted in-tank filter, or a defective fuel pump may supply adequate amounts of fuel at idle, but may not be able to supply enough fuel during heavy acceleration. D Water or alcohol in the fuel may cause low HO2S voltage during acceleration. D Check for faulty or plugged fuel injector(s). D Check for low fuel.
6E411
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 4. When the engine is idling or at steady cruise, the HO2S voltage should vary from between approximately 100 mV to 900 mV. It is possible to measure a satisfactory fuel pressure at idle even though the pressure may drop at high flow requirements. It may be necessary to watch fuel pressure at high engine load. 5. Wrap a shop towel around the fuel pressure connector to absorb any small amount of fuel leakage that may occur when installing gauge. Ignition ON, pump pressure should be 280-320 kPa. 7. Add Caution, Use correct pliers so damage to fuel lines will not occur.
6E412
DTC P1171 Fuel System Lean During Acceleration

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to component DTC charts Are any component-related DTCs set?
Go to Step 3
1. Check the vehicles fuel tank for an adequate amount of fuel. 2. Add fuel to the vehicles fuel tank if the tank is almost empty. Was fuel added to the vehicles fuel tank? Go to Step 4 Go to Step 5 1. Place the transmission in park. 2. Using a Tech 2, observe HO2S 1 voltage while running warm engine 75C-95C (167F-203F) at 1200 RPM. 3. HO2S 1 voltage should vary within the specified range. 4. Quickly open the throttle too halfway for a few seconds. Did the voltage suddenly rise toward the high end of the specified range? 100-900 mV
Go to Fuel System Electrical Test
Go to Step 5
1. Disconnect the fuel pump relay and crank the engine to relieve the fuel pressure. 2. Install the fuel pressure gauge. 3. Start the engine and idle at normal operating temperature. 4. Disconnect the vacuum line going to the fuel pressure regulator. With the engine running, is the fuel pressure within the specified range? 280-325 kPa (41-46 psi)
Go to OBD System Check Verify repair
6 7
Check for restricted fuel lines or restricted in-line filter. Was a problem found? 1. Ignition OFF. 2. Remove the fuel pump relay and replace it with a fused jumper which will connect the relays battery terminal to the terminal leading to the fuel pump fuse. 3. While the fuel pump is operating, use pliers to slowly close the return line (do not exceed the first specified value). Using the pliers to restrict the return line, can the fuel pressure be manipulated to exceed the second specified value?
325 kPa (46 psi) 414 kPa (60 psi)
Go to Step 8
Check for: D Faulty fuel pump D Restricted fuel pump strainer (sock) D Incorrect fuel pump D Incorrect fuel being used D Hot fuel Is the action complete? Verify repair
6E413
Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault
D06RY00088
Circuit Description
D The throttle position (TP2) sensor circuit provides a voltage signal relative to throttle blade angle. The throttle blade angle will vary about 8 % at closed throttle to about 92 % at wide open throttle (WOT). This code detects a continuous short to ground or high in either the cicuit or the sensor.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D The CKP sensor shares 5 Volt reference with the TP sensor 2. If these codes are also set, it could indicate a problem with the 5 Volt reference curcuit. D Poor connection at PCM-Inspect harness connectors for backed out terminals,improper mating,broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK,observe the TP sensor display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1120 cannot be duplicated,the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,performing the DTC P1120 Diagnostic Chart may isolate the cause of the fault.

D The Ignition is ON. D The throttle blade angle is less than 2.5 % or more tnan 97.5 % for 18 failres within 500 test samples (15.6m sec).


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condtion is no longer present. D A history DTC P1120 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P1120 can be cleared using the Tech2 Clear Info function or by disconnecting the PCM battery feed.
6E414
DTC P1220-TPS 2 Circuit Fault

Go to OBD System Check Go to ETC System Check
Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Disconnect the CKP sensor. 2. Connect a test 5 volt reference circuit and the CKP signal at the CKP sensor harness connector. 3. Observe the CKP reading on the DVM. Is the CKP reading less than the specified value? (If no, start with diagnosis chart for other sensors in the circuit and see if 5V returns.)
5V
Go to Step 5
Go to Step 4
1. Check the CKP signal circuit between the PCM and CKP ground circuit. 2. If the CKP signal circuit is open or shorted, repair as necessary. Was the CKP signal circuit open or shorted? Closed throttle APS2 = 8589% Wide open throttle APS2 = 1115% Verify repair Verify repair Go to Step 16 Replace the CKP sensor. Is the action complete? 1. Ignition ON, engine not running. 2. Observe the AP2 reading on the Tech2. Is the AP2 reading less than the specified value?
5 6
Go to Step 7
Go to Step 10
1. Disconnect the AP sensor 2. 2. Connect the Tech2 5 Volt reference circuit and the AP2 signal at the Ap2 sensor harness connector. 3. Observe the AP2 reading on the Tech 2. Is the AP2 reading less than the specified value? (If no, start with diagnosis chart forother sensors in the circuit and see if 5V returns.)
Go to Step 9
Go to Step 8
1. Check the Ap2 sensor signal circuit between the PCM and AP2 sensor grund circuit. 2. If the AP2 sensor signal circuit open or shoted, repair it as necessary. Was the AP2 sensor signal circuit open or shorted? Verify repair Verify repair Go to Step 16 Replace the AP sensor 2. Is the action complete?
6E415
DTC P1220-TPS 2 Circuit Fault (Cont'd)

10
1. 2. 3. 4.
Closed throttle NOTE: The value check of TPS must be performed in TPS2= less than 15 seconds. 8894% Wide Does the TP angle increase steadily and evenly from open throttle TPS2= the closed throttle value to the wide open throttle value? 1923% 11 Was the DTC P1220 stored?
Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
Go to Step 11
12 1. Connect a DVM between the 5Volt reference circuit and the TP2 sensor ground circuit at the TPsensor harness connector. 2. Observe the voltage using a DVM. Is the voltage near the specified value? 13 Check the following items; 1. TP2 signal circuit for a short to voltage. 2. TP2 sensor ground circuit for high resistance between the PCM and the TP2 sensor. 3. TP2 sensor ground circuit for a poor connection. 4. If a problem is found,repair wiring harness as necessary. Was a problem found? 14 Check the following items; 1. TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? 15 16 Replace the TP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? 5V
Go to Step 16
Go to Step 13
Go to Step 16
Verify repair
Go to Step 14
Verify repair
6E416
Diagnosis Truble Code(DTC) P1221 TPS1 TPS2 correlation(Circuit Performance)
D06RY00157
Circuit Description
D The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to DC motor coil in steps (%) to adjustment the valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP1) will vary about 13% at idle position to about 87% at open throttle(WOT). APS signal is used to determine which DC will adjusting throttle position. After the APS signal has been processed by the PCM, it will command DC motor to allow a move of throttle position.
D Acceleration pedal Check for objects blocking the AP sensor or pedal arm with spring, and excessive deposits in the acceleration pedal arm and on the acceleration pedal.
Diagnostic Aids
D An intermittent may be caused by a poor connection, rubbedthrough wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Throttle body Check for objects blocking the DC motor or throttle bore, excessive deposits in the ETC passage and on the valve spring, and excessive deposits in the throttle bore and on the throttle valve plate.
6E417
Diagnosis Truble Code(DTC) P1221 TPS1 TPS2 correlation(Circuit Perfoemance)

Was the On-Board (OBD) System Checkperformed? Go to Step 2
Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 Go to applicable DTC table Following below the DTCs stored: P1120,P1220 Do any of the above require a repair?
Go to Step 4
1. 2. 3. 4.
Closed throttle TPS1= 612% TPS2= 8894% Wide NOTE: The value check of TPS must be performed in open throttle less than 15 seconds. TPS1= 7983% Does the TP angle increase steadily and evenly from TPS2= the closed throttle value to the wide open throttle value? 1923% Was the DTC P1221 stored?
Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
Go to Step 5
6 1. Check the following items; D TPS1 and TPS2 signal curcuit for a short to boltag or GND. D TPS1 and TPS2 sensor ground curcuit for high resistance between the PCM and TP sensors. D TPS1 and TPS2 5 volt reference curcuit for high risistance between the PCM and TP sensors. 2. If aproblem found, repair wiring harness as necessary. Was a problem found? 7 1. Reobserve the TP angle reading on the Tech 2 while slowly operating the acceleration pedal.
Go to Step 9
Verify repair
Go to Step 7
Closed throttle TPS1= Does the TP angle increase steadily and eventry from 612% the closed throttle value to the wide open throttle TPS2= value? 8894% Wide open throttle TPS1= 7983% TPS2= 1923%
Verify repair
Go to Step 8
6E418
Diagnosis Truble Code(DTC) P1221 TPS1 TPS2 correlation(Circuit Perfoemance) (Cont'd)

8 9
1. Replace the TP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be Verify repair Go to Step 9
Refer to ONVehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the adtion complete? Verify repair
6E419
Diagnostic Trouble Code (DTC) P1271 APS 1 2 Correlation Error
D06RY00075
Circuit Description
D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP1) will vary about 13% at idle position to about 87% at wide open throttle(WOT). This code detects a correlation error between APS1 and APS2.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 1, APP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1271 cannot be duplicated,the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1271 Diagnostic Chart may isolate the cause of the fault.

D The Ignition is ON. D The acceleration pedal angle difference is less than 4.5 % between ASP1 and APS2 for 50 counts within 50 test samples (15.6 m sec).


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P1271 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault.
6E420
DTC P1271 APS 1 2 Correlation Error

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 Warming up the engine until the ECT rise at 80C Closed throttle APS1 Ignition OFF. = 1115% Ignition ON but not engine run. APS2 = Observe the AP angle reading on the Tech 2 while 8589% Wide alowly opening the throttle. open throttle Does the AP angle increase steadily and evenly from APS1 = the closed throttle value to the wide open throttle 8589% value? APS2 = 1115% 1. 2. 3. 4. Was the DTC P1271 stored?
Go to Step 4
Go to Step 5 Check the procedure. Refer to Diagnositec Aids
5 1. Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP1, AP2 sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value? 6 Check the following items; 1. AP1and AP2 signal circuit for a short to voltage. 2. AP1and AP2 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1and AP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found? 7 Check the following items; 1. AP1and AP2 signal circuit or 5 volge supply circuit for a poor connection. 2. AP1and AP2 signal circuit or 5 volge supply circuit for high resistance between the PCM and the AP1 and AP2 sensor. 3. If a problem is found,repair wiring harness as necessary. Was a problem found? 5V
Go to Step 9
Go to Step 6
Go to Step 7
Verify repair
Go to Step 7
Verify repair
Go to Step 8
6E421
DTC P1271 APS 1 2 Correlation Error (Cont'd)

8 9
Replace the AP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be Verify repair Go to Step 9
Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released ornot. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair
6E422
D06RY00075
Circuit Description
D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP2) will vary about 87 % at idle position to about 13 % at wide open throttle (WOT). This code detects a correlation error betweenAPS2 and APS3.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals,improper mating,broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 2, APP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1272 cannot be duplicated, the information includedin the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1272 Diagnostic Chart may isolate the cause of the fault.



6E423

Go to Step 4
Go to Step 5 Check the procedure.Re fer to Diagnositc Aids
5 1. Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP2 and AP3 sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value? 6 Check the following items; 1. AP2 and AP3 signal circuit for a short to voltage. 2. AP2 and AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP2 and AP3 sensor ground circuit for a poor connection. 4. If a problem is found,repair wiring harness as necessary. Was a problem found? 7 Check the following items; 1. AP2 and AP3 signal circuit or 5 volge supply circuit for a poor connection. 2. AP2 and AP3 signal circuit or 5 volge supply circuit for high resistance between the PCM and the AP2 and AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? 5V
Go to Step 9
Go to Step 6
Go to Step 7
Verify repair
Go to Step 7
Verify repair
Go to Step 8
6E424

8 9
Replace the AP sensor. Was a probelm corrected? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 9
6E425
D06RY00075
Circuit Description
D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP1) will vary about 13 % at idle position to about 87 % at wide open throttle (WOT). This code detects a correlation error between APS1 and APS3.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK,observe the APP sensor 1, APP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1273 cannot be duplicated,the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,performing the DTC P1273 Diagnostic Chart may isolate the cause of the fault.



6E426

Go to Step 4
5 1. Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP1 and AP3 sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value? 6 Check the following items; 1. AP1 and AP3 signal circuit for a short to voltage. 2. AP1 and AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1 and AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found? 7 Check the following items; 1. AP1 and AP3 signal circuit or 5 volge supply circuit for a poor connection. 2. AP1 and AP3 signal circuit or 5 volge supply circuit for high resistance between the PCM and the AP1 and AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? 5V
Go to Step 9
Go to Step 6
Go to Step 7
Verify repair
Go to Step 7
Verify repair
Go to Step 8
6E427

8 9
Replace the AP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released ornot. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair Verify repair Go to Step 9
6E428
Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault
D06RY00075
Circuit Description
D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP1) will vary about 13 % at idle position to about 87 % at wide open throttle (WOT). This code detects a continuous short to ground or high in either the cicuit or the sensor.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D The MAP sensor shares a 5 Volt reference with the Fuel Tank Pressure, APS1, APS3 and EGR value. D The MAP sensor shares a ground with the Fuel Tank Pressure, the ECT sensor, and the Transmission Fluid. D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK,observe the APP sensor 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1275 cannot be duplicated,the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1275 Diagnostic Chart may isolate the cause of the fault.

D The Ignition is ON. D The acceleration pedal angle is less than 2.5 % or more than 97 % for 12 counts within 500 test samples.

D The PCM will store condition which werepresent when the DTC was set as Freeze Frame and in the Failure Records data.

6E429
DTC P1275 APS 1 Circuit Fault

Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Closed Observe the AP angle reading on the Tech 2 while throttle APS1 alowly opening the throttle. = 1115% Wide open Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle throttle APS1 value? = 8589% 1. 2. 3. 4. Was the DTC P1275 sotred?
Go to Step 3
4 1. Connect a test light between the 5 Voltge supply circuit and the AP1 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value? 5 Check the following items; 1. AP1 signal circuit for a short to voltage. 2. AP1 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1 sensor ground circuit for a poor connection. 4. If a problem is found,repair wiring harness as necessary. Was a problem found? 6 Check the following items; 1. AP1 signal circuit or 5 volge supply circuit for a poor connection. 2. AP1 signal circuit or 5 volge supply circuit for high resistance between the PCM and the AP1 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? 7 8 Replace the AP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? 5V
Go to Step 8
Go to Step 5
Go to Step 6
Verify repair
Go to Step 6
Verify repair
6E430
D06RY00075
Circuit Description
D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP2) will vary about 87 % at idle position to about 13 % at wide open throttle(WOT). This code detects a continuous short to ground or high in either the cicuit or the sensor.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1280 cannot be duplicated, the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1280 Diagnostic Chart may isolate the cause of the fault.



6E431
DTC P1280 - APS 2 Circuit Fault

Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Closed Observe the AP angle reading on the Tech 2 while throttle APS2 alowly opening the throttle. = 8589% Wide open Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle throttle APS2 value? = 1115% 1. 2. 3. 4. Was the DTC P1280 stored?
Go to Step 3 Check the procedure. Go to Step 8
Go to Step 4 Refer to Diagnostid Aids
1. Connect a test light between the 5 Voltge supply circuit and the AP2 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value? 5V Go to Step 5 Go to Step 6 Check the following items; 1. AP2 signal circuit for a short to voltage. 2. AP2 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Go to Step 6
Check the following items; 1. AP2 signal circuit or 5 volge supply circuit for a poor connection. 2. AP2 signal circuit or 5 volge supply circuit for high resistance between the PCM and the AP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 7 Go to Step 8
7 8
Replace the AP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The replacement PCM must be programmed.Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair
6E432
D06RY00075
Circuit Description
D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP3) will vary about 87 % at idle position to about 34 % at wide open throttle(WOT). This code detects a continuous short to ground or high in either the circuit or the sensor.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D The MAP sensor shares a 5 Volt reference with the Fuel Tank Pressure, APS1, APS3 and EGR value. D The MAP sensor shares a ground with the Fuel Tank Pressure, the ECT sensor, and the Transmission Fluid. D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1285 cannot be duplicated, the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1285 Diagnostic Chart may isolate the cause of the fault.



6E433
DTC P1285 APS 3 Circuit Fault

Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Closed Observe the AP angle reading on the Tech 2 while throttle APS3 alowly opening the throttle. = 8589% Wide open Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle throttle APS3 value? = 3236% 1. 2. 3. 4. Was the DTC P1285 stored?
Go to Step 3
4 1. Connect a test light between the 5 Voltge supply circuit and the AP3 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value? 5 1. Check the following items; AP3 signal circuit for a short to voltage. 2. AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found? 6 Check the following items; 1. AP3 signal circuit or 5 volge supply circuit for a poor connection. 2. AP3 signal circuit or 5 volge supply circuit for high resistance between the PCM and the AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? 7 8 Replace the AP sensor. Was a problem corrected Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released ornot. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? 5V
Go to Step 8
Go to Step 5
Go to Step 6
Verify repair
Go to Step 6
Verify repair
6E434
Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode
D06RY00157
Circuit Description
D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle (AP1) will vary about 13 % at idle position to about 87 % at wide open throttle (WOT). This code detects that if the systm is in Forced Idle Mode. (Fail safe Mode)
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 1, APP sensor 2, APP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1290 cannot be duplicated, the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1290 Diagnostic Chart may isolate the cause of the fault.

D The Ignition is ON. D Forced Idle Mode is active. (Fail safe Mode)


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condtion is no longer present. D A history DTC P1290 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P1290 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
6E435
DTC P1290 - ETC Forced Idle Mode

Was the On - Board (OBD) System Check performed? Go to Step 2 1. Check for a poor conection at the AP1,AP2,AP3 sensor harness conector. 2. If a problem found, repair as necessary. Was a problem found ? Verify repair
Go to Step 3
1. Check the curcuit between the PCM and each terminal of AP1,AP2 and AP3 sensor. 2. If the curcuit is open or shorted, repair it as necessary. Was the curcuit open or short? Vefiry repair Go to Step 5 Go to Step 4 Replace the AP sensor. Is the action complate? Warming up the engine until the ECT rise at 80C Closed throttle APS1 Ignition OFF. = 11 15% Ignition ON but not engine run. APS2 = Observe the AP angle reading on the Tech 2 while 8589% alowly opening the throttle. APS3 = Does the AP angle increase steadily and evenly from 8589% Wide the closed throttle value to the wide open throttle open throttle value? APS1 = 8589 APS2 = 1115% APS3 = 3236% 1. 2. 3. 4. Replace the PCM; The replacement PCM must be programmed. Refer to ONVehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complate? Verify repair
4 5
Go to Step 6
6E436
Diagnostic Trouble Code (DTC) P1295 Power Management Mode
D06RY00088
Circuit Description
D The throttle position (TP) sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary about 8 % at closed throttle to about 92 % at wide open throttle (WOT). D The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). D The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain Control Module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantitiy of air entering the engine indicates an accleration or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40g/s at maximum engine load. D This DTC ditects that if the systm is in PowerManagement Mode.(Fail safe Mode)
D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure. D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the

D The ignition is ON. D Power Management Mode is active. (Fail safe Mode)


TP sensor 1, TP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.If DTC P1295 cannot be duplicated, the information included in the Faillure Records data can
6E437
be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1295 Diagnostic Chart may isolate the cause of the fault.
DTC P1295 - Power Management Mode

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. 2. 3. 4. Closed throttle TPS1= 612% TPS2= 8894% Wide NOTE: The value check of TPS must be performed in open throttle less than 15 seconds. TPS1= 7983% Does the TP angle increase steadily and evenly from TPS2= the closed throttle value to the wide open throttle value? 1923% Was the DTC P1295 stored? Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
Go to Step 4
5 1. Check the curcuit between the PCM and each terminal of TP1 and TP2 sensor. Was the curcuit open or shorted? 6 7 1. Repair the faulty wiring harness. Was a problem corrected? 1. Ignition On, engine Off. 2. Operate the throttle lever by hand (Dont operate the acceleration pedal ). Was the DTC P1515 or P1516 stored? 8 9 1. Replace the TP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be
Go to Step 9
Refer to ONVehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the adtion complete? Varify repair
6E438
Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode
D06RY00088
Circuit Description
D The throttle position sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary about 8% at closed throttle to about 92% at wide open throttle(WOT). D The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). D The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain Control Module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A laege quantitiy of air entering the engine indicates an accleration or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40g/s at maximum engine load. D This DTC ditects if the system is in ECT Forced Engine Shutdown Mode.(Fail safe Mode)


Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the

D The ignition is ON. D ECT Forced Engine Shutdown Mode is active. (Fail safe Mode)

TP sensor 1, TP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1299 cannot be duplicated, the information included in the Faillure Records data can
6E439
DTC P1299 - ETC Forced Engine Shutdown Mode

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. 2. 3. 4. Closed throttle TPS1= 612% TPS2= 8894% Wide NOTE: The value check of TPS must be performed in open throttle less than 15 seconds. TPS1= 7983% Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle TPS2= value? 1923% Was the DTC P1299 stored? Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
Go to Step 4
5 1. Check the curcuit between the PCM and each terminal of TP1 and TP2 sensor. Was the curcuit open or shorted? 6 7 1. Repair the faulty wiring harness. Was a problem corrected? 1. Ignition On, engine Off. 2. Operate the throttle lever by hand (Dont operate the acceleration pedal ). Was the DTC P1515 or P1516 stored? 8 9 1. Replace the TP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be
Go to Step 9
Refer to ONVehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the adtion complete? Varify repair
6E440
Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis
D06R200098
Circuit Description
The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. D The Deceleration Fuel Cut Off (DFCO) test is performed to evaluate the Combustion Quality (CQ) signal pulse width D If it is below a predetermined value, the value it is expected to be during DFCO conditions. If the CQ signal pulse width is above the predetermined threshold, the fail counter will be incremented. If the failure counter exceeds the calibration, then the test is complete and a failure will be reported. D The Power Enrichment (PE) test is performed to evaluate the Combustion Quality (CQ) signal pulse width D If it is below a predetermined value, the value is expected to be during PE conditions. If the CQ signal pulse width is above the predetermined threshold, the fail counter will be incremented. If the failure counter exceeds the calibration, then the test is complete and a failure will be reported. D The Combustion Quality (CQ) test is performed to check if inappropriate (CQ) signal status were detected. If missing CQ pulses or multiple CQ pulses or CQ pulse width calculation errors were detected, the fail counter will be incremented. If the failure counter exceeds the calibration, then the test is complete and a failure will be reported.

D D D D D D Ignition voltage is between 10volt and 16 volts. MAP sensor signal is between 26kPa and 100 kPa. Fuel level is more than 19%. Engine speed is between 650rpm and 6500rpm. No Crank DTCs set. No System voltage DTCs set.

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

6E441
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1310 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1310 Diagnostic Chart may isolate the cause of the fault.
DTC P1310 - ION Sensing Module Diagnostic

1. Ignition OFF. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 4 Go to Step 3 Check the ION Sensing harness between the PCM and ION Sensing module circuit harness connector. Was a problem found? Verify repair Go to Step 6 Go to Step 6 Go to Step 5 1. Disconnect the ignition coil. Is the action complete? Check the ION Sensing harness between the ignition coil and ION Sensing module circuit at the ION Sensing Module harness connector. Was a problem found? Verify repair Go to Step 7 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 9
5 6
8 9
Replace the Ignition coil. Is the action complete? Check the following items; 1. ION Sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Go to Step 10
6E442
DTC P1310 - ION Sensing Module Diagnostic (Cont'd)

10 11
Replace the ION Sensing module. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be Verify repair Go to Step 11
6E443
Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC Line 1 Circuit Fault
D06R200098
Circuit Description
D The Power Control Module (PCM) will compare the secondary current reading to predetermined maximum and minimum thresholds. If the secondary current signal pulse width is out of the predetermined range, the fail counter will be incremented. If the failure counter exceeds the calibration, then the PCM is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the PCM is complete and pass will be reported. This PCM will detect an open/short circuit in the secondary current sense input circuit, misfire on the entire bank for the secondary current sense input circuit, coil failure, and same internal Ignition Current Sense System (ICSS) module faults.



D D D D D Ignition voltage is between 10volt and 16 volts. MAP sensor signal is between 26kPa and 100 kPa. Fuel level is more than 19%. Engine speed is between 650rpm and 6500rpm. ION Sensing Module circuit is open or shorted signals on the SEC 1 line.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions:
6E444

D A change in the display will indicate the location of the fault. If DTC P1311 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. D If it is determined that the DTC occurs intermittently, performing the DTC P1311 Diagnostic Chart may isolate the cause of the fault.
D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor.
DTC P1311 - ION Sensing Module SEC Line 1 Circuit Fault

1. Ignition OFF. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 4 Go to Step 3 Check the ION Sensing module harness between the PCM and ION Sensing module circuit at the ION Sensing module harness connector. Was a problem found? Verify repair Go to Step 6 Go to Step 5 Go to Step 5 1. Disconnect the ignition coil. Is the action complete? Check the ION Sensing module harness between the ignition coil and ION Sensing module circuit at the SEC line 1 harness connector. Was a problem found? Verify repair Go to Step 7 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 9
5 6
8 9
6E445
DTC P1311 - ION Sensing Module SEC Line 1 Circuit Fault (Cont'd)
10 11
6E446
Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC Line 2 Circuit Fault
D06R200098
Circuit Description
D The Power Control Module (PCM) will compare the secondary current reading to predetermined maximum and minimum thresholds. If the secondary current signal pulse width is out of the predetermined range, the fail counter will be incremented. If the fail counter exceeds the calibration, then the PCM is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the PCM is complete and pass will be reported. This PCM will detect an open/short circuit in the secondary current sense input circuit, misfire on the entire bank for the secondary current sense input circuit, coil failure, and same internal Ignition Current Sense System (ICSS) module faults.



D D D D D Ignition voltage is between 10volt and 16 volts. MAP sensor signal is between 26kPa and 100 kPa. Fuel level is more than 19%. Engine speed is between 650rpm and 6500rpm. ION Sensing Module circuit is open or shorted signals on the SEC 2 line.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions:

D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor.
6E447
A change in the display will indicate the location of the fault. If DTC P1312 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1312 Diagnostic Chart may isolate the cause of the fault.
DTC P1312 - ION Sensing Module SEC Line 2 Circuit Fault

1. Ignition OFF. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 4 Go to Step 3 Check the ION Sensing module harness between the PCM and ICSS module circuit at the ION Sensing Module harness connector. Was a problem found? Verify repair Go to Step 6 Go to Step 5 Go to Step 5 1. Disconnect the ignition coil. Is the action complete? Check the ION Sensing module harness between the ignition coil and ION Sensing module circuit at the SEC line 2 harness connector. Was a problem found? Verify repair Go to Step 7 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 9
5 6
8 9
6E448
DTC P1312 - ION Sensing Module SEC Line 2 Circuit Fault (Cont'd)
10 11
6E449
Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault
D06R200098
Circuit Description
The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. D The test is performed to evacuate the Combustion Quality (CQ) signal pulse width if it is within a predetermined range. If the CQ signal pulse width is out of the predetermined range, the fail counter will be incremented. If the failure counter exceeds the calibration, then test is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the test is complete and a pass will be reported. This test will detect an open/short in the CQ line circuit, ION Sensing module faults and analog input faults in the PCM.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1326 cannot be duplicated, the information included in the Failure Records data can

D Ignition voltage is between 10volt and 16 volts. D No Crank DTCs set. D No cylinder ID DTCs set.

6E450
DTC P1326 - ION Sensing Module Combustion

1. Ignition OFF. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 4 Go to Step 3 Check the ION Sensing module harness between the PCM and ION Sensing module circuit at the QC line harness connector. Was a problem found? Verify repair Go to Step 6 Go to Step 5 Go to Step 5 1. Disconnect the ignition coil. Is the action complete? Check the ION Sensing module harness between the ignition coil and ICSS module circuit at the ION Sensing Module harness connector. Was a problem found? Verify repair Go to Step 7 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 9
5 6
8 9
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DTC P1326 - ION Sensing Module Combustion (Cont'd)

10 11
Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin .Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
6E452
Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)
D06R200098
Circuit Description
The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. D This test will return a fault if the cylinder synchronization routine has not been completed after a predetermined number of events after crank. This test will detect fault that will prevent the PCM from synchronization, such as Knock Signal (KI) Combustion Quality (CQ) lines being swapped, shorted spark plugs, ION Sensing module faults, an PCM hardware faults.


D D D D D D D Ignition voltage is between 11volts and 16 volts. Engine speed is between 650rpm and 6250rpm. No ECT DTCs set. No injector DTCs set. No Fuel Trim DTCs set. No Misfire DTCs set. No system voltage DTCs set.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor.

D The PCM will ON the MIL after second trip with detected the fault. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

A change in the display will indicate the location of the fault. If DTC P1340 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.
6E453
If it is determined that the DTC occurs intermittently, performing the DTC P1340 Diagnostic Chart may isolate the cause of the fault.
DTC P1340 - ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)
1. Ignition OFF. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 4 Go to Step 3 Check the ION Sensing module harness between the PCM and ICSS module circuit at the QC line harness connector. Was a problem found? Verify repair Go to Step 6 Go to Step 5 Go to Step 5 1. Disconnect the ignition coil. Is the action complete? Check the ION Sensing module harness between the ignition coil and ION Sensing module circuit at the ION Sensing Module harness connector. Was a problem found? Verify repair Go to Step 7 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 9
5 6
8 9
6E454
DTC P1340 - ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail) (Cont'd)
10 11
Replace the ION Sensing module. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 11
6E455
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed
D06R200087
Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if current pintle zero position is different from the learned zero position. If the PCM detects a pintle position signal indicates more than 30 % different between current zero position and the learned zero position for more than 5 seconds, and this condition exists 3 times during trip, then the PCM will set DTC P1404.

Diagnostic Aids
Check for the following conditions: D Excessive carbon deposit on EGR valve shaft and/or foreign material may cause the EGR valve not to fully seat. The carbon deposit may occur by unusual port operation. Remove foreign material and/or excessive carbon deposit on EGR valve shaft and to allow the EGR valve to be fully seated. D Poor connection or damaged harness Inspect the wiring harness for damage. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D D D D Ignition voltage is between 11 and 16 volts. Intake Air temp is more than 3C. Desired EGR position is more than 3 %. Difference of EGR pintle position between current and the learned zero is more than 30 % for more than 5 seconds, and exists three times to the above condition during a trip the PCM will set DTC 1404. Then it trigger the PCM light on.

D The PCM will illuminate the malfunction indicator lamp (MIL) after consecutive 2nd trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.
6E456
DTC P1404 EGR Stuck Closed

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC inf. for DTC P1404 until the DTC P1404 test runs. Note the result. Does the Tech 2 indicates DTC P1404 failed this ignition? Go to Step 3
1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Repair the damaged pin or terminal. Is the action complete? 1. Remove EGR valve from Engine. 2. Inspect EGR valve for any excessive carbon deposit on EGR shaft. 3. Inspect for any foreign material inside of EGR valve. Was excessive carbon deposit on EGR valve shaft and/or foreign material in EGR valve ? Go to Step 6 Go to Step 7
4 5
1. Clean up EGR valve shaft and inside of EGR valve. 2. Remove foreign material from EGR valve. 3. Visually inspect damage of pintle and seat to see if it is bent. If damaged, leakage may occur. Was there any severe damage which affects function? Go to Step 9 1. 2. 3. 4. 5. 6. Install the EGR valve. Ignition OFF. Install the Tech 2. Run the engine at idle. On the Tech 2, select EGR Control Test. Use the UP arrow to increase the EGR from 0% to 40%. Verify repair
Did EGR work properly? 8 1. Reset the learned zero EGR valve position. 2. Repeat step 7. Did EGR work properly?
Go to Step 8
Verify repair
Go to Step 9
6E457
DTC P1404 EGR Stuck Closed (Cont'd)

9 10
Replace the EGR valve. Does DTC P1404 still fail DTC test on the Tech 2? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Go to Step 10 Verify repair
6E458
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge
D06R200084
Circuit Description
Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge ON). The EVAP purge solenoid control is pulse-width modulated (PWM) or turned ON and OFF several times a second. The duty cycle (pulse width) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the output is commanded when the appropriate conditions have been met.
D Fuel level is between 15% and 85%. D All conditions are present for at least 3 seconds.


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P1441 will clear after 40 consecutive warmup cycles have occurred without a fault. D DTC P1441 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

D No active ECT sensor, IAT sensor, MAP sensor, or TP sensor DTCs set. D BARO reading is above 85 kPa. D Engine coolant temperature is below 70C (158F). D Start-up intake air temperature (IAT) and start-up engine coolant temperature (ECT) are both above 5C (41F). D The difference between start-up ECT and start-up IAT is less than 25C (45F). D TP sensor indicates a throttle position above 12%. D Battery voltage is between 11.5 volts and 16 volts. D Engine speed is between 800 and 6,000 RPM. D Canister purge duty cycle is below 3%.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wring harness for damage. A change in the display will indicate the location of the fault.

6E459
Test Description
3. Determines if the PCM is able to control the EVAP purge solenoid valve. 4. Determines if the DTC will set under the conditions present when the DTC was originally stored. If not, the fault is intermittent. 5. Checks for a grounded EVAP purge solenoid driver circuit, a faulty EVAP vacuum switch, or a leaking EVAP purge solenoid valve.
DTC P1441 EVAP System Flow During Non-Purge

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. 2. 3. 4. Ignition OFF. Remove the fuel filler cap. Ignition ON. Observe Fuel Tank Pressure on the Tech 2. 1.51V Go to Step 3
Is Fuel Tank Pressure at the specified value? 3 1. Re-install the fuel filler cap. 2. Using the Tech 2, command the EVAP Vent Solenoid Valve ON (Closed). 3. Disconnect the canister side rubber hose end that hose is connected between the Purge Solenoid Valve and Canister. IMPORTANT: Before continuing with the diagnosis, zero the EVAP pressure/purge cart J41413 (refer to the tool operating instructions). And them monitor the fuel tank inner pressure using the Tech 2. Does the fuel tank pressure remain the specified value? 4 1. Disconnect the EVAP pressure/purge cart J41413, and then plug the hose end. 2. Disconnect the rubber hose end of engine vacuum source side, (the hose connected between Purge Solenoid Valve and engine). 3. Connect the vacuum hand pump to this rubber hose end. 4. Then apply the -15 in H2O vacuum by the vacuum pump. 5. Monitor the fuel tank inner pressure using the Tech 2. Does the fuel tank inner pressure hold the specified value? 5 Replace the Purge Solenoid Valve.
Go to DTC P0452 or P0453
1.52 - 1.60V
Go to Step 4
Go to Step 6
1.47 - 1.51V
Go to Step 6 Verify Repair
Go to Step 5
6E460
DTC P1441 EVAP System Flow During Non-Purge (Cont'd)

1. Check leaks, kinks or pinched hoses at the EVAP system rubber hose line, and also check if the rubber hoses are correctly connected or not. 2. Check for a leak from Vent Solenoid Valve and EVAP system rubber hoses, and also check for clogged Filter of air separator which is located near the vent solenoid valve. Was a problem found? Using the Vacuum Hose Routing Diagram, repair or re-connect the rubber hoses correctly.
Verify Repair
Go to Step 7
1. Start engine. 2. Remove the Fuel Filler cap. 3. Using the Tech 2, command the EVAP Vent Solenoid Valve ON (closed) and Purge Solenoid Valve OFF (0%). 4. Replace the Fuel Filler Cap. 5. Run the engine at 2500RPM constant while monitoring Fuel Tank Vacuum on the Tech 2. Does the fuel tank vacuum remain at the specified value while the EVAP Vent Solenoid Valve ON (closed) and Purge Solenoid Valve OFF (0%)?
30 - 40 %
Verify Repair
6E461
Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error
D06RY00090
Circuit Description
D The throttle position (TP) sensor circuit provides a voltage signal relative to throttle blade angle. The throttle blade angle will vary about 8 % at closed throttle to about 92 % at wide open throttle (WOT). D The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain Control Module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantitiy of air entering the engine indicates an accleration or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40g/s at maximum engine load.

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure. D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.


D D D D The engine is running. No MAF sensor DTCs are set. Throttle actuation mode is not off. MAF reading-ETC estimated air flow is less than 40g/s for 250 failres within test 1000 test samples (15.6 m sec).
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions:
6E462

increase from about 3 7 g/s at idle to 100 g/s or greater at the time of the 1 2 shift. If not, check for a restriction. A change in the display will indicate the location of the fault. If DTC P1514 cannot be duplicated, the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1514 Diagnostic Chart may isolate the cause of the fault.
D Poor connection at PCM - Inspect harness connectors for backed out terminals, improper mating,broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness - Inspect the wiring harness for damage. If the harness appears to be OK, observe the Mass Air Flow, TP sensor 1, TP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. D Plugged intake air duct or filter element D A wide - open throttle acceleration from a stop should cause the mass air flow displayed on a Tech 2 to
DTC P1514 - TPS-MAF Correlation Error

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P1514. Does the Tech 2 indicate DTC P1514 failed this ignition? Go to Step 4
Check the procedure. Refer to Diagnostic Aids
1. Start the engine. 2. With the engine idling, monitor MAF Frequency display on the Tech 2. Is the MAF Frequency below the specified value? 3 7 g/s Go to Step 5 Go to Step 8 1. 2. 3. 4. Ignition OFF. Disconnect the MAF sensor connector. Ignition ON, engine idling. Using a Tech 2, monitor MAF Frequency. 0g/s Go to Step 6 Verify repair Go to Step 7
Does the Tech 2 indicate a MAF Frequency at the specified value? 6 7 Replace the MAF sensor. Is the action complete? 1. Check the MAF harness for incorrect routing near high voltage components (solenoids, relays, motors). 2. If incorrect routing is found, correct the harness routing. Was a problem found? 8 1. With the engine idling, monitor MAF Frequency. display on the Tech 2. 2. Quickly snap open throttle to wide open throttle while under a road load and record value. Does the Tech 2 indicate a MAF Frequency at thespecified value?
Verify repair
Go to Step 8
3 7 g/s
Go to Step 6
Go to Step 9
6E463
DTC P1514 - TPS-MAF Correlation Error (Cont'd)

1. IgnitionON, engine not running. 2. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value? 100 kPa Go to Step 10 Go to Step 13 1. Disconnect the MAP sensor. 2. Connect a test 5 volt reference circuit and the MAP signal at the MAP sensor harness connector. 3. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value? (If no, start with diagnosis chart for other sensors in the circuit and see if 5Vreturns.)
10
5V
Go to Step 11
Go to Step 18
11
1. Check the MAP signal circuit between the PCM and MAP ground circuit. 2. If the MAP signal circuit is open or shoted, repair it as necessary. Was the MAP signal circuit open or shorted? Verify repair Verify repair Go to Step 12 Replace the MAP sensor. Is the action complete? 1. 2. 3. 4. Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
12 13
Closed throttle TPS1= 612% TPS2= 8894% Wide NOTE: The value check of TPS must be performed in open throttle less than 15 seconds. TPS1= 7983% Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle TPS2= value? 1923% 1. Connect a DVM between the 5Volt reference circuit and the TP1 and TP2 sensor ground circuit at the TP sensor harness connector. 2. Observe the voltage using a DVM. Is the voltage near the specified value? 5V
Go to Step 18
Go to Step 14
14
Go to Step 15
Go to Step 18
15
Check the following items; 1. TP1 and TP2 signal circuit for a short to voltage. 2. TP1 and TP2 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1 and TP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Go to Step 16
6E464
DTC P1514 - TPS-MAF Correlation Error (Cont'd)

16
Check the following items; 1. TP1and TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1and TP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 17 Go to Step 18
17 18
Replace the TP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin.Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair
6E465
Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error
D06RY00088
Circuit Description
D The throttle position (TP) sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary about 8 % at closed throttle to about 92 % at wide open throttle(WOT). D The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). D This DTC ditects the difference between actual throttle position and command throttle position.


D The ignition is ON. D Throttle actuation mode is normal. D Command Throttle position - Actual Throttle position is more than + 5 % for 100 counts within test 1000 test samples (15.6 m sec) else Actual Throttle position is less than + 40 % and Command Throttle position Actual Throttle position is more than - 5 % or Command Throttle position - Actual Throttle position is more than - 20 % for 150 failres within test 1000 test samples (15.6 m sec).
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, mproper mating, locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the TP sensor 1, TP sensor 2 display on the Tech2 while

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.
6E466

moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1515 cannot be duplicated, the information included in the Faillure Records data can
DTC P1515 - Command - Actual TPS Correlation Error

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Ignition On, engine Off. 2. Operate the throttle lever by hand (Dont operate the acceleration pedal). Was the DTC P1515 or P1516 stored? Go to Step 4
Go to Step 6
1. Check the DC mortor harness between the PCM and DC mortor curcuit at the DC mortor harness connector. 2. If a problem found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 5 1. Replace the throttle assembly (DC mortor). Is the action complete? 1. 2. 3. 4. Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
5 6
Closed throttle TPS1= 612% TPS2= 8894% Wide NOTE: The value check of TPS must be performed in open throttle less than 15 seconds. TPS1= 7983% Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle TPS2= value? 1923% Check the following items; 1. TP1 and TP2 signal circuit for a short to voltage. 2. TP1 and TP2 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1and TP2 sensor ground circuit for a poor connection. 4. If a problem is found,repair wiring harness as necessary. Was a problem found?
Go to Step 10
Go to Step 7
Verify repair
Go to Step 8
6E467
DTC P1515 - Command - Actual TPS Correlation Error (Cont'd)

Check the following items; 1. TP1 and TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1 and TP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 9 Go to Step 10
9 10
Replace the TP sensor. Was a problem found? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair
6E468
Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error
D06RY00088
Circuit Description
D The throttle position (TP) sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary about 8% at closed throttle to about 92 % at wide open throttle (WOT). D The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). D This DTC detects the dufference between actual throttle position and command throttle position in steady state.


D The ignition is ON. D Throttle Actuation mode is normal. D Command Throttle position-Actual Throttle positionis less than 8 % when desird TPS is sutudy wihtin 0.5 %for 30 second within test samples (30 second)
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness - Inspect the wiring harness for damage. If the harness appears to be OK, observe the TP sensor 1, TP sensor 2 display on the Tech2 while moving connectors and wiring harnesses related to the sensor.

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure. D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

A change in the display will indicate the location of the fault. If DTC P1516 cannot be duplicated, the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set.
6E469
DTC P1516 - Command - Actual TPS Correlation Error

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Ignition On, engine Off. 2. Operate the throttle lever by hand (Dont operate the acceleration pedal). Was the DTC P1515 or P1516 stored? Go to Step 4
Go to Step 6
1. Check the DC mortor harness between the PCM and DC mortor curcuit at the DC mortor harness connector. 2. If a problem found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 5 Replace the throttle assembly (DC mortor). Is the action complete? 1. 2. 3. 4. Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
5 6
Closed throttle TPS1= 612% TPS2= 8894% Wide NOTE: The value check of TPS must be performed in open throttle less than 15 seconds. TPS1= 7983% Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle TPS2= value? 1923% Check the following items; 1. TP1 and TP2 signal circuit for a short to voltage. 2. TP1 and TP2 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1and TP2 sensor ground circuit for a poor connection. 4. If a problem is found,repair wiring harness as necessary. Was a problem found?
Go to Step 10
Go to Step 7
Verify repair
Go to Step 8
6E470
DTC P1516 - Command - Actual TPS Correlation Error (Cont'd)

Check the following items; 1. TP1 and TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1 and TP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 9 Go to Step 10
9 10
6E471
Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance
D06RY00088
Circuit Description
D The throttle position (TP) sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary about 8 % at closed throttle to about 92 % at wide open throttle(WOT). D The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). D This DTC ditects if the throttle return to the default position at key on, steady state.
Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Throttle function: Check for the throttle function. When ignition switch ON that throttle lever is smooth operated by step on the acceleration pedal. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the TP sensor 1, TP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1523 cannot be duplicated, the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set.

D The ignition is ON. D Normalized TPS is less than 7 % or Normalized TPS is more than 25 %.


D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condtion is no longer present. D A history DTC P1523 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault.
6E472
DTC P1523 - Actuator Control Return Performance

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. 2. 3. 4. Closed throttle TPS1= 612% TPS2= 8894% Wide NOTE: The value check of TPS must be performed in open throttle less than 15 seconds. TPS1= 7983% Does the TP angle increase steadily and evenly from TPS2= the closed throttle value to the wide open throttle value? 1923% 1. Ignition OFF. 2. Disconnect the DC motor. Is the DC motor reading near the specified value? 0.3 100 m Go to Step 5 Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.
Go to Step 7
Go to Step 4
Go to Step 6
1. Check the DC motor harness between the PCM and DC Motor circuit at the DC motor harness connector. 2. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 5 Check the procedure. Refer to Diagnostic Aids Replace the throttle assembly (DC motor). Is the action complete? Was the DTC P1523 stored?
6 7
8 1. Connect a DVM between the 5Volt reference circuit and the TP1 and TP2 sensor ground circuit at the TP sensor harness connector. 2. Observe the voltage using a DVM. Is the voltage near the specified value? 9 Check the following items; 1. TP1 and TP2 signal circuit for a short to voltage. 2. TP1 and TP2 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1and TP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found? 5V
Go to Step 12
Go to Step 9
Go to Step 10
Verify repair
Go to Step 10
6E473
DTC P1523 - Actuator Control Return Performance (Cont'd)

10
Check the following items; 1. TP1and TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1and TP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 11
11 12
6E474
Diagnostic Trouble Code (DTC) P1574 Brake Switch No Operation
D06R200076
Circuit Description
The brake switch has 3 functions. D Brake pedal operation check D Brake light operation (On and off) D Cruise control (Cancel) The PCM receives vehicle speed and switch position signals from the brake switch. The PCM sets brake operating conditions in response to these signals. If the brake switch is on, the brake system is in normal operation (cruise control cancelled).



D Two break switch signals do not acknowledge after signal changed. D Switch does not change during accelerating vehicle or decelerating. D VSS is not fault. D Engine is running.
Diagnostic Aids
6E475
DTC P1574 Brake Switch No Operation

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition Off. Engine Off. 2. Check following fuses. D BACK 15A D STOP LAMP 15A 3. If a problem found repair as necessary. Was a problem found? Verify repair
Go to Step 3
1. Make adjustment to the brake switch. (Refer to Brake switch in 10A CRUISE CONTROL SYSTEM.) 2. If a problem found repair as necessary. Was the problem found? Verify repair Go to Step 4
1. Push the shaft on brake switch. 2. Check shaft operation for smooth movement. 3. If a problem found repair as necessary. Was the problem found? Verify repair Go to Step 5 1. Disconnect the connector at brake switch. 2. Check following terminal pin by ohmmeter. (Leave the shaft position at brake switch. Dont Between pin1 push it.) and pin2 is D Between pin 1 and pin 2 0m, Between D Between pin 3 and pin 4 pin3 and pin4 Was it specified value? is m 1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Dont press the button of the brake switch.) D D Between pin 1 and pin 2 Between pin 3 and pin 4
Go to Step 6
Go to Step 9
Was it specified value? 7 1. Probe related circuits for open or short to ground. 2. If a problem was found, repair as necessary. Was a problem found? 8 1. Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Was the action completed? 9 1. Replace the brake switch. Was the action completed?
Between pin1 and pin2 is m, Between pin3 and pin4 is 0m
Go to Step 7
Go to Step 9
Verify repair
Go to Step 8
6E476
Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault
D06RY00077
Circuit Description
The TP sensor # 1 shares a 5 Volt reference with the PCM. If the PCM detects the 5 Volt reference for the TP sensor # 1 is failure, DTCP1635 will be set.

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condtion is no longer present. D A history DTC P1635 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P1635 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed. Tech2 Clear Info function or by disconnecting the PCM battery feed.

D The ignition is ON. D The 5 Volt reference voltage for the TP sensor # 1 is less than 4 volts. D The 5 Volt reference voltage for the TP sensor # 1 is more than 5 volts.

D The PCM will not illuminate the malfunction indicator lamp (MIL) .
6E477

1. Connect a DVM between the 5volt reference curcuit and the TP1 and TP2 sensor ground curcuit. 2. Check the voltage using a DVM. Is the voltage near the specified value? 5V Varify repair Go to Step 3 1. Check the TPS1and TPS2 5 volt reference curcuit. 2. If the curcuit is open or shorted, repair it as necessary. Was the curcuit open or short? Varify repair Go to Step 4 1. Check the TP1 and TP2 sensor ground curcuit. 2. If the curcuit is open or shorted, repair it as necessary. Was the curcuit open or short? Varify repair Go to Step 5 1. Observe the battery voltage and circuit. 2. If a problem found, repair it as necessary. Was a problem found? PCM must be Verify repair Go to Step 6 Replace the PCM. IMPORTANT: The programmed. replacement
6E478
Diagnostic Trouble Code (DTC) P1636 PCM RAM Stack

Circuit Description
The powertrain control module (PCM) monitors unexpected PCM reset. This will not turn on MIL light on, only record code DTC P1636.


D Clock or COP (Computer Operating Properly) reset.

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.
Diagnostic Aids
Check for the following conditions: D P1636 stored alone does not need diagnosis. Clear DTC code.
DTC P1636 PCM RAM Stack

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. 2. 3. 4. 1. 2. 3. 4. Ignition is ON. Install the Tech 2. Start the engine and let it Idle. On the Tech 2, select DTC info. Go to Step 3 Ignition is ON. Clear DTC P1636 by using the Tech 2 Clear Info. Start the engine and let it Idle. On the Tech 2, select DTC info. Go to Step 4
Go to OBD System Check Check the Procedure Refer to Diagnostic Aids Check the Procedure Refer to Diagnostic Aids
Does the Tech 2 indicate DTC P1636 failed? 3
Does the Tech 2 indicate DTC P1636 failed? 4 1. Check for aftermarket electronics, such as transceiver, stereos, and anti theft devices. They may radiate EMI into the control system if they are improperly installed. (This may cause a false sensor reading and turn on the MIL.) 2. If a problem is found, repair as necessary. Was a problem found?
Verify repair
6E479
D06RY00075
Circuit Description
The TP sensor # 1 shares a 5 Volt reference with the PCM. If the PCM detects the 5 Volt reference for the AP sensor # 1 is failure, DTCP1635 will be set.

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condtion is no longer present. D A history DTC P1639 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P1639 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed. Tech2 Clear Info function or by disconnecting the PCM battery feed.

D The ignition is ON. D The 5 Volt reference voltage for the AP sensor # 1 is less than 4 volts. D The 5 Volt reference voltage for the AP sensor # 1 is more than 5 volts.

D The PCM will not illuminate the malfunction indicator lamp (MIL) .
6E480

1. Connect a DVM between the 5volt reference curcuit and the AP1, AP2 and AP3 sensor ground curcuit. 2. Check the voltage using a DVM. Is the voltage near the specified value? 5V Varify repair Go to Step 3 1. Check the APS1, APS2 and APS3 5 volt reference curcuit. 2. If the curcuit is open or shorted, repair it as necessary. Was the curcuit open or short? Varify repair Go to Step 4 1. Check the AP1, AP2 and AP3 sensor ground curcuit. 2. If the curcuit is open or shorted, repair it as necessary. Was the curcuit open or short? Varify repair Go to Step 5 1. Observe the battery voltage and circuit. 2. If a problem found, repair it as necessary. Was a problem found? PCM must be Verify repair Go to Step 6 Replace the PCM. IMPORTANT: The programmed. replacement
6E481
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)

Circuit Description
Output driver modules (ODMs) are used by the powertrain control module (PCM) to turn ON many of the current-driven devices that are needed to control various engine and transmission functions. Each ODM is capable of controlling up to 7 separate outputs by applying ground to the device which the PCM is commanding ON. Unlike the Quad Driver Modules (QDMs) used in prior model years, ODMs have the capability of diagnosing each output circuit individually. DTC P1640 set indicates an improper voltage level has been detected on an ODM output. Since A/C is an option, No A/C will cause the air conditioning clutch relay output to always fail. If a fault is seen on the air conditioning clutch relay output, it will not be logged as a fault until the A/C request input interrupts a high voltage, indicating that A/C has been installed. D The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

D A history DTC P1640 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P1640 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the PCM, turn the ignition ON and observe a voltmeter connected to the suspect driver circuit at the PCM harness connector while moving connectors and wiring harnesses related to the MIL. A change in voltage will indicate the location of the fault. D Poor connection at component Examine for damaged connectors, unplugged connector, or damaged terminals at the following locations: Instrument cluster harness, canister purge solenoid, A/C clutch relay. An open ignition feed circuit at any of these components will cause DTC P1640 to be set. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D D D D Ignition ON. Engine running. Ignition voltage is above 13.2 volts for 4 seconds. Output voltage does not equal ignition voltage when output is OFF or output voltage is not less than 1 volt when output is ON. D Above conditions occur for at least 1 second.

DTC P1640 Driver-1-Output Circuit Fault (ODM)

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Check the fuse for the driver circuit that was shown as faulty. Was the fuse blown? Go to Step 3
Go to Step 4
1. Check for a short to ground between the fuse and the affected component. 2. Replace the fuse after making any necessary repairs. Is the action complete? Verify repair Disconnect the PCM connector for the affected driver circuit. Is there any damage to the PCM pin or connector? Go to Step 5 Verify repair Go to Step 7 Go to Step 6 Go to Step 13 Repair the damaged pin or terminal. Is the action complete? Were either of the lamp circuits for Check Engine or Check Trans indicated as faulty by the Tech 2?
5 6
6E482
DTC P1640 Driver-1-Output Circuit Fault (ODM) (Cont'd)

1. Leave the PCM connector for the lamp driver circuit disconnected. 2. Ignition ON. 3. Using a DVM, check the voltage at the PCM connector for the affected lamp driver circuit. Was the voltage equal to the specified value? B+ Go to Step 15 Go to Step 8 1. Ignition ON. 2. Check for battery voltage at the fuse for the affected lamp circuit. Was battery voltage available at the fuse? Go to Step 10 Go to Step 9 Repair the open circuit between the ignition switch and the fuse. Is the action complete? Verify repair 1. Ignition OFF. 2. Disconnect the PCM connector for the affected driver terminal. 3. Connect an ohmmeter between a good ground and the PCM connector for the affected driver. Did the ohmmeter indicate continuity? Go to Step 11 Go to Step 12 Repair the short to ground between the affected component and its PCM driver terminal. Is the action complete? Verify repair Repair the open circuit between the fuse and the PCM driver terminal for the affected circuit. Is the action complete? Verify repair 1. Connect the PCM. 2. Start the engine and let it idle. 3. Backprobe the affected terminal at the PCM with a DVM. Was the voltage equal to the specified value? +B Go to Step 15 Go to Step 14 1. Run the engine at idle. 2. Check for battery voltage at the fuse for the affected circuit. Was battery voltage available at the fuse? Go to Step 10 Go to Step 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
10
11
12
13
14
15
6E483
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module A Fault

Circuit Description
The Quad Driver Module (QDMs) are used by the powertrain control module (PCM) to turn ON currentdriven devices that are needed to control two engine functions. The PCM monitors open or short circuit of either of Canister Control Purge (CCP) Vent solenoid or Variable Intake Manifold (VIM).
Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the PCM, turn the ignition ON and observe a voltmeter connected to the suspect driver circuit at the PCM harness connector while moving connectors and wiring harnesses relates to the MIL. A change in voltage will indicate the location of the fault. D Poor connection at component Examine for damaged connectors, unplugged connector, or damaged terminals at the following locations: canister purge solenoid, fuel level sensor. An open ignition feed circuit at any of these components will cause DTC P1650 to be set. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D D D D Ignition ON. Engine running. Ignition voltage. Output voltage does not equal voltage and is not less than 1 volt when out put is ON. D Above conditions occur for at least 0.5 second.

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

The following PCM pins are controlled by Quad driver modules (QDMs):
D S74 VIM D S48 Canister control purge
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 4. The Tech 2 Driver Module Status indicates the PCM pin that is affected. 9.The Tech 2 may indicate short circuit even when the problem is an open circuit. The cause of an open circuit may be in the component itself. 11.A short to ground on the ignition side of the component will blow the fuse. Since the fuse was checked in Step 2, a short to ground would be between the affected component and the PCM.
6E484
DTC P1650 Quad Driver Module (QDM) Fault

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Check the fuse for the driver circuit that was shown as faulty. Was the fuse blown? Go to Step 3
Go to Step 4
1. Check for a short to ground between the fuse and the affected component. 2. Replace the fuse after making any necessary repairs. Is the action complete? Verify repair Disconnect the PCM connector for the affected driver circuit. Is there any damage to the PCM pin or connector? Go to Step 5 Verify repair Go to Step 7 Go to Step 6 Go to Step 13 Repair the damaged pin or terminal. Is the action complete? Were either of the lamp circuits for Check Engine or Check Trans. indicated as faulty by the Tech 2? 1. Leave the PCM connector for the lamp driver circuit disconnected. 2. Ignition ON. 3. Using a DVM, check the voltage at the PCM connector for the affected lamp driver circuit. Was the voltage equal to the specified value? B+ Go to Step 15 Go to Step 8 1. Ignition ON. 2. Check for battery voltage at the fuse for the affected lamp circuit. Was battery voltage available at the fuse? Go to Step 10 Go to Step 9 Repair the open circuit between the ignition switch and the fuse. Is the action complete? Verify repair 1. Ignition OFF. 2. Disconnect the PCM connector for the affected driver terminal. 3. Connect an ohmmeter between a good ground and the PCM connector for the affected driver. Did the ohmmeter indicate continuity? Go to Step 11 Go to Step 12 Repair the short to ground between the affected component and its PCM driver terminal. Is the action complete? Verify repair Repair the open circuit between the fuse and the PCM driver terminal for the affected circuit. Is the action complete? Verify repair
5 6 7
10
11
12
6E485
DTC P1650 Quad Driver Module (QDM) Fault (Cont'd)

13
1. Connect the PCM. 2. Start the engine and let it idle. 3. Backprobe the affected terminal at the PCM with a DVM. Was the voltage equal to the specified value? +B Go to Step 15 Go to Step 14 1. Run the engine at idle. 2. Check for battery voltage at the fuse for the affected circuit. Was battery voltage available at the fuse? Go to Step 10 Go to Step 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair
14
15
6E486
Symptom Diagnosis
Preliminary Checks
Before using this section, perform the On-Board Diagnostic (OBD) System Check and verify all of the following items: D The powertrain control module (PCM), and malfunction indicator lamp (MIL) (Check Engine lamp) and Reduced Power Lamp (RPL) are operating correctly. D There are no DTC(s) stored. D Tech 2 data is within normal operating range. Refer to Typical Scan Data Values. D Verify the customer complaint and locate the correct symptom in the table of contents. Perform the procedure included in the symptom chart.
Visual/Physical Check
Several of the symptom procedures call for a careful visual/physical check. This can lead to correcting a problem without further checks and can save valuable time. This check should include the following items: D PCM grounds for cleanliness, tightness and proper location. D Vacuum hoses for splits, kinks, and proper connections, as shown on the Vehicle Emission Control Information label. Check thoroughly for any type of leak or restriction. D Air intake ducts for collapsed or damaged areas. D Air leaks at throttle body mounting area, mass air flow (MAF) sensor and intake manifold sealing surfaces. D Ignition components for cracking, hardness, and carbon tracking. D Wiring for proper connections, pinches and cuts.
Intermittents
IMPORTANT: An intermittent problem may or may not turn on the malfunction indicator lamp (MIL) or store a DTC. DO NOT use the Diagnostic Trouble Code (DTC) charts for intermittent problems. The fault must be present to locate the problem. Most intermittent problems are caused by faulty electrical connections or wiring. Perform a careful visual/physical check for the following conditions: D Poor mating of the connector halves or a terminal not fully seated in the connector (backed out). D Improperly formed or damaged terminal. D All connector terminals in the problem circuit should be carefully checked for proper contact tension. D Poor terminal-to-wire connection. This requires removing the terminal from the connector body to check. Road test the vehicle with a J 39200 Digital Multimeter connected to a suspected circuit. An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored. Use a Tech 2 to help detect intermittent conditions. The scan tool has several features that can be used to locate
an intermittent condition. Use the following feature to find intermittent faults: D Using a Tech 2s Freeze Frame buffer or Failure Records buffer can aid in locating an intermittent condition. Review and record the information in the freeze frame or failure record associated with the intermittent DTC being diagnosed. The vehicle can be driven within the conditions that were present when the DTC originally set. To check for loss of diagnostic code memory, disconnect the MAP sensor and idle the engine until the MIL (Check Engine lamp) comes on. DTC P0107 should be stored and kept in memory when the ignition is turned OFF. If not, the PCM is faulty. When this test is completed, make sure that you clear the DTC P0107 from memory. An intermittent MIL (Check Engine lamp) with no stored DTC may be caused by the following: D Ignition coil shorted to ground and arcing. D MIL (Check Engine lamp) wire to PCM shorted to ground. D Poor PCM grounds. Refer to the PCM wiring diagrams. Check for improper installation of electrical options such as lights, cellular phones, etc. Check all wires from the PCM to the ignition coils for poor connections. Check for an open diode across the A/C compressor clutch and check for other open diodes (refer to wiring diagrams in Electrical Diagnosis). If problem has not been found, refer to PCM Connector Symptom tables. D Check the Calibration ID of the PCM, and compare it with the latest Isuzu service bulletins and/or Isuzu EEPROM reprogramming equipment to determine if an update to the PCMs reprogrammable memory has been released. To check the Calibration ID, connect the Tech 2, then look for Powertrain, then select Calibration ID. This identifies the contents of the reprogrammable software and calibration contained in the PCM. If the Calibration ID is not the most current available, it is advisable to reprogram the PCMs EEPROM memory, which may either help identify a hard-to-find problem or may fix the problem. D Calibration ID (example) Part number Broadcast Code Identifier 9377709 CYYD 801
6E487
Hard Start Symptom

DEFINITION: Engine cranks, but does not start for a long time. Does eventually run, or may start but immediately stall. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? Verify repair
Go to Step 4 Go to Visual/ Physical Check
Was a visual/physical check performed? Go to Step 5
Check engine coolant temperature (ECT) sensor for shift in value. After 8 hours with the hood up and the engine not running, connect the Tech 2. With the ignition ON and the engine not running, compare engine coolant temperature to intake air temperature. Are ECT and IAT within the specified value of each 5C ( 9F) other? Go to Step 9 Go to Step 6
1. Using a Tech 2, display the engine coolant temperature and note the value. 2. Check the resistance of the engine coolant temperature sensor. 3. Refer to Engine Coolant Temperature Sensor Temperature vs. Resistance chart on DTC P0118 Diagnostic Support for resistance specifications. Is the resistance value near the resistance for the temperature noted? Go to Step 8 Verify repair Go to Step 7
7 8
Replace the ECT sensor. Is the action complete? Locate and repair high resistance or poor connection in the ECT signal circuit or the ECT sensor ground. Is the action complete? Verify repair 1. Check for a faulty, plugged, or incorrectly installed PCV valve. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10 1. Check for water- or alcohol-contaminated fuel. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11 1. Perform the procedure in Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 12
10
11
6E488
Hard Start Symptom (Cont'd)

12
1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electric Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 13 1. Remove spark plugs. Check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14
13
14
1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 15 1. Remove the ignition coils and check the ignition coils for cracks or carbon tracking. 2. If a problem is found, replace affected coil(s) as necessary. Was a problem found? Verify repair Go to Step 16 1. Check for the following engine mechanical problems (refer to Engine Mechanical): D Low compression D Leaking cylinder head gaskets D Worn or incorrect camshaft D Camshaft drive belt slipped or stripped 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 17 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records buffer D All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
15
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17
Contact Technical Assistance
6E489
Surges and/or Chuggles Symptom

DEFINITION: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the accelerator pedal. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
Be sure that the driver understands transmission torque converter clutch and A/C compressor operation as explained in the owners manual. Inform the customer how the TCC and the A/C clutch operate. Is the customer experiencing a normal condition? System OK Go to Step 6 1. Check the fuel control heated oxygen sensors (HO2S, B1S1 and B2S1). The fuel control heated oxygen sensors (HO2S) should respond quickly to different throttle positions. If they dont, check them for silicone or other contaminants from fuel or use of improper RTV sealant. The sensors may have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The PCM will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. For more information, refer to Powertrain Control Module (PCM) and Sensors. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7
1. Check the fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 Monitor the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)? Go to Step 9 Go to Step 10
1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 11 Verify repair
6E490
Surges and/or Chuggles Symptom (Cont'd)

10
1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 11 Verify repair 1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electric Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 12 1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 13 1. Check the ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 1. Remove the spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 15
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1. Check the injector connections. 2. If any of the injector connectors are connected to an incorrect cylinder, correct as necessary. Was a problem found? Verify repair Go to Step 16 1. Check PCM grounds for the cleanliness, tightness and proper locations. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 17 1. Check MAF sensor connections. 2. If a problem is found, replace the faulty terminals as necessary. Refer to Electrical Diagnosis for wiring repair procedures. Was a problem found? Verify repair Go to Step 18 1. Visually/physically check vacuum hoses for splits, kinks, and proper connections and routing as shown on the Vehicle Emission Control Information label. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 19
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6E491
Surges and/or Chuggles Symptom (Cont'd)

19
1. Check the exhaust system for possible restriction: D Inspect the exhaust system for damaged or collapsed pipes. D Inspect the muffler for heat distress or possible internal failure. D Check for a possible plugged three-way catalytic converter by checking the exhaust system back pressure. Refer to Restricted Exhaust System Check. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 20 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records buffer D All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
20
6E492
Lack of Power, Sluggish, or Spongy Symptoms

DEFINITION: Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part-way. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
1. Remove and check the air filter element for dirt or restrictions. Refer to Air Intake System in ON-Vehicle Service. 2. Replace the air filter element if necessary. Was a repair required? Verify repair Go to Step 6 1. Check for low fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Check for water- or alcohol-contaminated fuel. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Install the Tech 2. 2. Run the engine at idle. 3. On the Tech 2, select F3: Miscellaneous Test, F6: Variable Intake Manifold. 4. Repeat Switch ON or OFF of VIM solenoid valve by using the Tech 2. 5. Check to see if the actuator works normally. 6. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electronic Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10
6E493
Lack of Power, Sluggish, or Spongy Symptoms (Cont'd)

10
1. Remove the spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11
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1. Check the ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 12 1. Check the PCM grounds for cleanliness, tightness and proper locations. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 13 1. Check the exhaust system for possible restriction: D Inspect the exhaust system for damaged or collapsed pipes. D Inspect the muffler for heat distress or possible internal failure. D Check for a possible plugged three-way catalytic converter by checking the exhaust system back pressure. Refer to Restricted Exhaust System Check. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 1. Check the torque converter clutch (TCC) for proper operation. Refer to 4L30-E Transmission Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 15 1. Check for an engine mechanical problem. Check for low compression, incorrect or worn camshaft, loose timing belt, etc. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 16 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records buffer D All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
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6E494
Detonation/Sparks Knock Symptoms

DEFINITION: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with throttle opening. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? Verify repair Go to Step 3 Go to Visual/ Physical Check Was a visual/physical check performed? Go to Step 4
If Tech 2 readings are normal (refer to Typical Scan Values) and there are no engine mechanical faults, fill the fuel tank with a known quality gasoline that has a minimum octane rating of 87 and re-evaluate the vehicle performance. Is detonation present? Go to Step 5 Verify repair 1. Check the transmission range switch circuit. Use a Tech 2 and be sure the Tech 2 indicates that the vehicle is in drive with the gear selector in drive or overdrive. 2. If a problem is found, diagnose and repair the transmission range switch as necessary (refer to 4L30-E Automatic Transmission Diagnosis). Was a problem found? Verify repair Go to Step 6 1. Check TCC operation. Refer to 4L30-E Transmission Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Check for obvious overheating problems: D Low engine coolant. D Restricted air flow to radiator, or restricted water flow through radiator. D Correct coolant solution should be a 50/50 mix of approved antifreeze/coolant and water. Refer to Engine Cooling. D EGR operation. Refer to DTC P0401. D ION sensing module fault. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Ignition OFF. 2. Disconnect the ION sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 9 Check the ION sensing harness between the PCM (F68) and ION sensing module circuit (RED Wire) at the Kl line harness connector. Was a problem found? Verify repair Go to Step 10
6E495
Detonation/Sparks Knock Symptoms (Cont'd)

10 11
1. Disconnect the ignition coil. Is the action complete? Check the ION sensing harness between the ignition coil and ION sensing module circuit at the DC motor harness connector. Was a problem found? Verify repair Go to Step 12 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 13 Go to Step 14 Go to Step 11
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Replace the Ignition coil. Is the action complete? Check the following items; 1. ION sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found? Go to Step 10 Verify repair Go to Step 15 Go to Step 16
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Replace the ION sensing module. Is the action complete? 1. Check fuel pressure. Refer to Chart Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 17 1. Check items that can cause an engine to run lean (long term fuel trim significantly in the positive range). For a lean condition, refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 18 1. Spark plugs for proper heat range. Refer to General Information. 2. If incorrect spark plugs are installed, replace spark plugs as necessary. Did any spark plugs require replacement? Verify repair Go to Step 19 1. Remove excessive carbon buildup with a top engine cleaner. Refer to instructions on the top engine cleaner can. 2. Re-evaluate vehicle performance. Is detonation still present? Go to Step 20 Verify repair
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6E496
Detonation/Sparks Knock Symptoms (Cont'd)

20
1. Check for an engine mechanical problem. Perform a cylinder compression check. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 21 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records buffer D All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
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6E497
Rough, Unstable, or Incorrect Idle, Stalling Symptom

DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? Go to Step 14
1. Check the PCM grounds for cleanliness, tightness and proper routing. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 6 Observe the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)? Go to Step 7 Go to Step 8
1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Go to Step 10 Go to Step 10 Is the long term fuel trim significantly in the positive range (lean condition)? 1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10 1. Check for incorrect idle speed. Ensure that the following conditions are present: D The engine is fully warm. D The accessories are OFF. 2. Using a Tech 2, monitor the Engine Speed. Is the Engine Speed within the specified values?
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10
Desired Idle Speed
Go to Step 12
Go to Step 11
6E498
Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont'd)

11
1. Visually/physically inspect for the following conditions: D Restricted air intake system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Large vacuum leak. Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty crankcase ventilation valve or a disconnected brake booster hose. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Check the injector connections. If any of the injectors are connected to an incorrect cylinder, correct as necessary. Was a problem found? Verify repair Go to Step 13 1. Perform the Injector Coil/Balance Test in Fuel Metering System. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 1. Check for fuel in the pressure regulator vacuum hose. 2. If fuel is present, replace the fuel pressure regulator assembly. Refer to Fuel Metering System. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 15 1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electronic Ignition System for the procedure. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 16 1. Remove spark plugs. Check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 17
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1. Check for a loose ignition coil ground and ION Sensing Module circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 18 1. Check ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 19
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6E499
Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont'd)

19
Using a Tech 2, monitor the throttle position 1 and 2 angle with the engine idling. Is the TP angle at the specified value and steady? 8 10% Go to Step 20 1. Check the positive crankcase ventilation (PCV) valve for proper operation. Refer to Crankcase Ventilation System. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
Refer to DTC for further diagnosis
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Go to Step 21
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1. Check the transmission range switch circuit. Use a Tech 2 and be sure the Tech 2 indicates that the vehicle is in drive with the gear selector in drive or overdrive. 2. If a problem is found, diagnose and repair the transmission range switch as necessary (refer to 4L30-E Automatic Transmission Diagnosis). Was a problem found? Verify repair Go to Step 22 1. Check for the following engine mechanical items. Refer to Engine Mechanical for diagnosis procedures: D Low compression D Sticking or leaking valves D Worn camshaft lobe(s) D Camshaft drive belt slipped or stripped D Incorrect valve timing D Worn rocker arms D Broken valve springs 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 23
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1. Check for faulty motor mounts. Refer to Engine Mechanical for inspection of mounts. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 24 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records buffer D All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
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6E500
Poor Fuel Economy Symptom

DEFINITION: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Non-standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it is actually normal.) Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
Check owners driving habits. D Is the A/C ON full time (defroster mode ON)? D Are tires at the correct pressure? D Are excessively heavy loads being carried? D Is acceleration too much, too often? Was a problem found? Go to Step 5 Go to Step 6 Review the items in Step 4 with the customer and advise as necessary. Is the action complete? System OK 1. Visually/physically check: Vacuum hoses for splits, kinks, and improper connections and routing as shown on the Vehicle Emission Control Information label. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Remove and check the air filter element for dirt or for restrictions. Refer to Air Intake System. 2. Replace the air filter element if necessary. Was a repair required? Verify repair Go to Step 8 1. Remove spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Spark Plug Replacement. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9
1. Check for low engine coolant level. Refer to Engine Cooling. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10
6E501
Poor Fuel Economy Symptom (Cont'd)

10
1. Check for an incorrect or faulty engine thermostat. Refer to Engine Cooling. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11 1. Check for low engine compression. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 12 1. Check the TCC operation. Refer to 4L30-E Transmission Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 13 1. Check the exhaust system for possible restriction: D Inspect the exhaust system for damaged or collapsed pipes. D Inspect the muffler for heat distress or possible internal failure. D Check for a possible plugged three-way catalytic converter by checking the exhaust system back pressure. Refer to Restricted Exhaust System Check. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 Check for proper calibration of the speedometer. Does the speed indicated on the speedometer closely match the vehicle speed displayed on the Tech 2? Go to Step 16 Go to Step 15
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Diagnose and repair an inaccurate speedometer condition as necessary. Refer to Vehicle Speed Sensor in Electrical Diagnosis. Was a problem found? Verify repair 1. Check the air intake system and the crankcase for air leaks. Refer to Air Intake System and Crankcase Ventilation System. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 17 1. Review all diagnostic procedures within this table. 2. When all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records buffer D All connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Contact Technical Assistance Go to Step 18 Perform the procedure in Fuel System Pressure Test. Was the fuel pressure normal?
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Verify repair
6E502
Excessive Exhaust Emissions or Odors Symptom

DEFINITION: Vehicle fails an emission test. Vehicle has excessive rotten egg smell. (Excessive odors do not necessarily indicate excessive emissions.) Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? Go to Step 13 Go to Step 3 Go to Visual/ Physical Check Was a thorough visual/physical check performed? Go to Step 4
1. Check for vacuum leaks. Check vacuum lines, intake manifold, throttle body, etc. 2. If a problem is found, repair as necessary. Were any vacuum leaks located? Go to Step 13 Go to Step 5 1. Check the fuel cap for proper installation. 2. Secure the fuel cap if necessary. Was the fuel cap installed properly? Go to Step 6 Go to Step 13 1. Check the fuel pressure. Perform the procedure in Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 13 Go to Step 7 1. Check for a faulty, plugged, or incorrectly installed crankcase ventilation valve; also check the crankcase ventilation system for plugging. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 13 Go to Step 8 1. Check the injector connections. 2. If any of the injectors are connected to an incorrect cylinder, correct as necessary. Was a problem found? Go to Step 13 Go to Step 9 1. Perform the Injector Coil/Balance Test in Fuel Metering System. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 13 Go to Step 10 1. Refer to Engine Cooling for cooling system diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 13 Go to Step 11 1. Check EVAP canister for fuel loading. Refer to Evaporative Emission Control System. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 13 Go to Step 12
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6E503
Excessive Exhaust Emissions or Odors Symptom (Cont'd)

12
1. Remove excessive carbon buildup with a top engine cleaner. Refer to the instructions on the top engine cleaner can. 2. Perform the exhaust emission test. Does the vehicle pass the test? System OK System OK Go to Step 14 Go to Step 14 Perform the exhaust emission test. Does the vehicle pass the test? Does the exhaust emission test indicate excessive CO and HC levels or is long term fuel trim significantly in the negative range (rich condition)? 1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. Make any necessary repairs. 2. Perform the exhaust emission test. Does the vehicle pass the test? System OK Go to Step 17 1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. Make any necessary repairs. 2. Perform the exhaust emission test. Does the vehicle pass the test? System OK Go to Step 17 1. Check the EGR system (refer to DTC P0401). 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 13 Go to Step 18 1. Check for an engine mechanical problem. Perform a cylinder compression check (refer to Engine Mechanical). 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 13 Go to Step 19
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Go to Step 15
Go to Step 16
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1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records butter D All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
6E504
Dieseling, Run-On Symptom

DEFINITION: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smooth, check ignition switch and adjustment. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
1. Check for a short between B+ and any of the ignition feed circuits. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 5 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records butter D All electrical connections within a suspected circuit and/or system 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
6E505
Backfire Symptom
DEFINITION: Fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
1. Check for proper ignition voltage coil output with spark tester J 26792 (ST-125). Refer to Electric Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 5 1. Remove spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. Refer to DTC P0172 to determine the cause of a rich condition or Engine Mechanical for an oil fouling condition. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 6
1. Visually/physically inspect the ignition coils for cracks. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Check for an intermittent ignition system malfunction: D Intermittent CKP 58X signal. D Intermittent ignition feed circuit or sensor ground circuit to the crankshaft position sensor. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Check the fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9
6E506
Backfire Symptom (Cont'd)

1. Check for the following engine mechanical conditions. Refer to Engine Mechanical for diagnosis procedures: D Low compression D Sticking or leaking valves D Worn camshaft lobe(s) D Camshaft drive belt slipped or stripped D Incorrect valve timing 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10
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1. Check the intake and exhaust manifold(s) for casting flash. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records butter D All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
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6E507
Cuts Out, Misses Symptom

DEFINITION: Steady pulsation or jerking that follows engine speed; usually more pronounced as engine load increases. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? Go to Step 14 Go to Step 3 Go to Visual/ Physical Check Go to ETC System Check Was a visual/physical check performed? Go to Step 4
Was the Electric Throttle Control (ETC) System Check performed? Go to Step 5 1. Check the PCM grounds for clearness, tightness and proper routing. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair
Go to Step 6
Observe the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)? Go to Step 7 Go to Step 8
1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Go to Step 10 Go to Step 10 Is the long term fuel trim significantly in the positive range (lean condition)? 1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10 1. Check for incorrect idle speed. Ensure that the following conditions are present: D The engine is fully warm. D The accessories are off. 2. Using a Tech 2, monitor the Engine Speed. Is the Engine Speed within the specified values?
8 9
10
Desired Idle Speed
Go to Step 12
Go to Step 11
6E508
Cuts Out, Misses Symptom (Cont'd)

11
1. Visually/physically inspect for the following conditions: D Restricted air intake system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Large vacuum leak. Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty PCV valve or brake booster hose disconnected . 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Check the injector connections. If any of the injectors are connected to an incorrect cylinder, correct as necessary. Was a problem found? Verify repair Go to Step 13 1. Perform the Injector Coil/Balance Test in Fuel Metering System. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 1. Check for fuel in the pressure regulator vacuum hose. 2. If fuel is present, replace the fuel pressure regulator assembly. Refer to Fuel Metering System. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 15 1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electronic Ignition System for the procedure. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 16 1. Remove spark plugs. Check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 17
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1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 18 1. Check ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 19 Refer to DTC P0123 for further diagnosis Using a Tech 2, monitor the TP 1, 2 angle with the engine idling. Is the TP angle at the specified value and steady? 8 10% Go to Step 20
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6E509
Cuts Out, Misses Symptom (Cont'd)

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1. Check the PCV valve for proper operation. Refer to Crankcase Ventilation System. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 21 1. Check the transmission range switch circuit. Use a Tech 2 and be sure the Tech 2 indicates that the vehicle is in drive with the gear selector in drive or overdrive. 2. If a problem is found, diagnose and repair the transmission range switch as necessary (refer to 4L30-E Automatic Transmission Diagnosis). Was a problem found? Verify repair Go to Step 22 1. Check the following engine mechanical items. Refer to Engine Mechanical for diagnosis procedures: D Low compression D Sticking or leaking valves D Worn camshaft lobe(s) D Camshaft drive belt slipped or stripped D Incorrect valve timing D Worn rocker arms D Broken valve springs 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 23
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1. Check for faulty motor mounts. Refer to Engine Mechanical for inspection of mounts. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 24 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records butter D All electrical connections within a suspected circuit and/or system 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
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6E510
Hesitation, Sag, Stumble Symptom

DEFINITION: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually most pronounced when first trying to make the vehicle move, as from a stop sign. May cause the engine to stall if severe enough. Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2
1. Check the fuel control heated oxygen sensors (HO2S, B1S1 and B2S1). The fuel control heated oxygen sensors (HO2S) should respond quickly to different throttle positions. If they dont, check them for silicon or other contaminants from fuel or use of improper RTV sealant. The sensors may have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The PCM will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. For more information, refer to Powertrain Control Module (PCM) and Sensors. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 6
1. Check the fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 Observe the TP 1, 2 angle display on the Tech 2 while slowly increasing accelerator pedal depression. Does the TP angle display steadily increase from 8 10% at closed throttle to 90 92% at WOT? Go to Step 8 Go to Step 9
Monitor the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)? Go to Step 9 Go to Step 10
1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11
6E511
Hesitation, Sag, Stumble Symptom (Cont'd)

10
1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11 1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electronic Ignition System for the procedure. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 12 1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 13 1. Check the ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 1. Remove spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 15
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1. Check the PCM grounds for clearness, tightness and proper routing. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 16 1. Check the MAF sensor connections. 2. If a problem is found, replace the faulty terminals as necessary. Refer to Electrical Diagnosis for wiring repair procedures. Was a problem found? Verify repair Go to Step 17
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6E512
Hesitation, Sag, Stumble Symptom (Cont'd)

17
1. Visually/physically check vacuum hoses for splits, kinks, and proper connections and routing as shown on the Vehicle Emission Control Information label. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 18 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: D Visual/physical inspection D Tech 2 data D Freeze Frame data/Failure Records butter D All electrical connections within a suspected circuit and/or system 3. If a problem is found, repair as necessary. Was a problem found? Verify repair
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6E513
Bank 1 Restricted Exhaust System Check

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Remove the Bank 1 HO2S 2. 2. Install the Exhaust Backpressure Tester (BT-8515-V or equivalent) in place of the Bank 1 HO2S 2. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge. Does the reading exceed the amount in the value column? 8.62 kPa (1.25 psi) Go to Step 3
Go to Step 4
Repair the restriction in the exhaust system after the catalytic converter. Possible faults include: D Collapsed pipe D Heat distress D Internal muffler failure Is the action complete? Verify repair 1. Install the Bank 1 HO2S 2. 2. Install the Exhaust Backpressure Tester in place of Bank 1 HO2S 1. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge. Does the reading exceed the amount in the value column? 8.62 kPa (1.25 psi) Go to Step 5 Verify repair
No trouble found. If a driveability symptom exists, refer to symptom charts
Repair the restriction in the catalytic converter. Is the action complete?
NOTE: DTCs will be set by running the vehicle to normal operating temperature after a cold start with the O2 sensor disconnected. After performing these tests, use the Tech 2 to erase the DTCs that were set by the lack of O2 sensor activity.
6E514
Bank 2 Restricted Exhaust System Check

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Remove the Bank 2 HO2S 2. 2. Install the Exhaust Backpressure Tester (BT-8515-V or equivalent) in place of the Bank 2 HO2S 2. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge. Does the reading exceed the amount in the value column? 8.62 kPa (1.25 psi) Go to Step 3
Go to Step 4
Repair the restriction in the exhaust system after the catalytic converter. Possible faults include: D Collapsed pipe D Heat distress D Internal muffler failure Is the action complete? Verify repair 1. Install the Bank 2 HO2S 2. 2. Install the Exhaust Back pressure Tester in place of Bank 1 HO2S 1. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge. Does the reading exceed the amount in the value column? 8.62 kPa (1.25 psi) Go to Step 5 Verify repair
No trouble found. If a driveability symptom exists, refer to symptom charts
Repair the restriction in the catalytic converter. Is the action complete?
NOTE: DTCs will be set by running the vehicle to normal operating temperature after a cold start with the O2 sensor disconnected. After performing these tests, use the Tech 2 to erase the DTCs that were set by the lack of O2 sensor activity.
6E515
Default Matrix Table

Service Procedure Default Strategy
A referral strategy has been established to assist the technician with additional information when the cause of the failure cannot be determined. If no problem is found after performing diagnostics, then refer to the default matrix table for further diagnostic information. Default Matrix Table Strategy Based Diagnostic Charts On-Board Diagnostic (OBD) System Check On-Board Diagnostic (OBD) System Check Initial Diagnosis Vehicle does not enter diagnostics. Vehicle enters diagnostics and communicates with the Tech 2. MIL is ON in diagnostics. Engine does not start and run. Engine starts and runs, no PCM codes set. Customer complains of vibration. Engine starts and runs, no PCM codes set. Customer complains of harsh or soft shift, poor performance, delayed or no engagement into drive or reverse, transmission fluid leak, transmission noise or vibration, or improper TCC operation. On-Board Diagnostic (OBD) System Check. On-Board Diagnostic (OBD) System Check. PCM power and ground circuits OK. Data link voltage incorrect. Engine starts and runs, no PCM codes set. Customer complains of harsh or soft shift, poor performance, delayed or no engagement into drive or reverse, transmission fluid leak, transmission noise or vibration, or improper TCC operation. Initial Diagnosis 1. On-board Diagnostic (OBD) system check. 2. Careful visual/physical inspections. 1. OBD system check. 2. ETC system check. 3. Sensors (ECT, MAP, MAF, TP) ; MAP output chart. 4. Fuel system electrical test, fuel system diagnosis. 5. Ignition system. Default Section(s) Chassis Electrical Ignition System Check
On-Board Diagnostic (OBD) System Check On-Board Diagnostic (OBD) System Check
Automatic Transmission
PCM Power and Ground Check PCM Power and Ground Check
Chassis Electrical Chassis Electrical
On-Board Diagnostic (OBD) System Check
Automatic Transmission
Symptoms Intermittents
Default Section(s) Chassis Electrical
Hard Starts
Engine Mechanical, Ignition System Check, Exhaust System Diagnosis
6E516

Symptoms Initial Diagnosis 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. 7. 8. OBD system check. ETC system check. Heated oxygen sensors. Fuel system diagnosis. Ignition system. OBD system check. ETC system check. Fuel system diagnosis. Ignition system. EGR operation. EGR system check. OBD system check. Transmission range switch. EGR operation. EGR system check. TCC operation. Fuel system diagnosis. Ignition system. ION sensing module check. Default Section(s) Calibration ID/Service Bulletins, Ignition System Check, Generator Output, Exhaust System Diagnosis, 4L30-E System Test Refer to Exhaust System in Engine Exhaust, TCC Operation, Calibration ID/Service Bulletins
Surges and/or Chuggles
Lack of Power, Sluggish or Spongy
Detonation/Spark Knock
TCC operation, Cooling System, Ignition System Check, Calibration ID/Service Bulletins
Rough, Unstable, or Incorrect Idle, Stalling
1. OBD system check. 2. ETC system check. 3. Fuel injector and fuel injector balance test. 4. EVAP emission canister purge valve check. 5. Ignition system. 6. EGR operation. 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. OBD system check. Careful visual/physical inspection. Ignition system. Cooling system.
MAP Output Check, Throttle Linkage, EGR System Check, A/C Clutch Control Circuit Diagnosis, Crankcase Ventilation System, Calibration ID/Service Bulletins, Generator Output Voltage (refer to Chassis Electrical), Exhaust Diagnosis TCC Operation, Exhaust System (refer to Engine Exhaust)
Poor Fuel Economy
Hesitation, Sag, Stumble
OBD system check. ETC system check. TP. MAP output check. Fuel system diagnosis. Fuel injector and fuel injector balance test. 7. EVAP emission canister purge valve. 8. Ignition system. 1. OBD system check. 2. Cylinder balance test. 3. ETC system check. 1. OBD system check.
EGR Operation, EGR System Check, Generator Output Voltage (refer to Chassis Electrical), Calibration ID/Service Bulletins, Ignition System Check
Cuts Out, Misses
Ignition System Check
Fuel System Electrical Diagnosis, Fuel System Diagnosis, Fuel Injector and Fuel Injector Balance Test.

