Korando

SECTION INDEX
SERVICE
MANUAL FRONT MATTER 0A
KORANDO GENERAL INFORMATION 0B
ENGINE 1
SUSPENSION 2
FOREWORD DRIVE LINE/AXLE 3
This manual includes procedure for mainte-

nance, adjustment, service operation and re- BRAKES 4
moval and installation of components.
All information, illustrations and specifications

contained in this manual are based on the latest TRANSMISSION 5
product information available at the time of
manual approval.
The right is reserved to make changes at any STEERING 6

time without notice.
HVAC
(HEATING, VENTILATION, 7
AND AIR CONDITIONING)
DAEWOO MOTOR CO., LTD.
RESTRAINTS 8
INCHON, KOREA
BODY AND ACCESSORIES 9
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PERSONAL INJURY CAUTION
Appropriate service methods and proper repair procedure are essential
for the safe, reliable operation of all motor vehicles, as well as for the
personal safety of the person doing the repair. There are many
variations in procedures, techniques, tools and parts for servicing
vehicles, as well as in the skills of the people doing the work. This
manual cannot possibly anticipate all such variations and provide advice
or precautions for each. Anyone who deviates from the instructions
provided in this manual must ensure their own safety and preserve
the safety and integrity of the vehicle. The following list contains general
precautions that should always be followed while working on a vehicle.
• Safety stands are required whenever a procedure calls for
underbody work.
• Do not smoke when you work on a vehicle.
• To prevent serious burns, do not touch any hot metal parts.
• Set the parking brake when you work on the vehicle.
• Turn the ignition switch OFF unless a procedure states
otherwise.
• The engine may operate only in a well-ventilated area.
• Avoid moving parts when the engine is running.
• Safety glasses must be worn for eye protection.

KORANDO
Service Manual
FOREWORD
This manual includes procedures for maintenance, adjustment, service operations, and re-
moval and installation of components for the KORANDO vehicle.
When reference is made in this manual to a brand name, number, or specific tool, an equiva-
lent product may be used in place of the recommended item.
All information, illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication approval. The right is reserved to make
changes at any time without notice.
Daewoo Motor Company, Limited

Overseas Technical Service Department
391-9 Chong Chon-2 Dong, Pu Pyung-Gu,
Inchon, Korea
Tel : 82-32-509-4161 ~ 4164
Fax : 82-32-509-4160
E-mail : m8610452@dwmc.co.kr
m9610883@dwmc.co.kr
Daewoo Motor Company, Limited

All rights Reserved
No part of this publication may be reproduced, stored in any retrieval system or transmitted, in
any form or by any means, including but not limited to electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of Daewoo Motor Company, Lim-
ited

TABLE OF CONTENTS
Section 0A Front Matter Section 5 Transmission
Section 5A Automatic Transmission
Section 0B General Information
Section 5B Manual Transmission
Section 1 Engine Section 5C Clutch
Section 1A1 M162 General Engine Information Section 5D1 Transfer Case (Part Time 4480)
Section 1B1 M162 Engine Mechanical Section 5D2 Transfer Case (TOD)
Section 1D1 M162 Engine Cooling
Section 6 Steering
Section 1E1 M162 Engine Electrical
Section 6A Power Steering System
Section 1F1 M162 Engine Controls
Section 6E Steering Wheel and Column
Section 1G1 M162 Engine Intake & Exhaust
Section 1A2 M161 General Engine Information Section 7 HVAC (Heating, Ventilation & Air
Section 1B2 M161 Engine Mechanical Conditioning)
Section 1D2 M161 Engine Cooling Section 7B/C Manual Control/Semiauto Tempera-
ture Control Heationg, Ventilation,
Section 1E2 M161 Engine Electrical
and Air Conditioning System
Section 1F2 M161 Engine Controls
Section 7D Full Automatic Temperature Control
Section 1G2 M161 Engine Intake & Exhaust Heationg, Ventilation, and Air Condi-
Section 1A3 OM600 General Engine Information tioning System
Section 1B3 OM600 Engine Mechanical
Section 8 Restraints
Section 1D3 OM600 Engine Cooling
Section 8A Seat Belts
Section 1E3 OM600 Engine Electrical
Section 8B Supplemental Restraint System
Section 1F3 OM600 Engine Controls
(SRS)
Section 1G3 OM600 Engine Intake & Exhaust
Section 9 Body and Accessories
Section 2 Suspension
Section 9A Body Wiring System
Section 2A Suspension Diagnosis
Section 9B Lighting Systems
Section 2B Wheel Alignment
Section 9D Wipers/Washer Systems
Section 2C Front Suspension
Section 9E Instrumentation/Driver Information
Section 2D Rear Suspension
Section 9F Audio
Section 2E Tires and Wheels
Section 9H Seats
Section 3 Drive Line / Axle Section 9L Glass and Mirrors
Section 3A Front Drive Axle Section 9N Front and Under Body
Section 3C Propeller Shaft Section 9O Bumpers and Fenders
Section 3D Rear Drive Axle Section 9P Doors
Section 9Q Roof
Section 4 Brakes
Section 9R Body Front End
Section 4A Hydraulic Brakes
Section 9T Remote Keless Entry and Anti-Theft
Section 4B Master Cylinder System
Section 4C Power Booster Section 9U Control Units and System
Section 4D Front Disc Brakes Section 9V Switches
Section 4E Rear Disc Brakes Section 9W Immobilizer System
Section 4F Antilock Brake System
Section 4G Parking Brakes

KORANDO
SERVICE MANUAL
ISSUED BY
OVERSEAS TECH. SERVICE
DAEWOO MOTOR CO., LTD.
391-9 CHONG CHON-2DONG, PU PYUNG-GU,

INCHON, KOREA
TELEPHONE : 82-32-509-4161~4164
FACSIMILE : 82-32-509-4160

ENGINE
CONTENTS
SECTION 1A1 M162 GENERAL ENGINE INFORMATION

SECTION 1B1 M162 ENGINE MECHANICAL
SECTION 1D1 M162 ENGINE COOLING
SECTION 1E1 M162 ENGINE ELECTRICAL
SECTION 1F1 M162 ENGINE CONTROLS
SECTION 1G1 M162 ENGINE INTAKE & EXHAUST
SECTION 1A2 M161 GENERAL ENGINE INFORMATION
SECTION 1B2 M161 ENGINE MECHANICAL
SECTION 1D2 M161 ENGINE COOLING
SECTION 1E2 M161 ENGINE ELECTRICAL
SECTION 1F2 M161 ENGINE CONTROLS
SECTION 1G2 M161 ENGINE INTAKE & EXHAUST
SECTION 1A3 OM600 GENERAL ENGINE INFORMATION
SECTION 1B3 OM600 ENGINE MECHANICAL
SECTION 1D3 OM600 ENGINE COOLING
SECTION 1E3 OM600 ENGINE ELECTRICAL
SECTION 1F3 OM600 ENGINE CONTROLS
SECTION 1G3 OM600 ENGINE INTAKE & EXHAUST

SUSPENSION
CONTENTS
SECTION 2A SUSPENSION DIAGNOSIS

SECTION 2B WHEEL ALIGNMENT
SECTION 2C FRONT SUSPENSION
SECTION 2D REAR SUSPENSION
SECTION 2E TIRES AND WHEELS

DRIVE LINE / AXLE
CONTENTS
SECTION 3A FRONT DRIVE AXLE

SECTION 3C PROPELLER SHAFT
SECTION 3D REAR DRIVE AXLE

BRAKE
CONTENTS
SECTION 4A HYDRAULIC BRAKES

SECTION 4B MASTER CYLINDER
SECTION 4C POWER BOOSTER
SECTION 4D FRONT DISC BRAKES
SECTION 4E REAR DISC BRAKES
SECTION 4F ANTILOCK BRAKE SYSTEM
SECTION 4G PARKING BRAKE

TRANSMISSION
CONTENTS
SECTION 5A AUTOMATIC TRANSMISSION

SECTION 5B MANUAL TRANSMISSION
SECTION 5C CLUTCH
SECTION 5D1 TRANSFER CASE (PART TIME 4408)
SECTION 5D2 TRANSFER CASE (TOD)

STEERING
CONTENTS
SECTION 6A POWER STEERING SYSTEM

SECTION 6E STEERING WHEEL AND COLUMN

HVAC (HEATING, VENTILATION &
AIR CONDITIONING)
CONTENTS
SECTION 7B/C MANUAL CONTROL/SEMIAUTO

TEMPERATURE CONTROL
HEATING, VENTILATION, AND
AIR CONDITIONING SYSTEM
SECTION 7D FULL AUTOMATIC

TEMPERATURE CONTROL
HEATING, VENTILATION, AND

RESTRAINTS
CONTENTS
SECTION 8A SEAT BELTS

SECTION 8B SUPPLEMENTAL RESTRAINT
SYSTEM (SRS)

BODY AND ACCESSORIES
CONTENTS
SECTION 9A BODY WIRING SYSTEM

SECTION 9B LIGHTING SYSTEM
SECTION 9C HORNS
SECTION 9D WIPERS/WASHER SYSTEM
SECTION 9E INSTRUMENTATION/DRIVER INFORMATION
SECTION 9F AUDIO SYSTEM
SECTION 9G INTERIOR TRIM
SECTION 9H SEATS
SECTION 9L GLASS AND MIRRORS
SECTION 9M EXTERIOR TRIM
SECTION 9N FRAME AND UNDERBODY
SECTION 9O BUMPERS AND FASCIAS
SECTION 9P DOORS
SECTION 9Q ROOF
SECTION 9R BODY FRONT END
SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT
SYSTEM
SECTION 9U CONTROL UNITS AND SYSTEM
SECTION 9V SWITCHES
SECTION 9W IMMOBILIZER SYSTEM

SECTION 0B
GENERAL INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 While Operating the Vehicle . . . . . . . . . . . . . 0B-12
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . 0B-12
Vehicle Dimensions and Weights . . . . . . . . . . 0B-5 At Least Twice A Month . . . . . . . . . . . . . . . . 0B-12
Standard Bolts Specifications . . . . . . . . . . . . . 0B-6 At Least Monthly . . . . . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Repair . . . . . . . . . . . . . . . 0B-7 At Least Twice a Year . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Lubrication . . . . . . . . . . . . . 0B-7 Each Time The Oil is Changed . . . . . . . . . . . 0B-13
Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . 0B-7 At Least Annually . . . . . . . . . . . . . . . . . . . . . 0B-13
Explanation of Scheduled Maintenance Recommended Fluids and Lubricants . . . . . 0B-14
Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-7 General Description and System
Scheduled Maintenance Charts Operation . . . . . . . . . . . . . . . . . . . . . . . . 0B-15
(Gasoline Engine) . . . . . . . . . . . . . . . . . . . . . 0B-8 General Repair Instructions . . . . . . . . . . . . . 0B-15
Scheduled Maintenance Charts Vehicle Identification Number System . . . . . . 0B-16
(Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . 0B-10 Vehicle Lifting Procedures . . . . . . . . . . . . . . 0B-19
Owner Inspections and Services . . . . . . . 0B-12
SPECIFICATIONS
TECHNICAL DATA
Performance-Manual Transaxle
Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 140 137 148 154 165 176
Minimum Turning Radius (m) 5.8 5.8 5.8 5.8 5.8 5.8
Performance-Autumatic Transaxle
Application 661LA 662NA 662LA 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 140 137 140 160 170
Minimum Turning Radius (m) 5.8 5.8 5.8 5.8 5.8

0B-2 GENERAL INFORMATION
Engine
Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH
Engine Type 4Cylinder 5Cylinder 5Cylinder 4Cylinder 4Cylinder 6Cylinder
DIESEL DIESEL DIESEL GASOLINE GASOLINE GASOLINE
Bore (mm) 89 89 89 89.9 90.9 89.9
Stroke (mm) 92.4 92.4 92.4 78.7 88.4 84
Total Displacement (cc) 2299 2874 2874 1998 2295 3199
Compression Ratio 22:1 22:1 22:1 9.6:1 10.4:1 10:1
Maximum Power (ps/rpm) 101/4000 95/4000 120/4000 135/5500 149/5500 222/5500
Maximum Torque (kg.m/rpm) 21.5/2400 19.6/2400 25.5/2400 19.3/4000 22.4/4000 31.6/3750
Ignition System
Application 2.0L DOHC 2.3L DOHC 3.2L DOHC
Ignition Type Distributorless ignition
Ignition Timing (BOTH) 6°± 2° 6°± 2° 8°± 2°
Ignition Sequence 1-3-4-2 1-3-4-2 1-5-3-6-2-4
Spark Plug Gap (mm) 0.8 ± 0.1 0.8 ± 0.1 0.8 ± 0.1
Spark Plug Maker Bosch, Chapion, Beru
Spark Plug Type F8DC4(BOSCH)
C11YCC(CHAMPION)
14F8DU4(BERU)
Clutch - Manual Type

Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Type Single Dry Diaphram
Outside Diameter (mm) 225 225 240 225 225 240
Inside Diameter (mm) 150 150 150 150 150 155
Thickness 9.2 9.2 9.2 9.2 9.2 9.3
Fluid Common use :Brake Fluid
Manual Transmission
Maker TREMEC TREMEC TREMEC TREMEC TREMEC TREMEC
Type or Model T5 T5 T5 T5 T5 T5
Gear Ratio : 1st 3.969 3.969 3.969 3.969 3.969 3.969
2nd 2.341 2.341 2.341 2.341 2.341 2.341
3rd 1.457 1.457 1.457 1.457 1.457 1.457
4th 1.000 1.000 1.000 1.000 1.000 1.000
5th 0.851 0.851 0.851 0.851 0.851 0.851
Reverse 3.705 3.705 3.705 3.705 3.705 3.705
Final Drive Ratio 4.55 4.55 4.27 4.89 4.55 3.73
Oil Capacity (L) 3.4 3.4 3.4 3.4 3.4 3.4

GENERAL INFORMATION 0B-3
Auto Transmission
Application 661LA 662LA 2.3L DOHC 3.2L DOHC
Maker BTRA BTRA BTRA BTRA
Type or Model M74 4WD M74 4WD M74 4WD M74 4WD
Gear Ratio : 1st 2.741 2.741 2.741 2.741
2nd 1.508 1.508 1.508 1.508
3rd 1.000 1.000 1.000 1.000
4th 0.708 0.708 0.708 0.708
Reverse 2.429 2.429 2.429 2.429
Final Drive Ratio 5.38 4.89 5.86 4.89
Oil Capacity (L) 9 9 9 9
Brake
Application Specifications
Booster Size non-ABS 8inch + 9inch
ABS 5.0 7inch + 8inch
ABS 5.3 8inch + 9inch
Master Cylinder Diameter (mm) f 25.4
Booster Ratio 5.6 : 1
Front Brake : Disc Type Ventilated
Rear Brake : Disc Type Solid
Tire and Wheel

Standard Tire Size P235/75 R15, 255/70 R15
Standard Wheel Size 7JJ ´ 15
Inflation Pressure At Full Lode
P235 / 75 : Front 30 Psi
Rear 30 Psi
P255 / 75 : Front 30 Psi
Rear 30 Psi
Steering System
Gear Type RACK & PINION
Wheel Alignment:
Front : Toe-in 0 - 4 mm
Front : Caster 2°30’ ± 30’
Front : Camber 0° ± 30’
Oil Capacity 1L

Suspension
Front Type Double Wishbone
Rear Type 5 - Link
Fuel System
Fuel Pump Type Electric Motor Pump
Fuel Capacity 70 L
Lubricating System
Lubricating Type 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Oil Pump Type External Gear pump
Oil Filter Type Combination(Full & Part) Full Flow
Oil Capacity (L) (Including Oil Filter) 8.0 9.0 9.5 7.2 7.5 8.2
Cooling System
Cooling Type 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Coolant Capacity (L) 9.5-10 10.5 10.5 - 11 10.5 10.5 11.3
Radiator Type Forced Circulation
Water Pump Type Centrifugal
Electric System
Battery (MF) 12V - 90AH
Generator 75A 75A 75A 75A 115A 115A
Starter 2.2kw 2.2kw 2.2kw 1.2kw 1.2kw 1.7kw

VEHICLE DIMENSIONS AND WEIGHTS

Vehicle Dimensions
Application Application
Overall Length (mm) 4330
Overall Width (mm) 1841
Overall Height (mm) 1840
Wheel Base (mm) 2840
Tread : Front (mm) 1510
Rear (mm) 1520
Vehicle Weights
Manual : Curb Weight (kg) 1790 1810 1830 1790 1790 1840
Gross Vehicle Weight (kg) 2515 2515 2515 2515 2515 2515
Automatic : Curb Weight (kg) 1810 1815 1850 - 1810 1860
Gross Vehicle Weight (kg) 2515 2515 2515 - 2515 2515
Passenger Capacity 5 5 5 5 5 5

STANDARD BOLTS SPECIFICATIONS

Torque (N·m / Ib-in)
Bolt* Standard Limit
4T 7T 9T 4T 7T 9T
M3 ´ 0.5 0.5 N·
·m 0.9 N··m 1.3 N·
·m 0.7 N··m 1.2 N·
·m 17 N··m
(4.5 lb-in) (8 lb-in) (12 lb-in) (6.3 lb-in) (11 lb-in) (15 lb-in)
M4 ´ 0.7 1.2 N·
·m 2.0 N··m 3.0 N·
·m 1.6 N··m 2.6 N·
·m 4.0 N·
·m
(11 lb-in) (18 lb-in) (27 lb-in) (14 lb-in) (23 lb-in) (36 lb-in)
M5 ´ 0.8 2.4 N·
·m 4.0 N··m 5.6 N·
·m 3.1 N··m 5.2 N·
·m 7.6 N·
·m
M6 ´ 1.0 4.0 N·
·m 6.7 N··m 9.7 N·
·m 5.4 N··m 9.0 N·
·m 12.7 N· ·m
M8 ´ 1.25 8.6 N·
·m 15.7 N· ·m 22.5 N··m 12.7 N· ·m 20.6 N··m 30.4 N· ·m
(77 lb-in) (12 lb-in) (17 lb-in) (9 lb-in) (15.2 lb-in) (22 lb-in)
M10 ´ 1.25 18.6 N··m 32.3 N· ·m 46.0 N··m 25.5 N· ·m 42.1 N··m 60.8 N· ·m
M10 ´ 1.5 18.6 N··m 30.4 N· ·m 44.1 N··m 24.5 N· ·m 41.2 N··m 58.8 N· ·m
M12 ´ 1.25 34.3 N··m 56.8 N· ·m 82.3 N··m 45.0 N· ·m 75.5 N··m 107.8 N· ·m
(25lb-in) (42 lb-in) (61 lb-in) (33 lb-in) (56 lb-in) (80 lb-in)
M12 ´ 1.75 32.3 N··m 53.9 N· ·m 77.4 N··m 43.1 N· ·m 71.5 N··m 98.0 N· ·m
M14 ´ 1.5 54.0 N··m 89.2 N· ·m 127.4 N· ·m 71.6 N· ·m 117.6 N· ·m 166.6 N· ·m
M16 ´ 1.5 81.3 N··m 107.8 N· ·m 196.0 N· ·m 107.8 N· ·m 186.2 N· ·m 264.6 N· ·m
M18 ´ 1.5 117.6 N· ·m 196.0 N· ·m 284.2 N· ·m 156.8 N· ·m 264.6 N· ·m 372.4 N· ·m
M20 ´ 1.5 166.6N· ·m 274.4 N· ·m 392.0 N· ·m 215.6 N· ·m 362.6 N· ·m 519.4 N· ·m
M22 ´ 0.5 225.4N· ·m 372.4 N· ·m 529.2 N· ·m 294.0 N· ·m 490.0 N· ·m 705.6 N· ·m
M24 ´ 1.5 284.2 N· ·m 480.2 N· ·m 686.0 N· ·m 382.2 N· ·m 637.0 N· ·m 921.2 N· ·m
M24 ´ 2.0 274.4 N· ·m 460.6 N· ·m 666.4 N· ·m 372.4 N· ·m 617.4 N· ·m 891.8 N· ·m
*Diameter ´ pitch in millimeters

MAINTENANCE AND REPAIR

MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE Fuel Filter Replacement
The maintenance instructions contained in the Replace the engine fuel filter every.
maintenance schedule are based on the assumption l Gasoline Engine : 60,000km (36,000 miles)
that the vehicle will be used for the following reasons: l Diesel Engine : 45,000km (24,000 miles)
l To carry passengers and cargo within the limitation
Spark Plug Replacement
of the tire inflation prassure. Refer to “Tire and Wheel”
in section 2E. Replace spark plugs with same type.
l To be driven on reasonable road surfaces and within l Type : BOSCH : F8DC4
legal operating limits. BERU : 14F-8DU4
Champion : C11YCC
EXPLANATION OF SCHEDULED l Gap : 0.8 ± 0.1 mm
MAINTENANCE SERVICES Spark Plug Wire Replacement

The services listed in the maintenance schedule are Clean wires and inspect them for burns, cracks or other
further explained below. When the following maintenance damage. Check the wire boot fit at the Distributor and at
services are performed, make sure all the parts are the spark plugs. Replace the wires as needed.
replaced and all the necessary repairs are done before Brake System Service
driving the vehicle. Always use the proper fluid and
Check the disc brake pads or the drum brake linings.
lubricants. Check the pad and the lining thickness carefully.
Engine Oil and Oil Filter Change Tire and Wheel Inspection and Rotation
Always use above the API SH grade or recommended
Check the tires for abnormal wear or damage. To
engine oil. equalize wear and obtain maximum tire life, rotate the
Engine Oil Viscosity tires. If irregular or premature wear exists, check the
Engine oil viscosity (thickness) has an effect on fuel wheel alignment and check for damaged wheels. While
economy and cold weather operation. Lower viscosity the tires and wheels are removed, inspect the brakes.
engine oils can provide better fuel economy and cold
weather performance; however, higher temperature Tire Rotation (Left-hand Drive Type)
weather conditions require higher viscosity engine oils
for satisfactory lubrication. Using oils of any viscosity
other than those viscosities recommended could result
in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer
to “Recommended Fluids And Lubricants” in this section.
Air Cleaner Element Replacement
Clean the air cleaner element every.
l Gasoline Engine : 15,000km (10,000 miles)
l Diesel Engine : 10,000km (6,000 miles)
Replace the air cleaner element every .
l Gasoline Engine : 60,000km (36,000 miles)
l Diesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty
conditions

SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)
Engine
MAINTENANCE INTERVAL Kilometers or time in months, whichever comes first
x1,000 km 1 15 30 45 60 75 90 105 120
MAINTENANCE
ITEM Months - 12 24 36 48 60 72 84 96
Drive belt I I I I I I I I I
Engine oil & filter (1) (3) I R R R R R R R R
Cooling system hose & connections I I I I I I I I I
Engine coolant (3) I I I I R I I I R
Fuel filter (2) - - - - R - - - R
Fuel line & connections I I I I I I I I I
Air cleaner (2) I I I R I I R
Ignition timing I I I I I I I I
Spark plugs - I R I R I R I R
Charcoal canister & vapor lines - - - I - - I - -
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R - Replace or change.
(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition. Change
engine oil and the filter every 7,500 km or 6 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving condition.
(3) Refer to “Recommended fluids and lubricants”.

Chassis and Body
x1,000 km 1 15 30 45 60 75 90 105 120
MAINTENANCE
ITEM Months - 12 24 36 48 60 72 84 96
Exhaust pipes & mountings - I I I I I I I I
Brake/Clutch fluid (3)(4) - I R I R I R I R
Parking brake/Brake pads F & R (5) - I I I I I I I I
Brake line & connections (including booster) I I I I I I I I I
Manual transmission oil (3) I I I R I I R I I
Clutch & brake pedal free play - I I I I I I I I
Front & Rear Differential Fluid (3) I I I R I I R I I
Transfer case fluid I I I R I I R I I
Automatic transmission fluid (MB W4A040) (6) I I I R I I R I
Automatic transmission fluid (BTRA M74) I I I I I I I I I
Chassis & underbody bolts & nuts tight/secure I I I I I I I I I
Tyre condition & inflation pressure I I I I I I I I I
Wheel alignment (7) Inspect & ADJUST when abnormal condition is noted
Steering wheel & linkage I I I I I I I I
Power steering fluid & lines* (3) I I I I I I I I
Drive shaft boots I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I I
Lubricate locks, hinges & bonnet latch I I I I I I I I
Chart Symbols :
(4) Change the brake / clutch fluid every 15,000 km if the vehicle is mainly driven under severe conditions:
- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low -
speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transaxle fluid and filter every 75,000 km if the vehicle is mainly driven under severe conditions.
- In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
- In hilly or mountainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)
Engine
MAINTENANCE INTERVAL
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
MAINTENANCE
ITEM Months - 6 12 18 24 30 36 42 48 54 60
Drive belt I I I I I I I I I I I
Engine oil & fillter (1) (3) R R R R R R R R R R R
Cooling system hose & connections I I I I I I I I I
Engine coolant (3) I R I
Fuel filter (2) R R
Fuel line & connections I I I I I I I I I I I
Glow plug I I I R I
Pre - fuel filter I I I I I I I I I I
Air cleaner (2) I I R I I R I I R I
Ignition timing (see NOTE 1) I I I I I I I I I I
NOTE 1 : Injection Timing :
Adjust as required :
- When excessive smoke is visible (black or white)
- Poor performance/economy
Chart Symbols:
(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition, change
engine oil every 5,000km or 3 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving conditing.

Chassis and Body
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
MAINTENANCE
ITEM Months - 6 12 18 24 30 36 42 48 54 60
Exhaust pipes & mountings I I I I I I I I I I
Brake/clutch fluid (3) (4) I I I R I I R I I R I
Parking brake/Brake pads (F & R) (5) I I I I I I I I I I
Brake line & connections (including booster) I I I I I I I I I I
Manual transmission fluid (3) I I I I R I I I I R
Clutch & brake pedal free play I I I I I I I I I I
F & R Differential fluid (3) I I I I I R I I I I R
Transfer case fluid (3) I I I I R I I I I R
Automatic transmission fluid (BTRA M74) (6) I I I I I I I I I I
Chassis & underbody bolts & nuts tight/secure I I I I I I I I I I I
Tyre condition & inflation pressure I I I I I I I I I I I
Wheel alignment (7) Inspect & ADJUST when abnormal condition is noted
Steering wheel & linkage I I I I I I I I I I
Power steering fluid & lines* (3) I I I I I I I I I I
Drive shaft boots I I I I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I I I I
Lubricate locks, hinges & bonnet latch I I I I I I I I I I I
Chart Symbols :
(4) Change the brake / clutch fluid more regularly if the vehicle is mainly driven under severe conditions :
- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low -
speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transmission fluid every 70,000 km if the vehicle is mainly driven under severe conditions.
- In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
- In hilly or mountainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

5. Add oil, if needed, to keep the oil level above the
OWNER INSPECTIONS lower mark. Avoid overfilling the engine, since this
AND SERVICES may cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.
WHILE OPERATING THE VEHICLE 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
Horn Operation pan fast enough to give a true oil level reading.
Blow the horn occasionally to make sure it works. Check Engine Coolant Level and Condition
all the button locations.
Check the coolant level in the coolant reservoir tank
Brake System Operation and add coolant if necessary. Inspect the coolant.
Be alert for abnormal sounds, increased brake pedal Replace dirty or rusty coolant.
travel or repeated puling to one side when braking. Also, Windshield Washer Fluid Level
if the brake warning light goes on, or flashes, something
may be wrong with part of the brake system. Check the washer fluid level in the reservoir. Add fluid if
necessary.
Exhaust System Operation
Be alert to any changes in the sound of the system or AT LEAST TWICE A MONTH
the smell of the fumes. These are signs that the system Tire And Wheel Inspection and Pressure
may be leaking or overheating. Have the system
inspected and repaired immediately.
Check
Check the tire for abnormal wear or damage. Also check
Tires, Wheels and Alignment Operation for damaged wheels. Check the tire pressure when the
Be alert to any vibration of the steering wheel or the tires are cold (check the spare also, unless it is a
seats at normal highway speeds. This may mean a wheel stowaway). Maintain the recommended pressures. Refer
needs to be balanced. Also, a pull right or left on a to “Tire and Wheel” is in section 0B.
straight, level road may show the need for a tire pressure
adjustment or a wheel alignment. AT LEAST MONTHLY
Steering System Operation Light Operation
Be alert to changes in the steering action. An inspection Check the operation of the license plate light, the
is needed when the steering wheel is hard to turn or headlights (including the high beams), the parking lights,
has too much free play, or is unusual sounds are noticed the fog lights, the taillight, the brake lights, the turn
when turning or parking. signals, the backup lights and the hazard warning flasher.
Headlight Aim Fluid Leak Check
Take note of the light pattern occasionally. Adjust the Periodically inspect the surface beneath the vehicle for
headlights if the beams seem improperly aimed. water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air
AT EACH FUEL FILL conditioning system after use is normal. If you notice
A fluid loss in any (except windshield washer) system fuel leaks or fumes, find the cause and correct it at once.
may indicate a problem. Have the system inspected and
repaired immediately. AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Engine Oil Level
Check the power steering fluid level. Keep the power
Check the oil level and add oil if necessary. The best
steering fluid at the proper level. Refer to Section 6A,
time to check the engine oil level is when the oil is warm.
Power Steering System.
1. After stopping the engine, wait a few minutes for the
oil to drain back to the oil pan. Brake Master Cylinder Reservoir Level
2. Pull out the oil level indicator (dip stick). Check the fluid and keep it at the proper level. A low
3. Wipe it clean, and push the oil level indicator back fluid level can indicate worn disc brake pads which may
down all the way. need to be serviced. Check the breather hole in the
reservoir cover to be free from dirt and check for an
4. Pull out the oil level indicator and look at the oil level open passage.
on it.

Weather-Strip Lubrication AT LEAST ANNUALLY
Apply a thin film silicone grease using a clean cloth.
Lap and Shoulder Belts Condition and
EACH TIME THE OIL IS CHANGED Operation
Inspect the belt system including: the webbing, the
Brake System Inspection buckles, the latch plates, the retractor, the guide loops
This inspection should be done when the wheels are and the anchors.
removed for rotation. Inspect the lines and the hoses
for proper hookup, binding, leaks, cracks, chafing, etc. Movable Head Restraint Operation
Inspect the disc brake pads for wear. Inspect the rotors On vehicles with movable head restraints, the restraints
for surface condition. Inspect other brake parts, the must stay in the desired position.
parking brake, etc., at the same time. Inspect the brakes
Spare Tire and Jack Storage
more often if habit or conditions result in frequent braking.
Be alert to rattles in the rear of the vehicle. The spare
Steering, Suspension and Front Drive Axle tire, all the jacking equipment, and the tools must be
Boot And Seal Inspection securely stowed at all times. Oil the jack ratchet or the
Inspect the front and rear suspension and the steering screw mechanism after each use.
system for damaged, loose or missing parts, signs of Key Lock Service
wear or lack of lubrication. Inspect the power steering
Lubricate the key lock cylinder.
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle Body Lubrication Service
boot and seals for damage, tears or leakage. Replace Lubricate all the body door hinges including the hood,
the seals if necessary. the fuel door, the rear compartment hinges and the
Exhaust System Inspection latches, the glove box and the console doors, and any
folding seat hardware.
Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the exhaust Underbody Flushing
system. Look for broken, damaged, missing, or out-of- Flushing the underbody will remove any corrosive
position parts as well as open seams, holes, loose materials used for ice and snow removal and dust control.
connections, or other conditions which could cause heat At least every spring clean the underbody. First, loosen
buildup in the floor pan or could let exhaust fumes seep the sediment packed in closed areas of the vehicle. Then
into the trunk or passenger compartment. flush the underbody with plain water.
Throttle Linkage Inspection Engine Cooling System
Inspect the throttle linkage for interference or binding, Inspect the coolant and freeze protection fluid. If the fluid
damaged, or missing parts. Lubricate all linkage joints is dirty or rusty, drain, flush and refill the engine cooling
and throttle cable joints, the intermediate throttle shaft system with new coolant. Keep the coolant at the proper
bearing, the return spring at throttle valve assembly, and mixture in order to ensure proper freeze protection,
the accelerator pedal sliding face with suitable grease. corrosion protection and engine operating temperature.
Check the throttle cable for free movements. Inspect the hoses. Replace the cracked, swollen, or
Engine Drive Belts deteriorated hoses. Tighten the clamps. Clean the
outside of the radiator and the air conditioning
Inspect all belts for cracks, fraying, wear and proper
condenser. Wash the filler cap and the neck. Pressure
tension. Adjust or replace the belts as needed.
test the cooling system and the cap in order to help
Hood Latch Operation ensure proper operation.
When opening the hood, note the operation of the
secondary latch. It should keep the hood from opening
all the way when the primary latch is released. The hood
must close firmly.

RECOMMENDED FLUIDS AND LUBRICANTS

Usage Capacity Fluid/Lubricant
Engine Oil 3.2L DOHC 8.2 L Quality class - API ; SH grade or above
(Change with filter) ACEA ; A2 or A3
2.3L DOHC 7.5 L MB sheet ; 229.1
Viscosity - MB sheet ; 224.1
662LA 9.5 L Quality class - API ; CG grade or above
ACEA ; B2 or B3
661LA 8.0 L MB sheet ; 228.1, 228.3,
228.5, 229.1
Viscosity - MB sheet ; 224.1
Engine Coolant 3.2L DOHC 11.3 L ALUTEC P-78
2.3L DOHC 10.5 L
662LA 10.5 - 11.0 L
661LA 9.5 - 10.0 L
Brake / Clutch Fluid Approx. 0.5L level must DOT-3 & SAE J 1703
be maintained between
MAX & MIN level
Power Steering System 1.0 L ATF DEXRON-II
Parking Brake Cable As required Grease
Hood Latch Assembly As required Grease
Hood and Door Hinges As required Spray type grease
Fuel Door Hinge
Rear Compartment Lid Hinges
Weatherstrips As required Silicone grease

l Use genuine DAEWOO parts.
GENERAL DESCRIPTION l Discard used cotter pins, gaskets, O-rings, oil seals,
AND SYSTEM OPERATION lock washers and self-locking nuts. Prepare new ones
for installation. Normal function of these parts cannot
be maintained if these parts are reused.
GENERAL REPAIR INSTRUCTIONS
l Keep the disassembled parts neatly in groups to
l If a floor jack is used, the following precautions are facilitate proper and smooth reassembly.
recommended.
l Keep attaching bolts and nuts separated, as they
l Park the vehicle on level ground, “block” the front or vary in hardness and design depending on the
rear wheels, set the jack against the frame, raise the position of the installation.
vehicle and support it with chassis stands and then
perform the service operation. l Clean the parts before inspection or reassembly.
l Before performing the service operation, disconnect l Also clean the oil parts, etc. Use compressed air to
the negative battery cable in order to reduce the make certain they are free of restrictions.
chance of cable damaged and burning due to short- l Lubricate rotating and sliding faces of parts with oil
cir cuiting. or grease before installation.
l Use a cover on the body, the seats and the floor to l When necessary, use a sealer on gaskets to prevent
protect them against damage and contamination. leakage.
l Handle brake fluid and antifreeze solution with care l Carefully observe all specifications for bolt and nut
as they can cause paint damage. torques.
l The use of proper tools, and the recommended l When service operation is completed, make a final
essential and available tools where specified, are check to be sure service was done properly and the
important for efficient and reliable performance of problem was corrected.
the service repairs.

VEHICLE IDENTIFICATION NUMBER SYSTEM
* K P T L 4 B 1 B S V P 000000 *
12~17.Production Serial Number

: 000001- 999999
11.Plant Code
P : PyongTaek Plant
10.Model Year
V : 1997
W : 1998
X : 1999
Y : 2000
9. Check Digit
S : All area except North America
8. Engine Type
6 : 2295cc, In-line 4Cylinder, Gasoline (E23)
A : 2299cc, In-line 4Cylinder, Diesel (OM661)
B : 2874cc, In-line 5Cylinder, Diesel (OM662)
7. Restraint System
1 : 3-Point Safety Belt, 2 : 2-Point Safety Belt
6. Trim Level
A : Standard, B : Deluxe, C : Super Deluxe
5. Body Type
2: 3-Door, 4: 3-Door Soft Top
4. Line Models
L : Korando, LHD, R : Korando, RHD
3. Vehicle Type
T : Passenger Car, A : Truck
2. Maker ldentification : P
1. Nation : K
*. Symbol according to No.

Manufacturer’s Plate
1.Type Approval No. 2.Vehicle Identification No.
Manufacturer’s Plate Location
Diesel Engine Gasoline Engine

Gasolind Engine Number Diesel Engine Number
162 993 1 0 012345 662 920 1 0 012345
Serial Number Serial Number
0 : Manual T/M 0 : Manual T/M

1 : Hydr - Auto Coupling 1 : Hydr - Auto Coupling
2 : Automatic T/M 2 : Automatic T/M
0 : Common 0 : Common
1 : Left - Hand Drive 1 : Left - Hand Drive
2 : Right - Hand Drive 2 : Right - Hand Drive
3 : KORANDO
99 : 3.2L 910 :Non-Intercooler Engine

97 : 2.3L 920 : Intercooler Engine
94 : 2.0L
661 : 2299cc
ENGINE TYPE
662 : 2874cc
Engine Number Location
IL6 3200 2300 DOHC

The engine number is stamped on the lower rear side The engine number is stamped on the upper rear left-
of the alternator. hand side of the cylinder block.

VEHICLE LIFTING PROCEDURES

To raise the vehicle, place the liffting equipment only at
the points indicated. Failure to use these precise
positions may result in permanent vehicle body
deformation.
Many dealer service facilities and service stations are
equipped with automative hoists that bear upon some
parts of the frame in order to lift the vehicle. If any other
hoist method is used, use special care to avoid damaging
the fuel tank, the filter neck, the exhaust system, or the
underbody.
Vehicle Lifting Points
Diesel Engine
The engine number is stamped on the cylinder block in
front of injection pump.
Using Jack
(Rearward of Front Tire)
Using Jack
(Forward of Rear Tire)

SECTION 1
ENGINE
SECTION 1A1(M162 ENGINE)
GENERAL ENGINE INFORMATION

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A1-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-7
Engine Specifications . . . . . . . . . . . . . . . . . . 1A1-1 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A1-7
Component Locator . . . . . . . . . . . . . . . . . . 1A1-3 Engine Cranking at The
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-3 Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A1-8
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-4 Compression Pressure Test . . . . . . . . . . . . . 1A1-9
Performance Curve . . . . . . . . . . . . . . . . . . 1A1-5 Cylinder Pressure Leakage Test. . . . . . . . . 1A1-11
E32 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-5 General Information . . . . . . . . . . . . . . . . . 1A1-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A1-6 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A1-13
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A1-6 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A1-13
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application E32 Engine
Engine Model M162.993
Displacement (CC) 3199
Cylinder (Bore x Stroke) (mm) 89.9 x 84.0
Fuel Injection / Ignition System MSE 3.62S
Compression Ratio 10 : 1
Number of Cylinders 6
Camshaft Valve Arrangement DOHC
Camshaft Drive Type Chain-Driven
Max. Output (ps/rpm) 222 / 5500
Max. Torque (kg•m/rpm) 31.6 / 3750
Firing Order 1-5-3-6-2-4
Ignition Type Distributorless Double Ignition
Ignition Timing BTDC 8° ± 2°
Valve Timing Intake Open/Close ATDC 11° / ABDC 34°
Exhaust Open/Close BBDC 31° / BTDC 14°
Valve Clearance Adjustment Automatic Control

1A1-2 GENERAL ENGINE INFORMATION
ENGINE SPECIFICATIONS (Cont'd)

Application E32 Engine
Idle Speed (rpm) 700 ± 50
Fuel Injection Pressure (kg/cm²) 3-4
Oil Capacity (liter) 8.2
Lubrication Type Forced by Gear Pump
Oil Filter Type Full Flow with Paper Filter
Fuel Unleaded Gasoline
MSE 3.62S/3.53S (Motorsteuer Elektronik : German)
MSE : Engine Control Electronic
3.62S : 6 Cylinder Version
3.53S : 4 Cylinder Version

GENERAL ENGINE INFORMATION 1A1-3
COMPONENT LOCATOR
FRONT VIEW
1 HFM Sensor 12 Intake Manifold

2 Intake Air Duct 13 Connecting Rod
3 Resonance Flap 14 Exhaust Manifold
4 Cylinder Head Cover 15 Crankshaft
5 Exhaust Camshaft 16 Engine Mounting Bracket
6 Intake Camshaft 17 Starter
7 Cylinder Head 18 Crankcase
8 Spark Plug Connector 19 Oil Pump Sprocket
9 Valve Tappet 20 Oil Strainer
10 Injector 21 Oil Pan
11 Exhaust Valve 22 Drain Plug

SIDE VIEW
23 Camshaft Adjuster 27 Oil Pump Drive Chain

24 Cooling Fan and Viscous Clutch 28 Oil Return Pipe
25 Piston 29 Timing Chain
26 Flywheel of Drive Plate 30 Oil Pump

PERFORMANCE CURVE
E32 ENGINE

SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 001 589 65 09 00

Torque Wrench Socket
001 589 76 21 00 119 589 01 09 00

Compression Pressure Spark Plug Wrench
Tester

DIAGNOSIS
OIL LEAK DIAGNOSIS Black Light and Dye Method
Most fluid oil leaks are easily located and repaired by A dye and light kit is available for finding leaks, Refer to
visually finding the leak and replacing or repairing the the manufacturer's directions when using the kit.
necessary parts. On some occasions a fluid leak may 1. Pour the specified amount of dye into the engine oil
be difficult to locate or repair. The following procedures fill tube.
may help you in locating and repairing most leaks. 2. Operate the vehicle normal operating conditions as
Finding the Leak directed in the kit.
1. Identify the fluid. Determine whether it is engine oil, 3. Direct the light toward the suspected area. The dyed
automatic transmission fluid, power steering fluid, etc. fluid will appear as a yellow path leading to the
source.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating Repairing the Leak
temperature, park the vehicle over a large sheet Once the origin of the leak has been pinpointed and
of paper. traced back to its source, the cause of the leak must be
2.2 Wait a few minutes. determined n order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
2.3 You should be able to find the approximate
new gasket will not repair the leak. The bent flange must
location of the leak by the drippings on the
be repaired also. Before attempting to repair a leak,
paper.
check for the following conditions and correct them as
3. Visually check around the suspected component. they may cause a leak.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that Gaskets
are hard to reach. l The fluid level/pressure is too high.
4. If the leak still cannot be found, it may be necessary l The crankcase ventilation system is malfunctioning.
to clean the suspected area with a degreaser, steam l The fasteners are tightened improperly or the threads
or spray solvent. are dirty or damaged.
4.1 Clean the area well. l The flanges or the sealing surface is warped.
4.2 Dry the area. l There are scratches, burrs or other damage to the
4.3 Operate the vehicle for several miles at normal sealing surface.
operating temperature and varying speeds. l The gasket is damaged or worn.
4.4 After operating the vehicle, visually check the l There is cracking or porosity of the component.
suspected component.
l An improper seal was used (where applicable).
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method. Seals
l The fluid level/pressure is too high.
Powder Method
l The crankcase ventilation system is malfunctioning.
1. Clean the suspected area.
l The seal bore is damaged (scratched, burred or
2. Apply an aerosol-type powder (such as foot powder)
nicked).
to the suspected area.
l The seal is damaged or worn.
3. Operate the vehicle under normal operating
conditoins. l Improper installation is evident.
4. Visually inspect the suspected component. You l There are cracks in the components.
should be able to trace the leak path over the white l The shaft surface is scratched, nicked or damaged.
powder surface to the source. l A loose or worn bearing is causing excess seal wear.

ENGINE CRANKING AT THE FRONT OF CRANKSHAFT

Preceding Work : Removal of cooling fan
1 Vibration Damper Assembly 3 Bolt ................................................. 8.6 ± 0.9 Nm

2 Crankshaft Pulley
Notice
l Remove the negative ground cable before proceeding the work.
l Rotate the pulley in normal engine rotating direction when cranking.
Tools Required
000 589 10 99 01 Torque wrench
001 589 65 09 00 Socket

COMPRESSION PRESSURE TEST
1 Compression Pressure Tester 3 Adaptor

2 Diagram Sheet 4 Sealing Cone
Tools Required
001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench
Standard Service Data

Compression Ratio 10 : 1
Normal Engine Temperature 80°C
Normal Compression Pressure General Min. 10 bar, Max. 14 bar
Fuel Optimization Min. 6 bar, Max. 10 bar
Permissible Pressure Difference Between Individual Max. 1.5 bar
Cylinders

Measuring Procedure
1. Warm the engine up to normal operating temperature.
2. Remove the spark plugs.
3. Place the diagram sheet to compression pressure
tester.
4. Connect the adaptor to compression pressure tester
and install it into the spark plug hole.
5. Crank the engine approx. eight revolutions by using
the start motor.
6. Compare the measurements of compression
pressure tester with the specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.
Notice
l Discharge the combustion residues in the cylinders
before testing the compression pressure.
l Apply the parking brake before cranking the
engine.

CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with

4 Vibration Damper Connecting Hose
Permissible Pressure Leakage

At Whole Engine Max. 25 %
At Valve and Cylinder Head Gasket Max. 10 %
At Piston and Piston Ring Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark OT (TDC) a (120°) b (240°)
Cylinder Number 1, 6 2, 5 3, 4
Universal Tool
Cylinder Pressure Leakage Tester Bosch, EFAW 210A
Sun, CLT 228

Leakage Test
2. Disconnect the negative battery cable.
4. Check the coolant level by opening the coolant surge tank
cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the scale
of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotating the

crankshaft.
9. Connect the connecting hose to tester and measure the

leakage volume after blowing up 5bar of compressed air.
Notice
Measure the leakage volume in the completely opening
condition of throttle valve by pulling the acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order : 1 - 5 - 3 - 6 - 2 - 4
11. Compare the leakage pressure with the specifications.

GENERAL INFORMATION
CLEANLINESS AND CARE Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
An automobile engine is a combination of many cables may result in damage to wire harness or other
machined, honed, polished and lapped surfaces with electrical parts.
tolerances that are measured in the ten-thousanths of
an inch. When any internal engine parts are serviced, ON-ENGINE SERVICE
care and cleanliness are important. A liberal coating of
enigne oil should be applied to friction areas during Caution: Disconnect the negative battery cable
assembly, to protect and lubricate the surfaces on initial before removing or installing any electrical unit, or
operation. Proper cleaning and protection of machined when a tool or equipment could easily come in
surfaces and friction areas is part of the repair contact with exposed electrical terminals.
procedure. This is considered standard shop practice Disconnecting this cable will help prevent personal
even if not specifically stated. injury and damage to the vehicle. The ignition must
also be in LOCK unless otherwise noted.
Whenever valve train components are removed for
service, they should be kept in order. They should be Notice: Any time the air cleaner is removed, the intake
installed in the same locations, and with the same mating opening should be covered. This will protect against
surfaces, as when they were removed. accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.

SECTION 1
ENGINE
SECTION 1A2(M161 ENGINE)

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A2-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-8
Engine Specifications . . . . . . . . . . . . . . . . . . 1A2-1 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A2-8
Component Locator . . . . . . . . . . . . . . . . . . 1A2-3 Engine Cranking At The
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-3 Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A2-9
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-4 Compression Pressure Test . . . . . . . . . . . . 1A2-10
Performance Curve . . . . . . . . . . . . . . . . . . 1A2-5 Cylinder Pressure Leakage Test. . . . . . . . . 1A2-12
E23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-5 General Information . . . . . . . . . . . . . . . . . 1A2-14
E20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-6 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A2-14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A2-7 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A2-14
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A2-7
SPECIFICATIONS
Application E23 Engine E20 Engine
Engine Model M161.973 M161.943
Displacement (CC) 2295 1998
Cylinder (Bore x Stroke) (mm) 90.9 x 88.4 89.9 x 78.7
Fuel Injection / Ignition System MSE 3.53S ¬
Compression Ratio 10.4:1 9.6:1
Number of Cylinders 4 ¬
Camshaft Valve Arrangement DOHC ¬
Camshaft Drive Type Chain-Driven ¬
Max. Output (ps/rpm) 149 / 5500 135 / 5500
Max. Torque (kg•m/rpm) 22.4 / 4000 19.3 / 4000
Firing Order 1-3-4-2 ¬
Ignition Type Distributorless ¬
Ignition Timing BTDC 6° ± 2° ¬
Valve Timing Intake Open/Close ATDC 19.25° / ABDC 28.76° ATDC 13.15° / ABDC 13.57°
Exhaust Open/Close BBDC 20.62° / BTDC 15.08° BBDC 16.58° / BTDC 17.05°
Valve Clearance Adjustment Automatic Control ¬


Application E23 Engine E20 Engine
Idle Speed (rpm) 750 ± 50 ¬
Fuel Injection Pressure (kg/cm²) 3.2 - 4.2 ¬
Oil Capacity (liter) 7.5 ¬
Lubrication Type Forced by Gear Pump ¬
Oil Filter Type Full Flow with Paper Filter ¬
Fuel Unleaded Gasoline ¬
MSE 3.62S/3.53S (Motorsteuer Elektronik : German)

MSE : Engine Control Electronic
3.62S : 6 cylinder version
3.53S : 4 cylinder version

COMPONENT LOCATOR
FRONT VIEW
1 HFM Sensor 12 Intake Manifold

2 Intake Air Duct 13 Cylinder Head
3 Cylinder Head Cover 14 Exhaust Manifold
4 Ignition Coil 15 Dipstick Guide Tube and Gauge
5 Spark Plug Connector 16 Connecting Rod
6 Fuel Distributor 17 Crankshaft
7 Injector 18 Engine Mounting Bracket
8 Exhaust Camshaft 19 Starter
9 Intake Camshaft 20 Crankcase
10 Valve Tappet 21 Oil Pump Sprocket
11 Intake Valve 22 Oil Pan

SIDE VIEW
23 Camshaft Adjuster 29 Oil Pump Drive Chain

24 Oil Filler Cap 30 Oil Strainer
25 Engine Hanger Bracket 31 Oil Pump
26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate
27 Oil Filter 33 Piston
28 Timing Chain

PERFORMANCE CURVE
E23 ENGINE

E20 ENGINE

SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 001 589 65 09 00

001 589 76 21 00 119 589 01 09 00

Compression Pressure Spark Plug Wrench
Tester

DIAGNOSIS
OIL LEAK DIAGNOSIS Black Light and Dye Method
Most fluid oil leaks are easily located and repaired by A dye and light kit is available for finding leaks, Refer to
visually finding the leak and replacing or repairing the the manufacturer's directions when using the kit.
necessary parts. On some occasions a fluid leak may 1. Pour the specified amount of dye into the engine oil
be difficult to locate or repair. The following procedures fill tube.
may help you in locating and repairing most leaks. 2. Operate the vehicle normal operating conditions as
Finding the Leak directed in the kit.
1. Identify the fluid. Determine whether it is engine oil, 3. Direct the light toward the suspected area. The dyed
automatic transmission fluid, power steering fluid, etc. fluid will appear as a yellow path leading to the
source.
2.1 After running the vehicle at normal operating Repairing the Leak
temperature, park the vehicle over a large sheet Once the origin of the leak has been pinpointed and
of paper. traced back to its source, the cause of the leak must be
2.2 Wait a few minutes. determined n order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
2.3 You should be able to find the approximate
new gasket will not repair the leak. The bent flange must
be repaired also. Before attempting to repair a leak,
paper.
check for the following conditions and correct them as
3. Visually check around the suspected component. they may cause a leak.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that Gaskets
are hard to reach. l The fluid level/pressure is too high.
4. If the leak still cannot be found, it may be necessary l The crankcase ventilation system is malfunctioning.
to clean the suspected area with a degreaser, steam l The fasteners are tightened improperly or the threads
or spray solvent. are dirty or damaged.
4.1 Clean the area well. l The flanges or the sealing surface is warped.
4.2 Dry the area. l There are scratches, burrs or other damage to the
4.3 Operate the vehicle for several miles at normal sealing surface.
operating temperature and varying speeds. l The gasket is damaged or worn.
4.4 After operating the vehicle, visually check the l There is cracking or porosity of the component.
suspected component.
l An improper seal was used (where applicable).
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method. Seals
Powder Method
l The crankcase ventilation system is malfunctioning.
l The seal bore is damaged (scratched, burred or
2. Apply an aerosol-type powder (such as foot powder)
nicked).
to the suspected area.
conditoins. l Improper installation is evident.
4. Visually inspect the suspected component. You l There are cracks in the components.
should be able to trace the leak path over the white l The shaft surface is scratched, nicked or damaged.
powder surface to the source. l A loose or worn bearing is causing excess seal wear.

ENGINE CRANKING AT THE FRONT OF CRANKSHAFT

1 Vibration Damper Assembly 3 Bolt ................................................. 8.6 ± 0.9 Nm

2 Crankshaft Pulley
Notice
l Remove the negative ground cable before proceeding the work.
l Rotate the pulley in normal engine rotating direction when cranking.
Tools Required
000 589 10 99 01 Torque wrench
001 589 65 09 00 Socket

1 Compression Pressure Tester 3 Adaptor

2 Diagram Sheet 4 Sealing Cone
Tools Required
001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench
Standard Service Data

Compression Ratio 10.4, 9.6
Normal Engine Temperature 80°C
Normal Compression Pressure E23 Engine(e = 10.4) Min. 11 bar, Max. 15 bar
E20 Engine(e = 9.6) Min. 10.5 bar, Max. 14 bar
Permissible Pressure Difference Between Individual Max. 1.5 bar
Cylinders

Measuring Procedure
3. Place the diagram sheet to compression pressure
tester.
4. Connect the adaptor to compression pressure tester
and install it into the spark plug hole.
5. Crank the engine approx. eight revolutions by using
the start motor.
6. Compare the measurements of compression
pressure tester with the specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.
Notice
l Discharge the combustion residues in the cylinders
before testing the compression pressure.
l Apply the parking brake before cranking the
engine.

3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with

5 Vibration Damper Connecting Hose
Permissible Pressure Leakage

Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark OT (TDC) UT (BDC : 180°)
Cylinder Number 1, 4 2, 3
Universal Tool
Cylinder Pressure Leakage Tester Bosch EF AW 210A
Sun, CLT 228

Leakage Test
4. Check the coolant level by opening the coolant surge tank
cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the scale
of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotating the

crankshaft.
9. Connect the connecting hose to tester and measure the

leakage volume after blowing up 5bar of compressed air.
Notice
Measure the leakage volume in the completely opening
condition of throttle valve by pulling the acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order : 1 - 3 - 4 - 2
11. Compare the leakage pressure with the specifications.

GENERAL INFORMATION
CLEANLINESS AND CARE ON-ENGINE SERVICE
An automobile engine is a combination of many Caution: Disconnect the negative battery cable be-
machined, honed, polished and lapped surfaces with fore removing or installing any electrical unit, or
tolerances that are measured in the ten-thousanths of when a tool or equipment could easily come in con-
an inch. When any internal engine parts are serviced, tact with exposed electrical terminals. Disconnect-
care and cleanliness are important. A liberal coating of ing this cable will help prevent personal injury and
enigne oil should be applied to friction areas during damage to the vehicle. The ignition must also be in
assembly, to protect and lubricate the surfaces on initial LOCK unless otherwise noted.
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair Notice: Any time the air cleaner is removed, the intake
procedure. This is considered standard shop practice opening should be covered. This will protect against
even if not specifically stated. accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.
service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when they were removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other
electrical parts.

SECTION 1
ENGINE
SECTION 1A3(OM600 ENGINE)

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A3-1 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A3-9
Engine Specifications . . . . . . . . . . . . . . . . . . 1A3-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1A3-10
Sectional View . . . . . . . . . . . . . . . . . . . . . . 1A3-3 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . 1A3-10
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-3 Compression Pressure Test . . . . . . . . . . . . 1A3-11
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-5 Cylinder Pressure Leakage Test . . . . . . . . . 1A3-13
Performance Curve . . . . . . . . . . . . . . . . . . 1A3-7 General Information . . . . . . . . . . . . . . . . . 1A3-15
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-7 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A3-15
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-8 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A3-15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A3-9
SPECIFICATIONS
Application OM662LA OM661LA
Engine Type Four-Stroke Diesel Four-Stroke Diesel
Displacement (CC) 2874 2299
Cylinder (Bore x Stroke) (mm) 89 x 92.4 89 x 92.4
Fuel Injection / Ignition System PES 5 M55 C320 RS 168 PES 5 M55 C320 RS 167
Compression Ratio 22:1 22:1
Number of Cylinders 5 4
Camshaft Valve Arrangement SOHC SOHC
Camshaft Drive Type Chain-Drive Chain-Drive
Max. Output (ps/rpm) 120 / 4000 101 / 4000
Max. Torque (kg•m/rpm) 25.5 / 4000 21.5 / 2400
Firing Order 1-2-4-5-3 1-3-4-2
Injection Timing BTDC 18°± 10° BTDC 18°± 10°
Valve Timing Intake Open/Close ATDC 11.33° / ABDC 17° ATDC 11.33° / ABDC 17°
(at 2mm lift) Exhaust Open/Close BBDC 28° / BTDC 15.25° BBDC 28° / BTDC 15.25°
Valve Clearance Adjustment Automatic Control Automatic Control


Application OM 662 LA OM 661 LA
Idle Speed (rpm) 720 - 820 750 - 850
Fuel Injection Pressure (bar) 135 - 143 135 - 143
Oil Capacity (liter) 8.0 - 9.5 6.5 - 8.0
Lubrication Type Forced by Gear Pump Forced by Gear Pump
Oil Filter Type Combined Full-Flow and Partial Flow Combined Full-Flow and Partial Flow
Filter Filter
Fuel Diesel Diesel

SECTIONAL VIEW
OM662LA ENGINE
Front View

Side View

OM661LA ENGINE
Front View

Side View

PERFORMANCE CURVE
OM662LA ENGINE
rpm

OM661LA ENGINE
rpm

SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 001 589 65 09 00

001 589 76 21 00 001 589 73 21 00

Compression Pressure Hand Vacuum Pump
Tester

DIAGNOSIS
OIL LEAK DIAGNOSIS 1. Pour the specified amount of dye into the engine
oil fill tube.
Most fluid oil leaks are easily located and repaired
2. Operate the vehicle normal operating conditions
by visually finding the leak and replacing or repairing
as directed in the kit.
the necessary parts. On some occasions a fluid leak
may be difficult to locate or repair. The following 3. Direct the light toward the suspected area. The
procedures may help you in locating and repairing dyed fluid will appear as a yellow path leading to
most leaks. the source.
Finding the Leak Repairing the Leak

1. Identify the fluid. Determine whether it is engine Once the origin of the leak has been pinpointed
oil, automatic transmission fluid, power steering and traced back to its source, the cause of the leak
fluid, etc. must be determined n order for it to be repaired
properly. If a gasket is replaced, but the sealing
flange is bent, the new gasket will not repair the
2.1 After running the vehicle at normal operating leak. The bent flange must be repaired also. Before
temperature, park the vehicle over a large attempting to repair a leak, check for the following
sheet of paper. conditions and correct them as they may cause a
2.2 Wait a few minutes. leak.
2.3 You should be able to find the approximate Gaskets
paper. l The fluid level/pressure is too high.
3. Visually check around the suspected component. l The crankcase ventilation system is
Check around all the gasket mating surfaces for malfunctioning.
leaks. A mirror is useful for finding leaks in areas l The fasteners are tightened improperly or the
that are hard to reach. threads are dirty or damaged.
4. If the leak still cannot be found, it may be l The flanges or the sealing surface is warped.
necessary to clean the suspected area with a l There are scratches, burrs or other damage to
degreaser, steam or spray solvent. the sealing surface.
4.1 Clean the area well. l The gasket is damaged or worn.
4.2 Dry the area. l There is cracking or porosity of the component.
4.3 Operate the vehicle for several miles at l An improper seal was used (where applicable).
normal operating temperature and varying
speeds.
Seals
4.4 After operating the vehicle, visually check
the suspected component. l The crankcase ventilation system is
4.5 If you still cannot locate the leak, try using malfunctioning.
the powder or black light and dye method. l The seal bore is damaged (scratched, burred or
nicked).
Powder Method
l Improper installation is evident.
2. Apply an aerosol-type powder (such as foot
l There are cracks in the components.
powder) to the suspected area.
l The shaft surface is scratched, nicked or
damaged.
conditions.
l A loose or worn bearing is causing excess seal
4. Visually inspect the suspected component. You
wear.
should be able to trace the leak path over the
white powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks,
Refer to the manufacturer's directions when using
the kit.

1 Test Adapter
2 Flexible Connector
3 Compression Pressure Recorder
Service Data
Normal Compression Pressure 28bar
Minimum Compression Pressure Approx.18bar
Permissible Pressure Difference Between Individual Cylinders Max. 3bar
lEngine at normal operating temperature of 80°C
Tools Required
000 589 65 09 00 Socket
001 589 73 21 00 Hand Vacuum Pump

Compression Pressure Measurement
Notice
Ensure that no gear is engaged and that the vehicle is
protected from rolling.
1. Run the engine to be the coolant temperature 80°C.
2. Remove the fuel injection nozzle.
Socket Wrench Insert 001 589 65 09 00

3. Install the test adapter (1) and connect the flexible
connector (2) to the compression pressure recorder.
Compression Pressure Recorder 001 589 76 21 00
4. Disconnect the vacuum line from the stop unit and

connect the hand vacuum pump to the stop unit.
5. Pump the hand vacuum pump and make the fuel injection
pump in stop position.
Operating Pressure Approx. 500bar
Hand Vacuum Pump 001 589 73 21 00
6. Using a starter motor, crank the engine 8 revolutions.

7. Measure the remaining cylinder compression pressure
in the same manner and compare it with service data.
Notice
If out of standard, do cylinder pressure leakage test.
8. Remove the compression pressure recorder.
9. Install the fuel injection nozzle.

1 Connector
2 Connection Piece
3 Connection Hose
Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80°C)

Commercial Tools
Cylinder Pressure Leakage tester BOSCH, EFAW 210 A or SUN CLT 228
Connection Piece BOSCH order no. 1 687 010 016

Leakage Test
1. Run the engine to be the coolant temperature 80°C.
3. Open the coolant subtank cap.
4. Check the coolant level and replenish if necessary.
5. Open the oil filler cap.
6. Remove the air cleaner cover and element.
7. Position the piston at TDC.
8. Install the connector (1) and connection piece (2).
9. Calibrate the tester and connect the connection hose
(3)
10. Pressurize with compressed air and compare the
pressure changes with permissible pressure leakage.
11. If permissible pressure leakage is out of standard,
check followings :
- Intake and exhaust lines.
- Sounds in oil filler area.
- Air bubbles in radiator coolant.
12. Do pressure leakage test for the remaining cylinders
according to the firing order.
l OM 662LA Engine : 1-2-4-5-3
l OM 661LA Engine : 1-3-4-2
13. Remove the tester.
14. Close the coolant pressure cap and oil filler cap.
15. Install the air cleaner element and cover.

GENERAL INFORMATION
CLEANLINESS AND CARE Battery cables should be disconnected before any
major work is performed on the engine. Failure to
An automobile engine is a combination of many disconnect cables may result in damage to wire
machined, honed, polished and lapped surfaces with harness or other electrical parts.
tolerances that are measured in the ten-thousanths
of an inch. When any internal engine parts are ON-ENGINE SERVICE
serviced, care and cleanliness are important. A liberal
coating of enigne oil should be applied to friction Caution: Disconnect the negative battery cable
areas during assembly, to protect and lubricate the before removing or installing any electrical unit,
surfaces on initial operation. Proper cleaning and or when a tool or equipment could easily come
protection of machined surfaces and friction areas in contact with exposed electrical terminals.
is part fo the repair procedure. This is considered Disconnecting this cable will help prevent
standard shop practice even if not specifically stated. personal injury and damage to the vehicle. The
ignition must also be in LOCK unless otherwise
noted.
service, they should be kept in order. They should
be installed in the same locations, and with the same Notice: Any time the air cleaner is removed, the
mating surfaces, as when they were removed. intake opening should be covered. This will protect
against accidental entrance of foreign material, which
could follow the intake passage into the cylinder
and cause extensive damage when the engine is
started.

SECTION 1B1
M162 ENGINE MECHANICAL

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B1-2 Camshaft Timing Position . . . . . . . . . . . . . . 1B1-63
Fastener Tightening Specifications . . . . . . . . 1B1-2 Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-66
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4 Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-70
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4 Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-71
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8 Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-74
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1B1-8 Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-79
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8 Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-80
Crankcase Ventilation System . . . . . . . . . . 1B1-15 Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-81
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-17 Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-82
Power Steering Pump and A/C Bracket . . . 1B1-18 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-84
Hydraulic Engine Mounting Insulator . . . . . . 1B1-21 Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-87
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-24 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-89
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-26 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-91
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-28 Engine Oil and Oil Filter Element . . . . . . . . 1B1-93
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-30 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-95
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-32 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-34 Oil Pressure Relief Valve . . . . . . . . . . . . . . 1B1-99
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-37 Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-100
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-39 Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-101
Belt Pulley and Vibration Damper . . . . . . . . 1B1-41 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-102
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-44 Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-102
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-45 Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-104
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-46 Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-107
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-52 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-109
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-54 Crankcase Mating Surface . . . . . . . . . . . . 1B1-111
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-57 Cylinder Head Mating Surface . . . . . . . . . 1B1-113
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-58

1B1-2 M162 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application N·
·m
Power Steering Hydraulic Lines 35 - 40
A/C High Pressure and Liquid Hose 10 - 15
Radiator Support Menber Bolt 5 - 10
Fuel Supply and Return Hose to Fuel Distributor 21 - 25
Exhaust Manifold and Pipe 30
Propeller Shaft to Transmission 56 - 66
Engine Mounting Nut 50 - 60
Alternator Carrier Bolt 10 - 15
Belt Pulley Bolt 41.5 - 49.5
Steering Pump Bolt 22.5 - 27.5
A/C Bracket Bolt 22.5 - 27.5
Intake Air Duct Bolt 9 - 11
Ignition Cable Cover Bolt 9 - 11
Cylinder Head Cover Bolt 22.5 - 27.5
Camshaft Adjuster Bolt 9 - 11
Cylinder Head Front Cover Bolt 22.5 - 27.5
Flange Bolt in Exhaust Camshaft Sprocket 10
+90°
Cylinder Head Bolt 55
+90°
+90°
Cooling Fan Bracket Bolt 22.5 - 27.5
Timing Gear Case Cover Bolt M8 22.5 - 27.5
M6 9 - 10
Crankshaft Rear Cover Bolt 9-10
Vibration Damper Center Bolt 200
+90°
Connecting Rod Bearing Cap Bolt 40
+90°
Flywheel Stretch Bolt 45
+90°
Amarture Bolt in Flywheel 35
Ring and Seal Cover Nut in Flywheel 9 - 11
Sprocket Bolt to Exhaust Camshaft 20
+90°
Camshaft Adjuster Flange Bolt 20
+90°
Intake Flange Shaft Bolt 20 / +90°
Exhaust Camshaft Sprocket Bolt 20 / +90°
Camshaft Bearing Cap Bolt 22.5 - 27.5

M162 ENGINE MECHANICAL 1B1-3
FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application N·
·m
Exhaust Camshaft Sproket Bolt 20 / +90°
Chain Tensioner Screw Plug 40
Chain Tensioner Assembly 72 - 88
Exhaust Camshaft Sprocket to Camshaft 20 / +90°
Oil Pump Sprocket Bolt 25 - 35
Tensioning Device Bolt 22.5 - 27.5
Water Pump Pulley 22.5 - 27.5
Upper Intake Manifold Bolt 22.5 - 27.5
Lower Intake Mainfold Bolt 22.5 - 27.5
Flange Bolt to Exhaust Mainfold 30
Exhaust Mainfold Nut to Stud Bolt 26 - 34
Rivet Nut in Exhuast Mainfold Hole 30
Pre-silencer Bolt 8 - 10
Oil Drain Plug 25
Oil Filter Cover 25
Oil Filter Bolt 22.5 - 27.5
Oil Pump Drive Sprocket Bolt 29 - 35
Oil Pump Mounting Bolt 22.5 - 27.5
Oil Strainer Bracket Bolt 9 - 11
Oil Pressure Relief Valve Screw Plug 50
Oil Dipstick Guide Tube Bolt 9 - 11
Oil Gallery Screw Plug 15

SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 000 589 40 37 00

Torque Wrench Hose Clamp
112 589 00 72 00 000 589 72 21 00

Oil Extractor Torque Wrench
001 589 66 21 00 124 589 15 21 00

Torque Wrench Radiator Cap
Testing Unit
000 589 01 10 00 116 589 02 34 00

Box Wrench Insert Screw-Fixed Pin

SPECIAL TOOLS TABLE (Cont’d)
104 589 01 01 00 111 589 01 59 00

Spanner Supporting Bar
111 589 18 61 00 111 589 25 63 00

Lever Pusher Thrust Piece
116 589 06 63 00 104 589 00 37 00

Magnetic Finger Pliers
119 589 00 43 00 000 589 58 43 00

Drift Chain Assembly

116 589 20 33 00 601 589 03 43 00

Sliding Hammer Sleeve
602 589 00 40 00 103 589 00 33 00

Engine Lock Puller
001 589 65 09 00 000 589 88 33 00

Socket Wrench Insert Puller
001 589 74 21 00 000 589 04 14 00

Torque Wrench Clamping Strap

103 589 01 63 00 615 589 01 33 00

Rivet Set Caulking Bolt
103 589 02 09 00 102 589 12 15 00

Oil Filter Drift
Socket Wrench
102 589 00 15 00 601 589 03 14 00

Drift Sleeve
000 589 51 37 00 001 589 72 21 00

Clamping Strap Torque Wrench


ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Tools Required
000 589 10 99 01 Torque Wrench
000 589 40 37 00 Hose Clamp
112 589 00 72 00 Oil Extractor
124 589 15 21 00 Radiator Cap Testing Unit
Removal & Installation Procedure

1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the under cover.
Installation Notice
Tightening Torque 28 - 47 Nm
4. Disconnect the coupling of HFM sensor and remove the air

cleaner cross pipe.
5. Remove the air cleaner cover. Remove the mounting bolts

and air cleaner housing and element assembly.

6. Loosen the radiator drain cock and drain the coolant.
Notice
Open the coolant reservoir cap.
7. Loosen the cylinder block drain plug and then drain the
coolant completely.
Installation Notice
Tightening Torque 30 Nm
Notice
Replace the seal before installation of the drain plug.
8. Remove the cooling fan shroud.
9. Disconnect the each hose from radiator.

10. Remove the upper mounting bolts of radiator and then
remove the radiator.
11. Remove the hydraulic pipe of power steering.

Notice
Completely drain the oil.
12. Discharge the refrigerant from A/C system, and disconnect

the discharge pipe and suction pipe from the compressor.
13. Remove the acceleration control cable and automatic

transmission pressure cable.

14. Remove the fuel feed and return line.
Notice
Before removing the fuel lines, release the pressure in the
fuel system.
Installation Notice
15. Remove the automatic transmission dipstick guide tube.
16. Disconnect the wire of alternator.
17. Disconnect the wire of starter motor and remove the starter
motor.
18. Disconnect the engine main harness ground.

19. Disconnect the engine ground wire.
20. Disconnect following sensors connector.
l HFM sensor.
l Coolant temperature sensor.
l 2 knock sensors.
l Camshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition
coil connector.
22. Remove the harness cover and disconnect the 6 injection
valve connectors. Disconnect the main harness
23. Separate the hose toward engine from canister purge

solenoid valve.
24. Remove the automatic transmission oil cooler line.

25. Separate the vacuum hose for brake booster.
26. Separate the other vacuum hoses.
27. Remove the propeller shaft from the front axle.

Installation Notice
28. By rotating the crankshaft from the front of engine, remove

the 6 torque converter mounting bolts from the engine
ring gear plate.
29. Remove the exhaust manifold and exhaust pipe.

Installation Notice

30. Remove the transmission mounting bolts and separate
the transmission from the engine.
Installation Notice
31. Remove the bolts for engine mounting bracket.

Installation Notice
32. Hook the chain to the bracket of engine and by using a

hoist or crane, carefully separate the engine assembly
from the vehicle.
33. Installation should follow the removal procedure in the
reverse order.

CRANKCASE VENTILATION SYSTEM
1 Crankcase 13 Intake Air Duct (Cross Pipe)

2 Air Admission Port in Crankcase 14 Cylinder Head Cover
3 Oil Drain Port 15 Oil Separator
4 Filter 16 Oil Separator
5 Gasket 17 Air Admission and Vent Connection
6 A/C Bracket 18 Air Admission and Vent Connection
7 Oil Drain Pipe 19 Throttle Valve
8 Oil Pan 20 Vent Line
9 Air Admission Line A Fresh Air
10 Vent Line B Blowby Gas in Partial Load
11 Restriction Hole (Diameter = 2 mm) C Blowby Gas in Full Load
12 Intake Manifold

Operation at Idling and Mid-Load
l It show that the throttle valve (19) is closed or very partially
opened and the vacuum pressure in intake manifold is high.
The blowby gas in the crankcase in partial load flows into
the intake manifold through the vent line (20) after passing
the air conditioner bracket (6) and the filter (4). The air
reentered into the intake manifold will be dilluted on the flow
through the restriction hole (11) in the vent line (10).
The circulated engine oil is separated at the air conditioner
bracket (6) and then returns into the oil pan through the
drain pipe (7).
The vacuum pressure generated at the crankcase sucks
fresh air from intake air line(13) through the air admission
and vent connection (17,18).
The fresh air prevents engine oil from being contami-nated
and the air admission and vent connection (17,18) is
designed to control the rapid pressure changes in intake
air line (13).
Operation at Full-Load
l The throttle valve (19) is fully opened.
All the blowby gases flow into the intake air duct (13) after
passing through the oil separator (15,16) of the cylinder
head cover (14) when fully loaded. This dilluted air will be
supplied to the combustion chamber through the intake
manifold (12).

ALTERNATOR
1 Nut (M8) ......................................... 22.5-27.5 Nm 4 Bolt (M8 x 70, 1 piece) ................... 22.5-27.5 Nm
2 Bolt (M8 x 30, 3 pieces) ................. 22.5-27.5 Nm 5 Bolt (M8 x 75, 1 piece) ................... 22.5-27.5 Nm
3 Bolt (M8 x 40, 1 piece) ................... 22.5-27.5 Nm

1. Remove the drive belt.
2. Remove the alternator.
3. Unscrew the alternator carrier bolts and remove the carrier.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm

reverse order.

POWER STEERING PUMP AND A/C BRACKET

Preceding Work : Removal of cooling fan and shroud
1 Vent Hose 8 A/C Bracket

2 Bolt (M8 x 91, 2 pieces) ................. 22.5-27.5 Nm 9 Gasket ................................................... Replace
3 Power Steering Pump 10 Bracket
4 Bolt (M8 x 105, 4 pieces) ............... 22.5-27.5 Nm 11 Bolt (M8 x 22, 2 pieces) ................. 22.5-27.5 Nm
5 Washer 12 Tensioning Pulley
6 A/C Compressor 13 Nut ................................................. 40.5-49.5 Nm
7 Bolt (M8 x 40, 3 pieces,
M8 x 95, 2 pieces) .......................... 22.5-27.5 Nm

1. Remove the belt pulley.
Installation Notice
Notice
Pull the tensioning pulley clockwise as shown in the figure.
2. Disconnect the hydraulic pipe of the power steering pump

and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump.

Installation Notice
4. Remove the compressor after disconnecting the wiring

connector and refrigerant pipe of A/C compressor.
Notice
Discharge all the refrigerant before removing the pipes.

5. Disconnect the vent hose from the A/C bracket.
6. Unscrew all the mounting bolts (arrows) and remove the

A/C bracket and the gasket.
Installation Notice
7. Clean the sealing surface.

8. Replace the gasket with new one.
reverse order.
10. Check the oil leakage by operating the engine after
installation.

HYDRAULIC ENGINE MOUNTING INSULATOR

Service Data

Sectional View
1 Rubber Body 9 Lower Orifice

2 Brackek 10 Upper Orifice
3 Core 11 Diaphram
4 Lower Bolt 12 Cover Plate
5 Rubber Plunger 13 Upper Bolt
6 Plunger Plate 14 Flange Bolt
7 Rubber 15 Rivet
8 Plate 16 Fluid

1 Upper Nut
2 Hydraulic Installor ................. 62-93 Nm
3 Lower Nut ............................. 28-47 Nm
Removal and Installation Procedure

1. Unscrew the upper nut(1) on engine mounting and remove
the engine.
Installation Notice
2. Unscrew the lower nut(3) and remove the hydraulic engine

mounting insulator.
Installation Notice
Notice
If the insulator is spotted with oil, replace the hydraulic
insulator assembly.
reverse order.

POLY V-BELT
1 Poly V-belt 2 Belt Tensioning Pulley

1. Release the belt tension by turning the belt tensioning pulley
nut clockwise.
2. Remove the poly v-belt.
Notice
Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley
clockwise.

Poly V-Belt Arrangement
1 Belt Tensioning Pulley 5 Alternator Pulley

2 Crankshaft Belt Pulley 6 Idler
3 A/C Compressor Pulley 7 Power Steering Pump Pulley
4 Cooling Fan Pulley 8 Cooling Fan and Water Pump Pulley

TENSIONING DEVICE
Preceding Work : Removal of poly v-belt
1 Belt (L = 2245) 3 Water Pump Pulley

2 Bolt Combi(M8 x 14, 3 pieces) + Washer 4 Nut
....................................................... 22.5-27.5Nm 5 Tensioning Pulley

2. Remove the tensioning pulley by turning its mounting nut
counter clockwise as shown in figure.
Installation Notice

3. Remove the 3 bolts (2) and remove the water pump pulley
(arrow).
Installation Notice
4. Remove the mounting bolts(M8 x 30, 3 pieces) at the

tensioning device, and remove the tensioning device (arrow).
Installation Notice

reverse order.

POLY V-BELT INSPECTION

l Make marks on the belt with chalk.
l Rotate the engine and check the belt for damage.
Notice
If one of the following types of damages is found, replace
the belt.
1. Rubber lumps in the base of rib.

2. Dirt or grit ingrained.
3. Pointed rib.
4. Belt cord visible in the base of rib.
5. Cord torn out at the side.

6. Outer cords frayed.

7. Rib detached from the base of belt.
8. Splits across the rib.

9. Sections of rib torn out.
10. Splits across several ribs.
11. Splits across the back of the belt.

CYLINDER HEAD COVER
1 Ignition Cable Dust Cover 6 Cylinder Head Cover

2 Bolt (M6 x 65, 8 pieces) ......................... 9-11 Nm 7 Gasket ................................................... Replace
3 Bolt (M6 x 50, 4 pieces) ......................... 9-11 Nm 8 Spart Plug Hole Seal .............................. Replace
4 Spacer Sleeve 9 Camshaft Seal ....................................... Replace
5 Thrust Piece
Composition of The Cylinder Head Cover Bolts
A. M6 x 50, 4 Pieces - Bolts + Washers

B. M6 x 65, 8 Pieces - Bolts + Washers

1. Remove the intake air duct.
Installation Notice
Tightening Torque 8.4 ± 0.65 Nm
2. Remove the ignition cable cover.

Installation Notice
Notice
Unscrew the seven (M6 x 60) bolts and remove the ignition
cable cover.
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2,3) and remove the head cover and
the gasket.
Installation Notice
Notice
Replace the gasket with a new one if necessary.
reverse order.
6. Check for oil leaks by operating the engine.

CYLINDER HEAD FRONT COVER

Preceding Work : Removal of cylinder head cover
Removal of coolant connection fitting
1 Camshaft Position Sensor 5 Bolt (M8 x 80, 3 pieces) ................. 22.5-27.5 Nm

2 Magnet Assembly 6 Front Cover
3 Upper Guide Rail 7 Rubber Gasket ...................................... Replace
4 Bolt (M6 x 60, 3 pieces) ................. 22.5-27.5 Nm 8 Bolt (M6 x 16, 3 pieces) ......................... 9-11 Nm

1. Remove the magnet assembly.
Installation Notice

2. Remove the cylinder head front cover (6).
Installation Notice
Apply the sealant at the mating surface of the cylinder head

and the front cover.
3. Remove the upper guide rail pin and the guide rail (3).
Installation Notice
Install it while the chain tensioner is loose.
4. Remove the gasket (arrow).

Installation Notice
Replace the gasket with new one and apply the sealant.
reverse order.

CYLINDER HEAD
Removal of cylinder head front cover
Removal of upper intake manifold
1 Cylinder Head Bolt (14 pieces) 4 Exhaust Camshaft Sprocket

.................................................... 1st step 55 Nm 5 Cylinder Head
2nd step 90° 6 Gasket ................................................... Replace
3rd step 90° 7 Dowel Sleeve
2 Washers (14 pieces)
3 Flange Bolts (3 pieces) ................ 1st step 20 Nm
2nd step 90°

Tools Required
000 589 01 10 00 Box Wrench Insert
116 589 02 34 00 Screw-fixed Pin
116 589 20 33 00 Sliding Hammer

1. Rotate the crankshaft so that the piston of number 1 cylinder
is at TDC.
Notice
Rotate the crankshaft in the normal engine direction.
2. Put the alignment marks (arrows) on the timing chain and
camshaft sprocket.
3. Drain the coolant from the crankcase.
4. Remove the three flange bolts in the exhaust camshaft

sprocket.
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
Do not reuse the removed bolts.
5. Separate the chain from the camshaft sprockrt.

Notice
Be careful not to drop the chain into the timing case.

6. Remove the guide rail fixing pin from the cylinder head using
the sliding hammer (01) and the threaded pin (02).
Sliding Hammer 116 589 20 33 00

Threaded Pin 116 589 02 34 00
7. Remove the cylinder head bolts in numerical order.

Installation Notice
1st step 55 Nm
Tightening Torque 2nd step 90°
3rd step 90°
Box Wrench Insert 000 589 01 10 00
8. Check the length of the cylinder head bolt.

Installation Notice
New 160 ± 0.8 mm

Length (L)
Max. 162 ± 0.7 mm
l Replace the bolt if the measured length exceed the max.

length.
l Apply the oil to the thread surface of bolt.
9. Carefully remove the cylinder head and check the mating

surface.

reverse order.

TIMING GEAR CASE COVER

Preceding Work : Removal of cylinder head front cover
Removal of alternator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper
1 Bolt (M8 x 60, 3 pieces) ................. 22.5-27.5 Nm 6 Seal

2 A/C Bracket 7 Timing Gear Case Cover
3 Bolt (M8 x 65, 3 pieces) ................. 22.5-27.5 Nm 8 Roll Pin
4 Bolt (M8 x 40, 1 piece) ................... 22.5-27.5 Nm 9 Bolt (M6 x 22, 6 pieces) ......................... 9-11 Nm
5 Bolt (M8 x 60, 1 piece) ................... 22.5-27.5 Nm

camshaft sprocket.
2. Unscrew the A/C bracket bolts (1) and remove the bracket.
Installation Notice

3. Remove the cooling fan and the viscous clutch. Unscrew
the three bolts from the cooling fan bracket and remove the
bracket (arrows).
Installation Notice
4. Remove the timing gear case cover after unscrewing the

bolts (3) and (4) from the timing gear case cover and the
bolt (9) from the oil pan.
Notice
Be careful not to damage the oil pan gasket.
Installation Notice
Bolt (3,4) 22.5 - 27.5 Nm

Tightening Torque
Bolt (9) 9 - 11 Nm
l Apply the sealant after cleaning the timing gear case

cover surface.
l Be careful not to stain the oil chamber of chain tensioner
with the sealant.

reverse order.
6. Warm up the engine and check for oil leaks.

CRANKSHAFT SEALING REAR COVER

Preceding Work : Removal of the automatic transmission drive plate
1 Bolt (M6 x 20, 6 pieces) ......................... 9-11 Nm 4 Sleeve

2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......................... 9-11 Nm
3 Rear Cover 6 Washer

Tools Required
601 589 03 43 00 Sleeve

1. Unscrew the bolts (1) and (5) and remove the closing cover
by pulling the rear cover lug (arrows).
Notice
2. Clean the sealing surface of the crankcase and the rear

sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
Notice
Do not use the grease.
6. Using the special tool, press the radial shaft seal and the
rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan
bolt (5) as specified and remove the special tool.
Installation Notice
Tightening Torque(Bolt 1,5) 9 - 11 Nm
Seal Assembler 601 589 03 43 00

BELT PULLEY AND VIBRATION DAMPER

Preceding Work : Removal of cooling fan and viscous clutch
Removal of fan shroud
Removal of drive belt
1 Center Bolt (M18 x 50) ...... 1st step 200- 220 Nm 4 Vibration Damper Assembly
2nd step 90°+10° 5 Key
2 Vibration Damper Disk 6 Bolt (M6 x 12, 4 pieces) ......................... 9-11 Nm
3 Bolt (M6 x 20, 6 pieces) ..................... 7.7-9.5 Nm 7 Cooling Fan Pulley

Components
1 Center Bolt (M18 x 50)

2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)
Service Data Standard

Permissble Deviation of The Vibration Damper Radial Runout 0.6 mm
Axial Runout 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
602 589 00 40 00 Engine Lock

1. Adjust the piston of number 1 cylinder to the TDC.

2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
1st step 200 - 220 Nm
Tightening Torque
2nd step 90° +10°
Engine Lock 602 589 00 40 00
4. Remove the vibration damper assembly using the puller.

reverse order.
Notice
If possible, don’t separate the vibration damper and the
pulley.

CRANKSHAFT FRONT RADIAL SEAL

Preceding Work : Removal of belt pulley and vibration damper

................................ 1st step 200-220 Nm
2nd step 90° +10°
3 Sleeve (Special Tool)
5 Key
Tools Required
601 589 03 14 00 Sleeve
Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal mounting
hole and the crankshaft.
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
1st step 200 - 220Nm
Tightening Torque
2nd step 90° + 10°
5. Remove the sleeve and install the belt pulley and the
vibration damper.
6. Check for leaks while operating the engine.

CRANKSHAFT REAR RADIAL SEAL

Preceding Work : Removal of flywheel or drive plate
1 Special Tool 3 Crankshaft Rear Seal

2 Special Tool
Tools Required
601 589 03 43 00 Sleeve
Replacement Proceudre
Notice
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
Notice
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.

CRANKSHAFT
Preceding Work : Removal of engine assembly
Removal of timing gear case cover
Removal of cylinder head
Removal of oil pump
Removal of oil shield
1 12-sided Stretch Bolt ........ 55 Nm x 90°, Iubricate 4 Lower Thrust Bearing

2 Crank Shaft Bearing Cap 5 Crank Shaft
3 Crank Shaft Low Main Bearing

Arrangement of the Thrust Bearing and the Main Bearing
1 Upper Main Bearing A Crankcase Side

2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side)
3 Crankshaft C Axial Fit Bearing (Number 5 Bearing Point)
4 Lower Main Bearing D Radial Bearing
5 Lower Thrust Bearing
1 - 12 Weight Balance/Color Marking Point

j1 - j7 Journal Main Bearing #1 - #7
l Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6 , 8

,10 ,12 and it indicates the diameter of crankshaft journal
by color as below.

Color Dot Marking Crankshaft Journal Diameter (mm)

Blue 57.960 - 57.965
Yellow 57.955 - 57.960
Red 57.950 - 57.955
White 57.945 - 57.950
Violet 57.940 - 57.945
Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating surface to
oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing according
to the punching mark when repaired.
Punching Mark Bearing Color Selected

· Blue
·· Yellow
··· Red
2. Crankshaft Bearing Cap Side

Select the crankshaft main bearing according to the marking
letter on the crankshaft main journal when repaired.
Marking Letter Bearing Color Selected
B Blue
Y Yellow
R Red
W White
V Violet
Service Data Unit : mm

Crankshaft Crankshaft Crankshaft Connecting Rod Connecting
Crankshaft Standard Bearing Jour- Bearing Journal Width Bearing Journal Rod Bearing
and Repair Size nal Diameter Diameter at fit bearing Diameter Jourmal Width
Standard size 57.950-57.965 58 24.50-24.533 47.94-47.96 27.958-28.042
1st repair size 57.700-57.715 47.75
2nd repair size 57.450-57.465 47.50 -
- -
3rd repair size 57.200-57.215 47.25
4th repair size 56.950-56.965 47.00

1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap.
Installation Notice
Tightening Torque 40 Nm + 90°
l Make sure that the upper and lower bearing shells do

not change each other.
l Coat the bearing shell with engine oil.
l Install the bearing cap according to the consecutive
number.
2. Unscrew the crankshaft bearing cap bolts and separate the

upper and lower bearing shells and thrust washers.
Installation Notice
l Remove the bearing cap from front (pulley side) to rear.

not change each other and coat with engine oil.
l The oil grooves (arrows) in the thrust washers must face
outward and insert the thrust bearing into the bearing
cap.
l There are five kinds of thrust washers by thickness. Select
the proper washer when repaired. Part No. : 601 030 00 62 2.15 mm
Part No. : 601 030 01 62 2.20 mm
3. Remove the crankshaft. Part No. : 601 030 02 62 2.25 mm
4. Installation should follow the removal procedure in the Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
reverse order.
5. After completion of the installation, check for the rotating
condition of the crankshaft.
Installation Notice
l Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed,
the projected part (arrow) locates in the left side (intake
manifold side).
l Assemble so that the projected part of the cap and
crankcase face the same direction.

Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated

on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft

bearing.
Notice
l Measure at 2 points (1, 2).
l Measure ‘A’,‘B’and ‘C’ as shown. If average value of ‘B’
and ‘C’is less than value ‘A’, then the average value of
‘B’ and ‘C’ is actual average value. If average value of
‘B’ and ‘C’ is more than value ‘A’is actual average value.
4. Measure and record the diameter of the crankshaft bearing

journal.
Notice
l Record the mean value when measured at 3 points (A,
B, C).
l Measure the inner diameter of bearing and the diameter
of journal and if it is out of the standard data, replace
the bearing shell.

Service Data Standard (Crankshaft Main Bearing Gap)
Item Measuring Position Gap (mm)
Main Bearing Journal Static condition :0.015 - 0.039
( NO. 1, 5, 7) Radial Dynamic condition: 0.031 - 0.051
(Consider the expansion 0.011 - 0.016)
Axial 0.010 - 0.254
Axial 0.010 - 0.254
(Connecting Rod Bearing Gap)

Connecting Rod Bearing Radial 0.030 - 0.050

FLYWHEEL / DRIVEN PLATE

Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) 3 Driven Plate (A/T)

............................................... 1st step 45+5 Nm 4 Dowel Pin
2nd step +90° +10°
2 Plate
Service Data Standard (Stretch Bolt)

Nominal Size D - M x 1.5
Stretch Side Diameter d When New 8.5 - 0.2 mm
Min. Diameter 8.0 mm
Bolt Length L When New 21.8 - 22.2 mm
Tightening Torque 1st step 50 Nm, 2nd step 90°

1. Unscrew the stretch bolt.
Installation Notice
1st step 45+5 Nm
Tightening Torque
2nd step 90° + 10°
l Replace the bolt when the stretch side diameter (d) of

the flywheel mounting bolt is less than 8.0mm.
l For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or

the driven plate (3), and plate (2) for Auto. transmission
vehicle.
reverse order.
Sectional View
1 Oil Pan
2 Cover
4 Flywheel MTG Bolt
5 Crankshaft
6 Dowel Pin
7 Plate
8 TGCC
9 Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear

CAMSHAFT ADJUSTER
1 Bolt (M6 x 16, 3 pieces) ........................ 9-11 Nm 13 Camshaft Sprocket and Position Indicator (b)
2 Electromagnetic Actuator (2 Pin Connector) 14 Adjuster piston
3 Bolt ........................................................... 35 Nm 15 Flange bolt (M7 x 13, 3 pieces)
4 Armature .............................................. 1st step 18-22 Nm
5 Roll Pin 2nd step 90° ± 5°
6 Nut (M20 x 1.5) .................................... 60-70 Nm 16 Flange Shaft
7 Front Cover 17 Compression Spring
8 Seal 18 Control Piston
9 Camshaft Position Sensor 19 Circlip
10 Bolt (M6 x 16, 2 pieces) ......................... 9-11 Nm 20 Oil Gallery
11 Seal 21 Pin
12 Seal Cover 22 Intake Camshaft

1. Turn the crankshaft to the direction of engine rotation and
position the no.1 cylinder piston at TDC which the camshaft
is positioned at OT.
2. Remove the cylinder head front cover.

3. Paint the alignment marks (arrows) on the intake and
exhaust camshaft sprocket and the timing chain.
4. Unscrew the bolt (3) from the armature (4) and remove the
armature.
Installation Notice
5. Unscrew the nut (6) and remove the ring and seal cover
(11).
Installation Notice
3 Bolt 12 Camshaft Sprocket

4 Amarture 17 Control Piston
6 Nut (M20 x 1.5) 21 Intake Camshaft
11 Seal Cover
6. Unscrew the sprocket bolt from the exhaust camshaft and
remove the sprocket.
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
The sprocket bolt is designed to be used only once, so

always replace with new one.

7. Remove the camshaft sprocket (13) and adjust piston (14),
and remove the flange shaft (16) from the intake camshaft
(22) after removing the bolt (15).
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
reverse order.
9. Adjust the camshaft timing.

CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
Notice
The sprocket bolts are designed to be used only once, so
C. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
Exhaust Camshaft Sprocket Bolt

1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
Notice
E. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft

CAMSHAFT
Preceding Work : Removal of cylinder head cover, removal of coolant connection fitting
1 Chain Tensioner Assembly .................. 72-88 Nm 5 Intake Camshaft Sprocket

2 Exhaust Camshaft Sprocket 6 Chain
3 Upper Guide Rail 7 Wrench (Special Tool)
4 Cylinder Head Front Cover

Tools Required
104 589 01 01 00 Spanner
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
3. Remove the chain tensioner.
4. Remove the cylinder head front cover and the upper guide
rail.
5. Put the alignment marks (arrows) on the camshaft sprocket

(2, 5) and the timing chain (6).
6. Unscrew the exhaust camshaft sprocket bolt and remove

the sprocket.
7. Separate the chain from the intake camshaft sprocket and
put the chain not to be dropped into timing case.

8. Unscrew the intake side bolts (8, 11, 13, 14) and the exhaust
side bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and
exhaust side camshaft bearing cap bolts.
Notice
Number the camshaft bearing cap bolts when removing
them, so that they don’t get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Install the exhaust camshaft bearing caps (2, 3, 5) and the
intake camshaft bearing caps (9, 10, 12). Tighten the bolts
with specified torque and install the remaining bearing caps.
Notice
Install the bearing caps according to the numbers on the

bearing caps.
3. Turn the camshaft using the wrench (special tool) so that

the intake camshaft adjustment hole lines up with the cylinder
head upper side (3 o’clock direction at the intake, 9 o’clock
direction at the exhaust).
Notice
Turn the crankshaft and adjust it to OT so that no. 1 cylinder’s
piston would be at TDC.

4. Turn the intake camshaft adjuster to the direction of camshaft
rotation by hard until it stops and then install the chain.
Notice
l Make sure that the camshaft sprocket and timing chain
are aligned with marks.
l Intake camshaft adjuster should be in retarded position.
5. Install the chain on the exhaust sprocket and tighten the

sprocket bolts.
Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
l Make sure that the camshaft sprocket and timing chain

are aligned with marks.
l Replace the sprocket bolt with new one.
6. Install the chain tensioner and tighten it as specified.

Notice
(1) 40 Nm
Tightening Torque
(2) 72 - 88 Nm
7. Rotate the crankshaft 2 revolutions and check followings:

- TDC of No. 1 cylinder : OT
- Alignment between camshaft adjustment hole and
cylinder head surface.
- Alignments between timing chain and sprocket marks.
Notice
l Turn the crankshaft in the direction of engine rotation.
l Read just if not aligned.

8. Install the upper guide rail and cylinder head front cover.
9. Install the alternator.

CAMSHAFT TIMING POSITION

1 Chain Tensioner Assembly 4 Cylinder Head Front Cover

2 Exhaust Camshaft Sprocket 5 Wrench (Special Tool)
3 Upper Guide Rail 6 Adjustment Hole Fitting Pin (f 4.0 mm)

Tools Required
104 589 01 01 00 Spanner
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning
the crankshaft.
Notice
When the OT mark on vibration damper is aligned with timing
gear case cover, the intake and exhaust cam of cylinder
will make the slope to the center and will face up. In this
way, the adjustment hole of the intake and exhaust camshaft
will match in line with the cylinder head upper end, at 3
o’clock, and 9 o’clock direction each other.
2. Check the timing as below procedure;
- Check if the camshaft adjustment hole is positioned to 3
o’clock direction at the intake side and to 9 o’clock
direction at the exhaust side, respectively and align with
the cylinder head mating surface.
- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30° .
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with the
cylinder head upper surface.
l Intake Side : 3 o’clock direction
l Exhaust Side : 9 o’clock direction
5. Secure the intake and exhaust camshaft.
6. Position the piston of No.1 cylinder at TDC (OT) by turning
the crankshaft.
7. Turn the camshaft adjuster of the intake camshaft to the
left as much as possible (cam adjuster ‘retarded’ position).
8. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in gear case
cover.

9. Install the chain to the exhaust camshaft sprocket and
install it to the camshaft.
Installation Notice (Sprocket Bolt)
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
replace with new one.
10. Install the chain tensioner.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
Tensioner Assembly 72 - 88 Nm
11. Check the camshaft timing.

VALVE SPRING
Preceding Work : Removal of camshaft
Removal of spark plug
1 Valve Tappet Assembly 7 Connecting Hose

2 Valve Cotter 8 Thrust Piece
3 Upper Retainer 9 Slide
4 Valve Spring .......... Check, Replace if necessary 10 Adjust Bolt
5 Valve Stem Seal 11 Lever Pusher
6 Lower Retainer 12 Supporting Bar

Tools Required
111 589 01 59 00 Supporting Bar
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece
116 589 06 63 00 Magnetic Finger

1. Place the supporting bar (12) and the slide (9) at the
camshaft bearing cap (Nos 1 & 7/8&14) and tighten them
with the bearing cap bolt.
Installation Notice
Supporting Bar 111 589 01 59 00
2. Turn the crankshaft to position the each cylinder piston at

TDC.
Mark on The Vibration Damper Cylinder
OT 1, 6
120° 2, 5
240 3, 4
Notice
l Remove the valve spring only at TDC.
l Always rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and for
smooth rotation.
3. Remove the valve tappet (1) using the magnetic finger.
4. Install the leakage tester connecting hose to the spark plug
hole.
5. Install the engine lock to the ring gear to prevent the
crankshaft from rotating.
6. Blow up with compressed air.

8. Install the lever pusher (11) and the thrust piece (8) to the
slide (9).
Lever Pusher 111 589 18 61 00
9. Mount the thrust piece (8) vertically to the valve spring

retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular
to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
13. Remove the valve cotter (2) using either the pincette (13)
or magnetic finger.
Magnetic Finger 116 589 06 63 00
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
Notice
Check the retainer for damages and replace with a new
one if necessary.
reverse order.

Test (Upper and Lower Valve Tappet and Valve
Cotter)
l Upper Valve Spring Retainer
(d) 8.5
Size (mm)
(D) 12.3
l Lower Valve Spring Retainer
Thickness (mm) (a) 0.8 - 1.0
l Valve Cotter
(B) 9.0
Size (mm)
(H) 9.2 - 9.8

VALVE STEM SEAL

Preceding Work : Removal of valve spring
1 Drift (Special Tool)

2 Valve Stem Seal
3 Protective Sleeve
Tools Required
104 589 00 37 00 Pliers
119 589 00 43 00 Drift
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
Pliers 104 589 00 37 00
2. Coat the valve stem seal with oil and assemble it with the
protective sleeve.
3. Insert the valve stem seal by pressing it with the drift.
Drift 119 589 00 43 00

CHAIN TENSIONER
1 Screw Plug ................................................ 40 Nm 5 Snap Ring

2 Seal 6 Thrust Pin
3 Filler Pin 7 Chain Tensioner Housing ..................... 72-88 Nm
4 Compression Spring 8 Seal
Removal Procedure
1. Position the No.1 cylinder to TDC (OT).
Notice
Remove the oil filler cap at adjustment position, and check
whether the intake camshaft cam’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.
If the chain tensioner is tightened again without completely
reducing its tension, then the detent spring doesn’t return
to the original position and the tension gets excedded.

4. Carefully unscrew the screw plug (1), and remove the seal
(2).
Notice
l For the removal of screw plug, be careful that it can be
jumped out due to the force of compression spring.
l Remove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring (4),
snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).
1. Connect the thrust pin (6) and the snap ring (5) to the chain
tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust pin far
enough so that it doesn’t protrude at the chain tensioner
housing.
2. Install the chain tensioner housing (7), thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
3. Insert the compression spring (4) with the filler pin (3) into
chain tensioner housing.

4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
5. Check for leaks by operating the engine.
Sectional View
1 Screw Plug 13 Chain Tensioner Housing

2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail
7 Compression Spring 19 Cylinder Head Gasket
8 Snap Ring 20 Timing Chain
9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface)
10 Ball (Nonreturn Valve) A Oil Supply Hole
11 Compression Spring B Chain Tensioner Oil Storage Hole
12 Thrust Piece

TIMING CHAIN
1 Pin 5 Link
2 New Timing Chain 6 Center Plate
3 Timing Chain (Used) 7 Outer Plate
4 Wedge

Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
1. Position the No.1 cylinder to TDC (OT).
2. Insert the f 4mm pin to the intake and exhaust camshaft

flange not to rotate camshaft.
4. Mount the wedges to both sides of the camshaft sprocket

as shown in the figure.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket with
the grinder.

6. Remove the outer plate (7) with the screw driver and
remove the link (5).
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the
link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.

12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool.
15. Replace the thrust piece (b) as shown in the figure.
16. Install the assembly tool to the link pin and tighten the
spindle (c).

17. Rivet the link pin.
Check the condition and it again if necessary.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
19. Check the camshaft timing position.

TENSIONING RAIL
Preceding Work : Removal of timing gear case cover
1 Tensioning Rail
2 Plastic Guide
3 Tensioning Rail Pin
4 Guide Rail

1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
3. Remove the tensioning rail (1) from the tensioning rail pin
(3).
Notice
l Replace the plastic guide (2) if it is damaged.
l For installation, exactly align the plastic guide (2) with
the tensioning rail (1).
reverse order.

CYLINDER HEAD GUIDE RAIL

1 Chain Tensioner
2 Upper Guide Rail
3 Upper Guide Rail Pin
4 Wrench (Special Tool)
Tools Required
104 589 01 01 00 Spanner

1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating direction
using the wrench (4) and loosen the timing chain at upper
guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of
rotation using the wrench (4, special tool : 104 589 01 01
00).
5. Check for damages at the upper sliding rail and replace it if
necessary. Install the upper guide rail pin.
Installation Notice
Screw Plug 40 Nm
Tightening Torque

CRANKCASE GUIDE RAIL

1 Guide Rail
2 Plastic Guide
3 Guide Rail Pin
4 Tensioning Rail

1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
l Replace the plastic guide (2) if damaged.
l Connect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
reverse order.

CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail
1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer .......... 29-35 Nm
2 Oil Pump Chain Bushing 7 Oil Pump Sprocket
3 Oil Pump Chain Spring 8 Oil Pump
4 Crankshaft Sprocket 9 Oil Pump Roller Chain
5 Key 10 Timing Chain

Tools Required
615 589 01 33 00 Puller

1. Put the assembly mark at the crankshaft sprocket (4) and
the timing chain (10) with the paint (arrow).
Installation Notice
Align the assembly marks on cranshaft sprocket and timing
chain. Also, align the assembly marks on camshaft sprocket
and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7)
from the oil pump.
Installation Notice
3. Remove the oil pump roller chain (9).

4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the puller (04,
special tool).
Notice
l Make sure not to lose the crankshaft pulley key(5) when
removing.
l Install the crankshaft sprocket(4) after warming it up.
reverse order.
Puller (04) 615 589 01 33 00

PISTON
Preceding Work : Removal of engine
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1 Connecting Rod Bearing Cap 4 Piston

2 Connecting Rod 5 Snap Ring
3 Connecting Rod Bolt (M9 x 52, 12 pieces) 6 Piston Pin
.................................................... 1st step 40 Nm
2nd step 90° + 5°

Tools Required
001 589 72 21 00 Torqued Wrench
000 589 04 14 00 Clamping Strap
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.
Notice
Make sure that the bearing cap and shell are not changed
each other.
3. Remove the snap ring (5) and pull out the piston pin (6).
Notice
Remove the snap ring using a clean cloth as shown in the
right picture so that the piston, piston ring, and the snap
ring don’t get damaged.

1. Check the piston ring gap and apply the engine oil to the
piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in
the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and the piston and coat them
with engine oil.
4. Install the piston ring using the tensioning strap(000 589
04 14 00).
5. Install the piston so that the arrow on the piston head faces
to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark
(// or a number), tighten the bolts.
Installation Notice
1st step 35 - 45 Nm
Tightening Torque
2nd step 90° + 5°
Apply the engine oil to the bearing cap upper and lower
bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating
it.

CONNECTING ROD
Preceding Work : Removal of piston
1 Connecting Rod Bushing

2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt
(M9 x 52, 12 m pieces) .. 1st step 40+5 Nm
2nd step 90°+10°
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]

Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing Bore Center 145 ± 0.05 mm
Width of The Connecting Rod (B) at Bearing Bore 21.940 - 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore 21.940 - 22.000 mm
Basic Bore at The Bearing Shell (D1) 51.600 - 51.614 mm
Basic Bore at The Bushing (d1) 24.500 - 24.571 mm
Bushing Inner Diameter (d) 22.007 - 22.013 mm
Clearance Between The Piston Pin and The Bushing 0.007 - 0.018 mm
Peak-to-valley Height of Connecting Rod Bushing on Inside 0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore 0.15 mm
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting 0.07 mm
Rod Bushing Core
Permissible Deviation of Connecting Rod Bearing Bore from Concentricity 0.01 mm
Permissible Difference of Each Connecting Rod in Weight 0.4 g

Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614mm, replace
the bearing or check the connecting rod.
2. Check connecting rod bolts.

Length When New (L) 51.7 - 52 mm
Max. Length (L) 52.9 mm
Tightening Torque 1st step 40 + 5 Nm
2nd step 90°+10°
Notice
If the length exceeds max. length, replace it.
3. Check the assembly mark(indication//or number:arrow) of

the connecting rods and the bearing cap when installing.
Notice
l Make sure it doesn’t exceed over 4g with other
connecting rods when replacing the connecting rods.
l Check if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing.

PISTON RING
1 Piston Compression Ring

2 Piston Compression Ring
3 Piston Oil Ring
4 -
5 Coil Spring and Control Ring
6 Hook Spring
Tools Required
1. Measure the piston ring’s gap.
End Gap of The Groove 1 0.20 - 0.40 mm
Piston Ring Groove 2 0.20 - 0.40 mm
Groove 3 0.20 - 0.45 mm
Gap Between Groove 1 0.015 - 0.050 mm
The Piston and Groove 2 0.020 - 0.040 mm
The Piston Ring
Groove 3 0.010 - 0.045 mm
Notice
If out of specification, replace the piston ring.

2. Remove the piston ring with a pliers.
Clamping Strap 000 589 51 37 00
3. For installation, position the piston ring to be the ‘TOP’ mark

on the piston ring upward and arrange the piston ring ends
to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away from
the ring end.

OIL PAN
1 Gasket ................................................... Replace 5 Bolt (M6 x 85) ............................................ 10 Nm

2 Bolt (M6 x 22, 6 pieces) ............................ 10 Nm 6 Bolt (M8 x 40) ............................................ 25 Nm
3 Drain Plug (M6 x 20) ................................. 25 Nm 7 Bolt (M10) ................................................. 40 Nm
4 Bolt (M6 x 20, 22 pieces) .......................... 10 Nm 8 Oil Pan

1. Remove the drain plug and drain the oil completely.
2. Disconnect the electric connector from oil level switch.
3. Unscrew the bolts (10) for oil level switch and check the O-
ring (11) for wear or damage. And replace it if necessary.
4. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
5. Clean the inside of oil pan and sealing surface, then apply
the sealant.
7. Install the oil pan with gasket, and tighten each bolt in M8 X 40, 4 pieces
specified torque. M6 X 85, 3 pieces
8. Check for oil leaks while running the engine. M6 X 35, 3 pieces
the rest M6 X 20, 28 pieces

Oil Circulation
1 Oil Pump 19 Oil Supply (To Intake Camshaft)

2 Oil Gallery (to oil filter) 20 Oil Supply (To Exhaust Camshaft Bearing)
3 Oil Filter 21 Oil Supply (To Intake Camshaft Bearing)
4 Oil Pressure Switch 22 Oil Gallery (Oil Supply to Exhaust Valve Tappet)
5 Main Oil Gallery 23 Oil Gallery (Oil Supply to Exhaust Valve Tappet)
6 Cylinder Head Closing Cover 24 Camshaft Closing Cover
7 Oil Gallery (At Chain Tensioner) 25 Ball (f 8 mm)
8 Oil Non-return Valve 26 Screw Plug
9 Chain Tensioner 27 Camshaft Adjuster
10 Vent (Chain Tensioner) 28 Front Closing Cover (Intake Camshaft)
11 Front Closing Cover (f 17 mm) 29 Front Treaded Bushing (Exhaust Camshaft)
12 Oil Gallery (Perpendicular to The Shaft) 30 Valve tappet
13 Ball (f 6 mm)
14 Oil Spray Nozzle (Timing Chain) a Oil Gallery (From Oil Pump to Oil Filter)
15 Oil Gallery (At Cylinder Head) b Main Oil Gallery
16 Ball (f 15mm) c Oil Return Line (Oil Returns to the Oil Pan when
17 Oil Restriction Inner (f 4mm) Replacing the Filter Element)
18 Oil Supply (To Exhaust Camshaft)

ENGINE OIL AND OIL FILTER ELEMENT

Tools Required
103 589 02 09 00 Oil Filter Socket Wrench
1. Install the socket wrench”7” (special tool : 103 589 02 09
00) on the oil filter cover (2).
Notice
Make the screw cover removable by tightening the bolt at
the side of the socket wrench (special tool).
2. Install the wrench to the upper bolt in the socket wrench
and remove the oil cover by turning it.
3. Remove the oil filter element.
Notice
Work with a cloth under the vehicle when removing the oil
filter element to not drain the oil.
4. Remove the drain plug (arrow) and drain the engine oil.
Notice
Leave the oil filler cap open to ease the engine oil discharge.
5. Tighten the engine oil drain plug after cleaning it.
Installation Notice
Replace the seal washer with new one.
6. Replace the O-ring(5) in the oil filter cover with new one.
Notice
Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover (2). Install the socket
wrench “7” (special tool : 103 589 02 09 00), and then
completely tighten it.
Installation Notice
2 Oil Filter Cover

5 O-ring
6 Oil Filter Element
7 Special Tool (Socket Wrench)

9. Fill up engine oil through the engine oil filler opening (3).
10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.
3 Oil Filler Cap

4 Dipstick Gauge

OIL FILTER
Preceding Work : Removal of starter motor
Removal of upper intake manifold
1 Coolant Line 5 Bolt ........................................................... 23 Nm

2 O-ring .................................................... Replace 6 Oil Filter
3 Clip 7 Gasket ................................................... Replace
4 Hose

1. Drain the coolant from the crank case.
2. Remove the each coolant line and hose.
3. Remove the oil filter bolt and then remove the oil filter.
Installation Notice
Notice
Replace the oil filter gasket.
reverse order.
5. Check engine oil level.
6. Run the engine at idle and check the engine for leaks.

OIL PUMP
1 Bolt (M8 x 20, 1 piece) ......................... 29-35 Nm 4 Spring Pin

2 Sprocket (Oil Pump Drive) 5 Oil Pump
3 Bolt (M8 x 35, 3 pieces) ................. 22.5-27.5 Nm

1. Remove the bolt (1) from the oil pump drive sprocket
(2) and separate the gear and the oil pump drive chain.
Installation Notice
2. Unscrew the oil pump mounting bolts (3).

Installation Notice

Tighten the baffle plate and the oil pump with the two bolts
in right side first, and then tighten the other bolt.
3. Unscrew the bolt (9) from the oil strainer bracket.
Installation Notice
4. Remove the oil pump and oil strainer assembly.

5. Replace the strainer in oil pump if necessary.
reverse order.

OIL PRESSURE RELIEF VALVE

1 Screw Plug ................................................ 50 Nm 3 Guide Pin

2 Compression Spring 4 Piston

1. Remove the screw plug (1).
Installation Notice
2. Remove the spring (2), guide pin (3) and the piston (4).
reverse order.
Notice
Don’t use the seal for the screw plug.

OIL NON-RETURN VALVE

1 Oil Non-return Valve
Functions
The non-return valve prevents the oil in the chain tensioner
from drying up. In other words, it stops oil-returning in order to
prevent the oil in the chain tensioner from getting dry. As a
result, the chain tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge 3 O-ring

2 Oil Dipstick Guide Tube 4 Bolt (M6 x 12, 1 piece) ........................... 9-11 Nm

1. Pull out the oil dipstick level gauge (1).
2. Remove the bolt (4) in the upper intake manifold and remove
the oil dipstick guide tube.
Installation Notice
3. Install new O-ring to the dipstick guide tube.

reverse order.
5. Check for leaks by starting the engine.

UNIT REPAIR
OIL GALLERY IN CRANKCASE
Preceding Work : Removal of crankshaft, removal of oil spray nozzle
1 Plug 3 Round Bar ................................... f 11 x 750 mm

2 Steel Ball
Cleaning Procedure
1. Remove the plug (1) with a screwdriver.
2. Using a round bar (3) and hammer, remove the steel ball
(2).
3. Using the compressed air, blow into the oil galleries and
clean it off.

1 Plug ....................................................... Replace 3 Screw Plug

2 Main Oil Gallery
Tools Required
102 589 12 15 00 Drift
Sealing Procedure
1. Enlarge the end of main oil gallery (4) to be diameter of
16mm, depth of 15mm.
2. Using an M16 x 1.5 thread (tap), make the thread at the
end of main oil gallery (4).
3. Throughly clean the oil gallery with compressed air and
tighten the screw plug (M16 x 1.5) after applying sealing
bond on it.
4. Apply Loctite 270 on new plug and tighten to the hole until
the drift is stopped after inserting new plug into the drift.

OIL GALLERY IN CYLINDER HEAD

Preceding Work : Removal of cylinder head
Removal of camshaft
Removal of tappet
1 Screw Plug ................................................ 15 Nm 3 Steel Ball (f 8mm)

2 Seal
Cleaning Procedure
1. Remove the screw plug (1) and the seal (2).
Installation Notice
Replace the seal with new one.
2. Clean the oil gallery using the compressed air.

Sealing Procedure
1. Remove the screw plug (1) and the seal.
Installation Notice
2. Remove the steel ball from the oil gallery (4), (5), (6) and
(7) using the round bar (12, f 6 x 700 mm).
3. Remove the plug (8) using the screw driver.
4. Enlarge the oil gallery at the rear of the cylinder head to be

diameter 9mm, depth 8mm.
5. Tap in the steel ball (3) from the side to the oil gallery using
the punch (13).
6. Pull out the steel ball (3) using the round bar (12).
7. Enlarge the oil gallery to be diameter 9mm, depth 8mm.

8. Make a screw hole at the oil gallery using M10 x 1 thread.
9. All the oil gallery should be cleaned with the compressed
air.
10. Apply the Loctite 270 to new plug and press in using a
suitable drift (arrow).
11. Tighten the screw plug with the seal (arrow).
Screw Plug (Part No. 000 908 01 00 02)

Seal (Part No. 007 603 01 01 03)

CORE PLUGS IN CRANKCASE

Preceding Work : Draining of the coolant
1 Core Plug ............................................... Replace

Tools Required
102 589 00 15 00 Drift
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes out
using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.

Notice
Wait for about 45minutes before filling the coolant so that
the Loctite 240 hardens.
6. Warm up the engine and check the coolant for leaks.

CYLINDER BORE
Group Code Letter and Cylinder Bore Size

Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm)
A A or X f 89.900 - f 90.906
X A, X or B f 89.906 - f 89.912
B X or B f 89.912 - f 89.918
X+5 X+5 f 89.950 - f 89.968
X + 10 X + 10 f 90.000 - f 90.018
Repair Size
Type Group Code Letter1) Cylinder Bore Size (mm)
Standard Size f 89.9 A f 89.900 - f 90.906
X f 89.906 - f 89.912
B f 89.912 - f 89.918
1st Repair Size A f 90.150 - f 90.156
(Standard Size + 0.25) X f 89.156 - f 90.162
B f 90.162 - f 90.168
2nd Repair Size A f 90.400 - f 90.406
B f 90.412 - f 90.418
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.