Symptoms Excessive Exhaust Emissions or Odors 1. 2. 3. 4. 5. 6. 7. 8. 9. Dieseling, Run-On Initial Diagnosis OBD system check. Emission test. Cooling system. Fuel system diagnosis. Fuel injector and fuel injector balance test. EVAP emission canister purge valve. Crankcase ventilation system. Ignition system. MAP output check.
6E517
Default Section(s) EGR System Check, Exhaust Diagnosis, Calibration ID/Service Bulletins
1. OBD system check. 2. Careful visual/physical inspection. 3. Fuel system diagnosis. 1. 2. 3. 4. OBD system check. Ignition system. Fuel system diagnosis. Fuel injector and fuel injector balance test. 5. EGR operation, EGR system check. 1. 2. 3. 4. OBD system check. Ignition system. Fuel system diagnosis. Fuel injector and fuel injector balance test.
Backfire
Exhaust System Diagnosis, Intake Casting Flash, Ignition System Check
Misfire
Vibrations, Transmission, Driveshaft and Axle
Catalyst Monitor
1. OBD system check. 2. Careful visual/physical inspection. 3. Heated oxygen sensors. 1. 2. 3. 4. OBD system check. Careful visual/physical inspection. Fuel system diagnosis. Heated oxygen sensors, MAF sensors.
Exhaust System
Fuel Trim
Exhaust System Intake Air System
Evaporative Emissions
1. OBD system check. 2. Careful visual/physical inspection. 3. Fuel system diagnosis. 1. OBD system check. 2. Careful visual/physical inspection.
Heated Oxygen Sensors
Exhaust System
6E518
On Vehicle Service Crankshaft Position (CKP) Sensor

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical connector to the CKP sensor. 3. Remove one bolt and the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out.
TS22909
3. Connect the electrical connector to the CKP sensor. 4. Connect the negative battery cable.
Engine Coolant Temperature (ECT) Sensor

Removal Procedure
NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system.
TS22909
Inspection Procedure
1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring.
1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System in Engine Cooling section. 3. Disconnect the electrical connector.
Installation Procedure
1. Install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. Tighten D Tighten the mounting bolt to 9 Nm (78 lb in.).
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4. Remove the ECT sensor from the coolant crossover. 3. Connect the electrical connector.
6E519
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1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten D Tighten the ECT sensor to 30 Nm (22 lb ft.).
4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System in Engine Cooling section. 5. Connect the negative battery cable.
Heated Oxygen Sensor (HO2S)

Removal Procedure
1. Disconnect the negative battery cable. 2. Locate the four oxygen sensors.
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060RW008
6E520

D Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left-hand catalytic converter.
D Bank 1 sensor 1 is mounted on the exhaust pipe ahead of the right-hand catalytic converter.
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TS22914
D Bank 1 sensor 2 is mounted behind the right-hand catalytic converter.
D Bank 2 sensor 2 is mounted behind the left-hand catalytic converter.
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TS22915

3. Disconnect the pigtail from the wiring harness.
6E521
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IMPORTANT: The pigtail is permanently attached to the sensor. Be careful not to pull the wires out. NOTE: Do not use a torch to remove an HO2S unless the sensor is being replaced. Using a torch could damage the sensor. 4. Remove the sensor from the exhaust pipe. D Because of the expansion and contraction of the metal in the exhaust system over time, this may be difficult if the engine temperature is below 48C (120F).
IMPORTANT: D There is a special anti-seize compound on the HO2S threads. This compound consists of glass beads suspended in a liquid graphite solution. The graphite burns away with engine heat, but the glass beads will remain, making the sensor easier to remove. D New or service sensors will already have the compound applied to the threads. If a sensor is removed and is to be reinstalled for any reason, the threads must have anti-seize compound applied. 1. Apply anti-seize compound or the equivalent to the threads of the oxygen sensor, if necessary. 2. Install the oxygen sensor on the exhaust pipe in its original position. Tighten D Tighten the oxygen sensor to 55 Nm (40 lb ft.).
060RY00128
All four sensors are identical. Inspect each in the same way. 1. Inspect the pigtail and the electrical connector for grease, dirt, corrosion, and bare wires or worn insulation. 2. Inspect the louvered end of the sensor for grease, dirt, or other contaminations.
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3. Connect the pigtail to the wiring harness. 4. Connect the negative battery cable.
6E522

3. Install the engine cover. 4. Connect the negative battery cable.
Intake Air Temperature (IAT) Sensor

Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the engine cover 3. The IAT sensor is located in the intake air duct, behind the throttle body. 4. Disconnect the electrical connector from the IAT sensor.
ION Sensing Module

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the ION sensing module connector. 3. Remove the bolts and the ION sensing module from the common chamber.
TS23741
060RY00087
5. Remove the IAT sensor from the intake air duct by using a rocking motion while pulling the sensor.
1. Install the ION sensing module on the common chamber with the bolts. Tighten D Tighten the ION sensing module to 4 Nm (35 lb in.).
1. Install the IAT sensor into the grommet in the intake air duct. 2. Correct the IAT electrical connector.
TS23741

2. Connect the ION sensing module connectors as shown in the illustration.
6E523
4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner.
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TS23781
Legend (1) Green Color Connector (2) Blue Color Connector 3. Connect the negative battery cable.
1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor.
Mass Air Flow (MAF) Sensor

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor.
TS23781
3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable.
TS23740
3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor.
6E524
Manifold Absolute Pressure (MAP) Sensor

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor.
1. Install the MAP sensor in the mounting bracket.
055RW002
2. Install the mounting bracket retaining bolt on the common chamber. Tighten D Tighten the bolt to 20 Nm (12 lb ft.). 3. Connect the MAP electrical connector.
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3. Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber. 4. Remove the MAP sensor from the mounting bracket.
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4. Connect the negative battery cable.
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6E525
Malfunction Indicator Lamp (MIL)

Removal and Installation Procedure
Refer to Warning light bulb, indicator light valve, illumination light bulb, A/T indicator light bulb in Meter and Gauge.
Reduced Power Lamp

The reduced power lamp (RPL) turns on when the ignition key is moved to the ON position. It should turn off in approximately 3 seconds or immediately after the engine starts. If the RPL turns on during vehicle operation, a vehicle system failure resulting in reduced engine output is indicated. If both the reduced RPL and the check engine light turn on, a serious problem affecting vehicle performance is indicated. Refer to the OBD system check NO and RPL ON steady in this manual.
D Do not touch the control module connector pins or soldered components on the control module circuit board. D Do not open the replacement part package until the part is ready to be installed. D Before removing the part from the package, ground the package to a known good ground on the vehicle. D If the part has been handled while sliding across the seat, or while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part. NOTE: To prevent internal PCM damage, the ignition must be in the OFF position in order to disconnect or reconnect power to the PCM (for example: battery cable, PCM pigtail, PCM fuse, jumper cables, etc.). IMPORTANT: When replacing the production PCM with a service PCM, it is important to transfer the broadcast code and production PCM number to the service PCM label. This will allow positive identification of PCM parts throughout the service life of the vehicle. Do not record this information on the metal PCM cover. IMPORTANT: The ignition should always be in the OFF position in order to install or remove the PCM connectors. Service of the PCM should normally consist of either replacement of the PCM or EEPROM programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to ensure it is the correct part. If it is, remove the faulty PCM and install the new service PCM. The service PCM EEPROM will not be programmed. DTC P0601 indicates the check sum error.
Powertrain Control Module (PCM)

Service Precaution
NOTE: To prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board.
Electrostatic Discharge (ESD) Damage

Electronic components used in the control systems are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4,000 volts for a person to even feel the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling and testing electronic components. NOTE: To prevent possible Electrostatic Discharge damage, follow these guidelines:
Removal Procedure
1. Disconnect the negative battery cable. 2. Block the wheels. 3. Remove the two screws from the PCM electrical connectors. 4. Disconnect the PCM electrical connectors.
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6E526

2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors.
5. After removing the clip which fixes the PCM to the bracket, remove PCM.
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1. Install the PCM to bracket and fix with the clip.
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6E527
EEPROM
General Description
The Electronically Erasable Programmable Read Only Memory (EEPROM) is a permanent memory that is physically soldered within the PCM. The EEPROM contains program and calibration information that the PCM needs to control powertrain operation.
3. Remove the bolts and the TP sensor from the throttle body.
EEPROM Programming
1. Set-up Ensure that the following conditions have been met: D The battery is fully charged. D The ignition is ON. D The Vehicle Interface Module cable connection at the DLC is secure. 2. Program the PCM using the latest software matching the vehicle. Refer to up-to-date Techline equipment users instructions. 3. If the PCM fails to program, proceed as follows: D Ensure that all PCM connections are OK. D Check the Techline equipment for the latest software version. D Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed.
060R200185
NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result.
Function Check
Use a Tech 2 to check the TP sensor output voltage at closed throttle. D The voltage should be TP1 about 0.4V, TP2 about 4.6V and TP3 about 4.6V. D If the reading is abnormal value, check the throttle shaft to see if it is binding.
Functional Check
1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for one minute. 3. Scan for DTCs using the Tech 2.
1. Install the TP sensor on the throttle body with the bolts.
Throttle Position (TP) Sensor

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector.
060R200185
2. Connect the TP electrical connector. 3. Install the negative battery cable.
6E528
Vehicle Speed Sensor (VSS)

Removal Procedure
CAUTION: The VSS is located on the right side of the transfer case just ahead of the rear propeller shaft and very close to the exhaust pipes for 4WD and on the extension cover for 2WD. Be sure that the exhaust pipes are cool enough to touch before trying to remove the VSS. If the pipes are hot, you could be burned. 1. Disconnect the negative battery cable. 2. Disconnect the VSS electrical connector.
1. Inspect the electrical connector for signs of corrosion or warping. Replace the VSS if the electrical connector is corroded or warped. 2. Inspect the VSS driven gear for chips, breaks, or worn condition. Replace the VSS if the driven gear is chipped, broken or worn. 3. Inspect the O-ring for wear, nicks, tears, or looseness. Replace the O-ring if necessary.
1. Install the VSS in the transfer case with the notch for the connector facing the rear. 2. Secure the VSS in place with the clamp and the bolt. Tighten D Tighten the bolt to 16 Nm (12 lb ft.).
TS23748
3. Remove the bolt and the clamp securing the VSS in place. IMPORTANT: Have a container ready to catch any fluid that leaks out when the VSS is removed from the transfer case for 4WD and on the extension cover for 2WD.
TS23780
3. Connect the VSS electrical connector.
TS23780
4. Remove the VSS from the transfer case by wiggling it slightly and pulling it straight out.
TS23748
4. Check the transfer case oil level. necessary. 5. Connect the negative battery cable.
Add fluid if
6E529
Air Cleaner/Air Filter

Removal Procedure
1. Loosen the clamp between the air cleaner lid and the mass air flow sensor.
1. Install the air cleaner housing in the vehicle with the retaining bolts. 2. Install the air filter element in the air cleaner housing. 3. Install the air cleaner lid on the MAF sensor and the air cleaner housing.
060R200240
2. Release the four latches securing the lid to the air cleaner housing. 3. Remove the air cleaner lid. 4. Remove the air filter element. 5. Remove the retaining bolts and the air cleaner housing from the vehicle.
060R200241
Legend (1) Air Cleaner Lid (2) Air Filter Element (3) Air Cleaner Housing (4) Mass Air Flow Sensor 4. Tighten the clamp and secure the four latches between the lid and the air cleaner housing.
Common Chamber
Refer to Common Chamber in Engine Mechanical section.
060R200220
Legend (1) Air Cleaner Lid (2) Air Filter Element (3) Air Cleaner Housing
6E530
Accelerator Pedal Replacement

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical harness accelerator position sensor. from the
1. Install the accelerator pedal assembly on the bulkhead. 2. Install the two screws to the accelerator pedal assembly. Tighten D Tighten the screws to 22 Nm (16 lb ft.).
060R200233 060R200234
Legend (1) Accelerator Position Sensor (2) Accelerator Pedal Assembly 3. Remove the two screws from the accelerator pedal assembly.
3. Connect the electrical harness to the accelerator position sensor.
060R200233
Legend (1) Accelerator Position Sensor (2) Accelerator Pedal Assembly

060R200234
4. Remove the accelerator pedal assembly from the bulkhead.
4. Install the negative battery cable.
6E531
Accelerator Position Sensor Replacement

CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it serviced. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following items as necessary.
Legend (1) AP Sensor (2) AP Screw 4. Remove all grease residues from the Accelerator Position Sensor mounting 5. Clean all connector pins with contact cleaner. Use LOCTITE / Permatex Electrical Contact Cleaner, or equivalent. NOTE: Do not use brake cleaner or carburetor spray.
Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor.
1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable.
Accelerator Position Sensor Adjustment

AP sensor is controled three maltiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to How to adjust for AP sensor.
Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor.
060R200233
Legend (1) AP Sensor (2) A Pedal Assembly 3. Remove the AP sensor.
How To Adjust For AP Sensor

1. Connect the Tech 2 to DLC on vehicle. 2. Ignition ON, engine OFF.. 3. Display the APS date list. Check the following item for AP position (%). AP position (%) Idle position A APS1 APS2 APS3 11 15% 85 89% 85 89% WOT position B 85 89% 11 15% 32 36%
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6E532
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4. If the problem was found, adjust as necessary.
NOTE: Replace the fuel filler cap with the same type of filler cap that was originally installed on the vehicle. D Check the seal ring in the filler cap for any abnormality and for seal condition. D Replace the filler cap if any abnormality is found.
Fuel Filter
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the fuel filler cap.
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Fuel Filler Cap

General Description
The fuel filler cap includes a vacuum valve and a pressure valve. If high vacuum or high pressure occurs in the fuel tank, each valve works to adjust the pressure in order to prevent damage to the tank.
060R200219

3. Disconnect the fuel hose from the fuel filter on the engine side. 4. Disconnect the fuel hose from the fuel filter on the fuel tank side. 5. Remove the bolt on the fuel filter holder.
6E533
1. Install the fuel filter in the correct direction. 2. Install the bolt on the fuel filter holder. Tighten D Tighten the screws to 20 Nm (14 lb ft.). 3. Connect the fuel hose on the engine side. 4. Connect the fuel hose on the fuel tank side.
041RW003
Legend (1) Fuel Hose (2) Fuel Filter Fixing Bolt (3) Fuel Filter 6. Remove the fuel filter.
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Legend (1) Fuel Hose (2) Fuel Filter Fixing Bolt (3) Fuel Filter 5. Install the fuel filler cap.
1. Replace the fuel filter when the following occur: D Fuel leaks from the fuel filter body. D The fuel filter body is damaged. D The fuel filter is clogged with dirt or sediment. 2. If the drain hole is clogged, clean the drain.
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6E534
Fuel Gauge Unit

Removal Procedure
Refer to Fuel Tank section.
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4. Remove the injector retainer clip.
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Fuel Injectors
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil may be contaminated with fuel. Check the oil for signs of contamination and change the oil and the filter if necessary. NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. The fuel injector is an electrical component and should not be immersed in any type of cleaner as this may damage the fuel injector.
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IMPORTANT: Fuel injectors are serviced as a complete assembly only. 1. Disconnect the negative battery cable. 2. Remove the common chamber. Refer to Common Chamber in Engine Mechanical section. 3. Remove the fuel rail. Refer to Fuel Rail section.
5. Remove the fuel injector assembly. 6. Remove the O-ring from the fuel injector. 7. Remove the O-ring backup from the fuel injector .
1. Inspect the O-rings for cracks or leaks. 2. Replace worn or damaged O-rings. 3. Lubricate the new O-rings with engine oil before installation.
6E535
1. Install the O-ring backup on the fuel injector. 2. Install the new O-ring on the fuel injector. 3. Install the fuel injector on the fuel rail.
Fuel Metering System

CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit servicing the fuel system components. CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnect is completed, place the towel in an approved container. 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay box. Refer to Fuel Pump Relay section.
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4. Use new fuel injector retainer clips to retain the fuel injector to the fuel rail. 5. Coat the end of the fuel injector with gasoline. 6. Install the fuel rail. Refer to Fuel Rail section.
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3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable.
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7. Install the common chamber. Refer to Common Chamber in Engine Mechanical section. 8. Install the engine cover. 9. Connect the negative battery cable.
6E536
Fuel Pump Assembly

Removal Procedure
4. Pull the relay straight up and out of the fuse and relay box.
060R200195
060R200225
Fuel Pump Relay

Removal Procedure
1. Remove the fuse and relay box cover from under the hood. 2. Consult the diagram on the cover to determine which is the correct relay. 3. Insert a small screwdriver into the catch slot on the forward side of the fuel pump relay. D The screwdriver blade will release the catch inside.
1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. D An audible click will be heard.
060R200195
3. Install the fuse and relay box cover.
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6E537
Fuel Rail Assembly

Removal Procedure
NOTE: D Do not attempt to remove the fuel inlet fitting on the fuel rail. It is staked in place. Removing the fuel inlet fitting will result in damage to the fuel rail or the internal O-ring seal. D Use care when removing the fuel rail assembly in order to prevent damage to the injector electrical connector terminals and the injector spray tips. D Fittings should be capped and holes plugged during servicing to prevent dirt and other contaminants from entering open lines and passages. IMPORTANT: An eight-digit identification number is stamped on the side of the fuel rail. Refer to this number when you service the fuel rail or when a replacement part is required.
2. If an injector becomes separated from the fuel rail, the infector O-ring seals and the retainer clip must be replaced. 3. Drain residual fuel into an approved container.
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8. If removal of the fuel pressure regulator is necessary, refer to Fuel Pressure Regulator section. 9. If removal of the fuel injectors is necessary, refer to Fuel Injectors section.
1. If the fuel injectors were removed, install them. Refer to Fuel Injectors section. 2. If the fuel pressure regulator was removed, install it. Refer to Fuel Pressure Regulator section. 3. Install the common chamber. Refer to common chamber in engine Mechanical section.
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Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner. Follow the spray package instructions. Do not immerse the fuel rails in liquid cleaning solvent. 1. Depressurize the fuel system. Refer to Fuel Pressure Relief Procedure in this Section. 2. Disconnect the negative battery cable. 3. Remove the engine cover. 4. Disconnect the throttle position sensor electrical connector from throttle body. 5. Disconnect the connectors from manifold absolute pressure sensor, solenoid valve, electric vacuum sensing valve. 6. Disconnect the vacuum hose on canister VSV and positive crankcase ventilation hose. 7. Remove the common chamber. Refer to the common chamber in Engine Mechanical section. 1. Lift up carefully on the fuel injectors. Do not separate the fuel injectors from the fuel rail.
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4. Connect the vacuum hose on Canister VSV and positive crankcase ventilation hose.
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5. Connect the connectors to manifold absolute pressure sensor, solenoid valve, electric vacuum sensing valve. 6. Connect the throttle position sensor electrical connector to throttle body. 7. Install the engine cover. 8. Connect the negative battery cable. 9. Crank the engine until it starts. Cranking the engine may take longer than usual due to trapped air in the fuel rail and in the injectors.
Fuel Tank
Removal Procedure
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4. Disconnect the vacuum hose below the air horn. 5. Remove the intake air duct clamp. 6. Disconnect the intake air duct. 7. Disconnect the coolant lines from the throttle body. 8. Remove the bolts from the common chamber. 9. Remove the throttle body from the common chamber. 10. Remove the gasket from the common chamber.
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Throttle Body (TB)

Removal Procedure
1. Disconnect the negative battery cable. 2. Drain the cooling system. Refer to Cooling System section. 3. Disconnect the electrical connectors: D Throttle position (TP) sensor. D Intake air temperature (IAT) sensor. Refer to Intake Air Temperature Sensor section.
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11. Remove the TP sensor. Refer to Throttle Position (TP) Sensor section.
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NOTE: Do not use solvent of any type when you clean the gasket surfaces on the intake manifold and the throttle body assembly. The gasket surfaces and the throttle body assembly may be damaged as a result. D If the throttle body gasket needs to be replaced, remove any gasket material that may be stuck to the mating surfaces of the manifold. D Do not leave any scratches in the aluminum casting.
9. Connect all the electrical connectors: D Throttle position (TP) sensor. D Intake air temperature (IAT) sensor. Refer to Intake Air Temperature Sensor section.
1. Install the TP sensor. Refer to Throttle Position (TP) Sensor section. 2. Install the gasket on the common chamber. 3. Install the throttle body on the common chamber. 4. Secure the gasket and the throttle body with the four bolts. D The vacuum lines must be properly routed under the throttle body before tightening the mounting bolts. Tighten D Tighten the throttle body mounting bolts to 10 Nm (87 lb in).
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10. Install the accelerator cable assembly. Refer to Accelerator Cable in Engine Speed Control System section. 11. Fill the cooling system. Refer to Cooling System section. 12. Install the negative battery cable.
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5. Install the coolant lines. 6. Connect all the vacuum lines. 7. Install the intake air duct. 8. Tighten the intake air duct clamp.
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CAUTION: Ignition coil assembly #6 is different from ignition coil assembly #1 to #5. Ignition coil assemblies #6 is short type. Be careful it when installing ignition coil assembly of #6.
Electronic Ignition System

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the ignition coil connector at the ignition coil assemblies. 3. Remove the two screws that secure the ignition coil assemblies to the rocker cover.
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Legend (1) Long Type Ignition Coil Assemblies (#1 #5) (2) Short Type Ignition Coil Assembly (#6)
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3. Install ignition coil assemblies and tighten the fixing bolts to the specified torque. Torque: 4 Nm (35.4 Ib in)
Legend (1) Ignition Coil Connectors (2) Bolts (3) Ignition Coil Assemblies 4. Remove the ignition coil assemblies and the spark plug boot from the spark plug. D Twist the ignition coil assemblies while pulling it straight up. 5. Use the appropriate spark plug socket in order to remove the spark plug from the engine.
NOTE: The plug must thread smoothly into the cylinder head and be fully seated. Use a thread chaser if necessary to clean the threads in the cylinder head. Cross-threading or failure to fully seat the spark plug can cause plug overheating, exhaust blow-by gases, or thread damage. Do not overtighten the spark plugs. Over tightening can cause aluminum threads to strip. 1. Install the spark plug in the engine. appropriate spark plug socket. Use the Legend (1) Ignition Coil Connectors (2) Bolts (3) Ignition Coil Assemblies 4. Connect the ignition coil connector at the ignition coil assemblies. 5. Connect the negative battery cable.
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Tighten D Tighten the spark plug to 18 Nm (13 lb ft.). 2. Install the ignition coil assemblies and spark plug boot over the spark plug.
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Catalytic Converter
Refer to Engine Exhaust in Engine section.
1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. D An audible click will be heard. 3. Install the fuse and relay box cover.
Air Conditioning Thermo Relay

Removal Procedure
1. Remove the fuse and relay box cover from under the hood. 2. Consult the diagram on the cover to determine which is the correct relay. 3. Insert a small screwdriver into the catch slot on the forward side of the fuel pump relay. D The screwdriver blade will release the catch inside.
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EVAP Canister Hoses

Service Information
To view the routing of the EVAP canister hoses, refer to Vehicle Emission Control Information in Diagnosis. Use 6148M or equivalent when you replace the EVAP canister hoses.
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4. Pull the relay straight up and out of the fuse and relay box.
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EVAP Canister
Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the three hoses from the EVAP canister.
4. Remove the retaining two bolts on the mounting bracket and slide the canister out of mounting bracket.
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3. Disconnect the fuel vapor connector and the purge hose from the EVAP canister vent solenoid.
1. Inspect the hoses for cracks and leaks. 2. Inspect the canister for a damaged case.
1. Slide the canister into mounting bracket and install the mounting bracket two bolts.
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2. Connect the fuel vapor connector to the EVAP canister vent solenoid. 3. Connect the three hoses to the EVAP canister. 3. Disconnect the connector and hose.
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4. Disconnect the negative battery cable.
1. Check for cracks or leaks. 2. Energize the solenoid and try to blow through it. The solenoid should not allow passage of air when energized. (J 35616 Connector Test Kit can be used to easily attach jumper wires from the battery to the solenoid).
EVAP Canister Vent Solenoid

Removal Procedure
1. Disconnect the negative battery cable. 2. Slide out the EVAP canister vent solenoid from mounting bracket.
1. Connect the connector and hose.
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2. Slide the EVAP canister vent solenoid into mounting bracket.
1. Install the rubber grommet on the fuel pump assembly.
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Fuel Tank Pressure (Vapor Pressure) Sensor

Removal Procedure
1. Remove the fuel pump assembly. Refer to Fuel Tank In Fuel Pump. 2. Carefully pry the fuel tank pressure sensor out of the top of the fuel pump assembly.
2. Install the fuel tank vapor pressure sensor on the fuel pump assembly. D Insert the sensor nipple firmly into the grommet. D Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 3. Install the fuel pump assembly on the fuel tank. Refer to Fuel Tank In Fuel Pump..
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1. Inspect the vapor pressure sensor for cracks in the housing and corrosion on the electrical terminals. 2. Inspect the rubber grommet for tears and signs of rot.
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EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve)

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the EVAP canister purge solenoid. 3. Disconnect the vacuum hoses from the EVAP canister purge solenoid.
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Fuel Tank Vent Valve (Vent Solenoid Valve)

Refer to Fuel Pump section.
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4. Remove the EVAP canister purge solenoid retaining bolt from the common chamber. 5. Remove the EVAP canister purge solenoid.
Linear Exhaust Gas Recirculation (EGR) Valve

Removal Procedure
1. Disconnect the negative battery cable. 2. Disconnect the electrical connector at the EGR valve.
1. Install the EVAP canister purge solenoid on the upper intake manifold. 2. Install the EVAP canister purge solenoid retaining bolt. Tighten D Tighten the bolts to 20 Nm (16 lb ft.). 3. Connect the vacuum hoses to the EVAP canister purge solenoid. 4. Connect the electrical connector to the EVAP canister purge solenoid.
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4. Connect the electrical connector at the EGR valve.
3. Remove the bolts from the common chamber.
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4. Remove the EGR valve from the common chamber manifold. 5. Remove the gasket from the common chamber manifold.
Positive Crankcase Ventilation (PCV) Valve

Removal Procedure
1. Remove the vacuum hose at the PCV valve. D Slide the clamp back to release the hose. 2. Pull the PCV valve from the rubber grommet in the right valve cover.
1. Install the gasket on the common chamber. 2. Install the EGR valve on the common chamber. 3. Secure the EGR valve and the gasket with the bolts. Torque: 25 Nm (18 Ib ft) NOTE: It is possible to install the EGR valve rotated 180 from the correct position. Make sure that the base of the valve is placed so that it aligns with the mounting flange.
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Before inspecting the PCV valve, make sure that the hoses are connected properly and are in good condition. Also check that the oil pan and rocker cover gaskets are sealing properly.
Wiring and Connectors

Wiring Harness Service
The control module harness electrically connects the control module to the various solenoids, switches and sensors in the vehicle engine compartment and passenger compartment. Replace wire harnesses with the proper part number replacement. Because of the low amperage and voltage levels utilized in powertrain control systems, it is essential that all wiring in environmentally exposed areas be repaired with crimp and seal splice sleeves. The following wire harness repair information is intended as a general guideline only. Refer to Chassis Electrical section for all wire harness repair procedures.
PCV Valve
1. Run the engine at normal operating temperature. 2. Disconnect the valve from the rocker cover. RESULT: A hissing noise should be heard from the valve. If no noise is heard, the PCV valve or hose is plugged. 3. Remove the PCV valve from the engine. a. Blow air into the rocker cover side of the valve. RESULT: Air should pass freely. b. Blow air into the air cleaner side of the valve. RESULT: Air should not pass through the valve. 4. Re-install the PCV valve and remove the oil filler cap. RESULT: A small vacuum should be felt at the oil filler hole.
Connectors and Terminals

Use care when probing a connector and when replacing terminals. It is possible to short between opposite terminals. Damage to components could result. Always use jumper wires between connectors for circuit checking. NEVER probe through Weather-Pack seals. Use an appropriate connector test adapter kit which contains an assortment of flexible connectors used to probe terminals during diagnosis. Use an appropriate fuse remover and test tool for removing a fuse and to adapt the fuse holder to a meter for diagnosis. Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor, or in the wiring harness, may temporarily correct the open circuit. Intermittent problems may also be caused by oxidized or loose connections. Be certain of the type of connector/terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently.
1. Push the PCV valve into the rubber grommet in the left valve cover. 2. Install the vacuum hose on the PCV valve and secure the vacuum hose with the clamp.
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3. Untwist the conductors. 4. Strip the insulation as necessary.
PCM Connectors and Terminals

Removal Procedure
1. Remove the connector terminal retainer. 2. Push the wire connected to the affected terminal through the connector face so that the terminal is exposed. 3. Service the terminal as necessary.
1. Bend the tab on the connector to allow the terminal to be pulled into position within the connector. 2. Pull carefully on the wire to install the connector terminal retainer.
Wire Harness Repair: Twisted Shielded Cable

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Removal Procedure
1. Remove the outer jacket. 2. Unwrap the aluminum/mylar tape. Do not remove the mylar.
1. Splice the wires using splice clips and rosin core solder. 2. Wrap each splice to insulate. 3. Wrap the splice with mylar and with the drain (uninsulated) wire.
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4. Tape over the whole bundle to secure.
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1. Use splice clips and rosin core solder in order to splice the two wires together.
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Twisted Leads
Removal Procedure
1. Locate the damaged wire. 2. Remove the insulation as required.
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2. Cover the splice with tape in order to insulate it from the other wires.
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3. Twist the wires as they were before starting this procedure.
Weather-Pack Connector
Tools Required
J 28742-A Weather-Pack II Terminal Remover
Removal Procedure
A Weather-Pack connector can be identified by a rubber seal at the rear of the connector. This engine room connector protects against moisture and dirt, which could form oxidation and deposits on the terminals. This protection is important, because of the low voltage and the low amperage found in the electronic systems. 1. Open the secondary lock hinge on the connector.
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4. Tape the wires with electrical tape. Hold in place.
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2. Use tool J 28742-A or the equivalent to remove the pin and the sleeve terminals. Push on J 28742-A to release. NOTE: Do the use an ordinary pick or the terminal may be bent or deformed. Unlike standard blade terminals, these terminals cannot be straightened after they have been improperly bent.
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3. Cut the wire immediately behind the cable seal.
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5. Push the terminal and the connector to engage the locking tangs.
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Make certain the connectors are properly seated and all of the sealing rings are in place when you reconnect the leads. The secondary lock hinge provides a backup locking feature for the connector. The secondary lock hinge is used for added reliability. This flap should retain the terminals even if the small terminal lock tangs are not positioned properly. Do not replace the Weather-Pack connections with standard connections. Read the instructions provided with the Weather-Pack connector and terminal packages. 1. Replace the terminal. 2. Slip the new seal onto the wire. 3. Strip 5 mm (0.2) of insulation from the wire. 4. Crimp the terminal over the wire and the seal.
6. Close the secondary locking hinge.
Com-Pack III
General Information
The Com-Pack III terminal looks similar to some Weather-Pack terminals. This terminal is not sealed and is used where resistance to the environment is not required. Use the standard method when repairing a terminal. Do not use the Weather-Pack terminal tool J 28742-A or equivalent. These will damage the terminals.
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Metri-Pack
Tools Required
J 35689 Terminal Remover
Metri-Pack terminals are also referred to as pull-to-seat terminals. 1. In order to install a terminal on a wire, the wire must be inserted through the seal (2) and through the connector (3). 2. The terminal (1) is then crimped onto the wire.
Removal Procedure
Some connectors use terminals called Metri-Pack Series 150. These may be used at the engine coolant temperature (ECT) sensor. 1. Slide the seal (1) back on the wire. 2. Insert the J 35689 tool or equivalent (3) in order to release the terminal locking tang (2).
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3. Then the terminal is pulled back into the connector to seat it in place.
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3. Push the wire and the terminal out through the connector. If you reuse the terminal, reshape the locking tang.
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General Description (PCM and Sensors)

58X Reference PCM Input
The powertrain control module (PCM) uses this signal from the crankshaft position (CKP) sensor to calculate engine RPM and crankshaft position at all engine speeds. The PCM also uses the pulses on this circuit to initiate injector pulses. If the PCM receives no pulses on this circuit, DTC P0337 will set. The engine will not start and run without using the 58X reference signal.
PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85C (185F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115.
A/C Request Signal

This signal tells the PCM when the A/C mode is selected at the A/C control head. The PCM uses this to adjust the idle speed before turning ON the A/C clutch. The A/C compressor will be inoperative if this signal is not available to the PCM. Refer to A/C Clutch Circuit Diagnosis section for A/C wiring diagrams and diagnosis for the A/C electrical system.
Crankshaft Position (CKP) Sensor

The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Refer to Electronic Ignition System section for additional information.
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Electrically Erasable Programmable Read Only Memory (EEPROM)

The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM.
Fuel Control Heated Oxygen Sensors

The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are mounted in the exhaust stream where they can monitor the oxygen content of the exhaust gas. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV to 900 mV. The heated oxygen sensor voltage can be monitored with a Tech 2. By monitoring the voltage output of the oxygen sensor, the PCM calculates the pulse width command for the injectors to produce the proper combustion chamber mixture. D Low HO2S voltage is a lean mixture which will result in a rich command to compensate. D High HO2S voltage is a rich mixture which will result in a lean command to compensate.
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Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at 40C (40F). High temperature causes a low resistance of 70 ohms at 130C (266F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the
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will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results.
An open Bank 1 HO2S 1 signal circuit will set a DTC P0134 and the Tech 2 will display a constant voltage between 400-500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) will set DTC P0131. A constant voltage above 800 mV in the circuit will set DTC P0132. Faults in the Bank 2 HO2S 1 signal circuit will cause DTC 0154 (open circuit), DTC P0151 (grounded circuit), or DTC P0152 (signal voltage high) to set. A fault in the Bank 1 HO2S 1 heater circuit will cause DTC P0135 to set. A fault in the Bank 2 HO2S 1 heater circuit will cause DTC P0155 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance.
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Catalyst Monitor Heated Oxygen Sensors

Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalysts ability to efficiently convert exhaust gases. If the catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM
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Legend (1) Bank 1 Sensor 1 (Fuel Control) (2) Catalytic Converter (3) Bank 1 Sensor 2 (Catalyst Monitor) (4) Bank 2 Sensor 1 (Fuel Control) (5) Bank 2 Sensor 2 (Catalyst Monitor)
Intake Air Temperature (IAT) Sensor

The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high

resistance of 100,000 ohms at 40C (40F). High temperature causes low resistance of 70 ohms at 130C (266F) . The PCM supplies a 5-volt signal to the sensor through a resistor in the PCM and monitors the signal voltage. The voltage will be high when the incoming air is cold. The voltage will be low when the incoming air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to the incoming air density. The Tech 2 displays the temperature of the air entering the engine. The temperature should read close to the ambient air temperature when the engine is cold and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the IAT sensor temperature and engine coolant temperature should read close to each other. A fault in the IAT sensor circuit will set DTC P0112 or DTC P0113.
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Linear Exhaust Gas Recirculation (EGR) Control

The PCM monitors the exhaust gas recirculation (EGR) actual position and adjusts the pintle position accordingly. The PCM uses information from the following sensors to control the pintle position: D Engine coolant temperature (ECT) sensor. D Throttle position (TP) sensor. D Mass air flow (MAF) sensor.
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Manifold Absolute Pressure (MAP) Sensor

The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine the following: D Manifold pressure changes while the linear EGR flow test diagnostic is being run. Refer to DTC P0401. D Barometric pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108. An intermittent low or high voltage will set DTC P1107, respectively. The PCM can detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set.
Mass Air Flow (MAF) Sensor

The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. Volume means the size of the space to be filled. Quantity means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (gm/s). At idle, the Tech 2 should read between 4-7 gm/s on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103.
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sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: D Fuel injector control D Ignition control module D ION sensing module D Automatic transmission shift functions D Cruise control D Evaporative emission (EVAP) purge D A/C clutch control

The powertrain control module (PCM) is located in the passenger compartment below the center console. The PCM controls the following: D Fuel metering system. D Transmission shifting (automatic transmission only). D Ignition timing. D On-board diagnostics for powertrain functions. The PCM constantly observes the information from various sensors. The PCM controls the systems that affect vehicle performance. The PCM performs the diagnostic function of the system. It can recognize operational problems, alert the driver through the MIL (Check Engine lamp), and store diagnostic trouble codes (DTCs). DTCs identify the problem areas to aid the technician in making repairs.
PCM Voltage Description

The PCM supplies a buffered voltage to various switches and sensors. It can do this because resistance in the PCM is so high in value that a test light may not illuminate when connected to the circuit. An ordinary shop voltmeter may not give an accurate reading because the voltmeter input impedance is too low. Use a 10-megohm input impedance digital voltmeter (such as J 39200) to assure accurate voltage readings. The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs. Not all outputs are always used.
PCM Function
The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: D Output Driver Module (ODM) D Quad Driver Module (QDM)
PCM Input/Outputs
Inputs Operating Conditions Read D D D D D D D D D D D D D D D D D D D D D D Air Conditioning ON or OFF Engine Coolant Temperature Crankshaft Position Exhaust Oxygen Content Electronic Ignition Manifold Absolute Pressure Battery Voltage Throttle Position Vehicle Speed Fuel Pump Voltage Power Steering Pressure Intake Air Temperature Mass Air Flow Engine Knock Acceleration Position EVAP Canister Purge Exhaust Gas Recirculation (EGR) Ignition Control Fuel Control ION Sensing Module Electric Fuel Pump Air Conditioning
Outputs Systems Controlled

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PCM Components
The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP)

D Diagnostics Malfunction Indicator Lamp Data Link Connector (DLC) Data Output D Transmission Control Module
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Transmission Fluid Temperature (TFT) Sensor

The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis section. A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally.
PCM Service Precautions

The PCM is designed to withstand normal current draws associated with vehicle operation. Avoid overloading any circuit. When testing for opens and shorts, do not ground or apply voltage to any of the PCMs circuits unless instructed to do so. These circuits should only be tested using digital voltmeter J 39200. The PCM should remain connected to the PCM or to a recommended breakout box.
Transmission Range Switch (Mode Switch)

IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to 4L30-E Automatic Transmission section.
Reprogramming The PCM

Reprogramming of the PCM is done without removing it from the vehicle . This provides a flexible and cost-effective method of making changes in software calibrations. Refer to the latest Techline information on reprogramming or flashing procedures.
Throttle Position (TP) Sensor

The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92% (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving.
Vehicle Speed Sensor (VSS)

The PCM determines the speed of the vehicle by converting a pulsing voltage signal from the vehicle speed sensor (VSS) into miles per hour. The PCM uses this signal to operate the cruise control, speedometer, and the TCC and shift solenoids in the transmission. For more information on the TCC and shift solenoids, refer to 4L30-E Automatic Transmission section.
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Use of Circuit Testing Tools

Do not use a test light to diagnose the powertrain electrical systems unless specifically instructed by the diagnostic procedures. Use Connector Test Adapter Kit J 35616 whenever diagnostic procedures call for probing connectors.
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D Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentary touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore it is important to use care when handling and testing electronic components. NOTE: To prevent possible electrostatic discharge damage, follow these guidelines: D Do not touch the PCM connector pins or soldered components on the PCM circuit board. D Do not open the replacement part package until the part is ready to be installed. D Before removing the part from the package, ground the package to a known good ground on the vehicle. D If the part has been handled while sliding across the seat, while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part.
Aftermarket Electrical and Vacuum Equipment

Aftermarket (add-on) electrical and vacuum equipment is defined as any equipment which connects to the vehicles electrical or vacuum systems that is installed on a vehicle after it leaves the factory. No allowances have been made in the vehicle design for this type of equipment. NOTE: No add-on vacuum equipment should be added to this vehicle. NOTE: Add-on electrical equipment must only be connected to the vehicles electrical system at the battery (power and ground). Add-on electrical equipment, even when installed to these guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to eliminate all aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, it may be diagnosed in the normal manner.
General Description (Air Induction)

Air Induction System
The air induction system filters contaminants from the outside air, and directs the progress of the air as it is drawn into the engine. A remote-mounted air cleaner prevents dirt and debris in the air from entering the engine. The air duct assembly routes filtered air to the throttle body. Air enters the engine by to following steps: 1. Through the throttle body. 2. Into the common chamber. 3. Through the cylinder head intake ports. 4. Into the cylinders.
Electrostatic Discharge Damage

Electronic components used in the PCM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4000 volts for a person to feel even the zap of a static discharge.
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There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. D An example of charging by friction is a person sliding across a vehicle seat.
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General Description (Fuel Metering)

Acceleration Mode
The PCM provides extra fuel when it detects a rapid increase in the throttle position and the air flow.
Battery Voltage Correction Mode

When battery voltage is low, the PCM will compensate for the weak spark by increasing the following: D The amount of fuel delivered. D The idle RPM. D Ignition dwell time.
Clear Flood Mode

Clear a flooded engine by pushing the accelerator pedal down all the way. The PCM then de-energizes the fuel injectors. The PCM holds the fuel injectors de-energized as long as the throttle remains above 80% and the engine speed is below 800 RPM. If the throttle position becomes less than 80%, the PCM again begins to pulse the injectors ON and OFF, allowing fuel into the cylinders.
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Fuel Metering System Components

The fuel metering system is made up of the following parts: D The fuel injectors. D The throttle body. D The fuel rail. D The fuel pressure regulator. D The PCM. D The crankshaft position (CKP) sensor. D The ION sensing module. D The fuel pump. D The fuel pump relay. Basic System Operation The fuel metering system starts with the fuel in the fuel tank. An electric fuel pump, located in the fuel tank, pumps fuel to the fuel rail through an in-line fuel filter. The pump is designed to provide fuel at a pressure above the pressure needed by the injectors. A fuel pressure regulator in the fuel rail keeps fuel available to the fuel injectors at a constant pressure. A return line delivers unused fuel back to the fuel tank. Refer to Section 6C for further information on the fuel tank, line filter, and fuel pipes.
Deceleration Mode
The PCM reduces the amount of fuel injected when it detects a decrease in the throttle position and the air flow. When deceleration is very fast, the PCM may cut off fuel completely for short periods.
Engine Speed/Vehicle Speed/Fuel Disable Mode

The PCM monitors engine speed. It turns off the fuel injectors when the engine speed increases above 6400 RPM. The fuel injectors are turned back on when engine speed decreases below 6150 RPM.
Fuel Cutoff Mode

No fuel is delivered by the fuel injectors when the ignition is OFF. This prevents engine run-on. In addition, the PCM suspends fuel delivery if no reference pulses are detected (engine not running) to prevent engine flooding.
Fuel Injector
The sequential multiport fuel injection (SFI) fuel injector is a solenoid-operated device controlled by the PCM. The PCM energizes the solenoid, which opens a valve to allow fuel delivery. The fuel is injected under pressure in a conical spray pattern at the opening of the intake valve. Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank. A fuel injector which is stuck partly open will cause a loss of fuel pressure after engine shut down, causing long crank times.
Fuel Metering System Purpose

The basic function of the air/fuel metering system is to control the air/fuel delivery to the engine. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve. The main control sensor is the heated oxygen sensor (HO2S) located in the exhaust system. The HO2S tells the PCM how much oxygen is in the exhaust gas. The PCM changes the air/fuel ratio to the engine by controlling the amount of time that fuel injector is ON. The best mixture to minimize exhaust emissions is 14.7 parts of air to 1 part of gasoline by weight, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a closed loop system.
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The PCM monitors signals from several sensors in order to determine the fuel needs of the engine. Fuel is delivered under one of several conditions called modes. All modes are controlled by the PCM.
Fuel Pressure Regulator

The fuel pressure regulator is a diaphragm-operated relief valve mounted on the fuel rail with fuel pump pressure on one side and manifold pressure on the other side. The fuel pressure regulator maintains the fuel pressure available to the injector at three times barometric pressure adjusted for engine load. It may be serviced separtely. If the pressure is too low, poor performance and a DTC P0131, DTC P0151,DTC P0171 or DTC P1171 will be the result. If the pressure is too high, excessive odor and/or a DTC P0132, DTC P0152,DTC P0172 will be the result. Refer to Fuel System Diagnosis for information on diagnosing fuel pressure conditions.
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Run Mode
The run mode has the following two conditions: D Open loop D Closed loop When the engine is first started the system is in open loop operation. In open loop, the PCM ignores the signal from the heated oxygen sensor (HO2S). It calculates the air/fuel ratio based on inputs from the TP, ECT, and MAF sensors. The system remains in open loop until the following conditions are met: D The HO2S has a varying voltage output showing that it is hot enough to operate properly (this depends on temperature). D The ECT has reached a specified temperature. D A specific amount of time has elapsed since starting the engine. D Engine speed has been greater than a specified RPM since start-up. The specific values for the above conditions vary with different engines and are stored in the programmable read only memory (PROM). When these conditions are met, the system enters closed loop operation. In closed loop, the PCM calculates the air/fuel ratio (injector on-time) based on the signal from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1.
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Fuel Pump Electrical Circuit

When the key is first turned ON, the PCM energizes the fuel pump relay for two seconds to build up the fuel pressure quickly. If the engine is not started within two seconds, the PCM shuts the fuel pump off and waits until the engine is cranked. When the engine is cranked and the 58 X crankshaft position signal has been detected by the PCM, the PCM supplies 12 volts to the fuel pump relay to energize the electric in-tank fuel pump. An inoperative fuel pump will cause a no-start condition. A fuel pump which does not provide enough pressure will result in poor performance.
Starting Mode
When the ignition is first turned ON, the PCM energizes the fuel pump relay for two seconds to allow the fuel pump to build up pressure. The PCM then checks the engine coolant temperature (ECT) sensor and the throttle position (TP) sensor to determine the proper air/fuel ratio for starting. The PCM controls the amount of fuel delivered in the starting mode by adjusting how long the fuel injectors are energized by pulsing the injectors for very short times.
Fuel Rail
The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors. Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines. The fuel goes through the fuel rail to the fuel pressure regulator. The fuel pressure regulator maintains a constant fuel pressure at the injectors. Remaining fuel is then returned to the fuel tank.
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Throttle Body Unit

The throttle body has a throttle plate to control the amount of air delivered to the engine. The TP sensor are also mounted on the throttle body. Vacuum ports located behind the throttle plate provide the vacuum signals needed by various components. Engine coolant is directed through a coolant cavity in the throttle body to warm the throttle valve and to prevent icing.
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Ignition Coils
A separate coil-at-plug module is located at each spark plug. The coil-at-plug module is attached to the engine with two screws. It is installed directly to the spark plug by an electrical contact inside a rubber boot. A three-way connector provides 12-volt primary supply from the 15-amp ignition fuse, a ground-switching trigger line from the PCM, and a ground.
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General Description (Electronic Ignition System)

Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Refer to Electronic Ignition System section for additional information.
Electronic Ignition
The electronic ignition system controls fuel combustion by providing a spark to ignite the compressed air/fuel mixture at the correct time. To provide optimum engine performance, fuel economy, and control of exhaust emissions, the PCM controls the spark advance of the ignition system. Electronic ignition has the following advantages over a mechanical distributor system: D No moving parts. D Less maintenance. D Remote mounting capability. D No mechanical load on the engine. D More coil cooldown time between firing events. D Elimination of mechanical timing adjustments. D Increased available ignition coil saturation time.
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Ignition Control
The ignition control (IC) spark timing is the PCMs method of controlling the spark advance and the ignition dwell. The IC spark advance and the ignition dwell are calculated by the PCM using the following inputs: D Engine speed. D Crankshaft position (58X reference). D Engine coolant temperature (ECT) sensor. D Throttle position (TP) sensor. D ION sensing module. D Park/Neutral position (PRNDL input).
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D Vehicle speed (vehicle speed sensor). D PCM and ignition system supply voltage. D The crankshaft position (CKP) sensor sends the PCM a 58X signal related to the exact position of the crankshaft.
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Ignition Control PCM Output

The PCM provides a zero volt (actually about 100 mV to 200 mV) or a 5-volt output signal to the ignition control (IC) module. Each spark plug has its own primary and secondary ignition coil assembly (coil-at-plug) located at the spark plug itself. When the ignition coil receives the 5-volt signal from the PCM, it provides a ground path for the B+ supply to the primary side of the coil-at -plug module. When the PCM shuts off the 5-volt signal to the ION sensing module, the ground path for the primary coil is broken. The magnetic field collapses and induces a high voltage secondary impulse which fires the spark plug and ignites the air/fuel mixture. The circuit between the PCM and the ignition coil is monitored for open circuits, shorts to voltage, and shorts to ground. If the PCM detects one of these events, it will set one of the following DTCs: D P0351: Ignition coil Fault on Cylinder #1 D P0352: Ignition coil Fault on Cylinder #2 D P0353: Ignition coil Fault on Cylinder #3 D P0354: Ignition coil Fault on Cylinder #4 D P0355: Ignition coil Fault on Cylinder #5 D P0356: Ignition coil Fault on Cylinder #6
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Based on these sensor signals and engine load information, the PCM sends 5V to each ignition coil.
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The PCM is responsible for maintaining proper spark and fuel injection timing for all driving conditions. To provide optimum driveability and emissions, the PCM monitors the input signals from the following components in order to calculate spark timing: D Engine coolant temperature (ECT) sensor. D Intake air temperature (IAT) sensor. D Mass air flow (MAF) sensor. D PRNDL input from transmission range switch. D Throttle position (TP) sensor. D Vehicle speed sensor (VSS) . D Crankshaft position (CKP) sensor.
This module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The Throttle PCM controls ignition timing and dwell time. Continuity and out-or-range value check: This diagnosis detects open circuit or short-circuiting in the Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. Diagnosis enabling conditions are as follows: D RPM is higher than the specified threshold. D EST line is enabled.
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Spark Plug
Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequency fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance. Follow the scheduled maintenance service recommendations to ensure satisfactory spark plug performance. Refer to Maintenance and Lubrication section. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the insulator portion of the spark plug. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as misfiring. This means the ignition spark is not igniting the air/fuel mixture at the proper time. While other ignition and fuel system causes must also be considered, possible causes include ignition system conditions which allow the spark voltage to reach ground in some other manner than by jumping across the air gap at the tip of the spark plug, leaving the air/fuel mixture unburned. Refer to DTC P0300. Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps. This is referred to as pre-ignition. Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. If misfiring occurs before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling and slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Very rich fuel mixtures or poor ignition system output may also be the cause. Refer to DTC P0172. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil during break-in of new or newly overhauled engines. Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug facing the intake valve.
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Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This may be due to improper gap adjustment or to excessive wear of the electrode during use. A spark plug gap that is too small may cause an unstable idle condition. Excessive gap wear can be an indication of continuous operation at high speeds or with engine loads, causing the spark to run too hot. Another possible cause is an excessively lean fuel mixture.
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Low or high spark plug installation torque or improper seating can result in the spark plug running too hot and can cause excessive center electrode wear. The plug and the cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep it from seating even though the proper torque is applied. Once spark plugs are properly seated, tighten them to the torque shown in the Specifications Table. Low torque may result in poor contact of the seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and will result in poor contact
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between the seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Cracked or broken insulators may be the result of improper installation, damage during spark plug re-gapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, when the spark plug is hit from the outside, or is dropped on a hard surface. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later.
A/C Clutch Circuit Purpose

The A/C compressor operation is controlled by the powertrain control module (PCM) for the following reasons: D It improvises idle quality during compressor clutch engagement. D It improvises wide open throttle (WOT) performance. D It provides A/C compressor protection from operation with incorrect refrigerant pressures. The A/C electrical system consists of the following components: D The A/C control head. D The A/C refrigerant pressure switches. D The A/C compressor clutch. D The A/C compressor clutch relay. D The PCM.
A/C Request Signal

This signal tells the PCM when the A/C mode is selected at the A/C control head. The PCM uses this to adjust the idle speed before turning on the A/C clutch. The A/C compressor will be inoperative if this signal is not available to the PCM. Refer to A/C Clutch Circuit Diagnosis section for A/C wiring diagrams and diagnosis for A/C electrical system.
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A/C Clutch Diagnosis

A/C Clutch Circuit Operation
A 12-volt signal is supplied to the A/C request input of the PCM when the A/C is selected through the A/C control switch. The A/C compressor clutch relay is controlled through the PCM. This allows the PCM to modify the idle air control position prior to the A/C clutch engagement for better idle quality. If the engine operating conditions are within their specified calibrated acceptable ranges, the PCM will enable the A/C compressor relay. This is done by providing a ground path for the A/C relay coil within the PCM. When the A/C compressor relay is enabled, battery voltage is supplied to the compressor clutch coil. The PCM will enable the A/C compressor clutch whenever the engine is running and the A/C has been requested. The PCM will not enable the A/C compressor clutch if any of the following conditions are met: D The throttle is greater than 90%. D The engine speed is greater than 6315 RPM. D The ECT is greater than 119C (246F). D The IAT is less than 5C (41F). D The throttle is more than 80% open.
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General Description (Evaporative (EVAP) Emission System)

EVAP Emission Control System Purpose
The basic evaporative emission (EVAP) control system used on all vehicles is the charcoal canister storage method. Gasoline vapors from the fuel tank flow into the canister through the inlet labeled TANK. These vapors are absorbed into the activated carbon (charcoal) storage device (canister) in order to hold the vapors when the vehicle is not operating. The canister is purged by PCM control when the engine coolant temperature is over 60C (140F), the IAT reading is over 10C (50F), and the engine has been running. Air is drawn into the canister through the air inlet grid. The air mixes with the vapor and the mixture is drawn into the intake manifold.
D A malfunctioning purge solenoid. D A damaged canister. D Hoses that are split, cracked, or not connected properly.
Enhanced Evaporative Emission Control System

The basic purpose of the Enhanced Evaporative Emissions control system is the same as other EVAP systems. A charcoal-filled canister captures and stores gasoline fumes. When the PCM determines that the time is right, it opens a purge valve which allows engine vacuum to draw the fumes into the intake manifold. The difference between this and other systems is that the PCM monitors the vacuum and/or pressure in the system to determine if there is any leakage. If the PCM determines that the EVAP system is leaking or not functioning properly, it sets a Diagnostic Trouble Code (DTC) in the PCM memory. The enhanced EVAP system is required to detect evaporative fuel system leaks as small as 0.040 in. (1.0 mm) between the fuel filler cap and purge solenoid. The system can test the evaporative system integrity by applying a vacuum signal (ported or manifold) to the fuel tank to create a small vacuum. The PCM then monitors the ability of the system to maintain the vacuum. If the vacuum remains for a specified period of time, there are no evaporative leaks and a PASS report is sent to the diagnostic executive. If there is a leak, the system either will not achieve a vacuum, or a vacuum cannot be maintained. Usually, a failure can only be detected after a cold start with a trip of sufficient length and driving conditions to run the needed tests. The enhanced EVAP system diagnostic will conduct up to eight specific sub-tests to detect fault conditions. If the diagnostic fails a sub-test, the PCM will store a Diagnostic Trouble Code (DTC) to indicate the type of detected.
EVAP Emission Control System Operation

The EVAP canister purge is controlled by a solenoid valve that allows the manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge on). The EVAP purge solenoid control is pulse-width modulated (PWM) (turned on and off several times a second). The duty cycle (pulse width) is determined by engine operating conditions including load, throttle positron, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM. The output is commanded when the appropriate conditions have been met. These conditions are: D The engine is fully warmed up. D The engine has been running for a specified time. D The IAT reading is above 10C (50F). A continuous purge condition with no purge commanded by the PCM will set a DTC P1441. Poor idle, stalling and poor driveability can be caused by:
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Legend (1) Vent Solenoid (2) EVAP Purge Solenoid (3) Throttle Body (4) Fuel Filler Neck (5) Fuel Tank (6) Rollover Valve (7) EVAP Canister (8) Ignition Feed (9) Ignition Feed
(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)
EVAP Purge Solenoid Driver Signal from PCM Vent Solenoid Driver Signal from PCM Vent Filter Fuel Tank Pressure Sensor Fuel Tank Pressure Signal to PCM 5 Volt Reference A Circuit from PCM Sensor Ground Circuit from PCM Fuel Level Sensor Fuel Level Signal to PCM 5 Volt Return
Electrical Components The electrical components that make up the enhanced EVAP system are: D Fuel Tank Pressure Sensor. The fuel tank pressure sensor is a three-wire strain gauge sensor similar to a common MAP sensor. However, the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel pump assembly. A three-wire electrical harness connects it to the PCM. The PCM supplies a five-volt reference
voltage and a ground to the sensor. The sensor will return a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel cap is removed, the output voltage of the sensor will be 1.3 to 1.7 volts. When the air pressure in the fuel tank is 4.5 in. H2O (1.25 kPa), the sensor output voltage will be 0.5 0.2 V. When there is neither vacuum nor pressure in the fuel tank, the sensor voltage will be 1.5 V. At 14 in. H2O (3.75 kPa), the sensor voltage will be 4.5 0.2 V.

D EVAP Canister Purge Solenoid. Normally closed, the purge solenoid opens upon the PCMs signal to allow engine vacuum to purge gasoline fumes from the canister. Mounted on the water pipe to front of the engine assembly.
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D Fuel Level Sensor. The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic. The PCM needs fuel level information to know the volume of fuel in the tank. The fuel level affects the rate of change of air pressure in the EVAP system. Several of the enhanced EVAP system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is less than 15% or more than 85% full. Be sure to diagnose any Fuel Level Sensor DTCs first, as they can cause other DTCs to set.
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D EVAP Canister Vent Solenoid. Located next to the canister, the vent solenoid opens to allow air into the EVAP system. Fresh air is necessary to completely remove gasoline fumes from the canister during purge. The EVAP vent solenoid closes to seal off the evaporative emissions system for leak testing.
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D Manifold Absolute Pressure (MAP) Sensor. The PCM compares the signals from the fuel tank pressure sensor and the MAP sensor to ensure that a relative vacuum is maintained the EVAP system.
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D Disconnected or damaged EVAP vent hose D Disconnected, damaged, pinched, or blocked fuel tank vapor line D Disconnected or faulty EVAP purge solenoid D Disconnected or faulty EVAP vent solenoid D Open ignition feed circuit to the EVAP vent or purge solenoid D Damaged EVAP canister D Leaking fuel sender assembly O-ring D Leaking fuel tank or fuel filler neck A restricted or blocked EVAP vent path is detected by drawing vacuum into the EVAP system, turning OFF the EVAP vent solenoid and the EVAP purge solenoid (EVAP vent solenoid OPEN, EVAP purge Pulse Width Modulate (PWM) 0%) and monitoring the fuel tank vacuum sensor input. With the EVAP vent solenoid open, any vacuum in the system should decrease quickly unless the vent path is blocked. A blockage like this will set DTC P0446 and can be caused by the following conditions: D Faulty EVAP vent solenoid (stuck closed) D Plugged, kinked or pinched vent hose D Shorted EVAP vent solenoid driver circuit D Plugged EVAP canister The PCM supplies a ground to energize the purge solenoid (purge ON). The EVAP purge control is PWM, or turned ON and OFF, several times a second. The duty cycle (pulse width) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the output is commanded when the appropriate conditions have been met. The system checks for conditions that cause the EVAP system to purge continuously by commanding the EVAP vent solenoid ON and the EVAP purge solenoid OFF (EVAP vent solenoid CLOSED, EVAP purge PWM 0%). If fuel tank vacuum level increases during the test, a continuous purge flow condition is indicated, which will set a DTC P1441. This can be cause by the following conditions: D EVAP purge solenoid leaking D EVAP purge and engine vacuum lines switched at the EVAP purge solenoid D EVAP purge solenoid driver circuit grounded
Non-Electrical Components D Purge/Vacuum Hoses. Made of rubber compounds, these hoses route the gasoline fumes from their sources to the canister and from the canister to the intake air flow. D EVAP Canister. Mounted on a bracket ahead of the fuel tank, the canister stores fuel vapors until the PCM determines that engine conditions are right for them to be remove and burned. D Fuel Tank. The tank has a built-in air space designed for the collection of gasoline fumes.
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D Vacuum Source. The vacuum source is split between two ports, one on either side of the throttle body. D Fuel Cap. The fuel cap is designed to be an integral part of the EVAP system. System Fault Detection The EVAP leak detection strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The PCM monitors vacuum level via the fuel tank pressure sensor. At an appropriate time, the EVAP purge solenoid and the EVAP vent solenoid are turned ON, allowing the engine vacuum to draw a small vacuum on the entire evaporative emission system. After the desired vacuum level has been achieved, the EVAP purge solenoid is turned OFF, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A small leak in the system will cause DTC P0442 to be set. If the desired vacuum level cannot be achieved in the test described above, a large leak or a faulty EVAP purge solenoid is indicated. Leaks can be caused by the following conditions: D Disconnected or faulty fuel tank pressure sensor D Missing or faulty fuel cap D Disconnected, damaged, pinched, or blocked EVAP purge line
General Description (Exhaust Gas Recirculation (EGR) System)

EGR Purpose
The exhaust gas recirculation (EGR) system is use to reduce emission levels of oxides of nitrogen (NOx). NOx emission levels are caused by a high combustion temperature. The EGR system lowers the NOx emission levels by decreasing the combustion temperature.
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D Rough idle. D DTC P0300 (misfire detected). Too little or no EGR flow may allow combustion temperatures to get too high. This could cause: D Spark knock (detonation). D Engine overheating. D Emission test failure. D DTC P0401 (EGR flow test). D Poor fuel economy.
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Linear EGR Valve

The main element of the system is the linear EGR valve. The EGR valve feeds small amounts of exhaust gas back into the combustion chamber. The fuel/air mixture will be diluted and combustion temperatures reduced.
Linear EGR Control

The PCM monitors the EGR actual positron and adjusts the pintle position accordingly. The uses information from the following sensors to control the pintle position: D Engine coolant temperature (ECT) sensor. D Throttle position (TP) sensor. D Mass air flow (MAF) sensor.
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EGR Pintle Position Sensor

The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406.
Linear EGR Valve Operation and Results of Incorrect Operation

The linear EGR valve is designed to accurately supply EGR to the engine independent of intake manifold vacuum. The valve controls EGR flow from the exhaust to the intake manifold through an orifice with a PCM controlled pintle. During operation, the PCM controls pintle position by monitoring the pintle position feedback signal. The feedback signal can be monitored with a Tech 2 as Actual EGR Pos. Actual EGR Pos. should always be near the commanded EGR position (Desired EGR Pos.). If a problem with the EGR system will not allow the PCM to control the pintle position properly, DTC P1406 will set. The PCM also tests for EGR flow. If incorrect flow is detected, DTC P0401 will set. If DTCs P0401 and/or P1406 are set, refer to the DTC charts. The linear EGR valve is usually activated under the following conditions: D Warm engine operation. D Above-idle speed. Too much EGR flow at idle, cruise or cold operation may cause any of the following conditions to occur: D Engine stalls after a cold start. D Engine stalls at idle after deceleration. D Vehicle surges during cruise.
General Description (Positive Crankcase Ventilation (PCV) System)

Crankcase Ventilation System Purpose
The crankcase ventilation system is use to consume crankcase vapors in the combustion process instead of venting them to the atmosphere. Fresh air from the throttle body is supplied to the crankcase and mixed with blow-by gases. This mixture is then passed through the positive crankcase ventilation (PCV) valve into the common chamber.
Crankcase Ventilation System Operation

The primary control is through the positive crankcase ventilation (PCV) valve. The PCV valve meters the flow at a rate that depends on the intake vacuum. The PCV valve restricts the flow when the inlet vacuum is highest. In
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During normal, part-throttle operation, the system is designed to allow crankcase gases to flow through the PCV valve into the throttle body to be consumed by normal combustion. A plugged valve or PCV hose may cause the following conditions: D Rough idle. D Stalling of slow idle speed. D Oil leaks. D Sludge in the engine. A leaking PCV hose would cause: D Rough idle. D Stalling. D High idle speed.
addition, the PCV valve can seal the common chamber off in case of sudden high pressure in the crankcase.
060R200198
While the engine is running, exhaust fuses and small amounts of the fuel/air mixture escape past the piston rings and enter the crankcase. These gases are mixed with clean air entering through a tube from the air intake duct.
060R200063
6E571
Special Tools
J 39200 High Impedance Multimeter (Digital Voltmeter DVM)
J 37027-A IAC Motor Analyzer
(1) PCMCIA Card (2) RS232 Loop Back Connector (3) SAE 16/19 Adapter (4) DLC Cable (5) TECH2
J 23738-A Vacuum Pump with Gauge
J 34142-B Unpowered Test Light
BT-8515/8515V Exhaust Back Pressure Tester
Connector Test Adapter Kit J 35616-A/BT-8637
J 39194-B Heated Oxygen Sensor Wrench
J 26792/BT-7220-1 Spark Tester
J 35689-A Terminal Remover
J 34730-E Port Fuel Injection Diagnostic Kit
J 28742-A Weather Pack II Terminal Remover
6E572

TOOL NO. TOOL NAME 1. J 41413 EVAP Pressure/Purge Diagnostic Station is a multipurpose tool which is used to perform several diagnostic procedures for enhanced emission testing. The station will accommodate a nitrogen gas filled cylinder which is used to pressurize the vehicle EVAP system for a leakdown test and leak location test when a vehicle is repaired for leakage in the enhanced evaporative emission control system. It also has two additional gauges (inches of mercury and inches of water) which are used to measure both source vacuum and EVAP canister purge vacuum to verify correct operation and vapor flow within the canister purge circuit. 2. J 41416 Ultrasonic Leak Detector is a microprocessor-based device used to detect leaks in the enhanced evaporative emission control system. The evaporative system is pressurized to 30 inches of water using the J 41413 EVAP Pressure/Purge Diagnostic System. Small leaks in the EVAP system will emit sound at a high frequency undetectable by a human ear but detectable with the J 41416. The technician traces along the evaporative system and can pinpoint leaks due to corroded lines, cracked hoses, or a damaged EVAP component. The detector includes a high quality set of headphones to block out surrounding shop noise and the LED sensitivity meter allows a visual reference for locating leaks in conjunction with the audio output heard through the headphones. Powered by (1) nine volt battery.
ILLUSTRATION
J 39021-90 Injector Switch Box
J 39021-65 Injector Test Light
J 41413! EVAP Pressure/Purge Diagnostic Station
J 41416@ Ultrasonic Leak Detector
SECTION
ENGINE EXHAUST
TROOPER
6F1
ENGINE
ENGINE EXHAUST
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . Front Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . Front Exhaust Pipe and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three Way Catalytic Converter LH . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three Way Catalytic Converter RH . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F2 6F3 6F3 6F3 6F3 6F4 6F4 6F4 6F5 6F5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Silencer . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Silencer and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . Rear Exhaust pipe and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 6F5 6F6 6F6 6F6 6F6 6F7 6F7 6F7 6F7 6F8
6F2
ENGINE EXHAUST
General Description
150R200017
When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating the floor pan and possible damage to the passenger compartment insulation and trim materials. Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may be an indication of a problem in one of these areas. Any faulty areas should be corrected immediately.
Three Way Catalytic Converter

The three way catalytic converter is an emission control device added to the exhaust system to reduce pollutants from the exhaust gas stream. CAUTION: The catalytic converter requires the use of unleaded fuel only. Periodic maintenance of the exhaust system is not required. If the vehicle is raised for other service, it is advisable to check the condition of the complete exhaust system. A dual bed monolith catalytic converter is used in combination with three way catalytic converter. Catalytic Types: Three way (Reduction/Oxidation) catalyst The catalyst coating on the three way (reduction) converter contains platinum and rhodium which lowers the levels of nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon monoxide (Co).
Hangers
Various types of hangers are used to support exhaust system(s). These include conventional rubber straps, rubber rings, and rubber blocks. The installation of exhaust system supports is very important, as improperly installed supports can cause annoying vibrations which can be difficult to diagnose.
Gasket
The gasket must be replaced whenever a new exhaust pipe, muffler or catalytic converter is installed.
ENGINE EXHAUST
6F3
Front Exhaust Pipe

Front Exhaust Pipe and Associated Parts
150R200005
Legend (1) Gasket (2) Front Exhaust Pipe RH Fixing Nuts (3) O2 Sensor Harness Connector (4) Front Exhaust Pipe RH Fixing Bolts and Nuts (5) Gasket (6) Front Exhaust Pipe Fixing Bolts and Nuts (7) Gasket
(8) (9) (10) (11) (12) (13) (14)
O2 Sensor Harness Connector Front Exhaust Pipe LH O2 Sensor Harness Connector Front Exhaust Pipe LH Fixing Nuts O2 Sensor Harness Connector Gasket Front Exhaust Pipe RH
Removal
1. Disconnect battery ground cable. 2. Raise the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connector (3)(8)(10)(12). 4. Remove front exhaust pipe fixing bolts and nuts (4)(6). 5. Remove front exhaust pipe fixing three stud nuts (2) (11) from exhaust manifold. 6. Remove front exhaust pipe (9)(14).
Installation
1. Install front exhaust pipe (9)(14) and tighten three stud nuts (2)(11) and two nuts (4)(6) to the specified torque. Torque Stud Nuts : 67 Nm (49 lb ft) Nuts(4) : 57 Nm (42 lb ft) Nuts(6) : 43 Nm (32 lb ft) 2. Reconnect O2 sensor harness (3)(8)(10)(12).
connector
6F4
ENGINE EXHAUST
Three Way Catalytic Converter LH

Removal
1. Disconnect battery ground cable. 2. Raise the vehicle and support with suitable safety stands. 3. Disconnect front O2 sensor harness connector and rear O2 sensor harness connector (3)(4). 4. Remove exhaust front pipe fixing three stud nuts (2) from exhaust manifold side and two nuts (6)(7) from rear end of exhaust front pipe (9).
Installation
1. Install exhaust front pipe (9) and tighten three studs nuts (2) and two nuts (6)(7) to the specified torque. Torque Stud nuts : 67 Nm (49 lb ft) Nuts(6) : 57 Nm (42 lb ft) Nuts(7) : 43 Nm (32 lb ft) 2. Reconnect O2 sensor harness connector (3)(4).
150R200006
Legend (1) Gasket (2) Front Exhaust Pipe Fixing Three Stud Nuts (3) O2 Sensor Harness Connector (4) O2 Sensor Harness Connector (5) Gasket (6) Front Exhaust Pipe RH Fixing Bolts and Nuts (7) Front Exhaust Pipe Fixing Bolts and Nuts (8) Gasket (9) Front Exhaust Pipe LH
ENGINE EXHAUST
6F5
Three Way Catalytic Converter RH

Removal
1. Disconnect battery ground cable. 2. Raise the vehicle and support with suitable safety stands. 3. Remove torsion bar. Refer to removal procedure in Front Suspension section. 4. Disconnect front O2 sensor harness connector (6) and rear O2 sensor harness connector (3). 5. Remove front exhaust pipe fixing bolts and nuts (4). 6. Remove three stud nuts (2) from exhaust manifold then remove the exhaust front pipe (7).
Installation
1. Install front exhaust pipe (7) and tighten three stud nuts (2) and two nuts (4) to the specified torque. Torque Stud nuts : 67 Nm (49 lb ft) Nuts : 57 Nm (42 lb ft) 2. Install the torsion bar and readjust the vehicle height. Refer to the installation and vehicle height adjustment instructions in the Front Suspension Section.
150R200007
Legend (1) Gasket (2) Front Exhaust Pipe Fixing Three Stud Nuts (3) O2 Sensor Harness Connector (4) Front Exhaust Pipe Fixing Bolts and Nuts (5) Gasket (6) O2 Sensor Harness Connector (7) Front Exhaust Pipe RH
6F6
ENGINE EXHAUST
Exhaust Silencer
Exhaust Silencer and Associated Parts
150R200014
Legend (1) Exhaust Silencer (2) Mounting Rubber (3) Rear Exhaust Pipe (4) Rear Exhaust Pipe Nuts (5) Gasket
(6) (7) (8) (9) (10) (11)
Rubber Support Nut Exhaust Silencer Fixing Bolts Gasket Exhaust Silencer Fixing Nuts Exhuast Front Pipe
Removal
1. Disconnect battery ground cable. 2. Raise the vehicle and support with suitable safety stands. 3. Remove rear exhaust pipe nuts (4) then disconnect rear exhaust pipe from exhaust silencer. 4. Remove exhaust silencer fixing bolts (8) then disconnect exhaust silencer from front exhaust pipe (11). 5. Remove exhaust silencer mounting nuts (12) from rubber support (6) chassis side then remove exhaust silencer (1).
Installation
1. Install the exhaust silencer (1) and tighten two nuts (12) to the specified torque. Nuts: 16 Nm (12 lb ft) 2. Install the exhaust silencer and tighten two bolts (8) on front exhaust pipe to specified torque. Bolts: 43 Nm (32 lb ft) 3. Install the rear exhaust pipe (3) and tighten on exhaust silencer to specified torque. Nuts: 43 Nm (32 lb ft)
ENGINE EXHAUST
6F7
Rear Exhaust pipe

Rear Exhaust pipe and Associated Parts
150R200009
Legend (1) Mounting Rubber (2) Rear Exhaust Pipe
(3) Rear Exhaust Pipe Fixing Nuts (4) Gasket
Removal
1. Disconnect battery ground cable. 2. Raise the vehicle and support with suitable safety stands. 3. Remove rear exhaust pipe fixing nuts (3), then disconnect rear exhaust pipe from exhaust silencer. 4. Remove mounting rubber (1). 5. Remove rear exhaust pipe (2).
Installation
1. Install the mounting rubber (1). 2. Install the exhaust pipe (2) and tighten two nuts (3) on exhaust silencer to specified torque. Nuts: 43 Nm (32 lb ft)
6F8
ENGINE EXHAUST

150R200015
SECTION
ENGINE LUBRICATION
TROOPER
6G1
ENGINE
ENGINE LUBRICATION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump and Associated Parts . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan and Crankcase . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G1 6G2 6G3 6G3 6G3 6G4 6G5 6G7 6G7 6G7 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Oil Seal . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specification . . . . . . . . . . . . . . 6G10 6G10 6G10 6G12 6G12 6G12 6G13 6G13 6G13 6G14
Service Precaution
6G2
ENGINE LUBRICATION
General Description
C06RW002
Legend (1) Oil Strainer (2) Oil Pump (3) Relief Valve (4) Oil Pressure Switch (5) Oil Filter (6) Safety Valve (7) Oil Pressure Unit (8) Oil Gallery (9) Crankshaft Bearing
(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)
Crankshaft Connecting Rod Bearing Connecting Rod Piston Oil Gallery; Cylinder Head Camshaft Camshaft Journal Front Journal; Camshaft Drive Gear Rear Journal; Camshaft Drive Gear Oil Pan
ENGINE LUBRICATION
6G3
Oil Pump
Oil Pump and Associated Parts
051RW005
Legend (1) Crankshaft Timing Pulley (2) Crankcase with Oil Pan (3) Oil Pipe (4) Oil Strainer (5) Oil Pump Assembly (6) Plug (7) Spring
(8) (9) (10) (11) (12) (13) (14)
Relief Valve Oil Pump Cover Driven Gear Drive Gear Oil Seal O-ring Oil Pump Body
Disassembly
1. Remove crankshaft timing pulley. 2. Remove crankcase with oil pan. 3. Remove oil pipe. 4. Remove oil strainer.
5. Remove oil pump assembly. 6. Remove plug. 7. Remove spring. 8. Remove relief valve. 9. Remove oil pump cover. 10. Remove driven gear.
6G4
ENGINE LUBRICATION
11. Remove drive gear. 12. Remove oil seal. 13. Remove O-ring.

CAUTION: Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found during inspection.
Relief Valve (8)

D Check to see that the relief valve slides freely. D The oil pump must be replaced if the relief valve does not slide freely. D Replace the spring and/or the oil pump assembly (5) if the spring is damaged or badly worn.
051RS004
D Measure the clearance between the drive gear and driven gear with a feeler gauge. Standard : 0.11 mm0.24 mm (0.0043 in0.0094 in) Limit : 0.35mm (0.0138 in)
051RS002
Body (14) and Gears (10, 11)

The pump assembly must be replaced if one or more of the conditions below is discovered during inspection. D Badly worn or damaged driven gear (10). D Badly worn drive gear (11) driving face. D Badly scratched or scored body sliding face (14) or driven gear (10). D Badly worn or damaged gear teeth. Measure the clearance between the body and the driven gear with a feeler gauge. Standard : 0.10 mm0.18 mm (0.0039 in.0.0070 in) Limit : 0.20mm (0.0079 in)
051RS003
D Measure the side clearance with a precision straight edge and a feeler gauge. Clearance Standard : 0.03 mm0.09 mm (0.0011 in0.0035 in) Limit : 0.15mm (0.0059 in)
ENGINE LUBRICATION
6. Install the plug (6). Torque : 8 Nm (69 lb in)
6G5
051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking and scoring are found, the oil strainer must be replaced.
051RS007
7. Install oil pump assembly (5). D Carefully remove any oil from the cylinder body and the pump. Apply sealant (TB1207B or equivalent) to the pump fitting face as shown in illustration. Take care that sealant is not applied to oil port surfaces. The oil pump assembly must be installed within 5 minutes after sealant application before the sealant hardens. CAUTION: Do not apply an excessive amount of sealant to the contact surface. Applying too much sealant will overflow the contact surfaces. This could cause serious damage to the engine. D Attach oil pump assembly to cylinder body. D Tighten the oil pump fixing bolts. Torque : 25 Nm (18 lbft)
051RS006
Reassembly
1. Install drive gear (11). 2. Install driven gear (10). 3. Install oil pump cover (9) and first, loosely tighten all of the attaching screws. Next, tighten the attaching screws to the specified torque. Torque : 10 Nm (89 lb in) After installation, check that the gear rotates smoothly. 4. Install relief valve (8) and apply engine oil to the relief valve and spring (7). 5. Install spring (7).
051RW002
6G6
ENGINE LUBRICATION
D Tighten fixing bolts to the specified torque. Torque : 10 Nm (89 lb in)
051RW001
Legend (1) Around Bolt Holes (2) Around Dowel Pin 8. Install the new oil seal (12). Apply engine oil to the oil seal lip before installation then use J39202 oil seal Installer, install oil seal.
013RW010
12. Install crankshaft timing pulley.
015RS001
9. Install oil strainer (4) with O-ring (13). Torque: 25 Nm (18 lb ft) 10. Install oil pipe (3) with O-ring (13). Torque: 25 Nm (18 lb ft) 11. Install crankcase with oil pan (2). D Remove oil on crankcase mounting surface and dry the surface. D Apply a proper 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the crankcase mounting surface. The bead must be continuous. D The crankcase must be installed within 5 minutes after sealant application before the sealant hardens.
ENGINE LUBRICATION
6G7
Oil Pan and Crankcase

Removal
1. Disconnect battery ground cable. 2. Lift vehicle by supporting the frame. 3. Remove under cover. 4. Drain engine oil. 5. Remove front wheels. 6. Remove oil level dipstick from level gauge tube. 7. Remove radiator under fan shroud. 8. Remove suspension cross member fixing bolts, 2 pcs each per side and remove suspension cross member. 9. Remove pitman arm and relay lever assembly, using the J-29107 remover, remove pitman arm from the steering unit and remove four fixing bolts for relay lever assembly. 10. Remove axle housing assembly four fixing bolts from housing isolator side and mounting bolts from wheel side. At this time support the axle with a garage jack and remove axle housing assembly. (For 44) 11. Remove starter fixing bolts. 12. Remove oil pan fixing bolts. 13. Remove oil pan, using J-37228 sealer cutter, remove oil pan.
013RS003
Installation
1. Install crankcase. A. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly. B. Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB-1207C or equivalent) to mounting surface of crankcase. Sealant beat must be continuous. D The crankcase must be installed within 5 minutes after sealant application before the sealant hardens.
013RS003
14. Remove crankcase fixing bolts. 15. Remove crankcase, using J-37228 sealer cutter, remove crankcase. NOTE: Do not deform or damage the flange of oil pan and crankcase. Replace the oil pan and/or crankcase if deformed or damaged.
013RW010
6G8
ENGINE LUBRICATION
3. Install starter and tighten fixing bolts. Torque: 40 Nm (30 lb ft) 4. Install axle housing assembly and tighten fixing bolts to the specified torque. (For 44) Axle case bolts Torque : 82 Nm (60 lb ft) Mounting bolts Torque : 152 Nm (112 lb ft)
C. Install crankcase, tighten crankcase fixing bolts to the specified torque. Torque : 10 Nm (89 lb in)
013RW004
2. Install oil pan 1. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly. 2. Properly apply a 4.5 mm (07 in) wide bead of sealant (TB-1207C or equivalent) to mounting surface of oil pan. Sealant beat must be continuous. D The crankcase must be installed within 5 minutes after sealant application befor the sealant hardens.
013RW005
5. Install relay lever assembly and tighten fixing bolts. Torque: 44 Nm (32 lb ft) 6. Engage teeth of pitman arm and steering unit, and tighten nut to the specified torque. Torque : 216 Nm (159 lb ft)
013RW003
3. Install oil pan, tighten oil pan fixing bolts to the specified torque. Torque : 25 Nm (18 lb ft)
013RW006
Legend (1) Pitman Arm (2) Relay Lever
ENGINE LUBRICATION
7. Install suspension cross member and tighten fixing bolts to the specified torque. Torque : 78 Nm (58 lb ft)
6G9
013RW007
8. Install radiator under fan shroud. 9. Install under cover. 10. Install engine oil level dipstick. 11. Fill engine oil until full level on engine oil gauge dipstick.
6G10
ENGINE LUBRICATION
Oil Pump
Removal
1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove crankcase assembly. D Refer to removal procedure for Oil Pan and Crankcase in this manual. 4. Remove crankshaft pulley. D Refer to removal procedure for Crankshaft Pulley in this manual. 5. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual. 6. Remove timing pulley from crankshaft. 7. Remove four fixing bolts from oil filter assembly. 8. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring. 9. Remove three bolts from oil pipe and O-ring. 10. Remove eight oil pump fixing bolts, then oil pump assembly. 11. Remove sealant from mounting surface of oil pump assembly, cylinder block and take care not to damage mounting surfaces of oil pump and cylinder block. D Use J-39202 installer when installing new oil seal. D Apply engine oil to oil seal lip. D Install oil pump assembly to the cylinder block. NOTE: Do not damage oil seal during installation of oil pump assembly.
015RS001
Installation
1. Install oil pump assembly D Apply sealant (TB-1207B or equivalent) to the oil pump mounting surfaces as shown in the illustration. D The oil pump assembly must be installed within 5 minutes after sealant application before the sealant hardens. NOTE: Do not apply sealant to the oil ports.
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the specified torque. Torque : 10 Nm (89 lb in) 3. Install oil strainer with O-ring, tighten fixing bolt to the specified torque. Torque : 25 Nm (18 lb ft)
051RW002
ENGINE LUBRICATION
4. Install oil filter assembly and tighten bolts to the specified torque. Torque : 25 Nm (18 lb ft)
6G11
050RW001
Legend (1) Oil Pump (2) Oil Filter (3) Oil Gallery (4) From Oil Filter (5) To Oil Filter 5. Install timing pulley on crankshaft. Install timing belt. D Refer to installation procedure for Timing Belt in this manual. 6. Install crankshaft pulley. D Refer to install procedure for Crankshaft Pulley in this manual. 7. Install crankcase assembly. D Refer to installation procedure for Oil Pan and Crankcase in this manual. 8. Refill engine oil until full level on engine oil dipstick.
6G12
ENGINE LUBRICATION
Oil Pump Oil Seal

Removal
1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove crankshaft pulley. D Refer to removal procedure for Crankshaft Pulley in this manual. 4. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual. 5. Remove timing pulley from crankshaft. 6. Remove oil pump oil seal using a sealer puller. NOTE: Take care not to damage sealing surfaces of oil pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip, then install oil seal using J-39202 installer.
015RS001
2. Install timing pulley to crankshaft. 3. Install timing belt. D Refer to installation procedure for Timing Belt in this manual. 4. Install crankshaft pulley. D Refer to installation procedure for Crankshaft Pulley in this manual. 5. Refill engine oil until full level.
ENGINE LUBRICATION
6G13
Oil Filter
Removal
1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove oil filter using J-36390 filter wrench.
Installation
1. Clean filter fitting surface and apply small amount of engine oil to sealing surface. 2. Install oil filter cartridge by hand until it comes in contact with sealing surface then rotate additional 2/3 turn to tighten using J-36390 filter wrench.
050RW001
Legend (1) Oil Pump (2) Oil Filter (3) Oil Gallery (4) From Filter (5) To Filter 3. Fill engine oil until full level on dipstick. 4. Reconnect battery ground cable.
6G14
ENGINE LUBRICATION
Main Data and Specification

Item Oil capacity Specifications 6VE1 5.3 liters
Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt cover, Oil pump, Oil gallery, Oil strainer
E06R200011
SECTION
ENGINE SPEED CONTROL SYSTEM
TROOPER
6H1
ENGINE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal and Associated Parts . . 6H1 6H2 6H2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H2 6H2
Service Precaution
6H2
Accelerator Pedal
Accelerator Pedal and Associated Parts Installation
1. Install Accelerator pedal assembly (2). 2. Connect AP sensor (1) harness connector. 3. Connect battery ground cable.
101RY00006
Legend (1) Accelerator Position Sensor (2) Accelerator Pedal Assembly
Removal
1. Disconnect battery ground cable. 2. Disconnect Accelerator position (AP) sensor (1) connector from Accelerator pedal assembly. 3. Remove Accelerator pedal assembly (2).
SECTION
INDUCTION
TROOPER
6J1
ENGINE
INDUCTION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J1 6J2 6J2 6J2 6J2
Service Precaution
6J2
INDUCTION
Air Cleaner Element

Removal
1. Remove positive ventilation hose connector(1). 2. Remove intake air temperature sensor(2). 3. Remove air flow sensor(3). 4. Remove air cleaner duct assembly(4). 5. Remove air cleaner element(5).
Installation
1. Install air cleaner element(5). 2. Attach the air cleaner duct cover to the body completely, then clamp it with the clip(4). 3. Install mass air flow sensor(3). 4. Install air temperature sensor(2). 5. Install positive crankcase ventilation hose connector(1).
130RW003
Inspection
Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged.
130RW003
Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty.
130RW002
SECTION
AUTOMATIC TRANSMISSION (4L30E)
TROOPER
7A1
TRANSMISSION
CONTENTS
Automatic Transmission (4L30E) . . . . . . . . . Transmission Control System (4L30E) . . . . Manual Transmission . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A 7A1 7B 7C

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Range Reference Chart . . . . . . . . . . . . . . . . . . Normal Operation Of 2000 4L30E Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver Information . . . . . . . . . . . . . . . . . . . . . . . General Diagnosis Procedure . . . . . . . . . . . . . Preliminary Inspection Chart . . . . . . . . . . . . . . Checking Transmission Fluid Level and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart . . . . . . . . . . . . . . . . . . . . Mechanical / Hydraulic Diagnosis Symptoms Index . . . . . . . . . . . . . . . . . . . . . . . . Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Pressure Test . . . . . . . . . . . . . . . . . . . . . . Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . Lockup Speed Chart . . . . . . . . . . . . . . . . . . . . . Changing Transmission Fluid . . . . . . . . . . . . . Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission (With Transfer Case / Extension Assembly) . . . . . . . . . . . . . . . . . . . Transmission And Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid (Main Case Valve Body) . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid (Adapter Case Valve Body) . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A3 7A3 7A4 7A5 7A5 7A5 7A8 7A9 7A10 7A11 7A12 7A13 7A23 7A23 7A24 7A26 7A27 7A27 7A27 7A27 7A28 7A29 7A29 7A29 7A31 7A31 7A32 7A33 7A38 7A38 7A38 7A39 7A39 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Body Assembly (Main Case) . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Body Assembly (Adapter Case) . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Sensor (Extension Housing) . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Oil Temperature Sensor (Main Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Oil Seal (Converter Housing) . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal (Extension Housing) . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission (4L30E) . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Converter Housing And Oil Pump Assembly Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Case Valve Body . . . . . . . . . . . . . . . . . . . 7A39 7A40 7A40 7A40 7A41 7A41 7A41 7A41 7A41 7A41 7A42 7A42 7A42 7A42 7A42 7A42 7A43 7A43 7A43 7A43 7A43 7A44 7A44 7A44 7A48 7A58 7A58 7A58 7A58 7A58 7A59 7A59 7A59 7A60 7A60 7A61
7A2

7A61 7A61 7A62 7A62 7A63 7A63 7A63 7A63 7A63 7A65 7A65 7A65 7A65 7A66 7A67 7A67 7A67 7A67 7A67 7A69 7A69 7A69 7A69 7A69 7A70 7A70 7A70 7A71 7A71 7A72 7A72 7A72 7A73 7A73 Reverse Clutch Piston And Center Support . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Overrun Clutch And Turbine Shaft . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data And Specification . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L30E Parts List . . . . . . . . . . . . . . . . . . . . . . . Extension Housing Assembly Oil Seal . . . . . . Extension Housing Assembly Rear Oil Seal and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extension Housing Assembly . . . . . . . . . . . . . Extension Housing Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extension Housing Assembly . . . . . . . . . . . . . Extension Housing Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extension Housing Assembly . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A74 7A74 7A74 7A75 7A75 7A76 7A76 7A77 7A77 7A77 7A79 7A83 7A86 7A94 7A94 7A94 7A94 7A96 7A96 7A97 7A97 7A99 7A99 7A100 7A100 7A102 7A103 7A103 7A104 7A105 7A106
Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter Case Valve Body . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Third Clutch And Sprag Unit . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Sprag Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Accumulator Piston . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
7A3
Service Precaution
Construction
A07RS001
Legend (1) Torque Converter Clutch (TCC) (2) Fourth Clutch (C4) (3) Overrun Clutch (OC) (4) Overdrive Unit (5) Reverse Clutch (RC) (6) Second Clutch (C2)
(7) (8) (9) (10)
Third Clutch (C3) Ravigneaux Planetary Gear Set Brake Band (B) Overdrive Free Wheel (One Way Clutch) (OFW) (11) Principle Sprag Assembly (One Way Clutch) (PFW)
7A4
Range Reference Chart
C07RY00032
7A5
Normal Operation Of 2000 4L30E Transmission

Torque Converter Clutch (Electronically Controlled Capacity Clutch : ECCC) Application Conditions:
The clutch apply is controlled by moving the converter clutch control valve by commanding Torque Converter Clutch (TCC) solenoid using the PWM signal. The TCC is normally applied in 2nd, 3rd and 4th gears only when all of the following conditions exist: The engine coolant temperature is above 70C (158F) and ATF temperature is above 18C (64.5F). The brake pedal is released. The shift pattern requests TCC apply. Moreover, TCC is always applied in 2nd, 3rd and 4th gears when the transmission oil temperature is above 135C (275F). This mode should be canceled at 125C (257F).
Diagnosis
Introduction
The systematic troubleshooting information covered by this Section offers a practical and systematic approach to diagnosing 4L30E transmission, using information that can be obtained from road tests, electrical diagnosis, oil pressure checks or noise evaluation. The key to correcting a complaint is to make use of all of the available symptoms and logically letting them direct you to the cause. When dealing with automatic transmission complaints, it is best to gather as many symptoms as possible before making the decision to remove the transmission from the vehicle. Frequently, the correction of the complaint does not require removal of the transmission from the vehicle.
Driver Information
To analyze the problem fill out a complete description of the owners complaint. Please draw a circle around the right information and complete the following form. (The next page is an example of a completed form). You can draw a circle around many numbers if you are not sure.
ATF Warning Lamp

The ATF warning lamp will be constantly on (not flashing) if the transmission oil temperature is above 145C (293F). The ATF warning lamp goes off again when the transmission oil temperature is below 125C (257F).
Reverse Lock Out

With the selector lever in reverse position, the PCM will not close the PWM solenoid until the vehicle is below 11 km/h (6.8 mph), thus preventing reverse engagement above this speed.
7A6
F07RT036
Example of form completed.
7A7
F07RT037
7A8
General Diagnosis Procedure
F07RT038
7A9
Preliminary Inspection Chart
F07RY00001
7A10

NOTE: Check transmission fluid temperature with scan tool. Minimum fluid level 57C (135F) Maximum fluid level 32C (90F)
Checking Transmission Fluid Level and Condition