Wear Limit in Longitudinal and Transverse Direction 0.1 mm
Permissible Deviation of Cylinder Out-of-round When new 0.007 mm
Wear limit 0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm
Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm
Chamfer Angle 60°
Honing Angle 50° ± 10°
Measurement of Cylinder Bore

1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size in
axial and transverse direction at three points (1,2,3).
1,2,3 Measuring Points

A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle

CRANKCASE MATING SURFACE

Height of The Crankcase “H” (When new) 282.25 - 282.35mm
Minimum Height After Milling 281.95mm
Flatness Crankcase Upper Mating Surface 0.03mm
Crankcase Lower Mating Surface 0.04mm
Permissible Deviation of Parallelism of The Axial Direction 0.1mm
Upper to Lower Mating Surface Transverse Direction 0.05mm
Peak-to-valley Height Crankcase Upper Mating Surface 0.005 - 0.020mm

Chamfering Procedure
1. Chamfer angle : 60°
2. Polish the lower chamfered area evenly with a grinder after

finishing the chamfering with a suitable tool (e.g., hand milling
cutter).

CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of valves

Overall Height of Cylinder Head 135.9 - 136.0 mm
Minimum Height After Machining 135.5 mm
Flatness Axial Direction 0.08 mm
Transverse Direction 0.0 mm
Distance ‘T’ Standard Size Intake 24.21 - 24.75 mm
(Between Camshaft Bearing Exhaust 22.21 - 22.75 mm
and Valve Stem) Repair Size Intake 23.96 - 24.51 mm
Exhaust 21.96 - 22.51 mm
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.

Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard).
Universal Tool
Sceledum, Type RTY
Surface Grinding Machine Roaro
Schio/Italy

SECTION 1B2
M161 ENGINE MECHANICAL

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2 Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B2-64
Fastener Tightening Specifications . . . . . . . . 1B2-2 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-65
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B2-4 Camshaft Timing Position . . . . . . . . . . . . . . 1B2-68
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B2-4 Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B2-71
Maintenance and Repair . . . . . . . . . . . . . . 1B2-9 Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B2-75
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1B2-9 Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B2-76
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B2-9 Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B2-79
Crankcase Ventilation System . . . . . . . . . . 1B2-16 Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B2-84
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-20 Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B2-85
Power Steering Pump and A/C Bracket . . . 1B2-21 Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B2-86
Hydraulic Engine Mounting Insulator . . . . . . 1B2-24 Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B2-87
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-27 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-89
Tensioning Deivce . . . . . . . . . . . . . . . . . . . . 1B2-29 Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B2-92
Tensioning Device Shock Absorber . . . . . . 1B2-30 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-94
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B2-31 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-96
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B2-34 Engine Oil and Oil Filter Element . . . . . . . . 1B2-98
Cylinder Head Front Cover . . . . . . . . . . . . . 1B2-36 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-100
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B2-38 Oil Pressure Relief Valve . . . . . . . . . . . . . 1B2-102
Timing Gear Case Cover . . . . . . . . . . . . . . 1B2-43 Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B2-103
Crankshaft Sealing Rear Cover . . . . . . . . . 1B2-46 Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B2-104
Belt Pulley and Vibration Damper . . . . . . . . 1B2-48 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B2-105
Crankshaft Front Radial Seal . . . . . . . . . . . 1B2-51 Core Plugs in Crankcase . . . . . . . . . . . . . 1B2-105
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B2-52 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B2-107
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-53 Crankcase Mating Surface . . . . . . . . . . . . 1B2-109
Flywheel/Driven Plate . . . . . . . . . . . . . . . . . 1B2-59 Cylinder Head Mating Surface . . . . . . . . . 1B2-111
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B2-61

SPECIFICATIONS
Application N·
·m
Power Steering Hydraulic Lines 35 - 40
A/C High Pressure and Liquid Hose 10 - 15
Radiator Support Menber Bolt 5 - 10
Fuel Supply and Return Hose to Fuel Distributor 21 - 25
Exhaust Manifold and Pipe 30
Propeller Shaft to Transmission 56 - 66
Alternator Carrier Bolt 22.5 - 27.5
Belt Pulley Bolt 41.5 - 49.5
Steering Pump Bolt 22.5 - 27.5
A/C Bracket Bolt 22.5 - 27.5
Intake Air Duct Bolt 9 - 11
Cylinder Head Cover Bolt 9 - 11
Camshaft Adjuster Bolt 9 - 11
Cylinder Head Front Cover Bolt 22.5 - 27.5
Flange Bolt in Exhaust Camshaft Sprocket 10
+90°
Cylinder Head Bolt 55
+90°
+90°
Cooling Fan Bracket Bolt 22.5 - 27.5
Timing Gear Case Cover Bolt M8 22.5 - 27.5
M6 9 - 10
Crankshaft Rear Cover Bolt 9-10
Vibration Damper Center Bolt 200
+90°
Connecting Rod Bearing Cap Bolt 40
+90°
Flywheel Stretch Bolt 45
+90°
Amarture Bolt in Flywheel 35
Ring and Seal Cover Nut in Flywheel 9 - 11
Sprocket Bolt to Exhaust Camshaft 20
+90°
Camshaft Adjuster Flange Bolt 20
+90°
Intake Flange Shaft Bolt 20 / + 90°
Exhaust Camshaft Sprocket Bolt 20 / + 90°
Camshaft Bearing Cap Bolt 22.5 - 27.5

FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application N·
·m
Exhaust Camshaft Sproket Bolt 20 / +90°
Chain Tensioner Screw Plug 40
Chain Tensioner Assembly 72 - 88
Exhaust Camshaft Sprocket to Camshaft 20 / +90°
Oil Pump Sprocket Bolt 25 - 35
Tensioning Device Bolt 22.5 - 27.5
Water Pump Pulley 22.5 - 27.5
Upper Intake Manifold Bolt 22.5 - 27.5
Lower Intake Mainfold Bolt 22.5 - 27.5
Flange Bolt to Exhaust Mainfold 30
Exhaust Mainfold Nut to Stud Bolt 26 - 34
Rivet Nut in Exhuast Mainfold Hole 30
Pre-Silencer Bolt 8 - 10
Oil Drain Plug 25
Oil Filter Cover 25
Oil Filter Bolt 22.5 - 27.5
Oil Pump Drive Sprocket Bolt 29 - 35
Oil Pump Mounting Bolt 22.5 - 27.5
Oil Strainer Bracket Bolt 9 - 11
Oil Pressure Relief Valve Screw Plug 50
Oil Dipstick Guide tube Bolt 9 - 11
Oil Gallery Screw Plug 15

SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 000 589 40 37 00

Torque Wrench Hose Clamp
112 589 00 72 00 000 589 72 21 00

Oil Extractor Torque Wrench
001 589 66 21 00 124 589 15 21 00

Torque Wrench Radiator Cap
Testing Unit
000 589 01 10 00 116 589 02 34 00

Box Wrench Insert Screw-Fixed Pin

104 589 01 01 00 111 589 01 59 00

Spanner Supporting Bar
111 589 18 61 00 111 589 25 63 00

Lever Pusher Thrust Piece
116 589 06 63 00 104 589 00 37 00

Magnetic Finger Pliers
119 589 00 43 00 000 589 58 43 00

Drift Chain Assembly

116 589 20 33 00 601 589 03 43 00

Sliding Hammer Sleeve
602 589 00 40 00 103 589 00 33 00

Engine Lock Puller
001 589 65 09 00 000 589 88 33 00

Socket Wrench Insert Puller
001 589 74 21 00 000 589 04 14 00

Torque Wrench Clamping Strap

103 589 01 63 00 615 589 01 33 00

Rivet Set Caulking Bolt
103 589 02 09 00 102 589 12 15 00

Oil Filter Drift
Socket Wrench
102 589 00 15 00 601 589 03 14 00

Drift Sleeve
000 589 51 37 00 001 589 72 21 00

Clamping Strap Torque Wrench

617 589 00 10 00 116 589 01 34 00

Wrench Socket Threaded Bolt
104 589 00 40 00 111 589 03 15 00

Holder Insert Pin


ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Tools Required
000 589 40 37 00 Hose Clamp
112 589 00 72 00 Oil Extractor
124 589 15 21 00 Radiator Cap Testing Unit

2. Remove the hood.
3. Remove the under cover.
Installation Notice
4. Disconnect the coupling of HFM sensor and remove the air

cleaner cross pipe.
5. Remove the air cleaner cover. Remove the mounting bolts

and air cleaner housing and element assembly.

6. Loosen the radiator drain cock and drain the coolant.
Notice
Open the coolant reservoir cap.
7. Loosen the cylinder block drain plug and then drain the
coolant completely.
Installation Notice
Notice
Replace the seal before installation of the drain plug.
9. Disconnect the each hose from radiator.

10. Remove the upper mounting bolts of radiator and then
remove the radiator.
11. Remove the hydraulic pipe of power steering.

Notice
Completely drain the oil.
12. Discharge the refrigerant from A/C system, and disconnect

the discharge pipe and suction pipe from the compressor.
13. Remove the acceleration control cable and automatic

transmission pressure cable.

14. Remove the fuel feed and return line.
Notice
Before removing the fuel lines, release the pressure in the
fuel system.
Installation Notice
15. Remove the automatic transmission dipstick guide tube.
16. Disconnect the wire of alternator.
17. Disconnect the wire of starter motor and remove the starter
motor.
18. Disconnect the engine main harness ground.

19. Disconnect the engine ground wire.
20. Disconnect following sensors connector.

l HFM sensor.
l 2 knock sensors.
l Camshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition
coil connector.
22. Remove the harness cover and disconnect the 6 injection
valve connectors. Disconnect the main harness.
23. Separate the hose toward engine from canister purge

solenoid valve.

24. Remove the automatic transmission oil cooler line.
25. Separate the vacuum hose for brake booster.

26. Separate the other vacuum hoses.
27. Remove the propeller shaft from the front axle.

Installation Notice
28. By rotating the crankshaft from the front of engine, remove

the 6 torque converter mounting bolts from the engine
ring gear plate.

29. Remove the exhaust manifold and exhaust pipe.
Installation Notice
30. Remove the transmission mounting bolts and separate

the transmission from the engine.
Installation Notice
31. Remove the bolts for engine mounting bracket.

Installation Notice
32. Hook the chain to the bracket of engine and by using a

hoist or crane, carefully separate the engine assembly
from the vehicle.
reverse order.

CRANKCASE VENTILATION SYSTEM

1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling)

2 Cylinder Head Cover 12 Crank Chamber
3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe
Mid-Load) 14 Oil Pan
4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover
5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase
6 Throttle Valve 17 Chain Housing
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling)
8 Intake Manifold A Fresh Air
9 Vent Line (Mid-Load at Idling) C Blow-by Gas
10 Air Conditioner Bracket D Vent Connection

l The throttle valve(6) is closed or very partially opened, and
the vacuum pressure in intake manifold is high.
The blow-by gas and the fresh air that is additionally supplied
through the vent connection(D) in the crankcase in partial
load gets supplied to the combustion chamber from the crank
chamber(12) through the oil separation chamber(11), air-
conditioner bracket(10), vent line(9), and restrictor(7)
mounted to the cylinder head.
The circulated engine oil returns to the oil pan through the
oil return pipe(13) at the bottom of oil separation
chamber(11).
The fresh air gets supplied to the crank chamber(12) through
the HFM sensor(1), intake air duct(4), vent line(5), oil
separation chamber(3), chain housing(17), and the timing
gear case cover(15).
The additional supply of the fresh air is needed to prevent
from forming the residues of the engine oil.

Operation When Full-Load at Partial Load
1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling)

2 Cylinder Head Cover 12 Crank Chamber
3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe
Mid-Load) 14 Oil Pan
4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover
5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase
6 Throttle Valve 17 Chain Housing
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling)
8 Intake Manifold A Fresh Air
9 Vent Line (Mid-Load at Idling) C Blow-by Gas
10 Air Conditioner Bracket D Vent Connection

Operation When Full-Load at Partial Load
l The throttle valve (6) is partially opened or fully opened.
The air flows very rapidly through the vent line(5)s
connection(D) and the intake air duct when full-load at partial
load.
Consequently, most of the low-by gases are supplied to the
combustion chamber through the timing gear case
cover(15), chain housing(17), oil separation chamber(3),
vent line(5), throttle valve(6), and intake manifold(8).

ALTERNATOR
1 Bolt (M8 X 40, 3 pieces) ................. 22.5-27.5 Nm 3 Bolt (M8 X 85, 1 piece) ................... 22.5-27.5 Nm
2 Bolt (M8 X 70, 2 pieces) ................. 22.5-27.5 Nm 4 Alternator Bracket

1. Remove the drive belt.
3. Unscrew the alternator carrier bolts (1,2,3) and remove the
carrier (4).
Installation Notice
Tightening torque 22.5 - 27.5 Nm
Notice
Apply 3Nm of torque when mounting the bolt (1); apply 25 ±
2.5Nm of torque when mounting the bolts (2), and (3); and
then tighten the bolt (1) with 25 ± 2.5Nm of torque.
reverse order.

POWER STEERING PUMP AND A/C BRACKET

Preceding Work : Removal of cooling fan and shroud
1 Nut ................................................. 35.2-28.8 Nm 5 A / C Bracket

2 Washer 6 A / C Compressor
3 Belt Pulley 7 Bolt ................................................ 22.5-27.5 Nm
4 Bracket 8 Bolt (M8 X 20, 2 pieces) ................. 22.5-27.5 Nm

1. Remove the belt pulley after removal of poly v-belt.
Installation Notice
Notice
Pull the tensioning pulley counterclockwise as shown in the
figure.
2. Disconnect the hydraulic pipe of the power steering pump

and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump.

Installation Notice
4. Remove the compressor after disconnecting the wiring

connector and refrigerant pipe of A/C compressor.
Notice
Discharge all the refrigerant before removing the pipes.

5. Disconnect the vent hose from the A/C bracket.
6. Unscrew all the mounting bolts (arrows) and remove the

A/C bracket and the gasket.
Installation Notice

reverse order.
10. Check the oil leakage by operating the engine after
installation.

HYDRAULIC ENGINE MOUNTING INSULATOR

Service Data

Sectional View
1 Rubber Body 9 Lower Orifice

2 Brackek 10 Upper Orifice
3 Core 11 Diaphram
4 Lower Bolt 12 Cover Plate
5 Rubber Plunger 13 Upper Bolt
6 Plunger Plate 14 Flange Bolt
7 Rubber 15 Rivet
8 Plate 16 Fluid

1 Upper Nut
2 Hydraulic Installer ................. 62-93 Nm
3 Lower Nut ............................. 28-47 Nm

1. Unscrew the upper nut(1) on engine mounting and remove
the engine.
Installation Notice
2. Unscrew the lower nut(3) and remove the hydraulic engine

mounting insulator.
Installation Notice
Notice
If the insulator is spotted with oil, replace the hydraulic
insulator assembly.
reverse order.

POLY V-BELT
1 Poly V-belt (2,155 mm) 3 Belt Tensioner

2 Belt Tensioning Pulley

1. Release the belt tension by turning the stud on the cap with
12 sided wrench or spanner counterclockwise.
Notice
Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt after prying the tensioning pulley.

Poly V-belt Arrangement
1 Belt Tensioning Pulley 5 Alternator Pulley

2 Crankshaft Belt Pulley 7 Power Steering Pump Pulley
3 A/C Compressor Pulley 8 Water Pump Pulley

TENSIONING DEVICE
Preceding Work : Removal of tensioning device shock absorber
1 Bolt (M8 x 75, 2 pieces) + 3 Tensioning Device

Washer .......................................... 22.5-27.5 Nm 4 Stud bolt
2 Bolt (M8 x 25, 1 pieces) + 5 Tensioning Arm
Washer .......................................... 22.5-27.5 Nm

1. Turn the stud bolt to counterclockwise.
2. Insert the pin (111 589 01 15 00) into the hole in tensioning
arm.
3. Unscrew the bolts (1, 2) and remove the tensioning device.
Installation Notice

reverse order.

TENSIONING DEVICE SHOCK ABSORBER
1 End Cover 5 Tensioning Device

2 Nut ................................................. 40.5-49.5 Nm 6 Bolt (M8 X 35) + Washer ................ 22.5-27.5 Nm
3 Tensioning Pulley 7 Shock Absorber
4 Bolt (M8 X 25) + Washer ................ 22.5-27.5 Nm

1. Remove the end cover (1).
2. Remove the nut (2) and remove the tensioning pulley (3).
Installation Notice
3. Unscrew the bolts (4,6) and remove the shock absorber

(7).
Installation Notice

POLY V-BELT INSPECTION

l Make marks on the belt with chalk.
l Rotate the engine and check the belt for damage.
Notice
If one of the following types of damages is found, replace
the belt.
1. Rubber lumps in the base of rib.

3. Pointed rib.
4. Belt cord visible in the base of rib.

7. Rib detached from the base of belt.
8. Splits across the rib.

9. Sections of rib torn out.
10. Splits across several ribs.

11. Splits across the back of the belt.

CYLINDER HEAD COVER
1 Ignition Coil Cover 4 Cylinder Head Cover

2 Spark Plug Connector 5 Gasket ................................................... Replace
3 Bolt (M6 X 45 : 4 pieces, M6 X 60 :
6 pieces) ............................................. 10 ± 1 Nm

1. Remove the intake air duct.
Installation Notice
2. Remove the ignition coil cover.

Installation Notice
Notice
Release 3 screws from the ignition cover and remove the
cover for M161 Engine coil.
3. Remove the spark plug connector and ignition cable.

CYLINDER HEAD FRONT COVER

Removal of thermostat housing assembly
Removal of engine hanger bracket
1 Bolt (M6 X 16, 3 pieces) ......................... 9-11 Nm 6 Front Cover (E20 : M161.940)
2 Camshaft Adjuster 7 Sleeve
3 Bolt (M8 X 35, 2 pieces) ................. 22.5-27.5 Nm 8 O-ring .................................................... Replace
4 Bolt (M6 X 22, 6 pieces) ......................... 9-11 Nm 9 Thermostat Housing
5 Front Cover (E23 : M161.970)

1. Disconnect the camshaft adjuster connector and remove
the camshaft adjuster (E23 engine only).
Installation Notice

Installation Notice
Tightening Torque (3) 22.5 - 27.5 Nm
Tightening Torque (4) 9 - 11 Nm

Apply the sealant at the mating surface of the cylinder head
and the front cover.
3. Remove the O-ring.
Installation Notice
Replace the O-ring with new one and apply the sealant.
reverse order.

CYLINDER HEAD
Removal of intake manifold
Removal of cylinder head lower line (intake manifold side)
1 Cylinder Head Bolt (M12 X 100, 10 pieces) 3 Camshaft Bearing cap ................... 22.5-27.5 Nm
.................................................... 1st step 55 Nm 4 Cylinder Head
2nd step 90° rotation added 5 Gasket ................................................... Replace
3rd step 90° rotation added 6 Dowel Sleeve ............................................... Note
2 Bolt (M8 X 35, 4 pieces) ................. 22.5-27.5 Nm

Tools Required
617 589 00 10 00 Wrench Socket
116 589 01 34 00 Threaded Bolt
001 589 66 21 00 Torque Wrence
104 589 00 40 00 Holder

1. Rotate the crankshaft so that the piston of No.1 cylinder is
at ATDC 20.
2. Put the pin into the camshaft bearing cap.
Pin 111 589 03 15 00

camshaft sprocket.
4. Remove the chain tensioner
Installation Notice

Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 85° - 95°
Notice
The flange bolt is designed to be used only once, so always

6. Remove the in take camshaft sprocket (E20 engine).
7. Remove the camshaft adjuster (E23, M161.973 engine).
Installation Notice (Flange Bolt)
1st step 18 - 22 Nm
Tightening Torque
2nd step 85° - 95°
Notice
1 Flange Shaft
2 Flange Bolt
3 Campression Spring
4 Adjust Piston
5 Camshaft Sprocket
6 Seal Cover
7 Nut
8. Remove the guide rail pin using the sliding hammer (02)
and the threaded pin (03).
Notice
Apply the sealant on guide rail pin when installation.
9. Unscrew the bolts (A).

Installation Notice
Bolt (A) : (M8 X 35, 4 pieces)

10. Remove the cylinder head bolts in the reverse order of
the numerics (No.10 ® No.1).
Installation Notice
Tighten the bolts as numerical order with specified torque
(No.1 ® No.10).
1st step 55 ± 5 Nm
Tightening Torque 2nd step + 90°
3rd step + 90°
Notice
Operate during engine cooling.
11. Remove the No. 1 bearing cap of the exhaust camshaft.

Installation Notice
12. Install the special tool (05) on the bearing cap removed
place and hook the engine hoist into them and remove
the cylinder head carefully.
Holder 104 589 00 40 00
1 Cylinder Head Bolt

2 M8 X 43 Bolt & Washer
3 Bearing Cap
4 Engine Hoist
5 Gasket
6 Hanger Bracket
13. Check the cylinder head mating surface and clean the
crankcase head bolt mounting hole.
14. Replace the cylind head gasket with new one.

15. Check the length of the cylinder head bolt.
When New 100 mm
Length of the bolt(L)
Max. Length 105 mm
Notice
Replace the bolt if the measured length exceed the max.
length.
reverse order.

TIMING GEAR CASE COVER

Preceding Work : Removal of viscous clutch
Removal of tensioning device
Removal of water pump
Removal of oil filter element
Removal of oil pan
Removal of alternator bracker
1 Bolt (M8 X 60, 3 Pieces) ................. 22.5-27.5 Nm 4 Timing Gear Case Cover
2 Bolt (M8 X 75, 1 Piece) .................. 22.5-27.5 Nm 5 O-ring
3 Seal 6 Sleeve

Tools Required

1. Remove the power steering belt pulley and A/C compressor
bracket.
2. Remove the oil line from power steering pump.
3. Rotate the crankshaft so that the piston of number, cylinder
is at ATDC20°

camshaft sprocket.
Installation Notice
6. Remove the intake and exhaust camshaft sprocket

(remove the camshaft adjuster assembly in E23 engine).
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 85° - 95°
Notice
7. Remove the guide rail pin using the sliding hammer (02)
and the threaded pin (03).
Notice
Apply the sealant on guide rail pin when installation.

Threaded Pin 116 589 02 34 00

8. Unscrew the bolts (A).
Installation Notice
9. Remove the belt pulley and vibration damper.

Installation Notice (Center Bolt)
1st step 180 - 220 Nm
Tightening Torque
2nd step 80° - 100°
10. Unscrew the bolts (1, 2) on timing gear case cover and
remove the timing gear case cover.
Installation Notice
Notice
Be careful not to damage the cylinder head gasket.
11. Remove the radial shaft seal
Notice
Installation note replace the seal with new one.
12. Clean the timing gear case cover and crankcase sealing
surface.
13. Replace the O-ring with new one and apply the sealant on
the sealing surface.
Notice
Be careful not to stain the oil chamber of chain tensioner
with the sealant.
14. Installation should follow the removal precedure in the
reverse order.
15. Warm up the engine and check for oil leaks.

CRANKSHAFT SEALING REAR COVER

Preceding Work : Removal of the automatic transmission drive plate or flywheel
1 Bolt (M6 x 20, 6 pieces) ......................... 9-11 Nm 4 Sleeve

2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......................... 9-11 Nm
3 Rear Cover 6 Washer

Tools Required
601 589 03 43 00 Sleeve

1. Unscrew the bolts (1) and (5) and remove the closing cover
by pulling the rear cover lug (arrows).
Notice
2. Clean the sealing surface of the crankcase and the rear

sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
Notice
6. Using the special tool, press the radial shaft seal and the
rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan
bolt (5) as specified and remove the special tool.
Installation Notice
Tightening Torque(Bolt 1,5) 9 - 11 Nm
Seal Assembler 601 589 03 43 00

BELT PULLEY AND VIBRATION DAMPER

Preceding Work : Removal of cooling fan and viscous clutch
Removal of fan shroud
1 Center Bolt 5 Vibration Damper Assembly

(M18 X 55) ....................... 1st step 200-220 Nm 6 Key
2nd step 90° + 10° rotation added
2 Vibration Damper Disk

Components

3 Vibration Damper and Pulley Assembly
4 Key
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

Permissble Deviation of The Vibration Damper Radial Runout 0.6 mm
Axial Runout 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 74 21 00 Puller
602 589 00 40 00 Engine Lock

1. Adjust the piston of number 1 cylinder to the TDC.

2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
Tightening Torque 1st step 180 - 220 Nm

2nd step + 90°
Engine Lock 602 589 00 40 00
4. Remove the vibration damper assembly using the puller.

reverse order.
Notice
If possible, don’t separate the vibration damper and the
pulley.


Preceding Work : Removal of belt pulley and vibration damper

............................... 1st step 200-220 Nm
2nd step 90° +10°
3 Sleeve (Special Tool)
5 Key
Tools Required
601 589 03 14 00 Sleeve
Notice
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
1st step 200 - 220Nm
Tightening Torque
2nd step 90° + 10°
5. Remove the sleeve and install the belt pulley and the
vibration damper.

CRANKSHAFT REAR RADIAL SEAL

Preceding Work : Removal of flywheel or drive plate
1 Special Tool 3 Crankshaft Rear Seal

2 Special Tool
Tools Required
601 589 03 43 00 Sleeve
Replacement Proceudre
Notice
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
Notice
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.

CRANKSHAFT
Removal of timing gear case cover
Removal of crankcase sealing rear cover
Removal of oil pan
Removal of oil pump
1 Bearing Cap Bolt

(M8 X 55-10 pieces) ............ 1st step 50-60 Nm
2nd step 90°+5° rotation added
2 Bearing Cap
3 Upper Main Bearing
4 Lower Main Bearing
5 Upper Thrust Bearing
8 Crank Shaft

Arrangement of the Thrust Bearing and the Main Bearing
1 Upper Main Bearing A Crankcase Side

2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side)
3 Crankshaft
4 Lower Main Bearing
1 - 8 Weight Balance/Color Marking Point

j1 - j5 Journal Main Bearing #1 - #5
l Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6

, 8 , and it indicates the diameter of crankshaft journal
by color as below.

Color Dot Marking Crankshaft Journal Diameter (mm)

Blue 57.960 - 57.965
Yellow 57.955 - 57.960
Red 57.950 - 57.955
White 57.945 - 57.950
Violet 57.940 - 57.945
Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating surface
to oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing
according to the punching mark when repaired.
Punching Mark Bearing Color Selected

· Blue
·· Yellow
··· Red
2. Crankshaft Bearing Cap Side

Select the crankshaft main bearing according to the
marking letter on the crankshaft main journal when
repaired.
Marking Letter Bearing Color Selected
B Blue
Y Yellow
R Red
W White
V Violet
Service Data Unit : mm

Crankshaft Crankshaft Crankshaft Connecting Rod Connecting
Crankshaft Standard Bearing Jour- Bearing Journal Width Bearing Journal Rod Bearing
and Repair Size nal Diameter Diameter at fit bearing Diameter Jourmal Width
Standard size 57.950-57.965 58 24.50-24.533 47.94 - 47.96 27.958 - 28.042
1st repair size 57.700-57.715 47.75
2nd repair size 57.450-57.465 47.50
- - -
3rd repair size 57.200-57.215 47.25
4th repair size 56.950-56.965 47.00

1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap.
Installation Notice

not change each other.
l Coat the bearing shell with engine oil.
l Install the bearing cap according to the consecutive
number.
2. Unscrew the crankshaft bearing cap bolts and separate

the upper and lower bearing shells and thrust washers.
Installation Notice
l Remove the bearing cap from front (pulley side) to

rear.
not change each other and coat with engine oil.
l The oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the
bearing cap.
l There are five kinds of thrust washers by thickness. Part No. : 601 030 00 62 2.15 mm
Select the proper washer when repaired. Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
3. Remove the crankshaft. Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
reverse order.
5. After completion of the installation, check for the rotating
condition of the crankshaft.
Installation Notice
l Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly
installed, the projected part (arrow) locates in the left
side (intake manifold side).
l Assemble so that the projected part of the cap and
crankcase face the same direction.

Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated

on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft

bearing.
Notice
l Measure at 2 points (1, 2).
l Measure ‘A’,‘B’and ‘C’ as shown. If average value of
‘B’ and ‘C’is less than value ‘A’, then the average value
of ‘B’ and ‘C’ is actual average value. If average value
of ‘B’ and ‘C’ is more than value ‘A’is actual average
value.
4. Measure and record the diameter of the crankshaft

bearing journal.
Notice
l Record the mean value when measured at 3 points
(A, B, C).
l Measure the inner diameter of bearing and the
diameter of journal and if it is out of the standard data,
replace the bearing shell.

Service Data Standard (Crankshaft Main Bearing Gap)
Axial 0.010 - 0.254
(Connecting Rod Bearing Gap)

Connecting Rod Bearing Radial 0.020 - 0.065

FLYWHEEL/DRIVEN PLATE
Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt 3 Driven Plate (A/T)

(M10 x 22, 8 pieces) ................ 1st Step 45 Nm 4 Dowel Pin
2nd Step 90°+10° 5 Flywheel (M/T)
2 Plate
Service Data Standard (Stretch Bolt)

Nominal Size D - M x 1.5
Stretch Side Diameter d When New 8.5 - 0.2 mm
Min. Diameter 8.0 mm
Bolt Length L When New 21.8 - 22.2 mm
Tightening Torque 1st step 50 Nm, 2nd step 90°

1. Unscrew the stretch bolt.
Installation Notice
1st step 45 Nm
Tightening Torque
2nd step 90°+10°
l Replace the bolt when the stretch side diameter (d) of

the flywheel mounting bolt is less than 8.0mm.
l For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles,

or the driven plate (3), and plate (2) for Auto. transmission
vehicle.
reverse order.
Sectional View
1 Oil Pan
2 Cover
3 Radial Seal
4 Bolt
5 Crankshaft
6 Dowel Pin
7 Washer (Thickness : 3.5 mm)
8 Washer
9 Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear

CAMSHAFT ADJUSTER
1 Bolt (M6 X 16, 3 pieces) ......................... 9-11 Nm 11 Flange Bolt

2 Cylinder Head Front Cover (M7 X 13, 3 pieces) ................. 1st Step 20±2 Nm
3 Bolt ........................................................... 35 Nm 2nd Step 90° ± 5° Rotation Added
4 Armature 12 Flange Shaft
5 Roll Pin 13 Compression Spring
6 Nut (M20 X 1.5) .................................... 60-70 Nm 14 Control Piston
7 Seal Cover 15 Circlip
8 Camshaft Sprocket 16 Oil Gallery
9 Adjust Piston 17 Straight Pin
10 Conical Spring 18 Intake Camshaft
Y49 Magnetic Actuator (2-pin connector)

1. Turn the crankshaft and position the No.1 cylinder piston at
ATDC 20°.
Notice
Turn the crankshaft in the direction of engine rotation.

and the timing chain.
4. Insert the insert pin into the No.1 and no.6 bearing cap hole
on camshaft to secure intake and exhaust camshaft.
6. Unscrew the exhaust sprocket bolt and remove the exhaust

camshaft sprocket.
Installation Notice
1st step 20 Nm
Tightening Torque
2nd step 90°
Notice

7. Unscrew the bolt (3) from the armature (4) and remove
the roll pin, and remove the armature.
Installation Notice
8. Unscrew the nut (6) and remove the seal cover (7).
Installation Notice
Tightening Torque 60- 70 Nm
Notice
Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical
spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft.
Installation Notice
1st step 20 Nm
Tightening Torque
2nd step + 95°
Notice

reverse order.
13. Check and adjust the camshaft timing.

CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
1st step 20 Nm
Tightening Torque
2nd step + 90°
Notice
C. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
Exhaust Camshaft Sprocket Bolt

1st step 20 Nm
Tightening Torque
2nd step + 90°
Notice
E. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft

CAMSHAFT
Removal of camshaft adjust actuator and cylinder head front cover
1 Bolt (M7 X 13, 3 pieces) ......... 1st Step 18-22 Nm 4b Camshaft Adjuster and Camshaft Sprocket (E23)
2nd Step 90°+ 5° Rotation Added 5 Bearing Cap Bolt (20 pieces) ......... 22.5-27.5 Nm
2 Exhaust Camshaft Sprocket 6 Camshaft Bearing Cap
3 Timing Chain 7 Wrench (Special Tool)
4a Intake Camshaft Spocket (E20)

Tools Required
104 589 01 01 00 Spanner

1. Turn the crankshaft and position the No.1 cylinder piston at
ATDC20°.

and the timing chain.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
4. Remove the exhoust camshaft sprocket.

Installation Notice
1st step 35 - 45 Nm
Tightening Torque
2nd step 85° - 95°
Notice
5. Take off the timing chain from intake camshaft sprocket,
and secute it not to fall down into the timing gear case.
6. Using the wrench (7), turn the camshaft until there is no

resistence in camshaft bearing area.

7. Remove the bearing cap, and remove the intake and the
exhaust camshaft.
Installation Notice
Notice
Check the numbers on the bearing cap not to be miked
up.
8. Apply the engine oil on the valve tappet and camshaft

bearing.
reverse order.
Notice
l Base circle of cam should cantact with the valve tappet.
l Install the camshaft bearing caps according to the
numbers on the cylinder head cast and bearing cap.

CAMSHAFT TIMING POSITION

1 Insert Pin (f 6.5mm, Special Tool) 5 Exhaust Camshaft Sprocket

2 Intake Camshaft Sprocket 6 Bolt (M7 X 13, 3 pieces) ......... 1st step 20 ± 2 Nm
3 Camshaft Bearing Cap 2nd step 90° ± 5° rotation added
4 Timing Chain 7 Strate Pin

Tools Required
104 589 01 01 00 Spanner
111 589 03 15 00 Insert Pin
Inspection Procedure
1. Position the No.1 cylinder piston to ATDC 20° by turning
the crankshaft
Notice
When the ATDC 20° mark on vibration damper is aligned
with timing gear case cover, the intake and exhaust cam of
cylinder will make the slope to the center and will face up.
In this way, the insert hole in No.1 and No.4 camshaft bearing
cap will match in line with the flange hole for camshaft
sprocket.
2. Check the timing as below procedure;
- Check if the insert pin (111 589 03 15 00) can be inserted
into the No.1 and No.4 bearing cap hole.
- At this condition, check if the ATDC 20° mark on vibration
damper aligns with the marker on the timing gear case.

1. Position the No.1 cylinder to ATDC 20° .
4. Adjust the timing position with inserting the insert pin (f
6.5mm, 111 589 03 15 00) into the No.1 and No.4 camshaft
bearing cap hole and flange hole while rotating the camshaft
by using wrench (104 589 01 01 00).
5. Install the chain to the intake camshaft sprocket.
6. Install the chain to the exhaust camshaft sprocket and
tighten the bolt.
Installation Notice
1st step 20 Nm
Tightening Torque
2nd step + 90°
Installation Notice
Screw plug 40 Nm
Tightening Torque
Tensioner assembly 80 ± 8 Nm
8. Check the camshaft timing.

VALVE SPRING
1 Valve Tappet Assembly 7 Connecting Hose

2 Valve Cotter 8 Thrust Piece
3 Upper Retainer 9 Slide
4 Valve Spring .......... Check, Replace if necessary 10 Adjust Bolt
5 Valve Stem Seal 11 Lever Pusher
6 Lower Retainer 12 Supporting Bar

Tools Required
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece

1. Place the supporting bar (12) and the slide (9) at the
camshaft bearing cap (Nos 1 & 7/8&14) and tighten them
with the bearing cap bolt.
Installation Notice
2. Turn the crankshaft to position the each cylinder piston at

TDC.
Mark on The Vibration Damper Cylinder
OT 1, 4
UT 2, 3
Notice
l Remove the valve spring only at TDC.
l Always rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and for
smooth rotation.
3. Remove the valve tappet (1) using the magnetic finger.
4. Install the leakage tester connecting hose to the spark plug
hole.
5. Install the engine lock to the ring gear to prevent the

crankshaft from rotating.
6. Blow up with compressed air.

8. Install the lever pusher (11) and the thrust piece (8) to the
slide (9).
Lever Pusher 111 589 18 61 00
9. Mount the thrust piece (8) vertically to the valve spring

retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular
to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
13. Remove the valve cotter (2) using either the pincette (13)
or magnetic finger.
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
Notice
Check the retainer for damages and replace with a new
one if necessary.
reverse order.

Test (Upper and Lower Valve Tappet and Valve
Cotter)
l Upper Valve Spring Retainer
(d) 8.5
Size (mm)
(D) 12.3
l Lower Valve Spring Retainer
Thickness (mm) (a) 0.8 - 1.0
l Valve cotter
(B) 9.0
Size (mm)
(H) 9.2 - 9.8

VALVE STEM SEAL

1 Drift (Special Tool)

2 Valve Stem Seal
3 Protective Sleeve
Tools Required
104 589 00 37 00 Pliers
119 589 00 43 00 Drift
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
Pliers 104 589 00 37 00
2. Coat the valve stem seal with oil and assemble it with the
protective sleeve.
3. Insert the valve stem seal by pressing it with the drift.
Drift 119 589 00 43 00

CHAIN TENSIONER
1 Screw Plug ................................................ 40 Nm 5 Snap Ring

2 Seal 6 Thrust Pin
3 Filler Pin 7 Chain Tensioner Housing ..................... 72-88 Nm
4 Compression Spring 8 Seal
Removal Procedure
1. Position the number 1 cylinder to ATDC 20°.
Notice
Remove the oil filler cap at adjustment position, and check
whether the intake camshaft cam’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.
If the chain tensioner is tightened again without completely
reducing its tension, then the snap ring doesn’t return to
the original position and the tension gets excedded.

4. Carefully unscrew the screw plug (1), and remove the seal
(2).
Notice
l For the removal of screw plug, be careful that it can be
jumped out due to the force of compression spring.
l Remove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring (4),
snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).
1. Connect the thrust pin (6) and the snap ring (5) to the chain
tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust pin far
enough so that it doesn’t protrude at the chain tensioner
housing.
2. Install the chain tensioner housing (7), Thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
3. Insert the compression spring (4) with the filler pin (3) into
chain tensioner housing.

4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
Sectional View
1 Screw Plug 13 Chain Tensioner Housing

2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail
7 Compression Spring 19 Cylinder Head Gasket
8 Snap Ring 20 Timing Chain
9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface)
10 Ball (Nonreturn Valve) A Oil Supply Hole
11 Compression Spring B Chain Tensioner Oil Storage Hole
12 Thrust Piece

TIMING CHAIN
1 Pin 5 Link
2 New Timing Chain 6 Center Plate
3 Timing Chain (Used) 7 Outer Plate
4 Wedge

Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
1. Position the No.1 cylinder to ATDC 20°.
2. Insert the pin to the intake and exhaust camshaft flange.

4. Mount the wedges to both sides of the camshaft sprocket

as shown in the figure.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket with
the grinder.

6. Remove the outer plate (7) with the screw driver and
remove the link (5).
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the
link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.

12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool.
15. Replace the thrust piece (b) as shown in the figure.
16. Install the assembly tool to the link pin and tighten the
spindle (c).

17. Rivet the link pin.
Check the condition and it again if necessary.
Installation Notice
Screw Plug 40 Nm
Tightening Torque

TENSIONING RAIL
1 Sliding Rail Pin 3 Timing Gear Case Cover

2 Sliding Rail

1. Remove the timing gear case cover (3).
Notice
Be careful not to damage the gasket.
2. Remove the sliding rail (1) from the sliding rail pin (2).
Notice
l Replace the plastic guide (2) if it is damaged.
l For installation, exactly align the plastic guide (2) with
the sliding rail (1).

reverse order.


1 Bolt (M6 X 45, 2 pieces) .................. 9-11 Nm

2 Guide Rail

1. Position the number 1 cylinder to ATDC20° guide rail.
2. Install the pin (special tool : 111 589 03 15 00) into the no.1
and no.6 bearing cap hole.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
4. Unscrew the bolt (1) and remove the guide rail.

Installation Notice

reverse order.

CRANKCASE GUIDE RAIL

1 Guide Rail Pin 3 Timing Gear Case Cover

2 Guide Rail

1. Remove the timing gear case cover (3).
Notice
Be careful not to damage the gasket when removing/
installing the timing gear case cover.
2. Remove the guide rail (2) from the guide rail pin(1).
Notice
l Replace the plastic guide (2) if damaged.
l Connect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
reverse order.

CRANKSHAFT SPROCKET
Removal of tensioning rail
Removal of crank case guide rail
1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer .......... 29-35 Nm
2 Oil Pump Chain Spring 7 Oil Pump Sprocket
3 Oil Pump Chain Bushing (Pin) 8 Oil Pump
4 Crankshaft Sprocket 9 Oil Pump Roller Chain
5 Key 10 Timing Chain

Tools Required
615 589 01 33 00 Caulking Bolt

1. Put the assembly mark at the crankshaft sprocket (4) and
the timing chain (10) with the paint (arrow).
Installation Notice
Align the assembly marks on cranshaft sprocket and timing
chain. Also, align the assembly marks on camshaft sprocket
and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7)
from the oil pump.
Installation Notice
3. Remove the oil pump roller chain (9).

4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (3), and the oil pump chain spring (2).
5. Remove the crankshaft sprocket (4) using the puller (04,
special tool).
Notice
l Make sure not to lose the crankshaft pulley key (5) when
removing.
l Install the crankshaft sprocket (4) after warming it up.

reverse order.
Caulking (04) 615 589 01 33 00

PISTON
Removal of oil pan
Removal of oil pump
1 Connecting Rod Bearing Cap 4 Piston

2 Connecting Rod 5 Snap Ring
3 Connecting Rod Bolt 6 Piston Pin
(M9 x 52, 8 pieces) ...................... 1st step 40 Nm
2nd step 90° +5°

Tools Required
001 589 72 21 00 Torqued Wrench
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.
Notice
Make sure that the bearing cap and shell are not changed
each other.
Notice
Remove the snap ring using a clean cloth as shown in the
right picture so that the piston, piston ring, and the snap
ring don’t get damaged.

1. Check the piston ring gap and apply the engine oil to the
piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in
the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and the piston and coat them
with engine oil.
4. Install the piston ring using the tensioning strap(000 589
04 14 00).
5. Install the piston so that the arrow on the piston head faces
to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark
(// or a number), tighten the bolts.
Installation Notice
1st step 35-45 Nm

Tightening Torque
2nd step 90°+5°
Apply the engine oil to the bearing cap upper and lower
bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating
it.

CONNECTING ROD
1 Connecting Rod Bushing

2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt
(M9 x 52, 8 pieces) ............ 1st step 40 Nm
2nd step 90°
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]

Distance (L) from The Connecting Rod Bearing to Bushing Bore Center E20 : 154 mm
E23 : 149 ± 0.05 mm
Width of The Connecting Rod (B) at Bearing Bore 21.940 - 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore 21.940 - 22.000 mm
Basic Bore at The Bearing Shell (D1) 51.600 - 51.614 mm
Basic Bore at The Bushing (d1) 24.500 - 24.571 mm
Bushing Inner Diameter (d) 22.007 - 22.013 mm
Clearance Between The Piston Pin and The Bushing 0.007 - 0.018 mm
Peak-to-valley Height of Connecting Rod Bushing on Inside 0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to 0.1/100 mm
Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod 0.045/100 mm
Bearing Bore to Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from 0.01 mm
Concentricity
Permissible Difference of Each Connecting Rod in Weight 0.4 g

Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614mm, replace
the bearing or check the connecting rod.
2. Check connecting rod bolts.
Length When New (L) 51.7 - 52 mm

Max. Length (L) 52.9 mm
Tightening Torque 1st step 40 + 5 Nm
2nd step 90°+10°
Notice
If the length exceeds max. length, replace it.
3. Check the assembly mark(indication // or number:arrow) of

the connecting rods and the bearing cap when installing.
Notice
l Make sure it doesn’t exceed over 4g with other
connecting rods when replacing the connecting rods.
l Check if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing.

PISTON RING
1 Piston Compression Ring (Top Ring)

2 Piston Compression Ring (2nd Ring)
3 Piston Oil Ring
4 -
5 Spacer
6 Side Rail
Tools Required
1. Measure the piston ring’s gap.
End Gap of The Groove 1 0.20 - 0.40 mm
Piston Ring Groove 2 0.20 - 0.40 mm
Groove 3 0.20 - 0.45 mm
Gap Between Groove 1 0.028 - 0.060 mm
The Piston and Groove 2 0.010 - 0.045 mm
The Piston Ring
Groove 3 0.010 - 0.045 mm
Notice
If out of specification, replace the piston ring.

2. Remove the piston ring with a pliers.
Clamping Strap 000 589 51 37 00
3. For installation, position the piston ring to be the ‘TOP’ mark

on the piston ring upward and arrange the piston ring ends
to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away from
the ring end.

OIL PAN
1 Bolt 5 Bolt
2 Bolt 6 Oil Pan
3 Bolt 7 Gasket
4 Bolt
1. Remove the drain plug and drain the oil completely.

2. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then apply
the sealant.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine.
M8 X 40, 4 pieces
M6 X 35, 1 pieces
M6 X 100, 2 piece
M6 X 85, 3 pieces
u M6 X 20, 20 pieces

Oil Circulation
1 Oil Strainer 16 Oil Supply (To Chain Tensioner)

2 Oil Pump 17 Camshaft
3 Oil Pan 18 Cam Bearing
4 Oil Non-Return Valve 19 Valve
5 Oil Filter 20 Oil Gallery (Supply Oil to Intake Tappet)
6 Oil Filter Bypass Valve 21 Oil Gallery (Supply Oil to Exhaust Tappet)
7 Main Oil Gallery 22 Ball (f 8mm)
8 Closing Ball (f 15mm) 23 Camshaft Plug
9 Crankshaft 24 Seal
10 Connecting Rod Bearing 25 Screw Plug
11 Crankshaft Bearing 26 Oil Return Gallery (Cylinder Head and
12 Connecting Rod Crankcase)
13 Piston 27 Oil Return Gallery (Crankcase)
14 Oil Spray (Piston Crown Area) 28 End Cover (f 20mm)
15 Non-Return Valve (Crankcase) 29 Oil Return Pipe

ENGINE OIL AND OIL FILTER ELEMENT
1 Oil Filter Cover .......................................... 25 Nm 4 Oil Drain Plug

2 O-ring .................................................... Replace 5 Oil Filter Bypass Valve
3 Oil Filter Element 6 Oil Filter Cap

Tools Required
103 589 02 09 00 Oil Filter Socket Wrench
1. Install the socket wrench”7” (special tool : 103 589 02 09
00) on the oil filter cover (2).
Notice
Make the screw cover removable by tightening the bolt at
the side of the socket wrench (special tool).
2. Install the wrench to the upper bolt in the socket wrench
and remove the oil cover by turning it.
3. Remove the oil filter element.
Notice
Work with a cloth under the vehicle when removing the oil
filter element to not drain the oil.
4. Remove the drain plug (1) and drain the engine oil.
Notice
Leave the oil filler cap (3) open to ease the engine oil
discharge.
5. Tighten the engine oil drain plug after cleaning it.
Installation Notice
Replace the seal washer with new one.
6. Replace the O-ring(5) in the oil filter cover with new one.
Notice
Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover (2). Install the socket
wrench “7” (special tool : 103 589 02 09 00), and then
completely tighten it.
Installation Notice
2 Oil Filter Cover

5 O-ring
6 Oil Filter Element
7 Special Tool (Socket Wrench)
9. Fill up engine oil through the engine oil filler opening.

10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.

OIL PUMP
1 Bolt (M8 X 35, 3 piece) ................... 22.5-27.5 Nm 6 Washer

2 Oil Pump 7 Sprocket (Oil Pump Drive)
3 Oil Strainer Assembly 8 Chain (Oil Pump Drive)
4 Bolt (M6 X 12, 2 pieces) ......................... 9-11 Nm 9 Plate-Baffle
(In E23 Engine, These Bolts are 10 Bolt (M6 X 12, 6 piece) ........................... 9-11 Nm
Combined with Baffle Plate) (E23 Engine Only : Baffle Plate Mounting Bolt)
5 Bolt (M8 X 20, 1 pieces) ....................... 29-35 Nm

1. Unscrew the bolt (6) from the oil pump drive sprocket and
separate the oil pump drive chain.
Installation Notice
2. Unscrew the bolts (4,5) and remove the oil strainer assembly
(3).
Installation Notice
Bolt (4) 9 - 11 Nm
Tightening Torque
Bolt (5) 9 - 11 Nm
Insert the steel gasket into the oil pump and bolt (4) mounting
surface.
3. Unscrew the six bolts (11) and remove the haffle plate.
Installation Notice
4. Unscrew the three bolt (1) and remove the oil pump.
Installation Notice

OIL PRESSURE RELIEF VALVE

1 Screw Plug ................................................ 50 Nm 3 Guide Pin

2 Compression Spring 4 Piston

1. Remove the screw plug (1).
Installation Notice
2. Remove the spring (2), guide pin (3) and the piston (4).
reverse order.
Notice
Don’t use the seal for the screw plug.

OIL NON-RETURN VALVE

1 Oil Non-Return Valve
Functions
The non-return valve prevents the oil in the chain tensioner
from drying up. In other words, it stops oil-returning in order to
prevent the oil in the chain tensioner from getting dry. As a
result, the chain tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge 4 Bolt (M6 X 16, 1 piece) ........................... 9-11 Nm
2 Oil Dipstick Guide Tube 5 Clamp
3 O-ring

1. Pull out the oil dipstick level gauge (1).
2. Unscrew the bolt (4) and remove the oil dipstick guide
tube (2).
Installation Notice
It is very hard to remove the oil dipstick guide tube without
special tool. If it is not necessary, do not remove the guide
tube.
reverse order.

UNIT REPAIR
CORE PLUGS IN CRANKCASE
Preceding Work : Draining of the coolant
1 Core Plug ............................................... Replace

Tools Required
102 589 00 15 00 Drift
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes out
using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.

Notice
Wait for about 45minutes before filling the coolant so that
the Loctite 241 hardens.

CYLINDER BORE
Group Code Letter and Cylinder Bore Size

Engine Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm)
A A or X f 90.906 - f 90.912
X A, X or B f 90.906 - f 90.912
E23 B X or B f 90.912 - f 90.918
X+5 X+5 f 90.950 - f 90.968
X + 10 X + 10 f 91.000 - f 91.018
A A or X f 89.900 - f 90.906
X A, X or B f 89.906 - f 89.912
E20 B X or B f 89.912 - f 89.918
X+5 X+5 f 89.950 - f 89.968
X + 10 X + 10 f 90.000 - f 90.018

Type Group Code Letter1) Cylinder Bore Size (mm)

Standard Size A f 89.900 - f 90.906
E20 : f 89.9 X f 89.906 - f 89.912
E23 : f 90.9 B f 89.912 - f 89.918
1st Repair Size A f 90.150 - f 90.156
B f 90.162 - f 90.168
2nd Repair Size A f 90.400 - f 90.406
B f 90.412 - f 90.418
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.

Wear Limit in Longitudinal and Transverse Direction 0.1 mm
Permissible Deviation of Cylinder Out-of-round When new 0.007 mm
Wear limit 0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm
Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm
Chamfer Angle 75°
Honing Angle 50° ± 10°
Measurement of Cylinder Bore

1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size in
axial and transverse direction at three points (1,2,3).
1,2,3 Measuring Points

A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle

CRANKCASE MATING SURFACE

Height of the Crankcase “H” (When New) 289.35 - 289.45mm
Minimum Height After Milling 289.05mm
Flatness Crankcase Upper Mating Surface 0.03mm
Permissible Deviation of Parallelism of the Axial Direction 0.1mm
Upper to Lower Mating Surface Transverse Direction 0.05mm
Peak-to-valley Height Crankcase Upper Mating Surface 0.012 - 0.009mm
Crankcase Lower Mating Surface 0.025 - 0.020mm

Chamfering Procedure
1. Chamfer angle : 75°
2. Polish the lower chamfered area evenly with a grinder after

finishing the chamfering with a suitable tool (e.g., hand milling
cutter).

CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of valves

Overall Height of Cylinder Head 135.9 - 136.0 mm
Minimum Height After Machining 135.5 mm
Flatness Axial Direction 0.08 mm
Transverse Direction 0.0 mm
Distance ‘T’ Standard Size Intake 24.21 - 24.75 mm
(Between Camshaft Bearing Exhaust 22.21 - 22.75 mm
and Valve Stem) Repair Size Intake 23.96 - 24.51 mm
Exhaust 21.96 - 22.51 mm
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.

Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard).
Universal Tool
Surface Grinding Machine Sceledum, Type RTY
Roaro
Schio/Italy

SECTION 1B3
OM600 ENGINE MECHANICAL

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B3-2 Valve Springs (Cylinder Head Installed) . . 1B3-109
Fastener Tightening Specifications . . . . . . . . 1B3-2 Valve Stem Seals . . . . . . . . . . . . . . . . . . . 1B3-112
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B3-4 Check and Replacement of
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B3-4 Valve Guides . . . . . . . . . . . . . . . . . . . . . 1B3-116
Valve Seat Rings . . . . . . . . . . . . . . . . . . . 1B3-122
Maintenance and Repair . . . . . . . . . . . . . 1B3-12
Check and Machining of Valves . . . . . . . . 1B3-127
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 1B3-12
Machining of Valve Seat . . . . . . . . . . . . . . 1B3-132
Engine Assembly . . . . . . . . . . . . . . . . . . . . 1B3-12
Camshaft Timing Test . . . . . . . . . . . . . . . . 1B3-137
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-21
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-139
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B3-23
Chain Tensioner . . . . . . . . . . . . . . . . . . . . 1B3-145
Poly V-Belt Alignment & Inspection . . . . . . . 1B3-26
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . 1B3-147
Prechamber . . . . . . . . . . . . . . . . . . . . . . . . 1B3-29
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . 1B3-151
Milling of Prechamber Sealing Surface . . . . 1B3-32
Cylinder Head Guide Rail . . . . . . . . . . . . . 1B3-152
TDC (TDC Sensor Bracket) Setting . . . . . . 1B3-35
Timing Case Cover Guide Rail . . . . . . . . . 1B3-156
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B3-37
Crankshaft Sprocket . . . . . . . . . . . . . . . . . 1B3-158
Timing Case Cover . . . . . . . . . . . . . . . . . . . 1B3-63
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-163
Crankshaft End Cover . . . . . . . . . . . . . . . . 1B3-71
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-169
Vibration Damper and Hub . . . . . . . . . . . . . 1B3-74
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-171
Crankshaft Front Radial Seal . . . . . . . . . . . 1B3-80
Oil Spray Nozzle . . . . . . . . . . . . . . . . . . . . 1B3-174
Crankshaft Ball Bearing . . . . . . . . . . . . . . . 1B3-82
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-175
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-83
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B3-177
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-93
Cylinder Head Pressure Leakage Test . . . 1B3-177
Machining of Flywheel . . . . . . . . . . . . . . . . 1B3-97
Facing Cylinder Head Mating Surface . . . . 1B3-178
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . 1B3-98
Replacement of Crankcase Core Plug . . . 1B3-180
Hydraulic Valve Clearance Compensation
Element Check . . . . . . . . . . . . . . . . . . . . 1B3-101 Facing Crankcase Contacting Surface . . . 1B3-182
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . 1B3-103 Oil Gallery Steel Ball . . . . . . . . . . . . . . . . . 1B3-183
Valve Springs Check . . . . . . . . . . . . . . . . . 1B3-105 Cylinder Bore Measurement . . . . . . . . . . . 1B3-187
Valve Springs (Cylinder Head Removed) . 1B3-106

1B3-2 OM600 ENGINE MECHANICAL
SPECIFICATIONS
Engine Assembly
Application N·
·m
Skid Plate Bolt 28 - 47
Drain Plug Bolt 30
Coolong Fan Shroud Bolt 3-7
Control Linkage Nut 8 - 18
Clutch Linkage Cylinder Nut 20 - 34
Exhaust Manifold Bolt 30
Propeller Shaft Bolt & Nut (Axle) 70 - 80
Propeller Shaft Bolt & Nut (T/C) 81 - 84
Crankshaft Assembly
Application N·
·m
Cooling Fan Belt Pulley Bolt 10
Socket Bolt 23
Tighten The Bolt 200 / 90°
End Cover Bolt 10
Crankshaft Bearing Cap Bolt 55 / 90°
Ball Bearing 45 / 90°
Camshaft Sprocket Bolt 25 / 90°
Oil Pump Sprocket Bolt 25
Piston
Application N·
·m
Connecting Rod Bolt 35 / 90°
Flywheel
Application N·
·m
12-Sided Stretch Bolt 45 / 90°
Cylinder Head
Application N·
·m
Prechamber Threaded Ring 130
Cylinder Head Cover Bolt 10
Fuel Injsction Pipe Nut 18
Socket Bolt 25
Fuel Filter Pipe Bolt 25
Idle Pulley Bolt 23
Damper Bolt 21

OM600 ENGINE MECHANICAL 1B3-3
Cylinder Head
Application N·
·m
Camshaft Bearing Cap Bolt 25
Camshaft Sprocket Bolt 25 / 90°
Exhaust Pipe Bolt& Nut 25
Chain Tensioner 80
Injection Nozzle 40
Intake Manifold Not 25
Injection Nozzle Pipe Not 18
Oil Dipstick Tube Bolt 10
Screw Plug M18 x 15 50
Cam Support & Shaft

Application N·
·m
Stud Bolt 12
Exhaust Manifold Not 25
CamShaft Bearing Cap Bolt 25
12-Sided Bolt (M11) 25 / 90°
Timing Cover
Application N·
·m
Oil Pan Bolt-Socket Bolt 10
Oil Pan Bolt- M6 10
Oil Pan Bolt- M23 23
Belt Pulley Bolt 32
Guide Pulley Bolt 4
Guide Pulley Bracket Nut 23
Chain Tensioner 80
Tesioning Lever Bolt 23

SPECIAL TOOLS
SPECIAL TOOLS TABLE
603 589 00 09 00 603 589 00 40 00

Serration Wrench Counter Holder
657 589 03 63 00 000 589 77 03 00

Sliding Hammer Box Wrench Insert
601 589 00 66 00 602 589 00 40 00

Counter Sink Engine Lock
667 589 00 23 00 116 589 20 33 00

Height Gauge Sliding Hammer

116 589 03 07 00 115 589 34 63 00

T Type Socket Wrench
601 589 00 10 00
Cylinder Head Bolt 102 601 589 00 25 00
102 589 12 15 00 102 589 00 15 00

(f 17) Drift (f 34) Drift
617 589 10 21 00 601 589 05 14 00

RI Sensor Assembly Cage

601 589 08 15 00 103 589 00 33 00

Drift Puller
001 589 53 21 00 601 589 03 14 00

Dial Gauge Sleeve
601 589 07 21 00 601 589 03 43 00

Depth Gauge Oil Seal Assembler
667 589 01 21 00 366 589 00 21 05

Fixing Device Extension

363 589 02 21 00 116 589 07 15 00

Dial Gauge Holder Drift
000 589 33 33 00 000 589 04 14 00

Counter Support Tensioning Strap
000 589 25 33 00 102 589 03 40 00

Internal Extractor Magnetic Bar
102 589 05 33 00 601 589 01 59 00

Puller Assembling Board

601 589 02 59 00 667 584 02 63 00

Supporting Bridge Supporting Bar
667 589 00 31 00 104 589 00 37 00

Press Lever Pliers
116 589 06 63 00 601 589 02 43 00

Magnetic Finger Drift
603 589 01 40 00 000 589 10 68 00

Holding Wheel Cylinder Brush

601 589 02 23 00 601 589 05 15 00

Go/No Go Gauge Drift (for Intake)
105 589 03 15 00 601 589 06 15 00

Drift (for Intake) Drift (for Exhaust)
103 589 02 15 00 000 589 10 53 00

Drift (for Exhaust) Reamer (for Exhaust)
346 589 00 63 00 000 589 21 53 00

Super Cooling Box Reamer (for Intake)

001 589 32 21 00 124 589 15 21 00

Dial Gauge Tester
001 589 53 21 00 667 589 02 21 00

Dial Gauge TDC Pulse Generator
000 589 58 43 00 501 589 73 21 00

Chain Assembling Vacuum Pump
Device
201 589 13 21 00 617 589 04 21 00

Vacuum Tester Tester

000 589 14 21 00 601 589 00 08 00

Tester Flange
001 589 65 09 00 116 589 02 34 00

Serration Wrench Thread Bolt
000 589 00 68 00 667 589 04 63 00

Cleaning Set Retaining Plate
601 589 05 21 00 617 589 08 21 00

Looking Screw Position Sensor


ON-VEHICLE SERVICE
ENGINE ASSEMBLY

2. Remove the hood.

3. Remove the skid plate.
Installation Notice
4. Remove the radiator drain cock and drain the coolant.

Notice
Open the coolant reservoir tank cap.
5. Remove the drain plug (1) and seal (2) from the cylinder
block and drain the coolant completely.
6. After draining, replace the seal and reinstall the drain
plug.
Installation Notice
7. Disconnect the lower coolant hose from the radiator.

8. Disconnect the upper coolant hose from the radiator.
9. Loosen the bolt and remove the coolant pipe and cooling
fan shroud.
Tightening Torque 3 -7 Nm
10. Remove the hoses (air intake to intercooler, intercooler

to intake duct).
11. Remove the pipes connected to intercooler.

12. Remove the hose(air cleaner to turbocharger) with blow
by hose.
13. Disconnect the air cleaner intake hose and remove the
air cleaner cover and element.
14. Disconnect the coolant hose from the water inlet.
15. Remove the air-conditioner lines from the compressor.

Notice
Evacuate the refrigerant before removal.

16. Remove the power steering pump lines.
Notice
Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the feed
pump on injection pump.
18. Vehicle with automatic transmission.

Remove the hydraulic lines (19, 20) from oil cooler (2).
19. Disconnect the engine harness.

20. Disconnect the preheating time relay cable.

21. Remove the fuel lines from the fuel filter and cover the
filter with plug.
22. Disconnect the brake booster hose from vacuum pump.

23. Disconnect the other vacuum lines.
24. Disconnect the ground cable.

25. Disconnect the alternator wires.
26. Disconnect the starter motor wires and remove the

starter motor.

27. Disconnect the preheating time relay sensor plug.
28. Disconnect the coolant temperature sensor plug.
29. Disconnect the accelerator cable from the control

linkage.
Installation Notice
30. Loosen the connection of control pressure cable (an

arrow) used in auto transmission.

31. Separate the exhaust pipe flange from the turbo
charger.
Installation Notice
32. Loosen the installing bolt of clutch release cylinder and

remove the clutch release cylinder.
Installation Notice
33. Disconnect the exhaust pipe flange from the exhaust

manifold.
Installation Notice
34. Remove the propeller shaft from the transmission.
Installation Notice
Axle 70 ~ 80 Nm
Tightening Torque
T/C 81 ~ 89 Nm
35. Remove the shift control cable.

36. Remove the transmission.

37. Loosen the engine mounting bracket nut.
Installation Notice
38. Remove the engine assembly from the vehicle by using

a hoist or crane.

reverse order.

POLY V-BELT
1 Nut ............................................................. 23Nm 4 Spring

2 Tensioning Lever 5 Tensioning Lever
3 Bolt 6 Poly V-Belt

1. Remove the nut.
2. Push the tensioning lever in direction of arrow with a rod
(F12 ´ 180mm) and pull out the bolt to the rear.
3. Push back the tensioning lever (arrow direction) to release

the spring tension and remove the belt.
4. Install the poly V-belt beginning at the tensioning pulley (7).
7 Tensioning Pulley
8 Crankshaft
9 Alternator
10 Coolant Pump
11 Guide Pulley
12 Power Steering Pump
13 Aircon. Compressor
Lengthe of Belt
With Air Conditioner 2,100 mm

Length (L)
Without Air Conditioner 2,040 mm

TENSIONING DEVICE
1 Bolt ............................................................ 21Nm 10 Tensioning Pulley

2 Damper 11 Socket Bolt ................................................. 29Nm
3 Nut ............................................................. 21Nm 12 Closing Cover
4 Tensioning Lever 13 Washer
5 Guide Rail Pin 14 Tensioning Lever
6 Bolt 15 Fit Bolt ...................................................... 100Nm
7 Poly V-Belt 16 Closing Cover
8 Belt Pulley 17 Spring
9 Bolt ............................................................ 10Nm 18 Bolt ............................................................ 20Nm

1. Remove the nut.
Installation Notice
2. Push the tensioning lever in direction of arrow with a rod (
F12 ´ 180mm ) and push out the bolt to the rear.
3. Push back the tensioning lever to release the spring tension

and remove the belt.
4. Remove the bolt (9) and then remove the belt pulley (8).
5. Remove the bolt (1, 18) and take off the damper (2).
Notice
Pay attention to installation position of the damper.

6. Pull off the tensioning lever (4) from guide rail pin.
7. Remove the spring (17).
Installation Notice
Insert spring (17) with color coding (blue/violet) facing up.
8. Pry off the closing cover (12) and remove the socket bolt
(11) and then remove the tensioning pulley (10).
Installation Notice
9. Pry off the closing cover (16) and remove the fit bolt (15).
10. Remove the tensioning lever (14) and washer (13).
11. Clean thread in the timing case cover and fit bolt.
Installation Notice
Apply Loctite on thread of fit bolt.

reverse order.

POLY V-BELT ALIGNMENT & INSPECTION

Without Air Conditioner
With Air Conditioner

l Mark poly V-belt at a clearly visible point with chalk.
l Rotate the engine and check the belt.
Notice
If one of the following types of damage is found, replace
the belt.
1. Rubber lumps in the base of rips.

3. Pointed rips.
4. Belt cord visible in the base of rips.


7. Belt detached from the base of rip.
8. Splits across the rips.

9. Sections of rip torn out.
10. Splits across several rips.
11. Splits across the back.

PRECHAMBER
Preceding Work : Removal of glow plug
Removal of fuel injection nozzle
1 Threaded Ring ........................................ 130 Nm 3 Cylinder Head

2 Prechamber

Tools Required
603 589 00 09 00 Serration Wrench

1. Using the serration wrench (4), remove the threaded ring
(1).
Serration Wrench 603 589 00 09 00
2. Install the sliding hammer into the prechamber.
3. Remove the perchamber (2).

Notice
After removing the prechamber, cover over the bores with
clean rag.
4. Inspect the prechamber.

Notice
If the prechamber seats in the cylinder head are leaking or
if the prechambers are replaced, the sealing surfaces in
the cylinder head must be remachined.

Assembly Procedure
Notice
In case the prechambers are reused, inspect the
prechambers thoroughly, if the ball pin by heat and fire is
broken, it can not be used.
1. Clean the sealing surface of the prechamber.

2. Insert the prechamber into the cylinder head at the same
time aligning the cam on the collar of the prechambers with
the slots in the cylinder head.
Notice
If the spacer rings are fitted to the prechambers, the spacer
rings should be replaced with rings of the same thickness.
Thickness of Spacer Ring 0.3, 0.6, 1.0 mm
3. Coat the threaded ring with oil and assemble the ring by
using the serration wrench.

MILLING OF PRECHAMBER SEALING SURFACE
1 Drift 4 Counter Sink (Special Tool - 601 589 00 66)

2 Sleeve 5 Cylinder Head
3 Milling Cutter
Tools Required
601 589 00 66 00 Counter Sink
667 589 00 23 00 Height Gauge
Milling of the Prechamber Sealing Surface

Notice
The prechamber sealing surface may only be remachined
once with the cylinder head fitted. It is essential to adhere
to the specified projection ‘C’ of the prechamber of 7.6 -
8.1mm.
This ensures that the required clearance exists between
prechamber and piston crown with the piston in TDC. For
this reason, spacer rings should be inserted on remachined
sealing surfaces.
Tightening Torque 0.3, 0.6, 1.0 mm

If a spacer ring is already fitted, or a marking is made on the
cylinder head, the cylinder head must be removed and size
‘C’ measured if further remachining is necessary on a
prechamber sealing surface.

1. Remove the injection nozzle.
2. Remove the prechamber.
3. Cover the prechamber bore to avoid any chips dropping
into the combustion chamber.
4. Remove the protective sleeve from the countersink and
rotate the countersink into the prechamber bore to be
machined as far as the stop.
Counter Sink 601 589 00 66 00
5. Maintain size ‘X’ from the top edge of mandrel to the top
edge of the sleeve with the gauge.
Height Gauge 667 589 00 23 00
6. Measure the ‘X’ by using a vernier caliper.
7. Mount the turning tool onto the countersink tool and rotate
to the right approx. 5 revolutions by applying slight pressure.

8. Remeasure size ‘X’ and compare it with the first
measurement and determine the thickness of spacer ring.
Ex Size before machining 25.7 mm

Size after machining 25.5 mm
The spacer ring should be selected so that it is at least
0.1mm and not more than 0.3mm thicker than the
measured on the sealing surface. In this example, the
necessary thickness of spacer ring should be within 0.3 ~
0.5mm and the thickness of spacer ring to be installed is
0.3mm.
9. Remove the countersink tool and clean the chips.
Notice
If the sealing surface is not completely flat, remachine the
sealing surface.
10. emove rag from the prechamber bore and crank the engine
with starter motor to threw out any chips which may have
got into the combustion chamber.
11. Insert the proper spacer ring into the prechamber sealing
surface.
12. Punch a mark on the cylinder head above the prechamber
sealing surface which has been machined.
13. Install the prechambers.
Notice
If the cylinder head is removed, the projection ‘C’ is
measured in place of size ‘X’ and the appropriate size of
spacer ring selected.
Normal Projection (c) 7.6 - 8.1mm

TDC (TDC SENSOR BRACKET) SETTING

Preceding Work : Removal of No.1 cylinder prechamber
1 Measuring Device
2 Dial Gauge
3 Cylinder Head
4 Piston ................................................. Set at TDC
Tools Service
001 589 32 21 00 Dial Gauge
601 589 07 21 00 Deqth Gauge
667 589 01 21 00 Fixing Device
Notice
l The TDC sensor bracket must be adjusted in case of
followings.
l When replacing the TDC sensor bracket.
l When replacing the crankshaft, the hub or the vibration
damper.
l When replacing or installing the timing case cover.
l After engine overhauling.
* If the cylinder head is removed, the measuring pin of the

dial gauge can be positioned on the piston crown.
This is done by placing the magnetic dial holder on the
mating surface of the crankcase.

Setting (with cylinder head installed)
1. Remove the prechamber of No. 1 cylinder.
2. Position the piston of No.1 cylinder at BTDC 10.
3. Install the measuring device into the prechamber bore and

position the dial gauge with a preload of 5mm.
Dial Gauge 001 589 53 21 00
Depth Gauge 601 589 07 21 00
4. Slowly rotate the crankshaft in the direction of engine rotation

until the large pointer on the dial gauge stops (TDC position).
Notice
The position of TDC is when the large pointer on the dial
gauge is stopped before moving back.
5. remove the reinstall the measuring device and position the

dial gauge scale at ‘0’.
6. Slowly rotate the crankshaft in the direction of engine rotation
until the dial gauge has moved back (counterclockwise) by
3.65mm.
7. Insert fixing device into the sensor bracket.

Notice
The pin on the vibration damper must engage into the slot
of the fixing device.
Fixing Device 667 589 01 21 00

8. If the pin does not engage, adjust the setting of the sensor
bracket by removing and tightening of the sensor bracket
bolts.Tightening Torque 10 Nm
Notice
The timing mark on the damper must be positioned at ATDC
20.

CYLINDER HEAD
1 Fuel Injection Pipe ..................................... 18Nm 21 Camshaft Drive Sprocket ....................... Replace
2 Cylinder Head 22 Washer
3 Gasket ................................................... Replace 23 Bolt(12-Sided) ................................... 25Nm + 90°
4 Bolt ............................................................ 25Nm 24 Sliding Rail
5 Washer 25 Sliding Rail Pin
6 Clamp 26 Sliding Rail Pin
7 Heater Feed Pipe 27 Chain Tensioner........................................ 80 Nm
8 Bolt 28 Gasket ................................................... Replace
9 Washer 29 Cooling Fan .............................................. Check
10 Bolt 30 Hexagon Socket Bolt ................................. 45 Nm
11 Nozzle Washer ....................................... Replace 31 Tensioning Lever
12 Fuel Injection Nozzle ............................ 35-40 Nm 32 Bolt ........................................................... 25 Nm
13 Hexagon Socket Bolt ................................. 25 Nm 33 Bolt
14 Washer 34 Nut ............................................................ 23 Nm
15 Bolt ........................................................... 25 Nm 35 Fuel Filter
16 Cylinder Head Bolt .............................. See Table 36 Turbo Charger
17 Cylinder Head Cover 37 Intake Duct
18 Bolt ........................................................... 10 Nm 38 Gasket ................................................... Replace
19 Gasket 39 Intake Manifold
20 Camshaft

Tightening Torque
Cylinder Bolts (12-sided socket head) stage1 10 Nm

(Engine cold) stage2 35 Nm
stage3 180°
M8 Cylinder Head Bolts 25 Nm
Tools Required
102 589 03 40 00 Magnetic Bar
116 589 02 34 00 Threaded Pin
116 589 03 07 00 Type Socket Wrench
601 589 00 10 00 Cylinder Head Bolt Wrench
602 589 00 40 00 Engine Lock
603 589 00 40 00 Counter Holder
Tightening Sequence for Cylinder Head Bolts

OM 662LA Engine
OM 661LA Engine

Notice
The cylinder head may only be removed when the engine
has cooled down. The cylinder head is removed together
with the exhaust manifold. As the cylinder head bolts
undergo a permanent tightening. They require to be
replaced if they exceed the maximum lengthes indicated
in the table.
Thread Dia. Length(L) When New Max. Length(L)
M10 80mm 82mm
M10 102mm 104mm
M10 115mm 117mm
The twelve-sided socket head bolts are tightened with each
stages of torque and torque angle.
It is not necessary to retighten the cylinder head bolts at
the 1000~1500km inspection or after 1000~1500km of
repairs.

Disassembly Procedure
1. Completely drain the coolant from the radiator and cylinder
block.
3. Hold the fan with counter holder and remove the bolt and
then remove the cooling fan.
Notice
Keep the fan in vertical position.
Counter Holder 603 589 00 40 00
4. Remove the bracket oil dipstick tube.
5. Remove the nut.

6. Remove the nut on the tensioning lever and insert the
rod(F12 ´ 180mm). By pushing the rod to the arrow direction,
pull back the bolt.
7. Push the tensioning lever to the opposite direction to release

the spring tension and remove the poly V-belt.

8. Remove the air cleaner cover and element and then
remove the air cleaner housing.
9. Remove the oil return hose and plug.
Notice
Cover them to prevent chips from coming into.
10. Unscrew the EGR pipe mounting bolts onto the exhaust
manifold.
11. Remove the duct bracket from the cylinder head.
12. Unscrew the intake duct mounting bolts onto the intake
manifold.
13. Separate the connecting rod from the control lever.

14. Pull out the accelerator control linkage.
15. Remove the fuel injection line(1) from the fuel injection
nozzle(12).
Box Wrench Inset 000 589 77 03 00
16. Remove the fuel injection line from the fuel injection pump.
17. Remove the bracket mounting bolts and then remove the
fuel injection line(1).

18. Disconnect the booster hose connected to intake manifold.
19. Remove the intake manifold and gasket.
20. Remove the cylinder head cover and gasket with the blow-
by gas hose.
21. Disconnect the glow plug cables.

22. Remove the cable channel.
23. Disconnect the cables from the glow plug sensor and
coolant temperature sensor.
24. Remove the heater pipe bracket from the oil filter.
25. Pry off the clamp and push the heater feed pipe forward
and then pull out the pipe.

26. Disconnect the fuel lines from the fuel filter.
27. Disconnect the fuel lines from the injection pump.
28. Remove the fuel filter(35).
29. Remove the fuel injection nozzle(12) and nozzle

washer(11).

30. Rotate the crankshaft and set the No.1 cylinder at TDC.
Notice
Do not rotate the crankshaft to the opposite direction of
engine revolution.
31. Place alignment marks on the camshaft gear and timing

chain.
32. Ensure that the camshaft and the bearing cap marking
are aligned.
33. Remove the starter motor and install the engine lock onto
the flywheel ring gear.
Engine Lock 602 589 00 40 00

34. Remove the turbocharger.
35. Remove the exhaust manifold and gasket.
36. Remove the chain tensioner and seal.
37. Remove the bolt and separate the drive sprocket(21).

Notice
During removal, be careful not to drop the sprocket and
chain into the timing case.
Carefully pull off the chain and then pull out the sprocket.

38. Remove the camshaft bearing cap bolts according to the
numerical sequence.
Notice
Remove the No.1 bolts first and then remove the No. 2
bolts. Do not remove the bolts at a time completely but
remove them step by step evenly or camshaft can be
seriously damaged.
OM662LA
OM661LA
39. Remove the bearing caps and then pull out the
camshaft(20) upward.
Notice
Be careful not to miss the locking washer.
40. Remove the locking washer.

Notice
Check the locking washer and replace if necessary.

41. Remove the bolt(32).
42. Separate the spring and pull out the tensioning lever(31).
43. Pry off the closing cover. Remove the bolt and then remove
the idle pulley.
44. Using the sliding hammer(36) and the threaded pin(37),

pull out the sliding rail pins(25, 26) and remove the sliding
rail(24).

Threaded Pin 116 589 02 34 00

45. Remove the vacuum line from the vacuum pump.
46. Disconnect the vacuum pipe from thermo valve.
47. Remove the socket bolts(13) of the chain box.
T Type Socket Wrench 116 589 03 07 00

Magnetic Bar 102 589 03 40 00
48. Remove the cylinder head bolts in numerical se-quence.
Cylinder Head Bolt Wrench 601 589 00 10 00
OM 662LA

OM 661LA
49. Remove the cylinder head(2) and gasket(3).

Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.

Notice
Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts.

Notice
If the max. length is exceeded, replace the bolts.
Thread Dia. Length(L) Max. Limit(L)

when new
M10 80mm 82mm
M10 102mm 104mm
M10 115mm 117mm
4. Coat the head contact surface of bolts and thread with oil OM662LA
and insert them as shown.
- Cylinder head bolts arrangement

Bore
1 ........................................... M10 × 80
2 ........................................... M10 × 102
3 ........................................... M10 × 115
4 ........................................... M 8 × 50
5 ........................................... M 8 × 80

5. Tighten the cylinder head bolts to specified torque and
torque angle.
Stage 1 15 Nm
Stage 2 35 Nm
Torque Angle 90 °
Wait For 10 minutes
Torque Angle 90°
OM 661LA OM 662LA
6. Install the socket bolts in the chain box.

7. Connect the vacuum pipe to the thermo valve.

8. Connect the vacuum lines to the vacuum pump.
9. Install the fuel filter and connect the pipe.

Notice
Be careful not to be confused the connections and hoses.
10. Connect the fuel pipe to the injection pump.
11. Install the sliding rail(24) and insert the sliding rail pins(25,
26).
Notice
Apply sealing compound on the each collar of the sliding
rail pins.

Threaded Pin 116 589 02 34 00

12. Install the idle pulley and fit the closing cover.
13. Insert the tensioning lever(31) and install the spring.
14. Install the damper.

Notice
Insert the tensioning lever bolts onto the mounting hole.
15. Insert the locking washer.

16. Inspect the valve tappet and check that the tappet moves
smoothly.

17. Coat the camshaft with oil and install the camshaft on the
cylinder head to be TDC mark(arrow) upward.
18. Measure the axial end play of the camshaft.
End Play 0.06 - 0.21mm
Notice
If out of standard, adjust it with the proper thickness of
locking washer.
19. Install the bearing caps on the camshaft according to the

number on the caps.
20. Tighten the bearing cap bolts according to the numerical

sequence.
Notice
Tighten the No. 1 bolts(light arrow) first and then tighten
the No. 2 bolts(dark arrow) stage by stage.
OM662LA
OM661LA

21. Position the camshaft on marking and install the camshaft
sprocket.
Notice
Align the alignment marks on the chain and sprocket.
22. Check the TDC position of the crankshaft.
23. Install the camshaft sprocket bolt.


Notice
Measure the max. length ‘L’ and replace the bolt if it exceeds
53.6mm.
24. Install the exhaust manifold and gasket.
25. Install the turbocharger.
26. Install the exhaust pipe onto the turbocharger.


27. Replace the seal and then install the chain tensioner(27).
28. Remove the engine lock.
29. Insert the nozzle washer into the hole to face round part
downward.
31. Connect the fuel hose.

32. Install the cable channel and connect the cables to glow
plugs.

33. Replace the gasket and install the cylinder head cover.
34. Install the blow-by hose.
35. Connect the wires to the coolant temperature sensor and

the glow plug sensor.
36. Replace the intake manifold gasket.
37. Install the intake manifold.


38. Replace the O-ring of heater feed pipe and install it to the
cylinder head.
Notice
For installation, clean the hole.
39. Install the bracket of heater feed pipe to the oil filter.
40. Install the fuel pipe and the accelerator control linkage.
41. Connect the fuel lines to the injection nozzles and to the
injection pump.

42. Install the poly V-belt.
Notice
Be careful not to contaminate the belt.
43. By inserting a rod into the tensioning lever upper hole and
pulling the rod, install the bolt and then tighten the nut.
44. Install the oil dipstick tube bracket.

45. Hold the cooling fan with the counter holder and tighten
the bolt.

TIMING CASE COVER

Preceding Work : Removal of the cooling fan
Rmoval of the V-belt tensioning device
Removal of the vibration damper and hub
Removal of the alternator
1Bolt ............................................................ 10Nm 13 Bolt ............................................................ 32Nm

2Cylinder Head Cover 14 Timing Case Cover
3Gasket ................................................... Replace 15 Bolt ............................................................ 23Nm
4Socket Bolt ................................................. 25Nm 16 Alternator Bracket
5Fuel Filter 17 Bolt ............................................................ 45Nm
6Square Nut 18 Bolt ............................................................ 25Nm
7Oil Pan 19 Bolt ............................................................ 10Nm
8Socket Bolt ................................................. 10Nm 20 Closing Cover
9Bolt .................................................... M6 : 10Nm 21 Socket Bolt ................................................. 23Nm
M8 : 23Nm 22 Guide Pulley
10 Power Steering Pump 23 Bolt .............................................................. 9Nm
11 Bolt 24 Guide Pulley Bracket
12 Belt Pulley 25 Nut ............................................................. 23Nm

Tools Required
116 589 03 07 00 Socket Wrench
Removal Procedure
1. Remove the fan clutch and cooling fan belt pulley.
2. Drain the engine oil completely.
3. Remove the oil dipstick tube bracket bolts.
4. Remove the crankshaft pulley.
5. Loosen the bolt (1) and then remove the cylinder head cover
(2) and gasket.
6. Remove the vacuum pump.
7. Detach the closing cover (20). Remove the bolts(21) and

then remove the guide pulley (22).
8. Remove the guide pulley bracket (24).

9. Disconnect the pipes of power steering pump and remove
the belt pulley.
Notice
Be careful not to lose the key.
10. Remove the nut and pull out the bolt and then remove the
power steering pump.
11. Remove the alternator bracket (16).
12. Remove the fuel filter.

13. Remove the camshaft.
14. Remove the socket bolts(4) in the chain box.
Socket Wrench 115 589 03 07 00
15. Remove the injection pump.

Notice
See the ‘Removal of fuel injection pump’.
16. Remove the oil pan bolts (8, 9) in the area of the timing
case cover (14).
17. Slightly loosen the remaining oil pan bolts.
18. Remove the timing case cover (19) bolts and then remove
the timing case cover (14).
Notice
Be careful not to damage the cylinder head gasket or oil
pan gasket.

1. Thoroughly clean the sealing surface and apply sealant.
2. Install the timing case cover.

Notice
Bolts arrangement
1.M6 x 60
2.M6 x 70
3.M6 x 40
3. Tighten the socket bolts in the chain box.

4. Tighten the oil pan bolts.
Socket bolt 10 Nm
Tightening Torque M6 bolt 10 Nm
M8 bolt 23 Nm

5. Install the flange, vibration damper and crankshaft belt
pulley.
Notice
Replace front radial seal if necessary.
6. Install the alternator bracket.
Front 25 Nm
Tightening Torque
Side 25 Nm
7. Install the alternator.
Upper 25 Nm
Tightening Torque
Low 25 Nm
8. Install the cylinder head cover.

9. Tighten the injection pump mounting bolts.

10. Install the fuel filter.

11. Install the vacuum pump.

12. Install the power steering pump.
13. Install the power steering pump pulley.
14. Install the guide pulley bracket.

15. Install the guide pulley (22) and fit the closing cover (20).
16. Replace the gasket (3) and install the cylinder head cover
(2).
17. Install the cooling fan belt pulley and fan clutch.
18. Install the belt tensioning device and then install the belt.
19. Install the cooling fan.
20. Fill the engine oil and check oil leaks by running the engine.

CRANKSHAFT END COVER

Preceding Work : Removal of flywheel and driven plate.
1 Crankshaft Flange 4 Radial Seal ............................................ Replace

2 End Cover .............................. Clean, Loctite 573 5 Dowel Sleeve
3 Bolt ......................................... 10Nm, Loctite 573 6 Bolt ......................................... 10Nm, Loctite 573

Tools Required
601 589 03 43 00 Oil Seal Assmbler
Removal Procedure
1. Remove the bolts (3, 6) from end cover, By pulling out the
lugs (arrow), remove the cover.
Notice
2. Remove the radial seal (4) with care not to damage the
sealing surface.
1. Thoroughly clean the sealing surface of end cover and apply
Loctite 573.
2. Clean the groove of radial seal.
3. Apply Loctite 573 on the bolts and install the end cover.
Notice
4. Install the inner oil seal assembler to the crankshaft flange.
Oil Seal Assembler 601 589 03 43 00

5. Coat a little oil on the sealing lip of new radial seal and
contacting surface.
Notice
Don’t use grease.
6. Insert the new radial seal (4) onto the oil seal assembler
(7).
Notice
The sealing lip of the repair radial seal is offset to the inside
by 3mm to ensure that it does not run in any groove which
the standard radial seal may have left on the crankshaft
flange.
A Standard Radial Seal
B Repair Radial Seal
7. Install the outer oil seal assembler on he seal and by

tightening the bolts, press the radial seal into the end cover
as far as the stop.
Notice
The seal must be positioned exactly at right angles in the
end cover to ensure that it provides a proper seal.
Oil Seal Assembler 601 589 03 43 00

VIBRATION DAMPER AND HUB

Removal of poly V-belt
1 Bolt ............................................................ 10Nm 6 Bolt ................................................ 200Nm + 90°

2 Cooling Fan Belt Pulley 7 Washer
3 Socket Bolt ................................................ 23Nm 8 Straight Pin
4 Crankshaft Belt Pulley 9 Hub
5 Vibration Damper 10 Oil Pan

Sectional View
3 Socket Bolt 9 Hub

4 Crankshaft Belt Pulley 11 Radial Seal
5 Vibration Damper 12 Timing Gear Case Cover
6 Bolt 13 Key
7 Washer 14 Crankshaft Sprocket
8 Straight Pin 16 Crankshaft
Notice
The mounting position of vibration damper is fixed by straight
pin (8).
Tools Required
602 589 00 40 00 Engine Lock
103 589 00 30 00 Puller

Removal Procedure
1. Remove the starter motor and install the engine lock into
the wheel ring gear.
Engine Lock 602 589 00 40 00
2. Remove the poly V-belt.

3. Remove the cooling fan.
Notice
Keep the fan in vertical position.
4. Remove the cooling fan belt pulley (2).

5. Place alignment marks (arrow) on the vibration damper (5)
and crankshaft belt pulley (4).
6. Remove the timing sensor bracket.

Notice
Remove if necessary.

7. Remove the socket bolts (3) and then remove the belt
pulley (4) and vibration damper (5).
8. Remove the washer and bolt.
9. Remove the hub by using a puller.
Puller 103 589 00 33 00

10. Replace the radial seal.

1. Install the hub.
Notice
Exactly align the woodruff key and the groove of hub (arrow).
2. Install the washer (7) and tighten the bolt (6).

Washer (new) : 1 EA 200 Nm + 90°
3. Install the vibration damper.

Notice
Exactly align and insert onto the straight pin.
4. Install the belt pulley.

Notice
Align the alignment marks.

5. Install the timing sensor bracket.
Notice
See the ‘TDC setting’.
6. Install the cooling fan pulley.

7. Install the cooling fan.
8. Install the fan belt.

1 Radial Seal 3 Woodruff Key

2 Timing Case Cover
Tools Required
601 589 03 14 00 Sleeve

Notice
The sealing lip of the repair radial seal is offset to the inside
by 2mm to ensure that is does not run in any groove which
the standard radial seal may have left on the crankshaft
flange.
A Standard Radial Seal
B Repair Radial Seal
1. Pull out the radial seal (1) and be careful not to damage the
sealing surface of timing case cover.
2. Thoroughly clean the mounting bore of the radial seal.
3. Coat a little oil on the sealing lip of new radial (1) and contact
surface.
Notice
Don’t use grease.
4. Install the radial seal (1) by using a sleeve (4).
Notice
Align the groove of sleeve and woodruff key(arrow).
Sleeve 601 589 03 14

CRANKSHAFT BALL BEARING
1 Spacer 3 Ball Bearing

2 Cover ......................................... Replace 4 Bolt ....................................... 45Nm + 90°
Notice
Manual transmission only.
Tools Required
000 589 33 33 00 Counter Support
000 589 25 33 00 Internal Extractor

1. Remove the manual transmission.
2. Using a puller, pull out the locking ring and ball bearing
together.
Counter Support 000 589 33 33 00

Internal Extractor 000 589 25 33 00
3. Apply Loctite 241 on the new ball bearing and then insert
the ball bearing to be stopped at the spacer ring by using a
proper mandrel.

CRANKSHAFT
Preceding Work : Removal of the end cover
Removal of the piston
Removal of the crankshaft sprocket
3 Crankshaft Main Bearing Shells (Upper) 7 Thrust Bearings (Lower)

4 Trust Bearings (Upper) 8 Crankshaft Bearing Cap
5 Crankshaft 9 Crankshaft Bearing Cap (Fit Bearing)
6 Crankshaft Main Bearing Shells (Lower) 10 12-sided Stretch Bolts ....................... 55Nm + 90°
Tools Required
001 589 53 21 00 Dial Gauge
363 589 02 21 00 Dial Gauge Holder
366 589 00 21 05 Extension

Thrust Washer and Bearing Arrangement
OM662LA Engine
3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings

4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.

OM661LA Engine
3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings

4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.

Crankshaft Standard and Repair Sizes
mm
Crankshaft bearing Thrust bearing Thrust bearing
journal diameter journal width journal diameter
24.500 - 24.533
Standard size 50.950 - 57.965 47.950 - 47.965
24.600 - 24.633
Repair size 1 57.500 - 57.715 24.700 - 24.733 47.700 - 47.715
Repair size 2 57.450 - 57.465 24.900 - 24.933 47.450 - 47.650
Repair size 3 57.200 - 57.215 25.000 - 25.033 47.200 - 47.215
Repair size 4 56.950 - 56.965 - 46.950 - 46.965
Bearing Clearances
mm
Thrust bearing Crankshaft bearing
Radial clearances New 0.027 - 0.051 0.026 - 0.068
Limit Max. 0.070 Max. 0.080
Axial clearances New 0.100 - 0.254 -
Limit Max. 0.300 -
Matching Fit Bearing Journal Width to Thrust Bearings

mm
Fit bearing journal width Thrust bearings thickness
24.500 - 24.533 2.15
24.600 - 24.633 2.20
24.700 - 24.733 2.25
24.900 - 24.933 2.35
25.000 - 25.033 2.40
Notice
l Measure crankshaft axial clearance and adjust with proper thrust Bearing.
l The same thickness of washer must be installed on both sides of the fit bearing.

Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft
Marking of basic bearing bore in lower Color code of relevant crankshaft

parting surface bearing shell
1 punch mark or blue Blue or white-blue
2 punch marks or yellow Yellow or white-yellow
3 punch marks or red Red or white-red
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft
Color code of relevant crankshaft

Marking of bearing journals on crank webs bearing shell
Blue or white-blue Blue or white-blue
Yellow or white-blue Yellow or white-yellow
Red or white-blue Red or white-red

1. Remove the bearing cab bolt.
2. Remove the bearing caps (8).
Notice
The crankshaft bearing caps are marked with stamped
numbers. Remove the bearing cap from the vibration
damper side.
3. Remove the crankshaft bearing caps (9) and lower thrust

bearings (7).
4. Remove the lower thrust bearings (6) from the bearing cap
(9).
5. Remove the crankshaft (5).
6. Remove the upper thrust bearings(4).

7. Remove the upper bearing shells (3) from crankcase.

8. Thoroughly clean the oil gallery.
9. Select a proper new bearing shells with reference to table.
10. Coat the new bearing shells with oil and insert into the
crankcase and into the crankshaft bearing caps.
Notice
Do not mix up upper and lower crankshaft bearing shells.
11. Install the bearing caps according to marking and tighten
the 12-sided stretch bolts.
Notice
No. 1 is vibration damper side.
12. Measure crankshaft bearing diameters (E).
Extension 366 589 00 21 05
13. Measure at 3 points (A, B and C) and if the average value

of B and C is less than A’s value, the average value of B
and C is the mean value and if more than A’s value, A’s
value is the mean value.
14. Measure crankshaft bearing journal diameter (F).

Notice
When measured in A and B, the runout should not exceed
0.010mm.

15. Measure radial clearance of crankshaft bearing (G).
Clearance ‘G’ 0.027 - 0.051mm
Notice
If ‘G’ is out of standard, replace the bearing shells and
adjust the radial clearance of crankshaft bearing.
Example) Measured value ‘E’ = 57.700mm
Measured value ‘F’ = 57.659mm
Clearance ‘G’ = 0.041mm
16. Remove the crankshaft bearing cap.
17. Measure width of thrust bearing journal (H) and adjust with
proper thrust bearings (see table).
Notice
The same thickness of thrust washers should be installed
on both sides of the thrust bearing.
18. Coat the upper thrust bearing (4) with oil and insert into
the crankcase so that the oil grooves are facing the crank
webs (arrow).
19. Coat the lower thrust bearing (7) with oil and insert into the
crankshaft bearing cap so that the oil grooves are facing
the crank webs (arrow).
Notice
The retaining lugs should be positioned in the grooves
(arrow).

Notice
If the max. length of bolts(L) exceed 63.8mm, replace them.
19. Coat the new crankshaft with engine oil and place it on the
crankcase.
20. Install the crankshaft bearing caps according to marking
and tighten the bolts.
Notice
Install from No. 1 cap.
22. Rotate the crankshaft with hand and check whether it

rotates smoothly.
23. Measure crankshaft bearing axial clearance.
Clearance 0.100 - 0.245mm
Notice
If the clearance is out of standard, adjust the axial clearance
of crankshaft bearing by replacing the thrust washers.
Dial Gauge 001 589 53 21 00

Dial Gauge Holder 363 589 02 21 00
Notice
The same thickness of thrust washers should be installed
on both sides of the thrust bearing.

24. Insert the new connecting rod bearing shells into the
connecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
26. Measure connecting rod bearing journal diameter (K).

Notice
Refer to measurement of the crankshaft bearing journal
diameter.
27. Measure the radial clearance (L) of the connecting rod
bearing.
Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial clearance ‘L’ 0.026 - 0.068mm

Notice
If the clearance is out of standard, adjust the radial
clearance of connecting rod bearing by replacing the
connecting rod bearing shells.
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotates
smoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve.
- clean the oil pump and oil filter housing carefully and
replace the hose if necessary.
Notice
After assembling the engine, check the camshaft timing,
adjust the start of fuel injection and check the TDC sensor
bracket setting.
32. Fill oil and run the engine and then check the oil pressure
and oil level.
Notice
Install the original oil filter element and then change the
engine oil and oil filter element after 1,000 - 1,500km.

FLYWHEEL
Preceding Work : Removal of the transmission
Removal of the clutch
1 Oil Pan 4 12-Sided Stretch Bolt ............ Check, 45Nm + 90°

2 Straight Pin 5 Drive Plate (Automatic Transmission)
3 Flywheel 6 Flywheel (Automatic Transmission)

l Manual transmission flywheel
OM662LA OM661LA
l Automatic transmission flywheel

Tools Required
602 589 00 40 00 Engine Lock

1. Install the engine lock.
Engine Lock 602 589 02 40 00
2. Remove the 12-sided stretch bolts (4).

Installation Notice
Notice
If the length ‘L’ of bolts exceeds 22.5mm, replace the bolts.
3. Remove the flywheel (3), if equipped with manual

transmission.
Installation Notice
Correctly align the position of dowel pin (2).

4. Remove the flywheel (6) and driven plate (5), if equipped
with automatic transmission.
Installation Notice
Correctly align the position of dowel pin (2).
reverse order.

MACHINING OF FLYWHEEL
1 Flywheel
Machining of Flywheel OM662LA OM661LA
Notice
Flywheels which have scorch marks, scoring or cracks in
the clutch surface should be machined by grinding or
precision-turning. If the scores or cracks are severe than
permissible specifications, replace the flywheel.
Distance ‘a’ 19.3 - 19.5 mm

Distance ‘b’ New 16.6 mm
Repair up to 15.6 mm
Max. axial runout 0.05 mm
l When machining the clutch surface ‘A’, the mounting

surface (B) for the clutch pressure plate should also be
machined in accordance with ‘A’ to keep the distance ‘a’.
l Do not machine under ‘b’ value.
l When machining, fix the flywheel exactly not to exceed the
standard runout.

FLYWHEEL RING GEAR

Preceding Work : Removal of flywheel
1 Ring Gear 3 Centering Collar Diameter

2 Flywheel
Tools Required
001 589 53 21 00 Dial Gauge

1. Drill a hole into the ring gear (1) (arrow) and snap with a
chisel.
2. Thoroughly clean the collar surfaces of ring gear.
3. Measure diameter (a) of centering collar.

Notice
If out of standard, replace the flywheel.
Diameter ‘a’ 275 + 0.5mm
4. Heat up the new ring gear up to 220°C by using a heating

device.
Notice
Use temperature measuring chalk.
5. Install the new ring gear (1) onto the flywheel by using a
drift.

6. Measure axial runout of ring gear (1) on a surface plate.
Limit Max. 0.4mm
Notice
For correct measurement, put the flywheel on the flat
measuring board.
Dial Gauge 001 589 53 21 00


HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK
1 Cylinder Head Cover 4 Valve Tappet

2 Bolt ............................................................ 10Nm 5 Cylinder Head
3 Gasket ................................................... Replace

Checking Procedure
Notice
The noise which continues short time during short travel
(frequent starting of the engine) or engine starting after a
long time storage is normal operating conditions. So, it does
not need to be repaired. Determine the malfunctions in valve
clearance compensation device with noise through following
tests. If defective, replace as respectively.
1. Run the engine at more than 3000rpm for approx. 4 minutes.
2. Stop the engine. After 5minutes, check the engine oil level
and adjust if necessary.
3. Remove the cylinder head cover.
4. Check the valve tappets at TDC position of each cylinders.
5. Using a drift, lightly press the valve tappet and measure
clearance between the cam and valve tappet.
Notice
If the clearance exceeds 0.4mm, replace the valve tappet.
6. If a valve tappet moves down too far in comparison to the
others, replace the valve tappet.
7. Rotate the engine and check the remaining valve tappets.
Notice
l Unnecessary rotation of the engine will damage the valve
tappets.
l Do not rotate the engine by using the camshaft sprocket
bolt or to the opposite direction of the engine rotation.

VALVE TAPPETS
1 Valve Tappet 4 Seal ....................................................... Replace

2 Cylinder Head 5 Screw Plug
3 Oil Gallery
Tools Required
102 589 03 40 00 Magnetic Bar

1. Pull out the valve tappet (1).
Magnetic Bar 102 589 03 40 00
2. Remove the plug (5) and blow compressed air into the oil
gallery (3). At this time, check that the outlet bores(arrow)
at the seat of the valve tappet are clear.
3. Replace the seal (4) and tighten the plug (5).
4. Insert the new valve tappet.
Notice
Coat the valve tappet with oil.

VALVE SPRINGS CHECK

1 Valve Spring 2 Spring Scale
Service Data
At preloaded
Outer diameter Wire diameter Free length
Length Tension (new) Limit
33.1mm 4.20mm 50.0mm 27mm 680 - 740N 612N

VALVE SPRINGS (CYLINDER HEAD REMOVED)
1 Valve Tappet 6 Stud Bolt .................................................... 12Nm

2 Valve Cotters 7 Washer
3 Spring Retainer 8 Nut .............................................. Replace, 25Nm
4 Valve Spring ........... Check, replace if necessary 9 Exhaust Manifold
5 Cylinder Head

Tools Required
102 589 03 40 00 Magnetic Bar
601 589 01 59 00 Assembling Board
601 589 02 59 00 Supporting Bridge
667 589 00 31 00 Press Lever

1. Remove the nuts (8) uniformly and then remove the washer
(7), exhaust manifold (9) and gasket.
Installation Notice
Check the stud bolt (6) for damage and replace if necessary.
Tighten Torque 12 Nm
Replace the gasket and tighten the nuts (8).
Tighten Torque 25 Nm
2. Install the assembling board (11) to the cylinder head with 4

cylinder head blots (10).
Assembling Board 601 589 01 59 00
3. Pull out the valve tappet (1) with magnetic bar (12).
Notice
Place the valve tappets upside down (open end upward).
Magnetic Bar 102 589 03 40 00
4. Install the supporting bridge (13) on the cylinder head (5).
Supporting Bridge 601 589 02 59 00

5. Using the press lever (14), press the spring retainer
downward and remove the valve cotters (2) with magnetic
finger (15).
Notice
Be careful not to damage guide bore of the valve tappet.
Press Lever 667 589 00 31 00

6. Remove the spring retainer (3) and spring (4).

Installation Notice
Install the valve spring with the color coding (arrow) facing
down.
7. Check the valve spring and replace if necessary.
reverse order.

VALVE SPRINGS (CYLINDER HEAD INSTALLED)

1 Valve Tappet 4 Valve Spring .......... Check, replace if necessary

2 Valve Cotters 5 Timing Chain
3 Spring Retainer 6 Cylinder Head
Notice
Remove the valve springs only when the piston is at TDC.
Tools Required
102 589 03 40 00 Magnetic Bar
603 589 01 40 00 Holding Wheel
667 589 00 31 00 Press Lever

1. Remove the valve tappet (1) with magentic lifter.
Notice
Place the valve tappets upside down (open end upward)
Magentic Liter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain of camshaft
sprocket piston.
Holding Wheel 603 589 01 40 00
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8).
5. Using the press lever (9), press the spring retainer(3)

downward and remove the valve cotters (2) with magnetic
finger (10).
Notice
Press Lever 667 589 00 31 00


6. Remove the spring retainer(3) and spring (4).
7. Check the valve spring and replace if necessary.
8. Insert valve spring (4) with the color coding (arrow) facing
down and insert valve spring Retainer(3).
9. By press the spring retainer(3) with press lever (90), install

the valve cotters with magnetic finger (10).
Press Lever 667 589 00 31 00

10. Remove the supporting bar.

11. Remove the holding wheel (7) from the timing chain (5).
13. Coat the valve tappet with oil and install it.
Magnetic Bar 102 589 03 40 00

VALVE STEM SEALS

Preceding Work : Removal of camshaft.
1 Valve Tappet 4 Valve Spring ........... Check, replace if necessary

2 Valve Cotters 5 Valve Stem Seal
3 Spring Retainer 6 Valve
Notice
Remove the valve stem seals when the piston is positioned at TDC.

Tools Required
667 589 00 31 00 Press Lever
104 589 00 37 00 Pliers
102 589 03 40 00 Magnetic Lifter
603 589 01 40 00 Holding Wheel
601 589 02 43 00 Drift
A : Intake valve stem seal B : Exhaust valve stem seal
Intake valve stem seal Exhaust valve stem seal

Chamfer Offset All round
Inner diameter ‘d’ 7.3mm 8.2mm
Color Brown Green
Wire ring Black Yellow

1. Remove the valve tappet (1) with magnetic lifter.
Notice
Place the valve tappets upside down (open end upward).
Magnetic Lifter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain (11).
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8).
5. Using press lever (9), press the spring retainer(3) downward

and remove the valve collets with magnetic finger (10).
Press Lever 667 589 00 31 00


6. Remove the spring retainer(3) and valve spring (4).
7. Remove the valve stem seal (5).
Pliers 104 589 00 37 00
8. Insert the cap (12) onto the valve (6) and install the new
valve stem seal (5) and then remover the cap.
Drift 601 589 02 43 00
9. By pressing the spring seat with press lever (9), install the
valve cotters(2) with magnetic finger (10).
Notice
Press Lever 667 589 00 31 00


CHECK AND REPLACEMENT OF VALVE GUIDES

Removal of valve spring
Removal of valve
1 Cylinder Head 3 Valve Seat Ring

2 Valve Guide a Basic Bore Diameter
Service Data
Item Outer Diameter ‘D’ Color Code Basic Bore Overlap Valve Guide Length ‘L’
Diameter ‘a’ ‘D’ - ‘a’ Inner Diameter ‘A’
Repair size 1 14.251 Red 14.200 - 14.211 0.029 8.000
Intake 39.5
Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051 - 8.030
Repair size 1 14.240 - 14.251 Red 14.200 - 14.211 0.029 9.000
Exhaust 37.7
Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051 - 9.050

Notice
Measure center (arrow) of the valve guide and if the inner
diameter ‘A’ exceeds standard value, replace the guide.
Tools Required
000 589 10 53 00 Reamer (for Exhaust)
000 589 10 68 00 Cylinder Brush
000 589 21 53 00 Reamer (for Intake)
102 589 00 23 00 GO / NO GO Gauge (for Intake)
103 589 02 15 00 Drift (for Exhaust)
103 589 03 15 00 Drift (for Intake)
117 589 03 25 00 GO / NO GO Gauge (for Exhaust)
346 589 00 63 00 Super Cooling Box
601 589 02 23 00 GO/NO GO Gauge
601 589 05 15 00 Drift (for Intake)
601 589 06 15 00 Drift (for Exhaust)
Matching Valve Seat - Broaching Tools - Guide Sleeves

Valve Seat Broaching Tool No. Guide Sleeve Tool No. Guide Sleeve Side
Intake 115 589 00 53 00 102 589 00 63 00 B
Exhaust (14.2mm) 102 589 08 63 00 B
Intake 115 589 01 53 00 A
601 589 15 63 00
Exhaust (14.4mm) B

Checking Procedure
1. Thoroughly clean the valve guide bore using a cylinder
brush.
Cylinder Brush 000 589 10 68 00
2. Insert the GO/NO GO gauge into the valve guide bore. If

the NO GO side is inserted fully, replace the valve guide
(Intake 8mm, Exhaust 9mm).
GO/NO GO Gauge 601 589 02 23 00
1. Drive out the valve guide (2) by using a drift (5).
Notice
The valve guide must be driven out upward of the cylinder
head.
Drift (for Intake) 103 589 03 15 00
Drift (for Exhaust) 103 589 02 15 00
2. Thoroughly clean the basic bore by using a cylinder brush.
Cylinder Brush 000 589 10 68 00
3. Check the basic bore in cylinder head for scoring marks

and ream to next repair size if necessary.

4. Reaming basic bore in cylinder head (repair size).
- Thoroughly remove carbon deposits in cylinder head.
Notice
Particularly remove the insides of the valve seat rings.
- Remove the elevation (arrow) of intake valve seat rings.
- Select correct broaching tool and guide sleeve (refer to

the table).
Notice
Before broaching work, the broaching tool must be cleared
of swarf with a stiff plastic brush.
- Lubricate the basic bore, guide sleeve and broaching tool

with petroleum.
- Push broaching tool (6) in broaching direction (arrow) into
the guide sleeve (7) far enough so that the first cut of the
broaching tool is positioned in the basic bore when guide
sleeve is fitted onto the valve seat ring (3).
6 B ndard tool
7 Guide sleeve
See the ‘standard data’
- Center the guide sleeve (7) in the valve seat ring (3) by
turning.
- Knock through the broaching tool (6) with a plastic hammer
(approx. 25g). and aluminum drift.

5. Heat the cylinder head (1) in a wear tank to approx. 80°C.
6. Cool down the new valve guide (2) with liquid nitrogen.
Notice
Do not touch the cooled valve guide by hand.
Super Cooling box 346 589 00 63 00
7. Drive in new valve guide with drift (8) until the wire ring makes
contact.
Notice
The valve guide must be driven in from the cylinder head
cover.
Drift (for Intake) 601 589 05 15 00
Drift (for Exhaust) 601 589 06 15 00
8. Check the valve guide bore with GO / NO GO gauge (9).

The GO side (marked ‘0’) should just still drop. If the GO
side cannot be inserted, the bore of valve guide should be
reamed.
Notice
Perform the check only on cooled down cylinder head.
GO / NO GO Gauge (for Intake) 102 589 00 23 00

GO / NO GO Gauge (for Exhaust) 117 589 03 23 00

9. If necessary, ream the valve guide bore evenly.
Notice
Never turn the reamer against the direction of rotation.
Reamer (for Exhaust) 000 589 10 53 00

Reamer (for Intake) 000 589 21 53 00

VALVE SEAT RINGS

Preceding Work : Removal of valve
Checking of valve guide, replace if necessary
Removal of prechamber
1 Cylinder Head D Valve Seat Ring Outer Diameter

2 Valve Seat Ring D1 Valve Seat Ring Inner Diameter
3 Valve Guide D2 Basic Bore Diameter
A Height (Cylinder Head Upper / Lower Surface) H Height of Valve Seat Ring
B Height (cylinder Head Cover Surface - Seat of
Valve Seat Ring)
Service Data
Item Intake Exhaust
D2 40.000 - 40.016mm 37.000 - 37.016mm
D 40.084 - 40.100mm 37.084 - 37.100mm
D1 33.400 - 33.600mm 30.400 - 30.600mm
H 6.955 - 7.045mm 6.955 - 7.045mm
Overlap U=D-D2 0.068 - 0.100mm 0.068 - 0.100mm
B 133.4mm 133.4mm
A 142.5mm 142.5mm

Commercial Tools
Cylinder Head Clamping Device Hunger
D-8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning Tool Hunger
D-8000 München 70
Type VDS 1A
Order No. 236 03 308
Ring Seat Turning Tool Hunger
D-8000 München 70
Type RDS 1
Order No. 219 00 100
Pneumatic Removal / Installation Device Hunger
(Drift : 8mm, 9mm, 14mm) D-8000 München 70
Type PVM 1
Tensioning Head Hunger
D-8000 München 70
Order No. 250 15 250
Cutting Tool for Recessing Grooves Hunger
D-8000 München 70
Order No. 217 93 601
Test Set for Valves Hunger
D-8000 München 70
Order No. 216 69 210
Internal Dial Gauge (Range : 25-60mm) Mahr
D-7300 Esslingen
Order No. 844
External Micrometer (Range : 25-60mm) Mahr
D-7300 Esslingen
Order No. 40 S
Electrically Heated Water Tank Otto Dürr
D-7123 Sachsenherm - Ochsenbach

Removal Procedure
1. Measure dimension ‘A’.
Limit 142.5mm
2. Clamp the cylinder head with clamping device.
3. Cut groove into the valve seat ring so that dimension ‘C’ is
approx. 2mm and dimension ‘E’ is approx. 6mm.
4. Remove the cylinder head from the clamping device and

place it onto wooden blocks.
5. Remove the valve guide (3).
Drift (Intake) 8mm

Drift (Exhaust) 9mm
6. Insert the tensioning head (4) and extracted wedges(arrow)

by turning the bolt (5).
Notice
Carefully tighten the bolt (5) otherwise the valve seat ring in
the cylinder head will be excessively tensioned.
7. Lock the bolt (5) with nut (6).

8. Turn over the cylinder head.
9. Remove the tensioning head (4) and valve seat ring (2)
with drift (14mm) and removal tool.
10. Clean the basic bore of valve seat ring.
11. Measure the basic bore diameter (D2) and outer diameter
(D) of the new valve seat ring (standard size).
12. Calculate the overlap value ‘U’ (D - D2).
Overlap value ‘U’ 0.068 - 0.100mm
Example) Measured value D = 37.100mm
Measured value D2 = 37.010mm
Overlap value ‘U’ = 0.090mm

If overlap value ‘U’ is out of standard, machine
the basic bore for the valve seat ring.
13. Clamp the cylinder head with clamping device.

14. Machining basic bore for valve seat ring (repair size).
Notice
Maintain minimum value of ‘B’.
- Machine the basic bore.
Limit
Intake 40.516mm
Max. D2
Exhaust 37.516mm
Min. B 133.4mm
- Measure machined basic bore and outer diameter ‘D’

of valve seat ring (repair size).
- Measure the overlap ‘U’
Overlap ‘U’ (D - D2) 0.068 - 0.100 mm
Example) Measured value D = 37.600 mm
Measured value D2 = 37.480 mm
Overlap U = 0.120 mm
The basic diameter D2 must be machined by
0.020mm in order to get the required overlap
value.

15. Hang the cylinder head (1) to the lifting device and heat in
a water tank to approx. 80°C.
16. Cool down new valve seat ring (2) into the cooling box with
liquid nitrogen.
Notice
Do not touch the cooled valve seat rings with hand.
Super Cooling Box 345 589 00 63 00
17. Drive in new valve seat ring (2) with a proper wooden drift.
18. Install the valve guide (3) with a proper drift and assembling
tool.
Notice
The valve guide must be driven in from the cylinder head
cover.
Drift (Intake) 8mm

Drift (Exhaust) 9mm
19. Machine the valve seats.

CHECK AND MACHINING OF VALVES

Preceding Works : Removal of cylinder head
Removal of the vale spring
Removal of the valve
I Valve Length Y Half Camshaft Basic Bore Diameter

W Camshaft Cam Basic Diameter Z Distance (Cylinder Head Cover Parting Surface -
X Distance (Camshaft Basic Bore - Valve Stem) Valve Stem)

Intake Valve Exhaust Valve
Item Intake Valve Exhaust Valve

Valve disc diameter ‘d’ 37.90 - 38.10 mm 34.90 - 35.10 mm
Valve disc height ‘h’ 1.7 mm 1.7 mm
Setting angle “a”o r machining the valve 45° 45°
Valve stem diameter ‘d1’ 7.955 - 7.970 mm 9.945 - 8.960 mm
Valve length ‘I’ Standard 106.20 - 106.60 mm 106.20 - 106.60 mm
Repair 105.30 - 105.70 105.30 - 105.70 mm
Max. permissible runout at valve stem and valve seat 0.03 mm 0.03 mm
Matching Valves
Camshaft cam basic dia. Camshaft cam basic dia. Valve to be used
w = 38.0 ± 0.2mm w = 36.6 ± 0.2mm
Use machined valve,
if needed
Size (x) 19.5 - 20.3mm 19.5 - 20.1mm
new repair valve
I = 105.5 ± 0.2mm
Size (x) 20.4 - 21.4mm 20.2 - 21.2mm Reuse valve
Use standard size
Size (x) 21.4 - 21.97mm 21.2 - 21.97mm valve
I = 106.4 ± 0.2mm

Tools Required
001 589 32 21 00 Dial Gauge
Commercial Tool
Valve corn grinding machine
Checking and Machining Procedure
1. Clean the valves and do visual check.
Valves with wobbled valve disc, with worn or scored valve
stem should be replaced.
2. Measure valve disc height ‘h’.
Intake 1.7 ± 0.15 mm
Service data
Exhaust 1.7 ± 0.15 mm
3. Machine the valve.

Notice
Pay attention to setting angle ‘a’.
4. Measure radial runout between valve stem and valve seat.
Limit Max. 0.03mm
Dial Gauge 001 589 32 21 00

5. Clean the vales, valve seats and valve guides.
6. Coat the valve stem with oil and insert it into valve guide.
7. Insert the valves (1) into the valve guides according to

marking.
8. Measure amount by which the valve arrears ‘a’.
Arrears ‘a’ 0.1 - 0.7 mm
Notice
If out of standard, replace the valve seat ring.
9. Measure camshaft cam basic diameter (w).
38 ± 0.2 mm
Diameter ‘w’
or 37.6 ± 0.2 mm
10. Measure distance ‘z’ (cylinder head cover parting surface

- valve stem).