Checking fluid level and condition (color and odor) at regular intervals will provide early diagnosis information about the transmission. This information may be used to correct a condition that, if not detected early, could result in major transmission repairs. IMPORTANT: When new, automatic transmission fluid is red in color. As the vehicle is driven, the transmission fluid will begin to look darker in color. The color may eventually appear light brown. A dark brown color with burnt odor may indicate excessive fluid deterioration and signal a need for fluid change.
Fluid Level
When adding or changing fluid, use only DEXRON III. Refer to Maintenance and Lubrication in General Information section for maintenance information and servicing interval. CAUTION: DO NOT OVERFILL. Overfilling will cause foaming, loss of fluid, abnormal shifting and possible damage to the transmission. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Check fluid level with engine running at idle. NOTE: Be sure that transmission fluid temperature is below 30C (86F). 3. Move the selector lever through all gear ranges. 4. Move the selector lever to Park. 5. Let engine idle for 3 minutes and open the overfill screw (1). 6. Add released transmission fluid until it flows out over the overfill screw opening. 7. Let engine idle until a fluid temperature between 32C (90F) and 57C (135F) is reached, then close the overfill screw (1). Torque: 38 Nm (28 lb ft) NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed.
242RW003
CAUTION: Do not open overfill screw with engine stopped. CAUTION: DO NOT CHECK FLUID LEVEL UNDER THESE CONDITIONS: D Immediately after driving at sustained highway speeds. D In heavy city traffic during hot weather. D If vehicle is towing a trailer. If the vehicle has been operated under these conditions, shut the engine off and allow the vehicle to cool for thirty (30) minutes. After the cool down period, restart the vehicle and continue from step 2 above.
7A11
Fluid Condition
FLUID CONDITION NORMAL* COLOR DRAIN REQUIRED? CONTAMINA TION RED OR LIGHT BROWN NO NONE BROWN YES Very small amount of foreign material in bottom of pan Remove both pans Change filter Flush cooler Add new fluid Check level CONTAMINATED NONTRANSPARENT / PINK YES Contamination by coolant or other source BROWN YES Large pieces of metal or other foreign material in bottom of pan Transmission overhaul required Flush cooler and cooler lines Add new fluid Check level
CORRECT LEVEL AND CONDITION
1. LOW LEVEL: A. Add fluid to obtain proper level & check for external leaks. B. Correct cause of leak. 2. HIGH LEVEL: Remove excess fluid
Repair/replace radiator cooler Transmission overhaul required Check for: D Damaged plates and seals D Contaminated solenoids Flush cooler Add new fluid Check level
*Fluid should be changed according to maintenance schedule.
Test Driving
Some 4L30E automatic transmission complaints will require a test drive as a part of the diagnostic procedure. Some codes will not set unless the vehicle is moving. The purpose of the test drive is to duplicate the customers complaint condition and set a current Powertrain Control Module (PCM) trouble code. Perform this procedure before each 4L30E automatic transmission repair, and again after repairs are made. IMPORTANT: D Duplicate the condition under which the customers complaint was observed. D Depending on the complaint, the line pressure gauge and the scan tool may be required during the test drive. D During the test drive, it is important to record all necessary data from the areas being monitored, for use in diagnosis. Also listen for and note any unusual noises. The following procedure should be used to test drive 4L30E automatic transmission complaint vehicles: 1. Turn the ignition ON without starting the engine. Check that the CHECK TRANS lamp comes on for approximately 2 seconds and then goes out and remains out. D If the lamp is flashing, GOTO Check Trans Indicator in Transmission Control System (4L30E) section. D If no serial data is present, GOTO OBD System Check. Refer to Driveability and Emissions in Engine section.
D If the lamp stays ON or stays OFF, GOTO Check Trans Check in Transmission Control System (4L30E) section. 2. Drive the vehicle. During the test drive, be sure that the transmission achieves normal operating temperature (approx. 20 minutes). Allow the transmission to go through all of its gear ranges, checking shift timing and firmness. Duplicate the owner s complaint condition as closely as possible during the test drive. 3. If, during the test drive, the CHECK TRANS lamp comes on, use the scan tool to check for trouble codes. 4. If, during the test drive, a problem is felt, but the CHECK TRANS lamp does not come on and no trouble codes are present, drive the vehicle with the PCM disconnected (manually shifting the vehicle). D In Manual L, the vehicle operates in first gear. D In Manual 2, the vehicle operates in third gear. D In Manual 3 or D, the vehicle operates in fourth gear. If the problem still exists with the PCM disconnected, refer to Mechanical/Hydraulic Diagnosis in this section. 5. If no problem has been found at this point, check all underhood connections that supply power to the PCM and ignition fuses. Physically and visually inspect all the PCM harness connectors for loose or corroded terminals. Inspect the PCM ground points.
7A12
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart

Perform Preliminary Inspection First!
F07RT013
When the CHECK TRANS indicator is flashing, it indicates that a problem related to the transmission, the Powertrain Control Module (PCM), or the vehicle harness has occurred. The system is now operating in a BACKUP MODE where the risk of further damaging the transmission has been reduced. The vehicle may be shifted manually. If the initial problem is intermittent or seldom, switching the engine OFF/ON might allow normal operation again until the problem reoccurs.
7A13
Mechanical / Hydraulic Diagnosis Symptoms Index

Perform Preliminary Inspection First! CHART 1 2 3 4 5a 5b 6 7 8 9a 9b 9c 10 11 12 13 14 15a 15b 16 SYMPTOMS NO ENGINE START IN NEUTRAL OR PARK NO FORWARD GEARS IN ANY RANGE/NO REVERSE NO ENGINE BRAKE IN ANY RANGE POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT) DELAYS IN DRIVE AND REVERSE DELAYS IN REVERSE ONLY DIAGNOSTIC TROUBLE CODE (DTC) P0730 HARSH 12 SHIFT HARSH 34 SHIFT 32 DOWNSHIFT COMPLAINT HARSH SHIFT WHEN SHIFTING INTO D OR ACCELERATING FROM STOP COASTDOWN HARSH SHIFT OR CLUNK AT 32 DOWNSHIFT INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED ENGINE FLARE AT SHIFTING DURING TURNING ONLY (USUALLY WITH WARM ENGINE) ENGINE FLARE DURING 12 OR 23 SHIFT SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING POSSIBLE CAUSES OF TRANSMISSION NOISE POSSIBLE CAUSES OF LOW LINE PRESSURE POSSIBLE CAUSES OF HIGH LINE PRESSURE POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS
NOTE: Numbers with parenthesis on the following charts refer to Parts List at end of this section.
Chart 1: No Engine Start In Neutral Or Park

Step 1 2 3 4 5 Action Does engine start when shift lever moved from drive to neutral mostly in hot condition? Does engine start in park at any condition? Does engine also not start in neutral when shift lever moved from park to neutral? Check mode switch (63) setting. Readjust if necessary. Problems fixed? Check start circuit of mode switch (63) open in neutral. Was open found? Retest vehicle Locate and repair open(s) Go to Step 5 Replace mode switch (63) Yes Go to Step 2 Retest vehicle Go to Step 4 No Go to Step 3 Go to Step 4 Go to Step 5
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Chart 2: No Forward Gears In Any Range/No Reverse

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 1. Check internal linkage: Manual linkage (58) not moving manual valve (326). 2. Check for internal mechanical damage: Turbine shaft (506) broken loose. Overrun roller clutch (516) broken loose. Was the problem found? Repair or replace Yes No Use Chart 15a: Possible Causes of Low Line Pressure in this section
Chart 3: No Engine Brake In Any Range

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 1. Check for overrun clutch leaks caused by: Damaged piston lip (513) Check ball defective (504) 2. Check for overrun lockout valve (705) stuck by foreign material. 3. Check for leaks at turbine shaft (506) caused by: Teflon seal rings damaged (508) Excessive wear of turbine shaft bearing surfaces. Was the problem found? Repair or replace Yes No Use Chart 15a: Possible Causes of Low Line Pressure in this section
7A15
Chart 4: Poor Shifting In All Gears (All Harsh Or All Soft)

Step 1 2 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? 1. Check for these conditions which could affect clutch apply time: Defective band apply solenoid (323). Defective servo or/and accumulator piston. Excessive clutch piston travel. 2. Check of possible causes of internal leaks: Cut or damaged sealing ring(s) Damaged sealing gasket(s) Check ball missing or out of location in 2nd and 3rd clutch pistons. 3. Check for causes of burned clutch plates or band. Was the problem found? 3 Was the line pressure high? Repair or replace Use Chart 15a: Possible Causes of Low Line Pressure in this section Use Chart 15b: Possible Causes of High Line Pressure in this section Go to Step 2 Go to Step 3 Yes No
Go to Step 4 4 Does DTC P0705 set? Diagnose those DTC(s) first
Chart 5a: Delays In Drive And Reverse

NOTE: A short delay (less than 3 seconds) when first engaging drive or reverse after allowing vehicle to sit overnight is normal. Step 1 Was line pressure normal? Action Check line pressure. Refer to Line Pressure Test in this section. Yes More than 3 second delay in drive and reverse with engine off 1 hour or less. Teflon seals (508) on turbine shaft damaged. Repair No
Use Chart 15a: Possible Causes of Low Line Pressure in this section.
Chart 5b: Delays In Reverse Only

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 Main case valve body gasket (88) damaged. Reverse check ball (85) in valve body (84) missing or out of location. Check for restrictions at valve body transfer plate orifice. Was the problem found? Repair Yes No Use Chart 15a: Possible Causes of Low Line Pressure in this section.
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Chart 6: Diagnostic Trouble Code (DTC) P0730

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 1. 1st and 2nd gear missing or 3rd and 4th gear missing. Check appropriate shift valve. If OK replace solenoid. 2. No engine brake in any range (All ranges in Drive and Reverse are OK). Check for suspected conditions modifying delays to clutch apply: Overrun clutch seal damaged. Excessive overrun clutch piston travel. Defective 34 accumulator piston. Causes of internal leaks. Causes of burned clutch plates. 3. 1st and 4th gear missing or 2nd and 3rd gear missing. Shift solenoid A stuck. Replace shift solenoid A. 4. DTC P0730 is set in D range 1st gear above 3500 rpm. Go to Step 3. 5. DTC P0730 is set in D range 3rd gear between 55-80 mph. NOTE: Perform this test within safe and legal limits. Check for suspected conditions modifying delays to clutch apply: 3 4th clutch seal damaged. Excessive 4th clutch piston travel. Defective 34 accumulator piston. Causes of internal leaks. Causes of burned clutch plates. Repair or replace Shift solenoid A stuck. Replace shift solenoid A. Yes No Use Chart 15b: Possible Causes of High Line Pressure in this section
Was the problem found? Check 3rd gear in D in winter mode. Does vehicle move? 4 Check for suspected conditions modifying delays to clutch apply: 2nd clutch seal damaged. Excessive 2nd clutch piston travel. Defective accumulator piston. Causes of internal leaks. Check ball missing or out of location in 2nd clutch. Seals cut, damaged or missing. Gaskets defective. Causes of burned clutch plates. Was the problem found?
Go to Step 4
Repair or replace
7A17
Chart 7: Harsh 12 Shift

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Yes Check for 12 accumulator valve (320) stuck by foreign material in main case valve body. No Use Chart 15b: Possible Causes of High Line Pressure in this section.
Chart 8: Harsh 34 Shift

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 1. Check for 34 accumulator valve (407) stuck in adapter case valve body (401). 2. Check for 34 accumulator piston (18) stuck in adapter case (20). Was the problem found? Repair or replace Yes No Use Chart 15b: Possible Causes of High Line Pressure in this section
Chart 9a: 32 Downshift Complaint

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 Does DTC P1850 set? Diagnose P1850 first Yes No Use Chart 15a: Possible Causes of Low Line Pressure in this section Replace band apply solenoid (PWM) (323)
Chart 9b: Harsh Shift When Shifting Into D Or Accelerating From Stop
Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 Does DTC P1850 set? Diagnose P1850 first Yes No Use Chart 15b: Possible Causes of High Line Pressure in this section Replace band apply solenoid (PWM) (323)
7A18
Chart 9c: Coastdown Harsh Shift Or Clunk At 32 Downshift

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 Does DTC P1850 set? Diagnose P1850 first Yes No Use Chart 15b: Possible Causes of High Line Pressure in this section Replace band apply solenoid (PWM) (323)
Chart 10: Intermittent 4TH TO 2ND Gear Downshift At Steady Speed

Step 1 Action Check for consistent speed sensor reading with scan tool. Was the reading correct? 2 1. Check for wiring harness damage or short to ground. If OK, go to (2). 2. Check transmission speed sensor connections. If OK, go to (3). 3. Replace transmission speed sensor. Was the replacement complete? Yes Replace mode switch for intermittent contact. No
Go to Step 2
Replace speed sensor.
Chart 11: Engine Flare At Shifting During Turning Only (Usually With Warm Engine)
Step 1 Action Check for oil leaks at transmission. Was the problem found? Yes Replace transmission oil filter and gasket No
Chart 12: Engine Flare During 12 Or 23 Shift

Step 1 Action Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal? Go to Step 2 2 1. Check for a stuck 12 accumulator valve (320). 2. Check for servo piston (106) leaks. 3. Check for a stuck band apply solenoid (323). Was line pressure normal? Repair or replace Yes No Use Chart 15a: Possible Causes of Low Line Pressure in this section
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Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying
Step 1 Action 1. TCC shudder is one of the most commonly misdiagnosed conditions in an automatic transmission. The key to diagnosing TCC shudder is to note when it happens and under what conditions. Once the TCC has been fully applied, it is nearly impossible to make it shudder. TCC shudder (short burst of noise normally less than 1 second) will only occur during clutch applying. It is not a steady state condition. 2. Drive until whole drivetrain is at normal operating temperature. On 4WD vehicles, the test must be performed with transfer case selector lever in 2H position. Shudder is a short burst of noise normally less than 1 second in duration, and can be induced by the following maneuver: 3. From coast condition at 50 mph in D range (Normal mode), depress the throttle to 1/4-1/3 throttle. If present, shudder will occur within 5 seconds together with TCC application.(The scan tool may be used to determine the exact time of TCC applying) Was the problem found? Yes No
Replace transmission fluid and filter (remove both pans) and flush cooler lines. Replace converter assembly and O-ring on turbine shaft
Perform mechanical inspection of other drivetrain components.
Chart 14: Possible Causes Of Transmission Noise

CAUTION: Before checking transmission for what is believed to be transmission noise, ensure presence and positioning of insulating plugs, pads etc. Also make sure that noise does not come from other drivetrain components. Condition Whine or Buzz Possible cause Oil level low Plugged or restricted oil filter Damaged oil filter gasket Knocking noise transmission transmission. from front of Loose bolts (Converter to flex plate) Cracked or broken flex plate Converter damaged Knocking noise while driving, mostly on acceleration. Transmission mount loose or broken Cooler line mounts loose or broken Cooler lines touching body or frame Knocking noise when vehicle is stationary stationary. Loose flex plate mounting bolts Cracked or broken flex plate Damaged converter Correction Fill with ATF, check for external leaks. Inspect oil filter. Replace oil filter or ATF as necessary. Replace oil filter gasket. Tighten to specifications. Replace flex plate. Replace converter. Tighten mount bolts or replace transmission mount. Tighten or replace cooler line mounts. Repair or replace as necessary. Tighten to specifications. Replace flex plate. Replace converter.
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Chart 15a: Possible Causes of Low Line Pressure

Step 1 2 3 Check oil level. Was the problem found? Check for defective throttle position sensor. Was the problem found? Check for plugged, loose, or damaged oil filter (79). Was the problem found? 4 Check for a stuck force motor plunger (404). (Adapter case valve body) Was the problem found? 5 6 7 Check for a stuck feed limit valve (412). (Adapter case valve body) Was the problem found? Check for loose converter bolts (4 & 5). Was the problem found? Check for a stuck pressure regulator valve (217). (Oil pump) Was the problem found? 8 9 Check for a stuck boost valve (213).(Oil pump) Was the problem found? Check for blocked intermediate oil passages to pressure regulator valve. (Oil pump) Was the problem found? 10 11 Check for defective oil pump (9, 201, 202 & 228). Was the problem found? Check for internal leaks. Check balls missing or out of location in valve bodies Seals cut or damaged Gaskets defective, etc. Was the problem found? Replace oil pump Install balls, or correct ball location Replace seals Replace gaskets Go to Step 11 Replace oil pump Go to Step 10 Fill with ATF Replace throttle position sensor Inspect oil filter, tighten bolts or replace oil filter (79) Replace force motor plunger (404) Replace feed limit valve (412) Tighten converter bolts (4 & 5) Replace pressure regulator valve (217) Replace boost valve (213) Go to Step 2 Go to Step 3 Action Yes No
Go to Step 4
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Chart 15b: Possible Causes Of High Line Pressure

NOTE: If transmission is operating in backup mode, high line pressure will be present. Step 1 2 Was the problem found? Check for a stuck force motor plunger (404). (Open circuit/intermittent) (Adapter case valve body) Was the problem found? 3 Check for a stuck feed limit valve (412). (Adapter case valve body) Was the problem found? 4 5 Check converter bolts (4 & 5). Was the problem found? Check for a stuck pressure regulator valve (217). (Oil pump) Was the problem found? 6 7 Check for a stuck boost valve (213). (Oil pump) Was the problem found? Check for internal leaks. Check balls missing or out of location in valve bodies Seals cut or missing Gaskets defective, etc. Was the problem found? Action Check for defective throttle position sensor. Yes Replace throttle position sensor. Replace force motor plunger (404) Replace force motor plunger (412) Tighten converter bolts (4 & 5) Replace pressure regulator valve (217) Replace boost valve (213) Install balls, or correct ball location Replace seals Replace gaskets No Go to Step 2.
Go to Step 3
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Oil leaks around the engine and transmission are generally carried toward the rear of the vehicle by the air stream. In determining the source of an oil leak, the following two checks should be made: 1. With the engine running, check for external line pressure leaks. 2. With the engine off, check for oil leaks due to the raised oil level caused by drainback of converter oil into the transmission.
Chart 16: Possible Causes Of Transmission Fluid Leaks

Before attempting to correct an oil leak, the actual source of the leak must be determined. In many cases, the source of the leak may be difficult to determine due to wind flow around the engine and transmission. The suspected area should be wiped clean before inspecting for the source of the leak.
Possible Causes Of Fluid Leaks Due To Sealing Malfunction
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Legend (1) Electrical Connector (Main Case) Seal (2) Transmission Vent (Breather) (3) Speed Sensor ORing (4) Extension (Adapter) Lip Seal (5) Extension (Adapter) to Main Case Gasket (6) Overfill and Oil Drain Screws Gasket (7) Oil Pan Gasket (Main Case) (8) Selector Shaft Seal
(9) Oil Cooler Connectors (2) (10) Oil Pan Gasket (Adapter Case) (11) Converter housing attaching bolts not correctly torqued (12) Converter Housing Lip Seal (13) Line Pressure Tap Plug (14) Electrical Connector (Adapter Case) Seal (15) Adapter Case Seal Rings (2)
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Stall Test
The stall test allows you to check the transmission for internal abrasion and the one way clutch for slippage. Torque converter performance can also be evaluated. The stall test results together with the road test results will identify transmission components requiring servicing or adjustment.
Stall Test Procedure:

1. Check the level of the engine coolant, the engine oil, and the automatic transmission fluid. Replenish if necessary. 2. Block the wheels and set the parking brake. 3. Connect a tachometer to the engine. 4. Start the engine and allow it to idle until the engine coolant temperature reaches 70 80C (158 176F). 5. Hold the brake pedal down as far as it will go. 6. Place the selector in the D range. 7. Gradually push the accelerator pedal to the floor. The throttle valve will be fully open. Note the engine speed at which the tachometer needle stabilizes. Stall Speed : 2,100 150 rpm NOTE: Do not continuously run this test longer than 5 seconds. 8. Release the accelerator pedal. 9. Place the selector in the N range. 10. Run the engine at 1,200 rpm for one minute. This will cool the transmission fluid. 11. Repeat Steps 7 10 for the 3, 2, L and R ranges.
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4. Start the engine and allow it to idle until the engine coolant temperature reaches 70 80C (158 176F). 5. Hold the brake pedal down as far as it will go. 6. Place the selector in the D range. 7. Note the pressure gauge reading with the engine idling. 8. Gradually push the accelerator pedal to the floor. The throttle valve will be fully open. Note the pressure gauge reading with the accelerator pedal fully depressed. NOTE: Do not continuously run this test longer than 5 seconds. 9. Release the accelerator pedal. 10. Place the selector in the N range. 11. Run the engine at 1,200 rpm for one minute. This will cool the transmission fluid. 12. Repeat Steps 7 11 for the 3, 2, L, and R ranges. 13. Install a pressure detection plug to the transmission case, applying recommended thread locking agent (LOCTITE 242) or its equivalent to thread of plug. Make sure that thread is cleaned before applying locking agents. 14. Tighten the pressure detection plug to the specified torque. Torque: 9 14Nm (7 10lb ft)
Line Pressure Test

The line pressure test checks oil pump and control valve pressure regulator valve function. It will also detect oil leakage.
Line Pressure Test Procedure:

1. Check the level of the engine coolant, the engine oil, and the automatic transmission fluid. Replenish if required. 2. Block the wheels and set the parking brake. 3. Remove the pressure detection plug at the left side of the transmission case. Set J29770A pressure gauge and adapter to the pressure detection plug hole.
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MODE LEVER POSITION D,3,2,L D REVERSE D, 3, 2, L D REVERSE ENGINE SPEED IDLE IDLE IDLE STALL SPEED STALL SPEED STALL SPEED LINE PRESSURE kPa 590 730 300 390 460 630 1,250 1,380 1,250 1,380 1,400 1,580 PSI 86 106 44 57 67 91 181 200 181 200 203 229 FORCE MOTOR CURRENT (mA) 680 720 1,020 1,060 880 920 70 110 70 110 340 380
NORMAL/POWER WINTER NORMAL/POWER WINTER NORMAL/POWER WINTER NORMAL/POWER WINTER
Shift Speed Chart

Transfer gear ratio: Rear axle ratio: High: 1.000 4.300
Normal mode
Upshift Range D (Drive) 3 (Third) 2 (Second) Throttle opening Fully opened Half throttle Fully opened Half throttle Fully opened Half throttle 12 23 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph) 53 59 (33 37) 32 38 (20 24) 53 59 (33 37) 32 38 (20 24) 53 59 (33 37) 32 38 (20 24) 110 116 (68 72) 57 63 (35 39) 110 116 (68 72) 57 63 (35 39) 34 (Third Gear) (Fourth Gear) km/h (mph) 166 172 (103 107) 99 105 (61 65)
Downshift Range Throttle opening Fully opened D (Drive) Half throttle Fully closed Fully opened 3 (Third) Half throttle Fully closed Fully opened 2 (Second) L (First) Half throttle Fully closed 12 23 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph) 45 51 (28 32) 14 20 (9 12) 13 19 (8 12) 45 51 (28 32) 14 20 (9 12) 13 19 (8 12) 45 51 (28 32) 14 20 (9 12) 13 19 (8 12) 48 54 (30 34) 87 93 (54 58) 33 39 (20 24) 19 25 (12 16) 87 93 (54 58) 33 39 (20 24) 19 25 (12 16) 92 98 (57 61) 92 98 (57 61) 92 98 (57 61) 34 (Third Gear) (Fourth Gear) km/h (mph) 155 161 (96 100) 64 70 (40 43) 27 33 (17 21)
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Power mode
Upshift Range D (Drive) 3 (Third) 2 (Second) Throttle opening Fully opened Half throttle Fully opened Half throttle Fully opened Half throttle 12 23 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph) 53 59 (33 37) 41 47 (25 29) 53 59 (33 37) 41 47 (25 29) 53 59 (33 37) 41 47 (25 29) 110 116 (68 72) 84 90 (52 56) 110 116 (68 72) 84 90 (52 56) 34 (Third Gear) (Fourth Gear) km/h (mph) 174 180 (108 112) 136 142 (84 88)
Downshift Range Throttle opening Fully opened D (Drive) Half throttle Fully closed Fully opened 3 (Third) Half throttle Fully closed Fully opened 2 (Second) L (First) Half throttle Fully closed 12 23 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph) 45 51 (28 32) 22 28 (14 17) 13 19 (8 12) 45 51 (28 32) 22 28 (14 17) 13 19 (8 12) 45 51 (28 32) 22 28 (14 17) 13 19 (8 12) 48 54 (30 34) 104 110 (65 68) 57 63 (35 39) 23 29 (14 18) 104 110 (65 68) 57 63 (35 39) 23 29 (14 18) 92 98 (57 61) 92 98 (57 61) 92 98 (57 61) 34 (Third Gear) (Fourth Gear) km/h (mph) 163 169 (101 105) 108 114 (67 71) 46 52 (29 32)
Winter mode
D range, winter mode ON OFF 31 37 km/h (19 23 mph)
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Lockup Speed Chart

Transfer gear ratio Rear axle ratio High: 1.000 4.300 ECCC Apply Mode D range Throttle opening i 6% 2nd Km/h (mph) 57 63 (35 39) 57 63 (35 39) 3rd Km/h (mph) 42 48 (26 30) 67 73 (42 45) 4th Km/h (mph) 43 49 (27 31) 57 63 (35 39) 2nd Km/h (mph) 52 58 (32 36) 52 58 (32 36) ECCC Release 3rd Km/h (mph) 32 38 (20 24) 32 38 (20 24) 4th Km/h (mph) 41 47 (25 29) 49 55 (30 34)
Normal Power
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Changing Transmission Fluid

There is no need to change the transmission fluid unless the transmission is used under one or more of the following heavy duty conditions. A. Repeated short trips B. Driving on rough roads C. Driving on dusty roads D. Towing a trailer If the vehicle is used under these conditions, change the fluid every 20,000 miles (32,000 km). 1. Place a large drain pan under the oil pan. 2. Remove the transmission oil drain screw (2) and drain fluid. 3. Tighten drain screw (2). Torque: 38 Nm (28 lb ft) 4. Remove the transmission overfill screw (1) and fill transmission through overfill screw opening, using DEXRONIII ATF. NOTE: Add transmission fluid until it flows out over the overfill screw opening. 5. Let engine idle until a fluid temperature between 32C (90F) and 57C (135F) is reached. 6. Add transmission fluid until it flows out over the overfill screw opening, then close the overfill screw (1). Torque: 38 Nm (28 lb ft)
NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed. NOTE: Check transmission fluid temperature with service scan tool. 7. Reset Oil Life Monitor data by using Tech 2. Refer to Tech 2 OBD II Connection in Transmission Control System (4L30-E) section.
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Selector Lever
Inspection
1. Make sure that when the selector lever is shifted from P to L, a clicking can be felt at each shift position. Make sure that the gear corresponds to that of the position plate indicator. 2. Check to see if the selector lever can be shifted as shown in illustration.
Removal
1. Disconnect battery ground cable. 2. Remove transfer control lever knob (44). 3. Remove front console. D Disconnect wiring harness connectors from front console. 4. Disconnect shift lock cable (1) from the selector lever assembly side.
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5. Disconnect shift control rod (2) from the selector lever assembly side.
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6. Disconnect wiring harness connectors from the selector lever assembly. 7. Remove selector lever assembly.
6. After adjustment, make sure that the selector lever operates normally, and that each selector position is properly indicated. (The red mark shows through the window.)
Adjustment of shift lock cable

1. Set ignition key in LOCK position and selector lever in P position. 2. Adjust cable screw cap on selector lever side to provide a gap (slack for cable) of 1 2 mm between rod on steering lock side and stopper. Adjust cap as follows: a. Pull screw cap (1) in arrow direction to remove inner cable slack. b. With cable kept as (a), adjust gap between nut (2) and bracket to 5 mm (0.2 in). c. Lock inner cable by turning nut (3) while holding nut (2) in place. Torque : 3.7 Nm (33 lb in) NOTE: Clean the cable threads, and do not apply oil to them.
Installation
Adjustment of select lever and control rod

1. Place the vehicle on a level surface. NOTE: If the vehicle is not on level surface, the shift select cable set positions will vary with the movement of engine. To prevent possible misadjustment of the cable, the vehicle must be placed on a level surface. 2. Install the shift control rod (1) to the transmission select lever (2), and then place the lever in the N position. 3. Set select lever in the N position. 4. Push select lever forward (R position side) and secure it (using a rubber band (3), etc.) so that the pin comes into contact with the wall of the detent plate. 5. Install the shift control rod (1) to the selector lever arm (4). Torque: 32 Nm (24 lb ft) NOTE: Do not apply oil to the threaded portions.
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3. Check the shift lock operation: a. Selector lever should not move out of P position with ignition key in Lock position. b. Selector lever can be moved out of P position with ignition key in ON position only when brake pedal is depressed. c. Ignition key can be turned to LOCK position only when selector lever is in P position (key can be pulled out). If (a) and (c) fail, readjust cable. If (b) fails, readjust connector wiring and brake pedal switch.
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Mode Switch
Removal
1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1). 4. Disconnect selector lever (2) from the mode switch. 5. Disconnect transmission harness from the mode switch connector (3). 6. Remove bracket with mode switch connector from the transmission case. 7. Remove mode switch connector (3) from the bracket (4). 8. Remove two mode switch bolts and nut then remove mode switch (5).
Installation
To install, follow the removal steps in the reverse order, noting the following points; 1. Torque Mode switch bolt: 13 Nm (113 lb in) Selector lever nut: 23 Nm (17 lb ft) 2. Mode switch setting procedure Perform either of the following adjustment procedures: Procedure 1 a. b. c. d. e. Place selector lever in neutral. Remove selector lever from the mode switch. Remove the mode switch cover. Loosen the two 10 mm screws. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 in. (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 Nm (113 lb in). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever.
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Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws. i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector.
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Transmission (With Transfer Case / Extension Assembly)

Transmission And Associated Parts
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Legend (1) Transfer Control Lever Knob (44) (2) Front Console (3) Selector Lever Assembly (4) Transfer Control Lever (44) (5) Transfer Protector (44) (6) Rear Propeller Shaft (7) Front Propeller Shaft (44) (8) Harness Protector (9) Rear Mount Nut (10) Third Crossmember
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Left Catalytic Converter Assembly Seat Belt Tension Rod Transmission Oil Cooler Pipe Starter Transmission Harness Connector Front Crossmember Under Cover Torque Converter Bolt Engine Transmission Bolt Transmission Assembly (With Transfer Case / Extension Assembly)
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Removal
NOTE: Before remove transmission and transfer assembly from vehicle, change the tansfer mode to 2WD using push button on dash panel. 1. Remove engine hood. 2. Disconnect battery ground cable. 3. Remove transfer control lever knob (1) (44) and disconnect wiring harness connectors, then remove front console (2). 4. Remove selector lever assembly (3). 5. Remove transfer control lever (4) (44). 6. Remove transfer protector (5) (44). 7. Disconnect shift control rod from the selector lever assembly side.
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16. Remove left catalytic converter assembly (11). 17. Loosen right catalytic converter nuts to exhaust manifold. NOTE: This will make the next steps easier. 18. Disconnect transmission oil cooler pipe (12) from A/T side. 19. Remove oil pipe clamp from torque converter housing bracket.
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8. Remove rear propeller shaft (6). 9. Remove front propeller shaft (7) (44). 10. Remove harness protector (8). 11. Support transfer case (44) or transmission (42) with a jack and remove two rear mount nuts (9) from the 3rd crossmember side. 12. Remove eight third crossmember bolts and third crossmember (10). 13. Remove front exhaust silencer mounting nuts. 14. Remove left seat belt tension rod. 15. Disconnect two left side oxygen sensor connectors from the transmission harness.
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20. Loosen oil pipe clamp bolt at the engine mount side. 21. Remove starter (14). 22. Disconnect fuel pipe clamp brackets from transmission side. 23. Disconnect transmission harness connectors (15) from transmission, transfer, and right catalytic converter. 24. Remove front crossmember (16). 25. Remove under covers (3 pieces) (17) from transmission case. 26. Remove flex plate torque converter fixing bolts (6 pieces) (18) by turning crankshaft.

27. Support the transmission with a transmission jack, and hoist engine with a chain block. 28. Remove engine transmission fixing bolts (19). 29. Remove transmission assembly with transfer case (44) / extension assembly (42) (20). 30. Remove transfer case / extension assembly from the transmission assembly if necessary.
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Installation
1. Slowly raise transmission jack until front of the transmission is aligned with rear of the engine, then install transmission assembly. 2. Tighten engine transmission bolts, to the specified torque.
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3. Support transfer case with a jack, and remove the transmission jack. 4. Install flex plate torque converter bolts (6 pieces) by turning crankshaft. Torque: 54 Nm (40 lb ft) NOTE: Do not reuse the flex plate torque converter bolt.
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7. Install the starter, and tighten the bolts to the specified torque. Torque: 40 Nm (30 lb ft) 8. Connect transmission harness connectors to transmission, transfer, and right catalytic converter. 9. Connect fuel pipe brackets to transmission side.
5. Install the under cover (3 pieces), and tighten the bolts to the specified torque. Torque: 8 Nm (69 lb in) 6. Install front crossmember. Torque: 78 Nm (58 lb ft) For 44 (TOD)
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For 44
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For 42
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10. Install transmission oil cooler pipe to transmission. Torque: 44 Nm (33 lb ft) 11. Install oil pipe clamp to torque converter housing bracket. 12. Tighten oil pipe clamp bolt at engine mount side. 13. Install right catalytic converter, tighten to the specified torque. Torque: 67 Nm (49 lb ft) 14. Install left catalytic converter assembly, and tighten the bolts to the specified torque. Exh. pipe to exh. manifold 67 Nm (49 lb ft) Exh. pipe flange bolt 43 Nm (32 lb ft)
15. Install left seat belt tension rod. Torque: 39 Nm (29 lb ft) 16. Connect two left side oxygen sensor connectors to the transmission harness. 17. Install front exhaust silencer mounting nuts. 18. Install third crossmember, and tighten the bolts to the specified torque. Torque: 76 Nm (56 lb ft) 19. Install rear mount nuts, and tighten the bolts to the specified torque. Torque: 50 Nm (37 lb ft) 20. Remove the jack from the transfer case.

21. Install harness protector.
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22. Install the front propeller shaft, and tighten the bolts to the specified torque (44). Torque: 63 Nm (46 lb ft) 23. Install the rear propeller shaft, and tighten the bolts to the specified torque. Torque: 63 Nm (46 lb ft) 24. Connect the shift control rod to selector lever assembly. 25. Install the transfer protectors, and tighten the bolts to the specified torque (44). Torque: 37 Nm (27 lb ft) 26. Install the transfer control lever (44). 27. Install the selector lever assembly. 28. Connect the wiring harness connectors to front console. 29. Install the front console. 30. Install the transfer control lever knob (44). 31. Connect the battery ground cable. 32. Install the engine hood.
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Solenoid (Main Case Valve Body)

Removal
1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Remove transfer protector (44). 4. Drain fluid. 5. Support transfer case with a jack and remove third crossmember. 6. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 7. Remove three 13 mm screws, oil filter. 8. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 9. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids. 10. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip.
Installation
1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc.
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3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 lb ft)
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5. Install magnet, main case oil pan with new gasket, sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 lb in) 6. Install third crossmember and rear mount nuts. Tighten the nuts and bolts to the specified torque. Third crossmember bolt: 76 Nm (56 lb ft) Rear mount nut: 50 Nm (37 lb ft) 7. Install the transfer protector. Tighten the bolts to the specified torque (44). Torque: 37 Nm (27 lb ft) 8. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRONIII. Refer to Changing Transmission Fluid in this section. 9. Connect the battery ground cable.
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Solenoid (Adapter Case Valve Body)

Removal
1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove adapter case oil pan twelve fixing 10 mm screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan and drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch PWM solenoid. Pull only on connectors, not on wiring harness. 6. Remove 11 mm bolt, bracket and converter clutch PWM solenoid with two Orings.
Installation
1. Install force motor solenoid, retainer, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 Nm (87 lb in) 2. Install converter clutch PWM solenoid with two O rings, bracket, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque : 10 Nm (87 lb in) 3. Connect wiring harness assembly to solenoids. 4. Install adapter case oil pan, new gasket, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque : 11 Nm (96 lb in) 5. Fill transmission through overfill screw hole oil pan, using ATF DEXRONIII. Refer to Changing Transmission Fluid in this section. 6. Connect battery ground cable.
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7. Remove 11 mm bolt, retainer, and force motor solenoid.
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Valve Body Assembly (Main Case)

Removal
1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Remove transfer protector (44). 4. Drain fluid. 5. Support transfer case with a jack and remove third crossmember. 6. Remove sixteen 10 mm screws, main case oil pan, magnet and gasket. 7. Remove three 13 mm oil filter fixing screws, then remove oil filter. 8. Remove two 13 mm manual detent fixing screws, then remove roller and spring assembly. 9. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 10. Remove four 13 mm servo cover fixing screws, then remove servo cover and gasket. 11. Remove seven 13 mm valve body fixing screws. 12. Remove main case valve body with manual valve link and transfer plate. Note the position of the link (long end into valve, short end into range selector lever). 13. Remove transfer plate gasket from main case. 14. Remove two check balls from main case. 4. Install seven 13 mm screws, and tighten them to the specified torque. Torque: 20 Nm (15 lb ft)
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5. Remove two guide pins from main case. 6. Install servo cover gasket, cover, and four 13 mm screws. Tighten the screws to the specified torque. Torque: 25 Nm (18 lb ft) 7. Connect wiring harness to band control and shift solenoids. 8. Install roller and spring assembly to manual detent. D Install two 13 mm screws, and tighten them to the specified torque. Torque: 20 Nm (15 lb ft) 9. Install oil filter and three 13 mm screws. Tighten the screws to the specified torque. Torque : 20 Nm (15 lb ft) 10. Install oil pan gasket, magnet, oil pan and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 lb in) 11. Install third crossmember and rear mount. Tighten the bolts and nuts to the specified torque. Torque Third crossmember bolt: 76 Nm (56 lb ft) Rear mount nut: 50 Nm (37 lb ft) 12. Install transfer protector. Tighten the bolts to the specified torque (44). Torque: 37 Nm (27 lb ft) 13. Fill transmission through overfill screw hole of oil pan, using ATF DEXRONIII. Refer to Changing Transmission Fluid in this section. 14. Connect battery ground cable.
Installation
1. Install two check balls to main case.
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2. Inspect electrical 7 way connector and seal of main case. Replace if necessary. 3. Use two J25025B guide pin to install main case. D Install valve body assembly and manual valve link. NOTE: Valve must be extended as the short end of manual valve link is connected to the range selector lever. Long end of link goes into valve.
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Valve Body Assembly (Adapter Case)

Removal
1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body.
Installation
1. Inspect electrical 4 way connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 Nm (15 lb ft) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 lb in) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRONIII. Refer to Changing Transmission Fluid in this section. 7. Connect battery ground cable.

Removal
1. Disconnect battery ground cable. 2. Disconnect PCM wiring harness connectors from PCM. 3. Remove PCM from bracket.
Installation
1. Install PCM to bracket. 2. Connect PCM wiring harness connectors to PCM. 3. Connect battery ground cable.
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7A42
Speed Sensor (Extension Housing)

Removal
1. Disconnect battery ground cable. 2. Remove front console. 3. Remove selector lever assembly. 4. Disconnect speed sensor harness connector from speed sensor. 5. Remove one 10 mm screw and speed sensor with Oring.
Installation
1. Inspect the speed sensor Oring, and replace it if necessary. 2. Install speed sensor assembly and 10 mm screw. Torque: 9 Nm (78 lb in) 3. Connect speed sensor harness connector to speed sensor. 4. Install selector lever assembly. D Adjust shift lock cable. Refer to Selector Lever in this section. 5. Install front console. 6. Connect battery ground cable.
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Transmission Oil Temperature Sensor (Main Case)

Removal
1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor.
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Installation
1. Install wiring harness assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way connector of main case.

2. Install oil pan gasket, oil pan, and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 Nm (96 lb in)
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3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRONIII. Refer to Changing Transmission Fluid in this section. 4. Connect battery ground cable.
Front Oil Seal (Converter Housing)

Removal
1. Remove transmission assembly with transfer case from the vehicle. Refer to Transmission (With Transfer Case / Extension Assembly) in this section. 2. Remove torque converter from converter housing. 3. Remove three screws and oil seal ring from converter housing.
Installation
1. Apply clean ATF to the new oil seal ring lip. D Install oil seal ring to converter housing. Tighten the screws to the specified torque. Torque: 3 Nm (26 lb in) 2. Install torque converter to converter housing. 3. Install transmission assembly with transfer case (44) / extension assembly (42) to the vehicle. Refer to Transmission (With Transfer Case / Extension Assembly) in this section.
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Rear Oil Seal (Extension Housing)

Removal
1. Remove transfer case assembly (44) or extension assembly (42) from the vehicle. Refer to Transfer Case in Drive Line/Axle section. 2. Remove rear oil seal from transmission extension housing.
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2. Install the transfer case assembly (44) or extension assembly (42) to the vehicle. Refer to Transfer Case in Drive Line/Axle section.
Installation
1. Use J36797 extension housing oil seal installer, and install the rear oil seal to the transmission extension housing.
Transmission (4L30E)
Disassembly
NOTE: During the disassembly and reassembly, perform the following: D Wash each part thoroughly, and blow air through each oil passage and groove to eliminate blockage. D Seal rings, roll pins, and gaskets should be replaced. D When assembling the components, apply DEXRONIII Automatic Transmission Fluid (ATF) to each seal, rotating part, and sliding part. D Do not dip part facings, such as clutch or brake drive plates, in cleaner when washing it. Also, always coat parts with new ATF two or three times after cleaning with solvent. 1. Remove torque converter (1). D Drain fluid from torque converter. D Attach J876302 holding fixture to the transmission and set it on J328920 holding fixture base. NOTE: Do not overtighten the tool, as case damage may result. 2. Remove Oring (2) from turbine shaft. 3. Remove two 10mm mode switch screws, selector lever nut, cover, and mode switch (3). 4. Remove twelve 10mm adapter case oil pan (4) fixing screws, adapter oil pan, and gasket. 5. Disconnect electrical wiring connections (5) from solenoids and 4 way connector of adapter case. Pull on connectors only, not on wiring harness. 6. Remove seven 13mm adapter case valve body (6) fixing screws, adapter case valve body assembly, transfer plate, and two gaskets. D Remove wiring harness and 4 way connector. 7. Remove sixteen 10mm main case oil pan (7) fixing screws, main oil pan, magnet, and gasket. 8. Remove three 13mm oil filter (8) fixing screws and oil filter. 9. Remove two 13mm manual detent (9) fixing screws, roller and spring, and manual detent. 10. Disconnect wiring harness assembly (10) from band apply solenoid, shift solenoids, and main case 7 way connector. Pull on connectors only, not on wiring harness. 11. Remove four 13mm servo cover (11) fixing screws, servo cover, and gasket. 12. Remove seven 13mm valve body screws and ground wire from main case. D Remove wiring harness assembly (5) from the adapter case side. D Remove main valve body assembly (12) with manual valve link and transfer plate. Note the position of the link (long end into valve, short end into range selector lever). D Remove 7 way connector. D Remove gasket transfer plate from main case.
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13. Remove two check balls (13) from main case.
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14. Turn transmission to vertical position to drain fluid. Return back to horizontal position when drained. D Install J23075 servo piston spring compressor with offset to the rear of case. D Compress servo piston assembly. D Remove servo piston retaining ring (14). D Slowly release servo piston assembly (15). D Remove tool.
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19. Remove speed wheel (21). 20. Remove wheel parking lock (with seal ring) (22).
15. Remove servo piston assembly (15), return spring (16), and servo apply rod (17).
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16. Rotate transmission to horizontal position, pan side down. D Remove one 10mm screw, and speed sensor (18) with O ring. 17. Remove seven 8mm extension housing hexagon socket head screws, extension housing assembly (19), and gasket. 18. Remove retaining ring (20). NOTE: Use extra long, needle- nose pliers.
21. Rotate transmission to vertical position, converter housing up. D Loosen the converter housing and oil pump assembly fixing screws, but do not remove the five 13 mm inner screws if oil pump disassembly is required. D Remove seven outer screws. D Remove converter housing and oil pump assembly (23). 22. Remove gasket (24).

23. Remove selective thrust washer (25). 28. Remove thrust washer (31).
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24. Remove fourth clutch retainer (26). 25. Grasp turbine shaft and lift out the overrun clutch housing assembly (27) and fourth clutch plates (28). 26. Remove thrust bearing assembly (29). 27. Remove overdrive internal gear (30).
29. Remove adapter case and center support assembly (with fourth clutch piston) (32). 30. Remove seal ring (33). 31. Remove selective thrust washer (34) and two Oring seals (35) from main case. 32. Use J23327 and J2332790 compressor to compress the fourth clutch spring retainer and springs (37). D Release snap ring (36) from groove. D Remove clutch compressor and snap ring (36). 33. Remove retainer and spring assembly (37). 34. Insert two converter housing/main case screws to hold adapter case while pulling out fourth clutch piston (38). D Remove fourth clutch piston assembly (38) from the adapter case. D Remove converter housing/main case screws. 35. Grasp intermediate shaft, twist and pull out the second and third clutch drum assemblies with reverse clutch plates while holding onto output shaft (39).
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NOTE: Insert wire in the center of the spring pin to prevent it from collapsing during removal. Be aware of pin height. Protect machined face of main case. 48. Remove parking lock and range selector lever 17 mm nut (57). 49. Remove parking lock and range selector lever (56), and actuator assembly. 50. Remove selector shaft (58). NOTE: Inspect the shaft for burrs before removing to prevent damaging seal. If necessary, remove burrs by lightly sanding with an oilstone.
36. Separate second (40) and third clutch (41) assemblies. 37. Remove thrust washer (42). 38. Remove reverse clutch plates (43 and 44) and reverse clutch pressure plate (45). 39. Remove bearing (46) and washer (47). 40. Remove planetary carrier assembly (48). 41. Remove thrust bearing (49). 42. Remove reaction sun gear (50) 43. Remove needle bearing (51). 44. Remove brake drum (52). 45. Remove brake band (53). 46. Remove thrust bearing (54).
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Reassembly
1. Inspect selector shaft seal, and replace it if necessary. NOTE: Use a seal installer when replacing the seal. D Install selector shaft. NOTE: Spring pin groove must be positioned inside the case. 2. Install spring pin. Be sure the selector shaft can move freely. Do not push the pin flush with the case surface. Leave enough height for removal. 3. Install actuator assembly (1). 4. Install parking lock and range selector lever (2) and new 17 mm nut. Tighten the nut to the specified torque. Torque: 22 Nm (16 lb ft)
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47. Rotate case to horizontal position, valve body side facing up. D Remove spring pin (55), using cutting pliers, then remove parking lock and selector lever assembly (56).
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11. Install the thrust bearing (9) on the output shaft. NOTE: Use petroleum jelly to hold the thrust bearing in place. 12. Align planetary pinions. Each pinion is marked with double points to indicate the master tooth space and exactly opposite with a single point to indicate the master tooth. The markings on the planetary carrier consist of double lines which are to be lined up with the double points on two opposite pinions; the single lines are to be lined up with the single points on the other two pinions. D After all four pinions are lined up, slide on the third clutch assembly. Rotate third clutch and check mark alignment. Considering that the ring gear tooth between the double points of one planetary pinion is tooth number 1, count the teeth to check that the single points on the two adjacent pinions are between teeth 23 and 24 of the ring gear, and that the ring gear tooth between the double points of the opposite pinion is tooth number 46. If the ring gear and pinions are not lined up, remove, and realign them. 13. Install planetary carrier (8) with third clutch (12). NOTE: Do not force. When properly aligned, the parts will fit together easily.
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5. Rotate main case to vertical position, extension end facing down. D Install brake band assembly (3). NOTE: Be sure to align servo pin area with the servo hole. 6. Install thrust bearing (4). NOTE: The case bushing acts as a guide for the thrust bearing. 7. Install brake drum (5). 8. Install reaction sun gear (6). 9. Install needle bearing (7). 10. Inspect planetary carrier assembly (8) for wear and damage. If necessary replace it. D Measure pinion end play clearance with a feeler gauge. Clearance: 0.13mm0.89mm (0.005 in0.035 in) If clearance is outside specified value, replace the planetary carrier assembly.
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14. Remove the third clutch (12). 15. Install bearing (11) and washer (10).
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18. Install second and third clutch assemblies into the main case. Twist output shaft and clutch assemblies to ensure proper fit.
NOTE: Use petroleum jelly to hold the washer and bearing in place.
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19. Install pressure plate (15) with lip side up, tang facing valve body face. 20. Install reverse clutch plates. Start with a steel plate (17) and alternate with a lined plate (16). 21. Install waved clutch plate (18) with center tang facing valve body side.
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16. Carefully align the second clutch plate inner tangs. D Install thrust washer, tangs pointing downward, and locating tang positioned in slot on second clutch hub. NOTE: Use petroleum jelly to hold thrust washer in place. 17. Install third clutch and intermediate shaft assembly (13) into the second clutch drum (14).
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22. Second clutch end play measurement 1. Install the J23085A Selective washer gauging tool (with spacer ring) on the case flange and against the intermediate shaft. 2. Position the inner shaft of the gauging tool against the thrust surface of the second clutch hub. 3. Tighten thumb screw. Remove the tool. 4. Fit the spacer ring on the inner shaft of the tool. 5. Measure the gap, and select the appropriate washer as shown in the chart. Selective Thrust Washer Gap: mm(in) 1.53 1.63 (0.060 0.064) 1.72 1.82 (0.068 0.072) 1.91 2.01 (0.075 0.079) 2.10 2.20 (0.083 0.087) 2.29 2.39 (0.090 0.094) 2.48 2.58 (0.098 0.102) Color Yellow Red Black
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Natural Green Blue
23. Inspect fourth clutch piston seals and replace if necessary. D Lubricate J38554 fourth clutch piston fitter and install it on fourth clutch piston (19). D Install fourth clutch piston (19) in adapter case (20). D Remove fitter.
FOLLOWING THE PROCEDURE SHOULD RESULT IN FINAL ENDPLAY FROM 0.36 mm TO 0.79 mm (0.014 in TO 0.031 in)
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26. Install selective washer using petroleum jelly. 27. Install two Oring seals (24) in main case and adapter case/main case seal ring (25). 28. Install J38588 guide pins. D Install adapter case and center support assembly to main case.
24. Install retainer and spring assembly (22) into fourth clutch piston (21). 25. Install snap ring (23) in adapter case. D Install J23327 and J2332790 fourth clutch spring compressor. D Seat snap ring in groove. D Remove compressor.
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29. Install thrust washer (26) into adapter case, with tangs pointing downwards. 30. Preassemble overdrive internal gear (27) and thrust bearing assembly (28) onto the turbine shaft and overrun clutch assembly. NOTE: Install bearing assembly, black side up. Use petroleum jelly to keep assembly in place. 31. Install overdrive carrier (30) and internal gear assembly into adapter case. 32. Install fourth clutch plates (29) in the following order: Steel, Lined, Steel, Steel, Lined, Steel. Steel plates go in with short tang facing towards valve body surface.
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33. Install fourth clutch retainer (31) with the notch facing up and positioned towards valve body surface.
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34. Overdrive clutch end play measurement 1. Install the J23085A selective washer gauging tool on the adapter case flange and against the input shaft. 2. Position the inner shaft of the tool against the thrust surface of the overrun clutch housing. 3. Tighten thumb screw. Remove the tool. 4. Measure gap. Select appropriate size washer as shown in the chart. 5. Set selective thrust washer aside. Selective Thrust Washer Gap: mm(in) 1.53 1.63 (0.060 0.064) 1.72 1.82 (0.068 0.072) 1.91 2.01 (0.075 0.079) 2.10 2.20 (0.083 0.087) 2.29 2.39 (0.090 0.094) 2.48 2.58 (0.098 0.102) Color Yellow Red Black Natural Green Blue
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35. Install selective washer (32). NOTE: Use petroleum jelly to hold selective washer in place. 36. Install gasket (33). 37. Install converter housing and oil pump assembly (34) to adapter case. D Fit and tighten seven outer 13 mm screws. Torque: 39 Nm (29 lb ft)
FOLLOWING THE PROCEDURE SHOULD RESULT IN FINAL ENDPLAY FROM 0.1 mm TO 0.8 mm (0.004 in TO 0.03 in)
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6. Remove axial play checking tool and puller. NOTE: If end play is not correct, repeat selective washer selection.
D Ensure free rotation of pump using J2308201 oil pump rotation tool.
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39. Inspect extension housing oil seal and replace if necessary, using J36797 extension housing oil seal installer. D Rotate transmission to horizontal position, with valve body side down. D Inspect parking wheel seal ring. necessary.
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Replace if
D Install wheel parking lock assembly (35). 40. Install speed wheel (36) and snap ring (37). NOTE: Use extra long, needle-nose pliers. 41. Install gasket onto extension assembly with a thin coating of oil. D Install extension housing assembly (38), and align parking pawl shaft. D Install actuator assembly into extension assembly. D Install seven 8 mm hexagon socket head screws. Torque: 32 Nm (24 lb ft) 42. Inspect speed sensor Oring. Replace if necessary. D Install speed sensor assembly (39) and 10 mm screw. Torque: 9 Nm (78 lb in)
38. Overdrive clutch end play measurement 1. Fit J25022 and J247731 turbine shaft puller on turbine shaft. 2. Position axial play checking tool on converter housing mating face. 3. Pull turbine shaft upwards with puller until first resistance is met. (due to weight of overdrive assembly). 4. Maintain shaft in this position and set indicator to zero. 5. Pull turbine shaft further upwards with puller. Read end play shown on indicator. End play: 0.1mm 0.8mm (0.004 in 0.031in)
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43. Main case end play measurement 1. Attach axial play checking tool on the extension housing and set indicator to zero on output shaft. 2. Manually push output shaft upwards. End play: 0.36mm 0.80mm (0.014 in 0.031in) 3. Remove axial play checking tool. 4. If end play is not correct, repeat selective washer selection.
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44. Inspect servo piston seal ring. Replace if necessary. D Ensure brake band is correctly positioned. Rotate output shaft if necessary. D Install J38428 servo piston fitter in servo bore. D Install apply rod (40), round end toward band, return spring (41) and piston assembly (42). 45. Install the J23075 servo spring compressor with offset to rear of case. D Compress servo piston seal ring, using fitter while tightening the tool screw. D Install servo piston retaining ring (43). D Remove tool. D Adjust the brake band by tightening the servo adjusting screw to 4.5 Nm torque. Be certain the lock nut is loose, then backoff the screw five turns exactly. Hold piston sleeve with wrench and tighten lock nut to 18.5 Nm torque. Be certain the adjusting screw does not turn.
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7A56

NOTE: Valve must be extended as the short end of manual valve link is connected to the range selector lever. Long end of link goes into valve. D Install seven 13 mm screws. Torque: 20 Nm (15 lb ft) D Remove two guide pins. 49. Install servo cover gasket, cover (46) and four 13 mm screws. Torque: 25 Nm (18 lb ft) 50. Connect wiring harness (47) to band control, shift solenoids, and main case 7 way connector. 51. Install manual detent roller and spring assembly (48) with clip. D Install two 13 mm screws. Torque: 20 Nm (15 lb ft) 52. Install oil filter (49), and three 13 mm screws. Torque: 20 Nm (15 lb ft) 53. Install oil pan gasket, magnet, main oil pan (50), and sixteen 10 mm screws. Torque: 11 Nm (96 lb in) 54. Inspect adapter case electrical connector and seal. Replace if necessary. D Install electrical five pin connector and harness assembly (52) in bottom of adapter case. 55. Install gasket, transfer plate, and gasket. D Install adapter case valve body (51) and seven 13 mm screws. Torque: 20 Nm (15 lb ft) 56. Connect wiring harness harness assembly (52) to converter clutch PWM solenoid, force motor, and 4 way connector. 57. Install oil pan gasket, adapter case oil pan (53), and twelve 10 mm screws. Torque: 11 Nm (96 lb in) D Rotate transmission, with bottom pan facing down. 58. Install mode switch (54), two 10 mm screws, selector lever nut, and cover. 10 mm screw Torque: 13 Nm (113 lb in) Nut Torque: 23 Nm (17 lb ft) D Adjust using setting tool, refer to Mode Switch in this section. 59. Install Oring (55) on turbine shaft. 60. Install torque converter (56). The converter assembly must be replaced under any of the following conditions: a. Evidence of damage to the pump assembly. b. Metal particles are found after flushing the cooler lines. c. External leaks in hub weld area. d. Converter pilot broken, damaged, or poor fit into crankshaft.
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46. Install two check balls (44).
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47. Inspect main case electrical connector and seal, replace if necessary. D Install electrical 7 way connector/main case and wiring harness. 48. Install two J25025B guide pins into main case. D Install main case valve body complete assembly (45) and manual valve link.

e. Converter hub scored or damaged. f. Internal failure in stator. g. Contamination from engine coolant. h. Excess end play. D Rotate transmission, bell housing up. converter to insure proper fit.
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61. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRONIII. Refer to Changing Transmission Fluid in this section. Spin
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7A58
Converter Housing And Oil Pump Assembly

Disassembled View
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Legend (1) Converter Housing (2) Outer Seal Ring (3) Gasket
(4) Wear Plate (5) Oil Pump Assembly (6) Oil Seal Ring
Disassembly
1. Remove oil pump assembly from converter housing. 2. Remove outer seal ring. 3. Remove gasket. 4. Remove wear plate. 5. Remove oil seal ring.
D Tighten five inner 13mm bolts in an alternating pattern. Torque: 20 Nm (15 lb ft)

Visual Check:
If any damage, deformation, or local wear is found in a converter housing, outer seal ring, wear plate, or oil seal ring, replace it.
Reassembly
1. Install wear plate onto oil pump assembly. 2. Install converter housing onto complete oil pump assembly. Align with two short J38588 guide pins on outer bolt holes. D Loosely install five 13mm bolts. D Center converter housing using J38557 centering tool. 3. Install oil seal ring (3 screws). Torque: 3 Nm (26 lb in) 4. Install gasket. 5. Install outer seal ring.
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Oil Pump
Disassembled View
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Legend (1) Oil Pump Drive Gear (2) Oil Pump Driven Gear (3) Pin (4) Plug (5) Seal Ring (6) Torque Converter Clutch Control Valve (7) Converter Clutch Control Valve Spring (8) Pin (9) Converter Clutch Regulator Sleeve (10) Converter Clutch Regulator Spring (11) Converter Clutch Regulator Valve (12) Isolator Spring (13) Isolator Valve (14) Pin
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29)
Enable Valve Spring Guide Enable Valve Spring Enable Valve Snap Ring Spring Seat Throttle Signal Accumulator Spring Throttle Signal Accumulator Piston Sleeve Pin Boost Valve Sleeve Boost Valve Spring Seat Pressure Regulator Valve Spring Spring Seat Pressure Regulator Valve Oil Pump Assembly
Disassembly
1. Remove oil pump drive gear (1) and driven gear (2). 2. Remove pin (3) from oil pump assembly (29). 3. Remove plug (4) and seal ring (5), torque converter clutch control valve (6) and spring (7). 4. Remove pin (8) from oil pump assembly (29).
5. Remove torque converter regulator sleeve (9), converter clutch regulator spring (10), converter clutch regulator valve (11), isolator spring (12) and isolator valve (13). 6. Remove pin (14) from oil pump assembly (29). 7. Remove enable valve spring (16), spring guide (15) and enable valve (17). 8. Remove snap ring (18) from oil pump assembly (29).
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9. Remove spring seat (19), spring (20) and throttle signal accumulator piston (21). 10. Remove sleeve pin (22) from oil pump assembly (29). 11. Remove boost valve sleeve (23), boost valve (24), spring seat (25), valve spring (26), spring seat (27), and pressure regulator valve (28).

Visual Check:
If any damage, deformation or wear is found, replace the damaged part.
Reassembly
1. Lubricate and preinstall pressure regulator spring seat (27) on valve (28), with the flat side against shoulder. 2. Install pressure regulator valve (28) and spring seat (27) assembly, valve spring (26), and spring seat (25) with the flat side away from spring to oil pump assembly (29). 3. Assemble boost valve (24) into sleeve (23). 4. Install boost valve and sleeve assembly, and sleeve pin (22) to oil pump assembly (29). 5. Install throttle signal accumulator piston (21), spring (20), and spring seat (19), with the flat side away from the spring, and snap ring (18) to oil pump assembly (29). 6. Install enable valve (17), spring guide (15), enable valve spring (16) and retainer pin (14) to oil pump assembly (29). 7. Assemble torque converter regulator spring (10) and torque converter regulator valve (11) into sleeve (9). 8. Install isolator valve (13), isolator valve spring (12) and the torque converter regulator sleeve and valve assembly into the oil pump assembly (29). 9. Install torque converter clutch control valve spring (7), torque converter clutch control valve (6), plug (4) and seal ring (5), and retainer pin (3) to oil pump assembly (29). 10. Install oil pump driven gear (2) and drive gear (1).
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Main Case Valve Body

Disassembled View
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Legend (1) Gaskets and Transfer Plate (2) Manual Valve (3) Band Control Solenoid (4) Pin (5) Waved Washer (6) Spring Pin (7) Solenoid A (8) Retainer (9) 12/34 Shift Valve (10) Spring (11) Spring Pin (12) Solenoid B (13) Retainer (14) 23 Shift Valve
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Spring Spring Pin Plug Spring Low Pressure Control Valve Spring Pin Plug Band Control Screen Assembly Spring Pin Plug 12 Accumulator Valve 12 Accumulator Control Valve Check Ball Main Case Valve Body
Disassembly
1. Remove two 11mm bolts from valve body (28), then remove gaskets and transfer plate (1). 2. Remove manual valve (2). 3. Push in band control solenoid (3) to compress waved washer (5), and remove pin (4). 4. Remove band control solenoid (3) and waved washer (5).
5. Remove spring pin (6) with a 3 mm dia punch. 6. Remove solenoid A (7) by grasping the metal tip. Do not grasp the connector housing. 7. Remove retainer (8), 12/34 shift valve (9), and spring (10). 8. Remove spring pin (11) with a 3 mm dia punch. 9. Remove solenoid B (12) by grasping the metal tip. Do not grasp the connector housing.
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9. Install gasket (valve body/transfer plate) and transfer plate using two J33872 guide pins. D Install two 11mm bolts. Torque: 13 Nm (113 lb in)
10. Remove retainer (13), 23 shift valve (14), and spring (15). 11. Remove spring pin (16), plug (17), spring (18), and low pressure control valve (19). 12. Remove spring pin (20), plug (21), and band control screen assembly (22). 13. Remove spring pin (23), plug (24), 12 accumulator valve (25), and 12 accumulator control valve (26). 14. Remove check ball (27) from valve body (28).

Inspect for the following, and replace any damaged or worn parts: 1. Damage or wear to each valve. 2. Damage in oil passeges. 3. Cracks or damage to valve body. 4. Valve operations. 5. Spring fatigue.
Reassembly
1. Install 12 accumulator control valve (26), 12 accumulator valve (25), plug (24), and spring pin (23). 2. Install band control screen assembly (22), plug (21), and spring pin (20). 3. Install low pressure control valve (19), spring (18), plug (17), and spring pin (16). 4. Install spring (15), 23 shift valve (14), retainer (13), solenoid B (12), and spring pin (11). 5. Install spring (10), 12/34 shift valve (9), retainer (8), solenoid A (7), and spring pin (6). 6. Install waved washer (5), band control solenoid (3), and pin (4). 7. Install manual valve (2). 8. Install check ball (27) to valve body (28).
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D Install gasket (transfer plate/main case).
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Adapter Case Valve Body

Disassembled View
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Legend (1) Bracket (2) Converter Clutch PWM Solenoid (3) Retainer (4) Force Motor Solenoid (5) Retainer (6) Plug (7) 3/4 Accumulator Valve (8) 3/4 Accumulator Control Valve
(9) (10) (11) (12) (13) (14) (15) (16)
Spring Retaining Ring Feed Limit Valve Plug Retainer ORing Plug Force Motor Screen Assembly Adapter Case Valve Body
Disassembly
1. Remove 11mm bolt from valve body. D Remove bracket (1) and converter clutch PWM solenoid (2). 2. Remove 11mm bolt and retainer (3) from valve body. D Remove force motor solenoid (4). 3. Remove retainer (5), plug (6), 3/4 accumulator valve (7), and 3/4 accumulator control valve (8). 4. Remove spring (9), retaining ring (10), and feed limit valve (11). 5. Remove plug retainer (12), Oring (13), plug (14), and force motor screen assembly (15). D Use 5 mm bolt to pull plug.

Inspect for the following, and replace any damaged or worn parts: 1. Damage or wear to each valve. 2. Damage in oil passeges. 3. Cracks or damage to valve body. 4. Valve operations. 5. Spring fatigue.
Reassembly
1. Install force motor screen assembly (15), plug (14), Oring (13), and plug retainer (12).
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2. Install feed limit valve (11), retaining ring (10), and spring (9). 3. Install 3/4 accumulator control valve (8), 3/4 accumulator valve (7), plug (6), and retainer (5). 4. Install force motor solenoid (4). D Place solenoid terminals pointing towards mating face. D Install retainer (3) and bolt. Torque: 10 Nm (87 lb in) 5. Install converter clutch PWM solenoid (2) with two Orings (2) and bracket (1) to valve body. D Install bolt. Torque: 10 Nm (87 lb in)
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Third Clutch And Sprag Unit

Disassembled View
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Legend (1) Retaining Ring (2) Input Sun Gear and Sprag Unit Assembly (3) Retaining Washer (4) Bearing
(5) (6) (7) (8)
Thrust Washer Clutch Plates Third Clutch Spring Cushion Plate Third Clutch Drum Assembly
Disassembly
1. Place the third clutch drum and intermediate shaft assembly upright, using the overdrive internal gear as a support. 2. Locate the ends of the retaining ring. Depress one end of the ring using a small screwdriver instead of the depressor handle provided with the tool J-38450-A. Slide one blade down between the third clutch drum and the retaining ring. 3. Remove a screwdriver and repeat this step for the other end of retaining ring. 4. Install the remaining four blades approximately (five) notches apart using a screwdriver to depress the retaining ring. 5. Pull up on input sun gear and sprag unit assembly (1 and 2) to release the retaining ring from third clutch drum assembly (8). 6. Remove the tool blades.
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7. Remove retaining washer (3), bearing (4), thrust washer (5), and clutch plates (6 and 7) from the third clutch drum assembly (8).

Visual Check:
7A66
Reassembly
1. Place third clutch drum and intermediate shaft assembly upright, using the overdrive internal gear as a support. 2. Install third clutch spring cushion plate (7), bevel face down. 3. Install third clutch plates (6) into third clutch drum assembly (8). Start with the steel clutch plate and alternate with lined plates. 4. Install thrust washer (5), bearing (4), and retaining washer (3). 5. Fully engage the hub splines of the input sun gear and sprag unit assembly (2) into the third clutch inner tangs. D Simultaneously rotate the outer sprag race to engage into the third clutch drum assembly (8). 6. Place J-38450-A blades between the retaining ring and the third clutch drum apporximately (five) notches apart, and one blade at each end of the retaining ring (1). Push down on sprag assembly until the assembly is seated into the third clutch drum assembly (8). 7. Remove the tool blades and engage retaining ring into groove of third clutch drum.
248RX002
7A67
Third Clutch
Disassembled View
248RS006
Legend (1) Retaining Ring (2) Spring Seat
(3) Springs (4) Piston Assembly (5) Third Clutch Drum
Disassemble
1. Compress spring seat using the J23075 spring compressor and J2307512 adapter tool. NOTE: Do not overstress the springs and seat. This will cause damage to the spring seat. D Remove the tool. D Remove retaining ring (1).
2. Release the spring seat (2). NOTE: Do not let the spring seat catch in the ring groove. D Remove spring seat (2) and springs (3). 3. Remove piston assembly (4) from third clutch drum (5).

Visual check:
Operation check:
Shake the piston and listen for check ball movement indicates proper check ball operation. Replace the piston if the check ball is missing or falls out.
Reassembly
1. The lip of the piston seal must point toward the front of the transmission. Lubricate the seal lip with transmission fluid. D Install piston assembly (4) into the third clutch drum (5). Use the J23084 third clutch piston installer to protect the outer seal during installation. D Remove the seal installer.
248RS007
7A68
248RS008
2. Install twelve springs (3) and spring seat (2). 3. Place retaining ring (1) onto spring seat. D Compress the piston springs, using the J23075 piston spring compressor and J2307512 adapter. CAUTION: Do not over stress the springs and seat. Do not let the spring seat catch in the ring groove. This may cause damage to the spring seat. D Install spring seat retaining ring (1). D Remove the piston spring compressor and adapter.
7A69
Sprag Unit
Disassembled View
248RS009
Legend (1) Retaining Ring (2) Sprag Outer Race (3) Ring
(4) Sprag Assembly (5) Ring (6) Third Clutch Hub and Sun Gear Assembly
Disassembly
1. Remove the sprag outer race, retaining ring, and sprag assembly from the third clutch hub and sun gear assembly. 2. Remove the rings and sprag assembly from the sprag outer race.
NOTE: Check correct rotation by holding the sun gear in your left hand and turning the outer race. The outer sprag race should turn freely towards you and should lock turning away from you.

Visual Check:
Reassembly
NOTE: Flared shoulder of the sprag cage faces the sun gear. This procedure must be followed exactly to be sure that the sprag assembly is installed properly. 1. Install rings and sprag assembly onto the third clutch hub and sun gear. 2. Install sprag outer race and retaining ring assembly over the sprag cage assembly. D Place third clutch hub and sun gear assembly on a flat surface, sun gear facing up. Place sprag outer race and sprag assembly over the sun gear assembly, push down and turn the input sun counterclockwise at the same time.
248RS010
7A70
Second Clutch
Disassembled View
247RW001
Legend (1) Retaining Ring (2) Ring Gear (3) Retaining Ring (4) Spacer (5) Clutch Plates
(6) (7) (8) (9) (10) (11)
Waved Washer Retaining Ring Spring Seat Springs Piston Assembly Second Clutch Drum
Disassembly
1. Remove retaining ring (1) from second clutch drum (11). 2. Remove ring gear (2), retaining ring (3), and spacer (4). 3. Remove clutch plates (5) and waved washer (6). 4. Remove retaining ring (7) using J23327 compressor to compress the spring seat (8). 5. Remove spring seat (8), springs (9) and piston assembly (10) from second clutch drum (11).
247RS006
7A71

Visual Check:
2. Install twentytwo piston springs (9) and spring seat (8) on the second clutch piston (10). Place retaining ring (7) onto spring seat. D Use the J23327 compressor to compress the piston springs. NOTE: Do not let spring seat catch in ring groove. D Remove the compressor. 3. Install waved plate (6) and clutch plates (5). Start with a steel plate and alternate with lined plates. D Align second clutch inner tangs. 4. Install spacer (4), with the fluted end toward clutch plates. 5. Install retaining ring (3), ring gear (2) and retaining ring (1).
Operation Check:
Shake the piston and listen for check ball movement. Movement indicates proper check ball operation. Replace the piston if the check ball is missing or falls out.
Reassembly
1. Install piston assembly (10) into the second clutch drum (11). D Lubricate the lip seal with transmission fluid. Use the J23080A second clutch piston installer to protect the outer piston lip seal. NOTE: Lip of the seal should point toward front of transmission. D Remove the installer.
247RS007
7A72
34 Accumulator Piston
Disassembled View
244RS005
Legend (1) Snap Ring (2) Cover
(3) Spring (4) Piston Assembly
Disassembly
1. Install the J38559A cover compressor on adapter case. D Compress piston cover then remove snap ring.
2. Install the J41096 cover remover and J38584 adapter to center hole of cover. D Use the J23907 slide hammer to remove cover. 3. Remove spring and piston assembly.
242RW001 242RS007
7A73

Visual Check:
Reassembly
1. Place the J38553 piston fitter into adaptor case and push the piston into position, using suitable diameter tube. D Remove the piston fitter.
244RS006
2. Install spring and cover. 3. Install snap ring, using the J38559A compressor tool. D Install snap ring in groove. D Remove the compressor tool.
242RS007
7A74
Reverse Clutch Piston And Center Support

Disassembled View
242RY001
Legend (1) Retaining Ring (2) Spring Seat (3) Springs (4) Piston Assembly (5) Center Support (6) Gasket (7) Transfer Plate (8) Gasket
(9) (10) (11) (12) (13) (14) (15) (16) (17)
Restrictor Retainer Plate Plug Spring Overrun Lock Out Valve Retainer Plate Plug Spring Reverse Lock Out Control Valve
Disassembly
1. Install the J23327 compressor tool on spring seat, then compress the spring seat. D Remove retaining ring (1). NOTE: Do not overstress the springs and seat, as this will cause damage to the spring seat. D Remove the compressor tool.
7A75
247RS008
242RS005
2. Remove spring seat (2) and springs (3). 3. Remove piston assembly (4). 4. Remove 8 bolts from center support (5), then remove center support (5) from adapter case. 5. Remove gasket transfer plate/outer support (6), center support transfer plate (7), and gasket transfer plate/adapter case (8). 6. Remove restrictor (9) from adapter case housing. 7. Remove retainer plate (10), plug (11), spring (12), and overrun lock out valve (13) from center support (5). 8. Remove retainer plate (14), plug (15), spring (16) and reverse lock out valve (17) from center support (5).
6. Install gasket transfer plate/adapter case (8), center support transfer plate (7), and gasket transfer plate/center support (6). 7. Install center support (5) with 8 bolts. Torque : 25 Nm (18 lb ft) 8. Install piston assembly (4) into center support (5). 9. Install twenty four springs (3), spring seat (2), and retaining ring (1). D Install the J23327 compressor and compress spring seat (2) and springs (3), then seat snap ring (1) in groove. D Remove the tool.

Visual Check:
Reassembly
1. Install reverse lock out valve (17) and spring (16) to center support. NOTE: Ensure correct assembly of valve. The spring should be located over the long small diameter end. 2. Install plug (15) and retainer plate (14). 3. Install overrun lock out valve (13) and spring (12) to center support. NOTE: Ensure correct assembly of valve. The spring should be located over the long small diameter end. 4. Install plug (11) and retainer plate (10). 5. Place restrictor (9) in the lube overdrive channel in the adapter case housing.
7A76
Overrun Clutch And Turbine Shaft

Disassembled View
252RW005
Legend (1) Snap Ring (2) Overdrive Carrier Assembly (3) Sun Gear (4) Turbine Shaft (5) Snap Ring (6) Backing Plate (7) Clutch Plates
(8) (9) (10) (11) (12) (13) (14) (15)
Snap Ring Overrun Roller Clutch Cam Roller Clutch Assembly Overrun Clutch Release Spring Retainer Diaphragm Spring Piston Assembly Overrun Clutch Drum Turbine Shaft Seal Rings
7A77
Disassembly
1. Position overrun clutch assembly upright, using the overdrive internal gear as a support. D Remove snap ring (1).

Overdrive Carrier Check
D Check pinion end play with a feeler gauge. Clearance: 0.24mm0.64mm (0.0094in0.025in) If clearance is outside specified value, replace overdrive carrier assembly.
252RS009
2. Remove overdrive carrier assembly (2), sun gear (3) and turbine shaft (4). 3. Remove snap ring (5), backing plate (6), and clutch plates (7). 4. Compress diaphragm spring with the J2332791 compressor, then remove snap ring (8).
252RS011
Visual Check:
If any damage, deformation or local wear is found, replace the damaged part.
Reassembly
1. Install turbine shaft seal rings (15) with grease (petroleum jelly).
252RS010
5. Remove overrun roller clutch cam (9) and roller clutch assembly (10). 6. Remove overrun clutch release spring retainer (11) and diaphragm spring (12). 7. Remove piston assembly (13) from overrun clutch drum (14). 8. Remove turbine shaft seal rings (15).
241RS008
7A78

3. Install diaphragm spring (12). 4. Install overrun clutch release spring retainer (11) (lip faces upwards), overrun roller clutch assembly (10), and cam (9). 5. Place snap ring loosely on spring retainer. D Hold the J2332791 compressor in a vise and compress piston return spring with compressor. D Set snap ring (8) in ring groove. D Remove the compressor. 6. Install clutch plates (7), start with steel plate and alternate with lined plates. 7. Install backing plate (6). 8. Install snap ring (5). 9. Install overdrive sun gear with countersink pointing downwards. 10. Install the overdrive carrier assembly (2). NOTE: Turn the assembly in a counterclockwise direction only until roller clutch enters the outer race. After installation, rotate the assembly and listen for loose rollers. 11. Install turbine shaft (4) and snap ring (1).
2. Install the J38555 inner installer on the drum (14). D Preinstall piston assembly into J38555 outer installer. D Install overrun clutch piston assembly (13). Use the outer installer while pushing piston into drum (14). D Remove the installer.
252RS012
252RS013
7A79
Main Data And Specification

Remarks Model Engine Type THM 4L30E V6 3.5L 6VE1 Automatic four speed overdrive in 4th gear lockup clutch torque converter Shift control Control systems Shift pattern Shift quality Lockup clutch 1st 2nd Gear ratio 3rd 4th (O/D) Reverse Gear set Oil used Torque converter Reverse clutch Second clutch Third clutch Brake band Fourth clutch Overrun clutch Overdrive Principal Input sun gear Pinion gear Ravigneaux g planetary gear set Long pinion Ring gear Long pinion Output sun gear Sun gear Overdrive O d i planel tary gear set Pinion gear Ring gear C4 OC OFW PFW RC C2 C3 Name Qty liter (qt) Hydraulic Electronic Electronic Electronic 2.856 1.618 1.000 0.723 2.000 Noiseless, high torque capability ATF DEXRONIII 8.6 (9.1) 2,100 150 4 6 6 Double wrap 2 1 10 26 30 19 23 90 19 46 31 24 81 Number of teeth Number of discs Number of rollers Number of sprags Number of discs Stall speed (rpm) DOHC
7A80
E07RY00013
7A81
E07RY003
7A82
E07RY001
7A83
Special Tools
J23075 Spring compressor (For servo piston)
J23085A Selective washer gauging tool
J38450A Third clutch snap ring compressor
J2332790 Fourth clutch spring compressor (Use with J23327)
J2307512 Third clutch spring compressor adapter (Use with J23075)
J38553 3/4 Accumulator piston fitter
J23084 Third clutch piston installer
J41096 Cover remover (Use with J38584)
J23327 Third clutch spring compressor
J38584 Slide hammer adapter (Use with J23907)
J23080A Second clutch piston installer
J38554 Fourth clutch piston fitter
7A84

TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME
ILLUSTRATION
J38588 Guide pins; adapter case to main case
J2308201 Oil pump rotation tool
J38555 Overrun clutch piston seal installer set
J25025B Guide pins; valve body to main case
J33872 Guide pins; gasket and transfer plate to valve body
J38428 Servo piston fitter
J25022 Turbine shaft puller (Use with J247731)
J2332791 Overrun clutch spring compressor
J23129 Oil seal remover (Use with J23907 and J38584)
J38559A 3/4 Accumulator piston cover compressor
J38557 Oil pump centering tool
J876302 Holding fixture

7A85
J36797 A/T extension housing oil seal installer (Inside)
J29770A Pressure gauge
J247731 End play fixture (Use with J25022)
J23907 Slide hammer
7A86
4L30E Parts List

Case And Associated Parts
241RY00001
Legend (1) Torque Converter (2) Screw, Seal Ring Assembly (3) Seal Ring Assembly, Converter Housing (4) Screw, Converter Housing/Main Case (5) Screw, Converter Housing/Oil Pump (6) Housing, Converter (7) Plug, Converter Housing (8) Seal, ORing (9) Wear Plate, Oil Pump Body (10) Pump Assembly, Oil (11) Gasket (12) Washer, Thrust Selective (13) Ring, Snap (14) Cover, 34 Accumulator Piston (15) Seal, ORing, 34 Accumulator (16) Spring, 34 Accumulator Piston
(17) (18) (19) (20) (22) (23) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37)
Pin, 34 Accumulator Piston Piston, 34 Accumulator Ring, 34, Accumulator Piston Case, Adapter Connector, Electrical/Adapter Case Screw, Pan Restrictor, Oil Gasket, Transfer Plate/Adapter Plate, Transfer Adapter/Center Support Support Assembly, Center Screw, Center Support Ring, Oil Seal Seal, ORing Main Case Fitting, Cooler Fitting Assembly, Cooler Case, Main Breather, Pipe

(38) (39) (42) (43) (44) (45) (46) (50) (52) (53) (54) (55) (56) (57) (58) (59) (60) (61) (62) (63) (64) (65) (67) (68) (69) (70) (71) (72) (73) (74) Seal, ORing Reservoir Gasket, Extension Case Extension Assembly Seal, ORing/Speed Sensor Sensor Assembly, Speed Screw, Speed Sensor Seal, Extension Assembly Screw, Extension/Main Case Spring, Parking Pawl Lock Pawl, Parking Lock Connector, Electrical/Main Case Actuator Assembly, Parking Lock Nut, Parking Lock Lever Link, Manual Valve Pin, Spring Lever, Parking Lock and Range Selector Shaft, Selector Seal, Selector Shaft Mode Switch Assembly Screw and Conical Washer Assembly Shield, Mode Switch Pan, Bottom/Adapter Case Gasket, Bottom Pan/Adapter Case Harness Assembly, Adapter Case Screw, Valve Body Valve Body Assembly, Adapter Case Gasket, Adapter Valve Body Plate, Adapter Valve Body/Transfer Pan, Bottom/Main Case (75) (76) (77) (78) (79) (80) (82) (84) (85) (86) (87) (88) (89) (90) (91) (92) (93) (94) (95) (96) (97) (98) (99) (100) (101) (102) (103) (104) (105) (106)
7A87
Gasket, Bottom Pan/Main Case Gasket, Oil Drain or Overfill Screw Screw, Oil Drain or Overfill Magnet, Chip Collector Filter Oil Harness Assembly, Main Case Roller and Spring Assembly, Manual Detent Valve Body Assembly, Main Case Ball, Check Gasket, Main V.B./Transfer Plate Plate, Main V.B./Transfer Gasket, Transfer/Main Case Screw, Transfer Plate on V.B. Screw, Servo Cover Cover, Servo Piston Gasket, Cover/Servo Piston Ring, Retaining Servo Piston Clip, Servo Piston Nut, Servo Screw Screw, Servo Piston Piston, Servo Seal, Ring/Servo Piston Spring, Cushion/Servo Piston Seat, Cushion Spring Sleeve, Servo Piston Adjust Rod, Apply/Servo Piston Spring, Return/Servo Piston Gasket, Adapter Case/Transfer Plate Powertrain Control Module Servo Piston Assembly
7A88
Pump Assembly
241RY003
Legend (201) Gear, Oil Pump Drive (202) Gear, Oil Pump Driven (203) Pin, Plug Converter Clutch Control (204) Plug, Converter Clutch Control Valve (205) Spring, Converter Clutch Control Valve (206) Valve, Converter Clutch Control (207) Ring, Snap/Throttle Signal Accumulator (208) Seat, Spring/Throttle Signal Accumulator (209) Spring, Throttle Signal Accumulator (210) Piston, Throttle Signal Accumulator (211) Pin, Boost Valve Sleeve (212) Sleeve, Boost Valve (213) Valve, Boost (214) Seat, Spring/Pressure Regulator Valve
(215) (216) (217) (218) (219) (220) (221) (222) (223) (224) (225) (226) (227) (228) (229)
Spring, Pressure Regulator Valve Seat, Spring/Pressure Regulator Valve Valve, Pressure Regulator Isolator Valve Spring, Isolator Valve, Converter Clutch Regulator Spring, Converter Clutch Regulator Sleeve, Converter Clutch Regulator Pin, Retainer Sleeve Valve, Enable Spring, Enable Valve Spring Guide, Enable Valve Pin, Enable Valve Pump Assembly Seal Ring, Plug
7A89
Valve Body Assemblies
244RS009
Legend (301) Body, Valve Main Case (302) Pin, Spring (303) Solenoid Assembly, ON/OFF N.C. (304) Valve, 12 and 34 Shift (305) Spring, 12 and 34 (23) Shift (306) Retainer, Valve (307) Solenoid Assembly, ON/OFF N.O. (308) Valve, 23 Shift (309) Pin, Spring (310) Plug, Valve Bore
(311) (312) (317) (318) (320) (321) (322) (323) (324) (325) (326)
Spring, Valve Low Pressure Control Valve, Low Pressure Control Ball, Check Valve, 12 Accumulator Control Valve, 12 Accumulator Washer, Waved PWM Solenoid Pin, Solenoid PWM Solenoid Assembly, Band Control PWM Screen Assembly, PWM Solenoid Plug, Screen Valve, Manual
7A90
243RY002
Legend (401) Body, Valve/Adapter Case (402) Screw, Solenoid Force Motor (403) Retainer, Force Motor (404) Solenoid, Force Motor (405) Plug, 34 Accumulator (406) Plug and Spring Retainer (407) Valve, 34 Accumulator (409) Valve, 34 Accumulator Control
(410) (411) (412) (413) (414) (415) (416) (417) (418)
Spring, Feed Limit Valve Ring, Retainer Valve, Feed Limit Seal, ORing Plug Filter Plug, Screen Screen Assembly, Force Motor Solenoid, Torque Converter Clutch, PWM Retainer, Screen Plug Bracket, PWM Solenoid
7A91
Overdrive Internal Components
252RW003
Legend (501) Retainer, 4th Clutch (502) Plate, 4th Clutch (Steel) (503) Plate Assembly, 4th Clutch (Lined) (504) Retainer And Ball Assembly, Check Valve (505) Seal, ORing/Turbine Shaft (506) Shaft, Turbine (508) Ring, Oil Seal/Turbine Shaft (510) Housing, Overrun Clutch (513) Piston, Overrun Clutch (514) Spring, Overrun Clutch Release (515) Retainer, Release Spring/Overrun Clutch (516) Roller Assembly, Overdrive Clutch (517) Cam, Overdrive Roller Clutch (518) Ring, Snap/Overrun Clutch Hub (519) Gear, Overdrive Sun
(520) (521) (522) (523) (524) (525) (526) (527) (528) (529) (530) (531) (532) (533) (534)
Plate, Waved/Overrun Clutch Plate, Overrun Clutch (Steel) Plate Assembly, Overrun Clutch (Lined) Plate, Backing/Overrun Clutch Ring, Snap/Overrun Clutch Housing Carrier Assembly, Overdrive Complete Ring, Snap/Turbine Shaft/Carrier Bearing Assembly, Thrust Gear, Overdrive Internal Washer, Thrust/Internal Gear/Support Ring, Snap/Adapter/4th Clutch Spring Retainer and spring assembly, 4th clutch Piston, 4th Clutch Seal, 4th Clutch Piston (Inner) Seal, 4th Clutch Piston (outer)
7A92
Internal Components
247RW002
Legend (608) Seal, Reverse Clutch Piston (Inner) (609) Seal, Reverse Clutch Piston (Outer) (610) Piston, Reverse Clutch (611) Spring, Piston Clutch (612) Seat, Spring/Reverse Clutch (613) Ring, Retaining (614) Plate, Waved/Reverse Clutch (615) Plate, Reverse Clutch (Steel) (616) Plate Assembly, Reverse Clutch (Lined) (617) Plate, Reverse Clutch Pressure/Selective (618) Drum Assembly, 2nd Clutch (620) Seal, 2nd Clutch Piston (Inner) (621) Seal, 2nd Clutch Piston (Outer) (622) Piston, 2nd Clutch (623) Seat, Spring/2nd Clutch (625) Plate, Waved/2nd Clutch (626) Plate, 2nd Clutch (Steel)
(627) (628) (629) (630) (631) (632) (634) (635) (636) (637) (638) (639) (640) (641) (642) (643) (644) (645)
Plate Assembly, 2nd Clutch (Lined) Spacer, 2nd Clutch Ring, Retaining Gear, Ring Washer, Thrust/2nd Clutch/3rd Clutch Thrust Washer, Clutch Hub Drum Assembly, 3rd Clutch Seal, 3rd clutch piston (Inner) Washer, Retaining Seal, 3rd Clutch Piston (Outer) Piston 3rd Clutch Seat, Spring/3rd Clutch Ring, Retaining Plate, Spring Cushion/3rd Clutch Plate, 3rd Clutch (Steel) Plate Assembly, 3rd Clutch (Lined) Washer, Thrust/Input Sun Bearing, Input Shaft/Gear Assembly

(646) (647) (648) (649) (650) (651) (652) (653) Gear Assembly, Input Sun Race Assembly, Sprag Ring, Retaining/Sprag Ring, Retaining Cage Assembly, Sprag Bearing, Output Shaft/Input Sun Washer, Output Shaft/Input Sun Carrier Assembly, Planetary (658) (659) (664) (667) (668) (672) (673) (675) Gear, Reaction Sun Drum, Reaction Sun Band Assembly, Brake Seal, Ring/Wheel Parking Lock Wheel, Parking Lock Wheel, Speed Ring, Retaining Bearing, Thrust Assembly
7A93
Center Support Assembly
242RY002
Legend (701) Center Support (702) Retainer Plate (703) Plug, Lockout
(704) Spring, Lockout (705) Valve, Overrun Lockout (706) Valve, Reverse Lockout Control
7A94
Extension Housing Assembly Oil Seal

Extension Housing Assembly Rear Oil Seal and Associated Parts
220RY00010
Legend (1) Propeller Shaft (2) End Nut and Companion Flange
(3) Oil Seal (4) Mass
Removal
1. Disconnect the propeller shaft (1) and mass (4) from the extension housing assembly. 2. Remove end nut and companion flange (2), using the companion flange holder J861411.
Installation
1. Install oil seal and apply engine oil to the oil seal outer surfaces. 2. Apply the recommended grease (BESCO L2) or equivalent to the oil seal lip. 3. Use the oil seal installer J39208 to install the rear seal (3) to the extension housing assembly.
266RW001
3. Use the universal puller to remove the companion flange and Oring. 4. Remove the oil seal from the extension housing assembly.
220RS016

4. Install the companion flange (2) and Oring (2). 5. Use the companion flange holder J861411 to install a new end nut (2) and tighten to the specified torque. Torque: 167 Nm (123 lb ft) 6. Use the punch J39209 to stake the end nut at two spots. NOTE: Be sure to confirm that there is no crack at the staked portion of the end nut (2) after staking.
7A95
7. Connect the mass and propeller shaft to the extension housing assembly and tighten to the specified torque. Torque: 63 Nm 46 (lb ft)
266RS001
266RW002
7A96
Extension Housing Assembly

Extension Housing Assembly and Associated Parts
260RY00006
Legend (1) Propeller Shaft
(2) Mass (3) Extension Housing Assembly
7A97
Removal
1. Disconnect battery ground cable. 2. Raise and support vehicle with suitable stands. 3. Disconnect harness connectors and fuel pipe fix bolt. Connector: speed sensor. 4. Removing the speedometer driven gear bushing and driven gear, drain extension housing assembly fluid. 5. Remove propeller shaft (1) and mass (2). NOTE: Apply alignment marks on the flange at both front and rear sides. 6. Remove extension housing assembly (3) from the vehicle.
Installation
1. Apply a thin coat of molybdenum disulfide grease to the extension shaft spline as shown in the figure.
260RY00004
7A98
2. Install extension housing assembly (3) to the transmission. Tighten extension housing assembly bolts as shown in the figure.
261RY00001
3. Install speedometer driven gear bushing and driver gear. 4. Connect harness connectors and fuel pipe fix bolt. Connector: speed sensor. 5. Install propeller shaft (1) and mass (2). Torque: 63 Nm (46 lb ft) 6. Fill extension housing assembly fluid. 7. Connect battery ground cable.
7A99

Extension Housing Assembly and Associated Parts
220RY00009
Legend (1) Speedometer Sensor, Speedometer Driven Gear and Plate
(2) Companion Flange (3) Extension Housing Assembly
7A100

2. Tighten the new transfer flange nuts to the specified torque. Torque Companion flange: 167 Nm (123 lb ft) 3. Use the punch J39209 to stake the companion flange nut (3) at two spots.
Removal
1. Remove the speedometer sensor (1). 2. Remove the plate (1). 3. Remove the speedometer driven gear bushing and driven gear (1). NOTE: Apply a reference mark to the driven gear bushing before removal. 4. Remove rear companion flange (2), using the flange companion holder J861411 to remove the end nut.
266RS001
266RW001
5. Remove the rear companion flange. NOTE: Use the universal puller to remove the rear companion flange.
Installation
1. Install companion flange (2), using the companion flange holder J861411 to tighten the flange nuts to the transfer case.
266RW002
266RW001