11. The distance ‘x’ (camshaft basic bore - valve stem).
‘x’ = ‘z’ - ‘y’.
Determine the valve to use according to this measurement
(See ‘matching valves’)
Example) Measured value ‘w’ = 38.2 mm

Measured value ‘z’ = 36.5 mm
Value ‘y’ = 15.5 mm
‘x’ = 36.5 - 15.5 = 21.0mm

In this case according to ‘Matching valves’ table, the
installed valve may be used.

MACHINING OF VALVE SEAT

Preceding Work : Removal of prechamber
Removal and inspection of valve, replace if necessary
Inspection of valve guide, replace if necessary
1 Valve a Valve Arreare

2 Valve Seat Ring b Valve Seat Width
3 Cylinder Head a Valve Seat Angle
4 Valve Guide b Valve Seat Free Angle

Service Data
Item Intake Exhaust
Valve arrears ‘a’ 0.1 - 0.7 mm 0.1 - 0.7 mm
Valve seat width ‘b’ 1.2 - 1.7 mm 1.5 - 2.0 mm
Valve seat angle ‘a’ 45° 45°
Valve seat free angle ‘b’ 65° 65°
Permissible radial runout 0.03 mm 0.03 mm
Valve length ‘I’ Standard 106.20-106.60 mm 106.20-106.60 mm
Repair 105.30-105.70 mm 105.30-105.70 mm
Matching Valves
Camshaft cam basic dia. Camshaft cam basic dia. Valve to be used
w = 38.0 ± 0.2 mm w = 37.6 ± 0.2 mm
Use machined valve,
if needed
Size (x) 19.5 - 20.3mm 19.5 - 20.1mm
use pair valve
1 = 105.5 ± 0.2mm
Size (x) 20.4 - 21.4mm 20.2 - 21.2mm Reuse valve
Use standard size
Size (x) 21.4 - 21.97mm 21.2 - 21.97mm valve
I = 106.4 ± 0.2mm
Commercial Tools
Cylinder Head Clamping Devie Hunger
D-8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning Tool Hunger
D-8000 München 70
Type VDS 1A
Order No. 236 03 308
Test Sat for Valves Hunger
D-8000 München 70
Order No. 217 93 601

Machining Procedure
Valve machining is required :
- When the valve is leaking.
- When replacing the valve.
- When replacing the valve guide.
- When replacing the valve seat or valve seat ring.
1. Machine the valve seat (a=45°).
2. Measure valve seat width ‘b’.
Valve seat Intake 1.2 - 1.7 mm

width ‘b’ Exhaust 1.5 - 2.0 mm
3. If the specification is exceeded, the valve seat width has to

be corrected at the lower free angle of ‘b’=65°.
4. Measure radial runout.

Runout Max. 0.03mm

5. Insert the valve (1) into the valve guide according to marking
and measure amount by which the valve arrears ‘a’.
Arrears ‘a’ 0.1 - 0.7mm
6. Measure camshaft cam basic circle diameter (w).

38 ± 0.2mm
Diameter ‘w’
or 37.6 ± 0.2mm
7. Measure distance ‘z’ (cylinder head cover parting surface

- valve stem).

I Length of Valve y Half Camshaft Basic Bore Diameter

w Camshaft Cam Basic Circle Diameter z Distance (Cylinder head cover parting surface - .
x Distance (Camshaft basic bore - valve stem) valve stem)
8. Measure ‘x’ (Camshaft basic bore - valve stem).

‘x’ = ‘z’ - ‘y’
9. Determine the valve to be used.
(See ‘Matching valves’)
Example) Measured value ‘w’ = 38.2 mm
Measured value ‘z’ = 36.5 mm
Value ‘y’ = 15.5 mm
‘x’ = 36.5 - 15.5 = 21.0 mm
In the case of a camshaft cam basic circle diameter
‘w’ = 38.2mm and a distance ‘x’ = 21.0mm, the installed
valve may be used.

CAMSHAFT TIMING TEST

1 Cylinder Head Cover 4 Valve Tappet

3 Gasket ................................................... Replace
Timing
Intake valve Exhaust valve
Condition of camshaft
Open Close Open Close
New ATDC 11.33° ABDC 17° BBDC 28° BTDC 15.25°
After approx. 20,000km ATDC 12° ABDC 18° BBDC 27° BTDC 14°
«
At 2mm of valve lifting stroke.

Tools Required
001 589 53 21 00 Dial Gauge
366 589 00 21 05 Extension
Measurement Procedure
1. Remove the cylinder head cover.
2. Rotate the engine in the direction of engine rotation until
the intake valve of no. 1 cylinder is completely closed. The
cam lobe faces up (arrow).
Notice
Do not rotate the engine at the bolt of the crankshaft
sprocket. Do not rotate the engine in the opposite direction
of engine rotation. If do, this will cause serious measuring
errors.
3. Install the dial gauge holder and dial gauge (7) with the
extension (8) to the cylinder head and position the tracer
pin (9) onto the valve tappet (intake valve of cylinder no.1)
with a preload of min. 3mm.
Notice
The tracer pin should be positioned exactly vertical.
Dial gauge Holder 363 589 02 21 00
Dial Gauge 001 589 53 21 00
Extension 366 589 00 21 05
4. Set the dial gauge to ‘0’.

5. Rotate the engine further in direction of rotation until the
dial gauge has moved back by 2mm (valve lift) to 1mm.
6. Check the timing.
New ATDC 11.33°
After approx. 20,000km ATDC 12°
Notice
If timing is out standard, the camshaft should be checked
for wear and the timing chain for stretch. If a difference of
more than 4° exists, the timing chain should be replaced.

CAMSHAFT

2 Washer 9 Oil Pan
3 Camshaft Bearing Cap 10 Camshaft Sprocket
4 Camshaft 11 Washer
5 Dowel Pin 12 12-Sided Bolt (M11) ............. Check, 25Nm + 90°
6 Locking Washer 13 Gasket ................................................... Replace
7 Timing Chain 14 Chain Tensioner ........................................ 80Nm

Tools Required
602 589 00 40 00 Engine Lock
Removal Procedure
1. Rotate the crankshaft and position the piston of No.1 cylinder
at TDC.
Notice
Do not rotate the crankshaft in the opposite direction of
engine rotation.
In this position, the markings of the camshaft/camshaft

bearing cap (arrow) must be aligned.
2. Place alignment marks on the camshaft sprocket and timing

chain.
3. Remove the starter motor and install the engine lock.
Engine Lock 602 589 00 40 00

4. Remove the bolt and then remove the camshaft sprocket.
Notice
During removal, be careful not to drop the sprocket with
chain. Remove the chain carefully and then pull out the
sprocket.
6. Remove the camshaft bearing cap bolts according to the

removal order.
Notice
Remove the camshaft bearing cap bolts of 1(dark arrow)
first and then remove the bolts of 2 (light arrow) one
revolution in stages until the counter-pressure is released.
In order to avoid damaging the camshaft, it is essential to
adhere to the removal order for the camshaft bearing caps.
OM 662LA
OM 661LA

7. Remove the camshaft bearing cap.
8. Pull off the camshaft.
Notice
Be careful not to miss front locking washer.
9. Pull out the locking washer.

Notice
Check the condition of locking washer and replace if
necessary.
1. Insert the locking washer.
2. Check the valve tappet and ensure that tappet moves
smoothly.
3. Coat the camshaft with oil and install the camshaft onto the
cylinder head so that the TDC marking (arrow) is positioned
upward vertically.
4. Install the camshaft bearing caps according to markings(1,

2, 3 etc.).

5. Tighten the camshaft bearing cap bolts acccording to
installation order.
Notice
Tighten the No. 1 bolts (light arrow) by one revolution in
stages first and then tighten the No.2 bolts (dark arrow).
OM 662LA
OM 661LA
6. Install the camshaft sprocket to be aligned the markings of

the camshaft / camshaft bearing cap (arrow).
Notice
Align the alignment marks on the timing chain and sprocket.
7. Tighten the camshaft sprocket bolt.

Tightening Torque 25Nm + 90°

Notice
If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm,
replace it.
Notice
Replace the seal.
Before installation, by pumping in the oil approx. 10 times,
fill the oil.
10. Check the TDC marking of OT on the crankshaft.

CHAIN TENSIONER
1 Chain Tensioner ........................................ 80Nm 2 Seal ....................................................... Replace

Notice
Always install the chain tensioner to be filled with oil.
Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up.
Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill
Faulty chain tensioners should be replaced completely.
3 Screw Plug 11 Valve Disc

4 Aluminum Gasket 12 O-Ring
5 Ball 13 Snap Ring
6 Ball Guide 14 Compression Spring
7 Compression Spring 15 Filler
8 Compression Spring
9 Housing A Feed Bore from Cylinder Head
10 Thrust Pin B To Oil Pan

TIMING CHAIN
Removal of chain tensioner
Removal of cooling fan
Removal of cylinder head cover
1 Chain Link
2 Timing Chain
3 Camshaft Sprocket
4 Outer Plate

Tools Required
000 589 58 43 00 Chain Assembling Device
1. Cover over the chain box with cleaning rag and grind off
both chain pins (arrow) at a chain link (1) of the timing chain.
2. Remove the outer plate (4) and chain link (1).

Notice
Ensure that the ends of the timing chain do not drop into
the chain box.
3. Loosen the chain tension with approx. 4 turns.

4. Connect the new timing chain (arrow) with chain link (1) to
the old timing chain (2).
5. By rotating the crankshaft in the of engine rotation, pull out

the old timing chain with installing the new timing chain.
6. Remove the old timing chain and hold the ends of the new
timing chain to camshaft sprocket (3) with wire (arrow).

7. Insert the new chain link (1) to connect the chain.
8. Insert the new outer plate (4) into the fitting tool (8) and
then the outer plate will be held by a magnet.
Chain Assembling Device 000 589 58 43 00
9. Place the fitting tool (8) onto the chain link and press the
outer plate on as far as the stop.
10. Switch over the die (9) of the fitting tool (8).

11. Place the fitting tool (8) onto the chain link and rivet the
chain pins one by one.
12. Check the riveting of chain pins and re-rivet if necessary.

13. Remove the wire.
14. Position the no.1 cylinder at TDC.
In this position, the marking on camshaft / camshaft bearing

cap (arrow) must also be aligned. If the markings are not
aligned, the timing chain must be re-set and the injection
pump timing has to be set.

TENSIONING RAIL
Removal of timing case cover
1 Tensioning Rail 2 Bearing Pin
Notice
The plastic coating of the tensioning rail can not be replaced.


Removal of poly V-belt
Removal of chain tensioner
1 Cylinder Head Cover 9 Bearing Pin ........................... Sealing Compound

2 Bolt ............................................................ 10Nm 10 Guide Rail
3 Gasket ................................................... Replace 11 Bearing Pin
4 Camshaft Sprocket 12 Guide Pulley
5 Washer 13 Socket Bolt ................................................ 23Nm
6 12-Sided Bolt (M11) ............ Inspect, 25Nm + 90° 14 Closing Cover
7 Tensioning Lever 15 Spring
8 Bolt ............................................................ 23Nm 16 Timing Chain

Tools Required
116 589 20 33 00 Threaded Pin
Removal Procedure
1. Removal the cylinder head cover.
2. Pull off the tensioning lever (7) and remove from the spring
(15).
3. Pry off the closing cover (14) and remove the bolt (13) and
then remove the guide pulley (12).
4. Place alignment marks (arrow) on the timing chain (16) and

camshaft sprocket (4).
5. Remove the camshaft sprocket.

6. Pull out the bearing pins (9, 11) with sliding hammer and
remove the guide rail 10.

Threaded Pin 116 589 02 34 00
1. Apply collar of both bearing pins with sealing compound.
2. Position the guide rail and insert the bearing pins.
3. Install the camshaft sprocket.
Notice
If the max. length ‘L’ of the 12-sided bolt exceeds 53.6mm,
replace it.
4. Position the No.1 cylinder at the TDC of OT.

In this position, the marking on the camshaft / camshaft
bearing cap (arrow) must also be aligned.
5. Install the guide pulley (12).

6. Attach the tensioning lever (7) to the spring (15) and install.

TIMING CASE COVER GUIDE RAIL

1 Bearing Pin 5 Crankshaft

2 Bearing Pin 6 Spring
3 Guide Rail 7 Bushing
4 Oil Pump Chain 8 Tensioning Lever

Removal Procedure
1. Pull out the tensioning lever (8) together with the spring (6)
and guide rail (3) far enough until the tensioning lever has
moved passed the oil pump chain (4) and is resting against
the crankshaft (5)
2. Pull the tensioning lever (8) off the bearing pin (2) and
carefully remove the spring (6). Remove the tensioning lever
(8) together with the spring (6) and bushing (7).
3. Remove the guide rail (3).
1. Install the guide rail (3). Attach the spring (6) to the guide
rail and to the tensioning lever (8).
Notice
Ensure that the spring is correctly located in the guide rail
(arrow).
2. Push the guide rail, spring, bushing and tensioning lever
together onto the bearing pin (1, 2).

CRANKSHAFT SPROCKET
Removal of timing case cover
1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90° 11 Bolt ............................................................ 25Nm
2 Washer 12 Crankshaft Sprocket
3 Camshaft Sprocket 13 Crankshaft
4 Timing Chain 14 Key
5 Bearing Pin 15 Guide Rail
6 Bearing Pin 16 Spring
7 Oil Pump 17 Bushing
8 Oil Pump Sprocket 18 Tensioning Lever
9 Oil Pump Chain
10 Washer

Special Tools
116 589 07 15 00 Drift
102 589 05 33 00 Puller
Removal
1. Pull out the tensioning lever (19) together with the spring
(17) and guide rail (16) far enough until the tensioning lever
has passed the oil pump chain (9) and is resting against
the crankshaft (13).
2. Pull out tensioning lever (19), spring (17) and bushing (18)
from the bearing pin (6).
3. Pull out the guide rail (16).
4. Remove the bolt(11) and then remove the washer (10), oil
pump chin (9) and sprocket (8).

crankshaft sprocket (12).
6. Remove the key(15).


9. Remove the bolt (1) and then remove the washer (2) and
10. Remove the crankshaft sprocket (12) by using a puller

(20).
Puller 102 589 05 33 00

Installation
1. Put the same alignment mark on the new crankshaft
sprocket as in the old sprocket.
Notice
Check the timing chain, camshaft sprocket, injection pump
timing sprocket, oil pump chain and oil pump sprocket for
wear and replace if necessary.
2. Install the new crankshaft sprocket (12) by using a drift (21).

Notice
Align the groove of sprocket and woodruff key (arrow)
exactly.
Drift 116 589 07 15 00
3. Fit the timing chain (4) on the crankshaft sprocket (12).

Notice
Align the alignment marks (arrow) on the chain and sprocket.
4. Install the camshaft sprocket (3).

Notice
Pay attention on the alignment marks and dowel pin (arrow).

Notice
If the max. length ‘L’ of the stretch bolt exceeds 53.6mm,
replace it.
5. Fit the oil pump chain (9) on the crankshaft sprocket (12)
and insert the oil pump sprocket (8) into the oil pump chain
and then install it on the oil pump.
Notice
The curved side of the oil pump sprocket should face the
oil pump.
6. Insert the woodruff key (15).
7. Install the guide rail (16). Attach the spring (17) to guide rail
and to tensioning lever together onto the bearing pins (5,6).
Notice
Ensure that the spring is correctly located in the guide rail
(arrow).

PISTON
Preceding Work : Removal of the cylinder head
Removal of the oil pump
1 Oil Ring 8 Connecting Rod

2 2nd Ring 9 Connecting Rod Upper Bearing Shell
3 Top Ring 10 Connecting Rod Lower Bearing Shell
4 Snap Ring .............................................. Replace 11 Connecting Rod Bearing Cap
5 Piston Pin 12 Connecting Rod Bolt ......................... 35Nm + 90°
6 Piston 13 Crankcase
7 Connecting Rod Bushing .......................... Check 14 Cylinder Bore
Notice
There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing
the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there
would be a unbalancing of engine.

Service Data
Piston clearance Max. 0.12 mm
Piston crown protrusion in TDC position 0.735 - 0.965 mm
Connecting rod bushing diameter 26.012 - 26.018 mm
Connecting Rod Bolt Dimensions

Thread M9 x 1
Stretch shaft(C) diameter (new) 7.4-0.1 mm
Minimum stretch shaft diameter (C) 7.1 mm
Length(L)(new) 52-0.3 mm
Tools Required
000 589 04 14 00 Tensioning Strap
001 589 53 21 00 Dial Gauge

Removal
1. Remove combustion residues from the cylinder bores.
2. Remove the connecting rod bolts (12) and then remove
the connecting rod bearing caps(11).
3. Remove the connecting rod bearing shells (9, 10).

Notice
Be careful not mix the bearing caps and shells each other.
4. Remove the piston (6) and connecting rod (8).
6. Separate the piston and connecting rod.

Installation
1. Fit the piston onto the connecting rod so that the arrow
(15) and the locking slot (16) are facing in direction of the
vehicle.
2. Coat the piston pin (15) with engine oil and insert it by hand.
Notice
Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (arrow).
4. Check the piston rings (1, 2, 3) and replace them if
necessary.
5. Install and arrange the piston rings to be evenly 120° from

each ends gap.

6. Coat the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and piston with oil.
7. Compress the piston rings with a tensioning strap (7).
Tensioning Strap 000 589 04 14 00
8. Insert the piston assembly into the cylinder with a wooden

stick (18).
Notice
The arrow on the piston crown must point toward the front
of vehicle.
9. Insert the connecting rod bearing shells (9, 10).

Notice
Be careful of the difference in upper and lower bearing
shells and not to be changed.
10. Position the connecting rod bearings caps.
Notice
Position so that the retaining lugs are on the same side of
the connecting rod bearing(arrow).
11. Measure stretch shaft diameter (C) of the connecting rod

bolts.
Limit ‘C’ 7.1mm

12. Coat the bolts (12) with oil and then tighten the bolts.
13. Rotate the crankshaft and check axial clearance between

the connecting rod and crankshaft.
14. Measure clearance between the piston crown and cylinder
Standard Max. 0.12mm
15. Position the piston at TDC and measure the distance

between the piston crown and the crankcase surface.
Standard Max. 0.965 mm
Notice
Measure at points marked.
Dial Gauge 001 589 00 53 21


OIL FILTER
1 Nut ............................................................ 25 Nm 6 Bolt (M6) .................................................... 10Nm

2 Oil Filter ..................................................... Cover 7 Oil Pressure Switch
3 O-Ring ................................................... Replace 8 Gasket
4 Oil Filter ............... Element Replace If necessary 9 Bolt ........................................................... 25 Nm
5 Oil Filter Housing

1. Remove the oil filter cover and then drain the oil.
2. Remove the oil pressure switch line.
3. Remove the oil filter housing.

reverse order.

OIL PAN
OM662LA OM661LA
1 Gasket ................................................... Replace 6 Lower Oil Pan

2 Upper Oil Pan 7 Combination Bolt ...................................... 25 Nm
3 Combination Bolt ...................................... 10 Nm 8 Drain Plug ................................................. 25 Nm
4 Combination Bolt ...................................... 10 Nm 9 Washer Seal .......................................... Replace
5 Gasket ................................................... Replace 10 Oil Pan
*Remove and install as numerical sequence.

Notice
Replace the washer seal with new one.

Oil Circulation

Oil Filter
a From Oil Pump

b To Main Oil Gallery
c To Oil Pan

OIL SPRAY NOZZLE
1 Fitting Sleeve 3 Combination Bolt ..................................... 10 Nm

2 Oil Spray Nozzle A Oil Duct
1. Remove oil pan or crankshaft.
2. Loose the bolt and then remove the nozzle.

OIL PUMP
1 Oil Pump 5 Screw Plug ................................................ 50 Nm

2 Piston 6 Combination Bolt ...................................... 25 Nm
3 Pressure Spring 7 Oil Strainer
4 Guide Pin 8 Bracket
1. Remove the oil pan.
2. Unscrew the mounting bolt of spracket.

3. Unscrew the oil strainer bracket bolt.
4. Remove the oil pump.
5. Unscrew the screw plug and remove the relief valve.

reverse order.

UNIT REPAIR
CYLINDER HEAD PRESSURE LEAKAGE TEST
Preceding Work : Removal of the cylinder head
Removal of the exhaust manifold
Removal of the valve
1 Feed Pipe
2 Bolt
3 Return Connection
4 Gasket ................................................................ Replace
5 Coolant Gallery ................................................... Sealing
6 Pressure Measuring Plate .................................. Completely tight to the cylinder head
7 Cylinder Head .....................................................
Immerse with pressure measuring plate into warm water of approx. 60°C and pressurize with compressed
airof 2 bar.
Notice
If air bubbles are seen, replace the cylinderhead.
Tools Required
115 589 34 63 00 Pressure Measuring Plate
601 589 00 25 00 Suspension Device

FACING CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of prechamber
Cylinder head pressure leakage test
1 Valve B Longitudinal Direction

2 Cylinder Head C Transverse Direction
3 Prechamber a Valve Arrears
A Height of Cylinder Head b Prechamber Protrusion
Service Data
Height ‘A’ 142.9 - 143.1mm
(Cylinder Head Surface - Cylinder Head Cover Surface)
Minimum Height After Machining 142.5mm
Permissible Unevenness of Parting Surface In Longitudinal Direction 0.08mm
In Transverse Direction 0.0mm
Permissible Variation of Parallelism (Longitud. Direction) Max. 0.1mm
Peak-to-Valley Height 0.0017mm
Valve Arrears ‘a’ Intake Valve 0.1 - 0.7mm
Exhaust Valve 0.1 - 0.7mm
Prechamber Protrusion 7.6 - 8.1mm

Measurement Procedure
1. Measure height ‘A’.
Limit 142.5 mm
Notice
If the height is less than 142.5mm, replace the cylinder head.
2. Insert the valve (1) and measure valve arrears ‘a’.

Valve arrears ‘a’ 0.1 - 0.7 mm
Notice
If out of standard, machine the valve seat.
3. Install the prechamber and measure protrusion ‘C’.

Protrusion ‘C’ 7.6 - 8.1mm
4. Assemble the engine and check the valve timing.

REPLACEMENT OF CRANKCASE CORE PLUG
Left Right
Core plug ....................................................... f34mm Core plug ....................................................... f34mm

OM661LA - 2EA OM661LA - 2EA
Left Right
Core plug ....................................................... f17mm Core plug ....................................................... f34mm


Tools Required
102 589 00 15 00 Drift
102 589 12 15 00 Drift
1. Completely drain the coolant.
2. Remove any parts which impede access.
(Example : transmission, injection pump)
3. Place the screwdriver to the deepdrawn edge of the core
plug and pull forward and then rotate 90°.
4. Pull out the core plug with pliers.
5. Thoroughly clean the sealing surface and apply Loctite 241.

6. Install the new core plug by using a drift.
Drift 102 589 00 15 00 (F34)

Drift 102 589 12 15 00 (F17)
7. Install the removed parts and fill the coolant.

Notice
The adhesive must be allowed to harden for about 45
minutes before filling of coolant.

FACING CRANKCASE CONTACTING SURFACE
1 Crankcase B Longitudinal Direction

2 Crankcase Contacting Surface C Transverse Direction
H Chamfer Height
Y Height (crankcase upper surface - crankcase b Chamfer Angle
lower surface)
Service Data
Height ‘Y’ Min. 299.62 mm
Permissible unevenness of contacting surface In longitudinal direction (B) 0.06 mm
In transverse direction (C) 0.06 mm
Permissible roughness upper contacting surface 0.0006 - 0.0016 mm
Permissible variation of parallelism of crankcase upper 0.05 mm
surface to lower surface in longitudinal direction
Piston protrusion at TDC to crankcase upper surface Max. 0.965 mm
Min. 0.735 mm

OIL GALLERY STEEL BALL

Removal of the coolant pump housing
Removal of the flywheel and driven plate
1 Steel Ball ................................................. f15mm 2 Screw Plug M16 x 1.5 ..............Loctite 241,50Nm
Notice
The screw plug (2) has to be installed as a repair solution if the steel ball (1) is leaking.

3 Steel Ball ................................................. f17mm 5 Screw Plug M18 x 1.5 ................................ 50Nm
4 Seal
Notice
The seal (4) and screw plug (5) have to be installed as a repair solution if the steel ball (3) is leaking.
Tools Required
601 589 08 15 00 Drift

1. Remove the timing case cover.
2. By inserting a round bar (6) approx. 0.7m from the back to
the front side through the oil gallery, knock out the steel
balls (1,3).
Notice
Be careful not to damage the bores of the steel balls.
6 Shop-made tool
3. Thoroughly clean the bores of steel balls.

4. Place the steel ball (3) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 15 00
5. Place the steel ball (1) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 15
6. Warm up the engine and check the oil for leaks.

Installation of screw plug
Notice
If steel ball leaks again, install the screw plug.
1. Remove the steel ball.
2. Tap thread into the bores of the oil gallery.
Notice
Front bore : M18 ´ 1.5, depth 10mm
Rear bore : M16 ´ 1.5, depth 14mm
3. Thoroughly clean the oil gallery.
4. Tighten the front plug (5) with seal (4).
5. Apply Loctite 241 and then tighten the rear plug (2).

CYLINDER BORE MEASUREMENT
a Longitudinal Direction
b Transverse Direction
c, d, e. Measuring Point
1 Crankcase Contacting Surface

2 TDC of 1st Piston Ring
4 BDC of Ring
Service Data
Standard size Code letter ‘A’ 89.000 - 89.006mm
Code letter ‘X’ 89.006 - 89.012mm
Code letter ‘B’ 89.012 - 89.018mm
Wear limit in direction of travel and in transverse direction - Max. 0.20mm
When new 0.01mm
Permissible deviation of cylinder shape Wear limit 0.05mm
Honing angle - 50° ± 10°

SECTION 1D1
M162 ENGINE COOLING

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D1-1 Coolant Drain and Fill Up . . . . . . . . . . . . . . . 1D1-5
General Specifications . . . . . . . . . . . . . . . . . 1D1-1 Coolant Connection Fitting . . . . . . . . . . . . . . 1D1-7
Fastener Tightening Specifications . . . . . . . . 1D1-2 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D1-3 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-10
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D1-3 Oil Cooler Pipe Line . . . . . . . . . . . . . . . . . . 1D1-11
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-4 Cooling Fan and Viscous Clutch . . . . . . . . . 1D1-12
System Leakage Test . . . . . . . . . . . . . . . . . . 1D1-4 Cooling Fan Shroud . . . . . . . . . . . . . . . . . . 1D1-14
Maintenance and Repair . . . . . . . . . . . . . . 1D1-5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-15
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1D1-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description
Cooling Type Water Cooling Forced Circulation
Radiator Circulation Type Double Cross Flow
Radiation Capability 70,000 kcal/h
Dimension(Width´Height´Thickeness) 580 x 482 x 45 mm
Cooling Fan f 460, Six Blades
Anti-Freeze Agent ALUTEC - P78
Mixing Ratio of Anti-Freeze Agen with Water (Anti-Freeze Agent : Water) 50 : 50
Coolant Capacity 11.3 L
Reservoir Capacity 3.4 L
Cap Operating Pressure (Reservoir Tank Pressure Cap) 1.4 bar

1D1-2 M162 ENGINE COOLING

Application N·
·m
Coolant Drain Plug 30
Engine Hanger Bracket and Coolant Outlet 22.5 - 27.5
Port Bolt
Thermostat Cover Bracket Bolt 9 - 11
Oil Cooler Pipe Line Bolt 9 - 11
Cooling Fan Bolt 9 - 11
Viscous Clutch Bolt 40.5 - 49.5
Automatic Transmission Oil Cooling Hose Bolt 3-7
Cooling Fan Shroud Bolt 3-7

M162 ENGINE COOLING 1D1-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
124 589 15 21 00 603 589 00 40

Tester Counter Holder

DIAGNOSIS
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester
Test Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, cap must not be opened unless the
coolant temperature is below 90°C.
2. Fill coolant up to upper edge (arrow) of reservoir.
3. Connect the special tool to the reservoir filler cap and apply
1.4 bar of pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at the all

coolant hoses and pipes and each connections. Replace
or retighten if necessary.


ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP
Draning & Filling up Procedure
the cap.
Notice
For the risk of scalding, the cap must not be opened unless
the coolant temperature is below 90oC.
2. Loosen the radiator lower drain cock and drain the coolant.
Notice
Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose

(dia. 14mm) onto the drain bolt on the side of crankcase
(exhaust manifold) and by loosening the plug.
Notice
l Just loosen the drain plug to drain the coolant and do
not remove the plug completely.
l Collect coolant by using proper container.
4. After complete draining of the coolant, remove the hose

connector to drain plug and reinstall the drain plug.
Installation Notice
5. Tighten the radiator lower drain cock.

6. Remove the de-aeration hose clamp in the coolant pump
and remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank.
Notice
l Match the anti-freeze and the water ratio to 50 : 50.
l Supplement the coolant until the coolant overflows to
the deaeration hose.
8. Insert the de-aeration hose and completely tighten the

clamp.
9. Check the coolant level in the coolant reservoir tank.
10. Warm up(until thermostat is opened) the engine and
recheck the coolant level in the reservoir tank. and fill up
the coolant if necessary.

COOLANT CONNECTION FITTING

Preceding Work : Removal of cooling fan shroud
1 Bolt (M8 X 100, 2 pieces) ............... 22.5-27.5 Nm 4 O-ring

2 Engine Hanger Bracket 5 Hose Mounting Clamp
3 Coolant Outlet Port 6 Hose

1. Drain coolant from the radiator.
2. Remove the hose mounting clamp (5) and disconnect the
coolant hose (6).
3. Remove the two bolts (1), the engine hanger bracket (2)
and coolant outlet port (3).
Installation Notice
Replace the O-ring with new one.

reverse order.
5. Fill up the coolant as specified.
6. Check the leaks in the cooling system.

WATER PUMP
Preceding Work : Removal of V-belt
Removal of air admission housing
1 Air Admission Housing 8 Coolant Hose

2 Oil Cooler Pipe Line 9 Inlet Coolant Hose
3 Seal ....................................................... Replace 10 Coolant Pump
4 Bolt ........................................................ 9-11 Nm 11 Bolt ........................................................... 21 Nm
5 Coolant Hose 12 Dowel Sleeve
6 Coolant Hose 13 Seal ....................................................... Replace
7 Outlet Coolant Hose

1. Drain the coolant.
2. Disconnect the coolant pump wire connector.
3. Loosen the hose clip and dsconnect all hoses from the
coolant pump
4. Remove the coolant line bolts (4) and then remove the
coolant line (2).
Installation Notice
Notice
Replace the seal (3).
5. Remove the mounting bolts (11) and carefully pull out coolant
pump (10).
Installation Notice
Notice

reverse order.
7. Fill up coolant.
8. Do coolaing system leakage test

THERMOSTAT
1 Thermostat Cover 5 Bolt (M6 X 25, 3 pieces) ......................... 9-11 Nm

2 Thermostat 6 Hose Mounting Clamp
3 O-ring 7 Heater Hose
4 Thermostat Cover Bracket

1. Drain the coolant from the radiator.
2. Loosen the hose mounting clamp (6) and remove the heater
hose (7).
3. Unscrew the three bolts (5) and remove the thermostat cover
bracket, thermostat cover and the thermostat in order.
Installation Notice
Tightening T orque 9 - 11 Nm
Do not separate the thermostat cover and thermostat.
4. Replace the O-ring if necessary.
5. Check the leakage in the cooling system.

OIL COOLER PIPE LINE

Preceding Work : Removal of upper intake manifold
1 Upper Intake Manifold 4 Oil Cooler Pipe Line

2 Bolt (M6 X 35, 1 piece) ........................... 9-11 Nm 5 O-ring .................................................... Replace
3 Bolt (M6 X 16, 2 pieces) ......................... 9-11 Nm

2. Unscrew the bolts (2, 3) and remove the oil cooler pipe line (4).
Replace the O-ring with new one.
Installation Notice
reverse order.
4. Fill up the coolant as specified.
5. Check the leaks in the cooling system.

COOLING FAN AND VISCOUS CLUTCH

1 Cooling Fan Pulley 4 Bolt (M6 X 12, 4 pieces) ......................... 9-11 Nm

2 Viscous Clutch 5 Bolt (M10 X 45, 1 piece) ................. 40.5-49.5 Nm
3 Cooling Fan

Tools Required

1. Hold the cooling fan pulley using the counter holder (special
tool : 603 589 00 40 00) and remove the cooling fan after
unscrewing the four bolts (4).
Installation Notice
2. Remove the bolt (5) from the viscous clutch and remove
the viscous clutch from the cooling fan pulley.
Installation Notice
reverse order.

COOLING FAN SHROUD
1 Clip 4 Fan Shroud Assembly

2 Lower Fan Shroud 5 Radiator
3 Bolt

1. Pull out the 2 clips (1) from the fan shroud assembly.
2. Remove the lower fan shroud (2).
Notice
For installation, exactly align the lower fan shroud pin into
the hole of the fan shroud assembly (4) and insert the
clips.
3. Remove the bolts (3) and then remove the cooling fan
shroud assembly (4).
Installation Notice

reverse order.

RADIATOR
1 Radiator Inlet Coolant Hose 6 Bolt

2 Radiator Outlet Coolant Hose 7 Insulator
3 Make Up Coolant Hose 8 Stopper
4 Automatic Transmission Oil Cooling Hose 9 Bolt ............................................................. 7 Nm
5 Automatic Transmission Oil Cooling Line 10 Radiator

2. Remove the coolant thermo connector from the radiator.
3. Remove the each coolant hoses.
4. Remove the automatic transmission oil cooling hose.

Installation Notice
5. Remove the automatic transmission oil cooling line bolts

and then remove the oil cooling line.
6. Remove the radiator upper mounting bolts and then
remove the bracket and insulator.
7. Remove the radiator.
8. Check the radiator pin for crack, damage, leakage and
bending and replace if necessary.

reverse order.
10. Do cooling system leakage test.

SECTION 1D2
M161 ENGINE COOLING

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D2-1 Coolant Drain and Fill Up . . . . . . . . . . . . . . . 1D2-5
General Specifications . . . . . . . . . . . . . . . . . 1D2-1 Cooling Fan and Viscous Clutch . . . . . . . . . . 1D2-7
Fastener Tightening Specifications . . . . . . . . 1D2-2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D2-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D2-3 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D2-11
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D2-3 Thermostat Housing Assembly . . . . . . . . . . 1D2-12
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D2-4 Removal and Installation of Cooling
Fan Shroud . . . . . . . . . . . . . . . . . . . . . . . 1D2-14
System Leakage Test . . . . . . . . . . . . . . . . . . 1D2-4
Removal and Installation of Radiator . . . . . 1D2-15
Maintenance and Repair . . . . . . . . . . . . . . 1D2-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1D2-5
SPECIFICATIONS
Cooling Type Water Cooling Forced Circulation
Radiator Circulation Type Down Flow
Radiation 61,500 kcal/h
Capability 58,000 kcal/h
Dimension(Width´Height´Thickeness) 680 x 415 x 25 mm
680 x 415 x 28 mm
Cooling Fan f 460, 9 Blades
Anti-Freeze Agent ALUTEC-P78, Dragon Power Coolant A
Mixing Ratio of Anti-Freeze Agen with Water (Anti-Freeze Agent : Water) 50 : 50
Coolant Capacity 10.5 L
Reservoir Capacity 3.4 L
Cap Operating Pressure (Reservoir Tank Pressure Cap) 1.4 bar


Application N·
·m
Coolant Drain Plug 30
Engine Hanger Bracket and Coolant Outlet 22.5 - 27.5
Port Bolt
Thermostat Cover Bracket Bolt 9 - 11
Oil Cooler Pipe Line Bolt 9 - 11
Cooling Fan Bolt 9 - 11
Viscous Clutch Bolt 40.5 - 49.5
Automatic Transmission Oil Cooling Hose Bolt 3-7
Cooling Fan Shroud Bolt 3-7

SPECIAL TOOLS
SPECIAL TOOLS TABLE
124 589 15 21 00 603 589 00 40

Tester Counter Holder
111 589 02 01 00 111 589 00 40 00

Open End Wrench Open End Wrench

DIAGNOSIS
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester
Test Procedure
the cap.
Notice
For the risk of scalding, cap must not be opened unless the
coolant temperature is below 90°C.
2. Fill coolant up to upper edge (arrow) of reservoir.
3. Connect the special tool to the reservoir filler cap and apply
1.4 bar of pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at the all

coolant hoses and pipes and each connections. Replace
or retighten if necessary.


ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP
Draning & Filling up Procedure
the cap.
Notice
For the risk of scalding, the cap must not be opened unless
the coolant temperature is below 90oC.
2. Loosen the radiator lower drain cock and drain the coolant.
Notice
Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose

(dia. 14mm) onto the drain bolt on the side of crankcase
(exhaust manifold) and by loosening the plug.
Notice
l Just loosen the drain plug to drain the coolant and do
not remove the plug completely.
l Collect coolant by using proper container.
4. After complete draining of the coolant, remove the hose

connector to drain plug and reinstall the drain plug.
Installation Notice
5. Tighten the radiator lower drain cock.

6. Remove the de-aeration hose clamp in the coolant pump
and remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank.
Notice
l Match the anti-freeze and the water ratio to 50 : 50.
l Supplement the coolant until the coolant overflows to
the deaeration hose.
8. Insert the de-aeration hose and completely tighten the

clamp.
9. Check the coolant level in the coolant reservoir tank.
10. Warm up(until thermostat is opened) the engine and
recheck the coolant level in the reservoir tank and fill up
the coolant if necessary.

COOLING FAN AND VISCOUS CLUTCH
1 Bolt (M6 X 14, 3 piece) ........................... 9-11 Nm 3 Viscous Clutch

2 Cooling Fan 4 Union Nut (Left Threaded Screw) ... 40.5-49.5 Nm

Tools Required
111 589 02 01 00 Open End Wrench
111 589 00 40 00 Open End Wrench

1. Install the holder (special tool : 111 589 00 40 00) to the bolt
at the pulley as shown in the right figure to hold the pulley.
2. Remove the viscous clutch using an open end wrench
(special tool : 111 589 02 01 00).
Installation Notice
Notice
The union nut is left threaded screw.
3. Remove the 3 bolts (1) from the viscous clutch and remove
the cooling fan and the viscous clutch.
Installation Notice
Notice
You may change the procedure (2) and (3) if necessary.
reverse order.

COOLANT PUMP
1 Bolt (M6 X 45, 1 piece) ........................... 9-11 Nm 7 Coolant Pump Pulley

2 Bolt (M6 X 95, 1 piece) ........................... 9-11 Nm 8 Coolant Inlet Hose
3 Bolt (M6 X 25, 4 piece) ........................... 9-11 Nm 9 Heater Hose
4 Bolt (M8 X 85, 2 piece) ................... 20.5-20.5 Nm 10 Coolant Bypass Hose
5 Coolant Pump Housing 11 Gasket
6 Bolt (M6 X 16, 4 piece) ........................... 9-11 Nm

Tools Required
124 589 15 21 00 Tester

2. Disconnect the coolant hoses (8, 9, 10).
3. Tak off the drive belt.
4. Unscrew the four bolts (6) from coolant pump pulley and
remove the pulley (7).
Installation Notice
Notice
Hold the pulley with special tool (603 589 00 40 00) while
removing the pulley.
5. Unscrew the bolts (1, 2, 3, 4) from coolant pump housing

(5) and remove the coolant pump.
Installation Notice
(1, 2, 3) 9 - 11 Nm
Tightening Torque
(4) 22.5 - 27.5 Nm

Notice
Apply the sealant when the sealing surface of coolant pump
housing and coolant mounting area is clean.

reverse order.

THERMOSTAT
1 Bolt (M6 X 25, 3 pieces) ........................ 9 -11 Nm 4 Coolant Outlet Hose

2 Thermostat Cover 5 Thermostat
3 De-aeration Hose 6 O-ring

1. Drain the coolant from the radiator.
2. Loosen the hose mounting clip and remove the coolant hose
(3, 4).
3. Unscrew the three bolts (1) and remove the thermostat cover
assembly from thermostat housing.
Installation Notice
Do not separate the thermostat cover and thermostat.
4. Replace the O-ring if necessary.

5. Check the leakage in the cooling system.

THERMOSTAT HOUSING ASSEMBLY

1a Bolt (M6 X 95, 2 pieces) ......................... 9-11 Nm 4 De-aeration Hose

1b Bolt (M8 X 75, 2 pieces) ................. 22.5-27.5 Nm 5 Coolant Outlet Hose
1c Bolt (M8 X 35, 1 piece) ................... 22.5-27.5 Nm 6 Coolant Bypass Hose
2 Thermostat Housing Assembly 7 Tensioning Device Shock Absorber
3 O-ring 8 Engine Hanger Brocket

2. Remove the de-aeration hose (4), coolant outlet hose (5)
and coolant bypass hose (6).
3. Disconnect the coolant temperature sensor connector.
4. Unscrew the bolt (1c) and pry off the tensioning device shock
absorber (7).
Installation Notice
5. Unscrow the bolts (1a, 1b) and remove the engine hanger
bracket and thermostat housing.
Installation Notice
(1a) 9 - 11 Nm
Tightening Torque
(1b) 22.5 - 27.5 Nm
6. Replace the O-ring with new one.

reverse order.
8. Check for leaks in cooling system.

REMOVAL AND INSTALLATION OF COOLING FAN SHROUD
1 Fan Suroud Assembly 2 Bolt (M6 X 16, 2 pieces) ........................... 3-7 Nm

1. Unscrew two bolts from cooling fan shroud and remove
the shrud.
Installation notice

reverse order.

REMOVAL AND INSTALLATION OF RADIATOR

1 Inlet Hose 7 Bolt (M6 X 20, 4 pieces) ........................... 3-7 Nm

2 Hose (to Engine) 8 Insulator
3 Hose (to 3-way Connector) 9 Radiator Bracket
4 Make-up Hose (to Coolant Reservoir) 10 Radiator
5 3-way Connector
6 Automatic Transmission Oil Cooling Hose (A/T
Equippend Vehicle)

2. Remove the coolant thermo connector from the radiator.
3. Remove the each coolant hoses.
4. Remove the automatic transmission oil cooling hose.

Installation Notice
5. Unscrew the bolts from radiator bracket and remove the

bracket and insulator.
Installation Notice
6. Remove the radiator upper mounting bolts and then

remove the bracket and insulator.
8. Check the radiator pin for crack, damage, leakage and
bending and replace if necessary.

reverse order.
10. Berform the cooling system leakage test.

SECTION 1D3
OM600 ENGINE COOLING

Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D3-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1D3-5
General Specifications . . . . . . . . . . . . . . . . . 1D3-1 Drain and Filling of Coolant . . . . . . . . . . . . . 1D3-5
Fastener Tightening Specifications . . . . . . . . 1D3-1 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D3-6
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-2 Coolant Pump Housing . . . . . . . . . . . . . . . . . 1D3-8
Cooling Circulation . . . . . . . . . . . . . . . . . . . . 1D3-2 Cooling Fan Clutch . . . . . . . . . . . . . . . . . . . 1D3-10
Thermostat Operation . . . . . . . . . . . . . . . . . 1D3-3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-12
Cooling System Leakage Test . . . . . . . . . . . 1D3-4 Cooling Sub-System . . . . . . . . . . . . . . . . . . 1D3-14
Maintenance and Repair . . . . . . . . . . . . . . 1D3-5 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-16
SPECIFICATIONS
Coolant ALUTEC P- 78
Mixing Ratio (Water : anticorrosion) 50 : 50
Capacity 10.5L - 11L (662LA)
9.5L - 10L (661LA)

Application N·
·m
Coolant Pump Bolt 10
Belt Pulley Bolt 10
Coolant Pump Housing Return Pipe Bolt 10
Thermostat Bolt 10
Cooling Fan Clutch Socket Bolt (Center) 45
Cooling Fan Clutch Socket Bolt (Side) 10
Radiator Bolt 3-7
Coolant Sub-tank Bolt 3-7

1D3-2 OM600 ENGINE COOLING
DIAGNOSIS
COOLING CIRCULATION
A Thermostat G Deaeration Line

B Radiator H Reservoir
D From Heater
E Hose

OM600 ENGINE COOLING 1D3-3
THERMOSTAT OPERATION
Operation
1. At warming up
Valve closes until temperature of coolant reaches to 85°C.
B. From Radiator
C. From Crankcase
D. To Crankcase
2. At partial opening.
Valve opens partially as temperature of coolant is maintained
between 85-100°C.
3. At full opening.
Valve opens full as temperature of coolant is more then
100°C.

COOLING SYSTEM LEAKAGE TEST

Tools Required
124 589 15 21 00 Tester
Test
1. Loosen the pressure cap by 1 notch and remove the cap
after.
Notice
Do not remove radiator cap when coolant is above 90°C.
2. Add the coolant to the arrow mark of coolant reservoir.
3. Connect the special tool to the injector of reservoir and apply

1.4bar pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check the hose, pipe

and leakage and, replace or retighten.


ON-VEHICLE SERVICE
DRAIN AND FILLING OF COOLANT
Preceding Work : Removal of skid plate
Drain / Filling
1. Loosen the pressure cap of reservoir by 1 notch and remove
pressure and then loosen the cap.
Notice
Do not remove radiator cap when coolant is above 90°C.
2. Open the drain plug and drain the coolant.

Notice
Collect the coolant by using the proper bottle.
3. Remove the drain plug(1) and seal(2) of cylinder block and

drain the coolant.
4. Replace the seal to new one and tighten the drain plug
Installation Notice
5. Tighten the drain plug of the lower radiator.

6. Fill the coolant through coolant reservoir-tank.
Notice
l A proportion of 50% by volume of water / anticorrosion
must be ensured
7. After engine is running at idle speed, check the level of
coolant. If necessary, add enough specified coolant.

COOLANT PUMP
Removal of V-belt
1 Tensioning Lever 4 Belt Pulley

2 Gasket ................................................... Replace 5 Bolt ........................................................... 10 Nm
3 Bolt ........................................................... 10 Nm 6 Coolant Pump

1. Loose the bolts(5) and remove the pulley (4).
Installation Notice
2. Loose the bolts (3).

Installation Notice
3. Pull the tensioning lever(1) to the arrow direction.

4. Remove the coolant pump(6).
Notice
Clean gasket residues on the sealing surface of coolant
pump and replace the gasket.
reverse order.

COOLANT PUMP HOUSING

Preceding Work : Removal of coolant pump
Removal of thermostat
Removal of alternator
1 Gasket ................................................... Replace 5 Coolant Hose

2 Coolant Pump Housing 6 Return Pipe
3 Connector 7 O-Ring
4 Bolt ........................................................... 10 Nm 8 Temperature Sensor
Notice
The bolt on the arrow should be installed last.

1. Disconnect the connector(3).
2. Separate the coolant hose (5) and return pipe(6).
3. Remove the bolts(4) evenly.

Installation Notice
Notice
Clean gasket residues on the sealing surface of coolant
pump and replace the gasket.
4. Remove the coolant pump housing(2).

reverse order.

COOLING FAN CLUTCH
1 Belt Pulley 4 Socket Bolt ................................................ 45 Nm

2 Cooling Fan Clutch 5 Socket Bolt ................................................ 10 Nm
3 Cooling Fan
Tools Required

1. Hold the bolt pulley with counter holder and remove the
bolt(4).
Counter Holder 603 589 00 40 00
Installation Notice
2. Remove the socket bolt(5) and then remove the cooling

fan(3) and fan clutch(2).
Notice
Keep the fan clutch vertically.
Installation Notice

reverse order.

RADIATOR
Preceding : Removal of cooling fan shroud
1 Radiator Inlet Hose ............... OM662LA : 220mm 5 Spring Clamp

............................................. OM661LA : 321mm 6 Bolt .......................................................... 3-7 Nm
2 Radiator outlet Hose 7 Radiator
3 Radiator Deaeration Tube & Hose 8 Spring Clamp
4 Clamp 9 Bolt ........................................................... 3-7Nm

2. Remove the coolant thermoswich connector from radiator.
3. Remove the each coolant hose.
4. Remove the auto T/M oil cooling hose and cooling line.
Installation Notice
Tightening Torque Hose : 29 - 40Nm
5. Loosen the radiator upper mounting bolt and remove the

mounting stopper and insulator.
7. Check the radiator pin for crack, leakage and bending and
replace it if necessany.
reverse order.

COOLING SUB - SYSTEM
1 Radiator 7 Mounting Bracket

2 Cooling Fan Shroud 8 Make-up Cooling Hose
3 Bolt .......................................................... 3-7Nm 9 Bolt ........................................................... 3-7Nm
4 Cooling Fan Shroud 10 Cooling Reservoir-tank Cap
5 Radiator Deaieration Hose 11 Cooling Reservoir-tank

Cooling Fan Shroud
1. Remove the radiator deaeration hose and tube.
Installation Notice
Tightening torque 3-7Nm

2. Check the shroud.
reverse order.
Coolant Sub-Tank
1. Drain the coolant from radiator.
2. Remove the each hose.
3. Loosen the mounting bolt of sub-tank and remove the

coolant sub-tank.
Installation Notice

reverse order.

THERMOSTAT
1 Thermostat 4 Coolant Hose

2 Seal ....................................................... Replace 5 Bolt ............................................................ 10Nm
3 Thermostat Housing Cover

1. Drain the coolant completely.
2. Disconnect the coolant hose(4) from the thermostat housing
cover(3).
3. Remove the bolts(5) and then remove the thermostat(1)

and housing cover(3)
Installation Notice
Align the groove on thermostat and the housing cover
rib(arrow).
Notice
Replace the seal(2).

reverse order.

SECTION 1E1
M162 ENGINE ELECTRICAL

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1E1-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1E1-4
Alternator Specifications . . . . . . . . . . . . . . . . 1E1-1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-4
Starting Motor Specifications . . . . . . . . . . . . 1E1-2 Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . 1E1-5
Battery Specifications . . . . . . . . . . . . . . . . . . 1E1-2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-6
Fastener Tightening Specifications . . . . . . . . 1E1-2 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1E1-3 Ignition Cable . . . . . . . . . . . . . . . . . . . . . . . . 1E1-9
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1E1-3 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 1E1-12
Maintenance and Repair . . . . . . . . . . . . . . 1E1-4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E1-12
SPECIFICATIONS
ALTERNATOR SPECIFICATIONS
Output Voltage 12 - 14 V
Current 115 A
Resistance Between Rotor Core and Slip Ring ¥ W

1E1-2 M162 ENGINE ELECTRICAL
STARTING MOTOR SPECIFICATIONS

Voltage 12 V
Output Power 1.7 KW
BATTERY SPECIFICATIONS
Capacity 90 Ah
Specific Gravity ³ 1.24
Max. Tolerance Between Cells ³ 0.04

Application N·m
Alternator Terminal B+Nut 14 - 18
Alternator Terminal D+Nut 4-5
Alternator Combinction Bolt 45 - 50
Battery Cable Nut on Starting Motor 12 - 15
Electric Wire Nut on Starting Motor 6-7
Starting Motor Mounting Nut 35 - 48
Battery Mounting Bracket Nut 12 - 18
Battery Negative Cable 12 - 18
Battery Positive Cable 12 - 18
Ignition Cable Bolt 9 - 11
Spark plug 25 - 30

M162 ENGINE ELECTRICAL 1E1-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
120 589 02 09 00
Spark Plug Wrench


ON-VEHICLE SERVICE
ALTERNATOR
Preceding Work : Removal of the drivebelt
1. Disconnect the negative battery terminal.
2. Unscrew the nut and disconnect the terminal (1).
Installation Notice
Installation Notice
1 Terminal (B+)
2 Terminal (D+)
4. Unscrew the combination bolt (3).

Installation Notice
reverse order.
3 Combination Bolt
4 Alternator

STARTING MOTOR
2. Unscrew the nut and disconnect the battery cable(1).
Installation Notice
3. Unscrew the nut and disconnect the engine electric wire
(2).
Installation Notice
Tightening Torque 6 - 7 Nm 1 Battery Cable
2 Engine Electric Wire
4. Unscrew the mounting bolts (3) of starting motor.

Installation Notice
5. Remove the starting motor.
reverse order.
3 Fixing Bolt
4 Starting Motor

BATTERY
1 Cable Terminal (-) 7 Battery holddown Bracket

2 Cable Terminal Cap (-) 8 Battery Clamp Bolt
3 Cable Terminal Cap (+) 9 Battery
4 Nut 10 Sub Tray
5 Fuseblink Box 11 Battery Tray
6 Terminal (+)

Notice
l Disconnect the battery negative cable first.
l Insert the clamp bolt (8) into the battery tray hole (11)
from inside when installing.

SPARK PLUG
Preceding Work : Removal of intake air duct
1 Ignition Coil Cable Cover T1/1 Ignition Coil : Cylinder 2 and 5

2 Bolt (M6 X 60, 7 pieces) ......................... 9-11 Nm T1/2 Ignition Coil : Cylinder 3 and 4
3 Spark Plug T1/3 Ignition Coil : Cylinder 1 and 6

Tools Required
120 589 09 00 Spark Plug Wrench
1. Remove the seven bolts (2) and remove the ignition cable
cover.
Installation Notice
2. Remove the two bolts (M6 X 25) from each ignition cable
and remove the ignition cable.
Installation Notice
3. Remove the spark plug using the special tool.

Installation Notice
Spark Plug Wrench 120 589 02 09 00

IGNITION CABLE
1 Control Cable Connection 5a,5b Secondary Voltage Connection

2 Ignition Cable E Iron Core
3 Spark Plug Connector L2 Primary Ignition Coil
4 Coupling Plug L1 Secondary Ignition Coil

Functions
1. Firing order : 1-5-3-6-2-4
2. The ignition cables are located on the cylinder head cover.
Each ignition coil provides the high voltage to two spark
plugs simultaneously.
- T1/1 : cylinder 2 and 5
3. The secondary output voltage (5a) is supplied to the No.2

cylinder spark plug through the spark plug connector. The
secondary output voltage (5b) is supplied to the No.5 cylinder
spark plug through the ignition cable. The guide pin (W)
acts as a ground while the ignition cable is operated.

1. Disconnect the negative battery cable (1).
2. Remove the ignition cable connector from the ignition cable.
3. Disconnect the secondary spark plug connectors from the
each spark plugs and remove the ignition cable.
Installation Notice
l Make sure that the ignition cables are correctly routed.
l Exactly install the ignition cable guide pin into the vehicle
to be grounded.
reverse order.

Circuit Diagram
Inspection & Maintenance Procedure (for MSE)

1. While the ignition switch is in 'OFF' position, remove the
wiring connectors (1 and 15) from ignition coil and measure
the primary resistance between terminal No.1 and No.15.
Specified Value 0.9 - 1.6 W (20°C)
Notice
If out of specified value, replace the ignition coil.
2. During engine cranking, measure primary voltage (T1/1)
between ECU terminal No. 71 and No. 69.
Specified Value 200 - 350 V
Notice
l Measure remaining cables.
- T1/2 : No. 72 and 69.
- T1/3 : No. 70 and 69.
l If out of specified value, check ignition cable and ECU.
3. Using a multi-tester, measure the secondary coil resistance
between 5a and 5b.
Specified Value 6 - 8.5 kW

UNIT REPAIR
BATTERY
Inspection
Notice
l When charging the battery, do not leave the inflammable
objects around it.
l When checking the electrolyte of battery, put on
an eye protector and gloves.
1. Inspect the surface of the battery and replace if any defects
were found on it.
2. Check if the specific gravity of the electrolyte is within the
specified value.
Battery capacity(Ah) 85
Battery specific gravity ³ 1.24
Max. tolerance between cells ³ 0.04
Notice
l Replace the battery if the maximum tolerance of the
electrolyte between cells is out of the specified value.
l Measure the specific gravity in the approx. 20°C
of ambient temperature.
3. Replenish the electrolyte if necessary.

SECTION 1E2
M161 ENGINE ELECTRICAL

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1E2-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1E2-4
Alternator Specifications . . . . . . . . . . . . . . . . 1E2-1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-4
Starting Motor Specifications . . . . . . . . . . . . 1E2-2 Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . 1E2-5
Battery Specifications . . . . . . . . . . . . . . . . . . 1E2-2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-6
Fastener Tightening Specifications . . . . . . . . 1E2-2 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1E2-3 Ignition Cable . . . . . . . . . . . . . . . . . . . . . . . . 1E2-9
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1E2-3 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 1E2-12
Maintenance and Repair . . . . . . . . . . . . . . 1E2-4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E2-12
SPECIFICATIONS
ALTERNATOR SPECIFICATIONS
Output Voltage 12 - 14 V
Current 115 A
Resistance Between Rotor Core and Slip Ring ¥ W

STARTING MOTOR SPECIFICATIONS

Voltage 12 V
Output Power 1.2 KW
BATTERY SPECIFICATIONS
Capacity 90 Ah
Specific Gravity ³ 1.24
Max. Tolerance Between Cells ³ 0.04

Application N·m
Alternator Terminal B+Nut 14 - 18
Alternator Terminal D+Nut 4-5
Alternator Combinction Bolt 45 - 50
Battery Cable Nut on Starting Motor 12 - 15
Electric Wire Nut on Starting Motor 6-7
Starting Motor Mounting Nut 35 - 48
Battery Mounting Bracket Nut 12 - 18
Battery Negative Cable 12 - 18
Battery Positive Cable 12 - 18
Ignition Cable Bolt 9 - 11
Spark plug 25 - 30

SPECIAL TOOLS
SPECIAL TOOLS TABLE
120 589 02 09 00
Spark Plug Wrench


ON-VEHICLE SERVICE
ALTERNATOR
Preceding Work : Removal of the drivebelt
1. Disconnect the negative battery terminal.
Installation Notice
Installation Notice
1 Terminal (B+)
2 Terminal (D+)
4. Unscrew the combination bolt (3).

Installation Notice
reverse order.
3 Combination Bolt
4 Alternator

STARTING MOTOR
2. Unscrew the nut and disconnect the battery cable(1).
Installation Notice
3. Unscrew the nut and disconnect the engine electric wire
(2).
Installation Notice
Tightening Torque 6 - 7 Nm 1 Battery Cable
2 Engine Electric Wire
4. Unscrew the mounting bolts (3) of starting motor.

Installation Notice
5. Remove the starting motor.
reverse order.
3 Fixing Bolt
4 Starting Motor

BATTERY
1 Cable Terminal (-) 7 Battery holddown Bracket

2 Cable Terminal Cap (-) 8 Battery Clamp Bolt
3 Cable Terminal Cap (+) 9 Battery
4 Nut 10 Sub Tray
5 Fuseblink Box 11 Battery Tray
6 Terminal (+)

Notice
l Disconnect the battery negative cable first.
l Insert the clamp bolt (8) into the battery tray hole (11)
from inside when installing.

SPARK PLUG
1 Screw (3 pieces) ................................ 9 - 11 Nm 6 Bolts (M6 X 25, 4 pieces) ................. 9 - 11 Nm

2 Adaptor (3 pieces) 7 Ignition Coil (T1/1)
3 Ignition Coil Cable Cover 8 Coupling Plug
4 Spark Plug Connector 9 Spark Plug ...................................... 25 - 30 Nm
5 Ignition Coil Connector 10 Ignition Coil (T1/2)
Tools Required
119 589 01 09 00 Spark Plug Wrence

1. Unscrew the three screws(1) and remove the ignition coil
cable cover
Installation Notice
Tightening Torque 9 - 11Nm
2. Disconnect the cable from ignition coil and spark plug.
3. Unscrew two bolts(M6 X 25) from each ignition coil and

remove the ignition coil(arrow) .
Installation Notice
4. Using the special tool, remove the spark plug .

Installation Notice
Clearance 0.8 + 0.1 mm
Spark Plug Wrench 119 589 01 09 00
Notice
l Tighten the spark plug with specified torque.
l nstall the ignition coil to No.2 and 4 cylinder, and
connect the cable to No.1, 4 and 2, 3 cylinder

IGNITION CABLE
1 Control Cable Connection 5a,5b Secondary Voltage Connection

2 Ignition Cable E Iron Core
3 Spark Plug Connector L2 Primary Ignition Coil
4 Coupling Plug L1 Secondary Ignition Coil

1. Disconnect the battery negative cable.
2. Unscrew the 3 screws and remove the ignition cable duct
cover.
Installation Notice
3. Seperate the cable from the ignition cable and the spark
plug.
4. Remove the 2 bolts from each ignition cable and remove
the ignition cables.
Installation Notice
Install the ignition cable to the cylinder 2 and 4 and connect
the cable from 1 to 4, and from 2 to 3.
- T1/1 : Cylinder 1 and 4
- T1/2 : Cylinder 2 and 3

reverse order.
Ignition Cable and Cable Lay-out

1. Firing Order : 1-3-4-2
2. T1/1 : Connect the cylinder 1 + 4
3. T1/2 : Connect the cylinder 2 + 3

Inspection & Maintenance (for E2.3 MSE)
1. Measure the primary resistance between the cable
terminals 1 and 15 after removing the ignition cable wiring
connector (1 and 15) with ignition switch OFF.
Notice
Replace the ignition coil if out of the specified resistance.
Specified Value 0.9 - 1.6 W

2. Measure the primary voltage(T1/1) between the ECU
terminals No.72 and No.69 during the engine cranking
(starter motor activated).
l T1/2 : between No.71 and No.69.
Notice
Check the ignition cable and the ECU if out of the specified
value.
3. Measure the secondary cable resistance between the
ignition coil 5a and 5b using a multimeter.
Specified Value 6 - 8.5 KW

UNIT REPAIR
BATTERY
Inspection
Notice
l When charging the battery, do not leave the inflammable
objects around it.
l When checking the electrolyte of battery, put on
an eye protector and gloves.
1. Inspect the surface of the battery and replace if any defects
were found on it.
2. Check if the specific gravity of the electrolyte is within the
specified value.
Battery Capacity(Ah) 85
Battery Specific Gravity ³ 1.24
Max. Tolerance between Cells ³ 0.04
Notice
l Replace the battery if the maximum tolerance of the
electrolyte between cells is out of the specified value.
l Measure the specific gravity in the approx. 20°C
of ambient temperature.
3. Replenish the electrolyte if necessary.

SECTION 1E3
OM600 ENGINE ELECTRICAL

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1E3-1 Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3-2
General Specifications . . . . . . . . . . . . . . . . . 1E3-1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3-6
Maintenance and Repair . . . . . . . . . . . . . . 1E3-2 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . 1E3-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1E3-2
SPECIFICATIONS
Alternator 12V - 75A
Starter 12V - 2.2kW
Glow Plug 11.5V

1E3-2 OM600 ENGINE ELECTRICAL

ON-VEHICLE SERVICE
GLOW PLUG
1 Wiring Harness 3 Wire Terminal

2 Nut .............................................................. 4 Nm 4 Glow Plug
Preheating System
General information
The preheating system consists of control, coolant temperature
sensor and glow plugs.
l Control relay - preheating time.
l Glow plug.

OM600 ENGINE ELECTRICAL 1E3-3
1. Preheating time - control relay.
Control relay functions as followings :
l Switching of preheating current.
l Indication of preheating finish.
l Control of preheating sequence.
l Indication of fault.
2. Coolant temperature sensor.

Coolant temperature sensor senses coolant’s temperature
and signals it to the preheating relay continuously.
3. Glow plug
The glow plug parts are housing with M12 ´ 1.25 thread
and heating pin in housing. It is connected in a parallel circuit
with the specified voltage of 11.5V.
The heating element has a heating coil and a control coil
and they are connected in series.
1 Control Coil
2. Heater Coil
4. Current and temperature of glow plug

l Current of glow plug
While the preheating system operates, current of about
30A flows in each glow plug and temperature of heating
coil rises very fast.
Due to the rise of temperature, the resistance of control
coil increases therefore the current is controlled to
about 8~15A and that protects the glow plug from over-
heating.
l Temperature of glow plug

The temperature of the glow plug reaches up to 900°C
after about 9 seconds and up to 1,050°C after 30
seconds.

Preheating system operation
1. Preheating before start.
Preheating time is different by coolant temperature and it is
on until the glow indicator light goes off.
2. Preheating after start.

Preheating continues for max. 60 seconds to rise in
characteristic of warming-up on engine after starting too.
3. Monitoring on glow plug.

Glow plugs are monitored by low current by the micro
processor in control relay respectively while running the
engine.
If glow indicator comes on after starting for about one minute,
it indicates on or several plugs are faulty.
Problem Possible cause
1 Glow indicator does not come on in preheating

- One or several glow are faulty
time and comes on after starting the engine.
- Faulty glow indicator

Glow indicator does not come on while
2 - Faulty circuit of glow indicator
preheating and after starting engine.
- Faulty control relay
- Circuits short in one or several glow plugs
3 Glow indicator does not come on and engine’s
- Faulty preheating circuits
starting is difficult or does not start at all.
- Faulty control relay
Glow indicator comes on after starting for
4 - One or several glow plugs are faulty
about one minute.

2. Remove the nut (2).
3. Remove the glow plug (4).

4. Install the glow plug (4).
5. Tighten the nut (2).


ALTERNATOR
Preceding Work : Removal of poly V-belt
1 Cooling Fan 4 Alternator

2 Bolt ............................................................ 45Nm 5 Plug Connection
3 Bolt ............................................................ 45Nm

1. Disconnect the negative terminal of the battery.
2. Disconnect the plug connection (5).
3. OM 662 Engine
Align the groove of cooling fan with bolt (2) (arrow).
4. Remove the bolts (2, 3) and take out the alternator.


reverse order.

STARTER MOTOR
1 Starter Motor 3 Nut ............................................................. 15Nm

2 Washer 4 Bolt ............................................................ 48Nm

1. Disconnect the battery terminals.
2. Disconnect the starter motor cable harnesses.
3. Remove the bolts and then remove the starter motor.
reverse order.

SECTION 1F1
M162 ENGINE CONTROLS

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F1-2 Injector Test . . . . . . . . . . . . . . . . . . . . . . . . 1F1-32
Fastener Tightening Specifications . . . . . . . . 1F1-2 Maintenance and Repair . . . . . . . . . . . . . 1F1-34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1F1-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F1-34
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1F1-3 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-34
Schematic and Routing Diagrams . . . . . . . 1F1-4 Fuel Pressure Regulator . . . . . . . . . . . . . . 1F1-45
E32 ECU (MSE) . . . . . . . . . . . . . . . . . . . . . . 1F1-4 Fuel Distributor . . . . . . . . . . . . . . . . . . . . . . 1F1-49
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-5 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-53
Self Diagnosis Socket Pin Numbers and Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-56
Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 1F1-5 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-57
Self Diagnosis Failure Code . . . . . . . . . . . . . 1F1-6 Purge Switchover Valve . . . . . . . . . . . . . . . 1F1-61
Test Box Connection . . . . . . . . . . . . . . . . . . . 1F1-9 Vacuum System . . . . . . . . . . . . . . . . . . . . . 1F1-63
Fuel Injection System Test (MSE 3.62) . . . . 1F1-10 Crankshaft Position Sensor . . . . . . . . . . . . 1F1-64
Ignition System Test . . . . . . . . . . . . . . . . . . 1F1-20 Camshaft Position Sensor . . . . . . . . . . . . . 1F1-66
Idling Control and Electronic Pedal Hot Film Air Mass (HFM) Sensor . . . . . . . . . 1F1-68
System Test . . . . . . . . . . . . . . . . . . . . . . . 1F1-25 Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . 1F1-71
Air Conditioner Control System Test . . . . . . 1F1-27 Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 1F1-73
Fuel Pressure and Internal Leakage Test . . 1F1-28 Coolant Temperature Sensor . . . . . . . . . . . 1F1-74
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F1-30 Accelerator Pedal Module . . . . . . . . . . . . . . 1F1-77

1F1-2 M162 ENGINE CONTROLS
SPECIFICATIONS
Application N·m
Fuel Return and Supply Line 25 - 30
Fuel Distributor Assembly Bolt 22.5 - 27.5
Pressure Test Connector 21.6 - 26.4
Fuel Inlet and Outlet Line 25 - 30
Fuel Filter Mounting Bracket Bolt 4-8
Crankshaft Position Sensor Bolt 9 - 11
Camkshaft Position Sensor Bolt 9 - 11
Knock Sensor Mounting Bolt 22.5 - 27.5
Coolant Temperature Bolt 18 - 22

M162 ENGINE CONTROLS 1F1-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
129 589 00 21 00 106 589 00 21 00

Test Box Pressure Tester
119 589 04 63 00 210201

Pressure Hose Adaptor Line
210 589 08 63 00
ECU Test Cable

SCHEMATIC AND ROUTING DIAGRAMS

E32 ECU (MSE)

DIAGNOSIS
SELF DIAGNOSIS SOCKET PIN NUMBERS AND DESCRIPTIONS
1 Ground 11 Remote Engine Start Unit(PIN 10)

2 Ignition 1 12 -
3 Battery Power Supply (Fuse NO.17) 13 Brake System
4 REKES :PIN 6 (ABS 5.3:PIN 11, ABS/ABD 5.3:PIN 46)
5 Engine Speed Signal :MSE PIN 60 14 MSE 3.62S/3.53S(ECU Data Output:PIN 58)
6 TCCU(Part-time) 15 TOD(PIN 20)
7 STICS(PIN 26) 16 Immobilizer
8 - 17 -
9 - 18 TCU(PIN 23)
10 Air Bag(PIN 20) 19 -
20 K-LINE(ECS:PIN 23)

SELF DIAGNOSIS FAILURE CODE
Failure Failure
code Description code Description
00 Coolant temperature sensor open 41 Purge valve open/short

01 Coolant temperature sensor short 44 Condenser fan(HI) relay short(PWR)
02 Coolant temperature sensor signal failure 45 Condenser fan(HI) relay short(GND)
03 Intake temperature sensor open 56 No.1 knock sensor signal failure
04 Intake temperature sensor short 57 No.2 knock sensor signal failure
05 Intake temperature sensor signal failure 58 No.1 cylinder synchronization failure
08 Low battery voltage 59 -
09 HFM sensor signal failure 60 -
10 HFM sensor signal failure(Low) 62 Cluster S/W defectave
11 HFM sensor signal failure(High) 64 No ignition voltage output(No.1 ignition coil)
17 Crankshaft position sensor signal failure 65 No ignition voltage output(No.2 ignition coil)
(no engine revolution signal) 66 No ignition voltage output(No.3 ignition coil)
18 Crankshaft position sensor signal failure 67 Crankshaft position sensor adaptation failure
(rpm > max. value) 71 Start signal recognition failure
19 No.1 cylinder recognition failure 72 No.1 injector short(PWR)
20 Crankshaft position sensor signal failure 73 No.1 injector open/short(GND)
(gab recognition failure) 74 No.2 injector short(PWR)
21 Transmission coding failure 75 No.2 injector open/short(GND)
23 CAN communication failure : ASR 76 No.3 injector short(PWR)
24 - 77 No.3 injector open/short(GND)
25 Transponder signal failure 78 No.4 injector short(PWR)
26 CAN communication failure : TCU(A/T only) 79 No.4 injector open/short(GND)
27 CAN communication failure : TOD(E32 only) 80 High oxygen sensor voltage
29 - 81 Low oxygen sensor amplifying voltage
30 - 82 Oxygen sensor operating failure
31 CAN communication failure : 83 Not excessive lean indication in oxygen
communication initialization failure sensor(during coasting)
34 Fuel pump relay short(PWR) 86 Oxygen sensor heater short(PWR)
35 Fuel pump relay open/short(GND) 87 Oxygen sensor heater open/short(GND)
40 Purge valve short 89 Low oxygen sensor voltage

Failure Failure
93 Short learning control failure 133 Cruise control acceleration failure

96 Lambda control failure (rich stop) 134 Cruise control deceleration failure
97 Lambda control failure (lean stop) 136 ECU failure(RAM)
98 Lambda idle adaptation failure(above rich 137 ECU failure(EPROM)
threshold) 139 Servo motor control output inter-ruption
99 Lambda idle adaptation failure(below lean memory failure
threshold) 140 Servo motor open/short
100 learning control failure(rich, low load) 141 Unprogramed ECU with Immobilizer
101 learning control failure(lean, low load) 142 Uncoded ECU
102 learning control failure(rich, high load) 143 ECU failure(NVRAM checksum failure)
103 learning control failure(lean, high load) 144 ECU failure(coding ID checksum failure)
104 Low throttle position sensor(IP1) voltage 145 ECU failure(coding checksum failure)
105 High throttle position sensor(IP1) voltage 146 ECU failure(programing checkusm failure)
108 Low throttle position sensor(IP2) voltage 150 ABD input signal short(power)
109 High throttle position sensor(IP2) voltage 151 ABD input signal short(GND)
110 Throttle actuator learning data fault 160 Low pedal valve sensor SP1 voltage
116 Throttle actuator learning control failure 161 High pedal valve sensor SP1 voltage
117 Exceed fuel-cut safety time 162 Low pedal valve sensor SP2 voltage
119 Throttle valve return spring failure 163 High pedal valve sensor SP2 voltage
120 Cruise control interruption memory failure 164 Different pedal valve sensor signal(1,2)
121 Throttle actuator failure 167 Pedal valve sensor 1,2 failure
122 Pedal module position sensor signal failure 185 HFM sensor, and throttle position sensor
123 Different HFM signal with throttle potentiometer failure
125 Both throttle potentiometer(IP1&IP2) failure 186 ECU failure(incompatible CPU)
126 IPS1 with IPS2 187 ECU failure(CPUs communication failure)
127 High permanent throttle signal 188 ECU failure(CPU(2) configuration failure)
129 Message counter failure® cruise control ’OFF’ 189 ECU failure(CPU(2) fault)
130 Vehicle speed signal failure 190 ECU failure(CPU run time failure between
131 Vehicle speed signal failure CPUs)
132 Cruise control lever failure 192 No.5 injector short(PWR)

Failure Failure
Description code Description
code
193 No.5 injector open/short(GND) 234 Control lever dual operation(CPU2)
194 No.6 injector short(PWR) 235 Control lever safety terminal failure(CPU2)
195 No.6 injector open/short(GND) 236 Unusual pedal position variation(CPU2)
198 Variable intake air valve short(PWR) 237 Unusal throttle position variation(CPU2)
199 Variable intake air valve open/short(GND) 238 Unusal throttle control data(CPU2)
226 Cam actuator short(PWR) 239 Unusal pedal position sensor(CPU2)
227 Cam actuator open/short(GND) 240 Throttle potentiometer fault(CPU2)
228 A/C compressor relay short(PWR) 241 Unusual CPU communication(CPU2)
229 A/C compressor relay open/short(GND) 242 Unusual CPU configuration(CPU2)
232 Over acceleration limit 243 AD converter failure(CPU2)
233 Over acceleration limit(CPU2)

TEST BOX CONNECTION
1 ECU 01 Test Box

2 Test Coupling(No.1 - 60) 02 ECU Test Cable
3 Test Coupling(No.61 - 120)
4 Multi-tester
Tools Required
129 589 00 21 00 Test Box
210 589 08 63 00 ECU Test Cable

FUEL INJECTION SYSTEM TEST (MSE3.62)
Failure Test Specified

Item Checking method Requirement Possible cause
code step value
08, Þ 1.0 · ECU:power · Ignition:ON 11 -14V · Þ 1.1

supply · Þ 1.2
- terminal 10 12
30(TM.30)
Þ 1.1 · Ground · Ignition:ON 11 -14V · Ground cable
cable: · Ground condition

Diagnosis
- Battery socket
ground 10 2
Diagnosis
socket
69 2
Þ 1.2 · Power · Ignition:ON 11 -14V · Power supply cable
supply:
Diagnosis
- terminal socket
30(TM.30) 1 12

supply · Þ 2.1
- terminal 5 11
87(TM.87)
cable
Diagnosis
- Electronic socket
ground 5 2
supply: · OVPR
Diagnosis
- terminal socket · Ignition:OFF < 1V
87(TM.87) 1 11
Þ 3.0 · Start signal: · Engine:in Cranking 11 -14 ·Cable
- terminal (during engine ·Ignition switch
50(TM.50) 5 2 cranking)


code step value
Þ 4.0 · HFM sensor · Ignition:ON 0.9 - 1.1V · Þ 4.1 - 4.3

09,
signal · Cable
10, 105 81 · Engine:in Idle 1.3 - 1.7V · External air inflow
11, (Coolant temperature · HFM sensor
: > 70°C )
: voltage value is
increased when
engine rpm is
increased
Þ 4.1 ·HFM sensor: · Ignition:ON 4.7 - 5.2V ·Cable

HFM
- 5V power sensor · HFM sensor · ECU coupling
supply 105 4 connector removed
Þ 4.2 ·HFM sensor: · Ignition:ON 4.7 - 5.2V · Þ 4.3

HFM
- 5V power sensor · HFM sensor · Cable
Þ 4.3 ·HFM sensor: · Ignition:ON 11 - 14V ·Cable

HFM
- 12V power sensor · HFM sensor · OVPR
03, Þ 5.0 · Intake air · Ignition:ON °C V · Þ 5.1

temperature 10 3.1 · ECU
04,
sensor: 105 80 20 2.65
05, - Voltage 30 2.18
40 1.76
50 1.4
60 1.1
± 5%
Þ 5.1 · Intake air · Ignition:OFF °C W ·Cable
temperature · No.2 ECU coupling 10 3600 · HFM sensor
sensor: 105 80 removed 20 2420

- Resistance 30 1662
40 1166
50 853
60 600
± 5%


Item Checking method Requirement value Possible cause
code step
Þ 6.0 · Fuel pump · Ignition:ON 11 - 14V ·Cable

34,
relay: (Fuel pump relay will (approx.1- ·Fuel pump relay
- Operation 33 11 operate for 1 - 2 2sec.)

seconds when the
ignition switch is
turned to "ON" after
stopping the engine)
· Engine:cranking 11 - 14V
(Cranking or
driving)
34, Þ 6.1 · Fuel pump · Ignition:ON 0.1 - 0.3A ·Cable
35, relay: · Fuel pump relay
- Current 5 33 ·ECU
consumption
00, Þ 7.0 · Coolant · Ignition:ON °C V · Þ 7.1

01,
sensor: 79 78 80 1.22
02, - Voltage 100 0.78
06, ±5%
Þ 7.1 · Coolant · Ignition:OFF °C W ·Þ 7.2

temperature (Remove the No.2 20 2500 ·Cable
sensor: 79 78 coupling from ECU) 80 322

& cable
±5%
Þ 7.2 · Coolant Coolant temperature · Remove the ·Þ refer to · Coolant

sensor:
temperature 1 4 connector from specified temperature
sensor: coolant temperature resistance sensor
- Resistance sensor and measure value of 7.1
the resistance
between No.1 and
No.2 pin with
multimeter.


code step value
32, Þ 8.0 · ECU: · Engine:in cranking or refer to figure ·Cable
33, - RPM signal idle 2 ·ECU
output 5 60
- Voltage · Engine:in cranking 6.0 - 7.0 V

or idle
5 60 (above 5V in idling)
80, Þ 9.0 · Oxygen · Keep the engine run There will be a ·ECU
81, sensor: above 2 minutes in voltage · Cable
- Signal 16 17 over 80°C of coolant fluctuation in ·Oxygen sensor

82,
83, temperature. the range of
89, - 0.2 -1.0V
85, Þ 10.0 · Oxygen · Keep the engine run 11 - 14 V ·ECU
86, sensor: above 2 minutes in · Cable
- Heating 9 11 over 80°C of coolant ·Oxygen sensor

87,
function temperature.
operated
- Current · Ignition:ON 0.2 - 2.0 A

consumption
5 9
Þ 11.0 · No.1 · When the coolant · Cable

72,
cylinder temperature is · ECU
73, 63 11
injector: approx. 20°C: · No.1 Injector
- Operating & - Engine:in cranking 8.0 ms · Coolant
injection temperature sensor

· When the coolant
time · Oxygen sensor
temperature is · Intake air
approx. 80°C: temperature sensor
- Engine:at idling approx.
speed 2.7 - 5.0ms
- Engine:at sharp approx.
acceleration(full 14ms
throttle)
(refer to figure 3 and
4)


code step Item Checking method Requirement Possible cause
value
- Internal · Ignition:OFF(injector 14 - 17 W
resistance temperature is 20°C)
(No.1 63 11
injector)

74,
75, 61 11 · No.2 Injector
injector: approx. 20°C:
injection temperature
· When the coolant
time sensor
temperature is
· Oxygen sensor
approx. 80°C:
· Intake air
temperature
speed 2.7 - 5.0ms
sensor
throttle)
4)
(No.2 61 11
injector)

76,

· When the coolant approx.
temperature is 2.7 - 5.0ms · Intake air
approx. 80°C: approx. temperature sensor
- Engine:at idling 14ms
speed
- Engine:at sharp
acceleration(full
throttle)
4)


code step value
(No.3 66 11
injector)
78, Þ 14.0 · No.4 · When the coolant · Cable

79,
injector: 62 11 approx. 20°C: · No.4 Injector

· When the coolant
temperature is
· Intake air
approx. 80°C
temperature sensor
speed 2.7 - 5.0ms
throttle)
4)
(No.4 62 11
injector)
192, Þ 15.0 · No.5 · When the coolant 8.0 ms ·Cable

193,
- Operating & - Engine:in cranking ·Coolant

time · When the coolant · Oxygen sensor
speed 2.7 - 5.0ms
throttle)
4)


code step value
(No.5 injector) 65 11
194, Þ 16.0 · No.6 · When the coolant · Cable

195,
injection · When the coolant temperature sensor

time temperature is · Oxygen sensor
approx. 80°C: · Intake air

- Engine:at idling approx. temperature sensor
speed 2.7 - 5.0ms
throttle)
4)
- Internal ·Ignition:OFF(injector 14 - 17 W
(No.6 injector) 64 11
198, Þ 17.0 · Variable · Engine:in cranking/ < 1V · ECU
199, intake air below 3500rpm · Cable
valve 97 11 · Variable intake air
(resonance · Engine:rpm > above 11 - 15V valve

flap switch 3500rpm
valve)
- Operating
- Current · Ignition:ON 0.4 - 0.6A

consumption
69 97
226, Þ 18.0 · Camshaft Camshaft actuator · Engine : in idling 1 - 1.5 A ·ECU
227, actuator: 1 2 - Coolant temperature · Þ 18.1

Current : above 70°C · Þ 19.0
consumption - Engine rpm :
increase up to 2000
rpm


code step value
Þ 18.1 · Camshaft · Ignition:OFF 8 - 12 W · Cable
actuator: ·Camshaft actuator

Diagnosis
Solenoid socket
resistance 73 2
226, Þ 19.0 · Camshaft · Engine:in idling Engine is · Mechanical failure of
227, actuator: - connect the bridge unstable or camshaft actuator

Mechanical 73 69 to the test box for stopped
Actuation approx. 10 seconds
40, Þ 20.0 · Purge · Engine:in idling The purge · ECU
41, control control valve · Cable

34 11 should be · Purge control valve
54, valve:
operated after
- Operating
approx.
1minute.
(refer to figure
5)

consumption
10 34
Þ 21.0 · Purge Connect the vacuum · Engine:in idling/ Creating · Vacuum line
control gauge between the normal operating above 50mbar · Purge control valve
valve: control valve and temperature of vacuum

- Vacuum canister after approx.
control 1 minute
22,23, Þ 22.0 · CAN data · Ignition:OFF 55 - 65 W ·Data bus
24,26, bus ·Þ 22.1

27,29, 38 37 ·Þ 22.2
30,31,
59,60,


code step value
Þ 22.1 · CAN module · Ignition:OFF 115 - 125 W · Cable
resistance in - disconnect the · ABS, ABD, ASR

ABS, ABD, 38 37 coupling "No.1" from control unit
ASR control ECU.
unit
22,23, Þ 22.2 · CAN module · Ignition:OFF 115 - 125 W · ECU
24,26, resistance in - disconnect the

27,29, ECU control 38 37 coupling "No.1" from
30,31, unit ECU.
59,60,
Þ 23.0 · Diagnosis · Ignition:ON 11 - 14 V · ECU
cable · Cable
operating 5 58

Reference Figures
Figure2. RPM Sgnal Output Figure 3. Injection Valve Wave(at idle speed)
Figure 4. Injection Valve Wave(at sharp Figure 5. Purge Control Valve Operationg Wave
acceleration)

IGNITION SYSTEM TEST

code step value
08, · ECU:power 11 - 14V ·Þ 1.1

supply ·Þ 1.2
- terminal 10 12
30(TM.30)
Þ 1.1 · Ground · Ignition:ON 11 - 14V · Ground cable

Diagnosis
- Battery socket (figure 1)
ground 10 2
Diagnosis
socket
69 2
Þ 1.2 · Power · Ignition:ON 11 - 14V · Power supply cable
supply: · Fuse No.8

Diagnosis
- terminal socket
30(TM.30) 1 12
08, Þ 2.0 · ECU:power · Ignition:ON 11 -14V ·Þ 2.1

supply ·Þ 2.2
- terminal 5 11
87(TM.87)
cable
Diagnosis
- Electronic socket
ground 5 2
supply: · OVPR
Diagnosis
- terminal socket
1 11 · Ignition:OFF < 1V
87(TM.87)
64, Þ 3.0 · Ignition · Ignition:ON 11 - 14 V ·Cable
coil(T1/1) ·Ignition coil(T1/1)
- No.2,5 69 ·Fuse No.17
Cylinder · Engine:in cranking > 10 V


code step value
65, Þ 4.0 · Ignition · Ignition:ON 11 -14 V ·Cable
- No.3,4 69 72 ·Fuse No.17
66, Þ 5.0 · Ignition · Ignition:ON 11 -14 V ·Cable
- No.1,6 69 70 ·Fuse No.17
17, Þ 6.0 · Crankshaft · Engine:in cranking Measure the · Þ 6.1

18, position signal (refer to · Increament failure in
20, sensor: 99 100 figure 6) driven plate

67, - Signal · Engine:in idling
- Voltage · Engine:in cranking > 2.5 V -

(alternating)
99 100
· Engine: in idling >5V-
Voltage value
is increased
when engine
rpm is
increased
17, Þ 6.1 · Crankshaft · Ignition:OFF 1050 - 1400W · Cable
18, position - Disconnect the · Crankshaft position
20, sensor: coupling "NO.2" sensor

67, - Resistance 99 100 from ECU
19, Þ 7.0 · Camshaft · Engine:in cranking Measure the ·Þ 7.1

58, position signal(refer to ·Cable
sensor: 104 106 figure 7) · Camshaft position
- Signal sensor


code step value
- Voltage · Engine:in cranking The value will

(alternating) be changed in
106 11 1.2 - 1.7 V
· Ignition:ON
Þ 7.1 · Camshaft 11 -14 V ·Cable
Camshaft position
- Remove the ·OVPR
position sensor
1 3 connector from the
sensor
Camshaft position
(E23 only)
sensor between
- Power
No.1 terminal and
supply
No.3 terminal.
· Ignition · Engine:in cranking
64, Þ 8.0 200 - 350 V ·Þ 8.1
coil(T1/1) (starter operating)
- primary coil - Measuring range:
71 11
voltage 400 V
(No.2 and 5 - Time range: 100 %
cylinder) (using engine tester)
Þ 8.1 · Connecting · Ignition:OFF 0.9 - 1.6 W · Cable
resistance of The · Ignition coil T1/1
ignition coil 71 72 resistance of · Ignition coil T1/2
between T1/ ignition coil at

1 and T1/2 20°C is
approached
0.6W
· Engine:in cranking
65, Þ 9.0 · Ignition 200 - 350 V ·Þ 9.1
(starter operating)
coil(T1/2)
- Measuring range:
- primary coil 72 11
400 V
voltage
- Time range: 100 %
(No.3 and 4
(using engine tester)
cylinder)

2 and T1/1 20°C is
approached
0.6W


step Item Checking method Requirement Possible cause
code value
· Ignition
66, Þ 10.0 · Engine:in cranking 200 - 350 V ·Þ 10.1
- primary coil - Measuring range:
11
voltage 400 V
(No.1 and 6 - Time range: 100 %
cylinder)

3 and T1/2 20°C is
approached
0.6W
· Engine:in cranking
64, Þ 11.0 · Ignition coil 8 - 20 KV ·Þ 11.1
Engine tester
65, (T1/1, T1/2, - Select the ignition · Ignition plug
66, T1/3) coil in order of T1/1, · ECU
- Secondary T1/2 · High tension cable
ignition - Measuring range:

voltage 20KV
- Time range:100 %
Þ 11.1 · Ignition coil Ignition coil · Remove the high 6 - 8.5 KW · Ignition coil T1/1
(T1/1, T1/2, T1/3)
(T1/1, T1/2, tension cable of T1/ · Ignition coil T1/2
TM.4a TM.4b
T1/3) 1, T1/2, T1/3. · Ignition coil T1/3
- Secondary
coil
resistance
56, Þ 12.0 · Knock · Ignition:OFF > 10 MW · Connecting
sensor 1 - Disconnect the condition

- Resistance 117 118 coupling "No.2" from · Cable
(cylinder ECU. · ECU
No1, 2, 3)
sensor 2 - Disconnect the condition

- Resistance 114 115 coupling "No.2" from · Cable
(cylinder ECU. · ECU
No.4, 5, 6)

Reference Figures
Figure 6. Crankshaft Position Sensor Signal Figure 7. Camshaft Position Sensor Signal
a Voltage
b Identifying the No.1 - 2 Missing Teeth
Figure 8. Signal Function

1 Crank Angle
2 Cylinder
3 Crankshaft Position Sensor Signal
4 Camshaft Position Sensor Signal
5 RPM Signal

IDLING CONTROL AND ELECTRONIC PEDAL SYSTEM TEST

code step Item Checking method Requirement value Possible cause
160, Þ 1.0 · Pedal valve · Ignition:ON ·Þ 1.1

161, sensor: · Position of · Cable
164, - Signal 31 47 accelerator pedal: · Pedal valve sensor
167, (potentiometer 1) - Closed throttle 0.3 - 0.7 V

position
- Full throttle with kick 4.3 - 4.8 V
down
Þ 1.1 · Pedal valve · Ignition:ON 4.75 - 5.25 V · Cable
sensor: · ECU
- Power 31 32
supply
(potentiometer 1)
162, Þ 2.0 · Pedal valve · Ignition:ON · Þ 2.1


position
down
sensor: · ECU
- Power 50 51
supply
(potentiometer 2)
104, Þ 3.0 · Throttle · Engine:in idling ·Þ 3.1

105, valve · Cable
108, actuator: · E-GAS actuator
109, - Signal
· Position of
116, Throttle valve
119, potentiometer 1 accelerator pedal:
84 87 - Closed throttle 0.3 - 0.9 V
185,
position
down


value
Throttle valve · Position of
potentiometer 2 accelerator pedal:

position
- Full throttle with 0.3 - 0.9 V
kick down
Þ 3.1 · Throttle · Ignition:ON 4.75 - 5.25 V · Cable
valve · ECU
actuator: 84 112
- Power
supply(5V)
Throttle valve
potentiometer
1+2
104, Þ 4.0 · Throttle · Ignition:ON 0.8 - 2.3 V · ECU
105, valve · Engine:in idling The value will · Cable
108, actuator: - Coolant be changed in · E-GAS actuator
109, - Signal temperature: 1.0 - 2.5V.

116, >70 °C
119, Throttle valve
185, actuator
· Ignition:OFF < 10 W
motor voltage 68 67
supply
Throttle valve
actuator
motor 68 67
resistance

AIR CONDITIONER CONTROL SYSTEM TEST

code step
44, Þ 1.0 · Air · Engine:In idling ·Þ 5.1

45, conditioner · Air conditioner · Cable
signal: 10 44 switch : ON/OFF · Thermo amp
- Input signal Air conditioner <1V · Auto amp

(input signal switch : OFF · Dual pressure
from thermo Air conditioner 11 - 14 V switch

amplifier) switch : ON · Air conditioner
control panel
Þ 1.1 · Air · Engine:In idling · Thermo amp
conditioner · Air conditioner · Auto amp

compressor: 10 27 switch : ON/OFF · Dual pressure
- Output Air conditioner <1V switch

signal switch : OFF · Air conditioner
Air conditioner 11 - 14 V control panel

switch:ON · ECU
Þ 2.0 · Condenser · Engine:In idling · Condenser fan
fan(HI) · Air conditioner relay

control: 10 35 switch : ON/OFF · Fan motor
Air conditioner 11 - 14 V · ECU
switch : OFF
Air conditioner 11 - 14 V
switch : ON
Coolant temperature: <1V
above 105 °C

FUEL PRESSURE AND INTERNAL LEAKAGE TEST

Preparation
01 Pressure Tester
02 Pressure Hose
03 Measuring Beaker
Connection of the Equipment

1. Turn the ignition switch to "OFF" position.
2. Remove the air cleaner cross pipe.
3. Remove the cap on fuel pressure test plug and connect the
pressure hose and pressure tester.
4. Prepare the beaker for measuring the amount of fuel.
Tools Required
103 589 00 21 00 Pressure Tester
119 589 04 63 00 Pressure Hose


code step value
Þ 1.0 · Fuel Connect the fuel · Engine:in idling 3.2 - 3.6 bar ·Þ Fuel pump test
pressure:in pressure test plug to - Close the valve · Fuel pressure
idling speed the pressure tester screw on pressure regulator

- When the (refer to the flgure on tester
vacuum is previous page).
applied
Þ 2.0 · Fuel Connect the fuel · Engine:in idling 3.7 - 4.2 bar · Fuel pressure
pressure:in pressure test plug to - Close the valve regulator

idling speed the pressure tester screw on pressure
not applied
Þ 3.0 · Fuel system Connect the fuel · Engine:stop > 3.0 bar · The pressure drops
internal pressure test plug to rapidly:non-return

leakage: the pressure tester valve in fuel pump
(refer to the flgure on
previous page).
· After 30 minutes from > 2.5 bar · The pressure drops
engine stop slowly:

- Injector test
- Fuel pressure
regulator
- O-ring

FUEL PUMP TEST

Preparation
1 ECU 03 Test Box

2 Test Coupling(No.1-60) 04 ECU Test Cable
3 Test Coupling(No.61-120)
4 Stop Watch
5 Measuring Beaker

2. Connect the test box to the ECU.
Tools Required
210 589 00 99 00 Adaptor Line
129 589 00 21 00 Test Box
210 589 08 63 00 Ecu Test Cable


code value
Þ 1.0 · Fuel pump: · Ignition:ON 1 liter of fuel ·Þ 2.0

- Fuel supply - Disconnect the fuel supply for · Check the fuel line
ratio 5 33 return pipe and max. 35

connect the host to seconds
beaker to collect the
supplied fuel
Þ 2.0 · Fuel pump: Multi tester(DC current) · Ignition:ON 5-9A · Fuel pump
- Current - Remove the fuel

3 1
consumption relay from the fuse
and relay box in
luggage
compartment and
connect the
amperemeter
between No.1 and
No.3 in relay
box(fuel pump relay
removed position)
for measuring
current consumption

INJECTOR TEST
Preparation
1 ECU 03 Test Box

4 Measuring Beaker
5 Shop Made Cable

1. Connect the test box to the ECU as shown in the figure.
2. Remove the 2-pin coupling from injector.
3. Remove the fuel distributor and injector with a unit. At this
time, do not remove the supply and return line.
4. Connect the shop made cable to the injector with a firing
order.
5. Collect the fuel from injector.
Tools Required
129 589 00 21 00 Test Box
210 589 08 63 00 Ecu Test Cable


code step value
Þ 1.0 · Injector: · Ignition:ON There should

- Leakage test - Remove the fuel be no leaks
5 33 distributor and fuel and later
injector with a unit. drops from
the injector
Þ 2.0 · Injector: · Ignition:ON The spray · Injector
- Function test - Connect the shop pattern of the

and spray 5 33 made cable to the injector most
pattern injector show in the
check - Collect the spraying figure 10.
fuel with a beaker
- Connect the shop
made cable to
No.21(+) and No.3
(-) terminal in test
box
Figure 9. Shop Made Cable Figure 10. Fuel Injector Normal Spary Pattern


ON-VEHICLE SERVICE
ECU
Appearance
1 Cover 5 Pin
2 Plate Vehicle Side : Number 13 - 60
3 Connector Engine Side : Number 73 - 120
4 Flat Pin A Vehicle Connector : Black
Vehicle Side : Number 1 - 12 B Engine Connector : Gray
Engine Side : Number 61 - 72

Location
Engine ECU is located at the inside of cowl side trim in right
bottom of instrument panel of passenger side.

2. Disconnect the battery negative cable
3. Remove the cowl side trim form passenger side.
4. Unscrew four securing nuts for ECU from mounting bracket.
Installation Notice
5. Pulling out the ECU from bracket.

6. Disconnect the vehicle side coupling(B).
reverse order.

ECU Pin Numbers and Descriptions
Vehicle Connector
Pin No. Description Abbreciation
1 - -
2 Starter motor TM.50 TM.50
3 - -
4 - -
5 Electronic ground GND
6 - -
7 - -
8 - -
9 Lambda probe 1 heating LSH1
10 Power ground TM.31 TM.31
11 V-BATTERY TM.87 TM.87
13 Immobilizer crypto read WFS I/O
14 Immobilizer crypto write WFS O
15 - -
16 Lambda probe 1 ground GND
17 Lambda probe 1 signal LS1
18 - -
19 - -
20 - -

Pin No. Decription Abbreciation
21 Brake switch BRS

22 - -
23 - -
24 - -
25 - -
26 - -
27 Air conditioning clutch relay KLIKU
28 Starter control 1 START
29 - -
30 - -
31 Pedal potentiometer 1 ground GND
32 Pedal potentiometer 1 supply SP1+5V
33 Fuel pump relay KP
34 Tank purge valve TEV
35 Engine fan ML
36 - -
37 CAN-Low CAN L
38 CAN-High CAN H
39 - -
40 - -
41 - -
42 - -
43 Clutch switch KPI
44 Air conditioning KLIMA
45 Electronic traction signal KLIMA
46 - -
47 Pedal potentiometer 1 signal SP1S
49 Brake light switch BLS
51 Pedal potentiometer 2 supply SP2+2.5V
52 Cruise accelerate/Set S+B
53 Cruise resume WA
54 Cruise decelerate/Set S-B
55 Cruise safety contact switch KSK
56 - -
57 Cruise off switch AUS
58 Diagnostics DIAG
59 Vehicle speed signal V-SIG
60 Engine speed signal TN-SIG

Engine Connector
Pin No. Decription Abbreciation

61 Injector-cylinder 2 EV5
67 E-GAS motor plus M+
68 E-GAS motor minus M-
70 Ignition coil cylinder 1+6 ZSC16
71 Ignition coil cylinder 2+5 ZSA25
72 Ignition coil cylinder 3+4 ZSB34
73 Camshaft control NWS
74 - -
75 - -
76 - -
77 - -
78 Engine coolant temperature MT
79 Temperature ground GND
80 Intake air temperature LT

Pin No. Description Abbreciation
81 Hot film air mass signal HFM

82 - -
83 - -
84 E-GAS potentiometer ground -
85 E-GAS potentiometer 2 signal IP2S
86 - -
88 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 Intake manifold resonance flap SRV
98 - -
99 Crankshaft sensor ground KW-
100 Crankshaft sensor signal KW+
101 - -
102 - -
103 - -
104 Camshaft sensor ground NOWE-
105 Hot film air mass ground GND
106 Camshaft sensor signal NOWE+
107 - -
108 Hot film air mass supply V-REF.HFM
109 - -
110 - -
111 - -
112 E-GAS potentiometer supply V-REF.DK
113 - -
114 Knock sensor 2 ground GND
115 Knock sensor 2 signal KS2
116 - -
119 - -
120 - -

Application
E32 ENG,
E32 ENG,
Pin No. Description Abbreviation 4speed A/T Remarks
(BTRA) 5speed M/T
1 - - - -
2 Starter motor TM.50 TM.50 l l
3 - - - -
4 - - - -
5 Electronic ground GND l l
6 - - - -
7 - - - -
8 - - - -
9 Lambda probe 1 heating LSH1 l l
10 Power ground TM.31 TM.31 l l
11 V-BATTERY TM.87 TM.87 l l
12 V-BATTERY TM.30 TM.30 l l
13 Immobilizer crypto read WFS I/O l l
14 Immobilizer crypto write WFS O l l
15 - - - -
16 Lambda probe 1 ground GND l l
17 Lambda probe 1 signal LS1 l l
18 - - - -
19 - - - -
20 - - - -
21 Brake switch BRS ¡ ¡
22 - - - -
23 - - - -
24 - - - -
25 - - - -
26 - - - -
27 Air conditioning clutch relay KLIKU l l
28 Starter control START ¡ ¡
29 - - - -
30 - - - -
l:Standard, ¡:Option

E32 ENG,
E32 ENG,
(BTRA) 5speed M/T
31 Pedal potentiometer 1 ground GND l l
32 Pedal potentiometer 1 supply SP1+5V l l
33 Fuel pump relay KP l l
34 Tank purge valve TEV l l
35 Engine fan ML l l
36 - - - -
37 CAN-Low CAN L l l
38 CAN-High CAN H l l
39 - - - -
40 - - - -
41 - - - -
42 - - - -
43 Clutch switch KPL ¡ l
44 Air conditioning KLIMA l l
45 Electronic traction signal(ABD) ETS ¡ ¡
46 - - - -
47 Pedal potentiometer 1 signal SP1S l l
48 Pedal potentiometer 2 signal SP2S l l
49 Brake light switch BLS ¡ ¡
50 Pedal potentiometer 2 ground GND l l
51 Pedal potentiometer 2 supply SP2+2.5V l l
52 Cruise accelerate/Set S+B l l
53 Cruise resume WA l l
54 Cruise decelerate/Set S-B l l
55 Cruise safety contact switch KSK l l
56 - - - -
57 Cruise off switch AUS l l
58 Diagnostics DIAG l l
59 Vehicle speed signal V-SIG l l
60 Engine speed signal TN-SIG l l

E32 ENG,
E32 ENG,
(BTRA) 5speed M/T
61 Injector-cylinder 2 EV5 l l
67 E-GAS motor plus M+ l l
68 E-GAS motor minus M- l l
69 Power ground TM.31 TM.31 l l
70 Ignition coil cylinder 1+6 ZSC16 l l
71 Ignition coil cylinder 2+5 ZSA25 l l
72 Ignition coil cylinder 3+4 ZSB34 l l
73 Camshaft control NWS l l
74 - - - -
75 - - - -
76 - - - -
77 - - - -
78 Engine coolant temperature MT l l
79 Temperature ground GND l l
80 Intake air temperature LT l l
81 Hot film air mass signal HFM l l
82 - - - -
83 - - - -
84 E-GAS potentiometer ground GND l l
85 E-GAS potentiometer 2 signal IP2S l l
86 - - - -
87 E-GAS potentiometer 1 signal IP1S l l
88 - - - -
89 - - - -
90 - - - -

E32 ENG,
E32 ENG,
(BTRA) 5speed M/T
91 - - - -
92 - - - -
93 - - - -
94 - - - -
95 - - - -
96 - - - -
97 Intake manifold resonance flap SRV l l
98 - - - -
99 Crankshaft sensor ground KW- l l
100 Crankshaft sensor signal KW+ l l
101 - - - -
102 - - - -
103 - - - -
104 Camshaft sensor ground NOWE- l l
105 Hot film air mass ground GND l l
106 Camshaft sensor signal NOWE+ l l
107 - - - -
108 Hot film air mass supply V-REF.HFM l l
109 - - - -
110 - - - -
111 - - - -
112 E-GAS potentiometer supply V-REF.DK l l
113 - - - -
114 Knock sensor 2 ground GND l l
115 Knock sensor 2 signal KS2 l l
116 - - - -
117 Knock sensor 1 ground GND l l
118 Knock sensor 1 signal KS1 l l
119 - - - -
120 - - - -

l when removing the ECU only
3. Disconnect the couplings from ECU.
4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly
bracket and remove the auxiliarly bracket from the bracket
assembly (2).
Installation Notice
(1) 6 - 8 Nm
Tightening Torque
(3) 5 - 7 Nm
5. Unscrew the four bolts (5) and disconnect the ECU (6) from
the bracket assenbly.
Installation Notice

reverse order.
l When Removing the ECU with ABS or ABS/ASR Unit

4. Disconnect the coupling from ABS or ABS/ASR unit.
5. Unscrew the bolt (1) and the left and right flange nuts.
6. Remove the ECU with ABS or ABS/ASR unit assembly.

7. Unscrew the left and right bolt (3) on the auxiliary bracket
and remove the auxiliary bracket from the bracket assembly.
Installation Notice
8. Unscrew the bolts (5) and disconnect the ECU (6) from the
bracket assenbly.
Installation Notice

reverse order.

FUEL PRESSURE REGULATOR
1 Vacuum Hose 4 O-ring ..................................................... replace

2 Circlip 5 O-ring ..................................................... replace
3 Fuel Pressure Regulator

1. Remove the fuel pressure test connector.
2. Discharge the pressure in fuel supply system by pressing

the service valve.
3. Disconnect the vacuum hose.

4. Disconnect the circlip and remove the fuel pressure
regulator.
5. Apply the oil to O-ring lightly and then replace it.
reverse order.
7. Check for fuel pressure and internal leaks by operating the
engine.

Function of the Fuel Pressure Regulator
The fuel pressure regulator maintains the fuel pressure in the
fuel line with the pressure of 3.2 bars to 3.8 bars according to
the intake manifold pressure. This operating pressure cannot
be changed, and the fuel injection volume will be only
determined by the injection time. Over supplied fuel returns to
the fuel tank through the return line.
<Operating at full load>
There is no negative pressure applied to the spring chamber(9)
during the full load, and it is separated from the fuel chamber(8)
by the diaphragm(5).
When the fuel pressure goes up, the diaphragm forces the
compression spring(6) in the direction of compression . At this
moment, the valve(3) sticks to the diaphragm by the fuel
pressure, and the fuel return line(2) opens. The fuel over
supplied returns to the fuel tank through the return line.
2. Fuel return line

3. Valve
5. Diaphragm
6. Compression Spring
8. Fuel Chamber A. Valves Closed
9. Spring Chamber B. Valves Opened
The pressure difference between the fuel pressure and the

intake manifold is about 3.8 bars during the full load.
1. Fuel Pressure Regulator

2. Intake Manifold
3. Fuel Return(to fuel tank)
4. Fuel Supply(form fuel pump)
5. Fuel Pressure(approx. 3.8 bars)
6. Intake Manifold Negative Pressure(0 bar)
<Operating at Idle and partial load>

The spring chamber(9) is connected to the intake manifold
with the vacuum hose at the intake pipe connection(7). The
negative pressure generated in the intake manifold activates
the diaphragm, and thus the fuel pressure gets reduced to the
rate of the operating extent of the diaphragm by the intake
manifold's negative pressure.
Consequently, the fuel pressure in the fuel distributor changes
by the intake manifold's negative pressure, and the injector's
fuel pressure gets reduced independently to the throttle valve's
position. Thus, the fuel injection volume can only be determined
according to the injector's injecting duration.

The pressure difference between the fuel pressure and
the intake manifold is approx. 3.2 bars during idling.
1. Fuel Pressure Regulator

2. Intake Manifold
4. Fuel Supply(from fuel pump)
8. Intake Manifold Negative Pressure(0.6 bars)
<Fuel Pressure Diagram>
A. Fuel pressure
B. Intake Manifold Negative Pressure
LL. Idling
TL. Partial load
VL. Full load

FUEL DISTRIBUTOR
1 Vacuum Hose 5 Bolt (M8 X 50) ................................ 22.5-27.5 Nm

2 Fuel Return Line ................................... 25-30Nm 6 Fuel Distributor
3 Fuel Supply Line ................................... 25-30Nm 7 O-ring .................................. Replace if damaged
4 Injector Connector 8 Injector

1. Discharge the fuel pressure from the fuel pressure test
connector.
2. Disconnect the battery ground cable.
3. Disconnect the vacuum hose from the fuel pressure
regulator.
4. Remove the cable guide.
5. Remove the fuel return and supply line.

Notice
l For removal, cover around parts with cloths not to be
stained by fuel.
l In case of checking the injector only, do not remove the
fuel return and supply line.
Installation Notice
6. Remove the six injector connectors.
7. Remove the two left and two right bolts and one center bolt
of the fuel distributor assembly from the intake manifold.
Installation Notice

8. Remove the injectors and the fuel distributor carefully.
reverse order.
10. Check for fuel pressure and internal leakage by operating
the engine.
Fuel Pressure Test

3. Connect the fuel pressure gauge to the fuel pressure test

connector.
4. Test the fuel pressure at idling by operating the engine.
Vacuum Hose Connected (bar) 3.2 - 3.6
Vacuum Hose Disconnected (bar) 3.7 - 4.2
5. Replace the pressure regulator diaphragm if out of the
specification.

Internal Leakage Test
connector.
2. Stop the engine for approx. 30 minutes and then check the
fuel pressure changes.
Pressure Change Possible Cause
· Fuel leakage at the
Fuel pressure injector
• Faulty fuel pressure
drops slowly regulator's
diaphragm and O-
ring.
Fuel pressure • Faulty check valve

drops rapidly in the fuel pump.
3. If there is no change in fuel pressure and maintain the

following pressure over 30 minutes, it is normal.
Fuel Pressure(bar) 2.5
Discharging the pressure in fuel system

Installation Notice
2. Remove the fuel pressure in fuel system by pressing the

service valve with a clean, pointy tool.
Notice
Place a cloth so that the fuel doesn't stain around.

INJECTOR
Preceding Work : Removal of fuel distributor
1 O-ring .................................... rplace, if damaged 4 O-ring .................................. replace, if damaged

2 Injector Bracket 5 Fuel Distributor
3 Injector

Check for damage and replace it if necessary.
2. Remove the injector bracket from the injector.
Installation Notice
Exactly seat the anti-twist lock into the square groove in
injector.
3. Separate the injector from the fuel distributor.
Inspection & Maintenance
Inspection of the Injector operation and spray pattern
1. Connect the contact box to the ECU.
2. Connect the shop made test plug to the injector and place
it into the tank.
3. Position the ignition switch to ON.
4. Connect the pin 63(+) and 69(-) of the contact box with a
test cable.
5. Check the injector spray pattern.
Notice
Replace the injector if the injector spray pattern is abnormal
or the fuel doesn't inject.
Injector Resistance Inspection
1. Remove the injector connector.
2. Measure the injector coil resistance using a resistance
tester.
Specified Value 14 - 17 W
Notice
Replace the injector if the measured values is out of the
specified values. Check the connector and wire connection
between the ECU and the injector if the measured values
are normal.

The Injector Spray Pattern Check
1. Connect the test box (129 589 00 21 00) to the ECU.
2. Disconnect the connector from connector.
3. Disconnect the fuel distributor and injector with a unit from
engine without removing the fuel supply and return line.
Notice
Prepare the beaker for taking the poping fuel.
4. Connect either end of shop made cable to the injector.
5. Connect the other end of shop made cable to the 63(+)
and 69(-) terminal of the test box.
6. Turn the ignition switch to "ON" position.
7. Check the injector for normal spray pattern as shown in the
figure. Check injector for leaks or later drops.
Notice
Refer to fuel injector test of engine diagnosis in this section
for detailed information.

FUEL FILTER
1 Fuel Filter 3 Inlet

2 Outlet

1. Open the fuel tank cap and remove the fuel tank pressure.
2. Remove the fuel at (2) and in (3).
Installation Notice
3. Remove the mounting bracket bolt (4) and remove the fuel
filter (1).
Installation Notice
Notice
Place the fuel pump pad. There may be a corrosion due to
the contact between the fuel filter and the bracket.
Notice
Installation should follow the removal procedure in the
reverse order.

FUEL PUMP
1 Reservoir Tank
2 Fuel Sensor (float/arm)
3 Resistance
4 Wiring Connector
5 Fuel Supply Pipe
7 Float
10 Flange and Harness Assembly
11 Fuel Pump
12 Spring
13 Thermister Housing
14 Thermister
15 Resistor Card and Wiper
16 Float Arm
Requirements for Fuel Pump
Item Specified Value Item Specified Value
System pressure 3.8 bar Minimum delivery at 8V 30 Litre/Hr
Maximum pressure 8.5 bar (12 V) Operating voltage 8V
Minimum pressure 5.0 bar (12 V) Maximum allowable current 7.5 A
Nominal voltage 12 V Ambient temperature -30 ~ +70°C
Minimum amount 114 Liter/Hr (12 V, 3.8 bar, - Maximum amount 165 Liter/Hr (12V, 3.8 bar,
of fuel supply 30 ~ +70°C) of fuel supply -30 ~ +70°C)

1 Fuel Pump Connector Wiring 5 Fuel Return Pipe

2 Fuel Return Pipe 6 Fuel Supply Pipe
3 Fuel Supply Pipe 7 Float
4 Bolts 8 Ground Stud (Sender "-")
Harness Location & Connector COLOR USE

1 A Pump "+" 2.0 BR
2 B Thermister "+" 0.5 W
3 C Ground 2.0 B
4 D Sender Unit "+" 0.5 RY

Tools Required
661 589 00 46 00 Cap Remover

2. Disconnect the harness connector (1).
3. Disconnect the fuel supply (6) and return (5) pipes.
4. Using a special tool, Unscrew the eight fuel retaining bolts
and remove the pump from fuel tank.
Notice
Check the condition of the seal and replace if necessary.
Drain the fuel before removing the pump.

Measure the Fuel Delivery From the Fuel Pump
1. Disconnect the return pipe from fuel distributor and insert
the appropriate hose into it.
2. Place the hose end into the beaker with the minimum capacity
of 1Liter.
4. Connect the terminal No.33 and No.5 of ECU with a service
wire.
5. Measure the fuel delivery from the fuel pump.
Specifed Value 1Liter/max.35sec.
Notice
Check the fuel filter and fuel line when the fuel delivery is
not within specified value.
Measure the Current Consumption of Fuel Pump
1. Remove the fuel pump relay from fuse and relay box in
trunk, and turn the ignition switch to "ON" position.
2. Using a multi-tester, measure the current consumption by
connecting the terminal No.1 and No.3 of pump.
Specifed Value 5 - 9A
Notice
Replace the fuel pump relay if the measured value is over
9A.

PURGE SWITCHOVER VALVE
1 Purge Switchover Valve

2 Line to Engine
3 Line to Canister
4 Canister
Functions
The fuel vaporization control system is installed to inhibit the
fuel vaporized gas from discharging into the atmosphere. The
fuel vaporized gas that is accumulated in the canister abstracts
through the purge switchover valve purification during the
engine combustion (except the decreasing mode) and coolant
temperature of over 80°C. For this reason, the ECU transacts
the engine speed, air inflow quantity, coolant temperature, and
intake temperature.
The purge switchover valve is activated by the ECU frequency
according with the engine rotating speed to adjust the
purification rate. The purification rate is determined by the
continuous valve opening interval.
The purge switchover valve is activated by the ECU for the
following conditions :
l Coolant temperature of over 80°C
l Engine speed of over 1000rpm
l 2 Minutes after starting
l When the fuel cut-off mode is not activated

Test
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECU terminal No.11 and No.34 and check for
normal operation through the output waves using the
scanner.
Notice
Test during purge control switchover valve operation after
the minimum of 1 minute after the engine turned on.
current consumption during the ignition switch ON.
Specified Value 0.3 - 0.5 Purge switchover valve output wave
4. Remove the line to canister and measure the pressure with
the vacuum pressure gauge.
> 50mbar
(after approx. 1min.)
Specified Value
purge switchover valve
operates at this time
Notice
Test while at normal temperature and at idling state by

VACUUM SYSTEM
1 Purge Control Valve 10 Vacuum Line Rubber Hose

2 Molded Hose 11 Vacuum Tube(Gray, 270mm)
3 Insulator 12 Molded Hose
4 Fuel Tube 13 Rubber Cap
5 Molded Hose 18 Rubber Hose
6 Idle Regulator 19 Vacuum Tube(Brown or Black, 770mm)
7 Resonance Flap 20 Rubber Hose
8 Intake Manifold A To Canicter

CRANKSHAFT POSITION SENSOR
1 Crankshaft Position Sensor 3 Segment

2 Bolt (M6 X 14) ........................................ 9 -11Nm 4 Flywheel

1. Disconnect the wiring connector at the crankshaft position
sensor.
2. Unscrew the bolt and remove the crankshaft position sensor
unit.
Installation Notice
Tightening Torque 9 -11Nm

reverse order.

Crankshaft Position Sensor Resistance
Inspection
1. Disconnect the coupling "E" of ECU while the ignition switch
is in "OFF" position.
2. Measure the resistance between the coupling terminal pin
No.99 and No.100 using a multimeter.
Notice
Measure the insulator resistance of the crankshaft position
sensor if out of the specified value.
Crankshaft Position Sensor Output Wave

Inspection
2. Measure the output wave between the ECU terminals No.99
and No.100 using the scanner or the oscilloscope while
engine cranking (starter motor activated).
Notice
Check the segment or crankshaft position sensor and air
gap if cannot get the output wave as shown in the figure.
Crankshaft Position Sensor Insulator Resistance

Inspection
1. Disconnect the engine coupling from ECU while the ignition
switch is in "OFF" position.
No.100 and No.69.
Specified Value > 20kW
Notice
Measure the check and ground terminal of the crankshaft
position sensor if out of the specified value.