NOTE: Be sure to confirm that there is no crack at the staked portion of the flange nut after staking. 4. Install the Oring (7) to the speedometer driven gear bushing (6). 5. Install the driven gear to the speedometer driven gear bushing (6). 6. Install the speedometer driven gear assembly to the extension housing assembly. 7. Install the plate (5) to the extension housing assembly and tighten to the specified torque. Torque: 15 Nm (11 lb ft) 8. Install the speedometer sensor and tighten to the specified torque. Torque: 27 Nm (20 lb ft)
7A101
225RY00003
Legend (4) Bolt (5) Plate (6) Bushing (7) Oring
7A102
220RY00011
Legend (1) Bearing Snap Ring (2) Front Ball Bearing (3) Extension Shaft (4) Bearing Snap Ring (5) Front Oil Seal
(6) (7) (8) (9) (10)
Ball Speedometer Drive Gear Rear Ball Bearing Air Breather Pipe Collar Extension Case
7A103
Disassembly
1. Remove front oil seal (5) from the extension housing assembly.
8. Remove extension shaft (3) from the front ball bearing (2), using a bench press and bearing remover J2291201.
220RY00007 220RY00005
2. Remove front snap ring (4), use a pair of snap ring pliers to remove the snap ring. 3. Remove the extension shaft with ball bearing from the extension case (10). 4. Remove rear ball bearing (8), using a bench press and the bearing remover J2291201.
9. Remove air breather pipe collar (9) from the extension housing assembly.
Reassembly
1. Install air breather pipe collar (9) to the extension housing assembly. CAUTION: PUT THE AIR BREATHER PIPE COLLAR INTO THE EXTENSION CASE AS MATCHING THE PROTRUSION OF THE AIR BREATHER PIPE COLLAR WITH THE DEPRESSION OF THE EXTENSION CASE. 2. Install front ball bearing (2) to the extension shaft (3), using the ball bearing installer J2291201. 3. Install bearing snap ring (1), using a pair of snap ring pliers. 4. Install ball (6). 5. Install speedometer drive gear (7). 6. Use the ball bearing installer J2291201 to install the rear ball bearing (8). 7. Install the extension shaft with ball bearing to the extension case (10). 8. Install front snap ring (4).
220RY00006
5. Remove speedometer drive gear (7). 6. Remove ball (6). 7. Remove bearing snap ring (1), using a pair of snap ring pliers.
7A104

2. If the measured value exceeds the specified limit, the ball bearing must be replaced. Limit : 0.2 mm (0.008 in)
9. Install front oil seal (5). CAUTION: Hammering the outside of the oil seal equally, install it to the extension case entirely.
220RY00008
226RS043
Legend (1) Front Oil Seal (2) Extension Case

1. Make the necessary repair or parts replacement if wear, damage or any other abnormal conditions are found during inspection. 2. Wash all parts thoroughly in clean solvent. Be sure all old lubricant, metallic particles, dirt, or foreign material are removed from the surfaces of every part. Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue.
Bearings
1. Inspect the condition of all bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to the bearings. NOTE: Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers. 2. Lubricate the bearings with a light oil and check them for roughness by slowly turning the race by hand. Ball Bearing Play 1. Use a dial indicator to measure the ball bearing play.
7A105

Oil capacity Type of lubricant 0.185 lit. (0.195 U.S. quart) ATF DEXRONIII
220RY00012
7A106
Special Tools
ILLUSTRATION PART NO. PART NAME
J2291201 Bearing remover/installer
J39209 Punch; end nut
J39208 Rear oil seal installer
J861411 Flange holder
SECTION
TRANSMISSION CONTROL SYSTEM (4L30E)
TROOPER
7A11
TRANSMISSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Electronic Control Diagram . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . Control System Diagram . . . . . . . . . . . . . . . Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . Band Apply Control . . . . . . . . . . . . . . . . . . . . Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Pressure Control . . . . . . . . . . . . . . . . . . OnBoard Diagnostic System . . . . . . . . . . . Fail Safe Mechanism . . . . . . . . . . . . . . . . . . . Torque Management Control . . . . . . . . . . . . ATF Warning Control . . . . . . . . . . . . . . . . . . . ABS Control . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Lock Out Control . . . . . . . . . . . . . . Downhill Control . . . . . . . . . . . . . . . . . . . . . . . Uphill Control . . . . . . . . . . . . . . . . . . . . . . . . . Shift Mode Control . . . . . . . . . . . . . . . . . . . . . Gear Shift Control . . . . . . . . . . . . . . . . . . . . . Winter Drive Mode . . . . . . . . . . . . . . . . . . . . . Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . Functions of Input / Output Components . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Diagnosis . . . . . . . . . . . . . . . . . . . Check Trans Indicator . . . . . . . . . . . . . . . . . . Diagnostic Check . . . . . . . . . . . . . . . . . . . . . . Check Trans Check . . . . . . . . . . . . . . . . . . Tech 2 OBD II Connection . . . . . . . . . . . . . . Transmission Data . . . . . . . . . . . . . . . . . . . . . OBD II Diagnostic Management System . . 16 Terminal Data Link Connector (DLC) . Malfunction Indicator Lamp (MIL) . . . . . . . . Types Of Diagnostic Trouble Codes (DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . PCM Precaution . . . . . . . . . . . . . . . . . . . . . . . Information On PCM . . . . . . . . . . . . . . . . . . . Intermittent Conditions . . . . . . . . . . . . . . . . . Transmission And PCM Identification . . . . . Isuzu Trooper . . . . . . . . . . . . . . . . . . . . . . . . . 7A12 7A12 7A13 7A14 7A15 7A16 7A16 Diagnostic Trouble Code (DTC) Identification . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0218 Transmission Fluid Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position . . . . . . . . . . . . DTC P0706 Transmission Range Switch (Mode Switch) Performance . . . . . . . . . . . . . . DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance . . . . . . . . . . . . . . DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input . . . . . . . . . . . DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input . . . . . . . . . . . DTC P0719 Brake Switch Circuit Low (Stuck On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input . . . . . . . . . . DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent . . . . . . . . . DTC P0724 Brake Switch Circuit High (Stuck Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0730 Gear Error Without Input Speed DTC P0742 Torque Converter Clutch (TCC) System Stuck On . . . . . . . . . . . . . . . . . . . . . . . DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical . . . . . . . . . . . DTC P0751 Shift Solenoid A Performance (Stuck OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0752 Shift Solenoid A Performance (Stuck ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0753 Shift Solenoid A Electrical . . . . . DTC P0756 Shift Solenoid B Performance (Stuck OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0757 Shift Solenoid B Performance (Stuck ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0758 Shift Solenoid B Electrical . . . . . DTC P1850 Brake Band Apply Solenoid Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1860 TCC PWM Solenoid Electrical . DTC P1870 Transmission Component Slipping (TCC Stuck OFF) . . . . . . . . . . . . . . . . . . . . . . . Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . 7A124 7A125 7A127 7A130 7A133 7A136 7A139 7A142 7A145 7A148 7A151 7A153 7A156 7A158 7A160 7A162 7A164 7A167 7A169 7A171 7A175 7A179 7A182 7A184
7A16 7A16 7A16 7A16 7A16 7A16 7A16 7A16 7A16 7A16 7A17 7A18 7A19 7A19 7A110 7A111 7A111 7A111 7A111 7A112 7A113 7A118 7A119 7A120 7A121 7A121 7A121 7A122 7A122 7A122 7A122 7A123 7A123
7A12
Service Precaution
General Description
The 4L30E is a 4speed fully automatic transmission. It uses a microcomputer as a control unit to judge running conditions including throttle opening rate and vehicle speed, then it sets the shifting point in the optimum timing so that best driving performance can be achieved. In addition, the builtin shift mode select function can select three shift modes according to the driver s preference: D Normal mode Normal shift pattern. D Winter mode Starts in 3rd gear to reduce slippage on ice or snow. D Power mode has a delayed upshift for when more powerful acceleration is required. Also, the builtin fail safe function (backup mode) assures driving performance even if the vehicle speed sensor, throttle signal or any solenoid fails. Further, the selfdiagnostic function conducts diagnosis in a short time when the control system fails, thus improving serviceability. The major features of 4L30E are as follows: D A compact structure consisting of 2 sets of planetary gears and flat torque converter. D Electronic control selects the optimum shift mode according to the driving conditions. D Electronic control maintains the optimum hydraulic pressure for clutch, band brake as well as transmission so that shift feeling is improved. D Two sets of planetary gears reduce friction of power train. Also, a lockup mechanism in the torque converter reduces fuel consumption. D Wide gear ratio and high torque rate of torque converter provide excellent starting performance.
7A13
Electronic Control Diagram
C07RY00034
7A14
C07RY002
7A15
Control System Diagram
C07RY00033
7A16
Shift Control
The transmission gear is shifted according to the shift pattern selected by the driver. In shifting gears, the gear ratio is controlled by the ON/ OFF signal using the shift solenoid A and the shift solenoid B.
Torque Management Control

The transmission control side sends the absolute spark advance signal to the engine control side while the transmission is being shifted. This controls the engine spark timing in compliance with the vehicle running condition to reduce the shocks caused by the change of speed.
Band Apply Control

The band apply is controlled when in the 32 downshift (engine overrun prevention) and the garage shift (shock control). The band apply solenoid is controlled by the signal from the Pulse Width Modulation (PWM) to regulate the flow of the oil.
ATF Warning Control

The oil temperature sensor detects the ATF oil temperature to control the oil temperature warning, TCC, and the winter mode.
ABS Control
When the select lever is at L or R range, a signal is sent to the ABS controller as one of the ABS control conditions.
Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)

The clutch apply is controlled by moving the converter clutch valve by commanding Torque Converter Clutch (TCC) solenoid using the PWM signal.
Reverse Lock Out Control

With the selector lever in reverse position, the PCM will not close the PWM solenoid until the vehicle is below 15 km/h (9.3 mph), thus preventing reverse engagement above this speed.
Line Pressure Control

The throttle signal allows the current signal to be sent to the force motor. After receiving the current signal, the force motor activates the pressure regulator valve to regulate the line pressure.
Downhill Control
This mode is automatically activated from NORMAL mode only when downhill conditions are recognized. The shift pattern is identical to NORMAL mode except 3-4 and 4-3 shift lines at low throttle modified to get engine braking on a larger speed range. ECCC lines unchanged compared to NORMAL mode.
OnBoard Diagnostic System

Several malfunction displays can be stored in the Powertrain Control Module (PCM) memory, and read out of it afterward. The serial data lines, which are required for the testing of the final assembly and the coupling to other electronic modules, can be regulated by this function.
Uphill Control
When Uphill condition are recognized the 2-3 and 3-4 shift and TCC apply are down only when the engine torque is sufficient in order to avoid shift hunting.
Fail Safe Mechanism

If there is a problem in the transmission system, the PCM will go into a backup mode. The vehicle can still be driven, but the driver must use the select lever to shift gears.
7A17
Shift Mode Control
F07RX001
7A18
Gear Shift Control
F07RT034
7A19
Winter Drive Mode

1. Operation The winter switch will operate when switched on after all of the following conditions are present: Conditions: a. The select lever position is D range only. b. Vehicle speed is 7 mph (11 km/h) or less. c. Transmission oil temperature is 130C (266F) or less. d. Accelerator opening is at 8% or less. 2. Cancel Release 1. Cancellation by driver a. Turning off the winter drive mode switch b. Shifting select position to 3, 2, or L (winter drive mode is not canceled by selecting D, N, R, or P). c. Ignition key is turned off. 2. Automatic cancellation a. When vehicle runs at 21mph (34 km/h) or more for 1 second or more b. When transmission oil temperature reaches 130C (266F) or above NOTE: The mode returns to normal drive mode or power drive mode after the winter drive mode is canceled.
Backup Mode
If a major system failure occurs which could affect safety or damage the transmission under normal vehicle operation, the diagnostic system detects the fault and overrides the Powertrain Control Module (PCM). The CHECK TRANS light flashes to alert the driver, and the transmission must be manually shifted as follows: Select lever position D Manual 3 Manual 2 Manual L R Gear Ratio Selected 4 (Fourth) 4 (Fourth) 3 (Third) 1 (First) Reverse
Shifts are firmer to prevent clutch slip and consequent wear. The fault should be corrected as soon as possible.
7A110 TRANSMISSION CONTROL SYSTEM (4L30E)
Functions of Input / Output Components

Components Speed sensor (fixed to transmission) Throttle position sensor (TPS) (fixed to engine) I N P U T S I G N A L Brake switch (fixed to brake pedal) Mode switch (fixed to transmission) Power drive switch (fixed to front console) T/M oil temperature sensor Engine coolant temperature sensor Engine speed signal Air conditioning information Winter switch (fixed to front console) Cruise controller (Overdrive OFF signal) Shift solenoid A, B S O O L U E T N P O U I T D S I G N A L Band apply solenoid Torque Converter Clutch PWM solenoid Force motor (Pressure regulator valve) Function Senses rotation of output shaft and feeds the data to Powertrain Control Module (PCM). Senses the extent of throttle valve opening and the speed of the throttle valve lever motion to open the valve. Feeds the data to PCM. Senses whether the driver has pressed the brake pedal or not and feeds the information to PCM. Senses the select lever position, and feeds the information to PCM. Senses whether the driver has selected the power mode, and feeds the information to PCM. Senses the T/M oil temperature and feeds the data to PCM Senses the engine coolant temperature, and feeds the data to PCM. Feeds the signals monitoring engine speed to PCM from crank angle sensor. Senses whether the air conditioner has been switched on or not, and feeds the information to PCM. Senses whether the driver has selected the winter mode, and feeds the information to PCM. Downshift takes place when overdrive OFF signal is received from auto cruise controller integrated in PCM. Selects shift point and gear position suited to the vehicle running condition on the basis of PCM output. Controls oil flow suited to the vehicle running condition on the basis of PCM output. Controls clutch apply suited to the vehicle running condition on the basis of PCM output. Adjusts the oil pump delivery pressure to line pressure suited to the vehicle running condition on the basis of PCM output. Informs the driver whether the vehicle is in power mode or not. Informs the driver whether the vehicle is in winter mode or not. Informs the driver of failure in the system. Lights when ATF oil temperature rises. When the select lever is at Reverse or L range, sends a signal to the ABS controller as one of the ABS control conditions.
Power drive mode lamp Winter drive mode lamp CHECK TRANS lamp ATF warning lamp ABS signal
7A111
Diagnosis
Electronic Diagnosis How To Diagnose The Problem
1. To avoid incorrect diagnostics, this book needs to be followed accurately. Unless stated, do not jump directly to a section that could contain the solution. Some important information may be missed. 2. The sections in CAPITALS and bold are the main sections that can be found in the contents. 3. The GOTO SECTION means to continue to check going to the section. 4. The GOTHROUGH SECTION means to go through the section and then to go back to the place the GOTHROUGH was written. 5. BASIC ELECTRIC CIRCUITS: You should understand the basic theory of electricity. This includes the meaning of voltage, amps, ohms, and what happens in a circuit with an open or shorted wire. You should also be able to read and understand wiring diagrams.
2. Turn on the ignition but not the engine. 3. Push F0 on Tech 2 to see the Diagnostic Trouble Code (DTC): 4. Do you have a DTC? YES: write down all code numbers and do the DTC CHECK NO: the DTC can not help you finding the problem. 1. GOTHROUGH CHECK TRANS CHECK 2. IF it is flashing and the flash is 0.2 seconds ON and 0.2 seconds OFF, this means that you should have a DTC stored. Please recheck GOTO DIAGNOSTIC CHECK and if you find the same problem, replace the Powertrain Control Module (PCM). Normal
Check Trans Indicator

Find CHECK TRANS indicator and verify if it is A. Flashing: GOTO DIAGNOSTIC CHECK. B. Staying on: GOTHROUGH CHECK TRANS CHECK. C. Is never ON when the ignition key is turned on: GOTHROUGH CHECK TRANS CHECK D. Is ON during 2 seconds at ignition but OFF after: Normal operation. No DTC or malfunction.
C07RY005
Abnormal
821RW018
Diagnostic Check
This test determines if the transmission or its input or output connections or sensors are failing. 1. Connect the Tech 2: GOTHROUGH Tech 2 OBD II CONNECTION.
C07RY004
Check Trans Check

1. Indicator it is ON during 2 seconds at ignition (or when the engine is cranked) but it is OFF after the engine starts. The indicator is working normally GOTO DIAGNOSTIC CHECK.
Abnormal
C07RY004
3. Indicator it is staying ON always when Ignition is ON. 1. This means that connection between the lamp and the PCM is shorted to ground.
821RW018
Normal
2. Verify if instrument panel terminal 3 (WO/TOD) or 6 (WO/TOD) of connector I9 is shorted to ground. 3. Verify if the PCM connector J2 (RED) terminal 46 is shorted to ground. 4. Verify that the instrument panel terminal 15 (WO/TOD) or 26 (W/TOD) of connector I9 is connected to battery. 5. IF problem solved: GOTO CHECK TRANS INDICATOR. NO:Replace Powertrain Control Module (PCM). 4. Indicator it is staying OFF with the ignition ON (engine OFF). 1. This means that connection between the lamp and the PCM is shorted to battery or opened. 2. Verify if instrument panel terminal 3 (WO/TOD) or 6 (WO/TOD) of connector I9 is shorted to battery or open.
C07RY005
2. Indicator it is flashing and the flash is 0.2 seconds ON and 0.2 seconds OFF always when ignition is on (engine cranked or not). This means that there is a malfunction. GOTO DIAGNOSTIC CHECK.
3. Verify if the PCM connector J2 (RED) terminal 46 is shorted to battery or open. 4. Verify that the instrument panel terminal 15 (WO/TOD) or 26 (W/TOD) of connector I9 is connected to battery. If not, check the fuses and the connections (terminal 10 of connector H25) voltage.

5. IF problem solved: GOTO CHECK TRANS INDICATOR. NO: Replace Powertrain Control Module (PCM).
7A113
D07RY00009
Tech 2 OBD II Connection

In order to access OBD II Powertrain Control Module (PCM) data, use of the Tech 2 scan tool kit (7000086) is required. 1. The electronic diagnosis equipment is composed of: 1. Tech 2 hand held scan tool unit (7000057) and DLC cable (3000095).
2. SAE 16/19 adaptor (3000098) (1), RS 232 loop back connector (3000112) (2), and PCMCIA card (3000117) (3).
F07RW033
901RW176

2. Connecting the TECH2
901RW180
Legend (1) PCMCIA Card (2) RS 232 Loop Back Connector D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 2000 System PCMCIA card (1) inserts into the Tech 2 (5).
(3) SAE 16/19 Adapter (4) DLC Cable (5) Tech 2
2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5) 4. Make sure the vehicle ignition is off.

5. Connect the Tech 2 SAE 16/19 adaptor to the vehicle DLC.
7A115
8. The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.
821RW021
6. The vehicle ignition turns on. 7. Verify the Tech 2 power up display.
060RW009
060R100102
NOTE: The RS232 Loop back connector is only to use for diagnosis of Tech 2 and refer to user guide of the Tech 2.

Once the test vehicle has been identified an Application (Powertrain) Menu screen appears. Please select the appropriate application. The following table shows, which functions are used for the available equipment versions. F0: Diagnostic Trouble Codes F0: Read DTC Info Ordered By Priority F1: Clear DTC Information F2: DTC Information F1: Data Display F0: Transmission Data F1: Output Driver Data F2: Snap Shot F3: Actuator Tests F0: Lamps F0: Check Light F1: Winter Drive Lamp F2: Power Drive Lamp F3: AT Oil Temperature Lamp F1: Solenoids F0: Solenoid 1-2/3-4 Test F1: Solenoid 2-3 Test F2: TCC Solenoid F3: Band Apply Solenoid F4: Pressure Control Solenoid (PCS) F4: Function Tests F0: Reset Oil Life Monitor
060R200253

Diagnostic Trouble Codes The purpose of the Diagnostic Trouble Codes mode is to display stored PCM trouble codes. When Diagnostic Trouble Codes is selected an Application Menu screen appears. Clear DTC Information The purpose of the Clear DTC Information mode is to command the clearing of stored PCM trouble codes. When Clear DTC Information is selected, a Clear DTC Information, warning screen appears. This screen informs you that by cleaning DTCs, all stored DTC information in controller will be erased. Do you want to clear DTCs (Yes/No). Press either the Yes or No key when answering. After clearing codes, confirm system operation by test driving the vehicle. Allow the vehicle to shift through all four forward gears in a manner which attempts to repeat the failure condition. NOTE: When the trouble has not been repaired and the trouble code cannot be erased, check the vehicle again. DTC Information When DTC Information is selected, an Application Menu appears with a list of DTC information function keys addressing DTC specifics and their origins. Function key selections may vary for particular vehicle and/or system. Data Display The purpose of the Data Display mode is to continuously monitor data parameters. The current actual values of all important sensors and signals in the system are display through F1 mode. When Data Display is selected an Application Menu appears. Please select either Engine or Transmission Data Display. See Transmission Data on next page. Snapshot When Snapshot is selected an Application Menu appears. When Transmission Snapshot application is selected from the Application Menu, a Snapshot Menu appears, displaying several options. Snapshot options may vary from one system to another. Snapshot allows a recording of all vehicle parameters. There parameters may then be replayed at a future point in time. This action allows you to focus on making the condition occur, rather than trying to view all of the data in anticipation of the fault. The snapshot will collect parameter information around a trigger point that you select. When a snapshot is taken. It is recorded onto the PCMCIA memory card. When the Tech 2 is powered down. Snapshots are not lost. Actuator Tests The purpose of Actuator Tests mode is to check for correct operation of electronic system actuators. Lamps You can operate the lamps by pressing the ON and OFF buttons.
7A117
Preconditions: none Solenoid Solenoid 1-2/3-4, Solenoid 2-3, TCC Solenoid You can operate the solenoids by pressing the ON and OFF buttons. Preconditions: PN position, no vehicle speed, no engine speed Band Apply Solenoid You can operate the solenoid by pressing the ON and OFF buttons. Preconditions: P-N position, idle engine speed, no vehicle speed. Pressure Control Solenoid (PCS) You can set desired PCS Current using the UP (+25) and DOWN (25) button. The PC Solenoid Data informs about PCS Current, Pressure and Duty Cycle. Preconditions: PN position, no engine speed, no vehicle speed Reset Oil Life Monitor Displays parameter Oil Life Monitor and resets to 100% if Yes-button is pressed on Reset-question. No leaves test. Preconditions: no vehicle speed, no engine speed
Transmission Data
Item Ignition Voltage Engine Speed Vehicle Speed AT Output Speed (Automatic Transmission) AT Input Speed Ratio (Automatic Transmission) Throttle Position AT Oil Temperature (Automatic Transmission) Transmission Temperature AT Oil Temperature Lamp (Automatic Transmission) AT Oil Life Monitor (Automatic Transmission) AT Oil Life Lamp (Automatic Transmission) Commanded Gear Current Gear Mode Switch A Mode Switch B Mode Switch C Mode Switch G Selector Position 12 Shift Solenoid A 23 Shift Solenoid B Solenoid Brake Band TCC Slip Speed TCC Solenoid TCC Duty Cycle PCS Current (Pressure Control Solenoid) PCS Duty Cycle (Pressure Control Solenoid) Desired PCS Pressure (Pressure Control Solenoid) Shift Pressure Brake Switch Kickdown Switch Winter Switch Winter Drive Lamp Power Switch Power Drive Lamp Emergency Mode ABS Status Off, On Off, On Off, On RPM Off, On % A % kPa kPa Off, On On, Off On, Off Off, On Power Drive Normal Off, On Off, On On, Off Inactive, Active Inactive, Active Inactive, Active Inactive, Active % C, F C, F Off, On % Off, On Unit V RPM km/h, MPH RPM Engine running at idle 12.8 14.1 V 750 900 RPM 0 MPH 0 RPM 0.0 0% 70 80C (158 176F) 75 110C (167 230F) Off 100 % Not used 1 1 Active Inactive Inactive Active Park Off On Off 750 900 RPM Off 0% approx. 1.0 A approx. 45 % 43 52 kPa 43 52 kPa On Not used Off Off Normal Off Off Off
7A119
OBD II Diagnostic Management System

Powertrain Control Module (PCM) Location
826RY001
826RY002
Class 2 Serial Data Bus OBD II technology requires a much more sophisticated PCM than does OBD I technology. The OBD II PCM diagnostic management system not only monitors systems and components that can impact emissions, but they also run active tests on these systems and components. The decision making functions of OBD II PCMs have also greatly increased. To accommodate this expansion in diagnostic complexity, Isuzu engineers have designed the Class 2 serial data bus, which meets SAE J1850 recommended practice for serial data. Serial Data refers to information which is transferred in a linear fashion over a single line, one bit at a time. A Data Bus is an electronic pathway through which serial data travels.
TROOPER previously used a 5 volt data bus called UART, which is an acronym for Universal Asynchronous Receive and Transmit. When neither the vehicles control module nor the diagnostic tool, such as a Tech 2, are talking, the voltage level of the bus at rest is 5 volts. The two computers talk to each other at a rate of 8,192 bits per second, by toggling or switching the voltage on the data bus from 5 volts to ground. Class 2 data, which is used on OBD II vehicles, is quite different. Data is transferred at a rate of 10.4 kilobits per second, and the voltage is toggled between zero and 7 volts.
C07RT006
Class 2 data is also pulse width modulated. Each bit of information can have one of two lengths: long or short. On the other hand, UART data bits come in only one length (short). The pulse width modulation of Class 2 data allows better utilization of the data line. The message carried on Class 2 data streams are also prioritized. This means that if two devices try to communication on the data line at the same time, only the higher priority message will continue. The device with the lower priority message must wait. NOTE: The Class 2 data wire is always terminal 2 of the new 16terminal Data Link Connector (DLC).
16 Terminal Data Link Connector (DLC)

OBD II standardizes Data Link Connector (DLC) configurations. The DLC, formerly referred to as the ALDL, will be a 16terminal connector found on the lower left side of the driver s side instrument panel. All manufacturers must conform to this 16terminal standard.
821RW021
7A121
Lamp (MIL) for emissions related DTCs. DTCs fall into four categories: A, B, C, and D; only types A and B are emission related The following descriptions define these categories: TYPE A Will store the DTC and turn on the MIL (Check Engine lamp) on the first trip in which an emission related diagnostic test has run and reported a test failed to the Diagnostic Executive. TYPE B Will store the DTC and turn on the MIL on the second consecutive trip in which an emission related diagnostic test has run and reported a test failed to the Diagnostic Executive. After one failure, the type B DTC is armed, or prepared to store a history code and turn on the MIL if a second failure occurs. One passed test will disarm a type B DTC. Some special conditions apply to misfire and fuel trim DTCs. For a type B DTC to store and turn on the MIL, two ignition cycles are required.
810RT022
PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16
DIAG. SW J1850 Bus + L line on 2wire systems, or single wire (Class 2) (Not used) Chassis ground pin Signal ground pin (Not used) ABS diagnostic enable TOD diagnostic enable Primary UART (Not used) (Not used) ABS diagnostic or CCM diagnostic enable SIR diagnostic enable (Not used) (Not used) Battery power from vehicle unswitched (4 AMP MAX.)
TYPE C Will store the DTC and turn on a SERVICE lamp (Check Trans lamp) on the first trip that a non emission related diagnostic test has run and reported a test failed to the Diagnostic Executive. This type of DTC will be used in future applications. TYPE D Will store a DTC but will not turn on the MIL on the first trip that a non emission related diagnostic test has run and reported a test failed to the Diagnostic Executive. These codes can be very helpful for vehicle service when the driver may comment about a condition, but the MIL did not turn on.
Clear DTC
NOTE: If you clear the DTC (Diagnostic Trouble Codes) you will not be able to read any codes recorded during the last occurrence. NOTE: To use the DTC again to identify a problem, you will need to reproduce the fault or the problem. This may require a new test drive or just turning the ignition on (this depends on the nature of the fault). 1. IF you have a Tech 2: 1. Connect the Tech 2 if it is still not connected GOTHROUGH Tech 2 OBD II CONNECTION. 2. Push F1: Clear DTC Information in the Application Menu and answer Yes to the question Do you want to clear DTCs? a. When a malfunction remains as it is the Tech 2 displays 4L30E CODES NOT CLEARED. This means that the problem is still there or that the recovery was not done. Please GOTO DTC CHECK. b. When a malfunction has been repaired and the recovery is done. The Tech 2 displays 4L30E CODES CLEARED. 2. IF you have no Tech 2: To clear the DTC, remove Fuse PCM (F13, 30A) for at least 10 seconds.
Malfunction Indicator Lamp (MIL)

The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with (CHECK ENGINE lamp). However, OBD II requires that it illuminate under a strict set of guidelines. Basically, the MIL is turned on when the PCM detects a DTC that will impact the vehicles emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if a component or system which has an impact on vehicle emissions indicates a malfunction or fails to pass an emissionsrelated diagnostic test. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissionsrelated faults.
Types Of Diagnostic Trouble Codes (DTCs)

The Diagnostic Executive classifies Diagnostic Trouble Codes (DTCs) into certain categories. Each type has different requirements to set the code, and the Diagnostic Executive will only illuminate the Malfunction Indicator
DTC Check
1. Diagnostic Trouble Codes (DTC) have been identified by Tech 2. 2. You have written the list of the DTCs. The order of the malfunctions has no meanings for this PCM. Usually only one or two malfunctions should be set for a given problem. 3. Check directly the DTCs you identified. The DTCs are sorted by number. Refer to Diagnostic Trouble Code (DTC) Identification in this section.
Information On PCM
1. The Powertrain Control Module (PCM) is located in the center console and is the control center of the electronic transmission control system. 2. The PCM must be maintained at a temperature below 85 (185F) at all times. This is most essential if the vehicle is put through a paint baking process. The PCM will become inoperative if its temperature exceeds 85C (185F). Therefore, it is recommended that the PCM be removed or that temporary insulation be placed around the PCM during the time the vehicle is in a paint oven or other high temperature process. 3. The PCM is designed to process the various inputs and then respond by sending the appropriate electrical signals to control transmission upshift, downshift, shift feel and torque converter clutch engagement. 4. The PCM constantly interprets information from the various sensors, and controls the systems that affect transmission and vehicle performance. By analyzing operational problems, the PCM is able to perform a diagnostic function by displaying DTC(s) and aid the technician in making repairs.
PCM Precaution
The PCM can be damaged by: 1. Electrostatic discharge 2. The short circuit of some terminals to voltage or to ground. Electrostatic Discharge Damage Description: 1. Electronic components used to control systems are often designed to carry very low voltage, and are very susceptible to damage caused by electrostatic discharge. It is possible for less than 100 volts of static electricity to cause damage to some electronic components. By comparison, it takes as much as 4,000 volts for a person to even feel the zap of a static discharge. 2. There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. An example of charging by friction is a person sliding across a car seat, in which a charge of as much as 25,000 volts can build up. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges for the same polarity are drained off, leaving the person highly charged with the opposite polarity. Static charges of either type can cause damage, therefore, it is important to use care when handling and testing electronic components. NOTICE: To prevent possible electrostatic discharge damage: 1. Do not touch the PCM connector pins or soldered components on the PCM circuit board. 2. Be sure to follow the guidelines listed below if servicing any of these electronic components: 3. Do not open the replacement part package until it is time to install the part. 4. Avoid touching electrical terminals of the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. 6. Always touch a known good ground before handling the part. This step should be repeated before installing the part if the part has been handled while sliding across the seat, while sitting down from a standing position or while walking some distance.
Intermittent Conditions
If the Tech 2 displays a diagnostic trouble code as intermittent, or if after a test drive a DTC does not reappear though the detection conditions for this DTC are present, the problem is most likely a faulty electrical connection or loose wiring. Terminals and grounds should always be the prime suspect. Intermittents rarely occur inside sophisticated electronic components such as the PCM. Use the DTC information to understand which wires and sensors are involved. When an intermittent problem is encountered, check suspect circuits for: 1. Poor terminal to wire connection. 2. Terminals not fully seated in the connector body (backed out). 3. Improperly formed or damaged terminals. 4. Loose, dirty, or corroded ground connections: HINT: Any time you have an intermittent in more than one circuit, check whether the circuits share a common ground connection. 5. Pinched or damaged wires. 6. ElectroMagnetic Interference (EMI): HINT: Check that all wires are properly routed away from coil, and generator. Also check for improperly installed electrical options, such as lights, 2way radios, etc. Use the F2 SNAPSHOT mode of the Tech 2 to help isolate the cause of an intermittent fault. The snapshot mode will record information before and after the problem occurs. Set the snapshot to trigger on the suspect DTC. If you notice the reported symptom during the test drive, trigger the snapshot manually.

After the snapshot has been triggered, command the Tech 2 to play back the flow of data recorded from each of the various sensors. Signs of an intermittent fault in a sensor circuit are sudden unexplainable jump in data values out of the normal range.
7A123
Transmission And PCM Identification

The chart below contains a list of all important information concerning rear axle ratio, Powertrain Control Module (PCM), and transmission identification. VEHICLE Type Isuzu / Trooper Engine Rr axle Ratio PCM ISUZU Parts No. 8972646942 8972656952 8973024771 8973024781 Calibration Code G26 TRANSMISSION Isuzu Part No. Model Code
3.5L V6
4.300
8960185070
YA
Isuzu Trooper
240R200028
Diagnostic Trouble Code (DTC) Identification

DTC NUMBER P0218 P0705 P0706 P0711 P0712 P0713 P0719 P0722 P0723 P0724 P0730 P0742 P0748 P0751 P0752 P0753 P0756 P0757 P0758 P1850 P1860 P1870 DTC NAME Transmission Fluid Over Temperature Transmission Range Switch (Mode Switch) Illegal Position Transmission Range Switch (Mode Switch) Performance Transmission Fluid Temperature (TFT) Sensor Performance Transmission Fluid Temperature (TFT) Sensor Circuit Low Input Transmission Fluid Temperature (TFT) Sensor Circuit High Input Brake Switch Circuit Low (Stuck ON) Automatic Transmission Output Speed Sensor (OSS) Low Input Automatic Transmission Output Speed Sensor (OSS) Intermittent Brake Switch Circuit High (Stuck OFF) Gear Error Without Input Speed Torque Converter Clutch (TCC) System Stuck ON Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical Shift Solenoid A Performance (Stuck OFF) Shift Solenoid A Performance (Stuck ON) Shift Solenoid A Electrical Shift Solenoid B Performance (Stuck OFF) Shift Solenoid B Performance (Stuck ON) Shift Solenoid B Electrical Brake Band Apply Solenoid Malfunction TCC Solenoid Electrical Transmission Component Slipping (TCC Stuck OFF) DTC TYPE D D D D D D D B B D C B C B B B B B B D B B ON ON Flash Flash ON ON ON ON ON ON ON Flash Flash Flash Flash Flash Flash Flash Flash Flash ON ON Flash Flash MIL CHECK ENGINE CHECK TRANS
DTC TYPE B C D
DEFINITION Emission related, turn on MIL (Check Engine) and flashing Check Trans after 2 consecutive trips (Removal to confirmed) Nonemission related, flashing Check Trans on 1st failure Nonemission related, no lamps
NOTE: On the following charts, refer to the Powertrain Control Module (PCM) section for the Wiring System, and the Body and Accessories section for circuit diagram details, parts location, and connector configuration.
7A125
DTC P0218 Transmission Fluid Over Temperature
D07RY00010
Circuit Description
The Transmission Fluid Temperature (TFT) sensor is a thermister that controls the signal voltage to the PCM. The PCM supplies a 5volt reference to the sensor on circuit RED/WHT. When the transmission fluid is cold, the sensor resistance is high and the PCM will sense high signal voltage. As the fluid temperature warms to a normal transmission operating temperature of 100C (212F), the sensor resistance becomes less and the voltage decreases to 1.5 to 2.0 volts. This DTC detects a high transmission temperature for a long period of time. This is a type D DTC.
Diagnostic Aids
D Inspect the wiring for poor electrical connections at the PCM and at the transmission 16way connectors. Look for possible bent, backed out, deformed, or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D Check harness routing for a potential short to ground in circuit RED/WHT. D Scan tool TFT sensor temperature should rise steadily to about 100C (212F), then stabilize. D Check for a skewed (misscaled) sensor by comparing the TFT sensor temperature to the ambient temperature after a vehicle cold soak. A skewed sensor can cause delayed garage shifts or TCC complaints. D Check for a possible torque converter stator problem. D Verify customer driving habits, trailer towing, etc.
Conditions For Setting The DTC

D No TFT DTCs P0712 or P0713. D TFT is greater than 135C (275F). D All conditions met for 21 seconds.
Action Taken When The DTC Sets

D Hot mode TCC Shift Pattern. D The PCM will not illuminate the Malfunction Indicator Lamp (MIL). D ATF Lamp ON. (TFT is greater than 145C (293F).) D Disable Eside TCC OFF request.
Test Description
The numbers below refer to the step numbers on the diagnostic chart. 3. This test checks for a skewed sensor or shorted circuit. 4. This test simulates a TFT DTC P0713.
Conditions For Clearing The DTC

D The DTC can be cleared from the PCM history by using a scan tool. D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
DTC P0218 Transmission Fluid Over Temperature

Step 1 Action Were you sent here from the Powertrain OnBoard Diagnostic (OBD) System Check? Yes No Go to OBD System Check Refer to Driveability and Emissions in Engine section
Go to Step 2 2 Perform the following checks: D Check for possible engine system problems. D Transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) Section. Were the checks performed? 3 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Failure Records for reference, as data will be lost when Clear Info function is used. 3. Record the DTC Failure Records. Is the TFT sensor signal voltage less than 0.33 volts? 4 1. Turn the ignition off. 2. Disconnect the transmission 16way connector H56 (additional DTCs may set). Is the TFT sensor signal voltage greater than 4.92 volts? 5 6 Inspect/repair circuit RED/WHT for a short to ground. Was a problem found? 1. Inspect the PCM for poor connections. 2. Replace the PCM if no poor connections were found. Is the replacement complete? 7 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and ensure the following conditions are met: TFT is less than 125C (257F) for at least 10 seconds. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 7 Go to Step 7 Go to Step 4 Go to Internal Wiring Harness Check. Go to Step 3
Go to Diagnostic Aids
Begin diagnosis again Go to Step 1
Repair verified Exit DTC table
7A127
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position
D07RY00011
Circuit Description
D The range switch supplies the Powertrain Control Module (PCM) with information regarding the selector lever position: P, R, N, D 3, 2 or L. The selector lever position is indicated by the state of four ON/OFF contacts. The range switch is located on one side of the transmission. It is on the transmission manual shaft and is fixed to the main case. D The range switch is also used to provide the information P or N to the engine crank wiring. The engine can be cranked only if connector M25 terminal 4(H) is connected to terminal 1(E) which is connected to ground. D The range switch is also used to provide the backup lamp power in reverse. This is why the range switch is supplied through a 15A fuse (C3). This fuse can burn due to a short circuit in the backup lamp. This DTC detects when a fuse is open or the range switch circuit does not work. This is a type D DTC.
D The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

Diagnostic Aids
D Refer to accompanying chart for the normal range signals and the illegal combinations. D Inspect the wiring for poor electrical connections at the PCM and at the transmission 8way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D Refer to the Range Switch Logic Table or Functional Test Procedure for further information.

D Range switch illegal positions met for 5 seconds.

D D D D Default to D position. Inhibit torque management. Maximum line pressure. Turn force motor OFF.
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks the indicated range signal to the manual valve actually selected. 6. This test checks for continuity between each selected range switch connector terminals. Range Switch Logic Table Range Position Park Reverse Neutral D4 D3 2 L Illegal Illegal Range Switch Pin A ON ON OFF OFF ON ON OFF OFF OFF B OFF ON ON ON ON OFF OFF OFF OFF C OFF OFF OFF ON ON ON ON OFF OFF P(G) ON OFF ON OFF ON OFF ON OFF ON
7A129
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position

Go to Step 2 2 Perform the following checks: D The transmission linkage from the select lever to the manual valve is adjusted properly. D Diagnostic circuit check. Were the checks performed? 3 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. Select each transmission range: D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the scan tool Range Switch display? 4 5 Are all range switch pin displays incorrect? Check fuse and wiring to the 8way connector terminal 5(D) for opens. Refer to Mode Switch in Automatic Transmission (4L30E) section. If no problem was found, replace the range switch. Is the replacement complete? 6 1. Disconnect the 8way range switch connector. 2. Using ohmmeter, check continuity between terminal 5(D) and respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8way range switch connector. 3. Move shift selector lever through all positions and compare results with Range Switch Logic Table. Is one range switch pin display incorrect? 7 8 Check the affected wiring and connector, and repair. Is the repair complete? Check the Powertrain Control Module (PCM) connectors for poor connection. If no problem was found, replace the PCM. Is the replacement complete? 9 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and road test the vehicle. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 9 Begin diagnosis again Go to Step 1 Go to Step 9 Go to Step 7 Go to Step 9 Go to Diagnostic Aids Go to Step 5 Go to Step 3
Go to Step 8
DTC P0706 Transmission Range Switch (Mode Switch) Performance
D07RY00011
Circuit Description
D The range switch supplies the Powertrain Control Module (PCM) with information regarding the selector lever position: P, R, N, D, 3, 2 or L. The selector lever position is indicated by the state of four ON/OFF contacts. The range switch is located on one side of the transmission. It is on the transmission manual shaft and is fixed to the main case. D The range switch is also used to provide the information P or N to the engine crank wiring. The engine can be cranked only if connector M25 terminal 4(H) is connected to terminal 1(E) which is connected to ground. D The range switch is also used to provide the backup lamp power in reverse. This is why the mode switch is supplied through a 15A fuse (C3). This fuse can burn due to a shot circuit in the backup lamp. D This DTC detects an invalid state of the range switch or the range switch circuit by deciphering the range switch inputs. This is a type D DTC.
D Output speed greater than 3,200 RPM. D Range switch indicates R. D All conditions met for 4 seconds.
Condition 2 (P or N bad position):

D D D D D D Engine is running. No TPS codes. Engine speed is less than 3,000 RPM. TP angle is greater than 20%. Range switch indicates P or N. All conditions met for 4 seconds.

D Default to D position. D The PCM will not illuminate the Malfunction Indicator Lamp (MIL).


This DTC will set if any of the following conditions occurs:
Condition 1 (R bad position):

D Engine is running. D No output speed DTCP0722, P0723.
7A131
Diagnostic Aids
D Refer to the accompanying chart for the normal range signals and the illegal combinations. D Inspect the wiring for poor electrical connections at the PCM and at the transmission 8way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D Refer to the Range Switch Logic Table or Functional Test Procedure for further information.
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks the indicated range signal to the manual valve actually selected. 6. This test checks for continuity between each selected range switch connector terminals. Range Switch Logic Table Range Position Park Reverse Neutral D4 D3 2 L Illegal Illegal Range Switch Pin A ON ON OFF OFF ON ON OFF OFF OFF B OFF ON ON ON ON OFF OFF OFF OFF C OFF OFF OFF ON ON ON ON OFF OFF P(G) ON OFF ON OFF ON OFF ON OFF ON
DTC P0706 Transmission Range Switch (Mode Switch) Performance

Go to Step 2 2 Perform the following checks: D The transmission linkage from the select lever to the manual valve is adjusted properly. D Diagnostic circuit check. Were the checks performed? 3 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. Select each transmission range: D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the scan tool Range Switch display? 4 5 Are all range switch pin displays incorrect? Check fuse and wiring to the 8way connector terminal 5(D) for opens. Refer to Mode Switch in Automatic Transmission (4L30E) section. If no problem was found, replace the range switch. Is the replacement complete? 6 1. Disconnect the 8way range switch connector. 2. Using ohmmeter, check continuity between terminal 5(D) and respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8way range switch connector. 3. Move shift selector lever through all positions and compare results with Range Switch Logic Table. Is one range switch pin display incorrect? 7 8 Check the affected wiring and connector, and repair. Is the repair complete? Check the Powertrain Control Module (PCM) connectors for poor connection. If no problem was found, replace the PCM. Is the replacement complete? 9 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and road test the vehicle. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 9 Begin diagnosis again Go to Step 1 Go to Step 9 Go to Step 7 Go to Step 9 Go to Diagnostic Aids Go to Step 5 Go to Step 3
Go to Step 8
7A133
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance
D07RY00010
Circuit Description
The TFT sensor is a thermister that controls the signal voltage to the PCM. The PCM supplies a 5volt reference signal to the sensor on circuit RED/WHT. When the transmission fluid is cold, the sensor resistance is high and the PCM detects high signal voltage. As the transmission fluid temperature increases to normal operating temperature of 100C (212F), the sensor resistance becomes less and the voltage decreases to 1.5 to 2 volts. When the PCM detects a TFT sensor that remains at the startup value, or a sensor that has a change delta of greater than 20C (36F) less than 1 second, DTC P0711 sets. DTC P0711 is a type D.
D If the sensor shows an unrealistic change, the TFT exhibits a change delta of greater than 20C (36F), greater than 14 times in 7 seconds.

D Transmission default temperature will be: 80C (176F) if engine temperature code is set. 100C (212F) if engine temperature is warm. 80C (176F) if engine run time is greater than 5 minutes. 21C (69.8F) if engine run time is less than 5 minutes. D The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

D D D D D D D D D D No VSS DTCs P0722 or P0723. No Transmission Component Slipping DTC P1870. Engine is running. TFT is between 20 A/D (Analog/Digital) counts and 248 A/D counts. TFT is between 40C (40F) and +21C (69.8F) at engine startup. Engine coolant temperature is greater than 70C (150F). Engine coolant temperature has changed by greater than 50C (90F) since engine startup. Vehicle speed has been greater than 5 mph for greater than 410 seconds since engine startup (cumulative timer). TCC slip speed has been greater than 120 rpm for greater than 410 seconds since engine startup (cumulative timer). Battery voltage is between 10 and 16 volts.

Diagnostic Aids
D Inspect the wiring for poor electrical connection at the PCM. Inspect the wiring for poor electrical connections at the transmission 16way connectors. Look for the following conditions: a. A bent terminal b. A backed out terminal c. A damaged terminal d. Poor terminal tension e. A chafed wire f. A broken wire inside the insulation
All of the above is true and either of the following occurs: D If the sensor is stuck, the TFT has not changed for greater than 2 counts (from startup temperature) for greater than 410 seconds.

D When diagnosing for an intermittent short or open connection, move the wiring harness while watching the test equipment for a change. D First diagnose and clear any engine DTCs or TP Sensor codes. Then inspect for any transmission DTCs that may have reset. Resistance Chart C 40 0 20 80 120 150 F 40 32 68 176 248 304 Resistance (kW) 672 65 25 2.5 0.78 0.37
Test Description
The number below refers to the step number on the diagnostic chart: 3. This test checks PCM and associated wiring up to the 16way connectors. If the voltage increases to match chart the problem is isolated to the transmission wiring.
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance

Step 1 Action Was the Powertrain OnBoard Diagnostic (OBD) System Check performed? Yes No Go to OBD System Check Refer to Driveability and Emissions in Engine section Go to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section
Go to Step 2 2 Perform the transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section. Did you perform the fluid checking procedure? Go to Step 3 3 1. Install the scan tool. 2. With the engine off, turn the ignition switch to the on position. NOTE: Before clearing DTCs, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the data. 3. Record the DTC Freeze Frame and Failure Records. 4. Select TFT on the scan tool. 5. While observing the scan tool display, move or massage the engine wiring harness from PCM connectors J266 and J220 to the transmission 16way connectors. Does the TFT change by more than 20C (36F)? 4 1. Turn the ignition off. 2. Disconnect the transmission 16way connector H56. 3. Install Jumper Harness on the transmission side of the 16way connector H56. 4. Using the J39200 DVOM and J35616 Connector Test Adapter Kit, connect the DVOM leads from terminal M74(F) to terminal M71(E). 5. Set the DVOM on MIN/MAX to measure resistance. 6. Record the TFT sensor resistance. 7. Move or massage the automatic transmission wiring harness assembly from the 16way connector H56 to the TFT sensor connector. Does the DVOM MAX display a resistance greater than the value recorded in Action item 6 of this step? 5 Does the DVOM MIN display a resistance less than the value recorded in Action item 6 of step 4? Go to Step 7 Go to Step 8 Go to Step 6
Go to Step 4
Go to Step 5
7A135
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance (Contd)

Step 6 Action Inspect circuit RED/WHT and RED/BLK of the engine wiring harness for an intermittent open or short condition. Repair the circuits if necessary. Did you find a problem? 7 Inspect the automatic transmission wiring harness assembly for an intermittent open in circuits RED/WHT and RED/BLK. Did you find a problem? 8 Inspect the automatic transmission wiring harness assembly for an intermittent shorted condition in circuits RED/WHT and RED/BLK. Did you find a problem? 9 10 Replace the automatic transmission wiring harness assembly. Is the replacement complete? Replace TFT Sensor. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30E) section. Is the replacement complete? 11 Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 12 In order to verify your repair, perform the following procedure. 1. Select DTC. 2. Select Clear Info. 3. Drive the vehicle and ensure the following conditions are met: D The TFT changes by more than 2.25C (4.05F) for 11 seconds since startup. D The TFT does not change by more than 20C (36F) within 0.200 second for a period of at least 11 seconds. 4. Select Specific DTC. 5. Enter DTC P0711. Has the test run and passed? System OK Go to Step 12 Go to Step 12 Go to Step 12 Go to Step 9 Go to Step 10 Go to Step 9 Go to Step 10 Go to Step 12 Go to Step 11 Yes No
Begin the diagnosis again Go to Step 1
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input
D07RY00010
Circuit Description
The TFT sensor is a thermister that controls the signal voltage to the PCM. The PCM supplies a 5volt reference signal to the sensor on circuit RED/WHT. When the transmission fluid is cold, the sensor resistance is high. The PCM detects high signal voltage. As the transmission fluid temperature increases to the normal operating temperature of 100C (212F), the sensor resistance becomes less and the voltage decreases to 1.5 to 2 volts. With transmission fluid over temperature and DTC P0218 also set, check the transmission cooling system. This DTC detects a continuous short to ground in the TFT signal circuit or the TFT sensor. This is a type D DTC.
D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
D Check harness routing for a potential short to ground in circuit RED/BLK. Scan tool TFT display should rise steadily to about 100C (212F), then stabilize. D Inspect the wiring for poor electrical connection at the PCM and at the transmission 16way connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D The temperature to resistance value scale may be used to test the TFT sensor at the various temperature levels to evaluate the possibility of a skewed (misscaled) sensor. A skewed sensor could result in delayed garage shifts or TCC complaints. D Verify customer driving habits, trailer towing, etc.

D D D D Battery voltage is between 10 and 16 volts. Ignition is on. TFT sensor indicating a voltage less than 0.4 volts. All conditions met for 20 seconds.

Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for a short to ground or a skewed sensor. 4. This test checks for an internal fault within the transmission by creating an open.

D The DTC can be cleared from the PCM history by using a scan tool.

Resistance Chart C 40 0 20 80 120 150 F 40 32 68 176 248 304 Resistance (kW) 672 65 25 2.5 0.78 0.37
7A137
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input
Step 1 Action Were you sent here from the Powertrain OnBoard Diagnostic (OBD) System Check? Yes No Go to OBD System Check Refer to Driveability and Emissions in Engine section Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section
Go to Step 2 2 Perform the transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section. Was the fluid checking procedure performed?
Go to Step 3 3 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. Does the scan tool display a TFT sensor signal voltage less than 0.4 volts? 4 1. Turn the ignition off. 2. Disconnect the transmission 16way connector H56. 3. Turn the ignition on. Does the TFT signal voltage change to match the voltage 4.92 volts? 5 Using the J39200 DVOM, measure the resistance between terminals M74(F) and M71(E). Is the resistance within specifications? (See Resistance Chart.) 6 1. Disconnect the transmission 7way connector M7. 2. Using the J39200 DVOM, measure the resistance between terminals M74(F) and M71(E). Is the resistance within specifications? (See Resistance Chart.) 7 1. Remove the transmission oil pan. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30E) section. 2. Check the internal wiring harness for a short to ground. Was a problem found? Go to Step 9 Go to Step 5 Go to Diagnostic Aids Go to Step 4
Go to Step 10
Go to Step 6
Go to Step 7
Go to Step 8
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (Contd)
Step 8 Action 1. Disconnect the internal wiring harness at the TFT sensor. 2. Measure the resistance of the TFT sensor. Is the resistance within specifications? (See Resistance Chart.) 9 10 11 12 Replace the TFT Sensor. Is the replacement complete? Check circuit RED/WHT for a short to ground. Was a problem found? Check the PCM for faulty connections. Was a problem found? Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 13 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and ensure the following conditions are met: TFT sensor indicates a voltage greater than 0.33 volts for 2 seconds. 2. Review the scan tool DTC info. Has the last test failed or is the current DTC displayed? Go to Step 13 Go to Step 13 Go to Step 12 Go to Step 13 Go to Step 11 Go to Step 13 Yes Go to Diagnostic Aids No
Go to Step 9
7A139
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input
D07RY00010
Circuit Description
The TFT sensor is a thermistor that controls the signal voltage to the PCM. The PCM supplies a 5volt reference signal to the sensor on circuit RED/WHT. When the transmission fluid is cold, the sensor resistance is high and the PCM will sense high signal voltage. As the transmission fluid temperature warms to the normal operating temperature of 100C (212F), the sensor resistance becomes less and the voltage decreases to about 1.5 to 2 volts. This DTC detects a continuous open or short to power in the TFT signal circuit or the TFT sensor. This is a type D DTC.
D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
D Inspect the wiring for poor electrical connection at the PCM and at the transmission 16way connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D Scan tool displays transmission fluid temperature in degrees. After transmission is operating, the temperature should rise steadily to about 100C (212F), then stabilize. D The temperature to resistance value scale may be used to check the TFT sensor at the various temperature levels to evaluate the possibility of a skewed (misscaled) sensor. A skewed sensor could result in hard shifts or TCC complaints.

D Battery voltage is between 10 and 16 volts. D Ignition is on. D TFT sensor indicating a voltage greater than 4.86 volts. D All conditions met for 20 seconds.

Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This check verifies problem in the TFT sensor circuit. 4. This test simulates a TFT sensor DTC P0712. If the PCM recognizes the low signal voltage (high temperature), and the scan tool displays 146C (295F) or greater, the PCM and wiring are OK.

D The DTC can be cleared from the PCM history by using a scan tool.

5. This test checks the TFT sensor and internal wiring harness. Resistance Chart C 40 0 20 80 120 150 F 40 32 68 176 248 304 Resistance (kW) 672 65 25 2.5 0.78 0.37
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input
Step 1 Action Were you sent here from the Powertrain OnBoard Diagnostic (OBD) System Check? Yes No Go to OBD System Check Refer to Driveability and Emission in Engine section Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section
Go to Step 2 2 Perform the transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section. Was the fluid checking procedure performed?
Go to Step 3 3 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. Does the scan tool display a TFT sensor signal voltage greater than 4.86 volts? 4 1. Turn the ignition off. 2. Disconnect the transmission 16way connector H56. 3. Install a fused jumper wire from terminal M74(F) and M71(E) on the engine harness. 4. Turn the ignition on. Does the TFT signal voltage drop to less than 0.4 volts? 5 1. Turn the ignition off. 2. Using the J39200 DVOM, measure the resistance between terminals M74(F) and M71(E). Is the resistance within specifications? (See Resistance Chart.) 6 1. Disconnect the transmission 7way connector M7. 2. Using the J39200 DVOM, measure the resistance between terminals M74(F) and M71(E). Is the resistance within specifications? (See Resistance Chart.) Go to Step 5 Go to Step 4
Go to Step 10
Go to Step 6
Go to Step 7
7A141
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input (Contd)
Step 7 Action 1. Remove the transmission oil pan. 2. Check the internal wiring harness for an open. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30E) section. Was a problem found and corrected? 8 1. Disconnect the internal wiring harness at the TFT sensor. 2. Measure the resistance of the TFT sensor. Is the resistance within specifications? (See Resistance Chart.) 9 Replace TFT sensor. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30E) section. Is the replacement complete? 10 11 12 13 Check circuit RED/WHT for an open or short to B+. Was a problem found? Check circuit RED/BLK for an open. Was a problem found? Check the PCM for faulty or intermittent connections. Was a problem found? Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 14 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and ensure the following conditions are met: 2. TFT sensor indicates a voltage less than 4.92 volts for 2 seconds. 3. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 14 Go to Step 14 Go to Step 13 Go to Step 14 Go to Step 12 Go to Step 14 Go to Step 11 Go to Step 14 Go to Step 14 Go to Diagnostic Aids Go to Step 8 Yes No
Go to Step 9
DTC P0719 Brake Switch Circuit Low (Stuck On)
D07RY00012
Circuit Description:
The brake switch indicates brake pedal status to the Powertrain Control Module (PCM). The brake switch is a normallyclosed switch that supplies battery voltage on circuit ORN to the PCM. Applying the brake pedal opens the switch, interrupting voltage to the PCM. When the brake pedal is released, the PCM receives a constant voltage signal. If the PCM receives a zero voltage signal at the brake switch input, and the Torque Converter Clutch (TCC) is engaged, the PCM deenergizes the Torque Converter Clutch Solenoid Valve (TCC Sol. Valve). The PCM disregards the brake switch input for TCC scheduling if there is a brake switch circuit fault (Refer to Diagnostic Aids). When the PCM detects an open brake switch circuit (0 volts, low input) during accelerations, then DTC P0719 sets. DTC P0719 is a type D DTC.

D The PCM does not illuminate the Malfunction Indicator Lamp (MIL). D DTC P0719 stores in PCM history.

D A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warmup cycles without a failure reported. D The PCM cancels the DTC default actions when the fault no longer exists and the ignition is OFF long enough in order to power down the PCM.
Diagnostic Aids
D Inspect the wiring for poor electrical connections at the PCM and brake switch. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D Check customer driving habits and/or unusual driving conditions (i.e. stop and go, highway). D Check brake switch for proper mounting and adjustment.

D No OSS Assy. DTCs P0722 or P0723. D The PCM detects an open brake switch or circuit (0 volts) for 15 minutes without changing for 2 seconds, and the following events occur seven consecutive times: D The vehicle speed is less than 8 km/h (5 mph); D then the vehicle speed is 832 km/h (520 mph) for 4 seconds; D then the vehicle speed is greater than 32 km/h (20 mph) for 4 seconds.
7A143
Test Description
The numbers below refer to the step numbers on the diagnostic chart. 3. This step isolates the brake switch as a source for setting the DTC.
DTC P0719 Brake Switch Circuit Low (Stuck On)

Step 1 Action Was the Powertrain OnBoard Diagnostic (OBD) System Check performed? Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch to the on position. NOTE: Before clearing the DTC(s), use the scan tool in order to record the Failure Records for reference. Using the Clear Info function will erase the stored Failure Records from the PCM. 3. Record the DTC Failure Records, then clear the DTC(s). 4. Select TCC Brake Switch on the scan tool. 5. Disconnect the brake switch connector from the brake switch. 6. Connect a test lamp from cavity B132 of the brake switch connector to a known good ground. Is the test lamp ON? 3 Install a J 36169A Fused Jumper Wire from terminal B133 to terminal B132 of the brake switch connector. Did the TCC Brake Switch status change from Open to Closed? 4 1. Remove the fuse C4 (15A). 2. Inspect the fuse for an open. Is the fuse open? 5 Inspect circuit BLU/WHT for a short to ground condition. Repair the circuit if necessary. Did you find a short to ground condition? 6 Inspect circuit ORN for a short to ground condition. Repair the circuit if necessary. Did you find a short to ground condition? 7 8 Replace the brake switch. Is the replacement complete? Inspect circuit BLU/WHT for an open condition. Repair the circuit if necessary. Did you find and correct an open condition? 9 Inspect circuit ORN for an open. Did you find an open condition? Go to Step 11 Go to Step 10 Go to Step 11 Go to Step 11 Go to Step 11 Go to Step 10 Go to Step 11 Go to Step 6 Go to Step 5 Go to Step 8 Go to Step 7 Go to Step 9 Go to Step 3 Go to Step 4 Yes No Go to Powertrain OBD System Check
DTC P0719 Brake Switch Circuit Low (Stuck On) (Contd)

Step 10 11 Replace the PCM. Is the replacement complete? In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. With the engine off, turn the ignition switch to the on position. 4. Do not depress the brake pedal. 5. Verify that the TCC Brake Switch status indicates Closed (12 volts) for 2 seconds. 6. Select Specific DTC. Enter DTC P0719. Has the test run and passed? System OK Go to Step 11 Action Yes No
Begin the diagnosis again. Go to Step 1
7A145
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input
D07RY00016
Circuit Description
Output speed information is provided to the PCM by the OSS, which is a permanent magnet (PM) generator. The PM generator produces a pulsing AC voltage. The AC voltage level and number of pulses increases as the speed of the vehicle increases. The PCM then converts the pulsing voltage to output speed, which is used for calculations. The vehicle speed can be displayed with a scan tool. This DTC detects a low output speed when there is a high engine speed in a drive gear range. This is a type B DTC.
Conditions For Clearing The MIL/DTC

D The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. D The DTC can be cleared from the PCM history by using a scan tool. The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

D No MAP DTCs P0107 or P0108, P0106, P1106, P1107. D No TPS DTCs P0122 or P0123. D Not in Park or Neutral. D TP angle is greater than 10%. D Engine vacuum is between 0 and 70kPa. D Engine speed is between 3,000 and 7,000 rpm. D Transmission output speed is less than 0 rpm. D All conditions met for 5 seconds.
Diagnostic Aids
D An OSS DTC P0722 will set when no output speed is at detected at start off. D Inspect the wiring for poor electrical connection at the PCM. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

D D D D Fixed to 4th gear. Maximum line pressure. Inhibit TCC engagement. For lamp illuminate refer to DTC type definition (type B).
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 4. This test checks the OSS circuit. 5. This test checks the integrity of the OSS. 7. This test checks the 5volt and ground circuit of the PCM.
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input
Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. Raise the drive wheels. 5. Start the engine. 6. Place the transmission in any drive range. With the drive wheels rotating, does the Trans Output Speed increase with the drive wheel speed? 3 4 Check for the most current and/or incorrect calibration. Is the calibration current? 1. Turn the ignition off. 2. Disconnect the J2 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between harness connector terminals J222 and J255. Is the reading 3,000 ohms? 5 1. Select AC volts. 2. Rotate the rear wheels, ensuring the driveshaft is turning. Is the voltage greater than 0.5 volts? 6 Inspect circuits RED and WHT for a poor connection or an open circuit. Was a problem found? 7 1. 2. 3. 4. Reconnect the J2 (RED) PCM connector. Disconnect the OSS harness from the OSS. With the engine off, turn the ignition on. Using the J 39200 DVOM, measure the voltage at the OSS harness connector terminals M152 and M151. Go to Step 16 Go to Step 17 Go to Step 7 Go to Step 5 Go to Step 16 Go to Diagnostic Aids
Go to Step 6
Go to Step 8
Go to Step 8
Is the reading between 4.0 to 5.1 volts? 8 1. Remove the OSS. 2. Check the output shaft speed sensor rotor for damage or misalignment. Refer to Speed Sensor (Extension Housing) in Automatic Transmission (4L30E) section. Was a problem found? 9 10 11 12 Replace the OSS. Is the replacement complete? Was the reading in step 7 less than 4.0 volts? Was the reading in Step 7 greater than 5.1 volts? Using the J 39200 DVOM to chassis ground, measure the voltage on circuit RED. Is the reading between 4.0 to 5.1 volts?
Go to Step 10
Go to Step 17 Go to Step 17 Go to Step 12 Go to Step 15
Go to Step 13
Go to Step 14
7A147
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input (Contd)
Step 13 14 15 16 Is the repair complete? Check circuit RED for a short to ground or open. Was a problem found and corrected? Repair the short to B+ in circuit RED. Is the repair complete? Replace the PCM. Refer to Powertrain Control Module (PCM) in automatic Transmission (4L30E) section. Is the replacement complete? 17 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and operate the vehicle under the following conditions: Transmission output speed is greater than 101 rpm for 3 seconds. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 17 Go to Step 17 Go to Step 17 Go to Step 16 Action Repair the open in circuit WHT. Go to Step 17 Yes No
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent
D07RY00016
Circuit Description
Output speed information is provided to the PCM by the OSS, which is a permanent magnet (PM) generator. The PM generator produces a pulsing AC voltage. The AC voltage level and number of pulses increases as the speed of the vehicle increases. The PCM then converts the pulsing voltage to output speed, which is used for calculations. The vehicle speed can be displayed with a scan tool. This DTC detects a low output speed when there is a high engine speed in a drive gear range. This is a type B DTC.

D The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive trips without a failure reported. D The DTC can be cleared from the PCM history by using a scan tool. D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without failure reported. D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

Drive range D Engine running time is greater than 5 seconds. D Output speed is greater than 1300 rpm for 2 seconds. D NORAW-NORAWLAST < 200 rpm for 2 seconds. NORAW Latest raw data of output shaft speed. NORAWLAST Filtered pervious data of output speed. D Transmission negative output speed change is greater than 1300 rpm. D Conditions met for 3 seconds.
Diagnostic Aids
D A OSS DTC P0723 will set when output speed has been detected and is lost. D Inspect the wiring for poor electrical connection at the PCM. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.
Action During Detection Time

Output speed value is frozen.
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 4. This test checks the OSS circuit. 5. This test checks the integrity of the OSS. 7. This test checks the 5volt and ground circuit of the PCM.

D D D D Fixed to 4th gear. Maximum line pressure. Inhibit TCC engagement. For lamp illumination refer to DTC type definition (type B).
7A149
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent

Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. Raise the drive wheels. 5. Start the engine. 6. Place the transmission in any drive range. With the drive wheels rotating, does the Trans Output Speed increase with the drive wheel speed? 3 4 Check for the most current and/or incorrect calibration. Is the calibration current? 1. Turn the ignition off. 2. Disconnect the J2 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between harness connector terminals J222 and J255. Is the reading 3,000 ohms? 5 1. Select AC volts. 2. Rotate the rear wheels, ensuring the driveshaft is turning. Is the voltage greater than 0.5 volts? 6 Inspect circuits RED and WHT for a poor connection or an open circuit. Was a problem found? 7 1. 2. 3. 4. Reconnect the J2 (RED) PCM connector. Disconnect the OSS harness from the OSS. With the engine off, turn the ignition on. Using the J 39200 DVOM, measure the voltage at the OSS harness connector terminals M152 and M151. Go to Step 16 Go to Step 17 Go to Step 7 Go to Step 5 Go to Step 16 Go to Diagnostic Aids
Go to Step 6
Go to Step 8
Go to Step 8
Is the reading between 4.0 to 5.1 volts? 8 1. Remove the OSS. 2. Check the output shaft speed sensor rotor for damage or misalignment. Refer to Speed Sensor (Extension Housing) in Automatic Transmission (4L30E) section. Was a problem found? 9 10 11 12 Replace the OSS. Is the replacement complete? Was the reading in step 7 less than 4.0 volts? Was the reading in Step 7 greater than 5.1 volts? Using the J 39200 DVOM to chassis ground, measure the voltage on circuit RED. Is the reading between 4.0 to 5.1 volts?
Go to Step 10
Go to Step 17 Go to Step 17 Go to Step 12 Go to Step 15
Go to Step 13
Go to Step 14
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent (Contd)
Step 13 14 15 16 Is the repair complete? Check circuit RED for a short to ground or open. Was a problem found and corrected? Repair the short to B+ in circuit RED. Is the repair complete? Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 17 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and operate the vehicle under the following conditions: Transmission output speed is greater than 101 rpm for 3 seconds. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 17 Go to Step 17 Go to Step 17 Go to Step 16 Action Repair the open in circuit WHT. Go to Step 17 Yes No
7A151
DTC P0724 Brake Switch Circuit High (Stuck Off)
D07RY00012
The brake switch indicates brake pedal status to the Powertrain Control Module (PCM). The brake switch is a normallyclosed switch that supplies battery voltage on circuit ORN to the PCM. Applying the brake pedal opens the switch, interrupting voltage to the PCM. When the brake pedal is released, the PCM receives a constant voltage signal. If the PCM receives a zero voltage signal at the brake switch input, and the Torque Converter Clutch (TCC) is engaged, the PCM deenergizes the Torque Converter Clutch Solenoid Valve (TCC Sol. Valve). The PCM disregards the brake switch input for TCC scheduling if there is a brake switch circuit fault (Refer to Diagnostic Aids). When the PCM detects a closed brake switch circuit (12 volts, high input) during decelerations, then DTC P0724 sets. DTC P0724 is a type D DTC.

D The PCM does not illuminate the Malfunction Indicator Lamp (MIL). D DTC P0724 stores in PCM history.

D A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warmup cycles without a failure reported. D The PCM cancels the DTC default actions when the fault no longer exists and the ignition is OFF long enough in order to power down the PCM.
Diagnostic Aids
D Inspect the wiring for poor electrical connection at the PCM. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D Check customer driving habits and/or unusual traffic conditions (i.e. stop and go, expressway). D Check brake switch for proper mounting and adjustment.

D No OSS Assy. DTCs P0722 or P0723. D The PCM detects a closed brake switch circuit (12 volts) without changing and the following events occur seven consecutive times: D The vehicle speed is greater than 32 km/h (20 mph) for 4 seconds; D then the vehicle speed is between 832 km/h (520 mph) for 4 seconds; D then the vehicle speed is less than 8 km/h (5 mph).
Test Description
The numbers below refer to the step numbers on the diagnostic chart. 2. This step isolates the brake switch as a source for setting the DTC.
DTC P0724 Brake Switch Circuit High (Stuck Off)

Step 1 Action Was the Powertrain OnBoard Diagnostic (OBD) System Check performed? Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch to the on position. NOTE: Before clearing the DTC(s), use the scan tool in order to record the Failure Records for reference. Using the Clear Info function will erase the stored Failure Records from the PCM. 3. Record the DTC Failure Records, then clear the DTC(s). 4. Select TCC Brake Switch on the scan tool. 5. Disconnect the brake switch connector from the brake switch. Did the TCC brake switch status change from Closed to Open? 3 4 Replace the brake switch. Is the replacement complete? Inspect circuit ORN for a short to B+ condition. Repair the circuit if necessary. Did you find a short to B+ condition? 5 6 Replace the PCM. Is the replacement complete? In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. With the engine off turn the ignition switch to the on position. 4. Apply the brake pedal. 5. Verify that the TCC brake switch status indicates Open (0 volts) for 2 seconds. 6. Select Specific DTC. Enter DTC P0724. Has the test run and passed? System OK Go to Step 6 Go to Step 6 Go to Step 5 Go to Step 6 Go to Step 3 Go to Step 4 Yes No Go to Powertrain OBD System Check
Begin the diagnosis again. Go to Step 1
7A153
DTC P0730 Gear Error Without Input Speed
D07RY00055
Circuit Description
D The Powertrain Control Module (PCM) calculates the slippage of the converter and transmission based upon the engine speed, the output speed, and the current gear ratio. D The slippage of the converter at a high enough engine speed is low. The transmission should not slip more than a given value when there is no shift. D This DTC detects a slip at each gear. This is a type C DTC.
D No Transmission Range Switch DTC(s) P0705, P0706. D 3 seconds since downshift. D 3 seconds since garage shift (ND). D And one of the following conditions occur: Slip is greater than 508 rpm in 1st gear. Slip is greater than 468 rpm in 2nd gear. Slip is greater than 449 rpm on 3rd gear. Slip is greater than 440 rpm on 4th gear. D All conditions met for 5.5 seconds.

D D D D No Output Speed Sensor DTC(s) P0722, P0723. Not in Park, Neutral, or Reverse. Engine speed is greater than 3,500 rpm. 3 seconds since upshift.

D Maximum line pressure. D The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

D The PCM will illuminate the CHECK TRANS Lamp. D Turn force motor OFF.
Diagnostic Aids
D Check for intermittent output speed sensor circuit problems. D Check for possible incorrect calibration. (PCM part No., tire specification, and rear axle ratio)
Conditions For Clearing The DTC/CHECK TRANS Lamp

D The PCM will turn off the CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. D The DTC can be cleared from PCM memory by using a scan tool. D The DTC can also be cleared from memory when the vehicle has made 40 warmup cycles without a failure reported. D The PCM will cancel the DTC Actions Taken items when the fault conditions no longer exist and the ignition is cycles off long enough to power down the PCM.
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This step checks for possible low fluid level causing slipping resulting in an undefined gear ratio. 4. This step checks for correct gear ratios for commanded gears. 5. This step checks for low line pressure.
DTC P0730 Gear Error Without Input Speed

Step 1 Action Were you sent here from the OnBoard Diagnostic (OBD) System Check? Yes No Go to OBD System Check Refer to Driveability and Emission in Engine section
Go to Step 2 2 Visually inspect the transmission cooling system for fluid leaks. D Refer to Chart 16: Possible Causes of Transmission Fluid Leaks of Mechanical/Hydraulic Diagnosis Symptoms Index in Automatic Transmission (4L30E) section Was condition found and corrected? 3 Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section. Has transmission fluid checking procedure been performed? Go to Step 7
Go to Step 3 Go to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30E) section
Go to Step 4 4 1. Install the scan tool. 2. Turn the ignition switch to the on position. 3. Engine not running. NOTE: Before clearing DTC(s) use the scan tool to record the Failure Records for reference, as data will be lost when the Clear Info function is used. 4. Record the Failure Record data. 5. Use the scan tool snapshot mode to record transmission gear ratios. 6. Drive vehicle in transmission gear ranges 1, 2, 3, and D with the engine speed is greater than 3,500 rpm for 5.5 seconds. 7. Record each transmission gear. 1st:2.73 2.99 2nd:1.54 1.71 3rd:0.93 1.05 4th:0.66 0.78 Does commanded gear ratio match ranges as shown?
Refer to Diagnostic Aids
Go to Step 5
7A155
DTC P0730 Gear Error Without Input Speed (Contd)

Step 5 Action Perform line pressure check. D Refer to Line Pressure Test in Automatic Transmission (4L30E) section. Was condition found and corrected? 6 Check for possible clutch slippage. D Refer to Chart 6: Diagnostic Trouble Code (DTC) P0730 of Mechanical/Hydraulic Diagnosis Symptoms Index in Automatic Transmission (4L30E) section. Was condition found and corrected? 7 1. After the repair is complete, use the scan tool to select DTC, then Clear info function. 2. Operate the vehicle under the following conditions: D Drive the vehicle in D4 with the engine speed greater than 3,500 rpm to obtain anyone of the following gear ratios for seven seconds. 1st 1:2.73 1:2.99 2nd 1:1.54 1:1.71 3rd 1:0.93 1:1.05 4th 1:0.66 1:0.78 Has the last test failed? Begin diagnosis again Go to Step 1 Repair verified Exit DTC table Go to Step 7 Go to Step 7 Go to Step 6 Yes No
DTC P0742 Torque Converter Clutch (TCC) System Stuck On
D07RY002
Circuit Description
The PCM energizes the TCC solenoid by creating an ignition voltage on circuit BRN/BLU. When ignition voltage is energized by the PCM, the TCC solenoid stops converter signal oil from exhausting. This causes converter signal oil pressure to increase and move the TCC valve. The TCC solenoid will deenergize when the PCM no longer provides ignition voltage. When the TCC solenoid is deenergized, it will exhaust fluid and release the TCC. This DTC detects low torque converter slip when the TCC is commanded off. This is a type B DTC.
D TCC slip speed is between 20 and 40 rpm for 2 seconds. D Vehicle speed is greater than 25 km/h (15 mph) and less than 120 km/h (75 mph). D Speed ratio is greater than 0.9 and less than 2.0.

D For lamp illuminate refer to DTC type definition (type B). D Inhibit TCC engagement.

D The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. D The DTC can be cleared from the PCM history by using a scan tool. D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

The following conditions occur once per TCC cycle, three consecutive times: D No TPS DTCs P0122 or P0123. D No OSS DTCs P0722 or P0723. D No TCC solenoid DTC P1860. D TP angle is greater than 20%. D Engine speed is greater than 500 rpm and less than 3,000 rpm. D Engine vacuum is between 0 and 70 kPa. D Commanded gear is not 1st. D Gear range is D4. D TCC is commanded off. D No TCC Stuck off DTC P1870.
7A157
Diagnostic Aids
D If the TCC is mechanically stuck on with the parking brake applied and any gear range selected, the TCC fluid will mechanically apply the TCC, possibly causing an engine stall.
Test Description
The number below refers to the step number on the diagnostic chart: 3. This test checks the mechanical state of the TCC. (When the PCM commands the TCC solenoid off, the slip speed should increase).
DTC P0742 Torque Converter Clutch (TCC) System Stuck On

Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. Using the scan tool, verify the TP Sensor operation. Are the TP Sensor values within 0.6 5.0 volts? 3 Drive the vehicle in the D4 drive range in fourth gear under steady acceleration, with a TP angle greater than 20%. Does the scan tool display TCC Slip Speed between 30 and +30 rpm, while the displayed TCC solenoid state is off? 4 The TCC is mechanically stuck on. Check the following items: D Clogged exhaust orifice in the TCC solenoid. D Converter clutch apply valve stuck in the apply position. D Misaligned or damaged valve body gasket. D Restricted release passage. Was a problem found and corrected? 5 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and ensure the following conditions are met: TCC slip speed must be between 200 and 2,500 rpm for 4 seconds. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 5 Go to Step 4 Go to Step 3
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical
D07RY00013
Circuit Description
The PCS is a PCMcontrolled device used to regulate transmission line pressure. The PCM compares TPS voltage, engine rpm, and other inputs to determine the line pressure appropriate for a given load. The PCM will regulate the pressure by applying a varying amperage to the PCS. The applied amperage can vary from 0.1 to 1 amp, and is monitored by the PCM. This DTC detects a continuous open or short to ground in the PCS circuit or the PCS. This is a type C DTC.
D The DTC can be cleared from PCM history by using a scan tool. D The DTC will be cleared from memory when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
D Inspect the wiring for poor electrical connection at the PCM and at the transmission 4way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

D Battery voltage is between 10 and 16 volts. D The PCM detects that the different between commanded and actual current is 200 milliampere (mA) for over 1 second. D Engine speed is greater than 300 rpm.

D The PCM will not illuminate the Malfunction Indicator Lamp (MIL). D Maximum line pressure. D The PCM will illuminate the CHECK TRANS Lamp. D Turn force motor OFF (Durability).
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the ability of the PCM to command the PCS. 3. This test checks the PCS and internal wiring harness for incorrect resistance.
Conditions For Clearing The DTC/CHECK TRANS Lamp

D The PCM will turn off the CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported.
7A159
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical
Step 1 Action Were you sent here from the Powertrain OnBoard Diagnostic (OBD) System Check? Yes No Go to OBD System Check Refer to Driveability and Emission in Engine section
Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Failure Records. 4. While the engine is operating, put the transmission in Park. 5. Using the scan tool, apply 0.1 amp through 1.0 amp while observing PC Ref. Current and PC Act. Current. Is the PC Act. Current reading always within 0.16 amp? 3 1. Turn the ignition off. 2. Disconnect the transmission 4way connector M6. 3. Using the J39200 DVOM, measure the resistance between terminals M62(B) and M64(C). Is the resistance within 37 ohms? 4 1. Remove the transmission oil pan. Refer to Solenoid (Adapter Case Valve Body) in Automatic Transmission (4L30E) section. 2. Disconnect the internal wiring harness at the PCS. 3. Measure the resistance of the PCS. Is the resistance within 37 ohms? 5 6 7 8 Replace the PCS. Is the replacement complete? Repair the internal wiring harness for an open. Is the repair complete? Inspect/repair circuits J147, M62(B), J143, and M64(C). Was a problem found? Inspect/repair circuits J147, M62(B), J143, and M64(C) for a short to ground or poor connections. Was a problem found? 9 Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 10 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and ensure the following conditions are met: The PCS duty cycle is not at its electrical high or low limit. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 10 Go to Step 10 Go to Step 10 Go to Step 10 Go to Step 10 Go to Step 6 Go to Step 7
Go to Step 3
Go to Step 4
Go to Step 9
DTC P0751 Shift Solenoid A Performance (Stuck OFF)
D07RT011
Circuit Description
The shift solenoid A is used to control fluid flow acting on the 12 and 34 shift valves. The solenoid is a normally close exhaust valve that is used with the shift solenoid B to allow four different shifting combinations. The DTC detects when there is only a 1144 shift pattern depending on the state of the mechanical failure instead of a 1234 shift pattern. This is a type B DTC.
Condition 2:
D D D D D D 3rd Gear is commanded for 1 sec. 40 Engine Torque 400 Nm Trottle position 10% 8000 TCC slip 8000 rpm Speed ratio 0.45 0.62 Modeled Ratio 0.92 for 3 seconds

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTC P0742, P1860, P1870. No shift solenoid A DTC P0753. No shift solenoid B DTC P0758. Gear range is D4. Output speed is greater than 375 rpm. Transmission temperature is between 20 and 130C (68 and 266F). D No range code P0705, P0706. D No torque code (to be confirmed). D Engine run for more 0 seconds and not influed cut-off (to be confirmed). All the above conditions have been met and the combination of conditions 1, 2 occur two consecutive times. D D D D D D D D

D Maximum line pressure. D For lamp illuminate refer to DTC type definition (type B). D Turn force motor OFF.
Conditions For Clearing The The MIL/DTC

Condition 1:
D D D D D D 2nd gear is commanded for 1 sec 40 Engine Torque 400 Nm Throttle positon 10% 800 TCC slip 4000 rpm Speed ratio 0.6 2.75 Modeled Ratio 3.2 for 1 seconds.
Diagnostic Aids
D Verify that the transmission meets the specifications in the 4L30E shift speed chart. D Other internal transmission failures may allow more than one shift to occur.
7A161
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the function of the range switch (mode switch). 3. This test checks that the scan tool commanded all shifts, all shifts solenoids responded correctly, but all the shifts did not occur.
DTC P0751 Shift Solenoid A Performance (Stuck OFF)

Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. With the engine operating, apply the brake pedal and select each transmission range D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the TR Switch on the scan tool? 3 1. While the engine is operating, raise the drive wheels. 2. With the transmission in D4 range, use the scan tool to command 1st, 2nd and 3rd, and 4th gears while accelerating the vehicle. Was a 23 or 14 only shift pattern detected? (Road testing the vehicle may be necessary). 4 Check the shift solenoid/hydraulic circuit for: D One or both of the shift solenoids for an internal malfunction. D Contamination or sediment in one or both of the shift solenoids. D Damaged seals on one or both of the shift solenoids. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30E) section. Was a problem found and corrected? 5 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and road test the vehicle. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 5 Begin diagnosis again Go to Step 1 Go to Step 4 Go to Step 3
Go to Range Switch Logic Table
DTC P0752 Shift Solenoid A Performance (Stuck ON)
D07RT011
Circuit Description
The shift solenoid A is used to control fluid flow acting on the 12 and 34 shift valves. The solenoid is a normally close exhaust valve that is used with the shift solenoid B to allow four different shifting combinations. The DTC detects when there is only a 2233 shift pattern depending on the state of the mechanical failure instead of a 1234 shift pattern. This is a type B DTC.
Condition 2:
D D D D D D 4th Gear is commanded for 1 sec. 40 Engine Torque 400 Nm Trottle position 10% 8000 TCC slip 8000 rpm Speed ratio 0.6 0.92 Modeled Ratio 1.5 for 7 seconds

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTC P0742, P1860, P1870. No shift solenoid A DTC P0753. No shift solenoid B DTC P0758. Gear range is D4. Output speed is greater than 375 rpm. Transmission temperature is between 20 and 130C (68 and 266F). D No range code P0705, P0706. D No torque code (to be confirmed). D Engine run for more 0 seconds and not influed cut-off (to be confirmed). All the above conditions have been met and the combination of condition 1, 2 occur two consecutive times. D D D D D D D D

Conditions For Clearing The The MIL/DTC

Condition 1:
D D D D D D D 1st gear is commanded for 1 sec 40 Engine Torque 400 Nm Throttle positon 10% 8000 TCC slip 8000 rpm Transmission out speed 375 rpm Speed ratio 0.3 1.5 Modeled Ratio 2.4 for 0.687 seconds
Diagnostic Aids
D Verify that the transmission meets the specifications in the 4L30E shift speed chart. D Other internal transmission failures may cause more than one shift to occur.
7A163
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the function of the range switch (mode switch). 3. This test checks that the scan tool commanded all shifts, all shifts solenoids responded correctly, but all the shifts did not occur.
DTC P0752 Shift Solenoid A Performance (Stuck ON)

Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. With the engine operating, apply the brake pedal and select each transmission range D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the TR Switch on the scan tool? 3 1. While the engine is operating, raise the drive wheels. 2. With the transmission in D4 range, use the scan tool to command 1st, 2nd and 3rd, and 4th gears while accelerating the vehicle. Was a 23 or 14 only shift pattern detected? (Road testing the vehicle may be necessary). 4 Check the shift solenoid/hydraulic circuit for: D One or both of the shift solenoids for an internal malfunction. D Contamination or sediment in one or both of the shift solenoids. D Damaged seals on one or both of the shift solenoids. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30E) section. Was a problem found and corrected? 5 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and road test the vehicle. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 5 Begin diagnosis again Go to Step 1 Go to Step 4 Go to Step 3
Go toRange Switch Logic Table
DTC P0753 Shift Solenoid A Electrical
D07RY00014
Circuit Description
D The shift solenoid A is a simple on/off solenoid located in the main case valve body. The solenoid is the normally closed type. In second or third gear, the Powertrain Control Module (PCM) energizes the solenoid to open a fluid inlet port. When the port is open, fluid pressure actuates the shift valve. D The solenoid is activated by current. This current is produced by applying a voltage to one side (the High side) and a ground to the other side (Low side). D The High Side Driver (HSD) is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage. The High side of the solenoid is permanently supplied with voltage, except in BACKUP MODE or when ignition is off the HSD is turned off. This DTC detects a continuous open or short to ground in the shift solenoid A circuit or the shift solenoid A. This is a type B DTC.

D D D D Maximum line pressure. Immediate landing to 4th gear. Inhibit TCC engagement. For lamp illuminate refer to DTC type definition (type B).


D Ignition is on, Engine run. D Battery voltage is between 10 and 16 volts. D The PCM commands the solenoid on and the voltage remains high (B+) or the PCM commands the solenoid off and the voltage remains low (zero volts). D All conditions met for 0.84 1.0 seconds.
Diagnostic Aids
D Inspect the wiring for poor electrical connection at the PCM and at the transmission 16way connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation.