CAMSHAFT POSITION SENSOR
1 Bolt (M6 X 14) ......................................... 9-11Nm 3 Shim

2 Camshaft Position Sensor 5 O-ring

1. Disconnect the wiring connector from the camshaft position
sensor.
2. Unscrew the bolt (2) and remove the camshaft position
sensor.
Installation Notice
3. Check the clearance and replace the shim if necessary.

4. Check the O-ring for damage and replace it if necessary.
reverse order.

Camshaft Position Sensor Signal Voltage
Inspection
2. Measure the voltage between the ECU terminal No.11 and
No.106 while the engine speed is at idle.
Specified Value 1.2 - 1.7 V

Notice
The signal voltage will be changed in the range of 1.2~1.7V.
Camshaft Position Sensor Output Wave

Inspection
2. Measure the output wave between the ECU terminal No.104
and No.106 using the scanner or the oscilloscope while the
engine speed is at idle.
Notice
Replace the camshaft position sensor if cannot get the
output wave as shown in the figure.
Camshaft Position Sensor Power Supply

Inspection
1. Turn the ignition switch to 'ON' position.
2. Disconnect the camshaft position sensor connector.
3. Measure the voltage between the No.1 and No.3 pin of
camshaft position sensor while the ignition switch is in "ON"
position.
Notice
If the measured value is not within the specified value, check
the cable.

HOT FILM AIR MASS (HFM) SENSOR
1 Housing 4 Connector
2 Protector Net 5 Hot film Sensor
3 Electronic Housing 6 Measuring Port

1. Turn the HFM sensor coupling in the direction shown in the
figure in the right so that it gets separated from the contact
surface.
Notice
Make sure the HFM sensor coupling connects completely
with the contact surface Installation.
2. Remove the clip with a screw driver.
3. Pry off two tensioning clamps.
4. Remove the HFM sensor.
reverse order.

Circuit Diagram
1 Housing
2 Electronic Housing
3 Connector
RH : Heat Resistance
RT : Temperature Resistance
RS : Sensor Resistance

HFM Sensor Input Voltage Inspection
1. Measure the HFM sensor signal voltage between the ECU
terminal No.81 and No.105.
Specified Value (coolant temperature is over 70°C)
Iginition"ON” 0.9 - 1.1 V
Engine at idle 1.3 - 1.7 V
If the measured value is not within the specified value, the
possible cause may be in cable or HFM sensor in itself.
Perform the 5V power supply inspection procedures.
HFM Sensor 5V Power Supply Inspection

1. Measure the voltage between the HFM sensor No.4 pin and
No.3 after removing the HFM sensor connector.

possible cause may be in cable or ECU coupling.

possible cause may be in cable or over voltage protection
relay.

OXYGEN SENSOR
1 Electricity Wire
2 Oxygen Sensor Housing
3 Sensor Ceramic
4 Electrode (Internal)
5 Electrode (External)
6 Heating Coil
7 Open Space
8 Protector Tube
Functions
The oxygen sensor optimizes the combustion (Air-Fuel Ratio
14.7:1) and resets the Air-fuel ratio in the ECU after sensing
the amount of oxygen from the exhaust gases to diminish the
exhaust gases.
- Rich(<1) above approx. 450mV
- Lean(>1) below approx. 450mV
Locatoin of Sensor
Oxygen sensor is located on the front exhaust pipe.

Oxygen Sensor Signal Voltage Inspection
1. Measure the oxygen sensor signal voltage between the ECU
terminal No.11 and No.9. Maintain the engine speed ia at
idle while the coolant temperature is over 80°C.
Specified Value -0.2 - 1.0 V

possible cause may be in cable, oxygen sensor or ECU.
Oxygen Sensor Heating Voltage Inspection

1. Measure the oxygen sensor heating voltage between the
ECU terminal No.11 and No.9. Maintain the engine speed ia
at idle while the coolant temperature is over 80°C.
Oxygen Sensor Heating Current Consumption

Inspection
1. Measure the oxygen sensor heating current consumption
between the ECU terminal No.9 and No.5 while the ignition
switch is in "ON" position.
Specified Value 0.2 - 2.0 A

KNOCK SENSOR
Functions
Vibration of the engine block is transmitted to the sensor and
transferred to the ECU in the form of an alternating voltage
signal via a shielded cable. The knock sensor is fastened to
the engine block to recognize knocking in all cylinders. The
ECU compares the signal and the retards firing point.

1. Disconnect the knock sensor connector from the intake
manifold bracket.
2. Unscrew the mounting bolt (M8 X 28) from the knock sensor
installed on the cylinder block and remove the knocking
sensor.
Installation Notice

reverse order.

COOLANT TEMPERATURE SENSOR
1 Artificial Resin Housing 4 Connector

2 Metal Housing 5 Coolant Temperature Sensor
3 NTC (negative temperature coefficient) Resistor

1. Remove the pressure by opening the pressure cap in the
coolant subtank.
2. Disconnect the connector and remove the coolant
temperature sensor.
Installation Notice
Replace the seals with new one.

reverse order.
4. Check for leaks at each connections after starting the engine.

Inspection
1. Measure the coolant sensor input voltage between the ECU
terminal No.79 and No.78 while the ignition switch in "ON"
position.
Temperature (°C) Voltage (V)
20 3.57
30 1.22
40 0.78
allowable error :±5%
2. Measure the resistance between the coolant temperature

sensor terminal No.1 and No.4 with the coolant temperature
sensor disconnected.
Temperature (°C) Resistance (W )
20 2,500
30 322
40 185

Notice
Replace wiring and coolant temperature sensor if out of
specified value.

Service Data
Temperature(°C) Resistance(W) Voltage(V) Temperature(°C) Resistance(W) Voltage(V)
-40 48,550 4.8991 60 594 1.8632
-30 27,000 4.8214 70 434 1.5132
-20 15,670 4.7001 80 322 1.2179
-10 9,450 4.5215 90 243 0.9775
0 5,890 4.4273 100 185 0.7806
10 3,790 3.9562 110 143 0.6255
20 2,500 3.5714 120 111.6 0.5020
30 1,692 3.1426 130 88.0 0.4044
40 1,170 2.6959 140 71.2 0.3323
50 826 2.2618 - - -
Resistance characteristic curve according to the coolant

temperature

ACCELERATOR PEDAL MODULE
1 Accelerator Pedal 4 6-Pin Connector

2 Accelerator Pedal Sensor 5 Kick Down Switch
3 Bolts (2 Pieces) ....................................... 4-8 Nm 6 Nut (1 Piece) ............................................ 4-8 Nm

1. Disconnect the 6-pin connector (arrow).
2. Unscrew the 2 bolts (3) / 1 nut (6) and remove the pedal
and sensor assembly.
Installatoin Notice
Tightining Torque 4 - 8 Nm
reverse order.

Accelerator Pedal Sensor Connector(Sensor Side)
Potentiometer 1.
Pin no. 3 :Red
Pin no. 1 :Yellow
Pin no. 5 :Brown
Potentiometer 2.
Pin no. 6 :Violet
Pin no. 4 :Green
Pin no. 2 :White
Accelerator Pedal Sensor Connector(Vehicle Side)

Potentiometer 1.
Pin no. 3 :Red-Black
Pin no. 1 :Blue-Green
Pin no. 5 :Yellow-Green
Potentiometer 2.
Pin no. 6 :Green
Pin no. 4 :Blue-Red
Pin no. 2 :LightGreen
Function
Pin no. 3 Potentiometer 1, Power Supply(+)
Pin no. 1 Potentiometer 1, Signal
Pin no. 5 Potentiometer 2, Ground
Circuit Diagram
Potentiometer 1.
Potentiometer 2.

SECTION 1F2
M161 ENGINE CONTROLS

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F2-2 Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F2-30
Fastener Tightening Specifications . . . . . . . . 1F2-2 Injector Test . . . . . . . . . . . . . . . . . . . . . . . . 1F2-32
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1F2-3 Maintenance and Repair . . . . . . . . . . . . . 1F2-34
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1F2-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F2-34
Schematic and Routing Diagrams . . . . . . . 1F2-4 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-34
E23 ECU (MSE) . . . . . . . . . . . . . . . . . . . . . . 1F2-4 Fuel Pressure Regulator . . . . . . . . . . . . . . 1F2-45
E20 ECU (MSE) . . . . . . . . . . . . . . . . . . . . . . 1F2-5 Fuel Distributor . . . . . . . . . . . . . . . . . . . . . . 1F2-49
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-6 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-54
Self Diagnosis Socket Pin Numbers and Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-57
Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 1F2-6 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-58
Self Diagnosis Failure Code Purge Switchover Valve . . . . . . . . . . . . . . . 1F2-62
(for E23 ENG.) . . . . . . . . . . . . . . . . . . . . . . 1F2-7 Vacuum System . . . . . . . . . . . . . . . . . . . . . 1F2-64
Test Box Connection . . . . . . . . . . . . . . . . . . 1F2-10 Crankshaft Position Sensor . . . . . . . . . . . . 1F2-66
Fuel Injection System Test . . . . . . . . . . . . . 1F2-11 Camshaft Position Sensor . . . . . . . . . . . . . 1F2-68
Ignition System Test . . . . . . . . . . . . . . . . . . 1F2-20 Hot Film Air Mass (HFM) Sensor . . . . . . . . . 1F2-70
Idling Control and Electronic Pedal Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . 1F2-73
System Test . . . . . . . . . . . . . . . . . . . . . . . 1F2-25 Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 1F2-75
Air Conditioner Control System Test . . . . . . 1F2-27 Coolant Temperature Sensor . . . . . . . . . . . 1F2-76
Fuel Pressure and Internal Leakage Test . . 1F2-28 Accelerator Pedal Module . . . . . . . . . . . . . . 1F2-79

SPECIFICATIONS
Application N·m
Fuel Return and Supply Line 25 - 30
Fuel Distributor Assembly Bolt 22.5 - 27.5
Pressure Test Connector 21.6 - 26.4
Fuel Inlet and Outlet Line 25 - 30
Fuel Filter Mounting Bracket Bolt 4-8
Crankshaft Position Sensor Bolt 9 - 11
Camkshaft Position Sensor Bolt 9 - 11
Knock Sensor Mounting Bolt 22.5 - 27.5
Coolant Temperature Bolt 18 - 22

SPECIAL TOOLS
SPECIAL TOOLS TABLE
129 589 00 21 00 106 589 00 21 00

Test Box Pressure Tester
119 589 04 63 00 210201

Pressure Hose Adaptor Line
210 589 08 63 00
ECU Test Cable


E23 ECU (MSE)

E20 ECU (MSE)

DIAGNOSIS
SELF DIAGNOSIS SOCKET PIN NUMBERS AND DESCRIPTIONS
1 Ground 12 -
2 Ignition 1 13 Brake System
3 Battery Power Supply (Fuse NO.17) (ABS 5.3:PIN 11, ABS/ABD 5.3:PIN 46)
4 REKES :PIN 6 14 MSE 3.62S/3.53S(ECU Data Output:PIN 58)
5 Engine Speed Signal :MSE PIN 60 15 TOD(PIN 20)
6 TCCU(Part-time) 16 Immobilizer
7 STICS(PIN 26) 17 -
8 - 18 TCU(PIN 23)
9 - 19 -
10 Air Bag(PIN 20) 20 K-LINE(ECS:PIN 23)
11 Remote Engine Start Unit(PIN 10)

SELF DIAGNOSIS FAILURE CODE (FOR E23 ENG)
Failure Failure
00 Coolant temperature sensor open 64 No ignition voltage output (No.1 ignition coil : 1, 4 cylinder)
01 Coolant temperature sensor short 65 No ignition voltage output (No.2 ignition coil : 2, 3 cylinder)
02 Coolant temperature sensor signal failure 67 Cranshaft position sensor adaption failure
03 Intake temperature sensor open 71 Start signal recognition failure
04 Intake temperature sensor short 72 No.1 injector short(PWR)
05 Intake temperature sensor signal failure 73 No.1 injector open/short(GND)
08 Low battery voltage 74 No.2 injector short(PWR)
09 HFM sensor signal failure 75 No.2 injector open/short(GND)
10 HFM sensor signal failure (Low) 76 No.3 injector short(PWR)
11 HFM sensor signal failure (High) 77 No.3 injector open/short(GND)
17 Crankshaft position sensor signal failure 78 No.4 injector short(PWR)
(no engine revolution signal) 79 No.4 injector open/short(GND)
18 Crankshaft position sensor signal failure 80 High oxygen sensor voltage
(rpm > max. value) 81 Low oxygen sensor amplifying voltage
19 No.1 cylinder recognition failure 82 Oxygen sensor operating failure
20 Crankshaft position sensor signal failure 83 Not excessive lean indication in oxygen
(gab recognition failure) sensor(during coasting)
21 Transmission coding failure 86 Oxygen sensor heater short(power)
25 Transponder signal communication failure 87 Oxygen sensor heater open/short(GND)
26 CAN communication failure : TCU(A/T only) 89 Low oxygen sensor voltage
31 CAN communication failure : 93 Short learning control failure
communication initialization failure 96 Lambda control failure (rich stop)
34 Fuel pump relay short(PWR) 97 Lambda control failure (lean stop)
35 Fuel pump relay open/short(GND) 98 Lambda idle adaptation failure(above rich
40 Purge valve short threshold)
41 Purge valve open/short 99 Lambda idle adaptation failure(below lean
44 Condenser fan(HI) relay short(PWR) threshold)
45 Condenser fan(HI) relay short(GND) 100 learning control failure(rich, low load)
56 No.1 knock sensor signal failure 101 learning control failure(lean, low load)
58 No.1 cylinder synchronization failure 102 learning control failure(rich, high load)

Failure Failure
103 learning control failure(lean, high load) 142 Uncoded ECU

104 Low throttle position sensor(IP1) voltage 143 ECU failure(NVRAM checksum failure)
105 High throttle position sensor(IP1) voltage 144 ECU failure(coding ID checksum failure)
108 Low throttle position sensor(IP2) voltage 145 ECU failure(coding checksum failure)
109 High throttle position sensor(IP2) voltage 146 ECU failure(programing checkusm failure)
110 Throttle actuator learning data fault 150 ABD input signal short(power)
116 Throttle actuator learning control failure 151 ABD input signal short(GND)
117 Exceed fuel-cut safety time 160 Low pedal valve sensor SP1 voltage
119 Throttle valve return spring failure 161 High pedal valve sensor SP1 voltage
120 Cruise control interruption memory failure 162 Low pedal valve sensor SP2 voltage
121 Throttle actuator failure 163 High pedal valve sensor SP2 voltage
122 Pedal module position sensor signal failure 164 Different pedal valve sensor signal(1,2) SP1
123 Defferent HFM signal with throttle potentiom- with SP2
eter 167 Pedal valve sensor 1,2 failure
125 Both throttle potentiomenter(IP1 & IP2) 185 HFM sensor, and throttle position sensor failure
failure 186 ECU failure(incompatible CPU)
126 Different IPS1 with IPS2 187 ECU failure(CPUs communication failure)
127 High permanent throttle signal deviation 188 ECU failure(CPU(2) configuration failure)
129 Message counter fault ® cruise control “OFF” 189 ECU failure(CPU(2) fault)
130 Vehicle speed signal failure 190 ECU failure(CPU run time failure between
131 Vehicle speed signal failure CPUs)
132 Cruise control lever failure 192 -
133 Cruise control acceleration failure 193 -
134 Cruise control deceleration failure 194 -
136 ECU failure(RAM) 195 -
137 ECU failure(EPROM) 198 -
139 Servo motor control output inter-ruption 199 -
memory failure 226 Cam actuator short(PWR)
140 Servo motor open/short 227 Cam actuator open/short(GND)
141 Unprogramed ECU with Immobilizer 228 A/C compressor relay short(PWR)

Failure Failure
Description code Description
code
229 A/C compressor relay open/short(GND) 243 AD converter failure(CPU2)
232 Decel limit defected by CPU2 244 Pedal position sensor setpoint fault berween
233 Accel limit defected by CPU2 CPU1 and CPU2
234 Cruise control lever double input(CPU2) 245 Position setpoint fault berween CPU1 and
235 Cruise control lever safety terminal CPU2
failure(CPU2) 246 -
236 Unusual pedal position variation(CPU2) 247 Idle controller setpoint fault berween CPU1
237 Unusual throttle position variation(CPU2) and CPU2
238 Unusual throttle control data(CPU2) 248 AD converter overflow degected by CPU2
239 Unusual pedal position sensor(CPU2) 249 ROM fault degected by CPU2
240 Throttle potentiometer fault(CPU2) 250 RAM fault degected by CPU2
241 Unusual CPU communication(CPU2) 251 Cycle monitor fault degected by CPU2
242 Unusual CPU configuration(CPU2)

TEST BOX CONNECTION
1 ECU 01 Test Box

2 Test Coupling(No.1 - 60) 02 ECU Test Cable
3 Test Coupling(No.61 - 120)
4 Multi-tester
Tools Required
129 589 00 21 00 Test Box
210 589 08 63 00 ECU Test Cable

FUEL INJECTION SYSTEM TEST

code step value

supply · Þ 1.2
- terminal 30 10 12
(TM.30)

Diagnosis
- Battery socket
ground 10 2
Diagnosis
socket
69 2
supply:
Diagnosis
- terminal 30 socket
(TM.30) 1 12

supply · Þ 2.1
- terminal 87 5 11
(TM.87)
cable
Diagnosis
- Electronic socket
ground 5 2
supply: · OVPR
Diagnosis
- terminal 87 socket · Ignition:OFF < 1V
(TM.87) 1 11
Þ 3.0 · Start signal: · Engine:in Cranking 11 -14 · Cable
- terminal 50 (during engine · Ignition Swith
(TM.50) 5 2 cranking)


code step value
Þ 4.0 · HFM sensor · Ignition:ON 0.9 - 1.1V · Þ 4.1 - 4.3

09,
signal · Cable
10, 105 81 · Engine:in Idle 1.3 - 1.7V · External air inflow
11, (Coolant temperature · HFM sensor
: voltage value
: > 70°C )
is increased
when engine
rpm is
increased
Þ 4.1 · HFM sensor: · Ignition:ON 4.7 - 5.2V · Cable

HFM
- 5V power sensor · HFM sensor · ECU coupling
Þ 4.2 · HFM sensor: · Ignition:ON 4.7 - 5.2V · Þ 4.3

HFM
- 5V power sensor · HFM sensor · Cable
Þ 4.3 · HFM sensor: · Ignition:ON 11 - 14V · Cable

HFM
- 12V power sensor · HFM sensor · OVPR
03, Þ 5.0 · Intake air · Ignition:ON °C V · Þ 5.1

04,
sensor: 105 80 20 2.65
05, - Voltage 30 2.18
40 1.76
50 1.4
60 1.1
± 5%
Þ 5.1 · Intake air · Ignition:OFF °C W · Cable
temperature · No.2 ECU coupling 10 3600 · HFM sensor
sensor: 105 80 removed 20 2420

40 1166
50 853
60 600
± 5%


code step
Þ 6.0 · Fuel pump · Ignition:ON 11 - 14V · Cable

34,
relay: (Fuel pump relay will (approx.1- · Fuel pump relay
35, 33 11
- Operation operate for 1 - 2 2sec.) · ECU
seconds when the

ignition switch is
turned to "ON" after
stopping the
engine) 11 - 14V
· Engine:cranking (Cranking or
driving)
Þ 6.1 · Fuel pump · Ignition:ON 0.1 - 0.3A · Cable
relay: · Fuel pump relay
- Current 5 33 · ECU
consumption
00, Þ 7.0 · Coolant · Ignition:ON °C V · Þ 7.1

01,
sensor: 79 78 80 1.22
02, - Voltage 100 0.78
06,
± 5%
Þ 7.1 · Coolant · Ignition:OFF °C W ·Þ 7.2

temperature (Remove the No.2 20 2500 · cable
sensor: 79 78 coupling from ECU) 80 322

& cable
± 5%
Þ 7.2 · Coolant Coolant temperature · Remove the ·Þ refer to · Coolant

sensor:
temperature 1 4 connector from specified temperature
sensor: coolant temperature resistance sensor
- Resistance sensor and measure value of 7.1.
the resistance
between No.1 and
No.2 pin with
multimeter.


code step value
32, Þ 8.0 · ECU: · Engine:in cranking refer to figure · Cable
33, - RPM signal or idle 2 · ECU
output 5 60
- Voltage · Engine:in cranking 6.0 - 7.0 V

or idle
5 60 (above 5V in idling)
80, Þ 9.0 · Oxygen · Keep the engine run There will be a · ECU
81, sensor: above 2 minutes in voltage · Cable
- Signal 16 17 over 80°C of coolant fluctuation in · Oxygen sensor

82,
83, temperature the range of
89, - 0.2 -1.0V.
85, Þ 10.0 · Oxygen · Keep the engine run 11 - 14 V · ECU
86, sensor: above 2 minutes in · Cable
87, - Heating 9 11 over 80°C of coolant · Oxygen sensor
function temperature.
operated

consumption
5 9

72,
73, 63 11
injector: approx. 20°C: · No.1 Injector

· When the coolant
speed 2.7 - 5.0ms
- Engine:at sharp approx.14ms
acceleration(full
throttle)
(refer to figure 3
and 4)


value
- Internal · Ignition:OFF (injector 14 - 17 W

(No.1 63 11
injector)

74,
injection temperature
· When the coolant
time sensor
temperature is
· Oxygen sensor
approx. 80°C:
· Intake air
temperature
speed 2.7 - 5.0ms
sensor
acceleration (full
throttle)
4)

(No.2 64 11
injector)

76,

· When the coolant
temperature is
· Intake air
approx. 80°C:
approx. temperature sensor
- Engine:at idling
speed 2.7 - 5.0ms
acceleration(full
throttle)
(refer to figure 3
and 4)



(No.3 65 11
injector)
Þ 14.0 · No.4 cylinder · When the coolant · Cable

78,
injector: temperature is · ECU
79,
- Operating & 66 11 approx.20°C: · No.4 Injector
injection time - Engine:in cranking 8.0 ms · Coolant
temperature sensor
· When the coolant
· Oxygen sensor
temperature is
· Intake air
approx.80°C:
temperature sensor
speed 2.7 - 5.0ms
acceleration(full
throttle)
(refer to figure 3
and 4)
- Internal · Ignition:OFF 14 - 17 W
resistance (injector temperature
(No.4 66 11 is 20°C)
injector)
Þ 15.0 · Camshaft Camshaft actuator · Engine : using a test 1 - 1.5 A · ECU

226,
actuator: 1 2 cable(102 589 63 00) ·Þ 15.1
227,
Current in idling, measure the · Þ 16.0
consumption current consumption

with below condition
- Coolant temperature
: above 70°C
- Engine rpm :
increase up to 2000
rpm


Þ 15.1 · Camshaft · Ignition:OFF 8 - 12 W · Cable
actuator: · Camshaft actuator

Diagnosis
Solenoid socket
resistance 73 2
(E23 only)
226, Þ 16.0 · Camshaft · Engine:in idling Engine is · Mechanical failure
227, actuator: unstable or of camshaft

Mechanical 73 69 stopped. actuator
actuation
(E23 only)
40, Þ 17.0 · Purge · Engine:in idling The purge · ECU
41, control control valve · Cable

34 11 should be · Purge control valve
54, valve:
operated after
- Operating
approx.
1minute.
(refer to figure
5)

consumption
10 34
40, Þ 18.0 · Purge Connect the vacuum · Engine:in idling/ Creating above · Power supply cable
41, control gauge between the normal operating 50mbar of · OVPR
54, valve: control valve and temperature vacuum after
- Vacuum canister approx.
control 1 minute
22,23, Þ 19.0 · CAN data · Ignition:OFF 55 - 65 W · Data bus
24,26, bus ·Þ 19.1

27,29, 38 37 ·Þ 19.2
30,31,
59,60,


code step value
Þ 19.1 · CAN module · Ignition:OFF 115 - 125 W · Cable
resistance in - disconnect the · ABS, ABD, ASR

ABS, ABD, 38 37 coupling"No.1" control unit
ASR control from ECU
unit
Þ 19.2 · CAN module · Ignition:OFF 115 - 125 W · ECU
resistance in - disconnect the

ECU control 38 37 coupling"No.1"
unit from ECU
Þ 20.0 · Diagnosis · Ignition:ON 11 - 14 V · ECU
cable · Cable
operating 5 58

Reference Figures
Figure1. RPM Sgnal Output Figure 2. Injection Valve Wave(at idle speed)
Figure 3. Injection Valve Wave(at sharp Figure 4. Purge Control Valve Operationg Wave
acceleration)

IGNITION SYSTEM TEST

code step value
08, Þ 1.0 · ECU:power · Ignition:ON 11 - 14V ·Þ 1.1

supply ·Þ 1.2
- terminal 30 10 12
(TM.30)

Diagnosis
- Battery socket (figure 1)
ground 10 2
Diagnosis
socket
69 2
supply:
Diagnosis
(TM.30) 1 12
08, Þ 2.0 · ECU:power · Ignition:ON 11 -14V ·Þ 2.1

supply ·Þ 2.2
- terminal 87 5 11
(TM.87)
cable
Diagnosis
- Electronic socket
ground 5 2
supply: · OVPR
Diagnosis
1 11 · Ignition:OFF < 1V
(TM.87)
64, Þ 3.0 · Ignition · Ignition:ON 11 - 14 V · Cable
coil(T1/1) · Ignition coil(T1/1)
- No.1,4 69 72 · Fuse No.17


65, Þ 4.0 · Ignition · Ignition:ON 11 -14 V · Cable
coil(T1/2) · Ignition coil(T1/2)
- No.2,3 69 71 · Fuse No.17
17, Þ 5.0 · Crankshaft · Engine:in cranking Measure the · Increament failure
18, position signal (refer to in driven plate

20, sensor: 99 100 figure 6) ·Þ 5.1
67, - Signal · Engine:idling
- Voltage · Engine:in cranking > 2.5 V -

(alternating)
99 100
· Engine:idling >5V-
Þ 5.1 · Crankshaft · Ignition:OFF 1050 - 1400W · Cable
position - Disconnect the · Crankshaft position
sensor: coupling “No.2” sensor

- Resistance 99 100 from ECU (engine
side coupling).
19, Þ 6.0 · Camshaft · Engine:in cranking Measure the ·Þ 6.1

58, position signal(refer to · Cable
sensor: 104 106 figure 8) · Camshaft position
(E23 only) sensor

- Signal
- Voltage · Engine:in cranking The value will

(alternating) be changed in
106 11 1.2 - 1.7 V.
Þ 6.1 · Camshaft · Ignition:ON 11 -14 V · Cable

Camshaft position
position sensor - Remove the · OVPR
sensor 1 3 connector from the

(E23 only) camshaft position
- Power supply sensor


code step value
64, Þ 7.0 · Ignition · Engine:in cranking 200 - 350 V ·Þ 7.1

- Primary coil 72 11 - Measuring range:
voltage 400 V
(No.1 , 4 - Time range: 100 %
Þ 7.1 · Connection
· Ignition:OFF 0.9 - 1.6 W · Cable
The · Ignition coil T1/1
ignition coil
resistance of · Ignition coil T1/2
between T1/ 72 71
ignition coil at
1 and T1/2
20°C is
approached
0.6W.
65, Þ 8.0 · Ignition · Engine:in cranking 200 - 350 V ·Þ 8.1

- Primary coil 71 11 - Measuring range:
voltage 400 V
(No.2 , 3 - Time range: 100 %
Þ 8.1 · Connection · Ignition:OFF 0.9 - 1.6 W · Cable
ignition coil The · Ignition coil T1/1
between T1/ 71 72 resistance of · Ignition coil T1/2
1 and T1/2 ignition coil at

20°C is
approached
0.6W.
64, Þ 9.0 · Ignition coil · Engine:in cranking 8 - 20 KV ·Þ 9.1

Engine tester
65, (T1/1, T1/2) - Select the ignition · Ignition plug
- Secondary coil in order of T1/1, · ECU
ignition T1/2 · High tension cable
voltage - Measuring range :

20KV
- Time range : 100%


Þ 9.1 · Ignition coil Ignition coil

· Remove the high 6 - 8.5 KW · Ignition coil T1/1
(T1/1, T1/2) (T1/1, T1/2) tension cable of · Ignition coil T1/2
- Secondary TM.4a TM.4b T1/1, T1/2

coil
resistance
sensor - Disconnect the condition

- Resistance 117 118 coupling "No.2" · Cable
from ECU. · ECU

Reference Figures
Figure 5. Crankshaft Position Sensor Signal Figure 6. Camshaft Position Sensor Signal
a Voltage
b Identifying the No.1 - 2 Missing Teeth
Figure 7. Signal Function

1 Crank Angle
2 Cylinder
3 Crankshaft Position Sensor Signal
4 Camshaft Position Sensor Signal
5 RPM Signal

IDLING CONTROL AND ELECTRONIC PEDAL SYSTEM TEST

160, Þ 1.0 · Pedal valve · Ignition:ON ·Þ 1.1


position
kick down
sensor: · ECU
- Power 31 32
supply
(potentiometer 1)
162, Þ 2.0 · Pedal valve · Ignition:ON · Þ 2.1


position
kick down
sensor: · ECU
- Power 50 51
supply
(potentiometer 2)
104, Þ 3.0 · Throttle · Engine:in idling ·Þ 3.1

105, valve · Cable
108, actuator: · E-GAS actuator

109, - Signal
· Position of
116, Throttle valve
119, potentiometer accelerator pedal:
185, 1
position
kick down


value
Throttle valve · Position of

potentiometer accelerator pedal:
2 84 85 - Closed throttle 4.0 - 4.6 V
position
kick down
Þ 3.1 · Throttle · Ignition:ON 4.75 - 5.25 V · Cable
valve · ECU
actuator: 84 112
- Power
supply
Throttle
valve
potentiometer
1+2
104, Þ 4.0 · Throttle · Ignition:ON 0.8 - 2.3 V · ECU
105, valve · Engine:in idling The value will · Cable
108, actuator: - Coolant be changed in · E-GAS actuator
109, - Signal temperature: 1.0 - 2.5V.

116, > 70 °C
119, Throttle valve
185, actuator
· Ignition:OFF < 10 W
motor 68 67
voltage
supply
Throttle valve
actuator
motor 68 67
resistance

AIR CONDITIONER CONTROL SYSTEM TEST

Item Checking method Requirement value
code step
44, Þ 1.0 · Air · Engine:In idling ·Þ 5.1

45, conditioner · Air conditioner · Cable
signal: 10 44 switch:ON/OFF · Thermo amp
- Input signal Air conditioner <1V · Auto amp

(input signal switch:OFF · Dual pressure
from thermo switch

amplifier) Air conditioner 11 - 14 V · Air conditioner
switch:ON control panel
Þ 1.1 · Air · Engine:In idling
conditioner · Air conditioner
compressor: 10 27 switch:ON/OFF
- Output Air conditioner <1V
signal switch:OFF
switch:ON
Þ 2.0 · Condenser · Engine:In idling
fan(HI) · Air conditioner
control: 10 35 switch:ON/OFF
switch:OFF
switch:ON
Coolant temperature: <1V

above 150 °C

FUEL PRESSURE AND INTERNAL LEAKAGE TEST

Preparation
01 Pressure Tester
02 Pressure Hose
03 Measuring Beaker

2. Remove the air cleaner cross pipe.
3. Remove the cap on fuel pressure test plug and connect the
pressure hose and pressure tester.
4. Prepare the beaker for measuring the amount of fuel.
Tools Required
119 589 04 63 00 Pressure Hose


code step value
pressure:in pressure test plug to - Colse the valve · Fuel pressure

applied
pressure:in pressure test plug to - Colse the valve · Fuel pressure

not applied
Þ 3.0 · Fuel system Connect the fuel · Engine:stop > 3.0 bar · The pressure drops
internal pressure test plug to rapidly:non-return

leakage: the pressure tester valve in fuel pump
(refer to the flgure on
previous page).
· After 30 minutes > 2.5 bar · The pressure
from engine stop drops slowly:

- Injector test
- Fuel pressure
regulator
- O-ring

FUEL PUMP TEST

Preparation
1 ECU 03 Test Box

4 Stop Watch
5 Measuring Beaker

Tools Required
210 589 00 99 00 Adaptor Line
129 589 00 21 00 Test Box
210 589 08 63 00 Ecu Test Cable


code value
Þ 1.0 · Fuel pump: · Ignition:ON 1 liter of fuel ·Þ 2.0

- Fuel supply - Disconnect the fuel supply for · Fuel line
ratio 5 33 return pipe and max. 35
connect the host to seconds
beaker to collect
the supplied fuel
Þ 2.0 · Fuel pump: Multi tester(DC current) · Ignition:ON 5-9A · Fuel pump
- Current - Remove the fuel

3 1
consumption relay from the fuse
and relay box in
luggage
compartment and
connect the
amperemeter
between No.1 and
No.3 in relay
box(fuel pump relay
removed position)
for measuring
current
consumption

INJECTOR TEST
Preparation
1 ECU 03 Test Box

4 Measuring Beaker
5 Shop Made Cable

1. Connect the test box to the ECU as shown in the figure.
2. Remove the 2-pin coupling from injector.
3. Remove the fuel distributor and injector with a unit. At this
time, do not remove the supply and return line.
4. Connect the shop made cable to the injector with a firing
order.
5. Collect the fuel from injector.
Tools Required
129 589 00 21 00 Test Box
210 589 08 63 00 ECU Test Cable


code step value
Þ 1.0 · Injector: · Ignition:ON There should ·Þ 2.0

- Leakage - Remove the fuel be no leaks · Injector
test 5 33 distributor and fuel and later

injector with a unit. drops from
the injector
Þ 2.0 · Injector: · Ignition:ON The spray · Injector
- Function - Connect the shop pattern of the

test and 5 33 made cable to the injector most
spray injector. show in the
pattern - Collect the figure 10
check spraying fuel with a
beaker
- Connect the shop
made cable to
No.11(+) and No.5
(-) terminal in test
box.
Figure 8. Shop Made Cable Figure 9. Fuel Injector Normal Spary Pattern


ON-VEHICLE SERVICE
ECU
Appearance
1 Cover 5 Pin
2 Plate Vehicle side : number 13 - 60
3 Connector Engine side : number 73 - 120
4 Flat pin A Vehicle Connector : Black
Vehicle side : number 1 - 12 B Engine Connector : Gray
Engine side : number 61 - 72

Location
Engine ECU is located at the inside of cowl side trim in right
bottom of instrument panel of passenger side.

2. Disconnect the battery negative cable
3. Remove the cowl side trim form passenger side.
4. Unscrew four securing nuts for ECU from mounting bracket.
Installation Notice
5. Pulling out the ECU from bracket.

6. Disconnect the vehicle side coupling(B).
reverse order.

ECU Pin Numbers and Descriptions
Vehecle Connector
Pin No. Description Abbreviation
1 - -
2 Starter motor TM.50 TM.50
3 - -
4 - -
5 Electronic ground GND
6 - -
8 - -
13 Immobilizer crypto read WFS I/O
14 Immobilizer crypto write WFS O
15 - -
18 - -

21 Brake switch BRS

22 - -
23 - -
24 - -
25 - -
26 - -
27 Air conditioning clutch relay KLIKU
28 - -
29 - -
30 - -
32 Pedal potentiometer 1 supply SP1+5V
33 Fuel pump relay KP
34 Tank purge valve TEV
35 Engine fan(IGH) ML
36 - -
37 CAN-Low CAN L
38 CAN-High CAN H
39 - -
40 - -
41 - -
42 - -
43 - KPI
44 Air conditioning KLIMA
45 Electronic traction signal ETS
46 - -
49 Brake light switch BLS
51 Pedal potentiometer 2 supply SP2+2.5V
52 Cruise accelerate/Set S+B
53 Cruise resume WA
54 Cruise decelerate/Set S-B
55 Cruise safety contact switch KSK
56 - -
57 Cruise off switch AUS
58 Diagnostics(K-Line) DIAG
59 Vehicle speed signal V-SIG
60 Engine speed signal TN-SIG

Engine Connector

61 - -
62 - -
67 E-GAS motor plus M+
68 E-GAS motor minus M-
70 - -
71 Ignition coil cylinder 2+3 ZSB23
72 Ignition coil cylinder 1+4 ZSA14
73 Camshaft control NWS
74 EGR (Exhaust Gas Recirculation) EGR
75 - -
76 Second air pump relay SLP
77 - -
78 Engine coolant temperature MT
79 Intake air temperature ground GND
80 Intake air temperature LT

81 Hot film air mass signal HFM

82 - -
83 Pressure sensor supply V-REF.PS
84 E-GAS potentiometer ground -
86 - -
88 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 - -
98 - -
99 Crankshaft sensor ground KW-
100 Crankshaft sensor signal KW+
101 - -
102 Intake manifold pressure signal PSAUG
103 Intake manifold pressure ground GND
104 Camshaft sensor ground NOWE-
105 Hot film air mass ground GND
106 Camshaft sensor signal NOWE+
107 - -
108 Hot film air mass supply V-REF.HFM
109 - -
110 - -
111 - -
112 E-GAS potentiometer supply V-REF.DK
113 - -
114 - -
115 - -
116 - -
119 - -
120 - -

Application
E23 ENG, E23 ENG, E20 ENG,

5speed A/T 4speed A/T 4speed A/T
1 - - - - -
2 Starter motor TM.50 TM.50 l l l
3 - - - - -
4 - - - - -
5 Electronic ground GND l l l
6 - - - - -
7 Lambda probe 2 heating LSH2 - - -
8 - - - - -
9 Lambda probe 1 heating LSH1 l l l
10 Power ground TM.31 TM.31 l l l
11 V-BATTERY TM.87 TM.87 l l l
12 V-BATTERY TM.30 TM.30 l l l
13 Immobilizer crypto read WFS I/O l l l
14 Immobilizer crypto write WFS O l l l
15 - - - - -
16 Lambda probe 1 ground GND l l l
17 Lambda probe 1 signal LS1 l l l
18 - - - - -
19 - - - - -
20 - - - - -
21 Brake switch BRS ¡ ¡ ¡
22 - - - - -
23 - - - - -
24 - - - - -
25 - - - - -
26 - - - - -
27 Air conditioning clutch relay KLIKU l l l
28 - - - - -
29 - - - - -
30 - - - - -
l:Standard, ¡:Option


31 Pedal potentiometer 1 ground GND l l l
32 Pedal potentiometer 1 supply SP1+5V l l l
33 Fuel pump relay KP l l l
34 Tank purge valve TEV l l l
35 Engine fan ML l l l
36 - - - - -
37 CAN-Low CAN L l l l
38 CAN-High CAN H l l l
39 - - - - -
40 - - - - -
41 - - - - -
42 - - - - -
43 - - - - -
44 Air conditioning KLIMA l l l

45 Electronic traction signal(ABD option only) ETS ¡ ¡ ¡
46 - - - - -
47 Pedal potentiometer 1 signal SP1S l l l

48 Pedal potentiometer 2 signal SP2S l l l
49 Brake light switch BLS ¡ ¡ ¡
50 Pedal potentiometer 2 ground GND l l l
51 Pedal potentiometer 2 supply SP2+2.5V l l l
52 Cruise accelerate/Set S+B ¡ ¡ ¡
53 Cruise resume WA ¡ ¡ ¡
54 Cruise decelerate/Set S-B ¡ ¡ ¡
55 Cruise safety contact switch KSK ¡ ¡ ¡
56 - - - - -
57 Cruise off switch AUS ¡ ¡ ¡

58 Diagnostics DIAG l l l
59 Vehicle speed signal V-SIG l l l
60 Engine speed signal TN-SIG l l l


61 - - - - -
62 - - - - -
63 Injector-cylinder 1 EV1 l l l
67 E-GAS motor plus M+ l l l
68 E-GAS motor minus M- l l l
69 Power ground TM.31 TM.31 l l l
70 - - - - -
71 Ignition coil cylinder 2+3 ZSB23 l l l
72 Ignition coil cylinder 1+4 ZSA14 l l l
73 Camshaft control NWS l l l
74 EGR(Exhaust Gas Recirculation) EGR ¡ ¡ ¡
75 - - - - -
76 Second air pump relay SLP ¡ ¡ ¡
77 - - - - -
78 Engine coolant temperature MT l l l
79 Temperature ground GND l l l
80 Intake air temperature LT l l l
81 Hot film air mass signal HFM l l l
82 - - - - -
83 - - - - -
84 E-GAS potentiometer ground - l l l
85 E-GAS potentiometer 2 signal IP2S l l l
86 - - - - -
87 E-GAS potentiometer 1 signal IP1S l l l
88 - - - - -
89 - - - - -
90 - - - - -


Pin No. Description Abbreiation
91 - - - - -
92 - - - - -
93 - - - - -
94 - - - - -
95 - - - - -
96 - - - - -
97 - - - - -
98 - - - - -
99 Crankshaft sensor ground KW- l l l
100 Crankshaft sensor signal KW+ l l l
101 - - - - -
102 - - - - -
103 - - - - -
104 Camshaft sensor ground NOWE- l l l
105 Hot film air mass ground GND l l l
106 Camshaft sensor signal NOWE+ l l l
107 - - - - -
108 Hot film air mass supply V-REF.HFM l l l
109 - - - - -
110 - - - - -
111 - - - - -
112 E-GAS potentiometer supply V-REF.DK l l l
113 - - - - -
114 - - - - -
115 - - - - -
116 - - - - -
117 Knock sensor 1 ground GND l l l
118 Knock sensor 1 signal KS1 l l l
119 - - - - -
120 - - - - -

· When removing the ECU only
4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly
bracket and remove the auxiliarly bracket from the bracket
assembly (2).
Installation Notice
(1) 6 - 8 Nm
Tightening torque
(3) 5 - 7 Nm
5. Unscrew the four bolts (5) and disconnect the ECU (6) from
the bracket assenbly.
Installation Notice
Tightening torque 5 - 7 Nm

reverse order.
· When Removing the ECU with ABS or ABS/ASR Unit

4. Disconnect the coupling from ABS or ABS/ASR unit.
5. Unscrew the bolt (1) and the left and right flange nuts.
6. Remove the ECU with ABS or ABS/ASR unit assembly.

7. Unscrew the left and right bolt (3) on the auxiliary bracket
and remove the auxiliary bracket from the bracket assembly.
Installation Notice
8. Unscrew the bolts (5) and disconnect the ECU (6) from the
bracket assenbly.
Installation Notice

reverse order.

FUEL PRESSURE REGULATOR
1 Vacuum Hose 4 O-ring ..................................................... replace

2 Circlip 5 O-ring ..................................................... replace

2. Discharge the pressure in fuel supply system by pressing

the service valve.
3. Disconnect the vacuum hose.

4. Disconnect the circlip and remove the fuel pressure
regulator.
5. Apply the oil to O-ring lightly and then replace it.
reverse order.
7. Check for fuel pressure and internal leaks by operating the
engine.

Function of the Fuel Pressure Regulator
The fuel pressure regulator maintains the fuel pressure in the
fuel line with the pressure of 3.2 bars to 3.8 bars according to
the intake manifold pressure. This operating pressure cannot
be changed, and the fuel injection volume will be only
determined by the injection time. Over supplied fuel returns to
the fuel tank through the return line.
<Operating at full load>
There is no negative pressure applied to the spring chamber(9)
during the full load, and it is separated from the fuel chamber(8)
by the diaphragm(5).
When the fuel pressure goes up, the diaphragm forces the
compression spring(6) in the direction of compression . At this
moment, the valve(3) sticks to the diaphragm by the fuel
pressure, and the fuel return line(2) opens. The fuel over
supplied returns to the fuel tank through the return line.
2. Fuel return line

3. Valve
5. Diaphragm
6. Compression Spring
8. Fuel chamber A. Valves Closed
9. Spring Chamber B. Valves Opened
The pressure difference between the fuel pressure and the

intake manifold is about 3.8 bars during the full load.
1. Fuel pressure Regulator

2. Intake Manifold
3. Fuel return(to fuel tank)
4. Fuel supply(form fuel pump)
5. Fuel pressure(approx. 3.8 bars)
6. Intake Manifold Negative Pressure(0 bar)
<Operating at Idle and partial load>

The spring chamber(9) is connected to the intake manifold
with the vacuum hose at the intake pipe connection(7). The
negative pressure generated in the intake manifold activates
the diaphragm, and thus the fuel pressure gets reduced to the
rate of the operating extent of the diaphragm by the intake
manifold's negative pressure.
Consequently, the fuel pressure in the fuel distributor changes
by the intake manifold's negative pressure, and the injector's
fuel pressure gets reduced independently to the throttle valve's
position. Thus, the fuel injection volume can only be determined
according to the injector's injecting duration.

The pressure difference between the fuel pressure and
the intake manifold is approx. 3.2 bars during idling.
1. Fuel pressure Regulator

2. Intake Manifold
4. Fuel Supply(from fuel pump)
8. Intake Manifold Negative Pressure(0.6 bars)
<Fuel Pressure Diagram>
A. Fuel pressure
B. Intake Manifold Negative Pressure
LL. Idling
TL. Partial load
VL. Full load

FUEL DISTRIBUTOR
1 Fuel Distributor 9 Fuel Return Line

2 Circlip 10 Seal Ring
3 Fuel Pressure Regulator 11 Hollow Bolt ..................................... 22.5-27.5 Nm
4 O-ring 12 Clamp
5 Fuel Pressure Test Connector 13 Bolt (M8 X 22) ........................................ 9-11 Nm
6 Seal Ring 14 Injector Bracket
7 Vacuum Hose 15 Injector
8 Combination Bolt (M8 X 120) ......... 22.5-27.5 Nm 16 O-ring

1. Discharge the fuel pressure from the fuel pressure test
connector by pushing service valve (arrow).
3. Disconnect the vacuum hose from the fuel pressure

regulator.
4. Disconnect the cable from ignition coil.
5. Remove the fuel return and supply line.

Installation Notice
Notice
l For removal, cover around parts with cloths not to
bestained by fuel.
l In case of checking the injector only, do not remove the
fuel return and supply line.
6. Remove the four injector connectors (arrows).
7. Unscrew the two combination bolts (8).

Installation Notice

8. Pull out the injector from intake manifold and remove the
fuel distributor.
Notice
Replace the injector O-ring with new one.

reverse order.
10. Check for fuel pressure and internal leakage by operating

the engine.
Ignition Coil & Cable

l Ignition coil T1/1 No.1 cylinder + No.4 cylinder
l Inition coil T1/2 No.1 cylinder + No.4 cylinder

Fuel Pressure Test

connector.
4. Test the fuel pressure at idling by operating the engine.
Vacuum Hose Connected (bar) 3.2 - 3.6
Vacuum Hose Disconnected (bar) 3.7 - 4.2
5. Replace the pressure regulator diaphragm if out of the
specification.

Internal Leakage Test
connector.
2. Stop the engine for approx. 30 minutes and then check the
fuel pressure changes.
Pressure Change Possible Cause
· Fuel leakage at the
Fuel pressure injector
• Faulty fuel pressure
drops slowly regulator's
diaphragm and O-
ring.
Fuel pressure • Faulty check valve

drops rapidly in the fuel pump.
3. If there is no change in fuel pressure and maintain the

following pressure over 30 minutes, it is normal.
Fuel Pressure(bar) 2.5
Discharging the pressure in fuel system

Installation Notice
2. Remove the fuel pressure in fuel system by pressing the

service valve with a clean, pointy tool.
Notice
Place a cloth so that the fuel doesn't stain around.

INJECTOR
Preceding Work : Removal of fuel distributor
1 O-ring ................................. Replace, if damaged 4 O-ring ................................. Replace, if damaged

2 Injector Bracket 5 Fuel Distributor
3 Injector

Check for damage and replace it if necessary.
2. Remove the injector bracket from the injector.
Installation Notice
Exactly seat the anti-twist lock into the square groove in
injector.
3. Separate the injector from the fuel distributor.
Inspection & Maintenance
Inspection of the Injector operation and spray pattern
1. Connect the contact box to the ECU.
2. Connect the shop made test plug to the injector and place
it into the tank.
3. Position the ignition switch to ON.
4. Connect the pin No.11 and No.5 of the contact box with a
test cable.
5. Check the injector spray pattern.
Notice
Replace the injector if the injector spray pattern is abnormal
or the fuel doesn't inject.
Injector Resistance Inspection
1. Remove the injector connector.
2. Measure the injector coil resistance using a resistance
tester.
Notice
Replace the injector if the measured values is out of the
specified values. Check the connector and wire connection
between the ECU and the injector if the measured values
are normal.

The Injector Spray Pattern Check
1. Connect the test box (129 589 00 21 00) to the ECU.
2. Disconnect the connector from connector.
3. Disconnect the fuel distributor and injector with a unit from
engine without removing the fuel supply and return line.
Notice
Prepare the beaker for taking the poping fuel.
4. Connect either end of shop made cable to the injector.
5. Connect the other end of shop made cable to the No.11
and No.5 terminal of the test box.
7. Check the injector for normal spray pattern as shown in the
figure. Check injector for leaks or later drops.
Notice
Refer to fuel injector test of engine diagnosis in this section
for detailed information.

FUEL FILTER
2 3
1 Fuel Filter 3 Inlet

2 Outlet

1. Open the fuel tank cap and remove the fuel tank pressure.
2. Remove the fuel out (2) and in (3).
Installation Notice
3. Remove the mounting bracket bolt (4) and remove the fuel
filter (1).
Installation Notice
Notice
Place the fuel pump pad. There may be a corrosion due to
the contact between the fuel filter and the bracket.
Notice
Installation should follow the removal procedure in the
reverse order.

FUEL PUMP
1 Reservoir Tank
2 Fuel Sensor (float/arm)
3 Resistance
4 Wiring Connector
5 Fuel Supply Pipe
7 Float
10 Flange and Harness Assembly
11 Fuel Pump
12 Spring
13 Thermister Housing
14 Thermister
15 Resistor Card and Wiper
16 Float Arm
Requirements for Fuel Pump
Item Specified Value Item Specified Value
System pressure 3.8 bar Minimum delivery at 8V 30 Litre/Hr
Maximum pressure 8.5 bar (12 V) Operating voltage 8V
Minimum pressure 5.0 bar (12 V) Maximum allowable current 7.5 A
Nominal voltage 12 V Ambient temperature -30 ~ +70°C
Minimum amount 114 Liter/Hr (12 V, 3.8 bar, - Maximum amount 165 Liter/Hr (12V, 3.8 bar,
of fuel supply 30 ~ +70°C) of fuel supply -30 ~ +70°C)

1 Fuel Pump Connector Wiring 5 Fuel Return Pipe

2 Fuel Return Pipe 6 Fuel Supply Pipe
3 Fuel Supply Pipe 7 Float
4 Bolts 8 Ground Stud (Sender "-")
Harness Location & Connector COLOR USE

1 A Pump "+" 2.0 BR
2 B Thermister "+" 0.5 W
3 C Ground 2.0 B
4 D Sender Unit "+" 0.5 RY

Tools Required
661 589 00 46 00 Cap Remover

2. Disconnect the harness connector (1).
3. Disconnect the fuel supply (6) and return (5) pipes.
4. Using a special tool, Unscrew the eight fuel retaining bolts
and remove the pump from fuel tank.
Notice
Check the condition of the seal and replace if necessary.
Drain the fuel before removing the pump.

Measure the Fuel Delivery From the Fuel Pump
1. Disconnect the return pipe from fuel distributor and insert
the appropriate hose into it.
2. Place the hose end into the beaker with the minimum capacity
of 1Liter.
4. Connect the terminal No.33 and No.5 of ECU with a service
wire.
5. Measure the fuel delivery from the fuel pump.
Specifed Value 1Liter/max.35sec.

Notice
Check the fuel filter and fuel line when the fuel delivery is
not within specified value.
Measure the Current Consumption of Fuel Pump
1. Remove the fuel pump relay from fuse and relay box in
trunk, and turn the ignition switch to "ON" position.
2. Using a multi-tester, measure the current consumption by
connecting the terminal No.1 and No.3.
Specifed Value 5-9

Notice
Replace the fuel pump relay if the measured value is over
9A.

PURGE SWITCHOVER VALVE
1 Purge Control valve

2 Line to engine
3 Line to canister
4 Canister
Functions
The fuel vaporization control system is installed to inhibit the
fuel vaporized gas from discharging into the atmosphere. The
fuel vaporized gas that is accumulated in the canister abstracts
through the purge switchover valve purification during the
engine combustion (except the decreasing mode) and coolant
temperature of over 80°C. For this reason, the ECU transacts
the engine speed, air inflow quantity, coolant temperature, and
intake temperature.
The purge switchover valve is activated by the ECU frequency
according with the engine rotating speed to adjust the
purification rate. The purification rate is determined by the
continuous valve opening interval.
The purge switchover valve is activated by the ECU for the
following conditions :
l Coolant temperature of over 80°C
l Engine speed of over 1000rpm
l 2 Minutes after starting
l When the fuel cut-off mode is not activated

Test
1. Maintain the normal temperature and idling state by
normal operation through the output waves using the
scanner.
Notice
Test during purge control switchover valve operation after
the minimum of 1 minute after the engine turned on.
current consumption during the ignition switch ON.
Specified Value 0.3 - 0.5 Purge switchover valve output wave
4. Remove the line to canister and measure the pressure with
the vacuum pressure gauge.
> 50mbar
(after approx. 1min.)
Specified Value
purge switchover valve
operates at this time
Notice
Test while at normal temperature and at idling state by

VACUUM SYSTEM
Manual Transmission
1 Purge Switchover Valve 8 Fuel Pressure Regulator

2 Molded Hose 9 Vacuum Line Rubber Hose (40 mm)
3 Fuel Tube (270 mm) 10 Vacuum Tube (Gray, 540 mm)
4 Clamp 11 Rubber Cap
5 Molded Hose 12 Molded Hose
6 Intake Manifold 13 Vacuum Tube (Brown)
7 Throttle Body 14 Connector

Automatic Transmission
15 Manual Transmission A. To Canister

16 Distributor B. To Auto Locking Hub

CRANKSHAFT POSITION SENSOR
1 Crankshaft Position Sensor (connector) 3 Sensor Unit

2 Bolt (M6 X 14) ........................................ 9-11 Nm

1. Disconnect the wiring connector at the crankshaft position
sensor.
2. Unscrew the bolt (2) and remove the crankshaft position
sensor unit (3).
Installation Notice

reverse order.

Crankshaft Position Sensor Resistance
Inspection
1. Disconnect the coupling "E" of ECU while the ignition switch
is in "OFF" position.
No.99 and No.100 using a multimeter.
Notice
Measure the insulator resistance of the crankshaft position
sensor if out of the specified value.
Crankshaft Position Sensor Output Wave

Inspection
2. Measure the output wave between the ECU terminals No.99
and No.100 using the scanner or the oscilloscope while
engine cranking (starter motor activated).
Notice
Check the segment or crankshaft position sensor and air
gap if cannot get the output wave as shown in the figure.
Crankshaft Position Sensor Insulator Resistance

Inspection
1. Disconnect the engine coupling from ECU while the ignition
switch is in "OFF" position.
No.100 and No.69.
Specified Value > 20kW
Notice
Measure the check and ground terminal of the crankshaft
position sensor if out of the specified value.

CAMSHAFT POSITION SENSOR
1 Bolt (M6 X 14) ......................................... 9-11Nm 3 Shim

2 Camshaft Position Sensor 5 O-ring

1. Disconnect the wiring connector from the camshaft position
sensor.
2. Unscrew the bolt (2) and remove the camshaft position
sensor.
Installation Notice
3. Check the clearance and replace the shim if necessary.

4. Check the O-ring for damage and replace it if necessary.
reverse order.

Camshaft Position Sensor Signal Voltage
Inspection
2. Measure the voltage between the ECU terminal No.11 and
No.106 while the engine speed is at idle.

Notice
The signal voltage will be changed in the range of 1.2-1.7V.
Camshaft Position Sensor Output Wave

Inspection
2. Measure the output wave between the ECU terminal No.104
and No.106 using the scanner or the oscilloscope while the
engine speed is at idle.
Notice
Replace the camshaft position sensor if cannot get the
output wave as shown in the figure.
Camshaft Position Sensor Power Supply

Inspection
2. Disconnect the camshaft position sensor connector.
3. Measure the voltage between the No.1 and No.3 pin of
camshaft position sensor while the ignition switch is in "ON"
position.
Notice
If the measured value is not within the specified value, check
the cable.

HOT FILM AIR MASS (HFM) SENSOR
1 Housing 4 Connector
2 Protector Net 5 Hot film Sensor
3 Electronic Housing 6 Measuring Port

1. Turn the HFM sensor coupling in the direction shown in the
figure in the right so that it gets separated from the contact
surface.
Notice
Make sure the HFM sensor coupling connects completely
with the contact surface Installation.
2. Remove the clip with a screw driver.
3. Pry off two tensioning clamps.
4. Remove the HFM sensor.
reverse order.

Circuit Diagram
1 Housing
2 Electronic Housing
3 Connector
RH : Heat Resistance
RT : Temperature Resistance
RS : Sensor Resistance

HFM Sensor Input Voltage Inspection
1. Measure the HFM sensor signal voltage between the ECU
terminal No.81 and No.105.
Specified Value (coolant temperature is over 70°C)
Iginition"ON” 0.9 - 1.1 V
Engine at idle 1.3 - 1.7 V
possible cause may be in cable or HFM sensor in itself.
Perform the 5V power supply inspection procedures.


possible cause may be in cable or ECU coupling.

possible cause may be in cable or over voltage protection
relay.

OXYGEN SENSOR
1 Electricity Wire
2 Oxygen Sensor Housing
3 Sensor Ceramic
4 Electrode (Internal)
5 Electrode (External)
6 Heating Coil
7 Open Space
8 Protector Tube
Functions
The oxygen sensor optimizes the combustion (Air-Fuel Ratio
14.7:1) and resets the Air-fuel ratio in the ECU after sensing
the amount of oxygen from the exhaust gases to diminish the
exhaust gases.
- Rich(<1) above approx. 450mV
- Lean(>1) below approx. 450mV
Locatoin of Sensor
Oxygen sensor is located on the front exhaust pipe.

Oxygen Sensor Signal Voltage Inspection
1. Measure the oxygen sensor signal voltage between the ECU
terminal No.11 and No.9. Maintain the engine speed ia at
idle while the coolant temperature is over 80°C.
Specified Value -0.2 - 1.0 V

Oxygen Sensor Heating Voltage Inspection

1. Measure the oxygen sensor heating voltage between the
ECU terminal No.11 and No.9. Maintain the engine speed ia
at idle while the coolant temperature is over 80°C.
Specified Value 11 - 14
Oxygen Sensor Heating Current Consumption

Inspection
1. Measure the oxygen sensor heating current consumption
between the ECU terminal No.9 and No.5 while the ignition
switch is in "ON" position.
Specified Value 0.2 - 2.0 A

KNOCK SENSOR
Functions
Vibration of the engine block is transmitted to the sensor and
transferred to the ECU in the form of an alternating voltage
signal via a shielded cable. The knock sensor is fastened to
the engine block to recognize knocking in all cylinders. The
ECU compares the signal and the retards firing point.

1. Disconnect the knock sensor connector from the intake
manifold bracket.
2. Unscrew the mounting bolt (M8 X 28) from the knock sensor
installed on the cylinder block and remove the knocking
sensor.
Installation Notice

reverse order.

COOLANT TEMPERATURE SENSOR
1 Artificial Resin Housing 4 Connector

2 Metal Housing 5 Coolant Temperature Sensor
3 NTC (negative temperature coefficient) Resistor

1. Remove the pressure by opening the pressure cap in the
coolant subtank.
2. Disconnect the connector and remove the coolant
temperature sensor.
Installation Notice
Replace the seals with new one.

reverse order.
4. Check for leaks at each connections after starting the engine.

Inspection
1. Measure the coolant sensor input voltage between the ECU
terminal No.79 and No.78 while the ignition switch in "ON"
position.
Temperature (°C) Voltage (V)
20 3.57
30 1.22
40 0.78
2. Measure the resistance between the coolant temperature

sensor terminal No.1 and No.4 with the coolant temperature
sensor disconnected.
Temperature (°C) Resistance (W )
20 2,500
30 322
40 185
Notice
Replace wiring and coolant temperature sensor if out of
specified value.

Service Data
Temperature(°C) Resistance(W) Voltage(V) Temperature(°C) Resistance(W) Voltage(V)
-40 48,550 4.8991 60 594 1.8632
-30 27,000 4.8214 70 434 1.5132
-20 15,670 4.7001 80 322 1.2179
-10 9,450 4.5215 90 243 0.9775
0 5,890 4.4273 100 185 0.7806
10 3,790 3.9562 110 143 0.6255
20 2,500 3.5714 120 111.6 0.5020
30 1,692 3.1426 130 88.0 0.4044
40 1,170 2.6959 140 71.2 0.3323
50 826 2.2618 - - -
Resistance characteristic curve according to the coolant

temperature

ACCELERATOR PEDAL MODULE
1 Accelerator Pedal 4 6-Pin Connector

2 Accelerator Pedal Sensor 5 Kick down Switch
3 Bolts (2 Pieces) ....................................... 4-8 Nm 6 Nut (1 piece) ............................................ 4-8 Nm

1. Disconnect the 6-pin connector(arrow).
2. Unscrew the 2 bolts (3) / 1 nut (6) and remove the pedal
and sensor assembly.
Installatoin Notice
Tightining Torque 4 - 8 Nm
reverse order.

Accelerator Pedal Sensor Connector(Sensor Side)
Potentiometer 1.
Pin no. 3 :Red
Pin no. 1 :Yellow
Pin no. 5 :Brown
Potentiometer 2.
Pin no. 6 :Violet
Pin no. 4 :Green
Pin no. 2 :White
Accelerator Pedal Sensor Connector(Vehicle Side)

Potentiometer 1.
Pin no. 3 :Red-Black
Pin no. 1 :Blue-Green
Pin no. 5 :Yellow-Green
Potentiometer 2.
Pin no. 6 :Green
Pin no. 4 :Blue-Red
Pin no. 2 :LightGreen
Function
Circuit Diagram
Potentiometer 1.
Potentiometer 2.

SECTION 1F3
OM600 ENGINE CONTROLS

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F3-1 Idle Speed Adjustment . . . . . . . . . . . . . . . . 1F3-16
Fastener Tightening Specifications . . . . . . . . 1F3-1 Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F3-18
Maintenance and Repair . . . . . . . . . . . . . . 1F3-2 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-21
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F3-2 Injection Nozzle Test . . . . . . . . . . . . . . . . . . 1F3-22
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-2 Injection Nozzles . . . . . . . . . . . . . . . . . . . . . 1F3-25
Fuel Injection Pump Coding . . . . . . . . . . . . . 1F3-3 Injection Nozzle Repair . . . . . . . . . . . . . . . . 1F3-27
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-4 Removal and Installation of
Injection Timing Device . . . . . . . . . . . . . . 1F3-30
Vacuum Control System Test . . . . . . . . . . . . 1F3-5
Injection Timing Device . . . . . . . . . . . . . . . . 1F3-35
Vacuum Pump(Sectional View) . . . . . . . . . . 1F3-10
Start of Delivery Test
Vacuum Pump Test . . . . . . . . . . . . . . . . . . . 1F3-11
(Position Sensor, RIV Method) . . . . . . . . . 1F3-37
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . 1F3-13
Fuel Injection Pump . . . . . . . . . . . . . . . . . . 1F3-46
Vacuum Unit Replacement . . . . . . . . . . . . . 1F3-15
SPECIFICATIONS
Application N·
·m
Fuel Tank Mounting Nut 28 - 47
Fuel Pump Pressure Line 13
Fuel Injection Nozzle 35 - 40
Fuel Injection Pipe 18
Nozzle Tensioning Nut 80
Screw Plug 30
Left-Hand Thread Bolt 46

1F3-2 OM600 ENGINE CONTROLS

ON-VEHICLE SERVICE
FUEL SYSTEM
1 Fuel Injection Pump 6 Fuel Return Hose

2 Fuel Feed Pump 7 Injection Line
3 Overflow Valve 8 Fuel Tank
4 Injection Nozzle 9 Fuel Filter
5 Pre-filter 10 Choke Orifice

OM600 ENGINE CONTROLS 1F3-3
FUEL INJECTION PUMP CODING

Model Code
OM661 LA Engine PES 4M 55C 320 RS 167
OM662 LA Engine PES 5M 55C 320 RS 168
Fuel Injection Pump Code

Example) PES 5M 55C 320 RS 168
P Pump
E Self-Driven
S End Flange Mounting
5 Number of Cylinders (5EA)
M Pump Size
55 Element Diameter
C Modification Letter
320 Assembly Number
R Direction of Rotation (clockwise)
S188 Special Version
RSF Governor
R Governor
S Coil Spring
F Drive Governor
Component Location
1. Fuel Injection Pump
2. Vacuum Unit (Stop Unit)
3. Control Lever
4. PLA Vacuum Unit (Idle Speed Adjustment)
5. Governor
6. Fuel Pump

FUEL TANK
1 Fuel Tank 8 Fuel Return Tube

2 The Sender of Fuel Tank 9 Filter Hose
3 2-way Check Valve 10 Fuel Tank Hose
4 Pre Filter 11 Fuel Filler Cap
5 Front Fuel Filler Neck 12 Clip
6 Rear Fuel Filler Neck 13 Clip
7 Fuel Supply Tube

VACUUM CONTROL SYSTEM TEST
2 Engine Cut-Off Valve (Ignition Key Switch) 8 30° Thermovalve

3 Auto-locking Hub Solenoid Valve 9 Fuel Injection Pump
4 Engine Stop Valve Unit 10 Filter with Restriction
5 PLA Vacuum Unit (Idle Speed Adjustment) 11 Check Valve
6 Engine 12 Modulating Pressure Line (Automatic T/M)
7 Vacuum Pump
Test Data
Idle Speed Increase At least 100 rpm at approx. 500mbr
Permissible Pressure Drop of System 400 - 500mbar approx. 1 min.

Tools Required
001 589 73 21 00 Vacuum Pump
201 589 13 21 00 Vacuum Tester
667 589 00 21 00 TDC pulse generator
Commercial Tools
e.g. Bosch MOT 001.03
Digital tester
Sun DIT 9000
e.g. Ahlborn, Therm 2263-2
Temperature measuring instrument with test probe
Eichenfeldstrabe 1 - 3
WB24
D-8150 Holzkirchen
Tester Connection
11 TDC Pulse Sender Unit

12 Digital Tester

Test step 1
Connect vacuum pump (14) with Y adapter to PLA

vacuum unit (5). Run engine at idle speed.
Vacuum >
= 500 mbar
YES NO
Lines and connections leaking.

Faulty PLA vacuum unit.
(Remove the connection hose from vacuum pump)
Connect vacuum pump (14) direct to PLA vacuum unit

(5) and pressurize with vacuum.
Vacuum is built up and idle speed increases approx.

150-200 rpm
YES NO
Faulty PLA vacuum unit
(Coolant Temperature 30°C)
Stop the engine Seal the air admission line with plug.
Connect the vacuum pump to line to thermovalve and
pressurize the line with vacuum.
Vacuum is built up.
YES NO
Lines and connectors leaking.

Faulty thermovalve.

Detach line downstream of air admission filter (13).

Vacuum drops.
YES NO
Faulty thermovalve
Fit the line onto air admission filter. Built up vacuum with
vacuum pump. Detach the plug from air admission line.
Vacuum drops.
YES NO
Faulty filter with restriction.
Go to test step 2.

Test step 2
Connect vacuum pump (14) with Y adapter to PLA
vacuum unit (5). Run the engine at idle speed.
Vacuum drops to ‘0’ at approx. 30°C of the thermovalve.
YES NO
Faulty thermovalve.
Defective filter with restriction.
Stop the engine. Detach the filter with restriction.
Filter with restriction is clear.
YES NO
Defective filter with restriction.

VACUUM PUMP (SECTIONAL VIEW)
2 Suction Valve 16 Roller Cam

4 Piston 17 Piston Rod
5 Pressure Valve 21 Inner Return Spring
6 Safety Valve 23 Upper Spring Retainer
7 O-Ring 28 Piston Ring
8 Pump Housing 30 Seal Ring
9 Pump Cover 31 Oil Return Valve
12 Lever 32 Restrictor
14 Outer Return Spring SB To Brake Booster
15 Inner Spring Retainer SK To Vacuum Lines

VACUUM PUMP TEST
1 Fuel Filter 3 Ancillaries Connection

2 Vacuum Line 4 Vacuum Tester
Tools Required
201 589 13 21 00 Vacuum Tester

Test Procedure
1. Remove the fuel filter (1) and keep the filter not to be
damaged from running engine.
2. Remove the vacuum line (2) from ancillaries connection (3).

3. Connect the vacuum tester (4) to the ancillaries connection
(3).
Vacuum Tester 201 589 13 21 00

4 Run the engine at idle and check vacuum pressure after 30
sec.
Standard > 70 mbar
Notice
If out of standard, replace the vacuum pump.
5. Remove the vacuum tester.
6. Connect the vacuum line to the ancillaries connection.
7. Install the fuel filter.

VACUUM PUMP
Preceding Work : Remove the poly V-belt
1 Bolt ............................................................ 10Nm 4 Vacuum Line (Brake Booster)

2 Vacuum Pump 5 Gasket ................................................... Replace
3 Vacuum Line (Ancillaries)

1. Remove the vacuum line (3, 4).
2. Remove the bolts (1) evenly.

Notice
If necessary, rotate the engine until the pressure on the
tappet of the vacuum pump is released.
3. Remove the vacuum pump (2).
4. Install the vacuum pump (2).
Notice
Clean the gasket residues of sealing surface of vacuum
pump and replace the gasket(5).
5. Connect the vacuum line (3, 4).

VACUUM UNIT REPLACEMENT
1 Bracket
2 Bolt
3 Vacuum Unit
4 Vacuum Line
5 Seal .............................................. Replace

IDLE SPEED ADJUSTMENT

Service Data
Engine Idle Speed
OM661LA Engine 750 - 850 rpm
OM662LA Engine 720 - 820 rpm
Tools Required
667 589 00 21 00 TDC Pulse Generato
Commercial Tool
e.g. Bosch, MOT 001.03
Digital tester
Sun, DIT 9000
Adjustment
1. Connect the digital tester (1) and TDC pulse sender unit
(11).
2. Run the engine and warm up the coolant to 60~80°C.
TDC pulse generator 667 589 02 21 00
3. Disconnect the vacuum hose (4) from the PLA unit to check
idle speed with tester.
4. Check idle speed with tester.
OM 661LA Engine 750 - 850rpm

OM 662LA Engine 720 - 820rpm
Notice
To adjust idle speed, loosen the locking nut (6) of PLA unit.

5. Ensure not to damage the idle spring in the governor and
adjust idle speed by turning the PLA unit (5) slowly.
Clockwise RPM Decrease
Counterclockwise RPM Increase
Notice
Do not rotate the PLA unit over ½ turn from the position
marking. If do, idle spring in the governor will be severely
damaged.
6. After adjustment, tighten the locking nut and place the

position marking with different color of paint.
Notice
If there are no changes in idle speed with PLA unit
adjustment, perform the service at a BOSCH Service Center.
7. Connect the vacuum pump to the PLA vacuum unit and

build up vacuum approx. 500mbar. If engine rpm increases
by approx. 100rpm, It is normal.
Vacuum Pump 001 589 73 21 00
8. Connect the vacuum line (4).

9. Switch on all ancillaries and check the idle speed.

FUEL PUMP TEST

Notice
Before test, replace the fuel filter cartridge and fuel prefilter.
Fuel Feed Test
1. Disconnect the fuel return line (1) and seal up it with plug.
2. Insert the plastic hose (5) and put the end into the measuring
beaker (6).
3. Disconnect the vacuum line (4) from vacuum unit (engine

stop) (5) and connect the vacuum pump (7) to the vacuum
unit.
4. To avoid the engine starting, build up vacuum (approx. 500
mbar).
5. Operate the starter motor for exactly 30 seconds and
measure fuel volume in the beaker.
3
Min. volume 150cm for 30 seconds

Fuel Pressure Test

Tools Required
617 589 04 21 00 Tester
1. Disconnect the fuel line (2) from the fuel filter.

2. Remove the banjo bolt (4) from the fuel injection pump and
remove the seals (3) and fuel line (2).
3. Connect the tester (5).
4. Start the engine and read off the fuel pressure on tester
(5).
Notice
At idle Speed > 0.3bar
At full load > 0.5bar
If out of standard, replace the fuel feed pump.
Tester 617 589 04 21 00
5. Stop the engine.
6. Remove the tester.

7. Replace the seal and connect the fuel line (2).

FUEL PUMP
1 Fuel Injection Pump 5 Gasket ................................................... Replace

2 Pressure Line ............................................ 13Nm 6 Spring Lock Washer
3 Suction Line 7 Hexagon Nuts
4 Hose Clip ............................................... Replace 8 Fuel Pump

INJECTION NOZZLE TEST

Preceding Work : Removal of fuel injection nozzle
1. Fuel Injection Nozzle ............. New : 115 - 125bar 2 Tester

Used : min. 100bar 3 Valve
A Closed Spray = good
B Stringy Spray = poor

Tools Required
000 589 14 27 00 Tester
Notice
When testing the injection nozzle, do not place your hand into
the spray of a nozzle. The spray will penetrate deep into the
skin and destroy the tissue.
1. Connect the fuel injection nozzle to the tester (2).
Tester 000 589 14 27 00
2. Close the valve (3) and pump 5 times strongly.
3. Chatter test :
Slowly operate the hand lever at tester (approx. 1 stroke
per second). The nozzle must spray with a gentle chattering.
4. Spray pattern test :

Operate the hand lever at tester rapidly (approx. 2~3 strokes
per second).
l Good
The spray pattern shows closed and well atomized.
l Poor
The spray pattern shows split, too wide and stringy.
(Repair the fuel injection nozzle)

5. Opening pressure test :
Open the valve (3) and slowly operate the hand lever at
tester (approx. 1 stroke / second) and measure opening
pressure.
New Nozzle 115 - 125bar
Used Nozzle Min. 100bar
Difference Between Nozzles Max. 5bar
Notice
If out of standard, repair the injection nozzle.
6. Leak test
Slowly operate the hand lever at the tester until get a
pressure of approx. 90bar. Maintain this pressure for more
than
20 seconds and within this period no drop of fuel should
build up at the nozzle tip.

INJECTION NOZZLES
1 Fuel Injection Nozzle ............................. 35-40Nm

2 Fuel Return Hose
3 Plug
4 Nozzle Washer ....................................... Replace
5 Fuel Injection Pipe ..................................... 18Nm

Tools Required
001 589 65 09 00 Serration Wrench

1. Remove the plastic clip from the injection pipe
2. Remove the fuel return hose.
3. Disconnect the injection pipes from the injection nozzles and

push them to the side.
Serration Wrench 001 589 65 09 00
Notice
Replace the washers.

reverse order.
Notice
Pay attention to the installation position of new nozzle washer
and tightening torque

INJECTION NOZZLE REPAIR

Preceding Work : Removal of fuel injection nozzle
1 Nozzle Holder 5 Intermediate Disc

2 Steel Washer 6 Nozzle Needle
3 Compression Spring 7 Nozzle Body
4 Thrust Pin 8 Nozzle Tensioning Nut ................................ 80Nm

Tools Required
000 589 00 68 00 Cleaning Set
Repair Procedure
1. Clamp the nozzle holder (1) in a vice and remove the nozzle
tensioning nut (8).
Notice
Use protective jaws for clamping.
2. Disassemble the fuel injection nozzle.

3. Clean the nozzle needle (6) and nozzle body (7) with an
abradant.
4. Clean the nozzle seat with cleaning cutter.
Cleaning Set 000 589 00 68 00
5. Immerse nozzle needle (6) and nozzle body (7) in filtered

diesel fuel. When the nozzle body is held vertical, the weight
of the nozzle needle must cause it to slide down toward the
nozzle needle seat.
6. Assemble the injection nozzle so that the tip of the thrust

(4) pin is facing toward the nozzle holder.
Notice
Nozzle needle (6) and nozzle body (7) should always be
replaced as a pair.

7. Check the fuel injection nozzle and adjust opening pressure
if necessary.
Opening pressure adjustment

Disassemble the fuel injection nozzle and replace the steel
washer (2).
Notice
Each 0.05mm thickness of the washer results in a pressure
difference of approx. 3bar.

REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE

Preceding Work : Removal of vacuum pump
1 Cylinder Head Cover 10 Washer

2 Bolt ............................................................ 10Nm 11 Bolt (Left-Hand Thread) ............................. 46Nm
3 Gasket ................................................... Replace 12 Camshaft Sprocket
4 Fuel Injection Pump 13 Washer
5 Seal ....................................................... Replace 14 12-Sided Stretch Bolt ............ Check, 25Nm + 90°
6 Screw Plug ................................................. 30Nm 15 Timing Chain
7 Oil Pan 16 Seal
8 Locking Pin 17 Chain Tensioner ......................................... 80Nm
9 Injection Timing Device

Tools Required
601 589 00 08 00 Flange
601 589 05 21 00 Locking Screw
667 589 04 63 00 Retaining Plate

1. Remove the bolts (2) and then remove the cylinder head
cover (1) and gasket (3).
Installation Notice
Notice
Replace the gasket.
Rotate the engine 1 revolution by hand and check TDC
marking of the crankshaft and camshaft.
2. Loosen the camshaft sprocket bolt (14).

Notice
Do not remove the bolt.
Installation Notice
Notice
If max. length of bolt exceeds 53.6mm, replace it.
3. Loosen the bolt (11) (left-hand thread).

Notice
Do not remove the bolt.

4. Position the no.1 cylinder at ATDC 15°.
Notice
Do not rotate the engine with camshaft sprocket bolt or
opposite direction of the engine rotation.
5. Remove the plug (6) and seal (5) from the fuel injection
pump and collect oil in a suitable vessel.
Installation Notice
Notice
Replace the seal.
6. Install the locking screw (18) into the injection pump.

Notice
Before tightening the bolts for the injection timing device
and the camshaft sprocket, always remove the locking screw
from the injection pump and reinstall the plug.
Locking Screw 601 589 05 21 00


8. Remove the chain tensioner (17).
Installation Notice
Notice
9. Pull out the 12-sided stretch bolt (14) and washer and
remove the camshaft sprocket (12).
10. Pull out the bolt (11) and washer (10).

Notice
Be careful that the bolt is left-hand thread.
Installation Notice
11. Using special tool (24, 25), remove the locking pin (8).

Threaded Bolt 116 589 02 34 00

12. Push back the timing chain with retaining plate (26) and
remove the injection timing device (9).
Retaining Plate 667 589 04 63 00

reverse order.
14. After assembling the engine, check start of delivery and
adjust if necessary.

INJECTION TIMING DEVICE

Preceding Work : Removal of injection timing device
1 Cam Sprocket ........................................... Check 4 Segment Flange and Drive Hub

2 Bushing .................................................... Check 5 Compression Springs
3 Governor Weights

Disassembly & Assembly
1. Remove the governor weights (3).
2. Pull out the compression springs (5) and cam sprocket (1)
from the segment flange (4).
3. Knock out the bushing with a proper drift.

reverse order.

START OF DELIVERY TEST (POSITION SENSOR, RIV METHOD)
1 Position Sensor 4 Seal ....................................................... Replace

2 Battery 5 Screw Plug ................................................. 30Nm
3 Fuel Injection Pump
Service Data
Start of Delivery (RIV) ATDC 14° - 16°

Tools Required
617 589 08 21 00 Position Sensor
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a
suitable vessel.
2. Install the position sensor (1) into the governor housing of

the injection pump to be the guide pin of the position sensor
facing up.
3. Connect the battery terminal of position sensor (1) to positive
terminal (+) of battery.
Position Sensor 617 589 08 21 00
4. Rotate the crankshaft by hand (in direction of engine rotation)

until the lamp ‘B’ lights up. Rotate the crankshaft carefully
further until both lamps ‘A and B’ come on. In this position,
check the Rl value on the crankshaft vibration damper.
Specification ATDC 14° - 16°
Notice
If only lamp ‘A’ lights up, repeat the test and if out of
specification, adjust start of delivery.

Digital Tester, RIV Method
(Connection Diagram for Testers Without Adapter)
1 Fuel Injection Pump 4 TDC Pulse Sender Unit

2 Rl Sensor 5 Battery
3 Digital Tester

(Connection Diagram for Testers With Adapter)
1 Fuel Injection Pump 4 TDC Pulse Sender Unit

2 Rl Sensor 5 Battery
3 Digital Tester 6 Rl Pulse Generator
Service Data
Idle Speed OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm

Tools Required
617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester
667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Item Tools
Digital Tester With Pulse Generator Bosch, MOT 001.03
Hartmann & Braun, EOMT3
Without Pulse Generator Bosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel - Tester 875
Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in a suitable
vessel.
2. Install the Rl sensor into the governor housing of injection

pump (1).
Rl Sensor 617 589 10 21 00
3. Connect the digital tester and TDC pulse sender unit

according to connection diagram.
4. Run the engine at idle speed and check the Rl value on the
digital tester
Rl Value ATDC 14° - 16°
Notice
If out of standard, adjust the start of delivery.
5. Stop the engine.
6. Remove the Rl sensor, digital tester and TDC pulse sender
unit.
7. Replace the seal and tighten the plug.
8. Check engine oil level and adjust if necessary.

After Testing
Preceding Work : Start of delivery test
Position Sensor (RIV method)
1 Adjusting Screw 4 Bolt ............................................................ 23Nm

2 Bolt ............................................................ 23Nm 5 Scale .......... Rl start of delivery = 14° - 16° ATDC
3 Fuel Injection Pump

Tools Required
617 589 08 21 00 Position Sensor
1. Position the No. 1 cylinder at ATDC 15°
Notice
Do not rotate the engine in opposite direction of engine
rotation.
2. Remove the bolt (2) at the supporting bracket.
3. Remove the bolt (4).
4. Turn the adjusting screw (1) until both lamps ‘A’ + ‘B’ on
the position sensor light up.
To the right Start of delivery retarded

To the left Start of delivery advanced
Notice
If the adjustment range is not adequate, remove the injection
pump and reinstall.
Position Sensor 617 589 08 21 00

5. After adjusting, retighten all the bolt to the specified torque.

Digital tester (RIV Method)
1 Bolt ............................................................ 23Nm 3 Bolt ............................................................ 23Nm

2 Adjusting
Screw ....... To the right : start of delivery retarded
To the left : start of delivery advanced
Service Data
Ldling Speed OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm
Tools Required
617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester
667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Item Tools
Digital Tester With Pulse Generator Bosch, MOT 001.03
Hartmann & Braun, EOMT3
Without Pulse Generator Bosch, ETD 019.00
Sun, DIT 9000
ALV, Diesel - Tester 875

1. Remove the bolt (3) at the supporting bracket.
2. remove the bolts (1) at the timing case cover.
3. Run the engine at idle speed.

4. Turn the adjusting screw (2) until the specification (15° ± 1°
ATDC) is indicated on the digital tester.
To the Right Start of Delivery Retarded
To the Left Start of Delivery Advanced

FUEL INJECTION PUMP

Preceding Work : Removal of vacuum pump
Removal of air cleaner housing
Removal of intake manifold
18 Chain Tensioner......................................... 80Nm 24 Oil Pan

19 Seal ....................................................... Replace 25 Fuel Injection Pump
20 Bolt(Left-Hand Thread) .............................. 46Nm 26 Seal ....................................................... Replace
21 Washer 27 Screw Plug ................................................. 30Nm
22 Bolt ............................................................ 23Nm 28 Square Nut
23 Seal ....................................................... Replace
Tools Required
601 589 00 08 00 Flange
601 589 05 21 00 Locking Screw
601 589 05 14 00 Assembly CageRemoval

Removal Procedure
1. Position then no.1 cylinder at 15° ATDC.
Notice
Do not rotate the engine in opposition direction of engine
rotation.
2. Remove the connecting rod (9).

3. Disconnect the vacuum lines (13, 14).
4. Remove the accelerator control damper (10).
(Manual transmission vehicle)
5. Remove the suction line (16) and pressure line (4).

6. Remove the banjo bolt (1) and then remove the seal (2)
and fuel line (3).
7. Remove the plastic clip (8) on the injection line.
8. Disconnect the injection lines (15) from the injection pump

(25).
9. Remove the banjo bolt (1) and then remove the seal (7)
and return line (5).

10. Install the assembly cage (29) and remove the bolt (20)
and pull off the washer (21).
Notice
Be careful that the bolt (20) is left hand thread.
Assembly Cage 601 589 05 14 00
11. Remove the chain tensioner (18) and seal (19).
12. Remove the bolt (12) and pull off the washer (11).
13. Remove the bolt (22) and pull off the square nut (28).
14. Pull out the fuel injection pump (25) and seal (23).

1. Remove the screw plug (27) and seal (26) and collect oil in
a vessel.
2. Insert flange (31) onto the injection pump camshaft and

turn until the cam of the governor is visible in the hole.
Flange 601 589 00 08 00
3. Tighten the locking screw.
Locking Screw 601 589 05 21 00
4. Ensure that the no.1 cylinder is positioned at ATDC 15°.

5. Coat the new seal (23) with engine oil and install it.
6. Insert the fuel injection pump (25) and tighten the bolts
(22).
7. Remove the locking screw (32).
8. Tighten the bolt(12).

9. Insert the washer (21) and tighten the bolts (20) and then
remove the assembly cage (29).
10. Connect the fuel pipes
Return Line 46 Nm
Fuel Injection Line 18 Nm
Fuel feed Line 13 Nm
Suction and Pressure Line 13 Nm
Notice
Replace the seal.

11. Assemble the plastic clip (8).
12. Connect the vacuum line (13, 14).
13. Connect the connecting rod (9).
14. connect the accelerator control damper (10).
(Manual transmission vehicle)

16. Install the vacuum pump.
17. Check the start of delivery.
18. Adjust the idle speed.

SECTION 1G1
M162 ENGINE INTAKE & EXHAUST

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G1-1 Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . 1G1-4
Fastener Tightening Specifications . . . . . . . . 1G1-1 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 1G1-5
Maintenance and Repair . . . . . . . . . . . . . . 1G1-2 Resonance Flap . . . . . . . . . . . . . . . . . . . . . . 1G1-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1G1-2 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 1G1-9
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 1G1-2
SPECIFICATIONS
Application Nlm
Air Cleaner Housing Cover Nut 9 - 11
Intake Manifold Bolt (M8 x 20) 22.5 - 27.5
Intake Manifold Bolt (M8) 22.5 - 27.5
Exhaust Mainfold Stud Bolt 9.5 - 12.5
Exhaust Pipe Nut (Engine) 15 - 28
Exhaust Pipe Bolt 28 - 47

1G1-2 M162 ENGINE INTAKE & EXHAUST

ON-VEHICLE SERVICE
AIR CLEANER
1 Element Assembly 4 Shield Assembly-Air Intake

2 Cleaner Assembly-Air 5 Braket Assembly-Air Cleaner Mounting
3 Shield Cover-Air Intake 6 Braket Assembly-Shield Surport

M162 ENGINE INTAKE & EXHAUST 1G1-3
1. Release the clamp securing HFM sensor and air cleaner.
2. Disengage the air cleaner assembly and HFM sensor
assembly.
3. Unserew the mounting bolt(6) from the bracket.
Installation Notice
4. Release the clamp from air cleaner assembly housing and

remove the cover.
5. Remove the air cleaner assembly.
6. Remove the air cleaner housing from insulator.
Notice
Make sure the air cleaner to be seated in insulator.
7. Disengage the air duct hose and air cleaner housing and
remove the housing.
8. Remove the air duct hose.
9. Unscrew the two bolts(7) from air inlet duct.
Installation Notice
10. Remove the air inlet duct.
reverse order.

INTAKE AIR DUCT
1 Clamp
2 Sleeve
3 Nut
4 Clamp
5 Intake Air Duct

1. Remove the clamp (1) and disconnect the HFM sensor.
2. Remove the nut (3) (arrow).
3. Remove the clamp (4).

4. Remove the intake air duct (5) carefully.
Installation Notice
Exactly seat the pin of intake air duct onto the crankcase
ventilation rubber mount.
reverse order.

INTAKE MANIFOLD
Preceding Work : Removal of fuel distributor and injection valve
1 Bolt (M6 X 40, 4 pieces) ......................... 9-11 Nm 13 Bolt (M6 x 40, 4 pieces) ......................... 9-11 Nm
2 Softcap 14 Throttle Body - Electric
3 Resonance Flap 15 Gasket ................................................... Replace
4 Gasket ................................................... Replace 16 Lower Intake Manifold .........................................
5 Upper Intake Manifold 17 Bolt (M8 x 40, 4 pieces) ................. 22.5-27.5 Nm
6 Bolt (M8 x 50, 9 pieces) ................. 22.5-27.5 Nm 18 Nipple .................................................... Replace
7 Gasket ................................................... Replace 19 Seal Ring
8 Blow-by Hose 20 Connection House
9 Blow-by Hose 21 Clamp
10 Clamp 22 Noise Damper Assembly
11 Blow-by Nipple 23 Tapping Screw
12 Inlet Air Housing

l Upper Intake Manifold
1. Disconnect the vacuum hose (8,9).
2. Loosen the clip (22).
3. Remove the upper intake manifold (5) after unscrewing the
bolt (6).
Installation Notice
Notice
Check the gasket and replace it if necessary.
reverse order.
l Lower Intake Manifold

Preceding work : removal of upper intake manifold
1. Remove the hose of brake booster vacuum line and idle
speed connector.
2. Disconnect the hot water inlet pipe from the bottom of lower
intake manifold.
3. Unscrew the bolt (17) and remove the lower intake manifold
(16).
Installation Notice
4. Start the engine and check for leaks at each connection
part.

RESONANCE FLAP
1 Soft Cap (2) 4 Vacuum Hose

2 Bolt (M6 x 25, 4 pieces) ......................... 9-11 Nm 5 Resonance Flap
3 O-ring 6 Gasket ................................................... Replace

1. Remove the 2 soft caps (1).
2. Remove the upper resonance flap coupling after removing
4 bolts (2).
Notice
Connect carefully the vacuum hose (4) for installation.
3. Check the O-ring (3) and replace it if necessary.
4. Remove the lower resonance flap (5).
5. Replace the gasket (6).
reverse order.

Function Description
A pneumatically actuated resonance flap (5) is located on the
intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled
by ECU and rpm.
1. Resonance flap closed (at idle/partial load : less than

3,800/rpm)
The switch valve (7) will be adjusted by ECU and resonance
falp will be colosed. By increasing air flow passage through
dividing intaking air flow toward both air collection housing
(8). This leads to a signficant increase in the torque in the
lower speed range.
2. Resonance flap open (at full load : over 3,800/rpm)

The switch valve (7) will not be adjusted by ECU and
resonance falp (5) will be open. The colllected air in the air
collection housing (8) will not be divided and intaking air
passage will be shorten.

EXHAUST MANIFOLD
Preceding Work : Removal of air cleaner
1 Nut ....................................................... 36-44 Nm 3 Exhaust Manifold

2 Gasket ................................................... Replace

Tools Required
103 589 01 39 00 Caulking Bolt

1. Remove the flange bolt from the exhaust manifold, and
disconnect the front exhaust pipe.
Installation Notice
Notice
Check for nut damages and replace the nut if necessary.
2. Remove the 23 nuts (1) from the stud bolt, and remove the
exhaust manifold.
Installation Notice
3. Replace the gasket (2).

4. Installation is reverse order of the removal.
Replacement of Rivet Nut

1. Pull out the rivet nut from the connecting point of the exhaust
manifold and the exhaust pipe using a proper bolt (arrow).
2. Insert a new rivet nut into the exhaust manifold hole, and
tighten with a special tool (Caulking Bolt).
Installation Notice
Caulking Bolt 103 589 01 39 00

Removal and Installation of Exhaust Line
1 Exhaust Manifold 10 Nut

2 Rivet Nut 11 Gasket ................................................... Replace
3 Bolt ........................................................... 30 Nm 12 Rubber Pad
4 Front Pipe 13 Nut ....................................................... 28-47 Nm
5 Oxygen Sensor 14 Center Muffler
6 Bolt ...................................................... 28-47 Nm 15 Rubber Pad
7 Rubber Pad 16 Tail Muffler
8 Catalytic Converter 17 Gasket ................................................... Replace
9 Gasket ................................................... Replace 18 Nut ....................................................... 28-47 Nm

SECTION 1G2
M161 ENGINE INTAKE & EXHAUST

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G2-1 Air Intake Shield . . . . . . . . . . . . . . . . . . . . . . 1G2-4
Fastener Tightening Specifications . . . . . . . . 1G2-1 Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . 1G2-5
Maintenance and Repair . . . . . . . . . . . . . . 1G2-2 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 1G2-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1G2-2 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 1G2-9
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 1G2-2
SPECIFICATIONS
Application Nlm


ON-VEHICLE SERVICE
AIR CLEANER
1 Air Cleaner Assembly 4 Air Duct Hose

2 Element Assembly 6 Bolt (M8 × 30 ) ................................... 22.5-27.5 Nm
3 Insulator

1. Release the clamp securing HFM sensor and air cleaner.
2. Disengage the air cleaner assembly and HFM sensor
assembly.
3. Unserew the mounting bolt(6) from the bracket.
Installation Notice
4. Release the clamp from air cleaner assembly housing and

remove the cover.
5. Remove the air cleaner assembly.
6. Remove the air cleaner housing from insulator.
Notice
Make sure the air cleaner to be seated in insulator.
7. Disengage the air duct hose and air cleaner housing and
remove the housing.
8. Remove the air duct hose.
9. Unscrew the two bolts(7) from air inlet duct.
Installation Notice
10. Remove the air inlet duct.

reverse order.

AIR INTAKE SHIELD

Preceding Work : Removal of air cleaner
1 Air Cleaner Assembly 5 Air Inlet Duct

3 Insulator 7 Bolt (M6 × 35 ) ........................................... 9-11 Nm
4 Air Duct Hose

1. Remove the upper cover (3) from the air intake shield (5)
upper mounting pin.
2. Remove the bolts (4 and 6).
3. Remove the air intake shield (5).
reverse order.

INTAKE AIR DUCT
1 Clamp
2 Sleeve
3 HFM Sensor
4 Intake Air Duct
5 Blow-by Hose
7 Clamp(2 pieces)
8 Intake Air Duct Mounting
Bracket

1. Release the clamp (1) and intake air duct.
2. Remove the Blow-by hose (5) (arrow).

3. Release the clamp (7) and remove the intake air duct.
Notice
Completely fit the intake air duct with the mounting bracket
(8).

INTAKE MANIFOLD
Preceding Work : Removal of intake air duce
Removal of fuel distributor and injector
1 Bolt (M6 X 40, 6 pieces) ................. 22.5-27.5 Nm 5 Idle Regulator

2 Intake Manifold 6 Intermediate Flange
3 Gasket (2 pieces) .................................. Replace 7 Bolt (M6 X 35, 4 pieces) ......................... 9-11 Nm
4 Bolt (M8 X 40, 3 pieces) ................. 22.5-27.5 Nm 8 Connection Piece With Seal Ring ........ 36-44 Nm

2. Remove idle speed control plug connector (arrow).
3. Disconnect the brake booster vacuum line and other

vacuum lines.
4. Disconnector the rod from bearing bracket assembly and
remove the connection piece (8).
Installation Notice
5. Unscrew the three bolts (4) and remove the idle regulator
and intermediate flange (6).
Installation Notice
6. Unscrew the two bolts (M8 X 16) and remove the support
assembly (arrow).
Installation Notice
7. Unscrew the intake manifold assembly mounting bolts (1)

and remove the intake manifold and gasket.
Installation Notice
Notice
Replace the gasket with new one.
reverse order.
9. Start the engine and check for leaks in each connection.

EXHAUST MANIFOLD
1 Oxygen Sensor .............................. 49.5-60.5 Nm 5 Exhaust Manifold

2 Bolt (4 pieces) ........................................ 9-11 Nm 6 Flange Bolt & Exhaust Pipe
3 Upper Cover Mounting Nut ............................................ 30 Nm
4 Nut (11 pieces)............................... 31.5-38.5 Nm 7 Gasket ................................................... Replace

1. Remove the oxygen sensor if necessary.
Installation Notice
2. Unscrew the bolt (2) and remove the exhaust manifold upper
cover (3).
3. Unscrew the flange bolt (6) of front exhaust pipe and
separate the front exhaust pipe.
Installation Notice
Notice
Check the exhaust pipe mounting nut, and replace it with
new one if necessary.

4. Unscrew the eleven nuts (4) and remove the exhaust
manifold (5) and gasket (7).
Installation Notice
5. Replace the gasket (7) with new one.
reverse order.

Removal and Installation of Exhaust Line
1 Pipe Assembly-Exhaust Front 9 Muffler Assembly-Complete

2 Converter Assembly-Complete 10 Pipe Assembly-Tail Exhaust
3 Gasket 11 Nut-Hex Flang (M8X1.25)
4 Hanger-Converter Mounting 12 Bolt-Hex (M8X1.25X55)
5 Ring 13 Bolt-Hex (M10X1.25X35)
6 Gasket-E/Pipe to Manifold 14 Nut-Hex Flang (M10X1.25)
7 Ring 15 Heat Protecter-L/ARM Mounting Bush
8 Ring-Exhaust Mounting

SECTION 1G3
OM600 ENGINE INTAKE & EXHAUST

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G3-1 Intake and Exhaust Manifold . . . . . . . . . . . . . 1G3-4
Fsatener Tightening Specifications . . . . . . . . 1G3-1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . 1G3-7
Maintenance and Repair . . . . . . . . . . . . . . 1G3-2 Charge Air System Diagram . . . . . . . . . . . . . 1G3-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1G3-2 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-8
Air Cleaner and Inlet Duct & Hose . . . . . . . . 1G3-2 Turbocharger Assembly . . . . . . . . . . . . . . . 1G3-10
SPECIFICATIONS
Application N·
·m

1G3-2 OM600 ENGINE INTAKE & EXHAUST

ON-VEHICLE SERVICE
AIR CLEANER AND INLET DUCT & HOSE
1 Air Intake Shield Assembly 5 Bolt ......................................................... 9-11Nm

2 Air Cleaner Assembly 6 House
3 Mounting Bracket 7 Clamp
4 Air Cleaner Element ........... Clean : 20,000km 8 Engine Cover Assembly (Turbo)
Replace : 60,000km 9 Mounting Bracket

OM600 ENGINE INTAKE & EXHAUST 1G3-3
1. Loosen the air duct hose clamp and then remove the air
cleaner and air duct hose.
2. Disconnect the air cleaner housing cover clamp and remove

the cover and element.
Clean every 20,000km
Operating Interval
Replace every 60,000km
3. Loosen the nut (4EA) and remove the air cleaner housing
from the intake manifold.
Notice
Do not fold the rubber.
4. Loosen the clamp and remove the air duct hose.
5. Loosen the mounting nut and bolt.
6. Remove the air inlet duct and hose.
reverse order.

INTAKE AND EXHAUST MANIFOLD
1 Nut ................................................. 22.5-27.5 Nm 7 Stud Bolt .......................................... 9.9-12.1 Nm

2 Washer 8 Bolt (M8) ........................................ 22.5-27.5 Nm
3 Support Assembly Bar 9 Intake Duct
4 Nut ................................................. 22.5-27.5 Nm 10 Intake Duct Gasket
5 Exhaust Manifold Assembly 11 Intake Manifold
6 Exhaust Gasket 12 Intake Gasket

Exhaust Line
1 Heat Protector Assembly 6 Muffler

2 Heat Protector Floor 7 Mounting
3 Exhaust Front Pipe Assembly 8 Heat Protector Front Floor
4 Ring 9 Tail Exhaust Pipe Assembly
5 Exhaust Rear Pipe Assembly

1. Remove the bolt from the exhaust manifold and then remove
the front exhaust pipe.
Installation Notice
Notice
When tightening the nut(3), maintain the clearance between
exhaust manifold(1) and front exhaust pipe.
2. Remove the nut from the front of center muffler and then
remove the front exhaust pipe.
Installation Notice
3. Remove the nut from the rear of center muffler and then
remove the tail muffler.
Installation Notice
4. Remove the muffler mounting hanger from the rubber pad

and remove the center muffler and tail muffler.
Notice
Check the gasket, if necessary, replace the new one.
reverse order.

TURBOCHARGER
CHARGE AIR SYSTEM DIAGRAM
1 Turbocharger Oil Inlet 6 Air Inlet

2 Turbine Wheel 7 Exhaust Gas Outlet
3 Waste Gate 8 Compressed Air Flow
4 Oil Outlet 9 Intercooler
5 Compressor Wheel 10 Cylinder

INTERCOOLER
1 Hoses 5 Cover
2 Pipes 6 Bolts
3 Hoses 7 Screws
4 Intercooler 8 Bolts

1. Remove the hose connected to turbocharger and intake
duct.
2. Remove the protective cover.
3. Loosen the clamps and remove the pipe and hose

connected to intercooler.
4. Unscrew the mounting bolts and remove the intercooler.

reverse order.

TURBOCHARGER ASSEMBLY
1 Oil Supply Line 3 Nuts

2 Oil Return Line 4 Turbocharger

1. Remove the 2 hoses connected to intercooler.
2. Remove the hose(air cleaner to turbocharger) with blow by

hose.
3. Disconnect the oil supply pipe.

4. Remove the oil return pipe.
5. Remove the support assembly.
6. Remove the 3 nuts(arrows).

7. Remove the turbocharger disconnecting the exhaust pipe
from the turbocharger.

reverse order.

SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Damping Force Control Logic . . . . . . . . . . . . . 2A-6
General Specifications . . . . . . . . . . . . . . . . . . 2A-1 Normal Control . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
General Diagnosis . . . . . . . . . . . . . . . . . . . . . 2A-3 Actuator Inspection . . . . . . . . . . . . . . . . . . . . . 2A-8
Input & Output Devices and Damping Schematic and Routing Diagrams . . . . . . . . 2A-9
Force Control Logic . . . . . . . . . . . . . . . . . 2A-5 ECS Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9
Input & Output Devices . . . . . . . . . . . . . . . . . . 2A-5 Self Diagnosis Test . . . . . . . . . . . . . . . . . . 2A-11
System Layout . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . 2A-11
SPECIFICATIONS
Application Front Rear
ECS Control Type 3-stage Variable Damping Force Control Type
Shock Max. Length (mm) 344 - 350 517 - 523
Absorber
Compressed Length (mm) 245 ± 3 331 ± 3
Stroke (mm) 102 188

2A-2 SUSPENSION DIAGNOSIS
GENERAL SPECIFICATIONS (Cont'd)

Body Power Voltage (V) 4.75 - 5.25
Vertical and
Lateral Consuming Current (mA) Less than 10
Acceleration Output Current (mA) Less than 2.0
Sensor
Operating Characteristics (Vertical Acceleration Sensor) (Lateral Acceleration Sensor)
Output Voltage Output Voltage
4.25 4.25
2.5 2.5
0.75 0.75
-1.5g 1g 3.5g -1g 0g 1g
Acceleration Acceleration
Damping Type 3-stage Rotary Step Motor Type

Force
Switching Voltage Rating (V) DC12
Actuator Current Rating (A) Less than 2.5
Current Time (mS) 95 - 105
Axle Vertical Power Voltage (V) 4.75 - 5.25
Acceleration
Consuming Current (mA) Less than 10
Sensor
(Wheel G Output Current (mA) Less than 2.0
Sensor)
Operating Characteristics
Output Voltage
4.25
2.5
0.75
-9g 1g 11g
Acceleration

SUSPENSION DIAGNOSIS 2A-3
DIAGNOSIS
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and vehicle first. If possible, do this road test with the
the wheels involve several systems. Consider all systems customer.
when you diagnose a complaint. Some problems, such Proceed with the following preliminary checks. Correct
as abnormal or excessive tire wear and scuffed tires, any substandard conditions.
may by the result of hard driving. Always road test the
Vehicle Rolling
Checks Action
Broken Stabilizer Bar Replace
Faulty Shock Absorber Replace
Abnormal Noises
Checks Action
Loosened Mountings Retightening
Damaged or Worn wheel Bearing Replace
Damaged Shock Absorber Replace
Damaged Tire Replace
Poor Riding
Checks Action
Over Inflated Tire Pressure Adjustment
Faulty Shock Absorber Replace
Loosened wheel Nut Tighten as Specified
Bent or Broken Coil Spring Replace
Damaged Tire Replace
Worn Bushing Replace
Vehicle Pulls to Right or Left

Checks Action
Deformed Arm Assembly Replace
Worn Bushing Replace
Bent or Broken Coil Spring Replace
Difference Between L/H & R/H Heights Adjust
Hard Steering
Checks Action
Incorrect Wheel Alignment Repair
Excessive Resistance of Lower Arm Ball Joint Replace
Insufficient Tire Pressure Adjust
Faulty Power Steering Repair or Replace

Steering Instability
Checks Action
Incorrect Front wheel Alignment Replace
Worn or Loosened Lower Arm Bushing Repair or Replace
Vehicle Bottoming
Checks Action
Worn or Broken Coil Spring Replace

INPUT & OUTPUT DEVICES AND DAMPING FORCE

CONTROL LOGIC
INPUT & OUTPUT DEVICES
Damping force of shock absorber will rotate shock absorber control rod in 3 modes by driving actuator on the upper
shock absorber when signaled from ECS.
Rotary valve in the shock absorber will control hydraulic flow according to rotation of control rod to adjust damping
force of shock absorber in SOFT« MEDIUM« HARD.
Speed Sensor Indicator Lamp

Axle Vertical Acceleration Sensor
(Wheel G Sensor)
Actuator
Stop Lamp Switch ECS
(ECU) Damping Force Adjustment
Body Vertical Acceleration Sensor
(Vertical Sensor) Shock Absorber
ECS Switch
Body Lateral Acceleration Sensor Self-Diagnosis Connector
(Lateral Sensor)
SYSTEM LAYOUT
1 ECS (ECU) 4 ECS Mode Switch

2 Body Vertical Acceleration Sensor (Vertical 5 Stop Lamp Switch
Sensor) 6 Axle Vertical Acceleration Sensor (Wheel G
3 Body Lateral Acceleration Sensor (Lateral Sensor)
Sensor) 7 Mode Actuator

DAMPING FORCE CONTROL LOGIC

Control Logic that applies on damping force variable suspension is comprised of road sensing driving comfort control
logic to increase driving comfort and vehicle speed sensing control logic, anti-roll control logic and anti-dive control
logic to secure control safety.
Axle
Sensor Speed
Vertical Lateral Acceleration Brake
Logic Sensor (2.5g) Sensor (1g) Sensor (10g)
Road Sensing Driving Comfort Control Logic

Anti-bounce Control Logic
Anti-roll Control Logic
Anti-dive Control Logic
Vehicle Speed Sensing Control Logic
NORMAL CONTROL
Initial Stage
When ignition switch is "ON", system initialization will be performed for approx. 3 seconds. During this time, warning
lamp will stay ON and damping force will be switched to Hard status. After 3 seconds, warning lamp will turn off and
normal control status will be restored.
Normal Damping Force Control Establishment

Damping force will have Soft® Medium® Hard status in AUTO mode and Medium® Hard status in SPORT mode.
When double control items are satisfied at the same time it will be Hard® Medium® Soft in order.
Normal Damping Force Control Release

Control mode release will be "Hard® Medium® Soft"or "Medium® Soft". In case that returned from Hard status to
Medium status during control, it will be done after elapse of setting times. Returning from Medium status to Soft status
will be done immediately without delay.

SELF-DIAGNOSIS
ECS-ECU indicates ECS circuit defectives to the driver by flickering ECS indicator lamp in the meter cluster 0.5
second of interval if there are defectives.
Code Defects Judging Conditions Set Time Remedy Release Conditions Set Time
01 Body vertical When sensor output Stop anti- Sensor Voltage

acceleration voltage is less than 0.9 - 1.1sec. bounce ride ³ 2.0 ± 0.1V
0.9 - 1.1sec.
sensor 0.5-4.5V, more than control ³ 3.0 ± 0.1V
4.5V.
02 Body lateral When sensor output Stop anti-roll Sensor Voltage

acceleration voltage is less than 0.9 - 1.1sec. control ³ 2.0 ± 0.1V
0.9 - 1.1sec.
sensor 0.55±0.15V, more than ³ 3.0 ± 0.1V
4.45±0.1V.
03 Axle vertical When sensor output Stop ride Sensor Voltage

acceleration voltage is less than 0.9 - 1.1sec. control ³ 2.0 ± 0.1V
0.9 - 1.1sec.
sensor (wheel G 0.5-4.5V, more than ³ 3.0 ± 0.1V
sensor) 4.5V.
Check step motor
Stop control
04 Front actuator power supply detecting IGN+ SW.
0.4 - 0.6sec. after returning
circuit for open and OFF® ON
to the previ-
short check for relative
ous mode
connectors.
When defective detect- Stop control

05 Rear actuator IGN+ SW.
ing circuit has detected 0.4 - 0.6sec. after returning
OFF® ON
defectives during to the previous
output OFF. mode
06 ECU When ECU does not 0.4 - 0.6sec. Stop control Reset
work normally.
1. Turn the ignition switch ON and if ECS system is normal, ECS indicator lamp will turn on for 3 seconds and then go
off. However if defective, ECS indicator lamp will flicker in the interval of 0.5 second continuously.
2. Identify fault code with Scanner.

ACTUATOR INSPECTION
Output position of the actuator should be changed as below when battery voltage is applied between actuator
connector terminals.
Connector
Battery Voltage Position of The Actuator Output Remark
terminal
1 (White) -
2 (Black) OPEN SOFT Mode
3 (Red) +
1 (White) +
2 (Black) - MEDIUM Mode
3 (Red) OPEN
1 (White) OPEN
2 (Black) + HARD Mode
3 (Red) -


ECS CIRCUIT

Connector Pin Number and Circuits
NO. Circuit NO. Circuit
1 Ignition 14 Chassis Ground
2 Actuator R-MEDIUM 15 Actuator R-HEAD
3 Actuator R-SOFT 16 Actuator F-MEDIUM
4 Actuator F-HEAD 17 Actuator F-SOFT
5 Select Switch 18 Brake Switch
6 Speed Sensor 19 -
7 Wheel G Sensor 20 Lateral G Sensor
8 Wheel G Sensor Ground 21 Lateral G Sensor Ground
9 - 22 Vertical G Sensor Ground
10 Vertical G Sensor 23 Diagnosis K Line
11 Sensor +5V 24 Diagnosis L Line
12 Chassis Ground 25 -
13 Indicator Lamp 26 -

SELF DIAGNOSIS TEST

DIAGNOSIS TEST
Special Tool Requirements : Scanner
1 Diagnosis Connector 3 Solenoid Valve

2 Fuse Box
1. Position the ignition switch to 'OFF'.

2. Connect Scanner harness connector to the engine
compartment diagnosis socket.
4. Select "Elctronic control vehicle diagnosis" from function
selection display and press "Enter".
5. Select "Korando ('98 model year)" from vehicle model
selection display and press 'Enter'.
6. Select "Elctronic suspension system (ECS)" from control
system selection display and press 'Enter'.
7. Select "Self-diagnosis" from diagnosis item selection display.
Notice
Check sensor value output display, if necessary.
8. Determine the fault code and check defective component.

Notice
Refer to self-diagnosis list.

Self - Diagnosis List
Fault
Defects Service Hint
Code
01 Vertical Acceleration Sensor 1. Check sensor supply voltage
l Condition - IGN ON
l Standard value - voltage between pin 11 and 8 of ECU :
4.5 - 5.0V
2. Check sensor output voltage.
l Standard value - voltage between pin 20 and 11 of ECU
: 0.5 - 4.5V
3. Check the sensor.
4. Check circuit for open.
5. Check connection of other connectors.
02 Lateral Acceleration Sensor 1. Check sensor supply voltage.

l Standard value - voltage between pin 11 and 8 of ECU :
4.5 - 5.0V
l Standard value - voltage between pin 10 and 11 of ECU
: 0.5 - 4.5V
03 Wheel Acceleration Sensor 1. Check sensor supply voltage.

l Standard value - voltage between pin 11, 8 and pin
7,11 of ECU : 4.5 - 5.0V
04 Front Step Motor 1. Check step motor supply voltage.

05 Rear Step Motor 1. Check step motor supply voltage.

06 ECU 1. Check connectors of ECU.

2. Replace the ECU.

SECTION 2B
WHEEL ALIGNMENT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . 2B-6
Wheel Alignment Specifications . . . . . . . . . . . 2B-1 General Description and System
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Tire Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Four Wheel Alignment . . . . . . . . . . . . . . . . . . 2B-9
Radial Tire Lead/Pull . . . . . . . . . . . . . . . . . . . 2B-3 Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Vibration Diagnosis . . . . . . . . . . . . . . . . . . . . . 2B-5 Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Maintenance and Repair . . . . . . . . . . . . . . . 2B-6 Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 2B-6
SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
Camber 0°± 30'
Caster 2°30' ± 30'
Toe-in 0 - 4 mm
King Pin Inclination 12°30'

2B-2 WHEEL ALIGNMENT
DIAGNOSIS
TIRE DIAGNOSIS
Irregular and Premature Wear
Irregular and premature tire wear has many causes.
Some of them are incorrect inflation pressures, lack of
regular rotation, poor driving habits, or improper wheel
alignment.
Rotate the tires if :
l The front tire wear is different from the rear.
l The left and right front tire wear is unequal.
l The left and right rear tire wear is unequal, Check
wheel alignment if :
l The left and right front tire wear is unequal.
l The wear is uneven across the tread of either front
tire.
l The front tire treads are scuffed with “feather” edges
on the side of the tread ribs or blocks.
Tread Wear Indicators

The original equipment tires have built-in tread wear
indicators to show when the tires need replacement.
These indicators appear as bands when the tire tread
depth becomes shallow. Tire replacement is
recommended when the indicators appear in three or
more grooves at six locations.
Radial Tire Waddle

Waddle is side-to-side movement at the front or rear of
the vehicle. It is caused by the steel belt not being straight
within the tire, or by excessive lateral runout of the tire
or wheel.
The vehicle must be road tested to determine which end
of the vehicle has the faulty tire. The rear end of the
vehicle will shake from side to side or “waddle” if the
waddle tire is on the rear of the vehicle. From the driver’s
seat, it feels as though someone is pushing on the side
of the vehicle. If the faulty tire is on the front of the vehicle,
the waddle is more visual. The front sheet meld appears
to be moving back and forth, and the drivers seat feels
like the pivot point in the vehicle.
Waddle can be diagnosed using the method of
substituting known good tire and wheel assemblies on
the problem vehicle
1. Road test the vehicle to determine if the waddle is
coming from the front or the rear of the vehicle.
2. Install good tires and wheels from a similar vehicle in
place of those on the offending end of the problem
vehicle. If the source of the waddle is not obvious,
change the rear tires.

WHEEL ALIGNMENT 2B-3
3. Road test the vehicle. If there is improvement, install
the original tires to find the offending tire. If there is
no a straight improvement, install good tires in place
of all four offending tires.
4. Install original tires one at a time to find the offending
tire.
RADIAL TIRE LEAD/PULL

Lead/pull is the deviation of the vehicle from a straight
path on a level road with no pressure on the steering
wheel. Lead is usually caused by:
l Incorrect alignment.
l Uneven brake adjustment.
l Tire construction.
The way in which a tire is built can produce lead/pull in
the vehicle.011-center belts on radial tires can cause
the tire to develop a side force while the vehicle rolls
straight down the road. If one side of the tire has even a
little larger diameter than the diameter of the other side,
the tire will tend to roll to one side. Unequal diameters
will cause the tire to develop a side force which can
produce vehicle lead/pull.
The radial lead/pull diagnosis chart should be used to
determine whether the problem originates from an
alignment problem or from the tires. Part of the lead
diagnosis procedure calls for tire rotation that is different
from the proper tire rotation pattern. If a medium- to high-
mileage tire is moved to the other side of the vehicle, be
sure to check for ride roughness. Rear tires will not cause
lead/pull.