D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. D An open ignition feed circuit can cause multiple DTCs to set. D A shift solenoid B DTC P0758 could also set with a shift solenoid A electrical failure.
7A165
5. This test measures the resistance of the component. 9. This test checks the function of the shift solenoid A and the transmission internal wiring harness. Shift Solenoid Status Chart Gear 1st 2nd 3rd 4th Shift solenoid A OFF ON ON OFF Shift solenoid B ON ON OFF OFF
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for power to the shift solenoid A from the ignition through the PCM.
DTC P0753 Shift Solenoid A Electrical

Go to Step 2 2 1. Install the scan tool. 2. With the engine on, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. Were DTCs P0753, P0758, P1860 set? 3 1. Turn the ignition on. 2. Using the J39200 DVOM, measure the voltage between PCM connector terminals J243 and J11 (GND). Is the voltage within 1012 volts? 4 1. 2. 3. 4. Turn the ignition off. Disconnect the J2 (RED) PCM connector. Turn the ignition on. Using the J39200 DVOM, measure the voltage between PCM connector terminals J15 and ground. Go to Step 11 Go to Step 4 Go to Step 3
Go to Step 5
Is the voltage within 10 12 volts? 5 1. Turn the ignition off. 2. Disconnect the J2 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between PCM connector terminals J243 and J15. Is the resistance within 18 20 ohms? 6 1. Disconnect the J1 (BLUE) and J2 (RED) PCM connectors. 2. Using the J39200 DVOM, check a continuity between PCM terminals J243 and ground. Is there a continuity? 7 1. Disconnect the 16way harness connector H56. 2. Using the J39200 DVOM, measure the resistance between terminals H5611 and H5610. Is the resistance within 1820 ohms?
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 12
Go to Step 8
Go to Step 14
Go to Step 9
DTC P0753 Shift Solenoid A Electrical (Contd)

Step 8 Action Using the J39200 DVOM, check a continuity between J2 (RED) PCM terminal 43 and ground. Is there a continuity? 9 1. Disconnect the transmission main case 7 pin connector M7. 2. Using the J39200 DVOM, measure the resistance between terminals M72(D) and M73(C). Is the resistance within 1820 ohms? 10 11 Check every connection at the PCM connector. Was a problem found? The wiring harness between PCM connector terminals J15 and transmission harness terminal M73(C) is shorted to voltage. Was a problem found and corrected? 12 The wiring harness between PCM connector terminal J15 and transmission harness terminal M73(C) is shorted to ground. Was a problem found and corrected? 13 The wiring harness between PCM connector terminals J243 and transmission harness terminal M72(D) is shorted to ground. Was a problem found and corrected? 14 The wiring harness between PCM connector J1 or J2 and transmission 16way connector H56 is open or poor connection. Was a problem found and corrected? 15 The wiring harness between transmission 16way connector H56 and transmission main case connector M7 is open or has a poor connection. Was a problem found and corrected? 16 The shift solenoid A is faulty. Replace the shift solenoid A. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30E) section. Is the replacement complete? 17 The PCM may be faulty. Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 18 19 Repair the PCM connector connection. Was a problem found and corrected? 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and operate the vehicle under the following conditions: D The shift solenoid A is commanded on and voltage drops to zero. D The shift solenoid A is commanded off and voltage increases to B+. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 19 Go to Step 19 Go to Step 19 Go to Step 19 Go to Step 19 Go to Step 19 Go to Step 19 Go to Step 19 Go to Step 18 Go to Step 17 Go to Step 15 Go to Step 16 Go to Step 13 Go to Step 10 Yes No
7A167
DTC P0756 Shift Solenoid B Performance (Stuck OFF)
D07RT011
Circuit Description
The shift solenoid B is used to control fluid flow acting on the 23 shift valves. The solenoid is a normally open exhaust valve that is used with the shift solenoid A to allow four different shift combinations. This DTC detects when there is only a 4334 shift pattern depending on the state of the mechanical failure instead of a 1234 shift pattren. This is a type B DTC.
Condition 2:
D D D D D D 2nd Gear is commanded for 1 sec. 40 Engine Torque 400 Nm Trottle position 10% 8000 TCC slip 8000 rpm Speed ratio 0.6 0.92 Modeled Ratio 1.5 for 0.687 seconds

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTC P0742, P1860., P1870. No shift solenoid A DTC P0753. No shift solenoid B DTC P0758. Gear range is D4. Output speed is greater than 375 rpm. Transmission fluid temperature is between 20 and 130C (68 and 266F). D No range code P0705, P0706. D No torque code (to be confirmed). D Engine run for more 0 seconds and influed cut-off (to be confirmed). All the above conditions have been met and the combination of condition 1, 2 occur two consecutive times. D D D D D D D D


D The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. D The DTC can be cleared from the PCM history by using a scan tool. D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exist and the ignition is cycled off long enough to power down the PCM.
Condition 1:
D D D D D D D 1st gear is commanded for 1 sec 40 Engine Torque 400 Nm Throttle position 10% 2300 TCC slip 200 rpm Transmission out speed 400 rpm Speed ratio 0.3 0.60 Modeled Ratio 1.49 for 1 seconds
Diagnostic Aids
D Verify that the transmission meets the specifications in the 4L30-E shift speed chart. D Other internal transmission failures may allow more than one shift to occur.
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the function of the range switch (mode switch). 3. This test checks for selected gear ratio vs. a ratio not obtainable under normal driving conditions.
DTC P0756 Shift Solenoid B Performance (Stuck OFF)

Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. With the engine operating, apply the brake pedal and select each transmission range D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the TR Switch on the scan tool? 3 1. While the engine is operating, raise the drive wheels. 2. With the transmission in D4 range, use the scan tool to command 1st, 2nd, and 3rd, and 4th gears while accelerating the vehicle. Was 1st gear commanded and not achieved, or 4th gear commanded and other than 4th gear occurred? (Road testing the vehicle may be necessary.) 4 Check the shift solenoid/hydraulic circuit for: D One or both of the shift solenoids for an internal malfunction. D Contamination or sediment in one or both of the shift solenoids. D Damaged seals on the one or both of the shift solenoids. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30E) section. Was a problem found and corrected? 5 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and road test the vehicle. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 5 Begin diagnosis again Go to Step 1 Go to Step 3
Go to Step 4
7A169
DTC P0757 Shift Solenoid B Performance (Stuck ON)
D07RT011
Circuit Description
The shift solenoid B is used to control fluid flow acting on the 23 shift valves. The solenoid is a normally open exhaust valve that is used with the shift solenoid A to allow four different shift combinations. This DTC detects when there is only a 1221 shift pattern depending on the state of the mechanical failure instead of a 1234 shift pattern. This is a type B DTC.
Condition 2:
D D D D D D 4th Gear is commanded for 1 sec. 15 Engine Torque 400 Nm Trottle position 10% 8000 TCC slip 8000 rpm Speed ratio 0.6 2.75 Modeled Ratio 3.2 for 2 seconds

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTC P0742, P1860, P1870. No shift solenoid A DTC P0753. No shift solenoid B DTC P0758. Gear range is D4. Output speed is greater than 375 rpm. Transmission fluid temperature is between 20 and 130C (68 and 266F). D No range code P0705, P0706. D No torque code (to be confirmed). D Engine run for more 0 seconds and not influed cut-off (to be confirmed). All the above conditions have been met and the combination of condition 1,2 occur two consecutive times. D D D D D D D D


Condition 1:
D D D D D D D 3rd gear is commanded for 1 sec 40 Engine Torque 400 Nm Throttle positon 10% 8000 TCC slip 8000 rpm Transmission out speed 375 rpm Speed ratio 0.6 1.44 Modeled Ratio 2.4 for 4 seconds
Diagnostic Aids
D Verify that the transmission meets the specifications in the 4L30-E shift speed chart. D Other internal transmission failures may cause more than one shift to occur.
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the function of the range switch (mode switch). 3. This test checks for selected gear ratio vs. a ratio not obtainable under normal driving conditions.
DTC P0757 Shift Solenoid B Performance (Stuck ON)

Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. With the engine operating, apply the brake pedal and select each transmission range D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the TR Switch on the scan tool? 3 1. While the engine is operating, raise the drive wheels. 2. With the transmission in D4 range, use the scan tool to command 1st, 2nd, and 3rd, and 4th gears while accelerating the vehicle. Was 1st gear commanded and not achieved, or 4th gear commanded and other than 4th gear occurred? (Road testing the vehicle may be necessary.) 4 Check the shift solenoid/hydraulic circuit for: D One or both of the shift solenoids for an internal malfunction. D Contamination or sediment in one or both of the shift solenoids. D Damaged seals on the one or both of the shift solenoids. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30E) section. Was a problem found and corrected? 5 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and road test the vehicle. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 5 Begin diagnosis again Go to Step 1 Go to Step 3
Go to Step 4
7A171
DTC P0758 Shift Solenoid B Electrical
D07RY00014
Circuit Description
D The shift solenoid B is a simple on/off solenoid located in the main case valve body. It is normally open. When the port is open, fluid pressure actuates the shift valve. In first or second gear, the Powertrain Control Module (PCM) energizes the solenoid to close a fluid inlet port. D The solenoid is activated by current. This current is produced by applying a voltage to one side (the High side) and a ground to the other side (Low side). D The High Side Driver (HSD) is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage. The High side of the solenoid is permanently supplied with voltage. In BACKUP MODE or when the ignition is off, the HSD is turned off. This DTC detects a continuous open or short to ground in the shift solenoid B circuit or shift solenoid B. This is a type B DTC.

D D D D Fixed to 4th gear. Maximum line pressure. Inhibit TCC engagement. The PCM will illuminate the Malfunction Indicator Lamp (MIL) and CHECK TRANS Lamp.


D Ignition is on, Engine run. D Battery voltage is between 10 and 16 volts. D The PCM commands the solenoid on and the voltage remains high (B+)or the PCM commands the solenoid off and the voltage remains low (zero volts). D All conditions met for 0.84 1.0 seconds.
Diagnostic Aids
D Inspect the wiring for poor electrical connections at the PCM and at the transmission 16way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation.

D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. Shift Solenoid Status Chart Gear 1st 2nd 3rd 4th Shift solenoid A OFF ON ON OFF Shift solenoid B ON ON OFF OFF
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 5. This test measures the resistance of the component. 7. This test checks the function of the shift solenoid B and the transmission internal wiring harness. 11.This test checks for power to the shift solenoid B from the ignition through the PCM.
DTC P0758 Shift Solenoid B Electrical

Go to Step 2 2 1. Install the scan tool. 2. With the engine on, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. Were DTCs P0753, P0758, P1860 set? 3 1. The engine on. 2. Apply brake pedal and select transmission range D. 3. Press and hold down the winter switch and select transmission mode winter. Does the scan tool display DTC P0758 at 3rd gear? 4 1. 2. 3. 4. Turn the ignition off. Disconnect the J1 (BLUE) and J2 (RED) PCM connectors. Turn the ignition on. Using the J39200 DVOM, measure the voltage between PCM connector terminals J231 and J11. Go to Step 15 Go to Step 8 Go to Step 4
Go to Step 3
Is the voltage within 10 12 volts? 5 1. Turn the ignition off. 2. Using the J39200 DVOM, measure the resistance between PCM connector terminals J243 and J231. Is the resistance within 18 20 ohms? 6 1. Disconnect the transmission 16way connector H56. 2. Using the J39200 DVOM, measure the resistance between terminals H5611 and H5612. Is the resistance within 18 20 ohms? 7 1. Disconnect the transmission main case connector M7. 2. Using the J39200 DVOM, measure the resistance between terminals M72(D) and M76(A). Is the resistance within 18 20 ohms?
Go to Step 5
Go to Step 16
Go to Step 6
Go to Step 17
Go to Step 7
Go to Step 18
Go to Step 19
7A173
DTC P0758 Shift Solenoid B Electrical (Contd)

Step 8 Action 1. Turn the ignition off. 2. Disconnect the J1 (BLUE) and J2 (RED) PCM connectors. 3. Using the J39200 DVOM, measure the resistance between PCM connector terminals J243 and J231. Is the resistance within 18 20 ohms? 9 Using the J39200 DVOM, check a continuity between PCM connector terminal J231 and ground. Is there a continuity? 10 1. Disconnect the transmission 16way connector H56. 2. Using the J39200 DVOM, measure the resistance between terminals H5611 and H5612. Is the resistance within 1820 ohms? 11 Using the J39200 DVOM, check a continuity between PCM connector terminal J243 and ground. Is there a continuity? 12 1. Disconnect the transmission main case connector M7. 2. Using the J39200 DVOM, measure the resistance between terminals M72(D) and M76(A). Is the resistance within 18 20 ohms? 13 Check every connection of the PCM and transmission 16way connector H56. Was a problem found and corrected? 14 1. Connect the J1 (BLUE) and J2 (RED) PCM connectors to the PCM. 2. Turn the ignition on, the engine on. 3. Repeat Step 3. Does the scan tool display DTC P0758 at 3rd gear? 15 The wiring harness between PCM connector terminal J231 and transmission main case terminal M76(A) is shorted to voltage. Was a problem found and corrected? 16 The PCM internal terminal J231 is shorted to voltage. Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 17 The wiring harness between PCM connector and transmission 16way connector is shorted. Was a problem found and corrected? 18 The wiring harness between transmission 16way connector and transmission main case connector is shorted. Was a problem found and corrected? 19 The shift solenoid B is faulty, or the internal wiring harness from the shift solenoid B is shorted. Was a problem found and corrected? 20 The wiring harness between PCM connector terminal J231 and transmission main case connector terminal M76(A) is shorted to ground. Was a problem found and corrected? Go to Step 26 Go to Step 26 Go to Step 26 Go to Step 26 Go to Step 26 Go to Step 26 Go to Step 25 Go to Step 26 Go to Step 14 Go to Step 23 Go to Step 24 Go to Step 22 Go to Step 13 Go to Step 21 Go to Step 12 Go to Step 20 Go to Step 11 Go to Step 9 Go to Step 10 Yes No
DTC P0758 Shift Solenoid B Electrical (Contd)

Step 21 Action The wiring harness between PCM connector terminal J231 and transmission 16way connector terminal H5612, or between PCM connector terminal J243 and 16way connector terminal H5611 is open. Was a problem found and corrected? 22 The wiring harness between PCM connector terminal J243 and transmission main case connector terminal M72(D) is shorted to ground. Was a problem found and corrected? 23 The wiring harness between transmission 16way connector terminal H5612 and transmission main case connector terminal M76(A), or between H5611 and M72(D) is open. Was a problem found and corrected? 24 The internal wiring harness from the shift solenoid B is open, or the shift solenoid B is faulty. Was a problem found and corrected? 25 26 Replace the PCM. Is the replacement complete? 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and operate the vehicle under the following conditions: D The shift solenoid B is commanded on and voltage drop to zero. D The shift solenoid B is commanded off and voltage increases to B+. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 26 Go to Step 26 Go to Step 26 Go to Step 26 Go to Step 26 Yes No
7A175
DTC P1850 Brake Band Apply Solenoid Malfunction
D07RY00014
Circuit Description
D The brake band apply solenoid is a normally open solenoid which controls the flow of fluid for brake band application. The Powertrain Control Module (PCM) uses Pulse Width Modulation (PWM) and changes the duty cycle to control the solenoid. The PCM turns the solenoid on (energized) and off (deenergized) at a constant frequency. The length of time the solenoid is energized during each on/off cycle is called the pulse width. By varying or modulating the pulse width, the solenoid output pressure is changed. Since the solenoid is normally open, increasing the pulse width increases the duty cycle and decreases the output pressure. PWM control provides smooth band application without an accumulator. The band is only applied in first and second gears. D In the event of an electrical failure (open), the solenoid regulates at the maximum oil flow (0% duty cycle). D The solenoid is activated by current. This current is produced by applying a voltage to one side (the High side) and a ground to the other side (Low side). D The High Side Driver (HSD) is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage. The High side of the solenoid is permanently supplied with voltage. When the ignition is off, the HSD is turned off.
This DTC detects a continuous open or short to ground in the brake band apply solenoid circuit or the brake band apply solenoid. This is a type D DTC.

D Battery voltage is between 10 and 16 volts. D Ignition is on, Engine run. D The PCM commands the solenoid on and the voltage remains high (B+) or the PCM commands the solenoid off and the voltage remains low (zero volts). D All conditions met in 1.34 1.56 seconds.

D Inhibit brake band apply solenoid. D The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

Diagnostic Aids
D Inspect the wiring for poor electrical connection at the PCM and at the transmission 16way connectors. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for power to the brake band apply solenoid from the ignition through the PCM. 4. This test checks the resistance of the transmission internal wiring harness and brake band apply solenoid. 5. This test checks the ability of the PCM and wiring to control the ground circuit.
DTC P1850 Brake Band Apply Solenoid Malfunction

Go to Step 2 2 1. Install the scan tool. 2. With the engine on, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. Were DTCs P0753, P0758 set? 3 Using the J39200 DVOM, back probe between PCM connector terminals J243 and J11. Is the voltage between 10 to 12 volts? 4 1. Turn the ignition off. 2. Disconnect the J1 (BLUE) and J2 (RED) PCM connectors. 3. Using the J39200 DVOM, measure the resistance between PCM connector terminals J243 and J210. Is the resistance within 1012 ohms? 5 Using the J39200 DVOM, back probe between PCM connector terminals J210 and J11. Is the voltage between 10 to 12 volts? 6 1. Turn the ignition off. 2. Disconnect the J1 (BLUE) and J2 (RED) PCM connectors. 3. Using the J39200 DVOM, check continuity between PCM terminal J243 and ground. Is there a continuity? 7 1. Disconnect the transmission 16way connector H56. 2. Using the J39200 DVOM, check continuity between connector H569 and ground. Is there a continuity? 8 1. Disconnect the transmission main case connector M7. 2. Using the J39200 DVOM, check continuity between the terminal M77(B) and ground. Is there a continuity? Go to Step 18 Go to Step 8 Go to Step 7 Go to Step 26 Go to Step 12 Go to Step 5 Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 13
Go to Step 4
Go to Step 9
Go to Step 17
Go to Step 19
7A177
DTC P1850 Brake Band Apply Solenoid Malfunction (Contd)

Step 9 Action 1. Disconnect the J1 (BLUE) and J2 (RED) PCM Connector. 2. Using the J39200 DVOM, measure the resistance between PCM connector terminals J243 and J210. Is the resistance within 1012 ohms? 10 1. Disconnect the transmission 16way connector H56. 2. Using the J39200 DVOM, measure the resistance between terminal H5611 and H569. Is the resistance within 1012 ohms? 11 1. Disconnect the transmission main case connector M7. 2. Using the J39200 DVOM, measure the resistance between terminals M72(D) and M77(B). Is the resistance within 1012 ohms? 12 Using the J39200 DVOM, check continuity between PCM terminal J210 and ground. Is there a continuity? 13 1. Disconnect the transmission 16way connector H56. 2. Using the J39200 DVOM, measure the resistance between terminal H5611 and H569. Is the resistance within 1012 ohms? 14 1. Disconnect the transmission 16way connector H56. 2. Using the J39200 DVOM, check continuity between terminal H569 and ground. Is there a continuity? 15 1. Disconnect the transmission main case connector M7. 2. Using the J39200 DVOM, measure the resistance between terminals M72(D) and M77(B). Is the resistance within 1012 ohms? 16 1. Disconnect the transmission main case connector M7. 2. Using the J39200 DVOM, check continuity between the terminal M77(B) and ground. Is there a continuity? 17 The wiring harness between PCM terminal J243 and transmission 16way connector terminal H5611 is open. Was a problem found and corrected? 18 The brake band apply solenoid is faulty, or the internal wiring harness from the brake band apply solenoid is shorted to ground. Was a problem found and corrected? 19 The wiring harness between the transmission 16way connector terminal H5611 and the transmission main case connector terminal M72(D) is shorted to ground. Was a problem found and corrected? 20 The wiring harness between the transmission 16way connector terminal H5611 and the transmission main case connector terminal M72(D) is open. Was a problem found and corrected? 21 The brake band apply solenoid is faulty, or the internal wiring harness from the brake band apply solenoid is open. Was a problem found and corrected? Go to Step 27 Go to Step 27 Go to Step 27 Go to Step 27 Go to Step 27 Go to Step 18 Go to Step 23 Go to Step 25 Go to Step 21 Go to Step 16 Go to Step 22 Go to Step 24 Go to Step 15 Go to Step 14 Go to Step 26 Go to Step 20 Go to Step 21 Go to Step 17 Go to Step 11 Go to Step 26 Go to Step 10 Yes No
DTC P1850 Brake Band Apply Solenoid Malfunction (Contd)

Step 22 Action The wiring harness between the PCM connector terminal J210 and transmission 16way connector terminal H569 is shorted to ground. Was a problem found and corrected? 23 The wiring harness between the transmission 16way connector terminal H569 and the transmission main case connector terminal M77(B) is shorted to ground. Was a problem found and corrected? 24 The wiring harness between the PCM connector terminal J210 and the 16way connector terminal H569 is open. Was a problem found and corrected? 25 The wiring harness between the transmission 16way connector terminal H569 and the transmission main case connector terminal M77(B) is open. Was a problem found and corrected? 26 Check every connection at the PCM. If OK, replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 27 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and ensure the following conditions are met: D The brake band apply solenoid is commanded on and the volts drop to zero. D The brake band apply solenoid is commanded off and the volts increase to B+. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 27 Go to Step 27 Go to Step 27 Go to Step 27 Go to Step 27 Yes No
7A179
DTC P1860 TCC PWM Solenoid Electrical
D07RY00015
Circuit Description
The PCM allows current to flow through the solenoid coil according to the duty cycle (percentage of on and off time). This current flow through the solenoid coil creates a magnetic field that magnetizes the solid core. The magnetized core attracts the check ball to seat against spring pressure. This blocks the exhaust for the TCC signal fluid and allows solenoid feed drive fluid to feed to TCC signal circuit. The TCC signal fluid pressure acts on the TCC regulator valve to regulate line pressure and to apply fluid pressure to the torque converter clutch shift control valve. When the TCC control valve is in the apply position, regulated apply fluid pressure is directed through the TCC valve to apply the torque converter clutch. The TCC PWM solenoid is used in conjunction with the TCC reglator valve to regulate fluid to the torque converter. The TCC PWM solenoid is attached to the valve body within the transmission. This DTC detects a continuous open or short to ground or ignition in the TCC circuit or the TCC PWM solenoid. This is a type B DTC.
D For lamp illuminate refer to DTC type definition (type B).

Diagnostic Aids
D Inspect the wiring for poor electrical connections at the PCM and at the transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. D When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

Battery voltage is between 10 and 16 volts. No shift solenoid A DTCs P0751 or P0752 or P0753. No shift solenoid B DTCs P0756 or P0757 or P0758. Ignition is on, Engine run. The PCM commands the solenoid on and the voltage remains low (zero volts). D The PCM commands the solenoid off and the voltage remains high (B+). D All conditions met for 0.875 1.25 seconds. D D D D D
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for voltage to the solenoid. 4. This test checks the ability of the PCM and wiring to control the ignition circuit. 9. This test checks the resistance of the TCC solenoid and the internal wiring harness.

D Inhibit TCC engagement.
DTC P1860 TCC PWM Solenoid Electrical

Go to Step 2 2 1. Install the scan tool. 2. With the engine on, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when theClear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. Go to Step 3 3 Using the J39200 DVOM, back probe between PCM connector terminals J251 and J233. Is the voltage 0 ? 4 1. Apply brake pedal and select transmission range D. 2. Do a test drive, and increase the vehicle speed to TCC on at 4th. Does the scan tool display DTC P1860 at TCC ON? 5 1. Turn the ignition off. 2. Disconnect the J2 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between PCM connector terminals J251 and J233. Is the resistance 100.5 ohms at 20C (68F) ? 6 The wiring harness between PCM connector terminal J251 and transmission adapter case connector terminal M61(A) is shorted to voltage. Was a problem found and corrected? 7 Intermittent condition. Check the wiring harness and terminals between PCM connector J2 and transmission adapter case connector M6. Was a problem found and corrected? 8 1. Disconnect the transmission 4way connector H54. 2. Using the J39200 DVOM, measure the resistance between terminal H542 and ground. Is the resistance 100.5 ohms at 20C (68F) ? 9 1. Disconnect the transmission adapter case connector M6. 2. Using the J39200 DVOM, measure the resistance between terminal M61(A) and ground. Is the resistance 100.5 ohms at 20C (68F) ? 10 1. Turn the ignition off. 2. Disconnect the J2 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between terminals J251 and J233. Is the resistance 100.5 ohms at 20C (68F) ? 11 1. Disconnect the transmission 4way connector H54. 2. Using the J39200 DVOM, measure the resistance between terminal H542 and ground. Is the resistance 100.5 ohms at 20C (68F) ? Go to Step 13 Go to Step 19 Go to Step 17 Go to Step 16 Go to Step 19 Go to Step 19 Go to Step 7 Go to Step 10 Go to Step 5
Go to Step 4
Go to Step 6
Go to Step 8
Go to Step 20
Go to Step 20
Go to Step 9
Go to Step 18
Go to Step 11
Go to Step 12
7A181
DTC P1860 TCC PWM Solenoid Electrical (Contd)

Step 12 Action 1. Disconnect the transmission adapter case connector M6. 2. Using the J39200 DVOM, measure the resistance between terminal M61(A) and ground. Is the resistance 100.5 ohms at 20C (68F) ? 13 The wiring harness between PCM connector terminal J251 and transmission 4way connector terminal H542 is shorted to ground. Was a problem found and corrected? 14 The wiring harness between transmission 4way connector H54 and adapter case connector M6 is shorted to ground. Was a problem found and corrected? 15 The TCC solenoid is faulty, or the internal wiring harness from the TCC solenoid is shorted to ground. Was a problem found and corrected? 16 The wiring harness between PCM connector terminal J251 and transmission 4way connector terminal H542 is open. Was a problem found and corrected? 17 The wiring harness between transmission 4way connector terminal H542 and adapter case terminal M61(A) is open. Was a problem found and corrected? 18 The TCC solenoid is faulty, or the internal wiring harness from the TCC solenoid is open. Was a problem found and corrected? 19 Check every connection at the PCM. If OK, replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30E) section. Is the replacement complete? 20 Check the PCM connector terminal J251, transmission 4way connector terminal H542 and transmission adapter case connector terminal M61(A). Was a problem found and corrected? 21 1. After the repair is complete, use the scan tool to select DTC, then Clear Info function and ensure the following conditions are met: D The TCC solenoid is commanded on and the volts increase to B+. D The TCC solenoid is commanded off and the volts drop to zero. 2. Review the scan tool DTC Info. Has the last test failed or is the current DTC displayed? Go to Step 21 Go to Step 21 Go to Step 21 Go to Step 21 Go to Step 21 Go to Step 21 Go to Step 21 Go to Step 21 Go to Step 14 Go to Step 15 Yes No
DTC P1870 Transmission Component Slipping (TCC Stuck OFF)
D07RY002
Circuit Description
The PCM monitors the difference in engine speed and transmission output speed. For example in D3 drive range with the ECCC commanded, the engine speed should closely match transmission output speed. This DTC detects excessive TCC slip when the ECCC is engaged. This is a type B DTC.
D Low (0.8) < TCC Capacity < hi (0.99) for 5 seconds

D Only stored in memory. D For lamp illuminate refer to DTC type definition (type B).

The following conditions are met for three TCC cycles with reported excessive TCC slip conditions. D No OSS DTCs P0722 or P0723. D No shift solenoid A DTCs P0751 or P0752 or P0753. D No shift solenoid B DTCs P0756 or P0757 or P0758. D No TCC solenoid DTCs P0742 or P1860 or P1870. D Engine speed is between 1,000 and 3,500 rpm for 0.5 seconds. D Gear range is D4. D 13% < TPS < 99% D 50 < Engine Torque < 300 Nm D TFT is between 20 and 150C (68 and 302F). D TCC slip speed is between 250 rpm and 800 rpm for 3 times 7 seconds. D Vehicle speed is between 25 km/h (15 mph) and 225 km/h (158 mph). D Speed ratio is between 0.6 and 0.95. D ECCC is ON.

D The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. D The DTC can be cleared from the PCM history by using a scan tool. D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. D The PCM will cancel the DTC default actions when the fault no longer exist and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
D Range switch malfunction could set a DTC P1870. D A mechanical failure of the shift solenoids, TCC solenoid, or TCC PWM solenoid could set a DTC P1870. D Internal transmission failures may set a DTC P1870. D An intermittent or incorrect engine speed signal may set a DTC P1870.
7A183
Test Description
The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the indicated range signal to the actual selected range. A faulty switch could set a DTC P1870. 3. This test checks the torque converter for slippage while in a commanded lockup state.
Range Switch Logic Table Range Position Park Reverse Neutral D4 D3 2 L Illegal Illegal Range Switch Pin A ON ON OFF OFF ON ON OFF OFF OFF B OFF ON ON ON ON OFF OFF OFF OFF C OFF OFF OFF ON ON ON ON OFF OFF P(G) ON OFF ON OFF ON OFF ON OFF ON
DTC P1870 Transmission Component Slipping (TCC Stuck OFF)

Go to Step 2 2 1. Install the scan tool. 2. With the engine off, turn the ignition switch on. NOTE: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. Apply the brake pedal. 5. Select each transmission range: D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the scan tool TR Switch display? 3 Drive the vehicle in 4th gear while the TCC is engaged. At any time is the TCC Slip Speed greater than 130 rpm for 8 seconds while the TCC is engaged? Go to System Diagnosis Charts Go to Step 3
Go to Range Switch Logic Table Go to Diagnostic Aids
Connector List
No. Connector face No. Connector face
B-13
H-41
E-53 (J2)
H-53
E-54 (J1)
H-54
H-8
H-55
H-10
H-56
H-11
H-57
H-24
I-9
H-25
M-6
H-32
M-7

No. Connector face No. Connector face
7A185
M-15
M-25
SECTION
MANUAL TRANSMISSION
TROOPER
7B1
TRANSMISSION
MANUAL TRANSMISSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission Assembly . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1 7B2 7B3 7B4 7B4 7B8 Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B13 7B16 7B34 7B36 7B62 7B64
Service Precaution
7B2
MANUAL TRANSMISSION
General Description
A07RW023
MANUAL TRANSMISSION
7B3
Diagnosis
Condition Abnormal noise Possible cause Flywheel pilot bearing worn Bearings worn or broken (Mainshaft, counter shaft, and transfer shaft) Gear tooth contact surfaces worn or scuffed (Mainshaft, counter shaft, reverse idler gear and transfer gears) Splines worn (Mainshaft, synchronizer clutch hub) Gear or bearing thrust face seized Lack of backlash between meshing gears Hard Shifting Improper clutch pedal free play Change lever sliding portions worn Shift block, shift rod and/or control box sliding faces worn Shift arm and synchronizer sleeve groove worn Thrust washer, collar, and/or gear thrust faces worn (Mainshaft and counter shaft thrust play) Synchronizer parts worn Walking or Jumping out of gear Detent ball worn Detent spring weakened or broken Shift rod and/or control box sliding faces worn Shift arm and synchronizer sleeve groove worn Thrust washer, collar, and/or gear thrust faces worn (Mainshaft and counter shaft thrust play) Bearings worn or broken Splines worn synchronizer hub) (Mainshaft, Replace Replace Replace Correction
Replace Replace Replace Readjust Repair or replace Regrease Replace Replace worn parts Replace worn parts
Replace Replace Replace Replace Replace worn parts Replace worn parts
Replace Replace Replace Tighten Replenish oil Replace Replace
Synchronizer spring weakened or broken Oil leakage Loose drain plug(s) and/or filler plug(s) Defective or improperly installed gasket(s) Oil seal worn or scratched
7B4
MANUAL TRANSMISSION
Manual Transmission Assembly

Removal
NOTE: Before remove the transmission and transfer assembly from the vehicle, change the transfer mode to 2WD using push button on dash panel. 1. Remove engine hood. 2. Disconnect battery ground cable. 3. Remove the gear control lever knob. 4. Remove the front console assembly. 5. Remove the grommet assembly. 6. Remove the transmission control lever and transfer control lever. 9. Remove the front propeller shaft. NOTE: Apply alignment marks on the flange at both the front and rear sides.
401RS003
10. Disconnect the reverse lamp switch, 4WD indicator switch, and 1-2 indicator switch harness connectors.
235RX001
7. Remove transfer protector. 8. Remove the rear propeller shaft. NOTE: Apply alignment marks on the flange at the both front and rear side.
230RW005
401RS002
MANUAL TRANSMISSION
11. Disconnect the speed sensor and 2WD-4WD actuator harness connectors.
7B5
13. Remove two transmission harness clamps from the transmission case and bracket .
225RW007
220RS028
12. Disconnect the 4WD indicator harness connector.
14. Remove four fuel pipe bracket.
220RW006
7B6
MANUAL TRANSMISSION
141RW024
15. Remove the heat protector.
16. Remove the slave cylinder.
225RW006
206RW002
MANUAL TRANSMISSION
D Remove the dust cover from the clutch housing. 17. Support the transfer case with a jack. 18. Remove two engine rear mount nuts.
7B7
27. Use the clutch release bearing remover J39207 to disconnect the clutch release bearing from the clutch pressure plate.
220RS002 022RT002
19. Remove third crossmember. 20. Disconnect four oxygen sensor connectors from the transmission harness. 21. Remove the right front exhaust pipe and catalytic converter assembly. 22. Remove the harness heat protector. 23. Remove two engine rear mount bolts. 24. Remove the rear mount from the transmission. 25. Remove three flywheel under cover. 26. Support the transmission with a transmission jack and then remove jack from the transfer case side.
Release bearing disconnection 1. Pull the shift fork toward the transmission to press the clutch release bearing against the clutch. 2. Insert the clutch release bearing remover between the wedge collar and the release bearing. 3. Turn the remover to separate the release bearing.
220RS001
7B8
MANUAL TRANSMISSION
NOTE: Be sure not to insert the remover between the wedge collar and the clutch.
220RS004
28. Remove the transmission retaining nuts and bolts. 29. Remove the transmission assembly with transfer case from the vehicle. NOTE: Remove the transfer case from the transmission assembly if the transmission disassembly required. Refer to Transfer Case in Drive Line/Axle section.
Installation
1. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline. 2. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the engine. The slope of the engine and the transmission must be the same. 3. Align the top gear shaft spline with the clutch driven plate spline.
220RW063
220RW064
220RS005
4. Install the transmission to the engine. Tighten the transmission retaining nuts and bolts.
MANUAL TRANSMISSION
7B9
225RX001
5. Apply a force of about 113 N (26 lb) to the tip of the shift fork in the direction of the transmission to engage the clutch pressure plate and release bearing. NOTE: A clicking sound is heard when the release bearing and the tip of the diaphragm spring engage each other. Check to see if they are securely engaged by pushing the tip of the shift fork toward the engine while applying a force of about 25 N (5.5 lb). If the shift fork will not move, then they are securely engaged.
220RS006
6. Install three flywheel under cover.
7B10 MANUAL TRANSMISSION

7. Install the engine rear mount to the transmission case and tighten the fixing bolts specified torque. Torque: 41 Nm (30 lb ft) 8. Install the harness heat protector. 9. Install the right front exhaust pipes and catalytic converter assembly. Torque Exh. pipe to exh. manifold: 67 Nm (49 lb ft) Exh. pipe flange bolt: 43 Nm (32 lb ft) 10. Connect four oxygen sensor connectors to the transmission harness. 11. Install the third crossmember to the frame and tighten the fixing bolts specified torque. Torque: 50 Nm (37 lb ft) 12. Tighten the engine rear mount nuts specified torque. Torque: 50 Nm (37 lb ft) 13. Remove the transmission jack. 14. Apply the grease to top hole portion of the shift fork. 15. Install the slave cylinder and tighten the fixing bolts specified torque. Torque: 43 Nm (32 lb ft) Install the clutch dust cover to the clutch housing and tighten the fixing bolts specified torque. Torque: 8 Nm (69 lb in) 16. Install the slave cylinder heat protector to the slave cylinder. 17. Install harness heat protector.
225RW006
18. Install four fuel pipe bracket.
220RS007
MANUAL TRANSMISSION
7B11
141RW024
19. Install bracket and two transmission harness clamps to the transmission case.
20. Connect the speedometer sensor and 2WD4WD actuator harness connector.
220RS028
225RW007

21. Connect the backup lamp switch, 4WD indicator switch, and 1-2 indicator switch harness connectors. 24. Install transfer protector and tighten the fixing bolts specified torque. Torque: 37 Nm (27 lb ft) 25. Install the transmission control lever and transfer control lever. 26. Install the grommet assembly. 27. Install the front console assembly. 28. Install the gear control lever knob.
230RW005
22. Install the front propeller shaft and tighten the fixing bolts and nuts specified torque. Torque: 63 Nm (46 lb ft) 23. Install the rear propeller shaft and tighten the fixing bolts and nuts specified torque. Torque: 63 Nm (46 lb ft) 29. Connect battery ground cable. 30. Install engine hood.
235RX001
MANUAL TRANSMISSION
7B13
Disassembled View
226RW182
Legend (1) Snap Ring (2) Bearing (3) Top Gear Shaft (4) Block Ring (5) Roller Bearing (6) Snap Ring (7) Clutch Hub No.2 Assembly (8) 3rd Block Ring (9) 3rd Gear (10) 3rd Gear Needle Roller Bearing (11) Mainshaft (12) Thrust Washer Pin (13) 2nd Gear Needle Roller Bearing (14) 2nd Gear (15) Synchronizer Assembly (16) Clutch Hub No.1 Assembly (17) Snap Ring (18) Synchronizer Assembly
(19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37)
1st Gear 1st Gear Bearing Spacer 1st Gear Needle Roller Bearing 1st Gear Thrust Washer Mainshaft Bearing Snap Ring 5th Gear Snap Ring Intermediate Plate Bearing Retainer Snap Ring Front Bearing Assembly Counter Gear Shaft Thrust Washer Pin Reverse Idle Gear Reverse Idle Gear Shaft Counter Gear Shaft Center Bearing Snap Ring Thrust Washer

(38) (39) (40) (41) Roller Bearing Counter 5th Gear Reverse Block Ring Synchronizer Assembly (42) Hub Sleeve No.3 (43) 5th Gear Spline Piece (44) Snap Ring
226RW181
Legend (1) 3rd-4th Shift Arm (2) 1st-2nd Shift Arm (3) 3rd-4th Shift Rod (4) Ball (5) Spring (6) 1st-2nd Shift Rod (7) Snap Ring (8) Interlock Pin
(9) (10) (11) (12) (13) (14) (15) (16)
Reverse Shift Arm Bracket ERing Reverse Shift Arm No.2 Reverse Shift Arm No.1 5th Reverse Shift Rod Spring Pin 5th Shift Arm Reverse Shift Rod
MANUAL TRANSMISSION
7B15
220RY002
Legend (1) Release Bearing and Shift Fork (2) Clutch Housing (3) Front Cover (4) Snap Ring (5) Snap Ring (6) 1st and 2nd Switch (7) Drain Plug (8) Backup Light Switch (9) Plug (10) Transmission Case
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Filler Plug Oil Receiver Pipe Reverse Restrict Pin Gear Control Rod Transfer Adapter Plug Gear Control Box Shift Lever Housing Oil Seal Plug
Disassembly
1. Remove the drain plag and filler plug. 1. Remove the drain plug (1) and gasket. 2. Remove the filler plug (2) and gasket.
3. Remove the switch. 1. Remove backup light switch (6) and gasket. 2. Remove 1st and 2nd switch (8) and gasket.
220RY001
220RW007
4. Remove the clutch housing. 1. Remove the 9 bolts.
2. Remove the clutch release bearing and shift fork. 1. Remove the clutch release bearing (3) from the front cover. 2. Remove the split pin (4). Remove the shaft from the under. Remove the shift fork (5).
241RW001
220RW086
MANUAL TRANSMISSION
2. Using a plastic hammer, carefully tap the clutch housing.
7B17
6. Remove transfer adapter. 1. Using a hexagon wrench, remove the plug (1).
220RW008
220RW010
5. Remove gear control box and gasket. 1. Remove the 6 bolts, gear control box and gasket.
2. Using a pin punch and hammer, drive out the slotted spring pin (2).
230RW001
230RW002

3. Using the M8 1.25 bolt, remove the gear control rod and the shift lever housing. NOTE: Turn the M8 bolt a few times, before remove the gear control rod. 5. Using a plastic hammer, tap the transfer adapter. NOTE: D Be careful not to lose the pin. D Cover the mainshaft splines with adhesive tape. This will prevent damage to the oil seal lip.
220RW098
4. Remove the 10 bolts and clamp.

220RW015
7. Disassemble the transfer adapter assembly. 1. Using a torx socket wrench(T40), remove the plug.
220RW016
220RW013
MANUAL TRANSMISSION
2. Using a pin punch and hammer, drive out the slotted spring pin. Remove the reverse restrict pin. 4. Remove the oil seal.
7B19
5. Using socket hexagon wrench, remove the plug.
220RW014 220RW012
3. Remove the oil receiver pipe.
8. Remove the front cover. 1. Remove the 8 bolts.
220RW011 220RW018

2. Using a plastic hammer, carefully tap the front cover. 10. Remove the transmission case. 1. Using a snap ring expander, remove the 2 snap rings (1)(2).
220RW017
9. Remove the front cover oil seal. 1. Mount the front cover through the aluminum plate in a vise. 2. Using screwdriver, remove oil seal (1).
226RW004
2. Using a plastic hammer, carefully tap the transmission case.
220RW020
220RW019
MANUAL TRANSMISSION
11. Mount the intermediate plate. 1. Mount the intermediate plate through the aluminum plate in a vise. 13. Remove the shift arm set bolt. 1. Remove the 2 bolts from the shift arm.
7B21
226RW023 226RW005
12. Remove the slotted spring pin. 1. Using a pin punch and hammer, drive out the pin from the arm.
14. Remove the counter 5th gear. 1. Using 2 screwdrivers and hammer, tap out the snap ring.
226RW024 226RW025

2. Using remover J42794 and attachment J42988, remove the 5th gear spline piece. 4. Remove the synchronizer pull ring, synchronizer cone ring, and synchronizer outer ring from hub sleeve No.3.
226RW021
3. Remove the hub sleeve No.3, block ring set, counter 5th gear, bearing and 5th shift arm.
226RW066
5. Remove the reverse block ring from the hub sleeve No.3. Remove the 3 inserts and 3 compression springs.
220RW101
226RW067
MANUAL TRANSMISSION
15. Remove the thrust washer. 1. Remove the thrust washer from counter gear shaft. 2. Remove the thrust washer pin from counter gear shaft.
7B23
17. Remove the reverse idle gear. 1. Pull out the shaft foward the rear and remove the reverse idle gear.
226RW020
226RW018
16. Remove the bearing plate. 1. Remove the 4 bolts and bearing retainer.
18. Remove the counter gear shaft. 1. Using snap ring plier, remove counter gear shaft center bearing snap ring.
226RW015
226RW016

2. Using remover J42795 and attachment J42988, remove counter gear shaft center bearing. NOTE: Be careful not to drop the counter gear, when removing the bearing. 19. Disassemble the counter gear shaft assembly. 1. Using snap ring pliers, remove the counter gear shaft front bearing snap ring.
226RW065
226RW036
2. Using bearing separator J2291201 and a press, remove the bearing.
3. Remove the counter gear from intermediate plate.
226RW068
226RW030
MANUAL TRANSMISSION
20. Remove the top gear shaft. 1. Remove the top gear shaft from mainshaft. NOTE: Dont fall needle roller bearing. 21. Disassemble the top gear shaft assembly. 1. Check for wear or damage.
7B25
226RW033
2. Remove the front bearing shaft snap ring.

226RW029
2. Remove the 4th block ring and roller bearing.
226RW062
226RW031

3. Using bearing separator J2291201 and a press, remove the bearing. 2. Using a plastic hammer, tap the 5th-reverse shift rod at the reverse shift side.
226RW069
226RW034
22. Remove the mainshaft. 1. Remove mainshaft bearing snap ring.
3. Remove the intermediate plate from a vise. 4. Remove the mainshaft, 1st-2nd shift arm and 3rd-4th shift arm.
226RW035
226RW014
MANUAL TRANSMISSION
23. Disassemble the main shaft assembly. 1. Inspect each gear thrust clearance. 1. Using thickness gauge, inspect clearance (1st gear, 3rd gear). 2. Inspect each gear radial clearance. thrust
7B27
1. Using a dial indicator, measure the radial clearance of each gear. Gear 1st 2nd 3rd Standard Clearanse 0.020 0.074 mm (0.00078 0.00291 in) 0.015 0.068 mm (0.00059 0.00268 in) 0.015 0.068 mm (0.00059 0.00268 in)
226RW077
2. Mount the mainshaft through the aluminum plate in a vise. 3. Using a dial indicator, measure each gear thrust clearance. Gear 1st 2nd 3rd Standard Clearanse 0.15 0.45 mm (0.0059 0.0177 in) 0.10 0.25 mm (0.0039 0.0098 in) 0.10 0.25 mm (0.0039 0.0098 in)
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3. Using 2 screwdrivers and hammer, tap out the snap ring.
226RW053
226RW070

4. Using bearing separator J2291201 and a press, remove the following parts. 1. 5th gear (1). 2. Mainshaft bearing (2). 3. 1st gear thrust washer (3). 4. 1st gear (4). 6. Using 2 screwdrivers and hammer, tap out snap ring.
226RW073
7. Using bearing separator J2291201 and a press, remove the following parts. 1. Clutch hub No.1 assembly (1). 2. Synchronizer assembly (2).
226RW072
5. Remove following parts from mainshaft. 1. Synchronizer assembly (1). 2. 1st gear thrust washer pin (3). 3. 1st gear needle roller bearing (4). 4. 1st gear bearing spacer (2).
3. 2nd gear (3). 4. 2nd gear needle roller bearing (4).
226RW074
226RW146
MANUAL TRANSMISSION
8. Remove the reverse gear from clutch hub No.1. 9. Remove the 3 inserts and 3 compression springs. D When removing the inserts, push the insert spring with a screwdriver. 11. Using a press, remove following parts. 1. Clutch hub No.2 assembly (1). 2. 3rd block ring (2). 3. 3rd gear (3). 4. 3rd gear needle roller bearing (4).
7B29
226RW075
10. Remove the snap ring.

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NOTE: Dont damage the bearing surface.
12. Using screwdriver, remove the 2 insert springs, hub sleeve No.2, clutch hub No.2 and 3 inserts.
226RW076
226RW090

24. Remove the shift parts and interlock parts. 1. Mount the intermediate plate through the aluminum plate in a vise. 2. Using a plastic hammer, tap the 5th shift rod on the neutral. 4. Using a magnetic finger, remove 3 springs and balls.
226RW049
5. Using 2 screwdrivers and a hammer, remove 2 snap rings from each shift fork rod.
226RW052
3. Using a torx socket wrench(T40), remove the 4 plugs.
226RW048
226RW050
MANUAL TRANSMISSION
6. Pull out the 3rd4th shift rod at the rear.
7B31
8. Pull out the 1st2nd shift rod at the rear.
226RW047
226RW045
7. Using a magnetic finger, remove the interlock pin and straight pin.
9. Using a magnetic finger, remove the interlock pin.
226RW042 226RW043

10. Using 2 screwdrivers and a hammer, remove 2 snap rings. 12. Using a magnetic finger, remove the interlock pin from the intermediate plate. Remove the ball from the reverse shift arm No.1.
226RW041
11. Pull out the 5th-reverse shift rod at the front.
226RW039
13. Pull out at the rear reverse shift rod, reverse shift arm No.1 and reverse shift arm No.2 at the same time.
226RW040
226RW038
MANUAL TRANSMISSION
14. Pull out reverse shift rod from reverse shift arm No.1. NOTE: Be sure remove at the rear.
7B33
16. Remove the reverse shift arm No.2 Ering. Remove the reverse shift arm No.2 from reverse shift arm No.1.
226RW089 226RW055
15. Using a magnetic finger, remove the ball and spring from reverse shift arm No.1.
17. Remove the 2 bolts and reverse shift arm bracket.
226RW054
226RW056
Inspection
1. Counter 5th gear radial clearance. 1. Install the following parts to the counter gear shaft. 1. Counter 5th gear thrust washer pin (1). 2. Counter 5th gear thrust washer (2). 3. Counter 5th gear needle bearing( 3). 4. Counter 5th gear (4).
4. Using a inside dial indicator, measure the gear inside diameter. Standard: 38.015 38.040 mm (1.49665 1.49763 in)
226RW085
2. 5th-reverse shift arm and hub sleeve No.3 clearance. 1. Using a vernier caliper, measure the 5th-reverse shift arm thickness. Reference: 10.2 mm (0.402 in)
226RW088
2. Mount the counter gear shaft through the aluminum plate in vise. 3. Using a dial indicator, measure the counter 5th gear radial clearance. Standard: 0.015 0.068 mm (0.00059 0.00268 in)
2. Using a vernier caliper, measure the center groove of hub sleeve No.3. Calculate the clearance between the hub sleeve No.3 and shift arm. Standard: 0.26 0.84 mm (0.0102 0.0331 in) Reference: Center groove dimension 10.5mm (0.413 in)
226RW183 226RW086
MANUAL TRANSMISSION
3. Reverse block ring set. 1. Using a thickness gauge, measure the clearance between the counter 5th gear spline piece and reverse block ring. Standard: 0.7 1.7 mm (0.028 0.067 in)
7B35
3. If the clearance exceeds the maximum, measure the gear inside diameter and shaft diameter. Standard Shaft Diameter: 23.979 24.000 mm (0.94405 0.94488 in) Gear Diameter: 24.040 24.061 mm (0.94645 0.94728 in)
226RW084
4. Reverse idle gear and reverse idle gear shaft. 1. Mount the reverse idle gear and reverse idle gear shaft in a vise. 2. Using a dial indicator, measure the reverse idle gear radial clearance. Standard: 0.040 0.082 mm (0.0016 0.0032 in)
226RW082
5. Reverse shift arm No.2 thrust clearance. 1. Using a thickness gauge, measure the clearance between the reverse idle gear and shift arm No.2. Standard: 0.05 0.35 mm (0.002 0.014 in)
226RW083
226RW081
Reassembly
1. Install the top gear shaft assembly. 1. Using installer J42904 and a press, install a new bearing. NOTE: Outer race snap ring groove (1) toward front.
3. Using a snap ring expander, install the new snap ring.
226RW062
4. Install the 4th block ring.
226RW092
2. Select a snap ring that will allow minimum axial play. Mark A B C D E F G Thickness 2.10 2.15 mm (0.083 0.085 in) 2.15 2.20 mm (0.085 0.087 in) 2.20 2.25 mm (0.087 0.089 in) 2.25 2.30 mm (0.089 0.091 in) 2.30 2.35 mm (0.091 0.093 in) 2.35 2.40 mm (0.093 0.095 in) 2.40 2.45 mm (0.095 0.097 in)
226RW063
226RW061
MANUAL TRANSMISSION
5. Using a thickness gauge, measure the clearance between the 4th block ring back and gear spline end. Standard: 0.75 1.65 mm (0.030 0.065 in)
7B37
3. Inspect block ring. 1. Using a thickness gauge, measure the clearance between the synchronizer ring back and gear spline end. Gear 1st 2nd 3rd Standard Clearanse 0.80 1.60 mm (0.032 0.063 in) 0.65 1.75 mm (0.026 0.069 in) 0.75 1.65 mm (0.030 0.065 in)
226RW064
6. Check the braking effect of the block ring. Turn the block ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the block ring.
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2. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
226RW060
7. Install the needle roller bearing. 2. Reassemble the mainshaft assembly. NOTE: Apply all parts with gear oil before installing them.
226RW106

4. Inspect hub sleeve and shift arm. 1st2nd shift arm 1. Using a vernier caliper, measure center groove of the 1st2nd shift arm. Reference: 5.28 mm (0.208 in) 2. Using a vernier caliper, measure flange of the reverse gear. Calculate the clearance between the reverse gear and shift arm. Reference: Reverse gear flange thickness 5.0 mm (0.197 in) Standard: 0.15 0.41 mm (0.006 0.016 in)
226RW095
5. Inspect clutch hub and hub sleeve. 1. Check for wear or damage. 2. Install the hub sleeve to the clutch hub, and check sliding smoothly.
226RW093
3rd4th shift arm 1. Using a vernier caliper, measure tip of the shift arm thickness. Reference: 10.0mm (0.39 in) 2. Using a vernier caliper, measure center groove of the hub sleeve No.2. Calculate the clearance between the hub sleeve No.2 and shift arm. Reference: Center groove dimension 10.2 mm (0.402 in)
226RW094
Standard: 0.15 0.35 mm (0.006 0.014 in)
6. Inspect gear inside diameter. 1. Using a inside dial indicator, measure the gear inside diameter. Gear 1st 2nd 3rd Standard Diameter 46.015 46.040 mm (1.8116 1.8126 in) 53.015 53.040 mm (2.0872 2.0882 in) 44.015 44.040 mm (1.7329 1.7339 in)
MANUAL TRANSMISSION
7B39
2. Using a micrometer, measure the mainshaft flange thickness. Standard: 5.0 mm (0.197 in)
226RW096
7. Inspect mainshaft. 1. Using a micrometer, measure the outer diameter of the mainshaft journal.
226RW079
Measure Positio n A B C
3. Install the mainshaft to V-blocks. Standard 37.984 38.000 mm (1.4954 1.4961 in) 46.984 47.000 mm (1.8498 1.8504 in) 38.979 38.995 mm (1.5346 1.5352 in) 4. Use a dial indicator to measure the mainshaft central portion run-out. Standard: less than 0.015 mm (0.0006 in)
226RW097
226RW078

8. Install 3rd gear. 1. Install the 3rd gear needle bearing, 3rd gear and 3rd block ring to the mainshaft. NOTE: D Align the block ring slots with the inserts. D Check that the gear rotates smoothly.
226RW098
9. Install the clutch hub No.2. 1. Install the clutch hub No.2 and hub sleeve No.2. NOTE: Be careful the direction of the clutch hub No.2, as shown. 2. Using a screwdriver, install 3 inserts and 2 springs. NOTE: Position the insert springs so that their end gaps are not in line.
226RW100
4. Select a snap ring that will allow minimum axial play. Mark A B C D E F G Thickness 1.80 1.85 mm (0.071 0.073 in) 1.85 1.90 mm (0.073 0.075 in) 1.90 1.95 mm (0.075 0.077 in) 1.95 2.00 mm (0.077 0.079 in) 2.00 2.05 mm (0.079 0.081 in) 2.05 2.10 mm (0.081 0.083 in) 2.10 2.15 mm (0.083 0.085 in)
226RW099
3. Using installer J42797 and a press, install the clutch hub No.2 and hub sleeve No.2 to the mainshaft.
226RW102
MANUAL TRANSMISSION
5. Using a snap ring expander, install the new snap ring. NOTE: Be careful not to damage the bearing surface.
7B41
10. Install the 2nd gear. 1. Install the synchronizer ring set NO.1 to the 2nd gear. NOTE: Align the nail of middle ring with gear spline slots.
226RW101
6. Using a thickness gauge, inspect the 3rd gear thrust clearance. Standard: 0.10 0.25mm (0.004 0.010 in)
226RW104
2. Install the needle roller bearing, 2nd gear and 2nd gear block ring set to the mainshaft.
226RW107 226RW103

11. Install the clutch hub No.1. 1. Install the 3 inserts and 3 insert springs to the clutch hub No.1. Reference: While pushing the insert spring with a screwdriver, install the inserts.
226RW110
4. Select a snap ring that will allow minimum axial play. Mark
226RW108
Thickness 2.30 2.35 mm (0.091 0.093 in) 2.35 2.40 mm (0.093 0.095 in) 2.40 2.45 mm (0.095 0.097 in) 2.45 2.50 mm (0.097 0.098 in) 2.50 2.55 mm (0.098 0.100 in) 2.55 2.60 mm (0.100 0.102 in) 2.60 2.65 mm (0.102 0.104 in)
A B C D E F G
2. Install the clutch hub No.1 to the reverse gear. NOTE: Check the clutch hub No.1 installing direction, as shown.
226RW109
3. Using installer J42798 and a press, install the hub No.1 by retaining the reverse gear. NOTE: D Align the projection of inner ring with hub No.1 slots. D Check that the gear rotates smoothly.
226RW111
MANUAL TRANSMISSION
5. Using a screwdriver and hammer, install the snap ring. NOTE: Be careful not to damage the bearing surface. 6. Check that the gear rotates smoothly. 1. Install the following parts: 1. 1st gear bearing spacer (4). 2. 1st gear needle roller bearing (3). 3. Synchronizer assembly (2). 4. 1st gear (1). NOTE:
7B43
D Align the projection of inner ring with hub No.1 slots. D Check that the gear rotates smoothly.
226RW112
7. Using a dial indicator, measure the 2nd gear thrust clearance. Standard: 0.10 0.25mm (0.004 0.010 in)
226RW114
2. Install the 1st gear thrust washer pin and 1st gear thrust washer to the mainshaft. NOTE: Align the straight pin with the thrust washer slot.
226RW113
12. Install the 1st gear.
226RW115

13. Install the mainshaft center bearing. 1. Using installer J42799 and a press, install the mainshaft center bearing. NOTE: Center bearing snap ring groove toward rear. Mark C D E F G H J K L M N P Thickness 2.75 2.80 mm (0.108 0.110 in) 2.80 2.85 mm (0.110 0.112 in) 2.85 2.90 mm (0.112 0.114 in) 2.90 2.95 mm (0.114 0.116 in) 2.95 3.00 mm (0.116 0.118 in) 3.00 3.05 mm (0.118 0.120 in) 3.05 3.10 mm (0.120 0.122 in) 3.10 3.15 mm (0.122 0.124 in) 3.15 3.20 mm (0.124 0.126 in) 3.20 3.25 mm (0.126 0.128 in) 3.25 3.30 mm (0.128 0.130 in) 3.30 3.35 mm (0.130 0.132 in)
226RW117
2. Using a thickness gauge, measure 1st gear thrust clearance. Standard: 0.10 0.45mm (0.004 0.018 in)
226RW116
3. Using a screwdriver and hammer, install the new snap ring.
226RW118
14. Install the 5th gear. 1. Using installer J42799 and a press, install the 5th gear. 2. Select a snap ring that will allow minimum axial play.
226RW127
MANUAL TRANSMISSION
15. Inspect each gear radial clearance. 1. Mount the mainshaft through the aluminum plate in a vise. 2. Using a dial indicator, measure the radial clearance of each gear. Gear 1st 2nd 3rd Standard Clearanse 0.020 0.073 mm (0.0008 0.0029 in) 0.015 0.068 mm (0.0006 0.0027 in) 0.015 0.068 mm (0.0006 0.0027 in)
7B45
3. Select a snap ring that will allow minimum axial play. Mark A B C D E F Thickness 2.00 2.05 mm (0.079 0.081 in) 2.05 2.10 mm (0.081 0.083 in) 2.10 2.15 mm (0.083 0.085 in) 2.15 2.20 mm (0.085 0.087 in) 2.20 2.25 mm (0.087 0.089 in) 2.25 2.30 mm (0.089 0.091 in)
226RW071
16. Install the counter gear shaft. 1. Check the new counter front bearing inner race and the side race, as shown. 2. Using installer J42800 and a press, install the counter gear shaft front bearing.
226RW128
4. Using a snap ring expander, install the new snap ring.
226RW129
226RW119

17. Install the front cover. 1. Using installer J42801, grip J8092 and a hammer, drive in a new oil seal. Drive in depth (from cover end): 11.7 0.5 mm (0.46 0.02 in) 2. Apply grease to the seal lip. 3. Install the oil receiver pipe.
220RW011
4. Install the reverse restrict to the transfer adapter.
220RW023
18. Install the transfer adapter. 1. Using installer J 42802, and a hammer drive in a new oil seal. Drive in depth (from transfer adapter): 10.95 0.5 mm (0.431 0.02 in) 2. Apply grease to the oil seal lip.
226RW059
220RW073
MANUAL TRANSMISSION
5. Using a pin punch and hammer, drive in the slotted spring pin.
7B47
9. Using hexagon wrench, install and torque the plug. Torque: 37 Nm (27 lb ft)
226RW058
6. Clean up the plug and plug hole. 7. Apply sealant to the plug threads. (THREE BOND 1344 or equivalent) 8. Using a torx socket wrench(T40), install and torque the plug. Torque: 18.5 Nm (13.5 lb ft)
220RW014
19. Install the reverse shift arm No.1 and reverse shift arm No.2. 1. Mount the intermediate plate through the aluminum plate in a vise.
226RW057
220RW013

2. Using 2 bolts, install reverse shift arm bracket. Torque: 18 Nm (13 lb ft) 4. Install reverse shift arm No.2 to the reverse shift arm bracket.
226RW012 226RW054
3. Install reverse shift arm No.2 to the reverse shift arm No.1. Using screwdriver and a hammer, install the new E-ring.
20. Install the reverse shift rod. 1. Install the reverse shift arm No.1 compression spring and ball to the reverse shift arm No.1.
226RW125 226RW138
MANUAL TRANSMISSION
2. Install the reverse shift rod from the rear side by pushing the ball on using a screwdriver.
7B49
3. Put in the reverse-5th shift rod from the front.
226RW011 226RW126
21. Install the reverse-5th shift rod. 1. Install the reverse shift arm No.1 lock ball to the reverse shift arm No.1. 2. Install the interlock pin to the intermediate plate.
4. Using a screwdriver and a hammer, install the 2 new shift rod snap rings to the 5th-reverse shift rod and reverse shift rod.
226RW037
226RW039

22. Install 1st2nd shift rod. 1. Install the interlock pin to the intermediate plate. 23. Install 3rd4th shift rod. 1. Install the straight pin and interlock pin to the intermediate plate.
226RW042
2. Put in the 1st2nd shift rod from the rear. 2. Put in the 3rd4th shift rod from the rear.
226RW043
226RW044 226RW046
MANUAL TRANSMISSION
24. Install the interlock parts. 1. Using a screwdriver and hammer, 2 new shift rod snap rings to the 1st2nd and 3rd4th shift rod.
7B51
5. Using a torx socket wrench(T40) install and torque the 4 plugs. Torque: 18.5 Nm (13.5 lb ft)
226RW051 226RW050
2. Install the 3 shift detent ball and springs to the intermediate plate.
25. Install mainshaft assembly. NOTE: Coat all parts with gear oil before installing them. 1. Using a plastic hammer, tap the 5th-reverse shift rod at the reverse shift.
226RW049
3. Clean up the plug hole. 4. Apply sealant to the plug threads. sealant: three bond 1344 or equivalent
226RW180

2. Install the shift arm No.1 and No.2 to the mainshaft. 4. Using a snap ring expander, install the snap ring.
226RW035 226RW010
3. Using a plastic hammer, tap the intermediate plate and install the mainshaft. Through the shift arm No.1 and No.2 to the shift rod.
5. Using a plastic hammer, tap the 5th-reverse shift rod at the neutral shift.
226RW008
226RW009
MANUAL TRANSMISSION
26. Install the top gear shaft. 1. Align the projection of the hub No.2 with the synchronizer ring slots, and install the top gear shaft assembly to the mainshaft. 2. Check that the gear rotates smoothly.
7B53
2. Using installer J42796 and a hammer, drive in the center bearing as shown. NOTE: Outer race snap ring groove toward rear.
226RW007
226RW006
27. Install the counter gear shaft. 1. Temporarily install the counter gear shaft to the intermediate plate.
Reference: Drive in the counter rear bearing by tapping on the front end of the counter shaft.
226RW022
226RW028

28. Install the reverse idle gear. 1. Install the reverse idle gear and reverse idle gear shaft. NOTE: D Insert the reverse idle gear shaft with the slot toward rear. D Install the reverse idle gear with the reverse shift arm No.2. 30. Install the 5th gear thrust washer. 1. Install the 5th gear thrust washer pin to the counter gear shaft. 2. Install the 5th gear thrust washer to the counter gear shaft. NOTE: Thrust washer must be assembled with the chamfered face of the washer toward the front.
226RW185 226RW019
29. Install the bearing plate. 1. Align the bearing plate to groove of the reverse idle gear shaft. Torque: 12.5 Nm (109 lb in)
31. Install the counter 5th gear. 1. Install the 3 inserts and 3 compression springs to the reverse block ring. Reference: Push the 3 inserts with the 3 compression springs to the reverse synchronizer ring.
226RW016 226RW120
MANUAL TRANSMISSION
2. Install the synchronizer outer ring, synchronizer cone ring, and synchronizer pull ring to the reverse block ring.
7B55
4. Install the hub sleeve No.3 and reverse block ring set to the counter 5th gear. NOTE: Check the hub sleeve No.3 direction, as shown. Reference: While pushing the 3 inserts, install the synchronizer ring assembly to the hub sleeve No.3.
226RW121
3. Turn to 30 degree the reverse synchronizer pull ring.

226RW184
5. Slide the hub sleeve No.3.
226RW080
226RW123

6. Install the counter 5th gear bearing, counter 5th gear and reverse block ring set to the counter gear shaft, through the 5th reverse shift arm to the 5th reverse shift rod. 8. Using thickness gauge, measure the counter 5th gear thrust clearance. Standard: 0.10 0.35mm (0.004 0.014 in)
220RW100 220RW101
7. Using installer J42796 and a press, install counter 5th gear spline piece. NOTE: D Align the projection of the cone ring to the holes of the 5th gear spline piece. D Check that the gear rotates smoothly.
9. Select a snap ring that will allow minimum axial play. Mark A B C D E F G Thickness 2.80 2.85 (0.110 0.112 in) 2.85 2.90 (0.112 0.114 in) 2.90 2.95 (0.114 0.116 in) 2.95 3.00 (0.116 0.118 in) 3.00 3.05 (0.118 0.120 in) 3.05 3.10 (0.120 0.122 in) 3.10 3.15 (0.122 0.124 in)
226RW013
226RW027
MANUAL TRANSMISSION
10. Install the new snap ring.
7B57
33. Install the shift arm slotted pin. 1. Using a pin punch and a hammer, drive in the slotted pin to the shift arm.
226RW026
32. Install the shift arm bolts. 1. Install and torque the 2 shift arm bolts. Torque: 19.5 Nm (14 lb ft) 34. Install the transmission case. 1. Clean up the fitting surface.
226RW025
2. Apply recommended liquid gasket (THREE BOND 1281 or equivalent), as shown. NOTE: D Dont dry the liquid gasket.
226RW023
220RW024

3. Stand the transmission by the wood blocks. 4. Using a plastic hammer, tap the transmission case and attach it to the intermediate plate. NOTE: Be careful not to add over force to bearing. NOTE: D Dont dry the liquid gasket.
220RW025
3. Clean up and dry the bolts.

220RW022
5. Using a snap ring expander, install the front bearing shaft snap ring (1) and counter gear shaft bearing snap ring (2).
4. Apply thread sealant (THREE BOND 1344 or equivalent) to the 8 bolts. 5. Using 8 bolts, install the front cover to the transmission case. Torque: 16.5 Nm (12 lb ft) NOTE: D Tighten the all bolts evenly. D Be careful not to damage the oil seal.
226RW004
6. Turn over the transmission. 35. Install the front cover. 1. Clean up the fitting surface. 2. Apply recommended liquid gasket (THREE BOND 1281 or equivalent), as shown.
220RW018
MANUAL TRANSMISSION
6. Check that the top gear shaft and mainshaft rotate. 36. Install the transfer adapter. 1. Clean up the fitting surface. 2. Apply recommended liquid gasket (THREE BOND 1281 or equivalent), as shown. NOTE: D Dont dry the liquid gasket.
7B59
4. Using 10 bolts, install the transfer adapter. Torque: 37 Nm (27 lb ft) NOTE: D Tighten the all bolts evenly. D Dont damage the lip of the oil seal. D Install the wire clamp (9) to the transfer adapter.
220RW083
220RW026
3. Using a plastic hammer, tap the transfer adapter and attach it to the intermediate plate.
37. Install the gear control box. 1. Align the projection of the shift lever housing to the shift rod groove, and install the gear control rod.
220RW034
230RW003

2. Using a pin punch and hammer, drive in the slotted spring pin (2) to the shift lever housing. NOTE: Be carefull not to drop the slotted spring pin. 6. Using 6 bolts, install the gear control box through the gasket. Torque 18 Nm (13 lb ft)
230RW002
230RW001
3. Apply sealant (THREE BOND equivalent) to the plug (1) thread.
1344
or
4. Using hexagon wrench, install and torque the plug (1). Torque: 18 Nm (13 lb ft)
38. Install clutch housing. 1. Install the clutch housing to the transmission case. Torque: 36 Nm (27 lb ft) NOTE: Tighten the all bolts evenly.
220RW010
241RW001
5. Clean up the bolts and bolt hole.
MANUAL TRANSMISSION
39. Install the switches. 1. Install the new gasket to the 1st and 2nd switch. 2. Install the 1st and 2nd switch assembly (8). Torque: 39 Nm (29 lb ft) 3. Install the new gasket to the backup light switch. 4. Install the backup light switch assembly (6). Torque: 44 Nm (33 lb ft)
7B61
220RW086
41. Install the drain plug and filler plug. 1. Install the drain plug (1) through the new gasket. Torque: 37 Nm (27 lb ft) 2. Install the filler plug (2) through the new gasket. Reference: Plug after the gear oil fill in. Torque: 37 Nm (27 lb ft)
220RY001
40. Install the clutch release bearing (3) and clutch shift fork (5). 1. Apply the clutch release grease. 1. Fitting surface of the cylinder push rod. 2. Fitting surface of the release bearing hub. 3. The hole of the fork split pin (4). 2. Apply the clutch release grease. 1. The spline surface of the top gear shaft. 3. Install the clutch shift fork (5). 4. Install the snap pin. 5. Install the clutch release bearing (3) to the clutch shift fork (5).
220RW007

Transmission type Control method Gear ratio 1st 2nd 3rd 4th 5th Rev Oil capacity lit (US qt) Type of lubricant Fully synchronized forward and reverse gears Direct control with the gear shift lever on the floor 3.954 2.330 1.436 1.000 0.788 3.918 2.7 (2.86) Engine oil : Refer to the chart in SECTION 0
E07RY002
MANUAL TRANSMISSION
7B63
E07RW030
Special Tools
J42794 Gear spline pieace remover
J42799 Installer
J42795 Center bearing remover
J42800 Counter gear shaft front bearing installer
J42988 Attachment
J42904 Top gear shaft front bearing installer
J42796 Counter gear shaft center bearing installer
J42801 Front rerainer oil seal installer
J42797 Clutch hub (No.2) installer
J42802 Transfer adapter oil seal installer
J42798 Clutch hub (No.1) installer
J8092 Driver handle
MANUAL TRANSMISSION
7B65
J2291201 Bearing separator
SECTION
CLUTCH
TROOPER
7C1
TRANSMISSION
CLUTCH
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . Clutch Assembly and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Control Parts . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . 7C1 7C2 7C6 7C7 7C7 7C7 7C8 7C12 7C15 7C15 7C15 7C15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C16 7C16 7C19 7C19 7C20 7C20 7C20 7C20 7C21 7C22 7C24
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM(SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFOMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastner in the proper location. When you reolace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that requir a replacement after removal. ISUZU will also call out the fasteners that requir thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED , do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fastners or fastner joint interfaces. Generally,such coatings adversely affect the fastner torque and the joint clamping force, and may damage the fastner. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
7C2
CLUTCH
General Description
Clutch
A07RW046
For 6VE1 (3.5L) engine model, the pull-type clutch is employed. The pull-type clutch is disengaged by pulling
the release lever (release bearing) to disengage the pressure plate.
CLUTCH
7C3
Master Cylinder
A07RW007
Slave Cylinder
A07RS005
7C4
CLUTCH
Pressure Plate Assembly
A07RS006
CLUTCH
7C5
Driven Plate Assembly
A07RS007
7C6
CLUTCH
Diagnosis
Condition Dragging Possible cause Fluid leakage. Air in hydraulic line. Master cylinder and slave cylinder seals worn. Driven plate warped. Diaphragm spring weakened or tip of fingers worn. Driven plate sticking on splines. Clutch spline worn. Release bearing worn or damaged. Slipping Driven plate facing worn or oil soaked. Diaphragm spring weakened. Pressure plate or flywheel warped. Master cylinder and slave cylinder seals worn. Chattering Engine mounts loose or damaged. Driven plate facing warped. Surface of facing hardened. Driven plate facing oil soaked. Damper broken. Noisy springs weakened or Repair Bleed Replace seals. Replace driven plate. Replace pressure plate Lubricate with grease or replace. Repair Replace release bearing. Replace driven plate and check for leaks. Replace pressure plate. Correct or replace. Replace seals. Tighten or replace. Replace driven plate. Replace driven plate Replace driven plate and check for leaks. Replace. Correct or replace. Correct, or replace if damaged, and lubricate. Replace release bearing. Lubricate. Replace pilot bearing. weakened or Replace driven plate. Replace driven plate. Clean out or replace. Repair or replace as needed. Correction
Pressure plate or flywheel warped. Replace bearing binding. Replace bearing worn or damaged. Release bearing poorly lubricated. Pilot bearing worn. Damper broken. Replace driven plate. springs
Rivets of driven plate exposed. Hydraulic line blocked. Master or slave cylinders binding.
CLUTCH
7C7
Clutch Assembly
Clutch Assembly and Associated Parts
201RW0181
Legend (1) Flywheel Assembly and Crankshaft Bearing (2) Driven Plate Assembly (3) Pressure Plate Assembly
(4) (5) (6) (7)
Transmission Assembly Front Cover Shift Fork Release Bearing
Removal
1. Remove transmission assembly, refer to MANUAL TRANSMISSION of Section 7B for Removal AND INSTALLATION procedure. 2. Remove pressure plate assembly (2). 3. Remove driven plate assembly (1), use the pilot aligner J-24547 to prevent the driven plate assembly (1) from falling free.
201RW005
7C8
CLUTCH
4. Mark the flywheel, clutch cover and pressure plate lug for alignment when installing. 5. Remove the release bearing (3) from the transmission case . 6. Remove the shift fork snap pin. 7. Remove the shift fork pin and shift fork (4) from the front cover. 8. Remove the front cover bolts. 9. Remove the front cover (5) from the transmission case.

Make necessary correction or parts replacement if wear, damage, or any other abnormal condition are found through inspection.
Pressure Plate Assembly
201RS002
1. Visually check the pressure plate friction surface for excessive wear and heat cracks. 2. If excessive wear or deep heat cracks are present, the pressure plate must be replaced.
220RW088
10. Remove flywheel assembly and crankshaft bearing, do not remove except for replacement. 11. Use the remover J5822 and sliding hammer J23907 to remove the crankshaft bearing.
Pressure Plate Warpage
201RS003
015RW050
CLUTCH
1. Use a straight edge and a feeler gauge to measure the pressure plate friction surface flatness in four directions. 2. If any of the measured values exceeds the specified limit, the pressure plate must be replaced. Pressure Plate Warpage Limit: 0.3 mm (0.012 in)
7C9
2. Place a new driven plate over the pressure plate. A metal sheet with A thickness of 8.3 mm (0.327 in) may be used in place of the driven plate. 3. Compress the pressure plate assembly until the distance B becomes 12 mm (0.472 in). 4. Note the pressure gauge reading. 5. If the measured value is less than the specified limit, the pressure plate assembly must be replaced. Clutch Set Force Standard: 7208 N ( 1621 lb) Limit: 6468 N (1454 lb)
Clutch Cover
Diaphragm Spring Finger Height
201RS004
1. Visually check the entire clutch cover for excessive wear, cracking, and other damage. 2. The clutch cover must be replaced if any of these conditions are present.
201RW009
Clutch Set Force
Legend (1) Release Side 1. Place a new driven plate or a 8.3 mm (0.327 in) spacer beneath the pressure plate. 2. Fully compress the pressure plate and diaphragm spring. 3. There are two ways to do this. 4. Use a bench press to press down on the assembly from the top. 5. Tighten the fixing bolts. NOTE: Preload on diaphragm spring finger must be 49 98 N (11 22 lb) in direction of release, when clutch cover assembly is bolted to the flywheel. 6. Measure the spring height from base to spring tip A. If the measured value exceeds the specified limit, the pressure plate assembly must be replaced. Spring Finger Height
201RS005
1. Invert the pressure plate assembly.
Standard: 49.9 mm 51.9 mm (1.965 in 2.043 in)
7C10
CLUTCH
1. Insert the clutch pilot aligner into the driven plate splined hub. 2. The clutch pilot aligner J-24547 must be held perfectly horizontal. 3. Set a dial indicator to the driven plate outside circumference. 4. Slowly turn the driven plate. 5. Read the dial indicator as you turn the driven plate. 6. If the measured value exceeds the specified limit, the driven plate assembly must be replaced. Driven Plate Warpage Standard: 0.7 mm (0.028 in) Limit: 1.0 mm (0.039 in)
Driven Plate Assembly
Driven Plate Splined Hub Spline Wear
201RS007
1. Visually check the torsion spring for looseness, breakage, and weakening. 2. If any of these conditions are discovered, the driven plate assembly must be replaced. 3. Visually check the facing surfaces for cracking and excessive scorching. 4. Visually inspect the facing surfaces for the presence of oil or grease. 5. If any of these conditions are discovered, the facing must be cleaned or replaced. 6. Check that the driven plate moves smoothly on the transmission top gear shaft spline. 7. Minor ridges on the top gear shaft spline may be removed with an oil stone.
201RS009
Driven Plate Warpage
1. Clean the driven plate splined hub. 2. Install the driven plate to the transmission top gear shaft spline. 3. Set a surface gauge to the driven plate outside circumference. 4. Slowly turn the driven plate counterclockwise. 5. Measure the spline rotation play as you turn the driven plate. 6. If the measured value exceeds the specified limit, the driven plate assembly must be replaced. Driven Plate Splined Hub Spline Wear Standard: 0.5 mm (0.020 in) Limit: 1.0 mm (0.039 in)
201RS008
CLUTCH
7C11
Rivet Head Depression
3. When replacing the release bearing, replace both the wedge collar and wire ring at the same time.
201RS010
1. Use a depth gauge or a straight edge with steel rule to measure the rivet head depression 1 from the facing surface 2. 2. Be sure to measure the rivet head depression on both sides of the driven plate. 3. If the measured value is less than the specified limit, the driven plate assembly must be replaced. Rivet Head Depression Standard: 1.95 mm (0.077 in) Limit: 0.2 mm (0.008 in)
201RW010
Legend (1) Wire Ring (2) Pressure Plate Assembly (3) Wedge Collar (4) T/M Side (5) Release Bearing (6) Engine Side
Wedge Collar
Release Bearing
201RS013
201RS011
1. Visually check the release bearing for excessive play, noise and breakage. 2. If any of these conditions are discovered, the release bearing must be replaced.
1. Visually check the surfaces of the wedge collar making contact with the release bearing for excessive wear and damage. 2. Replace any exhibiting excessive wear or damage.
7C12
CLUTCH
2. Install new flywheel fixing bolts in the order illustrated and tighten them to the specified torque. Torque: 54 Nm (40 lb ft) NOTE: Do not reuse the bolt and do not apply oil or thread lock to the bolt.
Shift Fork
201RS014
1. Visually check the surfaces of the shift fork making contact with the release bearing for excessive wear and damage. 2. Remove any minor stepping or abrasion from shift fork with an oil stone. 3. Replace any exhibiting excessive wear or damage.
015RS047
3. Install the front cover (5) to the transmission case. 4. Tighten three fulcrum bridge bolts to the specified torque. Torque: 16.5 Nm (12 lb ft)
Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Install flywheel assembly and crankshaft bearing, use the installer J-26516-A and driver handle J-8092 to install the crankshaft bearing then clean and lubricate with grease.
220RW088
5. Apply molybednum disulfide type grease to the pin hole inner circumferences and thrust surfaces. 6. Attach the shift fork to the front cover and insert the pin from below of the front cover.
015RS046
CLUTCH
7. Install the washer and snap pin.
7C13
9. Install the release bearing in the proper direction. NOTE: Ensure release bearing is properly positioned during installation, as shown in illustration.
201RW020
10. Install driven plate assembly, use the pilot aligner J-24547 to install the driven plate assembly.
201RW019
8. Apply molybdenum disulfide type grease to the areas shown in illustration.
201RS016
201RW012
7C14
CLUTCH
11. Install pressure plate assembly and tighten the bolts holding the pressure plate assembly in the order shown in illustration. Torque: 18 Nm (13 lb ft)
201RS017
12. Remove the aligner. NOTE: Do not strike the aligner with a hammer to remove it. 13. Install transmission assembly.
CLUTCH
7C15
Clutch Control
Clutch Control Parts
203RW001
Legend (1) Master Cylinder Assembly (2) Pedal Assembly and Switch
(3) Pin and Jaw Joint Pin (4) Oil Line Pipe (5) Slave Cylinder Assembly and Heat Protector
Removal
1. Remove pin and jaw joint pin. 2. Remove pedal assembly and switch. 3. Remove oil line pipe. 4. Remove slave cylinder assembly and heat protector. 5. Remove master cylinder assembly. 6. Remove damper cylinder assembly.

Make necessary adjustments, repairs, and part replacement if wear, damage or other problems are discovered during inspection.
7C16
CLUTCH
Installation
1. Install damper cylinder assembly. 2. Install master cylinder assembly. 3. Install slave cylinder assembly and heat protector. 4. Install oil line pipe. 5. Install pedal assembly and switch. 6. Install pin and jaw joint pin.
Adjustment
Clutch Pedal Adjustment
1. With clutch switch 1. Disconnect clutch switch (2) connector. 2. Loosen lock nut, then turn switch out until there is a gap between the switch plunger and clutch pedal.
203RW004
Legend (3) Floor Panel (4) Pedal Free Play (5) Clutch Pedal Height 3. Tighten push rod lock nut. 4. With clutch switch 1. Turn the clutch switch until the switch bolt just touches the clutch pedal arm.
203RW003
Legend (1) Push Rod (2) Clutch Switch 2. Loosen clutch master cylinder push rod lock nut. Turn push rod by hand to set clutch pedal height (5) to within specification. Clutch pedal height (5): 217 mm 227 mm (8.543 in 8.937 in)
203RW005
Legend (6) Blacket (7) Clutch Switch Bolt (8) Clutch Pedal Arm
CLUTCH
2. Adjust clutch switch by backing it out half a turn, and measure the clearance (E) between the clutch pedal arm and the clutch switch.
7C17
6. Clutch pedal engagement height inspection: 1. Operate the parking brake lever and block the wheels. 2. Start the engine, fully step on the clutch pedal, and move the shift lever to 1st position. 3. With the engine idling, release the clutch pedal slowly and measure its stroke just prior to its clutching position. Clutch Pedal Engagement Height (14) MIN. 30 mm (1.18 in) 7. If the measured value exceeds the specified limit, check the following points. Repair if necessary: D Hydraulic circuit for fluid leakage or air in circuit. D Clutch disc warped. D Diaphragm spring weakened or tip of fingers worn. D Driven plate sticking on sprines. D Release bearing worn or damaged. D Master cylinder and slave cylinder worn.
203RW006
Legend (9) Back out Switch 1/2 turn (10) Bracket (11) Clutch Switch Bolt (12) Lock Nut (13) Clutch Pedal Arm 3. Lock the lock nut. 4. Connect clutch switch connector. Clutch Switch and Clutch Pedal Clearance (E) 0.5 mm 1.5 mm (0.020 in 0.059 in) 5. After adjusting the clutch pedal height, push the clutch pedal by hand rightly to check the clutch pedal free play (4) to within specification. Pedal Free Play (4) 5 mm 15 mm (0.20 in 0.59 in) Legend (3) Floor Panel (14) Clutch Pedal Engagement Height
203RW007
203RW004
7C18
CLUTCH
D Master cylinder to dash panel Torque: 16 Nm (12 lb ft) D Clutch pedal to dash panel Torque: 21 Nm (15 lb ft) D Master cylinder push rod to yoke Torque: 17 Nm (12 lb ft) D Clutch pipe to master cylinder Torque: 12 Nm (9 lb ft) D Clutch pipe to flexible hose Torque: 16 Nm (12 lb ft) D Slave cylinder to case Torque: 43 Nm (32 lb ft) D Slave cylinder bleeder screw Torque: 8 Nm(69 lb in) D Flexible hose to slave cylinder Torque: 20 Nm (14 lb ft)
206RW003
Bleeding
1. Check the level of clutch fluid in the reservoir and replenish if necessary 2. Bleeding the slave cylinder. 1. Remove the rubber cap from the bleeder screw and wipe clean the bleeder screw. Connect a vinyl tube to the bleeder screw and insert the other end of the vinyl tube into a transparent container. 2. Pump the clutch pedal repeatedly and hold it depressed.
Legend (1) Slave Cylinder (2) Bleeder Screw (3) Vinyl Tube
203RS005
3. Loosen the bleeder screw to release clutch fluid with air bubbles into the container, then tighten the bleeder screw immediately. 4. Release the clutch pedal carefully. Repeat the above operation until air bubbles disappear from the clutch fluid being pumped out into the container. During the bleeding operation, keep the clutch fluid reservoir filled to the specified level. Reinstall the rubber cap.
CLUTCH
7C19
Master Cylinder
208RW017

Inspect the removed parts. If there are abnormalities such as wear, oil leak or other damage, replace the master cylinder assembly. NOTE: The master cylinder assembly cannot be disassembled because of pointstaked rod stopper.
7C20
CLUTCH
Slave Cylinder
Disassembled View
206RW004
Legend (1) Cylinder Body (2) Spring
(3) Piston and Piston Cup (4) Boot (5) Push Rod
Disassembly
1. Remove boot. 2. Remove push rod. 3. Remove piston and piston cup. 4. Remove spring. 5. Remove cylinder body.
Cylinder Body

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
206RS003
1. Clean the cylinder body. 2. Check the fluid return port for restrictions and clean it if necessary.
CLUTCH
7C21
Piston and Piston Cup

1. Visually inspect the disassembled piston and piston cup for excessive wear and damage. 2. Replace the inner parts with new parts shown in the illustration.
Reassembly
To reassemble, follow the disassembly steps in the reverse order, noting the following points: 1. Before installing the parts, apply a thin coat of rubber grease. 2. Install cup in groove in piston with the lip turned to the front of cylinder. Use care so as not to scratch the cylinder.
206RS004
3. Measure the clearance between slave cylinder wall and piston. 4. If the measured value exceeds the specified limit, the slave cylinder assembly must be replaced. Standard: 0.07 mm (0.0028 in) Limit: 0.15 mm (0.0059 in)
206RS006
206RS005
7C22
CLUTCH

Type Size Pressure plate Outside diameter Pressure plate Clamping force Pressure plate Spring finger height Driven plate Outside diameter x inside diameter Thickness Clutch disengaged Thickness Clutch engaged Total friction area Clutch control type Clutch pedal free play Clutch pedal height Clutch pedal stroke Dry single plate type with diaphragm spring 275 mm (10.83 in) 332 mm (13.07 in) 7208 N (1621 lb) 49.9 51.9 mm (1.965 2.043 in) 275 180 mm (10.83 6.69 in) 8.8 mm (0.346 in) 8.3 mm (0.327 in) 339 2 cm@ (52 2 in@) Hydraulic 5 15 mm (0.20 0.59 in) 217 227 mm (8.543 8.937 in) 152.5 162.5 mm (6.004 6.398 in)
E07RW032
CLUTCH
7C23
Torque Specifications (Contd)
E07RX001
7C24
CLUTCH
Special Tools
J-24547 Driven plate aligner
J-5822 and J-23907 Pilot bearing remover and Sliding hammer
J-26516-A Crankshaft pilot bearing installer
J-8092 Driver handle
SECTION
LIGHTING SYSTEM
TROOPER
8A1
BODY AND ACCESSORIES

CONTENTS
Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . Wiper / Washer System . . . . . . . . . . . . . . . . . . Entertainment . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . Meter and Gauge . . . . . . . . . . . . . . . . . . . . . . . 8A 8B 8C 8D 8E Body Structure . . . . . . . . . . . . . . . . . . . . . . . . . . Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Security and Locks . . . . . . . . . . . . . . . . . . . . . . Sunroof / Convertible Top . . . . . . . . . . . . . . . . Exterior / Interior Trim . . . . . . . . . . . . . . . . . . . . 8F 8G 8H 8I 8J
LIGHTING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight Adjustment . . . . . . . . . . . . . . . . . . Fog Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog Light Assembly . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog Light Adjustment . . . . . . . . . . . . . . . . . . Front Side Marker Light Bulb . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Light Bulb . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . License Plate Light Bulb . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . High Mount Stoplight . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Turn Signal Light Bulb . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A2 8A2 8A2 8A2 8A3 8A3 8A3 8A3 8A3 8A4 8A4 8A4 8A5 8A5 8A5 8A5 8A5 8A5 8A5 8A6 8A6 8A6 8A6 8A6 8A7 8A7 8A7 8A7 8A7 8A8 8A8 8A8 8A8 8A8 8A8 Rear Turn Signal Light Bulb . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Cornering Light Bulb . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backup Light Bulb . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Dome Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Room Light Bulb . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Courtesy Light Bulb . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Map Light Switch/Bulb . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ashtray Illumination Bulb . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glove Box Illumination Bulb . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vanity Mirror Illumination Bulb . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighting Switch (Combination Switch) . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A9 8A9 8A9 8A9 8A9 8A9 8A10 8A10 8A10 8A10 8A10 8A10 8A11 8A11 8A11 8A11 8A11 8A11 8A12 8A12 8A12 8A12 8A12 8A12 8A13 8A13 8A13 8A13 8A13 8A13 8A14 8A14 8A14 8A15 8A15
8A2
LIGHTING SYSTEM
8A15 8A16 8A16 8A16 8A17 8A17 8A17 8A18 8A18 8A18 8A18 8A18 8A19 8A19 8A19 8A20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Defogger Switch . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Heater Switch . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Remind Switch (Starter Switch) . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Illumination Controller . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 8A20 8A20 8A20 8A20 8A20 8A21 8A21 8A21 8A22 8A22 8A22 8A22 8A22 8A23 8A23 8A23 8A24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Switch (W/O Cruise Control) . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Switch (W/Cruise Control) . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Signal Switch/Cornering Light Switch (Combination Switch) . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Hazard Warning Switch . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Switch . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
Headlight Bulb
Removal
1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the cap(1) while turning it counter clockwise. 4. Pull the bulb(2) out from the headlight body. CAUTION: The halogen bulb develops a very high temperature. Do not touch the glass portion. If any stain is on the glass surface, It will scorch and the glass will be damaged.
801RS007
Installation
LIGHTING SYSTEM
8A3
Headlight
Headlight and Associated Parts
801RW003
Legend (1) Radiator Grille (2) Front End Lower Panel (3) Headlight Assembly (4) Headlight
(5) (6) (7) (8) (9)
Headlight Rim Headlight Bulb Rear Cover Bracket Front Combination Light
Removal
1. Disconnect the battery ground cable. 2. Remove the screw and pull out the two projecting portions on the fender to remove the front combination light. 3. Remove five clips and two screws to remove the radiator grille. 4. Remove tow screws to remove the front end lower panel(2). 5. Remove two bolts and two nuts to remove the headlight assembly (with bracket). 6. Remove the headlight bulb. 7. Remove two screws, two nuts and the spring for the headlight aim adjustment to remove the bracket. 8. Remove four screws to remove the rear cover. 9. Remove the headlight rim. 10. Remove the headlight.
Headlight Adjustment
Preparation
Place the unloaded vehicle on a level surface and check to see if the inflation pressure of the tires is correct, the lenses are clean, and the battery is sufficiently charged. Adjust the aim with the headlight tester, if necessary. When adjusting, follow the procedure of the tester manufacturer s.
Installation
To install, follow the removal steps in the reverse order. CAUTION: After installing the headlight, be sure to adjust the headlight aim.
801RS009
8A4
LIGHTING SYSTEM
Vertical adjustment
Use a screwdriver for vertical adjustment.
Horizontal adjustment
Use a screwdriver for horizontal adjustment.
801RW004
801RW005
Fog Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Open the rear cover(1) of the case. 3. Remove the dust cover. 4. Disconnect the bulb connector. 5. Remove the clip(3). 6. Remove the fog light bulb(2). 5. Close the rear cover(1) of the case.
801RS004
6. Connect the battery ground cable.
801RS004
Installation
1. Install the fog light bulb(2). 2. Install the clip(3). 3. Connect the bulb connector. 4. Install the dust cover.
LIGHTING SYSTEM
8A5
Fog Light Assembly

Removal
1. Disconnect the battery ground cable. 2. Remove two nuts from the bracket. 3. Disconnect the connector. 4. Remove the fog light assembly (1).
Fog Light Adjustment

Turn the adjusting screw with a screwdriver to adjust the aim of the fog light vertically.
801RW007
825RW104
Installation
To install, follow the removal steps in the reverse order. CAUTION: After installing the fog light, be sure to adjust the fog light aim.
Front Side Marker Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove the screw at the upper portion of the light bracket and then remove the bracket from the fender. 3. Remove the front combination light assembly(1). 4. Remove the front side marker light socket(2) by turning it counterclockwise. 5. Pull out the bulb(3) from the socket.
801RS003
Installation
8A6
LIGHTING SYSTEM
Parking Light Bulb

Removal and Installation
Refer to the Front Turn Signal Light Bulb in this section.
Taillight Bulb
Removal
1. Disconnect the battery ground cable. 2. Remove three screws and release locks at two locations to remove the rear combination light assembly(2). 3. Remove the socket(3) by turning it counterclockwise. 4. Turn the bulb(1) counterclockwise while pushing it to remove it from the socket.
Installation
803RS005
LIGHTING SYSTEM
8A7
License Plate Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove two screws to remove the lens(2). 3. Pull out the bulb(1) from the socket.
Installation
803RS006
Stoplight Bulb
Refer to the Taillight Bulb in this section.
8A8
LIGHTING SYSTEM
High Mount Stoplight

Removal
1. 2. 3. 4. 5. Disconnect the battery ground cable. Remove the clips(2). Pull out the high mount stoplight(1). Remove the connector. Remove the high mount stoplight.
Installation
1. Insert the clips(1)(3) into the high mount stoplight(2). 2. Reconnect the connector. 3. Install the high mount stoplight.
803RS004
803RS003
Front Turn Signal Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove the screw at the upper portion of the light bracket, and remove the bracket from the fender. 3. Remove the front combination light(1). 4. Remove the turn signal light socket(3) by turning it counterclockwise. 5. Remove the bulb(2) by turning it counterclockwise while pushing it at the same time.
801RS002
Installation
LIGHTING SYSTEM
8A9
Rear Turn Signal Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove the three screws and release the lock at two positions. 3. Remove the rear combination light(3). 4. Remove the turn signal light socket/bulb(1) by turning it counterclockwise. 5. Remove the bulb(2) by turning it counterclockwise while pushing it at the same time.
Installation
803RS002
Cornering Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove the screws at the upper portion of the light bracket, and remove the bracket from the fender. 3. Remove the front combination light(1). 4. Remove the cornering light bulb socket(3) by turning it counterclockwise. 5. Remove the bulb(2) by turning it counterclockwise while pushing it at the same time.
801RS001
Installation
8A10 LIGHTING SYSTEM
Backup Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove three screws and release the lock at two positions. 3. Remove the rear combination light(3). 4. Remove the backup light socket/bulb(1) by turning it counterclockwise. 5. Remove the bulb(2) by turning it counterclockwise while pushing it at the same time.
Installation
803RS001
Dome Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove the lens(2) by releasing the locks at three locations. 3. Remove the bulb(1).
Installation
805RS005
LIGHTING SYSTEM
8A11
Luggage Room Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove the lens(2) by releasing the locks at four locations. 3. Remove the bulb(1).
Installation
803RS007
Courtesy Light Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove two screws to remove the lens(1). 3. Pull out the bulb(2) from the socket.
Installation
805RS006
Map Light Switch/Bulb

Removal
1. Disconnect the battery ground cable. 2. Pull the map light body downward to release the lock. 3. Disconnect the connectors of the map light and the sun roof switch. 4. Remove the map light switch. 5. Turn the socket counterclockwise to remove it. 6. Pull out the bulb from the socket.
Installation
805RS008
Ashtray Illumination Bulb

Removal
1. Disconnect the battery ground cable. 2. Removal eight screws to remove the instrument cluster panel(1). 3. Remove the ashtray(5). 4. Remove four screws to remove the audio box(4). 5. Remove two screws to remove the ashtray guide(2). 6. Turn the socket counterclockwise to remove it then pull out the bulb(3).
742RS001
Installation
LIGHTING SYSTEM
8A13
Glove Box Illumination Bulb

Removal
1. Disconnect the battery ground cable. 2. Open the glove box lid, and then pull out the bulb(1).
Installation
805RS004
Vanity Mirror Illumination Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove the lens(2). 3. Remove the bulb(1).
Installation
743RW007
Starter Switch
Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly(1). Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly(2). Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover assembly(3). Refer to the Instrument Panel Assembly in Body Structure section.
Installation
To install, follow the removal steps in the reverse order noting the following point. 1. When installing the steering cowl(10), be sure to pass the harnesses through the route as shown in the figure so that the starter switch harness(7), the combination switch harness(8) and the inflator module harness(9) will not get caught.
431RW008
740R200050
5. Remove seven screws to remove the steering cowl(6). 6. Disconnect the connector, remove the screw(4) and then remove the starter switch(5).
431RW005
LIGHTING SYSTEM
8A15
Lighting Switch (Combination Switch)

Removal
1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover(5). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove seven screws to remove the steering cowl(4). 4. Disconnect the SDM (air bag controller) connector located at lower of the instrument panel driver lower cover. 5. Remove four fixing screws and disconnect the driver inflator module connector to remove the driver inflator module(3). CAUTION: When carrying a live inflator module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. Never carry the inflator module by the wires or connector on the underside of the module. When placing a live inflator module on a bench or other surface, always face the bag and trim cover up, away from the surface. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. 6. Remove the steering wheel(2). Refer to the Steering Wheel in Steering section. 7. Disconnect the SRS coil assembly connector,remove four fixing screws to remove the SRS coil assembly(1). 8. Disconnect the lighting switch connector, remove four fixing screws to remove the lighting switch(6). Torque: 34 Nm (25 lb ft) 3. When connect the double lock type of inflator module connector, insert the connector completely and lock at outside. Imperfect locking may cause malfunction of SRS system circuit. 4. When installing the steering cowl(11),be sure to pass the harnesses through the route as shown in the figure so that the starter switch harness(8), the combination switch harness(9) and inflator module harness(10) will not get caught. 1. Check to see if the vehicle is in the straight driving condition and turn the rotary section of the SRS coil assembly provided to the upper surface of the lighting switch (combination switch) counterclockwise fully until it stops. Then from where it stops, turn it back about 3 rotations to set the alignment marks(7) together before installing the steering wheel.
825RW099
2. Tighten the steering shaft nut to the specified torque.
825RS039
Installation
To install, follow the removal steps in the reverse order, noting the following points.
431RW014
Fog Light Switch

Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly(1). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly(2). Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover assembly(3). Refer to the Instrument Panel Assembly in Body Structure section.
Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. Push in the switch with your fingers until the switch is locked securely.
740R200050
5. Remove the instrument panel cluster assembly(4). Refer to the Instrument Panel Assembly in Body Structure section. 6. Disconnect the connector and push the lock from the back side of the instrument panel cluster assembly to remove the fog light switch(5).
825RW027
LIGHTING SYSTEM
8A17
Stoplight Switch (W/O Cruise Control)

Removal
1. Disconnect the battery ground cable. 2. Disconnect the connector(3), loosen the lock nut(1) and then remove the stoplight switch(2) by turning it.
310RS007
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Check to see if the brake pedal has been returned by the return spring to the specified position. 2. Turn the stoplight switch(1) clockwise until the tip of the threaded portion of the switch contacts the pedal arm(2). 3. Turn the switch counterclockwise until the space between the tip of the threaded portion and the pedal arm is 0.5 to 1.0 mm (0.02 0.04 in.).
310RS006
Brake Switch (W/Cruise Control)

Removal
1. Disconnect the battery ground cable. 2. Disconnect the connector(1), loosen the lock nut(3) and then remove the brake switch(2) by turning it.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Check to see if the brake pedal has been returned by the return spring to the specified position. 2. Turn the switch clockwise until the tip of the threaded portion of the brake switch contacts the pedal arm. 3. Turn the switch counterclockwise until the space between the tip of the threaded portion and the pedal arm is 0.5 to 1.0 mm (0.02 0.04 in.).
310RW010
310RS003
Turn Signal Switch/Cornering Light Switch (Combination Switch)

Refer to the removal and installation steps of the Lighting Switch (Combination Switch) in this section.
LIGHTING SYSTEM
8A19
Hazard Warning Switch

Removal
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Push in the switch with your fingers until it locks securely.
740R200050
5. Remove the instrument panel cluster assembly(4). Refer to the Instrument Panel Assembly in Body Structure section. 6. Disconnect the connector and push the lock from the back side of the instrument panel cluster assembly to remove the hazard warning switch(5).
825RW024
Tailgate Switch
Removal
1. Disconnect the battery ground cable. 2. Remove the screw and disconnect the connector(1) to remove the tailgate switch(2).
Installation
683RS014
Door Switch
Removal
1. Disconnect the battery ground cable. 2. Remove the screw and disconnect the connector to remove the door switch(1).
Installation
825RS043
LIGHTING SYSTEM
8A21
Rear Defogger Switch

Removal
Installation
740R200050
5. Remove the instrument panel cluster assembly(4). Refer to the Instrument Panel Assembly in Body Structure section. 6. Disconnect the connector and push the lock from the back side of the instrument panel cluster assembly to remove the rear defogger switch(5).
825RW023
Seat Heater Switch

Removal
1. Disconnect the battery ground cable. 2. Remove four fixing screws and disconnect the switch connectors to remove the front console assembly(4). 3. Push the lock from the back side of the front console assembly to remove the seat heater switch(5).
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Push the switch with your fingers until it locks securely.
825RW025
Key Remind Switch (Starter Switch)

Refer to the removal and installation on steps of the Starter Switch in this section.
LIGHTING SYSTEM
8A23
Illumination Controller
Removal
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Push in the switch with your fingers until the switch is locked securely.
740R200050
5. Remove the instrument panel cluster assembly(4). Refer to the Instrument Panel Assembly in Body Structure section. 6. Disconnect the connector and push the lock from the back side of the instrument panel cluster assembly to remove the illumination controller(5).
825RW026

Light and Bulb Specifications
801R200023
Legend (1) Dome Light (2) Luggage Room Light (3) Courtesy Light (4) Meter (5) Side Marker Light (6) Turn Signal Light/Parking Light (7) Cornering Light (8) Headlight
(9) (10) (11) (12) (13) (14) (15) (16)
Fog Light Map Light High Mount Stoplight License Plate Light Turn Signal Light Backup Light Taillight/Stoplight Rear Combination Light
Light Name Headlight Front Combination Light Fog Light Rear Combination Light Taillight/Stoplight Turn Signal Light Backup Light Turn Signal Light/Parking Light Side Marker Light Cornering Light
Bulb No. 9004 1157 194 1156 1157 1156 1156
Rated Power 65W/45W 27W/8W 3.8W 27W 55W 8W/27W 27W 27W
Number of Bulbs 2 2 2 2 2 2 2 2 50
Lens Color White White Amber White White Red Amber White Red
Remarks Halogen
Halogen
High Mount Stoplight
LED
LIGHTING SYSTEM
License Plate Light Map Light Dome Light Luggage Room Light Courtesy Light Air Conditioning Sw RR Defogger Sw AntiTheft Check Trans A/T Oil Temp Seat Heater SW Mirror Defogger Sw Fog Light SW Cruise Set Cruise Main Power Drive Winter Driver Turn Signal Upshift High Beam Indicator / Warning light ABS Seat Belt Malfunction Indicator (Check Engine) Low Fuel 4WD Oil Pressure Brake System Charge A/T Shift Position 194 74 74 74 74 74 74 74 74 74 74 80 74 74 74 74 74 74 74 5W 5W 10W 8W 3.8W 60mA 60mA 80mA 20mA 1.4W 1.4W 50mA 0.84W 0.7W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 2W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W 1 2 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 7 Green Green Amben Green Green Amben Blue Amben Red Amben Amben Green Red Red Red P,N,D,3,2, L : Green R : Amben Red Green Green Green Green Green Red Red Red White White White White White
8A25
w/o Timer w/Timer Warning box Meter Meter
Meter Meter Meter Meter Meter Meter Meter Meter Meter Meter Meter Meter Meter Meter Meter Meter
Air Bag Front1 Front2 TOD Front3 Rear Auto Check
80 74 74 74 74 74 74
2W 1.4W 1.4W 1.4W 1.4W 1.4W 1.4W
1 1 1 1 1 1 1
Meter
Application Steering Shaft Nut Nm 34 Lb Ft 25 Lb In
SECTION
WIPER/WASHER SYSTEM
TROOPER
8B1

WIPER / WASHER SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper/Washer System . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Windshield Wiper And Washer Switch . . . . . Removal and Installation . . . . . . . . . . . . . . . Windshield Wiper Motor . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Washer Motor . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper Linkage . . . . . . . . . . . . . . . . Windshield Wiper Linkage and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper Arm/Blade . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper Blade Rubber . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper/Washer System . . . . . . . . . . . . . . 8B1 8B2 8B2 8B2 8B2 8B2 8B2 8B2 8B3 8B3 8B3 8B4 8B4 8B4 8B4 8B5 8B5 8B5 8B6 8B6 8B6 8B7 General Description . . . . . . . . . . . . . . . . . . . . . Rear Wiper and Washer Switch . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm & Relay Control Unit . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Motor . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Arm/Blade . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Nozzle . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Nozzle Angle Adjustment . . . Rear Wiper Blade Rubber . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 8B7 8B7 8B7 8B7 8B8 8B8 8B8 8B9 8B9 8B9 8B9 8B9 8B9 8B10 8B10 8B10 8B10 8B10 8B10 8B10 8B11 8B11 8B11
Service Precaution
8B2
WIPER/WASHER SYSTEM
Windshield Wiper/Washer System

General Description
The circuit consists of the starter switch, windshield wiper & washer switch, windshield wiper motor, windshield washer motor and windshield intermittent relay. When the wiper & washer switch is turned on with the starter switch on, the battery voltage is applied to the wiper motor to activate the wiper. The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The intermittent relay is used to control motion of the wiper.
Windshield Wiper And Washer Switch

Refer to the Lighting Switch (Combination Switch) in Lighting System section.
Windshield Wiper Motor

Removal
1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove 4 mounting bolts. 4. Remove the windshield wiper motor(1).
Installation
880RW007
WIPER/WASHER SYSTEM
8B3
Windshield Washer Motor

Removal
1. Disconnect the battery ground cable. 2. Remove the fender inner liner (right side) (1). 3. Remove the screws and then remove the front combination light(2). 4. Remove 2 screws, the filler neck and the hose. 5. Disconnect the windshield washer motor connector and remove the washer tank (4). 6. Pull the windshield washer motor(3) from the washer tank(4).
Installation
880RS006
8B4
WIPER/WASHER SYSTEM
Windshield Wiper Linkage

Windshield Wiper Linkage and Associated Parts
880RW008
Legend (1) Windshield Wiper Arm/Blade (2) Vent Cowl Cover
(3) Windshield Wiper Linkage Assembly (4) Windshield Wiper Motor
Removal
1. Disconnect the battery ground cable. 2. Remove the windshield wiper arm/blade. 3. Remove the windshield wiper motor. 4. Remove the pivot assembly mounting nuts, fixing screws and then remove the vent cowl cover. 5. Take out the windshield wiper linkage assembly from the opening of the cowl.
Installation
WIPER/WASHER SYSTEM
8B5
Windshield Wiper Arm/Blade

Removal
1. Pry the cap(2) off with the tip of a screwdriver. 2. Remove the nut(3). 3. Remove the wiper/blade(1). D Tighten the nuts to the specified torque. Torque: 31 Nm (23 lb ft)
880RS005
Installation
880RS004
1. Wiper arm/blade D Before installing the wiper arm/blade to the shaft, confirm that the motor stops at the auto-stop position. D Set the wiper arm/blade so that the tips of both blades are positioned about 35 mm (1.37 in) from the upper edge of the cowl cover as shown in the figure.
8B6
WIPER/WASHER SYSTEM
Windshield Wiper Blade Rubber

Removal
1. Push the wiper blade lock(1) while pulling the wiper blade in the arrow direction as shown in the figure. CAUTION: When the wiper blade has been removed, wrap the tip of the wiper arm with cloth, to avoid damaging the glass.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Install the click of the blade stay in the groove of the new rubber and slide it in. Complete wiper blade installation by pushing the click.
885RS002 880RS011
2. Pull the end of rubber and remove the projection(3) from the click of the blade stay (2).
2. Finally, check that the click of the stay has caught in the hole of the rubber.
885RS001 880RS010
3. Pull the rubber out in the same direction.
WIPER/WASHER SYSTEM
8B7
Rear Wiper/Washer System

General Description
The circuit consists of the starter switch, rear wiper & washer switch, rear wiper motor, rear washer motor and rear intermittent relay. When the wiper & washer switch is turned on with the starter switch on, the battery voltage is applied to the wiper motor to activate the wiper. The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The intermittent relay is used to control motion of the wiper.
Rear Wiper and Washer Switch

Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly(1). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly(2). Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover(3). Refer to the Instrument Panel Assembly in Body Structure section. 5. Remove the instrument panel cluster assembly(4). Refer to the Instrument Panel Assembly in Body Structure section. 6. Disconnect the connector and push the lock from the back side of the instrument panel cluster assembly to remove the rear wiper & washer switch(5).
821RW023
Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. Push the switch with your fingers until it locks securely.
740R200050
8B8
WIPER/WASHER SYSTEM
Rear Wiper Motor

Removal
1. Disconnect the battery ground cable. 2. Remove the tailgate trim pad. 3. Remove the wiper arm/blade. Refer to the removal steps of the Rear Wiper Arm/Blade in this section. 4. Disconnect the connector remove the wiper shaft nut, remove the fixing screws and then remove the rear wiper motor(1).
885RS012
885RS013
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Before installing the wiper arm/blade to the motor shaft, confirm that the motor stops at the auto-stop position. 2. Install the wiper arm so that the blade gets parallel to the lowermost heat wire(2) of the rear defogger (w/rear defogger), or position the blade 20 mm (0.79 in) from edge of tailgate glass (W/O rear defogger).
885RS011
3. Tighten the motor shaft nut to the specified torque. Torque: 6 Nm (52 lb in) 4. Tighten the wiper arm nut to the specified torque. Torque: 9 Nm (78 lb in)
WIPER/WASHER SYSTEM
8B9
Alarm & Relay Control Unit

Removal
1. Disconnect the battery ground cable. 2. Remove the glove box. 3. Remove the instrument panel passenger lower cover assembly. 4. Remove the passenger Knee bolster reinforcement assembly. 5. Remove the fixing bolts, disconnect the connectors and then remove the alarm & relay control unit (1).
Installation
826RW020
Rear Washer Motor

Removal
1. Disconnect the battery ground cable. 2. Remove the tailgate trim pad(2). 3. Remove two screws, disconnect the connector, remove the washer hose and then remove the rear washer tank(3). 4. Pull out the rear washer motor(1) from the washer tank.
885RS009
Installation
8B10 WIPER/WASHER SYSTEM
Rear Wiper Arm/Blade

Removal
1. Remove the arm nut(2). 2. Remove the wiper arm/blade(1).
Installation
Refer to the installation steps of the Rear Wiper Motor in Wiper/Washer System section.
885RS008
Rear Washer Nozzle

Removal
1. Disconnect the hose(3). 2. Remove the lock nut(2), and then remove the washer nozzle(1).
Rear Washer Nozzle Angle Adjustment

Loosen the lock nut(2) of the washer nozzle(1) to adjust the injection angle of the cleaning fluid, and then retighten the lock nut(2).
885RS005 885RS004
Installation
WIPER/WASHER SYSTEM
Rear Washer Spray Pattern
8B11
885RS003
Legend (1) Washer Nozzle (2) Spray Target
Rear Wiper Blade Rubber

Refer to the Windshield Wiper Blade Rubber in this section.

Application Windshield Wiper Motor Shaft Nut Windshield Wiper Arm Nuts Rear Wiper Motor Shaft Nut Rear Wiper Arm Nut Nm 14 31 6 9 Lb Ft 23 Lb In 122 52 78
SECTION
ENTERTAINMENT
TROOPER
8C1

ENTERTAINMENT
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Clock and Outside Temp . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front ACC Socket . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear ACC Socket . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rod Type Antenna . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C1 8C2 8C2 8C2 8C2 8C3 8C3 8C3 8C4 8C4 8C4 8C4 8C4 8C4 8C5 8C5 8C5 Diversity Glass Antenna . . . . . . . . . . . . . . . . . . Glass Antenna System Parts Location . . . . Glass Antenna Pattern . . . . . . . . . . . . . . . . . . . Glass Antenna Amplifier Removal . . . . . . . Glass Antenna Amplifier Installation . . . . . . Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tweeter Assembly . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C6 8C6 8C7 8C7 8C7 8C8 8C8 8C8 8C9 8C9 8C9 8C9 8C9 8C9 8C10 8C10 8C10
Service Precaution
8C2
ENTERTAINMENT
Cigarette Lighter
General Description
When the cigarette lighter is pushed in with the starter switch at either ACC or ON position, a circuit is formed in the cigarette lighter case to heat the lighter coil. The cigarette lighter is sprung back to its original position after the lighter coil is heated.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. When installing the bezel, align the projected portion of the socket with the notch of the bezel.
Removal
1. Disconnect the battery ground cable. 2. Remove the lower cluster assembly(1). Refer to the Instrument Panel Assembly removal steps in Body Structure section. 3. Disconnect the connectors, remove the socket of the illumination light, the retaining ring(7), the outer case(6), the cigarette lighter(3) and socket(4), the bezel(5) and then remove the cigarette lighter assembly(2).
826RS007
ENTERTAINMENT
8C3
Digital Clock and Outside Temp

Removal
Installation
740R200050
5. Remove the instrument panel cluster assembly(4). Refer to the Instrument Panel Assembly in Body Structure section. 6. Disconnect the connector and push the lock from the back side of the instrument panel cluster assembly to remove the digital clock and outside temp (5).
821R200035
8C4
ENTERTAINMENT
Front ACC Socket

Removal
1. Disconnect the battery ground cable. 2. Remove the front cover assembly (1). Refer to the Instrument Panel Assembly in the Body Structure section of this manual. 3. Disconnect the connectors (2). 4. Twist the ACC cover (3) counterclockwise to remove it together with the ACC socket (4).
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. The projection portion socket is united with Bezel cutting and lacking, and is attached.
826R200029
Rear ACC Socket

Removal
1. Disconnect the battery ground cable. 2. Remove two screws and disconnect the connector to remove the ACC socket (1).
Installation
810RW311
ENTERTAINMENT
8C5
Rod Type Antenna

Removal
1. Disconnect the battery ground cable. 2. Turn the antenna rod(1) counterclockwise to remove it. 3. Remove three screws and nine clips to remove the fender inner liner(2). 4. Disconnect the feeder cable connector at the inside of the vehicle, remove the housing bracket screw, turn the lock nut counterclockwise to remove it together with the base mold and then remove the housing(3).
Installation
890RS004
8C6
ENTERTAINMENT
Diversity Glass Antenna

Glass Antenna System Parts Location
890R200050
Legend (1) Glass Antenna (LH) (2) Glass Antenna Amplifier (3) Glass Antenna (RH)
(4) Glass Antenna Amplifier (5) Connection with the audio side feeder cables at the dash side (RH)
ENTERTAINMENT
8C7
Glass Antenna Pattern
890RW016
Glass Antenna Amplifier Removal

1. Disconnect the battery ground cable. 2. Remove the luggage side trim cover. Refer to the Interior Trim Panels removal steps in Exterior/Interior Trim section. 3. Disconnect the connector(1)&(4), feeder cable(3) and remove two screws to remove the glass antenna amplifier(2).
890R200049
Glass Antenna Amplifier Installation

8C8
ENTERTAINMENT
Radio
Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly (1). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly (2). Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover assembly (3). Refer to the Instrument Panel Assembly in Body Structure section.
Installation
To install, follow the removal steps in the revers order.
740R200050
5. Remove the instrument panel cluster assembly(4). Refer to the Instrument Panel Assembly in Body Structure section. 6. Remove two screws and disconnect the radio connector(5) and antenna feeder plug(6) to remove the radio(7).
825RW039
ENTERTAINMENT
8C9
Front Speaker
Removal
1. Disconnect the battery ground cable. 2. Pull the grille(1) to release the locks and then remove it. 3. Remove four screws and disconnect the connector(3) to remove the speaker(2).
Installation
890RW013
Tweeter Assembly
Removal
1. Disconnect the battery ground cable. 2. Pull the tweeter, assembly(1) to release the clips(2) and disconnect the connector(3) to remove the tweeter assembly.
Installation
890RW017
8C10 ENTERTAINMENT
Rear Speaker
Removal
1. Disconnect the battery ground cable. 2. Pull the grille (1) to release the locks and then remove it. 3. Remove four screws and disconnect the connector (3) to remove the speaker (2).
Installation
890RW015
SECTION
WIRING SYSTEM
TROOPER
8D1

WIRING SYSTEM
CONTENTS
Fuse, Relay and Diode . . . . . . . . . . . . . . . . . . . Relay and Fuse Box / Fuse Box Location . Relay & Fuse Box . . . . . . . . . . . . . . . . . . . . . 8D2 8D2 8D3 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 8D4 8D5
8D2
WIRING SYSTEM
Fuse, Relay and Diode

Relay and Fuse Box / Fuse Box Location
810RY00003
Legend (1) Relay and Fuse Box (2) Fuse Box
WIRING SYSTEM
8D3
Relay & Fuse Box
810RY00004
Legend (1) Relay & Fuse Box (2) Lighting Relay (3) Not Used (4) Not Used (5) Not Used (6) Thermo Relay (7) Not Used (8) Compressor Relay (9) Horn Relay (10) Tail Relay (11) Not Used (12) Fuel Pump Relay (13) PCM Main Relay (14) Not Used (15) Not Used (16) Diode (17) Upshift Relay1 (18) Starter Relay (19) Not Used (20) Not Used (21) Not Used
(22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43)
ACC Socket Replay Cornering Relay Fog Light Relay Fusible Link (Main) Fusible Link (Key SW) Fusible Link (ECM) Not Used Not Used Fusible Link (ABS) Fuse F1 (Not Used) Fuse F2 (20A) Fuse F3 (15A) Fuse F4 (15A) Fuse F5 (15A) Fuse F6 (Not Used) Fuse F7 (15A) Fuse F8 (15A) Fuse F9 (20A) Fuse F10 (15A) Fuse F11 (Not Used) Fuse F12 (15A) Upshift Resistor
8D4
WIRING SYSTEM
Fuse Box
810RY00005
Legend (1) Fuse Box (2) Fuse C21 (10A) (3) Flasher Unit (4) H49 (5) Rear Defogger Relay (6) Power Window Relay (7) Heater & A/C Relay (8) Diode (Not Used) (9) Diode (Not Used) (10) Circuit Breaker C/B2 (11) Circuit Breaker C/B1 (Not Used) (12) Diode (Not Used) (13) Fuse C1 (10A) (14) Fuse C2 (15A) (15) Fuse C3 (15A) (16) Fuse C4 (15A) (17) Fuse C5 (15A) (18) Fuse C6 (10A)
(19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36)
Fuse C7 (Not Used) Fuse C8 (15A) Fuse C9 (15A) Fuse C10 (10A) Fuse C11 (10A) Fuse C12 (20A) Fuse C13 (10A) Fuse C14 (15A) Fuse C15 (20A) Fuse C16 (10A) Fuse C17 (25A) Fuse C18 (20A) Fuse C19 (25A) Fuse C20 (10A) Diode (Not Used) Diode (Not Used) Diode (Not Used) Diode (Lighting)
WIRING SYSTEM
8D5
Circuit Diagram
8D6
WIRING SYSTEM
Fuse Block Circuit
WIRING SYSTEM
8D7
Starter and Generator
8D8
WIRING SYSTEM
PCM1
D08R200292
WIRING SYSTEM
8D9
PCM2
D08R200221
8D10
WIRING SYSTEM
Headlight and Fog Light
WIRING SYSTEM
8D11
Illumination Light
D08R200295
8D12
WIRING SYSTEM
Turn Signal Light and Hazard Warning Light
WIRING SYSTEM
8D13
Stoplight and Rear Defogger
D08R200222
8D14
WIRING SYSTEM
Dome Light, Courtesy Light, Stop Light and Luggage Room Light
D08R200293
WIRING SYSTEM
8D15
Door Lock (W/ Keyless Entry)
8D16
WIRING SYSTEM
Door Lock (W/O Keyless Entry)
WIRING SYSTEM
8D17
Power Window
8D18
WIRING SYSTEM
Cruise Control
D08R200224
WIRING SYSTEM
8D19
ABS1
D08R200225
8D20
WIRING SYSTEM
ABS2
WIRING SYSTEM
8D21
A/T Shift Lock
8D22
WIRING SYSTEM
Antitheft W/ Keyless Entry
WIRING SYSTEM
8D23
Windshield Wiper and Washer
8D24
WIRING SYSTEM
Audio
D08R200294
WIRING SYSTEM
8D25
Door Mirror
8D26
WIRING SYSTEM
Meter (W/ T,O,D)
D08R200227
WIRING SYSTEM
8D27
Meter (W/O T,O,D)
D08R200228
8D28
WIRING SYSTEM
A/T Shift Indicator
WIRING SYSTEM
8D29
Air Conditioning (Manual)
D08R200229
8D30
WIRING SYSTEM
Air Conditioning (Auto)1
D08R200230
WIRING SYSTEM
8D31
Sun Roof
8D32
WIRING SYSTEM
Seat Heater
WIRING SYSTEM
8D33
SRSAir Bag
8D34
WIRING SYSTEM
Shift on the Fly
WIRING SYSTEM
8D35
Torque on Demand (T,O,D)
8D36
WIRING SYSTEM
Alarm and Relay Control Unit1
D08R200232
WIRING SYSTEM
8D37
Alarm and Relay Control Unit2
D08R200233
SECTION
METER AND GAUGE
TROOPER
8E1

METER AND GAUGE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights . . . Table for Meter/Gauge Connector Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E1 8E1 8E2 8E2 8E2 8E6 8E10 8E10 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 8E11 8E11 8E11 8E11 8E11 8E11 8E12 8E12 8E12 8E12 8E12 8E12 8E13
8E10 8E10 8E10
Service Precaution
General Description
The circuit consists of the starter switch, meter assembly, vehicle speed sensor, transmission switch, lighting switch, turn signal switch, thermo unit, oil pressure unit, Powertrain Control Module (PCM), fuel tank unit, 4WD switch, oil pressure switch, parking brake switch, brake fluid switch, seat belt switch, illumination controller, multi meter and ambient sensor.
8E2
METER AND GAUGE
Meter Assembly
General Description
The meter assembly has the speedometer, tachometer, engine coolant temperature gauge, fuel gauge and warning/indicator lights.In addition, the meter assembly containing TOD (Torque on Demand) has the TOD indicator light, or the meter assembly not containing TOD has the voltmeter and oil pressure gauge instead of the TOD indicator.
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights
Meter Assembly W/O TOD (Front View)
821R200036
Legend (1) Voltmeter & Engine Coolant Temperature Gauge (2) Tachometer (3) Warning Light Lens (4) Speedometer
(5) (6) (7) (8) (9)
Oil Pressure Gauge & Fuel Gauge Warning Light Lens Reset Knob A/T Shift Indicator Warning Light Lens
METER AND GAUGE
8E3
Meter Assembly W/O TOD (Rear View)
821R200038
Legend (10) LCD Light (11) Illumination Light
(12) Illumination Light (13) Illumination Light (14) Illumination Light
8E4
METER AND GAUGE
Meter Assembly W/TOD (Front View)
821R200037
Legend (1) TOD Indicator (2) Tachometer (3) Warning Light Lens (4) Speedometer
(5) (6) (7) (8) (9)
Coolant Temperature Gauge & Fuel Gauge Warning Light Lens Reset Knob A/T Shift Indicator Warning Light Lens
METER AND GAUGE
8E5
Meter Assembly W/TOD (Rear View)
821R200039
Legend (10) LCD Light (11) Illumination Light
(12) Illumination Light (13) Illumination Light (14) Illumination Light
8E6
METER AND GAUGE
Table for Meter/Gauge Connector Terminal Connections

Meter Assembly W/O TOD1
825RW037
METER AND GAUGE
8E7
Meter Assembly W/O TOD2

Connector No. I9 Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 2 position (A/T) Starter switch Ground (Gauge) Cruise set indicator light Cruise main indicator light 4WD indicator light Winter drive indicator light Oil pressure warning light Air bag warning light Power drive indicator light Up shift indicator light () Turn signal indicator light (Left) Up shift indicator light (+) Ground (Warning) Function A/T oil temp warning light Seat belt warning light Check trans warning light Brake warning light Check engine warning light Charge warning light Lighting switch Illumination controller Tachometer D position (A/T) A/T shift indicator control unit Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Reduced power Fuel warning light Oil pressure gauge Fuel gauge P position (A/T) N position (A/T) 3 position (A/T) High-beam indicator light () High-beam indicator light (+) ABS indicator light Battery (+) L position (A/T) R position (A/T) Engine coolant temperature gauge Speedometer Connector No. I10 Function Turn signal indicator light (Right)
8E8
METER AND GAUGE
Meter Assembly W/TOD1
825RW035
METER AND GAUGE
8E9
Meter Assembly W/TOD2

Connector No. I9 Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Tachometer Turn signal indicator light (Left) A/T shift indicator control unit 2 position (A/T) D position (A/T) Rear (TOD) Auto (TOD) Check (TOD) Cruise set indicator light Cruise main indicator light Oil pressure warning light Front 1 (TOD) Front 2 (TOD) Front 3 (TOD) Lighting switch Illumination controller Starter switch Winter drive indicator light Power drive indicator light Function Air bag warning light A/T oil temp warning light Charge warning light Seat belt warning switch Check trans warning light Brake warning light Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Fuel gauge Reduced power Engine coolant temperature gauge Fuel warning light Ground (Gauge) Check engine warning light Battery (+) P position (A/T) N position (A/T) 3 position (A/T) High beam indicator light () High beam indicator light (+) ABS indicator light L position (A/T) R position (A/T) Ground (Warning) Speedometer Connector No. I10 Function Turn signal indicator light (Right)
8E10 METER AND GAUGE
Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly(1). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly(2). Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover(3). Refer to the Instrument Panel Assembly in Body Structure section.
5. Remove four fixing screws and disconnect the meter connectors to remove the meter assembly(5).
825RW031
CAUTION: The removed meter assembly should be placed upright or with its face side up.
Installation
740R200051
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb
Removal
1. Disconnect the battery ground cable. 2. Remove the meter assembly(1). Refer to the Meter Assembly removal steps in this section. 3. Hold the bulb socket by hand and rotate it counterclockwise to remove the socket & bulb(2) from the meter body.
825RW032
Installation
METER AND GAUGE
8E11
Vehicle Speed Sensor

Removal
1. Disconnect the battery ground cable. 2. Disconnect the connector, remove the vehicle speed sensor body by rotating it and then remove the vehicle speed sensor(1).
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the vehicle speed sensor to the specified torque. Torque: 27 Nm (20 lb ft)
826RS009
Fuel Tank Unit

Removal
1. Disconnect the battery ground cable. 2. Remove the fuel tank(1). Refer to the Fuel Tank removal steps in Engine section 3. Disconnect the connectors, remove five screws and then remove the fuel tank unit(2).
Installation
140RS006
8E12 METER AND GAUGE
Multi Meter
Removal
1. Disconnect the battery ground cable. 2. Remove two caps, two screws and disconnect the connector to remove the multi meter(1).
Installation
To install, follow the removal steps in the revers order.
821RW036
Ambient Sensor
Removal
1. Disconnect the battery ground cable. 2. Disconnect the connector and remove the nut to remove the ambient sensor(1).
Installation
821RW035
METER AND GAUGE
8E13

Application Vehicle Speed Sensor Fixing Nm 27 Lb Ft 20 Lb In
SECTION
BODY STRUCTURE
TROOPER
8F1

BODY STRUCTURE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Dimensions . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Bumper Slider Bracket . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Bumper Slider . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Cowl Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Hood Hinge . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Hood Lock . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Grille And Front End Lower Panel . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Fender Panel . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Body Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F3 8F3 8F4 8F5 8F5 8F5 8F6 8F6 8F6 8F6 8F6 8F7 8F7 8F8 8F8 8F9 8F9 8F9 8F10 8F10 8F10 8F11 8F11 8F11 8F11 8F11 8F12 8F12 8F12 8F12 8F13 8F13 8F13 8F14 8F14 8F14 8F15 8F15 8F16 8F16 8F16 8F17 8F18 8F18 Removal (No.1 No. 2) . . . . . . . . . . . . . . . . Removal (No. 3 No. 6) . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Body Dimension . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross Beam Assembly . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Door Assembly . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Assembly . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Strikers . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Check Arm Assembly (Front & Rear) . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Window Regulator, Glass And Glass Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Window Regulator And Glass . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Fixed Glass And Glass Run . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Door Sash Moulding . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F18 8F19 8F20 8F21 8F22 8F40 8F40 8F41 8F45 8F46 8F46 8F46 8F47 8F48 8F48 8F48 8F48 8F49 8F49 8F49 8F50 8F50 8F50 8F51 8F51 8F51 8F52 8F52 8F52 8F52 8F54 8F55 8F55 8F55 8F56 8F57 8F57 8F57 8F58 8F59 8F59 8F59 8F59
8F2
BODY STRUCTURE
8F60 8F60 8F60 8F60 8F61 8F61 8F61 8F61 8F62 8F62 8F62 8F63 8F63 8F63 8F64 8F65 8F65 8F65 8F66 8F66 8F66 8F66 8F67 8F67 8F67 8F67 8F68 8F68 8F68 8F69 8F70 8F70 8F70 8F71 8F72 8F72 8F72 8F72 8F72 8F72 8F73 8F73 8F73 8F73 8F74 8F74 8F75 8F75 8F75 8F75 Tailgate Frame Cover (RH) . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Sash Trim Cover . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Outer Weatherstrip . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Center Weatherstrip . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Main Weatherstrip . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Tire Carrier . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Air Deflector . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roof Moulding . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Quarter Side Glass . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Glass . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F76 8F76 8F76 8F77 8F77 8F77 8F77 8F78 8F78 8F78 8F78 8F79 8F79 8F79 8F79 8F80 8F80 8F80 8F80 8F81 8F81 8F81 8F81 8F82 8F82 8F82 8F83 8F84 8F84 8F84 8F84 8F86 8F86 8F86 8F87 8F88 8F88 8F88 8F89 8F93 8F93 8F93 8F93 8F95 8F95 8F95 8F96 8F97 8F107
Rear Door Moulding . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Door Waist Seal . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Waist Seal . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Front Door Weatherstrip . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Weatherstrip . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Front Door Seal Finisher . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Seal Finisher . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Assembly (LH) . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Assembly (RH) . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Strikers . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Stopper Assembly . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Dove-Tail . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Dove-Tail Striker . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Frame Cover (LH) . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY STRUCTURE
8F3
Service Precaution
Frame
General Description
Proper frame alignment is important to assure normal vehicle life and performance of many other parts of the vehicle. If the vehicle has been involved in a fire, collision or has been overloaded, it is necessary to check the frame alignment.
8F4
BODY STRUCTURE
Frame Dimensions
501RW013
BODY STRUCTURE
8F5
General Description
This section describes how to remove and install front and rear bumpers. Each bumper is installed with two fixing bolts used on either side to fasten the backbar to the
frame, a slider is used to fasten the bumper fascia to the fender panel. The bumpers can be removed by taking them out forward or backward after removing the two fixing bolts on either side.
Front Bumper
Parts Location
601RX001
Legend (1) Front Bumper Assembly (2) Front Bumper Retainer Bolt (3) Clip (4) Bumper Spacer Support (5) Back Bar Fixing Bolt (6) Front Fog Light Connector (7) Front Bumper Slider Fixing Clip
(8) (9) (10) (11) (12) (13) (14) (15)
Front Bumper Slider Front Bumper Slider Fixing Nut Bumper Fascia Lower Bolt Front Fog Light Assembly Reinforce Assembly Reinforce Lower Bolt Front Bumper Fixing Bolt Back Bar
8F6
BODY STRUCTURE
9. Remove front fog light assembly. 10. Remove the front bumper slider(1). D Remove the two clips(4) and the two nuts(3), and release the claw from the washer(2).
Removal
1. Remove front fog light connector. 2. Remove front bumper assembly fixing bolt. D Remove the two bolts from both sides of the front bumper.
601RW009
601RW010
3. Remove front bumper assembly. 4. Remove bumper fascia lower bolts. 5. Remove front bumper retainer. 6. Remove reinforce lower bolts. D Loosen the five bolts and release claws. 7. Remove reinforce assembly. 8. Remove backbar fixing bolts. D Remove the four bolts at each backbar.
Installation
To install, follow the removal steps in reverse order noting the following points: 1. Tighten the front bumper assembly fixing bolts to the specified torque. Torque: 132 Nm (98 lb ft)
Front Bumper Slider Bracket

Removal
1. Remove the Front bumper. D Refer to Front Bumper in this section. 2. Remove the three nuts(1) and draw out the slider bracket(2).
601RW003
Installation
To install, follow the removal steps in reverse order.
BODY STRUCTURE
8F7
Rear Bumper
Parts Location
690RW001
Legend (1) Back Bars (2) Reinforce Assembly (3) Rear Bumper Slider Brackets (4) Rear Step Clips (5) Reinforce Lower Bolts (6) Reinforce Upper Bolts (7) Rear Bumper Fascia Brackets
(8) (9) (10) (11) (12) (13) (14)
Rear Bumper Fascia Bracket Screws Rear Bumper Assembly Rear Bumper Side Covers Mud Flaps Rear Bumper Assembly Fixing Bolts Rear Bumper Retainers Clips
8F8
BODY STRUCTURE
11. Remove reinforce assembly. D Pull out both ends of the bumper fascia and take out the reinforce assembly. 12. Remove backbars. D Remove the three bolts from each backbar. 13. Remove rear bumper slider brackets(4). D Remove the two clips(1) and two screws(3), and then remove claw caught in the washer(2).
Removal
1. Remove rear bumper side covers. 2. Remove mud flaps. D Remove three screws. 3. Remove bumper fascia bracket screws. 4. Remove rear bumper assembly fixing bolts. D Remove two bolts from each side.
690RW002
690RS003
5. Remove rear bumper assembly. 6. Remove rear bumper retainers. 7. Remove reinforce upper bolts. D Remove the rear bumper retainer from each side, and then remove two upper bolts. 8. Remove reinforce lower screws. 9. Remove clips. 10. Remove rear step clips.
14. Remove bumper fascia brackets. D Remove the fixing nut on the back side of the fender panel.
Installation
To install, follow the removal steps in reverse order noting the following points: 1. Tighten the front bumper assembly fixing bolts to the specified torque. Torque: 132 Nm (98 lb ft) 2. Apply chassis grease to the slider and the slider bracket moving surface.
BODY STRUCTURE
8F9
Rear Bumper Slider

Removal
1. Remove the rear bumper. D Refer to Rear Bumper in this section. 2. Remove the three bolts (2). 3. Remove rear bumper slider (1).
690RS004
Installation
To install, follow the removal steps in reverse order noting the following points: 1. Apply chassis grease to the slider and the slider bracket moving surface.
8F10
BODY STRUCTURE
General Description
This section includes items of front end sheet metal that are attached by bolts, screws or clips and related accessory components. Anti-corrosion materials have been applied to the interior surfaces of some metal panels to provide rust resistance. When servicing these panels, areas on which this material has been disturbed should be properly recoated with service-type anti-corrosion material.
Cowl Cover
Parts Location
605R200002
Legend (1) Front Wiper Arms (2) Front Window Lower Molding (3) Cowl Cover Seals
(4) Cowl Cover Stoppers (5) Cowl Cover Brackets (6) Cowl Cover
BODY STRUCTURE
8F11
Removal
1. Open the hood. 2. Support the hood. 3. Remove front wiper arms. D Refer to Windshield Wiper Arm/Blade Wiper/Washer System section. 4. Remove front window lower molding. 5. Remove cowl cover brackets. D Disconnect two screws each side.
6. Remove cowl cover. D Disconnect three screws. 7. Remove cowl cover seals. 8. Remove cowl cover stoppers. in
Installation
To install, follow the removal steps in reverse order.
Engine Hood
Removal
1. Open the hood. 2. Support the hood. 3. Remove windowshield washer nozzle tube. 4. Remove hood hinge bolts (3). D Before removing the hinges from the Engine hood (1), scribe a mark (2) showing location of the hinges to facilitate installation in the original position.
610RS003 880RS001
5. Remove engine hood.
Installation
To install, follow the removal steps in the reverse order noting the following points: 1. Tighten the engine hood fixing bolts to the specified torque. Torque: 13 Nm (113 lb in) 2. Adjust the engine hood mounting gap with reference to Body Dimension in this section. 3. Check and see if the engine hood lock operates normally.
8F12
BODY STRUCTURE
Engine Hood Hinge

Parts Location
610RW012
Legend (1) Hinge Fixing Bolts And Nuts (2) Hood End Seal
(3) Engine Hood Hinge (4) Engine Hood (5) Cowl Cover
Removal
1. Remove cowl cover. D Refer to Cowl Cover in this section. 2. Remove engine hood. D Refer to Engine Hood in this section. 3. Remove hinge fixing bolt and nut. 4. Remove engine hood hinge. 5. Remove hood end seal.
Installation
To install, follow the removal steps in reverse order noting the following points: 1. Tighten the hood hinge fixing bolt and nut to the specified torque. Torque 13 Nm (113 lb in)
BODY STRUCTURE
8F13
Engine Hood Lock

Parts Location
610RY001
Legend (1) Control Cable (2) Hood Lock Control Lever
(3) Inner Liner (4) Radiator Grille (5) Engine Hood Lock Assembly
Removal
1. Remove hood lock control lever. 2. Remove inner liner. 3. Remove control cable. D Remove the cable fixing clips from the body panel. 4. Remove radiator grille. D Refer to Radiator Grille And Front End Lower Panel in this section. 5. Remove engine hood lock assembly. D Apply setting marks (1) to the hood lock assembly and the body prior to removal.
610RS002
8F14
BODY STRUCTURE
Installation
To install, follow the removal steps in reverse order noting the following points: 1. Reroute the control cable to its original position, and check and see if the lock assembly and control lever work normally. 2. Tighten the hood lock assembly fixing bolts to the specified torque. Torque : 10 Nm (87 lb in)
Radiator Grille And Front End Lower Panel

Parts Location
603RY001
Legend (1) Radiator Grille (2) Front End Lower Panel
BODY STRUCTURE
8F15
Removal
1. Open the hood. 2. Support the hood. 3. Remove radiator grille. D Raise the five clips on the radiator grille and remove two screws.
603RS002
4. Remove front end lower panel. D Remove two fixing bolts and remove the panel from the fender.
Installation
To install, follow the removal steps in reverse order, noting the following point. 1. Install the radiator grille clips remaining on the body side in the radiator grille, and then install the radiator grille on the body.
8F16
BODY STRUCTURE
Front Fender Panel

Parts Location
605RY001
Legend (1) Cowl Cover (2) Front Mud Flap
(3) Front Fender Panel (4) Front Combination Lamp Assembly (5) Inner Liner
Removal
1. Open the hood. 2. Support the hood. 3. Remove cowl cover. D Refer to Cowl Cover in this section.
4. Remove front combination lamp assembly. D Disconnect fixing screw and connector. 5. Remove front mud flap. D Disconnect three fixing screws and four clips. 6. Remove inner liner.
BODY STRUCTURE
7. Remove front fender panel. D Disconnect ten fixing bolts and two nuts.
8F17
605RW001
Installation
To install, follow the removal steps in the reverse order noting the following points: 1. Tighten the front fender panel fixing bolts to the specified torque. (1) Torque : 9 Nm (78 lb in) (2) Torque : 7 Nm (61 lb in)
8F18
BODY STRUCTURE
Body Mounting
Parts Location
510RX001
Removal (No.1 No. 2)

1. Remove the front bumper. 2. Jack up the vehicle by the frame.
BODY STRUCTURE
3. Support the front side sill and rear axle with stands. Further, support the front jack up point with a jack.
8F19
4. Remove the mounting bolts (No. 1-4) on either side. D No. 1 Hold in check not to turn from the inside of the front fender. D No. 2 Remove the front door sill plate and dash side trim panel, turn over the floor carpet and hold the bolt in check not to turn. D No. 3 Remove the rear door sill plate and center pillar lower trim cover, turn over the floor carpet and hold the bolt in check not to turn. D No. 4 Remove the bolt from under the frame. 5. Loosen the mounting bolts (No. 5-6) on either side. 6. Remove the frame side mounting and washer. 7. Gently lower the jack supporting the front axle until the cab side mounting can be removed. 8. Remove the cab side mounting. D Be sure to use a splice bar around the mounting to be removed.
620RS001
501RS001
420RS001
Removal (No. 3 No. 6)

1. Remove the rear bumper. 2. Jack up the vehicle by the frame.
545RS001
8F20
BODY STRUCTURE
4. Remove the mounting bolts (No. 3-6) on either side. D No. 3 Remove the rear door sill plate and center pillar lower-trim cover, turn over the floor carpet and hold the bolt in check not to turn. D No. 4, 5 and 6 Remove the bolts from the lower side of the frame. 5. Remove the frame side mounting and washer. 6. Gently lower the jack supporting the rear axle until the cab side mounting can be removed. 7. Remove the cab side mounting. D Be sure to use a splice bar around the mounting to be removed. D As for No. 5 and 6, remove the frame side bracket fixing bolts after lowering the frame gently.
3. Support the rear side sill and frame stands, and support the rear axle with a jack.
620RS002
510RS001
Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. Tighten each mounting bolt to the specified torque. Torque : 50 Nm (37 lb ft)
501RS003
420RS002
BODY STRUCTURE
8F21
General Description
This section describes major items of the removal, installation and servicing procedures pertaining to the TROOPER body. Each servicing instruction is applicable to all models of the TROOPER, unless otherwise specifically mentioned. For those differing by specific models from the common procedures, they are detailed for each model.
8F22
BODY STRUCTURE
Body Dimension
Upper Body
A10RW001
BODY STRUCTURE
8F23
A10RY00001
8F24
BODY STRUCTURE
A10RY00002
BODY STRUCTURE
8F25
A10RY00007
8F26
BODY STRUCTURE
Front Section
A10RW003
BODY STRUCTURE
8F27
A10RW004
8F28
BODY STRUCTURE
Room Section
A10RW016
BODY STRUCTURE
8F29
A10RW005
8F30
BODY STRUCTURE
A10RW006
BODY STRUCTURE
8F31
Rear Section
A10RW007
8F32
BODY STRUCTURE
A10RW008
BODY STRUCTURE
8F33
Side Body
A10RW018
8F34
BODY STRUCTURE
A10RW009
BODY STRUCTURE
8F35
A10RW017
8F36
BODY STRUCTURE
Window Glass
A10RW010
BODY STRUCTURE
8F37
A10RW011
8F38
BODY STRUCTURE
A10RW012
BODY STRUCTURE
8F39
A10RW013
8F40
BODY STRUCTURE
Instrument Panel Assembly

Parts Location
740R200052
Legend (1) Vent Duct Assembly (2) Instrument Harness Assembly (3) Instrument Panel Assembly (4) Side Defroster Grille (5) Passenger Inflator Module (6) Control Lever Assembly / Control Panel Assembly (7) Passenger Knee Bolster Reinforcement Assembly (8) Instrument Panel Passenger Lower Cover Assembly
(9) (10) (11) (12) (13) (14) (15) (16) (17)
Glove Box Lower Cluster Assembly Front Console Assembly Instrument Panel Driver Lower Cover Assembly Driver Knee Bolster Assembly Radio Assembly Instrument Panel Cluster Assembly Meter Assembly Front Defroster Grille
BODY STRUCTURE
8F41
Removal
CAUTION: For precautions on installation or removal of SRS air bag system, refer to Supplemental Restraint System (SRS) AIR BAG in Restraint section. 1. Disconnect the battery ground cable. 2. Remove front console assembly. D Remove the 4 fixing screws and disconnect the switch connectors. 3. Remove lower cluster assembly. D Remove the 3 fixing screws (1) in order to disconnect the cigarette lighter (3) and the illumination (2) connectors.
5. Remove instrument panel passenger lower cover assembly. D Remove the 7 fixing screws (1) and 1 clip (2).
740RS012
6. Remove passenger knee bolster reinforcement assembly. D Remove the 4 fixing bolts (2) and 4 nuts (1).
740RS014
4. Remove glove box. D Remove the 2 fixing screws.
740RS011
740RT024
8F42
BODY STRUCTURE
10. Remove instrument panel assembly. D Remove the 2 fixing bolts on the SRS adjust bracket and the cross beam under the passenger inflator module. CAUTION: For precautions on installation or removal of SRS air bag system, refer to Supplemental RestraintSystem (SRS) AIR BAG in Restraint section.
7. Remove instrument panel driver lower cover assembly. D Remove the engine hood opener fixing screws. D Remove the 2 fixing screws (2), 1 fixing bolt (3), and 1 clip (4). Pull out the fasteners at the 4 positions (1).
740RS010
8. Remove driver knee bolster assembly. D Remove the 6 fixing nuts.
827RS021
D Disconnect the 3 air conditioner control cables on the unit side. D Remove the instrument harness connectors (5 connectors on the drivers side and 3 connectors on the passenger side), the passenger inflator module connector, the radio antenna cable plug, and the ground cable fixing bolt on the center bracket.
740RY00026
9. Remove front defroster grille. D Pry 8 claws on the front side toward you side (room side) and raise the grille upward.
BODY STRUCTURE
D Remove the 4 bolts (4) and the 2 nuts (3) under the instrument panel assembly, and the upper left and the upper right bolts (2) and the center nut (1).
8F43
740RS008
11. Remove passenger inflator module. D From the back of the instrument panel, remove the 4 fixing nuts (2) on the passenger inflator module (3) and the 2 fixing nuts (1) and washers on the support bracket (4), then disengage the 2 clips in order to remove the passenger inflator module.
12. Remove instrument panel cluster assembly. D Remove the 5 fixing screws (2) and pull the main unit toward you and remove the clips at the 4 positions (1). Disconnect the switch connectors.
740RS007
827RS022
8F44
BODY STRUCTURE
13. Remove meter assembly. D Remove the 4 meter assembly fixing screws and disconnect the meter harness connectors.
821RS034
14. Remove control lever assembly / control panel assembly. D Refer to Control Lever Assembly and / or Control Cable in HVAC section. 15. Remove radio assembly. D Remove 2 fixing screws. 16. Remove vent duct assembly. D Remove 5 fixing screws. 17. Remove instrument harness assembly. D Remove the 4 fixing screws, fasteners at the 4 positions and the clips at the 7 positions. 18. Remove side defroster grille. D NOTE: For the order of removal steps in which each items contained in the instrument panel assembly are removed individually, refer to the chart.
BODY STRUCTURE
8F45
Installation
To install, follow the removal steps in the reverse order. Removal Item Front console assembly Lower cluster assembly Glove box Instrument panel passenger lower cover Passenger knee bolster reinforcement Instrument panel driver lower cover Driver knee bolster Front defroster grille Instrument panel assembly Removal Procedure
Order Of Removal/Installation Steps For Each Item
Removal Step 1, 2 13 4 15 16 13, 7 13, 7, 8 9 110
Shift knob (M/T), Power & Winter SW (A/T), Transfer knob, Seat heater/Miller SW conn. and 4 screws 3 screws, Ciger lighter conn. and Ashtray illumination conn. 2 screws 7 screws and 1 clip 4 nuts and 4 bolts Engine hood opening fixing screw, 2 screws, 1 bolt, 1 clip and fasteners at 4 positions 6 nuts Claws at 8 positions 2 bolts (SRS adjust bracket cross beam), A/C control cable (Unit side at 3 position), Instrument harness connector (Driver side 5 position, assist side 3 position), SRS module conn., Radio antenna jack, Earth cable, 9 bolts and 3 nuts 4 nuts (SRS moduleInstrument panel), 2 nuts 0 and 2 washers (SRS modulesupport bracket) and 2 clips 5 Screws, fastener at 4 position and each SW conn. 4 screws and connectors 4 screws and connectors 2 screws 5 screws 4 screws, fasteners at 4 position, and clips at 7 position
Passenger inflator module Instrument panel cluster Meter assembly A/C control panel assembly Radio assembly Vent duct assembly Instrument harness assembly Side defroster grille
16, 11 13, 7, 12 13, 7, 12, 13 13, 7, 12, 14 13, 15 110, 16 110, 17 18
M/T = Manual Transmission A/T = Automatic Transmission SRS = Supplemental Restraint System A/C = Air Conditioning
8F46
BODY STRUCTURE
Cross Beam Assembly

Parts Location
740RT013
Legend (1) Cross Beam Center Bracket (2) Steering Column Fixing Bolts (3) Side Support Bracket Assembly (RH) (4) Instrument Panel Center Bracket
(5) (6) (7) (8) (9)
Steering Support Bracket Assembly Brake Pedal Mounting Bracket Assembly Side Support Bracket Assembly (LH) Cross Beam Assembly Instrument Panel Assembly
Removal
1. Disconnect battery ground cable. 2. Remove instrument panel assembly. D Refer to Instrument Panel Assembly in this section. 3. Remove side support bracket assembly (LH/RH). D Remove the 4 fixing bolts on both sides. 4. Remove cross beam center bracket D Remove 2 fixing nuts. 5. Remove instrument panel center bracket. D Disconnect the PCM and EBCM connector. D Remove the DERM (SRS) with 3 fixing nuts. CAUTION: For precautions on installation or removal of SRS air bag system, refer to Supplemental Restraint System (SRS) AIR BAG in Restraint section. D Remove the 2 fixing nuts (upper) and the 4 fixing bolts (lower).
740RT010
BODY STRUCTURE
6. Remove steering column fixing bolts. D Remove 2 fixing bolts.
8F47
8. Remove steering support bracket assembly. D Remove the 2 fixing bolts (upper side) (1) and the 3 fixing nuts (lower side) (2).
431RW007
7. Remove brake pedal mounting bracket assembly. D Disconnect the 2 brake pedal mounting bracket assembly fixing nuts, and remove the antitheft controller. D Disconnect the brake pedal link and the brake switch, and remove the 4 fixing bolts and the nuts on the bracket.
740RW024
9. Remove cross beam assembly. D Disconnect the harness clips from the crossbeam assembly, and remove 2 fixing bolts on both sides and 2 fixing nuts in the center.
Installation
310RS011
8F48
BODY STRUCTURE
Front Door Assembly

Parts Location
630RS001
Legend (1) Door Check Arm Pin (2) Front Door Assembly
(3) Door Hinge Assembly (4) Hinge Bolt (5) Door Harness Connection
Removal
1. Disconnect the battery ground cable. 2. Remove door check arm pin (1).
810RS001
5. Remove front door assembly.
Installation
630RS002
3. Remove hinge bolt. D Align the hinge bolt to the door side hinge and put a marker on it. 4. Remove door harness connection (2). D Pull the door harness grommet out in order to disconnect the harness connection.
To install, follow the removal steps in the reverse order, noting the following points: 1. Align the door fitting to the body by referring to Body Dimensions in this section. 2. Tighten the door hinge bolts to the specified torque. Torque : 34 Nm (25 lb ft) 3. Apply chassis grease to the door check arm pin and the door hinge moving surface.
BODY STRUCTURE
8F49
Rear Door Assembly

Parts Location
650R200006
Legend (1) Door Check Arm Pin (2) Door Harness Connection
(3) Rear Door Assembly (4) Hinge Bolt
Removal
1. Disconnect the battery ground cable. 2. Apply a setting mark on the body side hinge. 3. Remove door check arm pin (1).
4. Remove hinge bolt. D Open the front door and remove the body side hinge bolts (2).
650RS002
630RS002
8F50
BODY STRUCTURE
6. Remove door assembly
5. Remove door harness connection (3). D Pull the door harness grommet out in order to disconnect the door harness connection.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Align the door fitting to the body by refer to Body Dimensions in this section. 2. Tighten the door hinge bolts to the specified torque. Torque : 34 Nm (25 lb ft) 3. Apply chassis grease to the check arm pin and the door hinge moving surface.
810RS002
Door Strikers
Adjustment
632RS001
1. Loosen the striker (1) screws. 2. Tap with a plastic hammer to align. 3. Tighten the striker screws. Torque : 15 Nm (11 lb ft)
BODY STRUCTURE
8F51
Door Check Arm Assembly (Front & Rear)

Parts Location
630RS003
Legend (1) Front or Rear Door (2) Door Trim Panel (3) Check Arm Assembly
(4) Check Arm Pin Bracket (5) Check Arm Pin (6) Front or Center Pillar
Removal
1. Disconnect the battery ground cable. 2. Remove door trim panel. D Refer to Front / Rear Door Trim Panel in Exterior / Interior Trim section. 3. Remove check arm pin (1).
630RS002
8F52
BODY STRUCTURE
1. When installing the check arm assembly, note its marking to ensure using the appropriate part. 2. Tighten the check arm fixing nuts to the specified torque. Torque : 13 Nm (113 lb in) 3. Apply chassis grease to the check arm pin moving surface.
4. Remove check arm assembly. D Carefully peel off the water proof sheet as much as necessary, for check arm removal.
Installation
To install, follow the removal steps in the reverse order, noting the following point.
Front Window Regulator, Glass And Glass Run

Parts Location
631RS002
Legend (1) Speaker Box (2) Glass Run (3) Glass (4) Rear Guide Rail
(5) (6) (7) (8) (9)
Window Regulator Window Regulator with Power Window Window Regulator Motor Connector Door Trim Panel Waterproof Sheet
Removal
1. Disconnect the battery ground cable.
2. Remove door trim panel. D Refer to Front Door Trim Panel in Exterior / Interior Trim section. 3. Remove speaker box.
BODY STRUCTURE
4. Remove waterproof sheet.
8F53
D Remove the glass fixing bolts from the window regulator (2) and lower thefront side of the glass. When the front side of the glass comes off the glass run (3), turn the glass inside out and pull it up from its rear side.
631RS003
D Take notice of the door harness and the grommet, peel the waterproof sheet off the door panel carefully. 5. Remove glass. D Bring the glass (1) down to the position where the fixing bolts can be seen.
631RS005
6. Remove window regulator. D Remove the window regulator fixing bolts (4) and the rear guide rail fixing bolt (5). D Disconnect the window regulator motor harness connector, if equipped with power windows.
631RS004
631RS006
8F54
BODY STRUCTURE
2. Set the glass into the door panel with the front side of the glass lowered and insert the rear side of the glass into the glass run (1). Then insert the front side of the glass into the glass run in order to install the glass to the glass run while raising it up along the glass run. 3. Tighten the window regulator and the glass fixing bolts and nuts to the specified torque. Torque : 8 Nm (69 lb in) 4. Check to see of the window regulator operates smoothly and the glass opens and closes properly. Install the waterproof sheet with no clearance between the door panel and the waterproof sheet.
7. Remove glass run. D Pull the glass run (6) out from the door frame groove.
631RS007
8. Remove rear guide rail.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply soap and water to the door frame groove. Insert the glass run (1) to the door frame from the A corner in the arrowmarked directions. Install the glass run with its wider end pointed to the inside of the vehicle.
A10RS023
BODY STRUCTURE
8F55
Rear Window Regulator And Glass

Parts Location
651R200006
Legend (1) Window Regulator (2) Glass (3) Cable Fixing Clip
(4) Window Regulator Motor Connector (5) Door Trim Panel (6) Waterproof Sheet
Removal
1. Disconnect the battery ground cable. 2. Remove door trim panel. D Refer to Rear Door Trim Panel in Exterior / Interior Trim section. 3. Remove waterproof sheet (1). D Taking notice of the door harness, peel the waterproof sheet off the door panel carefully.
651RS002
8F56
BODY STRUCTURE
5. Remove window regulator. D Disconnect the regulator motor connector (4) and remove the window regulator cable fixing clip (3) from the door panel, if model is equipped with power windows. D Remove the window regulator 7 fixing bolts (2) and pull the regulator out from the lower hole of the door panel.
4. Remove glass. D Bring the glass down to the position where the bolt can be seen. D Remove the sash division 2 fixing bolts (1) and then remove the glass fixing bolt to remove the glass upwards.
651RS003
651RW011
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the window regulator and the glass fixing bolts to the specified torque. Torque : 8 Nm (69 lb in) 2. Install the waterproof sheet with no clearance between the door panel and the waterproof sheet.
651RW010
BODY STRUCTURE
8F57
Rear Door Fixed Glass And Glass Run

Parts Location
651R200007
Legend (1) Glass Run (2) Rear Fixed Glass (3) Sash Division
(4) (5) (6) (7)
Sash Division Fixing Bolts Door Trim Panel Waterproof Sheet Glass
Removal
1. Disconnect the battery ground cable. 2. Remove door trim panel. 3. Remove waterproof sheet. 4. Remove glass. D Refer to Rear Window Regulator and Glass in this section. 5. Remove glass run. D Pull the glass run (1) out from the door frame.
651RS007
8F58
BODY STRUCTURE
6. Remove sash division (2).
651RS008
7. Remove door fixed glass.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply soap and water to the fixed glass. 2. Apply soap and water to the door groove and insert the glass run (3) to the frame from the corner in the arrow-marked directions. 3. Be sure to install the glass run with its end pointed to the inside of the vehicle.
A10RW019
BODY STRUCTURE
8F59
Front Door Sash Moulding

Parts Location
645RS001
Legend (1) Front Door Sash Moulding
Removal
1. Remove front door slash moulding. D To avoid the weatherstrip (1) and pry the door sash moulding (2) out from the door panel.
Installation
1. Front door sash moulding. D Assemble the edge portion (A portion) of the moulding so that the clearance between the moulding and the waist seal becomes 1 mm (0.04 in).
645RS002
8F60
BODY STRUCTURE
Rear Door Moulding

Parts Location
645RS003
Legend (1) Rear Door Side Moulding
(2) Rear Door Corner Moulding (3) Rear Door Upper Moulding
Removal
1. Disconnect the battery ground cable. 2. Remove rear door side moulding. 3. Remove rear door upper moulding. 4. Remove rear door corner moulding. D Avoiding the weatherstrip (3), pry the moulding (2) out from the door frame (1).
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Install each moulding with no clearance between each piece of moulding. 2. Assemble the edge portion (A portion) of the moulding so that the clearance between the rear side moulding and the waist seal is 1 mm (0.04 in).
645RS004
BODY STRUCTURE
8F61
Front Door Waist Seal

Parts Location
631RS009
Legend (1) Nylon Washer
(2) Door Mirror (3) Front Door Waist Seal
Removal
1. Disconnect the battery ground cable. 2. Remove door mirror. D Refer to Door Mirror in this section. 3. Remove front door waist seal. D Remove the fixing screw and pull out the waist seal (1) from the door frame while prying it up.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Apply soap and water to the inside of the waist seal and align the screw hole of the waist seal to the door panel hole, and gently tap the seal with a rubber hammer. Be sure not to tap the seal hard. This may result in deforming the seal.
631RS010
8F62
BODY STRUCTURE
Rear Door Waist Seal

Parts Location
651RW013
Legend (1) Rear Door Waist Seal

Refer to Front Door Waist Seal in this section.
BODY STRUCTURE
8F63
Front Door Weatherstrip

Parts Location
631RS008
Legend (1) Check Arm Pin (2) Bracket
(3) Weather Strip (4) Clip
Removal
1. Remove check arm pin. 2. Remove front door weatherstrip. D Pull the weatherstrip (1) out from the door frame.
631RS011
8F64
BODY STRUCTURE
3. After positioning the weatherstrip (4) corner, insert the weatherstrip into the door frame groove from A point in the arrowmarked direction. 4. Insert the weatherstrip clip (5) into the door panel up to its base.
D Carefully remove the weatherstrip (2) from the door panel.
631RW003
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply soapy water to the door frame groove, when installing the front door weatherstrip (2). 2. Apply the sealing adhesive (3) to the upper A portion of the door frame (1) and press it for installation after assembling the weatherstrip (2).
631RW009
631RS013
BODY STRUCTURE
8F65
Rear Door Weatherstrip

Parts Location
655R200010
Legend (1) Check Arm Pin
(2) Rear Door Weather Strip (3) Clip

Refer to Front Door Weatherstrip in this section.
8F66
BODY STRUCTURE
Front Door Seal Finisher

Parts Location
635RS002
Legend (1) Front Door Sill Plate (2) Front Door Seal Finisher
Removal
1. Disconnect the battery ground cable. 2. Remove front door sill plate. 3. Remove front door seal finisher (1). D Pull the finisher out from the body panel.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Insert the finisher (2) into the A corner and install the finisher in the arrowmarked directions. 2. Take care not to allow the sill plate (1) to distort or twist the finisher.
635RS003
635RS002
BODY STRUCTURE
8F67
Rear Door Seal Finisher

Parts Location
655RS002
Legend (1) Rear Door Sill Plate and Luggage Side Lower Cover (2) Rear Door Seal Finisher
Removal
1. Disconnect the battery ground cable. 2. Remove rear door sill plate and the luggage side lower cover. 3. Remove rear door seal finisher (1). D Pull the rear door seal finisher (1) out from the body panel.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Insert the rear door seal finisher (2) into the A corner and install the finisher in the arrow-marked directions. 2. Be careful not to allow the sill plate the cover (1) to distort or twist the finisher.
655RS002 635RS003
8F68
BODY STRUCTURE
Tailgate Assembly (LH)

Parts Location
681RT001
Legend (1) Tailgate Fixing Bolt (2) Tailgate Hinge (3) Tailgate Harness Connection
(4) Tailgate Stopper Assembly (5) Tailgate Trim Panel (LH) (6) Tailgate Assembly (LH)
Removal
1. Disconnect the battery ground cable. 2. Remove tailgate time panel (LH). D Refer to Tailgate Trim Panel (LH) in Exterior / Interior Trim section. 3. Remove tailgate stopper assembly 4. Remove tailgate harness connection. D Open the luggage trim panel lid and disconnect the tailgate harness connection.
810RS003
BODY STRUCTURE
5. Remove tailgate fixing bolts.
8F69
681RS002
6. Remove tailgate assembly (LH). 7. Remove tailgate hinge. D Apply a setting mark (1) on the body side hinge and remove the hinge fixing bolts.
681RW007
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply chassis grease to the tailgate hinge and the tailgate stopper moving surface. 2. Align the tailgate fitting to the body by referring to Body Dimension in this section. 3. Tighten the hinge bolts to the specified torque. Torque : 34 Nm (25 lb ft)
8F70
BODY STRUCTURE
Tailgate Assembly (RH)

Parts Location
681R200012
Legend (1) Tailgate Assembly (LH) (2) Tailgate Trim Panel (RH) (3) Tailgate Harness Connection
(4) Rear Combination Light (RH) (5) Tailgate Fixing Bolt (6) Tailgate Hinge
Removal
1. Disconnect the battery ground cable. 2. Remove rear combination light (RH). 3. Remove tailgate trim panel (RH). D Refer to Tailgate Trim Panel (RH) in Exterior / Interior Trim section. 4. Remove tailgate harness connection. D Disconnect the tailgate harness connection.
810RS004
BODY STRUCTURE
5. Remove tailgate fixing bolt.
8F71
681R200013
6. Remove tailgate assembly (RH). 7. Remove tailgate hinge. D Apply a setting mark (1) on the body side hinge and remove the hinge fixing bolts.
681RW006
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Apply chassis grease to the tailgate hinge moving surface. 2. Align the tailgate fitting to the body. Refer to Body Dimension in this section. 3. Tighten the hinge bolts to the specified torque. Torque : 34 Nm (25 lb ft)
8F72
BODY STRUCTURE
Tailgate Strikers
Adjustment
1. Loosen the striker screws (3) (or bolts (2)). 2. Tap the striker (1) with a plastic hammer to align. 3. Tighten the striker screws (3) (or bolts (2)). Screw Torque : 15 Nm (11 lb ft) Bolt Torque : 12 Nm (104 lb in)
683RW012
Tailgate Stopper Assembly

Parts Location
683RS010
Legend (1) Tailgate
(2) Rear Bumper (3) Tailgate Stopper Assembly
Removal
1. Remove tailgate stopper assembly. D Remove the five bolts.
Installation
To install, follow the removal steps in the reverse order, nothing the following points. 1. Tighten the fixing bolts to the specified torque. Torque : 12 Nm (104 lb in) 2. Apply chassis grease to the stopper moving surface.
BODY STRUCTURE
8F73
Tailgate Dove-Tail
Parts Location
683RW011
Legend (1) Dove-Tail (2) Fixing Bolt
(3) Tailgate Striker (4) Rear Bumper (5) Tailgate (LH)
Removal
1. Remove tailgate dove-tail. D Remove the two bolts from each side.
Installation
To install, follow the removal steps in the reverse order, nothing the following points. 1. Apply chassis grease to the dovetail (A) moving surface. 2. Tighten the fixing bolts to the specified torque. Torque : 12 Nm (104 lb in)
8F74
BODY STRUCTURE
Tailgate Dove-Tail Striker

Adjustment
683RS012
1. Loosen the striker bolts. 2. Tap with a plastic hammer to align. D Gaps between DoveTail Striker (2) and bracket (1) are 0 mm (No clearance).
683RS013
3. Tighten striker bolts. Torque : 12 Nm (104 lb in)
BODY STRUCTURE
8F75
Tailgate Frame Cover (LH)

Parts Location
684RW001
Legend (1) High Mount Stop Light
(2) Washer Tube (3) Tailgate Frame Cover
Removal
1. Disconnect the battery ground cable. 2. Remove tailgate frame cover. D Pull the tailgate frame cover (2) out. D Disconnect the washer tube (1) at the nozzle and pull the washer tube out from the frame cover (2). D Disconnect the rear defogger and pull the harness from the cover.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Hit the lower A edge portion of the cover (1) to the tailgate flange. 2. Clearance between the frame cover and the tailgate panel (B portion) is 1 mm (0.04 in).
684RS008
684RW002
8F76
BODY STRUCTURE
Tailgate Frame Cover (RH)

Removal
1. Remove tailgate frame cover (RH). D Pull the frame cover out from the tailgate frame.
684R200008
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Hit the lower A edge portion (2) of the tailgate frame cover (1). 2. Clearance between the frame cover and the tailgate panel (B portion) is 1 mm (0.04 in).
684R200009
BODY STRUCTURE
8F77
Tailgate Sash Trim Cover

Parts Location
684R200010
Legend (1) Tailgate Sash Trim Cover
Removal
1. Remove tailgate sash trim cover (1). D Pry the tailgate trim cover retainers free from the tailgate panel.
Installation
1. Tailgate sash trim cover (1). D Insert the trim cover retainers into the tailgate hole securely so that there are no gaps between them.
684R200012
8F78
BODY STRUCTURE
Tailgate Outer Weatherstrip

Parts Location
682RW001
Legend (1) Tailgate Outer Weatherstrip
Removal
1. Disconnect the battery ground cable. 2. Remove tailgate outer weatherstrip (1). D Pry the tailgate outer weatherstrip clips (2) free from the body panel.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Insert the tailgate outer weatherstrip clip into the body panel hole securely in order to install the tailgate outer weatherstrip with the gap between the body panel and the weatherstrip.
682RS002
BODY STRUCTURE
8F79
Tailgate Center Weatherstrip

Parts Location
682R200004
Legend (1) Clip (2) Tailgate Center Weatherstrip D Clean the tailgate center weatherstrip (4) adhesive tape (2) and the butyl seal (3) fitting position of the tailgate panel. D Affix new adhesive tape and the butyl seal to the weatherstrip (lower side) in order to install the tailgate center weatherstrip to the tailgate panel with no gap between them.
Removal
1. Remove tailgate center weatherstrip. D Remove the fixing clips in order to pull the tailgate center weatherstrip out from the tailgate panel.
Installation
1. Tailgate center weatherstrip (1). D Start assembling at the A portion.
682RS004
682R200005
8F80
BODY STRUCTURE
Tailgate Main Weatherstrip

Parts Location
682RS005
Legend (1) Tailgate Main Weatherstrip
Removal
1. Remove tailgate main weatherstrip. D Pull the tailgate main weatherstrip out from the body panel.
Installation
1. Tailgate main weatherstrip. D Align the A and B positions to the corners of the body panel. Install the tailgate main weatherstrip to the body panel by gently tapping with a plastic hammer. There should be not clearance between the body panel the tailgate main weatherstrip.
BODY STRUCTURE
8F81
Spare Tire Carrier

Parts Location
530RS001
Legend (1) Spare Tire (2) Spare Tire Carrier
Removal
1. Remove spare tire. 2. Remove spare tire carrier by using spare tire carrier nut wrench J34355.
Installation
1. Install the spare tire carrier. D Tighten the carrier fixing bolts to the specified torque. Torque : 31 Nm (23 lb ft) 2. Install the spare tire. D Tighten the spare tire fixing bolts to the specified torque. Torque : 118 Nm (87 lb ft)
530RS002
8F82
BODY STRUCTURE
Headlining
Parts Location
666RW003
Legend (1) Clip (2) Interior Trim Panels (3) Sun Roof Finisher (W/Sun Roof) (4) Headlining (5) Dome Light
(6) (7) (8) (9) (10)
Sunvisors Map Light Sunvisor Holder Rear View Mirror Multi Meter
Removal
1. Disconnect the battery ground cable. 2. Remove interior trim panels. D Refer to the Exterior / Interior Trim section. 3. Remove dome light. D Remove the dome light lens and the fixing screws. D Disconnect the dome light connectors. 4. Remove multi meter (4). D Remove two caps (2), two screws (3) and disconnect the connector (1).
821RW241
BODY STRUCTURE
5. Remove rear view mirror. D Remove the rubber stopper (1). D Pry off the mirror stay cover (2) and remove 3 screws.
8F83
7. Remove sunvisors. D Remove the fixing screw and turn the sunvisor holder (1) to remove it. D Disconnect the vanity mirror illumination connector.
720RW004
743RS006
6. Remove map light/sun roof switch. D Pry the map light clip free from the map light/sun roof switch bracket and disconnect the connector.
8. Remove sun roof finisher (W/Sun roof). 9. Remove headlining. D Remove the headlining fixing clips.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Install the headlining so that the fixing clips will not come off. 2. To install the sun roof finisher (3), first fit in at one place with the head lining (2) close to the sun roof frame complete (1), then install the entire finisher tightly by hitting it with a plastic hammer, not allowing it to move up.
805RS001
665RS001
8F84
BODY STRUCTURE
Rear Air Deflector

Parts Location
667RW001
Legend (1) Rear Roof Trim Cover (2) Rear Air Deflector (3) Roof Rail (4) Rear Inner Roof Rail (5) Fixing Bolt (6) Nylon Washer
(7) (8) (9) (10) (11) (12) (13)
Rear Outer Roof Panel Seal Fixing Nut Rear Pillar Upper Reinforcement Rear Outer Roof Rail Roof Panel Grommet
Removal
1. Disconnect the battery ground cable 2. Remove rear roof trim cover. D Refer to Luggage Side and Quarter Upper Trim Cover in Exterior / Interior Trim section. 3. Remove rear air deflector. D Take notice of the grommet and the nylon washer.
Installation
BODY STRUCTURE
1. Install the grommet (1) to the air deflector (2) drain hole.
8F85
3. Install the air deflector (2) to the roof by referring to the specified values shown in the illustration.
667RW002
667RW003
2. Use a new nylon washer (4). Peel off the adhesive tape of the washer to install the nylon washer to the air deflector (3).
4. Tighten the deflector fixing to the specified torque. Bolt Torque : 6 Nm (52 lb in) Nut Torque : 8 Nm (69 lb in)
667RW004
8F86
BODY STRUCTURE
Roof Moulding
Parts Location
645RX002
Legend (1) Windshield Side Moulding Upper Clip (2) Roof Moulding
(3) Roof Moulding Clip (4) Roof End Moulding
Removal
1. Disconnect the battery ground cable. 2. Remove roof moulding. 3. Remove roof end moulding. D Remove the sealing adhesive and the adhesive tape of the roof end moulding from the panel using a knife or scraper while you peel them off. 4. Remove roof moulding clip. D Remove the clips.
BODY STRUCTURE
8F87
Installation
1. Install the roof moulding clip (1). D Install the clips to the specified positions on the roof panel flange (2).
645RW003
2. Install the roof end moulding (3). D Clean the body panel where the roof end moulding is installed. D Install the roof end moulding and the rear air deflector (2) so that the installation clearance between them is within the specified values. Securely fix it with the adhesive tape (4) and sealing adhesive (5).
645RW001
3. Install the roof moulding (9). D Assemble the windshield side moulding upper clip (8) to the roof panel with the clip positioning rib (6) (oblique lines portion) attached to the roof panel flange (7). Assemble the roof moulding (9) while you attach the front edge portion of the roof molding to the windshield side moulding (10).
645RX001
8F88
BODY STRUCTURE
Windshield
Parts Location
607RX001
Legend (1) Windshield Upper Moulding (2) Moulding Clip (3) Windshield Side Seal (4) Windshield Side Moulding (5) Spacer
(6) (7) (8) (9) (10)
Windshield Support Cowl Upper Rail Flange Windshield Wiper Front Cowl Cover Windshield
Removal
1. Disconnect the battery ground cable. 2. Remove windshield wiper. D Refer to Windshield Wipper Arm/Blade Wiper/Washer System section. 3. Remove front cowl cover. D Refer to Cowl Cover in this section.
in
4. Remove windshield side moulding. D Pull the moulding out from the windshield side moulding clip. 5. Remove windshield support. 6. Remove windshield side seal. 7. Remove windshield (2). D Use a knife or pick to make a hole in part of the adhesive caulking material.
BODY STRUCTURE
D Secure one end of a piece of steel piano wire (1) (0.02 inches in diameter) to a piece of wood that can serve as a handle.
8F89
Installation
1. Install the spacer (1). D Clean the bonding surfaces of both the windshield and the body panel. D When installing the spacers, align the lower side spacer to the R stop of the body panel and the side spacer to the end of the body panel. Be sure to always use a new spacer.
607RS002
D Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the windshield glass. D Secure the other end of the piano wire to another piece of wood. D With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the windshield glass. D Clean the remaining adhesive caulking material from the area of the body which holds the windshield. 8. Remove windshield upper moulding. D Taking notice of the adhesive tape, and peel the moulding off the windshield upper portion. 9. Remove moulding clip. 10. Remove spacer.
607RS003
8F90
BODY STRUCTURE
D Be absolutely sure to apply glass primer and body primer to the body panel as shown in the illustration.
607RW005
Legend (1) Front Cowl Cover (2) Windshield Lower Moulding (3) The portion of the cowl upper rail flange where sealing adhesive is additionally filled (4) Apply primer to the glass and portion where sealing adhesive is additionally filled (5) Windshield (6) Cowl Upper Rail
(7) (8) (9) (10) (11) (12) (13) (14) (15)
Cowl Upper Panel Body Primer Roof Panel Sealing Adhesive Windshield Upper Moulding Moulding Clip Front Pillar Outer Panel Windshield Side Moulding Sealing Adhesive
BODY STRUCTURE
2. Install the moulding clip (2). D Install new moulding clips to the fixed position of the windshield (3). D Always use new moulding clips (4).
8F91
3. Install the windshield upper moulding (1). D Peel off the adhesive tape (2) and install the moulding to the fixed position of the windshield (3). D Always use new upper moulding (1).
607RS004
607RS005
4. Install the windshield.
607RW005
Legend (1) Front Cowl Cover (2) Windshield Lower Moulding (3) The portion of the cowl upper rail flange where sealing adhesive is additionally filled
(4) Apply primer to the glass and portion where sealing adhesive is additionally filled (5) Windshield (6) Cowl Upper Rail (7) Cowl Upper Panel
8F92
(8) (9) (10) (11)
BODY STRUCTURE
(12) (13) (14) (15) Moulding Clip Front Pillar Outer Panel Windshield Side Moulding Sealing Adhesive
Body Primer Roof Panel Sealing Adhesive Windshield Upper Moulding
5. Install the windshield side seal. 6. Install the windshield support (2).
7. Install the windshield side moulding. D Insert the windshield (5) side moulding (1) into the moulding clip (2).
631RS014
D Apply a sealing adhesive (4) to the circumference of the windshield (5). D Apply the sealing adhesive to the frange portion of the cowl upper rail. D Adjust the gap clearance of the windshield (5). D Install the windshield to the body panel by applying pressure to the windshield. D Cure the adhesive at a temperature of 20~30C (6886F) for 24 hours. D Check that the windshield does not leak water.
607RS008
D Take care not to damage the side moulding when you install it. 8. Install the front cowl cover. 9. Install the windshield wiper.
607RS007
BODY STRUCTURE
8F93
Rear Quarter Side Glass

Parts Location
641RS005
Legend (1) Rear Quarter Upper Trim Panel (2) Fastener (3) Rear Quarter Side Glass (4) Valve Assembly
(5) (6) (7) (8) (9)
Ventilation Assembly Side Outer Panel Ventilation Assembly Ventilation Fixing Clip Rear Quarter Side
Removal
1. Disconnect the battery ground cable. 2. Remove rear quarter upper trim panel. D Refer to Laggage Side and Quarter Upper Trim Cover in Exterior / Interior Trim section. 3. Remove ventilation assembly. 4. Remove valve assembly. D Refer to Ventilation Assembly in this section. 5. Remove rear quarter side glass. D Refer to windshield in this section.
Installation
1. Install the rear quarter side glass. D Clean the bonding surfaces of both the glass and the body panel. D Install the fasteners (1) to the fixed positions of the glass and the body panel.
641RS006
D Always use new fasteners.
8F94
BODY STRUCTURE
D Be absolutely sure to apply glass primer to the side glass.
641RS007
D Apply a sealing adhesive (1) to the glass circumference.
D Check that the rear quarter side glass does not leak water. 2. Install the valve assembly. 3. Install the ventilation assembly. 4. Install the rear quarter upper trim panel.
641RS008
D Apply PVC primer (4) to the A clip portion. D Insert the fixing clip on the side glass into the body panel. D Push the side glass against the body panel and bond them. D Cure the adhesive at a temperature of 20~30C (68~86F) for 24 hours.
BODY STRUCTURE
8F95
Tailgate Glass
Parts Location
682R200003
Legend (1) Tailgate Glass Moulding (2) Tailgate Glass (3) Tailgate Glass Clip
(4) Glass Moulding (5) Clip (6) Body Panel
Removal
1. Remove battery ground cable. 2. Remove tailgate trim panel. 3. Remove tailgate sash trim cover (RH only). 4. Remove the tailgate frame cover. D Refer to Tailgate Frame Cover (RH & LH) in this section 5. Remove tailgate glass. D Refer to Windshield in this section.
682RS007
6. Remove tailgate glass clip.
8F96
BODY STRUCTURE
Installation
682RW009
Legend (1) Glass Moulding (2) Tailgate Glass (3) Clip
(4) Sealing Adhesive (5) Body Panel (6) Tailgate Frame
1. Install the tailgate glass clip.
2. Install the tailgate glass (2). D Clean the bonding surfaces of both the tailgate glass and the tailgate panel. D Be absolutely sure to apply glass primer to the tailgate glass and PCV primer to the glass moulding (1). D Apply a sealing adhesive to the circumference of the tailgate glass as shown. D Insert the clip of the tailgate glass A portion into the tailgate panel hole to position the glass. D Install the new tailgate glass clip to the clip of the tailgate glass B portion while sliding it, and bond the glass to the tailgate panel by applying pressure. Always use new tailgate glass clips. D Cure the bonding at a temperature of 20~30C (6886F) for 24 hours. D Check that the tailgate glass does not leak water.
682RS008
BODY STRUCTURE
8F97

E10RW001
8F98
BODY STRUCTURE
E10RW002
BODY STRUCTURE
8F99
E10R200008
8F100 BODY STRUCTURE
E10RX005
BODY STRUCTURE 8F101
E10R200009
E10RW001
E10RX001
E10RX002
E10RX003
E10RS010
Special Tools
J34355 Spare Tire Carrier Nut Wrench
SECTION
SEATS
TROOPER
8G1

SEATS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Seat Assembly . . . . . . . . . . . . . . . . . . . . Front Seat Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat Assembly . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat Switch . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8G1 8G2 8G2 8G2 8G2 8G3 8G4 8G5 8G6 8G6 8G6 8G7 8G9 8G9 8G9 8G9 8G10 8G10 Removal and Installation . . . . . . . . . . . . . . . Seat Heater System . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Seat Heater Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Unit Parts Location . . . . . . . . . . . . . . . . Heat Unit Removal and Installation . . . . . . Rear Seat Assembly . . . . . . . . . . . . . . . . . . . . . Rear Seat Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View (Split Type) . . . . . . . . . Disassembly (Split Type) . . . . . . . . . . . . . . . Reassembly (Split Type) . . . . . . . . . . . . . . . . Disassembled View (Bench Type) . . . . . . . Disassembly (Bench Type) . . . . . . . . . . . . . Reassembly (Bench Type) . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 8G10 8G11 8G11 8G11 8G11 8G11 8G12 8G12 8G12 8G12 8G13 8G14 8G15 8G16 8G17 8G18 8G18
Service Precaution
8G2
SEATS
Front Seat Assembly

Front Seat Assembly and Associated Parts
750R200027
Legend (1) Rear Cover (2) Front Seat Assembly (3) Seat Belt Warning Connector
(4) Door Sill Plate (5) Riser Cover (6) Front Cover
Removal
1. Disconnect the battery ground cable. 2. Remove the front cover. 3. Remove the rear cover. D Remove the cover fixing screw from the rear inner cover, if this model is equipped with the power seats. 4. Remove the door sill plate. 5. Remove the rear seat foot rest. D Refer to the Rear Seat Foot Rest in this section.
6. Remove the riser cover. 7. Remove the seat belt warning connector (Driver s side only). 8. Remove the front seat assembly. D Disconnect the power seat connector, if this model is equipped with the power seats.
Installation
SEATS
1. Tighten the front seat assembly fixing bolts to the specified torque. Torque: 40 Nm (30 lb ft)
8G3
2. Install the longest bolt to the rear inner side fixing location, if this model is equipped with power seats.
Disassembled View
750R200028
Legend (1) Spring Washer (2) Head Rest (3) Seat Back Assembly (4) Reclining Device (5) Trim Cover (6) Guide Holder (7) Pad & Frame Assembly (8) Slide Cover (9) Reclining Knob (10) Dial (W/Height Adjuster) (11) Lock Spring (12) Frame Assembly
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Pad Assembly Trim Cover Spacer (W/O Height Adjuster) Release Wire Seat Adjuster Seat Belt Knuckle Assembly Height Adjuster Seat Cushion Assembly Hinge Cover Pad & Frame Assembly Trim Cover Armrest Assembly
8G4
SEATS
6. Remove the trim cover. 7. Remove the pad and frame assembly. 8. Remove the hinge cover. 9. Remove the reclining device. D Turn up the seat back trim cover in order to remove the reclining device fixing bolts.
Disassembly
1. Remove the head rest. 2. Remove the reclining knob. 3. Remove the dial(1) (W/height adjuster). D Remove the side cover fixing screws and the dial lock spring(2).
750RS006 750RW025
4. Remove the side cover. 5. Remove the armrest assembly. D Open the armrest fastener and remove the armrest fixing bolt.
10. Remove the seat back assembly. D Remove the seat back assembly fixing nut on the opposite side of the reclining device.
750RS007
750RS004
SEATS
11. Remove the guide holder. D Pull the guide holder out by holding the bottom end of it from the seat back assembly. 12. Remove the trim cover. D Remove the trim cover hog rings from the back side of the seat back. D With close attention paid to the hog rings and the wire which connect the trim cover and the pad and frame assembly, remove the trim cover while turning it up. 13. Remove the pad and frame assembly. 14. Remove the seat adjuster. D Disconnect the release wire(4) and remove the fixing bolts.
8G5
750RW006
D Remove the seat belt buckle assembly. 15. Remove the height adjuster. 16. Remove the spacer (W/O height adjuster). 17. Remove the seat cushion assembly. 18. Remove the trim cover. D Remove the trim cover hog rings from the back side of the seat cushion assembly. D With close attention paid to the hog rings and the wire which connect the trim cover and the pad and frame assembly, remove the trim cover while turning it up. 19. Remove the frame assembly. 20. Remove the pad assembly.
Reassembly
To reassembly, follow the disassembly steps in the reverse order, noting the following points. 1. Tighten the armrest assembly fixing bolts to the specified torque. Torque: 18 Nm (13 lb ft) 2. Tighten the reclining device fixing bolts to the specified torque. Torque: 47 Nm (35 lb ft)
8G6
SEATS
Power Seat Assembly