Radial Tire Lead/Pull Diagnosis Chart
Step Action Values(s) Yes No
1. Perform wheel alignment preliminary inspection.
2. Check the brakes for dragging.
1
3. Road test the vehicle. -
Does the vehicle lead/pull? Go to Step 2 System OK
1. Cross switch the front tire and wheel assemblies.
2 2. Road test the vehicle. -
Does the vehicle lead/pull? Go to Step 3 System OK
1. Check the front wheel alignment. Adjust
3 - Go to Step 4
Is the alignment within specifications? alignment
1. Compare the front camber and front caster to
4 specifications. -
Are they within specifications? Go to Step 7 Go to Step 5
1. Check the vehicle frame.
5 Is the frame bent? - Go to Step 6 Go to Step 1
1. Straighten the frame.
6 Is the repair complete? - Go to Step 3 -
1. The probable cause is the tires.
2. Switch the left front tire and wheel assembly with
7 the left rear tire and wheel assembly.
3. Road test the vehicle. -
Does the vehicle still lead/pull? Go to Step 9 Go to Step 8
1. Switch the left front tire and wheel assembly with
the left rear tire and wheel assembly and replace the
8 left front tire. -
Does the repair complete? System OK Go to Step 1
1. Switch the right front tire and wheel assembly with
the right rear tire and wheel assembly.
9 2. Road test the vehicle. -
Does the vehicle still lead/pull? Go to Step 1 Go to Step 10
1. Switch the right front tire and wheel assembly with
the right rear tire and wheel assembly and replace
10 the right front tire. -
Is the repair complete? System OK Go to Step 1

VIBRATION DIAGNOSIS
Wheel imbalance causes most highway speed vibration
Preliminary Checks
problems. A vibration can remain after dynamic Prior to performing any work, always road test the car
balancing because: and perform a careful visual inspection for:
l A tire is out of round. l Obvious tire and wheel runout.
l A rim is out of round. l Obvious drive axle runout.
l A tire stiffness variation exists. l Improper tire inflation.
Measuring tire and wheel free runout will uncover only l Incorrect trim height.
part of the problem, All three causes, known as loaded l Bent or damaged wheels.
radial runout, must be checked using method of l Debris build-up on the tire or the wheel.
substituting known good tire and wheel assemblies on
l Irregular or excessive tire wear.
the problem vehicle.
l Improper tire bead seating on the rim,
l Imperfections in the tires, including: tread
deformations, separations, or bulges from impact
damage. Slight sidewall indentations are normal and
will not affect ride quality.
Tire Balancing
Balance is the easiest procedure to perform and should
be done first if the vibration occurs at high speeds. Do
an off-vehicle, two-plane dynamic balance first to correct
any imbalance in the tire and wheel assembly.
An on-vehicle finish balance will correct any brake drum,
rotor, or wheel cover imbalance, If balancing does not
correct the high-speed vibration, or if the vibration occurs
at low speeds, runout is the probable cause.


ON-VEHICLE SERVICE
WHEEL ALIGNMENT
Vehicle Height
1. Check the tire for proper inflation.
2. Measure ‘A’ from the center of the lower arm rear mounting
bolt end to the ground.
3. Measure ‘B’ from the center of the steering knuckle shaft to

the ground.
4. If the difference between ‘A’ and ‘B’ is not within specification,

adjust vehicle height using torsion bar height control bolt.
‘B’ - ‘A’ 31 - 36mm

Notice
Before wheel alignment, adjust vehicle height adjustment
first.
Toe-in
1. Measure toe-in.
Specification 0 - 4mm
2. If toe-in is not within specification, loosen the tie rod nuts

and adjust it by turning the tie rod.

Camber
1. Remove the free wheel hub.
2. Measure camber with a wheel alignment equipment.
Specification 0°±30’
3. If camber measurements are not within specification, adjust

it by increasing or decreasing the number of adjusting shims
(1) inserted between the upper arm shaft and cross bracket.
Camber Change
Adjusting Shims Increasing 1ea Decreasing 1ea
1.6 Iarge + 19’ - 19’
3.2 large + 38’ - 38’
Notice
Difference between the left and right should be adjusted
within 30’.
Caster
1. Remove the free wheel hub.
2. Measure caster with a wheel alignment equipment and a
turning radius gauge.
Specification 2° 30’ ± 30’

3. If caster measurements are not within specification, adjust
it by increasing 1ea (rear) or decreasing 1ea (front).
Caster Change
FRONT
Adjusting Shims
Increasing 1ea Decreasing 1ea
0.4 small - 11’ + 11’
1.6 small - 43’ + 43’
REAR
Adjusting Shims
Increasing 1 ea Decreasing 1 ea
0.4 small + 11’ - 11’
1.6 small + 43’ - 43’
Notice
Difference between the left and right should be adjusted
within 30’.

GENERAL DESCRIPTION AND SYSTEM OPERATION

FOUR WHEEL ALIGNMENT CASTER
The first responsibility of engineering is to design safe Caster is the tilting of the uppermost point of the steering
steering and suspension systems. Each component axis either forward or backward from the vertical when
must be strong enough to withstand and absorb extreme viewed from the side of the vehicle. A backward tilt is
punishment. Both the steering system and the front and positive, and a forward tilt is negative. Caster influences
the rear suspension must function geometrically with directional control of the steering but does not affect
thebody mass. tire wear. Weak springs or overloading a vehicle will affect
The steering and the suspension systems require that caster. One wheel with more positive caster will pull
the front wheels self-return and that the tire rolling effort toward the center of the car. This condition will cause
and the road friction be held to a negligible force in order the car to move or lean toward the side with the least
to allow the customer to direct the vehicle with the least amount of positive caster. Caster is measured in degrees.
effort and the most comfort.
A complete wheel alignment check should include
CAMBER
measurements of the rear toe and camber. Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the
Four-wheel alignment assures that all four wheels will
tires tilt outward, the camber is positive. When the tires
be running in precisely the same direction.
tilt inward, the camber is negative. The camber angle is
When the vehicle is geometrically aligned, fuel economy measured in degrees from the vertical. Camber
and tire life are at their peak, and steering and influences both directional control and tire wear.
performance are maximized.
If the vehicle has too much positive camber, the outside
TOE shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Toe-in is the turning in of the tires, while toe-out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the wheel
support system which occur when the vehicle is rolling
forward. The specified toe angle is the setting which
achieves 0 degrees of toe when the vehicle is moving.
Incorrect toe-in or toe-out will cause tire wear and
reduced fuel economy. As the individual steering and
suspension components wear from vehicle mileage,
additional toe will be needed to compensate for the wear.
Always correct the toe dimension last.

SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
General Specifications . . . . . . . . . . . . . . . . . . 2C-1 Front Lower and Upper Arm . . . . . . . . . . . . . . 2C-8
Fastener Tightening Specifications . . . . . . . . . 2C-2 Front Shock Absorber . . . . . . . . . . . . . . . . . 2C-10
Component Locator . . . . . . . . . . . . . . . . . . . 2C-3 Axle Vertical Acceleration Sensor
(Wheel G Sensor) . . . . . . . . . . . . . . . . . . . 2C-12
Front Suspension . . . . . . . . . . . . . . . . . . . . . . 2C-3
Vertical and Lateral Sensor . . . . . . . . . . . . . . 2C-13
Maintenance and Repair . . . . . . . . . . . . . . . 2C-4
ECS (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-14
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 2C-4
Front Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . 2C-4
SPECIFICATIONS
Type Double Wishbone
Spring Type Torsion Bar Spring
Torsion Bar Length 1,040 mm
Outer Diameter(f) 24.5 mm
Shock Absorber Cylindrical Reciprocation Type
Stabilizer Type Torsion Bar Spring

2C-2 FRONT SUSPENSION

Stabilizer Bar
Application Nlm
Stabilizer Bar Retaining Nut 30 - 45
Stabilizer Bar Link Nut 60 - 80
Lower Arm Nut 16 - 22
Torsion Bar
Application Nlm
Torque Arm Bolt M10 40 - 60
M12 60 - 80
Lower and Upper Arm

Application Nlm
Upper Arm Nut 120 - 140
Upper Arm End Castle Nut 80 - 150
Lower Arm Nut 150 - 180
Lower Arm End Castle Nut 120 - 180
Steering Knuckle and Drive Shaft

Application Nl m
Brake Caliper Hose Bolt 25 - 35
Brake Caliper Mounting Bolt 85 - 105
Tie Rod Retaining Nut 35 - 45
Upper Arm Retaining Nut 80 - 150
Lower Arm Retaining Nut 120 - 180

FRONT SUSPENSION 2C-3
COMPONENT LOCATOR
FRONT SUSPENSION
1 Shock Absorber 5 Stabilizer Bar Link

2 Upper Arm 6 Stabilizer Bar
3 Steering Knuckle 7 Suspension Bumper
4 Lower Arm


ON-VEHICLE SERVICE
FRONT STABILIZER BAR
7 Outer Washer
1 Front Stabilizer Bar 8 Bushing
2 Bolt ...................................................... 30-45 Nm 9 Center Washer
3 Fixing Cap 10 Lower Arm
4 Bushing 11 Bushing
5 Nut ....................................................... 60-80 Nm 12 Outer Washer
6 Stabilizer Bar Link Assembly 13 Nut ....................................................... 16-22 Nm


1. Remove the connecting nuts (1) from stabilizer bar link.
Installation Notice
2. Remove the connecting nuts (2) of the stabilizer bar and
link and then remove the link.
Installation Notice
3. Remove the stabilizer bar fixing cap bolts (arrow) and
remove the stabilizer bar.

reverse order.
Notice
The distance between the end of the nut and the end of the
link should be in 10-13 mm at the connection of the stabilizer
bar link and lower arm.

TORSION BAR
1 Nut 7 Torsion Bar

2 Torque Arm 8 Dust Cover
3 Washer 9 Height Control Arm Assembly
4 Bolt ............................................. M10, 40-60 Nm 10 Height Control Bolt End Piece
M12, 60-80 Nm 11 Height Control Bolt
5 Torsion Bar End Seat 12 Height Control Seat
6 Dust Cover

1. Remove the fixing nuts and bolts of the shock absorber
and lower arm connection.
Installation Notice
2. Remove the connecting nuts of the stabilizer bar link to the

lower arm.
Installation Notice
3. Turn the height control bolt until the distance between the
end of the height control bolt end piece and the bolt end
becomes 0-5 mm.
Installation Notice
Install the torsion bar spring and adjust the distance between
the end of the height control bolt and piece end the bolt
end to be 50-55 mm. Adjust the vehicle height.
4. Remove the torque arm fixing nuts and bolts and then
withdraw the torsion bar spring.
Installation Notice
M10 40 - 60 Nm
Tightening Torque
M12 60 - 80 Nm

reverse order.
6. Check and adjust the wheel alignment.

FRONT LOWER AND UPPER ARM

Preceding Work : Removal of the torsion bar spring
Removal of the steering knuckle and drive shaft
1 Nut ................................................... 120-140 Nm 10 Cotter Pin ............................................... Replace

2 Fulcrum Pin and Upper Arm Assembly 11 Nut ................................................... 150-180 Nm
3 Camber/Caster Adjusting Shim 12 Washer
4 Bolt 13 Bolt
5 Bolt 14 Lower Arm Assembly and Lower Arm End
6 Washer 15 Bolt
7 Upper Arm End 16 Washer
8 Nut ....................................................... 16-22 Nm 17 Nut ....................................................... 60-80 Nm
9 Castle Nut .......................................... 80-150 Nm

1. Remove the shock absorber.
Installation Notice
Upper Distance between the nut end 6 - 9 mm

and the screw end
Lower Tightening Torque 60 - 80 Nm
2. Remove the fulcrum pin mounting bolts and nuts and remove
the upper arm assembly.
Notice
Be careful not to damage or lose the adjusting shims.
Installation Notice
3. Remove the lower arm mounting bolts (2).

Installation Notice
4. Pull out the cotter pin from the lower arm ball end assembly
and remove lower arm after loosening the slotted nut.
Installation Notice

Notice
Replace the cotter pin with new one.

reverse order.

FRONT SHOCK ABSORBER
1 Front Shock Absorber 4 Center Washer

2 Washer 5 Actuator Mounting Bracket
3 Bush 6 Nut ........................................................ 40-60Nm

1. Disconnect actuator connector and unscrew bolt and remove
actuator assembly.
Notice
When installing the actuator to the mounting bracket, the
wiring should face the front of the frame.
2. Unscrew the upper nut (6).

Notice
When screwing the nut, actuator contacting surface of the
mounting bracket and rod end should be 0.5 - 1.5mm.
3. Remove the mounting bracket (5).

Notice
When installing the bracket, it should be vertical to the frame
side member.
4. Remove the bush and check for damage and replace if

necessary.
5. Unscrew shock absorber lower bolt and nut and remove

the shock absorber.
Notice
Shock absorber is filled with gas, never attempt to cut or
heat.

reverse order.

AXLE VERTICAL ACCELERATION SENSOR (WHEEL G SENSOR)
1 Axle Vertical Acceleration Sensor (wheel G 2 Extension Wiring

sensor) 3 Bolt (M6) ............................................. 20 - 30Nm

1. Disconnect extension wiring connector (2) from the axle
vertical acceleration sensor.
Notice
Installation of wiring connector should be as shown in the
right drawing.
2. Unscrew bolts (3) and remove the axle vertical acceleration

sensor (1).
Notice
When installing the sensor to the bracket, the sensor wiring
should be upward. 1 Actuator Connector
2 Axle Vertical Acceleration Sensor Connector
3 Front Hose Mounting Bracket
3. Installation should follow the removal procedure in the 4 Frame Side Member
reverse order.

VERTICAL AND LATERAL SENSOR

1. Disconnect vertical sensor and lateral sensor connectors.
Notice
When connecting the connectors, connector connection of
the lateral sensor (2) should be in the right and connector
connection of the vertical sensor (1) should face downward.
2. Unscrew bolts and remove vertical sensor and lateral sensor.

Installation Notice
Tightening Torque 20 - 30 Nm 1 Body Vertical Acceleration Sensor(Vertical Sensor)

2 Body Lateral Acceleration Sensor (Lateral Sensor)

reverse order.

ECS (ECU)
1 Electronically Controlled Suspension (ECU) 4 Parking Brake Lever

2 Connector 5 Over Voltage Protection Relay
3 Bolts (2 pieces)

1. Disconnect each connectors from the console box and
remove the console box.
2. Disconnect ECU connector.
3. Unscrew 10mm x 2 bolts and remove ECS (ECU).
reverse order.

SECTION 2D
REAR SUSPENSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3
General Specifications . . . . . . . . . . . . . . . . . . 2D-1 Component Locator . . . . . . . . . . . . . . . . . . . 2D-4
Fastener Tightening Specifications . . . . . . . . . 2D-1 Maintenance and Repair . . . . . . . . . . . . . . . 2D-5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 2D-5
Noise (During Straight Driving) . . . . . . . . . . . . 2D-2 Rear Suspension (5-Link) . . . . . . . . . . . . . . . . 2D-5
Oil Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2 Rear Shock Absorber . . . . . . . . . . . . . . . . . . . 2D-9
Noise (During Turning) . . . . . . . . . . . . . . . . . . 2D-2
SPECIFICATIONS
Type 5-link
Spring Type Coil Spring
Coil Spring Wire Diameter (mm) 13.8 mm
Diameter (mm) 126.8 mm
Free Height (mm) 384.5 mm
Outer Diameter (mm) f 139.6 mm
Spring Constant (kg·m) 2.58 kg
Shock Absorber Cylindrical Reciprocation Type
Stabilizer Type Torsion Bar Type
Application Nl m
Upper Nut 16 - 22
Stabilizer Bar Bolt 30 - 45
Lateral Rod Nut 150 - 180
Shock Absorber Mounting Nut Upper 50 - 65
Arm Fixing Nut 150 - 180

2D-2 REAR SUSPENSION
DIAGNOSIS
NOISE(DURING STRAIGHT DRIVING)
Check Action
Lack of Oil Replenish
Low Viscosity of Oil Replace
Insufficient Oil Replace
Excessive Backlash of Ring Gear Adjust
Worn or Damaged Tooth of Ring and Pinion Gear Replace
Worn or Damaged Drive Pinion Bearing Replace
Worn Spline of Side Bearing and Side Gear Replace
Bent Axle Housing Replace
Bent Differential Case Replace
Worn Pinion Shaft Replace
Incorrect Drive Pinion Preload Adjust
Incorrect Contact of Ring Gear and Pinion Retightening
OIL LEAKAGE
Check Action
Excessive Oil Adjust
Faulty Seal of Carrier Contact Surface Repair
Axle Housing Crack Replace
Worn or Damaged Oil Seal Replace
NOISE(DURING TURNING)
Check Action
Worn or Damaged Tooth of Pinion or Side Gear Replace
Excessive Backlash of Pinion Gear and Side Gear Replace
Excessive End-play of Rear Axle Shaft Adjust
Incorrect Contact of Side Gear and Differential Case Replace
Bent or Poor Installation of Drive Pinion Oil Seal Replace
Damaged or Torn Drive Pinion Oil Seal Replace
Loosened Bearing Collar Replace
Worn or Damaged Universal Joint Replace
Worn of Damaged Axle Shaft Bearing Replace

REAR SUSPENSION 2D-3
HEATING
Check Action
Insufficient Backlash of Gears Adjust
Excessive Preload of Bearing Adjust

COMPONENT LOCATOR
1 Spring Seat 5 Upper Arm

2 Coil Spring 6 Lower Arm
3 Lateral Rod 7 Connecting Link
4 Shock Absorber 8 Stabilizer Bar


ON-VEHICLE SERIVCE
REAR SUSPENSION (5 - LINK)


l Stabilizer bar
1. Remove the upper nut of the connecting link.
Installation Notice
Distance Between the Nut

10 - 13 mm
end and the Screw end
2. Remove the stabilizer bar cap fixing bolts (arrow) and

remove the stabilizer bar.
Installation Notice
l Lateral Rod
1. Remove the lateral rod fixing nut from the frame.
Notice
Completely press the coil springs.
Installation Notice
2. Remove the lateral rod fixing nut from the rear axle and
remove the lateral rod.
Installation Notice

l Shock Absorber.
1. Remove the lower mounting nut.
Installation Notice
2. Remove the upper mounting nut and remove the shock

absorber.
Installation Notice
Distance between the nut

6 - 9 mm
end and the screw end
l Upper Arm
1. Remove the upper arm fixing nut from the frame.
Installation Notice
2. Remove the upper arm fixing nut from the rear axle and
remove the upper arm.
Installation Notice
l Lower arm
1. Remove the parking brake cable bracket.

2. Remove the lower arm fixing nut from the frame.
Installation Notice
3. Remove the lower arm fixing nut from the rear axle and
remove the lower arm.
Installation Notice

REAR SHOCK ABSORBER
1 Rear Shock Absorber 4 Center Washer

2 Washer 5 Actuator Mounting Bracket
3 Bush 6 Nut (M12 x 1.25) ................................. 40 - 60Nm

1. Disconnect actuator connector and unscrew bolt and remove
actuator assembly.
Notice
l When installing the actuator to the mounting bracket,
the wiring should face outward of the frame.
l Actuator wiring should be fixed 40 - 50mm away from
the wiring ends when fixing it with the frame open clip.
2. Unscrew the upper nut (6).

Notice
When screwing the nut, actuator contacting surface of the
mounting bracket and rod end should be 0.5 - 1.5mm.
3. Remove the mounting bracket (5).

Notice
When installing the bracket, it should be parallel to the frame
side member.
4. Remove the bush and check for damage and replace if

necessary.
5. Unscrew shock absorber lower bolt and nut and remove
the shock absorber.
Notice
Shock absorber is filled with gas, never attempt to cut or
heat.

reverse order.

SECTION 2E
TIRES AND WHEELS

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2E-1 Wheel Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-3
General Specifications . . . . . . . . . . . . . . . . . . 2E-1 Component Locator . . . . . . . . . . . . . . . . . . . 2E-4
Fastener Tightening Specifications . . . . . . . . . 2E-1 Wheel and Tire . . . . . . . . . . . . . . . . . . . . . . . . 2E-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2 Maintenance and Repair . . . . . . . . . . . . . . . 2E-5
Wear Pattern Diagnosis . . . . . . . . . . . . . . . . . 2E-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 2E-5
Identification. . . . . . . . . . . . . . . . . . . . . . . . . 2E-3 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . 2E-5
Radial Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-3
SPECIFICATIONS
Wheel Material Alumimun
Size 7JJ X 15
Tire Type Radial Tire
Size and Tire Pressure P215 / 75R 15 - 30psi
P235 / 75R 15 - 30psi
P255 / 70R 15 - 30psi

Application Nlm
Wheel Bolt Steel 80 - 120
Alumimum 110 - 130

2E-2 TIRES AND WHEELS
DIAGNOSIS
WEAR PATTERN DIAGNOSIS
Wear Pattern Possible Cause Remedy
Wear on Both Tread Shoulders Under Inflation Adjust
Wear on Tread Center Over Inflation Adjust
Tread Torn Out Under Inflation Adjust
One-sided Tread Wear Incorrect Camber or Toe-in Adjust
Feather Edging of Tread Incorrect Toe-in Adjust
Spotty Tread Wear Out of Wheel Balance Adjust
W05-40-003
Spotty Wear-wear Localized on Out of Wheel Balance Adjust

Shoulder Sections Play in Hub Bearings Check play
Adjust preload
Play in Ball Joint Check
Defective Shock Absorber Check

TIRES AND WHEELS 2E-3
IDENTIFICATION
RADIAL TIRE
P 215/75 R 15 94 H M+S Section
Height
Four Season Mud & Snow
Speed Rating (max. 210km/h)
Load Range (below 670kg) Rim
Rim Diameter (inch) Diameter
Radial Tire
Aspect Ratio = (Section Height ¸ Section
Width) x 100
Section Width (mm)
Passenger Car
215/65 R 16 93 V
Speed Rating (max. 240km/h)

Load Range (below 650kg)
Rim Diameter (inch)
Radial Tire
Aspect Ratio = (Section Height ¸ Section
Width) x 100
Section Width(mm)
Summer Tire
WHEEL DISC
7 J x 16 ET 39
Wheel Offset (mm)

(Distance from rim center to wheel
nave contacting surface)
Rim Diameter (inch)

Identification for One-piece Well-base Rim
Code Letter for Height and Profile of Rim Flange
Rim Width (Inch)
ET : Distance from Rim Center to Wheel have Contacting

Surface (mm)
a: Rim Width (Inch)
d: Rim Diameter (Inch)

COMPONENT LOCATOR
WHEEL AND TIRE
1 Wheel Bolts ................. Steel Wheel : 80-120 Nm 4 Tire

.......................... Aluminium Wheel : 110-130 Nm 5 Steel Wheel Weight Balance
2 Steel Wheel 6 Hub Cap
3 Aluminium Wheel


ON-VEHICLE SERVICE
WHEELS AND TIRES
1. Inspection of tire
Check tread area for tread surface, crack, damage by nail
in or stones. Replace or repair if necessary.
2. Wear limit.
Limit 1.6mm
l Replace the tire if tread-wear indicator of the tread
grooves appears where marked 'D'.
l The wear limit of snow tire is the same as normal tire
(1.6mm) and indicator location is marked '¯'.
3. Runout measurement.
l Excessive runout of tires and wheels can cause the
abnormal wear of tire. Using a dial indicator, measure
wheel and tire runout.
l Measure radial runout at the rim flange and center of
the tire tread area.
Standard 2.66mm
l Measure lateral runout at the tire bead area of the wheel

and tire sidewall.
Standard 2.03mm
Notice
If runout is excessive, replace the tire or wheel.

4. Tire pressure inspection.
l Tire pressure.
Front & Rear 2

2.1kg/cm (30PSI)
(P235/75R15)
l Check tread contact with road.

Notice
l If underinflated, tire may come away from the wheel
during rapid steering.
l An overinflated tire will cause a hard riding and uneven
wear.
5. Wheel balance.
l Balance weights should be on each side. When the wheel
is out of balance or a tire has been repaired, be sure to
balance the wheel again.
l If total weight is over 150g, readjust the balance by

reinstalling the tire on the wheel.
l Balance weight should not protrude from the wheel rim
over 3mm.
l For aluminum wheel, use aluminum wheel balance weight
only.

l To correct unbalance, install equal weights 180° opposite
each other, one on the inside of the wheel and one on
the outside, at the point of unbalance.
l Balance Weight
10g 20g 30g 40g 50g 60g
0.4oz 0.7oz 1.10oz 1.40oz 1.80oz 2.1oz
6. Cautions for installation and removal.

l Clean the mounting surfaces of hub and wheel.
l Do not apply grease or oil on the nuts and bolts (It will
cause looseness and poor tightening).
l Using a jack, lift up the tire about 3cm from the ground.
l Tighten nuts in a criss-cross pattern 2-3 times.
Steel : 80 - 120Nm
Tighten Torque
Aluminium : 110 - 130Nm

SECTION 3A
FRONT DRIVE AXLE

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Maintenance and Repair . . . . . . . . . . . . . . . 3A-6
General Specifications . . . . . . . . . . . . . . . . . . 3A-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 3A-6
Fastener Tightening Specifications . . . . . . . . . 3A-2 Vacuum Line . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Component Locator . . . . . . . . . . . . . . . . . . . 3A-3 Steering Knuckle and Drive Shaft . . . . . . . . . . 3A-8
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-14
Auto-Locking Hub . . . . . . . . . . . . . . . . . . . . . . 3A-4 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
Vacuum Circuit . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
SPECIFICATIONS
Drive Shaft Type CV Joint
Axle Housing Type Build - up
Differential Type Conventional
Differential Gear Hypoid Gear
Reduction Ratio 661NA M/T 4.56
662NA M/T 4.56
A/T (MB) 3.73
661LA M/T 4.56
A/T (BTRA) 5.38
662LA M/T 4.27
A/T (BTRA) 4.89
E20 M/T 4.89
A/T (MB) 4.55
E23 M/T 4.55
A/T (MB) 4.55
A/T (BTRA) 5.86
E32 M/T 3.73
A/T (MB) 3.73
A/T (BTRA) 4.89
Oil Capacity 1.3 L
Oil Specification SEA 80W/90, API GL - 5

3A-2 FRONT DRIVE AXLE

Steering Knuckle and Drive Shaft
Application Nl m
Drive Shaft to Front Axle Inner Shaft 25 - 35
Wheel Speed Sensor 85 - 105
Drive Shaft Cover Bolt 50 - 60
Locking Hub Washer Screw 2-4
Hub Flange Bolt 70 - 90
Hub Nut 15

FRONT DRIVE AXLE 3A-3
COMPONENT LOCATOR
FRONT AXLE
1 Drive Shaft 5 Brake Disc

2 Axle Housing Mounting Bolt 6 Hub-Wheel
3 Axle Housing 7 Locking Hub
4 Cross Member

AUTO-LOCKING HUB
1 Cap 11 Body
2 Filter 12 Return Spring
3 Vacuum Diaphragm 13 Bearing
4 Diaphragm Retainer 14 O-ring
5 Piston 15 Retaining Ring
6 Bolt (M10) 16 Inner Drive Gear
7 Lock Washer 17 Oil Seal
8 O-ring 18 Oil Seal Race
9 Retaining Ring 19 Axle Retaining Ring
10 Clutch Ring

VACUUM CIRCUIT
1 Engine 6 Auto locking Hub Solenoid Valve

2 Vacuum Pump 7 T-connector Hose
3 3-way Connector 8 Hub Hose (left)
4 T-connector 9 Hub Hose (right)
5 Check Valve


ON-VEHICLE SERVICE
VACUUM LINE
1 Vacuum Auto-locking Hub Assembly 12 Check Valve

2 Bolt ...................................................... 50-60 Nm 13 Hose (L :100, green)
3 Cam Washer 14 Auto Locking Hub Solenoid Valve
4 Auto-locking Hub Cap 15 Bolt
5 Retainer Ring 16 Hose (L :100, green)
6 Shim 17 T-connector
7 Locking Hub 18 Hose (L : 720, yellow)
8 Band 19 Hose (L :2, 360 , red)
9 Hose (L : 400) 20 Corrugated Tube
10 T-connector 21 Clip
11 Hose (L : 250, white) 22 Clip

1. Be careful not to change the valve when connecting the
check valve and each hose.
2. Adjust the clearance between the retainer ring (5) and

locking hub (7) using the shim(6).
Normal Max. 0.2 mm

Notice
Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm
3. Tighten the auto locking hub cap bolt to the specified torque
and order.

STEERING KNUCKLE AND DRIVE SHAFT
1 Front Axle Inner Shaft 4 Bolt ...................................................... 45-60 Nm

2 Front Axle Drive Shaft 5 Steering Knuckle
3 Spring Washer

1. Remove the tire.
Installation Notice
Steel Wheel 80 - 120 Nm
Tightening Torque
Aluminum Wheel 110 - 130 Nm
2. Remove the autolocking hub vacuum hose.
3. With ABS
Remove the wheel speed sensor from the steering knuckle.
Installation Notice
4. Remove the mounting bolts and pull off the caliper assembly.
Installation Notice
Hose Bolt 25 - 35 Nm
Tightening Torque
Mounting Bolt 85 - 105 Nm
Notice
Be careful not to damage the brake hose.

5. With part time transfer case.
5-1. Remove the cover mounting bolts and pull off the cover.
Installation Notice
5-2. Remove the snap ring of the drive shaft and pull off the
hub body.
Notice
For assembly, adjust the clearance between the snap ring
and hub not to exceed 0.2 mm (Shim thickness : 0.1, 0.2,
0.3, 0.5, 1.0 mm).
5-3. Remove the screws and pull off the locking hub washer.
Installation Notice
6. With full time transfer case

6-1. Detach the hub cap with screw driver and remove the
snap ring on drive shaft.
Installation Notice
Notice
For assembly, adjust the clearance between the snap ring
and hub not to exceed 0.2 mm (Shim thickness : 0.1, 0.2,
0.3, 0.5, 1.0 mm).

6-2. Unscrew the bolts and remove hub flange.
Installation Notice
Before installation, apply loctite on the mating surface.
7. Remove the hub nut with special tool.
8. Remove the hub and disk assembly.
9. Remove the disk brake dust shield.

Installation Notice

10. Remove the cotter pin and slotted nut and then remove
the steering knuckle arm and tie-rod.
Installation Notice
11. Remove the cotter pin and nut from the steering knuckle
arm and upper arm ball joint connection.
Installation Notice
12. Remove the cotter pin and nut from the steering knuckle
arm and lower and lower arm boll joint connection.
Installation Notice
13. Carefully remove the knuckle arm.

14. Remove the drive shaft mounting bolts and remove the
drive shaft.
Installation Notice
Observe the tighening torque and sequence.

reverse order.

FRONT AXLE
Preceding Work : Removal of the front axle drive shaft
Removla of the steering gear box
1 Axle Mounting Bracket 9 Bushing

2 Breather Hose 10 Nut ..................................................... 95-142 Nm
3 Bolt (Rear) 11 Front Axle Assembly
4 Nut ..................................................... 95-142 Nm 12 Nut ....................................................... 70-80 Nm
5 Cross Member 13 Bolt
6 Bolt (Front) 14 Inner Axle Shaft (LH)
7 Bushing 15 Inner Axle Shaft (RH)
8 Spacer

1. Remove the propeller shaft from the front axle input shaft.
Notice
Before removal, place the alignment marks.
Installation Notice
2. Remove the breather hose.

3. Remove the axle housing mounting nuts (1) from the cross
member.
Installation Notice
4. Remove the cross member mounting nuts (2) from the frame
and remove the cross member.
Installation Notice
5. Support the axle housing on a suitable jack, Remove the

axle housing mounting bracket nuts.
Installation Notice
6. Lowering the jack carefully, remove the axle housing

assembly.

reverse order.

UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle housing

1 Front Axle Housing Mounting Bracket 20 Bearing
2 Inner Shaft (Left) 21 Oil Slinger
3 Bolt ...................................................... 55-65 Nm 22 Drive Pinion
4 Oil Seal .................................................. Replace 23 Oil Filler Plug ....................................... 28-41 Nm
Apply Grease to the Sealing Rib 24 Bolt ...................................................... 39-46 Nm
5 Snap Ring 25 Axle Housing Cover .............. Apply Liquid Gasket
6 Bearing to the Contact Surface
7 Snap Ring 26 Ring Gear
8 Oil Drain Plug ....................................... 28-41 Nm 27 Bearing
9 Front Axle Housing 28 Shim
10 Breather Nipple 29 Shaft Lock Pin
11 Inner Shaft (Right) 30 Differential Case
12 Pinion Lock Nut ................................ 240-310 Nm 31 Bolt ...................................................... 75-90 Nm
13 Washer 32 Bolt ...................................................... 48-69 Nm
14 Companion Flange 33 Washer
15 Oil Seal .................................................. Replace 34 Bearing Cap
Apply Grease to the Sealing Rib 35 Thrust Washer
16 Bearing 36 Side Gear
17 Shim 37 Differential Shaft
18 Bearing Baffle 38 Differential Pinion
19 Shim 39 Thrust Washer

1. Remove the drain plug and drain the oil. Reinstall the drain
plug.
Installation Notice
2. Unscrew the axle housing and housing mounting bracket

bolts and remove the bracket and inner shaft assembly.
3. Remove the bearing fixing snap ring of the inner shaft and
pull out the bearing. Separate the inner shaft and the
mounting bracket.
4. Remove the axle housing cover.

Notice
Clean the cover and housing contact surfaces.

5. Unscrew the bearing cap bolts and remove the bearing caps.
Pull out the differential carrier assembly.
Notice
Place alignment marks on the bearing cap not to change
the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
6. Disassemble the parts of the differential carrier assembly.
7. Remove the drive pinion lock nut. Disassemble the parts of

the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings :
l Check the ring gear and drive pinion for wear and
damage. If damaged, replace it as a set.
l Check the bearing for sticks, wear, noise and turning
resistance.
l Check the side gear, pinion, pinion shaft and thrust
washer for wear and damage.
l Check the differential carrier for crack and wear (bearing
contact surface). Check the gear case for crack.

2. Assemble the parts of the drive pinion.
Tightening Torque of the

240 - 310 Nm
Lock Nut
3. Assemble the parts of the differential carrier.

75 - 90 Nm
Ring Gear Bolts
4. Measure backlash of the side gear and pinion.

Standard 0 - 0.05 mm
5. Install the differential carrier assembly into the axle housing.

48 - 69 Nm
Bearing Cap Bolts
Notice
Be careful not to change the caps. Be sure to keep the
original position of the caps.

6. Measure backlash of the drive pinion and ring gear.
Specified Value 0.13 - 0.20 mm
7. Install the axle housing cover.

8. Assemble the parts of the front axle shaft and housing

mounting bracket.
Notice
Apply grease to the oil seal rib.
9. Align the axle shaft and differential carrier spline and insert
the axle shaft. Assemble the axle housing mounting bracket
to the axle housing.

Inspection of Ring Gear Tooth Contact Pattern
Normal Contact
Apply gear-marking compound (prussian blue / red lead) on
the ring gear teeth. Rotate the ring gear and check the tooth
contact pattern.
Abnormal Contact
Tooth Contact pattern Possible Cause Remedy
1. Heel Contact
Excessive backlash (little) Adjust backlash(Decrease backlash)
l Noise can be occurred l Select proper shim(s) to move the
drive pinion toward the ring gear
(toward toe)
2. Toe Contact
Insufficient backlash (little) Adjust backlash(Increase backlash)
l Tooth can be damaged l Select proper shim(s) to move the
or broken under heavy drive pinion against the ring gear
load (toward heel)
3. Face Contact
Excessive backlash (much) Adjust backlash(Increase pinion shim)
l Drive pinion shaft is apart l Move the drive pinion toward the ring
from the ring gear gear (toward center of ring gear)
l Noise can be occurred
4. Flank Contact Insufficient backlash (much)

l Gear contacts on the low
flank Adjust backlash(Decrease pinion shim)
l Gear can be damaged or l Move the ring gear toward the drive
worn pinion (toward ring gear center line)

SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 Maintenance and Repair . . . . . . . . . . . . . . . 3C-3
General Specifications . . . . . . . . . . . . . . . . . . 3C-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3C-3
Component Locator . . . . . . . . . . . . . . . . . . . 3C-2 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
M/T & A/T (Part-time T/C) . . . . . . . . . . . . . . . . 3C-2
SPECIFICATIONS
Construction Universal Joint with Yoke and Spider
Joint Type Spider (Needle Roller Bearing)
Number of Spider Front (Part-Time T/C) 3
Rear 2
Tube Run-Out E 32 Engine Within 0.3 mm
(after installation) The Others Within 0.4 mm
Front Shaft Dimension Diesel + M/T & A/T + 4408 579 ´ f 59.5 ´ f 63.5
(LÍ.DÓ.D) M161 + M/T & A/T + 4408 583.5 ´ f 44.7 ´ f 50.8
M161 + M/T & A/T Tongil 617.6 ´ f 44.7 ´ f 50.8
KSC 595.6 ´ f 44.7 ´ f 50.8
Rear Shaft Dimension Diesel & M161 + M/T & A/T + 4408 824 ´ f 59.5 ´ f 63.5
(LÍ.DÓ.D) M162 + M/T & A/T + TOD 777 ´ f 59.5 ´ f 63.5

3C-2 PROPELLER SHAFT
COMPONENT LOCATOR
M/T & A/T (PART-TIME T/C)
1 Flange Yoke 7 Oil Seal

2,3 3-Journal Cross and Bearing Kit (Including Snap 8 Split Washer
Ring) 9 Slip Tube Shaft
4 Slip Yoke Assembly 10 Tube
5 Grease Nipple 11 Tube Yoke
6 Dust Cap 12 Flange Yoke
Notice
Only the length of shaft is different and the components of front/rear shaft are the same.
(The deadener is inserted to the inside of tube of rear shaft, both ends)

PROPELLER SHAFT 3C-3

ON-VEHICLE SERVICE
PROPELLER SHAFT
1 Front Axle 6 Transfer Case

2 Bolt ...................................................... 70-80 Nm 7 Bolt ...................................................... 81-89 Nm
3 Front Propeller Shaft (661LA/662LA) 8 Rear Propeller Shaft
4 Front Propeller Shaft (E32) 9 Bolt ...................................................... 70-80 Nm
5 Bolt ...................................................... 81-89 Nm 10 Rear Axle
11 Front Propeller Shaft (E20/E23)

Removal Procedure
1. Place alignment marks and remove the propeller shaft.
2. Place alignment marks before removing the spider.
3. Using a snap ring pliers, remove the snap ring.
4. Slightly tapping the yoke shoulder using a brass hammer,

remove the bearing. Remove the remaining bearings in the
same way.

5. If difficult to remove, clamp the yoke side in a vise and tap
off the needle bearing, using a proper tool.
6. Disassemble the universal joint parts.

l As axles move up and down, universal joints allow drive
angles to change without binding propeller shaft.
1 Grease Nipple 4 Seal

2 Flange Yoke 5 Needle Roller Bearing
3 Spider 6 Snap Ring
1. Visual check.
Check the disassembled parts for wear or crack.
Replace them if necessary.
2. Spider outer diameter (mm).

Standard Limit
16.668 16.647

3. Clearance between the spider and bearing.
Standard Limit
0.03 - 0.098 mm 0.25 mm
4. Propeller shaft runout

l Using a dial indicator, measure propeller shaft runout by
turning the shaft. If runout exceeds limit, replace the
propeller shaft or correct it using a press.
Limit 0.4 mm
5. Universal joint starting torque.

Starting Torque 3 - 8 kglcm
6. Possible cause of vibration.

l Drift away of balance weights.
l Excessive runout of the propeller shaft.
l Using normal bolts.
l Excessive wear of the universal joint.
l Sticks in sleeve joint.
l Drive angle changes in universal joints or cross causes
vibration and can be detected around 60~100 km/h.

Clean the disassembled parts and replace them if damaged.
1. Align the alignment marks of the yoke and assemble the
spider, bearing and snap ring.
2. Apply grease to the inner of the bearing cap of the needle

roller bearing and assemble the needle roller.
Grease EP #2
3. Install the bearing cap to the yoke and insert the spider.
Install the opposite side cap by tapping with a plastic
hammer. Adjust clearance of the spider pin to be within 0.1
mm and install the snap ring.
4. Align the alignment marks and install the front and rear
propeller shaft. Tighten the nuts to the specified torque.

SECTION 3D
REAR DRIVE AXLE

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3D-1 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4
General Specifications . . . . . . . . . . . . . . . . . . 3D-1 Component Locator . . . . . . . . . . . . . . . . . . . 3D-5
Fastener Tightening Specifications . . . . . . . . . 3D-2 Maintenance and Repair . . . . . . . . . . . . . . . 3D-6
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3D-6
Noise (During Straight Driving) . . . . . . . . . . . . 3D-3 Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-6
Oil Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9
Noise (During Turning) . . . . . . . . . . . . . . . . . . 3D-3 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3D-11
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3 Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3D-11
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4 LSD (Limited Slip Diffrential) . . . . . . . . . . . . . 3D-16
SPECIFICATIONS
Axle Shaft Type Semi - floating
Axle Housing Type Salibury (Build-up)
Differential Type Conventional Type
Gear Hypoid Gear
Reduction Ratio 661NA M/T 4.55
662NA M/T 4.55
A/T (MB) 3.73
661LA M/T 4.55
A/T (BTRA) 5.38
662LA M/T 4.27
A/T (BTRA) 4.89

3D-2 REAR DRIVE AXLE
GENERAL SPECIFICATIONS(Cont'd)
Reduction Ratio E20 M/T 4.89
A/T (MB) 4.55
E23 M/T 4.55
A/T (MB) 4.55
A/T (BTRA) 5.86
E32 M/T 3.73
A/T (MB) 3.73
A/T (BTRA) 4.89
Oil Capacity 1.9 L
Oil Specification SEA 80W/90, API GL - 5

Application N·
·m
Inner Bracket Mounting Nut 50 - 65
Propeller Shaft to Rear Axle Input Shaft 70 - 80
Lower Arm Mounting Nut 150 - 180
Lower Shock Absorber to Axle Housing 50 - 65
Upper Arm Mounting Nut 150 - 180
Stabilizer Bar Mounting Bolt 30 - 45
Lateral Rod Mounting Nut 150 - 180
Drive Pinion Lock Nut 240 - 310
Oil Drain Plug 28 - 42
Ring Gear Mounting Bolt 75 - 90
Oil Filler Plug 28 - 42

REAR DRIVE AXLE 3D-3
DIAGNOSIS
NOISE (DURING STRAIGHT DRIVING)
Checks Action
Low Viscosity of Oil Replace
Insufficient Oil Replace
Excessive Backlash of Ring Gear Adjust
Worn or Damaged Tooth of Ring and Pinion Gear Replace
Worn or Damaged Drive Pinion Bearing Replace
Bent Axle Housing Replace
Bent Differential Case Replace
Incorrect Drive Pinion Preload Adjust
Incorrect Contact of Ring Gear and Pinion Retightening
OIL LEAKAGE
Checks Action
Excessive Oil Adjust
Faulty Seal of Carrier Contact Surface Repair
NOISE (DURING TURNING)

Checks Action
Worn or Damaged Tooth of Pinion or Side Gear Replace
Excessive Backlash of Pinion Gear and Side Gear Replace
Excessive End-play of Rear Axle Shaft Adjust
Incorrect Contact of Side Gear and Differential Case Replace
Bent or Poor Installation of Drive Pinion Oil Seal Replace
Damaged or Torn Drive Pinion Oil Seal Replace
Loosened Bearing Collar Replace
Worn or Damaged Universal Joint Replace
Worn or Damaged Axle Shaft Bearing Replace
HEATING
Checks Action
Insufficient Backlash of Gears Adjust
Excessive Preload of Bearing Adjust

VIBRATION
Checks Action
Faulty Connection of Sliding Joint Adjust
Bent Propeller Shaft Replace
Symmetry of Universal Joint Snap Ring Adjust
Loosened Yoke Bolts Tighten
NOISE
Checks Action
Worn or Damaged Universal Joint Bearing Replace
Fallen Off Universal Joint Snap Ring Adjust or Replace
Loosened Yoke Connection Tighten
Worn Sliding Joint Spline Replace
Insufficient Grease Apply as Necessary

COMPONENT LOCATOR



ON-VEHICLE SERVICE
AXLE SHAFT
1 Brake Disc 7 Parking Brake Lining and Back Plate Assembly

2 Dust Plug 8 Caliper Assembly
3 Rear Axle Shaft 9 Gasket
4 Nut ....................................................... 50-65 Nm 10 Bolt .................................................... 85-100 Nm
5 Washer 11 Rear Axle Housing
6 Parking Brake Cable

1. Remove the tire.
Installation Notice
Steel Wheel 80 - 120 Nm
Tightening Torque
Aluminum Wheel 110 - 130 Nm
2. Release the parking brake.
3. Remove the bolts and the brake caliper.

Installation Notice
Be careful not to damage the brake hose.
4. Remove the brake disc.

Notice
To remove the disc, install the bolts (M8 x 1.25) into the
service hole and uniformly tighten the bolts.
5. Disconnect the parking brake cable.

6. Remove the plug from the axle shaft flange and remove the
inner shaft mounting nuts.
Installation Notice
7. Remove the axle shaft, parking brake lining and back plate
assembly.

reverse order.

AXLE
1. Lift up the vehicle and support the frame safely.
2. Remove the axle shaft.
3. Remove the propeller shaft from the rear axle input shaft.
Installation Notice
Notice
Place alignment marks before removal.
4. Disconnect the parking brake cable and brake hose.
5. Remove the lower arm mounting nuts and remove the lower
arm from the axle housing.
Installation Notice

6. Separate the lower shock absorber from the axle housing.
Installation Notice
7. Remove the upper arm mounting nuts and remove the

upper arm form the axle housing.
Installation Notice
8. Remove the stabilizer bar.

Installation Notice
9. Remove the lateral rod mounting nuts and remove the

lateral rod from the axle housing.
Installation Notice
10. Lowering the axle housing slowly, remove the coil springs
and spring seats.

reverse order.

UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle shaft
Removal of the axle housing
1 Drive Pinion Lock Nut ...................... 240-310 Nm 17 Bolt .................................................... 87-124 Nm

2 Washer 18 Bearing
3 Companion Flange 19 Shim
4 Pinion Oil Seal 20 Ring Gear
5 Bearing Slinger 21 Shaft Lock Pin
6 Bearing 22 Differential Case
7 Shim 23 Ring Gear Mounting Bolt ...................... 75-90 Nm
8 Shim 24 Thrust Washer
9 Bearing Cup 25 Differential Pinion
10 Breather Nipple 26 Thrust Washer
11 Rear Axle Housing 27 Side Gear
12 Oil Drain Plug ....................................... 28-42 Nm 28 Differential Shaft
13 Shim 29 Housing Cover
14 Bearing 30 Bolt ...................................................... 38-46 Nm
15 Drive Pinion 31 Oil Filler Plug ....................................... 28-42 Nm
16 Bearing Cap

1. Remove the drain plug and drain the oil. Reinstall the drain
plug.
2. Remove the axle housing cover.

Notice
Clean the cover and housing contact surface.
3. Remove the bearing cap bolts and remove the bearing caps.
Pull out the differential carrier assembly.
Notice
Place alignment marks on the bearing cap not to change
the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
4. Disassemble the parts of the differential carrier assembly.

5. Remove the drive pinion lock nut. Disassemble the parts of
the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings.
l Check the ring gear and drive pinion for wear or damage.
If damaged, replace it as set.
l Check the bearing for sticks, wear, noise or turning
resistance.
l Check the side gear, pinion, pinion shaft and thrust
washer for wear or damage.
l Check the differential carrier for crack or wear (bearing
contact surface). Check the gear case for crack.
2. Assemble the parts of the drive pinion.
Tightening Torque of The 240 - 310 Nm

Pinion Lock Nut
3. Assemble the parts of the differential carrier.

Ring Gear Bolts

4. Measure backlash of the side gear and pinion gear.
Specified Value 0 - 0.05 mm
5. Install the differential carrier assembly into the axle housing.

Bearing Cap Bolts
Notice
Be careful no to change the caps. Be sure to keep the original
position of the caps.
6. Measure backlash of the drive pinion and ring gear.
Specified Value 0.13 - 0.20 mm
7. Install the axle housing cover.


Inspection of Ring Gear Tooth Contact Pattern
Normal Contact
Apply gear-marking compound (prussian blue / red lead) on
the ring gear teeth. Rotate the ring gear and check the tooth
contact pattern.
Abnormal Contact
Tooth Contact pattern Possible Cause Remedy
1. Heel Contact
Excessive backlash (little) Adjust backlash(Decrease backlash)
l Noise can be occurred l Select proper shim(s) to move the
drive pinion toward the ring gear
(toward toe)
2. Toe Contact
Insufficient backlash (little) Adjust backlash(Increase backlash)
l Tooth can be damaged l Select proper shim(s) to move the
or broken under heavy drive pinion against the ring gear
load (toward heel)
3. Face Contact
Excessive backlash (much) Adjust backlash(Increase pinion shim)
l Drive pinion shaft is apart l Move the drive pinion toward the ring
from the ring gear gear (toward center of ring gear)
4. Flank Contact Insufficient backlash (much)

l Gear contacts on the low
flank Adjust backlash(Decrease pinion shim)
l Gear can be damaged or l Move the ring gear toward the drive
worn pinion (toward ring gear center line)

LSD (LIMITED SLIP DIFFERENTIAL)
1 Limited Slip Differential Assembly 9 Shaft, Hub (Right)

2 Shaft, Hub (Left) 10 Thrust Washer
3 Shim 11 Face Cam (Right)
4 Thrust Washer 12 Cage
5 Face Cam (Left) 13 Thrust Bearing
6 Cam Whillom 14 Plate Spring
7 Thrust Bearing 15 Radial Bearing
8 Radial Bearing 16 Oil Catcher

Inspection
l Remove the LSD assembly and check the pre-load torque.
l If necessary, replace LSD assembly.
Procedure
1. Fix the right shaft of LSD to the special tool (A).
2. Install the special tool (B) to the left shaft and rotate
counterclockwise and check the pre-load torque.
Normal Torque 3.6 - 9.0kgm

Notice
If necessary, replace LSD assembly.

SECTION 4A
HYDRAULIC BRAKES
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this
cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Component Locator . . . . . . . . . . . . . . . . . . . 4A-4
General Specifications . . . . . . . . . . . . . . . . . . 4A-1 ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Noise or Vehicle Vibration When Applied Non-ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Maintenance and Repair . . . . . . . . . . . . . . . 4A-7
Pulls to One Side When Braking . . . . . . . . . . . 4A-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4A-7
Poor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . 4A-7
Increasing Pedal Stroke (Pedal Goes to Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
Floor) or Brake Dragging . . . . . . . . . . . . . . . 4A-3
LCRV (Load Conscious Reducing Valve) . . . 4A-12
Poor Braking of Parking Brake . . . . . . . . . . . . 4A-3
SPECIFICATIONS
Application MANDO Brake PBR Brake
Brake Pedal Type Suspended
Pedal Ratio 4.3 : 1 4.3 : 1
Pedal Stroke 138 mm 132 mm
Pedal Freeplay 1 - 4 mm
Master Cylinder Type Tandem Type with Lever Sensor
Inner Diameter f 25.4 mm f 23.81 mm
Brake Booster Type Vacuum Booster Type
Ratio 5.6 : 1 5.0 : 1
Front Brake Type Ventilated Disc
I.D. of Caliper Cylinder f 60 mm f 60.4 mm
Thickness of Brake Pad 10 mm
Thickness of Disc Plate 24 mm
Rear Brake Type Solid Disc ¬
I.D. of caliper Cylinder f 38.2 mm f 40.5 mm
Thickness of Brake Pad 10.0 mm 9.5 mm
Thickness of Disc Plate 10.4 mm ¬
Parking Brake Type Rear Wheel Internal Expansion Type
Operation Mechanical
Brake Fluid Specification SAE J1703, DOT3

4A-2 HYDRAULIC BRAKES
DIAGNOSIS
NOISE OR VEHICLE VIBRATION WHEN APPLIED BRAKE
Check Action
Incorrectly Mounted Back Plate or Caliper Repair
Loosened Bolt of Back Plate or Caliper Retighten
Crack or Uneven Wear of Brake Drum or Disc Replace
Pad or Lining Sticking to Contact Surface Replace
Excessive Clearance Between Caliper and Pad Repair
Uneven Contact of Pad Repair
Lack of Lubrication Lubricate
Loosened Suspension Retighten
PULLS TO ONE SIDE WHEN BRAKING

Check Action
Incorrect Tire Pressure Between Left and Right Adjust
Poor Contact of Pad or Lining Repair
Oil or Grease is Applied to Pad or Lining Replace
Bent or Uneven Wear of Drum Replace
Incorrectly Mounted Wheel Cylinder Repair
Faulty Auto Adjuster Replace
POOR BRAKING
Check Action
Dirty or Lack of Fluid Replenish or Replace(Check Eventual Leakage)
Air in Brake System Bleeding
Faulty Brake Booster Replace
Poor Contact of Pad or Lining Repair
Oil or Grease on Pad Replace
Over Heated Rotor Due to Dragging Pad or Lining Repair
Clogging Brake Line Repair
Faulty Proportioning Valve Repair ( If Low cut-in : Adjust )
( If Leakage : Replace )

HYDRAULIC BRAKES 4A-3
INCREASING PEDAL STROKE (PEDAL GOES TO FLOOR)

OR BRAKE DRAGGING
Check Action
Air in Brake system Bleeding
Fluid Leaking Repair
Excessive Clearance Between Push Rod and M/cylinder Adjust
Parking Brake is not Fully Released Repair
Incorrect Adjustment of Parking Brake Adjust
Weak Return Spring of Brake Pedal Replace
Incorrect Pedal Freeplay Repair
Broken Rear Drum Brake Shoe Return Spring Replace
Lack of Lubrication lubricate
Damaged Master Cylinder Check Valve or Piston Return Spring Replace
POOR BRAKING OF PARKING BRAKE

Check Action
Insufficient Clearance Between Push Rod and Master Cylinder Adjust
Worn Brake Lining Replace
Oil or Grease on Lining Replace
Binding Parking Brake Cable Replace
Excessive Lever Stroke Adjust or Check Cable

COMPONENT LOCATOR
ABS
1 Actuation Assembly (Booster + TMC) 7 Brake Hose

2 ABS Control Unit 8 Rear Tube
3 Master Cylinder 2nd Tube (Secondary) 9 Bolt ...................................................... 25-35 Nm
4 Master Cylinder 1st Tube (Primary) 10 2-way Connector
5 Front Tube (LH) 11 3-way Connector
6 Front Tube (RH)

ABS / ABD
1 Actuation Assembly (Booster + TMC) 6 Front Tube (RH)

2 Master Cylinder 1st Tube (Primary) 7 Rear Tube (RH)
3 Master Cylinder 2nd Tube (Secondary) 8 Rear Tube (LH)
4 Hydraulic Modulator 9 2-way Connector
5 Front Tube (LH)

NON-ABS/ABD
1 Actuation Assembly (Booster + TMC) 5 2-way Connector

2 3-way Connector 6 Rear Tube
3 Front Tube (LH) 7 3-way Connector
4 Front Tube (RH) 8 LCRV


ON-VEHICLE SERVICE
BLEEDING THE BRAKES
For Master Cylinder Replacement
1. Add oil after master cylinder replacement.
2. Run the engine and depress the brake pedal several times
to build pressure and then keep the pedal fully depressed.
3. Loosen the screws of primary and secondary pipe at the
master cylinder outlets to bleed air.
4. Repeat above step No.3 several times until there are no
more air bubbles.
5. Bleed air in the system at the hydraulic unit outlet pipe and
wheel if pressure building is not enough by depressing the
pedal only after above air bleeding.
For Caliper and Brake Hose Replacement

1. Check the oil level from the oil reservoir and refill if necessary.
2. Run the engine and depress the pedal several times to
build pressure and then keep the pedal fully depressed.
3. Connect a vinyl tube to the caliper breather and prepare a
container to coentain brake oil.
4. Loosen the breather screw until there are no more bubbles.
5. Bleed air in the system at four (4) wheels in order as shown

in right figure if pressure building is not enough by depressing
the pedal after above air bleeding.

For Hydraulic Unit Replacement
1. Add oil after hydraulic unit replacement.
2. Run the engine and depress the pedal several times to
build pressure and then keep the pedal fully depressed.
3. Loosen hydraulic pipe screws at the hydraulic unit outlets

to bleed air.
4. Repeat above step No.3 several times until there are no
more air bubbles.
5. Bleed air in the system from the wheels if pressure building
is not enough by pressing the pedal only after above air
bleeding.

BRAKE PEDAL
1 Clevis Pin 8 Return Spring

2 Brake Pedal 9 Pedal Mounting Bracket
3 Stop Lamp Switch 10 Washer
4 Pad 11 Nut ....................................................... 16-32 Nm
5 Nut ....................................................... 21-35 Nm 12 Bolt ........................................................ 8-18 Nm
6 Yoke Pin 13 Stopper Bolt .............................................. Adjust
7 Fulcrum Pin 14 Rubber Pad ........................................... Replace

1. Remove the stop lamp switch connector.
2. Remove the clevis pin and disconnect the brake booster

push rod.
Notice
l Install in the upper hole (1), in case of Mando brake and
in the below hole (2), incase of PBR brake.
l Install the snap pin fully in the hole of clevis pin.
l Apply the grease around the hole of clevis pin.
3. Loosen the nut (4EA) and bolt (2EA) and remove the brake
pedal.
reverse order.

1. Pedal Height
Height (A) 150 mm (From the carpet)
Notice
If pedal height is not in specified value, loosen the stop
lamp nut (B) and adjust the pedal height.
2. Pedal Stroke
Mando : 138 mm
Stroke (C)
PBR : 132 mm
Notice
If pedal stroke is not in specified value, loosen the stop bolt
and lock nut (F) and adjust the pedal stroke.
3. Free Play
Free Play (E) 1 - 4 mm
Notice
To adjust, depress the brake pedal several times until there
is no more vacuum left in the vacuum line.
To adjust, loosen the lock nut (D) of the push rod and turn
the rod.
1. Inspect the wear of bushing.
2. Inspect the warp and bend of brake pedal.
3. Inspect the return spring of brake pedal.
4. Inspect the conductivity when connecting the tester to the
stop lamp switch connector.

LCRV (LOAD CONSCIOUS REDUCING VALVE)
1 Brake Tube (from the master cylinder) 5 LCRV Assembly

2 Brake Tube (from the rear brake) 6 Connecting Link
3 LCRV Bracket 7 Spring Washer
4 Bolt ........................................................... 12 Nm 8 Nut ....................................................... 14-18 Nm

Construction
LCRV consists of sensing part and hydraulic control part.
1. Sensing Part
It detects the changes of vehicle height caused by vehicle
load. It consists of load sensing spring and control lever
which change according to vehicle load.
2. Hydraulic Control Part
It consists of valve stem devices which controls hydraulic
pressure according to load detected by sensing part.
Trouble Shooting
Poor Braking
Possible Cause Remedy
Air in Brake System Bleeding
Poor Adjustment of Sensor Spring Adjust
Damaged Sensor Spring Replace
Fluid Leaking from LCRV Replace
Abnormal Locking
Possible Cause Remedy
Poor Adjustment of Sensor Spring Adjust
Internal Fluid Leaking of LCRV Replace

LCRV Setting Method
1. LCRV setting should be performed with unladen vehicle

condition.
2. Install the connecting rod (a) to the No.1 hole.
3. Adjust the clearance “X” to be 0 mm and tighten the bolt (c)
using the lock nut (b).
4. Remove the connecting rod (a) from the No. 1 hole and
reinstall it to the No. 2 hole.
5. Place alignment marks between the lock nut (b) and

adjusting screw (c) after the valve setting.

SECTION 4B
MASTER CYLINDER
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4B-2
Fastener Tightening Specifications . . . . . . . . . 4B-1 Booster & Brake Master Cylinder . . . . . . . . . . 4B-2
Maintenance and Repair . . . . . . . . . . . . . . . 4B-2
SPECIFICATIONS
Application N·
·m
Master Cylinder Nut 14 - 22
Booster Nut 8 - 18

4B-2 MASTER CYLINDER

ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER
MANDO
PBR
1 Nut ....................................................... 14-22 Nm 9 Seal

2 Washer 10 Spacer
3 Master Cylinder Assembly 11 Nut ......................................................... 8-18 Nm
4 Oil Level Sensor 12 Front Tube (LH)
5 Check Valve 13 Front Tube (RH)
6 Booster 14 Rear Tube
7 Clevis Pin 15 1st Tube (Primary)
8 Snap Pin 16 2nd Tube (Secondary)

MASTER CYLINDER 4B-3
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.
Installatione Notice
Notice
l Be careful not to drop the oil when removing the tube.
l If the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose.

Notice
l Connect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder.

Installatione Notice
5. Remove the clevis pin and disconnect the pedal and brake
booster push rod.
Notice
l Install in the upper hole when PBR brake.
l Connect the snap pin in the hole of clevis pin fully.

4B-4 MASTER CYLINDER
6. Loosen the nut of booster and remove the booster from the
dash panel.
Installation Notice

reverse order.
8. Add the fluid and bleed.
9. If necessary, adjust the pedal height, pedal stroke and free
play.

SECTION 4C
POWER BOOSTER
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4C-2
General Specifications . . . . . . . . . . . . . . . . . . 4C-1 Booster & Brake Master Cylinder . . . . . . . . . . 4C-2
Maintenance and Repair . . . . . . . . . . . . . . . 4C-2 Pedal Stroke Inspection . . . . . . . . . . . . . . . . . 4C-5
SPECIFICATIONS
Type Vacuum Assisted
Ratio 5.6 : 1

4C-2 POWER BOOSTER

ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER
MANDO
PBR
1 Nut ....................................................... 14-22 Nm 9 Seal

2 Washer 10 Spacer
3 Master Cylinder Assembly 11 Nut ......................................................... 8-18 Nm
4 Oil Level Sensor 12 Front Tube (LH)
5 Check Valve 13 Front Tube (RH)
6 Booster 14 Rear Tube
7 Clevis Pin 15 1st Tube (Primary)
8 Snap Pin 16 2nd Tube (Secondary)

POWER BOOSTER 4C-3
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.
Installation Notice
Notice
l Be careful not to drop the oil when removing the tube.
l If the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose.

Notice
l Connect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder.

Installation Notice
5. Remove the clevis pin and disconnect the pedal and brake
booster push rod.
Notice
l Install in the upper hole when PBR brake.
l Connect the snap pin in the hole of clevis pin fully.

4C-4 POWER BOOSTER
6. Loosen the nut of booster and remove the booster from the
dash panel.
Installation Notice

reverse order.
8. Add the fluid and bleed.
9. If necessary, adjust the pedal height, pedal stroke and free
play.

POWER BOOSTER 4C-5
PEDAL STROKE INSPECTION

1. Start the engine and stop it after one or two minutes.
Depress the brake pedal several times.
If the pedal goes down furthest the first time, but gradually
rises after the second or third time, brake booster is normal.
If there is no change in pedal stroke, the brake booster is
abnormal.
2. Depress the brake pedal several times with engine stopped,

and depress the brake pedal and start the engine. If the
pedal goes down slightly, the booster is normal.
3. Depress the brake pedal with engine running, and stop it

with the pedal depressed. If there is no change in pedal
height during 30 sec., the booster is normal.

SECTION 4D
FRONT DISC BRAKES

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4D-1 Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-2
Fastener Tightening Specifications . . . . . . . . . 4D-1 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5
Maintenance and Repair . . . . . . . . . . . . . . . 4D-2 Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4D-2
SPECIFICATIONS
Application N·
·m
Caliper Mounting Bolt 85 - 105
Brake Hose Bolt & Nut 25 - 35
Caliper Bolt 22 - 34

4D-2 FRONT DISC BRAKES

ON-VEHICLE SERVICE
FRONT DISC BRAKE
Preceding Work : Removal of wheels and tires
1 Eye-Hose Bolt ...................................... 25-35 Nm 7 Front Disc Assembly

2 Gasket ................................................... Replace 8 Brake Pad
3 Brake Hose 9 Brake Hose and Nut ............................. 25-35 Nm
4 Brake Caliper 10 Gasket ................................................... Replace
5 Bolt ........................................................... 20 Nm 11 Washer
6 Washer 12 Bolt .................................................... 85-105 Nm

FRONT DISC BRAKES 4D-3
1. MANDO Brake
Remove the hose mounting nut and disconnect the hose.
Installation Notice
2. PBR Brake
Remove the eye-hose bolt and disconnect the hose.
Installation Notice
3. Remove the wheel speed sensor (for ABS vehicles).

Installation Notice
4. Remove the mounting bolts and then caliper assembly.

Installation Notice

4D-4 FRONT DISC BRAKES
5. Pull out the brake pads. Replace pads if necessary.
Notice
Always change the all pads on one wheel at a time.
reverse order.
7. Bleed the air from the system.

FRONT DISC BRAKES 4D-5
UNIT REPAIR
FRONT DISC BRAKE
1. Clean all components and visually check the followings.
l Check the cylinder and piston for wear, rust or damage.
l Check the caliper body and guide pin for wear, damage
or crank.
l Check the pads for uneven wear or oiliness.
l Check the boots for damage or tear.
2. Measure caliper housing inner diameter.

Item Standard Wear Limit
With PBR f 60.4 mm f 61.4 mm
With MANDO f 60.0 mm f 61.0 mm
3. Measure pad thickness.

Standard Wear Limit
10 mm 2.0 mm
Notice
4. Measure rotor disc thickness.

Standard Wear Limit
24 mm 22 mm
5. Check the rotor disc for score or runout.

SECTION 4E
REAR DISC BRAKES

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4E-1 Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-2
Fastener Tightening Specifications . . . . . . . . . 4E-1 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-4
Maintenance and Repair . . . . . . . . . . . . . . . 4E-2 Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4E-2
SPECIFICATIONS
Application N·
·m
Caliper Mounting Bolt 85 - 105
Brake Hose 15 - 18
Caliper Bolt 20

4E-2 REAR DISC BRAKES

ON-VEHICLE SERVICE
REAR DISC BRAKE
Preceding Work : Removal of wheels and tires
1 Rear Brake Disc Assembly 7 Brake Hose

2 Brake Pad 8 Gasket ................................................... Replace
3 Brake Caliper 9 Eye-Hose Bolt ...................................... 15-18 Nm
4 Gasket ................................................... Replace 10 Washer
5 Bolt ........................................................... 20 Nm 11 Bolt .................................................... 85-105 Nm
6 Gasket ................................................... Replace

REAR DISC BRAKES 4E-3
1. Remove the eye-hose bolt and disconnect the hose.
Installation Notice
2. Unscrew the mounting bolts and remove the brake caliper

assembly.
Installation Notice
3. Pull out the brake pads. Replace pads if necessary.

Notice

reverse order.
5. Bleed the air from the system.

4E-4 REAR DISC BRAKES
UNIT REPAIR
REAR DISC BRAKE
1. Clean all components and visually check the followings.
l Check the cylinder and piston for wear, rust or damage.
l Check the caliper body and guide pin for wear, damage
or crank.
l Check the pads for uneven wear or oiliness.
l Check the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item Standard Wear Limit

With PBR f 40.5 mm f 41.5 mm
With MANDO f 38.2 mm f 39.2 mm
3. Measure pad thickness.
Standard Wear Limit

9.5 mm 2.0 mm
Notice
4. Measure rotor disc thickness.
Standard Wear Limit

10.4 mm 9.3 mm
5. Check the rotor disc for score or runout.

SECTION 4F
ANTILOCK BRAKE SYSTEM

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4F-1 ABS, ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . 4F-7
General Specifications . . . . . . . . . . . . . . . . . . 4F-1 Defect Codes . . . . . . . . . . . . . . . . . . . . . . . . . 4F-9
Schematic and Routing Diagrams . . . . . . . . 4F-2 Maintenance and Repair . . . . . . . . . . . . . . 4F-15
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 4F-15
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-3 Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 4F-15
Component Locator . . . . . . . . . . . . . . . . . . . 4F-4 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . 4F-17
ABS, ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . 4F-4 ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-17
ABD System Description . . . . . . . . . . . . . . . 4F-5 ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . 4F-20
Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4F-7
SPECIFICATIONS
Model ABS 5.3 ABS/ABD 5.3
ECU Number of Pins 31 83
Operating Temperature -40 ~ +120°C -40 ~ +85°C
Hydraulic System Motor Operating Current Below MAX 40A Below MAX 45A
Solenoid Coil Resistance 8.04 - 9.04W except AV,
HSV 4.04 - 4.54W
Wheel Speed Sensor External Resistance 1.28KW - 1.92KW 1.28KW - 1.92KW
Impulse Ring Air Gap Front 0.35 - 1.60 mm 0.35 - 1.60 mm
Rear 0.15 - 1.20 mm 0.15 - 1.20 mm
Number of teeth Front 52 52
Rear 52 52

4F-2 ANTILOCK BRAKE SYSTEM

ABS 5.3

ANTILOCK BRAKE SYSTEM 4F-3
ABS/ABD 5.3

COMPONENT LOCATOR
ABS, ABS/ABD 5.3
1 ABS/ABD Hydraulic Unit (with ECU in cose of ABS 4 ABS Warning Indicator Light
only) 5 Diagnosis Connector
2 ABS/ABD ECU Unit (in case of ABD) 6 Front Wheel Speed Sensor
3 Rear Wheel Speed Sensor

ABD SYSTEM DESCRIPTION

General:
The Automatic Brake Differential Lock (ABD) is a traction system by means of brake intervention only, available in
a low speed range (< 60kph).
It workes on m-split roads with sidewise different friction coefficients.
The spinning driven wheel is braked and the drive torque can be transferred to the wheel on the high- m side.
During ABD active, the ABD information lamp is blinking.
The temperature of the brakes is calculated by a mathematical model and ABD is switched passive if the calculated
temperature is greater than a threshold value(500°C).
ABD is permitted again, when the calculated temperature is less than 350°C.
Control Algorithm: Speed difference driven wheels [kph]

The input signals for the control algorithm are the filtered
wheel speed signals from the ABS speed processing.
With the speed difference of the driven wheels, the control 18
ABD operation
deviation is calculated.
If the control deviation exceeds a certain threshold value,
the wheel with the greater slip is braked actively.
The threshold value depends on the vehicle speed:
It is reduced with increasing vehicle speed down to a constant 6
Vehicle
value. speed
12 60 [kph]
Pressure Modulation:
Depending on the control deviation and the wheel acceleration of the spinning wheel, pressure increase, hold and
decrease are made.
The pressure modulation is done with the conventional control with the valves. ASV, USV, EV and AV according
the the following table:
Increase Hold Decrease
ASV Open Open Open
USV Closed Closed Closed
EV Open Closed Closed
AV Closed Closed Open
Speed Range:
ABD is available in the speed range £ 60 kph.
Above 60 kph vehicle speed, ABD is passive.
It is possible to initiate ABD operation up to a vehicle speed of 55kph.

Temperature Model:
ABD operation is a high thermal load for the brakes.
To avoid any damages at the brakes, the disk temperature is calculated with a mathematical model for each driven
wheel separately. After ignition on, the calculation starts with 30°C and then three different phases are evaluated
separately and added:
ABD operation, braking and coling phase.
If the temperature is highter than 500°C, ABD is disabled for this wheel.
It is permitted again, if the model has calculated down the 350°C.
Lamp Concepts:
The system is equipped with an ABD information lamp, which is blinking during ABD operation.
The activation of the EBD, ABS warning lamp and the ABD info lampo is summarized in the following table:
System failure ABD passive due

Ignition ABS ABD
(EBD,ABS or ABD are to temperature
ON Operation Operation not distinguished)
model
ABS warning 2s on for lamp
OFF OFF ON OFF
lamp check
ABD info 2s on for lamp Dlinking
OFF OFF OFF
lamp check (Flashing)
EBD warning 2s on for lamp EBD operation
OFF ON OFF
lamp check / OFF

SELF DIAGNOSIS
ABS, ABS/ABD 5.3
Initialization
2. Using a service connector, ground the No.13 terminal of
diagnosis socket and No.1 ground terminal for 3-4 seconds.
Notice
If it is over 5 seconds, initialization will not be performed.
3. After completing the initialization, ABS warning lamp will be

turned on until the ignition switch is turned to "OFF" position.
Output of Fault Code

1. Normal : 1 pulse (normal code 01)
2. Abnormal : 1 pulse (fault code)
Notice
l If appeared initial fault code and above 2 differnt fault
code, perform again initialization.
l Fault code will be output the numbers of fault code with
a interval of 1 second.(turn on : 0.75 sec., turn off : 0.25
sec.)
Fault Code Elimination

After repairing the defect parts, eliminate the fault from ECU.
1. Ground the diagnosis No.13 terminal to No.1 ground terminal
for over 5 seconds.
2. Turn the igniotion switch to "OFF" position.
Notice
l If not eliminate the fault code, the code will be maintained.
l Check and find the other defect parts with performing
the imitialization again, if the fault code will be output,
repair the defect parts completely.

Diagnosis the Flash Code
[Ex]
l Time Differences of Normal Code 01 : TW1<T<Te<TW2
l Time Differences of Fault Code 15 : TW1<T<Te<TW2
Time Characteristics
1. Initialization
Tba < 5.0 sec.
Tba 1.8 - 2.2 sec.
2. Output of Fault Code
TW1 = 1.8 - 2.2 sec.
TW2 = 1.8 - 2.2 sec.
T = 0.75 sec., Te ³ 0.25 sec.
3. Elimination of Fault Code
Tb1 = 5.0 sec.

DEFECT CODES
Defect Code Application Description
01 Normal -
02 Defective ECU Replace the ECU
03 Front/left Wheel Speed l Check resistance of the wheel speed sensor : 1.280KW
Sensor (Wire) - 1.920KW
l Check wire for ground and open.
l Replace the sensor.
04 Front/right Wheel Speed l Check resistance of the wheel speed sensor : 1.280KW
05 Rear/left Wheel Speed l Check resistance of the wheel speed sensor : 1.280KW
06 Rear/right Wheel Speed l Check resistance of the wheel speed sensor : 1.280KW
07 Front/left Wheel Speed l Check wire for ground and open.
Sensor (Signal) l Check connection of the wheel speed sensor connec-
tor and ECU side connector.
l Measure air gap between wheel teeth and wheel speed
sensor and check installation of wheel tooth.
(Standard air gap : 0.35 - 1.60 mm)
l Check output voltage of the sensor by rotating the
wheel 1/2 - 1 revolution per second and shaking sen-
sor wire.
- When measured by multi - meter (AC) :
output voltage > 70 mV
- When measured in oscilloscope :
output voltage ³ 120 mV/P-P
08 Front/right Wheel Speed l Check wire for ground and open.
Sensor (Signal) l Check connection of the wheel speed sensor. con-
nector and ECU side connector.
l Measure the air gap between wheel teeth and wheel
speed sensor and check installation of wheel tooth.
sor wire.


09 Rear/left Wheel Speed l Check wire for ground and open.
Sensor (Signal) l Check connection of the wheel speed sensor con-
sor wire.
10 Rear/right Wheel Speed l Check wire for ground and open.
Sensor (Signal) l Check connection of the wheel speed sensor con-
l Measure air gap between wheel teeth and wheel
speed sensor and check installation of wheel tooth.
sor wire.
11 Wheel Rotor l Check number of teeth on the wheel rotor and its
condition.
- Number of teeth : 52
12 Valve Relay l Check valve relay voltage.
l Check connection of connector and terminals in the
ECU and hydraulic modulator.
l Check ground.
l Check terminals for open or short.
(When connector is removed)
l Replace the hydraulic modulator.


13 Front / left INLET Valve l Check each valve by using SCANER's solenoid valve
overriding function.
ECU hydraulic modulator.
14 Front / left OUTLET Valve l Check each valve by using SCANER's solenoid valve
15 Front / right INLET Valve l Check each valve by using SCANER's solenoid valve
16 Front / right OUTLET Valve l Check each valve by using SCANER's solenoid valve
17 Rear / left INLET Valve (ABD) l Check each valve by using SCANER's solenoid valve
18 Rear / left OUTLET Valve l Check each valve by using SCANER's solenoid valve
19 Rear / right INLET Valve l Check each valve by using SCANER's solenoid valve


20 Rear / right OUTLET Valve l Check each valve by using SCANER's solenoid valve
21 Function and Response of The l Check solenoid internal resistance of the prime(ASV)
Valve valve and pilot valve(USV) : 8.04 - 9.04 W
l Check each valve by using SCANER's solenoid valve
22 Function and Response of The l Check solenoid internal resistance of the prime(ASV)
Valve valve and pilot valve(USV) : 8.04 - 9.04 W
l Check each valve by using SCANER's solenoid valve
24 Motor Relay / Circulation Pump l Check each valve by using SCANER's pump motor
l Check resistance between pump motor ground ter-
minal and battery negative terminal : total resistance
should be less than 15 mW.
l Check body ground location.
l Check relay supply voltage : IGN on : 11 - 14 V
l Relay coil internal resistance : 70 - 80 W
27 Stop Lamp Switch l Check by using SCANER's stop lamp switch diagnos-
ing function from sensor value output function.
l Check connection of ECU connector side stop lamp
switch terminal.
l Check resistance of the stop lamp switch.
- Each end resistance value of the switch


when switch knob (planger) is pressed by 3mm : ¥
- Each ends resistance value of the switch when
switch knob(plunger) is not pressed :
less than 200 mW
l When brake is applied :
ECU (ABS:No.14, ABD:No.48) terminal 11 - 14 V
or VBattery.
When brake is released :
ECU (ABS:No.14, ABD:No.48) terminal 0 V
28 Power Voltage l Check battery voltage.
l Resistance between ECU (ABD:No.28 & 29,
ABS:No.19) pins and battery negative terminal :
less than 20 mW
l Resistance between ECU No.1 (ABS:No.15) pin and
ignition terminal : less than 60 mW
l Check that normal voltage is applied to ECU
(ABD:No.1, ABS:No.15) pin when ignition switch is
turned to "ON" or "OFF".
l Check ABS fuses of 15A and 80A.
l Replace the ECU.
29 Residual Temperature l Check wire (ECU No.50) for open or loose contact.
Measurement (ABD only)
42 Acceleration Sensor Signal (wire) l Check connection between connectors.
l Check relevant wires for open or short.
l Check voltage between ECU side ground (ABD:No.1,
ABS:No.15 pin) and acceleration sensor side ground
(ABD:No.1, ABS:No.15 pin / ECU side ABD:No.39,
ABS:No.30 pin)
(When connector is installed and power is applied)
- Voltage : less than 0.25 V
l Check voltage among related terminals.
- Voltage between ECU (ABD:No.43, ABS:No.28 pin
and ABD:No.39, ABS:No.30 pin)
: 4.75 - 5.25 V
- Signal voltage between ECU (ABD:No.51,
ABS:No.10) pin and (ABD:No.39, ABS:No.30) pin
: 1.95 V - 3.45 V
(Measure it by laying acceleration sensor horizon-
tally and without external force)


43 Acceleration Sensor Signal (Signal) l Check connection between connectors.
l Check relevant wires for open or short.
l Check and replace the acceleration sensor.
l Replace the ECU.
l Check voltage between ECU side ground (ABD:No.1,
ABS:No.15 pin) and acceleration sensor side ground
(ABD:No.1, ABS:No.15 pin / ECU side ABD:No.39,
ABS:No.30 pin)
- Voltage : less than 0.25 V
l Check voltage among related terminals.
- Voltage between ECU (ABD:No.51, ABS:No.10
pin and ABD:No39, ABS:No.30) pin
: 4.75 - 5.25 V
- Signal voltage between ECU (ABD:No.51,
ABS:No.10 pin and ABD:No39, ABS:No.30) pin
: 1.95 V - 3.45 V
(Measure it by laying acceleration sensor horizon
tally and without external force)


ON-VEHICLE SERVICE
WHEEL SPEED SENSOR
1 Bolt 4 Bolt
2 Front Wheel Speed Sensor 5 Rear Wheel Speed Sensor
3 Knuckle 6 Rear Axle

ABS Hydraulic Unit
1. Release the ABS wiring connector locking lever in arrow
direction and remove the connector.
Notice
l Do not force the connector when releasing in arrow
direction.
l For installation of the connetor, align and firmly seat
the connector of the hydraulic unit and wiring connector
while keeping the locking lever upward and then push it
down.
2. Remove the hydraulic lines of the hydraulic unit.

During removal, be careful not to drip brake fuid on the
body.
Installation Notice
3. Unscrew hydraulic unit mounting nuts (2EA) and remove

the unit from the bracket.
Installation Notice
Notice
When carrying a new unit, never recline it over 30°.
Removal of the ABS / ABD Unit

Location : Under the front passenger's seat.
1. Remove the wiring connector of the ABS/ABD(or ABS :
Attached type) ECU.
2. Remove the ground wire.
3. Unscrew the mounting bolts and remove the ECU.
reverse order.

HYDRAULIC CIRCUIT
ABS 5.3
Pressure Increased
1 Master Cylinder 6 Accumulator Chamber

2 Hydraulic Unit 7 Inlet Valve for Each Wheel
3 Damping Chamber 8 Outlet Valve for Each Wheel
4 Return Pump 9 Front Wheel
5 Return Pump Motor 10 Rear Wheel

Pressure Decreased


Pressure Maintained


ABS/ABD 5.3
Pressure Increased
1 Master Cylinder 7 Inlet Valve for Each Wheel

2 Hydraulic Unit 8 Outlet Valve for Each Wheel
3 Damping Chamber 9 Wheel
4 Return Pump 10 Prime Valve (ASV)
5 Return Pump Motor 11 Pilot Valve (USV)
6 Accumulator Chamber 12 Check Valve
13 ISD (Integrated Suction Damper)

Pressure Decreased


Pressure Maintained (Hold)


SECTION 4G
PARKING BRAKE
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4G-1 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
General Specifications . . . . . . . . . . . . . . . . . . 4G-1 Maintenance and Repair . . . . . . . . . . . . . . . 4G-3
Fastener Tightening Specifications . . . . . . . . . 4G-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4G-3
Component Locator . . . . . . . . . . . . . . . . . . . 4G-2 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-3
SPECIFICATIONS
Type Mechanically Operated Rear Wheel Expansion
Operating Type Manual

Application N·
·m
Parking Brake Lever Bolt 8 - 18
Cable Mounting Bracket Bolt 8 - 18

4G-2 PARKING BRAKE
COMPONENT LOCATOR
PARKING BRAKE
1 Parking Brake Lever 5 Nut

2 Bolt ........................................................ 8-18 Nm 6 Bolt ........................................................ 8-18 Nm
3 Front Parking Brake Cable 7 Rear Parking Brake Cable
4 Equalizer 8 Brake Disc

PARKING BRAKE 4G-3

ON-VEHICLE SERVICE
PARKING BRAKE
1. Disconnect the parking brake indicator switch connector.
2. Disconnect the right and left cable from equalizer while

parking brake lever is released.
3. Unscrew 8 bolts and remove the parking brake lever

assembly.
Installation Notice
Notice
Tighten the bolts with sequence number while the lever is
pulled up 4 to 6 notches.
4. Unscrew the frame and lower arm side cable mounting

bracket bolts.
Installation Notice

4G-4 PARKING BRAKE
5. Remove the retainer with a screwdriver and disconnect the
brake cable.

reverse order.

SECTION 5A
AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-45
Model Part Numbers and Applications . . . . . . 5A-2 One Way Clutches . . . . . . . . . . . . . . . . . . . . 5A-45
Model Specifications . . . . . . . . . . . . . . . . . . . . 5A-2 Planetary Gear Set . . . . . . . . . . . . . . . . . . . . 5A-45
Clutch Pack Details . . . . . . . . . . . . . . . . . . . . . 5A-3 Parking Mechanism . . . . . . . . . . . . . . . . . . . 5A-46
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Power Flows . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5A-4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Schematic and Routing Diagrams . . . . . . . . 5A-5 Power Flow - Park and Neutral . . . . . . . . . . . 5A-48
TCU Circuit (4WD-Diesel) . . . . . . . . . . . . . . . . 5A-5 Power Flow - Reverse . . . . . . . . . . . . . . . . . . 5A-49
TCU Circuit (4WD-Gasoline) . . . . . . . . . . . . . . 5A-6 Power Flow - Manual 1 . . . . . . . . . . . . . . . . . 5A-50
Shift Pattern Diagram . . . . . . . . . . . . . . . . . 5A-7 Power Flow - Drive 1 . . . . . . . . . . . . . . . . . . . 5A-51
661LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-7 Power Flow - Drive 2 and Manual 2 . . . . . . . 5A-52
661LA Power Mode . . . . . . . . . . . . . . . . . . . . 5A-8 Power Flow - Drive 3 and Manual 3 . . . . . . . 5A-54
662LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-9 Power Flow - Drive 3 Lock Up and Manual
662LA Power Mode . . . . . . . . . . . . . . . . . . . 5A-10 3 Lock Up . . . . . . . . . . . . . . . . 5A-56
662LA Low Mode . . . . . . . . . . . . . . . . . . . . . 5A-11 Power Flow - Drive 4 (Overdrive) . . . . . . . . . 5A-57
E32 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-12 Power Flow - Drive 4 Lock Up . . . . . . . . . . . . 5A-59
E32 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-13 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-60
E32 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-14 Diagnostic System . . . . . . . . . . . . . . . . . . . . 5A-60
E23 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-15 Mechanical Tests . . . . . . . . . . . . . . . . . . . . . 5A-69
E23 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-16 Self Diagnosis Test . . . . . . . . . . . . . . . . . . 5A-75
E23 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-17 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5A-79
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 5A-18 Hydraulic System . . . . . . . . . . . . . . . . . . . . . 5A-79
Operator Interfaces . . . . . . . . . . . . . . . . . . 5A-20 Transmission Fluid Test Procedure . . . . . . . . 5A-79
Gear Select Lever Operation . . . . . . . . . . . . 5A-20 Electronic Adjustments . . . . . . . . . . . . . . . . . 5A-80
Driving Mode Selector . . . . . . . . . . . . . . . . . 5A-21 Maintenance and Repair . . . . . . . . . . . . . . 5A-82
Control Systems . . . . . . . . . . . . . . . . . . . . . 5A-22 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5A-82
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22 Removal and Installation of Transmission . . . 5A-82
Electronic Control System . . . . . . . . . . . . . . . 5A-22 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5A-85
Hydraulic Control System . . . . . . . . . . . . . . . 5A-31 Rebuild Warnings . . . . . . . . . . . . . . . . . . . . . 5A-85
Power Train System . . . . . . . . . . . . . . . . . . 5A-42 Disassembly Procedure . . . . . . . . . . . . . . . . 5A-85
Torque Converter . . . . . . . . . . . . . . . . . . . . . 5A-43 Assembly Procedure . . . . . . . . . . . . . . . . . . . 5A-94
Clutch Packs . . . . . . . . . . . . . . . . . . . . . . . . . 5A-44 Front and Rear Band Adjustment . . . . . . . . 5A-128

5A-2 AUTOMATIC TRANSMISSION
SPECIFICATIONS
MODEL PART NUMBERS AND APPLICATIONS
DWMC P/NO Transmission Engine Version Torque Converter
36100-05420 (1) 0574-000001 (9) 661LA 179K
36100-05430 (1) 0574-000002 (8) E32 160K
36100-05410 (1) 0574-000004 (10) 662LA(Turbo) 160K
36100-05440 (1) 0574-000005 (7) E23 179K
MODEL SPECIFICATIONS
Application Descriprtion
Torque Converter
Mean diameter of fluid circuit 260
Maximum torque multiplication 2.0 : 1
Stall speed (rpm)
0574-000001 (D23LA) 2100 - 2250
0574-000002 (E32) 2050 - 2250
0574-000004 (D29LA) 2100 - 2200
0574-000005 (E23) 1800 - 2100
0574-000020
0574-000021
Gear Ratios
First 2.741 : 1
Second 1.508 : 1
Third 1.000 : 1
Fourth 0.708 : 1
Reverse 2.429 : 1
Lubricant
Type Castrol TQ95 or other approved fluid
Capacity
Dry System 9.0 Litres (approx)
Service Refill 4.5 Litres (approx)
Gear Train End Float 0.50 - 0.65 mm
Gear Set Pinion End Float 0.10 - 0.50 mm

AUTOMATIC TRANSMISSION 5A-3
CLUTCH PACK DETAILS

0574-000001, 0574-000004, 0574-000002
0574-000005
C1
Composition 4 5
Steel 6(2) 5(2)
C2
Composition 4 5
Steel 5(2) 4(2)
C3
Composition 3 4
Steel 5(2) 4(2)
C4
Composition 3 3
Steel 4(1) 4(1)
Note : Numbers in brackets indicate number of selective thickness steel plates required to achieve specifed
clutch pack clearance

SPECIAL TOOLS
SPECIAL TOOLS TABLE
Part Number Description

0555 - 332083 Solenoid / Thermistor, Electronic Tester
0555 - 336046 Solenoid, Bench Tester
0555 - 336256 Transmission Bench Cradle
0555 - 336257 Pump Puller
0555 - 336258 Pin Remover / Installer Tool (Cross Shaft / Detent Lever)
0555 - 336259 Clutch Spring Compressor
0555 - 336260 Clutch Pack Clearance Kit
0555 - 336261 Seal Removal Tool (Cross - Shaft)
0555 - 336262 Oil Seal Dolly (Cross - Shaft)
0555 - 336263 Assembly Bullet
0555 - 336264 Seal Compressor
0555 - 336265 Pin Press
0555 - 336266 Seal Dolly
0555 - 336267 Alignment Tool
0555 - 336268 Pump Seal Dolly
0555 - 336269 End Float Adaptor
0555 - 336270 End Float Shaft
0555 - 332895 Locknut Crimping Tool (W-Car Only)

TCU CIRCUIT (4WD-DIESEL)

TCU CIRCUIT (4WD-GASOLINE)

SHIFT PATTERN DIAGRAM

661LA NORMAL MODE

661LA POWER MODE

662LA NORMAL MODE

662LA POWER MODE

662LA LOW MODE

E32 POWER MODE

E32 NORMAL MODE

E32 LOW MODE

E23 POWER MODE

E23 NORMAL MODE

E23 LOW MODE

INTRODUCTION
The BTR Automotive Model 74 Four Speed Automatic Transmission is an electronically controlled overdrive four
speed unit with a lock-up torque converter. The lock-up torque converter results in lower engine speeds at cruise and
eliminates unnecessary slippage. These features benefit the customer through improved fuel economy and noise
reduction. Refer to table 1.1 for details of power, torque and configuration.
Of primary significance is the transmission control unit (TCU) which is a microprocessor based control system. The
TCU utilizes throttle position, rate of throttle opening, engine speed, transmission output speed, transmission sump
temperature, gear selector position and mode selector inputs, and in some applications a ‘kickdown’ switch to control
all shift feel and shift schedule aspects.
The TCU drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects.
The output pressure of this solenoid is controlled as a function of transmission sump temperature to maintain consistent
shift feel throughout the operating range.
Shift scheduling is highly flexible, and several independent schedules are programmed depending on the vehicle.
Typically the ‘NORMAL’ schedule is used to maximise fuel economy and driveability, and a ‘POWER’ schedule is used
to maximise performance. ‘WINTER’ schedule is used to facilitate starting at second gear.
Figure 1.1 details the differences between conventional and electronic transmission control systems.
Table 1.1 - M74 Torque, Power and Configuration

Model Max Torque (Nm) Min Torque (Nm) Configuration
M74 4WD 320 160 260 mm Torque Converter
Transmission Wide Ratio Gear Set
Splined Output for Transfer Case

Figure 1.1 - Conventional VS Electronic Transmission Control System

OPERATOR INTERFACES
There are three operator interfaces associated with the four speed transmission.
They are:
l The gear select lever
l The driving mode selector
l The indicator light
These operator interfaces are described below.
GEAR SELECT LEVER OPERATION

The transmission uses a conventional selector lever. The selector lever can be moved from one position to another
within the staggered configuration of the selector lever gate to positively indicate the gear -selection as shown on
figure 2.1. For information about the gear selections available refer to table 2.1.
Figure 2.1 - Typical Gear Selector and Mode Switch

Table 2.1 - Gear Selections
Downshift Type Inhibited Above
RANGE ‘1’ (MANUAL ‘1’): First gear operation only with inhibited engagement as a function of vehicle
speed. Engine braking is applied with reduced throttle.
RANGE ‘2’ (MANUAL ‘2’): First and second gear operation with inhibited engagement of second gear, as
a function of vehicle speed. Engine braking is applied with reduced throttle.
RANGE ‘3’ (MANUAL ‘3’): First, second and third gear operation with an inhibited third gear engagement
at high vehicle speed. Refer to the vehicle owner’s manual.
RANGE ‘D’ (DRIVE): Engine braking is applied with reduced throttle.
First, second, third and fourth gear operation. First to second (1-2), first to third
(1-3), second to third (2-3), second to fourth (2-4), third to fourth (3-4), fourth
to third (4-3), fourth to second (4-2), third to second (3-2), third to first (3-1)
and second to first (2-1), shifts are all available as a function of vehicle speed,
throttle position and the time rate of change of the throttle position (forced
downshift). Lockup clutch may be enabled in 3rd and 4th gears depending on
vehicle type. Refer to the owner’s manual.
RANGE ‘N’ (NEUTRAL): Rear band applied only, with inhibited engagement as a function of vehicle
speed, engine speed and throttle position. The inhibitor switch allows the en-
gine to start.
RANGE ‘R’ (REVERSE): Reverse gear operation, with inhibitor engagement as a function of vehicle
speed, engine speed and throttle position. The inhibitor switch enables reverse
lamp operation.
RANGE ‘P’ (PARK): Rear band applied only, with inhibited engagement as a function of vehicle
speed, engine speed and throttle position. The transmission output shaft is
locked. The inhibitor switch allows the engine to start.
DRIVING MODE SELECTOR

The driving mode selector consists of a mode selection switch and indicator light. The driving mode selector is
located on the centre console. See figure 2,1.
The schedules available to be selected vary with vehicle types. Typically the driver should have the option to select
between ‘NORMAL’ , ‘POWER’ or ‘WINTER’ modes.
When ‘NORMAL’ mode is selected upshifts will occur to maximise fuel economy and the indicator lights remain
extinguished. When ‘POWER’ mode is selected upshifts will occur to give maximum performance and the ‘POWER’
mode indicator light is switched on. When ‘WINTER’ mode is selected, starting at second gear is facilitated, the
‘WINTER’ mode indicator light is switched on and the ‘POWER’ mode indicator light is switched off.
Refer to the vehicle owner’s manual for specific modes for each vehicle type.

CONTROL SYSTEMS
GENERAL
There are two control systems associated with the transmission. The electronic control system monitors vehicle
parameters and adjusts the transmission performance. The hydraulic control system implements the electronic control
system commands.
ELECTRONIC CONTROL SYSTEM

The electronic control system is comprised of sensors, a TCU and seven solenoids. The TCU reads the inputs, and
under software control activates the outputs according to values stored in read only memory (ROM).
The TCU controls the hydraulic control system. This control is via the hydraulic valve body, which contains seven
electro-magnetic solenoids. Six of the seven solenoids are used to control the line pressure, operate the shift valves
and the torque converter lock-up clutch, and to turn on and off the two regulator valves (The two regulator valves
control the shift feel.).
The seventh solenoid is the proportional or variable pressure solenoid (VPS) which works with the two regulator
valves to control shift feel.
Figure 3.1 details a typical TCU control system schematic.
The individual component locations, operation and specifications which make up the electronic control subsystem
are covered in this section.
Figure 3.1 - Typical TCU Control System Schematic

Table 3.1 - Temperature / Resistance Characteristics
Temperature (°
°C) Resistance (Ohms)
Minimum Maximum
-20 13,638 17,287
0 5,177 6,616
20 2,278 2,723
100 177 196
135 (Overheat Mode Threshold) 75 85
Figure 3.2 - Temperature / Resistance Characteristics

Transmission Control Unit(TCU)
The TCU is an in-vehicle micro-processor based transmission management system. It is usually mounted in the
vehicle cabin, under the instrument panel, under the seat, behind the side kick panels or under the floor in the
footwell on the passenger side. Different control units are supplied for different vehicle applications.
The TCU contains:
l Processing logic circuits which include a central microcontroller and a back-up memory system.
l Input circuits.
l Output circuits which control external devices such as the variable pressure solenoid (VPS), on/off solenoid
drivers, a diagnostics output and the driving mode indicator light.
The various items which make up the TCU are discussed below.
Processing Logic
Shift schedule and calibration information is stored in an erasable programmable read only memory (EPROM).
Throttle input calibration constants and the diagnostics information are stored in electrically erasable programmable
read only memory (EEP ear state is different to the current gear state, the TCU initiates a gear shift to bring the two
states back into line.
Once the TCU has determined the type of gearshift required the software accesses the shift logic, estimates the
engine torque output, adjusts the variable pressure solenoid ramp pressure then executes the shift.
The TCU continuously monitors every input and output circuit for short or open circuits and operating range. When
a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and
implements a limp mode, The actual limp mode used depends upon the failure detected with the object to maintain
maximum driveability without damaging the transmission. In general input failures are handled by providing a default
value. Output failures, which are capable of damaging the transmission, result in full limp mode giving only third or
fourth gear and reverse. For further details of limp modes and memory retention refer to the Diagnostic Section.
The TCU is designed to operate at ambient temperatures between -40 and 85°C . It is also protected against
electrical noise and voltage spikes, however all the usual precautions should be observed, for example when arc
welding or jump starting.
TCU Inputs
To function correctly, the TCU requires engine speed, road speed, transmission sump temperature, throttle position
and gear position inputs to determine the variable pressure solenoid current ramp and on/off solenoid states. This
ensures the correct gear selection and shift feel for all driving conditions.
The inputs required by the TCU are as follows:
l Engine Speed
The engine speed signal is derived from the tachometer signal line, a dedicated sensor or a Controlled Area
Network (CAN).
l Road Speed
4WD (Diesel) - The shaft speed signal is derived from the speedo sensor located on the transfer case. This signal
is transmitted directly to the TCU.
4WD (Gasoline) - The speedo sensor sends the shaft speed signal to the engine control module (ECM). The
information is then transferred to the TCU via the CAN.
l Transmission Sump Temperature
The transmission sump temperature sensor is a thermistor located in the solenoid wiring loom within the transmission.
This sensor is a typical NTC resistor with low temperatures producing a high resistance and high temperatures
producing a low resistance.
Temperature/Resistance characteristics and location within the solenoid wiring loom are given in tables 3-1 and 3-
2, and figures 3.2 and 3.3.

If the transmission sump temperature exceeds 135°C, the TCU will impose converter lock-up at lower vehicle
speeds and in some vehicles flashes the mode indicator lamp. This results in maximum oil flow through the
external oil cooler and eliminates slippage in the torque converter. Both these actions combine to reduce the oil
temperature in the transmission.
Table 3.2 - Pin No. Codes for Temperature Sensor Location In Solenoid Loom
Pin No. Wire Color Connects To

1 Red Solenoid 1
2 Blue Solenoid 2
3 Yellow Solenoid 3
4 Orange Solenoid 4
5 Green Solenoid 5
6 Violet Solenoid 6
7 Brown Solenoid 7
8 Green Solenoid 5
9 White Temp Sensor
10 White Temp Sensor
Figure 3.3 - Temperature Sensor Location in Solenoid Loom

Throttle Position Sensor
The throttle position sensor(TPS) is a resistance potentiometer
mounted on the throttle body of the engine.
It transmits a signal to the TCU proportional to the throttle plate
opening.
The potentiometer is connected to the TCU by three wires:
5 volts positive supply, earth and variable wiper voltage.
Throttle voltage adjustments are as follows:
l Closed throttle voltage is 0.2V to 1.0V.
l Wide open throttle voltage is 3V -4.7V.
These measurements are taken between pins 29 and 27 of
the TCU.
Maintaining good shift feel through the transmission life span Notice
is dependant on having an accurate measure of Above figure of T.P.S. is for the diesel engine
the engine throttle position. To achieve this the TCU which is installed on the injection pump.
continuously monitors the maximum and minimum throttle
potentiometer voltages and, if a change occurs, stores the new
voltage values.
However these limits will be lost and will require relearning
should a new TCU be installed, or the throttle calibration data
is cleared by the execution of a particular sequence, This last
instance depends on the installation, and reference should be
made to the Diagnostics Section of this manual. The relearning
will happen automatically
Gear Position Sensor

The gear position sensor is incorporated in the inhibitor switch
mounted on the side of the transmission case.
(Refer to figure 3.5.) The gear position sensor is a multi-function
switch providing three functions:
l Inhibit starting of the vehicle when the shift lever is in a
position other than Park or Neutral
l Illuminate the reversing lamps when Reverse is
selected indicate to the TCU which lever position has
been selected by way of a varying resistance (Refer to
table 3.3.) Inhibitor
Switch
Figure 3.5 - Inhibitor Switch

Table 3.3 - Readings for Resistance/Shift Lever Positions
Shift Lever Position Resistance (OHMS)

Manual 1 1k - 1.4k
Manual 2 1.8k - 2.2k
Manual 3 3k - 3.4k
Drive 4.5k - 4.9k
Netural 6.8k - 7.2k
Reverse 10.8k - 11.2k
Park 18.6k - 19k
Diagnostics Inputs
The diagnostics control input or K-line is used to initiate the outputting of diagnostics data from the TCU to a diagnostic
test instrument. This input may also be used to clear the stored fault history data from the TCU’s
retentive memory. Connection to the diagnostics input of the TCU is via a connector included in the vehicle’s wiring
harness or computer interface. Refer to the vehicle manufacturer’s manual for the location of the self test
connectors.
Battery Voltage Monitoring Input

The battery voltage monitoring input connects to the positive side of the battery. The signal is taken from the
main supply to the TCU.
If operating conditions are such that the battery voltage at the TCU falls below 11.3V the transmission will adopt a ‘low
voltage’ mode of operating in which shifts into first gear are inhibited. All other shifts are allowed but may not occur
because of the reduced voltage. This condition normally occurs only when the battery is in poor condition.
When system voltage recovers, the TCU will resume normal operation after a 3 second delay period.
TCU Outputs
The outputs from the TCU are supplied to the components described below:
Solenoids
The TCU controls seven solenoids. Solenoids 1 to 6 (S1 to S6) are mounted in the valve body, while Solenoid 7 (S7)
is mounted in the pump cover. The normal state (OPEN/CLOSED) and the functions associated with the solenoids
are detailed in table 3.4. Table 3.5 details the S1 and S2 logic for static gear states. The logic during gear changes for
S1 to S4 and S7 is detailed in table 3.6.

Table 3.4 - Solenoid States and Functions
Solenoids 1 and 2 S1 and S2 are normally open On/off solenoids that set the selected gear.
These solenoids determine static gear position by operating the shift valves.
Refer to table 3.5. Note that S1 and S2 solenoids also send signal pres-
sure to allow or prohibit rear band engagement.
Solenoids 3 and 4 S3 and S4 are normally open On/off solenoids that combine to control
shift quality and sequencing. S3 switches the clutch regulator valve off or
on. S4 switches the front band regulator valve off or on.
Solenoid 5 S5 is a variable force solenoid that ramps the pressure during gear
changes. This solenoid provides the signal pressure to the clutch and
band regulator, thereby controlling the shift pressures.
Solenoid 6 S6 is a normally open On/off solenoid that sets the high/low level of line
pressure, Solenoid off gives high pressure.
Solenoid 7 S7 is a normally open On/off solenoid that controls the application of the
converter clutch. Solenoid on activates the clutch.
Table 3.5 - Solenoid Logic for Static Gear States
Gear S1 S2
1st ON ON
2nd OFF ON
3rd OFF OFF
4th ON OFF
Reverse OFF OFF
Neutral OFF OFF
Park OFF OFF

Table 3.6- Solenoid Operation During Gearshifts
Shift To Initiate Shift Typical S5 Current Ramp To Complete Shift

1-2 S1 OFF 750mA to 600mA S4 OFF
S4 ON
1-3 S1 OFF S3 OFF
S2 OFF 850mA to 750mA S4 OFF
S3 ON
S4 ON
1-4 S2 OFF S3 OFF
S3 ON 850mA to 750mA S4 OFF
S4 ON
2-3 S2 OFF S3 OFF
S4 ON
3-4 S1 ON 750mA to 600mA S4 OFF
S4 ON
4-3 S4 ON 750mA to 900mA S1 OFF
S4 OFF
4-2 S3 ON S1 OFF
750mA to 950mA S2 ON
S3 OFF
4-1 S3 ON S2 ON
S4 OFF
3-2 S2 ON 600mA to 450mA @ 20 kph. S4 OFF
S4 ON 550mA to 400mA @ 60 kph.
800mA to 650mA @ 100 kph.
3-1 S3 ON S1 ON
S4 ON 700mA to 950mA S2 ON
S3 OFF
S4 OFF
2-1 S4 ON 800mA to 950mA S1 ON
S4 OFF
Conv. Clutch
ON S7 ON 700mA to 400mA S7 OFF
OFF 600mA to 100mA

Solenoid Valve Symbols (On/off Solenoids)
The solenoid symbol shown adjacent to each solenoid on the
hydraulic system schematics indicates the state of the oil flow
through the solenoid valve with the power On or 0ff. Refer to
figure 3.6 for the On/off operational details of NO solenoid
valves.
Normally Open (NO) Solenoid

POWER ON
Line 500 port is closed. The output port is open to exhaust at
the solenoid valve.
POWER OFF
The exhaust port is closed. The output port is open to line 500, Figure 3.6- Normally Open (NO) Symbols
Variable Pressure Solenoid Multiplexing System

Friction element shifting pressures are controlled by the variable pressure solenoid (VPS).
Line pressure is completely independent of shift pressure and is a function of throttle position, gear state and engine
speed.
S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator
valves thereby controlling shift pressures.
VPS pressure is multiplexed to the clutch regulator valve, the band regulator valve and the converter clutch regulator
valve during automatic gearshifts.
A variable pressure solenoid produces a hydraulic pressure inversely proportional to the current applied. During a
gearshift the TCU applies a progressively increasing or decreasing (ramped) current to the solenoid. Current applied
will vary between a minimum of 200 mA and a maximum of 1000 mA, Increasing current decreases output (55)
pressure. Decreasing current increases output (55) pressure.
Line 500 pressure, (approximately 440 to 560 kPa), is the reference pressure for the VPS, and the VPS output
pressure is always below line 500 pressure.
When the VPS is at standby, that is no gearshift is taking place, the VPS current is set to 200 mA giving maximum
output pressure.
Under steady state conditions the band and clutch regulator valve solenoids are switched off. This applies full Line
500 pressure to the plunger and because Line 500 pressure is always greater than S5 pressure it squeezes the S5
oil out between the regulator valve and the plunger. The friction elements are then fed oil pressure equal to Line 500
multiplied by the amplification ratio.
When a shift is initiated the required On/off solenoid is switched on cutting the supply of Line 500 to the plunger.
At the same time the VPS pressure is reduced to the ramp start value and assumes control of the regulator valve by
pushing the plunger away from the valve. The VPS then carries out the required pressure ramp and the timed shift is
completed by switching Off the On/off solenoid and returning the VPS to the standby pressure.
This system enables either the band or clutch or both to be electrically controlled for each gearshift.
Mode Indicator Light

Depending on the application, the mode indicator light may be used to indicate the mode that has been selected or
if an overheat condition exists. The mode indicator light is usually located on the instrument cluster.
Communication Systems
CAN
The controller area network (CAN) connects various control modules by using a twisted pair of wires, to share
common information. This results in a reduction of sensors and wiring. Typical applications include using the engine
controller to obtain the actual engine speed and throttle position, and adding these to the network. The ABS controller
(if fitted) can be used to obtain the road speed signal. This information is then available to the TCU without any
additional sensors.

K-Line
The K-line is typically used for obtaining diagnostic information from the TCU. A computer with a special interface is
connected to the TCU and all current faults, stored faults, runtime parameters are then available. The stored fault
codes can also be cleared.
The K-line can be used for vehicle coding at the manufacturer’s plant or in the workshop. This allows for one TCU
design to be used over different vehicle models. The particular code is sent to the microprocessor via the K line and
this results in the software selecting the correct shift and VPS ramp parameters.
HYDRAULIC CONTROL SYSTEM

The hydraulic controls are located in the valve body, pump body and main case.
The valve body contains the following:
l Manual valve,
l Three shift valves,
l Sequence valve,
l solenoid supply pressure regulator valve,
l line pressure control valve,
l clutch apply regulator valve,
l band apply regulator valve,
l S1 to S6, and
l Reverse lockout valve.
l The pump body contains the following:
l Primary regulator valve for line pressure,
l converter clutch regulator valve,
l converter clutch control valve,
l S7,and
l C1 bias valve.
The main case contains the following:
l B1R exhaust valve
The hydraulic control system schematic is shown at figure 3.7.
All upshifts are accomplished by simultaneously switching on a shift valve(s), switching VPS pressure to the band
and/or clutch regulator valve, and then sending the VPS a ramped current. The shift is completed by switching the
regulators off and at the same time causing the VPS to reach maximum . pressure. All downshifts are accomplished
by switching VPS pressure to the band and/or clutch regulator valve and sending a ramped current to the VPS. The
shift is completed by simultaneously switching the regulators off, switching the shift valves and at the same time
causing the VPS to return to stand-by pressure.
The primary regulator valve is located in the pump cover and supplies four line pressures; high and low for forward
gears, and high and low for reverse. This pressure has no effect on shift quality and merely provides static clutch
capacity during steady state operation. Low pressure can be obtained by activating an On/off solenoid with high line
pressure being the default mode.
Torque converter lock-up is initiated by toggling the converter clutch control valve with an On/off solenoid. The actual
apply and release of the clutch is regulated by the VPS via the converter clutch regulator valve. As an additional
safety feature, the lock-up is hydraulically disabled in first and second gear by the bias valve which only supplies oil
to the lock-up solenoid when C1 is applied in third and fourth gears. This prevents the vehicle from being rendered
immobile in the unlikely event of S7 becoming stuck.
The solenoid supply valve provides reference pressure for all the solenoids.

Figure 3.7 - Hydraulic Control Circuit

Valve Body
Figure 3.8 depicts the valve body as a unit as viewed from the
transmission sump. Figure 3.9 depicts the pump cover.
Figure 3.8 - Valve Body
Figure 3.9 - Pump Cover

Manual Valve
The manual valve (refer to figure 3.10) is connected to the vehicle selector mechanism and controls the flow of oil to
the forward and reverse circuits. The manual valve function is identical in all forward gear positions except that in the
Manual 1 position an additional supply of oil is directed to the 1-2 shift valve for application of the rear band and the
C4 overrun clutch.
Figure 3.10 - Manual Valve
1-2 Shift Valve

The 1-2 shift valve (refer to figure 3.11) is a two position valve that must be switched to the (2,3,4) position in order to
get any forward gear other than first gear. It is used for all 1-2 and 2-1 gearshifts.
The switching of this valve is achieved by using S1 and/or S2.
During a 1-2 gearshift drive oil from the manual valve passes through to the second gear circuit. During a 2-1
gearshift the band apply feed oil is allowed to exhaust via the 1-2 shift valve.
The 1-2 shift valve works in conjunction with the 3-4 shift valve (described below) to disengage the C4 clutch in first
gear, and engage C4 in second gear. When Manual 1 is selected the C4 clutch and rear band (B2) are engaged.
Figure 3.11 - 1-2 Shift Valve

2-3 Shift Valve
The 2-3 shift valve (refer to figure 3.12) is a two position valve. It is used on all 2-3 and 3-2 gearshifts.
The switching of this valve is achieved by S2 which is located at the end of the valve spool.
When in the (1,2) position, second gear oil from the 1-2 shift valve is prevented from entering the third gear circuit.
When the valve is moved to the (3,4) position, oil from the second gear circuit is routed to the third gear circuit and the
transmission changes to third gear.
3-4 Shift Valve

The 3-4 shift valve (refer to figure 3,13) is a two position valve. It is used for all 3-4 and 4-3 gearshifts.
The switching of this valve is achieved by S1 which is located at the end of the valve spool.
During a 3-4 gearshift the 3-4 shift valve:
l Exhausts the front band release circuit (B 1R) thereby allowing the application of the front band (B1).
l Connects the inner apply area of the front servo (B 1AI) to the band apply feed circuit (BAF) thus allowing
greater apply forces to the front band.
l Exhausts the overrun clutch circuit (OC) which allows the C4 clutch to disengage.
During a 4-3 gearshift, the C4 clutch is engaged and the front band (B1) is released. These actions are sequenced
by the 4-3 sequence valve (described below).
The 3-4 shift valve also switches during 1-2 and 2-1 gearshifts (see 1-2 shift valve above) where its function is to
apply the overrun clutch (C4) in second gear but to release it in first gear. Note that the C4 clutch is applied in Manual
1 by virtue of the manual valve and the 1-2 shift valve (as described in the 1-2 shift valve section).