General Description
The circuit consists of the power seat switch, front tilt motor (driver s seat only), rear tilt motor (driver s seat only), slide motor and the recliner motor. The power seat switch has a tilt & slide switch and a recliner switch. The motor built in the seat can be actuated by operating these switches to move the seat to desired position, independent of the position of the starter switch.
Disassembled View
750R200024
Legend (1) Reclining Device (2) Inner Cover (3) Rear Cover (4) Armrest Assembly (5) Inner Lower Cover (6) Pad & Frame Assembly (7) Trim Cover (8) Front Lower Cover (9) Front Cover (10) Power Seat Harness
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)
Outer Lower Cover Adjuster Assembly Seat Cushion Assembly Connecting Shaft Outer Cover Fixing Screws Switch Assembly Outer Cover Switch Knob Outer Cover Cap Back Board Assembly Guide Holder
SEATS
(22) (23) (24) (25) (26) Trim Cover Pad Assembly Seat Heater Frame Assembly Pad Assembly (27) (28) (29) (30) (31) Trim Cover Seat Heater Frame Assembly Head Rest Seat Back Assembly
8G7
Disassembly
1. Disconnect the battery ground cable. 2. Remove the head rest. 3. Remove the switch knob. D Pull the switch knob out. 4. Remove the outer cover cap. 5. Remove the outer cover fixing screws. D Pull up the outer cover(1) to remove the cover from the reclining device(2).
750RS004
12. Remove the trim cover. 13. Remove the pad & frame assembly. 14. Remove the inner cover D Remove the cover fixing screw. D Pull up the inner cover to remove the cover from the reclining device(3).
750RS012
6. Remove the front cover. 7. Remove the front lower cover. 8. Remove the rear cover. 9. Remove the outer cover. D Disconnect the switch connectors and remove the harness fixing clips. 10. Remove the switch assembly. D Remove the switch fixing screws from the outer cover. 11. Remove the armrest assembly. D Open the armrest fastener and remove the fixing bolt.
750RW007
8G8
SEATS
15. Remove the back board assembly(4). D Remove the board fixing screws. D Pull the back board downward and remove the board from the seat back frame(5).
750R200026
17. Remove the seat back assembly. 18. Remove the guide holder(8). D Remove the trim cover fixing hog rings(9) from the backside of the seat back assembly. D Hold the tip end of the guide holder and pull the holder out from the seat back assembly.
750R200025
16. Remove the reclining device(7). D Remove the device lower side fixing bolt in order to separate the seat back from the seat cushion. D Disconnect the seat heater connector. D Remove the trim cover(6) hog rings from the backside of the seat back assembly. D Turn up the seat back trim cover to remove the reclining device upper side fixing bolt. D Disconnect the connecting shaft and the reclining device connectors.
750RW010
19. Remove the trim cover. D Remove the trim cover hog rings from the backside of the seat back. D With close attention paid to the hog rings and the wire which connect the trim cover and pad & frame assembly, remove the trim cover while turning it up. 20. Remove the seat heater. 21. Remove the pad assembly. 22. Remove the frame assembly. 23. Remove the outer lower cover. 24. Remove the inner lower cover. 25. Remove the adjuster assembly. D Disconnect the connectors and remove the fixing bolts.
SEATS
D Remove the power seat harness from the adjuster assembly. 26. Remove the seat cushion assembly. 27. Remove the trim cover. D Remove the trim cover hog rings from the backside of the seat cushion assembly. D With close attention paid to the hog rings and the wire which connect the trim cover and the pad & frame assembly, remove the trim cover while turning it up. 28. Remove the seat heater. 29. Remove the frame assembly. 30. Remove the pad assembly.
8G9
Reassembly
To reassemble, follow the disassembly steps in the reverse order, noting the following point. 1. Tighten the fixing bolts to the specified torque. D Refer to the Torque Specifications in this section.
Power Seat Switch

Removal
1. Remove the side cover(3). D Refer to the Power Seat Assembly in this section. 2. Remove the tilt & slide switch lever(4). D Hold the switch lever with your fingers and pull it toward you. 3. Remove the tilt & slide switch(2). D Remove two screws. 4. Remove the recliner switch(1). D Remove two screws.
Installation
750RS025
8G10 SEATS
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor
Parts Location Removal and Installation
Refer to the Power Seat Assembly in this section.
750RS027
Legend (1) Tilt Motor (2) Slide Motor (3) Tilt Motor
750RS028
Legend (4) Recliner Motor
SEATS 8G11
Seat Heater System

General Description
The circuit consists of the starter switch, seat heater switch and the heat unit. The seat heater is provided in driver s and front passenger seats (as option). When the seat heater switch is ON, the seat heat built in the seat back and cushion is switched on to warm the seats. To prevent the seats from being overheated, the circuit is fitted with a thermostat.
Seat Heater Switch Removal and Installation

Refer to the Seat Heater Switch in Lighting System section.
Heat Unit Parts Location

750RS019
Legend (2) Heat Unit (Seat Cushion Side)
Heat Unit Removal and Installation

Refer to the Power Seat Assembly in this section.
750RS018
Legend (1) Heat Unit (Seat Back Side)
8G12 SEATS
Rear Seat Assembly

Rear Seat Assembly and Associated Parts
755R200016
Legend (1) Fixing Bolts
(2) Rear Seat Assembly (3) Mounting Bracket Cover
Removal
1. Unlock the rear seat(1) lock to remove it. 2. Remove the mounting bracket cover. 3. Remove the fixing bolts.
4. Remove the rear seat assembly.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the rear seat fixing bolts to the specified torque. Torque: 19 Nm (14 lb ft)
755RS002
SEATS 8G13
Disassembled View (Split Type)
755R200013
Legend (1) Free Hinge Cover (2) Back Board (3) Seat Back Assembly (4) Armrest Assembly (5) Bush (6) Armrest Set Bracket (7) Clip (8) Armrest Board (9) Pillow Assembly (10) Band Hook Cover (11) Trim Cover (12) Pad & Frame Assembly (13) Release Knob (14) Connecting Shaft (15) Release Rod
(16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)
Linkage Bush Device Cover Trim Cover Seat Lock Cover Rear Seat Belt Buckle and Lock Assembly Frame Assembly Stopper Rubber Spring Collar Return Spring Mounting Bracket Pad Assembly Reclining Device Seat Cushion Assembly Linkage Bush Bush
8G14 SEATS
Disassembly (Split Type)

1. Remove the back board. D Remove the clips and the back board. 2. Remove the device cover. 3. Remove the release knob. D Turn the knob counterclockwise to remove it. 4. Remove the release rod. D Disconnect the rod from the linkage bush. 5. Remove the reclining device.
755RS017
10. Remove the armrest assembly. D Turn up the seat back trim cover and remove the fixing nuts. 11. Remove the armrest set bracket. 12. Remove the armrest board. 13. Remove the trim cover. D Remove the trim cover fixing hog rings from the backside of the seat back. D With close attention paid to the hog rings and the wire which connect the trim cover and the pad and frame assembly, remove the trim cover while turning it up. 14. Remove the pad & frame assembly. 15. Remove the seat cushion assembly. 16. Remove the seat lock cover. 17. Remove the rear seat belt buckle and lock assembly. 18. Remove the mounting bracket. 19. Remove the return spring. 20. Remove the spring collar. 21. Remove the trim cover. D Remove the hog rings and pull the trim cover out from the frame assembly groove. D With close attention paid to the hog rings and the wire which connect the trim cover and the pad & frame assembly, remove the trim cover while turning it up. 22. Remove the frame assembly. 23. Remove the pad assembly. 24. Remove the stopper rubber.
755RS004
6. Remove the connecting shaft. 7. Remove the seat back assembly. 8. Remove the band hook cover. 9. Remove the pillow assembly. D Turn up the seat back trim cover and slit the pad from the back around to the place where the lock spring(2) of the guide bush(1) is. Then insert a finger through the slit and pull out the pillow while you are pressing down on the lock spring.
SEATS 8G15
Reassembly (Split Type)

To reassemble, follow the disassembly steps in the reverse order, noting the following points. 1. Tighten the reclining device fixing bolts to the specified torque. Torque: 27 Nm (20 lb ft) 2. Loosen the rubber stopper lock nut(1). Adjust the stopper(3) so there is no clearance between the bottom of the stopper and the carpet(2) while you make sure the rear seat is firmly locked. Then tighten the lock nut securely.
755RS005
8G16 SEATS
Disassembled View (Bench Type)
755RW021
Legend (1) Trim Cover (2) Pillow Assembly (3) Band Hook Cover (4) Pad & Frame Assembly (5) Seat Back Assembly (6) Release Knob (7) Release Rod (8) Device Cover (9) Linkage Bush (10) Reclining Device
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Connecting Shaft Seat Cushion Assembly Connecting Link Seat Lock Cover Rear Seat Belt Buckle and Lock Assembly Trim Cover Stopper Rubber Mounting Bracket Frame Assembly Pad Assembly
SEATS 8G17
Disassembly (Bench Type)

1. Remove the device cover. 2. Remove the release knob. D Turn the knob to the counterclockwise to remove it. 3. Remove the release rod. D Disconnect the rod from the linkage bush. 4. Remove the reclining device.
9. Remove the trim cover. D Open the fastener(3), and with close attention paid to the hog rings and wire which connect the trim cover and the pad and frame assembly, remove the trim cover as you turn it up.
750RW011
755RS004
5. Remove the connecting shaft. 6. Remove the seat back assembly. 7. Remove the band hook cover. 8. Remove the pillow assembly. D Refer to the Disassembly (Split Type) in this section.
10. Remove the pad & frame assembly. 11. Remove the seat cushion assembly. 12. Remove the seat lock cover. 13. Remove the rear seat belt buckle and lock assembly. 14. Remove the mounting bracket. 15. Remove the trim cover. D Remove the hog rings and pull the trim cover out from the frame assembly groove. D With close attention paid to the hog rings and the wire which connect the trim cover and the pad and frame assembly, remove the trim cover while turning it up. 16. Remove the frame assembly. 17. Remove the pad assembly. 18. Remove the stopper rubber.
755RS017
8G18 SEATS
Reassembly (Bench Type)

To reassemble, follow the disassembly steps in the reverse order, noting the following points. 1. Tighten the reclining device fixing bolts to the specified torque. Torque: 27 Nm (20 lb ft) 2. Loosen the rubber stopper lock nut(1) and adjust the stopper rubber(3) so there is no clearance between the bottom of the stopper and the carpet(2), while ensuring the rear seat is firmly locked. Tighten the lock nut securely.
755RS005

E10R200010
SEATS 8G19
E10R200011
SECTION
SECURITY AND LOCKS
TROOPER
8H1

SECURITY AND LOCKS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Door Lock Assembly . . . . . . . . . . . . . . . Front Door Lock Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Outside Handle and Door Lock Cylinder Front Outside Handle, Door Lock Cylinder and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Lock Assembly . . . . . . . . . . . . . . . . Rear Door Lock Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Outside Handle . . . . . . . . . . . . . . . . . . . . Rear Outside Handle and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Inside Lock Knob Link . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Inside Lock Knob . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Inside Handle . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Tailgate Lock Assembly (LH) . . . . . . . . . . . . . . Tailgate Lock Assembly (LH) and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Lock Assembly (RH) . . . . . . . . . . . . . Tailgate Lock Assembly (RH) and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H2 8H2 8H2 8H3 8H3 8H4 8H4 8H4 8H5 8H7 8H7 8H7 8H8 8H9 8H9 8H9 8H10 8H10 8H10 8H10 8H11 8H11 8H11 8H11 8H11 8H12 8H12 8H12 8H13 8H14 8H14 8H14 8H15 Tailgate Inside Lock Knob . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Outside Handle and/or Tailgate Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Lock System . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Front Door Lock Actuator Removal . . . . . . Front Door Lock Actuator Installation . . . . . Rear Door Lock Actuator Removal . . . . . . . Rear Door Lock Actuator Installation . . . . . Tailgate Lock Actuator Removal . . . . . . . . . Tailgate Lock Actuator Installation . . . . . . . Anti-theft System . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Anti-theft & Keyless Entry Control Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft & Keyless Entry Control Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft Indicator Removal . . . . . . . . . . . . . Anti-theft Indicator Installation . . . . . . . . . . . Anti-theft Horn Removal . . . . . . . . . . . . . . . . Anti-Theft Horn Installation . . . . . . . . . . . . . . Engine Hood Switch Removal . . . . . . . . . . . Engine Hood Switch Installation . . . . . . . . . Keyless Entry System . . . . . . . . . . . . . . . . . . . . ID Code Registration . . . . . . . . . . . . . . . . . . . Antitheft & Keyless Entry Control Unit/Transmitter Replacement . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 8H15 8H15 8H15 8H16 8H16 8H16 8H17 8H18 8H18 8H18 8H19 8H19 8H19 8H19 8H19 8H20 8H20 8H20 8H21 8H21 8H21 8H21 8H21 8H22 8H22 8H22 8H22 8H22 8H23 8H23 8H25 8H26
8H2
SECURITY AND LOCKS

Service Precaution
Front Door Lock Assembly

Front Door Lock Assembly and Associated Parts
632RS003
Legend (1) Door Trim Panel (2) Waterproof Sheet (3) To Outside Handle
(4) Rear Guide Rail (5) Door Lock Assembly (6) Door Lock Switch Connector (W/Power Door Lock)
SECURITY AND LOCKS
8H3
Removal
1. Disconnect the battery ground cable. 2. Remove the door trim panel. 3. Remove the waterproof sheet. D Refer to the Front Window Regulator, Glass And Glass Run in Body Structure section. 4. Raise the glass up to the uppermost position, and then remove the rear guide rail. 5. Disconnect the door lock switch connector (w/power door lock) and locking links (arrow marks positions), then remove the door lock assembly fixing screws and door lock assembly.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the door lock assembly fixing screws to the specified torque. Torque: 7 Nm (61 lb in) 3. Check that the door lock operates smoothly.
632RS004
Legend (1) To Inside Lock Knob (2) Door Lock Assembly (3) To Actuator (4) Door Lock Switch Connector (5) To Inside Handle (6) Outside Handle
8H4
SECURITY AND LOCKS
Front Outside Handle and Door Lock Cylinder

Front Outside Handle, Door Lock Cylinder and Associated Parts
632RS006
Legend (1) Door Trim Panel (2) Waterproof Sheet (3) Outside Handle
(4) Door Lock Cylinder (5) Clip (6) Key Switch (W/Anti-Theft)
Removal
1. Disconnect the battery ground cable. 2. Remove the door trim panel. 3. Remove the waterproof sheet. D Refer to the Front Window Regulator, Glass And Glass Run in Body Structure section.
SECURITY AND LOCKS

4. Disconnect the locking links (arrow marks positions) and key switch connector (w/anti-theft) to remove the outside handle.
8H5
6. Remove the fixing clip(1) to remove the door lock cylinder(2).
632RS009 632RS005
Legend (1) Outside Handle (2) To Door Lock Assembly (3) Key Switch Connector 5. Remove the key Switch.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Be sure to install the door lock cylinder(2) at a right angle to the outside handle(1).
632RS008 632RS007
Legend (1) Outside Handle (2) Lock Cylinder (3) Key Switch
8H6
SECURITY AND LOCKS
2. For the anti-theft system, be sure to install the push rod(3) of key switch while pressing it to the door lock cylinder(5) so that there is no continuity between the key switch(4) side connector terminal No. D62 and D64 (No. D162 and D164: passenger side).
632RS010
3. Tighten the outside handle and key switch fixing bolts to the specified torque. Torque: 9 Nm (78 lb in) 4. Check for smooth outside handle and lock cylinder operation.
SECURITY AND LOCKS
8H7
Rear Door Lock Assembly

Rear Door Lock Assembly and Associated Parts
652R200002
Legend (1) Door Trim Panel
(2) Waterproof Sheet (3) Door Lock Assembly
Removal
1. Disconnect the battery ground cable. 2. Remove the door trim panel. 3. Remove the waterproof sheet. D Refer to the Rear Window Regulator And Glass in Body Structure section.
8H8
SECURITY AND LOCKS
4. Disconnect the locking links (arrow marks positions) and remove the fixing screws to remove the door lock assembly.
652RS002
Legend (1) Outside Handle (2) To Inside Lock Knob (3) To Inside Handle (4) To Actuator
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the door lock assembly fixing screws to the specified torque. Torque: 7 Nm (61 lb in) 3. Check that the door lock operates smoothly.
SECURITY AND LOCKS
8H9
Rear Outside Handle

Rear Outside Handle and Associated Parts
652R200003
Legend (1) Door Trim Panel
(2) Waterproof Sheet (3) Outside Handle
Removal
1. Disconnect the battery ground cable. 2. Remove the door trim panel. 3. Remove the waterproof sheet. D Refer to the Rear Window Regulator And Glass in Body Structure section. 4. Disconnect the locking link (arrow mark position) and remove three fixing bolts to remove the outside handle.
652RS003
8H10 SECURITY AND LOCKS
Installation
1. Tighten the outside handle fixing bolts to the specified torque. Torque: 9 Nm (78 lb in) 2. Check that the outside handle operates smoothly.
Rear Door Inside Lock Knob Link

Removal
1. Disconnect the battery ground cable. 2. Remove the door trim panel(3). 3. Remove the waterproof sheet(2). D Refer to the Rear Window Regulator And Glass in Body Structure section. 4. Remove the fixing screw(4) and disconnect the locking link at the door lock assembly to remove the rear door inside lock knob link(1).
Installation
635R200013
SECURITY AND LOCKS
8H11
Door Inside Lock Knob

Removal
1. Disconnect the battery ground cable. 2. Remove the door trim panel(1). D Refer to the Front / Rear Door Trim Panel in Exterior/Interior Trim section. 3. Turn the door inside lock knob counterclockwise and then remove the door inside lock knob (2).
Installation
632RS011
Door Inside Handle

D Refer to the Front/Rear Door Trim Panel in Exterior/Interior Trim section.
635RS008
Tailgate Lock Assembly (LH)

Tailgate Lock Assembly (LH) and Associated Parts
684RW004
Legend (1) Tailgate Trim Panel(LH)
(2) Waterproof Sheet (3) Tailgate Lock Assembly
Removal
1. Disconnect the battery ground cable. 2. Remove the tailgate trim panel (LH). D Refer to the Tailgate Trim Panel (LH) in Exterior/Interior Trim section. 3. Taking notice of the tailgate harness, peel the waterproof sheet off the tailgate panel carefully and then remove the waterproof sheet.
684RS005
SECURITY AND LOCKS

4. Disconnect the locking links (arrow marks positions), remove three fixing screws and then remove the tailgate lock assembly (LH).
8H13
683RS003
Legend (1) To Inside Lock Knob (2) To Actuator
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the tailgate lock assembly fixing screws to the specified torque. Torque: 7 Nm (61 lb in) 3. Check that the tailgate lock operates correctly after installing it.
Tailgate Lock Assembly (RH)

Tailgate Lock Assembly (RH) and Associated Parts
684R200011
Legend (1) Tailgate Trim Panel (RH) (2) Waterproof Sheet (3) Tailgate Lock Seal
(4) Clip (5) Screw (6) Tailgate Lock Assembly (RH)
Removal
1. Disconnect the battery ground cable. 2. Remove the tailgate trim panel (RH). D Refer to Tailgate Trim Panel (RH) in Exterior/Interior Trim section. 3. Peel the waterproof sheet off the tailgate panel carefully and then remove the waterproof sheet. 4. Remove three fixing bolts and then remove the tailgate lock assembly (RH).
683RW009
SECURITY AND LOCKS

5. Remove the tailgate lock seal fixing clip(1) and then remove the tailgate lock seal(2).
8H15
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the tailgate lock assembly fixing bolts to the specified torque. Torque: 11 Nm (95 lb in) 3. Check that the tailgate lock operates correctly after installing it.
683RW008
Tailgate Inside Lock Knob

Removal
1. Disconnect the battery ground cable. 2. Remove the tailgate trim panel (LH)(2). D Refer to the Tailgate Trim Panel (LH) in Exterior/Interior Trim section. 3. Take care of cushion to turn the lock knob counterclockwise and then remove the tailgate inside lock knob(1).
Installation
683RW007
Tailgate Outside Handle and/or Tailgate Lock Cylinder

Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts
684RW003
Legend (1) Tailgate Trim Panel (LH) (2) Waterproof Sheet (3) Grommet
(4) Tailgate Lock Cylinder (5) Tailgate Outside Handle (6) Key Switch
Removal
1. Disconnect the battery ground cable. 2. Remove the tailgate trim panel. 3. Remove the waterproof sheet. D Refer to the Tailgate Lock Assembly (LH) in this section. 4. Remove the grommet.
SECURITY AND LOCKS

5. Disconnect the locking links (arrow marks positions), key switch connector (w/anti-theft) and remove three fixing bolts to remove the tailgate outside handle.
8H17
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. For the anti-theft system, install the push rod(1) of the key switch(3) to the key cylinder(2) while pressing it so that there is not continuity between the key switch side connector terminals No. G52 and G54 as shown in the figure.
683RS007
Legend (1) To Actuator (2) Key Switch Connector (3) To Lock Assembly
683RS009
6. Remove the key switch fixing bolt(3) to remove the key switch(4) from the tailgate lock cylinder (w/anti-theft)(1). And remove the tailgate lock cylinder fixing bolt(2) to remove the tailgate lock cylinder.
2. Tighten the outside handle and key cylinder fixing bolts to the specified torque. Torque: 9 Nm (78 lb in) 3. Check that the outside handle and key cylinder operate correctly after installing them.
683RS008
Key
Key Coding
730RW001
Legend (1) Key(Actual Size) (2) Key Code Tag
(3) Position (4) Level
One key is used for the ignition, door, and tailgate lock cylinders. The keys are cut on both edges to make them reversible. Key identification is obtained from the five character key code stamped on the key code tag. From this key code, the key code cutting combination can be determined from a code list (available to owners of key cutting equipment from suppliers). If key codes are not available from records or tags, the key code can be obtained from the right hand door lock cylinder (if lock has not been replaced). Lock cylinders supplied by the factory as service parts are unmarked. If the original key is available, the key code cutting combination can be determined by laying the key on the diagram shown in the figure.
Key Styles
730RY00001
Legend (1) Blank Key Style A (2) Blank Key Style B The keys come in styles A or B depending on the key code cutting combination. When the first position in the combination is a 1, 2 or 3, Style A is used. When the first position is a 4, Style B (factory pre-cut key) is used.
SECURITY AND LOCKS
8H19
Power Door Lock System

General Description
The circuit consists of the door lock (& power window) switch, door lock actuator for the front and rear door, tailgate lock actuator and the door lock key switch. The front door lock switch LH is always provided with battery voltage. The key or the inside lock button on the both driver s and the front passenger s door can activate the lock mechanism of all the doors (including the tailgate). When the driver s door lock switch or the front passenger s door lock switch is turned on, current flows for about one second to the door lock actuator of each door connected in parallel with the front door lock (& power window) switch LH to activate the actuator to lock and unlock the doors.
Front Door Lock Actuator Removal

1. Refer to the Front Door Lock Assembly removal procedure in this section. 2. Remove the door lock actuator(1).
632RS020
Front Door Lock Actuator Installation

Rear Door Lock Actuator Removal

1. Refer to the Rear Door Lock Assembly removal procedure in this section. 2. Removal the door lock actuator(1).
632RS021
632RS019
Rear Door Lock Actuator Installation

Tailgate Lock Actuator Removal

1. Refer to the Tailgate Lock Assembly removal procedure in this section. 2. Remove the tailgate lock actuator(1).
632RY00002
Tailgate Lock Actuator Installation

SECURITY AND LOCKS
8H21
Anti-theft System
General Description
The circuit consists of the starter switch, anti-theft & keyless entry control unit, anti-theft horn, front door and tailgate key switch (detect and tamper switch), door lock (& power window) switch, door lock actuator for each door, engine hood switch, clutch start switch (M/T), ANTI-THEFT indicator light and mode switch (A/T). The system operates as follows: After locking the starter switch and removing the starter key (this sets the alarm), if the door is unlocked in any way other than with the proper key, the headlights start flashing, the horn sounds, and the starter circuit is disabled. (However, the engine hood and all the doors must be locked and closed.) Once the system has been placed in the warning or alarm condition, it can be released only when the starter switch is shifted from OFF to ACC by the starter key, or when the lock of the front door or the tailgate is released (to activate the detect switch) by the starter key.
Anti-theft & Keyless Entry Control Unit Removal

1. Disconnect the battery ground cable. 2. Remove the front console assembly. D Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly. D Refer to the Instrument Panel Assembly in Body Structure section. 4. Disconnect the connector(2). 5. Remove four screws to remove the anti-theft & keyless entry control unit with bracket(1).
825RW028
Anti-theft & Keyless Entry Control Unit Installation

Anti-theft Indicator Removal

1. Disconnect the battery ground cable. 2. Remove the front console assembly(1). D Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly(2). D Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover assembly(3). D Refer to the Instrument Panel Assembly in Body Structure section.
825RW029
6. Remove two nuts from the anti-theft & keyless entry control unit with bracket(3) to remove the anti-theft & keyless entry controller(4).
740R200050

5. Remove the instrument panel cluster assembly(4). D Refer to the Instrument Panel Assembly in Body Structure section. 6. Remove two screws and then remove the anti-theft indicator(5).
Anti-Theft Horn Installation

Engine Hood Switch Removal

1. Disconnect the battery ground cable. 2. Remove the cap(1). 3. Remove the lock nut(2). 4. Disconnect the connector(4). 5. Remove the engine hood switch(3).
821RW032
Anti-theft Indicator Installation

Anti-theft Horn Removal

1. Disconnect the battery ground cable. 2. Disconnect the connector and remove the fixing bolt to remove the anti-theft horn(1).
828RS011
Engine Hood Switch Installation

828RS007
SECURITY AND LOCKS
8H23
Keyless Entry System

ID Code Registration
There are four kinds of ID codes which can be registered, for which these two modes, ID code new registration and ID code additional registration, are available. Step 1 Action 1. Confirm that all the doors are closed and unlocked. 2. Open the driver s side door. 3. Insert the key into the starter switch. Is the action complete? 2 Turn the starter switch to ACC position and then to OFF position three times. NOTE: This step must be carried out within five seconds after step 1. Is the action complete? 3 Close the driver s side door and then open it two times. NOTE: This step must be carried out within ten seconds after step 2. Is the action complete? 4 1. Turn the starter switch to ACC position and then to OFF position five times. 2. Close the driver s side door and then open it. NOTE: This step must be carried out within ten seconds after step 3. Is the action complete? 5 6 The control unit locks and unlocks the doors one time. Does the control unit work normally? Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 5. Is the action complete? 7 8 The control unit locks and unlocks the doors one time. Does the control unit work normally? Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 7. Is the action complete? 9 The control unit compares the two codes sent from the transmitter. If the code succeeds in registration, the control unit locks and unlocks the doors one time. If the two codes are different from each other or fails in registration, the control unit locks and unlocks the doors three times. NOTE: In any case, this procedure is finished. Go to Step 1 Go to Step 1 Go to Step 9 Go to Step 1 Go to Step 8 Go to Step 1 Go to Step 7 Go to Step 1 Go to Step 6 Go to Step 1 Go to Step 5 Go to Step 1 Go to Step 4 Go to Step 1 Go to Step 3 Go to Step 1 Go to Step 2 Go to Step 1
ID Code New Registration

This procedure erases all registered ID codes and registers a new received ID code instead. Yes No
ID Code Additional Registration

This procedure additionally registers a new received ID code with holding registered ID codes. When total number of registered ID codes and newly registered ID code exceeds four, they are erased in order of older one. Step 1 Action 1. Confirm that all the doors are closed and unlocked. 2. Open the driver s side door. 3. Insert the key into the starter switch. Is the action complete? 2 Turn the starter switch to ACC position and then to OFF position three times. NOTE: This step must be carried out within five seconds after step 1. Is the action complete? 3 Close the driver s side door and then open it two times. NOTE: This step must be carried out within ten seconds after step 2. Is the action complete? 4 1. Turn the starter switch to ACC position and then to OFF position three times. 2. Close the driver s side door and then open it. NOTE: This step must be carried out within ten seconds after step 3. Is the action complete? 5 6 The control unit locks and unlocks the doors two times. Does the control unit work normally? Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 5. Is the action complete? 7 8 The control unit locks and unlocks the doors one time. Does the control unit work normally? Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 7. Is the action complete? 9 The control unit compares the two codes sent from the transmitter. If the code succeeds in registration, the control unit locks and unlocks the doors one time. If the two codes are different from each other or fails in registration, the control unit locks and unlocks the doors three times. NOTE: In any case, this procedure is finished. Go to Step 1 Go to Step 1 Go to Step 9 Go to Step 1 Go to Step 8 Go to Step 1 Go to Step 7 Go to Step 1 Go to Step 6 Go to Step 1 Go to Step 5 Go to Step 1 Go to Step 4 Go to Step 1 Go to Step 3 Go to Step 1 Go to Step 2 Go to Step 1 Yes No
SECURITY AND LOCKS
8H25
Antitheft & Keyless Entry Control Unit/Transmitter Replacement

Antitheft & Keyless Entry Control Unit Replacement
1. Remove and install the control unit. D Refer to Antitheft & Keyless Entry Control Unit Removal and Installation in this section. 2. Register ID code. D Refer to ID Code Registration in this section. 3. Check that the keyless entry system works normally.
Transmitter Replacement
1. Prepare a new transmitter. 2. Regiter ID code. D Refer to ID Code Registration in this section. 3. Check that the keyless entry system works normally.
Transmitter Battery Replacement

1. Remove a screw to remove the cover. 2. Remove the batteries. 3. Set the new batteries into the transmitter. 4. Install the cover to the transmitter. 5. Check that the keyless entry system works normally.

Application Front Door Lock Assembly Fixing Screws Front Outside Handle and Key Switch Fixing Bolts Rear Door Lock Assembly Fixing Screws Rear Outside Handle Fixing Bolts Tailgate Lock Assembly (LH) Fixing Screws Tailgate Lock Assembly (RH) Fixing Bolts Tailgate Outside Handle and Key Cylinder Fixing Bolts Nm 7 9 7 9 7 11 9 Lb Ft Lb In 61 78 61 78 61 95 78
SECTION
SUN ROOF/CONVERTIBLE TOP
TROOPER
8I1

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Sun Roof Glass . . . . . . . . . . . . . . . . . . . . . . . . . Sun Roof Glass and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Roof Deflector . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunshade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Roof Frame Complete Assembly . . . . . . Sun Roof Frame Complete Assembly and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8I1 8I2 8I2 8I2 8I3 8I4 8I4 8I4 8I4 8I4 8I5 8I5 8I6 8I6 8I6 8I7 8I7 8I7 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Roof Drain Hose (Front Side) . . . . . . . . . Sun Roof Drain Hose (Front Side) and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Roof Drain Hose (Rear Side) . . . . . . . . . Sun Roof Drain Hose (Rear Side) and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Roof Switch . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Roof Motor . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 8I8 8I9 8I9 8I9 8I9 8I10 8I10 8I10 8I10 8I11 8I11 8I11 8I11 8I12 8I12 8I12 8I13
Service Precaution
8I2
Sun Roof Glass

Sun Roof Glass and Associated Parts
665RS002
Legend (1) Sun Roof Weatherstrip (2) Sun Roof Glass
(3) Decoration Cover (4) Sun Roof Shim
Removal
1. Open the sun roof and pull the sun roof weatherstrip out from the roof panel. 2. Disconnect the battery ground cable. 3. Close the sun roof and open the sunshade(1). Then, remove the decoration cover fixing screws and decoration cover(2).
665RS003

4. Remove eight sun roof glass fixing screws to remove the sun roof glass(3). NOTE: If shims are used between the sun roof set plate and the glass, note the number of shims used.
8I3
3. Temporarily install the glass to the sun roof frame. 4. Open and shut the sun roof four to five times to position correctly the sun roof weatherstrip and the glass in the longitudinal and latitudinal setting positions. 5. Insert the original shims between the sun roof set plate and the glass. 6. Tighten the sun roof glass fixing screws to the specified torque. Torque: 10 Nm (87 lb in) 7. After the sun roof glass is installed, check the roof panel and sun roof glass for vertical install position. If out of standard, adjust with shim. For the installation standard, refer to Body Dimension in Body Structure section. 8. Install the decoration cover.
665RS004
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Clean the body panel of the weatherstrip fixing portion. D If the protective film(1) of the body panel is peeled, it cannot be reused. Install the new protective film around the body panel(2). 2. Install the new weatherstrip(3). D Always replace with a new one. D Be sure to install the sun roof weatherstrip so that the white marking location(4) of the weatherstrip is on the front side of the vehicle.
665RW016
8I4
Sun Roof Deflector

Removal
1. Open the sun roof. 2. Remove the fixing screws(2) to remove the sun roof deflector(1).
Installation
665RS006
Sunshade
Disassembled View
665RS007

Legend (1) Sunshade (2) Sunshade Stopper (3) Decoration Cover (4) Sun Roof Deflector
8I5
Removal
1. Remove the decoration cover. 2. Open the sun roof half position, remove the sunshade stopper screw and pull out the sunshade(6) until its front side protrudes a little from the sun roof glass(2) to remove the sunshade stopper. 3. Remove the sun roof deflector. D Refer to the Sun Roof Deflector in this section. 4. Open the sun roof completely. 5. Remove the sunshade guide rail stopper(5), and pull out the sunshade up to the rail edge. 6. Remove the guide pin(4) in the sunshade through the notch(7) of guide rail(1) and then draw the sunshade out of the roof by pushing inward the retaining clips(3) on both sides.
665RS008
Installation
8I6
Sun Roof Frame Complete Assembly

Sun Roof Frame Complete Assembly and Associated Parts
665RS009
Legend (1) Sun Roof Drain Hose (2) Sun Roof Frame Complete Assembly
(3) Headlining (4) Sun Roof Drain Hose
Removal
1. Disconnect the battery ground cable. 2. Remove the headlining. D Refer to the Headlining in Body Structure section. 3. Disconnect the sun roof drain hose at the sun roof frame side as shown in the figure.
665RS010
4. Disconnect the sun roof harness connection.

5. Remove two sun roof frame complete assembly fixing nuts (front side) and four fixing bolts (each side) from the frame complete, and then remove the sun roof frame complete assembly. NOTE: Be sure to remove the frame complete while supporting it.
8I7
1. Tighten the sun roof frame complete assembly fixing bolts and nuts to the specified torque. Torque: 10 Nm(87 lb in) 2. After installing the frame complete, loosen the sun roof glass fixing nuts and adjust the sun roof glass setting position. D Refer to the Sun Roof Glass in this section.
Installation
Disassembled View
665RW035
Legend (1) Sunshade (2) Sun Roof Glass (3) Sun Roof Motor
(4) (5) (6) (7)
Sun Roof Drive Unit Assembly Outer Tube Fixing Screw Sun Roof Frame Assembly Sun Roof Deflector
Disassembly
1. Open the sun roof. 2. Remove the sun roof deflector fixing screws and then remove the sun roof deflector. 3. Remove the sunshade. D Refer to the Sunshade in this section. 4. Close the sun roof, remove the decoration cover and the fixing screws and then remove the sun roof glass. 5. If the shims are used between the sun roof set plate and the glass, note the number of the shims.
8I8
6. Disconnect the sun roof motor connector, remove the sun roof fixing nuts and screws, and then remove the sun roof motor. 7. Remove the cable outer tube(2) fixing screws. 8. Remove the cable outer tube fixing clamps(1) and guide rail fixing nuts(5). 9. Prying the guide rail a little with a screwdriver, draw the outer tube out of the grommet(3). D At this time, the inner cable(4) remains on the frame assembly. 10. Remove the sun roof frame assembly.
665RS013
665RS012
Reassembly
To reassembly, follow the disassembly steps in the reverse order, noting the following points. 1. When installing the motor or drive unit, set the sun roof set plate in the full closed position by pushing the link(3) portion using the screwdriver(2). 2. When installing the sun roof glass(1) to the sun roof set plate, insert the original shims in the same position before removing the sun roof glass.
8I9
Sun Roof Drain Hose (Front Side)

Sun Roof Drain Hose (Front Side) and Associated Parts
665RS014
Legend (1) Clip (2) Sun Roof Drain Hose (3) Grommet
(4) Front Inner Liner (5) Headlining (6) Instrument Panel Assembly
Removal
1. Remove the front inner liner. 2. Remove the headlining. D Refer to the Headlining in Body Structure section. 3. Remove the instrument panel assembly. D Refer to the Instrument Panel Assembly in Body Structure section. 4. Disconnect the drain hose at the frame complete side. 5. Apply the soap and water to the body panel grommet. 6. Pass the string from the sun roof frame side through the drain port side, and remove the drain hose from the hose fixing clips. Taking care not to allow the body panel grommet to be removed together with the hose, pull the drain hose only to the inside of the vehicle. (The string should be kept as it is.)
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Apply the soap and water to the body panel grommet. 2. Install the drain hose from inside of the vehicle by utilizing, as a guide, the string passed during removal step. 3. The body panel grommet must not be twisted or caught in during installation. 4. Complete routing, avoiding extreme bends or curves. 5. After routing, install the trim with care not to allow the drain hose to be caught in. 6. Test the drain condition. 7. The protrusion of drain hose from the body panel must be within 50 mm (2.0 in). If it exceeds 50 mm (2.0 in) after correct routing, cut the leading edge so that the protrusion is within 50 mm (2.0 in).
8I10
Sun Roof Drain Hose (Rear Side)

Sun Roof Drain Hose (Rear Side) and Associated Parts
665RS015
Legend (1) Soft Tape (2) Pipe (3) Clip (4) Soft Tape (5) Sun Roof Drain Hose
(6) (7) (8) (9) (10) (11)
Tape Grommet Grommet Clip Headlining Rear Fender Inner Liner
Removal
1. Disconnect the battery ground cable. 2. Remove the rear fender inner liner. 3. Remove the headlining. D Refer to the Headlining in Body Structure section. 4. Disconnect the drive hose at the frame complete side.
5. Remove the hose fixing tapes and clips. 6. Apply the soap and water to the body panel grommet. 7. Pull the drain hose to the inside of the vehicle.
Installation

1. Apply the soap and water to the body panel grommet. 2. Insert the drain hose from inside of vehicle, restore routing, and fix with new soft tape and clip. If the grommet is removed during removal of drain hose, insert the grommet into drain hose from outside of the vehicle, and install on the body panel, avoiding any twisting. 3. After installing the drain hose, install the trim while taking care not to crush the drain hose. Also, care should be taken not to allow the drain hose connected to the pipe to be caught in.
8I11
4. Test the drain condition. 5. The protrusion of the drain hose from the body panel must be within 50 mm (2.0 in). If it exceeds 50 mm (2.0 in) after correct routing, cut the leading edge so that the protrusion is within 50 mm (2.0 in).
Sun Roof Switch

General Description
Sun roof operation can be controlled by pushing continuously the sun roof switch to activate the sun roof control unit and sun roof motor. While the switch is being pushed to the OPEN side, the sun roof stops about 165 mm (6.5 in) before fully open position. Push the switch again to the OPEN side to open it fully. When the switch is being continuously pushed to the CLOSE side, the sun roof stops about 180 mm (7.1 in) short of the fully closed position and remains in this state. Push the switch again to the CLOSE side to close it completely.
Removal
1. Disconnect the battery ground cable. 2. Pull down the switch housing(2) and disconnect the sun roof switch and map light connectors to remove the sun roof switch(1).
805RS002
Installation
8I12
Sun Roof Motor

Removal
1. Disconnect the battery ground cable. 2. Remove the headlining(2). D Refer to the Headlining in Body Structure section. 3. Disconnect the connector, and remove three nuts and two screws to remove the sun roof motor(1).
665RW034
Installation
8I13

Application Sun Roof Frame Complete Assembly Fixing Bolts Sun Roof Glass Fixing Screws Nm 10 10 Lb Ft Lb In 87 87
SECTION
EXTERIOR/INTERIOR TRIM
TROOPER
8J1

EXTERIOR / INTERIOR TRIM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Dash Side Trim Panel . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consoles and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Door Trim Panel . . . . . . . . . . . . . . . . . . . Front Door Trim Panel and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Trim Panel . . . . . . . . . . . . . . . . . . . . Rear Door Trim Panel and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Wood Panel Assembly . . . . . . . . . . . . . . Door Wood Panel Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Mirror and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Side and Quarter Upper Trim Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Side, Quarter Upper Trim Cover and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Pillar and Roof Side Trim Cover . . . . Center Pillar, Roof Side Trim Cover and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Pillar Trim Cover . . . . . . . . . . . . . . . . . . . Front Pillar Trim Cover and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J2 8J3 8J3 8J3 8J3 8J3 8J3 8J4 8J4 8J4 8J5 8J6 8J6 8J6 8J9 8J10 8J10 8J10 8J11 8J13 8J13 8J13 8J13 8J14 8J14 8J14 8J14 8J15 8J15 8J15 8J17 8J18 8J18 8J18 8J19 8J20 8J20 8J20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Pillar Assist Grip . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Assist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Fuel Filler Lid Opener Cable . . . . . . . . . . . . . . Fuel Filler Lid Opener Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Protector (Without Wheel Opening Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Protector (Without Wheel Opening Extension) and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Opening Extension and Rocker Protector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Opening Extension, Rocker Protector Assembly and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mud Flaps (With Wheel Opening Extension) Mud Flaps (With Wheel Opening Extension) and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilation Assembly . . . . . . . . . . . . . . . . . . . . . Ventilation Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Trim Panel (LH) . . . . . . . . . . . . . . . . . Tailgate Trim Panel (LH) and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Trim Panel (RH) . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J20 8J21 8J21 8J21 8J21 8J21 8J21 8J22 8J22 8J22 8J23 8J23 8J23 8J23 8J23 8J24 8J24 8J24 8J24 8J25 8J25 8J25 8J26 8J27 8J27 8J27 8J27 8J28 8J28 8J28 8J28 8J29 8J29 8J29 8J29 8J30 8J30 8J30
8J2
8J30 8J31 8J31 8J31 8J31 8J31 8J31 8J31 8J31 8J32 8J32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Mirror . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Power Window System . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Power Window Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Window Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 8J32 8J33 8J33 8J33 8J34 8J34 8J34 8J35 8J36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Floor Box . . . . . . . . . . . . . . . . . . . . . . Luggage Floor Box and Associated Parts . Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rope Hook Set . . . . . . . . . . . . . . . . . . . . . . . . . Rope Hook Set and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Mirror System . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal . . . . . . . . . . . . . . . . . . . . . .
8J32 CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Service Precaution
8J3
Dash Side Trim Panel

Removal
1. Disconnect the battery ground cable. 2. Remove the front door sill plate(2). 3. Remove the dash side trim panel(3). D Turn up the door inner seal(1) of the body panel to remove the clips of the trim panel. D Take care not to damage the harness and the controller on the back of the trim panel.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Lap the door inner seal over the trim panel to install them securely to the body panel.
643RS007
Assist Grip
Parts Location
745R200008

D Refer to the Consoles removal and installation steps in this section.
8J4
Consoles
Consoles and Associated Parts
745RX001
Legend (1) Shift Knob (M/T) / Transfer Knob (A/T) (2) Front Console Assembly (3) Front Seat Assembly (RH)
(4) Center Console Assembly (5) Fuel Filler Lid Opener (6) Assist Grip
Removal
1. Disconnect the battery ground cable. 2. Remove the shift knob (M/T) / transfer knob (4X4 Only). 3. Remove the front console assembly. D Remove four fixing screws and disconnect the switch connectors. 4. Remove the front seat assembly(RH). D Refer to Front Seat Assembly in Seats section. 5. Remove the assist grip. D Remove three bolts. 6. Remove the fuel filler lid opener. D Remove the fuel filter lid opener(1) and disconnect the cable(2).
686RS001
7. Remove the center console assembly(2). D Remove two fixing screws on the front side. Open the rear cover, remove two nuts, then the center console assembly. D Remove the rear heater duct(1) from the center console.
8J5
745RS005
Installation
8J6
Front Door Trim Panel

Front Door Trim Panel and Associated Parts
635RS006
Legend (1) Power Window Switch (2) Door Mirror Cover/Tweeter (3) Door Wood Panel (4) Door Trim Panel (5) Courtesy Light (6) Front Speaker (7) Speaker Cover
(8) (9) (10) (11) (12) (13) (14)
Regulator Handle Inside Handle Fixing Screw Inside Handle Hook Washer Inside Pull Handle Inside Pull Handle (W/O Power Window)
Removal
1. Disconnect the battery ground cable.
2. Remove the door mirror cover/tweeter(1). D On a model equipped with a tweeter, remove the connector(2).
8J7
4. Remove the power window switch(5). D Pry the power window switch out and disconnect the switch connector.
720RS007
825RW045
3. Remove the regulator handle(3). D Pull the hook(4) out and remove the regulator handle.
5. Remove the speaker cover. 6. Remove the front speaker. D Remove the front speaker fixing screws in order to disconnect the speaker connector. 7. Remove the inside handle fixing screw. D Remove the screw that fixes the inside handle(7), slide the inside handle to the position illustrated, and leave it there for the moment. CAUTION: Take care not to impose excessive force on the inside handle link(6), lest this link is elongated, which could make it impossible to operate the door with the inside handle.
631RW001
8J8
D Disconnect the courtesy light connector(13) to lift the door trim panel(14) and unlock the engagement of the waist seal(12) section. Then, pass the inside handle(11) through the mounting hole of the trim panel, and detach the trim panel.
632RW001
8. Remove the door trim panel(9). D Remove two fixing screws(8) in order to take off seven clips(10) from the door panel.
632RS015
9. Remove the inside handle. 10. Remove the door wood panel. D Refer to the Door Wood Panel Assembly in this section.
635RS007
8J9
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. When installing the inside handle(2), assemble it temporarily to the inside handle link(1).
632RW006
3. Fit the claw(10) of the inside handle(11) securely into the hole of the door panel and fix the inside handle with the screw.
632RS014
2. Pass the inside handle(4) through the mounting hole of the trim panel and assemble the trim panel. Engage seven clips(8) into the door panel. Also, connect the courtesy light connector(5) and leave the connectors of the speaker(7), tweeter(9) and power window(3) drawn out to their prescribed positions, so that they will not be caught. Then, put the inside handle(4) to the normal position of the inside handle link(6).
632RW007
8J10
Rear Door Trim Panel

Rear Door Trim Panel and Associated Parts
655R200011
Legend (1) Power Window Switch (2) Door Wood Panel (3) Door Trim Panel (4) Washer
(5) (6) (7) (8)
Clip Regulator Handle Inside Handle Fixing Screw Inside Handle
Removal
1. Disconnect the battery ground cable. 2. Remove the regulator handle(1). D Pull the hook(2) out and remove the regulator handle.
631RW002
3. Remove the power window switch(3). D Pry the power window switch out and disconnect the switch connector.
8J11
5. Remove the door trim panel(6). D Remove two fixing screws(8) to take off seven clips(7) from the door panel.
825RS084
655R200012
4. Remove the inside handle fixing screw. D Remove the screw that fixes the inside handle(5), slide the inside handle to the position illustrated, and leave it there for the moment. CAUTION: Take care not to impose excessive force on the inside handle link(4), lest this link be elongated, which could make it impossible to operate the door with the inside handle.
D Unplug the courtesy light connector to lift the trim panel and unlock the engagement of the waist seal section. Then, pass the inside lever through the mounting hole of the trim panel, and detach the trim panel. 6. Remove the inside handle. 7. Remove the door wood panel. D Refer to the Door Wood Panel Assembly in this section.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. When installing the inside handle(1), assemble temporarily to the inside handle link(2).
652RS006
632RW002
8J12
2. Pass the inside handle through the mounting hole of the trim panel. Assemble the trim panel. Engage securely seven clips into the door panel. Also, connect the courtesy light connector. Leave the connector of the power window drawn out to its prescribed position, so that it will not caught. 3. Put back the inside handle(3) to the original position of the link(5). Fit the claw(4) of the inside handle securely into the hole of the door panel. Fix the handle with the screw.
632RW011
8J13
Door Wood Panel Assembly

Door Wood Panel Assembly and Associated Parts
635R200014
Legend (1) Door Trim Panel (2) Door Wood Panel Assembly
Removal
1. Remove the door trim panel(1). D Refer to the Front / Rear Door Trim Panel in this section. 2. Remove the door wood panel assembly(2). D Remove four door wood panel assembly fixing screws and washers. NOTE: The removal and installation steps are common to both front and rear doors.
635RS009
Installation
8J14
Door Mirror
Door Mirror and Associated Parts Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. When you install the door mirror, install the bolt(1) to the mirror temporarily, hook the bolt to the door side hole and tighten the bolt from the inside.
720RS012
Legend (1) Door Mirror Cover / Tweeter (2) Door Mirror Connector (3) Door Mirror
720RS001
Removal
1. Disconnect the battery ground cable. 2. Remove the door mirror cover(1). D Remove the connectors(2) and the door mirror cover, if equipped with a tweeter.
2. When installing the door mirror, hold the glass run lip(2) between the door mirror base(3) and the center sash(4).
A10RS001
3. Tighten the door mirror fixing bolts to the specified torque. Torque: 8 Nm (69 lb in)
720RS007
3. Remove the door mirror connector. 4. Remove the door mirror.
8J15
Luggage Side and Quarter Upper Trim Cover

Luggage Side, Quarter Upper Trim Cover and Associated Parts
687RS001
Legend (1) Quarter Upper Trim Cover (2) Rear Seat Belt Anchor Bolt Cover and Anchor Bolt (3) Roof Side Trim Cover (4) Luggage Side Lower Cover (5) Luggage Side Trim Cover
(6) (7) (8) (9) (10) (11) (12)
Rear End Floor Trim Cover Luggage Side Cap Speaker Grille Rear Speaker Clip Luggage Room Light Rear Roof Trim Cover
Removal
1. Disconnect the battery ground cable. 2. Remove the rear end floor trim cover. 3. Remove the luggage side cap. 4. Remove the luggage side lower cover.
8J16
8. Remove the speaker grille.
5. Remove the luggage side trim cover (1). D Remove the rear side fixing screws and pry the trim cover retainers free from the body panel and the upper trim cover.
687RS003
687RS002
6. Remove the luggage room light. D Remove the luggage room light lens and the fixing screws. D Disconnect the luggage room light connector. 7. Remove the rear roof trim cover. D Pry the trim cover retainers free from the body panel.
9. Remove the rear speaker. D Remove the rear speaker fixing screws and disconnect the connector. 10. Remove the rear seat belt anchor bolt cover (2) and the anchor bolt (3).
760RW005
666RS001
11. Remove the quarter upper trim cover. D Remove the rear side clips of the trim cover and pry the quarter upper trim cover retainers free from the body panel.
8J17
687RS004
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the seat belt anchor bolt to the specified torque. Torque: 39 Nm (29 lb ft)
8J18
Center Pillar and Roof Side Trim Cover

Center Pillar, Roof Side Trim Cover and Associated Parts
643RW003
Legend (1) Roof Side Trim Cover (2) Front Pillar Trim Cover (3) Assist Grip (RH only) (4) Adjust Shoulder Anchor Assembly (5) Center Pillar Upper Trim Plate
(6) (7) (8) (9) (10) (11)
Door Sill Plate (Front and Rear) Center Pillar Lower Trim Cover Front Seat Anchor Bolt Cover and Anchor Bolt Center Pillar Assist Grip Assist Grip Rear Quarter Upper Trim Cover
Removal
1. Disconnect the battery ground cable. 2. Remove the door sill plate (front and rear). 3. Remove the center pillar lower trim cover (2). D Turn up the finisher (1) and pry the trim cover retainers free from the body panel, then slide the trim cover downward.
643RS003
4. Remove the front seat belt anchor bolt cover (3) and the anchor bolt (4).
8J19
8. Remove the assist grip (7). D Open the both side of the assist grip cover (8) and remove two fixing screws.
760RW006
5. Remove the center pillar upper trim cover (6). D Turn up the finisher (5) and pry the trim cover retainers free from the body panel.
743RW004
9. Remove the roof side trim cover (9). D Turn up the finisher (10) and pry the trim cover retainers free from the body panel.
643RS004
6. Remove the center pillar assist grip. 7. Remove the seat belt anchor plate.
643RS005
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Install the seat belt anchor bolts to the specified torque. Torque: 39 Nm (29 lb ft)
8J20
Front Pillar Trim Cover

Front Pillar Trim Associated Parts Cover and
2. Remove the front pillar trim cover (3). D Turn up the finisher (4) and pry the trim cover retainers free from the body panel.
743RS003 635RW001
Legend (1) Roof Side Trim Panel (2) Assist Grip (RH only) (3) Front Pillar Trim Panel
Installation
Removal
1. Remove the front pillar assist grip(1). D Open the both sides of the assist grip cover (2) and remove the fixing screws and the front pillar assist grip.
743RW003
8J21
Center Pillar Assist Grip

Refer to the Center Pillar and Roof Side Trim Cover in this section.
743RS004
Legend (1) Center Pillar Assist Grip
Assist Grip
Refer to the Center Pillar and Roof Side Trim Cover in this section.
743RS005
Legend (1) Assist Grip
8J22
Fuel Filler Lid Opener Cable

Fuel Filler Lid Opener Cable and Associated Parts
686RW002
Legend (1) Rear End Floor Trim Cover (2) Fuel Filler Lid Opener Cable (3) Chassis Harness (4) Cable (5) Marking (6) Clip
(7) (8) (9) (10) (11) (12)
Center Console Assembly Fuel Filler Lid Opener Front Seat (RH) Center Pillar Lower Trim Cover Rear Door Sill Plate (RH) Luggage Side Trim Panel (RH)
Removal
1. Disconnect the battery ground cable. 2. Remove the front seat (RH). 3. Remove the rear door sill plate (RH). 4. Remove the center pillar lower trim cover. 5. Remove the rear end floor trim panel. 6. Remove the luggage side trim panel (RH). D Refer to the Luggage Side and Quarter Upper Trim Cover in this section.
7. Remove the fuel filler lid opener(1). D Remove two opener fixing screws and disconnect the cable(2).
8J23
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Insert the opener cable(2) into the body panel(1) securely.
686RS001
8. Remove the center console assembly. 9. Remove the filler lid opener cable. D Roll up the floor carpet and remove the clips of the chassis harness and body panel to pull out the cable toward the fuel filter lid.
686RS002
2. Install the cable and clips to its original position to the chassis harness and the body panel. 3. Check that the opener operates smoothly.
Fuel Filler Door

Parts Location Removal
1. Remove the fuel filler door.
Installation
1. Install the fuel filler door.
686RS003
Legend (1) Fuel Filler Door
8J24
Rocker Protector (Without Wheel Opening Extension)

Rocker Protector (Without Wheel Opening Extension) and Associated Parts
603RW002
Legend (1) Rear Rocker Protector (2) Inner Liner (3) Spare Nut (4) Fixing Screw (5) Rocker Protector (6) Outer Side Panel
(7) (8) (9) (10) (11) (12) (13)
Outer Wheel House Panel Fixing Clip Outer Rocker Panel Door Panel Front Rocker Protector Clip (W/Rocker Protector) Fender Panel
Removal
1. Remove the rear rocker protector. 2. Remove the front rocker protector.
Installation
To install, follow the remove steps in the reverse order.
8J25
Wheel Opening Extension and Rocker Protector Assembly

Wheel Opening Extension, Rocker Protector Assembly and Associated Parts
620RW002
Legend (1) Front Wheel Opening Extension Assembly (2) Front Rocker Protector Assembly (3) Rear Rocker Protector Assembly
(4) Rear Quarter Wheel Opening Extension Assembly (5) Rear Door Wheel Opening Extension Assembly
Removal
1. Remove the front rocker protector assembly. D Loosen and pull clips, and remove the front rocker protector assembly. 2. Remove the rear rocker protector assembly. D Loosen and pull three clips, remove a rear screw, and remove the rear rocker protector assembly. 3. Remove the front wheel opening extension(2). D Let a 5mm drill(3) go through four blind rivets(5) to disengaged riveted portions. Remove two screws and disengage five clips, then remove the front wheel opening extension assembly.
620RS005
8J26
4. Remove the rear quarter wheel opening extension assembly. D Let a 5mm drill go through six blind rivets to disengage riveted portions. Disengage four clips, remove two screws, and remove the rear quarter wheel opening extension assembly. 5. Remove the rear door wheel opening extension assembly. D Let a 5mm drill go through a blind rivet to disengage riveted portions. Disengage three clips, peel off the bonded portions with two double surface adhesive tape and the rear door wheel opening extension assembly.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Use a new 2sided adhesive tape whenever installing each wheel opening extension assembly and rocker protector assembly. Using a white gasoline, clean the places in advance where a 2sided adhesive tape is affixed. Also, install the clips, screws and blind rivets in the order specified as shown in the figure.
620RW001
8J27
Mud Flaps (With Wheel Opening Extension)

Mud Flaps (With Wheel Opening Extension) and Associated Parts
620RW003
Legend (1) Front Bumper Assembly (2) Front Bumper Slider
(3) Front Mud Flap (4) Bumper Side Cover (5) Rear Mud Flap
Removal
Front Side
1. Remove the front bumper assembly. D Disconnect the front fog light connector and remove two bolts from both sides of the front bumper. 2. Remove the front bumper slider(1). D Remove two clips(4) and two nuts(3), release the claw from the washer(2).
3. Remove the front mud flap. D Remove four nuts and a clip.
601RW013
Rear Side
1. Remove the bumper side cover. 2. Remove the rear mud flap. D Remove four bolts and two nuts.
601RW009
Installation
8J28
Ventilation Assembly
Ventilation Assembly and Associated Parts
641RS001
Legend (1) Outlet Valve Assembly (2) Ventilation Assembly
Removal
1. Remove the ventilation assembly(1). D Pry the ventilation assembly retainers free from the body panel.
Installation
1. Install the outlet valve assembly. D Insert the upper and lower catches of the outlet valve into the body panel flange and fix them securely. 2. Install the ventilation assembly. D Fix the clips to the body panel securely so that the ventilation assembly will not come off the body panel.
641RS002
2. Remove the outlet valve assembly.
8J29
Tailgate Trim Panel (LH)

Tailgate Trim Panel (LH) and Associated Parts
683RS002
Legend (1) Tailgate Trim Panel (LH) (2) Clip
(3) Tailgate Panel (4) Cap and Screw
Removal
1. Disconnect the battery ground cable. 2. Remove the cap and screw. 3. Remove the tailgate trim panel (LH). D Pry the trim panel retainers free from the tailgate panel.
684RS001
Installation
8J30
Tailgate Trim Panel (RH)

Parts Location Installation
1. Install the trim panel (RH). D Insert the retainer of the trim panel into the tailgate panel and fix it securely.
684RS002
Legend (1) Tailgate Trim Panel
Removal
1. Disconnect the battery ground cable. 2. Remove the tailgate trim panel (RH). D Pry trim panel retainer free from the tailgate panel.
684RS003
8J31
Luggage Floor Box

Luggage Floor Box and Associated Parts Remove
1. Fold the rear seat assembly to the front direction. 2. Remove the luggage floor box cover. D Remove the clips which connect the floor carpet and the luggage floor box cover. 3. Remove the luggage floor box.
Installation
643RS006
Legend (1) Rear Seat (2) Floor Carpet (3) Luggage Floor Box (4) Luggage Floor Box Cover
Rope Hook Set

Rope Hook Set and Associated Parts
Legend (1) Rope Hook Set (2) Cover (3) Luggage Floor Carpet (4) Hook
Removal
1. Remove the rope hook set. D Open the hook cover and hook fixing bolt.
Installation
1. Install the rope hook set. D Tighten the hook fixing bolt to the specified torque. Torque: 13 Nm (113 lb in)
676RS003
8J32
Power Door Mirror System

General Description
The circuit consists of the starter switch, door mirror control switch, folding switch, defogger switch and door mirrors on both sides. The door mirror switch consists of the control switch, folding switch and defogger switch. When the control switch is operated with the starter switch at either ACC or ON position, the motors incorporated in the door mirrors on both sides rotates to allow the horizontal and vertical adjustment of mirror angles. The folding switch can be used to fold the mirror and return it to its original position. When turning on the door mirror defogger switch with the starter switch at ON position, built-in heater in the mirror is activated to perform the defogger function.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Depress the switch with your fingers until it locks securely.
Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly(2). D Remove four screws. D Remove the transmission shift lever knob. D Remove the transfer shift lever knob. D Disconnect the seat heater switch connectors (if so equipped). D Disconnect the door mirror switch connectors. D Disconnect the power & winter switch connectors. (A/T only) 3. Remove the door mirror switch assembly(1). D Push the lock from the back side of the front console.
825R200089
8J33
Power Door Mirror

General Description
Mirrors contain two driving motors for the horizontal and vertical movement of the mirror and one motor for folding the mirror. The movement of the mirror is controlled by the direction of current running through these motors. The housing portion of the mirror is provided with the auto-stop mechanism which is interlocked with the motor for folding the mirror. When the mirror moves to the stop position (with the mirror folded or returned to its original position), the current to the motor is shut off. When the mirror cannot operate due to some obstacle and the motor stops its rotation, the resistor prevents current overflow.
720RS004

Refer to the Door Mirror removal and installation steps in this section.
8J34
Power Window System

General Description
The circuit consists of the starter switch, (door lock &) power window switch for each of the front windows, power window switch for rear windows and power window motors. When the starter switch is turned on, the battery voltage is applied to each of the power window switches through the circuit breaker and the power window relay on the circuit. The Down switch of the driver s power window switch has a built-in function which can be operated by just touching it. Accordingly, the window will roll down automatically by just setting the switch to the AUTO position. When the driver s power lock switch at the driver side is depressed, the power source to the passenger s power window switches are shut off. So, even if these switches are operated, the power window motor will not operate. 2. Remove the switch(1). D Pull out the switch by pushing the spring with the tip of a screwdriver. D Disconnect the connector.
Power Window Switch Removal and Installation

Driver Seat Side
Removal 1. Disconnect the battery ground cable. 2. Remove the switch(1). D Pull out the switch by pushing the spring with the tip of a screwdriver. D Disconnect two connectors.
825RW046
Installation To install, follow the removal steps in the reverse order.
Rear-Left and Right Sides

Removal 1. Disconnect the battery ground cable. 2. Remove the switch(1). D Pull out the switch by pushing the spring with the tip of a screwdriver. D Disconnect the connector.
825RS052
Installation
Front Passenger Seat Side

Removal 1. Disconnect the battery ground cable.
825RS057
8J35
Power Window Motor Removal and Installation

Driver Seat Side
Removal 1. Disconnect the battery ground cable. 2. Remove the window regulator assembly (1). D Refer to Front Window Regulator, Glass and Glass Run in Body Structure section. 3. Remove the power window motor(2). D Remove three screws. CAUTION: When removing the motor from the regulator(1), be careful not to get injured by the strong repellent force of the regulator spring.
631RS015
Rear-Left Side
Removal 1. Disconnect the battery ground cable. 2. Remove the rear window regulator assembly. D Refer to Rear Window Regulator and Glass in Body Structure section. 3. Remove the power window motor(1). D Remove four screws.
631RS018
Front Passenger Seat Side

Removal 1. Disconnect the battery ground cable. 2. Remove the window regulator assembly (1). D Refer to Front Window Regulator, Glass and Glass Run in Body Structure section. 3. Remove the power window motor(2). D Remove three screws. CAUTION: When removing the motor from the regulator(1), be careful not to get injured by the strong repellent force of the regulator spring.
651RW014
Rear-Right Side
Removal and Installation Refer to the Rear Power Window Motor-Left Side in this section.
8J36

Application Door Mirror Fixing Bolts Seat Belt Anchor Bolts Hook Fixing Bolt Nm 8 39 13 Lb Ft 29 Lb In 69 113
SECTION
SEAT BELT SYSTEM
TROOPER
9A1
RESTRAINTS
CONTENTS
Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . Supplemental Restraint System (RSR) . . . . . Restraint Control System . . . . . . . . . . . . . . . . . 9A1 9J1 9J11
SEAT BELT SYSTEM

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Seat Belt and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Belt and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Seat Buckle Assembly . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Center Seat Belt / Buckle Assembly . . . Rear Center Seat Belt / Buckle Assembly and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A1 9A2 9A2 9A2 9A2 9A3 9A3 9A4 9A4 9A4 9A4 9A4 9A4 9A5 9A5 9A5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Lock Assembly . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Lock Assembly (Bench Type) . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Strikers . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Child Seat Tether Anchor Bracket (Child Restraint) . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Child Seat Tether Anchor Bracket and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 9A5 9A6 9A6 9A6 9A6 9A6 9A6 9A7 9A7 9A7 9A7 9A7 9A7 9A7 9A8
Service Precaution
9A2
SEAT BELT SYSTEM
Seat Belt
Front Seat Belt and Associated Parts
760RW014
Legend (1) Center Pillar Upper Trim Cover (2) Adjustable Shoulder Anchor Assembly (3) Center Pillar (4) Dust Cover (5) Retractor
(6) (7) (8) (9) (10)
Anchor Bolt (Lower) Door Sill Plate (Front & Rear) Center Pillar Lower Trim Cover Front Seat Belt Assembly Front Seat Belt Anchor Bolt Cover and Anchor Bolt
Removal
1. Disconnect the battery ground cable. 2. Remove the door sill plate (Front & Rear). 3. Remove the center pillar lower trim cover. 4. Remove the front seat belt anchor bolt cover and anchor bolt (Upper Side). D Refer to Center Pillar and Roof Side Trim Cover in Exterior/Interior Trim section. 5. Remove the seat belt lower anchor bolt and screw, and then remove the front seat belt.
D No smooth move of upper/lower anchors in the circumferential direction. D Damaged and/or deformed through ring. D Damaged and/or deformed tongue. D Damaged and/or frayed of webbing. D Deformed retractor bracket. D Seat belt not rewound up. D Resistance or abnormal sound when seat belt is wound out and rewound. D Retractor abnormality.
Inspection
If any of the following abnormalities is found, replace on an assembly basis: D Deform and malfunction of adjustable shoulder anchor.
SEAT BELT SYSTEM
9A3
Inspection of retractor
1. ELR (Emergency Locking Retractor) lock inclining angle check. D When the retractor is moved gently from its installing position, make sure it is not locked within 15 in any directions, and it remains locked at 45 or larger. 2. ELR lock check. D When the seat belt is drawn slowly with the retractor installed, make sure it is not locked. And when it is drawn quickly, make sure it is locked. 3. ALR (Automatic Locking Retractor)/ELR check (Except for driver s seat). D When rewound after winding out the seat belt, make sure the seat belt cannot be taken out. After rewinding, make sure it has returned to its normal operation.
CAUTION: Do not disassemble the retractor.
Installation
To install, follow the removal steps in the reverse order, noting the following points; CAUTION: The front seat belt for 99model is differently specified from that for 98model. When replacing, be sure to replace with the one for 99model after making sure of part No.. 1. Pass the seat belt through the lower trim cover hole, and tighten the seat belt anchor bolts to the specified torque. Torque: 39 Nm (29 lb ft) 2. After installing the trim cover to the body panel securely, close the lower trim cover.
Rear Seat Belt and Associated Parts
760RS006
Legend (1) Rear Seat Belt Anchor Bolt Cover and Anchor Bolt (Upper Side) (2) Quarter Upper Trim Cover (3) Rear Seat Belt Assembly
(4) (5) (6) (7) (8)
Dust Cover Retractor Anchor Bolt (Lower Side) Luggage Side Trim Cover Rear End Floor Trim Cover
9A4
SEAT BELT SYSTEM
Removal
1. Disconnect the battery ground cable. 2. Remove the rear end floor trim cover. 3. Remove the luggage side trim cover. D Refer to Luggage Side and Quarter Upper Trim Cover in Exterior/Interior Trim section. 4. Remove the rear seat belt anchor bolt cover and anchor bolt (Upper Side). 5. Remove the seat belt lower anchor bolt and remove the retractor from dust cover slit to remove the rear seat belt.
Inspection of retractor
1. ELR (Emergency Locking Retractor) lock inclining angle check. D When the retractor is moved gently from its installing position, make sure it is not locked within 15 in any directions, and it remains locked at 45 or larger. 2. ELR lock check. D When the seat belt is drawn slowly with the retractor installed, make sure it is not locked. And when it is drawn quickly, make sure it is locked. 3. ALR (Automatic Locking Retractor)/ELR check (Except for driver s seat). D When rewound after winding out the seat belt, make sure the seat belt cannot be taken out. After rewinding, make sure it has returned to its normal operation. CAUTION: Do not disassemble the retractor.
Inspection
If any of the following abnormalities is found, replace on an assembly basis: D No smooth move of upper/lower anchors in the circumferential direction. D Damaged and/or deformed through ring. D Damaged and/or deformed tongue. D Damaged and/or frayed of webbing. D Deformed retractor bracket. D Seat belt not rewound up. D Resistance or abnormal sound when seat belt is wound out and rewound. D Retractor abnormality.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the seat belt anchor bolts to the specified torque. Torque: 39 Nm (29 lb ft)
Front Seat Buckle Assembly

Removal
1. Disconnect the battery ground cable. 2. Disconnect the seat belt warning connector (driver s side) (3) and remove a clip(2). 3. Remove the front seat buckle assembly(1).
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Fix the buckle to the rotation-stop position(2) securely to install the front seat buckle assembly(1).
760RS005 760RT003
2. Tighten the buckle anchor bolt to the specified torque. Torque: 39 Nm (29 lb ft)
SEAT BELT SYSTEM
9A5
Rear Center Seat Belt / Buckle Assembly

Rear Center Seat Belt / Buckle Assembly and Associated Parts
760RW007
Legend (1) Rear Seat Belt Buckle Assembly (2) Seat Lock Cover
Removal
1. Remove the catch portions(2) & (3) of the seat lock assembly(4) from the cover, and then remove the seat lock cover(1).
Installation
1. Fix the rear seat buckle assembly(1) to the rotation stopper and tighten the anchor bolt to the specified torque. Torque: 39 Nm (29 lb ft)
760RW016
2. Remove the rear seat buckle assembly.

760RS013
2. Install the seat lock cover.
9A6
SEAT BELT SYSTEM
Rear Seat Lock Assembly

Removal
1. Remove the seat lock cover(3). 2. Remove the rear seat belt buckle assembly(1). 3. Remove the rear seat lock assembly(2).
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the seat lock fixing bolts to the specified torque. Torque:42 Nm (31 lb ft )
760RW002
Rear Seat Lock Assembly (Bench Type)

Removal
1. Remove the seat lock cover(3). 2. Remove the rear seat belt/buckle assembly(1). 3. Disconnect the link connecting the lock assemblies on the both sides, and then remove the rear seat lock assembly(2).
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the seat lock fixing bolts to the specified torque. Torque: 42 Nm (31 lb ft)
760RW003
SEAT BELT SYSTEM
9A7
Rear Seat Strikers

Removal
1. Fold the rear seat assembly to the front direction. 2. Remove the luggage floor box(1). 3. Remove the rear seat striker(2).
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the striker fixing bolts to the specified torque. Torque: 40 Nm (30 lb ft)
755RW015
Child Seat Tether Anchor Bracket (Child Restraint)

General Description
Plastic plug is provided at three places on the luggage floor panel. Remove the center plug from the floor panel. Install the bracket to the hole where the plug is removed. Alternatively, the bracket may be installed in the right-hand or left-hand plug hole. Legend (1) Rear Seat (2) Luggage Floor (3) Plug (4) Child Seat Tether Anchor Bracket (5) Floor Carpet (6) Child Seat Tether Anchor Bracket
Child Seat Tether Anchor Bracket and Associated Parts
Installation
1. Turn the plug counterclockwise to remove it. 2. Install the bracket such that its tether belt hook hole is facing toward the front of the vehicle. 3. Tighten the fixing bolt to the specified torque. Torque: 20 Nm (14 lb ft)
760R200027
9A8
SEAT BELT SYSTEM

Application Front Seat Belt Anchor Bolts Rear Seat Belt Anchor Bolts Front Seat Buckle Anchor Bolt Rear Seat Buckle Anchor Bolt Rear Seat Lock Fixing Bolts Rear Seat Striker Fixing Bolts Child Seat Tether Anchor Bolt Nm 39 39 39 39 42 40 20 Lb Ft 29 29 29 29 31 30 14 Lb In
SECTION
SUPPLEMENTAL RESTRAINT SYSTEM
TROOPER
9J1
RESTRAINTS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . SRS Component And Wiring Location View . Component Description . . . . . . . . . . . . . . . . . . Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS Connector Body Face Views . . . . . . . . . Repairs And Inspections Required After An Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . OnVehicle Service . . . . . . . . . . . . . . . . . . . . . . Air Bag Assembly Handling / Shipping / Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Precautions for SRS Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS Connectors . . . . . . . . . . . . . . . . . . . . . . . . Sensing And Diagnostic Module (SDM) . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver Air Bag Assembly . . . . . . . . . . . . . . . . . 9J1 9J2 9J4 9J4 9J7 9J8 9J9 9J9 9J10 9J11 9J20 9J24 9J25 9J27 9J27 9J27 9J27 9J29 Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS Coil Assembly . . . . . . . . . . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Column . . . . . . . . . . . . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Passenger Air Bag Assembly . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 9J29 9J29 9J30 9J31 9J31 9J31 9J32 9J34 9J34 9J34 9J35 9J37 9J37 9J37 9J39 9J41 9J41 9J41 9J42 9J42
Service Precaution
9J2
General Description
CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.
Restraint Devices
827RW005
827RW006
Legend (1) Deployed Air Bag (2) Knee Bolster (3) Seat Belt The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle. To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible.
9J3
System Description
The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly and the AIR BAG warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags.
D09RW001
9J4
SRS Component And Wiring Location View
810RW001
Legend (1) Battery (2) Relay & Fuse Box (3) Passenger Air Bag Assembly (4) SDM (5) Meter Assembly (6) SRS Coil Assembly
(7) (8) (9) (10) (11) (12) (13)
Driver Air Bag Assembly Starter Switch Fuse Box, C21 SRS Body Earth Body Harness Connector Instrument Harness Connector Engine Haness Connector
Component Description
SDM (Sensing and Diagnostic Module)
WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTED TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. The Sensing and Diagnostic Module (SDM) is designed to perform the following functions in the SRS:

1. Energy Reserve The SDM maintains 24Volt Loop Reserve (24VLR) energy supply to provide deployment energy when ignition voltage is lost in a frontal crash. 2. Frontal Crash Detection The SDM monitors vehicle velocity changes to detect frontal crashes which are severe enough to warrant deployment. 3. Air Bag Deployment When a frontal crash of sufficient force is detected, the SDM will cause enough current to flow through the air bag assembly to deploy the air bag. 4. Malfunction Detection The SDM performs diagnostic monitoring of SRS electrical components and sets a diagnostic trouble code when a malfunction is detected. 5. Frontal Crash Recording The SDM records information regarding SRS status during frontal crash. 6. Malfunction Diagnosis The SDM displays SRS diagnostic trouble codes and system status information through the use of a scan tool. 7. Driver Notification The SDM warns the vehicle driver of SRS malfunctions by controlling the Air Bag warning lamp. The SDM is connected to the SRS wiring harness by a 24pin connector. This harness connector uses a shorting clip across certain terminals in the contact area. This shorting clip connects the AIR BAG warning lamp to ground when the SDM harness connector is disconnected or CPA (Connector Position Assurance) is not inserted even if completely connected. This will cause the AIR BAG warning lamp to come ON steady whenever the ignition switch is at the ON or START positions with the SDM disconnected.
9J5
Air Bag Warning Lamp

Ignition voltage is applied to the AIR BAG warning lamp when the ignition switch is at the ON or START positions. The SDM controls the lamp by providing ground with a lamp driver. The AIR BAG warning lamp is used in the SRS to do the following: 1. Verify lamp and SDM operation by flashing SEVEN (7) times when the ignition switch is first turned ON. 2. Warn the vehicle driver of SRS electrical system malfunctions which could potentially affect the operation of the SRS. These malfunctions could result in nondeployment in case of a frontal crash or deployment for conditions less severe than intended. The AIR BAG warning lamp is the key to driver notification of SRS malfunctions. For proper lamp operation, refer to the SRS Diagnostic System Check in this section.
821RW037
SRS Coil Assembly

The SRS coil assembly consists of two current carrying coils. This is attached to the steering column and allow rotation of the steering wheel while maintaining continuous contact of the driver deployment loop to the driver air bag assembly. There is a shorting clip on the yellow 2pin connector near the base of steering column which connects the SRS coil to the SRS wiring harness. The shorting clip shorts to the SRS coil and driver air bag assembly when the yellow 2pin connector is disconnected. The circuit to the driver air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the steering column or other SRS components.
827RW004
Legend (1) SDM (2) SRS Harness (3) Connector Position Assurance
9J6

There is a shorting clip on the passenger air bag assembly connector which connects to the SRS harness. The shorting clip shorts across the passenger air bag assembly circuit when the passenger air bag assembly connector is disconnected. The circuit to the passenger air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the passenger air bag assembly, the instrument panel or other SRS components.
825RS017
Air Bag Assemblies

The air bag assembly consist of an inflatable air bag assembly and an inflator (a canister of gasgenerating material and an initiating device). When the vehicle is in a frontal crash of sufficient force. The SDM causes current flow through the deployment loops. Current passing through the inflator ignites the material in the air bag assembly. The gas produced from this reaction rapidly inflates the air bag assembly. There is a shorting clip on the driver air bag assembly connector which connects the SRS coil assembly. The shorting clip shorts across the driver air bag assembly circuits when driver air bag assembly connector is disconnected. The circuit to the driver air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the driver air bag assembly, the steering column or other SRS components.
827RS001
Steering Column
The steering column absorbs energy and is designed to compress in a frontal crash to decrease the chance of injury to the driver.
431RS006
Knee Bolster
The knee bolsters are used to absorb energy to protect knees and control the forward movement of the vehicles
827RS008

front seat occupants during a frontal crash, by limiting leg movement.
9J7
Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly Code, a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the Initiator Assembly Resistance Test. Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electrically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM Ignition 1 inputs, with ignition switch ON, is within the normal operating voltage range for at least ten seconds before turning ignition switch OFF. Ignition 1 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. Initiator Assembly Resistance Test Tests performed once each ignition cycle when no malfunctions are detected during TurnON or Continuous Monitoring. This test checks for the correct SDM configuration for the vehicle, shorts to Ignition 1 in the deployment loops, high resistance or opens in the Driver Side High, Driver Side Low, Passenger Side High and Passenger Side Low circuits and measures the resistance of the inflator assembly consisting of 1) Initiators, 2) SRS coil assembly (driver side only), 3) Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM Ignition 1 terminals and Ground terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the Initiator Assembly Resistance Test. Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from onboard computers via the data link connector.
740RT015
Definitions
Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupants head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). B+ Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key ON and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle, the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the AIR BAG warning lamp to flash seven times and then go OFF whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. Continuous Monitoring Tests performed by the SDM on the SRS every 100 milliseconds while Ignition 1 voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly DLC a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag.
9J8
SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two currentcarrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. TurnON Test which the SDM performs on the SRS once during each ignition cycle immediately after Ignition 1 voltage is applied to the SDM and before Continuous Monitoring.
Use Of Special Tools

WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERYPOWERED OR ACPOWERED VOLTMETER, OHMMETER, ETC, OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NON POWERED PROBETYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. YOU SHOULD BE FAMILIAR WITH THE TOOLS LISTED IN THIS SECTION UNDER THE HANDLING SRS SPECIAL TOOLS. You should be able to measure voltage and resistance. You should be familiar with proper use of a scan tool such as the Tech 2 Diagnostic Computer, SRS Driver/Passenger Load Tool J41433, Connector Test Adapter Kit J35616A, and the DVM (Digital Multimeter) J39200.
Diagnosis
WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERYPOWERED OR ACPOWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NONPOWERED PROBETYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT.

The SRS Diagnostic System Check must always be the starting point of any SRS diagnosis. The SRS Diagnostic System Check checks for proper AIR BAG warning lamp operation and checks for SRS diagnostic trouble codes using the scan tool. 1. Current diagnostic trouble codes Malfunctions that are presently being detected. Current diagnostic trouble codes are stored in RAM (Random Access Memory). 2. History diagnostic trouble codes All malfunctions detected since the last time the history memory was cleared. History diagnostic trouble codes are stored in EEPROM.
Scan Tool Diagnostics

A scan tool is used to read current and history diagnostic trouble codes and to clear all diagnostic trouble codes after a repair is completed. The scan tool must be updated to communicate with the SRS through a replaceable cartridge before it can be used for SRS diagnostics. To use the scan tool, connect it to the data link connector and turn the ignition switch ON. The scan tool reads serial data from the SDM Serial Data line terminal 24 to the data link connector terminal 9.
9J9
SRS Connector Body Face Views
D09RW003
Legend (1) SDM (2) Driver Air Bag Assembly (3) Passenger Air Bag Assembly
(4) Air Bag Warning Lamp (5) SRS Coil Assembly (6) DLC Connector
Repairs And Inspections Required After An Accident

NOTE: If any SRS components are damaged, they must be replaced. If SRS component mounting points are damaged, they must be replaced. D Never use SRS parts from another vehicle. This does not include remanufactured parts purchased from an authorized dealer; they may be used for SRS repairs. D Do not attempt to service the SDM, the SRS coil assembly, or the air bag assembly. Service of these items is by replacement only. D Verify the part number of replacement air bag assembly. CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from 00 model as follows. Yellow color for driver air bag assembly. White color for passenger air bag assembly.
Use only new air bag assembly proper to the Trooper which is being repaired. CAUTION: Proper operation of the sensors and supplemental restraint system (SRS) requires that any repairs to the vehicle structure return it to the original production configuration. Deployment requires, at a minimum, replacement of the SDM, air bag assembly and dimensional inspection of the steering column. Any visible damage to the SDM mounting bracket (s) requires replacement, and the steering column must be dimensionally inspected, whether deployment occurred or not.
Accident With Deployment Component Replacement And Inspections

Certain SRS components must be replaced or inspected for damage after a frontal crash involving air bag deployment. Those components are: D Air bag assembly D SDM
9J10

The SDM in DriverPassenger SRS can maintain sufficient voltage to cause a deployment for up to 15 seconds after the ignition switch is turned OFF, the battery is disconnected, or the fuse powering the SDM is removed. Many of the service procedures require removal of the C21 fuse, and disconnection of the air bag assembly from the deployment loop to avoid an accidental deployment. If the air bag assembly is disconnected from the deployment loop as noted in the Disabling the SRS procedure that follows, service can begin immediately without waiting for the 15 second time period to expire.
CAUTION: Refer to SDM Replacement Guidelines below for important information on SDM replacement in both deployment and non deployment crashes. D SRS coil assembly Inspect wiring and connector for any signs of scorching, melting, or damage due to excessive heat. Replace if damaged. Refer to section SRS Coil Assembly in this manual.
Accident With or Without Deployment Component Inspection

Certain SRS system components and rotation parts must be inspected after any crash, whether the air bag deployed or not. Those components are: D Steering column Refer to Inspection Required After an Accident in this manual. D Knee bolsters and mounting points Inspect for any distortion, bending, cracking, or other damage. D I/P steering column reinforcement plate Inspect for any distortion, bending, cracking, or other damage. D I/P braces Inspect for any distortion, bending, cracking, or other damage. D Seat belts and mounting points Refer to Seat Belts in Section Seat Belt of this workshop manual.
Disabling The SRS Removal

Turn the ignition switch to LOCK and remove key. 1. Remove SRS fuse C21, from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2pin connector at the base of steering column. 3. Remove glove box assembly, refer to Passenger Air Bag Assembly Replacement in this manual. 4. Disconnect yellow 2pin connector behind the glove box assembly. CAUTION: With the C21 fuse removed and ignition switch ON, the AIR BAG warning lamp will be ON. This is normal operation and does not indicate an SRS malfunction.
SDM Replacement Guidelines

SDM replacement policy requires replacement of SDM, after crash involving air bag deployment when SRS Warning Lamp turn ON, SRS Diagnosis should be done according to Section Restraint Control System.
Enabling The SRS Installation

CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from 00 model as follows. Yellow color for driver air bag assembly. White color for passenger air bag assembly. Use only new air bag assembly proper to the Trooper which is being repaired. Turn ignition switch to LOCK and remove key. 1. Connect yellow 2pin connector passenger air bag assembly. 2. Install glove box assembly. Refer to Passenger air bag assembly replacement in this manual. 3. Connect yellow 2pin connector at the base of steering column. 4. Install AIR BAG fuse C21 to left dash side lower fuse block or connect battery. Turn ignition switch to ON and verify that the AIR BAG warning lamp flashes seven times and then turns OFF. If it does not operate as described, perform the SRS Diagnostic System Check in this manual.
Wiring Damage
If any SRS wire harness is damaged, it should be replaced. Dont repair SRS harness. It is replace only.
SRS Connector (Plastic Body And Terminal Metal Pin) Damage

If any connector or terminal in the SRS wire harness (except pigtails) is damaged, it should be replaced.
SRS Wire Pigtail Damage

If the wiring pigtail (a wire or wires attached directly to the device, not by a connector) is damaged, the entire component (with pigtail) must be replaced. Examples of pigtail components are the driver air bag assembly, the passenger air bag assembly, and the SRS coil assembly.
OnVehicle Service
Service Precaution
WARNING: WHEN PERFORMING SERVICE ON OR AROUND SRS COMPONENTS OR SRS WIRING, FOLLOW THE PROCEDURES LISTED BELOW TO TEMPORARILY DISABLE THE SRS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
9J11
Handling / Installation / Diagnosis

1. Air bag assembly should not be subjected to temperatures above 65C (150F). 2. Air bag assembly, and SDM should not be used if they have been dropped from a height of 100 centimeters (3.28 feet) or more. 3. When a SDM is replaced, it must be oriented with the arrow on the sensor pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code. 5. The SRS Diagnostic System Check must be the starting point of any SRS diagnostics. The SRS Diagnostic System Check will verify proper AIR BAG warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement.
WIRES OR CONNECTOR ON THE UNDERSIDE OF THE MODULE.
Air Bag Assembly Handling / Shipping / Scrapping

Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a live (undeployed) air bag assembly. The rapid gas generation produced during deployment of the air bag could cause the air bag assembly, or an object in front of the air bag assembly, to be thrown through the air in the unlikely event of an accidental deployment.
827RS044
Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies
Service personnel should refer to the latest Service Bulletins for proper SRS air bag assembly shipping procedures.
Deployed Air Bag Assembly (Driver Side)

You should wear gloves and safety glasses. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present.
Air Bag Assembly Scrapping Procedure

827RV004
WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG OPENING IS POINTED AWAY FROM YOU. IN CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. NEVER CARRY THE AIR BAG ASSEMBLY BY THE
During the course of a vehicles useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) air bag assembly. This information covers proper procedures for disposing of a live air bag assembly. Before a live air bag assembly can be disposed of, it must be deployed. A live air bag assembly must not be disposed of through normal refuse channels.
9J12

NOTE: This information applies only to driver air bag assembly . Refer to Deployment Outside Vehicle (Passenger Air Bag assembly) in this section for information on passenger air bag assembly scrapping. 1. Turn ignition switch to LOCK, remove key and put on safety glasses. 2. Inspect J42986 SRS Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail adapter is damaged, discard and obtain a replacement. 3. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. SRS deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROPER SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. AN UNDPLOYED AIR BAG ASSEMBLY MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE, AND / OR LOCAL LAW. In situations which require deployment of a live air bag assembly, deployment may be accomplished inside or outside the vehicle. The method employed depends upon the final disposition of the particular vehicle, as noted in Deployment Outside Vehicle and Deployment Inside Vehicle in this section.
Deployment Outside Vehicle (Driver Air Bag Assembly)

Deployment outside the vehicle is proper when the vehicle is to be returned to service. This includes, for example, situations in which the vehicle will be returned to useful service after a functionally or cosmetically deficient air bag assembly is replaced. Deployment and disposal of a malfunctioning air bag assembly is, of course, subject to any required retention period. For deployment of a live (undeployed) air bag assembly outside the vehicle, the deployment procedure must be followed exactly. Always wear safety glasses during this deployment procedure until a deployed air bag assembly is scrapped or until an undeployed air bag assembly is shipped. Before performing the procedures you should be familiar with servicing the SRS and with proper handling of the air bag assembly. Procedures should be read fully before they are performed. The following procedure requires use of J42986 SRS deployment harness with appropriate pigtail adapter. Do not attempt procedure without J42986 adapter. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT HARNESS TO THE DRIVER AIR BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE.
827RS004
4. Connect the appropriate pigtail adapter to the SRS deployment harness. 5. Remove the driver air bag assembly from vehicle. Refer to Inflator Module Removal in this manual. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE AIR BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY.

6. Place the driver air bag assembly on a work bench or other surface away from all loose or flammable objects with its trim cover facing up, away from the surface.
9J13
10. Place a power source near the shorted end of the SRS deployment harness. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 11. Connect the driver air bag assembly to the pigtail adapter on the SRS deployment harness. Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. The driver air bag assembly will immediately deploy the air bag when a power source is connected to it. NOTE: Ensure that the pigtail adapter is firmly seated into the driver air bag assembly connector. Failure to fully seat the connectors may leave the shorting bar located in the driver air bag assembly connector functioning (shorted) and may result in nondeployment of the driver air bag assembly. 12. Verify that the area around the driver air bag assembly is clear of all people and loose or flammable objects. 13. Verify that the driver air bag assembly is resting with its trim cover facing up. 14. Notify all people in the immediate area that you intend to deploy the driver air bag. The deployment will be accompanied by a substantial noise which may startle the uninformed. 15. Separate the two banana plugs on the SRS deployment harness. NOTE: When the air bag deploys, the driver air bag assembly may jump about 30 cm (one foot) vertically. This is a normal reaction of the driver air bag to the force of the rapid gas expansion inside the air bag. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the driver air bag. WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY.
827RV003
7. Clear a space on the ground about 183 cm (six feet) in diameter where the driver air bag assembly is to be deployed. A paved, outdoor location where there is no activity is preferred. If an outdoor location is not available, a space on the shop floor where there is no activity and sufficient ventilation is recommended. Ensure no loose or flammable objects are within the deployment area.
827RV005
8. Place the driver air bag assembly, with its trim cover facing up, on the ground in the space just cleared. 9. Stretch the SRS deployment harness and pigtail adapter from the driver air bag assembly to its full length.
16. Connect the SRS deployment harness wires to the power source to immediately deploy the driver air bag. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS deployment harness leads together by fully seating one banana plug into the other.
9J14

WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR MODULE UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 26. Temporarily store the driver air bag assembly with its trim cover facing up, away from the surface upon which it rests.
19. In the unlikely event that the driver air bag assembly did not deploy after following these procedures, proceed immediately with Steps 24 through 26. If the driver air bag assembly did deploy, proceed with Steps 20 through 23. 20. Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed driver air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This power consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with the atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE INFLATOR MODULE TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR PERSONAL INJURY. AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN DEPLOYED, THE METAL CANISTER AND SURROUNDING AREAS OF THE DRIVER AIR BAG ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH THE METAL AREAS OF THE DRIVER AIR BAG ASSEMBLY FOR ABOUT TEN MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED DRIVER AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL, WEAR GLOVES AND HANDLE BY THE AIR BAG OR TRIM COVER. 21. Disconnect the pigtail adapter from the driver air bag assembly as soon after deployment as possible. This will prevent damage to the pigtail adapter or SRS deployment harness due to possible contact with the hot driver air bag assembly canister. The pigtail adapter can be reused. They should, however, be inspected for damage after each deployment and replaced if necessary. 22. Dispose of the deployed driver air bag assembly through normal refuse channels after it has cooled for at least 30 minutes. 23. Wash your hands with mild soap and water afterward. NOTE: The remaining steps are to be followed in the unlikely event that the driver air bag assembly did not deploy after following these procedures. 24. Ensure that the SRS deployment harness has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other. 25. Disconnect the pigtail adapter from the driver air bag assembly.
Deployment Outside Vehicle (Passenger Air Bag Assembly)

WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. UNDEPLOYED AIR BAG ASSEMBLIES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE AND/OR LOCAL LAWS. Deployment out of the vehicle is proper when the vehicle is to be returned to service. This includes, for example, situations in which a functionally or cosmetically deficient air bag assembly is replaced. Deployment and disposal of an air bag assembly is, of course, subject to any required retention period. For deployment of a live air bag assembly out of the vehicle, the deployment procedure must be followed exactly. Always wear safety glasses during this deployment procedure until the deployed air bag assembly is scrapped. Before performing the procedures, you should be familiar with servicing the SRS system and with proper handling of the air bag assembly. Procedures should be read fully before they are performed. The following procedure requires use of J42986 SRS Deployment Harness with the appropriate pigtail adapter. The procedure also requires the use of J41497 Passenger Side SRS Module Deployment Fixture. Do not attempt this procedure without J42986 and adapter, and J41497. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT HARNESS TO THE AIR BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE.