4-3 Sequence Valve
The 4-3 sequence valve (refer figure 3.14) is a two position spring loaded valve. It switches during 3-4 and 4-3
gearshifts although it performs no function during the 3-4 shift.
During the 4-3 shift the 4-3 sequence valve delays the connection of the clutch apply feed circuit (CAF) to the BIR
circuit until the BIR circuit has been fully pressurised by using the third gear circuit. This prevents objectionable
engine flare on completion of the 4-3 gearshift.
Figure 3.14 - 4-3 Sequence Valve
Solenoid Supply Pressure Regulator Valve

The solenoid supply valve (refer figure 3.15) supplies a constant pressure to all solenoids (51 to 57). Line pressure
is used as the feed oil to this regulator and the output is termed line 500.
Line Pressure Boost Valve

Line pressure is controlled by 56, which acts as the line pressure boost valve (refer figure 3.15). When 56 pressure
is applied to the end of the PRV it is opposed by spring force and causes LOW line pressure for light throttle
application and cruising.
Heavy throttle application causes the normally open 56 to open (switch Off) thus closing line 500 and opening 56 to
exhaust. Removal of 56 pressure from the PRV results in HIGH line pressure.
Figure 3.15 - Solenoid Supply Pressure Regulator Valve and Line Pressure Control Valve

Clutch Apply Regulator Valve
The clutch apply regulator valve (refer figure 3.16) is a fixed ratio valve. This valve provides a regulated pressure to
the C1 clutch and controls the rate of change of state of the clutch to give the desired shift quality.
This ratio is 2.25 : 1.
Third gear oil supplied to the valve is regulated to provide an output pressure (CAF) of 2.25 times the S5 signal
pressure when S3 is On. When S3 is Off the output pressure is 2.25 times the line 500 pressure.
Figure 3.16 - Clutch Apply Regulator Valve
Band Apply regulator Valve

The band apply regulator valve (refer figure 3.17) is a fixed ratio valve. It provides a regulated pressure to the front
servo, and controls the rate of change of state of the front band (B1) to give the desired shift quality.
This ratio is 1.4 : 1.
Second gear oil supplied to the valve is regulated to provide an output pressure (BAF) of 1.4 times the S5 signal
pressure when S4 is On. When S4 is Off the output pressure is 1.4 times the line 500 pressure.
Figure 3.17 - Band Apply Regulator Valve

Reverse Lockout Valve
The reverse lockout valve (refer figure 3.18) is a two position valve contained in the upper valve body. This valve
uses 51-52 pressure as a signal pressure and controls the application of the rear band (B2).
While the manual valve is in D,3,2, or 1 positions, drive oil is applied to the spring end of the valve, overriding any
signal pressures and holding the valve in the lockout position. This prevents the application of B2 in any of the
forward driving gears.
When the manual valve is in P, R or N positions, drive oil is exhausted and the reverse lockout valve may be toggled
by S1-S2 pressure.
B2 is applied in P, R, and N provided that the following conditions are satisfied:
1. In P or N, roadspeed < 3 km/h.
2. In R, road speed < 10 km/h.
3. Engine speed < 1400 rpm.
4. For diesel vehicles, throttle < 25%.
5. For gasoline vehicles, throttle < 12%.
Under these conditions, the TCU switches solenoids S1 and S2 to Off. The reverse lockout valve toggles under the
influence of the S1-S2 pressure, to connect the line pressure to the B2 feed. Oil is fed to both the inner and outer
apply areas of the rear servo piston, applying B2.
If any of the above conditions are not satisfied, the TCU switches solenoids S1 and S2 to On. S1- S2 pressure is
exhausted and the valve is held in the lockout position by the spring. In this position, engagement of B2 is prohibited.
This feature protects the transmission from abuse by preventing the undesirable application of B2 at high speed, and
by providing a reverse lockout function.
Note that if the transmission is in failure mode, the rear band will be applied at all times in P, R and N.
Figure 3.18 - Reverse Lockout Valve

Primary Regulator Valve
The primary regulator valve (PRV) (refer to figure 3.19) regulates the transmission line pressure (or pump output
pressure). This valve gives either high or low line pressure depending on whether S6 is switched Off or On, When S6
is switched On,S6 pressure is applied to the PRV moving it against spring pressure and opening the line pressure
circuit to the pump suction port resulting in reduced line pressure. Low line pressure is used during light throttle
applications and cruising. Heavy throttle will cause S6 to switch Off and thereby cause high line pressure.
This stepped line pressure control has no detrimental effect on shift feel because all shifting pressures are controlled
by separate band and clutch regulator valves, and the output of S5.
When reverse gear is selected, both the low and high line pressure values are boosted to guard against slippage.
This is achieved by applying reverse oil line pressure to the PRV to assist the spring load. The other end of the valve
contains ports for line pressure feedback and 56 pressure.
The PRV also regulates the supply of oil to the converter via the converter feed port. The cascade effect of the PRV
ensures the first priority of the valve is to maintain line pressure at very low engine speeds. When the engine speed
increases and the pump supplies an excess of oil the PRV moves to uncover the converter feed port thereby pressurising
the converter. If there is an excess of oil for the transmission’s needs then the PRV moves further to allow oil to return
to the suction port.
Figure 3.19 - Primary Regulator Valve

Converter Clutch Regulator Valve
The converter clutch regulator valve (refer figure 3.20) regulates
the pressure of the oil which applies the converter clutch. Input
oil from the line 500 circuit is regulated within the valve, with
the output pressure being variable according to the signal
pressure from the S5 circuit. Converter clutch apply and release
application is smoothed by electronically varying the S5 circuit
pressure.
Figure 3.20 - Converter Clutch Regulator Valve
Converter Clutch Control Valve

The converter clutch control valve (refer figure 3.21) is a two position valve which applies or releases the converter
clutch.
The switching of this valve is governed by the signal pressure from S7.
When the valve is in the off or released position, converter feed oil from the PRV is directed to the release side of the
converter clutch. After flowing through the converter, oil returns to the converter clutch control valve and is then
directed to the oil cooler.
When the valve is in the on or applied position, regulated oil from the converter clutch regulator valve is directed to
the apply side of the converter clutch. This oil remains within the converter because the converter clutch piston is
sealed against the flat friction surface of the converter cover. To provide oil flow to the cooler the converter clutch
control valve directs converter feed oil from the PRV directly to the cooler circuit.
Figure 3.21- Converter Clutch Control Valve

C1 Bias Valve
The C1 bias valve (refer figure 3.22) ensures that the converter lock-up clutch is only applied in third and fourth
gears. It uses C1 clutch oil pressure as the switching signal since C1 is only applied in third and fourth gears.
Line to 500 oil is routed through the C1 bias valve to S7. The C1 bias valve therefore acts as a safety feature to
ensure drivability in the event of S7 failure.
Figure 3.22- C1 Bias Valve
B1R Exhaust Valve

The B1R exhaust valve (refer figure 3.23) is a two position
spring loaded valve located in the transmission case directly
adjacent to the front servo. It permits the servo release oil to
be rapidly exhausted into the transmission case during
application of the front band (B1). This prevents the need to
force the oil back from the front servo through the valve body
and through the 3-4 shift valve. The spring positions the valve
to prevent oil entering the release area of the servo until the
B1R circuit oil pressure reaches approximately 100 kPa.
Figure 3.23 - B1R Exhaust Valve

POWER TRAIN SYSTEM

The Power Train System consists of:
l A torque converter with single face lock-up clutch
l Four multi-plate clutch assemblies
l Two brake bands
l Two one-way clutches
l Planetary gearset
l Parking mechanism
A conventional six pinion Ravigneaux compound planetary gearset is used with overdrive (fourth gear) being obtained
by driving the carrier.
The cross-sectional arrangement is very modular in nature. Four main sub-assemblies are installed within the case
to complete the build. These sub-assemblies are:
l Gearset-sprag-centre support
l C1 -C2-C3-C4 clutch sub-assembly
l Pump assembly
l Valve body assembly
One, or a combination of selective washers are used between the input shaft flange and the number 4 bearing to
control the transmission end float. This arrangement allows for extensive subassembly testing and simplistic final
assembly during production.
A general description of the operation of the Power Train System is detailed below. Refer to table 4.1 and figure 4.1.
First gear is engaged by applying the C2 clutch and locking the 1-2 One Way Clutch (1-2 OWC). The 1-2 shift is
accomplished by applying the B1 band and overrunning the 1-2 OWC. The 2-3 shift is accomplished by applying the
C1 clutch and releasing the B1 band. The 3-4 shift is accomplished by re-applying the B1 band and overrunning the
3-4 OWC. Reverse gear is engaged by applying the C3 clutch and the B2 band.
The C4 clutch is applied in the Manual 1,2 and 3 ranges to provide engine braking. In addition, the C4 clutch is also
applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting. The B2 band is
also applied in the Manual 1 range to accomplish the low-overrun shift.
Both the front and rear servos are dual area designs to allow accurate friction element matching without the need for
secondary regulator valves. All the friction elements have been designed to provide low shift energies and high static
capacities when used with the new low static co-efficient transmission fluids. Non-asbestos friction materials are used
throughout.
Table 4.1 - Engaged Elements vs Gear Ratios

ELEMENTS ENGAGED
Gear Gear C1 C2 C3 C4 B1 B2 1-2 3-4 LU
Ratio OWC OWC CLUTCH
First 2.741 X X X
Second 1.508 X X X
Third 1.000 X X X X X X*
Fourth 0.708 X X X X
Reverse 2.428 X X
Manual 1 2.741 X X X
* For Certain Vehicle Applications, Refer to the Owner's Manual.

Figure 4.1 - Power Flow Diagram
TORQUE CONVERTER
The torque converter (refer figure 4.2) consists of a turbine,
stator pump, impeller and a lock-up damper and piston
assembly. As in conventional torque converters, the impeller is
attached to the converter cover, the turbine is splined to the
input shaft and the stator is mounted on the pump housing via
a one way clutch (sprag).
The addition of the damper and piston assembly enables the
torque converter to ‘lock-up’ under favourable conditions. Lock-
up is only permitted to occur in third and fourth gears under
specified throttle and road speed conditions.
Lock-up is achieved by applying hydraulic pressure to the
damper and piston assembly which couples the turbine to the
converter cover, locking-up the converter and eliminating
unwanted slippage. Whenever lock-up occurs, improved fuel
consumption is achieved. Torsional damper springs are
provided in the damper and piston assembly to absorb any
engine torque fluctuations during lock-up. Figure 4.2 - Torque Converter Cross Section

CLUTCH PACKS
There are four clutch packs (refer to figure 4.3). All clutch packs are composed of multiple steel and friction plates.
C1 CLUTCH When applied, this clutch pack allows the input shaft to drive the planet carrier.
This occurs in third and fourth gears.
C2 CLUTCH When applied this clutch pack allows the input shaft to drive the forward sun gear via the 3-4 OWC.
This occurs in all forward gears.
C3 CLUTCH When applied this clutch pack allows the input shaft to drive the reverse sun gear. This only occurs in
reverse gear.
C4 CLUTCH When applied this clutch provides engine braking on overrun. This occurs in Manual 1, 2 and 3 and
also Drive 2 and Drive 3 to prevent objectionable free wheel coasting.
Figure 4.3 - Clutch Packs

BANDS
The transmission utilises two bands, the B1 band (sometimes known as the 24 band), and the B2 band (sometimes
known as the low-reverse band). Refer to figure 4.4.
The B1 band is a flexible band which is engaged by the front servo piston. B1 is activated in second and fourth gear.
When activated B1 prevents the reverse sun gear from rotating by holding the C3 clutch assembly stationary. In
second gear only the outer area of the apply piston is utilised. In fourth gear both areas are utilised for greater
clamping force.
The B2 band is a solid band which is engaged by the rear servo piston. B2 is activated in Park,
Reverse, Neutral and Manual 1. When activated B2 prevents the planet carrier assembly from rotating. In Manual 1
only the inner area of the apply piston is utilised. In Park, Reverse and Neutral, both areas are utilised for greater
clamping force.
Figure 4.4- Bands
ONE WAY CLUTCHES

The transmission uses two OWCs, the 1-2 OWC and the 34 OWC. (Note that a third OWC is located in the torque
converter, also known as a sprag.)
The 1-2 OWC is located between the planetary carrier assembly and the centre support. This allows the carrier to
rotate around the centre support in one direction only. The one way clutch is engaged only in Drive 1.
The 3-4 OWC is located between the C4 and the C2 clutch assemblies. This allows the C2 clutch to drive the forward
sun gear in first, second and third gears but unlocks in fourth gear and during overrun.
PLANETARY GEAR SET

The planetary gear set used in the transmission is a conventional six pinion Ravigneaux compound gear set.

PARKING MECHANISM
When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl (refer to (figure
4.5). The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case.
When Park is not selected a return spring holds the parking pawl clear of the output shaft, preventing accidental
engagement of Park.
Figure 4.5 - Park Rod and Cross Shaft

POWER FLOWS
INTRODUCTION
The power flows for the various transmission selections are listed below:
l Power Flow - Neutral and Park
l Power Flow - Reverse
l Power Flow - Manual 1
l Power Flow - Drive 1
l Power Flow - Drive 3 Lock Up
l Power Flow - Drive 4 (Overdrive)
l Power Flow - Drive4 Lock Up
Each power flow is described in the following sections.
Table 5.1 details the engaged elements versus the gear selected for all transmission selections.
Figure 5.1 - Engaged Elements vs Gear Selected

ELEMENTS ENGAGED
Gear State C1 C2 C3 C4 B1 B2 1-2 3-4 LU
OWC OWC CLUTCH
Park and Neutral - - - - - X - - -
Reverse - - X - - X - - -
Manual 1 - X - X - X - X -
Drive 1 - X - - - - X X -
Drive 2 and Manual 2 - X - X X - - X -
Drive 3 and Manual 3 X X - X - - - X -
Drive 3 Lock Up and X X X - - - X X
Manual 3 Lock Up -
Drive 4 Overdrive X X - - - - - - -
Drive 4 Lock Up X X - - - - - - X
Planetary Gear Set

POWER FLOW - PARK AND NEUTRAL

In Park and Neutral, there is no drive to the planetary gear set. The rear band is applied to eliminate ‘clunk’ on
engagement of the reverse gear, and to improve the low range engagement for 4WD applications. No other clutches
or bands are applied.
In Park the transmission is mechanically locked by engaging a case mounted pawl with teeth on the output shaft ring
gear.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows:
l Solenoids S1 and S2 are switched off.
l Line (pump) pressure is applied to the primary regulator valve (PRV) and to the solenoid supply valve.
l The converter, oil cooler, and lubrication circuits are charged from the primary regulator valve.
l The line 500 circuit is charged by the solenoid supply valve.
l The S5 circuit is charged by the variable pressure solenoid (S5).
l Line pressure is prevented from entering the drive circuit by the manual valve.
l The B1 circuit and all clutch circuits are open to exhaust.
Refer to figure 5.1 and table 5.2.
Table 5.2 - Engaged Elements - Park arid Neutral

ELEMENTS ENGAGED
OWC OWC CLUTCH
Park and Neutral - - - - - X - - -

POWER FLOW - REVERSE

In Reverse, transmission drive is via the input shaft and the forward clutch cylinder to the hub of the C3 clutch. The
elements of the transmission function as follows :
l The C3 clutch is engaged and drives the reverse sun gear in a clock-wise direction.
l The B2 band is engaged and holds the planetary gear carrier stationary causing the long pinion to rotate anti-
clockwise about its axis on the pinion shaft.
l The long pinion drives the internal ring fear in the same direction.
l The internal ring being splined to the output shaft drives it in an anti-clockwise or reverse direction.
Control
To maintain this arrangement in the steady state
solenoids and valves are activated as follows:
l Solenoids S1 and S2 are switched off.
l Line pressure is directed through the reverse lockout valve to both the inner and outer apply areas of the rear
servo piston for B2 band application.
l Line pressure feeds the reverse oil circuit via the manual valve.
l Reverse oil is routed from the manual valve to the C3 clutch.
l Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the
line pressure value.
l All other clutch and band apply circuits are open to exhaust.
Refer to figure 5.2 and table 5.3
Table 5.3 - Engaged Elements - Reverse

ELEMENTS ENGAGED
OWC OWC CLUTCH
Reverse - - X - - X - - -

POWER FLOW - MANUAL 1

In Manual 1, transmission drive is via the input shaft
to the forward clutch cylinder. The elements of the
transmission function as follows :
l The C2 clutch is engaged to drive the forward sun gear, via the 3-4 OWC.
l The B2 band is engaged to hold the planetary gear carrier stationary.
l The forward sun gear drives the short pinion anti-clockwise.
l The short pinion drives the long pinion clockwise.
l The long pinion rotating about its axis drives the internal ring gear and the output shaft in a clockwise or
forward direction.
l The C4 clutch provides engine braking through the 3-4 OWC on overrun.
Control
l Solenoids S1 and S2 are switched ON.
l The 1-2,2-3, and 34 shift valves are held in their first gear positions by line 500 pressure.
l Drive (line pressure) oil from the manual valve engages the C2 clutch.
l Lo-1st (line pressure) oil is routed through the 1-2 shift valve to the C4 clutch, and to the inner apply area of
the rear servo piston for B2 band application.
Table 5.4 - Engaged Elements - Manual 1

ELEMENTS ENGAGED
OWC OWC CLUTCH
Manual 1 - X - X - X - X -

POWER FLOW - DRIVE 1

In Drive 1, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission
function as follows :
l The C2 clutch is engaged to drive the forward sun gear.
l The 1-2 OWC prevents the planetary gear carrier from rotating under reaction force and the long pinion
rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction.
l There is no engine braking on overrun.
Control
l Solenoids S1 and S2 are switched On.
l The 1-2, 2-3, and 3-4 shift valves are held in their first gear positions by line 500 pressure.
Refer to figure 5.4 and table 5.5
Table 5.5 - Engaged Elements - Drive 1

ELEMENTS ENGAGED
OWC OWC CLUTCH
Drive 1 - X - - - - X X -

POWER FLOW - DRIVE 2 AND MANUAL 2

In Drive 2 and Manual 2, transmission drive is via the input shaft and forward clutch cylinder. The elements of the
l The C2 clutch is applied to drive the forward sun gear.
l The B1 band is applied holding the reverse sun gear stationary therefore the long pinion ‘walks’ around the
reverse sun gear taking the internal ring gear and output shaft with it in a clockwise or forward direction.
l The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoid S1 is
switched Off. S2 is switched On.
l Solonoid S1 is switched Off. S2 is switched On.
l When S1 switches off , S1 oil pressure, which is derived from line 500 pressure, moves the 3-4 shift valve to
the left. At the same time S1 oil is directed to the 1-2 shift valve which moves the valve to the second gear
position.
l 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve, and to the 2-3 shift
valve.
l The band apply regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ratio) to the
band apply feed (BAF) circuit.
l Band apply feed oil is directed to:
- The outer apply area of the front servo
- The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear
- The 3-4 shift valve for use when the transmission is shifted into fourth gear
l Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch.
Table 5.6 - Engaged Elements - Drive 2 and Manual 2

ELEMENTS ENGAGED
OWC OWC CLUTCH
Drive 2 and Manual 2 - X - X X - - X -


POWER FLOW - DRIVE 3 AND MANUAL 3

In Drive 3 and Manual 3, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the
l The C2 clutch is engaged to drive the forward sun gear.
l The C1 clutch is engaged to drive the planet carrier.
l The forward sun gear and the planet carrier are driven clockwise at the same speed therefore there is no
relative motion between the sun gear and the pinions.
l The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed.
l The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun.
Control
l Solenoid S1 is switched Off. S2 is switched Off.
l With S1 and S2 switched Off, the 2-3 and 3-4 shift valves are held in the third gear position by line 500
pressure.
l The 1-2 shift valve is held in the third gear position by S1-S2 oil pressure.
l 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve. and to the 2-3 shift
valve.
- The outer apply area of the front servo
- The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear
- The 3-4 shift valve for use when the transmission is shifted into fourth gear
l 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit.
l 3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve, and to the 4-3 Sequence Valve.
l The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the
clutch apply feed (CAF) circuit.
l The CAF oil is directed to:
- The C1 clutch
- The C1 bias valve
- The 4-3 sequence valve
l At the 4-3 sequence valve the CAF oil becomes band 1 release feed (B1R-F) oil, and is directed through the
3-4 shift valve to the spring end of the 4-3 sequence valve, and to the release side of the front servo piston to
hold band 1 off.
l Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch.
Table 5.7 - Engaged Elements - Drive 3 and Manual 3

ELEMENTS ENGAGED
OWC OWC CLUTCH
Drive 3 and Manual 3 X X - X - - - X -


POWER FLOW - DRIVE 3 LOCK UP AND MANUAL 3 LOCK HP

In Drive 3 Lock Up and Manual 3 Lock Up, transmission drive is the same as for Drive 3 but with the application of the
converter lock up clutch to provide positive no-slip converter drive.
Control
Control for Drive 3 Lock Up and Manual 3 Lock Up is the same as for Drive 3 with the addition of the converter clutch
circuit activated by solenoid S7.
l When S7 is switched On, S7 feed oil to the converter clutch control valve is switched off and allowed to exhaust
through the S7 solenoid. This allows the valve to move to the clutch engage position.
l Regulated apply feed oil, derived from line 500 oil at the converter clutch regulator valve, is directed by the
converter clutch control valve to the engage side of the converter clutch.
l Converter clutch release oil is exhausted at the converter clutch control valve.
l Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication
circuit.
Refer to figure 5.7and table 5.8.
Table 5.8 - Engaged Elements - Drive 3 Lock Up and Manual 3 Lock Up

ELEMENTS ENGAGED
OWC OWC CLUTCH
Drive 3 Lock Up and Manual 3 X X - X - - - X X
Lock Up

POWER FLOW - DRIVE 4 (OVERDRIVE)

In Drive 4 (Overdrive), transmission drive is via the input shaft to the forward clutch cylinder.
The elements of the transmission function as follows :
l The C1 clutch is applied to drive the planet carrier clockwise.
l The B1 band is applied to hold the reverse sun gear stationary.
l As the planet carrier tuns, the long pinion ‘walks’ around the stationary reverse sun gear and rotates around its
axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the
input shaft i.e. in overdrive ratio.
l The forward sun gear is also driven faster than the input shaft and overruns the 3-4 OWC.
l The C2 clutch is engaged to reduce the speed differential across the 3-4 OWC.
Control
l Solenoid S1 is switched On. S2 is switched Off.
l With S1 switched On the 3-4 shift valve is held in the fourth gear position by line 500 pressure on the small end
of the valve.
l With S2 switched Off the 2-3 shift valve is held in the fourth gear position by line 500 pressure on the large
end of the valve.
l The 1-2 shift valve is held in the fourth gear position by S2 oil pressure.
l 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve, and to the 2-3 shift
valve.
- the outer apply area of the front servo
- the inner apply area of the front servo piston via the 3-4 shift valve
- the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear
l 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit.
l 3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve, and to the 4-3 Sequence Valve.
l The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the
clutch apply feed (CAF) circuit.
l The CAF oil is directed to:
- the C1 clutch
- the C1 bias valve
- the 4-3 sequence valve
l Drive oil (line pressure) from the manual valve engages the C2 clutch
Table 5.9 - Engaged Elements - Drive 4 (Overdrive)

ELEMENTS ENGAGED
OWC OWC CLUTCH
Drive 4 (Overdrive) X X - - X - - X -


POWER FLOW - DRIVE 4 LOCK UP

In Drive 4 Lock Up, transmission drive is the same as for Drive 4 but with the application of the converter lock up clutch
to provide positive no-slip converter drive.
Control
Control for Drive 4 Lock Up is the same as for Drive 4 with the addition of the converter clutch circuit activated by
solenoid S7.
l When S7 is switched On, S7 feed oil to the converter clutch control valve is switched off and allowed to exhaust
through the S7 solenoid. This allows the valve to move to the clutch engage position.
l Regulated apply feed oil, delved from Line 500 oil at the converter clutch regulator valve, is directed by the
converter clutch control valve to the engage side of the converter clutch.
l Converter clutch release oil is exhausted at the converter clutch control valve.
l Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication
circuit.
Refer to figure 5.9 arid table 5.10.
Table 5.10 - Engaged Elements - Drive 4 Lock Up

ELEMENTS ENGAGED
OWC OWC CLUTCH
Drive 4 Lock Up X X - - X - - - X

DIAGNOSIS
DIAGNOSTIC SYSTEM
Recommended Test Equipment and Procedure
The test equipment is designed to be used with the control modules in all vehicles. The components used in the
transmission application are:
l Multi Function Tester, and
l Appropriate vehicle for testing.
Multi Function Tester (MFT)

The MFT is programmed with the special vehicle diagnostic software that allows selection of the unit under test.
The program allows the proper communication to the Transmission Control Unit (TCU).
It then requests information from the user via a menu system to select the required set up.
Examples are viewing codes, clearing error codes, and real-time operation. Set up and operation instructions are
detailed in the user manual.
This equipment can be used by trained personnel such as technicians and mechanics to diagnose electronic and
wiring problems relating to the vehicle transmission. Information that is available includes engine and road (shaft)
speed, transmission oil temperature, throttle position, solenoid/gear status and gear lever position. Current and
stored faults detected by the electronics are also available.
TCU Pin Description

The TCU pin descriptions are listed in table 6.1.1.
The wiring loom pins are shown in figure 6.1.1
Table 6.1.1 - TCU Pin Description

Pin Identification Type 4WD 4WD Description
No. (Diesel) (Gas)
1 Common Ground GND l l Main power ground (or the module. Connects
directly to the battery negative terminal.
2 Do not use - O O
3 Mode Indicator Lamp - OP l l Indicates ‘WINTER’ mode shift schedule is se-
‘Winter’ lected.
4 Gear Position ‘Park’ OP l l Drives the jewel in the instrument cluster to in-
Lamp dicate ‘PARK’ gear lever position.
5 Gear Position ‘Reverse’ OP l l Drives the jewel in the instrument cluster to in-
Lamp dicate ‘REVERSE’ gear lever position.
6 Gear Position ‘Neutral’ OP l l Drives the jewel in the instrument cluster to in-
Lamp dicate ‘NEUTRAL’ gear lever position.
7 Do not use - O O
8 Engine Speed Input IP l O Flywheel/Ring gear pulses to indicate engine
Sensor (-Ve) speed.


No. (Diesel) (Gas)
9 Mode Indicator Lamp - OP l l Indicates ‘POWER’ mode shift schedule is se-
‘Power ’ lected.
10 Throttle Position Sensor OP O O Provides an analogue signal of the throttle po-
Output as Pulse Width sition for the Torque on Demand (TOD) Con-
Modulation for TOD trol Module.
11 Air Conditioner Input Signal - l O Input
12 Kickdown Switch IP l l Switch to indicate when a kickdown is required
at high throttle position.
13 Mode Switch IP l l Switch to select ‘NORMAL’, ‘POWER’ or ‘WIN-
TER’ shift schedule.
Voltage varies from OV to 12V.
14 Transfer Case Input IP l l Switch to indicate 4WD’HIGH RANGE’ is se-
(High) -4WD Lamp High lected.
15 Ignition Switch IP l l Ignition power is used as the main power source
to drive the unit and the solenoids.
16 Do not use - O O
17 Gear Position ‘1’ Lamp/ OP l l Drives jewel in the instrument cluster to indi-
Gear Position Code 1 cate
18 *Gear Position ‘2’ Lamp/ OP l l gear leverposition’1'. Drives jewel in the instru-
Gear Position Code 2* ment cluster to indicate
19 Gear Position ‘3’ Lamp/ OP l l gear lever position’2'. Drives jewel in the instru-
Gear Position Code 3* ment cluster to indicate gear lever position’3'.
20 Gear Position ‘Drive’ OP l l Drives jewel in the instrument cluster to indi-
Lamp/ cate
Gear Position Code 4* ‘DRIVE’. gear lever position.
21 CAN (-ve) I/O O l CAN low side bus communication (CANL).
22 CAN (+ve) I/O O l CAN high side bus communication (CANH).
23 K-line Communication Link I/O l l Diagnostic information and vehicle coding.
24 Engine Speed Input IP l O Flywheel/Ring gear pulses to indicate engine
Sensor (+ve) speed.
25 Road Speed Pulses OP l l Road speed signals derived from shaft speed
sensors.
26 Shaft Speed Sensor IP l O This sensor transmit shaft speed signal to the
Signal TCU.
27 Throttle Position Sensor - GND l O Throttle position sensor ground.
Ground
28 Throttle Position Sensor - REF l O This is the 5V reference voltage supply gener-
Reference ated by the unit for the throttle position sensor.
29 Throttle Position Sensor - IP l O This sensor is a resistance potentiometer indi-
Input Signal cating throttle position.
Voltage varies 0V to 5V.
30 Transfer(or Case Input IP l l Switch to indicate 4WD’LOW RANGE’ is se-
(Low) - 4WD Lamp Low lected.


No. (Diesel) (Gas)
31 Gear Lever Position IP l l This switch has discreet values indicating the
positions selected by the gear shift lever
(PRNDL). Voltage varies 0V to 5V.
32 Transmission Oil IP l l Resistive sensor indicates transmission tem-
Temperature perature .
High R = low temp
Low R = high temp
Voltage varies 0V to 5V.
33 Solenoid 4 OP l l On/Off solenoid normally open, combines with
other On/off solenoid 3 for shift quality and se-
quencing.
34 Solenoid 1 OP l l On/off solenoid normally open, combines with
other On/off solenoid to set the selected gear.
35 Do not use - O O
36 Solenoid 5 IP l l This ensures the earth path for the VPS and
Return (-ve) the current in this line is monitored to give feed-
back control of the VPS.
37 Gear Lever Position - GND l l PRNDL switch ground.
Ground
38 Transmission Oil GND l l Ground reference for temperature sensor in-
Temperature - Ground put.
39 Solenoid 6 OP l l On/Off solenoid normally open, sets low/high
line pressure.
other On/off solenoid to set the selected gear.
On/off solenoid 4 for shift quality and sequenc-
ing.
42 Solenoid 7 OP l l On/off solenoid normally open, locks up the
torque converter to Increase cruising efficiency.
43 Do not use - O O
44 Solenoid 5 (+ve) OP l l This is the variable force solenoid which ramps
the pressure during gear changes and solenoid
switching, to enhance transmission shift quality.
Notice : l = circuit connected
O = circuit not connected
* = unique
OP = Output
IP = Input
I/O = Input/output
GND = Ground
REF = Reference

Figure 6.1.1 - Wiring Loom Pins

Default Transmission Operating Modes
The TCU relies on accurate information from its inputs and complete control of its outputs to effectively control the
transmission. To ensure that it has both valid inputs and functioning outputs, the TCU carries out both hardware and
software fault detection routines. The TCU will respond to any faults detected by adopting the operating modes which
are detailed below.
The following symptoms of faults are the most obvious results of each fault under ‘normal’ conditions.
There is always the possibility that a fault may not be detected. If undetected fault conditions are present, the
operation of the transmission is difficult to predict.
1 Throttle Fault
l All shifts will occur as if a nominal throttle (approx. 44%) were applied for shift scheduling.
l All shifts will be firm as full throttle and hence high engine torque is assumed.
l The torque converter will be unlocked at all times.
l All downshifts initiated by the shift lever will occur as though they were ‘automatic’ shifts. That is the engine
braking effect will not occur until near the end of the shift.
l Line pressure will always stay high (solenoid 6 OFF) to cope with assumed high throttle/torque.
If a fault is undetected, the percent throttle is most likely to be interpreted as higher than actual, resulting in late
upshifts, early downshifts, firm shifting and a harsh 3-1 shift when stopping.
2 Throttle Not Learnt Fault

The transmission operates from default throttle calibration values which results in the evaluation of the throttle being
higher (more open) than it is. There(ore at zero throttle settings, the transmission may calculate that sufficient throttle
opening is present to justify high line pressure and switch solenoid 6 to OFF.
Other symptoms are:
a. late upshifts and
b. lock-up maintained at zero throttle when the vehicle speed is sufficiently high.
3 Engine Speed Fault

l All shifts will be firm because an engine speed corresponding to peak engine torques is assumed.
If a fault is undetected, the engine speed is likely to be interpreted as stalled resulting in soft shifting possibly with an
end of shift bump.
4 Vehicle Speed Sensor Fault

l All shifts will be controlled by the shift lever with skip downshifts disabled and downshifts only allowed if the
engine speed is low. Fourth gear will be inhibited.
If a fault is undetected, the vehicle is likely to be interpreted as being stationary resulting in first gear operation at all
times. Note that speedometer transducer faults are likely to cause the vehicle’s speedometer to become inoperative.
5 Gear Lever Fault (Inhibitor/PRNDL Switch)

l The gear lever is assumed to be in the Drive position.
l The transmission is limited to 2nd,3rd, and R gears only.
l The rear band will apply at all times when the lever is shifted to P, R or N. (B2 inhibition and reverse lockout
protection is disabled.)
l Manually (gear lever) initiated downshifts will not be available.
If a fault is undetected, the gear lever position is likely to be interpreted as being higher than actual. Where Park is the
highest position and Manual 1 is the lowest, the result being the availability of higher gears than selected by the gear
lever.

If the gear lever is incorrectly adjusted, the transmission may shift gears on bumpy road surfaces.
6 Transmission Oil Temperature Sensing Fault

l All shifts will be firm until the transmission has warmed up, because a high transmission oil temperature is
assumed.
If a fault is undetected, the temperature is likely to be evaluated as being lower than actual, resulting in softer shifts
with ‘end bump’ (very firm feel at the end of the shift).
7 Mode Setting Fault

l All shifts will occur as if the mode is set to ‘NORMAL’.
l The mode indicator will always be off indicating that ‘NORMAL’ mode is selected.
l The mode indicator will not respond to changes in switch setting.
If a fault is undetected, the mode as indicated by the mode indicator is not likely to respond to the mode switch.
8 Battery Voltage Sensing Fault

If the battery voltage is low then shifts to first gear are inhibited.9 the battery voltage is high (>16.5V) then the
transmission goes into limp home (LHM) mode.
If a fault is undetected, the transmission is likely to incorrectly evaluate an ON/OFF solenoid fault resulting in limp
home mode (LHM) operation.
9 ON/OFF Solenoid Fault (Solenoids 1,2,3 and 4)

The transmission adopts its limp home mode (LHM) operation, described above. However, if solenoid 1 is faulty then
the fourth gear LHM strategy will be adopted independent of vehicle speed.
If a fault is undetected, the operation of the transmission is dependent on which solenoid is actually faulty. The
characteristics for different solenoid fault conditions are listed in table 6.1.2.
10 ON/OFF Solenoid Fault (Solenoids 6,7)

If solenoid 6 is found faulty it is always disabled resulting in high line pressure being applied continuously.
If solenoid 7 is found faulty it is disabled resulting in the transmission being locked always.
The transmission does not go into LHM.
11 Variable Pressure Solenoid Fault

The transmission adopts its LHM operation.
If a fault is undetected, the transmission shift feel is likely to be poor for all shifts.
12 Software Fault
The transmission adopts the third gear LHM strategy of operation, independent of vehicle speed. The operation of
the TCU under this condition is difficult to predict. Its operation may be erratic.
If a fault is undetected, the operation of the TCU is likely to be erratic.
13 Power Supply Fault

The transmission adopts the third gear LHM strategy of operation, independent of vehicle speed. If there is an
intermittent power supply connection, the TCU will power-up in fourth gear and then shift to the appropriate gear to
satisfy the conditions present. The power supply is not monitored for fault evaluation.
All faults except for solenoid faults can be recovered without having to turn the TCU off and back on. However, in
general the recovery requires that no faults are present for a period of time (approx. 3 or 30 seconds). Recovery from
a fault will not clear the fault from the keep alive memory
14 Transmission Sump Temperature Exceeding 135°C

l The converter lockup clutch will be applied at lower speeds, causing a shudder through the vehicle.
l The mode indicator will flash in some vehicles.
These faults can be due to the transmission oil overheating or due to an incorrect signal received from the temperature
sensor.

Diagnostic Trouble Messages
The diagnostic trouble messages generated by the TCU and their possible causes are listed in table 6.1.3.
Table 6.1.2 - Transmission Operations for On/Off Solenoid Faults

Solenoid Condition Transmission Operation
1 Always ON First gear instead of second and fourth gear instead of third.
This results in a 1® 4 shift as the vehicle accelerates from rest.
Always OFF Second gear instead of first and third gear instead of fourth.
This results in second gear starts.
2 Always OFF Fourth gear instead of first and third gear instead of second.
This results in fourth gear starts.
Always ON Second gear instead of third and first gear instead of fourth.
This results in a 1® 2 then 2® 1 (overrun) downshift as the vehicle
accelerates from rest.
3 Always OFF The following shifts become poor:
1® 3, 1® 4, 2® 1 2® 3, 2® 4, 4® 2, 4® 1.
Always ON The following shifts become poor:
3® 4, 4® 3, 3® 2.
There may be slippage in the gears during torque converter locking.
4 Always OFF The following shifts become poor:
1® 2, 1® 3, 1® 4, 2® 3, 2® 4, 3® 1, 3® 2 (All Including Manual), 3® 4,
4® 1,4® 3.
Always ON The following shifts become poor:
2® 4, 3® 2.
There may be slippage in the gears during torque converter locking.
6 Always OFF Line pressure always high.
Always ON Line pressure always low thus resulting in risk of slippage in gears.
7 Always OFF Torque converter always unlocked.
Always ON Torque converter always locked in 3rd and 4th gears, causing the
vehicle to shudder at lower speeds,

Table 6.1.3 - Diagnostic Trouble Messages
Solenoid Condition Description / Cause

1 Test Pass There have been no faults recorded since the TCU was last cleared. If
the fault history has never been cleared, then there have been no
faults recorded since the TCU was originally powered up.
2 Transmission Control There is an internal fault within the TCU.
Module Fault
3 Battery Voltage Input The voltage measured by the TCU corresponding to the battery sup-
Fault ply voltage has been outside the range of the maximum operating
voltage of 16.5 volts.
The minimum operating voltage depends on the transmission tem-
perature but is typically between 8-9 V for a warm transmission.
4 Throttle Input Fault The voltage measured by the TCU from the throttle potentiometer has
been outside acceptable levels.
This would typically indicate a loose connection in the wiring to, or
within, the throttle sensor which has caused the signal at the TCU to
read 0V or 5V.
5 Temperature Input Fault The voltage measured by the TCU across the temperature Input ter-
minals has been outside acceptable levels.
This would typically be caused by a loose connection or short to ground
in the wiring to, or within, the temperature sensor which has caused
the signal at the TCU to read 0V or 5V.
6 Shift Lever Position The voltage measured by the TCU across the shift lever input termi-
Input Fault nals has been outside acceptable levels for a significant length of
(Inhibitor/PRNDL Switch) time. This would typically be caused by a loose connection or short to
ground in the wiring to, or within, the inhibitor switch which has caused
the signal at the TCU to read 0V or 5V.
7 Engine Speed Sensor The signal from the ignition, of ignition pulses, has either been non-
Fault existent or has been unreliable.
There are two reasons this fault could occur. The first is due to a lack
of ignition pulses when other TCU inputs would indicate that the en-
gine is running, that is the gear lever is in a driving position, the throttle
is applied and vehicle speed increasing.
The second cause of this (aunt is the frequency of the pulses of the
ignition pulse input to the TCU indicate an unachievable engine speed.
8 Shaft Speed Sensor The pulses from the shaft speed sensor have either been non-exis-
Fault tent or have been unreliable.
(Speedo Sensor) There are three reasons this fault could occur. The first is due to a
sudden loss of speedometer pulses at a time when they were fre quent,
thus indicating an unachievable degree of deceleration of the drive
line. The second cause of this fault is that the frequency of the pulses
on the shaft speed sensor input to the TCU indicate an unachievable
propeller shaft speed. The third is the presence of a high engine speed
in a driving gear with no speedometer pulses.

Solenoid Condition Description / Cause

9 Mode Switch Input Fault The signal from the mode switch is unreliable.
(Power/Economy Mode) This fault is caused by too many changes in the mode input signal
over a period of time. Typical causes would be an intermittent connec
tion in the switch or wiring or an intermittent short to ground in the
wiring.
10 Data Output Link Fault The data link between the TCU and the engine management module
is found to be unreliable because the checksum, or the data received,
did not match the correct checksum.
This could be caused by an open circuit, short circuit to ground or a
loose connection in the link wire itself.
11 On/off Solenoid Fault Each solenoid in turn is switched off if it was energised, or switched on
(Solenoid 1,2,3,4,6,7) if it was not energised by a very small 100 ms pulse. This pulse is too
short for the solenoid to react so transmission operation is not af
fected.
The solenoid feedback voltage is measured before the 100 ms pulse
and again during the pulse. If the difference is outside the acceptable
limits the relevant fault messages are set.
Typical causes would be an open circuit in the wiring to or within the
solenoid, or a short circuit to ground in the wiring to, from or within the
solenoid in question.
If several of these fault codes are presents check the wiring or
connectors that are common to the selected solenoids, especially the
earth connections.
The state of the solenoid feedback voltage is outside acceptable
limits but the faulty solenoid could not be isolated.
12 Solenoid 5 Fault The current to solenoid 5 was outside acceptable limits.
(Variable Pressure This fault results from a mismatch between the current set point for
Solenoid) solenoid 5 and the current measured by the feedback within the TCU.
Typical causes would be an open circuit or short circuit to ground in
the wiring to, from or within the solenoid. It is also possible that there
has been a fault in the solenoid output circuit. If this is the case
however, the fault should be continually present.
13 Throttle Not Learnt The closed throttle position has not been learnt. This fault
may be caused by the transmission not having reached normal
operating temperature or the engine idle speed being incorrect.
The TCU will learn the closed throttle position automatically
when the transmission is brought to normal operating
temperature and the engine is allowed to idle in Drive with the
‘base idle’ correctly set and the air conditioner (if fitted)
switched off.

MECHANICAL TESTS
In Vehicle Transmission Checks
Carry out the following tests before removing the transmission.
l See Checking Transmission Fluid Level, Section 7.2.1.
l Check that the transmission oil is not burnt (colour and smell are correct).
l Ensure that the transmission is not in limp home mode (LHM).
l Check that the battery terminals and the earth connections are not corroded or loose.
l Check the engine stall speed is within the handbook value.
l Check that the cooler flow is not restricted.
l Check that all electrical plug connections are tight.
l Carry out a road test to confirm the symptoms, if necessary.
l Inspect the oil, ensure that there are no metal or other contaminants in the oil pan.
Diagnosing Oil Leaks

Determine the source of oil leaks by firstly cleaning down the affected area, then driving the vehicle.
Inspect the seals to confirm the source of the leak.
l To determine the source of a rear servo oil leak, raise the vehicle on a hoist, then carry out a reverse stall.
l To determine the source of a front servo leak, raise the vehicle on a hoist, then run the vehicle in second gear.
Troubleshooting Charts
The troubleshooting charts are set out as follows:
l Table 6.2.1 Drive Faults,
l Table 6.2.2 Faulty Shift Patterns.
l Table 6.2.3 Shift Quality Faults.
l Table 6.2.4 After Teardown Faults.
Table 6.2.1 - Drive Faults
Symptom Possible Cause Action

No Drive in D Insufficient auto transmission fluid. Check the fluid level. Top up as necessary.
Blocked feed in C1/C2 cylinder. Inspect and clean C1/C2 feed.
‘Z’ link displaced. Reinstall/renew the ‘z’ link.
Primal regulator valve (PRV) jammed open. Remove, clean and re-install the PRV.
Overdrive shaft or input shaft seal rings Inspect and replace as necessary.
failed.
3-4 or 1-2 one way clutch (OWC) installed Inspect and replace as necessary.
backwards or failed.
C2 piston broken or cracked. Inspect and replace as necessary.
No Drive in
Reverse
No engine braking Rear band or servo faulty. Check servo adjustment or replace rear band
in Manual 1 as necessary.
Engine braking in Failure in C3, C3 hub or C1/C2 cylinder. Check for failure in C3, C3 hub or C1/C2 cylin-
Manual 1 is OK der. Repair as necessary.
No drive in Drive Jammed primary regulator valve (PRV). Inspect and clean PRV.
and Reverse
Damaged/broken pump gears. Inspect and replace pump gears as necessary.
Dislodged output shaft snap ring. Inspect and repair as necessary.


2-3 shift only S1 always OFF. Inspect S1. Repair or replace as necessary.
(no 4th or 1st) Check for 12 Volts applied to S1 at all times or
for wiring fault.
1-4 shift only S1 always ON. Inspect S1. Repair or replace as necessary.
1-3-4 (Delayed Check for 12 Volts applied to S1 at all times or
1-2shift) for wiring fault.
4-3 shift only S2 always OFF. Inspect S2. Repair or replace as necessary.
Check for open circuit or wiring fault.
1-2-Neutral S2 always ON. Inspect S2. Repair or replace as necessary.
(1st over run) Check for open circuit or wiring fault.
1-3 shift only B1 failed.
Loose band adjustment. Inspect and adjust as necessary.
Front servo piston or seal failed. Inspect and repair as necessary.
S1/S2 ball misplaced, Inspect and replace or refit as necessary.
1-3-4 only Smaller’0’ring on front servo piston failed Inspect ‘O’ ring. Refit or replace as necessary.
or missing. Inspect the 2-3 shift valve. Repair or replace
2-3 shift valve jammed. as necessary.
1-2-1 only C1 clutch failed or slipping in 3rd and 4th. Inspect C1 clutch. Repair or replace as neces-
(Gives 1st in 3rd and 2nd in 4th.) sary.
No manual 4-3,3-2 Over-run clutch (OC)/low ball misplaced. Inspect ball. Refit or replace as necessary.
or 2-1 C4 failed or C4 wave plate broken. Inspect C4. Repair C4 or replace C4 wave plate
as necessary.
No manual 1st Rear band slipping when hot. Inspect rear band adjustment. Adjust as nec-
essary.
Reverse/Low-1st ball misplaced. Inspect ball- Refit or replace as necessary.
Rear servo inner ‘O’ ring missing. Inspect’0’ring. Refit or replace as necessary.
C4 failed or C4 wave plate broken. Inspect C4 and C4 wave plate. Repair or re-
place as necessary.
1st gear only or Inhibitor switch faulty. Inspect inhibitor switch.
2nd,3rd, and 4th Repair or replace as necessary.
only 1-2 shift valve jammed. Inspect the 1-2 shift valve.
Repair or replace as necessary
1st and 2nd only Inhibitor switch fault, 1-2 only. Inspect inhibitor switch.
or 1st, 3rd and 4th Repair or replace as necessary.
only 2-3 shift valve jammed. Inspect the 2-3 shift valve.
Repair or replace as necessary.

Table 6.2.2 - Faulty Shift Patterns

1st,2nd and 4th Inhibitor switch fault, 1-2-3 only. Inspect inhibitor switch. Repair or replace as
only or 1st,2nd, necessary.
and 3rd (tied up in 3-4 shift valve jammed. Inspect the 3-4 shift valve. Repair or replace
3rd) as necessary.
Jammed band 1 release valve. Inspect the release valve. Repair or replace as
Harsh 2-3 shift necessary.
Faulty S3 or S2 solenoid. Inspect S3 or S2. Repair or replace as neces-
sary.
Faulty clutch apply regulator valve. Inspect the regulator valve. Repair or replace
as necessary.
Missing or damaged clutch apply feed ball. Inspect the ball. Refit or replace as necessary.
Damaged input shaft sealing rings. Inspect the sealing rings. Refit or replace as
necessary.
Damaged C1 piston ‘O’ rings. Inspect the ‘O’ rings. Refit or replace as neces-
sary.
Damaged or dislodged C1 piston bleed Inspect the bleed ball. Refit or replace as nec-
ball. essary.
Faulty S1 or S4 solenoid. Inspect S1 or S4. Repair or replace as neces-
sary.
Harsh 3-4 shift Jammed band 1 release valve. Inspect the release valve. Repair or replace as
necessary.
Incorrect front band adjustment. Inspect the band. Adjust as necessary.
Damaged front servo piston ‘O’ rings. Inspect the ‘O’ rings. Refit or replace as neces-
sary.
Faulty or damaged variable pressure Inspect S5. Repair or replace as necessary.
solenoid (S5).
Faulty band apply regulator valve. Inspect the regulator valve. Repair or replace
as necessary.


All Shifts Firm Incorrect auto transmission fluid (ATF). Drain and fill with specified ATF.
S5 faulty won, or incorrectly fitted. Check that S5 is fitted correctly, or replace S5.
Band apply and clutch apply regulator Inspect band apply and clutch apply regulator
springs misplaced. springs. Refit or replace as necessary.
Manual 4-3-2-1 is Over-run clutch (OC)/Low-1st ball Inspect the ball. Refit or replace as necessary.
soft delayed or misplaced.
missing C4 clutch worn or burnt. Inspect C4 clutch. Replace or repair as neces-
sary.
C4 wave plate not lined up with the holes Check the alignment. ]Realign as necessary.
in the piston.
C4 wave plate failed. Inspect wave plate. Replace as necessary.
Firm 1-2 Hot S5 worn. Inspect S5 and replace as necessary.
S5 damper spring broken. Inspect the damper spring and replace as nec-
essary.
Front servo belleville spring broken. Replace spring as necessary.
4th Tied up Incorrect C4 pack clearance. Check the clearance and adjust as necessary.
Damaged C4 clutch. Inspect C4. Repair or replace as necessary.
Cracked C2 piston (leaking into C4). Inspect piston. Repair or replace as necessary.
Tied up on 2-3 Incorrect band adjustment Inspect and adjust band as necessary.
Front servo plastic plug missing Replace the plug.
B1R spring broken. Replace the spring.
Flare on 2-3 B1R spring/plug left out. Replace the spring/plug.
C1/B1R ball misplaced. Refit the ball.
C1 clutch damaged. Inspect the clutch. Repair the clutch as neces-
sary.
Restriction in C1 feed. Inspect and clean C1 feed.
C1 piston check ball jammed. Replace the piston.
Overdrive or input shaft sealing rings dam- Inspect and replace the sealing rings and/or
aged. shaft as necessary.
Slips in 4th C1/B1R ball misplaced. Inspect and replace the ball.
Overdrive or input shaft sealing rings dam- Inspect and replace the sealing rings and/or
aged. shaft as necessary.
C1 clutch damaged. Inspect and repair the C1 clutch as necessary.
Flare on 4-3, Flare 4-3 sequence valve in backwards. Refit the valve.
on 3-2
Firm Manual low Low-1st check ball misplaced. Replace the ball.
shift-high line
press.

Table 6.2.3 - Shift Quality Faults

Harsh 1-2 shift Faulty inhibitor switch. Check the resistance. Replace the inhibitor
switch as necessary.
Faulty throttle position sensor. Inspect and replace the sensor as necessary.
Incorrect front band adjustment. Inspect and adjust the band as necessary.
Damaged front servo piston’0’rings. Inspect and replace the’0’rings as necessary.
Faulty or damaged variable pressure so- Inspect, repair or replace S5 as necessary.
lenoid (S5).
Faulty S1 or S4 solenoid. Inspect, repair or replace S1 or S4 as neces-
sary.
Faulty band apply regulator valve (BAR). Inspect, repair or replace the BAR as neces-
sary.
Misassembled front servo return spring. Inspect and repair as necessary.
stalls when Drive Jammed converter clutch control valve Inspect and clean CCCV.
or Reverse (CCCV).
selected Shudder Faulty solenoid 7. Inspect, repair or replace as necessary.
on Rolldown

Table 6.2.4 - After Teardown Faults
C2 burnt T-bar linkage out of adjustment. Inspect, repair C2 and adjust the linkage as neces-
sary.
56 foiled - stuck low. Repair C2. Inspect, repair or replace S6 as neces-
sary.
Overdrive/output shaft sealing rings damaged. Repair C2. Inspect, replace the sealing rings and/
or shaft as necessary.
C2 piston cracked. Repair C2. Inspect, repair or replace the C2 piston
as necessary.
C4 burnt Incorrect C4 pack clearance. Inspect C4 and repair as necessary.
Inspect and adjust the C4 pack clearance as nec-
essary.
C4 wave plate broken. Repair C4. Inspect and replace the wave plate as
necessary.
C4 wave plate not lined up properly. Repair C4. Inspect and realign the wave plate as
necessary.
Overdrive or output shaft sealing rings dam- Repair C4. Inspect and realign the sealing rings
aged. and/or shaft as necessary.
3-4 one way clutch (OWC) in backwards. Repair C4. Inspect and refit the OWC as neces-
sary.
C2 piston cracked. Repair C4. Inspect and replace the C2 piston as
necessary.
Over-run clutch (OC)/low-1st ball misplaced. Repair C4. Inspect and refit the ball as necessary.
B1 burnt B1R spring broken. Inspect and repair B1 and replace the spring as
necessary.
Input shaft sealing ring cut. Replace sealing ring.
C1/B1R ball misplaced. Repair B1. Refit the ball as necessary.
C1 burnt B1R spring left out. Inspect and repair C1 and replace the spring.
Overdrive or input shaft sealing rings damaged. Repair C1. Inspect and replace the sealing tongs
and/or shaft as necessary.
C1 piston cracked. Repair C1. Inspect and replace the C1 piston as
necessary.
Ball capsule jammed. Repair C1. Inspect and refit the capsule as neces-
sary.
4-3 sequence valve in backwards. Repair C1. Inspect and refit the valve as neces-
sary.
Clutch apply feed (CAF)/B1R ball left out. Repair C1. Inspect and replace the ball as neces-
sary.
Slips in reverse - Rear band incorrectly adjusted or damaged. Inspect and adjust the band as necessary.
no manual 1st Reverse-low/first ball misplaced. Inspect and refit the ball as necessary.
Firm converter Input shaft ‘O’ ring missing or damaged. Inspect and replace the ‘O’ ring as necessary.
lock or unlock Converter clutch regulator valve in backwards. Inspect and refit the valve as necessary.
No lock up at light Input shaft ‘O’ ring missing or damaged. Inspect and replace the ‘O’ ring as necessary.
throttle C1 bias valve in backwards. Inspect and refit the valve as necessary.

SELF DIAGNOSIS TEST
1. Turn the ignition switch to “OFF” position.

2. Connect the scanner harness connector to the engine
3. Turn the ignition switch to “ON” position.
4. Select “Electronics control vehicle diagnosis” from the
function selection display and press “Enter”.
5. Select “Korando (98 face lift)” from the vehicle model
selection model selection display and press “Enter”.
6. Select “Transmission control unit(TCU)” from the control
system selection and press “Enter”.
7. Select “Self-diagnosis” from diagnosis items.
Notice
Check sensor output value displays if necessary.
8. Determine the fault code and check the detective Items.
Notice
Refer to sefadf3fnosfs list.

Self-diagnosis List

P1702 Throttle position sensor l Check cable for open / short.
l Check connection of other connectors.
l Check voltage between terminal 27 and 29 of TCU,
- Standard value : 0.2 - 4.7V
l Check TPS.
P1703 Engine RPM l Check cable for open / short.
l Check engine speed sensor.
l Check resistance between terminal 8 and 24 of TCU (when the
connector is disconnected).
- Standard value : 1 .9 - 0.2 kW
P1704 Vehicle speed l Check cable for open / short.
l Check vehicle speed sensor.
P4705 Shift lever l Check cable for open / short.
l Check engine speed sensor.
l Check inhibitor switch resistance between terminal 34 and 37 of
TCU(when the connector is disconnected).
- Standard value : 1st gear - 4 - 4.4 kW
2nd gear - 4,8 - 2.2 kW
3rd gear - 3 - 3.4 kW
D gear - 4.5 - 4.g kW
N gear - 6.8 - 7.2 kW
R gear - 10.8 -11.2 kW
P gear - 18.6 - 19 kW
l Check voltage between terminal 31 and 37 of TCU.
- Standard value : 0-5V(P,R,N,D,L)
P1706 W, E, P mode switch l Check cable for open / short.
l Check mode switch.
l Check condition between terminal 1 and 13 of TCU.
Winter mode :12V, Normal mode : Open status, Power mode : 0V
P1707 T/M oil temperature l Check cable for open / short.
- Standard value : 0-5V
l Check oil temperature sensor.
P1708 Battery voltage l Check cable for open / short.
l Check battery condition.
l Check alternator.


P1710 Air conditioner switch l Check cable for open / short.
- Standard value : when the A/C compressor is ON : 12V
when the A/C compressor is OFF : 0V
P1712 Kick down switch l Check cable for open / short,
- Standard value : when the kick down switch is ON : 12V
when the kick down switch is OFF : 0V
P1713 Pedal
P1714 Vehicle ID
P1715 VPS offset
P1716 Throttle position sensor l Fully depress accelerator pedal for 5 seconds(ignition key is ON).
initialization l Release accelerator pedal.
l Depress brake pedal and start the engine in ‘P’ position.
l Depress brake pedal and idle the engine for 5 seconds in ‘D’
position.
l Shift into ‘D’ position and determine fault code for throttle initial-
ization.
l Complete the initialization.
P1733 Solenoid 1 l Check cable for open / short.
l Check resistance between terminal 1 and 34 of TCU(when the
- Standard value : 26 - 30W
l Check solenoid.
l Check connection of other connectors,
l Check solenoid.
l Check solenoid.
connector is disconnected),


l Check solenoid.
- Standard value : 3.6 - 4.2W
l Check solenoid.
l Check solenoid.
l Check solenoid.
P1741 Short of solenoid 1 l Check cable for short.
l Check solenoid.
l Check solenoid.
l Check solenoid.
l Check solenoid.
l Check solenoid.
l Check solenoid.
l Check solenoid.

ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary
checks.
l Conduct a transmission fluid test procedure, refer to section 7.2.
l Check the manual linkage adjustment (refer to the vehicle workshop manual).
l Check engine idle speed (refer to Section 7.3).
l Conduct a stall test (it is outside the scope of this publication to detail this procedure)
l conduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE

Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be added
to the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (ATF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded.
Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below.
Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours
before adding transmission fluid (this will allow the transmission to be within the correct temperature
range).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park.
Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug.
Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.

6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level.
7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATF to the correct level.
8. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle.
9. Tighten the transmission filler plug to specification.
Checking, Adding Fluid and Filling - Drained or Dry Transmission

To set the correct fluid level proceed as follows.
1. Set the transmission selector to Park and switch the engine off.
2. Raise the vehicle on a hoist (or leave over a service pit).
3. Clean all dirt from around the service fill plug prior to removing the plug, Remove the oil service fill plug. Clean the
fill plug and check that there is no damage to the ‘O’ ring. Install the filler pump into the filler hole.
4. Lower the vehicle with the filler pump still connected and partially fill the transmission. This typically requires
approximately :
a. If the transmission torque converter is empty:
9.0 litres - 4WD
9.0 litres - RWD
b. If the transmission torque converter is full:
4.5 litres - 4WD
4.5 litres - RWD
5. Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.
6. Then add an additional 0.5 litres of ATF.
7. Switch off the engine and raise the vehicle on the hoist. Remove the filler pump and replace the filler plug. The
plug shall be tightened to specification.
8. The vehicle is then to be driven between 3.5 and 4.5 kilometers at light throttle so that the engine does not
exceed 2500 rpm. This should result in the transmission temperature being in the range 50 to 60°C.
9. With the engine idling, cycle the transmission selector through all gear positions with the brake applied.
10. Stop the engine. Raise the vehicle on the hoist, if applicable ensuring the vehicle is level.
11. Three minutes after the engine has stopped, but no longer than one hour, remove the filler plug. The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATP to the correct level.
12. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle. Tighten the
transmission Filler plug to specification.
ELECTRONIC ADJUSTMENTS
Idle Speed Adjustment
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration

Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic
trouble message, it may be re-established by the following procedure.
l Check that the hot engine idle speed is within specification.
l Allow the engine to idle in ‘Drive’ for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle
reference point in the TCU has now been set.
Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open
throttle reference point in the TCU has now been set.

Throttle Clearing
The leant throttle clearing routine uses the mode switch and gear lever. Carry out the following steps to complete the
automated throttle clearing procedure:
1. Switch ignition ‘ON’ with handbrake applied and engine ‘OFF’.
2. Select ‘M1’ and ‘WINTER’ mode.
3. Move the T-bar to ‘M2’ and then select ‘NORMAL’ or ‘POWER’ mode.
4. Move the T-bar to ‘M3’ and then select ‘WINTER’ mode.
Vehicle Coding
The vehicle coding is integrated as part of the diagnostic software. The coding applies to the following vehicle
models:
1. 4WD Gasoline E32.
2. 4WD Gasoline 523
3. 4WD Gasoline 520.
4. 4WD Diesel D29NA.
5. 4WD Diesel D29LA.
6. 4WD Diesel D23LA.
7. RWD E20.
8. RWD E23.


ON-VEHICLE SERVICE
REMOVAL AND INSTALLATION OF
TRANSMISSION
2. Disconnect the connectors from transfer case.
3. Disconnect the speedometer connector from transfer
case.
4. Disconnect the inhibitor and Sear position sensor
connector.
5. Remove the rear propeller shaft .

Installation Notice
6. Unscrew the eight bolts and two nuts, and remove the
cross member.

7. Remove the rear propeller shaft.
Installation Notice
8. Unscrew the five bolts and remove the transfer case.
9. Disconnect the 10-Pins Plug connector from transmission.
10. Separate the locking clip on shift lever and remove the
shift rod.
Notice
Removal and installation performed when the shift
procedure should be lever is in “D” range.
11. Remove the two pipes for oil cooler.

Installation Notice
12. Remove the service hall cover on torque converter.

13. Put the alignment mark for installation, and unscrew the
six mounting bolts for torque converter from drive plate
through the service hole (arrow) by rotating the engine
and remove the torque converter.
Installation Notice
Screw the six bolts mounting the torque converter through

the service hole by using a mirror and rotating the engine.

14. Remover the starter.
15. Unscrew the eight transmission housing bolts and remove
the transmission assembly.
Installation Notice
Be careful not to drop the torque converter while removing

the transmission.

reverse order.

UNIT REPAIR
REBUILD WARNINGS
Prior to rebuilding a transmission system, the following warnings
are to be noted.
l Ensure that, before replacing a transmission the cooler
lines are flushed out to remove any debris. This can be
done by applying compressed air to the rear cooler line
forcing oil and any contaminants out of the front cooler
line.
l The cooler flow should be checked after the transmission
has been fitted. With the front cooler line connected
and the rear line run into a suitable container, measure
the flow over 15 seconds with the vehicle idling in park.
l The flow rate should exceed 1 liter in 15 seconds.
l Be wary of any situation where water enters the
transmission. This may result in fluid foaming and leaking
through the breather.
l Ensure that both earth straps (one at the batted terminal
and one on the vehicle body) are connected in the
vehicle before connecting the positive side of the
battery.
l Follow the throttle position calibration procedure in
section 7 of this manual if the powertrain control module
transmission control unit (PCM/TCU) is swapped.
DISASSEMBLY PROCEDURE
Transmission
Notice
Remove the inhibitor switch before washing the transmission
in solvent or hot wash.
It is assumed that the transmission fluid has been drained
when the transmission was removed from the
vehicle and that the ‘special tools’ quoted are available.
The transmission is dismantled in a modular fashion, and the
details of disassembly for each module are given under the
appropriate subject. Refer to table 9.10 in section 9.6 for details
of all special tools required when performing disassembly
procedures.
Technicians overhauling these transmissions will also require
a selection of good quality Torx bit sockets, in particular
numbers 30, 40 and 50, and an 8 mm,10 mm and 12 mm
double hex socket.
To disassemble the transmission, proceed as follows:
1. Remove the converter and the converter housing.
2. Mount the transmission on the bench cradle
No.0555-331895.
3. Remove the sump and the sump seal.

4. Detach each end of the filter retaining clip from the valve
body and remove the filter.
5. Detach the wires from each solenoid and lay the wiring to
one side.
6. Remove the valve body securing screws and remove the
valve body from the case.
7. Remove the front servo cover circlip.
Remove the cover and piston.
Notice
The plastic servo block is retained by the piston return
spring only.
8. Where fitted, remove the flange yoke, and then remove
the extension housing (RWD model).
Remove the adaptor housing (4WD model).
9. Remove the pump to case bolts using a multi-hex 8 mm

spanner.
10. Using the pump puller No. 0555-332941, remove the pump.
11. Remove the input shaft, forward clutch cylinder, and the
overdrive shaft as an assembly, withdrawing them through
the front of the case.
12. Remove the C3 clutch cylinder and sun gears.
13. Remove the fronts band struts. Remove the front band.
14. Remove the two centre support retaining bolts using a
T50 Torx bit.
15. Remove the centre support retaining circlip.

Notice
Do not hammer the output shaft to remove the centre
support as this will cause permanent damage to the thrust
bearing surfaces.
16. Remove the centre support, 1-2 one way clutch, planetary
gear set and output shaft as an assembly.
17. Remove the parking rod cam plate. (T40 Torx bit).
18. Remove the rear band struts and remove the band.

Transmission Case
To teardown the transmission case, proceed as follows:
1. Remove the pin from the cross shaft inhibitor switch side
(4WD models) using tool No.0555-332942.
2. Remove the inhibitor switch from the case.

Remove the cross shaft seals with special tool No.0555-
331893.
3. Remove the circlip from the cross-shaft. Pull the shaft to

release the drive pin from the selector quadrant.
4. Using tool No. 0555-331897, press the pin from the cross-
shaft and withdraw the shaft from the case. Retrieve the
spring and pin
5. Remove the manual valve lever and the park rod.

6. Remove the 10 pin plug from the wiring loom bracket
adjacent to the inhibitor switch(RWD models),
7. Depress the tangs and withdraw the 10 pin connector from
the case. Remove the loom assembly.

8. Detach the No.7 solenoid wire from the front of the case.
9. Remove the parking pawl pivot pin and the pawl and spring
from the case.
10. Remove the shaft and the rear servo lever.
11. Remove the rear servo cover and piston assembly.
12. Remove the B1R circlip, valve and spring.
13. Remove both band adjustment shims.
14. Inspect the output shaft bushing in the case and replace if
necessary.
15. Inspect cooler line fittings and replace as necessary.
16. Inspect the case for damage.
17. To remove the park rod lever: Remove the circlip from the
inner end of the pivot shaft and tap the outer end of the
shaft until it moves free from the case, then using a wide
shallow tapered drift as a wedge, drive the pin out from
the inside of the case and remove the lever and spring.
Notice
Do not remove the park rod lever unless absolutely
necessary.

Figure 8.4 - Forward Clutch Cylinder Assembly
Forward Clutch Cylinder

To remove the forward clutch cylinder, refer to figure 8.4,
proceed as follows.
1. Place the assembly in a horizontal position.
2. Remove the thrust bearing and adjustment shims from the
input shaft.
3. Remove the circlip from the front of the clutch cylinder and
remove the input shaft.
4. Remove the overdrive shaft and the C1 clutch hub assembly
from the clutch cylinder.
5. Remove the C1 clutch plates from the cylinder.
6. Remove the circlip retaining the C3 clutch hub in the rear of
the clutch cylinder and remove the hub.
7. Remove the C2/C4 clutch hub assembly and remove the
thrust bearing from the C4 hub.
8. Remove the C2 clutch plates.
9. Invert the clutch cylinder and remove the C4 clutch sleeve,
clutch plates and the two wave washers. The 3-4 one way
clutch is located between the C2 and C4 clutch hubs, and
the hubs may be separated by rotating one hub clockwise
and withdrawing it from the other.

10. Remove the thrust block from the C4 clutch cylinder hub.
Notice
Make sure that the spring keeper is not caught in the circlip
groove, and that all the spring pressure is released, before
removing the tool.
11. Mount the clutch cylinder on tool No.0555-331899 with
the C2/C4 end uppermost and compress the piston return
spring. Remove the spring retaining circlip. Release the
tool and remove the circlip, keeper and spring.
12. Invert the clutch cylinder on the compressor tool and
remove the C1 clutch piston return spring in a similar
manner.
13. To remove the clutch pistons from the clutch cylinder, apply
air pressure to the apply ports in the bore of the cylinder.

C3 Clutch Cylinder
To remove the C3 clutch cylinder, proceed as follows:
1. Remove the forward sun gear and thrust bearing from the
C3 clutch cylinder.
2. Remove the nylon thrust bearing, bearing support, needle
thrust bearing and thrust block from the clutch cylinder hub.
3. Mount the clutch assembly on tool No.0555-331899 and

compress the piston return spring.
Remove the circlip and release the spring.
Notice
Make sure that the spring keeper has not been caught in
the circlip groove, and that all spring pressure has been
released, before removing the tool.
4. Remove the tool, circlip, keeper and spring.
5. Remove the sealing rings from the C3 clutch cylinder.
6. Remove the clutch plate retaining circlip and remove the
clutch plates.
7. To remove the clutch piston from the clutch cylinder, apply

air pressure to the port between the iron sealing rings on
the bearing journals of the cylinder.
8. Remove the reverse sun gear from the cylinder.

Planet Carrier and Centre Support
To remove the planet carrier and centre support, proceed as
follows.
1. Separate the planet carrier and centre support from the
output shaft. Remove the thrust bearings from the output
shaft and the planet carrier.
2. Separate the centre support from the planet carrier by
rotating it anti-clockwise.
3. Lift the one way clutch from the planet carrier.
4. Remove the circlip retaining the one way clutch outer race
in the planet carrier and remove the race.
5. Remove the one way clutch retainer from the planet carrier.
Pump
Note that the following valves are housed in the pump cover:
l Solenoid 7
l C1 bias valve
l Converter clutch control valve
l Converter clutch regulator valve
l Primary regulator valve
To remove the pump, proceed as follows.
1. Remove the wiring loom retainer plate and remove
solenoid 7 with a T30 Torx bit.
2. Remove the five washer head bolts from the cover plate
using a multi-point 8 mm socket.
3. Remove the five Torx head screws from the cover plate
(Torx bit No. 30). Note that the odd screw holds the pump
body to the pump body cover.
Notice
Do not strike the converter support tube to loosen the
pump body.
4. Separate the pump body from the pump cover.
5. Lift the cover plate from the cover.
6. Remove the two ball check valves and one spring from
the pump cover.
Notice
Some of the valves and plugs are preloaded by springs
and may unexpectedly fall out of the cover when the pins
are removed.
7. Depress the plug inward and remove the retaining pin for
each of the four valves.
8. Remove the four valves, plugs and springs.
9. Remove the pump gears from the pump body.
10. Remove the lip seal from the front of the pump body.

Valve Body
To disassemble the valve body, proceed as follows.
1. Remove the detent spring and retainer plate using a T40 Torx bit.
Notice
Be aware that the manual valve will fall out of the valve body.
2. Take note of the angular relationship of the solenoid terminals
to the valve body, then slide the manual valve out of the lower
valve body.
3. Remove the solenoid and valve assembly as follows:
l solenoid 1
l solenoid 2
l solenoid 3
l solenoid 4
l solenoid 5
l solenoid 6
4. Place the valve body assembly on the bench with the upper
body uppermost.
5. Remove the 24 clamping screws with a No. 30 Ton bit. Separate
the upper and lower valve bodies by lifting the upper body and
the separator plate together.
6. Upper body over and place it on the bench with the separator
plate uppermost.
7. Lift the separator plate and gaskets from the upper valve body.
8. Remove the five nylon check balls exposed in the valve body.
9. Remove the retainer plate, plug, spring and reverse lockout
valve.
10. Remove the two filters (and the large nylon check ball) from the
lower valve body.
Notice
Once the pins are removed, the plates are loose in the valve
body and will drop out when the valve body is turned over.
11. Remove the keeper plates and pins from the 1-2,2-3,3-4, BAR
and CAR valves. The pins can be removed with a magnet.
12. Remove the 1-2,2-3 and 3-4 shift valves.
Notice
The plug is preloaded by the spring and may unexpectedly fall
out of the valve body.
13. Depress the 4-3 sequence valve plug and remove the keeper
plate.
14. Remove the plug, valve and spring.
15. Depress the solenoid 5 valve. Remove the keeper pin and
remove the valve and spring.
Notice
The valve is preloaded by the spring and may unexpectedly fall
out of the valve body.
16. Depress the line pressure release valve, remove the keeper
pin, disc (if fitted), spring and valve.
17. Drive out the roll pin and remove the spring and ball check valve
adjacent to the BAR valve.

ASSEMBLY PROCEDURE
The transmission is assembled in modular fashion and details
of assembly for each module are given under the appropriate
subject. Refer to table 8.1 (at the end of Section 8.3) for the
torque specifications to be applied, and to table 9.10 in section
9.6 for details of all special tools required, when performing
assembly procedures. Technicians overhauling these
transmissions will also require a selection of good quality Torx
bit sockets, in particular numbers 30,40 and 50, and an 8 mm,10
mm and 12 mm double hex socket.
Transmission
Notice
1. Ensure that the B1R circlip is fitted to the case. (If this is not
fitted, the valve will peen its way into and through the
separator plate.)
2. Ensure that the ‘E’ clip is fitted to the cross shaft.
3. Ensure that all aspects of the parking mechanism are
working.
To assemble the transmission, proceed as follows:
1. Turn the transmission case upside down on the bench and
mount it to the transmission cradle No.0555-331895.
2. Install all fittings, plugs and the breather, applying a sealant
where applicable, Tighten the fittings to specifications.
Ensure that the breather is clear, and check that the lube
fitting in the rear of the case is fitted and clear of obstruction.
3. Assemble the B1R valve and spring, and secure with the
irclip. Refer to Ensure that the circlip is completely seated
in its groove.
4. Install the rear servo lever and pivot pin.

Notice
The lever must pivot freely on its pin.

Notice
Care must be taken when applying sealant to ensure that it is
not applied between the pin and the lever.
5. Assemble the park rod lever, complete with the return spring
and pivot pin, applying a small amount of sealant to the
outer end of the pivot pin.
Notice
That the lever must pivot freely on its pin and the spring
must return the park rod lever to its correct location.
6. Secure the pivot pin with the circlip.
Notice
The pawl must pivot freely on its pin.
7. Install the parking pawl pivot pin and spring.
8. Connect the park rod to the manual valve detent lever.

Ensure the spring and cam collar is firmly installed on the
rod.

9. Check that the cam collar slides freely on the rod.
10. Insert the cross shaft into the case, from the side opposite
to the inhibitor switch, then install the anti-rattle spring on
the shaft.
11. Position the manual valve detent lever, aligning it with the
cross-shaft bore in the case.
12. Push the shaft through the detent lever until it starts in the
detent lever side of the case.
13. Install the detent lever drive pin in the shaft using tool No.
0555-331897 with the adaptor over the pin.
14. Press the pin into the shaft until the tool bottoms.
15. Remove the tool and fit the spring retaining circlip to the
shaft.
16. Install the new cross shaft seals using tool No. 0555-
331894.
17. Install the inhibitor switch on the case. Torque the screws
as per specifications. Press the pin into the shaft until the
tool bottoms (4WD models) using tool No.0555-332942.
18. Thoroughly check the terminal wiring loom for condition
and continuity.
19. Position the loom and locate the solenoid 7 contact and
terminal in the pump mounting flange at the front of the
case. The solenoid 7 wire is routed under the park rod
and cross shaft in the case.

20. Install the ten pin connector in the case engaging the tangs
on the connector in the notches in case.
4WD MODELS ONLY
21. Route the portion of the wiring loom coming out of the
case down between the inhibitor switch and the case.
Position the ten pin plug on the wiring loom bracket .

Rear Band Assembly
To assemble the rear band assembly proceed as follows:
1. Check the rear band for any cracks or damage along the
lining and metal backing.
2. Install the reaction anchor strut into the main case, without
shims.
Notice
If fitting a new band, soak the new band in automatic
transmission fluid (or a minimum of five minutes prior to
assembly.
3. Carefully install the rear band into the transmission case
and ensure that it is properly fitted in the case.
4. Position the apply strut on the rear band then engage the Figure 8.18 - Rear Servo and Band
apply strut in the servo lever.
5. Install the cam plate and tighten the screws to specification.
Figure 8.19 - Thrust Bearing and Washer Locations

Output Shaft and Gear Assembly
To assemble the output shaft and gear assembly (refer to
(figure 8.19), proceed as follows:
1. Check that the output shaft bush is not won or damaged.
Replace if necessary.
2. Check for damage to parking pawl teeth on the ring gear.
3. Check that the sealing ring grooves have not been
damaged.
4. Lubricate the sealing rings with automatic transmission fluid.
5. Assemble the sealing rings to the output shaft with the scat
cut uppermost.
6. If previously dismantled, assemble the ring gear to the output
shaft and secure with circlip. Ensure that the circlip is firmly
seated in its groove.
7. Fit the thrust bearing assembly No. 10 onto the output shaft
using petroleum jelly.
8. Carefully install the output shaft assembly in the case to
prevent damage to the sealing rings.
Rear Servo Assembly

To assemble the rear servo assembly (refer to figure 8.18),
proceed as follows.
1. Check the servo piston ‘O’ rings and gasket for any damage.
2. Lubricate the servo piston ‘O’ rings with automatic
transmission fluid, and fit the ‘O’ rings to the piston grooves.
3. Assemble the piston to the cover, ensuring that ‘O’ ring
compression is adequate but not excessive.
4. Align the spring on the piston spigot, then position the rear
servo rod into the spigot.
Notice
Do not use petroleum jelly on the gasket.
5. Assemble the gasket to the cover and fit the assembly to
the case.
6. Apply Loctite 567 sealant to the bolts. Install the bolts and
tighten to specification.

Planet Carrier Assembly and Centre Support
To assemble the planet carrier assembly and centre support,
proceed as follows.
1. Check the carrier and planet assembly for any damage or
irregularity and ensure that all pinions rotate freely and
that the pinion end float is within the tolerance stated in
section 9.2.
2. Install the one way clutch (OWC) retainer to the planet
carrier with the inner edge pointing downwards. Inspect
the OWC race and the sprag assembly for wear or damage.
3. Install the outer race in the drum. Press the race to the
bottom of the drum and install the retaining circlip. Ensure
the circlip is firmly seated in its groove.
Refer to figure 8.21.
4. Install the OWC into the outer race with the lip edge
uppermost. Lubricate the sprags with automatic
transmission fluid. Refer to figure 8.20.
5. Check that the plugs are fitted to the centre support, then
assemble the centre support into the OWC, ensuring that
the support will rotate in an anti-clockwise direction only.
Figure 8.20 - Planet Carrier Assembly and

Centre Support
6. Lubricate the No.9 needle thrust bearing and the thrust

washer with petroleum jelly and fit them to the rear face of
the planet carrier. Refer to figure 8.19.
7. Install the planet assembly and the centre support into the
case, and align the centre support mounting bolt holes.
8. Install the centre support bolts finger tight.
9. Install the circlip retainer ensuring that the circlip is
completely seated in the groove of the case.
10. Remove the centre support bolts and apply Loctite 222 or
equivalent to the threads. Install the bolts and torque to
specifications.

Extension Housing Assembly
To assemble the extension housing assembly, proceed as
follows.
1. Check the condition of the extension housing roller bearing.
Replace if necessary (RWD models). Install the new bearing
from rear of extension housing. Press on the branded face
of bearing only.
2. Install a new seal to the extension housing or adaptor
housing. Refer to figure 8.21.
Notice
Do not use petroleum jelly to hold the gasket in position.
3. Position a new gasket onto the extension housing or adaptor
housing.
Notice
See section 8.3.17 for the procedure to assemble the output
Figure 8.21 - Extension Housing
flange assembly - RWD models.
4. Install the extension housing (RWD) or adaptor housing
(4WD) and torque the bolts to specification.
Front Servo Assembly

NOTICE
Ensure that the front servo snap ring is installed correctly.
Orient the circlip with the gap at the bottom, near the pan rail.
To assemble the front servo assembly (refer to figure 8.22),
proceed as follows.
1. Lubricate the cover ‘O’ ring with automatic transmission fluid
and fit to the cover.
2. Lubricate the piston ‘O’ rings with automatic transmission
fluid and fit to the piston.
3. Assemble the piston, push rod, spring, belleville washer,
seat and retaining ring.
Figure 8.22 - Front Servo and Band
4. Fit the piston push rod assembly into the front servo cover.
5. Install the front servo block and spring into the case.
6. Install the front servo assembly into the case.
7. Compress the servo cover and fit the servo cover retaining
circlip, aligning the gap with the pan rail, and ensuring that
it is completely seated in its groove.

Front Band Assembly
To assemble the front band assembly, proceed as follows.
1. Install the reaction anchor strut to the case.
2. Check the band for ally cracks or damage along its lining
and metal backing.
3. Position the strut retainers on the band (refer to figure
8.23).
NOTICE
If fitting a new band, soak the band in automatic
transmission fluid for a minimum of 5 minutes prior to
assembly.
4. Install the front band into the transmission case, ensuring
that it is properly seated in place. Figure 8.23 - Front Band Strut Installation
5. Position the reaction strut in its retaining clip and engage
it with the band and anchor strut.
Position the apply strut in its retaining clip and engage it
with the band and the servo piston rod.
C2/C4 Clutch Assembly

Notice
1. Check pistons for cracks.
2. Do not mix the clutch piston return springs.
3. Ensure that the snap rings are fitted correctly.
To assemble the C2/C4 clutch assembly (refer to figure 8.24),
proceed as follows.
1. Check the feed orifices in the cylinder bore are clear of
obstructions.
2. Check the C2 piston bleed orifices are clear of obstructions.
3. Lubricate the ‘O’ rings with automatic transmission fluid.
Notice
Figure 8.24 - Typical C2/C4 Clutch Assembly
‘O’ rings must not be twisted in the grooves.
4. Fit the small ‘O’ ring onto the inner groove, and the large
‘O’ ring onto the outer groove of the piston.
5. Check the C4 piston bleed orifices are clear of obstructions.
6. Lubricate the ‘O’ rings with automatic transmission fluid.
7. Fit the small ‘O’ rings onto the inner groove and the large
‘O’ rings onto the outer groove of the piston.
8. Position the clutch cylinder with the C2/C4 cavity facing
upwards.
9. Fit the C4 piston into the C2 piston with the bleed orifices
in alignment.
10. Install the C2/C4 piston assembly into the cylinder, with the
piston bleed orifices aligned with the holes on the outside
of the cylinder, until the outer diameter of the C2 piston
enters the inner diameter of the cylinder.

11. Assemble the piston return spring to the piston, and fit the
spring retainer over the spring.
Notice
The wire diameter of this spring is 4.3 mm.
12. Using special tool No. 0555-331899, compress the spring
sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then
remove the tool.
13. Check the C1 piston check valves are not damaged and
are free to move, and that the cylinder feed orifices are
clear of obstructions.
14. Lubricate the’0’rings with automatic transmission fluid and
fit them to their respective grooves.
Notice
15. Position the cylinder with the C1 cavity upwards. Install the
piston into the cylinder until the outer diameter of the piston
enters the inner diameter of the cylinder.
16. Install the spring and spring retainer onto the piston.
Notice
The wire diameter of this spring is 5.26 mm.
17. Using special tool No. 0555-331899, compress the spring
sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then
remove the tool.
18. Install the C2 wave washer into the cylinder with the crest
of one wave covering one of the bleed orifices in the C2
piston.
19. Measure and record the thickness of the flange of the C2
sleeve. Refer to figure 8.25.
20. Install the C4 clutch plates and wave washer into the C2
actuating sleeve, with the rounded edge of the steel plates
down, in the following sequence:
l Steel plate (selective)
l Friction disc
l Steel plate
l Friction disc
l Steel plate
l Friction disc
l Steel plate
l Wave washer

Figure 8.25 - C4 Clutch Pack Clearance

21. Holding the cylinder horizontal, install the sleeve and clutch
plate assembly into the cylinder, with the crest of one wave
of the washer In line with one of the holes in the outside of
the cylinder, until the sleeve contacts the C2 wave washer.
22. Check the C4 clutch pack clearance using special tool No.
0555-331900. Refer to figure 8.25.
Notice
With the C2 wave spring compressed, and the clutch Pack
supporting a 2 k9 weight, the dimension from the underside
of the C2 pressure plate to the selective steel is to be
between 1.4- 1.8 mm. If the clutch is to be gauged from
the top of the pressure plate, then the dimension is to be
the actual thickness of the pressure plate plus 1.4-1.8 mm.
23. Use selective plates to achieve the correct specification. If
new friction plates are being fitted, remove the clutch pack
and soak the friction plates in ATF for a minimum of 5
minutes prior to reassembly.
Notice
The clutch pack clearance must be taken before the
elements are soaked in Automatic Transmission Fluid
(ATF).
24. Reassemble the sleeve and clutch pack into the cylinder.
Observe the alignment of the wave washer to the hole in
the cylinder.
25. Install the C2 clutch plates in the cylinder in the following
sequence:
l Friction disc
l Steel plate
l Friction disc
l Steel plate
l Steel plate - 0574-000001, 0574-000003,
0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
l Friction disc
l Friction disc

26. Check the clutch pack clearance using only the weight
from tool No.0555-331900. Refer to figure 8.26.
Notice
With the clutch pack supporting a 2 kg weight, the
dimension from the C3 clutch hub locating step to the
friction plate is to be between 0.80-1.05 mm.
27. Use selective plates to achieve the correct specification.
If new friction plates are being fitted, remove the clutch
pack and soak the friction plates in ATF for a minimum
of 5 minutes prior to reassembly.
Notice
elements are soaked in ATF.
28. Lubricate and fit the 3-4 OWC and end caps to the C2
hub.
Figure 8.26 - Typical C2 Clutch Pack Clearance
29. Align the tangs and fit the nylon thrust washer onto the
C4 hub. Refer to figure 8.27.
30. Align and fit the C4 hub to the C2 clutch and the OWC
assembly.
31. Check the rotation of the C2 hub. While holding the
C4 hub, the C2 hub should rotate in the clockwise
direction and lockup in the anti-clockwise direction when
viewed from the C2 hub. Refer to figure 8.27.
Figure 8.27 - C2 - Hub Rotation
32. Apply petroleum jelly to the No. 5 thrust bearing and fit
it to the C4 hub. Refer to figure 8.19.
33. Remove the C2 clutch plates from the clutch cylinder.
34. Fit the thrust plate over the cylinder inner hub. Refer
to figures 8.24 and 8.19.
35. Engage the C2/C4 clutch hub assembly in the C4 clutch
plates.
36. Install the C2 clutch plates.
37. Install the C3 hub and secure it with the circlip, ensuring
that the circlip is firmly seated in its groove.

C3 Clutch and Reverse Sun Gear Assembly
To assemble the C3 clutch and reverse sun gear assembly
(refer to figure 8.28), proceed as follows.
1. Check the orifices in the cylinder are clear of obstructions.
2. Check the C3 cylinder bush outside diameter and the
centre support inside diameter are in good condition and
not damaged. Coat the sealing rings with automatic
transmission fluid and fit into the C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and thrust
face for condition. Coat the ‘O’ ring with automatic
transmission fluid and fit it to the groove of the reverse
sun gear.
4. Install the reverse sun gear in the C3 cylinder, ensuring
that the ‘O’ ring compression is adequate but not
excessive.
Notice
5. Coat the C3 piston ‘O’ rings with automatic transmission
fluid and fat the small ‘O’ ring onto the inner ring and the
large ‘O’ ring onto the outer ring of the C3 piston.
6. Check that the bleed orifices of the piston are clean and Figure 8.28 - C3 Clutch and Reverse Sun Gear
clear of obstructions.
7. Install the C3 piston in the cylinder until the outside
diameter of the piston enters the inside diameter of the
cylinder.
Notice
Take care not to cut the ‘O’ ring.
8. Assemble the spring and spring retainer on the piston.
Using tool No. 0555-331899 compress the spring
sufficiently to enable the installation of the retaining circlip,
ensuring that the circlip is firmly seated in the groove, and
remove the tool.
9. Fit the C3 wave plate to the C3 piston face, ensuring that
one crest of the wave plate of the C3 piston face is aligned
over one of the piston orifices.
10. Assemble the clutch plates and discs into the cylinder in
the following sequence :
l Steel plate
l Friction disc
l Steel plate
l Steel plate - 0574-000001, 0574-000003,
0574-000004,0574-000005,0574-000020,
0574-000021, or friction disc -0574-000002
l Friction disc
l Friction disc
11. Align and fit the pressure plate with the counterbore facing
away from the clutch plates.

12. Install the circlip.
13. Check the C3 clutch clearance (refer to figure 8.29) using
special tool No.0555-331900 in the following manner
(weight only).
a. Place the weight on the pressure plate and measure
the distance from the end of the cylinder to the top of
the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip and
measure the distance from the end of
the cylinder to the top of the pressure plate.
e. Record this figure.
f. Subtract the second reading from the first reading to
obtain the clutch pack clearance.
Notice
With the clutch pack supporting a weight of 2 kg, the Figure 8.29 - Typical C3 Clutch Assembly
clearance between the snap ring and the top of the
Clearance
pressure plate is to be between 1.20-1.45 mm.
14. If new friction plates are being fitted, remove the clutch
pack and soak the friction elements in automatic
transmission fluid for a minimum of five minutes prior to
reassembly.
Notice
elements are soaked in automatic transmission fluid.

Forward Sun Gear and C3 Clutch Pack Assembly
Figure 8.30 - Typical forward Sun Gear add C3 Clutch Assembly
To assemble the forward sun gear and C3 clutch pack assembly

(Refer to figure 8.30), proceed as follows:
1. Fit the No. 7 needle thrust bearing assembly over the forward
sun gear, ensuring that the thrust washer is between the
bearing and the sun gear.
2. Lubricate the thrust plate with petroleum jelly and fit the
thrust plate onto the reverse sun gear.
3. Align and fit the C3 clutch assembly over the forward sun
gear.
4. Lubricate the No. 6 needle thrust bearing with petroleum
jelly and fit it to the thrust plate. Ensure the lugs on the
outside diameter of the bearing fit in the thrust plate
counterbore.
5. Align and fit the plastic thrust washer to the thrust plate with
petroleum jelly.
Refer to to figures 8.19.
6. Install the assembly over the forward sun gear shaft against
the No.6 thrust bearing.
7. Place the assembly to one side.

C1 Clutch Overdrive Shaft and Input Shaft
Assembly
Notice
1. Ensure that the snap rings are fitted correctly.
2. Check pistons for cracks, especially the C1 piston.
3. Do not mix clutch piston return springs.
4. If the C1/C2 clutch packs separate from the C3 clutch pack,
make sure the No. 6 bearing doesn’t drop out of the bearing
retainer.
To assemble the C1 clutch overdrive shaft and input shaft
assembly, proceed as follows:
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with petroleum jelly
and fit them to the overdrive shaft. The sealing rings may
be held in place with a small amount of petroleum jelly.
3. Assemble the clutch plate and disc into the cylinder in the
following sequence:
l steel plate
Figure 8.31 - Typical C1 Clutch Assembly
l friction disc
Clearance
l steel plate
l friction disc
l steel plate
l steel plate - 0574-GOOGOl, 0574-000003,
0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
l steel plate (selective)
l friction disc
l steel plate (selective)
l friction disc
4. Check the clutch pack clearance using special tool No.0555-
331900. Refer to figure 8.31.
Use selective plates to achieve the correct specification.
Notice
The clutch pack supporting a 2 kg weight, the dimension
from the input shaft locating stop to the friction disc must
be 0.70-0.90 mm.
5. If new friction plates are being fitted, remove the clutch pack
and soak the friction elements in automatic transmission
fluid for a minimum of five minutes prior to assembly.
Notice
The clutch pack clearance must be taken before
elements are soaked in automatic transmission fluid.
6. Check the fit of the C1 clutch hub on the overdrive shaft. If
it is loose, the hub and shaft assembly must be replaced.

7. Coat the small nylon thrust spacer with petroleum jelly and
install it over the overdrive shaft. Refer to figure 8.19.
8. Carefully fit the overdrive shaft into the C1 cylinder so as
not to damage the sealing ring.
9. Fit the small bronze C1 hub thrust washer in place with
petroleum jelly. Refer to figure 8.19.
10. Check the input shaft for any defect. Fit the input shaft
into the cylinder and secure it with the circlip, ensuring
that the circlip is completely seated in the groove.
11. Coat the sealing rings with petroleum jelly and fit onto the
input shaft.
12. Assemble the C1/C2/C4 clutch assembly to the C3 clutch
and sun gear assembly. Refer to figures 8.32 and 8.33.
13. Install this assembly in the transmission case.

Pump Cover and Converter Support
Notice
1. Do not wash the nose of solenoids in solvent.
2. Ensure that the correct ‘O’ ring is fitted for the application.
3. Do not mix up the low first blow-off and the torque converter
blow-off ball springs.
4. Be careful not to damage the needle bearings on the
assembly. Avoid any axial impact loads during assembly.
5. Check the transmission end float. This will help to detect
any missing parts or incorrect assembly.
Notice
Figure 8.35 shows the orientation of the cross- sections for
figures 8.36 to 8.42.
To assemble the pump cover and converter support

(refer to figures 8.34 and 8.35), proceed as follows.
1. Check the pump body for any damage, chips or irregularity.
Check that the bush is firmly staked in the drive gear. Figure 8.34 - Pump, Cover and Converter
2. Install the seal flush with the front face of the pump body. Support
3. Lubricate the pump bush, and the drive and driven gears,
with automatic transmission fluid.
4. Install the pump driven gear and the pump drive gear into
the pump body.
5. Using a straight edge and thickness gauge, check that the
clearance between pump face and gears is 0.04 - 0.018
mm.
6. Lubricate the pump body ‘O’ ring with automatic transmission
fluid and fit it to the pump body. Put the pump body to one
side.
7. Ensure that the pump cover cavities, ports and holes are
clean and free of any obstruction.
8. Lubricate all loose parts with automatic transmission fluid
prior to assembly.
Figure 8.35 - Pump Cover Assembly

9. Assemble the primary regulator valve and plunger (refer
to figure 8.36) to the pump cover, ensuring that the
regulator valve slides freely, then fit the regulator valve
plug and ‘O’ ring.
Figure 8.36 - Primary Regulator Valve
10. Install the retaining pin.
11. Install the converter clutch regulator valve (refer to figure

8.37), plug, and ‘O’ ring.
Figure 8.37 - Converter Clutch Regulator Valve

12. Install the retaining pin. Refer to figure 8.39.
Figure 8.39 - Valve Retaining Plugs and Pins
13. Install the converter clutch control valve (refer to figure

8.38), spring, plug, and ‘O’ ring.
Figure 8.38 - Converter Clutch Control Valve

15. Install the C1 bias valve spring, valve, plug and ‘O’ ring.
Figure 8.40 - C1 Bias Valve
17. Install the converter release check ball and spring and the
feed ball. Refer to figures 8.41, 8.42 and 8.43.
Figure 8.41 - Converter Relief Ball and Spring
Figure 8.42 - Peed Ball
Figure 8.42 - Feed Ball

18. Install the gasket on the pump cover.
19. Install the cover plate, solenoid 7 with the retainer and the
solenoid wiring retainer to the pump cover, ensuring that
the periphery of the cover plate is flush with the periphery
of the pump cover. Refer to figure 8.34.
Tighten the screws to specification in the order (1-5), shown
in figure 8.44.
20. Tighten the solenoid 7 screw. Refer to figure 8.39.

Figure 8.44 - Pump Bolt Tightening Sequence
Notice
Check that neither the wiring nor the connector protrudes
excessively, in order that at assembly neither the wiring
and the connector contacts or rubs on the input shaft or
the C1/C2 clutch cylinder.
21. Assemble the pump to the pump cover.
Tighten all bolts and the crescent screw finger tight,
ensuring that the pump is flush against the pump cover.
Tighten the bolts and the screw to specification in the order
(A - F), shown in figure 8.44.
22. Install the pump to transmission case gasket onto the case.
23. Fit the ‘O’ ring to the pump cover outer diameter.
24. Install the pump and cover assembly over the input shaft
being careful not to damage the sealing rings. Tighten the
pump cover to case bolts to specification. Refer to figure
8.45.
Figure 8.45 - Tightening Sequence Pump to

Case

25. Check that the transmission end float is set to the tolerance
stated in section 9.2. Refer to figure 8.46. If the unshimmed
end float clearance is greater than specification, shims
are to be placed between the No. 4 bearing and the input
shaft bearing surface. Refer to figure 8.19. If the end float
clearance is less than 0.5 mm then the transmission has
been assembled incorrectly or the parts are out of
specification.
26. Perform the following steps to check the end float :
a. Attach a dial indicator to the front of the transmission
case with the stylus resting on the end of the input
shaft.
b. Apply a force of approximately 250 newtons or 25 kg to
the input shaft.
c. Zero the dial indicator.
d. Place a small lever behind the forward clutch cylinder
and lever the cylinder forward.
e. The measurement recorded on the dial indicator is the
transmission end float or clearance between the No.4
bearing and the converter support tube.
27. On completion of this procedure, adjust the front and rear
bands to specifications detailed in section 8.4.
Figure 8.46 - Gear Train End Float Check

Valve Bodies
Notice
1. Do not wash the nose of solenoids in solvent.
2. Be aware of ball positions in the upper valve body.
3. Be aware of 1-2 and 3-4 shift valve positions, they can be
swapped.
4. Check the 4-3 sequence valve and spring orientation.
5. Check that the 12 mm ball is in the lower body.
6. Do not mix up the low first blow-off and the torque converter
blow-off ball springs.
7. Check the line pressure relief valve for swarf, and be aware
of replacing the shims.
8. The orifices in the valve body are for stability and safeguard;
do not drill them any larger.
9. When servicing the transmission, ensure that the solenoid
5 damper spring is not broken.
10. Locate the detent spring central to the detent lever.
To assemble the valve bodies, proceed as follows.

1. Wash the upper and lower valve bodies (refer to figures
8.47 and 8.48) thoroughly with cleansing solvent and blow
dry.
2. Check the valve body cavities, ports and holes for damage
or obstructions.
3. Install the detent lever locating pin.
4. Thoroughly wash all loose components.
5. Check that all valves slide freely in their location.
Figure 8.47 - Lower Valve Body
Figure8.48 - Upper Valve Body Showing Check

Ball Locations

6. Install the lo-1st spring, ball check valve and roll pin. Refer
to figure 8.49.
7. Install the solenoid 5 damper guide spring, piston and
retaining pin. Refer to figure 8.49.
Figure 8.49 - Solenoid 5 and Damper, Lo-1st Check Valve Assemblies
8. Install the 1-2 shift valve, plug and retaining pin. Refer to
figure 8.50.

9. Install the 3-4 shift valve and retaining pin. Refer to figure
8.51.
10. Install the 2-3 shift valve and retaining pin. Refer to figure
8.52.
Figure 8.52 - Solenoid 2 and 2-3 Shift Valve
11. Install the 4-3 sequence valve, spring, plug and retaining
plate. Refer to figure 8.53.
Figure 8.53 - 4-3 Sequence Valve

12. Install the band apply regulator (BAR) valve (refer to figure
8.54), springs, plunger and retainer pin.
Figure 8.54 - Band Apply Regulator Valve and Solenoid 4
13. Install the clutch apply regulator (CAR) valve (refer to figure
8.55), springs, plunger and retainer pin.
Figure 8.55 - Clutch Apply Regulator Valve and solenoid 3
14. Install the solenoid supply valve, spring and retainer plate.
Notice
This aluminum valve is easily damaged.
Figure 8.56 - Solenoid Supply Valve and Solenoid 6

15. Install solenoid 6 plunger, spring and retaining pin.
16. Position the third feed ball (large nylon) in the valve body
and install the solenoid 5 filter and the solenoid 6 filter.
Refer to figures 8.5 and 8.56.
17. Check the separator plate for burrs and damage. Repair
or replace the separator plate as necessary.
18. Check the upper and lower valve body gaskets for
damage. Replace the gaskets as necessary.
19. Install the lower valve body gasket on the lower valve body.
20. Install the reverse lockout valve, spring, plug and retainer
plate. Ensure that the valve is correctly oriented. Refer to
figure 8.57.
Figure 8.57 - Reverse Lockout Valve
21. Position the five nylon ball checks in the upper valve body.
22. Fit the upper valve body gasket. Install the separator plate
over the upper valve body.

23. Holding the separator plate to the upper valve body to
prevent the check balls from falling out, install the upper
valve body on the lower valve body. Install all screws finger
tight then tighten the screws to specification in the
prescribed sequence. Refer to figure 8.58.
Figure 8.58 - Tightening Sequence Upper to Lower Valve Body
24. Install solenoids 1,2,3,4 and 6. Ensure the solenoid is firmly

secured by the retainer and that the screw is tightened to
specification.
25. Install solenoid 5. Ensure that the solenoid is pushed firmly
into the valve body by the retainer.
Notice
The wiring loom ground wire eyelet terminal is secured
beneath the solenoid retainer.
26. Install the line pressure relief valve, tapered end first, (refer
to figure 8.59), and the spring and disc. Secure with the
retaining pin.
Figure 8.59 - Line Pressure Relief Valve

27. Install the line pressure plug and tighten to specification.
Figure 8.62 - Wiring Installation
28. Install the detent spring assembly (spring, support plate

and screw), ensuring that the screw is tightened to
specification. Check the spring for wear or damage.
29. Install the manual shift valve. Refer to figure 8.60.
Notice
Be aware that the manual valve will fall out of the valve
body.
Figure 8.60 - Manual Shift Valve

30. Align the valve body assembly on the transmission case
and install the manual valve lever to manual valve link. Fit
the long end of the link to the manual valve first. Install the
securing bolts and tighten to specification in the specified
sequence. Refer to figure 8.61.
Figure 8.61 - Tightening Sequence Valve Body to Case
31. Check the alignment of the detent roller and the manual
lever quadrant.
32. Connect the solenoid wiring as detailed below:
l Solenoid 1 - red
l Solenoid 2 - bIue
l Solenoid 3 - yellow
l Solenoid 4 - orange
l Solenoid 5 - green
l Solenoid 6 - violet (Refer to figure 8.62.)
Notice
All hardware must be correctly installed and torqued to
specification.

Oil Filter and Pan Assembly
Notice
1. Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage has
occurred.
2. To aid the assembly of the pan gasket, use a small amount of Vaseline at the pan/gasket interface. This ensures
that the gasket remains on the pan ridge. Do not over torque pan bolts as this may distort the pan and cause
leaks.
3. Ensure that the internal line pressure plus in the valve body is fitted.
To assemble the oil filter and pan assembly (refer to figures 8.63 and 8.64), proceed as follows.
1. Lubricate the oil filter sealing ring with automatic transmission fluid.
2. Carefully assemble the oil filter to the valve body. The spigot must not lean on one side while being fitted. Refer to
figure 8.63.
3. Secure the oil falter assembly with the retainer.
4. Check that the magnet is located in the dimple in the comer of the oil pan.
5. Assemble the gasket on the pan lip. The gasket must be free of any distortion when installed.
6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence
(refer to figure 8.65). Do not over torque.
Figure 8.64 - Oil Filter Installation

Torque Converter and Housing Assembly
To assemble the torque converter and housing assembly,
proceed as follows.
1. Locate the torque converter housing on the transmission
main case.
2. Install and tighten the securing bolts to specification.
Notice
All the hardware must be correctly installed and torqued to
specification.
3. Fit the converter ensuring that the tangs are engaged in
the pump gear. Ensure that the tangs do not contact the
pump seal.
Figure 8.1 - Torque Specifications
Torque Specifications Nl m
Torque converter housing to case 54 - 68
Extension housing to case 54 - 68
Rear servo cover 25 - 35
Pan to case 4-6
Inhibitor switch to case 2.3 - 3.4
Cooler connectors 30 - 35
Transmission filler plug 30 - 35
Output flange lock nut (RWD models) 100 - 110
Centre support to case 20 - 27
Cam plate to case (parking pawl) 16 - 22
Valve body to case 8 - 13
Upper valve body to lower valve body 11 - 16
ON/OFF solenoid retainers 8 - 12
Variable pressure solenoid retainer 8 - 12
Line pressure plug 4-7
Detent spring 20 - 22
Pump cover to case 24 - 34
Pump cover plate to pump cover 13 - 16
Pump to pump adaptor 24 - 27
Pump cover plate to crescent 13 - 16
Adaptor to case 25 - 35

FRONT AND REAR BAND ADJUSTMENT

Front Band Setting Procedure
To set the front band, proceed as follows.
1. Measure the projection of the front servo push rod from the transmission case. Refer to figure 8.66, dimension A.
a. Apply air at 650/700 kPa to the front servo apply area (B1 outer). (Refer to figure 8.67.)
b. Measure the travel of the push rod and subtract 3 mm to find the shim size required.
c. Release the air.
Notice
A minimum of one shim is required at all times - minimum shim size is 1 mm. The thicknesses of available shims
are listed in table 8.2.
2. Fit the selected shim(s) to the shank of the anchor strut as follows:
a. Inspect the shim(s) for damage, wear or corrosion. Replace as necessary.
b. The shim(s) are to be installed between the case abutment face and the anchor strut flange. Refer to figure
8.66.
c. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced.
d. Shim(s) are to be pressed on by hand until an audible click is heard. The click indicates that the shim is clipped
home correctly.
3. Re-check that the push rod travel is 3 mm ± 0.25 mm.
Figure 8.66 - Front Band Settings

Rear Band Setting Procedure
To set the rear band, proceed as follows.
1. Measure distance ‘A’ from the rear servo piston to the inner face of the transmission case using vernier calipers.
a. Apply air at 650/700 kPa to the rear servo apply area (B2 outer). Refer to figure 8.67.
b. Measure the travel of the piston, subtract 3.75 mm and divide the remainder by 2.5 to find shim size.
c. Release the air.
Notice
A minimum of one shim is required at all times - minimum shim size is 1 mm. The thickness of available shims
are listed in table 8.2.
2. Fit the selected shim(s) to the shank of the anchor strut as follows.
a. Inspect the shim(s) for damage, wear or corrosion and replace as necessary. The shim(s) are to be installed
between the case abutment face and the anchor strut flange. Refer to figure 8.68.
c. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced.
d. The shim(5) are to be pressed on by hand until an audible click is heard. The click indicates that the shim is
clipped home correctly.
3. Re-check that the piston travel is 3.75 mm ± 0.625 mm.
Figure 8.68 - Rear Band Settings

Table 8.2 - Thickness of Available Shims
Thickness Part Number Thickness Part Number

0.95/1.05 0574-037017 1.93/2.07 0574-037021
1.15/1.25 0574-037018 2.12/2.28 0574-037022
1.44/1.56 0574-037019 2.42/2.58 0574-037023
1.73/1.87 0574-037020 2.61/2.79 0574-037024
Figure 8.68 - Thickness of Available Shims

SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . 5B-8
General Specifications . . . . . . . . . . . . . . . . . . 5B-1 Component Locator . . . . . . . . . . . . . . . . . . . 5B-9
Fastener Tightening Specifications . . . . . . . . . 5B-2 Maintenance and Repair . . . . . . . . . . . . . . 5B-11
External View . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5B-11
Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 Shift Control Cable . . . . . . . . . . . . . . . . . . . . 5B-11
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Transmission . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Will not Shift (Control Lever Moves) . . . . . . . . 5B-5 Major Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Hard Shift or Control Lever Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27
Will not Move Into Gear . . . . . . . . . . . . . . . . 5B-5 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32
Gears Crash When Shifting . . . . . . . . . . . . . . 5B-5 Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . 5B-34
Transmission Jumps Out . . . . . . . . . . . . . . . . . 5B-6 Extension Housing . . . . . . . . . . . . . . . . . . . . 5B-35
Transmission Locked in One Gear . . . . . . . . . 5B-6 Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36
Transmission Noise . . . . . . . . . . . . . . . . . . . . . 5B-6 Inspection of Components . . . . . . . . . . . . . . 5B-40
Transmission Leakage . . . . . . . . . . . . . . . . . . 5B-7 Pre-Installation Checks . . . . . . . . . . . . . . . . . 5B-45
SPECIFICATIONS
Model T5WC
Type Floor Change
Gear Ratio 1st 3.97 : 1
2nd 2.34 : 1
3rd 1.46 : 1
4th 1.00 : 1
5th 0.85 : 1
Reverse 3.71 : 1
Oil Specification ATF DEXRON II / III
Capacity(litre) 3.4 L
Change Interval Check : Every 15,000km, Replace : Every 50,000km
Weight (Dry) 33kg
Notice
Add LUBRIZOL (280cc) in oil after overhauling.

5B-2 MANUAL TRANSMISSION

Application Nl m
Transmission
Oil Filler Plug 25
Transmission Mounting Bolt (Housing) 77 - 87
Oil Drain Plug 25
Front Propeller Shaft (T/C) 81 - 89
Rear Propeller Shaft (T/C) 70 - 90
Cross Member Bolt (Center) 21 - 35
Cross Member Bolt (Side) 62 - 93
Control Cable
Shift Lever Bolt 20 - 30

MANUAL TRANSMISSION 5B-3
EXTERNAL VIEW
GEAR TRAIN

POWER FLOW

DIAGNOSIS
WILL NOT SHIFT(CONTROL LEVER MOVES)
Check Action
Control lever assembly broken or damaged. Replace control lever and housing assembly.
Damaged offset lever, shift fork, selector place or Remove extension, adapter or case cover.
selector arm. Check or replace damaged parts.
HARD SHIFT OR CONTROL LEVER WILL NOT MOVE INTO GEAR

Check Action
Clutch not releasing. Adjust or replace clutch.
Improper or low transmission oil. Add or replace with specified oil.
Shift or shift rail binding. Remove extension, adapter or case cover.
Check or replace damaged parts.
Binding of sliding synchronizers or gears. Remove extension, adapter or case cover.
Check synchronizers and gears and replace
damaged parts.
If reverse only, faulty backup switch. Check or replace backup switch.
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
GEARS CRASH WHEN SHIFTING

Check Action
Engine idle speed too high. Adjust idle speed to specified speed.
Damaged or faulty clutch. Adjust or replace clutch.
Pilot bearing between input shaft and output shaft binding. Replace or check roller bearings.
Damaged synchronizer. Check or replace synchronizer parts.
Bell housing misaligned. Align bell housing and bore.
Damaged gear(s). Check or replace gear(s).
Worn or damaged flywheel pilot bushing. Replace pilot bushing.

TRANSMISSION JUMPS OUT

Check Action
Loosened transmission or flywheel housing bolts, Tighten bolts to specified value. Realign if necessary.
improper alignment.
Synchronizer damaged or excessively worn. Check or replace synchronizer parts.
Blocking ring damaged, worn index slots or friction Check or replace blocking ring.
surfaces worn or damaged.
Excessive countershaft end play. Check worn or damaged parts. Adjust shim thickness
using roller bearings if necessary.
Worn or damaged fork due to loosened shaft, rail or Check for wear or damaged. Replace worn or
shifting fork. damaged parts.
TRANSMISSION LOCKED IN ONE GEAR

Check Action
Fork or offset lever loose on shaft or rail. Replace extension, adapter or case cover. Check or
replace loose parts on shaft or rail. Replace roll pin(s).
Worn or damaged forks, offset lever, shaft or rail. Remove extension, adapter or case cover. Check for
wear or damaged. Replace damaged parts.
Worn or damaged synchronizer. Check worn or damaged synchronizer parts and
replace if necessary.
Worn or damaged gears. Check worn or damaged gears and replace if neces-
sary.
TRANSMISSION NOISE
Check Action
Improper or low transmission oil. Add or drain and replace with proper oil.
Loose bolts or other attaching parts. Tighten as specified.
Improper flywheel housing to engine crankshaft Realign correctly.
alignment.
Noisy transmission bearing. Check bearings, bearing rollers and parts for wear or
damage.
Noisy gears. Check for worn or damaged gears
(including speedometer gear).

TRANSMISSION LEAKAGE
Check Action
Leakage from transmission. Clean all exposed surfaces, then check for leaks.
Vent or breather clogged. Clean or replace vent or breather.
Too much oil. Check oil level.
Loose bolts at sealing faces. Tighten as specified.
Improperly applied sealant. Clean leaking surfaces.
Reapply sealant.
Worn or damaged oil seal. Replace oil seal.

DIAGNOSIS TABLE
Condition
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front Part
Possible Faulty Part

l l Transmission Case
l l Extension Housing
l l l l Shift Cover / Shift Shift
l l Shift Control Lever
l l Input Bearing Retainer
l Input Gear Set
l l l 3rd Speed Gear Set
l l l 2nd Speed Gear Set
l Reverse Speed Gear Set
l l l 1st Speed Gear Set
l l 5th Speed Gear Set
l l Clutch Housing and Release Derive
l l Crankshaft Pilot Bushing and Release Bearing
l Input Bearing
l Main Shaft Input Bearing
l l Main Shaft Thrust Bearing
l l 3rd Speed Gear Bearing
l l 2nd Speed Gear Bearing
l l 1st Speed Gear Bearing
l Reverse Idler Gear Bushing
l Counter Shaft Front Bearing
l Counter Shaft Rear Bearing
l l l Counter Shaft Thrust Bearing
l l 5th Speed Drive Gear Bearing
l Slip Yoke Bushing
l Slip Yoke Seal
l Speedometer Drive / Driven Gears
l Speedometer Driven Gear Housing
l Input Shaft Seal
l l l l l l 1 - 2 Synchronizer Assembly
l l l l l l 3 - 4 Synchronizer Assembly
l l l l l 5th Synchronizer Assembly

COMPONENT LOCATOR

1 Filler/Drain Plug 38 Insert 72 Synchronizer Sleeve
2 Shift Mechanism Cover 39 Synchronizer Hub 73 3rd Speed Gear
3 Shift Shaft Lever 40 Roll Pin 74 Needle Bearing
4 Outer Select Lever 41 5th Shift Fork 75 Spacer
5 Inner Select Lever 42 Insert 76 Snap Ring
6 Offset Control Lever 43 Shift Rail Assembly 77 Thrust Washer
7 Bias Spring 44 Blocking Ring 78 2nd Speed Gear
8 Bolt 45 5th Speed Drive Gear 79 2nd Speed Gear Bearing
9 Pin 46 Snap Ring 80 Spacer
10 Washer 47 Speed Gear 81 Output Shaft Assembly
11 Bolt 48 Speed Gear Clip 82 Retaining Ring
12 Bolt 49 Bolt 83 Thrust Washer
13 Extension and Plate Assembly 50 Input Bearing Retainer 84 Inner Cone
14 Oil Seal 51 Oil Seal 85 Outer Cone Race
15 Oiling Funnel 52 Shim 86 1/2 Blocking Ring
16 Bolt 53 Bearing Cup 87 Spring
17 Alignment Bolt 54 Bearing Cone 88 Reverse Sliding Gear
18 Selector Arm Pin 55 Input Shaft 89 Insert
19 Shift Shaft 56 A. Roller Bearing 90 Pin
20 3/4 Shift Fork 56 B. Bearing Assembly 91 Shaft and Hub Assembly
21 1/2 Shift Fork 57 Spacer 92 Spring
22 Insert 58 Thrust Bearing 93 Pin Fork and Reverse Roller
23 Selector Arm Assembly 59 Thrust Bearing Race Assembly
24 Interlock Plate Assembly 60 5th Speed Driven Gear 94 Bolt
25 Selector Plate 61 Bearing Cup 95 Rear Retainer
26 O-ring 62 Bearing Cone 96 Shim
27 Plug 63 1st Speed Gear 97 Roll Pin
28 Case Cover 64 Bearing Sleeve Assembly 98 Reverse Idler Shaft
29 Retaining Ring 65 A. Bearing 99 Reverse Idler Gear Assembly
30 Pivot Pin 65 B. Bearing 100 O-ring
31 Back-up Switch 65 C. Spacer 101 Bearing Cup
32 5/Reverse Shift Lever 66 Sleeve 102 Bearing Cup Assembly
33 Snap Ring 67 Blocking Ring Assembly 103 O-ring
34 5th Synchronizer Retainer 68 3/4 synchronizer Assembly 104 Bearing Cup
35 5th Synchronizer Assembly 69 Synchronizer Spring 105 Bearing Cone
36 Synchronizer Spring 70 Synchronizer Sleeve 106 Counter Shaft Gear
37 Synchronizer Assembly 71 Insert 107 Transmission Case Assembly


ON-VEHICLE SERVICE
SHIFT CONTROL CABLE
1 Shift Lever Assembly 9 Select Cable

2 Bolt ...................................................... 20-30 Nm 10 Clip
3 Select Cable 11 Clip
4 Shift Cable 12 Snap Pin
5 Snap Pin 13 Snap Pin
6 Snap Pin 14 Protector
7 Transmission 15 Washer
8 Shift Cable

1. Position the shift lever in neutral and remove the knob.
2. Remove the screw from the console box side and remove
the shift lever cover.
3. Disconnect the cables by removing the snap pins from the

control cable connections to the select lever and shift lever.
4. Remove the shift lever an cable mounting snap pin and
washer of the select lever.

5. Pull out the clip from the bracket and remove the shift cable
and select cable.
1. The shift lever should be positioned in neutral.
2. Apply liquid gasket on the cable contact surface.
3. Keep 130 mm between the center of the cable end-eye
and floor.
Standard 130 mm
Notice
If necessary, adjust the adjust nut.

TRANSMISSION
Preceding Work : Removal of the shift control cable
1 Clutch Housing 12 Speedometer Cable

2 Oil Filler Plug ............................................ 25 Nm 13 Rear Propeller Shaft
3 Transmission Assembly 14 Washer
4 Back-up Switch 15 Bolt ...................................................... 70-80 Nm
5 Washer 16 Cross Member
6 Bolt ...................................................... 77-87 Nm 17 Washer
7 Oil Drain Plug ............................................ 25 Nm 18 Bolt ...................................................... 21-35 Nm
8 Bolt ...................................................... 81-89 Nm 19 Washer
9 Washer 20 Bolt ...................................................... 62-93 Nm
10 Front Propeller Shaft 21 Breather Hose
11 Transfer Case Assembly

1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug from the transmission housing and
drain the oil. Reinstall the drain plug.
Installation Notice
4. Disconnect the back-up switch connector.
6. Remove the speedometer connector and other wiring

harnesses and connectors.

7. Remove the front and rear propeller shafts from the
transmission.
Installation Notice
Front 81 - 89 Nm
Tightening Torque
Rear 70 - 90 Nm
8. Support the transmission on an suitable jack.

Unscrew the center mounting nuts and each sides
mounting bolts and remove the cross member.
Installation Notice
9. Unscrew the transmission mounting bolts.

Installation Notice
10. Move the transmission jack backward careful and

disengage the transmission input shaft from the engine.
Remove the transmission.
reverse order.

UNIT REPAIR
MAJOR UNIT
Removal of the transfer case
1. Install the removed transmission into a fixture.
2. Remove the drain plug and drain the oil. Using a 13 mm
wrench, remove the clamp bolt and position the offset lever
in the 3-4 position of neutral.
Notice
Removal of the offset lever in a position other than 3-4 of
neutral will be difficult.
3. Using a pin punch and a hammer, remove the roll pin to
remove the shift lever from the offset lever.
4. Using a 15 mm wrench, remove the 8 bolts from the extension
housing.
5. Separate the extension housing from the case and shift

cover.
Separate the offset lever from the shift.
Notice
Do not remove the offset lever while the extension housing
is still assembled to the case.
6. Remove the offset lever from the extension housing with

the detent ball and spring.
7. Remove the roll pin from either the offset lever or extension
housing.

8. Remove the counter shaft thrust race and bearing.
9. Carefully remove the oiling funnel from the end of the

counter shaft.
10. Using a 10 mm wrench, remove the 10 bolts from the shift

cover.
Notice
For assembly, note the location of the two bolts.
11. Lift up the shift cover after sliding it toward the drain plug
about 3 cm. At this time remove sealer bond.
12. Using a needle nose pliers, remove the 5-R lever clip.

13. Using a 21 mm wrench or a T-50 bit, remove the 5-R lever
pivot bolt.
Notice
Apply sealer bond to this bolt during assembly.
14. Using a 22 mm wrench, remove the back-up lamp switch

from the 5-R lever side.
Notice
Apply sealer to the threads.
15. Pull out the 5-R lever out of the transmission.
16. Using a snap ring pliers, remove the 5th synchronizer snap
ring from the end of the counter shaft.
17. Remove the 5th synchronizer assembly with its fork and
rail assembly from the counter shaft.

18. Remove the slip yoke snap ring from the main shaft.
19. Remove the 5th speed drive gear snap ring from the main
shaft.
20. Make alignment marks on the case and input bearing

retainer and remove the 4 input shaft bearing retainer bolts,
using a 13 mm wrench.
Notice
Apply sealer on these bolts during assembly.
Remove the input bearing retainer with the bearing outer
race and shim.
21. Remove the input shaft from the case by rotating it until
the flat surface appears.
22. Remove the following parts from the input shaft.
l 4th speed gear blocking ring.
l Main shaft thrust race and bearing.
l Main shaft pilot bearing rollers (15 rollers).
Notice
Be careful not to dissipate the pilot bearing rollers.