NOTE: This information applies only to passenger air bag assembly. Information for disposing of a live driver air bag assembly can be found in Deployment Outside Vehicle (Driver Air Bag Assembly) in this section. 1. Turn ignition switch to LOCK remove key, and put on safety glasses. 2. Inspect J42986 SRS Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail is damaged, discard and obtain a replacement. 3. Short the two SRS Deployment Harness leads together by fully seating one banana plug into the other. The SRS Deployment Harness shall remain shorted and not be connected to a power source until the air bag is to be deployed.
9J15
6. Clear a space on the ground approximately 183 cm (six feet) in diameter where the fixture with attached air bag assembly is to be placed for deployment. A paved outdoor location where there is no activity is preferred. If an outdoor location is not available, a space on the shop floor where is no activity and sufficient ventilation is recommended. Ensure that no loose or flammable objects are within the deployment area. 7. Place the J41497 on the bench vice. This is necessary to provide sufficient stabilization of the fixture during deployment. 8. Attach the passenger air bag assembly in the J41497. An air bag assembly must be mounted such that the bag will deploy upward. SECURELY HANDTIGHTEN ALL FASTENERS PRIOR TO DEPLOYMENT.
827RS003
4. Connect the appropriate pigtail adapter to the SRS Deployment Harness

901RW199
9. Stretch the SRS Deployment Harness and pigtail adapter from the air bag assembly to its full length. 10. Place a power source near the shorted end of the SRS deployment harness. (Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested.) 11. Connect the air bag assembly to the pigtail adapter on the SRS deployment harness. The SRS Deployment Harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. The air bag assembly will immediately deploy the air bag when a power source is connected to it. NOTE: Ensure that the pigtail adapter is firmly seated into the air bag assembly connector. Failure to fully seat the connectors may leave the shorting bar located in the air bag assembly connector functioning (shorting the deployment circuit) and may result in nondeployment of the air bag assembly.
827RS004
5. Remove passenger air bag assembly from vehicle. Refer to Passenger Air Bag Assembly Removal in this Section 9J3.
12. Verify that the area around the passenger air bag assembly is clear of all people and loose or flammable objects. 13. Verify that the passenger air bag assembly is firmly and properly in J41497.
9J16

THE DEPLOYED AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL, WEAR GLOVES AND HANDLE BY THE AIR BAG ITSELF. 21. Disconnect the pigtail adapter from the air bag assembly as soon after deployment as possible to avoid damage to the pigtail adapter or SRS deployment harness from contacting the hot air bag assembly canister. The pigtail adapter and SRS deployment harness are designed to be reused. They should, however, be inspected for damage after each deployment and replaced if necessary. 22. Dispose of the deployed air bag assembly through normal refuse channels after it has cooled for at least 30 minutes. 23. Wash your hands with mild soap and water afterward. NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did not deploy after following the above procedures. 24. Ensure that the SRS deployment harness has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other. 25. Disconnect the pigtail adapter from the air bag assembly. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 26. Temporarily store the air bag assembly with the bag facing up, away from the surface upon which it rests.
14. Notify all people in the immediate area of your intention to deploy the passenger air bag assembly. The deployment will be accompanied by a substantial noise which may startle the uninformed. 15. Separate the two banana plugs on the SRS deployment harness. NOTE: When air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the air bag assembly. WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. 16. Connect the SRS deployment harness wires to the power source to immediately deploy the air bag assembly. Recommended application : 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. 19. In the unlikely event that the passenger air bag assembly did not deploy after following these procedures, proceed immediately with Steps 24 through 26. If the passenger air bag assembly deployed as intended, proceed with Steps 20 through 23. 20. The passenger inflator requires no special precaution after deployment. 95% of the particulate emission are potassium ckloride (KLC), which is commonly sold as an edible saltsubstitutes. even if water is applied. Post deployment products are relatively pH neutral. Disposing the inflator by burying it in a landfill will not produce any hazardous products. As with any dusty environment, safety goggles, dust mask and gloves should be worn. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE DEPLOYED INFLATOR MODULE NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR PERSONAL INJURY. AFTER AN AIR BAG ASSEMBLY HAS BEEN DEPLOYED, THE METAL CANISTER AND SURROUNDING AREAS OF THE AIR BAG ASSEMBLY WILL BE HOT. DO NOT TOUCH THE METAL AREAS OF THE AIR BAG ASSEMBLY FOR ABOUT THIRTY MINUTES AFTER DEPLOYMENT. IF
Deployment Inside Vehicle (Vehicle Scrapping Procedure)

Deployment inside vehicle is proper when the vehicle is to be destroyed or salvaged for component parts. This includes, but is not limited to, the following situations: 1. The vehicle has completed its useful life. 2. The vehicle has been damaged beyond repair in a nondeployment type accident. 3. The vehicle has been stripped or damaged beyond repair in a theft. 4. The vehicle will be salvaged for component parts to be used on a vehicle with a different Vehicle Identification Number (VIN) as opposed to being rebuilt as same VIN. Never use SRS components from another vehicle. WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. UNDEPLOYED AIR BAG ASSEMBLIES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER

IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE AND/OR LOCAL LAWS. 1. Turn ignition switch to LOCK, remove key and put on safety glasses. 2. Remove all loose objects from front seats. 3. Disconnect driver air bag assembly, yellow 2pin connector located at the base of the steering column. 4. Cut the driver air bag assembly yellow 2pin harness connector from the vehicle leaving at least 15 cm (six inches) of wire at the connector. 5. Strip 13 mm (1/2 inch) of insulation from yellow green and yellow black wire lead of the connector. 6. Cut two 900 cm (30 feet) deployment wires from 0.8 mm@ (18 gauge) or thicker multistrand wire. These wires will be used to fabricate the driver deployment harness. 7. Strip 13 mm (1/2 inch) of insulation from both ends of the wires cut in the previous step. 8. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND BE NOT CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. 9. Twist together one connector wire lead to one deployment wire. The connection should be mechanically secure. 10. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 11. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. 12. Connect the deployment harness to the driver air bag assembly, yellow 2pin connector at the base of the steering column. Route deployment harness out the driver side of the vehicle. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL
9J17
STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 13. Disconnect passenger air bag assembly, yellow 2pin connector located behind glove box assembly. 14. Cut the passenger air bag assembly harness connector from the vehicle leaving at least 15 cm (six inches) of wire at the connector. 15. Strip 13 mm (1/2 inch) of insulation from bluewhite and pinkblue wire lead of the connector. 16. Cut two 900 cm (30 feet) deployment wires from 0.8 mm@ (18 gauge) or thicker multistrand wire. These wires will be used to fabricate the passenger deployment harness. 17. Strip 13 mm (1/2 inch) of insulation from both ends of the wires cut in the previous step. 18. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. 19. Twist together one connector wire lead to one deployment wire. The connection should be mechanically secure. 20. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 21. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. 22. Connect the deployment harness to the passenger air bag assembly, yellow 2pin connector located behind the glove box assembly. Route deployment harness out the passenger side of the vehicle. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY.
9J18

30. Connect the passenger deployment harness wires to a power source to immediately deploy the passenger air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested.(Driver air bag assembly) Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After an air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment.(Passenger air bag assembly) The passenger inflator requires no special precaution after deployment. 95% of the particulate emission are potassium chloride (KLC), which is commonly sold as an edible saltsubstitutes. even if water is applied. Post deployment products are relatively pH neutral. Disposing the inflator by burying it in a landfill will not products any hazardous products. As with any dusty environment, safety goggles, dust mask and gloves should be worn. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE HOT DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN FIRE OR PERSONAL INJURY. After an air bag assembly has been deployed, the metal canister and surrounding areas of the air bag assembly will be very hot. Do not touch the metal areas of the air bag assembly for about 30 minutes after deployment. If the deployed air bag assembly must be moved before it is cool, wear gloves and handle by the air bag or trim cover. 31. Short the driver deployment harness wires by twisting together one end from each. Repeat this procedure for the passenger deployment harness. 32. Carefully remove drop cloth from vehicle and clean off any fragments or discard drop cloth entirely. 33. Disconnect driver deployment harness and passenger deployment harness from vehicle and discard. 34. In the unlikely event that either or both of the air bag assemblies did not deploy after following these procedures, proceed immediately with Steps 36 through 37. If the air bag assembly deployed, proceed to step 35. 35. With both air bags deployed, the vehicle may be scrapped in the same manner as a nonSRS equipped vehicle.
23. Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable objects. 24. Stretch the driver and passenger deployment harness to their full length. 25. Completely cover windshield area and front door window openings with a drop cloth, blanket or similar item. This reduces the possibility of injury due to possible fragmentation of the vehicles glass or interior. 26. Notify all people in the immediate area that you intend to deploy the air bags. The deployment will be accompanied by a substantial noise which may startle the uninformed. 27. Separate the two ends of the driver deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the air bags. 28. Connect the driver deployment harness wires to a power source to immediately deploy the driver air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 29. Separate the two ends of the passenger deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY.

NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did not deploy after following these procedures. 36. Remove the undeployed air bag assembly (s) from the vehicle. For driver air bag assembly refer to in the Passenger Air Bag Assembly Removal in this manual. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN PERSONAL INJURY. 37. Temporarily store the air bag assembly with the air bag opening facing up, away from the surface upon which it rests.
9J19
Deployed Air Bag Assembly Handling

Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment.
9J20
Special Tools
WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERYPOWERED OR ACPOWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NONPOWERED PROBETYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT.
J39200 DVM
J41433 SRS Driver/Passenger Load Tool
901RS153
The J39200 DVM is the preferred DVM for use in SRS diagnosis and repair. However, J34029A may be used if J39200 is not available. No other DVMs are approved for SRS diagnosis and repair.
Scan Tool
901RS146
The SRS Driver/Passenger Load Tool J41433 is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag assembly deployment. The load tool has three yellow connectors attached to its case. The three small connectors are electrically functional and serve as resistive load substitutions. No more than two connectors are used at any time. One of the small connectors is used to substitute for the load of the driver air bag assembly when it is connected at the top of the column to the SRS coil assembly. Another small connector is used to substitute for the load of the driver air bag assembly and the SRS coil assembly when it is connected at the base of the column to the SRS wiring harness. The third small connector is used to substitute for the load of the passenger air bag assembly when connected to the passenger air bag assembly harness connector. By substituting the resistance of the load tool when called for, a determination can be made as to whether an inflator circuit component is causing system malfunction and which component is causing the malfunction. The load tool should be used only when specifically called for in the diagnostic procedures.
901RW176
The Tech 2 is used to read and clear SRS Diagnostic Trouble Codes (DTCs). Refer to the Tech 2 Operators, Manual for specific information on how to use the Tech 2.
9J21
J35616A Connector Test Adapter Kit
J41497 SRS Deployment Fixture
901RS151
901RW199
The J35616A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the appropriate adapter will ensure that no damage to the terminal will occur from the DVM prove, such as spreading or bending. The adapter will also give an idea of whether contact tension is sufficient, helping to find an open or intermittent open due to poor terminal contact.
The J41497 SRS Deployment Fixture must be used for deployment of the undeployed passenger side air bag.
J42987 SRS Adapter for Load Tool.
J42986 SRS Deployment Tool
901RW107
The J42987 SRS Adapter for Load Tool must be used with J41433 SRS Driver/Passenger Load Tool.
901RW106
The J42986 SRS Deployment Tool must be used for deployment of the undeployed air bag.
9J22
Tech 2 Scan Tool

740RW060
6. Turn on the vehicle ignition switch. 7. Verify the Tech 2 power up display.
901RW200
Legend (1) PCMCIA Card (2) RS 232 Loop Back Connector (3) SAE 16/19 Adaptor (4) DLC Cable (5) Tech2
Getting Started
D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. Insert the Isuzu 98 System PCMCIA card (1) into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5) 4. Make sure of the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle ALDL/DLC connector.
060RW009
NOTE: The RS232 Loop back connector is only used to diagnosis Tech 2. Refer to user guide of the Tech 2.
9J23
Operating Procedure
060RW019
060RY027
9J24

3. Connect yellow 2pin connector at the base of the steering column. 4. Install AIR BAG fuse C21 to left dash side lower fuse block or connect battery. Turn ignition switch to ON and verify that the AIR BAG warning lamp flashes seven times and then turns OFF. If it does not operate as described, perform the SRS Diagnostic System Check in this section.
Service Precautions for SRS Component Service

CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result. WARNING: WHEN PERFORMING SERVICE ON OR AROUND SRS COMPONENTS OR SRS WIRING, FOLLOW THE PROCEDURES LISTED BELOW TO TEMPORARILY DISABLE THE SRS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY OR OTHERWISE UNNEEDED SRS REPAIRS. The SDM in DriverPassenger SRS can maintain sufficient voltage to cause a deployment for up to 15 seconds after the ignition switch is turned OFF, the battery is disconnected, or the fuse powering the SDM is removed. Many of the service procedures require removal of the C21 fuse, and disconnection of the air bag assembly from the deployment loop to avoid an accidental deployment. If the air bag assembly is disconnected from the deployment loop as noted in the Disabling the SRS procedure that follows, service can begin immediately without waiting for the 15 second time period to expire.
Handling / Installation / Diagnosis

1. Air bag assembly should not be subjected to temperatures above 65C (150F). 2. Air bag assembly, and SDM should not be used if they have been dropped from a height of 100 centimeters (3.28 feet) or more. 3. When a SDM is replaced, it must be oriented with the arrow on the SDM pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code. 5. The SRS Diagnostic System Check must be the starting point of any SRS diagnostics. The SRS Diagnostic System Check will verify proper AIR BAG warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacements.
Disabling The SRS Removal

Turn the ignition switch to OFF and turn the steering wheel so that the vehicles wheels are pointing straight ahead. 1. Remove SRS fuse C21 from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2pin connector at the base of steering column. 3. Remove glove box assembly; Refer to Passenger air bag assembly replacement in this section. 4. Disconnect passenger air bag assembly yellow 2pin connector behind the glove box assembly. CAUTION: With the C21 fuse removed and ignition switch ON, the AIR BAG warning lamp will be ON. This is normal operation and does not indicate an SRS malfunction.
Inspections Required After An Accident

CAUTION: Certain SRS components must be replaced after a frontal crash involving air bag deployment. In all types of accidents regardless of Air Bag deployment, visually inspect all of the following components and replace as required: Driver air bag assembly Passenger air bag assembly Steering wheel SRS coil assembly Steering column Knee bolster and instrument panel mounting attachments Driver seat and belt Passenger seat and belt SDM SDM always should be checked according to SDM Replacement Guidelines. CAUTION: Refer to SDM Replacement Guidelines below for important information on SDM replacement in both deployment and nondeployment crashes. Inspect SRS coil assembly wiring and steering wheel for any sign of scorching, melting, or damage due to excessive heat. If coil assembly wire or steering wheel is
Enabling The SRS Installation

Turn ignition switch to LOCK and remove key. 1. Connect yellow 2pin connector passenger air bag assembly. 2. Install glove box assembly. Refer to Passenger Air Bag Assembly Replacement in this section.

damaged, replace them. The steering column and wheel must be dimensionally checked to determine if they are damaged. Refer to steering wheel of in this manual. Never use SRS parts from another vehicle. This does not include remanufactured parts purchased from an authorized Isuzu Retailer; they may be used for SRS repairs. Do not attempt to repair the SDM, the SRS harness, the SRS coil assembly, the air bag assembly, the steering wheel, or the steering column. Service of these items is replacement only. Verify replacement part numbers. CAUTION: Proper operation of the SDM and supplemental restraint system (SRS) requires that any repairs to the vehicle structure return it to its original production configuration.
9J25
Removal
To remove the connector, hold the cover insulator (1) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator (2).
SRS Connectors
CAUTION: The special yellow color connectors are used for supplemental restraint system-air bag circuit. When removing the oable harnese, do not pull the cables otherwile, cable disconnection may occur. When connect the SRS connector, insert the connector completely. Imperfect locking may cause malfunction of SRS circuit.
827RW028
9J26
Installation
To install the connector, hold the socket insulator (1) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator (2).
827RW027
9J27
Sensing And Diagnostic Module (SDM)

Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. NEVER POWER UP THE SRS WHEN SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE RIGIDLY ATTACHED TO THE VEHICLE STRUCTURE AND THAT THE ARROW ON THE SENSOR BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field. 5. Remove the three SDM fixing bolts and remove SDM.
827RW026
Installation
1. Install the SDM on bracket and fixing bolts and tighten the fixing bolts to the specified torque. Torque: 10 Nm (87 lb in) 2. Connect the SDM harness connector and after that, put CPA into connector. 3. Install the front console. 4. Install the transmission knob (for M/T) and transfer lever knob.
Removal
1. Disable the SRS (Refer to Disabling the SRS in this section). 2. Remove the transmission knob (for M/T) and transfer lever knob. 3. Remove the front console assembly and disconnect wiring harness connector. 4. Pull CPA (Connector Position Assurance) out and push connector lock down to disconnect the SDM harness connector.
9J28
5. Enable the SRS (Refer to Enabling the SRS in this section).
827RW026
9J29
Driver Air Bag Assembly

Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BYPRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING ALIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.
Removal
1. Disable the SRS (Refer to Disabling the SRS in this section). 2. Loosen the air bag assembly fixing bolts from behind the steering wheel assembly using a TORX driver or equivalent until the air bag assembly can be released from steering wheel.
827RT008
3. Disconnect the yellow 2pin connector located behind the air bag assembly and remove air bag assembly. Refer to SRS Connectors in this section for removal and installation.
827RT009
9J30
Installation
1. Connect air bag to wiring harness connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched.
827RT009
2. Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure. Torque: 8 Nm (69 lb in) CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from 00 model as follows. Yellow color for driver air bag assembly. White color for passenger air bag assembly. Use only new air bag assembly proper to the Trooper which is being repaired.
827RW007
9J31
Steering Wheel
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BYPRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING ALIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND RIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.
827RT008
3. Disconnect the yellow 2pin connector located behind the air bag assembly and remove air bag assembly.Refer to SRS Connectors in this section for removal and installation. 4. Disconnect horn lead.
Removal
827RT009
5. Remove steering wheel attachment nut.
9J32
6. Apply a setting mark across the steering wheel and shaft so parts can be reassembled in their original position.
Installation
1. Install the steering wheel and align the setting marks.
430RS004
430RS004
7. Move the tires to the straight ahead position before removing the steering wheel. Install steering wheel puller onto steering wheel and remove steering wheel with J29752.
2. Tighten the steering wheel fixing nut to the specified torque. Torque : 34 N m (25 lbft) 3. Connect horn lead. 4. Connect air bag to wiring harness connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched.
430RT009
8. Feed wiring through the wheel and remove wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.
827RT009

5. Install air bag into steering wheel and tighten bolts to specified sequence as show in figure. Torque: 8 Nm (69 lb in) CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from 00 model as follows. Yellow color for driver air bag assembly. White color for passenger air bag assembly. Use only new air bag assembly proper to the Trooper which is being repaired.
9J33
827RT008
9J34
SRS Coil Assembly

Service Precautions
827RT008
3. Disconnect the yellow 2pin connector located behind the air bag assembly and remove air bag assembly.Refer to SRS Connectors in this section for removal and installation. 4. Disconnect horn lead connector.
Removal
827RT009

5. Remove the steering wheel attachment nut. 6. Apply a setting mark across the steering wheel and shaft so parts can be reassembled in their original position.
9J35
12. Remove air conditioning lower duct. 13. Disconnect the 2pin wiring harness connectors located at the base of steering column. CAUTION: Never apply force to the steering wheel in the direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 14. Remove the combination switch assembly with SRS coil. NOTE: SRS coil is a part of combination switch assembly, which cannot be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly.
Installation
1. Install the combination switch assembly with SRS coil. 2. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark (1).
430RS004
7. Move the tires to the straight ahead position before removing the steering wheel and remove wheel with J29752.
CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage the cable in the SRS coil.
826RW014 430RT009
8. Feed wiring though the wheel and remove wheel. 9. Remove the steering lower cover and engine hood opening lever. 10. Remove the driver knee bolster assembly. 11. Remove the steering column cover.
3. Connect the wiring harness connectors located at the base of steering column. 4. Install the air conditioning lower duct. 5. Install the steering column cover.
9J36

11. Connect air bag to wiring harness connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air to prevent lead wire from being pinches.
CAUTION: When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harness starter switch, combination switch and SRS coil may not catch wiring.
827RT009 825RS048
6. Install the driver knee bolster assembly. 7. Install the steering lower cover and engine hood opening lever. 8. Install the steering wheel and align the setting marks.
12. Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure. Torque: 8 Nm (69 lb in) CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from 00 model as follows. Yellow color for driver air bag assembly. White color for passenger air bag assembly. Use only new air bag assembly proper to the Trooper which is being repaired.
430RS004
9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lbft) 10. Connect horn lead.
827RT0008
9J37
Steering Column
Service Precautions
827RT008
3. Disconnect the yellow 2pin connector located behind the air bag assembly and remove air bag assembly.Refer to SRS Connectors in this section for removal and installation.
Removal
827RT009
4. Disconnect horn lead connector. 5. Remove the steering wheel attachment nut.
9J38

9. Remove the steering lower cover and engine hood opening lever. 10. Remove the driver knee bolster assembly.
6. Apply a setting mark across the steering wheel and shaft so parts can be reassembled in their original position.
430RS004
740RT015
7. Move the tires to the straight ahead position before removing the steering wheel and removing wheel with J29752.
11. Remove the steering column cover. 12. Remove air conditioning lower duct. 13. Disconnect the wiring harness connectors located at the base of steering column. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 14. Remove the combination switch assembly with SRS coil. NOTE: SRS coil is a part of combination switch assembly, which cannot be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 15. Remove the snap ring. 16. Remove the cushion rubber. 17. Disconnect shift lock cable (A/T only). 18. Disconnect the starter switch harness connector located base of steering column. 19. Remove steering lock cylinder assembly.
430RT009
8. Feed wiring though the wheel and remove wheel.

20. Apply a setting mark across the universal joint and steering shaft to reassemble the parts in their original position.
9J39
7. Install cushion rubber. 8. Install snap ring. 9. Install the combination switch assembly with SRS coil. 10. Connect the wiring harness connector located on the base of steering column. 11. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark (1). CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil.
431RS013
21. Remove steering column assembly.
Installation
1. Install the steering column assembly and align the setting marks on the universal joint and steering shaft made during removal.
826RW014
12. Install steering column cover. CAUTION: When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harness starter switch, combination switch and SRS coil may not catch wiring.
431RS013
2. Tighten the steering column fixing bolts (dash panel side) to the specified torque. Torque: 20 Nm (14 lb ft) 3. Tighten the steering column fixing bolts (Pedal bracket) to the specified torque. Torque: 20 Nm (14 lb ft) 4. Tighten the universal joint to the specified torque. Torque: 31 Nm (23 lb ft) 5. Install steering lock cylinder assembly. 6. Connect shift lock cable (For A/T)
825RS048
9J40

CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label from 00 model as follows. Yellow color for driver air bag assembly. White color for passenger air bag assembly. Use only new air bag assembly proper to the Trooper which is being repaired.
13. Install the steering wheel and align the setting marks.
430RS004
14. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 15. Connect horn lead. 16. Connect air bag wiring harness connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched.
827RT008
827RT009
17. Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure. Torque: 8.8 Nm (78 lb in)
9J41
Passenger Air Bag Assembly

Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BYPRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING ALIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND RIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: IN THE EVENT DEPLOYMENT HAS OCCURRED, INSPECT COIL ASSEMBLY WIRE FOR ANY SIGNS OF SCORCHING, MELTING OR ANY OTHER DAMAGE DUE TO EXCESSIVE HEAT. IF THE COIL HAS BEEN DAMAGED, REPLACE IT.
Removal
827RS001
1. Disable the SRS (Refer to Disabling the SRS in this section). 2. Remove gear control knob. 3. Remove front console assembly. 4. Remove rear console assembly and disconnect harness connector. 5. Remove ECM and SDM cover. 6. Remove glove box assembly with lid. 7. Remove glove box cover. 8. Remove instrument panel assist side lower cover. 9. Disconnect engine hood opener lever. 10. Remove instrument panel door side lower cover. 11. Remove lower cluster with ashtray. 12. Remove meter cluster assembly and disconnect harness connector. 13. Remove instrument panel lower center cover. 14. Disconnect passenger air bag assembly harness connector. 15. Remove air bag assembly fixing bolts and nuts. 16. Remove passenger air bag assembly.
9J42

2. Install air bag assembly fixing nuts and tighten to specified torque. Torque: 6 Nm (52 lb in) 3. Connect air bag assembly harness connector. 4. Install instrument panel lower center cover. 5. Install meter cluster assembly and connect harness connector. 6. Install lower cluster with ashtray. 7. Install instrument panel door side lower cover. 8. Connect engine hood opener lever. 9. Install instrument panel assist side lower cover. 10. Install glove box cover. 11. Install glove box assembly with lid. 12. Install ECM and SDM cover. 13. Install rear console assembly and connect harness connector. 14. Install front console assembly. 15. Install gear control knob. 16. Enable the SRS (Refer to Enabling the SRS in this section).
Installation
827RS001
1. Install passenger air bag assembly.

Fastener Tightening Specification
Application SDM Driver air bag fixing bolt Steering wheel fixing bolt Steering column (dash panel side fixing bolts) Steering column (Pedal bracket fixing bolt) Steering column (Universal joint fixing bolt) Passenger Air Bag fixing nuts Nm 10 8.8 34 20 20 31 6 Lb Ft 25 14 14 23 Lb In. 87 78 52
SECTION
RESTRAINT CONTROL SYSTEM
Trooper
9J11
RESTRAINTS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information . . . . . . . . . . . . . . . . . . . System Schematic . . . . . . . . . . . . . . . . . . . . . . SRS Diagnostic System Check . . . . . . . . . . . . Chart A SDM Integrity Check . . . . . . . . . . . . . Chart B AIR BAG Warning Lamp Comes ON Steady . . . . . . . . . . . . . . . . . . . . Chart C AIR BAG Warning Lamp Does Not Come ON Steady (1/2) . . . . . . . . . . . . . DTC 15 Passenger Deployment Loop Resistance High . . . . . . . . . . . . . . . . . . . . . . . . DTC 16 Passenger Deployment loop Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . DTC 17 Passenger Deployment Loop Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 18 Passenger Deployment Loop Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . 9J11 9J12 9J14 9J14 9J16 9J18 9J110 9J113 9J115 9J117 9J119 DTC 19 Passenger Deployment Loop Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . DTC 21 Driver Deployment Loop Resistance High . . . . . . . . . . . . . . . . . . . . . . . . DTC 22 Driver Deployment Loop Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . DTC 24 Driver Deployment Loop Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . DTC 25 Driver Deployment Loop Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . DTC 26 Driver Deployment Loop Open . . . . DTC 51 Deployment Event Commanded . . . DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range . . . . . . . . . . . . . . . . . DTC 61 Warning Lamp Circuit Failure . . . . . DTC 71 Internal SDM Fault . . . . . . . . . . . . . . 9J121 9J123 9J126 9J128 9J130 9J132 9J134
9J136 9J138 9J140
Service Precaution
9J12

detected since the SRS codes were last cleared during service. 1. Active Codes Faults that are presently detected this ignition cycle. Active codes are stored in RAM (Random Access Memory). 2. History Codes All faults detected since the last time the history fault memory was cleared. History codes are stored in EEPROM. (Electronically Erasable Programmable Read only Memory)
Diagnostic Information
CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. fasteners that are not reused, and those requiring thread locking compound will be called out. the correct torque value must be used when installing fasteners that require it. if the above conditions are not followed, parts or system damage could result.
How To Read Trouble Codes

All codes (Active and history) can be read (or cleared) by using a scan tool or equivalent. If a PDT is not available, have the vehicle serviced by ISUZU dealer.
Diagnostic Procedures
WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERYPOWERED OR ACPOWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NON POWERED, PROBETYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. The diagnostic procedures used in this section are designed to aid in finding and repairing SRS problems. Outlined below are the steps to find and repair SRS problems quickly and effectively. Failure to carefully follow these procedures may result in extended diagnostic time, incorrect diagnosis and incorrect parts replacement. 1. Perform The SRS Diagnostic System Check. The SRS Diagnostic System Check should always be the starting point of any SRS diagnostics. The SRS Diagnostic System Check checks for proper AIR BAG warning lamp operation and checks for SRS trouble codes using both Flash Code and Scan Tool Methods. 2. Refer To The Proper Diagnostic Chart As Directed By The SRS Diagnostic System Check. The SRS Diagnostic System Check will lead you to the correct chart to diagnose any SRS problems. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis and incorrect parts replacement. 3. Repeat The SRS Diagnostic System Check After Any Repair Or Diagnostic Procedures Have Been Performed. Preforming the SRS Diagnostic System Check after all repair or diagnostic procedures will assure that the repair has been made correctly and that no other conditions exist.
How To Clear Trouble Codes

Trouble codes can only be cleared by using a Scan Tool. If a scan tool is not available then inform the owner of the stored codes and suggest that the codes are cleared upon the next visit to an Isuzu dealership.
Scan Tool Diagnostics

A scan tool can be used to read current and history codes and to clear all history codes after a repair is complete. The scan tool must be updated to communicate with the SRS through a replaceable cartridge or a manufacturers update before it can be used for SRS diagnostics. To use the scan tool, connect it to the DLC connector and turn the ignition switch ON. Then follow the manufacturers directions for communication with the SRS. The scan tool reads serial data from the SDM Serial Data output (terminal 24) to the DLC connector (terminal 9).
Basic Knowledge Required

Before using this section of the Service Manual, there is some basic knowledge which will be required. Without this knowledge, you will have trouble using the diagnostic procedures in this section. Use care to prevent harm or unwanted deployment. Read all cautions in the service manual and on warning labels attached to SRS components.
Basic Electrical Circuits

You should understand the basic theory of electricity including series and parallel circuits, and understand the voltage drops across series resistors. You should know the meaning of voltage (volts), current (amps), and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram.
Flash Code Diagnostics

Flash code diagnostics can be used to read active codes and to determine if history codes are present but cannot be used to clear codes or read history codes. Flash code diagnostics is enabled by grounding by terminal 4 shorting to terminal 13 of the DLC connector with the ignition switch ON. Grounding terminal 4 of the DLC connector pulls the Diagnostics Request input (Terminal 1) of the SDM low and signals the SDM to enter the flash code diagnostic display mode.
Diagnostic Codes
The Sensing and Diagnostic Module (SDM) maintains a history record of all diagnostic codes that have been

The SDM displays the trouble codes by flashing the warning lamp. Each code that is displayed will consist of a number of flashes which represents the tens digit, a 1.2 second pause, following by a number of flashes which represents the ones digit of the code. Each code is displayed one time before moving on to the next code. After all of the codes have been displayed, the entire code sequence will continually by repeated until ground is removed from terminal 4 of the DLC connector. Two special codes exist when reading in the flash code mode (Flash Code 12 and Flash Code 13). Flash Code 12 will always be the first code displayed when the flash code mode is enable Code 12 is not an indication of a SRS problem but an indication that the flash code mode has been enabled. If there are no active or history codes present, the SDM will display code 12 until ground is removed from the DLC connector at terminal 4. flash Code 13 will be displayed if history codes are present. To read the history codes a scan tool must be used.
9J13
9J14
System Schematic
D09RW001
SRS Diagnostic System Check

The diagnostic procedures used in this section are designed to find and repair SRS malfunctions. To get the best results, it is important to use the diagnostic charts and follow the sequence listed below: A. Perform the SRS Diagnostic System Check. The SRS Diagnostic System Check must be the starting point of any SRS diagnostics. The SRS Diagnostic System Check checks for proper AIR BAG warning lamp operation, the ability of the SDM to communicate through the Serial Data line and whether SRS diagnostic trouble codes exist. B. Refer to the proper diagnostic chart as directed by the SRS Diagnostic System Check. The SRS Diagnostic System Check will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis and incorrect parts replacement. C. Repeat the SRS Diagnostic System Check after any repair or diagnostic procedures have been preformed. Performing the SRS Diagnostic System Check after all repair or diagnostic procedures will ensure that the repair has been made correctly and that no other malfunctions exist
Circuit Description
When the ignition switch is first turned ON, Ignition 1 voltage is applied from the C21 fuse to the SDM at the Ignition 1 input terminals 12. The SDM responds by flashing the AIR BAG warning lamp seven times, while performing tests on the SRS.
Notes On System Check Chart:

1. The AIR BAG warning lamp should flash seven times after ignition is first turned ON. 2. After the AIR BAG warning lamp flashes seven times, it should turn OFF 3. This test checks for the proper operation of the Serial Data line. This test will also determine whether history diagnostic trouble codes are stored and, if so, identify them. 4. Improper operation of the AIR BAG warning lamp is indicated. This test differentiates a warning lamp stays ON condition from a warning lamp does not come ON condition. 5. This test checks for proper operation of the Serial Data line. This test will also identify the stored diagnostic trouble codes and whether they are current or history.
Diagnostic Aids:
The order in which diagnostic trouble codes are diagnosed is very important. Failure to diagnose the

diagnostic trouble codes in the order specified may result
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in extended diagnostic time, incorrect diagnosis and incorrect parts replacement.
SRS Diagnostic System Check

Step 1 2 3 Action Note the Air Bag warning lamp as ignition switch is turned ON. Does the AIR BAG warning lamp flash seven (7) times? Note the AIR BAG warning lamp after it flashed 7 times. Does the AIR BAG warning lamp go OFF? Note the AIR BAG warning lamp as ignition switch is turned ON. Does the AIR BAG warning lamp come ON steady? 4 1. Note the AIR BAG warning lamp as that ignition switch is turned ON. Ignition switch OFF. 2. Connect a scan tool to data link connector. 3. Follow direction given in the scan tool instruction manual. Ignition switch ON. 4. Request the SRS diagnostic trouble code display, recode all history diagnostic trouble code(s). specify as such, on repair order Is (are) diagnostic trouble code(s) displayed? Go to Chart B Ignition switch OFF When DTC 71 is set, go to DTC 71 Chart For all other history codes refer to Diagnostic Aids For that specific DTC A history DTC indicates the malfunction has been repaired or is intermittent Ignition switch OFF When DTC 53 is set, go to DTC 53 chart When DTC 51 is set, go to DTC 51 chart When DTC 19 is set, go to DTC 19 chart When DTC 25 is set, go to DTC 25 chart Diagnose remaining current DTCs from lowest to highest. When only history DTCs exist, refer to Diagnostics Aids for that specific DTC A history DTC indicates the malfunction has been repaired or is intermittent Go to Chart C Go to Step 4 Go to Step 5 Go to Step 2 Go to Step 3 Yes No
SRS is functional and free of malfuncitons, no further diagnosis is required If scan tool indicated NO DATA RECEIVED, refer to chassis electrical section8
1. 2. 3. 4. 5.
Ignition switch OFF. Connect a scan tool to data link connector. Follow directions as given in the scan tool instruction manual. Ignition switch ON. Request the SRS diagnostic trouble code display, Recode all diagnostic trouble code(s), specifying as current or history on repair order.
Is (are) diagnostic trouble code (s) displayed?
If scan tool indicates No Data Received, refer to chassis electrical section8
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Chart A SDM Integrity Check
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When the SDM recognizes Ignition 1 voltage, applied to terminals 12, is greater than 9 volts, the AIR BAG warning lamp is flashed 7 times to verify operation. At this time the SDM performs TurnON tests followed by Continuous Monitoring tests. When a malfunction is detected, the SDM sets a current diagnostic trouble code and illuminates the AIR BAG warning lamp. The SDM will clear current diagnostic trouble codes and move them to a history file when the malfunction is no longer detected and/or the ignition switch is cycled, except for DTCs 19, 25, 51, 53 and 71. DTC 71 can only be cleared using a scan tool Clear Codes command. If DTCs 51, 53 are not indicated then DTC 71 is not existing. DTCs 51, 53 and 71 can not be cleared after a Clear Codes command is issued.
Chart Test Description:

Number(s) below refer to step number(s) on the diagnostic chart: 1. This test confirms a current malfunction. If no current malfunction is occurring (history DTC set) the Diagnostic Aids for the appropriate diagnostic trouble code should be referenced. The SDM should not be replaced for a history diagnostic trouble code. 2. This test checks for a malfunction introduced into the SRS during the diagnostic process. It is extremely unlikely that a malfunctioning SDM would cause a new malfunction to occur during the diagnostic process. 3. When all circuitry outside the SDM has been found to operate properly, as indicated by the appropriate diagnostic chart, then and only then should the SDM be replaced.
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Chart A SDM Integrity Check

WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. Step 1 Action 1. This chart assumes that the SRS Diagnostic System Check and either a symptom chart or a diagnostic trouble code chart diagnosis have been performed. When all circuitry outside the SDM has been found to operate properly, as indicated by the appropriate diagnostic chart, and the symptom or DTC remains current, the following 2. Diagnostic procedures must be performed to verify the need for SDM replacement. 3. Ignition switch OFF. 4. Reconnect all SRS components, ensure all components are properly mounted. 5. Ensure the ignition switch has been OFF for at least 15 seconds. 6. Note AIR BAG warning lamp as ignition switch is turned ON. Does warning lamp flash 7 times then go OFF? 2 Using a scan tool request diagnostic trouble code display. Is the same symptom or DTC occurring as was when the SRS Diagnostic System Check was first performed? Go to Step 3 3 1. Clear SRS Diagnostic Trouble Codes. 2. Ignition switch OFF for at least two minutes. 3. Note AIR BAG warning lamp as ignition switch is turned ON. Does warning lamp flash 7 times then go OFF? 4 Reconnect all SRS components, ensure all components are properly mounted. Was this step finished? SRS is functional and free of malfunctions No further diagnosis is required Go to Step 4 Repeat the SRS Diagnostic System Check Yes No
The symptom or DTC is no longer occurring Clear SRS diagnostic trouble codes Repeat SRS Diagnostic System Check
Go to Step 2 Ignition switch OFF Go to the appropriate chart for the indicated malfunction
Ignition switch OFF Replace SDM Go to Step 4
Go to Step 4
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Chart B AIR BAG Warning Lamp Comes ON Steady
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When the ignition switch is first turned ON, Ignition 1 voltage is applied from the C10 fuse to AIR BAG, warning lamp which is connected to SRS Warning Lamp, terminal 7. The C21 fuses apply system voltage to the Ignition 1 inputs, terminals 12. The SDM responds by flashing the AIR BAG warning lamp 7 times. If Ignition 1 is less than 9 volts, the AIR BAG warning lamp will come ON solid with no DTCs set.
Chart Test Description:

Number(s) below refer to step number(s) on the diagnostic chart. 2. This test checks for an open in the Ignition 1 circuit to the SDM. 3. This test checks for the voltage of IGNITION 1. 4. This test determines whether the malfunction is a short to ground in CKT IB04WHT/RED.
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Chart B AIR BAG warning lamp comes ON Steady

Step 1 Action 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Ignition switch OFF. 3. Connect scan tool to data link connector, follow directions as given in the scan tool instruction MANUAL. 4. Ignition switch ON. 5. Request SRS diagnostic trouble code display. Dose scan tool indicate No Data Received? 2 1. Ignition switch OFF. 2. Inspect SDM harness connector connection to SDM. Is it securely connected to the SDM? Ignition switch OFF Replace SDM Go to Step 5 Go to Step 2 Go to Step 3 Connect SDM securely to deactivate shorting clip in SDM harness connector Go to Step 5 Ignition switch OFF Replace SDM Go to Step 5 Yes No
Using scan tool, request SRS data list. Is ignition more than 9 volts? Go to Step 4
1. Ignition switch OFF. 2. Disconnect SRS coil and passenger air bag assemblies. yellow 2pin connector located at base of steering column and behind the glove box assembly. Disconnect SDM. 3. Disconnect the connector of SRS Warning Lamp of instrument cluster. 4. Measure resistance from SDM harness connector terminal 6 to ground. Does J39200 display OL (Infinite)? Go to Chart A Repeat the SRS Diagnostic System Check Reconnect all SRS components, ensure all components are properly mounted. Was this step finished?
Replace SRS harness Go to Step 5
Go to Step 5
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Chart C AIR BAG Warning Lamp Does Not Come ON Steady (1/2)
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When the ignition switch is first turned ON, Ignition 1 voltage is applied from the C10 fuse to the AIR BAG warning lamp which is connected to SRS Warning Lamp, terminal 7. The C21 fuse apply system voltage to the Ignition 1 inputs, terminals 12. The SDM responds by flashing the AIR BAG warning lamp seven times. If Ignition 1 is more than 16 volts, the AIR BAG warning lamp will be still OFF solid with no DTCs set.
Chart Test description:

Number(s) below refer to step number(s) on the diagnostic chart: 1. This test decides whether power is available to SDM warning lamp power feed circuit.
2. This test determines whether the voltage is present in the warning lamp circuit. 3. This test determines if the malfunction is in the instrument cluster. 4. This test checks for open in the warning lamp circuitry. 5. This test isolates the IB04WHT/RED circuit and checks for a short in the IB04WHT/RED circuit to B+. 8. This test checks for a short from the SDM warning lamp power feed circuit to ground. 9. This test determines whether the short to ground is due to a short in the wiring.
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Chart C AIR BAG Warning Lamp Does Not Come ON Steady

Step 1 Action 1. When measurements are requested in this chart,use J39200 DVM with correct terminal adapter from J35616A. 2. Ignition switch OFF. 3. Remove and inspect C10 fuse to the AIR BAG warning lamp. Is fuse good? 2 1. Ignition switch OFF. 2. Disconnect SRS coil and passenger air bag assemblies. Yellow 2pin connector located at base of steering column and behind the glove box assembly. 3. Disconnect SDM. 4. Ignition switch ON. 5. Measure voltage on SDM harness connector from terminal 7 to terminal 6 (ground). Is system voltage present on terminal 7? 3 1. Ignition switch OFF. 2. Remove instrument meter cluster. 3. Check for proper connection to instrument cluster at IB04WHT/RED terminal. 4. If ok, then remove and inspect AIR BAG bulb. Is bulb good? 4 1. 2. 3. 4. Ignition switch OFF. Disconnect instrument meter cluster harness connector. Ignition switch ON. Measure voltage on SDM harness connector from terminal 7 to terminal 6 (GROUND). Go to Chart A Service instrument meter cluster Install instrument meter cluster Go to Step 6 Repeat the SRS Diagnostic System Check Go to Step 8 Install C10 fuse Go to Step 10 Go to Step 5 Go to Step 4 Go to Step 3 Go to Step 2 Go to Step 7 Yes No
Replace bulb Go to Step 6
Is voltage 1 volt or less? 5 1. Install bulb. 2. Measure resistance from instrument meter cluster harness connector IB04WHT/RED terminal to SDM harness connector terminal 7. Is resistance 5.0 ohms or less? 6 Reconnect all SRS components, ensure all components are properly mounted. Was this step finished? 7 8 Perform chart C. Was this step finished? 1. Replace C10 fuse. 2. Ignition switch ON wait 10 Seconds then ignition switch Off. 3. Remove and inspect C10 fuse. Is fuse good?
Go to Step 9
Chart C AIR BAG Warning Lamp Does Not Come ON Steady (Contd)
Step 9 Action 1. Disconnect SRS coil and passenger air bag assemblies. Yellow 2pin connector located at base of steering column and behind the glove box assembly. 2. Disconnect SDM. 3. Replace C10 fuse. 4. Ignition switch ON wait 10 seconds. 5. Ignition switch OFF. 6. Remove and inspection C10 fuse. Is fuse good? 10 Reconnect all SRS components, ensure all components are properly mounted. Was this step finished? Yes No
InstallC10 fuse Go to Chart A Repeat the SRS Diagnostic System Check
Replace SRS harness Replace C10 fuse Go to Step 10
Go to Step 10
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DTC 15 Passenger Deployment Loop Resistance High
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When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM then proceeds with the Resistance Measurement Test. Passenger Bag Low terminal 16 is grounded through a resister and the passenger current source connected to Passenger Bag High terminal 15 allows a known amount of current to flow. By monitoring the voltage difference between Passenger Bag High and Passenger Bag Low the SDM calculates the combined resistance of the passenger air bag assembly, harness wiring CKTs IB07YEL/GRN and IB08YEL/RED connector terminal contact.
Action Taken:
SDM turns ON the AIR BAG warning lamp and sets a diagnostic trouble code.
DTC Will Clear When:

The ignition switch is turned OFF.
DTC Chart Test Description:

Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies proper connection of the yellow 2pin connector. 4. This test checks for proper contact and/or corrosion of the yellow 2pin connector terminals. 5. The test checks for a malfunctioning passenger air bag assembly. 6. This test determines whether the malfunction is due to high resistance in the wiring.
DTC Will Set When:

The combined resistance of the passenger air bag assembly, harness wiring CKTs IB07YEL/GRN and IB08YEL/RED, and connector terminal contact is above a specified value. This test is run once each ignition cycle during the Resistance Measurement Test when: 1. No higher priority faults are detected during TurnON, 2. Ignition 1 voltage is in the specified value.
Diagnostic Aids:
An intermittent condition is likely to be caused by a poor connection at the passenger air bag assembly harness connector terminals 1 and 2, SDM terminal 15 and 16, or a poor wire to terminal connection in CKTs IB07YEL/GRN and IB08YEL/RED. This test for this diagnostic trouble code is only run while the AIR BAG

warning lamp is performing the bulb check, unless DTC 17 or DTC 26 is detected. When a scan tool Clear Codes command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.
DTC 15 Passenger Deployment loop Resistance High

Step 1 Action Was the SRS Diagnostic System Check Performed? Go to Step 2 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Use scan tool data list function, read and record the passenger deployment loop resistance. Is passenger resist. more than 2.9 ohms? 3 1. Ignition switch Off. 2. Make sure the passenger air bag assembly yellow 2pin connector located behind the glove box assembly is seated properly. Is the yellow 2pin connector connected properly? 4 1. Disconnect and inspect the passenger air bag assembly yellow 2pin connector located behind the glove box assembly. 2. If ok, reconnect the passenger air bag assembly 2pin connector. 3. Ignition switch ON. Is DTC 15 current? 5 1. Ignition switch Off. 2. Disconnect SRS coil and passenger air bag assembly, yellow 2pin connector located at the base of the steering column and behind the glove box assembly. 3. Connect J41433 SRS driver / passenger load tool and appropriate adapters to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch ON. Is DTC 15 Current? 6 1. Ignition switch Off. 2. There has been an increase in the total circuit resistance of the passenger inflator deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTS IB07YEL/GRN and IB08YEL/RED, and SDM connector terminal 15 and 16 to locate the root cause. Was a fault found? 7 1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was This step finished? Go to Step 6 Go to Step 5 Go to Step 7 Go to Step 4 Go to Step 3 Go to Chart A Seat passenger Air Bag assembly yellow 2pin connector properly Go to Step 7 Yes No Go to The SRS Diagnostic System Check
Ignition switch Off Replace the passenger air bag assembly Go to Step 7
Replace SRS harness Go to Step 7 Repeat the SRS Diagnostic System Check
Go to Chart A
Go to Chart 7
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DTC 16 Passenger Deployment loop Resistance Low
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When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM then proceeds with the Resistance Measurement Test. Passenger Bag Low terminal 16 is grounded through a resistor and the passenger current source connected to Passenger Bag High terminal 15 allows a known amount of current to flow. By monitoring the voltage difference between Passenger Bag High and Passenger Bag Low, the SDM calculates the combined resistance of the passenger air bag assembly, harness wiring CKTs IB07YEL/GRN and IB08YEL/RED connector terminal contact.
Action Taken:


Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies connection of the yellow 2pin connector. 4. This test cheeks for proper operation of the shorting clip in the yellow 2pin connector. 5. The test checks for a malfunction passenger air bag assembly. 6. This test determines whether the malfunctioning is due to shortening in the wiring.
DTC Will Set When:

The combined resistance of the passenger air bag assembly, harness wiring CKTs IB07YEL/GRN and IB08YEL/RED, and connector terminal contact is above a specified value. This test is run once each ignition cycle during the Resistance Measurement Test when: 1. No higher priority faults are detected during TurnON, 2. Ignition 1 voltage is in the specified value.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short between CKTs IB07YEL/GRN and IB08YEL/RED, or a malfunctioning shorting clip on the passenger air bag assembly which would require replacement of the air bag assembly. The test for this diagnostic trouble code is only run while AIR BAG warning lamp is performing the bulb

check, unless DTC 17 or DTC 26 is detected. When a scan tool Clear Codes command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.
DTC 16 Passenger Deployment loop Resistance Low

Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Using scan tool data list function, read and record the passenger deployment loop resistance. Is passenger resist. less than 1.4 ohms? 3 1. Ignition switch Off. 2. Make sure the passenger air bag assembly yellow 2pin connector located behind the glove box assembly is seated properly. Is the yellow 2pin connector connected properly? 4 1. Disconnect and inspect the passenger air bag assembly yellow 2pin connector located behind the glove box assembly. 2. If ok, reconnect the passenger air bag assembly 2pin connector. 3. Ignition switch ON. Is DTC 16 Current? 5 1. Ignition switch Off. 2. Disconnect SRS coil and passenger air bag assembly, yellow 2pin connector located at the base of the steering column and behind the glove box assembly. 3. Connect J41433 SRS driver/passenger load tool and appropriate adapters to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch ON. Is DTC 16 current? 6 1. Ignition switch Off. 2. There has been a decrease in the total circuit resistance of the passenger inflator deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTS IB07YEL/GRN and IB08YEL/RED, and SDM connector terminal 15 and 16 to locate the root cause. Was a fault found? 7 1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished? Go to Step 6 Go to Step 5 Go to Step 7 Go to Step 4 Go to Step 3 Go to Chart A Seat passenger air bag assembly yellow 2pin connector properly Go to Step 7 Yes No Repeat the SRS Diagnostic System Check
Replace SRS harness Go to Step 7 Repeat the SRS Diagnostic System Check
Go to Chart A
Go to Step 7
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DTC 17 Passenger Deployment Loop Open
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When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. During Continuous Monitoring diagnostics, a fixed amount of current is flowing in the deployment loop. This produces proportional voltage drops in the loop. By monitoring the voltage difference between Passenger Bag High and Passenger Bag Low, the SDM calculates the combined resistance of the passenger air bag assembly, harness wiring CKTs IB07YEL/GRN AND IB08YEL/RED, and connector terminal contact.
below a specified value for 500 milliseconds during Continuous Monitoring.

Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies proper connection of the yellow 2pin connector. 4. This test cheeks for proper contact and/or corrosion of the shorting clip in the yellow 2pin connector terminals. 5. The test checks for a malfunctioning passenger air bag assembly. 6. This test determines whether the open in the wiring.
DTC Will Set When:

The voltage difference between Passenger Bag High terminal 15 and Passenger Bag Low terminal 16 is above or equal to a specified value for 500 milliseconds during Continuous Monitoring.
Diagnostic Aids:
An intermittent condition is likely to be caused by a poor connection at the passenger air bag assembly harness connector terminals1 and 2, SDM terminals 15 and 16, or an open in CKT IB07YEL/GRN and IB08YEL/RED.
Action Taken:

The voltage difference between Passenger Bag High terminal 15 and Passenger Bag Low terminal 16 is
DTC 17 Passenger Deployment Loop Open

Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Using scan tool data list function, read and record the passenger differential voltage. Is passenger VDIF. 0.4 volts or more? 3 1. Ignition switch OFF. 2. Make sure the passenger air bag assembly yellow 2pin connector located behind the glove box assembly is seated properly. Is the yellow 2pin connector connected properly? 4 1. Disconnect and inspect the passenger air bag assembly yellow 2pin connector located behind the glove box assembly. 2. If ok, reconnect the passenger air bag assembly 2pin connector. 3. Ignition switch ON. Is DTC 17 current? 5 1. Ignition switch Off. 2. Disconnect SRS coil and passenger air bag assembly, yellow 2pin connector located at the base of the steering column and behind the glove box assembly. 3. Connect J41433 SRS driver / passenger load tool and appropriate adapters to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch ON. Is DTC 17 current? 6 1. Ignition switch Off. 2. There has been an open circuit resistance in the passenger deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTS IB07YEL/GRN and IB08YEL/RED, and SDM connector terminal 15 and 16 to locate the root cause. Was a fault found? 7 1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished? Go to Step 6 Go to Step 5 Go to Step 7 Go to Step 4 Go to Step 3 Go to Chart A Seat passenger air bag assembly yellow 2pin connector properly Go to Step 7 Yes No Go to the SRS Diagnostic System Check
Replace SRS harness Go to Step 7 Go to the SRS Diagnostic System Check
Go to Chart A
Go to Step 7
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DTC 18 Passenger Deployment Loop Short To Ground
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When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM monitors the voltages at Driver Bag Low terminal 4 and Passenger Bag Low terminal 16 to detect short to ground in the air bag assembly circuits.

Number(s) below refer to circled number(s) on the diagnostic chart. 2. This test determines whether the SDM is malfunctioning. 3. This test isolates the malfunction to one side of the passenger air bag assembly yellow 2pin connector behind glove box compartment. 4. This test determines whether the malfunction is in CKT IB07YEL/GRN. 5. This test determines whether the malfunction is in CKT IB08YEL/RED.
DTC Will Set When:

Neither of the two air bag assemblies is open. Ignition 1 is within the normal operating voltage range. Once these conditions are met and the voltage at Passenger Bag Low is below a specified value, DTC 18 will set. This test is run once each ignition cycle and Continuous Monitoring.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short to ground in the passenger air bag assembly circuit. Inspect CKTs IB07YEL/GRN and IB08YEL/RED carefully for cutting or chafing. If the wiring pigtail of the passenger air bag assembly is damaged, the component must be replaced.
Action Taken:

This malfunction is no longer occurring and the ignition switch is turned OFF.
DTC 18 Passenger Deployment Loop Short To Ground

Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Ignition switch OFF. 3. Connect scan tool data link connector. follow directions as given in the scan tool operators MANUAL. 4. Ignition switch ON. 5. Read passenger sense LO. Is passenger sense LO less than 1.5 volts? 3 1. Ignition switch OFF. 2. Disconnect passenger air bag assembly yellow 2pin connector behind the glove box assembly. 3. Leave driver air bag assembly connected. 4. Connect SRS driver / passenger load tool J41433 and appropriate adapter to passenger air bag assembly harness connector. 5. Ignition switch ON. Is DTC 18 current? 4 1. Ignition switch OFF. 2. Disconnect SRS driver / passenger load tool 3. Measure resistance on SDM harness connector from terminal 15 to terminal 16 (ground). Does J39200 display OL (Infinite)? 5 Measure resistance on SDM harness connector from terminal 16 to terminal 6 (ground). Does J39200 display OL (Infinite)? 6 1. Reconnect all components and ensure all component are Properly Mounted. 2. Clear diagnostic trouble codes. Was this step finished? Go to Chart A Go to the SRS Diagnostic system check Go to Step 5 Go to Step 4 Go to Step 3 Go to Chart A Yes No Go to the SRS Diagnostic System Check
Ignition switch OFF Replace passenger air bag assembly Go to Step 6
Replace SRS Harness Go to Step 6 Replace SRS Harness Go to Step 6
Go to Step 6
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DTC 19 Passenger Deployment Loop Short To Voltage
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When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM monitors the voltages at Driver Bag Low terminal 4 and Passenger Bag Low terminal 16 to detect short to B+ in the air bag assembly circuits.

Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test isolates the malfunction to one side of the passenger air bag assembly yellow 2pin connector behind glove box assembly. 4. This test determines whether the malfunction is in CKT IB07YEL/GRN. 5. This test determines whether the malfunction is in CKT IB08YEL/RED.
DTC Will Set When:

Ignition 1 is within the normal operating voltage range. Once these conditions are met and the voltage at Passenger Bag Low is above a specified value, DTC 19 will set. This test is run once each ignition cycle and Continuous Monitoring.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short to B+ in the passenger air bag assembly circuit. Inspect CKTs IB07YEL/GRN and IB08YEL/RED carefully for cutting or chafing. If the wiring pigtail of the passenger air bag assembly is damaged, the component must be replaced. A careful inspection of CKT IB07YEL/GRN and IB08YEL/RED, including the passenger air bag assembly pigtail is essential to ensure that the replacement SDM will not be damaged.
Action Taken:
SDM turns ON the AIR BAG warning lamp and sets DTC 19 and also DTC 71.

The SDM is replaced.
DTC 19 Passenger Deployment Loop Short To Voltage

CAUTION: When DTC 19 has been set, it is necessary to replace the SDM. Setting DTC 19 will also cause DTC 71 to set. When a scan tool CLEAR CODES command is issued and the malfunction is no longer present, DTC 71 will remain current. Ensure that the short to voltage condition is repaired prior to installing a replacement SDM to avoid damaging the SDM. Step 1 Action Perform the SRS Diagnostic System Check. Was the SRS Diagnostic System Check performed? 2 1. When measurements are requested in this chart use J39200 DVM With correct terminal adapter from J35616A. 2. Ignition switch OFF. 3. Connect scan tool data link connector. follow directions as given in the scan tool operators manual. 4. Ignition switch ON. 5. Read passenger sense LO. Is passenger sense LO more than 3.5 volts? 3 1. Ignition switch OFF. 2. Disconnect passenger air bag assembly yellow 2pin connector behind the glove box assembly. 3. Leave driver air bag assembly connected. 4. Connect SRS driver / passenger load tool J41433 and appropriate adapter to passenger air bag assembly harness connector. 5. Ignition switch ON. Is passenger sense LO more than 3.5 volts? 4 1. 2. 3. 4. Ignition switch OFF. Disconnect SDM. Disconnect SRS driver / passenger load tool. Measure resistance on SDM harness connector from terminal 15 to terminal 12 (ignition). Go to Step 5 Go to Step 4 Go to Step 3 Go to chart A Go to Step 2 Yes No Repeat the SRS Diagnostic System Check
Ignition switch OFF Replace passenger air bag assembly Go to Step 6
Does J39200 display OL (infinite)? 5 Measure resistance on SDM harness connector from terminal 16 and terminal 12 (ignition). Does J39200 display OL (infinite)? 6 1. Reconnect all components ensure all component are properly mounted. 2. Ignition switch ON. Is passenger senslo less than 3.5 volts? 7 1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?
Replace SRS harness Go to Step replace SRS harness Go to Step 6
Go to Chart A Ignition switch OFF Replace SDM Go to Step 7 Repeat the SRS Diagnostic System Check
Go to Chart A
Go to Step 7
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DTC 21 Driver Deployment Loop Resistance High
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When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM then proceeds with the Resistance Measurement Test Driver Bag Low terminal 4 is grounded through a current sink and the driver current source connected to Driver Bag High terminal 3 allows a known amount of current to flow. By monitoring the voltage difference between Driver Bag High and Driver Bag Low, the SDM calculates the combined resistance of the driver air bag assembly, SRS coil assembly, harness wiring CKTs IB05YEL and IB06YEL/BLK, and connector terminal contact.
Action Taken:
SDM turns ON the AIR BAG warning lamp and sets DTC 21.


Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies proper connection of the yellow 2pin connector at the base of the steering column. 4. This test checks for proper contact and/or corrosion of the 2pin connector terminals at the base of steering column. 5. This test isolate the malfunction to one side of the SRS coil assembly yellow 2pin connector located at the base of the steering column. 6. This test determines whether the malfunction is due to high resistance in the wiring. 7. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.
DTC Will Set When:

The combined resistance of the driver air bag assembly, SRS Coil assembly, harness wiring CKTs IB05YEL and IB06YEL/BLK, and connector terminal contact is above a specified value. This test run once each ignition cycle during the Resistance Measurement Test when: 1. No higher priority faults are detected during TurnON 2. Ignition 1 voltage is in the specified value.
Diagnostic Aids:
An intermittent condition is likely to be caused by a poor connection at terminals 1 and 2 of the SRS coil 2pin connector at the base of the steering column, terminal 1 and 2 of the driver air bag assembly 2pin connector at the top of the steering column, SDM terminals 3 and 4 or a poor wire to terminal connection in CKT IB05YEL or
IB06YEL/BLK. The test for this diagnostic trouble code is only run while the AIR BAG warning lamp is performing the bulb check, unless DTC 17 or DTC 26 is detected. When a scan tool Clear Codes command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.
DTC 21 Driver Deployment Loop Resistance High

Step 1 Action Perform the SRS Diagnostic System Check. Was the SRS Diagnostic System Check performed? 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Use scan tool data list function, read and record the driver deployment loop resistance. Is driver resistance more than 3.7 ohms? 3 1. Ignition switch OFF. 2. Disconnect SRS coil assembly yellow 2pin connector located at base of steering column is seated properly. Is the 2pin connector connected properly? 4 1. Disconnect and inspect the SRS coil assembly yellow 2pin connector located base of steering column. 2. If ok, reconnect the SRS coil assembly yellow 2Pin connector. 3. Ignition switch ON. Is DTC 21 current? 5 1. Ignition switch OFF. 2. Disconnect SRS coil and passenger air bag assembly, yellow 2pin connector located at the base of steering column and behind the glove box assembly. 3. Connect SRS driver / passenger load tool J41433 and appropriate adapter to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch ON. Is DTC 21 current? 6 1. Ignition switch Off. 2. There has been a increase in the total circuit resistance of the driver deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTS IB05YEL and IB06YEL/BLK, and SDM connector terminal 3 and 4 to locate the root cause. Was a fault found? Go to Step 6 Go to Step 7 Go to Step 5 Go to Step 8 Go to Step 4 Go to Step 3 Go to Chart A Seat SRS coil assembly 2pin connector properly Go to Step 8 Go to Step 2 Yes No Repeat the SRS Diagnostic System Check
Go to Chart A
9J125
DTC 21 Driver Deployment Loop Resistance High (Contd)

Step 7 Action 1. Ignition switch OFF. 2. Disconnect SRS driver / passenger load tool from SRS coil assembly harness connector. 3. Connect SRS driver / passenger load tool J41433 on the top of steering column. 4. Reconnect SRS coil assembly harness connector as the base of steering column. 5. Ignition switch ON. Is DTC 21 current? 8 1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished? Yes No
Ignition switch OFF Replace SRS coil assembly Go to Step 8 Repeat the SRS Diagnostic System Check
Ignition switch OFF Replace driver air bag assembly Go to Step 8
Go to Step 8
DTC 22 Driver Deployment Loop Resistance Low
D09RW001
When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM then proceeds with the Resistance Measurement Test Driver Bag Low terminal 4 is grounded through a current sink and the driver current source connected to Driver Bag High terminal 3 allows a known amount of current to flow. By monitoring the voltage difference between Driver Bag High and Driver Bag Low the SDM calculates the combined resistance of the driver air bag assembly, SRS coil assembly, harness wiring CKTs IB05YEL and IB06YEL/BLK and connector terminal contact.
Action Taken:
SDM turns ON the AIR BAG warning lamp and sets DTC 22.


Number(s) below refer to circled number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies proper connection of the yellow 2pin connector at the base of the steering column. 4. This test checks for proper operation of the shorting clip in the yellow 2pin connector. 5. This test isolate the malfunction to one side of the SRS coil assembly yellow 2pin connector located at the base of steering column. 6. This test determines whether the malfunction is due to shortening in the wiring. 7. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.
DTC Will Set When:

The combined resistance of the driver air bag assembly, SRS Coil assembly, harness wiring CKTs IB05YEL and IB06YEL/BLK and connector terminal contact is above a specified value. This test is run once each ignition cycle during the Resistance Measurement Test when: 1. No higher priority faults are detected during TurnON 2. Ignition 1 voltage is in the specified value.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short between CKT IB05YEL or IB06YEL/BLK or a

malfunctioning shorting clip on the driver air bag assembly or SRS coil assembly which would require replacement of the component. The test for this diagnostic trouble code is only run while the AIR BAG warning lamp is performing the bulb check, unless DTC
9J127
17 or DTC 26 is detected. When a scan tool Clear Codes command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.
DTC 22 Driver Deployment Loop Resistance Low

Step 1 Action Perform the SRS Diagnostic System Check. WAS THE SRS Diagnostic System Check performed? 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Use scan tool data list function, read and record the driver deployment loop resistance. Is driver deployment loop resistance less than 1.7 ohms? 3 1. Ignition switch OFF. 2. Make sure the SRS coil assembly yellow 2pin connector located at the base of steering column is seated properly. Is the 2pin connector connected properly? 4 1. Disconnect and inspect the SRS coil assembly yellow 2pin connector located base of steering column. 2. If ok, reconnect the SRS coil assembly yellow 2pin connector. 3. Ignition switch ON. Is DTC 22 current? 5 1. Ignition switch OFF. 2. Disconnect SRS coil and passenger air bag assembly, yellow 2pin connector located at the base of steering column and behind the glove box assembly. 3. Connect SRS driver / passenger load tool J41433 and appropriate adapter to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch ON. Is DTC 22 current? 6 1. Ignition switch OFF. 2. There has been a decrease in the total circuit resistance of the driver deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTS IB05YEL and IB06YEL/BLK, and SDM connector terminal 3 and 4 to locate the root cause. Was a fault found? 7 1. Ignition switch OFF. 2. Disconnect SRS driver / passenger load tool from driver air bag assembly harness connector. 3. Connect SRS driver / passenger load tool J41433 to the top of steering column 2pin connector. 4. Reconnect SRS coil assembly harness connector as the base of steering column. 5. Ignition switch ON. Is DTC 22 current? 8 1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished? Go to Step 6 Go to Step 7 Go to Step 5 Go to Step 8 Go to Step 4 Go to Step 3 Go to Chart A Seat driver air bag assembly 2pin connector properly Go to Step 8 Go to Step 2 Yes No Go to the SRS Diagnostic System Check
Go to Chart A
Ignition switch OFF Replace SRS coil assembly Go to Step 8 Go to the SRS Diagnostic System Check
Go to Step 8
DTC 24 Driver Deployment Loop Short To Ground
D09RW001
When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM monitors the voltage at Driver Bag Low terminal 4 and passenger Bag Low terminal 16 to detect shorts to ground in the air bag assembly circuits.

Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the SDM is malfunctioning 3. This test isolates the malfunction to one side of the SRS coil assembly yellow 2pin connector at the base of the steering column. 4. This test determines whether the malfunction is in CKT IB05YEL. 5. This test determines whether the malfunction is in CKT IB06YEL/BLK. 6. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.
DTC Will Set When:

Neither of the two air bag assemblies is open. Ignition 1 is within the normal operating voltage range. This test is run once each ignition cycle and Continuous Monitoring. Once these conditions are met and the voltage at Driver Bag Low is below a specified value, DTC 24 will set.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short to ground in the driver air bag assembly circuit. Inspect CKTs IB05YEL and IB06YEL/BLK carefully for cutting or chafing.
Action Taken:

The malfunction is no longer occurring and the ignition is turned OFF.
9J129
DTC 24 Driver Deployment Loop Short To Ground

Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. 2. Ignition switch OFF. 3. Connect scan tool data link connector. follow directions as given in the scan tool operators manual. 4. Ignition switch ON. 5. Read driver sense LO. Is driver sense LO less than 1.5 volts? 3 1. Ignition switch OFF. 2. Disconnect SRS coil assembly yellow 2pin connector located at base of the steering column. leave passenger air bag assembly connected. 3. Connect SRS driver / passenger load tool J41433 and appropriate adapter to SRS coil assembly harness connector. 4. ignition switch ON. Is DTC 24 current? 4 1. 2. 3. 4. Ignition switch OFF. Disconnect SDM. Disconnect SRS driver / passenger load tool. Measure resistance on SDM harness connector 3 to terminal 6 (ground). Go to Step 5 Go to Step 4 Go to Step 6 Go to Step 3 Go to Chart A Yes No Go to the SRS Diagnostic System Check
Does J39200 display OL (infinite)? 5 measure resistance on SDM harness connector from terminal 4 to terminal 6 (ground). Does J39200 display OL (infinite)? 6 1. Ignition switch OFF. 2. Disconnect SRS driver / passenger load tool J41433 from SRS coil assembly harness connector. 3. connect SRS driver / passenger load tool J41433 and appropriate adapter J35616A to driver air bag assembly harness connector. located top of the steering column 2pin connector. 4. Reconnect SRS coil assembly harness connector as the base of steering column. 5. Ignition switch ON. Is DTC 24 current? 7 1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?
Replace SRS harness Go to Step 7 Replace SRS harness Go to Step 7
Go to Chart A
Ignition switch OFF Replace SRS coil assembly Go to Step 7 Go to the SRS Diagnostic System Check
Go to Step 7
DTC 25 Driver Deployment Loop Short To Voltage
D09RW001
When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM monitors the voltage at Driver Bag Low terminal 4 and Passenger Bag Low terminal 16 to detect shorts to B+ in the air bag assembly circuits.
DTC Will Set When:

Ignition 1 is in the normal operating voltage range. This test is run once each ignition cycle and Continuous monitoring. Once these conditions are met and the voltage at Driver Bag Low is above a specified value, DTC 25 will set.
2. This test determines whether the SDM is malfunctioning. 3. This test isolates the malfunction to one side of the driver air bag assembly yellow 2pin connector at the base of steering column. 4. This test determines whether the malfunction is in CKT IB05YEL. 5. This test determines whether the malfunction is in CKT IB06YEL/BLK. 6. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short to B+ in the driver air bag assembly circuit. Inspect CKTs IB05YEL and IB06YEL/BLK carefully for cutting or chafing. If the wiring pigtail of the driver air bag assembly and SRS coil assembly is damaged, the components must be replaced. A careful inspection of CKT IB05YEL and IB06YEL/BLK, including the SRS coil assembly and driver air bag assembly is essential to ensure that the replacement SDM will not be damaged.
Action Taken:
SDM turns ON the AIR BAG warning lamp and sets DTC 25 and also DTC 71


Number(s) below refer to step number(s) on the diagnostic chart:
9J131
DTC 25 Driver Deployment Loop Short To Ignition

CAUTION: When DTC 25 has been set, it is necessary to replace the SDM. Setting DTC 25 will also cause DTC 71 to set. When a scan tool CLEAR CODES command is issued and the malfunction is no longer present, DTC 71 will remain current. Ensure that the short to voltage condition is repaired prior to installing a replacement SDM to avoid damaging the SDM. Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 1. When measurements are requested in this chart use J39200 DVM with correct terminal adapter from J35616A. Ignition switch OFF. Connect scan tool data link connector. follow directions as given in the scan tool operators manual. 2. Ignition switch ON. 3. Read driver sense LO . Is driver sense LO more than 3.5 volts? 3 1. Ignition switch OFF. 2. Disconnect SRS coil assembly yellow 2pin connector at the base of the steering column. leave passenger air bag assembly connected. 3. Connect SRS driver /passenger load tool J41433 and appropriate adapter to SRS coil assembly harness connector. 4. Ignition switch ON. Is driver sense LO more than 3.5 volts? 4 1. 2. 3. 4. Ignition switch OFF. Disconnect SDM. Disconnect SRS driver /passenger load tool. Measure resistance on SDM harness connector 3 to terminal 12 (ignition). Go to Step 5 Go to Step 4 Go to Step 6 Go to Step 3 Go to Chart A Yes No Go to the SRS Diagnostic System Check
Does J39200 display OL (infinite)? 5 Measure resistance on SDM harness connector from terminal 4 to terminal 12 (ignition). Does J39200 display OL (infinite)? 6 1. Ignition switch OFF. 2. Disconnect SRS driver / passenger load tool J41433 and appropriate adapter J35616A to driver air bag assembly harness 2-pin connector located at top of the steering column. 3. Reconnect SRS coil assembly harness connector as the base of steering column. 4. Ignition switch ON. Is driver sense LO more than 3.5 volts? 7 1. Reconnect all components, ensure all component are properly mounted. 2. Ignition switch ON. Is passenger senslo less than 3.5 volts? 8 1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?
Replace SRS harness Go to Step 7 Replace SRS harness Go to Step 7
Go to Chart A
Ignition switch OFF Replace SRS coil assembly Go to Step 7 Ignition switch OFF Replace SDM Go to Step 8 Go to the SRS Diagnostic System Check
Go to Chart A
Go to Step 8
DTC 26 Driver Deployment Loop Open
D09RW001
When the ignition switch is turned ON, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, Ignition 1, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. During Continuous Monitoring diagnostics, a fixed amount of current is following in the deployment loop. This produces proportional voltage drops in the loop. By monitoring the voltage difference between Driver Bag High and Driver Bag Low, the SDM calculates the combined resistance of the driver air bag assembly, SRS coil assembly, harness wiring CKTs IB05YEL and IB06YEL/BLK, and connector terminal contact.
specified value for 500 milliseconds during Continuous Monitoring.

Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies proper connection of the yellow 2pin connector at the base of the steering column. 4. This test checks for proper contact and/or corrosion of the yellow 2pin connector at the base of the steering column. 5. This test isolates the malfunction to one side of the SRS coil assembly yellow 2pin connector located at the base of steering column. 6. This test determines whether the open is in the wiring. 7. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.
DTC Will Set When:

The voltage difference between Driver Bag High terminal 3 and Driver Bag Low terminal 4 is above or equal to a specified value for 500 milliseconds during Continuous Monitoring.
Action Taken:
Diagnostic Aids:
An intermittent condition is likely to be caused by a poor connection at the driver air bag assembly harness 2pin connector terminals 1 and 2 at the top of the steering column, SRS coil assembly harness 2pin connection terminals 1 and 2, SDM terminals 3 and 4, or an open in CKTs IB05YEL and IB06YEL/BLK.

The voltage difference between Driver Bag High terminal 3 and Driver Bag Low terminal 4 is below a
9J133
DTC 26 Driver Deployment Loop Open

Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 1. When measurements are requested in this chart use J-39200 DVM with correct terminal adapter from J35616A. 2. use scan tool data list function, read and record the driver differential voltage. Is driver VDIF more than 4 volts? 3 1. Ignition switch OFF. 2. Make sure the SRS coil assembly yellow 2pin connector located at the base of steering column is seated properly. Is the yellow 2pin connector connected properly? 4 1. Disconnect and inspect the SRS coil assembly yellow 2pin connector located base of steering column. 2. If ok, reconnect the SRS coil assembly yellow 2pin connector. 3. Ignition switch ON. Is DTC 26 current? 5 1. Ignition switch OFF. 2. Disconnect SRS coil and passenger air bag assembly, yellow 2pin connector located at the base of steering column and behind the glove box assembly. 3. Connect SRS driver/passenger load tool J41433 and appropriate adapter to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch ON. Is DTC 26 current? 6 1. Ignition switch OFF. 2. there has been an open circuit in the driver inflator deployment loop. 3. use the high resolution ohmmeter mode of the DVM while checking CKTS IB05YEL and IB06YEL/BLK, and SDM connector terminal 3 and 4 to locate the root cause. Was a fault found? 7 1. Ignition switch OFF. 2. Disconnect SRS driver / passenger load tool from SRS coil assembly harness connector. 3. connect SRS driver / passenger load tool J41433 on steering column 2pin connector. 4. Reconnect SRS coil assembly harness connector at the base of steering column. 5. Ignition switch ON. IS DTC 26 CURRENT? 8 1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished? Go to Step 6 Go to Step 7 Go to Step 5 Go to Step 8 Go to Step 4 Go to Step 3 Go to Chart A Seat driver air bag assembly 2pin connector Go to Step 8 Yes No Go to the SRS Diagnostic System Check
Go to Chart A
Ignition switch OFF Replace SRS coil assembly Go to Step 8 Repeat the SRS Diagnostic System Check
Go to Step 8
DTC 51 Deployment Event Commanded
D09RW001
The SDM contains a sensing device which converts vehicle velocity changes to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags and causing DTC 51 to set.
Action Taken:
SDM turns ON the AIR BAG warning lamp records Crash Data, and sets a diagnostic trouble code.


Number(s) below refer to step number(s) on the diagnostic chart: 2. If air bag assembly (s) has not deployed, DTC 51 may have falsely set. 3. If DTC 51 has set with no signs of frontal impact, the diagnostic trouble code has falsely set.
DTC Will Set When:

The SDM detects a frontal crash, up to 30 degrees off the centerline of the vehicle, of sufficient force to warrant deployment of the air bags.
9J135
DTC 51 Deployment Event Commanded

WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 Ignition switch OFF. Have air bag assemblies deployed? Replace components and perform inspections as directed in repairs and inspections required after an accident in this section clear diagnostic trouble codes Repeat SRS Diagnostic System Check Replace components and perform inspections as directed in Repairs and Inspections Required After An Accident in this section Clear diagnostic trouble codes Repeat SRS Diagnostic System Check Yes No Go to the SRS Diagnostic System Check
Go to Step 3
Inspect front of vehicle and undercarriage for sings of impact. Were signs of impact found?
Ignition switch OFF Replace SDM Reconnect all SRS system components, ensure all components are properly mounted Repeat SRS Diagnostic System Check
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range
D09RW001
The SDM contains a sensing drive which converts vehicle velocity changes to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. DTC 53 is set accompanying with DTC 51 when a deployment occurs while an air bag assembly circuit fault is present that could possible result in a no deployment situation in one or both air bag assemblies.
Action Taken:
SDM turns ON the AIR BAG warning lamp records Crash Data, and sets a diagnostic trouble code.

The SDM is replaced. If DTC 53 is set, one or more DTCs will be set in addition to DTC 53. Malfunction(s) setting DTC(s) (other than DTC 71) must be repaired so that DTC(s) will not be set when a new SDM is installed.

Number(s) below refer to step number(s) on the diagnostic chart: 2. If air bag assembly have not deployed, DTC 53 may have falsely set. 3. If DTC 53 has set with no signs of frontal impact, the diagnostic trouble code has falsely set.
DTC Will Set When:

The SDM detects a frontal crash, up to 30 degrees off the centerline of the vehicle, of sufficient force to warrant deployment of the air bags and an inflator circuit fault is present..
9J137
DTC 53 Deployment Commanded WITH Deployment Loop Fault Or Energy Reserves Out Of Range
WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 Ignition switch OFF. Have air bag assembles deployed? Replace components and perform inspections as directed in Repairs And Inspections Required After An Accident in this section Clear diagnostic trouble codes Repeat the SRS Diagnostic System Check Replace components and perform inspections as directed in Repairs And Inspections Required After An Accident in this section Clear diagnostic trouble codes Repeat SRS Diagnostic System Check Yes No Go to the SRS Diagnostic System Check
Go to Step 3
Inspect front of vehicle and undercarriage for signs of impact. Were signs of impact found?
Ignition switch OFF Replace SDM Reconnect all SRS system components, ensure all components are properly mounted Repeat the SRS Diagnostic System Check
DTC 61 Warning Lamp Circuit Failure
D09RW001
When the ignition switch is turned ON, battery voltage is applied to the AIR BAG warning lamp and to the Ignition 1 input terminal 12. The SDM responds by flashing the AIR BAG warning lamp seven times. The SDM monitors the lamp driver output by comparing the output state at SRS Warning Lamp terminal 7 to the microprocessor commanded state. When Ignition 1 is in the specified value, and the output state does not match the commanded state of the lamp driver for 500 milliseconds, DTC 61 is set.
the commanded state of the lamp driver for 500 milliseconds. This test is run every 100 milliseconds during Continuous Monitoring tests and once per each ignition cycle at the beginning.
Action Taken:
SDM attempts to turn ON the AIR BAG warning lamp and sets a diagnostic trouble code.

DTC Will Set When:

Ignition 1 voltage is in the specified value and the output state at the SRS Warning Lamp terminal does not match
Diagnostic Aids:
Refer to Charts B and C to diagnose warning lamp circuit malfunctions.
9J139
DTC 61 Warning Lamp Circuit Failure

Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 1. Malfunctions within the AIR BAG warning lamp circuitry will set this diagnostic trouble code. 2. These malfunctions are addressed in the SRS Diagnostic System Check via Chart B and Chart C. 3. Failure to properly perform the SRS Diagnostic System Check may result in misdiagnosis. 4. Ignition switch ON. 5. Clear SRS diagnostic trouble codes. IS DTC 61 set? Yes No Go to the SRS Diagnostic System Check.
Ignition switch OFF. Go to Chart A.
Repeat the SRS Diagnostic System Check.
DTC 71 Internal SDM Fault
D09RW001
DTC 71 is an indication of a potential internal SDM malfunction and will set if any of the following conditions are detected: 1) Deployment or microprocessor energy reserve failure. 2) EEPROM failure. 3) ROM failure. 4) RAM failure. 5) Calibration check sum failure. 6) Deployment switch faults. 7) Accelerometer fault. 8) Arming sensor fault. 9) Diagnostic current faults. 10) DTC 19 11) DTC 25 12) DTC 51 13) DTC 53
DTC Will Set When:

Any of the above indicated malfunctions are detected by the SDM. The malfunctions described above are tested mainly during Continuous Monitoring and some ones run each ignition cycle.
Action Taken:

A scan tool Clear Codes commanded is received by the SDM. Some of the indicated malfunctions will only allow the AIR BAG warning lamp to go out. But when DTC 19, 25, 51, 53 are also set, SDM is replaced.
9J141
DTC 71 Internal SDM Fault

WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. CAUTION: When DTC 19 or 25 has been set, it is necessary to replace the SDM. Setting DTC 19 and 25 or 51 or 53 will also cause DTC 71 to set. When a scan tool CLEAR CODES command is issued and the malfunction is no longer present, DTC 51 or 53 and DTC 71 will remain current. Ensure that the short to voltage condition DTC 19, 25 is repaired prior to installing a replacement SDM to avoid damaging the SDM. Step 1 Action Was the SRS Diagnostic System Check performed? Go to Step 2 2 Note SRS Diagnostic System Check. Is DTC 19 or 25 or 51 or 53 also set (CURRENT OR HISTORY)? (refeer to notice above.) Go to DTC 19 if DTC 19 is set Go to DTC 25 if DTC 25 is set Go to DTC 51 if DTC 51 is set Go to DTC 53 if DTC 53 is set Yes No Go to the SRS Diagnostic System Check
Ignition switch OFF Replace SDM Repeat the SRS Diagnostic System Check
SECTION
CRUISE CONTROL SYSTEM
TROOPER
10A1
CONTROL SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A1 10A1 10A2 10A2 10A2 10A3 10A3 10A3 10A3 10A4 10A4 10A4 Cruise Control Main Switch . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise Control Switch (Combination Switch) Removal and Installation . . . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic trouble cade . . . . . . . . . . . . . . . . 10A5 10A5 10A5 10A5 10A5 10A5 10A5 10A5 10A5 10A6 10A6
Service Precaution
General Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received . When the main switch AUTO CRUISE is turned on with the vehicle in the running mode, the battery voltage is applied to the control unit. When a signal from the control switch is input to the PCM while the vehicle is in this state, the cruise control system is activated. Also, while the system is operating, the AUTO CRUISE indicator light in the meter assembly lights up.
1. SET/COAST Switch Function

1. Set Function: When the SET/COAST switch is pressed and released with the main switch on, the speed at which the vehicle is running at that moment is stored in the memory, and the vehicle automatically runs at the stored speed. 2. Coast-down Function: When the SET/COAST switch is kept on while the vehicle in running, the vehicle decelerates during that time. The speed at which vehicle is running when the control switch is turned off is stored in the memory, and the vehicle automatically returns to the stored speed. 3. Tap-down Function: When the SET/COAST switch is turned on and off instantaneously while the vehicle is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the vehicle was running when the SET/COAST was turned off last is stored in the memory, and the vehicle automatically returns to this stored speed.
10A2 CRUISE CONTROL SYSTEM
2. RESUME/ACCEL Switch Function

1. Resume Function: When the RESUME/ACCEL switch is turned on/off after the system is temporarily deactivated by pressing the brake or clutch pedal while the vehicle is running, the vehicle resumes the speed stored before the system was released, and the vehicle automatically runs at the stored speed . 2. Accelerate Function: When the RESUME/ACCEL switch is kept on after the system is released completely, the vehicle accelerates its speed during that time. The vehicle speed at which the vehicle was running when the switch was turned off is stored in the memory, and the vehicle automatically returns to this speed. 3. Tap-up Function: When the RESUME/ACCEL switch is turned on and off instantaneously while the vehicle is running, the vehicle accelerates a mile for each on/off operation. The vehicle speed at which the vehicle was running when the switch was turned off last is stored in the memory, and the vehicle automatically returns to this stored speed.
3. CANCEL Function
1. Temporary Cancellation: D When the cancel switch is turned on. D When the brake pedal is pressed. D When the clutch pedal is pressed. (M/T) D When the select lever is shifted to any position other than D, 3, 2. (A/T) D When the cancel switch is operated. D When the vehicle speed exceeds about 12.5mph over the vehicle speed stored in the memory. D Turning the RESUME/ACCEL switch will return the vehicle to the speed stored in the cruise control memory. D When the vehicle speed gets lower than 22.5 mph (36 km/h). 2. Complete Cancellation: D When the starter switch or the main switch is turned off. D When the fail-safe function is activated.
Brake Switch
Removal
1. Disconnect the battery ground cable. 2. Remove the brake switch (1). D Disconnect the connector. D Loosen the lock nuts of the switch. D Remove the switch by turning it.
Installation
To install, follow the removal steps in the reverse order, noting the following points. 1. Check to see if the brake pedal has been returned by the return spring to the specified position. 2. Turn the switch clockwise until the tip of the threaded portion of the brake switch contacts the pedal arm. 3. Turn the switch counterclockwise until the space between the tip of the threaded portion and the pedal arm is 0.5 to 1.0 mm (0.02-0.04 in.) as shown in the figure.
310RS004
310RS003
10A3
Adjustment
1. Check to be sure that the brake pedal (3) has been completely returned by the return spring. 2. Disconnect the switch connector. 3. Loosen the lock nut (1) of the switch (2). 4. Turn the switch clockwise until the tip of screw portion of the brake pedal hits the pedal arm. 5. Turn the switch counterclockwise until the clearance between the tip of the screw portion and the pedal arm becomes 0.5 to 1.0 mm (0.02-0.04 in). 6. Tighten the lock nut. 7. Connect the switch connector.
310RW006
Clutch Switch
Refer to the Clutch Control removal and installation steps in Clutch section.
Adjustment
1. Check to be sure that the clutch pedal (1) has been completely returned by the return spring. 2. Disconnect the switch connector. 3. Loosen the lock nut (2) of the switch (3). 4. Push the switch by hand until the push rod cannot be seen from the tip portion of the switch. 5. Give the switch one reverse rotation. 6. Tighten the lock nut. 7. Connect the switch connector.
203RW002
Starter Switch
Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly (1). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly (2). Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover assembly (3). Refer to the Instrument Panel Assembly in Body Structure section.
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. When installing the steering cowl (10), be sure to pass the harnesses through the route as shown in the figure so that the starter switch harness (7), the combination switch harness (8) and the inflator module harness (9) will not catch.
740R200050
5. Remove seven screws to remove the steering cowl (6). 6. Disconnect the connector, remove the screw (4) and then remove the starter switch (5).
825RW058
431RW005
10A5
Cruise Control Main Switch

Removal
1. Disconnect the battery ground cable. 2. Remove the front console assembly (1). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the lower cluster assembly (2). Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the instrument panel driver lower cover assembly (3). Refer to the Instrument Panel Assembly in Body Structure section. 5. Remove the instrument panel cluster assembly (5). Refer to the Instrument Panel Assembly in Body Structure section. 6. Disconnect the and push the lock from the side of the instrument panel cluster assembly to remove the cruise control main switch (4).
821RW079
Installation
To install, follow the removal steps in the reverse order, noting the following point. 1. Push in the switch with your fingers until the switch is locked securely.
740R200050
Cruise Control Switch (Combination Switch)

Refer to the Lighting Switch (Combination Switch) removal and installation steps of Lighting System in Body and Accessories section.

Refer to Powertrain Control Module (PCM) in Engine section.
Mode Switch
Refer to the Mode Switch removal and installation steps in Automatic Transmission section.
Diagnosis
Diagnostic trouble cade
Cruise control system is controlled by the PCM as well as 6VE1 engine and automatic transmission. DTC codes are stored in the PCM if troubles occur in the circuit. DTC codes categorized type D are shown only by the Tech 2 scan tool. The following chart only shows some typical DTCs for cruise control system. Refer to PCM Diagnostic Trouble Codes in Driveability and Emissions for entire DTC diagnosis. DTC: Diagnostic Trouble Code NOTE: The DTCs are detected while the engine is running

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TABLE OF CONTENTS GENERAL INFORMATION

WORKSHOP MANUAL TROOPER (UX)

1A 2A 3C 3D 3E 4A1 4A2 4B1 4B2 4C 4D1 4D2

This manual applies to 2002 models.

General Repair Instruction

D Gas other than ambient air D Hot air flow

Lubrication point oil or fluid

Lubrication point grease

Lubrication point jelly

Engine Serial Number

Transmission Serial Number

Theft Prevention Standard

Anti Theft Stamping/Plate/Label

Anti Theft Stamping/Label/Plate Location

Manual Transmission (AR5)

Automatic Transmission (THM)

(6) Fender (7) Rear Quarfer Panel (8) Front Bumper

Legend (9) Back Door Left Side

(10) Back Door Right Side (11) Rear Bumper

Body Label Instructions

Lifting Points and Supportable Point Locations

Standard Bolts Torque Specifications

Bolt Diameter Pitch (mm)

Service Parts Identification Plate

Maintenance Schedule List

Severe Driving Conditions

MAINTENANCE AND LUBRICATION

Mileage Only Items

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

Explanation of Complete Maintenance Schedule

Valve Clearance Adjustment

Front and Rear Axle Lubricant Replacement

Front Wheel Bearings Lubricant Replacement

Manual Transmission Lubricant Replacement

Radiator Core and Air Conditioning Condenser Cleaning

Fluid Level Check

Transfer Case Lubricant Replacement

Extension Lubricant Level Check (2WD only)

Air Cleaner Element Replacement

Spark Plug Replacement

Cooling System Service

Timing Belt Replacement

MAINTENANCE AND LUBRICATION

Battery fluid level Check fluid level in the battery.

Fluid Leak Check

Steering System Operation

Engine Oil and Oil Filter Replacement

Brake Systems Operation

Engine Cooling System Inspection

Parking Brake and Transmission Park Mechanism Operation

Exhaust System Inspection

Fuel Cap, Fuel Lines, and Fuel Tank Inspection

Drive Belt Inspection

Starter Safety Switch Operation (Automatic Transmission)

Wheel Alignment, Balance and Tires Operation

Starter Safety Switch Operation (Manual Transmission)