23. Remove the main shaft in 2 steps.
l To remove the rear bearing outer race, push the main
shaft rearward.
l Tilt and lift the main shaft from the case.
24. Remove the reverse fork and spring from the case.
25. Remove the counter shaft as follows:

l Using a punch and hammer, pry up the lock tabs.
l Using a 13 mm wrench or T-40 bit, remove the 4 bolts.
l Remove the retainer and shim from the case.
l Push the counter shaft rearward to remove the rear
bearing outer race.

26. Using a pin punch and a hammer, remove the roll pin fixed
on the reverse idler shaft.
27. By pushing the reverse idler shaft rearward and out of the
case, remove the reverse idler gear and O-ring.
28. Using a puller, remove the rear bearing assembly from the
counter shaft.

Assembly Procedure
1. Using a hydraulic press and a supporting tool, press the
counter shaft rear bearing into the case. Be sure that the
supporting tool inside of the case should support the counter
shaft.
2. Without the shim, install the retainer and counter shaft rear
bearing outer race. Tighten the 4 retainer bolts.
3. Place a dial indicator on the case and measure counter

shaft end play by moving up and down.
4. Select a shim which is the same thickness as the indicator

rearing (up to 0.004 inch) and assemble it.
5. When the end play is correctly adjusted, remove the counter
shaft rear bearing retainer and outer race.
6. Using a pin punch and rubber hammer, install the reverse
idler shaft, gear and O-ring.

7. Install the counter shaft rear bearing outer race, shim and
retainer.
l Using a punch and hammer, bend the lock tabs on the

retainer.
8. Install the following parts :

l Install the main shaft into case.
l Install the main shaft rear bearing outer race into the
rear of the case.
l Install the 4th speed blocking ring onto the front of the
main shaft.
l Install the input shaft onto the front of the main shaft.
l Install the input bearing retainer without shim onto the
front of the case.
l Using a torque wrench, tighten the 4 bolts.
9. Install the 5th speed drive gear and blocking ring on the
counter shaft.
10. Install the 5th synchronizer and rail/fork.
11. Install the 5th synchronizer snap ring and oiling funnel.
12. Align the slots of the lever with the rollers of the reverse
fork and 5th shift rail. Apply sealer on the 5-R lever pivot
bolt and install it into the case.
13. Using a needle nose pliers, install the 5-R lever clip.

14. Using a needle nose pliers, install the reverse fork spring
to its pin inside the case. Check the operation of the 5-R
shift mechanism at this time.
15. Using a snap ring piers, install the slip yoke snap ring onto
the end of the main shaft.
16. Make sure that the 1-2 and 3-4 synchronizer sleeves and
5-R shift lever are in neutral position.
17. Align the holes the case and cover with alignment-type
bolts. Tighten the 10 bolts.
18. Apply ‘RTV’ sealant on the sealing surface of the extension
housing.
19. Apply grease on the detent/guide plate in the extension
housing. Install the detent ball in the 3-4 position.
20. Place the detent spring and offset lever in the extension
housing and push the extension against the case and shift
cover.

21. Completely compress the detent spring.
22. To install the extension housing to the case, apply sealer
to the top two bolts and tighten them and tighten the 6
bolts.
23. Apply sealer to the back-up lamp switch and drain plug
and tighten them.
24. Using a hammer, install the offset lever-to-shift roll pin.
25. Turn the transmission case reversely and place a dial

indicator on the extension housing. Move the input and
main shift up and down and measure end play. Select a
shim which is the same thickness as the measurement (±
0.001 inch). After shim installation, the end play should be
‘0’.
26. Remove the input bearing retainer and do the following :

l Install the adjusting shim behind the input bearing outer
race in the retainer and if 2 shims are used, install the
thinner one in first.
l Install the retainer to the case and tighten the bolts.
l If end play is not ‘0’change the shim again.
l Apply RTV sealant to the sealing surface of the retainer.
l Apply sealer to the 4 retainer bolts and tighten them.
27. Remove the fill plug.

28. Remove the transmission from the holding fixture and install
it to the vehicle.
29. Clean the sealing surface of the shift control lever.
30. Install the control cables to the shift lever.

MAIN SHAFT
1. For correct reassemble, place an alignment mark on the 3-
4 Synchronizer hub and sleeve.
2. Using a hydraulic press and puller plate, remove the 3-4
Synchronizer assembly and the 3rd speed gear.
3. Remove the 3rd speed gear bearing and spacer.
4. Using a snap ring pliers, remove the 2nd speed gear snap
ring.
5. Remove the 2nd speed gear thrust washer.
6. Remove the 2nd speed gear, bearing and spacer.

7. Using a screwdriver, remove the spiral retaining ring.
8. Remove the thrust washer and three-piece 2nd speed

blocking ring assembly.
9. For correct reassembly, place an alignment mark on the

1-2 synchronizer hub and sleeve.
10. Remove the 1-2 synchronizer sleeve from the hub with
following parts :
l The anti-rattle ball and spring.
l The three keys.
l One of the 3 springs.
11. Using a hydraulic press and puller plate, remove the 5th
speed driven gear from the main shaft.

12. Remove the main shaft rear bearing assembly from the
shaft.
13. Remove the 1st speed gear and bearing.
14. Remove the inner race.
15. Remove the tree-piece 1st speed blocking ring assembly

and remaining synchronizer spring.
16. Check and clean all removed parts and replace if
necessary.

Assembly Procedure
1. When assemble the synchronizer, make sure that the hubs
and sleeves are matched and the 3 keys are installed
properly. Also align blocking rings with keys during
installation.
Notice
Before assembly, coat all parts with lubricant. In case of the
paper-lined blocking rings, soak them in Dexron II before
installation.
2. Assemble the following parts :

l 1st speed blocking ring.
l Alignment pin and 1st speed gear bearing race.
l 1st speed gear and its bearing.
3. Install the rear bearing assembly to the main shaft.
4. Using a hydraulic press and installer, press the 5th driven

gear onto the main shaft. While the main shaft is still on the
press bed, install the 5th driven gear snap ring. If the snap
ring does not fit completely, continue pressing the 5th driven
gear.
5. Install the following parts :

l 2nd speed blocking ring assembly.
l Thrust washer for the blocking ring inner cone.
l Spiral retaining ring (Use special tools).
l 2nd speed gear spacer, bearing and gear.
l 2nd gear thrust washer and snap ring.
l 3rd speed gear spacer, bearing and gear.
l 3rd speed blocking ring.

6. Using a hydraulic press and installer, install the 3-4
synchronizer hub onto the main shaft.
Notice
Align the blocking ring with the synchronizer keys while installing
the hub.

INPUT SHAFT
1. Remove the following parts from the input shaft :
l Main shaft thrust race and bearing.
l Main shaft pilot bearing rollers (15 rollers).
2. Using a hydraulic press and puller plate, remove the input

shaft bearing assembly from the shaft.
3. Remove the input bearing.
4. Remove the input shaft seal.

5. Check and clean all removed parts and replace if necessary.

Assembly Procedure
1. Using a hydraulic press and installer, press the input shaft
bearing onto the input shaft.
2. Apply grease to the thrust bearing inner roller (15 rollers)
and install the main shaft thrust bearing and its race in the
rear of the input shaft.
3. Using a rubber hammer and installer, install the input bearing

retainer and input shaft seal after applying grease.
4. Install the bearing outer race to the retainer without end
play adjusting shim.

COUNTER SHAFT
1. Using a hydraulic press and special tool, remove the front
bearing assembly from the counter shaft.
Assembly Procedure
1. Using a hydraulic press and installer, press the front bearing
assembly onto the counter shaft.
2. Install is as follows :
l Install a new O-ring on the counter shaft outer race and
lubricate it.
l Using a installer, lightly tap the race into its bore until the
O-ring is compressed.
l Install the race to be fully seated on the inside of the
case.

EXTENSION HOUSING
1. Remove the vent from the extension housing.
2. Remove the O-ring and steel ring from the rear of the
extension housing.
Assembly Procedure
1. Install the O-ring and steel ring to the rear of the extension
housing.
2. Install the vent to the extension housing.

SHIFT COVER
1. Using a hammer and a pin punch (3/16) remove the selector
arm roll pin.
2. Before removal, note the correct position of the interlock

plate and selector arm and remove the shift shaft.
Assembly Procedure
1. If the shaft cup plug was removed, apply plug outer surface
with sealer and install it into the cover.
2. Install the fork pads and selector plates onto the 1-2 and 3-
4 shift forks.
3. Assemble the sift cover parts as follows :

Push the shift shaft into the cover until the front of the shaft
is at the inside of the cover.

l Install the 1-2 shift fork and its selector plate.
l Push the shift shaft through the 1-2 shift fork.
l Place the selector arm and interlock plate in the cover

Note the position of the interlock plate and selector arm.

l Install the 3-4 shift fork and its selector plate.
l Install the roll pin that fixes the selector arm to the shift
shaft.
4. Check the shift cover parts for proper assembly as follows :

l Insert a pin punch (3/16) into the offset lever hole of
the shift shaft.
l Place the shift cover to the flat ground and rotate the
shift shaft so that the punch is vertical.

l Selector arm should be aligned with the 3/4 shift fork
selector plate.
5. Lubricate and install the O-ring on the rear of the shift cover.

INSPECTION OF COMPONENTS
1. Clean all parts with solvent and dry them with compressed
air. Check the following parts for cracks and damaged
sealing surfaces.
l Case
l Extension housing
l Shift Cover
l Input bearing retainer
l Counter shaft rear bearing retainer
2. Check the parts which support bearings and shafts for

excessive wear and replace them if necessary.
3. Check the bearing surfaces of the following parts ;

l Input shaft
l Main shaft and its gears
l Counter shaft and 5th drive gear
4. Check the reverse idler shaft and its gears.

Notice
Replace excessive wear parts and do not file on the
hardened surface and precision ground.

5. Check the shift mechanism parts as follows :
l Wear of the shift shaft.
l Wear of the detent/guide plate and offset lever.
l Check worn edges on the following parts :

- Selector arm.
- Interlock plate.
- Selector plates for the 1-2 and 3-4 shift forks.
- 5-R shift lever and the rollers on the reverse fork and
the 5th shift rail/fork.
l Check worn mating surfaces on the following parts :

- 1-2 shift fork, pads and synchronizer sleeve.
- 3-4 shift fork, pads and synchronizer sleeve.
- 5th shift rail/fork pads and synchronizer sleeve.
- Reverse fork and reverse idler gear sleeve.

6. Check the following Bearing for excessive war:
l Crankshaft pilot bushing for the front of the input shaft.
l Clutch release bearing.
l Input shaft bearing.
l Main shaft pilot bearing rollers.
l Main shaft thrust Bearing and its surfaces.
l Speed gear roller bearing on the main shaft.

l Main shaft rear bearing.
l Counter shaft front and rear bearings.
7. Check the gear tooth surfaces of all gear sets.
8. Check the reverse gear set surfaces. Check the surfaces

of gear teeth for excessive wear, pitting, scoring and spalling
and replace if necessary.

9. Take apart the three synchronizer assemblies and check :
l The 1-2 synchronizer.
l The 5th blocking ring.
10. Check the fit between the hub and sleeve of each
synchronizer
l Excessively tight or loose hub-to-sleeve fit.
l Wear of the cone clutch surfaces of brass blocking
rings and gears.
11. Measure the clearance between the blocking ring and the
speed gear
l New 1-2 blocking ring : 0.87-1.4mm
l New 3-4 blocking ring : 0.88-1.5mm
Notice
Excessive wear of the blocking ring or the speed gear cone
surface will cause shift block-out gear clash.

12. Check for gear clash on the synchronizer sleeve teeth or
the clutch teeth on the speed gear.
13. Check the synchronizer sleeve and gear clutch tooth for
hop-out.

PRE-INSTALLATION CHECKS
Checking Procedure
1. Separate the clutch release fork from the pivot and remove
the pivot from the clutch housing.
2. Check the pivot. Fork and release bearing.
3. Check the pressure plate spring.

Notice
Inspect each parts and replace the excessively worn parts.
4. Check the clutch housing alignment as follows :

l Place the magnetic base on the pressure plate spring.
l Check the housing bore alignment.

- Place the dial indicator on the bore.
- By rotating the crankshaft one revolution, record the
dial indicator reading.

l Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution, record the
dial indicator reading.
Notice
If the reading is greater than 0.010 inch, insert the shim between
the engine and clutch housing and adjust the alignment.
5. Check the following parts :

l Pressure plate spring assembly
l Disc
l Flywheel
l Input shaft pilot bearing
Notice
Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork pivot head
during assembly.

SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
General Specifications . . . . . . . . . . . . . . . . . . 5C-1 Component Locator . . . . . . . . . . . . . . . . . . . 5C-6
Fastener Tightening Specifications . . . . . . . . . 5C-2 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3 Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4 Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4 Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5 Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17
SPECIFICATIONS
Type Hydraulic
Clutch Pedal Type Suspended
Max. Pedal Stroke 158 mm
Pedal Free Play 5 - 10 mm
Clutch Disc Type Single Dry Diaphragm
Thickness of Disc Free 9.85 - 10.2 mm
With Load 9.2 mm
Clutch Master Cylinder Stroke 19.8 mm
Inner Diameter f 15.87 mm
Clutch Release Cylinder Stroke 14.0 mm
Inner Diameter f 17.46 mm
Clutch Fluid SAE J1703 / DOT3

5C-2 CLUTCH

Application N··m
Clutch Cover Bolt 37
Clutch Housing Bolt 47
Clutch Release Cylinder 30 - 40
Master Cylinder Nut 8 - 18
Clutch Tube Nut 15 - 18
Pedal Push Rod Nut 16 - 22
Pedal Mounting Bracket Bolt 8 - 18
Stopper Bolt 21 - 25

CLUTCH 5C-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
602 589 00 40 00 661 589 00 15 00

Engine Lock Centering Pin

5C-4 CLUTCH
DIAGNOSIS
CLUTCH SLIPS
Checks Action
Excessive Wear of Facing Replace
Hard or Oily Facing Repair or Replace
Damaged Pressure Plate or Flywheel Replace
Damaged or Burnt Diaphragm Spring Replace
Clutch Pedal Freeplay Insufficient Adjust
Faulty Operation of Clutch Pedal Repair or Replace
Worn or Damaged Clutch Disc Replace
POOR DISENGAGEMENT
Checks Action
Vibration or Excessive Run-out of Disc Replace
Rust or Wear of Disc Spline Repair or Replace
Oily Facing Repair or Replace
Damaged Diaphragm Spring Replace
Excessive Clutch Pedal Freeplay Adjust
HARD TO SHIFT OR WILL NOT SHIFT

Checks Action
Excessive Clutch Pedal Freeplay Adjust Pedal Freeplay
Faulty Clutch Release Cylinder Repair Release Cylinder
Worn Disc, Excessive Run-out, Damaged Lining Repair or Replace
Dirty or Burred Splines on Input Shaft or Clutch Disc Repair as Necessary
Damaged Clutch Pressure Plate Replace
CLUTCH CHATTERS WHEN STARTING

Checks Action
Oily Facing Repair or Replace
Hard or Faulty Facing Replace
Burnt Torsion Spring Replace
Faulty Pressure Plate Replace
Bent Clutch Diaphragm Spring Replace
Hard or Bent Flywheel Repair or Replace
Engine Mounts Loose or Burnt Lever Tighten or Replace

CLUTCH 5C-5
DIFFICULT PEDAL OPERATION

Checks Action
Poor Lubrication on Clutch Cable Lubricate or Replace
Poor Lubrication on Pedal Shaft Lubricate or Replace
Poor Lubrication on Clutch Pedal Repair
CLUTCH NOISY
Checks Action
Not Using the Clutch Insufficient Clutch Pedal Freeplay Adjust
Excessive Wear of Facing Replace
After Disengagement Worn or Damaged Release Bearing Replace
When Disengaging Poor Lubricationon Contact Surface of Bearing Replace
Faulty Installation of Clutch Assembly or Bearing Repair
Clutch pedal is partially depressed Damaged Pilot Bushing Replace
and vehicle speed is reduced

5C-6 CLUTCH
COMPONENT LOCATOR
CLUTCH ASSEMBLY
1 Clutch Disc 8 Bolt

2 Clutch Cover 9 Release Fork
3 Clutch Housing 10 Bolt
4 Release Bearing 11 Spring Lock Washer
5 Release Fork Pivot 12 Transmission Input Spline
6 Release Cylinder 13 Release Bearing Contacting Surface
7 Release Fork Boot 14 Contacting Point of Release Fork and Pivot
Notice
Apply the long-term grease (DBL 6811.00) to No.12,13 and 14.

CLUTCH 5C-7
PEDAL AND MASTER CYLINDER
1 Clutch Pedal 5 Clutch Tube

2 Clutch Master Cylinder 6 Clutch Hose
3 Clutch Tube 7 Clutch Release Cylinder
4 Clutch Damper Cylinder

5C-8 CLUTCH

ON-VEHICLE SERVICE
BLEEDING OF CLUTCH SYSTEM
Bleeding Procedure
Notice
Keep the fluid level over ‘MAX’ in reservoir during
bleeding operation.
Do not let fluid contact a painted surface.
1. Remove the air bolt cap of the release cylinder.
Connect a vinyl tube to the bolt.
2. Insert the other end of the tube in a vacant container.
3. Slowly depress the clutch pedal sever81 times.
4. With clutch pedal fully depressed, open the air bolt and
release air rind fluid in the fluid line,
5. Repeat this procedure until there are no more air bubbles
in the fluid flows.

CLUTCH 5C-9
CLUTCH DISC
1 Clutch Disc 5 Washer

2 Clutch Cover Assembly 6 Bolt ........................................................... 23 Nm
3 Release Bearing 7 Washer
4 Clutch Housing 8 Bolt ........................................................... 44 Nm
Tools
602 589 00 40 00 Engine Lock
661 589 00 15 00 Centering Pin

5C-10 CLUTCH
1. Remove the starter motor. Install the special tool to the
flywheel through the starter motor mounting holes.
Engine Lock 602 589 00 40 00
2. Unscrew the release cylinder mounting bolts and remove

the release cylinder.
3. Unscrew the clutch housing bolts and remove the clutch

housing, release fork and release bearing.
Installation Notice
4. Insert the centering pin into the clutch spline.

Loosen the clutch cover bolts 1/2 turn in crisscross sequence
until the spring tension is released.
Notice
Do not remove the bolts at a time, or clutchcover can be
damaged or deformed.
Centering Pin 661 589 00 15 00

CLUTCH 5C-11
5. Unscrew the bolts and remove the clutch cover, pressure
plate and clutch disc.
Notice
Be careful not to drop the pressure plate and clutch disc.
Installation Notice

reverse order.
Notice
l Before installation, clean oil and grease on the
flywheel surface.
l Do not clean the clutch disc and release bearing in
solvent.

5C-12 CLUTCH
1. Clutch Cover
l Check the diaphragm spring tip for wear and height
unevenness.
Unevenness Limit 0.8 mm
l Check the pressure plate surface for wear, crack and

discoloration.
l Check the strap plate rivet for looseness and replace
the clutch cover if loosened.
2. Clutch Disc
l Check the facing for rivet looseness, excessive runout,
sticks, oil and grease.
l Measure the rivet head depth.
If out limit, replace the disc.
Wear Limit 0.3 mm
3. Clutch Release Bearing

l The release bearing is permanently lubricated and
requires no cleaning.
l Check the bearing for sticks, damage, abnormal noise,
turning drag and wear.
4. Release Fork
l If there is abnormal wear in contact point with bearing,
replace the release fork.

CLUTCH 5C-13
MASTER CYLINDER
1 Snap Pin 9 Clamp

2 Clevis Pin 10 Reservoir
3 Clevis 11 Spring
4 Lock Nut 12 Piston Assembly
5 Flange Nut ........................................... 30-40 Nm 13 Boot
6 Push Rod 14 Plate
7 Cylinder Body 15 Snap Ring
8 Oil Pipe ................................................ 15-18 Nm
Notice
Do not disassemble the No.12.

5C-14 CLUTCH
1. Draw out the fluid.
2. Pull out the snap pin and clevis pin from the clutch pedal
connection.
3. Remove the oil pipe.
Installation Notice
Notice
Be careful not the fluid contact a painted surface.
4. Remove the master cylinder mounting nuts and pull off the
master cylinder.
Installation Notice

reverse order.
6. Check the clutch pedal operation.
7. Bleed the clutch system.

CLUTCH 5C-15
CLUTCH PEDAL
1 Snap Pin ................................................ Replace 9 Turn Over Spring .......................... Apply Grease
2 Clevis Pin ...................................... Apply Grease 10 Bushing ......................... Replace, Apply Grease
3 Master Cylinder Push Rod 11 Full Stroke Stopper Contact Pad
4 Gasket 12 Clutch Pedal
5 Nut ....................................................... 16-22 Nm 13 Pedal Pad
6 Spring washer 14 Pedal Mounting Bracket
7 Bolt ........................................................ 8-18 Nm 15 Stopper Bolt .......................................... 21-25Nm
8 Fulcrum Pin 16 Clutch Interlock Switch
Notice
Assembly should follow the disassembly procedure in the reverse order.
Grease specification : Long - term grease (T/Mn DBL6611.00)

5C-16 CLUTCH
1. Pedal Stroke (A).
Max. Stroke 148 mm
Notice
To adjust the pedal stroke, loosen the lock nut (H) of the
interlock switch (G) and turn the two lock auto until the stroke
is correct.
2. Pedal Height (B).

Height (From the Floor Carpet) 169.5 - 172.5 mm
Notice
To adjust the pedal height, loosen the lock nut (C) of the
stopper bolt (D) and turn the stopper bolt until the height is
correct.
3. Pedal free play (E).

Free Play 5 - 15 Nm
Notice
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is
correct.
4. Check the fulcrum pin and the bushing for wear, the pedal
for bending and the spring for damage.

CLUTCH 5C-17
CLUTCH OIL CHAMBER
1 Clutch Master Cylinder 4 Clutch Oil Chamber

2 Hydraulic Tube 5 Hydraulic Tube
3 Bolt 6 Clutch Release Cylinder
Notice
l Installation should follow the removal procedure in the reverse order.
l When installing, perform the bleeding procedures from chamber cylinder and release cylinder.

SECTION 5D1
TRANSFER CASE (PART TIME 4408)

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D1-1 Diagnostic Diagram . . . . . . . . . . . . . . . . . . . 5D1-9
General Specifications . . . . . . . . . . . . . . . . . 5D1-1 Maintenance and Repair . . . . . . . . . . . . . 5D1-10
Schematic and Routing Diagram . . . . . . . . 5D1-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D1-10
Part Time Transfer Case - 4408 . . . . . . . . . . 5D1-2 Maintenance of Transfer Case Lubricant . . 5D1-10
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1-3 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-11
Self- Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5D1-4 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
System Description . . . . . . . . . . . . . . . . . . . . 5D1-4 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Self-Diagnosis Test . . . . . . . . . . . . . . . . . . . . 5D1-8 Transfer Case Control Unit (TCCU) . . . . . . 5D1-36
SPECIFICATIONS
Model Part-Time 4408 (E)
Type E.S.O.F. Type
Gear Ratio High 1:1
Low 2.48 : 1
Oil Specification ATF S - 3, S - 4 or DEXRON II, III
Capacity 1.2 L
Lubrication Check : Every 15,000 km
Replace : Every 50,000 km
Manufacturer Borg Warner
Weight 30 kg

5D1-2 TRANSFER CASE (PART TIME 4408)
SCHEMATIC AND ROUTING DIAGRAM

PART TIME TRANSFER CASE - 4408

TRANSFER CASE (PART TIME 4408) 5D1-3
DIAGNOSIS
Electric Shift Problems
Checks Action
Faulty or Damaged TCCU, Speed Sensor, Motor, Clutch Overhaul and check, replace if necessary.
or Internal Wirings
Damaged or Worn Shift Cam, Hub, Fork and Rail Shift Overhaul and check for wear and damage.
Binding Shift Fork, Hub Collar or Gear Check sliding parts, replace if necessary.
Cannot Front Wheel Drive when Shifted 4H,4L

Checks Action
Broken Drive Chain Check sliding parts, replace if necessary.
Noise in 4WD Operation

Checks Action
Improper or low oil Drain and replace with specified oil.
Loosened bolts or mounted parts Retighten as specified.
Noisy T/C bearing Disassemble bearings and parts and check for wear or
damage. Replace if necessary.
Noisy gears Check for wear and damage including speedometer
gear, replace if necessary.
Noise in 4H or 4L
Checks Action
Worn or Damaged Sprockets or Drive Chain Disassemble and check for wear and damage, replace
if necessary.
Incorrect Tire Pressure Adjust tire pressure.
Transfer Case Oil Leakage

Checks Action
Cracked Transfer Case Replace the case.
Leakage from Other Parts Clean case and parts and check for leakage.
Breather Clogging Remove breather hose and clean, replace if necessary.
Improper or too much Oil Use specified oil and adjust oil level.
Loosened Sealing Bolts Retighten
Improperly Applied Sealant Use specified sealant and retighten.

SELF- DIAGNOSIS
SYSTEM DESCRIPTION
1. TCCU detects transfer case system malfunctions and
indicates malfunctioning part(s) through flashing 4H,4L
indicator lights.
Using a service connector, connect it to the diagnosis box
in the engine room and read the flashing of the ‘4WD
CHECK’ indicator light.
The flashing indicator light will show you defective code(s).
2. Identify 7 defective codes after reading the flashing indicator
light.
l TCCU
l Shift motor
l Magnetic synchronizer clutch
l Speed sensor
l Hub solenoid
l Selector switch
l Motor position sensor
3. Transfer case system is malfunctioning when:
l 4H ,4L indicator lights are remain on after 0.6 second
when turning the ignition switch ‘ON’
l 4H,4L indicator lights are continuously come on during
driving.
4. If only 1 part is malfunctioning, ‘4WD CHECK’ indicator light
will display defective code 3 times continuously.
5. If more then 2 part is malfunctioning, the first malfunctioning
part will be displayed 3 times and following malfunctioning
parts will be displayed .
6. To read defective code, connect the service connector and
turn the ignition switch 'ON'.
7. After repairing, eliminate the defective code stored in the
TCCU.
Notice
Before replacing the malfunction parts with defective code,
check the wires and connectors for proper condition.

Defective Code Reading

1. Position the ignition switch to ‘OFF’
2. Using a service connect the No.2 pin ( lgnition ) and No.6
pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to 'ON'.
4. Read the flashing ‘4WD CHECK’ indicator light and identify
the malfunctioning part.
How to Eliminate the Falut Code

1. Position the ignition switch to ‘OFF’
2. Using a service connector, connect the No.2 pin (GND) and
No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to ‘ON’ over 5 seconds.
4. Do defective code reading and make sure that all defective
codes are eliminated.

Diagnostic Table
Connect a service connector. If turn the ignition switch ‘ON’
‘4WD CHECK’ indicator light will come on for 0.6 second and
turn off for 3 seconds and then display a defective code 3times
continuously.
No. Defective Code Malfunctioning Part
4WD
Defective Code CHECK
Light
1 TCCU
ON
OFF
4WD
Light
2 Shift Motor
ON
OFF
4WD
Light
3 Synchronizer Clutch
ON
OFF
4WD
Light
4 Speed Sensor
ON
OFF
4WD
Light
5 Hub Solenoid
ON
OFF

No. Defective Code Malfunctioning Part
4WD
Light
6 Selector Switch
ON
OFF
4WD
Light
Motor Positon Sensor
7
ON
OFF

SELF-DIAGNOSIS TEST
Test Procedure
1. Connect the scanner harness connector to the engine
3. Select "Electronic control vehicle diagnosis" from the function
selection display and press "Enter".
4. Select "Korando" from vehicle model selection display and
press "Enter".
5. Select "TCCU" from control system selection display and
press "Enter".
6. Select "TCCU Part Time" from TCCU diagnosis selection
display.
Notice
Check sensor valve output display if necessary.
7. Select "Self-diagnosis" from diagnosis items selection display.
8. Turn the ignition switch to "OFF" position and press
"ENTER". Turn the ignition swtich to "ON" position again
and press "ENTER".
9. Determine fault code and check the defective component.
Notice

DIAGNOSTIC DIAGRAM


ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER CASE
LUBRICANT
Oil Level Check
l Clean the oil level plug and surrounding area.
l Remove the oil level plug and check whether oil is drip
out or not.
l Tighten the oil level plug.
Oil Change
l Clean the oil level plug and surrounding area
l Place a suitable container under the transfer case.
l Remove the oil and tighten the drain plug.
l Fill the oil through the oil level plug until oil begins to
drip out.
l Tighten the oil level plug.
Cautions for oil level check and plugs tightening

l Do not use an impact wrench to remove or tighten the
oil level plug or drain plug since this will damage the
threads in the transfer case.

TRANSFER CASE
1 Rear Companion Flange 8 Transmission Adapter

2 Case Cover 9 Bolt ..................................................... 81-59 Nm
3 Front Companion Flange 10 Washer
4 Breather Plug 11 Front Propeller Shaft
5 Case 12 Bolt ..................................................... 81-89 Nm
6 Input Shaft 13 Washer
7 Mounting Bolt ..................................... 38-52 Nm 14 Rear Propeller Shaft

1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug and drain the oil.
Reinstall the drain plug.
* If planal damper is installed, unscrew 4bolts and remove
the planar damper.
Installation Notice
5. Disconnect the speedometer cable connector and other

cable connectors and wiring harnesses.
6. Support the transfer case with jack and remove the front
and rear propeller shafts from the transfer case.
Installation Notice
Front 81 - 89 Nm
Tightening Torque
Rear 70 - 80 Nm

7. Remove the center mounting nuts and end sides mounting
bolts of the cross member and then remove the cross
member.
Installation Notice
Tightening Torque(1) 21 - 35 Nm
Tightening Torque(2) 62 - 93 Nm
8. Remove the transfer case by removing the bolts attaching

the transfer case to the transmission.
Installation Notice
Notice
Apply long-term grease to the inner spline of the transfer
case input shaft.
reverse order.

UNIT REPAIR
TRANSFER CASE
Preceding Work : Removal of the transfer case

1 Nut 36 Lock-up Assembly 73 Breather Hose
2 Spring Washer 37 Snap Ring 74 Bolt
3 Oil Seal 38 Lock-up 75 Front Adapter Assembly
4 Companion Flange 39 Sleeve Return Spring 76 Snap Ring
5 Snap Ring 40 Lock-up Collar 77 Oil Seal
6 Torsional Damper 41 Rail Shaft 78 Spiral Pin
7 Pipe Plug 42 Lock-up Fork 79 Front Adapter
8 Bolt 43 Snap ring 80 Snap Ring
9 Bolt 44 Spacer 81 Bearing
10 Speed Sensor and Harness 45 Drive Sprocket 82 Input Shaft Assembly
Bracket 46 Driven Sprocket 83 Sleeve Assembly
11 Speed Sensor Assembly 47 Drive Chain 84 Needle Bearing
12 Speed Sensor 48 Shaft and Pump Assembly 85 Input Shaft
13 O-Ring 49 Screw 86 Thrust Washer
14 Locking Clip 50 Pump Housing 87 Retaining Ring
15 Connector 51 Pump Gear Set 88 Thrust Plate
16 Motor Assembly 52 Pump Cover 89 Sun Gear
17 Oil Seal 53 Spring Pin 90 Gear Carrier Assembly
18 Bearing 54 Hose Clamp 91 Planet Carrier
19 Bolt 55 Hose Coupling 92 Pinion Shaft
20 Tag 56 Oil Strainer 93 Thrust Washer
21 Decal 57 Output Shaft 94 Pinion Gear
22 Wiring Harness Clip 58 Reduction Hub 95 Needle Roller Bearing
23 Bolt 59 Shift Fork Assembly 96 Pinion Needle Spacer
24 Cover Assembly 60 Shift Fork Facing 97 Electric Shift Cam
25 Nut 61 Pin, Roller and Retainer 98 Torsion Spring
26 Snap Ring 62 Pin 99 Spacer
27 Bearing 63 Cam Roller 100 Shift Shaft
28 Needle Bearing 64 Retainer 101 Case Assembly
29 Cover 65 Reduction Shift Fork 102 Oil Seal
30 Clutch Coil Assembly 66 Nut 103 Snap Ring
31 Speed Gear 67 Plane Washer 104 Bearing
32 Oil Seal 68 Oil Seal 105 Dowel Pin
33 Return Spring 70 Companion Flange 106 Ring Gear
34 Magnet 71 Spacer 107 Case
35 Clutch Housing 72 Front Output Assembly

<Companion Flange>
1. Holding the companion flange, remove the nut and washer
and then remove the companion flange and oil seal.
2. Remove the 2 plugs from the cover.
1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug
25 Cover
<Extension Electric Shift>

1. Remove the bolt, washer,3 bolts and harness bracket.
2. Remove the sensor assembly and remove the O-ring from
the speed sensor.
3. Remove the motor assembly.
6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket
10 Sensor Assembly
11 Speed Sensor
12 O-ring
13 Motor Assembly
25 Cover

<Cover Assembly>
1. Remove the 9 bolts, wiring harness clip and 4. Remove the snap ring and pull out the ball bearing
identification tag. from the cover to remove the speed gear.
Notice 5. Pull out the needle bearing from the cover.
Identification tag has information required for ordering 6. Pull out the oil seal from the slot in cover.
replacement parts, so be careful not to lose it. 7. Remove the magnet form the slot in case.
2. Using a screw driver, pry and disconnect the sealant 8. Remove the return spring from the rail shaft.
bond of the cover and case. 9. Be careful not to damage the metal surface when
3. Remove the oil seal, bearing, 3 nuts and clutch coil removing the sealant of the cover and case.
assembly of the electric shift unit.
14 Bolt 24 Needle Bearing

15 Wiring Clip 25 Cover
16 Identification Tag 26 Magnet
17 Cover Assembly 27 Speed Gear
18 Oil Seal 28 Oil Seal
19 Bearing 29 Return Spring
20 Nut 38 Rail Shaft
21 Clutch Coil Assembly 55 Output Shaft
22 Snap Ring 111 Transfer Case
23 Ball Bearing

<Lock-up Shift Parts>
1. Remove the retaining ring and clutch housing from the shift
collar hub.
2. Remove the shift collar hub from the output shaft.
3. Separate the 2WD - 4WD lock-up assembly and lock-up
fork from the output shaft and remove the rail shaft.
4. To remove the 2WD - 4WD lock-up assembly, separate the
return spring, lock-up hub and snap ring from the lock-up
collar.
30 Retaining Ring
31 Clutch Housing
32 Shift Collar Housing
33 2WD/4WD Lock-up Assembly
34 Snap Ring
35 Lock-up Hub
36 Return Spring
37 Lock-up Collar
38 Rail Shaft
39 Lock-up Fork
55 Output Shaft
<Drive Chains>
1. Remove the snap ring and spacer from the output shaft.
2. Remove the drive chain, driven sprocket and drive sprocket
from the output shaft.
3. Separate the chain and sprocket when removing the
assembly.
40 Snap Ring
41 Spacer
42 Drive Sprocket
43 Driven Sprocket
44 Drive Chain
55 Output Shaft(Rear)
71 Output Shaft(Front)
<Pump Parts>
1. Remove the 4 bolts and retainer and separate the output
shaft and rear pump cover.
2. Loosen the hose clamp and remove the hose coupling from
the pump housing.
3. Remove the hose clamp, hose coupling and strainer.
4. Remove 2 pump pins and spring from the output shaft.
5. Separate the front pump and remove the output shaft.
45 Shaft and Pump Assembly
46 Bolt
47 Pump Retainer
48 Rear Pump Cover
49 Hose Clamp
50 Hose Coupling
51 Pump Housing
52 Pump Pin
53 Spring
54 Front Pump Cover
55 Output Shaft
56 Strainer

<Reduction Shift Parts>
1. Remove the reduction hub and reduction shift fork assembly
from the case.
2. Remove the 2 shill fork facings from the shift fork assembly.
3. To remove the roller cam and pin, cut elf the plastic retainer
when disassembling the fork assembly.
57 Reduction Hub
58 Shift Fork Facing
59 Reduction Shift Fork Assembly
60 Roller Pin and Retainer Assembly
61 Retainer
62 Pin
63 Roller Cam
64 Reduction Shift Fork
<Front Output Assembly>

1. Holding the companion flange, remove the nut and washer
and then remove the companion flange and oil seal.
2. Remove the output shaft.
65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (front)
111 Case

<Adapter, Input Shaft and Carrier Gear>
1. Remove the breather. 5. After removing snap ring, pull out the bearing and
2. After removing 6 bolts, remove the front adopter by thrust washer from the input shaft assembly and
separating the adapter sealer bond from the case separate the input shaft assembly from the carrier
using a screw driver. gear assembly.
Notice 6. Remove the needle bearing and sleeve bearing from
the input shaft assembly.
Be careful not to damage the contacting surface of
the case and adapter. 7. Remove the retaining ring, thrust plate rind sun gear
from the planet carrier assembly.
3. Remove the adapter assembly, input shaft assembly
and carrier gear assembly. Notice
4. Remove the snap ring and oil seal from the front Do not disassemble the planet carrier assembly.
adapter.
72 Breather 82 Sleeve Bearing

74 Adapter Assembly 84 Input Shaft
75 Snap Ring 85 Thrust Bearing
76 Oil Seal 86 Carrier Gear Assembly
77 Spiral Pin 87 Retaining Ring
78 Front Adapter 88 Thrust Plate
79 Retaining Ring 89 Sun Gear
80 Bearing 90 Planet Carrier Assembly
81 Input Shaft Assembly 111 Case

<Electric Shifts Cam Parts>
1. Remove the electric shift cam parts from the case assembly.
2. Separate the electric shift cam from the shift shaft.
3. Holding the shift shaft in a vise, remove the torsion spring
and spacer from the shift shaft using a screw driver.
100 Electric Shift Cam

101 Torsion Spring
102 Spacer
103 Shift Shaft
111 Case
<Case Assembly>
1. Remove the oil seal.
2. Remove the retaining ring and bearing.
3. Remove the pin from the transfer case.
Notice
Be careful not to damage the pin.
4. Using a press, remove the ring gear from the case.
105 Transfer Case Assembly

106 Oil Seal
107 Retaining Ring
108 Ball Bearing
119 Pin
110 Ring Gear
111 Case

Cleaning Procedure
Notice
Before cleaning, check the magnet for the
presence of metal particles which indicate internal
chipping of the transfer case.
1. Using cleaning solvent, clean the residual oil and dirt
deposits.
Notice
During cleaning, be careful not to damage the metal
surfaces.
2. After cleaning, dry the parts with low pressure (Max. 20 psi)
compressed air.
3. Lubricate the ball bearings and needle bearings with transfer
case oil after cleaning.
Notice
Protect the lubricated bearings from dust.
1. Visually check the all removed parts.
Notice
Always replace the hose coupling, O-ring and oil seal with
new parts.
2. Inspection Terms
l Burr : Local rise of material forming protruding sharp
edge
l Chip : An area from which a small fragment has been
broken off or cut
l Crack : Surface break of line nature indicating partial or
complete separation of material.
l Excessive wear : Heavy or obvious wear beyond
expectations considering conditions of operation.
l Indentation : Displacement of material caused by localized
heavy contact.
l Galling : Breakdown of metal surface due to excessive
friction between parts. Particles of the softer material
are torn loose and welded to the harder material.
l Nick : Local break or notch, usually displacement of
material rather than loss.
l Scoring : Tear or break in metal surface from contact
under abnormal pressure.
l Step wear : Heavy wear that produces a step that can
be seen or felt between adjacent contact and noncontact
surfaces.
l Uneven wear : Condition of localized, unevenly distributed
wear Includes hollows, shiny spots, uneven polish and
other visual indications.

3. Specific Inspection
l Referring to normal gear tooth face, specifically inspect
the uneven wear and chips of gear tooth.
Replace or repair if necessary.
4. Inspection of Contact Patterns
Description Normal Abnormal
Normal Wear
End Face Wear
Traveling Face Wear
Upper Face Wear
Lower Face Wear

Description Repair Description Repair
Corner chip Chip within

at drive face contact pattern
Edge chip Chip completely

at drive face through tooth
Corner chip Side edge chip

at coast face at drive face

Assembly Procedure
General Information
1. Use special tools during assembly of oil seals and bearings.
2. Lubricate bearings, oil seals and bushings before assembly.
105 Case Assembly

106 Oil Seal
107 Retaining Ring
108 Ball Bearing
109 Pin
110 Ring Gear
111 Case
Transfer Case
1. If the ring gear was removed, align the outer diameter of
the new replaced ring gear with transfer case and assemble
it.
2. Insert the pin.
3. Insert the ball bearing to the case and install the retaining
ring.
4. Install the new oil seal by pressing into the case.
5. Make sure that all parts are correctly and firmly installed
into the case.
106 Oil Seal

109 Pin
110 Ring Gear
111 Case
Electric Shift Cam Parts

1. Insert the spacer into torsion spring.
2. Insert the end of the shift shaft into the spacer smoothly.

101 Torsion Spring
102 Spacer
103 Shift Shaft

3. Slide the torsion spring and spacer to the left of the shift
shaft and position the end of the first spring to fix on the
drive tang.
101 Torsion Spring

102 Spacer
103 Shift Shaft
4. Push the end of the second spring to right and fix it on the
drive tang.
101 Torsion Spring

102 Spacer
103 Shift Shaft
5. Push the torsion spring and spacer together back them

completely.
6. Slide the electric the electric shift cam onto the shift shaft.
7. Install the electric shift cam assembly into the transfer case
after installation of the shift fork.
101 Torsion spring

102 Spacer
103 Shift Shaft

Adapter, Input Shaft and Carrier
1. Place the planet carrier assembly on work bench to be the
retaining ring mounting groove upward.
2. Install the sun gear with the hub end up into the planet
carrier assembly and rotate the sun gear to make sure that
gears are fully engaged.
3. Align the tabs and install the thrust plate into the planet
carrier assembly.
4. Install the retaining ring to the planet carrier assembly.
5. Press the needle bearing into the input shaft and press the
new sleeve bearing into the input shaft assembly.
72 Breather 82 Sleeve Bearing

74 Adapter Assembly 84 Input Shaft
75 Snap Ring 85 Thrust Washer
76 Oil Seal 86 Carrier Gear Assembly
77 Spiral Pin 87 Retaining Ring
78 Front Adapter 88 Thrust Plate
79 Retaining Ring 89 Sun Gear
80 Bearing 90 Planet Carrier Assembly
81 Input Shaft Assembly 111 Case

6. Install the planet carrier assembly onto the input shaft
and install the thrust washer. Press the bearing over
input shaft.
7. After pressing the bearing, install the retaining ring.
8. Press the pin into the front adapter.
9. Slowly press the oil seal into the front adapter.
10. Install the front adapter assembly.
Notice
After installation, make sure that snap ring is correctly
installed into the groove.
11. Position the input shaft assembly over front cover and
engage into the bearing groove by expanding the ends of
snap ring.
12. Apply 1.6mm bead of sealant on the mounting face for
the transfer case and tighten the 6 bolts.
13. Install the breather.
Item Tightening Torque
6 Bolts 28 - 48 Nm 75 Snap Ring
76 Oil Seal
Breather 8 - 20 Nm 77 Spiral Pin
78 Front Adapter
82 Sleeve Bearing
83 Needle Bearing
84 Input Shaft

Front Output Shaft
1. Press the deflector onto yoke.
2. Position the output shaft in transfer case and install the
companion flange assembly, oil seal, washer and nut.
3. Holding the companion flange, tighten the nut.
65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (Front)
111 Transfer Case
Reduction Shift Parts

1. Install the new pin, roller and retainer into the reduction
shift fork.
2. Press the pin, roller and retainer into the reduction spilt fork
bore completely.
Notice
Make sure that the cam roller turns freely.
3. Install the 2 fork facing on the reduction shift fork assembly.
4. Install the reduction shift fork onto the previously installed
reduction hub in the transfer case.
5. Install the output shaft spline into the reduction hub and
engage the output shaft end with input shaft bearing.
Notice
For installation of the output shaft, assemble
the oil pump temporarily. 55 Output Shaft
57 Reduction Hub
58 Shift Fork Facing
60 Roller, Pin and Retainer Assembly
61 Retainer
62 Pin
63 Roller Cam
64 Reduction Shift Fork

Oil Pump
1. Install the pump front cover to be the ‘TOP’ mark down and
turn the cover to be the ‘TOP’ mark up when installed in
vehicle.
2. Install the 2 pump pins and spring to the output shaft.
Notice
Flat surface of the pins must point out and align the center
line of pins and spring.
3. Connect the hose coupling to the strainer coupling and
install the strainer foot into the transfer case slot.
Notice
The hose coupling must face the pump assembly.
4. Install the pump housing to be the 'REAR' mark up and seat
the 2 pump pins inside of the pump housing by moving
pump pins inward and compressing the spring. 45 Shaft and Pump Assembly
5. Tighten the hose to pump housing by hose clamp. 46 Bolt
47 Pump Retainer
6. Position the pump rear cover to be the ‘TOP REAR’ mark 48 Rear Pump Cover
up and located at the top of transfer case when installed in 49 Hose Clamp
vehicle. Position the pump retainer on the cover so that tab 50 Hose Coupling
on the retainer is in notch in the transfer case. Apply Loctite 54 Pump Housing
52 Pump Pin
to the bolts and tighten the bolts with turning the output 53 Spring
shaft by hand to make the pump pins move freely. 54 Front Pump Cover
55 Output Shaft
Tightening Torque 4 - 8.5 Nm 56 Strainer
Drive Chain
1. Position the drive sprocket to the rear output shaft end and
driven sprocket to the front output shaft end.
2. Install the drive chain onto the sprocket.
3. Holding each sprocket to be the drive chain tight and parallel
with transfer case, install the drive chain assembly to the
output shafts.
4. Rotate the driven sprocket slightly to engage splines on
the front output shaft.
5. Install the spacer to the front output shaft and insert the
snap ring into the shaft groove over spacer.
40 Snap Ring
41 Spacer
42 Drive Sprocket
43 Driven Sprocket
44 Drive Chain
55 Output Shaft (Rear)
71 Output Shaft (Front)

Lockup Shift
1. Install the lockup hub and return spring to the lockup collar
and insert the snap ring.
2. Install the rail shaft through reduction shift fork assembly
previously installed and into the blind hole in case.
3. Engage the lockup fork into the 2WD/4WD groove and
check operation.
4. Install the shift collar hub to the output shaft spline.
5. Install the previously assembled electric shift cam and
assemble the clutch housing as follows.
l Rotate the shift cam assembly to right so that the end of
the torsion spring contacts with reduction shift fork side.
l Holding the rail shaft, lift up the fork assembly slightly.
Adjust electric shift cam assembly so that the roller on
reduction shift fork assembly is in groove in shift cam
and button on lockup fork is on cam end.
l Install the clutch housing over shift collar hub and insert
the retaining ring into the clutch collar hub groove. 30 Retaining Ring 35 Lockup Hub
31 Clutch Housing 36 Return Spring
32 Shift Collar Housing 37 Lockup Collar
33 2WD/4WD 38 Rail Shaft
Lockup Assembly 39 Lockup Fork
34 Snap Ring 55 Output Shaft
38 Rail Shaft
39 Lockup Fork
101 Torsion Spring

Cover
1. Position the cover to be the open end up on the work table.
2. Position the end of needle bearing to be identification mark
up and press into the cover until upper end of bearing is
40.47 - 40.97mm below cover face that contacts with transfer
case.
3. Press the ball bearing into the cover and install the snap
ring .
4. Install remaining parts as follows.
l Install the 4 O-rings on the stud bolts of the clutch coil
assembly.
l Install the clutch coil assembly inside the cover and
tighten 3 nuts.
18 Oil Seal
l Install the bearing and motor bearing into the cover. 19 Bushing
20 Nut
21 Clutch Coil Assembly
22 Snap Ring
23 Ball Bearing
24 Needle Bearing
25 Cover

Cover Assembly
1. Install the return spring over rail shaft in the transfer case.
2. Insert the magnet into the transfer case slot.
3. Apply 1.6mm bead of Loctite RTV 598 to the transfer case
mounting surface.
Notice
For installation of cover, align the transfer case with cover
not to use excessive force.
14 Bolt
15 Wiring Clip
16 Identification Tag
17 Cover Assembly
26 Magnet
27 Speed Gear
28 Oil Seal
29 Return Spring
38 Rail Shaft
111 Case
4. Install the cover onto the transfer case as follows :

l Align the cover bores with transfer case pins.
l Align the cover bearings with output shafts.
l Align the cover blind hole with rail shaft and make sure
that return spring is not cocked.
29 Return Spring
38 Rail Shaft
55 Output Shaft
71 Front Output Shaft
103 Shift Shaft
109 Dowel Pin
5. Tighten 9 bolts positioning identification tag and wiring clip.
6. Install the speed gear over output shaft spline in the cover
assembly.
7. Press the new oil seal into the cover assembly.
13 Motor Assembly
14 Bolt
15 Wiring Clip
16 Identification Tag

External Electric Shift
1. Align the motor with shift shaft and position the motor
assembly onto the cover.
2. Install the motor to the shift shaft and contact cover androtate
the motor clockwise direction to check correctengagement.
6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket
10 Sensor Assembly
14 Speed Sensor
12 O-ring
13 Motor Assembly
25 Cover
3. Insert the 0-ring on the speed sensor speed sensor

assembly to the cover.
4. Install the bracket to the motor assembly and tighten 3bolts.
13 Motor Assembly
103 Shift Shaft

Companion Flange
1. Install the 2 plugs to the cover.
2. Install the companion flange, oil seal and washer.
3. Holding the companion flange, tighten the nut.
Notice
Apply loctite 262 to nut before installation.
1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug
25 Cover

TRANSFER CASE CONTROL UNIT

(TCCU)
System Description
TCCU is located under the driver’s seat and permits the vehicle
to shift from two-wheel drive to four-wheel drive (and back shift)
according to driver’s switch operation during driving (For the
shifting between 4WD HIGH and 4WD LOW, stop the vehicle).
1. Shifting from 2H to 4H
l Position the transfer case switch from '2H' to '4H'.
l Shifting is possible during driving.
l '4WD Hl' indicator light will turn on.
2. Shifting from 4H to 2H
l Position the transfer case switch from '4H' to '2H'.
l Shifting is possible during driving.
l '4WD Hl' indicator light will turn off.
3. Shifting between 4H and 4L

l Shifting is possible when the vehicle is almost stopped
(approx. 2 km/h), so it would be better stop the vehicle.
l In case of manual transmission equipped vehicle, apply
clutch pedal.
l In case of outo transmission equipped vehicle, put the
lever position into 'N'.
l Position the transfer case switch '4H' to '4L' or '4L' to
'4H'.
l According to the shifted position, indicator light will turn
on.
Notice
If there are malfunctions in shifting,'4H' or '4L' indicator light
will flash.

Inspection and Repair
1. 4H and 4L indicator light inspection
l When turn the ignition switch to "ON" position, 4H and
4L indicator light will turn on for 0.6 second and will turn
off immediately.
Notice
If indicator light does not turn on, check bulb, wiring harness
and TCCU.
2. TCCU inspection
Pin No. Operation Condition Voltage(V)

4H or 4L 4.75 - 5.35
J1 - 7
2H 0 - 0.50
4H indicator light ON < 1.00
J1 - 8
4H indicator light OFF > 11.00
2H or 4H 4.75 - 5.35
J1 - 13
4L 0 - 0.50
Clutch pedal applied < 0.50
J1 - 14
Clutch pedal released > 11.00
4L indicator light ON < 1.00
J1 - 15
4L indicator light OFF > 11.00
Motor OFF < 1.00
J1 - 16
Motor ON > 11.00
Motor OFF < 1.00
J1 - 17
Motor ON > 11.00
Auto locking hub ON > 11.00
J1 - 23
Auto locking hub OFF < 1.00
Notice
l DC 12V for the TCCU operation should be maintained.
l In case of J1-8 and J1-15, indicator light will turn on for 0.6
second when turn the ignition switch ON.
l If 4H and 4L indicator lights remain turned on when turn the
ignition switch on or during driving, perform the TCCU
diagnosis.

SECTION 5D2
TRANSFER CASE (TOD)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D2-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-19
General Specifications . . . . . . . . . . . . . . . . . 5D2-1 Maintenance and Repair . . . . . . . . . . . . . 5D2-31
Function Description . . . . . . . . . . . . . . . . . 5D2-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D2-31
TOD Control Unit . . . . . . . . . . . . . . . . . . . 5D2-10 TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-31
Schematic and Routing Diagrams . . . . . . 5D2-12 Transfer Case (TOD) . . . . . . . . . . . . . . . . . 5D2-32
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-12 Speed Sensor in Front and Rear
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 5D2-36
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-13
Replacement of Oil . . . . . . . . . . . . . . . . . . . 5D2-38
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . 5D2-13
Diagnostic Trouble Codes (DTC's) . . . . . . . 5D2-15 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D2-39
Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-16 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D2-39
Eliminate the Memorized Fault Code . . . . . 5D2-18
SPECIFICATIONS
Model TOD(Torque On Demand) Transfer Case (4423E)
Length (mm) 343.0
Weight (kg) 36.6
Shift Mode 4H and 4L
Gear Ratio High 1:1
Low 2.48 : 1
Oil Specification ATF S-3, S-4 or Dexron II, III
.
Capacity =. 1.4 L
Interval Inspect Every 15,000km, Replace Every 50,000km
.
Max. Torque 550 lb·ft (=. 76kg·m)

5D2-2 TRANSFER CASE (TOD)
FUNCTION DESCRIPTION
l TOD System Select Mode (4H and 4L)
4H is the mode when drive normally of which gear ratio is 1:1 and 4L mode distributes power to front and rear
wheels 50:50 of which gear ratio is 2.48:1.
l TOD System Function (select 4H mode)
TOD system controls clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference
exceeds the permissible range, corresponding power is distributed into front wheel through EMC (Electro-Magnetic
Clutch).
Hall effect sensor signals speed on front and rear propeller shafts going through with TOD control unit.
Transfercase clutch coil is activated by variable current on exceeding difference of speed in front and rear propeller
shafts.
l Function of 4L Mode
When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor
rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetary
gear set.
l Shift Motor
It locates backside transfer case, which drives rotary helical cam.
When mode select switch changes to 4L, shift fork is on position for 2.48:1 by rotation of helical cam.
l Transfer Case
TOD transfer case distributes power into front and rear axle by operation of 4H/4L switch and shift motor.
Shifting 4H to 4L, is performed towards reducing HI-LO collar by means for connection HI-LO shift fork with
output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary
gear. Front planetary gear join with output shaft and drives LO position.

TRANSFER CASE (TOD) 5D2-3
Definitions
Rear Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in
response to a rotating 30 tooth wheel coupled to the rear propshaft inside the
Transfer Case. Each rotation of the rear propshaft will result in 30 speed sensor
pulse.
Front Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in
response to a rotating 30 tooth wheel coupled to the front propshaft inside the
Transfer Case. Each rotation of the front propshaft will result in 30 speed sensor
pulse.
EMC An Electromagnetic clutch used to control the amount of torque applied to the
front propshaft.
TODTM Torque on DemandTM.
Duty Cycle Duty Cycle is the time the EMC is on divided by the period in which it is being
modulated.
Touch-off A minimum amount of duty cycle applied to the EMC.
Front Overrun A condition where the front propshaft is turning at a rate which is faster than the
rear propshaft.
Rear Overrun A condition where the rear propshaft is turning at a rate which is faster than the
front propshaft.
High Range The highest (numerically lowest = 1 :1) gear ratio between the input and outputs
of the Transfer Case.
Low Range The lowest (numerically highest = 2.48:1) gear ratio between the input and outputs
of the Transfer Case.
4H/4L Switch A switch which selects the desired gear ratio.
Shift Motor Electric motor which changes the Transfer Case range.
Position Encoder A set of 4 Gray code switches which provide feedback to the TCCU indicating the
position of the Shift Motor.
Clutch Interlock Switch A switch on vehicles equipped with a manual transmission which indicates that
the clutch pedal is depressed.
Neutral Safety Switch A switch on vehicles equipped with an automatic transmission which indicates
that the transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speed
is indicated by propshaft speed measurement.

Input/Output diagram
TOD control unit and main wiring harness is linked by 30 pin
connector. Each pin joins with switche and actuator whose
details refer to the below diagram.
Battery Power 4 22 CAN H

19
Ignition ON/OFF 5
23 CAN L
Position Encoder 1 27
2 Shift Motor output port

10
(LO-HI)
Position Encoder 2 15
1 Shift Motor output port

Position Encoder 3 28 (HI-LO)
14
Position Encoder 4 30 3 EMC
4H / 4L Switch Signal 9
21 '4L' Indicator
A/T “N” Position Signal 24
6 Position Return
Speed / TPS Supply 16
7 '4WD CHECK' IND

Front Speed Sensor Input 11
Rear Speed Sensor Input 29 13 TPS/speed Sensor Ground

(Speed / TPS Return)
ABS Operation Signal 25

20 K-Line
Brake Switch Signal 26
17
18

Classification of Pin No.
Classification Pin No. Pin Name Description
17,18 Ground TOD control unit ground

Power Supply
4,19 Battery TOD control unit battery supply : (Fuse No 13,20A)
Signal Input 5 Ignition Ignition ON / OFF
27 Position 1 Position encoder 1 : check of shift motor position
9 4H/4L Switch Transfer case mode input
24 Auto T/M Neutral Check of neutral gear position in Auto T/M

16 Speed 5V supply (TPS / speed sensor)
11 Front Speed Front speed sensor signal input
29 Rear Speed Rear speed sensor signal input
25 ABS Operation ABS ON / OFF
6 Position Return Position encoder ground
13 Speed / TPS Return Ground for speed sensor / TPS
22 CAN-L CAN bus low line
23 CAN-H CAN bus high line
Signal Output 2,15 Motor LO-HI Motor output port

- LO to HI : join with battery
- HI to LO (or motor brake) : join with ground
1,14 Motor HI-LO Motor output port

- HI to LO : join with battery
- LO to HI (or motor brake) : join with ground
3 EMC TOD output

21 4L Illumination Illuminates “4L” indicator
7 Diagnosis Display 4WD check lamp illuminator

- Upon defect ; Ground circuit
20 K-LINE1) Diagnosis
1. K-LINE : Communication line for coding and diagnosis with SCANNER.

Initial Operation of TOD Control Unit
When ignition “ON”, “4L” and "4WD check" lamps illuminates
for 0.6second to check bulb in instrument panel, then perform
diagnosis of system.
Position Encoder
The Position Encoder is used by the TCCU to determine the
position of the Shift Motor. Each motor position is identified by
a position code as shown.
Position Code 1/2/3/4 Motor Position Position Code 1/2/3/4 Motor Position
1110 Left Stop 1001 Neutral
1010 Left of High 0001 Zone 2
0010 High 0101 Low
0000 Right of High 0100 Right Stop
1110 Zone 1
Notice
1. All other position codes are invalid
2. Position Input Open Circuit (> 4.5V) = 1
3. Position Input shorted to Speed/Position Return (< 0.5V) = 0

Position Sensor Interpretation
1. When the module powers up, it will read the position sensor
and the 4H/4L switch input and respond to the possible
codes as follows
4H/4L Switch Input Motor Position Action

4H Left Stop No action required. 4L bulb off.
4H Left of High No action required. 4L bulb off.
4H High No action required. 4L bulb off.
4H Right of High Blink 4L bulb. After the shift conditions are met, attempt a shift
to 4H under conditions of below 87 rpm in front and rear
propshaft and “Neutral” position. After succesfully shifting into
4H, stop blinking 4L bulb.
4H Zone 1 Same as above
4H Neutral Same as above
4H Zone 2 Same as above
4H Low Same as above
4H Right Stop Same as above
4L Left Stop Blink 4L bulb. After the shift conditions are met, attempt a shift
to 4L. After succesfully shifting into 4L, stop blinking 4L bulb.
4L Left of High Same as above
4L High Same as above
4L Right of High Same as above
4L Zone 1 Same as above
4L Neutral Same as above
4L Zone 2 Same as above
4L Low No action required. 4L bulb on.
4L Right Stop No action required. 4L bulb on.
2. A command to shift will only be acted upon if the TCCU is

reading a valid code at the time the command to shift is
made.
3. After a shift has started, the TCCU will power the shift motor
until the code for the requested position is read. If an invalid
code is read, the TCCU will go into a default mode.
4. During a shift attempt, the shift motor will be energized for a
maximum of 5 seconds.

Electric Shift System Operation
The Electric Shift System is responsible for changing the Transfer Case gear ratio by controlling the electric shift
motor. The TCCU monitors the 4H/4L switch, neutral switch, speed sensors, position encoder, and ignition switch.
A range change is initiated when
1. The 4H/4L Switch is changed from 4H to 4L or from 4L to 4H.
2. The motor position (as indicated by the position encoder) does not match the 4H/4L Switch immediately after the
ignition is turned on.
1. Shift Criteria
When a range change is initiated a Diagnostic Test will be completed on the motor, speed sensors, and position
encoder. If the Diagnostic Test fails, the shift will not be attempted. If all components are operating properly, the
TCCU will attempt a range change after the following shift criteria are met:
a. The transmission is in neutral for 2 seconds after the shift is requested.
b. Both propshaft speeds are below 87 rpm (2580 pulses/minute).
If the transmission is taken out of neutral before 2 seconds has elapsed, or either propshaft speed increases
above the limit, the shift will be suspended and the 4L Indicator will continue to blink until the criteria are met again
or the 4H/4L Switch is returned to the original position.
2. Range Change
When the shift criteria are met, the motor is rotated in the appropriate direction (as determined by the selector
switch) until one of the following occurs:
a. The motor reaches its destination.
b. The motor is on for 5 seconds without reaching its destination. The shift has failed and the TCCU will respond
as default mode.
c. A fault occurs with either the motor or position encoder. Refer to the diagnosis requirement.
When the motor is energized, the Ignition, 4H/4L Switch, propshaft speeds, and transmission neutral inputs are
ignored.
3. Indicator Function
Once a range change has been initiated the 4L Indicator will begin to blink at a rate of 0.3 seconds on, 0.3
seconds off until the shift is completed or canceled.
If a successful shift has been completed, the 4L Indicator will be illuminated if the motor is in Low and it will be
turned off if the motor is in High.
4L Indicator illuminates as below figure.
·4H ® 4L ·4L ® 4H
@ : shift is completed @ : shift is completed

4. Electric Shift Default Mode
If the motor fails to reach its destination, the TCCU will attempt the following (in order):
a. The TCCU will wait 3 seconds then attempt the shift again.
b. If the second attempt to reach the destination fails the TCCU will wait 3 seconds then attempt to rotate the
motor back to the original position. If successful, all future shifts will be inhibited until the Ignition is cycled.
c. If the attempt to return to the original position fails, the TCCU will wait 3 seconds then attempt to rotate the
motor to the original position again. If the second attempt to return to the original position is successful, the
“4WD CHECK” lamp will be illuminated, and all future shifts will be inhibited until the Ignition is cycled.
d. If the second attempt to return to the original position fails the motor will be turned off, the “4WD CHECK” lamp
will be illuminated, and all future shifts will be inhibited until the Ignition is cycled.
TODTM System Operation
The TODTM System is responsible for distributing torque between the front and rear axles. The TCCU monitors the
propshaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to
the front axle by Pulse Width Modulating the current applied to the EMC.
1. Touch-off Torque
The minimum EMC Duty Cycle is based on the vehicle speed and throttle position
The TCCU receives the TPS signal from the following sources:
On vehicles equipped with CAN, the TCCU receives the TPS signal from the CAN bus.
2. When Slip Detection
The TCCU continuously monitors the front and rear propshaft speeds to detect wheel slip.
3. Wheel Slip Control
When wheel slip is detected the TCCU controls the EMC duty cycle as necessary until the wheel slip is reduced
below the allowable limit. The EMC Duty Cycle will then be reduced to the Touch-Off value.
4. Brake/ABS Strategy
When the ABS System is active, the EMC Duty Cycle is set to a fixed duty cycle (30%) to aid in braking without
counteracting the ABS System.
5. 4L Strategy
When the system is operating in 4L, the TCCU continues TODTM (operation provided that the propshaft speed is
below 175 rpm (5220 pulses/minute)). When the speed increases above 175 rpm, the EMC Duty Cycle is set to
the maximum value (88%) which applies the maximum available torque to the front axle.

TOD CONTROL UNIT
Location of TOD Control Unit

It locates below front left handed seat towards door side, which is beside rear heating duct on the floor.
Shape and function of TOD Control Unit

Pin Function Pin Function Pin Function Pin Function

1 Motor HI-LO 9 HI / LO Switch 17 Ground 25 ABS Input
2 Motor LO-HI 10 Position 2 18 Ground 26 Brake Switch
3 EMC 11 Front Speed 19 Battery (+) 27 Position 1
4 Battery (+) 12 TPS Supply (Diesel) 20 K-LINE 28 Position 3
5 Ignition 13 Speed/TPS Return 21 4L Illumination 29 Rear Speed
6 Position Return 14 Motor HI-LO 22 CAN-H 30 Position 4
7 Diagnosis Display 15 Motor LO-HI 23 CAN-L - -
8 - 16 Speed Reference 24 Auto T/M, Neutral - -
Speed Sensor/Clutch Coil and Motor Connector

Speed senso /clutch coil and shift motor connector locate upper
backside transfer case (upper part of shift motor).
- Shift motor connector : Black
- Speed sensor and clutch coil connector : White
Shift Mtor Connector Speed Sensor/Clutch Coil Connector
Rear View for Connector Rear View for Connector

Pin Function Pin Function
A Position 4 H Clutch Coil (EMC)
B Motor (Counter-Clockwise) I Front Speed Return
C Position 3 J Front Speed
D Position 2 K Front Speed Sensor Supply
E Position 1 L Rear Speed Sensor Supply
F Position Retum M Rear Speed
G Motor (Clockwise) N Rear Speed Return

14
Motor HI-LO(clockwise)
Motor LO-HI(counterclockwise)
TOD CONTROL UNIT
PIN 13

DIAGNOSIS
While the TCCU is active it periodically monitors its inputs and outputs. If a fault is detected the “4WD CHECK” lamp
is illuminated and a fault code is stored in the TCCU memory.
When requested, fault codes are downloaded to a diagnostic connector (K-line) serial communications using SCAN-
100.
DIAGNOSTIC TESTS
1.TCCU Internal Function
When the Ignition is turned on the TCCU tests its ROM and RAM. If there is a fault, the TCCU immediately resets
itself and re-tests the ROM and RAM. If the fault persists the TCCU continues to reset and re-test until the fault is
corrected or the ignition is turned off. All TCCU functions are inhibited until the fault is corrected. The “4WD
CHECK” lamp is not illuminated if there is a ROM or RAM fault.
If the ROM/RAM passes the EEPROM memory is tested. If there is a fault the “4WD CHECK” lamp is illuminated
and the TCCU continues to operate using the default calibration data stored in ROM. Fault codes are not stored
when there is an EEPROM fault.
An EEPROM fault can only be cleared by cycling ignition off-on.
2.Shift Motor Assembly Test
If the TCCU detects a shift motor or position encoder fault continuously for one second the ‘4WD CHECK” lamp is
turned on and the appropriate fault code is stored in memory.
a. A shift motor fault when the motor is off is defined as follows:
Motor H-L shorted to Ground
Motor L-H shorted to Ground
Motor open circuit
b. A shift motor fault when the motor is energized is defined as follows:
Motor H-L shorted to Ground
Motor L-H shorted to Ground
Motor H-L shorted to Motor L-H
Motor open circuit
c. A position encoder fault is defined as follows:
Any position code which does not correspond to the valid 9 codes.
A short to ground on any of the encoder lines.
d. If no shifts are in progress when a failure occurs the TCCU will not respond to any shift commands.
e. If a shift command has been received, but not acted upon when a failure occurs the TCCU will cancel the
command and not respond to any subsequent shift commands.
f. If a shift command is in progress when an invalid position code is confirmed it will be halted and the TCCU will
turn the motor toward the high position. Afterwards the TCCU will not respond to any shift commands.

g. If the shift motor/position encoder assembly failure (other than a motor failure which occurs when the motor is
energized) recovers continuously for one second the TCCU will function normally. The “4WD CHECK” lamp is
turned off but the fault code will remain in memory.
h. A motor failure (i.e. open or short circuit) which occurs when the motor is energized can only be cleared by
cycling the ignition off-on.
3. Front Speed Sensor Test

If a Front Speed Sensor fault is detected continuously for 0.5 second the “4WD CHECK” lamp is illuminated. The
TCCU then responds as follows:
a. If the system is in High Range the TCCU uses the Rear Speed Sensor to determine the EMC Touch Off level
and wheel slip control is suspended.
b. If the system is in Low Range, the EMC Duty Cycle is set to maximum (independent of vehicle speed) until the
system is shifted out of 4L.
c. All Electric Shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed.
If the Front Speed Sensor recovers continuously for O.5 second the TCCU will function normally. The “4WD
CHECK” lamp is turned off but the fault code will remain in memory.
4. Rear Speed Sensor Test

If a Rear Speed Sensor fault is detected continuously for 0.5 second the “4WD CHECK” lamp is illuminated. The
TCCU then responds as follows:
a. If the system is in High Range the TCCU uses the Front Speed Sensor to determine the EMC Touch Off level
and wheel slip control is suspended.
b. If the system is in Low Range, the EMC Duty Cycle is set to maximum (independent of vehicle speed) until the
system is shifted out of 4L.
If the Rear Speed Sensor recovers continuously for 0.5 second the TCCU will function normally. The “4WD
CHECK” lamp is turned off but the fault code will remain in memory.
5. Both Speed Sensor Faulty

If both the Front and Rear Speed Sensors are faulty continuously for 0.5 seconds the “4WD CHECK” lamp is
illuminated. The TCCU then responds as follows:
a. If the system is in High Range the TCCU sets the EMC Touch Off level based on a vehicle speed of 0 and wheel
slip control is suspended.
b. If the system is in Low Range, the EMC Duty Cycle is set to maximum until the system is shifted out of 4L.
If both Speed Sensors recover continuously for 0.5 second the TCCU will function normally. The “4WD CHECK”
lamp is turned off but the fault code will remain in memory.
6. EMC Test
The EMC is tested for open circuit or short circuit to ground. If a fault is detected continuously for 0.8 second the
“4WD CHECK” lamp is turned on and all TODTM activity is halted.
If the EMC recovers continuously for 0.8 second the TCCU will function normally. The “4WD CHECK” lamp is
turned off but the fault code will remain in memory.

DIAGNOSTIC TROUBLE CODES

(DTC’S)
1. Diagnostic Trouble Code Retention
The first time a fault is detected a DTC is stored in the TCCU’s
Non-Volatile memory. This DTC will remain in memory until
the TCCU is instructed to erase DTC’s by SCAN-100. DTC’s
will not be erased by disconnecting power to the TCCU.
2. Diagnostic Trouble Code Assignments
Classification Code Description
TCCU 1714 EEPROM Checksum Fault
1715 TPS Loss of Signal
1716 TPS Out of Range
EMC 1721 EMC Open / Short to Battery
1722 EMC Short to ground
Speed Sensor 1731 Front Speed Sensor Voltage Low
1732 Front Speed Sensor Voltage High
1733 Rear Speed Sensor Voltage Low
1734 Rear Speed Sensor Voltage High
1735 Speed Sensor Reference Voltage Low
1736 Speed Sensor Reference Voltage High
Shift Motor 1741 Motor Open / Shorted to Battery
1742 Motor Output Shorted to Ground
1743 Shift System Timeout
Position Encoder 1750 General Position Encoder Fault (Invalid Code)
1751 Position 1 Shorted to Ground

CODING
Coding Tool
SCANNER
Connection of Coding Tool

Construct SCANNER into diagnosis connector (20 pins) near fuse box in engine room as below figure.
1 Diagnosis Connector 2 SCANNER
Notice
Coding ; An input activity of data for the proper
performance by matching specification, devices and
system with control unit.

Coding Required
1. Replacement of TOD control unit.
2. Adjustment by input error.
3. Change of tire specification.
Coding items
Classification Items
Engine Type Gasoline Engine (E32)
661 Diesel Engine
661LA Diesel Turbo Engine
662 Diesel Engine
662LA Diesel Turbo Engine
Transmission/Vehicle Type Manual Transmission
Automatic Transmission
MUSSO
KORANDO
Axle Ratio 3.73
4.55
4.89
5.38
5.86
Tire Size P215
P235
P255
P275
Coding Method
1. Check and record engine type, axle ratio and tire size.
2. Ignition “OFF”.
3. Connect SCANNER with diagnosis connector in engine
room.
4. Ignition “ON”.
5. Read the current memorized specification in TOD control
unit.
6. Compare memorized specification with the checked record.
If not matched, perform a coding.
7. Read again memorized coding specification in TOD control
unit for confirmation of coding.
8. Check coding specification whether it matches with vehicle
or not. If not, perform a coding again.

ELIMINATE THE MEMORIZED FAULT

CODE
When diagnose by SCANNER, it is required that you make
adequate service on defects against all fault codes. And then
you should delete the memorized fault codes in TOD control
unit using SCANNER as follows;
1. Connect SCANNER with diagnosis connector.
2. Select “trouble code clear” in SCANNER.
3. In “trouble code clear” screen, press “enter” key to erase
the fault code.
4. Confirm deletion of fault code and, if not, repeat 2.-3.
process.

DIAGNOSIS
Malfunction interior TOD control unit ; fault code
1714
l Phenomenon
1. When ignition “ON”, “4WD CHECK” lamp illuminates
continuously.
2. On diagnosis by SCAN-100, it displays fault code “1714”.
l Cause ; Error of EEPROM checksum in TOD control unit
Test Stage / Contents Result

Specified Value Countermeasure
Stage Test Contents and Procedure
/Yes/No
Check power supply for TOD control unit.
1. Disconnect 30 pin connector from TOD control unit.
A1 3. Using multi-tester, measure voltage between pin 5(+)
and 17/18 (-). 11-14 Vdc
- Specified value Yes Perform A2 stage
- Measured value is within specified range ? No Perform A3 stage
Check connection status in TOD control unit connector.

1. Check connection status.
- Is it connected exactly? Yes Perform A3 stage
No Perform A2 stage
2. In case of mal-connection, connect tightly then perform
A2 the follows.
a. Delete fault code using Scan-100.
b. Ignition “OFF”.
c. Ignition “ON”.
d. Diagnose by Scan-100. Yes Perform A3 stage
- Does it display fault code “1714”? No Normal system
Check short of 10A fuse (fuse No.20).

1. Detach No.20 fuse from engine room fuse box.
A3 2. Check the existence of short.
- Is fuse normal? Yes Perform A4 stage
No Replace fuse, then
perform A1 stage
Check ground of TOD control unit.
2. Check voltage between 4/19 (+) pin and 17/18 (-)
using multi-tester (keep connection status).
- Specified value (battery is good) 12Vdc (battery
voltage)
A4 - Measured value Yes Perform A4-3 stage
No Replace TOD control
3. Check short between 17/18 pin and body after unit
disconnect 30 pin connector.
- Is resistance "¥"? Yes Repair ground wiring
No Ground is O.K.,
perform A5 stage


/Yes/No
Check function of TOD control unit.
1. Even A1, A2, A3 and A4 test, if you could not find defect,
it is required to replace TOD control unit on basis of
below phenomena.
a. ”4WD CHECK” lamp illuminates continuously when
ignition “ON”.
A5 b. Shift is not possible even 4H/4L switch operation.
c. Upon diagnosis by Scan-100, it displays on
“impossible communication with TOD control unit”
or fault code “1714, 1715, 1716”.
- Do occur the above defects? Yes Replace TOD control
unit
No Normal system

Error of signal in engine throttle position ; fault
code 1715, 1716
l Phenomenon
1. Upon diagnosis by SCAN-100, it display on 1715,
1716 codes.
l Cause
1. Bad communication line between E/G ECU and CAN.
2. Defect of TOD control unit.
3. Defect of E/G ECU.

/Yes/No
Check connection status of connector through CAN
communication line.
1. Check connection of connector.
- Does connector connect correctly between TOD Yes Perform B2 stage
control unit and E/G ECU? No Perform B1-2 stage
2. In case of bad connection, connect correctly then
B1 perform the follows ;
a. Delete the memorized fault code using SCANNER.
d. Diagnose by SCANNER.
- Does it display fault codes “1715” or “1716”. Yes Perform B2 stage
No Normal system
Check connection status of CAN communication line towards
E/G ECU.
2. Disconnect 30 pin connector towards TOD control unit.
3. Measure resistance between pin No.22 and 23 in wiring
B2 connector using multi-tester.
- Specified value 115-125W
- Measured value is within specified range? Yes Perform B3 STAGE
No Perform B4 stage,
check and replace E/
G ECU
Check connection status of CAN communication line towards
TOD control unit.
2. Disconnect coupling of E/G ECU (gray, 1-60 pin).
3. Measure resistance between pin No.37 and 38 in
B3 coupling using multi-tester.
- Specified value 115-125W
- Measured value is within specified range? Yes Perform B5 STAGE
unit


/Yes/No
Check CAN communication line by diagnosis of E/G ECU.
1. Diagnose E/G ECU with SCANNER.
B4 2. Does it display on fault code “27”? Yes Perform B1, B2, B3
stages
No Perform B5 stage
Check power supply and signal output on throttle valve
position sensor (potentiometer) 1,2.
1. Diagnose E/G ECU with SCANNER.
- Fault codes : 104, 105, 108, 109, 119, 185
B5 Does it display on above code ? Yes Perform B6 stage
unit or perform A1-
A5 stages
Check power supply (5V) of throttle valve position sensor.
1. Ignition “ON”
2. Measure voltage between pin 112(+) and 84(-) keeping
coupling connection status using multi - tester.
- Specified value
B6 - Measured value is within specified range? 4.75-5.25Vdc
Yes Perform B7 stage
No Replace E/G ECU or
perform B1-2 stage
after checking cable.
Check output signal from throttle position sensor 1 and 2.
1. Keep E/G idle status.
2. Measure output voltage between pin 87 (+) and 84 (-)
keeping E/G ECU coupling connection status using multi-
tester. (potentiometer 1)
- Specified value min. acc. Pedal 0.3-0.9Vdc
max. acc. Pedal 4.6-4.9Vdc
- Measured value is within specified range? Yes Perform B7-3 stage
No Replace throttle body
actuator or check
B7 cable.
3. Measure output voltage between pin 85 (+) and 84 (-)
keeping E/G ECU coupling connection status using multi-
tester. (potentiometer 2)
- Specified value min. acc. Pedal 4.6-4.9Vdc
max. acc. Pedal 0.3-0.9Vdc
- Measured value is within specified range ? Yes Replace TOD control
unit
No Replace throttle body
actuator or check
cable

Error in electro - magnetic clutch : fault code
“1721”, “1722”
l Phenomenon
1. Upon diagnosis by SCAN-100, it displays on fault
codes “1721,1722”.
l Cause
1. Defect in electro - magnetic clutch
2. Defect in connector or wiring
- Open or short from EMC to the supply : 1721
- Short EMC to ground : 1722

/Yes/No
Check relevant connector connection status.
1. Check relevant connector connection status with TOD
control unit.
- Does it connect correctly ? Yes Perform C1-2 stage
No Perform C1-3 stage
2. Check connection status of speed sensor and clutch
coil connector (7 pin) in transfer case.
- Does it connect correctly ? Yes Perform C2 stage
C1
3. In case of bad connection, connect it correctly then
perform the follows :
a. Delete the memorized fault code in control unit with
Scan - 100.
d. Diagnose by SCAN-100
- Does it display on fault codes “1721,1722” ? Yes Perform C2 stage
No Normal system
Check supply voltage into electro-magnetic clutch.

1. Ignition “ON”
2. Measure voltage between pin 4/19(+) and 17/18(-) in
TOD control unit connector.
- Specified value 11-15Vdc
- Measured value is within specified range ? Yes Perform C3 stage
3. If the specified value would not be measured, perform
C2 the follows :
a. Check battery voltage (charging condition)
b. Check open circuit on No.13 fuse (20A)
c. Check relevant wires.
- Is the above 3a, 3b, 3c normal ? Yes Perform C3 stage
No l Charging/
Replace battery
l Replace fuse
l Repair wires


/Yes/No
Check resistance of electro-magnetic clutch.
1. Disconnect 30 pin connector from TOD control unit.
2. Measure resistance between pin 3 and 7 in wiring
C3 connector using multi-tester.
- Specified value 2.5W
- Measured value is within specified range? Yes Perform C4 stage
No l 0W : short
l ¥ W : open

Defect in speed sensor : fault code 1731, 1732,
1733, 1734, 1735,1736
l Phenomenon
1. Upon diagnosis by SCANNER, it displays on fault code
1731, 1732, 1733, 1734, 1735 and 1736.
2. “4WD CHECK” lamp illuminates continuously when
ignition “ON”.
l Cause
1. Defect of speed sensor (front, rear).
2. Defect of power supply.

/Yes/No
Check power supply of speed sensor.
1. Ignition “ON” or driving mode
2. Measure supply voltage between pin 16 (+) and 13 (-) in
D1
TOD control unit connector using digital multi-tester.
- Specified value 4.75-5.25Vdc
- Measured value is within specified range ? Yes Perform D3 stage
No Perform D2 stage
Check connection status of connector.
1. Check connection status of speed sensor/clutch coil

connector and TOD control unit connector.
- Does it connect correctly ? Yes Perform D3 stage
No Perform D2-2 stage
2. In case of bad connection, connect it correctly then
D2 perform the follows:
a. Delete the memorized fault code in control unit by
SCANNER.
d. Diagnose by SCANNER.
- It does not display fault code. Yes Normal system
- It displays one or more fault code among 1731 to Yes Perform D3 stage
1736.
Check output wave of front and rear speed sensor.
1. Upon driving mode.

2. Check output wave of each speed sensor by SCANNER.
D3 3. Is it normal on output wave? Yes Perform D4 stage
No Replace speed
sensor then
perform D2-2 stage


/Yes/No
Check output voltage of front and rear speed sensor.
1. Upon driving mode
2. Measure output voltage of front and rear speed sensor
by multi-tester. Check voltage whether it varies within
specified range.
- Specified value
• Front speed sensor
: Pin 11(+), 13(-) in TOD control unit connector
D4 • Rear speed sensor
: Pin 29(+), 13(-) in TOD control unit connector
- Measure value is within specified range ? Yes Check function of
control unit.
It necessary,
replace then delete
fault codes and re-
diagnose .
No Perform D5 stage

Shift motor malfunction : Fault code ® 1741,
1742, 1743
l Phenomenon
1. When change the 4H/4L switch from 4H to 4L, ‘4L’
indicator lamp turn off after blinking for a time and then
‘4WD CHECK’ indicator lamp turn on.
2. Fault codes display by diagnosis of SCAN-100 : 1741,
1742, 1743
3. The shifting operation is not occurred when 4H / 4L switch,
is operating.
l Cause
Defect in shift motor, improper voltage provided, incorrect
connection in connector, short of wiring.

/Yes/No
Check the input voltage of shift motor.
1. Turn the ignition switch to “ON” position.
2. Measure the Hi/Low voltage of motor which is located
between No.1/No.14 and No.2/No.15 connector of TOD
control unit with digital Multi-tester or which is located
between No.G connector and body after detaching T/C
motor connector.
E1 - The specified value (When operates 4H/4L switch) 11-14 V
(Battery voltage)
- Measured value is within specified range ? Yes Perform E1-3 stage
3. Measure the Hi/Low voltage of motor which is located No Perform E2 stage
between No.2/No.5 and No.1/No.14 connector or which
is located No.B connector and body after detaching T/C
motor connector
- The specified value (When operates 4H/4L switch) 11-14 V
(Battery voltage)
- Measured value is within specified range ? Yes Perform E4 stage
No Perform E2 stage
Check the fault condition of the relevant connector.

1. Check the installation condition of TOD control unit 30pin
connector and T/C shift motor connector.
- Is it installed properly ? Yes Perform E3 stage
No Perform E2-2 stage
2. If the connector installation is improper, install properly
E2 and then perform follows :
a. Delete the fault code of control unit by scan scope
b. Turn off the ignition switch
c. Turn on the ignition switch
d. Re-diagnosis of system
It displays one or more fault code among 1741 to 1743. Yes Perform E3 stage
No Normal system


/Yes/No
Check the wiring of shift motor whether it is shorted or not.
1. Turn off the ignition switch.
2. Detach the 30pin connector from TOD control unit
3. Perform short test between the wiring connector No.1/
No.14 and No.2/No.5.
- Is there resistance of 0W ? Yes Hi-Low motor and
Lo-Hi wiring are
shorted each other.
Repair or replace.
No Perform E3-4 stage.
E3 4. Perform the short test between No.1/No.14 Connector
and body, No2/No.15 connector and body.
- Is there resistance of 0W ? Yes Related wiring is
shorted with ground.
Repair or replace.
No Perform E3-5 stage.
5. Execute E1 stage to check whether wiring is shorted
between Hi-Low motor and LOW-HI motor.
- Is the provided voltage proper? Yes Perform E4 stage.
No Wiring is shorted.
Repair or replace.
Check the resistance of shift motor
1. Turn off the ignition switch.
2. Measure the resistance between No.1/No.14 and No.2/
No.15 connector after detaching 30pin connector of TOD
control unit Or, check the resistance between No.G and
No.B after detaching motor connector of T/C side.
E4 - Specified value
- Measured value is within specified range ?
Yes The defective T/C or
perform E5 stage.
No Replace the shift
motor.
Execute the test after detaching shift motor, when the fault
is not solved after executing E1~E4 stage.
1. Detach the motor connector from T/C.
2. Remove the shift motor.
3. Connect motor connector with the removed shift motor.
4. Operate the 4H/4L switch.
E5 - Does motor rotate ? Yes Check and fix due to
the defective T/C
ass’y.
No Replace the motor
or delete fault code
and rediagnosis
system.

Position incoder and position 1,2,3,4 malfunction
:Fault code®1750,1751,1752,1753, 1754
l Phenomenon
The ‘4WD check’ lamp can not go out when the ignition
switch positioned to ‘ON’.
The fault code display 1750, 1751, 1752, 1753, 1754 by
diagnosis of SCAN-100.
l Cause
The portion of position incoder malfunction, each wiring is
shorted with ground.

/Yes/No
Check the installation condition of connector.
1. Check the installation condition between 30 pin connector
of TOD control unit and motor connector of T/C portion.
- Is it installed properly ? Yes Perform F2 stage
No Perform F1-2 stage
2. If the connector installation is improper, install properly
F1
and then execute follow procedure.
a. Delete the all fault code from memory by scan scope.
b. Turn off ignition switch.
c.Turn on ignition switch.
d. Rediagnosis the system.
- Does the fault codes display one or more among Yes Perform F2 stage
1750 ~ 1754. No Normal system
Check the each wiring whether it is shorted or not.

1. Turn off the ignition switch
2. Detach the 30 pin connector of TOD control unit.
3. Perform short test each connector, No.27 (Position 1),
No.10 (Position 2), No.28 (Position 3),No.30 (Position
4), No.6 with body.
- Is there resistance of 0W ? Yes Repair or replace
F2 due to wiring short
No 1. Replace the
motor Ass’y due
the defective
position incoder
portion.
2. And then, perform
F1-2 stage.

l Phenomenon
“4L” lamp on cluster continuous blinking and can not go
off, when operated 4H/4L switch as 4L« 4H.
l Cause
Shifting failure.

/Yes/No
1. Stop the vehicle
2. Return the 4H/4L switch to first position (before
operating).
- The blinking of 4L indicator lamp is stopped. Yes Perform 2 stage
No Diagnose TOD
Note
control unit
G1 If the first position before switch operating is ‘4L’,
lamp goes on after stopping blink, otherwise it
is ‘4H’ lamp goes off.
3. Reoperate 4H/4L switch to 4H«4L on the below
condition.
• Positioned Auto T/M to neutral.
• At this time, keep the neutral position for 2 second.
• Stop the vehicle (The R.P.M of front & Rear propeller
shaft is below 80).
4. ‘4L’ lamp blinks based on 0.3 second.
5. When the shifting is engaged, the blinking of ‘4L’ lamp
is stopped.
- 4H®4L : goes on ‘4L’ lamp Yes Normal system
- 4L®4H : goes on ‘4L’ lamp No Perform system test
Auto T/N positioned
to neutral
Check/Replace the
relay
6. When the ‘4L’ indicator lamp continuous blinking,
repositioned to first position and diagnose the system
and then fix it.


ON-VEHICLE SERVICE
TOD CONTROL UNIT
TOD Electric Characteristics
Voltage Normal Operation Range 9 - 16 Vdc
CAN communication Operation Range 6 - 16 Vdc
Parasitic Current Ignition “OFF” 2 mA
(Under max. operation Voltage) Ignition “ON” 1A
Max. Operation Current Motor “OFF” 7A
(Under max. operation Voltage) Motor “ON” 20 A

2. Remove 30 pin connector from TOD control unit.
3. Unscrew 2 bolts (1).
Installation Notice

reverse order.
Notice
When replace TOD control unit, it is required to make a
coding correspondent with vehicle specification.
1 Bolt (M6 x 16, 2pieces) ................ 9-11 Nm
2 TOD control unit

TRANSFER CASE (TOD)
1 Transmission 5 Front Propeller Shaft

2 TOD Transfer Case 6 Bolt ....................................................... 81-89Nm
3 Extension Housing 7 Rear Propeller Shaft
4 Bolt ....................................................... 35-60Nm 8 Bolt ....................................................... 81-89Nm

1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety.
Notice
Be careful for catalytic converter due to high temperature
after driving or engine running.
3. Prepare a vessel to drain transfer case and manual
transmission oil.
4. Release drain plug and drain transfer case and manual
transmission oil.
If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Notice
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector back

side transfer case.
Notice
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect shift motor/clutch coil connect (Black 7 pin)
connector upper backside.
7. Disconnect front and rear speed sensor connector (white
7 pin).
8. Disconnect speedometer sensor connector right upper
side.
9. Disconnect breather tube front upper side transfer case

(upper connecting point of transfer case and front
propeller).
10. Prepare hydraulic jack and support transfer case assembly.

11. Unscrew 4 units of M12 bolts from case flange then
disconnect front propeller shaft from transfer case.
Installation Notice
12. Unscrew 4 units of M12 bolts from case flange then

disconnect rear propeller shaft from transfer case.
Installation Notice
13. Unscrew 5 units of mounting bolt (M12) from extension

housing in transmission.
Installation Notice
Notice
Make sure the connecting surface is clean.
Applying long-life grease spline inside transfer case input
shaft.

reverse order.

Replacement of Shift Motor
2. Disconnect shift motor/clutch coil connector (black pin7)
upper backside.
3. Unscrew 3 units of shift motor mounting bolts (M10).
4. Unscrew 1unit of bracket mounting bolt (M10).
Installation Notice
Notice
When disconnecting shift motor and mounting bracket, it is
required to unscrew 2 units of adjusting bolts (M10) form
motor and bracket.
5. Keep shift motor even then pull rearward.
6. Clean connection surface of transfer case and shift motor.
7. If necessary, make a test by SCAN-100 with shift motor
assembly.
Notice
Do not disassemble shift motor. If necessary, replace by
shift motor assembly unit.
8. Applying sealant into connecting surface for new shift motor.
reverse order. Before installation, make sure that motor
position match with mode of 4H/4L switch.
Reference
When accord position of motor with 4H/4L switch and transfer
case match position of the disconnected motor and new
one.

SPEED SENSOR IN FRONT AND REAR

PROPELLER SHAFT
2. Detach shift motor assembly.
3. Disconnect front and rear speed sensor connector (white 3
pin) upper backside transfer case.
4. Disconnect speed sensor connect from locking sleeve by
pushing.
5. Disconnect wire stick cap from the detached connector.
6. Unscrew rear speed sensor mounting bolt (M10) from upper

side of rear case flange.
7. Detach sensor from transfer case by lifting up using tool.

Notice
When disconnect sensor, make sure on adequate pressure
due to sensitiveness with shock.
8. Disconnect taping from both protection tube ends that wrap

3 wires of speed sensor and 1 wire of clutch coil.
9. Disconnect tube.

10. Disconnect pin and wire from speed sensor connector by
pulling sticking long-nose plier into “L” pin in connector.
11. On the same way, disconnect pin and wire “M” and “N”
from connector.
Notice
Do not touch the wires related with EMC.
12. Prepare new speed sensor.

13. Connect 3 pins with wires of speed sensor to coincide with
each connection position.
14. Using long-nose plier, connect tightly by pulling pins.
15. Apply rubber cap into connector using long-nose plier not
to detach.
16. Connect protection tube with wire.
17. Tape both ends of tube.
18. Putting rear speed sensor into hole, connect exactly
pushing both ends.
19. Screw 1 unit of bolt (M10).
Installation Notice
20. Connect speed sensor connector, then locking sleeve.

Reference
Front propeller shaft should be premised by removal of
shift motor.
After disconnecting shift motor, procedure of replacement
on sensor assembly of accords with one of rear speed
sensor.

REPLACEMENT OF OIL
Oil Specification
Standard A.T.F S-3, S-4 or Dexron II, III
Specification .
Capacity =. 1.4 Litre
Service Inspection every 15,000km, Replacement every 50,000km
Specified Oil Level
Oil Replacement
1. Lift on vehicle then make sure on safety.
2. Prepare a vessel to drain transfer case oil.
3. Release filler plug.
4. Drain oil completely.
5. Wash drain plug and than tighten.
Installation Notice
6. Replenish standardized oil by specified level through filler

plug hole.
7. Tighten filler plug after washing.
Installation Notice
8. Check oil leakage.

UNIT REPAIR
TRANSFER CASE

1 Bearing 42 Shift Rail
2 Bushing 43 Shaft, Shift
3 Carrier Assembly 44 Spacer
4 Sun Gear 45 Torsion Spring
5 Thrust Plate 46 Shift Cam
6 Input Shaft 47 Transfer Case Shift Motor
7 Output Shaft Thrust Washer 48 Bolt
8 Bearing 49 J-clip
9 Retaining Ring 50 Connector Retainer
10 Snap Ring 51 Bolt
11 High-low Collar 52 Support Stud
12 Rear Output Shaft 53 Lower Speed Sensor (Front)
13 Oil Strainer 54 Plug
14 Coupling Hose 55 Identification Decal
15 Hose Clamp 56 Cover
16 Pump Assembly 57 Tone Wheel, Lower
17 Thrust Washer 58 Chain, Drive
18 Sprocket, Drive (24T) 59 Sprocket, Driven (24T)
19 Clutch Pack Assembly 61 Magnet
20 Insulator Washer 62 Case
21 Armature 63 Case Flange and Output Shaft
22 Snap Ring 64 Barb, Breather
23 Wave Washer 68 Spiral Pin
24 Apply Cam 69 Oil Seal
25 Ball 70 Pin, Dowel
26 Cam and Coil Assembly 71 Ring Gear
27 Nut, Metric 72 Retaining Ring
28 Output Shaft Yoke Washer 73 Snap Ring
29 Oil Seal 74 Bearing
30 Case Flange 75 Snap Ring
31 Bolt 76 Bearing
32 Upper Speed Sensor (Rear) 77 Speedometer Drive Gear
33 Nut 78 Facing, Shift Fork
34 Washer 79 Upper Tone Wheel
37 Bolt 80 Oil Seal
38 Tag, Identification 81 Bearing Sleeve
39 Thrust Bearing 82 Bearing
40 Clutch Coil Assembly
41 Fork, Reduction Shift

1. Disconnect transfer case from vehicle
2. Using a 30mm thin-wall socket, first remove the rear output
nut, output shaft yoke washer, oil seal then the case flange.
Installation Notice
3. Disconnect shift motor/clutch coil connector and speed
sensor connector from upper bracket of transfer case.
Notice
When disconnect connector, pull forwards grasping
connector housing.
27 Nut
4. Remove outer tube on speed sensor connector. 28 Washer
30 Case Flange
5. Remove wire supporting cape back side of speed sensor
connector.
6. Disconnect pin of clutch coil wire (yellow) from speed sensor
connector (white 7 pin) using long-nose plier.
7. Remove shift motor.
Notice
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
8. Disconnect front and rear speed sensor.

9. Remove the bolts that retain the front case to the
rear case. Make sure that the front case is facing
downward so that the rear cover is facing upwards.
Pry on the bosses and separate the front case from
the rear case. Remove all traces of gasket sealant
from the mating surfaces of the front case and rear
case.
10. If the speedometer drive gear is to be replaced, first
remove the flange seal by prying and pulling the
curved-up lip of the flange seal. Do not damage the
bearing, bearing cage or case. Remove and discard
the flange seal. Remove the speedometer drive gear
and upper tone wheel.
69 Yoke to Flange Seal
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
79 Upper Tone Wheel
11. If the rear output shaft bearing requires replacing, remove

the internal snap ring that retains the bearing in the bore.
From the outside of the case, drive out the bearing.
12. Remove the three nuts and washers retaining the clutch
coil assembly to the rear case. Pull the assembly, along
with the O-ring and wire, from the case.
40 Clutch Coil
40a Clutch Coil Retaining Bolts
40b Wire
13. Remove bearing assembly from output shaft.

Remove the clutch housing from the output shaft.
Remove the balls and apply cam and wave washer from
the output shaft.
Remove snap ring from output shaft. Remove clutch pack
assembly from output shaft.
25 Ball
26 Cam and Coil Assembly

19 Clutch Pack Assembly

22 Snap Ring
23 Wave Washer
24 Apply Cam
14. Remove the chain, driven sprocket and drive sprocket

as an assembly.
15. Remove thrust washer from output shaft.
16. Remove the magnet from the slot in the front of the case
bottom. Remove the output shaft and oil pump as an
assembly.
Notice
If there is removal resistance, do not pound or use force
to disassemble the pump.
17. If required, to remove the pump from the output shaft,
rotate the pump to align.
18. Pull out the shift rail.
18 Drive Sprocket
58 Drive Chain
59 Driven Sprocket
19. Remove the helical cam from the front case. If required,
remove the helical cam, torsion spring and sleeve from
the shaft.
20. Remove the high-low range shift fork and collar as an
assembly.
21. Expand the tangs of the large snap ring in the case. With
the input shaft against a bench, push the case down and
slide the main drive gear bearing retainer off the bearing.
Lift the input shaft and front planet from the case.
22. If required, remove the oil seal from the case by prying
and pulling on the curved-up lip of the oil seal. Do not
damage the bearing, bearing cage or case.
12 Rear Output Shaft

16 Oil Pump
61 Magnet

23. Remove the internal snap ring from the planetary carrier
and separate the front planet from the input shaft.
24. Remove the external snap ring from the input shaft. Place
the input shaft in a vise and remove the bearing. Remove
the thrust washer, thrust plate and the sun gear off the
input shaft.
25. Inspect the bushing and needle bearing in the end of the
input shaft for wear or damage.
Notice
Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing and needle bearing must be replaced as a set.
26. If replacement of the needle bearing and bushing is

required, press the bearing and bushing is required, press
the bearing and bushing out as follows: 6 Input Shaft
8 Bearig
a. Position the input shaft on Axle Bearing/Seal plate,and 01 Pinion Bearing Cone Remover
using Pinion Bearing Cone Replacer as a spacer. 02 Compress the Dowel
b. Insert Input Shaft Bearing Remover into the input shaft
so it is resting on top of the bearing cage.
c. Tighten the actuator pin until it stops, then press the
bearing and bushing out together.
27. If required, remove the front yoke to flange seal by prying

and pulling on the curved-up lip of the yoke to flange seal.
Do not damage the bearing, bearing cage or case.
28. If required, remove the internal snap ring retaining the
front output shaft ball bearing and remove the bearing.

Assembly Procedure
Assembly
Before assembly, lubricate all parts with Automatic Transmission
Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.
Drive the bearing in staight, making sure it is not cocked in
the bore. Install the internal snap ring that retains the bearing
to the front case.
2. If removed, install the front yoke to flange seal in the front
case bore.
3. If removed, install the yoke to flange seal into the mounting
adapter bore.
4. If the input shaft needle bearing and bushing were removed,

install a new bearing and bushing as detailed in the following
steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or
equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove
on the bearing outer race should be toward the rear of the
transfer case. The stepped face of the thrust washer should
face toward the bearing.
Slide the sun gear, thrust plate and thrust washer into
position on the input shaft. Press the bearing over the input
shaft. Install the external snap ring to the input shaft.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring

6. Install the front planet to the sun gear and input shaft.
Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring
with snap ring pliers and install planetary carrier assembly.
Check installation by holding the case and carefully tapping
the face of the input shaft against a wooden block to make
sure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an
assembly into the front planet.
Notice
Make sure that the nylon wear pads are installed on the
shift fork and snapped securely into place.
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
Notice
Do not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump rotates
freely.
Notice
Do not remove the plastic insert from the bore of the new
pump. Discard it after it slides out during pump installation
to the rear output shaft.
Notice
While turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If
there is no discoloration in the pump housing, gear or cover,
and the pump bore and the lube holes of the output shaft
show evidence of oil, the pump is working.

13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body

12. Install the output shaft and oil pump in the input shaft.
Make sure that the internal splines of the ouput shaft
engage the internal splines of the high-low shift collar. Make
sure that the oil pump retainer arm and oil filter leg are in
the groove and slot of the front case.

13 Oil Strainer
16 Oil Pump
16a Pump Retainer
13. Install the magnet in the slot in the front case just above
the oil filter leg.
14. Install the front output shaft in the front case.
15. Install the thrust washer on the rear output shaft. Install
the chain, drive sprocket and driven sprocket as an
assembly over the output shaft.
Notice
The driven sprocket (on the front output shaft) must be
installed with the marking REAR facing toward the rear
case, if so marked.
Notice
Drive sprocket has a bushing pressed into it. 12 Rear Output Shaft 61 Magnet
16 Oil Pump
16. Install tone wheel onto the front output shaft. Make sure
the spline on the tone wheel engages the spline on the
front output shaft.
17. Install clutch pack assembly onto the rear output shaft.
Make sure the spline of the clutch pack engages to the
spline of the sprocket.
18. Install snap ring onto the rear output shaft. Start the snap
ring over the spline and use the wave spring to seat the
snap ring in the snap ring groove. If the snap ring will not
install, the thrust washer inside the clutch pack may not
be seated properly.

19. Install wave spring, insulator washer and armature. (Three
offset slots must align with housing to be installed)
Notice
Three slots on the thrust washer must be aligned with the
three tabs on the clutch pack housing.
20. Install apply cam onto the rear output shaft, install three
balls into the apply cam, install cam and coil housing
assembly onto rear output shaft. Install thrust bearing
assembly onto output shaft.
21. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing
Replacer and Driver Handle.
22. If removed, install the rear output bearing in the rear case
bore. Drive the bearing into the rear case bore with Output
Shaft Bearing Replacer and Driver Handle. Make sure that
the bearing is not cocked in the bore. Install the internal
snap ring that retains the bearing to the rear case.
23. Install the clutch coil from inside the rear case until the
wire and studs extend through the cover. Install the washers
and nuts and tighten.
CAUTION
Do not kink or trap the wire while seating the clutch coil to
the case.
24. Slide the spring spacer on the camshaft and position it
beneath the drive tang. Place the torsion spring on the
camshaft. Position the first spring tang to the left of the
camshaft drive tang(View A). Wind the second spring tang
clockwise past the drive tang(View B). Push the torsion
spring and sleeve in as far as it will go (View C). This will
seat the second spring tang on the right side of the drive
tang. Install the helical cam and slide the drive tang between
the torsion spring tangs as far as it will go.

25. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs so
that they are pointing toward the top side of the transfer
case and just touching the high-low shift fork.
CAUTION
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang
end of the motor shaft.
26. Install the shift rail through the high-low shift fork and make
sure that the reverse gear shift rail is seated in the front
case bore.
27. Install upper and lower speed sensors into the cover. Feed
the coil wire through the upper speed sensor wire shield.
28. Install upper tone wheel, speedometer gear and rear output
seal. Use Output Shaft Seal Replacer and Driver or
equivalent to install seal.
29. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
30. The following procedure must be followed prior to installing
the rear case onto the front case half:
a. Align the output shaft with the rear case output shaft bore.
b. Align the helical cam with the rear case motor bore.
If difficulty is encountered with seating the rear case, tap
the rear output shaft with a sharp blow using a rubber
mallet in a direction away from the triangular shaft while
pushing down on the rear case.
31. Install the bolts retaining the case halves and tighten.

32. Install shift shaft oil seal if it is not installed.
33. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor. If triangular shaft will not rotate, rotate
the rear output shaft.
34. Slightly loosen the two nuts that attach the slotted support
bracket to the end of the motor house.
35. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
36. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Notice
The wire harness must be routed as shown to provide
clearance and to prevent the wire harness from grounding
the damper.
37. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lockwasher to 8-11 Nm (72-96 lb-
in).
38. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
39. Install the clutch coil wire terminal and sensor wires.

40. Install the rear case flange on the output shaft. Install the
rubber seal, output shaft yoke washer and nut. Tighten
the nut.
41. Install the drainplug and tighten.

42. Fill the transfer case with 1.4 liters of Automatic

Transmission Fluid or equivalent.
Notice
Fluid level should be just below the filler plug hole.
43. Install the fill pulg and tighten.

44. Install the transfer case as outlined in removal and

Installation, transfer case in the section.
Notice
Make sure proper drain and fill plugs are installed if case
is replaced.

SECTION 6A
POWER STEERING SYSTEM

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Abnormal Noise From Steering System . . . . . 6A-3
General Specifications . . . . . . . . . . . . . . . . . . 6A-1 Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Fastener Tightening Specifications . . . . . . . . . 6A-1 Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2 Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2 Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3 Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
SPECIFICATIONS
Steering Wheel Number of Spoke 4
Outer Diameter 396 mm
Steering Gear Box Type Rack and Pinion
Gear Ratio ¥
Inner Steering Angle 33°37'
Outer Steering Angle 31°50'
Oil Pump Type Vane
Maximum Pressure 75-82 kg/cm2
Steering Column Upper Tilting Angle 4.646°
Lower Tilting Angle 6.969°
Minmum Turning Radius 5.7m
Oil Type ATF DEXRON II
Capacity 1L
Change Interval Every 24,000 km

Application Nlm
Steering Shaft Bolt 30-40
Pressure Hose Bolt 12-18
Return Pipe Nut 12-18
Slotted Nut 35-45
Steering Gearbox Bolt 35-45

6A-2 POWER STEERING SYSTEM
DIAGNOSIS
HARD STEERING
Checks Action
Lack of Lubrication Lubricate
Abnormal Wear or Binding of Steering Ball Joint Replace
Damaged or Faulty Steering Gear Replace gear assembly
Improper Preload of Steering Pinion Adjust
Faulty Steering Shaft Joint Replace
Steering Fluid Leaks Repair or replace
Lack of Fluid or Air-in System Replenish or bleed
Faulty Steering Oil Pump Replace
Damaged or Loosened Pump Drive Belt Adjust or replace
Clogging Oil Line Repair or replace
Damaged Wheel or Tire Repair or replace
Faulty Suspension System Repair or replace
STEERING PULLS TO ONE SIDE

Checks Action
Damaged Steering Linkage Repair
Damaged Wheel and Tire Repair or replace
Faulty Brake System Repair or replace
EXCESSIVE WHEEL PLAY

Checks Action
Worn Steering Gear Replace gear assembly
Worn or Damaged Steering Ball Joint Replace
Loosened Steering Gearbox Bolts Retighten
POOR RETURN OF STEERING WHEEL

Checks Action
Damaged or Binding Steering Ball Joint Replace
Improper Preload of Steering Pinion Replace gear assembly

POWER STEERING SYSTEM 6A-3
STEERING WHEEL SHIMMY

Checks Action
Damaged Steering Linkage Replace
Loosened Steering Gearbox Mounting Bolt Retighten
Damaged or Binding Steering Ball Joint Replace
Worn or Damaged Front Wheel Bearing Replace
ABNORMAL NOISE FROM STEERING SYSTEM

Checks Action
Loosened Steering Gearbox Mounting Bolt Retighten
Faulty Steering Gear Replace gear assembly
Steering Column Linterference Replace
Loosened Steering Linkage Retighten
Damaged or Loosened Oil Pump Drive Belt Adjust or replace
Loosened Oil Pump Bracket Retighten
Loosened Oil Pump Mounting Bolt Retighten
Air-in System Bleed
Faulty Oil Pump Replace

COMPONENT LOCATOR
STEERING SYSTEM
1 Steering Wheel 5 Lower Shaft

2 Steering Column Shaft 6 Oil Reservoir
3 Steering Gear Box 7 Oil Pump
4 End Ass'y - Tie Rod 8 Steering Knuckle


ON-VEHICLE SERVICE
INSPECTION
Steering Wheel Freeplay Inspection Procedure
1. Start the engine and set the wheels in straight ahead position.
2. Slightly move the steering wheel to the left and right and
measure steering wheel free play when the front wheel is
start to move.
Standard Max. 30mm
Notice
If exceeds specification, the steering column shaft
connections and steering linkage .clearance. Replace or
repair if necessary.
Steering Angle Inspection Procedure

1. Place the front wheel on a measuring tool.
2. Rotate steering wheel all the way right and left and measure
steering angle
Inner 33°37'
Standard
Outer 31°50'
Notice
If out of standard, check or adjust toe-in.
Steering Effort Inspection Procedure

1 Place a vehicle on the paved flat ground with front wheels
in a straight ahead position.
2 Start the engine and run it at 1,000rpm.
3 Using a scale, measure the steering effort in both directions.
Standard Max. 3.0kg

Notice
The difference in steering effort of left and right should be
within 0.6 kg.

OIL PUMP PRESSURE CHECK

Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect a
pressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering
wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
Relief Pressure 75 -82 kg/cm2
Notice
Do not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure

hose.
6. Do bleeding procedure.
BLEEDING OF POWER STEERING

SYSTEM
Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the
engine and turn the steering wheel from lock to lock 5 or
6times.
Notice
Do bleeding with engine cranking. If bleed with idling, there
can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no
more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level
change.
Notice
l If oil is not changes more than 5mm, do bleeding again.
l If oil level rises suddenly when stopped engine, again.

STEERING GEAR BOX
1 Bolt ....................................................... 30-40Nm 7 Slotted Nut ............................................ 35-45Nm

2 Spring Washer 8 Nut
3 Lower Shaft 9 Spring Washer
4 Pressure Hose ...................................... 12-18Nm 10 Bolt ....................................................... 35-45Nm
5 Return Pipe .......................................... 12-18Nm 11 Washer
6 Cotter Pin 12 Steering Gearbox Assembly

1. Remove the cotter pin and nut and separate the steering
gear box tie rod from the steering knuckle arm.
Installation Notice
Bend both ends of the split pin after installation.
2. Remove the coupling bolt and separate the lower sha

from the steering gear box.
Installation Notice
Tighten the bolt toward threadless side of lower shaft
coupling.
3. Remove the oil pipe from the steering gear box and drain
the oil.
Installation Notice
4. Remove the clamp bolts and remove the steering gear box
assembly.
Installation Notice
Notice
l Be careful not to damage the rubber(1).
l When installing tighten the bolt (3) with the rubber
(2)being inserted to the hole of clamp.
5. Bleed the air from system.
6. Check the toe-in.

1. Check the distance of tie rod and toe-in data and, if
necessary, adjust as below.
2. Adjustment
l Unscrew the adjuster nut (1) and adjust the distance by
turning the rod (2) counterclockwise.
Distance of Tie Rod 152mm
l Check the toe-in date (A~B)
Toe-in 0 - 4 mm
l If the ton-in is normal, tighten the adjuster nut (1) to the
specified toque with tie rod (2) being fixed.
Tightening
Torque 65 - 80Nm

SECTION 6E
STEERING WHEEL AND COLUMN

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6E-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 6E-2
Fastener Tightening Specifications . . . . . . . . . 6E-1 Steering Column . . . . . . . . . . . . . . . . . . . . . . . 6E-2
Maintenance and Repair . . . . . . . . . . . . . . . 6E-2
SPECIFICATIONS
Application Nlm
Steering Wheel Mounting Nut 50-80
Shaft Bolt 30-40
Steering Column Shaft Bolt 9-14
Steering Column Mounting Bolt 15-20

6E-2 STEERING WHEEL AND COLUMN

ON-VEHICLE SERVICE
STEERING COLUMN
1 Horn Pad 10 Bolt

2 Nut ....................................................... 50-80 Nm 11 Crash Pad Panel
3 Washer 12 Bolt ...................................................... 30-40 Nm
4 Steering Wheel 13 Spring Washer
5 Combination Switch Assembly 14 Lower Shaft
6 Combination Switch Lower Cover 15 Bolt ........................................................ 9-14 Nm
7 Combination Switch Upper Cover 16 Bolt ...................................................... 13-40 Nm
8 Bolt 17 Steering Column Shaft
9 Bolt

STEERING WHEEL AND COLUMN 6E-3
1. Remove the horn pad from the steering wheel and
disconnect the connectors .
2. Place an alignment marks on the column shaft end and

fixing nut and then remove the fixing nut.
Installation Notice
3. Remove the steering wheel and combination switch covers.
4. Remove the crash pad panel.

Notice
Remove the hood release wire and the other switch
connectors.

6E-4 STEERING WHEEL AND COLUMN
5. Release the weld clip and disconnect the wire connectors.
6. Disconnect the vacuum hose from ignition switch (Diesel
only).
7. Remove the combination switch assembly.
8. Disconnect the steering column shaft from lower shaft by

unscrewing the bolt.
Installation Notice
9. Unscrew the steering column housing fixing bolts to fixing

bolts to floor.
Installation Notice

STEERING WHEEL AND COLUMN 6E-5
10. Unscrew the steering column upper bolt and remove the
column assembly.
Installation Notice

reverse order.

SECTION 7B/C
MANUAL CONTROL /
SEMIAUTO TEMPERATURE CONTROL
HEATING, VENTILATION AND
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . 7B/C-2 Component Locator . . . . . . . . . . . . . . . . . 7B/C-6
Cooling Capacity . . . . . . . . . . . . . . . . . . . . 7B/C-2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-6
Compressor . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-2 Air Conditioner System . . . . . . . . . . . . . . 7B/C-8
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-2 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . 7B/C-8
Receiver Drier . . . . . . . . . . . . . . . . . . . . . . 7B/C-2 Gasoline Engine . . . . . . . . . . . . . . . . . . . . . 7B/C-9
Dual Pressure Switch . . . . . . . . . . . . . . . . . 7B/C-2 Heater System . . . . . . . . . . . . . . . . . . . . . 7B/C-10
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-3 Maintenance and Repair . . . . . . . . . . . . 7B/C-11
Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-3 Refrigerant Charging . . . . . . . . . . . . . . . . 7B/C-11
Fastener Tightening Specifications . . . . . . . 7B/C-3 Condenser . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-15
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-4 Receiver Drier . . . . . . . . . . . . . . . . . . . . . 7B/C-17
Defectives in Fan Motor Circuit . . . . . . . . . . 7B/C-5 Air-Conditioner Compressor . . . . . . . . . . . 7B/C-19
Defectives in Compressor Circuit . . . . . . . . 7B/C-5 Heater and Air Conditioner Control Box . . 7B/C-20

7B/C-2 MANUAL & SEMIAUTO-HVAC
SPECIFICATIONS
COOLING CAPACITY
Type Air mix type
Max. Capacity 4,500kcal/h
Max. Blowing Capacity 7.Om3/mim
Refrigerant R134a
Refrigerant Amount 650 - 75Og
COMPRESSOR
Model FK- ll
Type Vane rotary type
Output 140.5cc/rev
Oil ZXL 200PG (PAG oil)
Magnetic Clutch Output 45W
CONDENSER
Type Parallel type (Multi Flow Condenser)
Capacity 11,000 kcal/h
Condenser Fan Motor Output 160W
RECEIVER DRIER
Desiccant XH - 9 (30g)
Type Aluminum type
Capacity 240cc
DUAL PRESSURE SWITCH

High OFF: 27±2kgf / cm2, DIFF : 6±2kgf / cm2G
Low OFF : 1.8±0.2kgf / cm2, ON 1.9±0.3kgf/ cm2G

MANUAL & SEMIAUTO-HVAC 7B/C-3
EVAPORATOR
Type Tank laminated
Expansion Valve Uniform external pressure type (1.5 RT)
Resistance 4 stage (Coil resistance)
Thermo Amp Sensor type OFF : 2±0.5°C, DIFF : 2±0.5°C
HEATER UNIT
Heater Core Type 2-ROW
Heating Capacity 4,600 kcal/h (AT 300 CMH)
Heater Core Size (LxWxT) 219.5x151.8x52.0

Application Nlm
Condenser Bolt 4-6
Condenser Fan Nut 4-6
Condenser Bolt 4-6
Receiver Drier Pipe Bolt 5-8
Receiver Drier Pipe Bolt (Condenser) 4-6
Pressure Pipe Bolt 20-30
Pressure Mounting Bolt 20-26

DIAGNOSIS

DEFECTIVES IN FAN MOTOR CIRCUIT

Fan Motor Does Not Run
Checks Action
Blown fuse Check for short and replace fuse.
Battery voltage is low Check battery voltage.
Faulty wiring Check connectors’ connection.
Do not apply grease. This can cause voltage down.
Faulty ground Remove body painting and completely ground,
Tighten ground bolts and make sure body ground connection.
Fan Motor Runs in ‘4’position Only (‘3’, ‘2’, ‘1’ : Does Not Run)
Checks Action
Blown resister temperature fuse Replace resistor.
Air leakage in parts connection Check heater, cooling unit and blower for proper connection.
Motor Runs With Poor Blowing

Checks Action
Clogged or blocked intake grille Clogged or blocked intake grille reduces blowing capacity.
Frosted Evaporator
Checks Action
Faulty thermo amp Frosted evaporator reduces cooling capacity.
Off compressor and maximize blowing capacity
DEFECTIVES IN COMPRESSOR CIRCUIT

Compressor Does Not Run
Checks Action
Faulty high/low pressure Check compressor magnet voltage supply.
Faulty A/C relay A/C relay.
Magnetic Clutch Slips /Idles

Checks Action
Oily clutch plate Clean oily plate using cleaning agent.
Low voltage Charge battery or check for cause.
Faulty electric connection or operation Check wire continuity
Check A/C switch and fan switch for continuity and ground.
Magnetic Clutch Plays By Hand Only

Checks Action
Excessive clearance between Adjust clutch clearance (0.2-0.6mm).
Clutch plate and clutch coil

COMPONENT LOCATOR
VENTILATION
1 Foot / Face 4 Defroster

2 Foot / Defroster 5 Face
3 Foot

Air Flow
Switch Mode Switch Recirculation Switch Temperature
VENT B/L FOOT D/F DEF REC FRE Control Lever
[MANUAL]
INDI. INDI.
On Off [SEMI AUTO]
Door
A B C C C - - -
VENT Door
FOOT Door C B A B C - - -
DEF Door D D D B A - - -
INTAKE Door - A B -
AIR MIX Door - A B C

AIR CONDITIONER SYSTEM

DIESEL ENGINE
1 Compressor 7 Liquid (B)

2 High Pressure Hose 8 Evaporator Assembly
3 Condenser 9 Blower Unit
4 Condenser Fan 10 Heater Unit
5 Liquid Pipe (A) 11 Low Pressure Hose
6 Receiver Drier

GASOLINE ENGINE
1 Evaporator Assembly 11 Pipe Assembly-Suction

2 Condenser Assembly 12 Pipe-Liquid-A
3 Screw-Hex SEMS(M8x1.5x35) 13 Pipe-Liquid-B
4 Fan & Shroud Assembly-Main 14 Resister-Condenser Fan
5 Fan & Shroud Assembly-Add 15 Clip-Closed-CT(M8)
6 Supplement Assembly-c/fan Mounting 16 Bolt-Hex FLG(M8x1.25x25)
7 Receiver & Bracket Assembly 17 Nut-Hex(M6x1.0)
8 Hose-Discharge 18 Screw-Hex SEMS(M6x1.0x25)
9 Bolt-Hex Sems(M8x1.25x30) 19 Screw-Hex SEMS(M6x1.0x16)
10 Hose Assembly-Suction

HEATER SYSTEM
1 Heater/Heater Control Assembly 8 Duct Assembly-HTR to Blower

2 Heater Unit 9 Duct Assy-Side A/VENT No.1-LH
3 Heater Control Box Assembly 10 Water Inlet Hose
4 Heater Unit Amp. 11 Water Outlet Hose
5 Mix Actuator Assembly 12 Heater Pipe Gromet
6 Mode Actuator Assembly 13 Duct Assy-HTR Connector
7 Blower Unit


REFRIGERANT CHARGING
Installation of Manifold Gauge
1. Close both high/low pressure hand valve of gauge before
installation of gauge to the charging valve.
2. Connect the low pressure hose of the gauge to the low

pressure charging valve and the high pressure hose of the
gauge to high pressure charging valve. Tighten the hose
nuts by hand.
Discharging of Refrigerant
1. Connect the manifold gauge to the charging valve.
2. Place the free end of center hose in a shop towel.
3. Slowly open the high pressure hand valve and discharge
refrigerant.
Notice
If refrigerant is allowed to escape too fast, compressor oil
will be drawn out of the system.

4. After the high pressure gauge reading drops below 3.5kg/
cm2 , slowly open the low pressure valve.
5. When both high and low pressure gauges reading drops to
0 kg/cm, discharging is completed.
Evacuating Refrigeration System

1. Connect the manifold gauge to the charging valves.
2. Connect the center hose of the gauge to the vacuum pump.
3. Run the vacuum pump and open both high and low pressure
hand valves.
4. Run the vacuum pump 15-20 minutes.
5. Check that both high and low pressure gauge reading is
more than (-) 750mmHg of vacuum and close both valves.
6. Stop the vacuum pump and wait about 5 minutes.

7. After 5 minutes, check that low pressure gauge reading is
changed or not.
8. If low pressure gauge reading is changed, check the system
for leaks and repair as necessary and repeat steps from ‘1’
to ‘7’.
9. If there are no changes in low pressure gauge reading,
disconnect the vacuum pump.
Check for Refrigerant Leaks

1. Connect the center hose of the gauge to the refrigerant
tank.
2. Open the high pressure valve of the gauge to charge with
refrigerant gas.
3. Charge until the low pressure gauge reads 1.0kg/cm2 and
close the valve.
4. Using a gas leak detector, check the system for leaks.
5. If a leak is found, replace a O-ring or repair the faulty
connection

Charging Refrigerant
1. Connect the manifold gauge to the charging valve and
evacuate the system.
2. Connect the center hose of the gauge to the refrigerant
tank.
3. Open the high pressure valve and charge the system with
350g of refrigerant.
4. Close the high pressure valve and start the engine and run
the compressor.
Notice
Never open the high pressure valve when the compressor
is running. Refrigerant gas will be charged reverse.
5. Slowly open the low pressure valve and charge the system
with refrigerant.
Standard 650 - 750 g
6. Close the low pressure valve after charging.
Notice
Checking the pressure through the sight glass is impossible
by applying & R-134a.
7. Stop the engine and disconnect the manifold gauge from
the system.
Operation Check
1. Place a dry bulb thermometer to the front duct.
2. Place a psychrometer close to the inlet of the cooling unit
(under the glove box).
3. Run the engine at 1,500 rpm.
4. Set the blower switch at ‘HI’ and A/C switch ‘ON”.
5. Set the temperature control lever at ‘COOL’.
6. Set the air flow control at ‘REC’.
7. Check that air conditioning system is stabilized.
Temperature of Air Inlet 25 - 35°C
High Pressure Gauge Reading 13.2 - 18.5 kg/cm2

Replacement of Refrigerant Connection (O-ring
Type)
1. When connecting a O-ring type, apply compressor oil to
portions shown in illustration. Be careful not to apply oil to
threaded portion.
Notice
Use specified compressor oil.
2. O-rings must be closely attached to inflated portion of pipe

and always replace used O-rings.
3. After inserting the pipe to the union, tighten the nut by hand
as much as possible and tighten the nut to specified torque.
4. When connecting liquid pipe(B) and low pressure hose(A)

to evaporate pipe, apply compressor oil to the O-ring.
5. When tightening, set the center of pipe and tighten fully.
6. Tighten the nut by specified wrench.
Installation Notice
Inlet Side to 12 - 15Nm

Tightening Torque
Low Pressure Hose (A) 30 - 35 Nm

CONDENSER
Preceding Work : Removal of the radiator
1 Condenser 4 Sub Fan (Gasoline Engine)

2 Bolt .......................................................... 4-6 Nm 5 Resister (Gasoline Engine)
3 Condenser Fan

1. Disconnect the inlet and outlet pipes of condenser.
Notice
Before disconnection, evacuate the refrigerant from the
system.
Inlet Side to 10 - 15 Nm
Tightening Torque
Outlet Side to 4 - 6 Nm
Notice
When installing, check the O-ring and apply compressor oil.
2. Remove the mounting bolts (2EA) and condenser assembly.

Installation Notice
3. Remove the main condenser fan from condenser.

reverse order.

RECEIVER DRIER
1 Condenser 4 Bolt .......................................................... 5-8 Nm

2 Receiver Drier 5 Bracket
3 Bolt ......................................................... 4-6 Nm

1. Disconnect the negative(-) terminal from the battery.
2. Discharge refrigerant from the system.
Notice
By connecting a manifold gauge connection hose to High/
Low pressure line, discharge the refrigerant.
3. Disconnect the inlet and outlet pipes of receiver drier.

Notice
When installing, check the O-ring and apply the compressor
oil.
Installation Notice
4. Remove the bracket bolt and then remove the receiver drier.
Installation Notice
reverse order.

AIR-CONDITIONER COMPRESSOR
1 Compressor Bracket 3 Low Pressure Hose

2 High Pressure Hose 4 Compressor

1. Disconnect the negative(-) terminal from the battery.
2. Discharge refrigerant from the system.
Notice
By connecting a manifold gauge connection hose to High/
Low pressure line, discharge the refrigerant.
3. Disconnect the high / low pressure pipe and wire connectors.
4. Remove the mounting bolt from the compressor bracket

and remove compressor assembly.
Notice
Place the removed compressor in vertical position.
reverse order.

HEATER AND AIR CONDITIONER CONTROL BOX
MANUAL
SATC
1 Blower Switch 4 A/C Switch

2 Recirculation Switch 5 Temperature Control Lever
3 Mode Switch 6 In-vehicle Sensor

1. Remove the switch panel.
Notice
Be careful not to damage the switch panel.
2. Remove the fixing screws (4 screws) of the control box.
3. Disconnect the wire connectors and remove the control box.


SECTION 7D
FULL AUTOMATIC TEMPERATURE

CONTROL HEATING, VENTILATION AND
FATC (Full Automatic Temperature Control) is full automatic heater and airconditioning system that detects
incar temperature, ambient temperature, sun load and coolant temperature and controls airconditioner system
blowing capacity, outlet temperature and intaking/outlet mode to maintain interior comfort.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 7D-1 Ventilation System . . . . . . . . . . . . . . . . . . . . . . 7D-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7D-1 Function Description . . . . . . . . . . . . . . . . . . . . 7D-7
Service Specifications . . . . . . . . . . . . . . . . . . . 7D-3 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Schematic and Routing Diagrams . . . . . . . . 7D-4 Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 7D-4 Maintenance and Repair . . . . . . . . . . . . . . 7D-11
FATC Block Diagram . . . . . . . . . . . . . . . . . . . . 7D-5 FATC Control Panel . . . . . . . . . . . . . . . . . . . 7D-11
Component Locator . . . . . . . . . . . . . . . . . . . 7D-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 7D-15
SPECIFICATIONS
SPECIFICATIONS
Refrigerant
Capacity 650-750 g
Type R134a
Evaporator Unit
Core Size (LxWxT) 237.0x232.0x92.0
Core Type Aluminum plate
Expansion Valve Type Angle
Thermostat ON:4.5±0.6°C, OFF:1.5±0.6°C
Resister Type Aluminum plate
Cooling Capacity 4,300 Kcal/h(AT 420 CMH)

7D-2 FATC-HAVC
Blower Unit
Motor Type Magnetic
Motor Size f70 x 145
Compressor
Model FK-II(DKV 14C)
Type Vane rotary
Displacement (cc/rev.) 140.5
Pulley f143.0
Oil ZXL 200 PG (PAG Oil)
Condenser
Size (WxHxT) 650x339.2x22.0
Capacity 11,000 Kcal/h
Type Parallel Flow
Receiver Drier
Material Aluminum
Capacity 250cc
Desiccant XH-9 or equivalent 35g
Pressure Switch
Type Direct
High (OFF) OFF : 27±2Kgf/cm2, DIFF : 6±2Kgf/cm2
Low (ON) OFF : 1.8±2Kgf/cm2, ON : 1.9±0.3Kgf/cm2
Air Filter
Replacement Every 10,000 km (replace earlier if air pollution is heavy)
Heater Unit
Heater Core Type 2-ROW
Heating Capacity 4,600 Kcal/h (AT 300 CMH)
Heater Core Size (LxWxT) 219.5 x 151.8 x 52

FATC-HAVC 7D-3
SERVICE SPECIFICATIONS
Input Section
Incar Sensor Resistance (25°C) 2.186kW ±0.07kW
Voltage Rating 5V
Current Rating 3mA
Ambient Sensor Resistance (25°C) 1.0kW ±0.03kW
Voltage Rating 5V
Current Rating 3mA
Coolant Temperature Sensor Resistance (25°C) 0.55kW ±0.02kW
Voltage Rating 5V
Current Rating 3mA
Output Section
Intake Actuator Current Rating (at 12V) 70±30mA
LOCK Current Less than 500mA
Mode Actuator Current Rating (at 12V) 100±40mA
Mix Actuator Current Rating (at 12V) 100±40mA
Power TR Ic 30A
Pc 200W
Blower Motor Power Consumption 220W

7D-4 FATC-HAVC

CIRCUIT DIAGRAM

FATC-HAVC 7D-5
FATC BLOCK DIAGRAM
INCAR SENSOR VFD
AMBIENT SENSOR
MAX HI RELAY
WATER TEMPERATURE SENSOR BLOWER
MOTOR
POWER T/R
SUN LOAD SENSOR
C
O ECU COMPRESSOR
TEMPERATURE SWITCH N
T
BLOWER SWITCH
R
MIX ACTUATOR MIX DOOR
MODE SWITCH O
L
DEFROSTER SWITCH
INTAKE SWITCH INTAKE ACTUATOR INTAKE DOOR
U
N
I Airconditioner output
AUTO SWITCH
T
A/CON SWITCH
OFF SWITCH
MODE ACTUATOR MODE DOOR
TEMP DOOR POSITION FEEDBACK

VOLTAGE
POWER TRANSISTOR COLLECTOR

VOLTAGE

7D-6 FATC-HAVC
COMPONENT LOCATOR
VENTILATION SYSTEM

FATC-HAVC 7D-7
FUNCTION DESCRIPTION 5. DEFROST switch

l By pressing this switch, DEF will turn on and mode
1. AUTO switch
door will be fixed at DEF.
l By pressing the AUTO switch, set temperature,
l Recirculation/fresh air switch will be fixed as FRESH.
AUTO, fan speed, air source, air flow mode will be
appeared on the VFD display. l When airconditioner is turned ON and ambient
temperature is less than 1.5°C, the airconditioner will
l Following items will be controlled automatically
be turned off.
according to set temperature.
l Selection of airconditioner OFF is possible by manual.
- Mode and intake door
- Temperature door 6. A/C switch
- Blower fan speed l The airconditioner system will be turned ON or OFF
by pressing this switch.
- Compressor ON/OFF control
l When AUTO switch is released, other functions will 7. Recirculation•fresh air switch
be controlled automatically except for manually l Air intake will be automatically switched to recirculation
selected switches. or fresh air (REC® FRE) by pressing this switch.
2. MODE switch 8. Blower switch (UP/DOWN)
l By pressing the MODE switch while the AUTO switch l Blower speed can be controlled by manual and if fan
is turned ON, AUTO indicator light will go off and air UP/DOWN switch is pressed when AUTO mode is
flow mode will be controlled manually in the order of selected, fan speed will UP/DOWN based on current
VENT® B/L® FLR® MIX® VENT. fan level.
3. OFF switch l When 6 segments are turned on, it is max. HI
operation.
l Press this switch and the airconditioner system will
be turned OFF. l When pressed more than 1 second, it will be
automatically UP/DOWN by interval of 0.28 sec. after
4. Temperature UP/DOWN switch 1 second.
l This switch is a switch increasing or decreasing set l When segment is changed stage 2® stage 1 (LO),
temperature and position of the temperature door stage 5® stage 6 (HI) and HI switch is pressed in HI
will be automatically controlled according to set status or DOWN switch is pressed in LO status, there
temperature and outlet temperature will be controlled will be operating sounds 3 times during 0.1 sec.
by adjusting blending ratio of cold and hot air.
l When switch is operated in OFF status, it will be
l By operating the switch, set temperature will be operated as stage 1 (1 segment display).
increased/decreased by 0.5°C.
l Set temperature range is 17 - 32°C.
l Max. cold function will be performed at set temperature
of 17°C and max. hot function will be performed at
set temperature of 32°C.
l When pressed more than 1 second, it will be
automatically UP/DOWN by interval of 0.28 sec. after
1 second.
l When it changed 17.5°C® 17°C, 31.5°C® 32°C and
DOWN switch is pressed after 17°C or UP switch is
pressed after 32°C, there will be operating sounds 3
times during 0.1 sec.

7D-8 FATC-HAVC
DIAGNOSIS
DIAGNOSIS TEST
FATC airconditioner system has self-diagnosis function. pressed, then it will diagnose incar sensor, ambient
Turn the ignition switch ON and press intake switch more sensor, water temperature sensor and temperature
than 4 times within 2 seconds while the AUTO switch is actuator for open/short and will display numerical fault
code on the set temperature display of VFD.
1 AUTO Switch 4 Airconditioner Switch

2 Intake Switch 5 Set temperature Display
3 OFF Switch
Self-diagnosis Method
Ignition switch “ON”
Press the intake switch more than 4 times within

2 seconds while pressing the AUTO switch
Self-diagnosis will start after turning off all displays on

VFD for 2.5 seconds
Self-diagnosis items check Press OFF

(continuous action)
Press AUTO Press AUTO
Self-diagnosis items check

(step action)
Press OFF
Airconditioner control

FATC-HAVC 7D-9
Diagnosis Item and Fault Code
00: normal 15: coolant Sensor Open

11: incar Sensor Open 16: coolant Sensor Short
12: incar Sensor Short 17: temperature Actuator Open/Short
13: ambient Sensor Open 18: temperature Actuator Drive Fault
14: ambient Sensor Short
Self-diagnosis Display
1. Data will be displayed at the set temperature display as 2-digit number during self-diagnosis function and other set
temperature displays will be OFF.
2. Display of self-diagnosis fault code will be blinking fault code number in the intervals of 0.5 sec.
3. Following fault code number will be displayed at the set temperature display during self-diagnosis function.
4. If no defective, normal display number (00) will blink.
Display during continuous action

A. Normal or 1 fault (00 or 11)
ON ON
Display OFF OFF
0.5 sec. 0.5 sec.
® ¬ 0.1 sec. ® ¬ 0.1 sec.
Buzzer
B. Multiple faults (11,13,15.........)
Fault 13 Fault 15
Display OFF OFF
0.5 sec. 0.5 sec.
® ¬ 0.1 sec. ® ¬ 0.1 sec.
Buzzer
Display during step action

A. Normal or 1 fault : the same as continuous action
B. Multiple faults
Fault Fault 17 Fault Fault 17 Fault Fault 11

Display 13 17 11
Airconditioner
AUTO switch
switch
pressed pressed
Buzzer

7D-10 FATC-HAVC
Fault Safety Function
FATC airconditioner system not only performs self-diagnosis
but also has safety function against faults if there is open or
short in the incar sensor, ambient sensor, water temperature
sensor and temperature door potentiometer.
NO. Item Defects Fault safety function

1 Incar sensor Open or short Control When substituted 25°C
2 Ambient sensor Open or short Control When substituted 20°C
3 Water temperature sensor Open or short Perform heating maneuver control function under
refrigeration maneuver control entering conditions
and release after 10 minutes.
4 Temperature door potentiometer Open or short Set temperature 17 - 24.5°C:max. COLD position
Set temperature 25 - 32°C:max. HOT position

FATC-HAVC 7D-11

FATC CONTROL PANEL
1 AUTO Switch 6 Airconditioner Switch

2 MODE Switch 7 Recirculation•fresh Air Switch
3 OFF Switch 8 Blower Switch (UP/DOWN)
4 Temperature UP/DOWN Switch 9 VFD (Vacuum Fluorescent Display)
5 Defrost Switch

7D-12 FATC-HAVC
Pin Number and Connection Circuit
16-pin (A) 20-pin (B)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20
Connector A Connector B
Pin No. Connection circuit Pin No. Connection circuit

1 Rheostat 1 Incar sensor (+)
2 Tail lamp 2 Ambient sensor (+)
3 Battery (+) 3 Coolant sensor (+)
4 Power TR (B) 4 Sensor voltage 5V
5 Power TR (C) 5 Sensor ground
6 Temperature actuator (CCW) 6 Intake (ambient)
7 IG2 7 Intake (incar)
8 Ground 8 -
9 Airconditioner switch ground 9 -
10 HI speed relay 10 -
11 Photo sensor (+) 11 VENT
12 Photo sensor (-) 12 B/L
13 Temperature actuator F/B 13 FLR
14 Temperature actuator (CW) 14 MIX
15 IG2 15 DEF
16 Ground 16 -
17 -
18 -
19 -
20 -

FATC-HAVC 7D-13
1. Turn the ignition switch to OFF position.
2. Remove the digital clock.
3. Unscrew the screw from the center panel, pull out each
switches and remove the center panel.
4. Unscrew the 6 screws and remove the audio control panel

assembly.
5. Unscrew the 4 screws and remove the airconditioner control

panel assembly.
reverse order.

7D-14 FATC-HAVC
Air Filter; replace
Replacement Interval Every 10,000km
Notice
Replace earlier if air pollution is heavy.
Replacement1.
1. Open the glove box and pull it inward to release the upper
left and right locking portion.
Notice
Remove the glove box by unscrewing lower 2 screws, if
necessary.
2. Press the 2 filter cover holds and remove the air filter cover.
3. Remove the 2 air filters.
Notice
For installation, remember the installed direction of the air
filter before removal.

FATC-HAVC 7D-15
TROUBLESHOOTING
Check and Service
Incar sensor is a sensor that detects interior air temperature
and a thermistor that decreases its resistance when temperature
up and increases when temperature down.
1. Check that there are incar sensor fault code (11,12) by
using self-diagnosis function.
2. Disconnect incar sensor 2-pin connector that installed on

inner lower instrument panel cover of driver’s side and
remove the sensor.
3. Check that measured resistance value among incar sensor

terminals is as shown in the right side graph.
Notice
Measure resistance value by soaking the sensor in the ice
water and check changes in resistance values after soaking
it in the very hot water.
4. If resistance value is out of specification, replace the incar
sensor.
5. Install the sensor and turn the ignition switch to ON position

and check that voltage between No. 12A terminal of incar
sensor and body (-) is 5V. 12B 12A Incar sensor connector
6. Check current between the No. 12B and 12A connector
terminals of the incar sensor and the No. 1 and 5 connector V
terminals of the airconditioner control unit and repair the
wire if defective. 0.5LW 0.5BL
¯ ¯
1 5
Airconditioner control unit connector

7D-16 FATC-HAVC
Ambient Sensor
Ambient sensor is a sensor that detects ambient temperature
and a thermistor that decreases its resistance when temperature
up and increases when temperature down.
1. Check that there are ambient sensor fault code (13,14) by
2. Disconnect ambient sensor 2-pin connector that installed

on front right side of the frame and remove the sensor.
3. Check that measured resistance value among ambient

sensor terminals is as shown in the right side graph.
Notice
4. If resistance value is out of specification, replace the ambient
sensor.

and check that voltage between No. 10 terminal of the
ambient sensor and body (-) is 5V.
Ambient sensor connector 9 10
6. Check current between the No. 10 and 9 connector terminals
of the ambient sensor and the No. 2 and 5 connector
terminals of the airconditioner control unit and repair the V
0.5W 0.5BL
wire if defective.
¯ ¯
2 5

FATC-HAVC 7D-17
Water Sensor
Water sensor is a thermistor that detects engine coolant
temperature to operate the blower speed to LO when water
temperature is less than 50.
1. Check that there are water sensor fault code (15,16) by
2. Disconnect water sensor 2-pin connector that installed on

the heater unit of inner instrument panel and remove the
water sensor.
3. Check that measured resistance value among water sensor

terminals is as shown in the right side graph.
Notice
4. If resistance value is out of specification, replace the water
sensor.

and check that voltage between No. 7a terminal of the water
sensor and body (-) is 5V. Water sensor connector 7b 7a
6. Check current between the No. 7a and 7b connector
terminals of the water sensor and the No. 3 and 5 connector
V
terminals of the airconditioner control unit and repair the
wire if defective. 0.5RB 0.5BL
¯ ¯
3 5

7D-18 FATC-HAVC
Sun load Sensor
Sun load sensor is a photo diode that detects lights. Resistance
of diode can be measured as current by using multimeter Sun load sensor
13b 13a connector
according to increasing sun loads.
1. Check current on the circuits between the sun load sensor
and the airconditioner control unit.
Airconditioner
control unit
11 12 connector
- -
0.5WL 0.5WR
2. Turn the ignition switch to ON position and check that voltage

between No. 13a terminal of the sun load sensor and vehicle
ground is 5V.
Sun load sensor

13b 13a connector
3. Measure current between No. 13a terminal of the sun load

sensor and No. 11 terminal of the control unit and check it is
as shown in the below graph.
13a
4. If current value is out of specification, replace the sun load Airconditioner
sensor. control unit
connector
mA
11
Output current (mA)
0.32
200 400 600 (660) 800

2
(Kcal/m h)

FATC-HAVC 7D-19
Fault : intake (recirculation/fresh air) door inoperative
Remove the glove box.
Disconnect 3-pin connector of the intake mode

actuator and turn the ignition switch to ON position.
Measure voltage between 6c terminal positive pole (+)

and body (-). 6A 6B 6C Wiring side connector
No
Measured voltage is 12V. Check No. 24 fuse (15A) in the box.
Yes
Turn the ignitin switch OFF and disconnect harness of

the intake actuator.
6C 6B 6A
Check that it operates toward each direction after
- + Actuator connector
connecting the battery to the 6C terminal of intake
actuator and ground 6A & 6B to the body.
No
Intake actuator is normal. Repair and replace the intake actuator.
Yes
Disconnect 20-pin connector from the airconditioner Check intake actuator linkage and door for
control unit. proper operation and repair if necessary.
0.5YB 0.5LgR
Check current between the intake actuator (6A, 6B)
¯ ¯
and the airconditioner control unit (6,7).
6 7
No
Is there current? Repair open wire between the intake
actuator and the control unit.
Yes
Replace the good control unit and re-check. If no fault,

replace the control panel.

7D-20 FATC-HAVC
Fault : air flow does not change toward panel side.
Remove the center panel of the instrument panel.
Disconnect 8-pin connector of the mode actuator and

turn the ignition switch to ON position.
8I
Measure voltage between 8I terminal positive pole (+) Wiring side connector
and body (-).
No
Measured voltage is 12V. Check No. 24 fuse (15A) in the fuse box.
Yes
Mode actuator
Turn the ignition switch OFF and disconnect harness of connector
the mode actuator.
8I 8A
8J 8H 8F 8D 8B
Check that it operates toward each directions when
ground is connected to terminal (8J, 8H, 8F, 8D, 8B) of - +
the mode actuator alternatively.
No
Mode actuator is normal. Repair and replace the mode actuator.
Yes
Disconnect 20-pin connector from the airconditioner Check the intake actuator linkage and door
control unit. for proper operation and repair if necessary.
Check current between the mode actuator (8J, 8H, 8F,

8D, 8B) and the airconditioner control unit (11, 12, 13, Control unit
14, 15). connector
11 12 13 14 15
Mode actuator connector

8B 8D 8F 8H 8J
No
Is there current? Repair open wire between the mode actuator
and the control unit.
Yes
Replace the good control unit and re-check. If no fault,

replace the control panel.

SECTION 8A
SEAT BELTS
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8A-1 General Description and System
Fastener Tightening Specifications . . . . . . . . . 8A-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
Component Locator . . . . . . . . . . . . . . . . . . . 8A-2 Driver Seat Belt Warning . . . . . . . . . . . . . . . . 8A-4
Front Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 Operation and Functional Checks . . . . . . . . . 8A-4
Rear Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
SPECIFICATIONS
Application Nl m
Anchor Bolt 35 - 55

8A-2 SEAT BELT
COMPONENT LOCATOR
FRONT SEAT BELT
1 Seat Belt Assembly (3-Point) 5 Seat Belt Reel Assembly

2 Buckle Assembly 6 Anchor Bolt .......................................... 35-55 Nm
3 Seat Belt Dust Cover 7 Anchor Bolt .......................................... 35-55 Nm
4 Seat Belt Webbing Guide 8 Anchor Bolt .......................................... 35-55 Nm

SEAT BELTS 8A-3
REAR SEAT BELT
1 Seat Belt Assembly (3-point) 5 Webbing Buckle Assembly (Rear)

2 Seat Belt Stalk Plate Assembly 6 Webbing Hanger
3 Seat Belt Assembly (2-Point) 7 Seat Belt Dust Cover
4 Webbing Buckle Assembly (Center) 8 Webbing Guide

8A-4 SEAT BELT
GENERAL DESCRIPTION
AND SYSTEM OPERATION
DRIVER SEAT BELT WARNING
The driver's safety belt incorporates a safety belt
reminder light in the instment cluster remind the driver if
the safety belt is not fastened when the ignition is turnd
ON.
OPERATION AND FUNCTIONAL

CHECKS
Caution:
l Keep sharp objects and potentially damaging
objects away from the seat belts.
l Avoid bending or damaging any portion of the
buckle or the latch plate.
l Do not bleach or dye the belt webbing. Use only
mild soap and water in order to clean the belts.
l When installing the seat belt anchor bolts and
the screws, start the bolts and screws by hand
in order to prevent crossthreading.
l Do not attempt any repairs on the retractor
mechsemblies with new assemblies.
l Replace any belts that are cut r damaged in any
way.
1. Inspect all saet belt anchor bolts and the screw in
order to verify that they are secure.
2. Inspect the seat belt buckle. The buckle must lock
and unlock easily.
3. After inserting the latch into the buckle, tug sharply
on the belt. The buckle must remain locked.
4. Fully extend the shoulder belt portion to make sure
that there is no twisting or tears in the belt.
5. Let the shoulder belt retract fully. The belt should
retract easily.

SECTION 8B
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8B-1 Maintenance and Repair . . . . . . . . . . . . . . 8B-17
General Specifications . . . . . . . . . . . . . . . . . . 8B-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 8B-17
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 Air Bag Module . . . . . . . . . . . . . . . . . . . . . . . 8B-17
Function Description . . . . . . . . . . . . . . . . . . 8B-3 Clock Spring . . . . . . . . . . . . . . . . . . . . . . . . . 8B-18
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-6 Air Bag Control Unit (AC4) . . . . . . . . . . . . . . 8B-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-6 General Description and System
Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9 Operation . . . . . . . . . . . . . . . . . . . . . . . . 8B-21
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . 8B-15 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-21
Air Bag Diagram . . . . . . . . . . . . . . . . . . . . . . 8B-16 Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-21
SPECIFICATIONS
Air bag System Deployment Time < 20ms
Detection Time < 5ms
Operating Temperature -40°C - +85°C
Storage Temperature -40°C - +90°C
Air Bag Replacement Interval Every 10-year after installation
Voltage Range 9-16V
Current Consumption 5ms after ignition switch ON < 1A,
5ms - 5sec. <300mA, after 5sec. < 100mA
Acceleration Range +/-50g
Max. Acceleration +/-600g pulse
Voltage Ramp 0.5 - 2.0 V/s
Energy Reservation 150ms after battery disconnection
Inflator Ignition Energy 4.3mJ
Squib Resistance 2.15 ± 0.35 W
Air Bag Warning Lamp ON Time (When Ignition ON) 6 sec.

8B-2 SUPPLEMENTAL RESTRAINT SYSTEM(SRS)
CAUTIONS
Failure to follow the correct service procedure can cause air bag damage or personal injury due to unexpected air
bag deployment. Before service (removal and installation of part, check for replacement), please be weal noticed of
following items for your correct service.
1. For service, turn the ignition switch to ‘LOCK’ position and wait for 30 seconds after disconnecting the negative
battery cable.
2. If the vehicle collapsed, remove the air bag ECU first to reserve the crash records.
3, Never use other vehicles’ air bag components and replace with specified new part.
4. Never disassemble or repair the air bag module, air bag unit and wiring harness to re-use.
5. Replace the air bag module and air bag unit with new if it dropped, cracked or damaged.
6. Only qualified technicians in service shop should check or repair the air bag,
7. Before service, should be well noticed of warning labels on the vehicle.
A. Sun Visor Side D. Engine Compartment

[Warning] [Warning]
Pull down the sun visor and see SRS air bag This vehicle Ss equipped with air bag. Before
warning lamp on the head lining. checking the engine compartment, read service
manual first. Faultuy check and service can cause
SRS air bag deployment and system defects that
B. Head Lining can be led to severe damage.
[Warning]
1 . This vehicle is equipped with air bag. Air bag is E. Battery Cable
supplemental device for the seatbelt. Fasten
your seatbelt. [Warning]
2. This air bag should be replaced by authorized Before disconnecting the battery power, read
supplier within replacement intervals. service manual first.
3. When the ignition key is turned to ON position,
SRS warning lamp will turn on for 6 sec. and go
off. In this case, the system is normal.
For the following cases, see service manual.
- SRS warning lamp does not turn on.
- SRS warning lamp does not go off.
- SRS warning lamp continues to blink.
C. Steering Wheel Body Inner

[Warning]
Before removing the steering wheel, read service
manual first. Set the front wheels straight forward
and align the center position marks of SRS clock
spring. Improper removal or installation of the
steering wheel can damage the SRS components.

SUPPLEMENTAL RESTRAINT SYSTEM(SRS) 8B-3
Air Bag Control Unit (AC4)
Air bag control unit (AC4) is installed on the center portion of
the front floor tunnel.
It is a central control unit that control all functions and determines
whether deploy the air bag or not with the collision signal from
the built-in accelerometer sensor and has function of diagnosing
system defects.
Internal air bag control unit is consisted as follows;
l Microprocessor
l ASICs (Upper side ASIC & lower side ASIC)
l Accelerometer sensor
l Arming sensor
l System energy backup condenser
l Squib energy backup condenser

Input & Output Function
Electronic air bag control and diagnosis module is connected
by full 30-pin connectors.
Input : ground
Output : 1 squib line, warning lamp
Input/output : communication, diagnosis
5
IGN +
2
GND -
Ground connection or open
Air bag 1
Warning lamp Air bag lamp
control
unit
20 Communication/
RxD/TxD
diagnosis
13
Inflator line 1
14
Connector Pins
15 1
30 16
1 Lamp 16 Shorting Bar

2 Ground 17 Shorting Bar
3 N/A 18 Shorting Bar
5 Ignition 20 Diagnosis
8 CONF 23 No Pin
9 N/A 24 No Pin
12 N/A 27 N/A
13 Squib Line 1(upper) 28 Shorting Bar
14 Squib Line 1(lower) 29 Shorting Bar
15 N/A 30 N/A

Air Bag Module
Air bag module is installed in the pad of steering wheel center and inflator is consisted of igniter, explosives, gas
generating material and bag. When crashed, the air bag control unit sends current to the air bag module through
squib line and this current ignites as ignition energy (6mJ) momentarily igniting explosives and bag will be inflated
by nitrogen gas protecting driver at the same and then deflates.
1 Air bag Module 5 Retainer Ring

2 Module Housing 6 Inflator
3 Bag 7 Horn Switch
4 Module Bracket 8 Backing Plate

DIAGNOSIS
DESCRIPTION
Air bag control unit continuously controls system function as follows during ignition ON or driving.
- Recognition of collision
- Internal diagnosis
- External diagnosis
If recognize or detect defects, warning lamp will turn on. If there is danger of improper deployment, the system will
enter overall shutdown status and the air bag will not inflate.
Air bag control unit will store detected internal and external defects in the EEPROM.
System Control
Battery Voltage Check
Battery voltage will be monitored continuously. If voltage is out of normal operating range, all system diagnosis will
stop and warning lamp turn on.
Battery Voltage (V) Function
< 8.7 System diagnosis stops and warning lamp turns on
9-16 Normal operation range
> 16.3 System diagnosis stops and warning lamp turns on
Squib Diagnosis
It checks not only high (4.50.5) or low (1.40.5) resistance but also short resistance (1- 10k) status between the
battery and ground to indicate defects in squib line by blinking warning lamp. Air bag control unit (AC4) can measure
squib resistance.
Warning Lamp Turning On

Air bag control unit detects system defects during ignition ON or driving and displays following 2 warning lamps.
- Warning lamp ON: internal defects of the air bag control unit
- Warning lamp blinking: higher resistance than standard in the squib line or short at the battery or ground,
Safety Function Check

It checks defects during operation of the arming sensor If the sensor is shorted for more than 2 seconds, the module
will enter overall shutdown mode.
Temperature Sensor
Function of the temperature sensor will be monitored continuously. If there is fault due to defective sensor or short,
the lamp will turn on and program will take calibration temperature (25) of collision conditions.
Power Supply
Airbag control unit operates in 9-16V and the characteristic of the system has backup condenser to supply the power
for max.150ms if there is power defect during collision.

Energy Reserve System
Energy reserve system is consisted of condensor and energy switch and will check following items continuously
during system operation.
- High voltage
- Low voltage
- Low rating capacity
- Function of the energy reserve switch
If there is fault in the energy reserve system, warning lamp will turn on. And defects are found by continuous
checking of the condenser voltage, the system will enter overall shutdown status for safety reason.
Shutdown Switch
There is 1 energy shutdown switch in the system and it will be checked during start-up. And it also checks that
condenser is discharging properly. If shutdown switch is short, it will be detected during condensor voltage test.
If squib line fault is obvious, the warning lamp will turn on and the module will enter overall shutdown status.
Accelerometer Check
Accelerometer function will be checked during start-up. During operation, accelerometer off-set signal will be checked,
If there is fault, module will enter overall shutdown status.
ASIC Overheat
Module monitors upper side ASIC overheats continuously. If overheated, the module will enter overall shutdown
status.
Microprocessor Fault
Module checks EEPROM, ROM checksum and RAM during start-up. EEPROM tests checksum operation.
If RAM or ROM checksum is defective, module will not allow start-up continuously but will be re-set,
If EEPROM is defective, warning lamp will turn on and the module will enter overall shutdown status.
During operation, RAM will continuously verify the proper operation of temporary memory program data usage. If
there is fault, the module will enter overall shutdown status and the warning lamp will turn on.
Watchdog Test
Watchdog function will be tested in start-up. If there is fault during the test, warning lamp will turn on and the module
will enter overall shutdown status.

Diagnosis
Air bag control unit diagnoses each function in the intervals of 250ms - 20 sec. during start-up or driving to prevent
unwanted air bag deployment. If there is defect, it turns on or blinks warning lamp to indicate defects in the air bag
system to the driver. And fatal defect is found, air bag control unit enters overall or partial shutdown status and fault
code will be stored.
Air bag control unit diagnoses following items.

Diagnosis Condition Diagnosis Items
Start-up (ignition ON) - Ignition TR
- Acceleration
- Microprocessor, RAM and ROM
- Watchdog
- Shutdown Switch
During Driving - Squib resistance

- Squib line short to battery and ground
- Energy reserve system
- Lamp output
- Battery voltage
- ASIC communication
- Arming sensor
- ASIC overheating
- RAM and W/D
- EEPROM
Lamp Blinking Mode

There are 2 kinds of blinking mode
1. When system internal fault is found, the lamp will stay on.
2. The lamp will blink according to external fault and there are 2 blinking codes.
Blinking code 1 (Squib resistance fault in the driver’s air bag squib line)
Blinking code 2 (Squib short on plus and minus in the air bag squib line)
Lamp blinking code is as follows. The last blinking will be within 0.5 sec. and 1 cycle of blinking will be repeated every
5 seconds.
Blinking Code 1
(Sec.) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
Blinking Code 3
(Sec.) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

SELF DIAGNOSIS
1 Diagnosis Connector 3 Solenoid Valve

2 Fuse Box
1. Position the ignition switch to ‘OFF’.

2. Connect the harness connector of scanner to the diagnosis
socket in engine compartment.
3. Turn the ignition switch to ‘ON’ position.
4. Select “Electronic control vehicle diagnosis” from function
selection display and press ‘Enter’.
5. Select “Korando (’98 model year)” from vehicle model
selection display and press ‘Enter’.
6. Select “Electronic air bag” from control system selection
display and press ‘Enter’.
7. Select “Self-diagnosis” from diagnosis item selection display.
Notice
Check sensor value of output display, if necessary.
8. Determine the fault code and trace defective component.
Notice

Self-Diagnosis List
Fault Appli-
Defects Service Hint
Code cation
01 Driver’s squib (+) side No. 1 l Short of (+) side No. 1 in the driver’s squib circuit.
l Check connection of connector.
l Check the ECU.
02 Driver’s squib (+) side No. 2 l Short of (+) side No. 2 in the driver’s squib circuit. X
l Check the ECU.
03 Driver’s squib (+) side No. 3 l Short of (+) side No. 3 in the driver’s squib circuit. X
l Check the ECU.
04 Driver’s squib (+) side No. 4 X
05 Driver’s squib ground (-) side No. 1 l Short of ground side No. 1 in the driver’s squib
circuit.
l Check and replace the ECU.
06 Driver’s squib ground (-) side No. 2 l Short of ground side No. 2 in the driver’s squib X
circuit.
circuit.
circuit.
09 Energy shutdown switch No. 1 l Air bag control unit internal defects.
10 Energy shutdown switch No. 2 l Air bag control unit internal defects. X
13 Ignition switch wire No. 1 l Air bag control unit internal defects.
14 Ignition switch wire No. 2 l Air bag control unit internal defects. X

Fault Defects Service Hint Appli-

Code cation
17 Squib No. 1 resistance l Driver’s squib resistance is higher than standard
(4.5±0.5W).
l Check related circuits for open/short.
l Check the ECU.
l Replace the squib wire.
l Plus side short : 7k, ground side short : 6kW.
18 Squib No. 2 resistance l Driver’s squib resistance is higher than standard X
(4.5±0.5W).
l Check the ECU.
(4.5±0.5W).
l Check the ECU.
(4.5±0.5W).
l Check the ECU.
21 Squib No. 1 resistance l Driver’s squib resistance is lower than standard
(1.4±0.3W).
l Check the ECU.
22 Squib No. 2 resistance l Driver’s squib resistance is lower than standard X
(1.4±0.3W).
l Check the ECU.
(1.4±0.3W).
l Check the ECU.

Fault Defects Service Hint Appli-

Code cation
(1.4±0.3W).
l Check the ECU.
25 Energy reserve No. 1 voltage l Air bag control unit internal defects.
26 Energy reserve No. 2 voltage l Air bag control unit internal defects. X
31 Energy reserve No. 1 current off l Air bag control unit internal defects.
capacity l Check and replace the ECU.
32 Energy reserve No. 2 current off l Air bag control unit internal defects. X
35 Energy reserve No. 5 current off l Air bag control unit internal defects.
36 Condensor voltage l Air bag control unit internal defects.

37 Collision times checksum l Air bag control unit internal defects.

38 Driver’s acceleration sensor l Air bag control unit internal defects.

39 Driver’s acceleration sensor off-set l Air bag control unit internal defects.
40 Arming sensor l Air bag control unit internal defects.

41 Major USA l Air bag control unit internal defects.


Fault Appli-
Code Defects Service Hint
cation
42 Over heat l Air bag control unit internal defects.
43 SENS l Air bag control unit internal defects.

44 Standard band gap l Air bag control unit internal defects.

45 Temperature sensor l Air bag control unit internal defects.

46 Warning lamp l Open/short in the warning lamp circuit.

l Check the ECU.
47 Battery voltage l Power wire voltage is out of standard voltage (9
- 16V).
l Check the battery for voltage and charging.
l Check the ECU.
49 Fault code list l Air bag control unit internal defects.
l Check the ECU.
50 USA communication l Air bag control unit internal defects.

51 LSA communication l Air bag control unit internal defects.

52 No EEPROM program l Air bag control unit internal defects.

53 EEPROM checksum l Air bag control unit internal defects.

54 EEPROM map l Air bag control unit internal defects.

55 External watchdog 1 l Air bag control unit internal defects.

56 Arming sensor-no close l Air bag control unit internal defects.

57 RAM check l Air bag control unit internal defects.

58 System l Air bag control unit internal defects.

59 External watchdog 2 l Air bag control unit internal defects.

60 Pulse l Air bag control unit internal defects.


Fault Appli-
Code Defects Service Hint
cation
127 Collision signal l Air bag control unit internal defects.
128 Collision number l Air bag control unit internal defects.


CIRCUIT DIAGRAM

AIR BAG DIAGRAM


ON-VEHICLE SERVICE
AIR BAG MODULE
1. Remove the steering wheel rid (LH,RH) with a screwdriver.
Installation Notice
Each position mark (LH,RH) is stamped on the inner surface
of the rids.
2. Unscrew the bolts from both sides.

Installation Notice
3. Disconnect the connectors and remove the air bag module.

reverse order.

CLOCK SPRING
General Specification
Voltage DC 12V
Rating Operating Voltage DC 6-18V
Current Rating Air Bag 10-30mA(6A,0.1second)
Horn (Relay) 200-220mA
Remote Control (Electronic Circuit) 15mA
Air Bag Circuit Resistance 0.16-0.38W (-40°C - 85°C)
Isolating Resistance 5MW
Rotating Range 2.7-3.1 Rotation from neutral
Position to Both Sides
Notice
l Clock spring can not be repaired.
l Do not disassemble or modify.
l To adjust to the center position, rotate clockwise until it
stops and then rotate it counterclockwise 2.3 ± 0.2
revolutions and align marks. If not, airbag system can
not work normally and driver can be injured seriously.

preceding work : removal of steering wheel
1. Turn the ignition switch to “OFF” position and disconnect
the battery negative cable. Start the procedure after waiting
over 3oseconds.
2. Unscrew 3 screws from lower cover on steering column shaft
and remove the lower cover.
3. Unscrew 4 screws from clock spring and remove the clock

spring
Installation Notice
l Don’t try to repair and modify the clock spring.
l When aligning the neutral position, turn to clockwise until it
stops, and turn to counter clockwise until the marks are
aligned

AIR BAG CONTROL UNIT(AC4)

AC4 is installed on the center portion of the front floor tunnel.
Built-in accelerometer sensor detects collision and determines
action or non-action and ignition time.
Notice
Do not disassemble the AC4 to repair. If defective, replace it.
AC4 should not be shocked or vibrated by dropping on the
ground or bumping.
Replace the AC4 with new after air bag inflation.
1. Disconnect the negative battery cable and wait for 30
seconds before starting service.
Notice
Though battery cable is disconnected, air bag control unit
will maintain backup power for 150ms and air bag can be
inflated, so wait for min.30 seconds.
2. Remove the console box and center fascia panel assembly.
3. Remove the heater control switch and audio assembly.
4. Remove the lower side panel of the driver’s portion and
glove box.
5. Remove the lower main panel.
6. Release the lock lever of the AC4 connector and disconnect
the connector.
7. Unscrew 3 nuts and remove the AC4.
Notice
For installation, horizontal position should be secured for
the better changes of collision pulse between the vehicle
body and air bag control unit.
reverse order.
1. Check AC4 case and welt bolts for crack or deformation.
2. Check connector, lock lever and terminal for deformation.
Notice
Replace the AC4 with new if dust, deformation or corrosion
found.

GENERAL DESCRIPTION
AND SYSTEM OPERATION
INTRODUCTION
SRS (Supplemental Restraint System) air bag protects driver
and passenger by inflating air bag under collision and seat
belt pre - tensioner is a supplemental equipment for seat belt
reducing shocks from the collision by pulling passenger’s body
against seat back at the same time of air bag inflation.
Air bag unit has diagnosis functions and indicates system
malfunctions to the driver by turning on the air bag warning
lamp.
CAUTION
Perform the service procedures for the air bag system as
ordered, if not, the air bag can be operated suddenly and it
could result in damage of air bag or injury. Before service
(removal, installation, checking and replacement of parts),
observe the following instructions and service correctly.
1. To service, turn the ignition switch to ‘LOCK’ position and
disconnect the negative battery cable and continue the
procedures after approx. 30 seconds.
2. If the vehicle is damaged due to accident, remove the air
bag ECU first to get the accident records.
3. Never use the other vehicle’s air bag parts and replace with
genuine part, if required.
4. Do not disassemble or repair the air bag module, air bag
unit and wiring harness to reuse.
5. Replace the air bag unit or air bag module if dropped,
cracked or damaged.

SECTION 9A
BODY WIRING SYSTEM

noted.
TABLE OF CONTENTS
Schematic and Routing Diagrams . . . . . . . . 9A-2 Engine Room . . . . . . . . . . . . . . . . . . . . . . . . 9A-10
Power Distribution . . . . . . . . . . . . . . . . . . . . . . 9A-2 Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-11
Starting and Charging (Gasoline) . . . . . . . . . . 9A-3 Floor and Rear . . . . . . . . . . . . . . . . . . . . . . . 9A-13
Starting and Charging (Diesel) . . . . . . . . . . . . 9A-4 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . 9A-14
Fuse Box and Relay . . . . . . . . . . . . . . . . . . . 9A-5 Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-16
Location of Connectors by Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-17
Wiring Harness . . . . . . . . . . . . . . . . . . . . 9A-10 Tail Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-19

9A-2 BODY WIRING SYSTEM

POWER DISTRIBUTION

BODY WIRING SYSTEM 9A-3
STARTING AND CHARGING (GASOLINE)

STARTING AND CHARGING (DIESEL)

FUSE BOX AND RELAY
1 Automatic Door Lock Relay 5 Interior Relay

2 Engine Room Fuse Box 6 Window Auto Down Relay
3 ABD Motor and Valve Relay 7 Over Voltage Protection Relay : OVPR
4 Interior Fuse Box

Engine Room Fuse (EF) and Relay Box
Relay Fuse Fusible link

1. Tail Lamp 10. Horn - (10A) 15. OVPR (Gasoline) - (20A)
2. Horn 11. Tail/Rear Fog Lamp - (15A) 16. Tail Lamp - (30A)
3. Register(Gasoline) 12. Head Lamp (HI) - (15A) 17. Head Lamp - (30A)
4. Front Fog Lamp 13. Head Lamp (LO) - (15A) 18. Engine - (30A)
5. Condenser Fan 14. Front Fog Lamp (15A) 19. Ignition Switch - (30A)
6. Compressor (Diesel) & 20. Battery - (50A)
Condenser Fan (Gasoline)
7. Condenser Fan
8. Head Lamp (HI)
9. Head Lamp (LOW)

Fuse Box in the Interior
F1 ABS, ABD ECU 15A F15 Stop Lamp Switch 15A

F2 TCU, ECS Relay, Seat Warmer Unit 10A F16 Air Conditioner, Door Lock, Seat 15A
Warmer Unit
F3 Immobilizer(Diesel), Stop Switch 10A F17 Power Window Relay, Diagnosis 10A
Connector
F4 AUDIO Switch, AUDIO 10A F18 Engine Room Relay, Hazard Switch 15A
F5 O/S MIRR, C/LIGHTER 15A F19 Back up Lamp 10A
F6 Room Lamp, Door Lamp, 10A F20 T.O.D, T.C.C.U, Sun Roof, Auto Dimming 10A
Luggage Room Lamp Room Mirror
F7 Hazard Switch 15A F21 Speed Sensor, Diagnosis Connector, 10A
Joint Conn. #5
F8 Defogger Relay 20A F22 Diode, OVPR, Preheat Control Unit, 10A
Shift Lock Relay
F9 STICS Joint Conn. #1, Audio 10A F23 Air Bag Unit 10A
F10 Power Relay 30A F24 ECS Relay 15A
F11 ABD ECU 15A F25 Antenna Motor 10A
F12 Sun Roof Relay 20A F26 FRT Wiper Relay, Motor 15A
F13 T.C.C.U, T.O.D unit 20A F27 RR Washer / Wiper Motor 10A
F14 Blower Motor Relay 30A F28 A/C Relay, Joint Conn. #3 10A

Relay Box in Vehicle
1. Front Wiper Relay 5P
2. ABD 5.0 Ground Relay 5P
3. Hazard Warning Flasher Relay 3P
4. Fuel Pump Relay 5P
5. Shift Lock Relay 4P
6. Defogger Relay 4P
7. ECS Relay 4P
8. Rear Fog Lamp Relay 4P
9. Power Window Relay 4P
10. Air Conditioner Relay 4P
11. Sun Roof Relay 4P(N/C Type)
12. Clutch lnterlock Relay 4P(Manual Transmission)
Neutral Relay 4P(Automatic Transmission)
Checking The Fuses

It is possible to check the condition of blade type fuses without
pulling out them from fuse block.
Lighting on the test lamp is normal when the one lead wire of
test lamp is contacted with fuse end and the other one is
grounded.
1. In case of melting out the fuse owing to the over-voltage

replace the damaged fuse to the rated one after removing
the causes of the failure or abnormal parts.
2. In case of melting out the fuse owing to the frequent 'ON','Off'

replace the damaged fuse to the rated one.

Relay

LOCATION OF CONNECTORS BY WIRING HARNESS

ENGINE ROOM
1 Brake Fluid Leveling Sensor 26 Thermos Switch 2 (E20 Only)

2 Constar Plug Solenoid Valve 27 RH Condenser Fan Motor
4 Locking Hub 28 RH Front Fog Lamp
6 Octane Selector (Gasoline, E20 Only) 29 RH Head Lamp
8 Fusiblink Box 30 RH Head Lamp Leveling Deivce
9 Ground 31 Hood Switch
10 Turn Signal Lamp (LH) & Tail Lamp 32 Turn Signal Lamp (RH) & Tail Lamp
11 Black Out Lamp (DOM) 33 Ground 2
12 LH Head Lamp 34 Alternator
13 LH Head Lamp Leveling Device 35 Alternator Extension Wiring Connector
14 LH Front Fog Lamp 36 Receiver Drier
15 Compressor 37 Washer Motor
17 Front Wheel Speed Sensor 39 Front Wheel Speed Sensor
18 LH Condenser Fan Motor 40 Side Repeater
19 Resistor 41 Main Wiring Connector2 (ABS 5.3)
22 Ambient Sensor 43 Main Wiring Connector1
23 LH Horn 44 Main Wiring Connector2 (ABS 5.3)
24 Cooling Fan Motor Relay 46 ABS 5 ECU (ABS 5.3)
25 RH Horn 47 Engine Room Relay Box
48 Thermo Sensor 2 (E20, E23 only)

MAIN
1 Engine Wiring Connector (LH) 25 Clutch Switch2 (M/T)

2 Engine Wiring Connector (LH) 26 Stop Lamp Switch
4 LH Side Repeater 27 Multifunction Switch1
6 Relay Box 28 Multifunction Switch2
7 Fuse Box 29 Ignition Switch
8 Joint Connector 30 Auto Cruise Switch
9 Door Wiring Connector (Driver's) 31 Multifunction Switch3
10 Head Lamp Leveling Device Switch 32 Immobilizer Antenna Connector (4pin)
11 Outside Mirror Switch 33 Diagnosis Connector
12 Rear Washer & Wiper Switch 37 Transmission Wiring Connector
13 Ground 38 Transmission Wiring Connector (A/T)
14 Power Window Control Unit 39 Transmission Wiring Connector (M/T)
15 Door Lock Relay 41 REKES Unit
16 Cluster1 42 Kick Down Switch (A/T)
17 Sun Roof 43 Black Out Switch
18 Roof Wiring connector 44 Black Out Switch
19 T.C.C.U 45 Sun Sensor
20 Ground 46 Cluster
22 Floor Wiring Connector 47 Cluster
23 Floor Wiring Connector 48 Cluster
24 Clutch Switch1 (M/T)

49 Joint Connector 82 ECS Unit Connector
50 Ground 83 T.C.U (A/T BTRA Only)
51 Joint Connector 85 STICS
52 Mode Actuator 86 STICS
53 Audio Ground 87 STICS
54 Seat Belt Switch 88 Ground
55 Joint Connector 92 ABD 5 ECU
56 Hazard Switch 93 ABD 5 ECU Ground
57 Defogger Switch 95 Parking Brake Switch
59 Rear Fog Lamp Relay 96 O2 Sensor
60 Unlock Switch 97 Shift Lock Solenoid
61 - 98 P/W Mode Switch
62 Ground 100 "P" Position Switch
63 Joint Connector 102 RH Engine Wiring Connector
64 Resistor 103 Combination Connector
65 Seat Warmmer Connector 104 O2 Sensor (E20, E23)
66 T.O.D (E32 Only) 105 Engine Wiring Connector (ABD 5.3)
67 Blower Relay 106 ABD 5 Modulator (ABD 5.3)
68 Water Sensor 107 Front Wiper Motor
69 Thermo Amp 108 Siren
70 Antenna Feeder Cable 109 Engine Main Wiring connector
71 A/C Wiring Connector 110 Intake Actuator
72 A/C Switch 112 Antenna
73 Control Amp 113 Door Wiring Connector (Passenger's)
74 Blower Fan Switch 114 Blower
75 Audio 115 MSE ECU Connector
76 Cigarette Lighter 116 Ground
77 Audio 117 Ground
78 Buzzer 118 4WD Switch
79 Chime 119 EGR Solenoid Connector (Diesel Only)
80 Accelerator Sensor (ABD 5.3 only)

FLOOR AND REAR
3 Door Switch 12 Ground

4 Wheel Speed Sensor (Rear Right) 13 Luggage Room Lamp
5 Wheel Speed Sensor (Rear Left) 14 LH Rear Combination Lamp
6 Main Wiring Connector 15 Rear Bumper Wiring Connector
7 Main Wiring Connector 16 Tail Gate Wiring Connector
8 RH Rear Speaker 17 Tail Gate Wiring Connector
9 Tail Gate Switch 20 RH Rear Damper
10 RH Rear Combination Lamp 21 LH Rear Damper
11 LH Rear Speaker 22 Door Switch

AIR CONDITIONER
Semi A/C
1 Main Wiring Connector 9 Mix Actuator

2 Floor Fan Switch 10 Auto Amp
3 A/C Diode 11 Auto Amp
4 HI Relay 12 Floor Switch
5 MH Relay 13 Mode Switch
6 ML Relay 14 PTC
7 LO Relay 15 In-Car Sensor Connector
8 A/C Relay

Full A/C
1 Mode Actuator 4 High Speed Relay

2 In-Car Sensor 5 Intake Actuator
3 Blower Relay 6 Temperature Actuator

ROOF
1 Main Wiring Connector 4 Sun Roof

2 Sun Roof Wiring Connector 5 Center Room Lamp
3 Front Room Lamp

DOOR
Dirver's Door
1 Main Wiring 6 Power Window Switch(Main)

2 Tweeter Speaker 7 Door Cylinder Switch
3 Outside Mirror Motor 8 Door Lamp
4 Power Window Motor(Main) 9 Door Lock Actuator
5 LH Front Speaker

Passenger's Door
1 Main Wiring Connector 6 Power Window Switch(Sub)

2 Tweeter Speaker 7 Door Cylinder Switch
3 Outside Mirror Motor 8 Door Lamp
4 Power Window Motor (Sub) 9 Door Lock Actuator
5 RH Front Speaker

TAIL GATE
1 Floor Wiring Connector 6 Linkage Lamp

2 Floor Wiring Connector 7 Tail Gate Lock Actuator
3 Rear Heated Glass (+) 8 Rear Heated Glass (+)
4 Rear Wiper Motor 9 Tail Gate Cylinder Switch
5 Rear Washer Motor

SECTION 9B
LIGHTING SYSTEM
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 9B-1 Back-Up Lamp and Stop Lamp . . . . . . . . . . . . 9B-5
Bulb Usage Chart . . . . . . . . . . . . . . . . . . . . . . 9B-1 Front and Rear Fog Lamp . . . . . . . . . . . . . . . 9B-6
Schematic and Routing Diagrams . . . . . . . . 9B-2 Room Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-7
Tail Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-2 Maintenance and Repair . . . . . . . . . . . . . . . 9B-8
Head Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9B-8
Turn Signal Lamp and Hazard Lamp . . . . . . . . 9B-4 Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-8
SPECIFICATIONS
BULB USAGE CHART
Application Watt/Quantity
Position Lamp Front 5W / 2
Rear 5W / 2
License Plate 5W / 2
Head Lamp Low Beam 55W / 2
High Beam 60W / 2
Turn Signal Lamp Front 27W / 2
Rear 21W / 2
Side 5W / 2
Room Lamp Front Room 8W / 2
Center Room 10W / 1
Luggage Room 8W / 1
Door Courtesy Lamp 5W / 2
Front Fog Lamp 55W / 2
Stop Lamp 21W / 2
Back up Lamp 21W / 2

9B-2 LIGHTING SYSTEM

TAIL LAMP

LIGHTING SYSTEM 9B-3
HEAD LAMP

TURN SIGNAL LAMP AND HAZARD LAMP

BACK-UP LAMP AND STOP LAMP

FRONT AND REAR FOG LAMP

ROOM LAMP


ON-VEHICLE SERVICE
LAMPS
Front and Room Lamps
1 Head Lamp 7 Bulb

2 Bulb 8 Screw
3 Front Fog Lamp 9 Side Repeater Lamp
4 Bulb 13 Front Room Lamp
5 Front Turn Signal & Position Lamp 14 Center Room Lamp
6 Bulb 15 Luggage Room Lamp

Rear Lamps
16 License Plate Lamp 19 Screw

17 Door Courtesy Lamp 20 Screw
18 Rear Combination Lamp
Notice
Removing and installing order is followed by the nos on
the above picture.

Alignment for Head Light Angle
1. Adjust the tire pressure as specified and unload the all
luggages from the vehicle except driver and spare tire.
2. Set the vehicle onto the flat ground and adjust the
distance(A) from tester to vehicle.
Distance A: 10m
3. Turn on the head light switch during engine is idling.

4. Align the head light angle by turning the adjusting screw.
l Horizontal adjustment screw 1
l Vertical adjustment screw 2
5. Adjust the head light angle to 150mm - 25mm at the tester
by turning the adjusting screw.
Alignment for Fog Lamp

1. Set the vehicle onto the flat ground and adjust the
distance(25m) from fog lamp tester to vehicle.
2. Adjust the vertical angle of fog lamp to maximum 50mm by
using adjusting knob.
l Adjusting knob
l Clockwise : Downward
l Counter clockwise : Upward

SECTION 9C
HORNS
noted.
TABLE OF CONTENTS
Schematic and Routing Diagrams . . . . . . . . 9C-2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C-2

9C-2 HORN

HORN

SECTION 9D
WIPERS/WASHER SYSTEM
noted.
TABLE OF CONTENTS
Schematic and Routing Diagrams . . . . . . . . 9D-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9D-3
Rear Wiper and Washer . . . . . . . . . . . . . . . . . 9D-2 Front Wiper and Washer . . . . . . . . . . . . . . . . 9D-3
Maintenance and Repair . . . . . . . . . . . . . . . 9D-3 Rear Wiper and Washer . . . . . . . . . . . . . . . . . 9D-6

9D-2 WIPERS/WASHER SYSTEM

REAR WIPER AND WASHER

WIPERS/WASHER SYSTEM 9D-3

ON-VEHICLE SERVICE
FRONT WIPER AND WASHER
1 Windshield Wiper Linkage 5 Windshield Washer Reservir Assembly

2 Nut 6 Washer Nozzle
3 Wiper Arm 7 Washer Hose
4 Blade 8 Mounting Holder

1. Remove the wiper arm and blade.
2. Remove the linkage connected to the wiper motor.
3. Disconnect the connector from the wiper motor.
4. Unscrew the locking bolts from wiper motor.
reverse order.

Connector Appearance and Connecting Circuit
Connector Terminal
H HI(high speed)
P Intermittent
B Ground
L Low(low speed)
Diagram for Connecting Circuit

REAR WIPER AND WASHER
1 Blade 6 Wiper Cap

2 Clip 7 Washer Reservoir Assembly
3 Wiper Arm Assembly 8 Washer Nozzle
4 Wiper Cap 9 Wiper Motor
5 Wiper Cap Mounting Nut

1. Remove the spare tire.
2. Unscrew the locking nut and remove the wiper.
3. Unscrew the locking nut of wiper motor.
4. Remove the tailgate trim panel.

5. Disconnect the connector from the wiper motor.
6. Unscrew four screws(arrows) and remove the wiper motor.

reverse order.

Connector Terminal
B+ Battery Power Source
E Ground
WP From Switch
E WP E WS
OFF
ON
WS

SECTION 9E
INSTRUMENTATION/DRIVER INFORMATION
noted.
TABLE OF CONTENTS
Schematic and Routing Diagrams . . . . . . . . 9E-2 Maintenance and Repair . . . . . . . . . . . . . . . 9E-4
Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9E-4
Component Locator . . . . . . . . . . . . . . . . . . . 9E-3 Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-4
Combination Meter . . . . . . . . . . . . . . . . . . . . . 9E-3

9E-2 INSTRUMENTATION/DRIVER INFORMATION

CLUSTER

INSTRUMENTATION/DRIVER INFORMATION 9E-3
COMPONENT LOCATOR
COMBINATION METER
1 LH Turn Signal Lamp 17 Brake & Parking Brake Warning Lamp

2 RH Turn Signal Lamp 18 Seat Belt Warning Lamp
3 Tachometer 19 Fuel Level Warning Lamp
4 Speedometer 20 Air Bag Warning Lamp
5 Digital Clock 21 Pre-Glow
6 Selector Lever Position Indicator (A/T) 22 WINTER Mode Indicator
7 Temperature Gauge 23 Rear Heated Glass Indicator
8 Fuel Gauge 24 Front Fog Lamp Indicator
9 Trip Meter Reset Button 25 4WD Multfunction Indicator
10 Power Mode Indicator (A/T) 26 Hazard Warning Lamp
11 HI Beam Indicator 27 TCS Indicator
12 EBD Indicator 28 4WD LO Indicator
13 ECS SPORT Mode Indicator 29 4WD HI Indicator
14 ABS Warning Lamp 30 Door Ajar Warning Lamp
15 Alternator Warning Lamp 31 Digital Clock Setting Knob
16 Oil Pressure Warning Lamp

9E-4 INSTRUMENTATION/DRIVER INFORMATION

ON-VEHICLE SERVICE
CLUSTER
1. Loosen the screw and remove the fascia assembly (1).
Notice
When assembling, there should be no clerance between
crash pad assembly (4) and cluster fascia assembly, and
the clearance between combination meter (3) and cluster
fascia have to be maintained 2mm.
2. Remove 4 screws.
3. Disconnect connectors and remove the combination meter.

leverse order.

INSTRUMENTATION/DRIVER INFORMATION 9E-5
1. Speedometer
(DIESEL) (km/h)
Speed 20 40 60 80 100 120 140 160
+4 +3 +4 +5 +5 +5.5 +5.5 +5.5
Tolerance +0 +0 +0 +0 +0 +0 +0.5 +0.5
(GASOLINE) (km/h)
Speed 20 40 60 80 100 120 140 160 180 200
+4 +3 +4 +5 +5 +5.5 +5.5 +5.5 +6 +6
Tolerance +0 +0 +0 +0 +0 +0.5 +0.5 +0.5 +1 +1
2. Tachometer
(DIESEL)
Revolution 1000 2000 3000 4000 5000
+137 +199 +261 +298 -
Tolerance -63 -51 -39 -2
(GASOLINE)
Revolution 1000 2000 3000 4000 5000 6000
Tolerance ±100 ±125 ±150 ±150 ±150 ±180
3. Fuel Gauge
Classification E 1/2 F
Resistance(W ) 97 32.5 6
Tolerance( °) ± 2.5° ± 5° ± 2.5°
4. Temperature Gauge (Temperature Sensor)

Temperature ( °) Resistance (W )
50 156.9
86 44.5
105.5 27.3
120 19.4

SECTION 9F
AUDIO SYSTEM
noted.
TABLE OF CONTENTS
Schematic and Routing Diagrams . . . . . . . . 9F-2 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-3
Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-2 General Diagnosis . . . . . . . . . . . . . . . . . . . . . 9F-3

9F-2 AUDIO SYSTEM

AUDIO

AUDIO SYSTEM 9F-3
DIAGNOSIS
GENERAL DIAGNOSIS
No sounds

SECTION 9G
INTERIOR TRIM
noted.
TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 9G-2 Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . 9G-2

9G-2 INTERIOR TRIM
COMPONENT LOCATOR
CONSOLE BOX
1 Console Box 7 Facia (M/T)

2 Tray 8 Boot Assembly (M/T)
3 Arm Rest 9 Facia (MB A/T)
4 Parking Lever Strip 10 Rear Facia Strip
5 Facia (BTRE A/T) 11 Rear Facia Cap
6 Indicator Cover

SECTION 9H
SEATS
noted.
TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 9H-2 Front Seat & Rear Seat . . . . . . . . . . . . . . . . . 9H-2

9H-2 SEATS
COMPONENT LOCATOR
FRONT SEAT & REAR SEAT
1 Front Seat Assembly (Driver’s) 5 Rear Seat Head Restraint

2 Front Seat Assembly (Passenger’s) 6 Arm Rest
3 Head Restraint 7 Bolt ...................................................... 17-27 Nm
4 Rear Seat Assembly 8 Bolt ...................................................... 35-55 Nm

SECTION 9L
GLASS AND MIRRORS

noted.
TABLE OF CONTENTS
Schematic and Routing Diagrams . . . . . . . . 9L-2 Auto Dimming Room Mirror . . . . . . . . . . . . . . . 9L-4
Outside Mirror . . . . . . . . . . . . . . . . . . . . . . . . . 9L-2 Maintenance and Repair . . . . . . . . . . . . . . . 9L-5
Component Locator . . . . . . . . . . . . . . . . . . . 9L-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9L-5
Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L-3 Auto Dimming Room Mirror . . . . . . . . . . . . . . . 9L-5

9L-2 GLASS AND MIRRORS

OUTSIDE MIRROR

GLASS AND MIRRORS 9L-3
COMPONENT LOCATOR
GLASS
1 Wind Shield Tinted Glass 5 Side Fixed Glass

2 Wind Shield Dam 6 Side Glass Nut
3 Spacer Pad 7 Tailgate Tinted Glass Assembly
4 Wind Shield Upper Mounlding 8 Tailgate Glass Moulding

AUTO DIMMING ROOM MIRROR
1 Auto Dimming Room Mirror Assembly 4 Switch

2 Sensor (Front) 5 Cover
3 Sensor (Rear) 6 Lamp

GLASS AND MIRRORS 9L-5

ON-VEHICLE SERVICE
AUTO DIMMING ROOM MIRROR
Function
When ignition switch is turned ON, green lamp on auto dimming
mirror will turn in and glare reflection ratio will be automatically
adjusted. By positioning AUTO switch to ON, 2Sensors will
automatically adjust refection ratio after sensing rear and
surrounding brightness to reduce driver’s eye fatigue during
driving though tunnel or in night.
When OFF switch is pressed, the lamp goes out and it will be
operated as a normal rear view mirror and shift lever is
positioned in reverse, the auto dimming function will be
automatically OFF.
Specifications
Voltage Rating DV 12V
Operating Current 1A
Over Current 3A
Check & Service

If reflection ratio is not adjusted automatically during night
driving when AUTO switch is pressed, check each connectors
for proper connection and power flow to the auto dimming room
mirror using multi tester.
1. Yellow (Connected to back-up lamp)
2. Blue (Ground)
3. White (Power)

1. Removal the room mirror cover (arrow).
2. Disconnect 3-pin connector.

3. Removal the mirror assembly.
reverse order.

SECTION 9M
EXTERIOR TRIM
TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 9M-2 Rear End Trim . . . . . . . . . . . . . . . . . . . . . . . . 9M-3
Side Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-2 Under Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-4

9M-2 EXTERIOR TRIM
COMPONENT LOCATOR
SIDE TRIM
1 Rivet 9 Side Step Upper Cover

2 B Piller Cover 10 Bolt
3 Air Extractor Grill 11 Wheel Arch Clip
4 Air Extractor Grill Tape 12 Garnish Clip
5 Door Moulding 13 Garnish Clip
6 Front Wheel Arch Moulding 14 Door Moulding Clip
7 Rear Eheel Arch Moulding 15 Door Moulding Strip
8 Side Step

EXTERIOR TRIM 9M-3
REAR END TRIM
1 Clip 5 Roof Moulding

2 “C” Piller Cover 6 Roof Moulding Endcap
3 Clip 7 Clip
4 Tailgate Garnish

9M-4 EXTERIOR TRIM
UNDER TRIM
1 Wheel House Cover ‘A’ 7 Splash Guide

2 Wheel House Cover ‘B’ 8 Flange Cap Nut
3 Rivet 9 Rivet
4 Front Mud Guard 10 Rear Wheel House Cover
5 Rear Mud Guard 11 Rear Wheel House Geaner
6 Spring Nut

SECTION 9N
FRAME AND UNDERBODY
TABLE OF CONTENTS
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . 9N-2 Body Mounting-Sectional View . . . . . . . . . . . . 9N-5
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9N-2 Maintenance and Repair . . . . . . . . . . . . . . . 9N-6
Component Locator . . . . . . . . . . . . . . . . . . . 9N-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9N-6
Body Mountings . . . . . . . . . . . . . . . . . . . . . . . 9N-4 Skid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9N-6

9N-2 FRAME AND UNDERBODY
DIMENSION
FRAME
178.5
S51
99
50
1035
485
681
722.8
166
232
47
420.5
910
Length
Length
Length

FRAME AND UNDERBODY 9N-3
Point A : Transmission Mounting Point

Length
Point

COMPONENT LOCATOR
BODY MOUNTINGS
1 Assembly 12 Upper Insulator

2 No. 1 Insulator Assembly 13 Upper Plate
3 No. 2 Insulator Assembly 14 Lower Insulator
4 No. 3 Insulator Assembly 15 Upper Insulator
5 No. 4 Insulator Assembly 16 Bolt
6 No. 5 Insulator Assembly 17 Plain Washer
7 Blind Plug 18 Lower Insulator
8 Bolt (M10 × 1.25) 19 Nut
9 Washer (M14) 20 Bolt
10 Washer and Tube 21 Plain Washer
11 Upper Insulator

FRAME AND UNDERBODY 9N-5
BODY MOUNTING-SECTIONAL VIEW
1 Upper Insulator 9 Plug-M40

2 Lower Insulator 10 Washer and Tube
3 Washer and Tube 11 Washer and Tube
4 Washer 12 Washer and Tube
5 Bolt ...................................................... 25-30 Nm 13 Plate
6 Nut-M10 ............................................... 25-30 Nm 14 Bolt ...................................................... 25-30 Nm
7 Washer-M14 15 Upper Insulator
8 Nut-M10 ............................................... 25-30 Nm 16 Lower Insulator


ON-VEHICLE SERVICE
SKID PLATE
1 Mounting Bolt ....................................... 28-47 Nm 2 Skid Plate

1. Loosen the mounting bolts(4EA) of skid plate and remove
the skid plate.
Installation Notice
reverse order.

SECTION 9O
BUMPERS AND FASCIAS

TABLE OF CONTENTS
Maintenance and Repair . . . . . . . . . . . . . . . 9O-2 Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . 9O-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9O-2 Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . 9O-4

9O-2 BUMPERS AND FASCIAS

ON-VEHICLE SERVICE
FRONT BUMPER
1 Front Bumper Assembly 5 Rivet

2 Pad 6 Bolt
3 Fog Lamp Mounting Bracket 7 Front Nudge Bar Assembly
4 Side Mounting Bracket 8 Side Support Bracket
Notice
Removal and installation is as shown in upper drawings.

BUMPERS AND FASCIAS 9O-3
Mounting Inspection
1. Clearance between the upper bumper and radiator grille.
Clearance 10 - 13 mm
2. Clearance between the upper bumper and headlamp

moding.

9O-4 BUMPERS AND FASCIAS
REAR BUMPER
1 Front Bumper Assembly 6 Side Bracket

3 Rivet 7 Nut
4 Protection Tape 8 License Lamp Assembly
5 Rear Bumper Spacer
Notice
Removal and installation is as shown in upper drawings.

BUMPERS AND FASCIAS 9O-5
Mounting Inspection
1. Clearance between the upper bumper facia and tailgate.
2. Clerance between the facia of rear bumper and quarter

outer panel.

SECTION 9P
DOORS
noted.
TABLE OF CONTENTS
Schematic and Routing Diagrams . . . . . . . . 9P-2 Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-3
Power Window . . . . . . . . . . . . . . . . . . . . . . . . 9P-2 Tail Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-5
Maintenance and Repair . . . . . . . . . . . . . . . 9P-3 Power Window Motor . . . . . . . . . . . . . . . . . . . 9P-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9P-3

9P-2 DOORS

POWER WINDOW

DOORS 9P-3

ON-VEHICLE SERVICE
FRONT DOOR
1 Door Trim Panel Assembly 11 Door Courtesy Lamp

2 Center Upper Panel 12 Screw
3 Inside Handle Mounting Plate 13 Door Pull Handle Mounting Support Bracket
4 Door Pull Handle 14 Door Trim Complete Mounting Clip
5 Door Defroster Nozzle 15 Door Inside handle Mounting Gromet
6 Door Defroster Duct 16 Door Defroster Gromet
7 Door Trim Panel 17 Door Defroster Gromet Vessel
8 Door Pocket 18 Door Pocket Mounting Screw
9 Belt Inside Strap 19 Door Trim Pad
10 Door Trim Mounting Fastener

9P-4 DOORS
1. Install door striker to side outer panel and tighten the screw
slightly.
2. Unlock the door and check the clearance between door
and side outer panel.
Clearance 3.5 - 5.5 Nm
3. If necessary, insert the seam.

4. Adjust latch lever to the center of striker and tighten the
screw.

DOORS 9P-5
TAIL GATE
1 Upper Bracket 4 Tail Gate

2 Lower Bracket 5 Stopper
3 Bolt

9P-6 DOORS
1. Remove the lower hinge bolt of tail gate and stopper
mounting bolt.
2. Disconnect the wiring connector.
3. Remove the mounting bolt and remove the tail gate.
Adjustment
<Door Striker>
Adjust the striker in horizontal/vertical directions and then adjust
the height of striker.
l Clearance between tailgate and quarter outer rear panel.
Clearance 4.3 - 6.3 Nm

DOORS 9P-7
POWER WINDOW MOTOR
1 Door 6 Door Trim Mounting Bracket

2 Door Trim Panel 7 Door Defroster Grommet
3 Inside Handle Mounting Plate 8 Power Window Motor
4 Door Opening Lamp 9 Regulator
5 Door Pulling Handle

9P-8 DOORS
1. Unscrew the screw (arrow) and remove the door pulling
handle.
2. Disconnect the connector and remove the power window

switch assembly.
3. Remove the inside handle mounting plate.
4. Remove the door trim panel assembly.
5. Unscrew two screws (arrows) and remove the door lock

opening handle assembly and disconnect opening handle
ratch dar.
6. Unscrew three screw (arrow) and remove the door trim

mounting bracket.
7. Disconnect the opening lamp connector.

DOORS 9P-9
8. Remove the door vinyl.
9. Unscrew the upper and lower nuts(4 piecess) and remove
the door regulator.
10. Unscrew three nuts(arrow) and remove the power window

motor.

9P-10 DOORS
1. Power Window Main Switch (Driver's Door)
Terminal No. Connecting Circuit Size and Color
1 B+ 2.0 YR
2 E- 2.0 B
3 ILL (+) 1.25 GW
4 D1 1.25 LW
5 U+ 1.25 BR
6 D2 1.25 LR
7 U2 1.25 BW
8 U- 1.25 BL
2. Power Window Sub-Switch (Passenger's Door).

Terminal No. Connecting Circuit Size and Color
1 D2 2.0 LR
2 U2 1.25 BW
3 B+ 1.25 YR
4 MU 1.25 BR
5 MD 1.25 L
6 ILL(+) 1.25 GW
7 ILL(-) 1.25 GB

SECTION 9Q
ROOF
TABLE OF CONTENTS
Maintenance and Repair . . . . . . . . . . . . . . . 9Q-2 Sun Roof System . . . . . . . . . . . . . . . . . . . . . . 9Q-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9Q-2

9Q-2 ROOF

ON-VEHICLE SERVICE
SUN ROOF SYSTEM
1 Inner Sliding Sun Roof Assembly 7 Mounting Bracket Assembly

2 Sun Roof Body Mounting Bracket 8 Sun Roof Mounting Bracket
3 Drain Hose Rear Grommet 9 Drain Front Hose
4 Sun Roof Motor Spanner 10 Drain Rear Hose
5 Mounting Clip 11 Sun Roof Module Assembly
6 Mounting Bracket

ROOF 9Q-3
1. Disconnect the connector and remove the sun roof module
assembly.
2. Disconnect the front and rear drain hose.
3. Unscrew the sun roof mounting bracket bolts (arrows) and

remove the inner sliding and sun roof assembly

SECTION 9R
BODY FRONT END
TABLE OF CONTENTS
Maintenance and Repair . . . . . . . . . . . . . . . 9R-2 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 9R-2

9R-2 BODY FRONT END

ON-VEHICLE SERVICE
HOOD
1 Bolt 5 Hood Lifter Assembly

2 Hood Striker Safety Assembly 6 Bolt
3 Bolt 7 Hood Hinge Assembly
4 Mounting Ball Stud 8 Hood

BODY FRONT END 9R-3
1. Remove the hood striker assembly.
Notice
When installing, tighten the bolt after setting the hole
between wratch and hood striker assembly.
Installation Notice
Tightening Toque 8 - 11 Nm
2. Remove the hood bolt(2EA) of hood lifter assembly.

Installation Notice
3. Remove the hood lifter assembly from the upper ball stud.
Notice
Insert the hood lifter assembly into ball stud fully until it
sounds "click".
4. Loosen the hood hinge assembly bolt and remove the hood.
Installation Notice

reverse order.

9R-4 BODY FRONT END
1. Alignment between hood striker and latch hole.
l Loosen the mounting bolt of hood latch slightly and adjust
hood in forward/rearward and left/right directions. Then
align the center between hood striker and latch hole.
Notice
Tighten the bolt fully after alignment.
Installation Notice
2. Adjusting the height of hood overslam bumper.

Unlock the hood and check the clearance between hood
and fender by adjusting the hood overslam bumper in left/
right directions.
Normal 20 - 22 Nm

SECTION 9T
REMOTE KEYLESS ENTRY AND

ANTI-THEFT SYSTEM
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 9T-1 Maintenance and Repair . . . . . . . . . . . . . . . 9T-5
REKES Specifications . . . . . . . . . . . . . . . . . . . 9T-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9T-5
Schematic and Routing Diagrams . . . . . . . . 9T-2 REKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T-5
REKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T-2 Function Description . . . . . . . . . . . . . . . . . . 9T-8
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T-3 Burglar Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 9T-8
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . . 9T-3
SPECIFICATIONS
REKES SPECIFICATIONS
Receiver
Rated Voltage DC 12V
Rated Range of Operating Voltage DC 8V - 16V
Rated Range of Operating Temperature -30°C - +80°C
Insulating Resistance Above 5M W
Arm Current Maximum 3mA
Transmitter
Rated Voltage DC 3V
Rated Range of Operating Temperature -10°C - 60°C
Model Changeable Coin Type LITHIUM Battery
(CR2032)
Durability Above 2 years (10 times/day)

9T-2 REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM

REKES

REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM 9T-3
DIAGNOSIS
DIAGNOSIS TEST
Introduction
Using the service connector, possible defects in power section,
input·output section of internal STICS unit can be detected and
each normal status and defect mode can be checked.
Diagnosis Method
1. Use buzzer for diagnosis check status output.
2. Following function outputs should not act when diagnosis
switch is ON (STICS in the diagnosis socket box:connection
of No. 7 and ground No.1).
- Tail lamp ON warning (buzzer output stop, door lock/
unlock output stop)
- Seat belt warning (chime bell output stop)
- Key reminder warning (chime bell output stop, door lock/
unlock output stop)
- Central door lock (door lock/unlock output stop)
3. Functions in No. 2 should be restored when diagnosis switch
is OFF.
4. Checked output should be made once while the diagnosis
switch is ON.
5. When inputs are made by operating each different switches
more than 2 continuously, make output according to input
order (buzzer ON) and turn off the buzzer for 1 second and
than make other remaining outputs for input switch.

6. Buzzer output is as follows.
T1 : 0.3±0.1 sec.
T2 : 0.3±0.1 sec.
T : 0.6±0.2 sec.
Notice
l In case of checking related devices, diagnosis switch
should always be ON.
l When operating the diagnosing related devices, there
will be buzzer sound if it is normal and no buzzer sound
if it is defective.
Self - Diagnosis List
NO. Required Condition Related device check (operation) Normal output Remark
1 Diagnosis switch ON Confirm the diagnosis function start Buzzer once
2 Battery voltage supply Check the battery Buzzer twice
3 Tailgate, rear door lock switch Buzzer once
4 Driver’s door lock switch Buzzer once
5 Operation of battery Passenger’s door lock switch Buzzer once
6 and related devices Driver's door switch Buzzer once
7 Passenger and rear door switch Buzzer once
8 REKES input Buzzer once
9 IGN key insertion Key reminder switch Buzzer once
GN2 buzzer twice,
10 IGN and power window relay IGN1 buzzer once, Diagnosis
power window buzzer Switch ON
3 times
11 Parking brake switch Buzzer once
12 Seat belt switch Buzzer once
Operation of IGN Wiper motor parking 3
13 and related devices Washer switch times, washer switch
once, wiper relay twice
Wiper motor parking 3
times, wiper auto
14 Wiper auto switch switch once, wiper
relay twice
15 ALT ‘L’ Buzzer once
16 Operation of IGN and Volume variable switch Buzzer once
17 starting and related Defogger switch Buzzer once
18 devices Speed sensor signal Buzzer once


ON-VEHICLE SERVICE
REKES
1 REKES Receiver 3 Bolt

2 Antenna 4 Wiring Connector (6P)

Input Memory
l When the REKES transmitter is lost
1. Connect the battery terminal No.3 and REKES terminal No.4
which are on the diagnosis socket in engine room with service
lead wire.
2. Push the lock or unlock button on the REKES transmitter.

3. Input Memory and close all doors.
4. Check the operation of door locking system by pushing the
lock or unlock button on the REKES transmitter.
1 REKES Transmitter
l When the transmitter is faulty
1. Replace the REKES transmitter with a new one and connect
the wiring connector.
2. Set the input switch of the REKES receiver onto the No.1 or
No.2 position and push the lock or unlock button on the
REKES transmitter.
3. Set the input switch of the REKES receiver onto the central
position and close all doors.
4. Check the operation of door locking system by pushing the
lock or unlock button on the REKES transmitter.
2 Input Switch of the REKES Receive

3 REKES Switch

Characteristic Signal
1. Lock or unlock all doors according to the REKES signal
when the key is removed from the key hole.
2. Characteristic Signal : Right Picture
3. Time Interval
T1 : 0.05 ± 0.02sec.(lock signal)
T2 : 0.1 ± 0.02sec.(unlock signal)
T3 : within 0.25sec.
T4 : 0.5 ± 0.1sec.
T6,T7 : 0.5 ± 0.1sec.
T8 : 1 ± 0.25sec.
Pin No. Connecting Circuit
1 B+
2 Memory Terminal
3 Key Reminder Switch
4 STICS
5 Ground
6 Memory Terminal

BURGLAR ALARM
Diagram for Burglar Alarm

Characteristic Signal
l Prepare The Burglar Alarm
1. It is possible to prepare the burglar alarm only when the
door is locked by REKES transmitter.
If the door is lock by key, the burglar alarm can’t operate.
2. When the ignition key is removed and all doors and hood
are closed, all lock switches on doors must be changed
from “ON” to “OFF” within 0.5 second after the locking signal
turns back from “LOW” to “HIGH”.
3. The system must prepare the burglar alarm within 0.35
second after all lock switches were changed from “ON” to
“OFF”.
4. If the system prepare the burglar alarm, siren will operate
for 0.05second and the tail lamp will light up twice for 0.5
second.
5. Character Signal : Right Picture
6. Time Interval
T1 : 0.05 ± 0.02sec.
T3 : 0.5 ± 0.1sec.
T4 : within 0.5sec.
T6 : 0.05 ± 0.01sec.
T7,T8 : 0.5 ± 0.1sec.
l Operate The Burglar Alarm

1. Burglar alarm must operate immediately when the door,
tailgate or hood is opened with improper ways after all doors
and hood were closed and continued this status for 2
seconds.
2. Siren will operate three series of warning for 30 second’s
“ON” and 10 second’s “OFF”.
3. If this warning condition is completed, the system block up
the current for starting motor by running the start protection
relay.
4. If the tailgate is opened by key when the system is on the
burglar alarm condition, the system must be changed to
the second burglar alarm condition from normal condition.

6. Time Interval
T1 : 2 ± 0.2sec.
T2 : three series of 30sec. “ON”, 10sec. “OFF”
T3 : 10min. ± 1min.
T4 : 0.25 ± 0.05sec.
T5 : 0.25 ± 0.05sec.
l Cancellation of The Burglar Alarm

1. It is only possible to release the burglar alarm when unlocking
the driver’s door key cylinder switch, unlocking by REKES
transmitter or turning on the IGN 1,2.
2. Cancellation by an ignition key
4. Time Interval
T1 : 1 ± 0.25sec.
5. Cancellation by REKES transmitter

6. Characteristic Signal : Light Picture
7. Time Interval
T1 : 1 ± 0.2sec.

SECTION 9U
CONTROL UNITS AND SYSTEM

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 9U-1 STICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9U-3
STICS Specifications . . . . . . . . . . . . . . . . . . . 9U-1 Maintenance and Repair . . . . . . . . . . . . . . 9U-10
Schematic and Routing Diagrams . . . . . . . . 9U-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 9U-10
STICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9U-2 STICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9U-10
Function Description . . . . . . . . . . . . . . . . . . 9U-3
SPECIFICATIONS
STICS SPECIFICATIONS
Voltage Rating DC 12V
Voltage Rating Dc 9V - 16V
Current Consumption Less than 1mA(key is removed and all doors locked)
Operating Temperature -30°C - +80°C
Voltage Drop Max. 1.2V Between terminal No.5 and 3,4,8,12,18,25
(at DC 12V) Max. 1.8V Between terminal No. 5 and 2,6,7,16,17
Max. 2.0V Between terminal No.5 and 11, 27

9U-2 CONTROL UNITS AND SYSTEM

STICS

CONTROL UNITS AND SYSTEM 9U-3
STICS
Operating Functions
NO. Application Deseription
1 Wiper INT sensing vehicle speed l By operating INT time control volume, variable time will be
changed within 1.5 - 20 seconds.
2 Washer relating wiper l Wiper begins to operate within 0.6 - 1 sec when the washer
switch is ON and it operates 3 times after the washer switch is
OFF while the IGN2 switch in ON.
3 Dimming room lamp l When room lamp is coupled with door, it turns on if door is
opened. After closing the door it maintains 2 seconds of lighting
and dims off whithin 3 seconds.
4 Time delayed power window control l Power window can be operated within 30 seconds after turning
the IGN1 switch from ON to OFF. If driver’s/passenger’s door is
opened within the 30 seconds, time will be prolonged for more
30 seconds from that moment.
5 Rear defogger timer l The rear defogger will be operated for 12 min. by turning ON the
defogger switch while engine is running.
l Defogger will be stopped by pushing the switch again.
l The defogger will be operated 6 min, if push ON the switch within
10 min. after 12 min. of operation.
6 Seat belt warning l The warning lamp will be turned on for about 6 sec. with an
intermittent chime bell when the IGN. switch is ON unless
fastening the seat belt.
7 Parking brake warning l The indicator lamp will flash if drive while the parking brake is
applied.
8 Tail lamp lighting warning l When the driver’s door is opened while the tail lamp is still ON,
the buzzer operates intermittently. In this condition, the door will
be automatically unlocked when it locked.
9 Door ajar warning l The indicator lamp will be blinking when the door is not closed
completely and driving.
10 IGN key reminder l The chime will be operated intermittently if the driver’s door is
opened while the IGN key is still remaining in the ignition switch.
In this condition, the door will be automatically unlocked when it
locked.
11 Central door lock l All doors will be locked/unlocked by locking/unlocking the
driver’s or passenger’s door.

NO. Application Deseription

12 Coupled with REKES l Being coupled with REKES (remote keyless entry system), all
doors will be locked/unlocked according to signals of transmitter
when the ignition key is not inserted.
13 Ignition key hole illumination l Coupled with door switch, ignition key hole illumination lamp will
turn on when the driver’s door is opened and will dim off after 10
sec. after closing the door.
14 Auto door lock l All doors will be locked automatically if the vehicle speed
reaches 50km/h though the doors are in unlock.
15 Auto door unlock l All doors will be automatically unlocked if the vehicle crashes
while driving (over 15km/h).
16 Input checking function l Self diagnostic function for each sensor switches and loads for
the system.

Operating Characteristics
1. Wiper INT sensing vehicle speed IGN1 SW ON
T1 : within 0.5 sec. OFF
T2 : Wiper motor 1 revolution time

IGN2 SW ON
T3 : 1.5±0.2 sec. - 20±2 sec. OFF
AUTO SW ON
OFF
WIPER ON
MOTOR OFF
2. Washer relating wiper

T1 : 0.6 - 1.0 sec.
IGN1 SW ON
T2 : motor 3 revolution (including motor revolution time) OFF
IGN2 SW ON
OFF
WASHER ON
SW OFF
WIPER ON
OUTPUT OFF
3. Dimming room lamp

T1 : 2±0.3 sec.
T2 : 3±0.5 sec
4. Time delayed power window control

T : 30±2 sec

5. Rear defogger timer
T1 : 12±2 min.
T2 : within 10±1 min.
T3 : 6±1 min.
6. Seat belt warning timer

T1 : 6±1 sec.
T2 : 0.3±0.1 sec.
T3 : 0.6±0.1 sec.
7. Parking brake warning

T1 : 0.3±0.1 sec.
T2 : 0.3±0.1 sec.
V1 : 3km/h - 5km/h
8. Tail lamp lighting warning

l When the driver’s door is opened after removing the IGN
key while the tail lamp switch is still ON, the buzzer should
be operated.
T1 : 0.3±0.1 sec.
T2 : 0.3±0.1 sec.

l After 1), the driver’s or passenger’s door should be
unlocked when it locked.
T1 : within 0.2±5 sec.
T2 : 5±0.5 sec.
9. Door ajar warning

T1 : 0.3±0.1 sec.
T2 : 0.3±0.1 sec.
V1 : 3 - 5km/h
10. IGN key reminder warning

T1 : within 0.2 sec.
T2 : 5±0.5 sec.
T3 : 0.3±0.1 sec.
T4 : 0.3±0.1 sec.
T5 : 0.5±0.1 sec.

11. Central door lock
T2 : 0.5±0.1
12. Coupled with REKES mode

T1 : 0.05±0.02 sec. (lock signal)
T2 : 0.1±0.02 sec. (unlock signal)
T3 : within 0.2±5 sec.
T4 : 0.5±0.1 sec.
T6, T7 : 0.5±0.1 sec.
T8 : 1±0.25 sec.
13. Ignition key hole illumination

14. Auto door lock
V1 : 50±5km/h
T1 : 0.5±0.1 sec.
15. Auto door unlock

T1 : 0.5±0.1 sec.
V1 : 15km/h


ON-VEHICLE SERVICE
STICS
STICS, electonic control warning device, controls 16 functions and contains the self diagnostic function detecting any
malfunctions in the sensors and load.
1 STICS Unit 3 STICS Unit Fastening Bolt

2 STICS Connector 4 Parking Brake Lever

1. Disconnector the battery negative cable.
2. Unscrew 4screw from center console box.
3. Remove the center console box and disconnect 3 STICS
connectors.
4. Unscrew 3 fastening bolts and remove the STICS unit.
reverse order.

SECTION 9V
SWITCHES
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 9V-1 Maintenance and Repair . . . . . . . . . . . . . . . 9V-4
General Specifications . . . . . . . . . . . . . . . . . . 9V-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9V-4
Component Locator . . . . . . . . . . . . . . . . . . . 9V-2 Combination Switch . . . . . . . . . . . . . . . . . . . . 9V-4
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9V-2 Other Switches . . . . . . . . . . . . . . . . . . . . . . . . 9V-8
SPECIFICATIONS
Light Switch Load Rating (relay load) each 0.2 - 0.3A
Operating Force (knob rotation) 0.8 - 1.7Kgf·Cm
Free Play Axial:less than 1.0mm, Radial:less than 1.5mm
Turn Signal Load Rating (Lamp Load) each 6.1 - 6.7A
lamp Switch Free Play Less than 2.5mm in width from the lever end
Dimmer and Load Rating(Each Lamps Load) HU:15A, HL:10A, P:20A
Passing Switch
Wiper Switch Load Rating(Relay Load) INT:0.25±0.05A
Load Rating(Motor Load) LO:6A, HI:8A, LOCK:max. 23A
Free Play Less than 2.5mm in width from the lever end
Washer Switch (Motor Load Rating) 4A
Horn Contact Load Rating Max. : 7A
Front Fog Lamp Switch Load Rating 0.2 - 0.3A
Variable INT Volume Switch Max. : 25mA

9V-2 SWITCHES
COMPONENT LOCATOR
SWITCHES
1 - 9 Rear Wiper And Washer Switch

2 Hazard Switch 10 4WD Switch
3 Rear Heated Window Switch 11 4WD Switch Cover
4 Center Fascia Switch Cover 12 Kick Down Switch(4P)
5 - 13 Outside Mirror Switch
6 ECS Switch 14 Head Lamp Leveling Switch Assembly
7 Glove Box Switch (Optional Item)
8 Air-Conditioner Panel Assembly

SWITCHES 9V-3
15 Hood Switch 22 Power Window Sub Switch

16 Door Switch 23 Band
17 Tail Gate Switch 24 Multi-Function Switch Assembly
18 Atmospheric Sensor 25 Blanking Cover
19 Sun Light Sensor Assembly
20 Speed Sensor Assembly
21 Power Window Main Switch

9V-4 SWITCHES

ON-VEHICLE SERVICE
COMBINATION SWITCH
1. Turn the ignition switch to ‘OFF’ position, disconnect the
negative battery cable and go next step after waiting at least
30 seconds.
2. Separate both left and right covers from the steering wheel
and unscrew 2 bolts(10mm)
Installation Notice
3. Disconnect steering wheel audio remote control connector,

horn connector and airbag module connector and remove
the airbag module.
Notice
Refer to airbag module removal.
4. Mark the alignment marks on the steering nut and upper

column shaft and unscrew nut (22mm).
Installation Notice

SWITCHES 9V-5
5. Unscrew the 3 screws from the steering column shaft lower
cover and remove both upper and lower covers.
6. Unscrew the 4 screws of clock spring and remove the clock

spring.
Notice
Refer to clock spring removal for its installation notes.
7. Unscrew the 3 screws and remove the multifunction switch.

reverse order.

9V-6 SWITCHES
Connector Terminal Number & Circuit
NO. Circuit Wiring Item
1 EB 2.0B Head lamp beam ground
2 HU 2.0RL Head Lamp Upper Beam Power
3 HL 2.0R Head Lamp Lower Beam Power
4 TS 0.3R Tail Lamp Switch
5 HS(1) 0.3LW Head Lamp Switch
6 HS(2) 1.25LW Head Lamp Switch Passing
7 TB 0.85GR Flasher Unit Power
8 TL 0.5W Turn Signal Lamp (LH) (Light switch connector)
9 TR 0.5Y Turn Signal Lamp (RH)
10 ES 0.3B Head lamp Switch Ground
11 HO 0.5BW Horn
12 WA 0.5LY Washer
13 P 0.85GB Wiper Parking
14 HI 0.85RB Wiper High Speed
15 INT 0.5G Intermittent Wiper
16 LO 0.85GR Wiper Speed (LO)
17 ES 0.85B Wiper and Washer Ground
18 - - -
19 F(2) 0.3Br Front Fog Lamp
20 FR 0.3G Front fog Lamp Ground
(Wiper and washer switch connector)
21 - - -
22 - - -
23 - - -
24 - - -
25 HO 0.5GR Horn
26 ES 0.5BW Remote Control Ground
27 AUD 0.5Y Remote Control Signal
28 ACC 0.5L Remote Control Switch
29 DSL 0.5f L Driver’s Inflator (LOW)
30 DSH 0.5f Br Driver’s Inflator (HIGH)
37 E(T) 0.3BY Intermittent Wiper Ground
38 INT(T) 0.3R Intermittent Wiper

SWITCHES 9V-7
Check and Service
After disconnecting the connectors, operate the multifunction
switch and check each terminals for current flow.
Light Switch
Terminal No.
1 2 3 4 5 6 7 8 9 10 19 20
Switch
Head Lamp OFF
Tail
Head
OFF
Turn Signal
LH
RH
Dimmer and Passing

Passing LOWER
UPPER
Front Fog OFF

Lamp ON
Wiper and Washer Switch
Terminal No.
12 13 14 15 16 17 21 22 23 24 37 38
Switch
Front Wiper OFF
and Washer AUTO
®
Switch
LO
HI
Washer

9V-8 SWITCHES
OTHER SWITCHES
Maintenance and repair
(Tailgate Glass Defogger)
1. Check the defogger
Before checking the electric equipment’s, usually disconnect
the battery negative(-) terminal.
1) Check the tailgate defogger after battery is fully charged
by running the engine at idle speed.
2) Check the heated wire voltage at tailgate glass center
position “A” by using circuit tester when the tailgate glass
defogger switch is “ON”. If the voltage is approx. 6V, the
system is normal.
3) If the voltage indicates 12V at point “A” , it is considered
that there is a short between “A” and (-) terminal.
4)Find out where the voltage abruptly changes to the 0V by
moving tester bar to the (-) terminal side slightly.
5) If the voltage indicates 0V at point “A”, it is considered
that there is a short between “A” and (+) terminal.
6) Find out where the voltage abruptly changes to the 12V
by moving tester bar to the (-) terminal side slightly.

2. Checking the switch
1) Remove the tailgate glass defogger switch wire from
instrument panel.
2) Turn on the switch and carry out the continuity test
Terminal NO.
Switch position 1 4 2 5 6
OFF
ON
between terminals.
Notice
: It means the electrical continuity between
terminals.
3. Checking the relay
Remove the tailgate glass defogger relay from the relay
box.

SWITCHES 9V-9
Circuit Diagram
1. Hazard Switch
2. Rear defogger & Door unlock switch
3. ECS switch

SECTION 9W
IMMOBILIZER SYSTEM
noted.
TABLE OF CONTENTS
Function Description . . . . . . . . . . . . . . . . . . 9W-2 Diesel Engine Immobilizer . . . . . . . . . . . . . . . 9W-12
System Description . . . . . . . . . . . . . . . . . . . . . 9W-3 Gasoline Engine Immobilizer . . . . . . . . . . . . . 9W-13
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 9W-8 Maintenance and Repair . . . . . . . . . . . . . . 9W-14
Gasoline Engine . . . . . . . . . . . . . . . . . . . . . . . 9W-8 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 9W-14
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . 9W-10 Immobilizer Antenna . . . . . . . . . . . . . . . . . . . 9W-14
Schematic and Routing Diagrams . . . . . . . 9W-12

9W-2 IMMOBILIZER SYSTEM
Immobilizer is a device disabling vehicle ignition unless a speific key is used and designed to help prevent vehicle
theft.
Immobilizer is comprised of two devices, a key with encoded transponder and engine control unit(ECU) with the same
encoding of the transponder. When a key is inserted into the key hole to start vehicle and turned to ‘ON’, the ECU
reads and decodes the transponder code and, if the same, starts the engine, it is called immobilizer. It means
immobilizer system disables starting by stopping fuel supply if the code in the transponder does not match the code
stored in ECU each other.
Notice
l If vehicle is equipped with immobilizer system and the engine
cranks normally but not start, check immobilizer system first Cases that requires immobilizer
rather than ignition and other electrical systems because it programming
can be disabled fuel supply of injectors by ECU due to
defective immobilizer system. 1. Replacement ECU
l Programming of the immobilizer system will be performed In this case, replace the every transponder
by authorized personnel only. If following defective codes of the key at once.
for immobilizer system appear during diagnosis of vehicle 2. Replacement of the transponder
with SCANNER, ask immobilizer programming to authorized 3. Additional key for lost 1 or 2 keys
personnel and actual programming should be performed
1) Clear all codes for current keys from the
by authorized personnel only.
ECU
Display of defectives relevant to immobilizer system :
2) When using current key : clear code of
SCANNER
the transponder and re-program it
1. No communication with transponder
3) Additional (purchased) key : perform
2. No immobilizer programming programming
l The transponder in the key can be damaged by shocks of 4. When lost all keys
dropping or hitting other objectives, so handle it with care.
1) Clear all memorized key codes from the
l Each supplied key has programming of code on its own. ECU
Accordingly if ECU needs to be replaced, replace the
2) Replace the key and key set
transponder in the key.
3) Immobilizer programming
l The vehicle equipped with immobilizer system will never be
started with remote ignition device, so do not attempt to
install it.
l The immobilizer system will never be removed from the
vehicle. So never attempt to remove it to install a remote
ignition device or others.
l If engine does not start during service, use every key to
start the engine and then check immobilizer system finally.

IMMOBILIZER SYSTEM 9W-3
SYSTEM DESCRIPTION
Gasoline Version
The Immobilizer System consists of an electronic device with integrated coil, called ‘Active Antenna’, the crypto
transponder, which is integrated in the ignition key, and the engine management system (EMS).
The Active Antenna is mounted at the ignition lock and handles the following tasks :
l To supply the transponder with power
l To receive the data from the EMS and transmit it to the transponder
l To receive and demodulate the data from the transponder and transmit it to the EMS
The whole Immobilizer software, the authentication and the management of valid keys is completely managed by the
EMS.
Immobilizer system for gasoline vehicle

Active Antenna
l Connector
1 : IGN (red) 2 : Ground (brown)
1 2 3 4 3 : Data in (yellow) 4 : Data Out (green)
Notice
Pin arrangement and spec. of connector is same for gasoline and diesel vehicles.
l Wire circuit diagram
IGN Ground
· 13 : Crypto read
E/G 14 : Crypto write
Ant. 3 14
ECU
4 13

Diesel Version
The Immobilizer System consists of an electronic device with integrated coil, called ‘Active Antenna’, the crypto
transponder, which is integrated in the ignition key, and the Immobilizer-Control-Unit (ICU).
The Active Antenna is mounted at the ignition lock and handles the following tasks :
l to supply the transponder with power
l to receive the data from the ICU and transmit it to the transponder
l to receive and demodulate the data from the transponder and transmit it to the ICU
The whole Immobilizer software, the authentication and the management of valid keys and controlling the fuel valve
is managed completely by the ICU.
Immobilizer System for Diesel Vehicles

Solenoid Fuel Valve
l Connector
- Immobilizer unit - Solenoid valve
16 15 14 13 12 11 10 9 1 2 3
8 7 6 5 4 3 2 1 1 : IGN (Brown)
1 : Data out 3 : Data in 6 : Ground 2 : Code (Green)
7 : Data line 8 : K-Line 9 : IGN 3 : Ground (Black)
l Wire circuit diagram
3 1 Immo. 7 2
Solenoid
Antenna 4 3 unit valve
1 2 8 6 9 3 1
IGN
K-line (Diagnosis)


System Integration
The med 98.2 immobilizer is an anti-theft protection device allowing the start of the engine only if a specific authorization
is obtained during the start up phase. The med 98.2 will allow (prohibit) the start of the engine by driving ON (OFF) an
internal solenoid valve.
The med 98.2 is a single unit integrating the following subsystem :
l a valve that allows (valve open) or blocks (valve closed) the fuel flow through the engine fuel system
l a microprocessor control system to control and activate the valve during the start up of the engine, in order to
allow the start up only when a specific permission is given
the med 98.2 task is, therefore, to prevent the non authorized start up of the engine.
The functional unit includes also a basic set of electronic components whose function is to reduce its dependence on
the microprocessor control system: a part from a short temporarily period, during the start up phase, the electronics
allows the control system to excite and open the valve, but it doesn’t allow to close it.
The valve can be shut off only after the KL 15 has been deactivated.
The structure allows to obtain the highest degree of safe-operation (functionality fail-start): a failure in the
microprocessor unit cannot cause the shut-off of the valve. The main consequence of this type of failure is to prevent
the next engine start up.
As a result of the above considerations, the med 98.2 immobilizer can realize its anti-theft functionality only in conjunction
with a control device: the ICU.
The ICU, when requested, sends a coded message to med 98.2 according to a settled communication protocol. The
med 98.2 will allow the start of the engine based upon this message.
In addition to the basic anti-theft functionality, the 98.2 immobilizer provides a number of diagnostic services when it
is connected to an external test instrument (SCAN-100). Those connections are depicted in the following integration
diagram (Fig. 1), where the dashed line indicates a temporary link for diagnostic purposes, and the shaded area the
med 98.2 system’s physical boundaries:
Fig. 1 - System Integration
Explanation of symbols:
med 98.2 Immobilizer
ICU Immobilizer Control Unit
TESTER Device that can be connected for diagnostic purposes
K-LINE Serial line for communication with ICU
KL15 Ignition key (Power supply for med 98.2)
GND Ground

DIAGNOSIS
GASOLINE ENGINE
Cause and Remedy for Defective When Diagnosed by Scanner
Defects Possible cause Remedy
No communication with 1. Defective wiring harness 1. Connect/replace the wire correctly.

transponder
- Power supply/Open/short of ground
- Open/short of signal terminal or
mis-conneting(between ECU
terminal No. 13 and 14)
2. Damaged transponder 2.1 Replace the transponder

2.2 Immobilizer programming
3. Defective antenna 3. Replace the antenna
4. Defective ECU 4.1 Replace the ECU

4.2 Replace all transponder of the keys
No immobilizer 1. Replace the transponders and ECU 1. Perform immobilizer programming

programming
with new
(Components and
wiring harnesses are ; Immobilizer programming is not
normal but codes in performed
ECU and transponders
are not registered 2. Replace transponders only(new) 2. Perform immobilizer programming
normally) ; Immobilizer programming is not
performed
3. Replace ECU only(new) 3.1 Replace the transponders with new

3.2 Perform immobilizer programming
4. Replace the transponder only 4.1 Replace the transponders with new
; Programmed for other ECU 4.2 Perform immobilizer programming
5. Re-programming is not performed 5. Immobilizer programming

after clearing transponder code stored
in ECU that normally used system
Notice
1. Application of ex-programmed transponder into other ECUs.
; In this case, it can not be removed for the settled “lock bit” in transponder even though you perform immobilizer
problem normally. Moreover it is impossible to start engine, so replace the transponder with new and perform
immobilizer programming.

Check and Remedy when Engine Does not Start
Starter operates normally?
Yes No
l Check fuses (No. 8 and 27) l Check battery voltage

l Check ECU and antenna power l Check battery wiring
ECU terminal
- No. 12 (Power)
- No. 11 (Ignition)
- No.5/10 (Ground)
l Check signal wires between ECU l Check starter wires

and antenna l Check TCU wires (only for 5-
- Immobilizer No.3 wire (0.5BY) = speed automatic transmission)
ECU No. 14 pin (0.75BW) l Check starter and TCU
: Writing immobilizer code number
- Immobilizer No.4 wire (0.5Y) =
ECU No.13 pin (0.75Y)
: Reading immobilizer cod number
Notice1)
l ECU No.2 pin : check normal
signal of the starter 1) MSE ECU equipped vehicle is designed to
- Engine cranking voltage : 8-15V make fuel injection when the engine speed
for initial cranking is over 450rpm if there
are no start switch inputs in ECU No. 2 pin.
l Check engine speed sensor wires

and replace
l Replace immobilizer antenna
l Replace transponder and ECU
If transponder and ECU are replaced,

perform programming.

DIESEL ENGINE
Cause and Remedy for Defective When Diagnosed by Scanner
Defects Possible cause Remedy
No communication with 1. Defective wiring harness 1. Connect/replace the wire correctly.
transponder - Power supply/Open/short of ground
mis-conneting(between ICU
2. Damaged transponder 2.1 Replace the transponder
3. Defective antenna 3. Replace the antenna
4. Defective ICU 4.1 Replace the ICU
4.2 Replace all transponder of the keys
No immobilizer 1. Replace the transponders and ICU 1. Perform immobilizer programming
programming with new
(Components and
; Immobilizer programming is not
wiring harnesses are
normal but codes in performed
ICU and transponders 2. Replace transponders only(new) 2. Perform immobilizer programming
are not registered ; Immobilizer programming is not
normally)
performed
3. Replace ICU only(new) 3.1 Replace the transponders with new
3.2 Perform immobilizer programming
4. Replace the transponder only 4.1 Replace the transponders with new
; Programmed for other ICU 4.2 Perform immobilizer programming
5. Re-programming is not performed 5. Immobilizer programming
after clearing transponder code stored
in ICU that normally used system
No communication with 1. Defective wiring harness 1. Connect/replace the wire correctly
valve - Power supply/Open/short of ground
mis-conneting(between ICU
2. Defective ICU 2. Replace the transponder
3. Defective valve 3.1 Replace the valve
3.2 Turn Ign sw on
3.3 Turn Ign sw OFF & ON
Notice
1. Application of ex-programmed transponder into other ICUs.
; In this case, it can not be removed for the settled “lock bit” in transponder even though you perform immobilizer
problem normally. Moreover it is impossible to start engine, so replace the transponder with new and perform
immobilizer programming.

Check and Remedy when Engine Does not Start
Starter operates normally?
Yes No
l Check fuses (No. 19) l Check battery voltage

l Check ECU and antenna power
l Check battery wiring
and solenoid valve
ECU terminal
- No. 9 (Ignition)
- No. 6 (Ground)
l Check signal wires between ICU l Check starter wires

and antenna l Check TCU wires (only for 5-
- Immobilizer No.3 wire (0.5Y) = speed automatic transmission)
ICU No. 1 pin (0.75BW) l Check starter and TCU
: Writing immobilizer code number
- Immobilizer No.4 wire (0.5G) =
ECU No.3 pin (0.75Y)
: Reading immobilizer cod number
l ECU No.2 pin : check normal

signal of the starter 1)
- Engine cranking voltage : 8-15V
Notice2)
New valve is possible coded either with a
new ICU or an already used ICU. But old
l Check engine speed sensor wires
coded valve is only possible coded with a
and replace new ICU.
l Replace immobilizer antenna
2)
l Replace transponder and ICU l Replace the valve
If transponder and ICU are replaced, 1. Turn Ign sw ON

perform programming. 2. Turn Ign sw OFF & ON
(To learn the valve correctly it is necessary
to switch on Ignition twice for at least 5
seconds.)


DIESEL ENGINE IMMOBILIZER
NO. 3
10A

GASOLINE ENGINE IMMOBILIZER


ON-VEHICLE SERVICE
Notice
For circuit diagram of gasoline vehicle, refer to the ECU diagram.
IMMOBILIZER ANTENNA
Immobilizer antenna is installed in key set outer surface (it is
installed in the location of key hall illuminat-
ion).(see the figure)
1 Immobilizer Antenna 3 Transponder

2 Key

1. Open the cover on key handle.
2. Remove the small screw in symmetrical position of key
illumination.
3. Remove the cover.
4. Remove the transponder. Carefully remove the old shock

absorbing sealant with a razor blade if applied.
5. Replace the transponder with new one, and apply the small
amount of shock absorbing sealant.
reverse order.
1 Transponder

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SECTION INDEX

KORANDO GENERAL INFORMATION 0B

FOREWORD DRIVE LINE/AXLE 3

This manual includes procedure for mainte-

All information, illustrations and specifications

The right is reserved to make changes at any STEERING 6

BODY AND ACCESSORIES 9

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SECTION 1A1 M162 GENERAL ENGINE INFORMATION

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SECTION 2A SUSPENSION DIAGNOSIS

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SECTION 3A FRONT DRIVE AXLE

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SECTION 4A HYDRAULIC BRAKES

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SECTION 5A AUTOMATIC TRANSMISSION

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SECTION 6A POWER STEERING SYSTEM

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SECTION 7B/C MANUAL CONTROL/SEMIAUTO

SECTION 7D FULL AUTOMATIC

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SECTION 8A SEAT BELTS

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SECTION 9A BODY WIRING SYSTEM

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Clutch - Manual Type

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Tire and Wheel

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VEHICLE DIMENSIONS AND WEIGHTS

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STANDARD BOLTS SPECIFICATIONS

*Diameter ´ pitch in millimeters

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MAINTENANCE AND REPAIR

MAINTENANCE SERVICES Spark Plug Wire Replacement

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SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)

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SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)

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VEHICLE IDENTIFICATION NUMBER SYSTEM